OnLine Power Power Wave 4 User Manual

Power Wave 4

Emergency Lighting Inverter (ELI) 10 – 160 KVA

*200 - 500 KVA

User Manual

Installation Operation

Maintenance

Doc #. 6005-145

Rev. A

Due to continuous product improvement this document is subject to change without prior notice.

CAUTION!

HAZARDOUS VOLTAGE EXISTS INSIDE THE ELI (INCLUDES THE CONNECTION TERMINALS). CABLE CONNECTION AND MAINTENANCE SHOULD BE DOBE BY PROFESSIONAL OR QUALIFIES PERSONNEL. THE ELI HAS ITS OWN INTERNAL POWER SOURCE (BATTERIES). THE OUTPUT TERMINALS MAY BE LIVE EVEN WHEN THE ELI IS NOT CONNECTED TO THE AC SUPPLY. DC CAPACITORS ARE EMPLOYED IN THIS UNIT. HAZARDOUS VOLTAGE STILL EXITS EVEN WHEN THE UNIT IS NOT ENERGIZED. DO NOT TOUCH ANY PART OF THE INSIDE OF THE ELI.

WARNING!

BE SURE TO OPERATE THE ELI WITHIN THE RATED POWER LEVEL. PREVENT DIRECT EXPOSURE TO DIRECT SUNLIGHT, RAIN OR CONTAMINATING ENVIRONMENT. ONLY QUALIFIED TECNICIANS SHOULD REPLACE THE BATTERIES. SINCE BATTERIES HAVE HIGH SHORT-CIRCUIT CURRENT CAPACITY, MISTAKES IN CONNECTION OR DISCONNECTION CAN CAUSE SEVERE BURS OR DEATH TO SERVICING PERSONNEL.

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TABLE OF CONTENTS

CONTENTS …………………………………………….……………………….……………………….Page SAFETY

SYSTEM OVERVIEW

1.1. Construction of the ELI ............................................................................................................................... 1-1

1.2. Features and Advantages............................................................................................................................. 1-5

1.3. Rectifier ....................................................................................................................................................... 1-8

1.4. Inverter ....................................................................................................................................................... 1-10

1.5. Static Switch ..............................................................................................................................................1-11

1.6. Maintenance Bypass ................................................................................................................................. 1-12

1.7. Main Input Circuit Breaker ....................................................................................................................... 1-12

1.8. Main Output Circuit Breaker .................................................................................................................... 1-12

1.9. Battery Circuit Breaker ............................................................................................................................. 1-12

..................................................................................................................... a

............................................................................................. 1-1

1.10 Battery ....................................................................................................................................................... 1-12

1.11 Single Line Diagram (120/208Y) ............................................................................................................ 1-13

1.12 Single Line Diagram (277/480Y) ............................................................................................................ 1-14

1.13 Dimensions & Drawings .......................................................................................................................... 1-15

1.14 Front Panel ................................................................................................................................................ 1-21

TECHNICAL SPECIFICATION

2.1. Specification for 208/120V Unit ............................................................................................................................... 2-1

2.2. Specification for 480/277V Unit ............................................................................................................................... 2-2

2.3 Model Number Chart .................................................................................................................................... 2-3

INSTALLATION

3.1. Site & Environment Consideration ............................................................................................................ 3-1

3.2. Unpacking .................................................................................................................................................... 3-4

3.3. Cable Selection ............................................................................................................................................ 3-5

3.4. Input/Output Protective Device Rating Chart ............................................................................................ 3-6

3.5. Terminal Connection ................................................................................................................................... 3-7

OPERATIONS

............................................................................................................................................. 3-1

.................................................................................................................................................. 4-1

................................................................................................. 2-1

4.1. Start-up Procedure ....................................................................................................................................... 4-1

4.2. Shutdown Procedure .................................................................................................................................... 4-2

4.3. From Inverter to Maintenance Bypass Procedure ..................................................................................... 4-3

4.4. From Maintenance Bypass to Inverter Procedure ..................................................................................... 4-4

4.5.

Green mode selection

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.................................................................................................................................... 4-5

CONTENTS ................................................................................................................................................. Page

LCD DISPLAY

5.1. Menu 0 – Main Menu ................................................................................................................................ 5-1

5.2. Menu 1 – Select Menu .............................................................................................................................. 5-2

5.3. Menu 2 – Status / Warning Menu .................................................................................................................... 5-3

5.4. Menu 3 – Real Time Data Menu ...................................................................................................................... 5-4

5.5. Menu 4 – Historical Event Menu .............................................................................................................. 5-5

5.6. Menu 5 – Parameter Setting Menu ........................................................................................................... 5-6

5.7. Menu 6 – Rectifier Data Menu .................................................................................................................. 5-7

5.8. Menu 7 – Output Data Menu ..................................................................................................................... 5-8

5.9. Menu 8 – Other Data Menu ....................................................................................................................... 5-8

5.10. Menu 9 – Reserve Data Menu ......................................................................................................................................... 5-9

5.11. Menu 10 – Boost Charge Setting Menu ................................................................................................................ 5-9

5.12. Menu 11 – Data Time Setting Menu ........................................................................................................................... 5-11

5.13. Menu 12 – Other Setting Menu ........................................................................................................................... 5-12

.................................................................................................................................. 5-1

INTERFACE CONNECTIONS

6.1. Dry Contacts .............................................................................................................................................. 6-1

6.2. External Shutdown ..................................................................................................................................... 6-4

6.3. DB9 Connection ......................................................................................................................................... 6-4

OPTIONS

7.1. Emergency Power Off Switch (EPO) ....................................................................................................... 7.1

7.2. Remote Control Panel ................................................................................................................................ 7.1

7.3. Software for PC Monitoring ...................................................................................................................... 7.2

7.4. Auto Dialing Module ................................................................................................................................. 7.2

7.5. Battery Monitoring Module - DCMAN .................................................................................................... 7.2

7.6. Input Transient Voltage Surge Suppressor (TVSS) ................................................................................. 7.2

7.7. Web/SNMP Card ........................................................................................................................................ 7.3

7.8. Output AUX Circuit Breakers ................................................................................................................... 7.3

7.9. Higher Kaic Circuit Breakers .................................................................................................................... 7.3

7.10. Delta Input ................................................................................................................................................ 7.3

................................................................................................ ..................................... 7-1

................................................................................................ .. 6-1

7.11. Dual Input ................................................................................................................................................. 7.3

7.12. Seismic Bracket. ....................................................................................................................................... 7.3

7.13. Factory Set Green Mode .......................................................................................................................... 7.3

7.14. Battery Cabinet and Battery run time...................................................................................................... 7. 4

7.15. Battery Cabinet Arrangement Drawings ................................................................................................. 7.6

7.16. Replaceable Parts List ............................................................................................................................ 7.11

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CONTENTS ................................................................................................................................................. Page

REDUNDANCY

8.1. Serial Redundancy ....................................................................................................................................... 81

8.2. Parallel Redundancy .................................................................................................................................. 8-4

MAINTENANCE

9.1. Safety and Precautions .............................................................................................................................. 9-1

9.2. When to call ............................................................................................................................................... 9-3

9.3. Step to take ................................................................................................................................................. 9-3

9.4. Preventive Maintenance ............................................................................................................................ 9-4

9.4.1 Maintenance Log ..................................................................................................................................... 9-4

9.4.2 Periodic Testing of Unit .......................................................................................................................... 9-5

.............................................................................................................................................. 8-1

............................................................................................................................................ 9-1

9.4.3 Maintaining Batteries .............................................................................................................................. 9-5

9.4.4 Battery Cabinets ...................................................................................................................................... 9-7

9.4.5 Power Connections .................................................................................................................................. 9-7

9.4.6 Battery Terminals .................................................................................................................................... 9-8

9.5. Online Power Customer Service and Support ......................................................................................... 9-8

9.5.1 Start-Up Services ..................................................................................................................................... 9-8

9.5.2 Maintenance Agreements........................................................................................................................ 9-8

9.5.3 Warranties ................................................................................................................................................ 9-8

9.5.4 Help .......................................................................................................................................................... 9-9

Appendix A

Battery Exerciser setting ................................................................................................................................ 9-15

6005-145 Rev. A d

OnLine Power, Inc.

Reproduction or Distribution forbidden

NOTICE: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION

This document contains proprietary and confidential information of

OnLine Power, Inc. (”OnLine Power”). In consideration of the

receipt of this document, the recipient agrees not to copy any of its contents, nor to disclose them to or allow them to be used by any person not currently an OnLine Power employee or an employee of the recipient having a need to know, without the express written consent of OnLine Power, and further agrees to surrender this document to OnLine Power when the reason for its receipt has terminated. Due to continuous product improvement this document is subject to change without prior notice.

6005-145 Rev. A e

Serial Number:

KVA/Power Rating:

Input Voltage:

Output Voltage:

Manufacturer Date:

Congratulations on selecting one of the fine products from OnLine Power, the leader in power protection technology. Our wide product offering includes UPS (Uninterruptible Power Systems), power conditioners, automatic voltage regulators and specialty transformers (e.g., computer-grade, medical-grade). Since our founding in 1972, OnLine Power has shipped many of these fine products to discerning customers around the world for use on sensitive equipment and in critical applications.

One of our goals is to make our manuals both comprehensive and easy to use. The new format of our user manual is the result of ideas and inputs from customers like you who have taken an active interest in our continued success. We invite and appreciate your feedback on our products and documentation via e-mail, fax, mail, or telephone.

HEADQUARTERS OnLine Power 5701 Smith Street Commerce, CA 90040

SALES

Phone: (800) 227-8899 FAX No: (323) 721-5017 E-mail: sales@onlinepower.com

Office Hours are 7:00 AM to 5:00 PM PST SERVICE

If you require assistance, please call our 24-hour toll free hot line 800-PWR- SRVC (800-797-7782) or email to info@800pwrsrvc.com. Please have the

following information from your unit’s nameplate available to speed

assistance:

Due to continuous product improvement this document is subject to change without prior notice.

6005-145 Rev. A f

Danger!

ONLY FACTORY TRAINED OR AUTHORIZED PERSONNEL SHOULD ATTEMPT TO INSTALL OR REPAIR THE UNIT OR ITS BATTERY SYSTEM. IMPROPER INSTALLATION HAS PROVEN TO BE THE SINGLE MOST SIGNIFICANT CAUSE OF START-UP PROBLEMS. HIGH AC AND DC ELECTRICAL VOLTAGES ARE PRESENT THROUGHOUT THE UNIT (S) AND INCORRECT INSTALLATION OR SERVICING COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT MALFUNCTION.

Danger!

READ THIS MANUAL IN ITS ENTIRETY BEFORE PERFORMING INSTALLATION, START-UP, OPERATION, AND MAINTENANCE OF THE UNIT OR BATTERY SYSTEMS. FAILURE TO DO SO COULD RESULT IN ELECTROCUTION, FIRE, EXPLOSION, OR EQUIPMENT MALFUNCTION.

Caution

SAFETY

Following safety precautions is important when operating or servicing electrical equipment. The symbols shown are used extensively throughout this manual. Always heed these precautions since they are essential to the safe operation and servicing of this product.

Boxes labeled with the “ Danger!” symbol indicate that there is a high risk of personal injury or death if instructions are not followed.

Warnings labeled with the symbol indicate that there is a high probability of equipment malfunction, damage, or destruction if instructions are not followed.

6005-145 Rev. A g

Danger!

EXERCISE EXTREME CARE WHEN HANDLING UNIT AND BATTERY CABINETS TO AVOID EQUIPMENT DAMAGE OR INJURY TO PERSONNEL. CABINETS WEIGH SEVERAL HUNDRED POUNDS.

Danger!

ALL POWER CONNECTIONS MUST BE COMPLETED BY A LICENSED ELECTRICIAN WHO IS EXPERIENCED IN WIRING THIS TYPE OF EQUIPMENT. WIRING MUST BE INSTALLED IN ACCORDANCE WITH ALL APPLICABLE NATIONAL AND LOCAL ELECTRICAL CODES. IMPROPER WIRING MAY CAUSE DAMAGE TO THE EQUIPMENT, INJURY OR DEATH OF PERSONNEL. VERIFY THAT ALL HIGH AND LOW VOLTAGE INPUT POWER CIRCUITS ARE DE-ENERGIZED AND LOCKED OUT BEFORE INSTALLING CABLES OR MAKING ANY ELECTRICAL CONNECTIONS.

Danger!

OBSERVE ALL BATTERY SAFETY PRECAUTIONS DURING INSTALLATION OR SERVICE OF THE UNIT OR BATTERIES. EVEN WITH THE BATTERY CIRCUIT BREAKER IN THE OFF POSITION, THE DANGER OF ELECTROCUTION MAY STILL BE PRESENT. THE BATTERY POWER TO THE

UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE PERFORMING ANY SERVICE OR WORK ON THE UNIT. THE BATTERY MANUFACTURER’S

SAFETY INFORMATION AND MATERIAL SAFETY DATA SHEET IS LOCATED IN A POCKET ATTACHED TO THE INSIDE OF LEFT DOOR OF EACH UNIT. FAILURE TO FOLLOW INSTRUCTION LISTED ABOVE AND ELSEWHERE IN THIS MANUAL COULD RESULT IN AN EXPLOSION, FIRE, EQUIPMENT MALFUNCTION, OR ELECTROCUTION.

Danger!

TEST LIFT AND BALANCE THE CABINETS BEFORE MOVING. MAINTAIN MINIMUM TILT FROM VERTICAL AT ALL TIMES. THE BOTTOM STRUCTURE WILL SUPPORT THE UNIT ONLY IF THE FORKLIFT FORKS ARE COMPLETELY UNDERNEATH THE UNIT.

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Danger!

ALL POWER TO THE UNIT MUST BE LOCKED AND TAGGED “OFF” BEFORE

PERFORMING ANY SERVICE OR WORK ON THE UNIT. FAILURE TO DO SO COULD RESULT IN ELECTROCUTION.

Danger!

EXTREME CAUTION IS REQUIRED WHEN PERFORMING MAINTENANCE. LETHAL VOLTAGES EXIST WITHIN THE EQUIPMENT DURING OPERATION. OBSERVE ALL WARNINGS AND CAUTIONS IN THIS MANUAL. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH. OBTAIN QUALIFIED SERVICE FOR THIS EQUIPMENT AS INSTRUCTED.

Danger!

BE CONSTANTLY AWARE THAT THE UNIT SYSTEM CONTAINS HIGH DC AS WELL AS AC VOLTAGES. WITH INPUT POWER OFF AND THE BATTERY, DISCONNECTED, HIGH VOLTAGE AT THE FILTER CAPACITORS AND POWER CIRCUITS SHOULD DISCHARGE WITHIN 30 SECONDS. HOWEVER, POWER CIRCUIT MALFUNCTIONS CAN OCCUR, SO YOU SHOULD ALWAYS ASSUME THAT HIGH VOLTAGE MIGHT STILL EXIST AFTER SHUTDOWN. VERIFY THAT POWER IS OFF USING AC AND DC VOLTMETERS BEFORE MAKING CONTACT.

Danger!

IN A FIRE INVOLVING ELECTRICAL EQUIPMENT, ONLY USE CARBON DIOXIDE FIRE EXTINGUISHERS, OR THOSE APPROVED FOR USE ON ELECTRICAL EQUIPMENT. USE OF WATER ON FIRES INVOLVING HIGH VOLTAGE ELECTRICAL CIRCUITS COULD RESULT IN ELECTROCUTION .

Danger!

SOME COMPONENTS WITHIN THE CABINETS ARE NOT CONNECTED TO CHASSIS GROUND. ANY CONTACT BETWEEN FLOATING CIRCUITS AND THE CHASSIS IS A LETHAL SHOCK HAZARD.

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Danger!

LEAD-ACID BATTERIES CONTAIN HAZARDOUS MATERIALS. BATTERIES MUST BE HANDLED, TRANSPORTED, AND RECYCLED OR DISCARDED IN ACCORDANCE WITH FEDERAL, STATE, AND LOCAL REGULATIONS. BECAUSE LEAD IS A TOXIC SUBSTANCE, LEAD-ACID BATTERIES MUST BE RECYCLED OR DISCARDED AS HAZADEROUS WAIST.

HARMFUL TO THE SKIN AND EYES AND MAY BE TOXIC.

OF ELECTRICAL SHOCK. THE FOLLOWING PRECAUTIONS SHOULD BE OBSERVED WHEN WORKING ON BATTERIES:

1. REMOVE WATCHES, RINGS OR OTHER METAL OBJECTS.

2. USE TOOLS WITH INSULATED HANDLES.

3. WEAR RUBBER GLOVES AND BOOTS.

4. DO NOT LAY TOOLS OR METAL PARTS ON TOP OF BATTERIES.

5. DISCONNECT CHARGING SOURCE PRIOR TO CONNECTING OR DISCONNECTING BATTERY TERMINALS.

6 DETERMINE IF BATTERY IS INADVERTENTLY GROUNDED. IF SO,

REMOVE THE SOURCE OF THE GROUND. CONTACT WITH ANY PART OF A GROUNDED BATTERY CAN RESULT IN ELECTRICAL SHOCK. THE LIKELIHOOD OF SUCH SHOCK WILL BE REDUCED IF SUCH GROUNDS ARE REMOVED DURING INSTALLATION AND MAINTENANCE.

7 LEAD-ACID BATTERIES CAN PRESENT A RISK OF FIRE BECAUSE THEY

GENERATE HYDROGEN GAS. THE FOLLOWING PROCEDURES SHOULD BE FOLLOWED:

1. DO NOT SMOKE WHEN NEAR BATTERIES.

2. DO NOT CAUSE FLAME OR SPARK IN BATTERY AREA.

8 DISCHARGE STATIC ELECTRICITY FROM YOUR BODY BEFORE

TOUCHING BATTERIES BY FIRST TOUCHING A GROUNDED SURFACE.

Danger!

INTERNAL BATTERY STRAPPING MUST BE VERIFIED BY THE CUSTOMER PRIOR TO MOVING THIS UNIT.

THIS UNIT CONTAINS NON-SPILLABLE BATTERIES. KEEP THE UNIT UPRIGHT. DO NOT STACK. DO NOT TIP. ALWAYS FOLLOW THE BATTERY

MANUFACTURER’S SAFETY INFORMATION LOCATED IN A POCKET

ATTACHED TO THE INSIDE OF THE LEFT DOOR OF YOUR UNIT TO PREVENT AN ACCIDENT THAT COULD RESULT IN INJURY OR DEATH.

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................................................................................................. 6-4

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1. SYSTEM OVERVIEW

1.1. Construction of the ELI

General Topology

The ELI system is composed of input breakers, input filter & protection network, rectifier, battery bank, inverter, static switch, bypass breaker, isolation transformer and output filter. The basic topology is shown in the diagram above. Under normal AC mode, energy from the AC source is converted to DC power and supplied to the inverter to charge the batteries to its full capacity all the time, ready to support the output load in case of AC source failure.

Although the principle and operation of a ELI seems simple and straightforward, the requirement for a reliable and intelligent ELI makes the design and manufacturing of a high power ELI one requiring advanced technology, intelligence, experience and most important, consideration of the user interface. Many years have been spent in designing the most rugged, intelligent and reliable ELI for the market, and a safe and convenient ELI for the user.

Choosing the best and most suitable ELI for a given application can be easy or difficult, depending on the client’s knowledge of key parameters. The most obvious specification, output power, depends on the size of the load. Often, an allowance of 50% more power is added to the present load requirement, both for tolerance and for future expansion.

6005-145 Rev. A 1-2

Another important issue is reliability. The prime aim of a ELI is to protect your load. Therefore, the ELI should be much more reliable than the AC source. An unreliable ELI may suffer the problem of frequent break down, even more frequent than AC failure, and the cost of repair may become more than the cost of the unit itself.

Generally, there are four different modes of operation, the NORMAL OPERATION MODE, the BACK-UP (BATTERY) MODE, the RESERVE MODE and the MAINTENANCE BYPASS MODE. These are explained below.

Normal Operation Mode:

The rectifier converts the AC input to DC power to supply the inverter and charge the batteries simultaneously. All the fluctuations, surges and spikes of the AC input are removed during AC to DC conversion. Therefore, the AC supplied by the inverter is clean and stable.

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Back-up Mode:

Since the batteries are connected directly to the DC bus, when the AC fails, the batteries change immediately from receiver to donor, supplying energy to the inverter instead of receiving energy from the rectifier. The output AC is not interrupted. Therefore, the load connected to the output is protected.

Reserve Mode:

When the inverter is in an abnormal condition, such as over temperature, short circuit, abnormal output voltage or overloaded for a period exceeding the inverter’s limit, the inverter will automatically shut down in order to protect itself from damage. If the utility power is normal, the static switch shall transfer the load to the reserve source without interruption of AC output.

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Maintenance Bypass Mode:

In case of ELI maintenance or battery replacement, and where the load cannot be interrupted, the user can turn off the inverter, close the bypass breaker and then open the rectifier and reserve breakers. The AC output will not be interrupted during manual bypass transfer procedure. Therefore, the maintenance bypass switch keeps continuously supplying power to the load. Electricity will not exist in ELI except the output transformer, thus ensuring the safety of service personnel.

Generally, the ELI is expected to run 24 Hours a day in normal operation mode once it is installed, except when the utility power fails, under overload conditions, or during maintenance.

Normal operation with batteries connected provides clean, stable, regulated and uninterrupted power to the load, free from any spikes and surges. Therefore, the ELI can be regarded as a perfect AC power source, limited in back-up time, under mains failure, only by the capacity of the batteries.

Green Mode:

Hybrid design allows customer to select this operation mode for higher efficiency (fast transfer less than 2ms).

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1.2. Features and Advantages (a) Reliable input protection: Circuit breakers are placed in each individual

input loop to ensure power can continue through another loop in case of breaker trip caused by an abnormal condition in either rectifier or load.

(b) Input surge protection: An MOV (surge protector) is added at the input,

providing protection to both ELI and the load from any lightning surges, or surges caused by neighboring large loads.

limits. Therefore, very low noise is emitted, and no interference is supplied to other equipment connected to the same AC source.

(d) Ruggedness: The rectifier employs phase control technology to regulate

the DC bus voltage. This is the most efficient method to charge the batteries. The SCR used are inherently rugged. Additionally, a large inductor is added at the input to avoid deforming the AC source waveform.

(e) High frequency design: The inverter uses high frequency, high efficiency

IGBT, PWM methodology to convert the DC power to AC power. Therefore, the number of components is fewer, reliability is improved, and the size and weight of ELI is reduced, performance is improved, and acoustic noise is minimized.

(f) True Galvanic isolation: An isolation transformer is placed at the output.

This can solve the problem of poor input grounding, can allow a different ground between input and output, can avoid the annoying problem of ground leakage current, and can be tied to any potential provided on site. The AC output is isolated under every mode of operation. Additionally, the user gets the bonus of attenuation of common mode noise from the output isolation transformer.

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(g) Plug & Play Modular design: The power circuit is separated into several

modules plugged into slots in the ELI, which are easy to pull out, permitting quick maintenance and easier trouble shooting.

(h) Cold start function: the ELI can be started without an AC source, that is,

can be started with battery power only. This is possible because current limit circuitry is added, preventing the problem of large inrush current blowing the battery fuse and damaging the DC capacitors when batteries are connected to an empty DC bus (before the DC bus is energized).

(i) Multi-CPU design: Several CPUs are employed in the control circuit, and

critical functions are designed with parallel redundancy to improve reliability. Therefore, in case of one CPU failure, the other CPUs keep the ELI operational, and the output AC is not affected.

(j) Protection against misuse: The ELI is designed with breaker on/off

sensor, power supply sensor, etc. Therefore, any operational mistake made by the user causes no harm to the ELI.

(k) Accepts wide input range: The ELI is designed to accept a wide input

range, so that it can work effectively under an unstable AC source. All of the input components used are specifically selected to handle extreme high voltage and high current.

(l) Operating environment: Each component of the ELI is chosen with large

safety margin to accommodate extreme environments, such as temperature, humidity, altitude, shock or contamination.

(m) Intelligent charger: The ELI will automatically recharge (boost charge)

the batteries every time the batteries are depleted to a voltage level equal to 2V/Cell. Thus, the batteries can be restored to full capacity as soon as possible, and made ready for the next back-up requirement. In order to keep the batteries in the best condition, the ELI will boost charge the batteries for several hours (selectable) automatically every month. To avoid over charging the batteries, boost charge will stop when the ambient temperature is over 35oC (95oF).

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(n) Intelligent battery test: The batteries are tested after every boost

(initiated by battery discharge or by the monthly boost charge cycle). This is done without interrupting the operation of the rectifier, preventing the risk of output AC failure in case of a bad battery. The user is informed of the battery condition, so that action can be taken before the full capacity of the batteries is needed.

(o) Huge charging power: The charging power is selectable (Lo/Me/Hi)

according to Ah rating of the batteries, and can charge up battery banks providing more than 8Hrs back-up time without adding an extra charger.

(p) MTBF of fans are extended: Fans used to cool the ELI, are designed to

slow down under light load, so that the life expectancy of the fans is extended beyond the normal.

(q) Redundant power supply: A supplemental power supply is added to

provide redundancy for supplying power to the static switch, so that there will be AC output no matter what happens to the ELI.

(r) Variety of accessory (options): With built-in intelligent communication

interface as well as output ports of RS-232, RS-485, and dry contacts, there are several options are hence available such as remote control panel, 3 phases software for PC monitoring, auto dialing module, battery monitoring module, 3 phases SNMP card.

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6-PULSE FULL CONTROL RECTIFIER

INPUT

RECTIFIER

BREAKER INDUCTOR

CAPACITOR

SCR

OUTPUT

1.3. Rectifier

The main function of a rectifier is to convert the AC input to DC power, and supply it to the inverter. The inverter then converts the DC power to AC power for the load. The ELI use the DC power to charge the batteries as well, which is the most efficient method of charging.

ELIs in the sizes 10KVA to 100KVA use 6-pulse fully controlled rectification (optional 12-pulse). An inductor is added before the rectifier to improve the power factor, smooth the current waveform and eliminate the harmonic current. The control circuit regulates the DC bus within 1%. Soft walk-in circuitry (approximately 20sec.) and current limit circuitry is used to prevent over current or instantaneous surge current.

Extra under-voltage and over-voltage protections are added to improve reliability and to shutdown the rectifier in case of abnormal conditions. The DC bus is adjustable to fit different types of batteries. The power component used in the rectifier is specially selected to handle extreme high voltage and high current. The rectifier is designed to operate under a wide range of AC input, from 177 to 300VAC, to operate under the poor power conditions found in some areas.

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12-PULSE FULL CONTROL RECTIFIER

INPUT

RECTIFIER

BREAKER INDUCTOR

CAPACITOR

SCR

OUTPUT

SCR

PHASE SHIFT

TRANSFORMER

In order to further improve the power factor and reduce harmonic current drawn by the rectifier, ELI at 120KVA and above, use the 12-pulse full controlled rectifier. The total current harmonic current can be reduced to around 15%, and power factor improved to over 0.8. A phase shift transformer is added to achieve this performance. The input inductor is retained also to obtain the best result. Although this results in higher cost, the unit is much more reliable and rugged. Users do not need to increase the input breaker and cable sizes, since input KVA and harmonic current drawn is minimized, fulfilling the worldwide energy saving requirements.

The harmonic current can be further lowered by adding harmonic filters (factory installation available). The total harmonic current can be reduced to approximately 9%.

Another alternative method to reduce the harmonic current (especially for very large KVA unit) is to employ 18-pulse full controlled rectifier (available as an option). The total harmonic current can be reduced to approximately 7%.

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DC+

DC-

IGBT INVERTER

1.4. Inverter

The inverter is composed of IGBT, inductor, capacitor, snubber, control circuitry and protection circuitry. The inverter converts the DC power from the DC bus to AC power to supply the output load. The ELI uses IGBT technology which switches at frequencies beyond the audible range, therefore producing no audible noise.

The ELI uses voltage regulation circuitry to limit the voltage variation within 1%. Special compensation circuitry is added to eliminate the output distortion. Every component is oversized to accept the wide DC input range (from 285 to 420VDC), so that the output waveform remains sinusoidal throughout the range. With the aid of dynamic feedback loop the inverter will keep a sine waveform even under non-linear load.

An independent inverter is used for each phase. Although it is more expensive, each inverter has its independent feedback, so that the voltage is unaffected when load is added to the adjacent phase, producing excellent voltage regulation under 100% unbalanced load.

The IGBT is operated in its optimal condition to obtain best efficiency, so as to minimize the power cost of the user.

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FILT E R

TO L O A D

RESERVE

FILT E R

TO L O A D

INVERTER

RESERVE

INVERTER

RESERVE MODE INVERTER MODE

Usually, the most frequent failures of the ELI occur at the inverter. Therefore, we have added redundant protection circuitry to protect the inverter. A strong snubber is added to suppress the spikes and noise, oversized, high quality components are used throughout, semi-conductor fuses are provided, and ventilation is maximized. The result of this design is a more rugged, reliable and high efficient inverter. At the same time, the inverter can sustain overload and high peak current drawn by the load. Additionally, a longer MTBF is achieved.

1.5. Static Switch

The static switch is composed of two pairs of SCRs, connected back-to-back. The switch can transfer the load from reserve to inverter or from inverter to reserve without losing power at the output. Therefore, it is a very important portion of a ELI.

Detection circuitry is added to the control circuit to achieve zero dead time transfer. Extra detection logic is employed to control when the static switch should transfer. For example, when output is short circuited, under normal mode operation, the ELI detects the short circuit and stops the inverter. The static switch will not transfer power to the reserve circuit, which might damage the reserve breaker. In case of an overload, the ELI will stop the inverter after a period the inverter can endure, and then transfer the load to the reserve circuit, since the overload capability of the static switch is higher than the inverter.

The transfer action is determined according to the reserve-input voltage and frequency to protect supplying incorrect power to the load. Finally, there is a double check by the CPU as to whether the transfer is successful or not.

6005-145 Rev. A 1-12

1.6. Maintenance Bypass

Unlike other ELI, the maintenance bypass switch is already installed inside the ELI for convenience. It should be open under normal operation, and only closed during maintenance. For the sake of safety of maintenance personnel, all power supplies inside the ELI should be disconnected before touching any parts inside the ELI. Thus, the maintenance bypass switch is a necessity to maintain AC power at the output and yet keep maintenance personnel safe at the same time. If the bypass breaker is closed under normal operation, the inverter will stop and the load will be automatically transferred to reserve to prevent the inverter connecting directly to the AC source. Of course, you cannot switch on the inverter as long as the maintenance bypass breaker is closed.

To properly use the maintenance bypass breaker, switch off the inverter first. The static switch will automatically transfer the load to reserve without dead time. Then one can close the maintenance bypass breaker, then open the reserve breaker, so that the load gets power from the output without interruption.

1.7. Main Input Circuit Breaker

The main input circuit breaker provides the unit with incoming power isolation as a well as means of disconnect and input over current protection.

1.8. Main Output Circuit Breaker

1.9. Battery Circuit Breaker

1.10. Battery

The battery bank; Provides the reserve energy to sustain the load when suitable AC input power is not present. The batteries are designed and tested to meet UL 924 requirements. The standard VRLA (Valve Regulated Lead Acid) batteries are sealed and maintenance-free.