OPTI-UPS DS160KD33 User Manual

OPTI-UPS

User’s Guide

Durable Series

Models DS-D33

www.opti-ups.com

Contents Page

1. SYSTEM OVERVIEW

1.1. Construction of the UPS

1.2. Features and

1.3. Rectifier

1.4.

Inv

1.5. Static Switch

erter

Advantages......................................................................

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1.6. Maintenance Bypass Switch

1.7. Dimension & Drawings

1.8. Front Panel

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2. TECHNICAL SPECIFICATION

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2.1. 20KVA ~ 60KVA UPS 3–Phase Input / 3-Phase

2.2. 80KVA ~ 160KVA UPS 3–Phase Input / 3-Phase

2.3. 20KVA ~ 50KVA UPS 3–Phase Input / 1-Phase

3. INSTALLATION

3.1. Site & Environment

3.2.

Unp

ack

3.3. Cable Selection

3.4. Terminal

4. OPERATIONS

4.1. Switch on Procedure

4.2. Shutdown Procedure

4.3. From Inverter to Bypass Procedure

4.4. From Bypass to Inverter Procedure

5. LCD

DISPLAY ..............................................................................................

5.1. Menu 0 – Main

5.2. Menu 1 – Select Menu

5.3. Menu 2 – Status / Warning

5.4. Menu 3 – Real Time Data

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Consideration ......................................................

ing ............................................................................................

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Conn

ect

ion ............................................................................

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Menu...........................................................................

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Menu.........................................................

Menu ..........................................................

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Output ......................

Output ....................

Output ......................

1-1 1-1

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1-8

1-9

2-1

2-1 2-4 2-7

3-1

3-4

3-5 3-7

4-1

4-1 4-2

4-3

4-4

5-1

5-2

5-3

5-4

Contents Page

5.5. Menu 4 – Historical Event

5.6. Menu 5 – Parameter Setting

5.7. Menu 6 – Rectifier Data Menu

5.8. Menu 7 – Output Data Menu

5.9. Menu 8 – Other Data Menu

5.10. Menu 9 – Reserve Data

5.11. Menu 10 – Boost Charge Setting

5.12. Menu 11 – Data Time Setting

5.13. Menu 12 – Other Setting

6. INTERFACE C

6.1. Dry Contacts

6.2. External

6.3. DB9

OPTIONS .......................................................................................................

7.1. Battery Cabinet

ONNECTIONS .....................................................................

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Shutdown ...............................................................................

Conn

ection

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7.2. Emergent Stop Switch

7.3. Remote Control Panel –

7.4. Software for PC Monitoring –

7.5. Auto Dialing Module –

7.6. Battery Monitoring Module -

REDUNDANCY ............................................................................................

8.1. Serial Redundancy

HELP..............................................................................................................

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Menu .........................................................

Menu.......................................................

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Menu..............................................................

Menu ...............................................

Menu ..................................................

Menu..........................................................

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UPSCAN™

UPSCOM™

UPSCALL™

DCMAN™

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5-6 5-7 5-8 5-8

5-9

5-11

5-12

6-1

6-1 6-3 6-3

7-1

7-1 7-2

7-2

7-3

8-1

9-1

CAUTION !

☆ Hazardous voltage exits inside the UPS (includes the connection

terminals), cable connection and maintenance should be done by

professional or qualified personnel.

☆ The UPS has its own internal battery source (battery). The output

terminals may be live even when the UPS is not connected to the AC supply.

☆ DC capacitors are employed in this unit, hazardous voltage still

exists even when the unit is not energized. Do not touch any part of the UPS inside.

WA RNING !

☆ Be sure to operate the UPS within the rated power of the UPS. ☆ Prevent direct exposure to direct sunlight rain or contaminating

environment.

☆ Only qualified technicians should replace the batteries. Since

batteries have high short-circuit current capacity. Mistakes in connection or disconnection can cause severe burns or death to servicing personnel.

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1. SYSTEM OVERVIEW

1.1. Construction of the UPS

General Topology：

The UPS system is composed of input breakers, input filter & protection network, rectifier, battery

bank, inve

rte

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 supply to the inverter and charge the battery to its full capacity all the time, ready to support the output load in case of AC source failure.

Perhaps one may doubt if it is worthwhile to buy a UPS. But when you use a calculator to add up the

dire

ct and indirect loss caused by AC failure, you will immediately find that the money you save in 2 or 3 times of AC failure can already compensate the cost of a UPS. Besides, the life expectancy of a UPS is at least 5 to 8 years, you may already get back the expense on the UPS within one year.

Although the principle and operation of a UPS seems simple and straightforward,

for

the requirement

a reliable and intelligent UPS makes the design and manufacturing of a high power UPS requires advanced technology, intelligence, experience and the most important, be c

ons

iderate to the user. Therefore we spend years and huge investment in developing the most rugged, intelligent and reliable UPS for the market, safe and convenient UPS for the user.

1-2

Besides, the knowledge of choosing the best and most suitable UPS can be easy or can be difficult, it depends on whether you know the key points or not. The most

obvious specification is the power, it depends on how lar

e is your load. Usually, an allowance of 50% more power must be added to the current power you needed, both for tolerance and future expansion. Of course you can add more than 50% if you expect a larger increase of load in the future.

Another important point is the reliability, the prime aim of a UPS is to protect your load, and therefore the UPS should be much more reliable than the AC source. Those unfortunate UPS users who bought a unreliable

UPS

may suffer the problem of frequent break down of the UPS, even more frequent than AC failure, the cost of repairing is more the cost of the unit itself.

The last point is to choose an honest and experienced suppler who can help you to choose the correct UPS, react promptly in case of UPS problem. Then, you can save your money as well as buy a correct, suitable, and reliable UPS that is the same as buy insurance to your load.

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. They are explained as below.

Normal Operation Mode:

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

1-3

Back-up Mode:

Since the battery is connected directly to the DC bus, when the AC failure, the battery change immediately instead of receiving energy from the rectifier. The

from

receiver to donor, supply energy to the inverter

output AC

is not interrupted.

Therefore, the load connected to the output is protected.

Reserve Mode:

When the inverter is in abnormal conditions, such as over temperature, short circuit, abnormal output voltage or overloaded for a period exceed the inverter’s limit, the inverter will automatically shutdown, 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.

1-4

Maintenance Bypass Mode:

In case of UPS maintenance or battery replacement, and 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 maintenance bypass switch keeps continuously power supply to the load. Electricity will not exist in UPS except the output transformer, thus ensure the safety of service personnel.

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

The normal operation with battery connected can provide a clean, stable, free from any spikes and surges, regulated and uninterruptible power to the load. Therefore, the UPS and be regarded as a perfect AC

power source

except the back-up time

under mains failure is limited by the capacity of battery connected.

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

loop to ensure power can continue through the other loop in case of breaker trip caused abnormal condition in either rectifier or load.

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

sufficient protection to both UPS and the load from any lightning or surge caused by neighboring large loads.

therefore, very low

noise

is emitted and never interfere other equipment

connected to the same AC source.

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

DC bus voltage, so it can charge the battery directly, it is the most efficient method to charge the battery. Besides, the component used is SCR, the component get merits by its ruggedness under poor condition. Also, big 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 method

to conv

ert the DC power to AC power. Therefore, number of components is fewer, in return, reliability is improved, size and weight of UPS is reduced, then the transportation cost is cheaper, performance improved and the acoustic noise is eliminated too.

(f) True Galvanic isolation: An isolated transformer is put at the output, can

solve the problem of

poor input

grounding and can accept 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. Besides, the user gets the bonus of

attenuation of common mode noise from the output isolation transformer.

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(g) P&P Modular design: The power circuit is separated into several modules

plugged into slots in

UPS,

which is easy to pull out, permit quick maintenance and easier trouble shooting. Therefore, it can be regarded as plug and play modules.

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

be started with battery only, because current limit circuitry is added. It can prevent the problem of many UPS that the big inrush current blow the battery fuse and hurts the DC capacitors when battery is connected to empty DC bus (before the DC bus is energized).

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

functions are designed to parallel redundancy to improve reliability. Therefore, in case of one CPU fails the other CPUs keep on their duty and the output AC will not be affected.

(j) Defense to mis-operation: The UPS is designed with breaker on/off sensor,

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

(k) Wide input range: The UPS is designed to accept extra wide input range, so

that it can work comfortable under poor AC source. Also, all the input components used are especially selected to handle extreme high voltage and high current.

(l) Tolerate harsh environment: Each component of the UPS is chosen with

larger safe margin to accept extreme environment, such as temperature, humidity, attitude, shock or contamination.

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

battery every time after the battery is consumed to a voltage 2V/Cell, so that the battery can be recovered to the full capacity as soon as possible to be ready for the next back-up. Besides, in order to keep the battery in the best condition, the UPS will boost charge the battery for several hours (selectable) automatically every month. To avoid over charging the battery, Boost charge will stop when the ambient temperature is over 35 ℃(95℉).

1-7

(n) Intelligent battery test: Battery is tested after every boost charge of battery

(either initiated by battery discharge or by one month has elapsed) without stopping the rectifier to prevent the risk of output AC failure in case of battery bad. And can inform the user the battery condition, so that the user can take action before the capacity of the battery is needed.

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

to Ah of the battery, and can charge up battery of more than 8Hrs back-up time without adding extra charger.

(p) MTBF of fans is extended: Fans will slow down under light load, so that

the life expectancy of the fans are longer than it is specified.

(q) Redundant power supply: An extra power supply is connected redundantly

to supply power of the static switch, so that, there will be AC output no matter what happen to the UPS.

(r) Intelligent interface: One remote control panel (or one PC) can monitor up to

99 UPS, all of them can be remotely switched on or off, and when any one of them encounters emergent condition, it will warn the user immediately. All the

UPS status, data or commands are transmitted

external modules through 4

RS-485 ports (for long distance communication under harsh environment).

(s) Emergent stop is available: In case of hazard, for example electric shock,

fire or earthquake, the UPS can be shutdown (will have no AC at the output) either through a switch (can be added upon request) or through smoke detector signal (can be added upon request) to prevent further injuries or destruction.

1-8

1.3. Rectifier

The main function of a rectifier is to convert the AC input to DC power, supply it to the inverter; the inverter then converts the DC power to AC power to the load. Our UPS use the DC power to charge the battery as well, which i

s th

e most efficient way

of charging.

INPUT

6-PULS E FULL CONTROL RECTIFIER

RECTIFIER

BREAKER INDUCTOR

SCR

OUTPUT

CAPACITOR

The rectifier of from 20KVA to 80KVA UPS uses 6-pulse full controlled rectifier. An inductor is added before the rectifier to improve the power factor, smooth the current waveform and eliminate the harmonic current as well. 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 battery. The power component use in rectifier is especially selected to handle extreme high voltage and high current. The rectifier is designed to operate under wide range of AC input, from 177 to 300VAC, to fit the poor power conditions in some area.

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PHASE SHIFT

INPUT

RECTIFIER

BREAKER INDUCTOR

TRANSFORMER

SCR

OUTPUT

CAPACITOR

12-PULSE FULL CONTROL RECTIFIER

In order to further improve the power factor and reduce harmonic current drawn by the rectifier, our UPS from 100KVA and above use the 12-pulse full controlled rectifier. The total current harmonic current can be reduced to around 15%, and power factor is improved to over 0.8. A phase shift transformer is added to achieve the performance. The input inductor is retained too to obtain the best result. Although the cost is higher, it is most reliable and rugged topology. Users need not to increase the input breaker and cable, input KVA and harmonic current drawn is minimized to fulfill the worldwide energy saving requirements.

The harmonic current can be further lowered by adding harmonic filters (install upon request). The total harmonic current will be around 9%.

Another alternative method to reduce the harmonic current (especially for very large KVA UPS) is to employ 18-pulse full controlled rectifier. The total harmonic current will be around 7%.

1.4. Inverter

DC+

DC-

IGBT

INVERTER

1-10

TO LOAD

The inverter is composed of IGBT, inductor, capacitor, snubber, control circuitry and protection circuitry. It can convert the DC power from the DC bus to AC power supply to the output load. Our UPS use IGBT technology which can switched to frequency beyond audible range, therefore no audible noise.

Our UPS use voltage regulation circuitry to limit the voltage variation within 1%. Also 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.

We use independent inverter 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, that is excellent voltage regulation under 100% unbalanced load.

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

Usually, the most frequent failure of UPS happens at the inverter, therefore we added redundant protection circuitry suppress the spikes and noise, use over sized and

protect the inverter, strong snubber is added to

high

quality components, add semi-conductor fuse and good ventilation etc. Every step aims at a rugged, reliable and high efficient inverter. At the same time, the inverter can sustain overload and high peak current drawn by the load. And the MTBF must be long than one expects.

1.5. Static Switch

RESERVE

INVERTER

FILTER

RESERVE

INVERTER

FILTER

RESERVE MO DE INVERT ER MO DE

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The static switch is composed of two pairs of back-to-back connected SCR. It can transfer the load from reserve to inverter or from inverter to reserve without dead time at the output. Therefore, it is a very important portion of a UPS.

Detection circuitry is added to the control circuit to achieve zero dead time transfer. Extra detection logic is employ to control when should the static switch transfer. For example, when output is short circuited under normal mode operation, the UPS detect the short circuit and stop the inverter after a period which the inverter can endure,

then the static switch will not transfer to reserve to prevent tripping and hurting the reserve breaker. But in case of overload, the UPS will stop the inverter after a period the inverter can endue, and then transfer the load to reserve

because the

overload capability of the static switch is higher than the inverter.

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

1.6. Maintenance Bypass Switch Unlike other UPS, the maintenance bypass switch is already installed inside the UPS

for convenience. It should be opened under normal operation, and only closed during maintenance. For the sake of maintenance personnel’s safety, all power supply inside the UPS should be disconnected before touch any parts inside the UPS; therefore, the maintenance bypass switch is a necessity to maintain AC power at the output and can keep 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 connect directly to the AC source. Of course, you cannot switch on the in

verter as long as the maintenance bypass breaker is closed.

The operation of the maintenance bypass breaker is that, switch off the inverter first then the static switch will automatically transfer the load to reserve without dead time. Then now you can close the maintenance bypass breaker now, and then open the reserve breaker, so that the load can get AC from the output without interruption.

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1.7. Dimension & Drawings

20KVA ~ 60KVA

OUTLINE DRAWING

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20KVA ~ 60KVA

INTERIOR DRAWING

1-14

80KVA ~ 160KVA

OUTLINE DRAWING

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80KVA ~ 160KVA

INTERIOR DRAWING

1-16

200KVA ~ 320KVA

OUTLINE DRAWING

1-17

200KVA ~ 320KVA

INTERIOR DRAWING

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INTER-PCB DIAGRAM

1.8.

Front Panel

1-19

INVERTER ON

INVERTER SS

SHORT CIRCUIT

FUSE/OVER

TEMP SD

INVERTER FAIL SHUTDOWN

BYPASS ON SHUTDOWN

HIGH DC SHUTDOWN

OVERLOAD SHUTDOWN

70%LOAD

110%LOAD

125%

150%LOAD

LOAD

RESERVE AC FAIL

RESERVE FREQ FAIL

BATTERY LOW

BATTERY LOW SHUTDOWN

RECT AC FAIL

ROTATION ERROR

RECTIFIER SHUTDOWN

HIGH DC

BOOST CHARGE

BATTERY TEST

EM STOP DATA LINE

ERGENT

～～

～

TRUE GALVANIC ISOLATED UPS

～

RECT AC FAIL

FAIL

RESERVE

FUSE

TEMP

OVERLOAD

WARN

INVERTER

LCD

DOWN

ING

HIGH DC

BAT

BAT LOW STOP

FAULT

OFF

LOW

ENTER

D E F G H I J K L M N O

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The front panel is located at the front of the PCB holder. It gathers the real time information of the UPS for controlling and setting the UPS. So, through this

and shows

them clearly to the user. It also provides switches

panel,

the UPS can be not only a stand alone machine supplying the load but closely related to the user. Each part of the panel is explained below.

A: LCD display: Real time status, data or historical events is displayed on the LCD.

The UPS parameters, real time clock, inverter, buzzer also can be set through this LCD. The LCD is

light

by LEDs for purpose of a sharp display, but in

back order to lengthen the LED’s life time, the LED will be automatically shut off 3 minute a

fter

no key is activated, will light

again when one of the

up/down/enter key is pushed.

B: Status LEDs: 24 LEDs representing all the important information of the UPS

provide most update information to the user. Therefore these LEDs are especially important when abnormal conditions happen. The 24 information are as below:

INVERTER ON – inverter is running. INVERTER SS – inverter static switch conducts while the reserve static

switch is opened.

SHORT CIRCUIT – UPS output is in short circuit state. FUSE/OVER TEMP SD – inverter shutdown due to either fuse broken or

temperature too high.

INVERTER FAIL SHUTDOWN – inverter shutdown due to inverter output

voltage too low.

BYPASS ON SHUTDOWN – inverter shutdown due bypass breaker is closed

when the inverter is running.

HIGH DC SHUTDOWN – inverter shutdown due to DC bus too high when

the inverter is running.

OVERLOAD SHUTDOWN – inverter shutdown due overload the inverter

for a period over the inverter can endue, will restart after 7 seconds.

70% LOAD – load connected to the output is over 70% of the UPS rating. 110% LOAD – load connected to the output is over 110% of the UPS rating. 125% LOAD – load connected to the output is over 125% of the UPS rating. 150% LOAD – load connected to the output is over 150% of the UPS rating.

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RESERVE AC FAIL – reserve AC magnitude is out of range. RESERVE FREQ FAIL – reserve frequency is out of range. BATTERY LOW – DC bus (or battery) is lower than 320VDC, low battery

shutdown is approaching.

BATTERY LOW SHUTDOWN – inverter shutdown due to DC bus (or

battery) is lower than 295VDC (lower than the acceptable DC voltage of the inverter.

RECT AC FAIL – rectifier AC magnitude is out of range. ROTATION ERROR – rectifier AC phase rotation is incorrect. RECTIFIER SHUTDOWN – rectifier shutdown due to DC bus too high

(over 445VDC), will automatically restart 30 seconds after abnormal situation has been cleared.

HIGH DC – DC voltage over 430VDC and the bus voltage will be limited at

this voltage.

BOOST CHARGE – the battery is being boost charged by the rectifier. BATTERY TEST – battery is being tested. EMERGENT STOP –inverter shutdown due to emergent stop switch is

pushed.

DATA LINE – blinks when data is transmitted to or received from the

communication port.

C: Warning LEDs: When abnormal condition happens, these LEDs will lit to warn

the user according to the cause of the faulty condition. Therefore all these LEDs should be extinguished under normal condition. These LEDs are as below:

RECT AC FAIL – rectifier AC input is abnormal either due to AC magnitude

out of the range or phase rotation error, rectifier shutdown.

RESERVE FAIL – reserve AC input is abnormal either due to AC magnitude

out of range or frequency out of range.

FUSE/TEMP

– either inverter fuse is blown or over temperature. OVERLOAD – output is overloaded by over 110%, 125% or 150%. HIGH DC – the LED will lit as long as the DC voltage is over 430VDC.

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