Powerware SOLA 4000 User Manual
Uninterruptible Power Supply
SOLA 4000
OPERATING MANUAL
JUE 401263
Contents of JUE 401263
SOLA 4000 Operating Manual
The SOLA 4000 Operating Manual consists of the following documents:
SECTION 0: JUE 401263 INDEX AND SAFETY INSTRUCTIONS
SECTION 1: JUE 401264 GENERAL SYSTEM DESCRIPTION
SECTION 2: JUE 401265 INSTALLATION AND INITIAL START-UP
SECTION 3: JUE 401266 OPERATION
SECTION 4: JUE 401267 OPERATING PANEL
SECTION 5: JUE 401268 PCB DESCRIPTION
SECTION 6: JUE 401269 TECHNICAL DATA
We reserve the right to modify the contents of this document without notice. BEST POWER- BORRI ELETTRONICA INDUSTRIALE S.r.l Via 8 Marzo Soci, Bibbiena (AREZZO)
ISSUED
See Rev. Doc. JSE401440A
04.02.97
20.06.97
T. Boon
T. Boon
04.02.97M. Porpora
A4 31
JUE 401263
3
SOLA 4000 - Operating Manual
Safety Instructions
SAFETY INSTRUCTIONS
The unit must be used as intended. Follow the instructions given in
the Operating Manual.
Dangerous voltages are present inside the unit.
Installation and use of this equipment must comply to all national
and local regulations and procedures.
To prevent overheating do not obstruct the flow of air for ventilation openings to the unit.
The components inside the unit are not repairable by the user. The
user must not open the UPS cabinet or auxiliary cabinets or remove any protective covers from inside the UPS cabinet.
This equipment must be installed and serviced by qualified personnel.
The unit contains Lead-Acid batteries which must be disposed of
correctly, in compliance with the local regulations.
To completely isolate the equipment, the switches IRP, IRE,
IBY,IUG and IB must be switched off, the input supply and the
battery supply must be isolated from the UPS and the output
isolated from other modules if the unit is part of a multi-module
system. For 10-30kVA units with an internal battery, intermediate
links must be removed in order to isolate the battery in sections of
a safe working voltage.
High leakage current: connect protective earth before power
supply cables.
JUE 401263
4
SOLA 4000 - Operating Manual
Safety Instructions
Earth leakage protection: this device has a high leakage current
towards protective earthing. The maximum earth leakage current is
300 mA. When setting the threshold of the earth leakage circuit
breaker installed upstream from this equipment consider this
amount of current and that due to the loads.
All primary power switches installed downstream of the UPS must
be labelled as follows: "Isolate UPS (Uninterruptible Power Supply)
before working on this circuit.
The unit is provided with the E.P.O. (Emergency Power Off)
function. This function is activated by pressing simultaneously the
two push buttons on the bottom part of the Front Panel. This
function provides UPS disconnection from the load and from the
battery. Dangerous voltages will still be present inside the unit, if a
shunt-trip of the input supply switch is not provided for.
During electrolysis, batteries release hydrogen gas. There is a risk
of an explosion if the amount of hydrogen in the battery room
becomes too high. Ensure appropriate ventilation of the battery
room according to the standard EN50091-1, to prevent the risk of
an explosion.
JUE 401263
Contents of JUE 401264
SOLA 4000 - General System Description
Chapters
1 UPS ASSEMBLY 2
1.1 Features 2
1.2 UPS System Structure 3
1.3 Rectifier/Battery Charger 3
1.4 Battery (Accumulator) 4
1.5 Inverter 4
1.6 Static Switches 4
1.7 Maintenance Bypass 6
1.8 Hot-Standby Systems 6
1.9 Parallel-Redundant Systems 7
1.10 Parallel Systems 7
2 OPERATING PANEL 8
2.1 Functional Description 8
Figures
FIG. 1.1 UPS Block-Diagram 3
FIG. 1.2 Rectifier Block-Diagram 3
FIG. 1.3 12-Pulse Rectifier Block-Diagram 3
FIG. 1.4 Inverter Block-Diagram 4
FIG. 1.5 Static Switches Block-Diagram 4
FIG. 1.6 Maintenance Bypass Block-Diagram 6
FIG. 1.6.1 Wall-mounted Maintenance Bypass
Block-Diagram 6
FIG. 1.7 Hot-Standby Operation Block-Diagram
6
FIG. 1.8 Parallel Operation Block-Diagram 7
FIG. 2.1 SOLA 4000 Operating Panel 8
2.2 Remote Monitoring 8
2.3 Emergency Power Off 8
We reserve the right to modify the contents of this document without notice. BEST POWER- BORRI ELETTRONICA INDUSTRIALE S.r.l Via 8 Marzo Soci, Bibbiena (AREZZO)
ISSUED
See Rev. Doc. JSE401440A 20.06.97 T. Boon
04.02.97
T. Boon
04.02.97M. Porpora
A4 81
JUE 401264
SOLA 4000 - General System Description
JUE 401264
1 UPS Assembly
1 UPS ASSEMBLY
1.1 Features
CE This equipment complies to the essential requirements of Euro-
pean Directives 89/336/EEC and 73/23/EEC, and complies to
EN50091-2 (1995) and EN50091-1 (1991) standards.
UPS Function The uninterruptible power supply (UPS) is connected between the
consumer's critical equipment (the load) and supply mains. Its
function is to guarantee a continuous and conditioned power supply
to the load. Even in the case of a total blackout it will supply the
load for a predetermined time (autonomy time). In addition, the
UPS provides the following advantages in comparison with conventional supply systems (mains, motor generator sets, etc.):
Better Output Power Characteristics The UPS output voltage control of frequency and amplitude guar-
antees consistent and stabilised output power. Mains voltage
fluctuations and frequency changes that are usually present in
electricity supply systems do not affect the UPS output voltage.
Uncoupling from Mains Distortion By using double energy conversion from ac to dc and back to ac
and using an isolation transformer in the inverter output, all mains
distortions are filtered out. Therefore, all loads connected to the
UPS system are protected against mains disturbances that can be
present in industrial electricity supply systems. This is especially
important for sensitive electronic devices, e.g. computer systems,
control systems, medical equipment.
Complete Protection against
Mains Failures
During long term or short term ac mains supply interruption, the
UPS system guarantees continuous supply to the connected loads
by means of a battery. The battery is connected to the rectifier
output and the inverter input of the UPS system. In normal operation the inverter (which feeds the load) is fed by the rectifier. In
case of a mains failure, the connected battery automatically feeds
the inverter. Thus the load is supplied without interruption. However, the load can only be supplied by the battery for a certain time
(autonomy time, see chapter 1.4 "Battery"). If longer autonomy
times are required, we recommend the use of a Diesel Generator
Set. In this case the battery autonomy time only has to be sufficient
for the time span between mains failure and full operating capacity
of the Diesel-Generator-Set.
This is a class A product.
In a domestic environment, this product may cause radio
interference, in which case, the user may be required to take
additional measures.
SOLA 4000 - General System Description
JUE 401264
1 UPS Assembly
1.2 UPS System Structure
The basic SOLA 4000 power supply unit is an ac/dc/ac converter;
the block diagram: Figure 1.1 illustrates six essential functional
components:
• Rectifier/battery charger (6 pulse) (RECT.)
• Battery (BATT.)
• Inverter (INV.)
• Static inverter switch (SSI)
• Static bypass (SSB)
• Maintenance bypass (IBY)
All components are located in a single housing. They are explained
in detail on the following pages.The control electronics of the
rectifier, inverter and static bypass sections are completely independent of each other. i.e. a failure in any one section will not
cause a failure in another section.
1.3 Rectifier/Battery Charger
In the standard configuration the charger is a three phase/6 pulse
rectifier that converts ac voltage to dc voltage. No isolation transformer is used and the rectifier is connected to the mains via the
commutation chokes which reduce the mains distortion created by
the rectifier. The dc output of the rectifier feeds the inverter and the
battery. The battery is connected to the rectifier through a saturation choke which reduces ac ripple current to the battery, thus
ensuring the maximum battery life-time.
The rectifier is designed to feed both the inverter at maximum load
conditions and simultaneously the battery with maximum charging
current. Normally, the battery voltage is constantly regulated at 432
V dc (floating charge, maintenance-free lead battery, 2.25 volts per
cell). The rectifier's recharge characteristic is of the I/U type. This
means that the recharging current limitation is accomplished by
reduction of the dc voltage, thus assuring that the batteries will not
be damaged by excessive charging currents.
A 12-pulse rectifier is optional and requires the addition of a second rectifier bridge inside the UPS cabinet and a phase shifting
transformer in a separate cabinet.
FIG. 1.3 - 12-pulse Rectifier Block-Diagram
SOLA 4000 - General System Description
JUE 401264
1.4 Battery (Accumulator)
The battery supplies power in case of a short interruption or a total
breakdown of the ac mains supply. In case of a rectifier failure (no
dc voltage output), the load will be fed by the battery.
The battery is only capable of feeding the load for a certain time
(autonomy time), depending on battery capacity and actual load.
The number of cells within the battery depends on the battery type
and may also vary due to specific customer requirements. The
standard number is 192 cells for lead-acid batteries and 300 cells
for NiCd batteries. The battery capacity (Ah) depends on the UPS
output power and the required autonomy time. The battery of 1030kVA units is installed inside the UPS cabinet as standard. For
40-120kVA units (or 10-30kVA units with extended battery autonomy), batteries are installed in external battery cabinets.
1.5 Inverter
The inverter converts dc voltage supplied by the rectifier or battery
to ac voltage of a precisely stabilised amplitude and frequency that
is suitable for power supply to most sophisticated electrical equipment.
The inverter output voltage is generated by sinusoidal pulse width
modulation (PWM). The use of a high carrier frequency for the
PWM and a dedicated ac filter circuit consisting of the transformer
and capacitors, ensure a very low distortion of the output voltage
(THD<1% on linear loads).
Every phase voltage of the inverter output is controlled separately,
thus ensuring constant and equal UPS output voltages even with
highly unbalanced loads.
The inverter is designed specifically for the application of today's
loads i.e. The output harmonic distortion will be maintained at low
levels due to a unique adaptive correction technique, even with the
application of highly distorted loads.
The inverter control logic restricts the maximum output current to
150% of the nominal current in case of a short circuit. In case of
overload (up to 125% of the nominal current), the output voltage is
maintained constant. For higher currents the output voltage is
reduced, however, this will only occur if the bypass supply is not
available. Otherwise the UPS will switch to bypass operation for
currents higher than 110% of the nominal current.
The inverter IGBT transistors are fully protected from severe short
circuits by means of a desaturation monitor or "electronic fuse".
1 UPS Assembly
1.6 Static Switches
The block diagram illustrates the two static switch sections that use
thyristors as switching elements. During normal UPS operation,
SSI is closed and SSB is open, thus connecting the load to the
inverter output.
SOLA 4000 - General System Description
JUE 401264
1 UPS Assembly
During overload or inverter failure conditions, SSI is switched off
and SSB is switched on, providing power supply from a backup
source (mains, output of another UPS system, diesel generator
set....). By always actuating both switches together for a short
period, an uninterrupted power supply during the switching is
ensured. This is an essential condition to reliably meet all power
supply requirements for connected sensitive equipment.
The control for each static switch (SSB and SSI) is performed
totally independently of each other, thus ensuring that a failure in
one static switch does not affect the other.
Switching Conditions, Inverter - Bypass
The voltage and frequency of the bypass line have to be within
set tolerance limits, and the inverters have to be synchronised
with the bypass line.
Under inverter failure conditions:
(i) the UPS switches to bypass operation, for a single unit. (SSB
switches on, and SSI off).
(ii) for hot-standby units, the load is commutated to the second
inverter, and will switch to bypass only when no inverter is ready to
take the load.
(iii) in parallel systems, all units switch to bypass operation together
only if the load is more than the rated value for the remaining on-line
units.
If the conditions above for the bypass line and synchronisation
are not met:
• the inverter will continue to operate with reduced output voltage
under overload conditions, or
• the inverter will stop if an inverter failure occurs.
In this second case, the system will:
(i) commutate to a second standby-inverter in the case of a hot-
standby system
(ii) the remaining inverters will take the load in the case of a
parallel-redundant system or,
(iii) the UPS will commutate to the bypass supply with a very short
interruption of 10msec if the supplies are not synchronised, for the
case of a single UPS unit.
Under overload conditions, all UPS modules present will
switch to the bypass supply, and remain in bypass until the
overload is removed.
Switching Conditions, Bypass - Inverter a) The UPS switches automatically back to inverter operation
when inverter voltage and frequency are within tolerance limits,
the overload has been removed and the inverter is synchronised with the bypass line (SSI switches on and SSB off).
b) If the UPS unsuccessfully attempts five times within 3 minutes
to switch to inverter operation, the UPS remains in bypass
operation and signals an alarm. After pressing the reset-button
once to reset the audible alarm, it should be pressed a second
time to automatically switch back to inverter operation.
c) If the UPS remains blocked on bypass operation and a mains
failure occurs, the UPS will switch automatically to inverter
operation if the inverter voltage and frequency are within
tolerance and the inverter is synchronised to the mains.
SOLA 4000 - General System Description
JUE 401264
1.7 Maintenance Bypass
The maintenance bypass function is to supply power directly to the
connected load during UPS maintenance. The bypass consists
essentially of one switch IBY.
With SOLA 4000 series UPS systems, switching from different
operating modes to maintenance bypass can be performed without
interruption. With the maintenance bypass on, the UPS system
may be completely switched off, thus permitting maintenance work
to be carried out safely ( there will only be voltage at the input and
output terminals and their connections to the circuit-breakers).
In order to prevent erraneous switching of the maintenance bypass
switch IBY that could possibly cause parallel connection of the
bypass line and the inverter line, IBY is electronically interconnected with the static inverter switch SSI. Thus, during actuation of
IBY, switch SSB will be closed and switch SSI opened automatically, preventing parallel operation of the maintenance bypass
network and the inverter.
1 UPS Assembly
As an option, an external wall-mounted no-break maintenance
bypass switch (see FIG. 1.6.1) may be supplied by SOLA.This
switch provides simple one-step transfer to maintenance bypass
(version 1) without the possibility of erraneous switching and
without interruption to the load.For the version 2 type maintenance
bypass, an additional position is provided in order to completely
isolate the UPS with the one bypass switch.In this way, the UPS
may be isolated totally from all supply by switching off the input
supply to the UPS.
1.8 Hot-Standby Systems
A hot-standby UPS system basically consists of two (or more)
single UPS units which operate independently of each other. Any
one unit can be feeding the load at any time.
• All units are continuously in operation; but only one is supplying
the load, at any one time.
• In case of a failure in the unit currently supplying the load,
another unit is ready to takeover the load without an interruption on the output side. i.e. the load is still supplied with conditioned and stabilised power.
• The load is supplied by the static bypass, only if there is no
inverter ready in the system to takeover the load.
SOLA 4000 - General System Description
JUE 401264
1 UPS Assembly
1.9 Parallel-Redundant Systems
A parallel UPS system consists of 2 to 8 single UPS units connected in parallel, sharing the load current equally. Each unit has an
individual static bypass, thus ensuring also redundancy of the static
bypasses in a redundant system, i.e. if one static bypass should fail,
the bypass system will still be available.
There is no common electronic device for the parallel system. Each
unit has its own parallel-operation electronics that controls all of its
functions, thus ensuring perfect redundancy.
1.10 Parallel Systems
This is identical to the configuration in section 1.9 except that the
rated load is normally equal to the rating of the UPS and there is
therefore no redundant unit. UPS units of different kVA ratings may
be connected in parallel in this configuration, proportionally sharing
the load.
Note that the parallel configuration is identical to the parallelredundant configuration if the load is reduced to a value such that
the system minus one (or more) units is capable of supplying the
reduced load. Therefore one (or more) units become redundant and
the control is identical.
FIG. 1.8 - Parallel Operation - Block Diagram
SOLA 4000 - General System Description
JUE 401264
2 OPERATING PANEL
2.1 Functional Description
The operating panel is the user-interface of the UPS. It offers the
following functions:
• Indication of important data (actual load, battery charging
status, battery autonomy during the "BACK UP" phase)
• Protective functions ( Battery Running Down, Battery Test)
• Indication of the UPS operating mode
• Alarm signalling (audible and visual)
• Start push button
• Reset function after retransfer blocked condition
• Emergency-Power-Off function
The panel can be subdivided in four functional sections:
1. Block diagram with status LEDs
2. Battery autonomy and charging status
3. Percentage of load supplied
4. E.P.O. push-button
2 Operating Panel
2.2 Remote Monitoring
The operating panel provides an option to communicate with a
computer through RS232 and RS485 interfaces. The RS232 serial
interface communicates with a PC or mainframe computer, with a
SNMP protocol (SEC). With the RS485 interface it is possible to
transmit all necessary data up to a distance of 400m or to connect
a remote monitoring panel.
2.3 Emergency Power Off
In case of emergency it is possible to switch off the entire UPS
system. This is done by simultaneously pressing the "Emergency
Power Off" (E.P.O.) push-buttons located on the operating panel.
This function provides UPS disconnection from the load and the
battery, when a separate shunt-trip battery circuit breaker is installed.
In the case of parallel and hot-standby configurations, activating
E.P.O on one unit, automatically switches OFF the entire system
(when IUG is closed on that unit).
Contents of JUE 401265
SOLA 4000 - Installation and Initial Start-Up
Chapters
1 INSTALLATION 3
1.1 Mechanical Installation 3
1.2 Electrical Installation 8
1.3 Install. of Additional Optional Cabinets 13
1.4 Installation of an External Maintenance
Bypass 16
1.5 CPNET Interface Card 18
1.6 Remote Emergency Power off 20
1.7 Diesel - Generator Operation 21
1.8 Common Alarm Contacts 22
1.9 Remote Reset 22
1.10 Installation of Hot-Standby Systems 23
1.10.1Installation of the Interconnection Cable 25
1.11 Installation of Parallel Systems 26
1.11.1Installation of the Interconnection Cable 29
1.12 Battery Installation 30
1.12.1Installation of the Internal Batteries SOLA
4000 10-30kVA 30
1.12.2Installation of External Batteries 32
Figures
FIG.1.1.1 Moving the UPS 10-60kVA units 3
FIG.1.1.2 10-60kVA UPS floor space 4
FIG.1.1.3 80-120kVA UPS floor space 4
FIG.1.1.4 AC001 transformer cabinet 4
FIG.1.1.5 AC002 transformer cabinet 4
FIG.1.1.6 10-60kVA UPS room size 5
FIG.1.1.7 80-120kVA UPS room size 6
FIG.1.1.8 80-120kVA UPS room size 7
FIG.1.2.1 UPS connection diagram, version 1 9
FIG.1.2.2 UPS connection diagram, version 2 11
FIG.1.3.1 UPS connection diagram, with input
and output transformers 13
FIG.1.3.2 UPS connection diagram, with bypass
input transformer 13
FIG.1.3.3 UPS connection diagram, with THD
filters 14
FIG.1.3.4 Installation of 12-pulse units without
galvanic isolation 15
FIG.1.3.5 Installation of 12-pulse units with
galvanic isolation 15
2 INITIAL START- UP 38
2.1 Start-Up Procedure 38
3 ADDITIONAL START- UP
PROCEDURE FOR MULTI-UNIT
SYSTEMS 42
3.1 Start-Up Procedure for
Hot-standby Systems 42
3.2 Start-Up Procedure
for Parallel Systems 43
We reserve the right to modify the contents of this document without notice. BEST POWER- BORRI ELETTRONICA INDUSTRIALE S.r.l Via 8 Marzo Soci, Bibbiena (AREZZO)
ISSUED
See Rev. Doc. JSE401479B08.08.97
See Rev. Doc. JSE401490
C
See Rev. Doc. JSE401547D23.09.97 T. Boon
04.02.97
01.09.97
M. Porpora
M. Porpora
FIG.1.4.1 External maintenance bypass switch,
version 1 16
FIG.1.4.2 External maintenance bypass switch,
version 2 17
FIG.1.6.1 Connection of remote EPO with N.C.
contact 20
FIG.1.6.2 Connection of remote EPO witn N.O.
contact 20
FIG.1.6.3 Connection of remote emergency
power off - input and battery circuit
breaker trip circuit 20
FIG.1.7.1 Connection for diesel generator
operation - syncronisation disable 21
FIG.1.7.2 Connection for diesel generator
operation - second level current
limitation 21
M. Porpora
T. Boon
04.02.97
A4 441
JUE 401265
SOLA 4000 - Installation and Initial Start-Up
SOLA 4000 - Installation and Initial Start-Up
FIG.1.8.1 Connec. of remote common alarm 22
Figures
FIG.1.9.1 Connection of remote reset 22
FIG.1.10.1Interconnection of hot-standby units
with integrated maintenance bypasses
and separate bypass terminals 23
FIG.1.10.2Interconnection of hot-standby units
with external maintenance bypass and
separate bypass terminals. 24
FIG.1.10.3Interconnection of control BUS cable
for hot-standby units 25
FIG.1.11.1Interconnection of parallel units with
integrated maintenance bypasses and
separate bypass terminals. 27
FIG.1.11.2Interconnection of parallel units with
common maintenance bypass and
separate bypass terminals 28
FIG.1.11.3Location of connectors on the
IBYBP-CP pcb 29
FIG.1.11.4Interconnection of control BUS cables
between parallel units 29
FIG.1.12.1Internal battery connections 31
FIG.1.12.2B3/38: battery tray in the first level 32
FIG.1.12.3B3/38: batt. trays in the second and the
third level 32
FIG.1.12.4Battery cabinet B3/38 32
FIG.1.12.5B3/38:switch IB and terminals 33
FIG.1.12.6B3/38 internal electrical connec. 34
FIG.1.12.7Battery cabinet B3/65 35
FIG.1.12.8B3/65:switch IB and terminals 35
FIG.1.12.9B3/65 internal electrical connec. 36
FIG.1.12.10UPS with additional batt. cabinet 37
SOLA 4000 - Installation and Initial Start-Up
1 Installation
1 INSTALLATION
1.1 Mechanical Installation
Equipment Delivery and Storage After delivery, check equipment for any damage that may have
occurred during shipment. The shipper and your SOLA agency
must be notified in writing about damages due to shipment, including a detailed description of visual defects. If you do not wish to
install the equipment immediately, please observe the following
storage recommendations:
• Store equipment in a vertical position in a well conditioned
room, protected against humidity. Do not store the equipment
in close proximity to frequently used passageways and keep it
away from movable parts.
• If the UPS system is already unpacked, please ensure storage
in a clean environment protected from dust, away from heat
sources.
Handling the UPS System The UPS can be simply lifted and moved by means of a lifting
truck or a fork lifter for 80-120kVA units. For 10-60kVA units,
remove the front side and rear side base sheets and attach two
angle irons with 8MA bolts to the right front and rear side of the
UPS. The UPS can now be moved with a lifting fork. Remove the
angle irons when the UPS is set in the correct position.
Caution: Secure equipment against being knocked over
Setting Up The UPS system should be installed in a dry, clean and lockable
room. Provisions have to be made to remove heat created by the
system. Under all installation conditions, the unrestricted flow of
cooling air must be assured.
SOLA 4000 - Installation and Initial Start-Up
Weight
1 Installation
Floor Space Required
Type
SOLA
4000
100 840 - 1219
120 870 - 1263
TAB. 1.1.1 UPS weight
Weight
without
Battery
[kg]
10 310 597 1277(*)
15 310 597 1277(*)
20 335 622 1330(*)
30 350 637 1362(*)
40 480 - 1026
60 520 - 1112
80 810 - 1176
Weight
with
Battery
[kg]
Static
Load
-
[kg/m²]
FIG. 1.1.2 10-60kVA UPS floor space FIG. 1.1.3 80-120kVA UPS floor space
SOLA 4000 - Installation and Initial Start-Up
1 Installation
Room Size for 10-60 kVA UPS
FIG. 1.1.6 UPS 10-60kVA room size
SOLA 4000 - Installation and Initial Start-Up
Room Size for 80-120 kVA UPS with
auxiliary AC001 cabinet
AC001 cabinets are used for SOLA 4000 units with 12 pulse
chargers without galvanic separation and with THD Filters.
1 Installation
FIG. 1.1.7 UPS 80-120kVA room size
SOLA 4000 - Installation and Initial Start-Up
1 Installation
Room Size for 80-120 kVA UPS with
auxiliary AC002 cabinet
AC002 cabinets are used for SOLA 4000 units with 12 pulse
chargers with galvanic separation and with auxiliary transformers.
FIG. 1.1.8 UPS 80-120kVA room size
SOLA 4000 - Installation and Initial Start-Up
1.2 Electrical Installation
This equipment must be installed by qualified service personnel.
Switch off IRP, IRE, IB, IUG, IBY circuit breakers to completely
isolate the equipment.
Earth leakage protection: this device has high leakage current
towards protective earthing. Earth leakage circuit breakers
shouldn't be installed upstream from this equipment or a correct
threshold should be set.
High leakage current - it is essential to connect the protective
earth before connecting the power supply.
All primary power switches installed remotely from the UPS area
must be fitted with the following label: "Isolate uninterruptible
power supply (UPS) before working on this circuit".
1 Installation
General
All electrical connections must be made in accordance with local
standards and all input terminals (1-L1, 1-L2, 1-L3 and, if existing,
4-L1, 4-L2, 4-L3) must be protected by external fuses. The tables
give recommended values for fuse sizes and cable cross-sections.
These may vary, depending on local standards. They are valid for
voltages 380/220 V, 400/230 V and 415/240 V. Ensure clockwise
connection of conductors L1, L2 and L3 at input and output terminals.
If possible, install battery cables separately from other power
cables in order to avoid possible RF interference. Before wiring,
open all system switches (IRP, IRE, IBY, IUG) plus the battery
switch (IB).
SOLA 4000 - Installation and Initial Start-Up
1 Installation
Version 1 SOLA 4000 with Common Input
for Rectifier and Bypass
FIG. 1.2.1 UPS connection diagram, version 1
(*) Note: Internal Battery only for 10-30kVA units
(**) Note: Customer supplied input fuses - see table 1.2.1
SOLA 4000 - Installation and Initial Start-Up
Version 1 SOLA 4000 with Common Input for
Input Cables / Fuses
1 Installation
Rectifier and Bypass
Output / Battery Cables and Max. Cur-
rent Ratings for Battery Overcurr. pro-
tection
Type
SOLA
4000
10 4x10 25 16
15 4x10 35 16
20 4x16 50 16
30 4x25 63 25
40 4x35 100 25
60 4x35 125 25
80 4x70 160 50
100 4x70 200 50
120 4x120 250 70
TAB.1.2.1 UPS input cables
and fuses, version 1
Type
SOLA
4000
100 2x95 4x70 250
120 2x120 4 x120 300
Input
cables
[mm²]
Battery
cables
10 2x16 4x10 25
15 2x16 4x10 40
20 2x25 4x16 50
30 2x25 4x35 75
40 2x35 4x25 100
60 2x50 4x35 150
80 2x70 4x50 200
[mm²]
Input
fuses
[A]
Output cables
earth
cable
[mm²]
[mm²]
Max. inv. input
current
(Vdc=320V)
TAB.1.2.2 UPS output cables and fuses, version 1
SOLA 4000 - Installation and Initial Start-Up
1 Installation
Version 2 SOLA 4000 with Separate Inputs
for Rectifier and Bypass
FIG. 1.2.2 UPS connection diagram, version 2
(*) Note: Internal Battery only for 10-30kVA units
(**) Note: Customer supplied rectifier input fuses - see table 1.2.5
(***) Note: Customer supplied bypass input fuses - see table 1.2.5
SOLA 4000 - Installation and Initial Start-Up
Version 2 SOLA 4000 with Separate Inputs
Input Cables
Type
SOLA
4000
10 3x10 4x10 16
15 3x10 4x10 16
20 3x16 4x16 16
30 3x25 4x25 25
40 3x25 4x25 25
60 3x35 4x35 25
80 3x50 4x50 50
100 3x70 4x70 50
120 3x120 4x120 70
Rect.
cables
[mm²]
1 Installation
for Rectifier and Bypass
Bypass
cables
[mm²]
earth
cable
[mm²]
Input Fuses
Output / Battery Cables
TAB. 1.2.3 UPS input cables, version 2
Type
SOLA
Rect.
Fuses
4000
10 25 25
15 35 35
20 50 50
30 63 63
40 100 100
60 100 125
80 125 160
100 160 200
120 200 250
TAB. 1.2.4 UPS input fuses, version 2
Type
SOLA
4000
10 2x16 4x10 25
15 2x16 4x10 40
20 2x25 4x16 50
30 2x25 4x35 75
40 2x35 4x25 100
60 2x50 4x35 150
80 2x70 4x50 200
100 2x95 4x70 250
120 2x120 4 x120 300
Battery
cables
[mm²]
Bypass Fuses
[A]
[A]
Output cables
[mm²]
Max. inv. input
current
(Vdc=320V)
TAB. 1.2.5 UPS output cables and fuses, version 2
SOLA 4000 - Installation and Initial Start-Up
1 Installation
1.3 Installation of additional optional cabinets
SOLA 4000 with input and output transformers for voltage adaption
FIG. 1.3.1 UPS connection diagram, with input and output transformers to adapt the
UPS to the on-site voltage.
SOLA 4000 with isolation transformer of the bypass supply
FIG. 1.3.2 UPS connection diagram, with bypass input transformer to isolate the
neutral line (** 4-N may be connected to the supply neutral or earth or left disconnected.)
(*) Note: Internal Battery only for 10-30kVA units
SOLA 4000 - Installation and Initial Start-Up
SOLA 4000 with THD filters
1 Installation
FIG. 1.3.3 UPS connection diagram, with THD filters
(*) Note: Internal Battery only for 10-30kVA units
SOLA 4000 - Installation and Initial Start-Up
1 Installation
SOLA 4000 with 12-pulse charger / rectifier
FIG. 1.3.4 Installation of 12-pulse units without galvanic isolation
SOLA 4000 with 12-pulse charger / rectifier and galvanic isolation of the input supply.
FIG. 1.3.5 Installation of 12-pulse units with galvanic isolation
(*) Note: Internal Battery only for 10-30kVA units
SOLA 4000 - Installation and Initial Start-Up
1.4 Installation of an External Maintenance
Bypass
When an external maintenance bypass is installed, a normally
open, voltage free contact must be available. This contact must be
connected to the connector M4, Pin1 and Pin 2 at the top left hand
corner of the mother board for the inverter/bypass electronics
(IBYBP-CP see figure 1.10.3).
If the standard SOLA no-break wall-mounted maintenance bypass
switch is used (optional) in the MB3 cabinet, a normally open
contact is provided.For the version 2 maintenance bypass (3
position), an additional contact is provided which automatically
isolates the UPS system (EPO) when switched to the "UPS ISOLATED" position (see FIG 1.4.2).
1 Installation
FIG.1.4.1 External Maintenance Bypass Switch Version 1 (2 position)
SOLA 4000 - Installation and Initial Start-Up
1 Installation
FIG.1.4.2 External Maintenance Bypass Switch Version 2 (3 position)
Note1: For Hot-Standby or parallel systems, it is sufficient to
feed one contact into one unit only, however they may be
connected in parallel at M4 (of IBYBP-CP) Pin1 and Pin 2 for
all units. In this case separate terminals may be provided
within the MB3 cabinet (see FIG. 1.9.2 and 1.10.2)
Note2: The cable used must be twisted pair, with a total shield.
This shield must be grounded at one end (the cabinet of the
UPS may be used).
SOLA 4000 - Installation and Initial Start-Up
1.5 CPNET Interface Card
The CPNET interface card is used for remote signalling of four
standard alarm conditions by means of voltage-free contacts in
programmable configurations.
1.5.1 Installation
The CPNET interface card is a small pcb that is installed directly
underneath the CPU/NCP pcb, inside the front door of the UPS
cabinet.
It is connected to the UPS via the connector CN1 on the CPNET
pcb to CN10 on the CPU/NCP pcb.
It can be connected to remote devices via two different connectors:
• CN2, a 9 pin sub-D connector for standard computer connection. The following interface cables are available (see also
JUE 300 599):
- IBM AS-400
- Novell
- 3-COM
- Banyan Vines
• M1, a terminal block for individual configurations.
1 Installation
1.5.2 Functions
Contacts for the following alarm conditions are available:
Inverter Operation (N) (CN1, pin 6)
Bypass Operation (B) (CN1, pin 8)
Mains Failure (MF) (CN1, pin 5)
Battery Low (BL) (CN1, pin 7)
By means of the DIP switch SW1, the single relays and output pins
can be configured for each requirement.
SW1
1 2 3 4 5 6 7 8
0 0 0 1 0 1 1 0 IBM-AS400
0 0 0 0 - - 0 1 NOVEL
0 0 1 0 - - - - 3-COM
0 0 0 0 - - - - BANYAN-VINES
0 1 1 0 - - 0 1 BORRI VIKING
0 0 1 0 - - 0 1 BORRI SIDEKICK
0 0 1 0 - - 0 1 AMERICAN POWER
INTERFACE
TAB. 1.5.2.1 Programming of the CP-NET pcb
Note: Maximum rating of relay contacts: 250Vac, 6A (only when using
connector M1)
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