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Project:

Customer:

2.2 MTPA DHDT PLANT - VADODARA REFINERY


INDIAN OIL CORPORATION LTD

P.O.: FAO 3293/2007 &


3293/2007/18008326
DUAL UPS Apodys 70kVA
400VDC 1x110V

Installation, Operation and Maintenance manual

Chloride ref: 318107


Project ID: 080930 / 05
OF: W015939

INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
INDIAN OIL CORPORATION LTD
2.2 MTPA DHDT PLANT - VADODARA
REFINERY PROJECT
P.O. FAO 3293/2007 & 3293/2007/18008326
DUAL UPS Apodys 70kVA 400VDC 1x110V
CHLORIDE REF : DT 318107
PROJECT : 080930 / 05
OF : W015939

CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF REVISIONS
ISSUE

DATE

REVISED PAGES

00

07/09/09

First Issue

Page 2 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF CONTENTS

Title

Page

1. SAFETY

1.1. GENERAL

1.2. NATURE OF HAZARD

1.3. SAFETY PRECAUTIONS

1.4. EMERGENCY ACTION AND TREATMENT

1.5. BATTERY

1.6. COSHH STATEMENT

11

2. DESCRIPTION AND OPERATION

14

2.1. DESCRIPTION

14

2.2. TOPOLOGY

14

2.3. OPERATING MODES

17

3. SYSTEM SPECIFICATION

22

3.1. CHARACTERISTICS

22

4. INSTALLATION

23

4.1. HANDLING ON ARRIVAL

23

4.2. STORAGE

24

4.3. PUTTING INTO INSTALLED POSITION

24

4.4. ELECTROLYTE / CELL OIL

25

4.4.1. Cells delivered filled

25

4.4.2. Cells delivered empty

25

4.5. CABLE ENTRIES

25

4.6. TERMINAL CONNECTIONS

25

4.6.1. Phase rotation

25

4.6.2. Battery

25

4.6.3. Neutral

26

4.6.4. Earth

26

Page 3 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

4.7. VENTILATION

26

4.8. BATTERY-VENTED CADMIUM NICKEL

26

4.9. BATTERY INSTALLATION

26

5. OPERATING INSTRUCTIONS

28

5.1. LIGHT EMITTING DIODES (LEDS)

29

5.2. DISPLAY

30

5.3. CONTROL PUSH-BUTTONS

31

5.4. PRESENTATION OF THE MENUS

32

5.5. GENERAL MENU

32

5.6. UPS BLOCK MENUS

33

5.7. CONTROL PANEL MENUS

36

5.8. CHANGE CHARGER MODE

41

5.9. MEASURES, FAULTS AND WARNINGS

42

5.10. HEADING

42

5.11. RECTIFIER/CHARGER INFORMATION

45

5.12. BATTERY INFORMATION

46

5.13. INVERTER INFORMATION

46

5.14. RESERVE INFORMATION

47

5.15. LOAD AND STATIC SWITCH INFORMATION

47

5.16. OPERATING INSTRUCTIONS

48

5.16.1. First start-up

48

5.16.2. Maintenance procedure

50

5.16.3. Transfer to maintenance for a stand-alone inverter

52

5.16.4. Return from maintenance for a stand-alone inverter

52

5.16.5. Global maintenance procedure

53

5.16.6. Black start procedure

53

6. ROUTINE MAINTENANCE

54

6.1. GENERAL

54

6.2. ONCE A WEEK

54

6.3. ONCE A MONTH

54

6.4. AT LEAST 4 TIMES PER YEAR

55

Page 4 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

6.5. ANNUALLY

55

6.6. FANS

55

7. FAULT DIAGNOSIS

56

7.1. CHARGER DISPLAY MENU

57

7.2. CHARGER DEFAULTS

58

7.3. CHARGER VOLUNTARY STOPPED

59

7.4. CHARGER WARNING

59

7.5. BATTERY FAULT

60

7.6. BATTERY WARNING

60

7.7. INVERTER DISPLAY MENU

61

7.8. INVERTER FAULTS

62

7.9. INVERTER VOLUNTARY STOPPED

63

7.10. INVERTER WARNING

63

7.11. RESERVE WARNING

64

7.12. AC LOAD/ STATIC SWITCH FAULT

64

7.13. AC LOAD/STATIC SWITCH WARNING

65

8. SPARE PARTS

66

8.1. GENERAL NOTES

66

9. DRAWINGS

67

9.1. GENERAL NOTES

67

10. ATTACHMENTS

68

10.1. BATTERY MANUAL

68

Page 5 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

LIST OF ILLUSTRATIONS
Title

Page

Figure 2.1 : Block Diagram

14

Figure 2.2 : Voltage Current Characteristic of Charger

15

Figure 2.3 : Normal Mode

17

Figure 2.4 : Primary AC Supply Fail Mode

18

Figure 2.5 : DC Alarms During Primary Supply Failure

18

Figure 2.6 : Reserve to Load

19

Figure 2.7 : Maintenance Bypass Mode

20

Figure 2.8 : One UPS Fail

21

Page 6 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

1. SAFETY
Title

Page

1.1. GENERAL

1.2. NATURE OF HAZARD

1.3. SAFETY PRECAUTIONS

1.4. EMERGENCY ACTION AND TREATMENT

1.5. BATTERY

1.6. COSHH STATEMENT

11

1.1. GENERAL
Read this section and this manual before starting work on any part of the system.
When working on live equipment (batteries are always live), a second person who is aware of
all safety precautions and emergency actions should be present at all times.
It is the responsibility of each individual to be aware of national legislation, local legislation
and site rules governing safety and working practices. If in doubt ask.
Use only good quality insulated tools and accessories, properly maintained and calibrated
instruments, and suitable and adequate supports and lifting equipment.
It is essential that all safety instructions are strictly observed.
Note

A note in this style is used to emphasise an important point in the text

CAUTION :

USED TO PREVENT DAMAGE TO EQUIPMENT

WARNING :

A WARNING IS USED TO ALERT PERSONNEL TO


HAZARDS TO PERSONAL SAFETY.

Installation, maintenance and repair of the equipment and batteries should only be
undertaken by trained, experienced and authorised electrical personnel.
The handling, installation and maintenance of the battery associated with this equipment must
be in accordance with the instructions and safety precautions published by the battery
manufacturer and supplied with the battery.

Page 7 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

1.2. NATURE OF HAZARD


ELECTRICAL ENERGY can be supplied from the battery, the charging equipment, the AC
supply or the external alarm or auxiliary control terminals. The battery terminals are LIVE at
all times. A short circuit, even on a discharged battery, will result in a high current which can
cause personal injury, fire or damage to the battery or battery cables.
BATTERY ELECTROLYTE in ALL batteries is dangerous and can cause severe burns if
allowed to come into contact with the skin or eyes. It will also attack clothing and some paint
finishes and metals. NICKEL CADMIUM batteries contain potassium hydroxide (Caustic
Potash) solution.
HYDROGEN and OXYGEN are given off at the cell plates during charging and can be
present at other times, particularly if cells are moved or shaken. Hydrogen in conjunction with
air or oxygen can be explosive in the presence of sparks or flame.
In sealed cells the amount of gas produced is reduced by the use of restricted charging
techniques. If sealed cells are over charged hydrogen and oxygen will be released to the air
via the pressure vent.
Battery cells or cellblocks can be very heavy and often have to be moved to positions with
difficult access. When working on batteries with many cells or blocks, muscle strain may
occur suddenly or after battery installation is complete. The immediate results and long term
effects can be dangerous and painful.
1.3. SAFETY PRECAUTIONS
Use only insulated tools, particularly when connecting a battery. Stand on a rubber mat.
Personal effects of metal such as rings, watches, bracelets and necklaces which may cause a
short circuit and metal objects (pens, tools etc) which may fall from open pockets while
bending over batteries or chargers should be removed.
Transfer to MAINTENANCE MODE (See Section 5) before working on the equipment.
If it is necessary to make adjustments with the equipment connected to the AC supply and/or
the battery, remove only those protective covers which are absolutely necessary for access.
Always use eye protection and rubber gloves when handling cells. Handle cells with care,
ensuring they are kept upright.
Use properly constructed staging or platforms as a resting-place close to the final position and
enlist assistance with large cells or large numbers of cells. Keep the back straight and upright
when lifting cells. Use only proper lifting techniques.
Do not smoke. Do not use open flames. Avoid creating an arc or sparks when working on this
equipment. Avoid wearing clothing which is susceptible to discharge of static electricity.
After work is complete, refit all protective covers and close and lock all doors.

Page 8 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

1.4. EMERGENCY ACTION AND TREATMENT


ELECTRICAL SHOCK - Immediate action is essential. Severe electric shock may affect
heart action and breathing.
Make sure it is safe to approach. If the casualty is in contact with a live conductor, isolate by
switching off the supply. See section 5 "EMERGENCY SHUTDOWN".
If this is not possible, or it is doubtful whether the system is electrically isolated, stand on dry
insulating material and pull or push the casualty clear using dry insulating material, e.g. wood,
plastic, fabrics etc.
If necessary give artificial respiration. Seek the assistance of others to summon medical
attention.
ELECTRICAL BURNS - Apply a dry sterile dressing.
ELECTROLYTE CONTACT - EYES - Irrigate the eyes with a saline solution. If saline
solution is not available wash with clean running water for at least 10 minutes
SKIN - Wash skin burns with plenty of clean water. Remove any contaminated clothing.
Cover the area with dry gauze.
IN ALL CASES SEEK IMMEDIATE MEDICAL ATTENTION.
ELECTROLYTE SPILLAGE - These should be washed away using large volumes of clean
water or mopped up using absorbent material which should then be sealed in secure
containers and sent to a recognised chemical disposal company.
Operatives handling spillage should wear adequate clothing including eye protectors and
gloves. Electrolyte will attack many fabrics. In the event of spillage on clothing, the garments
should be removed and washed thoroughly in large volumes of clean water or discarded.
1.5. BATTERY
WARNING :

IN CASES WHERE THE UNIT IS NOT BEING USED, E.G.


DURING MAINTENANCE, IT IS RECOMMENDED TO
DISCONNECT THE BATTERY TO AVOID IT DISCHARGING
AND BEING DAMAGED.

Nature of hazard.
The hazards are :
Risk of electric shock
Risk of electric burns
Risk of chemical burns
Risk of poisoning

Page 9 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

ELECTRIC SHOCK
An electric shock from d.c. is more damaging than a shock from a.c. of the same voltage
because d.c. has the characteristics "NO-LET-GO" due to the muscles being contracted by the
single direction of flow of the current. Risk of d.c. shock between battery terminals and earth
is limited in this equipment by incorporating double wound transformers in both the inverter
and rectifier so that the entire d.c. link is floating. Anyone coming into contact with it
experiences only the equalising charge which is unlikely to cause injury. However, this
protection could be defeated if, for example, a metal tool were to fall between a battery
terminal and earth (wooden battery stands are preferred for this reason).
The system would continue to perform normally but the battery and d.c. link would be in a
dangerous condition for anyone intending to carry out maintenance work on it.
Where an earth fault detector is fitted this will raise an alarm. The principle of operation is to
verify that the d.c. positive and negative rails are respectively at symmetrical voltages with
respect to earth. Any abnormal short, even of high resistance, will disrupt this symmetry.
WARNING

IF THE EARTH FAULT ALARM IS ACTIVE DO NOT CARRY


OUT MAINTENANCE ON THE BATTERY.

The other possibility for electric shock would be if a person were to come into contact with
two distant battery terminals in the same string. This possibility is avoided by arranging for
the battery layout to be configured so that the maximum distance separates the highest voltage
difference.
ELECTRIC BURNS
The prospective short circuit current from a battery is very great. So even a modest cell will
deliver over a thousand amps into a short circuit such as a metal watch strap, ring or an
uninsulated tool. The battery assembly may consist of well over a hundred cells in series in
many applications so the potential for serious injury exists.
WARNING

REMOVE METAL RINGS AND WATCHSTRAPS WHEN


WORKING WITH BATTERIES. USE PROPERLY
INSULATED TOOLS.

CHEMICAL BURNS FROM ELECTROLYTE


The electrolyte is Potassium Hydroxide (Caustic Potash). It is corrosive to clothing and to
living tissue. Even minute traces can cause irritation and make holes in clothes.
Protect the eyes nose and mouth either with goggles and face mask or wear a full face visor.
Protect the body with all enclosing overalls.
Protect the hands with gauntlets.
Protect the feet with boots that have sealed seams. Stitched seams can allow seepage.
An eyewash must be available and any splashes must be flooded with copious amounts of
water or saline solution to dilute the electrolyte. Seek medical attention.
Neutralising agent must be on hand. Scatter it on any electrolyte spills.

Page 10 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

NOTE: Lead acid electrolyte is acidic, Nickel Cadmium electrolyte is alkaline so


different neutralising agents are needed.
POISONING
If electrolyte is swallowed it will be corrosive to internal organs.
Medical opinion is divided on whether to attempt to dilute it with milk or water or to do
nothing until medical help arrives.
Therefore at the outset consult the local medical authority who would have to deal with an
emergency and post suitable notices in the battery room.
EXPLOSION
During the recharge cycle the voltage of the battery will be raised above the gassing voltage
Hydrogen and oxygen will be given off .
Risk of explosion exists when the concentration of hydrogen in air is more than 3.8%.
Therefore the battery room must be adequately ventilated. Volume flow for the required
air change can be calculated as follows;
Q = 55 x N x I ( for vented cells )
Where
Q = The required volume flow in litres / hour
N = The number of cells
I = The maximum charge current
This calculation applies to normal land based installations. Shipboard installations need twice
this calculated flow rate in order to comply with maritime regulations.
If this damages the battery casing there can be a flood of battery electrolyte with risk of acid
burns to the feet of anyone caught in the way. Therefore approach any battery explosion with
caution. The battery room must be adequately ventilated to disperse gases, particularly during
Charge mode or Boost charge. Preclude all sources of ignition. Do not smoke. Ensure all
electrical connections between cells are securing and tight to prevent sparking.
1.6. COSHH STATEMENT
When this equipment finally reaches the end of its useful life it must be disposed of with due
care. It contains material which could present a variety of hazards to the environment and to
living organisms if not dealt with properly. Contact a reputable disposal service. The
following information is a guide to the disposal problems as known at the time of
manufacture.
BATTERY ELECTROLYTE
Nickel Cadmium batteries contain a corrosive electrolyte of Potassium Hydroxide (Caustic
Potash). It must never be washed into public or general-purpose drains.

Page 11 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

BATTERY PLATES
The plates will be of Nickel, Oxides of Nickel, Cadmium and Oxides of Cadmium or a
combination of these dependant upon the condition of the battery. The plates may be porous
and impregnated with Potassium Hydroxide.
SEMICONDUCTORS
There are large semiconductors mounted on extruded aluminium, finned heat sinks. These are
thyristors and diodes. They are all doped silicon semi conductors incorporating P type and N
type silicon. These materials will be hermetically sealed inside discrete devices. Some contain
silicon, copper and other metals and metallic compounds including beryllium. They are sealed
and must not be opened. If the seal is broken, use protective gloves when handling the semiconductors and seal them into tough plastic bags before disposal.
PRINTED CIRCUIT BOARDS
The circuit boards are constructed of fibreglass and resin board with copper track. The
components include metal film resistors, silicon transistors, capacitors (both bipolar and
electrolytic). Silicon diodes, micro chips type CMOS, high speed CMOS and TTL.
INDICATOR PANEL
The indicator panel includes light emitting diodes and liquid crystal displays.
WIRES AND CABLES
The internal wiring is of copper bar and copper wire covered with flame retardant PVC.
HEATSINKS
These are of aluminium.
METAL PARTS
These are of mild steel painted with an epoxy resin paint finish.
CAPACITORS
These contain no PCBs or similarly toxic materials. Capacitors are sealed and must not be
opened. If the seal is broken use protective gloves when handling the capacitors and seal them
into tough PVC bags before disposal.

Page 12 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Restricted Sales Distribution


WARNING:
This is a product for restricted sales distribution to informed
partners. This product must be operated by only personnel
authorised to enter restricted access location. Installation
restrictions or additional measures may be needed to prevent
disturbances.

Page 13 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

2. DESCRIPTION AND OPERATION


Title

Page

2.1. DESCRIPTION

14

2.2. TOPOLOGY

14

2.3. OPERATING MODES

17

2.1. DESCRIPTION
The Uninterruptible Power System (UPS) is designed to supply AC sinusoidal, electric power
that cannot be interrupted by abnormal occurrences on the public electricity supply. It is
designed on the "double conversion" principle whereby the public supply is used to power a
battery charger in order to store energy to be used during a power cut. This DC supply is then
inverted within the equipment to a pure quality sine wave which is immune to defects on the
incoming AC supply.
2.2. TOPOLOGY
The System consists of two UPS equipments connected in parallel to share the load. Each unit
on its own is rated to support the full load. If either one fails then the surviving unit will
sustain the full load without break.
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.1 : Block Diagram

Page 14 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Each equipment consists of four major parts, see Figure 2.1. Block Diagram, the Rectifier/
Charger, the Battery, the Inverter and the Static Switch. The reserve is through a transformer.
VOLTAGE
Boost
Charge
Float

CURRENT

Figure 2.2 : Voltage Current Characteristic of Charger


RECTIFIER/CHARGER
Converts the Primary AC supply to a regulated D.C. voltage which charges the battery,
powers the inverter and therefore the load. It operates in four possible modes.
Mode 1.

FLOAT MODE. This is the normal mode. It is a constant-voltage charge mode so


battery charge current will tend to taper off to near zero as the battery becomes
fully charged. The voltage chosen is that value at which the internal losses are
compensated by the charge current into a charged battery. The battery is
maintained fully charged yet remains below gassing voltage so that the rate of
loss of electrolyte is negligible.

Mode 2.

AC SUPPLY FAIL MODE. When the power to the charger is interrupted the
charger stops and without any switching taking place or operator intervention the
battery supplies the inverter and hence the load.

Mode 3.

CHARGE MODE Automatically selected when the AC supply is restored.


Slightly higher constant voltage charge to shorten the time to recharge the
battery. It is controlled by two timers. Timer No.1 selects CHARGE MODE after
an AC supply fail has lasted more than a minimum specified time. Timer No. 2
terminates CHARGE MODE after a specified duration. It can be engaged or
terminated manually by an operator by means of push buttons inside the cubicle.

Mode 4.

BOOST MODE Very high constant voltage charge. Intended for use at
commissioning to complete the forming process of the battery plates. It can only
be engaged manually, by an operator. It is terminated either manually or by an
inbuilt clock. For safety the battery charging current limit threshold reduced
during BOOST mode.

Page 15 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

BATTERY
This stores energy from the charger to be used during a power cut when it will discharge to
power the inverter and load.
The autonomy of the system during a mains fail depends on the amp-hour capacity of the
installed battery.
INVERTER
Converts the d.c. power to sinusoidal a.c. power. Uses a high frequency pulse width
modulation (PWM) switching technique to achieve low distortion sinewave power while
retaining good transient response voltage regulation. Operates in the following modes.
Mode 1.

NORMAL Constant voltage output regulated to 1% for power loading between


0 and 105%.

Mode 2.

OVERLOAD. 105% to 150%.of rated load. Constant voltage output but 10


minute timer initiated which upon expiring will shutdown the inverter. This is
long enough to cope with start up surges and current inrushes in the load.

Note. When the load exceeds 105% the static switch will normally transfer the load to
reserve (if available) so inverter overloads should be a rare occurrence.
Mode 3.

CURRENT LIMIT. When the load is 150% or more of nominal then the inverter
changes to a constant current characteristic to protect itself. This can result in the
output voltage falling drastically. If reserve is available it will have transferred to
reserve immediately instead. If transfers are inhibited for any reason then the
inverter will continue in current limit until either the load subsides to normal or
the 10 minute timer expires.

STATIC SWITCH
The static switch is an automatic, solid state, changeover switch having a make-before-break
action so that no interruption to the load occurs. Therefore the inverter will be permanently
synchronised to the reserve in order to avoid phase jumps or even phase reversals to the load
at the instant of transfer. It monitors the operating status of the various parts of the UPS and
the logic will select one of two modes either INVERTER-TO-LOAD or RESERVE-TOLOAD.
Mode 4.

INVERTER TO LOAD. This is the normal mode for the unit and is automatically
selected whenever possible.

Mode 5.

RESERVE TO LOAD. Transfer to reserve occurs automatically when certain


specified abnormal conditions prevail. It returns to inverter 10 seconds after the
alarm conditions clear.

It has no moving parts, the active components being switching thyristors to preclude arcing
and sparking during switching for long term reliability. Note transfers can take place at any
place in the cycle, they do not have to be at a zero crossover.

Page 16 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

MAINTENANCE BYPASS
For safety during maintenance and repair a wrap-around manual bypass is incorporated into
the equipment. It can be selected only by the operator not by the control logic. It provides
safety isolation of major internal parts for purposes of repair and maintenance.
2.3. OPERATING MODES
NORMAL
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.3 : Normal Mode


The two inverters power the load in parallel sharing the load between them. They are each
synchronised to the reserve supply.

Page 17 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

PRIMARY AC SUPPLY FAIL MODE


RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.4 : Primary AC Supply Fail Mode


The reserve supply may or may not be available depending on the configuration of supplies
into the UPS. Each charger stops and their respective batteries each power the inverter and
hence the load. The DC voltage falls and the following alarms occur
M A IN S
FA IL

FLO A T
V O LTA GE

INVERTER
SHUTDOWN
IMMINENT
LO W DC TRIP

Figure 2.5 : DC Alarms During Primary Supply Failure


When the primary AC supply returns the charger will start in Float Mode after a short AC
supply failure or Charge Mode after a long AC supply Failure.

Page 18 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

RESERVE-TO-LOAD MODE
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.6 : Reserve to Load


mode is selected if:
The output overload is 105% or more returning to the inverters when it falls below 100%
The inverters stop
The inverters are in current limit
The MAINTENANCE switch is operated.
Once on reserve it will wait ten seconds after all alarms have cleared before returning to
inverter.

Page 19 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

MAINTENANCE BYPASS MODE


Used by Maintenance Engineer to facilitate safe maintenance.
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.7 : Maintenance Bypass Mode

CAUTION:

INDISCRIMINATE OPERATION OF THE MAINTENANCE


SWITCH MAY JEOPARDISE THE LOAD AND THE UPS.
SEE SECTION 5. OPERATING INSTRUCTIONS.

Page 20 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

ONE UPS FAIL


RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
CHARGER 2

INVERTER 2

STATIC
SWITCH

INVERTER 1

STATIC
SWITCH

BATTERY
CHARGER 1

BATTERY

Figure 2.8 : One UPS Fail


If one UPS fails, it will be isolated by its own static switch. The surviving UPS will continue
to support the load without break.

Page 21 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

3. SYSTEM SPECIFICATION
Title

Page

3.1. CHARACTERISTICS

22

3.1. CHARACTERISTICS
CHARGER

Nominal AC supply voltage:


Frequency:
Maximum current per phase:
Floating voltage:
Charge voltage :
Boost voltage :
Charger nominal current:
Maximum heat dissipation:
High voltage setting:

Battery
Capacity:
Number of cells
Autonomy

415 V
50 Hz
150 A
413,13 V
483,45 V
498,1 V
209 A
3360 W
triggering: 529 V
KBM310
310 Ah
293
60 min

INVERTER

Inverter nominal power:


Inverter nominal voltage:
Inverter nominal frequency:
Inverter nominal current:
Reserve supply nominal voltage
Maximum heat dissipation
High voltage setting:

70 kVA
110 V
50 Hz
636,4 A
415 V
6,2 kW
triggering: 529 V

Page 22 of 68

EQUIPMENT

CHARGER TEST
REPORT

POWER SUPPLY
Item: CH1
N: L09-0831

WO: 15939
RB: 318107

LOAD
V 3 Ph
Hz

Voltage
415
Frequency
50

TAG CUSTOMER :

Battery type :

Ah
310
293
Cells
Vented Ni Cd

AUTOMATIC MONITORING AND OPTIONS

PRELIMINARY CHECK
Dielectric

2000 Vac

~ / ground

Equalizing / Floating

Dielectric

2000 Vac

= / ground

Equalizing / Floating

Dielectric

2000 Vac

~/=

Boost time

Insulation

500 Vdc

R > 10 M

Compensation U= f (C)

R < 0,10

Battery current limitation

Ground continuity 25Adc

V
A

370
209

Protection device calibration

min

X
N/A
X

62.0

Batt. test: 323.90 V

SAFETY AND ALARMS

15 H

by battery current checking

mV / C / cells

N/A

A equalize / float

3 min. Setting 337.00 V

Time

Earth fault monitoring

Mains fault monitoring

Output

Charger stop alarm

Power sharing of charger

Input protection

Internal lightning

DC fuse tripping

Anti-condensation heater

Signalling test

Communication

Remote alarm test

Test instrument calibration


529.00 V

Low limit alarm / Reset

Pv = 640.0

Losses no load

DC ripple without battery :

+ 10

- 10

Nominal U
Nominal U

I DC

CHECKING
Phase equilibrium (3 phases)

NO LOAD TEST AND DC RIPPLE

Supply

Type : Aucun

Upper limit disconnecting / Reset

CONTROL
Charge
Mode

Type : Modbus

Ufloat =

Regulation

FAUX Ripple without battery

Efficiency

0.42931 %

Ucharge =

V at In/2

413.10

483.50 V at In/2

Uboost =

X
1.0

1.0

95.0

498.10

NOK

Lim. Iboost =

U12

I1

U23

I2

U31

I3

PT

UDC

IDC

P( U x I )

0,1 In 455.0

62 A

PF

Ripple
VRMS

456.0

455.0

485.1 19.3

1.38

In

374.0

375.0

374.0

484.5 206.0

1.30

In

416.0 148.0

417.0

147.0

416.0 147.0

104100.0 484.5 206.0

Lim. I 415.0 148.0

416.0

148.0

415.0 147.0

472.0 209.0

99807

95.88

0.98

2.08
2.18

SUBJECT
External aspect

IEC 529

File conformity

IEC 439

Mounting

IEC 439
IEC 73H0354
Wiring

Identification

IEC 439
Cleaning

CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts

EMC Directive : IEC 62040 - 2


Comments :

Tested by :

MMO

CHECKED

CUST.

COMMENTS

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

LV Directive : IEC 62040 - 1 - 2


Date and customer's visa :

Date : 12/8/2009

Charger Test

Checked by :

LDU Date :
Page
Reference
Index

12/08/09
PGE 18 UK

EQUIPMENT

INVERTER TEST
REPORT

LOAD
Item: INV1
N: L09-0831

WO: 15939
RB: 318107

POWER SUPPLY
V 1 Ph
Hz
kVA

Voltage
110
Frequency
50
Power
70

TAG CLIENT :

2000 Vac

= / ground

Dielectric

2000 Vac

~ / ground

Dielectric

2000 Vac

~/=

Insulation

500 Vdc

R > 10 M
R < 0,10

Ground contunuity 25Adc

Ah
310
293
Cells
Vented Ni Cd

Battery type :
OPTIONS

PRELIMINARY CHECK
Dielectric

V
A

370
209

Protection device calibration

Precharge DC

N/A

Emergency Power Off

N/A

AC earth fault monitoring

N/A

Output

Internal ligthning

Anti-condensation heater
Communication

Types : Modbus

SAFETY AND ALARMS

Aucun

TRANSFER AND BYPASS

Inverter stop alarm

Inverter type

Fan failure

Transfer time

Signalling test

Synchronisation limit (Volts)

Remote alarm test

Synchronisation limit (Degrees) =

Bypass frequency limits

Test instrument calibration

ON LINE
Main->Inv

OFF LINE
Inv->Main

0 ms
U =

0 ms

0.0 V

0.00

3.00 %

10.00%

High DC Voltage / Threshold

572.00 V

Bypass voltage limits

Imminent Shutdown / Threshold

Inverter -> Mains transfer no-break

End Of Discharge / Threshold

Mains -> Inverter transfer no-break

X
X

NO LOAD TEST

Manual transfer no-break

Losses no load

Pv = 2670.0

Voltage no load

US = 110.00

F = 50.00

Hz

Frequency no load

CHECKING
Phase equilibrium (in 3 Ph)

CURRENT SETTINGS AND BRIDGE TYPE

Regulation

10 min overload at cos =1

I = 574.6

Distortion = 3% at cos = 1

Overload transfer at cos=1

I = 547.3

Efficiency

Short circuit

I = 1190.0

REGULATION

Bridge type :

UDC

IDC

P( U x I )

N/A
1.0

X
X

92.0 %

IFH42S400

U12

U23

U31

I1

I2
A

I3

Ptotale

cos

Ubatt. High 0,1 In

484.5

19.2

9302.4

109.6

61.3

6718.5

72.2

2.4

Ubatt. High

In

481.7

162.0

78035.4

109.0

639.0

69651.0

89.3

2.8

Ubatt. Low

0,5 In

302.0

128.0

38656.0

109.4

319.6

34964.2

90.4

2.4

Ubatt. Low

In

301.4

256.0

77158.4

109.0

639.0

69651.0

90.3

2.6

SUBJECT
External spect

IEC 529

CHECKED

CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications

X
X
X
X
X
X

- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen

X
X
X
X
X
X
X

Wiring

- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing

X
X
X
X
X
X

Identification

- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate

X
X
X
X
X

- Vacuum cleaning to remove any stray parts

File conformity

IEC 439
Mounting

IEC 439
IEC 73H0354

IEC 439
Cleaning

EMC directive : IEC 62040 - 2

COMMENTS

LV directive : IEC 62040 - 1 - 2

Comments :
Tested by : MMO

CUST.

X
X
X
X
X
X
X

Date and Customer's visa :


Date: 12/8/2009

Inverter test

Checked by :

LDU Date:
Page
Reference
Index

12/08/09
PGE 20 UK

EQUIPMENT

CHARGER TEST
REPORT

POWER SUPPLY
Item: UPS1+A1+CH
N: L08-1262

WO: 16939
RB: 318107

LOAD
V 3 Ph
Hz

Voltage
415
Frequency
50

TAG CUSTOMER :

Battery type :

Ah
310
293
Cells
Vented Ni Cd

AUTOMATIC MONITORING AND OPTIONS

PRELIMINARY CHECK
Dielectric

2000 Vac

~ / ground

Equalizing / Floating

Dielectric

2000 Vac

= / ground

Equalizing / Floating

Dielectric

2000 Vac

~/=

Boost time

Insulation

500 Vdc

R > 10 M

Compensation U= f (C)

R < 0,10

Battery current limitation

Ground continuity 25Adc

V
A

370
209

Protection device calibration

min

X
N/A
X

62.0

Batt. test: 323.91 V

SAFETY AND ALARMS

15 H

by battery current checking

mV / C / cells

N/A

A equalize / float

3 min. Setting 336.95 V

Time

Earth fault monitoring

Mains fault monitoring

Output

Charger stop alarm

Power sharing of charger

Input protection

Internal lightning

DC fuse tripping

Anti-condensation heater

Signalling test

Communication

Remote alarm test

Test instrument calibration


529.00 V

Low limit alarm / Reset

Pv = 700.0

Losses no load

DC ripple without battery :

+ 10

- 10

Nominal U
Nominal U

I DC

CHECKING
Phase equilibrium (3 phases)

NO LOAD TEST AND DC RIPPLE

Supply

Type : Aucun

Upper limit disconnecting / Reset

CONTROL
Charge
Mode

Type : Modbus

Ufloat =

Regulation

FAUX Ripple without battery

Efficiency

0.47423 %

Ucharge =

V at In/2

413.13

483.45 V at In/2

Uboost =

X
1.0

1.0

95.0

498.10

NOK

Lim. Iboost =

U12

I1

U23

I2

U31

I3

PT

UDC

IDC

P( U x I )

0,1 In 455.5

62.0 A

PF

Ripple
VRMS

457.0

456.0

486.0 23.6

1.60

In

373.5

375.0

374.0

485.0 207.2

1.24

In

414.5 147.8

415.5

146.8

415.0 147.7

103700.0 485.0 206.9

Lim. I 414.0 149.8

415.5

148.5

415.0 149.3

475.0 211.5

100346.5

96.77

0.98

2.30
2.09

SUBJECT
External aspect

IEC 529

File conformity

IEC 439

Mounting

IEC 439
IEC 73H0354
Wiring

Identification

IEC 439
Cleaning

CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts

EMC Directive : IEC 62040 - 2


Comments :

Tested by :

YMA

CHECKED

CUST.

COMMENTS

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

LV Directive : IEC 62040 - 1 - 2


Date and customer's visa :

Date : 31/7/2009

Charger Test

Checked by :

LDU Date :
Page
Reference
Index

12/08/09
PGE 18 UK

EQUIPMENT

INVERTER TEST
REPORT

LOAD
Item: UPS1+A1+INV
N: L08-1262

WO: 16939
RB: 318107
TAG CLIENT :

POWER SUPPLY
V 1 Ph
Hz
kVA

Voltage
110
Frequency
50
Power
70

2000 Vac

= / ground

Dielectric

2000 Vac

~ / ground

Dielectric

2000 Vac

~/=

Insulation

500 Vdc

R > 10 M
R < 0,10

Ground contunuity 25Adc

Ah
310
293
Cells
Vented Ni Cd

Battery type :
OPTIONS

PRELIMINARY CHECK
Dielectric

V
A

370
209

Protection device calibration

Precharge DC

N/A

Emergency Power Off

N/A

AC earth fault monitoring

N/A

Output

Internal ligthning

Anti-condensation heater
Communication

Types : Modbus

SAFETY AND ALARMS

Aucun

TRANSFER AND BYPASS

Inverter stop alarm

Inverter type

Fan failure

Transfer time

Signalling test

Synchronisation limit (Volts)

Remote alarm test

Synchronisation limit (Degrees) =

Bypass frequency limits

Test instrument calibration

ON LINE
Main->Inv

OFF LINE
Inv->Main

0 ms
U =

0 ms

0.0 V

0.00

3.00 %

10.00%

High DC Voltage / Threshold

572.00 V

Bypass voltage limits

Imminent Shutdown / Threshold

Inverter -> Mains transfer no-break

End Of Discharge / Threshold

Mains -> Inverter transfer no-break

X
X

NO LOAD TEST

Manual transfer no-break

Losses no load

Pv = 2381.4

Voltage no load

US = 109.90

F = 50.00

Hz

Frequency no load

CHECKING
Phase equilibrium (in 3 Ph)

CURRENT SETTINGS AND BRIDGE TYPE

Regulation

10 min overload at cos =1

I = 602.0

Distortion = 3% at cos = 1

Overload transfer at cos=1

I = 574.7

Efficiency

Short circuit

I = 1246.0

REGULATION

Bridge type :

UDC

IDC

P( U x I )

N/A
1.0

X
X

92.0 %

IFH42S400

U12

U23

U31

I1

I2
A

I3

Ptotale

cos

Ubatt. High 0,1 In

485.0

18.2

8827.0

109.7

61.7

6768.5

76.7

2.6

Ubatt. High

In

482.0

152.7

73601.4

109.3

620.0

67766.0

92.1

2.7

Ubatt. Low

0,5 In

294.8

128.2

37793.4

109.5

318.1

34832.0

92.2

2.9

Ubatt. Low

In

294.5

246.7

72653.2

109.3

622.0

67984.6

93.6

2.8

SUBJECT
External spect

IEC 529

CHECKED

CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications

X
X
X
X
X
X

- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen

X
X
X
X
X
X
X

Wiring

- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing

X
X
X
X
X
X

Identification

- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate

X
X
X
X
X

- Vacuum cleaning to remove any stray parts

File conformity

IEC 439
Mounting

IEC 439
IEC 73H0354

IEC 439
Cleaning

EMC directive : IEC 62040 - 2

COMMENTS

LV directive : IEC 62040 - 1 - 2

Comments :
Tested by : YMA

CUST.

X
X
X
X
X
X
X

Date and Customer's visa :


Date: 4/8/2009

Inverter test

Checked by :

LDU Date:
Page
Reference
Index

12/08/09
PGE 20 UK

EQUIPMENT

CHARGER TEST
REPORT

POWER SUPPLY
Item: CH2
N: L09-0831

WO: 15939
RB: 318107

LOAD
V 3 Ph
Hz

Voltage
415
Frequency
50

TAG CUSTOMER :

Battery type :

Ah
310
293
Cells
Vented Ni Cd

AUTOMATIC MONITORING AND OPTIONS

PRELIMINARY CHECK
Dielectric

2000 Vac

~ / ground

Equalizing / Floating

Dielectric

2000 Vac

= / ground

Equalizing / Floating

Dielectric

2000 Vac

~/=

Boost time

Insulation

500 Vdc

R > 10 M

Compensation U= f (C)

R < 0,10

Battery current limitation

Ground continuity 25Adc

V
A

370
209

Protection device calibration

min

X
N/A
X

62.0

Batt. test: 323.90 V

SAFETY AND ALARMS

15 H

by battery current checking

mV / C / cells

N/A

A equalize / float

3 min. Setting 337.00 V

Time

Earth fault monitoring

Mains fault monitoring

Output

Charger stop alarm

Power sharing of charger

Input protection

Internal lightning

DC fuse tripping

Anti-condensation heater

Signalling test

Communication

Remote alarm test

Test instrument calibration


529.00 V

Low limit alarm / Reset

Pv = 720.0

Losses no load

DC ripple without battery :

+ 10

- 10

Nominal U
Nominal U

I DC

CHECKING
Phase equilibrium (3 phases)

NO LOAD TEST AND DC RIPPLE

Supply

Type : Aucun

Upper limit disconnecting / Reset

CONTROL
Charge
Mode

Type : Modbus

Ufloat =

Regulation

FAUX Ripple without battery

Efficiency

0.45417 %

Ucharge =

V at In/2

413.10

483.50 V at In/2

Uboost =

X
1.0

1.0

95.0

498.10

NOK

Lim. Iboost =

U12

I1

U23

I2

U31

I3

PT

UDC

IDC

P( U x I )

0,1 In 455.0

62 A

PF

Ripple
VRMS

456.0

455.0

485.1 19.4

1.40

In

374.0

375.0

375.0

484.4 206.2

1.40

In

415.0 149.0

416.0

147.0

415.0 149.0

104200.0 484.4 206.4

Lim. I 415.0 150.0

416.0

148.0

415.0 149.0

472.0 209.7

99980.16

95.95

0.98

2.20
2.30

SUBJECT
External aspect

IEC 529

File conformity

IEC 439

Mounting

IEC 439
IEC 73H0354
Wiring

Identification

IEC 439
Cleaning

CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts

EMC Directive : IEC 62040 - 2


Comments :

Tested by :

MMO

CHECKED

CUST.

COMMENTS

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

LV Directive : IEC 62040 - 1 - 2


Date and customer's visa :

Date : 12/8/2009

Charger Test

Checked by :

LDU Date :
Page
Reference
Index

12/08/09
PGE 18 UK

EQUIPMENT

INVERTER TEST
REPORT

LOAD

WO: 15939
RB: 318107

POWER SUPPLY
V 1 Ph
Hz
kVA

Voltage
110
Frequency
50
Power
70

Item: INV2
N: L09-0831

TAG CLIENT :

2000 Vac

= / ground

Dielectric

2000 Vac

~ / ground

Dielectric

2000 Vac

~/=

Insulation

500 Vdc

R > 10 M
R < 0,10

Ground contunuity 25Adc

Ah
310
293
Cells
Vented Ni Cd

Battery type :
OPTIONS

PRELIMINARY CHECK
Dielectric

V
A

370
209

Protection device calibration

Precharge DC

N/A

Emergency Power Off

N/A

AC earth fault monitoring

N/A

Output

Internal ligthning

Anti-condensation heater
Communication

Types : Modbus

SAFETY AND ALARMS

Aucun

TRANSFER AND BYPASS

Inverter stop alarm

Inverter type

Fan failure

Transfer time

Signalling test

Synchronisation limit (Volts)

Remote alarm test

Synchronisation limit (Degrees) =

Bypass frequency limits

Test instrument calibration

ON LINE
Main->Inv

OFF LINE

0 ms

Inv->Main

U =

0 ms

0.0 V

0.00

3.00 %

10.00%

High DC Voltage / Threshold

572.00 V

Bypass voltage limits

Imminent Shutdown / Threshold

Inverter -> Mains transfer no-break

End Of Discharge / Threshold

Mains -> Inverter transfer no-break

X
X

NO LOAD TEST

Manual transfer no-break

Losses no load

Pv = 1680.0

Voltage no load

US = 110.00

F = 50.00

Hz

Frequency no load

CHECKING
Phase equilibrium (in 3 Ph)

CURRENT SETTINGS AND BRIDGE TYPE

Regulation

10 min overload at cos =1

I = 602.0

Distortion = 3% at cos = 1

Overload transfer at cos=1

I = 574.6

Efficiency

Short circuit

I = 1190.0

REGULATION

Bridge type :

UDC

IDC

P( U x I )

N/A
1.0

X
X

92.0 %

IFH42S400

U12

U23

U31

I1

I2
A

I3

Ptotale

cos

Ubatt. High 0,1 In

484.0

20.2

9776.8

110.0

67.6

7436.0

76.1

2.4

Ubatt. High

In

483.0

160.0

77280.0

109.0

637.0

69433.0

89.8

2.5

Ubatt. Low

0,5 In

301.0

127.0

38227.0

109.5

319.3

34963.4

91.5

2.1

Ubatt. Low

In

300.5

255.0

76627.5

110.0

637.0

70070.0

91.4

2.4

SUBJECT
External spect

IEC 529

CHECKED

CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications

X
X
X
X
X
X

- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen

X
X
X
X
X
X
X

Wiring

- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing

X
X
X
X
X
X

Identification

- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate

X
X
X
X
X

- Vacuum cleaning to remove any stray parts

File conformity

IEC 439
Mounting

IEC 439
IEC 73H0354

IEC 439
Cleaning

COMMENTS

LV directive : IEC 62040 - 1 - 2

EMC directive : IEC 62040 - 2

Date and Customer's visa :

Comments :
Tested by : MMO

CUST.

X
X
X
X
X
X
X

Date: 12/8/2009

Inverter test

Checked by :

LDU Date:
Page
Reference
Index

12/08/09
PGE 20 UK

EQUIPMENT

CHARGER TEST
REPORT

POWER SUPPLY
Item: UPS2+A3+CH
N: L08-1262

WO: 16939
RB: 318107

LOAD
V 3 Ph
Hz

Voltage
415
Frequency
50

TAG CUSTOMER :

Battery type :

Ah
310
293
Cells
Vented Ni Cd

AUTOMATIC MONITORING AND OPTIONS

PRELIMINARY CHECK
Dielectric

2000 Vac

~ / ground

Equalizing / Floating

Dielectric

2000 Vac

= / ground

Equalizing / Floating

Dielectric

2000 Vac

~/=

Boost time

Insulation

500 Vdc

R > 10 M

Compensation U= f (C)

R < 0,10

Battery current limitation

Ground continuity 25Adc

V
A

370
209

Protection device calibration

min

X
N/A
X

62.0

Batt. test: 323.91 V

SAFETY AND ALARMS

15 H

by battery current checking

mV / C / cells

N/A

A equalize / float

3 min. Setting 336.95 V

Time

Earth fault monitoring

Mains fault monitoring

Output

Charger stop alarm

Power sharing of charger

Input protection

Internal lightning

DC fuse tripping

Anti-condensation heater

Signalling test

Communication

Remote alarm test

Test instrument calibration


529.00 V

Low limit alarm / Reset

Pv = 570.0

Losses no load

DC ripple without battery :

+ 10

- 10

Nominal U
Nominal U

I DC

CHECKING
Phase equilibrium (3 phases)

NO LOAD TEST AND DC RIPPLE

Supply

Type : Aucun

Upper limit disconnecting / Reset

CONTROL
Charge
Mode

Type : Modbus

Ufloat =

Regulation

FAUX Ripple without battery

Efficiency

0.43299 %

Ucharge =

V at In/2

413.1

483.45 V at In/2

Uboost =

X
1.0

1.0

95.0

498.10

NOK

Lim. Iboost =

U12

I1

U23

I2

U31

I3

PT

UDC

IDC

P( U x I )

0,1 In 455.0

62 A

PF

Ripple
VRMS

457.0

456.0

485.0 23.6

1.63

In

373.0

375.0

373.0

485.0 207.0

1.30

In

414.5 146.9

416.5

146.0

415.0 145.9

103300.0 485.0 206.9

Lim. I 415.0 148.7

417.0

147.1

415.5 147.6

474.0 211.1

100346.5

97.14

0.98

2.10
2.20

SUBJECT
External aspect

IEC 529

File conformity

IEC 439

Mounting

IEC 439
IEC 73H0354
Wiring

Identification

IEC 439
Cleaning

CHECK
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs
- Technical sheet
- Drawings, parts list
- Layout
- Wiring sections
- Special specifications
- Mechanical welds
- Subassemblies, screws, rivets
- Subassembly fixing, transformers, chokes
- Diodes and thyristors mounting on heat sink
- Front panel removal
- Terminal blocks accessibility
- Switchgear handle direction, protection screen
- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing
- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate
- Vacuum cleaning to remove any stray parts

EMC Directive : IEC 62040 - 2


Comments :

Tested by :

YMA

CHECKED

CUST.

COMMENTS

X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

LV Directive : IEC 62040 - 1 - 2


Date and customer's visa :

Date : 31/7/2009

Charger Test

Checked by :

LDU Date :
Page
Reference
Index

12/08/09
PGE 18 UK

EQUIPMENT

INVERTER TEST
REPORT

LOAD
Item: UPS2+A3+INV
N: L08-1262

WO: 16939
RB: 318107
TAG CLIENT :

POWER SUPPLY
V 1 Ph
Hz
kVA

Voltage
110
Frequency
50
Power
70

2000 Vac

= / ground

Dielectric

2000 Vac

~ / ground

Dielectric

2000 Vac

~/=

Insulation

500 Vdc

R > 10 M
R < 0,10

Ground contunuity 25Adc

Ah
310
293
Cells
Vented Ni Cd

Battery type :
OPTIONS

PRELIMINARY CHECK
Dielectric

V
A

370
209

Protection device calibration

Precharge DC

N/A

Emergency Power Off

N/A

AC earth fault monitoring

N/A

Output

Internal ligthning

Anti-condensation heater
Communication

Types : Modbus

SAFETY AND ALARMS

Aucun

TRANSFER AND BYPASS

Inverter stop alarm

Inverter type

Fan failure

Transfer time

Signalling test

Synchronisation limit (Volts)

Remote alarm test

Synchronisation limit (Degrees) =

Bypass frequency limits

Test instrument calibration

ON LINE
Main->Inv

OFF LINE
Inv->Main

0 ms
U =

0 ms

0.0 V

0.00

3.00 %

10.00%

High DC Voltage / Threshold

572.00 V

Bypass voltage limits

Imminent Shutdown / Threshold

Inverter -> Mains transfer no-break

End Of Discharge / Threshold

Mains -> Inverter transfer no-break

X
X

NO LOAD TEST

Manual transfer no-break

Losses no load

Pv = 2435.0

Voltage no load

US = 110.10

F = 49.99

Hz

Frequency no load

CHECKING
Phase equilibrium (in 3 Ph)

CURRENT SETTINGS AND BRIDGE TYPE

Regulation

10 min overload at cos =1

I = 602.0

Distortion = 3% at cos = 1

Overload transfer at cos=1

I = 574.7

Efficiency

Short circuit

I = 1202.0

REGULATION

Bridge type :

UDC

IDC

P( U x I )

N/A
1.0

X
X

92.0 %

IFH42S400

U12

U23

U31

I1

I2
A

I3

Ptotale

cos

Ubatt. High 0,1 In

485.0

19.9

9651.5

110.0

61.6

6776.0

70.2

3.0

Ubatt. High

In

482.0

153.2

73842.4

109.2

619.3

67627.6

91.6

3.0

Ubatt. Low

0,5 In

295.6

127.5

37689.0

109.6

317.9

34841.8

92.4

3.0

Ubatt. Low

In

294.9

247.8

73076.2

109.2

622.0

67922.4

92.9

2.8

SUBJECT
External spect

IEC 529

CHECKED

CHECK LIST
- Aspect of sheet metal, painting
- Meter alignment
- Lamps, leds, labels
- CHLORIDE plate
- Door mounting, locks, keys
- Document holder
- Earth wire
- Photographs in file
- Technical sheet
- Drawings ,parts list
- Layout
- Wiring sections
- Special specifications

X
X
X
X
X
X

- Mechanical welds
- Subassemblies ,screws ,rivets
- Subassembly fixing, transformers, choke
- Diodes and thyristors mounting on heatsink
- Front panel removal
- Terminal block accessibility
- Switchgear handle direction, protection screen

X
X
X
X
X
X
X

Wiring

- Connection quality
- Crimping
- Tightness of all connections
- Soldering
- Wiring ducts (size and position)
- Wire routing

X
X
X
X
X
X

Identification

- Wires
- Components
- Terminals, transformer, couplers
- Customer terminal blocks
- Manufacturer plate

X
X
X
X
X

- Vacuum cleaning to remove any stray parts

File conformity

IEC 439
Mounting

IEC 439
IEC 73H0354

IEC 439
Cleaning

EMC directive : IEC 62040 - 2

COMMENTS

LV directive : IEC 62040 - 1 - 2

Comments :
Tested by : YMA

CUST.

X
X
X
X
X
X
X

Date and Customer's visa :


Date: 4/8/2009

Inverter test

Checked by :

LDU Date:
Page
Reference
Index

12/08/09
PGE 20 UK

CHLORIDE
INDUSTRIAL SYSTEMS

4. INSTALLATION
Title

Page

4.1. HANDLING ON ARRIVAL

23

4.2. STORAGE

24

4.3. PUTTING INTO INSTALLED POSITION

24

4.4. ELECTROLYTE / CELL OIL

25

4.4.1. Cells delivered filled

25

4.4.2. Cells delivered empty

25

4.5. CABLE ENTRIES

25

4.6. TERMINAL CONNECTIONS

25

4.6.1. Phase rotation

25

4.6.2. Battery

25

4.6.3. Neutral

26

4.6.4. Earth

26

4.7. VENTILATION

26

4.8. BATTERY-VENTED CADMIUM NICKEL

26

4.9. BATTERY INSTALLATION

26

4.1. HANDLING ON ARRIVAL


Unpack the equipment. Take care not to short circuit battery terminals together. Do not
discard keys, battery connectors or accessories when disposing of packing materials.
The cubicle keys will be in a bag taped to the cubicle door
Check the contents against the consignment note. The equipment has a rating plate normally
affixed inside the door panel at the front which will identify the cubicle. Report immediately
to the carrier and supplier if anything is missing or damaged. Delay in reporting may invalid
claims for free repair or replacement.
NOTE: The battery and equipment cubicle often arrive separately.

Page 23 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

The cubicle and battery must be handled with care, keep them upright. Do not drop or subject
them to impact. Cubicles are often top heavy with offset centres of gravity.
The transit case is designed to be handled by a fork lift truck. Note the centre of gravity is
often offset and cubicles may be top heavy, so take care to position the lift forks safely.
The equipment may be lifted by crane. It will be necessary to pass slings underneath the
cubicle. The slings should be positioned under the extremities of the cubicle with safety straps
to prevent them slipping towards the centre when under vertical tension. Also protect
protrusions such as meters and switches from accidental damage from the lifting slings.
4.2. STORAGE
The cubicle should be stored in a clean dry environment. Although it is designed to operate in
an ambient of 0C to 40C it can be stored in temperatures as low as -20C.
If it is to be stored for a long period of time some packing will be needed to prevent dirt
getting inside through grilles and openings. When storing or shipping batteries at sub-zero
temperatures the electrolyte must not be allowed to freeze otherwise mechanical damage can
occur to the plates. Freezing occurs at about -20C. Batteries should be maintained fully
charged as this keeps the freezing point low. Follow the manufacturer's instructions.
4.3. PUTTING INTO INSTALLED POSITION
The equipment will have to be lifted from its pallet and manoeuvred into position. Note that
battery cubicles are extremely heavy and adequately strong lifting gear is needed.
Once in position adjacent cubicles should be fastened to each other by means of through bolts
(these are provided inside plastic bags inside the cubicles), and to the floor using anchor
bolts. Before fitting each anchor bolt, level the cubicles for both horizontal and vertical planes
as required using incompressible shims.
The procedure for fixing the panels together is as follows:
Take the kit comprising of 4 screws and nuts (HM6 x 70mm)
Remove the 2 transfer screws on the separating panel
But the cubicles together holding the separating panel in place. The separating panel is
sandwiched between the cubicles
Take the 4 screws and open the panel doors
Put the screws through the holes in the uprights which go through the separating panel.
There are 2 at the top and 2 at the bottom. Put the nut on the screw and tighten.

Page 24 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

4.4. ELECTROLYTE / CELL OIL


4.4.1. Cells delivered filled
Check the level of electrolyte. The cells must have a level of electrolyte above the plates. If it
is not the case, adjust the level of electrolyte with distilled or deionised water to 5 mm above
the plate tops. Cells delivered filled have already the cell oil in place.
4.4.2. Cells delivered empty
Fill empty cells with electrolyte to 5 mm above the plate tops. Then add the oil with the
syringe, according to the quantity indicated in the table on the reverse of this card.
NOTE: Please, always refer to manufacturers manual.
4.5. CABLE ENTRIES
Refer to the general arrangement drawing for cable entry positions.
Cable sizes are not specified in this manual. The installer must assess the requirements of
each site with regard to the regulations and the relevant codes of practice.
Before making the connections set all power switches, isolators and circuit breakers to OFF.
Remove the battery fuse (if any).
The incoming cables must be secured by means of a strain relief glands to the gland plate
where they enter the cubicle. The gland plate is not pierced so a suitable hole will have to the
cut for each cable entry. The gland plate must be removed from the equipment and taken
elsewhere to be drilled to prevent swarf entering the unit. The wires are then to be routed
to their respective terminals ensuring that there is enough slack to prevent strain on the
terminal. Cable runs should be cleated at intervals of 1/2 metre to rigid structure inside the
cubicle.
4.6. TERMINAL CONNECTIONS
4.6.1. Phase rotation
The equipment requires the phase rotation to be correct for correct operation. Terminals are
labelled for that purpose.
4.6.2. Battery
The battery cable should be connected with the battery fuse removed and the battery isolator
OFF. Check and double check that the polarity of the battery connection is correct. An error
here can cause major damage to the system.
WARNING :

DO NOT CLOSE BATTERY ISOLATOR OR FIT FUSES


UNTIL THE FILTER CAPACITORS HAVE BEEN PRECHARGED BY THE CHARGER.

Page 25 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

4.6.3. Neutral
Within the rectifier if no neutral-to-earth link is provided the rectifier neutral adopts the same
potential as the incoming Reserve Neutral if present. Therefore if the Reserve input has no
fixed neutral the rectifier output Phase and Neutral will float.
Note: Do not set up a neutral line that has two separate connections to earth
because this will set up an EARTH LOOP which can have the effect of
introducing noise into the rectifier output.
4.6.4. Earth
The cubicle earth bar must be grounded to a suitable earth point.
Apart from the mandatory safety protection it provides, it also acts as a drain for spurious
noise. Consequently there is a continuous leakage to earth of several tens of mA in normal
operation. Therefore Earth Leakage Trips (ELT) or RCCD on the input should take into
account this small leakage.
4.7. VENTILATION
All ventilation apertures must be kept free and clean. These systems can work in a continuous
environment within 0 to 40C temperature range, although, ideally the ambient temperature
should be below 25C.
The heat can be removed from the equipment room by a forced cooling ventilation system or,
alternatively, an air conditioning system.
The required air changes per hour will depend on the system rating, the heat loss and the
cooling air temperature.
4.8. BATTERY-VENTED CADMIUM NICKEL
The battery is a vented cadmium nickel type. It gives off significant amounts of gas (hydrogen
and oxygen).
A specially ventilated battery room is required.
The battery needs its electrolyte topped up routinely
However the battery is suitable for boost charging.
4.9. BATTERY INSTALLATION
WARNING:

REMOVE RINGS AND METAL WATCHSTRAPS WHEN


WORKING ON BATTERIES. ALSO USE INSULATED TOOLS.

It is the responsibility of the installer to arrange suitable protection.


The installer will have to connect the inter-cell cables as shown in the battery diagram in
section 10 of this manual.
Before starting, remove the battery fuses and ensure the battery breaker or isolator is OFF.

Page 26 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

BATTERY INSTALLATION CHECK LIST


Battery isolator OFF
Battery fuse removed
Batteries on each group interconnected.
Voltage check of each battery group
Check no short from battery to earth
Check metal battery cubicles (or metal stands) are earthed.
Interconnect the battery in accordance with Battery Diagram.
Use voltmeter to check the voltage of each half of the battery.
Terminate the cables linking the battery and the UPS.
Make absolutely sure these are the correct polarity, as an error will cause substantial damage
when the equipment is started up.
CAUTION:

DO NOT CONNECT BATTERY POWER TO THE UPS UNTIL


THE RECTIFIER SOFT START HAS BEEN ALLOWED TO
PRECHARGE THE SMOOTHING CAPACITORS SEE
SECTION 5 FIRST START UP.

Check the ambient temperature and once the system is running measure the temperature in the
battery cubicle.
Once the system is running check the charge voltage in:
FLOAT MODE
CHARGE MODE
BOOST MODE

Page 27 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5. OPERATING INSTRUCTIONS
Title

Page

5. OPERATING INSTRUCTIONS

28

5.1. LIGHT EMITTING DIODES (LEDS)

29

5.2. DISPLAY

30

5.3. CONTROL PUSH-BUTTONS

31

5.4. PRESENTATION OF THE MENUS

32

5.5. GENERAL MENU

32

5.6. UPS BLOCK MENUS

33

5.7. CONTROL PANEL MENUS

36

5.8. CHANGE CHARGER MODE

41

5.9. MEASURES, FAULTS AND WARNINGS

42

5.10. HEADING

42

5.11. RECTIFIER/CHARGER INFORMATION

45

5.12. BATTERY INFORMATION

46

5.13. INVERTER INFORMATION

46

5.14. RESERVE INFORMATION

47

5.15. LOAD AND STATIC SWITCH INFORMATION

47

5.16. OPERATING INSTRUCTIONS

48

5.16.1. First start-up

48

5.16.2. Maintenance procedure

50

5.16.3. Transfer to maintenance for a stand-alone inverter

52

5.16.4. Return from maintenance for a stand-alone inverter

52

5.16.5. Global maintenance procedure

53

5.16.6. Black start procedure

53

Page 28 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

The UPS incorporates the necessary controls, instruments and indicators to allow the operator to
monitor the system status and performance and take any appropriate action. Furthermore, interfaces
are available, which allow extended monitoring and control, as well as service functions.
5.1. LIGHT EMITTING DIODES (LEDS)
The UPS has three Light Emitting Diodes (LEDs) to indicate the overall system operation status as
well as the condition of the sub-assemblies. These LEDs interact with the active mimic diagram
displayed on the graphical display.

Led view

Led colour

Description

Comments

Green

UPS normal operation

AC load supplied by the inverter


and the charger is running

Green flashing

load on reserve, or
inverter running on
battery

Load powered by reserve or


inverter running on battery

Orange

UPS warning

One or more subassemblies are


affected but UPS not stopped

Red

UPS fault

One or more subassemblies are


faulty and stopped or manually
stopped.

Red flashing

CAN communication
fault

The UPS communication CAN BUS


is not correctly plugged or in
failure.

STO

The three LEDs are functioning in a permanent way. It is not compulsory to be on the mimic diagram
part of the display to activate the operation of the LEDs.
The LEDs are functioning independently the ones from the others and they can be lit simultaneously in
some circumstances.

Page 29 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.2. DISPLAY
A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD) is provided to enable the
operating parameters, all the measurements and the active mimic diagram of the UPS to be monitored.
The LCD messages are accessed by push-buttons (see figure below).
The text is available in English, French, Spanish or German.
This local human-machine interface is composed of:
1 A graphical (64 x 128 pixels) illuminated Liquid Crystal Display (LCD).
2 Three LEDs indicating global system functioning and subassemblies functioning.
3 Four push-buttons to access different menus and showed measures.
4 Two push-buttons to power ON / OFF the equipment.
5 One push-button to cut the audible alarm.

The display has two operating modes:


1. Visualization of an active mimic diagram which gives a graphic representation of the UPS
status.
2. Navigation through various menus for visualization of status or measurements information or
possible actions on the UPS.

Page 30 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

User push-buttons used to control the Graphical Liquid Crystal Display:


Select previous
Up in menus.
Select next
Down in menus.
Validate parameters
Enter in menus.

OK

Cancel parameters
Back in menus.

User push-button used to control the alarm buzzer:


Cancel audible alarm
It cancels internal audible alarm until a new alarm occurs.

5.3. CONTROL PUSH-BUTTONS


In the right part of the display there are two further push-buttons to control the UPS:

Rectifier

Inverter

Starts / Stops rectifier/charger operation:


The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the button for 2 seconds before the charger stops. SWITCH OFF
CHARGER message is temporarily displayed on the LCD and an OFF pictogram
appears on the charger block.
To start the charger, it is necessary to push this same button for 1 second: SWITCH
ON CHARGER message is temporarily displayed and the OFF pictogram on the
charger block disappears.
Starts / Stops inverter operation :
The control incorporates a safety feature to prevent inadvertent operation yet still
allow rapid shutdown in the event of an emergency. This shall be achieved by
pressing the STOP button for 2 seconds before the inverter stops. SWITCH OFF
INVERTER message is temporarily displayed on the LCD and an OFF pictogram
appears on the inverter block.
To start the inverter, it is necessary to push this same button for 1 second. SWITCH
ON INVERTER message is temporarily displayed on the LCD and the OFF
pictogram on the inverter block disappears.

Page 31 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

REMARK:

The START / STOP push-buttons are permanently active. The action is valid when an
ON or OFF message appears on the display. Then graphical display shows the mimic
diagram to confirm the new UPS status. The LCD mimic diagram enables to
understand the actual status of both charger and inverter to immediately know if both
blocks were OFF or ON before pushing the control buttons.

5.4. PRESENTATION OF THE MENUS


The information available on the display is of two types: mimic diagram or menu.
The UPS is structured in "blocks". The organization of the information in the menus is the reflection
of this structure.
You will find in the General Menu all the UPS blocks as well as some controls.
Examples of menus:
MENU

Charger
Battery
Inverter
Reserve
ACLoad

General menu

CHARGER

Status
ChangingMode
Measurements
Faults
Warnings

Charger menu

CHARGERMEASURES

UDC=220.1V
IDC=60.0Amp
U12=241.2V
U23=242.0V
U31=241.0V
I1=70.0Amp

Charger measures
(three-phase UPS)
5.5. GENERAL MENU
The general menu allows access to the following sub-menus:
Sub-menus for the five UPS blocks:

Charger

Battery

Inverter

Reserve

AC Load

Sub-menus for the controls:

Reset

Black Start (Optional)

Event log

Display Setting

Contact

About

Page 32 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

To navigate in the menus, use the push-buttons:


to come back to the previous item
to move to the next item

OK

to validate the chosen item and access to the sub-menu corresponding to this item.

NOTES:

The menus and sub-menus are circular roll down menus.

The selected item is indicated by an arrow (4) at the beginning of the line.

5.6. UPS BLOCK MENUS


1. CHARGER
MENU

Charger
Battery
Inverter
Reserve
ACLoad

This module allows entry to the following menus:


CHARGER

Status
ChangingMode
Measurements
Faults
Warnings

Charger status menu (to display the charger operational


status).

Change charger mode menu (used to change the battery


charge mode).
See Change charger mode chapter for more details.

Charger measurements menu (for a list of measurements


on the charger).
See Measures and Faults chapter for more details.

Charger faults menu (for a list of active faults on the


charger).

Charger warnings menu (for a list of active warnings on


the charger).

Page 33 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

2. BATTERY
MENU

Charger
Battery
Inverter
Reserve
ACLoad

This module allows entry to the following menus:


BATTERY

Status
Measurements
Faults
Warnings

Battery status menu (to display the battery operational


status).

Battery measurements menu (for a list of measurements


on the battery).

Battery faults menu (for a list of active faults on the


battery).

Battery warnings menu (for a list of active warnings on


the battery).

3. INVERTER
MENU

Charger
Battery
Inverter
Reserve
ACLoad

This module allows entry to the following menus:


INVERTER

Status
Measurements
Faults
Warnings

Inverter status menu (to display the inverter operational


status).

Inverter measurements menu (for a list of measurements


on the inverter).

Inverter faults menu (for a list of active faults on the


inverter).

Inverter warnings menu (for a list of active warnings on


the inverter).

Page 34 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

4. RESERVE SUPPLY
MENU

Charger
Battery
Inverter
Reserve
ACLoad

This module is displayed only if a reserve supply network is confirmed on the customers technical
specification. This module allows entry to the following menus:
RESERVE

Status
Measurements
Faults
Warnings

Reserve supply status menu (to display the reserve supply


operational status)

Reserve supply measurements menu (for a list of


measurements on the reserve supply)

Reserve supply faults menu (for a list of active faults on the


reserve supply)

Reserve supply warnings menu (for a list of active


warnings on the reserve supply)

5. AC LOAD
MENU

Charger
Battery
Inverter
Reserve
ACLoad

This module allows entry to the following menus:


ACLOAD

Status
Measurements
Faults
Warnings

AC load status menu (to display the AC load operational


status)

AC load measurements menu (displays the list of


measurements on the AC load)

AC load faults menu (for a list of active faults on the AC


load)

AC load warnings menu (for a list of active warnings on


the AC load)

Page 35 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.7. CONTROL PANEL MENUS


1. RESET
MENU

Inverter
Reserve
ACLoad
Reset
BlackStart

This module allows entry to the following menus:


RESET

ChargerReset
InverterReset
EventLogReset
AutonomCalculRst

RESET charger menu (to erase the memorized charger


defaults)

RESET inverter menu (to erase the memorized inverter


and static switch defaults)

RESET Log event menu

RESET Autonom Calcul Rst menu (to get the initial


value of Battery Capacity used for the calculation of the
battery autonomy

To validate charger or inverter or Event log RESET, click on


OK of the RESET to erase. The display will automatically
go back to the general menu.
To erase the charger and inverter blocks stored defaults,
repeat the previous operation for both parts.

Page 36 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

2. BLACK START (OPTIONAL)


MENU

Inverter
Reserve
ACLoad
Reset
BlackStart

This module is only available on parallel inverters. It allows entry to the following menu:
BLACKSTART

StarttheInverter
withoutReserve?

NO
YES

This menu gives the possibility to start parallel inverters, if the


Reserve Supply is not present:

Start both inverters by the control push buttons on each


display: the inverters will not yet start, as the Reserve
Supply is not present.

Select the Black Start menu on one of both inverters.

Select YES with the Down push-button and click on


O K to validate.
Both inverters will start simultaneously.

Page 37 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

3. EVENT LOG
MENU

Reserve
ACLoad
Reset
BlackStart
EventLog

This module allows to display one by one all the events memorised into the historical record, in a
chronological order.
Example of event:
EVENTN1
InverterFault
HighDCvoltage
Memorised

Initiated:
17fev0506:18:37

To access the Event Log, select the item Event Log in the general menu of the equipment. The first
event of the list is then displayed. If no event has occurred yet, the message No event is displayed.
Every event is detailed as follows:
The concerned block,

The text of the detected fault or alarm,

The nature of the event (indicates if the event appeared or disappeared)

The date and time when the event occurred.

The scheduling and the memorizing of the events depend on the choice of the event mode memorizing
in the Event Log:
Saturable Mode:
The first memorised event corresponds to the first fault or alarms that occurred on the
equipment, after a UPS power on, or after a Even Log reset.
The Event Log is limited up to 100 events and any more events past this limit are memorized.
The classification of the events never changes.
N1 : the first event which has occurred (oldest).
N100: the 100th event.
FIFO Mode:
The first event corresponds to the fault or warning memorized occurred most recently.
Once the limit of 100 events memorized in the Event log, if a new event occurs, the oldest
event of the Event log will be removed and event which has just occurred will be memorized.
The classification of the events always corresponds to the order of which has occurred of the
events.
N1 : the most recent
N100: oldest. (if 100 recorded events).
See chapter 4 Display Setting for the selection of the Event Log Mode.

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CHLORIDE
INDUSTRIAL SYSTEMS

4. DISPLAY SETTING
MENU

ACLoad
Reset
BlackStart
EventLog
DisplaySetting

This module allows entry to the following menus:


DISPLAYSETTING

Seriallink
Language
EventLogMode

Serial link menu (to direct the serial link of the display
board)

Language menu (to read information in different


language.

Event Log Mode menu (to chose between the to mode of


Event Log memorizing.

Select with Up and Down push-buttons the option requested: to


validate, click on OK . You will then enter the item chosen.
SERIAL LINK: This module allows entry to the following menus indicating the two possibilities.
SERIALLINK

Internal
External
SelectedLink:
Internal

Internal menu (to direct the serial link to SUB D9 (SK8)


of the display board)

External menu (to direct the serial link to RJ 45 (SK6) of


the display board)

Select with Up and Down push-buttons the serial link


requested: to validate, click on
enter the new serial link chosen.

OK

. You will then

LANGUAGE: This module allows entry to the following menus:


LANGUAGE

English
French
Spanish
German
Italian

English menu (to read information in English).

French menu (to read information in French).

Spanish menu (to read information in Spanish).

German menu (to read information in German).

Italian menu (to read information in Italian).

To validate the language, click on O K corresponding to


your choice using arrows to go up and down. The display will
then return to the general menu.

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CHLORIDE
INDUSTRIAL SYSTEMS

EVENT LOG MODE: This module allows entry to the following menus indicating the two

possibilities.
EVENTLOGMODE

SaturableMode
FIFOMode
ActualSetting:
FIFOMode

Saturable Mode (allow to memorize the first 100 events)

FIFO Mode (allow to memorize permanently until the last


100 events )

Select with Up and Down push-buttons the mode requested: to


validate, click on OK . You will then enter the new mode
chosen.
It is advised to make a Reset of Event Log after having
changed mode.

5. CONTACT
This module allows access to CHLORIDE contact information.

6. ABOUT
This module allows access to the equipment information (serial number, issue).

NOTE: The Contact and About sub-menus are not circular roll menus but only roll down menus.

Page 40 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.8. CHANGE CHARGER MODE

CHARGER

Status
ChangingMode
Measurements
Faults
Warnings

CHANGINGMODE

RequestAction
NoRequest
ChargerStatus
Floating

CHANGINGMODE
RequestAction
NoRequest
Floating
Equalisation
Boost
BatteryTest

In the Charger menu, click O K on Changing Mode to enter


the sub-menu:

Request action

Charger status

Click O K on Request Action to enter sub-menu:


Request Action
No request
Floating
Equalisation
Boost
Battery test
Select the needed mode and click O K . The display will go
back to the previous menu to display the required action and
also if the charger has really changed the mode.
C to come back to previous menus.
Click
Nota: access to certain modes is not always possible depending
on battery types.

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CHLORIDE
INDUSTRIAL SYSTEMS

5.9. MEASURES, FAULTS AND WARNINGS


Each sub-menu Measures, Faults and Warnings are circular roll down menus which can be scanned
with arrows :
To select previous item
To select next item
For Faults and Warnings menus, if no fault or warning is present, you can read a label saying No
fault or No warning.
5.10. HEADING
The heading displays the active mimic diagram of the UPS system (see figures below). By pressing
the
or

or

buttons, the user can enter the general menu. While

navigating in the menus, the user can return to the active mimic diagram by pressing the
button as many times as necessary.
NOTE: If the user does not request any action (such as pressing a button) for 5 minutes while
displaying the menus, the system will automatically return to the display of the heading active mimic
diagram.

Active mimic panel


(single phase output UPS)

Active mimic panel


(Three-phase output UPS)

The active mimic diagram displays the following information:


9

Graphical view of the connected load,

Graphical view and percentage of the battery charge level,

Graphical view of the power flow,

Graphical view of the status of each subassembly.

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CHLORIDE
INDUSTRIAL SYSTEMS

Below are two examples of active mimic situations:

Mains input failure


Charger stopped
AC load still supplied
Battery discharging

Active mimic panel (single phase)

UPS running
AC load supplied
Inverter not synchronised on reserve

Active mimic panel (single phase)

The display shows the following information:


1

Charger status

Bypass switch status

Battery status

Synchronization status

Inverter status

Battery current status

Static switch status

10

Output current status

AC load status

11

Battery charge level status

Reserve input status


7

10

11

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CHLORIDE
INDUSTRIAL SYSTEMS

Pictograms list:
Charger block
Charger ON and OK
Charger ON but with warnings ON
Charger stopped following faults detection
Charger voluntary OFF
Communication problem with the charger
Battery block
Battery OK
Battery warnings detection
Battery faults detection
Communication problem with the battery
Add to battery pictograms battery status:
Battery in charge
Battery in discharge
Inverter block
Inverter ON and OK
Inverter ON but with warnings ON
Inverter stopped following faults detection
Inverter voluntary OFF
Inverter waiting for start (only in parallel inverter case)
Inverter waiting for stop (only in parallel inverter case)
Communication problem with the inverter
Static switch block
Static switch in ITL position (inverter AC load)
Static switch in RTL position (reserve supply AC load)
Static switch in IRTL position (inverter + reserve supply AC load
transitional status)
Static switch in open position (AC load is not powered with the switch)
Static switch ON but with warnings ON
Static switch OFF following faults detection
Communication problem with the static switch
....
__

cut off flow


continuous flow

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CHLORIDE
INDUSTRIAL SYSTEMS

NOTE 1:
has priority on
Pictogram voluntary OFF
has priority on .
Pictogram

and

NOTE 2:
When pictogram
appears on inverter block, it means that the inverter is not
synchronized with the reserve supply.
5.11. RECTIFIER/CHARGER INFORMATION
Status indications
Charger OFF
Initialisation
Charger Stop
Equalisation mode
Equalisation imposed
Floating mode
Battery test mode
Battery test imposed
Boost mode

Faults indications
No fault
High DC voltage
High DC voltage memorised
Too high I battery memorised
Charger fuse blown
Input protection open
Charger off
Wrong phase sequence

Warnings indications
Test mode
Fan failure
Overload inhibit
Charger in current limit

Measurements indications
Charger output DC voltage
Charger output DC current
Charger input voltage (between each phase)
Charger input current (on each phase)
Charger input frequency
Number of mains failures

AC supply fault

Page 45 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.12. BATTERY INFORMATION


Status indications
Normal
Discharging
Charging
Fault or warning

Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open

Warnings indications
DC earth fault
Battery begin discharge
Imminent shutdown

Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)

5.13. INVERTER INFORMATION


Status indications
Inverter synchronised
Inverter on crystal
Inverter not running
Inverter switched off

Warnings indications
No warning
Faults indications
No fault
Inverter switched off
VCE brigde fault memorised
Inverter overload fault memorised
Over-temperature fault memorised
Low DC voltage
Repeated low DC voltage memorised
High DC voltage memorised
Microcontroller fault memorised
High AC voltage memorised
Frequency fault memorised

Commissioning mode
Software time-out
Fan failure
Inverter overload warning

Measurements indications
Inverter input DC voltage
Inverter output voltage (between phases and
neutral)
Inverter frequency

Page 46 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.14. RESERVE INFORMATION


Status indications
No warning ; no fault
Warning ; no fault
No warning ; fault
Warning + fault

Warnings indications
No warning
Reserve voltage fault
Reserve frequency fault
Wrong phase sequence

Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency

5.15. LOAD AND STATIC SWITCH INFORMATION


Status indications
Load on inverter
Load on reserve
Manual bypass on
Load not supplied

Faults indications
No fault
Static switch overload fault memorised
Inverter static switch fault memorised
Reserve static switch fault memorised
Static switch hardware fault memorised

Warnings indications
No warning
Manual bypass closed
Static switch overload

Measurements indications
Load voltage (between phases and neutral)
Load current (on each phase)
Load frequency
Load power (on each phase in kVA)
Load power (on each phase in kW)
Total time on inverter
Load current ratio (%)

Page 47 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.16. OPERATING INSTRUCTIONS

5.16.1. First start-up


Starting situation: All switches, breakers and isolators are open, except Q21 which is closed.

Check the voltage and frequency of the Reserve.

Switch on Reserve input isolator Q31.

On both UPSs, switch charger primary supply ON. Close charger AC input isolators Q3.
Wait 30 seconds for initialisation of the chargers.

Turn both chargers on (Push Charger ON/OFF button 0/1 Charger for 1 second until
SWITCH ON CHARGER is displayed on the display). If the text reads SWITCH OFF
CHARGER, this means the charger was already running: in this case, please push the
button again to restart the charger.

Using a hand-held voltmeter, check amplitude and polarity of the charger output voltage,
on both chargers.

Also check amplitude and polarity of the battery voltage, on both batteries.

If all previous voltages are correct in amplitude and polarity, close both battery isolators
Q5.

Wait until both displays are correctly powered (no more question mark).

Operate an inverter reset on each inverter by the control push buttons (Reset part of the
LCD General Menu).

Close Q26 and Q27.

Close Q22: the inverters are now in TEST mode. After 10 seconds, the Reserve Static
Switch will be closed (visible on the synoptic diagram of the Displays).

Using a hand-held voltmeter, check that Output Distribution is correctly powered.

On each display, check the correct display of the DC voltage (Inverter Measurement
Menu) and of the AC output voltage (AC Load Measurement Menu).

If you want to check the load transfers, proceed as follows:


Turn both inverters on by the control push buttons (Push Inverter ON/OFF button
0/1 Inverter for 1 second, until SWITCH ON INVERTER is displayed on the
display): The inverters will not yet start.
Press S22: INVERTER 1 will start and the Static Switch will transfer from Reserve to
INVERTER 1.
Release S22: The Static Switch will transfer back from INVERTER 1 to Reserve, and
INVERTER 1 will stop.
Press S23: INVERTER 2 will start and the Static Switch will transfer from Reserve to
INVERTER 2.
Release S23: The Static Switch will transfer back from INVERTER 2 to Reserve, and
INVERTER 2 will stop.

Page 48 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

At the end of this test, even if the inverters are not running, turn both inverters off by
the control push buttons (Push Inverter ON/OFF button 0/1 Inverter for 1 second,
until SWITCH OFF INVERTER is displayed on the display).

Close Q23.

Open Q21.

Start both inverters by the control push buttons: both inverters will start simultaneously
once you start the second inverter.

The inverters are now running in AUTOMATIC mode.

Page 49 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.16.2. Maintenance procedure


Disconnecting one inverter, supposing that the load will be continuously supplied by the
other inverter (This is only possible if the total load is sure never to exceed the nominal
power of one inverter).
In this procedure, the inverter to be disconnected for Maintenance will be called
INVERTER M, and the Remaining inverter will be called INVERTER R.

Open Q26/Q27 of INVERTER M: the load is now supplied by INVERTER R alone.

On the MPPOI-03 board in the Bypass cubicle, disconnect the 10-pin flat cable coming
from INVERTER M (INVERTER 1 is connected to SK1 and INVERTER 2 is connected
to SK2 of MPPOI-03).

On the right of INVERTER M, disconnect both SUB-D25 cables, MC and FC (cables


coming from INVERTER R), from the SUB-D25 socket. Plug MC into FC. (This will
cause an Inverter Fault and a Reserve Warning to occur on the display!)

Reset the inverter alarms on INVERTER R: Inverter block and Reserve are getting normal
again on the display.

In the Bypass cubicle, open the isolating terminals X943-A or X943-B connected to
INVERTER M.

Stop INVERTER M by the control push buttons.

Isolate INVERTER M from DC side: Stop the charger, open Q3 and open Q5. Be sure
that Q4 is also open. Wait long enough to let the capacitors discharge themselves:
INVERTER M is now isolated, except the cables beyond the switches and breakers, which
may remain live.

INVERTER M is now disconnected.

Before any maintenance operation, always make sure that no more voltage is present
on any part you will have to touch.

INVERTER R goes on running normally: it can be switched OFF and ON by the control push
buttons (if Reserve voltage is present!). It is also possible to do Maintenance operation on
INVERTER R, by following the Maintenance procedures Maintenance Procedure for a
stand-alone inverter and Return from Maintenance for a stand-alone inverter here below.

Page 50 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Reconnecting the second inverter (INVERTER M), supposing that the load is supplied
by one inverter alone (INVERTER R).
In this procedure, the inverter which was disconnected for maintenance will be called
INVERTER M, and the inverter which supplies the load since the beginning will be called
INVERTER R.
INVERTER R is supposed to supply the load alone, without any Warning or Fault.
Energise the DC supply to INVERTER M. Wait until the display is correctly powered (no
more question mark).

Operate an inverter reset by the control push buttons of INVERTER M.

In the Bypass cubicle, close the isolating terminals X943-A or X943-B connected to
INVERTER M.

On the right of INVERTER M, disconnect SUB-D25 cable FC from MC (cables


coming from INVERTER R) and plug these cables into the SUB-D25 socket (MC into
FS and FC into MS). This will cause an Inverter Fault and a Reserve Warning to
occur on the display, and the Reserve Static Switch of INVERTER M to be opened
(visible on the synoptic diagram of the Display).

Operate an inverter reset by the control push buttons on both inverters, in order to clear all
Warnings and Faults.

On the MPPOI-03 board in the Bypass cubicle, connect the 10-pin flat cable coming from
INVERTER M (INVERTER 1 is connected to SK1 and INVERTER 2 is connected to
SK2 of MPPOI-03).

Close Q26/Q27 of INVERTER M.

Start INVERTER M: the load will be shared between both inverters.

INVERTER M is now reconnected.

Page 51 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.16.3. Transfer to maintenance for a stand-alone inverter

Check on the inverter display that the inverter is synchronised with Reserve, and that the
Reserve voltage is ok (Message Synchro is not flashing on the synoptic diagram, and
Reserve Status = No Warn; No Fault).
CAUTION:
If the inverter is not synchronised AND is supplying the load, or if
the Reserve supply is not ok, do not proceed because the supply of
the load could be interrupted.
Stop the inverter: the load will be transferred without a break to Reserve.

Close Q21.

Open Q23 and Q22.

Isolate the inverter from DC side: Stop the charger, open Q3 and open Q5.

Wait long enough to let the capacitors discharge themselves: the inverter is now isolated,
except the cables beyond the switches and breakers, and the complete Reserve and Bypass
cabling which may remain live.

Before any maintenance operation, always make sure that no more voltage is present
on any part you will have to touch.

5.16.4. Return from maintenance for a stand-alone inverter

Energise the DC supply. Wait until the display is correctly powered (no more question
mark).

Operate an inverter reset by the control push buttons.

Close Q22: the inverter is now in TEST mode. After 10 seconds, the Reserve Static
Switch will be closed (visible on the synoptic diagram of the Display).

If you want to check the load transfers, proceed as follows:


Turn the inverter on by the control push buttons (SWITCH ON INVERTER message
on the display): The inverter will not start.
Press S22 (for INVERTER 1) or S23 (for INVERTER 2): The inverter will start and
the Static Switch will transfer from Reserve to Inverter.
Release S22/S23: The Static Switch will transfer back from Inverter to Reserve, and
the inverter will stop.
At the end of this test, even if the inverter is not running, turn the inverter off by the
control push buttons (SWITCH OFF INVERTER message on the display).

Close Q23.

Open Q21.

Start the inverter by the control push buttons.

The inverter is now running in AUTOMATIC mode.

Page 52 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

5.16.5. Global maintenance procedure


If you want to transfer both inverters simultaneously to Maintenance, in order to isolate both
inverters, please refer to the paragraphs Maintenance Procedure for a stand-alone inverter
and Return from Maintenance for a stand-alone inverter here above. All instructions
concerning one inverter have to be executed on both inverters.

5.16.6. Black start procedure


If you want to start the (parallel) inverters while the Reserve voltage is not present, you have
to use the Black Start option, on the front door display:
Power up the DC supply of the inverters, as described here before.

Wait until both displays are correctly powered (no more question mark).

Operate an inverter reset on each inverter by the control push buttons (Reset part of the
LCD General Menu).

Start both inverters by the control push buttons on each display: the inverters will not yet
start, as the Reserve Supply is not present.

On one of both inverters, on the General Menu of the LCD, choose the option Black
Start. Select Yes and confirm by OK. Both inverters will start simultaneously.

Both inverters are now running in AUTOMATIC mode. There is no memorisation of the
Black Start, so you dont have to reset anything, once the Reserve Supply has come back.

Page 53 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

6. ROUTINE MAINTENANCE
Title

Page

6.1. GENERAL

54

6.2. ONCE A WEEK

54

6.3. ONCE A MONTH

54

6.4. AT LEAST 4 TIMES PER YEAR

55

6.5. ANNUALLY

55

6.6. FANS

55

6.1. GENERAL
Under normal operating conditions only preventative maintenance is required. The intervals
between maintenance actions will vary according to the level of remote monitoring and the
standard of cleanliness of the equipment room.
6.2. ONCE A WEEK
Check all alarm and status indicators.
Check meter readings are normal. Compare them with the test certificate. Check the cause of
any significant changes. For example, change in load, recent discharge
Record all abnormal occurrences in the service log
6.3. ONCE A MONTH
Check ventilation apertures are clean and clear of obstructions
On cells check the battery electrolyte levels and top up if necessary in accordance with the
manufacturers instructions.

Page 54 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

6.4. AT LEAST 4 TIMES PER YEAR


Check ventilation grilles
Visually check electrical connections and component for signs of overheating or corrosion.
Rectify as necessary.
Check painted and plated components for signs of damage or corrosion. Rectify as necessary
6.5. ANNUALLY
Carry out a test discharge of the battery for the specified autonomy.
Note:

The test should be carried out at a time of low risk and followed immediately by
a full recharge. Consult the battery manufacturer's instructions for guidance on
frequency of testing, depth of discharge etc.

6.6. FANS
Fans are rated for a 5-year life. It is recommended that fan failures be pre-empted by renewing
them after four years.

Page 55 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7. FAULT DIAGNOSIS
Title

Page

7. FAULT DIAGNOSIS

56

7.1. CHARGER DISPLAY MENU

57

7.2. CHARGER DEFAULTS

58

7.3. CHARGER VOLUNTARY STOPPED

59

7.4. CHARGER WARNING

59

7.5. BATTERY FAULT

60

7.6. BATTERY WARNING

60

7.7. INVERTER DISPLAY MENU

61

7.8. INVERTER FAULTS

62

7.9. INVERTER VOLUNTARY STOPPED

63

7.10. INVERTER WARNING

63

7.11. RESERVE WARNING

64

7.12. AC LOAD/ STATIC SWITCH FAULT

64

7.13. AC LOAD/STATIC SWITCH WARNING

65

Page 56 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7.1. CHARGER DISPLAY MENU

Charger fault is designed by


pictogram.

on the charger

Select Charger in the general menu and click on


OK to valid.

In order to have access to the Faults menu, select


Faults in the Charger menu and click on OK to
valid.

In this menu all faults appear (instantaneous and


memorized faults)

If no faults are shown on the display then No


faults appears in this menu.
Click twice on Cancel to come back to the
general menu.

Page 57 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7.2. CHARGER DEFAULTS

CHARGER FAULTS

POSSIBLE CAUSES

SOLUTIONS

AC Supply fault

Loss of AC supply, lack of one


phase, too high or too low
amplitude, wrong phase
sequence for three phase charger

Wrong phase sequence

On three phase charger, the


phase sequence is not correct

AC voltage NOK

Amplitudes of one or several


phases are not OK

High DC Voltage

Loss of charger voltage


regulation in case of charger
alone configuration (The fault is
not memorized and the charger
runs intermittently in order to
continue to supply the DC load).
Loss of charger voltage
regulation in case of parallel
configuration charger (The fault
is memorized and the charger is
cut) . The DC load is supplied
by the redundant charger(s)

Check fault nature on the LCD


display (amplitude or phase
problem).
Check input supplies.
If AC supply is OK on power
input terminals, check auxiliary
fuses on internal electronic door
(F10)
Interchange two phases, to
reverse direction of phase
rotation
Check input supply on power
input terminals. If AC supply is
OK on power input terminals,
check auxiliary fuses on internal
electronic door (F10)
Check all the wires connected
to the INCA circuit board. If the
wiring is correct, the problem
can be linked with card
problem:
Call engineer.
Check all the wires connected
to the INCA circuit board. If the
wiring is correct, the problem
can be linked with card
problem: Call engineer.
Reset this memorized fault with
the LCD display charger reset.
Check all the wires connected
to the INCA board and the
battery current Hall effect
sensor. If the wiring is correct,
the problem can be linked with
card or sensor problem: Call
engineer.
Reset this memorized fault with
the LCD display charger reset.
Check loading, thyristors,
renew fuse, rearm the
microswitch detector. In case of
a new occurrence, check the
control wiring on the INCA
board. The problem can be
linked with a board: Call
engineer.

High DC Voltage
Memorized

Too high I battery


Memorised

Loss of battery current


regulation.

Charger fuse blown

Charger bridge high speed fuse


blown due to sudden short
circuit on the DC side or
problem on charger control
loop.

Page 58 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Input protection opened

Input protection tripped or


opened.

Check loading and possible


short circuit or overload on the
DC side. Rearm the protection.

Remote emergency stop

Optional remote charger switch


is acting. (Optional switch)
(or redundant high DC voltage
monitor is acting).

Check if the charger is not


cut by an external remote
switch.
(Check if the redundant
voltmetric relay is not acting on
the INCA board by looking at
red LED10)

3 other charger fault specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA)
7.3. CHARGER VOLUNTARY STOPPED
Charger switch Off

The charger is cut from the


CANDIS board.

Give an ON charger order with


CANDIS push button.

7.4. CHARGER WARNING


CHARGER
WARNING

POSSIBLE CAUSES

SOLUTIONS

Fan failure

One charger bridge fan is not


supplied or blocked (in case of
forced air cooling charger
bridge)
The charger DC voltage is not
yet in voltage level regulation:
Overload on the DC side, or
battery is charging in current
limitation after a discharge, or
possible problem of voltage
regulation due to a too low AC
mains level.

Remove the charger AC and DC


power supply, and isolate it.
Replace the fan in failure.

DC voltage low

Test mode

The charger is in special


production or commissioning
mode.

Check if the DC load is not too


high or if the charger is in
battery current limitation, by
looking at IDC or Ibatt current
level on the display board. If
both preceeding points are not
satisfied, check if the AC mains
amplitude is not too low before
to call engineer.
Call engineer

3 other charger warning specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA)

Page 59 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7.5. BATTERY FAULT


BATTERY FAULTS

POSSIBLE CAUSES

SOLUTIONS

Battery Test Fault


Memorized

Following an automatic or a manual


battery test, a battery fault has been
detected due a too rapid discharge
rate.

End of discharge

Low DC trip level has been passed.

Battery protection opened

Battery fuse or circuit breaker open.

Check battery connections.


Check battery not damaged.
Call engineer.
Reset this memorized fault with
the LCD display charger reset.
If AC supply fail, no action.
Check no charger fault.
Call engineer.
Check DC loading then reconnect.

3 other battery fault specific messages can be detected in this part due to equipment
customisation. Check these optional messages in the General Arrangement drawing (PA)
7.6. BATTERY WARNING
BATTERY
WARNINGS

POSSIBLE CAUSES

DC Earth fault

Current leakage between battery and


earth or DC polarities and earth.

SOLUTIONS

Danger, DO NOT CARRY OUT


BATTERY MAINTENANCE
.Check battery cable insulation.
Check battery cell insulation. Try
to isolate the failed part by
switching DC load or battery off.
Call engineer.
Battery begin of discharge AC supply fail.
If AC supply fail, no action.
Check no charger fault.
Call engineer.
Imminent shutdown
AC supply fail.
If AC supply fail, no action.
Battery voltage is low. Indicates
Check no charger fault.
battery discharged close to trip level.
Call engineer
Temp sensor fault
The battery temperature sensor used to Check the connection of battery
temperature sensor.
memorized
achieve the battery voltage
compensation control is in failure and Reset this memorized fault with
the LCD display charger reset.
the charger runs with a temperature
If new occurrence, call engineer.
default value of 20C.
BMS Battery Cell
See BMS User Manual
warning
BMS Hardware Fault
See BMS User Manual

3 other battery warning specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement drawing (PA).

Page 60 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7.7. INVERTER DISPLAY MENU

Inverter fault is designed by

on the

inverter pictogram.

Select Inverter in the general menu and click on


OK to valid.

In order to have access to the Faults menu, select


Faults in the Inverter menu and click on OK to
valid.

In this menu all faults appear (instantaneous and


memorized faults)

If no faults are shown on the display then No


faults appears in this menu.
Click twice on Cancel to come back to the
general menu.

Page 61 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

7.8. INVERTER FAULTS

INVERTER FAULTS

POSSIBLE CAUSES

SOLUTIONS

VCE Fault M.

Inverter bridge transistor


desaturation detected due to an
excessive current. Inverter is
stopped.

Inv. Overld Flt M.

Inverter is stopped due to a too long


overload time or repetitive transfer
on reserve.

Overtemp. Flt M.

An overtemperature is detected on
the inverter bridge due to a problem
of cooling (possible fan failure or
air input /output blocked ).

Low DC voltage.

The inverter is stopped due to a low


DC voltage input.

Repeated Low DC M.

The inverter is stopped as result of


repetitive low DC voltage
detection.

High DC voltage M.

Inverter is stopped due to a too high


DC voltage input caused by a
charger problem. A possible cause
can be also linked with a bad static
switch running.

High AC voltage M.

Inverter output regulation problem.

Check the AC load.


Reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer (inverter bridge or
driver problem).
Reduce load.
Reset this memorized fault
with the LCD display
inverter reset.
Check the air input/output
cleanness and the fan
running. After correction,
reset this memorized fault
with the LCD display
inverter reset. If new
occurrence, call engineer.
Check why the DC voltage
inverter input is too low.
(Charger running or battery
exhausted).
Check why the DC voltage
inverter input is too low.
(Charger running or battery
exhausted). Reset this
memorized fault with the
LCD display inverter reset.
Check the charger DC
voltage. After correction,
reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer.
Check the wiring of the
inverter LION interface
board. After correction,
reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer.

Page 62 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Frequency Fault M.

Inverter output regulation problem.

Paral. Com. Flt M.

Problem detected in the


communication between the
different parallel running units (in
case of inverter parallel running)
Inverter running stopped by a
microcontroller fault on the Inverter
CUdSMC board.

Microcontroller fault

Check the wiring of the


inverter LION interface
board. After correction,
reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer.
Check correct insertion and
wiring of optional POB
board.
Reset this memorized fault
with the LCD display
inverter reset.
If new occurrence, call
engineer

3 other inverter fault specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement Drawing (PA).
7.9. INVERTER VOLUNTARY STOPPED
Inv. switched Off

The inverter is cut from the


CANDIS board.

Give an ON inverter order with


CANDIS push button.

7.10. INVERTER WARNING


INVERTER
WARNINGS

POSSIBLE CAUSES

Redundant fan failure

One inverter bridge fan is not supplied Follow the maintenance inverter
or blocked (in case of forced air cooling procedure in order to isolate the
inverter bridge)
inverter part from an electrical
point of view .Replace the fan in
failure.
The inverter is feeding a too high AC
Check the overload reason and
load. If this overload is not diminished reduce the load.
rapidly the inverter will stopped after a
time depending on the overload level.
Transient microcontroller problem,
Call engineer
inverter may still be running.
Running mode used for commissioning. Modify the configuration with
PPVIS software.
Operator has forgotten to replace the
inverter in normal operation
configuration.
Fan used is too old.
Check the expected lifetime of
the different fans of the
equipment, and replace them if
required.

Inv. Overload warning

S/W Time-out.
Commissioning

Fan Life expired

SOLUTIONS

Page 63 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

3 other inverter warning specific messages can be detected in this part due to equipment
customisation. Check these messages in General Arrangement Drawing (PA)
7.11. RESERVE WARNING
Remark : For ON LINE INVERTER configuration, a reserve NOK is not considered as a fault
but as a warning, because it doesnt imply a direct loss of the AC load.
RESERVE WARNINGS POSSIBLE CAUSES

Reserve Voltage NOK

Res. Frequency NOK

Phase Sequence

Reserve Inhibited
Paral. Res. Flt M.

SOLUTIONS

The reserve voltage is not correct or the Check the reserve amplitude, try
reserve is absent.
to establish a correct reserve. No
action on the inverter.
The reserve frequency is not correct
Check the reserve frequency, try
to establish a correct reserve. No
action on the inverter.
For three phase inverter, the phase
Interchange two phases, to
sequence is not correct.
reverse direction of phase
rotation
Error of software configuration.
Call engineer.
In case of paral. Com. Flt M. active, Check the displayed reserve
refer to comments of this fault. In the
voltage and frequency, and
other case, there is a problem on one of reserve warning messages on
the parallel reserve supplies.
each UPS.

3 other reserve warning specific messages can be detected in this part due to equipment
customisation. Check these messages in the General Arrangement Drawing
7.12. AC LOAD/ STATIC SWITCH FAULT
AC LOAD/ STATIC
SWITCH FAULTS

POSSIBLE CAUSES

SOLUTIONS

Emerg. Power Off

The AC load is no more supplied due


to an Emergency power Off order sent
to the dedicated input.
The reserve static switch has fed a too
high AC load for a too long time.

Check the reason of the


volunteer Emergency Power Off
order.
Reduce load. Reset this
memorized fault with the LCD
display inverter reset.
Check the wiring of the inverter
static switch and its associated
driver (both anti parallel SCRs
must be driven so as to have
positive and negative voltage on
the AC load).
After correction, reset this
memorized fault with the LCD
display inverter reset.

S.S Overload Flt M.

Inv. Stat Sw Flt M.

The inverter static switch is in failure


and is not correctly controlled.

Page 64 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

Res stat Sw Flt M.

The reserve static switch is in failure


and is not correctly controlled.

Stat Sw H/W Flt M.

Problem in the power supply of the


reserve static switch driver board.

If new occurrence, call engineer.


Check the wiring of the reserve
static switch and its associated
driver (both anti parallel SCRs
must be driven so as to have
positive and negative voltage on
the AC load). After correction,
reset this memorized fault with
the LCD display inverter reset.
If new occurrence, call engineer.
Check the power supply of the
COGAS or CDCS boards.

3 other AC LOAD/ Static Switch fault specific messages can be detected in this part due to
equipment customisation. Check this messages in the General Arrangement Drawing (PA)
7.13. AC LOAD/STATIC SWITCH WARNING
AC LOAD/ST.SW
WARNINGS

POSSIBLE CAUSES

AC Earth Fault

An AC earth Fault has been detected on In case of several AC loads, try


the AC load part (Option).
to define which load is in failure
by cutting the supply of the
different load.
The AC load is supplied by the reserve After Maintenance operation,
with the Manual bypass for
dont forget to come back in
maintenance purpose.
automatic configuration in order
to have the maximum autonomy
and reliability.
Check the overload reason, and
The reserve static switch is feeding a
too high AC load. If this overload is not reduce the load.
diminished rapidly, the reserve static
switch will be shut off.

Manual Bypass On

S.S. Overld Warn.

SOLUTIONS

3 other AC LOAD/ STATIC SWITCH warning specific messages can be detected in this part
due to equipment customisation. Check this messages in the General Arrangement Drawing
(PA)

Page 65 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

8. SPARE PARTS
Titre

Page

8.1. GENERAL NOTES

66

8.1. GENERAL NOTES


To maintain the high level of performance and reliability of these secure power systems the
following rules are applied:

Careful choice of components


Manufacturing according to recognised standards and codes of practice
Strict quality control
Careful adjustment and regulation.

However, in use, problems can occur which require parts to be replaced or repaired.
Replacement of defective parts can sometimes be made by the user to restore correct
operation of the system which may then be returned to service. For this spare parts will be
required.
For continued reliability only approved, identical replacement parts may be used. Where
necessary these must be adjusted to the original set values. Chloride Industrial Systems After
Sales Service Department has records of recommended spares for all equipment.
When ordering spare parts it is essential to identify the equipment by quoting the serial
number and the design number (RB) stamped on the rating plate.

Page 66 of 68

CHLORIDE
INDUSTRIAL SYSTEMS

9. DRAWINGS
Title

Page

9.1. GENERAL NOTES

67

9.1. GENERAL NOTES


The drawings included in this manual are current at time of issue but are not necessarily
changed at each revision. Check the site master drawing system for the latest issue status.
Wire numbering. Internal wiring is identified on a point to point basis. Each wire has an
individual number and is identified at both ends unless too short for two markers. All wire
numbers and termination points are detailed on the schematic diagrams.
Terminal identification. Terminals are identified on the schematic.
Drawing identification. The Chloride drawing prefixes identify the type of drawing
PA

- General arrangement drawing

PA-318107

SU

- Single line diagram

SU-318107

DT

- Technical file

DT-318107

Circuit card drawings. Detailed circuit drawings are not provided. These represent the
proprietary knowledge and experience of Chloride Industrial Systems and are commercially
confidential. In addition they do not assist with the understanding, operation and maintenance
of the UPS systems. Except in the hands of adequately trained, experienced and qualified
personnel we have found that these diagrams are often used to adjust or modify the systems in
ways detrimental to the performance and reliability of the systems.
These diagrams will only be supplied to personnel who have successfully completed a
Chloride Industrial Systems training course or who have adequately proved to the quality
manager of Chloride Industrial Systems that their level of training, experience and
qualification is sufficient to enable them to use the information safely. Such issue is on a
personal basis and does not authorise 3rd party use.

Page 67 of 68

Page

Titre/Title

00

01

02

03

04

TITLE PAGE

xx xx xx xx xx

GENERAL ARRANGEMENT

xx xx xx xx

CUBICLE FOOTPRINT DETAIL

xx xx xx

BOTTOM GLAND PLATE ARRANGEMENT

DISPLAY DETAIL PAGE 1

xx xx

DISPLAY DETAIL PAGE 2

xx xx

NAMEPLATE DETAIL

xx

BATTERY PROTECTION BOX

05

06

07

08

09

10

11

12

13

CUSTOMER

: INDIAN OIL CORPORATION LTD., NEW DELHI

PROJECT

: 2.2MTPA DHDT PLANT, VADODARA

EQUIPMENT

: DUAL UPS Apodys 70kVA 370VDC 1x110VAC

xx

XX

xx

xx

TAG NUMBER : 38 UPS-4-05 & 38 UPS-2-03

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

GENERAL ARRANGEMENT
03/09/2009

MHS

AS BUILT

04

29/07/2009

MCC

UPDATED

03

01/04/2009

MHS

INPUT LIGHTS ADDED

02

16/03/2009

LML

UPDATED FOLLOWING COMMENTS

01

07/11/2008

MHS

FOR APPROVAL

00

Date

Creat.

Description modif.

Indice/Issue

Verif.

App.

PA318107

Indice/
Issue

Page

04

Height :
Width :
Depth :
Protection :
Paint :
Lock :
Key :
Cable entry :

1982 mm
4800 mm
1008 mm
IP31
631 as per IS:5
Retractable Handle
1333
BOTTOM

=UPS1+A1

=BYP1+A2

=UPS2+A3

N
P
TAG A

1800mm

TAG B

TAG C

H1 H2 H3

H1 H2 H3

P
Hz

1982

H1 H2 H3

OPERATING HEIGHT
OF THE SWITCHES

LABEL / TAG :

100

TAG A : UPS 1
TAG B : BYP 1
TAG C : UPS 2

1180 kg

500 kg

1180 kg

1600

1200

1600

200 mini
WALL

1008

CHARGER
-H1 : CHARGER SUPPLY - PHASE 1 OK
-H2 : CHARGER SUPPLY - PHASE 2 OK
-H3 : CHARGER SUPPLY - PHASE 3 OK
BYPASS
-H1 : BYPASS SUPPLY - PHASE 1 OK
-H2 : BYPASS SUPPLY - PHASE 2 OK
-H3 : BYPASS SUPPLY - PHASE 3 OK

300mm

200 mini

=UPS1+A1 : UPS 1 CUBICLE


=BYP1+A2 : BYPASS CUBICLE
=UPS2+A3 : UPS 2 CUBICLE

282x120

282x120

282x120

282x120

182x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

182x120

282x120

282x120

282x120

282x120

282x120

282x120

SHIPPING BREAK

J.REQ.NO: 18-3293-00/O.65/0223/OO
800

PROJ. NO: 18-3293

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

GENERAL ARRANGEMENT
30/07/2009

MCC

Date

Creat.

Verif.

App.

UPDATED
Description modif.

PA318107

Ind/Rev

Page

03

1030

830

1600

92.5

92.5

1200

715.0

1008

715.0

830

715.0

1008

315.0

1430

13

72.5

J.REQ.NO: 18-3293-00/O.65/0223/OO

100

72.5

100

72.5

100

13

62.5

62.5
125

PROJ. NO: 18-3293

CIS FILE NO.: PA318107

ANGLE FOOT DETAIL

CUST. : CHLORIDE INDUSTRIAL SYSTEMS

CENTRAL FOOT
DETAIL

PROJ. : 2.2 MTPA DHDT PLANT


CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

CUBICLE FOOTPRINT DETAIL


01/04/2009

MHS

Date

Creat.

Verif.

App.

INPUT LIGHTS ADDED


Description modif.

PA318107

Ind/Rev

Page

02

282x120

182x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

282x120

131

282x120

60

182x120

131

60

1008

1600

1008

1200

77
109.0

189

77
79.5

77
159

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

BOTTOM GLAND PLATE ARRANGEMENT


01/04/2009

MHS

Date

Creat.

Verif.

App.

INPUT LIGHTS ADDED


Description modif.

PA318107

Ind/Rev

Page

02

STOP

Sync.

UPS

1 2 3
100%

100%

LED view

LED colour

OK

Description

Rectifier

Inverter

Comments

UPS normal
operation
Load on battery or on
reserve

Loads powered by battery or


reserve.

Orange

UPS
WARNING

One or more subassembly are


affected but not stopped.

Red

UPS
FAULT

Subassembly are faulty and


stopped or manually stopped.

Red flashing

CAN communication
FAULT

The UPS communication CAN


BUS is not correctly plugged or
in failure.

Green
Green flashing

STOP

Cancel audible alarm


(It cancels internal audible alarm until a new alarm occurs)
User switches used to control the Graphical Liquid Crystal Display:

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107

Select previous
Up in menus

Select next
Down in menus

OK

Cancel parameters
Back in menus

CUST. : CHLORIDE INDUSTRIAL SYSTEMS


PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd

Valid parameters
Enter in menus

MFR. : CIS, CHASSIEU, FRANCE

DISPLAY DETAIL PAGE 1


16/03/2009

LML

Date

Creat.

Verif.

App.

UPDATED FOLLOWING COMMENTS


Description modif.

PA318107

Ind/Rev

Page

01

Rectifier information

Inverter information

Status indications
Charger OFF
Initialisation
Charger Stop
Equalisation mode
Equalisation imposed
Floating mode
Battery test mode
Battery test imposed
Boost mode

Measurements indications
Charger output DC voltage
Charger output DC current
Charger input voltage (between each phase)
Charger input current (on each phase)
Charger input frequency
Number of mains failures

Faults indications
No fault
High DC voltage
High DC voltage memorised
Too high Ibattery memorised
Charger fuse blown
Input protection open
Charger off
Wrong phase sequence
AC supply fault

Warnings indications
Test mode
DC voltage low
Overload inhibit
Charger in current limit

Status indications
Inverter synchronised
Inverter on crystal
Inverter not running
Inverter switched off

Warnings indications
No warning
Commissioning
Software time-out
Fan failure
Inverter overload warning

Measurements indications
Inverter input DC voltage
Inverter ouput voltage (between phases and neutral)
Inverter frequency
Faults indications
No fault
Inverter switched off
VCE bridge fault memorised
Inverter overload fault memorised
Over-temperature fault memorised
Low DC voltage
Repeated low DC voltage memorised
High DC voltage memorised
Microcontroller fault memorised
High AC voltage memorised
Frequency fault memorised

Reserve information
Battery information
Status indications
Normal
Discharging
Charging
Fault or warning

Warnings indications
DC earth fault
Battery begin discharge
Imminent shutdown

Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)

Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open

REMOTE ALARM

Warnings indications
No warning
Reserve voltage fault
Reserve frequency fault
Wrong phase sequence

Charger common alarm


UPS charger failure
UPS inverter failure
Battery discharged
Battery isolated

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT

Status indications
No warning ; no fault
Warning ; no fault
No warning ; fault
Warning + fault

Load and static switch information


Status indications
Load on inverter
Load on reserve
Manual bypass on
Load not supplied

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency

Faults indications
No fault
Static switch overload fault memorised
Inverter static switch fault memorised
Reserve static switch fault memorised
Static switch hardware fault memorised

Measurements indications
Load voltage (between phases and neutral)
Load current (on each phase)
Load frequency
Load power (on each phase in kVA)
Load power (on each phase in kW)
Total time on inverter
Load current ratio (%)
Warnings indications
No warning
Manual bypass closed
Static switch overload

CLIENT : IOCL Vododara, Gujarat


CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

DISPLAY DETAIL PAGE 2


16/03/2009

LML

Date

Creat.

Verif.

App.

UPDATED FOLLOWING COMMENTS


Description modif.

PA318107

Ind/Rev

Page

01

Quantit/quantity :

Matire/material :

Engraved plate

Epaisseur/thickness :

15/10me

Couleur de fond/background
colour :

Blanc/White

Couleur de caractres/letters
colour :

Noir/Black

Hauteur de caractres/letters
height :

2mm

Police/letters type :

SL513 ( Arial )

100mm
5mm

5mm

4 x 3.2

MANUFACTURER : CHLORIDE INDUSTRIAL SYSTEMS


30 av Montgolfier

69680 CHASSIEU (France)


Tel : (+33) 4 78 40 13 56
Fax : (+33) 4 78 90 58 90

100mm

EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC

J.REQ.NO: 18-3293-00/O.65/0223/OO

AC Input Voltage :
Input Phases :
Input Frequency :
DC Voltage :
DC Current :
Battery Type :
Number of Cells :
Capacity :
Autonomy :
AC Output Voltage :
Output Phases :
Output Frequency :

415V
3
50Hz
370V
209.34A
CdNi
293
310Ah
60mn
110V
1
50Hz

Serial Number :
Equipment tag number :

L08-1262/L09-0831
38UPS-4-05/38UPS-2-03

Year of manufacture :

2008

PROJ. NO: 18-3293

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

NAMEPLATE DETAIL
29/07/2009

MCC

Date

Creat.

Verif.

App.

UPDATED
Description modif.

PA318107

Ind/Rev

Page

03

400mm

800mm

960mm

1000mm

1000 mm
800 mm
400 mm
IP31
631 as per IS:5
BOTTOM

1045mm

Height :
Width :
Depth :
Protection :
Paint :
Cable entry :

LOCKING

4x
FASTENING 9mm

760mm
845mm

12.5

BOTTOM
GLAND PLATE

310 x 96

35

310 x 96

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: PA318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

BATTERY PROTECTION BOX


16/03/09

LML

Date

Creat.

Verif.

App.

UPDATED FOLLOWING COMMENTS


Description modif.

PA318107

Ind/Rev

Page

01

Page

Titre/Title

00

01

02

03

04

TITLE PAGE

xx xx xx xx xx

SINGLE LINE DIAGRAM

xx xx xx xx

05

06

07

08

09

10

11

12

13

CUSTOMER

: INDIAN OIL CORPORATION LTD., NEW DELHI

PROJECT

: 2.2MTPA DHDT PLANT, VADODARA

EQUIPMENT

: DUAL UPS Apodys 70kVA 370VDC 1x110VAC

TAG NUMBER : 38 UPS-4-05 & 38 UPS-2-03

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: SU318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat
CONSLT : Jacobs Engineering India Pvt Ltd
MFR. : CIS, CHASSIEU, FRANCE

SINGLE LINE DIAGRAM


03/09/2009

MHS

AS BUILT

04

30/07/2009

MCC

UPDATED

03

01/04/2009

MHS

INPUT LIGHTS ADDED

02

16/03/2009

LML

UPDATED FOLLOWING COMMENTS

01

07/11/2008

MHS

FOR APPROVAL

00

Date

Creat.

Description modif.

Indice/Issue

Verif.

App.

SU318107

Indice/
Issue

Page

04

=BYP1+A2
H1-H2-H3

-T31
70kVA
2Ph/415VAC -1Ph/110VAC
50Hz

X
-Q31
(200A)

BYPASS SUPPLY
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5

-U31
100kVA
110VAC +/-1%

=UPS1+A1

APODYS
DISPLAY

H1-H2-H3
U, I, F

U, I

CHARGER 1
370VDC/147-208A

-Q3
(200A)

AC SUPPLY 1
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5

-V2
(250A)

U
-Q2
(250A)

INVERTER 1 70kVA
1Ph/110VAC
50Hz
U

U, F
-V18

-Q26
(800A)

K100

=BAT1+A4

BATTERY 1 370VDC
Type
: NiCd
Reference : KBM 277
Number of Cells : 293
Capacity : 277h
Autonomy : 60min

BATTERY 2 370VDC
Type
: NiCd
Reference : KMB277
Number of Cells : 293
Capacity : 277Ah
Autonomy : 60min

Float
: 1.41V/cell
Charge
: 1.65V/cell
Manu. Boost : 1.70V/cell
End of Disch.: 1.00V/cell

-Q5_1
(250A)

(P40)

(P40)

U, F

-Q4
(250A)

U, F

-Q5_2
(250A)

(P40)

(P40)

-V21

-Q22
(800A)
U, F, I, W
-Q23
(800A)

K100

-Q21
(800A)

AC LOAD
1Ph / 110VAC
50Hz
Cu 50x5

U, F, I, W

=UPS2+A3

APODYS
DISPLAY

H1-H2-H3
U, I, F

X
-Q3
(200A)

AC SUPPLY 2
TPN / 415VAC +/-10%
50Hz
Terminals Cu 50x5

U, I

-V2
(250A)

-Q2
(250A)

CHARGER 2
370VDC/147-208A

SIZE OF TERMINALS

-T31 : BYPASS TRANSFORMER


-U31 : STABILISER
-V2 : CHARGER OUTPUT BLOCKING DIODE
-V18/V21 : STATIC SWITCH
-K100 : DC EARTH FAULT

P6
: 0.14 to 4 mm
P8
: 0.2 to 6 mm
P10
: 0.5 to 10 mm
P12
:1.5 to 16 mm
P16
: 1.5 to 35 mm
P32 (M10) : 25 to 50 mm
P40 (M12) : 35 to 95 mm
P46 (M12) : 50 to 150 mm
P53 (M16) : 70 to 240 mm
Cu Busbars: Copper busbars

J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293

CIS FILE NO.: SU318107


CUST. : CHLORIDE INDUSTRIAL SYSTEMS
PROJ. : 2.2 MTPA DHDT PLANT
CLIENT : IOCL Vododara, Gujarat

INVERTER 2 70kVA
1Ph/110VAC
50Hz
U

-Q
AUTO
TRANSITION
TEST
MAINTENANCE

U, F

-V18

-Q27
(800A)

21 22 23

NEUTRAL TO EARTH

XX
X XX
XX
X

-Q2 : CHARGER OUTPUT ISOLATOR


-Q3 : CHARGER INPUT FUSE SWITCH
-Q5-1 & 2 : BATTERY CIRCUIT BREAKER
-Q21 : BYPASS SWITCH
-Q26 : INVERTER 1 OUTPUT ISOLATOR
-Q27 : INVERTER 2 OUTPUT ISOLATOR
-Q31 : BYPASS INPUT FUSE SWITCH
-H3 : CHARGER SUPPLY ON

=UPS1+A1 : UPS 1 CUBICLE


=BYP1+A2 : BYPASS CUBICLE
=UPS2+A3 : UPS 2 CUBICLE
=BAT1+A4 : BATTERY PROTECTION BOX

CONSLT : Jacobs Engineering India Pvt Ltd

INTERCONNECTION CABLES
NOT SUPPLIED BY CHLORIDE

MFR. : CIS, CHASSIEU, FRANCE

30/07/2009

MCC

Date

Creat.

SINGLE LINE DIAGRAM


UPDATED
Verif.

App.

DESCRIPTION

SU318107

Ind/Rev

Page

03

CHLORIDE
INDUSTRIAL SYSTEMS

10. ATTACHMENTS
Title

Page

10. ATTACHMENTS

68

10.1. battery manual

68

10.1. BATTERY MANUAL

Page 68 of 68

NCPP
Nickel Cadmium Pocket Plate

Operation and Service manual

CONTENTS

1.0

TECHNICAL SPECIFICATION

2.0

INTRODUCTION

3.0

SAFETY PRECAUTIONS

4.0

RECEIVING THE SHIPMENT

5.0

STORAGE

6.0

INSTALLATION

7.0

ELECTROLYTE PREPARATION

10

8.0

ELECTROLYTE FILLING

11

9.0

CHARGING

12

10.0

MAINTENANCE

14

11.0

ELECTROLYTE REPLACEMENT

19

12.0

DOS AND DO NOTS

21

13.0

DM/ DI WATER SPECIFICATION

23

14.0

SERVICE LOG

24 -25

15.0

TOOLS & ACCESSORIES

26

16.0

DRAWINGS

27

2.0 INTRODUCTION
We thank you for purchasing our reliable and long life nickel cadmium pocket plate
battery. Please read and follow the instructions given in this manual to obtain the
best performance and life from your battery. Inspect the battery at regular intervals
and use the service log sheet provided at the end of the manual for maintaining the
records. Contact Customer Service, for any additional help and guidance that you
may require.

2.1 ELECTROCHEMISTRY
The basic principle of the rechargeable battery is the conversion of electrical energy
into chemical energy and vice versa. The storage battery consists of a number of
individual cells connected in series to produce the required voltage. Each cell
consists of positive plates (containing nickel hydroxide as the active constituent)
and negative plates (containing cadmium hydroxide) immersed in a solution of
potassium hydroxide in DM/DI water with lithium hydroxide as an additive.
The simplified overall reversible electrochemical reaction given below produces a
nominal discharge voltage of 1.2 volts per cell:

2 Ni(OH)2 + Cd(OH)2

Charge

Discharge

2 NiOOH + Cd + 2H2O

When the cell is charged, the active materials initially present as hydroxides are
changed. The cadmium hydroxide is reduced to cadmium and nickel hydroxide
attains a higher degree of oxidation. On discharge, the process is reversed and the
active materials revert to their original state.
The potassium hydroxide electrolyte doesnt take part in these reactions and acts
only as a carrier of ions. The lithium hydroxide additive in the electrolyte
significantly increases the life of the cell since it has a beneficial effect on the
positive electrodes. This beneficial effect is more pronounced at higher operational
temperatures.

2.2

CONSTRUCTION
The first still the most reliable electrode design for nickel cadmium batteries is the
pocket plate. The active material in each electrode is encapsulated in pockets of
double perforated, nickel plated steel strips. Several pockets are mechanically
joined together and cut in suitable lengths to form plate pieces. Both cut edges of
the plate pieces are sealed by U-section steel strips. The nickel-plated steel tab is
joined to the plate piece and the U-section steel strips by spot welding. The plate
assembly is compressed together to establish good contact between the active
material, double perforated steel strips and U-section steel strips. The U-section
steel strips and tab are the Current collectors of the plate.

Several plates of the same polarity are either bolted to the terminal post or welded to
the terminal post. Negative and positive plate groups are interleaved so that plates
of opposite polarities are alternated. The plate groups are insulated from one another
by insulating each plate from the next by either a combination of insulating rods and
edge insulation or grid insulation. The plate block is firmly strapped together using a
suitable number of polypropylene straps.
The cell container is of the either polypropylene or stainless steel. Matching cell lids
are made of the same material as that of the cell container. Mirror welding is
employed for thermally fusing the mating surfaces of polypropylene cell containers
and lids, while TIG fusion welding is employed in case of stainless steel cell
containers and lids. The choice of material depends on the application and operating
conditions. The polypropylene containers are translucent and completely free from
corrosion in wet and saline conditions. The assembly is compact and easy, and the
polypropylene has high impact resistance.
Polypropylene cells are assembled on steel racks with step arrangement in order to
permit visual electrolyte level maintenance checks. Alternatively, polypropylene cells
are mounted in stainless steel crates, each holding a suitable number of cells to suit
the space constrained battery boxes as in the case of mobile applications.
Steel cell are mounted in insulated wooden crates, each holding a suitable number of
cells to suit the space constrained battery boxes as in the case of mobile
applications. The wooden crates are also placed in steel racks (without the step
arrangement) for stationary applications.

3.0 SAFETY PRECAUTIONS


3.1 ELECTROLYTE
The alkaline electrolyte (solution of potassium hydroxide in DM/DI water) is a strong
caustic agent. Wear rubber gloves, eye protection and long sleeved clothing when
working on the battery. Before working with electrolyte, make sure that water for
washing is easily available. If electrolyte is splashed on the skin or clothing, wash
immediately with water for 10 to 15 minutes. If eyes are affected, flood with water
followed by eye wash solution and obtain immediate medical attention.
3.2 KEEP FLAMES AWAY
The battery will produce a mixture of oxygen and hydrogen gases during the last
portion of high rate charging.
Do not adjust connections etc., while charging or in the first hour after charging.
Discharge any possible static electricity from clothes by touching earth connected
part.
Do not smoke in the battery room.
Keep the battery location well ventilated to prevent buildup of the oxygen and
hydrogen gases, and do not cover the battery during charging.

3.3

TOOLS
Use tools with insulated handles / surfaces.
Do not place or drop metal objects on top of the battery.
Remove rings, wristwatch, loose coins from the pockets and articles of clothing with
metal parts that might come in contact with the battery terminals.

4.0 RECEIVING THE SHIPMENT


4.1 UNPACKING AND INSPECTION
Do not over-turn the packages.
Unpack the batteries immediately upon the arrival and inspect for possible damage
in shipment.
Make sure that small packages are not thrown out together with the packing
material.
Check that all the material listed in the packing list has been received.
PLEASE INFORM HBL NIFE IMMEDIATELY IN CASE OF ANY DAMAGE OR
SHORTAGES IN THE CONSIGNMENT.
4.2 SHIPPING METHOD I
THE BATTERY SHIPPED IN FILLED AND CHARGED CONDITION
Remove immediately the transport seal (red plastic film) from the vent cap. Remove
the transit cap (blue/red), wherever mounted on cell terminals for big size cells.
Check the electrolyte level in the cells and add electrolyte if necessary.
The battery is then ready for installation or storing.
THE BATTERY MUST NEVER BE CHARGED WITH THE TRANSPORT SEAL IN
PLACE AS THIS CAN CAUSE PERMANENT DAMAGE.
4.3 SHIPPING METHOD II
THE BATTERY SHIPPED IN DISCHARGED AND EMPTY CONDITION

Do not remove the transport seal (red plastic film), from the vent cap until ready to fill
the battery. Remove the transit cap (blue/red).
The battery electrolyte is supplied in either dry or liquid form. Dry electrolyte is
supplied in the separately sealed packages containing potassium hydroxide and
lithium hydroxide. Liquid electrolyte (a mixture of potassium hydroxide, lithium
hydroxide and DM/DI water in the required proportions) is supplied in sealed jerry
cans or drums.
Do not open the sealed packages or containers until ready to mix the electrolyte or fill
the battery.
Read the instructions for electrolyte preparation / or filling as required. Also remove
the transit cap (blue/red), wherever mounted on cell terminals for big size cells.

5.0 STORAGE
5.1 STORAGE OF NEW BATTERY IN FILLED AND CHARGED CONDITION
A filled and charged battery can be stored for a maximum period of one year.
Store the battery in a clean, dry and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not store other material on top of the battery.
After removing from storage, the battery should be discharged to an average cell
voltage of 1.0 volt at 0.2 C5 Amps, and charged as per the instructions for first
charging.
5.2 STORAGE OF NEW BATTERY IN DRY & DISCHARGED CONDITION
A dry and discharged battery can be stored for prolonged periods, around ten years.
Store the battery in a clean, dry and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not remove the plastic film sealing the flip top vent.
Do not store other material on top up of the battery.
After removing from storage, follow the instructions for electrolyte filing and first
charging.
5.3 STORAGE OF USED BATTERY IN FILLED & CHARGED CONDITION
If the battery is going to be left idle for a long period of time, but not more than one
year, it should be removed from service and properly stored.
Top up with DM/DI water to the maximum level mark and charge the battery to a fully
charging state.
Clean the battery thoroughly, and then coat the inter-cell and inter-crate connectors
with anti-corrosion oil.
Inter-crate connectors should be removed for cleaning, and then stored in a separate
package.
Store the battery in a clean dry, and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct sunlight.
Do not store other material on top up of the battery.
After removing from storage, the battery should be discharged to an average cell
voltage of 1.0 volt at 0.2 C5 Amps, and charged as per the instructions for first
charging. However, use only DM/DI water for adjusting the electrolyte level after
waiting for at least two hours after the first charge has been completed.
6

5.4

STORAGE OF USED BATTERY IN DRY & DISCHARGED CONDITION


If the storage period is to exceed one year, the batteries should be fully discharged
at 0.2 C5 Amps, to an end voltage 0.6 volts per cell, and the electrolyte fully drained
by inverting the batteries for about 5 minutes. Use a plastic film to seal the flip top
vent.
Clean the battery thoroughly, then coat the inter-cell and inter-crate connectors with
anti-corrosion oil.
Inter-crate connectors should be removed for cleaning, and then stored in a
separate package.
Store the battery in a clean, dry and cool location. Cover the battery with a sheet of
plastic or similar protective cover to keep out water and shield against direct
sunlight.
Do not store other material on top of the battery.
Store the electrolyte in clean, airtight plastic containers for future use. After
removing the battery from storage, follow the instructions for electrolyte filling, first
charging and installing the battery.

6.0 INSTALLATION
The battery should be installed in a clean and dry area.
The battery should never be placed direct on the floor where it is subject to
dampness and dirt accumulation.
Batteries do not give off corrosive gas and therefore can be installed together with
other electrical equipment.
To avoid accelerated ageing of the plastic due to ultra violet radiation, batteries using
plastic cell containers and lids should not be exposed to direct sun light for long
periods.
6.1 TEMPERATURE
Avoid placing the battery in a hot place or in front of a window.
The battery will give the best performance and maximum service life when working at
a temperature between 10 and 30 degrees centigrade.
With adequate electrolyte specific gravity, the battery will perform properly within the
temperature range 40 to + 50 degrees centigrade.
Freezing will not cause damage to the battery.
6.2

VENTILATION
During the last part of high-rate charging, the battery gives off gas
(oxygen-hydrogen mixture)
At normal float-charge the gas evolution is very small.
The ventilation requirement of the battery as per DIN 57510 can be expressed by the
relation :
Q=55 x N x I, where Q is the quantity of air to be replaced from battery room in
litres /hour.
N is the number of cells in the battery, and I is the charging current at the end of high
rate charging.
Normally, no extra means of ventilation (exhaust fan etc.) is needed unless the
battery room is extremely small in proportion to the size of the battery.

6.3

MOUNTING AND CONNECTIONS


HBL NIFE battery racks are recommended for proper installation.
These racks are made of steel components, which are protected with alkali-resistant
paint. The step construction of the racks permit visual electrolyte level checks to be
made on all cells and greatly facilitates the maintenance activity of topping up with
demineralized water.
Battery racks are available in 2,3, or 4 steps in one or two tier configurations. Racks
can be positioned alongside each other or back to back to suit the available space in
the battery location. Ensure that the floor is level while positioning the racks.
8

All racks are supplied with insulators. However, the racks also have provision for
direct bolting to the floor.
Assemble the racks with the help of the drawing, enclosed with this manual.
Position the cells on the rack suitably so as to permit connection of the positive and
negative terminals according to the wiring diagram.
FOLLOW THE POLARITY TO AVOID SHORT CIRCUITING OF THE CELLS.
Connect the battery terminals to the equipment only after marking all the other intercell and inter-row connections
ONLY NICKEL PLATED COPPER CABLE LUGS SHOULD BE USED.
NEVER USE ALUMINUM CABLES AT THE BATTERY TERMINALS.
Use the correct torque to tighten the terminal bolts as indicated below:
RECOMMENDED TORQUE

BOLT DIAMETER
M 5
M 8
M 10

7.5 Nm (0.75 kgfm)


20 Nm (2.0 kgfm)
30 Nm (3.0 kgfm)

Ensure correct torque by using an appropriate torque wrench.


Improper torque will affect battery performance.
It is important that the battery is mounted firmly.
When there is a risk of crate movement as in the case of mobile applications, use
wooden or plastic wedges for arresting the movement.

7.0 ELECTROLYTE PREPARATION FOR FIRST FILLING


Please read and follow the safety precautions carefully while preparing the electrolyte.
The quantity of Electrolyte (if supplied in liquid form) per cell is given in the Technical
Specifications.
The quantities of solid lithium hydroxide or solid potassium hydroxide required for each
Battery, if supplied in dry & discharged condition are given in separate sheet. Use this
data as proportions for preparing the electrolyte.
1000 cc Type B electrolyte contains the following quantities of potassium hydroxide,
lithium hydroxide and DM/DI water.
Electrolyte
Type

B-22, Density
1.20
B-30,
Density1.28

Potassium
Hydroxide
(88-90%)
268 gms.

384 gms.

Lithium
Hydroxide
(55%)
40 gms.

54 gms.

Demineralised
Water

890 cc

840 cc

Cell Type

Standard

For special
Application(solar)

Type B Electrolyte is a solution of lithium hydroxide crystals and potassium hydroxide


flakes in DM/DI water. The number following the B represents the quantity of lithium
hydroxide in grams (assuming 100% assay) per litre of electrolyte.
The required quantity of D.M. Water is first into the container and appropriate quantity
of lithium hydroxide crystals are added with constant stirring. When all the lithium
hydroxide has dissolved, potassium hydroxide flakes are slowly added with constant
stirring. The solution will become hot.
After cooling to room temperature, adjust the density as required within a tolerance of
+/-0.01 by adding D.M. Water.
7.1 APPARATUS

Use only clean vessels of plastic or steel for preparing the electrolyte. Copper,
aluminium or Galvanised Vessels must not be used. Do not use accessories already
used for lead acid batteries. Transfer the Electrolyte into the cells using a clean
plastic jug. The electrolyte must not be exposed to air for long periods. Ensure that
the electrolyte does not get contaminated.
7.2 GUARANTEE CONDITIONS
Use only electrolyte approved by HBL Nife Power Systems Limited, for our Ni-Cd
batteries.
10

8.0

ELECTROLYTE FILLING
Flip open the top of the vent or unscrew the cap in case of screw type vent cap and
remove the transport seal (plastic film) if you have not already done so.
Do not completely remove the vent for filling the cells, but only flip open the top of flip
top vent cap & unscrew the cap in screw type vent cap for easy access. Only special
spill proof vents like SUNICA vents require to be fully removed for electrolyte filling
and topping up.
Use the correct electrolyte as specified In the Technical Specifications and fill the
cells slowly until the level of electrolyte is about 15 mm below the maximum level
indication.
Check the cells after 30 minutes and add electrolyte upto max. level indication.
Check the Technical Specifications for correct levels of electrolyte before filling. This
is required for cells in stainless steel containers, since these containers are not
provided with the level indication stickers as in the case of cells in polypropylene
containers. Use the capillary tube provided for checking the electrolyte level in cells
with stainless steel containers.
The specific gravity of the B-22 electrolyte in the cell will now stabilize at 1.19 +/- 0.01
from the initial filling electrolyte with specific gravity 1.20 +/- 0.01.
For Special cells (for solar applications), the specific gravity of the B-30 electrolyte in
the cell will now stabilize at 1.26 +/- 0.01 from the initial filling electrolyte with specific
gravity 1.28 +/- 0.01.

11

9.0 CHARGING
The battery can be charged by all normal constant current and constant voltage
methods.
Batteries in parallel operation with charger and load are generally charged with
constant voltage.
In operations where the battery is charged separated from the load, charging with
either constant current or constant voltage can be carried out.
9.1 FIRST CHARGING (DURING COMMISSIONING)
The cell vent caps should be closed during charging. Ensure that the transport seal
strip used for preventing electrolyte spillage during transportation has been removed
before charging. Also ensure that the transit caps (blue / red), wherever mounted on
cell terminals for big size cells.
First charging should be done using constant current only.
Charge the battery with the current recommended in the Technical specifications.
The duration of charge should be such that a charge input of 200% of C5 AH is given.
If the charger maximum voltage setting is too low to supply constant current charging,
divide the battery into two parts to be charged individually.
The charger must be able to work continuously at current limit without being
damaged. HBL NIFE chargers can do this.
A generous first charge with 200% charge input is important for obtaining maximum
battery performance.
Add electrolyte after waiting for a period of at least two hours after the first charge
has been completed.
At the same time, check the electrolyte density and adjust if necessary within the
specified limits.
After this final adjustment, the quantity of electrolyte in the battery is correct and
battery is ready for service.
Electrolyte should not be added later. For normal topping up, only DM/DI water
should be used.
THE ELECTROLYTE DENSITY IS NOT AFFECTED BY THE STATE OF CHARGE
OF THE BATTERY.

12

9.2.0 ROUTINE CHARGING (DURING USAGE)


During regular usage the charging method and parameters are to be determined by
charger, load and battery to ensure the system compatibility.
9.2.1 SEPARATE CHARGING
When the battery is being charged separate from its load, we recommend charging
for 8 hours with a current for 0.2 C5 Amps, to recharge a fully discharged battery to
full state of charge.
A lower charging current can be applied for a proportionally longer time, however the
current should not be less than 0.1 C5 A for H cells and 0.05 C5 A for M and L cells.
Constant voltage charging can be used but it requires longer recharge time. The
charging parameters are as per high rate charging under clause 9.2.3
9.2.2 PARALLEL OPERATION
For continuous parallel operation with occasional battery discharge, use a floatcharging voltage in the range of 1.40 to 1.42 volts per cell.
9.2.3 HIGH RATE CHARGING
For recuperative charging of the battery after a discharge, adjust the charging voltages to a level corresponding to:
1-53 1.67V/Cell for H cells
1.54 1.69 V/Cell for M cells and
1.55 1.70 / Cell for L cells
charging current limit should be within 0.1 to 0.2 C5
9.2.4 OVER CHARGING
Over charging within reasonable limits will not damage the battery, but water
consumption will be increased.
9.2.5 UNDER CHARGING
A Ni-Cd battery can be left standing for short periods at any state of charge without
damage.
But continuous undercharging combined with deep discharging will affect the battery
life.
Note : If the battery is continuously on float charge, it is recommended to boost charge
once in every 6 months to make sure that the state of charge is at top. The boost
charging should be for 8 hours.

13

10.0

MAINTENANCE

10.1 CLEANLINESS
It is important to keep the battery dry and clean. This will contribute to top the
performance and maximum service life and non-contamination of cells during topping
up.
If potassium carbonate crystals (grey white deposits) form on top of the battery, rub
with a soft brush and wipe with a clean damp cloth followed by a clean dry cloth.
Do not use a wire brush or solvents of any kind, such as gasoline, thinner, acetone,
kerosene etc.,
10.2

VENT CAPS
Vent caps should be kept clean to avoid blocking of holes and prevent venting of
gases produced during charging.
Vent caps can be removed from the cells, rinsed in clean water, dried and replaced,
vent caps can also be cleaned by wiping with a clean damp cloth followed by a clean
dry cloth while mounting on the cells.

10.3 CONNECTORS
Check at least once a year that all connectors are tight. This is especially important if
the battery is subjected to vibration or shocks during service.
The connectors and terminal screws should be corrosion protected by coating with a
thin layer of anti-corrosion oil / petroleum jelly.
10.4

TOPPING UP
The electrolyte level should be always-within the maximum and minimum level marks
by replenishing the water.
Use only DM/DI water for toping up.
It is not necessary to add water frequently in an attempt to keep the electrolyte at
maximum level.
Never let the level fall below the top of the plates.
Do not add water to the maximum level during high rate charge since accurate level
reading is not possible when the battery is gassing.
Avoid splashing water when topping up. A wet battery can result in earth faults and
/or erratic operation.
Always keep the flame arresting vents closed except for the moment of topping up.

10.5

NEVER USE SULPHRIC ACID


Sulphuric acid will ruin the alkaline battery.
Filling bottles, hydrometers etc., used with lead acid batteries must never be used
with alkaline batteries in order to prevent acid contamination.
14

10.6 SPECIFIC GRAVITY


The electrolyte specific gravity should be as mentioned in technical specifications.
The specific gravity is not influenced by the state of charge, but increases slightly
when the electrolyte level is lowered due to water loss.
Electrolyte specific gravity should not be measured immediately after water has been
added.
10.7

CHECKING THE CHARGING


In parallel operation it is great importance that the recommended charging voltage is kept
unchanged. The charger should be checked at least once a year.
High water consumption of the battery is usually caused by a high float voltage setting of the
charger, which give higher current than required during float operation.

10.8

TROUBLE SHOOTING
Even though HBL Nife Power Systems Limited nickel cadmium batteries themselves
are very reliable and trouble free, they are part of a larger system that can introduce
abnormal conditions, and batteries are also exposed to different quality of
maintenance.
The following list of possible problems, causes and action will be of good use.

S.No.
01.

SYMPTOM

PROBABLE CAUSE

RECOMMENDED CORRECTIVE
ACTION
Erratic
charger Wrong polarity of cell, Check each cell or block for correct
behaviour
block, row of battery.
polarity.
Interruption at
connector

Interruption
empty cell

Check that no connector or cable is


missing and that all connections are
tight and cables securely fastened in
cable lugs.
due

to Check if the cell is empty because of


leakage. If so, remove or short circuit
the cell and use the battery with one
cell less, until replacement is made. If
the cell is part of the block, do not
remove the block, just short circuit the
cell.
If the battery is filled with electrolyte
on site it could be that one cell has
been forgotten. If so, disconnect the
cell and fill it with electrolyte.

Faulty charger

15

See
charger
troubleshooting.

instructions

for

S.No.
02.

SYMPTOM
Earth fault
indication

PROBABLE CAUSE
Small leak or leaks

Battery wet
overfilling

03.

04.

05.

due

RECOMMENDED CORRECTIVE
ACTION
Check for wetness on battery stand,
or with a voltmeter, area of the battery
having the lowest potential to ground.
See (1) for procedure if a cell is
leaking.
to Disconnect few connectors to avoid
high or over boiling voltage and clean
the battery. See (8).

Other equipment of
system
Continuous
Charging voltage is
heavy gassing
above
the
recommended
float
voltage .
No power or Interruption
at
capacity at all
connector

Too
short
discharge time.
The
voltage
decreases
quickly at the
end.

Isolate various parts of the DC system


to find the fault.
See
charger
instructions
for
information on charging mode and
settings.
See SL.No: 1.

Interruption due to See SL.No: 1.


empty cell
Battery
completely Determine why the battery is
discharged.
discharged. The reason could be
faulty charger or fuse, wrong float
voltage or interruption in the battery.
Recharge the battery according to
instructions.
Too larger load.
The load may be larger that what the
battery was intended for. Check the
discharge
against
battery
performance data. Note that the rated
number of ampere hours can only be
delivered at discharges, of 5 hours or
longer.
For short discharges,
batteries will give higher currents but
less ampere-hour.
Insufficient charging.
Determine why the battery is not
charged to a correct level.
The
reason could be low float voltage, no
high-rate recharge after previous
heavy discharge, too short high-rate
recharge, of high-rate recharge to
voltage that is too low. Recharge the
battery as per instructions and
discharge again.
Too
low
battery If the same result is achieved after full
capacity.
and complete charging, the battery
capacity is low. It may still be able to
work its application, especially if it is
high-rate discharges such as in
switchgear operation or engine
starting. The reason for low capacity
could be age, heavy use, insufficient
charging or unsuitable storage.

16

S.No.
06.

SYMPTOM

PROBABLE CAUSE

Low
discharge Very low voltage for
voltage during a one or few cells.
major
part
of
discharge.

Battery designed with


high cell end voltage.
The
discharge
preceded by long term
float charge without
discharge.

07

08

RECOMMENDED CORRECTIVE
ACTION
Check the individual cell voltages during
discharge and full recharge. If the
voltage of an individual cell does not
come up nearly as high discharge. As
others, the cells have a partial short
circuit and therefore not accepting
charge. (If the charging voltage is fine
but the cell voltage collapses early in
the discharge the cell capacity is
abnormally low). The reason could be
unsuitable handling at installation or
contamination in the electrolyte.
This condition sometimes occurs if the
design cell end voltage is 1.14 1.18
volt per cell and the battery has been in
service for sometime. It does not mean
that the capacity has decreased. It is
best handled by using more cells in the
battery and thus lowering the final cell
voltages, and high rate or boost
charging now and then.
Insufficient charging, See(06)

battery
Too
low
for Discharged
engine
starting. due to insufficient
The engine does charging
not turn at all, or
with
too
low
speed to fire
Loose connector
Tighten all connectors. For high power
discharges this is very important, both
from a performance and safety
viewpoint. A loose connector will cause
voltage drops and can spark and ignite
charging gasses.
Too low temperature
If the temperature is lower than the
design temperature for the starting
system, it will be difficult to start
because the battery gives less power
whereas the engine requires more
power to turn. Use the correct engine oil
for the temperature and try to arrange
preheating of the engine and battery if
possible.
Engine trouble
If cranking speed appears to be good,
failure to start may depend on the fuel
or engine. The battery can not do more
than crank engine at sufficient speed.
Wet battery
Overfilling or over Disconnect a few connectors to avoid
boiling
high voltage and clean the battery. Use
proper filling equipment to avoid
overfilling. Over boiling is the result of
too high electrolyte level and high rate
charging. Normal level and charging at
too high rate may also cause over
boiling.

17

S.No.

SYMPTOM

PROBABLE CAUSE

RECOMMENDED CORRECTIVE
ACTION
Sudden eruption of Disconnect a few connectors to avoid
electrolyte from one high voltage and clean the battery. Fill
cell
the electrolyte or DM/DI water in the
cell, which has lost the electrolyte and
charge the cell individually. Then
replace the cell in the battery and
recharge the complete battery. Check
the individual cell voltages.
If one cell in a battery with high
current load such as engine starting is
completely discharged it may spew
out electrolyte when the high current
is applied.
Electrolyte leakage at After sometime in service, electrolyte
posts and vents.
may penetrate the seals around the
posts, vents and connectors. In the
normal cleaning of the battery, it does
not affect the performance of the
battery to any extent.
Electrolyte
leakage A leakage through a pore or small
through
pores
or crack could be so small that it does
cracks.
not affect the electrolyte level
noticeably, but will cause earth faults
and the cell or block should be
replaced.

09

Uneven
Poor filling or topping If the levels of electrolyte vary
electrolyte levels up.
throughout the battery, the reason is
in the battery
probably poor topping up or leveling
off after filling.
Different float voltages

Leaking cell

Batteries are often divided in two


halves, which is good from reliability
and maintenance viewpoints. If each
half has a separate charger and the
voltage is different, the electrolyte
levels in the two halves will be
different

If one cell has a lower electrolyte level


than all the others, it is probably
leaking. The leak could be small and
difficult to find, but the battery stand is
probably wet from electrolyte under
the cell. One individual cell could not
consume more water than the others
as the same current goes through all
cells.
Short circuit in one A cell with partial or complete short
cell
circuit will consume less water than
the others. Let the cell remain until
replacement is arranged.

18

11.0

ELECTROLYTE REPLACEMENT
In most stationery battery applications, the electrolyte will retain its effectiveness for
the life of the battery. However, under special battery service conditions, such, as
high temperature and / or frequent cycling, potassium carbonate build up in the
electrolyte may reach a level that will influence the battery performance. If the
potassium carbonate reaches a level of about 25 % of the electrolyte, is said to be
carbonized, and the battery performance can be restored to a great extent by
replacing the electrolyte.
The type of electrolyte to be used for replacement is given below.

CEL L TYPE

Standard

ELECTROLYTE TYPE
FOR FIRST FILLING

ELECTROLYTE TYPE
FOR REPALCEMENT

B-22, Density 1.20

B-5, Density 1.19

B22, Density 1.20

B-12, Density 1.25

B30, Density 1.28

Special Application B-30, Density 1.28


(Solar)

ELECTROLYTE TYPE
FOR COMMISSIONING
IF SUPPLIED DRY

11.1 PREPARATION OF ELECTROLYTE


1000 cc Type B electrolyte contains the following quantities of potassium hydroxide,
lithium hydroxide and DM/DI water.
ELECTROLYTE
TYPE FOR
REPLACEMENT

POTASSIUM
HYDROXIDE
(88-89%)

LITHIUM
HYDROXIDE
(55%)

DM/DI
WATER

B-5, Density 1.19

276 gms..

9 gms.

910 cc.

B-12, Density 1.25

363 gms.

22 gms.

870 cc.

Use this data as proportions for preparing the electrolyte for the battery in suitable
batch quantities depending on the size of the vessels available for electrolyte
preparation.
11.2 DISCHARGE
Before emptying the electrolyte, discharge the battery to a voltage corresponding to
about 0.6 volt/cell with a current not higher than of 0.2 C5 Amps. The plates shall
never be exposed to atmosphere in charged condition.
11.3 EMPTYING
Open the vents and place the battery inverted to drain the cells. Let the cells drain for
about 5 minutes. Do not shake the cells.
Beware of electrolyte splashes.
Do not rinse with water, as this may cause trouble in obtaining correct electrolyte
19

density after filling.


Never let cells remain empty if they are not entirely discharged as this can cause
permanent damage.
It is not advisable to pour the used electrolyte into the sink. Follow norms for
chemical waste disposal, which are valid in your area.
11.4

FILLING
Immediately after emptying, fill the cells according to the instructions for the
electrolyte filling.

11.5

CHARGE
Charge the battery according to the instructions for first charging.
A generous charge is important for the restoration of the battery performance.

20

12.0 DOS AND DO NOTS


12.1 DOS
1. Keep the battery always dry and clean. This will prevent leakage of current and
protect the nickel plating on the external battery components.
2. Check inter-cell connectors for proper tightness. This will prevent heat
generation at the point of loose contact, which causes damage to the
components and can be a fire hazard. Loose contact can also cause battery
failure due to creation of an open circuit.
3. Ensure that the cell connections have been made as per the wiring diagram
provided. Normally Red washer on cell terminal indicates positive polarity and
blue washer indicates negative polarity.
4. Ensure that the battery cable lugs are electro plated. This will prevent the
copper from reacting with the electrolyte.
5. Ensure that the transport seal (plastic strip in vent cap) is removed before
charging. This will permit escape of the oxygen and hydrogen gases generated
during charging.
6. Keep vent caps always closed during charging and discharging. This will
prevent the carbon dioxide from the air from combining with the alkaline
electrolyte and producing potassium carbonate, thereby reducing the electrical
conductivity of the electrolyte.
7. Check the electrolyte level and ensure that it does not fall below the minimum
level, which is indicated, on the cell-marking label. This active material
contained in the portion of the plates, which are exposed above the Electrolyte,
will be permanently damaged if the battery remains in service.
8. Use only DM/DI water to top up the cells. (During initial Commissioning use
only electrolyte to make up for loss of electrolyte during transportation). Only
DM/DI water is to be used to compensate for the loss of water during charging,
and maintain the required electrolyte level and specific gravity.
9. Ensure proper functioning of charger and proper connections to the battery.
Correct voltage and current settings are important for keeping the battery in
charged, ready to use condition.
10. Use insulated tools while working on the battery to prevent accidental short
circuit and consequent damage.
11. Use alkaline electrolyte only since this is an alkaline battery.

21

12.2 DO NOTS

1. Do not use apparatus, like hydrometers, capillary tubes, and thermometers

etc., used in lead acid batteries in order to prevent contamination of electrolyte.


2. Do not use petrol, kerosene, or any strong chemicals for cleaning batteries.
3. Do not use wire or any hard brush to clean deposits on the intercell connectors
and terminals since this will damage the nickel plating.
4. Do not use aluminum cables for making connections to the battery terminals
since aluminum reacts with the alkaline electrolyte.
5. Do not keep vent caps open and expose electrolyte to air, since this will cause
some of the electrolyte to be converted to potassium carbonate and thereby
reduce the conductivity of the electrolyte.
6. Do not spill water or electrolyte on and around the battery since this will create
conductive paths leading to leakage of current.
7. Do not measure specific gravity immediately after adding DM/DI water since
this will indicate a lower specific gravity due to inadequate mixing of the water
with electrolyte in the cell. Specific gravity can be measured after one hour.
8. Do not install the Battery in places where it is exposed to sunlight, since this
will cause accelerated ageing of plastic components due to ultra violet
radiation.
9. Do not remove vent caps (in case of flip type vent caps) for topping up since
frequent removal can damage the vent cap and the cell lid. In case of flip type
vent caps, gently press the cap to open the spring loaded vent lid and in case
of threaded type vent cap, gently unscrew the vent cap lid.
10. Do not use acid since the battery requires alkaline electrolyte. Addition of acid
will cause it to react with the alkaline electrolyte, and cause permanent battery
damage.
11. Do not charge the battery without removing the transport seal from the vent, or
while the battery is covered, since it is important to ventilate the battery and
permit the gases produced towards the end of charge to escape.
12. Do not adjust terminal connections during usage to prevent sparking which
can ignite the oxygen and hydrogen gases which are given off by the battery
towards completion of charge, and cause a fire / explosion.
13. Do not smoke in the battery room since it is a fire hazard.
14. Do not keep Batteries in the same room where acid batteries are kept.

22

13.0 DM / DI WATER SPECIFICATION


13.1 PERMITTED IMPURITIES IN WATER
IMPURITY

CALCULATED AS

TOPPING UP
WATER MAXIMUM
g/l

WATER FOR
PREPARATION OF
ELECTROYTE
MAXIMUM g/l

Chloride

KCl

Traces

0.06

Sulphate

K2SO4

Traces

0.05

Nitrate

KNO3

Traces

Traces

Silico

SiO2

Traces

Traces

Aluminium

Al2O3

Traces

Traces

Calcium &
Magnesium

CaO+MgO

Traces

Traces

Traces

0.03

0.05

0.15

0.03

0.06

Heavy Metals
Evaporation
Organic
impurities

KMNO4

Note : Topping up must be with DM/DI water with the conductivity less than 10 micro
siemens /cm

23

14.0 SERVICE LOG


Date of installation and commissioning: _________________________________
Battery No.: ___________________________
Date : _______________________________

CELL NOS

DISCREPANCIES NOTICED

24

CORRECTIVE ACTIONS / REMARKS

Service Log (Continue)


Date: _________________________

CELL NOS

DISCREPANCIES NOTICED

25

CORRECTIVE ACTIONS / REMARKS

15.0 TOOLS & ACCESSORIES

26

16.0 DRAWINGS

27

Corp.Mktg/12-2003/NCPP/O&S

HBL NIFE Power Systems Limited


Road # 10, Banjara Hills, Hyderabad - 500 034. INDIA
E-mail: contact@hblnife.com
www.hblnife.com