Borri B9000FXS 80kVA Product Manual

Borri B9000FXS 80kVA Product Manual

3ph/3ph
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PRODUCT MANUAL

UNINTERRUPTIBLE POWER SUPPLIES

 B9000FXS 60kVA (3PH / 3PH)
B9000FXS 80kVA (3PH / 3PH)
B9000FXS 100kVA (3PH / 3PH)
B9000FXS 125kVA (3PH / 3PH)
B9000FXS 160kVA (3PH / 3PH)
The present manual is an integrant part of the products technical back-up documentation. Read the warnings
with attention as they give important instructions concerning safety.
This equipment must be used only for its appointed operation. Any other use is to be considered incorrect and
therefore dangerous. The manufacturer cannot be held responsible for damages caused by incorrect, wrong and
unreasonable use.
Borri holds itself responsible only for the equipment in its original configuration.
Any intervention altering the structure or the operating cycle of the equipment has to be carried out and
authorized directly by Borri.
Borri cannot be held responsible of the consequences deriving from the use of non original spare parts.
Borri reserves its right to carry out technical modifications on the present manual and equipment without giving
any notice. If any typing errors or mistakes are detected, they will be corrected in the new versions of the
manual.
Borri holds itself responsible for the information given in the original version of the manual in Italian language.
Right of ownership – copying prohibited. Borri protects its rights on the drawings and catalogues by law.
Descrizione
Rev.
Description
F
Code upgrade
Borri S.p.A.
Via 8 Marzo, 2 – Soci
52010 Bibbiena (AR)
Tel. +39 0575 5351 – Fax +39 0575 561438
Web site: www.borri.it – e-mail: info@borri.it
Data
Date
20.05.13
E. Biancucci
Emesso
Approvato
Issued
Approved
F. Berti
English
Lingua
Pagina
di Pag.
Language
Page
of Pag.
E
1
54
Codice / Code
OMD10078

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Summary of Contents for Borri B9000FXS 80kVA

  • Page 1: Uninterruptible Power Supplies

    If any typing errors or mistakes are detected, they will be corrected in the new versions of the manual.  Borri holds itself responsible for the information given in the original version of the manual in Italian language.  Right of ownership – copying prohibited. Borri protects its rights on the drawings and catalogues by law.
  • Page 2: Table Of Contents

    Index     UPS GENERAL DESCRIPTION ............6     RECTIFIER / BATTERY CHARGER ..............7     1.1.1 Operation with ONE charging level ............8     INVERTER ......................8     1.2.1 Operation with non-linear load ............... 9  ...
  • Page 3     4.4.4 Environmental installation conditions ..........28     ELECTRICAL CONNECTION ................ 30     BACKFEED PROTECTION DEVICE .............. 32     TERMINAL BOARDS ..................33     CONNECTION OF POWER CABLES ............34     CONNECTION OF AUXILIARY CABLES ............35  ...
  • Page 4     5.2.13 Cables inlet from the top ..............50     5.2.14 Special painting .................. 51     5.2.15 “Load-Sync-Bus” kit for single unit ..........52     5.2.16 Kit “Parallel system Load-Sync-Bus” ..........53     5.2.17 Back feed (protection from power return to mains) ......54 Index of pictures  ...
  • Page 5   Picture 32 – BOOST charge diagram ......................42   Picture 33 – Charging voltage / temperature curve ..................44   Picture 34 – Example of UPS units connected in parallel ................47   Picture 35 – Battery isolator connection ..................... 48  ...
  • Page 6: Ups General Description

    UPS GENERAL DESCRIPTION The UPS of the B9000FXS 60÷160kVA series is the type “ON LINE DOUBLE CONVERSION” and is connected between main power and user loads (see picture 1). As far as architecture and lay-out is concerned, this project is optimised with particular care in order to make it suitable for applications where reliability and high performances are fundamental for critical loads.
  • Page 7: Rectifier / Battery Charger

     Static Switch: Static Inverter Switch (SSI) and Static Bypass Switch (SB)  Manual Bypass (MB) RECTIFIER / BATTERY CHARGER The Rectifier/Battery charger converts the AC input voltage to DC voltage, feeding the inverter and keeping the battery charged. Picture 2 – Rectifier The AC/DC conversion is carried out by a three-phase three-level PWM rectifier, combining a three-phase diode bridge with a DC/DC step-up converter.
  • Page 8: Operation With One Charging Level

    1.1.1 Operation with ONE charging level This type of charge is generally used with sealed lead acid batteries that, owing to the manufacturing technology, have a very narrow voltage range. In fact, the nominal charging voltage ranges between 2.25÷2.27 V/cell, with a maximum value of 2.3 V/cell. The picture below shows the charging curves at different charging currents;...
  • Page 9: Operation With Non-Linear Load

    capacitors, a low-pass filter that provides to eliminate the high frequency ripple and keep the total harmonic distortion (THD) of voltage lower than 2% (with linear load). The inverter, thanks to its manufacturing technology and to the microprocessor control, is able to supply indifferently inductive or capacitive loads. . In case the load is highly capacitive (p.f.
  • Page 10: Overload Management

    1.2.2 Overload management Inverter can provide continuously 100% of nominal load and can tolerate overload conditions up to 125% for 10 minutes or 150% for 1 minute. Peak conditions such as take-off of engines or magnetic parts are managed limiting the output current to 200% for 5 cycles, then reducing to 125%.
  • Page 11: Short-Circuit Operation

    2) BYPASS NOT AVAILABLE As soon as an overload is detected the algorithm starts to calculate the increment of the energy. When the threshold value is reached inverter switched off to avoid severe damages components. As soon as the bypass is available again the load is supplied static...
  • Page 12: Igbt Bridge Protection

    1.2.4 IGBT bridge protection The inverter input current monitoring is carried out by the current transducer connected upstream the inverter bridge. Therefore the control logic is able to distinguish an output short-circuit from an IGBT short-circuit. The behaviour of the inverter in case of short-circuit on the load has been described at 2.2.3;...
  • Page 13: Battery

    BATTERY On the B9000FXS 60÷160kVA UPS, the battery is always installed in external additional cabinets. The battery charger control logic is completely integrated inside the rectifier control board; the battery is charged, according to the DIN 41773 Standard, every time it has been partially or completely discharged.
  • Page 14: Inverter  Emergency Line Transfer

    1.4.1 Inverter  Emergency Line Transfer The transfer is activated only if the emergency line is in tolerance (in less than 0.5 ms), for the following reasons: CAUSES COMMUTATION CONDITIONS Output short-circuit Emergency line within tolerance limits Fault of inverter or inverter voltage out of tolerance Emergency line within tolerance limits DC voltage out of tolerance (Inverter OFF) Emergency line within tolerance limits...
  • Page 15: Operating Modes

    OPERATING MODES NORMAL OPERATION During normal operation all the circuit breakers/isolators are closed, except for MBCB (maintenance bypass). The three-phase input AC voltage feeds the rectifier via the filter inductor; the rectifier supplies the inverter and compensates mains voltage fluctuations as well as load variation, maintaining the DC voltage constant.
  • Page 16: Battery Operation

    BATTERY OPERATION In the event of mains failure, or rectifier failure, the battery feeds the inverter without interruption. The battery voltage drops as a function of the magnitude of the discharge current. The voltage drop has no effect on the inverter output voltage since it is kept constant by varying the PWM modulation.
  • Page 17: Bypass Operation

    BYPASS OPERATION Bypass operation may occur for both manual or automatic change-over. The manual transfer is due to the BYPASS SWITCH, that forces the load to bypass. In the event of a bypass failure the load is transferred back to inverter without interruption. Picture 14 –...
  • Page 18: Manual Bypass

    MANUAL BYPASS The manual bypass operation is necessary every time the functionality of the UPS needs to be checked or during maintenance or repair works. The manual bypass procedure is described in the UPS operating manual and must be followed carefully in order to avoid damages to the UPS. During the functional check of the UPS, all the breakers can be closed, except for the output breaker OCB, and the full functionality can be tested.
  • Page 19: Front Panel

    FRONT PANEL The front panel of the UPS, consisting of a double row alphanumeric display plus 5 function keys, allows the complete monitoring of the UPS status. The mimic flow helps to understand the operating status of the UPS. For the full navigation of the display, refer to the Operating Manual of the UPS.
  • Page 20 GREEN AC line on rectifier input within tolerance LED 1 GREEN Wrong phase rotation     AC mains failure on rectifier input GREEN AC bypass line within tolerance GREEN Wrong phase rotation     LED 2 AC bypass line out of tolerance AC bypass line failure GREEN Rectifier off or faulty...
  • Page 21: Alarms And Operating Status

    ALARMS AND OPERATING STATUS ALARMS MAINS FAULT A29 MAINTENANCE REQ INPUT WRONG SEQ A30 COMMON ALARM BOOSTER STOPPED A31 MBCB BUS CLOSED BOOSTER FAULT A32 EPO BUS CLOSED DC VOLTAGE FAULT A33 ASYMMETRIC LOAD BATTERY IN TEST A34 SERVICE REQUIRED BCB OPEN A35 DIESEL MODE BATTERY DISCHARGE...
  • Page 22: Measurements On The Display

      STATUSES BOOSTER OK BATTERY OK INVERTER OK INVERTER FEEDS LOAD BYPASS INVERTER SYNCHR BYPASS OK BYPASS FEEDS LOAD BOOST CHARGE MASTER INVERTER SYNCHR MEASUREMENTS ON THE DISPLAY The measures shown on the display are listed below. Displayed data Accuracy Sub-menu (1) (2) Rectifier input voltage...
  • Page 23: General Technical Information

    GENERAL TECHNICAL INFORMATION TECHNICAL DATA For information regarding the technical data of the product, please refer to the technical specification. INSTRUCTIONS FOR INSTALLATION 4.2.1 Receipt of the UPS Please inspect the device before installing it. In case any damage is noticed from the conditions of the package and/or from the outside appearance of the equipment, contact the shipping company or your dealer immediately.
  • Page 24: Handling Of The Ups

    HANDLING OF THE UPS The UPS is packed on a pallet. It is handled from the transport vehicle to the installation (or storage) place via a fork lift. The device has a heavy weight  Avoid turnover during the transport of the UPS.  ...
  • Page 25: Positioning And Installation

    POSITIONING AND INSTALLATION The UPS B9000FXS must be installed indoor, in a clean and dry room, preferably without dust or humidity infiltrations. Special environmental conditions   It is necessary to implement specific protective measures in case of unusual environmental conditions: ...
  • Page 26: Overall Dimensions

    4.4.2 Overall dimensions Picture 22 – Overall dimensions of UPS B9000FXS UPS (kVA) L – mm P – mm H – mm 1670 OMD10078 rev F...
  • Page 27: Minimum Distances From The Walls And Ventilation

    4.4.3 Minimum distances from the walls and ventilation The UPS must be so installed as to ensure its serviceability and to allow a correct air flow as much as possible. With regard to the minimum distances from the walls, for all of the UPS sizes the same installation conditions apply as indicated in the table below.
  • Page 28: Environmental Installation Conditions

    4.4.4 Environmental installation conditions The air is classified by the EN 60721-3-3 standard (Classification of environmental parameters and their severities – Stationary use at weather-protected locations) based on climatic and biological conditions as well as on mechanically and chemically active substances.
  • Page 29  Classification of chemically active substances (EN 60721-3-3) Class Environmental parameter 3C1R 3C1L a) Sea salt Salt fog Salt fog Salt fog b) Sulphur dioxide 0,01 [mg/m c) Hydrogen sulphide 0,0015 0,01 0,01 [mg/m 0,001 0,01 d) Chlorine [mg/m 0,001 0,01 e) H ydrochloric acid...
  • Page 30: Electrical Connection

    ELECTRICAL CONNECTION The electrical connection is part of the work which is normally provided by the company that carries out the product installation. For this reason, the UPS manufacturer shall not be held responsible for any damages due to wrong connections. Use qualified personnel only All the operations related to the electric connection must be carried out by qualified and trained personnel.
  • Page 31 that is needed to determine the maximum length of the line protected. The protection against short-circuit must operate on the line before any thermal and electrothermal effects of the overcurrents may damage the cable and relevant connections. During the electrical installation take particular care to respect the phase rotation. The terminal boards for cables connection are positioned at the front of the UPS, under the breakers.
  • Page 32: Backfeed Protection Device

    BACKFEED PROTECTION DEVICE The back-feed protection device, as indicated by the EN 62040-1 Standard, is optional and can be installed during the UPS production phase; the installation on site can only be carried out by skilled personnel. The device is a contactor that automatically disconnects the bypass line in case of failure of the static switch, in order to avoid voltage feed-back on the input terminals during the a mains failure.
  • Page 33: Terminal Boards

    TERMINAL BOARDS UPS B9000FXS is provided with terminal boards for the power connections and auxiliary contacts. Picture 24 – Position of power terminals of B9000FXS OMD10078 rev F...
  • Page 34: Connection Of Power Cables

      UPS (kVA) X – mm Y – mm Z – mm Connection data of terminal boards UPS (kVA) Section (mm 25x6 30x5 Hole diameter (mm) Cable terminal hole Max. cable section (mm 2x95 2x150 Tightening force (Nm) CONNECTION OF POWER CABLES For the electric connection of UPS B9000FXS, connect the following cables: ...
  • Page 35: Connection Of Auxiliary Cables

    CONNECTION OF AUXILIARY CABLES The UPS systems of the B9000FXS line can be connected to external controls/components specifically designed to improve the safety and reliability of the device. The standard UPS B9000FXS is already provided with the FCI card (Free Contact Interface) which allows to place some external controls remotely, such as: ...
  • Page 36: External Manual Bypass

    Picture 26 – Auxiliary terminals of B9000FXS 4.9.1 External manual bypass Auxiliary contact of the External Manual Bypass Switch on terminals MBY1-MBY2. A normally open contact has to be connected to the UPS terminals (MBY1-MBY2); when the contact is closed (see Manual Bypass procedure), the microprocessor will acquire the status of the contact and shut down the inverter.
  • Page 37: Serial Interfaces

    4.10 SERIAL INTERFACES The UPS is provided with serial interfaces for the external communication of the operating status and parameters.  RS232/USB: is used for connection to the proprietary programming and control software.  MODBUS (OPTIONAL): is used for the transmission of data to the outside via MODBUS protocol (RS485).
  • Page 38: Positioning And Connection Of Batteries

    4.11 POSITIONING AND CONNECTION OF BATTERIES CAUTION A battery can present a risk for electrical shock and high short circuit current. The following precautions should be observed when working on batteries: Remove watches, rings or other metal objects; Use tools with insulated handles; Wear rubber gloves and boots;...
  • Page 39: Picture 28 – Dimensions Of The External Battery Cabinet

    4.11.1.1 Dimensions and weights Picture 28 – Dimensions of the external battery cabinet Picture 29 – Base plan of the external battery cabinet OMD10078 rev F...
  • Page 40: Picture 30 – Battery Cabinets Connections

      Cabinet AS764 (50 blocks) AS764 (100 blocks) Weight without battery - kg Cabinet AS764 (50 blocks) AS764 (100 blocks) Number of 12V blocks Max. dim. of single block (mm) 350x190x290 350x190x290 Max. nominal capacity per block 140 Ah 140 Ah Weight of single block 45 kg 45 kg...
  • Page 41: Options

    OPTIONS STANDARD OPTIONS INCLUDED TO BE SET VIA SOFTWARE Diesel generator Off-line Two-level charge Programmable rectifier soft-start (Walk-In) Sequential rectifier start for parallel systems (Hold-off) Frequency converter DCM function 5.1.1 Diesel generator The Diesel Mode function can be enabled via the Test Software. The UPS is already provided with the internal wiring as well as with terminals XD1-XD2 to be connected to the Generator.
  • Page 42: Two-Level Charge "Boost Charge

    5.1.3 Two-level charge “Boost Charge” The function values of the two-level charge “BOOST CHARGE” can be enabled and set via the Test Software. This type of charge, according to DIN41773, is used with vented lead acid (open type) or Ni-Cd batteries that have a wide voltage range (Pb: 2,2÷2,7 V/cell.). Picture 32 –...
  • Page 43: Programmable Rectifier Soft-Start (Walk-In)

    5.1.4 Programmable rectifier soft-start (Walk-in) The values of the “Walk-In” Soft-Start function can be enabled and set via the Test Software. The setting range of the values is 5 to 30 seconds. The Walk-in function allows to change the rectifier soft-start from the DC voltage generated by the SCR bridge to the one imposed by the Battery charge or by the floating voltage.
  • Page 44: Thermal Compensation Of Battery Charge

    5.2.1 Thermal compensation of battery charge This option provides a temperature sensor to be installed near the battery room in order to detect the operating temperature. This transducer is able to interface with the control logic of the rectifier in order to modify its floating voltage based on temperature, according to the typical curve supplied by the battery manufacturer.
  • Page 45: Alarm Card Src (Alarm Relay Card)

    5.2.4 Alarm card SRC (ALARM RELAY CARD) Card SRC is an interface used to make the main UPS statuses and alarms available on volt free contacts (NO/NC switching contacts). During normal operation, without alarms, all the relays are energized. Relay Alarms/Status Status Pins...
  • Page 46: Serial Interface Rs-485 (Mod-Bus Protocol)

    5.2.5 Serial interface RS-485 (Mod-Bus protocol) It consists of an additional card which must be installed in a specific space provided on the UPS front. This card contains a “+”, “-“ and “ground” three-pole connector, as well as a serial port RS485 which must be used for the connection to the MODBUS- master.
  • Page 47: Picture 34 – Example Of Ups Units Connected In Parallel

    Also for the power parallel system, the automatic sharing control of AC current equalizes the currents of “n” units and reduces the offset to less than 10% under any load condition. The load is supplied by the inverters in parallel also in the event of an instantaneous overload ...
  • Page 48: Battery Cabinet

    5.2.9 Battery cabinet Please refer to chapter 4.10.1. 5.2.10 Wall mounted isolator with battery fuses The isolator with battery fuses is used to separate the UPS from the external battery. The isolator is required in plants where the battery is installed in a dedicated room, therefore it is necessary to use an isolation device between the UPS and the battery.
  • Page 49: Technical Data

    5.2.12 Technical data Picture 36 – Technical data of battery isolator Colour: RAL 7035 Protection degree: IP20 UPS (kVA) L – mm P – mm H – mm L1 – mm H1 – mm UPS (kVA) Isolator type 4-pole Isolator + Fuses Fuse size (A) 200 gG 200 Gg 200 Gg 250 Gg 315 Gg OMD10078 rev F...
  • Page 50: Cables Inlet From The Top

    5.2.13 Cables inlet from the top This option allows to obtain the cables inlet from the top with an additional cabinet. Picture 37 – UPS dimensions with additional cabinet for cables inlet from the top Picture 38 – UPS dimensions with additional cabinet for cables inlet from the top  ...
  • Page 51: Special Painting

    Picture 39 – Base plan of UPS with additional cabinet for cables inlet from the top 5.2.14 Special painting All the RAL colours can be requested with an additional cost. OMD10078 rev F...
  • Page 52: Load-Sync-Bus" Kit For Single Unit

    5.2.15 “Load-Sync-Bus” kit for single unit The “Load-Sync-Bus” function for single unit is available only for two UPSs. This is a special operating mode which allows to have the UPS outputs synchronized in the different operating statuses. With regard to the load management, the UPS units behave as if they were single units independent of each other.
  • Page 53: Kit "Parallel System Load-Sync-Bus

    Picture 41 – Example of UPS units in Sync-Load configuration – single configuration 5.2.16 Kit “Parallel system Load-Sync-Bus” The “Load Sync Bus” function can also be available for parallel systems with up to maximum 6 UPS in parallel configuration. Picture 43 explains the interconnection of two systems “A”...
  • Page 54: Back Feed (Protection From Power Return To Mains)

    Picture 43 – Example of UPS units in Sync-Load configuration – parallel configuration 5.2.17 Back feed (protection from power return to mains) This option prevents the risks deriving from power return to mains and from the faults caused by the failure of the SCR’s of the static bypass switch. OMD10078 rev F...

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