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70kva 2 X Ups 400v 110v Dt318107 l09 0831 Iocl DHDT Plant Vadodara
70kva 2 X Ups 400v 110v Dt318107 l09 0831 Iocl DHDT Plant Vadodara
LIST OF REVISIONS
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CHLORIDE
INDUSTRIAL SYSTEMS
LIST OF CONTENTS
Title Page
1. SAFETY 7
1.1. GENERAL 7
1.5. BATTERY 9
4. INSTALLATION 23
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CHLORIDE
INDUSTRIAL SYSTEMS
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CHLORIDE
INDUSTRIAL SYSTEMS
9. DRAWINGS 67
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CHLORIDE
INDUSTRIAL SYSTEMS
LIST OF ILLUSTRATIONS
Title Page
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CHLORIDE
INDUSTRIAL SYSTEMS
1. SAFETY
Title Page
1.1. GENERAL 7
1.5. BATTERY 9
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
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
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.
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
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.
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
Nature of hazard.
The hazards are :
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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.
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
POISONING
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;
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.
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
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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 semi-
conductors and seal them into tough plastic bags before disposal.
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.
The internal wiring is of copper bar and copper wire covered with flame retardant PVC.
HEATSINKS
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
Title Page
2.1. DESCRIPTION 14
2.2. TOPOLOGY 14
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
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
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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
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 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.
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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-TO-
LOAD.
Mode 4. INVERTER TO LOAD. This is the normal mode for the unit and is automatically
selected whenever possible.
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.
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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.
NORMAL
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
The two inverters power the load in parallel sharing the load between them. They are each
synchronised to the reserve supply.
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CHLORIDE
INDUSTRIAL SYSTEMS
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
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
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CHLORIDE
INDUSTRIAL SYSTEMS
RESERVE-TO-LOAD MODE
RESERVE
TRANSFORMER
RESERVE
SUPPLY
STATIC
SWITCH
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
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.
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CHLORIDE
INDUSTRIAL SYSTEMS
STATIC
SWITCH
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
Page 20 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
STATIC
SWITCH
BATTERY
CHARGER 1 INVERTER 1 STATIC
SWITCH
BATTERY
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
Battery KBM310
Capacity: 310 Ah
Number of cells 293
Autonomy 60 min
INVERTER
Page 22 of 68
EQUIPMENT POWER SUPPLY LOAD
CHARGER TEST WO: 15939 Item: CH1 Voltage 415 V 3 Ph 370 V 310 Ah
REPORT RB: 318107 N°: L09-0831 Frequency 50 Hz 209 A 293 Cells
TAG CUSTOMER : Battery type : Vented Ni Cd
CONTROL Charge Ufloat = 413.10 V at In/2 Ucharge = 483.50 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 456.0 455.0 485.1 19.3 1.38
- 10 % In 374.0 375.0 374.0 484.5 206.0 1.30
Nominal U In 416.0 148.0 417.0 147.0 416.0 147.0 104100.0 484.5 206.0 99807 95.88 0.98 2.08
Nominal U Lim. I 415.0 148.0 416.0 148.0 415.0 147.0 472.0 209.0 2.18
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
CONTROL Charge Ufloat = 413.13 V at In/2 Ucharge = 483.45 V at In/2 Uboost = 498.10 V Lim. Iboost = 62.0 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.5 457.0 456.0 486.0 23.6 1.60
- 10 % In 373.5 375.0 374.0 485.0 207.2 1.24
Nominal U In 414.5 147.8 415.5 146.8 415.0 147.7 103700.0 485.0 206.9 100346.5 96.77 0.98 2.30
Nominal U Lim. I 414.0 149.8 415.5 148.5 415.0 149.3 475.0 211.5 2.09
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
CONTROL Charge Ufloat = 413.10 V at In/2 Ucharge = 483.50 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 456.0 455.0 485.1 19.4 1.40
- 10 % In 374.0 375.0 375.0 484.4 206.2 1.40
Nominal U In 415.0 149.0 416.0 147.0 415.0 149.0 104200.0 484.4 206.4 99980.16 95.95 0.98 2.20
Nominal U Lim. I 415.0 150.0 416.0 148.0 415.0 149.0 472.0 209.7 2.30
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
CONTROL Charge Ufloat = 413.1 V at In/2 Ucharge = 483.45 V at In/2 Uboost = 498.10 V Lim. Iboost = 62 A
Mode U12 I1 U23 I2 U31 I3 PT UDC IDC P( U x I ) η PF Ripple
Supply I DC V A V A V A W V A W % VRMS
+ 10 % 0,1 In 455.0 457.0 456.0 485.0 23.6 1.63
- 10 % In 373.0 375.0 373.0 485.0 207.0 1.30
Nominal U In 414.5 146.9 416.5 146.0 415.0 145.9 103300.0 485.0 206.9 100346.5 97.14 0.98 2.10
Nominal U Lim. I 415.0 148.7 417.0 147.1 415.5 147.6 474.0 211.1 2.20
SUBJECT CHECK CHECKED CUST. COMMENTS
External aspect - Aspect of sheet metal, painting X
- Meter alignment X
- Lamps, leds, labels X
- CHLORIDE plate X
IEC 529 - Door mounting, locks, keys X
- Document holder X
- Earth wire X
File conformity - Photographs X
- Technical sheet X
- Drawings, parts list X
IEC 439 - Layout X
- Wiring sections X
- Special specifications X
Mounting - Mechanical welds X
- Subassemblies, screws, rivets X
- Subassembly fixing, transformers, chokes X
IEC 439 - Diodes and thyristors mounting on heat sink X
- Front panel removal X
IEC 73H0354 - Terminal blocks accessibility X
- Switchgear handle direction, protection screen X
Wiring - Connection quality X
- Crimping X
- Tightness of all connections X
- Soldering X
- Wiring ducts (size and position) X
- Wire routing X
Identification - Wires X
- Components X
- Terminals, transformer, couplers X
IEC 439 - Customer terminal blocks X
- Manufacturer plate X
Cleaning - Vacuum cleaning to remove any stray parts X
4. INSTALLATION
Title Page
4.2. STORAGE 24
4.6.2. Battery 25
4.6.3. Neutral 26
4.6.4. Earth 26
4.7. VENTILATION 26
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.
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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 0°C to 40°C it can be stored in temperatures as low as -20°C.
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 -20°C. Batteries should be maintained fully
charged as this keeps the freezing point low. Follow the manufacturer's instructions.
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.
Page 24 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
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.
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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
4.7. VENTILATION
All ventilation apertures must be kept free and clean. These systems can work in a continuous
environment within 0 to 40°C temperature range, although, ideally the ambient temperature
should be below 25°C.
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.
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
Page 26 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
Check the ambient temperature and once the system is running measure the temperature in the
battery cubicle.
Page 27 of 68
CHLORIDE
INDUSTRIAL SYSTEMS
5. OPERATING INSTRUCTIONS
Title Page
5. OPERATING INSTRUCTIONS 28
5.2. DISPLAY 30
5.10. HEADING 42
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.
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.
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.
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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).
1 3 2
5 4
The display has two operating modes:
1. Visualization of an active mimic diagram which gives a graphic representation of the UPS
status.
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Select previous
Up in menus.
Select next
Down in menus.
Validate parameters
OK Enter in menus.
Cancel parameters
C Back in menus.
In the right part of the display there are two further push-buttons to control the UPS:
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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.
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 CHARGER
Inverter Status
Reserve Changing Mode CHARGER MEASURES
AC Load
Measurements UDC = 220.1 V
Faults IDC = 60.0 Amp
Warnings U12 = 241.2 V
U23 = 242.0 V
General menu
U31 = 241.0 V
I1 = 70.0 Amp
Charger menu
Charger measures
(three-phase UPS)
5.5. GENERAL MENU
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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.
1. CHARGER
MENU
Charger
Battery
Inverter
Reserve
AC Load
CHARGER
Charger status menu (to display the charger operational
Status
status).
Changing Mode
Measurements Change charger mode menu (used to change the battery
Faults charge mode).
Warnings
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).
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2. BATTERY
MENU
Charger
Battery
Inverter
Reserve
AC Load
BATTERY
Battery status menu (to display the battery operational
Status status).
Measurements
Faults Battery measurements menu (for a list of measurements
Warnings 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
AC Load
INVERTER
Inverter status menu (to display the inverter operational
Status status).
Measurements
Faults Inverter measurements menu (for a list of measurements
Warnings 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).
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4. RESERVE SUPPLY
MENU
Charger
Battery
Inverter
Reserve
AC Load
This module is displayed only if a reserve supply network is confirmed on the customer’s technical
specification. This module allows entry to the following menus:
RESERVE
Reserve supply status menu (to display the reserve supply
Status
operational status)
Measurements
Faults Reserve supply measurements menu (for a list of
Warnings 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
AC Load
AC LOAD
AC load status menu (to display the AC load operational
Status status)
Measurements
Faults AC load measurements menu (displays the list of
Warnings 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)
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1. RESET
MENU
Inverter
Reserve
AC Load
Reset
Black Start
RESET
RESET charger menu (to erase the memorized charger
Charger Reset defaults)
Inverter Reset
Event Log Reset RESET inverter menu (to erase the memorized inverter
Autonom Calcul Rst 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
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MENU
Inverter
Reserve
AC Load
Reset
Black Start
This module is only available on parallel inverters. It allows entry to the following menu:
BLACK START
This menu gives the possibility to start parallel inverters, if the
Start the Inverter Reserve Supply is not present:
without Reserve?
Start both inverters by the control push buttons on each
NO display: the inverters will not yet start, as the Reserve
YES 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.
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3. EVENT LOG
MENU
Reserve
AC Load
Reset
Black Start
Event Log
This module allows to display one by one all the events memorised into the historical record, in a
chronological order.
Example of event:
EVENT N° 1
Inverter Fault
υHigh DC voltage
Memorised
Initiated:
17 fev 05 06:18:37
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.
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.
N°1 : the first event which has occurred (oldest).
N°100: 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.
N°1 : the most recent
N°100: oldest. (if 100 recorded events).
See chapter 4 Display Setting for the selection of the Event Log Mode.
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4. DISPLAY SETTING
MENU
AC Load
Reset
Black Start
Event Log
Display Setting
DISPLAY SETTING
Serial link menu (to direct the serial link of the display
Serial link board)
Language
Event Log Mode 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.
SERIAL LINK
Internal menu (to direct the serial link to SUB D9 (SK8)
Internal of the display board)
External
Selected Link: External menu (to direct the serial link to RJ 45 (SK6) of
Internal the display board)
Select with Up and Down push-buttons the serial link
LANGUAGE
English menu (to read information in English).
English
French French menu (to read information in French).
Spanish
German Spanish menu (to read information in Spanish).
Italian
German menu (to read information in German).
Italian menu (to read information in Italian).
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EVENT LOG MODE: This module allows entry to the following menus indicating the two
possibilities.
EVENT LOG MODE
Saturable Mode (allow to memorize the first 100 events)
Saturable Mode
FIFO Mode FIFO Mode (allow to memorize permanently until the last
Actual Setting: 100 events )
FIFO Mode
Select with Up and Down push-buttons the mode requested: to
validate, click on OK . You will then enter the new mode
chosen.
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.
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CHARGER
Status
Changing Mode
Measurements
Faults
Warnings
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Each sub-menu Measures, Faults and Warnings are circular roll down menus which can be scanned
with arrows :
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.
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UPS running
AC load supplied
Inverter not synchronised on reserve
1 5
9
10
11 2 3 4
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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
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NOTE 1:
NOTE 2:
When pictogram appears on inverter block, it means that the inverter is not
synchronized with the reserve supply.
Measurements indications
Faults indications Charger output DC voltage
No fault Charger output DC current
High DC voltage Charger input voltage (between each phase)
High DC voltage memorised Charger input current (on each phase)
Too high I battery memorised Charger input frequency
Charger fuse blown Number of mains failures
Input protection open
Charger off
Wrong phase sequence
AC supply fault
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Faults indications
No fault
Battery test fault memorised
End of discharge
Battery protection open Measurements indications
Battery voltage
Battery current
Battery temperature
Battery autonomy (%)
Status indications
Inverter synchronised
Inverter on crystal
Inverter not running
Inverter switched off
Warnings indications
No warning
Commissioning mode
Faults indications Software time-out
No fault Fan failure
Inverter switched off Inverter overload warning
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 Measurements indications
High AC voltage memorised Inverter input DC voltage
Frequency fault memorised Inverter output voltage (between phases and
neutral)
Inverter frequency
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Measurements indications
Reserve voltage (between phases and neutral)
Reserve frequency
Status indications
Load on inverter
Load on reserve
Manual bypass on
Load not supplied
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 (%)
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Starting situation: All switches, breakers and isolators are open, except Q21 which is closed.
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¾ 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.
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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).
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.
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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.
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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.
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:
¾ Turn the inverter on by the control push buttons (‘SWITCH ON INVERTER’ message
on the display): The inverter will not start.
¾ Press S22 (for INVERTER 1) or S23 (for INVERTER 2): The inverter will start and
the Static Switch will transfer from Reserve to Inverter.
¾ Release S22/S23: The Static Switch will transfer back from Inverter to Reserve, and
the inverter will stop.
¾ 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.
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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.
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 don’t have to reset anything, once the Reserve Supply has come back.
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6. ROUTINE MAINTENANCE
Title Page
6.1. GENERAL 54
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.
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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.
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7. FAULT DIAGNOSIS
Title Page
7. FAULT DIAGNOSIS 56
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AC Supply fault Loss of AC supply, lack of one Check fault nature on the LCD
phase, too high or too low display (amplitude or phase
amplitude, wrong phase problem).
sequence for three phase charger Check input supplies.
If AC supply is OK on power
input terminals, check auxiliary
fuses on internal electronic door
(F10)
Wrong phase sequence On three phase charger, the Interchange two phases, to
phase sequence is not correct reverse direction of phase
rotation
AC voltage NOK Amplitudes of one or several Check input supply on power
phases are not OK input terminals. If AC supply is
OK on power input terminals,
check auxiliary fuses on internal
electronic door (F10)
High DC Voltage Loss of charger voltage Check all the wires connected
regulation in case of charger to the INCA circuit board. If the
alone configuration (The fault is wiring is correct, the problem
not memorized and the charger can be linked with card
runs intermittently in order to problem:
continue to supply the DC load). Call engineer.
High DC Voltage Loss of charger voltage Check all the wires connected
Memorized regulation in case of parallel to the INCA circuit board. If the
configuration charger (The fault wiring is correct, the problem
is memorized and the charger is can be linked with card
cut) . The DC load is supplied problem: Call engineer.
by the redundant charger(s) Reset this memorized fault with
the LCD display charger reset.
Too high I battery Loss of battery current Check all the wires connected
Memorised regulation. 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.
Charger fuse blown Charger bridge high speed fuse Check loading, thyristors,
blown due to sudden short renew fuse, rearm the
circuit on the DC side or microswitch detector. In case of
problem on charger control a new occurrence, check the
loop. control wiring on the INCA
board. The problem can be
linked with a board: Call
engineer.
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Input protection opened Input protection tripped or Check loading and possible
opened. short circuit or overload on the
DC side. Rearm the protection.
Remote emergency stop Optional remote charger switch Check if the charger is not
is acting. (Optional switch) cut by an external remote
(or redundant high DC voltage switch.
monitor is acting).
(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)
Charger switch Off The charger is cut from the Give an ON charger order with
CANDIS board. CANDIS push button.
Fan failure One charger bridge fan is not Remove the charger AC and DC
supplied or blocked (in case of power supply, and isolate it.
forced air cooling charger Replace the fan in failure.
bridge)
DC voltage low The charger DC voltage is not Check if the DC load is not too
yet in voltage level regulation: high or if the charger is in
Overload on the DC side, or battery current limitation, by
battery is charging in current looking at IDC or Ibatt current
limitation after a discharge, or level on the display board. If
possible problem of voltage both preceeding points are not
regulation due to a too low AC satisfied, check if the AC mains
mains level. amplitude is not too low before
to call engineer.
Test mode The charger is in special Call engineer
production or commissioning
mode.
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)
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INDUSTRIAL SYSTEMS
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)
DC Earth fault Current leakage between battery and Danger, DO NOT CARRY OUT
earth or DC polarities and earth. 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
memorized achieve the battery voltage temperature sensor.
compensation control is in failure and Reset this memorized fault with
the charger runs with a temperature the LCD display charger reset.
default value of 20°C. If new occurrence, call engineer.
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).
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Frequency Fault M. Inverter output regulation problem. 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.
Paral. Com. Flt M. Problem detected in the Check correct insertion and
communication between the wiring of optional POB
different parallel running units (in board.
case of inverter parallel running)
Microcontroller fault Inverter running stopped by a Reset this memorized fault
microcontroller fault on the Inverter with the LCD display
CUdSMC board. 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).
Inv. switched Off The inverter is cut from the Give an ON inverter order with
CANDIS board. CANDIS push button.
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.
Inv. Overload warning 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.
S/W Time-out. Transient microcontroller problem, Call engineer
inverter may still be running.
Commissioning Running mode used for commissioning. Modify the configuration with
Operator has forgotten to replace the PPVIS software.
inverter in normal operation
configuration.
Fan Life expired Fan used is too old. Check the expected lifetime of
the different fans of the
equipment, and replace them if
required.
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3 other inverter warning specific messages can be detected in this part due to equipment
customisation. Check these messages in General Arrangement Drawing (PA)
Reserve Voltage NOK 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.
Res. Frequency NOK The reserve frequency is not correct Check the reserve frequency, try
to establish a correct reserve. No
action on the inverter.
Phase Sequence For three phase inverter, the phase Interchange two phases, to
sequence is not correct. reverse direction of phase
rotation
Reserve Inhibited Error of software configuration. Call engineer.
Paral. Res. Flt M. 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
Emerg. Power Off The AC load is no more supplied due Check the reason of the
to an Emergency power Off order sent volunteer Emergency Power Off
to the dedicated input. order.
S.S Overload Flt M. The reserve static switch has fed a too Reduce load. Reset this
high AC load for a too long time. memorized fault with the LCD
display inverter reset.
Inv. Stat Sw Flt M. The inverter static switch is in failure Check the wiring of the inverter
and is not correctly controlled. 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.
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Stat Sw H/W Flt M. Problem in the power supply of the Check the power supply of the
reserve static switch driver board. 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)
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.
Manual Bypass On The AC load is supplied by the reserve After Maintenance operation,
with the Manual bypass for don’t forget to come back in
maintenance purpose. automatic configuration in order
to have the maximum autonomy
and reliability.
S.S. Overld Warn. The reserve static switch is feeding a Check the overload reason, and
too high AC load. If this overload is not reduce the load.
diminished rapidly, the reserve static
switch will be shut off.
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
To maintain the high level of performance and reliability of these secure power systems the
following rules are applied:
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
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.
Drawing identification. The Chloride drawing prefixes identify the type of drawing
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 05 06 07 08 09 10 11 12 13
0 TITLE PAGE xx xx xx xx xx
1 GENERAL ARRANGEMENT xx xx xx xx
2 CUBICLE FOOTPRINT DETAIL xx xx xx CUSTOMER : INDIAN OIL CORPORATION LTD., NEW DELHI
3 BOTTOM GLAND PLATE ARRANGEMENT xx
4 DISPLAY DETAIL PAGE 1 xx xx PROJECT : 2.2MTPA DHDT PLANT, VADODARA
5 DISPLAY DETAIL PAGE 2 xx xx
6 NAMEPLATE DETAIL xx XX xx EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC
7 BATTERY PROTECTION BOX xx
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
GENERAL ARRANGEMENT
03/09/2009 MHS AS BUILT 04
Key : 1333 H1 H2 H3 H1 H2 H3 H1 H2 H3
1982
OPERATING HEIGHT
OF THE SWITCHES
LABEL / TAG :
TAG A : UPS 1
TAG B : BYP 1
100
TAG C : UPS 2
300mm
=UPS1+A1 : UPS 1 CUBICLE
=BYP1+A2 : BYPASS CUBICLE 1180 kg 500 kg 1180 kg
=UPS2+A3 : UPS 2 CUBICLE 200 mini
CHARGER WALL
-H1 : CHARGER SUPPLY - PHASE 1 OK 1600 1200 1600
-H2 : CHARGER SUPPLY - PHASE 2 OK
-H3 : CHARGER SUPPLY - PHASE 3 OK
BYPASS
200 mini
SHIPPING BREAK
282x120 282x120 282x120 282x120 182x120 282x120 282x120 282x120 282x120 282x120 282x120
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
800
1008
1008
830
830
1200 1600
92.5
92.5
Ø13 Ø13
100
100
72.5
72.5
72.5 62.5 62.5
J.REQ.NO: 18-3293-00/O.65/0223/OO
100 125
PROJ. NO: 18-3293
1008
60
60
182x120 282x120 282x120 282x120 282x120 282x120 282x120
131
77 77 77
109.0 189 79.5 159
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
Sync. C UPS
1 2 3
100%
100% 0
OK 0 1
Rectifier
0 1
Inverter
Epaisseur/thickness : 15/10ème
5mm
height : MANUFACTURER : CHLORIDE INDUSTRIAL SYSTEMS
30 av Montgolfier – 69680 CHASSIEU (France)
Police/letters type : SL513 ( Arial ) Tel : (+33) 4 78 40 13 56 Fax : (+33) 4 78 90 58 90
EQUIPMENT : DUAL UPS Apodys 70kVA 370VDC 1x110VAC
100mm
Battery Type : CdNi
Number of Cells : 293
Capacity : 310Ah
Autonomy : 60mn
AC Output Voltage : 110V
Output Phases : 1
Output Frequency : 50Hz
J.REQ.NO: 18-3293-00/O.65/0223/OO
Year of manufacture : 2008
1000mm
1045mm
960mm
LOCKING
4x
FASTENING Ø 9mm
760mm
845mm
BOTTOM
GLAND PLATE
12.5
310 x 96 310 x 96
35
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
0 TITLE PAGE xx xx xx xx xx
1 SINGLE LINE DIAGRAM xx xx xx xx
CUSTOMER : INDIAN OIL CORPORATION LTD., NEW DELHI
J.REQ.NO: 18-3293-00/O.65/0223/OO
PROJ. NO: 18-3293
=UPS1+A1 APODYS
H1-H2-H3 DISPLAY
U, I, F U, I U INVERTER 1 70kVA U, F
X CHARGER 1
370VDC/147-208A
1Ph/110VAC
50Hz
U -V18
AC SUPPLY 1 -Q3 -V2 -Q2 -Q26
TPN / 415VAC +/-10% (200A) (250A) (250A) (800A)
50Hz
Terminals Cu 50x5
K100
H1-H2-H3 DISPLAY U, F
AUTO XX
U, I, F U, I U INVERTER 2 70kVA TRANSITION X XX
X CHARGER 2 1Ph/110VAC TEST XX
370VDC/147-208A 50Hz
-Q3 -V2 -Q2
U -V18 -Q27
MAINTENANCE X
AC SUPPLY 2
TPN / 415VAC +/-10% (200A) (250A) (250A) (800A)
50Hz
Terminals Cu 50x5
-T31 : BYPASS TRANSFORMER -Q2 : CHARGER OUTPUT ISOLATOR =UPS1+A1 : UPS 1 CUBICLE
-U31 : STABILISER -Q3 : CHARGER INPUT FUSE SWITCH =BYP1+A2 : BYPASS CUBICLE
-V2 : CHARGER OUTPUT BLOCKING DIODE -Q5-1 & 2 : BATTERY CIRCUIT BREAKER =UPS2+A3 : UPS 2 CUBICLE
-V18/V21 : STATIC SWITCH -Q21 : BYPASS SWITCH =BAT1+A4 : BATTERY PROTECTION BOX
SIZE OF TERMINALS -K100 : DC EARTH FAULT -Q26 : INVERTER 1 OUTPUT ISOLATOR
P6 : 0.14 to 4 mm² -Q27 : INVERTER 2 OUTPUT ISOLATOR
J.REQ.NO: 18-3293-00/O.65/0223/OO P8 : 0.2 to 6 mm² -Q31 : BYPASS INPUT FUSE SWITCH
P10 : 0.5 to 10 mm² -H3 : CHARGER SUPPLY ON
PROJ. NO: 18-3293
P12 :1.5 to 16 mm²
CIS FILE NO.: SU318107 P16 : 1.5 to 35 mm²
P32 (M10) : 25 to 50 mm²
CUST. : CHLORIDE INDUSTRIAL SYSTEMS
P40 (M12) : 35 to 95 mm²
PROJ. : 2.2 MTPA DHDT PLANT P46 (M12) : 50 to 150 mm²
P53 (M16) : 70 to 240 mm²
CLIENT : IOCL Vododara, Gujarat
Cu Busbars: Copper busbars INTERCONNECTION CABLES
CONSLT : Jacobs Engineering India Pvt Ltd
* NOT SUPPLIED BY CHLORIDE
MFR. : CIS, CHASSIEU, FRANCE
10. ATTACHMENTS
Title Page
10. ATTACHMENTS 68
Page 68 of 68
NCPP
Nickel Cadmium Pocket Plate
2.0 INTRODUCTION 2
5.0 STORAGE 6
6.0 INSTALLATION 8
9.0 CHARGING 12
10.0 MAINTENANCE 14
16.0 DRAWINGS 27
1
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.
Charge
2 Ni(OH)2 + Cd(OH)2 ⇔ 2 NiOOH + Cd + 2H2O
Discharge
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 doesn’t 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.
2
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
3.0 SAFETY PRECAUTIONS
3.1 ELECTROLYTE
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.
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
4.0 RECEIVING THE SHIPMENT
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.
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.
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
5.0 STORAGE
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.
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.
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.
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.
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.
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.
Store the electrolyte in clean, air–tight plastic containers for future use. After
removing the battery from storage, follow the instructions for electrolyte filling, first
charging and installing the battery.
7
6.0 INSTALLATION
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
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 :
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.
Connect the battery terminals to the equipment only after marking all the other inter-
cell and inter-row connections
Use the correct torque to tighten the terminal bolts as indicated below:
When there is a risk of crate movement as in the case of mobile applications, use
wooden or plastic wedges for arresting the movement.
9
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.
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.
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.
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.
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.
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.
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
For continuous parallel operation with occasional battery discharge, use a float-
charging voltage in the range of 1.40 to 1.42 volts per cell.
For recuperative charging of the battery after a discharge, adjust the charging volt-
ages to a level corresponding to:
Over charging within reasonable limits will not damage the battery, but water
consumption will be increased.
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.
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.,
10.3 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.
14
10.6 SPECIFIC GRAVITY
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.
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.
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.
15
S.No. SYMPTOM PROBABLE CAUSE RECOMMENDED CORRECTIVE
ACTION
02. Earth fault Small leak or leaks Check for wetness on battery stand,
indication or with a voltmeter, area of the battery
having the lowest potential to ground.
See (1) for procedure if a cell is
leaking.
Battery wet due to Disconnect few connectors to avoid
overfilling high or over boiling voltage and clean
the battery. See (8).
Other equipment of Isolate various parts of the DC system
system to find the fault.
03. Continuous Charging voltage is See charger instructions for
heavy gassing above the information on charging mode and
recommended float settings.
voltage .
04. No power or Interruption at See SL.No: 1.
capacity at all connector
16
S.No. SYMPTOM PROBABLE CAUSE RECOMMENDED CORRECTIVE
ACTION
06. Low discharge Very low voltage for Check the individual cell voltages during
voltage during a one or few cells. discharge and full recharge. If the
major part of voltage of an individual cell does not
discharge. 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.
Battery designed with This condition sometimes occurs if the
high cell end voltage. design cell end voltage is 1.14 – 1.18
The discharge volt per cell and the battery has been in
preceded by long term service for sometime. It does not mean
float charge without that the capacity has decreased. It is
discharge. 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.
07 Too low for Discharged battery Insufficient charging, See(06)
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.
08 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.
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.
Standard B-22, Density 1.20 B-5, Density 1.19 B22, Density 1.20
Special Application B-30, Density 1.28 B-12, Density 1.25 B30, Density 1.28
(Solar)
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
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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
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12.0 DO’S AND DO NOT’S
12.1 DO’S
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.
10. Use insulated tools while working on the battery to prevent accidental short
circuit and consequent damage.
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12.2 DO NOT’S
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.
14. Do not keep Batteries in the same room where acid batteries are kept.
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13.0 DM / DI WATER SPECIFICATION
Note : Topping up must be with DM/DI water with the conductivity less than 10 micro
siemens /cm
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14.0 SERVICE LOG
Date : _______________________________
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Service Log (Continue)
Date: _________________________
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15.0 TOOLS & ACCESSORIES
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16.0 DRAWINGS
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Corp.Mktg/12-2003/NCPP/O&S