Operating manual
APOTRANS
25 – 63A
400V / 50Hz
APOTRANS
IN1
PILLER
~
~
OFF
OUT
RESET
OFF
IN2
A Langley Holdings Company
~
~
PILLER POWER SYSTEMS
CONTENTS
91.9.045.0019 5.0 16.01.07
1
CONTENTS........................................................................... 1-1
2
INTRODUCTION ................................................................... 2-1
3
SAFETY NOTES ................................................................... 3-1
3.1
General notes............................................................................................. 3-1
3.2
3.2.1
3.2.2
Protection against electric shocks .......................................................... 3-2
Protection against direct contact ................................................................. 3-2
Protection against indirect contact .............................................................. 3-2
4
DESCRIPTION OF THE SYSTEM ........................................ 4-1
4.1
General ....................................................................................................... 4-1
4.2
4.2.1
4.2.2
4.2.3
Performance under special operating conditions ................................. 4-2
Overload ...................................................................................................... 4-2
Short-circuit on the load busbar .................................................................. 4-2
System malfunctions ................................................................................... 4-2
4.3
Description of the static switch ............................................................... 4-2
4.4
Description of static switch controller .................................................... 4-3
4.5
Description of system controller ............................................................. 4-4
4.6
Technical data............................................................................................ 4-5
4.7
Dimensions ................................................................................................ 4-6
4.8
Space requirement .................................................................................. 4-10
5
INSTALLATION AND CONNECTIONS ................................ 5-1
5.1
5.1.1
5.1.2
5.1.3
Installation notes ....................................................................................... 5-1
Transportation ............................................................................................. 5-1
Storage ........................................................................................................ 5-1
Choice of installation site............................................................................. 5-1
5.2
5.2.1
5.2.2
5.2.3
5.2.4
Electrical connections .............................................................................. 5-2
General........................................................................................................ 5-2
Internal connection (system with terminal connection/19 inch system) ...... 5-2
External connection with 5-way CEE plugs and couplers (unit with plugs). 5-4
Remote control connections (optional)........................................................ 5-5
6
OPERATING INSTRUCTIONS ............................................. 6-1
6.1
6.1.1
General ....................................................................................................... 6-1
Operator control panel................................................................................. 6-1
6.2
6.2.1
Operator controls ...................................................................................... 6-2
Mimic display indicators .............................................................................. 6-2
6.3
6.3.1
6.3.2
Commissioning.......................................................................................... 6-3
Tools required.............................................................................................. 6-3
Commissioning the APOTRANS ................................................................. 6-4
6.4
6.4.1
6.4.2
6.4.3
Operating the APOTRANS transfer switch ............................................. 6-5
Switching on and manual changeover ........................................................ 6-5
Switching off: with load supply interruption ................................................. 6-6
Switching off: without load supply interruption ............................................ 6-6
1-1
PILLER POWER SYSTEMS
CONTENTS
6.4.4
Fault procedures ......................................................................................... 6-6
6.5
Settings ...................................................................................................... 6-7
6.6
Programming mode .................................................................................. 6-8
7
MAINTENANCE AND CUSTOMER SERVICE ......................7-1
7.1
Maintenance .............................................................................................. 7-1
7.2
Customer service ...................................................................................... 7-1
8
ADDITIONAL INFORMATION ...............................................8-1
8.1
Mounting plan APOTRANS 19 inch......................................................... 8-1
8.2
Mounting plan APOTRANS 25-63 A ........................................................ 8-4
8.3
8.3.1
8.3.2
8.3.2.1
8.3.2.2
Customer interface card (optional) ......................................................... 8-8
Terminal strip X1, X3, X6 and X30.............................................................. 8-9
Terminal strip X2, programmable relays................................................... 8-11
Description of programmable relays ......................................................... 8-12
Standard relay assignment ....................................................................... 8-12
8.4
Protocol gateway (Option) ..................................................................... 8-13
8.5
8.5.1
8.5.2
Event recorder (event memory)............................................................. 8-14
Description of operation ............................................................................ 8-14
List of event recorder entries .................................................................... 8-14
8.6
8.6.1
8.6.2
8.6.3
8.6.4
8.6.5
Static switch ............................................................................................ 8-17
General ..................................................................................................... 8-17
Measured value acquisition ...................................................................... 8-17
Monitoring ................................................................................................. 8-17
Operating the static switches .................................................................... 8-18
Arrangement of light-emitting diodes
and connection terminals on the controller board..................................... 8-20
9
APPLICATION NOTES..........................................................9-1
9.1
Neutral conductor current........................................................................ 9-1
9.2
Loop resistance/short-circuit current measurement
in UPS systems with APOTRANS transfer switches............................. 9-1
9.3
Short-circuit current calculation in UPS systems
with APOTRANS transfer switches. ........................................................ 9-1
The descriptions and specifications in this
operating manual are dated 09.01.07
We reserve the right to change without notice!
1-2
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PILLER POWER SYSTEMS
INTRODUCTION
2
INTRODUCTION
Uninterruptible power supply systems (UPS) are used to protect sensitive loads from
disturbances in the local supply system. Such disturbances can be: transient power
failures, short interruptions, distortion, voltage and frequency deviation.
Even if they last only a few milliseconds, each of these irregularities can have serious
operational consequences for the loads, and can also be costly.
This manual describes the APOTRANS transfer switch which forms part of this product
range. The APOTRANS is an automatic transfer switch that increases the supply security
of critical loads. If the preselected standard power source, for example a UPS system, the
APOTRANS can change over the critical load to a second supply system without
interruption and thus increase the security of the supply many times.
Piller uninterruptible power supplies enable you to reliably protect your systems from such
disturbances.
When you have read the explanations in this manual you will know how to handle the
equipment and utilise all its advantages.
NOTE
Of course, an operating manual cannot cover all the possible factors
encountered during installation, operation, maintenance or servicing.
If problems arise, or if the data in the manual are insufficiently detailed or
you require further information, please contact one of our representatives
who will be pleased to offer assistance.
Fig. 2-1 APOTRANS 25-63 A, 19 inch
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2-1
INTRODUCTION
PILLER POWER SYSTEMS
Fig. 2-2 APOTRANS 25-63 A, terminal connection
Fig. 2-3 APOTRANS 25-63 A, plug connection
2-2
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PILLER POWER SYSTEMS
SAFETY NOTES
3
SAFETY NOTES
3.1
General notes
The APOTRANS transfer switch is a piece of electrical equipment which carries voltages
and current that are hazardous to personnel. You should therefore observe the following
points.
1. Installation, operation and maintenance of the APOTRANS must only be carried out
according to the instructions in this manual.
2. Ensure that the equipment is handled only by well-trained and authorised personnel.
3. Provide suitable measures to ensure that only operating and maintenance have
access to the plant room and to the interior of the equipment; the doors should be
kept locked and the key held by authorised persons only.
4. All personnel who have to work on equipment should be familiar with first-aid
procedures relating to electrical accidents.
5. The local electricity supply company’s current regulations and other safety
instructions (e.g. VDE) must be observed.
6. Even when the equipment is completely switched off, a few internal parts are “live” as
long as they are still connected to the AC supply.
7. Built-in capacitors can remain charged up, even when the system is completely
“dead”. They should be suitably discharged by trained personnel before contact is
made with the connections.
8. The warning and hazard notices inside the equipment must be observed.
9. The equipment environment must be kept as clean as possible and always be free of
aggressive agents. Particular care must be taken to prevent metallic or other
electrically-conducting dust particles from entering the equipment.
Explanation of the warning symbols and notes in this operating manual:
91.9.045.0019 5.0 16.01.07
WARNING
Indicates all instructions that must be strictly complied with to prevent
personal injury and serious damage to equipment.
IMPORTANT
Indicates all instructions that must be strictly complied with to prevent
damage to equipment and/or malfunctions.
NOTE
Indicates instructions that must be strictly complied with during
installation, operation or maintenance/servicing.
3-1
PILLER POWER SYSTEMS
SAFETY NOTES
3.2
Protection against electric shocks
3.2.1
Protection against direct contact
‘Protection against direct contact means that the
electrical equipment is designed so that contact with
operational “live” parts is eliminated. This is always
the case if the live parts are enclosed by a housing
that has protection type > IP20.
All components of the transfer switch, such as the
thyristor switch, operator control panel, distribution
system, etc., meet these requirements.
The shock protection test using the IEC test finger in
accordance with DIN 54470, corresponding to IEC
60529, has been carried out on this system.
Y
L1
L2
L1
APOTRANS
L2
L3
L3
PE/N
PE/N
Fig. 3-1 IT system (isolated neutral)
3.2.2
Protection against indirect contact
Parts which are normally not live can become so if an
insulation fault occurs. In this case, protection against
shock can be provided by interconnecting all parts of
the equipment to a common ground system, and
providing a suitable connection to the power supply.
A transformer must be used if the neutral conductor
is different at the AC supply side and the load side
(see IT system), since this is necessary for the proper
operation of the transfer switch.
L1
L1
L2
APOTRANS
L2
L3
L3
N
N
PE
Fig. 3-2 TT system (earthed neutral)
Protective devices at the load side, such as r.c.d.
protection, can be used if required. In these cases we
recommend that you seek the advice of our specialist
department.
L1
L1
L2
APOTRANS
L2
L3
L3
N
N
PE
PE
Fig. 3-3 TN system (earthed neutral)
3-2
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PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4
DESCRIPTION OF THE SYSTEM
4.1
General
The APOTRANS automatic transfer switch described below has been manufactured to
the latest state of the art. The latest know-how in power electronics and digital control
technology has been implemented in order to provide an optimum solution to power
supply problems. The equipment is used for “no-break” switching between two
independent synchronous or even asynchronous supply systems, e.g. different
uninterruptible power supplies. One of the two infeeds is connected to the critical load via
a static switch. If this infeed fails, an automatic transfer to the second source takes place.
The two static switches SS1 and SS2 are connected in parallel to the critical load. In
addition, both infeeds are connected to the load with a separate bypass via the manual
changeover switch Q5.
In the normal mode, Q5 is in the neutral position. The preselected infeed is switched
through to the load by means of the thyristor switch. If this fails or the voltage no longer
meets the quality requirements, the system automatically changes over to the other
source. Depending on how the service engineer configures the system, source 1 can be
set as the standard source. In this case, on restoration of the power supply, the system
switches back to the original source after 0.1 to 60 seconds (adjustable by service
personnel - standard setting 10 seconds).
As well as the automatic changeover under special operating conditions, a manual
transfer can be initiated by pressing a key on the control panel or by means of an external
signal.
The power section and electronics can be electrically isolated for maintenance purposes
by means of the maintenance bypass, without interrupting the supply to the load.
Static switch 1
Mains 1
~
~
Static switch 2
Mains 2
~
Output
~
Change over switch Q5
Fig. 4-1 Block diagram of APOTRANS 25-63 A
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4-1
PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4.2
Performance under special operating conditions
4.2.1
Overload
The static switches can carry up to 120 % of their rated power for 10 minutes and up to
150 % for 2 minutes. A fault is indicated if the overload periods are exceeded, but in the
standard mode the switch is not turned off. An overload shutdown can be activated by
service personnel.
4.2.2
Short-circuit on the load busbar
In the event of a short-circuit in the downstream load, no transfer takes place from the
active to the inactive source. Within 4 s the transfer switch switches the faulty load off.
4.2.3
System malfunctions
In the event of malfunctions in a path within the APOTRANS, for example an open-circuit
thyristor is detected, the system automatically changes to the second AC supply.
4.3
Description of the static switch
Each of the static switches SS1 and SS2 consists of four antiparallel double thyristor
modules which are controlled by one trigger card. No additional commutation or filter
devices are required.
Measured value acquisition and control is provided by redundant microprocessor control.
The transfer operation is phase selective and takes place in the current zero crossing to
prevent circulating currents flowing between the two infeeds (break before make). The
current zero crossing is detected by means of current and voltage monitor.
A100
Redundant static switch
controller
A101/A102
Triggercard and
voltage monitor
A1
Mains 1
Mains 2
Output
Q5
Fig. 4-2 Construction of static switch
4-2
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PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4.4
Description of static switch controller
The operation of the static switch is automatic. The following switching operations and
APOTRANS states are controlled and monitored by the static switch controller board:
!
Monitoring of both input voltages and the output voltage
The voltage and frequency tolerance of each phase of the two input systems is
monitored. If the tolerance of the preferred infeed is outside the set tolerance window,
an automatic transfer to the second source is triggered. This transfer is inhibited if the
alternative infeed is also outside the tolerance window. Depending on the user
settings, the system switches back automatically to the preferred infeed if the
conditions are again fulfilled.
!
Monitoring of phase angle
The two maximum permissible phase differences for manual or automatic transfer,
respectively, are monitored.
!
Control of phase-selective changeover
After the current zero crossing has been detected in one phase, the respective
thyristors of the other system are switched on after the necessary circuit-commutated
recovery time has elapsed.
!
Monitoring of load short-circuit
The changeover is inhibited in the event of an output short-circuit.
!
Monitoring of the static switch
In the event of short-circuited thyristors the transfer to the other supply system is
inhibited. A transfer is triggered in the case of open-circuited thyristors.
Redundant
static switch controller
~
Mains 1
SS2
~
Mains 2
Q5
SS1
~
~
Output
Fig. 4-3 Measured value acquisition and control
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4-3
DESCRIPTION OF THE SYSTEM
4.5
PILLER POWER SYSTEMS
Description of system controller
The system controller in the APOTRANS is of a redundant construction. Two independent
microcontrollers process the same control software in the master/slave mode. If the
master controller fails, the slave controller immediately takes over control. In this case
there is no interruption to the supply to the load. The failure of a CPU is indicated
accordingly.
Control commands are transmitted by the control panel to the static switch controller,
evaluated there and converted into the corresponding actions.
Operational messages are displayed by the static switch controller in the mimic diagram
of the operator control panel.
For remote indication, three potential-free (changeover) contacts, which can output the
pre-programmed fault messages, are provided on the optional customer interface card. A
fault in mains 1 or mains 2 can be externally input via the 4 existing digital inputs, or a
transfer lockout can be activated at the sources.
Display
Redundant
static switch controller
Customer interface card
Control and
monitoring static switch
Fig. 4-4 System controller components
4-4
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PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4.6
Technical data
Type
Rated current
AT
25
35
50
63
A
25
35
50
63
380 V ± 10 % / 400 V ± 15 % / 415 V ± 10 %
Rated voltage
50 Hz ± 5 %
Rated frequency
Equipment fuse NH00 gL/gG
A
25
35
50
Power factor cos ϕ
0 (cap.) ... 1 ... 0 (ind.)
Overload capacity
- 10 min
- 2 min
120 %
150 %
- 10 ms
48 x In
34 x In
Crest factor
2
> 99 %
2
As
15000
Transfer times
- phase selective transfer
- phase simultaneous transfer
< 2 ms manual, typical 3 ms automatic
< 5 ms at 0 ms waiting period, adjustable
Number of poles / number of phases
4/3
Periodical peak voltage
800 V
max. rate of voltage rise
< 1000 V/µs
max. rate of current rise
150 A/µs
Leakage current
max. power dissipation
(with symmetrical load)
19 x In
>5
Efficiency
I t value
24 x In
63
25 mA
kW
Noise level (at a distance of 1 m)
< 0,12
< 0,15
< 0,19
< 0,23
< 40 dB(A)
0 – 40° C (daily average ≤ 35° C)
Ambient temperature
Humidity
20 – 90 % non-condensing
Installation altitude
< 1000 metres above mean sea level
Type of protection
IP 20
Paint finish
RAL 7032
Dimensions
see section 4.7
1
Weight
19 inch
Optional module 19 inch
Terminal connection
Plug connection
kg
kg
kg
kg
20
6
34
34
Relevant specifications:
DIN VDE 0100
DIN EN 60664:2003-11
DIN EN 60529:2000-09
DIN EN 60146-1-1:1994-03
DIN IEC 60721-2-1:1992-07
DIN EN 61000-6-2 (VDE 0839-6-2):2002-08
DIN EN 61000-6-4 (VDE 0839-6-4):2002-08
1
rounded values
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4-5
PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4.7
Dimensions
150
38
191
266 (6HE)
33
483
9
300
422
62
30
465
40
436
133
(3HE)
Option:
40
296
436
Fig. 4-5 Dimensions of APOTRANS, 19 inch with optional module
4-6
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PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
300
19,5
APOTRANS
PILLER
150
43
80
2
272
36
100
300
14
402
500
Bypass
bypass
o
1
500
Fig. 4-6 Dimensions of APOTRANS 25-63 A, terminal connection
91.9.045.0019 5.0 16.01.07
4-7
PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
300
19,5
150
43
80
36
Bypass
bypass
0
2
402
500
1
Last
load
Netz 2
mains 2
100
300
b
a
64 mm
79 mm
b
128,5 mm
158 mm
a
Type
AT25
AT35-63
14
272
Netz 1
mains 1
Last
Netz 1 load Netz 2
mains 1
mains 2
500
Fig. 4-7 APOTRANS 25-63 A, plug connection
4-8
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PILLER POWER SYSTEMS
25
DESCRIPTION OF THE SYSTEM
46
179
296
1
Ø1
450
24,5
447
26
29
247
137
26
24,5
Fig. 4-8 Dimensions holding device of APOTRANS 25-63 A (not available for AT19 inch)
91.9.045.0019 5.0 16.01.07
4-9
PILLER POWER SYSTEMS
DESCRIPTION OF THE SYSTEM
4.8
Space requirement
min. 300 mm
Bypass
bypass
0
1
Netz 1
mains 1
2
Last
load
Netz 2
mains 2
min. 100 mm
Leave room for
expansion if required
200*
Aperture angle
of the doors 120°
480
500
Access way to
VDE 0100 part 729
*Only if the air inlet in the base is blocked (e.g. standing installation).
Fig. 4-9 Space requirement of APOTRANS 25-63 A
4-10
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INSTALLATION AND CONNECTIONS
PILLER POWER SYSTEMS
5
INSTALLATION AND CONNECTIONS
5.1
Installation notes
Piller’s final inspection ensures that the mechanical and electrical condition of the
APOTRANS is satisfactory before it leaves the factory. Immediately the equipment
arrives, please check for any freight damage and if necessary report this to the freight
operator. Under no circumstances put a damaged APOTRANS into service before you
have consulted us!
5.1.1
Transportation
Ensure that the equipment is transported in an upright position only. It must not be tilted
or turned over. Always avoid sharp impacts. Where possible, leave the equipment in its
original packing when moving it, thus providing the best possible protection against
damage.
5.1.2
Storage
The equipment should be stored in a dry, well-ventilated room that is free of aggressive
materials. Where possible, the original packing should not be removed during storage.
The APOTRANS must never be left stacked or stored outside!
5.1.3
Choice of installation site
The APOTRANS is designed for mounting against a wall, i.e. access for operation and
maintenance is possible from the front only. The following criteria should be taken into
account when selecting the installation site:
a) Space requirement
As already mentioned, the APOTRANS can be placed with its rear panel against a
wall. In no circumstances should the heatsink at the rear of the unit be blocked or
covered.
A clearance of approximately one metre should be provided in front of the set to
provide unimpeded access to the cabinet. Local and general safety regulations, e.g.
escape routes as per VDE 100, part 729, should be observed. A clearance of at least
30 cm should be left above the APOTRANS to allow the warm air to be freely
exhausted. If the air inlet in the base is blocked, e.g. standing installation, a lateral
space of 20 cm is necessary.
b) Installation altitude, temperature and humidity
The APOTRANS is designed for an installation altitude up to 1000 metres above
mean sea level, an ambient temperature of 0 to 40 °C (daily average ≤ 35 °C) and a
relative humidity up to 90 %. The optimum temperature is approximately 20 °C.
Please consult us if you are planning to install the system at altitudes above 1000
metres. Any existing air-conditioning plant should meet these conditions and be able
to remove the heat dissipated in the unit. Details are shown in the technical data. The
cooling air must always be free of aggressive agents and dust particles.
c) Holding device (optional)
The dimensions for mounting the holding device resp. the APOTRANS on the device
are shown in Fig. 4-8.
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5-1
PILLER POWER SYSTEMS
INSTALLATION AND CONNECTIONS
5.2
Electrical connections
5.2.1
General
IMPORTANT
You must ensure that the phases of the AC connections (clockwise
rotating field) are correct as incorrect connections can damage the
equipment.
For connecting the APOTRANS, terminal strips are provided compartment for the power
connections (mains 1, mains 2, load) and for the remote indications. The cables can be
introduced through the bottom and sides of the unit.
5.2.2
Internal connection (system with terminal connection/19 inch system)
The following table shows the power cables required for the APOTRANS system:
APOTRANS
Mains 1 and Mains 2, Load
25 A
NYCWY 4x6 re/6
35 A
NYCWY 4x6 re/6
50 A
NYCWY 4x10 re/10
63 A
2 x NYCWY 4x10 re/10
1 x NYCWY 4x 16 re/10
AT19 Inch
Outer- , neutral
conductor
and protective earth
rigid
2
2
0,5 mm ... 25 mm
flexible
2
2
0,5 mm ... 16 mm
AT25-63 with
rigid
terminal connection
Outer- , neutral
conductor
flexible
AWG
2
2
2 x 2,5 mm ... 16 mm
AWG 12 ... 2
or
2
2
1 x 25 mm oder 35 mm
2
2
1 x 2,5 mm ... 16 mm
1 x 2,5 mm ... 50 mm
Protective earth
1 x 2,5 mm ... 25 mm
2 terminals per mains
and output
5-2
AWG
AWG 20 ... 4
2
2
2
2
AWG 12 ... 4
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PILLER POWER SYSTEMS
INSTALLATION AND CONNECTIONS
Q005
A240
X230
X001
X230
X002
X100
X240
X003
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
X001/X002/X003
L1 L2 L3 N PE
Fig. 5-1 AT19 inch, connections
Terminal X001
Terminal X002
Terminal X003
Mains 1
Mains 2
Output
X001
PE
1 2 3 N1
PE
7 8 9 N3
F001
F002
A230
PE
4 5 6 N2
Fig. 5-2 AT25-63 A, connections
Terminal X001
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1
2
3
N1
Mains 1
Mains 1
Mains 1
Mains 1
L1
L2
L3
N1
4
5
6
N2
Mains 2
Mains 2
Mains 2
Mains 2
L1
L2
L3
N2
7
8
9
N3
Output
Output
Output
Output
L1
L2
L3
N3
5-3
INSTALLATION AND CONNECTIONS
5.2.3
PILLER POWER SYSTEMS
External connection with 5-way CEE plugs and couplers (unit with plugs)
The unit’s AC supply and load connections should be made via flexible cables with 5-way
CEE plugs and couplers. CEE couplers should be provided for mains infeeds 1 and 2 and
a CEE plug for the load output.
The following table shows the couplers, plugs and cables that are required for the
APOTRANS system:
APOTRANS
Mains 1 and mains 2
Load
25 A
32 A, 400 V, 3P+N+PE
CEE-coupler, if necessary with
hinged cover for arresting device
H07RN-F 5G 6,0
32 A, 400 V, 3P+N+PE
CEE-plug, if necessary with
retaining lug for arresting device
H07RN-F 5G 6,0
35 A
63 A, 400 V, 3P+N+PE
CEE-coupler, if necessary with
hinged cover + bayonet system for
arresting device
H07RN-F 5G 6,0
63 A, 400 V, 3P+N+PE
CEE-plug, if necessary with
retaining lug + bayonet system
H07RN-F 5G 6,0
50 A
63 A, 400 V, 3P+N+PE
CEE-coupler, if necessary with
hinged cover + bayonet system for
arresting device
H07RN-F 5G 10,0
63 A, 400 V, 3P+N+PE
CEE-plug, if necessary with
retaining lug + bayonet system
H07RN-F 5G 10,0
63 A
63 A, 400 V, 3P+N+PE
CEE-coupler, if necessary with
hinged cover + bayonet system for
arresting device
H07RN-F 5G 16,0
63 A, 400 V, 3P+N+PE
CEE-plug, if necessary with
retaining lug + bayonet system
H07RN-F 5G 16,0
Fig. 5-3 Connections for Mains 1, Load and Mains 2
5-4
91.9.045.0019 5.0 16.01.07
INSTALLATION AND CONNECTIONS
5.2.4
PILLER POWER SYSTEMS
Remote control connections (optional)
The A230 card in the right-hand lower cabinet compartment enables the customer to
adapt the APOTRANS to his own electronic installation. Four external remote control
signals are provided, which are interrogated in the static controller’s software.
For the cable entry, the APOTRANS has a 13.5 heavy-gauge conduit thread at the
bottom of the rear panel.
If these signals are to be used, in the event of a fault the 24-volt signal applied to terminal
2.1 must be connected to the corresponding terminals 2.2 to 2.4 by means of a potentialfree contact.
The card also contains three pre-programmed user relays.
The table below and Fig. 5-3 show the terminal pin assignments:
Terminal
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
A230
X2
1
Function
internal + 24 V supply
Mains 1 fault (ext.)
Transfer to Mains 2 blocked (ext.)
Transfer to Mains 2 blocked (ext.)
Mains 2 fault (ext.)
N/O contact: relay 1
N/C contact: relay 1
Changeover terminal: relay 1
N/O contact: relay 2
N/C contact: relay 2
Changeover terminal: relay 2
N/O contact: relay 3
N/C contact: relay 3
Changeover terminal: relay 3
+24V
2
mains 1 fault
3
transfer to mains 2 blocked
4
transfer to mains 1 blocked
5
mains 2 fault
6
7
8
relay 1
general failure
9
10
11
relay 2
fault mains 1
12
13
14
relay 3
fault mains 2
15
16
Fig. 5-4 Pin assignment A230 X2
91.9.045.0019 5.0 16.01.07
5-5
PILLER POWER SYSTEMS
OPERATING INSTRUCTIONS
6
OPERATING INSTRUCTIONS
6.1
General
This chapter describes how the APOTRANS is to be operated. The steps for
commissioning and switching the system on and off are explained after an introduction to
the operator controls and indicators. A smooth sequence of operations is only achieved if
the individual steps are carried out in the specified order.
6.1.1
Operator control panel
The control panel contains a mimic display with LED indicators, an alarm horn and the
necessary push-buttons for operation.
The current status is shown in the mimic display by different coloured LEDs.
If changes occur, the LEDs change their colour or flash.
APOTRANS
IN1
PILLER
~
~
OFF
OUT
RESET
OFF
IN2
91.9.045.0019 5.0 16.01.07
~
~
6-1
PILLER POWER SYSTEMS
OPERATING INSTRUCTIONS
6.2
Operator controls
IN1
“IN 1” button for switching on infeed 1
RESET
IN1
To switch off infeed 1:
Press “IN 1” and “RESET” buttons simultaneously.
RESET
“RESET” button for acknowledging faults, switching off the horn and
for a lamp test, but only when no fault is present.
IN2
“IN 2” button for switching on infeed 2
RESET
IN2
To switch off infeed 2:
Press “IN 2” and “RESET” buttons simultaneously.
6.2.1
Mimic display indicators
The following transfer switch components are displayed by LEDs:
1
2
3
Input: infeed 1
Input: infeed 2
Output
1
Input 1
Input 2
2
~
~
~
~
Output
3
Fig. 6-1 Mimic diagram with LED indicators
6-2
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
OPERATING INSTRUCTIONS
Information about the current operating status of the APOTRANS can be obtained from
the table below:
LED
colour and state
Green flashing
Green
Yellow flashing
1
2
3
Overload: static switch 2
Infeed 2 on
Infeed 1 on and infeed 2
asynchronous
Infeed 2 available
Overload
Output and load OK
Red
Overload: static switch 1
Infeed 1 on
Infeed 2 on and infeed 1
asynchronous
Infeed 1 available
Reverse transfer timer for
default source not yet
expired
Fault:
static switch 1
Fault:
static switch 1 and infeed 1
on
Mains fault: infeed 1
Fault:
static switch 2
Fault:
static switch 2 and infeed 2
on
Mains fault: infeed 2
Load fault, short-circuit,
general fault
Load fault, short-circuit,
general fault and output
on
Mains fault: output
Red-yellow falshing
Bypass 2 is engaged
Bypass 1 is engaged
Yellow
Green-yellow flashing
Red flashing
Green-red flashing
6.3
Output available
Commissioning
Check the following prior to commissioning:
IMPORTANT
1. Is the equipment damaged? If so, do not put the equipment into
service before consulting us.
2. Have the cables been correctly installed (AC input, output, remote
control, etc.)? Correct if necessary.
6.3.1
Tools required
You need the following to put the APOTRANS into service:
91.9.045.0019 5.0 16.01.07
!
Multimeter
!
Rotating field measuring instrument
!
Various screwdrivers
6-3
OPERATING INSTRUCTIONS
6.3.2
PILLER POWER SYSTEMS
Commissioning the APOTRANS
WARNING
1. Commissioning should be carried out only by trained personnel since
operations involve components that can be “live”!
IMPORTANT
2. Commissioning operations should be carried out if
- the system is being put into service for the first time,
- modifications or repairs have been carried out
3. Ensure that the individual steps are carried out in the correct order.
1. Set Q5 to the neutral position.
2. Disconnect fuses F1 and F2.
3. Switch on the power supply for the unit and check a clockwise rotating field appears
at terminals X1.1/2/3 and X1.4/5/6.
4. Connect fuses F1 and F2.
5. Carry out a lamp test by pressing the “Reset” button (only possible in there is no fault
present).
6. The system is now ready for operation.
6-4
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
OPERATING INSTRUCTIONS
6.4
Operating the APOTRANS transfer switch
6.4.1
Switching on and manual changeover
Explanation of LEDs in the following drawings:
= not illuminated
= yellow steady
= green steady
= red steady
1. Check that the “Input 1 and “Input 2” LEDs show
yellow when the AC supplies are available. At
least one AC supply must be available for
commissioning. If the phase angle of the AC
supplies is > 30°, the LEDs of “Input 1” and
“Input 2” are flashing yellow.
Input 1
Input 2
2. Press the “IN 1” button. The “Input 1” LED and
“Output” Led should show green.
Input 1
Input 2
3. Press the “IN 2” button. A transfer to the second
source takes place provided both infeeds are
synchronous. If the sources are not synchronous,
there will be no transfer to the second source.
Input 1
Input 2
NOTE
~
~
~
~
~
~
~
~
~
~
~
~
Output
Output
Output
General operation:
Press button, wait for audible signal, on
releasing the button the push of the
button is accepted.
To select the preferred mains supply:
Select the mains, press the mains
button, wait for audible signal, keep
button pressed and wait until second
beep is heard (after 5 seconds). On
releasing the button the selected mains
supply is now the preferred mains
supply.
91.9.045.0019 5.0 16.01.07
6-5
OPERATING INSTRUCTIONS
6.4.2
PILLER POWER SYSTEMS
Switching off: with load supply interruption
NOTE
The load is no longer supplied when you have carried out the following
step.
Press “Reset” and “IN 1” or “IN 2” simultaneously. The “Output” LED shows yellow, i.e.
the output is switched off.
WARNING
6.4.3
Some components inside the set are live, even when the system is
switched off. Only skilled personnel should be allowed to work on the
system.
Switching off: without load supply interruption
You should select this operating mode if you wish to switch the system off for any reason,
but the supply to the load is not to be interrupted.
1. Operate switch Q5 so that the active static switch is shunted by the bypass inserted
by Q5. Now switch off the set as described above.
2. If you wish to return to normal operation, start the APOTRANS as described in
section 6.4.1 above. Ensure that you activate the static switch corresponding to the
bypass and then immediately set switch Q5 to the neutral position.
6.4.4
Fault procedures
When a fault occurs, the horn also sounds. This can be switched off by pressing the
“Reset” button, even if the fault has still not been cleared. After fault has been cleared,
the APOTRANS can be reset by means of the “Reset“ button.
When a fault occurs, proceed as follows:
1. Press the “Reset” button to switch off the horn.
2. Press the “Reset” button again to cancel the fault. If this clears the fault you can
restart the system.
3. Piller Central Service can be contacted around the clock by phoning:
+ 49 (0) 55 22 / 311 311
6-6
91.9.045.0019 5.0 16.01.07
OPERATING INSTRUCTIONS
6.5
PILLER POWER SYSTEMS
Settings
The individual sub-menus and possible settings are described in order below.
1. Language
German, otherwise respective to the delivery country.
Set the language in which the display items are to appear.
2. Transfer modes
!
“Automatic" transfer
means that in the event of a fault, the system is automatically transferred to the
standby source.
!
“Manual" transfer:
If manual transfer is set, in the event of a fault the system does not change over.
!
“Automatic" retransfer (see chapter 6.6):
means that after a transfer to the standby source the system is automatically
retransfered to the preselected source if the necessary mains quality is restored
and the sources are located in the synchronisation window for manual transfer.
!
“Manual" retransfer (see chapter 6.6):
No retransfer takes place - the load is run from the standby source. If a fault also
occurs in this AC supply, then the system again attempts to transfer to the
preselected source provided that this supply is again available. It can be changed
over manually at any time.
!
Preset retransfer:
With “automatic retransfer" and restored infeed, the retransfer takes place on
expiry of the time set here (0 to 120 seconds).
The default settings are: transfer mode = automatic, retransfer = automatic and
retransfer time = 10 seconds.
3. Voltage limit
The default voltage limits which trigger an automatic transfer are ± 10 %.
4. Frequency limit
The default frequency limits which trigger an automatic transfer are ± 5 %.
5. Input
Source 1 is factory-set as the preselected source.
6. Synchronisation window
!
Manual transfer
The factory default of the phase difference angle for the manual transfer is 30°. If
the phase difference angle of the infeeds is greater than set here, manual
transfer is no longer possible.
!
Automatic transfer
If the phase difference angle is greater than the value set here, a simultaneous
phase transfer is effected in the case of an automatic transfer (e.g. mains failure).
The factory default is 180°.
The standard value of the waiting time for a simultaneous phase transfer is 0.
NOTE
If adjustments are necessary please contact our Piller Central Service:
Phone: +49 (0) 55 22 / 311 311
91.9.045.0019 5.0 16.01.07
6-7
PILLER POWER SYSTEMS
OPERATING INSTRUCTIONS
7. Autostart
After restoration or initial application of one or both mains voltages, the system
attempts to connect the mains selected as the preferred supply to the output.
If after 10 seconds (standard setting) the preferred mains is still not within the voltage
and frequency limits, at the end of this period the system attempts to switch through
the other mains supply. If this also is not within the tolerance limits, the autostart
process is aborted after a further 10 seconds. Appropriate event messages
accumulate during the autostart process.
The autostart function can be activated and deactivated in the programming mode.
See Chapter 6.6. Factory setting: autostart function deactivated.
The waiting time for connection of the mains supplies can be set by a service
specialist in the range 0.1 to 25.6 seconds, as required.
WARNING
6.6
When “Autostart“ is ON, this can be hazardous to personnel working on
the equipment during a mains failure.
Programming mode
IMPORTANT
Prior to commissioning, the unit should be configured in the normal mode
since it is necessary to switch off the mains voltages in order to activate
the programming mode.
To obtain the programming mode, at least 5 seconds after a mains voltage is applied the
“RESET“ button must be pressed and held until the LEDs IN1 and IN2 flash rapidly on the
control panel. The “RESET“ button must now be released.
The following settings can be implemented in the programming mode:
!
automatic/manual reverse transfer
!
a•utostart active/inactive
The status of the settings is determined by the colour of the LED:
LED
IN1 green flashing
IN1 red flashing
IN2 green flashing
IN2 red flashing
Setting
automatic reverse transfer (factory setting)
manual reverse transfer
autostart active
autostart inactive (factory setting)
The corresponding setting is changed to the other state by pressing the relevant button
for more than 5 seconds (until the acknowledgement tone sounds):
Button
IN1
IN2
Change
Reverse transfer
Autostart
To put the unit with the displayed setting into the normal mode, both mains voltages must
be switched off for 10 seconds and then switched on again.
In order to change settings in the normal mode, communication with the microcontroller
board is required and this should only be carried out by a service specialist.
6-8
91.9.045.0019 5.0 16.01.07
MAINTENANCE AND CUSTOMER SERVICE
PILLER POWER SYSTEMS
7
MAINTENANCE AND CUSTOMER SERVICE
7.1
Maintenance
To ensure troublefree operation we recommend that the heatsink be examined and if
necessary cleaned at regular intervals (e.g. monthly), e.g. by sucking out the fins.
IMPORTANT
In no circumstances use compressed air since this can blow dust
particles into the interior and cause malfunctions.
If for safety reasons you want the system to be regularly checked, e.g. annual inspection,
please contact us. We will be happy to send you a quotation for a suitable contract.
7.2
Customer service
Our central service department is available 24 hours a day for customer service requests
via telephone number
+49 (0) 55 22 311 311
Details of the APOTRANS or other products in our range can be obtained from one of our
representatives or
Piller Power Systems GmbH
Power Supply Sales
Postbox 1851
37508 Osterode am Harz
Germany
Phone: +49 (0) 55 22 / 311 0
Fax: +49 (0) 55 22 / 311 414
email: info@piller.com
91.9.045.0019 5.0 16.01.07
7-1
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8
ADDITIONAL INFORMATION
8.1
Mounting plan APOTRANS 19 inch
Q005
A240
X230
X001
X100
X002
X240
X003
Fig. 8-1 APOTRANS 19 inch
A230
Fig. 8-2 Internal view of APOTRANS 19
91.9.045.0019 5.0 16.01.07
A230
A240
Q005
Remote control unit
Control panel
Load switch
X003
X100
X230
X001
X002
Connection mains 1
Connection mains 2
X240
Connection output
Service interface
System I/O card
(Customer connection card
CAN - Interface
8-1
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
T001
C001
C002
T002
T013, T011, T012
T023, T021, T022
Fig. 8-3 Power unit
A102
A101
A100
X005
Fig. 8-4 Power unit
A100
A101
A102
C001
C002
T001
T002
8-2
Controllerboard
8 times thyristor firing
8 times thyristor firing
Capacitor
Capacitor
Transformer
Transformer
T011
T012
T013
T021
T022
T023
X005
Current transformer
Current transformer
Current transformer
Current transformer
Current transformer
Current transformer
High current plug connection
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PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
A001 A002
X001/ X002/
F001 F002
A741
A23*
A72*
Fig. 8-5 Optional module
A001
A002
A23*
A72*
91.9.045.0019 5.0 16.01.07
24 V-Supply
24 V-Supply
I/O Card
Protocol gateway
A741
X001
X002
SNMP-Adapter
inlet connector for non-heating appliances
inlet connector for non-heating appliances
8-3
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8.2
Mounting plan APOTRANS 25-63 A
A240
Q005
Fig. 8-6 APOTRANS 25-63 A, terminal connection
A240
Q005
X010
X030
X020
Fig. 8-7 APOTRANS 25-63 A plug connection
8-4
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
Power unit
T001/T002
A230
Fig. 8-8 Internal view of APOTRANS 25-63 A
A230
A240
Q005
T001
T002
X010
X020
X030
System I/O card
(Customer connection card)
Control panel
Load switch
Transformer mains 1
Transformer mains 2
Connection mains 1
Connection mains 2
Connection output
X001
PE
1 2 3 N1
4 5 6 N2
PE
7 8 9 N3
F001
F002
A230
PE
Fig. 8-9 Terminal arrangement APOTRANS 25-63 A
Terminal X001
91.9.045.0019 5.0 16.01.07
1, 2, 3, N1
4, 5, 6, N2
7, 8, 9, N3
Mains 1
Mains 2
Output
8-5
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
X100
C001
A100
C002
X005
Fig. 8-10 Power unit
T012
T022
T032
A102
T011
T021
T031
A101
A100
X100
Fig. 8-11 Power unit
A100
A101
A102
C001
C002
T011
T012
8-6
Controllerboard
8 times thyristor firing mains 1
8 times thyristor firing mains 2
Capacitor
Capacitor
Current transformer
Current transformer
T013
T021
T022
T023
X005
X100
Current transformer
Current transformer
Current transformer
Current transformer
High current connection
Service interface
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
A401
Option 1
A72*/A23*
A400
Option 2
A72*/A23*
Fig. 8-12 Customer connections cards, optional
A23*
A72*
NOTE
91.9.045.0019 5.0 16.01.07
I/O Card
Protocol gateway
A400
A401
24 V-Supply
24 V-Supply
Each of the options 1 and 2 enables up to two input/output cards or
protocol gateways to be installed.
8-7
ADDITIONAL INFORMATION
8.3
PILLER POWER SYSTEMS
Customer interface card (optional)
The customer interface card is used to connect the system to external operator control
and indicator devices.
Fig. 8-13 Customer interface card
8-8
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
The optional customer interface card is connected to the controller board via the CAN
bus. It has 12 fully programmable digital inputs and 6 fully programmable relays with
single-pole changeover contacts, as well as 6 digital outputs (24 V/300 mA).
2 x 24 V-supplies are available at the customer end for the inputs.
The terminals of the customer interface card are divided into five functions:
!
Terminal strip X1, connection of digital inputs
!
Terminal strip X2, connection of customer relays
!
Terminal strip X3, connection of analogue input and output, connection of
temperature monitoring
!
Terminal strip X6, connection of normally open and normally closed contact
!
Terminal strip X30, connection of digital outputs
8.3.1
Terminal strip X1, X3, X6 and X30
The terminal assignment of terminal strip X1 is shown in the table below
Terminal No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
91.9.045.0019 5.0 16.01.07
Description
Intern_EPO_N
EPO_N
L+24.2
GND
DGND.1
DIN1
DIN2
DIN3
DIN4
DIN5
DIN6
DIN7
DIN8
DIN9
DIN10
DIN11
DIN12
DGND.2
GND
L+24.2
Function
internal 24 V
Ground
external ground for inputs 1-6
digital input 1
digital input 2
digital input 3
digital input 4
digital input 5
digital input 6
digital input 7
digital input 8
digital input 9
digital input 10
digital input 11
digital input 12
external ground for inputs 7-12
Ground
internal 24 V
8-9
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
The terminal assignment of terminal strip X3 is shown in the table below
Terminal No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Description
AOUT+1
Aout-, AGND
PE
L+24.3
GND
L+24.3
AIN+
AINPE
TEMP+1
Temp-1, AGND
PE
TEMP+2
Temp-2, AGND
PE
TEMP+3
Temp-3, AGND
PE
TEMP+4
Temp-4, AGND
PE
Function
Earth connection (screen)
Ground
Earth connection (screen)
Earth connection (screen)
Earth connection (screen)
Earth connection (screen)
Earth connection (screen)
The terminal assignment of terminal strip X30 is shown in the table below
Terminal No.
1
2
3
4
5
6
7
8
9
10
11
12
8-10
Description
DOUT1
DOUT2
DOUT3
DOUT4
DOUT5
DOUT6
GND
GND
GND
L+24.2
L+24.2
L+24.2
Function
digital Output 1
digital Output 2
digital Output 3
digital Output 4
digital Output 5
digital Output 6
Ground
Ground
Ground
internal 24 V
internal 24 V
internal 24 V
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8.3.2
Terminal strip X2, programmable relays
6 free programmable relays with changeover contacts are located on the customer
interface card. The relay contacts are connected to terminal strip X2.
1
1
3
3
4
4
6
6
7
7
11
12
13
14
15
16
17
18
Relay K3
8
8
9
Relay K2
5
5
10
Relay K1
2
2
9
10
Relay K4
11
12
13
Relay K5
14
15
16
Relay K6
17
18
Fig. 8-14 Contact assignment of terminal strip X2
Contact loading:
– max. 250V AC, 2 A
– max. 300V DC, 50 W
NOTE
The relay contacts are gold-plated and are therefore suited for use with
extra low voltages.
IMPORTANT
Once the relay has been used for switching at higher voltages or current
(e.g. 230 V) the gold-plating on the terminals will evaporate, and the relay
can subsequently not be used for extra low voltages.
Each relay has a logic function that is programmed at the factory with event numbers.
91.9.045.0019 5.0 16.01.07
8-11
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8.3.2.1 Description of programmable relays
Each relay is associated with a logic function which consists of two input gates and one
output gate.
+
&
$
+
&
+
$
K1
&
$
Fig. 8-15 Logic function
The event numbers occurring in the APOTRANS can be programmed at the inputs of the
two input gates. The table at the end of this section gives an overview of the useable
events.
A logic function consists of two input gates which are linked to an output gate.
The inputs and outputs of the input gates can be inverted. OR, AND, and EXOR logic
functions can be obtained by suitable programming of the input and output gates.
The output gates can be configured as NAND, NOR, or EXNOR by inverting the inputs.
All unused inputs of the two input gates should be at LOW or HIGH logic level in order to
fulfil the gate function.
The symbols used in the gate functions shown have the following meanings:
!
the „+“ character indicates the OR function
!
the „&“ character indicates the AND function
!
the „$“ character indicates the EXOR function
The inputs and outputs are inverted by filling in the input or output inversion circles.
The relay functions are programmed with the aid of the software Term ++.
8.3.2.2 Standard relay assignment
The relays have the following factory-set assignments:
8-12
!
K1: static switch 1 is on
!
K2: static switch 2 is on
!
K3: bypass 1 is on
!
K4: bypass 2 is on
!
K5: infeeds are outside the synchronisation window for manual transfer
!
K6: general fault
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8.4
Protocol gateway (Option)
The protocol gateway card (Fig. 8-16) is used to connect a remote control and
APOCONNECT for example. Up to two protocol gateway cards can be fitted in the
APOTRANS.
or
Monitor mode with Termplus via
crossover cable
or
Printer with serial interface
RS232
or
SNMP adapter
or
Protocol gateway
Customer software supporting
Modbus protocol
CAN
UNMS (central monitoring)
or
SNMP adapter via converter
(RS232/RS485 converter)
Modbus
RS485
or
protocol
Display controller as remote control
or
Customer software supporting
Modbus protocol
Fig. 8-16 Protocol gateway with connectivity options
The protocol gateway card provides connectivity via two interfaces - RS232 and RS485 which currently communicate via the Modbus protocol.
The RS232 interface enables the monitor mode with the Termplus software to be
connected via a crossover cable or a printer with a serial interface, or an SNMP adapter
or special software (customer software), which controls the Modbus software.
It is also possible to connect a modem for the APOCONNECT remote diagnostics
application, in which case the RS232 interface would no longer be available.
The UNMS central monitoring or the display controller can be connected as a remote
control to the RS485 interface, or an SNMP adapter via an RS485/RS232 converter, also
special software (customer software) which supports the Modbus protocol.
Limitation:
The APOCONNECT application and the display controller as remote control can only
ever be connected to the first protocol gateway card.
91.9.045.0019 5.0 16.01.07
8-13
ADDITIONAL INFORMATION
8.5
Event recorder (event memory)
8.5.1
Description of operation
PILLER POWER SYSTEMS
The event recorder in the APOTRANS stores every event that occurs (key press,
switching operation, faults) along with the date and time. Up to 1199 entries can be
stored. With more than 1199 events the event recorder always stores the last 1199
events in accordance with the FIFO (first in, first out) principle.
The following are displayed:
!
date and time
!
description of event (e.g. F6 fuse fault, Q5 contact is closed)
!
event code and event number
The event code signifies the following:
Exxxx
*xxxx
Rxxxx
Axxxx
A non-acknowledged event has occurred.
An event which must be acknowledged has occurred but has still not
been acknowledged.
An event which must be acknowledged has been acknowledged.
The time of the acknowledgement is being recorded.
NOTE
xxxx stands for a four-digit decimal number.
NOTE
The event memory can be read only by our service personnel. In this
connection please contact Piller Central Service.
Phone: +49 (0) 55 22 / 311 311
8.5.2
List of event recorder entries
Event No.
0001
0002
0003
0004
0005
0006
0007
0008
0009
0010
0023
0024
0025
0026
0027
0028
0029
0030
0101
8-14
Event
Push button mains 1: 1 -> 0
Push button mains 1: 0 -> 1
Push button mains 2: 1 -> 0
Push button mains 1: 0 -> 1
Push button RESET: 1 -> 0
Push button mains 1: 0 -> 1
Bypass 1: 1 -> 0
Bypass 1: 0 -> 1
Bypass 2: 1 -> 0
Bypass 2: 0 -> 1
system input 1 0 -> 1
system input 1 1 -> 0
system input 2 0 -> 1
system input 2 1 -> 0
system input 3 0 -> 1
system input 3 1 -> 0
system input 4 0 -> 1
system input 4 1 -> 0
static switch 1 is on
91.9.045.0019 5.0 16.01.07
ADDITIONAL INFORMATION
Event No.
0102
0103
0104
0105
0107
0109
0111
0113
0115
0117
0119
0255
0256
0283
0284
0285
0286
0381
0383
0384
0385
0386
0389
0391
0393
0395
0401
0402
0403
0404
0405
0406
0407
0408
0409
0410
0411
0412
0413
0414
0415
0417
0421
0422
0423
0424
0425
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PILLER POWER SYSTEMS
Event
static switch 1 is off
static switch 2 is on
static switch 2 is off
source 1 overvoltage
source 1 undervoltage
source 1 overfrequency
source 1 underfrequency
source 2 overfrequency
source 2 underfrequency
source 2 overvoltage
source 2 undervoltage
POWER UP
POWER DOWN
CPU 0 is active
CPU 0 is inactive
CPU 1 is active
CPU 1 is inactive
output voltage failure
CPU 0 is available
CPU 0 is not available
CPU 1 is available
CPU 1 is not available
system input: External mains 1 failure
system input: External mains 2 failure
system input: Transfer to mains 1 blocked
system input: Transfer to mains 2 blocked
general failure
load > 100%
load > 120%
load > 150%
static switch 1 thyristor failure
static switch 2 thyristor failure
static switch 1 thyristor open
static switch 2 thyristor open
source 1 rotation failure
source 2 rotation failure
failure 24V supply 1
failure 24V supply 2
failure supply on A101
failure supply on A102
static switch overtemperature
failure temp.sensor
short circuit
source 1 N current > 170%
source 2 N current > 170%
disconnect overload static switch 1
disconnect overload static switch 2
8-15
ADDITIONAL INFORMATION
Event No.
0426
0428
0429
0430
0431
0481
0482
0483
0484
0485
0486
0513
0514
0630
0681
0683
0697
0701
0771
0882
0888
0952
0954
0960
8-16
PILLER POWER SYSTEMS
Event
static switch temperature warning
setup failure
status error
no redundancy
Switched to wrong bypass
system relay K1 0 -> 1
system relay K1 1 -> 0
system relay K2 0 -> 1
system relay K2 1 -> 0
system relay K3 0 -> 1
system relay K3 1 -> 0
retransfer time started
retransfer time stopped
redundancy in existence
Reset all events
All Events are reseted
reset transfer counter 1 -> 2
reset transfer counter 2 -> 1
retransfer timeout
sources synchronous
switch off shortcircuit
sources not synchronous
Sync.request timeout
Key operation
91.9.045.0019 5.0 16.01.07
ADDITIONAL INFORMATION
8.6
Static switch
8.6.1
General
PILLER POWER SYSTEMS
Each of the two static switches consists of four antiparallel double thyristor modules
whose control functions are digital. The control software runs along with the control
program of the APOTRANS on two redundant SAB 80c167 microcontroller, they are
located on the A100 controller board.
Basically, three tasks have to be carried out:
!
mains monitoring and mains failure detection of both AC inputs, detection and
signalling of threshold limit overshoots and load short-circuit detection
!
Phase selective or phase simultaneous AC supply transfer by means of the static
switches
!
Acquisition and calculation of the necessary measured values.
8.6.2
Measured value acquisition
The following measured values are required for the operation of the APOTRANS:
!
Efficiencies of the voltages of both input systems and the output
!
Efficiency and instantaneous values of the output currents
!
frequencies of the input systems
!
phases between the input systems
!
detection of current zero crossing of the static switches.
Currents and voltages are sampled 32 times per period in phase with the respective
active supply system. The rectified mean values are calculated for each phase from the
sampled values.
The frequency and phase measurements are also taken separately on all three phases.
Sliding average values are calculated from these for the respective supply system. The
phase measurement is always with respect to the currently active system.
8.6.3
Monitoring
The input and output voltages of all nine phases, as well as the six input currents, mains
frequencies and the phases of both AC supply systems, are monitored for limit violations.
All threshold overshoots are communicated to the control program.
The voltage and current monitoring is phase-selective, i.e. if a threshold is exceeded in
one phase, this results in a signal to the control program. Voltage monitoring uses an
overvoltage and an undervoltage threshold value and current monitoring employs three
overcurrent threshold values.
Both input systems are examined for overfrequency and underfrequency with the aid of
threshold values.
There are two threshold values for the phase between the input systems. If either of these
values is exceeded, this fact is signalled separately to the control program.
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8-17
ADDITIONAL INFORMATION
8.6.4
PILLER POWER SYSTEMS
Operating the static switches
A switching operation is initiated exclusively via the control program. There are different
chronological sequences for the operation of the static switches, which depend on the
respective operating circumstance:
1. Switching on SS1 or SS2
The power-up algorithm is only activated if at the time of the request by the control
program, none of the static switches is switched on.
In contrast to a transfer, a static switch is not switched on in a phase-selective
manner. All Thyristors are switched on immediately following the request by the
control program.
The possible reasons for a power-up request by the control program are:
!
when the system is switched on for the first time
!
switch-on at the end of the wait time during an phase simultaneous transfer.
2. Transfer from SS1 (SS2) to SS2 (SS1)
If, at the time of a power-up request one of the two static switches is switched on and
this does not coincide with the switch requested by the control program, then a
transfer is initiated.
If there is a transfer request, the trigger signals of the static switch of the currently
active supply system are cancelled first.
!
Phase-selective transfer method
In this transfer method the phases are transferred individually to the static switch
that is to be switched into circuit. That is to say, if the current in one phase has
gone to zero, the thyristors are triggered by this phase in the static switch that is
to be connected.
The neutral conductors are connected during the entire transfer process.
!
Simultaneous phase transfer method
In a simultaneous phase transfer there is an initial waiting period until all
thyristors of the currently active static switch are switched off, i.e. non-conducting.
The optional waiting time, which is set to 0 as standard, now starts. At the end of
this waiting time all thyristors are triggered simultaneously in the static switch that
is to be switched into circuit. The neutral conductors are not interconnected
during the transfer process. It should be noted that in the worst case, in this
transfer method the voltage interruptions in a single-phase power failure can
amount to 12 ms (mains half-cycle period + detection time) in the faulty phase.
However, a simultaneous phase transfer never occurs with the default factory
settings.
If all three static switches of the new power supply system are in circuit, then a
check-back signal is sent to the control program.
Possible reasons for a control program transfer request are:
8-18
!
limit value overshoots within the currently active supply
!
transfer request via the control panel
!
external transfer request (e.g. UPS, PLC,…) through the system I/O card
(customer connection)
91.9.045.0019 5.0 16.01.07
ADDITIONAL INFORMATION
PILLER POWER SYSTEMS
3. Switching off SS1 and SS2
The disconnect algorithm is only activated when one of the two static switches is in
circuit when the control program requests a disconnection. The thyristor trigger
signals are immediately cancelled after the request by the control program at
switching off.
Possible reasons for a control program turn-off request are:
91.9.045.0019 5.0 16.01.07
!
the set is switched off (manually)
!
short circuit
8-19
PILLER POWER SYSTEMS
ADDITIONAL INFORMATION
8.6.5
Arrangement of light-emitting diodes and connection terminals on the
controller board
X20 X19 X18 X17
X9
X10
X43
X42
X40
X41
H23 H24 H25 H26 H27 H28 H43 H42 H12 H13 H14 H15 H22 H21 H20
X1
X13
X4
X16
X12
X8
X15
X21
X14
X11
X2
X22
X3
X5
X6
X7
Fig. 8-17 Arrangement of LEDs and connection terminals on the controller board
LED-No.
H20
H21
H22
H15
H14
H13
H12
H42
H43
H28
H27
H26
H25
H24
H23
8-20
Colour
yellow
yellow
yellow
yellow
yellow
yellow
yellow
green
green
green
red
red
green
red
red
Function
System relay card K1 is energised
System relay card K2 is energised
System relay card K3 is energised
System input 4 set to 1
System input 3 set to 1
System input 2 set to 1
System input 1 set to 1
CPU 1 is active
CPU 0 is active
CPU 1 (control program) is running
CPU 1 (control program) has stopped
CPU 1 has detected a fault in CPU 0
CPU 0 (control program) is running
CPU 0 (control program) has stopped
CPU 0 has detected a fault in CPU 1
91.9.045.0019 5.0 16.01.07
ADDITIONAL INFORMATION
Terminal
X1
X2
X4
X5
X6
X7
X8
X9
X10
X12
X13
X14
X15
X17 – X20
X21
91.9.045.0019 5.0 16.01.07
PILLER POWER SYSTEMS
Function
Service
CAN-Bus
System I/O
Connection control panel
Power supply
Backup capacitor
Triggercard A101
Current transformer
Current transformer
Temperature input channel 1...12
Temperature input channel 9...15
Reserved for later operating extension
Reserved for later operating extension
Temperature input channel 1...4
Triggercard A102
8-21
PILLER POWER SYSTEMS
APPLICATION NOTES
9
APPLICATION NOTES
9.1
Neutral conductor current
As shown in the following table, the systems can carry more current in the neutral
conductor.
APOTRANS
N-current
25
250 %
35
180 %
50
125 %
63
100 %
IMPORTANT
9.2
It should be noted that in a system comprising several APOTRANS sets,
the neutral conductors to the rear of the APOTRANS units must not
under any circumstances be connected together, since this can produce
excessively high neutral conductor currents.
Loop resistance/short-circuit current measurement in UPS systems with
APOTRANS transfer switches
In principle, a loop resistance/short-circuit current measurement in a power distribution
system with APOTRANS equipment has to be carried out with both supply systems one
after another in the bypass mode. In this operating mode the thyristors are bridged with
manual switches. The loop resistance/short-circuit current measurement is then carried
out at the output of the transfer switch - first with Mains 1 (Bypass 1 engaged) and then
with Mains 2 (Bypass 2 engaged).
Fault measurement is possible if the measurement is carried out with the static switch in
circuit.
9.3
Short-circuit current calculation in UPS systems with APOTRANS transfer
switches.
The on-state slope resistance of the thyristors must be taken into account when
calculating the short-circuit current within a UPS system with APOTRANS systems.
The value is typically at rThy = 2,2 mΩ.
91.9.045.0019 5.0 16.01.07
9-1
91.9.045.0019 16.01.07
Piller Power Systems GmbH
Postbox 1851
37508 Osterode
Germany
Tel: +49 (0) 55 22 311 0
Fax: +49 (0) 55 22 311 414
e-mail: info@piller.com