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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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. 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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 91.9.045.0019 5.0 16.01.07 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. 91.9.045.0019 5.0 16.01.07 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