PTC PTC-0110BA-2 Manuel utilisateur
Publication Number: PTC-0110BA2UM, REV(A) November, 2003
P.T.C. Production & Trading Company AG
UNINTERRUPTIBLE POWER SYSTEM400Hz IN, 60Hz OUT
SINGLE PHASE – 1kW / 2kVA
PTC-0110BA-2
MADE IN THE U.S.A
USER’S MANUAL
P.T.C.
Production & Trading Co. AG
P.O. Box
CH-6330 Cham
Switzerland
Phone: (+41 41) 740 45 54
Fax: (+41 41) 740 46 64
E-Mail: [email protected]
Web: http://www.ptcag.ch
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Table of Contents
Page
Safety Instructions .................................................................................................iii
1. General Description.................................................................................................1
1.1 Intended Applications .............................................................................................1
1.2 Functional Overview ...............................................................................................1
2. (Deleted) ...................................................................................................................3
3. Installation Instructions ..........................................................................................3
4. Front Panel Description ..........................................................................................4
4.1 Front Panel: Main Components ............................................................................4
4.2 Front Panel: Indicators and Switches ..................................................................5
5. Rear Panel Description ...........................................................................................6
6. Operation, Controls and Indicators .......................................................................7
6.1 Turning the UPS ON and OFF ................................................................................7
6.2 Visual Indicators ......................................................................................................7
6.2.1 Normal Operation ....................................................................................................7
6.2.2 Standby Mode ..........................................................................................................7
6.2.3 Input AC Failure .......................................................................................................8
6.2.4 Overload Condition .................................................................................................8
6.2.5 Over Temperature Condition..................................................................................8
6.3 Battery Test ..............................................................................................................9
7. Taking Care of the Battery......................................................................................9
7.1 Battery Service Life .................................................................................................9
7.2 Replacing the Battery Pack ..................................................................................10
8. Communications and Remote Control................................................................11
8.1 Dry Contacts Interface ..........................................................................................11
8.1.1 Option 0 (Standard) Dry Contacts Interface .......................................................11
8.1.2 Option 1 Dry Contacts Interface...........................................................................12
8.2 RS-232 Communication Interface ........................................................................13
8.3 Remote ON/OFF Interface…………………………………………………………….15
9. Specifications ........................................................................................................14
List of Figures
Page
Fig. 1 Block Diagram..........................................................................................................2
Fig. 2 Electrical Connections............................................................................................3
Fig. 3 Front Panel - Main Components ............................................................................4
Fig. 4 Front Panel - Indicators ..........................................................................................6
Fig. 5 Rear Panel ................................................................................................................6
Fig. 6 Dry Contacts - Option 0.........................................................................................12
Fig. 7 Dry Contacts - Option 1.........................................................................................12
List of Tables
Page
Table 1 Dry Contacts Connector J3 Pin Assignment (Option 0)....................................11
Table 2 Dry Contacts Connector J3 Pin Assignment (Option 1)....................................12
Table 3 RS232 Connector J4 Pin Assignment .................................................................13
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IMPORTANT SAFETY INSTRUCTIONS
• The 37&110BA-2 contains an internal high voltage, high energy power source (96VDC battery)
DQGlarge high voltage (340VDC) capacitors.
• The unit should not be tampered with by unauthorized personnel !!!
• Turning off the Input ON/OFF Switch and/or disconnecting the input connector do not turn off
the UPS !!!
• The unit should only be plugged into an approved double-pole and fused 20A electrical outlet !!!
• The Replaceable Battery Pack of the 37&110BA-2 (P/N M357380) contains lead-acid batteries.
The Battery Pack should not be opened. It can only be replaced with a new pack (battery cells
cannot be replaced individually).
• Dispose the Battery Pack properly. Careless disposal (such as into a fire) may cause an
explosion. Local regulations may require controlled disposal of lead-acid batteries. Please check
your local regulations before disposal.
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1. General Description
1.1 Intended Applications
The 37&110BA-2 is a high quality, rugged, 400Hz IN 60Hz OUT, 1kW / 2KVA, 19” rack-mounted
8Qinterruptible Power Source (UPS). In addition to full compliance with all the requirements of MIL-
STD-1399 (Section 300), the 37&110BA-2 is specifically designed to meet the harsh military ship
ERDUGenvironment. The high reliability and ruggedness of the 37&110BA-2 make it an excellent
FKRLFHQRWonly for military shipboard applications, but for tactical shore-based applications as well.
1.2 Functional Overview
The 37&110BA-2 consists of two main sections: Power Conditioner and UPS (see Fig. 1).
The Power Conditioner is a 400Hz isolation transformer (with RFI filters and spike absorbers).
In addition to 115Vac to the UPS section, the isolation transformer provides a low voltage for the
24Vdc contactor supply. When AC input drops, the 24Vdc is provided from battery power. The
Power Conditioner contains internal fuses on its input. These internal fuses are intended only as a
safety feature in case of an internal failure.
The UPS is composed of a high power factor AC-DC Converter, a Removable Battery Pack, a
Battery Charger, a DC-AC Inverter and a microcontroller-based Control Circuit.
The AC-DC Converter is a high frequency switching converter that provides 320VDC to the DC-AC
inverter. The AC-DC converter draws clean sine input current waveform and does not induce
electrical noise into the input lines.
The Removable Battery Pack contains the energy source used by the UPS to provide power during
AC input failures. The Battery Pack includes eight 12V / 5AH lead-acid, sealed, maintenance-free
type cells. It provides 10 minutes of full rated output power. The Battery Pack is not a serviceable
item. It cannot be disassembled, and can only be replaced as a single unit.
The Battery Charger is a high frequency, voltage-regulated and current-limited DC to DC converter.
It is powered from the 320VDC output of the AC-DC Input Converter and provides temperature-
compensated float charge to the Battery Pack.
The DC-AC Inverter is a high frequency inverter that generates a clean sine-shape 60Hz, 115VAC
voltage from the 320VDC output of the AC to DC Input Section. The DC-AC Inverter is current-
limited and has an overload protection circuit that turns it off (latched) after a delay from the time
the load exceeds 120%. The delay depends upon the overload level.
The Control Circuit is a microcontroller-based circuit that provides monitoring of the unit’s status
(battery charge, load level, input and output levels, etc.) and supports communications and front
panel status indicators.
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Figure 1: 37&110BA-2 Block Diagram
Power Conditioner
RFI FILTER
& VARISTOR
ISOLATION
TRANSFORMER
RFI FILTER
& VARISTOR
AC-DC
CONVERTER DC-AC
INVERTER
CONTROL
&
MONITOR
BATTERY
CHARGER
BATTERY
PACK
24VDC24VRTN
INPUT
ON/OFF
SWITCH
MASTER
ON/OFF
SWITCH
REMOTE
ON/OFF
SWITCH
2 POLES INPUT
CONTACTOR2 POLES OUTPUT
CONTACTOR
J1
AC INPUT
115VAC,400Hz
J2
AC OUTPUT
115VAC,60Hz
J5
J5
J4 RS-232
J3 DRY
CONTACTS
320 Vdc
120 VDC
24 VDC
Low Voltage To
Contactors
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2. (Deleted)
3,nstallation Instructions
Before installing the unit, please read carefully the Safety Instructions at the beginning of this
manual.
Make sure that the Master switch is in the OFF position.
Two circular connectors (J1 and J2) are provided on the rear panel of the UPS (see Figure 5). J1 is
the input connector, J2 is the output of the UPS.
Figure 2 below, shows the electrical power connections of the 37&110BA-2.
After the unit is installed and ready to be turned ON, see paragraph 6.1 (Turning the UPS ON and
OFF) for operating instructions.
Figure 2 – Electrical Connections
J1 MS3102A-22-2P or comp.
J2 MS3102A-22-2S or comp.
Chassis GND
Input Phase 1
Input Phase 2
Chassis GND
AC Out (Hot)
AC Out (Neutral)
Safety GND
Rear panel
GND connection
J1
J2 UPS
115VAC
60Hz to
LOAD
115VAC/400Hz
INPUT
VIA 20AMP
CIRCUIT
BREAKER
A
A
B
B
C
C
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4. Front Panel Description
4.1 Front Panel: Main Components (See Figure 3)
1. Removable air filter (of the Power Conditioner’s cooling air).
2. Visual Indicators and Switches (for detailed view see Figure 4).
3. Air Inlet (of main UPS heatsink).
4. Input ON/OFF Switch.
5. Master ON/OFF Switch.
Figure 3 - Front Panel: Main Component
37&110BA-2
1KW,400HZ IN 60HZ OUT UPS.
15
43
2
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4.2 Front Panel: Indicators and Switches (See Figure 4)
4. Input ON/OFF switch.
5. Master ON/OFF switch.
6. Input Fail LED (red).
7. Input OK LED (green).
8. Output Standby LED (yellow).
9. Output OK LED (green).
10. Output Fail LED (red).
11. On Battery Warning LED (blinking yellow).
12. Alarm Off Push-button.
13. Low Battery Warning LED (blinking yellow).
14. Overload Shutdown LED (red).
15. Overtemperature Warning LED (blinking yellow).
16. Overtemperature Shutdown LED (red).
17. Load Level Bar Graph (marked in %, 100% = 1000W ).
18. Battery Charge Bar Graph (marked in %., 100% = 10 minutes at 1000W load).
19. Set Battery Charge to 100% Push-button (for maintenance only).
20. Battery Test Passed LED (green).
21. Battery Test Push-button.
22. Battery Test Failed LED (red).
Figure 4 - Front Panel: Indicators and Switches
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6. Operation, Controls and Indicators (ref. Figures 3 and 4)
6.1 Turning the UPS ON and OFF
In order to turn the UPS ON (after the electrical connections are made), turn ON the Input ON/OFF
switch (4), the Master ON/OFF switch (5) and if used, the remote ON/OFF switch. (The order is not
important). If remote ON/OFF is not used, the connections of J5 (described in paragraph 8.3)
should be installed before the unit is turned on.
When the Master ON/OFF switch (5) or the remote ON/OFF switch are turned off, the internal
contactors open and disconnect both the input and the output of the UPS and it turns OFF.
When the UPS operates, turning off the Input ON/OFF switch (4) disconnects the UPS from the AC
input, and the UPS then runs on battery power only.
To turn the UPS off, the Master ON/OFF switch or the remote ON/OFF switch must be in the OFF
position. (It will automatically disconnect the input connector too).
Note: The UPS will not start on battery power (to avoid battery discharge during shipping and
storage). Hence, the Input ON/OFF switch must be ON and AC voltage must be present at the input
in order to start the UPS.
When a remote control of the UPS is desired, the Input ON/OFF and the Master ON/OFF switches
on the front panel should be both in the ON position. Turning the remote ON/OFF switch ON and
OFF will turn the UPS ON and OFF. (Please see paragraph 8.3).
6.2 Visual Indicators
6.2.1 Normal Operation
When the UPS is running on AC input power and both Master and Input switches are ON, the two
bar graphs (17, 18), the green Input OK LED (7) and the green Output OK LED (9) are on.
The Load Level Bar Graph (17) indicates the loading percentage of the UPS. 100% load is equal to
1000W of output power. The lower six positions of the Load Level Bar Graph (15% to 75%) are
green. The next three positions (80%, 110%, 120%) are orange and the two uppermost positions
(130% and 140%) are red. The colors do not have any special significance and are only intended to
assist fast scanning of the load level.
The Battery Charge Bar Graph (18) indicates the percentage charge level of the battery. 100%
signifies that at least 10 minutes of full load will be supported by the battery, 50% signifies
5 minutes at full load and so on. Lower loads result in longer expected battery operation time.
When the battery is being charged, the uppermost active segment of the Battery Charge Bar Graph
blinks to indicate that charging is on.
6.2.2 Standby Mode
When the yellow Output Standby LED (8) is on, the UPS is in the Standby Mode. In this Mode the
DC-AC inverter is OFF and the output contactor is open, but all other function of the UPS are active
(including battery charging and RS-232 communication port). The UPS reaches this mode when
command by the RS-232 or the “dry relays” into this mode.
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6. Operation, Controls and Indicators (ref. Figures 3 and 4)
6.1 Turning the UPS ON and OFF
In order to turn the UPS ON (after the electrical connections are made), turn ON the Input ON/OFF
switch (4), the Master ON/OFF switch (5) and if used, the remote ON/OFF switch. (The order is not
important). If remote ON/OFF is not used, the connections of J5 (described in paragraph 8.3)
should be installed before the unit is turned on.
When the Master ON/OFF switch (5) or the remote ON/OFF switch are turned off, the internal
contactors open and disconnect both the input and the output of the UPS and it turns OFF.
When the UPS operates, turning off the Input ON/OFF switch (4) disconnects the UPS from the AC
input, and the UPS then runs on battery power only.
To turn the UPS off, the Master ON/OFF switch or the remote ON/OFF switch must be in the OFF
position. (It will automatically disconnect the input connector too).
Note: The UPS will not start on battery power (to avoid battery discharge during shipping and
storage). Hence, the Input ON/OFF switch must be ON and AC voltage must be present at the input
in order to start the UPS.
When a remote control of the UPS is desired, the Input ON/OFF and the Master ON/OFF switches
on the front panel should be both in the ON position. Turning the remote ON/OFF switch ON and
OFF will turn the UPS ON and OFF. (Please see paragraph 8.3).
6.2 Visual Indicators
6.2.1 Normal Operation
When the UPS is running on AC input power and both Master and Input switches are ON, the two
bar graphs (17, 18), the green Input OK LED (7) and the green Output OK LED (9) are on.
The Load Level Bar Graph (17) indicates the loading percentage of the UPS. 100% load is equal to
1000W of output power. The lower six positions of the Load Level Bar Graph (15% to 75%) are
green. The next three positions (80%, 110%, 120%) are orange and the two uppermost positions
(130% and 140%) are red. The colors do not have any special significance and are only intended to
assist fast scanning of the load level.
The Battery Charge Bar Graph (18) indicates the percentage charge level of the battery. 100%
signifies that at least 10 minutes of full load will be supported by the battery, 50% signifies
5 minutes at full load and so on. Lower loads result in longer expected battery operation time.
When the battery is being charged, the uppermost active segment of the Battery Charge Bar Graph
blinks to indicate that charging is on.
6.2.2 Standby Mode
When the yellow Output Standby LED (8) is on, the UPS is in the Standby Mode. In this Mode the
DC-AC inverter is OFF and the output contactor is open, but all other function of the UPS are active
(including battery charging and RS-232 communication port). The UPS reaches this mode when
command by the RS-232 or the “dry relays” into this mode.
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