Page 3 - High leakage current:; Safety Instructions
JUE 401263 3 SOLA 4000 - Operating Manual SAFETY INSTRUCTIONS The unit must be used as intended. Follow the instructions given inthe Operating Manual. Dangerous voltages are present inside the unit. Installation and use of this equipment must comply to all nationaland local regulations and procedure...
Page 4 - SOLA 4000 - Operating Manual; Earth leakage protection:
JUE 401263 4 SOLA 4000 - Operating Manual Earth leakage protection: this device has a high leakage current towards protective earthing. The maximum earth leakage current is300 mA. When setting the threshold of the earth leakage circuitbreaker installed upstream from this equipment consider thisamoun...
Page 5 - Chapters; UPS ASSEMBLY; Figures
Chapters 1 UPS ASSEMBLY 2 1.1 Features 2 1.2 UPS System Structure 3 1.3 Rectifier/Battery Charger 3 1.4 Battery (Accumulator) 4 1.5 Inverter 4 1.6 Static Switches 4 1.7 Maintenance Bypass 6 1.8 Hot-Standby Systems 6 1.9 Parallel-Redundant Systems 7 1.10 Parallel Systems 7 2 OPERATING PANEL 8 2.1 Fun...
Page 6 - UPS Assembly
SOLA 4000 - General System Description JUE 401264 6 1 UPS ASSEMBLY 1.1 Features CE This equipment complies to the essential requirements of Euro-pean Directives 89/336/EEC and 73/23/EEC, and complies toEN50091-2 (1995) and EN50091-1 (1991) standards. UPS Function The uninterruptible power supply (UP...
Page 7 - SOLA 4000 - General System Description; UPS System Structure
SOLA 4000 - General System Description JUE 401264 7 1 UPS Assembly 1.2 UPS System Structure The basic SOLA 4000 power supply unit is an ac/dc/ac converter;the block diagram: Figure 1.1 illustrates six essential functionalcomponents: • Rectifier/battery charger (6 pulse) (RECT.) • Battery (BATT.) • I...
Page 9 - Under inverter failure conditions:; Under overload conditions
SOLA 4000 - General System Description JUE 401264 9 1 UPS Assembly During overload or inverter failure conditions, SSI is switched offand SSB is switched on, providing power supply from a backupsource (mains, output of another UPS system, diesel generatorset....). By always actuating both switches t...
Page 12 - Operating Panel
SOLA 4000 - General System Description JUE 401264 12 2 OPERATING PANEL 2.1 Functional Description The operating panel is the user-interface of the UPS. It offers thefollowing functions: • Indication of important data (actual load, battery charging status, battery autonomy during the "BACK UP"...
Page 13 - INSTALLATION; SOLA 4000 - Installation and Initial Start-Up
Chapters 1 INSTALLATION 3 1.1 Mechanical Installation 3 1.2 Electrical Installation 8 1.3 Install. of Additional Optional Cabinets 13 1.4 Installation of an External MaintenanceBypass 16 1.5 CPNET Interface Card 18 1.6 Remote Emergency Power off 20 1.7 Diesel - Generator Operation 21 1.8 Common Alar...
Page 14 - SOLA 4000 - Installation and Initial Start-Up
SOLA 4000 - Installation and Initial Start-Up JUE 401265 14 SOLA 4000 - Installation and Initial Start-Up FIG.1.8.1 Connec. of remote common alarm 22 Figures FIG.1.9.1 Connection of remote reset 22 FIG.1.10.1 Interconnection of hot-standby units with integrated maintenance bypassesand separate bypas...
Page 15 - Equipment Delivery and Storage; Handling the UPS System; Installation
SOLA 4000 - Installation and Initial Start-Up JUE 401265 15 1 INSTALLATION 1.1 Mechanical Installation Equipment Delivery and Storage After delivery, check equipment for any damage that may haveoccurred during shipment. The shipper and your SOLA agencymust be notified in writing about damages due to...
Page 16 - Weight
SOLA 4000 - Installation and Initial Start-Up JUE 401265 16 Weight Type SOLA 4000 Weight without Battery [kg] Weight with Battery [kg] Static Load - [kg/m²] 10 310 597 1277(*) 15 310 597 1277(*) 20 335 622 1330(*) 30 350 637 1362(*) 40 480 - 1026 60 520 - 1112 80 810 - 1176 100 840 - 1219 120 870 - ...
Page 17 - Room Size for 10-60 kVA UPS
SOLA 4000 - Installation and Initial Start-Up JUE 401265 17 1 Installation Room Size for 10-60 kVA UPS FIG. 1.1.6 UPS 10-60kVA room size
Page 20 - Electrical Installation; Earth leakage protection; General
SOLA 4000 - Installation and Initial Start-Up JUE 401265 20 1 Installation 1.2 Electrical Installation This equipment must be installed by qualified service person-nel. Switch off IRP, IRE, IB, IUG, IBY circuit breakers to completelyisolate the equipment. Earth leakage protection : this device has h...
Page 22 - tection
SOLA 4000 - Installation and Initial Start-Up JUE 401265 22 Version 1 SOLA 4000 with Common Input for Rectifier and Bypass Input Cables / Fuses Type SOLA 4000 Input cables [mm²] Input fuses [A] earth cable [mm²] 10 4x10 25 16 15 4x10 35 16 20 4x16 50 16 30 4x25 63 25 40 4x35 100 25 60 4x35 125 25 80...
Page 24 - Input Cables
SOLA 4000 - Installation and Initial Start-Up JUE 401265 24 Version 2 SOLA 4000 with Separate Inputs for Rectifier and Bypass Input Cables Type SOLA 4000 Rect. cables [mm²] Bypass cables [mm²] earth cable [mm²] 10 3x10 4x10 16 15 3x10 4x10 16 20 3x16 4x16 16 30 3x25 4x25 25 40 3x25 4x25 25 60 3x35 4...
Page 25 - SOLA 4000 with isolation transformer of the bypass supply
SOLA 4000 - Installation and Initial Start-Up JUE 401265 25 1.3 Installation of additional optional cabi- nets SOLA 4000 with input and output transformers for voltage adaption FIG. 1.3.1 UPS connection diagram, with input and output transformers to adapt theUPS to the on-site voltage. SOLA 4000 wit...
Page 26 - SOLA 4000 with THD filters
SOLA 4000 - Installation and Initial Start-Up JUE 401265 26 SOLA 4000 with THD filters FIG. 1.3.3 UPS connection diagram, with THD filters (*) Note: Internal Battery only for 10-30kVA units 1 Installation
Page 27 - SOLA 4000 with 12-pulse charger / rectifier
SOLA 4000 - Installation and Initial Start-Up JUE 401265 27 SOLA 4000 with 12-pulse charger / rectifier FIG. 1.3.4 Installation of 12-pulse units without galvanic isolation SOLA 4000 with 12-pulse charger / rectifier and galvanic isolation of the input sup-ply. FIG. 1.3.5 Installation of 12-pulse un...
Page 32 - Nominal Rating of Contacts
SOLA 4000 - Installation and Initial Start-Up JUE 401265 32 1.6 Remote Emergency Power off A Remote Emergency Power Off may be connected to the system.The connection terminals are M4 Pin 5 and Pin 6, using a nor-mally-open, voltage-free contact as a pushbutton.(See FIG. 1.6.1.and FIG 1.6.2.) FIG. 1....
Page 37 - Installation of the Interconnection Cable
SOLA 4000 - Installation and Initial Start-Up JUE 401265 37 1.10.1 Installation of the Interconnection Cable The supplied cable must be connected between the units within thesystem. This must be connected at either of the connectors CN12or CN13 on the mother-board of the Inverter/Bypass electronics(...
Page 41 - Installation of the Interconnection Cables
SOLA 4000 - Installation and Initial Start-Up JUE 401265 41 1.11.1 Installation of the Interconnection Cables There are two interconnection cables supplied with the units foreach additional unit to the first unit. These cables must be con-nected between the units as shown in FIG. 1.11.4 One cable is...
Page 43 - Internal Electrical Connections
SOLA 4000 - Installation and Initial Start-Up JUE 401265 43 Internal Electrical Connections Cable (1) n° 3; L = 280 mm; diameter 16 mm 2 Cable (2) n° 8; L = 420 mm; diameter 16 mm 2 Cable (3) n° 4; L = 490 mm; diameter 16 mm 2 Cable (4) n° 2; L = 650 mm; diameter 16 mm 2 Support (CA1) n° 4; See Fig....
Page 44 - Warning
SOLA 4000 - Installation and Initial Start-Up JUE 401265 44 1.12.2 Installation of External Batteries External Battery (38 Ah) Installation 38 Ah external batteries are installed in a B3/38 battery cabinet. Toassemble the battery cabinet: • Place four battery blocks on the trays of the first level (...
Page 45 - IB
SOLA 4000 - Installation and Initial Start-Up JUE 401265 45 Important: Open battery switch IB before connecting the cables. • Place the trays with the batteries on the correspond-ing levels in the UPS. • Connect the battery blocks of the various levels to thebattery switch IB , and IB to the termina...
Page 49 - Connection of Auxiliary Contacts
SOLA 4000 - Installation and Initial Start-Up JUE 401265 49 Connection Between UPS and AdditionalBattery Cabinets Important: Open all battery switches IB before connecting the cables. Observe the indicated wiring polarity. • For UPS systems with external batteries: connect the external batteries as ...
Page 50 - yes
SOLA 4000 - Installation and Initial Start-Up JUE 401265 50 2 INITIAL START-UP 2.1 Start-Up Procedure General With the Start-Up procedure the correct installation of the UPSaccording to the previous section is checked. It must be carried outby specialised personnel. Safety precautions according to t...
Page 51 - B: Inverter Voltage Adjustment
SOLA 4000 - Installation and Initial Start-Up JUE 401265 51 B: Inverter Voltage Adjustment • On the SS/FY pcb, measure the voltage at the screws Inverter R, Inverter S, Inverter T with respect to the neutral terminal 5-N. ? Does this voltage correspond to the desired voltage? no • Adjust the voltage...
Page 52 - IUG; F: Synchronisation Check
SOLA 4000 - Installation and Initial Start-Up JUE 401265 52 • If your unit has separate supplies for the rectifier and bypass (terminals 4-L1, 4-L2, 4-L3, 4-N), switch on the external supplyfor the bypass. Check that the bypass supply voltage at termi-nals 4-L1, 4-L2, 4-L3, 4-N is within ±10% of the...
Page 57 - OPERATING MODES; OPERATING INSTRUCTIONS
Chapters 1 OPERATING MODES 2 1.1 General 2 1.2 Led Indication 3 2 OPERATING MODES STAND-ALONE UNIT 4 2.1 Normal Operation 4 2.2 Battery Operation 4 2.3 Bypass Operation 5 2.4 Maintenance Bypass Operation 5 2.5 Standby Operation 5 3 OPERATING MODES HOT-STANDBY OPERATION 6 3.1 Normal Operation 6 3.2 O...
Page 58 - Security concept; Operating Modes
SOLA 4000 - Operation JUE 401266 58 1 OPERATING MODES 1.1 General There are four different operating modes of the standard stand-alone on-line UPS-system (5 for hot-standby and 6 for parallelsystems), ensuring uninterrupted power supply of the load under allconditions. Transitions between these oper...
Page 60 - Operating Modes Stand-alone Unit; Battery Operation
SOLA 4000 - Operation JUE 401266 60 2 Operating Modes Stand-alone Unit 2 OPERATING MODES STAND-ALONEUNIT 2.1 Normal Operation "Normal Operation" is the standard operating mode of the UPS • Mains power is present. • The rectifier converts ac power to dc power which charges the batteries and f...
Page 61 - Maintenance Bypass Operation
SOLA 4000 - Operation JUE 401266 61 2 Operating Modes Stand-alone Unit 2.3 Bypass Operation The "Bypass Operation" mode is activated by an inverter failure oran overload • The rectifier supplies dc power only to the battery. • The static inverter switch SSI opens automatically after the stat...
Page 62 - Operating Modes Hot-Standby Operation
SOLA 4000 - Operation JUE 401266 62 3 OPERATING MODES HOT-STANDBYOPERATION 3.1 Normal Operation "Normal Operation" is the standard operating mode of the hot-standby system. • Mains power is present. • The rectifiers of all units convert ac power to dc power which charges the batteries and fe...
Page 63 - Maintenance Bypass Operation
SOLA 4000 - Operation JUE 401266 63 • If an additional failure in the first unit occurs, or when the battery of that unit is exhausted, the inverter of another unit willtakeover the load, continuing in battery operation until themains returns or the second battery is exhausted. 3.4 Bypass Operation ...
Page 64 - Partial Load Operation
SOLA 4000 - Operation JUE 401266 64 4 Operating Modes Parallel and Parallel/Redundant Operation 4 OPERATING MODES PARALLEL ANDPARALLEL/REDUNDANT OPERATION 4.1 Normal Operation "Normal Operation" is the standard operating mode of the UPS ifthe system load is at its nominal value or the system...
Page 66 - Maintenance Bypass Operation; Operating Modes Parallel and Parallel/Redundant
SOLA 4000 - Operation JUE 401266 66 4.5 Bypass Operation The "Bypass Operation" mode is activated by a multiple inverterfailure or overload • If the load is greater than 110% of the load capacity of all available inverters, the static bypasses of all individual unitswill connect the load wit...
Page 67 - Operating Instructions
SOLA 4000 - Operation JUE 401266 67 5 Operating Instructions 5 OPERATING INSTRUCTIONS 5.1 Switching On the UPS System / from Maintenance Bypass Initial UPS Operating Mode: The UPS is switched off, the load may or may not be supplied bymaintenance bypass, IBY and all other power switches are open. Op...
Page 68 - Final UPS Operating Mode:
SOLA 4000 - Operation JUE 401266 68 5 Operating Instructions Final UPS Operating Mode: The UPS is now in normal operating mode, as described in chapter"2.1. Stand-alone unit", "3.1 Hot standby systems" or "4.1 Parallelsystems". The green LEDs (L1, L2, L5, L3, L16, L17, L26, L...
Page 69 - tenance Bypass
SOLA 4000 - Operation JUE 401266 69 5.2 Switching Off the UPS System / to Main- tenance Bypass Initial UPS Operating Mode: The UPS is in any operating mode described in the previoussections "Operating Modes" (except maintenance bypass opera-tion). All power switches except IBY are closed, an...
Page 70 - Switching On any one unit within a Sys-
SOLA 4000 - Operation JUE 401266 70 5 Operating Instructions 5.3 Switching On any one unit within a Sys- tem (Parallel and Hot-standby Systems) Initial UPS Operating Mode The UPS module was switched off using the procedure in section5.4, all of the power switches in this module are in the off positi...
Page 72 - Emergency Power Off
SOLA 4000 - Operation JUE 401266 72 5.5 Emergency Power Off Operating Steps: • To activate the Emergency Power Off, press simultaneously the two pushbuttons in the E.P.O. section of the operatingpanel (For hot-standby and parallel systems, the operationneeds to be performed at one unit only). Attent...
Page 73 - SOLA 4000 - Operating Panel; FUNCTIONS
SOLA 4000 - Operating Panel ISSUED A4 19 1 JUE 401267 Chapters 1 FUNCTIONS 2 1.1 Indication of Important Data 2 1.2 Battery Monitoring 2 1.3 UPS Operating Mode Indication 3 1.4 Alarm Signalling 3 1.5 Remote Monitoring 3 1.6 Emergency Power Off 4 2 LED INDICATION 5 3 COMMUNICATION WITH A PC 9 3.1 Con...
Page 74 - Actual Load; Battery Monitoring; Low Battery; Functions
JUE 401267 74 SOLA 4000 - Operating Panel 1 FUNCTIONS 1.1 Indication of Important Data Actual Load The actual load of the UPS is indicated as a percentage of itsnominal load capacity. Battery Charging Status While the battery is being charged (green LED 5 on), the actualcharging status of the batter...
Page 75 - UPS Operating Mode Indication; LED Off; Remote Monitoring
JUE 401267 75 SOLA 4000 - Operating Panel 1 Functions 1.3 UPS Operating Mode Indication On the operating panel a block diagram of the UPS is shown. Theoperating mode of the UPS is indicated with LEDs integrated intothe block diagram. LED Off If a LED is not illuminated at all, the corresponding sect...
Page 77 - LED Indication
JUE 401267 77 SOLA 4000 - Operating Panel 2 LED INDICATION The block diagram of the UPS, with integrated LEDs, allows aquick check of the UPS operating status. FIG. 2.1 - LED Indication 2 LED Indication
Page 80 - LOAD PERCENTAGE; COMMON ALARM; BOOST CHARGE
JUE 401267 80 SOLA 4000 - Operating Panel LOAD PERCENTAGE The actual load is indicated by LEDs as a percentage of the nomi-nal load. • All LEDs off => Actual load = 0 - 10% • Green LED 20% cont. illumin. => Actual load = 10 - 30%• Green LED 40% cont. illumin. => Actual load = 30 - 50%• Gree...
Page 81 - Cable Specification; Communication with a PC
JUE 401267 81 SOLA 4000 - Operating Panel 3 COMMUNICATION WITH A PC 3.1 Connection to PC The UPS is connected to the PC via the RS232 interface. Therespective connector is the female 9-pin sub-D connector on theCPU/ NCP pcb on the inside of the UPS front door. At the PC aserial port is used which ca...
Page 82 - NT; PC Requirements
JUE 401267 82 SOLA 4000 - Operating Panel 3.2 SNMP MODE With DIP7 of SW2 in the ON position, the UPS can be monitoredand controlled from a remote location by a PC through a SNMPprotocol converter. In this mode, software packages such asSMARTMON from Systems Enhancement Corporation may be directly ...
Page 85 - Boost Charge
JUE 401267 85 SOLA 4000 - Operating Panel 3.5 UPS status Additionally to the above alarms, the following status conditions arerealised: Boost Charge The rectifier is re-charging the battery with a boost charge (accord-ing to DIN 41773). Output Switch OFF The output switch (IUG) is OFF and the load i...
Page 86 - Panel Settings
JUE 401267 86 SOLA 4000 - Operating Panel 4 PANEL SETTINGS 4.1 DIP Switch Settings With the DIP switches SW1 and SW2 on the CPU/NCP pcb insidethe front door , the operating parameters can be set according toactual conditions. Note: The following settings apply only with the software V2.0 or later. D...
Page 88 - Panel Settings
JUE 401267 88 SOLA 4000 - Operating Panel 4.2 Location of DIP-switches and pushbuttons on the CPU/NCP pcb The CPU/NCP pcb is located inside the front door at the UPScubicle. FIG. 4.3Layout of the CPU/NCP pcb PL1 Microprocessor RESET PL2 Emergency Power Off (E.P.O.) RESET 4 Panel Settings
Page 89 - Remote Panel
JUE 401267 89 SOLA 4000 - Operating Panel 5 REMOTE PANEL 5.1 General The Remote Panel is used for remote monitoring of SOLA 4000systems for distances of up to 400m. It is connected by cable via aRS485 interface. It can be installed in a control room and providesthe same user interface as the local o...
Page 91 - Communication timing
JUE 401267 91 SOLA 4000 - Operating Panel 5 Remote Panel Communication timing When an alarm condition occurs, the Remote Panel calls the firstprogrammed number. If the line is busy and only one number is to be called, the RemotePanel waits for 5 minutes and, if the alarm condition is still present,i...
Page 92 - UPS CONTROL LOGIC
SOLA 4000 - PCB Description Chapters 1 UPS CONTROL LOGIC 2 1.0 UPS Control Logic 2 1.1 Legend of symbols used 2 1.2 Rectifier 3 1.3 Inverter 5 1.4 Bypass 10 Figures FIG. 1.1 - IF/PS - R front view 3 FIG. 1.2 - CPHC16 - R front view 4 FIG. 1.3 - ICP front view 6 FIG. 1.4 - ICT-2 front view 7 FIG. 1.5...
Page 93 - SOLA 4000 - PCB Description; UPS Control Logic; Legend of symbols used; Potentiometer
SOLA 4000 - PCB Description JUE 401268 93 1 UPS Control Logic 1 UPS CONTROL LOGIC 1.0 UPS Control Logic The UPS Control logic is situated in the centre of the front part ofthe UPS. It consists of one rack with 7-8 PCBs (depending on thesystem configuration). On the covers of the rack, the variouspot...
Page 94 - PSPA
SOLA 4000 - PCB Description JUE 401268 94 1.2 Rectifier The rectifier control logic consists of two PCBs. IF/PS - R Rectifier electronic power supply • input voltage sensing • rectifier electronics power supply CPHC16 - R Rectifier control and regulation • rectifier output voltage regulation • recti...
Page 95 - CPHC16 - R Front View; DIAGNOSTICS
SOLA 4000 - PCB Description JUE 401268 95 CPHC16 - R Front View FIG. 1.2 illustrates the display, switches and connectors of theCPHC16 - R PCB which are accessible from the front. - 7 segment display for diagnostics (see table below) - Reset max. Vdc pushbutton: press when the character "4" ...
Page 96 - ICP
SOLA 4000 - PCB Description JUE 401268 96 1 UPS Control Logic In normal condition the display shows a red seg-ment rotating clockwise. During the starting phase,a blinking central segment "-" is displayed. Duringparameter acquisition through the serial interface,the character "A" is ...
Page 97 - ICP Front View
SOLA 4000 - PCB Description JUE 401268 97 Inverter control and regulation (parallel configuration) • parallel regulation of up to 8 inverters • system control for up to 8 inverters (together with ICP pcb) • cold-standby control • load monitoring • redundancy monitoring ICP Front View FIG. 1.3 illust...
Page 100 - IPR front view
SOLA 4000 - PCB Description JUE 401268 100 IPR front view FIG. 1.6 illustrates the LEDs, potentiometers, switches and test sleeves of the IPR pcb that are accessible from the front. - Parallel Operation On: This inverter is connected with another or more inverters to the output in parallel. - Redund...
Page 103 - CPHC16 - S Front View
SOLA 4000 - PCB Description JUE 401268 103 CPHC16 - S Front View FIG. 1.8 illustrates the display, switches and connectors of theCPHC16 - S PCB which are accessible from the front. • 7 segment display for diagnostics (see table below) • Manual transfer to bypass pushbutton • RS232 connector (male) •...
Page 104 - SYSTEM DATA
ISSUED 04.02.97 A4 5 1 04.02.97 JUE 401269 SOLA 4000 - Technical Data Figures 1 SYSTEM DATA 2 FIG. 1.1 - System Data 2 2 RECTIFIER DATA 3 FIG. 2.1 - Rectifier Data 3 3 BATTERY DATA 4 FIG. 3.1 - Battery Data 4 4 INVERTER DATA 5 FIG. 4.1 - Inverter Data 5 M. Porpora We reserve the right to modify the ...
Page 105 - System Data
SOLA 4000 - Technical Data JUE 401269 105 FIG. 1.1 - System Data 1 System Data Technical Data / System Data Type SOLA 4000 10 15 20 30 40 60 80 100 120 System configuration On-line (double conversion) Nominal input voltage 3Ph+N x 380 ÷ 415 V Tolerance: ± 10% Nominal input frequency 50 / 60 Hz Toler...
Page 106 - Rectifier Data
SOLA 4000 - Technical Data JUE 401269 106 IG. 2.1 - Rectifier Data 2 Rectifier Data Technical Data / Rectifier Data Type SOLA 4000 10 15 20 30 40 60 80 100 120 Input voltageTolerancewith reduced output (DC) voltage refer to system datarefer to system data-20 % Input frequencyTolerance refer to syste...
Page 107 - Battery Data
SOLA 4000 - Technical Data JUE 401269 107 FIG. 3.1 - Battery Data 3 Battery Data Technical Data / Battery Data Charger input voltage 10 15 20 30 40 60 80 100 120 Input charging voltage 3 x 380 V 3 x 400 V 3 x 415 V Number of cells (standard)Lead-Acid openLead-Acid maintenance freeNi-Cd 192192300 192...
Page 108 - Inverter Data
SOLA 4000 - Technical Data JUE 401269 108 FIG. 4.1 - Inverter Data 4 Inverter Data Technical Data / Inverter Data Type SOLA 4000 10 15 20 30 40 60 80 100 120 Permissible input DC voltage range 320 - 480 V/DC Input power at rated load- [kW] 8,7 13 12,4 26 35,1 52,7 70,3 87,9 105,5 Inverter input curr...
