mas batt rech gb r00

1 of 22 SOCOMEC- SICON UPS (VILLAVERLA VI)

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BATTERIES AND RECHARGING METHODS

The battery charger control principle allows the user to choose the type of battery and the appropriate recharging procedure.

The battery charger can be configured on the Assist or on the mimic panel as described below:

Types of battery: Sealed lead [0] Open Vented [1] Nickel-Cadmium [2]

Charging procedures: Single level or Floating [0] Dual level [1] Step Charge [2] BMS or Automatic [3]

Recharging phases: Maintenance Boost Charge Recharge (Second level) Equalisation Forming (or deep Charge) (*)

(*): Forming and deep charge have the same operating principle but have different voltages (2.70V and 2.55V respectively) that are settable via the Assist.

Naturally, not all types of batteries support the available recharging procedures - see the principle illustrated in Figure 1.


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BRIEF DESCRIPTION OF RECHARGING METHODS:

Single level or Floating: this is the method used by sealed lead acid batteries [0] and has one voltage level and one recharge current limit. The voltage may also be adjusted to match the battery operating temperature.

The following EEprom parameters must be set: EEprom parameter Description Assist: All Parameters section

UPS Main Configuration Parameters Batt_Type Type of battery Battery Configuration Capbat_Tot Total battery capacity Battery Configuration Perc_Icblim Recharge current limit Battery Configuration Num_El_Batt Number of elements in a battery leg Battery Configuration Float_Volt_El Recharge voltage per element Battery Configuration Temp_Comp_En Enable temperature compensation Battery Configuration Delta_Temp Battery delta temperature regulation Battery Configuration Batt_Char_Type Recharge method Battery Configuration

Advanced Battery Parameters Perc_Vmax_El Maximum battery voltage Battery elements Coeff_Temp Compensation coefficient value Advanced general parameters Batt_available Battery available Advanced general parameters

Dual level: this is the default method (Figure 2) used by Open Vented [1] and Nickel-Cadmium [2] batteries. It has two voltage levels depending on the current flow in the battery (there is also a third level for boost recharging). The switch over between the two recharge levels is controlled by two current thresholds. The recharge current limit is determined by a third current threshold.

Forming recharge: this operation is carried out only when the batteries are charged for the first time after filling the batteries with acid. At the users discretion the operation may also be carried out during the battery life from time to time to equalise the batteries. The charge is activated and terminated manually (from the mimic panel or the Assist) using the appropriate commands.

The current limit is lowered and operation must be carried out within a set time. The following EEprom parameters must be set: EEprom Parameter Description Assist: All Parameters Section

UPS Main Configuration Parameters Batt_Type Type of battery Battery Configuration Capbat_Tot Total battery capacity Battery Configuration Perc_Icblim Recharge current limit Battery Configuration Num_El_Batt Number of elements in a battery leg Battery Configuration Float_Volt_El Floating voltage per element Battery Configuration Vbat_Rchrg_El Recharge voltage per element Battery Configuration Vbat_Boost_El Boost voltage per element Battery Configuration Icblim_Boost Boost current limit Battery Configuration Batt_Char_Type Recharge method Battery Configuration

Advanced Battery Parameters Perc_Vmax_El Maximum battery voltage Battery elements Icb_Batt_Fl_Rech Floating recharge switch over Charge currents Icb_Batt_Rech_Fl Recharge floating switch over Charge currents Max_Rech_Time Maximum recharge time Charge currents Batt_available Battery available Advanced general parameters


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Dual Level Charge

BOOST Charge

TIME

V/A

2.23V/E

0.04*C

0.15*C

0.07*C

2.4V/EL

TIME

V/A

1.41V/E0.1*CA

1.7V/EL

12h


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Step Charge: this method (Figure 3) is used by sealed lead acid batteries [0] and charges the batteries periodically in steps (Ton) depending on the battery operating temperature (max. 10 minutes configurable on the Assist).

Step charge

2.35 V/el

Umin

I2

Time

VoltageCurrent

Ton

Toff

Umax

I1

Ton is a configurable parameter between 0 and 255 minutes. The standard value is 10 minutes at 20C. The time depends on the temperature as indicated below:

Temperature


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Boost charging : x per year

2.35 V/el

Umin

I2

(Ton / Ton_Standard) x 24 (h) Time

VoltageCurrent

Step charge

I1

UmaxTon

Following a prolonged mains power failure that discharged the batteries to a residual capacity of less than 90% of the initial capacity, the batteries will be recharged as shown in the diagram below:

Charge cycle after a discharge over 10 % of the capacity

2.35 V/el

UminI1

I2

Tcharge Time?

VoltageCurrent

Normal charge Step charge

Umax

The duration of the charge with a higher current limit will depend on the ambient temperature in the battery cabinet.

Tcharge = 24 hours at a temperature of 35 C Tcharge = 12 hours at 35 C < Temperature 45 C Tcharge = 8 hours at a temperature of > 45 C

Equalisation charge: this is an automatic operation that is carried out only when battery problems are identified (Toff/Ton ratio too low). Again, the duration of the recharge (in hours) will depend on the battery operating temperature.


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The following EEprom parameters must be set: EEprom Parameter Description Assist: All Parameters Section

UPS Main Configuration Parameters Batt_Type Type of battery Battery Configuration Capbat_Tot Total battery capacity Battery Configuration Num_El_Batt Number of elements in a battery leg Battery Configuration Vbat_Equal_El Equalisation voltage per element Battery Configuration Batt_Char_Type Recharge method Battery Configuration

Advanced Battery Parameters Perc_Vmax_El Maximum battery voltage Battery elements Max_Icb_Equal_Rech Recharge current limit for equalisation Charge currents Min_Volt_Sc Minimum Step Charge voltage(Toff) Step charge mode Vbatt_El_Sc Step Charge voltage (Ton) per element Step charge mode Max_Volt_Sc Maximum Step Charge voltage Step charge mode Perc_icblim_Sc Current limit duringTon Step charge mode Idiv_Sc Ton and Toff current limit ratio Step charge mode Ton_Sc Ton duration Step charge mode T_Boost_Sc Interval in days between 2 Boost Charges Step charge mode T_Rest_Save_Sc Wait for first Boost Charge Step charge mode Toff_Ton_Sc Ratio between Toff and Ton Step charge mode Batt_available Battery available Advanced general parameters

BMS (Automatic Floating/Step Charge): this is the default method used by Sealed lead acid batteries [0] and automatically switches between one recharge method and another depending on the battery operating temperature as shown below:

Floating (=25C). There is a temperature inductance of 2C to avoid continuous switching at temperatures of

25 C.

Table summing up the types of batteries and the appropriate recharge method:

Sealed Lead Acid Open Vent Lead Ni-Cd Charge Phase Recharge method Recharge

method Recharge method

BMS Floating Step Charge Float St.Ch.

Dual level Dual level

Maintenance 2.27 2.35 2.27 2.35 2.23 1.4 Boost Charge 2.35 2.35 Second level 2.4 1.45 Equalisation 2.35 2.35 2.35 Deep charge 2.55 1.65

Forming 2.7 1.7

Figure 1


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EQUALISATION CHARGE

Equalisation is a recharge phase that can be carried out only if the recharge methods Step Charge or BMS have been set, i.e. if a sealed lead acid battery is configured [0] .

This is an automatic recharge operation and is activated when the ratio between Toff (battery charger off time) and Ton (battery charger on time) is less than an EEprom parameter value that can be altered on the Assist.

The calculation is carried out on an average of 10 consecutive Toff/Ton samples.

The duration of the equalisation charge depends on the operating temperature as follows:

Temperature


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Figure 4

Ton/Toff Sub program

Boost charge

Ton/Toff Sub program

A < X

Battery test

Battery Failure alarm

No

Yes

A > X

No

Yes

Test OK

No

Yes

Battery weak alarm

X is an EEprom settable parameter (between 1 and 256)

The default value is 3


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Calculating back up time Back up time (expressed in minutes) is calculated only during battery discharge using the following formula:

Minutes_back up = Available capacity * 60 / Ibatt ,

where the available capacity is the remaining charge in accordance with the discharge current.

An estimate of the remaining back up time can be calculated when the UPS runs on mains power. Activate the Assist option and look at the Autonomy_charge parameter. The calculation is given when the battery is fully charged and takes into accounts the load percentage on the output.


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MINIMUM AND PRE-MINIMUM BATTERY VOLTAGES

The following EEprom parameters must be set: EEprom Parameter Description Assist: All Parameters section

UPS Main Configuration Parameters Vmin_El_final Minimum voltage per element (IoutNom) Battery Configuration Vpremin_El_final Pre-minimum voltage per elem. (IoutNom) Battery Configuration Vmin_El_init Minimum voltage per element (Iout = 0A) Battery Configuration Vpremin_El_init Pre-minimum voltage per elem. (Iout =

0A) Battery Configuration

Graph showing pre-minimum and minimum battery voltage thresholds:

Battery voltage in function of discharge current

1.201.301.401.501.601.701.801.902.00

0 10 20 30 40 50 60 70 80 90 100 110Nominal current (%)

V/el

em. (V

)

PreminimaMinima

Default:

Vmin_El_final 1.65V/el Vpremin_El_final 1.80V/el Vmin_El_init 1.73V/el Vpremin_El_init 1.95V/el


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BATTERY CURRENT

Calculating the battery recharge current

The diagram below shows the battery charger operating curves.

Iout [mA] depending on regulation duty cycle

0

500

1000

1500

2000

2500

3000

3500

4000

0 10 20 30 40 50 60 70 80 90 100Duty cycle [%]

Iou

t [m

A]

V=185 V=265 V=345


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60-80KVA recharge curve

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

11.00

12.00

13.00

14.00

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Command PWM duty cycle

Iou

t [A

]

V=175 V=248 V=320 V=210


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Calculating the battery discharge current The battery discharge current is calculated by the DSP and the result is sent directly to the

battery logic.

Comments on the battery charger characteristics Some characteristics/functions of the logic, which controls the 4th leg of the battery charger,

are listed below. The operating voltage range is 170-400V. The maximum battery charger current must be 3.6A at 220V (the software limitation is

from 170V to 220V battery voltage; at higher voltages, the 100% duty cycle is automatically self-limiting).

Saturation I @ 3.6A with max. duty cycle

140

150

160

170

180

190

200

210

220

68 73 78 83 88 93 98Max. duty cycle

Vbat

t


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The maximum formation charge is 2.7V/el (with 24 Batteries): using voltages higher than 370V, the battery charger hardware starts operating in particular conditions and, as a result, the current falls to 2.7A.

Iout [mA] depending on Vbatt

27002800290030003100320033003400350036003700

140 190 240 290 340 390Vbatt

Iou

t [ m

A]

MASTERYS 15-40KVA

Curva carico per tarature a 300 e 280

8,38,48,58,68,78,88,9

99,19,29,39,49,5

170 180 190 200 210 220 230 240 250 260 270 280 290 300 310 320 330

Duty

Iou

t

Taratura 280V

MASTERYS 60-80KVA

Vbatt

Iout (A) depending on VBatt


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BATTERY TEST

The battery test principle runs four types of test.

Scheduled Battery Test: this is run periodically to test the battery efficiency. The parameters that regulate the scheduled test are all available in EEprom and can be

modified on the Assist. They are basically as follows: Enable battery test. Interval between battery tests (indicated in days). The test can be run in the following conditions:

No alarms Output on inverter Mains power available for at least 12 hours Remaining battery charge greater than 96% Battery voltage greater than set-point Estimated battery current less than 80% of nominal current.

This test takes a maximum time of 6 minutes.

Manual Battery Test: this may be run manually via the Assist or mimic panel during initial installation or following maintenance on the batteries. The Enable battery test parameter regulates the manual test.

The test can be run in the following conditions: No alarms Output on inverter Remaining battery charge greater than 90% Battery voltage greater than set-point Estimated battery current less than 80% of nominal current

This test takes a maximum time of 6 minutes.

Automatic Battery Test: The automatic battery test corresponds to the scheduled test except that in this case it is run automatically on two consecutive Toff/Ton calculations with negative result (see the Step Charge text in the charge methods paragraph for more details).

The parameters that regulate the automatic test are all available in EEprom, can be modified on the Assist and are the same as those for the scheduled test.

The test can be run in the same conditions as those listed for the scheduled test.

Battery Check: this checks the status of the batteries when a power failure occurs.


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The following EEprom parameters must be set: EEprom Parameter Description Assist: All Parameters Section

UPS Main Configuration Parameters Test_Interval Interval between two scheduled tests Battery Configuration

Battery Advanced Parameters Batt_Test_Enable Enable the battery test Advanced general parameters Interval_Batt_Test Interval between any two Tests Advanced general parameters

The test can be run in the following conditions: Output on inverter Mains power available for at least 12 hours Remaining battery charge greater than 96% Battery voltage greater than set-point Estimated battery current less than 80% of the nominal current.

When the check is run during a power failure, it lasts a maximum of 6 minutes (even if the power failure lasts longer) exactly as for the scheduled test.

Running the test: The test is based on the effective battery discharge. If the conditions for carrying out the test are positive (the wait time for conditions is set at a

maximum of 10 hours, after which the test is considered to have failed), the voltage is checked without batteries and the battery charger is switched off.

If the voltage measured is greater than 2.1V, the test continues, otherwise it fails. Then, depending on the output load and on whether both batteries are inserted or not: the test is run separately - first the positive leg and then the negative leg if the output load is

35% less than the nominal load. The test is run separately if only one battery leg is available and the output load is 50% less

than the nominal load (71% on the mimic panel). The test is run simultaneously on both legs, if the positive and negative batteries are

available and the output load is 35% greater than the nominal load.

If during the test on a single battery the load increases by more than 45%, the test will be interrupted.


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Results of the test: Testing the battery voltage: The test is successful if the battery voltage remains above the

preset battery threshold (60% of nominal capacity) for the entire duration of the test while the charge lost during the test must not exceed 10% of the nominal charge. There is also a pre-alarm threshold value beneath which a Perform preventive maintenance on the batteries warning is generated to notify the user of the battery status. This alarm has no effect on the logic and corresponds to 65% of the nominal capacity. Naturally, these two threshold values depend on the discharge current.

Minimum and Pre-minimum in Battery Test

1.40

1.50

1.60

1.70

1.80

1.90

2.00

2.10

0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8 3.0

Battery Current (Amp./Cap)

Bat

tery

Vo

ltage

(V

/ele

m.)

Minima Preminima

Graph 1: curves to calculate the minimum battery voltage during the test


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Check the battery capacity: in addition to checking the battery efficiency, if the test is successful, it will also give the new initial capacity value.

By initial capacity we mean the maximum capacity value with the batteries full charged (not at the end of the recharge phase).

Graph 2: curves to check the initial capacity during the battery test

How the new initial capacity value is calculated: Depending on the discharge current value we can identify a work curve (graph 2). The

battery voltage is checked during the discharge and the minimum value reached is stored. With this value, a nominal capacity percentage can be determined and to this we can add the real capacity lost during the discharge. Multiplying the result by the nominal capacity we then get the new initial battery capacity value. For a new battery, the result will be 100%, while as the battery gets older, the test shows how the initial charge gradually decreases.

(?) When the calculated capacity is lower than threshold value X, an equalisation charge cycle will be activated.

Checking the Battery voltage during the Battery Test: If the battery test is run during a mains power failure, only the battery prealarm value (65% of the nominal capacity) is considered. Below this value the Perform preventive maintenance on the batteries alarm (A92) is generated.

CSB HR1234WF2

11,211,411,611,8

1212,212,412,612,8

60 70 80 90 100% CAPACITY

VBATT V I=22A I=8,5A


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PARALLEL BATTERY CHARGER (DERATING OF THE RECHARGE CURRENT)

The standard UPS MASTERYS version is sized to recharge the batteries with a current equal to 10% C10 in the following conditions:

a. Inverter with 100% of nominal load b. Input power at 80% of nominal voltage.

In cases with lower loads or with higher input power, the battery recharge current may reach:

a. The SW configuration limit (e.g.:20% C10) b. The HW limit of the battery charger (3.6A)

Battery chargers can be connected in parallel to deal with cases of long back-up times that require strong battery current.

In all events, the battery charger supplies the current configured via SW, except for critical load or input power situations where the recharge current is automatically reduced.

If the current falls below 4% C10, the A95 alarm is generated.

The figure below shows the logic implemented with loop control on the input current.

Ibattery= Irect Max-IRectifier,

Max. value = Configuration limit (20% C10) or HW battery charger limit (3,6A* number of battery chargers)

Principle Implemented: A maximum reference rectifier current is configured using the following formula:

IRect_Max = UPS Rating * K

where K = 1.58 which is the ratio between the max. current of the windings and the nominal input current.

The following EEprom parameters must be set:

Total battery charger

IRect_Max

IBattery

IRectifier - +

+

+

Ref CB


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EEprom Parameter Description Assist: All Parameters Section Advanced Battery Parameters

BattCurr_Derating Threshold value signalling that Derating is in progress

Advanced general parameters

The battery current will not be derated as long as the rectifier current (that is the sum of the inverter current and the battery recharge current) is lower than the calculated IRect_Ref value.

If the rectifier current exceeds the reference current, derating of the recharge current will begin. In fact, by lowering the recharge current, the rectifier current will also be limited.

Example for 30kVA

IRectifier (real)

I_Rect Max (49A)

I battery


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BATTERY CHARGER SWITCH ON LOGIC

BATTERY CHARGER CONTROL LOGIC

The battery charger is switched on providing:

The rectifier is operating on mains power (ON_MAINS input logic status).

Note: the logic will switch on the battery charger even if no batteries are inserted.

The logic checks the positive and negative battery chargers separately, via the two enable_cb_pos and enable_cb_neg bits. For example, it may happen that the positive battery charger is on while the negative battery charger is off (Step change charge method).

The following condition has been set to monitor the correct operation of the battery charger: A period of 16 hours is counted every time mains power returns, after which battery

voltage is checked to verify whether it is greater than the set point voltage. The Battery Charger Failed alarm is generated.

If the correction of the recharge voltage is enabled in accordance with the temperature, the control set point will also depend on the temperature. In cases of Step Charge or Automatic BMS charge methods, the battery charger control logic will monitor the battery voltage following16 hours of continuous mains power. If:

(VbattPos || VbattNeg) < (SET_POINT * Num.Elem) 10V

the battery charger has not charged the batteries and so it is not working.

If the battery charger fails, a Warning message is generated that does not affect the operating principle. It is therefore a temporary alarm:

If mains power fails, the alarm is cleared and the check will be repeated when mains power returns.

After the 16 hours battery voltage is monitored continuously with respect to the active set point value.

HANDLING AND PROTECTING THE BATTERY CHARGER AGAINST OVERTEMPERATURE

If the radiators overheat during normal battery charger operation (due to a failure or improper use), a protection is activated that works as follows:

If the temperature measured exceeds the first threshold value (Prealarm), the logic will halve the maximum current limit.


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If the temperature measured exceeds the second threshold value (Alarm), the logic will shutdown the battery charger and generate a Maximum Battery Charger Temperature alarm.

The battery charger will become operative again only if, after the forced shutdown, the temperature falls below the first threshold value (Prealarm). The Maximum Battery Charger Temperature remains active until this value is reached.

Slow discharge protection

The following logic is adopted to protect the batteries against slow discharge:

- the inverter is switched off if both of the following conditions are fulfilled:

a. At least 5 hours of battery operation b. Available capacity is lower than 20% of the nominal capacity.

An Imminent Stop alarm is generated before switching off the inverter.

The rectifier is also switched off after the Imminent Stop alarm and consequently also the power supply unit.

Batteries Disconnected Alarm (15-40kVA)

The Batteries disconnected alarm is generated (bAlmBattPosAbsent) if the internal UPS battery disconnecting switch is open.

The rectifier is shutdown if the internal UPS battery disconnecting switch is opened during the battery discharge.

If the batteries are disconnected without activating the disconnecting switch, the alarm is generated in a different way.

The battery charger raises the battery voltage above the max. battery voltage threshold. The battery charger is kept switched off for 60 seconds after which the battery voltage is checked. If it is below the min. battery voltage the Batteries disconnected extended alarm (bAlmBattPosAbsent) is generated.

mas batt rech gb r00

Documents

types of battery

battery life

battery operating temperature

recharge voltage

recharge levels

following eeprom parameters

single level

current flow