HELIOS R500HI Series 500W DC UPS User Manual

R500HI Series 500W DC UPS
User Manual

STANDARD FEATURES

| 3 Relay Alarms-Form C
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| Float Charger –Lead Acid Batteries
| Temperature Sensor on 1.7m lead with adhesive pad: -4mV / °C /cell ±10%
| ELVD : Electronic low voltage disconnect

OPTIONAL FEATURES

| Comms:
• RS232
• RS485
• Modbus RTU
• SNMP V1 & Webpages
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| Customizable Digital I/O
| BCT: Battery Condition Test.
| N+1 Redundancy
| Rack Mounting
| Internal Meter

SAFETY

The user is responsible for ensuring that input and output wiring segregation complies with local standards and that in the use of the equipment, access is confined to  operators and service personnel. A low resistance earth connection is essential to ensure safety and additionally, satisfactory EMI suppression (see below).
HAZARDOUS VOLTAGES EXIST WITHIN A POWER SUPPLY ENCLOSURE AND ANY REPAIRS MUST BE CARRIED OUT BY A QUALIFIED SERVICEPERSON.
Electrical Strength Tests
Components within the power supply responsible for providing the safety barrier between input and output are constructed to provide electrical isolation as required by the relevant standard. However EMI filtering components could be damaged as result of excessively long high voltage tests between input, output and ground. Please contact our technicians for advice regarding electric strength tests.
Earth Leakage
Where fitted, EMC suppression circuits cause earth leakage currents which may be to a maximum of 3.5mA.
Ventilation
High operating temperature is a major cause of power supply failures, for example, a 10 C rise in the operating temperature of a component will halve its expected life. Therefore always ensure that there is adequate ventilation for the equipment. Batteries in particular suffer shortened lifetimes if subjected to high ambient temperatures.
Water / Dust
Every effort must be made in the installation to minimise the risk of ingress of water or dust. Water will almost always cause instant failure. The effects of dust are slower in causing failure of electronic equipment but all electrical equipment should be cleaned free of any dust accumulation at regular intervals.
Electromagnetic Interference (EMI)
Switching power supplies and converters inherently generate electrical noise. All wiring should be as short as practicable and segregated from all equipment wiring which is sensitive to EMI. Residual noise can be reduced by looping DC wiring through ferrite cores (sleeves). These are most effective as close to the power supply as possible and as many turns of the wire taken through the core (+ and – in the same direction) as the core will accommodate.
External fuse protection
Fuses or circuit breakers must be used in all battery circuits to protect against short circuits. External fuses should be used for power supplies/chargers even though they are usually internally protected.
Connection polarity
It is critical to check the polarity carefully when connecting DC devices even with models which have non-destructive reverse polarity protection.
Glossary of terms used in our user manuals
PSU = power supply unit
ELVD = electronic low voltage disconnect
SNMP = Simple Network Management Protocol
BCT = battery condition test
RPP = reverse polarity protection
EMC = Electromagnetic compatibility
ECB = electronic circuit breaker
EMI = electromagnetic interference
DOD = depth of discharge

INTRODUCTION:

The No-Break ™DC SR500Hi switch mode power supply is designed to provide DC power to lead acid batteries for critical back up applications.No-Break ™ DC UPS systems maximise the integrity of standby battery installations, whilst optimising the life and availability of back up batteries. A built in Low Voltage Disconnect (LVD) will protect the battery from over discharge after extended periods of backup operation when AC power has failed.

SR500HI Series – SYSTEM BLOCK DIAGRAM

OPERATION OF ELECTRONIC CIRCUIT BREAKER (ECB) FOR PROTECTION OF BATTERY

CIRCUIT & BATTERY

The ECB will operate on overcurrent as above & is also activated for the low voltage disconnect function on mains fail (no input power).
It will reset when input power is restored, or can be manually reset by briefly shorting the BAT- and LOAD- terminals together when there is no input power.

BACK & FRONT PANEL LAYOUT

1. AC INPUT IEC60320 – C13 10A

2. Digital Inputs (pins 1,2)/ Input or Output (pin 3)/ Return (pin 4) I/O terminals are customizable and if used, the product will have a unique code.

3. ALARMS RELAY FORM C
   AUX : Activated by BCT ( Battery Condition Test)
   POWER (Mains Fail):
   • Loss of mains input power. This alarm has 30 seconds delay before activation upon mains failure.
   • PSU fails
   BATTERY:
   • Battery Low: 1.8V/cell (for 2V cells) – operates only when no mains power present.
   • Battery Missing or fault in battery circuit wiring (alarm does not activate for up to battery detection interval time.
   • BCT fail

4. LOAD & BATTERY CONNECTION ( M8 brass stud, plug-in style phoenix & plug-in style Anderson connector options)

5. LED INDICATIONS CODE ( For full list of LED flash codes please refer to the next page)
   Battery OK: LED on: Battery present and above V batl
   Power OK: LED on: Charger output present. LED off: no mains input or charger in standby mode
   Standby: LED on: Charger in standby mode ( no output from charger) . Push the STANDBY button briefly to put into standby mode.

6. Comms Port (if installed) , for models with communications please refer to
   • RS232 (ASCII) https://www.heliosps.com/sr-series-downloads/#rs232-rs485 -commands-sr-series
   • RS485 (ASCII) https://www.heliosps.com/sr-series-downloads/#rs232-rs485 -commands-sr-series
   • Modbus RTU https://www.heliosps.com/sr-series-downloads/#serial-modbus-rtu- sr-series
   • SNMP, Webpages https://www.heliosps.com/sr-series-downloads/#snmp-sr- series

NOTES
Reverse polarity protection
If the battery is connected in reverse, the internal battery protection fuse may be ruptured and the unit should be returned to the manufacturer for repair. If the fuse is good,
the voltage measured as at step 3 above should be exactly .

CONNECTION AND INITIAL TESTING

1. Check input and output voltages of system, ensure that they match the equipment. All loads should be isolated.
2. Check polarity of all wiring. Place temperature sensor probe near or on batteries.
3. Plug in ac input and turn power on. Both LEDs will light up after approx. 4 sec, “BATT OK” LED will go out after another 10 secs (since there is no battery connected). DC output voltage should appear at both load and battery outputs (ensure screws are tightened down on the connector block).
4. Turn off input power.
5. Connect battery.
6. Check that ELCB (internal electronic circuit breaker) closes by shorting together the BATTERY –ve and LOAD –ve terminals for about 2-3 sec. You will hear a relay operate and both LEDs will light up. If this does not happen, there is a fault in the wiring or the internal battery protection fuse is ruptured (see Note 2 below). The battery voltage will then appear at the load terminals and the “BATTERY OK” relay energises. The “POWER OK” LED stays on for about 30 seconds.
7. Connect load wiring to LOAD+ and LOAD- terminals. Check that the load does not exceed 110% of the unit. Any peak loads which are > 110% must be connected to the B+ and B-terminals.
8. Turn on ac power.
9. After the batteries are fully charged, check that the battery continues to power up the load when the input power is turned off.

LED INDICATION

LEGEND :
=on
=fast flash
=slow flash
=off

Battery
System OK
LED| Power OK
LED| Stand-by
LED| Battery System OK Alarm| Power OK
Alarm| Condition
---|---|---|---|---|---
| | | Normal| Normal| System Normal: Input power on, battery circuit is OK
| | | Normal| Normal| Battery detection test in progress
| | | Alarm| Normal| Input power on, battery system fault:
1.Internal battery fuse has opened or
2.Battery circuit wiring open circuit, battery missing, ECB has tripped
| | | Normal| Alarm| Input power off, battery system is OK (battery volts > Vbatl)
| | | Alarm| Alarm| Input power off and battery has discharged to < V batl
| | | Alarm| Alarm| Input power off, ELVD has activated and disconnected battery from load.
| | | Normal| Normal| BCT is in progress: LEDs flash slowly
| | | Alarm| Normal| Input power on, battery condition unserviceable- battery voltage < Vpres during a
BCT
| | | Normal| Normal| PSU in standby, input power on, battery system OK
| | | Alarm| Alarm| PSU in standby, input power present battery missing.
| | | Alarm| Normal| PSU in standby and system has failed previous BCT
| | | Normal| Normal| Fan fail/stall, Aux relay will toggle every 5 seconds and the POWER Ok LED will slow flash during this 5 second period
| | | Normal| Normal| Fan fail/stall occurs at the same time as BCT, the BCT talks priority until the BCT is finished. The Aux relay will then resume toggling every 5 second to show fan fail/stall

SR500HI – DC SETTINGS (at 20 degrees C)

V pres = Voltage threshold for battery detection & battery condition test (BCT). If voltage drops to this level during BCT then the test is aborted and a BATLOW alarm generated| 12.| 24.| 31.| 37.| 49.| 2.03V/cell
V shutd = Output voltage of PSU during battery detecLion & BCT| 12.| 23| 29.| 35.| 46| 1.92V/cell
V batl = Battery voltage when BATLOW alarm generated during mains fail| 11| 22| 28.| 33| 44| 1.84V/cell
V disco = Battery disconnect voltage during mains fail| 10| 20| 25| 30| 40| 1.66V/cell
Bccl = Maximum charge current as % of rated PSU rated current| 100%*1
Comms = communications mode of PSU: F = continuous data stream of status M = responds only to request made by a control-ler| F
BatDetect = Battery detection interval time, active only when no battery charge current is detected (the unit may not detect a missing battery for up to this time)| 60 min
BCT Jumper: if fitted automatic BCT is enabled| Not fitted
BCT = length of battery condition test| 20 min
Ret = retest option: N = after a failed BCT further scheduled Bas are inhibited Y = after a failed BCT further scheduled Bas will be allowed| Y
CC = Length of charge cycle in minutes/hours/days. ie. time between battery condition tests| 40m/23h/027d
MfiBCT = time before mains fail check during BCT. A mains fail during a BCT will stop the BCT. If set longer than BCT time no mains fail check will occur.| 30 min

*1 Except for 12V which is set at 50%

MOUNTING DETAILS

SR500HI – CONNECTIONS – Typical Examples

• Standard No-Break™DC charger and battery bank
This is the basic connection which is most commonly used, and provides adequate protection for the majority of systems requiring DC back up in the event of a mains power failure.

Alarms Available

Input Fail| YES
Battery Missing| YES
Battery Low| YES
Battery Condition Test Fail| YES

Note: On stud connected output models the L+/B+ is one stud labelled “+ COMMON”
Peak load connection using No-Break™DC charger
Peak loads which may exceed 1.5 x max. charger output can be connected to bypass the internal overcurrent trip circuit.

Alarms Available

Input Fail| YES
Battery Missing| YES
Battery Low| YES
Battery Condition Test Fail| YES

• N+1 connection using two complete No-Break™DC systems with each one capable of supplying the loads- positive common

Alarms Available

Input Fail| YES
Battery Missing| YES
Battery Low| YES
Battery Condition Test Fail*1| YES

1*interlock circuit required for automated BCT

MODEL CODING AND OPTIONS

H-SERIES INTERNAL METER OPTION

SR500H & SR750H L & I models both have the internal meter option and the parameters displayed vary depending on the model. The H-Series internal meter shows the status of the PSU and Battery which has certain meanings. Check below each one of them to understand the information displayed. SR500/750HI model with Internal meter:
Code A:
CC – charge cycle (normal operation)
MF – mains fail (mains failure, system on battery power)
OL – system overloaded, output voltage is below Vpres setting
BCT – battery condition test is in progress
Code B:
M? – possible mains fail, ie. No mains detected but brown out timer not expired (30sec)
m? – possible mains fail, ie. No mains detected but brown out timer not expired (30sec). But has failed the previous BCT
BP – battery present, system OK
bP – battery present, system OK. But has failed the previous BCT
B? – No battery charge current detected, up to the next scheduled battery detection, uncertainty about the presence of the battery exists.
b? – No battery charge current detected, up to the next scheduled battery detection, uncertainty about the presence of the battery exists. But has failed the previous BCT.
BM – battery is missing, the battery detection routine did not find a battery to be present. This will also reset the ‘battery condition not good’ of any failed BCT.
BO – battery is in ‘OK’ state during mains fail
bO – battery is in ‘OK’ state during mains fail. But has failed the previous BCT
BL – battery is in ‘LOW’ state during mains fail
bL – battery is in ‘LOW’ state during mains fail. But has failed the previous BCT
SD – system will shut-down if no mains present and output voltage stays below Vdiscon for 30 seconds.
Displayed values following Code B:
Vout = output voltage of PSU
Ibat = battery charging/discharging current
Ipsu = Total PSU output current+20o
C = temperature measured by temp. sensor

TECHNICAL SPECIFICATIONS

88V-132VAC (on-request)
Output Voltages| 12V, 24V, 30V, 36V, 48V
Voltage Adj. Range| 85% – 120% of Vout
Frequency| 45-65Hz
**Fusing/Protection| Input fuse and varistor
Battery fuse plus ECB for battery circuit
****Overcurrent protection| ** Constant current limit under overload and short circuit conditions
Isolation| Input – earth – 2.5KVdc / Output – earth – 500Vdc
Efficiency| > 85%
Noise| <1%
Operating temperature| -20 to 50 °C ambient at full load
OVP| Over-voltage protection on output at ~130% of nominal output voltage
Humidity| 0 – 95% relative humidity non – condensing
Cooling| Fan cooled ( 2 fans)
**LED Indication| Green: Batt OK Green: Power OK
Flash code for different operating states
Alarms Relay| Form C contacts 30VDC,2A/110VDC,0.3A,125VAC, 0.5A
AUX (Activated by BCT, Fan fail/stall (toggle every 5 sec))
POWER (main fails, PSU fails)
BATTERY (batt missing , batt low, BCT fail)
Temp. Compensation| Temperature sensor on 1.7m lead with adhesive pad: -4mV/ °C / cell ± 10% (customizable)
Battery Charge Current Limit| ** Customizable on request.
**Battery Monitoring| ** Detects for presence of battery on start up, then every 60 minutes when charge current < 200mA
Battery Circuit Protection| Electronic circuit breaker (ECB) operates under the following conditions:
Low Battery Volts: Battery Voltage drops to 1.67V/cell
Overload: Max load must not exceed 110% of rated current. Peak loads must be connected to B+ & B– terminals.
Short Circuit: <2ms, backed up by fuse

OPTIONS

· RS485 (ASCII)
· Modbus RTU
· SNMP, Webpages
Digital Inputs/Outputs| Digital Input (pins 1,2) / Input or Output (pin 3) / Return (pin 4)
Battery Condition Test (BCT)| Option auto test enabled on start-up
Mounting| · Standalone
| · 19”Rack Mount . Optional V/I meter for subrack : SR-Meter
| · Wall – Floor Mount Cabinet
Internal Meter| Internal V/I meter displaying PSU operating states. Add code +INT-METER
N+1 Redundancy| Using 2 chargers & output diodes
Boost Charger| Customizable feature on request for boost charging capabilities
Conformal Coating| For harsh environments

STANDARDS

CUSTOMISED MODELS

internal V/I meter
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TERMS OF WARRANTY

Helios Power Solutions warrants this product for 24 months from date of shipment against material and workmanship defects. Liability under this warranty is limited to the replacement or repair of the defective product as long as the product has not been damaged through misapplication, negligence, or unauthorized modification or repair.

New Zealand: sales@heliosps.co.nz 
Australia: sales@heliosps.com.au
Middle East & Asia: sales@heliosps.asia

References

• SR Series - Downloads | Helios Power Solutions International
• SR Series - Downloads | Helios Power Solutions International
• SR Series - Downloads | Helios Power Solutions International

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