Industrial UPS

Industrial UPSs are regarded as fully customized power supply systems for rugged environments and designed particularly to safeguard critical loads in industrial applications where voltage transients, created by degraded mains supply, can seriously damage both UPS and the critical load.

Industrial UPS Systems are fully flexible and customizable and designed for active–on line installation between the power source, by-pass source and critical load where the inverter delivers regulated AC voltage and frequency to the load and rectifier delivers regulated DC voltage / current to the DC load at all times without interruption.

The power conversion process isolates the critical load from the normal mains disturbances and isolates the mains from load induced reflected harmonics affecting other loads connected to the input mains feeder. The rectifier converts AC power into DC to charge lead acid or nickel cadmium batteries; it also provides the necessary DC for continuously rated capacity of the inverter. IGBT semiconductor modules are used in PWM inverter and the control logic creates the precise sinusoidal output waveform with a very low harmonic content. Thyristor semiconductor modules are also used in rectifier for reliable operation.

The system consists of rectifier / charger, inverter, static bypass, maintenance bypass, rectifier isolation transformer, inverter isolation transformer, bypass line isolation transformer, automatic line stabilizer, DC distribution, AC distribution, controls and monitoring. The AC output of the inverter is connected to the critical load, the storage battery is connected between the inverter input and rectifier / charger output through a battery isolation MCB. The normal AC input power is connected to the rectifier; the bypass circuit also takes power from the same power source to provide power for the critical load during bypass operation when the system is in maintenance mode.

ASTOR Industrial UPS Systems are widely used in different industries such as Power Generation, Power Distribution, Power Transmission, Manufacturing, Transportation, Mining, Refining, Petrochemical Plants, Oil & Gas, Hospitals, Airports with different applications such as Gas Turbine Control, Switchgear tripping, Signalling, Alarms, Emergency Lighting, DCS (Distributed Control System) etc.

GENERAL
Model	KGK Series
Topology	Double Conversion Online System with Output Isolation Transformer
Control	Microprocessor Controlled System

GENERAL

Model

KGK Series

Topology

Double Conversion Online System with Output Isolation Transformer

Control

Microprocessor Controlled System

RECTIFIER
Topology	Full Bridge Phase Angle Controlled Thyristor Module Rectifier
Control	Microprocessor Controlled System
Isolation Transformer (OPTIONAL)	Galvanically Isolated
Nominal Input Voltage	110 VAC / 220 VAC / 230 VAC / 240 VAC / 380 VAC / 400 VAC / 415 VAC / 480 VAC ±15%
Nominal Input Frequency	50 hz. ±5% or 60 hz. ±5%
Input Cosφ	≥ 0.8 Inductive (6 Pulse) ≥ 0.85 Inductive (12 Pulse) ≥ 0.95 Inductive (12 Pulse with active harmonic elimination)
Total harmonic Distortion (THDi)	≤ 30% (6 Pulse), ≤ 10% (12 Pulse), ≤ 5% (12 Pulse with active harmonic elimination)
Nominal DC Voltage	110 VDC / 125 VDC / 144 VDC / 220 VDC / 264 VDC / 360 VDC
Battery Charging Principle	Constant Current / Constant Voltage
Float Charge Voltage (V/Cell)	2,4 Lead Acid Battery 1,60 NiCd Battery (Based on battery brand and type)
Boost Charge Voltage (V/Cell)	2.23 Lead Acid Battery 1,40 NiCd Battery Based (Based on battery brand and type)

Protections	Input: Thermic-Magnetic Over Current Protection, Over Voltage Protection, Phase Sequence Free Operation (3 Phase), Soft Start, MCB Output: Short Circuit Protection, Over Voltage Protection Battery: L-C filters, Overcurrent and Over Voltage Protection

Measurements	LCD Display for Line Voltage / Frequency / Current (Standard in 1 Phase, Optional for 3 Phase), Battery Output Voltage / Current, Load Output Voltage, Charger Total Output Current
Indicators	Float Mode, Boost Mode, Current Mode, Equalize Mode, Battery Ending, Low Battery, Battery Test Failure, Line Failure, Fan Failure, Over Voltage, Under Voltage, Over Temperature, Rectifier Failure, SCR Fuse Failure, Mains Available, Load MCB, Battery MCB
Adjustable Parameters	Float Charge Voltage, Boost Charge Voltage, Equalize Charge Voltage, Battery Charge Current, Rectifier Total Output Current, Low Battery Voltage Alarm, Earth Fault Leakage Current Alarm (only available in 4 line LCD), Battery Ending Voltage Alarm, Online Battery Test Parameters, Auto Boost Charge Parameters, Password
Event History	Last 250 events recorded and displayed on front panel and on PC via RS 232
Open or closed free alarm contacts	Low Battery, Mains Input Normal / Failure, Charger Failure, Overtemperature, Charger Overvoltage, Load MCB ON/ OFF, Battery MCB ON / OFF, Earth Fault
Sound Alarm	On Warning Messages 2 Short ‘beep’ per 2 seconds

RECTIFIER

Topology

Full Bridge Phase Angle Controlled Thyristor Module Rectifier

Control

Microprocessor Controlled System

Isolation Transformer (OPTIONAL)

Galvanically Isolated

Nominal Input Voltage

110 VAC / 220 VAC / 230 VAC / 240 VAC / 380 VAC / 400 VAC / 415 VAC / 480 VAC ±15%

Nominal Input Frequency

50 hz. ±5% or 60 hz. ±5%

Input Cosφ

≥ 0.8 Inductive (6 Pulse) ≥ 0.85 Inductive (12 Pulse) ≥ 0.95 Inductive (12 Pulse with active harmonic elimination)

Total harmonic Distortion (THDi)

≤ 30% (6 Pulse), ≤ 10% (12 Pulse), ≤ 5% (12 Pulse with active harmonic elimination)

Nominal DC Voltage

110 VDC / 125 VDC / 144 VDC / 220 VDC / 264 VDC / 360 VDC

Battery Charging Principle

Constant Current / Constant Voltage

Float Charge Voltage (V/Cell)

2,4 Lead Acid Battery 1,60 NiCd Battery (Based on battery brand and type)

Boost Charge Voltage (V/Cell)

2.23 Lead Acid Battery 1,40 NiCd Battery Based (Based on battery brand and type)

Protections

Input: Thermic-Magnetic Over Current Protection, Over Voltage Protection, Phase Sequence Free Operation (3 Phase), Soft Start, MCB Output: Short Circuit Protection, Over Voltage Protection Battery: L-C filters, Overcurrent and Over Voltage Protection

Measurements

LCD Display for Line Voltage / Frequency / Current (Standard in 1 Phase, Optional for 3 Phase), Battery Output Voltage / Current, Load Output Voltage, Charger Total Output Current

Indicators

Float Mode, Boost Mode, Current Mode, Equalize Mode, Battery Ending, Low Battery, Battery Test Failure, Line Failure, Fan Failure, Over Voltage, Under Voltage, Over Temperature, Rectifier Failure, SCR Fuse Failure, Mains Available, Load MCB, Battery MCB

Adjustable Parameters

Float Charge Voltage, Boost Charge Voltage, Equalize Charge Voltage, Battery Charge Current, Rectifier Total Output Current, Low Battery Voltage Alarm, Earth Fault Leakage Current Alarm (only available in 4 line LCD), Battery Ending Voltage Alarm, Online Battery Test Parameters, Auto Boost Charge Parameters, Password

Event History

Last 250 events recorded and displayed on front panel and on PC via RS 232

Open or closed free alarm contacts

Low Battery, Mains Input Normal / Failure, Charger Failure, Overtemperature, Charger Overvoltage, Load MCB ON/ OFF, Battery MCB ON / OFF, Earth Fault

Sound Alarm

On Warning Messages 2 Short ‘beep’ per 2 seconds

INVERTER
Topology	3 Full Bridge 6 high Frequency IGBT Inverter Modules (3 Phase); 1 Full Bridge 2 high Frequency IGBT Inverter Modules (1 Phase)
Isolation Transformer	Galvanically Isolated (standard)
Power Factor	0.8
Nominal Input Voltage	110 VDC / 125 VDC / 144 VDC / 220 VDC / 264 VDC / 360 VDC
Nominal Output Voltage	110 VAC / 220 VAC / 230 VAC / 240 VAC / 380 VAC / 400 VAC / 415 VAC / 480 VAC
Voltage Tolerance
Static	± 1%
Dynamic with 100% load change	± 10% in 50 msec.
Overload
Between 100% – 125%	10 min.
Between %125 – 150%	1 min.
Between %150 – 300%	1 sec.
Waveform	Pure Sinusoidal
Total harmonic Distortion (ThDv)
at Linear Load	< 3%
at Non-Linear Load	< 7%
Crest Factor	3 : 1 (1 second)
Nominal Output Frequency
While synchronized with the line	50 Hz / 60 Hz ±2%
While not synchronized with the line	50 Hz / 60 Hz ± 0.1%
Switching Frequency	16 Khz.
Short-circuit behaviour:	3 x Nominal Output Current
Protection	Short Circuit Protection, Over Voltage Protection, Under Voltage Protection, Over Current Protection and Over Temperature Protection
Front Panel Indicatiors	Inverter not Synchronized, Inverter DC Input High/Low, Bypass Out of Limit, Battery Fuse OFF, Bypass MCB OFF, DC Input MCB OFF, Inverter Overload, Internal Overtemperature, Inverter Failure, IGBT SCR Fuse Failure, Bypass Overtemperature Failure, Inverter Output High / Low, Inverter Overtemperature
Front Panel Set Menu	UPS Mode (UPS, ECO, Bypass Inhibit), DC Cut off, Low Battery Level, Output Voltage Adjustment, Set Output Frequency, Auto Start ON/OFF, Date, Alarm Sound ON/OFF, Password
Alarm Contacts (1 Open 1 Closed)	Inverter Failure, Overtemperature, Load on Bypass / Inverter, Inverter not Synchronized, DC Input Low /High, Battery Fuse OFF, Bypass out of Limit, Inverter Overload
Communication (OPTIONAL)	RS 485 / RS 232 / Ethernet Ports, Remote PC Control, Modbus, Profibus, SNMP, DNP 3.0 Protocols and TCP/IP options
Paralleling (OPTIONAL)	Parallel Redundancy

INVERTER

Topology

3 Full Bridge 6 high Frequency IGBT Inverter Modules (3 Phase); 1 Full Bridge 2 high Frequency IGBT Inverter Modules (1 Phase)

Isolation Transformer

Galvanically Isolated (standard)

Power Factor

0.8

Nominal Input Voltage

110 VDC / 125 VDC / 144 VDC / 220 VDC / 264 VDC / 360 VDC

Nominal Output Voltage

110 VAC / 220 VAC / 230 VAC / 240 VAC / 380 VAC / 400 VAC / 415 VAC / 480 VAC

Voltage Tolerance

Static

± 1%

Dynamic with 100% load change

± 10% in 50 msec.

Overload

Between 100% – 125%

10 min.

Between %125 – 150%

1 min.

Between %150 – 300%

1 sec.

Waveform

Pure Sinusoidal

Total harmonic Distortion (ThDv)

at Linear Load

< 3%

at Non-Linear Load

< 7%

Crest Factor

3 : 1 (1 second)

Nominal Output Frequency

While synchronized with the line

50 Hz / 60 Hz ±2%

While not synchronized with the line

50 Hz / 60 Hz ± 0.1%

Switching Frequency

16 Khz.

Short-circuit behaviour:

3 x Nominal Output Current

Protection

Short Circuit Protection, Over Voltage Protection, Under Voltage Protection, Over Current Protection and Over Temperature Protection

Front Panel Indicatiors

Inverter not Synchronized, Inverter DC Input High/Low, Bypass Out of Limit, Battery Fuse OFF, Bypass MCB OFF, DC Input MCB OFF, Inverter Overload, Internal Overtemperature, Inverter Failure, IGBT SCR Fuse Failure, Bypass Overtemperature Failure, Inverter Output High / Low, Inverter Overtemperature

Front Panel Set Menu

UPS Mode (UPS, ECO, Bypass Inhibit), DC Cut off, Low Battery Level, Output Voltage Adjustment, Set Output Frequency, Auto Start ON/OFF, Date, Alarm Sound ON/OFF, Password

Alarm Contacts (1 Open 1 Closed)

Inverter Failure, Overtemperature, Load on Bypass / Inverter, Inverter not Synchronized, DC Input Low /High, Battery Fuse OFF, Bypass out of Limit, Inverter Overload

Communication (OPTIONAL)

RS 485 / RS 232 / Ethernet Ports, Remote PC Control, Modbus, Profibus, SNMP, DNP 3.0 Protocols and TCP/IP options

Paralleling (OPTIONAL)

Parallel Redundancy

STATIC BY-PASS
Topology	Uninterruptible static switch with back-feed protection
Bypass System	No break semiconductor thyristor – thyristor
Isolation Transformer (OPTIONAL)	Galvanically Isolated
Nominal Frequency	50/60 Hz ± 2%
Inverter/Bypass transfer time
Inverter failure	Max. 5 msec.
Overload or manual transfer	0 msec.
Bypass/Inverter transfer time	0 msec.
Efficiency	>99%

STATIC BY-PASS

Topology

Uninterruptible static switch with back-feed protection

Bypass System

No break semiconductor thyristor – thyristor

Isolation Transformer (OPTIONAL)

Galvanically Isolated

Nominal Frequency

50/60 Hz ± 2%

Inverter/Bypass transfer time

Inverter failure

Max. 5 msec.

Overload or manual transfer

0 msec.

Bypass/Inverter transfer time

0 msec.

Efficiency

>99%

MECHANICAL BY-PASS
Topology	Make before break mechanical switch with locking system (OPTIONAL:External By-Pass Switch)

MECHANICAL BY-PASS

Topology

Make before break mechanical switch with locking system (OPTIONAL:External By-Pass Switch)

SAFETY & ENVIRONMENT
Over Voltage Protection	IEEE 587 4500 A, 110 Joules (standard) / 40kA Surge Arrestor (OPTIONAL)
Electrical Interference Reduction	FCC Part 15 Class B
Electrical Standards	IEC 62040-3 (Performance), EN 50091-1 (Security) / EN 50091-2 (EMC)
Protection Level / Color	IP 20 / RAL 7035 (Standard), (Higher IP rating and different colors are available, please consult)
MTBF	100,000 hrs. (w/out battery group)
Enclosure Material	Mild Steel, Zinc-phosphate coated; 100 µm electrostatic paint; 1.5 mm thickness
Cooling	Forced Fan (Standard) / Natural (OPTIONAL)
Cable Entry	Bottom (Standard) / Top (OPTIONAL)
Heater & Lightning	OPTIONAL
Distribution	OPTIONAL
Operating Temperature	-10 / +40 °C. (Higher operating temperatures are available, please consult)
Relative humidity	5 – 90 %
Operating Altitude	Max. 1000 Mt. (Higher altitudes requires de-rating, please consult )
Noise Level	Max. 60 db

SAFETY & ENVIRONMENT

Over Voltage Protection

IEEE 587 4500 A, 110 Joules (standard) / 40kA Surge Arrestor (OPTIONAL)

Electrical Interference Reduction

FCC Part 15 Class B

Electrical Standards

IEC 62040-3 (Performance), EN 50091-1 (Security) / EN 50091-2 (EMC)

Protection Level / Color

IP 20 / RAL 7035 (Standard), (Higher IP rating and different colors are available, please consult)

MTBF

100,000 hrs. (w/out battery group)

Enclosure Material

Mild Steel, Zinc-phosphate coated; 100 µm electrostatic paint; 1.5 mm thickness

Cooling

Forced Fan (Standard) / Natural (OPTIONAL)

Cable Entry

Bottom (Standard) / Top (OPTIONAL)

Heater & Lightning

OPTIONAL

Distribution

OPTIONAL

Operating Temperature

-10 / +40 °C. (Higher operating temperatures are available, please consult)

Relative humidity

5 – 90 %

Operating Altitude

Max. 1000 Mt. (Higher altitudes requires de-rating, please consult )

Noise Level

Max. 60 db

Industrial UPS

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