Mas Batt Rech GB r00

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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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SOCOMEC- SICON UPS (VILLAVERLA VI)
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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
Batt_Type
Capbat_Tot
Perc_Icblim
Num_El_Batt
Float_Volt_El
Temp_Comp_En
Delta_Temp
Batt_Char_Type
Perc_Vmax_El
Coeff_Temp
Batt_available
Description
Assist: All Parameters section
UPS Main Configuration Parameters
Type of battery
Battery Configuration
Total battery capacity
Recharge current limit
Number of elements in a battery leg
Recharge voltage per element
Enable temperature compensation
Battery delta temperature regulation
Recharge method
Advanced Battery Parameters
Maximum battery voltage
Battery elements
Compensation coefficient value
Advanced general parameters
Battery available
Dual level: this is the default method (Figure 2) used by Open Vented [1] and NickelCadmium [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.
EEprom Parameter
Batt_Type
Capbat_Tot
Perc_Icblim
Num_El_Batt
Float_Volt_El
Vbat_Rchrg_El
Vbat_Boost_El
Icblim_Boost
Batt_Char_Type
Perc_Vmax_El
Icb_Batt_Fl_Rech
Icb_Batt_Rech_Fl
Max_Rech_Time
Batt_available
Description
Assist: All Parameters Section
Type of battery
Recharge current limit
Floating voltage per element
Recharge voltage per element
Boost voltage per element
Boost current limit
Recharge method
Battery elements
Floating recharge switch over
Charge currents
Recharge floating switch over
Charge currents
Maximum recharge time
Charge currents
Battery available
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V/A
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2.4V/EL
2.23V/E
0.15*C
0.07*C
0.04*C
TIME
Dual Level Charge
V/A
1.7V/EL
1.41V/E
0.1*CA
12h
TIME
BOOST Charge
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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
T on
2.35 V/el
Umax
Umin
I1
I2
T off
Time
Voltage
Current
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 <15 C
15C < Temperature < 25C
Temperature 45 C
Ton = 2 * standard_Ton = 10 minutes

Ton = standard_Ton
Ton = standard_Ton /2
There is also an EEprom parameter that defines the ratio between the Ton and Toff current
limits.
Boost Charge: this is an automatic and periodic operation (every 120 days) that is carried out
to improve the battery charge. The duration (in hours) depends on the battery operating
temperature. See the ES/STE/0206 specifications. The time interval between two Boost
Charges can be configured on the Assist.
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Boost charging : x per year
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Step charge
Ton
2.35 V/el
Umax
Umin
I1
I2
(Ton / Ton_Standard) x 24 (h)
Time
Voltage
Current
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
Normal charge
Step charge
2.35 V/el
Umax
Umin
I1
I2
?
Time
T charge
Voltage
Current
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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EEprom Parameter
Batt_Type
Capbat_Tot
Num_El_Batt
Vbat_Equal_El
Batt_Char_Type
Perc_Vmax_El
Max_Icb_Equal_Rech
Min_Volt_Sc
Vbatt_El_Sc
Max_Volt_Sc
Perc_icblim_Sc
Idiv_Sc
Ton_Sc
T_Boost_Sc
T_Rest_Save_Sc
Toff_Ton_Sc
Batt_available
Description
Type of battery
Equalisation voltage per element
Recharge method
Battery elements
Recharge current limit for equalisation
Charge currents
Minimum Step Charge voltage(Toff)
Step charge mode
Step Charge voltage (Ton) per element
Step charge mode
Maximum Step Charge voltage
Step charge mode
Current limit duringTon
Step charge mode
Ton and Toff current limit ratio
Step charge mode
Ton duration
Step charge mode
Interval in days between 2 Boost Charges
Step charge mode
Wait for first Boost Charge
Step charge mode
Ratio between Toff and Ton
Step charge mode
Battery available
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)
Step Charge (>=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
Recharge method
Charge Phase
Floating
Maintenance
Boost Charge
Second level
Equalisation
Deep charge
Forming
2.27
Step
Charge
2.35
2.35
Float
2.27
2.35
2.35
BMS
St.Ch.
2.35
2.35
2.35
Open Vent Lead

Recharge
method
Dual level
Ni-Cd
Recharge
method
Dual level
2.23
1.4
2.4
1.45
2.55
2.7
1.65
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 <15 C
Temperature 45 C
48 hours
24 hours
12 hours
6 hours
2 hours
FORCING THE STEP CHARGE:

When the Floating method is used in the event of a BMS (Automatic) charge at temperatures
lower than 25C, and if this single level charge lasts for a period of over 3 months, the logic will
run a control cycle on the Toff/Ton and if necessary launch the equalisation charge.
When the three months have expired, the Step Charge method is forced so as to control the
Toff/Ton. A 4-hour time interval is left before making the calculation.
Figure 4 below shows the equalisation charge activation logic.
Note that the automatic battery test is run after two consecutive Toff/Ton cycles that give a
negative result. No Toff/Ton calculations are carried out during the cycles.
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Ton/Toff Sub program
No
A<X
Yes
Boost charge
X is an EEprom settable
parameter (between 1 and 256)
Ton/Toff Sub program
The default value is 3

No
A>X
Yes
Battery test
No
Battery Failure alarm
Test OK
Yes
Battery weak alarm
Figure 4
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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

EEprom Parameter
Description
Assist: All Parameters section
Minimum voltage per element (IoutNom)
Pre-minimum voltage per elem. (IoutNom)
Minimum voltage per element (Iout = 0A)
Pre-minimum voltage per elem. (Iout =
0A)
Vmin_El_final
Vpremin_El_final
Vmin_El_init
Vpremin_El_init
Graph showing pre-minimum and minimum battery voltage thresholds:

Battery voltage in function of discharge current
2.00
1.90
V/elem. (V)
1.80
Preminima
Minima
1.70
1.60
1.50
1.40
1.30
1.20
0
10
20
30
40
50
60
70
80
90
100
110
Nominal current (%)
Default:
Vmin_El_final
Vpremin_El_final
Vmin_El_init
Vpremin_El_init
1.65V/el
1.80V/el
1.73V/el
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

4000
3500
3000
Iout [mA]
2500
2000
1500
1000
500
0
0
10
20
30
40
50
60
70
80
90
100
Duty cycle [%]

V=185
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V=265
V=345
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75
80
60-80KVA recharge curve

14.00
13.00
12.00
11.00
10.00
9.00
Iout [A]
8.00
7.00
6.00
5.00
4.00
3.00
2.00
1.00
0.00
0
10
15
20
25
30
35
40
45
50
55
60
65
70
85
90
95
100
Command PWM duty cycle
V=175
V=248
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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
220
210
200
Vbatt
190
180
170
160
150
140
68
73
78
83
88
93
98
Max. duty cycle
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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
3700
3600
3500
Iout [ mA]
3400
3300
3200
3100
3000
2900
2800
2700
140
190
240
290
340
390
Vbatt
MASTERYS 15-40KVA
Curva
carico peron
tarature
Iout
(A) depending
VBatt a 300 e 280
Iout
9,5
9,4
9,3
9,2
9,1
9
8,9
8,8
8,7
8,6
8,5
8,4
8,3
170 180
190 200 210 220 230
240 250 260 270 280
290 300 310 320 330
Vbatt
Duty
Taratura 280V
MASTERYS 60-80KVA
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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.
No alarms
Output on inverter
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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EEprom Parameter
Test_Interval
Batt_Test_Enable
Interval_Batt_Test
Description
Interval between two scheduled tests
Battery Advanced Parameters
Enable the battery test
Interval between any two Tests

Output on inverter
Mains power available for at least 12 hours
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

Battery Voltage (V/elem.)
2.10
2.00
1.90
1.80
1.70
1.60
1.50
1.40
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)

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).
CSB HR1234WF2
12,8
12,6
12,4
VBATT V
12,2
I=22A
12
I=8,5A
11,8
11,6
11,4
11,2
60
70
80
90
100
% CAPACITY
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.
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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.
IRect_Max
IRectifier
Ref CB
Total battery charger
+
IBattery
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.
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EEprom Parameter
BattCurr_Derating
Description

Threshold value signalling that Derating is
in progress
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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
OVERTEMPERATURE
THE
BATTERY
CHARGER
AGAINST
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.
22 of 22

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BATTERIES AND RECHARGING METHODS

SOCOMEC- SICON UPS (VILLAVERLA VI)

BRIEF DESCRIPTION OF RECHARGING METHODS:

SOCOMEC- SICON UPS (VILLAVERLA VI)

Dual Level Charge

SOCOMEC- SICON UPS (VILLAVERLA VI)

Ton = 2 * standard_Ton = 10 minutes

SOCOMEC- SICON UPS (VILLAVERLA VI)

Boost charging : x per year

SOCOMEC- SICON UPS (VILLAVERLA VI)

The following EEprom parameters must be set:

Open Vent Lead

SOCOMEC- SICON UPS (VILLAVERLA VI)

FORCING THE STEP CHARGE:

SOCOMEC- SICON UPS (VILLAVERLA VI)

Ton/Toff Sub program

Ton/Toff Sub program

The default value is 3

SOCOMEC- SICON UPS (VILLAVERLA VI)

Calculating back up time

SOCOMEC- SICON UPS (VILLAVERLA VI)

MINIMUM AND PRE-MINIMUM BATTERY VOLTAGES

Graph showing pre-minimum and minimum battery voltage thresholds:

Nominal current (%)

SOCOMEC- SICON UPS (VILLAVERLA VI)

Iout [mA] depending on regulation duty cycle

Duty cycle [%]

SOCOMEC- SICON UPS (VILLAVERLA VI)

60-80KVA recharge curve

Command PWM duty cycle

SOCOMEC- SICON UPS (VILLAVERLA VI)

Calculating the battery discharge current

Comments on the battery charger characteristics

Max. duty cycle

SOCOMEC- SICON UPS (VILLAVERLA VI)

190 200 210 220 230

240 250 260 270 280

290 300 310 320 330

SOCOMEC- SICON UPS (VILLAVERLA VI)

SOCOMEC- SICON UPS (VILLAVERLA VI)

The following EEprom parameters must be set:

The test can be run in the following conditions:

SOCOMEC- SICON UPS (VILLAVERLA VI)

Results of the test:

Minimum and Pre-minimum in Battery Test

Battery Current (Amp./Cap)

SOCOMEC- SICON UPS (VILLAVERLA VI)

Checking the Battery voltage during the Battery Test:

SOCOMEC- SICON UPS (VILLAVERLA VI)

PARALLEL BATTERY CHARGER

Total battery charger

Ibattery= Irect Max-IRectifier,

SOCOMEC- SICON UPS (VILLAVERLA VI)

Advanced Battery Parameters

Assist: All Parameters Section

SOCOMEC- SICON UPS (VILLAVERLA VI)

BATTERY CHARGER SWITCH ON LOGIC

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

SOCOMEC- SICON UPS (VILLAVERLA VI)

Slow discharge protection

Batteries Disconnected Alarm (15-40kVA)

SOCOMEC- SICON UPS (VILLAVERLA VI)