BEG, Mirza, Akmal (27 Hadley Road, Pepperell, MA, 01463, US)
GRENIER, Marcel, Bertrand (101 Penguin Avenue, East Greenwich, RI, 02818, US)
CHENNAKESAVAN, Venkatraman (170 Crosswinds Drive, Groton, MA, 01450, US)
KOTLYAR, Edward (936 Central Avenue, Needham, MA, 02492, US)
BEG, Mirza, Akmal (27 Hadley Road, Pepperell, MA, 01463, US)
GRENIER, Marcel, Bertrand (101 Penguin Avenue, East Greenwich, RI, 02818, US)
CHENNAKESAVAN, Venkatraman (170 Crosswinds Drive, Groton, MA, 01450, US)
CLAIMS
1 An uninterruptible power supply ("UPS") comprising an input module including a plurality of inputs, and at least one jumper element configured to selectively couple at least one input of the plurality of inputs to at least one other input of the plurality of inputs, wheiem the plurality of inputs and the at least one jumper element are constructed and arranged to selectively achieve the following configurations - single power feed, single phase input and single phase output, dual power feed, single phase input and single phase output, single power feed, thiee phase input and single phase output, dual power feed, three phase input and single phase output, single power feed, three phase input and three phase output, and dual power feed, three phase input and three phase output
2 The UPS of claim 1, wherein the plurality of inputs compπse thiee primary inputs Ll , L2 and L3 and three bypass inputs Bl, B2 and B3
3 The UPS of claim 2, wherein the at least onejumpei element compiises a bypass shorting jumper element configured to couple the thiee bypass inputs Bl , B2 and B3 to one another to achieve the dual power feed, three phase input and single phase output configuration
4 The UPS of claim 3, wherein the at least one jumper element further comprises a mam shortmgjumpei element configuied to couple the thiee pπmaiy inputs Ll , L2 and L3 to one another to achieve the dual power feed, single phase input and single phase output configuration
5 The UPS of claim 3, wherein the at least onejumpei element fuithei compπses a fϊist secondaiy jumpei element configuied to couple the pπmaiy input Ll and the bypass input Bl to one anothei to achieve the single powei feed, thiee phase input and single phase output configuiation
6. The UPS of claim 4, wherein the at least one jumper element further comprises a first secondary jumper element configured to couple the primary input Ll and the bypass input Bl to one another, a second secondary jumper element configured to couple the primary input L2 and the bypass input B2 to one another, and a third secondary jumper element configured to couple the primary input L3 and the bypass input B3 to one another to achieve the single power feed, single phase input and single phase output configuration.
7. The UPS of claim 2, wherein the at least one jumper element comprises a first secondary jumper element configured to couple the primary input Ll and the bypass input Bl to one another, a second secondary jumper element configured to couple the primary input L2 and the bypass input B2 to one another, and a third secondary jumper element configured to couple the primary input L3 and the bypass input B3 to one another to achieve the single power feed, three phase input and three phase output configuration.
8. The UPS of claim 2, wherein the dual feed, three phase input and three phase output configuration is achieved without the at least one jumper element coupled to any of the plurality of inputs.
9. The UPS of claim 3, wherein the plurality of inputs further comprise a neutral input and a ground input, and wherein each input of the plurality of inputs comprises at least one screw lug configured to secure a wire to each input.
10. The UPS of claim 9, wherein the ground input comprises at least two screw lugs positioned adjacent one another.
11. The UPS of claim 1 , wherein the at least one jumper element includes at least one blocking segment to selectively block the coupling of a wire to at least one of the plurality of inputs.
12. The UPS of claim 1 , further comprising an output module including a plurality of outputs and an output module jumper element configured to couple at least two outputs of the plurality of outputs to one another.
13. The UPS of claim 12, wherein the plurality of outputs comprises outputs Ll , L2 and L3.
14. The UPS of claim 13, wherein the plurality of outputs further comprise a neutral output and a ground output.
15. The UPS of claim 14, wherein the jumper element further couples the neutral output to at least one of the plurality of outputs.
16. The UPS of claim 12, further comprising a battery pack power distribution unit coupled to one of the plurality of outputs of the output power module.
17. A method of selectively achieving multiple power configurations in an uninterruptible power supply of the type comprising an input module having three primary inputs Ll , L2 and L3 and three bypass inputs B 1 , B2 and B3, and at least one jumper element configured to selectively couple at least one input of the plurality of inputs to at least one other input of the plurality of inputs, the at least one jumper element comprising a mam shorting jumper element configured to couple the three primary inputs Ll , L2 and L3 to one another, a bypass shorting jumper element configured to couple the three bypass inputs Bl , B2 and B3 to one another, a first secondary jumper element configured to couple the primary input Ll to the bypass input Bl , a second secondary jumper element configured to couple the primary input L2 to the bypass input B2, and a third secondary jumper element configured to couple the primary input L3 to the bypass input B3, the method comprising: installing the bypass shorting jumper element to achieve a dual power feed, a three phase input and a single phase output configuration.
18. The method of claim 17, further comprising installing the main shorting jumper element to achieve a dual power feed, a single phase input and a single phase output configuration
19. The method of claim 17, further comprising installing the first secondary jumper element to achieve a single power feed, a three phase input and a single phase output configuiation 20 The method of claim 17, further comprising installing the mam shorting jumper element, the first secondaiy jumper element, the second secondary jumper element and the third secondary jumper element to achieve a single feed, a single phase input and a single phase output configuiation
21 The method of claim 17, further comprising selectively blocking the coupling of a wire to at least one of the plurality of inputs using one of the jumper elements
22 A method of selectively achieving multiple power configurations m an uninterruptible power supply of the type comprising an input module having three primary inputs Ll , L2 and L3 and three bypass inputs Bl, B2 and B3, and at least one jumper element configuied to selectively couple at least one input of the plurality of inputs to at least one other input of the plurality of inputs, the at least one jumper element comprising a first secondaiy jumper element configuied to couple the primary input Ll to the bypass input Bl, a second secondary jumpei element configured to couple the pπmary input L2 to the bypass input B2, and a third secondaiv iumper element configured to couple the primary input L3 to the bypass input B3, the method comprising installing the fiist secondary jumper element, the second secondary jumper element and the third secondary jumper element to achieve a single power feed, a three phase input and a three phase output configuration
23 The method of claim 22, further comprising selectively blocking the coupling of at least one of the pluiahty of inputs
24 An unmteπ uptible power supply ("UPS ') comprising an input module including a pluiahty of inputs and means to selectively couple the inputs to achieve the following configurations - single powei feed, single phase input and single phase output, dual pow ei feed, single phase input and single phase output, single powei teed, tin ee phase input and single phase output, dual powei feed, thiee phase input and single phase output, single powei leed, thi cc phase input and thiee phase output, and dual powei feed thite phase input and thiee phase output 25 The UPS of claim 24, further comprising an output module including a plurality of outputs and an output module jumper element configured to couple at least one output of the pluiahty of outputs to at least one othei output of the plurality of outputs.
26. The UPS of claim 25, wherein the plurality of outputs comprise terminals Ll ,
L2 and L3.
27. The UPS of claim 26, further comprising a batteiy pack power distribution unit coupled to one of the plurality of outputs of the output power module.
28. The UPS of claim 25, further comprising an alternate power source coupled directly to the output module. |
INPUT AND OUTPUT POWER MODULES CONFIGURED TO PROVIDE SELECTIVE POWER TO AN UNINTERRUPTIBLE POWER SUPPLY
BACKGROUND OF THE INVENTION 1 Field of the Invention
Embodiments of the present invention are directed to power inputs and outputs used in a power system, and more particularly to a power input and a power output that may be selectively configured to accommodate changes in the power requirements of an uninterruptible powei supply
2 Discussion of Related Art
The use of an uninterruptible power supply or "UPS" to provide power to a critical load is well known in the art The UPS is designed to protect electronic equipment from utility power blackouts, brownouts, sags and surges The UPS may also protect electronic equipment from small utility fluctuations and large disturbances In most configurations, the UPS provides battery backup until utility power returns to safe levels or the battenes are fully discharged Known uninterruptible power systems include on-line UPSs and off-lme UPSs On-line UPSs provide conditioned AC power as well as backup AC power upon interruption of a primary source of AC power Off-line UPSs typically do not provide conditioning of input AC power, but do provide backup AC power upon interruption of the pπmary AC power source On-lme UPSs of the type described above are available from American Powei Conversion Corpoiation, West Kingston, Rhode Island under a variety of different trade names In certain configurations, a UPS may include an input circuit bieaker/filtei, a lectifier, a control switch, a controller, a battery, an inverter, and a bypass switch The UPS also may include an input for coupling to an AC power source and an output for coupling to a load
The on-lme UPS as desciibed may be configured to opeiate as follows The circuit breaker/filtei receives input AC power fiom the AC power souice thiough the input, filteis the input AC powei and piovides filteied AC powei to the rectifier The iectifiei iectifies the input voltage The contiol switch leceives the rectified power and also leceives DC power fiom the batteiy The contioller determines whether the power available fiom the iectifiei is within predetermined toleiances, and if so controls the contiol switch to provide the powei fiom the iectifiei to the mvertei If the pov\ ei fiom the iectifier is not within the predetei mined toleiances which may occui because of biownout oi blackout conditions, oi
due to power surges, for example, then the controller controls the control switch to provide the DC power from the battery to the inverter. The inverter of the UPS receives DC power and converts the DC power to AC power and regulates the AC power to predetermined specifications. Depending on the capacity of the battery and the power requirements of the load, the UPS can provide power to the load during brief power source dropouts or for extended power outages. The bypass switch is used to provide a bypass of UPS circuitry to provide the input power directly to the output. The bypass switch may be controlled by the controller to provide bypass of the UPS circuitry upon a failure condition of the UPS.
To provide further power redundancy, it is known to use a second power source to supply power to a bypass switch of a UPS from a second source of AC power. Systems of this type are often referred to as dual main systems, which are similar to the UPS described above except that it includes a second input to couple to a second power supply. The dual main UPS may include a bypass switch that selectively couples the second input directly to the output of the UPS. In dual main systems, typically, a utility power source is coupled to the first power input of the system and a backup power source, such as a generator or utility power from a different grid, is coupled to the second power input of the system. Upon failure of the utility power source, the power system is able to continue to provide power to a load using the battery mode of operation of the UPS, while the generator is powered on and brought to full output voltage. Once the generator is on line, the power system can continue to provide output power in a bypass mode for an extended period of time from the generator.
Power inputs and outputs for such systems are usually selected based on the user requirements for the particular UPS. For example, for systems requiring single phase input and single phase output, a UPS is selected to meet this requirement. Similarly, for systems requiring either three phase input and single phase output, or any other combination of input and output phases, a UPS meeting this requirement is selected. If power requirements change, a user must acquire a different UPS to meet the new requirement.
SUMMARY OF THE INVENTION
An aspect of the invention may be directed to an uninterruptible power supply ("UPS") comprising an input module including a plurality of inputs, and at least one jumper element configured to selectively couple at least one input of the plurality of inputs to at least one other input of the plurality of inputs. The plurality of inputs and the at least one jumper element may be constructed and arranged to selectively achieve the following configurations: single power feed, single phase input and single phase output; dual power feed, single phase
input and single phase output, single power feed, three phase input and single phase output, dual power feed, three phase input and single phase output, single power feed, three phase input and three phase output, and dual power feed, three phase input and three phase output
Embodiments of the UPS may include providing the plurality of inputs with three primary inputs Ll , L2 and L3 and three bypass inputs Bl, B2 and B3 The at least one jumper element may comprise a bypass shortmg jumper element configured to couple the three bypass inputs Bl , B2 and B3 to one another to achieve the dual power feed, three phase input and single phase output configuration The at least one jumper element further may compπse a mam shortmg jumper element configured to couple the three pπmary inputs Ll, L2 and L3 to one anothei to achieve the dual power feed, single phase input and single phase output configuration The at least one jumper element further may comprise a first secondary jumper element configured to couple the pπmary input Ll and the bypass input Bl to one another to achieve the single power feed, three phase input and single phase output configuration The at least one jumper element furthei may comprise a first secondary jumper element configured to couple the pπmary input Ll and the bypass input Bl to one another, a second secondary jumpei element configured to couple the primary input L2 and the bypass input B2 to one another, and a third secondary jumper element configmed to couple the pπmary input L3 and the bypass input B3 to one anothei to achieve the single power feed, single phase input and single phase output configuration The at least one jumper element may comprise a fust secondary jumper element configuied to couple the pπmary input Ll and the bypass input Bl to one another, a second secondary jumper element configured to couple the primary input L2 and the bypass input B2 to one anothei, and a third secondary jumpei element configured to couple the primary input L3 and the bypass input B3 to one another to achieve the single power feed, three phase input and three phase output configuration The dual feed, three phase input and three phase output configuiation may be achieved without the at least one jumper element coupled to any of the pluiahty of inputs The plurality of inputs further may comprise a neutral input and a ground input, and wherein each input of the pluiahty of inputs compiises at least one sciew lug configured to secure a wn e to each input The ground input may compiise at least two sciew lugs positioned adjacent one anothei The at least one jumper element may include at least one blocking segment to selectively block the coupling of a wne to at least one of the pluiahty of inputs The UPS furthei may compπse an output module including a plurality of outputs and an output module jumpei element configuied to couple at least two outputs of the pluiahty of outputs to one anothei The pluiahty of outputs may compiise outputs Ll , L2 and L3 The
pluiahty of outputs further may comprise a neutral output and a giound output The jumper element further may couple the neutral output to at least one of the plurality of outputs The UPS further may comprise a battery pack power distribution unit coupled to one of the pluiahty of outputs of the output power module Another aspect of the invention may be directed to a method of selectively achieving multiple power configurations m an uninterruptible power supply of the type comprising an input module having three pnmaiy inputs Ll, L2 and L3 and three bypass inputs Bl, B2 and B3, and at least one jumper element configured to selectively couple at least one input of the plurality of inputs to at least one other input of the plurality of inputs The at least one jumper element may comprise a mam shortmg jumper element configured to couple the three primary inputs Ll, L2 and L3 to one another, a bypass shorting jumper element configured to couple the three bypass inputs Bl , B2 and B3 to one another, a first secondaiy jumper element configured to couple the primary input Ll to the bypass input Bl , a second secondary jumper element configured to couple the primary input L2 to the bypass input B2, and a third secondary jumpei element configured to couple the pnmaiy input L3 to the bypass input B3 In one embodiment, the method may comprise installing the bypass shortmg jumper element to achieve a dual power feed, a three phase input and a single phase output configuration
In other embodiments, the method further may comprise installing the mam shortmg jumper element to achieve a dual power feed, a single phase input and a single phase output configuration The method further may comprise installing the fust secondary jumper element to achieve a single powei feed, a three phase input and a single phase output configuration The method further may comprise installing the mam shorting jumpei element, the first secondary jumper element, the second secondary jumper element and the thud secondary jumper element to achieve a single feed, a single phase input and a single phase output configuiation In another embodiment, the method may further comprise selectively blocking the coupling of a wne to at least one of the plurality of inputs using one of the jumpei elements
A further aspect of the invention may be directed to a method of selectively achieving multiple powei configuiations in an uninterruptible powei supply of the type comprising an input module having thiec pnmaiy inputs Ll . L2 and L3 and thiee bypass inputs Bl . B2 and B3, and at least one jumpei element configuied to selectively couple at least one input of the pluiahty of inputs to at least one othei input of the plurality of inputs The at least one jumpei element may compiise a fust secondaiy jumpei clement configuied to couple the
primary input Ll to the bypass input Bl , a second secondary jumper element configured to couple the primary input L2 to the bypass input B2, and a third secondary jumper element configured to couple the primary input L3 to the bypass input B3. In one embodiment, the method may comprise installing the first secondary jumper element, the second secondary jumper element and the third secondary jumper element to achieve a single power feed, a three phase input and a three phase output configuration.
Embodiments of the method may include selectively blocking the coupling of at least one of the plurality of inputs
Yet another aspect of the invention may be directed to an uninterruptible power supply ("UPS") comprising an input module including a plurality of inputs and means to selectively couple the inputs to achieve the following configurations: single power feed, single phase input and single phase output; dual power feed, single phase input and single phase output; single power feed, three phase input and single phase output; dual power feed, three phase input and single phase output; single power feed, three phase input and three phase output; and dual power feed, three phase input and three phase output.
Embodiments of the UPS may comprise an output module including a plurality of outputs and an output module jumper element configured to couple at least one output of the plurality of outputs to at least one other output of the plurality of outputs. The plurality of outputs may comprise terminals Ll , L2 and L3. In one embodiment, the UPS further may comprise a battery pack power distribution unit coupled to one of the plurality of outputs of the output power module. In another embodiment, the UPS further may comprise an alternate power source coupled directly to the output module.
BRIEF DESCRIPTION OF THE DRAWINGS For a better understanding of the present invention, reference is made to the drawing figures which are incorporated herein by reference and in which:
FIG. 1 is an exploded perspective view of an uninterruptible power supply ("UPS ' ') having a input power module and an output power module of embodiments of the invention removed from a mam body of the UPS; FIG. 2 is a rear clcvational view of the UPS having the input power module and the output power module secured to the mam body of the UPS:
FIG 3 is a rear perspective view of the input power module having a cover assembly removed to reveal an inteπoi of the input powei module:
FIG 4 is a front exploded perspective view of the input power module with the cover assembly shown pπor to its attachment to a housing of the input power module,
FIG 5 is a front elevational view of the input power module,
FIG 6 is a cross-sectional view of a wire connected to a screw lug, FIG 7 A is a rear perspective view of the output power module having a cover removed to reveal an interior of the output power module,
FIG 7B is a front perspective view of the output power module shown in FIG 7A
FIG 8 is a top plan view of the input power module showing a single feed, a single phase input and a single phase output configuration, FIG 9 is a top plan view of the input power module showing a dual feed, a single phase input and a single phase output configuration,
FIG 10 is a top plan view of the input power module showing a single feed, a three phase input and a single phase output configuration,
FIG 11 is a top plan view of the input power module showing a dual feed, a three phase input and a single phase output configuration,
FIG 12 is a top plan view of the input power module showing a single feed, a three phase input and a three phase output configuration,
FIG 13 is a top plan view of the input power module showing a dual feed, a three phase input and a thi ee phase output configuration, FIG 14 is a top plan view of the output power module showing a single phase hardwire output configuration,
FIG 15 is a top plan view of the output power module showing a thiee phase hardwire output configuration,
FIG 16 is a top plan view of the output power module showing a single phase output configui ation that is connected to a battery pack power distribution unit, and
FIG 17 is a schematic block diagram of the UPS of embodiments of the invention
DETAILED DESCRIPTION OF THE INVENTION
Foi the purposes of illustiation only, and not to limit the geneiality, the piesent invention will now be described in detail with iefeience to the accompanying figures This im ention is not limited m its application to the details of wmsti uction and the aiiangcmcnt of components set forth m the following desci iption oi illustrated in the di aw ings The invention is capable of othci embodiments and of being piacticed oi being earned out m λ aπous ways Also the phiaseology and teiminology used heiem is foi the puipose of
descπption and should not be regarded as limiting The use of "including," "comprising,' "having.' "containing," "involving," and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items
Embodiments of the invention provide an input module and an output module for use m a UPS, such as the UPS configurations descπbed above Embodiments of the invention can be used m systems and electronic devices, other than UPSs, that require electrical connections Still other applications of embodiments of the invention are envisioned
Refeiπng to FIGS 1 and 2, an uninterruptible power supply ("UPS") is shown and generally indicated at 10 The UPS 10 can be a domestic or an international UPS model sold by American Power Conversion Corporation of West Kingstown, Rhode Island, the assignee of the present invention As discussed above, a UPS assists in providing a substantially consistent flow of power from a power source to electronic devices that are connected to the UPS The UPS 10 includes a mam body 12 having a plurality of functional components housed withm the mam body FIGS 1 and 2 illustrate a rear panel 14 of the mam body 12 adapted to receive a power terminal input module generally indicated at 16 and a power terminal output module generally indicated at 18 The purpose of the input module 16 and the output module 18 is to provide electrical connections for peπpheral elect ical devices, while keeping wires of such devices sufficiently separated For example, peripheral electrical devices can include, but are not limited to, servers, HVAC devices, refrigeration devices, control panels and motoi controls, which are operated under the control of a conti oiler (not shown in FIGS 1 and 2) provided within the UPS
Refeπmg to FIGS 3 and 4, the input module 16 that can be used in a UPS is shown in perspective view with a pair of top covers 20, 22 removed in FIG 3 to show the inteπoi of the module As shown, the input module 16 includes a housing generally indicated at 24 having a bottom wall 26, two side walls 28, 30, a front 32 and a back wall 34, which togethei define an inteiior region of the housing An insert 36, which may be fabricated from any suitable haid plastic oi polymeiic mateπal, is disposed within the inteiior iegion of the housing 24 adjacent the fiont 32 of the housing The insert 36 may be suitably secuied to the housing 24 by sciew fasteners (not shown) and/oi integrated tabs that snap fit within openings or peiforations foimed in the bottom wall 26 and side walls 28, 30 of the housing Refeπmg to FIG 4, the anangement is such that the two top cover panels 20, 22, when secuied to the housing in the mannei shown, e g , by sciew fasteneis 38, completely enclose the mteπoi i egion of the housing 24
As best shown m FIGS 4 and 5, the insert 36 is configured at the front 32 of the housing 24 with seven socket terminals, each indicated at 40, and one pm terminal 42 The fiont 32 of the housing 24 of the input module 16 may be inserted and plugged into an input receptacle 44 provided in the UPS 10 m the manner illustrated in FIGS 1 and 2. As shown in FIG 5, the six left-hand socket terminals 40a, 40b, 40c, 4Od, 4Oe and 4Of are adapted to transfer a mam alternating cuπent ("AC " ) source and an auxiliary AC source to the UPS The remaining socket terminal 4Og and the right-hand pm terminal 42 are configured to connect a neutral wire and earth ground wires (both not shown), respectively, to the UPS 10 The interior region of the housing 24 of the input module 16 may be further configured to have eight stalls, each stall defining an electrical connection terminal.
Specifically, the terminals are designated Ll , L2, L3, Bl , B2, B3, N and G m FIGS 3 and 8- 13, with the six right-hand terminals (designated B3, B2, Bl, Ll , L2 and L3 from right to left m FIGS 3 and 8-13) being adapted to receive a mam AC source and an auxiliary AC source in the manner described in greater detail below Each of the six terminals Ll, L2, L3, Bl , B2 and B3 have a screw lug each indicated at 46 configuied to secure an electrical wire or cable (not shown) m a well-known manner The electrical wire may be crimped, screwed or otherwise fastened into a contacting position with the screw lug For electπcal and mechanical connection, the screw lugs 46 aie substantially exposed within their respective stalls As shown, the six right-hand terminals (i e , B3, B2, Bl , Ll, L2 and L3 in FIGS 3 and 8-13) may be positioned adjacent respective socket terminals (i e , 40a, 40b, 40c, 4Od, 4Oe and 4Of, lespectively) The two left-hand terminals (i e , N and G as shown in FIGS 8-13) are adapted to i eceive neuti al and ground wires (not shown) and correspond to the remaining socket terminal (i e , 4Og) and the pm teπninal (i e , 42) desciibed above As shown, the neutral N terminal includes two screw lugs 48, 50 and the ground terminal G includes four screw lugs 52, 54, 56 and 58 The provision of two sciew lugs 48, 50 within the neutral teimmal N and foui screw lugs 52, 54, 56 and 58 within the ground teimmal G enables the connection of the neutial and ground wires from both AC sources (main and auxiliary) with the foiwaid sciew lug (e g , screw lug 52) secured to the baie wire and the leaiward sciew lug (e g , sciew lug 54) secuied to the insulation in the manner illustrated in FIG 6 The securement of the leaiwaid screw lug to the insulation may piovide strain iehef to the wire or cable
Refeπing back to FIG 3, in a certain embodiment, the back wall 34 includes a back wall portion 60 and two side wall portions 62, 64, each side wall portion extending at an angle fiom opposite sides of the back wall portion The back wall 34 has foui ciicularly-
shaped, perforated cutouts, each indicated at 66, formed theiem As shown, two cutouts 66 aie formed on the back wall portion of the housing and each side wall portion (62, 64) has a cutout 66 formed therein The cutouts 66 are provided to be selectively removed from the back wall 34 of the housing 24 to enable cables or wires to pass therethrough for connection to the terminals Three tabs 68, 70 and 71 are provided to secure the input module 16 to the UPS 10 in the manner shown in FIG 2
Referring to FIGS 7A and 7B, the output module 18 includes a housing generally indicated at 72 having a front wall 74, two side walls 76, 78, a top wall 80 and a bottom 82, which together define an interior region of the housing The anangement is such that a cover 84, when secured to the housing 72, completely encloses the interior region of the housing Screw fasteners 86 may be provided to secure the cover 84 to the housing 72 The output module 18 is configured with seven pm terminals 87 provided m a formation 88 projecting from the front wall 74 of the housing, which is pluggable into a socket 90 provided m the UPS l O (FIG 1) An insert 92 is disposed within the mteπor region of the housing 72 The insert 92 may be suitably secured to the housing 72 by sciew fasteneis (not shown) and/or tabs that snap fit within openings or perforations formed in the fiont wall 74 and/or the side walls 76, 78 of the housing The pm terminals are designed to leceive conditioned power from the UPS
The mterioi legion of the housing 72 of the output module 18 may be further configured to have five stalls, each stall defining an electrical connection terminal, which correspond to five of the seven pm terminals desciibed above Specifically, the insert 92 of the output module may be configured with five socket teiminals corresponding to terminals L2, L2, L3, N and G shown m FIGS 14-16 In one embodiment, and as described above, the front wall 74 of the housing 72 may be configured with the seven pm terminals withm the formation 88 that enable the output module to be inserted and plugged into the output socket ieceptacle 90 provided m the UPS in the manner illustrated in FIG 1 Tabs, each indicated at 94, may be piovided to secui e the output module 18 to the UPS 10
As described above, the inseit 74 is piovided w ith five terminals, which coirespond to five of the seven pm terminals that are plugged into the UPS 10, each terminal having a sciew lug 96 configuied to secure an electrical wiie oi cable (not shown), which is connected to a ict such di> d computei, monitoi, pi inter seivei etc that is coupled to the UPS As with the input module 16 the electrical wne may be ci imped screwed or otherwise fastened into a contacting position with the sciew lug 96 IΌI electiical and mechanical connection the sciew lugs 96 aie substantially exposed within then respective stalls The thiee light-hand
terminals Ll , L2 and L3 may be configured to receive three phase wires The two left-hand terminals N and G are adapted to leceive neutral and ground wires, respectively This aspect of the invention will be discussed in greater detail with reference to the description of FIGS 14-16 below The remaining two pm terminals may serve to provide two different detection signals to the UPS 10 For example, the first signal may provide an indication whether the output module 18 is plugged into the UPS 10 When the output module is unplugged from the UPS, the UPS power output shuts down, thereby assuring safety at the output contacts Also, the UPS 10 output is not allowed to turn ON if the output module 16 is missing or not plugged in The second signal may be provided to indicate one or three phase distribution The presence of an output shorting jumper (as described below) indicates that the UPS 10 is configured for single phase output
In a certain embodiment, the top wall 80 of the housing 72 of the output module 18 includes a circulaily-shaped, perforated cutout 98 formed therein The cutout 98 is provided to be selectively removed from the top wall 80 of the housing 72 to enable cables or wnes to pass therethrough for connection to the terminals
Turning now to FIGS 8-13, the input module may be selectively configured to accommodate a variety of wiπng schemes In particular, FIG 8 illustrates a single feed, a single phase input and a single phase output configuration FIG 9 illustrates a dual feed, a single phase input and a single phase output configuration FIG 10 illustrates a single feed, a three phase input and a single phase output configuration FIG 1 1 illustrates a dual feed, a three phase input and a single phase output configuration FIG 12 illustrates a single leed, a three phase input and a three phase output configuration And finally, FIG 13 illustiates a dual feed, a three phase input and a thiee phase output configuration In a certain embodiment m ordei to achieve any one of the desired configurations, a kit of jumper elements may be pi ovided Specifically, by installing jumper elements m the manner described below, a desired configuiation may be achieved by a person installing the input module 16 When a shorting jumpei element is installed, the respective socket teimmals 40 aie connected in paiallel and the total alternating current ("AC ) is distiibuted equally among these paialleled teiminals In another embodiment, the jumpei elements may be replaced by a contiol such as a iotaiy switch oi lelays, to piovide the desned connections of the teimmals
Rcfeii ing fiist to FIG 8, to achieve a single powei feed, a single phase input and a single phase output configuiation, the input module 16 may be configuied with a mam shorting jumpei element 100 a bypass shorting jumpei element 102, and thiee secondaiy
shortmg jumper elements 104, 106 and 108 In a certain embodiment, the jumper elements 100, 102, 104, 106 and 108 may be secured to their respective terminals Ll , L2, L3, Bl, B2 and B3 in the manner descπbed below by screw fasteners (not shown) Single phase AC current provided by a main source may be connected by means of a wire, cable or other suitable flexible connector (referred to as a "wire" or "cable" herein) to screw lug 46 of terminal Ll This connection is represented by arrow HO m FIG 8 Arrows 112 repiesent the socket terminals 40a, 40b, 40c, 4Od, 4Oe and 4Of, which are connected m parallel The total AC current through the wire repiesented by arrow 110 is distributed among socket terminals Ll , L2, L3 oi Bl, B2, B3 depending on the UPS 10 mode of operation To complete the connection, the neutral wire is connected to sciew lugs 48, 50 and the ground wire is connected to screw lugs 52, 54 or 56, 58, which are provided on the neutral terminal N and ground terminal G, respectively Arrows 1 13, 1 14 represent the connection of the wires to the respective neutral and ground terminals, respectively Arrows 1 16, 1 18 represent the connection of the neutral and ground terminals to the UPS 10 via the socket terminal 40 (specifically 4Og in FIG 5) and the pin terminal 42
To prevent the unwanted connection of the single phase mam source wire to the other sci ew lugs 46 of the mam source connections, i e , terminals L2 and L3, the mam shortmg jumper element 100 is configured with two blocking segments 120, 122 As shown m FIG 3, the blocking segments 120, 122 extend along a generally vertical plane from the main shorting jumper element In one embodiment, the mam shortmg jumper element 100 and the blocking segments 120, 122 are fabiicated from a piece of stamped metal mateπal suitable to provide electrical communication between the terminals The blocking segments 120, 122, as with the blocking segments descπbed below, are sized so as to prevent the physical connection of a wne to the terminals L2 and L3 Similaily, to prevent the unwanted connection of the single phase mam source wire to the screw lugs 46 of the bypass source connections, i e , terminals B l , B2 and B3, the bypass shortmg jumper element 102 includes two blocking segments 124, 126 In addition, the three secondai y j umper elements each have a blocking segment to pi event the unwanted connection of the single phase mam souice wne to any of the bypass souice connections Specifically, the fust secondary jumpei element 104, which provides electiical communication between teiminals Ll and Bl , includes a blocking segment 128 to pi event access to tciminal B l The second secondai y jumpei element 106, which piovides electiical communication between teiminals L2 and B2, includes a blocking segment 130 to pi event access to teiminal B2 And lastly, the thud
secondary jumper element 108, which provides electrical communication between terminals L3 and B3, includes a blocking segment 132 to pi event access to terminal B3
Referring to FIG 9, to achieve a dual feed, a single phase input and a single phase output configuration, the input module 16 may be configured with the main shortmg jumper element 100 and the bypass shorting jumper element 102 As shown, single phase AC current provided by a main source is connected by means of a wire to the screw lug of terminal Ll This connection is represented by arrow 134 in FIG 9 Similarly, a single phase AC current by an alternate source is connected by a wne to the screw lug of terminal Bl This connection is represented by arrow 136 As described above, the alternate source may be taken from a second power source, e g , secondary AC power source, battery, generator, or any other suitable backup power source Aπows 138 represent the socket terminals 4Od, 4Oe, 4Of, which are connected in parallel The total AC cuπent provided by the mam power source through the wire represented by arrow 134 is distπbuted among socket terminals Ll , L2, L3 to the UPS 10 During bypass operation of the UPS 10, arrows 140 represent the socket terminals 40a, 40b, 40c, which are connected in parallel The total AC current piovided by the alternate power source thiough the wire iepresented bv arrow 136 distπbuted among socket terminals Bl , B2, B3 to the UPS 10 To complete the connection, the neutral and ground wires are connected to sciew lugs 48, 50, 52, 54, 56 and 58 provided on the neutral terminal N and the ground terminal G, respectively Aπows 142, 144 represent the connection of the wires to the respective neutral and ground terminals Arrows 146, 148 represent the connection of the neutral and ground terminals to the UPS 10 via the socket terminal 4Og and the pin terminal 42
To prevent the unwanted connection of the single phase mam souice wire to the other screw lugs 46 of the mam souice connections, i e , terminals L2 and L3, the mam shortmg jumper element 100 is configured with two blocking segments 120, 122 positioned m front of these terminals Similarly, to prevent the unwanted connection of the single phase alternate souice wne to the sciew lugs of the bypass souice connections, i e , terminals B2 and B3, the bypass shortmg jumper element 102 includes two blocking segments 124, 126 positioned m front of these terminals Refeirmg to FIG 10, to achieve a single feed, a thiee phase input and a single phase output configuiation the input module 16 may be configuied w ith the bypass shoiting jumpei element 102 and the fust secondary jumpei element 104 As shown thiee phase AC cuπent piovided by a mam source is connected by means of thiee wπes to the sciew lugs of teiminals Ll , L2 and L3 This connection is icpiesented by aπows 150 152 and 154 in FlG
10. Arrows 156, 158 and 160 represent the connection of the socket terminals corresponding terminals Ll , L2 and L3 to the UPS 10 (specifically, socket terminals 4Od, 4Oe and 4Of as shown in FIG. 5) and during bypass operation of UPS 10, arrows 156 represent the socket terminals 40, 40b, 40c, which are connected in parallel. The total AC current through the wire represented by arrow 152 is distributed among socket terminals Bl, B2, B3. To complete the connection, the neutral and ground wires are connected to the screw lugs provided on the neutral terminal N and ground terminal G, respectively. Arrows 162, 164 represent the connection of the wires to the respective neutral and ground terminals. Arrows 166, 168 represent the connection of the neutral and ground terminals to the UPS 10 via the socket terminal 40g and the pin terminal 42.
To prevent the unwanted connection of the three phase main source wires to the screw lugs of the alternate power source connections, i.e., terminals Bl, B2 and B3, the bypass shorting jumper element 102 is configured with two blocking segments 124, 126 positioned in front of two of the bypass terminals, e.g., terminals B2 and B3, and the first secondary jumper element 104 is configured with a single blocking segment 128 positioned in front of the remaining bypass terminal, e.g., terminal Bl .
Referring to FIG. 11, to achieve a dual feed, a three phase input and a single phase output configuration, the input module 16 may be configured with the bypass shorting jumper element 102 only. As shown, three phase AC current provided by a main source is connected by means of three wires to the screw lugs of terminals Ll, L2 and L3. This connection is represented by arrows 170, 172 and 174 in FIG. 11. Similarly, a single phase AC current by an alternate source is connected by a wire to the screw lug of terminal Bl . Arrow 176 represents this connection to terminal Bl . Arrows 178, 180, 182 represent the connection of socket terminals corresponding to teπninals Ll , L2, L3 to the UPS (specifically, socket terminals 4Od, 4Oe, 4Of, respectively, as shown in FIG. 5). Arrow 184 represent the socket teπninals 40a, 40b, 40c, which are connected in parallel. The total AC current through the wire represented by arrow 176 is distributed among socket teπninals Bl , B2, B3. To complete the connection, the neutral and ground wires are connected to the screw lugs provided on the neutral teπninal N and ground terminal G, respectively. Arrows 186, 188 represent the connection of the wires to the respective neutral and ground terminals. Arrows 190, 192 represent the connection of the neutral and ground teπninals to the UPS via the socket terminal 4Og and the pin terminal 42.
To prevent the unwanted connection of the single phase alternate source wire to the other screw lugs of the alternate source connections, i.e., terminals B2 and B3, the bypass
shotting jumper element 102 is configmed with two blocking segments 124, 126 positioned in front of these terminals
Referring to FIG 12, to achieve a single feed, a three phase input and a three phase output configuration, the input module 16 may be configuied with the first secondary jumper element 104, the second secondary jumper element 106 and the third secondary jumper element 108 As shown, three phase AC current provided by a mam power source is connected by means of three wires to the screw lugs of terminals Ll, L2 and L3 This connection is represented by arrows 194, 196 and 198 in FIG 12 Arrows 200, 202 and 204 represent the cuπent through the socket terminals corresponding to terminals Ll , L2, L3 (specifically, socket terminals 4Od, 4Oe, 4Of, respectively, as shown in FIG 5) to the UPS 10 or through the socket terminals corresponding to terminals Bl, B2, B3 (specifically, socket terminals 40a, 40b, 40c, as shown m FIG 5) depending on the UPS 10 mode of operation To complete the connection, the neutral and ground wires are connected to the screw lugs provided on the neutral terminal N and ground terminal G, respectively Arrows 206, 208 represent the connection of the wires to the respective neutral and ground terminals Arrows 210, 212 represent the connection of the neutral and giound terminals to the UPS 10 via the socket terminal 4Og and the pm teimmal 42
To prevent the unwanted connection of the three phase mam power source wnes to the screw lugs of the alternate source connections, i e , tennmals Bl, B2 and B3, the first, second and third secondaiy jumpei elements 104, 106, 108 aie configured with blocking segments 128, 130, 132, lespectively, which are positioned in front of these terminals As shown, the first, second and third secondary jumpei elements 104, 106, 108 may direct power fiom the mam AC source to the mam UPS circuit and to the bypass UPS circuit
Referring to FIG 13, to achieve a dual feed, a three phase input and a three phase output configuiation, the input module may be configured without any of the afoiementioned jumpei elements, i e , jumper elements 100, 102, 104, 106 and 108 As shown, three phase AC current piovided by a mam powei souice is connected by means of three wnes to the screw lugs of terminals Ll , L2 and L3 This connection is repiesented by arrows 214, 216 and 218 in FIG 13 Similarly, three phase AC cuπent piovided by a bypass source is connected by means of thiee wnes to the sciew lugs of tennmals Bl , B2 and B3 Anows 220, 222 and 224 iepiesent this connection Anows 226, 228, 230. 232, 234 and 236 iepiesent the connection of the socket tennmals coiiespondmg to terminals Ll , L2 L3, Bl , B2 and B3 to the UPS 10 (specifically, socket tennmals 4Od 40c, 4Of, 40a, 40b and 40c respectiN cly, as shown in FIG 5) To complete the connection, the neutial and giound wn es
aie connected to the screw lugs provided on the neutral terminal N and ground terminal G, respectively Aπows 238, 240 represent the connection of the wires to the respective neutral and ground terminals Arrows 242, 244 represent the connection of the neutral and ground terminals to the UPS 10 via the socket terminal 4Og and the pm terminal 42 Turning to FIGS 14-16, and more particularly to FIG. 14, to achieve a single phase output connection, the output module 18 may be configured with an output shortmg jumper element 246 In a certain embodiment, the output shortmg jumpei element 246 may be secured to terminals Ll, L2, L3 and N by screw fasteners As shown, single phase current is provided from the UPS 10 by means of pm terminals on Ll , L2 and L3, which are provided in the formation 88 projecting from the front wall 74 of the housing, and the output shortmg jumper element 246 The formation 88 is pluggable into the socket 90 provided m the UPS 10 (see FIG. 1) This connection is iepiesented by arrows 248 in FIG. 14 Arrow 250 represents the connection of the terminal corresponding to terminal L3 to a desired hardwired output It should be understood that the connection could be made either of the other two terminals Ll and L2 To complete the connection, the neutral and ground wires aie connected to screw lugs 96 provided on the neutral terminal N and ground terminal G, respectively Arrows 254, 252 represent the connection of the wnes to the i espective neutral and ground terminals to the output As described above, the wires represented by arrows 250, 252, 254 may be connected to any device requiring conditioned power For example, the device may include but is not limited to computeis, servers, auxihaiy devices, etc
The UPS 10 may be configured to communicate with sensors that measure voltages across all of the terminals Ll , L2, L3, Bl , B2 and B3 The information obtained from the sensors may be piocessed for determining as to the type of AC power source connected to the UPS, and for warning an operator of an improper configuration Referring to FIG 15, to achieve a three phase output connection, thiee phase cuπent is piovided fiom the UPS 10 by means of three pm terminals Ll , L2 and L3 of the output module 18 This connection is iepresented by aπows 256, 258, 260 in FIG 15 Anows 262, 264 and 266 represent the connection of the terminals corresponding to terminals Ll . L2 and L3, respectively to a desπed haidwired output To complete the connection, the neutial and neutial wnes aie connected to sciew lugs 96 provided on the neutral terminal N and giound tciminal G. lespectively Anows 268, 270 repiu>ent the connection of the wnes to the i espective neutial and giound terminals to the output
Refeiπng now to FIG 16, to achieve a single pha^e output connection to a batteiy pack powei distiibution unit ("PDU " ) 272 the output module 18 may be configuied with the
output shorting jumper element 246 As shown, single phase current is provided from the UPS 10 by means of a PDU connector to screw lug 96 of terminal Ll This connection is represented by arrow 276 in FIG 16 Arrow 278 repiesents the connection of the terminal corresponding to terminal Ll to the desired hardwired output As with the configuration illustrated in FIG 14, to complete the connection, a neutral connector 280 and a ground connector 282 associated with the battery pack 272 are connected to screw lugs 96 provided on the neutral terminal N and ground terminal G, respectively Arrows 284, 286 represent the connection of the connectors 280, 282 to the neutral and ground terminals, respectively Arrows 288, 290 represent the connection of the wires to the respective neutral and ground terminals to the desired hardwired output
As further illustrated m FIGS 14-16, the output module 18 may be provided with a strain relief bar 292 to secure the assist in preventing the unwanted or unintentional lemoval of the wires connected to the terminals
The output module 18, when provided with the output jumper element 246, provides single phase AC output When the output jumper element 246 is removed, the output module 18 may be wired to pi ovide three phase AC power to the desired hardwired output The UPS 10 may be configured to communicate with sensors that measure voltages across all of the terminals Ll , L2 and L3 and/or the output jumper element 246 of the output module 18 The information obtained fiom the sensors may be piocessed foi determining an impropei power configuration, and for warning an opei ator of the improper configuration
FIG 17 illustrates the operation of the input module 16 and the output module 18 within the UPS 10 FIG 17 illustiates schematically the input module 16, the output module 18, a converter 300 of the UPS 10, a battery 302, and a controller 304, which controls the operation of the UPS As discussed above, during normal operation, the UPS converter 300 is designed to covert utility power to conditioned powei for a connected load 306
As shown, power navels from a primary power source into and fiom the input module 16, to the UPS converter 300, and to the output module 18 along line 308 Dming a powei distuibance oi inteπuption, foi example, the UPS 10 may be configured to piovide powei to the connected load 306 via the output module 18 fiom the batteiy 302 (oi battenes) foi a finite peπod of time Specifically the UPS 10 transfers to battery operation if the supply of utility powei fails oi is outside piedefined limits As shown the batteiv 302 provides powei dnectly to the conveitei 300 along line 310 and to the output module 18
Pow ei tia\els fiom the pπmaiy (oi an alternate) pow ei souice mto and from the input module 16 around the UPS com eitei 300 and to the output module 18 along line 312
During bypass operation, bypass mode is reached either as a user selection or automatically under the control of the controller by employing a switch 314 For example, the UPS 10 may be configured with a display (not shown) that provides a menu screen to manually select the bypass mode. Alternatively, the controller 304 may be configured to automatically switch to bypass mode if, for example, the following conditions occur both normal and battery operation modes are unavailable, an output overload condition occurs, or if the UPS incurs an internal fault or trigger. As shown, during bypass operation, the utility power is connected to the load 306, bypassing the converter 300. If bypass mode becomes unavailable, the UPS will automatically switch to mam power In the event the mam power is unavailable, the controller 304 will switch to battery power
In one embodiment, a rotary switch may be piovided in place of the mam, bypass and supplemental jumpers. In another embodiment, the input module and the output module may be configured to provide split phase power. In yet another embodiment, the voltages of the terminals Ll, L2, L3, Bl, B2, B3 of the input module may be sensed and processed by the controller for determining the type of AC source connected and for determining and providing a warning to the operator of any improper configuration
Thus, it should be obseived that the UPS of embodiments of the invention may enable a system operator to have one UPS for different input and output power configurations, which ultimately i educes cost of ownership of the system, simplifies and reduces cost of manufactuπng, service, repair and installation In addition, the UPS of embodiments of the invention may be configured to accept AC power input from up to two separate sources In a first instance, the first source may be configured to eithei feed both the mam UPS circuit and the bypass UPS circuit in the case of a single feed application In a second instance, the first soui ce feeds the mam UPS ciicuit and the second source feeds the bypass UPS circuit in the case of a dual feed application Each ot these input soui ccs may be configured as one phase or three phases independently fiom each othei
Also, the UPS of embodiments of the invention may be configuied to have AC input and output jumpei s, and with respect to the input module, the input jumpeis may be furthei configuied to pi event the miswiπng of the input output module Based on all six input voltage measui ements and output phase configuiation jumpei a determination may be made of impiopci power configuiation
Having thus descπbed at least one lllustiativc embodiment of the invention, vaπous alteiations, modifications and impiovements will ieadih occui to those skilled in the ait
Such alteiations, modifications and impiovements die intended to be within the scope and
spirit of the invention Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's limit is defined only in the following claims and the equivalents thereto.
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