GB2505646A - Connector for an uninterruptible power supply - Google Patents

Abstract

A plug connector 10 for an uninterruptible power supply (UPS) 1 comprises a connector housing 14 which houses the terminals of at least two UPS power connections 15, 16, 17 and the terminals of at least one UPS signal line 12. The UPS connector ensures the safe connection of the power and signal terminals by preventing the positions of the terminals from being altered. Further, due to the fact that multiple terminals are contained within a single housing, the time for connecting and disconnecting a module to the UPS via the plug connector is shorter, as there is no need to connect the power lines and the signal lines one after another. Preferably, each UPS power connection comprises at least one phase conductor and a neutral line in addition to a signal line. The UPS connector is also preferably adapted to be connected to a maintenance bypass module 2.

Description

Plug connector of an uninterruptible power supply and UPS connector arrangement The present invention disclosure refers to a plug connector of an uninterruptible power supply (UPS), comprising a connector housing, and to a UPS connector arrangcmcnt, comprising at least one plug connector according and at least one connector socket adapted to receive the plug connector.

For certain kinds of load devices driven by electric power, such as computers, semiconductor manufacturing lincs, or medical dcviccs, it is not acceptable to bc stopped even for a momcnt, because of their functional and versatile importance. Such load devices arc therefore provided with an uninterruptible power supply unit (abbreviated as UPS hereafter) between the power supply and the load devices so that emergency power is supplied to the latter during a prede-termined period even when the power supply fails.

Certain parts comprised in a UPS, such as a battery, a cooling fan and the like, have a shorter service life compared to other parts. For maintaining normal operation of a UPS, it is neees- sary to regularly or, if it is required, check and replace certain parts with new ones, or to re-place the complete UPS with new one.

During maintenance, an alternate UPS is used instead of the regularly used UPS which is dis- connccted from the load dcvice. After thc maintenance of the rcgularly used UPS is complct-ed, the alternate UPS is replaced with the regularly used UPS again. However, as described above, some kinds of load devices, such as computers can not accept any stoppage, even for a moment. Thus, it is necessary to replace a part or whole of the UPS with a new one without stoppage of power supply to the load device even when replacing it with a new one. Hence, in order to avoid such stoppage, a maintenance bypass device (MBP) is connected between the power supply and the UPS so that it continues to supply power to the load device or devices during replacing the UPS with a new one.

According to US 2010/0 187908 Al, a maintenance bypass device capable of achieving safety and efficiency in replacing work of a UPS is provided. The maintenance bypass device is equipped between a power supply and a load device and in parallel with an uninterruptible power supply unit, and supplies power from the power supply to said load device when the uninterruptible power supply unit is being detached. In the maintenance bypass device, the connection portions of connecting wires connected to the uninterruptible power supply unit are disposed on a front panel disposed on the front side and are a connector type that enables the connection portions to be connected to and disconnected from the connection wires with-out using a tool.

It is desirable to shorten time for performing wire connections between the devices as to effi-ciently connect electric devices and/or disconnect them. However, regulations for operational safety have to be met as well. It is an object of this invention to provide a plug connector of an uninterruptible power supply (UPS) and a UPS connector arrangement, respectively, that meet operational safety requirements and allow for faster connection operations.

The objective is achieved by a plug connector according to claim I and a UPS connector ar- rangement comprising the plug connector. Preferred embodiments are described in the de-pendent claims.

The plug connector of an uninterruptible power supply comprises a connector housing. Ac-cording to the invention, terminals ofat least two UPS power connections and terminals ofat least one UPS signal line are installed in the connector housing. This is a UPS specific con-nector with both signal and power built-in. As there is no way of changing the positions of the power connections or the signal line, the plug connector according to the invention allows safe connecting operations. Further, the time for connecting and disconnecting a module to the UPS via the plug connector according to the invention is shorter, as there is no need to connect the power lines and the signal lines one after another. Particularly, each UPS power connection comprises at least one phase conductor and a neutral line.

According to a preferred embodiment, the UPS power connections comprise a UPS power output, a UPS power input and a UPS bypass power input. The UPS is preferably designed for a power range of 8 WA to 11 kVA.

An advantageously safe embodiment provides that the terminals of the UPS power output and the terminals of the at least one signal line are protected by a protective wall, the protective wall surrounding the terminals.

According to another preferred embodiment of the plug connector, the terminals of the liPS power input and the UPS power input bypass are protected by a slidable shroud. The slidable shroud is preferably resiliently loaded towards a protective position. More preferable, the slidable shroud is loaded towards a protective position by two coil springs. Furthermore it is preferred, that the slidable shroud is detachably arrested in a protective position by a clip. It is an advantage that the slidable shroud covers the terminals, so an operator cannot get into con-tact with the terminals. To unlock the slidable shroud, the clip has to be manipulated which provides a two-hand operation to increase safety when connecting the UPS to a device mod-ule.

According to yet another preferred embodiment of the plug connector, the connector housing is substantially comprised of two half shells, the two half shells forming an opening at a rear part of the connector housing, which is arranged opposite to the side from which the terminals extend, the opening being adapted for an insertion of the cables of the UPS power connections and the signal line. The rear part of the connector housing is preferably completed by a central portion substantially closing the opening and thus forming a plurality of smaller collets, one for each of the TIPS power connections and for the UPS signal line. The rear part of the con-nector housing is preferably inclined by 45 degree to advantageously avoid bending of the UPS power connections and the signal line. The connector housing preferably comprises at least one unloosable screw to fix the connector housing to a connector socket.

Preferably, the connector housing is adapted to be connected to a connector socket of a maintenance bypass module. According to yet another preferred embodiment of the plug con-nector, an unloosablc screw is arranged on the connector housing for securing thc connection to the connector socket.

A further object of the invention, that achieves the objective, is a UPS connector arrangement, comprising at least one plug connector according to the invention and at least one connector socket adapted to receive the plug connector.

A preferred embodiment of the UPS connector arrangement comprises three power connec-tion cables and one signal line cable, at least the power connection cables being connected to the UPS by hard wiring.

According to another preferred embodiment of the UPS connector arrangement, the connector socket comprises socket terminals for contacting the plug terminals, wherein the connector socket comprises a socket protective wall for shielding the socket terminals. Preferably, the socket waH is adapted to push back the slidable shroud of the plug connector, after the shroud has been released by manipulating the clip. Furthermore preferred, the connector socket com-prises a recess to accommodate the protective wall extending from the connector housing. Yet furthermore preferred, the connector socket comprises inner protective walls dividing the socket terminals into groups.

According to yet another preferred embodiment of the UPS connector arrangement, the con-nector socket comprises at least one screwed coupling for at least one screw of the connector plug to provide a mechanical link.

According to yet another preferred embodiment of the UPS connector arrangement, the con-nector socket comprises a pivotably supported door, which is biased towards a closed position by torsion springs, wherein the socket terminals arc covered by the cover lid in the closed position.

The invention will further be described with respect to the embodiment shown in the drawing sheets.

In the Figures: Fig. I shows an uninterruptible power supply connected to a maintenance bypass device by a UPS connector arrangement according to an embodiment of the invention;

S

Fig. 2 depicts the UPS connector arrangement of Fig. 1 in a disconnected state, illustrating an embodiment of the plug connector according to the invention and a connector socket in detail.

Fig. 3 shows a front view of the plug connector of Fig. 2; Fig. 4 shows the plug connector of Fig. 2 in a perspective view with the connector housing parts separated; Fig. 5 shows a front view of the connector socket of Fig. 2; Fig. 6 -8 show a connector arrangement in different views.

In Fig. 1, an unintcrruptiblc power supply 1 for a power range of 8 to 11 kVA is illustrated in a perspective view, seen from the rear part of the UPS 1. Attached to the rear wall of a ex- tended battery module 3, there is a maintenance bypass module 2, which is a device that al-lows the UPS 1 or an internal battery of the UPS I to be removed from a system (not shown), while still providing unintcrruptible power to a load (not shown). The maintenance bypass module 2 is an advantageous supplement for the UPS I. If maintenance needs to be performed on the system, the UPS 1 can be easily removed without requiring the load to be shut off This is critical for any loads that cannot be interrupted.

The UPS 1 comprises three UPS power connections 15, 16, 17 and a UPS signal line (12, cf Fig. 2), which are connected to the maintenance bypass device 2, coupled by a UPS connector arrangement according to an embodiment of the invention. The UPS connector arrangement comprises a plug connector 10 with a connector housing, which is described in more detail with respect to Fig. 2.

In Fig. 2, the plug connector 10 and the connector socket 20 are shown in a disconnected state and in greater scale. As can be seen in Fig. 2, the terminals of the three UPS power connec-tions 15, 16, 17 and terminals of the UPS signal line 12 are installed in the connector housing 14. Each UPS power connection 15, 16, 17 comprises at least one phase conductor and a neu-tral line. In the embodiment shown, the UPS power connections are a UPS power output 15, a UPS power input 16 and a UPS bypass power input 17. Further, the UPS connector arrange- ment comprises a connector socket 20 adapted to receive the plug connector 10, which con- nector socket 20 is mounted in a housing of the maintenance bypass unit 2. The plug connect-or 10 is described in more detail with respect to the following Fig. 3 and 4. The connector socket 20 is described in more detail with respect to Fig. 5 later.

Fig. 3 shows a front view of the plug connector 10, with four terminals 112 of the UPS signal line and two female bullet terminals 113 of the UPS power output 15 being protected by a protective wall 18. Four male bullet terminals 114 of the UPS power input 16, arranged in a middle row, two male bullets 115 of the UPS bypass power input 17, and one long male bullet terminal 116, which serves as a common ground for the UPS power connections, are protect- ed by a slidable shroud 30, which is arrested in a closed position. The slidable shroud is un- locked by operating a clip 32. The signal line 12 comprises a signal cable with a known con-nector, like for example, an RJ1 1 connector (not shown), which is plugged to the UPS 1 via a female RJI I connector on the UPS rear panel (Fig. 1). This permits the signal information exchange between maintenance bypass module 2 and UPS 1, to give to UPS 1 the information of maintenance bypass module 2 detection, and a detection about the mode of the mainte- nance bypass module 2, i.e. normal operation or bypass operation. The two female bullet ter-minals 113 provide one phase and one neural line of the UPS power output 15, the four male bullet terminals 114 provide three phases and one neutral line of the UPS power input 16 and the two male bullets 115 in the bottom row provide one phase and one neutral line of the UPS bypass power input 17. [he common ground male bullet terminal 116 is longer than the rest of the male bullet terminals, which ensures that the ground line is connected first.

In Fig. 4, the connector housing 14 is depicted with two half shells 33 of the housing disas-sembled. The two half shells 33, form an opening at a rear part of the connector housing 14, which is arranged opposite to the side from which the terminals extend, the opening being adapted for an insertion of the cables of the UPS power connections (15, 16, 17, Fig. 2) and of the signal line (12, Fig. 2). The rear part of the connector housing 14 is completed by a central portion 35 substantially closing the opening and thus forming a plurality of smaller collets 36, one for each of the UPS power connections and for the UPS signal line. The slidable shroud is guided in the connector housing 14 and it is loaded towards a protective position by two coil springs 31. The connector housing 14 further comprises an unloosable screw 19 to fix the connector housing 14 to a connector socket (20, Fig. 5) of a maintenance bypass module (2, Fig. 1).

The UPS connector arrangement according to the embodiment comprises the plug connector 10 and the connector socket 20 adapted to receive the plug connector, which is now described with respect to Fig. 5. The connector socket 20 comprises socket terminals 21 for contacting the plug terminals (112 -116) and it comprises a socket protective wall 22 shielding the socket terminals 21. A recess 27 is provided to accommodate the protective wall 18 extending from the connector housing 14. The socket protective wall 22 is adapted to push back the slidable shroud 30 of the plug connector 10. The connector socket 20 further comprises a pivotably supported door 23, which is biased towards a closed position by torsion springs (24). The connector socket 20 comprises at least one screwed coupling 29 for at least one screw 19 of the connector plug 10 to provide a mechanical link.

The protective walls 18, 22 and the slidable shroud 30 advantageously prevent that an opera- tor's finger gets into contact with one of the terminals. The Fig. 6-8 show another UPS con- nector arrangement, comprising a plug A and a connector socket B. The connector arrange- ment of Fig. 6 -8 is intended to illustrate the properties of protective walls and is not an em-bodiment according to the invention. The protective walls are provided in the form of specific ribs C to comply with safety rules, and in particular the safety pin tool test, wherein direct electrical contact has to be avoided between a safety pin tool (not shown) and the internal electrical terminals of the connector (IEC 60-950 standard).

Reference Numerals Uninterruptible power supply, UPS 2 Maintenance bypass module 3 External battery module Plug connector 112-116 TerminaLs 12 UPS signal line 14 Connector housing UPS power connection, UPS power output 16 UPS power connection, UPS power input 17 UPS power connection, UPS bypass power input 18 Protective wall 19 Unloosable screws Connector socket 21 Socket terminals 22 Connector protective wall 23 Door 24 Torsion springs 27 Recess 29 Screwed couplings Slidable shroud 31 Coil springs 32 Clip 33 Half shells Central portion 36 Collets A Plug B Socket C Ribs

Claims (15)

1. Claims 1. Plug connector (10) ofan uninterruptible power supply (1), with a connector housing (14), characterised in that temiinals (11) ofat least two UPS power connections (15, 16, 17) and tcrminals of at icast one UPS signal linc (12) arc installcd in the conncctor housing.
2. 2. Plug conncctor according to claim 1, charactcriscd in that cach UPS powcr connection (15, 16, 17) comprises at least one phasc conductor and a neutral line.
3. 3. Plug connector according to claim 1, characterised in that the UPS power connections comprise a UPS power output (15), a UPS power input (16) and a UPS bypass power input (17).
4. 4. Plug connector according to any one of the preceding claims, characterised in that the ter-minals of the UPS power output (15) and the terminals of the at least one signal line (12) are protected by a protective wall (18).
5. 5. Plug connector according to any one of the preceding claims, eharacterised in that the ter-minals of thc UPS bypass power input (17) and of the UPS power input (16) arc protected by a slidable shroud (30).
6. 6. Plug connector according to claim 5, characterised in that the slidable shroud (30) is resili-ently loaded towards a protective position.
7. 7. Plug connector according to any onc of claims 5 or 6, characterised in that the slidable shroud (30) is loaded towards a protective position by two coil springs (31).
8. 8. Plug connector according to any one of claims 5 to 7, characterised in that the slidable shroud (30) is detachably arrested in a protective position by a clip (32).
9. 9. Plug connector according to any one of the preceding claims, characterised in that the con-nector housing (14) is substantially comprised of two half shells (33), the two half shells forming an opening at a rear part of the connector housing, which is arranged opposite to the side from which the terminals extend, the opening being adapted for an insertion of the cables of the UPS power connections (15, 16, 17) and of the signal line (12).
10. 10. Plug connector according to claim 9, characterised in that the rear part of the connector housing (14) is completed by a central portion (35) substantially closing the opening and thus forming a plurality of smaller collets (36), one for each of the UPS power connections (15, 16, 17) and for the UPS signal line (12).
11. 11. Plug connector according to any one of the preceding claims, charactcrised in that the connector housing (14) is adapted to be connected to a connector socket (20) of a maintenance bypass module (2), wherein an unloosable screw is arranged on the connector housing for securing the connection to the connector socket.
12. 12. UPS connector arrangement, comprising at least one plug connector (10) according to any one of the preceding claims and at least one connector socket (20) adapted to receive the plug connector.
13. 13. UPS connector arrangement according to claim 12, characterised in that the connector socket (20) comprises socket terminals for contacting the plug terminals, wherein the con-nector socket comprises a socket protective wall (22) shielding the socket terminals.
14. 14. UPS connector arrangement according to any one of claims 12 or 13, characterised in that the socket protective wall (22) is adapted to push back the slidable shroud (30) of the plug connector (10).
15. 15. UPS connector arrangement according to any one of claims 12 to 14, characterised in that the connector socket (20) comprises a pivotably supported door (23), which is biased towards a closed position by torsion springs (24).