Training ProgramTraining Program

UPSUPS

UUninterruptible ninterruptible PPower ower SSupplyupply

Purpose of UPSPurpose of UPS

Uninterrupted power supply for a Uninterrupted power supply for a predetermined period of time.predetermined period of time.

Continuous and Reliable source regardless of Continuous and Reliable source regardless of power input fluctuation.power input fluctuation.

Voltage and Frequency Constancy for Voltage and Frequency Constancy for sensitive and critical load. sensitive and critical load.

Single Line Diagram of Single Line Diagram of UPSUPS

Parallel Redundant UPS Parallel Redundant UPS SystemSystem

Major Sections of UPSMajor Sections of UPS

1. Rectifier / Charger1. Rectifier / Charger

2. Battery2. Battery

3. Inverter3. Inverter

4. Static By-Pass switch4. Static By-Pass switch

5. Manual By-Pass switch5. Manual By-Pass switch

Rectifier / ChargerRectifier / Charger

The rectifier / charger converts the incoming AC supply The rectifier / charger converts the incoming AC supply into the accurately controlled DC voltage suitable for into the accurately controlled DC voltage suitable for charging the battery and for supplying the DC charging the battery and for supplying the DC requirements of the Inverter.requirements of the Inverter.

The Rectifier / Charger effectively compensates for wide The Rectifier / Charger effectively compensates for wide variations in supply voltage and frequency.variations in supply voltage and frequency.

Combined with Battery provides a very effective buffer Combined with Battery provides a very effective buffer against most transients, dips and other commonly against most transients, dips and other commonly occurring fluctuations in the AC supply.occurring fluctuations in the AC supply.

BatteryBattery

The Battery is connected across the output of the The Battery is connected across the output of the Rectifier / Charger.Rectifier / Charger.

It is permanently on Float mode.It is permanently on Float mode.

It stores the energy to be supplied to the Inverter for It stores the energy to be supplied to the Inverter for specific period (backup time) in case of input power specific period (backup time) in case of input power failure.failure.

InverterInverter

The Inverter converts the DC power to a regulated AC.The Inverter converts the DC power to a regulated AC.

PWM technique is used to generate the sine wave.PWM technique is used to generate the sine wave.

Short circuit and over load protected.Short circuit and over load protected.

Static Bypass SwitchStatic Bypass Switch

In the event of Inverter failure the supply of power to In the event of Inverter failure the supply of power to the load will be maintained without break by the load will be maintained without break by connecting it to the incoming bypass supply.connecting it to the incoming bypass supply.

In case of overload, current sensing circuit causes the In case of overload, current sensing circuit causes the transfer of load to bypass supply automatically without transfer of load to bypass supply automatically without an interruption.an interruption.

The inverter will try to maintain frequency The inverter will try to maintain frequency synchronism and phase relationship with the bypass synchronism and phase relationship with the bypass supply as long as they are within the tolerance.supply as long as they are within the tolerance.

Manual Bypass SwitchManual Bypass Switch

The UPS is bypassed.The UPS is bypassed.

Whatever input comes at the bypass supply reaches at Whatever input comes at the bypass supply reaches at the output.the output.

Required at the time of UPS maintenance.Required at the time of UPS maintenance.

Description of OperationDescription of Operation

Normal OperationNormal Operation

Normal Operation with 1 unit activeNormal Operation with 1 unit active

Battery OperationBattery Operation

Bypass Operation- auto and manualBypass Operation- auto and manual

Charger OnlyCharger Only

Standby / Off Standby / Off

Normal OperationNormal Operation

The AC input supply is fed to the phase controlled The AC input supply is fed to the phase controlled rectifier.rectifier.

The rectifier compensates mains voltage fluctuations and The rectifier compensates mains voltage fluctuations and maintains the DC voltage constant.maintains the DC voltage constant.

The ripple is reduced by means of smoothing circuit.The ripple is reduced by means of smoothing circuit.

The rectifier supplies the inverter and connected battery The rectifier supplies the inverter and connected battery is kept in float charge (or boost charge depending on the is kept in float charge (or boost charge depending on the condition of the battery). condition of the battery).

The downstream inverter converts the DC Voltage into The downstream inverter converts the DC Voltage into AC Voltage and supplies the load via the static switch.AC Voltage and supplies the load via the static switch.

Battery OperationBattery Operation

In the event of input supply failures the inverter is no longer supplied with In the event of input supply failures the inverter is no longer supplied with power by the rectifier.power by the rectifier.

The battery which is connected in the DC circuit comes into the service The battery which is connected in the DC circuit comes into the service automatically without interruption to supply the current.automatically without interruption to supply the current.

The battery voltage drops in function of the duration and the magnitude The battery voltage drops in function of the duration and the magnitude of the discharging current.of the discharging current.

The battery voltage drop is compensated by the inverter, whereby the The battery voltage drop is compensated by the inverter, whereby the UPS output voltage is kept constant. UPS output voltage is kept constant.

If the limit of discharging is reached the system changes to the bypass If the limit of discharging is reached the system changes to the bypass operation, if the bypass source is available and within the tolerance range. operation, if the bypass source is available and within the tolerance range. If bypass mains is not within tolerance range the system will shutdown If bypass mains is not within tolerance range the system will shutdown automatically.automatically.

On mains recovery the rectifier resumes its normal function of supplying On mains recovery the rectifier resumes its normal function of supplying the inverter and charging of battery.the inverter and charging of battery.

Bypass OperationBypass Operation

The system enables the load to be changed over to direct mains The system enables the load to be changed over to direct mains power supply (Bypass Mains) without interruption and adhering power supply (Bypass Mains) without interruption and adhering to the specified tolerance.to the specified tolerance.

The changeover can be initiated automatically by a control signal, The changeover can be initiated automatically by a control signal, or manually.or manually.

Interrupt free changeover, whether automatic or manual is Interrupt free changeover, whether automatic or manual is possible only if Voltage, Frequency and Phase angle of the UPS possible only if Voltage, Frequency and Phase angle of the UPS system are synchronized with the bypass mains.system are synchronized with the bypass mains.

If mains failure occurs during bypass operation, the system will If mains failure occurs during bypass operation, the system will automatically switch to battery operation without loss of output automatically switch to battery operation without loss of output Voltage, If battery is available and within tolerance.Voltage, If battery is available and within tolerance.

Standby / OffStandby / Off

The load is not supplied with energy.The load is not supplied with energy.

Sizing of the UPSSizing of the UPSA Mixed Load SituationLoad kVA PF kW kVARMotor 50 0.6 30 40Resistive 150 1.0 150 0Heater 20 0.8 16 12Total 196 52

kVA = (kW2 + kVAR2)= (196) 2 + (52) 2

= 203

Resultants PF= 196/203= 0.97

The UPS must satisfy 196 kW, 203 kVA or higher.

PF rating of UPS is normally 0.8

The required kVA = 196/0.8 = 245kVA

Add safety factor of 30%

The UPS rating required = 318.5 kVA

GUTORGUTOR

UPS SystemUPS System

Name Plate DetailsName Plate Details

PEW 1175-400/110-EAN-RPEW 1175-400/110-EAN-R

Two types:Two types:

PEWPEW

PDWPDW

Technical dataTechnical data

RECTIFIER:RECTIFIER:

I/P V= 415 +/- 10%I/P V= 415 +/- 10%

I/P f = 50 +/- 8 %I/P f = 50 +/- 8 %

RECTIFIER O/P or DC Circuit:RECTIFIER O/P or DC Circuit:

Float Charge V = 427 V DCFloat Charge V = 427 V DC

Boost Charge V = 482 V DCBoost Charge V = 482 V DC

Battery Current Limitation = 297 A DCBattery Current Limitation = 297 A DC

Total Current Limitation= 700 A DCTotal Current Limitation= 700 A DC

DC Earth Fault: 10 mADC Earth Fault: 10 mA

Low DC V (warning) = 336 VLow DC V (warning) = 336 V

Low DC V(shutdown) = 290 VLow DC V(shutdown) = 290 V

High DC V( warning) = 495 V DCHigh DC V( warning) = 495 V DC

High DC V( shutdown) = 531 V DCHigh DC V( shutdown) = 531 V DC

Battery MCCB Rating:Battery MCCB Rating:

500V, 800A500V, 800A

INVERTER:INVERTER:

I/P V= 400V DCI/P V= 400V DC

O/P V = 110 +/- 1%O/P V = 110 +/- 1%

O/P f = 50 +/- .01 %O/P f = 50 +/- .01 %

BYPASS MAINS:BYPASS MAINS:

I/P V = 415 +/- 10 %I/P V = 415 +/- 10 %

I/P f = 50 +/- 6%I/P f = 50 +/- 6%

O/P V = 110 +/- 2%O/P V = 110 +/- 2%

LOAD:LOAD:

Overload allowed isOverload allowed is

150 % for 1 min150 % for 1 min

125% for 10 min125% for 10 min

GUTOR UPS SCHEMATICGUTOR UPS SCHEMATIC

Front Panel DisplayFront Panel Display

OPERATING STATUS INDICATIONS

POS

.

DESIGNATION EXPLANATION

1. RECT. MAINS OK (green)

The rectifier mains is present and within the specified tolerance ranges for voltage and frequency.

2. RECT. OPERATION (green)

The rectifier is switched on. The firing pulses to the thyristors are enabled.

3. BOOST CHARGE (yellow)

The boost charge has been initiated manually or automatically.

4. BATT. OPERATION (yellow)

The batter is supplying the inverter with energy.

5. INV. OPERATION (green)

The inverter is switched on. The inverter control logic releases the firing signals to the TSM blocks.

6. SYNCHRONOUS (yellow)

Illuminates, if the inverter is synchronized to the bypass mains.

7. INV VOLTAGE OK. (green)

The inverter voltage is within the specified tolerance range.

8. EA-MAINS (green)

The bypass mains voltage is within the specified tolerance range.

9. BYPASS MAINS OK (green)

Bypass is present and within the tolerance range.

10.

MANUAL BYPASS (green)

The UPS system is switched to the bypass mains for test

11.

BATT. MCCB ON (green)

The fuse is inserted or the MCCB is switche

Description of TRIP alarms: Designation

Explanation

DC OUT OF TOLERANCE

The inverter is shut down , since the DC voltage is out of tolerance range of “DC low—shut down”.

Battery Discharged The battery voltage is dropped below “DC-low alarms”

INVERTER FAULT The indication illuminates only, if all the following events occur simultaneously:

Inverter not overloaded, and Inverter output voltage out of tolerance range. OR inverter switched

OFF OR in case of over tempr on the inverter power units.

INVERTER FUSE BLOWN

One or more of the inverter fuses have blown or the inverter input switch(option) is open.

OVER TEMPERATURE The following elements have a thermal monitoring: Rectifier bridge Rectifier transformer DC choke TSM Inverter transformer AC choke SSW EN

DESCRIPTION OF NON TRIP ALARMS Designation Explanation

RECTIFIER MAINS FAULT

The indication illuminates if one or more phases of the mains voltage as well as the frequency are out of tolerance.

Rectifier failure The indication illuminates only if all the following events occur simultaneously: The rectifier is not operating in current limitation, And the rectifier voltage drops below the level “DC low-alarm” or in

case of over-temperature on the rectifier power units.

BATT. OPERATION The energy for the inverter is supplied from the battery

BATT. DISCONNECTED

The battery is disconnected from the system and the battery fuse or MCCB has released. If a battery MCCB is inserted, this indicates whether the MCCB has tripped or manually been disconnected.

EARTH FAULT DC The DC earth fault current for the battery (+) or (-) has exceeded the alarm level.

OVERLOAD INV. BYPASS

Over load at the inverter or bypass. (Over load=>100% load)

Asynchronous The inverter is asynchronous to the bypass mains

BYP. MAINSFAULT

The bypass mains voltage or the frequency, measured at the input of the staticswitch EN, is out of tolerance.

MANUAL BYP ON The manual bypass switch is in position “BYPASS”; in the case of a switch with3 switching positions in position” TEST or BYPASS”.

EN INHIBITED The mains-side static switch EN is inhibited if: The bypass mains voltage is out of tolerance, The bypass mains freq is out of tolerance, SSW EN over temperature

FAN FAILURE One or more fans in the system have failed.

POWER SUPPLYFAULT

One of the electronic supplies(+5V/+-12V/+20V) is out of tolerance, or thefeeding of one of the power supplies is not available(Rectifier/Bypass mainsor DC)

BYPASS FUSEBLOWN

One or both bypass fuses F092 or F093 have blown.

ELIMINATION OF SIMPLE MALFUNCTIONS

DISTURBANCE REASON Rectifier doesn’t Start MCB of rectifier mains input switched OFF

Rectifier mains voltage out of tolerance or wrong phase sequence Over temperature signalization of rectifier power components Supply voltage for the electronics fails or is out of tolerance Plug connection of the electronics to the rectifier bridge

Inverter doesn’t start DC voltage out of tolerance Supply voltage for the electronuics fails or is out of tolerance Over temperature signalization of inverter power components

No changeover from EN to EA

EA Inhinited Overtemperature of EA Components Ineverter out of tolerance Overload Synch Fault.

TROUBLE SHOOTING TROUBLE SHOOTING AT ALARM INDICATION

Alarm Indication Source of errors Test possibilities Elements Rect. Mains failure Rectifier input

voltage, f, phase is out of tolerance

Measure input voltage

Fuses, F001, F002, F003

Rect failure Electronics and power supply

Power semiconductor

Over temperature of rectifier power units

Measure power supply of electronics

Power Supply Fan

DC out of tolerance Rectifier out of operation

Battery discharged

Battery fuse switch disconnector F041/F042

Measure DC voltage

Battery fuse switch disconnector F041/F042

Interface Battery fuse

switch disconnector F041/F042

Battery

Battery Disconnected Battery fuse switch disconnector F041/F042

Measure Battery Voltage

Battery fuse switch disconnector F041/F042

Earth fault Earth Fault Battery

Isolate Battery Battery DC Circuit

Inverter Fault Output voltage out of tolerance with turned on inverter

Overtemperature of Inverter power units

Measure output Voltage at F021

F021 Interface Controller Fan

Over Load Inv/Bypass Load current higher than the nominal current of the system

Measure Load Current

Current transformer P013

Inv. Fuse Blown Power Fuse F021 Check Fuse F021

Fuse F021

ASYNCHRONOUS Bypass frequency out of tolerance

Measure voltage between bypass and system output

Controller

MANUAL BYPASSON

Manual Bypassswitch not atposition “AUTO”

Position ofmanual bypassswitch

Manual bypassswitch

EN INHIBITED Bypass mainsvoltage orfrequency out oftolerance

OvertemperatureEN PowerComponents

Measure bypassmains voltage

Static Switch EN

OVERTEMPERATURE Heat sink of thepowercomponents toohot

Winding materialtoo hot

Too high ambienttemperature

Air inletobstructed

Measuretempurature

Check air flowthrough thesystem

Thermostat onpowercomponents andwiring material

FAN FAILURE Fans Fan monitoring Fan transformer

board Power supply for

the fans

Check air flow Check power

supply Fan

disconnection

Fan monitoringA006

Fuse F055

POWER SUPPLYFAULT

Power Supply AC or DC Power

supply sources Fuse p.c.board

A001

Measure outputvoltage of thepower supply

Measure supplyvoltage for thepower supply,AC and DC

PSUTransformerT003 and T004

F004, F005,F036

Fuse p.c.boardA001

BYPASS FUSEBLOWN

Bypass FusesF092/F093

Check bypassfuses F092/F093

Bypass FusesF092/F093

START OPERATION

Starting the UPS:

WARNING:-If the system is programmed for “AUTOSTART” and the rectifier mains is switched onand within the tolerance range, the system will start automatically after 60 secs.

1.Switch on the rectifier mains supply. The display shows:.

System type UPS.XXXKVXXXV

for 10 secs, thereafter the display changes to

Standby

2. Push the button S1 ”System ON”. The display shows:

Normal OperationLoad PowerXXX%

3. Connect the battery.

4. Switch ON the bypass mains supply.

5.Push twice the button C to reset the alarm LEDs in the “Alarm indications”.

Now the UPS is turned ON.

STOPPING THE UPS

Attention:Ensure that all consumers are informed before proceeding with the following steps andalways safe programme works before turning OFF the system.

Turn OFF the system from normal operation:1. Switch OFF the bypass mains supply

2. Push the button S1 “system ON” and simultaneously “S2 OFF” to turn OFF thesystem.

The display shows

Standby

3. Disconnect the battery.

4. Turn OFF the rectifier mains supply.The display shows no indication.

Thereafter the UPS is turned OFF. All LED indications are OFF.

Changeover Normal Operation TO Bypass operation

Push Hatch Key

Push Arrow Keys up and down until the display shows

By Pass Operation OFF

Push Timer and if bypass mains is within the tolerance range the display shows:

By Pass Operation

The load is now supplied directly from the bypass mains but mains and O/P voltage isstill monitored.

If a mains failure occurs in this situation, the system will automatically switch to batteryoperation with out loss of O/P voltage, if battery is available and within tolerance.

CHANGE OVER BYPASS OPERATION TO NORMAL OPERATION

Push Hatch Key

Push arrow up or down keys until the display shows:

By Pass Operation ON

Push “*” Key ; The display shows :

Normal OperationLoad power XXX%

Now the load is supplied by the inverter.

Complete shutdown of one UPS (GUTOR)The following instructions are related to the UPS-

Isolation procedure of one UPS

•.Turn OFF the UPS-2 by pushing simultaneously the push buttons S1 and S2 on the front panel. The load is supplied completely by the other system (UPS-1) while this one changes to Standby

•.Open the Battery fuse switch-disconnector F042 of UPS-2.

•.Open the rectifier input circuit breaker Q001

•.Remove the bypass fuse F093 and remove the bus link Q095.

Restarting procedure after complete shut down of one UPS

.Ensure that UPS-1 operates correctly and no alarm is pending.

.Switch over UPS-1 to bypass operation using the front panel keypad. Check that UPS goes to static bypass mode and display shows “BYPASS OPERATION”.

.Turn manual bypass switch Q050 to position “BYPASS”.

.Turn OFF the UPS-1 by pushing simultaneously the push buttons S1 and S2 on the front panel.

.Insert bus link Q095.

.Insert bypass fuse F093.

.Close rectifier input circuit breaker Q001 of UPS-2. If the UPS is programmed for “AUTOSTART” and the rectifier mains is within the tolerance range the UPS will start automatically after 60 seconds.

.Turn ON the UPS-2 (if not set for “AUTOSTART”) by pushing S1 (ON) on the front panel.

.Switch over the system to bypass operation using the front panel keypad. Check that UPS goes to static bypass mode and display shows “BYPASS OPERATION”.

. Close the Battery fuse switch-disconnector F042. Check the charging current.

.Turn ON UPS-1 by pushing S1 (ON) on the front pane.

.Switch back the system to normal operation using the front keypad. Check that the green LED “INV VOLTAGE” illuminates and the display shows “NORMAL OPERATION”.

.Check that the other system is in normal operation as well.

.Turn manual bypass switch Q050 to position “AUTO”.

.Reset alarms

Thank YouThank You