UPS - 2x85kva manual - Dubas.pdf

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CONGRATULATION

Congratulation for choosing dubas

product. You now

belong to dubas family of over many satisfied

customer

across

the

world.

dubas

is a 100%

dedicated company to Power Electronics Industry.

With

absolute

knowledge

of

technologies

and

understanding the importance of UPS in a critical

automated environment, we have built our products

to

provide

reliability

to

the

industry

and

commerce. dubas

is been in power electronics

industry over a decade and has done various

pioneering works in power electronics. dubas is an

ISO

9001

certified

company.

dubas

delivers

uncompromised quality products and services to

accomplish highest customer satisfaction.

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Operational & Instructional Manual For

2x85kVA Parallel Redundant

UPS System

DESCRIPTION

: 2 x 85 KVA, 3φ - 1φ ON-LINE UPS

RATING

: 2 x 85 KVA, 3φ - 1φ

INPUT

: 415 V AC, ± 10%,

OUTPUT

: 230 V AC, ± 1%, 50HZ

DC VOLT

: 268V

UNIT SL #

:

W.O.NO : 1301001

This manual is accompanying the above-referred product, which has been manufactured in accordance with the customer purchase order, conforming to dubas quality systems for manufacturing quality. The operating procedure, maintenance, installation, trouble shooting in the event of fault occurrence has been given in this manual. Electrical hazards given in this manual must be understood and strictly followed otherwise it could prove fatal. Please refer to warranty certificate for warranty cover details.

PLEASE READ THE MANUAL THOROUGHLY,

BEFORE OPERATING THE SYSTEM.

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Table Of Contents Un-interrupted Power Supply (UPS)

1.0 System Description --- 5

2.0 Technical Specification --- 7

3.0 Drawings Single line diagram --- 09

General arrangement --- 10

Room layout diagram --- 11

Interconnection power wiring diagram --- 12

Interconnection control wiring diagram --- 12

System power wiring --- 13

4.0 Installation & Commissioning General --- 15 Installation --- 16 Commissioning --- 18 Functional Checks --- 19 5.0 Indications, Controls Controls --- 20

Indications and Alarms --- 21

6.0 Display at UPS --- 23

7.0 Routine Maintenance for UPS --- 25

8.0 Trouble Shooting For UPS --- 25

9.0 Failure Report --- 29

10.0 Warranty Details --- 30

11.0 Quality Policy --- 31

12.0 Electrical Supply Better Way --- 31

13.0 Product Varieties --- 32

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1.0 SYSTEM DESCRIPTION

Double conversion, Online Uninterruptible power supply here after known as UPS provides emergency back-up power in the event of a black-out and also protects the electrical and electronic equipment from critical power disturbances such as spikes, noise, sags and surges.

The main objective of GX-III Series UPS is to take polluted, fluctuating and erratic electrical power that exists in the main power supply today and replace it with well regulated, computer grade power. The back-up time is a function of the amount of battery reserve that is available along with the system.

The whole unit consists of 2 nos. of GX-III Series UPS systems, a SW Cubicle and one number of servo stabilizer. The whole system operates in Parallel mode.

Operating Modes

During Normal operation two units will be paralled and feed the load. (ie 50% each and 85 kva total ) On failure of AC input supply, the inverter will obtain the power from battery and continues to feed the load without disturbance at the load. The battery will supply back up power to Inverters for a specified period. On power resumption the converter output voltage gradually builds to the set value and recharges the battery simultaneously feeding the inverters.

If any one of the ups goes fault, the second unit will take the load. After clearing the fault the rectified inverter gets paralled and share the load equally.

On Failure of both inverters the load will be transferred to Static bypass source. The retransfer of load from static bypass source to Inverter shall be done by automatically.

Note:

1) There is no common battery bank for the ups system.

For periodic UPS maintenance or for rectification of fault, Manual bypass switch is provided to bypass the UPS and to feed the power to load from bypass source; this operation is achieved without load break.

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• CONVERTER

• BATTERY CHARGER / BUCK CONVERTER • INVERTER

• BOOSTER

• STATIC BYPASS

A. CONVERTER

Input Voltage is connected to the rectifier module configured by IGBTs, which is controlled by DSP with active Power Factor Correction. The IGBTs are switched ON / OFF by means of gate pulses generated by the DSP control card. Output of the IGBT Bridge; is connected to parallel bank of DC capacitors. Input active Power Factor Controller circuit maintains the input power factor near to unity and the input current pattern exactly follows the input voltage .DC output, line voltage & line currents are sensed by signal conditioning network in Control PCB & then given to the analog inputs of the DSP. Bonded on the feedback, the gate pulse is varied within the DSP, which controls & regulates the DC voltage along with power factor correction. This well-regulated DC output from 3ph-IGBT Bridge, is connected to the capacitor bank.The Converter control logic is fully software based & is performed by World’s leading Digital Signal Processor. Converter Control card which is a combination of analog and a digital card generates the sine weighed pulses, whose width is modulated as per the feed back signals. The input current is sensed via Hall Sensor. The output of converter is supported to inverter and battery charger / buck converter. All the input parameters of the converter are directly displayed on to the LCD screen provided in the front panel.

B. BUCK CONVERTER

The output of the converter is connected to the buck converter. The function of this module is step Down the dc voltage to required battery voltage. Output of this module is connected to the battery to Charging purpose. Battery charging current is sensed through hall sensor and is connected at the Output of this module. Battery float & boost mode of working is decided by this current sensor. Normally battery is charging under float mode by constant voltage and current limit. The voltage and

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Current feedbacks are sensed through Digital signal processor. The control logic of this Operation is Fully software based. The battery float charging and boost charging voltage is setted as per battery Float and boost Charging voltage recommended by manufacturer. In this unit we setted float voltage As 248V (Number of cell X float volt per cell. i.e.110X2.25=248V) and boost Voltage as 303V (number Of cell X boost volt per cell. i.e.110X2.75=303V). The float charging current setted as 10% of the Battery AH i.e. 65A and is adjustable 5-65A. Boost charging current normally setted as 5% of the Battery AH i.e. 32A and is adjustable 5-65A. Battery boost charging ENABLE/DISABLE option is Given in the setting. The charging current is limited to the specified value by using the current Feedback through a current sensor provided in the battery path. The excessive demand of battery Current is reduced by bringing down the dc o/p voltage using the DC Fold back action as per the Signals from the current sensors at the battery charging path. All the DC (battery) parameters are Directly displayed on to the LCD screen provided in the front panel.

C. INVERTER

DC output of the converter is the input to the 1ø bridge configured Inverter. The output of the inverter bridge is isolated by output transformer. Harmonic voltages are filtered by output filter capacitor.

IGBT’s are switched ON and OFF as per the pulses from driver cards, received at their gate terminals. IGBT’s Q1 to Q4 are switched ON and OFF as per the driver pulses received at their basis from driver card.

The inverter control logic is software based & is performed by worlds leading Digital Signal Processor. Inverter Control card which is a combination a analog and a digital card generates the sine weighed pulses, whose width is modulated as per the feedback signal. The output current is sensed via current transformers.

Indications and alarms are generated for announcing the status of the system. All the output parameters and the fault status of the UPS are directly displayed on to the LCD screen for user information.

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During failure of AC mains supply, this module supports the inverter using the battery voltage without disturbed the load. Input for this module is from battery. The function of this module is boosting the battery voltage to required input voltage for the inverter. Discharging current is sensed through hall sensor, which is located at this module.

E. STATIC BYPASS

If load is on inverter and bypass source is in healthy condition, then load will transfer to bypass source, if inverter is tripped. If load is connected to bypass source and Ups is healthy, then output load will retransfer to inverter automatically.

For maintenance work of UPS, UPS is bypassed to bypass source through Manual Bypass Switch, so that maintenance work can be done on ups panel.

2.0 TECHNICAL SPECIFICATION

Sl.

No UPS PARTICULARS/SPECIFICATION DATA

GENERAL

1.0 Make & Country ‘DUBAS’ INDIA

2.0 Type Double Conversion Online

3.0 Input Voltage No. of Phase Frequency P.F 415V, ±10% 3ø, 5wire (3P+N+Earth) 50Hz. ±5% > 0.9 at rated load 4.0 UPS Capacity At 0.8 PF 68KW

5.0 Output Voltage and regulation 1ø, 230V AC, ± 2%

6.0 Frequency and regulation 50 Hz ± 0.5%

Type LCD (32 Bit display) with operating key pads 7.0 Metering

Accuracy ±2%

8.0 Type of cooling Forced Air

CONVERTER

1.0 Type Constant voltage current limit type

2.0 Type of Control DSP Based PWM Technology

3.0 Input voltage 415V+ 10%

4.0 output Voltage 400 VDC

5.0 Voltage Regulation for AC Input Variations of + 10% & Load Variations

+ 1%

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7.0 Power Walk-in circuit provided Yes BATTERY CHARGER/BUCK CONVERTER

3.0 Input voltage 400 VDC

4.0 Nominal Output Voltage 248 VDC

Float Voltage Float Current

Boost voltage

Boost current 248V

65A Factory set 303V

90A starting current 45A finishing current 5.0 Voltage Regulation for Input Variations & Load

Variations

+ 2 %

6.0 Ripple < 2%

7.0 Power Walk-in circuit provided Yes INVERTER SYSTEM

1.0 Type Solid state, static control, using IGBTs

3.0 Input 400V DC

4.0 Output AC voltage 1ø, 230V AC

5.0 Accuracy (Steady State) Better than 98%

6.0 Output Frequency 50 Hz @ free running condition

7.0 Frequency regulation + 0.5%

8.0 Harmonic Distortion < 3% on 100% linear load

9.0 Transient Voltage For 50% step load change

Sudden input voltage change of ± 10% Loss and return of input AC power

± 5% ± 5% ± 5% TRANSIENT RECOVERY TIME

Recovery to 95% <15 m sec.

BOOSTER

2.0 Type of Control _{DSP Based PWM Technology}

3.0 Input voltage 193-248 VDC

4.0 Output Voltage 400 VDC

STATIC TRANSFER SWITCHES

1.0 Type Solid state static control (SCR based)

2.0 Voltage 230 V

3.0 Frequency 50Hz, + 5%

4.0 Transfer time < 4 msec (sync transfer)

INVERTER / RECTIFIER TRANSFORMER

1.0 Type Dry type, Forced Air cooled, Double wound

2.0 Type of cooling Forced air

3.0 Insulation class Class H with temperature raise limit to Class F

MANUAL BYPASS SWITCH

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ENCLOSURE

1.0 Type Free standing, Floor vertical mounted

2.0 Sheet Thickness Frame 2 mm

3.0 Degree of protection IP 42

4.0 Paint Shade RAL 7035

5.0 Cable Entry TOP

6.0 Overall Dimensions WXDXH

Converter 800x800x2200mm

Inverter 800x800x2200mm

Switching cubicle 600x800x2200mm

SCVS (BYPASS) 800x800x2200mm

Single line diagram for 2x85 kva UPS system

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Fig-1

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Fig-2

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Fig-3

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Fig 4

INTERLOOPING CONTROL WIRING DIAGRAM

CONVERTER TO INVERTER CONVERTER TO SWITCHING CUBICLE

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SWITCHING CUBICLE TO CONVERTER

Fig-5

System Power wiring diagram

1. Converter block

Fig-6

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Fig-7

3. Static switch block

Fig-8

4.0 INSTALLATIONS AND COMMISSIONING

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General Awareness

1. Confirm the product by noting down the name plate details and model No. Provided in the system.

2. Inspect the product for external damage caused during transit. If any damage found, report to the transport and dubas immediately.

3. Handle the equipment carefully and install the equipment according to the installation details given.

4. Install the equipment in safe area, protected from moisture sunlight, harmful gases. 5. Do not store or use corrosive materials in the vicinity of the UPS.

NOTE: UNAUTHORIZED PERSON SHOULD NOT TOUCH, ELECTRICAL HAZARD AREA, SINCE

THE SYSTEM IS WORKING WITH HIGH VOLTAGE.

System Packing

The system is fully tested and quality control inspection done prior to delivery.

1. The whole system consists of UPS-2No, 1 Sw Cubicle, 1 Servo Stabilizer and 1 battery bank, 2. Each unit is covered with a bubble sheet and thermacoal. Finally each wrapped unit is placed

inside a wooden box.

3. Bottom Sockets with all its accessories and interloping cables are packed in separate boxes cotton box.

INSTALLATION

Initial Checks - General

1. On receipt of material unload the material carefully, to rest on its bottom. Store the equipment in safe area protected from harmful gases, water, theft etc. Please store the material in packed condition if the installation is expected to take a while.

2. After unpacking, before installation & Power ON, please check the equipment for transportation damages. Incase of damage to equipment, please notify the manufacturer & transport company. 3. Check for loose connections; especially all the fasteners for tightness, & cable terminations & interconnections; tighten them if required.

4. Check all the wiring connections & flat-band connectors for loose contacts. Ensure proper contact of wire terminations & plug / sockets.

Place of Installation

CAUTION: ONE SET CONSISTS OF 2 UPS SYSTEMS, ONE SWITCHING CUBICLE, ONE SERVO STABILIZER AND 1 SET OF BATTERY BANK. IN CASE ANY ONE SYSTEM IS MISSING, THEN

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1. Ensure that the equipment is installed as per FIG-3 at a place conforming to the ambient operating conditions as specified in technical Specification and please ensure that it is housed indoor, in a closed safe room; having adequate ventilation and light.

2. Avoid installing equipment near heat generating units or extreme dirt, high moisture & harmful gases. These can damage the equipment seriously.

3. Maintain minimum clearance of 1000mm from front side and 800mm from rear side for maintenance purpose.

Battery Bank Installation

1. Battery bank has to be protected from sunlight and rain.

2. Place the battery on the Battery Rack/Enclosure as per the Battery GA drawing. 3. Connect the entire intercell / battery interlinks as per the drawing.

4. Battery contains acid, which are harmful to human body in contact and to be disposed carefully or to be returned back to us.

NOTE: A Battery terminal gives electrical shock. The battery will flashover and explode if

battery terminals are shorted accidentally.

Pre Connection Checks

Before making the power supply connection, please observe that, all the switches are in OFF position. Ensure that the utility power connection has voltage and frequency as per the rating given on nameplate, or specification sheet.

Connection

1. Provide suitable breakers as per chart shown below for individual UPS system at customer Distribution Board.

2. Ensure input source is not live & then connect Input cable (as per the given chart) through gland plate to the Input terminals of SWC at the front bottom of the system.

3. Use suitable glands and ensure cable weight does not fall on the terminals.

4. Connect Load cable (as per the given chart) through gland plate to the output terminals. The entire system has to be operated only by skilled operators, with necessary authorization.

Only qualified service technicians shall have the access to open the door. Inside of UPS have Very dangerous electrical components, which can potentially electrocute the careless operator.

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5. Connect all the Power and control interconnection cables between CONVERTER1 to INVERTER1, INVERTER1 to SWC, CONVERTER1 to SWC, CONVERTER2 to INVERTER2, INVERTER2 to SWC, CONVERTER2 to SWC and INVERTER1 to INVERTER2 as per FIG-4 & 5

6. Check the Battery voltage; verify if it corresponds to the UPS DC bus range & design. 7. Wire the battery + ve & - ve lead from battery bank to the battery Terminal Block.

8. Connect the cable + ve & - ve leads to their corresponding terminals on battery terminals.

9. At any instance UPS output should not be shorted or paralleled to EB output. Hence care has to be taken in power distribution network.

10. Connect utility ground to the earth bus for all the equipments provided at the both side of each system.

Cable Selection Chart

Cable Description Recommended Cable size Switchgear Remarks Input Cable–UPS &

Bypass 95 sq mm,4 Core,1R,copper cable/70 sq mm, 4 core, 2R, Alluminium 200A,50kA, TP, 415V AC , MCCB cables are Customer scope Output Cable from SWC

to ACDB for 400A Main DB incomer 95 sq mm,2 Core,2R,copper cable/150 sq mm, 2 core, 2R, Alluminium 400A,TP, 415V AC , MCCB cables are Customer scope Output Cable from SWC

to ACDB for 63A Boiler DB incomer 16 sq mm,2 Core,1R,copper cable/25 sq mm, 2 core, 1R, Alluminium 63A,DP, 415V AC MCB cables are Customer scope Output Cable from SWC

to ACDB for 63A Turbine DB incomer 16 sq mm,2 Core,1R,copper cable/25 sq mm, 2 core, 1R, Alluminium 63A,DP, 415V AC MCB cables are Customer scope Battery Cable 95 sq mm,2 Core,2R,copper cable/150 sq mm, 2 core, 2R, Alluminium 400A,TP,DC, MCCB cables are Customer scope Interconnection input

power Cable , AC 21.sq mm, 4 core, 1R, uninyvin

N.A cables are dubas scope Interconnection output

power Cable , AC 21.sq mm, 2 core, 4R, uninyvin

N.A cables are dubas scope Interconnection DC

power Cable 21.sq mm, 2 core, 4R, uninyvin

N.A cables are dubas scope

NOTE: a) Use flexible pipe with cable gland for communication and power interloping cable.

b) If output earth is improper, spurious electrical noise will enter the ups output, which may lead to malfunctioning of the ups.

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a) Make all the interloping power and control wiring as per wiring diagram. b) Ensure proper earthing is connected for all the panels.

c) Ensure all the connectors and wires connected to PCA’s are in without loose connection. d) Ensure all the breakers and control switches are in OFF position.

e) Switch on the input breaker of separate source to UPS1, UPS2 and BYPASS at customer distribution board.

f) Check the voltage at SWC input terminal using voltmeter.

g) Switch on Input breaker of UPS1 first and check the Mains ON Indication is ON in front display of converter panel.

h) After few seconds the front door control panel gets energized. Press ‘ACK’ keypad at LCD display unit to silence the alarm.

i) Check the input voltage at LCD Display on front meter plate & confirm as per technical specification. j) Press the soft start push button until main contactor gets energized.

k) Press ‘RESET’ switch to release the trip indications on Converter. Check the DC voltage at LCD display.

l) Switch on the input breaker for SCVS(BYPASS) panel.

m) Check the output voltage of SCVS(bypass) panel at before static input breaker for both UPS1 & UPS2.

n) Switch on Static input breaker of ups1. o) Check Load on Bypass indication is ON.

p) Switch ON the ‘CONVERTER CTR’ switch provided. DC voltage builds up gradually to set value after few seconds. Check for Converter ON indication is ON

q) Switch on BATTERY breaker of UPS1.

r) Check Battery charging current at display unit is reading and battery on charge indication is ON. s) Press ‘RESET’ switch to release the trip indications on Inverter.

t) Keep output breaker in off condition before switch on the inverter control switch.

u) Switch ON ‘INV. CTR’ switch the output voltage gradually builds to the set value. Check Inverter ON indication is ON and voltage at LCD display unit is reading.

v) Same procedure is follows for switch on the UPS2.

w) After switch on the both the UPS individually, switch off static input breaker for both the UPS and switch off the inverter control switch.

x) Switch on the output breaker of both the UPS.

y) Switch on the static bypass input breaker for both the UPS one by one.

z) Switch on the inverter control switch for UPS1 first. After voltage builds, ‘master unit’ indication is glow on front indication card at UPS1.

aa) Switch on the second UPS inverter control switch, after output voltage builds, both the unit will be paralleled.

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cc) If the load is connected initially before switch on the inverter control switch, load will be in bypass. After switch on the inverter control switch, load will be transferred to UPS automatically.

dd) Check all the parameter and indications on front user display panel.

FUNCTIONAL CHECKS Transfers/Re-Transfers

Check/transfer the load from inverter output to Static Bypass Source a) Switch OFF INV CTR switch of UPS-1 and UPS2

RE-Transfer the Load from Static Bypass to Inverter

a) Press RESET switch of both the UPS and clear the faults if any exists. b) Switch ON INV CTR switches of both UPS-1 and UPS-2 sequentially. c) After inverter voltage build, load will transferred to UPS and paralled.

5.0 INDICATION, CONTROLS

FIG-9: USER INTERFACE FRONT CONTROL PANEL FOR UPS

1: LCD DISPLAY UNIT

2: CONVERTER ON/OFF ‘SWITCH

3: RESET SWITCH

4: INV. ON/OFF ‘SWITCH 2

3 1

4

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5: UPS SYSTEM STATUS INDICATION

CONTROLS:

‘RESET’: Operate this switch for clearing the faults at both Conv. & Inv. (HOLD FOR FEW SECONDS)

‘INV. CONTROL’: This switch is provided on the front door. This switch facilitates inverter output to be switched OFF/ON. This is to be operated whenever load is not active, but battery charging will be carried on irrespective of the status of this switch.

‘CONV. CONTROL’: This switch shall be made ON only during initial START UP of the UPS and shall be always kept in ON condition once the UPS is feeding the Load. (Note: by turning OFF this switch the converter turns OFF and battery gets discharged through Inverter)

INDICATIONS AND ALARMS

Indication Status What it Says? (WIS) What to Do? (WTD)

INDICATION ON

(Green)

Input breaker is ON, Input voltage is healthy and within specified range.

Healthy Condition

Mains ON

OFF

a)Input breaker OFF b)Input Phase Fail

c)Input voltage out of specified range

d)Input fail

a)Switch on Input breaker

b) Check and restore all the 3 phases. c) Wait till the voltage reaches within specified range.

d) Wait till Input Supply is restored. ON

(Green)

Converter is ON and the Converter

output voltage is = 248V DC Healthy Condition Converter ON

OFF a)Conv. Control switch OFF b)Conv. Fault

a)Ensure switch is kept always ON c)Check WTD of Conv. Fault ON

(Green)

Converter is ON and battery

charging is under process Healthy Condition Batt. ON

Charge

OFF a)Conv. OFF/Fault b)Battery Breaker OFF

a) Check WTD of Conv.OFF & Conv.Fault b) Switch ON the breaker

ON (Green)

Inverter is on and the output

voltage is greater 204V Ac Healthy Condition Inverter ON

OFF

a)Inv. Control switch OFF

b)Output voltage is less than 204V AC

c)Inverter Fault

a)Switch On the Inv. Control switch b)Check Inv. Output voltage set (240V) c)Check WTD of Inv.Fault

ON (Green)

Self Inverter is ON and feeding the

load Healthy Condition

Load on UPS

OFF a)Self Inverter is OFF/fault b)Load on Static Bypass

a)Check WTD of Inv.OFF & Inv.Fault b)Check WTD of Load on Static Bypass

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ON (Green)

static input breaker in on condition and bypass input voltage is with in the range

Healthy Condition Bypass

Healthy

OFF

a) Static input breaker off b) SCVS output voltage out of specified range

a) Switch on the breaker

b) Wait till the voltage reaches within specified range.

ON (Yellow)

Battery is supported to inverter for the following condition.

a)converter fault b)mains fail

a)Check WTD of CON.Fault b)Check the mains voltage Load on

battery

OFF Converter in healthy condition

Batt. Low Pre-Alarm

ON (Yellow)

Gives alarm when battery has discharged to its cut-off level before Inv. Trips on Batt. Low Trip under following condition.

a)Conv.OFF/Fault

b) Mains ON indication OFF

a)Check WTD of Conv.OFF&Conv.Fault b) Ensure Input supply (If Mains ON is Off) is made ON within 5 minutes after hearing of 1st Batt.low pre-alarm or turn OFF the entire load.

Load On Bypass

ON (Yellow)

Load is fed through static switch under following conditions

A) Self & Alnt. UPS tripped on Inv. Fault.

B) Self & Alnt. UPS Inv. ON indication OFF.

a) Check WTD of Inv. Fault b) Check WTD of Inv. ON

TRIP INDICATION WITH ALARM

Converter trip

ON (Red)

Converter has tripped under following conditions

a)Mains ON indication OFF b)Converter output voltage high c)Input Current high

a)Check WTD of Mains ON

b) Check Conv. Set voltage is as per requirement & press RESET switch. c) Check Input over current set & press RESET switch. Input Under/Over volt ON (Red)

Input Voltage is out of specified limits

Check Input supply for phase fail or ensure the Input supply is within specified limits

DC Low ON (Red)

Battery has got discharged to its cutoff level their by tripping inverter.

Ensure converter is ON and battery is on charge.

Inverter trip ON (Red)

Inverter has tripped under following conditions a) dc low.

b) output voltage out of specified range.

c) inverter overload

a) Check WTD of dc low

b) Check output voltage setting & press Reset switch

c) Check the load percentage & put the load with in the unit rating.

Inverter Under/Over

volt

ON

(Red) Inverter has tripped as output _{voltage is low or High} Check output under & over voltage _{setting and press Reset switch.}

Inverter Overload

ON

(Red) Inverter has tripped on any one of _{overloaded band as per Chart-1} Reduce the load and pres Reset switch.

System Over Temp.

ON (Red)

Inverter has tripped as any module component temperature is beyond max. limit

Check individual module fans are working and ambient temperature is within

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press Reset switch.

Master unit ON (Green)

Based on which system is switched

on first. Healthy Condition

Parallel mode ON (Green)

If both the ups are working in

parallel conditions. Healthy Condition Load on

alternate ups

ON

(Green) If load is feeding by the other ups

Check WTD of Inv.OFF & Inv.Fault in self inverter.

Sync ok ON

(Green)

If bypass voltage is synchronization

with UPS output voltage Healthy Condition

NOTE: TRIP INDICATIONS ARE ACKNOWLEDGED BY PRESSING RESET SWITCH AND SYSTEM WILL RESET FOR ITS OPERATION.

6. USER INTERFACE DISPLAY

Fig.10 Display Unit

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Scroll the mode one by one.

To return to main mode.

To acknowledge the buzzer.

Enter into the sub modes of that selected mode.

How to operate front panel Display unit at UPS?

To Measure Input Parameters (Line Voltage, Line Current & Frequency, power, P.F)

Press Mode key and scroll till INPUT PARAMETER is displayed. Then press increment key, phase-phase voltage in Volts shall be displayed. By pressing increment key again and again input parameters of current, frequency, power, and p.f shall be displayed.

To Measure DC Bus Parameters (DC Voltage, Charging Current & Discharging Current) Press Mode key and scroll till DC BUS PARAMETER is displayed then press increment key DC voltage in Volts shall be displayed. On the same mode press increment key again to measure battery

CHARGING/DISCHARGING current. Any one of the current shall be displayed depending upon ‘BATT. ON CHARGE’ or ‘BATT. ON DISCHARGE’

To Measure Output Parameters (Voltage, Current, Frequency & Power)

ESCAPE KEY

ENTER KEY

INCREMENT KEY

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Press Mode key and scroll till OUTPUT PARAMETER is displayed. Then press increment key output voltage in Volts shall be displayed. Press same increment key again and again to measure output current in Amps along with %Full load current, frequency in Hz & output power in Kilo Watts respectively.

To Measure Bypass Parameters (Voltage & Frequency)

Press Mode key and scroll till BYPASS PARAMETER is displayed then press increment key bypass voltage in Volts shall be displayed.

To Monitor UPS Status

Press Mode key and scroll till UPS STATUS is displayed then press Increment Key or Decrement Key to toggle between various UPS status which are listed at ‘Indications and Alarms’.

To test all the indication along with alarm (LED Test)

Press Mode key and scroll till INDICATION TEST is displayed then press increment. All the LED’s lit one by one along with buzzer beep for which ever indication is applicable. All indications are tested twice, to stop in between press Mode Key.

POP-UP Display messages

Display Unit shall POP-UP the following messages

‘PRE ALARM FOR : When battery is discharged to its cut-off level after delivering the rated load for BATT LOW’ a specified back-up time.

‘ALARM FOR : When inverter output is overloaded as per the Chart: INV OVERLOAD’

7.0 ROUTINE MAINTENANCE FOR UPS

1. Record output voltage read from the output voltmeter periodically. 2. Check battery health condition periodically.

a. Measure the individual voltage of the battery with AC input power off condition.

b. Immediately measure and log the values in a periodicity of 45 days, take another reading at battery per alarm.

c. Compare the voltage values of corresponding batteries recording time instance.

d. Fall of corresponding battery voltage indicates need for maintenance service requirement. If the battery voltages are comparable the battery is healthy.

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FAULT DIAGNOSTICS OF UPS Sl.

No. FAULT REPORT CHECK POINT

OBSERVATION & ACTION TO BE TAKEN

Input MCCB If input MCCB is OFF, then switch-ON the MCCB & wait for 5 minutes.

1

Mains is present but “Main-ON” indication

is OFF Input Voltage If the input voltage is not within the specified range then wait till the voltage comes back.

2

Mains is present but “Converter Trip”

indication is ON

Front user display and indication

Check the type of trip. If the display reads “CONVERTER TRIP”

AC OV = Input Over Voltage trip AC UV = Input Under Voltage trip. AC OC = Input Over Current trip. DC OV = DC Over Voltage trip. DC UV = DC Under Voltage trip.

If “AC OV” or “ACUV” or “DCUV” trip occurs, then check the input voltage & wait till the voltage returns.

If “ACOC” or “DCOV” or “OT” trip occurs, then press “Converter Reset” switch provided in the front panel. The trip will be cleared only if the system is free from fault.

If the fault persists for longer time, then call for the service.

3 Inverter is loaded on Battery always

If the Converter is tripped due to any one of the above reasons, then press reset & re-energize the Converter.

4 Battery is not charging

Check the “Battery Current” & DC voltage display. If the DC voltage is less than the float voltage & Battery current is zero, then there may be some loose connections. Consult the service engineer for further help.

5 Low Battery Back-up Battery

Loose connections.

Battery not in Healthy condition. Battery electrolyte is drained.

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6 Abnormal Heat Fans Check whether all Fans are ON. If any fan is OFF, then it should be replaced.

7 Electrical Noise Ground connections Checks whether the system is earthed properly otherwise check the earth connections.

8 Abnormal noise & trip at

switch-ON Load

Disconnect the load & try to switch-ON the System again. If it continues, then contact the service personnel.

Fig-11:

Overload Chart for UPS

LIST OF ALL POSSIBLE ERROR / TRIP MESSAGES GIVEN THROUGH INTERNAL DISPLAY

Error Displayed Error Description Action to be taken

INVERTER

I N V E R T E R T R I P U V

“Inverter Output Under Voltage” trip. The UPS output has dropped below the set voltage level.

Press RESET switch, If problem persists inform to the Authorized service personnel. I N V E R T E R T R I P

O V

“Inverter Output Over Voltage” trip. The UPS output has risen above the set voltage level.

Press RESET switch, If problem persists inform to the Authorized service personnel.

I N V E R T E R T R I P B I

“DC bus LOW” trip

This indicates that the battery has fully given up its backup power.

Switch OFF inverter, allow the battery to get charged, press reset switch and switch ON inverter. If problem persists call dubas. Overload Chart 0 10 20 30 40 50 60 70 1.04 1.10 1.16 1.22 1.28 1.34 1.40 1.46 Load Current x In T im e in M in .

Load Current Duaration Trip display 100% Continous ----> 100% to 110% 60 minutes OL1 > 110% to 125% 10 minutes OL2 > 125% to 150% 60 seconds OL3 > 150% < 1sec. OL4

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I N V E R T E R T R I P B H

“DC bus HIGH” trip

This indicates that the DC bus voltage is beyond the specified limit.

Press RESET switch, If problem persists inform to the Authorized service personnel. I N V E R T E R T R I P

O L 1 O L 2 O L 3 O L 4

“Inverter Over Load or Over current” trip. This indicates that the Inverter Output current/ power has exceeded its rated value. (refer Fig-11)

Load has to be reduced. Press reset If problem persists call dubas.

A L A R M F O R

O L Inverter is overload for OL1/2/3

Load has to be reduced. Then alarm & countdown stops automatically.

A L A R M F O R B L

Battery is discharged to its end cell cut-Off voltage

Ensure load is switched OFF or input source is restored.

Error Displayed Error Description Action to be taken

CONVERTER

C O N V E R T E R T R I P A C O V

“Input Over Voltage” trip.

This trip occurs when the Mains supply is above the specified window (Above 10% of the nominal input voltage)

Wait till the Input source is healthy. Press RESET switch, If problem persists inform to the Authorized service personnel.

C O N V E R T E R T R I P A C U V

“Input Under Voltage” trip.

This trip is due to the low input voltage (Below 10% of the nominal input voltage)

Wait till the Input source is healthy. Press RESET switch, If problem persists inform to the Authorized service personnel.

C O N V E R T E R T R I P O C

“Input Over Current” trip.

This indicates that the line current is more than the rated current of the system.

If it happens frequently, then check the Inverter load & check input voltage. If problem persists contact dubas

C O N V E R T E R T R I P D C O V

“DC Over Voltage” trip.

This indicates that the DC voltage has raised above the specified level.

Press RESET switch, If problem persists inform to the Authorized service personnel.

C O N V E R T E R T R I P D C U V

“DC Under Voltage” trip.

This indicates that the DC voltage has fallen below the specified value of the Converter.

Check the DC bus voltage OR this can happen even during short circuit.

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Glossary

UPS : Un-interrupted Power Supply IT : Isolation Transformer

Inv. : Inverter Conv. : Converter

9.0 FAILURE REPORT

All failures to be reported to Service Department, DUBAS ENGINEERING PVT. LTD

Before reporting a complaint call, check the following. 1. Input breaker ON.

2. Battery MCCB ON.

3. Output Distribution is OK.

4. No excessive or faults loads are connected.

While reporting a faulty; please inform, 1. Nature of fault

2. Indication on the, front panel.

3. Serial number of the unit / rating of the unit / date of installation / location / premises / name of the contact person.

Please register your call at the following address

DUBAS ENGINEERING PVT. LTD.,

# 43(P) 2nd Phase, Electronics City, Hosur Main Road Bangalore - 560 100

Phone: (080) 4033 6000 Fax: (080) 4033 6222

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10.0 WARRANTY DETAILS

dubas engineering pvt. Ltd. warrants its products against all manufacturing defects, faulty workmanship for a period of 12 months from the date of Invoice, subjected to the terms and condition mentioned below.

TERMS AND CONDITIONS

1. The customer will notify the company promptly of any defects noticed and give the company adequate opportunity to inspect Test, and remedy them, for which the customer will deposit the goods if necessary with company’s office/service center along with original invoice. 2. Inspections and Test Report of the Company/Service Center will be final and binding under

the warranty for determining defects, repairs/ alterations required or carried out or certifying working of goods thereafter. The company is entitled to retain any defective parts replaced under the warranty.

3. The company’s liabilities under the warranty will be limited only to defects, which occur under.

4. Conditions of normal operations and proper use. It excludes defects occurring because of abuse, faulty care, or maintenance repairs/ alteration to goods or parts by unauthorized persons, use under conditions beyond specified or damage caused by lightening.

5. In case Batteries are used along with our system the responsibility to do regular maintenance of the batteries lie with the customer. Customers are required to maintain the batteries under optimum working conditions as specified by the battery manufacturer’s certification that the batteries are well maintained.

6. Our warranty or any other services is limited to manufacturing defects in the equipment only.

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11.0 QUALITY POLICY

We shall strive continually to be a dedicated team delivering UN compromised quality products and services, befitting and be-timed value to accomplish highest customer satisfaction.

12.0 ELECTRICITY SUPPLY – BETTER WAY

At any moment an AC mains supply can be subjected to the electrical disturbances such as spikes (usually lightning induced), electrical noise (flashes on monitors and TV screens), sags (lights go dim), surges (lights go bright) and blackouts or complete loss of power.

1. Blackout – Blackouts can be caused by excessive demand on the power grid, lightning storms, equipment failure or any accident, which brings down a power line.

2. Sag or Brownout – Sags or brownouts can be caused by heavy equipment coming on-line, short circuits, undersized electrical circuitry, or when the utility company deliberately decreases voltage levels in order to cope with peak load times (rolling brown outs). Brownouts usually occur during the summer heat waves.

3. Spikes – Spikes are generally caused by a nearby lightning strike, or if utility power lines are downed in a storm or as a result of an accident.

4. Surge – A surge is usually caused when high-powered appliances in the area are turned off. Short circuits or undersized electrical circuits can also cause them.

5. Noise – Lightning, load switching, generators, transmitters, transformers, and industrial equipment can cause EMI and RFI noise.

These electrical disturbances will damage sensitive electrical / electronic equipments, unscheduled Power shutdown, corruption of data, system hangs ups etc. These disturbances can be prevented and it comes in the form of Uninterruptible Power Supply (UPS).

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13.0 PRODUCT VARIETIES

1. UPS SYSTEMS:

DU-Series are available from 1 KVA to 120KVA range

GX-Series are available from 6KVA to 480KVA in single modules. Seamless paralleling up to 6 modules are possible in the GX-Series.

DUBAS UPS Systems are employed in thousands of mission critical applications in Data Centres, Hospitals, Avionics, Critical Railway applications etc.

2. INDUSTRIAL STABILIZERS:

Industrial Voltage Stabilizers are available from 1KVA to 1200KVA.

Air cooled versions are available up to 250KVA and Oil cooled versions are available up to 1200KVA Dubas Stabilizers are deployed in various countries in critical applications safeguarding various critical loads from voltage uncertainties.

3. FREQUENCY CONVERTERS:

Frequency converters are available up to 200KVA rating with various voltage configurations. dubas is a premier supplier of 60HZ or 400HZ Frequency converters for critical test laboratories and avionics industry.

4. DC POWER PLANTS:

Dubas manufactures entire range of thyristor based rectifiers / chargers up to 900 Amps in various voltage configurations. Major users include Power Substations, Process Plants, and Telecom Networks etc.

5. ULTRA ISOLATION TRANSFORMERS:

Ultra Isolation Transformers are available from 1KVA to 200KVA range in air-cooled version; the equipments can be configured for any specified voltage configurations. These transformers provide ultimate isolation parameters for critical loads against switching spikes, surges and any electrical ground noise.

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14.0 MAJOR BILL OF MATERIALS

Sl.

No Item Description Specs / Cat No. Legend Qty

CONVERTER

1. INPUT TXM MODULE ONU-31/85/268/GX3-ITTP ---- 1

2. INPUT CHOKE MODULE ONU-31/85/268/GX3-CHL --- 1

3. SOFTSTART MODULE ONU-31/85/268/GX3-SSM ---- 1

4. CON BRIDGE MODULE CONV/3FC/85I/268/GX3-CBM ---- 1

5. CAPACITOR MODULE ONU-31/85/268/GX3-CM ---- 1

6. BUCK CON MODULE ONU-31/85/268/GX3-BCM ---- 1

7. MAIN CONTROL CARD MODULE ONU-31/85/268/GX3-MCCM ---- 1

8. POWER SUPPLY MODULE ONU-31/85/268/GX3-PSM ---- 1

9. FAN POWER SUPPLY MODULE ONU-31/85/268/GX3-FPSM ---- 1

10. LCD DISPLAY DU3013R1 -- 1

11. INDICATION CARD DU2036 PCB 20 1

12. SPACE HEATER 80W 230V AC SPH 1

13. SOCKET 6A 3PIN 240V AC SKT 1

14. CFL LAMP WITH HOLDER 11/12W, 230V AC LAMP 1

15. DOOR SWITCH 6A, 230V AC DS 1

16. COOLING FANS 3” 24V DC F1,F2,F3,F5 27NOS

17. COOLING FAN 4” 240V AC F4 1NO

18. EXHAUST FAN 6” 240V AC -- 5NO

INVERTER

19. TXM & FILTER MODULE ONU-31/85/268/GX3-ITSP ---- 1

20. STATIC MODULE ONU-31/85/268/GX3-SM ---- 1

21. INV BRIDGE MODULE ONU-31/85/268/GX3-IBM ---- 1

22. BOOSTER MODULE ONU-31/85/268/GX3-BM ---- 1

23. CAPACITOR MODULE ONU-31/85/268/GX3-CM ---- 1

24. MAIN CONTROL CARD MODULE ONU-31/85/268/GX3-MCCM ---- 1

25. POWER SUPPLY MODULE ONU-31/85/268/GX3-PSM ---- 1

26. FAN POWER SUPPLY & PARALLEL

BLOCK MODULE ONU-31/85/268/GX3-FPSPBM ---- 1

31. COOLING FANS 3” 24V DC F7-F9 29NOS

32. COOLING FAN 4” 240V AC F6,F10 2NO

SWITCHING CUBICLE

34. INPUT MCCB FOR UPS

200 A, TP, 415VAC T3S 250 FF TMD R200 ISDA051268R1 (50 KA )

M1-M2 2

35. INPUT MCCB FOR SCVS

250A, TP, 415VAC 50KA, T3S250FF TMD

R200,1SDA051269R1)

M3 1

36. BATTERY MCCB 400A, 3P, 500V DC,

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37. UPS OUTPUT MCCB 400 A, 3P, 415VAC

T5N 400FF TMA R400 M9-M10 2

38. STATIC / BYPASS INPUT MCCB 400 A, 3P, 415 VAC

T5N 400FF TMA R400 M7-M8 2

39. MANUAL BYPASS MCCB 400 A, 3P, 415 VAC

T5N 400FF TMA R400 M11 1

SCVS (BYPASS PANEL)

44. BUCK BOOST TRANSFORMER SCVS/11/85/00-ITSP BB1&BB2 2

45. SENSING TRANSFORMER DU-SVS-SENS-01 ST1 1

46. ISOLATION TRANSFORMER IT-31/85/00/TX-F TXM3 1

47. VARIAC 60A 2COIL A/C TYPE VR1&VR2 2

48. MOTOR 220 V, 1φ, 50Hz, 60 RPM, 10 Kg –

cm --- 1

49. COOLING FAN 6”, 230V AC --- 6

51. INPUT METER 3 ½ DIGITAL (VAF 3φ) M1 1

52. OUTPUT METER 3 ½ DIGITAL (VAF 1φ) M2 1

53. CONTACTOR 115A TP AC CR3 1

54. CONTROL CARD DP-01

DP-001 M0 0 --- 1

57. SOCKET 6A 230V AC SKT 1

Sl.No ITEM DESCRIPTION MAKE

1 MAGNETICS DUBAS

2 SWITCHGEAR / MCCB SCHNEIDER / ABB / L & T / SEIMENS

3 PCA DUBAS

4 CAPACITOR SARDA / ALCON / RESCON / KENDEIL

5 COOLING FAN HICOOL / NISIKI / SUNON

6 IGBT SEMIKRON/FUJI/INFINEON/ MITSUBISHI

7 ENCLOSURE DUBAS

8 BATTERY EXIDE

9 _VARIAC _RADIOTONE

10 _{SERVO MOTOR} _{PRECISSION / ALL-STEP}