UPS Training
HIPULSE UPS
Sachin Parsekar
1
FEATURES
High reliability IGBT inverter
Available with 6 or 12 pulse rectifier
Paralleling of up to six units using either modular
or centralised static bypass switch
High efficiency EcoMode
Advanced battery management
Backfeed protection
Battery ground fault warning
Available in LBS topology for “High availability ”
applications
Frequency converter 50/60 Hz with or without battery
SNMP network compatible with dynamic monitoring
BMS connectivity through either Modbus,
JBus or PROFIBUS
Optional monitoring through Netcom Card by
using LAN Network or Internet.
Many other optional features to suit your power needs
12/11/2010
2
OGA-1
FRONT VIEW
............................................
............................................ ............................................
............................................ .......................
....................... ...............................
............................... ............................................
............................................ .......................
.......................
............................................
............................................ ............................................
............................................ .......................
....................... ...............................
............................... ............................................
............................................ .......................
.......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
1900
............................................ ............................................ .......................
1900
............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
............................................ ............................................ ....................... ............................... ............................................ .......................
900 1250 1890
80kVA 6 pulse UPS 120kVA 6 pulse UPS 120-200kVA 12 pulse UPS
12/11/2010
3
OGA-2
TOP VIEW
1680
1100 2090
80kVA 6 pulse UPS 120-200kVA 6 pulse UPS 120-200kVA 12- pulse UPS
12/11/2010
4
PCBs
Rectifier logic board
Inverter logic board
UPS logic board
Parallel logic board
Parallel Conn. board
AS400 board 1
X3
Q1 Q2 Q4
12
HVI board X4
12
Q3
-
U1 V1 W1 U3 V3 W3 N3 N2 U2 V2 W2
12/11/2010
5
PCBs (contd.)
Operator Control MIMIC
Operator logic board
DC-DC board
AC-DC board
Rectifier Driver Board
1
X3
Q1 Q2 Q4
Static switch driver board 12
X4
12
Q3
IGBT driver PCB
+
-
U1 V1 W1 U3 V3 W3 N3 N2 U2 V2 W2
12/11/2010
6
Basic Block Diagram of UPS
Maintenance Bypass
Isolator Q3
Input Maintenance Bypass Line
Bypass
Supply Bypass Isolator Q2
Static Bypass Line BYP.STATIC
SWITCH
Output
DC Bus INV.STATIC Isolator Q4
RECTIFIER INVERTER
SWITCH
Input Input Output
Isolator Q1
Mains Supply
UPS MODULE
Supply
Battery
Breaker
BATTERY
12/11/2010
7
POWER CIRCUIT
Q2
BYPASS
SUPPLY
Q4
Q1
O/P OUTPUT
INPUT I/ P STATIC
RECTIFIER INVERTER TXR SUPPLY
MAINS CHOKE SWITCH
SUPPLY CAP
INPUT
FUSES
REC IGBT
DCCT
DRV DRV
DC
INPUT INPUT F/B. INVERTER INVERTER
VOLTAGE C.T. Battery DCCT F/B
RLB ILB
Breaker
Box
12/11/2010
8
POWER CIRCUIT
MANTENANCE
Q3 BYPASS
BYPASS BYPASS
Q2 VOLTAGE FUSES
BYPASS CT
BYPASS
BYPASS
SUPPLY
SUPPLY
Q4
O/P OUTPUT
INPUT STATIC
RECTIFIER INVERTER TXR SUPPLY
MAINS SWITCH
SUPPLY CAP
OUTPUT OUTPUT
VOLTAGE CT
12/11/2010
9
POWER CIRCUIT
BYPASS
SUPPLY
OUTPUT
INPUT STATIC
RECTIFIER INVERTER SUPPLY
MAINS SWITCH
SUPPLY
REC IGBT ST/ SW
DRV DRV DRV
RLB ILB
OLB MIMIC
HVI ULB PLB
AS400
12/11/2010
10
CONTROL POWER GENERATION
Q2 BYPASS
FUSES
BYPASS
BYPASS
SUPPLY
SUPPLY
SPLIT
SPLIT
BYPASS
BYPASS
LINK
LINK INPUT
FUSES Q4
Q1
INPUT INPUT STATIC OUTPUT
MAINS RECTIFIER INVERTER SUPPLY
CHOKE SWITCH
SUPPLY
CONTROL CONTROL CONTROL
FUSES FUSES FUSES
+12V AC-DC T2 T3 DC-DC +12V
RECTIFIER INVERTER
0 POWER TXR TXR POWER 0
LOGIC LOGIC
SUPPLY SUPPLY
BOARD - 12V - 12V BOARD
BOARD BOARD
12/11/2010
11
RECTIFIER CONTROL SYSTEM
Q1 I/p Fuses
INPUT
I/ P TO
MAINS RECTIFIER
CHOKE INVERTER
SUPPLY
REC
DRV
BATT.
CURRENT
FEEDBACK
DC VOLTAGE
INPUT C.T.
RLB
RLB BATTERY
BREAKER
INPUT VOLTAGE
BOX
OLB MIMIC
MIMIC
ULB PLB
AS400
AS400
ON GENERATOR
HVI
12/11/2010
12
INVERTER CONTROL SYSTEM
O/P TO
INVERTER TXR & STATIC
CAP. SWITCH
D.C. BUS
IGBT
DRV
INVERTER
LOGIC BOARD
INVERTER DCCT
INVERTER VOLTAGE
MIMIC OLB
PLB ULB
INVERTER OFF AS400
HVI
12/11/2010
13
STATIC SW CONTROL SYSTEM
BYPASS
SUPPLY
Q4
OUTPUT
STATIC SUPPLY
INVERTER
SWITCH
ST.SW.
DRV.
MIMIC
OUTPUT CT
BYPASS VOLTAGE
BYPASS CT
INVERTER VOLTAGE
OUTPUT VOLTAGE
ULB OLB
HVI
12/11/2010
14
HVI Board:-
12/11/2010
15
Rectifier Logic Board:-
12/11/2010
16
Inverter Logic Board:-
12/11/2010
17
OPERATOR LOGIC BOARD:-
12/11/2010
18
UPS LOGIC BOARD:-
12/11/2010
19
Parallel Logic Board PCB:-
12/11/2010
20
LED’S ON MIMIC
Inverter OK Load Bypass LCD Screen Load Bar Graph
% of load
NORMAL
OPERATION
Bypass OK
Rectifier OK
Battery CB open ESC MENU ENTER
Inverter switched OFF Battery Bar Graph
through this switch Load inv Hooter Cancel % of Battery charge
12/11/2010
21
UPS PARAMETER
MENU
MEASUREMENT
FUNCTION
MAINTENANCE
SETUP
12/11/2010
22
TROUBLE SHOOTING-1
The UPS provides three level of indication for fault diagnosis
1) LED indication on PCB 2) LCD display 3) Code no on UPS Logic Board
LCD- MESSAGE DETAILS RECTIFICATION
NORMAL OPERARTION
BYPASS SWITCH OPEN Switch position checked check aux contact of power switch
OUTPUT SWITCH OPEN through aux contact check HVI connector
RECTIF. SWITCH OPEN check HVI & UPSLB board
BATTERY CB OPEN
MANUAL BYPASS CLOSED
BYPASS ABSENT Bypass supply < 50V check bypass supply voltage
(bypass switch closed) availability
BYPASS OVERVOLTAGE Bypass voltage crossing check setting in SET –
BYPASS UNDERVOLTAGE its limits VOLTAGE- LIMITS UPPER-
LOWER
BYP.FREQUENCY ERROR Check bypass voltage is within
selected frequency range,
SETUP – FREQUENCY SYNC
WINDOW
BYP.PHASE ROT ERROR It monitors Supply phase sequence The supply lines have been cross-
12/22/2010 connected and the phase sequence
is incorrect
23
TROUBLE SHOOTING-2
LCD- MESSAGE DETAILS RECTIFICATION
EMERGENCY STOP This will shut down the Rectifier, Check EPO switch pressed on
nverter,Bypass, Battery due to UPS panel or Remotely , check
local or remote EPO the continuity of the circuit to
the remote switch , aux terminal
block X4 pin5 and 6 normally
closed.
INV OFF Inverter is not producing its correct Check inv switched off
output voltage error intentionally,
INV UNDERVOLTAGE Check PWM pulses on ILB,
waveform
INV OVERVOLTAGE Check for Led status on ILB
OUTPUT : NO VOLTAGE Check for output voltage peak
has flattened
OUTPUT :WAVEFORM ERR Check for Output voltage w.r.t.
its Limits set
INV FREQUENCY ERROR Check for proper selection of
12/22/2010 jumper for single or parallel
mode operation
24
TROUBLE SHOOTING-3
LCD- MESSAGE DETAILS RECTIFICATION
INV. OVERTEMPER Inv. Stops & load transfer Check outside & inside ambient 0C
OVER TEMP. SHUTDOWN to Bypass.after 3min. Check cooling restriction,fan failure
Check Thermostat’s continuity
Check X12 jumper on ILB closed
OVERLOAD PRESENT Load will transfer to bypass after Check output current for verification
OVERLOAD SHUTDOWN predetermined time Check kVA entered in SETUP menu
Check CT ratio & no open circuit
condition via X19,20,21 on HVI
BATTERY: FUSE FAIL If mains power fails load Check micro switch on fuse
power fails
BATTERY : TEST FAILED While battery testing,If this alarm Check BCB for correct operation
is not accompanied by a required Check Battery Cell Voltage.
[Battery C.B. open ] or
[BATTERY: FUSE FAIL ]
message
12/11/2010
25
TROUBLE SHOOTING-4
LCD- MESSAGE DETAILS RECTIFICATION
RECT: CURRENT LIMIT Messages are self explanatory Check Rectifier SCR, DC
capacitor, Battery , Inverter arm,
AC capacitor shorting Check RLB
RECT FUSE FAIL Messages are self explanatory Check HVI jumper X17 1-2
BYP: SCR FAILURE One or more of the static switch SCR’s Check Bypass side SCR for
has developed a fault. The bypass short condition
would not support the load in the event Check Static switch driver board
of UPS failure
INV.UNSYNCHRONIZED Bypass supply being outside an Check the rate at which input
acceptable frequency window . Frequency is varing
Check the frequency window
12/11/2010
26
TROUBLE SHOOTING-5
LCD- MESSAGE DETAILS RECTIFICATION
DC BUS :UNDER VOLTAGE When the inv.is operating on the Check Rectifier Float voltage
If the input a.c. power battery,& Check Battery parameter correctly
this message is displayed cannot set in the SETUP menu
be restore, then when the battery
voltage has fallen below a preset
value shut down loads
BATTERY : ON LOAD This is a status warning that the Check Battery Discharge Current
battery is discharging . It normally Check Battery parameter correctly
accompanies a [BYP:ABSENT] set in the SETUP menu
or [RECT: OFF]message Check Rectifier Float voltage
BATTERY E.O.D. The inv. Will transfer to Bypass. Reset the UPS system by restart
This alarm comes whenever the Check the rectifier float level
rectifier(battery charger) is not Check the battery parameter
producing its correct o/p Volts
correctly set in the setup menu
BATTERY: UNDER TEST Periodic battery test --
12/11/2010
27
TROUBLE SHOOTING-6
LCD- MESSAGE DETAILS RECTIFICATION
BOOST TIME EXPIRED This is only applicable to systems Check battery string for faulty cells
which include boost charge option Press reset on UPSLB
RECT: OFF This shows that rectifier has been Check the rectifier selected ON on
RECT: OFF VIA DISPLAY selected off by the operator from operator control panel.
either front panel or an external Check the rectifier block led ON on
PC or by a switch on ups PCB the RLB.
INV.: OFF Inv. Has been selected off either by Check the inverter selected ON on
front panel or by external p.c. operator control panel.
INV.: OFF VIA DISPLAY Check the Inverter block led ON on
the ILB.
BYP.: XFER COUNT BLOCK Due to fault in Inverter, if load Check ILB output
transfers to Bypass, and back to Check UPSLB output
Inverter, more than 8 times
LOAD ON BYPASS Load is being powered by bypass Check IGBT driver board
check for other fault message Check ILB output
12/11/2010
28
Emerson - Consider It Solved
THANK YOU FOR CHOOSING EMERSON
12/11/2010
29
