UPS Training

HIPULSE UPS

Sachin Parsekar
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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

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OGA-1

FRONT VIEW

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900 1250 1890

80kVA 6 pulse UPS 120kVA 6 pulse UPS 120-200kVA 12 pulse UPS

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OGA-2
TOP VIEW

1680
1100 2090

80kVA 6 pulse UPS 120-200kVA 6 pulse UPS 120-200kVA 12- pulse UPS

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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

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 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

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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

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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

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 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

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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

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 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

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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

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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

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 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

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HVI Board:-

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Rectifier Logic Board:-

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Inverter Logic Board:-

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OPERATOR LOGIC BOARD:-

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UPS LOGIC BOARD:-

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Parallel Logic Board PCB:-

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 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

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UPS PARAMETER
MENU

MEASUREMENT

FUNCTION

MAINTENANCE

SETUP

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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
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TROUBLE SHOOTING-2

LCD- MESSAGE DETAILS RECTIFICATION

EMERGENCY STOP This will shut down the Rectifier,
nverter,Bypass, Battery due to
local or remote EPO
Check EPO switch pressed on
UPS panel or Remotely , check
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
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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

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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

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TROUBLE SHOOTING-5
LCD- MESSAGE DETAILS
DC BUS :UNDER VOLTAGE When the inv.is operating on the
If the input a.c. power battery,&
this message is displayed cannot
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
battery is discharging . It normally
accompanies a [BYP:ABSENT]
or [RECT: OFF]message
BATTERY E.O.D. The inv. Will transfer to Bypass.
This alarm comes whenever the
rectifier(battery charger) is not
producing its correct o/p Volts
correctly set in the setup menu
BATTERY: UNDER TEST Periodic battery test
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RECTIFICATION
Check Rectifier Float voltage
Check Battery parameter correctly
set in the SETUP menu
Check Battery Discharge Current
Check Battery parameter correctly
set in the SETUP menu
Check Rectifier Float voltage
Reset the UPS system by restart
Check the rectifier float level
Check the battery parameter
--
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

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Emerson - Consider It Solved

THANK YOU FOR CHOOSING EMERSON

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