Operational Manual for 2x85kVA Parallel UPS System

Operational & Instruction Manual for 2x85kVA Parallel Redundant UPS system
2x85kva Parallel Redundant UPS System
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Operational & Instructional Manual For

2x85kVA Parallel Redundant
UPS System
This
DESCRIPTION
: 2 x 85 KVA, 3 - 1 ON-LINE UPS
RATING
: 2 x 85 KVA, 3 - 1
INPUT
: 415 V AC, 10%,
OUTPUT
: 230 V AC, 1%, 50HZ
DC VOLT
: 268V
UNIT SL #
W.O.NO
: 1301001
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
----------
2.0
Technical Specification
----------
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
5.0
Installation & Commissioning

General
----------
15
Installation
----------
16
Commissioning
----------
18
Functional Checks
----------
19
Controls
----------
20
Indications and Alarms
----------
21
Indications, Controls
6.0
Display at UPS
----------
23
7.0
Routine Maintenance for UPS
----------
25
----------
25
----------
29
8.0
9.0
Trouble Shooting For UPS

Failure Report
10.0 Warranty Details
----------
30
11.0 Quality Policy
----------
31
12.0 Electrical Supply Better Way
----------
31
13.0 Product Varieties
----------
32
14.0 Bill of materials
----------
33
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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.
The UPS System consists of essentially 5 blocks.
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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
Worlds 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 1 bridge configured Inverter.
The output of the
inverter bridge is isolated by output transformer. Harmonic voltages are filtered by output filter
capacitor.
IGBTs are switched ON and OFF as per the pulses from driver cards, received at their gate terminals.
IGBTs 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.
D. BOOSTER
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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.
UPS PARTICULARS/SPECIFICATION
No
GENERAL
1.0
Make & Country
2.0
Type
3.0
4.0
Input

Voltage

No. of Phase

Frequency

P.F
UPS Capacity
At 0.8 PF
5.0
6.0
Output Voltage and regulation

Frequency and regulation
7.0
Metering
DUBAS INDIA
Double Conversion Online
415V, 10%
3, 5wire (3P+N+Earth)
50Hz. 5%
> 0.9 at rated load
68KW
1, 230V AC, 2%
50 Hz 0.5%
Type
Accuracy
8.0
Type of cooling
CONVERTER
1.0
Type
LCD (32 Bit display) with operating key pads

2%
Forced Air
Constant voltage current limit type
2.0
Type of Control
3.0
4.0
5.0
Input voltage
output Voltage
Voltage Regulation for AC Input Variations of +
10% & Load Variations
Ripple
6.0
DATA
DSP Based PWM Technology

415V+ 10%
400 VDC
+ 1%
< 2%
7.0
Power Walk-in circuit provided
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Yes
BATTERY CHARGER/BUCK CONVERTER

1.0
Type
2.0
3.0
Type of Control
Input voltage

400 VDC
4.0
Nominal Output Voltage

Float Voltage

Float Current

Boost voltage

Boost current
248 VDC
248V
65A Factory set
303V
90A starting current
45A finishing current
5.0
+2%
6.0
Voltage Regulation for Input Variations & Load

Variations
Ripple
7.0
Power Walk-in circuit provided
Yes
< 2%
INVERTER SYSTEM
1.0
Type
Solid state, static control, using IGBTs
2.0
Type of Control
3.0
Input
400V DC
4.0
Output AC voltage
1, 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
9.0
Harmonic Distortion
Transient Voltage For
50% step load change
Sudden input voltage change of 10%
Loss and return of input AC power
< 3% on 100% linear load
TRANSIENT RECOVERY TIME

Recovery to 95%
BOOSTER
1.0
Type
2.0
Type of Control
5%
5%
5%
<15 m sec.
3.0
Input voltage
193-248 VDC
4.0
Output Voltage
400 VDC
STATIC TRANSFER SWITCHES

1.0
Type
2.0
Voltage
3.0
Frequency
4.0
Transfer time
INVERTER / RECTIFIER TRANSFORMER
1.0
Type
2.0
Type of cooling
3.0
Insulation class
Solid state static control (SCR based)

230 V
50Hz, + 5%
< 4 msec (sync transfer)
Dry type, Forced Air cooled, Double wound
Forced air
Class H with temperature raise limit to
Class F
MANUAL BYPASS SWITCH

1.0
Capacity
Full rated
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ENCLOSURE
1.0
2.0
3.0
4.0
5.0
6.0
Type
Sheet Thickness Frame
Degree of protection
Paint Shade
Cable Entry
Overall Dimensions
Converter
Inverter
Switching cubicle
SCVS (BYPASS)
Free standing, Floor vertical mounted

2 mm
IP 42
RAL 7035
TOP
WXDXH
800x800x2200mm
800x800x2200mm
600x800x2200mm
800x800x2200mm
Single line diagram for 2x85 kva UPS system
PART DESCRIPTION:
10
Fig-1
General arrangement diagram for 2x85 kva UPS system
11
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Fig-2
ROOM LAYOUT ARRANGEMENT DIAGRAM FOR 2X85 KVA UPS SYSTEM

12
Fig-3
INTERLOOPING POWER WIRING DIAGRAM

13
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Fig 4
INTERLOOPING CONTROL WIRING DIAGRAM

CONVERTER TO INVERTER
CONVERTER TO SWITCHING CUBICLE
INVERTER TO CONVERTER & SWC
INVERTER1 TO INVERTER2
14
SWITCHING CUBICLE TO CONVERTER
Fig-5
System Power wiring diagram

1. Converter block
Fig-6
2. Inverter block
15
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Fig-7
3. Static switch block
Fig-8
4.0 INSTALLATIONS AND COMMISSIONING

16
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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.
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
IT IS NOT POSSIBLE TO INSTALL AT THE SITE.
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
17
1.
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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.
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.
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.
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Operational & Instruction Manual for 2x85kVA Parallel redundant UPS system
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
Output Cable from SWC

to ACDB for 400A Main
DB incomer
95 sq mm, 4 Core,1R,copper
cable/70 sq mm, 4 core, 2R,
Alluminium
Alluminium

to ACDB for 63A Boiler
DB incomer
Alluminium
63A,DP, 415V AC
MCB
cables are
Customer scope

to ACDB for 63A
Turbine DB incomer
Alluminium
63A,DP, 415V AC
MCB
cables are
Customer scope
Battery Cable
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
N.A
cables are
dubas scope
Interconnection DC
power Cable
N.A
cables are
dubas scope
Input CableUPS &

Bypass
200A,50kA, TP,
415V AC , MCCB
cables are
Customer scope
400A,TP, 415V
AC , MCCB
cables are
Customer 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.
Commissioning procedure:
19
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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 PCAs 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.
bb) Put the load at output and observe the sharing of the load percentage at both UPS LCD display.
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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
5
2
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
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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)
Mains ON
OFF
ON
(Green)
Converter ON
Batt. ON
Charge
a)Input breaker OFF

b)Input Phase Fail
c)Input voltage out of specified
range
d)Input fail
Converter is ON and the Converter
output voltage is = 248V DC
OFF
a)Conv. Control switch OFF

b)Conv. Fault
ON
(Green)
Converter is ON and battery

charging is under process
OFF
ON
(Green)
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.
Healthy Condition
Healthy Condition
a)Conv. OFF/Fault
b)Battery Breaker OFF
a) Check WTD of Conv.OFF & Conv.Fault

b) Switch ON the breaker
Inverter is on and the output

voltage is greater 204V Ac
OFF
ON
(Green)
Self Inverter is ON and feeding the

load
OFF
Healthy Condition
a)Ensure switch is kept always ON

c)Check WTD of Conv. Fault
a)Inv. Control switch OFF

b)Output voltage is less than 204V
AC
c)Inverter Fault
Inverter ON
Load on UPS
Input breaker is ON, Input voltage

is healthy and within specified
range.
a)Self Inverter is OFF/fault

b)Load on Static Bypass
Healthy Condition
a)Switch On the Inv. Control switch
b)Check Inv. Output voltage set (240V)
c)Check WTD of Inv.Fault
Healthy Condition
a)Check WTD of Inv.OFF & Inv.Fault
b)Check WTD of Load on Static Bypass
22
ON
(Green)
Bypass
Healthy
OFF
Load on
battery
ON
(Yellow)
OFF
Batt. Low
Pre-Alarm
ON
(Yellow)
Load On
Bypass
ON
(Yellow)
Converter
trip
ON
(Red)
Input
Under/Over
volt
ON
(Red)
DC Low
ON
(Red)
static input breaker in on condition

and bypass input voltage is with in
the range
a) Static input breaker off
b) SCVS output voltage out of
specified range
Battery is supported to inverter for
the following condition.
a)converter fault
b)mains fail
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Healthy Condition
a) Switch on the breaker
b) Wait till the voltage reaches within
specified range.
a)Check WTD of CON.Fault

b)Check the mains voltage
Converter in healthy condition

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
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.
TRIP INDICATION WITH
Converter has tripped under
following conditions
a)Mains ON indication OFF
b)Converter output voltage high
c)Input Current high
Input Voltage is out of specified
limits
Battery has got discharged to its
cutoff level their by tripping
inverter.
Inverter has tripped under
following conditions
a) dc low.
b) output voltage out of specified
range.
c) inverter overload
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.
a) Check WTD of Inv. Fault

b) Check WTD of Inv. ON
ALARM
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.
Check Input supply for phase fail or
ensure the Input supply is within specified
limits
Ensure converter is ON and battery is on
charge.
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 trip
ON
(Red)
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
23
Check individual module fans are working

and ambient temperature is within
specified range. Wait for few minutes and
dubas
press Reset switch.
Master unit
Parallel mode
Load on
alternate ups
Sync ok
ON
(Green)
Based on which system is switched

on first.
Healthy Condition
ON
(Green)
ON
(Green)
If both the ups are working in

parallel conditions.
Healthy Condition
If load is feeding by the other ups
Check WTD of Inv.OFF & Inv.Fault in self

inverter.
If bypass voltage is synchronization

with UPS output voltage
Healthy Condition
ON
(Green)
NOTE: TRIP INDICATIONS ARE ACKNOWLEDGED BY PRESSING RESET SWITCH AND SYSTEM
WILL RESET FOR ITS OPERATION.
6. USER INTERFACE DISPLAY
Fig.10 Display Unit
KEY ITS FUNCTION
MODE KEY
24
dubas
Scroll the mode one by one.
ESCAPE KEY
To return to main mode.
ENTER KEY
To acknowledge the buzzer.
INCREMENT KEY
Enter into the sub modes of that selected mode.
DECREMENT KEY
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)
25
dubas
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 LEDs 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
BATT LOW
ALARM FOR
: When battery is discharged to its cut-off level after delivering the rated load for
a specified back-up time.
: 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.
8.0 TROUBLE SHOOTING FOR UPS

26
dubas
FAULT DIAGNOSTICS OF UPS

Sl.
No.
FAULT REPORT
Mains is present but

1
CHECK POINT
Input MCCB
Main-ON indication
is OFF
Input Voltage
OBSERVATION &
ACTION TO BE TAKEN
If input MCCB is OFF, then switch-ON the MCCB
& wait for 5 minutes.
If the input voltage is not within the specified
range then wait till the voltage comes back.
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.
Mains is present but

2
Converter Trip
indication is ON
Front user display

and indication
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.
Inverter is loaded on
Front user display
Battery always
and indication
If the Converter is tripped due to any one of

the above reasons, then press reset & reenergize the Converter.
Check the Battery Current & DC voltage
Battery is not
Front user display
charging
and indication
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.
Loose connections.
Low Battery Back-up
Battery
Battery not in Healthy condition.

Battery electrolyte is drained.
27
dubas
Check whether all Fans are ON. If any fan is OFF,
Abnormal Heat
Fans
Electrical Noise
Ground connections
Checks whether the system is earthed properly

otherwise check the earth connections.
Disconnect the load & try to switch-ON the System
Abnormal noise & trip at
Load
switch-ON
Time in Min.
then it should be replaced.
again. If it continues, then contact the service

personnel.
70
Overload Chart
60
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
50
40
30
20
10
0
1.04
1.10
1.16
1.22
1.28
1.34
1.40
1.46
Load Current x In
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 Output Under Voltage trip.
Press RESET switch, If problem
The UPS output has dropped below the set
persists
voltage level.
Authorized service personnel.
Inverter Output Over Voltage trip.
The UPS output has risen above the set
persists
voltage level.
INVERTER
INVERTER TRIP
UV
INVERTER TRIP
OV
inform
inform
to
to
the
the
Switch OFF inverter, allow the

INVERTER TRIP
BI
DC bus LOW trip
battery to get charged, press
This indicates that the battery has fully
reset switch and switch ON
given up its backup power.
inverter.
If
call dubas.
28
problem
persists
dubas
INVERTER TRIP
BH
INVERTER TRIP
OL1
OL2
OL3
OL4
A L A R M FO R
OL
A L A R M FO R
DC bus HIGH trip
This indicates that the DC bus voltage is
persists
beyond the specified limit.
Inverter Over Load or Over current trip.

This indicates that the Inverter Output
current/ power has exceeded its rated
value. (refer Fig-11)
inform
to
the
Load has to be reduced. Press

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

Inverter is overload for OL1/2/3
alarm
&
countdown
stops
automatically.
Battery is discharged to its end cell cut-Off
Ensure load is switched OFF or
voltage
input source is restored.
Error Description
Action to be taken
Input Over Voltage trip.
Wait till the Input source is
CONVERTER TRIP
This trip occurs when the Mains supply is
healthy. Press RESET switch, If
AC OV
above the specified window (Above 10%
problem persists inform to the
of the nominal input voltage)
BL
Error Displayed
CONVERTER
CONVERTER TRIP
AC UV
CONVERTER TRIP
OC
CONVERTER TRIP
DC OV
Wait till the Input source is
Input Under Voltage trip.

This trip is due to the low input voltage
(Below 10% of the nominal input voltage)
healthy. Press RESET switch, If

problem persists inform to the
If it happens frequently, then
Input Over Current trip.

This indicates that the line current is more
than the rated current of the system.
check the Inverter load & check

input
voltage.
If
problem
persists contact dubas
DC Over Voltage trip.
This indicates that the DC voltage has
persists
raised above the specified level.
DC Under Voltage trip.

CONVERTER TRIP
This indicates that the DC voltage has
DC UV
fallen below the specified value of the

Converter.
29
inform
to
the
Check the DC bus voltage OR

this can happen even during
short circuit.
dubas
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
30
dubas
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 companys 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 companys 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 manufacturers
certification that the batteries are well maintained.
6. Our warranty or any other services is limited to manufacturing defects in the equipment
only.
31
dubas
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).
32
dubas
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.
33
dubas
14.0 MAJOR BILL OF MATERIALS

Sl.
No
Item Description
Specs / Cat No.
1.
INPUT TXM MODULE
2.
Legend
Qty
ONU-31/85/268/GX3-ITTP
----
INPUT CHOKE MODULE
ONU-31/85/268/GX3-CHL
---
3.
SOFTSTART MODULE
ONU-31/85/268/GX3-SSM
----
4.
CON BRIDGE MODULE
CONV/3FC/85I/268/GX3-CBM
----
5.
CAPACITOR MODULE
ONU-31/85/268/GX3-CM
----
CONVERTER
6.
BUCK CON MODULE
ONU-31/85/268/GX3-BCM
----
7.
MAIN CONTROL CARD MODULE
ONU-31/85/268/GX3-MCCM
----
8.
POWER SUPPLY MODULE
ONU-31/85/268/GX3-PSM
----
9.
FAN POWER SUPPLY MODULE
ONU-31/85/268/GX3-FPSM
----
10.
LCD DISPLAY
DU3013R1
--
11.
INDICATION CARD
DU2036
PCB 20
12.
SPACE HEATER
80W 230V AC
SPH
13.
SOCKET
6A 3PIN 240V AC
SKT
14.
CFL LAMP WITH HOLDER
11/12W, 230V AC
LAMP
15.
DOOR SWITCH
6A, 230V AC
DS
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
----
20.
STATIC MODULE
ONU-31/85/268/GX3-SM
----
21.
INV BRIDGE MODULE
ONU-31/85/268/GX3-IBM
----
22.
BOOSTER MODULE
ONU-31/85/268/GX3-BM
----
23.
CAPACITOR MODULE
ONU-31/85/268/GX3-CM
----
24.
MAIN CONTROL CARD MODULE
ONU-31/85/268/GX3-MCCM
----
25.
POWER SUPPLY MODULE
ONU-31/85/268/GX3-PSM
----
26.
FAN POWER SUPPLY & PARALLEL

BLOCK MODULE
ONU-31/85/268/GX3-FPSPBM
----
27.
SPACE HEATER
80W 230V AC
SPH
28.
SOCKET
6A 3PIN 240V AC
SKT
29.
11/12W, 230V AC
LAMP
30.
DOOR SWITCH
6A, 230V AC
DS
31.
COOLING FANS
3 24V DC
F7-F9
29NOS
32.
COOLING FAN
4 240V AC
F6,F10
2NO
33.
EXHAUST FAN
6 240V AC
--
5NO
M1-M2
M3
M4-M6
SWITCHING CUBICLE
34.
INPUT MCCB FOR UPS
35.
INPUT MCCB FOR SCVS
36.
BATTERY MCCB
200 A, TP, 415VAC

T3S 250 FF TMD R200
ISDA051268R1 (50 KA )
250A, TP, 415VAC 50KA,
T3S250FF TMD
R200,1SDA051269R1)
400A, 3P, 500V DC,
T5N 400FF TMA R400
34
dubas
37.
UPS OUTPUT MCCB
38.
STATIC / BYPASS INPUT MCCB
39.
MANUAL BYPASS MCCB
40.
SPACE HEATER
41.
SOCKET
42.
400 A, 3P, 415VAC

T5N 400FF TMA R400
400 A, 3P, 415 VAC
T5N 400FF TMA R400
400 A, 3P, 415 VAC
T5N 400FF TMA R400
M9-M10
M7-M8
M11
80W 230V AC
SPH
6A 3PIN 240V AC
SKT
11/12W, 230V AC
LAMP
43.
DOOR SWITCH
6A, 230V AC
DS
44.
BUCK BOOST TRANSFORMER
SCVS/11/85/00-ITSP
BB1&BB2
45.
SENSING TRANSFORMER
DU-SVS-SENS-01
ST1
46.
ISOLATION TRANSFORMER
IT-31/85/00/TX-F
47.
VARIAC
60A 2COIL A/C TYPE
48.
MOTOR
49.
SCVS (BYPASS PANEL)
TXM3
VR1&VR2
220 V, 1, 50Hz, 60 RPM, 10 Kg

cm
---
COOLING FAN
6, 230V AC
---
50.
EXHAUST FAN
6 240V AC
--
5NO
51.
INPUT METER
3 DIGITAL (VAF 3)
M1
52.
OUTPUT METER
3 DIGITAL (VAF 1)
M2
53.
CONTACTOR
115A TP AC
CR3
54.
CONTROL CARD
DP-01
DP-001 M0 0
---
55.
SPACE HEATER
80W 230V AC
56.
11/12W, 230V AC
57.
SOCKET
58.
DOOR SWITCH
Sl.No ITEM DESCRIPTION
SPH
LAMP
6A 230V AC
SKT
6A, 230V AC
DS
MAKE
MAGNETICS
DUBAS
SWITCHGEAR / MCCB
SCHNEIDER / ABB / L & T / SEIMENS
PCA
DUBAS
CAPACITOR
SARDA / ALCON / RESCON / KENDEIL
COOLING FAN
HICOOL / NISIKI / SUNON
IGBT
SEMIKRON/FUJI/INFINEON/ MITSUBISHI
ENCLOSURE
DUBAS
BATTERY
EXIDE
VARIAC
RADIOTONE
10
SERVO MOTOR
PRECISSION / ALL-STEP
11
METER
EIC
35

Operational Manual for 2x85kVA Parallel UPS System

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Operational Manual for 2x85kVA Parallel UPS System

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Operational & Instruction Manual for 2x85kVA Parallel Redundant UPS system

2x85kva Parallel Redundant UPS System

Congratulation for choosing dubas product. You now

understanding the importance of UPS in a critical

pioneering works in power electronics. dubas is an

accomplish highest customer satisfaction.

Operational & Instructional Manual For

: 2 x 85 KVA, 3 - 1 ON-LINE UPS

: 415 V AC, 10%,

: 230 V AC, 1%, 50HZ

PLEASE READ THE MANUAL THOROUGHLY,

Room layout diagram

Interconnection power wiring diagram

Interconnection control wiring diagram

System power wiring

Installation & Commissioning

Indications and Alarms

Routine Maintenance for UPS

Trouble Shooting For UPS

10.0 Warranty Details

11.0 Quality Policy

12.0 Electrical Supply Better Way

13.0 Product Varieties

14.0 Bill of materials

1.0 SYSTEM DESCRIPTION

The UPS System consists of essentially 5 blocks.

The output of the

2.0 TECHNICAL SPECIFICATION

Output Voltage and regulation

LCD (32 Bit display) with operating key pads

DSP Based PWM Technology

Power Walk-in circuit provided

BATTERY CHARGER/BUCK CONVERTER

Constant voltage current limit type

DSP Based PWM Technology

Nominal Output Voltage

Voltage Regulation for Input Variations & Load

Power Walk-in circuit provided

Solid state, static control, using IGBTs

DSP Based PWM Technology

Accuracy (Steady State)

Better than 98%

50 Hz @ free running condition

< 3% on 100% linear load

TRANSIENT RECOVERY TIME

STATIC TRANSFER SWITCHES

Solid state static control (SCR based)

MANUAL BYPASS SWITCH

Free standing, Floor vertical mounted

Single line diagram for 2x85 kva UPS system

General arrangement diagram for 2x85 kva UPS system

ROOM LAYOUT ARRANGEMENT DIAGRAM FOR 2X85 KVA UPS SYSTEM

INTERLOOPING POWER WIRING DIAGRAM

INTERLOOPING CONTROL WIRING DIAGRAM

CONVERTER TO SWITCHING CUBICLE

INVERTER TO CONVERTER & SWC

SWITCHING CUBICLE TO CONVERTER

System Power wiring diagram

3. Static switch block

4.0 INSTALLATIONS AND COMMISSIONING

interconnections; tighten them if required.

contact of wire terminations & plug / sockets.

gases. These can damage the equipment seriously.