BATTERY SIZING CALCULATIONS

UPS RATING : 5 KVA Battery Type : 12V SMF

INV EFF. : 89% No. of Cells : 60
Load P.F. : 0.8 End Cell Voltage : 1.8
Back-up Time : 60 min

UPS rating x 1000x Load P.F.

IDC1 =
No of cells x Inv Eff. x End Cell voltage

5 x 1000 x 0.8
IDC1 =
60 x 89% x 1.8

= 41.615 A

Considering Factors:
K-Factor for 60 min = 1.56

Required Ah Rating = IDC1 x K factor

64.92 Ah

Referring Batery Manufacturer's Catalogue;

Battery Selected: 12V SMF, 65Ah, 10 blocks - 1set for 60min backup
Battery Make: EXIDE

REVISION : 00 PAGE :- 1 of 1 HHPE DOC. No. : 175BS12407

SUPPLIER HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
 CHARGER & INPUT TRANSFORMER SIZING CALCULATIONS

Sr. No UPS Rating IN KVA 5

1 Output Power Factor 0.8
2 Inverter Efficiency at 50% load 0.885
3 Battery AH Rating 65
4 No of Cells 60
5 Cell Nominal Voltage 2
6 Cell Float Voltage 2.25
KVA Rating x 1000 x Load PF
7 Inverter Input Current (Max) A 33.48
Inv. Eff x No of cells x Cell Float Voltage
8 Imax
9 Battery Charging Current B 10
10 Charger Rating C A+B 43.48
11 Charger KW Rating D C x No of cells x Cell Float Voltage / 1000 5.87
12 Charger Efficiency 0.94
13 Input Power Factor 0.8
14 Input Transformer Rating E D / (chrg eff x input PF) 7.81

SELECTED INPUT TRANFORMER IN KVA 8

REVISION : 00 PAGE :- 1 of 1 HHPE DOC. No. : 175CH12407

SUPPLIER HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
 HEAT LOSS CALCULATION

Charger efficiency @ 50% load = 92%

Inverter efficiency @ 50% load = 88.5%

Overall UPS efficiency @ 50% load = 0.92 x 0.885

= 0.8142
= 81.42%

UPS output KW = 5 KVA = 5 x 0.8 = 4 KW

Output KW 4
Input KW = ------------------ = -----------
Overall efficiency 0.8142
= 4.91 KW

Heat Loss = Input KW – Output KW

= 4.91 – 4
= 0.91 KW

Bypass (No load loss) = 0.08 KW

Total UPS Heat Loss = 0.08 KW +0.91KW

= 0.99KW

PAGE :- 1 of 1 HHPE DOC NO : 175HL12407

SUPPLIER HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
REV:0
B - 14/1 171, GIDC Electronics Zone,
Sector-25, Gandhinagar - 382044, Gujarat
TECHNICAL DATA SHEET

A SYSTEM DATA
1 Make HITACHI HI-REL
2 Rating 5KVA / 4KW
3 Configuration Parallel Redundant UPS System
4 UPS Overall Efficiency 84.60% at 100% load & Nominal Voltage
Dynamic Response under following
5
conditions
5.1 For 50% step load ± 5%
5.2 For 100% step load & unload ± 5%
5.3 Power supply interruption & restoration ± 1%
5.4 Load Transferred to bypass Line ± 10%
Recovery time after load change (100%-0-
5.5 Recovers to 98% in < 20 msec for single system
100%)
6 Audible Noise @ 1 meter distance <65 dbA
7 Enclosure Protection IP – 42
8 Finish Colour RAL – 7035 (Interior & Exterior)
9 Cable Entry Bottom
10 Type of cooling Forced Air Cooling (Internal Fans)
11 Testing Standards IEC 62040-3

B ENVIRONMENTAL
1 Design Ambient Temperature 50 deg. C
2 Relative Humidity 95% RH Non-Condensing
3 Altitude 1000 meter from MSL

C UPS INPUT POWER SUPPLY

1 Input Phase / Wire 3 PH, 3 WIRE
2 Input Voltage 415V
3 Voltage Tollerance ± 10%
4 Input Frequency 50HZ
5 Frequency Tollerance ± 5%
6 Power Factor (Approx. at rated load) 0.8
7 Recommended feeder KVA 2 times rated KVA with HRC fuse links

D RECTIFIER / CHARGER
1 Rectifier Unit 6 Pulse
2 DC Voltage (Nominal Voltage) 120V DC
3 Voltage Range 108V DC – 135V DC
4 Float Voltage 135V DC
5 Boost Voltage N.A.
6 Charging Type Automatic Float / Boost mode selection with current limit
7 Voltage Regulation ± 1%
8 Ripple With Batteries 1% RMS
9 Ripple Without Batteries 2% RMS
10 Recharge time on battery boost charge 8-10 Hrs.
11 Power Walk in time 10 - 30 Sec.

Title: "TECHNICAL DATA SHEET" FOR 2 X 5KVA Rev.: 0

Client: M/S XICON INTERNATIONAL LTD.
HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
Project: Rayalaseema Thermal Power Project, Stage-IV, Unit #6
Doc. No.: 175DS12407 Page 1 of 3
B - 14/1 171, GIDC Electronics Zone,
Sector-25, Gandhinagar - 382044, Gujarat
TECHNICAL DATA SHEET

E INVERTER
1 Type Designation IGBT based PWM Inverter
2 Rating (at specified ambient) 5KVA / 4KW
3 Output Voltage / No. of Phase 240V AC, 1 PHASE
4 Voltage Regulation ± 1% (Steady State)
5 Range of adjustment of output voltage ± 5% at rated load
6 Frequency 50HZ
7 Frequency Regulation ± 0.1% (Internal Oscillator)
8 Synchronizing Range 47HZ - 53HZ
9 Slew Rate 1Hz / Second
10 Inverter Efficiency 89% at 100% load
11 Voltage Waveform Sinusoidal
12 Load Power Factor 0.6 lag to Unity within KVA & KW rating
13 Load crest factor 3:1
< 2.5% for Linear Load
14 Harmonic Distortion at rated load
< 5% for Non-Linear Load
125% for 10 min,
15 Over loading capacity & duration 150% for 60 sec.
(20 minutes spacing between subsequent over loads)
30% rated (Semiconductor type)
16 Fuse Clearing (<1/4th cycle)
10% rated (High Speed type)

F STATIC SWITCH
1 No. of Static switch Two in each UPS system
Fully rated, Solid State employing back to back
2 Type of static switch
connected thyristors.
< 4 msec in Synch Mode
3 Transfer Time
< 20 msec In Asynch Mode
125% for 10 min,
4 Over loading capacity & duration
150% for 60 sec.
5 Short circuit capacity & duration 1000% for 10 msec.

G MANUAL BYPASS SWITCH

1 Make KAYCEE
2 Type Designation Make before break

H BATTERY
1 Make / Model EXIDE
2 Type of Battery cell SMFB
3 AH Rating 65AH
4 No. of Cells / Battery 10 NO.
5 Nominal Cell Voltage 12V / Cell
6 End Cell Voltage 10.8V / Cell
7 Back-Up time 60 MIN.
8 No. of battery banks TWO
9 Mounting arrangement/Rack dimensions Please Refer BATTERY GAD drg.

Title: "TECHNICAL DATA SHEET" FOR 2 X 5KVA Rev.: 0

Client: M/S XICON INTERNATIONAL LTD.
HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
Project: Rayalaseema Thermal Power Project, Stage-IV, Unit #6
Doc. No.: 175DS12407 Page 2 of 3
B - 14/1 171, GIDC Electronics Zone,
Sector-25, Gandhinagar - 382044, Gujarat
TECHNICAL DATA SHEET

I BYPASS TRANSFORMER WITH SERVO CONTROL VOLTAGE STABILISER

1 Make HITACHI HI-REL
2 Type Designation SCVS (Aux)
3 Rating 5KVA / 4KW
4 Input / Output voltage (SCVS) 240V / 240V, 1Ph
5 Accuracy of stabiliser ± 1%
6 Isolation X'mer voltage ratio / Freq. 415V, 3Ph, 50Hz / 240V, 1Ph, 50Hz

J AC DISTRIBUTION BOARD
1 Rating of board 5 KVA
2 Construction Non-compartment
3 Mounting Wall mounted type
4 Enclosure Protection IP-42
5 Incomer & Outgoing Feeder Details Please refer page 02 of 175CS12407

Title: "TECHNICAL DATA SHEET" FOR 2 X 5KVA Rev.: 0

Client: M/S XICON INTERNATIONAL LTD.
HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
Project: Rayalaseema Thermal Power Project, Stage-IV, Unit #6
Doc. No.: 175DS12407 Page 3 of 3
0HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED (Unit-II)
QUALITY ASSURANCE PLAN QAP # A12170407(0) Page # 1 of 4 FF – QAG – 20 (4)

W.O. Po/LOI CUSTOMER / CONSULTANT O/P Voltage BATTERIES – 2 SETS MODEL ITEM CONFIGRATIO
# N
TYPE AH QTY. I4 B4 STALLIO OTHE SA DR PR
N R
0407 3642,13 M/s Xicon international Ltd 240V AC SMFB 65 10N - - 5 KVA
/391- Project : Rayalaseema AH OS
325 Thermal Power project,
Stage-IV, Unit #6 (1x600
MW)

UPS AUXILIARY ACDB DCDB BATTERIES BATTERY BATTERY SPARES CELL RS485
SCOPE OF SUPPLY J.B. Rack BOOSTER
- - - -

RESPONSIBILITY TABLE (while approving Customer can also put his choice in the blank box ) ABBRIVIATION
AREA RESPONSIBILITY REMARKS BY CUSTOMER P PERFORM
SUPPLIER HHPE CUSTOMER / TPIA V VERIFY (Documents)
Incoming Inspection P V&P NA W WITNESS
Process Inspection N/A P NA N/A NOT APPLICABLE
System Testing N/A P V/W
Heat Run requirement N/A P V
Finished Goods Inspection N/A P V
Batteries: SMFB/LATB/PLANTE/NI- P V V
CD
Site Acceptance Test N/A P V/W
CLIENT’S REMARKS & APPROVAL >>> MARK / W (Witness) / V (Verification Of Records)

DOCUMENTS REQUIRED ANY OTHER COMMENTS BY CLIENT APPROVAL COMMENTS

DRAWINGS FOR APPROVAL
BILL OF MATERIAL FOR APPROVAL
LIGHT & FULL-LOAD TEST
INSPECTION VISIT
ANY SPECIFIC REMARKS & COMMENTS

HIREL CUSTOMER’s APPROVAL & DATE

Engineering By APPROVED BY DATE

02-02-2018

Dhruvil Patel Himanshu Mehta

0HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED (Unit-II)
QUALITY ASSURANCE PLAN QAP # A12170407(0) Page # 2 of 4 FF – QAG – 20 (4)

Other Abbreviations W.O. = Work Order, P.O. = Purchase Order, AH = Ampere Hour, SA = Stand Alone, DR = Dual Redundant, PR = Parallel Redundant, ACDB =
used in this QAP AC Distribution Board, DCDB = DC Distribution Board, J.B. = Junction Box, HV = High Voltage, HVHF = High Voltage High Frequency,
GRN = Goods Receipt Note, WI = Work Instruction, TR = Test Report, FF = Forms / Formats, BOM = Bill of Material, FRS = Fault Report Sheet,
MOM = Minutes of Meeting (of inspection), WS = Workmanship Standards, PH File = Product History File, SAT = Site Acceptance Test
Incoming Goods
# Item / Component Characteristics Type of Quantum Applicable Acceptance Responsibility Record Remarks
Check Documents Norms
1 Power Transformers Dimension, HV, NL Visual 100% GRN, WI Drawings, Register &
Voltages, Finishing, Physical Mfr. TR FF
Control Transformers
Marking / Labeling Electrical
2 Enclosures Dimension, Coating Visual 01 / Batch GRN, IS-5, WI, Register &
Thickness Measurement Drawings FF
3 Fabricated & Punched Dimension, Punching Visual 01 / Batch GRN, WI, Drawings Register &
Items FF
4 Heat-sink Dimension, Surface Visual 100% GRN, WI, Drawings Go No Go
Finishing, Mounting Measurement
holes
5 Rubber items Dimension, Finish Visual 5% GRN, WI, Drawings Go No Go
(Gaskets, Grommets) Measurement
6 Bus-bars & Hardware Dimension, Finish, Visual 100% GRN, WI, Drawings Go No Go
Threads Measurement
7 Acrylic Material Dimension, Finish Visual 100% GRN, WI, Drawings Go No Go
Compliance
Measurement
8 Current Transformers O/P Accuracy Visual 100% GRN, WI, Catalog, to Register &
Measurement 01 / Batch FF
9 Switch gears Physical, NO/NC, Visual 100% GRN, IS-13947, WI, the QA Register &
Auxiliary Contacts Measurement Catalog FF
10 Fuses & Fuse Holders Physical, Continuity, Visual 100% GRN, WI, Catalog Applicable Register &
Type FF
11 Capacitors Physical, Visual 100% GRN, WI, Catalog Documents Register &
Capacitance, Type Measurement 10% FF
12 Semiconductor Physical Visual 100% GRN, WI, Catalog Register &
Device FF
13 Wires, Cables Physical, HV, Type Visual 100% GRN, WI, Catalog Register &
& Cable Glands Measurement FF
14 Batteries Physical Visual & OCV 100% GRN, WI, Catalog, Register &
Mfr.’s Test Report, FF
for LATB only Type
Test Report
15 Fans Smooth running, Visual & 100% GRN, WI, Catalog Register &
Physical Running FF
16 Indicating Devices Physical & Test Visual, 100% GRN, WI, Catalog Register &
(Lamps, LED etc.) Measurement FF
17 Meters Physical, Accuracy As Above 100% GRN, WI, IS-1248 Register &
FF
18 Packing Material Physical, Type of Visual 100% GRN, WI, Documents Go No Go
( Wood, Thermocol ) material

19 PCBs Material, Tracks, Visual 100% GRN, Drawing, Film Go No Go

Leveling
 0HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED (Unit-II)
QUALITY ASSURANCE PLAN QAP # A12170407(0) Page # 3 of 4 FF – QAG – 20 (4)

PCB Manufacturing & Testing

# Item / Component Characteristics Check Quantum Applicable Documents Acceptance Responsibility Record Remarks
Norms
1 PC Assembly Room Physical, Visual Every 6 IS-10087, WI
(and storage facility ) ESD Measures Testing months
2 Stuffing Mounting Visual 100% BOM, Drawing, WI
3 Soldering (Wave/Manual) Dry Solder Visual 100% WI & WS Fault
Solder Joints Compliance
4 Inspection Cleaning, material Visual 100% WI & WS to all the Production Report
as per BOM, applicable Supervisor
Short Links documents Sheet
5 Testing Functional, Electrical 100% WI, Specification
Burn-in
6 Ana-bond Physical Visual 100% WI, WS
7 Conformal Coating (CRC) Physical Visual 100% WI

Process Inspection
# Item / Component Characteristics Type of Check Quantum Applicable Documents Acceptance Responsibility Record Remarks
Norms
1 Company’s Logo Position Visual 100% Drawing
2 Rating Plate System Details Visual 100% Drawing
3 BOM, Drawings : Matching, Visual 100% Drawing & BOM
Product consistency Availability, Layout
4 Fitting Mounting, Visual 100% Drawing
Tightening
5 Lugging & Crimping Appropriate size, Visual 100% WS
firm joint
6 Cabling & Wiring Routing, Tying, Visual 100% WI, WS, Drawing Check-List
Finishing, Color- Continuity Compliance Production
/ FRS
Code, Ferruling to all the Supervisor
applicable
7 Painting & Finishing Uniform Coating, Visual 100% WS, IS-5
documents
Color
8 Doors, Locks & Hinges Smooth Working Visual 100% WI
9 Clearance & Creepage Dimension Visual 100% Drawing
10 IR Test (after & before HV) Resistance Value Measurement 100% WI
11 HV Test Breakdown Value Measurement 100% WI

Unit / System Test

# Item / Characteristics Check Quantum Applicable Acceptance Responsibility Record Remarks
Component Documents Norms
1 Functional Test Dimensions, Setting of parameters, Load Electrical 100% HHPE Specs Compliance Testing Test Shall be
Test, Regulation, Efficiency, Noise Level, Visual Test Report to Applicable Engineer Reports witnessed by
, Annunciation(If applicable), Alarms Physical Documents & client
Approved
Data Sheet

FINAL INSPECTION
# Item / Component Characteristics Check Quantum Applicable Acceptance Norms Responsibility Record Remarks
Documents
1 Inspection Completion of - Visual 100% FRS, MOM, PH Compliance to QA FRS,
Scope of Supply, File, WI Applicable Check-List
MOM & FRS Points Documents
 0HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED (Unit-II)
QUALITY ASSURANCE PLAN QAP # A12170407(0) Page # 4 of 4 FF – QAG – 20 (4)

Site Acceptance Test

# Item / Characteristics Check Quantum Applicable Acceptance Responsibility Record Remarks
Component Documents Norms
4 Final & Operation of Panel Meters, Normal Visual
Complete Check Functioning of LED, Normal Physical
Functioning of Indications, Alarms, Electrical
Panel Ground Check with System
ON, Briefing to End-user about
System Operation, Spares, AC-DC
O/P adjustment (if required),