Operation Manual of UPS System

Hi-Rel Electronics Pvt. Ltd.
I4 Operation Manual
Operation Manual
Uninterruptible Power Supply System
I4 UPS System
Hi-Rel Electronics Pvt. Ltd

B-1 1 7,1 1 8, GIDC Electronics Zone, Sector-25,
Gandhinagar -382 044, Gujarat - India
Ph : +91 -79-232871 80/81
Fax : +91 -79-232871 82
www .hirel.net
Version V.0 Page 1

Hi-Rel Electronics Pvt. Ltd. I4 Operation Manual
Model : I4
Version : V.0
COPYRIGHT © 2011 by Hi-Rel Electronics Pvt. Ltd.
All rights reserved
The information contained in this publication is intended solely for the

purposes indicated.
The present manual and any other documentation supplied with the UPS
system is not to be reproduced, either in part or in its entirety, without the
prior written permission of Hi-Rel Electronics Limited.
The illustrations and plans describing the equipment are intended as general
reference only and are not necessarily complete in every detail.
In the spirit of innovation, the contents of this manual are subject to

modification or change without notice.
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Objective of this Manual:

The objective of this manual is to educate the user for proper installation
and the system to be use.
Scope Statement:
The scope of this manual covers only general operations of the DC UPS
system. How-ever, some information on primary maintenance can be found
in this manual.
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Table of Contents:
Sr. No. Chapter Page #
1 Safety 5
2 Introduction 10
Components of the UPS System 11
Description of I4 UPS Module 13
Modes of Operation 17
3 Technical Specifications 20
4 Installation 22
Selecting the UPS Room 22
Lifting & shifting 23
Placing & Positioning 23
Wiring Connections 27
5 System Start-Up 30
Getting Acquainted With Your System 30
Electrical Start-Up & Shut down procedure 32
Energization 33
De-energization 34
Bypass 35
LED Mimic 37
LCD Screen 40
Dealing With Alarms 43
Parameter Adjustments 51
6 Maintenance 58
7 Contact Details 60
8 Drawing 62
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1. Safety
For the purpose of this manual and the product the following symbols are used.
SYMBOL DESCRIPTION
Alerts a person that high voltage is present which could result
in severe bodily injury or loss of life. Relevant instructions &
electrical safety measures must be adopted. DO NOT attempt
to bypass the instructions given in this manual. Always consult
DANGER HI-REL in case of doubt, BEFORE proceeding with other
actions not included in this manual.
Alerts a person that if procedures are not followed, damage
! to or destruction of the equipment could result.
CAUTION
Qualified person – who is formally trained by Hi-Rel
t Electronics Limited, to perform the specific job.
TRAINED
NOTE Calls for attention to the information that is especially
significant in understanding the operation.
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Attention:
Please read the safety instructions contained in the following pages prior to
installing, starting up and maintaining the UPS system, the options and the
batteries.
Safety Regulations:
GENERAL:
• The equipment must be moved only in an upright position, in
the original packing to the final destination room.
• The equipment must be lifted only with a forklift or lifting
belts.
• Check for sufficient floor loading capacity.

• If you notice any visible damages to the packaging or the UPS,
do not install or start the system. Contact the nearest Hi-Rel
service center.
• WARNING! THERE IS RISK OF ELECTRICAL SHOCK: do not
remove the covers – there are no user serviceable parts
inside.
• THE UPS MUST NOT BE ENERGIZED UNLESS CONNECTED TO
EARTH
o The first connection to make is between the
grounding lead and the terminal indicated with the
symbol
o The field wiring outlets may be electrically alive even
when the UPS is disconnected from the mains.
o Dangerous voltages may be present during battery
operation.
o Disconnect batteries during maintenance or service
work.
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o Potentially hazardous voltages are present within the

UPS.
o BEWARE! The inverter can restart automatically,
when mains voltage is restored.
• Only Hi-Rel qualified personnel should carry out any
maintenance or service work
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INSTALLATION:
• The installation and connection of the UPS must be carried out
only by Hi-Rel trained personnel.
• During commissioning and maintenance, the following aspects
must be properly verified:
o Any damaged parts
o Squeezed wires and cables
o Improperly inserted plugs
• Ensure all earthing connections are properly attached.
• Switching off the UPS DOES NOT isolate the UPS from the
mains!
• The UPS system must not be installed in excessively humid
environment or near water.
• Install the unit in a sufficiently ventilated area; the ambient
outside temperature should not exceed 45˚C (113˚F)
o There should be free air circulation around and through
the unit. Air vents should not be blocked.
o Avoid direct sunlight or locations near heat sources.
• Ambient temperature should not exceed 25˚C (77˚F) in order
to derive optimum battery life.
STORAGE:
• The UPS and accessories must be stored in a dry location.
• Storage temperatures must be within -25˚C (-13˚F) to + 55˚C
(131˚F)
• If the unit is likely to be stored for a period exceeding three
months, the batteries must be recharged periodically – time
depending on storage temperature.
POSITIONING OF THE UPS:

• Provide for at least one meter in front of the machine to leave
plenty of room for maintenance operations.
• Space of minimum 60 cms must be left between the back of
the UPS and the wall to provide for flow of air from the fans
and for maintenance operation of the fans.
• No objects should be placed on top of the machine.
• The AC-DC INPUT / OUTPUT cables should enter from the
bottom of the UPS.
BATTERIES:
• Battery voltages are dangerous for a person’s safety.
• Batteries should never be short circuited.
• Remove all metal objects like watches, rings, etc from person
while working with the battery. Always use insulated tools.
• When replacing batteries, always use same numbers, voltage
(V) and capacity (Ah).
• Batteries should never be disposed off in a fire – they may
explode.
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• The electrolyte contents of the battery are extremely toxic;

batteries should never be opened or mutilated.
• Batteries should never be charged in a sealed container.
• Protect the environment – dispose batteries safely in
accordance with local codes for safe disposal.
Safety instructions when working with batteries:

EXTERNAL BATTERIES MUST BE INSTALLED AND CONNECTED TO
THE UPS ONLY BY QUALIFIED SERVICE PERSONNEL.
BEFORE HANDLING THE UPS AND BATTERIES, THE
INSTALLATION PERSONNEL MUST READ THIS ENTIRE SECTION
DANGER VERY CAREFULLY.
• Battery terminals always carry full voltage current.
• The batteries used in this system carry extremely high currents
and provide dangerous voltages. There is always a risk of
electric shock.
• If the terminals are shorted together or grounded – they may
cause severe injury.
• Do not touch un-insulated battery terminals.
• Exercise extreme caution to avoid electric shock and burns that
are caused when battery terminals are contacted or shorting
terminals during battery installation.
All qualified operating personnel should adhere to the following

precautions:
• Always use protective gear such as rubber gloves, boots and
protective eye shades.
o If mishandled, caustic acids and toxic materials from the
batteries can rupture or leak.
o Before handling batteries, ensure removal of rings, metal
wristwatches, key chains and other metal objects, including
jewelry.
o Carrying metal objects, especially in the top pockets runs risks
of them falling into the battery cabinet.
• Ensure that tools have insulated handles and are insulated so that
they will not short the battery terminals.
• Do not lay tools or metal parts on top of the battery and do not place
them where they are likely to fall on the battery or into the cabinet.
• Install batteries only as per the Battery Installation Manual of the
battery manufacturer.
• When connecting terminals, never allow a cable to short across a
battery’s terminals, the string of a battery, the cabinet or the rack.
• Cable lugs must be so aligned on the battery terminals, such that the
cable lug will not come in contact with any part of the cabinet or
rack, even if the battery is moved.
• Cables must be kept away from sharp metal edges.
• Battery cables must be so installed that the UPS or battery cabinet
doors do not pinch them.
• Battery terminals must never be connected to ground.
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• If battery terminal is inadvertently grounded, remove the source of

ground. Contacting any part of the grounded battery can cause the
risk of an electrical shock.
• Batteries must be installed in a temperature and humidity controlled
indoor area, free of contaminants, to reduce risk of fire or electric
shock.
• The battery system chassis ground must be connected to UPS chassis
ground.
o If a conduit is used, the ground conductor must be routed in
the same conduit as the battery conductor.
• When replacing the batteries or repairing the battery connections,
SHUT OFF the UPS and remove the battery fuses / breakers.
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2. Introduction
Uninterruptible Power Supply or UPS is normally regarded as the ultimate
solution to electrical power problems. It protects the critical AC load, which
needs a reliable, continuous power from AC Utility supply interruptions. The
various utility (Mains) supply problems are as listed below.
• Temporary Interruption
• Long-Term Interruption
• Momentary Interruption
• Sag or Under-Voltage
• Swell or Over-Voltage
• Transient, Impulse or Spike
• Notch
• Noise
• Harmonic Distortion
These disturbances have different effect on loads such as:

1) Reduced personnel safety
2) Equipment/machine failures
3) Reduction in the operating life of the machines
4) Increase the general costs and losses in economical terms.
5) Decrease in lifespan the equipment.
The UPS not only protects the load against above power hazards but also
provides continuous regulated pure AC power to the load.
The I4 UPS are an On-line UPS, also sometimes called Double Conversion
UPS. In the UPS the AC electrical power from the utility (Mains) supply is fed
into the charger to be converted in to DC. This DC will maintain the charge
on the battery and at the same time supply DC power to the inverter. The
inverter will then invert the DC source to become an AC supply for the
critical load.
During a power failure, the DC power for the inverter will be drawn from
the battery bank for uninterruptible supply to load. When AC power is
restored, the charger will then charge the battery and continue to supply
energy for the inverter, which powers the load.
Typical Applications include: -

• Process control and Monitoring systems
• Security systems
• Telecommunication systems
• Health care systems
• Data Centers. Server farms &Computers
• Pharmaceuticals & lab equipment’s/analyzers etc
• And many more---
Key Features of I4 UPS:
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• High efficiency resulting from the combination of latest generation

IGBT and DSP based control circuitry.
• High branch fuse clearing ability in the event of short circuit at the
load end.
• Front and back access oriented layout affording ease of handling and
maintenance.
• Extremely flexible – offering tailor made options like parallel or hot
standby redundancy, input harmonic filters, galvanic isolation
transformers, bypass line regulator and additional connectivity
features like Modbus, Profibus, SNMP and potential free contacts.
(For details of more options, contact factory)
Components of an UPS System:
Auxiliary
Module
Mains Output L
UPS
Distribution Distribution
Module
Unit Module O
A
Battery
Module D
• = Items available from Hi-Rel, depending on the purchase

contract.
Refer to your purchase contract / drawings for specific details.
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Mains Distribution Unit

This unit is already a part of your installation. It distributes the Mains
(utility) and / or Generator power to your facility and will also supply input
power to your UPS system. The safety “earth” connection for the UPS
system is also considered to be a part of the Mains distribution unit.
Auxiliary Module
An Auxiliary module generally comprises a Voltage stabilizer (Static type or
Servo type) to provide a stable Alternate supply to the UPS.
UPS module
It consists of the UPS (without battery). Depending upon the configuration
selected one or more UPS modules can be employed.
Battery module
This module comprises the battery pack for supplying power to the UPS
module in the event of a mains failure. There are various types of batteries
- SMFB, LATB, Ni-Cad, etc. Battery module may either be in the form of an
enclosure or may be supplied as a rack. Vented batteries such as LATB can
emit acidic fumes & require a special room.
Output Distribution Module

Output of the UPS system needs to be distributed to various loads. Such a
module generally comprises switches, fuses, etc for each load. The co-
ordination of fuses is important to avoid faults in a particular load from
affecting the other loads supported by the UPS.
The scope of this manual is limited to UPS MODULE only
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Description of I4 UPS Module

(A) Block diagram with 6 Pulse UPS
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(B) Block diagram with 12 Pulse UPS
I4 UPS Module Description
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Charger -
- Converts the AC mains to regulated DC power.
- Charges the Battery when mains are present.
Inverter
- Converts DC into Frequency & Voltage controlled AC supply
Battery (separate module)

- Stores energy while mains supply is present.
- Delivers energy (DC supply) to the Inverter when mains supply is absent.
Static Switch (A bi-directional solid state transfer switch)

- Normally connects the Inverter output to the load
- Automatically transfers the load to an Alternate supply if Inverter fails or
overloads.
- Automatically re-transfers the load from the Alternate supply to the
Inverter, once the Inverter is healthy or the overload condition has ceased.
In case of parallel system when all inverter fails or trips on overload then
only it will transfer automatically to static bypass.
MBS (Maintenance Bypass Switch)

The maintenance bypass switch is a special make before break switch, in
normal position connects the inverter output to load, when changed to
Bypass position connects bypass ac power to load without interruption,
leaving the UPS available for maintenance.
(Caution! please refer operating procedure before operating this switch)
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Major power components of the I4 UPS Module
Component Description
CBI Mains input circuit breaker
CBA Alternate input circuit breaker
CBB Battery isolating circuit breaker
MIS Module isolator switch
MBS Maintenance Bypass Switch
FC Charger input fuse
FD DC link fuse
FA Alternate static switch fuse
FB Battery circuit fuse.
LD DC link filter choke
CD DC link filter capacitors – multiple units
CO Output AC filter capacitors – multiple units
LO Output filter choke
T2 Inverter output isolation transformer
Control section
 Charger
I4 charger module uses three thyristor-thyristor modules. The charger
control generates the required firing angles so as to maintain a regulated DC
o/p. Charger performs the function of battery charging as well as providing
dc supply to the inverter. The Battery charging current is monitored by the
charger control & will operate the charger so as to limit the charging
current of the battery to a preset value.
 SMPS
A Switch Mode Power supply generates the control power supplies for the
Control of I4 UPS module (Inverter, Static switch, etc). This power supply
receives input from the DC link as well as the Alternate supply lines,
enabling it to operate under all eventualities.
 System control.
The system control card is the heart of the I4 UPS module. It employs an
advanced, digital signal processor based, control for the Inverter & the
Static switch. It monitors the performance of the UPS module &
communicates the status to the user interface card. It also receives
operational commands from the user interface & controls the UPS module
accordingly.
 Gate Drivers
The main function of the gate driver is to drive the Inverter IGBT power
devices. The gate driver employs a sophisticated hybrid circuit in order to
drive as well as protect the IGBT. It acts on the PWM signals generated by
the system control.
 System F/B (Feedback).
The system f/b (feedback) assembly taps all the required information
(voltages, currents, etc) from various parts of the I4 UPS module as provides
the feedback to the system control.
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 User Interface
It employs a powerful micro controller based circuitry along with a non-
volatile memory. It controls the LCD-Keypad as well as the LED mimic for
status reporting as well as programming the parameters of the UPS module.
Modes of operation:
Normal Mode
MBS
Bypass Static switch

(Alternate) source
Load
Input utility Static switch

Charger Inverter
source (Mains)
Battery
In normal mode the input utility (Mains) power is converted in to DC power

by charger, this DC power is converted into AC Power by Inverter. This ac
power generated by inverter passes through static switch to the load. Also
this power is used to charger battery.
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Battery Mode
MBS
Bypass
(Alternate) source Static switch Load
Input utility Inverter Static switch

Charger
source (Mains)
Battery
In an event of mains (utility) power failure or out of tolerance, the charger

turns off, the dc power required by inverter to generate AC power is drawn
from battery source and through static switch it reaches to the load.
Static bypass Mode
MBS
Bypass
Input utility Static switch

Charger Inverter
source (Mains)
Battery
In this mode , in an event of inverter voltage going out of tolerance , due to

inverter failure or due to any other reason , the load will transfer to static
bypass as shown in fig. with a transfer time less than 4 ms. If input utility
supply is available and in range, the battery charging will continue as
normal through charger .
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Maintenance bypass Mode
MBS
Bypass
Input utility
source (Mains) Charger Inverter Static switch
Battery
The maintenance bypass switch (MBS) is provided for taking the system for
maintenance without disturbing the load. During this mode the load is
served by Bypass (Alternate source) .The MBS switch is a special make
before brake switch .It has two positions, a NORMAL and BYPASS. In Normal
mode of switch the inverter output is connected to the load. Where as in
later Bypass (Alternate) source feeds the load.
COUTION: please refer operating procedure of this switch, wrong operating

procedure may affect the load and UPS system.
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3. Technical Specification for I4

Input voltage 415V +10% , - 15% 3 Phase 3 Wire
Input
Input frequency range 50Hz ± 6 %
Alternate input Voltage 230V ± 10% single phase two wire
Bypass/Alternate
Alternate input Frequency 50Hz ± 6%
Charger walk in time 35 seconds
Charger type Full bridge Full controlled converter
Charger output voltage 405V ± 1% Nominal
Full discharge battery within 6-8
Charger Charger capable of charging hours. Max. backup time envisaged
on UPS will be 2 hours
10 to 25 % of AH of battery.
Battery charging current limit (Adjustable). Max. limit is 25% of
rated power capacity of the UPS
Inverter output voltage 230V single phase two wire (110 V
available as option)
Inverter output Frequency 50Hz
±1% static load (No load to full load
Voltage Regulation
at nominal DC)
± 5% transient load , recovery time
Voltage Transient Response
to 98% in less than 20 milliseconds
Inverter output voltage 5% of the nominal voltage
adjustability
Inverter Max. 5% RMS THD with non-linear
Harmonic distortion loads (Crest factor 3:1)
Max 3 % for linear loads
Inverter frequency stability ± 0.1 % free-running
1) 125% of rated output power (kW)
for 10 minute.
Overload capacity ( on Inverter) 2) 150% of rated output power (kW)
for 1 minute,
At 45deg.C and minimum DC bus
Output Load Crest Factor 3:1
Frequency range for ± 6% of 50Hz (± 1% to ± 6% field
synchronization to alternate line programmable)
Static Switch
Overload capacity (on static
800% of FLA for one cycle
Bypass(alternate) )
Output Rated power @ 0.8 lagging power factor
Frequency slew rate 1.0 Hz/second
Efficiency AC to AC of the UPS at 85% minimum from 25% to 100% full
nominal AC input and floating rated load
battery
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Meters –digital-LCD: Metering

Voltage meters Mains Power Meter Total KVA
Bypass(Alternate) Total kW
Battery/ Charger Total Power Factor
Inverter UPS KVA
Load UPS kW
UPS Power Factor
Frequency Meters Mains Current Meter Mains
Bypass(Alternate) Battery
Inverter
Load
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4. Installation
Selecting the UPS Room:
The UPS being complex equipment meant to support mission critical

application, the selection of the right location / room, assumes very
significant importance to ensure best performance of the system.
NOTE
• Ensure that the room / location selected is clean and free from
conductive & corrosive dust and is freely ventilated.
• If it is not possible to ensure freely ventilated environment, the room

has to be adequately air-conditioned.
• The recommended ambient temperature for the UPS room is 45˚C

(113˚F)
• Before placing the UPS system at the designated location, ensure

sufficient floor load capacity. If additional / optional cabinets or
cubicles are planned to be installed in the same location, floor
loading for these should also be taken into consideration.
• While selecting the location / room for the UPS, take into account
the dimensions of the UPS modules as well as any optional /
additional cubicles (if any) to be located in the designated area. For
dimensions of the UPS modules for various ratings – refer Technical
Specifications.
• Provide for at least one meter in front of the machine to leave plenty
of room for maintenance operations.
• Space of minimum 60 cms must be left between the back of the UPS
and the wall to provide for flow of air from the fans and for
maintenance operation.
• It is recommended that a minimum of 400mm (16 inches) clearing

should be provided for between the top of the UPS and ceiling, to
ensure proper ventilation and heat dissipation.
• The AC-DC INPUT / OUTPUT cables should enter from the bottom of
the UPS.
• The UPS module is not free standing and requires bolting to the floor.
Ensure that proper foundation and eyelets have been provided as per
footprint drawing provided with the system.
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• Normally, Ni-Cad and LATB batteries are not installed in the same
room as the UPS modules. How-ever SMFB batteries may be installed
in the same room. In this case, ensure that the dimension of the
battery bank as well as floor loading and operating temperature
requirements for batteries are taken into consideration.
Lifting and Shifting:
• The UPS module must be moved only in an upright position and in the
original packing, along with the pallet, to the designated location of
placement.
• It is recommended to use a forklift to move the UPS module. In case a

crane has to be used, ensure to use suitable lifting straps and
spreader bars. The center of gravity should be taken into
consideration while moving the package.
• In case of additional / optional cubicles, exercise the same care and

caution as applicable to lifting and shifting of the UPS module.
Placing and Positioning:
Place the UPS module at the planned location, unpack the top and sides of
the packing case and remove the pallet while keeping the package gently
raised.
• Unpack additional / optional cubicles in the same manner as the UPS.
• Before lowering the UPS module on to the foundation, ensure that

the UPS bolting holes are aligned with the foundation eyelets and
bolted to the foundation. Ensure same procedure for optional
cubicles.
• The additional / optional cubicles must be lined up and as per the GA

(General Arrangement) diagram, and coupled to the UPS module with
the baying kit provided with the system.
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Panel Baying Diagram
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Wiring Connections:
!
CAUTION
• Before connecting the power cables of the various inputs and outputs
of the UPS, verify that the mains voltage and frequency, bypass
voltage and frequency, output load voltage and frequency and
battery bank (number of cells, float / boost voltage, AH capacity)
conform to the information given in Technical Specifications.
• Select the proper rating of fuses / breakers and cables for the input,
bypass and battery source feeders.
• The first connection to be made is the earthing to all cubicles

including the UPS module.
• The earthing cable is to be terminated at the designated position

located on the UPS module.
• In case flexible earthing cable is used, the cable size should be same
as the cable used for input mains.
• In case additional / optional cubicles are used, their earth must be

terminated at the UPS main earth.
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UPS Earthing
Location
Auxiliary Panel Earthing Location
• Before proceeding with connecting of cables for UPS input, bypass,

battery and output, ensure that all source feeders are switched off
and fuses / battery isolators are removed.
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Input / Output Cable Termination Location:
1 2 3 4 5 6 7 8 9 10 11 12 13
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Terminal No. Description

1 Utility(Mains) Input R-Phase( Line-1)
2 Utility(Mains) Input Y-Phase( Line-2)
3 Utility(Mains) Input B-Phase( Line-3)
4 From Battery bank final +ve of battery bank
5 From Battery bank final -ve of battery bank
6 For Common Battery application. Applicable for only parallel/dual redundant
UPS.
NOT USED FOR STANDALONE UPS SYSTEM
7 For Common Battery application. Applicable for only parallel/dual redundant
UPS.
8 Bypass (Alternate) source input Phase
9 Bypass (Alternate) source input Neutral
10 UPS output Phase for paralleling 2 ups output. Applicable for only parallel
system.
11 UPS output Neutral for paralleling 2 ups output. Applicable for only parallel
system.
12 UPS output Phase
13 UPS output Neutral
t
TRAINED
• Unlock the door of the UPS panel and remove the protection plate
mounted on the terminals.
• Terminate the cables at the designated terminals as per Input /
output cable termination location.
• Wiring of the battery bank must be done by referring to the manual
of the battery manufacturer and final positive and negative terminals
of the battery bank must be terminated at the UPS end on to the
designated terminal. In case battery junction box / battery isolator is
used externally, this must be located as close as possible to the
battery bank.
• The UPS to battery bank cable should be selected in such a manner
that the voltage drop is not more than 5% of the nominal DC. The
lesser the voltage drop than 5% is better.
• After all the input / output connections are made, ensure that they
are tightly screwed on to the terminals in such a way that they do not
come in contact with nearby terminals, which may create a short
circuit.
• Ensure that all the fuse holders inside the UPS have a fuse of the
proper rating, inserted and are in closed position.
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• Once the power wiring is complete, control wiring for customer

interface board may be taken up. For details, refer Table No: 6
Customer Interface Board.
Customer Interface Cable Routing Diagram
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Customer Interface Connections:
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5. System Start-up
Getting Acquainted With Your System:
Power Switches:
• I4 UPS has been provided with four main breakers:
o CBI - Circuit Breaker Input
o CBA - Circuit Breaker Alternate
o CBB - Circuit Breaker Battery
o MIS - Module isolation Switch
Circuit Breaker Input (CBI)
• This breaker is used to connect / disconnect input utility source to
charger section of the UPS.
Circuit Breaker Alternate (CBA)
• This breaker is used to connect / disconnect alternate source of
supply to static switch section of the UPS.
Circuit Breaker Battery (CBB)
• This breaker is used to connect / disconnect charger output to
battery bank.
Manual Isolation Switch (MIS)
• This breaker is used to connect / disconnect static switch output of
the UPS to load.
CBA
CBI
MIS
CBB
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Front Panel Keypad

Left Navigation Key
Right Navigation Key
Up Scroll Key
Down Scroll Key
Enter Key
Activate the metering menu
Activate the alarm menu
Activate the parameter menu
Activation performs self test of all front panel

LEDs, all LEDs will be blinking automatically.
Activation will shut OFF the audio buzzer, if

active.
When kept pressed for 3 seconds will turn ON

the INVERTER.
When kept pressed for 5 seconds will turn OFF

the INVERTER, if it is ON.
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Electrical Start-up and Shutdown Procedure

Once you have acquainted yourself with the various switches and system
components, you are ready for electrical start-up of the system.
Before electrical startup, make sure that all the input / output terminals
are tightly screwed, all fuse holders have fuses inserted and are in closed
position, the input / output terminal protection is in place and the UPS is
properly grounded.
Turn on the input feeder of the UPS from the utility source and then follow
the steps detailed here below:
Start / Stop.
The UPS inverter can be started using the ON key. The UPS inverter can be
stopped using the OFF/Reset key.
ON OFF/
ON Reset
NOTE  The ON / OFF key must be kept depressed for approximately 5

seconds in order to initiate the action.
(This is incorporated to allow intentional operations only)
NOTE  The UPS inverter is designed for continuous operation as such
start / stop operation may not be required.
 It is recommended that the UPS be left ON as far as possible.
 Stopping the UPS inverter may cause a transfer to the Alternate
!
supply (if available & synchronized). High voltage supply will
still be available at the terminals & at the LOAD.
CAUTION
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Energization
 Follow the Energization procedure in steps & in the
!
sequence mentioned in the procedure.
 Non compliance to the procedure can result in serious
injury to the personnel as well as damage to the
CAUTION equipment.
 DO NOT switch ON the battery isolator CBB, in case the
! Input mains power supply is not available and charger

voltage is not fully developed otherwise it may result in
failure of “FB” fuse and damage the system.
CAUTION
 The UPS module has High voltage supplies connected.
Don’t touch metallic parts, wires, PC cards, etc. When
the front door is open.
DANGER
 Energization to be performed by qualified personnel
t ONLY. Who have specifically practiced the above

procedure during training
TRAINED
 Energization of a module shall be done after the
NOTE necessary installation checks.
 This is not a routine operation. It is recommended that
the UPS system remain in ON condition ALWAYS and
should NOT be switched OFF in the evenings or during
holidays, unless absolutely necessary.
Preconditions required for Energization

Mains, Alt & Batt supply at terminals - Available
Input (Mains) supply CBI OFF
Alternate (Bypass) supply CBA OFF
Battery isolator CBB OFF
Module Isolator Switch MIS OFF
Maintenance bypass switch MBS Normal
Energization Procedure
1. Open the Front door.
2. Switch CBA to ON position.
3. Switch CBI to ON position and wait for one minute till DC voltage of charger develops.
Check the voltage of charger in 'Metering' on LCD.
4. Switch CBB to ON position.
5. Switch MIS to ON position. Supply will be available to load through alternate supply.
Check the status of static switch on Mimic.
6. Give start command to the Inverter through ON push button (press pushbutton for
approx. 5 seconds). The load will now be transferred to the inverter. Check the status of
static switch on Mimic.
7. Close the front door. Energization completes!
Version V.0 Page 35

De – Energization
 Follow the de-energization procedure in steps & in the
! sequence mentioned in the procedure.

CAUTION equipment.
 DO NOT switch the Maintenance bypass switch MBS till de-
! energization is complete.
CAUTION
Don’t touch metallic parts, wires, PC cards, etc. when
 Capacitors inside the UPS module can store charge for a
DANGER long time. Before touching such parts ensure that these
have completely discharged and NO harmful voltage
present
 De-energization to be performed by qualified personnel
t ONLY. Who have specifically practiced the above

procedure during training.
TRAINED
NOTE  De - Energization is required only for major repairs /

replacement of the components of the UPS module or for
disconnecting the unit from service.
 For routine STOP operation - refer to the START /STOP
procedure.
Procedure for De-energization

2. Give stop command to the Inverter through OFF/RESET push button (press pushbutton for
approx. 5 seconds).
3. Switch MIS to OFF position.
4. Switch CBB to OFF position.
5. Switch CBI to OFF position.
6. Switch CBA to OFF position.
7. Wait for 5 minutes.
8. Close the front door. – UPS Shutdown complete!
Version V.0 Page 36

Bypass
 Follow the procedure in steps & in the sequence
!
mentioned.
CAUTION equipment

Don’t touch metallic parts, wires, PC cards, etc. when
DANGER
 This operation should be performed by qualified
personnel ONLY. Who have specifically practiced the
t above procedure during training.
TRAINED
 Bypass is a maintenance procedure to carry out
repairs / maintenance on the UPS by transferring the
NOTE load to the Alt supply.
 This is not a routine operation.
Preconditions required for transfer to Bypass
Manual bypass switch position (MBS) NORMAL

Static switch position on INV
Inverter supply ON & healthy
Inverter output to Alternate supply Synchronized
Procedure for transfer to Bypass
1. Go in to CONTROL menu, and change “MANUAL BYPASS TO YES” in LCD display.

2. Give ENTER command.
3. Load will be transferred to alternate through static switch.
4. Confirm the status of static switch to bypass on Mimic card.
5. Change over the position of MBS switch from NORMAL to BYPASS.
6. Shutdown the UPS system as per the de-Energization procedure.
Version V.0 Page 37

Return from Bypass

 Follow the procedure in steps & in the sequence
! mentioned.
CAUTION
equipment.
Don’t touch metallic parts, wires, PC cards, etc. when the
front door is open.
DANGER
 Bypass is a maintenance procedure to carry out repairs /
maintenance on the UPS by transferring the load to the Alt
NOTE supply.
 This is not a routine operation.
Preconditions for return from Bypass

BYPASS Manual bypass switch position (MBS)
Procedure for return from Bypass
2. Switch CBA to ON position of both UPS and monitor the Alternate voltage in
manager card.
3. Switch ON the MIS one by one in both UPS. The output of UPS will be available
through the Bypass. Check the MIMIC indication of Load on bypass LED in both UPS.
4. Switch the MBS to Normal condition. The output load will be transferred to UPS.
5. Switch CBI to ON position and wait for one minute till DC voltage of charger
develops. Check the voltage of charger in 'Metering' on LCD.
6. Switch CBB to ON position of both UPS.
7. Give start command to the Inverter through ON push button in both UPS one by
one. Monitor the inverter voltage in the manager card of the both UPS.
8. Load will be transferred to the inverter through the static switch.
9. Confirm the status of static switch to Inverter in both UPS.
Version V.0 Page 38

LED Mimic
Version V.0 Page 39

Sr. No. Indication Condition Status

1 Bypass Input Absent Red
Within range Green
Out of Range Red
2 Mains Input Absent OFF
Within range Green
Out of Range Blinking Green
3 Charger Operation ON Green
OFF Red
Trip Blinking red
4 Battery Discharge Red
5 Battery Operation Boost charge Red
Float Charge Green
Discharge Off
6 Battery MCCB ON Green
OFF/TRIP Blinking Red
7 Inverter Operation ON Green
OFF Red
Trip Blinking red
8 Load on Inverter Inverter SSW ON Green
Inverter SSW OFF OFF
9 Load on Bypass Bypass SSW ON Red
Bypass SSW OFF OFF
10 Synchronization Sync Steady yellow
No sync Blinking yellow
No alarms and
previous alarms are
Common Alarm acknowledged by
11 Indication user. OFF
No alarms and no
acknowledgement
provided by user for
previous alarms. Red
Any alarm present Blinking red
LCD SCREEN
This user interface consists in a permanent back lit LCD screen having:
• 2 lines with 16 characters (standard version for English characters)
• And 12 keys (the function is described for each operating mode).
The operation is extremely simple and is structured on three important
main menus related to the UPS operation, as follows:
Version V.0 Page 40

Metering
UPS must offer some metering information for the user to be able to
examine the operating status at any time of electric parameters and
information screen.
Alarms
In the event of mains failures or abnormal functioning, the UPS must
keep a history of what has happened as a series of events.
Parameters
The user must be able to program certain functions of the UPS (user
parameters, accessible with password) to his needs.
Version V.0 Page 41

LCD screen standard version:

The 3 keys existing on the left side of the screen are used to activate the
operating modes, while the buttons on the right side are used to carry out
functions inside these operating modes.
METERING METERING SUBMENU
ALARMS ALARM SUBMENU
PARAMETER PARAMETER SUBMENU
 METERING MODE: The metering mode is entered any time the [Metering]
button is pressed.
 After Pressing of the [Metering] button auto scroll will be activated
which will scroll the metering parameters without pressing [Up] or
[Down] button. This auto scroll will be deactivated when [Up] or [Down]
button will pressed.
 While in this mode the LCD will display a series of screens containing
metering information.
In this mode the keys perform the following functions:
• [Metering] - Enter into the metering menu;
• [Up] - Scrolls the backward to the next screen;
• [Down] - Scrolls the forward to the next screen;
There is no function of Left, Right and Enter key.
NOTE The meter readings displayed are for general indicative
purposes only. For more precise measurements, dedicated
instruments are recommended.
Version V.0 Page 42

Metering menu navigation
METERING
IN R XXX V
XXX A XX.XX Hz
IN Y XXX V
XXX A XX.XX Hz
IN B XXX V
XXX A XX.XX Hz
Display example (Input YB line)

IN Y 415 V
22 A 48. 08 Hz
Similarly for other.

This menu allows, when the keypad metering is pressed, to show on the
LCD panel a series of screens containing metering information about system
parameters. There is no submenu so use only up and down key see the
information.
Input R Phase
IN-R XXX V The Input R Phase Voltage
XXXX A XX.XX HZ The Input R Phase Current
The Input R Phase Frequency
Input Y Phase
IN-Y XXX V
XXXX A XX.XX Hz The Input Y Phase Voltage
The Input Y Phase Current
The Input Y Phase Frequency
Input B Phase
IN-B XXX V
The Input B Phase Voltage
XXXX A XX.XX Hz
The Input B Phase Current
The Input B Phase Frequency
Output
OUT XXX V The Output Voltage
XXXX A XX.XX Hz The Output Current
The Output Frequency
Alternate
ALT XXX V The Alternate Voltage
XXXX A XX.XX Hz
Version V.0 Page 43

The Alternate Current

The Alternate Frequency
Load
LOAD XXX.XKVA The Total Load in KVA
XXX.X KW X.XX PF The Total Load in KW
Load Power Factor
UPS
UPS
UPS XXX.X
XX.XX KVA
KVA The UPS Module Load in KVA
XXX.X KW XX.X
XX.XX KW X.XXPF
PF The UPS Module Load in KW
UPS Module Power Factor
Load Percentage (With Respect to UPS Rating in

TOT LD XXX.X % KVA)
UPS LD XXX.X %
The Total Load
The Ups Load
BATT_V
BATT_V XXX V The Charger / Battery Voltage
XXX.X A CHG/DISCHG
The Battery Current (charging or
discharging)
Inverter Voltage
INV_V XXXV
UPS_I XXXXA The Inverter Voltage
Inverter Current
OUT_PEAK_CURRENT
Output Peak Current
XXXX A The Output Peak Current
CLOCK DATE Date

XX/XX/XX The Current Time
Time
CLOCK TIME The Current Date
XX:XX:XX
Version V.0 Page 44

Dealing With Alarms:

Alarms are messages indicating an abnormal functioning of the UPS. These
messages are displayed on the front panel LCD screen both visually and with
an audio buzzer. These alarms are alerted to the user in the following three
modes, simultaneously:
• Text readout on the front panel LCD screen

• By a red flashing visual LED
• By an audio buzzer (which has an auto reset of 10 SECONDS)
Following is the list of alarms along with the cause that has triggered the
alarm:
ALARMS LIST
Sr. Alarm Name Probable Cause Action
No.
1 SC SUPPLY FAIL 1. SC Power supply failed 1. Call for service support if problem
2. SC Power supply output persist
shorted/overloaded
3. SC Power supply input is not
present
4. SC Power supply fuse is blown
2 INV OVER LD T SC 1. Inverter tripped due to overload1. Remove excess load.
2. After 20 minutes inverter will start
automatically if unsuccessful – Call
for service support.
3 INV CL ACTIVE 1. The inverter output is 1. Remove excess load IMMEDIATELY
overloaded by 150% of nominal or the inverter may trip.
full load current.
4 INV SAT TRIP 1. The inverter output was 1. Check load side for overload
severely overloaded. /short circuit – Remove fault.
2. SMPS for gate drive is faulty or 2. Press Reset Key to clear the SAT
fail. TRIP alarm. After clearing the SAT
3. Cooling FAN failure TRIP alarm, try to start inverter.
3. Try starting the inverter & if
unsuccessful – Call for service
support.
5 LOW BATTERY 1. Reserve (battery) power has 1. You only have few minutes of
been nearly exhausted. battery backup left.
LOW BATTERY TRIP 1. Reserve (battery) power has 1. Wait till mains resume and
been exhausted 2. Battery to charge.
7 INV OVER TEMP 1. Cooling fan failure. 1. Reduce load & try to start the unit
2. Excess load. – if unsuccessful – Call for service
3. Ambient temperature above support.
specified limits. 2. Measure the ambient temperature
at approximately 1mt from the
unit – if found in excess of
specified limits – take actions to
Version V.0 Page 45

reduce it (room ventilation, a/c,

etc.) – wait for approximately 20
min. to allow cooling & try to start
the unit – if unsuccessful – Call for
service support.
8 PRC SUPPLY FAIL 1. PRC Power supply failed 1. Call for service support if problem
2. PRC Power supply output persist
shorted/overloaded
3. PRC Power supply input is not
present
4. PRC Power supply fuse is blown
9 SC CAN1 FAIL 1. CAN communication between 1. Call for service support if problem
SC-PRC is fail persist
10 STOP COMMAND 1. Stop command is Activated to ***
inverter
11 INV LOW 1. Inverter is stop or trip 1. Check the trip conditions if
2. Adjustment/Calibration Error inverter is trip.
2. Check the adjustment for Inverter
low & inverter voltage reference.
3. Call for service support if
condition persists.
12 INV HIGH 1. Inverter control problem 1. Check the adjustment for Inverter
2. Adjustment/Calibration Error high & inverter voltage reference.
2. Call for service support if
condition persists.
13 ALT LOW 1. Alternate supply low/absent. 1. Check the Alt low adjustment
2. Adjustment/Calibration Error 2. Measure actual value with a
MULTIMETER & if found to be in
specified limits – Call for service
support.
14 ALT HIGH 1. Alternate supply High. 1. 1. Check the Alt high adjustment
2. Adjustment/Calibration Error. 2. Measure actual value with a
MULTIMETER & if found to be in
specified limits – Call for service
support
15 ALT FO 1. Alternate supply problem. 1. Check the alternate supply.
2. Adjustment error 2. Check the adjustment for the
frequency tolerance if alternate
supply is found OK.
3. Call for the service support if
problem persists.
16 MIS OFF 1. MIS switch is Off 1. Check the MIS contact connections
2. MIS contact not sensed by the if alarm is present even after MIS
SC/PRC card. is ON.
problem persists.
17 MANUAL TRANSFER 1. Manual transfer command is ON.1. When it is not required make it
OFF otherwise if bypass source is
not present or unhealthy there will
be no output supply available.
Version V.0 Page 46

18 NO SYNC 1. Inverter o/p is not synchronized 1. If bypass is present then after

with alternate or bypass source some time this alarm will be
removed.
9 SC SUPPLY FAIL 1. SC Power supply failed 1. Call for service support if problem
2. SC Power supply output persist
shorted/overloaded
3. SC Power supply input is not
present
4. SC Power supply fuse is blown
20 OUTPUT UNDER V 1. Static switch i1.11. 1. Check the trip conditions for
Inverter/Alternate supply inverter.
not available 2. Check the adjustment value for
2. Fault in static switch Output Low.
3. Adjustment/ Calibration error 3. Call for service supports. If
condition persist.
21 OUTPUT OVER V 1. Inverter/Alterna11. 1. Check the trip conditions for
Inverter/Alternate problem inverter.
output high voltage 2. Check the adjustment value for
2. Adjustment/ Calibration error Output Low.
3. Call for service supports. If
condition persist.
22 OVER LOAD 1. The inverter output is 1. Remove excess load IMMEDIATELY.
overloaded. If Alt source is not healthy and
load is on inverter then inverter
will trip after predefine time and
output will also trip.
22 INV OVER LD TRIP 1. The inverter tripped due to 1. Remove excess load.
overload. 2. After 20 minutes inverter will start
automatically if unsuccessful – Call
for service support.
23 LOAD ON BYPASS 1. Inverter is stopped or tripped. 1. Check the conditions for inverter
2. Manual transfer to bypass. trip.
problem persists.
24 ALT SSW ERROR 1. Alternate static switch is faulty. 1. If problem persist call for service
support
25 INV SSW ERROR 1. Inverter static switch is faulty. 1. If problem persist call for service
support
26 PRC SUPPLY FAIL 1. PRC Power supply failed 1. Call for service support if problem
2. PRC Power supply output persist
shorted/overloaded
3. PRC Power supply input is not
present
4. PRC Power supply fuse is blown
27 MAINS HIGH 1. Mains supply problem 1. Measure actual value of mains
2. Adjustment /Calibration input supply with a multi-meter &
parameter error if found to be in specified limits.
2. Check the mains high adjustment.
3. Call for service support if both of
Version V.0 Page 47

above points found OK.

28 MAINS LOW 1. Mains supply problem 1. Measure actual value of mains
2. Adjustment /Calibration input supply with a multi-meter &
parameter error if found to be in specified limits.
2. Check the mains high adjustment.
3. Call for service support if both of
above points found OK.
29 MANUAL BOOST 1. Manual boost mode is present. ***
30 HIGH DC 1. Charger control problem. 1. If condition persist call for service
SHUTDOWN support.
2.
31 BAT MCCB OFF 1. Battery MCCB is OFF. 1. Check the Battery MCCB contact
CHG 2. Failure in sensing the contact of connections to charger control
Battery MCCB by the charger card if alarm is present even after
control card. Battery MCCB is ON.
2. Call for service support if problem
persists.
32 CHG OVER TEMP 1. Cooling fan failure. 1. Call for service support.
2. Excess load. 2. Reduce load & try to start the unit
3. Ambient temperature above – if unsuccessful – Call for service
specified limits support.
3. Measure the ambient temperature
at approx 1mt from the unit – if
found in excess of specified limits
– take actions to reduce it (room
ventilation, a/c, etc.) – wait for
approximately 20 min. to allow
cooling & try to start the unit – if
unsuccessful – Call for service
support.
33 SC COMM FAIL 1. Serial communication between 1. Check the RS485 bus Connections
UI & SC is failed. 2. Call for the service support if
2. Loose connections in RS485 problem persists.
communication bus.
34 PRC COM M FAIL 1. Serial communication between 1. Check the RS485 bus Connections
UI & PRC is failed. 2. Call for the service support if
communication bus.
35 CHG COMM FAIL 1. Serial communication between 1. Check the RS485 bus Connections
UI & Charger is failed. 2. Call for the service support if
communication bus.
36 MAINS FAIL 1. Mains input supply is not 1. Check mains input supply.
present 2. If alarm is present even after
2. Failure of Logic supply of UI mains supply is present check logic
supply of UI.
37 BAT DISCHARGE 1. Battery is discharging due to 1. Check mains input supply.
absence of mains input supply 2. Check the charger trip condition if
or charger trip. mains input supply is available.
Version V.0 Page 48

38 DC GROUND 1. Earth fault on DC BUS 1. Call for the service support if

Problem persists.
39 BATT MCCB OFF UI 1. Battery MCCB is OFF. 1. Check the Battery MCCB contact
2. Failure in sensing the contact of connections to UI card if alarm is
Battery MCCB by the UI card. present even after Battery MCCB is
ON.
2. Call for service support if problem
persists.
40 INV HIGH DC 1. Inverter trip due to inverter 1. Monitor the charger DC voltage in
input DC voltage > Predefined LCD. Try to restart the inverter
reference. through RESET and ON keys if DC
Voltage < Predefined reference.
problem persists.
41 STANDBY UPS FO 1. Reference frequency from the 1. Check the fiber connections
SC/PRC card of another UPS is between SC/PRC cards of two UPS.
not received in PR mode. 2. Call for the service support if
problem persists.
42 OUTPUT FO 1. Output frequency out of 1. Check the bypass frequency is
tolerance band. within tolerance band or not.
bypass frequency is within range.
43 UPS IS 1. Failure in receiving the PMI 1. Check the PMI connections
STANDALONE signal from the SC/PRC card of between SC/PRC cards of two UPS.
another UPS in PR mode. 2. Call for the service support if
problem persists.
44 PRC CAN FAIL 1. Failure in receiving data on CAN 1. Check the CAN connections
bus from PRC section of SC/PRC between SC/PRC cards of two UPS.
card of another UPS in PR 2. Call for the service support if
mode. problem persists.
45 I/P PHASE OUT 1. Failure of input phase. 1. Check the mains supply.
2. Failure of input sensing control 2. Call for the service support if
fuse. problem persists.
46 CHG PMI FAIL 1. Failure in receiving the PMI 1. Check the PMI connections
signal from the charger card of between charger cards of two UPS.
another UPS in PR mode only. 2. Call for the service support if
problem persists.
47 MAINS FREQ O TOL 1. Mains frequency is out of 1. Check the mains supply.
tolerance. 2. Call for the service support if
problem persists.
48 SC CAN2 FAIL 1. CAN communication failure 1. Call for the service support if
generated during PR mode. problem persists.
49 SSW OT 1. Cooling fan failure. 1. Reduce load & try to start the unit
2. Excess load. – if unsuccessful – Call for service
3. Ambient temperature above support.
specified limits. 2. Measure the ambient temperature
at approximately 1mt from the
unit – if found in excess of
specified limits – take actions to
Version V.0 Page 49

reduce it (room ventilation, a/c,

etc.) – wait for approximately 20
min. to allow cooling & try to start
the unit – if unsuccessful – Call for
service support.
50 MBS ON 1. Manual Bypass Switch operated ***
51 CHG CAN FAIL 1. CAN communication failure 1. Call for the service support if
between charger control cards, problem persists.
generated in PR mode only.
52 SYS ON BATT 1. Battery in discharging mode 1. Battery discharging due to charger
off
53 POWER DEMAND
54 BAT LIQ LOW LEVL
55 ABNORM ROOM
TEMP
56 EQUALIZE CHG DIS
57 ABNOR BAT TEMP
58 GENERATOR OP
59 DISABLE
60 REMOTE START
61 REMOTE STOP
62 REMOTE MUTE
63 ASYNC COMMAND
64 RETRANSFER
Version V.0 Page 50

Alarm Log
• All alarms (currently pending as well as those that have been cleared)
are logged.
• The log stores a max of 999 alarms along with the date-time stamp of
occurrence.
• The log works on a FIFO (First In First Out) basis, as such will display the
last 999 alarms that have occurred.
• Date and Time of occurrence of alarm is display on the screen
Alarm Log submenu navigation

SUBMENU
<ALARM LOG> ALARM NAME

LOG #1 dd:mm:yy / hh:mm:ss
Return to ALARM LOG ALARM NAME

LOG #2 dd:mm:yy / hh:mm:ss
.........
.........
.........
Return to ALARM LOG ALARM NAME
LOG#999 dd:mm:yy / hh:mm:ss
Display example (Inverter Under voltage)
INV UV
LOG #10 19:05:00
INV UV
LOG #10 10/01/10
Similarly for others.

• An alarm once generated and then released will be displayed with a * at
beginning.
Version V.0 Page 51

Alarm Assign submenu navigation

Hear you can select the Relay to assign
SUBMENU
<ALARM ASSIGN> RELAY 1

<ALARM NAME>

<ALARM NAME>
.............
.............
.............
<ALARM NAME>
Display example (Inverter Under voltage)
RELAY 1
OVERLOAD
Similarly for others.
There are 8 Relays in the UPS, which can be assigned for any alarm
condition.
So when that particular alarm will be generated you can get changeover in
relay output which has been assigned for that particular alarm.
You can assign the Alarms to Relay navigate the menu of alarms like below,
If you want to assign Alarm to that Relay then press Enter key.
Version V.0 Page 52

Parameter Adjustments:
PARAMETER ADJUSTMENT PARAMETER
CALIBRATION PARAMETER
CONTROL PARAMETER
In Parameter mode three submenus are there.
1. Adjustment Parameter
All reference parameters are included in this submenu. This menu is
password protected.
In this menu if you simply press right button you can enter in
Adjustment Parameter and see the parameter value but you cannot
modify the parameters value. There is a method to enter in
Adjustment of Parameters.
• You have to press Parameter button for 5 seconds continuously
then on LCD screen one message display.
ENTER PASSWORD
XXXXX
There is 5-digit password you can enter password by setting of up and

down key press.
Procedure To Enter the Password
1. Press Parameter button for 5 Sec.
2. Use Up and Down key to enter the correct password.
3. Use RIGHT key to move on next character flashing cursor
to the next parameter.
4. Repeat steps 2 & 3 to set new value.
5. If whole password set then Press ENTER key. If password match
then you can see the screen 1.ADJUSTMENT, you can set those
parameters.
Procedure for changing the Adjustment Parameter.
Procedure To change the Adjustment Parameter
1. Press the Right Button to activate the flashing cursor.
2. Use Up and Down key to increase or to decrease the
value and set the data.
3. Use ENTER key to store the value.
4. Now you can navigate into Adjustment Parameter through UP
and DOWN key and if you want to change the other parameter
the Repeat steps 1,2 & 3 to set new value.
Version V.0 Page 53

Sr No Parameter Name Description
Version V.0 Page 54

1 INV VOLTAGE REF. To set inverter voltage

2 INV I. LIMIT REF. To set Inverter Current Limit Reference
3 LOW BATTERY REF. To set Low battery Alarm reference Voltage
4 DC VOLT LOW REF. To set Low Battery Trip reference Voltage
5 DC VOLT HIGH REF. To set the threshold for inverter trip due to high DC
bus voltage
6 INV LOW V REF. To set Inverter low voltage limit
7 INV HIGH V REF. To set Inverter high voltage limit
8 ALT LOW V REF. To set Alt low voltage limit
9 ALT HIGH V REF. To set Alt high voltage limit
10 FREQ BAND To set Frequency tolerance band
11 OUT LOW V REF. To set output low voltage limit
12 OUT HIGH V REF. To set output high voltage limit
13 MAINS LOW V REF. To set Mains low voltage limit
14 MAINS HIGH V REF. To set Mains high voltage limit
15 I BAT CHG REF To set the battery charging current limit in %
16 V DC FLOAT REF To set charger float voltage
17 V DC BOOST REF. To set charger boost voltage
18 CHG. HIGH REF. To set the charger high dc reference
19 OVERLOAD REF. To set the overload limits of the ups in KVA.
20 INVERTER FREQ To set the switching frequency of Inverter in KHz
21 CL FLOAT BOOST To set the float to boost change over limit in Ampere
22 CL BOOST FLOAT To set the boost to float change over limit in Ampere
23 BOOST TIMER REF To set he boost timing in minutes
24 IR COMPENSATION To set the IR compensation in Voltage for charger
25 125% OL-TRIP To set time for 125% overload in minutes
26 150% OL-TRIP To set time for 150% overload in minutes
27 OUT IR COMP To set the IR compensation in Voltage for inverter
28 SYS ON BATT REF To set system on battery reference Voltage
29 O/P PF FOR OL To set PF(power factor) for overload
Version V.0 Page 55

2. Calibration Parameter
All metering parameters are included in this submenu. This menu is also
password protected. In this menu if you simply press Parameter button
then you enter into Parameter submenu and by pressing DOWN key you can
see Calibration Parameter and by pressing RIGHT key you can see the
calibration parameter data. There is a method to enter in password, which
is same as above procedure for Adjustment Parameter.
Procedure to change the Parameter value is same as the Adjustment

Parameter. But the password is different than the Adjustment and Control
Parameter.

1 IN_R Input R Phase voltage
XXX Volts
2 IN_R Input R Phase current
XXXX Amp
3 IN_Y Input Y Phase voltage
XXX Volts
4 IN_Y Input Y Phase current
XXXX Amp
5 IN_B Input B Phase voltage
XXX Volts
6 IN_B Input B Phase current
XXXX Amp
7 OUT Output voltage
XXX Volts
8 OUT Total Output current of PRC
XXXX Amp
9 ALT Alternate Voltage
XXX Volts
10 DC_V DC Bus voltage
XXX Volts
11 DC_I DISCHARGE Battery Discharge Current
XXX.X Amp
12 DC_I CHARGE Battery Charging Current
XXX.X Amp
13 INV_V Inverter Voltage of system control
XXX Volts
14 BATT_V Charger voltage
XXX V
15 INV V RMS PRC Inverter Voltage of PRC
XXX Volts
16 OUT I RMS SC Total Output current System control
XXXX Amp
17 UPS I RMS UPS current
XXXX Amp
18 SET SECOND To set the second of RTC clock
XX:XX:XX
Version V.0 Page 56

19 SET MINUTE To set the minute of RTC clock

XX:XX:XX
20 SET HOUR To set the hour of RTC clock
XX:XX:XX
21 SET DATE To set the date of RTC clock
XX/XX/XX
22 SET MONTH To set the month of RTC clock
XX/XX/XX
23 SET YEAR To set the year of RTC clock
XX/XX/XX
24 NODE ADDRESS To set the node address for
XXX communication
24 UPS NO To set the Node address of ups
XXX
Version V.0 Page 57

3. Control Parameter
All Control parameters are included in this submenu. This menu is not
password protected. In this menu if you simply press Parameter button
then you enter into Parameter submenu and by pressing DOWN key you
can see Control Parameter and by pressing RIGHT key you can see the
Control parameter data.
Procedure to change the Parameter value is same as the Adjustment

Parameter.
CONTROL PARAMETER NAVIGATION
CONTROL TRANSFER MODE
MANUAL TRANSFER
MANUAL BOOST
INV. CONFIG.
CHG. CONFIG.
Transfer mode submenu navigation

TRANSFER MODE
1. SYNC-1
TRANSFER MODE
2. SYNC-2
TRANSFER MODE
3. ASYNC-1
TRANSFER MODE
4. ASYNC-2
Version V.0 Page 58

Manual Transfer submenu navigation

MANUAL TRANSFER
NO
MANUAL TRANSFER
YES
Manual Boost submenu navigation
MANUAL BOOST
NO
MANUAL BOOST
YES
After pressing the ENTER key, we can enter the following submenu.
BOOST TIMER
001 MIN
. . .
. . .
. . .
BOOST TIMER
999 MIN
Inverter Configuration submenu navigation
INV. CONFIG.
STAND-ALONE
INV. CONFIG.
PARALLEL
Charger Configuration submenu navigation
CHG. CONFIG.
STAND-ALONE
CHG. CONFIG.
PARALLEL
After selecting yes or no press ENTER key to assign selected data.
Version V.0 Page 59

Input Assign submenu navigation

Here you can select the Input parameters
SUBMENU
<INPUT ASSIGN> INPUT 1
<INPUT NAME>

<INPUT NAME>
.............
.............
.............
<INPUT NAME>
Display example (Power Demand)

INPUT 1
POWER DEMAND
Similarly for other Inputs & There are 8 Input in the UPS.
You can assign any input data to Input navigate the menu of Input data like
below, If you want to assign Input data to that Input parameters then press
Enter key. Here you can select the Input data for the particular relay as per
following list.

1 DISABLE No Action
2 POWER DEMAND Reserved
3 BAT LIQ LOW LEVEL Battery Liquid low level alarm
4 ABNORM ROOM TEMP. Abnormal room temp alarm
5 REMOTE START Inverter start command
6 REMOTE STOP Inverter stop command
7 EQUALIZE CHG/DISCHARGE Reserved
8 ABNORMAL BAT TEMP. Abnormal battery temp alarm
9 REMOTE MUTE Alarm mute command
10 ASYNC COMMAND Reserved
11 GENERATOR OPERATION Generator operation status
12 RETRANSFER Reserved
ON KEY: Press ON key for 2 sec to start the Inverter. In case of Sat trip reset
the Sat trip and then try to start the inverter.
OFF/RESET KEY: Press OFF key for 5 sec to stop the Inverter. In case of Sat
trip this key will work as a RESET key: pressing this key for one sec
will reset Sat trip.
MUTE KEY: Press MUTE key to stop the buzzer.
TEST KEY: Press TEST key to test the LEDs on key pad.
Version V.0 Page 60

6. Maintenance
As any other electrical equipment, the UPS system also needs periodic
preventive maintenance to ensure higher reliability and trouble free
performance.
It is highly recommended that the preventive maintenance of the UPS be

carried out by either company trained service personnel or by qualified
trained service technician. We therefore recommend that you sign a
Maintenance & Service contract with the local service center organization.
The following tips will guide the user in proper maintenance during the life
of the system:
• The UPS system should be serviced once a year by qualified service

personnel. The necessary shutdown / de-energization should be
planned accordingly.
• Always follow startup and shutdown procedures as mentioned in the
operation manual.
• Keep the UPS clean and dust free externally and internally.
• Clean the UPS system using only a soft and slightly dampened cotton
cloth.
 DO NOT use corrosive chemicals or soap to clean the
! panels.
 DO NOT open the front door or side covers while
cleaning.
CAUTION  DO NOT attempt cleaning the UPS module from inside.
 This requires De-Energization and will be done during
scheduled maintenance visits by authorized service
• As high temperature of the UPS and / battery room affects the
lifespan of several components inside the Ups system, it is required
to maintain the UPS / battery room temperature well within the
specified limits and free from dust.
• It is recommended that periodic cleaning of ventilation channels and
grids should be carried out in order to ensure proper air circulation.
• It is recommended that the fans be replaced in the units, every
20,000 hours.
• Components such as power filter capacitors and lithium batteries (for
backup of data on the control board) should be replaced every 50,000
hours.
• Ensuring health of the batteries is of utmost importance as without
healthy batteries, the UPS will not deliver the desired performance.
For this periodic checking of the battery health is a must. For battery
maintenance, refer the battery manufacturer’s manual.
• Manual battery mode test should be performed at least once a
month, especially if the batteries are not sufficiently discharged
during the normal operations. Discharge time you use should be at
least half of the battery run time.
Version V.0 Page 61

• In case some of the cells of the battery bank are found to be weak,
immediate replacement of those cells with new cells of same rating,
make and capacity should be carried out.
• In the event the UPS is kept under shutdown for longer durations, the
battery needs to be charged minimum once in three months, for
duration of 12 hours.
• During maintenance shutdown, visual and mechanical inspection of
the UPS must be carried out.
• Never use wire links in place of fuses.
• Always use the recommended rating / make / type of fuses as per
this operations manual.
• Check the calibration of all the parameters like input voltage,
current, output voltage, current, frequency, etc and recalibrate if
required as per the procedure given in this manual.
• Carry out functional checks of thyristors, diodes, transformers, filter
components etc to ensure that they are operating within the
specified design parameters.
• All functional tests like mains failure simulation, load transfer on
static bypass simulation, load transfer on maintenance bypass
simulation should be carried out at least once a year.
• Monitoring battery operation in discharge and recharge mode
including any boost charge should be carried out at least once a year.
Version V.0 Page 62

7. Contact Details
BRANCH ADDRESS
Works: Customer Support:

HI-REL ELECTRONICS LTD.,
B-117,118, GIDC ELECTRONICS ZONE, Mr.Aniruddh Brahmbhatt
SECTOR - 25,
GANDHINAGAR - 382 044. HI-REL ELECTRONICS LTD.,
GUJARAT (INDIA). B-161, GIDC ELECTRONICS ZONE,
PH. NO. : 079 232 87180 / SECTOR - 25,
232 87181 GANDHINAGAR - 382 044.
FAX NO. : 079 232 87182 GUJARAT (INDIA).
EMAIL : contact@hirel.net PH. NO. : 079 232 87190 /
232 87189
FAX NO. : 079 232 87182/ 89 / 90
EMAIL : aniruddh_brahmbhatt@hirel.net
Mumbai Bangalore
Mr. Paresh Shah – General Manger Mr. A Gopal – Dy.General Manager (Salaes)
HI-REL ELECTRONICS LTD., HI-REL ELECTRONICS LTD.,
202/203, APOLLO ARCADE 2nd FLOOR ,MYLAR MANSION , NO 1 ,
R.K. SINGH MARG, ANDHERI (E), 9th CROSS , SWIMMING POOL EXTENSION,
MUMBAI – 400 069 MALLESWARAM,
PH. NO. : 022-28395980 / BANGALORE-560 003
09987686258 PH. NO. : 080-23344761 / 097400 00614
FAX NO. : 022-28395970 / FAX NO. : 080- 23344762
EMAIL :
EMAIL : sales_bang@hirel.net,gopal@hirel.net
sales_bom@hirel.net,paresh_shah@hirel.net
New Delhi Kolkata
MR. Y Gongel – Asst. Vice President (Sales) MR. Sanjeev Sharma- Manager (Salaes)
HI-REL ELECTRONICS LTD., HI-REL ELECTRONICS LTD.,

203,SAHYOG BUILDING, P-384, KEYATOLA LANE,
58, NEHRU PLACE KOLKATA – 700 029.
NEW DELHI - 110 019. WEST BENGAL
PH. NO. : 011 – 26464517 / PH. NO. : 033-24646525 / 097484 84880
FAX NO. : 011 – 26464516 FAX NO. : 033-24646525
MOBILE: 09958692379 EMAIL :
EMAIL : sales_cal@hirel.net,sanjeev_sharma@hirel.net
Version V.0 Page 63

sales_del@hire.net,y_gongel@hirel.net
Hyderabad Chennai
MR. Sagar S R – Sr. Engineer (Sales) MR. K. Ramalingam General Manger (Sales)
HI-REL ELECTRONICS LTD. HI-REL ELECTRONICS LTD.,

PLOT NO 10 , GRUHALAXMI COLONY , NEW NO: 100/1A , OLD NO:80/1A ,
KAKAGUDA , L.B.ROAD,ADYAR ,
SECUDDERABAD- 500 015 CHENNAI-600 020
PH. NO. :040 27813159 / 099592 22392 PH. NO. : 044-24414023 /
FAX NO. : 040 27813157 044 42114096 / 097899 79385
EMAIL : sales_hyd@hirel.net , FAX NO. : 044-42114185
t_durgesh@hirel.net EMAIL : sales_chennai@hirel.net,
k_ramalingam@hirel.net, b_ramasamy@hirel.net
Pune
Mr. S B Rangnekar – Dy.General Manger (Sales)
HI-REL ELECTRONICS LTD.

PRANDYA OFFICES’ COMPLEX
9/4, SANE GURUJI ROAD
BESIDES NEELAYAM THEATRE
B/H HOTEL ASHOKA
PUNE – 411 030.
PH. NO. 020 24331686 / 24334026
FAX No. 020 24337850
EMAIL: sales_pune@hirel.net
Version V.0 Page 64

Operation Manual of UPS System

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Hi-Rel Electronics Pvt. Ltd.

Uninterruptible Power Supply System

Hi-Rel Electronics Pvt. Ltd

Version V.0 Page 1

COPYRIGHT © 2011 by Hi-Rel Electronics Pvt. Ltd.

All rights reserved

The information contained in this publication is intended solely for the

In the spirit of innovation, the contents of this manual are subject to

Version V.0 Page 2

Objective of this Manual:

Version V.0 Page 3

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! to or destruction of the equipment could result.

t Electronics Limited, to perform the specific job.

Version V.0 Page 5

• Check for sufficient floor loading capacity.

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o Potentially hazardous voltages are present within the

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POSITIONING OF THE UPS:

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• The electrolyte contents of the battery are extremely toxic;

Safety instructions when working with batteries:

All qualified operating personnel should adhere to the following

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• If battery terminal is inadvertently grounded, remove the source of

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These disturbances have different effect on loads such as:

Typical Applications include: -

Version V.0 Page 11

• High efficiency resulting from the combination of latest generation

• = Items available from Hi-Rel, depending on the purchase

Version V.0 Page 12

Mains Distribution Unit

Output Distribution Module

The scope of this manual is limited to UPS MODULE only

Version V.0 Page 13

Description of I4 UPS Module

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(B) Block diagram with 12 Pulse UPS

I4 UPS Module Description

Version V.0 Page 15

Battery (separate module)

Static Switch (A bi-directional solid state transfer switch)

MBS (Maintenance Bypass Switch)

(Caution! please refer operating procedure before operating this switch)

Version V.0 Page 16

Major power components of the I4 UPS Module

Version V.0 Page 17

Bypass Static switch

Input utility Static switch

In normal mode the input utility (Mains) power is converted in to DC power

Version V.0 Page 18

Input utility Inverter Static switch

In an event of mains (utility) power failure or out of tolerance, the charger

Input utility Static switch

In this mode , in an event of inverter voltage going out of tolerance , due to

Version V.0 Page 19

Maintenance bypass Mode

COUTION: please refer operating procedure of this switch, wrong operating

Version V.0 Page 20

3. Technical Specification for I4

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