UPS and Battery System Design, Testing and Maintenance Training

• Industrial, Commercial, Institutional Electrical Engineers
• Electrical Maintenance Tradespeople & Technicians
• Instrumentation and Control Engineers
• Power System Protection and Control Engineers
• Consulting Electrical Engineers
• Building Service Designers
• Data Systems Planners and Managers
• Other electrical personnel involved in the maintenance industrial, commericial and institutional power systems.

UPS System Design, Application, Testing and Maintenance

DAY ONE

1. Review: Electrical and Electronic Fundamentals

• Electrical (Resistance, Inductance And Capacitance)
• Electronic (Diode, SCR, Bi-Polar Transistor And IGBT)
• Understanding The Linear And Non-Linear Theory
• Power Factor, Displacement Power Factor, Crest Factor And K-Rating Term
• Electrical Disturbance (Control And Un-Control)

2. Building Blocks of UPS Systems

• Kinetic (Motor Generator Sets)
• Flywheel
• Static And Components
• Rectifiers
• Choppers
• Batteries
• Inverters
• Internal Bypass Static Switches
• Other Components

3. Types of Static UPS

• Traditional UPS
• Static UPS
• Static UPS With Bypass

4. UPS Operation Overview

• The Need For UPS System
• Power System Disturbances
• Basic Types Of UPS Systems
• UPS Topologies
• Single Phase
• Three Phase

5. UPS I/O Sections

• Local Control, Displace, Relay, SNMP, Different Communication Bus And Interface

6. UPS Specification

• In-Depth Study Of Rectifier And Charger Operation Theory
• Input Requirement And Limitation ( Voltage, Current Frequency And Rate Of Change Of X )
• DC Bus Upper And Lower Setting And Alarm

10. Choppers and Inverters

• Chopper Requirement
• Inverter Theory ( Steps And PWM Techno Ledge )
• SCR, Transistor And IGBT ( Pro And Con )
• Inverter Duty Cycle And Operation Frequency.
• Output Requirement ( Voltage, Current, Frequency, Rate Of Changed, Regulation
• Static And Dynamic Response, Synchronization, Overload Capacity, Protection,
• Forward, Reverse And Force Transfers

11. Static Switches ( internal and external )

• SS Operational Limitation
• Fully Rated And Partial Rated

12. UPS Interface

• Standby Generator With UPS
• Potential Generator Issues ( Sizing, Harmonics, In-Rush I, Hunting, Oscillation Etc )
• Building Communication Interface ( Static Contact And Real Time On Line )
• Smoke, Fire, Heat , Security, Water, Repo And Others

13. UPS Grounding and Neutral Configuration

• Most Common Issue
• Principle And Method

14. UPS System Testing and Commissioning 

• Factory And On-Site Testing
• Non-Destructive And Destructive Testing
• Most Items Requires As Per Specification
• Load Bank ( Linear Or Non-Linear )
• Battery Discharge Testing
• Battery Recharging Test
• Performance Testing

15. UPS Testing and Maintenance Procedures

• Charger And Rectifier Maintenance
• Input Filter
• Failure Detection And Maintenance
• DC Bus Capacitor Bank Filter Maintenance And Replacement
• Inverter Maintenance
• Forced Cooling System Malfunction
• Maintenance Of Output Filter And Output Transformer
• Maintenance Of Bypass Electronic Switch
• Maintenance Of Power Electronic Board Control
• Main Control Board Replacement And Alarm System Troubleshooting
• Optimization Of Settings Of The UPS Parameters
• Optimum Maintenance Of The UPS Battery System
• Remote Communications Of UPS With Fire Systems And Building Automation
• Typical Installation Requirements Of UPS Systems
• Grounding Requirements Of UPS Systems
• EMI Issues And UPS Control Systems
• Typical Protection Schemes For UPS Systems

16. UPS System Applications

• Factors That Affect The UPS Application
• Initial Cost, Operational Cost, Footprint, Weight, Dimensions
• Nature Of The Load, Environmental Consideration

DAY TWO

Battery Systems and Maintenance

1. Battery Basics

• Introduction To Various Battery Technologies
• The Objective Of Battery Design
• Universal Law Of Conservation Of Energy

2. Types of Batteries

• Primary, Secondary And Reserve Types
• Dry And Wet Cell Batteries
• Lead Calcium, Lead Antimony, Value Regulate Lead Acid, Absorbed Glass Mat Batteries
• Gel Cell, Automotive And Deep Cycle Batteries

3. Battery Requirements

• Types Of Batteries
• Theory Of Battery Operation Using Ohm Law
• Factors That Affect Battery Performance And Life Cycle
• DC Maximum And Cut Off Voltage
• Monitoring Systems

4. Lead Acid Batteries

• Chemistry
• Different Types
• Capacity Factors
• S-Curves
• Battery Safety And Maintenance
• Float And Equalize Voltages
• Load Testing

5. Nickel Cadmium Batteries

• Chemistry
• Battery Types
• Capacity Factors
• Battery Safety And Maintenance
• Float And Equalize Voltages
• Load Testing

6. Battery Basic Construction

• Terminals, + And – Plates, Electrolyte, Relief Valve, Separators And Container

7. Factors To Determine Battery Electrical Characteristics

• Selection Of Active Materials And Weight Of The Active Materials
• Theoretical And Practical Parameters (Voltage And Amp Per Hour)

 
8. Battery Sizing Determination

• KW And KVA Of Electrical Equipment
• Efficiency Of Electrical Equipment
• Battery Watt Per Cell Calculation
• Selection Of Battery, Number Of Cells, Number Of Battery Units And Number Of Cells Per Battery Block
• Single Or Shared Battery Configuration Considerations

9. Battery Installation

• Important Factors
• Space, Environment, Temperature/Humidity, Ventilation, Flooring Weight
• Anchoring, Configuration, Cabling, Eye Water Station, Grounded And Ungrounded Systems

10. Battery Charging

• Charger Selection
• Switching Mode, Linear, Shunt, Chopper, Pulsed, USB And Inductive Types

11. Charging Methods

• Constant Voltage, Constant Current, Pulsed Trickle, Slow And Fast

12. Nature Of Charging

• Initial (Equalization) Normal Float, Termination Time And Temperature Relationship

13. Charger Performance

• Voltage And Current Regulation, AC Ripple, Efficiency, Inrush Current, Power Factor, 2nd Current Limitation

14. Wet Cell Battery Installation Certification

• Third Party Battery Inspection
• Initial And Final Open Battery Voltage And Battery Specific Gravity Measurement

15. Factors Affecting Battery Performance

• Battery Voltage, Nature Of Discharging, Charger Voltage Regulation, AC Ripple,
• Impurity Of Battery Active Material, Internal Battery Temperature, Charging
• Methods, Number Of Deep And Normal Discharging And Battery Aging

16. VRLA Battery Thermal Runaway

• Battery Internal Impedance And Temperature Relationship
• Causes And Prevention

17. Battery Safety

• Electrocution, Fault, Explosion, Acid, Gases, Weight, Equipment And Chothing

18. Battery Maintenance

• Monthly, Quarterly And Annual Check Lists
• System Voltage, Charger AC Ripple, Internal Battery Temperature
• Electrolyte Level, Specific Gravity, Individual Cell Voltage, Internal Ohm
• Inter-Cell Resistance Housing, Terminals Corrosion, Pole Discolor And Leaking

19. Battery Cleaning

• Battery Individual Cell Posts And Connectors, Safety Precautions And Cleaning Materials

20. Signs Of Battery Failure

• Electrolyte Levels, Plates Deformation, Sediment, Sinking Poles And Abnormal Heat

21. Battery Testing

• R And Z Relationship With Heat
• Internal Self-Discharging
• Battery Impedance And Resistor Type Testers, Ground Fault Condition And Detection
• Battery Replacement Guidelines

COURSE TIMETABLE

Start: 8:00 a.m.
Coffee Break: 10:00 a.m.
Lunch: 12:00 noon (included with course)
Restart: 1:15 p.m.
Finish: 4:30 p.m.