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.
