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Services Quality Standard - UPS

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procedure

UPS commissioning manual

define the operating procedures for commissioning UPS units

objective

contents
page

introduction
role of the manual number of reports per device definition of commissioning report sections equipment and documents required

3 3 3 3 3 4 4 4 4 5 5 5 6 6 6 6 7 7 7 8 8 8 8 8

UPS room
1 installation manual present 2 compliance with installation rules 3 type of room 4 ventilation of the room 5 taking into account of the ventilation of UPS heat losses 6 taking into account of maximum permissible temperatures for the UPS and its battery

battery room (if separate battery)

7 compliance with battery installation conditions 7.1 floors and walls 7.2 ventilation 7.3 arrangement of the batteries 7.4 setting up of a service floor 7.5 connection of the batteries 7.6 fire-fighting equipment 7.7 safety equipment 7.8 inspection equipment 7.9 sensors 8 battery room temperature

rev. lev. D

date 25.11.02

checked by

signature

type of change first issue

approval of latest revision level by: date:

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electrical environment

9 9 accessibility of protection devices 9 10 conformity of protection devices 9 11 separation of normal AC source and bypass AC source protection devices 9 12 conformity of cable cross-sections 9 13 conformity of earthing 10 14 conformity of UPS and battery connections 10 15 presence of a bypass transformer 10 16 presence of a genset 11 17 type of application 12

checking of the UPS

18 conformity of equipment delivered and equipment ordered 19 visual inspection of the device(s) 20 checking of all connections made on site 21 visual inspection of the connectors 22 commissioning and checking of charger operation 23 commissioning and checking of UPS operation 24 checking of battery-powered operation 25 option(s) installed 26 measurements

12 12 12 12 12 13 13 14 14 14 16 16 16 16 16

information
27 operating manual present 28 operating instructions given 29 presentation of MGE UPS SYSTEMS services to the customer 30 technical documents

annex
18 31 commissioning report number 32 commissioning report 18 18

please note:

use of this document is restricted to MGE UPS SYSTEMS personnel only

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introduction
role of the manual
o the manual is to be used for commissioning; it gives information on the

different sections of the commissioning report to be filled in, with the chapter numbers matching the section numbers of the report o the manual may refer to other documents that already explain the required operation. number of reports per device
o for the commissioning of one UPS, fill in only one report. o for the commissioning of several UPS units, fill in one report per unit. o ordering customer: identify the company that has ordered the UPS from

definition of commissioning report sections

MGE, o requesting party: identify the company that has ordered the commissioning operation on behalf of the ordering customer, o job site contact: enter the name of the person who will be your correspondent, o equipment concerned: this refers to the equipment to be commissioned, fill in the sections (see chapter 21). For the type of battery, enter: manufacturer and type of battery, o reiteration of the name of the room - across from the heading: equipment concerned on page 1 of the report, - across from the heading: (UPS) room on page 2 of the report, this allows us to match up the two pages of the report when several reports are issued, o customer and MGE observations: these are comments on the installation and UPS environment that do not affect the satisfactory operation of the UPS installation, o customer and MGE reservations - the reservations noted by the customer must be acknowledged and solved, when the reservations are lifted, the customer signs and commissioning is complete, - the reservations noted by MGE UPS SYSTEMS may release MGE UPS SYSTEMS from the warranty concerning the satisfactory operation of the UPS installation. o accepting party: person in charge of being in attendance at the commissioning operation and signing the commissioning report.
o the equipment required is the tooling which technicians normally have at

equipment and documents required

their disposal o there are special tools for each device that may be used for commissioning (e.g. electronic wrench, "soft tunor" software). Those tools are described in the documents given to the technicians as training or selftraining material.

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UPS room
1 installation manual present
n refer to the installation manual to fill in the sections of the commissioning report; it contains all the rules, an installation manual is always supplied with the UPS.
o when the manual(s) is missing, have a search made or propose the procurement of a new one from the MGE UPS SYSTEMS sales department

2 compliance with installation rules

n referring to the installation manual, check that o access to the UPS and auxiliary room is not subject to particular conditions (observation), o the clearance dimensions have been respected (reservation), o the different UPS control and monitoring components are accessible and/or visible (observation), o the UPS ground load and weight have been taken into account (observation), o the mechanical assembly of the different UPS and battery cubicles has been done, since the failure to comply with this assembly can create risks of radio-electric disturbances in the installation (reserve), o the UPS has been immobilised (in cases of immobilisation by cylinders) (observation).

3 type of room

n give a brief description of the room and examine the room. n notify the customer of the following risks o risk of fouling of the unit by airborne dust and/or dust that adheres (warehouse, garage, locker,...), o risk of corrosion by salty air, a chemical environment, high relative humidity (> 90%) (dairy plant, sugar plant, chemical plant), o risk created by the passage of water pipes, air conditioners above the UPS: condensation, freezing, bursting, leakage, - in the case of sprinklers or sprayers above the device, the device should be protected, o risk of flooding for UPS units installed in basements, o risk created by certain types of conductive dust (carbon fibres, aluminised sheets), - recommend an appropriate filter option (if possible) or pressurise the UPS room, o major temperature variations in rooms subjected to outdoor conditions (room under the roof or metal sheet or outside...), n if the risk appears obvious to you, make a note of it in the reservation section.

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4 ventilation of the room

n note the chosen type of ventilation. n check for the presence of a thermostat that triggers the fan at an appropriate setting, in the case of mechanical ventilation (see chapters 5 and 6). n make sure that the supply of cool air and ventilation of hot air are consistent. o point out that, in general, cool air is sucked in through the bottom of the device and hot air is discharged through the top. n in the case of cool air intake through a raised floor, check that an opening has been made. n if the risk appears obvious to you, make a note of it in the reservation section.

5 taking into account of the ventilation of UPS heat losses

n note whether the installer has taken into account the heat to be ventilated (see installation manual). n if the risk of temperature rise (see chapter 6) appears obvious to you, make a note of it in the reservation section.

6 taking into account of maximum permissible temperatures for the UPS and its battery

n note whether the installer has taken into account the maximum permissible temperatures for the UPS and its battery ( refer to UPS installation manual ). n for your information: o MGE UPS SYSTEMS UPS units can operate in a continuous ambient temperature of 35C, or 40C for a maximum of 8 hours, o for optimal installation of the battery, it is advisable for it to be in an air conditioned room between 15C and 25C. Above 25c, the service time of components as DC or AC capacitors, fans or batteries decreases significantly. About the batteries, service life is divided by two every 10C, o when the batteries and UPS are located in the same room, the recommendation for the battery is to be given priority, n if the risk of temperature rise appears obvious to you, make a note of it in the reservation section.

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battery room (if separate battery)

7 compliance with battery installation conditions
(open lead or cadmium nickel battery, sealed lead or gas recombination battery). n note whether the installer has taken into account the NFC 15-100 and IEC 60364 standards. For further information, consult the battery manual. For your information, the following extract from the "Practical guide for EPS 2000 EPS 5000" provides information on the content of the standard. n whatever type of installation is used, the batteries must be arranged in such a way as to meet the following requirements:

7.1 floors and walls

n gradient of the floor towards the catch drain leading to a catch trough. n anti-acid covering on the floor and walls (H > 0.5 m) for example: asphalt for lead batteries, chlorine or PVC based paint for alkaline batteries.

7.2 ventilation
n calculation of the flow rate: the flow rate of air to be ventilated depends on the maximum charging current and the type of battery, o for installations that include several batteries, the volumes of air to be ventilated are added up, o open batteries: f = 0.05 x N x Im f: flow rate in m3 per hour N: number of cells Im: maximum charging current in amps, determined by the NF C 58-311 standard o recombination batteries: it is accepted, according to the NF C 58-311 standard, that the ventilation conditions of a general-purpose room are sufficient; when such conditions are not met, the flow rate of air to be ventilated is to be calculated in the same way as for an open battery. o safety: an automatic device should shut off the charging device in the event of the failure of the ventilation system, o location: ventilation should be in the highest part of the room.

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7.3 arrangement of the batteries

n the batteries should be arranged in such as a way that it is impossible for two exposed conductive parts with a voltage between them of > 150 V to be touched inadvertently at the same time. o this condition may be met by appropriate coupling of the cells, o insulating terminal shields may also be used and connections made using insulated cables. Example:

low voltage between 2 cells that are accessible at the same time

7.4 setting up of a service floor

(compulsory for voltage > 150 V) n this floor must be: o non-slippery, o insulated from the ground, o developed sufficiently for it to be impossible to touch the ground or a conductive part connected to the ground and one of the battery cells (width > 1 m).

7.5 connection of the batteries

n the connections should be as short as possible.

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n access, o make sure that there is easy access for convenient checking of the levels and in the case of sealed batteries, make sure that nothing can interfere with the operation of the safety valves.

7.6 fire-fighting equipment

n permissible extinguishers: powder or CO2 or sand.

7.7 safety equipment

n safety glasses, n gloves, n fire hose stations.

7.8 inspection equipment

n hydrometer, n filler for levels, n thermometer.

7.9 sensors
n hydrogen detector, n temperature sensor, n access,

8 battery room temperature

n take into account the maximum permissible temperatures for the battery (see chapter 6), o the recommendation given applies for all types of battery. o if the risk of temperature rise appears obvious to you, make a note of it in the reservation section.

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electrical environment
9 access to protection units
n identify the location of the upstream and downstream UPS protection units prior to commissioning. n make sure that the circuit breakers are marked or identified by labelling. n note in the observation section if particular arrangements are required before any handling of the protection units: protection units in closed rooms, immobilisation, ...

10 conformity of protection units

n make sure that the protection units recommended in the installation manuals are used, if not, make a note of it in the reservation section and notify the customer of the risks incurred: no protection of people, no discrimination, cable overheating, nuisance tripping, ...

11 separation of normal AC source and bypass AC source protection units

n point out that in order to obtain continuity of service, it is preferable to have two separate power supplies for the UPS (if the type of UPS allows it). o regarding 3-phase/single-phase UPS units, refer to the next chapter.

12 conformity of cable cross-sections

n make sure that the recommended cable cross-section is used or that the cross-sections of the cables installed are consistent with the rated currents announced (see installation manual). o if not, make a note of it in the reservation section. o for your information, the cable cross-section depends on: - rating of the current flowing through them, - maximum permissible voltage drop: . 3% for 50 or 60 Hz AC circuits, . 1% for DC circuits. - permissible temperature build-up; this is limited by the insulating material withstand and depends on: . type of cable core (copper or aluminium), . cable-laying method, . number of joined cables. o the standard (NFC 15-100 ) gives the permissible current rating for each type of cable. o for a given power supply, each of these parameters leads to a permissible minimum cross-section; it is compulsory for the largest of those crosssections to be used.

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13 conformity of earthing

n the exposed conductive parts must be electrically connected to an earth electrode or a groups of interconnected earth electrodes with appropriate resistances, o the standards that govern the protection of people are, for the installation: the IEC 60364-4-41 and NFC 15-100 chapter 41. n make sure that the metal frames of the UPS installation cubicles are interconnected and connected to an earth electrode. It is essential for this connection to be made prior to any energising. o for your information: - the earthing of metal frames allows fault currents to be run off into the ground, - the earthing system design should take into account certain standard practices: . attempt to have an equipotential earthing system, . meshing of earthing, . interconnection of building earthing.

14 conformity of UPS and battery connections

n for integrated batteries, the connections are made in the factory. n for side-by-side battery cubicles, make sure of the conformity of the power and auxiliary connections (battery circuit breaker undervoltage coil and auxiliary contact) (see installation manual). n for separate batteries, make sure that the connections are compliant (see installation manual). n for the choice of the battery circuit breaker (if not supplied by MGE), refer to the UPS installation. o for your information: the battery short-circuit current is approximately 10 times is capacity in amps per hour and the maximum short-circuit current is always less than 20 times its capacity given in amps per hours.

commissioning of the poles

15 presence of a bypass transformer

The transformer may or may not be supplied by MGE, in any case, check: n the transformer power rating, which must be greater than or equal to the power of the UPS installation (stand-alone or parallel). n the transformer wiring (220 V or 380 V) if energising is to be done.

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n the connection of the transformer metal frame and, when applicable, its shield, to an earth cable or earth electrode. n the curve of the upstream protection circuit breaker, which should take into account the transformer energising inrush current. n the transformer that performs galvanic isolation; it allows the use of different upstream and downstream earthing arrangements. o make sure that this factor is taken into account and check that the protection units downstream from the transformer are suited to the new earthing arrangement o for more information, refer to =S= technical review # 129

16 presence of a genset

n note whether the installation includes a genset liable to replace the normal AC source of the UPS. n make sure that harmonic phenomena upstream from the rectifier-charger have been taken into account in the evaluation of the power of the genset (see =S= technical review # 152). High voltage source

Power share Non priority Loads

Priority loads

general layout of an installation that includes a UPS and a genset

o for your information - harmonic filters may be installed upstream from certain MGE UPS units MGE, - some UPS units can limit charging impacts at the time of the starting and stopping of the charger,

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- the testing of the genset supplying the UPS is a separate service. It is provided to ensure that the installation is operating correctly. o note the value and stability of the frequency supplied by the generator (measurement section).

17 type of application

n give a brief description of the type of application: o computer equipment, medical equipment, machine-tools, PLCs, cash registers...

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checking of the UPS

18 conformity of equipment delivered and equipment ordered
n check that the equipment delivered (type and characteristics) matches the equipment ordered. o to identify the equipment, use the manufacturer plate (serial number, item number), customisation or configuration (battery life, power, voltages, options...) in the commissioning notice.

19 visual inspection of the device

The installed equipment is inspected: UPS, battery and auxiliary cubicle(s): n check that the cubicles have not been undergone shocks (scratches, dented metal plates, position of subassemblies) during the various handling operations (transport, unloading, installation), o in the event of major shocks that can have an adverse effect on the operation of the UPS, make a note of this in the reservations. n check that all the UPS sheet metal plates, panels and PVC protection covers are present. However, remove the PVC plates set on top of the battery cells for proper battery ventilation (see installation manual). n check that the equipment is clean, after the installation of the UPS and any outfitting work.

20 checking of all connections made on site

n check that the cables connected by the installer (to the UPS and the options supplied by MGE UPS SYSTEMS) have been tightened, since incorrect tightening of a power cable can cause the destruction of a part of the cable by excessive heat dissipation at the terminals of a contact resistor. n check that the connections made match the installation file, checking in particular for: o inversion of the bypass AC input and application cables, o inversion of the phase and neutral conductors (single-phase UPS) o matching of normal AC input phases in parallel UPS installations, o connection of any remote information devices.

21 visual inspection of the connectors

n check the position of the different secondary wires and flat cables, and the plugging in of the electronic modules and boards.

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22 commissioning and checking of charger operation

It is considered that the charger characteristics announced have been tried and tested in the factory. n before energising, make sure that the rotation of the normal AC input phases is correct (some UPS units include this check), and that the amplitude of normal AC source is compatible with the tolerances allowed by the charger (greater than -10% or -15%). o measure the normal AC input and enter the values in the measurement section o the normal AC input tolerances are given in the installation manual; the device configuration must be taken into account (chapter 26) o when the tolerances are reached, action must be taken with respect to the amplitude of the normal AC input; propose a step-down or step-up transformer; modification of the upstream transformer tapping points n check that the voltage supplied by the charger matches the number of battery cells with a variance of less than 1%; this value is entered in the measurement section. n for a sealed lead battery, apply the following recommendations: o given that the battery is sealed, no hydrogen should be released. It is therefore strictly prohibited to do any equalisation or formation with this type of battery, o the charging voltage and floating voltage are the same, n for open lead or CD/NI batteries, comply with the manufacturer's requirements.

23 commissioning and checking of UPS operation

It is considered that the UPS characteristics announced have been tried and tested in the factory. n before energising, make sure that: o the phase sequence of the bypass AC input is correct (some UPS units include this check ). o the transfer conditions are correct, if not, make a note of it in the observation section of the report. o Q3BP and Q5N switches position is correct. o measure the bypass AC input and enter the values in the measurement section of the report. o the bypass AC input tolerances are given in the installation manual; the device personnalisation must be taken into account (chapter 21), when the tolerances are reached, action must be taken with respect to the amplitude of the bypass AC input; propose a step-down or step-up transformer; modification of the upstream transformer tapping points n check that the voltage and frequency supplied by the UPS match the product requested by the customer (220 V, 240 V, 380 V, 400 V, 415 V and/or 50 Hz, 60 Hz, 400 Hz). (see chapter 5.4) n check the coupling and uncoupling functions using the mimic diagram

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24 checking of batterypowered operation

n if possible, make sure that the battery has not undergone prolonged storage; compare the unit delivery date and commissioning date. If it is the case, note it in the restriction part of the report. o in the case of excessive storage time (longer than 6 months) and without any charging cycle (at least every 3 months), there is a risk of irreversible downgrading of the battery: contact the battery supplier who will determine whether the battery can be recovered or needs to be replaced, o the testing of battery-powered operation consists of ensuring that the UPS continues to operate after the shutdown of the charger, o battery life testing is a separate service; it implies that the battery is sufficiently recharged (18 hours at floating voltage) and that the UPS is charged to the rated value by the application or a test load. o battery life testing consists of ensuring that the contractual battery life is complied with.

25 option(s) installed

n fill in the section and inform the customer of the possible options that can be installed with his device ( communication, supervision, electrical environment ).

26 measurements

n fill in the section, the measurements are taken using a digital multimeter and an oscilloscope for the calculation of the crest factor. n the following measurements are taken with the UPS operating and connected to the load; the crest values may differ on the UPS and the supply, these measurement differences being linked to the difference between source impedance and cable lengths. o for your information, the crest factor is the ratio between the peak value of a signal and its true rms value n note the load rms current(s) n using the oscilloscope and a current clamp take a reading of the peak value of the load current. o calculate the crest factor and enter the values in the measurement section of the report. o depending on the crest factor value, the rms value of the current may not be representative of the power still available on the UPS ( crest current limitation ).

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n rules for scaling a device: the peak load current should not be more than L x 2 x In of the technical power. L = "limitation" or "peak overload" value according to the UPS unit; this value may change, refer to the UPS technical characteristics ( Services View ). In = rated rms current of the device. 2 = 1.414 (this factor may sometimes be included in L). o the rms current of the load should not exceed In of the commercial power, applying the derating linked to the cosinus phi. o the cosinus phi (phase displacement of the load current and voltage) or power factor for non-linear loads (general case) entails a derating factor; this factor depends on the characteristics and therefore on the type of UPS. o example for a 20 kVA EPS: In = 31 A with 380 V I limitation = 65 A peak derating with cosinus phi 1= 0.77, i.e. In = 23.8 A rms hence a crest factor capacity of (65/23.8) 2.7 for cosinus phi 1 n according to the results obtained with the crest factor calculation and the load rms current value, notify the customer of the possibilities of changing his load and note this in the observation part of the report.

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information
27 operating manual present
n fill in the section. o when the manual is missing, have a search made or propose the procurement of the manual from the MGE UPS SYSTEMS commercial
engineering department

28 operating instructions given

n give the operating instructions: o to the persons in charge of checking the operation of the UPS,
o or to the users or facilities managers, o or to the accepting party of the commissioning report.

n general operating information is given. n the operating instructions may be accompanied by operations on the device: o commissioning of the device (charger and UPS), o decommissioning of the device (charger and UPS), o de-energising of the device (by-pass).

29 presentation of MGE UPS SYSTEMS services to the customer

n present the various service possibilities that our activity can offer, in particular regarding servicing contracts. n to do so, give the customer the document holder which contains: o the report o promotional brochures . UPS maintenance . teleservice . maintenance contract selling point sheets.

30 technical documents

n additional documents may be necessary to present arguments on technical points: o UPS and peripheral device / accessory manuals For each type of device, there is a complete list of the manuals concerning the device and its options; this list is available from the MGE UPS SYSTEMS printing department in Montbonnot. The operating and installation manuals intended for customers and installers are normally supplied with the devices. Should they be missing, they are available from the sales department. o =S= cahiers techniques (technical review) the technical review are available by downloading from the internet site: http://www.schneider-electric.com/ - CT 129 protection of people and static uninterruptible power supplies (earthing systems) - CT 130 static uninterruptiple power supplies - harmonics - CT 141 electrical disturbances in LV - CT 152 harmonic disturbances in industrial networks and treatment - CT 159 UPS and harmonics (non-linear loads)

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o training course tools

This is the documentation that you are given during UPS training courses. When maintenance is performed, most of the inspections make reference to this documentation.

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annex
31 commissioning report number 32 commissioning report
n commissioning report QS699

n copy attached o the commissioning report available on Lotus Notes data bases are filled in by

the technician using a laptop computer with the automatic software