BATTERY SIZING CALCULATION

UPS RATING
INVERTER EFFICIENCY
LOAD POWER FACTOR
NO. OF BATTERY
End Cell Voltage
Back Up Time
K Factor
Make

10KVA /8 KW.
0.91
0.8
31
10.50
120 Minutes
2.8
AMARARAJA

Idc= Maximum Inverter Input Current on Full Load & at Min.DC

IDC(Max)

IDC(Max)

K Factor

KVAX1000X P.F
.
E.C.V X No. OF CellsX Inverter Effi.
10 X 1000 X 0.8
10.50 X 31 X0.91

27.01A

27.01 X 2.8

75.62AH or 75AH

Hence Nearest Battery Selected 12V SMF LEAD ACID 75 AH, 31 Nos BATT.
FOR 120 Minutes Back Up FOR 10KVA/ 08 KW Load, each bank.
Total Two Banks (Separate Battery bank for each set of UPS).
Make : AMARARAJA

REVISION : 0

PAGE :- 1 of 1

DOC. NO. - 135BS08250

CLIENT

M/S JINDAL STEEL & POWER LTD.

RATING

2x10 KVA PARALLEL REDUNDANT UPS SYSTEM

SUPPLIER

HITACHI HI-REL POWER ELECTRONICS PVT. LTD.

TECHNICAL DATA SHEET

A
1
2
3
4

SYSTEM DATA
Make
Rating
Configuration
UPS Overall Efficiency
Dynamic Response under following
5
conditions
5.1 For 50% step load

HITACHI HI-REL
10KVA / 8KW
Parallel Redundant With Separate Battery Bank
86.45%

5%

5.2 For 100% step load & unload

5.3 Power supply interruption & restoration

5%
1%

5.4 Load Transferred to bypass Line

Recovery time after load change (100%5.5
0-100%)
6 Audible Noise @ 1 meter distance
7 Enclosure Protection

10%

8
9

Finish Colour
Cable Entry

Recovers to 98% in < 20 msec for single system

<65 dbA
IP 42
RAL 7032
Bottom

10 Type of cooling
11 Testing Standards

Forced Air Cooling (Internal Fans)

IEC 62040-3

B
1
2
3

ENVIRONMENTAL
Design Ambient Temperature
Relative Humidity
Altitude

50 deg. C
95% RH Non-Condensing
1000 meter from MSL

C
1
2
3
4
5
6
7

UPS INPUT POWER SUPPLY

Input Phase / Wire
Input Voltage
Voltage Tollerance
Input Frequency
Frequency Tollerance
Power Factor (Approx. at rated load)
Recommended feeder KVA

3 PH, 3 WIRE
415V
+10%, - 15%
50HZ
6%
0.92
2 times rated KVA with HRC fuse links

D
1
2
3
4
5
6
7
8
9
10

RECTIFIER / CHARGER
Rectifier Unit
DC Voltage (Nominal Voltage)
Voltage Range
Float Voltage
Boost Voltage
Charging Type
Voltage Regulation
Ripple With Batteries
Ripple Without Batteries
Power Walk in time

6 Pulse
372V DC
325.5V DC 418.5V DC
418.5V DC
NA For SMFB
Automatic Float / Boost mode selection with current limit
1%
1% RMS
2% RMS
10 - 30 Sec.
Rev.: 1

Title: "TECHNICAL DATA SHEET" FOR 2x10KVA

Client: MS JINDAL STEEL & POWER LTD.

HITACHI HI-REL POWER ELECTRONICS PVT. LTD.

Doc. No.: 135DS08250

Page 1 of 3

TECHNICAL DATA SHEET

E
1
2
3
4
5
6
7
8
9

INVERTER
Type Designation
Rating (at specified ambient)
Output Voltage / No. of Phase
Voltage Regulation
Range of adjustment of output voltage
Frequency
Frequency Regulation
Synchronizing Range
Slew Rate

IGBT based PWM Inverter

10KVA / 8KW
230V AC, 1 PHASE
1% (Steady State)
5% at rated load
50HZ
0.1% (Internal Oscillator)
47HZ - 53HZ
1Hz / Second

10 Inverter Efficiency
11 Voltage Waveform

91.00%
Sinusoidal

12 Load Power Factor

13 Load crest factor

0.6 lag to Unity within KVA & KW rating

3:1
< 2.5% for Linear Load
< 5% for Non-Linear Load

14 Harmonic Distortion at rated load

15 Over loading capacity & duration

125% for 10 min,

150% for 60 sec.
(20 minutes spacing between subsequent over loads)

16 Fuse Clearing (<1/4th cycle)

30% rated (Semiconductor type)

10% rated (High Speed type)

F
1

STATIC SWITCH
No. of Static switch

Type of static switch

Transfer Time

Over loading capacity & duration

Short circuit capacity & duration

Two in each UPS system

Fully rated, Solid State employing back to back
connected thyristors.
< 4 msec in Synch Mode (Bump less)
< 20 msec In Asynch Mode
125% for 10 min,
150% for 60 sec.
1000% for 10 msec.

G
1
2

MANUAL BYPASS SWITCH

Make
Type Designation

KAYCEE
Make before break

F
1

BATTERY
Make / Model

AMARARAJA

2
3

Type of Battery cell

AH Rating

SMFB
75 AH

4
5

No. of Cells / Battery

Nominal Cell Voltage

31 NOS.
12V / Batt.

6
7
8
9

End Cell Voltage

Back-Up time
No. of battery banks
Mounting arrangement/Rack dimensions

10.5V / Batt.
120 Min.
Two
Please Refer BATTERY GAD drg.

Title: "TECHNICAL DATA SHEET" FOR 2x10KVA

Client: MS JINDAL STEEL & POWER LTD.

Rev.: 1
HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
Doc. No.: 135DS08250

Page 2 of 3

TECHNICAL DATA SHEET

G
1
2
3
4
5
6

BYPASS TRANSFORMER WITH SERVO CONTROL VOLTAGE STABILISER

Make
HITACHI HI-REL
Type Designation
SCVS (Aux-2)
Rating
10KVA / 8KW
Input / Output voltage (SCVS)
230V / 230V, 1Ph
Accuracy of stabiliser
1%
Isolation X'mer voltage ratio / Freq.
415V, 3Ph, 50Hz / 230V, 1Ph, 50Hz

Title: "TECHNICAL DATA SHEET" FOR 2x10KVA

Client: MS JINDAL STEEL & POWER LTD.

Rev.: 1
HITACHI HI-REL POWER ELECTRONICS PVT. LTD.
Doc. No.: 135DS08250

Page 3 of 3

HITACHI HIREL POWER ELECTRONICS PVT.LIMITED (Unit-II)

A 1308250(1)

QUALITY ASSURANCE PLAN

W.O.
#

Po/LOI

CUSTOMER / CONSULTANT

O/P
Voltage

BATTERIES
TYPE

250

45410
11129

M/s Jindal Steel & Power

SMFB

230V

1 PH

Limited

MODEL

AH

QTY.

I4

B4

75

31

UPS

AUXILIARY

ACDB

DCDB

BATTERIES

SCOPE OF SUPPLY

BATTERY
J.B.
-

RESPONSIBILITY TABLE (while approving Customer can also put his choice in the blank box )
AREA
RESPONSIBILITY
REMARKS BY CUSTOMER
SUPPLIER
HIREL
CUSTOMER / TPIA
Incoming Inspection
P
V&P
NA
Process Inspection
N/A
P
NA
System Testing
N/A
P
V/W
Heat Run requirement
N/A
P
V
Batteries
P
V
V
Distribution panels
Site Acceptance Test

N/A

NOT APPLICABLE
P

BILL OF MATERIAL FOR APPROVAL

LIGHT & FULL-LOAD TEST
INSPECTION VISIT

FF-QAG-20(4)

RATING

OFFICER

OTHER

CONFIGRATIO
N
SA DR
PR

10 KVA

BATTERY
Rack

SPARES
-

P
V
W
N/A

SOFTWA
RE

RS232 C
-

ABBRIVIATION
PERFORM
VERIFY OF TR/TC
WITNESS
NOT APPLICABLE

CLIENTS REMARKS & APPROVAL >>>

DOCUMENTS REQUIRED
DRAWINGS FOR APPROVAL

PAGE # 1 OF 4

MARK / W (Witness) / V (Verification Of Records)

ANY OTHER COMMENTS BY CLIENT

APPROVAL COMMENTS

ANY SPECIFIC REMARKS & COMMENTS

Engineering By

HIREL
APPROVED BY

Sunil kambli

Himanshu Mehta

Other Abbreviations
used in this QAP

CUSTOMERs APPROVAL & DATE

DATE
12-08-2013

W.O. = Work Order, P.O. = Purchase Order, AH = Ampere Hour, SA = Stand Alone, DR = Dual Redundant, PR = Parallel Redundant, ACDB =
AC Distribution Board, DCDB = DC Distribution Board, J.B. = Junction Box, HV = High Voltage, HVHF = High Voltage High Frequency,
GRN = Goods Receipt Note, WI = Work Instruction, TR = Test Report, FF = Forms / Formats, BOM = Bill of Material, FRS = Fault Report Sheet,
MOM = Minutes of Meeting (of inspection), WS = Workmanship Standards, PH File = Product History File, SAT = Site Acceptance Test

QUALITY ASSURANCE PLAN

#
1

Incoming Goods
Item / Component
Power Transformers
Control Transformers

Enclosures

Fabricated & Punched

Items
Heat-sink

HITACHI HIREL POWER ELECTRONICS PVT.LIMITED (Unit-II)

A 1308250(1)

Characteristics
Dimension, HV, NL
Voltages, Finishing,
Marking / Labeling
Dimension, Coating
Thickness
Dimension, Punching
Dimension, Surface
Finishing, Mounting
holes
Dimension, Finish

Rubber items
(Gaskets, Grommets)
Bus-bars & Hardware

Acrylic Material

Dimension, Finish,
Threads
Dimension, Finish

Current Transformers

O/P Accuracy

Switch gears

10

Fuses & Fuse Holders

11

Capacitors

12

14

Semiconductor
Device
Wires, Cables
& Cable Glands
Batteries Only

Physical, NO/NC,
Auxiliary Contacts
Physical, Continuity,
Type
Physical,
Capacitance, Type
Physical

15

Fans

16

Indicating Devices
(Lamps, LED etc.)
Meters

13

Physical, HV, Type

Physical

Quantum
100%
01 / Batch

Applicable
Documents
GRN, WI Drawings,
Mfr. TR

Acceptance
Norms

Responsibility

FF-QAG-20(4)

Record
Register &
FF

01 / Batch

GRN, IS-5, WI,

Drawings
GRN, WI, Drawings

Visual
Measurement

100%

GRN, WI, Drawings

Register &
FF
Register &
FF
Go No Go

Visual
Measurement
Visual
Measurement
Visual
Measurement
Visual
Measurement
Visual
Measurement
Visual

5%

GRN, WI, Drawings

Go No Go

100%

GRN, WI, Drawings

Go No Go

100%

GRN, WI, Drawings

100%
01 / Batch
100%

GRN, WI, Catalog,

Visual
Measurement
Visual

100%
10%
100%

GRN, WI, Catalog

Visual
Measurement
Visual

100%

GRN, WI, Catalog

100%

Visual &
Running
Visual,
Measurement
As Above

100%

GRN, WI, Catalog,

Mfr.s Test Report,
for LATB only Type
Test Report
GRN, WI, Catalog

100%

GRN, WI, Catalog

100%

GRN, WI, IS-1248

100%

GRN, IS-13947, WI,

Catalog
GRN, WI, Catalog

GRN, WI, Catalog

Go No Go

Compliance
to
the
Applicable
Documents

QA

Register
FF
Register
FF
Register
FF
Register
FF
Register
FF
Register
FF
Register
FF

&
&
&
&
&
&
&

18

Packing Material
( Wood, Thermocol )

Physical, Type of
material

Visual

100%

GRN, WI, Documents

Register &
FF
Register &
FF
Register &
FF
Go No Go

19

PCBs

Material, Tracks,
Leveling

Visual

100%

GRN, Drawing, Film

Go No Go

17

Smooth running,
Physical
Physical & Test

Type of
Check
Visual
Physical
Electrical
Visual
Measurement
Visual

PAGE # 2 OF 4

Physical, Accuracy

Remarks

QUALITY ASSURANCE PLAN

HITACHI HIREL POWER ELECTRONICS PVT.LIMITED (Unit-II)

A 1308250(1)

PAGE # 3 OF 4

FF-QAG-20(4)

PCB Manufacturing & Testing

#

Item / Component

2
3

PC Assembly Room
(and storage facility )
Stuffing
Soldering (Wave/Manual)

Inspection

Testing

6
7

Ana-bond
Conformal Coating

(CRC)

Characteristics

Physical,
ESD Measures
Mounting
Dry Solder
Solder Joints
Cleaning, material
as per BOM,
Short Links
Functional,
Burn-in
Physical
Physical

Check

Quantum

Applicable Documents

Visual
Testing
Visual
Visual

Every 6
months
100%
100%

IS-10087, WI

Visual

100%

WI & WS

Electrical

100%

WI, Specification

Visual
Visual

100%
100%

WI, WS
WI

BOM, Drawing, WI
WI & WS

Acceptance
Norms

Responsibility

Record

Remarks

Fault
Compliance
to all the
applicable
documents

Production
Supervisor

Report
Sheet

Process Inspection
#

1
2
3

Item / Component

Companys Logo
Rating Plate
BOM, Drawings :
Product consistency
Fitting

Lugging & Crimping

Cabling & Wiring

Painting & Finishing

8
9
10
11

Doors, Locks & Hinges

Clearance & Creepage
IR Test (after & before HV)
HV Test

Unit / System Test

#
Item / Component
1

Functional Test

Characteristics

Position
System Details
Matching,
Availability, Layout
Mounting,
Tightening
Appropriate size,
firm joint
Routing, Tying,
Finishing, ColorCode, Ferruling
Uniform Coating,
Color
Smooth Working
Dimension
Resistance Value
Breakdown Value

Type of Check

Quantum

Applicable Documents

Visual
Visual
Visual

100%
100%
100%

Drawing
Drawing
Drawing & BOM

Visual

100%

Drawing

Visual

100%

WS

Visual
Continuity

100%

WI, WS, Drawing

Visual

100%

WS, IS-5

Visual
Visual
Measurement
Measurement

100%
100%
100%
100%

WI
Drawing
WI
WI

Characteristics

Check

Dimensions, Setting of
parameters, Load Test, Transferretransfer, Regulation, Efficiency,
Noise Level, Auxiliary Modules,
Annunciation, Alarms, over load,
THD(at Linear Load)

Electrical
Visual
Physical

Quantum
100%

Applicable
Documents
IEC-62040-3
Hi-Rel Specs
Test Report

Acceptance
Norms

Compliance
to all the
applicable
documents

Acceptance
Norms
Compliance
to Applicable
Documents &
Approved
Data Sheet

Responsibility

Production
Supervisor

Record

Check-List
/ FRS

Responsibility
Testing
Engineer

Remarks

Record

Remarks

Test
Reports

Shall be
witnessed by
client

QUALITY ASSURANCE PLAN

FINAL INSPECTION
#
Item / Component
1

Inspection

Site Acceptance Test

#
Item / Component
1

Stand Alone System

Parallel Redundant
System

Auxiliary Units

Final & Complete Check

HITACHI HIREL POWER ELECTRONICS PVT.LIMITED (Unit-II)

A 1308250(1)

Characteristics
Completion of
-Scope of Supply,
MOM & FRS Points

Check
Visual

Quantum
100%

Applicable
Documents
FRS, MOM, PH
File, WI

Characteristics

Check

Quantum

Loose Connections, Physical

Damage, Input Voltage,
Input Current, Charger O/P,
DC Current, O/P Voltage, O/
P Current, O/P Frequency,
Transfer-Retransfer (auto &
manual)
Loose Connections, Physical
Damage, Input Voltage,
Input Current, Charger O/P,
DC Current, O/P Voltage, O/
P Current, O/P Frequency,
Transfer-Retransfer (auto &
manual), Load-Sharing,
Master-Slave Change-Over
Transfer from Inverter to
Bypass by Inverter Low &
OT Simulation, Auto
Transfer-Retransfer, Manual
Transfer-Retransfer, Bypass
Voltage Bypass Current

Visual
Physical
Electrical

Visual
Physical
Electrical

Operation of all Fans,

Operation of Panel Meters,
Normal Functioning of LED,
Normal Functioning of
Indications, Alarms, Panel
Ground Check with System
ON, Briefing to End-user
about System Operation,
Spares, AC-DC O/P
adjustment (if required),
Mains Failure Test, back up
time test and SCVS action
on UPS output fails

Visual
Physical
Electrical

Acceptance Norms
Compliance to
Applicable
Documents

PAGE # 4 OF 4

Responsibility
QA

FF-QAG-20(4)

Record
FRS,
Check-List

Acceptance
Norms
Compliance
to WI

Responsibility

Record

100%

Applicable
Documents
Work-Instruction

Site /
Commissioning
Engineer

SAT
Format

100%

Work-Instruction

Compliance
to WI

Site /
Commissioning
Engineer

SAT
Format

(at No-load,
Light-load &
actual-load
conditions)

(at No-load,
Light-load &
actual-load
conditions)

Visual
Physical
Electrical
(at No-load,
Light-load &
actual-load
conditions)

Remarks

Remarks
The Customer
shall provide
load. In case
Actual Load is
not available,
SAT will be
carried out on
NL & Partial
Load (also to be
provided by
customer)

conditions.

100%

Work-Instruction

Compliance
to WI

Site /
Commissioning
Engineer

SAT
Format

Customer
Signature in
SAT Format is
mandatory.
Test with
Generator to
be done only if
recommended
and
contractually
agreed.

PARALLEL REDUNDANT UPS SYSTEM i4 SERIES

Redundant UPS systems are used to power critical loads wherein the continuity of power supply to the load is
ensured even in the event of failure of one UPS system.

A typical, basic, redundant UPS system is shown in figure 1 and comprises the following

2 X Rectifiers with input isolation transformer of 100% capacity each.

2 X Inverters of 100% capacity each.
2 X Static switches of 100% capacity each.
1 X Battery banks 100% capacity
1 X Bypass line regulator.
Maintenance Bypass MCCB.

Apart from the above the system may also include other items such as input isolation transformers, Output AC
distribution boards, Remote monitoring units, etc depending upon specific requirements.
Parallel Redundant UPS system
UPS A and UPS B, as shown in fig 1 operate in parallel and share the load.
Should any of the UPS fail, it isolates itself from the output bus and the remaining UPS supports the entire load.
Should the redundant UPS also fail, the load is transferred to the Bypass line. However in this case there is no
battery back up available.
i4 series Parallel redundant systems operate on the MASTER/ SLAVE principle.
A MASTER UPS establishes the output bus by synchronizing with the

Bypass line (if its frequency is within acceptable limits).

Internal oscillator (if Bypass line frequency is out of limits)

The SLAVE UPS instantaneously tracks output bus and operates in parallel with the MASTER.

HITACHI HI-REL POWER ELECTRONICS PVT. LTD

The MASTER/SLAVE method of parallel operation has distinct advantages over any other method.

Parallel operating inverters are susceptible to cross currents. Incase both UPS systems try to
synchronize with the output bus individually, large cross currents between inverters can flow due to unequal
rates of synchronization, resulting into simultaneous failure of both UPS systems.

In the MASTER/slave operation only one UPS (MASTER) establishes synchronization, thereby
eliminating the possibility of cross currents.
In the i4 series, any UPS system (UPS A or B) that is started first, automatically designates itself as MASTER
while the remaining UPS is automatically designated as SLAVE.
The MASTER establishes synchronization first and the slave instantaneously follows.
Should the slave UPS fail, the MASTER UPS support the entire load.
Should the MASTER UPS fail, the slave UPS is automatically designated as the new MASTER and
instantaneously supports the entire load.
In the unlikely event of failure of both UPS systems the load is transferred to the Bypass line.
All i4 series UPS systems are digitally controlled by microcontrollers. The 1+1 control circuitry of each UPS
communicates the necessary signals with the redundant UPS for parallel operation.
In i4 series UPS systems the designation of an UPS as a MASTER or SLAVE is done automatically and under
software control.
Both UPS systems are identical and there are no common parts.
Redundancy in Rectifiers
As shown in fig 1, rectifiers of both UPS systems operate in parallel.
Should any rectifier fail, the redundant rectifier can supply both inverters as well as charge the battery banks.
Redundancy in input feeders
It is recommended that separate feeders for both UPS systems and the Bypass line regulator be provided which
is useful in the maintenance of input feeders and up stream switchgear .
Bypass Auxillary system
The bypass panel comprises of Bypass isolation transformer and Voltage stabilizer.The output of the stabilizer is
fed to the bypass input supply terminal of UPS system 1 & 2.

HITACHI HI-REL POWER ELECTRONICS PVT. LTD