Chapter 6

UPS Operating/Maintenance Procedures

This chapter in the manual deals with the specific operating and maintenance for UPS that the ABC engineer is liable to encounter.

WARNING

UPS CONTAIN HIGH VOLTAGES AND BATTERIES WHICH ARE A SOURCE OF HIGH POWER AND VOLTAGE. THERE IS A DANGER OF ELECTRIC SHOCK AND OR BURNS. ENSURE THAT ALL SAFETY PRECAUTIONS DETAILED IN SAFETY ISSUES ON PAGE 2-1 ARE OBSERVED.

6. 1

Routine UPS Maintenance

All UPS and associated system components need periodic maintenance and occasional replacement of parts in order to ensure optimum reliability. Each UPS, battery and generator supplier will have its own Planned Maintenance (PM) programmes which will typically include the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Inspect site log for incidents since previous PM visit. Check and record equipment meter readings and verify accuracy. Check that meters and instrumentation operate correctly. Verify the correct status indications for the local and remote monitoring panels and communication facilities. Check that all indication lamps are operational. Check that all switch gear operates correctly. Check the air flow in and around the equipment. Replace the air filters if fitted. Remove any material and obstructions from around the equipment. Check the environment for abnormal conditions. Check for excessive heat, noise and vibration. Visually inspect all components for signs of damage. Visually inspect power and control wiring. Check for loose connections. Inspect the ac and dc capacitors for swelling and leakage. Check the power supply voltages and the power waveforms. Check the operation of the circuit breakers and associated trips and/or undervoltage releases. Check the overall operation of the UPS. Maintain the site log with written service reports.

Additional checks and testing will be required if a parallel UPS system is installed.

A.B.C. Training Manual Issue 1 January 2002

6-1

Chapter 6 - UPS Operating/Maintenance Procedures Powering down a UPS

6. 2

Powering down a UPS

When carrying out a routine maintenance on a UPS it is important that the equipment is placed in a safe working state this will generally need the following actions to be carried out.

Important Note

The Critical Load connected to the UPS must be either powered down prior to maintenance being carried out or the user informed that the UPS is to be placed into a bypass condition and the load will not be protected from failure of the input supply.

6.2.1

UPS Fitted With Maintenance Bypass

1. The UPS must first be switched into the static bypass Mode. This is usually carried out from the UPS operator control panel and will entail switching the Inverter from normal output to static bypass.

Note:
2.

When in Static Bypass the critical load is supplied from the input AC supply.
The UPS can now be switched into the maintenance bypass position. The maintenance bypass is usually selected by a manually operated isolator or Castell interlocking system. The UPS output isolator can now be opened.

3.

Note:
4. 5. 6.

The Maintenance Bypass Isolator is quite often locked to prevent misuse.

Once in maintenance bypass the inverter output is switched OFF. This is usually carried out from the UPS control panel. The battery isolator or fuses are now removed to isolate the battery from the UPS. The input supply isolator or fuses can now be opened. The UPS is now electrically save.

Caution

There is a potential hazard in some models of UPS if fitted with an internal maintenance bypass. Input AC power will still be present at the line side of the Input Isolator or fuses, the bypass isolator and output terminals.

6.2.2

UPS with Static Bypass Only

1. Switch the UPS into the static bypass Mode. This is usually carried out from the UPS operator control panel and will entail switching the Inverter from normal output to static bypass. If power to the critical load is to be maintained, the UPS can be left in Static Bypass. The inverter output is switched OFF. This is usually carried out from the UPS control panel. The battery isolator or fuses are now removed to isolate the battery from the UPS. On some UPS the rectifier can be switched OFF usually from the operator control panel. Further Isolation may be possible by removing the rectifier fuses or opening the rectifier isolator, but this is only possible if the power is maintained to the static bypass line.

2. 3. 4. 5.

Caution

Isolating the input supply to the rectifier may result in loss of the control power supply, which may open the Static bypass causing a loss of power to the critical load. 6. If the UPS has no maintenance bypass system then for complete isolation the Critical load must be powered down and the input AC supply to the UPS opened.

6-2

A.B.C. Training Manual Issue 1 January 2002

Chapter 6 - UPS Operating/Maintenance Procedures Test Procedure for Galatrek Microbak UPS systems.

6. 3

Test Procedure for Galatrek Microbak UPS systems.

Bypass Box

Figure 6-1 6.3.1

Typical Microbak with Bypass box on wall on left hand side.

Before commencing tests check the Operational status of the system. Note: 1. 2. 3. 4. Follow the Bypass Switching Procedure For Galatrek Microbak on page 6-4. If the UPS running with the Bypass switch in the normal position continue with testing. If the UPS is in Bypass test the battery but be sure that the system is operating correctly before switching back to normal following the test. If no bypass is installed - abort the test and take all details of UPS and Switch type and information from the rating plates. If UPS is switched OFF or there is any other abnormal condition check with HQ or Siemens before continuing.

Status Checks

Important

Check correct rating and type of MCB in the customers Consumer Unit - do not proceed if below recommended rating.

6.3.2

Battery Test Procedure

1. 2. 3. 4. 5. 6. If the UPS has an LCD Display, record all readings. If the UPS has no LCD Display record system load current using AVO AC Clamp meter. Turn Maintenance Bypass switch to Bypass position. (see Figure 6-2) Press on/off button on UPS for 5 - 10 seconds until UPS switches off. Switch off UPS supply switch on Maintenance Bypass box. Switch off the battery CB on the rear of the UPS and on the rear of any extension cabinet(s).
LH Switch UPS Supply RH Switch Normal or Bypass Supply

Figure 6-2
A.B.C. Training Manual Issue 1 January 2002

Bypass Box
6-3

Chapter 6 - UPS Operating/Maintenance Procedures Bypass Switching Procedure For Galatrek Microbak
7. Remove UPS casing by undoing eight screws at the back of the UPS - four down each side. Case should be pulled forward from body of UPS. Be careful not to strain either the ribbon cable that runs from the LCD panel on the Case to the electronic circuits mounted above the batteries or the small earth wire.(see Figure 6-3) Visually inspect batteries for faults and record their age. Complete an impedance test on the battery. (4 x 12 volt blocks of 24 or 38AH rating) Remove Case from any extension cabinets in a similar manner. Extension cabinets may have two batteries, if so, remove an end lead from one of them so they are not in parallel during the impedance test.

Ribbon Cable To Case

8. 9. 10.

Figure 6-3
11. 12. Switch On battery CB(s).

Battery in UPS Cabinet Casing Removed

Reconnect any disconnected wires and replace Case(s).

6.3.3

Restarting system
1. 2. 3. 4. 5. 6. Switch ON UPS supply on Bypass box. Press on/off button on UPS for 5 - 10 seconds until UPS starts. If LCD display fitted record all readings, ensuring that the UPS output voltage is correct and that charging LED (Amber) is lit. Wait for at least 30 seconds before switching Bypass switch to normal. Ensure all items are complete on test results sheets. Check telephones are operating correctly before leaving site.

6. 4

Bypass Switching Procedure For Galatrek Microbak

6.4.1 Turning UPS off / Bypass
1. 2. 3. 4. Turn Maintenance Bypass Switch (Usually Mounted on wall) to Bypass, Position 1. Press on/off button on front panel and keep pressed for 5-10 second, until UPS stops. Switch off UPS supply switch, also mounted on wall. Switch off battery breaker on the back of UPS and Extension cabinets if in use.

6.4.2

Turning UPS On
1. 2. 3. 4. Switch on UPS Supply. Switch on battery breakers (UPS and cabinets). Press ON/OFF button for 5- 10 Seconds until UPS is running. Wait for 1 minute then turn Maintenance bypass to Normal (Position 2).

6-4

A.B.C. Training Manual Issue 1 January 2002

Chapter 6 - UPS Operating/Maintenance Procedures Bypass Procedure for Galatrek Powerbak

6. 5

Bypass Procedure for Galatrek Powerbak

Note: 6.5.1 The Galatrek Powerbak is obsolete and work should only be completed on these UPS with agreement by HQ and Siemens.
Switch maintenance bypass from Position 1(Normal) through Position 2, to Position 3 (Bypass). Switch found on back of UPS. Turn Bypass/Inverter switch to Bypass. On front panel of UPS. Turn Inverter Switch on front panel to off. (alarm will Sound). Remove Battery fuse on front panel (Alarm will die after a few seconds). Remove Mesh Panels on back of UPS and Extension Cabinets (If fitted), And turn off battery breakers, these are in the bottom right of UPS and Cabinets. Remove battery tray securing bolts found also in back of UPS/cabinets Remove front panels from UPS/cabinets. Carry out test /Installation as required, replace all security bolts on completion.

Switching UPS to Bypass

1. 2. 3. 4. 5. 6. 7. 8.

6.5.2

Switching UPS On.

1. 2. 3. 4. 5. 6. 7. Switch on battery breakers in back of UPS/Cabinets, and replace Mesh Panels. Refit battery fuse on front panel. Switch Maintenance Bypass from Position 3, Through Position 2 to Position 1(Normal). Turn inverter switch to ON. Wait Approximately 30 Seconds. Switch Bypass/ Inverter Switch to inverter. Check phones still working OK.

6.5.3

About the PowerBak

The Galatrek PowerBak is an old design which was superseded by the MicroBak and, more recently by the Elite. Because of the age of the PowerBak and the heat generated by the UPS during normal operation the majority of PowerBaks which are still operational have reached a stage where if work is carried out on them, including the replacement of batteries, the continued reliable operation of the UPS can not be guaranteed.

A.B.C. Training Manual Issue 1 January 2002

6-5

Chapter 6 - UPS Operating/Maintenance Procedures Test procedure for Galarek Elite

6. 6

Test procedure for Galarek Elite

Before commencing tests check the Operational status of the system. If the UPS is running with the Bypass switch in normal position continue test. If the UPS is in Bypass test the battery but be sure the UPS is operating correctly before switching back to normal following the test. If no Bypass is installed - abort the test, take full details of UPS and Switch type and all information from rating plates. If UPS is switched off or there is any other abnormal condition check with HQ or Siemens before continuing.

Important: Check location of protection device - MCB in consumer unit or Switch Fuse. Check rating of MCB or Fuse if possible

6.6.1

Procedure for Closing Down the system and testing batteries

1. 2. 3. 4. 5. Turn Maintenance Bypass Switch to Bypass position Press ON/OFF button on UPS for 5 - 10 seconds until UPS switches off Switch off UPS Supply switch on Maintenance Bypass box. Switch off the battery Circuit Breaker on the rear of the UPS and on the rear of any extention cabinets. Remove UPS casing by removing eight screws at the back of the UPS, four down each side. Case should be pulled forward from body of UPS. Be careful not to strain either the Ribbon cable which runs from the LCD panel on the case to the electronic circuit board mounted above the batteries or the earth wire. Visually inspect batteries for faults and record their age. Complete an impedance test on the battery. Remove cases from any extention cabinets in a similar manner.Extention cabinets may include two batteries, if so remove an end lead from one of them so they are not in parallel during the impedance test. After test reconnect any disconnected wires and replace cases. Switch on Battery Circuit Breakers. 11. 12. 13. 14. 15. 16. Restarting System Switch on UPS Supply on Bypass Box Press on/off button on UPS for 5 - 10 seconds until UPS starts. If LCD display fitted record all readings, ensuring that the UPS output voltage is correct and that the charging LED is lit. Wait for at least 30 seconds brfore switching bypass switch to normal. Ensure all items are complete on test results sheets. Check telephones are operation correctly before leaving site.

6. 7. 8.

9. 10.

. 6. 7

Test Procedure Siemens Masterguard UPS

The following is a suggested on-site procedure for contract maintenance visits. Time on site approx. 1 hour. 1. 2. 3. 4. Carry out a visual inspection of UPS condition and environment. Check the operating conditions using Laptop computer, running Masterguard software and connected to serial port. Transfer UPS to Maintenance Bypass. Check Batteries - impedance test followed by capacity (load) test.

6-6

A.B.C. Training Manual Issue 1 January 2002

Chapter 6 - UPS Operating/Maintenance Procedures Maintenance Bypass Operation - Gresham UPS

5. 6. 7. 8. Clean internally and fans using approved methods. Restart UPS checking operation of cooling fans. Return to UPS operation. Repeat computer operational check. Electrical and environmental operating condition. Condition and future life expectancy of batteries. Autonomy time available at recorded load. Any recommendations to achieve improved reliable operating conditions.

Following the visit a full report would be provided including items as follows:

Parameters measured will be restricted if a Maintenance Bypass Switch is not available.

. 6. 8

Maintenance Bypass Operation - Gresham UPS

6.8.1 Power Down UPS
1. 2. 3. 4. Switch UPS to internal bypass by pressing ON/OFF Button & Alarm Button together. See Bypass indicator lamp on front panel. (flashes) Rotate Load Switch (B) from Mains to Load position (Vertical) Rotate Mains Switch (A) to OFF (Vertical) Turn UPS OFF.

6.8.2

Power ON:
1. 2. 3. 4. Rotate Mains Switch to Mains to UPS position. Ensure UPS is switched to internal static bypass Rotate Load Switch to UPS position Transfer UPS to Inverter output (Press two buttons together again)

. 6. 9

Keysource Sentinal UPS

To put UPS into Bypass Mode 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Put into internal bypass by switching the red switch on the front of the UPS to the off position. Turn bypass switch to the Service Bypass position. Switch off battery breaker on UPS and external cabinets if fitted. Switch on battery breaker(s) Switch Red Switch to UPS position (Inverter Light on panel should come on) Turn Bypass to Machine Bypass (Battery & Inverter Light ON) This shows UPS is working. Turn back to Service Bypass Turn OFF red switch on UPS Turn Bypass Switch to Normal Turn Red Switch back on.

To out UPS back on

A.B.C. Training Manual Issue 1 January 2002

6-7

Chapter 6 - UPS Operating/Maintenance Procedures Keysource Sentinal UPS

6-8

A.B.C. Training Manual Issue 1 January 2002