Maintenance Management Operations and Maintenance Plan for UPS

Uninterruptible Power Supply (UPS)

An uninterruptible power supply, (UPS) is an electrical apparatus that provides emergency power to a
load when the input power source, typically the main power supply, fails. A UPS differs from an
auxiliary or emergency power system or standby generator in that it will provide instantaneous or
near-instantaneous protection from input power interruptions by means of one or more attached
batteries and associated electronic circuitry for low power users.

A variety of design approaches are used to implement UPS systems, each with distinct performance
characteristics. The most common design approaches are as follows:

• Standby
• Line Interactive
• Standby-Ferro
• Double Conversion On-Line
• Delta Conversion On-Line
During the project work the observed types of UPS are Stand by and Double Conversion On-Line at
the IT Faculty building and an on line dual conversion UPS at the Department of Building Economics.

1. Stand- by UPS
The Standby UPS is the most common type used for Personal Computers. The Offline / Standby UPS
(SPS) offer only the most basic features, providing surge protection and battery backup. With this type
of UPS, a user's equipment is normally connected directly to incoming utility power with the same
voltage transient clamping devices used in a common surge protected plug strip connected across the
power line.

Advantages of Stand-by UPS

Figure 1: Stand by UPS

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Maintenance Management Operations and Maintenance Plan for UPS

 Low cost
 High efficiency
 Compact

At the IT Faculty building there are mainly stand by UPS. For servers they have used stand by UPS
with a longer back up time period while having a shorter back up UPSs individually for other
computers in labs.

Below tables illustrate the specification of two observed UPSs at IT faculty building.

Table 1 : UPS of an individual computer

Model DCP 650VA/ 390W

Battery 7AH x 1
DC voltage of long backup 12 VDC
Type of load Computer, displayer
Input voltage 230/240 + 25%
Input frequency 50/60 Hz + 10%
Output voltage 230/240 + 10%
Output frequency 50/60 Hz + 0.5Hz (in battery mode)
Back up time 8 ~ 20 mints (rated computer as load)
Transfer time < 10ms
Short-circuit protection Fuse in AC mode, limited output currency in
inverter mode
Efficiency of power >80% in inverter mode
Temperature 00c – 400c
Humidity 10% - 90%

Table 2 : UPS of a server computer

Model PC 650
Capacity 650 VA
Input Voltage Range 160 – 275 V
Frequency 40 – 70 Hz
Phase Single + GND
Output Voltage range 220 VAC
Battery mode 220 VAC + 15%

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Maintenance Management Operations and Maintenance Plan for UPS

Frequency 50 Hz + 1Hz (battery mode)

Transfer time 2ms typical
Battery Type and number 12 V7AH – 1pc
Back up time 8 – 20 minutes depending on load
Recharge time 90% capacity after 8 hours
Protection/ Monitoring Short circuit Line mode – fuse and software protection
protection (CPU)
Battery mode – Software protection (CPU)
Surge protection Yes
Alarms Audible and Visual
Over Temperature >750C Alarm will sound
Protection >850C the system will shutdown
General Noise < 45dB
Temperature 00C-400C
Humidity 0%-95% relative humidity
Power factor Up to 0.7
Built in AVR Yes

Currently Prevailing Maintenance Activities and Drawbacks

The main ongoing maintenance activity for UPS is battery replacements. Normally when purchasing
these stand-by UPS units, one year warranty is taken from the supplier. Therefore as for normal
practise, the batteries are checked after two years of operation.

When the main power is disconnected manually and UPS is being loaded, if it is unable to provide at
least five minute back up, the remedial action is taken which means a replacement of the battery. The
time constraint is taken as 5 minutes since to on stand-by generators and to provide the generator
power to the building that much time is spent. There are specifications for replacement batteries as
given in below table.

Table 3 : Specification for UPS battery

Rated Voltage 12 V

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Maintenance Management Operations and Maintenance Plan for UPS

Rated Capacity 7.0 AH or 7.2 AH

Dimensions Length 5.94”
Width 2.54”
Height 3.70”
Total Height 3.94”
Terminal Type F2 (0.25” wide)
Chemical Sealed Lead Acid

At the replacement a sticker is pasted on the UPS with the replaced date and after a year the UPS back
up time is checked again. If it is more than 5 minutes the battery condition is good and it will not be
changed until a failure occurs.

In addition to that corrective maintenance is done for receiving complaints.

Drawbacks of current procedures

 Do not maintain a proper record system with installed date, replacement dates, complaints
received, etc which may help to predict troubles and for easiness of reference.
 Only check UPS conditions when complaints received.

2. Double conversion on line UPS

In the Double Conversion On-Line design, failure of the input AC does not cause activation of the
transfer switch, because the input AC is charging the backup battery source which provides power to
the output inverter. Therefore, during an input AC power failure, on-line operation results in no
transfer time.
Both the battery charger and the inverter convert the entire load power flow in this design, resulting in
reduced efficiency with its associated increased heat generation.

Figure 2: Double conversion on line UPS

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Maintenance Management Operations and Maintenance Plan for UPS

Advantages of On-line UPS

 No time gap between power failure and supply

 Excellent voltage conditioning

Table 4: On line dual conversion UPS

Model LP10-31T
Rating 10kVA/ 8kW
Battery 240V/ 12Ah
Typical back up time 50% load - 22 minutes
100% load – 8 minutes
Enclosure 680 x 313 x 720 mm
Net weight including battery 170kg
Input power factor 0.99
Input frequency 40 – 70 Hz
Output voltage 220/230/240V (user selectable)
Output voltage regulation +/- 1
Output frequency 50/60 Hz
Humidity 95% non condensing
Ambient operating temperature 0-400C
Audible noise 40-55 dB

Currently Prevailing Maintenance Activities

At present all the maintenance activities of the UPS system are performed by Energy Net (pvt), Ltd. A
technician from the above mentioned company comes in every four months and check for any
abnormal condition of the system while measuring Input voltage, rectifier voltage, load percentage,
power / electronic controls of cooling fans, UPS loading and etc.

He fills a check list and original copy is given to the department while keeping a copy to him. Format
of the check list is attached in annexure.

If any break down occurs, it is informed to the company through a telephone call and they will come
to check and perform the necessary remedial actions.

Draw backs

 Maintenance only centred through outsourced company

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Maintenance Management Operations and Maintenance Plan for UPS

Since no maintenance or inspection is done by the owner of the UPS, hardly a failure will be witnessed
by them. If they record relevant operating parameters daily (eg: Main voltage, Inverter voltage, Load
percentage, supply return frequencies) then there is a possibility to identify any deviating
circumstance.

Additionally if the owner himself can visually check the panel fans monthly the risk of switching off
of the UPS due to the heat generated inside as malfunctioning of fans, can be minimized.

Proposed Preventive Maintenance Schedule for UPS

Table 5 : Proposed maintenance schedule

Duration Maintenance Activities

Monthly For stand-by UPS
- Turn off the UPS,
 Check the air way for any blockage
 Make sure the UPS cover is not covered by dust
 Check input, output and battery connecting lines are firm or not
 Check line insulation effective or not
- Turn on the UPS
- Let the UPS work in battery mode for about 5 minutes
For On line UPS
- Check the panel fans
Quarterly - Visually inspect equipment for loose connections, burnt insulation or any
other signs of wear
- Connect the UPS to AC and turn on the UPS, charge the battery for at least 10
hours, noting the load status (Only for On line UPS)
Bi - annually - Check for liquid contamination from batteries

Corrective and Preventive Maintenance activities implementation procedure

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Maintenance Management Operations and Maintenance Plan for UPS

Individual UPS:

 Initially all the UPS units will be given with a separate code number in accordance with the
relevant lab number, in order to keep all the information relating to undergone maintenance
activities.
 Since the maintenance technicians are now given the preventive maintenance schedule, all
preventive maintenance are performed in an effective manner.
 They will also be given a below mentioned kind of a format to keep all the records of
preventive maintenance. (At this table the dates of the performed maintenance are required to
be written).

Table 6: Preventive Maintenance Record Sheet

Preventive Maintenance Records

Location: Lab no....................

Total UPS units: ....................

Bi-
Monthly Quarterly
UPS code annually
J F M A M J J A S O N D M J S D J D

 I
f

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Maintenance Management Operations and Maintenance Plan for UPS

there is any abnormal condition or a failure, it will be informed to the maintenance division of
computer systems at IT faculty through phone. Mostly addressed problems are as follows.

Table 7: Troubleshooting of stand-by UPS

Problem Possible causes Solution

Normal LED does not light 1. AC power not on 1. Turn on AC power
up when UPS is turn on. 2. Power cable not properly 2. Insert power cable
Inverter LED is red and UPS inserted properly
beeping. 3. Fuse blown 3. Change the fuse
4. Faulty wall socket 4. Change to another wall
socket
UPS beeps occasionally on 1. UPS may be overloaded 1. Check that equipment
AC mode and UPS may 2. Unstable AC supply matches the specified
heated up capacity of UPS
2. Check the AC supply
and wiring
Battery backup time is short. 1. UPS may be overloaded 1. Remove any non
Long beeping sound is heard. 2. Battery not fully charged critical equipment
3. Battery may be near the 2. Charge the battery for
end of its life span at least 8 hours before
use
3. Battery is replaced

 In troubleshooting if the UPS is still under warranty period, the dealer will be contacted over
the phone when a battery replacement or any sever failure occurs.
 All the corrective actions will also be recorded for further reference.
 The preventive maintenance activities are carried out when the labs are vacant.

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On Line Dual Conversion UPS:

 According to the service agreement, the Energy Net company technicians will come for
quarterly service. They are bound to come for the service as to a negotiated timetable. Prior to
their visit the Department will be informed through a phone call since the necessary permission
is needed to be taken from the security.
 The technicians are always accompanied with the lab assistant throughout the service.
 After the completion of the service, the check list they have filled with the conditions of the
UPS will be authorized from the lab assistant.
 All the records will be kept filed at the department.
 Any failure of the system will be informed to the company over the phone and as for the
agreement they are bound to take remedial actions as soon as possible. Department will pay
additional payments for these kinds of requirements.

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Maintenance Management Operations and Maintenance Plan for UPS

Annexure

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