BATTERY SIZING CALCULATION

12V SMFB
RATING 7.5 KVA Battery Type SMFB
INV EFF. 90.0% No. of Blocks 29
Load P.F. 0.8 End Cell Voltage 10.5
Back-up Time 30MIN

UPS rating x 1000x Load P.F.

IDC (Max.) =
No of cells x Inv Effi. x End Cell voltage

7.5 x 1000 x 0.8

IDC=
29 x 90.0% x 10.5

= 21.9 Amp

Aging Factor 1.25 = 27.37 Amp

Temp.correction factor 1.06 1.06 = 29.01 Amp
K factor 0.89 = 25.8 AH
Battery selected from catalogue 26 AH

Selected AH 26
No. Of Blocks 29
Model EP
Make EXIDE
TITLE: “BATTERY SIZING CALCULATION” Rev.: 00
CLIENT: DigiTech Controls & Automations (I) Pvt.Ltd
HITACHI HI-REL POWER ELECTRONICS PRIVATE
PROJECT: ACC- Ametha Project Materials Handling Package A/c Takraf
LIMITED
India Pvt Ltd , Chennai
END USER: ACC Cement Ltd Ametha MP DOC NO-215BS07220 SHEET 2 of 2
 HEAT LOSS CALCULATION
CHARGER EFFICIENCY AT 100% LOAD = 95.0%
INVERTER EFFICIENCY AT 100% LOAD = 90.0%

OVERALL UPS EFFICIENCY = 0.8550

= 85.50%

OUTPUT KW = 7.5 KVA

= 6 KW

OUTPUT KW
INPUT KW = ----------------------------
OVERALL EFFICIENCY

= 7.02 KW

HEAT LOSS = INPUT KW – OUTPUT KW

= 1.02 KW

SCVS (BYPASS) NO LOAD LOSS = 0.12 KW

TOTAL HEAT LOSS = 1.14 KW(Approx)

TITLE: “HEATLOSS CALCULATION” Rev.: 00

CLIENT: DigiTech Controls & Automations (I) Pvt.Ltd
PROJECT: ACC- Ametha Project Materials Handling Package A/c Takraf India Pvt Ltd , HITACHI HI-REL POWER ELECTRONICS PRIVATE LIMITED
Chennai
END USER: ACC Cement Ltd Ametha MP DOC NO-215HL07220 SHEET 2 of 2
 Technical specification

1 MODEL NAME : I4
1.1 Power Rating in kVA 7.5KVA
1.2 Power Rating in kW 6KW

2 MAIN INPUT
2.1 Rated Voltage 415 VAC, 3 Phase, 3 Wires
2.2 Voltage Range +10%, -15%
2.3 Rated Frequency 50 Hz
2.4 Frequency Range ±6%

3 OUTPUT (INVERTER)
3.1 Rated AC voltage 110 VAC
3.2 Voltage Regulation ±1%
3.3 Power Factor 0.8
3.4 Inverter Efficiency 90.00%
3.5 Rated Frequency 50 Hz
3.6 Frequency Regulation - unsynchronized ±0.1%
3.7 Synchronized Range ±3 Hz
3.8 Max rate of Change of Frequency 1 Hz/ Sec
3.9 Transient Response @ rated Load change ±5%
3.10 Transient recovery to 98% 1 Cycle
Output Voltage Distortion
Non linear load <5%
3.11 Linear load <3%
3.12 Transfer time from Inverter to Bypass
3.13 Synchronized Mode < 4 Millisecond
3.14 Unsynchronized Mode < 20 Millisecond
3.15 Crest Factor 3:1
110% for 60 minutes
Overload capability 125% for 10 minutes
150% for 1 minutes
3.16

Branch fuse clearing ability 30% of UPS rated current (Fast acting semiconductor type fuse)
3.17

4 BATTERY / CHARGER
4.1 Charger Voltage Regulation ±1%
4.2 Maximum Boost Voltage 391.5 VDC
4.3 DC Under voltage 304.5 VDC
4.4 Nominal Nos of Battery 29 NOS, 26AH
4.5 Type of Battery 12V SMF,MAKE:EXIDE -1 SET
4.6 Ripple voltage <2 % rms

Title: "TECHNICAL SPECIFICATIONS" Doc. No.: 215DS07220 SHEET 2 OF 3

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY
0 30.07.21 FOR APPROVAL DHK KBP AJP

Hitachi Hi-Rel Power Electronics Private Limited

Gujarat, INDIA
 Technical specification

5 STATIC BYPASS INPUT

5.1 Rated Bypass Voltage 110 VAC
5.2 Rated Frequency 50 Hz
5.3 Synchronized Range +/-1% to 6% Field

6 SYSTEM
6.1 Ingress Protection Class IP-42
6.2 Operating Temperature 50°C
6.3 Relative Humidity 95% Non Condensing
6.4 Noise <65 dBA
6.5 Altitude 1000 Meters ASL
6.6 Color / Panel Finish (Power Coated) RAL 7035
6.7 Cable Entry Front - Bottom
6.8 Cooling Forced - Air Cooled
6.9 Applicable Standard IEC 62040-3 edition 2 (2011-03)

7 MANUAL BYPASS SWITCH

7.1 Make KAYCEE
7.2 Type Designation MAKE BEFORE BREAK

8 BYPASS TRANSFORMER / VOLTAGE STABILISER

8.1 Make HITACHI HI-REL
8.2 Type Designation SCVS (AUX)
8.3 Rating 7.5 KVA
8.4 Input voltage 415 VAC(+10%, -15%), 3PH,3W,50Hz
8.5 Output voltage 110 VAC, 1PH,2W, 50Hz
8.6 Accuracy of stabiliser ±2%

Title: "TECHNICAL SPECIFICATIONS" Doc. No.: 215DS07220 SHEET 3 OF 3

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY
0 30.07.21 FOR APPROVAL DHK KBP AJP

Hitachi Hi-Rel Power Electronics Private Limited

Gujarat, INDIA
 HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED
QUALITY ASSURANCE PLAN W.O. NO : A07210220(0)
W.O. O/P Voltage BATTERIES MODEL CONFIGURATION
PO/LOI CUSTOMER / CONSULTANT RATING
# TYPE AH QTY. I4 I4T I6S I6S SA DR PR
M/s DigiTech Controls & Automations (I) Pvt.Ltd
DCA/PO-279/ 110 VAC 26
0220 PROJECT : ACC- Ametha Project Materials Handling SMF 29 No.s - - - 7.5 KVA - -
JN181/2K21 1 PH AH
Package A/c Takraf India Pvt Ltd , Chennai

SCOPE OF UPS AUXILIARY ACDB DCDB BATTERIES BATTERY J.B. BATTERY RACK SPARES RS-485 No. of sets
SUPPLY - - - - - 1 Set

RESPONSIBILITY TABLE (while approving Customer can also put his choice in the blank box) ABBREVIATION
AREA RESPONSIBILITY REMARKS BY CUSTOMER P PERFORM
SUPPLIER HHPE CUSTOMER / TPIA R REVIEW/VERIFICATION OF TR/TC
Incoming Inspection P R&P NA W WITNESS
Process Inspection NA P NA NA NOT APPLICABLE
System Testing NA P R/W
Heat Run test requirement NA P R ** Scope of supply as per work order.
Batteries P R R **Only 1 system shall be witnessed out of batch which are having
Distribution panels NOT APPLICABLE same rating.
Site Acceptance Test NA P R
CLIENT’S REMARKS & APPROVAL >>>  MARK / W (Witness) / R (Review Of Records)
DOCUMENTS REQUIRED ANY OTHER COMMENTS BY CLIENT APPROVAL COMMENTS
Drawings for approval 
Bill of material for approval 
Inspection visit 

HHPE CUSTOMER’S APPROVAL & DATE

Engineering By Prepared By Approved By DATE

Devansh Pankit Dave Ashok Mangtani 30/07/2021

DOCUMENT NO: HHPE/QA/QAP/03/03/15/REV.02 Prepared by: Authorized by:

Bharat Bhut Ashok Mangtani

Page 1 of 5
 HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED
QUALITY ASSURANCE PLAN W.O. NO : A07210220(0)
Other 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. =
Abbreviations used Junction Box, HV = High Voltage, 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
in this QAP (of inspection), WS = Workmanship Standards, PH File = Product History File, SAT = Site Acceptance Test, FAT = Factory Acceptance Test
Incoming Goods
Sr Applicable Acceptance
Item / Component Characteristics Type of Check Quantum Responsibility Record Remarks
No. Documents Norms
Dimension, HV, NL Visual
Power & Control GRN, WI Drawings,
1 Voltages, Finishing, Physical 100% Inspection report
Transformers Mfr. TR
Marking / Labeling Electrical
Dimension, Coating Visual GRN, IS-5, WI, QA
2 Enclosures 01 / Batch Compliance Inspection report
Thickness Measurement Drawings
to
Dimension, Surface Visual
3 Heat-sink 100% GRN, WI, Drawings the Inspection report
Finishing, Mounting holes Measurement
Applicable
Dimension, Finish, Visual Documents
4 Bus-bars 100% GRN, WI, Drawings Inspection report
Threads Measurement
Visual 100%
5 Current Transformers Physical,Rating GRN, WI, Catalog, Inspection report
Measurement 01 / Batch
Switch gears Physical, NO/NC, Auxiliary Visual 100% GRN, IS-13947, WI,
6 Inspection report
Contacts Measurement Catalog

7 Fuses Physical, Continuity, Type Visual 100% GRN, WI, Catalog Inspection report

Physical, Capacitance, Visual 100%

8 Capacitors GRN, WI, Catalog Inspection report
Type Measurement 10%
9 Semiconductor Device Physical Visual 100% GRN, WI, Catalog Inspection report

10 Cables Physical, HV, Type Visual 100% GRN, WI, Catalog Inspection report
Measurement
GRN, WI, Catalog, Mfr.’s Inspection report/
11 Batteries Only Physical Visual 100%
Test Report MFG TC
12 Fans Smooth running, Physical Visual & smooth 100% GRN, WI, Catalog Inspection report
Running
13 Meters Physical, Accuracy Visual, Accuracy 100% GRN, WI, IS-1248 Inspection report

DOCUMENT NO: HHPE/QA/QAP/03/03/15/REV.02 Prepared by: Authorized by:

Bharat Bhut Ashok Mangtani

Page 2 of 5
 HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED
QUALITY ASSURANCE PLAN W.O. NO : A07210220(0)
PCB Manufacturing & Testing
Sr Type of Applicable Acceptance
Item / Component Characteristics Quantum Responsibility Record Remarks
No. Check Documents Norms
1 Stuffing Mounting Visual 100% BOM, Drawing, WI
Dry Solder
2 Soldering (Wave/Manual) Visual 100% WI & WS
Solder Joints
Cleaning, material as per Compliance
3 Inspection Visual 100% WI & WS Production Check-List
BOM, Short Links to all the
Supervisor / FRS
applicable
4 Testing Functional Electrical 100% WI, Specification
documents
5 Ana-bond Physical Visual 100% WI, WS
Conformal Coating
6 Physical Visual 100% WI
(CRC)

Process Inspection:
Sr Type of Applicable Acceptance
Item / Component Characteristics Quantum Responsibility Record Remarks
No. Check Documents Norms
1 Company’s Logo Position Visual 100% Drawing
2 Rating Plate System Details Visual 100% Drawing
BOM, Drawings: Matching, Availability,
3 Visual 100% Drawing & BOM
Product consistency Layout
4 Fitting Mounting, Tightening Visual 100% Drawing
Compliance Production
Appropriate size, firm to all the Supervisor Check-List
5 Lugging & Crimping Visual 100% WS
joint applicable / FRS
Routing, Tying, Finishing, Visual documents
6 Cabling & Wiring 100% WI, WS, Drawing
Color-Code, Ferruling Continuity
7 Painting & Finishing Uniform Coating, Color Visual 100% WS, IS-5
8 Doors, Locks & Smooth Working Visual 100% WI
Hinges(as applicable)
9 Clearance & Cree page Dimension Visual 100% Drawing

DOCUMENT NO: HHPE/QA/QAP/03/03/15/REV.02 Prepared by: Authorized by:

Bharat Bhut Ashok Mangtani

Page 3 of 5
 HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED
QUALITY ASSURANCE PLAN W.O. NO : A07210220(0)

Unit / System Test (FAT)

Sr Item / Type of Applicable Acceptance
Characteristics Quantum Responsibility Record Remarks
No. Component Check Documents Norms
(1)Dimensions & BOM,
(2)Setting of parameters,
(3)Load Test,
(4)Transfer-re transfer,
(5)Regulation,
(6)Efficiency, Compliance
(7)Noise Level, Electrical IEC-62040-3 to Applicable
Functional Testing
1 (8)Auxiliary device check, Visual 100% HHPE Specs Documents & Test Reports Shall be witnessed by client
Test Engineer
(9)Annunciation, Physical Test Report Approved
(10)Alarms, Data Sheet
(11)THD at linear load,
(12)Over load test at 125% for 10
minutes and 150% for 60 seconds.
(13)Parallel redundant UPS check(for
PR UPS system only)

Final Inspection (HHPE Internal)

Sr Item / Type of Applicable Acceptance
Characteristics Quantum Responsibility Record Remarks
No. Component Check Documents Norms
Compliance
Completion of -Scope of Supply, FRS, MOM, FRS
1 Inspection Visual 100% to Applicable QA
MOM & FRS Points PH File, WI /Check-List
Documents

DOCUMENT NO: HHPE/QA/QAP/03/03/15/REV.02 Prepared by: Authorized by:

Bharat Bhut Ashok Mangtani

Page 4 of 5
 HITACHI HIREL POWER ELECTRONICS PRIVATE LIMITED
QUALITY ASSURANCE PLAN W.O. NO : A07210220(0)

Site Acceptance Test

Sr Item / Applicable Acceptance
Characteristics Type of Check Quantum Responsibility Record Remarks
No. Component Documents Norms
Visual
Loose Connections, Physical
Physical
Damage, Input Voltage, Input Site /
Electrical
Stand Alone Current, Charger O/P, DC Current, Work- Compliance Commissioning
1 (at No-load, 100% SAT Format
System O/P Voltage, O/P Current, O/P Instruction to WI Engineer
Light-load &
Frequency, Transfer-Re transfer
actual-load
(auto & manual)
conditions)
Loose Connections, Physical Visual
Parallel Damage, Input Voltage, Input Physical
Site /
Redundant Current, Charger O/P, DC Current, Electrical
Work- Compliance Commissioning
2 System O/P Voltage, O/P Current, O/P (at No-load, 100% SAT Format 1. The Customer shall provide load. In
Instruction to WI Engineer
(As Frequency, Transfer-Re transfer Light-load & case Actual Load is not available, SAT will
applicable) (auto & manual), Load-Sharing, actual-load be carried out on NL & Partial Load (also
Master-Slave Change-Over conditions) to be provided by customer) conditions.
Visual
Transfer from Inverter to Bypass Physical 2. Customer Signature in SAT Format is
Auxiliary by Inverter Low & OT Simulation, Electrical Site / mandatory.
Work- Compliance SAT
3 (As Auto Transfer-Re transfer, Manual (at No-load, 100% Commissioning
Instruction to WI Format
applicable) Transfer-Re transfer, Bypass Light-load & Engineer 3. Test with Generator to be done only if
Voltage Bypass Current actual-load recommended and contractually agreed.
conditions)
Operation of all Fans, Operation
of Panel Meters, Normal
Functioning of LED, Normal
Final & Functioning of Indications, Visual Site /
Work- Compliance SAT
4 Complete Alarms, Panel Ground Check with Physical 100% Commissioning
Instruction to WI Format
Check System ON, Briefing to End-user Electrical Engineer
about System Operation, Spares,
AC-DC O/P adjustment (if
required), Mains Failure Test

DOCUMENT NO: HHPE/QA/QAP/03/03/15/REV.02 Prepared by: Authorized by:

Bharat Bhut Ashok Mangtani

Page 5 of 5