A TECHNICAL PUROPOSAL ON

THE ERECTION OF NEW EATON

93PM 80KVA UPS
INTRODUCTION

Requirements of quality and reliability of electric power supply systems concern the design,
manufacture, operation and decommissioning of equipment and electrical installations. Meeting the
requirements such as uninterruptible power of users or proper technical parameters of electricity
are particularly important in relation to systems and installations, where each case of power failure
means the loss of utility functions and the considerable material damage. The quality of the electrical
project or design of electrical devices installed in the electrical system as well as the quality of
assembly, testing and operation, remain the overriding categories compared to the group of mutual
conditions.

Every operational procedure are designed to prolong life of equipment, apparatus or other electrical
devices, prevent any accidents and malfunctions, and the detection of particularly vulnerable places to
certain abnormal conditions. Unfortunately, they also cause some inconveniences like possible to
temporarily disable equipment from the operation, damage or reduce the potential utility of efficient
devices. On the other hand, tests and examinations performed under load can detect any faults and
failures prior to the actual operation. Those tests have different purposes, (i.e. technical, economic and
social) l.

So this proposal has ensured major technical recommendations for future expandability and reliable
operation of the system.
CONTENTS

SECTION 1: OVERVIEW OF UPS INSTALLATION AND MAIN BLOCK

1.1 The main feeder cable and protective devices

1.2 The UPS room configuration

SECTION 2: EVALUATION OF ELECTRICAL WIRING AND DRAWINGS

2.1 External maintenance switch panel (EMBS) and power cables terminations
2.2 The DB (distribution board) panel and wiring installations
2.3 Earth Grounding regulations
2.4 The submitted technical documents
2.5 Battery connections

SECTION 3: TEST REPORT ON UPS PERFORMANCE AND BATTERY

3.1 Load sharing of the DB2 (distribution board) ON UPS performance

3.2 UPS power interruption and load changes performance
3.3 The UPS loading system and battery drainage with load

4 SECTION 4: TECHNICAL RECOMMENDATION

4.1 Important safety instructions
4.2 Preventive maintenance
4.2.1 Daily maintenance
4.2.2 Monthly maintenance
4.2.3 Periodic maintenance
4.2.4 Annual maintenance
4.3 Technical recommendation
4.4 Table summary of technical advice on the installation of EATON 93PM 80KW UPS
SECTION 1: OVERVIEW OF UPS INSTALLATION AND MAIN BLOCKS

1.1 The main feeder cable and protective devices

The main feeder cable (PVC insulated 4X70mm 2) is fed about 960 meters long from the transformer
house (main distribution board) to the UPS room. The EATON 93PM UPS can be installed where there is
TN or TT power distribution system. The MDB at the transformer room has TT power distribution
system, but here feeder cable and the breaker switchgear board at the transformer room are not
properly grounded. At least, ground cable of 1x35mm 2 must be used for proper grounding. The breaker
switch- gear board at transformer house is not protected for grounding failures.

On the Eaton UPS user installation guide, the minimum recommended multi-core cables and fuse size
rating are given. So the minimum cable size is 4x70mm 2 and the fuses rating is 3x160A. But at the
installation, no fuses are used for protection; at least fuses must be installed at the rectifier input.

1.2 The UPS room configuration

The Eaton UPS is not installed according proper installation procedures given in the installation guide.
The UPS cabinets use forced air cooling to regulate internal component temperature. By standard, air
inlets are in the front of the cabinet and outlets are in the back. You must allow clearance in front of and
behind each cabinet for proper air circulation.

The room provided for the UPS is small in area. The UPS minimum clearances are given in table

Eaton 80-100KW Recommended (Eaton ) Actual measure inside the room

From the top of cabinet 800mm (80cm) 801mm(80.6cm)
From the front of the cabinet 900mm (90cm) 740mm(74cm)
From the back of the cabinet 400mm (40cm)x 145mm(14.5cm)

So at the back of the cabinet the clearance between the UPS and the wall is not enough for air
circulation, cabling space, preventive maintenance and periodic checkups. And at the same time, the
front clearance is very small, not enough space for periodic checkups and not safe for the UPS as
electrical power cables, distribution boards are suited in front of the UPS. Any of electrical fires,
overheating of cables, electrical sparks would definitely damage the UPS as it is erected right front to
the DB. It would have been better to mount the external maintenance bypass switch (EMBS) panel and
the distribution board (DB) on the opposite side of the wall.

SECTION 2: EVALUATION OF ELECTRICAL WIRING AND DRAWINGS

2.1 External maintenance switch panel (EMBS) and power cables terminations

The Eaton 93PM provides internal maintenance bypass switch (MBS) that enables power to completely
bypass and isolate the UPS , so that the UPS can be safely serviced or replaced without interrupting
power to critical systems. Alternatively, MBS solutions are also available in external enclosure as
accessory items.

At the UPS room external three switch MBS panel is mounted on right side of the UPS. Here the cable
lags have no proper insulation terminations for the utility supply, input to UPS and output to UPS power
cables. (See figure below)

The panel also is not properly grounded; a ground cable of 1X35mm 2 should been connected at the
ground bus bar inside the panel. All power cables, the utility supply, input to UPS, Output from UPS and
output to the system are laid in the ground with open channel duct, are exposed to electrical hazard,
short circuits and electrical harmonic distortion. Even they are at risk of mouse (diminutive rats) cutting
the insulation of the power cables and shorting the lines.

They should have been well insulted inside galvanized metal or PVC pipes fitted to the wall. Thus,
protecting the systems from electrical fires and damages and putting more cabling space. This
installation does not obey IEE regulations.
2.2 The DB (distribution board) panel and wiring installations

The DB panel is mounted right in front of the UPS with all wiring connections and breaker modules for
all load appliances of the system. Here the wiring inside the panel is not properly installed. The wiring is
not clear enough, not installed safely inside PVC duct (channel) and without insulation.

The wiring installation has used neutral wire a blue color. But here on the top figure the installer has
also used a blue color for phase line, which is not recommended according to IEEE ( ) regulations. So it is
better to use phase line colors like black, brown or green.

Far more, the installation is more open and less insulation are used for electrical harmonic distortions,
cable overlapping and overheating, and phase inductive current failures.
2.3 Earth Grounding regulations

The installer puts a copper bus bar rod at the bottom of the wall as main ground rod within the UPS
room to the system. This is not recommended to the IEE standard regulations; rather it should have
been connected to main costumer’s installation panel where all exposed-conductive parts are suited.

The whole compound installation and the installer used a TT system (exposed-conductive-parts of the
installation connected via an independent installation earth electrode, by protective conductor with the
source earth) for grounding. So electrical safety must be obeyed, where the grounding conductor is
connected within the costumer’s installation containing exposed conductive parts.

2.4 The submitted technical documents

The technical documents are provided from the installer for all of the necessary electrical and site plan
documents. The installer have 7 technical electrical drawing; the lighting design (EL01/07), the power
socket design (EL02/07), Air conditioning (EL03/07), ceiling fan (EL04/07), MDB details (EL05/07), UPS
connection details (EL06/07), site plan (EL07/07).

All of the technical electrical drawings from EL01/07 up to EL04/07 are matched to the existing and new
added appliances. But if we see match more with MDB details and UPS connection details, we can
simply doubt that DB2 is not user friendly labeled , tagged and not same as it assembled at site. Because
if we take one example, the air-conditioning wiring installation within the DB2 is given with 10 breaker
modules; 7 erected with 3x6mm2 cables each and 3 reserves by the installer. However at the site the
actual order and the cable size of data center floor mounted AC are 6 and 7, cable size of 3x4mm 2 and
25A breaker each. But the submitted drawing on EL05/07 puts on order 2 and 3, cable size of 3x6mm 2
and 32A breaker each.

The UPS connection details also need more clarity for user. If we see the EMBS connection details, we
see that the isolators are labeled twice: Q1, Q2 and Q3 on breakers and other notes on the panel board.

2.5 Battery connections

At the UPS room batteries are mounted by the installer on painted open case metal frame. The batteries
are arranged in two battery string: one battery string contains 36 pieces of battery totaling 72 batteries.
Here rather than putting all batteries on open case, it should have been best to arranged them either in
separate closed metal frame case for each string or both strings on big metal compact frame.

Arranging them on such manner would definitely protect any personnel from direct contact to high DC
(direct current) battery voltage (i.e. about 484 DCV), any of battery explosive damage to the system and
any personnel. Far more, the Eaton user installation guide puts the minimum recommended cable and
fuse rating for battery connection is 2x150mm 2 and 400A respectively. Even though the UPS has an
internal battery breaker at the front right bottom of the UPS panel, it is recommended to mount either
fused disconnect breaker or rated external disconnect breaker. But the installer has neither put any of
the safety disconnects switch mounted to the wall.

Again, the battery feeder cables are laid simply alongside all exposed conductive parts, open for any
electrical short circuits and with no proper insulations.

SECTION 3: TEST REPORT ON UPS PERFORMANCE AND BATTERY

3.1 Load sharing of the DB2 (distribution board) ON UPS performance

It is obvious that at any of three phase electrical installation of a system, load sharing must be obeyed by
the installer according to the IEE load balancing regulations. The line-to-line unbalanced output
capability of the UPS is limited only by the full load per phase current values for AC output to critical
load. The recommended line-to-line load unbalance is 50% or less.

The installer has distributed load balancing of the system by dividing same load per 3 phase lines. So
accordingly the loads seem to be shared, but the diversity factor should come into account that to
effectively balance the three phase system. With all heavy duty appliances and all ac working the
measured current load values are
Three phase lines Full load Current (all AC Normal load current UPS output load (KVA)
high cool working) (normal working rate) respectively
Black (L1) 17.5A--22A 17.5A - 18.5A 5.2KVA /4.3KVA
Red (L2) 20A--24.5A 8.0A --8.4A 5.7KVA /1.9KVA
Yellow (L3) 40A--45.6A 18.5A --28.5A 10.7KVA/6.7KVA

If we see table above, load balancing during the normal working load of the ICT facilities phase line load
exceeded the other 2 times or 1.5 times. Even when working with full load where all appliances are
loaded the estimated load difference is significant. According to the EATON UPS user guide, the
recommended line-to-line load unbalance is 50% or less.

Thus it is recommended to secure load balancing phase lines of the critical load to ensure effective
performance of the UPS and expandability for future installation.

3.2 UPS power interruption and load changes performance

The UPS was tested for power interruption and voltage fluctuations at the transformer house. The
transformer no-load voltage or nominal voltage is 415V and voltage drops with load to 400V.

Input voltage at UPS Input load at the UPS Output load at the UPS Efficiency
rectifier room room
415 V 13.9KW /14.2KVA 13.3KW 96.1%
400V 13.89KW/ 14.2KVA 13.27KW 96.1%

So from the table above, the UPS can tolerate any load changes with great efficiency. We have used
almost all loads we have which is about 20% of rated capacity of the UPS.

So any load changes within the compound can be tolerated by the UPS. Again the UPS by design can
tolerate input current distortion of 30KW meaning it can withstand instant input load of 30KW with
great efficiency and without affecting the system.

3.3 The UPS loading system and battery drainage with load

The UPS was designed to effectively transfer power to critical load without interruption from two
sources. One and the most backup source is the battery. The batteries used in the design are one of the
most top brand batteries in the world. We have tested the UPS loading system for the batteries.

Load at (10 to 13KW) Battery % / battery voltage Battery estimated runtime

Starting 100%/469V 511.9 min (81/5 hr.)
After 1 hour battery mode 86%/442V 390.2min (61/5 hr.)
After 21/5 hour battery mode 70%/358V 300min (5 hr.)
After 4 hour battery mode 51%/269V 258min (430min hr.)
So from the above figure, we see that with range difference of 3KW approximately, the battery drainage
is steady and accurate. Here it is recommended to notice not any heavy duty appliances like AC
compressor or others loading and unloading several times on battery mode, because they use to drain
the battery current more at a time.

The end of discharge voltage given for the Eaton UPS is 1.67VPC to 1.75VPC (Voltage per cell). The
installer has used ENERROCKET batteries of end of discharge voltage 1.60VPC to 1.8VPC. So the battery
must not be discharged more than the capacity specified in the performance data tables in the user
guide. So the end discharge voltage of one string will be

36 batteries x 13V (full charged) = 468V 36 batteries X 1.8VPC= 64V

(64V/468V) X 100% = 15% (approximate), so the UPS is controlling drainage of batteries below this
level. But it is recommended to observe not the battery end voltage goes below 1.8VPC as it shortens
battery life.

Limitation of the charging current is not required under floating condition. During the initial or an
equalizing charge, the current should be limited to 30% of the Ah (ampere hour) rating of the battery.

Example: ESC 200-12 FR (EnerRocket) =200Ah, the maximum charging current is 0.3X200=60A

Float Charge

Batteries must be maintained on float charge and should be fully recharged within 24 hours of any
discharge. The recommended float charge voltage is 2.25VPC at 25˚C. Floating the batteries above
2.25VPC will lead to overcharging as well as a shorter service life. Floating the batteries under 2.25VPC
without a regular equalize charge will lead to reduced capacity, sulfating build-up and premature failure.
For these reasons, we recommend 2.25VPC at 25°C, whenever possible.

The system float voltage should equal to: (No of cells in system) x 2.25Vpc = System Float Voltage. Float
voltage should not vary by more than +/-1%. Should the float voltage of any cell vary by +/-0.05Vpc
apply an equalize charge and contact your sales office correct the problem.

The charging current and system float voltage was measured at the battery terminals.

Battery string System float voltage Float charge voltage/ cell

A (upper ) 81.01 VDC 2.2545 VDC
B (lower) 81.02VDC 2.2533 VDC

SECTION 4: TECHNICAL RECOMMENDATION

Now, to function and operate the UPS properly it is recommended to obey and follow all the safety
instructions and technical advice. This design allows authorized service personnel to perform routine
maintenance and servicing quickly. Schedule periodic performance checks of your UPS system to keep it
running properly. Regular routine checks of the operation and system parameters enable your system to
function efficiently for many trouble-free years.

4.1 Important safety instructions

1. All service and maintenance work must be performed only by service personnel qualified and
authorized by Eaton.
2. LETHAL VOLTAGE. Do not operate the UPS system without the cabinet doors or protective
panels secured. Do not make any assumptions about the electrical state of any cabinet in the
UPS system.
3. Do not attempt to access any internal area of the battery string your-self. Voltages are always
present in the battery strings. If you suspect that a battery string needs service, contact your
service representative.

4.2 Preventive maintenance

The UPS system requires very little preventive maintenance. However, inspect the system periodically to
verify that the units are operating normally and that the batteries are in good condition.

4.2.1 Daily maintenance

1. Check the area surrounding the UPS system. Make sure that the area is not cluttered,
allowing free access to the unit.
2. Check that the air intakes (vents on the front door of the UPS cabinet) and the exhaust
openings (at the rear of the UPS cabinet) are not blocked.
3. Make sure that the operating environment is within the UPS parameters. Like working
temperature must not exceed +40 oC.
4. Check that the UPS is in the normal mode (the normal mode status indicator is illuminated).
If an alarm lamp is illuminated or the normal mode status indicator is not illuminated,
contact an Eaton service representative.

4.2.2 Monthly maintenance

1. Check the system parameters on the control panel

2. If the optional air filters are installed, check them (located behind the front doors) and
wash or replace them, if needed. Contact your service representative for replacement
filters. To replace the filters:
a. Open the UPS front door.
b. Replace the filters.
c. Close the UPS front door.
3. Record the check results and any corrective actions in a service log

4.2.3 Periodic maintenance

Inspect the UPS periodically to determine if components, wiring, and connections exhibit evidence of
overheating. Pay particular attention to bolted connections. Bolted connections must be re-torqued
periodically.

4.2.4 Annual maintenance

Only authorized personnel that are familiar with the maintenance and servicing of the UPS system are
allowed to perform annual preventive maintenance.

4.3 Technical recommendation

1. Periodically, check the DB1 panel at the transformer house is closed and ensure the door of
distribution room at the transformer house is secured.
2. During the rainy season, check water leakage on manholes if any of the manholes are broken.
3. Check weekly if any of the rats have started cutting any wiring insulation on the ups room
4. Check weekly any of AC not working properly or cooling properly as they may load and unload
the ups multiple times and drain the battery during battery mode.
5. Annually Increase the earth ground rod conductivity, adding conductive metals, salts and
carbons.
6. During prolonged battery mode, observe and record battery drain according to the load.
7. Check the DB2 panel is always closed not any of electrical failure like electrical fires not damage
the UPS.

4.4 Table summary of technical advice on the installation of EATON 93PM 80KW UPS

At remark: compulsory – more series and must be done

Recommended – moderate series, technically advisable

Section Description Location Remark

1.1 Ground cable 1X35mm2 Transformer house for Compulsory
for the feeder cable and the feeder cable and
panel panel
1.1 Fuses 3X160A Either DB1 output or Recommended
UPS input
1.2 Small clearance back of UPS room Recommended
the UPS cabinet
1.2 Clearance front panel UPS room Recommended
and risk of damage
2.1 Cable lag insulation EMBS (UPS room) Recommended
2.1 Power cables insulation UPS room Compulsory
ducts (metals, PVC)
2.1 Grounding EMBS panel EMBS panel (UPS room) compulsory
board at ground
terminal
2.2 Install the DB2wiring DB2 (UPS room) compulsory
 inside a PVC channel
2.2 Change blue wire for DB2 (UPS room) Recommended
lines by brown or other
2.3 Enclose the ground bus UPS room Recommended
bar or inside EMBS
2.4 DB2 drawing tagging, DB2 (UPS room) compulsory
sequences, terminating
2.5 Enclosed Metal frame UPS room compulsory
case frame for battery
2.5 Battery isolator (fused UPS room compulsory
breaker) or external
breaker
2.5 Insulation for battery UPS room compulsory
feeder cables
3.1 Load balancing DB1 (UPS room) Recommended