Many industries need to be able to guarantee normal power supply under any circumstances, and the UPS power supply system is needed here. UPS power supply is an important equipment to ensure the stability and continuity of power supply. Because of its high degree of intelligence, the energy storage equipment uses maintenance-free batteries, which neglects the maintenance and overhaul of the system during operation. In fact, the quality of the maintenance has a great impact on the life and failure rate of the power supply. The following describes the precautions and daily maintenance requirements of the UPS power supply according to the specific conditions and maintenance experience in use.
Although the model and system capacity of the UPS power supply system configured by each enterprise are different, the principle and main functions are basically the same. In the UPS power type selection, each station has selected the online type. At this time, because the online UPS power system has zero time switching for various types of power supply, the length of its own power supply time can be selected, and it has voltage regulation, frequency stabilization, and purification. Features.
When the UPS power system itself fails, there is an automatic bypass function. When it is necessary to repair, manual bypass can be used, so that maintenance and power supply do not affect each other. In terms of power selection, Laiwu Steel's medium and small bar production line used a medium power system. 
1, ups uninterruptible power supply composition
The UPS power system consists of four parts: rectification, energy storage, conversion and switching control. The voltage regulation function of the system is usually completed by a rectifier. The rectifier device uses a thyristor or high-frequency switching rectifier, and has a function of controlling the output amplitude according to changes in external power, so that when the external power changes (the change should satisfy the system) Requirement), the rectified voltage whose output amplitude is basically constant. The purging function is performed by the energy storage battery. Since the rectifier can not eliminate the transient pulse interference, the rectified voltage still has interference pulses. In addition to the function of storing direct current energy, the energy storage battery is like a large container capacitor for the rectifier, and its equivalent capacitance is proportional to the capacity of the energy storage battery. Since the voltage across the capacitor cannot be abruptly changed, that is, the smoothing characteristic of the capacitor is used to eliminate the pulse interference, and the purification function is also used, which is also called the shielding of the interference. The stability of the frequency is done by the converter, and the frequency stability depends on the stability of the oscillation frequency of the converter. In order to facilitate the daily operation and maintenance of the UPS power system, the system work switch, the automatic bypass switch after the host self-test fault, and the bypass switch such as the bypass switch are designed.
When the grid voltage is working normally, the load is supplied as shown, and at the same time, the energy storage battery is charged; when the power failure occurs, the UPS power supply starts to work, and the energy storage battery supplier supplies the power required by the load to maintain normal production ( Such as thick black → shown); when the load is severely overloaded due to production needs, the grid voltage is directly rectified to supply power to the load (as indicated by the dotted line).
The UPS power system is mainly divided into two parts, the main unit and the energy storage battery. The rated output power depends on the host part and is related to the nature of the load. Because the UPS power supply has different load driving capabilities for different performances, the load power should normally meet 70% of the rated power of the UPS power supply. The selection of the energy storage battery capacity depends on the length of the backup time after the load power is determined. This time varies depending on the situation of each enterprise. It is mainly determined by the access time of the backup power supply, usually in a few minutes or several hours. . Laiwu Steel's small and medium-sized bar production line is not allowed to be powered off due to production needs. Therefore, after detecting the grid voltage interruption, the UPS power system can start the power supply by itself, and as the energy storage battery is slowly discharged, the capacity of the energy storage battery will follow. The time will gradually decrease. Considering that the energy storage battery capacity drops to 50% at the end of life and leaves a certain margin, the working time of our UPS power system is 2 hours when the energy storage battery is full, and the half capacity is 1 hour. .
2, ups uninterruptible power supply working principle
2.1.1 AC-DC conversion: The AC power from the power grid is stepped down by the autotransformer, full-wave rectified, and filtered into a DC voltage for supply to the inverter circuit. The AC-DC input has a soft-start circuit to avoid the impact on the grid when it is turned on.
2.2 .2 DC-AC inverter circuit: It adopts high-power IGBT module full-bridge inverter circuit, which has a large power margin. The output impedance is extremely small in the output dynamic range and has fast response characteristics. Due to the use of high-frequency modulation current limiting technology and fast short-circuit protection technology, the inverter can work safely and reliably whether it is a supply voltage transient or a load shock or short circuit.
2.3.3 Control drive: Control drive is the core of complete machine function control. In addition to providing detection, protection, synchronization and various switch and display drive signals, it also completes SPWM sinusoidal pulse width modulation control due to static and dynamic Dual voltage feedback. The dynamic characteristics and stability of the inverter are greatly improved. The block diagram of the uninterruptible power supply is shown in Figure 2.
3, ups uninterruptible power supply working process When the mains power is normal 380Vac, the DC main circuit has DC voltage, supply DC-AC AC inverter, output stable 220Vac AC voltage, and the mains charge current. When the mains is under voltage or suddenly loses power, the battery pack feeds the DC loop through the isolation diode switch. There is no switching time from grid power to battery power. When the battery energy is about to run out, the uninterruptible power supply emits an audible and visual alarm, and stops the inverter operation at the lower limit of the battery discharge, and the alarm sounds. The uninterruptible power supply also has an overload protection function. When an overload occurs (150% load), it jumps to the bypass state and automatically returns when the load is normal. When a serious overload occurs (more than 200% of rated load), the uninterruptible power supply immediately stops the inverter output and jumps to the bypass state, at which point the front air switch may also trip. After the fault is eliminated, just close the switch and restart the work after restarting. In order to make the uninterruptible power supply work properly and avoid running under overload or underload, the power supply is first calculated before the power is turned on. FR-UK type uninterruptible power supply (nominal rated power) 80% resistive load design load capacity, generally with a computer load can withstand the following type of estimation:
∑i=1 n Pi≤P
Where P is the uninterruptible power supply output capacity (VA), P is the i-th load volt-amperes per set PLC power: 220V*0.5=110VA
Power per station: 220V*2A=440VA
IBM PC client and server: 220V*1.5A=330VA
Then the total power: 10*110VA+4*440VA+11*330VA=6490VA
6490VA/0.8=8112VA
Therefore, in this bar production line, it is more suitable to use an uninterruptible power supply of 10KVA.
4, the use and maintenance of UPS power system
1, UPS power system is on, off
1.1 First boot
(1) Close the switch in the following order: energy storage battery switch → automatic bypass switch → output switch is set to “ONâ€.
(2) Press the “ON†button on the UPS start panel, the UPS power system will start slowly, and the “inverter†indicator will light. After 1 minute delay, the “bypass†light will go out and the UPS will turn to the inverter power supply to complete the boot.
After about 10 minutes of no-load operation, the load is started in a power-up sequence from small to large.
1.2 Daily Power On Simply press the “On†button on the UPS panel. After about 20 minutes, you can turn on the computer or other instruments. Usually, after the UPS starts to enter stable operation, the load device power switch can be turned on (Note: The manual maintenance switch is in the "OFF" state when the UPS is in normal operation).
1.3 Shutdown First turn off the computer or other instruments, let the UPS run for 10 minutes under no load. After the heat in the standby is discharged, press the “OFF†button on the panel.
2, UPS power system use precautions
Due to its high degree of intelligence, the UPS power system uses a maintenance-free battery, which brings a lot of convenience to the use. However, it should be paid attention to in many aspects during use to ensure safe use.
(1) UPS power supply host does not require high ambient temperature, +5 °C ~ 40 °C can work normally, but requires indoor cleaning, less dust, otherwise dust and moisture will cause the host to work disorderly. The energy storage battery has higher temperature requirements. The standard operating temperature is 25 °C, and it should not exceed +15 °C to +30 °C. If the temperature is too low, the capacity of the storage battery will drop. When the temperature drops by 1 °C, its capacity drops by 1%. Its discharge capacity increases with increasing temperature, but its life is reduced. If used at high temperatures for a long period of time, the battery life is reduced by about half for every 10 °C temperature increase.
(2) The parameters set in the host cannot be changed at will during use. In particular, the parameters of the battery pack will directly affect its service life, but as the ambient temperature changes, the float voltage should be adjusted accordingly. Generally, at 25 ° C, the float voltage should be increased by 18 mV (relative to the 12 V battery) for every 1 ° C increase or decrease in ambient temperature.
(3) When no external power is supplied by the UPS power supply system, the UPS power supply should be avoided with load. The load should be turned off first, and then the load should be turned on after the UPS power system is started. When the load is instantaneously powered, there will be a shock battery. The surge current of multiple loads and the required supply current will cause the UPS power supply to be instantaneously overloaded. In severe cases, the inverter will be damaged.
(4) The UPS power system requires a small amount of power according to the requirements of use. In use, it is necessary to avoid adding extra power to the extra equipment, and it is not allowed to run for a long time under full load. However, the nature of the work determines that the UPS power system is running almost in an uninterrupted state. Adding a high-power load, even if it is working under the basic full load condition, will cause the host to malfunction, and will seriously damage the converter.
(5) The output voltage of the self-supplied generator, the waveform, frequency and amplitude should be full of the input voltage requirements of the UPS power supply. The power of the generator should be much longer than the rated power of the UPS power supply. Otherwise, any condition will be dissatisfied. The UPS power supply is working abnormally or damaged.
(6) Due to the high voltage of the assembled battery pack, there is a danger of electric shock. Therefore, the safety protection should be applied when loading and unloading the conductive connecting strip and output line. The tool should adopt insulation measures, especially the output contact should have anti-touch measures.
(7) Whether it is in the floating charge working state or in the charging and discharging maintenance test state, it is necessary to ensure that the voltage and current meet the specified requirements. Excessive voltage or current may cause thermal runaway or water loss of the battery. If the voltage or current is too small, the battery will lose power. This will affect the service life of the battery. The former has a greater impact.
(8) In any case, short-circuit or deep discharge of the battery should be prevented because the cycle life of the battery is related to the depth of discharge. The deeper the depth of discharge, the shorter the cycle life. In the capacity test or during the discharge repair, it is usually sufficient to discharge 30% to 50% of the capacity.
(9) The battery should avoid large current charge and discharge. Although it can accept large current during charging, it should be avoided in the actual operation, otherwise it will cause the battery plate to expand and deform, causing the active material of the plate to fall off and the internal resistance of the battery to increase. Large, the higher the temperature rise, the more serious the capacity will be reduced, and the life expectancy will be terminated early.
3. Daily maintenance and overhaul
(1) Under normal use, the UPS power supply has little maintenance work, mainly dustproof and regular dust removal. Especially in areas with dry climate, there are more ash particles in the air. The fan inside the machine will bring dust into the machine. When the air is wet, it will cause the host to control the disorder, causing the host to work abnormally, and inaccurate alarms occur. Dust can also cause poor heat dissipation in the device. It should be thoroughly cleaned every quarter. The second is to check whether the connectors and connectors are loose or not in contact when dust is removed.
(2) Although the energy storage battery pack currently uses maintenance-free batteries, it only eliminates the previous measurement, ratio, and regular addition of distilled water. However, the influence of the external working state on the battery has not changed, and the impact of the abnormal working state on the battery has not changed. This part of the maintenance and repair work is still very important, and a large number of maintenance and repair work of the UPS power system is mainly in the battery part.
a. The operation of the energy storage battery is all in a floating state, in which case the discharge should be performed at least once a year. Before the discharge, the battery pack should be balanced and charged to achieve the balance of the whole battery. Be aware of the backward battery that already exists in the battery pack before discharge. If one of the discharges reaches the discharge termination voltage, the discharge should be stopped. Continue to discharge and then remove the backward battery before releasing.
b. Checking the discharge is not the first to pursue the release of the capacity, but to pay attention to the discovery and treatment of the backward battery, after the treatment of the backward battery and then the nuclear discharge test. This will prevent accidents, so as to prevent the battery from deteriorating into a reverse polarity battery during discharge.
c. At least 8 batteries should be used as the indicator battery for each group of batteries. As a reference for understanding the working condition of the whole battery pack, the marked battery should be regularly measured and recorded.
d. Items that need to be checked frequently in daily maintenance are: clean and test the voltage and temperature at both ends of the battery; whether there is looseness at the joint, corrosion phenomenon, and detection of the pressure drop of the connecting strip; whether the appearance of the battery is intact, whether there is shell deformation and leakage; Whether there is acid mist around the pole and safety valve; whether the host equipment is normal.
e. Maintenance-free battery maintenance, not a nonsense, should be based on a broad sense of maintenance, to ensure the operation, daily management of thoughtful, meticulous and normative, to ensure that equipment (including host equipment) to maintain good operating conditions, thereby extending The service life is guaranteed; the DC bus always maintains the qualified voltage and the discharge capacity of the battery; the battery operation and personnel are safe and reliable. This is the purpose of battery maintenance, as well as the content and rules of the battery operating procedures.
(3) When the UPS battery system fails, the cause should be first identified, whether it is the load or the UPS power system; whether it is the host or the battery pack. Although the UPS host has a fault self-test function, it is opposite to the point, and it is convenient to replace the parts. However, to repair the fault point, a lot of analysis and testing work still needs to be done. In addition, if the self-test part fails, the displayed fault content may be incorrect.
(4) If there is a breakdown of the host, break the fuse or burn the device, be sure to find out the cause and eliminate the fault before restarting, otherwise the same fault will occur in succession.
(5) When a battery with reverse voltage, large voltage drop, large pressure difference and acid mist leakage is found in the battery pack, it should be restored and repaired in time according to the corresponding method. If it cannot be recovered and repaired, it must be replaced, but it cannot be different. Capacity, different performance, and battery from different manufacturers are combined, otherwise it may adversely affect the entire battery. Replace the battery pack whose life has expired in time to avoid affecting the host.
5, ups uninterruptible power supply principle according to the working mode of UPS, can be divided into online (on-line) UPS and off-line (off-line) UPS. Off-line UPS, also known as post-UPS, can also be divided into sine wave output, square wave output, with or without voltage regulation.
(1) After all kinds of UPS, all kinds of UPS means that the inverter in the UPS only works in the state of commercial power interruption or undervoltage abnormality (undervoltage value is about 170V, that is, UPS investment voltage), and supplies power to the load. However, the inverter does not work normally and is in various states.
Figure 1 shows the power flow diagram of the various UPSs. When the mains supply is normal, the mains is directly passed through the AC bypass branch switch and output to the load via the filter; on the other hand, through the power transformer, after rectification, it becomes DC, and then the charging circuit is charged to the battery pack. When the mains supply is interrupted, the stored energy of the battery is converted into alternating current through the inverter, and the filter continues to supply power to the load. In the latter UPS, the actual circuit also contains various control loops such as protection and alarm, which is more complicated. 
(2) On-line UPS Figure 2 shows the online UPS energy flow chart. When the mains supply is normal, after the mains passes through the power transformer and the rectifier, the inverter is output to the load through the inverter and the filter; the other is charged to the battery pack via the charging circuit. When the mains supply is interrupted, the battery terminal voltage is lower than the set value or the inverter is faulty, the mains supply power to the load through the bypass switch via the changeover switch and filter. It can be seen that the inverter of the online UPS is always working regardless of whether the mains is normal or interrupted.
(3) The main components of UPS are mainly composed of inverter, battery, rectifier/charger and transfer switch. The inverter is mainly composed of a crystal triode, a transformer and a control circuit. Its function is to change the direct current to the AC output. It is the core part of the UPS. The technical performance and quality of the UPS mainly depend on it. The battery is a UPS energy storage device. The battery in the UPS should have good high-current discharge characteristics, can withstand repeated charge and discharge, and has a long service life. Currently, the UPS is commonly used as a maintenance-free sealed lead-acid battery. The rectifier/charger is a device that converts utility power into direct current to provide power to the inverter and battery. The function of the transfer switch (static switch) is to pass the instantaneous high-speed detection circuit. When there is interference or large surge in the mains, the UPS is quickly turned to the bypass output to protect the UPS; its second function is to provide Maintenance access. The switching switch requires fast switching time and large overload capability. 
(4) Characteristics of various types of UPS 1 Features of online UPS.
a. The online UPS is a sinusoidal output, the most notable feature of which is the true uninterrupted power supply to the load.
b. The online UPS provides anti-interference power to the load. Because the online UPS is powered by the mains or battery to the load, it must be carried out through the inverter, which may fundamentally eliminate all voltage fluctuations from the mains grid and the impact of electrical interference on the load, the UPS always to the load Provide a high-quality AC power supply with stable voltage regulation. Moreover, the online UPS has the smallest sinusoidal distortion factor.
c. Compared with the various UPSs, when the online UPS has excellent transient characteristics, its output voltage changes less than 4% and the time is about 10 to 40ms at 100% load loading or load shedding.
d. Online UPS has high operational reliability.
2 Backup sine wave output UPS features.
a. Generally, various sinusoidal output UPS circuits adopt anti-interference grading voltage regulation technology. When the commercial power is in the range of 180-250V, it can output a sinusoidal voltage with anti-interference regulation.
b. The switching time is short, about 4ms, and the shortest is 2ms.
c. The neutral and live wires at the output are fixed because the mains supply in the UPS or the inverter supplies the load to the load by the same power transformer. Therefore, users should comply with the manufacturer's regulations when connecting such UPS. After the sine wave output of the UPS has zero, fire line error circuit, once the input terminal zero, the fire line and the UPS requirements are inconsistent, the UPS will automatically protect, there is no output. It should also be pointed out that the zero line of the 220V input in the various UPSs is the ground line of the UPS control line.
After 3 kinds of square wave output UPS features.
a. Like the UPS of various sine wave outputs, the line adopts anti-interference grading voltage regulation technology. When the mains changes between 180 and 250V, its voltage regulation accuracy is 5% to 10%; When the power is interrupted, the inverter provides a square wave power supply with ±5% stability and no interference to the load.
b. The control circuit of the backup UPS outputted by the square wave does not adopt the technology of synchronizing with the commercial power, and the switching time is correspondingly longer than the UPS of the sine wave output, about 4 to 9 ms.
c. Like the UPS of the various sine wave outputs, its output is zero and the live line is fixed. When in use, the polarity of the AC input should be in accordance with the factory regulations.
d. Can not connect to the nature of the load like fluorescent lamps, otherwise it will not reach the factory specifications of the machine, or damage the UPS itself. Also, it cannot be frequently shut down and started. After the UPS is turned off, if it is restarted immediately, it will not work normally. At this time, there is no voltage output and the buzzer sounds long, which is called startup failure. Therefore, after shutting down, if you need to reboot, wait for more than 6s.
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