Pacific Power Source MS Operation Manual

Download

Page 1

PACIFIC

POWER SOURCE



MS SERIES

AC POWER SOURCE

OPERATIONS

MANUAL

Page 2

Limited Warranty:

Pacific Power Source (PPS) warrants each unit to be free from defects in material and workmanship. For the period of two (2) years from the date of shipment to the purchaser, PPS will either repair or replace, at its sole discretion, any unit returned to its factory in Irvine, California. Excepted from this warranty are fuses and batteries, which carry the warranty of their original manufacturer if applicable. It does not cover damage arising from misuse of the unit or attempted field modifications or repairs. This warranty specifically excludes damage to other equipment connected to this unit.

Upon notice from the purchaser within thirty (30) days of shipment of units found to be defective in material or workmanship, PPS will pay all shipping charges for the repair or replacement. If notice is received more than thirty (30) days from shipment, all shipping charges shall be paid by the purchaser. Units returned on debit memo will not be accepted and will be returned without repair.

This warranty is exclusive of all other warranties, expressed or implied.

Service & Spare Parts Limited Warranty:

Pacific Power Source (PPS) warrants repair work to be free from defects in material and workmanship for the period of ninety (90) days from the invoice date. This warranty applies to replaced parts or subassemblies only. This warranty does not include batteries. All shipping and packaging charges are the sole responsibility of the buyer. Pacific Power Source will not accept debit memos for returned power sources or subassemblies. Debit memos will cause return of power sources or assemblies without repair.

This warranty is exclusive of all other warranties, expressed or implied.

Page 3

3060-MS

SOLID-STATE

AC POWER SOURCE/FREQUENCY CONVERTER

INSTALLATION AND OPERATION MANUAL

THE INFORMATION CONTAINED IN THIS MANUAL

IS PROPRIETARY TO PACIFIC POWER SOURCE, INC.

THIS MANUAL MAY NOT BE COPIED OR REPRINTED

WITHOUT THE EXPRESSED WRITTEN CONSENT

OF PACIFIC POWER SOURCE, INC..

PACIFIC POWER SOURCE, INC.

17692 FITCH

IRVINE, CA., U.S.A. 92614

PHONE: (949) 251-1800

FAX: (949) 756-0756

February 2013

MANUAL PART NO. 126050

Revision E

DWG NO. 126050-10e

Page 4

THIS PAGE INTENTIONALLY BLANK

Page 5

TABLE OF CONTENTS

Section Description Page

1.0 GENERAL DESCRIPTION................................................................................ 1-1

1.1 MANUAL DESCRIPTION ....................................................................................................... 1-1

1.2 USING THIS MANUAL ........................................................................................................... 1-1

1.3 SAFETY NOTICES ................................................................................................................. 1-1

1.4 GENERAL PRODUCT DESCRIPTION .................................................................................. 1-3

1.5 DEFINITIONS ......................................................................................................................... 1-4

1.6 DETAILED DESCRIPTION .................................................................................................... 1-5

1.6.1 3060-MS CABINET .......................................................................................................... 1-5

1.6.2 RECTIFIER CIRCUIT....................................................................................................... 1-5

1.6.3 INVERTER MODULE....................................................................................................... 1-6

1.6.4 MULTI-CABINET PARALLELED SYSTEM ..................................................................... 1-6

2.0 SPECIFICATIONS ............................................................................................ 2-1

2.1 ELECTRICAL SPECIFICATIONS .......................................................................................... 2-1

2.1.1 INPUT POWER ................................................................................................................ 2-1

2.1.2 OUTPUT POWER ............................................................................................................ 2-2

2.2 MECHANICAL SPECIFICATIONS ......................................................................................... 2-3

2.3 ENVIRONMENTAL SPECIFICATIONS ................................................................................. 2-3

3.0 INSTALLATION ................................................................................................ 3-1

3.1 PLANNING THE JOB ............................................................................................................. 3-1

3.2 MOVING, UNCRATING, AND INSPECTION ......................................................................... 3-4

3.3 CHANGING INPUT VOLTAGE .............................................................................................. 3-6

3.4 SETTING THE CABINET INTO PLACE ............................................................................... 3-12

3.5 SAFETY GROUNDING / EARTHING .................................................................................. 3-12

3.6 CONNECTING THE INPUT SERVICE ................................................................................ 3-12

3.7 CONNECTING THE OUTPUT SERVICE ............................................................................ 3-15

3.8 MULTIPLE CABINET SYSTEM............................................................................................ 3-18

3.9 ELECTRICAL SURVEY CHECKLIST .................................................................................. 3-21

Page 6

TABLE OF CONTENTS

Section Description Page

4.0 OPERATION ..................................................................................................... 4-1

4.1 INSPECTION OF INSTALLATION ......................................................................................... 4-1

4.2 INSTALLATION RECORD ..................................................................................................... 4-1

4.3 DESCRIPTION OF CONTROLS AND INDICATORS ............................................................ 4-4

4.3.1 LCD AND INTERROGATION SWITCHES ...................................................................... 4-5

4.3.1.1 INPUT KEY ................................................................................................................. 4-6

4.3.1.2 OUTPUT KEY ............................................................................................................. 4-6

4.3.1.3 STATUS KEY ............................................................................................................. 4-8

4.3.1.4 DIAGNOSTIC KEY ................................................................................................... 4-10

4.3.1.5 HELP KEY ................................................................................................................ 4-11

4.3.1.6 ALARM KEY ............................................................................................................. 4-13

4.3.1.7 SPECIAL KEY COMBINATIONS ............................................................................. 4-14

4.3.2 MODE SELECT, EMERGENCY OFF, AND ON-RESET SWITCHES .......................... 4-14

4.3.2.1 MODE SELECT SWITCH......................................................................................... 4-14

4.3.2.2 EMERGENCY OFF AND START/RESET SWITCHES ........................................... 4-15

4.3.3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST .............................................. 4-16

4.3.3.1 FREQUENCY SELECT SWITCH ............................................................................. 4-16

4.3.3.2 VOLTAGE ADJUST CONTROLS ............................................................................ 4-16

4.4 OPERATING PROCEDURES .............................................................................................. 4-17

4.4.1 MODES OF OPERATION .............................................................................................. 4-18

4.4.2 FIRST TIME OPERATION ............................................................................................. 4-21

4.4.3 PARALLEL CABINET OPERATION .............................................................................. 4-22

4.4.4 NORMAL SHUTDOWN PROCEDURE ......................................................................... 4-23

4.4.5 EMERGENCY SHUTDOWN PROCEDURE ................................................................. 4-23

4.5 SETUP SWITCHES .............................................................................................................. 4-24

4.5.1 DISPLAY PCB (126072 or 126172) ............................................................................... 4-26

4.5.2 CONTROL PCB (126070 or 126079) ............................................................................ 4-28

4.6 FEATURE CONNECTORS .................................................................................................. 4-30

4.6.1 P1, P2 PARALLELING ................................................................................................... 4-30

4.6.2 J3 AND J4 SERIAL I/O .................................................................................................. 4-32

4.6.3 J6 EXTERNAL OSCILLATOR ....................................................................................... 4-35

4.6.4 J5 AND J7 SYSTEM METERING OUTPUTS ................................................................ 4-35

4.6.5 J8 REMOTE METERING INPUTS ................................................................................. 4-36

4.6.6 J9 AUXILIARY ALARM OUTPUTS ................................................................................ 4-36

5.0 MAINTENANCE ................................................................................................ 5-1

5.1 MAINTENANCE SCHEDULE ................................................................................................. 5-1

Page 7

TABLE OF CONTENTS

Section Description Page

6.0 SERVICE ........................................................................................................... 6-1

6.1 DESCRIPTION ....................................................................................................................... 6-1

6.1.1 MAINFRAME DESCRIPTION .......................................................................................... 6-1

6.1.2 CONTROL MODULE DESCRIPTION ............................................................................. 6-4

6.1.3 INVERTER DESCRIPTION ............................................................................................. 6-6

6.2 THEORY OF OPERATION .................................................................................................... 6-8

6.2.1 THEORY OF OPERATION - POWER CONVERSION CIRCUITS ............................... 6-11

6.2.2 THEORY OF OPERATION - CONTROL CIRCUITS ..................................................... 6-13

6.2.3 THEORY OF OPERATION - DC POWER SUPPLY ..................................................... 6-15

6.2.4 THEORY OF OPERATION - DISPLAY CIRCUITS ....................................................... 6-17

6.2.5 THEORY OF OPERATION - PARALLELING CIRCUITS .............................................. 6-18

6.3 TROUBLESHOOTING PROCEDURE ................................................................................. 6-20

6.3.1 PERFORMANCE CHECK ............................................................................................. 6-21

6.3.2 LVPS SERVICE PROCEDURE ..................................................................................... 6-23

6.3.3 DISPLAY SERVICE PROCEDURE ............................................................................... 6-24

6.3.4 EMER OFF SERVICE PROCEDURE ............................................................................ 6-26

6.3.5 NO-INVERTER-VOLTS SERVICE PROCEDURE ........................................................ 6-28

6.3.6 ABNORMAL VOLTAGE SERVICE PROCEDURE ........................................................ 6-30

6.4 SCHEMATIC DIAGRAMS .................................................................................................... 6-32

6.5 ASSEMBLY REPLACEMENT PROCEDURES .................................................................... 6-35

6.5.1 INVERTER ASSEMBLY REPLACEMENT .................................................................... 6-36

6.5.2 CONTROL PCB ASSEMBLY REPLACEMENT ............................................................ 6-37

6.5.3 MODULATOR PCB ASSEMBLY REPLACEMENT ....................................................... 6-38

6.5.4 DISPLAY PCB ASSEMBLY REPLACEMENT ............................................................... 6-38

6.5.5 LVPS PCB ASSEMBLY REPLACEMENT ..................................................................... 6-39

6.5.6 DISCHARGE PCB ASSEMBLY REPLACEMENT ......................................................... 6-40

6.5.7 DRIVER PCB ASSEMBLY REPLACEMENT ................................................................ 6-41

6.5.8 SNUBBER PCB ASSEMBLY REPLACEMENT ............................................................. 6-42

6.6 COMPONENT REPLACEMENT PROCEDURES ................................................................ 6-42

6.6.1 INPUT POWER PANEL COMPONENT REPLACEMENT ............................................ 6-43

6.6.2 DC POWER SUPPLY COMPONENT REPLACEMENT ............................................... 6-44

6.6.3 INVERTER COMPONENT REPLACEMENT ................................................................ 6-45

6.7 RETURNING ASSEMBLIES FOR REPAIR ......................................................................... 6-46

Page 8

TABLE OF CONTENTS

Figure Description Page

List of ILLUSTRATIONS and TABLES

FIGURE 2.1.1 INPUT RATINGS ................................................................................ 2-1

FIGURE 2.1.3 OUTPUT RATINGS ............................................................................ 2-2

FIGURE 2.2 OUTLINE DRAWING ........................................................................... 2-4

FIGURE 3.1 INSTALLATION DETAIL – (MECHANICAL CLEARANCES) ............... 3-2

TABLE 3.1 ENVIRONMENTAL SURVEY CHECKLIST ............................................. 3-3

FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING .................................. 3-5

FIGURE 3.3.1 480 V INPUT CONFIGURATION ........................................................ 3-8

FIGURE 3.3.2 380 V INPUT CONFIGURATION ........................................................ 3-9

FIGURE 3.3.3 240 V INPUT CONFIGURATION ...................................................... 3-10

FIGURE 3.3.4 208 V INPUT CONFIGURATION ...................................................... 3-11

TABLE 3.6.1 INSTALLATION WIRING ................................................................... 3-13

FIGURE 3.6 INPUT TERMINAL DETAIL ............................................................... 3-13

FIGURE 3.6.1 CUSTOMER INPUT WIRING DETAIL .............................................. 3-14

FIGURE 3.7 OUTPUT TERMINAL DETAIL ........................................................... 3-16

FIGURE 3.7.1 OUTPUT CONTACTOR.................................................................... 3-17

(CUSTOMER LOAD WIRING DETAIL) ...................................................................... 3-17

FIGURE 3.7.2 OPTIONAL OUTPUT CIRCUIT BREAKER ....................................... 3-17

(CUSTOMER LOAD WIRING DETAIL) ...................................................................... 3-17

FIGURE 3.8.1 MULTIPLE CABINET SYSTEM OUTLINE ........................................ 3-19

FIGURE 3.8.2 MULTIPLE CABINET SYSTEM WIRING .......................................... 3-20

FIGURE 3.9 ELECTRICAL SURVEY CHECKLIST ..................................................... 3-21

TABLE 4.2 INSTALLATION RECORD .......................................................................... 4-2

FIGURE 4.3.1 LCD AND INTERROGATION SWITCHES .......................................... 4-5

FIGURE 4.3.2 MODE SELECT, EMER OFF, AND START/RESET ......................... 4-15

FIGURE 4.3.3 FREQUENCY SELECT AND VOLTS ADJUST ................................. 4-16

FIGURE 4.4.1 SLAVE CONTROL MODE ................................................................ 4-20

FIGURE 4.5 CABINET ASSEMBLY ....................................................................... 4-25

FIGURE 4.5.1A DISPLAY PCB ASSY., 126072 ....................................................... 4-27

FIGURE 4.5.1B DISPLAY PCB ASSY., 126172 ....................................................... 4-27

FIGURE 4.5.2 CONTROL PCB ASSY., 126070 AND 126079 .................................... 4-29

FIGURE 4.6 CABINET TOP VIEW - FEATURE CONNECTOR DETAIL ................ 4-31

TABLE 5.1.1 6 MONTH MAINTENANCE CYCLE ..................................................... 5-1

FIGURE 5.1.1 REAR OF MS-SERIES CABINET – BACK PANEL REMOVED ............. 5-2

FIGURE 5.1.2 UNDERSIDE OF MS-SERIES INVERTERS .......................................... 5-2

TABLE 5.1.2 4-6 WEEK MAINTENANCE CYCLE .................................................... 5-3

FIGURE 5.1.3 FIRESCREEN LOCATION FOR CLEANING ......................................... 5-3

FIGURE 5.1.4 MS-SERIES MAINTENANCE LOG ..................................................... 5-4

FIGURE 6.1.1 MAINFRAME ...................................................................................... 6-3

FIGURE 6.1.2 CONTROL MODULE .......................................................................... 6-5

FIGURE 6.1.3 INVERTER.......................................................................................... 6-7

FIGURE 6.2.1 BLOCK DIAGRAM POWER CONVERSION CIRCUITS ................... 6-12

Page 9

TABLE OF CONTENTS

Figure Description Page

List of ILLUSTRATIONS and TABLES (continued)

FIGURE 6.2.2 BLOCK DIAGRAM SYSTEM CONTROL CIRCUITS ......................... 6-14

FIGURE 6.2.3 BLOCK DIAGRAM DC POWER SUPPLY ......................................... 6-16

FIGURE 6.2.4 BLOCK DIAGRAM DISPLAY CIRCUITS........................................... 6-17

FIGURE 6.2.5 BLOCK DIAGRAM PARALLELING CIRCUITS ................................. 6-19

FIGURE 6.3.1 PERFORMANCE CHECK FLOW CHART ........................................ 6-22

FIGURE 6.3.2 LVPS FLOW CHART ................................................................ ........ 6-23

FIGURE 6.3.3 DISPLAY FLOW CHART .................................................................. 6-25

FIGURE 6.3.4 EMER OFF FLOW CHART ............................................................... 6-27

FIGURE 6.3.5 NO-INVERTER-VOLTAGE FLOW CHART ....................................... 6-29

FIGURE 6.3.6 ABNORMAL VOLTS FLOW CHART ................................................. 6-31

FIGURE 6.4.1 LVPS SCHEMATIC ........................................................................... 6-32

FIGURE 6.4.2 INPUT POWER SCHEMATIC ........................................................... 6-33

FIGURE 6.4.3 DC POWER SUPPLY SCHEMATIC ................................................. 6-34

FIGURE A.1 3060-MS MAINFRAME MAINTENANCE/SERVICEABLE PARTS A-1 FIGURE A.2 3060-MS INVERTER ASSEMBLY MAINTENANCE/SERVICEABLE

PARTS A-2 FIGURE B.1 MS3060 SYSTEM SCHEMATIC B-1

Page 10

SECTION 1 GENERAL

1.0 GENERAL DESCRIPTION

1.1 MANUAL DESCRIPTION This manual is written to provide the information required to use the MS-Series

AC Power Source effectively. This Operations Manual describes proper installation, operation and maintenance of the MS series power source units.

1.2 USING THIS MANUAL This manual primarily covers installation and operation. It is very important that

the user reads Section 3, INSTALLATION and Section 4, OPERATION, prior to installing this equipment. A thorough understanding of these two sections is required to operate this equipment properly.

If questions arise while reading this manual, the user is encouraged to call Pacific Power Source Inc. Pacific maintains a toll-free number which is 1-800-854-2433 (949-251-1800 Outside the USA), Fax 949-756-0756 or contact us through our website: www.pacificpopwer.com

Section 5 discusses maintenance, Section 6 is for service. These sections need to be read only when such activities are required to be performed.

1.3 SAFETY NOTICES MS-Series equipment is capable of transferring very large amounts of electrical

energy very quickly. This basic quality is fundamental to any high-performance power source. The warnings and cautions listed below should be observed at all times.

Warnings indicate potentially hazardous situations which, if not avoided, could result in death or serious injury. All warnings throughout this manual will appear as shown below.

Page 11

SECTION 1 GENERAL

WARNING

THIS EQUIPMENT CONTAINS HIGH ENERGY, LOW IMPEDANCE CIRCUITS!! LETHAL POTENTIALS ARE CONTAINED WITHIN THE CABINET.

CARE MUST BE EXERCISED WHEN SERVICING THIS EQUIPMENT IN ORDER TO PREVENT SERIOUS OPERATOR INJURY OR EQUIPMENT DAMAGE.

OBSERVE THE FOLLOWING WHEN SERVICE AND MAINTENANCE ARE REQUIRED:

1) REMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS EQUIPMENT. THIS PREVENTS THE POSSIBILITY OF SHORTING THROUGH THE JEWELRY AND CAUSING BURNS TO THE OPERATOR.

2) WEAR SAFETY GLASSES WHEN SERVICING THIS EQUIPMENT TO PREVENT EYE INJURY DUE TO FLYING PARTICLES CAUSED BY ACCIDENTAL SHORT CIRCUIT CONDITIONS.

3) DO NOT REMOVE ANY PANEL OR COVER WITHOUT FIRST REMOVING THE INPUT SERVICE BY OPENING ALL CIRCUIT BREAKERS.

4) SERVICE OTHER THAN EXTERNAL CLEANING SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE FACTORY TO SERVICE THIS EQUIPMENT.

CAUTION -

Read Section 3, INSTALLATION, and Section 4, OPERATION,

of this manual before installing or operating this equipment.

CAUTION

USING IMPROPER GAUGE OF INPUT CABLE MAY OVERHEAT AND DAMAGE THE

EQUIPMENT. SEE SECTION 2.0 SPECIFICATIONS FOR THE PROPER SIZING OF

INPUT CABLE.



Cautions indicate a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. A caution also may be used to alert against unsafe practices. Cautions will appear as shown below. All cautions should be rigorously observed.

To protect equipment from damage a caution will be used as follows:

Page 12

SECTION 1 GENERAL

WARNING

IF THIS EQUIPMENT IS NOT USED IN A MANNER SPECIFIED BY THE

MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE

IMPAIRED



1.4 GENERAL PRODUCT DESCRIPTION The intended use of the Pacific Power Source MS-Series equipment is basic

frequency or voltage conversion with manually adjustable settings. With the optional external programmable controller (UPC) it is suitable for testing applications such as sag, surge, etc. The MS-Series power sources are a family of Line-Conditioners/Frequency-Changers covering the power range from 62.5 to 750 kVA (50 - 600 kW), at output frequencies of 50 - 400 Hz. The basic 62.5 kVA / 50 kW unit is designated as the model 3060-MS. Up to 12 units can be paralleled to provide 750 kVA / 600 kW.

The 3060-MS functions as a double conversion power source. Input AC power is rectified to DC by a special power supply that provides both isolation and low input current distortion. The DC power is then converted back to AC by a high frequency pulse-width modulated inverter stage, under the control of a highly stable digital oscillator.

The 3060-MS unit is designed to provide high quality output power. Output regulation and total harmonic distortion are of the order of 1% at 50 or 60Hz and 2% at 400Hz. Response time to a 100% step load change is 300 microseconds. The machine is therefore capable of delivering very high pulse current loads. The fast response time and excellent regulation of the MS-Series are extremely important in applications where mixed or switched loads may cause power interference and load "Cross-talk".

MS Series equipment is designed for long term, continuous operation in a sheltered (no rain) environment. Because there are no batteries, it will accept a wide ambient temperature range. The equipment is efficient (about 90%), circulates little cooling air and is relatively tolerant of dusty environments. The MTBF of a single cabinet 3060-MS is high (approx. 5 years).

System operation is controlled by simple, high reliability digital logic. A microprocessor provides internal diagnostics and communicates with the operator via a 160 character digital display.

Page 13

SECTION 1 GENERAL

Power Source

All components functioning together which convert input AC power to isolated, conditioned, variable frequency and variable voltage output AC power to the load.

Cabinet

One enclosure that contains a Power Source.

System

One or more enclosures which make up a paralleled cabinet power source.

Rectifier

The circuit component that contains the equipment and controls necessary to convert the input AC power to DC power.

Inverter

The circuit component that contains the equipment and controls necessary to convert DC power from the rectifier to AC power required by the load. A high frequency pulse-width modulated switcher.

Internal Control System

The signal processing circuits that regulate the power conversion processes, detect fault conditions, and control the sequence of operation of the Power Source. This term may be shortened to "Control System."

Operator Controls

The controls which are used by the operator to monitor and operate the Power Source. They are located on the front of the cabinet exterior.

Input Power

Power provided by the electrical utility company, or auxiliary generator, connected to the input of the Power Source.

Output Power

Power provided by the Power Source to the load, connected to the output of the Power Source.

1.5 DEFINITIONS Common terms and component names, as used throughout this MS-Series

manual are defined below:

Page 14

SECTION 1 GENERAL

1.6 DETAILED DESCRIPTION This paragraph provides a detailed description of each major sub-assembly, its

purpose, and its general operation.

1.6.1 3060-MS CABINET The cabinet consists of a rectifier, three-phase inverter, protective devices, and

accessories as required for proper operation.

1.6.2 RECTIFIER CIRCUIT The rectifier circuit is a solid-state assembly designed to provide direct current to

the inverter unit. A 12 pulse input rectifier is used, reducing current harmonic feedback into the

input AC line to a nominal 12%rms. The rectifier also controls the input power factor so that it remains above 0.85 lagging at full load.

For input isolation and adapting to a variety of available input voltages, a dry type power transformer is used before the rectifier unit. The transformer's winding temperature is monitored by Internal Control System diagnostics to ensure that the transformer temperature does not exceed design limits.

The rectifier circuit provides a soft start-up feature whereby when the AC power is first applied, the total initial power drawn at the input terminals will not exceed 100% of rated input power.

DC overvoltage protection is provided so that if the DC Bus voltage rises above the pre-set limit, the Power Source will shut down automatically.

DC undervoltage protection is provided so that if the DC Bus voltage drops below the pre-set limit, the Power Source will shut down automatically.

AC overvoltage protection on the AC input circuit shuts down the power source when the input voltage rises above a preset percent of input voltage.

The Low Voltage Power Supply has its own undervoltage protection to shut down the power source should the power supply voltage to the control circuits fall below an acceptable level.

Page 15

SECTION 1 GENERAL

1.6.3 INVERTER MODULE The inverter module is a solid-state device that converts power from the rectifier

circuit to provide the rated AC system output within specified limits. The output frequency of the inverter is controlled by a digital oscillator.

The oscillator is adjustable over the range of 47 to 500Hz in the variable position. In the fixed frequency positions, the oscillator is designed to control the inverter

output frequency within ±0.01%. Drift will not exceed ±0.01% during a 24-hour period. Total frequency deviation, including short time fluctuations and drift, is typically within ±0.01% from the specified frequency.

The inverter is capable of supporting transient overloads up to 150%, or any continuous load within its rating, without reducing the output voltage. Loads greater than 150% may cause a reduction of the output voltage.

The inverter will current limit at 150% of rated current. The inverter is capable of supplying at least 200% of rated RMS current for short circuit conditions. If the short circuit is sustained, the inverter will shut down and disconnect automatically from the output.

Each inverter output phase voltage is independently regulated to ±0.5%, with AGC enabled, such that unbalanced loading will not cause the output voltage to exceed the specified voltage unbalance.

An output power filter is incorporated in the inverter unit. The filter reduces the inverter output sine wave voltage harmonics to 1% RMS total and single harmonics to 0.5% RMS maximum for linear loads at 50-60Hz.

Power semiconductors in the inverter unit are fused with fast acting fuses, so that loss of any one power semiconductor will not cause cascading failures.

1.6.4 MULTI-CABINET PARALLELED SYSTEM Up to twelve cabinets may be paralleled together for higher power systems.

Each 3060-MS is capable of operating as either a SLAVE or MASTER in multicabinet parallel operation but only one Master may be active at a time.

Parallel system architecture is such that any failed slave unit automatically drops off-line.

A failed MASTER turns the entire system off. In this event an operator can select any other paralleled unit as the MASTER from a front panel control and restore system operation.

Page 16

SECTION 2 SPECIFICATIONS

Voltage:

480, 416, 400, 380, 240 or 208 VAC

L-L

±15%.

Frequency:

47-63 Hz (other frequencies optional)

Magnetizing Sub Cycle:

100% of normal full load input, inrush current, maximum.

Power Factor:

Not less than 0.85 lagging at full load.

Current Distortion:

12% THD nominal

MODEL

NUMBER

INPUT

(KVA)

INPUT

(KW)

3060-MS

Input Volts

Input Amps

Recommended

Input Service

Taps Available

480

80 A

Nom, -7%, -10%

416

100 A

Nom, -9%, -4%, +3%, +8%

400

100 A

Nom, -9%, -5%, +4%, +8%

380

100 A

Nom, +5%, +10%, -4%, -8%,

-17%

240

150

175 A

Nom, -13%

208

170

175 A

Nom, +15%, -9%

2.0 SPECIFICATIONS

Electrical and mechanical specifications of the MS Series AC Power Source are listed in the following tables.

2.1 ELECTRICAL SPECIFICATIONS

2.1.1 INPUT POWER MS-Series equipment is intended for use on a Category II supply.

FIGURE 2.1.1 INPUT RATINGS

Input Controls: Contactors provide input ON-OFF control. An input circuit

breaker disconnects all input power from the cabinet.

Protection: Meets National Electrical Code Protection requirements for

single phase, and reversed-phase rotation protection.

Voltage Transients: Meets the Institute of Electrical and Electronics Engineers

587 requirements at 4000 V peak. Up to 150% line voltage for ½-cycle.

Phase Rotation: Unit will operate properly with any input phase rotation.

There are no input phase rotation sensitive devices.

Isolation: An input transformer with an electrostatic shield provides

isolation between the input and output of the system.

Balance: All three input phases are equally loaded regardless of

output phase load unbalance.

Page 17

SECTION 2 SPECIFICATIONS

MODEL

NUMBER

Output

(KVA)

Output RMS

(KW)

Output

(CURRENT/Ø)

Output Short

Circuit

(CURRENT/Ø)

3060-MS

62.5

175A

>350A peak

2.1.2 OUTPUT POWER

Power: 50 kW Volt-Amps: 62.5 kVA

Voltage: 120/208 3Φ WYE. May be loaded WYE or DELTA.

0-132 VAC

Adjustment Range, with nominal input,

L-N

adjustable by front panel controls Other voltages available as options..

Volt Regulation 0-100% Load Step: ±1% of output voltage regardless of load

unbalance, with AGC enabled.

Transient Voltage Regulation and Recovery: Output voltage recovers from a

50% load step to within 1% of nominal in less than 150 microseconds.

Harmonic Voltage Content for Linear Loads: Maximum 1% RMS total,

maximum 0.5% any single harmonic for linear loads 5060Hz, 2% RMS total for 400Hz. Paralleled Systems maybe higher.

Current: 175 amps per phase. Inverter Fault Clearing Current: Greater than 200% of full load. Pulse Current: Greater than 200% per phase of pulse current for driving

non-linear loads.

Inverter Overload: - 150% of full load for 30 seconds

- 125% of full load for 10 minutes

- 110% of full load for 1 hour

Frequency Range Selectable, fixed frequencies at 50, 60, 400 Hz.

Variable frequency range 47-500 Hz. External Oscillator input available.

Frequency Accuracy and Stability: ±0.01% typically for fixed frequencies. Frequency Drift: ±0.01% for fixed frequencies. (24hr period)

Load Power Factor: No Restrictions

FIGURE 2.1.3 OUTPUT RATINGS

For a paralleled cabinet system multiply the above ratings by the number of cabinets in the system.

Page 18

SECTION 2 SPECIFICATIONS

Weight:

1550 Lbs (705 Kg)

Height:

72" (183cm)

Width:

36" (91.5cm)

Depth:

30" (76.2cm)

Installation Clearance:

36" (91.5cm) at front of cabinet for service, 12" (30.5cm) at top for airflow 0 side and rear

Air Flow:

1200 CFM (566 l/s) bottom intake, top exhaust

Noise level:

65dbA at 3 feet

Ambient Temperature:

Operating 0 to 40ºC Storage -10 to +70ºC

Relative Humidity:

(non-condensing)

0 to 80% (standard configuration) 0 to 95% (conformal coated PCB option)

Elevation:

Operating 6500 Ft.(1970 m) Derate to 70% at 11,500 Ft.(3480 m) Storage 40,000 Ft.(12,120 m)

Heat Dissipation at 50kW,

62.5kVA load:

20 kBTU/hr.

Pollution Environment:

Degree 2 or better Indoor Use Only

2.2 MECHANICAL SPECIFICATIONS

2.3 ENVIRONMENTAL SPECIFICATIONS

Page 19

SECTION 2 SPECIFICATIONS

FIGURE 2.2 OUTLINE DRAWING

Page 20

SECTION 3 INSTALLATION

WARNING

THE PROPER INSTALLATION OF AN MS-SERIES AC POWER SOURCE REQUIRES

A THOROUGH UNDERSTANDING OF THE INFORMATION PRESENTED IN THIS

SECTION OF THE MANUAL.

IF THIS EQUIPMENT IS NOT INSTALLED AND USED IN A MANNER SPECIFIED BY

THE MANUFACTURER, THE PROTECTION PROVIDED BY THE EQUIPMENT MAY

BE IMPAIRED

Planning the job. (Refer to paragraph 3.1)

Uncrating and Moving the system. (Refer to paragraph 3.2)

Changing Input Voltage, if required. (Refer to paragraph 3.3)

Setting the cabinet into place. (Refer to paragraph 3.4)

Making Input Connections. (Refer to paragraph 3.6)

Making Output Connections. (Refer to paragraph 3.7)

Multiple Cabinet Paralleled Systems. (Refer to paragraph 3.8)

Inspecting the Installation. (Refer to paragraph 3.9)



3.0 INSTALLATION

Should any question arise regarding the installation of this equipment, the user is encouraged to call Pacific Power Source, toll free in the USA at 1-800-854-2433 or 949251-1800 internationally.

Installation of an MS Power Source consists of the following steps:

3.1 PLANNING THE JOB The main objective in planning the job is to determine the hardware required to

install the MS-Series Power Source. Proper consideration of the items below will allow the installation to proceed in an orderly manner.

The first step in planning the job is to determine the size of power source required to service the load. In normal situations the load should not exceed 80% of the power source's full load ratings. This margin allows the user to add future loads to the Power Source without sacrificing surge and overload capabilities.

Page 21

SECTION 3 INSTALLATION

After a particular model has been selected, location of the Power Source, input and output wiring and environmental conditions must be considered. Table 3.1, Environmental Survey Checklist, is provided to verify environmental conditions. Be sure to refer to the clearances required for ventilation in Figure 3.1 for planning the mechanical installation.

The cabinet should be placed as close as possible to the load to minimize output wiring lengths. This is done to reduce distribution losses between the load and power source. Shorter output wiring will provide higher quality power to the load. If there is a choice between shorter power source input or output wiring, choose shorter output wiring. Final equipment location must maintain the minimum physical clearances as shown in Figure 3.1 Installation Detail.

FIGURE 3.1 INSTALLATION DETAIL – (MECHANICAL CLEARANCES)

Page 22

SECTION 3 INSTALLATION

Ambient temperature between 0-40 degrees Centigrade.

Cooling and air exchange rates in the room adequate to support the heat load.

A minimum of 12" above the Cabinet for exhaust.

Unrestricted air intake at the lower front and rear of the cabinet. (Exception: Forced air intake from raised floor installations requires sealing off of the lower front and rear areas. Consult factory.)

A minimum of 24" in front of the Cabinet for service.

Altitude of installation does not exceed 6500 feet. Altitudes in excess of 6500 feet require the derating of maximum operating levels.

Relative humidity does not exceed 80% (95% with conformal coat PCB option) non-condensing. It is suggested that equipment not be located directly under cooling equipment due to the danger of condensing vapor.

CHECK AT RIGHT WHEN CONFIRMED

TABLE 3.1 ENVIRONMENTAL SURVEY CHECKLIST

Page 23

SECTION 3 INSTALLATION

CAUTION

TO AVOID DAMAGE TO THE EQUIPMENT, LIFTING FORKS MUST EXTEND

COMPLETELY THROUGH THE LIFTING CHANNEL UNDER THE CABINET AS

SHOWN IN FIGURE 3.2, CRATING AND MOVING OUTLINE DRAWING.

WARNING

TIP OVER HAZARD.

USE CAUTION WHEN MOVING UNITS

EQUIPPED WITH THE CASTER

OPTION. THE CENTER OF GRAVITY IS

RAISED BY 3” AND THE BASE IS

SMALLER.



3.2 MOVING, UNCRATING, AND INSPECTION Unless specified otherwise, all Pacific MS-Series cabinets will be shipped in one

wooden crate, with a crated weight between 1,700-1,800 lbs depending upon the model and options selected. Dimensions and center of gravity can be seen in figure 3.2, Crating and Moving Outline drawing. The weight will be marked on all sides for safe handling. The crate is constructed of wood and designed to be moved with a forklift or hand truck of adequate capacity.

Upon receiving the equipment, remove the packing list. Separate and remove the top then the sides of the crate setting these aside for the moment. Inspect all equipment for signs of damage in shipping. If any damage has occurred, contact the shipper and the Pacific factory for instructions. If the cabinet is to be returned, it must be shipped back in the original crate.

If no signs of damage are evident, the equipment may be removed from the pallet. A forklift is required to lift the cabinets off the pallets. Do not attempt to "rock" or slide them off as damage may occur to the equipment or injury may occur to personnel.

Page 24

SECTION 3 INSTALLATION

FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING

Page 25

SECTION 3 INSTALLATION

Input Volts

CB1

F1, F2, F3

480

80 A (P/N 716016)

1 A (P/N 712043)

416

100 A (P/N 716049)

1½ A (P/N 712045)

400

100 A (P/N 716049)

1½ A (P/N 712045)

380

100 A (P/N 716049)

1½ A (P/N 712045)

380 [CE]

100 A (P/N 716084)

1½ A (P/N 712045)

240

175 A (P/N 716048)

2 A (P/N 712044)

208

175 A (P/N 716048)

2 A (P/N 712044)

WARNING

ELECTROCUTION HAZARD.

OPENING INPUT CONTACTOR DOES

NOT REMOVE INPUT VOLTAGE FROM

INPUT TRANSFORMER. FOR SAFETY, OPEN THE INPUT CIRCUIT BREAKER.

CAUTION

DAMAGE TO THE EQUIPMENT MAY RESULT IF INCORRECTLY WIRED. VERIFY

CONNECTIONS ARE MADE TO PROPER TAPS.



3.3 CHANGING INPUT VOLTAGE Configure the system for the correct input voltage prior to installing. All voltages

listed in this procedure are line to line. When changing the input voltage, the input circuit breaker and fuses must also

be changed to accommodate the different current required. The input transformer, T1, and LVPS transformer, T2, must be reconnected to the correct taps. See figure 3.3.1 through figure 3.3.4.

Each mainframe, dependent upon model number, will require the following Input Circuit Breaker and Fuses:

Page 26

SECTION 3 INSTALLATION

CHANGING INPUT VOLTAGE

Verify no input power is connected. Open Input Circuit Breaker.

Remove front covers and sub-panels. Remove rear panel.

Remove input circuit breaker CB1. Install new CB1 with correct amperage for new input voltage.

NOTE: Wires between CB1 and the terminal block on the Input Power Panel must be sized appropriately for the new input power form, see Table 3.6.1 for wire size reference.

Remove input fuses F1, F2 and F3. Install new fuses with correct amperage for new input voltage.

Rewire T1 and T2 per fig 3.3.1, 3.3.2, 3.3.3 or 3.3.4 as required

Reinstall rear panel. Reinstall front covers and sub-panels.

Go to section 4.3.1 for first time operation.

INPUT VOLTAGE

Fig.

INPUT

CONNECT

Actual

Nominal

TAPS

480

3.3.1

1,8

4-5

448

480-7%, 416+8%

3.3.1

1,8

3-5

430

480-10%, 416+3%, 400+8%

3.3.1

2,8

4-5

416

416, 400+4%, 380+10%

3.3.1

1,7

3-5

398

400, 416-4%, 380+5%

3.3.1

1,8

3-6

380

380 416-9%, 400-4%

3.3.2

2,8

4-6

366

400-9%, 380-4%

3.3.2

2,7

3-5

348

380-8%

3.3.2

2,8

3-6

240

240, 208+15%

3.3.3

1,8

1-5,4-8

208

208, 240-13%

3.3.4

1,7

1-5,3-7

190

208-9%

3.3.4

2,8

2-6,4-8

The system may be configured for any of the following input voltages:

Page 27

SECTION 3 INSTALLATION

716016

80A

FIGURE 3.3.1 480 V INPUT CONFIGURATION

Page 28

SECTION 3 INSTALLATION

716049

100A

716084

[CE]

FIGURE 3.3.2 380 V INPUT CONFIGURATION

Page 29

SECTION 3 INSTALLATION

716048

175A

FIGURE 3.3.3 240 V INPUT CONFIGURATION

Page 30

SECTION 3 INSTALLATION

716048

175A

FIGURE 3.3.4 208 V INPUT CONFIGURATION

Page 31

SECTION 3 INSTALLATION

WARNING

ELECTROCUTION HAZARD.

LETHAL VOLTAGES PRESENT AT

INPUT OF MACHINE. REFER

CONNECTION TO A QUALIFIED

ELECTRICIAN.



3.4 SETTING THE CABINET INTO PLACE Depending on the site, it may be advisable to rough-in the input and output wiring

prior to moving the cabinet into place. This is best evaluated by the installation team and they should proceed appropriately. Observe clearances as shown in Figure 3.1.

3.5 SAFETY GROUNDING / EARTHING Prior to any input power connections the safety ground or earth ground must be

connected. Observe minimum wire sizes as stated in TABLE 3.6.1

3.6 CONNECTING THE INPUT SERVICE

NOTE

IT IS THE USER'S RESPONSIBILITY TO MEET ALL APPLICABLE LOCAL AND

NATIONAL CODE REQUIREMENTS WHEN INSTALLING THIS EQUIPMENT.

When connecting the input service, certain requirements relating to safety are stated in these instructions and should be followed rigorously.

Input connections to the MS-Series AC Power Source are made at the Circuit Breaker labeled "INPUT POWER." Refer to figure 3.6 AND 3.6.1 for location and orientation of terminals.

The input terminals are compression type. It is very important that the connections are clean and properly tightened. Torque input connector set screws to 55 lb-in [120 lb-in for the CE option].

The MS-Series is not sensitive to input phase sequence.

Page 32

SECTION 3 INSTALLATION

MODEL NUMBER 3060-MS

INPUT

VOLTAGE

FORM

100%

LOAD

RECOMMENDED

INPUT SVC.

MINIMUM INPUT WIRE

SIZE@75°C (167°F)

(COPPER CONDUCTOR)

AWG

mm2

480

DELTA

75A

80A

380

DELTA

94A

100A

240

DELTA

150A

175A

1/0

208

DELTA

170A

175A

2/0

ALL

N/A

SAFETY GROUND /

EARTH

2/0

Each mainframe in an MS series system will draw the following load currents:

TABLE 3.6.1 INSTALLATION WIRING

FIGURE 3.6 INPUT TERMINAL DETAIL

Page 33

SECTION 3 INSTALLATION

CUSTOMER INPUT WIRING PHASE A,B,C

(INPUT IS NOT PHASE ROTATION SENSITIVE)

FIGURE 3.6.1 CUSTOMER INPUT WIRING DETAIL

Page 34

SECTION 3 INSTALLATION

MODEL

NUMBER

Output

(KVA)

Output RMS

(KW)

Output

(AMPS/Ø)

Output Short

Circuit

(AMPS/Ø)

3060-MS

62.5

175A

>350A

WARNING

ELECTROCUTION HAZARD

LETHAL VOLTAGES PRESENT AT OUTPUT OF MACHINE

REFER CONNECTION TO A QUALIFIED ELECTRICIAN.



3.7 CONNECTING THE OUTPUT SERVICE When connecting the output service, certain requirements relating to safety are

stated in the following procedure and should be followed rigorously. The standard output form of the MS-Series is 120/208Y, 50, 60, 400 Hz or

Variable frequency. Phase sequence of the output is ABC. Maximum output current for each 3060-MS in a system is:

The CE option incorporates output fuses F12-F14 in the mainframe cabinet. (No output fuses are provided within the Cabinet in the standard configuration.)

Output connections in the standard MS-Series AC Power Source are made at the output contactor terminals. Refer to figures 3.7, 3.7.1, 3.7.2 for location and orientation of terminals.

The output terminals are compression type. It is very important that the connections are clean and properly tightened. Torque output connector set screws to 150 in-lbs (17 N-m).

If the optional output circuit breaker is installed, connect the output wiring to the output breaker.

Page 35

SECTION 3 INSTALLATION

NOTE

IT IS THE USER'S RESPONSIBILITY TO MEET ALL APPLICABLE LOCAL AND

NATIONAL CODE REQUIREMENTS WHEN INSTALLING THIS EQUIPMENT.

FIGURE 3.7 OUTPUT TERMINAL DETAIL

Page 36

SECTION 3 INSTALLATION

PHASE A

PHASE B

PHASE C

OUTPUT SAFETY

GROUND / EARTH

SYSTEM NEUTRAL

CONNECTION

OUTPUT POWER

CONNECTION

FIGURE 3.7.1 OUTPUT CONTACTOR

(CUSTOMER LOAD WIRING DETAIL)

FIGURE 3.7.2 OPTIONAL OUTPUT CIRCUIT BREAKER

(CUSTOMER LOAD WIRING DETAIL)

Page 37

SECTION 3 INSTALLATION

CAUTION

WHEN THREE OR MORE CABINETS ARE CONNECTED IN PARALLEL, A

PARALLELING / OUTPUT LOAD CENTER WITH INDIVIDUAL CIRCUIT BREAKERS

FOR EACH CABINET MUST BE INSTALLED TO PROTECT OUTPUT WIRING AND

CABINETS.

3.8 MULTIPLE CABINET SYSTEM When connecting the two or more cabinets in parallel to make a Multiple Cabinet

System, follow the procedure as described below. Install each cabinet as a single cabinet power source with each cabinet next to

each other. No side clearance is necessary. Connect the input wiring to each cabinet. See figure 3.8.1 for a Multiple Cabinet System Outline.

Connect a paralleling cable PN (126088) between each cabinet of the paralleled system. Connect one cable from Cabinet #1-P2 to Cabinet #2-P1. Connect another cable from Cabinet #2-P2 to Cabinet #3-P1, etc. Connect as many paralleling cables (up to eleven for a twelve cabinet system) as needed. This paralleling cable contains all of the control signals necessary to operate the Multiple Cabinet System.

All five output wires (Chassis, Neutral, Phase A, Phase B and Phase C) from each cabinet need to be paralleled. Each individual output wire from each Cabinet to the output load connection MUST BE THE SAME LENGTH AND WIRE SIZE. Refer to figure 3.8.2 for Multiple Cabinet System Wiring.

For three or more cabinets in parallel an Output Load Center is REQUIRED. The Output Load Center must contain INDIVIDUAL CIRCUIT BREAKERS, one for each 3060-MS unit. The circuit breaker must be sized for the individual cabinet's output voltage and frequency. Pacific Power's Part Number 716048, a 175 Amp Circuit Breaker may be used for standard 120/208 volt direct coupled output. Refer to modification or option documentation for other output voltage forms and frequencies.

Page 38

SECTION 3 INSTALLATION

FIGURE 3.8.1 MULTIPLE CABINET SYSTEM OUTLINE

Page 39

SECTION 3 INSTALLATION

FIGURE 3.8.2 MULTIPLE CABINET SYSTEM WIRING

Page 40

SECTION 3 INSTALLATION

Check input service, voltage and frequency, with the service listed on the Cabinet Identification Plate on the upper rear of the cabinet.

Check input service ratings. Circuit breakers and wiring to be sized in accordance with currents listed in Section 3.0. Circuit breaker time-overload curves should be compatible with published curves on the Cabinet.

Safety wiring should be sized in accordance with currents listed in Section 3.6. Ground for the Cabinet shall be connected to the Cabinet from the building ground.

All power input and output wiring shall be run in individual conduits. All control wiring shall be contained in separate conduit runs.

Only one neutral point is to be used by the cabinet. Input neutral is not connected and is not required. Output neutral shall be connected at the output neutral terminal. Refer to Figure 3.5.

Verify that all pressure terminations are tightened per specifications listed in Section 3.6 and 3.7.

3.9 ELECTRICAL SURVEY CHECKLIST This paragraph provides a comprehensive checklist to be performed prior to first

time power-up of the MS-Series Power Source. All work must be performed in accordance with applicable local, state, and

national electrical codes. In the event of conflict between this document and the aforementioned codes, the codes shall be observed. It is requested that in the event of conflict, the factory be notified.

CHECK AT RIGHT WHEN CONFIRMED:

FIGURE 3.9 ELECTRICAL SURVEY CHECKLIST

Page 41

SECTION 4 OPERATION

4.0 OPERATION

4.1 INSPECTION OF INSTALLATION Inspection of the installation is a very important step prior to operation of the MS-

Series AC Power Source. This is done as a safety measure to prevent injury to personnel or damage to equipment. Before the cabinet is first turned on, the wiring and distribution system should be checked. Input and output wiring should be examined carefully.

Solid-state power sources are capable of delivering large amounts of energy. This is by design and the primary mission of the power source. Make sure that the loads attached match the output voltage and frequency of the Power Source.

First time operation requires a more in depth inspection than would otherwise be indicated. Specific items to check on first time turn on are:

1. Proper input voltage brought into the Power Source.

2. Input connections properly tightened. No nicked or damaged wires, etc.

3. Output connections made properly. Also, are loads attached of the proper voltage and frequency rating.

The operator should refer to Section 3.0, Installation, if there is any doubt regarding the above conditions.

4.2 INSTALLATION RECORD During first time operation, the Power Source Installation Record, Table 4.2,

should be completed. This information will record initial operating parameters as well as providing the beginning of the maintenance and service record.

After installation of the power source, if commissioning service has been contracted, contact the Pacific Power Source factory for check-out and initial turn-on. Two weeks should be allowed in scheduling personnel, with a maximum of two days normally required on site. The first half of the Installation Record should be completed prior to the arrival of factory personnel. The second half will be recorded by factory personnel during the commissioning field service.

If a factory visit has not been contracted, the following record should be completed by properly trained personnel only.

Page 42

SECTION 4 OPERATION

1.0 Cabinet and Site Information (Paragraph 4.1, 4.2)

Model Number

Serial Number

Purchase Order#

Work Order#

Modification Numbers

Customer Name

Technical Contact

Name

Title

Phone Number

Ext.

Site Address

Test Technician

Date

Comments on Installation:

TABLE 4.2 INSTALLATION RECORD

Page 43

SECTION 4 OPERATION

Parameter

Phase A

Phase B

Phase C

Input Voltage (L-L)

Input Current

Output Voltage

Output Current

Output kVA

Percent Load

Output Frequency

Switch Position Number

Dip Switch

1 2 3 4 5 6 7

Control PCB – S14

Display PCB – S41

Display PCB – S42

TABLE 4.2 INSTALLATION RECORD (cont.)

2.0 Technical Record (Paragraph 4.1)

TABLE 4.2 - INSTALLATION RECORD

Page 44

SECTION 4 OPERATION

4.3 DESCRIPTION OF CONTROLS AND INDICATORS The controls and indicators for the MS-Series equipment are located on the front

panel of the Power Source cabinet. As shown in figure 4.3 the Front Panel is divided into 3 basic regions:

1. LCD and Interrogation Section. Used to solicit Power Source parametric

values.(Refer to paragraph 4.3.1)

2. Mode Select, Emer Off, and Start/Reset switches. Used to control the

operational state of the Power Source (Refer to paragraph 4.3.2).

3. Frequency Select and Volts Adjust. Used to control the Internal Oscillator

and select Master or Slave operation in Parallel Systems (Refer to paragraph

4.3.3).

FIGURE 4.3 MS SERIES FRONT PANEL

Page 45

SECTION 4 OPERATION

4.3.1 LCD AND INTERROGATION SWITCHES This paragraph provides a detailed description of each Power Source message,

how it is obtained, and its meaning. A four line, 160 character display provides the communication interface between

the Power Source and the operator.

FIGURE 4.3.1 LCD AND INTERROGATION SWITCHES

Page 46

SECTION 4 OPERATION

I1: INPUT V XXX/XXX XXX/XXX XXX/XXX (AB)NORMAL A XXX XXX XXX kW XX.X XX.X XX.X FREQ=XXX.X kVA XX.X XX.X XX.X

O1: CABINET V XXX/XXX XXX/XXX XXX/XXX OUTPUT A XXX XXX XXX EFF=XX% kW XX.X XX.X XX.X FREQ=XXX.X kVA XX.X XX.X XX.X

4.3.1.1 INPUT KEY The INPUT Key is used to display the current status of all power source input

power parameters. It may be pressed any time while power is applied to the unit. I1 displayed when the INPUT key is pressed.

NORMAL input power is acceptable. ABNORMAL input power is not acceptable. FREQ input frequency. V input volts, phase to neutral / phase to phase. A input amps for each phase. kW input kilowatts for each phase kVA input kilo-Volt-Amps for each phase.

4.3.1.2 OUTPUT KEY The OUTPUT Key is used to display the current status of all power source output

power parameters. It may be pressed any time power is applied to the unit. Any one of several OUTPUT displays can be seen by pressing OUTPUT and one of the function keys (f1-f4) as follows:

O1 displayed when the OUTPUT then f1 keys are pressed, showing basic output parameters for that cabinet.

V output volts, phase to neutral / phase to phase A output amps for each phase. EFF single cabinet operating efficiency kW single cabinet output kilowatts for each phase FREQ output frequency kVA single cabinet output kilo-Volt-Amps for each phase.

Page 47

SECTION 4 OPERATION

O2: CABINET V XXX/XXX XXX/XXX XXX/XXX OUTPUT %I-PEAK XXX XXX XXX %kVA XXX XXX XXX FREQ=XXX.X %kW XXX XXX XXX

O3: SYSTEM V XXX/XXX XXX/XXX XXX/XXX SUMMARY A XXXX XXXX XXXX OUTPUT kW XXX XXX XXX FREQ=XXX.X kVA XXX XXX XXX

O4: REMOTE V XXX/XXX XXX/XXX XXX/XXX OUTPUT A XXXX XXXX XXXX KW XXX XXX XXX FREQ=XXX.X kVA XXX XXX XXX

O2 displayed when the OUTPUT then f2 keys are pressed, showing output usage for that cabinet.

V output volts, phase to neutral / phase to phase %I-PEAK percent of maximum peak amps for each phase. %kVA percent of maximum kVA for each phase FREQ output frequency %kW percent of maximum kilowatts for each phase

O3 displayed when the OUTPUT then f3 keys are depressed, showing system basic output parameters for multiple cabinet systems.

V output volts, phase to neutral / phase to phase A total system output amps for each phase. kW total system output kilowatts for each phase FREQ output frequency kVA total system output kilo-Volt-Amps for each phase.

O4 displayed when the OUTPUT then f4 keys are depressed, showing remote sense metering parameters.

V remote sense output volts, phase to neutral / phase to phase A total system output amps for each phase. kW total system output kilowatts for each phase FREQ output frequency kVA total system output kilo-Volt-Amps for each phase.

If any OUTPUT display is already active, it is not necessary to press the OUTPUT key each time to view another message. Simply pressing another f1-f4 key will display the corresponding message.

Page 48

SECTION 4 OPERATION

S1: CAB EMER OFF- WARNING - NO OUTPUT PRESS DIAG KEY

S2: CAB IS OFF – READY FOR OPERATION

S3: CAB IS STBY - READY FOR OPERATION

S4: CAB IS ON - OPERATION NORMAL V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S5: CAB IS ON - WARNING - OVERLOAD V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

4.3.1.3 STATUS KEY The STATUS key is used to display the operating status of the Power Source.

This key may be pressed at any time power is applied to the cabinet. Based on internal sense circuits one of the following messages may be displayed.

S1 Displayed when the Power Source is in an Emergency Off state. The

EMER OFF lamp shall be lit.

S2 Displayed when the Power Source is in the Normal Off state. The OFF

lamp shall be lit.

S3 Displayed when the Power Source is in the Standby state. The STANDBY

lamp shall be lit.

S4 Displayed when the Power Source is in the Normal ON state. The ON

lamp shall be lit. Output Frequency and %LOAD (the highest percent load shown in the Output O2 message) is displayed. Single Cabinet output volts and amps information are displayed for each phase.

S5 Displayed when the Power Source is OVERLOADED. The Power Source

is overloaded when %LOAD is greater than 100%. The ON lamp shall be lit. Output Frequency and %LOAD (the highest percent load as shown in the Output O2 message) is displayed. Single Cabinet output volts and amps information are displayed for each phase.

Page 49

SECTION 4 OPERATION

S6: CAB IS EMER OFF-WARNING-OVERTEMP V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S7: CAB IS ON - WARNING UNDER VOLTAGE V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S8: CAB IS ON - WARNING OVER VOLTAGE V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S9: CAB IS ON - WARNING UNDER FREQUENCY V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S10: CAB IS ON - WARNING OVER FREQUENCY V XXX/XXX XXX/XXX XXX/XXX A XXX XXX XXX FREQ=XXX.X %LOAD XXX

S6 Displayed when the Power Source is in an Emergency Off state caused by

an OVERTEMP condition. The EMER OFF lamp shall be lit.

S7 Displayed when the Power Source is in an Alarm condition caused by an

OUTPUT UNDER VOLTAGE.

S8 Displayed when the Power Source is in an Alarm condition caused by an

OUTPUT OVER VOLTAGE.

S9 Displayed when the Power Source is in an Alarm condition caused by an

OUTPUT UNDER FREQUENCY.

S10 Displayed when the Power Source is in an Alarm condition caused by an

OUTPUT OVER FREQUENCY.

Page 50

SECTION 4 OPERATION

D1: DIAGNOSTIC

NO EMERGENCY OFF

D1: DIAGNOSTIC

EMERGENCY OFF CAUSED BY

MASTER EMERGENCY OFF

SUSTAINED OVERLOAD

INVERTER FAULT

EMER OFF BUTTON

TRANSFORMER OVERTEMP

INVERTER OVERTEMP

LVPS FAULT

Bus VOLTAGE > 240 VDC

EXTERNAL EMERGENCY OFF

NO MASTER ON LINE

D2: DIAGNOSTIC TEMPERATURE DATA XFMR: XXX DEG C INV: OK

D3: DIAGNOSTIC INTERNAL VOLTAGES BUS LVPS +XXX VDC +XX.X VDC XXX VDC XX.X VDC

4.3.1.4 DIAGNOSTIC KEY The Diagnostic (DIAG) key is dual purpose. First, by saving the cause of the

Emergency Off state, an audit trail is provided for trouble shooting purposes. Second, technical operating parameters are displayed and recorded for determining Power Source operational status.

When the DIAG then f1 keys are depressed the cause of the Emergency Off state is displayed.

When the DIAG then f2 keys are pressed the input transformer temperature in degrees C and inverter temperature status (OK/Not OK) are displayed.

When the DIAG then f3 keys are pressed the internal High and Low Voltage are displayed.

When the DIAG then f4 keys are pressed the digital inputs to the Display PCB are displayed.

Page 51

SECTION 4 OPERATION

D4: PORT # 2 PORT # 3 PORT # 4 PORT # 5 PWR XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX EMER XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX NOW XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX

BIT

PORT # 2

PORT # 3

KYBD f3

KYBD f4

INV OVERTEMP

MASTER EMER OFF

EMER OFF SW

XFMR OVERTEMP

SUSTAINED O/L

LVPS FAULT

INPUT LINE FAULT

Q6 1 C0

VDC > 240

EXT EMER OFF

BIT

PORT # 4

PORT # 5

VDC > 160

SPARE

INV FAULT

MOD ENABLE

S3 CLOSE COMM

SPARE

S5 CLOSE COMM

INV TEST OK

S7 CLOSE COMM

SPARE

INV O/L

POLARITY

SPARE

H1: INPUT SERVICE IS NOT CORRECT. CHECK ALL THREE INPUT PHASES FOR PROPER VOLTAGE.

This display shows the status of all of the 32 digital inputs to the Display PCB at the last PWR down (when the + 18 VDC fell below 12.3VDC,) the last EMER off (when Q6 went hi) and NOW (present real time.)

If a DIAGNOSTIC display is already active, it is not necessary to press the DIAG key each time to view another message. Simply pressing another f1-f4 key shall display the corresponding message.

4.3.1.5 HELP KEY The HELP key is provided to direct the operator with the proper course of action

to turn on and operate the machine. Six different help messages are available for display. If the HELP key is pressed the first applicable message, H1 through H6, is displayed.

H1 Displayed when the Input Voltage is not within acceptable range.

Page 52

SECTION 4 OPERATION

H2: CABINET IS IN EMERGENCY OFF STATE. PRESS DIAG KEY TO DETERMINE FAULT. TO CLEAR FAULT PRESS START/RESET. IF FAULT REMAINS, SERVICE IS REQUIRED.

H3: SYSTEM IS IN NORMAL OFF STATE. TO PLACE IN STANDBY, ROTATE THE MODE SELECT SWITCH TO STANDBY AND PRESS START/RESET.

H4: SYSTEM IS IN STANDBY STATE. TO TURN ON THE OUTPUT, ROTATE THE MODE SELECT SWITCH TO ON.

H5: SYSTEM IS IN ON STATE. TO READ METERING INFORMATION PRESS THE ASSOCIATED BUTTON.

H2 Displayed when the cabinet is in an Emergency Off State, instructs the

user to press the DIAG then f1 keys to determine the cause of the FAULT. Instructs the user to press the START/RESET to clear the FAULT. Instructs the user that service is required if the fault cannot be cleared.

H3 Displayed when the cabinet is in a Normal Off State. Instructs the user

how to place the cabinet in the Standby state by rotating the MODE SELECT switch to the STANDBY position and pressing the START/RESET button. This will charge up the internal high voltage dc power supplies and start the inverter operating.

H4 Displayed when the cabinet is in the Standby State. The cabinet is ready

to deliver output power but the output contactor is open. Instructs the user to rotate the MODE SELECT switch to the ON position to turn on the output contactor.

H5 Displayed when the cabinet is in the On State. The cabinet's output

terminals are energized. The output contactor is closed. Instructs the user to press a button to read metering information.

Page 53

SECTION 4 OPERATION

H6: SYSTEM IS IN ALARM STATE. PRESS STATUS TO DETERMINE CAUSE OF ALARM. PRESS ALARM TO SILENCE.

A1: ALARM DISABLED- PRESS f1> OV XXX AND HOLD ALARM TO ENABLE. f2> UV XXX USE f1 f2 f3 f4 BUTTONS f3> OF XXX TO CHANGE LIMITS f4> UF XXX

H6 Displayed when the cabinet is in the Alarm State. Instructs the user to

press the STATUS button to determine the cause of the alarm. Instructs the user to press the ALARM button to silence the audible alarm.

4.3.1.6 ALARM KEY Whenever ALARM is pressed message A1 appears. It remains displayed until

some other button is pressed. Pressing ALARM momentarily there after has no effect. Pressing and holding ALARM for 2+ seconds shall cause the ALARM buzzer to change state between ENABLED and DISABLED (display text changes accordingly).

Whenever message A1 is displayed, limits are subject to change by use of f1 through f4 buttons.

First press and hold of f1 causes OV to increase at about 5 volts per second. Second press and hold causes OV to decrease at about 5 volts per second. Similarly for f2, f3 and f4.

If ALARM is ENABLED and any parameter exceeds its limit the ALARM BUZZER shall sound. When parameter returns to limits buzzer shall extinguish.

When RAM is cleared, ALARM system shall be DISABLED and default limits shall be:

OV 132 UV 108 OF 440 UF 47

This feature monitors CABINET PARAMETERS ONLY. No system or remote parameters are monitored. The alarm shall NOT sound if enabled and the output contactor is open.

Page 54

SECTION 4 OPERATION

INPUT/ STATUS/ HELP:

Pressed simultaneously shall cause a software reset of the display CPU.

OUTPUT/ DIAG/ ALARM:

Pressed simultaneously shall clear the RAM.

OFF

The cabinet is shut off. No power is supplied to the load. A red LED next to the OFF position is lighted when there is no power applied to the output and diagnostic checks are OK.

STANDBY

The cabinet is in the Standby State. The internal high voltage power supplies are energized. The inverter is operating. The cabinet is ready to deliver output power but the output contactor is open. A red LED next to the STANDBY position is lighted.

The output terminals are energized. The output contactor is closed and supplying power to the load. A red LED next to the ON position is lighted.

4.3.1.7 SPECIAL KEY COMBINATIONS

4.3.2 MODE SELECT, EMERGENCY OFF, AND ON-RESET SWITCHES As the name implies, these switches control the operational mode of the Power

Source. The operator must be fully familiar with these switches and their function prior to operating the Power Source.

4.3.2.1 MODE SELECT SWITCH During normal operation of the MS, control of the cabinet is through the MODE

SELECT switch. The design of the switch is such that only one Mode Position can occur at any time. The three available switch positions are defined as follows:

Page 55

SECTION 4 OPERATION

FIGURE 4.3.2 MODE SELECT, EMER OFF, AND START/RESET

4.3.2.2 EMERGENCY OFF AND START/RESET SWITCHES During normal operation of the Power Source, return to the OFF state is

accomplished through the use of the Mode Select Switch. In the event of an emergency, the EMER OFF button may be used to cause an immediate shutdown of the cabinet. Manual reset of the Mode Select switch to the OFF position, and pushing the START/RESET switch is then required before the cabinet can be brought back on line.

Two off lamps are used to indicate the Off states. The Emergency Off state is indicated by a lamp that illuminates the EMER OFF push button. A lamp next to the OFF text on the Mode Select switch indicates that the cabinet is in the Normal Off State. The Normal Off state lamp is inhibited from being ON when an EMERGENCY OFF condition exists.

When power is first applied during turn-on, the cabinet is automatically set to the Off state. If the cabinet is in the Emergency Off state the operator must switch the MODE SELECT switch to OFF and press START/RESET to reset the cabinet. The operator may then proceed to Power Source operation.

Page 56

SECTION 4 OPERATION

50, 60 and 400

These are fixed, crystal controlled frequencies for the internal oscillator.

VAR

This is a 47 to 500 Hz variable frequency control for the internal oscillator.

EXT

This selects an external oscillator input for the Power Source.

SLAVE

In this position this cabinet is a SLAVE to another master in a Multiple Cabinet System. One and only one cabinet may be MASTER in a Multiple Cabinet System. The MASTER Frequency shall control the entire Multiple Cabinet System.

4.3.3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST These switches also control the operation of the Power Source. The operator

must be fully familiar with these switches and their function prior to operating the Power Source.

4.3.3.1 FREQUENCY SELECT SWITCH The primary of the Frequency Select Switch is to control the internal Oscillator. It

also is used to determine whether the cabinet is a MASTER or SLAVE.

4.3.3.2 VOLTAGE ADJUST CONTROLS The Voltage Adjust Controls control the internal Oscillator output voltage. The

center control is for all three output phases. ØB and ØC are for Phase B and Phase C trim adjustments only. These controls only work if the cabinet is a master and the internal oscillator is selected.

FIGURE 4.3.3 FREQUENCY SELECT AND VOLTS ADJUST

Page 57

SECTION 4 OPERATION

CAUTION -

BEFORE APPLYING POWER OF ANY KIND TO THE POWER SOURCE, READ

SECTION 4.0 OF THIS MANUAL ENTIRELY AND DO NOT PROCEED UNTIL ITS

CONTENTS ARE FULLY UNDERSTOOD.

4.4 OPERATING PROCEDURES This paragraph describes Power Source modes of operation and the various

operating procedures to be used in operating the MS-Series Power Source.

This section is divided into four sub-paragraphs:

1. Power Source Modes of Operation

Provides definition of Power Source operational states.

2. First Time Turn-On Procedure

To be performed at initial turn-on or when service has been performed.

3. Normal Shut-Down Procedure

To be performed when Power Source power is secured for load maintenance.

4. Emergency Shutdown Procedure

Action taken to secure Power Source output power in emergency situations.

Operation of the MS-Series Power Source has been designed to be simple and straightforward. This is done for several reasons the primary reason being safety. The addition of an Emergency Off Switch allows for quick action in the case of an emergency.

It cannot be stressed too many times that Solid-State Power Sources are capable of delivering tremendous amounts of energy. Things happen quickly

when something goes wrong. However, good habits and a methodical approach, when operating this equipment will, avoid most hazards.

Page 58

SECTION 4 OPERATION

4.4.1 MODES OF OPERATION

There are six possible modes of operation:

1. Off State

2. Stand By State

3. On State

4. Emergency Off State

5. Slave State

6. Auto Re-Start

These states are achieved as described below:

OFF STATE

The OFF state is achieved by rotating the Mode Select Switch to Off. If the EMER OFF switch is illuminated, pressing START/RESET is also required to change the state from EMER OFF to normal OFF.

OFF causes the machine to be dead except for the low voltage power supply. OFF shall be achieved if the following are true:

A) The EMER OFF lamp is off. B) The OFF lamp is on. C) The STANDBY lamp is off. D) The ON lamp is off.

STANDBY STATE

STANDBY is when the input contactor is closed and the machine is ready to deliver power to a load but the output contactor is open. The STANDBY lamp is on. Observe the following start sequence to achieve STANDBY:

A) The EMER OFF lamp is off. B) The OFF lamp is on. C) The MODE SELECT switch is rotated to STANDBY. D) The START/RESET button is pushed. E) The slow turn on contactor is closed and the modulator is enabled. F) The main input contactor closes. G) The slow input contactor opens. The machine is now in STANDBY

mode.

ON STATE

Page 59

SECTION 4 OPERATION

ON is when the output contactor is closed and the machine is ready to deliver power to a load. The ON lamp is on. Observe the following sequence to achieve ON:

A) The STANDBY lamp is on. B) The MODE SELECT switch is rotated to ON. The machine is now

in ON mode.

A) The EMER OFF lamp is off. B) The MODE SELECT switch is in the ON position and the

START/RESET switch is pressed. The machine shall go to STANDBY mode and then to ON mode.

EMER OFF STATE

EMER OFF causes the machine to be dead except for the low voltage power supply. The EMER OFF push button shall be lit. The following shall cause an EMER OFF:

A) EMER OFF BUTTON, the EMER OFF push button has been

pressed.

B) MASTER EMERGENCY OFF, The Master Cabinet is in an

EMERGENCY OFF STATE and this machine is a SLAVE. C) INPUT LINE FAULT, the input power is not within limits. D) LVPS FAULT, one of the low voltage power supplies has failed. E) BUS VOLTAGE > 240 VDC, one of the high voltage power supplies

has exceeded 240 VDC. F) INVERTER FAULT, one of the inverters has failed. G) INVERTER OVERTEMP, one of the inverters is too hot. H) TRANSFORMER OVERTEMP, the large input transformer has

overheated. I) SUSTAINED OVERLOAD, the power source has been in current

limit for a long time. J) EXTERNAL EMERGENCY OFF, an external signal has caused an

emergency off.

Page 60

SECTION 4 OPERATION

MASTER

(Mode Switch

Position)

OFF

STANDBY

SLAVE

(Mode

Switch

Position)

OFF

STANDBY

OFF

STANDBY

OFF

STANDBY

WARNING

IF AUTO RE-START IS ENABLED, THE OUTPUT TERMINALS OF POWER SOURCE

MAY BE ENEGRIZED AUTOMATICALLY WHEN INPUT POWER IS APPLIED



SLAVE STATE

SLAVE causes the machine to act as a slave in a multi cabinet system. The machine is a SLAVE if the FREQUENCY SELECT switch is rotated to SLAVE, and a MASTER if in any other position. The SLAVE lamp and either EMER OFF, OFF, STANDBY or ON lamps shall be lit. The control mode shall be determined by the following table:

FIGURE 4.4.1 SLAVE CONTROL MODE

AUTO RE-START

If AUTO RE-START is enabled, the Power Source shall start AUTOMATICALLY when input power is applied. The Power Source shall attain the mode as selected by the MODE SELECT switch if all internal diagnostics check out ok.

Page 61

SECTION 4 OPERATION

FIRST TIME OPERATION

STEP 1:

Verify the AUTO RE-START option has been disabled by switching S14-1 OFF (refer to Section 4.5.2, Figure 4.5.2.)

STEP 2:

Inspect the installation. Verify that the wiring is correct (refer to Section 3.0, figure

3.6, and figure 3.7.) If this is first time turn-up operation, complete Table 4.2, (Installation Record) as operation proceeds.

STEP 3:

Open main breakers of output distribution system. No load should be connected to cabinet at this point.

STEP 4:

Close input power circuit breaker. The OFF lamp on the Power Source Mode Select switch should illuminate.

If this lamp does not light the EMER OFF lamp should be on. Press the DIAG then f1 keys to determine the cause of the EMERGENCY OFF. If the EMERGENCY OFF is caused by INPUT LINE FAULT, check the input power by pressing the INPUT key on the front panel. ABNORMAL will be indicate if the input power is not within limits and NORMAL if input power is within limits. Correct the fault, if any, and proceed.

Rotate the Mode Select Switch to OFF and press START/RESET. The EMER OFF indicator will go out.

STEP 5:

Place the cabinet in the STANDBY state by rotating the Mode Select Switch to STANDBY and pressing the START/RESET button. The STANDBY lamp will illuminate. The high voltage power supplies are now energized and the inverters are producing voltage. The output contactor is open. Cabinet output voltages and frequency may be checked by pressing the OUTPUT then f1 keys on the front panel.

STEP 6:

If inverter voltage is not at desired levels, it may be changed by adjusting the VOLTS ADJUST controls on the front panel. The center VOLTS ADJUST control adjusts all three outputs simultaneously. ØB and ØC are trim adjustments.

Frequency may be changed by using the FREQUENCY SELECT switch. 50, 60, and 400Hz are fixed crystal stabilized frequencies. The VAR position is variable from 47 to 500Hz. The EXT position allows external oscillator input on connector J6. The SLAVE position makes this cabinet a slave.

STEP 7:

Place the cabinet in the ON State by rotating the Mode Select Switch to ON. The internal output contactor is now closed, and the cabinet is ready to deliver load power. Cabinet output voltages may be checked by pressing the OUTPUT then f2 keys on the front panel.

STEP 8:

Close main breakers of the output distribution system. Monitor output voltages. The output voltage should not change as load is applied.

4.4.2 FIRST TIME OPERATION This procedure is to be used to turn on a one Cabinet Power Source for the first

time, or when service has been performed. Proceed as follows:

Page 62

SECTION 4 OPERATION

PARALLEL CABINET OPERATION

STEP 1:

Inspect the installation. Verify that the wiring is correct (refer to Section

3.8, figure 3.8.2). Open all Circuit Breakers in the Output Load Center.

STEP 2:

Rotate the MODE SELECT switch to the OFF position for each Cabinet in the System. Rotate the FREQUENCY SELECT switch to the SLAVE position for each Cabinet in the system. This should cause an EMER OFF in ALL Cabinets.

STEP 3:

Select ONE Cabinet to be MASTER. Operate the ONE MASTER Cabinet as a Single Cabinet Power Source as described in section 4.4.2.

STEP 4:

Verify operation of each Cabinet individually as described in steps 2 and 3 above.

STEP 5:

Rotate the MODE SELECT switch to OFF for all Cabinets. Select ONE Cabinet, in the middle of the System, to be MASTER. Select all other Cabinets to be slaves. Disconnect any load from the output of the system. Close all of the Circuit Breakers at the Output Load Center. Press OUTPUT then f1 keys on all Cabinets in the system to monitor each Cabinet's output voltages and currents.

STEP 6:

On the MASTER, turn the Volts Adjust down to 0 VAC. Rotate the MODE SELECT to ON and press START/RESET. Select one and only one SLAVE. Rotate its MODE SELECT to ON, and press START/RESET. Verify the MASTER and SLAVE output currents are less than 10 amps.

STEP 7:

On the MASTER, turn the Volts Adjust up to 120 VAC. Verify the MASTER and SLAVE output currents are less than 10 amps. If output currents are large, check for miswires.

STEP 8:

Verify operation of each SLAVE individually as described in steps 6 and 7 above.

STEP 9:

Turn ON all Cabinets in the system. On the MASTER, rotate the MODE SELECT switch to standby and verify all cabinets go to STANDBY. On the MASTER, press EMER OFF and observe all Cabinet go to EMER OFF.

STEP 10:

Connect the load. Bring up the MASTER, then all Cabinets to the STANDBY state. Leave the MASTER in the STANDBY state. Rotate the MODE SELECT switch to ON for all the SLAVES. Rotate the MASTER MODE SELECT to ON. Verify all Cabinet output currents are ±10% of each other. The system is now fully operational.

4.4.3 PARALLEL CABINET OPERATION This procedure is to be used to turn on the Paralleled Cabinet System for the first

time, or when service has been performed on a cabinet. Proceed as follows:

Page 63

SECTION 4 OPERATION

To secure power from the Power Source proceed as follows:

STEP 1:

Turn off all loads and open output circuit breaker if provided.

STEP 2:

Rotate the Mode Select Switch to the OFF position. Verify that the OFF lamp is lit. Verify that the STANDBY and ON lamps are extinguished.

To secure all power to and from the Power Source proceed as follows:

STEP 1:

Turn off all loads and open output circuit breaker if provided.

STEP 2:

Rotate the Mode Select Switch to the OFF position.

STEP 3:

Open the input power circuit breaker. This removes all power to and from the cabinet.

4.4.4 NORMAL SHUTDOWN PROCEDURE This procedure describes how to place the Power Source into the normal Off

state. One of two conditions may be desired when turning off the Power Source:

1. Secure power from the Power Source. Turn off high voltage power

supplies, inverters and output to the load. Control circuits remain active.

2. Secure all power; no power applied to either the Power Source or the

Load.

4.4.5 EMERGENCY SHUTDOWN PROCEDURE Emergency shutdown is accomplished by depressing the EMER OFF Switch at

any time. The principle function of the Emergency Off state is to open the input and output

contactors in the event of internal Power Source failure. A secondary purpose is to protect against overheating of the inverter or input

transformer in the event of excessive load current for extended time (an unlikely occurrence due to conservative thermal design.)

A third function is to give the operator a quick "Turn Off" means in the event of an emergency - since pressing EMER OFF is slightly faster than rotating the Mode Select Switch to Off.

The Emergency Off state can only be removed by rotating the Mode Select Switch to Off and pressing START/RESET. The EMER OFF lamp will extinguish and the cabinet will be in a normal Off state.

Page 64

SECTION 4 OPERATION

Display PCB, Paragraph 4.5.1 S41:

Machine ID and Baud Rate

S42:

For testing and future use.

Control PCB, Paragraph 4.5.2 S14:

Auto restart and AGC control.

CAUTION

ALL CABINET SWITCHES ARE FACTORY PRESET.

CHANGING ANY SWITCH POSITION, WITHOUT PROPERLY IDENTIFYING ITS

LOCATION AND PURPOSE, MAY CAUSE SERIOUS EQUIPMENT DAMAGE.

WARNING

IF AUTO RE-START IS ENABLED, THE OUTPUT TERMINALS OF POWER SOURCE

MAY BE ENEGRIZED AUTOMATICALLY WHEN INPUT POWER IS APPLIED



4.5 SETUP SWITCHES This paragraph describes the PC mounted dip switches contained within the MS-

Series AC Power Source, their purpose and location. Every effort has been made to simplify the Power Source design and its

maintenance. To this end, many common components are used throughout the product family. To maintain commonality within the product family, logic switches are used to convey certain operating characteristics to the cabinet. These switches are summarized as follows:

Refer to Figure 4.5, Cabinet Assembly Drawing, for PC Board location.

Page 65

SECTION 4 OPERATION

FIGURE 4.5 CABINET ASSEMBLY

Page 66

SECTION 4 OPERATION

S41-1

S41-2

Machine Size

OFF

62.5kVA

OFF

Undefined

OFF

Undefined

S41-3 Undefined

S41-4 Undefined

S41-5

S41-6

Serial Port "A" Baud Rate

OFF

300

OFF

1200

OFF

2400

9600

S41-7

S41-8

Serial Port "B" Baud Rate

OFF

300

OFF

1200

OFF

2400

9600

S41-1

OFF

62.5kVA Machine

S41-2

OFF

62.5kVA Machine

S41-3

OFF

Undefined

S41-4

OFF

Undefined

S41-5

OFF

1200 Baud Serial Port A

S41-6

1200 Baud Serial Port A

S41-7

OFF

1200 Baud Serial Port B

S41-8

1200 Baud Serial Port B

S42-ALL

OFF

Undefined

4.5.1 DISPLAY PCB (126072 or 126172) Refer to figure 4.5.1, Display PCB. Two switches are located on this assembly.

Switch S42 is for testing and future use. Switch S41 provides the following configuration information to the Power Source:

Normal Shipping Configuration is as follows:

Page 67

SECTION 4 OPERATION

FIGURE 4.5.1a DISPLAY PCB ASSY., 126072

FIGURE 4.5.1b DISPLAY PCB ASSY., 126172

Page 68

SECTION 4 OPERATION

S14-1

Auto Restart

Normal

Configuration

as Shipped

OFF

S14-2

Undefined

OFF

S14-3

Phase A AGC

OFF

LOCAL

OFF

REMOTE

S14-4

Phase B AGC

OFF

LOCAL

OFF

REMOTE

S14-5

Phase C AGC

OFF

LOCAL

OFF

REMOTE

S14-6

Phase A AGC

OFF

DISABLED

ENABLED

S14-7

Phase B AGC

OFF

DISABLED

ENABLED

S14-8

Phase C AGC

OFF

DISABLED

ENABLED

4.5.2 CONTROL PCB (126070 or 126079) Refer to figure 4.5.2, Control PCB. One switch is located on this assembly.

Switch S14 provides for enabling of the auto restart option and local or remote AGC (automatic gain control.)

Switch S14 assignments are as follows:

Page 69

SECTION 4 OPERATION

WARNING

IF AUTO RE-START IS ENABLED, THE OUTPUT TERMINALS OF POWER SOURCE

MAY BE ENEGRIZED AUTOMATICALLY WHEN INPUT POWER IS APPLIED



FIGURE 4.5.2 CONTROL PCB ASSY., 126070 and 126079

Page 70

SECTION 4 OPERATION

Pin#

Description

ØA (Error Signal)

ØB (Error Signal)

ØC (Error Signal)

Common (Error Signal)

Triangle Wave Sync

Master on line

Remote mode 0

Remote mode 2

Remote Emer Off

Remote Start

ØA System Amps

ØB System Amps

ØC System Amps

14-17

Gnd

+12VDC

Ext Emer Off

20-22

No Connection

23-25

Gnd

4.6 FEATURE CONNECTORS This paragraph describes the Feature Connectors contained within the MS-

Series AC Power Source, their purpose, location, and pin numbers. The use of these connectors is optional. Refer to figure 4.6 for location of these connectors.

4.6.1 P1, P2 PARALLELING These are used for Paralleling cabinets in multiple cabinet systems. They are

DB25P type. Pin numbers are as follows:

Page 71

SECTION 4 OPERATION

FIGURE 4.6 CABINET TOP VIEW - FEATURE CONNECTOR DETAIL

Page 72

SECTION 4 OPERATION

4.6.2 J3 AND J4 SERIAL I/O This paragraph describes the Serial Ports available on the MS-Series Power

Source. The MS Series Power Source is provided with Dual Serial Communication Ports

designated COM A and COM B. These output are RS-232-C Ports with bidirectional logic. Power Source status is stored in an internal register and transmitted through these ports when interrogated.

PHYSICAL CONFIGURATION

Refer to Figure 4.6. J3, or COM A, is a female, DB-25 socket. This socket is a Data Communications Equipment (DCE) Port configured to be interfaced with a Data Terminal Equipment (DTE) device such as a "dumb" terminal, or PC set up as a DTE.

J4, or COM B, is a DTE port configured to be interfaced with a DCE device such as a modem. A female, DB-25 socket is also provided for this port.

BAUD RATE

The Baud Rates for data transmission are 300, 1200, 2400 or 9600 as selected by switch S41 on the Display PCB Assembly. (Refer to Figure 4.5.1.)

COMMUNICATION DATA FORMAT

Data is transferred as an 8 bit word with 1 Start, 1 Stop, and no Parity bit.

DATA TRANSMISSION

Serial Port design is such that no "Handshaking" is required in hardware or software. Due to this fact, data transmitted to the MS must be limited to 5 characters per second. Data bursts are sent from the MS in approximately 200ms increments.

Refer to Table 4.6.2. Hardware handshaking signals, (i.e. TXDA, CTSA, DCDA, etc) are provided for operator convenience. The MS requires only 3 lines: Receive, Transmit and Ground.

Page 73

SECTION 4 OPERATION

PORT

MNEMONIC

DESCRIPTION

COM A

RXDA

RECEIVE DATA PORT A

3 TXDA

TRANSMIT DATA PORT A

4 CTSA

CLEAR TO SEND PORT A

DCDA

DATA CARRIER DETECT PORT A

8 DSRA

DATA SET READY PORT A

5 RTSA

REQUEST TO SEND PORT A

7 GRD

GROUND PORT A

COM B

RTSB

REQUEST TO SEND PORT B

DTRB

DATA TERMINAL READY PORT B

2 TXDB

TRANSMIT DATA PORT B

3 RXDB

RECEIVE DATA PORT B

8 DCDB

DATA CARRIER DETECT PORT B

5 CTSB

CLEAR TO SEND PORT B

7 GRD

GROUND

TABLE 4.6.2 SERIAL I/O CONNECTIONS

With the serial port, it is possible to obtain all Front Panel Display information described in section 4.3.1.

This paragraph provides the syntax and a brief description of all MS recognized commands. Section 4.3.1 should be reviewed for detailed descriptions of returned messages.

Page 74

SECTION 4 OPERATION

Command

Command Type

Information Type

I1 <RET>

Input Screen #1

VLN, VLL, Amps, kW, kVA, Frequency, Input NORMAL OR ABNORMAL.

O1 <RET>

Output Screen #1

CABINET VLN, VLL, Amps, kW, kVA, Frequency, Efficiency.

O2 <RET>

Output Screen #2

CABINET VLN, VLL, %Peak Current, %kVA, %kW, Frequency.

O3 <RET>

Output Screen #3

SYSTEM VLN, VLL, Amps, kW, kVA, Frequency.

O4 <RET>

Output Screen #4

REMOTE VLN, VLL, Amps, kW, kVA, Frequency.

S <RET>

Status Screen

Varies

D1 <RET>

Diag. Screen #1

Cause of Emergency Off.

D2 <RET>

Diag. Screen #2

Temperature Data

D3 <RET>

Diag. Screen #3

Internal Voltages

D4 <RET>

Diag. Screen #4

Binary Ports 2-5

H <RET>

Help Screen

Varies

ST <RET>

Reset Display CPU

Q <RET>

Alarm Silence

R <RET>

Continuously Repeat Last Command. Use <SPACE BAR> <RET> to stop.

SERIAL PORT COMMAND SET

Page 75

SECTION 4 OPERATION

4.6.3 J6 EXTERNAL OSCILLATOR This is an External Oscillator Input. This connector is a DA15S type. If the

Frequency Select Switch is rotated to the EXT position and the cabinet is ON, inputs applied to J6 are amplified 25 times at the output terminals.

Example: 4.80 VAC, 60 Hz input at J6 equals 120 VAC, 60 Hz at the output contactor.

Pin Numbers are as follows: 7 Ext Phase A Oscillator Input

15 Ext Phase B Oscillator Input 8 Ext Phase C Oscillator Input 10 Gnd

4.6.4 J5 AND J7 SYSTEM METERING OUTPUTS J5 is a System Volts output signal connector. System Volts are divided down by

25 to 1 and sent to this connector. This connector is a DA15S type. Example: 120 VAC, 60 Hz at the output contactor equals

4.80 VAC, 60 Hz at J5. Pin Numbers are as follows: 1 Phase A System Volts Output

11 Phase B System Volts Output 8 Phase C System Volts Output 2,7,12 Gnd

J7 is a System Amps output signal connector. System Amps are divided down by 400 to 1 and sent to this connector. This connector is a DA15S type.

Example: 400 AAC, 60 Hz total system output equals

1.00 VAC, 60 Hz at J7. Pin Numbers are as follows: 2 Phase A System Amps Output

7 Phase B System Amps Output 11 Phase C System Amps Output 1,8,12 Gnd

Page 76

SECTION 4 OPERATION

4.6.5 J8 REMOTE METERING INPUTS J8 is a Remote Metering Input signal connector. Remote Volts are divided down

by 100 to 1 and sent to this connector. Remote Amps are divided down by 400 to 1 and sent to this connector. This connector is a DA15S type.

Example: 120 VAC, 60 Hz at the remote location = 1.20 VAC, 60 Hz at J8. Example: 400 AAC, 60 Hz at the remote location = 1.00 VAC, 60 Hz at J8. Pin Numbers are as follows:

1 Phase A Remote Volts Input 2 Phase B Remote Volts Input 3 Phase C Remote Volts Input 4 Phase A Remote Amps Input 5 Phase B Remote Amps Input 6 Phase C Remote Amps Input 7 Neut Remote Amps Input 8 Gnd

4.6.6 J9 AUXILIARY ALARM OUTPUTS This connector alerts the user to conditions that cause alarm status in the

cabinet. These are digital 0 to +5 VDC outputs designed to operate small relays which the user may utilize to operate remote lights and buzzers. This connector is a DA15S type.

Pin Numbers are as follows: 1 Overload 2 Over/Under Voltage 3 Audible Alarm at Cabinet 4 Undefined 5 No connection 6 No connection 7 -18 VDC 8 Gnd 9 Overtemp 10 Over/Under Frequency 11 Undefined 12 Undefined 13 No connection 14 No connection 15 +18 VDC

Refer to section 4.3.1.6 for information on setting ALARM parameter limits. Disabling ALARM at the cabinet will be reflected here as no output on pin 3 during an ALARM condition.

Page 77

SECTION 5 SERVICE

STEP 1:

Record cabinet input data by pressing the INPUT key on the front panel display.

STEP 2:

Record cabinet output data by pressing the OUTPUT then f1 and f2 keys on the front panel display.

STEP 3:

Record the current Status message by pressing the STATUS key on the front panel display.

STEP 4:

Record Diagnostic messages by pressing the DIAGNOSTIC then f1 then f2 then f3 and f4 keys on the front panel display.

STEP 5:

Inspect the cabinet carefully. Listen for noisy fan bearings, etc.

STEP 6:

Turn the unit off and inspect the inside of the cabinet

STEP 7:

Clean the Inverter Air Filters by, first, removing the back panel of the power source (FIGURE 5.1.1). Use a vacuum cleaner and a soft brush on the underside of each inverter (FIGURE 5.1.2) to clean each of the two filters per inverter. If rear access is not available then remove the inverters per section 6.5.1. Clean and replace.

STEP 8:

Clean the outside of the machine. Make comments as appropriate in the maintenance log.

STEP 9:

Turn the unit back on.

5.0 MAINTENANCE

The MS-Series equipment has been designed so that maintenance is kept to an absolute minimum. This section describes the maintenance requirements of this equipment. Paragraph 5.1 describes the maintenance required by the Power Source. If there are any questions please call Pacific Power Source, Inc. at 800854-2433 in the United States. For international support dial 1-949-251-1800.

5.1 MAINTENANCE SCHEDULE Routine maintenance of the MS equipment consists of the steps below. Pacific

recommends the use of a maintenance checklist of the form shown in FIGURE

5.1.3. to help guarantee regular performance of maintenance. Additionally, equipment history is then created. This is sometimes helpful when servicing the equipment, particularly when attempting to solve an application type problem.

MAINTENANCE PROCEDURES (Refer to FIGURE 5.1.3) The following procedure is recommended to be performed at 3 month intervals.

TABLE 5.1.1 6 MONTH MAINTENANCE CYCLE

Page 78

SECTION 5 SERVICE

FIGURE 5.1.1 REAR OF MS-SERIES CABINET – BACK PANEL REMOVED

FIGURE 5.1.2 UNDERSIDE OF MS-SERIES INVERTERS

Page 79

SECTION 5 SERVICE

STEP 1:

Clean the flame baffle underneath the bottom of the MS using a vacuum cleaner with a brush attachment

The following procedure is recommended to be performed at 4 to 6 week intervals.

TABLE 5.1.2 4-6 WEEK MAINTENANCE CYCLE

FIGURE 5.1.3 FIRESCREEN LOCATION FOR CLEANING

Page 80

SECTION 5 SERVICE

EQUIPMENT MODEL NO.

EQUIPMENT SERIAL NO.

DATE:

TECHNICIAN:

1. CABINET DATA

I1: INPUT

/ / /

NORMAL

FREQ=

kVA

O1: CABINET

/ / /

OUTPUT

EFF

% kW

FREQ

KVA

O2: CABINET

V / / /

OUTPUT

%I-PEAK

%kVA

FREQ %kW

O3: SYSTEM

V / / /

SUMMARY

OUTPUT

FREQ

KVA

O4: REMOTE

V / / /

OUTPUT

FREQ

KVA

MS-SERIES MAINTENANCE LOG

FIGURE 5.1.4 MS-SERIES MAINTENANCE LOG

Page 81

SECTION 5 SERVICE

S : CAB

D1: DIAGNOSTIC

D2: DIAGNOSTIC

TEMPERATURE DATA

XFMR:

DEG C

INV:

DEG C

D3: DIAGNOSTIC

INTERNAL VOLTAGES

BUS

LVPS

VDC

VDC -

VDC

D4:

Port # 2

Port # 3

Port # 4

Port # 5

PWR

EMER

NOW

MS-SERIES MAINTENANCE LOG (cont)

2. STATUS INFORMATION

3. DIAGNOSTIC INFORMATION

COMMENTS/APPEARANCE

Page 82

SECTION 6 SERVICE

6.0 SERVICE

MS-Series equipment has been designed using a subassembly concept. This design feature allows for service by replacing a faulty assembly. The service procedures described in this section will isolate a problem to the replaceable assembly or component level as appropriate. Printed circuit board assemblies are considered to be replacement items. Mainframe components such as contactors, diode bridges, filter capacitors, etc. are considered replaceable components.

For factory assistance call Pacific Power Source, Inc. at 800-854-2433 (in the United States. For international support dial 1-949-251-1800)

This section is organized as follows:

Paragraph 6.1 Provides a brief description of each assembly. Paragraph 6.2 Provides the theory of operation required to

troubleshoot the system. Paragraph 6.3 Provides step-by-step troubleshooting procedures. Paragraph 6.4 This section contains schematic diagrams for the

LVPS, Input Power, DC Power Supply and Inverter

assemblies. Paragraph 6.5 Provides procedures for replacing defective

assemblies. Paragraph 6.6 Provides procedures for replacing defective

components. Paragraph 6.7 Provides instructions for returning assemblies for

repair.

6.1 DESCRIPTION

6.1.1 MAINFRAME DESCRIPTION This paragraph describes the various assemblies and components of the

Mainframe. The function of each assembly and component is described below. The part numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.1 for the location of the assemblies and components.

Page 83

SECTION 6 SERVICE

MAINFRAME ASSEMBLY (P/N 126000)

The 3060-MS unit. The mainframe assembly contains the main cabinet components, input transformer and input and output power contactors.

POWER SUPPLY PANEL ASSEMBLY (P/N 126100)

A ±200 VDC power supply for the inverter assemblies. This assembly is not a replaceable piece, but individual components such as fuses, filter capacitors and rectifier diodes are field replaceable.

DISCHARGE PCB ASSEMBLY (P/N 126075)

This PCB assembly contains a soldi-state switch which is active during shutdown sequences to load the high voltage DC supply so that the DC voltages are discharged to safe levels, less than 48 VDC. This board also contains signal conditioning circuits that scale down high voltages to low voltages which are required for the control and display PCB's. [With the CE Option. a High Voltage DC blocking PCB Assembly (P/N

126370) is mounted with the Discharge PCB Assembly.]

COMPONENTS

 R4 and R5, Discharge Resistors (P/N 769990-056)  S3, Input Contactor (P/N 717067)  S7, Slow Start Input Contactor (P/N 717005)  CB1, Input Circuit Breaker:

 480 VAC Input: 80A (P/N 716016)  380 VAC Input: 100A STD (P/N 716049), 100A CE (P/N 716084)  240 VAC Input: 175A (P/N 716048)  208 VAC Input: 175A (P/N 716048)

 F1-3, LVPS Fuses

 480 VAC Input: 1A@500V (P/N 712043)  380 VAC Input: 1A@500V (P/N 712045)  240 VAC Input: 2A@500V (P/N 712044)  208 VAC Input: 2A@500V (P/N 712044)

 [Option] CB2, Output Circuit Breaker (P/N 716048)  CT11-13, Input CT's (P/N 731029)  C10-15, Filter Caps (P/N 720096-10)  R1-3, Slow turn on resistors (P/N 769990-037)  S5, Output Contactor (P/N 717067)  BR1-6, Diode Bridges (P/N 743009)  C30-39, Power Supply Caps (P/N 720219-12)  F10 and F11, DC fuses 300A@500V (P/N 712042)  T2, 3Φ LVPS Transformer (P/N 531247)  T1, 3Φ Input Transformer (P/N 531246)

Page 84

SECTION 6 SERVICE

FIGURE 6.1.1 MAINFRAME

Page 85

SECTION 6 SERVICE

CONTROL PCB ASSEMBLY (P/N 126070 or 126079)

A circuit assembly which contains logic, comparator and oscillator circuits. This board determines the state of the system and controls the system function. It also contains a crystal-referenced local oscillator which develops the output waveform. The oscillator output is a digitally synthesized sine wave.

MODULATOR PCB ASSEMBLY (P/N 126071)

This circuit assembly receives the output of the oscillator and produces the pulse-width-modulated signals required to drive the inverter assemblies.

DISPLAY PCB ASSEMBLY (P/N 126072 or 126172)

This circuit assembly is mounted to the front panel and contains a CPU which drives an LCD for metering, status, diagnostics and alarms. Two RS232 serial ports are also available for a remote terminal or modem.

LVPS PCB ASSEMBLY (P/N 126074)

This is a smaller circuit assembly which is used to develop regulated ±18 VDC. This DC voltage is distributed throughout the mainframe and is used to create low voltage DC for the control circuits on each PCB.

COMPONENTS

C21 and C22, LVPS caps (P/N 720449-95) S12 and S13, Push button switches (P/N 710023) EMER OFF lamp (P/N 701024) B1, fan (P/N 703104)

6.1.2 CONTROL MODULE DESCRIPTION The function of the various assemblies and components of the Control Module is

described below. The numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.2 for the location of the assemblies and components listed below.

Page 86

SECTION 6 SERVICE

FIGURE 6.1.2 CONTROL MODULE

Page 87

SECTION 6 SERVICE

INVERTER ASSEMBLY (P/N 126225)

A 21kVA inverter assembly which contains the power circuits that convert DC to AC and drives the output. The inverter assembly is housed in a metal case. This inverter assembly has been designed to reduce RFI/EMI.

DRIVER PCB ASSEMBLY (P/N 126270)

This PCB assembly receives control signals from the modulator, provides isolation and then drives the power transistors. This PCB is a subassembly of the inverter assembly.

SNUBBER PCB ASSEMBLY (P/N 126272)

This PCB assembly is used to snub voltage spikes on the power transistors. This PCB is a subassembly of the inverter assembly.

COMPONENTS

C11-13, Feed through cap (P/N 720545-30) C1-8, Filter cap (P/N 720096-10) CT1, Current sensor (P/N 703130) B1 and B2, Fan (P/N 703106) R1-8, Snubber resistor (P/N 760180-10) TAS1-4, Temp sensor (P/N 710039) L1-12, Filter inductor (P/N 530014)

6.1.3 INVERTER DESCRIPTION The function of the various assemblies and components of the Inverter module is

described below. The part numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.3 for the location of the assemblies and components listed below. Refer to Section 6.5.1 for removal and replacement procedures.

Page 88

SECTION 6 SERVICE

FIGURE 6.1.3 INVERTER

(side view with covers removed)

Page 89

SECTION 6 SERVICE

Control Term Definitions

3 PHASE PRESENT

True when all three input phases are present.

AGC (Automatic Gain Control)

Improves steady state regulation of the output voltage.

AUTO RESTART PULSE

Same as POWER ON RESET if selected.

Control mode 0.

Control mode 2.

DISCHARGE

True if S3 CLOSE and S7 CLOSE COMM are false.

EMER OFF SW

True when switch is pressed. Momentary contact panel switch with integral lamp.

EMER OFF LAMP

Is lit whenever Q6 is true.

ERROR IN

Error signal to the modulator.

ERROR OUT

Error signal from the modulator.

ERROR

System Error signal from the master modulator.

EXT EMER OFF (External Emergency Off)

External contacts have shorted connector P1-18 to P1-19 causing an emergency off.

6.2 THEORY OF OPERATION The basic theory of operation for the MS-Series Power Source is defined in the

information which follows and is provided as technical reference to aid any troubleshooting of the equipment.

The MS-Series Power Source consists of five basic subsystems which are as follows:

1. Power Conversion Circuits (Paragraph 6.2.1)

2. System Control Circuits (Paragraph 6.2.2)

3. DC Power Supply Circuits (Paragraph 6.2.3)

4. Metering and Display Circuits (Paragraph 6.2.4)

5. Paralleling Circuits (Paragraph 6.2.5)

Each of the circuits is discussed in detail in each of the above referenced paragraphs.

When the DIAG then f4 keys are pressed the status inputs to the Display PCB are displayed (Reference section 4.3.1.4). This display may be used to determine the state of control terms in the system.

Control Terms are defined as follows:

Page 90

SECTION 6 SERVICE

Control Term Definitions

IAC

Input AC Normal.

INPUT VOLTS

Line to neutral input voltage.

INPUT LINE FAULT

True when Input voltage is less than 80 % of nominal or greater than 120 % of nominal or 3 PHASE PRESENT is false.

INPUT AMPS

Input amps from current transformers.

INV OVERTEMP

One of the inverters has overheated.

INV HOLD COMM

Inverter Hold Command.

INV FAULT

Is true when INVERTER HOLD COMM and MXEN are true and INV TST OK is false. Possible shorted transistor.

INV TST OK

Inverter test OK indicates that the Inverters, 2 per phase, are switching at approximately 30 kHz and no fuses are blown. Does not test the quality of the sine wave being produced and does not care if inverter is in current limit.

INV VOLTS

Inverter output voltage. Inverter side of the output contactor.

INV AMPS

Inverter output amps.

INV O/L

Inverter is in current limit.

Local Master, the FREQUENCY SELECT switch is not in the SLAVE position.

Local Slave, the FREQUENCY SELECT switch is in the SLAVE position.

LVPS FAULT

Checks ± 12 VDC on PCB's.

MASTER LAMP

Is lit whenever the FREQUENCY SELECT switch is not in the SLAVE position.

MASTER EMER OFF

The master cabinet is in an EMER OFF state.

Master on line, at least one Cabinet is a Master.

MOD ENABLE

Modulator enable.

OAC

Output AC Normal.

OFF LAMP

Is lit if Q6, S3 CLOSE COMM and S7 CLOSE COMM are false.

ON LAMP

Is lit if S5 CLOSE COMM is true.

OSC IN

Oscillator signal.

Page 91

SECTION 6 SERVICE

Control Term Definitions

OVER FREQUENCY

OF Condition exists if output frequency is greater than preset limit. Limit is set by the ALARM KEY.

OVER VOLTAGE

OV Condition exists if output voltage is greater than preset limit. Limit is set by the ALARM KEY.

OVERTEMP

Either INV OVERTEMP or XFMR OVERTEMP is true.

POLARITY

Polarity of the signal is being metered.

POWER ON RESET

Pulse, after 3 PHASE PRESENT is true.

Local EMER OFF state.

Remote mode 0.

Remote mode 2.

REMOTE VOLTS

Remote line to neutral voltage.

REMOTE SENSE

Voltage and current metering from a remote location. AGC may be selected to regulate to this point.

REMOTE START

True if the master is starting.

REMOTE AMPS

Remote amps from remote current transformers.

S3 CLOSE COMM S5 CLOSE COMM S7 CLOSE COMM

Drive signal which causes the relay to close. SLAVE LAMP

Is lit whenever the FREQUENCY SELECT switch is in the SLAVE position.

STANDBY LAMP

Is lit if S3 CLOSE COMM or S7 CLOSE COMM is true and S5 CLOSE COMM is false.

START/RESET SW

True when switch is pressed. Momentary contact.

SUSTAINED O/L

Inverter is in current limit for more than 50% duty cycle for longer than 20 seconds.

SYSTEM AMPS

Total system output amps from all of the inverters in a paralleled system.

SYSTEM VOLTS

System output volts on the output side of the output contactor.

TRI SYNC

Triangle Wave synchronization signal.

UNDER FREQUENCY

UF Condition exists if output frequency is less than preset limit. Limit is set by the ALARM KEY.

Page 92

SECTION 6 SERVICE

Control Term Definitions

UNDER VOLTAGE

UV Condition exists if output voltage is less than preset limit. Limit is set by the ALARM KEY.

VDC > 160

Term goes true when both BUSES are greater than 180 VDC. Term goes false when either Bus goes below 160 VDC.

VDC > 240

True when either Bus voltage exceeds 240 VDC.

XFMR OVERTEMP

Input Transformer has overheated.

XFMR TEMP

Analog signal from embedded thermocouple in input transformer.

6.2.1 THEORY OF OPERATION - POWER CONVERSION CIRCUITS The power conversion circuits of the MS-Series power source consist of the

following assemblies:

1. Control PCB which contains the Oscillator

2. Modulator PCB

3. Inverter Assemblies (3 each) Figure 6.2.1 is a block diagram of the inverter assembly. The oscillator generates three low level sine waves which are at the fundamental

output frequency. The amplitude of these signals is 4.8 VAC is set to 120 VAC

. Potentiometers R261, R262 and R263 supply DC voltage

l-n

when the output

rms

levels which control the amplitude of the appropriate oscillator outputs. Automatic Gain Control (AGC) can be enabled to improve output voltage regulation. S14 enables or disables and selects local or remote operation of AGC. When the Frequency Select Switch is in the EXT or SLAVE positions, all outputs of the oscillator are disabled and will be 0 VAC.

The oscillator output is fed to the modulator PCB which creates a pulse width modulated digital signal, as required by the inverter assemblies. The modulator also receives six current signals, two from each inverter assembly, which are representative of individual inverter assemblies’ output current. These signals are used to guarantee current sharing between assemblies on the same phase. The modulator develops the INV AMPS term which is used to drive the system output ammeter. The output voltage of each phase is fed back to the modulator PCB. This is done to achieve high waveform quality.

The inverter assembly uses large transistors which switch between the +/- 200 VDC power supplies as controlled by the modulator. The output of this switch is filtered to create the output sine wave.

Page 93

SECTION 6 SERVICE

FIGURE 6.2.1 BLOCK DIAGRAM POWER CONVERSION CIRCUITS

Page 94

SECTION 6 SERVICE

6.2.2 THEORY OF OPERATION - CONTROL CIRCUITS The Control PCB is mounted to the rear of the keyboard sub-panel and performs

the central system control of an MS-Series mainframe. This PCB monitors key system parameters and either allows or prohibits operation accordingly. Figure

6.2.2 is a block diagram of the system control circuits within the mainframe. When input power is applied and the input circuit breaker is closed the LVPS is

on. At this point, the Control PCB is performing preliminary diagnostics and will light the red System Off LED on the front panel when all diagnostic tests have been passed. The INPUT LINE FAULT signal will be at -12 VDC when all input diagnostic tests have been passed.

If the machine has an internal fault the EMER OFF push button will light. After the fault has been cleared, pressing the START/RESET push button will allow normal operation.

Rotating the MODE SELECT switch to STANDBY and then pressing START/RESET will turn on S7, the Slow-Turn-On Contactor. Resistors R1, R2 and R3 limit the inrush current during transformer turn on and charging of the power supply capacitors. At this point the MODULATOR ENABLE signal is high allowing the inverter to create sine waves at the output. When the power supplies have charged S3, the input power contactor, will close. Rotating the MODE SELECT switch to ON will close the output contactor, S5.

Rotating the MODE SELECT switch to OFF will open all input and output contactors and cause the Discharge PCB to become active. The Discharge PCB switches in a pair of resistors, R4 and R5, whose sole purpose is to discharge the DC supplies.

Pressing the red EMER OFF switch will open all input and output contactors and cause the Discharge PCB to become active. The emergency off flip-flop, Q6, is also set.

Figure 6.2.2 shows the various control signals used in the system. These signals are named appropriately to aid understanding.

Page 95

SECTION 6 SERVICE

FIGURE 6.2.2 BLOCK DIAGRAM SYSTEM CONTROL CIRCUITS

Page 96

SECTION 6 SERVICE

6.2.3 THEORY OF OPERATION - DC POWER SUPPLY The low voltage power supply transformer, T2, generates 3 phase 16/28 VAC for

the low voltage DC power supplies and 3 phase 115 VAC for fans and contactor coils. The LVPS PCB generates a regulated ±18 VDC from the 16/28 VAC. The Control PCB continuously monitors the ±18 VDC Low Voltage DC supplies. If any of these become abnormal, logic circuits on the Control PCB will initiate system shutdown. Refer to Figure 6.2.3 for the block diagram of this circuit.

The main input power transformer, T1, and power supply panel assembly, which contains the rectifiers, capacitors and DC fuses, make up the main DC Power Supply Circuits. The main DC Power Supply is a bipolar supply which produces ±200 VDC. This supply is an unregulated supply. It is actually two independent 200 VDC supplies which are stacked on top of each other. The rectifiers are configured as two, full-wave three-phase bridges. These two bridges are connected as shown and feed the capacitor assembly. The capacitors filter the bridge outputs and DC is produced. The common point of this supply is Output Neutral and is connected to the chassis. Two red LEDs, one for positive and one for negative, on the Discharge PCB indicate BUS voltages are present.

The Control PCB continuously monitors the ±200 VDC and will shut down the system if the DC is higher than 240 VDC or lower than 160 VDC.

Page 97

SECTION 6 SERVICE

FIGURE 6.2.3 BLOCK DIAGRAM DC POWER SUPPLY

Page 98

SECTION 6 SERVICE

6.2.4 THEORY OF OPERATION - DISPLAY CIRCUITS The Display PCB is mounted to the rear of the keyboard sub-panel. The

metering circuits are contained on the Display PCB assembly. A CPU is used to meter and display system information on an LCD. The Discharge PCB assembly contains the resistor voltage dividers to scale down system voltages to a low level. These system voltages are sent to the Control PCB. The Control PCB provides all input signals (analog and digital), except input amps, to the Display PCB. CT11-CT13 provide the input current terms required by the Display PCB. Figure 6.2.4 is the block diagram for the meter and display portion of the MSSeries power source.

The Control PCB drives the EMER OFF, OFF, STANDBY, ON, MASTER and SLAVE lamps.

FIGURE 6.2.4 BLOCK DIAGRAM DISPLAY CIRCUITS

Page 99

SECTION 6 SERVICE

6.2.5 THEORY OF OPERATION - PARALLELING CIRCUITS The paralleling circuits are located on the Control PCB. The Control PCB is

mounted to the rear of the keyboard sub-panel. The Master Cabinet's Control PCB assembly is central to the system control of a Multi-Cabinet paralleled system. This PCB monitors key system parameters and either allows or prohibits operation accordingly. Figure 6.2.5 is a block diagram of the paralleling circuits within all cabinets of the paralleled system.

P1 and P2 are the paralleling connectors. Tying pin 18 and pin 19 together with isolated external contacts shall cause an external emergency off of the system.

If a cabinet is a Master and in an EMER OFF state, it will cause all paralleled cabinets to be in an EMER OFF state. The master EMER OFF must be cleared first; then any slave EMER OFF may be cleared.

When all slave cabinets have no EMER OFF and the mode select switch is in the ON position, the MASTER controls total system operation.

Each cabinet in a paralleled system generates its own inverter amps signal. This signal is summed together to create the system amps signal. System amps is total amps of the system and may be displayed at any cabinet.

Page 100

SECTION 6 SERVICE

FIGURE 6.2.5 BLOCK DIAGRAM PARALLELING CIRCUITS

Pacific Power Source MS Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual