Powertronix Quasar, 10kVA, 15kVA, 20kVA, 30kVA Service Manual

Download

Manual Registration

Prelim Page i3x3 UPS Preliminary Pages

Issue 2 - November 2001

Manual Registration

S THIS MANUAL IS A CONTROLLED DOCUMENT AND WILL BE PERIODICALLY UPĆ

DATED.

S IN ORDER TO ENSURE THAT YOU RECEIVE ANY AMMENDMENT PLEASE REGĆ

ISTER THIS MANUAL WITH THE TECHNICAL SUPPORT DEPARTMENT BY REĆ TURNING A COPY OF THIS FORM TO:

Manual Registration

Number

Name of Registered Holder

Address of

Holder

Company

Name/Building

Street/Road

Area/region

Town/City

County/State

Post/Zip Code

Country

Telephone Number

FAX Number

E Mail Address

Amendment Record

Service Manual

Manual Serial

Number:

Please enter the Manual Serial Nº

for future record

Issue

Nº

Issue

Date

Amendment Amended By Date

Initial issue

ć ć

Service Manual

Amendment Record

Prelim Page iii 3x3 UPS Preliminary Pages

This Service manual contains information concerning the installation operation and service of the folĆ

lowing UPS

EQUIPMENT PART NUMBER

With battery Without battery

10 kVA UPS

15 kVA UPS

20 kVA UPS

30 kVA UPS

UTILITY SUPPLY WARNING

PLEASE NOTE

Service Manual

Limitations of Use

Prelim Page iv 3x3 UPS Preliminary Pages

Issue 2 - November 2001

Limitations of Use

ELECTROMAGNETIC COMPATABILITY

The equipment covered by this manual complies with the requirements of the EMC DirecĆ tive 89/336/EEC and the published technical standards. Continued compliance requires installation in accordance with these instructions and use of manufacturer approved accesĆ sories only.

WARNINGThe UPS is a Class A product.

When used in a domestic environment a unit may cause radio interference, If this is the case the user may be required to take additional measures

WARNING HIGH EARTH LEAKAGE CURRENT.

Earth connection is essential before connecting the utility supply. This equipment must be earthed in accordance with local electrical codes.

WARNING This UPS does not incorporate automatic backĆfeed protection. A warning label must be

fitted to all external primary power isolators stating: ISOLATE THE UNINTERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS CIRCUIT.

The UPS should not be supplied from electrical power systems of the `IT' (Impédance à Terre) type. (IEC 364 Ć ELECTRICAL INSTALLATION OF BUILDINGS) Note: Where use on `IT' systems is required an optional input isolation transformer should be fitted.

CAUTION This equipment is fitted with RFI suppression filters

Earth leakage exceeds 3.5mA but is less than 300mA. Transient and steadyĆstate earth leakage currents, which occur when starting the equipĆ ment, should be taken into account when selecting instantaneous RCCB or RCCD devices. Note also that the earth leakage currents of the load will be carried by this RCCB or RCCD.

These products are intended for Commercial/Industrial use only, and are not suitable for use in any life support applications.

Service Manual

Important Instructions for safe use

Prelim Page v 3x3 UPS Preliminary Pages

Important Instructions for safe use

GENERALThe UPS must be approved engineer before it is put into serĆ

vice. Failure to observe this condition will invalidate any implied warranty.

In common with other types of high power equipment, dangerous voltages are present with the UPS and battery enclosure. The risk of contact with these voltages is minimised as the live component parts are housed behind a hinged lockable door. Further internal safety screens make the equipment protected to IP20 standards. No risk exists to any personnel when operating the equipment in the normal manner, followĆ ing the recommended operating procedures. All equipment maintenance and servicing procedures involving internal access, should be carried out by trained personnel.

The UPS is for indoor use only. It must be protected from rain or excessive moisture and installed in a clean environment, free from flammable liquids, gasses, or corrosive subĆ stances. Do not put drinks, plants, or any other containers holding liquids, on top of the unit.

BATTERIES Battery manufacturers supply details of the necessary precautions to be observed when

working on, or in the vicinity of, a large bank of battery cells. These precautions should be followed at all times. Particular attention should be paid to the recommendations concerning local environĆ mental conditions and the provision of protective clothing, first aid and fireĆfighting facilities.

TEST EQUIPMENT

When the battery is under charge it is earthĆreferenced about its midĆpoint e.g. if the battery is being charged at 460V the battery extremities will be =230V and Ć230V with respect to neutral (earth). When using mains powered test equipment such as oscilloscopes in the UPS high voltage area, always use a differential mode of operation to avoid the need to disĆ connect the oscilloscope frame earth.

PERSONNEL

When working inside the UPS (trained personnel only) is recommended that protection be worn to prevent eye damage, should an electric arc be struck by mishandling or severe electrical fault. Some of the power components are very heavy. If their removal is necessary ensure that sufficient manpower is available, otherwise use adequate mechanical handling equipment. When working in the general area of the UPS where high voltages are present, a second person should be standingĆby to assist and summon help in case of accident.

Service Manual

Personnel Categorisation

Prelim Page vi3x3 UPS Preliminary Pages

Issue 2 - November 2001

Personnel Categorisation

The following definitions are given to categorise the scope, and use of this service manual:

Operator/User

This service manual is outside the scope for use by personnel who have received instrucĆ tion on the correct operation of the UPS controls; limited to operation of the unit circuit breakers and the Front Control Panel; operator/users are not permitted to remove any panĆ els which are retained by screws.

Competent Personnel

The Troubleshooting section, and Service procedures contained in this manual are norĆ mally outside the scope of personnel categorised competent; though they may be aware of the dangers appropriate to working with hazardous voltages. A Competent engineer is deemed to have sufficient technical skills/training to make electrical connections, install batteries, close and open circuit breakers/fuses etc. (i.e. a qualified electrician) he is not categorised as service personnel.

Service Personnel

This etraining and are password authorised.

Service manual is designed for use by engineers who have received the relevant

Important Symbols

The warning triangle shown above indicate personal safety instructions. Follow these instructions carefully to avoid injury.

Service Manual

Specification

Prelim Page vii UPS Preliminary Pages

Issue 2 - November 2001

Specification

10kVA 15kVA 20kVA 30kVA

Input Data

Nominal Input Voltage 400V 3 phase, neutral and earth

Input Voltage Range 300 ć 480Vac (330 ć 480Vac full charging capability)

Nominal Input Frequency 50/60Hz

Input Frequency Range 40 ć 70Hz

Maximum Input Current at Nominal Input Voltage 18.5A 25.3A 31.7A 45.0A

Input Current Harmonic Distortion (THD) <30% (without filter)

Input Power Factor 0.95 (over specified load and voltage ranges)

Output Data

Nominal Output Voltage 380, 400 or 415Vac selectable

Output Voltage Adjustment Range 360 ć 415Vac

Output Voltage Stability

Static Balanced Load Static 50% Unbalanced Load Static 100% Unbalanced Load Dynamic 50% Load Step Dynamic 100% Load Step

±1% ±3% ±5% ±3% ±5%

Output Voltage Transient Recovery Time <30ms (to 3% RMS)

Output Voltage Distortion (THD)

Linear Load Non Linear Load (100% 3:1 Crest Factor Load)

<3% <5%

Output Voltage Phase Displacement

Balanced Load 100% Unbalanced Load

120° ±1% 120° ±3%

Nominal Output Frequency 50 or 60Hz

Output Frequency Regulation

Synchronised With Input Free Running

±1% or ±4%, selectable

±0.005%

Maximum Slew Rate 1Hz/sec

Nominal Output Power Rating

kVA kW

15 12

20 16

30 24

Output Nominal Power Factor 0.8

Overload Capability on Inverter (Load Will Transfer to Static Bypass if Times are Exceeded)

125% for 10 minutes, 150% for 10 seconds

Output Short Circuit Current 300% of nominal current for 100ms

Maximum Load Crest Factor 3:1 (at full load without deĆrating)

Service Manual

Specification

Prelim Page viiiUPS Preliminary Pages

Issue 2 - November 2001

10kVA 15kVA 20kVA 30kVA

Intermediate DC Circuit Data

Internal Battery Type valve regulated, sealed, lead acid cells

Number of Battery Cells 192

Nominal Battery Voltage 384Vdc

Internal Battery Rating 7.2Ahr 2 x 7.2Ahr 2 x 7.2Ahr 3 x 7.2Ahr

Full Load Autonomy Time With Standard Internal Battery (For part load and battery configuration Autonomy times refer to the table on page Ćxiii)

6 minutes 9 minutes 6 minutes 6 minutes

DC Bus Overvoltage Trip 500Vdc

End of Battery Discharge Voltage 320Vdc

Battery PreĆalarm Discharge Voltage Level 350Vdc

Battery Charger Nominal Float Voltage at 20°C 432Vdc Battery Charger Voltage Stability ±1%

Battery Charger Output Voltage Ripple <1%

Maximum Battery Recharging Current 1, 3, 5 or 7A (Selectable)

Automatic Battery Test 12, 24 or 48 hour impedance test

System Data

Topology

True OnĆline double conversion, high frequency,

transformerless design

Power Upgrade Yes ć up to a maximum rating of 30kVA

StartĆup On Battery Yes

System Efficiency (Excluding Battery Charging)

50% Linear Load 100% Linear Load

88% 90%

89% 91%

90% 91%

Full Load Inverter Efficiency 94% 94% 94% 94%

Operating Temperature Range 0° Ć 40°C (20°C for optimal battery lifetime) Storage Temperature Range Ć20° to 70°C (excluding battery)

Operating Relative Humidity Range <95% (nonĆcondensing)

Maximum Altitude Above Sea Level 1000m before deĆrating

Audible Noise Level At 1 Metre <52dBA

Relay Communications Card

Alarm Contacts

DB9 connector

On Battery

Low Battery

Internal Terminals

On Battery

Low Battery

On Bypass

UPS On

Remote Stop Contacts Open to disable inverter and static bypass

Cable Entry Bottom entry at rear of unit

Service Manual

Specification

Prelim Page ixUPS Preliminary Pages

Issue 2 - November 2001

10kVA 15kVA 20kVA 30kVA

Bypass Data

Input Voltage Range For Bypass Switching Nominal ±10%

Overload Capability on Static Bypass 150% for 30 minutes, 1000% for 100 m seconds

Mechanical Data

Unit Dimensions (w x h x d) 530 x 1220 x 950 mm

Unit Weight Without Battery 185kg

Unit Weight With Standard Battery 275kg 365kg 365kg 455kg

Shipping Dimensions (w x h x d) 545 x 1260 x 965 mm

Unit Shipping Weight Without Battery 215kg

Unit Shipping Weight With Standard Battery 305kg 395Kg 395kg 485kg

Enclosure Rating IP20

Colour

RAL 7035 Metal Covers

RAL 7042 Plastic Door

Design Standards

Safety Radio Frequency Interference (RFI) Electromagnetic Compatibility (EMC) European Directive Quality

EN50091Ć1Ć1

EN50091Ć2 Class A

CE marked compliance LVD / EMC

ISO9001

Service Manual

Specification

Prelim Page xUPS Preliminary Pages

Issue 2 - November 2001

BATTERY AUTONOMY TIMES

Configuration Part Nº

Approximate Autonomy Time in Minutes at

Stated Load and 25°C

Configuration

Part N

100% 75% 50% 25% 10%

3 Phase 10kVA

UPS with 1 internal set of batteries (Standard configuration)

6 9 17 35 115

UPS with 2 internal sets of batteries

+ 1 x BATT

17 24 40 82 282

UPS with 3 internal sets of batteries

+ 2 x BATT

28 41 66 133 486

UPS with 4 internal sets of batteries

+ 3 BATT

41 57 94 191 600

3 Phase 15kVA

UPS with 2 internal sets of batteries (Standard configuration)

9 14 24 55 157

UPS with 3 internal sets of batteries

+ 1 x BATT

17 24 40 91 269

UPS with 4 internal sets of batteries

+ 2 x BATT

24 35 56 128 398

3 Phase 20kVA

UPS with 2 internal sets of batteries (Standard configuration)

6 9 17 39 108

UPS with 3 internal sets of batteries

+ 1 x BATT

11 17 28 64 178

UPS with 4 internal sets of batteries

+ 2 xBATT

17 24 40 91 263

3 Phase 30kVA

UPS with 3 internal sets of batteries (Standard configuration)

6 9 17 40 110

UPS with 4 internal sets of batteries

+ 1 x BATT

9 14 24 56 157

Service Manual

Table of Contents

Prelim Page i3x3 UPS Preliminary Pages

Issue 1 - May 2001

Table of Contents

Manual Registration i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Amendment Record ii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limitations of Use iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Important Instructions for safe use v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Personnel Categorisation vi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specification vii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents xi. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 1 - Overview 1 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 - Introduction 1 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 - Equipment Construction 1 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 - Principle of operation 1 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 - UPS Power Configuration 1 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.3 - Battery fuses switch 1 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 2 - Installation 2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 - Installation (Mechanical) 2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1.1 - Preliminary Checks 2 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 - Installation (Electrical) 2 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.1 - Power Cabling 2 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.2 - Power Cable connections 2 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.3 - Safety Earth 2 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2.4 - Protective devices 2 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 - Battery Installation 2 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.1 - Battery Safety 2 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2 - Battery Installation Check 2 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3 -Installing the Battery Upgrade Kit (BATTCABLE)2 - 9. . . . . . . . . . . . . .

2.4 -Setting Standard Relay Interface PCB2 - 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 - Setting Options on the standard Relay Interface 2 - 12. . . . . . . . . . . . . . . . .

2.4.2 - Relay Interface Connections 2 - 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3 - Remote EPO (Emergency Power Off) 2 - 14. . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4 - Emergency Power Off (E.P.O.) pushĆbutton connection 2 - 14. . . . . . . . . . .

2.4.5 - Connection to Personal Computer 2 - 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.6 - UPS Monitoring 2 - 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 3 - Commissioning 3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 - PreĆpower Checks 3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 - Validating the Installation 3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 - Positioning 3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.2 - Preliminary checks 3 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 - Setting UPS Parameters 3 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 - Control Logic PCB CS0072. 3 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 - Driver Interface PCB CS0071 Settings 3 - 2. . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 - Auxiliary DC-DC PSU Converter PCB CS0070 Settings 3 - 3. . . . . . . . . .

3.3.4 - Battery Charger PCB CS0074 Setting 3 - 3. . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.5 - LCD Display Monitor Board CS0077 Settings 3 - 3. . . . . . . . . . . . . . . . . . .

Service Manual

Table of Contents

Prelim Page iiUPS Preliminary Pages

Issue 1 - May 2001

3.4 - Initial UPS Start-up. 3 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 - Converter and Inverter Output Calibration. 3 - 4. . . . . . . . . . . . . . . . . . . . . .

3.4.2 - Inverter to Bypass Synchronisation Check. 3 - 6. . . . . . . . . . . . . . . . . . . . .

3.4.3 - Battery Charger Output Calibration. 3 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 - Power Checks 3 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 - Bupass Failure Test 3 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2 - Mains Failure Checks 3 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.3 - Test Transfer to the Reserve Line (Automatic Bypass). 3 - 8. . . . . . . . . . . .

3.5.4 - Manual Bypass Operation Check 3 - 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.5 - Local EPO 3 - 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.6 - External EPO 3 - 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 - Normal UPS Start-Up Instructions 3 - 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.1 - LCD Messages and LED status after starting the UPS. 3 - 12. . . . . . . . . . .

3.7 - Normal Shutdown to Manual Bypass 3 - 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 - Setting Options 3 - 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1 - Setting options on the Relay card 3 - 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 4 - Operation and control4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 - Operator Control Panel 4 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 5 - Functional description 5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 - Control Logic PCB CS0072 5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 - Potentiometer adjustment 5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 - Link and Jumper functions 5 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 - Auxiliary Supply PCB CS0070 5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 - Battery Threshold settings 5 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3 - Driver Interface PCB CS007I 5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 - Bypass Voltage Threshold Adjustment 5 - 3. . . . . . . . . . . . . . . . . . . . . . . . .

5.3.2 - Link and Jumper functions 5 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 - Battery Charger CS0074 5 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.1 - Battery Charger Voltage Adjustment 5 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.2 - Link and Jumper Functions 5 - 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4.3 - Battery test 5 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5 - UPS monitor board PCB CS0077 5 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6 - Relay Interface PCB CS0082 5 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.1 - EPO Connections. 5 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6.2 - Optional Second Relay Interface PCB 5 - 6. . . . . . . . . . . . . . . . . . . . . . . . . .

5.7 - LCD MIMIC DISPLAY CS0075 5 - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.7.1 - Control panel indicator LEDs 5 - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 6 - Maintenance 6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 - Scheduled Maintenance 6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 - Daily Checks 6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2 - Weekly Checks 6 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.3 - Annual Maintenance 6 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 - Battery Maintenance 6 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 - Factors Effecting Battery Use 6 - 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2 - Battery Testing 6 - 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Manual

Table of Contents

Prelim Page iii3x3 UPS Preliminary Pages

Issue 1 - May 2001

6.2.3 - Battery capacity testing. 6 - 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 - Battery Replacement 6 - 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.4 - UPS Storage 6 - 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 7 - Troubleshooting 7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 - Introduction 7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 - General Fault Identification Procedure 7 - 1. . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 - Special Tools. 7 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3 - Removing the UPS Covers 7 - 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 - Component Location 7 - 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 - Fault Identification 7 - 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 -Typical Voltage Values7

7.7 -Fuse Check List7 - 12

- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 -Test Procedures7 - 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.1 - DC Bus Discharge Routine, Shutdown to Maintenance Bypass. 7 - 13. . .

7.8.2 -DC offset7 - 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.3 - IGBT Replacement 7 - 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.4 -IGBT testing7 - 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.5 - SCR Testing 7 - 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.6 - Inverter Drive Signal Testing 7 - 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8.7 -Checking power circuit capacitors.7 - 27. . . . . . . . . . . . . . . . . . . .

7.9 -PCB Replacement Procedures7 - 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9.1 - Auxiliary DC Ć DC Converter Part Nº OSDE0070 (PCB Label: CS0070 Exx) 7 - 28

7.9.2 - LCD UPS Monitor Board OSDE0077 (PCB Label: CS0077 Exx) 7 - 29. . . .

7.9.3 - Inverter Driver/Feedback Interface Part Nº OSDE0071 7 - 30. . . . . . . . . . . .

7.9.4 - 3ph TL Control Logic Part Nº OSDE0072 * (PCB Label: CS0072 Exx) 7 - 32. . .

7.9.5 - Battery Charger Part Nº OSDE0074 (PCB Label: CS0074) 7 - 34. . . . . . . .

7.9.6 - Input Filter Part Nº OSDE0079 (PCB Label: CS0079 Exx) 7 - 36. . . . . . . . .

7.9.7 - Operator Control Panel (LDC) Part Nº OSDE0075 (PCB Label: CS0075 Exx)7 - 36

Chapter 8 - Optional Equipment 8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 - Second Relay card (Optional) 8 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2 - Remote Alarm Panel 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.2.1 - Remote Alarm Panel connection 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3 - Upgrade Kit 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.4 - Isolation Transformer 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.5 - Internal Extended Battery Kit 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.6 - Battery Connecting Kit 8 - 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 9 - Spare Parts 9 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter 10 - Schematic Diagrams 10 - 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 - 13x3 UPS Overview

Issue 2 - November 2001

Chapter 1 - Overview

1.1 - Introduction

The aim of this chapter is to give a general overview of the, control principles and construction of the series onĆline Uninterruptible Power Supply (UPS).

The UPS is a standĆalone, single module, system designed to furnish a well regulated 3 phase power supply to a critical load, such as a computer, under all rated load and input supply conditions. The unit is of a category known as an `onĆline' UPS and is therefore permanently connected between the utility 3Ćphase supply and the load equipment and operational at all times

A battery provides the standĆby power source for the UPS when the input utility supply fails. The system offers the user the following advantages:

Increased power quality. The UPS has its own internal voltage and frequency regulator circuits

which ensure that its output is maintained within close tolerances independent of voltage and frequency variations on the utility power lines.

Increased noise rejection. By rectifying the input AC power to DC power, and then converting it

back to AC, any electrical noise present on the input utility supply line is effectively isolated from the UPS output, therefore the critical load sees only clean power.

Powewr blackout protection. If the utility power fails, the UPS continues to power the critical load

from its backĆup battery source, leaving the load immune from power disturbances ć even complete power blackouts.

1.2 - Equipment Construction

The equipment is constructed around a steel frame with removable panels. The door which can be seĆ cured with a key is opened to give easy access to the input, bypass, output, reserve line circuit breakers and battery C.B. fused switch, protecting them from accidental operation.

A string LED and control panel on the front of the cabinet permits the operator to monitor the UPS. The cabinet houses both the power components and the batteries. It is carried on four wheels. Jacking feet help to support the UPS, and also prevent it from moving once

it has been wheeled into its final position. These feet are also used to secure the equipment to its shipĆ ping pallet during transit.

Cooling is by internal fan. Air is drawn in from beneath the UPS and exhausted through ventilation grills of the front panel. These areas must be kept free of anything that may avoid the air flow into and out of the unit.

Figure 1-1Front view of cabinet.

Service ManualChapter 1 - Overview

Equipment Construction

1 - 23x3 UPS Overview

Issue 2 - November 2001

1.2.1 - Principle of operation

Normal operation

During normal operation, i.e. when the UPS input supply is present and within specification, both the converter and inverter sections are active and the automatic byĆpass is turned on to connect the inverter output to the critical load terminals. The battery fuseĆholder switch is also closed and the battery is thereĆ fore permanently float charged at the d.c. terminals voltage level.

Mains Failure

If the mains has a failure or is out of tolerance the converter will be supplied from the battery, while the Inverter will continue to operate for a period of time which depends on the load and the capacity of the battery. If the mains supply has not returned within this time, the Inverter will go off automatically and an alarm condition will appear on the UPS operator control panel.

Critical load will not be interrupted in the event of a drop or return of the AC power mains.

Return of power mains

When the mains returns within the required tolerance, the converter will be automatically supplied from mains, supplying power to the Inverter and recharging the battery at the same time. There will be no interruption of the critical load.

UPS fault

In the event of an inverter failure, the automatic byĆpass will automatically transfer the load onto the mains with no interruption. In such an event, request qualified technical assistance.

The load will be transferred with no interruption if the inverter is synchronised with the mains; if this is not the case, there will be an interruption of some milliseconds.

The intervention of the automatic byĆpass line is shown on the front panel by the yellow led on.

WARNING CAUTION: When the load is being supplied from the bypass line through the automatic byĆ

pass, it is connected directly to the mains supply and is therefore no longer protected against mains faults.

Maintenance Bypass

A second bypass circuit contained in the UPS cabinet, identified as the 'Maintenance Bypass' line is included to enable the reserve supply to be made available to the load while facilitating a safe working environment for carrying out scheduled UPS system maintenance or trouble shooting. The circuit is manually selected by the Manual Bypass Switch (3) which can be padlocked in the OFF position.

WARNING CAUTION CAUTION: If an automatic circuit breaker device is not present in the input disĆ

tribution panel, there remains a dangerous voltage at the output terminals and also on the input terminals of the UPS module that is switched off.

Note: The load is not protected from mains aberrations when operating on the

maintenance bypass mode.

Service Manual Chapter 1 - Overview

Equipment Construction

1 - 33x3 UPS Overview

Issue 2 - November 2001

Figure 1-2Split Bypass" configuration

UPS Output

UPS Input

Battery

UPS

Split

Bypass

Link

1.2.2 - UPS Power Configuration

Common Bypass

The UPS is factory set to operate in the Common Bypass" configuration. Split Bypass links shown in Figure 1-2 connect the Input Mains supply to the Reserve Input (Bypass) line creating a common input. A separate Reserve Input is therefore not required.

Split Bypass

To configure the with a Split Bypass input, the Split Bypass links shown in Figure 1-2 are removed by the commissioning engineer. In the Split Bypass" configuration the static bypass line is connected by a separate power switch to a dedicated `bypass' power source which also feeds the maintenance bypass line. Where a separate power source is not available the Reserve and Converter input supply connections would be linked together.

With the exception of the maintenance bypass switch (3), all the isolators shown must be closed during normal UPS operation.

1.2.3 - Battery fuses switch

The battery is connected to the d.c. bus through a battery fuses switch (5) fitted inside the UPS cabinet

2 - 13x3 UPS Installation

Issue 2 - November 2001

Chapter 2 - Installation

2.1 - Installation (Mechanical)

2.1.1 - Preliminary Checks

Before installing the UPS hardware the following preliminary checks must be carried out:

1. Verify that the UPS room satisfies the environmental conditions stipulated in the equipment specification, paying particular attention to the ambient temperature and air exchange system.

Material admittance

1. Remove any packaging debris, then visually examine the UPS and battery equipment for transit damage, both internally and externally. Report any such damage to the shipper immediately.

2. Ascertain that the material supplied corresponds with that on the freight bill.

Identification

The equipment supplied is provided with an adhesive identification label placed on the UPS rear panel reporting type of UPS model and power.

The cases used to transport the equipment must be unpacked as specified by the procedure stated below.

Packing material removal

During this operation observe the indications (FRAGILE, UP) printed on the case to avoid damaging the UPS

To remove the packing material proceed in the following manner:

1. Place the equipment on the floor as instructed on the outer case (UP, DOWN).

2. Cut the tape and open the flaps at the top of the cardĆboard box.

3. Remove the extruded elements used as protective packing.

4. Position the forks of the lifting truck under the UPS taking care not to damage the UPS castors and lift it a few centimetres from the floor. Back up the forklift and position the UPS. Lower to the floor.

Hinet is provided with wheels to allow ease of movement.

5. Retain the packing material. The original transit packing should be used if the equipment is be returned to the maintenance centre, or moved to another position.

6. Check that the equipment has not been damaged. Any damage should immediately be reported to the Sales Representative.

7. Locate the four battery fuses. Do not fit at this point.

8. Locate the door key and panel bolt spanner secured on the rear of the UPS. Retain for future use.

9. The operator manual and communication cable are located behind the hinged front door.

Moving the cabinets

WARNING Ensure that any lifting equipment used for moving the UPS cabinet has sufficient lifting caĆ

pacity. Ensure that the UPS weight is within the designated surface weight loading (Kg/cm2) of any handling equipment. See the UPS specification for weight details. The UPS can be lifted using a fork lift. Take care when using either method not to damage the UPS castors located on the bottom of the unit.

Service ManualChapter 2 - Installation

Installation (Mechanical)

2 - 23x3 UPS Installation

Issue 2 - November 2001

Locating the unit in the operating position

The UPS cabinets are fitted with castors on the base to allow ease of movement and positioning. When the equipment has been finally positioned ensure the adjustable feet are set so that the UPS will remain stationary and stable

Ensure the following considerations are observed when locating the equipment:

a) Easy connection.

b) Enough space to ensure good access when servicing the UPS.

c) Exchange of air sufficient enough to dispel heat produced by UPS.

d) Protection against atmospheric agents.

e) Protection against excessive humidity and very high heat sources.

f) Protection against dust.

g) Compliance with the current fire prevention regulations.

h) Operating environment temperature is within +20° C and +25° C.

The batteries are at maximum efficiency in this temperature range.

Clearances

Cooling air enters the module through ventilation grills located at the bottom of the cabinet and is exĆ hausted through the fan grills located on the front panel; you must therefore allow for a minimum gap of 170 mm behind the unit to allow adequate air flow. Clearance around the front of the equipment should be sufficient to enable free passage of personnel with the door fully opened.

Raised floor installation

If the equipment is to be located on a raised floor it must be mounted on a pedestal suitably designed to accept the equipment point loading. Refer to the base view to design this pedestal.

Cable entry

Cables enter the UPS cabinet from the rear.

UPS Mechanical Characteristics

Rated power kVA 10 15 20 30

Height mm 1220

Width mm 530

Depth mm 950

Weight:

Hinet cabinet 185

with 1 battery strings

275

with 2 battery strings

365

with 3 battery strings 455

with 4 battery strings 545

Ventilation Ć forced Airflow full speed

Air flow half speed

m3/h

600 300

Protection grade Ć IP 20

Cable entry Ć Bottom

Service Manual Chapter 2 - Installation

Installation (Electrical)

2 - 33x3 UPS Installation

Issue 2 - November 2001

2.2 - Installation (Electrical)

The UPS requires connection of the power cables once it has been mechanically installed. All auxiliary cables, whether screened or not, should be run separate from the power cables in metal conduits, or metal ducts electrically bonded to the cabinet metalwork to which they are connected.

2.2.1 - Power Cabling

WARNING BEFORE CABLINGĆUP THE UPS, ENSURE THAT YOU ARE AWARE OF THE LOCATION AND

OPERATION OF THE EXTERNAL ISOLATORS THAT CONNECT THE UPS INPUT/BYPASS SUPPLY TO THE MAINS DISTRIBUTION PANEL. CHECK THAT THESE SUPPLIES ARE ELECTRICALLY ISOLATED, AND POST ANY NECESSĆ ARY WARNING SIGNS TO PREVENT THEIR INADVERTENT OPERATION.

2.2.2 - Power Cable connections

The cable connection terminal block shown in Figure 2Ć1 is located at the rear of the cabinet.

1. Prepare the power cable ends and locate in the lower terminals of the terminal block.

2. Connect Input Mains to terminals 14 (U1), 15 (V1), 16 (W1) & 17 (N1).

Caution When preparing the power cables for connection, provide sufficient spare cable to allow

the UPS to be moved if necessary from it's normal operating position for servicing access. Spare cable can be coiled beneath the unit.

3. Tighten the terminal block lower securing screws and check that each cable is secure.

4. Connected the UPS Output power cables to terminals 1 (U2), 2 (V2), 3 (W2) & 4 (N2) as shown in Figure 2Ć1.

5. Secure the cables to the cable securing bar adjacent to the terminal block using appropriate cable clamps.

Note: If connecting a battery to the External Battery input connections ensure

that connections are made with the correct polarity.

Split Bypass Configuration

If the UPS is to operate with a separate Reserve Input (Bypass) supply.

1. Connect the power connections for the Bypass to terminals 10 (U3), 11 (V3), 12 (W3) & 13 (N3)

2. Connect the Input Mains to terminals to 14 (U1), 15 (V1), 16 (W1) & 17 (N1) as shown in

Figure 2Ć1.

Caution When the UPS is to be operated in the Split Bypass" configuration, the Split Bypass shortĆ

ing links must first be removed by the Commissioning Engineer before Power is applied to the unit.

Note: The maximum cable size that can be connected to the UPS power

terminal block is 25mm

Service ManualChapter 2 - Installation

Installation (Electrical)

2 - 43x3 UPS Installation

Issue 2 - November 2001

Figure 2-1Connections to distribution Terminal Block.

PE1U22V23W24N25+6+7ć8ć9U310V311W312N313U114V115W116N117PE

Ground

UPS Output Ext. Battery Input Reserve Input (Bypass) Input Mains

1.. Ground (ground lead for load connection) 2.. Input reserve (Bypass) phase U3

3.. Output phase U2 4.. Input reserve (Bypass) phase V3

5.. Output phase V2 6.. Input reserve (Bypass) phase W3

7.. Output phase W2 8.. Input Reserve (Bypass) Neutral N3

9.. Output Neutral N2 10.. Input Mains phase U1

11.. Battery Positive (ext. Battery input) 12.. Input Mains phase V1

13.. Battery Positive (ext. Battery input) 14.. Input Mains phase W1

15.. Battery Negative (ext. Battery input) 16.. Input Mains Neutral N1

17.. Battery Negative (ext. Battery input) 18.. Ground (Incoming ground wire from UPS input mains connected to this terminal)

Figure 2-2 Cable Securing Bar

Cable Securing Bar

Service Manual Chapter 2 - Installation

Installation (Electrical)

2 - 53x3 UPS Installation

Issue 2 - November 2001

2.2.3 - Safety Earth

The safety earth busĆbar is located near the UPS output terminals. The safety earth cable must be conĆ nected to the earth terminal and bonded to each cabinet in the system.

All cabinets and cable trunking must be earthed in accordance with local regulations.

WARNING FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN ELECTRIC

SHOCK HAZARD TO PERSONNEL, OR THE RISK OF FIRE, SHOULD AN EARTH FAULT OCCUR. BEFORE ANY OTHER CABLE CONNECTION THE PE SAFETY CONDUCTOR SHALL BE CONNECTED

2.2.4 - Protective devices

Protection against earth faults (RCD devices):

In the event of a differential (RCD) device being installed upstream of the input supply, the transient and steady state earth leakage currents that are produced during startĆup of the UPS must be taken into acĆ count.

The presence of an RFI suppression filter inside the UPS, determines a residual earth current no greater than 500 mA.

Residual current circuit breakers (RCCB) must be sensitive to d.c. unidirectional pulse (class A) in the mains and insensitive to transient current pulses.

Service ManualChapter 2 - Installation

Battery Installation

2 - 63x3 UPS Installation

Issue 2 - November 2001

2.3 - Battery Installation

All UPS models are normally shipped with an internal battery fitted, therefore a thorough check of the battery installation is required before applying power to the unit. The battery capacity, number of cells and installation is dependent on the unit power rating and autonomy option ordered. A full break down of the different battery configurations can be found in the Specification on preliminary page Ćxiii.

In addition to the standard battery fitted to the UPS extra strings may be added (to a maximum of 4) to upgrade the battery autonomy. Full fitting instructions for the battery upgrade are included with each kit, however this information has been also included in this section of the manual for continuity.

The UPS may also have an extended battery option to be fitted either in a separate or atĆ tached cabinet, therefore the same basic checks apply.

Before

2.3.1 - Battery Safety

WARNING THE BATTERY CHAIN IS A HIGH VOLTAGE ENERGY SOURCE. WHICH CAN BE VERY DANĆ

GEROUS GIVING A POTENTIAL RISK OF SHOCK OR BURNS. GREAT CARE SHOULD BE EXERCISED AT ALL TIMES WHEN WORKING WITH BATTERIES.

S Special care should be taken when working with the batteries associated with this

equipment.

S When connected together, the battery terminal voltage will exceed 380Vdc and is

potentially lethal.

S Eye protection should be worn to prevent injury from accidental electrical arcs.

S If a battery leaks electrolyte, or is otherwise physically damaged, it should be

placed in a container resistant to sulphuric acid and disposed of in accordance with local regulations.

S If electrolyte comes into contact with the skin the affected area should be washed

immediately.

2.3.2 - Battery Installation Check

1. Gain access to the battery safety cover by first opening the front hinged door.

a) Disconnect the Earth bonding cable from the safety cover.

b) Remove the two top M6 retaining bolts.

c) Release the two bottom retaining bolts and lift the cover from the UPS.

2. Remove the Main Switch Cover held by four M6 retaining bolts.

3. Carefully ease the cover away from the control switches.

Note:Each battery string are held in 3 trays positioned as

shown in Figure 2Ć3, up to four strings can be fitted dependent on model.

4. Check the battery security in each tray.

5. Check that the FastĆon connecters to each battery are secure and that each connector is correctly positioned on the battery terminals.

6. Check that the battery linking connectors are correct for each tray.

7. Check that the +ve cable from lower battery tray connector is connected to the correct battery fuse, as shown in Figure 2Ć4

8. Check that the ćve battery from the top battery tray connector is secured to the common battery ćve connection bar.

Service Manual Chapter 2 - Installation

Battery Installation

2 - 73x3 UPS Installation

Issue 2 - November 2001

Figure 2-3 Battery Tray Installation for one battery string

Battery Fuses (shown removed)

Battery Earth Bar

Battery String Voltage Check

Note: Battery fuses are removed for transit and should only be fitted by the

commissioning engineer. The fuses can be found with the User manual, in the document pocket on the battery safety cover.

Battery String Voltage check

1. Ensure the battery fuses are removed from the switched fuse holders.

Warning Do not fit the battery fuses into the fuse holders or close the fuse holders.

2. With a DVM set to a DC range of above 450V, check for each individual battery string voltage. This voltage for a serviceable battery should be between +385V and +416V DC.

3. Measure the battery string voltage from the lower connecting screw of the appropriate fuse holder and the battery ćve connection bar. As shown in Figure 2-3

4. If a voltage of less than +385V is recorded reĆcheck the battery connections and reĆtest the string voltage.

Note: A measured voltage substantially less then +385V DC may point to a

defective battery block this can be further isolated by disconnecting each individual tray and carry out a further check of each tray voltage. This should be grater than 132V for trays of 11 battery blocks and 120V for 10 blocks.

F1 F2 F3 F4

Battery Fuses

Battery ćve Connection Bar

Battery String 3 Top Battery Tray (10)

Battery String 3 Middle Battery Tray (11)

Battery String 3 Bottom Battery Tray (11)

CN1

CN2

CN3

Note: Battery strings 1 & 3 shown connected

Battery String 1 Top Battery Tray (10)

Battery String 1 Middle Battery Tray (11)

Battery String 1 Bottom Battery Tray (11)

CN1

CN2

CN3

Service ManualChapter 2 - Installation

Battery Installation

2 - 83x3 UPS Installation

Issue 2 - November 2001

Figure 2-4 Battery Cable Connections for one string

Service Manual Chapter 2 - Installation

Battery Installation

2 - 93x3 UPS Installation

Issue 2 - November 2001

2.3.3 -Installing the Battery Upgrade Kit

Note: Installation of a battery upgrade kit must only be carried out by a suitably

qualified, manufacturer approved engineer.

Kit Contents

Prior to installing the battery upgrade kit thoroughly check the items for damage and ensure that they are in a serviceable condition.

Check that the battery kit contains the following items:

Item Description Part Nº Quantity

Mylar insulating sheet CM 0319 3 Battery tray CM 0470 3 Battery retaining bracket CM 0743 3 Lexan protection CM 0101 3 Battery cable harness OS 001 1 Adhesive foam strip ? ć Cable holder self adhesive ? 9 Label `High Voltage' ? 3

Note: The 32 battery blocks are not included in the upgrade kit Part Nº

BATTCABLE, but are supplied separately as Battery Kit Part Nº INTBATT.

Figure 2-5 Battery Tray Assembly

Mylar Insulating Sheet

Battery Blocks (links fitted)

Lexan protection strip

Cable Holder

Battery Tray

Battery Cable

Retaining Bracket

Foam Strip

Battery Tray

Mylar Insulating Sheet (fold to fit batteries)

Battery Cable Connector (Secure to retaining bracket with cable tie)

Retaining Bracket

Cable Holder

Lexan protection strip

Service ManualChapter 2 - Installation

Battery Installation

2 - 103x3 UPS Installation

Issue 2 - November 2001

Battery Tray Assembly

1. Place the Mylar insulation strip on to the battery tray.

2. With a DVM check each individual battery block terminal voltage is within 12.5V to 13.0V. Voltages measured below this may indicate a defective battery block. Refer to `Battery

Maintenance' on Page 6Ć5 Chapter 6 `Maintenance' for information on battery testing.

3. Fold the mylar insulation to fit the batteries and place the 11 battery blocks on to the battery tray, as shown in Figure 2-5

(Note 10 battery blocks are fitted to the top battery tray.

4. Stick the adhesive foam strip to the battery fixing bracket.

5. Screw the battery retaining bracket to the battery tray. Connect the batteries using the short battery interconnecting links.

6. Fit the lexan protection to the battery fixing bracket.

7. Place the three adhesive cable retaining clips to the lexan insulating strip, one in the middle and one at each end.

8. Identify the cable Anderson type connecter supplied with a red and black interconnecting cable and connect the red cable to the remaining +ve battery connection and the black cable to the ćve battery connection.

9. Secure the cables in the cable retaining clips.

10. Secure the red cable to the battery retaining bracket at the rear of the assembled battery tray using a cable tie supplied.

11. Stick the `High Voltage' label to the lexan insulating strip.

Repeat the above procedure for the remaining two battery trays.

Note: The upper battery tray is fitted with 10 batteries.

Battery String Connection

1. Ensure that the UPS has been powered down.

Note: When positioning the battery trays in the UPS, slight downward pressure

may be required on the front of the tray to clear the chassis metalwork at the rear.

2. Fit the lower battery tray of 11 batteries to the lower position and secure using the battery tray retaining bolt.

3. Fit the second battery tray of 11 batteries to the middle position and secure using the battery tray retaining bolt.

4. Fit the upper battery tray of 10 batteries to the top position and secure using the battery tray retaining bolt.

5. Refer to the schematic diagram (Figure ) locate the battery string interconnecting links from the battery cable set.

6. Thread the Red +ve wire of the lower Anderson type cable connector through the appropriate access hole and connect it to the battery fuse lower cable terminal.

Note: Fuse F1 is used for the first battery string, F2 for the second etc.

7. Thread the Black ćve wire of the top Anderson type cable connector through the appropriate access hole and connect it to the ćve battery connection bar cable stud.

8. Connect the wiring harness connectors to the battery tray Anderson connectors.

a) CN1 to the top battery tray.

b) CN2 to the middle battery tray.

c) CN3 to the lower battery tray.

9. Secure the Anderson type battery connectors to the battery retaining bracket using the cable ties supplied with the kit.

Service Manual Chapter 2 - Installation

Battery Installation

2 - 113x3 UPS Installation

Issue 2 - November 2001

Battery String Voltage Check

1. Ensure the battery fuses are removed from the switched fuse holders.

Warning Do not fit the battery fuses into the fuse holders or close the fuse holders.

2. With a DVM set to a DC range of above 450V, check for each individual battery string voltage. This voltage for a serviceable battery should be between +385V and +416V DC.

3. Measure the battery string voltage from the lower connecting screw of the appropriate fuse holder and the battery ćve connection bar. As shown in Figure 2-3

4. If a voltage of less than +385V is recorded reĆcheck the battery connections and reĆtest the string voltage.

Note: A measured voltage substantially less then +385V DC may point to a

defective battery block this can be further isolated by disconnecting each individual tray and carry out a further check of each tray voltage. This should be greater than 132V for trays of 11 battery blocks and 120V for 10 blocks.

Service ManualChapter 2 - Installation

Setting Standard Relay Interface PCB

2 - 123x3 UPS Installation

Issue 2 - November 2001

2.4 - Setting Standard Relay Interface PCB

The preĆsettings required are only those which concern the interfaces wiring to any external devices, i.e., personal computer, safety switch, remote panel.

2.4.1 - Setting Options on the standard Relay Interface

A standard Relay Card is situated on the left side of the rear panel. This card is typically supĆ plied and is factory preĆset to operate with the PC.

When the operation is through the remote indication panel, the factory will deliver the card already preset to operate with the remote panel.

Figure 2-6 Setting options on the standard Relay Board

FUNCTION JUMPER CLOSED JUMPER OPEN

Use With PC JP4 JP5

Use With Remote Panel JP5 JP4

EPO Enabled ć JP6

EPO Disabled JP6 ć

Note: If an optional second relay interface PCB is to be fitted Refer to the `Relay

Interface PCB CS0082' on Page 5Ć7 Chapter 5 `Functional Description'

for further information on Link settings.

Service Manual Chapter 2 - Installation

Setting Standard Relay Interface PCB

2 - 133x3 UPS Installation

Issue 2 - November 2001

2.4.2 - Relay Interface Connections

The relay interface PCB provides two sets of volt free contacts rated at 50V 1A the PCB receives the UPS status signals from the Display Control Logic PCB Part Nº CS0073 and is connected to CN1.

Output signals from the relay interface are made to the terminal block M1 shown in Figure 2Ć7, or from the RS232 DB9 connector P1 (fitted to later equipment only).

Figure 2-7 Relay Interface Outputs

Service ManualChapter 2 - Installation

Setting Standard Relay Interface PCB

2 - 143x3 UPS Installation

Issue 2 - November 2001

2.4.3 - Remote EPO (Emergency Power Off)

A connection is provided for a switch, which can be located remotely from the UPS, and which has the same function as the internal EPO switch. When it is operated it shuts down the inverter, and inhibits the static switch so that power is removed from the load.

WARNING Pressing the Remote EPO push button will turn the inverter off and remove power from the

load. The mains input, bypass input and battery terminals still carry lethal voltages after pressing the EPO switch. Do not remove cover from these parts. Only competent personnel must remove protection panel held in place with screws.

2.4.4 - Emergency Power Off (E.P.O.) pushĆbutton connection

Refer to Figure 2-6 and Figure Figure 2-7 to make a pushĆbutton connection to the standard Relay Card.

1. Obtain a suitable length (not more than 100 m.) twoĆwire cable (0.6 sq. mm cross section)

2. Connect one end of the cable to the N.C. pins of a fire preventing button.

3. Connect the other end to the standard Relay Card connector M2.

2.4.5 - Connection to Personal Computer

The UPS contains a standard DB9 Female connector located on the rear of the UPS.

Several signals are provided on this port and assigned as follow:

PIN Description

1 Low Battery (N.O.)

2 T.B.D.

3 T.B.D.

4 N.C.

5 Common

6 N.C.

7 Low Battery (N.O.)

8 Mains Fail (N.O.)

9 Mains Fail (N.O.)

Service Manual Chapter 2 - Installation

Setting Standard Relay Interface PCB

2 - 153x3 UPS Installation

Issue 2 - November 2001

2.4.6 - UPS Monitoring

The UPS has the capability of being monitored with stand alone computers, network workstations, network servers, or UNIx hosts via the DBĆ9 female connector (1) located on the rear of the UPS.

The capability is used in applications requiring the UPS to provide status and power monitoring informaĆ tion to the computer system. For example, during a mains power failure, the information can be used by the computer's operating system or application program to automatically save information in buffers, to close files, and shutdown operations prior to battery capacity depletion.

Monitoring of the UPS via a computer system is easily made with a Liebert Multilink Software and a special cable (2) shipped with the Unit.

Figure 2-8 UPS Monitoring cable connection

3 - 13x3 UPS Commissioning

Issue 2 - November 2001

Chapter 3 - Commissioning

3.1 - PreĆpower Checks

WARNING The UPS must be commissioned by a suitably qualified, and manufacturer approved enĆ

gineer. Failure to ensure proper commissioning may invalidate any implied warranty.

WARNING During the commissioning procedure the UPS output terminals will become live.

If any load equipment is connected to the UPS output terminals, fully isolate it from the UPS to ensure that no damage is caused in the extremely unlikely event of a UPS failure

WARNING During the commissioning procedure it may be necessary to power up the unit with the side

or top covers removed, in this situation exposure to potentially lethal voltages is possible even with the input utility supply switched off. Take great care at all times to minimise the risk of contact with live voltages, especially when working around the battery or the dc busbar.

3.2 - Validating the Installation

Before carrying out the following checks, refer to the `Installation Manual' supplied with the equipment or the information contained in Chapter installation in this manual.

3.2.1 - Positioning

1. Check that the UPS has been correctly positioned with at least 150mm clear space at the rear.

2. Check that there is sufficient space at the sides of the unit to gain access. If no access is available the UPS input and output cabling must be of sufficient length to allow the unit to be moved forward.

3.2.2 - Preliminary checks

1. Ensure that all the UPS isolators, including he fused battery switch, are open (i.e. OFF or in position `0').

2. Check the voltage of the input mains supply.

3. Check that the cable connections to the distribution terminal block are correct. Refer to

Figure 2Ć1 on page 2Ć4.

4. Check that the internal battery connections are secure and any external battery connected to the Ext.Battery Input terminals are connected in the correct polarity. Refer to the `Battery

Installation' procedure on page 2Ć6.

Input mains voltage checks

1. Apply mains voltage to input terminals 14 (U1), 15 (V1), 16 (W1) & 17 (N1).

2. Measure line to line voltage of all three phases and ensure that the values are within ±10% of

nominal rating.

3. Ensure correct phase rotation clockwise R, S, T using an oscilloscope or phase rotation meter

Note: If a split bypass is fitted, apply bypass mains voltage to the bypass

terminals 10 (U3), 11 (V3), 12 (W3) & 13 (N3) and duplicate the check for the Input Mains.

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 2 3x3 UPS Commissioning

Issue 2 - November 2001

3.3 - Setting UPS Parameters

Check that the following factory set parameters are correct for the normal operating Conditions of the UPS.

Standard link positions are shown in bold text.

3.3.1 - Control Logic PCB CS0072.

General Operation:

LINK POSITION FUNCTION

OPEN Eco mode operation (bypass line preferred)

CLOSED

Normal operation (inverter line preferred)

OPEN Bypass frequency window 4%

CLOSED Bypass frequency window 1%

OPEN Inverter output frequency 60Hz

CLOSED Inverter output frequency 50Hz

Output voltage selection:

Link 380Vac 400Vac 415Vac

J4 Open Closed Open J5 Closed Open Open

The following link position set the UPS overload level relative to the UPS kVA rating. (As shown on the factory rating plate)

Link 10kVA 20kVA 30kVA

J6 Open Closed Open J7 Closed Open Closed J8 Closed Closed Open

The following link position set the inverter and converter peak current limits which is dependent on the UPS kVA rating. (as shown in the factory rating plate). Ensure that these links are set according to the following table:

Link 10kVA 20kVA 30kVA

J9 Open Open Open J10 Open Open Open J11 Closed Closed Closed J12 Closed Closed Closed

3.3.2 - Driver Interface PCB CS0071 Settings

Bypass value setting

Link 380Vac 400Vac 415Vac

J1A Closed Open Open J2A Open Closed Open

J3A

Open Open Closed

Service / test mode for the secondary DC bus voltage

DC V/Link J4A J5A

375 Vdc Closed Closed

750Vdc Open Open

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 33x3 UPS Commissioning

Issue 2 - November 2001

3.3.3 - Auxiliary DC-DC PSU Converter PCB CS0070 Settings

No link setting are required.

3.3.4 - Battery Charger PCB CS0074 Setting

Set the correct battery current limit according to the following link chart.

Link/Ampere 1Amp 3Amps 5Amps

JP1 Open Open Closed JP2 Open Closed Open

We recommed to used the following battery current limint setting:

Battery size 7.5 Ah 2x7.5Ah 3x7.5Ah 4x7.5Ah

Battery current 1Amp 1Amp 3Amps 3Amps

Link Position Function

Open Boost recharge disable

JP3

Closed Boost recharge enable

Open Battery charger temperature compensation disable

JP4

Closed Battery charger temperature compensation enable

Battery test settings

Links JP5 to JP10 set the capacity of the standard battery, check the battery Ah to set the corĆ rect value as shown in the table below

Link JP10 JP9 JP8 JP7 JP6 JP5

Ah 7.2Ah 2x7.2Ah 3x7.2Ah 4x7.2Ah 38Ah 65Ah

JP11 SHOULD BE ALWAYS CLOSED

Set the automatic battery test interval referring to the table below (it is recommanded to use 48h)

Link J4 J5 J6

Time 12Hours 24Hours 48Hours

3.3.5 - LCD Display Monitor Board CS0077 Settings

Used for PCB testing porposes only.

Link Position Funktion

JP1 1–2 close for normal operation. JP3 2–3 close for normal operation.

Note: THE SILKSCREEN IDENT (JP1/JPS) IS NEXT TO PIN NUMBER 3.

LINK JP2 ( External EPO ):

JP2 is used to enable the operation of the optional external EPO.

Link Ext EPO fitted Ext EPO not fitted

JP2 Open Close

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 43x3 UPS Commissioning

Issue 2 - November 2001

3.4 - Initial UPS Start-up.

The following procedure describes the start-up and calibration of the UPS at the initial Start-up.

Figure 3-1 Operator Control Panel

Note: The following instructions refer to the controls on the UPS OPERATOR PANEL

(shown above). The user interface consits of 4 status indica tor LEDs (la bled 1-4), a LCD panel and 4 control push buttons (labled a-d).

3.4.1 - Converter and Inverter Output Calibration.

The Secondary DC bus and Inverter Output settings will be automatically set by the Voltage parameters set on the UPS Control Boards (see Setting UPS Parameter Section for more details). The following table shows the correct levels of the Inverter AC volts and the Secondary DC Bus volts, depending on the Voltage Parameters:

Voltage Parameter/

Inverter AC (L–L) Voltage.

Secondary DC Bus Voltage.

380Vac 715Vdc 400Vac 750Vdc 415Vac 800Vdc

Before starting the UPS connect a DVM set to DC volts to the UPS Secondary DC bus as shown below:

Figure 3-2 DC Bus Voltage check

Check Secondary DC bus between Fuse F3 & F2 765V DC

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 53x3 UPS Commissioning

Issue 2 - November 2001

1. Close the MAINS INPUT MCB (I1).

2. Close the UPS OUTPUT MCB (I4).

3. Wait approx. 20 seconds and check that the following sequence occurs:

D The Operator display Panel LCD energises (if required adjust Language settings as described in

chapter 4).

D The Red `ALARM' (2) LED illuminates. D The Alarm Buzzer sounds. D The Secondary DC Bus has risen to approx. 650Vdc (shown on the DVM).

4. Start the Inverter using the following procedure: a) Press the `MENU' push button (a) on the FRONT PANEL. b) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. c) Confirm the `COMMAND' menu selection by pressing the `BACK' and `NEXT' push-buttons at the same

time (i.e. ENTER). d) Select the `INVERTER ON- OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) To start Inverter, press `BACK' and `NEXT' at the same time.

D A *CONFIRMED* message will be displayed.

D The Inverter Section will now be started and be brought on-line.

f) Press `CLEAR' (d) twice to return to the main menu.

5. Wait 20 seconds and confirm that:

D The Green `LOAD on INV' LED has illuminated. D Using the DVM check that the Secondary DC has risen to within 1% of the appropriate level shown in the

table above (e.g. 750Vdc for a 400Vac installation).

If required the level of the secondary DC bus can be adjusted using the Potentiometer P2 on the 3 Phase Control Logic PCB (CS0072). Note: Turn P2 Counter-Clock Wise (CCW) to increase the Secondary DC Bus.

6. Remove the DVM from the DC bus, set it to AC Volts and reconnect to the UPS output terminals (2 and 3) to give a Line to Line voltage measurement. As shown below:

Figure 3-3Connections to distribution Terminal Block

PE1U22V23W24N25+6+7ć8ć9U310V311W312N313U114V115W116N117PE

Ground

UPS Output Ext. Battery Input Reserve Input (Bypass) Input Mains

7. Check that the Inverter Output Voltage has risen to within 1% of the appropriate level (e.g. 400Vac).

If required the level of the Inverter AC can be adjusted using the Potentiometer P1 on the 3 Phase Control Logic PCB (CS0072). Note: Turn P1 Counter-Clock Wise (CCW) to increase the Inverter Output Voltage.

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 63x3 UPS Commissioning

Issue 2 - November 2001

3.4.2 - Inverter to Bypass Synchronisation Check.

The following procedure describes the checking of the Inverter Phase-lock-loop circuit.

1. Using an appropriate oscilloscope connect: Probe 1 to the Reserve Mains `U' phase voltage (termial 10). Probe 2 to the UPS Output `U' phase voltage (terminal 2).

Note:Note: Use the Reserve Mains Neutral (termial 13) should be used a common

reference, therefore the scope channels should be set to differential mode.

2. Close the RESERVE MAINS MCB (I2).

3. Ensure that:

D The LCD shows the message:

BYPASS LINE WITHIN LIMITS

D The Zero crossings of the Inverter and Bypass sinewaves are synchronised.

3.4.3 - Battery Charger Output Calibration.

The following procedure describes the calibration of the UPS's Battery charger output.

Connect a DVM set to DC Volts to the UPS's External Battery terminals (+ve at terminals 6 or 7 and ćve at terminals 8 or 9).

Ensure that:

D The DC value at the battery terminals is at 432Vdc +/-1%.

If required the Battery Charger voltage can be adjusted using the potentiometer P1 on the Battery Charger Board (CS0070).

Note: Turn P1 Counter-Clock Wise (CCW) to increase the Battery Charger Output Voltage.

Insert the appropriate number of fuses into the INTERNAL BATTERY Fused Switch (I5) and Close.

Ensure that:

The red `ALARM' LED extinguishes.

The green `NORMAL' LED illuminates.

The LCD shows a `- UPS in Operation ć` heading.

THE START UP AND CALIBRATION OF THE UPS IS NOW COMPLETE.

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 73x3 UPS Commissioning

Issue 2 - November 2001

3.5 - Power Checks

Once the initial start up and commissioning have been completed the UPS should be functionally checked and before connecting to the critical load.

The following procedure describes the recommended functional checks:

3.5.1 - Bypass failure test.

3.5.2 - Mains failure checks.

3.5.3 - Load Transfer Test

3.5.4 - Maintenance bypass check.

3.5.5 - Internal EPO check.

3.5.6 - External EPO (if required).

3.5.1 Bupass Failure Test

The purpose of this test is to ensure that the UPS correctly recognises a Bypass failure (simulated by opening the Reserve MCB) and that the Inverter remains stable.

1. Open the `RESERVE INPUT' MCB. ( I2 ).

2. On the LCD ensure that the following alarms are displayed:

D UPS ALARM ć (heading) D MAINS WITHIN LIMITS. D BATTERY VOLTAGE WITHIN LIMITS. D INVERTER OPERATING. D LOAD ON INVERTER. D BYPASS LINE OUT OF LIMITS.

D The green `NORMAL' LED ( 1 ) will extinguish. D The red `ALARM' LED ( 2 ) will illuminate. D The green `LOAD on INV' LED ( 3 ) remains illuminated. D The alarm buzzer should sound, press `CLEAR' (d) push button to silence the alarm.

3. Using a DVM check that the output Voltage and frequency at output terminals is correct (e.g. 400Vac and 50Hz).

4. Close the `RESERVE INPUT' MCB. ( I2 )

5. The UPS should now return to normal Operation. Ensure that:

D The `ć UPS in Operation ć` returns to the LCD. D The green `NORMAL' LED ( 1 ) has illuminated, D The red `ALARM' LED ( 2 ) has extinguished, D The yellow `BYPASS ON' LED ( 4 ) has extinguished D The green `LOAD-on-INV' LED ( 3 ) has illuminated.

3.5.2 Mains Failure Checks

The purpose of this test is to ensure that the UPS correctly recognises a Mains Failure (Simulated by opening the MAINS INPUT MCB) and is able to operate from the internal Battery.

1. Open the `MAINS INPUT' MCB. ( I1 )

2. On the LCD ensure that the following alarm are displayed:

D UPS ALARM ć (heading) D MAINS OUT OF LIMITS. D BYPASS LINE WITHIN LIMITS. D INVERTER OPERATING. D INVERTER-BYPASS LINE SYNCHRONIZED. D LOAD ON INVERTER. D The green `NORMAL' LED ( 1 ) has extinguished.

D The red `ALARM' LED ( 2 ) has illuminated. D The green `LOAD on INV' LED ( 3 ) remains illuminated. D The Alarm buzzer should sound, press `CLEAR' (d) push button to silence the alarm.

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 83x3 UPS Commissioning

Issue 2 - November 2001

3. Using a DVM check that the output Voltage and frequency at output Terminals is correct (e.g. 400Vac and 50Hz). Using a DVM check that the Battery Voltage at the battery Terminals is correct (405V +/- 10V).

4. Close the `MAINS INPUT' MCB (I1).

The UPS should now return to normal Operation. Ensure that:

D The `ć UPS in Operation ć` returns to the LCD.

D The green `NORMAL' LED ( 1 ) has illuminated, D The red `ALARM' LED ( 2 ) has extinguished, D The yellow `BYPASS ON' LED ( 4 ) has extinguished D The green `LOAD-on-INV' LED ( 3 ) has illuminated.

3.5.3 Test Transfer to the Reserve Line (Automatic Bypass).

Testing the transfer to the reserve bypass line, is carried out by forcing the automatic By-pass circuit to switch and then checking that the load is still being powered.

If no other alarms occur, the UPS will automatically re-transfer back to inverter operation after 20 seconds on completion of the test.

1. Press the `MENU' push button (a) on the FRONT PANEL. a) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER). c) Select the `SWITCH LOAD' function by pressing either `BACK' or `NEXT'. d) Confirm `SWITCH LOAD' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

2. Press `CLEAR' (d) twice to return to the main menu.

The follow change over sequence will should occur:

D The yellow `BYPASS ON' LED ( 4 ) will be illuminated (UPS ON BYPASS) D After 20 seconds the yellow `BYPASS ON' LED ( 4 ) will turn off and the load will be re-transferred back

to inverter.

D The green `LOAD on INV' LED ( 3 ) will illuminate (UPS ON INVERTER).

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 93x3 UPS Commissioning

Issue 2 - November 2001

3.5.4 Manual Bypass Operation Check

The manual bypass allows the UPS to be switched OFF while the critical load is maintained.

The following procedure describe the confirmation of this function.

D A ***CONFIRMED*** message will be displayed

2. Press `CLEAR' (d) twice to return to the main menu.

The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:

D The yellow `BYPASS ON' LED ( 4 ) is illuminated D The green `LOAD on INV' LED is extinguished.

3. To turn off the Inverter follow the procedure below: a) Press the `MENU' push button (a) on the FRONT PANEL. b) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER). d) Select the `INVERTER ON-OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) Confirm `INVERTER OFF' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

f) Press `CLEAR' twice to return at the main screen.

4. The follow sequence should occur:

D The Alarm buzzer is activated.

D The Red general `ALARM' red LED ( 2 ) will illuminate. D The Yellow `BYPASS ON' LED ( 4 ) will illuminate. D The Green `NORMAL' LED will extinguish. D The LCD will display the following messages:

`LOAD ON BYPASS' and `INVERTER OFF'.

5. Remove the Mechanical Lock from the MANUAL BYPASS MCB ( I3 )

6. Close the. MANUAL BYPASS MCB ( I3 )

7. Open the `UPS OUTPUT' MCB ( I4 ).

8. Open the `MAINS INPUT' MCB ( I1 ).

9. Open the `RESERVE INPUT' MCB ( I2 ).

10. Open the `INTERNAL BATTERY' fused switch ( I5 ).

11. Check that the load continues to be powered from the Maintenance Bypass Mains supply while the UPS is off.

RETURN FROM MANUAL BYPASS TO NORMAL OPERATION

1. Close the `RESERVE INPUT' MCB. ( I2 )

D wait until the fan is running, indicating that the output voltage is present.

2. Close the `MAINS INPUT' MCB. ( I1)

Wait until the Operator panel shows the following indications:

D LCD is energize and D The alarm buzzer sounds. D The red `ALARM'LED ( 2 )

D The yellow `BYPASS ON' LED will illuminate.

3. Close the `INTERNAL BATTERY' fused switch. ( I5 ).

4. Close the `UPS OUTPUT' MCB. ( I4 ).

5. Open the `MANUAL BYPASS' MCB. ( I3 ).

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 103x3 UPS Commissioning

Issue 2 - November 2001

d) Select the `INVERTER ON- OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) Confirm `INVERTER ON' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

f) Press `CLEAR' (d) twice to return at the main screen.

7. Within approximately 20 sec. and the follow sequence should occur:

D The green `NORMAL' LED ( 1 ) has illuminated. D The red `ALARM' LED ( 2 ) has extinguished. D The yellow `BYPASS ON' LED ( 4 ) has extinguished. D The green `LOAD-on-INV' LED ( 3 ) has illuminated.

Place the mechanical lock, onto the `MANUAL BYPASS' MCB.

The UPS is now in the normal operating condition with the Inverter supplying the load.

3.5.5 Local EPO

The following procedure describes the testing of the UPS's Emergency Power Off (EPO) functions. The activation of the EPO circuit will shutdown all UPS functions, causing the disconnection of the Critical Load.

Ensure that it is safe to carry out this test before proceeding.

1. Press the front panel EPO push button and hold it for at least 3 seconds to confirm it.

2. All UPS functions will stop and UPS will disconnect the critical load. Check that the following indications are seen:

D The Alarm buzzer sounds. D The red `ALARM' LED has illuminated. D The green `NORMAL' LED has extinguished D The green `LOAD-on-INV' has extinguished. D The LCD shows the alarm `EMERGENCY POWER OFF'.

To restart the UPS after an EPO, carry out the following procedure:

1. Open the `UPS OUTPUT' MCB. ( I4)

2. Open the `INTERNAL BATTERY' fused switch. ( I5 )

3. Open the `RESERVE INPUT' MCB. ( I2 )

4. Open the `MAINS INPUT' MCB. ( I1 )

D Wait until the display has de-energized.

5. Restart the UPS by following the start up procedure in chapter 3.4.

3.5.6 External EPO

Ensure that it is safe to carry out this test before proceeding.

1. Press the External EPO push button and hold it for at least 3 seconds to confirm it.

2. All UPS functions will stop and UPS will disconnect the critical load. Check that the following indications are seen:

To restart the UPS after an EPO, carry out the following procedure:

3. Open the `UPS OUTPUT' MCB. ( I4)

4. Open the `INTERNAL BATTERY' fused switch. ( I5 )

5. Open the `RESERVE INPUT' MCB. ( I2 )

6. Open the `MAINS INPUT' MCB. ( I1 )

D Wait until the display has de-energized.

7. Restart the UPS by following the start up procedure in chapter 3.4.

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 113x3 UPS Commissioning

Issue 2 - November 2001

3.6 - Normal UPS Start-Up Instructions

After calibration the following procedure can be used to activate the UPS:

Figure 3-4ups power switches

RESERVE INPUT MCB

MAINS INPUT MCB

MANUAL BYPASS MCBI4UPS OUTPUT MCBI5INTERNAL BATTER Y

FUSED SWITCH

1. Close the RESERVE INPUT MCB (Miniature Circuit Breaker) (I2).

2. Close the UPS OUTPUT MCB (I4).

D Wait until the fan is running, indicating that the output voltage is present.

3. Close the MAINS INPUT MCB (I1).

D The display will energize, the `BYPASS ON' (4) and the `ALARM' (2) LEDs will illuminate (see figure 3-3).

D The Alarm Buzzer will sound.

4. Fit the battery fuses into the fused battery switch. (The fuses are removed for transit and can be found with the User manual in the document pocket on the battery safety cover).

5. Close the `INTERNAL BATTERY' fused switch. (I5).

6. Check the status of the UPS Operator Panel:

D The Amber `BYPASS ON' ( 4 ) LED will be illuminated

D The red `ALARM' (2) led will be illuminated.

D The LCD will display the following messages:

MAINS WITHIN LIMITS; BY-PASS LINE WITHIN LIMITS; BATTERY VOLTAGE WITHIN LIMITS; LOAD ON BY-PASS and INVERTER OFF.

7. To Silence the buzzer press the`CLEAR' (d) push button.

8. To Start the Inverter carry out the following instructions:

a) Press the `MENU' push button (a) on the FRONT PANEL. b) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.

c) Confirm the `COMMAND' menu selection by pressing the `BACK' and `NEXT' push-buttons at the same

time (i.e. ENTER).

d) Select the `INVERTER ON- OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) To start Inverter press `BACK' and `NEXT' at the same time.

D A *CONFIRMED* message will be displayed.

D The Inverter Section will now be started and be brought on-line.

f) Press `CLEAR' (d) twice to return to the main menu.

9. After 20 seconds:

D The Amber `BYPASS ON' LED ( 4 ) will extinguish.

D The Green `LOAD on INV'LED will illuminate.

D the Green `NORMAL' LED will illumunate.

THE UPS IS NOW IN THE NORMAL OPERATING CONDITION.

Service ManualChapter 3 - Commissioning

Validating the Installation

3 - 123x3 UPS Commissioning

Issue 2 - November 2001

3.6.1 - LCD Messages and LED status after starting the UPS.

During the Normal Operation of the UPS LCD panel will show the following messages:

D MAINS WITHIN LIMITS.

D BYPASS LINE WITHIN LIMITS.

D BATTERY VOLTAGE WITHIN LIMITS.

D INVERTER OPERATING.

D INVERTER-BYPASS LINE SYNCHRONIZED.

D LOAD ON INVERTER.

D The `NORMAL' green LED ( 1 )and the `LOAD on INV' green LED ( 3 ) are illuminate. The buzzer alarm is off.

Note:Note: for a full explanation of the control panel LCD and LED function refere to

chapter 4.

3.7 - Normal Shutdown to Manual Bypass

After calibration the following procedure can be used to shutdown the UPS to a Manual bypass condition, and then to normal operation:

c) Select the `SWITCH LOAD'function by pressing either `BACK' or `NEXT'. d) Confirm `SWITCH LOAD' function by pressing `BACK' and `NEXT' at the same time.

D A *CONFIRMED* message will be displayed

2. Press `CLEAR' (d) twice to return to the main menu.

The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:

D The yellow `BYPASS ON' LED ( 4 ) is illuminated

D The green`LOAD on INV' LED is extinguished.

c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER). d) Select the `INVERTER ON-OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) Confirm `INVERTER OFF' function by pressing `BACK' and `NEXT' at the same time.

D A **CONFIRMED** message will be displayed

f) Press `CLEAR' twice to return at the main screen.

4. The follow sequence should occur:

a) The Alarm buzzeris activated. b) the Red general `ALARM' red LED ( 2 ) will illuminate. c) the Yellow `BYPASS ON' LED ( 4 ) will illuminate.

d) the Green `NORMAL' LED will extingaquish. e) The LCD will display the following messages:

`LOAD ON BYPASS' and `INVERTER OFF'.

5. Remove the Mechanical Lock from the MANUAL BYPASS MCB ( I3 )

6. Close the. MANUAL BYPASS MCB ( I3 )

7. Open the `UPS OUTPUT' MCB ( I4 ).

8. Open the `MAINS INPUT' MCB ( I1 ).

9. Open the `RESERVE INPUT' MCB ( I2 ).

10. Open the `INTERNAL BATTERY' fused switch ( I5 ).

11. Check that the load continues to be powered from the Maintenance Bypass Mains supply while the UPS is off.

Service Manual Chapter 3 - Commissioning

Validating the Installation

3 - 133x3 UPS Commissioning

Issue 2 - November 2001

RETURN FROM MANUAL BYPASS TO NORMAL OPERATION

1. Close the `RESERVE INPUT' MCB. ( I2 )

D wait until the fan is running, indicating that the output voltage is present.

2. Close the `MAINS INPUT' MCB. ( I1)

Wait until the Operator panel shows the following indications:

D LCD is energize and D The alarm buzzer sounds. D The red `ALARM'LED ( 2 ) D The yellow `BYPASS ON' LED will illuminate.

3. Close the `INTERNAL BATTERY' fused switch. ( I5 ).

4. Close the `UPS OUTPUT' MCB. ( I4 ).

5. Open the `MANUAL BYPASS' MCB. ( I3 ).

6. Start the inverter as follow: a) Press the `MENU' push button (a) on the FRONT PANEL. b) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER). d) Select the `INVERTER ON- OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button. e) Confirm `INVERTER ON' function by pressing `BACK' and `NEXT' at the same time.

D A **CONFIRMED** message will be displayed

f) Press `CLEAR' (d) twice to return at the main screen.

7. Within approximately 20 sec. and the follow sequence should occour:

D The green `NORMAL' LED ( 1 ) has illuminated. D the red `ALARM' LED ( 2 ) has extinguished. D the yellow `BYPASS ON' LED ( 4 ) has extinguished. D the green `LOAD-on-INV' LED ( 3 ) has illuminated.

8. Place the mechanical lock, onto the `MANUAL BYPASS' MCB, or secure with a Pad-lock.

The UPS is now in the normal operating condition with the Inverter supplying the load.

Service ManualChapter 3 - Commissioning

Setting Options

3 - 143x3 UPS Commissioning

Issue 2 - November 2001

3.8 - Setting Options

The preĆsetting checks required are to the relay interfaces PCB links and wiring, to any fitted external devices, i.e. personal computer, EPO switch, remote panel.

3.8.1 - Setting options on the Relay card

The relay card is supplied as an option at the customers request. If supplied the card shall have to be preset according to specific Customer requirements.

The link configuration required for the application with a PC or with the remote indication panel is deĆ scribed in the following table. Output signals from the relay interface are used for the control of customer peripheral computer equipment and connections are made to the terminal block M1 shown in Figure

3Ć6, or from the RS232 DB9 connector P1 (fitted to later equipment only).

Figure 3-5 Setting options on the Relay card

Table 3-1 Relay Interface PCB Output

Link

Relay UPS Function Signal Function

JP4 JP5

Mains NOT OK Closed Open

RL1 MAINS STATUS

Mains OK Open Closed

RL2 BYĆPASS ON

RL3 UPS Ć RUN

No associated link

RL4

PREĆALARM

No associated link

Links fitted to the PCB allow the input mains status to be set and the serial port P1 to be enabled as shown in Table 3-2. These signals are generated on the display control logic PCB and connected to the relay PCB at connector CN4.

Service Manual Chapter 3 - Commissioning

Setting Options

3 - 153x3 UPS Commissioning

Issue 2 - November 2001

Table 3-2 Serial Port P1 DB9 Connector Connections

Link

Nº

Function Relay

JP1 JP2 JP3 JP4 JP5

5 COMMON N/A Closed ć ć

3 UPS RX N/A ć Closed ć

2 UPS TX N/A ć ć Closed

89MAINS

STATUS

RL1 ć

MainsĆ

NOK

MainsĆOK

1 7

PRE ALARM RL4 ć

Figure 3-6 Relay Interface Outputs

4 - 13x3 UPS Operation and control

Issue 2 - November 2001

Chapter 4 - Operation and control

4.1 - Operator Control Panel

Introduction

On the front of the UPS there is a control panel, from which it is possible to easily verify the status of the UPS, battery and alarms. The operator control panel consists in a LCD display that indicates the operational and alarm status of the UPS and the EPO push-button that is located at the left side. The LCD Display Panel displays textual messages and operating parameters on a LCD screen capable of showing 4 rows of 20 characters. The displayed screen is organized in a multi-level menu system and selected by using push button located to the right of the screen

Figure 4-1 UPS Operator control panel

LCD control panel

Figure 4-2 LCD Display make-up

Service ManualChapter 4 - Operation and control

Operator Control Panel

4 - 23x3 UPS Operation and control

Issue 2 - November 2001

Control panel indicator LEDs

The Table 4-1 shows that the menu contains three levels. The main level is the State and Alarm Menu. In this menu it is possible to see the state and operative condition of the UPS, the CLEAR Button is used to scroll through the different windows of this menu. From the main menu the User may have access to different menu pressing the MENU Button (second level). Once in this level the first row will show < menu choice > and the NEXT and BACK push Button enable the User to move from one menu level to another. Pressing both NEXT and BACK push button at the same time the ENTER command is selected and the next lower level will be reached, while CLEAR take you back to the previous level. To verify the acquisition of ENTER a Beep will be heard and CONFIRMED will appeared on the Display. The NEXT/BACK selector keys are used to scroll through different windows in the same menu.

Table 4-1 LCD Display Main Menu Path

STATUS ALARM MENU

CLEAR

ENTER

BACK

COMMAND MODE

BACK

EVENT HISTORY

BACK

OPERATING LANGUAGE

BACK

CLOCK

UPS CONFIGURATION

BACK

BATTERY TEST

BACK

SWITCH LOAD

INVERTER ON–OFF

BACK

DISPLAY EVENTS

DELETE EVENTS

ENTER

NEXT BACK

ITALIAN

BACK

ENGLISH

FRENCH

BACK

GERMAN

SPANISH

ENTER

BACK

SERIAL NUMBER

BACK

PHONE NUMBER

BATTERY CAPACITY

ENTER

BACK

CALIBRATION

BACK

DATE

HOUR

ENTER

CLEAR

BATTERY VOLTAGE WITHIN LIMITS

BYPASS LINE WITHIN LIMITS

MAIN WITHIN LIMTTS

INVERTER – BYPASS SYNCRONISED

LOAD ON INVERTER

LOAD ON BYPASS

INVERTER OPERATING

CLEAR

Service Manual Chapter 4 - Operation and control

Operator Control Panel

4 - 33x3 UPS Operation and control

Issue 2 - November 2001

From the main menu (STATUS ALARMS MENU) the User may have also access to the Input/Output measured paraĆ meters and the internal parameters as well as the UPS temperature and the battery back-up time. To scroll through these parameters use Next and Back Push Buttons. (see Table 4-2)

Table 4-2 Input/Output Parameters Menu

STATUS ALARM MENU

INPUT VOLTAGE Phase/Neutral Vrn,Vsn,Vtn

BACK

NEXTBACK

INPUT VOLTAGE Phase/Phase Vrs,Vst,Vtr

NEXTBACK

OUTPUT VOLTAGE Phase/Neutral Vrn,Vsn,Vtn

NEXTBACK

OUTPUT VOLTAGE Phase/Phase Vrs,Vst,Vtr

BACK

NEXT BACK

OUTPUT CURRENT Ir , Is , It

NEXTBACK

INPUT CURRENT Ir , Is , It

BATTERY V, I , Autonomy: %

FREQUENCY fin, fout

UPS TEMPERATURE t emp.

OUTPUT POWER kW , kVA, cos

UPS SETTING fout, Vout

STATUS ALARM MENU

This menu is characterized by the first raw of the message that can be UPS IN OPERATION or UPS ALARM, depenĆ ding whether the status of the UPS is in normal operation or an alarm condition has been detected. The meaning of the message given are the following.

UPS in Operation

MESSAGE INTERPRETATION

MAIN WITHIN LIMITS

The Main Input Line is present and the voltage is in the specified range

BYPASS LINE WITHIN LIMITS

The Input Bypass Supply Line is present and the volĆ tage is within the specified tolerance

BATTERY VOLTAGE WITHIN LIMITS The Battery voltage is within specifications limits

INVERTER OPERATING

The inverter is turned-on and behave with regularity operation

INVERTER ć BYPASS SYNCRONISED

Indication of regular synchronism state between inverĆ ter and bypass line

LOAD ON INVERTER The load is supplied from the inverter

LOAD ON BYPASS

The load is supplied from the bypass line. This can be a temporary condition lasting for 20 sec when a fast overĆ load occurs.

UPS in Alarm

In case of a failure in the UPS, the default screen will be replaced by the Alarm Screen. In this display the User will have an overview on the type of malfunction occurred .A buzzer will be activated and can be cleared by pressing CLEAR button. In this screen by pressing ENTER it will be shown a list of instruction to guide the Operator to underĆ stand the meaning of the Alarm. The CLEAR push button allow to scroll through different messages As the alarm condition is removed the current default screen will be displayed.

UPS ALARM TYPE OF ALARM

ENTER

CAUSE OF THE ALARM ACTIONS

ENTER

Service ManualChapter 4 - Operation and control

Operator Control Panel

4 - 43x3 UPS Operation and control

Issue 2 - November 2001

The List of possible Alarm and the associate help messages is displayed below.

ALARM MESSAGE

CAUSE ACTION

INVERTER OFF

Initial Start Up Permanent Overload has been deĆ tected

Start the Inverter Check Output

INVERTER OVERLOAD

Continuos Overload on UPS OutĆ put

Check Output Load and Restart Inverter Check for Output Short-Circuit

BYPASS SWITCH LOCKED

High Transient Loads on UPS OutĆ put. Inrush Load Current After 3 times

Check Output Load and Restart Inverter

BATTERY FAILURE Battery Test not OK

Check Battery Check Battery fuses

INVERTER SHUT-DOWN IMMINENT

Battery almost flat, next to Shut-Down of inverter

Make shut-down to the connecĆ ted Loads

BYPASS SWITCH FAILURE

One or more Phases in the Output are missing

Check SCR of Bypass Check Bypass external connecĆ tions

MANUAL BYPASS ON UPS on Maintenance

MAIN OUT OF LIMITS

Breaker is Open Main Input is missing

Check Main line Voltage and Breaker position

BYPASS LINE OUT OF LIMITS

The input phase rotation is not corĆ rect Input Voltage Missing

Check Bypass line Voltage Check Phase Rotation

EMERGENCY POWER OFF

The Command EPO has been seĆ lected

Restart the UPS Fully switch-off the Breakers and the Battery Fuse, wait till the LCD is complete switch-off then restart the UPS

BATTERY NOT CONNECTED

Battery Switch Open Battery Test Failed

BATTERY CHARGER FAULT

Call Service Office, to replace the Battery Charger

HIGH BATTERY VOLTAGE LEVEL Battery Charger in Fault

Call Service Office, to replace the Battery Charger

END OF BATTERY DISCHARGE Main is missing for long time

COMMAND MODE MENU

In this menu is possible to give some operative command to the UPS.

MESSAGE INTERPRETATION

BATTERY TEST

With this message displayed by pressing ENTER an automatic test on the Battery will be performed instantaneously

SWITCH LOAD

With this message displayed by pressing ENTER the load is switched from inverter to the Bypass Line. This command is also used for reset the alarm conditions on the bypass line. For instance when the Alarm Bypass Switch Locked is present because for three consecutive times the load has been connected to Bypass for transient overload. To reconnect the load on inverter is necessary to activate this command by ENTER

INVERTER ON/OFF

With this message displayed by pressing ENTER the User can Turn-on or Turn-off the Inverter in a permanent way and connect it to the Load. It is necessary Turn-on the Inverter at the start-up and after a permanent overload.

Service Manual Chapter 4 - Operation and control

Operator Control Panel

4 - 53x3 UPS Operation and control

Issue 2 - November 2001

EVENT HISTORY MENU

In this menu the user may scroll through the past n°512 Alarm occurrences in chronological order.

The Event Log display can be opened from the menu EVENT HISTORY by pressing ENTER twice. The Log screen will display Date and Time of the last EVENT occurred. The Back push button will be used to scroll Date and Time of the previous EVENTS and the Next push button will be used to scroll other statements and Alarm Messages conĆ nected to the same EVENT.

In any position of the EVENT List by pressing Menu the Display Screen will go back in the last EVENT occurred.

DISPLAY EVENTS

DATE & TIME LAST EVENT

ALARM & ST ATE LAST EVENT MESSAGE 1

BACK

DATE & TIME PREVIOUS EVENT LAST–1

BACK

DATE & TIME PREVIOUS EVENT LAST–2

ALARM & ST ATE LAST EVENT MESSAGE 2

BACK

ALARM & ST ATE LAST EVENT MESSAGE M

BACK

ALARM & ST ATE PREV. EVENT N–1 MESSAGE 1

BACK

ALARM & ST ATE PREV. EVENT N–1 MESSAGE 2

BACK

ALARM & ST ATE PREV.EVENT N–1 MESSAGE M

BACK

ENTER

CLEAR

ALARM & ST ATE PREV. EVENT N–2 MESSAGE 1

BACK

ALARM & ST ATE PREV. EVENT N–2 MESSAGE 2

BACK

ALARM & ST ATE PREV.EVENT N–2 MESSAGE M

BACK

DATE & TIME FIRST EVENT

ALARM & ST ATE FIRST EVENT MESSAGE 1

BACK

ALARM & ST ATE FIRST EVENT MESSAGE 2

BACK

ALARM & ST ATE FIRST EVENT MESSAGE M

BACK

To delete all unwanted EVENT first move in the DELETE EVENTS display, then press ENTER.

EVENT HISTORY

DELETE EVENTS

ENTER

CLEAR

ENTER

CLEAR

DATE & TIME LAST EVENT

EVENT CANCELLED

BACK CLEAR

DATE & TIME PREVIOUS EVENT N–1

BACK CLEAR

DATE & TIME PREVIOUS EVENT N–2

ENTER

EVENT CANCELLED

ENTER

EVENT CANCELLED

ENTER

Service ManualChapter 4 - Operation and control

Operator Control Panel

4 - 63x3 UPS Operation and control

Issue 2 - November 2001

OPERATING LANGUAGE MENU

Up to five language are available in this menu. To select one language first move into the OPERATING LANGUAGE display press ENTER and scroll the different languages up the desired one using NEXT button, than press ENTER to confirm.

CLOCK MENU

This menu allows User to change the Date and Time setting on Hinet. To select Date or Time press first ENTER from CLOCK menu then NEXT. When the Date or TIME are displayed the cursor will be over the last right character. To scroll consecutive numbers use BACK and NEXT buttons, to move on the left use MENU button. Then type the whole Date and press ENTER to confirm. If something is wrong in the Date or Time the message ERROR will be displayed and the setting restart.

UPS CONFIGURATION MENU

It is strongly recommended that only trained people can have access to this menu.

In this menu the following parameters can be adjusted:

D Serial Number of the Unit D Telephone number of Service Dept. D Battery Capacity (Battery Ah at the C10 rate)

D Calibration'. Display calibration of the following parameters:

1. Input Current and Voltage. Calibration of measured Values

2. Output Current and Voltage. Calibration of measured Values

3. Battery Current and Voltage. Calibration of measured Values

To enter in one of these menu follow the procedure below:

a) Press the `MENU' push button (A) on the FRONT PANEL. b) Select the `UPS Configuration' screen by pressing either the `BACK' ( C ) or `NEXT' ( B ) push button. c) Confirm the `UPS Configuration' menu selection by pressing the `BACK' and `NEXT' push-buttons at the

same time (i.e. ENTER).

d) Select one of the following parameters (Serial Number, Service Phone Number, Battery capacity, Calibration)

by pressing either `BACK' ( C ) or `NEXT' ( B ) push button.

e) Confirm the selection by pressing and hold for at least 20 seconds `BACK' and `NEXT' push button at the

same time. f) Select the correct value by pressing either `BACK' ( C ) or `NEXT' ( B ) push button. g) Confirm the correct value by pressing `MENU' push button. h) Press the `CLEAR' key to return to the main menu.

Note: These parameters are factory set and it is not recommanded to adjust them during

commissioning.

5 - 1 3x3 UPS Functional description

Issue 2 - November 2001

Chapter 5 - Functional description

This chapter describes the principal PCB `s fitted to the UPS, there function, and configuration of the potentiometers, test points and jumpers.

Abbreviations

The following abbreviations are used throughout.

P = potentiometer

TP = test point

JP = Jumper

5.1 - Control Logic PCB CS0072

The Control logic PCB integrates all the UPS'S functions, converter, inverter, static bypass. The control is accomplished with programmable logic IC's fitted to the PCB. Their use significantly reduces the disĆ crete components required, thus keeping any faults or problems to a minimum.

The principal circuit functions of the control logic are:

a) Feedback circuits (inverter voltage, converter voltage, static bypass voltage, inverter

output current). b) Peak limit current detector circuits (inverter current and converter current).

c) Control logic power supply detector.

d) Overload detector. e) UPS status and alarms generated by the UPS's PCB's.

5.1.1 - Potentiometer adjustment

a) P1 = adjust the inverter output voltage.

b) P2 = adjust the converter DC voltage.

c) P3 = adjust the UPS output threshold at ± 15%.

5.1.2 - Link and Jumper functions

a) J1ĆJ2ĆJ3 define the UPS characteristics.

Link Close Open

J1 OnĆLine OffĆline

J2 Freq. Tolerance 1% Freq. Tolerance 4%

J3 50Hz 60Hz

b) J4ĆJ5 define the parameters of the inverter output voltage and DC Bus voltage.

Output V/Link J4 J5

Service close close

380 open close

400 close open

415 open open

Service ManualChapter 5 - Functional description

Auxiliary Supply PCB CS0070

5 - 23x3 UPS Functional description

Issue 2 - November 2001

c) J6ĆJ7ĆJ8 define the overload level related to the UPS ratings

Link 10K 20K 30K

J6 open close open

J7 close open close

J8 close close open

d) J9ĆJ10ĆJ12 defines the inverter peak current limit for the appropriate UPS output rating.

Link 10K 20K 30K

J9 open close open

J10 open open close

J12 open open open

e) J11 define the converter peak current limit. (normally closed for all UPS output ratings).

5.2 - Auxiliary Supply PCB CS0070

The auxiliary power supply is based on a flyĆback converter circuit, the source supply being the 750 volt DC Bus. Secondary windings of the power supply transformer provide the control logic and the power component gate drive circuits.

The auxiliary power supply generates a regulated 7. 5Vdc and l5Vdc voltage.

Adjustments to the battery threshold voltage are made from the auxiliary power supply by setting the potientiometers P1, P2 and P3.

5.2.1 - Battery Threshold settings

a) Maximum voltage (500 Vdc) adjusted with P1.

b) Minimum voltage (320 Vdc) adjusted with P2.

c) PreĆalarm voltage (350 Vdc) adjusted with P3.

Service Manual Chapter 5 - Functional description

Driver Interface PCB CS007I

5 - 33x3 UPS Functional description

Issue 2 - November 2001

5.3 - Driver Interface PCB CS007I

The principle circuit functions of the driver interface PCB are:

a) Inverter and converter IGBT gate drives (connectors JI IĆJ9ĆJ12 for the inverter, J14 for

the converter)

b) Static bypass thyristors and inverter gate drives (connectors J3ĆJ4ĆJ5 for the inverter, JI

J2ĆJ5 J6 for the static bypass)

c) Input thyristor driver (J16)

d) Converter DC feedback (+DC, ĆDC)

e) Inverter feedback

f) Bypass supply circuit and bypass threshold (P1 and P2)

g) DC Bus unbalanced sensing (SI reset).

5.3.1 - Bypass Voltage Threshold Adjustment

a) P1 = adjusts the maximum bypass voltage threshold (+10%)

b) P2 = adjusts the minimum bypass voltage threshold (Ć10%)

5.3.2 - Link and Jumper functions

a) J4AĆJ5A sets the DC Bus voltage.

DC V/Link J4A J5A

375V (service maintenance mode) close close

750V (normal operation.) open open

b) JIAĆJ2AĆJ3A sets the UPS nominal bypass voltage;

Link 380V 400V 415V

J1A close open open

J2A open close open

J3A open open close

Service ManualChapter 5 - Functional description

Battery Charger CS0074

5 - 4 3x3 UPS Functional description

Issue 2 - November 2001

5.4 - Battery Charger CS0074

The battery charger used in the UPS is a PWM controlled `Buck/Boost' DCĆDC converter which produces a battery recharge float voltage of 230 Vdc.

The principals circuit components are:

a) Power section (PD1Ć2, LI, Q1, Dl, L2). b) Supply section (+l5Vdc, Ć 6.2 Vdc). c) PWM generation and feedback section (U10 Ć U3). d) The battery test section (U4).

The input mains voltage is rectified by the diode bridge PD1 and PD2, steppedĆdown by the main power components L1, D1, L2 with the voltage stabilised by the switching of IGBT Q2 the PWM gate drive signal generated by U10. This configuration produces a stable battery recharging float voltage of 432 Vdc.

5.4.1 - Battery Charger Voltage Adjustment

a) P1 = adjusts the float voltage level to 432 Vdc b) P2 = adjusts the boost voltage level. This setting is dependant on the type of battery

fitted.

c) P3 = adjusts the float voltage when the temperature compensation option is enabled.

5.4.2 - Link and Jumper Functions

a) JPI ĆJP2 sets the recharging current.

Link/Amper

IA 3A 5A

JPI open open close

JP2 open close open

b) JP3 enable/disables the boost charge.

Link Boost Disable Boost Enable

JP3 open close

c) JP4 enable/disables the temperature compensation circuit.

Link

Th Comp.

Disable

Th. Comp.

Enable

JP4 open close

d) Jumpers JP5 to JPI0 set the capacity for the installed battery, this is used for the battery

test function.

Link JP10 JP9 JP8 JP7 JP6 JP5

7.2Ah

2 x

7.2Ah

3 x

7.2Ah

4 x

7.2Ah

38Ah 65Ah

e) JP11 when selected open inhibits the battery test regime.

Note: JP11 is always set closed.

f) J4ĆJ5ĆJ6 set the automatic battery test interval

Link J4 J5 J6

Time 12 Hours 24 Hours 48 Hours

Service Manual Chapter 5 - Functional description

Battery Charger CS0074

5 - 53x3 UPS Functional description

Issue 2 - November 2001

5.4.3 - Battery test

The battery test circuit will automatically initiate at the time interval selected by the links J4, J5 and J6. The test duration is set at 10 seconds, during this period the battery charger logic switches off the mains power by opening the input test relay K1 which shuts down the charger circuit. The terminal voltage of the battery is then monitored to verify the battery status, if this is correct and stable over a 20 seconds period, the battery charger will restart and continue to charge the battery.

If the battery check fails detecting a parameters different from the expected value, the control logic initiĆ ates a battery fault alarm. The fault will give a flashing red LED on the front mimic panel. If the battery test is satisfactory the green battery LED will illuminate indicating that the battery is OK.

5.5 - UPS monitor board PCB CS0077

The function of UPS monitor board is to interface the UPS control and status alarm signals with the OperĆ ator LCD Control panel Part Nº CS0075 , the Relay Interface PCB Part Nº CS0082 and the SNMP adapter.

SNMP CARD

UPS CONTROL LOGIC

P/N CS0072

LCD MIMIC DISPLAY P/N CS0075

UPS MONITOR BOARD CS0077

Inverter Driver & Feedback CS0071

RELAY

INTERFACE

P/N CS0082

OPTIONAL RELAY

INTERFACE P/N CS0082

J3 J5

This board has a microprocessor that manage and control the serial port, the SNMP adapter, the LCD messages and UPS menu.

The LCD Display Panel displays textual messages and operating parameters on a LCD screen capable of showing 4 rows of 20 characters.

The displayed screen is organized in a multi-level menu system and selected by using push button located to the right of the screen.

LD1 illuminated indicates that the monitor board is failed and must be replaced.

BT2 is an hardware and software reset.

Links setting:

JP1 1-2 close and JP3 2-3 close are factory setting.

JP2 close disable the second remote EPO, JP2 open enable the second remote EPO.

Service ManualChapter 5 - Functional description

Relay Interface PCB CS0082

5 - 63x3 UPS Functional description

Issue 2 - November 2001

5.6 - Relay Interface PCB CS0082

The relay interface PCB provides two sets of volt free contacts rated at 50V 1A which enable the UPS functions listed below in Table 5-1 to be monitored externally. The relay interface PCB receives the UPS status signals from the Display Control Logic PCB Part Nº CS0073 and is connected to CN1.

Output signals from the relay interface are used for the control of customer peripheral computer equipĆ ment and connections are made to the terminal block M1 shown in Figure 5Ć2, or from the RS232 DB9 connector P1 (fitted to later equipment only).

Table 5-1 Relay Interface PCB Output

Link

Relay UPS Function Signal Function

JP4 JP5

Mains NOT OK Closed Open

RL1 MAINS STATUS

Mains OK Open Closed RL2 BYĆPASS ON RL3 UPS Ć RUN

No associated link

RL4

PREĆALARM

No associated link

Links fitted to the PCB allow the input mains status to be set and the serial port P1 to be enabled as shown in Table 5-2. These signals are generated on the display control logic PCB and connected to the relay PCB at connector CN4.

Table 5-2 Serial Port P1 DB9 Connector Connections

Link

Nº

Function Relay

JP1 JP2 JP3 JP4 JP5

5 COMMON N/A Closed ć ć 3 UPS RX N/A ć Closed ć

2 UPS TX N/A ć ć Closed 89MAINS

STATUS

RL1 ć

MainsĆ

NOK

MainsĆOK

1 7

PRE ALARM RL4 ć

5.6.1 - EPO Connections.

Provision has been made on the relay interface PCB to connect an external `Emergency Power Off' switch, to allow remote shut down of the UPS to be implemented.

Connection for the EPO is provided by the terminal block M2.

Caution When connecting an EPO switch to the relay PCB the Link JP6 must be opened.

5.6.2 - Optional Second Relay Interface PCB

If a second set of outputs is required, an optional relay interface PCB can be connected to CN3 on the display control logic PCB.

Caution With two relay PCB's connected. Link JP1 on the display logic PCB must be opened in

addition to JP6 on the optional relay PCB, to allow the use of a Second EPO switch.

Service Manual Chapter 5 - Functional description

Relay Interface PCB CS0082

5 - 73x3 UPS Functional description

Issue 2 - November 2001

Figure 5-1 Relay Interface Outputs

Service ManualChapter 5 - Functional description

Relay Interface PCB CS0082

5 - 83x3 UPS Functional description

Issue 2 - November 2001

5.7 - LCD MIMIC DISPLAY CS0075

LCD control panel

5.7.1 - Control panel indicator LEDs

The menu contains three levels. The main level is the State and Alarm Menu.

In this menu it is possible to see the state and operative condition of the UPS, the CLEAR Button is used to scroll through the different windows of this menu.

From the main menu the User may have access to different menu pressing the MENU Button (second level).

Once in this level the first row will show < menu choice > and the NEXT and BACK push Button enable the User to move from one menu level to another.

Pressing both NEXT and BACK push button at the same time the ENTER command is selected and the next lower level will be reached, while CLEAR take you back to the previous level. To verify the acquisition of ENTER a Beep will be heard and CONFIRMED will appeared on the Display.

The NEXT/BACK selector keys are used to scroll through different windows in the same menu.

(See Chapter 4)

Safety Precautions

6 - 13x3 UPS Maintenance

Issue 2 - November 2001

Chapter 6 - Maintenance

This section contains the procedures necessary to effect general maintenance of the UPS and battery. Certain procedures entail gaining internal access to the UPS, and should be undertaken only by a comĆ petent engineer who is familiar with the operation and layout of the equipment and is fully conversant with the areas of potential hazard. If there are any doubts concerning safety, or the method of carrying out any procedure then contact an approved service agent for assistance or advice.

The equipment contains live voltages at ALL Swiss unless externally isolated from the mains supply, bypass supply and batteries. When working on the UPS it is essential that the safety and precautionary notes in this manĆ ual are read and FULLY UNDERSTOOD before touching any UPS internal component part.

6.1 - Scheduled Maintenance

The UPS utilises solidĆstate components not subjected to wear, with the only moving part the cooling fan. Scheduled maintenance requirements, beyond ensuring that the environmental conditions remain suitably cool and clean, are therefore minimal. However, a well documented periodic program of inspecĆ tion and preventive maintenance, as suggested below; will ensure optimum equipment performance and serve to detect minor malfunctions prior to them developing into a major fault.

6.1.1 - Daily Checks

Carry out a daily walkĆby inspection of the UPS, checking the following points:

1. Carry out a spot check of the Operator Control Panel; ensuring that all mimic LED indications are normal and no alarm messages are present.

2. Check for obvious signs of overheating.

3. Check for continuous exit air flow from the extractor fans on the front door.

4. Ensure that the ventilation grills around the UPS are unobstructed.

5. If possible, log the results of the inspection, noting any discrepancies from the norm.

6.1.2 - Weekly Checks

Perform the following checks and log the results:

1. Measure and record the battery charge voltage.

2. Measure and record the battery charge current.

3. Measure and record the UPS output voltage on all three phases.

4. Measure and record the UPS output line currents.

If there are significant differences from the values previously recorded, note the size, type and location of any additional load connected to the UPS supply since the previous inspection. This type of informaĆ tion could prove useful to the troubleshooting engineer should a problem occur.

If any of the above indications differ greatly from the previously logged values for no apparent reason you should contact the Customer Service & Support Department at the address given at the front of this manual for advice.

Service ManualChapter 6 - Maintenance

Scheduled Maintenance

6 - 23x3 UPS Maintenance

Issue 2 - November 2001

6.1.3 - Annual Maintenance

Caution We strongly recommend that the annual maintenance is carried out by a manufacturerĆ

trained engineer who is fully aware of the hazards concerned and will carry out this proĆ cedure, where necessary with the load connected to the maintenance bypass supply

WARNING LETHAL VOLTAGES ARE PRESENT IN THE UPS UNIT EVEN IF THE UNIT HAS BEEN

SWITCHED OFF AND ISOLATED

The following procedure is intended as a guide to carrying out an annual preventative maintenance schedule. It is assumed that the engineer carrying out this procedure has been trained in the operation of the UPS and is able to operate the unit in the `Maintenance Mode'.

Preliminary checks

1. Visually inspect the outside of the UPS and determine that the operating environment is correct.

2. Carry out the checks detailed in `Weekly Checks'.

3. Determine if any abnormal faults have been previously recorded.

4. Confirm with the load user that it is safe to transfer the unit to maintenance bypass before proceeding.

Transfer to the Maintenance Bypass

The manual bypass allows the UPS to be switched OFF while the critical load is maintained.

To transfer the load to Maintenance Bypass:

1. Press the `MENU' push button ( A ) on the FRONT PANEL.

a) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push

button.

b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same

time (i.e. ENTER). c) Select the `SWITCH LOAD' function by pressing either `BACK' or `NEXT'. d) Confirm `SWITCH LOAD' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

2. Press `CLEAR' ( d ) twice to return to the main menu.

The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:

D The yellow `BYPASS ON' LED ( 4 ) is illuminated D The green `LOAD on INV' LED is extinguished.

3. To turn off the Inverter follow the procedure below: a) Press the `MENU' push button ( A ) on the FRONT PANEL. b) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push

button.

c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same

time (i.e. ENTER).

d) Select the `INVERTER ON-OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (B)

push button.

e) Confirm `INVERTER OFF' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

f) Press `CLEAR' twice to return at the main screen.

4. The follow sequence should occur:

D The Alarm buzzer is activated. D The Red general `ALARM' red LED ( 2 ) will illuminate.

Service Manual Chapter 6 - Maintenance

Scheduled Maintenance

6 - 33x3 UPS Maintenance

Issue 2 - November 2001

D The Yellow `BYPASS ON' LED ( 4 ) will illuminate.

D The Green `NORMAL' LED will extinguish.

D The LCD will display the following messages:

`LOAD ON BYPASS' and `INVERTER OFF'.

5. Remove the Mechanical Lock from the MANUAL BYPASS MCB ( I3 )

6. Close the. MANUAL BYPASS MCB ( I3 )

7. Open the `UPS OUTPUT' MCB ( I4 ).

8. Open the `MAINS INPUT' MCB ( I1 ).

9. Open the `RESERVE INPUT' MCB ( I2 ).

10. Open the `INTERNAL BATTERY' fused switch ( I5 ).

11. Check that the load continues to be powered from the Maintenance Bypass Mains supply while the UPS is off.

12. Wait a minimum of 10 minutes before proceeding to allow the DC bus voltage to discharge.

WARNING THE DC BUS VOLTAGE OF 750VDC MAY TAKE SEVERAL MINUTES TO DISCHARGE TO A

SAFE LEVEL.

13. Remove the top cover of the UPS to gain internal access to the unit.

RETURN FROM MANUAL BYPASS TO NORMAL OPERATION

The following procedure describe how to start the ups and transfer the load from the maintenance byĆ pass to the ups inverter.

1. Close the `RESERVE INPUT' MCB. ( I2 )

D wait until the fan is running, indicating that the output voltage is present.

2. Close the `MAINS INPUT' MCB. ( I1) Wait until the Operator panel shows the following indications:

D LCD is energize and

D The alarm buzzer sounds.

D The red `ALARM'LED ( 2 )

D The yellow `BYPASS ON' LED will illuminate.

3. Close the `INTERNAL BATTERY' fused switch. ( I5 ).

4. Close the `UPS OUTPUT' MCB. ( I4 ).

5. Open the `MANUAL BYPASS' MCB. ( I3 ).

6. Start the inverter as follow:

a) Press the `MENU' push button ( A ) on the FRONT PANEL.

b) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push

button.

c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same

time (i.e. ENTER).

d) Select the `INVERTER ON- OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (

b ) push button.

e) Confirm `INVERTER ON' function by pressing `BACK' and `NEXT' at the same time.

D A ***CONFIRMED*** message will be displayed

f) Press `CLEAR' ( d ) twice to return at the main screen.

7. Within approximately 20 sec. and the follow sequence should occur:

D The green `NORMAL' LED ( 1 ) has illuminated.

D The red `ALARM' LED ( 2 ) has extinguished.

D The yellow `BYPASS ON' LED ( 4 ) has extinguished.

D The green `LOAD-on-INV' LED ( 3 ) has illuminated.

Place the mechanical lock, onto the `MANUAL BYPASS' MCB.

The UPS is now in the normal operating condition with the Inverter supplying the load.

Service ManualChapter 6 - Maintenance

Scheduled Maintenance

6 - 43x3 UPS Maintenance

Issue 2 - November 2001

Mechanical inspection

1. Carry out the weekly checks detailed above

2. Ensure that the UPS is totally powered down. a) Check for input AC voltage at the rectifier input connections SKD 82/12 terminals 14, 15

& 16 b) Check for Battery voltage at the battery connection terminals 6 & 7 ćve, 8 & 9 +ve. c) Check for AC voltage at the output terminal connections 2, 3 & 4. d) Check for an AC voltage at the Reserve Bypass input terminal connections 10, 11 & 12.

Note: Refer to Figure 2Ć1 on page 2Ć4 for terminal connection detail.

3. Gain access to the UPS interior by removing the top cover panel.

4. Carry out a thorough examination of the UPS power components and subĆassemblies, paying particular attention to the following:

a) Electrolytic capacitors Ċ check for signs of leakage, distortion etc. b) Magnetic components Ċ check for signs of overheating, security of fixture and

deĆlamination. c) Cables and connections Ċ check cables for signs of overheating. d) Check that all printed circuit board connectors are secure. e) Printed circuit boards Ċ check the cleanliness and integrity of the PCB's and replace if

any signs of deterioration are found.

5. Thoroughly clean inside the equipment enclosure using a vacuum cleaner and low pressure air to remove any foreign debris.

6. Reconnect the UPS input mains power.

Power checks

1. Start the UPS following the appropriate operating procedure.

2. Carry out a calibration of the DC Bus Voltage and Inverter output voltage.

3. Connect a DVM set to DC volts to the DC bus and a second DVM set to AC volts to the UPS output.

4. Select I1 (Input mains) to ON

a) The DC voltage will increase slowly up to 650 Vdc. b) After 10 sec. the converter and the inverter will start regulating respectively

The DC Bus voltage to 750 Vdc ± 1% The output inverter voltage to 400 Vac ± 1% (Assuming the UPS is set for an output of

400 Vac)

5. If the measured values are incorrect, reĆadjustment of the voltage settings can be carried out using the potentiometers on the UPS control logic PCB Part Nº CS0072.

Note: Turning P1 Inverter feedback potentiometer CCW will increase the

voltage. Turning P2 Converter feedback potentiometer CCW will increase the voltage.

Service Manual Chapter 6 - Maintenance

Scheduled Maintenance

6 - 53x3 UPS Maintenance

Issue 2 - November 2001

Table 6-1 Output Voltage PCB Link Settings

Link

PCB Part Nº 38OVac 400Vac 4l5Vac

J4 CS0072 open close open

J5 CS0072 close open open

JIA CSOO7I close open open

J2A CSOQ7I open close open

J3A CSOO71 open open close

lnverter Bypass Phase Lock check

1. Using a dual trace oscilloscope operating in the differential mode (insulated from mains) on the inverter driver interface PCB (CSOO7I) connect:

a) Probe 1 to the bypass `R' phase voltage terminal stud N9.

b) Probe 2 to the inverter output phase `R' voltage terminal stud N 7.

2. Check both sine waves are perfectly in phase. The phase adjustment is fixed and is determined by R23 on the driver interface CSOO7I (1 Mohm).

The check of the CONVERTER and INVERTER section is now complete.

Battery charger checks

Float voltage adjustment and battery reĆcharging current

1. Connect a DVM set to DC volts to the battery DC bus terminal connecting block (terminal 6Ć7 positive, 8Ć9 negative).

2. Open the battery power fuses F1 to F4.

3. Check that the value at the battery DC bus terminal connections is 432 Vdc ± 1%.

If the measured value is different it is possible to reĆadjust using the potentiometer P1 on the battery charger PCB C50074.Ć

Note: Turning P1 CCW will increase the float voltage

4. Refit the battery fuses.

5. Check the battery reĆcharging current with a DC clamp meter.

Service ManualChapter 6 - Maintenance

Battery Maintenance

6 - 6UPS Maintenance

Issue 2 - November 2001

6.2 - Battery Maintenance

The batteries fitted within the UPS are valve regulated and require very little maintenance.

It is wrong to describe them as completely `maintenance free', because the batteries still require a mainĆ tenance check, but at a significantly greater interval than the unsealed type.

The removal of the need to continually top up batteries, is a major advantage, but by removing access, a visual examination of the cell plates, and electrolyte is impossible.

Battery condition and capacity can therefore only be determined as a complete 12V battery block.

The battery is an important component in the UPS system, as the UPS function relies on the battery power, on failure of the input AC supply To ensure that the battery will support the UPS operation it should be checked annually for performance.

6.2.1 - Factors Effecting Battery Use

The following factors affect the overall operation and ultimately the useful life of the UPS battery. These considerations must be taken into account when deciding the serviceability of a battery.

Service life

Temperature is the major factor in determining the effective life of a battery if the battery is operating above 200 C it will reduce the battery life. It is also important that the charge voltage is within limits. TypiĆ cally a 5 year life battery will start to decline after 3 years in service, therefore the need for regular checks is important.

Charge voltage

The nominal charge voltage is normally 2.25 volts per cell, multiplied by the number of cells in series. Operation at voltages below 2.2 volts per cell, will lead to a undercharge and sulphation. Operation at

2.3 volts per cell and above, will cause overcharge and rapid positive plate corrosion. Positive plate corĆ rosion is known to be the major life limiting component in all batteries, therefore for optimum life, battery cell voltages must be within the range of 2.25 to 2.3 volts per cell.

The UPS has 32 x 12V batteries and is designed to operate with a float charge voltage of 432 V DC.

Battery capacity

Battery capacity is used to define endĆofĆlife of the battery for example if the battery cannot supply 80% it is deemed to be at the end of its effective life. For some applications 80% may be decreased to 50% to mark the end of the batteries effective life.

Battery capacity from manufacture, usually increases slightly after 2 or 3 discharges and will be enĆ hanced by high temperature and reduced by low temperature.

As the battery ages beyond 12 months the battery capacity will fall at a rate determined by the operating temperature and the charge voltage. These adverse factors, will cause accelerate erosion to the positive plate grid, reducing the effective battery capacity The life of the battery will then depend on the requireĆ ments of the system, if the capacity of the UPS has been oversized then the load may only need 50% of the normal duty.

In most applications, the battery is essentially on continuous float charge, and rarely will experience a input supply failure longer than the end of the battery autonomy.

Therefore a battery in poor condition may well continue to support the load for short autonomies, but will fail if the loss of the input AC supply exceeds 30 seconds.

It is therefore highly recommended that a battery autonomy test, is carried out as part of a regular mainĆ tenance program.

Open circuit voltages

Measurement of the battery open circuit voltage is not a good indicator of the available capacity of the battery It may apply to batteries on the shelf but not to batteries that have been on charge, up to 72 hours prior to measurement. The terminal voltage of batteries that have been on charge, have an actual cell voltage, plus a polarization voltage.

Service Manual Chapter 6 - Maintenance

Battery Maintenance

6 - 73x3 UPS Maintenance

Issue 2 - November 2001

The polarization voltage will disappear once loaded, but can lead to misleading terminal voltage measurements.

To use the open circuit voltage of a battery as a guide to its capacity it must have been disconnected for at least 72 hours. This measurement is taken off load and can only be used as a guide, it will not indiĆ cate a battery with high internal resistance.

Float voltage

The float voltage of each battery connected in a series string, is determined by its impedance, relative to other batteries. The voltage measured at each battery while on charge can give an indication to its serviceability A battery on charge taking above the minimum float current, will have a different voltage distribution to one that is fully charged. This measurement can therefore give an indication of the charge of the battery however a valid voltage reading can only be obtained if the battery has been on float charge for at least 48 hours.

For maintenance purposes, the ideal is to check the float voltage of each battery before shutting the UPS down, if the test is carried out after shut down, the reading will not be valid until the float current normalĆ izes back to its original level, prior to shut down.

It is recommended that a float voltage check is carried out on the unit if a battery problem is suspected, a defective battery will normally give an abnormal terminal voltage.

6.2.2 - Battery Testing

When working on batteries, regardless of size, remember they have considerable energy content under short circuit conditions.

They cannot be switched off or isolated as is normal in electric circuits.

WARNING RISK OF DEATH, SHOCK OR BURN. WHEN THIS BATTERY IS ASSEMBLED, IT IS A SOURCE

OF 390 VOLTS.

Caution Use extreme care to ensure that batteries are not accidentally short circuited by tools, rings,

watch straps etc.

Use insulated hand tools.

Wear eye protection during handling of batteries.

Before tightening or making connections on battery strings, ensure the battery is isolated from the UPS circuit and is earth free.

In the event of a battery breakage occurring, dispose of in a container resistant to sulphuric acid.

Should electrolyte contact the skin, wash the affected area immediately

Site testing

It is not normally possible to check the float voltage of the battery string prior to turning the UPS off, but the float voltage may need to be checked subsequently.

Float voltage test

Batteries on float below 13.0 V per I2V battery will ultimately sulphate.

Batteries above 13.8 V will have a short service life, and indicates a deteriorating cell.

Investigate the serviceability of batteries with a float voltage below 13.4 V and above 13.98 V If the averĆ age float voltage is at the correct level, check and replace if necessary any batteries that fall outside the float voltage parameters.

Visual examination

1. After shutdown examine the batteries for the following:

Service ManualChapter 6 - Maintenance

Battery Maintenance

6 - 83x3 UPS Maintenance

Issue 2 - November 2001

a) White deposits around the terminal seals which indicate seal failure.

Replace any batteries found.

2. Check the security of the terminal connections. Examine for signs of corrosion or overheating.

3. Inspect battery cases for distortion, splits or bulges.

a) Batteries near the end of their effective life, will exhibit bulges in the case, due to

increasing pressure of the positive plates as they grow in size.

b) Severe distortion may also be apparent, caused by the higher resistance of the corroded

plates, which tends to generate heat during charge and discharge. In turn the plastic of the case will creep and failure of a single cell will cause the side of that cell to bulge.

c) Total end of life condition will normally cause all cells to bulge or distort.

6.2.3 - Battery capacity testing.

There are generally two ways in which the capacity of a battery can be tested by impedance measureĆ ment, or by load testing.

Impedance measurement

Measurement of the battery AC impedance requires special test equipment, but gives a measure of how the battery impedance has changed since new. Any battery that has been on continuous float charge prior to the test, should not exhibit more than twice the new battery value.

Values in excess of this, indicate the battery is nearing the end of its effective life, while batteries exhibitĆ ing 4 or more Swiss the new value, need immediate replacement.

This test will only look at the battery level and not the individual cell level, therefore, a cell with above normal impedance to the others, will not be indicated.

Discharge test

The more common method of determining the capacity and serviceability of the batteries, is to carry out a discharge test.

A suitable resistor designed to draw a current equal to the Ah size of the battery is placed across the battery terminals. The battery terminal voltage is then monitored.

A fairly large wattage, 5 W resistor capable of taking 11A is connected across the battery terminals. After 10 minutes discharge, the battery terminal voltage should not fall below 11.2 V indicating the 50% capacĆ ity level.

If a battery has high internal resistance and reduced capacity the terminal voltage will fall quickly.

Batteries with a capacity above 50% may continue to be used, but will reduce the autonomy of the sysĆ tem. It is recommended that they be replaced, however batteries below 50%, should always be reĆ placed.

Note: A higher resistance value, discharge resistor may be used to discharge

the battery. The terminal voltage measured will then give an indication of the serviceability of the battery, but is not an accurate measure of the battery capacity.

Service Manual Chapter 6 - Maintenance

Battery Replacement

6 - 93x3 UPS Maintenance

Issue 2 - November 2001

6.3 - Battery Replacement

When deciding to replace a battery the following must be considered, and a decision taken, to mix old or new batteries in the series string. Adding new batteries to a series string that has been in use for more than 18 months, may induce problems due to the difference in capacity A new undercharged battery placed into a fully charged old string, may fail to achieve full charge. The other batteries in the string may limit the charge current, as the older batteries may only require a charge current of some milliamps, this may then cause the new battery to sulphate. If a new battery is fully charged before inclusion, the probĆ lem should not arise, however the effective life of the new battery is limited to that of the originals. The new battery may also have a higher terminal float voltage.

Replacing more than one battery may cause redistribution of the float voltages, causing over and underĆ charging. Attempts to equalize the string by using a top charge of 2.4 volt per cell, may cause temporary overheating and the test should only be carried out with continual monitoring.

Applying a top charge, (equalization) to a battery of unknown quality can lead to rapid overheating and the possible release of acid fumes. Equalization on a long series string has not shown to be of any beneĆ fit, due to the ability of the batteries to absorb the excess charge over a large number of cells. However~ equalization of a single battery introduced into a string, is effective.

Since a site visits to replace a single battery is a costly process, a point will be reached where it is more cost effective to replace an entire battery string than to properly asses the battery condition, and carry out single or multiple replacements. This decision has the additional advantage of enhancing the reliaĆ bility of the system, and has the benefit of a 12 month warranty on the new battery.

6.4 - UPS Storage

If the UPS is to be transported, or stored in a powered down condition for any length of time, the internal battery may discharge below the minimum battery voltage.

To prevent this condition occurring, remove the battery fuses and retain with the unit.

For periods of storage in excess of 12 weeks, the batteries will exceed their shelf life.

This can be prevented by operating the UPS and allowing them to reĆcharge for 24 hours.

Battery recharging is done by:

1. Connect the UPS to an input AC supply

2. Fit the battery fuses.

3. Power up the UPS and allow it to operate for 24 hours.

7 - 13x3 UPS Troubleshooting

Issue 2 - November 2001

Chapter 7 - Troubleshooting

7.1 - Introduction

The UPS contain complex electronic control circuits which require a firm understanding, in order to carry out comprehensive fault diagnosis and repair of the equipment. The aim of the informaĆ tion contained in this chapter is to provide sufficient guidance to the trained service engineer, to enable successful fault location to printed circuit board level. Once a faulty circuit board or component has been identified, it should be replaced or returned to the nearest service centre for repair.

The troubleshooting information has been divided into the following main areas:

a) Component location and identification. b) Diagnostic information. c) Troubleshooting procedures. d) Test procedures.

Note: When following the procedures cross referencing is inevitable, therefore

it is recommended that this chapter is read in its' entirety, before commencing work on the equipment.

There is no practical way of detecting an impending UPS malfunction, as most problems do not emerge as a gradual performance degradation. Generally the UPS will either work correctly or shut down with or without a warning indication.

In the event of a UPS malfunction troubleshooting should be carried out methodically along the following guide lines.

7.1.1 - General Fault Identification Procedure

When first summoned to a UPS fault the immediate action should be to observe and record the LED indication displayed on the unit operator panel.

1. Determine the UPS power Status.

2. Note the control switch configuration, and also the warning horn sequence if it is operating.

WARNING During troubleshooting it will be necessary to power up the unit with the side or top covers

removed, in this situation exposure to potentially lethal voltages is possible even with the input utility supply switched off. Take great care at all Swiss to minimise the risk of contact with live voltages, especially when working around the battery or the DC bus.

3. Power down the unit, and ensure that the DC Bus Safety discharge check is carried out.

4. Gain access to the internal components follow the procedure for removing the UPS covers.

5. Check the serviceability of the UPS Fuses refer to the check list on page 7Ć12.

6. Apply power and analyse PCB LED indications.

7. Refer to the common fault identification chart on page 7Ć9 to identify possible fault conditions.

8. Check DC converter power components. Refer to the procedures on page 7Ć19.

9. Check Inverter power components. Refer to the procedure on page 7Ć19.

Note: When checking signal levels refer to the table of typical normal values on

page 7Ć11 for comparison.

Service ManualChapter 7 - Troubleshooting

Special Tools

7 - 2 3x3 UPS Troubleshooting

Issue 2 - November 2001

7.2 - Special Tools.

No special tools are required to service the UPS, a normal electricians tool kit will be adequate. However, to carry out the check procedures contained in this chapter the following test equipment will be required.

Oscilloscope.

A dual beam oscilloscope, which has the ability to sum the two channels, allowing differential voltage measurements to be made.

For the measures points that it is needed to check it is very important to have the oscilloscope insulated from the supply with a transformer.

A storage facility is useful but not essential.

WARNING ENSURE THAT ANY OSCILLOSCOPE USED IS RATED FOR USE ON 1000 V AND IS FITTED

WITH APROPRIATE 1000 V LEADS AND TEST PROBES.

Digital volt meter (DVM).

The voltages quoted in this manual assume that a true RMS reading AC voltmeter is used. A meter that also has the ability to test electronic components such as diode's and similar electronic devices is reĆ quired.

WARNING ENSURE THAT ANY DVM USED IS RATED FOR USE ON 1000 V AND IS FITTED WITH

APROPRIATE 1000 V LEADS AND TEST PROBES.

Service Manual Chapter 7 - Troubleshooting

Removing the UPS Covers

7 - 33x3 UPS Troubleshooting

Issue 2 - November 2001

7.3 - Removing the UPS Covers

To gain access to the UPS components the following covers must first be removed.

Figure 7-1 UPS Cover Removal

Battery Safety Cover

Covers Removed

Main Switch Cover

Top Heatsink Cover

Top Cover

Right Side Cover

Lockable Front Door

1. Front Door Panel

a) To gain access to the power switches and battery compartment the front door panel is

first unlocked and hinged forward.

2. Battery Safety Cover

a) Disconnect the Earth bonding cable. b) Remove the two top M6 retaining bolts. c) Release the two bottom retaining bolts and lift the cover from the UPS.

Note: The battery safety cover has slots on the lower edge for easy removal and

repositioning.

3. Main Switch Cover

a) Remove the four M6 retaining bolts. b) Carefully ease the cover away from the control switches.

4. Heatsink Cover

a) Remove the four M6 retaining bolts. a) Carefully ease the cover away from the front of the UPS.

5. Top Cover.

WARNING DANGER OF SEVERE SHOCK OR BURNS. 800V DC IS EXPOSED WHEN TOP COVER IS

REMOVED DO NOT REMOVE THE COVER UNLESS THE UPS HAS BEEN COMPLETELY POWERED DOWN AND THE DC BUS ALLOWED TO DISCHARGE FOR 10 MINITUES

Service ManualChapter 7 - Troubleshooting

Removing the UPS Covers

7 - 43x3 UPS Troubleshooting

Issue 2 - November 2001

a) Ensure that the UPS has been correctly switched off and the battery fuse switches are

opened. b) Wait for at least 10 minutes to allow the DC bus to fully discharge. a) Carefully lift the cover from the retaining ball studs.

6. Side Panels a) Remove the three M6 retaining screws securing each side panel at the rear of the UPS. b) Disconnect the earth cable fitted to the top rear of each side panel, from the UPS chassis

by removing the M6 earthing bolt.

c) Push the panel forward to disengage the front locating studs and lift the panel from the

UPS.

Rear Cover Removal

7. Power Distribution Terminal Block Cover. a) Remove the six M6 retaining screws from the terminal block cover and lift from the UPS.

Refer to Figure 7Ć2.

Figure 7-2 Rear Cover Removal

Rear Covers Fitted

Distribution Terminal Block Cover

Removed

Side Cover

Retaining Bolts

Rear Side Cover Earth Cables

Service Manual Chapter 7 - Troubleshooting

Component Location

7 - 53x3 UPS Troubleshooting

Issue 2 - November 2001

7.4 - Component Location

Before starting to repair or service the UPS models, correct identification of the main compoĆ nents and their location is required. All the main power component are mounted on the power heatsink under the driver interface board.

The following information is primarily to furnish the repair engineer with a quick reference to the basic component identification and location. A detailed breakdown of the equipment components and spare parts kits available can be found in Chapter 9 Spare Parts.

Figure 7-3 Main PCB Location

3Ph TL Control Logic PCB

Part Nº 0SDE0072

Battery Charger PCB

Part Nº 0SDE0074

Inverter Driver/Feedback PCB

Part Nº 0SDE0071

Input Filter PCB

Part Nº 0SDE0079

Fan PCB

Part Nº 0SDE0078

Auxiliary DCĆDC Converter PCB

Part Nº 0SDE0070

UPS Monitor PCB

Part Nº 0SDE0077

Battery Charger PCB

Part Nº 0SDE0074

Service ManualChapter 7 - Troubleshooting

Component Location

7 - 63x3 UPS Troubleshooting

Issue 2 - November 2001

Figure 7-4 Semiconductor Components

Inverter SCR's (x 3) 91A (S1 S3 S5) Part Nº 0CASR212391

Inverter IGBT's 150A 150A (Q1 Q2 Q3) Part Nº 0CATRCM150BU24F

Transfer Diode 60A (CD1) Part Nº 0CSDRFBYT261P12

Snubber Diodes 30A (CD4 CD5) Part Nº 0CADR210230

Converter IGBT 200A (Q4) Part Nº 0CATD212420

Input Bridge (PD1) Part Nº 0CADTSSKD82/12

Input SCR 132A (S7) Part Nº 0CSSX212413

Bypass SCR's (3) 91A (S2 S4 S6) Part Nº 0CASR212391

Transfer Diode 60A (CD2) Part Nº 0CSDRFBYT261P12

Snubber Diode 30A (CD3) Part Nº 0CADRFBYT231

Input SCR 132A (S8) Part Nº 0CSSX212413

Service Manual Chapter 7 - Troubleshooting

Component Location

7 - 7UPS Troubleshooting

Issue 2 - November 2001

Figure 7-5 Passive components

Thermostat 55oC (ST2) Part Nº 0CEX50CLSD

Thermostat 85oC (ST1) Part Nº 0CEX-SONDA

Inverter CT's 1/1000 (TA1 TA2 TA3) Part Nº 0CEMC316610M019

Inv Snubber Capacitors

2.5ìF (C9 C10) Part Nº 0CPCPP525850

Capacitor 5ìF (C5) Part Nº 0CPCPP505700

Sec. DC Bus Filter Caps 4400ìF (x 3 of 6) Part Nº 0CPA08440400

DC Bus Fuse 125A (F3) Part Nº 0CEFXV412

Capacitor

0.47ìF (C4 C3) Part Nº 0CPCPP4471200

Primary DC Bus Fuse 125A (F1) Part Nº 0CEFXV412

Output Filter Caps (x 6) 60ìF (C1 C2 C3 C4 C5 C6) Pt. Nº 0CPCPA06600450

Capacitor 15ìF (C7) Part Nº 0CPCPP615400

Capacitor 15ìF (C8) Part Nº 0CPCPP615400

DC Bus Fuse 125A (F3) Part Nº 0CEFXV412

Primary DC Bus Cap 15ìF (C1) Part Nº 0CPCPP615400

Primary DC Bus Fuse 125A (F4) Part Nº 0CEFXV412

Primary DC Bus Cap 15ìF (C2) Part Nº 0CPCPP615400

Sec. DC Bus Filter Caps 4400ìF (x 3 of 6) Part Nº 0CPA08440400

Saturable Inductor (L4) Part Nº 0CEXE3206203F3 (E) Part Nº 0CEXEPLT322033F3 (I)

Saturable Inductor (L3) Part Nº 0CEXE3206203F3 (E) Part Nº 0CEXEPLT322033F3 (I)

Converter Current Transformer 1/100 (TA4) Part Nº 0CEMC316410M006

Inductors (L2 L1) Part Nº 0CEMI316313M073

Service ManualChapter 7 - Troubleshooting

Component Location

7 - 83x3 UPS Troubleshooting

Issue 2 - November 2001

Figure 7-6 Miscellaneous Component Location

Battery Charger PCB Part Nº 0SDE0074

Fan PCB Part Nº 0SDE0078

Relay PCB Part Nº 0SDE0082

Battery Fuses 32A (FS1 FS2 FS3 FS4) Part Nº 0CEFNC332

Power Circuit Breakers 63A (I1 I2 I3 I4) Part Nº 0CESO4063

LCD Display PCB Part Nº 0SDE0075

Output Current Transformers 1/1000 (TA1 TA2 TA3) Part Nº 0CEMC316610M019

Cooling Fan (accessed from side) VT1 Part Nº 0CEVTM2200800

Service ManualChapter 7 - Troubleshooting

Fault Identification

7 - 93x3 UPS Troubleshooting

Issue 2 - November 2001

7.5 - Fault Identification

The following table lists all alarm conditions shown on the Operator panel LCD, the cause of the alarm, what checks should be carried out and possible solutions.

The activation of any alarm condition will illuminate the Red ALARM LED on the OPERATOR PANEL.

Table 7-1 General Fault Identification Check List

LCD MESSAGE CAUSE CHECKS SOLUTIONS

INVERTER OFF

The inverter is OFF. Check for other active alarm messages. If no other alarm indications are seen: At the initial inverter start up an overload has been detected (>125%).

Check the output current on each phase. Attempt to re-start the Inverter.

Reduce the load to acceptable level. Re start Inverter via the Operator Panel.

INVERTER OVERLOAD

Continuos Overload on UPS Output (between 100% and 125%).

Check the output current of each phase.

Reduce the load to acceptable level. Re-start Inverter via the Operator Panel.

STATIC SWITCH LOCKED

High Transient Loads on UPS Output. During initial closure of the Bypass Static Switch an over Load Current is detected. After 3 attempts the Bypass Static Switch will be blocked.

Check Output Load and Restart UPS.

Reduce the load to acceptable level. Re start UPS.

BATTERY FAILURE

The automatic Battery Test has failed.

Check condition of Battery. Check Battery fuses (F1-4).

Replace defective battery (see paragraph 6.3 on page6-8) Replace Battery fuses.

BATTERY PRE-ALARM

This indication warns that the battery is approaching its end-of-discharge voltage.

This alarm is Normally seen during an extended Mains Failure.

Confirm the alarm is genuine by measuring the battery voltage.

If the alarm is not genuine replace the Auxiliary DC-DC Converter.

STATIC SWITCH FAILURE

Upon closing the Internal Static Switch one or more phases are missing at the UPS Output.

Check SCR of Bypass. Check Bypass external connections.

Replace the faulty devices as necessary.

MANUAL BYPASS ON

Manual bypass MCB (I3) is closed.

Check the status of the MCB.

If the indicated circuit breaker status does not agree with the actual position then carry out a check of the auxiliary contact monitoring circuit and rectify as required.

MAINS OUT OF LIMITS

The Mains input voltage (supply to I1) is out of tolerance.

Check the status of the MAINS INPUT MCB I1. Check that the input voltage is present, and within tolerances (+/-10% of nominal).

If the MAINS INPUT MCB I1 has opened, secure load to the bypass supply and shutdown the UPS. Check the input rectifier/converter devices for fault before attempting to restart unit. Reconnect the Mains Supply to module.

BYPASS LINE OUT OF LIMITS

The Bypass input voltage (supply to I2) is out of tolerance. This condition is detected by the Inverter Driver & Feedback Board (Voltage detection or phase rotation detector circuits are active).

Check the status of the RESERVE INPUT MCB I2. Check that the Bypass (reserve) input voltage is within tolerances (+/-10% of nominal). Check the phase rotation of the Bypass supply.

If the RESERVE INPUT MCB I2 has opened, secure load to the bypass supply and shutdown the UPS. Check the bypass devices for fault before attempting to restart unit. Reconnect the Mains Supply to module. If the alarm continues replace the Inverter Driver and Feedback Board (P/N OSDE0071).

Service ManualChapter 7 - Troubleshooting

Fault Identification

7 - 10 3x3 UPS Troubleshooting

Issue 2 - November 2001

LCD MESSAGE CAUSE CHECKS SOLUTIONS

EMERGENCY POWER OFF (+INVERTER OFF + STATIC SWITCH FAILURE)

The front panel EMERGENCY push button or the External Emergency Power Off circuit has been activated.

Check the integrity of the internal EPO push button contact (Normally open) and the external EPO push button circuit (at the customer connection terminal block, Normally closed) to ensure alarm is genuine.

If the alarm is genuine then check the reason for the EPO circuit activation and rectify as necessary. Restart UPS.

BATTERY BREAKER OFF

This alarm is activated if the Battery is not connected or if the Battery Test Fails.

Check the battery fuses in the INTERNAL BATTERY fused breaker and check Battery for open or short circuit cell.

Replace defective fuses or battery.

BATTERY CHARGER FAILURE

This alarm is activated if a failure in the Battery Charger is detected.

Check integrity of Battery Fuses (F1-F5). Check IGBT Q1 on the battery charger board

Change battery charger if necessary.

HIGH BATTERY VOLTAGE LEVEL

This alarm is activated by the detection of a High Battery Voltage/Charger Output.

Check fuses F1-F5 on Battery Charger Board.. Check IGBT Q1 on the Battery Charger Board

Change battery charger if necessary.

END DISCHARGE BATTERY VOLTAGE

This alarm is activated when the battery voltage is below the `end of discharge' level (set on the Auxiliary DC-DC Power Supply Board).

This alarm is Normally seen during an extended mains Failure.

Check the level of the battery voltage. If level is low check function of the Battery Charger Board.

If the alarm is not genuine (i.e. Battery level is correct) replace the auxiliary DC-DC power supply board.

Service Manual Chapter 7 - Troubleshooting

Typical Voltage Values

7 - 113x3 UPS Troubleshooting

Issue 2 - November 2001

7.6 - Typical Voltage Values

The following table of values have been taken from a serviceable UPS and are intended to give a typical reference when carrying out fault diagnosis.

Table 7-2 Typical Measured Voltage Values and LED indications

PCB Test Point/LED Indication Normal Value Comment

3Ph TL Control Logic SE0072

TP2 (+ve) to TP3 (Ćve)

4.27V dc

Inverter feedback signal to U8 Level adjusted by P1.

TP4 (+ve) to TP5 (Ćve)

4.31V dc

Converter feedback signal to U9 Level adjusted by P2.

TP6 (+ve) to TP7 (Ćve)

4.28V dc

Static Switch feedback signal to U8 Level adjusted by P3.

TP9

Logic Low

NO MAINS OK signal from U12A.

TP10

2.49 Ć 2.29V dc

MAINS FREQ signal from U12B.

TP11

5.48V dc

TEMP ALARM signal from U14C (Active Low).

TP12

0.021V dc

MANĆBYP signal from U12D.

TP14

0.37V dc

MAINS PRESENT signal from U12F.

TP15

0.025V dc

NO BATTERY HIGH signal from U13A.

TP16

5.01V dc

BATTERY LOW signal from U13B.

TP17

0.016V dc

NO BATTERY PREALARM signal from U13C.

LED LD1 (green)

UPS Normal (OFF indicates an over temperature ST1, a DC offset condition or PCB power failure)

Auxiliary DCĆDC Converter SE0070

U2A pin 1

8.88V dc

Battery voltage monitor.

R36

5.59V dc

VMAX level adjustment (P1) sets battery high level 500V.

R37

7.89V dc

VMIN level adjustment (P2) sets battery low level 320V.

R39

7.53V dc

PREALARM level adjustment (P3) 350V.

Molex Connector PM2 Pin 1 16.83V dc

+15V supply to Inv. driver feedback PCB.

Molex Connector PM2 Pin 2 7.68V dc

+7.5V supply to Inv. driver feedback PCB.

Molex Connector PM2 Pin 3 0V

Ground.

Molex Connector PM2 Pin 4 15.33V dc

Battery high output to Inv. driver feedback PCB.

Molex Connector PM2 Pin 5 0.616V dc

Battery low output to Inv. driver feedback PCB.

Molex Connector PM2 Pin 6 15.47V dc

Battery Prealarm output to Inv. driver feedback PCB.

Inverter Driver Feedback SE0071

R66

6.43V dc

Reserve Bypass Vmin level adjustment (P2)

R69

5.54V dc

Reserve Bypass Vmax level adjustment (P1)

R149

9.53V dc

Temperature alarm reference adjustment (P3)

LED LD1

OFF

ON indicates incorrect phase rotation.

LED LD2

OFF

ON indicates DC Offset unbalanced load.

Battery Charger SE0074

Note: No voltage measurements can be carried out safely on this PCB.

LED LD1 FLASHING FLASHING indication when float charging battery.

Service ManualChapter 7 - Troubleshooting

Fuse Check List

7 - 12 3x3 UPS Troubleshooting

Issue 2 - November 2001

7.7 - Fuse Check List

Prior to any fault diagnosis, a serviceability check of the fuses is recommended. Failure of a fuse can give an indication of a defective power device or component.

1. Using the list shown in Table 7Ć3 check each fuse for serviceability.

2. Determine the serviceability of any related component or PCB and repair or replace as

required.

3. Replace the fuse with a serviceable item.

4. Continue with any required fault diagnosis.

Table 7-3 Fuses

Fuse Value Function Location

F1 32A

Battery Bank 1

F2 32A

Battery Bank 2

F3 32A

Battery Bank 3

Battery Fuses Front Switch Panel

F4 32A

Battery Bank 4

F1 125A

Primary DC bus +ve

F4 125A

Primary DC bus ćve

Upper Power Section See Figure 7Ć5

F2 125A

Secondary DC bus +ve

F3 125A

Secondary DC bus ćve

Upper Power Section See Figure 7Ć5

F1 1A

DC+ Input

F2 1A

DCć Input

Auxiliary DCĆDC Converter PCB

F1 10A

Input Phase R

F2 10A

Input Phase S

F3 10A

Input Phase T

Battery Charger PCB

F4 10A

Battery +

F5 10A

Battery ć

F1 1A Cooling Fan Protection Fan PCB

Service Manual

Test Procedures

7 - 133x3 UPS

Issue 2 - November 2001

7.8 - Test Procedures

7.8.1 - DC Bus Discharge Routine, Shutdown to Maintenance Bypass.

After calibration the following procedure can be used to shutdown the UPS to a Manual bypass condiĆ tion, and then to normal operation:

1. Press the `MENU' push button ( A ) on the FRONT PANEL. a) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push

button.

b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same

time (i.e. ENTER). c) Select the `SWITCH LOAD' function by pressing either `BACK' or `NEXT'. d) Confirm `SWITCH LOAD' function by pressing `BACK' and `NEXT' at the same time.

D A *CONFIRMED* message will be displayed

2. Press `CLEAR' ( d ) twice to return to the main menu.

The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:

D The yellow `BYPASS ON' LED ( 4 ) is illuminated D The green `LOAD on INV' LED is extinguished.

button.

c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same

time (i.e. ENTER).

d) Select the `INVERTER ON-OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (B)

push button.

e) Confirm `INVERTER OFF' function by pressing `BACK' and `NEXT' at the same time.

D A **CONFIRMED** message will be displayed

f) Press `CLEAR' twice to return at the main screen.

4. The follow sequence should occur: a) The Alarm buzzer is activated. b) the Red general `ALARM' red LED ( 2 ) will illuminate. c) the Yellow `BYPASS ON' LED ( 4 ) will illuminate. d) the Green `NORMAL' LED will extinguish. e) The LCD will display the following messages:

`LOAD ON BYPASS' and `INVERTER OFF'.

5. Remove the Mechanical Lock from the MANUAL BYPASS MCB ( I3 )

6. Close the. MANUAL BYPASS MCB ( I3 )

7. Open the `UPS OUTPUT' MCB ( I4 ).

8. Open the `MAINS INPUT' MCB ( I1 ).

9. Open the `RESERVE INPUT' MCB ( I2 ).

10. Open the `INTERNAL BATTERY' fused switch ( I5 ).

11. Check that the load continues to be powered from the Maintenance Bypass Mains supply

while the UPS is off.

WARNINGWait at least 10 minutes after Shutting Down the UPS before proceeding with a StartĆ

Up procedure. to allow the DC bus to fully discharge

Note: To completely isolate the UPS from the input AC supplies, the main

external input power isolator must be opened. On the primary input utility supply distribution panel post a label advising personnel that the UPS circuit is under maintenance.

Service Manual

Test Procedures

7 - 14 3x3 UPS

Issue 2 - November 2001

Primary and Secondary DC Bus Voltage Check (refer to Figure 7Ć7)

1. Remove the UPS top cover.

2. With a DVM check the secondary DC bus across F3 and F2 has fallen less than 20V dc.

3. With a DVM check the primary DC bus across F1 and F4 has fallen less than 20V dc.

The UPS is now safe to carry out further investigation.

Note: The half DC bus level can also be monitored if required by connecting the

DVM across the +ve or Ćve fuse and the DC common (neutral) bus bar as show n in Figure 7Ć7.

Figure 7-7 DC Bus Voltage check

Check Secondary DC bus between Fuse F3 & F2 765V DC

To Check Half Secondary DC bus Voltage check for 382V DC between Fuse F3 and Neutral Bus. (a similar check can be carried out from F2)

Service Manual

Test Procedures

7 - 153x3 UPS

Issue 2 - November 2001

7.8.2 - DC offset

Fault indication

The output of the UPS is monitored by the Inverter Driver Feedback PCB for any DC component on the output waveform. If the level of DC exceeds the limit of 400mV, a signal is generated and switched to the control logic PCB. This signal is switched through the thermostat ST1 as shown below in Figure 7Ć8.

Figure 7-8 DC Offset Alarm Signal

The UPS will transfer to the bypass and the red LED LD 2 on the inverter driver/feedback PCB Part Nº OSDE0071, will illuminate. The red LED D11 on the 3ph TL control logic PCB Part Nº OSDE0072 will extinguish. The UPS will remain on bypass until the alarm condition is reset using the Reset push switch S1 on the PCB, or the UPS is completely powered down and restarted.

Figure 7-9 Typical output current waveforms with DC offset.

Normal output current waveform

Output current waveform showing DC Offset

Effect on the Output current waveform with unbalanced non linear load

DC Offset

DC Offset Condition

The most likely cause of a `DC OFFSET' condition could be:

1. The UPS is supplying an unbalanced non linear load, this could be on any phase.

2. The load is drawing DC current.

A common reason for this is an input bridge rectifier on a computer power supply is defective and only half wave rectifying its input power.

3. An inverter gate drive circuit is defective.

This could cause the inverter EIGHT's switching to be out of balance.

Service Manual

Test Procedures

7 - 163x3 UPS

Issue 2 - November 2001

Action

1. To determine if the DC offset problem is load related. Replace the normal load temporarily with a resistive load and monitor the alarm condition, if it disappears then the problem lies with the load.

2. To measure the level of DC offset present, connect the test circuit shown in Figure 7Ć9 to the output of the UPS.

Figure 7-10 DC offset test circuit.

U3 W3N3

Meter

All R = 120kÙ 2Watt

All C = 1ìF 250V

DC checked across each capacitor normal level 50mV

3. Measure the DC mV across each phase capacitor the nominal level should be 50mV the maximum 400mV.

a) Measure the DC offset level with the load connected if it is out of limits then the problem

is load related.

b) Check again with no load if the DC offset level is out of limits then the problem may lie

with the UPS.

4. If the DC Offset appears to be generated by the UPS, check the voltage across D94 and D89 on the inverter driver/feedback PCB Part Nº OSDE0071. The voltage should be equal.

5. If an unequal voltage is measured then the fault is likely to be in either the inverter gate drive or IGBT's. Check that the IGBT drive circuit is correct and the IGBT devices are serviceable.

6. If the circuit and IGBT checks are OK the problem points to a defective monitoring circuit in the inverter driver/feedback PCB. Replace the inverter driver/feedback PCB.

7. Reconnect all cables and fit any covers removed.

8. Restore the UPS to its normal running condition.

Service Manual

Test Procedures

7 - 17 3x3 UPS

Issue 2 - November 2001

7.8.3 - IGBT Replacement

General Fitting Information.

When fitting heatsink mounted devices the following factors must be observed.

1. Ensure that when handling devices correct anti static precautions are taken and the handler is connected to earth using a antistatic wrist band.

2. Take care when handling devices. Do not fit any device that may have been dropped or damaged.

3. Spread a thin film of heatsink compound Part Nº 04010340 over the whole of the base area. Ensure there are no gaps and the base and heatsink are free of foreign material before fitting.

4. Position the device on the heat sink and insert the correct length screws listed in Table 7Ć4

5. Tighten the screws to finger tightness, ensuring that the threaded holes are not damaged.

6. Tighten screws alternately part way before applying the full torque to individual screws, to prevent unnecessary strain being applied to the device substrate.

7. Use the tightening sequence shown in Figure 7Ć10.

Figure 7-11 Screw tightening sequence.

8. Finally tighten the screws to the appropriate torque shown in Table 7Ć4.

Torque Nm

Circuit Ref. Part Nº

Pan head

Sems

Heatsink Terminal

Bridge PD1 0CADTSSKD82/12 M4 X 12FL 2 2

Diode CD1 CD2 0CSDRFBYT261P12 3.5 3.5

Diode CD4 CD5 0CADR210230 2 2

Diode CD3 0CADRFBYT231 2 2

SCR S7 S8 0CASR212132 M5 X 16FL 3 3

SCR S1, 2, 3, 4, 5 & S6 0CASR212391 M5 X 16FL 3 3

IGBT Q1, Q2, Q3 (Inverter) 0CATR210415 M5 X 13FL 3

M4 Ć 2 M5 Ć 3

IGBT Q4 (Converter) 0CATD212420 M5 X 16FL 2.5 2

Table 7-5 Torque settings for Hinet devices.

Inverter IGBT (Q1 Q2 Q3) Removal

1. Power down the UPS and carry out the DC bus discharge routine.

2. Gain access to the UPS power section by removing the top and side covers.

3. Disconnect and remove the Inverter driver/feedback PCB Part NºOSDE0071. Follow the procedure on page 7Ć32.

4. Disconnect fuse F2 and F3.

5. Remove capacitors C9 and C10

6. Remove the Inverter bus bar retaining screws from the IGBT's and lift off the bus bars.

Service Manual

Test Procedures

7 - 183x3 UPS

Issue 2 - November 2001

7. Disconnect the cables attached to current transformer TA1 TA2 and TA3 IGBT connection extension pillars and lift off the CT's.

Note: An inĆsitu test for a short circuit IGBT can be carried out at this point

before the devices are removed.

8. Disconnect the gate drive fastĆon connectors from the IGBT's and note their position for reĆassembly.

9. Remove the four retaining IGBT securing Allen screws from each IGBT and remove each IGBT.

10. Test each IGBT for serviceability follow the IGBT test procedure on page 7Ć20.

11. Replace any components found defective.

IGBT fitting is the reverse of the removal procedure refer to Table 7-6 for correct IGBT gate drive conĆ nector location.

Table 7-6 Inverter IGBT Gate Drive Connectors

IGBT Gate Lead Terminal

IGBT Connector

4 5 7 6

Q1 J11 Red Black Black Red

Q2 J9 Blue Black Black Blue

Q3 J11 Red Black Black Red

Converter IGBT (Q4) Removal

1. Power down the UPS and carry out the DC bus discharge routine.

2. Gain access to the UPS power section by removing the top and side covers.

3. Disconnect and remove the Inverter driver/feedback PCB Part NºOSDE0071. Follow the procedure on page 7Ć32.

4. Remove the converter bus bar retaining screws from IGBT Terminal 2 and 4.

5. Remove capacitors C9 and C10 from the bus bars.

6. Remover the connecting screws from diodes CD4 and CD5

7. Remove the bus bar retaining screws from the insulated pillar.

8. Slacken the converter current transformer (TA4) mounting bolt securing the CT and bus bar, and reposition to gain access to Q4.

Note: An inĆsitu test for a short circuit IGBT can be carried out at this point

before the devices are removed.

9. Disconnect the gate drive fastĆon connectors from the IGBT and note their position for reĆassembly.

10. Remove the four retaining IGBT securing Allen screws and remove from IGBT from the heatsink.

11. Carry out a test of the IGBT for serviceability follow the IGBT test procedure on page 7Ć20.

12. Replace IGBT if found defective.

IGBT fitting is the reverse of the removal procedure refer to Table 7-7 for correct IGBT gate drive conĆ nector location.

Table 7-7 Converter IGBT Gate Drive Connectors

IGBT Gate Lead Terminal

IGBT

3 5

Q4 Red Black

Service Manual

Test Procedures

7 - 193x3 UPS

Issue 2 - November 2001

7.8.4 - IGBT testing

Two types of IGBT are used on the series UPS.

a) Twin pack devices used in the inverter section. b) A single pack devices used on the converter.

All the devices currently used on the , are the latest `advanced second' or `third' generation type, these have a higher gate emitter impedance. Difficulty can be experienced testing this type of IGBT using a standard DVM, as they lack the battery power to switch on the device.

This difficulty can give rise to an incorrect diagnosis and a perfectly serviceable IGBT may be marked as defective.

As a normal DVM cannot produce a high enough voltage to switch on a advanced second or third generĆ ation IGBT, it is recommended that the functional test is carried out with the use of an external dc power supply.

Note: A 9V PP3 battery can successfully be used as the external voltage source.

Hinet Third Generation IGBT's

Circuit Ref. IGBT Type Liebert Hiross Part Nº

IGBT Q1, Q2, Q3 EUPEC BSM150GB120DN2 Twin 0CATR210415

IGBT Q4 EUPEC BSM200GA120DN2 (6) Single 0CATD212420

Table 7-8 Third generation IGBT usage

Testing the IGBT

1. Power down the UPS and gain access to the power sections by following the procedure on page 7Ć3.

2. Ensure that the power sections have been completely isolated, check using a DVM.

3. Locate the IGBT to be tested and totally isolate it by disconnecting its gate drive lead from the inverter drivers and feedback PCB, and the power leads from the screwed terminals.

4. Test the IGBT using a DVM and a 9V dc power source. Follow the procedure shown in Table 7Ć6. Refer to Figure 7Ć11 for the IGBT internal circuit.

5. Replace the IGBT if required. Ensure the correct fitting procedure is used. Refer to Table 7Ć4 for correct torque values.

6. Reconnect the IGBT gate drive and power connections.

7. Carry out a test of the Inverter or Converter.

8. Replace all panels removed and restore the UPS to its normal working condition.

Service Manual

Test Procedures

7 - 203x3 UPS

Issue 2 - November 2001

Table 7-9 Functional check of power IGBT's

Action

DVM/Battery Lead

Connection

DVM

Indication

(mV)

Interpretation

+ve to: Ćve to: IGBT

Connect DVM across the emitter cathode junction.

[1]

2 Ć 7

[2 Ć 5]

IGBT switched off a serviceable condition.

Reverse DVM leads to check internal diode.

2 Ć 7

[2 Ć 5]

[1]

0.355

Diode forward resistance.

ReĆconnect DVM leads across emitter cathĆ ode.

[1]

2 Ć 7

[2 Ć 5]

Connect the 9V power supply (battery) negative Ćve

2 Ć 7

[2 Ć 5]

Touch the +ve Battery lead to gate (base).

[3]

2 Ć 7

[2 Ć 5]

0.345

This will switch on the device.

ReĆcheck the emitter cathode junction.

[1]

2 Ć 7

[2 Ć 5]

0.345

Low mV reading indicates IGBT has switched on and is serviceable.

Disconnect the battery +ve and Ćve leads.

ć ć 0.345

Turn off the device by shorting B2(G2) and E2.

[1]

2 Ć 7

[2 Ć 5]

High resistance indicates the IGBT is off.

Note: Terminal connections for single pack IGBT are shown in [square brackets]

Testing the second IGBT

Connect DVM across the emitter cathode junction.

3 1 OL

IGBT switched off a serviceable condition.

Reverse DVM leads to check internal diode.

1 3 0.336

Diode forward resistance.

ReĆconnect DVM leads across emitter cathĆ ode.

3 1 OL

Connect the 9V power supply (battery) negative Ćve

1 OL

Touch the +ve Battery lead to gate (base).

4 1 0.345

This will switch on the device.

Disconnect the battery +ve and Ćve leads.

ć ć 0.345

ReĆcheck the emitter cathode junction.

3 1 0.345

Low mV reading indicates IGBT has switched on and is serviceable.

Turn off the device by shorting B1 and E1.

3 1 OL

High resistance indicates the IGBT is off

Note: The DVM readings shown in the above table are typical they will vary

slightly from device to device and with the type of meter used.

Service Manual

Test Procedures

7 - 213x3 UPS

Issue 2 - November 2001

Figure 7-12 IGBT internal circuit and external connections.

Twin pack IGBT (Part Nº OCATR210415)

Single pack IGBT (Part Nº OCATD212420)

Service Manual

Test Procedures

7 - 223x3 UPS

Issue 2 - November 2001

7.8.5 - SCR Testing

The UPS use two types of SCR devices, one to switch the reserve bypass and inverter output to the load. The second type to connect the battery to the primary DC bus in the event of failure of the utility supply.

The two different types of device used to perform these functions are both of twin pack construction howĆ ever S7 and S8 have a single SCR and Diode. arrangement.

Table 7-10 SCR

Circuit Ref. SCR Type Part Nº

SCR S1 S2 S3 S4 S5 S6

SEMIKRON SKKT 92/12E 91A Twin Pack 0CASR212420

SCR S7 S8 SEMIKRON SKKH132/12E

132A combined SCR &

Diode Pack

0CASR212132

Failure of a static switch or battery SCR will initiate the appropriate indication on the LED display and will normally fail open circuit O/C or short circuit S/C. If a faulty device is suspected it can be checked using a DVM. A short circuit across the anode cathode junction will be quickly apparent, however an open circuit cannot so easily be diagnosed as the high resistance indicated is the normal state of the device when turned off.

The Gate Cathode resistance can also be measured and should be in the range of 10 to 20 ohms for a serviceable SCR, a high resistance would indicate an open circuit.

It is therefore recommended that a functional test of the SCR is carried out using the simple test circuits shown in Figure 7Ć12 and Figure 7Ć14.

Twin Pack SCR Replacement (S1 S2 S3 S4 S5 S6)

1. Power down the UPS and carry out the DC bus discharge routine.

2. Gain access to the UPS power section by removing the top and side covers.

3. Disconnect and remove the Inverter driver/feedback PCB Part NºOSDE0071. Follow the procedure on page 7Ć32.

4. Remove the two SCR gate drive leads from terminals 4 and 6 from each SCR and note their position.

Note: Note SCR S6 has the gate drive leads reversed blue to 4 red to 6.

5. Remove the terminal standoffs and screws to release the bus bars from SCR terminals 1. 2 and 3.

6. Disconnect the second gate drive leads from SCR terminals 1 and 2.

Table 7-11 SCR Gate Drive Lead Connection

Gate Drive Terminal

SCR

4 6 1 2

S1 Blue Red Black Brown

S2 Red Blue Brown Black

S3 Blue Red Black Brown

S4 Red Blue Brown Black

S5 Blue Red Black Brown

S6 Blue Red Black Brown

7. Remove the two SCR Allen retaining screws from each SCR and lift from the Heatsink

8. Carry out the following functional test on each SCR and replace if required.

SCR fitting is the reverse of the removal procedure refer to 12. for correct SCR gate drive connector locaĆ tion.

Service Manual

Test Procedures

7 - 233x3 UPS

Issue 2 - November 2001

Figure 7-13 Testing the twin pack SCR

9 volt power source and switch

+ve

ćve

9 volt power source

Test lamp

9 volt power source

+ve

ćve

+ve ćve

+većve

Twin pack SCR

To functionally test a twin pack SCR as shown in Figure 7Ć12 a DC power source and test lamp is reĆ quired, typically a 9V PP3 battery and 12V bulb.

1. Connect the bulb and battery to SCR1 as shown, connect the +ve to the anode (1) and ćve to the cathode (2) terminal.

2. Using a second power source or link from the battery connect the +ve lead to SCR1 gate terminal 4 and the ćve lead gate terminal 5.

3. Switch on the SCR by briefly making the gate circuit, use a switch if available. The SCR will fire and the bulb will light and remain on. The bulb provides a current source for the SCR and it will continue to fire.

4. Remove the +ve connection from terminal 1. The bulb will extinguish an the SCR will switch off.

5. Repeat the test for SCR2.

Service Manual

Test Procedures

7 - 243x3 UPS

Issue 2 - November 2001

Single SCR and Diode Pack Replacement. (S7 S8)

1. Power down the UPS and carry out the DC bus discharge routine.

2. Gain access to the UPS power section by removing the top and side covers.

3. To gain access to the SCR's disconnect and remove the Input Filter PCB Part NºOSDE0079. Follow the procedure on page 7Ć38.

SCR S7

4. Disconnect the Red and Black gate drive Connectors from 4Q1 (red) and 5K1 (black).

5. Disconnect the Battery negative bus bar from SCR terminal 2.

6. Disconnect Fuse F4 bus bar from SCR terminal 1.

7. Disconnect black leads from R2 to SCR terminal 1 and 2.

8. Remove red leads from SCR terminal 1 and 2 which connect to the fast on connectors F12 (SCR 1) and F11 (SCR 2) on the Inverter driver/feedback PCB.

Note: There is no connection to SCR terminal 3.

9. Remove the two SCR Allen retaining screws from the SCR and lift from the Heatsink.

Note: There is a deĆcoupling capacitor linking the heatsink from SCR mounting

screw to the neutral bus bar.

SCR S8

10. Disconnect the battery +ve cable from SCR terminal 3.

11. Disconnect red leads from R1 to SCR terminal 1 and 2.

12. Remove fuse F1 bus bar from SCR terminal 2.

13. Remove the input bridge bus bar from SCR terminal 1.

14. Remove red leads from SCR terminal 1 and 2 which connect to the fast on connectors F13 (SCR 1) and F14 (SCR 2) on the Inverter driver/feedback PCB.

15. Carry out the following functional test on each SCR and replace if required.

SCR fitting is the reverse of the removal procedure.

Figure 7-14 Single SCR Test.

9 volt power source and switch

+ve

ćve

Test lamp

9 volt power source

+ve ćve

Single SCR & Diode pack

Powertronix Quasar, 10kVA, 15kVA, 20kVA, 30kVA Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual