Powertronix 20kVA User manual

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

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Name of Registered Holder

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Holder

Company

Name/Building

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Area/region

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Amendment Record

Service Manual

Manual Serial

Number:

Please enter the Manual Serial Nº

for future record

Issue

Nº

Issue

Date

Amendment Amended By Date

1

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

10

8

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%

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

Confi

g

uration 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

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