9355 30kVA Service Manual_A02
Short Description
9355 30kVA Service Manual...
Description
Powerware® 9355 20-30 kVA UNINTERRUPTIBLE POWER SUPPLY
Service Manual
July 2006 164201621 Revision A02
Notice of Proprietary Information The equipment discussed herein is capable of causing great harm to life, limb and/or property. Installation, maintenance, and/or repair, of the equipment referenced herein must be performed by Eaton Electrical duly authorized or trained certified personnel. Notwithstanding the foregoing, Eaton Electrical assumes NO responsibility for any damage or injury to any persons or property which may be caused to any extent by reliance on the information provided herein except to the extent such damage or injury results solely and directly from the willful negligence of Eaton Electrical, it’s agents or employees. Additionally, Eaton Electrical shall not be liable for any indirect, special incidental or consequential damages, such as, but not limited to, loss of anticipated profits, good will or other economic loss in connection with or arising out of the existence of, the furnishing of, or the use of the information provided for in this agreement, whether or not the possibility of damage was disclosed to or could have been reasonably foreseen by Eaton Electrical. The information contained herein is proprietary to Eaton Electrical and may be used or copied only in accordance with written agreement with Eaton Electrical. It is UNLAWFUL TO COPY OR REPRODUCE THIS DOCUMENT OR ANY PART THEREOF IN ANY MEDIA OR TO USE OR REFERENCE SAME EXCEPT FOR THOSE PURPOSES IN THE MEANS AND QUANTITIES SPECIFIED BY WRITTEN AGREEMENT WITH EATON ELECTRICAL. Periodically, changes are made to the contents herein. Please contact Eaton Electrical or your original source for any modification, updates or new additions. Due to the possibility of such changes, RELIABILITY ON THE CONTENTS HEREIN IS AT RECIPIENT’S/USERS’S OWN RISK. The equipment provided by Eaton Electrical contains areas that conduct lethal voltages. The maintenance of Eaton Electrical equipment requires factory trained personnel that are aware of the potential danger areas.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Table of Contents
Table of Contents Chapter 1 System Overview 1.1 System Description 1.1.1 Single Module Systems 1.2 Single Module–Reverse Transfer (RT) Modes of Operation 1.2.1 NORMAL Mode 1.2.2 BATTERY Mode 1.2.3 Power Share Operation 1.2.4 BYPASS Mode 1.3 Parameter Settings 1.3.1 Parameter List 1.4 Input Isolation Transformer (60 Hz Only) 1.4.1 PW 9355 1.5 Seismic Capability 1.6 External Battery Cabinets 1.7 Remote Emergency Power Off (REPO) 1.8 Environmental Monitoring Probe (EMP) 1.9 Parallel Tie Cabinet with System Bypass
1-1 1-1 1-4 1-4 1-6 1-8 1-8 1-12 1-12 1-16 1-16 1-16 1-16 1-16 1-16 1-17
Chapter 2 Safety 2.1 General Safety Considerations 2.1.1 Tools, Equipment, and Expendable Field Service Supplies 2.1.2 General Safety Rules 2.2 Environmental Safety 2.3 Electrical Safety 2.4 Mechanical Safety 2.5 Eye Safety 2.6 UPS Safety 2.6.1 Operating Environment 2.6.2 Normal Operation 2.6.3 Maintenance/Service 2.6.4 Batteries 2.7 Site Safety 2.8 Summary 2.9 Electrostatic Discharge (ESD) Procedure And Equipment Requirements 2.9.1 Purpose 2.9.2 Objective 2.9.3 Applicable Documents and Materials 2.9.4 Definitions 2.9.5 Procedure 2.9.6 Removal of Boards 2.9.7 Packaging of Boards 2.9.8 General Handling Guidelines for ESD Protection
2-1 2-1 2-1 2-2 2-3 2-4 2-4 2-5 2-5 2-5 2-5 2-6 2-7 2-8 2-8 2-8 2-8 2-8 2-9 2-9 2-10 2-11 2-11
Chapter 3 Installation and Startup 3.1 MODEL 9355 20 – 30kVA SINGLE MODULE (RT) 3.1.1 Mechanical Inspection 3.1.2 Electrical Inspection © 2006 - Eaton Corporation
3-1 3-1 3-5 i
Table of Contents
ii
9355 20 – 30 kVA
Operational Inspection 3.2 MODEL 9355 20 – 30kVA Parallel (PC/PR) 3.2.1 Mechanical Inspection 3.2.2 Electrical Inspection 3.2.3 Operational Inspection 3.2.4 Inspection Completion
3-7 3-10 3-10 3-16 3-19 3-21
Chapter 4 Functional Descriptions 4.1 Model 9355 20 – 30kVA 4.1.1 Overview 4.1.2 X-Slot Connections 4.1.3 Native RS Port 4.2 Electronics Module Functional Sections 4.2.1 Display Panel 4.2.2 Control Board 4.2.3 Power Module Boards 4.2.4 Bypass Control Board 4.2.5 I/O Board 4.2.6 EMI / Surge Board 4.2.7 Contactors 4.2.8 Internal Battery 4.2.9 External Battery 4.2.10 Battery Circuit Breaker 4.2.11 Ferrite Toroids 4.2.12 Chokes 4.2.13 Fans 4.3 LCD Display Panel 4.3.1 Overview 4.3.2 Detailed Description of Settings 4.3.3 User Settings 4.3.4 Service Settings 4.4 CONTROL BOARD (PCB) 4.4.1 Firmware Description and Operation 4.4.2 Shutdown State 4.4.3 Startup State 4.4.4 Battery Starting State 4.4.5 Utility Starting State 4.4.6 Inverter Starting State 4.4.7 Standby State 4.4.8 User Interface & XCP 4.4.9 On Inverter State 4.4.10 On Bypass State 4.4.11 The Bleeding State 4.4.12 Bypass-Locked State 4.4.13 Failure Shutdown State 4.4.14 Methods of Turning the UPS Off 4.4.15 XCP Command Codes 4.4.16 Hardware Signals 4.5 POWER MODULE BOARD (PCB)
4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-4 4-4 4-4 4-5 4-5 4-5 4-5 4-6 4-6 4-9 4-11 4-11 4-12 4-13 4-15 4-16 4-18 4-19 4-20 4-20 4-21 4-25 4-26 4-27 4-28 4-28 4-29 4-31
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Table of Contents
4.5.1 Introduction & Overview 4.5.2 Description and Operation 4.5.3 Other Connector Descriptions 4.6 Power Board Functional Blocks 4.6.1 Voltage Sensing 4.6.2 Rectifier 4.6.3 Battery Converter 4.6.4 Inverter 4.6.5 IGBT Gate Drives 4.7 Advanced Battery Management 4.7.1 Introduction 4.7.2 Purpose 4.7.3 General Terms 4.7.4 Charging Cycles 4.7.5 Temperature Compensation 4.7.6 Forcing on Rest Mode 4.7.7 User Disabling of ABM Charging Cycles 4.7.8 Battery Failure Testing 4.8 Battery Lifetime 4.8.1 Introduction 4.8.2 Operational Sequence 4.8.3 Battery Discharge 4.8.4 Run-Time and Temperature 4.9 Battery Test 4.9.1 Introduction 4.9.2 Battery Test 1 4.9.3 Battery Test 2 4.9.4 Battery Test Calculations 4.10 I/O BOARD (PCB) 4.10.1 Overview 4.10.2 I/O Connector Descriptions 4.11 I / O Board Functional Sections 4.11.1 Auxiliary Power Supply 4.11.2 Rail Precharge 4.11.3 Voltage Sensing 4.12 Current Measurements and Hardware Current limits 4.12.1 Output Current Measurement 4.12.2 Input and Output Filtering Scheme 4.12.3 Inverter/Rectifier Fault Methodology 4.12.4 Single Feed/Dual Feed Input Contactors 4.12.5 Battery Relay, Battery Start and Current Measurement 4.12.6 Balancer Relays and Drive 4.12.7 Battery CB Trip 4.12.8 Input/Output CB Trip 4.12.9 Other Sensing 4.12.10 X-Slots 4.12.11 AC Fans 4.12.12 Chassis GND 4.12.13 Troubleshooting © 2006 - Eaton Corporation
4-31 4-32 4-32 4-33 4-33 4-33 4-33 4-34 4-34 4-35 4-35 4-35 4-36 4-38 4-39 4-40 4-41 4-42 4-44 4-44 4-44 4-44 4-45 4-45 4-45 4-45 4-45 4-46 4-49 4-49 4-50 4-59 4-59 4-59 4-59 4-60 4-60 4-60 4-61 4-61 4-61 4-62 4-62 4-62 4-62 4-62 4-63 4-63 4-63 iii
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iv
9355 20 – 30 kVA
4.13 Bypass Board System Overview 4.14 Bypass Board Functional Blocks 4.14.1 BAUX Power Supply 4.14.2 Voltage Sensing 4.14.3 Input Contactor 4.14.4 Alarm Supply 4.14.5 EPO Alarm 4.14.6 Building Alarms 4.14.7 RS-232 4.14.8 NO/NC Relay Contacts 4.15 Bypass SCR Gate Drive and SCRs 4.15.1 Standalone Bypass Functionality 4.15.2 Bypass State Machine 4.15.3 AC Fans 4.16 ELECTRO-MAGNETIC INTERFERENCE (EMI) BOARD (PCB) 4.16.1 Introduction 4.16.2 EMI Board Functional Sections
4-64 4-66 4-66 4-66 4-67 4-67 4-67 4-67 4-67 4-67 4-67 4-68 4-68 4-72 4-73 4-73 4-73
Chapter 5 Connectivity and Communications 5.1 9355 GENERAL CONNECTIVITY DEVICES 5.1.1 Basic Serial Communication 5.1.2 Relay Signaling 5.1.3 Building Alarm Inputs 5.1.4 Additional Connectivity & Software 5.2 9355 X-SLOT CONNECTIVITY DEVICES 5.2.1 Modem Handling 5.2.2 Modem Operation 5.2.3 Modem Call Handling States 5.2.4 Communication During a Modem Session 5.3 9355 COMMUNICATION 5.3.1 Default Communication Access Passwords 5.3.2 Signal Inputs & Programmable Functions 5.3.3 Programmable Functions 5.3.4 Signal Inputs on Front Panel Display 5.3.5 Configuration Fields 5.3.6 HyperTerminal
5-1 5-1 5-1 5-1 5-1 5-2 5-2 5-4 5-8 5-16 5-19 5-19 5-19 5-19 5-22 5-23 5-27
Chapter 6 Options 6.1 Communications and Connectivity Options 6.1.1 Single Port RS-232 Serial or AS/400 Signal Card 6.1.2 Multi-Port/Multi-Server Card 6.1.3 Low Voltage (LV) Relay Interface Card 6.1.4 High Voltage (HV) Industrial Relay / RMP Interface Card 6.1.5 ConnectUPS Network Adapters 6.1.6 MODBUS Communications Card 6.1.7 Modem Card 6.1.8 USB Module 6.1.9 CAN Bridge Card 6.1.10 Remote Monitor 6.2 Options Cabinet
6-2 6-2 6-3 6-5 6-7 6-8 6-9 6-10 6-13 6-14 6-14 6-15
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Table of Contents
6.3 Power Distribution Unit (PDU) 6.4 Remote Power Panel (RPP) 6.4.1 IQ 100 Series RPP 6.4.2 IQ 200 Series RPP
6-18 6-19 6-19 6-19
Chapter 7 Troubleshooting and Maintenance 7.1 Troubleshooting Charts 7.1.1 Action Levels 7.1.2 Alarm, Notice, Status & Flag Definitions 7.1.3 Detailed Definitions 7.1.4 Failure Analysis 7.1.5 Electronics Module and Other Failures
7-1 7-1 7-3 7-22 7-27 7-36
Chapter 8 Removal and Replacement 8.1.1 Removal Preparation 8.1.2 Removing the L3 Power Module 8.1.3 Replacing the L3 Power Module 8.1.4 Removing the L2 Power Module 8.1.5 Replacing the L2 Power Module 8.1.6 Removing the L1 Power Module and Bypass Board 8.1.7 Replacing the L1 Power Module / Static Switch Assembly 8.1.8 Removing the I/O Board Assembly 8.1.9 Replacing the I/O Board 8.2 TECHNICAL SUPPORT KNOWLEDGE BASE
8-1 8-1 8-4 8-6 8-7 8-8 8-12 8-13 8-19 8-21
Chapter 9 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5 9.1.6 9.1.7 9.1.8 9.1.9 9.1.10 9.1.11
9-4 9-5 9-7 9-8 9-9 9-10 9-11 9-12 9-14 9-15 9-16
Calibration Calibrate Bypass AC Input Voltage Calibrate Utility AC Input Voltage Calibrate Battery Voltage Calibrate DC Link Voltage Calibrate UPS AC Output Voltage Calibrate Inverter AC Output Voltage Calibrate Inverter DC Output Voltage Calibrate Bypass Current (Output) Calibrate Utility Current Calibrate Battery Current Calibrate Inverter Current
Chapter 10 Parts 10.1 PW 9355 30kVA SPARE PARTS LISTINGS 10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N 106711170 10.1.2 High Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N 10.2 PW 9355 30kVA UPS Subassemblies 10.2.1 LV Electronic Module 10.2.2 HV Electronic Module 10.3 Parts Break-down / Look-up Procedure 10.3.1 Requirements: 10.3.2 Procedure
10-1 10-1 10-2 10-2 10-2 10-3 10-4 10-4 10-4
Chapter 11 Prints
© 2006 - Eaton Corporation
v
Figure List
9355 20 – 30 kVA
Figure List Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. vi
EATON-Powerware® 9355 20–30kVA UPS .............................................. 1-1 PW9355 30kVA Basic Single Module System............................................ 1-2 PW 9355 NORMAL Mode (single feed)...................................................... 1-4 PW 9355 NORMAL Mode (dual feed) ........................................................ 1-5 PW 9355 BATTERY Mode (single feed)..................................................... 1-6 PW 9355 BATTERY Mode (dual feed) ....................................................... 1-7 PW 9355 BYPASS Mode (single feed)...................................................... 1-9 PW 9355 BYPASS Mode (dual feed) ........................................................ 1-9 PW9355 Service Position ......................................................................... 1-11 PW9355 Maintenance Bypass Position ................................................ 1-11 Parallel Tie Cabinet with System Bypass.............................................. 1-17 Front door panel removed...................................................................... 3-1 Right side skin panel removed................................................................ 3-2 Wiring Access After Dead Front Panel Removal .................................... 3-2 XCP Tool Battery Toggle Positions......................................................... 3-6 Front door panel removed..................................................................... 3-10 Right side skin panel removed.............................................................. 3-10 Wiring Access After Dead Front Panel Removal .................................. 3-11 CAN Bridge Board Jumper Settings ..................................................... 3-13 Parallel Control Wiring .......................................................................... 3-13 XCP Tool Battery Toggle Positions....................................................... 3-17 Display Panel.......................................................................................... 4-5 9355 Control Board............................................................................... 4-11 9355 Control Board Machine States ..................................................... 4-12 9355 Power Board ................................................................................ 4-31 Typical Battery Charging Cycle............................................................. 4-38 PW 9355 I/O Board............................................................................... 4-49 Bypass Control Board ........................................................................... 4-64 State Diagram....................................................................................... 4-68 Modem Call Handling States .................................................................. 5-8 No Modem State..................................................................................... 5-9 Modem Idle State.................................................................................. 5-11 Modem Dialing State ............................................................................ 5-13 Modem Session State........................................................................... 5-14 Hanging Up State ................................................................................. 5-15 Path to HyperTerminal Application ....................................................... 5-27 HyperTerminal Opening Screen Selections .......................................... 5-27 Select COM1 or COM2 from the drop-down menu ............................... 5-28 Port Parameter Setup ........................................................................... 5-28 File, Properties menu options, Settings tab, Emulation drop-down....... 5-29 Font Settings menu............................................................................... 5-29 Single Port Serial Card ........................................................................... 6-2 Multi-Port Serial Card.............................................................................. 6-3 Low Voltage Relay Interface Card .......................................................... 6-5 High Voltage Industrial Relay Card......................................................... 6-7 10 Megabyte SNMP/Web 10/100 Megabyte SNMP/Web/Hub........ 6-8 SNMP / Web / Hub Card Components.................................................... 6-8 © 2006 - Eaton Corporation
9355 20 – 30 kVA
Figure 48. Figure 49. Figure 50. Figure 51. Figure 52. Figure 53. Figure 54. Figure 55. Figure 56. Figure 57. Figure 58. Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80. Figure 81.
Figure List
MODBUS Communications Card............................................................ 6-9 MODBUS Communications Card Components ...................................... 6-9 Modem Card ......................................................................................... 6-10 X-Slot Modem Functional Parts ............................................................ 6-11 USB Module.......................................................................................... 6-13 CAN Bridge Card .................................................................................. 6-14 CAN Bridge Card J3 Terminals............................................................. 6-14 Options Cabinet with MBS Wiring ......................................................... 6-15 Options Cabinet with Dual-Feed Wiring ................................................ 6-16 Options Cabinet with Output Transformer Wiring ................................. 6-17 Remote Power Panels Series 100 and 200 .......................................... 6-20 Damage Sustained by the IGBTs Due to Severed Wiring....................... 8-2 Top Fan Dead Front and Bracket Plates................................................. 8-2 L3 and Fan Removal Points on the I/O Board ........................................ 8-3 Bypass Board Silk Screen ...................................................................... 8-3 L3 PM Shelf Insertion.............................................................................. 8-4 L2 Removal Points on the I/O Board ...................................................... 8-6 Positive Battery String Wires .................................................................. 8-8 Bypass Static Switch Connections.......................................................... 8-9 I/O Board Wiring Connections to Static Switch ..................................... 8-10 Static Switch Housing and SCRs.......................................................... 8-11 DC Link Check Points ........................................................................... 8-13 Removing the control board from the I/O board.................................... 8-14 Wiring Locations ................................................................................... 8-15 Wiring Removal Diagram ...................................................................... 8-16 TB5 ....................................................................................................... 8-17 Bus bar and neutral bolts ...................................................................... 8-17 Chassis Screws .................................................................................... 8-18 Analog Potentiometer Diagram............................................................... 9-1 Analog to Digital Circuit........................................................................... 9-1 Digital Potentiometer Diagram ................................................................ 9-2 9355 Front Calibration Points ................................................................. 9-5 I/O Board Bypass Phase A, B and C .................................................... 9-12 208V DC Link Voltage Calibration test points ....................................... 9-13
© 2006 - Eaton Corporation
vii
Figure List
9355 20 – 30 kVA
164201621 Change sheet Revision
A001
A002
viii
Item
Section(s)
Change
Table of Contents
Accommodates new pages
Figure List
Accommodates new figures 8-3
Figure 62 added for procedure elaboration
8-9
Figure 66 added for procedure elaboration
Prints
Page 9
110720639 TOPS Rev B00
Chapter 1 (System Overview)
Section 1.3
“Parameter Settings” added.
Chapter 3 (Installation and Startup)
Section 3.1.1
Elucidated item 1.e. under module inspection — check ALL wiring.
Chapter 9 (Calibration)
All
Emphasis placed on XCP software tool use
Prints
CTO charts
Added to hard copy
Chapter 8 (Removal and Replacement)
© 2006 - Eaton Corporation
1 System Overview 1.1 System Description Refer to Figure 1, EATON-Powerware® 9355 20–30 kVA UPS and Figure 2, Basic Single Module System.
1.1.1
Single Module Systems
The EATON-Powerware® 9355 UPS is intended to be an Online Double Conversion Uninterruptible Power Supply rated at 20kVA–30kVA, 3-phase in/3phase out, with 4 basic models: •
20kVA — 30kVA 230/400
•
20 or 30kVA 120/208
The power-train topology is unique to the PW9355 design but uses the same control board as the PW9155 and PW9355-15kVA.
Figure 1.
EATON-Powerware® 9355 20–30kVA UPS © 2006 - Eaton Corporation
1-1
System Overview
Figure 2.
9355 20 – 30 kVA
PW9355 30kVA Basic Single Module System
A digital signal processor (DSP) is used to provide all software functionality (that is, analog metering, digital signal sampling, power-train control including Pulse Width Modulated (PWM) gate signals, serial communications, and user interface processing). The UPS incorporates Flash ROM for upgrades to DSP firmware using the PW Flash Utility (via serial port communication). For more information on the Control board, see paragraph 4.4. These systems are designed to be one of the most enhanced and improved EATON-Powerware® UPS products, using a compilation of the most successful features found in previous products. The basic system consists of:
1-2
•
a rectifier
•
battery converter
•
inverter
•
monitoring / operation control panel
•
integrated communications server
•
and microprocessor controlled (DSP) logic.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
System Overview
A single module operates independently, providing conditioned and uninterruptible AC power to support an applied critical load. During an outage, the module continues to operate, supporting power to the critical load from the batteries. If the module requires service, critical loads can be manually transferred to internal maintenance bypass. No additional cabinets or equipment are required. UPS input is derived from a power factor corrected, current controlled, and half bridge boost rectifier. The conditioned output comes from a current controlled half bridge buck inverter. The battery converter is a current controlled boost converter, and the charger is a current controlled buck converter. Power Share mode limits the utility current and provides DC link rail voltage regulation. Internal batteries within the UPS are replaceable and can be hot swapped by a qualified service technician without affecting the critical load (the UPS will not have battery back-up available during the swap out). Frequency / phase converter operation is possible with a de-rated output load capacity to 80%. Frequency / phase converter mode can be configured from the front panel or through the XCP configuration command. With default frequency converter configuration, bypass will not be available. Integral bypass can perform an automatic transfer (0 msec, no break) of attached critical loads from the UPS to a bypass source if required. The unit will recover from automatic bypass without dropping the critical load if the unit does not indicate damage.
© 2006 - Eaton Corporation
1-3
System Overview
9355 20 – 30 kVA
1.2 Single Module–Reverse Transfer (RT) Modes of Operation The EATON–Powerware® 9355 UPS will support a critical load in three different modes of operation: 1.
NORMAL
2.
BATTERY
3.
BYPASS
The UPS can automatically use all three modes without operator intervention. To achieve this, sophisticated detection and control logic is used to ensure that any change in operating mode is automatic and transparent. Internal monitoring systems indicate the current mode of operation. A more detailed explanation of the three modes of operation, using block diagrams, will follow.
1.2.1
NORMAL Mode
Refer to Figure 3 and Figure 4 NORMAL Mode. During normal UPS operation, power for the system is delivered from a utility input source to the rectifier input breaker CB-1. The rectifier converts the incoming AC (alternating current) power to DC (direct current) using IGBT (Isolated Gate Bipolar Transistor) devices to produce a regulated DC voltage for the inverter, while the battery is charged through a buck / boost DC converter. S ervice
B ypass
UP S
B ypass
S ervice
UP S
S ervice
Input TB
B ypass
Bypass Input
UP S
MBS
Single feed jumper Output TB
Rectifier Input
CB-3
CB-1
Optional
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter
CB-2
<
Remote External Battery
Figure 3.
1-4
Up and Match < Line External Battery
PW 9355 NORMAL Mode (single feed)
© 2006 - Eaton Corporation
LOAD
S er vice
B ypa ss
UP S
B ypa ss
UP S
S er vice
MBS
B ypa ss
Input TB
S er vice
System Overview
UP S
9355 20 – 30 kVA
Bypass Input Output TB
LOAD
Rectifier Input
CB-3
CB-1
Optional
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter
CB-2
<
Remote External Battery
Figure 4.
<
Line Up and Match External Battery
PW 9355 NORMAL Mode (dual feed)
The DC converter derives its input from the regulated DC output of the rectifier and provides a regulated, boosted DC voltage charge to the battery. The battery charge condition is monitored by the UPS and reported by status indicators located on the LCD monitor panel. The battery is always connected to the UPS and ready to support the inverter should the utility input become unavailable. The system has a shunt trip for the battery and can disconnect the battery under a fault condition or Remote Emergency Power Off (REPO) activation, see paragraph 1.7 for details. The neutral from the system input is connected to the neutral throughout the system.
CAUTION The output neutral of the system is connected with the required neutral for the customer’s critical load and should never be bonded to ground at the module output.
The inverter produces three phase AC output to a customer’s critical load without the use of a transformer. The inverter derives regulated DC from the DC Link and uses IGBT devices and PWM (pulse-width modulation) to produce a regulated and filtered AC output. The AC output of the inverter is delivered to the system output by way of the inverter output contactor K-3. “NORMAL” appears on the module front panel to indicate that the system is providing clean and protected power to the connected critical loads. © 2006 - Eaton Corporation
1-5
System Overview
1.2.2
9355 20 – 30 kVA
BATTERY Mode
Refer to Figure 5 and Figure 6 BATTERY Mode. The UPS enters into BATTERY mode automatically during a utility power failure, when the input power to the rectifier is out of specification (refer to the specifications in your generator manual), and in some cases during a noncatastrophic rectifier failure. During a utility power failure, the rectifier no longer has an AC utility source to supply the DC output power required by the inverter. When the rectifier is turned off, the supply of DC current to the inverter is drawn from the awaiting charged batteries. When the rectifier is partially operational, Power Share mode is implemented.
Bypass
Service
UPS
Bypass
UPS
Service
MBS Bypass
Bypass Input Input TB
Service
UPS
Power Share mode provides DC link rail voltage by drawing supplemental power from the batteries (that is, Power Share mode apportions energy jointly from the batteries and from the rectifier to supply adequate energy to the inverter to maintain the critical load). See paragraph 1.2.3 on for more details about Power Share.
Single feed jumper Output TB
Rectifier Input
CB-3
CB-1 Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter
CB-2
Figure 5.
1-6
<
Remote External Battery
<
Line Up and Match External Battery
PW 9355 BATTERY Mode (single feed)
© 2006 - Eaton Corporation
LOAD
Optional
9355 20 – 30 kVA
System Overview
Bypass Input
Bypass
Service
UPS
Bypass
Service
UPS
Bypass
Input TB
Service
UPS
MBS
Output TB
Rectifier Input
LOAD
CB-3
CB-1
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter
<
Remote External Battery
CB-2
<
Figure 6.
Line Up and Match External Battery
PW 9355 BATTERY Mode (dual feed)
When the rectifier can no longer supply energy to the inverter, energy stored in the battery is supplied instantaneously to the DC converter and is boosted so that the inverter can support the customer’s critical load without interruption. To prevent battery output from back-feeding, the rectifier contactor (K-1) opens on separate feed, but this is not true of a dual fed system when the UPS goes to battery. Opening K-1 on a single fed system prevents static system voltages from bleeding backwards through the rectifier “snubber” components and reentering the input source. For more information on the Battery Boost Converter, refer to paragraph 4.6.3. While in BATTERY mode, the UPS will annunciate an audible horn, light a visual indicator lamp on the front panel (ON BATTERY), and make an entry into the alarm event history. As the battery discharges, the converter and inverter constantly make minute adjustments to maintain steady output. The UPS will remain in this operating mode until the input power to the rectifier is again within specification. If the input power fails to return, or is not within the acceptance window required for normal operation, the battery will continue discharging until a DC voltage level is reached and the inverter output can no longer support the critical load. When this occurs, the UPS will issue another set of audible and visual alarms indicating SHUTDOWN IMMINENT. Unless the rectifier has an immediate valid input, the output will only be supported for approximately one (1) minute before the UPS shuts down, dropping the critical load.
© 2006 - Eaton Corporation
1-7
System Overview
9355 20 – 30 kVA
If the input power becomes available during battery discharge, the rectifier contactor (K-1) is closed; the rectifier turns on and provides power to the DC Link for the inverter, and begins recharging the battery. At this point, the unit returns to NORMAL operation. Depending on the amount of load on the system and the duration of the battery discharge, battery and rectifier input current limit alarms might be seen for a short time due to the current required to recharge the battery. The UPS total operating time on battery will depend on many factors. Some factors that affect battery support are battery type and capacity, the number of parallel strings, environmental temperatures, battery age, and fluctuations in load demand during battery discharge. The greater the load, the less support time the battery can sustain; as the load decreases, the battery support time generally increases.
1.2.3
Power Share Operation
Power Share mode pulls energy from the batteries and from the rectifier to supply energy to the inverter. Two conditions that cause the unit to enter power share mode are: 1.
A scheduled battery test and
2.
The rectifier exceeds the maximum input current
The utility voltage determines the maximum power that the rectifier may provide and the maximum input current allowed. If the power required by the inverter exceeds the maximum rectifier power, the rectifier is run in a constant power mode, and the battery converter is turned on to make up the deficit. In this way, the UPS draws maximum power from the rectifier while supplementing the power shortfall as efficiently as possible using the batteries. When the battery test is running, rectifier power is regulated so that the power required for testing is drawn from the batteries. For more details on Advanced Battery Management, refer to paragraph 4.7.
1.2.4
BYPASS Mode
Refer to Figure 7 and Figure 8, BYPASS Mode. When the inverter is unable to support the critical load, the UPS will transfer the load to the internal bypass to ensure the critical load remains energized. In BYPASS mode, the output of the system is provided with three-phase AC power directly from the system input (or utility source). While in this mode, the output of the system is not protected from voltage, frequency fluctuations or power outages. Some power line filtering and spike protection is provided to the critical load, but no active power conditioning or battery support is available to the critical load during the bypass mode of operation.
1-8
© 2006 - Eaton Corporation
9355 20 – 30 kVA
System Overview Bypass
Service
UPS
Bypass
Service
UPS
Bypass
Input TB
Bypass Input
Service
UPS
MBS
Single feed jumper Output TB
Rectifier Input
CB-3
CB-1
LOAD
Optional
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter CB-2
<
Remote External Battery
Figure 7.
<
Line Up and Match External Battery
PW 9355 BYPASS Mode (single feed)
Bypass Input
Bypass
Service
UPS
Bypass
Service
UPS
Bypass
Input TB
Service
UPS
MBS
Single feed jumper Output TB
Rectifier Input
CB-3
CB-1
LOAD
Optional
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter CB-2
Figure 8.
<
Remote External Battery
<
Line Up and Match External Battery
PW 9355 BYPASS Mode (dual feed) © 2006 - Eaton Corporation
1-9
System Overview
9355 20 – 30 kVA
The internal bypass is comprised of a solid-state Silicon Controlled Rectifier (SCR) static switch. The (SCR) static switch is rated as a continuous duty device that is used anytime the inverter is unable to support the applied critical load. The bypass static switch is an electronically controlled device, so if a system fault occurs necessitating an emergency transfer to bypass, the static switch can be turned on immediately to pick up the critical load from the inverter, while the inverter output contactor (K-3) automatically opens to isolate the inverter. During an outage, transfers to BYPASS are prohibited with single feed input. For the safety of those who may be working on the power lines upstream from the UPS, back-feed protection is provided by opening the bypass contactor (K-5), which prevents system output voltage from bleeding across the bypass static switch (SCR) components to the input source. The output of the system will be transferred automatically to the internal bypass if any of the following abnormal conditions occur on the output of the system: •
the output of the system exceeds acceptable voltage or frequency tolerances.
•
the system is overloaded.
•
there is an inverter failure.
The transfer is initiated by turning on the bypass static switch (SCR) and by opening the inverter output contactor (K-3). This kind of transfer is normally referred to as a “make-before-break” transfer, or emergency transfer to bypass. The transfer should take place in less than 4 msec (one-quarter cycle) to ensure critical loads on the system output are not interrupted. The bypass static switch (SCR) remains on until either the inverter is able to support the system output, or until the unit is placed in maintenance configuration to facilitate repairs. If the UPS automatically initiates transfer to bypass without operator intervention, the UPS will attempt to automatically restart the inverter, and to transfer the UPS back to on-line status to support the system output. Three attempts will be made automatically within ten minutes to bring the inverter back on-line before the UPS will lock out any further attempts. After three (3) attempts have been made, the UPS will remain in BYPASS and an alarm condition will be annunciated. The UPS can also be manually transferred to BYPASS using the front panel controls. A Maintenance Bypass Switch (MBS) is installed on all units. When the switch is in the “UPS” position it operates as discussed in the previous paragraphs. When the switch is in the “Service” position the critical load is powered by utility, and the UPS has power available for troubleshooting and maintenance (see Figure 9). When the switch is in the “Bypass” position power to internal bypass is secured and the critical load is supplied by utility (see Figure 10). CB-1 controls the input power to the rectifier in a single or dual feed UPS. For more information on Bypass Mode, refer to paragraph 4.4.10. 1-10
© 2006 - Eaton Corporation
Byp ass
Se rvi ce
U PS
Byp ass
UPS
Se rvi ce
MBS Byp ass
Input TB
Se rvi ce
System Overview
UPS
9355 20 – 30 kVA
Bypass Input Single feed jumper Output TB
Rectifier Input
CB CB-3
CB-1
LOAD
Optional
Static Switch K-5
K-3
K-1
Rectifier
Inverter
Battery Converter
CB-2
<
<
Bypass Input
Byp ass
Se rvice
UPS
Bypass
Se rvice
MBS UPS
Se rvice
Input TB
Line Up and Match External Battery
PW9355 Service Position
UPS
Figure 9.
Byp ass
Remote External Battery
Single feed jumper Output TB
Rectifier Input
CB-3
CB-1
LOAD
Optional
Static Switch K-5
K-3
K-1 Rectifier
Inverter
Battery Converter CB-2
<
Remote External Battery
Figure 10.
<
Line Up and Match External Battery
PW9355 Maintenance Bypass Position © 2006 - Eaton Corporation
1-11
System Overview
9355 20 – 30 kVA
1.3 Parameter Settings This section describes the parameters list option in the 9X55 service menu. This menu is intended so that a service technician can change UPS settings without serial communication. This list is correct for 9X55 ESW version 1.06.xx for the 9355.
1.3.1
Parameter List
Note: Send over CAN means that in a parallel system, updating 1 unit will update all units in the parallel system that are connected to the CAN network. Numbers missing in numerical sequence either apply to 9155 units exclusively or the setting has been disabled. Table 1. Parameters List Setting for the 9X55 LV Service Menu Param Num
0 1
3 4 5 6
7
8 9
1-12
Description Start Screen Language
Horn enable
Default
Options
0
0
Power ware logo
1
Mimic Screen
0
English
1
French
2
Spanish
0
Horn is disabled
1
Horn is enabled
0
Transfer to bypass immediately
1
Transfer to bypass after a delay
0
Synchronization is not required
1
Synchronization is required
0
Synchronization to bypass is enabled
1
Synchronization to bypass is disabled
0
Transfer to bypass is allowed
1
Transfer to bypass is not allowed
0
Site fault is enabled
1
Site fault is disabled
0
REPO is enabled
1
REPO is disabled
0
1
Overload transfer to bypass
1
Sync required for bypass transfer
1
Sync disable
0
Bypass disable
Site fault disable REPO disable
0
0 0
Option description
© 2006 - Eaton Corporation
Send over CAN No No
No YES YES YES
YES
No YES
9355 20 – 30 kVA
10
11
12
13
14
15
System Overview
Disable control commands from X-Slot1
0
Disable control commands from X-Slot1/Service port
0
Automatically schedule battery test
1
ABM disable
0
Charger temp. compensation disable
0
Modem installed
0
0
Control commands from X-Slot1 are allowed
1
Control commands from X-Slot1 are not allowed
0
Control commands from XSlot1/ service port are allowed
1
Control commands from XSlot2/ service port are not allowed
0
Battery test will only run when requested from LCD or XCP
1
Battery test will run every ABM cycle without user intervention
0
ABM cycling is disabled (constant float)
1
ABM cycling is enabled
0
Temperature compensation is enabled
1
Temperature compensation is disabled
0
No modem is installed
1
Modem is installed in X-Slot1
2
Modem is installed in X-Slot2
No
No
No
No
No
No
16
On battery delay
5
0-99
Time in seconds before “UPS on Battery “ alarm is activated
YES
17
XCP Auto-on delay
0
0-32767
XCP auto-on delay in seconds
YES
-1
Restart through LCD or remote only
XCP Auto-off delay
-1
0-32767
XCP auto-off delay in seconds
18
-1
YES
Disabled
19
Input signal shutdown delay
120
0-65535
Used if input signal is programmed for delayed shutdown
20
X-Slot signal input activation delay
5
0-65
After the set time delay, the RS323 pin is recognized to be an active signal (3-12 Vdc). Refers to function of signal inputs
No
21
Number of internal battery strings
Model specific
0-22
Number of parallel strings of internal batteries
No
23
Internal battery capacity
34
1-32767
Capacity, in W/cell of internal batteries at 15min rate
No
© 2006 - Eaton Corporation
YES
1-13
System Overview
9355 20 – 30 kVA
24
Battery low alarm level
1880
17501950
Voltage, in mV/cell, that sets the “Battery Low” alarm
YES
25
Constant float voltage
2300
21502335
Battery float voltage, in mV/cell when ABM cycling is disabled
No
26
Max charge current
340
50-3400
Maximum battery charge current, in mA * 100, per battery string
No
27
Nominal Output voltage
1200
1200
Nominal output voltage is 120Vac to neutral
1270
Nominal output voltage is 127Vac to neutral
YES
28
Bypass voltage high limit
10
1-20
Upper voltage window for bypass, in percent nominal voltage
YES
29
Bypass voltage low limit
-15
(-1)- (20)
Lower voltage window for bypass, in percent nominal voltage
YES
30
Sync window
2000
10003000
Frequency window around nominal that inverter will sync to bypass in mHz
YES
31
Utility sync window
2000
10003000
Frequency window around nominal that inverter will sync to utility in mHz
YES
32
Nominal output frequency
60000
50000
Nominal output frequency is 50Hz
YES
60000
Nominal output frequency is 60Hz
35
Reset Modem
NA
1
Causes the UPS to send a reset command to the modem
No
36
Reset History
NA
1
Clears the UPS event history
No
37
Reset to factory defaults
NA
1
Resets all parameters on this list to factory default
No
38
Lock X-Slot2 to service port
0
0
X-Slot2/service port are multiplexed
No
1
X-Slot2 is disabled, service port only is usable
NA
1
Requests battery commissioning test to run
No
1
0
UPS is not allowed to back feed utility during battery test
No
1
UPS is allowed to back feed utility during battery test
40
Scheduled battery commissioning test
41
Enable full power battery test
1-14
© 2006 - Eaton Corporation
9355 20 – 30 kVA
42
43
46
Auto-sense input frequency
System Overview 1
Parallel UPM number
0
Parallel mode
0
0
Do not auto-sense input frequency, get inverter frequency configuration from eeprom
1
On next power-up, auto-sense input frequency and configure inverter to match, then clear this bit. (One time only)
0
Single unit configuration
1-4
YES
No
Parallel system configuration. Each UPM in parallel system must have a different UPM number
0
Parallel redundant system
1
Parallel capacity system
YES
47
Start parallel auto-calibration
NA
1
Initiates parallel system autocalibration
YES
48
Start No-load/full load
NA
1
Initiates no load/full load test
No
49
Error state reset
NA
1
Clears parallel comm errors. Also resets 0xC9 encryption lock out
YES
50
Remove offset
NA
1
Initiates offset auto-calibration
51
Force xcp subunit
0
0
Parallel unit accepts system and sub-module commands
1
Forces parallel unit to submodule mode always
53
Number of external battery strings
56
Reset battery alarms
0
0-65535
Number of external battery strings of different capacity than internal batteries
NA
1
Clears “Battery needs service” and “battery test failed” alarms
© 2006 - Eaton Corporation
No
No
1-15
System Overview
9355 20 – 30 kVA
1.4 Input Isolation Transformer (60 Hz Only) 1.4.1
PW 9355
The input isolation transformer is contained in the Options Cabinet and can come in various configurations. See chapter 6.
1.5 Seismic Capability Seismic stands will be provided as necessary. A non-operating seismic test will derive test methods from NEBS GR-63-CORE, ANSI T1 329, or EN 60068-2, as appropriate.
1.6 External Battery Cabinets The UPS will operate with up to three (3) External Battery Cabinets (EBCs), containing four battery strings in each cabinet. The EBCs can increase battery capacity to a maximum of 18 battery strings, Including the internal batteries: a maximum of twelve (12) strings of 24 ampere-hour batteries in the EBCs and six (6) internal battery strings of 9 ampere-hour batteries.
1.7 Remote Emergency Power Off (REPO) The remote emergency power off (REPO) switch is a provision for powering down the customers critical load when rapid shutdown is required. The REPO function is activated by an external contact. Both normally open and normally closed REPO contacts are provided. The REPO control can be used in conjunction with a room or building REPO, so that the utility can be removed no matter what position the UPS Maintenance Bypass Switch (MBS) is in.
WARNING AN ACTIVE REPO SIGNAL WILL DE-ENERGIZE THE CRITICAL LOAD. When REPO is activated with utility present or on battery, the load is deenergized immediately. The UPS will shut down all converters, de-energize all system contactors, trip the CB-1 and CB-2 breakers, and fully power down the UPS within 10 to 15 seconds. Note: If the REPO switch is not connected to the feeder breaker, the Customer critical load will maintain power in the Maintenance Bypass position.
1.8 Environmental Monitoring Probe (EMP) The Environmental Monitoring Probe is used only with a Web/SNMP Card. Refer to the Supporting Documents for information on installation and for additional information. 1-16
© 2006 - Eaton Corporation
9355 20 – 30 kVA
System Overview
1.9 Parallel Tie Cabinet with System Bypass The Parallel Tie Cabinet is capable of paralleling up to 4 UPMs. It has a maintenance bypass switch and auxiliary contacts to force the UPS to bypass mode when the UPS maintenance output breakers (MOBs) are closed and the UPS in normal operating mode.
CB1
UPM#1 Input Breaker
CB1
UTILITY INPUT
UPM#2
#1
#2
#3
#4
Input Breaker CB1
Input Breaker
UPM#3 CB1
TO LOAD
Input Breaker
UPM#4
Figure 11.
Parallel Tie Cabinet with System Bypass
© 2006 - Eaton Corporation
1-17
System Overview
9355 20 – 30 kVA
This page was left blank intentionally.
1-18
© 2006 - Eaton Corporation
2 Safety 2.1 General Safety Considerations 2.1.1
Tools, Equipment, and Expendable Field Service Supplies
When performing service calls or procedures on Eaton Electrical equipment, the following rules must be observed. These rules pertain to tools, testers, solvents, adhesives, and lubricants: •
Ensure that electrical hand tools, such as power drills, are inspected regularly.
•
Replace worn and broken tools and test equipment with new tools and equipment.
2.1.2
General Safety Rules
Adhere to the following safety rules for working with electrical and mechanical equipment in the maintenance and repair procedures: •
The UPS must be used as intended. Follow the instructions given in the user guide and installation manual.
•
Installation and use of the UPS must comply with all national and local safety regulations and procedures.
•
All primary power switches installed downstream from the UPS must be labeled as follows: “ISOLATE UPS (Uninterrupted Power Supply) before working on this circuit.”
© 2006 - Eaton Corporation
2-1
Safety
9355 20 – 30 kVA
2.2 Environmental Safety Observe the following rules:
WARNING DO NOT WORK ALONE AS DANGEROUS VOLTAGES ARE PRESENT INSIDE THE UNIT. THE UPS MUST BE INSTALLED AND SERVICED ONLY BY SERVICE PERSONNEL FROM THE MANUFACTURER OR FROM AN AGENT AUTHORIZED BY THE MANUFACTURER. 1.
Always inform the appropriate supervisor/manager of conditions or voltages that might pose a threat to safety. Take all steps necessary to maximize safety.
2.
Always look for possible hazards, such as moist floors, nongrounded extension cables, power supplies, and missing safety grounds.
3.
Do not make un-authorized changes or modifications to the equipment. This creates a hazard and unsafe equipment.
4.
Before starting the equipment, ensure that other service and customer personnel are not exposed to any unsafe conditions.
5.
Do not wear loose clothing that can be trapped in the moving parts of a machine. Ensure sleeves are fastened or rolled above the elbow.
6.
If wearing a necktie or scarf insert it into the clothing or fasten it with a nonconductive clip at approximately 8 centimeters (3 inches) from its end. This prevents the tie from being caught by a moving part of the equipment.
7.
If your hair is worn long, fasten it to make it safe.
8.
Lift the equipment or parts by using your leg muscles to prevent back strain. Do not lift any heavy equipment or parts that cannot be lifted comfortably.
9.
Always keep tool kits away from walk areas to prevent a tripping hazard. If possible, keep all tools and tool kits on or under a table.
10. Observe good housekeeping practices in the area of the UPS while performing maintenance and after completing the job. 11. Place removed UPS covers in a safe place while servicing the UPS. Reinstall the covers before returning the UPS to the customer. 12. Reinstall all safety devices, such as guards, shields, and ground wires. Replace safety devices that are worn or defective with new ones. Remember that safety devices protect personnel from a hazard. Ensure all safety devices are reinstalled when the maintenance/service has been completed. 2-2
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Safety
2.3 Electrical Safety Observe the following rules when working on electrical machinery: 1.
2.
Follow the manual shut down and maintenance bypass procedures to prevent loss of power to the customers load. Switch input and logic power off if recommended in the service manual and: •
before removing or assembling the main units of the equipment.
•
before working near power supplies.
•
before inspecting power supplies.
•
before installing changes in machine circuits.
Unless the maintenance documents specifically instruct otherwise:
WARNING DO NOT SERVICE INPUT, OUTPUT, OR BYPASS CIRCUIT BREAKERS, TRANSFORMERS, CTS, OR PTS WITH POWER ON. 3.
If working on equipment that has exposed live electric circuits, OBSERVE the following precautions: •
To protect against high leakage current; connect protective earth (PE or ground) before connecting power supply cables.
•
Ensure another person who is properly trained in the power-off controls is in a close proximity at all times to switch off power, if necessary.
•
Remove jewelry, chains, metal frame eyeglasses, or other personal metal objects.
•
Use only insulated probe tips or extenders.
•
Use one hand while working on or near energized equipment. Keep one hand in your pocket or behind your back to prevent electric current flow across the heart.
•
Do not touch objects that are grounded, such as metal floor strips, machine frames, or other conductors. Use suitable rubber mats. Obtain the mats locally, if necessary.
When using test equipment, set the controls as referenced in the operator’s, or service, manual. Use only properly insulated probes. 4.
When working with machines having voltages more than 30 VAC or 42.4 VDC, observe special safety instructions (referenced in the service manual). © 2006 - Eaton Corporation
2-3
Safety
9355 20 – 30 kVA
5.
The output neutral of the system is connected with the required neutral for the customers load and should never be bonded to ground at the module output.
6.
Ensure ALL battery breakers, and EBMs, are open before checking voltages.
WARNING NEVER ASSUME THAT POWER HAS BEEN REMOVED FROM A CIRCUIT. CHECK AND ENSURE THAT POWER HAS BEEN REMOVED BY USING A VOLTMETER. 7.
Do not touch live electric circuits with the surface of a dental mirror. The mirror handle is conductive and can cause equipment damage and/or personal injury.
8.
If an electrical accident occurs: •
Instruct another person to get medical aid
2.4 Mechanical Safety
CAUTION Do not touch moving mechanical parts at any time (Including fans). To prevent overheating, do not obstruct the air flow or block the ventilation openings to the unit.
2.5 Eye Safety
CAUTION Safety glasses shall be worn at all times.
Use additional caution when using the following equipment or when performing procedures listed below:
2-4
•
Using a hammer
•
Using a power drill
•
Using a spring hook
•
Soldering parts
•
Cutting wire or removing steel bands
•
Using solvents, chemicals, or cleaners to clean parts
•
Working in any other condition that might cause eye injury (that is, a UPS module under power, input or bypass)
© 2006 - Eaton Corporation
9355 20 – 30 kVA
•
Safety
Do not wear soft contact lenses when working on or around electrical equipment.
2.6 UPS Safety
WARNING THE OSCILLOSCOPE MUST BE ISOLATED BY USING AN ADAPTER THAT ISOLATES THE SCOPE AND EARTH GROUND. USE EXTREME CAUTION; THE SCOPE WILL HAVE POTENTIAL BETWEEN THE UPS FRAME AND THE SCOPE. DO NOT TOUCH THE UPS AND THE SCOPE AT THE SAME TIME.
2.6.1
2.6.2
Operating Environment 1.
Keep surroundings clean and free from excess moisture.
2.
Do not operate in close proximity to gas or electric heat sources.
3.
The system is not intended for outdoor use.
4.
The operating environment should be within the parameters listed in Chapter 1.
Normal Operation 1.
Keep equipment doors closed to ensure proper cooling airflow, and to protect you from dangerous voltages within the unit.
2.
Ensure all conduit knockouts and/or unnecessary openings are sealed.
3.
Do not make any assumptions about the electrical state of the UPS. CHECK THE ELECTRICAL STATUS WITH A VOLTMETER!
WARNING THIS UPS CONTAINS LETHAL VOLTAGES. ALL REPAIRS AND SERVICE SHOULD BE PERFORMED BY AUTHORIZED SERVICE PERSONNEL ONLY. THERE ARE NO USER SERVICEABLE PARTS INSIDE THE UPS. The following safety cautions are intended to provide important specific information about the safe operation of the UPS. Violation of these precautions could result in serious damage to the UPS and/or injury or death.
2.6.3
Maintenance/Service 1.
Always wear appropriate eye protection.
2.
Remove restrictive clothing and remove all jewelry.
3.
Use correct documentation and appropriate tools as outlined in this manual. © 2006 - Eaton Corporation
2-5
Safety
9355 20 – 30 kVA
2.6.4
4.
Use static secured work area and procedures when performing component replacement or modifications.
5.
Ensure power is disconnected before performing installation or service when possible.
6.
Observe all CAUTIONS, WARNINGS, and DANGER notices fixed to the inside and/or outside of the equipment.
7.
Always comply with more detailed safety precautions described at the appropriate paragraph later in this manual.
Batteries 1.
The lead-acid batteries are maintenance-free sealed batteries. No electrolyte/water can be added. Lead-acid batteries must be disposed of correctly in compliance with the local regulations.
CAUTION The battery breaker on the rear of the electronic module or Extended Battery Module (EBM) shall be in the OFF position prior to connecting or disconnecting batteries. The RED wires from the electronics module must be connected to the POSITIVE (+) terminal of the battery trays and the BLACK wires from the electronics module must be connected to the NEGATIVE (-) terminal of the battery trays. There is a risk of explosion if a battery or batteries are replaced by an incorrect type.
2.
Dangerous voltage is always present at battery terminals.
WARNING BATTERIES CAN PRESENT A RISK OF ELECTRICAL SHOCK OR BURN FROM HIGH SHORT CIRCUIT CURRENT AND HIGH VOLTAGE. OBSERVE PROPER PRECAUTIONS. INCORRECT CONNECTION OF BATTERIES MAY CAUSE ELECTRICAL SHOCK, FIRE, INJURY, OR DEATH. 3.
The battery contains sulfuric acid. If any spillage occurs, take the following precautions:
If acid comes in contact with skin: •
Wash immediately with soap and water
•
Contact a physician if any burn results
If acid is splashed in the eyes: • 4.
2-6
Wash for 20 minutes under running water
Contact a physician.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Safety
2.7 Site Safety Personnel associated with the UPS should be aware of the presence of potentially lethal voltages. Observe the following precautions to ensure personnel safety and continued equipment operation. 1.
Keep surroundings clean and free from excess moisture.
2.
Do not operate in close proximity to gas or electric heat sources.
3.
The system is not intended for outdoor use.
4.
The operating environment should be within the parameters listed in Chapter 1.
WARNING VOLTAGES ACROSS CHARGED CAPACITORS CAN BE IN EXCESS OF 300 VDC. BE CERTAIN THE FILTER CAPACITORS ARE FULLY DISCHARGED AND INPUT POWER IS OFF BEFORE PERFORMING ANY MAINTENANCE OR TROUBLESHOOTING. 5.
Ensure the site is safe.
6.
Inspect power cables and plugs; check for loose, damaged, or worn parts.
7.
Review all procedures in the maintenance documents before removing a part that can hold an electric charge. Carefully discharge the parts exactly as instructed by the procedures.
8.
Do not use a normal light (for example, a table lamp) for illumination when performing maintenance on the UPS. Use a flashlight with a nonconductive case.
NOTICE Never assume that a UPS or a circuit is safe. Follow all procedures and safety precautions in the maintenance documents and all other applicable manufacturers publications.
© 2006 - Eaton Corporation
2-7
Safety
9355 20 – 30 kVA
9.
Always be aware of the following potentially hazardous conditions. Take the necessary safety steps to protect against the existence of these potential hazards. At the minimum inspect the following: •
Power receptacles wired incorrectly.
•
Safety devices or features missing or defective.
•
Maintenance or change history that is wrong or incomplete.
•
A UPS design problem.
•
A UPS that has shipping damage.
•
An unsafe change or attachment installed in the UPS.
•
An engineering change or a sales change installed Incorrectly.
•
A defective part.
•
A potentially unsafe old UPS or one that has been operated in an extreme environment.
2.8 Summary Prevention is the key and main aid to electrical safety. Always think about electrical safety and use good preventive practices before performing any work on equipment. These are some of the ways that the condition of the UPS that could affect safety. Before starting maintenance or repair procedures, USE GOOD PREVENTIVE JUDGMENT and USE CAUTION. SAFETY COMES FIRST!
2.9 Electrostatic Discharge (ESD) Procedure And Equipment Requirements 2.9.1
Purpose
To provide guidelines on handling electrostatic sensitive materials.
2.9.2
Objective
To provide a procedure which specifies ESD criteria when handling electrostatic sensitive materials.
2.9.3
2-8
Applicable Documents and Materials
•
3M Product catalog 1986/1987
•
3M Series 2100 bags or better
•
Wrist strap 3M 2221-2223 or better
•
Table mats (grounded) 3M 8200 series or better
•
Antistatic (pink poly) © 2006 - Eaton Corporation
9355 20 – 30 kVA
Safety
•
3M Dissipative mats (field kits) or better
•
Tables (grounded) with equivalent or better than surface of mat
2.9.4
Definitions
Antistatic material: Material that neither generates static electricity nor does it provide protection against a static field, and typically has a surface resistance of 109 to 1014 ohm/cm. Conductive material: Material that provides a Faraday cage effect and protects against static generation and a static field with a surface resistance of 210 VDC.) a.
Connect all black connectors, leaving the red connectors on each string disconnected.
b.
Verify each individual string prior to making final connections.
c.
The battery must NOT be ground referenced (either pole tied to ground).
d.
If a string doesn’t indicate > 210 VDC, verify the inner connections and recheck.
Verify battery strings, each pole to ground < 1 VDC.
Electrical Inspection
WARNING BE AWARE THAT THE FOLLOWING STEPS WILL ENERGIZE THE UPS MODULE AND ITS OUTPUT! IF CUSTOMER LOADS ARE NOT TO BE ENERGIZED AT THIS TIME, ENSURE DOWN STREAM BREAKERS ARE OPEN AND LOADS ARE DISCONNECTED OR UNPLUGGED BEFORE PROCEEDING.
NOTICE Use Startup Worksheets and Checksheet found at the end of this chapter.
1.
Verify CB-1 is open and the MBS is in the UPS position.
2.
Apply utility power to the UPS. (If dual feed also apply bypass input power) Note:
The bypass control board will have power applied to it but it will not energize logic power in the remainder of the UPS. © 2006 - Eaton Corporation
3-5
Installation and Startup
3.
9355 20 – 30 kVA
Using a DVM, verify the system has correct input voltages a.
Using a DVM, verify AC voltages: phase-to-phase, phase-toneutral, phase-to-ground
b.
Using a DVM, verify voltage neutral to ground is less than 5 VAC RMS (Root-mean square).
4.
Using an oscilloscope or phase rotation meter, verify phase rotation at the rectifier and bypass inputs.
5.
Energize the system input, close CB-1. The following events occur:
6.
a.
Logic power starts
b.
The display energizes
c.
The ALARM lamp on the front panel is lit
d.
The active event for the batteries is disconnected
e.
Horn sounds once every 3 seconds (pushing any button silences the horn)
Using the XCP Service Software Tool, verify the unit setup: a.
Using the CTO (Configuration to Order) tab, verify that the unit CTO number and power ratings correspond to the unit labeling and installation - You may have to enter the CTO the first time you connect.
b.
Using the Battery Setup tab, configure the UPS for the connected battery
The battery vendor’s data sheet or the battery label may be required. If there are only internal batteries, enter the total number of strings and watts per cell on the Battery 1 Battery Selection toggle switch if it is not already set, see Figure 21. If the external batteries are the same type as the internal batteries then include both on the Battery 1 Battery Selection toggle switch if it is not already set on the XCP Service Tool, see Figure 21. If the external battery is different from the internal battery, enter the number of strings and watts per cell on the Battery 2 Battery Selection toggle switch on the XCP Service Tool, see Figure 21.
Figure 15.
XCP Tool Battery Toggle Positions
To clear the setup required bit: 3-6
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Installation and Startup
- After verifying the battery setup push the “Battery Setup Complete” button. This will clear the setup required bit. - A pop up will appear, click on the “Battery Configuration Complete” to continue. As soon as the setup bit is cleared the unit will start precharge, K5 will close, K1 will close after precharging is complete (approx. 1 minute), The front inverter fans will start. c.
Using the OPTIONS tab, verify the availability of customer options. - Verify that the required setups for the Configure To Order (CTO) type are enabled
d.
Using the MODEM tab, configure the unit for outcall operations (if applicable)
Refer to the outcall setup procedures for specific instructions 7.
Confirm the status of the following indicators: a.
The LCD display indicates the following active event messages: - Batteries Disconnected
b. 8.
The ALARM LED is lit.
Verify the following front panel operations: a.
The time and date are set correctly (the clock is a 24 hour clock)
b.
All screens correctly show the current operating status
c.
All buttons are in working order
d.
Status in the “UPS STATUS” window displays: - UPS is OFF - BATTERY NOT CONNECTED
Note: Auto-Frequency detection is enabled from the factory when input power is first applied. Once the system has initialized, the auto-frequency detection is disabled. It can be reenabled using the XCP Service Tool.
Operational Inspection 1.
Start the UPS: a.
Close battery breaker CB-2.
b.
Close output breaker CB-3 if installed.
c.
Select “UPS ON/OFF”, cycle to select “TURN UPS ON,” and hold the enter key until the beeping stops.” © 2006 - Eaton Corporation
3-7
Installation and Startup
2.
3.
9355 20 – 30 kVA
d.
The output contactor closes; the NORMAL lamp on the front panel is lit, the output fans energize and the rear fans energize.
e.
Verify the output voltage
f.
Investigate and resolve any alarms or notices before continuing.
Verify BATTERY operation: a.
Open utility input breaker for 30 seconds.
b.
Using a DVM, verify stable output voltage & frequency, the battery screen shows discharge.
c.
Using the front panel meter screen, verify that NORMAL, BATTERY, and NOTICE lamps are lit on the front panel, and the horn sounds every 3 seconds.
d.
Close the utility input breaker, verify battery recharge, and that the system indicates NORMAL.
e.
Review the module event history queue for expected events.
f.
Investigate and resolve any unexpected events.
Verify the operation of all applied equipment options (where applicable) for External Maintenance Bypass, and so on. The module must be in bypass. a.
External and / or Internal Maintenance Bypass: - The UPS must be in bypass or standby mode. - Check voltage across external MBP, it should be SERVICE SETTINGS -> PARALLEL OPERATION SETTINGS -> PARALLEL UNIT NUMBER. - Select parallel operation “Redundant or Capacity”: Select: SETTINGS -> USER SETTINGS -> PARALLEL OPERATION SETTINGS -> PARALLEL OPERATION MODE.
Note: For a reverse transfer UPM the ID will be zero (0); if the UPM ID is changed to zero (0) the UPM will act as an RT UPS. 12. Repeat Steps 7 through 11 on each UPM.
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© 2006 - Eaton Corporation
9355 20 – 30 kVA
3.2.3
Installation and Startup
Operational Inspection 1.
Close CB-1 input breakers on all UPMs:
2.
After all UPMs are in standby (fans running): a.
Close battery breaker CB-2. - The LED should turn off.
3.
b.
Close output breaker CB-3 if installed.
c.
Close the MOBs to all UPMs.
On any UPM turn the SYSTEM ON.
Note: After the first startup, the load sharing of the system needs to be calibrated. For best results No Load is preferred for auto-calibration; however, the system can still be calibrated on load. 4.
Select: Settings->Service Settings->PARALLEL OPERATION ->SETTINGS->START AUTO CALIBRATION
5.
After completing the parallel calibration allow 10 minutes for the UPMs to stabilize and verify that they share the load equally. If load share is lop-sided, perform the parallel calibration again. (With smaller loads the system may not load share equally).
6.
Verify BATTERY operation: a.
Open CB-1 input breaker for 30 seconds on each UPM (only perform on one UPM at-a-time) and verify the following: - Using a DVM, verify stable output voltage and frequency, the battery screen shows discharge. - Using the front panel meter screen, verify that NORMAL, BATTERY, and NOTICE lamps are lit on the front panel, and the horn sounds every 3 seconds.
b.
Close the CB-1 input breaker, verify battery recharge, and that the UPM indicates NORMAL.
c.
Review the module event history queue for expected events.
d.
Investigate and resolve any unexpected events.
7.
Repeat Step 6 as a system test by opening CB-1 on all UPMs at the same time.
8.
Verify the operation of all applied equipment options (where applicable). a.
External Maintenance Bypass only: - The UPS must be in bypass or standby mode. - Check voltage across external MBP, it should be 50V, then set the bypass breaker failure alarm, open the battery breaker and jump to the bleeding state. 11. Wait 100ms and initialize slow bypass voltage measurements to fast measurements. 12. If the unit is not in parallel mode and bypass is not active and the output voltage is > 50V, then set the abnormal output voltage and bypass SCR failure alarms, open the battery breaker and jump to the bleeding state. 13. If bypass is available and not active, then request bypass idle mode. 14. Wait 20ms. 15. Activate the DC_CHARGE to charge the positive rail. 16. Check positive rail voltage after 10 seconds: if it is below 20V, then set DC charge failure alarm, open the battery breaker and jump to the bleeding state. 17. Wait until positive rail voltage is above battery voltage by 45V. If unresponsive after 2 minutes, then set the DC charge failure alarm, open the battery breaker and jump to the bleeding state. 18. Stop charging the positive rail. 19. Wait 10ms. © 2006 - Eaton Corporation
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Functional Descriptions
9355 20 – 30 kVA
20. Use the input phase 1 upper IGBT to transfer energy from positive to negative rail. 21. Request battery relay balancing. 22. If negative DC voltage goes over 233V, then set the balancer relay failure alarm, open the battery breaker and jump to the bleeding state. 23. Check the negative voltage after 20s, if below 50V, then set the balancer relay failure alarm, open the battery breaker and jump to the bleeding state. 24. Wait until the battery relay is balanced. Maintain minimum positive rail voltage (120V). If not ready after 2 minutes, then set the balancer relay failure alarm, open the battery breaker and jump to the bleeding state. 25. Stop the charging negative rail. 26. Wait 1 second. 27. Deactivate the DC_CHARGE. 28. Ramp boost the voltage starting from lower rail voltage 240V / 1 second. 29. Wait until final rail reference is reached (188V). 30. Startup the balancer. 31. Ramp boost voltage again starting from lower rail voltage 40V / 1 second, now with the balancer active. 32. Wait 1 second. 33. Turn on 12V_2 (X-Slots), accept X-Slot communication.
4.4.5
4-16
Utility Starting State 1.
Clear the old EPO alarm.
2.
Activate EPO.
3.
Start monitoring utility voltages, jump to shutdown if not good.
4.
Check the site wiring fault and shutdown if the chassis voltage measurement is > 50V.
5.
Wait 500ms.
6.
If not in parallel mode, bypass is not active and output voltage > 50V, then set the abnormal output voltage alarm and jump to the bleeding state.
7.
If bypass is enabled and not active and bypass voltage > 50V, then set the bypass breaker failure alarm and jump to the bleeding state.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
8.
Wait 100ms and initialize slow bypass voltage measurements to fast measurements.
9.
Enable gate power and PLDs.
10. If rail is already up, exit the Utility starting state sequence and go to the “turn inverter on” state. Otherwise, continue the sequence and turn rectifier L1 on, in a mode which bleeds the balancer capacitor down. 11. Request bypass idle mode. 12. Wait 100ms. 13. If capacitor voltage is < 25V, close the balancer relay. 14. Wait 40ms. 15. Activate the DC_CHARGE to charge the positive rail. 16. Check positive rail voltage after 10s; if below 20V, then set DC charge failure alarm and jump to the bleeding state. 17. Wait until (+) rail voltage is above L1 positive peak by 45V. If it is not ready after 2 minutes, then set DC charge failure alarm and jump to the bleeding state. 18. Use input phase 1 upper IGBT to transfer energy from (+) to (-) rail. 19. Check negative voltage after 20 seconds. If below 50V, then set the balancer relay failure alarm and jump to the bleeding state. 20. Wait until negative DC is higher than L1 maximum peak + 55V or 233V. If not ready after 2 minutes, then set balancer relay failure alarm and jump to the bleeding state. 21. Stop charging the negative rail. 22. Wait until the positive rail voltage is above L1 positive peak by 45V. If not ready after 1 minute, then set the balancer relay failure alarm and jump to the bleeding state. 23. Wait 5 seconds. 24. Deactivate the DC_CHARGE. 25. Use the input phase 1 lower IGBT to transfer energy from the (-) rail to the (+) rail. 26. Wait until positive and negative rails are equal (+/-5V). If not ready after 20 seconds, then set the balancer relay failure alarm and jump to the bleeding state. 27. Wait 5 seconds. 28. Open the balancer relay, K1-K4, and wait 20ms. 29. Close the K1 contactor. The contactor is too slow to operate at zero crossing. Wait 100ms. © 2006 - Eaton Corporation
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Functional Descriptions
9355 20 – 30 kVA
30. Set the initial rectifier reference to higher rail voltage + 15V or 188V. 31. L1 Rectifier on. 32. Ramp up rectifier reference voltage (10V / 1s). 33. Wait until the final rail reference is reached (188V). If not ready after 10 seconds, then set rectifier failed alarm and jump to the bleeding state. 34. L1 Rectifier off. 35. L1, L2 and L3 Rectifier ON. 36. Wait 100ms while the rectifier is running normally. If not ready after 10 seconds, then set the rectifier failed alarm and jump to the bleeding state. 37. Set the flag which communicates that the rail is high enough to commutate the battery SCR if it was turned on. 38. Turn on the 12V_2 (X-Slots), accept x-slot communication.
4.4.6
Inverter Starting State 1.
If the unit is on bypass, configure the inverter (this is for flash recovery), enable the battery, close the battery contactor, transfer the unit to bypass and exit the inverter starting state.
2.
Configure the inverter.
3.
Inverter ON.
4.
Wait 40ms.
5.
Check the inverter fuses. If inverter voltage is under 50V, then set the fuse failure and inverter startup failure alarms and jump to the bleeding state.
6.
Check that the inverter is within its operational window. If not, then set the inverter startup failure and jump to the bleeding state.
7.
If not in parallel mode, bypass is not active and UPS output voltage is > 50V, then set the abnormal output voltage and inverter startup failure alarms and jump to the bleeding state.
8.
Enable battery operations and close the battery contactor.
9.
Wait 5 seconds.
10. Jump to the standby state.
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© 2006 - Eaton Corporation
9355 20 – 30 kVA
4.4.7
Functional Descriptions
Standby State
The UPS is brought to this state on the first startup after auxiliary power comes up, load is not on bypass and startup is possible. During standby state the load is down and the X-Slots are powered; the inverter, rectifier and battery operations are active; and the output SCRs are open. The batteries are charged if utility is good. Auxiliary power is drawn from utility or from the battery if utility isn’t available. During standby the UPS output has been turned off. The UPS is ready to turn the output on when commanded to do so, or when the utility is OK, depending on the standby precursory condition resolution. Standby stays active as long as all of the following conditions are met and the load is not commanded on. Table 6. Active Standby Conditions Conditions Required to Maintain DC Bus Voltages
Timeout Before Action
Inverter hardware over current limit
0ms
Rectifier hardware over current limit
0ms
Overload >100% and shutdown timeout reached
0ms
Auxiliary power failure
0ms
DC bus over voltage (>250 V)
0ms
DC bus very low voltage ( 144V
0ms
Utility not available and boost/charger hardware over current limit 0ms Utility not available and boost/charger over temperature shutdown 0ms Utility not available and low battery shutdown *
0ms *
Inverter output out of window
300ms
Temperature sensor failure
300ms
Rectifier over temperature shutdown
300ms
Inverter over temperature shutdown
300ms
Balancer over temperature
300ms
Boost/charger hardware over current limit
300ms
* Low battery shutdown timeout is 60 minutes on standby state.
When utility power fails and auxiliary power is taken from the battery, a 60minute countdown starts. When the countdown expires or the battery voltage reaches 1.67 volts/cell, the unit goes to the bleeding state and auxiliary power is shut down. If utility returns, the counter counts backwards until the 60-minute limit is reached. If standby was caused by a low battery shutdown, there is a © 2006 - Eaton Corporation
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Functional Descriptions
9355 20 – 30 kVA
60-minute countdown mentioned above, but load will be powered when utility returns.
4.4.8 •
User Interface & XCP XCP status = UPS OFF
4.4.8.1
Hardware
•
Bypass off
•
Inverter thyristors off
•
X-Slots are on
4.4.8.2
Other
Restarts automatically if the “automatic on function” is enabled and when the turn-off reason is: •
Automatic off delay OR
•
Binary input delayed shutdown function OR
•
4.4.8.3
XCP delayed load power off and restart command.
Operation
The restart flag indicates if the UPS output is automatically turned back on when the utility is OK. The minimum time to remain in standby after turn-off is 10 seconds. This feature prevents inadequate breaks on the UPS output voltage. While the UPS is in this state UPS communications is working (this means the D-sub, X-Slots, binary inputs, signal relay, and so on). Battery power is used, when necessary. The UPS must be ready to restart when commanded to do so. While remaining in this state, the battery voltage is constantly monitored. If battery voltage decreases to the shut down level, battery draining ceases and the UPS is turned off; if a one-hour-long utility break occurs, the same shut down sequence occurs. The utility break counter is decreased when utility is good. If the UPS is turned off, the restart flag state is stored. When the utility returns, the state of the flag is checked, and the UPS output is automatically restarted.
4.4.9
On Inverter State
The load is fed by the inverter. Energy is taken from the utility and/or from the batteries. The X-Slots are powered.
4-20
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
4.4.9.1
User Interface & XCP
The XCP status is given in the following prioritized order: •
XCP status = ON BATTERY, when discharging batteries
•
XCP status = OUTPUT OVERLOAD, when the UPS is overloaded
•
XCP status = SYSTEM NORMAL, when there are no alarms
•
XCP status = UPS SUPPORTING LOAD, when alarms are active
4.4.9.2
Hardware
•
Bypass off
•
Inverter thyristors on
•
X-Slots are on
4.4.9.3 •
Other
None
4.4.9.4
Operation
During the program loop, the firmware checks for any conditions that would invoke a transfer on bypass, output shutdown, or conditions preventing a transfer on bypass. When a transfer on bypass is possible, the state of the UPS changes to a ”transfer on bypass” state. The firmware checks the conditions that caused inverter output shutdown and transfer to bypass, and the output is remedied accordingly. The XCP load off commands will then change the state of the UPS to standby. Other conditions may require rail discharge in addition to securing the output. Depending on the condition, shutdown may also be delayed. A “Delayed Pending Shutdown” is aborted if conditions become inactive before the delay has expired.
4.4.10
On Bypass State
The table below shows the conditions that normally will cause the transfer to bypass. If the transfer cannot be made, the table shows whether a condition causes an output shutdown. Table 7. Conditions Prompting an Output Shutdown Conditions Requesting Transfer to ON Bypass
Transfer Disabled if...
If Transfer is Disabled, Shutdown After...
User command to use bypass operation
ABC
-
Overload level 1 ≥102%
ABC
10 minutes
Overload level 2 ≥111%
ABC
60 seconds
© 2006 - Eaton Corporation
4-21
Functional Descriptions
9355 20 – 30 kVA
Table 7. Conditions Prompting an Output Shutdown Conditions Requesting Transfer to ON Bypass
Transfer Disabled if...
If Transfer is Disabled, Shutdown After...
Overload level 3 ≥126%
ABC
5 seconds
Overload level 4 ≥151%
AB
300ms
Inverter output out of window
AB
300ms
Temperature sensor failure
AB
300ms
Rectifier over temperature shutdown
AB
300ms
Inverter over temperature shutdown
AB
300ms
Balancer over temperature
AB
300ms
Battery low limit counter expired and load on battery
AB
0ms
Battery usage prevented and load on battery
AB
0ms
Hardware over current limit
AB
0ms
Auxiliary power failure
AB
0ms
DC bus very low voltage (250 V)
AB
0ms
A
-
Service command to use forced bypass operation
A. Disable bypass mode or bypass not installed. B. Bypass voltage/frequency is unacceptable, bypass has been disabled by signal input, minimum time (3 seconds) on the inverter hasn’t expired, neutral fault, bypass failure, bypass processor not ready or unsynchronized transfers are disabled and the inverter is not synchronized to bypass. C. Bypass temporarily inhibited or the minimum time on battery before bypass counter hasn’t expired (4 seconds). This table lists other conditions to shutdown the output. Table 8. Other Condtions Prompting Output Shutdown Conditions to Shutdown the Output
Transfer Disabled if...
If Transfer is Disabled, Shutdown After...
Battery connected, Battery low limit counter expired
-
0ms
Emergency power off (EPO)
-
0ms
Turn UPS off command from front panel
-
0ms
Automatic off delay function
-
0ms
XCP ”UPS off” command
-
0ms
XCP ”delayed off” command
-
0ms
Output transformer over temperature
-
Configurable
4-22
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
The following table shows the conditions that prevent the transfer to inverter from bypass. The transfer is done 5 seconds after the last active condition becomes inactive. The following table also shows the conditions that don’t prevent transfers when bypass fails. Table 9. Condition Preventing Bypass to Inverter Transfer Conditions Preventing Transfer From Bypass to Inverter User command to use bypass operation
Doesn’t Prevent Transfer if Bypass is Bad S
Service command to use forced bypass operation Overload >100%
* Prevents Soft transfers
Hardware over current limit Inverter output fuse failure Rectifier failure Rectifier over temperature alarm
* Prevents Soft transfers
Rectifier over temperature shutdown Inverter over temperature alarm
* Prevents Soft transfers
Inverter over temperature shutdown DC bus over voltage (>250 V) DC bus very low voltage ( U out + 10% Bypass frequency < 47Hz Bypass frequency > 53Hz Bypass processor in unknown state Neutral failure
The following table shows the conditions, which cause output shutdown. Table 11. Conditions that Shutdown the Output From Bypass Neutral failure and inverter not available Emergency power off (EPO) Turn UPS off command from front panel XCP ”UPS off” command XCP ”delayed off” command
4.4.10.1 User Interface & XCP The XCP status is given in the following prioritized order: •
XCP status = OUTPUT OVERLOAD, when the UPS is overloaded
•
XCP status = ON BYPASS
4.4.10.2 Initialization 4.4.10.3 Hardware •
Bypass on
•
Inverter thyristors off
•
X-Slots are on
4.4.10.4 Other •
None
4.4.10.5 Operation During the program loop, the firmware checks the conditions to transfer on inverter or to require output shutdown. The firmware checks for a condition that warrants turning the inverter off or the rectifier off. If such a condition exists, the rails stay peak charged and the converters are turned off. 4-24
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
If the rectifier or inverter is off, and all failures are clear, then the rectifier and inverter should be restarted. Let the inverter run at least 5 seconds prior to transferring online. The firmware checks conditions that prevent transfer on inverter. The firmware checks if the bypass condition forces the transfer on inverter. The firmware checks the conditions that cause output shutdown (these conditions include a neutral fault while the inverter is unavailable and the UPS off command). The output is turned off accordingly.
4.4.11
The Bleeding State
In the bleeding state the DC bus is drained. The rectifier, inverter and battery operations are shut down. All measurements are disabled for 50 seconds at the end of bleeding. Bleeding is not allowed if the unit was on bypass, because the ABF relay is feeding both the rectifier and bypass. If bleeding is justified and the unit is on bypass, the bypass state takes priority and bleeding does not occur. If utility is good after bleeding and there are no active alarms, the UPS will continue to the shutdown state; or, if the load is on bypass, to the startup state. If the utility is bad after bleeding, the auxiliary power shuts down. Bleeding can be interrupted by a front panel UPS ON command.
4.4.11.1 User Interface & XCP •
XCP status = UPS OFF
4.4.11.2 Initialization 4.4.11.3 Hardware •
X-Slots are off
4.4.11.4 Other •
None
4.4.11.5 Operation The X-Slots are off. The DC bus is drained. Measurements are disabled at the end of this state. The following steps are done at UPS DC bus discharge: 1.
Open the inverter output contactor.
2.
Turn off the inverter.
3.
Wait 30ms.
4.
Stop monitoring rail voltages, disable battery operations, open the battery relay, shut down the rectifier, turn off X-Slot power.
5.
Wait 2ms. © 2006 - Eaton Corporation
4-25
Functional Descriptions
9355 20 – 30 kVA
6.
Open the ABF relay.
7.
Wait 40ms.
8.
Disable EPO.
9.
Wait 100ms for ABF to open.
10. Bleed the balancer capacitor down with rectifier L1. 11. Wait 100ms. 12. If voltage cannot be bled less than 25V, set the balancer relay failed flag and interrupt the bleed routine. 13. If bleed down was okay, close the balancer relay. 14. Wait 60ms. 15. Use the input phase 1 lower IGBT to transfer energy from negative rail to positive rail. 16. Make sure that the positive rail stays between 188V and 178V. 17. Wait 40 seconds, or until the negative rail is lower than -20V before continuing. 18. Check for UPS on command; if TRUE, turn back on; if FALSE, disable GATE_ENABLE and PLD rectifier gate outputs. 19. Wait 10 seconds or until the positive rail is lower than 150V before continuing. 20. Wait 40ms. 21. Open the balancer relay. 22. Wait 40ms. 23. Disable all meters and meter based alarms. 24. Shut down the main 12V. 25. Request an EEPROM restart bit write. 26. Wait for EEPROM write completion. 27. Wait 40 seconds. 28. Jump to the initialization state or failure shutdown state.
4.4.12
Bypass-Locked State
The load is on bypass. The UPS auxiliary power is off. The unit restarts and transfers the load on inverter as soon as utility returns and startup is possible.
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© 2006 - Eaton Corporation
9355 20 – 30 kVA
4.4.13
Functional Descriptions
Failure Shutdown State
If bleeding was caused by an alarm listed below, the unit goes to the failure shutdown state. This state ensures that the X-Slots are powered and the modem can be used to communicate the failure. •
Auxiliary power startup failure
•
Back-feed failure
•
Abnormal output voltage at startup
•
Bypass SCR failure
•
DC charger failure
•
Balancer relay failure
•
Rectifier failure
•
Inverter startup failure
•
Fuse failure
4.4.13.1 User Interface & XCP •
XCP status = UPS OFF
•
XCP status = ON BYPASS
4.4.13.2 Initialization 4.4.13.3 Hardware •
Bypass off
•
Inverter thyristors off
•
X-Slots are on
•
All analog measurements are disabled
4.4.13.4 Other •
None
4.4.13.5 Operation The purpose of this state is to maintain communication, possibly alarming a shut down cause. The only way to turn the output back on is to use the front panel UPS ON function. While the UPS is in this state the X-Slot communication is working. However, all measurements are disabled because auxiliary power is reserved for the XSlots. The DC bus isn’t maintained in this state. It means that auxiliary power shuts down and all communication is lost during a utility break. © 2006 - Eaton Corporation
4-27
Functional Descriptions
4.4.14
9355 20 – 30 kVA
Methods of Turning the UPS Off
This section describes user signals or settings that can be used to shut down the UPS output.
4.4.14.1 Front Panel UPS Off The normal means to shut down the UPS. The UPS will restart only from the front panel.
4.4.14.2 Emergency Power Off (EPO) The signal acceptance is configurable. When accepted, it shuts down the UPS. The UPS will restart only from the front panel.
4.4.14.3 Automatic Off Function This is a user settable parameter for automatically turning the output off in case of utility failure (actually, any time when operating on battery). 1.
AutoOffDelay = -1 = 65535, no automatic off function. This is the factory setting (default value).
2.
AutoOffDelay = 0…65534, the number of seconds before the output is automatically turned off if the UPS has been discharging batteries. If the UPS transfers to some other state, the automatic off countdown is aborted.
Note The automatic off countdown is not active when a service command or a battery test (or similar reason) has caused the transfer on battery. After shutdown, the output off follows the functionality of the XCP Delayed Power off and Restart command. The UPS restarts automatically when the utility returns, but only after a minimum 10 second down time.
4.4.15
XCP Command Codes
XCP command codes are issued remotely, or from a local laptop computer, by the XCP software tool.
4.4.15.1 Delayed Power Off & Restart A command code: turn UPS output off after a delay, restart automatically when utility is OK. The command is disabled when communication control commands are disabled from the front panel.
4.4.15.2 UPS Off Command A command code: turn UPS output off immediately. Restarts when commanded with XCP, or from the front panel. The command is disabled when communication control commands are disabled from the front panel. 4-28
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
4.4.15.3 Scheduled Off A command code: turn UPS output off after a delay. Restarts when commanded with XCP, or from the front panel. The command is disabled when communication control commands are disabled from the front panel.
4.4.16
Hardware Signals
4.4.16.1 X-Slot Signal The X-Slot shutdown signal uses a serial communication receive data line. Both X-Slots (serial channels) implement this shutdown function similarly, but independently. The X-Slot shutdown signals are disabled when communication control commands are disabled from the front panel. This shutdown works also from the service port D-sub, as it is multiplexed with X-Slot 2. This function is independent from normal serial communication. Normal communication is functional, while receive lines are monitored for the shutdown signal. When a logic 0 is received continuously for 5 seconds (as the same value for both channels), the shutdown flag is activated. When a logic 1 is received, the flag becomes inactive without the delay after slight filtering. The shutdown flag may be mapped to one of three shutdown functions: •
The UPS output is shut down after delay, automatic restart.
•
The UPS output is controlled off and on with the signal. Note that there is always the delay (default 5 seconds) before the flag activates.
•
The UPS output is turned off. Note: The shut down signal from X-Slot 2 does not work while the service port D-sub is used for communication. This is because the D-sub communication disables X-Slot 2 communication and receive input.
4.4.16.2 Building Input Either building input can be mapped to function as a shutdown flag. The shutdown flag may be mapped to one of three shutdown functions: •
The UPS output is shut down after delay, automatic restart.
•
The UPS output is controlled off and on with the signal.
•
The UPS output is turned off.
© 2006 - Eaton Corporation
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Functional Descriptions
9355 20 – 30 kVA
4.4.16.3 Remote Off with Automatic Restart This function has a user selectable control source. When the signal is active: •
The UPS output is shut down after 120 seconds (EEPROM setting).
•
After shut down, the output is off at least 10 seconds.
•
When utility voltage is OK, the UPS restarts automatically if allowed by the user settable “Automatic ON Delay”. Note: The utility condition doesn’t affect shutdown signal acceptance, the signal is always accepted.
4.4.16.4 Remote On - Off This function has a user selectable control source. When the signal is active, the UPS output is off. When the signal is inactive, the output is on.
4.4.16.5 Remote Off This function has a user selectable control source. The UPS is shut down and requires the user to turn it back on via the front panel. This is the same as if the front panel UPS OFF function were used.
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© 2006 - Eaton Corporation
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Functional Descriptions
4.5 POWER MODULE BOARD (PCB) Reference Documents: PW 9355 1024051 Power Board Schematic, see the Prints chapter at the end of this document.
Figure 25.
4.5.1
9355 Power Board
Introduction & Overview
The description contained in this section pertains only to the hardware found on the Power Module Board. The Power Module Board provides interconnections to the I/O Board. It contains the system power train. Each Power Board is the location of the 3 main power converters: one phase of the Boost Rectifier—1/3 of the Battery Boost/Buck Charger, one phase of the Buck Inverter—their respective gate drives, and one IGBT thermal sensor. This board along with chokes and heat sink comprise a power module capable of handling 1/3 of the output power. DC voltage sensing is provided on this board. It is the home of the positive and negative rail bulk storage caps. There is also a heat sink thermostat sensor. Each interfaces with the I/O board through a 20-pin ribbon cable.
© 2006 - Eaton Corporation
4-31
Functional Descriptions
4.5.2
9355 20 – 30 kVA
Description and Operation
4.5.2.1
X11 Connector Description
X11 connector is a 20-pin ribbon connector that connects the I/O board to the Power Board. Table 12.
X11 Pinout
Pin
Signal
Description
1
Logic ground
Ground
2
PWRCLK0
Gate clock
3
Logic ground
Ground
4
Temperature1
IGBT module temp sensor (middle)
5
Spare
NC
6
INVDC_L2
Inverter choke hot end sense
7
INVDC_L1
Battery choke hot end sense
8
IO1
Thermostat (heatsink)
9
POWMOD_GOOD
Power Module good signal (detects blown gate drive fuse)
10
Logic ground
Ground
11
GATE 14
Battery gate drive signal
12
GATE 13
Battery gate mode select (boost or charger)
13
GATE 8,10,12
Lower Inverter gate drive signal
14
GATE 7,9,11
Upper Inverter gate drive signal
15
GATE 6,4,2
Lower Rectifier gate drive signal
16
GATE 1,3,5
Upper Rectifier gate drive signal
17
Logic ground
Ground
18
+12V
+12V to power gate drives
19
Logic ground
Ground
20
+12V
+12V to power gate drives
4.5.3
Other Connector Descriptions
Reference Designator
4-32
Description
X1
Negative rail busbar
X2
Positive rail busbar
X3
Neutral busbar
X5, X6
Rectifier Choke connections
X7, X8
Inverter Choke connections
X9, X10
Battery Choke connections
X12
Heatsink Thermostat connector
X13
Heatsink Neutral tie connector © 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
4.6 Power Board Functional Blocks The following paragraphs describe the functional blocks of the Power Board.
4.6.1
Voltage Sensing
The Power Board provides DC voltage sense resistors for voltage sense measurements done on the Control Board. Voltage sense resistors are two 1Meg ohm resistors in series. The measurements are differential measurements with respect to neutral. Redundant battery and inverter DC are sensed.
4.6.2
Rectifier
The three-phase 20khz rectifier circuit consists of an IGBT half bridge converter located in position (V3) of the IGBT module, on the heatsink closest to the busbars of each power module (that is, Power Modules L1, L2, L3). During startup one rectifier half bridge (PM L1) is first used in balancer mode (~50% duty cycle), together with rectifier chokes (L7A/B) and balancer relay (K1-3 on the I/O board), to pre-charge the negative rail capacitors from the pre-charge energy stored in the positive rail capacitors. This rail pre-charge takes place in order for the input contactor to close without causing a high inrush current from the utility to the rail caps. After this precharge period ends the balancer relays are opened and the input contactor is closed. The 3 phase rectifier half bridges (PM L1, L2, L3) midpoints are then connected to utility through parallel input chokes (L1A/B, L4A/B, L7A/B) and begin operating in boost PFC mode, boosting the rail caps to +/-195VDC wrt neutral for the inverter to use. While maintaining the boosted rail voltage it also draws a sine wave of current from utility. After the input contactor is opened during battery operation, if utility fails the rectifier relays return to the above balancer mode, in order to balance the voltage on the rail caps wrt neutral coming from the Battery Boost converter (see the next section).
4.6.3
Battery Converter
4.6.3.1
Battery Boost
The 20khz Battery Boost circuit consists of parts of three IGBT half bridge converters located in middle (V1) IGBT module position on the main heatsink of each power module. In this mode it only involves the lower IGBT and the upper diodes operating in boost mode. The negative side of the battery is connected to the negative rail. The positive side of the battery is connected through two parallel chokes (L2A/B, L5A/B and L8A/B) to the midpoint of each half bridge. The lower IGBT of each half bridge is turned on storing energy in the respective battery chokes. When the lower IGBTs are turned off the stored energy in the chokes is dumped through the upper half bridge diodes into the positive rail. This 216VDC nominal battery voltage is then boosted to 380VDC rail-to-rail. The L1 rectifier balances the rail voltages to +/-195VDC. Each power module gate drive is staggered 120 degrees to draw an effective 60khz ripple from the battery and its filter cap. © 2006 - Eaton Corporation
4-33
Functional Descriptions
4.6.3.2
9355 20 – 30 kVA
Battery Charger
The 20khz battery charger circuit consists of remaining parts of three IGBT half bridge converters located in the middle (V1) IGBT module on the main heatsink of each power module. In this case the upper IGBTs and the lower diode operate in buck mode. The upper IGBT of each half bridge is turned on storing energy in the battery chokes while charging the battery. Then, when the upper IGBTs are turned off, the stored energy in the chokes are dumped through the lower half bridge diodes into the battery as well. This then bucks the ~390VDC rail-to-rail voltage online down to the battery voltage required for floating the battery, charging it in the process. The power module gate drives are also staggered 120 degrees to supply an effective 60khz ripple to the battery and its filter cap. This charger is capable of quickly charging many parallel battery strings and is only limited by maximum input current.
4.6.4
Inverter
The 3 phase 20khz inverter circuit consists of an IGBT half bridge converter located in the (V2) IGBT module on the main heatsink furthest from the busbars in each power module (Power Modules L1, L2, L3). Its sine wave PWM bucks the +/-195VDC rail down in order to create a 120VAC nominal sine wave output voltage wrt neutral. The half bridge midpoints are connected through parallel inverter chokes (L3A/B, L6A/B, L9A/B), through fuses (F1-F3), and the inverter contactor located on the I/O board assembly, out to the load.
4.6.5
IGBT Gate Drives
The above converter gate drive circuits are located on this board. The gate waveforms are +17V/-8V, 20khz PWM signals. These signals are derived from the control board (see connector table X11) and feed optically isolated drivers to each individual gate: •
(V4, V22 for each rectifier),
•
(V44, V66 for each inverter),
•
(V41 for each battery boost),
•
and (V14 for each charger).
With signals from the DSP, Logic IC-U3 selects whether it is in charger or boost mode.
4.6.5.1
IGBT Gate Drives Power Supplies
There are three independently fused-isolated-forward converter supplies for the above gate drives located on this board. They get their clock signal from PWRCLK0. The supplies get their power from +12V and put out +18V/-9V to the above gate driver ICs.
4-34
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
The battery boost/charger gate supply consists of : •
FETs V31,
•
XFMR T1,
•
and fuse F1.
The inverter gate supply consists of: •
FETs V121,
•
XFMR T11,
•
and fuse F2.
The rectifier gate supply consists of: •
FETs V18,
•
XFMR T12,
•
and fuse F3.
U1 provides a POWMOD_GOOD signal if all the fuses are ok.
4.6.5.2
IGBT Module Thermal Sensor
The thermal sensor of the central IGBT module on each heatsink is the only one that is being monitored by the DSP. If the temperature gets too high, the IGBTs are turned off and the unit is put on bypass.
4.7 Advanced Battery Management 4.7.1
Introduction
The purpose of this section is to describe common (platform) ABM operation with common terminology. For details about Power Share, refer to paragraph 1.2.3.
4.7.2
Purpose
The purpose of ABM is to extend the life of valve regulated, absorbed electrolyte lead-acid (VRLA) batteries employed in standby service of an Uninterruptible Power Supply (UPS).
© 2006 - Eaton Corporation
4-35
Functional Descriptions
9355 20 – 30 kVA
Studies on the “end of life” mechanisms of batteries in stand-by service reveal that the cause of battery failure is positive grid corrosion due to constant float charging. A key feature of ABM is that the batteries be held at rest rather than on float for most of their service life. This is accomplished by giving them a periodic freshening charge and allowing them to rest. The length of time for the freshening and the timing of the initiating event can mitigate the benefit of rest. Care must be taken in limiting the initiating events for freshening so that the excess charging does not occur.
4.7.3
General Terms
battery rest – a battery state where it is neither charging nor discharging. This is done by disconnecting the battery from its charger. charge mode - begins a charging cycle; the battery voltage is being recharged after discharging, after an extended inactive period, and when open cell voltage decreases below batOpChrgV in rest mode. The mode ends when the battery voltage reaches batChargeV, or if the mode has lasted batChargeTMax time. charging cycle - consists of charge, float and rest modes. Battery voltage is charged in charge mode, then the voltage is kept steady in float mode, and finally batteries are inactive. continuous-float charging - batteries are held at constant voltage, batConstFloatV, instead of using a charging cycle scheme: user selectable. float charging - during ABM cycling: charging at a higher voltage level than in continuous-float charging; used to bring all cells in a battery string to their full charge state. This is done for a limited duration. float mode - after charge mode the battery voltage is kept constant at batEqualizeV during (batFloatTExt + batFloatT) time OCV - open cell voltage rest mode - batteries are inactive after float mode, without discharging nor charging. VPC - volts per cell
4.7.3.1
Values and Limits
batChargeT - charge time: how long the charge mode lasted. batChargeTMax – maximum charge time—default is 100 hours; the time-out for charge mode after which the float mode is started, even if the battery voltage has not yet reached batChargeV level. batChargeV - charge voltage—default 2.335VPC / 25ºC; the level where charge mode changes to float mode. batChrgI - charging current in charge mode. batChrgRefV - charger voltage reference in charge mode—default 2.385VPC / 25ºC. 4-36
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Functional Descriptions
batConstFloatV - continuous-float voltage—default 2.30VPC / 25ºC: used to constantly charge batteries when ABM charging cycles are disabled by the user. batDischT - cumulative discharge time—calculated internally by the UPS. batEqualizeV - ABM cycling float mode voltage—default 2.30VPC / 25ºC. batFloatT - ABM cycling float time—default 48 hours. batFloatTExt - ABM cycling float time extension: batFloatTExt = 1.5 y batChargeT. batMaxRestT - maximum rest mode time—default is 28 days: duration of rest mode, if neither discharging nor batOpChrgV have initiated a new charging cycle. batMinDischT - minimum discharge time—default 20 seconds: limit for cumulative discharge times after charge mode to initiate a new charging cycle. batOpChrgV - opportunity charge voltage—default 2.10VPC; if battery voltage decreases below this limit in rest mode, a new charging cycle is initiated immediately. batRestFailT - battery OCV failure time—default 10 days in rest mode. batSuppTestT - battery support test time moment—default 24 hours from the beginning of float mode. batSuppTestV - low voltage limit for battery support test—default 1.75VPC.
4.7.3.2
Discharging
XCP Battery data block reports ABM status: discharging. Discharging of batteries interrupts any charging mode. Cumulative discharging time is being calculated in batDischT. If after a discharge period, the value of batDischT exceeds batMinDischT, then a new charging cycle is initiated; otherwise the previous charging mode is continued.
© 2006 - Eaton Corporation
4-37
Functional Descriptions
4.7.4
9355 20 – 30 kVA
Charging Cycles Charge Mode
Rest Mode
ABM Float Mode Battery Test 1 8% of expected runtime (varies based on batteries installed)
batChrgRefV 2.39V batChargeV 2.34V batEqualizeV 2.30V batConstFloatV 2. 2.30V
Battery Test 2 30 seconds initial commissioning test; 50 seconds thereafter.
batOpChrgV 2.10V user configured over voltage level.
4
Bypass ac under voltage
UPS bypass unavailable
Bypass voltage is < user configured over voltage level.
33
Bypass breaker fail
A Relay, Contactor, or Breaker has failed
Bypass voltage is detected at startup (should be mapped to alarm #195, "Back-feed contactor failure")
188
Bypass failure
A Relay, Contactor, or Breaker has failed
DSP cannot read status of bypass pic, or bypass pic is not changing states when commanded to
105
Bypass not available
UPS bypass unavailable
Bypass voltage and/or frequency is out of configured limits, bypass transfer is not allowed
© 2006 - Eaton Corporation
Notes
7-5
Troubleshooting and Maintenance Alarm #
7-6
LCD Description
9355 20 – 30 kVA Web card description
UPS bypass unavailable
Comments
119
Bypass phase rotation
Indicates bypass phase displacement is different from inverter phase displacement, bypass transfer is not allowed
109
Bypass Switchgear Open
38
Bypass Uncalibrated
A UPS Notice condition exists
This is a warning that the autocalibration has failed, while calibrating Bypass sensor.
5
Bypass under/over frequency
UPS bypass unavailable
Bypass frequency is outside of user configured window
21
Charger over temperature
An internal temperature is out of tolerance
Battery converter / Charger IGBT module temperature exceeds its limit
249
Charger over temperature shutdown
An internal temperature is out of tolerance
Boost IGBT temperature exceeded shutdown level (90ºC)
140
Charger Status
Not Applicable
The charger is on.
121
Check Parallel Board
UPS hardware fault detected
The board used for paralleling control appears to have failed.
36
Check Static Switch
A Relay, Contactor, or Breaker has failed
Static switch fault: The static switch appears to have failed.
224
Configuration error
UPS hardware fault detected
EEROM error. Eeprom section does not match mirror, eeprom section needed to be rebooted, or eeprom version is higher than code supports (back rev)
241
Contact Service (battery test failed)
UPS hardware fault detected
Battery failed to reach float voltage in time allowed
244
Contact service (illegal instruction)
UPS hardware fault detected
Internal CPU error
The bypass breaker is open.
© 2006 - Eaton Corporation
Notes Using the XCP Tool, Options Tab, enable auto freq detect. Shut the unit down completely (no logic power) and restart. Unit will autoconfig and auto freq will disable.
9355 20 – 30 kVA Alarm #
Troubleshooting and Maintenance
LCD Description
Web card description
Comments
138
Control Power Status
N.A.
Control power has been applied. This status is set when the controls first power up. It is used to record the date and time of return of power after a power fail.
146
CPU ISR error
UPS hardware fault detected
This alarm is listed in the alarm block, but is never set in DSP firmware
28
dc link over voltage
UPS hardware fault detected
Either positive rail was greater than 250V, or negative rail was less than 250V
29
dc link under voltage
UPS hardware fault detected
Either positive rail was less than 100V, or negative rail was greater than -100V
178
DC Start Occurred
N.A.
The UPS has been started on battery when AC input power is not present. This alarm is used to record the date and time of this event.
42
DC Voltage Uncalibrated
A UPS Notice condition exists
This is a warning that unit is not calibrated.
193
Fan failure
The failure of one or more fans in the UPS has been detected
Fan tach pulses are too slow
95
From Bypass Command
191
Fuse failure
The UPS batteries need to be replaced (IETF).
If no separate bypass input, is set if bypass voltage is not equal to utility voltage. Also set if no inverter voltage when the inverter is turned on.
73
Heatsink Over Temperature
An internal temperature is out of tolerance
Heat sink fault: the heat sink temperature at an unspecified module exceeds the upper temperature limit for normal operation
Notes
A command has been received to transfer the load from bypass to the inverter. This command may come from a local control panel or from a remote source.
© 2006 - Eaton Corporation
7-7
Troubleshooting and Maintenance Alarm #
7-8
LCD Description
9355 20 – 30 kVA Web card description
Comments
74
Heatsink temperature sensor fail
UPS hardware fault detected
Rectifier/inverter IGBT sensor or ambient temp sensor read either unreasonably high or low, indicating open/shorted sensor
212
Incoming Modem Call Started
N.A.
A modem connected to the UPS has received an incoming call and has begun to negotiate a connection.
6
Input ac over voltage
Utility power has failed
Input voltage is greater then eeprom limit (144VAC), unit can't run utility, is on battery
8
Input under/over frequency
Utility power has failed
Input frequency is outside of limits (45-65Hz for normal unit, 55-65Hz for transformer unit) Unit is on battery
1
Inverter ac under voltage
UPS Inverter fault detected
Set if phase-to-phase or phase-to-neutral voltage is < 90% of set point.
221
Inverter output failed
UPS Inverter fault detected
Fast inverter UV, inverter voltage outside window limit
27
Inverter output over current
UPS Output overloaded
Hardware current limit trip, Unit saw inverter current reached the hardware limit for 20 consecutive line cycles
24
Inverter over temperature
An internal temperature is out of tolerance
Inverter IGBT temperature sensor is reading higher than eeprom limit (80ºC). Has 2 levels 80ºC is warning level, 90ºC is transfer to bypass if available, dump load if not.
111
Inverter Over Temperature Trip
An internal temperature is out of tolerance
The inverter temperature has exceeded it s rating operating temperature.
48
Inverter startup failure
UPS Inverter fault detected
Startup alarm, inverter alarm present when inverter is started, inverter voltage below limit, output voltage present when inverter started (SCR failure)
139
Inverter Status
N.A.
The inverter is on. © 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
Troubleshooting and Maintenance
LCD Description
Web card description
Comments
41
Inverter Uncalibrated
A UPS Notice condition exists
This is a warning that the autocalibration has failed, while calibrating inverter.
159
L1 Overload
UPS Output overloaded
PHA VA or watts greater than 111% UPS rating
165
L1 Overload (Extreme Level)
UPS Output overloaded
PHA VA or watts greater than 149% UPS rating
162
L1 Overload (High Level)
UPS Output overloaded
PHA VA or watts greater than 126% UPS rating
160
L2 Overload
UPS Output overloaded
PHB VA or watts greater than 111% UPS rating
166
L2 Overload (Extreme Level)
UPS Output overloaded
PHB VA or watts greater than 149% UPS rating
163
L2 Overload (High Level)
UPS Output overloaded
PHB VA or watts greater than 126% UPS rating
161
L3 Overload
UPS Output overloaded
PHC VA or watts greater than 111% UPS rating
167
L3 Overload (Extreme Level)
UPS Output overloaded
PHC VA or watts greater than 149% UPS rating
164
L3 Overload (High Level)
UPS Output overloaded
PHC VA or watts greater than 126% UPS rating
170
Load Dumped (Load Power Off)
UPS output has been turned off
No power is being provided to the load (load dump). This alarm is used to record the date and time of a power-off event.
173
Load Off Command Received
N.A.
A load control command to turn OFF the/an output has been issued to the UPS (may be with a delay). This alarm is used to record the date and time of this event.
172
Load Power On Command Received
N.A.
A load control command to turn ON the/an output has been issued to the UPS (may be with a delay). This alarm is used to record the date and time of this event.
174
Low battery shutdown
UPS Battery completely discharged
Battery voltage is less than 1.75V/cell, 1 minute shutdown timer is started
143
Maintenance Bypass Mode
The UPS has been placed on Maintenance / Manual Bypass by an
The load is being supplied power by a wrap-around maintenance bypass switch.
© 2006 - Eaton Corporation
Notes
7-9
Troubleshooting and Maintenance Alarm #
LCD Description
9355 20 – 30 kVA Web card description
Comments
operator
216
Modem call completion failed
N.A.
A modem connected to the UPS has failed to successfully complete a transaction sequence as expected.
214
Modem Connection Established
N.A.
A modem connected to the UPS has established a connection with a remote modem or paging service.
211
Modem failed
N.A.
Can’t communicate with modem
53
Non-volatile RAM failure
UPS General System Test failed
EEPROM has failed
213
Outgoing Modem Call Started
N.A.
A modem connected to the UPS has gone off hook and has begun to either dial a number or negotiate a connection.
10
Output ac under voltage
The output condition (other than Output Overload) is out of tolerance
This alarm is listed in the alarm block, but is never set in DSP firmware
25
Output overload
UPS Output overloaded
Greater than 102% load on any output phase
58
Output Short Circuit
The output condition (other than Output Overload) is out of tolerance
Output short circuit detected
72
Power supply 12 volt fault
UPS hardware fault detected
Digital input from control board power supply monitoring chip
71
Power supply 5 volt fault
UPS hardware fault detected
Digital input from control board power supply monitoring chip
70
Power supply failure
UPS hardware fault detected
One of the internal power supplies is failed
30
Rectifier failed
An uncorrected problem has been detected within the UPS charger subsystem
Startup failure, either rectifier didn't report "normal" status or was unable to maintain dc link voltage after rail precharge.
7-10
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
LCD Description
Troubleshooting and Maintenance Web card description
Comments
26
Rectifier input over current
UPS hardware fault detected
Hardware current limit trip, Unit saw rectifier current reached the hardware limit for 20 consecutive line cycles
223
Rectifier over temperature
An internal temperature is out of tolerance
Rectifier IGBT temperature sensor is reading higher than eeprom limit (80ºC). Has 2 levels 80ºC is warning level, 90ºC is transfer to bypass if available, dump load if not.
225
Redundancy Loss Due To Overload
In a parallel UPS system, one of the power modules has failed or the specified power rating has been exceeded
The specified power rating of an "n+1" parallel system has been exceeded. The load is supported, but the system lacks redundant protection while this overload persists.
12
Remote emergency power off
UPS output has been turned off
Signal input, output is deenergized and battery breaker is tripped. Output can't be energized while active
220
Selective Trip Of Module
One module in a parallel or multiple component system has failed
A UPS module has been automatically removed from a parallel system, usually due to improper load sharing or other fault.
55
Shutdown imminent
UPS Shutdown Imminent Alarm condition exists
UPS will shut the load down, either from low battery or delay UPS off command pending
194
Site fault
UPS hardware fault detected
Measure chassis voltage too high measured against neutral
176
Software incompatibility detected
UPS General System Test failed
Wrong PLD version, wrong DSP rev, wrong unit
229
System Alarm Active
A System / Subsystem Alarm is active
Critical Alert (Summary Alarm): If non-zero, there is at least one severe alarm active at the system level at this time.
© 2006 - Eaton Corporation
Notes
7-11
Troubleshooting and Maintenance Alarm #
LCD Description
9355 20 – 30 kVA Web card description
Comments
132
System Not Redundant
In a parallel UPS system, one of the power modules has failed or the specified power rating has been exceeded
For an "n+1" parallel system, the load is supported, but the system is no longer has redundant protection.
257
System Test in Progress
A UPS Notice condition exists
One of the Systems Tests has begun.
258
Test Aborted
A UPS Notice condition exists
A Battery or Systems Test has been aborted while running due to conditions or operator command, or was inhibited from starting.
94
To bypass command
UPS internally bypassed
Signal input used to send unit to bypass
201
Transformer over temperature
An internal temperature is out of tolerance
Signal input
237
UPS Normal
N.A.
The UPS is in its normal operating mode of operation.
168
UPS on battery
UPS switched to battery power
UPS is on battery
169
UPS on bypass
UPS internally bypassed
UPS is on bypass
248
UPS on generator
The system is being powered by its Alternate Power Source
Signal input
57
Utility fail
Utility power has failed
Utility voltage or frequency outside limits. Does not necessarily mean unit is on battery.
59
Utility not present
Utility power has failed
Utility voltage is outside limits, unit is on battery
192
Alarm # 1
7-12
Notes
The failure of one or more fuses has been detected
LCD Description Inverter AC under voltage
Web card description
Comments
UPS Inverter fault detected
Set if Phase to phase or phase to neutral voltage is < 90% of setpoint.
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
LCD Description
Troubleshooting and Maintenance Web card description
Comments
3
Bypass ac over voltage
UPS bypass unavailable
Bypass voltage is > user configured over voltage level.
4
Bypass ac under voltage
UPS bypass unavailable
Bypass voltage is < user configured over voltage level.
5
Bypass under/over frequency
UPS bypass unavailable
Bypass frequency is outside of user configured window
6
Input ac over voltage
Utility power has failed
Input voltage is greater then eeprom limit (144Vac), unit can't run utility, is on battery
8
Input under/over frequency
Utility power has failed
Input frequency is outside of limits (45-65Hz for normal unit, 55-65Hz for transformer unit) Unit is on battery
10
Output ac under voltage
The output condition (other than Output Overload) is out of tolerance
This alarm is listed in the alarm block, but is never set in DSP firmware
12
Remote emergency power off
UPS output has been turned off
Signal input, output is deenergized and battery breaker is tripped. Output can't be energized while active
14
Building alarm 6
One of the defined building alarms has occurred
Signal input, user configurable
15
Building alarm 5
One of the defined building alarms has occurred
Signal input, user configurable
16
Building alarm 4
One of the defined building alarms has occurred
Signal input, user configurable
17
Building alarm 3
One of the defined building alarms has occurred
Signal input, user configurable
18
Building alarm 2
One of the defined building alarms has occurred
Signal input, user configurable
19
Building alarm 1
One of the defined building alarms has occurred
Signal input, user configurable
© 2006 - Eaton Corporation
Notes
7-13
Troubleshooting and Maintenance Alarm #
LCD Description
9355 20 – 30 kVA Web card description
Comments
21
Charger over temperature
An internal temperature is out of tolerance
Battery converter / Charger IGBT module temperature exceeds it's limit
24
Inverter over temperature
An internal temperature is out of tolerance
Inverter IGBT temperature sensor is reading higher than eeprom limit (80ºC). Has 2 levels 80ºC is warning level, 90ºC is transfer to bypass if available, dump load if not.
25
Output overload
UPS Output overloaded
Greater than 102% load on any output phase
26
Rectifier input over current
UPS hardware fault detected
Hardware current limit trip, Unit saw rectifier current reached the hardware limit for 20 consecutive line cycles
27
Inverter output over current
UPS Output overloaded
Hardware current limit trip, Unit saw inverter current reached the hardware limit for 20 consecutive line cycles
28
dc link over voltage
UPS hardware fault detected
Either positive rail was greater than 250V, or negative rail was less than -250V
29
dc link under voltage
UPS hardware fault detected
Either positive rail was less than 100V, or negative rail was greater than -100V
30
Rectifier failed
An uncorrected problem has been detected within the UPS charger subsystem
Startup failure, either rectifier didn't report "normal" status or was unable to maintain dc link voltage after rail precharge.
33
Bypass breaker fail
A Relay, Contactor, or Breaker has failed
Bypass voltage is detected at startup (should be mapped to alarm #195, "Back-feed contactor failure")
36
Check Static Switch
A Relay, Contactor, or Breaker has failed
Static switch fault: The static switch appears to have failed.
38
Bypass Uncalibrated
A UPS Notice condition exists
This is a warning that the auto calibration has failed, while calibrating Bypass sensor.
7-14
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA
Troubleshooting and Maintenance
Alarm #
LCD Description
Web card description
Comments
41
Inverter Uncalibrated
A UPS Notice condition exists
This is a warning that the auto calibration has failed, while calibrating inverter.
42
DC Voltage Uncalibrated
A UPS Notice condition exists
This is a warning that unit is not calibrated.
47
Battery current limit
UPS hardware fault detected
Hardware current limit trip, Unit saw boost or charger current reached the hardware limit for 20 consecutive line cycles
48
Inverter startup failure
UPS Inverter fault detected
Startup alarm, inverter alarm present when inverter is started, inverter voltage below limit, output voltage present when inverter started (SCR failure)
53
Non-volatile RAM failure
UPS General System Test failed
EEPROM has failed
55
Shutdown imminent
UPS Shutdown Imminent Alarm condition exists
UPS will shut the load down, either from low battery or delay UPS off command pending
56
Battery low
Low Battery Alarm present
Battery voltage is below configured level (1.88V/cell). Only active if unit is on battery
57
Utility fail
Utility power has failed
Utility voltage or frequency outside limits. Does not necessarily mean unit is on battery.
58
Output Short Circuit
The output condition (other than Output Overload) is out of tolerance
Output short circuit detected
59
Utility not present
Utility power has failed
Utility voltage is outside limits, unit is on battery
68
Battery dc overvoltage
UPS hardware fault detected
Battery voltage higher than 50mV/cell above charger float voltage, shunt trips battery breaker
70
Power supply failure
UPS hardware fault detected
One of the internal power supplies is failed
71
Power supply 5 volt fault
UPS hardware fault detected
Digital input from control board power supply monitoring chip
© 2006 - Eaton Corporation
Notes
7-15
Troubleshooting and Maintenance
9355 20 – 30 kVA
Alarm #
LCD Description
72
Power supply 12 volt fault
UPS hardware fault detected
Digital input from control board power supply monitoring chip
73
Heatsink Over Temperature
An internal temperature is out of tolerance
Heat sink fault: the heat sink temperature at an unspecified module exceeds the upper temperature limit for normal operation
74
Heatsink temperature sensor fail
UPS hardware fault detected
Rectifier/inverter IGBT sensor or ambient temp sensor read either unreasonably high or low, indicating open/shorted sensor
94
To bypass command
UPS internally bypassed
Signal input used to send unit to bypass
95
From Bypass Command
105
Bypass not available
UPS bypass unavailable
Bypass voltage and/or frequency is out of configured limits, bypass transfer is not allowed
107
Battery contactor open
UPS Circuit Breaker Alarm condition exists
Signal input, disables charger
109
Bypass Switchgear Open
111
Inverter Over Temperature Trip
An internal temperature is out of tolerance
The inverter temperature has exceeded it s rating operating temperature.
119
Bypass phase rotation
UPS bypass unavailable
Indicates bypass phase displacement is different from inverter phase displacement, bypass transfer is not allowed
121
Check Parallel Board
UPS hardware fault detected
The board used for paralleling control appears to have failed.
7-16
Web card description
Comments
A command has been received to transfer the load from bypass to the inverter. This command may come from a local control panel or from a remote source.
The bypass breaker is open.
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
LCD Description
Troubleshooting and Maintenance Web card description
Comments
132
System Not Redundant
In a parallel UPS system, one of the power modules has failed or the specified power rating has been exceeded
For an "n+1" parallel system, the load is supported, but the system is no longer has redundant protection.
138
Control Power Status
N.A.
Control power has been applied. This status is set when the controls first power up. It is used to record the date and time of return of power after a power fail.
139
Inverter Status
N.A.
The inverter is on.
140
Charger Status
N.A.
The charger is on.
143
Maintenance Bypass Mode
The UPS has been placed on Maintenance / Manual Bypass by an operator
The load is being supplied power by a wrap-around maintenance bypass switch.
146
CPU ISR error
UPS hardware fault detected
This alarm is listed in the alarm block, but is never set in DSP firmware
149
Battery needs service
Replace Battery Warning condition exists
Detected reversed battery polarity
159
L1 Overload
UPS Output overloaded
PHA VA or watts greater than 111% UPS rating
160
L2 Overload
UPS Output overloaded
PHB VA or watts greater than 111% UPS rating
161
L3 Overload
UPS Output overloaded
PHC VA or watts greater than 111% UPS rating
162
L1 Overload (High Level)
UPS Output overloaded
PHA VA or watts greater than 126% UPS rating
163
L2 Overload (High Level)
UPS Output overloaded
PHB VA or watts greater than 126% UPS rating
164
L3 Overload (High Level)
UPS Output overloaded
PHC VA or watts greater than 126% UPS rating
165
L1 Overload (Extreme Level)
UPS Output overloaded
PHA VA or watts greater than 149% UPS rating
166
L2 Overload (Extreme Level)
UPS Output overloaded
PHB VA or watts greater than 149% UPS rating
167
L3 Overload (Extreme Level)
UPS Output overloaded
PHC VA or watts greater than 149% UPS rating
© 2006 - Eaton Corporation
Notes
7-17
Troubleshooting and Maintenance Alarm #
LCD Description
9355 20 – 30 kVA Web card description
Comments
168
UPS on battery
UPS switched to battery power
UPS is on battery
169
UPS on bypass
UPS internally bypassed
UPS is on bypass
170
Load Dumped (Load Power Off)
UPS output has been turned off
No power is being provided to the load (load dump). This alarm is used to record the date and time of a power off event.
172
Load Power On Command Received
N.A.
A load control command to turn ON the/an output has been issued to the UPS (may be with a delay). This alarm is used to record the date and time of this event.
173
Load Off Command Received
N.A.
A load control command to turn OFF the/an output has been issued to the UPS (may be with a delay). This alarm is used to record the date and time of this event.
174
Low battery shutdown
UPS Battery completely discharged
Battery voltage is less than 1.75V/cell, 1 minute shutdown timer is started
176
Software incompatibility detected
UPS General System Test failed
Wrong PLD version, wrong DSP rev, wrong unit
178
DC Start Occurred
N.A.
The UPS has been started on battery when AC input power is not present. This alarm is used to record the date and time of this event.
188
Bypass failure
A Relay, Contactor, or Breaker has failed
DSP cannot read status of bypass pic, or bypass pic is not changing states when commanded to
191
Battery test failed
Replace Battery Warning condition exists
1 or more of the ABM battery tests failed, see ABM documentation
191
Fuse failure
The UPS batteries need to be replaced (IETF).
If no separate bypass input, is set if bypass voltage != utility voltage. Also set if no inverter voltage when inverter is turned on.
7-18
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
LCD Description
192
Troubleshooting and Maintenance Web card description
Comments
Notes
The failure of one or more fuses has been detected
193
Fan failure
The failure of one or more fans in the UPS has been detected
Fan tach pulses are too slow
194
Site fault
UPS hardware fault detected
Measure chassis voltage too high measured against neutral
199
Batteries disconnected
Replace Battery Warning condition exists
Battery circuit breaker open, or voltage less than disconnected limit
201
Transformer overtemperature
An internal temperature is out of tolerance
Signal input
202
Ambient under temperature
UPS Temperature Alarm condition exists
This alarm is listed in the alarm block, but is never set in DSP firmware
203
Ambient over temperature
UPS Temperature Alarm condition exists
Ambient temperature sensor reads higher than limit (45ºC)
206
Automatic shutdown pending
UPS turn off countdown underway
Unit has received scheduled off command from XCP
211
Modem failed
N.A.
Can’t communicate with modem
212
Incoming Modem Call Started
N.A.
A modem connected to the UPS has received an incoming call and has begun to negotiate a connection.
213
Outgoing Modem Call Started
N.A.
A modem connected to the UPS has gone off hook and has begun to either dial a number or negotiate a connection.
214
Modem Connection Established
N.A.
A modem connected to the UPS has established a connection with a remote modem or paging service.
216
Modem call completion failed
N.A.
A modem connected to the UPS has failed to successfully complete a transaction sequence as expected.
219
Autocalibration Failed
UPS General System Test failed
An attempt to automatically (re-)
© 2006 - Eaton Corporation
7-19
Troubleshooting and Maintenance Alarm #
LCD Description
9355 20 – 30 kVA Web card description
Comments calibrate the UPS has failed.
220
Selective Trip Of Module
One module in a parallel or multiple component system has failed
A UPS module has been automatically removed from a parallel system, usually due to improper load sharing or other fault.
221
Inverter output failed
UPS Inverter fault detected
Fast inverter UV, inverter voltage outside window limit
222
Abnormal output voltage at startup
The output condition (other than OutputOverload) is out of tolerance
Voltage detected on the output when there shouldn't be any (bypass SCRs assumed bad)
223
Rectifier over temperature
An internal temperature is out of tolerance
Rectifier IGBT temperature sensor is reading higher than eeprom limit (80ºC). Has 2 levels 80ºC is warning level, 90ºC is transfer to bypass if available, dump load if not.
224
Configuration error
UPS hardware fault detected
EEROM error. Eeprom section does not match mirror, eeprom section needed to be rebooted, or eeprom version is higher than code supports (back rev)
225
Redundancy Loss Due To Overload
In a parallel UPS system, one of the power modules has failed or the specified power rating has been exceeded
The specified power rating of an "n+1" parallel system has been exceeded. The load is supported, but the system lacks redundant protection while this overload persists.
229
System Alarm Active
A System / Subsystem Alarm is active
Critical Alert (Summary Alarm): If non-zero, there is at least one severe alarm active at the system level at this time.
237
UPS Normal
N.A.
The UPS is in its normal operating mode of operation.
241
Contact Service (battery test failed)
UPS hardware fault detected
Battery failed to reach float voltage in time allowed
244
Contact service (illegal instruction)
UPS hardware fault detected
Internal CPU error
7-20
© 2006 - Eaton Corporation
Notes
9355 20 – 30 kVA Alarm #
LCD Description
Troubleshooting and Maintenance Web card description
Comments
248
UPS on generator
The system is being powered by its Alternate Power Source
Signal input
249
Charger over temperature shutdown
An internal temperature is out of tolerance
Boost IGBT temperature exceeded shutdown level (90C)
256
Battery Test in Progress
A UPS Notice condition exists
A Battery Test has begun.
257
System Test in Progress
A UPS Notice condition exists
One of the Systems Tests has begun.
258
Test Aborted
A UPS Notice condition exists
A Battery or Systems Test has been aborted while running due to conditions or operator command, or was inhibited from starting.
© 2006 - Eaton Corporation
Notes
7-21
Troubleshooting and Maintenance
7.1.3
9355 20 – 30 kVA
Detailed Definitions
7.1.3.1
Automatic Off Delay
This is user settable parameter for automatically turning the output off in case of utility failure (any time when operating on battery). 1.
AutoOffDelay = -1 = 65535, no automatic off function. This is factory setting (default value).
2.
AutoOffDelay = 0…65534, the number of seconds preceding output turn-off if the UPS has been discharging batteries. If the UPS transfers to some other state, the automatic-off countdown is aborted.
Note that the automatic-off countdown is not active when a service command or battery test is issued (or for some other operator initiated reason) causing the transfer on battery.
7.1.3.2
Automatic On Delay
This is user settable parameter for adding extra delay before turning UPS output on. This parameter can also be used for disabling the automatic restarts. 1.
AutoOnDelay = 0, no extra delay. This is factory setting (default value).
2.
AutoOnDelay = 1…65534—the number of seconds that is counted down when the output is about to be turned on (at startup, at automatic restart, and so on)
3.
AutoOnDelay = -1 = 65535—the number of seconds automatic restarts (any non-commanded) are disabled after low battery shutdown.
7.1.3.3
Batteries Disconnected
The battery relay can be closed only when the battery circuit breaker is closed. On start-up, and after closing the battery breaker, the UPS performs the following steps: 1.
2.
7-22
During startup and if battery circuit breaker is closed, then a.
Check that battery voltage isn’t negative.
b.
Trip battery breaker and give “Battery Needs Service” alarm if test fails
Equalize battery relay voltages using boost and charger IGBTs a.
Close the battery relay
b.
Wait 2 seconds
c.
Check that battery voltage and battery backup voltage measurements are about equal (±10V)
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
3.
7.1.3.4
d.
Trip battery breaker and give “Battery Contactor Fail” alarm if test fails
e.
Make sure that “Battery Over Temperature” shutdown and battery hardware current limit alarms aren’t active.
If battery circuit breaker is open, then: a.
Open battery relay
b.
Give “Battery Contactor Open” alarm
c.
Disable battery operation until the battery circuit breaker has been closed
Battery DC Overvoltage
Battery voltage has been too high for a constant period. The factory setting of the time limit is 60 seconds. The voltage level follows the temperature compensated battery charging scheme (if the temperature compensation is disabled, then the voltage level stays the same): •
Battery over voltage level = batChargeV + 0.05VPC
where batChargeV is the battery voltage, where charge mode changes to float mode (see ABM document), and 0.05VPC is taken from EEPROM. Causes “Battery DC Overvoltage” alarm and the battery circuit breaker to be opened; this will disable battery operation.
7.1.3.5
Battery Low
This is the alarm level of battery voltage (about 1.88VPC). Battery low alarm is enabled when the charger has been running for 100ms, after opening the battery relay, or when boost is active. The alarm stays active until boost is deactivated and Low Battery Shutdown is inactive.
7.1.3.6
Battery Needs Service
Battery Needs Service is activated when the UPS senses negative voltage on battery measurement. Negative battery voltage is checked during UPS startup. The alarm is triggered when battery voltage is below 100 volts.
7.1.3.7
Binary Input - Delayed Shutdown Function
A binary input can be set to use this function. When the input signal is active, the UPS output is turned off after a configurable delay (factory setting is 120 seconds). The output is turned on when the utility is OK.
7.1.3.8
Binary Input - On / Off Function
A binary input can be set to use this function. When the input signal is active, the UPS output is turned off. When the signal becomes inactive, the UPS output is turned back on. © 2006 - Eaton Corporation
7-23
Troubleshooting and Maintenance
7.1.3.9
9355 20 – 30 kVA
Binary Input - Shutdown Function
A binary input can be set to use this function. When the input signal is active, the UPS output is turned off, as when the front panel menu function is used to shut down the unit.
7.1.3.10 Bypass Disable Timer Bypass is disabled for 3 seconds when transferring from bypass because of bypass power failure.
7.1.3.11 Bypass Disabled Flag This is a service settable mode, useful with emergency lighting for example. In this mode, the bypass operation is always disabled.
7.1.3.12 Bypass Down Flag A small bypass processor controls the bypass hardware. This processor signals when bypass is ”up” and bypass control is possible. When the signal is inactive, bypass is ”down”: it is not controllable and bypass voltage measurement is not possible. When the bypass is “down”, the back-feed contactor is controlled-open. •
When the bypass becomes “up”, the back-feed contactor is controlledclosed, and after few seconds, bypass voltage measurement is usable and use of bypass is possible.
7.1.3.13 Bypass Operation Preferred to Discharging Batteries This is user setting. When the UPS On Battery alarm is active, the load will transfer to bypass, if bypass is acceptable. Load stays on battery for 4 seconds before transferring on bypass.
7.1.3.14 DC Bus Low Voltage Low DC voltage, on either or both sides, causes the battery converter to begin discharging the batteries. •
Voltage limit is 29V below rail setpoint.
7.1.3.15 EPO - Emergency Power Off Shuts down the inverter and the batteries are disconnected (CB opened). The load becomes unpowered. Usually, if the load is on bypass, the bypass is also shut down; but when DSP is unable to communicate with the bypass processor (PIC), the bypass stays on. EPO input is disabled during shutdown, startup, failure shutdown, bleeding and bypass-locked states. The user can also set a disable EPO parameter.
7-24
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
7.1.3.16 Input Transformer Overtemperature Input Transformer Overtemperature will drop the load after a configurable delay and the UPS remains in standby mode. The default delay is 120 seconds.
7.1.3.17 Inverter Temporary Inhibit There is a mechanism to prevent the UPS from constantly transferring from inverter to bypass and vice versa. It is possible that the UPS doesn’t detect a reason to transfer to bypass, but the inverter cannot support the load. If the UPS transfers load from inverter to bypass 3 - 5 times within ten minutes, transfers to the inverter are temporarily inhibited. A variable ForcedFromInverterCounter is initialized to the value of three (3) once in ten minutes. Every time the UPS transfers load from inverter to bypass the variable is decremented. If the variable becomes zero, then flag InvTmpInhibit is set. The transfers are automatically enabled once in an hour, the flag InvTmpInhibit is cleared, and the variable ForcedFromInverterCounter is reset to value three (3). The user can enable transfers by pressing any front panel button, which does the same initialization.
7.1.3.18 Low Battery Shutdown If on-battery status is active and the battery voltage has dropped below the minimum limit (typically 1.75VPC), the timer counts down (typically for 60 seconds), after which discharging of batteries must be stopped. The counter is initialized when the Low Battery Shutdown alarm is inactive. If battery voltage drops to absolute minimum limit (typically 1.67VPC), the timer duration is reduced to 1 sec. •
Low battery shutdown alarm stays active until the rectifier is running or the system is not on bypass.
7.1.3.19 Neutral Fault Detection Neutral fault is triggered when chassis voltage is over 15V and voltage on either DC bus is over 250V. Neutral fault can be disabled by a user parameter. A neutral fault causes transfer on the battery. The neutral fault is reset every minute so that the UPS can attempt to use the utility again. When the neutral fault is detected, the “Neutral fault” alarm is activated and the utility voltage and bypass voltage alarms are disabled. The “Utility Fail” and “Bypass not Available” alarms are activated. The neutral fault alarm is cleared only after neutral fault flag has been cleared for one minute. If the neutral fault is detected again after transfer online, the same alarm persists and a new alarm is not generated.
© 2006 - Eaton Corporation
7-25
Troubleshooting and Maintenance
9355 20 – 30 kVA
7.1.3.20 On Battery Status This status is given when batteries are discharging. Status is not given if a battery test is in progress and the low battery alarm is not active. This is not an alarm, but only shows that the UPS is discharging batteries. See “UPS On Battery Alarm” for battery alarm status.
7.1.3.21 Output Shutdown When bypass is not available, then: •
UPS load level 4 ≥151% will shut down the output after 300ms
•
UPS load level 3 ≥126% will shut down the output after 5 sec.
•
UPS load level 2 ≥111% will shut down the output after 60 sec.
•
UPS load level 1 ≥102% will shut down the output after 10 min.
7.1.3.22 Overload Loading condition is detected from output wattage and output current ,compared to nominal (100%) level, to determine the load level for each. For units with multi-phase outputs, the loading condition for each individual phase is detected. The quantity, which has highest load level, determines the UPS load level. When the UPS load level is above 100%, the UPS is overloaded.
7.1.3.23 Site Wiring Fault Site wiring fault is checked during startup. If chassis voltage measurement is over 50V, the “Site Wiring Fault” alarm becomes active and startup is aborted.
7.1.3.24 Transfer to Bypass When bypass is available and the UPS load level is above 102%, the UPS transfers to bypass. The following delays are used when delayed transfer to bypass on overload is set in EEPROM: •
UPS load level 4 ≥151% will transfer to bypass after 0 seconds
•
UPS load level 3 ≥126% will transfer to bypass after 0 seconds
•
UPS load level 2 ≥111% will transfer to bypass after 5 seconds
•
UPS load level 1 ≥102% will transfer to bypass after 5 seconds
As long as the bypass is OK and the UPS load level is above 100%, the UPS will stay on bypass.
7-26
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
7.1.3.25 UPS on Battery Alarm Normally, when the UPS has been continuously discharging batteries for 5 seconds, this alarm is given. This alarm is not given during battery testing, nor when service command is forcing batteries to be discharged, if battery low alarm is not active. This alarm is the signal for the software to start the shutdown countdown.
7.1.3.26 Utility Overvoltage To prevent very high voltage on the rectifier and/or DC bus, >144V (EEPROM value) at the rectifier input on any phase causes a transfer to battery operation.
7.1.3.27 XCP Delayed Load Power Off & Restart Command When this command is given, the UPS output is shut down after the delay duration defined with the command. After the shutdown, the UPS waits until the utility is OK and restarts. The output shutdown has a minimum 10 second duration.
7.1.3.28 XCP Scheduled Load Power Off Command When this command is given, the UPS output is shut down after the delay duration defined with the command. The UPS output is kept off until an ON command is received.
7.1.3.29 XCP Scheduled Load Power On Command When this command is given, and the UPS output was turned off with an XCP command, the UPS will turn on the output after the delay duration defined with the command. If the utility is down, then turning on the output is delayed until the utility is OK.
7.1.3.30 XCP UPS Off Command When this command is given, the UPS output is turned off immediately. The UPS output is kept off, until an ON command is received.
7.1.3.31 XCP UPS On Command The UPS output has been turned off with an XCP command when this command is given. The UPS will turn on the output as soon as the utility is OK.
7.1.4
Failure Analysis
The following are lists of all the various notices and alarms that can be annunciated or acted upon by the Powerware® 9355 UPS. Use these charts with the charts in paragraph 7.1.1 Action Levels and paragraph 7.1.2, Alarm, Notice, Status, and Flag Definitions to determine course of action.
© 2006 - Eaton Corporation
7-27
Troubleshooting and Maintenance
7.1.4.1 FAILURE MODE
9355 20 – 30 kVA
Definitions of Table Headings FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
FAILURE MODE - These are the ways in which the activities / processes associated with Equipment could ”fail, or go wrong” FAILURE EFFECT - How would the customer feel this failure? What impact would it have? There may be more than 1 effect for each failure. POTENTIAL CAUSE - Why might this failure happen? What could lead to its occurrence? •
USE THE 5 WHYs - Follow these steps to get to the root cause:
d.
First, identify what you believe to be the cause
e.
Then ask yourself ”why” would this problem occur and what would cause it
f.
Then, starting with the answer to this question, repeat steps a. and b. five times until you arrive at the real cause for this failure
OCCURRENCE - Rate the failure (1-10). How likely is the failure to occur? •
1 is unlikely
•
10 is very likely (inevitable)
CONTROLS - What exists that might detect the failure or the impact of the failure? RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE Battery Charger Circuit - No Charge
7-28
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
Batteries do not get charged, Unit alarms within 24 hours.
Component failure
3
FW measurement detection
Verify if any other alarms are active. If the system appears to be operating normally, with the exception of the battery charger, verify the batteries and the battery fuse are not bad. If the batteries and fuse are good, change the IGBTs on the Power Board. Inspect the Power Board, if any
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
Battery Charger Circuit - Over Charge Battery
Batteries will get hot, swell
Component failure
3
Battery breaker will shunt trip, Measure battery voltage, LED red blinking, alarm
Verify if any other alarms are active. If the system appears to be operating normal with the exception of the battery charger verify the batteries and the battery fuse are not bad. If batteries and fuse are good, change the IGBTs on the Power Board. Inspect Power Board, if any damage is present replace the Power Board also.
Battery Converter
On battery - load dropped
Electrical over stress, IGBT devices possible spring failure, gate drives.
3
Sufficient electrical margin.
Check correct torque values. Replace Power Board and IGBTs
On battery - load dropped
Thermal Overstress
2
Sufficient thermal margins verified, calculated and measured
Verify ambient temperature in the room. If the room temperature is too hot, the fans cannot create enough cool airflow over the heat sink.
If online - switch to Bypass
Customer Overloads and abnormal conditions, thermal overstress
3
Online - go to bypass
Electrical over stress, IGBT devices possible spring failure, gate drives
4
Rectifier
© 2006 - Eaton Corporation
CONTROLS
RECOMMENDED CORRECTIVE ACTION damage is present replace the Power Board also.
Verify Customers load, room temperature, or any other abnormal conditions. Current limiting and sensing, MOVs on input
Verify input current and if within specifications replace IGBTs. Inspect the Power Board for damage if IGBTs are destroyed then 7-29
Troubleshooting and Maintenance
9355 20 – 30 kVA
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION replace the Power Board also if needed.
Thermal overstress
4
Concerned with overload conditions.
Verify customers load is not in a overload condition. Check ambient room temperature.
On battery - load dropped
Electrical over stress, IGBT devices possible spring failure, gate drives
3
Sufficient electrical margin.
Check correct torque values. Replace Power Board and IGBTs
On battery - load dropped
Thermal overstress
3
Sufficient thermal margins verified, calculated and measured.
Verify ambient temperature in the room. If the room temperature is too hot the fans cannot create enough cool airflow over the heat sink.
Online go to bypass
Electrical over stress, IGBT devices possible spring failure , gate drives
3
Current limiting and sensing.
Verify input current and if within specifications replace IGBTs. Inspect Power Board for damage if IGBTs are destroyed, then replace the Power Board also if needed.
Online go to bypass
Thermal overstress
3
Thermal margin verified calculated and measured
Verify ambient temperature in the room. If the room temperature is to hot the fans cannot create enough cool airflow over the heat sink.
on battery - load dropped
Electrical over stress, IGBT devices possible spring failure, gate drives
3
Sufficient electrical margin.
Replace Power Board and IGBTs
on battery - load
Thermal
3
Thermal
Verify ambient
Online - go to bypass
Inverter Circuit
7-30
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE
FAILURE EFFECT dropped
POTENTIAL CAUSE
OCC.
overstress
CONTROLS
RECOMMENDED CORRECTIVE ACTION margin temperature in the verified room. If the room calculated and temperature is to hot measured. the fans cannot create enough cool airflow over the heat sink.
Communications - X-Slot Short circuit
No Communications
X-Slot failure
2
Separate supply from critical circuits.
If the X-Slot card is not working swap positions and verify it’s not he position. If the problem is still present try a new card. If the problem is still present replace the Power Board.
User Interface (LCD)
No display and or front panel user controls
LCD, cable, component failure
1
Proven Design and circuit used in HV by HPO
Replace Display Assembly
Internal Voltage Sensing
Online - Goes to Bypass
Component failure
2
Component not overstressed.
Using the calibration procedure to identify voltage checks, verify all voltages are present and no fuses are open. After verifying all correct verify the LED on the Control board is flashing if not replace the Control Board. Test sensing voltages from I/O Board to X6 and verify sensing voltages are going to the Control Board.
On battery drops load
Component failure
2
Component not overstressed, mature design
Verify Battery Breaker has not failed or open. Verify Batteries are good.
Over voltage on PS, Failed component
2
FW and auxiliary set of contacts, FW monitors PS voltage
Replace Power Board or I/O Board. Check Power Supply voltage on each board.
Battery disconnect control trips breaker
On battery Dropped load
© 2006 - Eaton Corporation
7-31
Troubleshooting and Maintenance
9355 20 – 30 kVA
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
Online - Transfer Over voltage to Bypass, once on PS, Failed DSP reset, component transfer to online, alarm
2
FW and auxiliary set of contacts, FW monitors PS voltage
Replace Power Board or I/O Board. Check Power Supply voltage on each board.
Battery disconnect control cannot trip breaker
Back-feeding on an EPO event
Failed Component, loss of A_AUX supply
2
All-pole break, and FW
IGBT Gate Drive Circuits
Online go to bypass
Component failure
2
Proven design Replace Power Circuit used in Board and IGBTs HV by HPO
On battery drop load
Component failure
2
Proven design Replace Power Circuit used in Board and IGBTs HV by HPO
Control board failure during Hypot
Component failure
1
Calculations and measurement
Engineering Test Failure N/A to field personnel.
On battery drops load
Component failure
1
Sufficient Electrical Margin
Replace IGBTs and maybe Power Board.
EPO Circuit Failure
Safety, battery still connected
Component failure
2
Proven design Replace I/O Board. Circuit used in HV by HPO
Alarms
Loss of customer customization
Component failure
2
Proven design Replace Control Circuit used in Board. HV by HPO
Ambient Temp Sensor
No overtemp warning
Component failure
2
Alternate temp sensing (heatsink)
Heatsink temp sensor
Online - Goes to Bypass
Component failure - part indicates overtemp
4
FW detection
FW and DVT
Online - Goes to Bypass
Component failure - part does not indicate overtemp
2
FW detection
FW and DVT
On Battery drops load
Component failure - part does not indicate overtemp
2
FW detection
Bridging Resistors
7-32
FAILURE EFFECT
POTENTIAL CAUSE
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
RECOMMENDED CORRECTIVE ACTION - possible ways to correct this failure.
Table 41. Power Board Failures FAILURE MODE LPS
FAILURE EFFECT Goes to Bypass, yellow LED, Alarm
POTENTIAL CAUSE
OCC.
Component failure
1
CONTROLS
RECOMMENDED CORRECTIVE ACTION None
Table 42. Control Board Failures FAILURE MODE Control board disengaged
FAILURE EFFECT Online - Goes to Bypass
POTENTIAL CAUSE Shipping
OCC.
9
CONTROLS
RECOMMENDED CORRECTIVE ACTION
Mechanical / Reseat card DVT
Table 43. I/O Board Failures FAILURE MODE Voltage Sensing
Current Sensing Battery
Current Sensing Input
Current Sensing Output
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
On output goes to bypass
Component failure
2
Proven design Circuit used in HV by HPO
Replace I/O Board
On battery, drops load
Component failure
2
Proven design Circuit used in HV by HPO
Replace I/O Board
If on battery trip battery breaker and drop load
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If online alarms, no effect
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If online - switch Component to Bypass failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If on-battery no effect
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If online - switch Component to Bypass failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If on-battery Drops Load
3
Proven design Circuit used in HV by HPO
Replace I/O Board
Component failure
© 2006 - Eaton Corporation
7-33
Troubleshooting and Maintenance
9355 20 – 30 kVA
Table 43. I/O Board Failures FAILURE MODE Current Sensing Bypass
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
If online Alarms, no effect
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If on-Battery Alarms, no effect
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
If on-bypass Alarms, no effect
Component failure
3
Proven design Circuit used in HV by HPO
Replace I/O Board
Bypass SCR
Bypass in parallel with UPS
Over current, breakdown voltage is exceeded, DVDT
1
MOV front end and Snubber
Replace I/O Board
Inverter Fuse
On-battery drops load
Component failure
2
HW Current limit
FW Current limit, verify settings. Replace fuse.
On-battery drops load
Unusual load conditions
4
HW Current limit
FW Current limit, check fuse, Replace I/O Board
On utility - and bypass not available lose load
Unusual load conditions
4
HW Current limit
FW Current limit, Replace I/O Board
On utility - and bypass is not available
Unusual load conditions
4
HW Current limit
FW Current limit, Replace I/O Board
On Battery and Bypass is not available Drop load
Defective Component
1
Fused
FW Controls , Check fuses, Replace I/O Board
Online - go to bypass
Defective Component
1
Fused
Check fuses
On Battery and Bypass is not available Drop load
Defective Component
1
Proven design Circuit used in HV by HPO
Replace I/O Board
Online - go to bypass
Defective Component
1
Proven design Circuit used in HV by HPO
Replace I/O Board
Bypass in parallel with UPS
Component failure
2
Proven design Circuit used in HV by HPO
Replace I/O Board
On Bypass Drops Load
Component failure
2
Proven design Circuit used in HV by HPO
Replace I/O Board
Inverter SCR
Inverter SCR Gate Drive Circuits
Bypass SCR Gate Drive Circuits
7-34
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Troubleshooting and Maintenance
Table 43. I/O Board Failures FAILURE MODE
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
LPS
Goes to Bypass, yellow LED, Alarm
Component failure
1
Mature proven design
Replace I/O Board
Battery Start Circuit
Will not battery start
Component failure
6
DVT
Replace I/O Board
Battery life Component reduction in rest failure mode
6
DVT
Complete calculations for battery life reduction. Add to user’s manual to open battery breaker if unit is powered down for an extended period
Bypass Fuse open due to high in-rush
Drop load
Load characteristics
3
Return to inverter
Replace Fuses
Rectifier fuse open
If on battery no effect
Electrical overstress
3
Current limit, and FW
Replace Fuses
If online go to bypass
Electrical overstress
3
Current limit, and FW
Replace Fuses
Table 44. Relay Failures FAILURE MODE
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
Battery Relays Sticks Closed
Relay sticks battery drain after unit shutoff
Breaking or making current, not sharing, rating exceeded
3
3 relays Check relays on I/O sharing, equal board and if need trace lengths replace I/O Board.
Battery Relays Never closes
Alarm sounds
Component failure
2
FW Controls, current sensing, and voltage sensing
Replace I/O Board.
Balancer Relay stuck on Battery
UPS will not start
Defective Component
1
None
Replace I/O Board.
Contactor Driver relay Open, cannot close
Drop on Over-voltage, Battery, Battery Relay that alarm, drives coil fails schedules shutdown
1
Detected through power-up, cannot start
Replace I/O Board.
Contactor Driver relay Closed when should be open
Safety
3
FW detection
Replace I/O Board.
Relay failure
© 2006 - Eaton Corporation
7-35
Troubleshooting and Maintenance
9355 20 – 30 kVA
Table 45. Fan Failures FAILURE MODE
FAILURE EFFECT
POTENTIAL CAUSE
OCC.
CONTROLS
RECOMMENDED CORRECTIVE ACTION
Fan Failure
Alarm sounds
Fan component failure
4
Tach and F/W
Replace Fan
Tach Fails
Alarm sounds
Fan or Tach Circuit
2
none
Replace I/O Board.
7.1.5
Electronics Module and Other Failures
FAILURE MODE
POTENTIAL CAUSE
OCC.
Converter failure
Windings shorted to core
7
None
Replace Inductor Assembly.
Lack of current sharing
Bad connection either at PCB or internal
7
EM test limits, current scalers
Individual component testing on current sensors. See Calibration procedure.
DC Coil Contactor Fails to close or opens unexpectedly
Goes on battery, alarm, write to log, scheduled shut down
Over-voltage, Relay that drives coil fails
1
No controls in place, scheduled shutdown
Replace I/O Board.
DC Coil Contactor Fails to open (back-feed)
Possible back-feed after EPO
Contactor welded
1
FW controls
Replace Contactor.
EMI / Surge Assembly
Loss of surge withstand capability
Electrical overstress
2
Mature Design within Powerware
Replace EMI Board
One Battery String not connected
Latent failure mode on battery, short runtime
Battery open
5
Should be detected by Service at start-up during battery test
Inductors
7-36
FAILURE EFFECT
CONTROLS
© 2006 - Eaton Corporation
RECOMMENDED CORRECTIVE ACTION
8 Removal / Replacement 8.1.1
Removal Preparation 1.
Remove the UPS front door panel.
2.
Remove the top fan dead front, see Figure 60.
3.
Bleed the DC Bus or check for TP, Vo = Active
Analog Potentiometer Diagram
Refer to Figure 77, Analog to Digital Circuit. Like the analog circuit, a digital circuit can be altered in a similar manner. In place of the analog potentiometer, a digital circuit will use an analog to digital (A/D) converter to process the analog signal into a numeric representation for use by a digital processor. A voltage of 6VDC may be represented in the A/D converter by the hexadecimal number 2315. Although 2315 has no significant meaning to us, this number represents 6VDC to the processor. This number is often called a “RAW” value, meaning that the digital number is assigned by the A/D converter to represent the 6VDC analog signal. The manner in which an A/D Converter represents the analog data it detects is dependant on the type of converter and its parameters. Analog (6vdc) Vi
Digital (0010 0011 0001 0101)
A/D Figure 77.
6vdc
CPU
Laptop
Analog to Digital Circuit
© 2006 - Eaton Corporation
9-1
Calibration
9355 20 – 30 kVA
Refer to Figure 78, Digital Potentiometer Diagram. Calibration in a computer environment can be looked at as a digital potentiometer, variable resistor, or trim pot having a minimum and maximum limit. Like analog adjustment devices, digital pots also have minimum and maximum limits. Since values found in EEP are 16 bits in length, the range of an individual EEP address is 0000 to FFFF in HEX or 0 to 65535 in decimal. This becomes the minimum and maximum limits for the digital pot. 32,768
(+)
(-)
(+)
(-)
10,000
(Calibration)
0
Digital Potentiometer Range: 0 - 65535
Figure 78.
Digital Potentiometer Diagram
In a digital circuit (like those found in the Powerware® 9355), the raw value can be altered or scaled so that the value seen by the user has more meaning. A formula (created by a firmware engineer) is used by the CPU firmware to make this transition. This value now becomes known as a “Metered Value.” An element of that formula is called a “Meter Calibration Factor” and serves to provide a means to adjust the value used by the CPU firmware. The calibration factor is stored in an EEPROM (EEP) location as a percentage of the computed value from the A/D converter. These metered values and their associated calibration factors are stored in the EEPs of the DSP processor and are accessible by the XCP Service Tool. All calibration factors are stored as a percentage: 10,000 represents 100.00% of scale Values are usually linear which means: •
If the Calibration Factor is increased, the reading increases
•
If the Calibration Factor is decreased, the reading decreases
The formula typically used to adjust any 10000 based calibration factor is as follows: Actual × Cal . Factor = New Cal . Factor Unit
9-2
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Calibration
Actual = a reading taken from a calibrated DVM: •
On a single feed unit from X1-1, X1-2, and X1-3.
•
On a dual feed unit at CB-1 (2, 4, 6).
Unit = the metered value (on display) from the unit or METERS tab on XCP Service Tool. (Preferred method is XCP Service Tool.) Cal. Factor = value found in the associated EEP location New Cal. Factor = the resulting cal. factor entered into EEP Example #1, (Meter Calibration) DSP EEPROM 3040 – UTILITY VOLTAGE PHASE A CALIBRATION FACTOR Value found in this location is 10000 Meter value as seen by the XCP Service Tool (and DSP) shows 208VAC. Meter value as seen by a calibrated DVM shows 215VAC. There is a calibration error of 7VAC. To calibrate this metering input, the formula presented above is used: 215 ⎞ Example: ⎛⎜ ⎟ × 10000 = 10336 ⎝ 208 ⎠
This means that this meter calibration factor must be increased by 3.36% to a new EEP value of 10336 (103.36%). 10000 in DSP EEP 3013 is replaced with a value of 10336. The metered value now read by the UPS should be 215VAC, a true representation of the actual voltage measurement. Note: Exact EEP values for meter calibration factors may have to be altered slightly from the calculated result in order to be able to achieve the exact meter values desired.
The same techniques just illustrated above are used for calibrating meter values and display values as they relate to current and power values.
CAUTION It is good practice to map the system EEPROMS prior to performing Calibration to circumvent potential problems.
© 2006 - Eaton Corporation
9-3
Calibration
9.1.1
9355 20 – 30 kVA
Calibrate Bypass AC Input Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation.
9-4
1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open).
2.
Begin with the UPS in Standby mode.
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate the Bypass AC Input Voltage (see Figure 79 for 208V test points: •
Measure Bypass AC Input: (208V) X1-1 (Phase A) to X-4 (N).
•
Double-click on the Bypass AC Phase A input meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Bypass AC Input: (208V) X1-2 (Phase B) to X-4 (N).
•
Double-click on the Bypass AC Phase B input meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Bypass AC Input: (208V) X1-3 (Phase C) to X-4 (N).
•
Double-click on the Bypass AC Phase C input meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify meters on the Front Display, XCP Service Tool and DVM and match them to within 2%. If they are not within 2%, then repeat Step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
9.1.2
Calibration
Calibrate Utility AC Input Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. 1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open).
2.
Begin with the UPS in Standby mode.
L1, L2, L3 CB1 contacts
Input L1, L2, L3 X1-1, X1-2, X1-3 X4 - Neutral
X4 - Neutral
Output L1, L2, L3 X2-1, X2-2, X2-3
Figure 79.
9355 Front Calibration Points
© 2006 - Eaton Corporation
9-5
Calibration
9355 20 – 30 kVA
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate the Utility AC Input Voltage, see Figure 79 for 208V test points. •
Measure Utility AC Input (208V) X1-1 (Phase A) to X-4 (Neutral).
Note: For a dual feed UPS use the L1 contact point at the CB-1 input. •
Double-click on the Utility AC Phase A input meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Utility AC Input: (208V) X1-2 (Phase B) to X-4 (Neutral).
Note: For a dual feed UPS use the L2 contact point at the CB-1 input. •
Double-click on the Utility AC Phase B input meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Utility AC Input: (208V) X1-3 (Phase C) to X-4 (Neutral).
Note: For a dual feed UPS use the L3 relay point at the CB-1 input. •
9-6
Double-click on the Utility AC Phase C input meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify meters on the Front Display, XCP Service Tool and DVM and match them to within 2%. If they are not within 2%, then repeat Step 4.
6.
Calibration complete
© 2006 - Eaton Corporation
9355 20 – 30 kVA
9.1.3
Calibration
Calibrate Battery Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. The battery breaker must be closed to calibrate battery voltage. The UPS must be off with logic power only. Once the battery breaker is closed, the system can be returned to bypass mode. 1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open).
2.
Begin with battery breaker closed and the UPS off with logic power only.
3.
Connect your laptop to the UPS and run the XCP Service Tool:
4.
•
Select the Meters tab
•
Verify DC is less than 25 Volts
•
Verify that Battery voltage is greater than 216 Volts
Calibrate the Battery Voltage: •
Measure Battery Voltage from the positive connection X49 to the negative connections X34. ⎛ DVM Re ading ⎞ ⎟⎟ × 10000 = EEPROM entry ⎝ Meters Re ading ⎠
Using the calibration equation ⎜⎜ •
Double click on the Battey meter on the XCP Service Tool and enter the measured value from the DVM. The service tool will ask you to enter it a second time, enter the same reading you entered the first time.
5.
Verify meters on the Front Display, XCP Service Tool and DVM and match them to within 2%. If they are not within 2%, then repeat Step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
9-7
Calibration
9.1.4
9355 20 – 30 kVA
Calibrate DC Link Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM) Table 46. DC Link Voltage Calibrations Output Voltage
DC Link:
208
(+) or (-) 194.5
400
(+) or (-)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. Note: Write down EEPROMs before beginning this procedure.
1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open.
2.
Begin with UPS on NORMAL and Battery Charger off.
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate the DC Link Rail Voltages: (see Figure 81 for 208V test points). •
Measure the Positive DC Link Voltage: (208V) from connector X47 (DC+) to X52 (Neutral); or you may test from the bus bar.
•
Double-click on the +DC meter on the XCP Service Tool and enter the target voltage from Table 46 and the measured value from the DVM.
Note: The DC Link Voltage is not shown on the UPS LCD.
9-8
5.
Wait until the battery charger is on and confirm voltage with a DVM.
6.
Verify XCP Service Tool meters and DVM match within 2%. If they are not within 2%, then repeat Step 4.
7.
Calibration complete.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
9.1.5
Calibration
Calibrate UPS AC Output Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. 1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open).
2.
Begin with UPS on BYPASS.
3.
Connect to the XCP Service Tool and go to the Meters Tab.
4.
Calibrate the UPS AC Output Voltage: (see Figure 79 for 208V test points). •
Measure UPS AC Output: X2-1 (Phase A) to X-4 (Neutral)
•
Double-click on the Output AC Phase A output meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure UPS AC Output: X2-2 (Phase B) to X-4 (Neutral)
•
Double-click on the Output AC Phase B output meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure UPS AC Output: X2-3 (Phase C) to X-4 (Neutral)
•
Double-click on the Output AC Phase C output meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify XCP Service Tool meters and DVM match within 2%. If they are not within 2%, then repeat Step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
9-9
Calibration
9.1.6
9355 20 – 30 kVA
Calibrate Inverter AC Output Voltage
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation.
NOTICE When performing a whole system calibration, the inverter voltage must be done last. When calibrating the Inverter AC Output, the calibration adjustment is not to match the measured voltage, but to adjust the measured voltage as seen in Table 47, Inverter Voltage Calibrations. The output meters on the display were adjusted with the bypass calibration while the unit was in bypass.
Table 47. Inverter Voltage Calibrations Output Voltage
Calibrate To:
208
120.1
400
230.9
1.
UPS / Customer load should be on maintenance bypass wraparound or off (down stream breakers open).
2.
Begin with UPS on NORMAL.
3.
Connect the XCP Service Tool and go to the Meters Tab.
NOTICE Once the Inverter has reached its target voltage, the XCP Service Tool meters stabilize and do not change during normal operation. The objective with Inverter AC Output calibration is to adjust the inverter output until the DVM meter is at the target voltage listed in Table 47. The output meters should indicate the change but the inverter meters will not. 9-10
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Calibration
4.
9.1.7
Calibrate the Inverter AC Output Voltage: (see Figure 79 for 208V test points): •
Double click on the Inverter AC Phase A output meter on the XCP Service Tool and enter the target voltage from Table 47.
•
Enter the measured value from the DVM for each phase. After entering phase “A” the tool will ask for phase “B” and then for phase “C”.
•
Measure Inverter AC Output: (208V) X2-1 (Phase A) to X-4 (Neutral).
•
Measure Inverter AC Output: (208V) X2-2 (Phase B) to X-4 (Neutral).
•
Measure Inverter AC Output: (208V) X2-3 (Phase C) to X-4 (Neutral).
5.
Verify that the XCP Service Tool output target voltage and the DVM match within 2%. If they are not within 2% then repeat step 4.
6.
Calibration complete.
Calibrate Inverter DC Output Voltage
Due to the special metering required to accurately measure the DC on the inverter output, this calibration cannot be performed at this time and is not required; however, this calibration is performed at the factory after manufacturing. If the Control Board must be changed, every effort must be made to set EEPROM 3070 & 3072 on the new Control Board to the same setting as the old Control Board. Otherwise, EEPROM 3070 & 3072 should be set to the default of 10000.
© 2006 - Eaton Corporation
9-11
Calibration
9.1.8
9355 20 – 30 kVA
Calibrate Bypass Current (Output)
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
•
AMP Clamp
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. This calibration procedure requires a minimum of 80% load to be accurate. If this procedure is not conducted with the minimum load requirement (80%), metering results may be skewed as much as 5% or more at 100% load. Default of 10000 is better than mis-calibration. 1.
UPS / Customer load should be on or a load bank attached to the output of the UPS.
2.
Begin with UPS on BYPASS.
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate Bypass Current: •
Measure Bypass Phase A current: (208V) at X40 on the I/O Board. (see Figure 80)
Figure 80.
9-12
I/O Board Bypass Phase A, B and C
•
Double click on the Bypass Phase A current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Bypass Phase B current: at X41 on the I/O Board. (see Figure 80).
•
Double click on the Bypass Phase B current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Bypass Phase C current: at X42 on the I/O Board. (see Figure 80) © 2006 - Eaton Corporation
9355 20 – 30 kVA
Calibration
•
Double click on the Bypass Phase C current meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify that the XCP Service Tool meters and DVM match within 2%. If they are not within 2% repeat step 4.
6.
Calibration complete.
X61 X60
DC+
BATT CD TRIP X50
X55
DC+ X47
X12
X6
X7
X11
INV
AAUX
INV L3
X21 X27
INV L2 FANS
INV L1
K3
DC neut RECT L3 X78 X2 IN/OUT CB TRIP
BAT COLD START
L3 X76
K1
BATT BKUP X46
X45
BAT
DC-
X82 L3 L2 L1 X28 X29 X4
DCX43
BATTERY CHOKES
Batt Bkup X46
X79
X25
Figure 81.
X23 X13
X54
X42 X41 X40
Batt Plus X49 208V DC Link Voltage Calibration test points
© 2006 - Eaton Corporation
9-13
Calibration
9.1.9
9355 20 – 30 kVA
Calibrate Utility Current
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
•
AMP Clamp
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. This calibration procedure requires a minimum of 80% load to be accurate. If this procedure is not conducted with the minimum load requirement (80%), metering results may be skewed as much as 5% or more at 100% load. Default of 10000 is better than mis-calibration.
9-14
1.
UPS / Customer load should be on or a load bank attached to the output of the UPS.
2.
Begin with UPS on NORMAL.
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate Utility Input Current , (see Figure 81 for 208V test points): •
Measure Utility Phase A current: (208V) X1-1 (Phase A) to X-4 (Neutral)
•
Double click on the Utility Phase A current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Utility Phase B current: (208V) X1-2 (Phase B) to X-4 (Neutral)
•
Double click on the Utility Phase B current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Utility Phase C current: (208V) X1-3 (Phase C) to X-4 (Neutral)
•
Double click on the Utility Phase C current meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify that the XCP Service Tool meters and DVM match within 2%. If they are not within 2% repeat step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
9.1.10
Calibration
Calibrate Battery Current
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
•
Clamp-on DCCT
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. This procedure requires that the battery be discharging for a short period of time so the discharge current can be measured and calibrated. This calibration procedure also requires a minimum of 80% load to be accurate. If this procedure is not conducted with the minimum load requirement (80%), metering results may be skewed as much as 5% or more at 100% load. Default of 10000 is better than mis-calibration. At the beginning of the procedure, the system must be in NORMAL mode with the battery breaker closed. 1.
Connect the XCP Service Tool and go to the Meters Tab.
2.
Put the system in battery mode by opening the Utility Input breaker, simulating a utility outage.
3.
Calibrate Battery Current (with 80% load while discharging) : a.
Measure Battery Current on the battery wire connected to: (208V) X49, see Figure 81
b.
Double click on the Battery current meter on the XCP Service Tool and enter the measured value from the DVM.
4.
Restore utility input to the system. (System should automatically return to NORMAL mode.)
5.
Verify that the XCP Service Tool meters and the DVM match within 2%. If they are not within 2% repeat step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
9-15
Calibration
9.1.11
9355 20 – 30 kVA
Calibrate Inverter Current
Tools Required: •
XCP Service Software Tool
•
Computer with software tool authorization
•
Calibrated, True RMS Digital Volt Meter (DVM)
•
AMP Clamp
If at any time during this procedure an alarm condition prevents the continued execution of the following steps, consult paragraph 7.1.2, Alarm, Notice, Status & Flag Definitions to determine and correct the cause of the event annunciation. This calibration procedure requires a minimum of 80% load to be accurate. If this procedure is not conducted with the minimum load requirement (80%), metering results may be skewed as much as 5% or more at 100% load. Default of 10000 is better than mis-calibration.
9-16
1.
UPS / Customer load should be on or a load bank attached to the output of the UPS.
2.
Begin with UPS on NORMAL.
3.
Connect the XCP Service Tool and go to the Meters Tab.
4.
Calibrate Inverter Output Current: •
Measure Inverter Phase A current (for 208V see Figure 79 for Phase A test points X2-1 and X-4).
•
Double click on the Inverter Phase A current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Inverter Phase B current (for 208V see Figure 79 for Phase B test points X2-2 and X-4).
•
Double click on the Inverter Phase B current meter on the XCP Service Tool and enter the measured value from the DVM.
•
Measure Inverter Phase C current (for 208V see Figure 79 for Phase C test points X2-2 and X-4).
•
Double click on the Inverter Phase C current meter on the XCP Service Tool and enter the measured value from the DVM.
5.
Verify that the XCP Service Tool meters and the DVM match within 2%. If they are not within 2% repeat step 4.
6.
Calibration complete.
© 2006 - Eaton Corporation
10 Parts Chapter 10 Parts 10.1 PW 9355 30kVA SPARE PARTS LISTINGS 10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N 106711170 10.1.2 High Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N 10.2 PW 9355 30kVA UPS Subassemblies 10.2.1 LV Electronic Module 10.2.2 HV Electronic Module 10.3 Parts Break-down / Look-up Procedure 10.3.1 Requirements: 10.3.2 Procedure
10-1 10-1 10-2 10-2 10-2 10-3 10-4 10-4 10-4
10.1 PW 9355 30kVA SPARE PARTS LISTINGS
NOTICE Part numbers are subject to change. CSE’s should always check the latest assembly and part numbers on PRMS ACCESS to verify part numbers before ordering.
10.1.1 Low Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N 106711170 Component
Description
UM
Qty
1021278
PCBAS CONTROL BOARD
EA
1
1024053
PCBAS K30 LV 3PH I/O BOARD
EA
1
1024049
PCBAS K30 LV 3PH PWR BOARD
EA
1
1021994
IGBT 3X94A 600V HB SKIIP2
EA
3
103004890
SUBAS K15 DISPLAY PANEL
EA
1
101073763
EMI BOARD
EA
1
128308001-012
FUSE, 200 A, 500 VAC
EA
1
1024057
BYPASS BOARD
EA
1
129400054-002
THERMAL INTERFACE PAD
EA
6
143319005-001
SCR, DUAL, MODULE, 160A, 1600V
EA
3
© 2006 - Eaton Corporation
10-1
Parts
9355 20 – 30 kVA Component
Description
UM
Qty
8052457
160A 240V 160LET Fuse
EA
3
1024046
FAN 119x119x39 51l/s 115VAC UL
EA
2
129400066-001
THERMAL INTERFACE PAD, IGBT
EA
6
10.1.2
High Voltage PW 9355 30kVA Spare Parts Kit “A” P/ N Component
UM
Qty
PCBAS CONTROL BOARD
EA
1
PCBAS K30 LV 3PH I/O BOARD
EA
1
PCBAS K30 LV 3PH PWR BOARD
EA
1
IGBT 3X94A 600V HB SKIIP2
EA
3
SUBAS K15 DISPLAY PANEL
EA
1
EMI BOARD
EA
1
FUSE, 200 A, 500 VAC
EA
1
BYPASS BOARD
EA
1
THERMAL INTERFACE PAD
EA
6
SCR, DUAL, MODULE, 160A, 1600V
EA
3
8052457
160A 240V 160LET Fuse
EA
3
1024046
FAN 119x119x39 51l/s 115VAC UL
EA
2
129400066-001
THERMAL INTERFACE PAD, IGBT
EA
6
1021278
103004890 128308001-012 129400054-002
Description
10.2 PW 9355 30kVA UPS Subassemblies 10.2.1
LV Electronic Module P/N
10-2
DESC
QTY
1021278
PCBAS CONTROL BOARD
1
103004890
SUBAS K30 DISPLAY PANEL
1
1021994
IGBT 3X94A 600V HB SKIIP2
9
1024046
FAN 119X119X39 51L/S 115VACUL
6
157809032
TRAY, BATTERY
24
101073763-001
9355 30kVA EMI / MOV PCB
1
1024049
PCBAS, POWER BOARD 3K30LV
3
1024053
PCBAS, IO BOARD 3K30LV
1
1024057
PCBAS, BYPASS BOARD 3K30LV
1
122129008-001
CIRCUIT BREAKER, 2 POLE, 200 A
1
122161004-001
CIRCUIT BREAKER, 3 POLE, 125 A
1
123118002-001
CONT, 115A, 480VAC,3 POLE, NO
1
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Parts
P/N
DESC
QTY
123118002-002
CONT, 130A, 480VAC,3 POLE, NO
2
128308001-012
FUSE, 200 A, 500 VAC
3
129400054-002
THERMAL INTERFACE PAD
3
129400066-001
THERMAL PAD, SKIIP2 PACKAGE
9
143319005-001
SCR, DUAL, MODULE, 160A, 1600V
3
145205027-001
SWITCH, SELECTOR, 100 A, 600 V
1
145301073-001
SWITCH, PUSHBUTTON, SPST, N.O.
1
151201040-004
AIR FILTER, STRATADENSITY
1
151501017-001
FAN GUARD, 4.125" MOUNT
6
58700036-001
BATTERY, 12V, 9 AH
10.2.2
108
HV Electronic Module P/N
1021278
DESC
QTY
PCBAS CONTROL BOARD
1
SUBAS K30 DISPLAY PANEL
1
IGBT 3X94A 600V HB SKIIP2
9
FAN 119X119X39 51L/S 115VACUL
6
TRAY, BATTERY
24
9355 30kVA EMI / MOV PCB
1
PCBAS, POWER BOARD 3K30LV
3
PCBAS, IO BOARD 3K30LV
1
PCBAS, BYPASS BOARD 3K30LV
1
CIRCUIT BREAKER, 2 POLE, 200 A
1
CIRCUIT BREAKER, 3 POLE, 125 A
1
CONT, 115A, 480VAC,3 POLE, NO
1
CONT, 130A, 480VAC,3 POLE, NO
2
FUSE, 200 A, 500 VAC
3
THERMAL INTERFACE PAD
3
THERMAL PAD, SKIIP2 PACKAGE
9
SCR, DUAL, MODULE, 160A, 1600V
3
SWITCH, SELECTOR, 100 A, 600 V
1
SWITCH, PUSHBUTTON, SPST, N.O.
1
AIR FILTER, STRATADENSITY
1
FAN GUARD, 4.125" MOUNT
6
BATTERY, 12V, 9 AH
© 2006 - Eaton Corporation
108
10-3
Parts
9355 20 – 30 kVA
10.3 Parts Break-down / Look-up Procedure This procedure is designed to ensure that Customer Service Engineers have the flexibility to look up the most current part number and/or research a previously listed part number on any Powerware® product.
10.3.1
10.3.2
Requirements: a.
Access to Eaton’s Powerware Division Intranet: http://poweratwork/usa/
b.
An assembly number where the parts are located. A CTO Number
Procedure
Once you have the assembly or CTO number, you can break it down and retrieve the part number using the following steps:
NOTICE The PRMS system may be slow, depending on the number of Logins and time of day. If at any time during this process you receive a web page message stating that it is not available, your session has timed out and you will have to start over.
10-4
1.
Go to http://poweratwork/usa/
2.
Under “Applications” on the right hand side, select “PRMS ACCESS.”
3.
For “User” enter “LSGINQ” (upper or lower case)
4.
For “Password” enter “ky9ag” (upper or lower case)
5.
Leave all other entries blank.
6.
At top left of the next page select “ENTER” (at top left).
7.
Select “ENTER” two more times (to bypass the Sign On and Display Messages pages.)
8.
In the “Option” block, enter “1” and press “ENTER” for “Production Utility”.
9.
In the “Option” block, enter “1” and press “ENTER” for “Product Structure Inquiry”.
© 2006 - Eaton Corporation
9355 20 – 30 kVA
Parts
At this point you have some options: a.
Option One: - To simply break down an assembly to its various components (part numbers), go to step 10.
b.
Option Two - To break down the assembly to its various component parts from a previous date, (an earlier product release) go to step 11.
c.
Option Three: - If you have a part number to a part, other than the one you want, but it is in the same assembly, you can look up a “where used”. You can then look for the part number of the component you’re looking for. Go to step 12.
d.
Option Four: - To look up assembly and component (part) numbers using the Configuration to Order (CTO) number, go to step 13.
10. In the assembly block enter the assembly number and press ”ENTER”. (Use the buttons at the bottom of the web page to navigate to the next pages containing additional components for that assembly. If ’More...’ is shown on bottom of right column, click the ’Next Page’ button to see the remaining parts. The last page of parts will show ’Bottom.’) 11. In the assembly block enter the assembly number and in the effective date block enter a previous date (format mmddyy) and press ”ENTER”. 12. Select “F2” at the bottom of the web page. In the “Component” block enter the part number and press ”ENTER”. The system will provide you with the assembly numbers on every unit where that part is used. If it is a common part across platforms you will have several pages of information. 13. In the assembly block enter the CTO number and press ”ENTER”. (You must use the buttons at the bottom of the web page to navigate to the subsequent pages containing additional components for that assembly.)
NOTICE If you need to look up another assembly number, or a sub-assembly of the assembly you just looked up, you must use the “F” buttons near the bottom of the web page, not the “F” keys on your keyboard.
© 2006 - Eaton Corporation
10-5
Parts
9355 20 – 30 kVA
This page was left blank intentionally.
10-6
© 2006 - Eaton Corporation
11 Prints PW 9355 20 - 30 kVA Prints Table Of Contents PAGE
DRAWING
SHT
CATEGORY
DESCRIPTION
REV
1
1024051
1
Schematic
Power Board 30kVA LV
2
2
1024055
1
Schematic
I/O Board 30kVA
B
3
2
4
3
5
1024056
1
Silkscreen
I/O Board
B
6
1024059
1
Schematic
Bypass Board 30kVA LV
3
7
1024062
1
Silkscreen
Bypass Board
3
8
110720620
1
Drawing
9355 EMI Filter
A00
9
110720639
1
Schematic
Top Level 30kVA 9355 LV
1
10
110720676
1
Schematic
9355 Options Cabinet
C00
11
2
12
3
13
4
14
5
15
6
16
7
17
8
18
110720683
1
Drawing
9355 30kVA EMI Filter
B00
19
110720684
1
Drawing
9355 30kVA EMI Filter
A00
20
110720687
1
Drawing
9355 30kVA Input EMI Filter
A00
21
121102093
1
Drawing
Rectifier/Inverter Choke
A00
22
121102094
1
Drawing
Battery Choke
A00
23
CTO Chart
1
Table
110577093
C00
24
2
© 2006 - Eaton Corporation
11-1
Prints
9355 20 – 30 kVA
This page was left blank intentionally
11-2
© 2006 - Eaton Corporation
1024055B.sch-1 - Wed Dec 28 10:01:09 2005
1024055B.sch-2 - Wed Dec 28 10:01:14 2005
1024055B.sch-3 - Wed Dec 28 10:01:23 2005
Page 5
10240593.sch-1 - Mon Nov 21 08:40:23 2005
Page 7
1
1
9355 30kVA Option Cabinet
120V
120V 120V
9355-30 Options cabinet - 208/208, 480/208, 600/208 Bypass Transformer
1
8
9355 30kVA Option Cabinet
9355-30 Options Cabinet - MBS only
2
8
9355 30kVA Option Cabinet
120V
120V 120V
9355-30 Options cabinet - 208/208, 480/208, 600/208 Mains Input transformer
3
8
9355 30kVA Option Cabinet
T1 277V 208V
277V
208V
277V
208V
9355-30 Options Cabinet - 208/480 Output Transformer
4
8
9355 30kVA Option Cabinet 9355 30kVA UPS Cabinet
120V
120V 120V
9355-30 Options Cabinet - System - Single feed 208/208, 480/208, or 600/208
5
8
9355 30kVA Option Cabinet 9355 30kVA UPS Cabinet
9355-30 Options Cabinet - System - Single feed, MBS only
6
8
9355 30kVA Option Cabinet
9355 30kVA Option Cabinet 9355 30kVA UPS Cabinet
120V
120V 120V
T1 277V 208V
277V
208V
277V
208V
9355-30 Options Cabinet - System - Single feed 480/480
7
8
9355 30kVA Option Cabinet
9355 30kVA Option Cabinet 9355 30kVA UPS Cabinet
120V
120V 120V
120V
120V 120V
9355-30 Options Cabinet - System - Dual feed 208/208, 480/208, or 600/208
8
8
NOTES: 1. Materials/com ponents shall meet RoHS regulations per Eaton Power Quality RoHS specification 164080496. 2. Bulk packaging shall indicate contents are RoHS com pliant. 3. Docum entation indicating m aterials/components are RoHS com pliant (Certificate of Compliance and M aterial Analysis) shall be available upon request.
NOTES: 1. M aterials/com ponents shall meet RoHS regulations per Eaton Power Quality RoHS specification 164080496. 2. Bulk packaging shall indicate contents are RoHS com pliant. 3. Docum entation indicating m aterials/components are RoHS com pliant (Certificate of Compliance and M aterial Analysis) shall be available upon request.
1 Model Type
K
PW9355
2 Product Family
A
9355-15 (See 110577092)
B
9355-30
3-4 UPS KVA Rating
5 Application
20
20 KVA
1
30
30 KVA
2
6 Battery Configuration
R/T
Note: Selections in this column can't be 0-4, 6, 7,D, S, L.
(no output breaker) (Factory default)
Parallel (no output breaker)
3
3x battery shelves 9Ah (108 batteries)
7 UPS Configuration
8 Comm Option (Slot 1)
9 Future Option
10 Future Option
11 Future Option
12 Future Option
13 Future Option
14 OEM
0
0
0
0
0
1
1
120/208V in/out 50/60 Hz Autodetect
0
None
2
127/220V in/out 50/60 Hz Autodetect
3
Connect UPSX Web/SNMP
3
R/T with output breaker
4
Modbus Card
4
Parallel with output breaker
5
Relay Card
6
Industrial Relay Card
7
Modem Card
None
None
None
None
None
15 Future Option
Eaton
0
None
Only Slot 1 populated from factory
Notes: 1
Supporting Documents: Schematic - 30kVA UPS Schematic - 30kVA EBC Option Cabinet CTO
110720639 110720675 110577094
Description: CTO Created By:
CHART, 9355 30KVA UPS HARDY_J
Modified By:
Date: 05-JAN-06 Date:
OBJECT ID:
110577093
Checked By:
WALLACE_T
Date: 21-MAR-06
ECN 9355-0164
Revision: C00
Approved By:
HARDY_J
Date: 21-MAR-06
Status: RELEASED
Sheet 1 of 2
These Drawings and Specifications Are the Property Of Eaton / Powerware and Shall Not be Reproduced or Copied or Used as the Basis for Manufacture of Sale of Apparatus Without Permission
Position
1 Model Type
2
3-4
Product UPS KVA Rating Family
5
6
7
8
Application
Battery Configuration
UPS Configuration
Comm Option
Base unit K
B
20 or 30
BOM 1
103004897
R/T (no output breaker)
103005372
BOM 3 3 battery shelves
103004887 (12x)
BOM 1
0 None
3 Connect UPS-X 2 Parallel (no output breaker)
103005372 + 101073663-001
2
3 R/T with output breaker
4 Parallel with output breaker
103005373
103005373 + 101073663-001
9-12
4
13
14
15
Future Option
OEM
Future Option
BOM
BOM
NA
1
103004888
103002974-5501
4 Modbus Card
103002511-551 + 103002818 + 164201376
5 Relay Card
1018460
6 Industrial Relay Card
103002686 + 164201433
7 Modem Card
1019017
5
6
Only Slot 1 populated from factory
Options REPO Remote Monitor Wall mount MBS Parallel Tie Cabinet External battery (4 strings) External battery (2 strings) kVA Upgrade 20 to 30 Parallel Upgrade Kit Seismic Kit
103002939 103002687-001 + 103003055 124100026-001 124100026-001 103004868 103005183 103004901 103005160 103004896
X-slot Communication Options (Order separate, field install) Parallel (CAN Bridge) 103004336 Connect UPS-X Web/SNMP 103002974-5501 Modbus Card 103002510-5501 Relay Card 1018460 Industrial Relay Card 103003055 Modem Card 1019017
Description: CTO
CHART, 9355 30KVA UPS OBJECT ID:
Created By:
HARDY_J
Date: 05-JAN-06
Modified By:
X
Date:
Checked By:
WALLACE_T
Date: 21-MAR-06
ECN 9355-0164
Revision: C00
Approved By:
HARDY_J
Date: 21-MAR-06
Status: RELEASED
Sheet 2 of 2
110577093
These Drawings and Specifications Are the Property Of Eaton / Powerware and Shall Not be Reproduced or Copied or Used as the Basis for Manufacture of Sale of Apparatus Without Permission
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