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The copyright of this handbook is the property of Chloride Power Electronics Limited. The information contained herein may not be copied, communicated to a third person nor stored in a data retrieval system without agreement in writing from Chloride Power Electronics Limited. In pursuing a policy of continuous product development we reserve the right to vary product design, specification or components without prior notice. Whilst every effort has been made to ensure the accuracy of the information in this handbook, Chloride Group PLC cannot be made liable for any errors, incidental or consequential damages.
This manual includes: the description of the software used up to FSB = 29 and the one used from FSB = 30
CHLORIDE
SILECTRON
Via Umbria, 6 I 40060 Osteria Grande BO ITALY Tel. (++39) (+51) 6959111 Fax. (++39) (+51) 945634
TECHNICAL MANUAL
PART NUMBER
10B52041PT1C rev. 5
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CONTENTS
1 SAFETY
1.1 General 1.2 Electric shock 1.3 Safety warning
MAINTENANCE PROCEDURES
2.1 Tools & Test equipment 2.2 Procedures 2.3 Fuse blowing 2.4 Fans replacement
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5a
SOFTWARE FUNCTIONAL DESCRIPTION (for UPS having FSB status < 30)
5a.1 General 5a.2 Accessing information 5a.3 Measurements 5a.4 Alarm Message and digital output 5a.5 Buzzer 5a.6 LEDs 5a.7 Inverter Stop/Start 5a.8 RAU & AS400 outputs 5a.9 POWER HISTORY 5a.10 Battery autonomy 5a.11 RS232 port 5a.12 Inverter Voltage control 5a.13 Display Board trip settings 5a.14 DIL Switch settings
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5b. SOFTWARE FUNCTIONAL DESCRIPTION (for UPS having FSB status > = 30)
5b.1 5b.2 5b.3 5b.4 5b.5 5b.6 5b.7 5b.8 5b.9 5b.10 5b.11 5b.12 5b.13 5b.14 5b.15 5b.16 GENERAL ACCESSING INFORMATION MEASUREMENTS ALARM MESSAGE AND DIGITAL OUTPUT BUZZER LEDS INVERTER STOP/START DATA STORAGE METHOD DESCRIPTION RECTIFIER STARTUP CONTROL RAU & AS400 OUTPUTS POWER HISTORY BATTERY AUTONOMY RS232 PORT INVERTER VOLTAGE CONTROL DISPLAY BOARD TRIP SETTINGS DIL SWITCH SETTINGS
6. TROUBLE SHOOTING
6.1 TROUBLE SHOOTING (for UPS having FSB status < 30) 6.2 TROUBLE SHOOTING (for UPS having FSB status > = 30)
MAINTENANCE
7.1 Periodical maintenance 7.2 Float voltage settings
CIRCUIT DIAGRAMS
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DO NOT TOUCH THE CASUALTY WITH YOUR BARE HANDS UNTIL HE IS CLEAR OF ANY CONDUCTOR. SEND IMMEDIATELY FOR TRAINED, QUALIFIED HELP.
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Chap 1 = SAFETY
1.3 Safety Warning
1) If either the AC supply or the batteries are connected, do not remove the access covers unless you have undergone a Chloride approved training course. 2) Arrange safety cover. Ensure somebody is available to isolate the electricity supply if necessary. 3) Stand on an approved rubber insulating mat when working on the equipment. WARNING ! : Some rubber mats contain a carbon based pigment and are not suitable! 4) Remove watches, rings earrings and other metal jewellers and any loose metal pens, tools or metal objects from pockets before working on the equipment. 5) Do not touch printed circuit boards, except in Bypass mode. High voltages exist, there is an electric shock hazard. 6) Use only insulated tools. 7) Batteries contain ACID, which is poisonous and corrosive. It can cause burns on contact with skin and eyes. If acid is spilt on clothes or gets into eyes, wash well with plenty of clean water. Batteries can give off EXPLOSIVE gases. Keep sparks, flames and lighted cigarettes away.
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MAINTENANCE PROCEDURES
2.1 Tools and Test Equipment
In addition to the usual hand tools, the following equipment is needed: 1) Oscilloscope. Dual beam, at least 15MHz band width. This should be a fully floating earth type because it will be used to measure signals with reference to potentials other than earth. 2) Digital multimeter. This must be accurately calibrated. 3) A fused inline wire link with adaptor. 4) Protective insertion and removal tools for handling CMOS integrated circuits which are susceptible damage from incorrect handling.
2.2 Procedures
When troubleshooting in this equipment remember that high voltages exist on printed circuit boards and on exposed terminals. Therefore do not touch any component until you have checked it is safe. When monitoring test points, always switch to BYPASS mode to fit the probe or meter, then switch to an operating mode to make the observation. Finally return to BYPASS to remove the measuring instrument. This will avoid inadvertent fuse blowing from spurious signals.
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1) Switch to bypass mode. Wait 3 minutes. 2) Check all the switches, excepted ByPass, are OFF, and remove the battery fuse. 3) Use a multimeter to check all the power components in the inverter including snubbers, power transformer and filter circuits (refer to section 3 of manual). 4) When power components are verified, disconnect base drive (plugs PL1013) 5) Turn on main switch. Verify DC rail voltage, and that the control and drive logic is working correctly (refer to section 5 of manual). 6) Switch off main switch. Wait 3 minutes. 7) Refit battery fuse F2 and base drive connectors. If F2 was faulty replace it. 8) Start up the equipment.
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2.4 Fans replacement Procedure for fans replacement on UPS ratings 30 or 40 kVA
Driver board
1 Remove the Driver following the arrow 2 Unscrew the fans support screw 3 Remove the fan following the arrow
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BATTERY CHARGERRECTIFIER
The rectifier converts the mains ac voltage into DC voltage in order to feed the inverter and the battery.
INVERTER
The inverter transforms the DC voltage supplied by the rectifier, or the battery into ac voltage for feeding the load.
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T2,
C2
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3.3 DC Choke
The choke L2, fitted on the rating up to 20kVA only, in conjunction with capacitor CE forms a lowpass filter circuit. On the ratings above 20kVA this is done by the AC choke L1. This provides the voltage smoothing and current ripple reduction on the DC supply which is necessary to ensure correct operation of the inverter. The current to the battery is smoothed again by the saturable choke L3, assuring then a trouble free battery charging.
3.4 DC Capacitor
A bank of electrolytic capacitors CE in conjunction with the DC choke form a filter as above described. Resistors in the inverter bridge are fitted across the bank to ensure safe discharge of these capacitors when the UPS is OFF (allow 3 minutes for discharge).
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Power Circuit:
The threephase AC main, through a high reactance star connected autotransformer or an AC choke, supplies a fully controlled 3 phase thyristor rectifier. The DC filter choke and the integrated AC chokes have been optimized to reduce harmonic distortion of the input current waveform. Isolated current feedback is derived from a hall effect current sensor in the battery lead. Voltage feedback is derived via impedance buffer amplifiers assuring electrical isolation > 300 k.
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Firing
Y>B XOR R>Y
Ranges
B>R XOR Y>B
Voltage Demand
Firing Pulses for B input of Logic Array Fig. 1 Timing Diagram for Firing Angle Control
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G1 : Pin 19
G2 : Pin 18
G4: Pin 16
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G1: Pin 19
G2:pin 18
G3: Pin 17
G4: Pin 16
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Soft Start:
This circuit ensures that at switch on the DC rail ramps up slowly over a period of approximately 10 seconds. The circuit, formed round IC3c acts as a virtual capacitor exhibiting an equivalent capacitance 100 times that of C3 at the junction of R14 and R15. At switch on the virtual capacitor charges through R15 to the 2.45V reference level which is buffered to the output of IC3 suppling the voltage reference pot VR1.
Battery Test:
To test the batteries the DC voltage is reduced by 20%. This test is initiated by the microprocessor controlled display driver PCB. Under test conditions PL6/12 is pulled low causing the output of IC4a to change state connecting R17 to 0v forming a potential divider with R26 which reduces the reference voltage seen by the virtual capacitor circuit. Charge is taken out of C3 reducing the voltage across VR1 and hence the reference to the voltage feedback amplifier. When PL6/12 is released R17 is switched out and the charge on C3 increases, the output voltage ramps up to the nominal level.
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Rectifier Shutdown:
This operates when PL6/13 is pulled low, it is connected to a simple comparator circuit which switches low inhibiting the system. This function is controlled directly from: the display control board the Interface board (EPO, VDC HIGH, RESERVE HIGH/LOW).
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Temperature Compensation:
A temperature sensor (IC7) provides temperature compensation in the feedback loop. It is designed so that the output voltage of the system is reduced as the temperature rises. This ensures maximum battery life is achieved.
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Each error signal (Verr) is compared to the trianglewave by the three comparators IC40A, IC40B and IC38A. The three PWM signals at IC40 pins 1 and 7 and at IC38 pin 1 are fed into PWM control chips IC26, IC27 and IC28 which generate dead time of 10.4Sec. (15.2Sec. if H2 is not fitted) and generate complementary outputs for a single input. IC15 and IC19 provide a current protection by switching off the PWM when the IPK is active. Signal INV OFF forces the outputs into tristate when the inverter is switched off. The PWM at TP11 to TP16 is fed into the DRIVER board through the transistors T4 to T9.
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Clock Generation:
IC6A in conjunction with crystal XL1 forms the main clock at 2.4576Mhz. The clock frequency is then divided by either 5 or 6 depending on SW1.3. Thus the clock frequency (IC6 pin 17) also used for synchronizing the rest of the control logic, is shown on the following table: SW1.3 ON OFF UPS Frequency 50Hz 60Hz f on IC16 pin 17 409.6 kHz 491.5 kHz
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General:
The display control circuit is based around the Philips PCB80C552 singlechip 8bit microcontroller. This is based on the 80C51 CPU with 256 bytes of RAM, timers, AnalogtoDigital converter, PWM outputs, digital I/O ports and a full duplex UART on board. For detailed information on this component refer to the relevant data sheets. Although there are many 80C51 based microcontrollers with similar features to the 80C552 there is currently no direct second source for this component. To increase the capability of the 80C552 and to perform all of the functions required for the display control board, additional RAM, EPROM, EEPROM and digital input and output lines have been added.
Data Memory:
The 64K data area is made up of RAM and digital input and output lines. 32K is allocated to the RAM, although only 8K is used (IC12 pin 26 tied to +5V by LK3D). IC5 and IC6 are the output data latches. When the address is 8006h or 8007h IC19 pulls the /CSOUT 0 or /CSOUT 1 low, respectively. When this line returns high the data appearing on the data bus is latched through to the output. IC8 and IC9 provide open collector outputs for these signals. IC10 is a series of darlington drivers used to drive the LEDs on the mimic board. Four outputs from IC6 and 2 outputs taken directly from IC2 are the signals for the LED drives.
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Frequency Inputs:
The inverter and reserve zero crossing detector outputs are fed into pins 16 and 17 of the microcontroller via buffer IC3. Pins 16 and 17 are coupled to timer T2 of the 80C552 which is configured as a 16 bit counter, free running at 1MHZ. At each positive going edge of the signals at Pin 16 and 17, the contents of timer T2 is saved to a register. By reading this register following two consecutive edges, the period of the squarewave can be determined and hence its frequency can be calculated.
Analogue Inputs:
Port 5 of IC2 is used for the analogue inputs for the analogue to digital converter on board the 80C552. This is a 10 bit converter with eight multiplexed inputs. The inverter voltage and load current waveforms appear on pins 1 and 68 of IC2. These waveforms are sampled once every 250 microseconds during the sampling cycle and from this data R.M.S calculations are performed. For this reason only small noise filters can be used on these lines. The other four analogue inputs are DC levels which are read once every l00mSec. Each of these inputs has a filter comprising of a l00K resistor and a 1F capacitor. The analogue reference for the analogue to digital converter is derived from a 2.5 volt zener diode. This voltage represents the full scale voltage for all of the analogue inputs. The accuracy of this voltage is not critical as any error is compensated for in software by the self calibration routine.
Analogue Output:
Pin 5 of IC2 is a PWM output controlled by the 80C552. This is configured to operate at a frequency of 23.5kHz with a duty cycle variable from 0 to 100%. The squarewave output from pin 5 is filtered by R6 and G13 to give a d.c. level proportional to the duty cycle of the PWM at the base of TR2. TR2 acts as a buffer for this analogue voltage. The greater the duty cycle at pin 5, the higher the d.c level at PL8 pin 43. This d.c level is used to vary the inverter output voltage, by varying the reference level on the inverter drive board.
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Crystal Oscillator:
The oscillator for the microprocessor is built into the 80C552 device and requires only the crystal QZ1 and capacitor C10 and C11 to produce the necessary clock. The oscillator which is used for the RS232 baud rate is based around the GAL, IC7. This uses a 4.9152 MHz crystal frequency which is then divided by 16 to provide a frequency reference of 307.2 kHz. This is then fed into the timer1 input of the microprocessor. The 80C552 then performs the necessary division to provide a baud rate of 1200, 4800, 9600 or 19200 baud depending on the setting of the relevant DIL switches.
RS232C Interface:
The RS232C port uses the UART (Universal Asynchronous Receiver Transmitter) which is part of the 80C552. The data lines are TXD (IC2 pin 25) for data transmitted from the microcontroller and RXD (IC2 pin 24) for data received. Where necessary, data flow through external devices such as the RS232C to RS2422A converter can be controlled using the line DTR (from IC2 pin 23). These three lines are buffered by IC3 and leave the display control board in TTL format. Conversion into RS232C levels is performed on the interface board.
LCD Interface:
The LCD module is driven through the parallel ports on the 80C552. Port 4 is used for the data transfer and three lines from Port 1.
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ii) Acts as a distribution point for routing control signals. iii) provides a startpoint ground for all other PCBs. This startpoint is connected to chassis through the inductance L1. iv) Provides Opencollector drives for the rectifier and static switch phototriac. v) Provides isolation for RS232, AS400 and R.A.U. interfaces using relays. vi) Provides control logic and drive circuit for D.C.. vii) Provides the display pcb with two positive signals (charge/discharge current) derived from the halleffect current transducer. viii) Provides precision rectification of A.C. signals to feed the display pcb. ix) Provides Output Voltage, Reserve Voltage and Mains Voltage detectors. x) Provides rectifier current limit.
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ii) When the bypass and output breakers are simultaneously ON, iii) When the emergency Power OFF is initiated, iv) When the main switch is opened, and the inverter is OFF.
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Para 4.5 INTERFACE PCB 4.5.8 Inverter, Reserve and Rectifier Thyristor Drives:
The following figure shows the circuit which drives phototriacs (on the firing board) for SCR static switch.
When ITL is active (load on inverter) the output of IC14 is LOW, the current through the resistors A and C switches on the phototriac, and is limited to 10 mA. The resistor B and D limits the voltage in the diode of phototriac. The same currents are for the drivers for rectifiers SCRs.
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5a
key moves from one column to the top row of the next column.
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After the last active alarm, pressing the key will move through the following pages of measurements: D.C. Voltage and Rectifier Current D.C. Voltage and Battery Current
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After the last active alarm, pressing the key will move through the following pages of measurements: Load Current Load Peak Factor and Percentage Loading Reserve Voltage and Frequency
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and pressing again will return to the first column. If no key is pressed for 5 minutes, the display changes back to the top row of the first column of information.
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Para 5a = SOFTWARE DESCRIPTION ( FSB < 30 ) 5a.3 Measurements 5a.3.1 D.C. voltage
One sample is taken every 100mSec and the displayed reading is filtered over 10 consecutive samples. This reading is scaled so that an input signal of 2.215V will give a display reading of 326V.
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Para 5a = SOFTWARE DESCRIPTION ( FSB < 30 ) 5a.3.5 Reserve Voltage and Frequency
The reserve voltage is full wave rectified and smoothed in hardware. This DC level is then read once every 100mSec and the display reading is filtered over 10 consecutive samples. The sampling is synchronized to the reserve frequency to over come aliasing effects caused by ripple on the DC level, thus if the reserve frequency signal is not present, the displayed voltage will be zero. A DC level of 1.09V will give a displayed voltage of 240v. The reserve frequency is determined from the period of one complete cycle every 100mSec. This is taken from the output of the reserve zero crossing detector as the time between two consecutive positive going edges at pin 17 of the microcontroller. The displayed reading is filtered over 10 consecutive samples.
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Para 5a = SOFTWARE DESCRIPTION ( FSB < 30 ) 5a.4 ALARM MESSAGES AND DIGITAL OUTPUTS.
Alarm messages and digital outputs are set on the basis of conditions set at the digital inputs and also by conditions set by the level of the displayed analog readings. For trip settings of analog measurements, refer to Section 5a.13.
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A1 = T1 x (K12 1) for the magnetics 2 A2 = T2 x (K1 1.25) for the heatsink where A1 max = 337.5 and A2 max = 0.625
Below 100% loading, another curve which relates the load percentage to the time, calculates the time required to obtain again the nominal overload capacity.
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Para 5a = SOFTWARE DESCRIPTION ( FSB < 30 ) 5a.4.22 The following list of alarms depend solely on the levels at
their respective inputs and are not conditioned in software other than the filtering during the reading of the inputs and the delays before the sounding of the buzzer. ALARM PRIMARY SUPPLY FAIL PHASE SEQUENCE ERROR OVER TEMPERATURE BATTERY CONTACTOR OPEN LOAD ON RESERVE INVERTER FAULT RESERVE SUPPLY FAULT RESERVE FREQ FAULT RESERVE VOLTS HIGH RESERVE VOLTS LOW STATIC SWITCH FAULT HARMONIC FILTER OPEN BATT. CHARGE INHIBIT INPUT Primary Supply Fail Input Primary Phase Fail Input Overtemperature Input Battery Contactor Open Input Load On Reserve Input Inverter Fail Input Reserve Fail Input Res F Out of Limits Input Reserve Voltage High Input Reserve Voltage Low Input Static switch Fail Input Harmonic Filter Open Input Battery Charge Inhibit Input ACTIVE HIGH LOW HIGH LOW HIGH HIGH HIGH HIGH HIGH HIGH HIGH HIGH LOW
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5a.5 BUZZER
The buzzer will sound when any alarm goes active. For some alarms there is a delay before the buzzer sounds. These delays are as follows: Primary Supply Fail 30 Seconds Primary Phase Fail 30 Seconds Battery Discharging 30 Seconds DC Voltage High 30 Seconds Out of Sync 30 Seconds Inverter Volts Low 10 Seconds Overload 10 Seconds Load On Reserve 30 Seconds Reserve Supply Fault 30 Seconds Reserve Volts High 30 Seconds Reserve Volts Low 30 Seconds Reserve Freq Fault 30 Seconds In each case, the LED mimic and LCD messages will be updated as soon as the alarm becomes active. Only the sounding of the buzzer is delayed. The buzzer will be cancelled when all alarms clear or can be manualIy cleared by pressing the buzzer mute key. If the mute key is pressed after an alarm goes active but before the above delay has passed, this will not prevent the buzzer sounding at the end of the delay.
5a.6 LEDS
There are six LEDs on the UPS mimic which show at a glance the operating condition of each block of the UPS. Five LEDs are green and are one for each block as indicated by the mimic line diagram: Rectifier, Battery, Inverter, Reserve, Load. A continuous green LED indicates that that block is operating normally. A flashing green LED indicates a fault or alarm condition in the corresponding block of the UPS. The following list shows which LEDs are affected by which alarms:
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Pressing the key when the exit message is displayed does not exit from the power history but moves on to display the measurements.
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INVERTER VOLTAGE
380V
400V
360.0V 440.0V 2.0V
415V
373.5V 456.5V 2.0V
Inverter Voltage LOW 342.0V Inverter Voltage HIGH 418.0V Hysterisis for Inverter Low Trip 2.0V
144 cells
237.6V 309.6V 316.8V 252.0V 273.6V 345.6V 340.0V 326.7V 425.7V 435.6V 346.5V 376.2V 475.2V 467.5V
* = shutdown imminent is reset when battery is no longer discharging (i.e. > VDC battery Discharging).
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23.9A 31.9A 47.9A 63.8A 79.8A 95.7A 21.7A 28.9A 43.3A 57.7A 72.2A 86.6A 57.0A 76.0A 114.0A 151.9A 189.9A 227.9A 22.8A 30.4A 45.6A 60.8A 76.0A 91.2A
LOAD CURRENT @ 400V 10kVA 15kVA 20kVA 30kVA 40kVA 50kVA 60kVA Overload Trip Current 15.2A Overload Trip Reset Current 13.7A Max Peak Load Current * 38.0A Max RMS Load Current * 14.4A
22.7A 30.3A 45.5A 60.6A 75.8A 90.9A 20.6A 27.4A 41.1A 54.8A 68.6A 82.3A 57.0A 76.0A 114.0A 151.9A 180.4A 216.5A 21.7A 28.9A 43.3A 57.7A 72.2A 86.6A
LOAD CURRENT @ 415V 10kVA 15kVA 20kVA 30kVA 40kVA 50kVA 60kVA Overload Trip Current 14.6A Overload Trip Reset Current 13.2A Max Peak Load Current* 38.0A Max RMS Load Current * 13.9A
21.9A 29.2A 43.8A 58.4A 73.0A 87.6A 19.8A 26.4A 39.6A 52.9A 66.1A 79.3A 57.0A 76.0A 114.0A 151.9A 173.9A 209A 20.9A 27.8A 41.7A 55a.6A 69.6A 83.5A
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10kVA 15kVA 20kVA 30kVA 40kVA 50kVA 60kVA ON OFF ON OFF ON OFF OFF ON OFF ON ON ON 10kVA but should not be used.
SW1.4 OFF ON OFF SW1.5 OFF OFF ON SW1.6 OFF OFF OFF Any non valid combination will result in System test Mode SW1.8 ON = System test Mode OFF = normal UPS operation
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UPS Identifier for EASY1000 Software SW2.7 SW2.6 SW2.5 SW2.4 UPS n 1 OFF OFF OFF OFF (normal setting) UPS n 2 OFF OFF OFF ON UPS n 3 OFF OFF ON OFF UPS n 4 OFF OFF ON ON UPS n 5 OFF ON OFF OFF UPS n 6 OFF ON OFF ON UPS n 7 OFF ON ON OFF UPS n 8 OFF ON ON ON UPS n 9 ON OFF OFF OFF UPS n 10 ON OFF OFF ON UPS n 11 ON OFF ON OFF UPS n 12 ON OFF ON ON UPS n 13 ON ON OFF OFF UPS n 14 ON ON OFF ON UPS n 15 ON ON ON OFF UPS n 16 ON ON ON ON Where only one UPS is connected to a PC, set to UPS number = 1 (i.e. SW2.4 to Sw2.7 all OFF) Pcb Self Test SW2.8 OFF = ON = pcb self test procedure use only with self test rig. normal pcb operation.
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After the last active alarm, pressing the key will move through the following pages of measurements: D.C. Voltage and Rectifier Current D.C. Voltage and Battery Current
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5b.2.4 The fourth column contains information relevant to the Load and Reserve. The first line of the display will show: LOAD/RES ALARMS While the second line will show the first active message from the following: NO ALARM ACTIVE NOT CALIBRATED LOAD ON RESERVE LOAD NOT SUPPLIED BYPASS SWITCH CLOSED RESERVE SUPPLY FAULT RESERVE FREQ FAULT RESERVE VOLTS HIGH RESERVE VOLTS LOW STATIC SWITCH BLOCKED ON INVERTER STATIC SWITCH BLOCKED ON RESERVE INVERTER STATIC SWITCH FAULT OVERLOAD OUTPUT SWITCH OPEN RESERVE SWITCH OPEN PHASE SEQUENCE FAULT RESERVE INHIBITED If more than one of these alarms is ON, pressing the list of active messages. key will move through the
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5b.2.5 The fifth column is normally used to select the language for LCD messages. Using the and keys changes the language and pressing the key returns to the first column with the messages displayed in the selected language. Once a language has been selected, this will remain in use until it is changed using the language selection column. If the UPS is switched OFF and then ON again it will power up in the selected language. If POWER HISTORY information is available the pressing the fourth column will cause the LCD to display: POWER HISTORY DOWN TO ACCESS Pressing the key will now enter into the Power History information. When the Power History is exited, the display will return to this entry message. Pressing the key from here will move on to the language selection column, key from the
will return to the first column. and pressing again If no key is pressed for 5 minutes, the display changes back to the top row of the first column of information.
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.3 Measurements 5b.3.1 D.C. voltage
One sample is taken every 100mSec and the displayed reading is filtered over 8 consecutive samples. This reading is scaled related to the battery elements number as follow: Elements Sense Input Displayed readings 144 2.215 V 326.0 V 198 2.215 V 449.5 V 240 2.215 V 544.8 V
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.3.4 Inverter Voltage and Frequency
The inverter voltage is full wave rectified and smoothed in hardware. This DC level is then read once every 100mSec. and the display reading is filtered over 2 consecutive samples. The sampling is synchronized to the inverter frequency to overcome aliasing effects caused by the ripple on the DC level. A DC level of 1.6V will give a displayed voltage of 240V. The inverter frequency is determined from the period of one complete cycle every 100mSec. The displayed reading is filtered over 2 consecutive samples. The period is the time between two consecutive positive going edges at pin 16 of the microcontroller.
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.3.10 Total mains fail number and duration
This page shows the total number of mains failure and the total duration since the machine installation. The value is recorded on a non volatile memory so it is not lost when the machine is off. It is possible to reset this values by setting and resetting the SW 1.8 on the display board.
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.4.2 Testing Battery and Battery Test Output
A battery test is automatically initiated every seven days minus 5 hours after the unit is switched on. To initiate the test the microcontroller sets the BATTERY TEST output low and the message TESTING BATTERY replaces the SYSTEM NORMAL message on the display. This automatic test is inhibited for two days following one of the below condition to prevent the testing of a discharged battery: primary mains fault input breaker open batt discharging dc feedback fault A battery test is also initiated following a DC voltage high condition to prevent overcharging of the batteries. A battery test can be manually initiated by pressing both and keys on the display simultaneously. This manual test is not inhibited following a mains failure. The next automatic test will occur one week after a manually requested test. The test lasts one minute during which time the battery voltage is continuously monitored. If the voltage falls below the Minimum Battery Test Voltage given in Sec. 5b.15 then the test is terminated and the alarm BATTERY FAULT is generated, otherwise the test is terminated after one minute and no alarm is generated. If the BATTERY FAULT alarm was active prior to the test, then the alarm is cancelled while the test is being made and may be set again depending on the test result. At the end of the test, the BATTERY TEST output is reset high and after 10 seconds the TESTING BATTERY message is cleared. This allows 10 seconds for the rectifier to phase up following the removal of the battery test signal. A battery test is automatically initiated at the start up 5 sec. after the system is normal but only if the battery are not discharged (Ibatt.pos < 1 A). This gives the possibility to check the battery connection after the UPS installation.
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A1 = T1 x (K12 1) for the magnetics 2 A2 = T2 x (K1 1.25) for the heatsink where A1 max = 337.5 and A2 max = 0.625
Below 100% loading, another curve which relates the load percentage to the time, calculates the time required to obtain again the nominal overload capacity.
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.4.27 Inverter frequency out of range 1% and Verifying inverter freq.
The inv. freq. out range 1% alarm is generated if the inverter is start up with out the reserve and if the frequency does not reach the nominal value + 1% after 15 sec. During the 15 sec. if the frequency is out the 1% window the verifying inv. freq. alarm will appear on the INVERTER ALARMS column. The alarm will be reset when the frequency goes inside the + 1% window. The nominal frequency value is selected by the SW 3.6 (OFF = 50 Hz, ON = 60 Hz).
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.4.32 Static switch blocked on inverter
This alarm is generated if the static switch fail input signal is active (HIGH) and if the load is on inverter.
5b.4.36 Load on reserve, Reserve supply fault, Reserve freq. fault, Reserve voltage high, Reserve phase fail and Reserve voltage low.
All the above alarms are generated by the respective input signals (all active HIGH excepted for reserve phase fail active LOW). The signals are masked when is present an EPO request to avoid wrong alarms while the power supply is going down.
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Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.4.38 The following list of alarms depend solely on the levels at their
respective inputs and are not conditioned in software other than the filtering during the reading of the inputs and the delays before the sounding of the buzzer. ALARM PHASE SEQUENCE ERROR BATT. CONTACTOR OPEN HARMONIC FILTER OPEN BATT. CHARGE INHIBIT INPUT SWITCH OPEN OUTPUT SWITCH OPEN RESERVE SWITCH OPEN INPUT Primary Phase Fail Input Batt. Contactor Open Input Harmonic Filter Open Input Battery Charge Inhibit Input Input Switch open Output Switch open Reserve Switch open ACTIVE LOW LOW HIGH LOW HIGH HIGH HIGH
5b.5 BUZZER
The buzzer will sound when any alarm goes active. For some alarms there is a delay before the buzzer sounds. These delays are as follows: Primary Supply Fail 30 Seconds Primary Phase Fail 30 Seconds Battery Discharging 30 Seconds DC Voltage High 30 Seconds Out of Sync 30 Seconds Inverter Volts Low 10 Seconds Overload 10 Seconds Load On Reserve 30 Seconds Reserve Supply Fault 30 Seconds Reserve Volts High 30 Seconds Reserve Volts Low 30 Seconds Reserve Freq Fault 30 Seconds In each case, the LED mimic and LCD messages will be updated as soon as the alarm becomes active. Only the sounding of the buzzer is delayed. The buzzer will be cancelled when all alarms clear or can be manualIy cleared by pressing the buzzer mute key. If the mute key is pressed after an alarm goes active but before the above delay has passed, this will not prevent the buzzer sounding at the end of the delay.
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LOAD LED: PRIMARY NOT CALIBRATION LOAD ON RESERVE LOAD NOT SUPPLIED INVERTER FAULT BYPASS SWITCH CLOSED STATIC SWITCH BLOCKED ON INVERTER STATIC SWITCH BLOCKED ON RESERVE OVERLOAD OUTPUT SWITCH OPEN The sixth LED is red and is a summary alarm LED. This LED is normally off and comes on when any alarm goes active. If the buzzer is sounding, the red LED is on continuously. If the buzzer is muted, the red LED flashes to indicate that the fault condition has been accepted by the user. When all alarms clear, the red LED will return to its normal off condition.
Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.10 RAU and AS400 outputs
There are five outputs which are used to drive the RAU and AS400 interfaces, these are: System normal output: This is set when there are no active alarms. Load on Reserve Alarm Output: This is set according to the signal read at load on reserve input. Primary Supply Fail Alarm Output: This is set if either the primary supply fail input or primary phase fail input is active. Shutdown imminent Alarm Output: This output is set when the shutdown imminent alarm is active. Inverter Fail Alarm Output: This is set if any of the following conditions is active: Out of sync alarm, Over temperature alarm, Inverter fail input, Inverter voltage high, Inverter voltage low, Overload with load in inverter. Each output has a delay of 10 seconds before it goes active following its respective alarm being set. The outputs will go off as soon as the alarm clears. This is to prevent transients from unnecessarily alerting the user.
DOWN TO ACCESS This message indicates that information is available and would not otherwise be displayed. Pressing the key at this point moves into the power history information. When power history information is displayed, the arrow keys are redefined. The and move backwards and forwards through time in 0.1 second steps. This takes it possible to determine the exact moment in which an alarm became active with respect to another alarm or measurement change, so the actual sequence of events leading up to the inverter block can be examined. The key moves from one alarm to the next. Only alarms which were active at some time during the eleven second history period will be displayed. This makes it easier to locate a particular alarm without the need to step through a long list of alarms which do not apply. When the power history information is first accessed, the display shows the first alarm which was active and its condition at time = 0.0 seconds, the instant at which the block occurred. The top line shows the time in seconds relative to the moment the block occurred The bottom line of the display shows the alarm message The top line shows on the right hand side, whether the alarm was on or off at this moment in time. Pressing the key moves through each of the active alarms. After the last alarm the option is given to exit from the power history information by pressing the key: POWER HISTORY UP TO EXIT returns to the history entry message and Pressing the columns of information as described in Section 2. then moves on through
Pressing the key when the exit message is displayed does not exit from the power history but moves on to display the measurements.
Measurements are displayed on the bottom line of the LCD. The top line shows the Section of the UPS to which the readings refer and time, relative to the moment the block occurred, at which the readings were taken. Pressing the RIGHT key now moves through the measurements and then back to the first alarm.
Para 5b = SOFTWARE DESCRIPTION ( FSB >= 30 ) 5b.15 EDP70 Display Board trip settings
The following is a list of voltage and current trip points which are controlled by the display control board.
INVERTER VOLTAGE
380V
400V
358.0V 438.0V 2.0V
415V
374.0V 457.2V 2.0V
Inverter Voltage LOW 342.0V Inverter Voltage HIGH 419.0V Hysterisis for Inverter Low Trip 2.0V
DC VOLTAGE
Low DC Trip 237.6V 326.7V 396.0V Low DC Trip Reset 309.6V 425.7V 516.0V VDC 217 Battery Discharging 302.4V 415.8V 504.0V VDC 215 Battery Discharging 310.5V 425.7V 516.9V VDC 210 Battery Discharging 312.5V 429.7V 520.8V Rectifier 50 % trip 163.4V 224.7V 272.4V Rectifier 90 % trip 294.0V 404.6V 490.3V VDC Shutdown Imminent * 252.0V 346.5V 420.0V Minimum Battery Test Voltage 273.6V 376.2V 456.0V High DC Trip 345.6V 475.2V 576.0V High DC Trip Reset 340.0V 467.5V 566.7V Loss dc reaction trip 230.4V 316.8V 384.0V * = Shutdown imminent is reset when battery is no longer discharging (i.e. > VDC 217 Battery Discharging).
15.9A 23.9A 31.8A 47.7A 63.6A 79.8A 95.7A 37.9A 56.8A 75.8A 113.6A 151.5A 189.9A 227.9A 15.2A 22.7A 30.3A 45.5A 60.6A 76.0A 91.2A
LOAD CURRENT @ 400V 10kVA 15kVA 20kVA 30kVA 40kVA 50kVA 60kVA Overload Trip Current Max Peak Load Current * Max RMS Load Current *
15.2A 22.8A 30.4A 45.7A 60.9A 75.8A 90.9A 36.2A 54.3A 72.5A 108.7A 144.9A 180.4A 216.5A 14.5A 21.7A 29.0A 43.5A 58.0A 72.2A 86.6A
LOAD CURRENT @ 415V 10kVA 15kVA 20kVA 30kVA 40kVA 50kVA 60kVA Overload Trip Current 14.6A 21.9A 29.2A 43.8A 58.3A 73.0A 87.6A Max Peak Load Current* 34.7A 52.1A 69.4A 104.2A 138.9A 173.9A 209A Max RMS Load Current * 13.9A 20.8A 27.8A 41.7A 55.5A 69.6A 83.5A * = Used for percentage load calculation
6kVA
7.5kVA 8kVA
SW1.4 OFF ON OFF ON OFF ON SW1.5 OFF OFF ON ON OFF OFF SW1.6 OFF OFF OFF OFF ON ON Any non valid combination will result in 10kVA but should not be used. EDP70 UPS RATING
SW1.4 OFF ON OFF ON OFF ON OFF SW1.5 OFF OFF ON ON OFF OFF ON SW1.6 OFF OFF OFF OFF ON ON ON Any non valid combination will result in 10kVA but should not be used. Auto voltage control SW1.7 ON = auto control voltage on OFF = no auto control voltage
System test Mode SW1.8 ON = System test Mode OFF = normal UPS operation Test terminal OFF OFF LIFE OFF ON EASY JBUS ON OFF ON ON
4800 ON OFF
9600 OFF ON
19200 ON ON
1200 ON OFF
1200 OFF ON
1200 ON ON
UPS Identifier for EASY1000 Software SW2.7 UPS No 1 OFF UPS No 2 OFF UPS No 3 OFF UPS No 4 OFF UPS No 5 OFF UPS No 6 OFF UPS No 7 OFF UPS No 8 OFF UPS No 9 ON UPS No 10 ON UPS No 11 ON UPS No 12 ON UPS No 13 ON UPS No 14 ON UPS No 15 ON UPS No 16 ON When only 1 UPS is connected switches OFF) SW2.8 NOT USED SW2.6 SW2.5 SW2.4 OFF OFF OFF (std setting) OFF OFF ON OFF ON OFF OFF ON ON ON OFF OFF ON OFF ON ON ON OFF ON ON ON OFF OFF OFF OFF OFF ON OFF ON OFF OFF ON ON ON OFF OFF ON OFF ON ON ON OFF ON ON ON to a PC, Identifier No 1 MUST be used (all
EDP RETROFIT (EDP50 only) SW3.3 OFF = normal setting ON = early EDP50 (without Idc measurement)
SW3.6
LIFE MANUAL CALL Press keys UPS IN SERVICE Press keys SETUP LIFE Press keys START RECTIFIER or AUTONOMY TEST Press keys BATTERY TEST Press keys POWER HISTORY Press keys DOWN + RIGHT for 2 seconds UP + DOWN for 2 seconds UP + RIGHT for 2 seconds RIGHT + BUZZER MUTE for 2 seconds DOWN + BUZZER MUTE for 2 seconds UP + BUZZER MUTE for 2 seconds
TROUBLE SHOOTING
6.1 TROUBLE SHOOTING (for UPS having FSB status < 30)
The following is a guide to troubleshooting, starting from ALARM MESSAGES appearing on UPS display. As some messages can be generated by other messages, in this case the action is referred to the originating message(s). ALARM MESSAGES are organized on display in pages and are here presented per page.
GENERAL INSTRUCTIONS
RISK OF ELECTRICAL SHOCK AND DAMAGE TO UPS AND LOAD Instruction hereinafter contained require to be performed by trained personnel, being fully aware of the more detailed information contained in the Technical Manual of which this is a section. UPSs are subject to continuous improvement, therefore before to proceed with following troubleshooting check that any upgrade FSB has been applied to the unit. This troubleshooting does not recall all the time that the fault can be due to bad connections. Check all connections before entering into a deeper investigation. In many cases the replacement of boards is suggested as a tentative, therefore it is suggested that, if replacement does not solve the problem, the old board is reinstalled before proceeding to next step in order to save spare boards. Replacement of most of the boards must be done following the procedure included with the spare board and not recalled here.
6.2 TROUBLE SHOOTING (for UPS having FSB status > = 30)
The following is a guide to troubleshooting, starting from ALARM MESSAGES appearing on UPS display. The target of this document is to describe how each alarm of this eprom is generated. The alarm list is divided in the same 4 groups that are present on the machine display: MAINS ALARMS RECTIFIER / BATTERY ALARMS INVERTER ALARMS LOAD / RESERVE ALARMS To help the users in the alarms recognizing, each item is reported in all the 5 languages present on the UPS. Legend: .. input with input are identified the display board digital inputs. Refer to DISPLAY CONTROL BOARD electrical drawing. .. output with output are identified the display board digital outputs. Refer to DISPLAY CONTROL BOARD electrical drawing. .. condition with condition are identified the machine status that could be a combination of digital and analog input. dc voltage, battery current, inverter voltage ph1, inverter voltage ph2, inverter voltage ph3, reserve voltage, load current ph1, load current ph2, load current ph3: all these are display board analog inputs. AND is a boolean operator. The expression is true if both the operands that are before and after the operator are true. OR is a boolean operator. The expression is true if at least one operator is true. not is a logical operator the invert the operand value. (PLXX.YY) this string identify connector (XX) and the pin (YY) related to the digital input or output
MAIN ALARMS
1. SYSTEM TEST MODE SWITCH POSIT. TEST TESTBETRIEB SISTEMA IN VERIFICA TEST DEL SISTEMA The machine is in test mode if the SW 1.8 of the display board is set in ON. 2. TESTING BATTERY BATTERIE EN TEST BATTERIETEST PROVA DELLA BATTERIA PRUEBA DE BATERIAS This message is active while the UPS is testing the battery. 3. TESTING AUTONOMY AUTONOMIA EN TEST AUTONOMIETEST TEST AUTONOMIA PRUEBA DE AUTONOMIA This message is active while a autonomy test is executing. 4. E.P.O. ACTIVE ARRET URGENCE ACTIVE NOTAUS AKTIV E.P.O. ATTIVO E.P.O. ACTIVO This alarm is generated by the following condition: (inverter reset input) (PL8.26) AND (not inverter reset output) (PL8.26) AND (not bypass breaker closed input) (PL8.17) AND (not output breaker open input) (PL8.14)
12. DC VOLTAGE LOW SOUSTENSION DC DCUNTERSPANNUNG TENS. CONTINUA BASSA TENS. BATERIA BAJA This alarm is generated if the dc voltage is less the low dc trip voltage. This is a software regulated threshold that increases with the battery discharging time. It starts from 1.65 V/el at the battery discharging beginning until to 1.8 V/el after 10 hours. 13. INPUT SWITCH OPEN INTER. ENTREE OUVERT HAUPTSCHALTER OFFEN SEZ. INGRESSO APERTO INT. ENTRADA ABIERTO This alarm is generated if is active the digital input: input breaker open input (PL8.13) 14. HARMONIC FILTER OPEN FILTRE HARMONIQ. OFF FILTER NICHT AKTIV FILTRO ARMONICA OFF FILTRO ARMONICOS OFF This alarm is generated if is active the digital input: harmonic filter open input (PL8.16)
INVERTER ALARMS
1. NOT CALIBRATED NON ETALONNE NICHT JUSTIERT NON CALIBRATO NO CALIBRADO This alarm is present in the this page means a primary not calibration. 2. PCB SUPPLY FAULT DEFAUT ALIM.CARTES VERSORGUNGSFEHLER PL GUASTO ALIM. PCB FALLO ALIM.CONT. This alarm is active if the following equation is true: (inverter off condition) AND (peak limit input) (PL8.3) AND (current limit input) (PL8.2) AND ((batt charging condition) OR (not dc voltage under 90 condition)) AND (not rectifier shutdown output) (PL8.26) where: inverter off condition is true when the inverter has been stop by hand or when inhibited or blocked or at the machine start up. batt charging condition is true if: (battery current > i batt charging) AND (not battery contactor open input) (PL8.18) where: i batt charging = 1 A not dc voltage under 90 condition means that the dc voltage is greater than the 90% of nominal voltage.
Chap. 7 = MAINTENANCE
MAINTENANCE
7.1 Periodical maintenance
To ensure continuous reliable service it is recommended that the equipment and battery are serviced twice a year by a qualified and competent electrical engineer who has the tools, test equipment and specialist knowledge and skills to work safely on this equipment. It is also recommended that the equipment be checked daily and monthly by a competent person and that an equipment log be kept detailing the results of the maintenance checks, any faults that occur, any modifications carried out and any time that the equipment has been used to maintain the load in the event of a mains power supply failure. WARNING !! HAZARDOUS VOLTAGES EXIST WITHIN THE UPS CUBICLE AND WITHIN THE BATTERY CUBICLE EVEN WHEN THE SWITCHES ARE IN THE OFF POSITION. MAINTENANCE MUST BE PERFORMED BY A COMPETENT PERSON USING ALL THE SAFETY PRECAUTIONS. Daily: Check all readings are within the specified tolerance. Monthly: Carry out a visual check to ensure that all connections are secure, there is no sign of overheating and all ventilation grills are free and clean. Maintain the battery cell electrolyte levels in accordance with the Battery Manufacturers instructions (not required for sealed recombination battery cells). Lightly grease the battery cell terminals with petroleum jelly for lead acid and komoline jelly for nickelcadmium battery cells (not required for sealed recombination battery cells). Check that the battery and its housing are clean and dry.
Chap. 7 = MAINTENANCE
Six monthly: Carry out the monthly checks Check that the battery is fully charged, simulate mains failure and ensure that the battery maintains the load for 25% of its rated period. Twelve monthly: Carry out a battery electrolyte specific gravity test and adjust as necessary (not required for sealed recombination battery cells). Carry out the six monthly checks. Three yearly: Support the load on the BYPASS supply, switch the equipment off and disconnect the battery. Carry out a detailed continuity and insulation test Carry out an earth bonding check Reconnect the battery and switch the equipment on. Carry out a battery electrolyte specific gravity test and adjust as necessary (not required for sealed recombination battery cells). Carry out the monthly checks Simulate a mains failure and ensure that the battery maintains the load for 100% of its rated period.
Chap. 7 = MAINTENANCE
System Circuit: for UPS up to 20kVA for UPS above 20 & up to 40 kVA for UPS above 40kVA Rectifier Control Board: Inverter Control Board: Static Switch Control Board: Display Control Board: Interface Board : Base driver Board: Mimic PCB: St. Sw. Firing & Snubber Board: Rectifier Firing & Snubber Boar: R.F.I. Filter Board: S.M.P.S. Board: Transformer Board:
10C71148 10C71178 10C71245 15C90073 15C70512 15C90074 15C90072 15C70516 15C70533 15C90075 15C70517 15C70536 15B70559 15C70514 15C70515