Product Update Number:

Medium Voltage Support Technical Services Update

PF7000_GEN-37

Title:
2

Powerware 9120 UPS

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Date:
May 27, 2003

Issued By:
Gary Bankay

Product Affected
PowerFlex 7000 MV Drive

Only personnel who have been trained and understand the Bulletin 1500 and
PowerFlex product line are to work on this equipment. Suitable safety
equipment and procedures are to be used at all times.
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Please refer to the attached sheet.

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Please submit any questions you have in regards to this document to:
Rockwell Automation Canada Inc.
135 Dundas Street
Cambridge, Ont.
N1R 5X1
Attn: Medium Voltage Product Support

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Phone:
Fax:

1.519.740.4790 (Product Support)

1.519.740.4756

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Problem/Issue:
Inform field service representatives of the use of a new Un-interruptible Power
Supply (UPS) available for use in the PowerFlex 7000

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Component affected:
UPS
Product affected:
PowerFlex 7000 A, B and C frame

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Details:
The PowerFlex 7000 may use a UPS as part of the control power scheme. There
are two options on how to install the UPS: external to the drive or internal to the
drive. An external UPS is one which is supplied by the end customer and it is there
component to maintain. This UPS is physically external to the drive. The internal
UPS is supplied by Rockwell Automation|Cambridge and is located inside the drive.
This document refers only to the internal UPS option.
The original model of UPS used in the drive was the Prestige model. The vendor has
now rendered that model obsolete. The replacement for the Prestige model is the
Powerware 9120.

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UPS Model
Prestige
Powerware 9120
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Rockwell Automation part number

80026-077-01
80026-077-02
80026-077-03
80026-345-01

Power rating (kVA)

1.0
1.5
2.0
2.0

The two types of UPS are functionally and electrically compatible; however, the
physical size is different. A retrofit kit is being designed to provide a smooth
transition for a possible field replacement of a Prestige to a Powerware 9120 model.
From this point forward, any reference to a UPS will be with regard to the Powerware
9120 UPS.

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The layout at the rear of the Powerware 9120 is shown below for reference:
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The items most commonly used are the Communication Slot, the REPO port, and the
5-20 receptacles.
Communication Slot:
The UPS used in the PowerFlex 7000 will have its status monitored by the drive.
The UPS status is sent to the drive Customer Interface Board (CIB) via a serial 15
pin communication cable. The UPS must have a AS400 Relay Card installed which
provides the port to connect the communication cable. The relay card is installed
internally to the UPS and accessed at the communication slot of the UPS.
NOTE: An external UPS will not have its status monitored.
REPO port:
The Remote Emergency Power Off (REPO) port on the UPS is used to shut down the
output of the UPS when the input to the port is open circuit. Under normal
operations the input to the REPO port must be closed. This port may be useful for
those customers who demand to have complete drive isolation when the 3 low
voltage supply to drive is removed by the opening of the fan disconnect switch. An
auxiliary contact on the fan disconnect switch is connected to the REPO port. When
the fan disconnect switch is open, the REPO port is open resulting in a shutdown of
the UPS. After re-closing the fan disconnect switch, the UPS must be manually restarted by pressing the ON button the front of the UPS.

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The connection of the communication cable to the CIB is shown below for reference:

PH

PS1 AC Fail

PS1 DC Fail 1

PS1 DC Fail 2

PS1 DC Fail 3

PS1 DC Fail 4

PS1 DC Fail 5

PS1 DC Fail 6

PS1 COMM

PS2 DC Fail

PS2 DC Warn

3 PS2 SPGDB Fail

4

CIB
J11

J 5B

PS2 COMM

1 PS3 AC300 Fail

2 PS3 DC300 Fail

UPS
15 pin

PS3 COMM

UPS ON

BATT LOW

ON BYPASS

ON BATT

COMM

A_CIB1_OUT+

A_CIB1_OUT-

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A_CIB2_OUT+

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A_CIB2_OUT-

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A_CIB3_OUT+

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A_CIB3_OUT-

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METER1_OUT

COMM

METER2_OUT

COMM

METER3_OUT

COMM

METER4_OUT

COMM

J12

GND

Comm Cable

Analog CIB Ports

J13

Analog METER Ports

Input

PH

Output

J9

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The parameters and alarms related to a drive which has an internal UPS are
summarized in the following table:

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Drive Hardware Parameters
Fault Configuration Parameters
Fault Configuration Parameters
Fault Parameters
Fault Parameters

UPS Installed (P573)

Power Fault Mask (P104)
Power Warning Mask (P105)
Control Power Fault (P287) read only
Control Power Warning (P288) read only

Faults

UPS Battery Low (F154)

UPS Fault (F156)

Warnings

UPS Battery Low (W106)

UPS on Battery (W105)
UPS on Bypass (W104)

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The following is a list of parts and Rockwell Automation|Cambridge part numbers

required to interface the Powerware 9120 to the PowerFlex 7000:
Powerware 9120 UPS
Communication Cable to connect to the CIB
AS400 Relay Card
Powerware 9120 batteries

80026-345-01
80026-300-01
80026-346-01
80026-347-01

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Corrective Action:
This document created to inform field representatives of the model change in UPS
used in the PowerFlex 7000.

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Field Actions:
Always check the electrical drawings to determine how the UPS is installed in
the drive. Opening of the fan disconnect switch may not remove control
power to the Drive Control Board (DCB), Customer Interface Board (CIB), etc.
Be aware that control power may still exist within the drive after the source of
power to the drive is removed.
Allow the batteries in the UPS to fully charge prior to its first use. Leave the
UPS energized for at least 24 hours the first time it is energized. Refer to the
Powerware 9120 Users Manual for more information.
Per the Powerware 9120 Users Manual, recharge the UPS batteries every 10
months if the UPS is stored for a long period of time. Our experience with
these types of batteries shows that they should be recharged every 3 months.
Advise customer to fully recharge the batteries every 3 months if the UPS is
stored for a long period of time.
If the drive annunciates a UPS related alarm, check the LCD display on the
UPS to verify it is a real alarm not a nuisance/noise related event.

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Document Revision History:

Date
Revision
May 23, 2003

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1.0

Author
Gary Bankay

Description
Original document

If you have any questions or concerns, please contact MV Product Support at 519-740-4790.

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