9355 30kVA Service Manual_A02

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


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

Table of Contents

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


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


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


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)


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.


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.


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)


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

<


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.


Rectifier Input

CB-3

CB-1 Static Switch K-5

K-3

K-1

Rectifier

Inverter

Battery Converter

CB-2

Figure 5.

1-6

<


<


PW 9355 BATTERY Mode (single feed)


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

<


CB-2

<

Figure 6.


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.


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


9355 20 – 30 kVA

System Overview Bypass

Service

UPS

Bypass

Service

UPS

Bypass

Input TB

Bypass Input

Service

UPS

MBS


Rectifier Input

CB-3

CB-1

LOAD

Optional

Static Switch K-5

K-3

K-1

Rectifier

Inverter

Battery Converter CB-2

<


Figure 7.

<


PW 9355 BYPASS Mode (single feed)

Bypass Input

Bypass

Service

UPS

Bypass

Service

UPS

Bypass

Input TB

Service

UPS

MBS


Rectifier Input

CB-3

CB-1

LOAD

Optional

Static Switch K-5

K-3

K-1

Rectifier

Inverter


Figure 8.

<


<


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


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


PW9355 Service Position

UPS

Figure 9.

Byp ass



Rectifier Input

CB-3

CB-1

LOAD

Optional

Static Switch K-5

K-3

K-1 Rectifier

Inverter


<


Figure 10.

<


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


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


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


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


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


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


1-17

System Overview

9355 20 – 30 kVA

This page was left blank intentionally.

1-18


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.”


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


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)


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.


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.


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 <105 Ω per cm. Dissipative material: Material that provides some protection against a static field and typically has a surface resistance of 105 to 109 Ω per cm. Faraday Cage or Faraday Shield: A conductive enclosure capable of protecting its contents from any outside static charge or electrostatic field. An example would be an ESD bag that is closed. Frame ground: Any unpainted surface of a unit or subassembly to which a wrist strap may be firmly connected. Ground: Building/earth ground. Static safeguard stations: Any area with provisions for controlling electrostatic discharge. Static sensitive material: Any static sensitive component/device (semiconductors, film resistors and capacitors, and so on) or boards with such components/devices mounted on them. Static shield: Must be capable of providing a Faraday cage (protective from static discharge as well as electrostatic fields). Static Protective equipment/tools: Must include as a minimum, but not be limited to, a wrist strap with 1 meg ohm resistor, a conductive table mat or grounded work surface and dissipative mats for field engineers.

WARNING 100% ESD PREVENTION REQUIRES REMOVAL OF ALL POWER FROM THE UPS (THAT IS, INPUT, BYPASS, AND LOAD) CAUSING A LOAD INTERRUPTION. THE FOLLOWING RECOMMENDATIONS ARE MADE TO ENSURE THE BOARDS AND OTHER STATIC SENSITIVE COMPONENTS WILL NOT BE DAMAGED.

2.9.5

Procedure 1.

All static sensitive material shall be packaged in approved antistatic protective packaging.

2.

Wrist straps and grounded mats, or a grounded surface with equivalent or better ground than the surface of the mat, shall be used when handling static sensitive material. © 2006 - Eaton Corporation

2-9

Safety

9355 20 – 30 kVA

2.9.6

3.

When removing or installing boards in a unit or subassembly, a wrist strap shall be used and it shall be connected to the frame of the unit or subassembly.

4.

Rejected boards (returned to factory/rework center) equally sensitive to electrostatic discharge and shall be handled with the same protection as good/accepted boards (that is, in a static protected environment).

5.

All static sensitive devices and boards with such devices shall be stored/handled in their static protected tubes and bags that provide a complete Faraday cage. The protection for both is required at all times.

6.

All sales and field engineering personnel are required to use a portable static controlled field service kit when handling static sensitive material.

Removal of Boards

CAUTION When removing a board without pull out tabs, handle the board on the edges. Lethal voltage may be present on the traces of the board.

Use the correct removal procedure to remove all boards from the unit. If the board has pull out tabs, remove the board with the use of these tabs. For boards without pull out tabs, pull the board by grabbing the edge of the board. Do not touch any static sensitive component/device (semiconductors, film resistors, and capacitors, and so on). The following procedure provides guidelines on handling electrostatic sensitive materials.

2-10

1.

All static sensitive material shall be packaged in approved antistatic protective packaging.

2.

Wrist straps and grounded mats, or a table with a surface ground equivalent or better than that of a mat, shall be used when handling static sensitive material.

3.

When removing or installing boards in a unit or subassembly, a wrist strap shall be used and it shall be connected to the frame ground of the unit or subassembly.

4.

Rejected boards (returned to factory/rework center) are just as sensitive to electrostatic discharge and shall be handled with the same protection as good/accepted boards (that is, in a static protected environment).

5.

All static sensitive devices and boards with such devices shall be stored/handled in their static protected tubes and bags. The protection for both is required at all times.


9355 20 – 30 kVA

Safety

6.

2.9.7

All CSEs are required to use a portable static controlled field service kit when handling static sensitive material.

Packaging of Boards

NOTICE Packaging of boards, unless otherwise specified, will be packaged in egg-crate type cartons, separating each board with partitions.

2.9.8

General Handling Guidelines for ESD Protection

All printed circuit boards without static sensitive components must, as a minimum, have a pink poly wrap for static protection. Boards with semiconductor devices must be in ESD shielded bags. Boards with on-board batteries must be wrapped with pink poly (for protection against battery discharge) prior to insertion into standard shielded bags. 1.

The packing material used is designed to protect static sensitive components and assemblies from both internal and external static charge during transfer between static safe work areas.

2.

Protective bag construction must provide protection inside against static buildup from movement of devices, outside against electrostatic fields and must insulate against a direct static discharge.

3.

Resistance requirements are as follows: •

Interior (anti-static) 109 to 1014 W per square.

NOTICE The resistance will be the same for any size square. 144 x 144 x 144 will have the same resistance as a 244 x 244 x 244 square. •

Inter-layer resistance (insulating and direct discharge protection) greater than 1014 W per square.

•

Exterior resistance (conductive) less than or equal to 105 W per square.

•

Total thickness of static bags (including all layers) must be 3 MILS minimum.

•

Static bags must be sealed in some manner.


2-11

Safety

9355 20 – 30 kVA

HANDLING FLOWCHART Handling of Boards

Handling of Components

Handling for Field Engineers and Sales Personnel

| |

| |

| |

Wrist straps and grounded mats, or tables with an equivalent surface will be used when handling all static sensitive material.

Wrist straps and grounded mats, or tables with an equivalent surface will be used when handling all static sensitive material.

Dissipative mats are to be used by field engineers and sales personnel.

| |

| |

| |

Boards without static sensitive material, as a minimum, must be in pink poly wrap for protection.

All static sensitive components must arrive in antistatic tubes or shielding packages.

Field engineering personnel shall be equipped with portable static controlled field service kits.

| |

| |

| |

Boards with static sensitive material must be in static shield bags. | | All boards with on-board batteries must be placed in pink poly wrap prior to insertion in static shielding bag.

Static sensitive components shall be handled at a static safe-guard station only | | Transport static sensitive components in a static shielding bag or container.

| | Rejected boards are to be handled with the same care as accepted boards.

2-12


All other ESD procedures for boards and components will be observed by field personnel.

3 Installation and Startup 3.1 MODEL 9355 20 – 30kVA SINGLE MODULE (RT) 3.1.1

Mechanical Inspection 1.

Visually inspect the module for any shipping damage: a.

Remove the front right side door and battery dead front panels.

Figure 12. b.

Front door panel removed

If possible, remove the right side skin panel, see Figure 17.


3-1

Installation and Startup

9355 20 – 30 kVA

Figure 13. c.

Figure 14.

3-2

Right side skin panel removed

Remove bolts from the dead front panel for wiring access.

Wiring Access After Dead Front Panel Removal


9355 20 – 30 kVA


d.

Perform an external and internal inspection (no dents, paint blemishes, frame is straight).

e.

Inspect to ensure that all internal subassemblies are secure and ALL wiring connections are secure: - Check input/output connections on the I/O Board, (see Figure 71 and Figure 72). - Check K1 and K3 contactor wiring connections (see below).

Ensure wiring is secure

2.

f.

Remove the protective film from the unit front panel (use a ground strap while removing the protective film) if installed.

g.

Inspect the auxiliary cabinets for shipping damage. (transformer, battery, or other cabinets)

Visually inspect the module for proper installation: a.

Check for properly rated feeder-breaker and wire size (reference the installation and operation manual for recommended breaker and wire sizes).

b.

The UPS label matches the application (voltage, kVA, frequency, power).

c.

Ensure that the input and bypass connections are properly wired and torqued (refer to users manual).

d.

The system neutral must be supplied by the utility input power source.

CAUTION Do NOT bond neutral to ground internally in the UPS module.

3.

Verify all options are installed and wired properly: a.

X-Slot Connectivity Devices: - Connect the UPS SNMP / Web adapter © 2006 - Eaton Corporation

3-3


9355 20 – 30 kVA

- Inspect the multi-port serial card - Inspect the relay card (isolated form C contacts, AS400 type status) - Inspect the single port serial card (RS-232 and AS400 signal levels) - Inspect the USB module / card - Inspect the X-Slot modem card (either V.34 or V.90) (XSlot-1 only) b.

External Maintenance Bypass Switch (If provided)

c.

Remote Emergency Power Off (REPO)

d.

External Power Distribution (PDM module or customer provided)

e.

External Transformers (optional cabinet or customer provided)

f.

Remote Monitoring Panel (RMP)

WARNING STEP 4. CANNOT BE PERFORMED IF THE UPS INPUT IS ENERGIZED. 4.

Verify there are no installation ground faults using a properly functioning DVM (this includes the UPS module and any optional cabinets): Note: The MBS should be in the UPS position. - Neutral may have to be lifted removing the input source neutral to ground bond a.

Verify there are no faults on the main inputs, phase to phase and phase to ground

b.

Verify there are no faults on themain outputs, phase to phase and phase to ground - All readings should be 2Meg Ω or greater. - Output Phase “A” to GND should be 80 Ω

c.

Reconnect neutral if removed previously.

CAUTION The battery circuit breaker on the UPS and/or EBC must 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

3-4


9355 20 – 30 kVA


5.

6.

7.

3.1.2

Verify that the Internal and External Battery Cabinet (EBC) battery strings have been properly assembled and attached to the UPS: a.

Verify CB-2 is open.

b.

Verify Inter-tray connections (Red to Black, Black to Red) for batteries in series (use the diagram on the battery cabinet and/or the UPS).

c.

Verify inner-cabinet connections for strings in parallel.

d.

Using a DVM, verify that the polarity of all parallel strings match BEFORE making final connections.

Verify each string in the UPS, and EBC if installed. (Open cell voltage for any string should be >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


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


9355 20 – 30 kVA


- 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


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 <1VAC. - Check the voltage across the input terminal block and the output terminal block for internal MBP, it should be <1VAC - UPS output should be recorded using a scope during transfers.

b.

X-Slot connectivity \ communication options: - Refer to specific product instructions for setup and verification.

c.

Remote monitoring panels or status relays: - Refer to specific product instructions for setup and verification.

d.

Eaton - Powerware Remote Monitoring (if applicable): - Refer to specific instructions for setup and testing.

WARNING IF THE CUSTOMER’S EPO IS A BUILDING EPO AND THE UPS EPO IS CONNECTED TO THE BUILDING EPO, A BUILDING LOAD DUMP COULD OCCUR DURING UPS REPO TESTING. 3-8


9355 20 – 30 kVA


e.

Remote Emergency Power Off (REPO): - Exercised while the module is operating in NORMAL operation. - The UPS battery breaker will open. - The input contactor will open. - CB-1 will open. - The Inverter / rectifier will turn off. - After testing REPO — restart the UPS.

f.

Check building alarm inputs (if used) - After REPO the display and LEDs will sound and flash until the UPS bleeds down.


3-9


9355 20 – 30 kVA

3.2 MODEL 9355 20 – 30kVA Parallel (PC/PR)

NOTICE This process for converting a 9355 RT to a Parallel Unit is described in document #164700576.

3.2.1

Mechanical Inspection 1.

Visually inspect the module for any shipping damage: a.

Remove the front right side door and battery dead front panels.

Figure 16. b.

Remove the right side skin panel, see Figure 17.

Figure 17. c. 3-10

Front door panel removed

Right side skin panel removed

Remove bolts from the dead front panel for wiring access. © 2006 - Eaton Corporation

9355 20 – 30 kVA


Figure 18.

2.

Wiring Access After Dead Front Panel Removal

d.

Perform an external and internal inspection (no dents, paint blemishes, frame is straight).

e.

Inspect to ensure that all internal subassemblies are secure and ALL wiring connections are secure.

f.

Remove the protective film from the unit front panel (use a ground strap while removing the protective film) if installed.

g.

Inspect the auxiliary cabinets for shipping damage. (transformer, battery, or other cabinets)

Visually inspect the module for proper installation: a.

Check for properly rated feeder-breaker and wire size (reference the installation and operation manual for recommended breaker and wire sizes).

b.

The UPS label matches the application (voltage, kVA, frequency, power).

c.

Ensure that the input and bypass connections are properly wired and torqued (refer to users manual).

d.

The system neutral must be supplied by the utility input power source.

e.

Check the phase rotation on all connection points. This is extremely critical, failure to have all phase connections correct WILL result in damage to all UPMs. © 2006 - Eaton Corporation

3-11


9355 20 – 30 kVA

CAUTION Do NOT bond neutral to ground internally in the UPS module.

WARNING IF CHECKING THE ACROSS MOBS FOR PROPER PHASE ROTATION WHEN THE CUSTOMERS LOAD IS ON EXTERNAL BYPASS THERE WILL BE VOLTAGE PRESENT ON THE MOBS. CLOSING THE MOBS WILL RESULT IN THE UPM BEING BACKFED. MAINTAIN ELECTRICAL SAFETY PRECAUTIONS HIGH VOLTAGE IS PRESENT.

WARNING IF THE TERMINAL CONNECTIONS, PHASE “A”, “B”, AND “C”, ARE SWAPPED, RESULTING IN A MISMATCH IN PHASES WHEN PARALLELING, IT COULD RESULT IN DAMAGE TO ALL UPMS. SPECIAL ATTENTION SHOULD BE GIVEN TO ENSURE THE CONNECTIONS ARE CORRECT. 3.

Inspect Parallel Wiring Configuration a.

3-12

Remove the CAN Bridge card and verify jumpers are set correctly on the CAN Bridge Board in accordance with Figure 19 and re-install in each UPM. Set jumpers on first and last UPM CAN Bridge Board J7 to Pins 1 and 2. On middle UPM(s), set jumper on J7 to Pins 2 and 3. If only two UPMs are being paralleled, then both cards should be set to Pins 1 and 2.


9355 20 – 30 kVA


Figure 19. b.

CAN Bridge Board Jumper Settings

Verify all parallel control wiring is connected in accordance with Figure 20. The CAN connections should be a maximum of 18 gauge twisted pair with optional shield. It’s recommended a shielded wire bundle be used. CAN Bridge boards can be installed in X-Slot one or two. Note:

A modem card can only be used in X-Slot 1. If both a modem and CAN Bridge board are used the CAN Bridge board must go into X-Slot 2.

Figure 20.

Parallel Control Wiring


3-13


4.

9355 20 – 30 kVA

Verify all options are installed and wired properly: a.

X-Slot Connectivity Devices: -

Connect the UPS SNMP / Web adapter Inspect the multi-port serial card Inspect the relay card Inspect the single port serial card Inspect the USB module / card Inspect the X-Slot modem card (X-Slot-1 only)

b.

External Maintenance Bypass Switch (If provided)

c.

Remote Emergency Power Off (REPO)

d.

External Power Distribution (PDM module or customer provided)

e.

External Transformers (optional cabinet or customer provided)

f.

Remote Monitoring Panel (RMP)

g.

Internal MBS should always remaining the UPS position - Only operate during maintenance when the MOB is open and all parallel control wiring is disconnected.

WARNING STEP 4. CANNOT BE PERFORMED IF THE UPS INPUT IS ENERGIZED. 5.

Verify there are no installation ground faults using a properly functioning DVM (this includes the UPM and any optional cabinets): - Neutral may have to be lifted removing the input source neutral to ground bond

CAUTION If the unit has external maintenance bypass you may also have to lift the output neutral.

a.

Main inputs, phase to phase and phase to ground

b.

Main outputs, phase to phase and phase to ground - All readings should be 2Meg Ω or greater. - Output Phase “A” to GND should be 80 Ω due to the rear fan.

c.

3-14

Reconnect neutral if removed previously.


9355 20 – 30 kVA


CAUTION The battery circuit breaker on the UPM and/or EBC must 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

6.

7.

8.

Verify that the Internal and External Battery Cabinet (EBC) battery strings have been properly assembled and attached to the UPS: a.

Verify CB-2 is open.

b.

Verify Inter-tray connections (Red to Black, Black to Red) for batteries in series (use the diagram on the battery cabinet and/or the UPMs).

c.

Verify inter-cabinet connections for strings in parallel.

d.

Using a DVM verify the polarity of all parallel strings match BEFORE making final connections.

Connect the Positive (red) wire to each string from the UPM or EBC a.

Open cell voltage for any string should be >210 VDC.

b.

Verify each individual string prior to making final connections.

c.

The battery must NOT be ground referenced (either pole tied to ground).

Verify battery strings, each pole to ground < 1 VDC.


3-15


3.2.2

9355 20 – 30 kVA


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 one UPM at a time. (If dual feed also apply bypass input power). DO NOT CLOSE CB-1. Note:

The bypass control board will have power applied to it but it will not energize logic power in the remainder of the UPS. 3.

4.

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.

Using an oscilloscope or phase rotation meter, verify phase rotation at the rectifier and bypass inputs. •

3-16

Secure power to the UPM and repeat Steps 1-4 for each additional UPM.

5.

Apply utility power to all UPMs:

6.

Perform steps 7 through 11 on one UPM at-a-time ensuring that the previous UPM is off before starting the next UPM.

7.

Close CB-1; the following will occur: a.

Alarm will sound (press any key to silence)

b.

Alarm light is lit

c.

“UPS status = OFF” on the UPS status screen

d.

“BATTERIES DISCONNECTED” appears on the UPS battery status screen

e.

Within 30 seconds K-5 will close with an audible “click.” © 2006 - Eaton Corporation

9355 20 – 30 kVA


8.

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

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 21.

XCP Tool Battery Toggle Positions

To clear the setup required bit: - 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, 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 © 2006 - Eaton Corporation

3-17


9.

9355 20 – 30 kVA

Confirm the status of the following indicators: a.

The LCD display indicates the following active event messages: - Batteries Disconnected

b.

The ALARM LED is lit.

c.

The alarm was previously silenced when acknowledged in previous step 7a.

10. 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

11. Set up Parallel System (you cannot have the same UPM ID on multiple UPMs) a.

Using the XCP Service Tool Option (IF THIS OPTION IS USED YOU DO NOT NEED TO PERFORM THE FRONT DISPLAY OPTION) Connect to each UPM and on the PCB Tab select - UPM ID = Unit #1, Unit #2, Unit #3 or Unit #4 - Slide bar to Parallel Redundant or Parallel Capacity (Must be the same for all UPMs)

b.

Using the Front Display Option (IF THIS OPTION IS USED YOU DO NOT NEED TO PERFORM THE XCP SERVICE TOOL OPTION) - On the XCP Service Tool Options Tab enable the service menu option. - For each UPM select ID number in parallel system: UPM #1, UPM #2, UPM #3 or UPM #4. Select: SETTINGS -> 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.

3-18


9355 20 – 30 kVA

3.2.3


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 <1VAC. - UPS output should be recorded using a scope during transfers.

b.

Test MBP/Tie Cabinet AUX contents: © 2006 - Eaton Corporation

3-19


9355 20 – 30 kVA

c.

With UPMs in NORMAL, close the external MBS UPMs should go to BYPASS Open MBS UPMs should go back to NORMAL

X-Slot connectivity \ communication options: - Refer to specific product instructions for setup and verification.

d.

Remote monitoring panels or status relays: - Refer to specific product instructions for setup and verification.

e.

Eaton - Powerware Remote Monitoring (if applicable): - Refer to specific instructions for setup and testing.

WARNING IF THE CUSTOMER’S EPO IS A BUILDING EPO AND THE UPS EPO IS CONNECTED TO THE BUILDING EPO, A BUILDING LOAD DUMP COULD OCCUR DURING UPM REPO TESTING. f.

Remote Emergency Power Off (REPO):

Note: Unless all REPOs are paralleled only one UPM will shut down. If UPMs are paralleled, all UPMs will shut down. - Exercised while the module is operating in NORMAL operation. - The UPM battery breaker will open. - The input contactor (K-1) and out (K-3) will open. - CB-1 will open (and CB-3 if installed). - The inverter / rectifier will turn off. - After testing REPO — restart the UPM. Note: UPMs will alarm and turn completely off after the capacitors are drained. g.

Check building alarm inputs (if used) - After REPO the display and LEDs will sound and flash until the UPS bleeds down.

3-20


9355 20 – 30 kVA

3.2.4


Inspection Completion 1.

Temporarily apply the customer’s load, if available, or load bank to the system and using a DVM verify all measured values against the values that are displayed by both the unit front panel and the XCP Service Software Tool meters tab. a.

Use the provided work sheet as needed.

b.

Perform calibration of those parameters that are outside of tolerances. (Refer to Chapter 8 for calibrations)

c.

Shut down the unit, reinstall all panels and restore unit to normal condition.

d.

Restart the unit and place it online.

e.

With the XCP Service Tool enable battery commissioning.

Note: Do not cycle logic power after the battery commissioning button is selected (it will reset it). 2.

Unit Data and Customer Reports

3.

Download Setup Values

4.

a.

Download Unit History

b.

Download Alarm / Event Nodes (if applicable)

Installation Acceptance Completion: a.

Conduct unit operation training for the customer.

b.

If logic power cycles before battery testing, battery commissioning must be re-enabled.

c.

Provide a signed copy of the installation and startup check sheet and a hardcopy of the unit setup values to the customer.


3-21


9355 20 – 30 kVA

Installation and Startup CHECKsheet (the linked CD MSWord form can be filled-out and saved) Powerware® 9355 (20 - 30 kVA) 1.

Apply customers load before final readings / measurements

2.

Using a DVM verify all measurements and readings are within 1%

3.

Make copies of this worksheet and fill one out for each UPM.

Single Module (RT) Parallel Redundant / Capacity

UPM#

SN

IP Address

Location

Recorded Values

Expected

AC VOLTAGE MEASUREMENTS Measured

XCP Tool

A-B

V

B-C

V

A-C

V

(L1 = Phase “A”)

A-N

V

V

(L2 = Phase “B”)

B-N

V

(L3 = Phase “C”)

C-N

V

(N = Neutral)

A-G

V

(G = Ground)

B-G

V

C-G

V

Neutral to Ground

N-G

V

UPS Output

A-B

V

B-C

V

C-A

V

A-N

V

V

(L2 = Phase “B”)

B-N

V

(L3 = Phase “C”)

C-N

V

(N = Neutral)

A-G

V

(G = Ground)

B-G

V

C-G

V

Input

3-22

LCD V V V V

OK(√ ) 208

400

208

400

208

400

V

120

230

V

V

120

230

V

V

120

230

120

230

120

230

120

230

V V V V V V V V V V

<5 208

400

208

400

208

400

V

120

230

V

V

120

230

V

V

120

230

120

230

120

230

120

230

V V V V


9355 20 – 30 kVA


AC CURRENT MEASUREMENTS Location

Recorded Values Measured

XCP Tool

OK (√ )

LCD

UPS Input (L1)

ØA

A

A

A

UPS Input (L2)

ØB

A

A

A

UPS Input (L3)

ØC

A

A

A

UPS Input (L1)

ØA

A

A

A

UPS Input (L2)

ØB

A

A

A

UPS Input (L3)

ØC

A

A

A

DC MEASUREMENTS Location


XCP Tool

LCD

DC Link Voltage

VDC

V

V

V

Battery Voltage

VDC

V

V

V

Battery Current

ADC

A

A

A

%

%

Expected Values

OK (√ )

% Batt. Time Remaining

Mins.

Battery Charge Level

%

POWER Location


Input Power

XCP Tool

LCD

OK (√ )

kVA KW Hz PF

Output Power

kVA KW Hz PF


3-23


9355 20 – 30 kVA

Powerware® 9355 (20 - 30 kVA) Single Module (RT) Parallel Redundant / Capacity DATE: CUSTOMER SITE

PHONE

UPS

S/N:

REQUEST/ORD

CTO

Installation Inspection

OK

Mechanical Inspection

OK


OK

Operational Inspection

OK

Environmental Evaluation

OK

Installation Notes / Comments / Recommendations:

CUSTOMER ACCEPTANCE:

SERVICE REPRESENTATIVE:

DATE:

CUSTOMER SIGNATURE: DATE:

3-24


4 Functional Descriptions This chapter provides a functional description for the Powerware® 9355 20kVA to 30 kVA power train and the printed circuit boards.

4.1 Model 9355 20 – 30kVA 4.1.1

Overview

Reference Documents: 110720639 Electronics Module Schematic in the Prints chapter at the end of this document. The power-train topology is common among all 9355 UPS models and is developed using common control and display boards. The three phase low volt Electronics Module (EM) contains the I/O, EMI, control, bypass and power module boards. The I/O board provides interconnections to the control board. The power module boards contain the system power-train components. The control board contains the microprocessor and controls the entire UPS. The EMI Board handles surge protection and EMI.


4-1

Functional Descriptions

4.1.2

9355 20 – 30 kVA

X-Slot Connections X-Slot One

X-Slot Two

Reference Designator

Description


Description

X55-1

GND

X55-1

GND

X55-2

GND

X55-2

GND

X55-3

GND

X55-3

GND

X55-4

GND

X55-4

GND

X55-5

PAR RED1

X55-5

PAR RED1

X55-6

TX

X55-6

TX

X55-7

PAR RED2

X55-7

PAR RED2

X55-8

RX

X55-8

RX

X55-9

K3 DRV

X55-9

K3 DRV

X55-10

K1 DRV

X55-10

K1 DRV

X55-11

GND

X55-11

GND

X55-12

DTR

X55-12

DTR

X55-13

GND

X55-13

GND

X55-14

K4 DRV

X55-14

K4 DRV

X55-15

CAN HI

X55-15

CAN HI

X55-16

K2 DRV

X55-16

K2 DRV

X55-17

NC

X55-17

NC

X55-18

+12VDC

X55-18

+12VDC

X55-19

CAN LO

X55-19

CAN LO

X55-20

+12VDC

X55-20

+12VDC

4.1.3

Native RS Port Reference Designator

Description

X53-1

DCD

X53-2

RXD

X53-3

TXD

X53-4

DTR

X53-5

GND

X53-6

DSR

X53-7

RTS

X53-8

CTS

X53-9

4-2


9355 20 – 30 kVA


4.2 Electronics Module Functional Sections 4.2.1

Display Panel

Refer to paragraph 4.3 Display Panel. The Display Panel is the user interface. It has an LCD for displaying system information and buttons for navigating through the menus. The Display Board communicates with the control board over the CAN network via a PIC18F448 Micro Controller and provides the user interface.

4.2.2

Control Board

Refer to paragraph 4.4 Control Board. The Control Board contains the DSP micro-controllers and is responsible for overall operation of the UPS except for certain bypass functions. The Control Board contains a Texas Instruments (TI) TMS320F2812A Digital Signal Processor (DSP). The 150 MIPS TI DSP provides software functionality, that is: analog sensing, digital signal sampling, power-train control including Pulse Width Modulated gate signals, serial communications, serial EEPROM, and a CAN 2.0B network.

4.2.3

Power Module Boards

Refer to paragraph 4.5 PW9355 Power Board. The Power Board Assembly (1024049) contains IGBT modules for the converters, IGBT gate drives, and for additional sensing.

4.2.4

Bypass Control Board

Refer to paragraph 4.13 PW9355 Bypass Control Board. The Bypass Board Assembly (1024057) provides self-contained bypass functionality and provides external interfaces to the customer.

4.2.5

I/O Board

Refer to paragraph 4.2.5 1.X PW9355 I/O Board. The IO Board Assembly (1024053) handles IO. It controls the rectifier and inverter contactors as well as tripping the circuit breakers. The I/O Board also provides interconnect to the Control Board.

4.2.6

EMI / Surge Board

Refer to paragraph 4.2.6 EMI Board. The Electro-Magnetic Interference (EMI) Board provides input filtering and surge protection for the UPS.


4-3


4.2.7

9355 20 – 30 kVA

Contactors

The Rectifier Input Contactor K1 provides: •

Input protection to the rectifier.

Inverter Output Contactor K3 provides: •

inverter isolation when open.

Bypass Back-feed Contactor K5 provides: •

Back-feed protection when open.

The control for each contactor is: •

K1 (24VDC signal from a connection to the I/O board at X27-1 and X27-3)

•

K3 (24VDC signal from a connection to the I/O board at X21-1 and X21-3)

•

K5 (24VDC signal from a connection to the Bypass board at X51-1 and X51-3)

4.2.8

Internal Battery

The system can be configured with up to six (6) strings of batteries. Each string is eighteen (18) 12V batteries connected in series. The strings are then connected in parallel on a connection board located behind the battery breaker.

4.2.9

External Battery

The external battery has the positive connection to the circuit breaker line side along with the internal batteries. The negative connection is to the load side of the breaker. This ensures that all wiring is protected by circuit breakers and that accessible terminals are disconnected when the breakers are tripped.

4.2.10

Battery Circuit Breaker

The battery circuit breaker is a magnetic type with a DCV rating of 300V including a trip coil (24V) and an auxiliary contact, both on the same circuit. The coil voltage must be removed after tripping the breaker or it is possible to damage the trip coil. The I/O board provides the signal for tripping the circuit breaker from the X50 connector. Embedded software determines when the breaker shall be tripped; otherwise, when the current through the breaker exceeds the breaker rating the breaker will trip.

4.2.11

Ferrite Toroids

PW9355 Ferrite Toroids There are several Ferrite Toroids throughout the 9355 UPS system. Used as transformers in main power supplies, toroidal coils reduce resistance, due to the larger diameter and smaller number of windings. The magnetic flux in the toroids is confined to the core, preventing its energy from being absorbed by nearby objects. 4-4


9355 20 – 30 kVA

4.2.12


Chokes

The following is a list of PW9355 Chokes:

4.2.13

•

Battery Chokes: L2, L5, L8

•

Inverter Chokes: L3, L6, L9

•

Rectifier Chokes: L1, L4, L7

Fans

The PW9355 UPS has six (6) vane axial fans rated at 120VAC/110CFM. The fans are housed in the fan assembly. Table 2. Fan Assembly Iteration with Associated Serial Numbers 9355 20-30 kVA Fan Assembly Evolution

Associated Serial Numbers

old fan assemblies and old switchgear

EY213KXX07 and lower last digit

"new fan assembly" and "new switchgear"

EY213KXX08 and higher last digit

4.3 LCD Display Panel

Figure 22.

4.3.1

Display Panel

Overview

This section describes the functionality of the PW9355 display firmware and the basic principles of operation. The PW9355 display module has four push buttons, four light-emitting diodes (LEDs), a buzzer and a graphical Liquid Crystal Display (LCD). These are controlled by a micro-controller (PIC) which communicates with the main processor (DSP) using the Controller Area Network (CAN) bus. Refer to © 2006 - Eaton Corporation

4-5


9355 20 – 30 kVA

paragraph paragraph 6.1.9 CAN Bridge Card and Figure 53 for more information about the Controller Area Network. Character images are stored to the PIC flash memory. The PIC provides the time-bases for LED flashing and buzzer control. The PIC also takes care of low-level LCD handling.

4.3.2

Detailed Description of Settings

Refer to the details of the user settings that are listed in the 9355 UPS User’s Guide. CSEs have access to these settings as well as the CSE Service Settings.

4.3.3

User Settings

For details of the User Settings, refer to the user setting information that is listed in the 9355 UPS User’s Guide. Table 3. Disable control commands via communication user settings Front Panel LCD User Setting

Setting Definition

To disable all control commands from a communication channel. The setting is done independently per channel.

The control commands are all XCP commands that change/modify any parameters, variables, UPS operation, and so on in the UPS; or hardware commands that are multiplexed to communication receive lines, thus simulating a long break.

Display Contrast Adjustment

The user can adjust the best LCD display contrast for the environment.

Change Language

The language selection is between English and other languages.

Start Screen in the Display

The default screen: Eaton Powerware logo or the mimic screen. This screen is displayed at reset, when ESC is pushed until the system menu returns to the top, or when the display has been untouched for a specific time period.

User Settings Password

Sets if the password is required for user settings.

Lock Communication to D-Sub

Disables the automatic multiplexing of communication channel 2 between the X-Slot 2 and the D-sub, and directs the communication to D-sub permanently.

Table 4. Disable control commands via communication user settings Front Panel LCD User Setting (or XCP command)

Setting Definition

Set Date & Time

The date and time is used for time-stamping the history log items.

Serial Port Configuration

The available speeds are 1200bps, 2400bps, 9600bps, and 19200bps, which are set independently per communication channel.

Go to Bypass

The transfer is done only if bypass is available.

4-6


9355 20 – 30 kVA



Setting Definition

Battery Test Command

When the test is launched with the XCP command, the test duration is given in the command. The test selected from the LCD has fixed time. The following is a sample of a Battery Commissioning Test using command B.: BATTERY COMMISSIONING TEST BATTERY TEST # 1 TIME: 12:31:30 DATE: 11/14/2004 TEST 1 NOT COMPLETED VOLTAGE 0.00 POWER (W/CELL) 0.00 TEST 2 NOT COMPLETED VOLTAGE 0.00 POWER (W/CELL) 0.00 OPEN CIRCUIT VOLTAGE 0.00 CALCULATED RESISTANCE 0.0000 BATTERY HEALTH 0.0000

Audible Alarms

The settings are: Disable audible alarms and normal sound.

Set Nominal Output Voltage

With XCP, the value can be set with 0.1V steps. The front panel setting has larger steps. Changing this value will automatically change the voltage window defined by Bypass Voltage High Limit and Bypass Voltage Low Limit.

Bypass Voltage High Limit

The value is a positive percentage added to Nominal Output Voltage, and it follows changes automatically in the Nominal Output Voltage setting. It can be set with 1% steps, for example: +10%.

Bypass Voltage Low Limit

The value is a negative percentage subtracted from Nominal Output Voltage, and it automatically follows changes in the Nominal Output Voltage setting. It can be set with 1% steps. Example: -15%.

Synchronization Window

The value can be set with ±0.1Hz steps. This sets the frequency window used for synchronization around the Nominal Output Frequency, and it automatically follows changes in the Nominal Output Frequency setting.

Number of Battery Strings

Zero (0) means that no batteries are connected. Total battery size is number_of_strings × W/cells × cells/strings. (W/cell, 15 min rate to 1.67 VPC at 25° C)

Battery Size Setting

The size is given as Watts per battery cell, in 1W steps. Total battery size is number_of_strings × W/cells × cells/strings. (W/cell, 15 min rate to 1.67 VPC at 25° C)

Battery Low Alarm Level

The maximum current used for charging the batteries is set with this setting, in 0.1A steps.

Automatic On Delay

Values 0 ... 32767 define the extra delay in seconds, which is counted down every time the UPS is about to © 2006 - Eaton Corporation

4-7


9355 20 – 30 kVA


Setting Definition turn on its output. With value -1, the automatic restarts are disabled; the UPS will not turn on automatically (uncommanded) after low battery shutdown.

Nominal Output Frequency

With an XCP command, the nominal output frequency can be set with 0.001Hz steps (the front panel has larger steps). Changing this value will move the Synchronization window in accord with it.

ABM Charging Cycling Disable

Disables the cyclic ABM charging and uses the continuous mode.

Output Frequency Slew Rate

The maximum speed of changing the output frequency that the UPS uses while synchronizing or maintaining synchronization; set with 0.1Hz/sec steps.

Operation Priority While Rectifier Input Break

This selects if the UPS will prefer bypass operation to battery operation when rectifier input fails, and bypass is available.

Rectifier Current Limit

The maximum current drawn from utility by the rectifier is set here, in 0.1A steps.

Alarm Relay Configuration

For each alarm, the user selects the relay to activate.

Signal Inputs Function

For each alarm input, the user selects the function.

Input Signal Delayed Shutdown Delay

This is the delay for hardware Remote off with automatic restart command. Factory setting is 120 sec, but the user may modify it.

X-Slot Shutdown Signal Input Activation Delay

This is the delay duration the X-Slot hardware shutdown signal (connector pin 8) must be below before the associated function is activated. Factory setting is 5 sec.

Unsynchronized Transfer to Bypass

This selects if synchronization is required for making transfers to bypass.

Synchronization to Bypass

This selects if the synchronization to bypass is done.

Usage of Bypass

This selects if the bypass is used (enabled) when needed / required, or if it is never used (disabled).

Site Wiring Fault (NOTICE)

The user can enable or disable this alarm. When set as ”Disabled”, no alarm nor notice is given on the front panel. Nothing is logged into the history log. When set as ”Enabled”, the factory setting is used, alarm activation and inactivation are logged. Note: With Nodebits (service setting) it is possible to make a more detailed setting. The user setting (front panel) shows as ”Disabled” when set as event and not logged. Otherwise, the user setting shows as ”Enabled”.

4-8


9355 20 – 30 kVA

4.3.4


Service Settings

The following Service Settings are available to the CSEs for troubleshooting. In addition, CSEs have access to the User Settings that are listed in paragraph 4.3.3. For details of the User Settings, refer to the user setting information that is listed in the 9355 UPS User’s Guide. The default access to Service Settings on the LCD Display in PW9355 for the U.S. and Canada will be disabled. In other overseas markets the Service access will be enabled. Table 5. Service Settings Front Panel LCD User Setting (or XCP command)

Setting Definition

Service Control

This is an implementation defined parameter, which allows service to do special hardware controlling

Rectifier Synchronization Window

This setting defines the rectifier input frequency window that is used for synchronization when the bypass voltage has failed.

Auto Frequency Detection Back-feed Enable Battery Charging Temperature Compensation

This setting defines the number of battery cells in a battery string.

On Battery Alarm Delay

This setting defines the number of seconds the UPS is on battery operation before ”UPS on battery” alarm is given.

Battery Test Schedule EPO Disable

This setting disables/enables the Emergency Power Off signal and functions.

Modem Communication

Define the communication channel where the modem is connected. A value of zero (0) means that no modem is connected.

Modem Call Number Setting

This string is sent to the modem when a call is initiated. It holds the call command and the phone number to dial.

Modem Initialization String

This string is used when the modem is to be initialized.

Modem Communication Password

This string defines the password that is required when someone tries to change the UPS configuration or control the UPS through a modem line.

Modem Hang Up String

This string is used to hang up (disconnect) the modem/phone line.

Set Modem Call Command Set Modem Call Events Adjust Events Reset Custom Event Settings Adjust Parameters Reset Configuration to Factory Setting

With this setting it is possible to reset most of the UPS configuration to the factory settings.


4-9


9355 20 – 30 kVA

Table 5. Service Settings Front Panel LCD User Setting (or XCP command)

Setting Definition

Clear History Log

With this setting it is possible to reset the UPS event history log.

Constant Float Voltage

This setting defines the battery charging voltage (volts per cell) when ABM charging cycles are disabled.

Nodebits

Service setting. Each event can be configured several different ways. An alarm, notice, or non-alarming event Logged into the event log or not Cause a modem call Cause an audible alarm

4-10


9355 20 – 30 kVA


4.4 CONTROL BOARD (PCB) Reference Documents: 1021280 Control Board Schematic

Figure 23.

4.4.1

9355 Control Board

Firmware Description and Operation

Refer to Figure 24 Control Board Machine States The 9355 has the following operation states: Shutdown - Shutdown commanded from the display or the rails can’t be powered. The load is powered-up after the UPS is commanded from the display, or the load is on bypass and the UPS is waiting until conditions accomodate transfer to normal mode. The X-Slots are not powered. Startup - The unit performs startup-steps to power up rails. The X-Slots are not powered. Standby - The inverter is ready to feed the load. The X-Slots are powered. The XCP tool can be used to power-up the load. On Inverter - The load is fed by the inverter. Energy is taken from the utility and/or from the batteries. The X-Slots are powered. On Bypass - The load is fed through the bypass line. Energy for the load is taken from the bypass/utility, but battery energy may be used for UPS testing and for other internal purposes. The X-Slots are powered, the ABF relay is closed, and the rails cannot be bled down. Bleeding – UPS performs full shutdown. The DC bus is drained. Bleeding cannot be called if the unit is on bypass. The X-Slots are disabled. Bypass-Locked - The load is on bypass. The UPS is internally shut down and will automatically restart when utility power returns. This is done during flash recovery. © 2006 - Eaton Corporation

4-11


9355 20 – 30 kVA

Failure Shutdown – There is an active alarm that prevents UPS startup. It is possible to clear this alarm by starting the UPS from the display. The X-Slots are powered during this state.

Shutdown Bypass-

locked

Failure shutdown

Startup Bleeding

On bypass

Standby

On inverter

Figure 24.

4.4.2

9355 Control Board Machine States

Shutdown State

The load is down. The X-Slots are not powered. The only way to restart the UPS is to use the front panel “UPS On” function. If auxiliary power goes active while startup is not possible, the unit stays in the shutdown state. If auxiliary power goes active while the load is on bypass and startup is not possible, the unit waits until startup is possible and transfers the load to the inverter.

4.4.2.1

4-12

User Interface & XCP

•

XCP status = UPS OFF

•

XCP status = ON BYPASS


9355 20 – 30 kVA


4.4.2.2

Initialization

4.4.2.3

Hardware

•

Bypass off

•

Inverter thyristors off

•

X-Slots are off

4.4.2.4 •

Other

None

4.4.2.5

4.4.3

Operation 1.

Wait for front panel UPS on command.

2.

Wait for good startup conditions and change the state to start-up state if the load was on bypass when start-up state was called.

Startup State

The UPS is performing its start-up sequence and automatically progressing toward standby operation or “load on inverter” operation. The load can be on bypass if commanded. The X-Slots are not powered up. The UPS powers up the DC bus. Rectifier, inverter and battery operations start.

4.4.3.1


•


•


4.4.3.2

Operation

4.4.3.3

Initializing State

This state is always called before shutdown state. Some startup procedures are executed here. The next state is utility startup, battery startup or shutdown depending on the conditions. 1.

Disable EPO, disregard all measurements as X-Slot and other measurements are taken from the Control Board signals, with the exception of 24V measurement.

2.

Check that the unit is 9355, that the Control Board is supported and the PLD version is known. If not, set the software incompatibility detected alarm and jump to failure shutdown state.

3.

Wait until the 24V measurement is higher than 17V; if not registering higher than 17V after 6 seconds, set the auxiliary power startup failure alarm, and jump to failure shutdown state.

4.

Wait for correct bypass status information. © 2006 - Eaton Corporation

4-13


9355 20 – 30 kVA

5.

Initialize bypass signals.

6.

Activate I/O_GOOD (Control board logic good).

7.

Set bypass to Idle state if fire state is not detected.

8.

Turn on PWRCLK0 (Gate power clock).

9.

Turn on PWRCLK1 (Aux. power clock).

10. Turn on 12V_1 (Main circuit +12V). 11. Wait 500ms. 12. Reset the auxiliary voltage monitoring alarms in PLD. 13. Wait 400ms. 14. Enable the meters. 15. Wait 100ms. 16. Initialize slow utility measurements to fast measurement values. 17. Reset CLK_FAIL and EPO alarms. 18. Wait 1 second. 19. Enable auxiliary voltage alarm monitoring. 20. Wait 1 second to settle filtered measurements. 21. Check 12V, continue monitoring. If ok, all measurements and monitoring signals are functioning now. 22. Clear auxiliary power startup failure, the back-feed failure, the abnormal output voltage alarm, the bypass SCR failure, the DC charger failure, the balancer relay failure, the rectifier failure, the inverter startup failure, the fuse failure, and the DCOV and DCUV alarms. 23. Initialize rectifier control values. 24. Start monitoring temperature alarms, building alarms, voltages, and so on. 25. Auto zero Hall Sensor offsets. Inverter and rectifier sensors are zeroed. 26. If utility startup is possible, perform utility startup. 27. If battery startup is possible, perform battery startup, otherwise shutdown.

4.4.3.4

Shutdown State 1.

Wait for the front panel UPS ON command. OR

1.

4-14

Wait for the proper startup conditions when the load is on bypass.


9355 20 – 30 kVA


2.

4.4.4

Prepare to lose auxiliary power and jump back to the initializing state if the utility fails.

Battery Starting State 1.

Clear the old EPO alarm.

2.

Activate the EPO.

3.

Close the balancer relay.

4.

Wait 60ms.

5.

Activate GATE_ENABLE and the PLD gate outputs.

6.

Use the input phase 1 lower IGBT to transfer energy from negative rail to positive rail in order to keep auxiliary power up and running.

7.

Wait for the front panel ON command or utility voltage before continuing. If nothing happens in 3 minutes, open the battery breaker. Jump to utility startup if utility voltage is good.

8.

Wait 500ms.

9.

If not in parallel mode, bypass is not active and the output voltage is > 50V, then set the abnormal output voltage alarm, open the battery breaker and jump to the bleeding state.

10. If bypass is not active and the bypass voltage is > 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

4-15


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.


9355 20 – 30 kVA


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

4-17


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.

4-18


9355 20 – 30 kVA

4.4.7


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 (<100 V)

0ms

Inverter output fuse failure

0ms

Any phase of utility > 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

4-19


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

•


•

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.

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9355 20 – 30 kVA


4.4.9.1


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


ABC

60 seconds


4-21


9355 20 – 30 kVA

Table 7. Conditions Prompting an Output Shutdown Conditions Requesting Transfer to ON Bypass




ABC

5 seconds


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 (<100 V)

AB

0ms

DC bus over 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



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


9355 20 – 30 kVA


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


Rectifier over temperature shutdown Inverter over temperature alarm


Inverter over temperature shutdown DC bus over voltage (>250 V) DC bus very low voltage (<100 V) Auxiliary power failure Balancer over temperature Temperature sensor failure Battery under voltage


Inverter inhibit


Inverter not synchronized to bypass


Inverter output out of window CAN bus transfer command (used in paralleling) Redundant transfer command (used in paralleling) * The condition prevents ”soft” transfers only. ”Hard” transfers (bypass failures) are allowed

It is possible that the load is on bypass, on shutdown, startup, the bleeding and bypass-locked states. Transfer to inverter is never possible in these states.


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9355 20 – 30 kVA

The following table shows conditions that prevent using bypass. Any of these will cause immediate transfer to the inverter, if possible. Table 10. Conditions Forcing Hard Transfer From Bypass to Inverter Bypass voltage < U out – 15% (fast ”one cycle” meter) Bypass 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

•


4.4.10.2 Initialization 4.4.10.3 Hardware •

Bypass on

•


•

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


9355 20 – 30 kVA


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 •



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


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.

4-26


9355 20 – 30 kVA

4.4.13


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 •


•



Bypass 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


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


9355 20 – 30 kVA


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.


4-29


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.

4-30


9355 20 – 30 kVA


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.


4-31


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


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


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


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


9355 20 – 30 kVA


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).


4-35


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


9355 20 – 30 kVA


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.


4-37


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 <10days batRestFailT batStartChrgV 2.00V batTestMinV 1.90V batDCUVLogicPwrV 1.80V batDCUV 1.75V

24Hrs batSupTestT

batAbsDCUV 1.56V

100Hrs max

48Hrs +

28 days

batFloatT + batFloatTExt batChargeT batMaxRestT batChrgRefV 2.39V Shoot for target when starting charge mode. BTR = Battery Time Remaining batChargeV 2.34V Stop at voltage to begin ABM float charge. ABM Float charge level. batEqualizeV 2.30V batConstFloatV 2.30V ABM is DISABLED - Constant Float charge level. batOpChrgV 2.10V Starts charger if volt level is reached in <10days of rest mode. batOCV 2.07V For BTR, only used prior to a commissioning test. batStartChrgV 2.00V For BTR, to determine the state of charge on battery. batTestMinV 1.83V If reached during battery test - cancels the test. batDCUVLogicPwrV 1.80V ACTIVE only after load loss when on battery, shuts logic power off & opens battery breaker. batDCUV 1.75V DCUV level during battery mode, ”low battery shutdown alarm, logic power on only, starts 2 min. timer. batAbsDCUV 1.67V Absolute DCUV if reached prior to end of 2 min. timer.

Figure 26.

4.7.4.1

Typical Battery Charging Cycle

Charge Mode

XCP Battery data block reports ABM status: charging. When a battery is being charged, it is charged at the batChrgI constant current rate until it reaches a set voltage (batChargeV). The charging cycle is then changed to float mode. While charging the battery voltage, the charger voltage reference is set to batChrgRefV, which prevents excessive battery voltage in the event of faulty battery voltage measurement. The charge mode duration is measured and stored in UPS internal variable batChargeT. This data is used to determine the value of batFloatTExt.

4-38


9355 20 – 30 kVA


4.7.4.2

Float Mode

XCP Battery data block reports ABM status: floating. At initialization of float mode the value for batFloatTExt is calculated: •

batFloatTExt = 1.5 × batChargeT

The battery voltage is kept at constant voltage batEqualizeV for time (batFloatTExt + batFloatT). Automatic Battery Support test (batSuppTestV) is done 24 hours after float mode begins.

4.7.4.3

Rest Mode

XCP Battery data block reports ABM status: resting. The battery is effectively disconnected from the UPS. The rest mode lasts until: •

time defined by batMaxRestT has expired.

•

the value of batDischT exceeds batMinDischT.

•

the battery voltage has dropped below level batOpChrgV.

4.7.5

Temperature Compensation

4.7.5.1

Introduction

Battery temperature variation is compensated for by modifying battery-charging voltage. In ABM charge and float modes, and when ABM charging cycles are disabled, the charger voltage reference is adjusted according to the highest battery temperature measurement. The adjusted values are: •

BattChargeV—the level where charge mode changes to float mode.

•

BattEqualizeV—ABM cycling float mode voltage.

•

BattConstFloatV—used ABM charging cycles are disabled by user setting.

BattChrgRefV is adjusted. This is the voltage reference value for the charger while in charge mode. If an ABM charging scheme is working properly this reference limit is never reached, but has changed to float mode at BattChargeV. The values are adjusted in temperature ranges from 0ºC to 50ºC. Outside of these limits, the values stay the same.


4-39


4.7.5.2

9355 20 – 30 kVA

Algorithm

The compensation temperature range is from 0ºC to 50ºC, the voltage per cell is decreased 3 mV for each ºC. The EEPROM values mean the voltage levels at 25ºC. The charger values uses the following algorithm:

value (T ) = eeprom _ value − 3mV × (T − 25°C ) T = battery temperature Under 0ºC, value (0ºC) is used. Above 50ºC, value (50ºC) is used.

NOTICE IEEE optimum temperature for battery life is 25ºC (77ºF). Example Using default values for the settings, the voltage values at some temperatures are: Charging Voltage – Volts Per Cell Parameter

ºC

10ºC

25ºC

40ºC

50ºC

BattEqualizeV

2.380

2.350

2.305

2.260

2.230

BattChargeV

2.410

2.380

2.335

2.290

2.260

BattChrgRefV

2.460

2.430

2.385

2.340

2.310

BattConstFloatV

2.345

2.315

2.270

2.225

2.195

•

BattChargeV = BattEqualizeV + 0.03 VPC

•

BattChrgRefV = BattEqualizeV + 0.08 VPC

4.7.5.3

Disabled or Impossible Compensation

The temperature compensation can be disabled using a user setting. In this case, the EEPROM values (compensation values at 25ºC) are used directly. Also, when the battery temperature measurement is not available, 25ºC is assumed.

4.7.6

Forcing on Rest Mode

There is an internal flag, ForceRestMode, which disables battery charging. For example, one of the building inputs in the unit can be directed to this flag. When active, batteries are discharged when needed, but otherwise the flag forces the ABM rest mode. The original mode is resumed when the ForceRestMode flag becomes inactive. While forced on rest mode, battery failure testing/monitoring is not done. While the ForceRestMode flag is active, discharging time (batDischT) is monitored normally. If it exceeds batMinDischT, then a new charging cycle is initiated when the ForceRestMode flag becomes inactive. 4-40


9355 20 – 30 kVA


This flag also works when the ABM charging cycles are disabled by the user. When active, the charging is disabled (rest mode is forced). When the flag becomes inactive, continuous-float charging is resumed.

4.7.7

User Disabling of ABM Charging Cycles

The user has the option of disabling the charging cycles and to select a continuous charging scheme. Cycling enabled is the factory default setting. When batteries are not discharging, the charger functions to keep batteries at a constant voltage, defined by batConstFloatV. Although batteries are charged constantly, the UPS keeps the normal ABM timer running. The operation is very similar to normal ABM cycling: 1.

Charge mode begins when - the cumulative discharging time (batDischT) exceeds batMinDischT OR - when time batFloatTExt + batFloatT + batMaxRestT has gone since the last charge mode.

2.

Charge mode changes to float mode at batChargeV.

3.

The external battery charger is controlled just as with normal ABM cycling: during charge mode and during float time extension, batFloatTExt.

4.

Battery support tests are done normally, at a point defined by batSuppTestT, just as though cycling was enabled.

5.

While in float mode, the battery voltage is kept at constant voltage, defined by batEqualizeV.

6.

Rest mode is never entered, but float mode is continued over the batMaxRestT time at the batConstFloatV, except when ABM forced rest mode is initiated.

The differences to ABM cycling are: •

Float voltage is lower, batConstFloatV.

•

There is no rest mode; float mode continues until cumulative discharging time (batDischT) exceeds batMinDischT, or batMaxRestT time has gone.

•

Battery testing/monitoring is reduced: open cell voltage monitoring test is not done.

•

The charge failure test measures charge mode time. This test is done normally, the only difference being a lower float mode voltage level.

•

As the ABM cycling timing is internally running, the battery support test is done normally, just as when cycling was enabled.

•

The ABM status is reported normally, charge or float. (including rest mode when in forced rest mode). © 2006 - Eaton Corporation

4-41


•

4.7.8

9355 20 – 30 kVA

The external battery charger is controlled just as with normal ABM cycling: during charge mode and during float time extension, batFloatTExt.

Battery Failure Testing

Several battery tests are performed to try and determine the overall usability of the attached batteries, and to try and detect when the attached batteries will no longer provide adequate discharge time. Specific tests are performed to detect failed batteries and to detect battery end-of-life. The tests that are covered in this section are: •

Battery test / Commissioning test (user initiated)

•

Detection of failed (shorted) cell(s) caused by failure to reach float voltage

•

Detection of failed (shorted) cell(s) caused by a rapid drop of open cell voltage in rest mode

•

Detection of loss of capacity caused by failing to maintain cell voltage under load.

4.7.8.1

Battery test / Commissioning test

The battery test and battery commissioning test are almost identical, but the commissioning test is performed: •

the first time the unit batteries are initially charged for 24 hours,

•

whenever the batteries are replaced,

•

and whenever batteries are added or removed.

The results of this test are stored in EEPROM and are the baseline for subsequent battery tests. The test consists of taking data when the UPS is at 2 levels, typically at 25% load and at 100% load. This topology is accomplished by running the rectifier and battery converter at the same time (Power Share mode). For more details on Power Share, refer to paragraph 1.2.3. The Power Share control sets the rectifier sine reference magnitude to regulate battery power at the desired level. The rectifier is running in a constant current mode while the battery converter operates normally to regulate the rails. Experiments have shown that running the second part of the test at or near full load yields the best results. If full load is not available at the output of the UPS, full load on the battery can still be achieved by allowing the rectifier to backfeed power to the utility. Back-feeding the rectifier is the preferred method of running the test, but the user can disable back-feeding from the front panel. If the user disables back-feeding, the second part of the test will be run with the available load, which must be at least 50% of the UPS rating. When the test starts, battery power is set to 25% of load. Unfortunately, when the load is first put on the battery, the voltage will drop, and then recover (termed “crack of the whip”). In order to get past this phenomenon, the test runs for 8% of the expected runtime at load level 1 before taking the measurement. After test 1, 4-42


9355 20 – 30 kVA


the power is set to test level 2 and run for 30 seconds on the initial commissioning test, and for 50 seconds thereafter. The battery voltage and power level are recorded. When the test executes, it will be transparent to the user. Unless the battery test detects a bad battery, there will be no beeping alarms and the front panel will not change state because the test is being performed. The XCP status will not change to “On Battery”. The battery test section of the LCD control menu will give an indication of test progress.

4.7.8.2

Battery Impedance / Open Cell Voltage Measurement

The battery impedance and open cell voltage will be determined by performing the following steps: Run test level 1 at 25% of the full UPS watt rating on the battery. The test duration is 8% of the expected runtime at this power level. The battery voltage and power are recorded at the end of test level 1. Current is also recorded for XCP battery data block only and does not impact runtime calculations. Run test level 2 at the full available load for 50 seconds. After 50 seconds, battery voltage and power are recorded. Current is also recorded for XCP battery data block only and does not impact runtime calculations. Calculate Open Cell Voltage: Open Cell Voltage = ((Test 1 Voltage × Test 2 Power ) − (Test 2 Voltage × Test 1 Power )) ÷ (Test 2 Power − Test 1 Power )

If this is a commissioning test, this voltage is stored as is; otherwise it is filtered with previous test results. Calculate Battery Resistance: Battery impedance = (Open Cell Voltage − Test 1 Voltage ) ÷ Test 1 Power

If this is a commissioning test, then calculated battery impedance is stored as both commissioning impedance and test impedance, otherwise: ⎛3 ⎞ Battery test impedance = (3 × Battery test impedance + calculated battery impedance ) ÷ 4 ⎜ filter ⎟ ⎝4 ⎠

If this is a commissioning test the battery health is set to 1, otherwise: Battery health = Commissioning impedance ÷ Battery test impedance

4.7.8.3

Cell Voltage Failure Under Load

When the unit drops on battery, the battery cell voltage is monitored during the first 25% of the discharge as determined by the battery runtime prediction. If the battery cell voltage drops below a certain level during the first 25% of discharge, “Battery Test Failed” is set. Failure of this test represents a loss of battery capacity and is not considered a potentially hazardous condition. This alarm is not stored in EEPROM and charging is not disabled as a result of test failure. This alarm is cleared when power is cycled, the batteries are replaced, or the battery test successfully completes. This test is active during the battery test/commissioning test. © 2006 - Eaton Corporation

4-43


9355 20 – 30 kVA

The failure limit for this test is 1.833V/cell if expected runtime is greater than 15 minutes, or 1.81V/cell if expected runtime is less than or equal to 15 minutes.

4.8 Battery Lifetime 4.8.1

Introduction

The 9355 battery lifetime algorithm is executed every second. It accounts for run-time, chronological (wall clock) time, battery temperature, and battery discharges when calculating the expected battery lifetime available.

4.8.1.1

User Interface

Battery lifetime, in hours, is maintained in nonvolatile memory and is displayed as a percentage of nominal.

4.8.1.2

4.8.2

User Selectable Values 1.

Battery Lifetime can be reset to whatever value the user wants, as long as it is equal to or less than the nominal battery lifetime. The default value is 43830 hours or five years.

2.

Nominal Battery Lifetime can be set by the user to any value less than 4,294,967,296 (2^32) hours. The default value is 43830 hours or 5 years.

3.

Battery Discharge Coefficient is the amount of time that is subtracted from Battery Lifetime every time the unit runs from battery. The default value is one hour.

Operational Sequence

When the PW9355 first powers up, 2 hours are subtracted from the battery life as UPS down time is not monitored. If it is known that the unit has been powered down for longer than 2 hours, it is recommended that the Battery Lifetime be updated accordingly. Based on the calculated Battery Lifetime, the percentage of remaining battery lifetime is calculated for display on the battery meter screen. The battery lifetime routine is called every second. After the initial call of the battery lifetime routine, only battery discharge and run-time effects are calculated, until a temperature sensor for the batteries is available.

4.8.3

Battery Discharge

If the unit goes to battery, the amount of time specified by the Battery Discharge Coefficient is subtracted from the Battery Lifetime. This value can be changed with the XCP Service Tool. If the battery discharge is short (less than 1 second), the discharge may occur between a call to the battery lifetime routine, in which case the routine may not detect the discharge and the Battery Lifetime will not be updated.

4-44


9355 20 – 30 kVA

4.8.4


Run-Time and Temperature

A run-time and temperature algorithm currently does not compensate for the temperature degradation of the battery, due to a lack of battery temperature sensors. Once an hour, an hour is subtracted from the battery lifetime. This number is stored to nonvolatile memory every 3 hours. The counter does not run when the unit is off, since there is no real time clock. The counter algorithm does not account for the depth of battery discharge.

4.9 Battery Test 4.9.1

Introduction

This section describes the operation of ABM and battery test in PW9355.

4.9.1.1

Battery Test Run Time

The run time calculation uses voltage load and battery information to give a prediction of battery run time.

4.9.1.2

Battery Test Operation

Battery testing occurs periodically and each time that the unit performs an ABM charging cycle. The test starts at a fixed time after ABM begins. The time relative to the start of the ABM float charge cycle is programmable, but it is typically set to half of the float time.

4.9.2

Battery Test 1

The Battery Test begins with test 1. During this test, the battery is discharged at the specified load for a specified duration. At the end of the test, the voltage and power level are recorded. If the required discharge load is less than the output load, the rectifier will backfeed the line with the excess power. The test will abort if the utility is lost, if battery voltage falls below a preset level, or if a charger malfunction occurs.

4.9.3

Battery Test 2

The Battery Test ends with test 2. During this test, the battery is discharged at a specified load for a specified duration. At the end of the test, the voltage and power level are recorded. If the required discharge load is less than the output load, the rectifier will backfeed the line with the excess power. The test will abort if the utility is lost, if battery voltage falls below a preset level, or if a charger malfunction occurs.

4.9.3.1

Battery Test Levels and Times

Test 1 is typically set for 25% of load for an 8% discharge of the battery (6 minutes). Test 2 is set for 100% of load for 30 seconds.


4-45


4.9.4

9355 20 – 30 kVA

Battery Test Calculations

The following parameters are recorded during the battery test. •

Date and Time

•

Status

•

Test 1 - End voltage

•

Test 1 - Power level

•

Test 2 - End voltage

•

Test 2 - Power level

From the above data, the Battery Open Circuit voltage, Battery resistance and Battery health are calculated. The data is then used to alter the battery time remaining algorithm. Table 13. Battery Setup Data Name

Effects

Battery setup

Charger ABM

Num cells

String Calcs

Number of cells in a single battery string

Num Strings

String Calcs

Number of battery Strings

Battery DCOV

Alarm

Battery Equalize

Charger ABM

The level that is used to charge the batteries for the Battery Float Time, typically 48 hours

Battery Charge

Charger ABM

The target voltage level at the beginning of an ABM charge cycle. This voltage is higher than Battery Equalize.

Battery is Charged Level

Description Setup Bitword for the battery

Battery DCOV level

Charger ABM Lower than Battery Charge, the level that ends regulation to Battery Charge.

Battery Float Level

Charger Float

Level to regulate to, if ABM is disabled.

Battery Not Charged

ABM ALARM

If the battery voltage falls below this level within the rest fail time, a “Check Battery” alarm is annunciated, otherwise an ABM cycle is started.

Battery DCUV

ABM BTR ALARM OPER.

This is the level that triggers the low Battery shutdown alarm. The system will shutdown in the programmed Battery DCUV Time

BATTERY DCUV Shutdown Time

BTR OPER

Time in seconds before shutdown if the Battery voltage falls below Battery DCUV.

Absolute Battery DCUV

OPER

If the Battery Voltage falls below this level, the system is shutdown within a few seconds.

Battery DCUV for Logic Power Off

OPER

The power supply is disabled if the battery is sully the power and the battery voltage falls below this

4-46


9355 20 – 30 kVA


Table 13. Battery Setup Data Name

Effects

Description level.

Battery temperature compensation

Nothing

Place holder for future applications

Battery Charge Current Limit

Charger

Level at which the battery charge current is limited.

Battery Charge Current Limit On Generator

Nothing

Place holder for future applications

Support Test Time

Batt Test

Hours, When ABM enters float, the Battery test runs after float charging the Battery for this time.

Battery Charge Time Max

ABM

Hours, ABM must reach equalize voltage before this time or a “Check Battery” alarm is annunciated

Battery Float Time

ABM

Hours, ABM float charges the battery for this time during each ABM Charge cycle.

Battery rest fail Time

ABM

Hours, If the battery voltage falls below a preset level before this time, a “Check Battery” alarm is annunciated.

Max Rest Time

ABM

Hours, the time before an ABM charge cycle is initiated.

Maximum Battery Discharge Time before Charge

ABM

Seconds, if the unit drops on battery for greater than this time an ABM charge cycle is initiated.

Battery Run Time at Battery Watts

BTR

Tenth minutes, Run Time at Battery Watts, typically full load run time

Battery Watts

BTR

Watts/cell, Battery watts at Battery run Time

Battery open Cell Voltage

Batt test BTR

Volts/cell, used only until commission test occurs

Battery Start charge

BTR

Volts/cell, Used by BTR to determine the state of charge on the battery while resting or charging.

Battery resistance

BTR

Q15, milliohms, used by BTR until the commissioning test runs

Battery Test 1 voltage

BTR

Volts/cell, Used by BTR until the commissioning test runs.

Lin Pred

BTR

Not used

Lin PUV

BTR

Not Used

On Battery delay

ALARM

Battery Current Meter zero

Meter

Battery Discharge Coef.

Battery Lifetime

Number of hours to subtract off of battery life when we drop on battery

Expected Battery Lifetime

Battery Lifetime

Number of hours before replacement of battery is recommended.

Battery Lifetime left

Battery Life Time

Battery Test 1 Power

Batt Test BTR

Delay time before queuing “ON Battery” Number of tenth amps below which the battery current meter is zeroed

Number of hours the battery currently has left before replacement is needed Tenth KW, Total KW for Battery Test 1


4-47


9355 20 – 30 kVA

Table 13. Battery Setup Data Name

Effects

Description

Battery test 1 Time

Batt test

Seconds, Time Battery test 1 runs at Battery Test 1 Power

Battery Test 2 Power

Batt Test

Tenth KW, Total KW for Battery Test 2

Battery test 2 Time

Batt Test

Seconds, Time Battery test 2 runs at Battery Test 2 Power

Battery Test Min Voltage

Batt Test

If the battery voltage falls below this level during battery test, the test is aborted and a “Check Battery” alarm is annunciated.

4.9.4.1

User Interface to Battery Test Information

4.9.4.2

Battery Test Queue Printing

The battery test queue can be viewed in TERMINAL mode by entering “ESC B” at any serial port. The commissioning test and the contents of the battery test log are printed. The information provided by the printout is shown below: •

Battery Test Number

•

Date and Time of the battery test

•

If the test failed, the reason Battery Test Status

•

Test 1 results, voltage per cell and power

•

Test 2 results, voltage per cell and power

•

Calculated open circuit voltage

•

Calculated Battery Resistance in Milliohms V/P not V^2/P

•

Calculated Battery Health (percentage health)

4.9.4.3

Battery Test Information via XCP

The Battery Test information is transmitted in the XCP Battery Test data block.

4-48


9355 20 – 30 kVA


4.10 I/O BOARD (PCB) Reference Documents: PW9355 1024055 I/O Board Schematic, see the Prints chapter at the end of this document. For detailed descriptions of board components, refer the Chapter 8, Removal and Replacement.

Figure 27.

4.10.1

PW 9355 I/O Board

Overview

The IO Board has many functions within the Electronics module. It provides input and output filtering (including EMI) for the system. AC and Battery Voltage sensing is provided in many locations. Current sensing for the inverter, rectifier, and battery converter and load are contained here - along with level shifting for the control board. Fusing is provided for the inverter path only. In this topology the inverter is connected to the output by a contactor - which is contained on the IO Assembly. The IO Board feeds input mains to the Power Board and provides battery start capability. Single or dual feed mains input with a separate Rectifier contactor is contained here. Also, the balancer and battery relays are contained on this board. Battery start circuitry and AC Fan power to 3 of the fans is provided here. © 2006 - Eaton Corporation

4-49


9355 20 – 30 kVA

It also contains an Auxiliary Power supply that is derived from mains (or battery) during startup and then runs from the positive rail. This A-aux supply powers the relays, control board, and the X-Slot, and it powers the IGBT gate drives and alarms circuitry. The control board interface is located on this board, a battery circuit breaker trip circuit/sensor, a manual bypass switch position sensor, and an input output circuit breaker trip. Finally it contains the rail cap pre-charge circuitry.

4.10.2

I/O Connector Descriptions

4.10.2.1 Control Board Interconnect Description Table 14. Control Board Interconnect Description Pin

Signal

Description

X8-1

Logic ground

Ground

X8-2

XSLOT2_K4

X8-3

XSLOT2_K3

X8-4

XSLOT2_K2

X8-5

XSLOT2_K1

X8-6

XSLOT1_K4

X8-7

XSLOT1_K3

X8-8

XSLOT1_K2

X8-9

XSLOT1_K1

X8-10

Logic ground

X8-11

XSLOT2_TX

X8-12

XSLOT1_RX

X8-13

XSLOT2_RX

X8-14

XSLOT1_TX

X8-15

Logic ground

X8-16

CAN_HI

X8-17

CAN_LO

X8-18

ID

X8-19

Not Used

X8-20

Logic ground

X8-21

XSLOT1_DTR

X8-22

XSLOT2_DTR

X8-23

PAR_RED1

X8-24

PAR_RED2

X8-25

POWMOD_GOOD

Gate drive fuses OK

X8-26

Logic ground

Ground

4-50

Ground

Ground

connected to logic ground Ground


9355 20 – 30 kVA


Table 14. Control Board Interconnect Description Pin

Signal

Description

X8-27

IO1

Thermostat

X8-28

Not Used

DC Fan (unused)

X8-29

+12_2ON

X8-30

Not Used

DC Fan (unused)

X8-31

Not Used

DC Fan (unused)

X8-32

Logic ground

Ground

X8-33

Not Used

DC Fan (unused)

X8-34

EPO_ ENABLE

X8-35

V114 gate

X8-36

Not Used

X8-37

Not Used

X8-38

Not Used

X8-39

IO_GOOD

X8-40

Logic ground

X8-41

SER_RX

X8-42

SER_TX

X8-43

ALARM_RELAY

X8-44

BLD_ALARM2

X8-45

BLD_ALARM1

X8-46

EPO_ ENABLE

X8-47

Logic ground

X8-48

Not Used

X8-49

Not Used

X8-50

Not Used

X8-51

Not Used

X8-52

Not Used

X8-53

Not Used

X8-54

DALLAS_IN

X8-55

DALLAS_OUT

X8-56

Logic ground

Ground

X8-57

Logic ground

Ground

X8-58

+5V

X8-59

Logic ground

Ground

X8-60

Logic ground

Ground

X8-61

+5V

Reserved for display

Enables IGBT gate drive (unused) Ground

Ground


4-51


9355 20 – 30 kVA


Signal

X8-62

+12_ON

X8-63

DC_CHARGE

X8-64

Not Used

X8-65

Not Used

X8-66

Logic ground

X8-67

+12V /control

X8-68

Logic ground

Ground

X8-69

+24V

AAUX

X8-70

+12V/control

X8-71

Logic ground

Ground

X8-72

+24V

AAUX

X8-73

Logic ground

Ground

X8-74

Logic ground

Ground

X8-75

GATE13

Battery L1 gate

X8-76

GATE14

Battery Boost/Charger Mode Select

X8-77

GATE5

Upper Rectifier L3 gate

X8-78

GATE6

Lower Rectifier L3 gate

X8-79

Logic ground

Ground

X8-80

GATE3


X8-81

GATE4


X8-82

GATE1


X8-83

GATE2


X8-84

Logic ground

Ground

X8-85

GATE15

Battery L3 gate

X8-86

GATE16

Battery L2 gate

X8-87

GATE11

Upper Inverter L3 gate

X8-88

GATE12

Lower Inverter L3 gate

X8-89

Logic ground

Ground

X8-90

GATE9


X8-91

GATE10


X8-92

GATE7


X8-93

GATE8


X8-94

POWERCLOCK0

unused

X8-95

POWERCLOCK1

Gate supply, EPO supply, BLD ALMS supply , and rail precharge clock

X8-96

Logic ground

Ground

4-52

Description

Ground


9355 20 – 30 kVA



Signal

Description

X9-1

Logic ground

Ground

X9-2

CHASSIS_VOLT

Chassis Voltage measurement referenced to Neutral

X9-3

OUTP_DCVOLT_L1

Inverter L1 DC sense

X9-4

DCN1


X9-5

Logic ground

Ground

X9-6

DCN2


X9-7

OUTP_DCVOLT_L2


X9-8

DCN3


X9-9

OUTP_DCVOLT_L3


X9-10

Logic ground

Ground

X9-11

RAIL_VOLTS_PLUS

Rail sense

X9-12

RAIL_VOLTS_MINUS

Rail sense

X9-13

BATT_VOLT1

Measures L1 input cap voltage

X9-14

BATT_VOLT2

Battery + Voltage (before Battery relay) measurement referenced to Neutral

X9-15

Logic ground

Ground

X9-16

BATT_VOLT1_BACKUP

Negative battery sense

X9-17

BATT_VOLT2_BACKUP

Positive battery sense after the chokes on L1 power module

X9-18

Unused

X9-19

+5V_REF

Unused

X9-20

Logic ground

Ground

X9-21

N1

Neutral reference for rail (and battery) voltage sense

X9-22

N1_BACKUP

Neutral reference for rail (and battery) voltage sense

X9-23

Logic ground

Ground

X9-24

UTI_CURR_L1

Line 1 Rectifier Choke current measurement

X9-25

UTI_CURR_L2


X9-26

UTI_CURR_L3


X9-27

Logic ground

Ground

X9-28

OUT_CURR_L1

Line 1 Output Current measurement

X9-29

OUT_CURR_L2


X9-30

OUT_CURR_L3


X9-31

Logic ground

Ground

X9-32

INV_CURR_L1

Line 1 Inverter Choke current measurement

X9-33

INV_CURR_L2


X9-34

INV_CURR_L3



4-53


9355 20 – 30 kVA


Signal

Description

X9-35

Logic ground

Ground

X9-36

BATT_CURR1

Battery Choke current measurement

X9-37

CASE_TEMPERATURE

Ambient Temp measurement

X9-38

Logic ground

Ground

X9-39

TEMPERATURE1

Battery Boost IGBT module temperature sensor L1 power module

X9-40

TEMPERATURE2


X9-41

TEMPERATURE3


X9-42

Logic ground

Ground

X9-43

UTIL_VOLT_L1N

Line 1 Utility Voltage Measurement L-N before contactor

X9-44

UTIL_VOLT_L2N


X9-45

UTIL_VOLT_L3N


X9-46

Logic ground

Ground

X9-47

INV_VOLT_L1N

Line 1 Inverter Voltage Measurement L-N

X9-48

INV_VOLT_L2N


X9-49

INV_VOLT_L3N


X9-50

Logic ground

Ground

X9-51

BUPASS_VOLT_L1N

Line 1 Bypass Voltage Measurement L-N after Bypass Relay and Fuse

X9-52

BUPASS_VOLT_L2N


X9-53

BUPASS_VOLT_L3N


X9-54

Logic ground

Ground

X9-55

OUTP_VOLT_L1N

Line 1 Output Voltage Measurement L-N

X9-56

OUTP_VOLT_L2N


X9-57

OUTP_VOLT_L3N


X9-58

Logic ground

Ground

X9-59

Logic ground

Ground

X9-60

SPI_SI

Signals to backup EPROM

X9-61

SPI_CS


X9-62

SPI_SD


X9-63

SPI_CLOCK


X9-64

Logic ground

Ground

X9-65

ID0

Connected to logic ground

4-54


9355 20 – 30 kVA



Signal

Description

X9-66

ID1

NC

X9-67

ID2


X9-68

ID3


X9-69

INV_SCR/CONTACTOR

Enable signal for Inverter Contactor – active low

X9-70

Logic ground

Ground

X9-71

Not Used

X9-72

INVONLINE

Output signal used to control D1 state machine for Bypass

X9-73

MBS

MBS switch position

X9-74

REL_BAL

Balancer relay drive – active low

X9-75

BATT_CB_TRIP

BATT CB trip signal

X9-76

REL_L2-3

Redundant Input Rectifier Contactor Drive – active low

X9-77

Logic ground

Ground

X9-78

Not Used

X9-79

REL_L1

Input Rectifier Contactor Drive – active low

X9-80

BYP_RDY

Output from D1 used by control to determine state of D1

X9-81

BACK-FEED

Bypass Contactor Drive

X9-82

EPOCBTRIP

EPO CB Trip (if needed)

X9-83

B_UP_OK

Not used

X9-84

Logic ground

Ground

X9-85

BYP_AVAIL

Output signal from control board used to control D1 state machine

X9-86

BATT_CB_STATE

BATT CB switch state sense

X9-87

SPARE_IN1

Not used

X9-88

SPARE_IN2

Not used

X9-89

Logic ground

Ground

X9-90

Not Used

X9-91

RES_ON

Signal for turning on contactor cap reservoir

X9-92

Logic ground

Ground

X9-93

Not Used

X9-94

REL_BAT

X9-95

Not Used

X9-96

Logic ground

Battery Relay Drive – active low Ground


4-55


9355 20 – 30 kVA

Table 15. Interconnect Descriptions Reference Designator X50

4-56

Description To Battery CB Trip

X48, X49

Batt + from CB

X34, X51

Batt - from CB

X26

From Rect Contactor to L1 Rect input

X24


X22


X13

L3 input, also to rectifier contactor

X23


X25


X54

N input

X78

To Output CB Trip

X2

To Input CB Trip

X37

Inv L1 Out to Inv Contactor

X36


X35


X38

N output (unused)

X40

From Inv Contactor to L1 output

X41


X42


X3, X20

Neutral connection to Power Board Neutral Bursar

X34, X51

Battery Neg connection to Power Board Ned Rail Busbar

X30

Pos Rail connection to Power Board Pos Rail Busbar

X67

AC Fan connection (inverter L1-N)

X66


X65


X21

Inverter Contactor Control

X27

Rectifier Contactor Control

X17

Display jack

X44

AAUX 24V

X5

L1 Rectifier choke connection

X70

L1 Rectifier choke current sense connection

X10


X69

L2 Rectifier choke current sense connection

X14


X68

L3 Rectifier choke current sense connection © 2006 - Eaton Corporation

9355 20 – 30 kVA


Table 15. Interconnect Descriptions Reference Designator

Description

X74

L1 Battery Choke current sense connection

X4

L1 Battery Choke connection

X75


X29


X76


X28


X19

L1 Inverter choke connection

X73

L1 Inverter choke current sense connection

X18


X72


X15


X71


X58, X59

Marine ground connection

X79

Battery start pushbutton connector

X43, X45, X46, X47, X52 X55, X56

Table 16. 4.10.3

Hipot/test connectors X-Slot connectors

X6, X7, X11 Connector Pinout

Pin

Signal

Description

1

Logic ground

2

PWRCLK1

3

Logic ground

4

TEMPERATURE1,2,3

5

SPARE

6

OUTP_DCVOLT_L1N,L2N,L3N

7

BATT_VOLTS2_BACKUP

8

THERMAL SWITCH

9

POWMOD_GOOD

10

Logic ground

11

GATE14

Battery Boost/Charger Mode Select

12

GATE13

Battery gate

13

GATE8, 10, 12

Lower Inverter L1, L2, L3 gate

14

GATE7, 9, 11

Upper Inverter L1, L2, L3 gate

15

GATE2, 4, 6

Lower Rectifier L1, L2, L3 gate

16

GATE1, 3, 5

Upper Rectifier L1, L2, L3 gate

Ground Gate Clock Ground IGBT module Temp sensor from power board Unused Inverter DC feedback Batt Choke hot end Heatsink Thermostat Closes on Temperature Gate drive fuses OK Ground


4-57


Table 16. 4.10.3

9355 20 – 30 kVA

X6, X7, X11 Connector Pinout

Pin

Signal

Description

17

Logic ground

18

+12V

19

Logic ground

20

+12V

Ground +12V for gate drive supply Ground +12V for gate drive supply

Table 17. X12 Connector Pinout

4-58

Pin

Signal

Description

1

Logic ground

2

BUPASS_VOLT_L1N


3

BUPASS_VOLT_L2N


4

BUPASS_VOLT_L3N


5

Logic ground

6

AAUX

7

ALARM_RELAY

8

MBS

9

BAUX

10

Unused

11

SER_RX

12

SER_TX

13

Logic ground

14

EPO_ ENABLE

15

BLD_ALARM1

16

BLD_ALARM2

17

Logic ground

Ground

18

INVONLINE

Output signal used to control D1 state machine for Bypass

19

BYP_RDY


20

BACK-FEED


21

Logic ground

Ground

22

B_UP_OK

23

BYP_AVAIL

24

IO_GOOD

Ground

Ground +24V supply on IO board

+24V supply on BYP board

Ground

Not used Output signal from control board used to control D1 state machine


9355 20 – 30 kVA


Table 17. X12 Connector Pinout Pin

Signal

Description

25

LED_OVERRIDE

Display

26

Logic ground

Ground

4.11 I / O Board Functional Sections 4.11.1

Auxiliary Power Supply

This circuit (N8, V62, T1) is an 80W-isolated flyback switching power supply. It receives input power from rectified 120VAC during an AC start or 216VDC nominal battery during a DC start. Once the Rails are charged it runs from nominal 195VDC positive rail. This input is then converted to 24VDC (AAUX). This 24V output supplies input power for the RS-232 supply and alarms on the bypass board. It is also powers the Battery and Balancer relays. It is used for operating the rectifier, inverter contactors, and momentarily to power the battery circuit breaker shunt trip from the cap reservoir. The Aux Power Supply is stepped down by two buck converters to 12VDC. The first buck converter circuit (N10) outputs (+12V) capable of ~3A, powers the rail precharge circuit, contactor relays, input/output CB trip relays, and IGBT gate drives on the Power Board. The second circuit (N12) output (+12V_2), capable of ~1A, only powers the two X-Slots. There is a linear voltage regulator (N1) that reduces it to (+12V) for use by the Control Board.

4.11.2

Rail Precharge

The Rail Precharge circuit (V70, V68, V69, T3, N9, L2) function is to precharge the positive rail capacitors located on the power boards during startup. It receives its input from rectified 120VAC during an AC start or from 216VDC nominal battery during a DC start. This constant current converter takes several seconds to charge all these caps to near input voltage. (T_ON) is the signal that is used to power this converter (N9). This circuit continues to precharge the positive rail until precharge of both rail caps are done (see next section).

4.11.3

Voltage Sensing

The IO Board provides Voltage Sense Resistors for most of the AC and DC voltage sense measurements (including chassis) done by the Control Board. There are also some additional sense resistors located on the power board and the bypass board. Voltage sense resistors are made up of two 1Meg ohm resistors in series for safety reasons. The measurements are differential measurements with respect to Neutral. Op Amps are referenced to signal +5V_REF created on the control board. Outputs of the Op Amps are divided down to a 1.5V reference to the DSP with an anti-aliasing filter. © 2006 - Eaton Corporation

4-59


9355 20 – 30 kVA

4.12 Current Measurements and Hardware Current limits Inverter, Rectifier, and Battery Current Measurements are made on the IO board. The measurements are made by the LEM-LAS100 closed loop hall sensor. All measurements made are choke current measurements. There are two chokes in parallel in each phase of the Inverter and Rectifier, but only 1 choke is measured. The battery converter has 6 chokes in staggered parallel; however, only 3 chokes are measured, one from each power module. See paragraph 4.5.3 for respective choke connections. Table 18. Phase and Battery Chokes Sensor

Converter

Choke

Split

B1

Rectifier Line 1

L7A

2

B2

Rectifier Line 2

L4A

2

B3

Rectifier Line 3

L1A

2

B7

Inverter Line 1

L9A

2

B6

Inverter Line 2

L6A

2

B4

Inverter Line 3

L3A

2

B8

Battery

L2A L5A L8A

2

LEM sensors are powered by +5V which is derived from the control board. They output a nominal 2.5V with no current. The +5V is buffered and divided to 3.3V and used as the reference voltage for N3-A, N3-B, N3-C, N5-D, N5-C, N5B and N5-A. Each Op amp will now put out a nominal +3.3V with no current running through its respective LEM sensor. Measurements are scaled so that control board hardware current limit is set at approximately 240Apk @ 20kHz. This allows for overload conditions and system non-linear loads with high crest factors. Calibration takes care of any slop caused by current splitting scheme used to measure current. Software current limits are also in place.

4.12.1

Output Current Measurement

Line 1, 2, 3 phase currents are monitored by B5, B9, B10 CTs respectively. These measurements (currents) are not split. R54 and R55 adjusts gain for Line 1 measurement, R146 and R147 adjusts Line 2 measurement gain, and R148 and R149 adjusts Line 3 measurement gain. This measurement is sized to handle 110% overload on the inverter with 1% low tolerance and a 3:1 crest factor. Measurement will also handle the 150% overload at low line at a 2.2:1 crest factor per the PDR (reference 1).

4.12.2

Input and Output Filtering Scheme

High Frequency Y-Caps are provided on Input, Output, Neutral, and Battery Connections to Chassis: High Frequency X-Caps are provided on Input, Output Connections to Neutral and across the Battery: • 4-60

Ferrite cores are also placed strategically to form a common mode choke pi filter on the input for emi. © 2006 - Eaton Corporation

9355 20 – 30 kVA

•


Input and output filter capacitors for the rectifier and inverter carrier rejection are provided on the I/O board: - C115-117, C129-134, C210-212

These caps along with the system inductor provide a 2nd order filter with the following corner frequency: fr = 1/ (2π√L⋅C) = 1960Hz where L = 50µH and C = 132µF

4.12.3

Inverter/Rectifier Fault Methodology

An input breaker feeds the rectifier path, which may trip if there is a bus fault with the rectifier or inverter. If the fault is due to a inverter IGBT module failure, fuses (F1, 2, 3) may clear also. The inverter and rectifier have hardware and software current limit protection. The inverter output path is fused with 160A LET semiconductor fuses (F1, 2, 3). The inverter path is connected through a contactor to the bypass SCR output. These paths are OR’d, which leads to fast transfer times in the unit. This connection is then run through the load CTs. In an output short circuit condition, the inverter will current limit, transfer to bypass, and then open the inverter contactor if the load short circuit does not clear. Software keeps the inverter from going back online after bypass until the load short circuit has cleared. The bypass feed is protected by fuses (not on this board), and an upstream (customer) circuit breaker.

4.12.4

Single Feed/Dual Feed Input Contactors

The Low Voltage UPS module uses either a single feed or dual feed by adding or removing a jumper. There are separate contactors for the Bypass and Rectifier paths. The redundant drive for the rectifier contactor (circuit consisting of K12, K14, X27) is located on this board. The drive for the inverter contactor (circuit consisting of K11, X21) is located on this board. Both drives are powered from the 24V reservoir capacitors. It takes approximately 4A for about 100ms (100W) to pull in the contactors.

4.12.5

Battery Relay, Battery Start and Current Measurement

The Low voltage UPS module contains a system battery breaker; Battery + and Battery – connections come to the IO board. Battery capacitors C15, 81, 14 are provided and work with the two parallel battery chokes to form a carrier ripple filter. The Battery Relay (K5-10—six 40 Amp relays in parallel), is driven by way of V7D and V7C and clamped with V1. The battery relay connects the battery-tobattery chokes once the rails are charged, so there is no inrush. Battery current is then measured by LEM sensor B8. Choke currents from each power module are each split by two (see paragraph 4.5.3) so that half of battery current is sensed by the LEM.


4-61


9355 20 – 30 kVA

During a battery start SCR V6 provides battery start capability in absence of utility. This SCR is triggered by a battery start pushbutton connected to X79 once the battery breaker is closed. This circuit then provides power to the AAUX supply. Once the battery start circuit latches, control board power comes up and the control board comes alive. A precharge circuit then pumps up the positive rail to hold up the AAUX power supply. The balancer relay (K19-21) closes and the L1 rectifier converter, acting as a balancer, transfers charge to the negative rail. Software waits for a “UPS on” command from the front display. If the unit is not started, software properly shuts down the unit.

4.12.6

Balancer Relays and Drive

A Line 1 Rectifier converter is used to balance the rails to neutral when on battery and during startup. Balancer Relay (K1-4) is used to connect Line 1 after the contactor is opened to Neutral. The coils are powered with +24V from AAUX and are driven by V8-C, V8-G and are clamped by V11. Firmware is in place to keep the Balancer relay and the rectifier contactor from being closed at the same time avoiding a short on the utility and welded relays.

4.12.7

Battery CB Trip

This circuit shunt trips the battery CB. It gets its power from +24V reservoir capacitors through FET V105 out connector X50. It takes approx 4A for ~100ms (100W) to trip the breaker.

4.12.8

Input/Output CB Trip

The circuit (K4,14, X2, 78) shunt trips the input/output CB. It gets its power for the input trip coil from the L1 input and for the output trip coil from the L1 output.

4.12.9

Other Sensing

There are three buffers dedicated for sensing. The state of the Battery CB is reported back to the control board through buffer V91-G from connector X50. The state of the SPARE_IN1 is reported back to the control board through buffer V91-D from connector X61. The state of the SPARE_IN2 is reported back to the control board through buffer V91-C from connector X60. Ambient temperature is sensed by U1.

4.12.10 X-Slots Connectors X55 and X56 go out to the two X-Slots. The X-Slots each get +12V_2 through a 5 ohm 1A PTC thermistor R285, R286 plus signals to and from the control board.

4-62


9355 20 – 30 kVA


4.12.11 AC Fans There are three AC fans powered from this board. Fan 1 (X65) is connected phase L3- N across the inverter. Fan 2 (X66) is connected phase L2-N across the inverter. Fan 3 (X67) is connected phase L1-N across the inverter. All are located after the inverter fuse. They can also be powered by the output when the inverter is off by closing the inverter contactor.

4.12.12 Chassis GND Chassis screws E14, E15, normally ground logic common. The emi Y-caps are connected via screws E13, E16.

4.12.13 Troubleshooting 4.12.13.1 Fuses The IO Board contains the inverter (F1-3) fuses that disconnect any failed converters on the power modules.

4.12.13.2 Circuits If the display is not working check the F4 fuse going to the AAUX supply. Look for the presence of +24V on X44.

4.12.13.3 Relays Check for welded balancer relays (K1-3) if the rectifier CB is tripped open or a rectifier converter has failed. Check for welded battery relays (K5-10) after a battery converter failure.


4-63


9355 20 – 30 kVA

4.13 Bypass Board System Overview Reference Documents: PW9355 1024059: Bypass Board Schematic and 1024062: silkscreen, see the “Prints” chapter at the end of this document.

Figure 28.

Bypass Control Board

Each Power Board is the location for 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, and their respective gate drives,

•

and one IGBT thermal sensor.

This board, along with chokes and heatsink, 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 heatsink thermostat sensor. Each interfaces with the I/O board containing a 20 pin ribbon cable Table 19. Interconnect Description Reference Designator

4-64

Description

X24

Bypass L3 input to SCRs after contactor

X8


X9


X10

N input © 2006 - Eaton Corporation

9355 20 – 30 kVA


Table 19. Interconnect Description Reference Designator

Description

X25

From MBS switch status

X51

To Bypass Back-feed contactor

X53

RS-232 9 pin DSUB

X5

L1 output after SCRs

X11


X13


X1

PIC flash phone jack

X17

AC Fan connection Bypass L1-N load side

X18


X1


X27

Pull Chain connection

X2-4, X14-16

Bypass SCR gate connectors


Signal

Description

1

Logic ground

2

BUPASS_VOLT_L1N


3

BUPASS_VOLT_L2N


4

BUPASS_VOLT_L3N


5

Logic ground

6

AAUX

7

ALARM_RELAY

8

MBS

9

BAUX

10

Unused

11

SER_RX

12

SER_TX

13

Logic ground

14

EPO_ ENABLE

15

BLD_ALARM1

16

BLD_ALARM2

17

Logic ground

Ground

18

INVONLINE

Output signal used to control D1 state machine

Ground

Ground +24V supply on IO board

+24V supply on BYP board

Ground


4-65


9355 20 – 30 kVA


Signal

Description for Bypass

19

BYP_RDY


20

BACK-FEED


21

Logic ground

Ground

22

B_UP_OK

23

BYP_AVAIL

24

IO_GOOD

25

LED_OVERRIDE

Display

26

Logic ground

Ground

Not used Output signal from control board used to control D1 state machine

4.14 Bypass Board Functional Blocks 4.14.1

BAUX Power Supply

This circuit (N1, Q1, T2) is an 80W isolated flyback switching power supply. It receives input power from rectified 120VAC during an AC start. This input is then converted to 24VDC (BAUX). It is used for operating the bypass contactor from the cap reservoir circuit of N8, C34, and C35. The BAUX Power Supply is stepped down by a buck converter to 12VDC (+12V_2). The buck converter circuit (N11) output (+12V) capable of ~3A, powers the bypass SCR gate drives. It is then stepped down by linear regulator (N2) to +5V (+5V_2), capable of ~1A to power the bypass PIC (D1). The +5V is stepped down by linear regulator (N10) to serve as a +2.5V reference. This circuit is protected by fuse F4.

4.14.2

Voltage Sensing

The Bypass Board provides Voltage Sense Resistors for bypass voltage sense measurements done on the Control Board. The measurements are made after the bypass contactor and fuses. Voltage sense resistors are two 1Meg ohm resistors in series. Reference sense resistors to Neutral are provided on the Power Board. The measurements are differential measurements with respect to Neutral. Op Amps are referenced to signal +5V_REF created on the control board. Outputs of the Op Amps are divided down to a 1.5V reference to the DSP with an antialiasing filter. Voltage measurement signals are described in paragraph 4.5.2.1.

4-66


9355 20 – 30 kVA

4.14.3


Input Contactor

The system uses an “input all pole break” input bypass contactor. The drive for the contactor (a circuit consisting of K1, X51) is located on this board. It is powered from the 24V reservoir capacitors. It takes approx 4A for ~100ms (100W) to pull in the contactor.

4.14.4

Alarm Supply

There is a separate un-fused forward converter for supplying EPO and Building Alarms. Alarm Supply gets its power from +24V (AAUX on I/O) and is reduced to +12V by (N5) and uses a gate signal from N3. The circuit consists of FET V87 and XFMRs T4, 5, 6. This results in three isolated ~12VDC outputs for use by the alarms.

4.14.5

EPO Alarm

There is a normally open EPO input on X12 and a normally closed input on X52. Opto isolator V110 sends this alarm to the control board.

4.14.6

Building Alarms

There are two building alarms on X44 and X45 that can be programmed to be used in a number ways by the customer (via the display board) just by adding a jumper. OPTO isolators V108 and V84 send these alarms to the control board.

4.14.7

RS-232

There is another separate un-fused forward converter for supplying isolated RS-232 power. The circuit consists of N13, N14, V113, and T7. It runs from the 24V (AAUX on I/O) input and outputs +/-6V for use by the transmit and receive circuits of isolators V102 and V103. This appears on DB9 RS-232 connector X53 as RxD, TxD, and GND.

4.14.8

NO/NC Relay Contacts

There is a set of isolated NO/NC relay contacts K7 ouput on connector X57.

4.15 Bypass SCR Gate Drive and SCRs Bypass SCRs are mounted on the back of the lower power module heatsink. The gate drives operate at approximately 22kHz with a 25% duty cycle. The drive is controlled by N4, which is a UC3845A Current Mode controller that gets its power from +24V (BAUX). Transformers T18, T19, T21, T22, T23, and T24 provide gating pulses. These transformers provide SELV isolation from the line to the gate drive, which operates from system logic ground. _2 is regulated with a linear regulator N2. This voltage is used for the logic power for bypass PIC D1.


4-67


4.15.1

9355 20 – 30 kVA

Standalone Bypass Functionality

Bypass function is controlled by PIC processor D1. The processor is a microcontroller and operates at 5MIPS. Pins 6, 9, and 10 control the processors state transition. Pin 8 tells the main processor what state it is in with a clocked output. Pin 5 feeds a window comparator with a clock. This comparator disables the bypass gate drive with a brownout condition, clock failure, or watchdog failure. Pin 7 locks the LED on the unit display when the unit goes to bypass. Pin 11 drives Darlington drivers V6-C, V8-B, and V43-H. These drivers turn on the Static Switch gate drive, latch on the contactor drive relay. LED V4 shows what state the processor is in and is driven via a Darlington driver with pin 12. Connector X1 is used to program the processor.

4.15.2

Bypass State Machine

Operation of the Bypass Control Board is described below using machine states. Bypass machine states can be viewed as modes of operation. Each table below describes a machine state. The last group of tables describes all possible machine state transitions

Fire

Ready Armed

Ready

Idle

Init

Figure 29.

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State Diagram


9355 20 – 30 kVA


The following tables describe the Bypass Control states show in Figure 29: Table 21. Fire State [FIRE STATIC SWITCH]

= ON

[CLOSE BYPASS]

= ON

[CLOCK OUT]

= 50% duty cycle 10KHz

[BYPASS READY]

= 50% duty cycle square wave (1020 Hz)

[BYPASS RELAY]

= ON

[GREEN LED]

= ON

Table 22. Ready State [FIRE STATIC SWITCH]

= OFF

[CLOSE BYPASS]

= OFF

[CLOCK OUT]

= OFF

[BYPASS READY]


[BYPASS RELAY]

= OFF

[GREEN LED]

= 1 Hz 10% duty cycle BLINKING

Table 23. Ready Armed State [FIRE STATIC SWITCH]

= OFF

[CLOSE BYPASS]

= OFF

[CLOCK OUT]

= OFF

[BYPASS READY]


[BYPASS RELAY]

= OFF

[GREEN LED]

= TOGGLE EVERY .5 SEC

Table 24. Idle State [FIRE STATIC SWITCH]

= OFF

[CLOSE BYPASS]

= OFF

[CLOCK OUT]

= OFF

[BYPASS READY]

= 20 millisecond square wave (50Hz)

[BYPASS RELAY]

= OFF

[GREEN LED]

= OFF


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9355 20 – 30 kVA

During the Intialization state the Microcontroller is initialized and tested. All Microcontroller outputs will be disabled. Table 25. Initialization State [FIRE STATIC SWITCH]

= OFF

[CLOSE BYPASS]

= OFF

[CLOCK OUT]

= OFF

[BYPASS READY]

= OFF

[BYPASS RELAY]

= OFF

[GREEN LED]

= OFF

Machine State Transitions Table 26. From Initialization to Idle State For 100 milliseconds: {INVERTER ON LINE}

= TRUE AND

{BYPASS AVAILABLE}

= FALSE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE

Table 27. From Idle State to Ready State For 100 milliseconds: {INVERTER ON LINE}

= FALSE AND

{BYPASS AVAILABLE}

= TRUE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE

Table 28. From Ready State to Ready Armed State For 100 milliseconds: {INVERTER ON LINE}

= FALSE AND

{BYPASS AVAILABLE}

= FALSE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE

Table 29. From Ready State to Fire State For 750 microseconds:

4-70

{INVERTER ON LINE}

= TRUE AND

{BYPASS AVAILABLE}

= TRUE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE


9355 20 – 30 kVA


This state transfer should only be executed when the system is configured as parallel for redundancy. Table 30. From Ready Armed State to Fire State For 750 microseconds: {INVERTER ON LINE}

= TRUE AND

{BYPASS AVAILABLE}

= TRUE AND

{POWER FAIL}

= FALSE OR

{IO GOOD}

= FALSE AND

{POWER FAIL}

= FALSE

Table 31. From Fire State to Ready Armed State For 750 microseconds: {INVERTER ON LINE}

= FALSE AND

{BYPASS AVAILABLE}

= FALSE AND

{IO GOOD

= TRUE

I/O GOOD insures we don’t come off of bypass and drop load if the Control Board Logic Voltage fails. Make sure that bypass “available true” in hardware is not “naturally pulled-up state.” That way if in logic there is “Failure on Interface Board” we stay on bypass. Table 32. From Armed State to Ready State For 5 milliseconds: {INVERTER ON LINE}

= FALSE AND

{BYPASS AVAILABLE}

= TRUE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE

Table 33. From Ready State to Idle State For 50 millisecond: {INVERTER ON LINE}

= TRUE AND

{BYPASS AVAILABLE}

= FALSE AND

{POWER FAIL}

= FALSE AND

{IO GOOD}

= TRUE


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9355 20 – 30 kVA

4.15.2.1 Control Interface The Control Interface is comprised of three dedicated control signals: •

Inverter on line (input)

•

Bypass Available (input)

•

O GOOD (input) and Bypass Ready (output).

The Inverter uses the first two control signals to tell the Bypass Control Board what the "State" the whole system is in. The Bypass Control uses these signals (Inverter on Line and Bypass Ready) to transition from state to state. The Bypass Control uses IO GOOD (input) to insure that the system does not drop load if there is a logic failure on the control board. The Bypass Control uses the third control signal to tell the Inverter Control what state the Bypass Control is in.

4.15.2.2 Clock signals All clock signals generated by the bypass board should vary in frequency by no more than 5%. Since CLK_OUT and FIRE_STSW are generated directly by an ISR they should not vary. BYP_READY is generated by the state machine and could vary, but no more than +/- 5%. This state is entered when a Microcontroller reset occurs. Reset could occur because of any of the following reasons: Table 34. From All Machine States to Initialization States LOGIC POWER RESET FROM THE LOGIC POWER FAIL STATE WATCHDOG TIMEOUT S/W MALFUNCTION. {RESET IN}

= TRUE

{INVERTER ON LINE}

= DON'T CARE

{BYPASS AVAILABLE}

= DON'T CARE

{POWER FAIL}

= DON'T CARE

{FIRE BYPASS}

= DONT CARE

4.15.3

AC Fans

There are three AC fan connectors X17, X18, and X19. X17 is connected phase L1- N across the output. X18 is connected phase L2- N across the output. X19 is connected phase L3- N across the output.

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9355 20 – 30 kVA


4.16 ELECTRO-MAGNETIC INTERFERENCE (EMI) BOARD (PCB) Reference Documents: EMI Board Schematic (110720620) in the “Prints” chapter at the end of this document.

4.16.1

Introduction

The EMI Board handles surge protection and EMI filtering.

4.16.1.1 EMI Connector Descriptions 4.16.2

EMI Board Functional Sections

4.16.2.1 Surge (PW 9355) 4.16.2.2 EMI Filter (PW 9355) 4.16.2.3 Paralleling Inductors (PW 9355) TBD

4.16.2.4 Miscellaneous The connection to the logic power supply on the I/O Board comes from the connections J1 and J2 on the EMI board. This connection bypasses the ABF contactor.


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9355 20 – 30 kVA

This page was left blank intentionally. .

4-74


5 Connectivity and Communication 5.1 9355 GENERAL CONNECTIVITY DEVICES 5.1.1

Basic Serial Communication

Two serial ports are available with the standard unit. One of the serial ports is dedicated to an X-Slot. The other port is exclusively an X-Slot or it can be shared with a local DB9 RS-232 port. The second X-Slot can be used at the customer’s discretion.

5.1.2

Relay Signaling

One general-purpose relay, with SELV compliant contacts, is available for output signaling. The default set-up for this relay is “Alarm.”

5.1.3

Building Alarm Inputs

The unit will have two configurable, galvanic isolated (SELV) “building alarm” inputs.

5.1.4

Additional Connectivity & Software

The UPS will support the XCP protocol. The units will support the following: •

LanSafe-power management software for system data integrity

•

PowerVision-UPS performance analysis, monitoring software

•

Foreseer

•

Modem-based Remote Notify

•

Power Strategy Command

•

XCP-based service tools

UPS Firmware “flashing” at all levels will be accommodated through any serial channel. Flashing of controls and communications code segments will be handled separately.


5-1

Connectivity and Communication

9355 20 – 30 kVA

5.2 9355 X-SLOT CONNECTIVITY DEVICES The Powerware® 9355 supports a variety of connectivity devices from additional RS-232 and RS-485 serial ports to SNMP (Simple Network Management Protocol) network and web adapters. To accommodate these devices, the Powerware® 9355 product supports two (2) X-Slots which house these devices. Slots 1 and 2 can be used for any of the available cards. An optional X-Slot driver board (Mini-CSB) may add three (3) additional external XSlots. All X-Slot cards are “Hot-Swappable,” meaning that the UPS does not have to be powered down or transferred to BYPASS for the card to be installed or removed. For additional information and specific details pertaining to the setup and configuration of each connectivity device, refer to www.powerware.com for sales brochures and product manuals. Table 35. X-Slot Connectivity Device Options PART NUMBER

DESCRIPTION

05146533-5501

X-Slot, Single Port RS-232 / Serial / AS400 (Field Kit)

05146447-5501

X-Slot, Multi-Port / Multi-Server Serial / AS400 Signals (Field Kit)

05146508-551

X-Slot, USB Module

05146288-5501

X-Slot, ConnectUPS-M SNMP (Field Kit)

IPK-0330

X-Slot, ConnectUPS-X SNMP / Web Adapter 10 (Field Kit)

103002974-5501

X-Slot, ConnectUPS-S SNMP / Web / Hub 10/100 (Field Kit)

1018460

X-Slot, Low Voltage (LV) Relay Interface (Field Kit)

103003055

X-Slot, High Voltage (HV) Industrial Relay / RMP Interface (Field Kit)

103002510-5501

X-Slot, MODBUS (Field Kit)

1019017

X-Slot, Modem (Generic) (Field Kit)

1019018

X-Slot, Modem (New Zealand, Australia) (Field Kit)

103002687-001

Remote Monitoring Display Field Kit (Powerware®)

103004336

X-Slot CAN Bridge Card

*Field Kits include Board, Cable, Screws, Manual, and Software

For more details on X-Slot cards, refer to the 9355 UPS User’s Guide, Communication Options.

5.2.1

Modem Handling

A modem can be connected so that the UPS can receive calls and the UPS can make out-going calls when a programmed event occurs (Remote Notify and P-record Phone Home). When connected, the modem is pinged periodically.

5-2


9355 20 – 30 kVA

5.2.1.1


Modem Pinging

The Modem is pinged not only to ensure that is connected, but also for modem hang-up, initialization and also prior to making any out-call to assure that the modem is functional. A transfer to the pinging state occurs for the following reasons. •

The modem is pinged whenever the serial port has not received data for 15 minutes

•

Communication Server Board (CSB) Logic Power On

•

Remote Notify or P-record Phone Home Request

5.2.1.2

Modem Connected (Incoming Call)

When the Modem Connected Response is received from a serial port connected to a Modem, the status “Modem Connected” is queued in the event history queue.

5.2.1.3

Remote Notify State or XCP Modem Call Request

Any event in the system can cause a XCP Phone Home or Remote Notify call when the event transitions to its active state. The modem is always pinged prior to the call to ensure that the modem is functional and initialized. To do this, a transfer to the Ping Modem State occurs when a call is requested. All of the following items must be true for an out-call to be initiated: •

A request is made for a Remote Notify or XCP call. (See requesting calls, below.)

•

One minute has expired since an out-call to any Phone # has been made.

•

This serial port is set up to make the corresponding Remote Notify call.

•

Input as not be received for 15 Minutes. Note: Only one modem can be connected.

After the Outcall, the modem is hung up if inactivity occurs for 1 minute.

5.2.1.4

Requesting Calls

As shown below, any event can trigger an out-call. When the event goes active, the request activates if enabled for the corresponding serial port.


5-3


9355 20 – 30 kVA

P-

The Call requests are made periodically until the Call request is cleared. Up to three calls are made hourly. The modem must be disconnected for fifteen minutes before a call is initiated.

5.2.2

Modem Operation

5.2.2.1

Modem Communication Terminology

AT command set – fairly standardized command set used by modems. Most commands to the modem start with ”AT” and end to a carriage-return. Carriage-return – the ASCII code 0x0D, that is commonly used as string/line termination. D-sub – the 9-pin communication connector in PW9355. FORS – software running in a service center host computer. Whenever there is some active alarm requiring service attention, the UPS calls to FORS. Also, FORS may periodically call to the UPS to request the state and history log from the unit. Modem – a communication device that allows using serial communication over public telephone lines. XCP – the communication protocol used with PW9355. X-Slot – an extension card slot. PW9355 has two X-Slots, 1 and 2.

5-4


9355 20 – 30 kVA

5.2.2.2


Introduction

This document describes the modem support in PW9355. The modem handling is designed to work with FORS service system and any modem that uses the industry standard ”AT” command set. When the UPS requires service attention, it automatically calls to the service center. Then, using the normal XCP, the service center host computer requests data from the UPS. The service center may initiate the call to the UPS. This makes modem handling in the UPS simple. The UPS is only responsible for: •

Detecting the condition that requires service attention: this is done by correctly selecting and setting the alarms, which cause the UPS to make the call.

•

Making the call: this is done by periodically sending a correctly set command string to the modem. This is repeated until the connection is created, or predefined number of tries has been made.

•

Responding: while the connection is active, the UPS responds normally to any XCP monitoring commands. All control commands are disabled, until the required password is given.

•

Disconnecting the line: this is done by periodically sending a correctly set hang-up string to the modem, until the modem responds expectedly.

The 9355 modem support uses binary XCP. The ASCII Computer Mode (ACM), which is mentioned in the XCP Protocol Specification, is not used.

5.2.2.3

Communication Speed

The communication speed for the modem communication channel (between the UPS and the modem) must be set correctly. Modems may be able to detect this speed automatically, but the recommendation is to use a fixed speed in the modem. •

The factory setting for both communication channels is 19200bps.

5.2.2.4

Lock Communication to D-Sub

Normally the serial communication of channel 2 is done via the X-Slot 2. When the D-sub is used for communication, then channel 2 is automatically switched there from the slot. When the D-sub isn’t used anymore, the channel 2 is switched back to the X-Slot 2. The setting disables the automatic switching between the two, and locks the communication to the D-sub. This removes the possibility of losing the first command/message when a communication session is started with the UPS. This setting is recommended if channel 2 communication is used only by the Dsub. For example, this is the case when the modem is installed to the D-sub while the serial communication in the X-Slot 2 is unused. This setting has no effect on communication channel 1. The factory setting is FALSE, ”not locked to D-sub”. © 2006 - Eaton Corporation

5-5


5.2.2.5

9355 20 – 30 kVA

Control Commands Inhibition

This setting is for security: it disables all control and configuration commands coming from the communication channel. There is an independent setting for each channel. This is settable using the front panel LCD menu only. When this setting is ”not allowed” for the modem communication channel, all UPS control and configuration commands via the modem are disabled. To allow any control of the UPS via the modem, this setting must be set to ”allowed” for the communication channel, and the correct modem communication password must be given during the modem session. Note: The factory setting for both channels is ”not allowed”.

5.2.2.6

Modem Communication

This setting tells the UPS if a modem is connected to the UPS. Zero value means that no modem is installed. Other values define the communication channel where the modem is installed. All modem handling and communication restrictions (”AT” commands and password requirements, for example) are directed to this channel. The other communication channel operates normally. When the modem is installed and this parameter is correctly set, the UPS will automatically make a call when an event requires it. The call is made to the number defined by the modem call number string. •

The factory setting is zero, ”modem not installed”.

5.2.2.7

Modem Call Number

This is a string that holds the call command and the cal number. The maximum string length is 39 characters. To initialize a modem call, the UPS simply sends this string to the modem; it must include all (commands/numbers) the modem needs to make the call. For example, the phone number of the service center computer is 123-4567: Modem call number = ”ATDT1234567”. The string may also include other modem control commands. •

The factory setting is an empty string, only the automatically added carriage-return is sent to the modem.

5.2.2.8

Modem Initialization String

This string is used to initialize the modem. Normally, the correct configuration is stored into the modem non-volatile memory, and this string only directs the modem to reset itself and use the stored configuration. The maximum string length is 47 characters. While the modem handling is in the modem idle state, the UPS firmware automatically sends the initialization string to the modem every 15 minutes. The modem initialization can be commanded using a XCP parameter or with the

5-6


9355 20 – 30 kVA


front panel. Using this command causes the modem to be initialized immediately. If there is an open modem call, it will be hung up. •

The factory setting is ”ATZ0.”

5.2.2.9


When a new modem call begins, only UPS monitoring is allowed; this means commands that retrieve normal ”user” data from the UPS, meters, status, alarms, history log, and so on. To make any UPS control or configuration via the modem, a password must be given. The given password is valid only during the present modem session, and it must be given again when a new modem call is made. The password is given using the XCP Configuration Field command. The password is a write-only string for the user. Service may change the password. The maximum string length is 9 characters. In addition to giving the correct password, the control commands must be allowed for the communication channel. •

The factory setting is an empty string - the user must use the XCP Configuration Fields command to fill the empty string.

5.2.2.10 Modem Hang-up String This string is used for “escaping” the modem to command mode and hangingup the line. The maximum string length is 31 characters. All other characters except comma ’,’ (ASCII 0x2C) are sent to the modem. The comma character causes a 2 second pause before continuing. •

The factory setting is ”,+++,ATH0”.

5.2.2.11 Modem Message String When this string is set, (its length > 0) then the operation changes when the UPS makes the call. About 5 seconds after the connection is made (”CONNECT”), the UPS sends this string to the line, then sends the internal alarm message string and number (in ASCII format) that requested the call, then the UPS disconnects the line and returns to Modem Idle state. The maximum string length is 31 characters, or preferably 63 bytes if there is room in the EEPROM. The factory setting is an empty string.


5-7


5.2.3

9355 20 – 30 kVA

Modem Call Handling States

No Modem

Modem Idle Modem Initializing

Modem Hanging Up Modem Dialing

Modem Session

Figure 30.

Modem Call Handling States

Modem handling has six states:

5-8

1.

No Modem: the parameter “modem communication” has the value zero. The serial communication works normally without extra modem handling.

2.

Modem Idle: no active communication is occurring through the modem. The firmware is waiting on an incoming call, or an alarm causing the UPS to make a call.

3.

Modem Initializing: the modem is being initialized.

4.

Modem Dialing: the modem is dialing, trying to make the connection with the remote host computer.

5.

Modem Session: communication with the remote host computer is active.

6.

Modem Hanging Up: the modem is disconnecting the line.


9355 20 – 30 kVA

5.2.3.1


No Modem

Refer to Figure 31 No Modem State As long as the parameter “modem communication” is zero, the modem handling firmware stays in this state. The serial communication operates normally to both communication channels without additional modem handling. When the parameter value is changed to 1 or 2, the modem handling is directed to that channel, and the firmware changes to modem idle state.

NO modem

NO

Modem The parameter < > 0

YES Modem idle

Figure 31.

No Modem State


5-9


5.2.3.2

9355 20 – 30 kVA

Modem Idle

Refer to Figure 32 Modem Idle State In this state, the modem is disconnected from the phone line. On entering to this state, the modem handling is initialized and all active call requests from currently active alarms are cleared. Only a new alarm will cause the modem call. The internal flag “modem communication password given” is cleared. If the service needs to use control commands in the next modem session, the password must be given again. A new alarm that requests a modem call will cause the firmware to start the dialing sequence. First, a simple test is made that the modem really is off-hook. This is achieved by sending the “AT” command, which the modem should respond to with “OK”. If this is not responded to correctly after two attempts, the hang up state will be executed before dialing. The state then changes to modem dialing. If a command, or a string starting with CONNECT, is received from the modem, then a call to the UPS has been received. The state changes to modem session. While looping in this state, the UPS periodically initializes the modem by sending the modem initialization string to the modem.

5-10


9355 20 – 30 kVA


Modem idle

Clear call requests of currently active alarms. (A modem call is initialized only by a new alarm.) Clear internal flag Modem Communication Password Given.)

Time to initialize the modem?

YES Send the initialization string to the modem.

NO

Connect or a command from the modem?

YES Modem session

NO

YES

An alarm a call?

Modem dialing

NO

YES Modem installed?

The parameter < > 0

NO NO

Figure 32.

Modem Idle State


5-11


5.2.3.3

9355 20 – 30 kVA

Modem Initializing

In this state, the initialization string is sent to the modem. The response “OK” is expected as an indication of successful initialization. Depending on the situation, after initialization the modem either returns to idle state or continues dialing.

5.2.3.4

Modem Dialing

Refer to Figure 33 Modem Dialing State To initialize the call, UPS sends the modem call number string to the modem. When the connection is opened, the UPS receives a string that starts with CONNECT, or any command from the line. If the connection is not made in the dialing time of 50 seconds, dialing is interrupted by sending a carriage-return (0x0D) to the modem. The dialing time (factory setting 50 seconds) is an EEPROM value, and changeable by service. The UPS makes call attempts (up to 9 times) until the connection made. The sequence consists of three groups of three attempts. A new attempt in a group is done about one minute after the previous one. The groups have 10 minutes in between them. When starting a new re-attempt group, an additional initialization of the modem is performed. The dialing is stopped if the connection cannot be opened during nine call attempts. The call requests are cleared and the firmware jumps to “modem idle” state to wait the next new alarm to request a call.

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9355 20 – 30 kVA


Modem dialing

Initialize dialing sequence

Send the call number string to the modem

YES Connect or a command received from the modem?

Modem session

NO NO 50 seconds gone?

YES Interrupt the dialing by sending a carriage return to the modem

NO Wait a while.

Dialing sequence done? YES Modem idle

Figure 33.

5.2.3.5

Modem Dialing State

Modem Session

Refer to Figure 34 Modem Session State The monitoring commands (status, meters, history log, and so on) work normally during a modem session. The control commands require that they be allowed for the communication channel, and that the modem communication password is correctly given during the session. The password is valid only during the current session; it must be given again for the new session.


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9355 20 – 30 kVA

When the UPS receives a hang-up command, 5 minutes (EEPROM setting) has elapsed since the last command was received, string OK+carriage return, or a string starting as “NO CARRIER” is received, then the firmware state changes to “hanging up.” Modem session

Execute any monitoring commands. If the control commands are allowed via the channel and the internal flag Modem Comm. Password Given is set, execute control commands.

Correct "Modem communication password" given?

YES

Set the internal flag "Modem communication password given".

NO

YES Hang up command?

NO

"OK"+carriage-return or "NO CARRIER" received?

YES

NO

NO

5 minutes gone since the last command received?

YES

Modem hanging up

Figure 34.

5-14

Modem Session State


9355 20 – 30 kVA

5.2.3.6


Hanging Up

Refer to Figure 35 Hanging Up State The “modem hang up” string is sent to the modem every 10 seconds until the modem responds with “OK”+ a carriage return, meaning the modem is hanging up. The firmware jumps to the modem idle state. Note that the comma ’,’ in the “modem hang-up” string has a special meaning: it is not sent to the modem, but a 2-second pause is observed before continuing with the next character in the string.

Modem hanging up

Send the hang up string to the modem. Initialize 10 sec timer.

"OK"+carriage-return

Modem idle

received?

NO

NO 10 seconds gone?

YES

Figure 35.

Hanging Up State


5-15


5.2.3.7

9355 20 – 30 kVA

Modem Failure

After sending a command (except the off-hook test in Idle Mode) when the “OK” response is expected but is not received, sending the same command is repeated up to 10 times. After each try, the anticipated response duration is 10 seconds. If the modem still fails to respond correctly after the retries, the “modem failed” notice will become active. Modem failure does not affect the behavior of modem handling, but it causes an additional initialization if a new modem call is requested. Modem failure will be deactivated (“modem OK” in history log) when the modem is working properly again, that is, either the periodic initialization is carried out successfully or an incoming call is answered.

5.2.4

Communication During a Modem Session

5.2.4.1

XCP Monitoring Commands

All XCP monitoring commands work normally. These commands are the ones that read information from the UPS, but do not write or change anything.

5.2.4.2

XCP Control Commands

To be able to use the control commands during a modem session, the control commands must be enabled for the modem communication line, and the modem communication password must already be given during that session. The control commands must be preceded by an appropriate authorization code.

5.2.4.3

Requesting the History Log

An ASCII dump of the history log in PW9355 can be requested with a special command L (= 0x1B, 0x4C). There is no XCP command for this. The history log dump can easily be requested using simple terminal software. The following is a sample of a 9355 History Log using L command. [2J01/24/2005 16:30:07.590 Event #173: UPS Off Command 01/24/2005 16:30:07.660 Event #139: Inverter Off 01/24/2005 16:30:12.860 Event #140: Charger Off 01/24/2005 16:30:16.260 Alarm #199: Batteries Disconnected 01/24/2005 16:30:21.605 Notice #059: Utility Not Present 01/24/2005 16:30:21.960 Notice #008: Input Under or Over Frequency 01/24/2005 16:30:21.960 Notice #057: Utility Fail 01/24/2005 16:30:24.960 Notice #105: Bypass Not Available 01/01/0001 00:00:00.000 Event #138: Control Power On 01/24/2005 16:30:22.260 Alarm #199: Batteries Disconnected 01/24/2005 16:30:23.460 Alarm #199: Batteries Connected 01/24/2005 16:30:59.355 Event #172: UPS On Command 01/24/2005 16:31:12.960 Notice #105: Bypass Not Available 01/24/2005 16:31:13.160 Notice #105: Bypass Not Available ok 01/24/2005 16:31:21.560 Event #139: Inverter On 01/24/2005 16:31:36.660 Event #140: Charger On 5-16


9355 20 – 30 kVA


5.2.4.4

Hang-Up Command

At the end of a session, the host can, and should, command the UPS to hang up. This ensures that the UPS knows that the session has ended and is immediately ready for the next call. The hang up command is the Exit XCP to Unspecified Mode (0xFF). The host sends first the standard authorization code, and then: SFD AB

LEN 01

CMD FF

CSUM XX

Note: PW9355 “exit XCP to unspecified mode (0xFF)” command in one of the control commands that is always resident, as the service center host computer uses it as the hang-up command.

5.2.4.5

Giving the Modem Communication Password

The modem communication password is given with the XCP configuration field command (0x96) using field number 0xFFFE, “enter access password.” The modem user initially has a lower access level than a normal user with direct connection: he can use only monitoring commands. By giving the correct modem password, the user is raised to the “normal user” level. This affects not only 0x96 commands, but all control commands. The PW9355 checks the given password immediately. If the password is accepted, then XCP response is executed (0x31). If the password is incorrect, then the response is “parameter out of range” (0x35). Example 1: To give the factory default password (empty string), the host sends first the standard authorization code, and then: SFD

LEN

CMD

AB

05

96

Field # FE

FF

format

length

CSUM

01

00

XX

Example 2: To give the password ”WHATISTHIS”, the host first sends the standard authorization code, and then: SFD LEN CMD AB

0F

96

Field # FE

FF

format length 01

0A

string W

H

A


T

I

S

CSUM T

H

I

S

XX

5-17


5.2.4.6

9355 20 – 30 kVA

Setting the Modem Communication Password

To set the modem communication password, the XCP configuration field command (0x96) field number 0x0017, “modem communication password” must be used. Prior to issuing this command, the user must have used the configuration field command field 0xFFFE “enter access password” to get the correct access level for setting this string. Example 1: To set the password of ”WHATISTHIS”, the host first sends the standard authorization code, and then: SFD LEN CMD Field # format length AB

5-18

0F

96

17 00

01

0A

string W

H

A

T


I

S

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H

I

S

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9355 20 – 30 kVA


5.3 9355 COMMUNICATION 5.3.1

5.3.2

Default Communication Access Passwords Access

Password

User

-

Service

SERV

Signal Inputs & Programmable Functions

This section describes the signal inputs used in the Powerware 9355 UPS. The signal inputs are control inputs that can be used to trigger a programmable function. This section also discusses both how to use the signal inputs and what programmable functions are available.

5.3.2.1

Signal Inputs 1 & 2

The UPS incorporates two programmable inputs: X44 and X45. The connectors X44 and X45 can be found on the front of the UPS. Shorting the pins with a maximum resistance of 10 ohms activates the input signal. The function programmed to the input is triggered after the input has been in the active state for at least 1ms (±0.2ms) continuously. The same timing applies for inactivation. The inputs can also be programmed to use reverse logic. In that case, the input would be shorted by default, then opened to activate the programmable function. The logic direction is selectable from the front panel display.

5.3.2.2

X-Slot Inputs 1 & 2

Pulling the X-SLOT serial port RX-signal to a voltage between +3V and +15V for more than 5 seconds activates the input signal. The time for activating the signal is user configurable and can be selected between 0 and 65 seconds from the front panel display. The same parameter can be found in the service menu. The input signal related to X-SLOT 2 can also be activated from the service (Dsub) connector since the signals are multiplexed. The programmed function goes inactive after the activating condition has been absent for 1 second.

5.3.3

Programmable Functions

The signal inputs can be used to trigger a programmable function. By default, each signal input is linked to a building alarm, which is active while the corresponding input signal is active. The only exceptions are if the signal input is configured to the “empty” setting or to trigger another building alarm.


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9355 20 – 30 kVA

The corresponding building alarms are listed below. •

INPUT 1

Building Alarm 1

•

INPUT 2

Building Alarm 2

•

X-SLOT 1

Building Alarm 3

•

X-SLOT 2 / SERVICE

Building Alarm 4

5.3.3.1

Disable Bypass

This command disables the usage of bypass. While the signal is active, the unit will not change to bypass, neither in normal operation nor as a response to the bypass command. While active, it prefers dropping the load to changing to bypass. This function is only overridden using the “Force Bypass” setting.

5.3.3.2

Shutdown

Causes the unit to shut down immediately when activated. This function does not initiate the automatic restart itself, but if the automatic restart is already pending, it will not cancel it either. This function is edge activated. Shutting the unit down using this function will not prevent starting it up again using the front panel display or XCP. Note: The LV unit bleeds the DC rails down and does a full shut down, whereas the HV unit goes to Standby Mode.

5.3.3.3

Remote On / Off

Activating the function causes the unit to shut down. Inactivation causes the unit to start up again. If two or more input signals configured to this function are active, the start-up will be triggered when the last of the inputs inactivate. Shutting the unit down using this function will not prevent starting it up again using the front panel display or XCP.

5.3.3.4

Delayed Shutdown

Activating this function causes the unit to shut down after a user-defined delay. The default shutdown delay is 120 seconds. It can be changed on the front panel display. After shutting down, the automatic restart is initialized which will start the unit up after a delay. The pending automatic restart has higher priority than starting the unit up by XCP or by other signal input function.

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9355 20 – 30 kVA


Both the pending shutdown and automatic restart can be cancelled by pressing the front panel display on/off button (TURN UPS OFF). While the automatic restart is pending, the front panel display can be used to turn the unit ON immediately.

5.3.3.5

Force Bypass

Forces the unit to bypass operation immediately when the signal activates. The transfer is unconditional and causes load loss if bypass operation is not possible (bypass not available, etc.). Note: Force Bypass does not have any effect if the usage of bypass is disabled with the user parameter.

5.3.3.6

Request Bypass

The unit tries to transfer to bypass operation for two seconds each time when the function activates. This function is edge-triggered and only responds to the activation. The unit will not transfer to bypass if bypass is disabled with an active “disable bypass” signal input function The unit will not transfer to bypass if bypass is disabled with the user parameter.

5.3.3.7

Request Normal

This function clears an active bypass request. When the unit is in requested bypass operation, this function will cause the unit to return to normal operation. This function is edge-triggered and only responds to the activation.

5.3.3.8

Normal / Bypass

The unit tries to transfer to bypass operation for two seconds each time this function is activated. If bypass operation was achieved, the inactivation of this function causes the bypass request to be cleared and the unit to return to normal operation. If two or more input signals configured to this function are active, the normal command is given when the last one is inactivated.

5.3.3.9

External Battery Breaker

This is the external battery breaker status. While this status is active, it causes the “Battery Breaker Open” alarm to be active. The alarm remains active while one or more signal inputs configured to this function are in the active state. During the active state the batteries will not be charged (ABM: battery not connected). When the function is inactivated, the ABM will start a new charging cycle. This function also causes the active “Battery Test Failed” notices to be cleared.


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9355 20 – 30 kVA

5.3.3.10 Charger Off Turns off the charger and forces the ABM cycling to the resting status. The “battery charging disabled” notice is active while the function is active. It stays active while one or more signal inputs configured to this function are in active state. The ABM returns to normal operation when the function is deactivated.

5.3.3.11 Building Alarms Causes the selected building alarm to be active while the input signal is active. The building alarm stays active while one or more signal inputs causing the same alarm are in the active state.

5.3.3.12 External Transformer Overtemperature Starts the ”Transformer Overtemperature” alarm. If the signal is constantly active during the user settable delay, the UPS output is shut down.

5.3.3.13 On Generator While active, the UPS detects that the input is fed from a generator.

5.3.3.14 Empty This is an empty function that does not do anything. It does not cause the default building alarm to activate.

5.3.4

Signal Inputs on Front Panel Display

The input signal configuration menu on front panel display can be found under “Settings? / User Settings? / Signal Inputs”.

5.3.4.1

Selecting the Input Signal

In the first phase, the desired input signal is selected using the up/down arrow buttons. While selecting, the current settings can be seen on the display. Pressing enter (↵) selects the desired signal input for reconfiguring.

5.3.4.2

Selecting the Function

In this phase, the desired function can be selected using the up/down arrow buttons. Pressing the bent arrow (the leftmost button) cancels the selection and returns to selecting the signal. On input signals 1 and 2, pressing enter (↵) moves on to selecting the logic setting. If the selected signal is either of the X-SLOT input signals, pressing the enter button confirms the selection and it will be taken into use. 5-22


9355 20 – 30 kVA


Note: If the selected input signal is active when confirming the selection, the function will activate immediately. There is a danger of load loss if the selected function is, for example, ‘shutdown’ and the unit is online.

5.3.4.3

Selecting the Logic Setting

In this phase, the desired logic setting can be selected using the up/down arrow buttons. Logic 1 means that the function is active when the input is shorted (normally open). Logic 0 means that the function is active when the input is opened (normally closed). Pressing the bent arrow (the leftmost button) cancels the selection and returns to selecting the signal. Pressing the enter (↵) button confirms the selection and activates the new function. Note: If the selected input signal is active when confirming the selection, the function will activate immediately. There is a danger of load loss if the selected function is, for example, ‘shutdown’ and the unit is online.

5.3.5

Configuration Fields

This command is used to set or modify the UPS configuration (parameters, variables). This is an XCP command that allows various types of configuration settings. Table 36. Configuration Settings NAME

DESCRIPTION

UNITS

TYPE

Audible Alarms

0 = disable horn, 1 = normal, 2 = mute current alarms

Nominal Output Voltage

Changing this value will also adjust the window set by Bypass Voltage Maximum and Bypass Voltage Minimum

0.1V

U16_T 16-bit, range -32768 … +32767.

Bypass Voltage Maximum

Max accepted bypass deviation from Nominal Output Voltage. Follows changes in Nominal Output Voltage setting

1%

S8_T 8-bit, range -128 … +127.

Bypass Voltage Minimum

Min. accepted bypass deviation from Nominal Output Voltage. Follows changes in Nominal Output

1%

S8_T 8-bit, range -128 …


U8_T 8-bit, range 0 … 255.

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9355 20 – 30 kVA

Table 36. Configuration Settings NAME

DESCRIPTION

UNITS

Voltage setting Nominal Output Frequency

Changing this value will also adjust the Synchronization Window accordingly

Synchronization Window

Accepted bypass frequency deviation from Nominal Output Frequency. Follows changes in Nominal Output Frequency setting

Output Frequency Max Slew Rate

The maximum speed for UPS to change the output frequency

Number Of Battery Strings

Battery Watts Per Cell

15 min. rate to 1.67 VPC at 25 C

Battery Cells Per String

TYPE +127.

0.001 Hz

U16_T 16-bit, range 32768…+32767

0.1 Hz

U8_T 8-bit, range 0 … 255.

0.1 Hz/s

U16_T 16-bit, range -32768 … +32767.

1

U16_T 16-bit, range -32768 … +32767.

1 W/cell

U16_T 16-bit, range -32768 … +32767.

1

U16_T 16-bit, range -32768 … +32767.

Constant Float Voltage

Sets the battery charging voltage when ABM cycling is disabled

0.001 V/cell

U16_T 16-bit, range -32768 … +32767.

Low Battery Warning Level

Voltage level at which the low battery alarm is given

0.001 V/cell

U16_T 16-bit, range -32768 … +32767.

On Battery Alarm Delay

The number of seconds on battery after which ”UPS on Battery” alarm is given

1s

U16_T 16-bit, range -32768 … +32767.

Maximum Charge Current

The maximum current for battery charging

0.1 A

U16_T 16-bit, range -32768 … +32767.

Automatic On Delay

Values 0...32767 = extra turn-on delay in seconds; value -1 = no automatic restarts

1s

U16_T 16-bit, range -32768 … +32767.

Automatic Off Delay

Values 0...32767 = seconds on battery after which output is automatically turned off; value -1 = no timed turn-off

1s

U16_T 16-bit, range -32768 … +32767.

Hardware Remote Off Delay

The delay before the shutdown, when hardware Remote off with restart command is activated.

1s

U16_T 16-bit, range -32768 … +32767.

X-Slot shutdown signal activation delay

The filtering delay, before the input signal is considered active.

1s

U16_T 16-bit, range -32768

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9355 20 – 30 kVA



DESCRIPTION

UNITS

TYPE … +32767.

Rectifier Current Limit

Maximum current the rectifier draws from utility

0.1 A

U16_T 16-bit, range -32768 … +32767.


Which communication channel the modem is installed to; value 0 = no modem

1

U8_T 8-bit, range 0 … 255.

Modem Call Number

The call command and number for the modem to make the call

SSTRING_T String. Maximum 128 bytes.

Modem Initialization String This string is used to initialize the modem




Giving this password is required to control the UPS via modem

Unit Telephone Number


CTO Number


Serial Number


Part Number


UPS Family Name

For XCP ID block, front panel display, etc


Reset

Changes automatically back to zero after execution Bit 0: Reset most configuration fields to factory setting Bit 1: Reset the history log Bit 2: Reset & initialize the modem

BMASK16_T

Battery Handling

Bit 0: Automatic battery support test: 0=enable/1=disable Bit 1: ABM charging cycling: 0=enable/1=disable Bit 2: Charging temperature compensation: 0=enable/1=disable

BMASK16_T


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9355 20 – 30 kVA


DESCRIPTION

UNITS

TYPE

Operation Settings

Bit 0: Preferred operation mode during rectifier input fail: 0=on battery/1=on bypass Bit 1: In case of overload, transfer on bypass 0=immediately/1=after a delay Bit 2: To transfer on bypass, the synchronization is 0=not required/1=required (never transfers unsynchronized) Bit 3: Synchronization is 0=enabled/1=disabled Bit 4: Usage of bypass is 0=enabled/1=disabled Bit 5: Site wiring fault alarm is 0=enabled/1=disabled

BMASK16_T 8-bit bit field + 8-bit mask defining the implemented bits.

Service Control

This is UPS specific control, read service manual for details

U16_T 16-bit, range -32768 … +32767.

5.3.5.1

CAN Traffic

The bridge will monitor the internal CAN bus for messages that have 0xD in the Source field of the routing identifier. The bridge will then modify the source solely to identify which bridge card the message is being transferred from, and transmit the message on the external CAN bus. The bridge will also monitor the external CAN bus for messages with a destination field that matches its identifier, all units identifier (0xE), or the “everyone” identifier (0xF). The bridge will then strip the destination and replace it with 0xD and transmit the message on the internal CAN bus.

5.3.5.2

CAN IDs

5.3.5.3

Baud Rates

The internal CAN bus is 1 Mbit and the external CAN bus is 250 Kbit.

5.3.5.4

Serial Port

The RS-232 serial port on the bridge card has two modes of operation. If the Serial Function (Command 0x04) is set to 0, the RS-232 will be a pass-through to the X-Slot interface. If the Serial Function is set to 1, the RS-232 will be a serial over CAN interface. The RS-232 serial port on the bridge card will be controlled by a serial to CAN routine to pass the information to the serial processing on the Control Board (or Mini-CSB).

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9355 20 – 30 kVA

5.3.6


HyperTerminal

5.3.6.1

HyperTerminal Emulation Configuration for the Powerware® 9355 UPS 1.

Click on the Start Button, go to Programs, go to Accessories, go to Communications, Click on HyperTerminal, Figure 36.

Figure 36.

2.

Path to HyperTerminal Application

Click on HyperTerminal.exe Enter a name for the emulation and select an icon, when complete Select OK, Figure 37.

Figure 37.

HyperTerminal Opening Screen Selections © 2006 - Eaton Corporation

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3.

The Connect To window appears, Connect using: COM1 or COM2 – Select OK after selecting the active serial port from the drop-down menu, Figure 38.

Figure 38.

4.

9355 20 – 30 kVA

Select COM1 or COM2 from the drop-down menu

When the COM1 or COM2 Properties window appears, make the following selections on the screen, Figure 39: -

Bits per second: 19200 Data Bits: 8 Parity: None Stop Bits: 1 Flow Control: None when complete select OK

Figure 39.

5-28

Port Parameter Setup


9355 20 – 30 kVA

5.


Go to the File menu on the Menu bar, click on Properties, Figure 40.

Figure 40.

File, Properties menu options, Settings tab, Emulation drop-down

6.

The Properties window comes up, click on the Tab labeled Settings, Figure 40.

7.

In the window click on the Emulation drop-down menu and select ANSI - Go to the View menu on the Menu bar, click on Font, ensure that the Font selected is Terminal

Figure 41.

Font Settings menu

When you have completed the previous instructions – don’t forget to save your new emulation. Go to File and select Save. The following functions are available in the Terminal Emulation: •

ESC B – Battery Test Queue

•

ESC L – Set to Print out the History Log, see para 5.2.4.3.

These buttons should be pressed sequentially, not simultaneously. Failure to follow this procedure may cause communications to lock-up. Example: Press and release the ESC key, wait 2 seconds and press the L (log history) key. © 2006 - Eaton Corporation

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9355 20 – 30 kVA

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5-30


6 Options 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 6.3 Power Distribution Unit (PDU) 6.4 Remote Power Panel (RPP) 6.4.1 IQ 100 Series RPP 6.4.2 IQ 200 Series RPP


6-2 6-2 6-3 6-5 6-7 6-8 6-9 6-10 6-13 6-14 6-14 6-15 6-18 6-19 6-19 6-19

6-1

Options

9355 20 – 30 kVA

6.1 Communications and Connectivity Options 6.1.1

Single Port RS-232 Serial or AS/400 Signal Card

Figure 42.

Single Port Serial Card

This card makes an additional RS-232 communications port available, and AS/400 interface signals via open collector outputs, containing the following signals: •

PS Available/On Bypass

•

Utility Failure

•

Low Battery

Connection to the card is accomplished with a single DB9 female connector:

6-2

Pin 1 = (OUT)

“Low Battery” signal (Open Collector (O.C.)

Pin 2 = (OUT)

TXD Transmit to external device

Pin 3 = (IN)

RXD Receive from external device

Pin 4 = (IN)

DTR PnP from external device

Pin 5 = (GND)

Signal common

Pin 6 = (OUT)

DSR Module Ready to external device

Pin 7 = (IN/OUT)

RTS PnP from external device (default) or “On Bypass” signal (O.C.) (jumper-selectable)

Pin 8 = (OUT)

“AC Fail” signal (O.C.)

Pin 9 = (OUT)

Power Source +V (8 to 24 volts DC power)


9355 20 – 30 kVA

6.1.2

Options

Multi-Port/Multi-Server Card

Figure 43.

Multi-Port Serial Card

This card provides multiple RS-232 ports for communications between several UPS modules or multiple computer servers and is available for use on any of the provided X-Slots. Six (6) DB-9 female connectors (COM1 – COM6) are provided. COM1 (configuration port) supports both RS-232 and AS/400 signals. AS/400 signals are all open collector type outputs: •

UPS Available/On Bypass

•

Utility Failure

•

Low Battery

Pin 1 = (OUT)

“Low Battery” signal (Open Collector (O.C.))

Pin 2 = (OUT)


Pin 3 = (IN)


Pin 4 = (IN)


Pin 5 = (GND)

Signal common

Pin 6 = (OUT)

DSR Module Ready to external device

Pin 7 = (IN/OUT)

RTS PnP from external device (default) or “On Bypass” signal (O.C.) (jumper-selectable)

Pin 8 = (OUT)

“AC Fail” signal (O.C.)

Pin 9 = (OUT)

Power Source +V (8 to 24 volts DC power)


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Options

9355 20 – 30 kVA

COM2 – COM6 are RS-232, but only configurable for the following modes:

6-4

•

Terminal

•

Computer (XCP)

•

Modem

Pin 1 = (IN)

DCD input

Pin 2 = (OUT)


Pin 3 = (IN)


Pin 4 = (IN)


Pin 5 = (GND)

Signal common

Pin 6 = (OUT)

DSR .Module Ready” to external device

Pin 7 = (IN)

RTS From external device

Pin 8 = (OUT)

CTS To external device

Pin 9 = (OUT)

Power Source +V (8 to 24 VDC power) Out


9355 20 – 30 kVA

6.1.3

Options

Low Voltage (LV) Relay Interface Card

Figure 44.

Low Voltage Relay Interface Card

This card provides true FORM C relay contacts (NC and NO) through two methods which are: 1) a single 15 point terminal block, and 2) a single two row DB-15 male connector. Table 37. Low Voltage Relay Interface Contacts RELAY #

SYSTEM STATE

K1: Utility Fail

D15 / TB1

CONTACT *

1

C

Utility OK

2

NC

Utility Failure

3

NO

4

C

Normal Battery

5

NC

Low Battery

6

NO

7

C

UPS Alarm

8

NC

UPS OK

9

NO

10

C

On Bypass

12

NC

On Inverter

11

NO

LV Supply **

13

+12 VDC

14

C

15

(IN)

K2: Battery

K3: UPS Alarm

K4: Bypass

UPS Shutdown **

* - Normally Closed (NC) and Normally Open (NO) are indicated when the card / relay is de-energized. ** - To activate a UPS shutdown via an external contact closure, the UPS shutdown input (Pin 15) must be held high (+12VDC) for a minimum of 5 seconds. Relay contacts are rated for a maximum 1A at 30VAC or 200 ma at 60 VDC. All relay outputs are galvanically isolated from other circuits in the UPS (IEC 950, EN 50091-1). © 2006 - Eaton Corporation

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9355 20 – 30 kVA

NOTES: The shut down function is only supported by single-phase products. The relay contacts must not be galvanically connected to any mains connected circuits. Do not use Pin 13 (+12 VDC) as a power supply source to support external devices. Reinforced insulation to the mains is required for equipment and cables connected to these devices.

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9355 20 – 30 kVA

6.1.4

Options

High Voltage (HV) Industrial Relay / RMP Interface Card

Figure 45.

High Voltage Industrial Relay Card

This card provides both an RMP signal interface and four sets of Form C relay contacts serving as both an RMP driver and a Relay Interface Module (RIM). The RMP signals and relay status contacts can be used simultaneously but cannot be programmed separately. RMP Signal Interface:

J1 (6 total positions, 2 plugs, 3 positions each)

Relay Contact Interface: J2 (12 total positions, 4 plugs, 3 positions each) The Industrial Relay Card (IRC) can provide the following signals as shown in the following table: Table 38. High Voltage Relay Interface Contacts RELAY # K1: Utility Fail

K2: Bypass

K3: Battery

K4: UPS Alarm

SYSTEM STATE

J2

CONTACT *

1

NC

2

C

Utility Failure

3

NO

On Bypass

4

NC

5

C

On Inverter

6

NO

Normal Battery

7

NC

8

C

Low Battery

9

NO

UPS Alarm

10

NC

11

C

12

NO

Utility OK

UPS OK

* Normally Closed (NC) and Normally Open (NO) are indicated when the card / relay is de-energized.. Relay contacts are rated for a maximum 5A at 250 VAC or 1A at 60 VDC. All relay outputs are galvanically isolated from other circuits in the UPS (IEC 950, EN 50091-1).


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9355 20 – 30 kVA

6.1.5

ConnectUPS Network Adapters

These devices provide UPS data to one or more computers over an Ethernet network. Board connections include: •

RJ-45 network connector

•

DB-9, RS-232 configuration port

There are several different vintages of these adapters: •

Classic (external enclosures, non-X-Slot)

•

Models M, MX, X

•

10 MB SNMP/Web Card Adapter

•

10/100 MB SNMP/Web/Hub Card Adapter

Figure 46.

10 Megabyte SNMP/Web

Figure 47. 6-8

10/100 Megabyte SNMP/Web/Hub

SNMP / Web / Hub Card Components © 2006 - Eaton Corporation

9355 20 – 30 kVA

6.1.6

Options

MODBUS Communications Card

Figure 48.

MODBUS Communications Card

The MODBUS card provides both RS-232 and RS-485 serial data to a customer’s Building Management System (BMS). Board connections include: •

Both a 2 wire and 4 wire topology

•

RS-232 and RS-485 Communications

•

RS-485 Hard Wire Terminal Block

•

RS-485 DB-9 MOD Bus Port

•

RS-232 DB-9 MOD Bus Port

•

RS-232 DB-9 Configuration Port

Figure 49.

MODBUS Communications Card Components


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9355 20 – 30 kVA

Table 39. MODBUS Communications Card Connector Pins SIGNAL

RS-232 (DB-9F) RS-485 (DB-9F)

RS-485 (TB)

TxD (+)

2

2

1

RxD (+)

3

1

2

TxD (-)

-

7

3

RxD (-)

-

6

4

Signal Ground

5

5

5

6.1.7

Modem Card

Figure 50.

Modem Card

The X-SLOT Modem is made for UPS remote monitoring purpose. The modem card allows the unit to be connected to remote computers via a standard phone line connection. It is installed to UPS X-SLOT extension place and it offers one RJ-11 phone-jack connector for telephone network connection and four LEDs to indicate its status on its faceplate. There are also an on-board RS-232 port and DC-socket for the purpose of configuration which are not available when the Modem is installed in the UPS. The X-SLOT Modem is based on Conexant SocketModem or Multitech ModemModule chip. SocketModem is a fully functional modem that needs only +5 VDC and some external components for the interfaces to operate. The following will explain the functional parts of the modem board.

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9355 20 – 30 kVA

Options

Figure 51.

6.1.7.1

X-Slot Modem Functional Parts

Functional Parts 1.

SocketModem chip (C9, M1, R2, R5) Fully functional modem chip. There are two alternative manufacturers: Conexant and Multitech.

2.

Jumpers (J1 - J3) These jumpers set modem behavior in terms of hardware signals. The assembly picture explains how to assemble these jumpers. By default, hardware signals are not used.

3.

Telephone network interface (F1, V9, X7) The telephone network interface consists of RJ-11 connectors and overvoltage-(V9) and overcurrent (F1) surge arresters.

4.

Indicator LEDs (R13 - R16, V1 - V4) Indicator LEDs shows modem status. There are four LEDs: Receiving (RX), Sending (TX), Data Carrier Detect (off-hook) (DCD) and Data Terminal Ready (that is, modem is ready (DTR)), which will nearly always be lit.


6-11

Options

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9355 20 – 30 kVA

5.

RS-232 interface (C4 - C8, D1, R17, X3) RS-232 interface consists of a 9-pin RS-232 port and MAX3232 voltage level conversion IC (D1). This port is for configuration purposes. Modem should be configured before it is assembled in the UPS.

6.

+5V DC-DC converter (C1 - C3, C10, L1, N1, R1, V5, V8) This circuit will make the operating voltage for the modem board. It will convert 8 - 25 VDC input from the X-SLOT +V to +5 VDC. This DC-DC converter is based on National Simple Switcher® IC (N1).

7.

Current limiter (C11, R3, R4, R7 - R11, V6, V7) The current limiter is situated between the X-SLOT +V (8-25 VDC) output and +5V DC-DC converter input. It protects UPS power supplies from overloading. Current is limited to under 550mA with transistor circuitry. Short-circuit protection is implemented with fusible resistors R3 and R4.

8.

DC-socket (X4) This DC-socket is for configuration purposes. 9 - 25 VDC is supplied via this connector when the modem board is configured.

9.

Faceplate screw terminals (X5, X6) The faceplate of the modem board is attached through these terminals. There is not any electrical connection between modem circuitry and faceplate terminals.

10.

X-SLOT connector (X1) The modem draws its power and communicates with the UPS through the X-SLOT connector when the modem is assembled into the UPS.


9355 20 – 30 kVA

6.1.8

Options

USB Module

The X-Slot Universal Serial Bus (USB) Module Card is an X-Slot connectivity device that allows your UPS system to communicate with a USB - compliant computer using LanSafe power management software.

Figure 52.

USB Module

The following requirements must be met to install the USB Module: •

A computer with a USB port

•

LanSafe III power management software (v4.15 or higher)

•

Microsoft Windows 98 or higher


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Options

9355 20 – 30 kVA

6.1.9

CAN Bridge Card

Figure 53.

CAN Bridge Card

A CAN Bridge Card is connected between two different CAN networks denoted the ICAN and ECAN. The CAN Bridge receives messages that are addressed to it and re-transmits these messages on the other network. Refer to Figure 53 of the CAN Bridge Card. The function of the CAN Bridge Card is to provide a translation interface between the internal CAN bus and the external CAN. One CAN Bridge Card per module is required for a 9355 parallel system. The bridge card also controls one relay, one building alarm, and an RS-232 serial port.

6.1.10

Remote Monitor

The Remote Monitor panel has a two-wire connection. The breakdown of the connections is shown below in Figure 54 CAN Bridge Card J3 Terminals.

J3

Building Alarm 2 replacement, or can be used for Pull-Chain wiring if Building Alarm 2 on TB1 is already in use.

Connections for Parallel System Control

Connections for Bypass Status

Figure 54. 6-14

Connections for RMP, RIM, or SCM

CAN Bridge Card J3 Terminals


9355 20 – 30 kVA

Options

6.2 Options Cabinet

NOTICE For more in-depth information about the Options Cabinet, including setup and installation, download the 9355 UPS 20/30kVA User’s Guide from www.Powerware.com.

The Options Cabinet is available in four models: 1.

Options Cabinet with a maintenance bypass switch that provides wrap-around bypass for UPS maintenance or service without shutting down the load, see Figure 55.

Options Cabinet with MBS Only L1 L2 L3 Input N N L1 L2 L3

Output

N N

Maintenance Bypass Auxiliary Contacts

Options Cabinet with MBS and Input Isolation Transformer L1 L2 Input L3

L1 L2 L3

Output

N N

Figure 55.

2.

Options Cabinet with MBS Wiring

Options Cabinet with both MBS and input isolation transformer that allows operation from a 208V, 480V, or 600V 60-Hz source (input transformer in single-feed systems or bypass transformer in dual-feed systems). © 2006 - Eaton Corporation

6-15

Options

9355 20 – 30 kVA

3.

Options Cabinet for dual-feed systems, see Figure 56, provides the second input from a 208V, 480V, or 600V 60-Hz source.

Second Options Cabinet with Rectifier Transformer

Second Options Cabinet with MBS Only

L1

L1

L2 Input

L2

L3

L3 Input N N L1 L2 L3

Output

N N


Figure 56.

6-16

Options Cabinet with Dual-Feed Wiring


9355 20 – 30 kVA

Options

4.

Options Cabinet with an output isolation transformer for 480V loads, see Figure 57.

Second Options Cabinet with Output Transformer

First Options Cabinet with MBS Only L1 L2 L3 Input N N

L1

L1

L2

L2

L3

Output

L3

N

N

N

N

Output


Figure 57.

Options Cabinet with Output Transformer Wiring


6-17

Options

9355 20 – 30 kVA

6.3 Power Distribution Unit (PDU) The 9355 20-30kVA UPS module(s) may be connected to an optional Power Distribution Unit, see publication 164201641, Powerware PDU 30-300kVA. A three phase power input is wired to the input of the Power Distribution Unit (PDU) and distributed to numerous output panels (one to ten). Each of these output panels contains a main circuit breaker that feeds up to 42 smaller branch circuit breakers and / or sub-feed breakers. The branch circuit breakers can be single or multi-phase and are wired to the customers load. The PDU may also contain a transformer for isolation and/or voltage conversion.

6-18


9355 20 – 30 kVA

Options

6.4 Remote Power Panel (RPP) 6.4.1

IQ 100 Series RPP

Eaton’s Cutler-Hammer IQ 100 is designed for basic feeder applications where minimal data is required by the end user, see Figure 58. This simple-to-use meter provides accurate measurement and displays up to 12 electrical parameters including average voltage and current for the system, plus line-to-line and line-to-neutral measurements. As an option, frequency can also be monitored. The IQ 100 has programmable voltage and current transformer ratios and true RMS indication for accurate measurement of distorted waveforms, which can be viewed through four screens via a high visibility LED display. The IQ 100 is an invaluable tool for all power monitoring applications. There are two models in the IQ 100 series of meters: •

The IQ 110 models provide voltage and current measurement only.

•

The IQ 115 models provide frequency monitoring in addition to voltage and current measurement.

All other characteristics are identical in all meters in the IQ 100 series.

6.4.2

IQ 200 Series RPP

Eaton’s Cutler-Hammer IQ 200 compact size and flexible mounting capabilities make it perfectly suited for machine control panels such as panel board and switchboard mains and feeders, low voltage metal-enclosed switchgear feeders, motor control centers, and especially for individual load monitoring, see Figure 58. The base module can be display mounted, panel-mounted, DIN-rail mounted or side mounted. The display fits into a standard 1/4 DIN cutout, and for retrofit applications a 100mm ANSI collar is available. One IQ 200 provides an alternative to an assortment of individually wired and mounted ammeters, voltmeters, ammeter and voltmeter switches, watt-meters, var-meters, power factor meters, frequency meters, watt hour and demand meters. ANSI C12 Class 10 revenue metering accuracy make the IQ 200 an ideal choice for sub-metering and sub-billing applications. The IQ 200 can be easily programmed and monitored from the faceplate keypad which features a 4 line x 20 character LED back-lit LCD display. Opting for the compatible Eaton Cutler-Hammer Power Net system allows the user to program and monitor the meter remotely from a PC. Retrofit Opportunities: •

Retrofit of existing electrical distribution systems with the IQ 200 for load and energy monitoring

•

Five mounting options makes installation easier


6-19

Options

9355 20 – 30 kVA

IQ 100 series Figure 58.

6-20

IQ 200 series

Remote Power Panels Series 100 and 200


7 Troubleshooting and Maintenance 7.1 Troubleshooting Charts 7.1.1

Action Levels

The following table explains the various action levels and actions taken for the Powerware® 9355. This table is to be used when determining a course of action to respond to a system event generated by the UPS Events or Web Card. See paragraph 7.1.2 and paragraph 7.1.4 for Failure Analysis. Table 40. 9355 Action Levels Name of Action Level

Description of Action to be Taken

Examples

Mon. SW Alert Level

Advisory

User should be aware that a condition exists which does not threaten the protected equipment, but that might need to be checked.

Building Alarm, Shutdown Scheduled, Some Events

Inform

Alarm Level 1 (User Alarm - User action required)

The User should note the condition and may need to take immediate action. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Alarm Lamp will light when the associated bit is active.

Check Modem, Battery Voltage Low, and so on.

Major

Alarm Level 2

Not defined.

Alarm Level 3 (Shutdown is Imminent)

This alarm condition indicates that shutdown of the UPS could occur. The Shutdown could result in a load loss. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Alarm Lamp will light when the associated bit is active.

Load Over 100%, OverTemperature, and so on.

Critical

Alarm Level 4 (Schedule Service)

A condition in the UPS has been detected that requires servicing but could be scheduled and does not require immediate service. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Alarm Lamp

Check Battery, Redundant Fan Failure, and so on.

Minor


7-1

Troubleshooting and Maintenance

9355 20 – 30 kVA

Table 40. 9355 Action Levels Name of Action Level


Examples

Mon. SW Alert Level

will light when the associated bit is active. Alarm Level 5 A technically oriented alarm condition. The (Service Information) user should call for service to evaluate the condition. These conditions may clear but may indicate a pending problem. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Alarm Lamp will light when the associated bit is active.

7-2

Inverter Current Limit, Inverter Overload, Rectifier Overvoltage, DC Link Overvoltage

Minor

Alarm Level 6 (Service Required)

Service of the UPS is required. In some Inverter Failure, UPS products, the message is displayed on Fan Failure, and the Active Alarm/Notice Screen and the so on. Alarm Lamp will light when the associated bit is active.

Major

Command

UPS Control Commands

UPS ON, UPS OFF, and so on.

Inform

Immediate Service

A condition exists which can threaten the protected equipment; it must be addressed today.

On Bypass, Fan Failure

Major

Load Power Off

The UPS is not providing power to the protected equipment at this time.

UPS Off by Command, DCUV

Critical

Non-Critical Shutdown

A condition exists in which the UPS may not be able to continue protecting all loads; non-critical equipment should be shutdown at this time.

Normal

None

(Normal)

Notice Level 1 (Information Only)

Notice conditions that are for Information only. These Notices require no action. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Notice Lamp will light when the associated bit is active.

Input AC Under Voltage, Equalizing Battery, and so on.

Inform

Notice Level 2 (User Interaction)

Notice conditions that tell the User to do something. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Notice Lamp will light when the associated bit is active.

User is being told to close the Input Breaker.

Minor

Notice Level 3 (Protection Level)

Notice conditions that inform the User that the level of load protection has increased or decreased. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Notice Lamp will light when the associated bit is active.

Bypass is Not Available, System Not Redundant, System Redundant, and so on.

Minor

Notice Level 4 (Investigate UPS)

The user should investigate the UPS. In some UPS products, the message is displayed on the Active Alarm/Notice Screen and the Notice Lamp will light when

Building Alarms, Emergency Transfer to Bypass

Minor


Major

9355 20 – 30 kVA


Table 40. 9355 Action Levels Name of Action Level


Examples

Mon. SW Alert Level

the associated bit is active. Notice Level 5

Not Defined.

Notice Level 6

Not Defined

Notification

Simple Event Notification; no action required

Some Events

Inform

OFF

An Indicator, LED, or Switch is OFF; no action required.

Front Panel LED

Inform

ON

An Indicator, LED, or Switch is ON; no action required.

Front Panel LED

Inform

Safety Hazard

A condition exists which may imperil personnel near the UPS.

Door Ajar with Voltage Present

Major

Schedule PM

A condition exists which must be addressed Battery Health by scheduling service for the UPS. Low

Minor

Service Status (Information Only)

Status conditions that are service oriented

Inverter On, Input Filter closed

Inform

Shutdown Required

The UPS can only provide power to the protected equipment for less than the configured Low Battery Warning Time; all protected equipment should commence shutdown procedures immediately.

Low Battery Shutdown Pending, Shutdown Imminent

Critical

User Status (Information Only)

Status conditions that are User oriented.

On Battery, Unit Normal, Input Breaker Closed

Inform

Warning

User should be aware that a condition exists which does not currently threaten the protected equipment but that it indicates an underlying problem and may lead to a situation that will.

On Battery Battery not charged, Output Overload

Minor

7.1.2

Alarm, Notice, Status & Flag Definitions

The following are lists of all the various notices and alarms that can be annunciated or acted on by the Powerware® 9355 UPS. Use these charts with the charts in paragraph 7.1.2, Action Levels and paragraph 7.1.4, Failure Analysis to determine the course of action. The functional descriptions are also an excellent source for determining the expected machine states during start up and shut down. This can help narrow down which board is generating the problem error.


7-3


9355 20 – 30 kVA

Definitions (Alarm # = Node Bit #)(Listed in alphabetical order of LCD Description) for PW9355 Alarm #

7-4

LCD Description

Web card description

Comments

Notes After replacing SCRs, 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.

222


The output condition (other than Output Overload) is out of tolerance

Voltage detected on the output when there shouldn't be any (bypass SCRs assumed bad)

203

Ambient over temperature

UPS Temperature Alarm condition exists

Ambient temperature sensor reads higher than limit (45ºC)

202

Ambient under temperature


This alarm is listed in the alarm block, but is never set in DSP firmware

219

Autocalibration Failed

UPS General System Test failed

An attempt to automatically (re-) calibrate the UPS has failed.

206

Automatic shutdown pending

UPS turn off countdown underway

Unit has received scheduled off command from XCP

199

Batteries disconnected

Replace Battery Warning condition exists

Battery circuit breaker open, or voltage less than disconnected limit

107

Battery contactor open

UPS Circuit Breaker Alarm condition exists

Signal input, disables charger

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

68

Battery DC over-voltage


Battery voltage higher than 50mV/cell above charger float voltage, shunt trips battery breaker

56

Battery low

Low Battery Alarm present

Battery voltage is below configured level (1.88V/cell). Only active if unit is on battery


9355 20 – 30 kVA Alarm #

LCD Description

Troubleshooting and Maintenance Web card description

Comments

149

Battery needs service


Detected reversed battery polarity

191

Battery test failed


1 or more of the ABM battery tests failed, see ABM documentation

256

Battery Test in Progress

A UPS Notice condition exists

A Battery Test has begun.

19

Building alarm 1

One of the defined building alarms has occurred

Signal input, user configurable

18

Building alarm 2



17

Building alarm 3



16

Building alarm 4



15

Building alarm 5



14

Building alarm 6



3

Bypass ac over voltage

UPS bypass unavailable

Bypass voltage is > user configured over voltage level.

4

Bypass ac under voltage


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


DSP cannot read status of bypass pic, or bypass pic is not changing states when commanded to

105

Bypass not available


Bypass voltage and/or frequency is out of configured limits, bypass transfer is not allowed


Notes

7-5

Troubleshooting and Maintenance Alarm #

7-6

LCD Description

9355 20 – 30 kVA Web card description


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


This is a warning that the autocalibration has failed, while calibrating Bypass sensor.

5

Bypass under/over frequency


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


Boost IGBT temperature exceeded shutdown level (90ºC)

140

Charger Status

Not Applicable

The charger is on.

121

Check Parallel Board


The board used for paralleling control appears to have failed.

36

Check Static Switch


Static switch fault: The static switch appears to have failed.

224

Configuration error


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)


Battery failed to reach float voltage in time allowed

244

Contact service (illegal instruction)


Internal CPU error

The bypass breaker is open.


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 #


LCD 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



28

dc link over voltage


Either positive rail was greater than 250V, or negative rail was less than 250V

29

dc link under voltage


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


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


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.


7-7


7-8

LCD Description


Comments

74

Heatsink temperature sensor fail


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


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


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


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


The inverter temperature has exceeded it s rating operating temperature.

48



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 #


LCD Description


Comments

41

Inverter Uncalibrated


This is a warning that the autocalibration has failed, while calibrating inverter.

159

L1 Overload


PHA VA or watts greater than 111% UPS rating

165

L1 Overload (Extreme Level)



162

L1 Overload (High Level)



160

L2 Overload


PHB VA or watts greater than 111% UPS rating

166




163




161

L3 Overload


PHC VA or watts greater than 111% UPS rating

167




164




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.


Notes

7-9


LCD 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


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



25

Output overload


Greater than 102% load on any output phase

58

Output Short Circuit


Output short circuit detected

72

Power supply 12 volt fault


Digital input from control board power supply monitoring chip

71




70

Power supply failure


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


Notes

9355 20 – 30 kVA Alarm #

LCD Description


Comments

26

Rectifier input over current


Hardware current limit trip, Unit saw rectifier current reached the hardware limit for 20 consecutive line cycles

223

Rectifier over temperature


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


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


Measure chassis voltage too high measured against neutral

176

Software incompatibility detected


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.


Notes

7-11


LCD Description


Comments

132

System Not Redundant


For an "n+1" parallel system, the load is supported, but the system is no longer has redundant protection.

257

System Test in Progress


One of the Systems Tests has begun.

258

Test Aborted


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


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 is on bypass

248

UPS on generator

The system is being powered by its Alternate Power Source

Signal input

57

Utility fail


Utility voltage or frequency outside limits. Does not necessarily mean unit is on battery.

59

Utility not present


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


Comments


Set if Phase to phase or phase to neutral voltage is < 90% of setpoint.


Notes

9355 20 – 30 kVA Alarm #

LCD Description


Comments

3

Bypass ac over voltage


Bypass voltage is > user configured over voltage level.

4

Bypass ac under voltage


Bypass voltage is < user configured over voltage level.

5

Bypass under/over frequency


Bypass frequency is outside of user configured window

6

Input ac over voltage


Input voltage is greater then eeprom limit (144Vac), unit can't run utility, is on battery

8

Input under/over frequency


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



12

Remote emergency power off


Signal input, output is deenergized and battery breaker is tripped. Output can't be energized while active

14

Building alarm 6



15

Building alarm 5



16

Building alarm 4



17

Building alarm 3



18

Building alarm 2



19

Building alarm 1




Notes

7-13


LCD Description


Comments

21

Charger over temperature


Battery converter / Charger IGBT module temperature exceeds it's limit

24

Inverter over temperature


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


Greater than 102% load on any output phase

26

Rectifier input over current


Hardware current limit trip, Unit saw rectifier current reached the hardware limit for 20 consecutive line cycles

27

Inverter output over current


Hardware current limit trip, Unit saw inverter current reached the hardware limit for 20 consecutive line cycles

28

dc link over voltage


Either positive rail was greater than 250V, or negative rail was less than -250V

29

dc link under voltage


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


Bypass voltage is detected at startup (should be mapped to alarm #195, "Back-feed contactor failure")

36

Check Static Switch


Static switch fault: The static switch appears to have failed.

38

Bypass Uncalibrated


This is a warning that the auto calibration has failed, while calibrating Bypass sensor.

7-14


Notes

9355 20 – 30 kVA


Alarm #

LCD Description


Comments

41

Inverter Uncalibrated


This is a warning that the auto calibration has failed, while calibrating inverter.

42

DC Voltage Uncalibrated


This is a warning that unit is not calibrated.

47

Battery current limit


Hardware current limit trip, Unit saw boost or charger current reached the hardware limit for 20 consecutive line cycles

48



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


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 voltage or frequency outside limits. Does not necessarily mean unit is on battery.

58

Output Short Circuit


Output short circuit detected

59

Utility not present


Utility voltage is outside limits, unit is on battery

68

Battery dc overvoltage


Battery voltage higher than 50mV/cell above charger float voltage, shunt trips battery breaker

70

Power supply failure


One of the internal power supplies is failed

71





Notes

7-15


9355 20 – 30 kVA

Alarm #

LCD Description

72




73

Heatsink Over Temperature


Heat sink fault: the heat sink temperature at an unspecified module exceeds the upper temperature limit for normal operation

74

Heatsink temperature sensor fail


Rectifier/inverter IGBT sensor or ambient temp sensor read either unreasonably high or low, indicating open/shorted sensor

94

To bypass command


Signal input used to send unit to bypass

95

From Bypass Command

105

Bypass not available


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


The inverter temperature has exceeded it s rating operating temperature.

119

Bypass phase rotation


Indicates bypass phase displacement is different from inverter phase displacement, bypass transfer is not allowed

121

Check Parallel Board


The board used for paralleling control appears to have failed.

7-16


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.


Notes

9355 20 – 30 kVA Alarm #

LCD Description


Comments

132

System Not Redundant


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



149

Battery needs service


Detected reversed battery polarity

159

L1 Overload



160

L2 Overload



161

L3 Overload



162




163




164




165




166




167





Notes

7-17


LCD Description


Comments

168

UPS on battery

UPS switched to battery power

UPS is on battery

169

UPS on bypass


UPS is on bypass

170

Load Dumped (Load Power 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


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


DSP cannot read status of bypass pic, or bypass pic is not changing states when commanded to

191

Battery test failed


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


Notes

9355 20 – 30 kVA Alarm #

LCD Description

192


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


Measure chassis voltage too high measured against neutral

199

Batteries disconnected


Battery circuit breaker open, or voltage less than disconnected limit

201

Transformer overtemperature


Signal input

202

Ambient under temperature



203

Ambient over temperature


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


An attempt to automatically (re-)


7-19


LCD 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


Fast inverter UV, inverter voltage outside window limit

222


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


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


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


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)


Battery failed to reach float voltage in time allowed

244

Contact service (illegal instruction)


Internal CPU error

7-20


Notes

9355 20 – 30 kVA Alarm #

LCD Description


Comments

248

UPS on generator

The system is being powered by its Alternate Power Source

Signal input

249

Charger over temperature shutdown


Boost IGBT temperature exceeded shutdown level (90C)

256

Battery Test in Progress


A Battery Test has begun.

257

System Test in Progress


One of the Systems Tests has begun.

258

Test Aborted


A Battery or Systems Test has been aborted while running due to conditions or operator command, or was inhibited from starting.


Notes

7-21


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)


9355 20 – 30 kVA


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


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


9355 20 – 30 kVA


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.


7-25


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

•


•


•


As long as the bypass is OK and the UPS load level is above 100%, the UPS will stay on bypass.

7-26


9355 20 – 30 kVA


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.


7-27


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


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


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.

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


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


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


9355 20 – 30 kVA



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.



3


Check correct torque values. Replace Power Board and IGBTs


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


3


Replace Power Board and IGBTs

on battery - load

Thermal

3

Thermal

Verify ambient


Inverter Circuit

7-30


9355 20 – 30 kVA




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


7-31


9355 20 – 30 kVA



OCC.

CONTROLS


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


Component failure - part indicates overtemp

4

FW detection

FW and DVT


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


9355 20 – 30 kVA



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


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


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


Replace I/O Board

If on battery trip battery breaker and drop load

Component failure

3


Replace I/O Board

If online alarms, no effect

Component failure

3


Replace I/O Board

If online - switch Component to Bypass failure

3


Replace I/O Board

If on-battery no effect

Component failure

3


Replace I/O Board

If online - switch Component to Bypass failure

3


Replace I/O Board

If on-battery Drops Load

3


Replace I/O Board

Component failure


7-33


9355 20 – 30 kVA

Table 43. I/O Board Failures FAILURE MODE Current Sensing Bypass

FAILURE EFFECT

POTENTIAL CAUSE

OCC.

CONTROLS


If online Alarms, no effect

Component failure

3


Replace I/O Board

If on-Battery Alarms, no effect

Component failure

3


Replace I/O Board

If on-bypass Alarms, no effect

Component failure

3


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


4

HW Current limit

FW Current limit, Replace I/O Board

On utility - and bypass is not available


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


Defective Component

1

Fused

Check fuses

On Battery and Bypass is not available Drop load

Defective Component

1


Replace I/O Board


Defective Component

1


Replace I/O Board

Bypass in parallel with UPS

Component failure

2


Replace I/O Board

On Bypass Drops Load

Component failure

2


Replace I/O Board

Inverter SCR

Inverter SCR Gate Drive Circuits

Bypass SCR Gate Drive Circuits

7-34


9355 20 – 30 kVA


Table 43. I/O Board Failures FAILURE MODE

FAILURE EFFECT

POTENTIAL CAUSE

OCC.

CONTROLS


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


3

Current limit, and FW

Replace Fuses

Table 44. Relay Failures FAILURE MODE

FAILURE EFFECT

POTENTIAL CAUSE

OCC.

CONTROLS


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


7-35


9355 20 – 30 kVA

Table 45. Fan Failures FAILURE MODE

FAILURE EFFECT

POTENTIAL CAUSE

OCC.

CONTROLS


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


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



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 <20VDC.

4.

Remove the fan wires directly from fans 4, 5 and 6

5.

Unplug the fan wires to remove the fan assembly.

6.

•

(If this is an older unit, remove the right front cover if it is not integrated with the fan assembly).

•

Remove the inverter fan plugs from the I/O board and push the wires through, and away from, the I/O board (X65, X66, and X67, see Figure 61).

•

Remove the fan plugs on the bypass fan assembly, see Figure 62.

Unplug the battery start (cold start) wires, see Figure 61 for location.

Note : If there is an External Battery Cabinet (EBC), ensure that the EBC breaker is open.

7.

With a DVM, ascertain an absence of voltage on the front Input and output terminals, X1 and X2, power connections.

Note : CB-1 and CB-2 need to be open. If this is a dual feed unit, check for an absence of voltage at CB-1.

8.1.2

Removing the L3 Power Module

WARNING THE MBS NEEDS TO BE IN BYPASS WITH CB-1 AND CB-2 OPEN. WAIT UNTIL THE DC LINK VOLTAGE HAS BLED DOWN BEFORE PROCEEDING.


8-1

Removal and Replacement

9355 20 – 30 kVA

CAUTION Be careful to avoid scraping or cutting any wiring during the removal and replacement of the L3 Power Module, see Figure 59.

Figure 59.

Damage Sustained by the IGBTs Due to Severed Wiring

Figure 60.

1.

8-2

Top Fan Dead Front and Bracket Plates

Remove the DC link screws from the I/O board, see Figure 61.


9355 20 – 30 kVA

Removal and Replacement X11 Ribbon Cable

X61 X60

DC+

BATT CD TRIP X50

X55

DC Link Screws L3

X6

X12

X7

X11

INV

AAUX

INV L3

X71, X15

X21 X27

INV L2 FANS

INV L1

Fan Plugs

K3

RECT L3

X68, X14

X45

BAT

DC-

X25

Figure 61.

X78 X2 IN/OUT CB TRIP

BAT COLD START

X79

K1

BATT BKUP X46

X82 L3 L2 L1 X28 X29 X4

BATTERY CHOKES

X28

L3 X76

X76

X23 X13

X54

X42 X41 X40

L3 and Fan Removal Points on the I/O Board

Figure 62.

Bypass Board Silk Screen


8-3


9355 20 – 30 kVA

2.

Remove the right front bracket plate, see Figure 60.

3.

Cut the tie wraps from the ribbon cable and other wiring.

4.

Remove the bus bar screws.

5.

Remove wires at X71, X15, X68, X14, X28 and X76 from the I/O board, see Figure 61.

6.

Remove ribbon cable X11 from the I/O board, see Figure 61.

7.

Slide the L3 Power Module out of the UPS by grasping the lower module lip.

CAUTION Do not grasp the middle aluminum bar to remove the Power Module. Be aware of the proximity of wiring so that wires near the top and sides are not severed by the UPS frame during removal.

8.1.3

Replacing the L3 Power Module

The following procedure reverses the preceding removal procedure.

CAUTION Be careful to avoid scraping or cutting any wiring during the removal and replacement of the L3 Power Module

1.

Perform Removal Preparation, see paragraph 8.1.1.

2.

Slide the L3 Power Module into the top front shelf of the UPS being careful to avoid cutting any loose wiring on the UPS shelf lip, see Figure 63.

Figure 63.

3. 8-4

L3 PM Shelf Insertion

Replace the bus bar screws. © 2006 - Eaton Corporation

9355 20 – 30 kVA


4.

Attach ribbon cable X11 to the I/O Board, see Figure 61.

5.

Re-attach wires at X71, X15, X68, X14, X28 and X76 to the I/O board, see Figure 61, and secure the wiring with tie-wraps.

6.

Insert and tighten the I/O board DC link screws, see Figure 61.

7.

Plug the battery cold start wiring into the I/O board.

8.

Placing the fan assembly in place on the UPS:

9.

•

thread the fan wiring through the UPS assembly to the I/O board, reattaching the inverter fan plugs (X65, X66, and X67, see Figure 59).

•

Re-attach the fan plugs to the bypass fan assembly, see Figure 60. (If this is an older unit, replace the right cover if it is not integrated with the fan assembly)

Re-attach the top fan dead front, Figure 60.


8-5


8.1.4

9355 20 – 30 kVA

Removing the L2 Power Module


WARNING 1.

Perform removal preparation, see section 8.1.1.

2.

The MBS needs to be in bypass with CB-1 and CB-2 open.

Note : If this is a dual feed unit, check for an absence of voltage at CB-1.

3.

Remove the DC Link screws from the I/O board, see Figure 61. X7 Ribbon Cable

X61 X60 BATT CD TRIP X50

X55

DC+ X12

X7

X6

X11

INV

AAUX

INV L3

X21 X27

INV L2

X72, X18

FANS

INV L1

DC Link Screws L2

K3

RECT L3

X69, X10

X45

BAT

DC-

X25

Figure 64.

8-6


BAT COLD START

K1

BATT BKUP X46

X82 L3 L2 L1 X28 X29 X4

BATTERY CHOKES

X29

L3 X76

X75

X79

X23 X13

X54

X42 X41 X40

L2 Removal Points on the I/O Board

4.

Cut the tie wraps from the ribbon cable and other wiring.

5.

Remove wires at X18, X72, X10, X69, X75 and X29, see Figure 64. © 2006 - Eaton Corporation

9355 20 – 30 kVA


6.

Remove ribbon cable X7 from the I/O board, see Figure 64.

7.

Slide the L2 Power Module out of the UPS by grasping the shelf lower module lip.

CAUTION Do not grasp the middle aluminum bar to remove the Power Module. Be aware of the proximity of wiring so that wires near the top and sides are not severed by the UPS frame during removal.

8.1.5

Replacing the L2 Power Module


The following procedure reverses the preceding removal procedure. 1.

Slide the L2 Power Module into the UPS.

2.

Re-attach the ribbon cable to X7, see Figure 64.

3.

Re-attach wires at X18, X72, X10, X69, X75 and X29, see Figure 64.

4.

Replace the bus bar screws.

5.

Consolidate and secure the wiring with tie-wrap.

6.

Insert and tighten the DC link screws on the I/O board, see Figure 61.

7.

Plug the battery cold start wiring into the I/O board.

8.

Placing the fan assembly in place on the UPS:

9.

•

thread the fan wiring through the UPS assembly to the I/O board, reattaching the inverter fan plugs (X65, X66, and X67, see Figure 59).

•

Re-attach the fan plugs to the bypass fan assembly, see Figure 60. (If this is an older unit, replace the right cover if it is not integrated with the fan assembly)

Re-attach the top fan dead front, Figure 60.


8-7


8.1.6

9355 20 – 30 kVA

Removing the L1 Power Module and Bypass Board

CAUTION Be careful to avoid scraping or cutting any wiring during the removal and replacement of the L1 Power Module Use needle nose pliers to disconnect the plugs from the Bypass Board, do not pull the plugs by the plug wires.

WARNING BEFORE PERFORMING THIS PROCEDURE ENSURE THAT THE UPS IS IN EXTERNAL MAINTENANCE BYPASS, THAT ALL MAIN BREAKERS ARE OPEN, AND THAT THE POWER TO THE UPS IS OFF. IF USING SIDE ACCESS, THIS PROCEDURE MAY BE PERFORMED USING INTERNAL MAINTENANCE BYPASS.

8.1.6.1

Removing the Power Module L1 / Static Switch Assembly from the UPS. 1.

Perform Removal Preparation, see section 8.1.1.

2.

Unplug the battery start (cold start) wires.

3.

Remove the battery dead front and disconnect the positive red wires (6) from the each battery string: T1, T3, T5, T7, T9 and T11, see Figure 65.

Figure 65.

8-8

Positive Battery String Wires


9355 20 – 30 kVA


Note : If there is an External Battery Cabinet (EBC), ensure that the EBC breaker is open. If this is a dual feed unit, check for an absence of voltage at CB-1.

4.

With a DVM, ascertain an absence of voltage on the front X1 and X2 power connections.

5.

Unplug the static switch ribbon cable and remove the front, side panel.

6.

Disconnect the X25 plug and push it through the assembly.

7.

Unplug the X10 neutral wire from the bypass board in the Static Switch module, see Figure 66. X10 X23,X26,X22

X51

Figure 66.

Bypass Static Switch Connections

8.

Disconnect the gate drive plug, X51, and the plugs at X23, X26 and X22 (from front to back) on the Bypass Board in the Static Switch Assembly, see Figure 66.

9.

Remove the bus bar screws.


8-9


9355 20 – 30 kVA

Note : Tilt the screws slightly downward once they extend beyond the I/O Board to prevent the washers from falling into the UPS cabinet.

10. Remove the ribbon cables from I/O board X6 and pull to the front of the UPS. 11. Using a 3/16” wrench, disconnect Power Cables 1, 2, and 3 from TB5, see Figure 73. 12. Remove the side panel. •

Using an 5/16” wrench remove the K5 wiring.

13. Let the removed wires hang from the front of the UPS. 14. Using an 5/16” wrench disconnect the wires X73, X19, X70, X5, X74, and X4 from the I/O board, see Figure 67.


X55

DC+ X6

X12

X7

X11

INV

AAUX

INV L3

X21 X27

INV L2 FANS

INV L1

X73,X19

K3

RECT L3 BAT COLD START

L3 X76

X79

K1

BATT BKUP X46

X45

BAT

DC-

X82 L3 L2 L1 X28 X29 X4

X4

BATTERY CHOKES

X74

X25

Figure 67.


X70,X5

X23 X13

X54

X42 X41 X40

I/O Board Wiring Connections to Static Switch

15. Slide the L1 Power Module forward, removing it from the UPS.

8-10


9355 20 – 40 kVA


CAUTION Do not grasp the middle aluminum bar. Verify the correct placement of all plugs on their plug pins during removal and installation of the Bypass Board

8.1.6.2

Removing the Bypass Board from the Static Switch Housing 1.

Turn the Static Switch module on its side.

CAUTION Do not damage the Static Switch assembly connector during handling, see Figure 68.

2.

Remove the two (2) Bypass Board assembly screws to remove the board assembly from the power module housing.

3.

Remove the power wires connecting the Static Switch to the SCRs.

Note: If you are replacing the SCRs, remove the SCRs from the heat sink. If you have the initial release of the UPS (serial number digit 7 = “X”), your SCR wiring harness sequence is 3, 1, 2. The subsequent UPS release (serial number digit 7 = “A”), has an SCR wiring harness sequence of 1, 2, 3, see Figure 68 . 4.

Remove the front terminal block connections.

5.

Remove the seven (7) screws securing the Bypass Board to replace the Static Board. Handle side of assembly with care, board protrusion and connector susceptible to damage during handling

3 1 1 or 2 2 3

Figure 68.

Static Switch Housing and SCRs


8-11


8.1.6.3

9355 20 – 30 kVA

Replacing the Bypass Board

The following procedure reverses the preceding removal procedure.

8.1.7

1.

Attach and secure the Bypass Board to the L1 assembly with the seven (7) screws.

2.

Replace the front terminal block connections.

3.

Attach the power wires connecting the SCRs to the Static Switch.

4.

Attach the board assembly to the power module housing using the two (2) Bypass Board assembly screws.

Replacing the L1 Power Module / Static Switch Assembly

The following procedure reverses the preceding removal procedure. 1.

Slide the L1 module into the the UPS.

2.

Plug the X10 neutral wire from the Static Switch module to the bypass board, and reconnect the gate drive plug, X51, and the plugs at X23, X26 and X22, see Figure 66.

3.

Connect the wires X73, X19, X70, X5, X74, and X4, see Figure 67.

4.

Routing the wiring through the front of the UPS, connect the ribbon cables to I/O board X6.

5.

Replace the bus bar screws.

6.

Attach the K5 wiring.

7.

Connect the X25 plug bringing it through the UPS assembly.

8.

Connect the Power Cables 1, 2, and 3 going to TB5, see Figure 73.

9.

Plug in the static switch ribbon cable.

10. Connect the positive red wires (6) to each battery string (T1, T3, T5, T7, T9 and T11), see Figure 65. 11. Plug-in the battery cold start wires. 12. Place the top fan dead front in position on the UPS and re-attach the fan plugs to the I/O board. 13. Secure the top fan dead front and UPS front door panel if appropriate.

8-12


9355 20 – 30 kVA

8.1.8


Removing the I/O Board Assembly 1.

Perform removal preparation, see section 8.1.1.

2.

Remove the UPS front side metal panel between the I/O board and the Power Module (the panel is slotted at the bottom).

3.

Remove the UPS side metal panel.

4.

Using a DVM, check the DC link for voltage (you can use the DC+ connector at the top of the I/O board and the DC– connector at the bottom of the I/O board as testing points).

Figure 69.

DC Link Check Points

WARNING WAIT UNTIL THE DC LINK VOLTAGE HAS BLED DOWN BEFORE PROCEEDING.

5.

Remove the tie wraps from the inductor and power module wires.


8-13

Removal/Replacement

9355 20 – 30 kVA

6.

Grasp the Control Board that is sitting on top of the I/O Board and gently move it from side to side to lift it off of the I/O Board, see Figure 70.

Figure 70.

Removing the control board from the I/O board

CAUTION When removing wiring from the I/O board ensure that all washers are accounted for and correctly placed.

7.

8-14

Place the Control Board in a static-free area.


9355 20 – 30 kVA


8.

9.

Using an 8mm (5/16”) socket, remove the inverter wiring from the I/O board connectors, see Figure 71: •

Inverter L3 wires X71, X15

•


•


Remove the rectifier wiring from the I/O board connectors, see Figure 71: •

Rectifier L3 wires X68, X14

•


•


10. Remove battery choke wires, see Figure 71: •

Remove L3 battery choke wires at X76, X28.

•

Remove L2 battery choke wires at X75, X29.

•

Figure 71.

Wiring Locations

Remove L1 battery choke wires at X74, X4


8-15

Removal/Replacement

9355 20 – 30 kVAt

11. Remove fan power plugs from X65, X66, X67, see Figure 72. 12. Remove the cold-start ribbon cable at X79. 13. Remove the ribbon cables at X11, X7, X6 and X12. 14. Unplug the XSlot cables and keyed ribbon cables X-55 and X-56, see Figure 72. 15. Unplug the display (CAT-5) cable connector, see Figure 72. 16. Remove the TB1 output ( X25, X23, X13 and X54) and K1 wires (X13 and X54), and the K3 output wires (X42, X41, X40). Note: If removing the I/O board from the assembly I/O board assembly, remove the K3 and K1 disconnect wires, see Figure 72, and remove the second set of wires attached to the TB1 output connectors and K3 output connectors.. X55, X56, X11, X7, X6, X12 ribbon cables 5

T CA


X55

DC+

X21, X27

X12

X7

X6

X11

INV

AAUX

INV L3

X21 X27

INV L2

INPUTS TO K3 DISCONNECT

FANS

INV L1

K3

RECT L3

INPUTS TO K1 DISCONNECT

X45

BAT

DC-

X25

Figure 72. 8-16


K1

BATT BKUP X46

L3 L2 L1 X28 X29 X4

BATTERY CHOKES

L3 X76

BAT COLD START

X79

X23 X13

X54

X42 X41 X40

Wiring Removal Diagram


9355 20 – 30 kVA

Removal/Replacement

17. Remove the 3 sets of wires (should be thread through the CTs) from the I/O Board side of TB5 using a 4.5mm Allen wrench, see Figure 73.

Figure 73.

TB5

18. Remove negative battery bus bar bolts at X51, X34, and at X82, see Figure 74. 19. Remove DC bus bar bolt X30, X81, X80 and Inverter neutral bolts X20 and X3 (behind the blue current sensor B3), see Figure 74. X61 X60 BATT CD TRIP X50

X55

DC+ X6

X12

X7

X11

INV

AAUX

INV L3

X21 X27

INV L2 FANS

INV L1

K3

RECT L3 X78 X2 IN/OUT CB TRIP

K1

BATT BKUP X46

X45

BAT

DC-

X82 L3 L2 L1 X28 X29 X4

BATTERY CHOKES

L3 X76

BAT COLD START

X79

X25

Figure 74.

X23 X13

X54

X42 X41 X40

Bus bar and neutral bolts


8-17


9355 20 – 30 kVA

CHASSIS SCREWS


X55

DC+ X12

X7

X6

X11

INV

AAUX

INV L3

X21 X27

INV L2 FANS

INV L1

K3

RECT L3 X78 X2 IN/OUT CB TRIP

K1

BATT BKUP X46

X45

BAT

DC-

L3 L2 L1 X28 X29 X4

BATTERY CHOKES

L3 X76

BAT COLD START

X79

X25

Figure 75.

X23 X13

X54

X42 X41 X40

Chassis Screws

Note: If you are removing the I/O Board from the assembly mounting, skip items 20 and 21 and perform step 22.

20. Remove the Philips head retaining bracket screws and chassis screws on the I/O assembly mounting plate to remove the I/O assembly from the UPS.

CAUTION The I/O board assembly is slot-mounted, so lift the board from its slotted position when removing.

21. Tilt the I/O assembly forward to disconnect the assembly from the side slots. Then lift the board assembly off the bottom slots and set it down in a static-free open area. 22. Remove the ten (10) plastic stand-offs around the board perimeter and from the center of the I/O board, and the chassis screws, see Figure 75, to remove the I/O board. 8-18


9355 20 – 30 kVA

8.1.9

Removal/Replacement

Replacing the I/O Board

The following procedure reverses the preceding removal procedure. Note: If you removed the I/O Board from the assembly skip steps 2 and 3.

1.

Attach the I/O board to the I/O board assembly using the ten (10) plastic stand-offs around the board perimeter and the center of the I/O board and reattach the chassis screws (see Figure 75).

2.

Attach the I/O assembly to the UPS by aligning it with the side and bottom slots.

3.

Secure the I/O assembly to the UPS by inserting the bracket screws and chassis screws with a Philips head screwdriver.

4.

Attach the DC bus bar bolts X30, X81, X80 and Inverter neutral bolts X20 and X3 (behind the blue current sensor B3), see Figure 74.

5.

Attach the negative battery bus bar bolts at X51, X34, and at X82, see Figure 74.

6.

Thread the 3 sets of wires going to the I/O Board through the CTs.

7.

Attach the 3 sets of wires to the I/O Board side of TB5 using a 4.5mm Allen wrench, see Figure 73.

8.

Attach the TB1 output ( X25, X23, X13 and X54) and K1 wires (X13 and X54), and the K3 output wires (X42, X41, X40).

Note: If the I/O board was removed from the I/O board assembly, attach the K3 and K1 disconnect wires and the second set of wires attached to the TB1 output connectors and K3 output connectors.

9.

Attach the 3 sets of wires from the I/O Board side of TB5 using a 4.5mm Allen wrench, see Figure 73.

10. Plug-in the display (CAT-5) cable connector, see Figure 72. 11. Plug-in the XSlot cables and all ribbon cables observing the orientation of the red pin 1 wire, see Figure 72. 12. Attach the ribbon cables at X11, X7, X6 and X12, see Figure 72. 13. Attach the cold-start ribbon cable at X79. 14. Attach the fan power plugs from X65, X66, X67, see Figure 72. 15. Attach the battery choke wires, see Figure 71: •

L3 battery choke wires at X76, X28.

•

L2 battery choke wires at X75, X29.

•

L1 battery choke wires at X74, X4


8-19


9355 20 – 30 kVA

16. Attach the rectifier wiring from the I/O board connectors, see Figure 71: •


•


•


17. Using an 8mm (5/16”) socket, attach the inverter wiring to the I/O board connectors, see Figure 71: •


•


•


18. Attach the control board to the I/O board, see Figure 70. 19. Secure the inductor wiring and power module wiring with tie wraps. 20. Re-attach the UPS side metal panel, if appropriate. 21. Attach the front metal panel between the Power Module and the I/O board, if appropriate.

8-20


9355 20 – 30 kVA

Removal/Replacement

8.2 TECHNICAL SUPPORT KNOWLEDGE BASE CSEs should regularly search the Knowledge Base, updated by Technical Support personnel, for 9355 UPS information, such as: •

Troubleshooting and maintenance

•

Connectivity and communication issues

•

Software and monitoring

•

Back up times

•

Technical and non-technical questions

Eaton CSEs can find the Knowledge Base by going to Powerware Intranet at: http://poweratwork/usa/ Go to USA Groups, then click on Global Services Intranet On Powerware Global Services page, go to Technical Support Centers, and click on: Technical Support Knowledge Base Click on “View Top Solutions,’ and ’Find More Solutions.’ Click the Search in ’ALL Topics’ pulldown. 9355 information will be available under Three Phase, 9355. Here CSEs will see detailed information on issues, causes, and resolutions for each product. Authorized Distributors can find other Knowledge Base information on the Powerware Internet at: http://www.powerware.com/USA/default.asp Click on Powerware 9355 Click on Powerware UPS Product Page Click on Services for 9355 UPS Click on Technical Support Knowledge Base Here Distributors will see Customers’ Frequently Asked Questions and responses for each product. Additionally, Eaton CSEs and Authorized Distributors can find Bulletin Board information on the Powerware Intranet for documentation, technical support and training. Go to the Powerware Global Services Bulletin Board and login with your User Name and Password. CSEs: Go to the Intranet, click on USA Groups/CSE/Quicklinks/Technical Support Distributors: Enter this URL into your Browser address: http://gstechsup.powerware.com/.


8-21


9355 20 – 30 kVA


8-22


9 Calibration Calibration is the adjustment of a given parameter based on known or proven data to make that parameter truer or more consistent. Refer to Figure 76, Analog Potentiometer Diagram. In an analog control system, a potentiometer (or variable resistor) has often been used to alter a DC voltage on a given test point. The adjusted voltage could be an alarm threshold or trigger point for many different types of analog circuits. When the voltage at the input of the circuit reaches or exceeds the value set by the variable resistor, the circuit becomes active or inactive depending on the design of the circuit. Vi

12vdc TP

TP

Vi

Figure 76.

Vo

Vi < TP, Vo = Inactive Vi > 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


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


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.


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.


9355 20 – 30 kVA

9.1.2

Calibration

Calibrate Utility AC Input Voltage

Tools Required: •


•


•


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.


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


9-5

Calibration

9355 20 – 30 kVA

3.


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.


6.

Calibration complete


9355 20 – 30 kVA

9.1.3

Calibration

Calibrate Battery Voltage

Tools Required: •


•


•


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.


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.


6.



9-7

Calibration

9.1.4

9355 20 – 30 kVA

Calibrate DC Link Voltage

Tools Required: •


•


•

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.


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.



9355 20 – 30 kVA

9.1.5

Calibration

Calibrate UPS AC Output Voltage

Tools Required: •


•


•


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.


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.



9-9

Calibration

9.1.6

9355 20 – 30 kVA

Calibrate Inverter AC Output Voltage

Tools Required: •


•


•


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.


2.

Begin with UPS on NORMAL.

3.


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


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.


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.


9-11

Calibration

9.1.8

9355 20 – 30 kVA

Calibrate Bypass Current (Output)

Tools Required: •


•


•


•

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.


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.


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


9-13

Calibration

9.1.9

9355 20 – 30 kVA

Calibrate Utility Current

Tools Required: •


•


•


•

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.


2.


3.


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.



9355 20 – 30 kVA

9.1.10

Calibration

Calibrate Battery Current

Tools Required: •


•


•


•

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.


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.



9-15

Calibration

9.1.11

9355 20 – 30 kVA

Calibrate Inverter Current

Tools Required: •


•


•


•

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.


2.


3.


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.



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


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


EA

3


EA

1

EMI BOARD

EA

1


EA

1

BYPASS BOARD

EA

1


EA

6


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


1

1021994


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


1

123118002-001

CONT, 115A, 480VAC,3 POLE, NO

1


9355 20 – 30 kVA

Parts

P/N

DESC

QTY

123118002-002


2

128308001-012


3

129400054-002


3

129400066-001

THERMAL PAD, SKIIP2 PACKAGE

9

143319005-001


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


1


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


1


1


1


2


3


3

THERMAL PAD, SKIIP2 PACKAGE

9


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


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”.


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.


10-5

Parts

9355 20 – 30 kVA


10-6


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


11-1

Prints

9355 20 – 30 kVA

This page was left blank intentionally

11-2


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


9355-30 Options Cabinet - MBS only

2

8


120V

120V 120V

9355-30 Options cabinet - 208/208, 480/208, 600/208 Mains Input transformer

3

8


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


9355-30 Options Cabinet - System - Single feed, MBS only

6

8



120V

120V 120V

T1 277V 208V

277V

208V

277V

208V

9355-30 Options Cabinet - System - Single feed 480/480

7

8



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

9355 30kVA Service Manual_A02

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