Tripp Lite SU60KX manual

1 PRELIMIN AR Y SU-Series 3-Phase UPS Har d ware: Intr oduction and T r oubleshooting 1111 W . 35th Street, Chicago, IL 60609 USA +1.773.869.1234 • www .tripplite.com[...]

2 PRELIMIN AR Y T able of Contents 1 Basic Operation 3 1.1 T echnical Specifi cations 3 KX Models 3 K and KTV Models 4 SU80K Model 5 1.2 Features 6 1.2.1 Advanced Features 6 1.2.2 Control Panel Features 6 1.2.3 Front and Rear Panel Features 7 1.3 Operating Principles 13 1.3.1 System Layout 13 1.3.2 Internal Battery Layout 13 1.3.3 Power Module Lay[...]

3 PRELIMIN AR Y 1 Basic Operation 1.1 T echnical Specifi cations KX Models: Model SU20KX SU40KX SU60KX SU80KX (Capacity) (20kV A/16kW) (40kV A/32kW) (60kV A/48kW) (80kV A/64kW) Input Input V oltage 220/380V , 230/400V or 240/415V AC , 3O, 4-wire + g round, wye V oltage Regulation -25% ~ +20% Har monic Distor tion < 5% (Full Load) PFC (Full Load[...]

4 PRELIMIN AR Y 1 Basic Operation (continued) 1.1 T echnical Specifi cations (continued) K and KTV Models: Model SU40K SU60K SU60KTV SU80KTV (Capacity) (40kV A/32kW) (60kV A/48kW) (60kV A/48kW) (80kV A/64kW) Input Input V oltage 120/208V AC , 3O, 277/480V AC , 3O , 4-wire + ground, wy e 4-wire + ground, wye V oltage Regulation -25% ~ +20% Har moni[...]

5 PRELIMIN AR Y 1 Basic Operation (continued) 1.1 T echnical Specifi cations (continued) SU80K Model: Model (Capacity) SU80K (80kV A/64kW) Input Input V oltage 120/208V AC , 3Ø, 4-wire + ground, wye V oltage Regulation -25% ~ +20% Har monic Distor tion < 5% (Full Load) PFC (Full Load) > 0.99 Frequency 50 / 60 Hz Frequency T olerance 45 ~ 65[...]

6 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features “NORMAL” LED: • This green light illuminates to indicate that the UPS system is in online (normal) mode. The primary A C input supply is present and within standard operating parameters. “B A TTERY” LED: • This amber light illuminates when the UPS system is in battery backup mod[...]

7 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) 1.2.3 Front and Rear P anel Features Note: Individual models may vary fr om diagrams. Unit shown with fr ont bezels r emoved. Control P anel: • The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.) Internal P owe[...]

8 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary fr om diagrams. Unit shown with fr ont bezels r emoved. Levelers: • The lev elers provide long-term support for the UPS system. Casters: • The casters are designed for small position adjustments within the f inal installation location only; t[...]

9 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary fr om diagrams. Unit shown with fr ont bezels r emoved. Control P anel: • The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.) Internal P ower Modules: • 20kV A internal power [...]

10 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary fr om diagrams. Unit shown with fr ont bezels r emoved. Levelers: • The lev elers provide long-term support for the UPS system. Casters: • The casters are designed for small position adjustments within the f inal installation location only; [...]

11 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary fr om diagrams. Unit shown with fr ont bezels r emoved. Control P anel: • The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.) Internal P ower Modules: • 20kV A internal power[...]

12 PRELIMIN AR Y 1 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary fr om diagrams. Unit shown with br eaker guar d r emoved. Levelers: • The lev elers provide long-term support for the UPS system. Casters: • The casters are designed for small position adjustments within the f inal installation location only[...]

13 PRELIMIN AR Y 1 Basic Operation (continued) 1.3 Operating Principles 1.3.1 System Lay out Q1 LOAD MAIN Q2 20kVA/3U POWER MODULE 20kVA/3U POWER MODULE 20kVA/3U POWER MODULE 20kVA/3U POWER MODULE BATTERY Manual Input Bypass Input Main STS Q4 Output Circuit Breaker Q3 Manual Bypass Circuit Breaker Bypass Input Circuit Breaker Main Input Circuit Bre[...]

14 PRELIMIN AR Y 1 Basic Operation (continued) 1.3 Operating Principles (continued) 1.3.3 P ower Module Lay out 1.4 Opening and Closing the Unit [PENDING] Charger R S T N U V W N INPUT OUTPUT BATTERY F ig 1.3.3a P ower Module Block Diagram The SU-Series 3-Phase UPS double-con version power modules consist of three components (Figure 1.3.3a): 1) An [...]

15 PRELIMIN AR Y 1 Basic Operation (continued) 1.5 Operating Modes This section provides a basic description of the UPS system’ s operating modes. For more information about switching between operating modes, refer to Section 1.6 – Start-Up, Shutdown and Bypass . 1.5.1 Online (Normal) Mode (Single UPS) In online (normal) mode, the UPS system’[...]

16 PRELIMIN AR Y 1.5.5 Online Mode (P arallel UPS) Parallel redundanc y (1+1) provides UPS system redundancy or increased total capacity . Under parallel redundancy , the total load is shared by two UPS systems. If one of the UPS systems malfunctions, the total connected equipment load is supported by the remaining UPS system. If the total load exc[...]

17 PRELIMIN AR Y 1 Basic Operation (continued) 1.5 Operating Modes (continued) 1.5.8 Manual Bypass Mode (P arallel UPS) Similar to manual bypass mode for a single UPS system ( Section 1.5.4 ), except with parallel (1+1) UPS systems. Note: Both UPS systems must be switched into manual bypass mode . 1.5.9 Hot Standby Mode (P arallel UPS) For added fa[...]

18 PRELIMIN AR Y W arning: The UPS system’ s output voltage is set at 220/380V by default. If you r equire output voltage of 230/400V or 240/415V , you must change the UPS system’ s output voltage by accessing the output setup menu described in Section 10-9 of the owner’ s manual. Y ou must place the UPS system in bypass mode befor e changing[...]

19 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.3 Standard Start-Up Procedure (Single UPS) (contin ued) Switch on the output circuit breaker switch • A and bypass input circuit breaker switch B . After a brief initialization process, the LCD screen will show “ON A UTO BYP ASS”, the “BYP ASS?[...]

20 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.5 Manual Bypass Pr ocedure (Single UPS) W arning: Placing the UPS system in manual bypass will disable the in verter and power all loads from the manual bypass (r eserve) source, but the UPS system will still be ener gized. Before perf orming maintenan[...]

21 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.6 Shutdown Pr ocedure (Single UPS) (continued) Confirm that the UPS system is of f and that all main output circuits • are off. If the UPS system is connected to an e xternal battery cabinet, turn off the e xternal battery cabinet circuit breaker swi[...]

22 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.8 Start-Up Procedure (P arallel UPS) (continued) Switch on the bypass input circuit breaker switch • A of each UPS system. After a brief initialization process, the LCD screen will show “ON A UTO BYP ASS” and the “BYP ASS” LED will illuminate[...]

23 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.9 Shutdown Pr ocedure (Parallel UPS) (continued) For the UPS system you wish to shut do wn, switch off the bypass • input circuit breaker switch A . When the UPS system is completely shut down, the LCD screen • will be completely off. If the UPS sy[...]

24 PRELIMIN AR Y 1 Basic Operation (continued) 1.6 Start-Up, Shutdo wn and Bypass (continued) 1.6.10 Manual Bypass Pr ocedure (Parallel UPS) (continued) If the UPS systems hav e external battery cabinets connected, switch • off the e xternal battery cabinet circuit breaker switch A of each battery pack. In this mode, only the output circuit break[...]

25 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) T able 1.7a lists the printed circuit boards present in each UPS system: T able 1.7a SU80KX SU80K SU80KTV SU60KX SU60K SU40KX SU40K SU20KX PCB name P/N Description TO P V V V V NH-SYS-LCD 16-5505001323 Circuit for LCM, Circuit f or LED and Function K ey V V V V NH-SYS-[...]

26 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.1 PCB Location (System) 1.7.1.1 KX Models SU20KX and SU40KX: X LA and LB R B LCD M FB F A (BYP) F A (MAIN) SA O/P CT FC BYP ASS SCR P[...]

27 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.1 KX Models (continued) SU60KX and SU80KX: X B LA, LB, LC , LD R LCD F1 (MAIN) F2 (BYP) F2 (MAIN) F1 (BYP) F3 FB M O/P CT S PC P[...]

28 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models SU40K: F A (BYP) F A (MAIN) M R X LA, LB FB B P I/P T ransfer O/P T ransfer Bypas SCR FC O/P CT SA LCD[...]

29 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models (continued) SU60K: I/P Tx F3 X LA, LB, LC F1 (BYP) F1 (MAIN) F2 (BYP) F2 (MAIN) FB P B LCD M R O/P Tx Bypas SCR S O/P CT FC[...]

30 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models (continued) SU80K: X R M P B LCD FB F2 F1(BYP) F1(MAIN) Bypass SCR S O/P CT FC O/P Tx I/P Tx F2(BYP) F2(MAIN) LA, LB, LC , LD[...]

33 PRELIMIN AR Y 1 Basic Operation (continued) 1.7 Printed Circuit Boar ds (PCB) (continued) 1.7.2 PCB Location (P ower Module) PCB Board Name Description NH-PM-A Rectifi er of Phase R and S, Inductance and Switching De vices of DC-DC Conv er ter , Bus Capacitors and Battery SCR circuit NH-PM-K Rectifi er of Phase T and S, Inductance and Switchin[...]

34 PRELIMIN AR Y 1 Basic Operation (continued) 1.8 Block and Wiring Diagrams (continued) 1.8.1 KX Models Input: 3-phase 4-wire 230/380V ac Output: 3-phase 4-wire 230/380V ac The SU20KX (Figure 1.8.1a) has a model rating of 20kV A UPS and contains one power module and 40 internal batteries (which can be increased to 80, if necessary). (See Figure 1.[...]

51 PRELIMIN AR Y 2 Theory of Operation (continued) 2.2 DC A uxiliary Po wer Circuit (contin ued) 2.3 A uxiliary Po wer Failure Detection Located at NH-SYS-M board (System MCU and Control Circuit) Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit)[...]

52 PRELIMIN AR Y 2 Theory of Operation (continued) 2.4 Output Current Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit) R P 119 CP 2 5 CP 8 9 R P 126 G1 R P 120 RP 1 2 5 3 2 1 4 11 UP 1 9A CP 2 6 CP 9 0 G1 G1 +1 2V S -1 2 V S R P 124 R[...]

53 PRELIMIN AR Y 2 Theory of Operation (continued) 2.5 Input V oltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit) (a) MCU detects RMS value of bypass 3-phase v oltage via Vbyp_R (89), Vbyp_S (91) and Vbyp_T (93). (b) MCU detects [...]

54 PRELIMIN AR Y 2 Theory of Operation (continued) 2.6 Output V oltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit) OP / R R P 128 R P 127 CP 7 2 RP 1 3 4 RP 1 2 3 CP 7 3 5 6 7 UP 1 7 B G1 R P 132 R P 131 RP 1 3 3 RP 1 2 9 OP / S [...]

55 PRELIMIN AR Y 2 Theory of Operation (continued) 2.7 Battery V oltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit) (a) MCU detects battery voltage via Vbatt_+ (98) and Vbatt_- (100). + 12VS CP 8 0 G1 CP 7 9 -1 2 V S G1 RP 9 0 CP[...]

56 PRELIMIN AR Y 2 Theory of Operation (continued) 2.8 Bypass SCR Short-Circuit Detection Located at NH-SYS-FB board (Circuit for Bypass Back-Feed Detect) Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located at NH-SYS-M board (System MCU and Control Circuit) (a) During backup mode, bypass 3 SCRs sh[...]

57 PRELIMIN AR Y 2 Theory of Operation (continued) 2.9 Bypass SCR Driver Located at NH-SYS-S or NH-SYS-SA board (Driv er Circuit for Bypass SCR) Located at NH-SYS-M board (System MCU and Control Circuit) Located at NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots[...]

58 PRELIMIN AR Y (a) The bypass SCR driv er signal “BYPSTS1” is controlled by MCU or “TOBYP_J” according to the signal “CENTRAL_OK. ” (b) “CENTRAL_OK” is the output of MCU watchdog. If MCU is operating normally , “CENTRAL_OK” will be high and the bypass SCR dri ver signal will be controlled by “BYPSTS” (1) (high activ e). If[...]

59 PRELIMIN AR Y (a) MCU detects the status of EPO button (on LCD display panel) via “EPO” (85) (lo w active). When the EPO button is acti vated, UPS will shut down the output and turn of f the in verter . When the EPO button is released, UPS will stay in bypass mode. (b) MCU can control the LCD backlight via “U-lcmBL” (62). (c) MCU can adj[...]

60 PRELIMIN AR Y 2 Theory of Operation (continued) 2.12 Fan Contr ol Circuit Located on NH-SYS-M board (System MCU and Control Circuit) Located on NH-SYS-P board (Auxiliary Power for System, Detect Circuit for V oltage and Current) Located on NH-SYS-S or NH-SYS-SA board (Driv er Circuit for Bypass SCR) - 7 + 14 1 2 3 U M 12A 4081 4 13 UM 8 D U LN 2[...]

61 PRELIMIN AR Y 2 Theory of Operation (continued) 2.13 Bypass SCR T emperature Detection 2.14 Communication Cir cuit for RS232 Located on NH-SYS-M board (System MCU and Control Circuit) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-S[...]

62 PRELIMIN AR Y 2 Theory of Operation (continued) 2.15 Communication Cir cuit for Slots Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-SYS-M board (System MCU and Control Circuit) G4 RR4 3 5VS G1 #R X_232 2 3 6 5 8 7 1 4 UR 2 0 CR2 7 [...]

63 PRELIMIN AR Y 2 Theory of Operation (continued) 2.16 Communication Cir cuit for Output Dry Contact Located on NH-SYS-M board (System MCU and Control Circuit) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) (a) System MCU sends out dry contact sign[...]

64 PRELIMIN AR Y 2 Theory of Operation (continued) 2.17 Communication Cir cuit for Input Dry Contact and REPO Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-SYS-M board (System MCU and Control Circuit) REPO 1 2 4 3 UX 1 1 G4 RE P O RX [...]

65 PRELIMIN AR Y 2 Theory of Operation (continued) 2.18 External Battery Cabinet T emperature Detection Located on NH-SYS-X board (Circuit for REPO, Input Dry Contact and Circuit for sense External Battery Cabinet T emperature) Located on NH-SYS-M board (System MCU and Control Circuit) (a) UX1, UX2, UX3 and UX4 are linear photo. (b) CNX6, CNX7, CNX[...]

66 PRELIMIN AR Y 2 Theory of Operation (continued) 2.19 Detection Circuit f or Manual Bypass Switch 2.20 Detection Circuit f or Output Breaker Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-SYS-R board (Circuit for RS232, Output Dry Co[...]

67 PRELIMIN AR Y 2 Theory of Operation (continued) 2.21 Control Cir cuit for P ower Module Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-SYS-M board (System MCU and Control Circuit) (a) VS is the voltage source for the parallel signal[...]

68 PRELIMIN AR Y 2 Theory of Operation (continued) 2.21 Control Cir cuit for P ower Module (continued) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Located on NH-SYS-M board (System MCU and Control Circuit) RR2 5 10K 5VS 1 2 4 3 UR 1 4 TLP 421 ( G[...]

69 PRELIMIN AR Y 2 Theory of Operation (continued) 2.21 Control Cir cuit for P ower Module (continued) Located on NH-SYS-M board (System MCU and Control Circuit) Located on NH-SYS-M board (System MCU and Control Circuit) (e) D A T A_BUS is the communication bus between the system and its po wer modules. This signal also connects to the e xternal pa[...]

70 PRELIMIN AR Y 2 Theory of Operation (continued) 2.21 Control Cir cuit for P ower Module (continued) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Po wer Module, Circuit for 2 Slots) Control Cir cuit for External P arallel Located on NH-SYS-R board (Circuit for RS232, Output Dry Co[...]

71 PRELIMIN AR Y 2 Theory of Operation (continued) 2.22 T ransformer Over T emperature Detection (This function is only for SU40K, SU60K, SU80K, SU60KTV , and SU80KTV models) Located on NH-M board (System MCU and Control Circuit) (a) CNM10 connects to the output transformer , CNM11 connects to the input transformer . (b) Thermal switch sensors are [...]

72 PRELIMIN AR Y 3 Comm unication W arning: Do not use the paralleling cab le that came with the UPS system for these procedures. Use a RS232 cable. 3.01 RS232 Port The UPS provides a RS232 port in one D-sub 9 female connector . This RS232 port performs the following functions: 3.1) Sets EEPR OM on the NH-M board 3.2) Sets Output Dry Contact status[...]

73 PRELIMIN AR Y 3 Comm unication (continued) Remote Emergency P ower Off (REPO) The Remote Emergenc y Power Of f (REPO) input connection (P1 in Figure 3.02b) allows you to connect the UPS system to your facility’ s EPO circuit — enabling remote emergenc y shutdown of the UPS system’ s output. Connect EPO input to a user-supplied remote switc[...]

74 PRELIMIN AR Y 3 Comm unication (continued) 3.1 Setting EEPROM on the NH-M Boar d 3.1.1 Polling and Updating EEPR OM W ARNING: This procedure m ust be performed in bypass mode (see section 1.6). Instructions for polling and updating the EEPR OM are as follows (Figure 3.1.1a): a) Link the UPS with a PC via the RS232 port b) Run the program “ NH_[...]

75 PRELIMIN AR Y 3 Comm unication (continued) 3.1 Setting EEPROM on the NH-M Boar d (continued) 3.1.2 Calibrating EEPR OM Gain W ARNING: This procedure m ust be performed in bypass mode (see section 1.6). b) Select the parameter you want to calibrate and click its gain icon c) Ke y in the actual value to the “ Actual Measured: ” column of the d[...]

76 PRELIMIN AR Y 3 Comm unication (continued) 3.2 Setting Output Dry Contact Status The UPS provides six output dry contact closures. The status of each output dry contact closure can be programmed from 19 status events: 1. Load on inv erter ( Default ) 2. Load on auto bypass ( Default ) 3. Backup mode input main failure ( Default ) 4. Battery low [...]

77 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d Before upgrading your fi rmware, please verify the fi rmware version using the control panel (Figure 3.3a). (Maintenance Others SN & FW V ersion) F ig 3.3a W ARNING: Make sure that the UPS is in bypass mode and that all po wer modules have been complete[...]

78 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d (continued) T o upgrade the system’ s fi rmware: a) Confi rm that the Main Input Breaker (Q1) and Output Breaker (Q4) are both OFF , and that Bypass Input Break er (Q2) and Manual Bypass Breaker (Q3) are both ON (Figure 3.3b). F ig 3.3b Q 4 Q 3 Q 2 Q 1 Q1[...]

79 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d (continued) b) Select “System Firmware Upgrade” using the LCD panel (Figure 3.3c). (Maintenance Firmware Upgrade Login (Administrator) System Firmware) F ig 3.3c E C N P A U N T E E E R T S U N I A M  S P U S A E M E C N P A U N T E E E R T S U N I A M[...]

80 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d (continued) c) After confi rming the command, wait for the LCD to display “READ Y TO DOWNLO AD FIRMW ARE!” (Figure 3.3d). Note 1: Once you confi rm the command, the system will go into “system fi rmwar e upgrade” mode. If you want to cancel the upg[...]

81 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d (continued) g) Disable “ Reading Comparison ” (Figure 3.3f). F ig 3.3e F ig 3.3f e) Run the program “ FSL 3.75.exe ” (Figure 3.3e). f) Select the PC COM P ort and Click “ Open. ”[...]

82 PRELIMIN AR Y 3 Comm unication (continued) 3.3 Upgrading Firmware for the System Boar d (continued) 3.4 Upgrading Firmware for the P ower Module h) Load the new fi rmware fi le and click “ Upgrade ” (Figure 3.3g). i) Once the system fi nished upgrading its fi rmware, it will auto-reset into manual bypass mode (Figure 3.4h). F ig 3.3g F i[...]

83 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) T o upgrade the power module’ s fi rmware: a) Confi rm that the Main Input Breaker (Q1) and Output Breaker (Q4) are both OFF , and that the Bypass Input Breaker (Q2) and Manual Bypass Breaker (Q3) are both ON. (Figure 3.4b) Before upgrading yo[...]

84 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) Note: Confi rm that you’ve turned on the br eaker for the external battery cabinet or internal battery . b) Select “ P o wer Module F irmware Upgrade ” using the LCD panel. (Figure 3.4c) (Maintenance Firmware Upgrade Login (Administra- tor)[...]

85 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) Note 1: Once you confi rm the command, the system will go into “system fi rmwar e upgrade” mode. If you want to cancel the upgr ade command befor e pr ogramming, the BYP ASS input breaker (Q2) must be turned of f. Note 2: The F irmwar e Upgr[...]

86 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) F ig 3.4e F ig 3.4f g) Select the PFC DSP chip or INV DSP chip, along with power modules 1-4 (Figure 3.4f). e) Run the program “ NH_PM_V1_4B1207.exe ” (Figure 3.4e). f) Click the “ F irmware Upgrade ” icon, select PC COM P ort and click ?[...]

87 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) F ig 3.4g h) Load the new fi rmware fi le for the PFC (or In verter) and click “ Upgrade ” (Figure 3.4g).[...]

88 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) F ig 3.4h F ig 3.4i Note 1: During pr ogramming, the status indicator is r ed. When upgrade is complete, the status indicator will turn gr een (F igur e 3.4h). Note 2: When one power module upgrade is complete, the system will automatically be gin[...]

89 PRELIMIN AR Y 3 Comm unication (continued) 3.4 Upgrading Firmware for the P ower Module (continued) F ig 3.4j F ig 3.4k i) Once all fi rmware upgrades are complete, select “ OFF ” to disable the po wer module fi rmware upgrade. (Figure 3.4k) Note: When you disable the power module’ s fi rmware upgr ade, the power module will r eset and [...]

90 PRELIMIN AR Y 3 Comm unication (continued) 3.5 Downloading the Event Log T o download the UPS e vent log: a) Link the UPS with a PC via the RS232 port. b) Run the program “ NH-EventLog v1.0b1115.exe ” (Figure 3.5a). c) Select PC COM P ort and click “ Open COM P ort. ” d) Click “ Get UPS Event Log ” (Figure 3.5b). F ig 3.5a F ig 3.5b[...]

91 PRELIMIN AR Y 4 Internal Battery The SU20KX, SU40KX and SU40K models all use a +/-240Vdc (480V) DC internal battery system. An internal battery pack (number of packs vary by model) supplies the UPS system with battery backup po wer . Each internal battery pack consists of 40 12Vdc VRLA batteries arranged in two strings: one string of 20 positi v[...]

92 PRELIMIN AR Y 4 Internal Battery (continued) 4.1 Installing and Removing Internal Batteries Place the UPS system in bypass (or turn it completely off) and turn • off the internal battery circuit break er switch, located on the rear of the UPS system. Remov e the battery access bezels, located on the front of the UPS • system. Remov e the bat[...]

93 PRELIMIN AR Y 4 Internal Battery (continued) 4.1 Installing and Removing Internal Batteries (contin ued) Slide a battery string with a red cable into an empty slot within • the battery compartment. Make sure the battery string is oriented as shown in the diagram. Note: Start with the empty slots at the bottom of the battery compartment and wor[...]

94 PRELIMIN AR Y 4 Internal Battery (continued) 4.1 Installing and Removing Internal Batteries (contin ued) Use a voltmeter (user -supplied) to test the voltage of each internal • battery pack. Observing proper polarity , connect the v oltmeter’ s black probe to the battery pack’ s black connector; connect the voltmeter’ s re d probe to the[...]

95 PRELIMIN AR Y 4 Internal Battery (continued) 4.2 Battery Cabinet The standard battery cabinet includes two models: BP480V26B (Figure 4.2a) and BP480V40C (Figure 4.2b). (See T able 4.2a for battery cabinet weight and fl oor loading) BP480V26B BP480V40C W eight 470 kg 700 kg Floor Loading 1064 kg/m^2 1575 kg/m^2 Battery Capacity 40 40 V oltage 12[...]

96 PRELIMIN AR Y 4 Internal Battery (continued) 4.2 Battery Cabinet (continued) Both battery cabinet models hav e a Q board installed on the rear (Figure 4.2c). Q board functions include: • Battery temperature detection: The UPS detects the temperature of the battery cabinet and compensates the battery v oltage. • Battery circuit breaker status[...]

97 PRELIMIN AR Y 4 Internal Battery (continued) 4.2 Battery Cabinet (continued) F ig 4.2d W1 and W2 Cables F ig 4.2e Connection between UPS and Battery Cabinet F ig 4.2f W iring between UPS and Battery Cabinet P3 P4 P5 P6 P7 1 2 3 4 5 1 2 3 4 5 Q board Temperature sensor Battery Cabinet (for standard B/C type) UPS W1 W2 T o connect the external bat[...]

98 PRELIMIN AR Y 5 T r oubleshooting 5.1 Alarm Messages Alarm messages are displayed on the LCD control panel. Press the “UP” and “DO WN” buttons to scroll through all alarm messages. T able 5.1a Warning Messa g e List W arning Message Condition Chapter Index MAIN VOL T/FREQ NOK Main input voltage abnormal ( load<70%: 120V~276V , load>[...]

99 PRELIMIN AR Y 5 T r oubleshooting (continued) 5.1 Alarm Messages (continued) Alarm messages are displayed on the LCD control panel. Press the “UP” and “DO WN” buttons to scroll through all alarm messages. T able 5.1b P ower Module Warning Messa g e List W arning Message Condition PWR MODULE #n PFC FUSE OPEN P ow er module #n main input f[...]

100 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts 5.2.1 “MAIN V OL T/FREQ NOK” St art Is th e ma in input ci rcuit breake r (Q1) t urned on? Turn on t he mai n inp u t c irc u it b re ak e r Is the ma in i nput volt age or f requenc y out of range? C a lib ra te p a ra mete r o n EEPROM (2 ) Replace P board or M board (3) N N Y Y END END act[...]

101 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.2 “MAIN SEQUENCE NOK” This may occur during startup or if the customer changes their charger generation or main input source improperly . 5 T r oubleshooting (continued) F ig 5.2.2a St art Is the mai n input ext ernal w iri ng correct ? C orre ct th e w iring Correc t phase ro[...]

102 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.3 “BYP ASS V OL T/FREQ NOK” 5 T r oubleshooting (continued) St art Are the the mai n or bypass input ci rcuit breake r (Q1 and Q2) tur ned on? T u rn o n th e ma in o r bypass input ci rcuit brea ker Is the mai n input volt age or f requenc y out of range? C a lib ra te p a ra[...]

103 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.4 “BYP ASS SEQUENCE NOK” 5.2.5 “BYP ASS ST A TIC SWITCH O VER TEMPERA TURE” 5 T r oubleshooting (continued) Note (1): The fans ar e installed at the heat-sink of the bypass static switch. (See section 1.5) Note (2): The NTC is mounted on the heat-sink of bypass static swit[...]

104 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.6 “BYP ASS ST A TIC SWITCH F AUL T” 5.2.7 “BYP ASS ST A TIC SWITCH O VERLOAD” 5 T r oubleshooting (continued) St art Are the bypass S CR s functioning ? (1) Rep lace t he S C R Rep lace t he M board (2 ) N Y END Does the fault still occur w/ UPS in bypass mode? Replace the[...]

105 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.8 “UPS INTERNAL COMM ABNORMAL” 5 T r oubleshooting (continued) F ig 5.2.8a F ig 5.2.8b Note (1): Check W2A, W2B, W2C, W2D, W4A, W4B and W6 (F ig 5.2.8b). Note (2): Remove wir es W61A, W65A and W68A. St art Has the com muni cati on w ir e sli pped ? (1 ) Re-insert com muni cati[...]

106 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.9 “B A TTERY TEST F AIL” 5.2.10 “B A TTERY O VER CHARGE” 5 T r oubleshooting (continued) St art Are the actual val ue and LCD value the same ? N Y END Batt ery vol tage < +/ - 256Vdc Check batt ery bank a nd consi der r eplacing t he ba tte ry C alibra te p ara meter on[...]

107 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.11 “B A TTERY B AD” 5 T r oubleshooting (continued) F ig 5.2.11a F ig 5.2.11b Note (1): W ir e #31 connects CNP10 on the NH-SYS-P board to CNB7 on the NH-SYS-B boar d (F igure 5.2.11b). Note (2): T o learn about EEPR OM parameter settings and calibration, turn to section 3.2. [...]

108 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.12 “BYP ASS F AN F AILURE” 5 T r oubleshooting (continued) St art Is fan A spinning? Fan A and B fai led Replace fan A and (2) fan B (3) Replace the P board or M boar d (1 ) N Y Fan A fa iled Replace fan A (2 ) Is the UP S in bypa ss m ode? Is fan C spinning? Is fan B spinning[...]

109 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.13 “TRANSFORMER O VERHEA T” 5 T r oubleshooting (continued) F ig 5.2.13a F ig 5.2.13b Note (1): Models with C–cabinets ar e: SU40K, SU60K, SU80K, SU60KTV and SU80KTV . Note (2): See F igure 5.2.13b for location. Note (3): F or the location of the NH-SYS-M board, turn to sect[...]

110 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.14 “PS OUTPUT V OL T NOK” 5 T r oubleshooting (continued) F ig 5.2.14a F ig 5.2.14b Note (1): W ir e #10 connects CNP9 on the NH-SYS-P board with CNFC20 on the NH-SYS-FC boar d (F igure 5.2.14b). Note (2): T o learn about EEPR OM parameter setting and calibration, r efer to se[...]

111 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.15 “PS EXT P ARALLEL COMM ABNORMAL” 5 T r oubleshooting (continued) F ig 5.2.15a F ig 5.2.15b Note (1): The external par allel wire is located on the r ear panel (F igure 5.2.15b). St art Has the parallel wire slipped? Check firmware first, follow firmware procedure (1 ) Paral[...]

112 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.16 “P ARALLEL F AILURE” 5 T r oubleshooting (continued) St art Are both system’s EEPROM power rating settings the same? (1 ) Make sure that para lle l (2 ) ID s ar e diffe ren t N Y END Make sure the units are identical. Synchronize power rat ing s ett ings (1 ) F ig 5.2.16a[...]

113 PRELIMIN AR Y 5.2 T roubleshooting Flo w Char ts (continued) 5.2.17 “REDUND ANCY LOSS” 5 T r oubleshooting (continued) F ig 5.2.17a Note (1): Access the r edundancy setting using the LCD control panel (only in bypass mode). (UPS SETUP REDUNDANCY SETUP) Select the power module’ s redundancy number . EX: 40kV A UPS, load < 20kV A, redund[...]

114 PRELIMIN AR Y 6.1 Failure P ower Module Identify 6 P o wer Module W ARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it continues to supply po wer to the critical load (the critical load is suppor ted directly b y utility power). These instructions will help you diagnose which power modules ha ve f[...]

115 PRELIMIN AR Y 6.1 Failure P ower Module Identify (continued) 6 P o wer Module (continued) 3) Check the information of DC BUS v oltage. (Figure 6.1c) (Maintenance Others Module DC BUS v olt Administrator) Normally , the DC BUS v oltage of a power module is about +/- 370Vdc. Use this number to confi rm which power module is abnormal. 4) Check th[...]

116 PRELIMIN AR Y 6.1 Failure P ower Module Identify (continued) 6 P o wer Module (continued) Set UPS to manual bypass mode. If the UPS is on normal mode, press the “OFF” button to enter bypass mode. Then turn on the manual bypass circuit breaker (Q3) and turn off the output circuit breaker (Q4). (Figure 6.1e) Next, turn of f the main input cir[...]

117 PRELIMIN AR Y 6.2 P ower Module Replacement 6 P o wer Module (continued) T o remove the po wer module: W ARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it continues to supply po wer to the critical load (the critical load is suppor ted directly b y utility power). W ARNING: Make sure that the UPS[...]

118 PRELIMIN AR Y 6.2 P ower Module Replacement (contin ued) 6 P o wer Module (continued) F ig 6.2c F ig 6.2d R S T N +12V Rev . + N – ID Detect Comm. Port Comm. Port N T S R A C INPUT DC INPUT OUTPUT b) Disconnect the power module (Figures 6.2c and 6.2d). W61A W65A W2A W5 W3A W4A W6 W2B W6 W6 W2C W6 W6 W2D W6 W4B W5 W5 W5 W5 W5 W2B W68A W62B W66[...]

119 PRELIMIN AR Y 6.2 P ower Module Replacement (contin ued) 6 P o wer Module (continued) F ig 6.2e F ig 6.2f F ig 6.2g e) Unscrew the front bezel (Figure 6.2g). f) Remove the front bezel. c) Unscrew the rear panel of the power module (Figure 6.2e). d) Remov e the corner bezels of the power module from the front side (Figure 6.2f).[...]

120 PRELIMIN AR Y 6.2 P ower Module Replacement (contin ued) 6 P o wer Module (continued) g) Unscrew the front of the po wer module (Figure 6.2h). h) Remov e the power module (Figure 6.2i). F ig 6.2h F ig 6.2i[...]

121 PRELIMIN AR Y 7.1 Safety Overview 7.2 Suggested tools and supplies 7.3 UPS Procedure 7 Preventive Maintenance Hazardous voltages and currents are present in this equipment! Hazardous ener gy is stored and will still be present even when the equipment is turned off and remo ved from power mains! Personal protectiv e equipment is required when wo[...]

122 PRELIMIN AR Y 7.3.5 Measure Ø to Ø and Ø to Neutral output voltage and output current as abo ve and enter the values on the form. Compare the readings to the LCD display . If the v oltage readings are within +/- 1% and the current readings are within +/- 1 ampere, check output metering OK on the form. If there is a greater discrepancy , ente[...]

123 PRELIMIN AR Y 7 Preventive Maintenance (continued) Appendix A Service Equipment and T ools 7.4 Internal Battery Procedure Recommended Equipment and T ools Software T ools c) Use the infrared thermometer to measure the ambient temperature near the battery module and the internal temperature of the battery module. Note that the best place to read[...]

124 PRELIMIN AR Y Appendix B T or que T able T ables B.1 and B.2 list the torque for terminal block connection. (For TB locations, see Figure B.a.) T able B.1 KX Models SU20KX T orque lb-in (kgf-cm) Scre wdriver Input TB 15.6 (18) Slotted Screwdriver Bypass TB 15.6 (18) Slotted Screwdriver Battery TB 15.6 (18) Slotted Scre wdriver OUTPUT TB 15.6 (1[...]

125 PRELIMIN AR Y Appendix B T or que T able (continued) T able B.3 lists the torque for terminal block connection. (For SU40K and SU60K TB locations, see Figure B.b .) (For SU80K TB locations, see Figure B.c.) T able B.3 T able B.2 KX Models (continued) K Models SU60KX T orque lb-in (kgf-cm) Scre wdriver Input TB 50 (57.6) Slotted Screwdriver Bypa[...]

126 PRELIMIN AR Y Appendix B T or que T able (continued) K Models F ig B.b . F ig B.c.[...]

127 PRELIMIN AR Y Appendix B T or que T able (continued) KTV Models F ig B.d. T able B.4 lists the torque for terminal block connection. (For TB locations, see Figure B.d.) T able B.4 SU60KTV T orque lb-in (kgf-cm) Scre wdriver Input TB 50 (57.6) Slotted Screwdriver Battery TB 50 (57.6) Slotted Scre wdriver OUTPUT TB 50 (57.6) Slotted Screwdriver G[...]

128 PRELIMIN AR Y Appendix C PCB and T est P oint TPP1: Reference ground (GND) of control circuit power TPP2: +12V of control circuit power TPP4: -12V of control circuit power TPR1: Reference ground (GND) of control circuit power TPR2: Synchronous signal TPR3: Reference ground (GND) of communication circuit power TPR4: +5V of communication circuit [...]