Pacific Power Source 3060-UMS Operation Manual Download

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Summary of Contents for 3060-UMS

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Page 3: ...ONTAINED IN THIS MANUAL IS PROPRIETARY TO PACIFIC POWER SOURCE INC THIS MANUAL MAY NOT BE COPIED OR REPRINTED WITHOUT THE EXPRESSED WRITTEN CONSENT PACIFIC POWER SOURCE INC 17692 FITCH IRVINE CA 92614 PHONE 949 251 1800 FAX 949 756 0756 May 2001 MANUAL PART NO 126550 MANUAL DWG NO 126550 REV B ...

Page 4: ...REVISION CONTROL PAGE Revision Date Pages Approved B 10 20 04 Per EO5696 Title Page Revision Control Page 173 Rev B 173G Rev B DRH ...

Page 5: ...ATIONS 13 2 1 ELECTRICAL SPECIFICATIONS 13 2 1 1 INPUT POWER 13 2 1 2 BATTERY POWER 16 2 1 3 OUTPUT POWER 18 2 2 MECHANICAL SPECIFICATIONS 20 2 2 1 3060 UMS 20 2 2 2 BATTERY CABINET 22 3 INSTALLATION 25 3 1 PLANNING THE JOB 26 3 2 MOVING UNCRATING AND INSPECTION 28 3 3 CHANGING INPUT VOLTAGE 30 3 4 SETTING THE CABINET INTO PLACE 36 3 5 CONNECTING THE INPUT SERVICE 40 3 6 CONNECTING THE OUTPUT SERV...

Page 6: ...4 DIAGNOSTIC KEY 84 4 4 1 5 HELP KEY 87 4 4 1 6 ALARM KEY 89 4 4 1 7 SPECIAL KEY COMBINATIONS 90 4 4 2 MODE SELECT EMERGENCY OFF AND ON RESET SWITCHES 92 4 4 2 1 MODE SELECT SWITCH 92 4 4 2 2 EMERGENCY OFF AND START RESET SWITCHES 94 4 4 3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST 96 4 4 3 1 FREQUENCY SELECT SWITCH 96 4 4 3 1 VOLTAGE ADJUST CONTROLS 96 4 5 SETUP SWITCHES 98 4 5 1 DISPLAY PCB 100 4 ...

Page 7: ...ICE PROCEDURE 152 6 3 4 EMER OFF SERVICE PROCEDURE 154 6 3 5 NO INVERTER VOLTS SERVICE PROCEDURE 158 6 3 6 ABNORMAL VOLTAGE SERVICE PROCEDURE 160 6 4 ASSEMBLY REPLACEMENT PROCEDURES 162 6 4 1 INVERTER ASSEMBLY REPLACEMENT 163 6 4 2 CONTROL PCB ASSEMBLY REPLACEMENT 165 6 4 3 MODULATOR PCB ASSEMBLY REPLACEMENT 166 6 4 4 DISPLAY PCB ASSEMBLY REPLACEMENT 167 6 4 5 LVPS PCB ASSEMBLY REPLACEMENT 168 6 4...

Page 8: ...SYSTEM ONE LINE DIAGRAM 56 FIGURE 3 9 RSP IV CONNECTIONS 57 FIGURE 3 10 ELECTRICAL SURVEY CHECKLIST 59 TABLE 4 2 INSTALLATION RECORD 63 FIGURE 4 4 3060 UMS FRONT PANEL 77 FIGURE 4 4 1 LCD AND INTERROGATION SWITCHES 78 FIGURE 4 4 2 MODE SELECT EMER OFF AND START RESET 93 FIGURE 4 4 3 FREQUENCY SELECT AND VOLTS ADJUST 97 FIGURE 4 5 CABINET ASSEMBLY 99 FIGURE 4 5 1 DISPLAY PCB PART NUMBER 126572 101 ...

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Page 11: ...ion and operation It is very important that the user reads sections 3 and 4 prior to installing this equipment A thorough understanding of these two sections is required to operate this equipment properly If questions arise while reading this manual the user is encouraged to call the Pacific Power Source Corporation Pacific maintains a toll free number which is 1 800 854 2433 1 800 472 8465 inside...

Page 12: ...SECTION 1 GENERAL 2 FIGURE 1 1 3060 UMS ...

Page 13: ...dangerous situation which may damage the equipment but is not a threat to life or limb Cautions will assume the format shown on the following page All cautions should be rigorously observed WARNING THIS EQUIPMENT CONTAINS HIGH ENERGY LOW IMPEDANCE CIRCUITS LETHAL POTENTIALS ARE CONTAINED WITHIN THE CABINET CARE MUST BE EXERCISED WHEN SERVICING THIS EQUIPMENT IN ORDER TO PREVENT SERIOUS OPERATOR IN...

Page 14: ... FIRST REMOVING THE INPUT SERVICE BY OPENING ALL CIRCUIT BREAKERS 4 SERVICE OTHER THAN EXTERNAL CLEANING SHOULD BE REFERRED TO PERSONNEL AUTHORIZED BY THE FACTORY TO SERVICE THIS EQUIPMENT WARNING CAUTION READ SECTIONS 3 AND 4 OF THIS MANUAL BEFORE INSTALLING OR OPERATING THIS EQUIPMENT CAUTION ...

Page 15: ...ortion are of the order of 1 at 50 or 60Hz and 2 at 400Hz Response time to a 100 step load change is 300 microseconds The machine is therefore capable of delivering very high pulse current loads The fast response time and excellent regulation of the 3060 UMS is extremely important in applications where mixed or switched loads may cause power interference and load Cross talk 3060 UMS equipment is d...

Page 16: ...SECTION 1 GENERAL 6 FIGURE 1 3 UPS FUNCTIONAL BLOCK DIAGRAM ...

Page 17: ...AC power to the load 1 4 2 CABINET An enclosure that contains the rectifier charger inverter and controls required to provide the specified AC power to the load 1 4 3 BATTERY CABINET A cabinet that contains maintenance free sealed batteries sufficient to maintain UPS output in accordance with the specifications The Battery Cabinet contains a battery disconnect contactor and fuses The contactor is ...

Page 18: ...temperature is monitored by the Diagnostic System to ensure that the transformer temperature does not exceed design limits The rectifier charger unit provides a soft start up feature whereby when the AC power is first applied the total initial power drawn at the input terminals will not exceed 100 of rated input power If the output power is in excess of 100 then the input power may increase over 1...

Page 19: ...ithin its rating without reducing the output voltage Overloads will cause the machine to overheat and shutdown Loads greater than 150 may cause a reduction of the output voltage The inverter will current limit at 150 of rated current The inverter is capable of supplying at least 210 of rated RMS current for short circuit conditions If the short circuit is sustained the inverter will shut down and ...

Page 20: ...f line A failed MASTER turns the entire system off In this event an operator can select any other paralleled unit as the MASTER from a front panel control and restore system operation 1 4 8 LOW VOLTAGE POWER SUPPLY LVPS A 18 VDC power supply to power all low voltage circuits 1 5 ON LINE BATTERY TEST The UPS is provided with an On Line battery test capability that tests the UPS battery and battery ...

Page 21: ...SECTION 1 GENERAL 11 FIGURE 1 6 GROUNDING ...

Page 22: ...SECTION 1 GENERAL 12 THIS PAGE INTENTIONALLY BLANK ...

Page 23: ...will increase by the number of cabinets on line 2 1 ELECTRICAL SPECIFICATIONS 2 1 1 INPUT POWER Voltage Range 480 380 240 or 208 VACL L 15 Normally configured for 480 VACL L Frequency Range 47 63 Hz Power 55 kW nominal 60 kW when charging batteries Volt Amps 68 kVA nominal 74 kVA when charging batteries Input Volts Amps Taps Available 480 100 Nom 7 10 380 125 Nom 5 10 4 8 17 240 200 Nom 13 208 250...

Page 24: ... Electrical Code Protection requirements for single phase protection and reversed phase rotation protection Transients Meets Institute of Electrical and Electronics Engineers 587 requirements at 4000 volts peak Up to 150 line voltage for 1 2 cycle Phase Rotation Unit will operate with any input phase rotation There are no input phase rotation sensitive devices Isolation An input transformer with a...

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Page 26: ...used for faster recharging Initially 2 36 V P C or 212 volts per bus Float voltage is 2 27 V P C or 204 volts per bus Charge time 6 hours for a full load discharge cycle Discharge 1 78 V P C or 160 volts per bus voltage Discharge 150 160 amps D C at full load current Protection Fuses 300A located in the battery cabinet Breaker 225A located in battery cabinet Control Contactor located in the batter...

Page 27: ...SECTION 2 SPECIFICATIONS 17 FIGURE 2 1 2 BATTERY SUPPORT TIME ...

Page 28: ...e with AGC enabled Transient Voltage Recovers to 3 regulation band in Regulation and a 200 microseconds for a 50 load Recovery step b 400 microseconds for a 100 load step Harmonic Voltage Maximum 1 RMS total maximum Content for Linear 0 5 any single harmonic for Loads linear loads 50 60Hz 2 RMS total for 400Hz Paralleled Systems may be higher Current 175 amps per phase Inverter Fault Greater than ...

Page 29: ...llator is included covering the range 47 500 Hz In addition provision is made for an External Oscillator input Frequency 0 01 for fixed frequencies Accuracy and Stability Power Factor No Restrictions Overload 150 30 sec 125 10 min 110 1 hour For a paralleled cabinet system multiply the above ratings by the number of cabinets on line in the system ...

Page 30: ...ake top exhaust Noise level 65dbA at 3 feet Installation 36 at front of cabinet for service Clearance 12 top 0 side and rear Ambient Operating 0 to 40 C Temperature Storage 10 to 70 C Relative 0 to 95 non condensing Humidity Elevation Operating 6500 Ft Derate to 70 at 11 500 Ft Storage 40 000 Ft Heat Dissipation 20 kBTU HR at 50 kW 62 5 kVA load ...

Page 31: ...SECTION 2 SPECIFICATIONS 21 FIGURE 2 2 1 3060 UMS OUTLINE DRAWING ...

Page 32: ...BINET Weight 2800 LBS including batteries Height 60 Width 40 Depth 35 5 Installation 36 at front of cabinet for service Clearance 0 top and sides 12 rear Ambient 20 to 30 C Temperature Relative 0 to 95 non condensing Humidity Elevation 0 6500 Ft ...

Page 33: ...ION 2 SPECIFICATIONS 23 FIGURE 2 2 2 BATTERY CABINET OUTLINE DRAWING 40 60 FRONT 32 5 SIDE VENTILATION SLOTS BACK TRIPLE KNOCKOUTS 1 3 32 x 1 31 32 x 3 4 PLCS EACH SIDE 1 1 2 SINGLE KNOCKOUTS 6 PLCS BOTTOM ...

Page 34: ...SECTION 2 SPECIFICATIONS 24 THIS PAGE INTENTIONALLY BLANK ...

Page 35: ...472 8465 inside Ca The installation of the UPS consists of the following steps 1 Planning the job Refer to paragraph 3 1 2 Uncrating and Moving the system Refer to paragraph 3 2 3 Changing Input Voltage if required Refer to paragraph 3 3 4 Setting the UMS cabinet and battery cabinet into place Refer to paragraph 3 4 5 Making Input Connections Refer to paragraph 3 5 6 Making Output Connections Refe...

Page 36: ...load capabilities After a particular model has been selected location of the Power Source input and output wiring and environmental conditions must be considered Section 3 1 Environmental Survey Checklist is provided to verify environmental conditions The UMS cabinet should be placed as close as possible to the battery cabinet and load to minimize output wiring lengths This is done to reduce distr...

Page 37: ...ations requires sealing off of the lower front area Consult factory 5 A minimum of 36 in front of the UPS Cabinet _____ and 36 in front of and to one side of the battery cabinet for service 6 Altitude of installation does not exceed 6500 feet _____ Altitudes in excess of 6500 feet require the derating of maximum operating levels 7 Relative humidity does not exceed 95 non condensing _____ It is sug...

Page 38: ...to be moved with a forklift or hand truck of adequate capacity Upon receiving the equipment remove the packing list Separate and remove the top then the sides of the crate setting these aside for the moment Inspect all equipment for signs of damage in shipping If any damage has occurred contact the shipper and the Pacific factory for instructions If the cabinet is to be returned it must be shipped...

Page 39: ...SECTION 3 INSTALLATION 29 FIGURE 3 2 CRATING AND MOVING OUTLINE DRAWING ...

Page 40: ...model number will require the following Input Circuit Breaker and Fuses Input Volts CB1 F1 F2 F3 480 100 A P N 716049 1 A P N 712043 380 125 A P N 716056 1 A P N 712045 240 200 A P N 716057 2 A P N 712044 208 225 A P N 716032 2 A P N 712044 If a non standard input is required the machine may be configured for any of the following INPUT VOLTAGE INPUT TAPSCONNECT TAPS Fig 480 480 1 8 4 5 3 3 1 480 7...

Page 41: ... Remove old CB1 the input circuit breaker Install new CB1 with correct amperage for new input voltage STEP 4 Remove old F1 F2 and F3 the input fuses Install new fuses with correct amperage for new input voltage STEP 5 Rewire T1 AND T2 as per figure 3 3 1 or 3 3 2 or 3 3 3 or 3 3 4 as required CAUTION DAMAGE TO THE EQUIPMENT MAY RESULT IF INCORRECTLY WIRED VERIFY CONNECTIONS ARE MADE TO PROPER TAPS...

Page 42: ...SECTION 3 INSTALLATION 32 FIGURE 3 3 1 480 V INPUT CONFIGURATION ...

Page 43: ...SECTION 3 INSTALLATION 33 FIGURE 3 3 2 380 V INPUT CONFIGURATION ...

Page 44: ...SECTION 3 INSTALLATION 34 FIGURE 3 3 3 240 V INPUT CONFIGURATION ...

Page 45: ...SECTION 3 INSTALLATION 35 FIGURE 3 3 4 208 V INPUT CONFIGURATION ...

Page 46: ...ey should proceed appropriately Observe clearances as shown in Figures 2 2 1 and 2 2 2 When installing the UPS the battery cabinet should be installed at this time Refer to paragraph 3 7 for battery cabinet installation The weight of the battery cabinet may approach 2800 lbs dependent upon the batteries selected In this state it is recommended that the battery cabinet be moved using a forklift or ...

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Page 48: ...SECTION 3 INSTALLATION 38 BATTERY CABINET FIGURE 3 4A SYSTEM INTERCONNECT WIRING ...

Page 49: ...SECTION 3 INSTALLATION 39 FIGURE 3 4B SYSTEM INTERCONNECT WIRING ...

Page 50: ...ependent upon model number will draw the following load currents Input Volts Amps Taps Available 480 100 Nom 7 10 380 125 Nom 5 10 4 8 17 240 200 Nom 13 208 250 Nom 15 9 Input connections to the 3060 UMS AC Power Source are made at the Circuit Breaker labeled INPUT POWER Refer to figure 3 5 for location and orientation of terminals The input terminals are compression type It is very important that...

Page 51: ...SECTION 3 INSTALLATION 41 CAUTION ...

Page 52: ...SECTION 3 INSTALLATION 42 FIGURE 3 5 INPUT TERMINAL DETAIL ...

Page 53: ... is desired on the output distribution system it is available as an option or may be mounted external to the cabinet and is provided by the user WARNING LETHAL VOLTAGES PRESENT AT OUTPUT OF MACHINE REFER CONNECTION TO A QUALIFIED ELECTRICIAN WARNING Output connections from the 3060 UMS AC Power Source are made at the output contactor labeled OUTPUT POWER Refer to figure 3 6 for location and orient...

Page 54: ...SECTION 3 INSTALLATION 44 FIGURE 3 6 OUTPUT TERMINAL DETAIL ...

Page 55: ...in the battery cabinet WARNING WHEN FOUR OR MORE BATTERIES ARE CONNECTED IN SERIES LETHAL POTENTIALS EXIST WEAR SAFETY GLASSES WHEN MAKING CONNECTIONS TO BATTERIES BATTERIES ARE CAPABLE OF DELIVERING EXTREMELY HIGH CURRENTS IF SHORTED BATTERIES MAY EXPLODE IF SHORTED USE EXTREME CARE TO PREVENT ACCIDENTAL SHORTING OF TOOLS ACROSS BATTERIES REMOVE ALL WATCHES RINGS AND OTHER JEWELRY BEFORE SERVICIN...

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Page 57: ...rear clearance should be maintained to allow for battery service and allow access to the battery contactor and fuses The cabinet weighs approximately 2800 lbs with batteries installed Attention must be given to floor loading relative to the strength of the floor when placing this assembly Place the battery cabinet near the side or rear of the UPS Cabinet as required CAUTION IT IS THE USER S RESPON...

Page 58: ...SECTION 3 INSTALLATION 48 FIGURE 3 7 1 BATTERY CABINET SERVICE CLEARANCES ...

Page 59: ...Refer to figures 3 7 2 and 3 7 3 It is mandatory that these connections are clean and tightened properly Be sure to observe polarity positive to positive negative to negative and neutral to neutral The hex screw of these terminals must be torqued to 150 inch lbs The battery contactor coil wires from the battery cabinet to the UPS Cabinet should be a minimum of 18 AWG Single conductors or jacketed ...

Page 60: ...SECTION 3 INSTALLATION 50 FIGURE 3 7 2 UPS CABINET BATTERY TERMINAL DETAIL ...

Page 61: ...RE BATTERIES ARE CONNECTED IN SERIES LETHAL POTENTIALS EXIST WEAR SAFETY GLASSES WHEN MAKING CONNECTIONS TO BATTERIES BATTERIES ARE CAPABLE OF DELIVERING EXTREMELY HIGH CURRENTS IF SHORTED BATTERIES MAY EXPLODE IF SHORTED USE EXTREME CARE TO PREVENT ACCIDENTAL SHORTING OF TOOLS ACROSS BATTERIES REMOVE ALL WATCHES RINGS AND OTHER JEWELRY BEFORE SERVICING THE BATTERIES WARNING ...

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Page 63: ...attery are installed using 120 inch pounds torque on the connections A cable from the top shelf is connected from the positive battery terminal to the positive fuse block The cable from the bottom shelf negative battery terminal is connected to the negative fuse block The cables connected to the neutral terminal block TB5 are connected to battery 15 and battery 16 terminals on the middle shelf A j...

Page 64: ...SECTION 3 INSTALLATION 54 FIGURE 3 7 3 BATTERY ORIENTATION AND WIRING ...

Page 65: ...tween each cabinet of the paralleled system Connect one cable from Cabinet 1 P2 to Cabinet 2 P1 Connect another cable from Cabinet 2 P2 to Cabinet 3 P1 Connect as many paralleling cables up to nine for a ten cabinet system as needed This paralleling cable contains all of the control signals necessary to operate the Multiple Cabinet System All five output wires Chassis Neutral Phase A Phase B and P...

Page 66: ...SECTION 3 INSTALLATION 56 FIGURE 3 8 1 MULTIPLE CABINET SYSTEM OUTLINE ...

Page 67: ...SECTION 3 INSTALLATION 57 FIGURE 3 8 2 MULTIPLE CABINET SYSTEM ONE LINE DIAGRAM ...

Page 68: ...P IV The RSP IV connects to the 3060 UMS via J9 which is a DA15S connector on top of the machine A DA15P is supplied for mating to this connector Connect the RSP IV to the 3060 UMS as shown in figure 3 9 The RSP IV may be mounted up to 1000 feet away from the 3060 UMS when using 18 AWG wire FIGURE 3 9 RSP IV CONNECTIONS ...

Page 69: ...s the codes shall take precedence over this document It is requested that in the event of conflict the factory be notified by calling 714 898 2691 WARNING WHEN FOUR OR MORE BATTERIES ARE CONNECTED IN SERIES LETHAL POTENTIALS EXIST WEAR SAFETY GLASSES WHEN MAKING CONNECTIONS TO BATTERIES BATTERIES ARE CAPABLE OF DELIVERING EXTREMELY HIGH CURRENTS IF SHORTED BATTERIES MAY EXPLODE IF SHORTED USE EXTR...

Page 70: ... service voltage and frequency with the _____ service listed on the Cabinet Identification Plate on the upper rear of the cabinet 4 Check input service ratings Circuit breakers and _____ wiring should be sized in accordance with currents listed in Section 3 5 5 Safety wiring should be sized in accordance with _____ currents listed in Section 3 5 Ground for the Cabinet shall be connected to the Cab...

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Page 72: ...ources are capable of delivering tremendous amounts of energy This is by design and the primary mission of the power source Make sure that the loads attached match the output voltage and frequency of the Power Source First time operation requires a more in depth inspection than would otherwise be indicated Specific items to check on first time turn on are 1 Proper input voltage brought into the Po...

Page 73: ...nd record Set Up Switch Positions After installation of the Power Source and if commissioning service has been contracted contact the PACIFIC factory for check out and initial turn on Two weeks should be allowed in scheduling personnel with a maximum of two days normally required on site The first half of the Installation Record should be completed prior to the arrival of factory personnel The sec...

Page 74: ... Name Title Phone Number ________________ Ext _____ Site Address ___________________________ ___________________________ Test Technician ___________________________ Date ___ ___ ___ Comments on Installation ___________________________ ____________________________________________________ ____________________________________________________ ____________________________________________________ ______...

Page 75: ...utput Voltage L N _______ _______ _______ Output Current _______ _______ _______ Output kVA _______ _______ _______ Percent Load _______ _______ _______ Output Frequency _______ Set Up Switch Positions Switch Position Number Dip Switch 1 2 3 4 5 6 7 8 Control PCB S14 ___ ___ ___ ___ ___ ___ ___ ___ Display PCB S41 ___ ___ ___ ___ ___ ___ ___ ___ Display PCB S42 ___ ___ ___ ___ ___ ___ ___ ___ ...

Page 76: ...r Source power is secured for load maintenance 3 Emergency Shutdown Procedure Action taken to secure Power Source output power in emergency situations 4 Power Source Modes of Operation Provides definition of Power Source operational states Operation of the 3060 UMS Power Source has been designed to be simple and straightforward This is done for several reasons the primary reason being safety The a...

Page 77: ...up operation complete Table 4 2 Installation Record as operation proceeds STEP 3 Open main breakers of output distribution system No load should be connected to cabinet at this point STEP 4 Close input power circuit breaker The OFF lamp on the Power Source Mode Select switch should illuminate If this lamp does not light the EMER OFF lamp should be on Check the input power by pressing the INPUT the...

Page 78: ...panel The center VOLTS ADJUST control adjusts all three outputs simultaneously φB and φC are trim adjustments Frequency may be changed by using the FREQUENCY SELECT switch 50 60 and 400Hz are fixed crystal stabilized frequencies The VAR position is variable from 47 to 500Hz The EXT position allows external oscillator input on connector J6 The SLAVE position makes this cabinet a slave STEP 7 Place ...

Page 79: ... SLAVE position for each Cabinet in the system This should cause an EMER OFF in ALL Cabinets STEP 3 Select ONE Cabinet to be MASTER Operate the ONE MASTER Cabinet as a Single Cabinet Power Source as described in section 4 3 1 STEP 4 Verify operation of each Cabinet individually as described in steps 2 and 3 above STEP 5 Rotate the MODE SELECT switch to OFF for all Cabinets Select ONE Cabinet in th...

Page 80: ... output currents are large check for mis wires STEP 8 Verify operation of each SLAVE individually as described in steps 6 and 7 above STEP 9 Turn ON all Cabinets in the system On the MASTER rotate the MODE SELECT switch to standby and verify all cabinets go to STANDBY On the MASTER press EMER OFF and observe all Cabinet goes to EMER OFF STEP 10 Connect the load Bring up the MASTER then all Cabinet...

Page 81: ...either the Power Source or the Load To secure power from the Power Source proceed as follows STEP 1 Turn off all loads and open output circuit breaker if provided STEP 2 Rotate the Mode Select Switch to the OFF position Verify that the OFF lamp is lit Verify that the STANDBY and ON lamps are extinguished To secure all power to and from the Power Source proceed as follows STEP 1 Turn off all loads ...

Page 82: ...ating of the inverter or input transformer in the event of excessive load current for extended time an unlikely occurrence due to conservative thermal design A third function is to give the operator a quick Turn Off means in the event of an emergency since pressing EMER OFF is slightly faster than rotating the Mode Select Switch to Off The Emergency Off state can only be removed by rotating the Mo...

Page 83: ...elow OFF STATE The OFF state is achieved by rotating the Mode Select Switch to Off If the EMER OFF switch is illuminated pressing START RESET is also required to change the state from EMER OFF to normal OFF OFF causes the machine to be dead except for the low voltage power supply OFF shall be achieved if the following are true A The EMER OFF lamp is off B The OFF lamp is on C The STANDBY lamp is o...

Page 84: ... RESET button is pushed E The slow turn on contactor closes F The main input contactor closes G The 200 VDC supplies charge the battery contactor closes the modulator is enabled The machine is now in STANDBY mode ON STATE ON is when the output contactor is closed and the machine is ready to deliver power to a load The ON lamp is on Observe the following sequence to achieve ON A The STANDBY lamp is...

Page 85: ... LVPS FAULT one of the low voltage power supplies has failed D Bus VOLTAGE GREATER THAN 240 VDC one of the high voltage power supplies has exceeded 240 VDC E INVERTER FAULT one of the inverters has failed F INVERTER OVERTEMP one of the inverters has exceeded 85 C G TRANSFORMER OVERTEMP the large input transformer has exceeded 200 C H SUSTAINED OVERLOAD the power source has been in current limit fo...

Page 86: ... and either EMER OFF OFF STANDBY or ON lamps shall be lit The control mode shall be determined by the following table MASTER MODE OFF STANDBY ON SLAVE MODE OFF OFF OFF OFF STANDBY OFF STANDBY STANDBY ON OFF STANDBY ON CONTROL MODE AUTO RE START If AUTO RE START is enabled the Power Source shall start AUTOMATICALLY when input power is applied The Power Source shall attain the mode as selected by th...

Page 87: ...ection Used to solicit Power Source parametric values Refer to paragraph 4 4 1 2 Mode Select Emer Off and Start Reset switches Refer to paragraph 4 4 2 Used to control the operational state of the Power Source 3 Frequency Select and Volts Adjust Refer to paragraph 4 4 3 Used to control the Internal Oscillator and select Master or Slave operation in Parallel Systems This section is divided into the...

Page 88: ...SECTION 4 OPERATION 78 FIGURE 4 4 3060 UMS FRONT PANEL ...

Page 89: ...SECTION 4 OPERATION 79 FIGURE 4 4 1 LCD AND INTERROGATION SWITCHES ...

Page 90: ...ut Volts Phase to Neutral and Phase to Phase A displays Input Amps for each phase kW displays Input Kilowatts for each phase and kVA displays Input Kilo Volt Amps for each phase I1 INPUT V XXX XXX XXX XXX XXX XXX ABNORMAL A XXX XXX XXX kW XX X XX X XX X FREQ XXX X kVA XX X XX X XX X When the INPUT then f2 Keys are pressed message I2 will be displayed LVPS is internal Low Voltage Power Supply volta...

Page 91: ... IN kW Batt discharge When the OUTPUT then f2 keys are depressed message O2 will be displayed showing Single Cabinet output Frequency Single Cabinet output volts Phase to Neutral and Phase to Phase I PEAK percentage of maximum peak amps kVA percentage of maximum kVA and kW percentage of maximum kW information are displayed for each phase O2 CABINET V XXX XXX XXX XXX XXX XXX OUTPUT I PEAK XXX XXX X...

Page 92: ...another f1 f4 key shall display the corresponding message 4 4 1 3 STATUS KEY The STATUS key is used to display the operating status of the Power Source This key may be pressed at any time power is applied to the cabinet Based on internal sense circuits one of six basic messages may be displayed Section 6 2 1 is a list of control term definitions S1 Displayed when the Power Source is in an Emergenc...

Page 93: ...100 The ON lamp shall be lit Output Frequency and LOAD the highest of any percent load as described in the Output O2 message is displayed Single Cabinet output volts Phase to Neutral and Phase to Phase Amps information is displayed for each phase S5 CAB IS ON WARNING OVERLOAD V XXX XXX XXX XXX XXX XXX A XXX XXX XXX FREQ XXX X LOAD XXX S6 Displayed when the Power Source is in an Emergency Off state...

Page 94: ... XXX A XXX XXX XXX FREQ XXX X LOAD XXX S10 Displayed when the Power Source is in an Alarm condition caused by an OUTPUT OVER FREQUENCY S10 CAB IS ON WARNING OVER FREQUENCY V XXX XXX XXX XXX XXX XXX A XXX XXX XXX FREQ XXX X LOAD XXX S11 Displayed when the Power Source is in an Alarm condition caused by loss of input power S10 CAB IS ON WARNING INPUT POWER HAS FAILED LOAD ON BATTERY BATT TIME XX MIN...

Page 95: ...then f1 keys are depressed the cause of the Emergency Off state is displayed D1 DIAGNOSTIC NO EMERGENCY OFF or D1 DIAGNOSTIC EMERGENCY OFF CAUSED BY MASTER EMERGENCY OFF SUSTAINED OVERLOAD INVERTER FAULT EMER OFF BUTTON TRANSFORMER OVERTEMP INVERTER OVERTEMP LVPS FAULT Bus VOLTAGE 240 VDC EXTERNAL EMERGENCY OFF NO MASTER ON LINE When the DIAG then f2 keys are pressed the input transformer temperat...

Page 96: ...UTPUT IS OFF AND BATTERY THERE IN NO LOAD TEST TEST NOT POSSIBLE If the f3 key is pressed again and the output contactor is closed the following message is displayed D6 DIAGNOSTIC PRESS f2 AND f4 BATTERY TOGETHER TEST WITHIN 5 SECONDS TO INITIATE If f2 and f4 are not pressed within 5 seconds the D3 message is displayed If f2 and f4 are pressed within 5 seconds a new battery test starts This test w...

Page 97: ... 12 3VDC the last EMER off when Q6 went hi and NOW present real time BIT PORT 2 PORT 3 7 KYBD f3 ML 6 KYBD f4 INV OVERTEMP 5 MASTER EMER OFF EMER OFF SW 4 XFMR OVERTEMP SUSTAINED O L 3 LVPS FAULT INPUT LINE FAULT 2 LS Q6 1 C0 VDC 240 0 LM EXT EMER OFF BIT PORT 4 PORT 5 7 VDC 160 SPARE 6 INV FAULT MOD ENABLE 5 S3 CLOSE COMM SPARE 4 S4 CLOSE COMM SPARE 3 S5 CLOSE COMM INV TEST OK 2 S7 CLOSE COMM SPA...

Page 98: ...eys to determine the cause of the FAULT Instructs the user to press the START RESET to clear the FAULT Instructs the user that service is required if the fault cannot be cleared H2 CABINET IS IN EMERGENCY OFF STATE PRESS DIAG KEY TO DETERMINE FAULT TO CLEAR FAULT PRESS START RESET IF FAULT REMAINS SERVICE IS REQUIRED H3 Displayed when the cabinet is in a Normal Off State Instructs the user how to ...

Page 99: ...5 Displayed when the cabinet is in the On State The cabinet s output terminals are energized The output contactor is closed Instructs the user to press a button to read metering information H5 SYSTEM IS IN ON STATE TO READ METERING INFORMATION PRESS THE ASSOCIATED BUTTON H6 Displayed when the cabinet is in the Alarm State Instructs the user to press the STATUS button to determine the cause of the ...

Page 100: ...F XXX Whenever message A1 is displayed limits are subject to change by use of f1 through f4 buttons First press and hold of f1 causes OV to increase at about 5 volts per second Second press and hold causes OV to decrease at about 5 volts per second Similarly for f2 f3 and f4 If ALARM is ENABLED and any voltage frequency temperature or percent load parameters exceeds its limits the ALARM BUZZER sha...

Page 101: ...CTION 4 OPERATION 91 4 4 1 7 SPECIAL KEY COMBINATIONS INPUT STATUS HELP Pressed simultaneously shall cause a software reset of the display CPU OUTPUT DIAG ALARM Pressed simultaneously shall clear the RAM ...

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Page 103: ... time The three available switch positions are defined as follows OFF The cabinet is shut off No power is supplied to the load A red LED next to the OFF position is lighted when there is no power applied to the output and diagnostic checks are OK STANDBY The cabinet is in the Standby State The internal high voltage power supplies are energized and the batteries are on line The inverter is operatin...

Page 104: ...SECTION 4 OPERATION 94 FIGURE 4 4 2 MODE SELECT EMER OFF AND START RESET ...

Page 105: ... The Emergency Off state is indicated by a lamp that illuminates the EMER OFF push button A lamp next to the OFF text on the Mode Select switch indicates that the cabinet is in the Normal Off State The Normal Off state lamp is inhibited from being ON when an EMERGENCY OFF condition exists When power is first applied during turn on the cabinet is automatically set to the Off state If AUTO RESTART i...

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Page 107: ...al oscillator VAR This is a 47 to 500 Hz variable frequency control for the internal oscillator EXT This selects an external oscillator input for the Power Source SLAVE In this position this cabinet is a SLAVE to another master in a Multiple Cabinet System One and only one cabinet may be MASTER in a Multiple Cabinet System The MASTER Frequency shall control the entire Multiple Cabinet System 4 4 3...

Page 108: ...SECTION 4 OPERATION 98 FIGURE 4 4 3 FREQUENCY SELECT AND VOLTS ADJUST ...

Page 109: ...ity within the product family logic switches are used to convey certain operating characteristics to the cabinet These switches are summarized as follows 1 Display PCB Paragraph 4 5 1 S41 Machine ID and Baud Rate S42 For testing and future use 2 Control PCB Paragraph 4 5 2 S14 Auto restart and AGC control Refer to Figure 4 5 Cabinet Assembly Drawing for PC Board location CAUTION All Cabinet Switch...

Page 110: ...SECTION 4 OPERATION 100 FIGURE 4 5 CABINET ASSEMBLY ...

Page 111: ... Undefined ON ON Undefined S41 3 Machine Type OFF NON UPS ON UPS S41 4 Undefined S41 5 S41 6 Serial Port A Baud Rate OFF OFF 300 OFF ON 1200 ON OFF 2400 ON ON 9600 S41 7 S41 8 Serial Port B Baud Rate OFF OFF 300 OFF ON 1200 ON OFF 2400 ON ON 9600 Normal Shipping Configuration is as follows S41 1OFF 62 5kVA Machine S41 2OFF 62 5kVA Machine S41 3ON UPS S41 4OFF Undefined S41 5OFF 1200 Baud Serial Po...

Page 112: ...SECTION 4 OPERATION 102 FIGURE 4 5 1 DISPLAY PCB PART NUMBER 126572 ...

Page 113: ...ON S14 2Undefined S14 3Phase A AGC OFF LOCAL ON REMOTE S14 4Phase B AGC OFF LOCAL ON REMOTE S14 5Phase C AGC OFF LOCAL ON REMOTE S14 6Phase A AGC OFF DISABLED ON ENABLED S14 7Phase B AGC OFF DISABLED ON ENABLED S14 8Phase C AGC OFF DISABLED ON ENABLED Normal Shipping Configuration is as follows S14 1OFF Auto Restart Disabled S14 2OFF Undefined S14 3OFF Phase A Local AGC S14 4OFF Phase B Local AGC ...

Page 114: ...SECTION 4 OPERATION 104 FIGURE 4 5 2 CONTROL PCB PART NUMBER 126570 ...

Page 115: ...multiple cabinet systems They are DB25P type Pin numbers are as follows 1 φA Error Signal 2 φB Error Signal 3 φC Error Signal 4 Common Error Signal 5 Triangle Wave Sync 6 Master on line 7 Remote mode 0 8 Remote mode 2 9 Remote Emer Off 10 Remote Start 11 φA System Amps 12 φB System Amps 13 φC System Amps 14 17 Gnd 18 12VDC 19 Ext Emer Off 20 22 No Connection 23 25 Gnd Pins 18 and 19 may be wired t...

Page 116: ...SECTION 4 OPERATION 106 FIGURE 4 6 FEATURE CONNECTOR DETAIL ...

Page 117: ...ON Refer to Figure 4 6 J3 or COM A is a female DB 25 socket This socket is a Data Communications Equipment DCE Port configured to be interfaced with a Data Terminal Equipment DTE device such as a dumb terminal or PC set up as a DTE J4 or COM B is a DTE port configured to be interfaced with a DCE device such as a modem A female DB 25 socket is also provided for this port BAUD RATE The Baud Rates fo...

Page 118: ...CTSA DCDA etc are provided for operator convenience The 3060 UMS requires only 3 lines Receive Transmit and Ground PORT PIN MNEMONIC DESCRIPTION COM A 2 RXDA RECEIVE DATA PORT A 3 TXDA TRANSMIT DATA PORT A 4 CTSA CLEAR TO SEND PORT A 20 DCDA DATA CARRIER DETECT PORT A 8 DSRA DATA SET READY PORT A 5 RTSA REQUEST TO SEND PORT A 7 GRD GROUND PORT A COM B 4 RTSB REQUEST TO SEND PORT B 20 DTRB DATA TER...

Page 119: ...ed descriptions of returned messages Command Command Type Information Type I1 RET Input Screen 1 VLN VLL Amps kW kVA Frequency Input NORMAL OR ABNORMAL I2 RET Input Screen 2 LVPS Bus BATT voltages Battery amps and kW O1 RET Output Screen 1 CABINET VLN VLL Amps kW kVA Frequency Efficiency O2 RET Output Screen 2 CABINET VLN VLL Peak Current kVA kW Frequency O3 RET Output Screen 3 SYSTEM VLN VLL Amps...

Page 120: ...BATTERY TEST display D3 prompts you for display D5 starts the battery test from display D5 Same as pressing f2 and f4 keys X cancels the battery test Same as pressing DIAG key D4 RET Diag Screen 4 Binary Ports 2 5 H RET Help Screen Varies ST RET Reset Display CPU Same as pressing Input Status and Help keys Q RET Alarm Silence Same as Alarm Key R RET Continuously Repeat Last Command Use SPACE BAR R...

Page 121: ...M METERING OUTPUTS J5 is a System Volts output signal connector System Volts are divided down by 25 to 1 and sent to this connector This connector is a DA15S type Example 120 VAC 60 Hz at the output contactor equals 4 80 VAC 60 Hz at J5 Pin Numbers are as follows 1 Phase A System Volts Output 11 Phase B System Volts Output 8 Phase C System Volts Output 2 7 12 Gnd J7 is a System Amps output signal ...

Page 122: ...to this connector This connector is a DA15S type Example 120 VAC 60 Hz at the remote location equals 1 20 VAC 60 Hz at J8 Example 400 AAC 60 Hz at the remote location equals 1 00 VAC 60 Hz at J8 Pin Numbers are as follows 1 Phase A Remote Volts Input 2 Phase B Remote Volts Input 3 Phase C Remote Volts Input 4 Phase A Remote Amps Input 5 Phase B Remote Amps Input 6 Phase C Remote Amps Input 7 Neut ...

Page 123: ...ts tied to 12 VDC The RSP IV operates off of 12 VDC and 12 VDC This connector is a DA15S type Pin Number Description True False 1 Overload 5 0 2 Over or Under Voltage or Frequency 5 0 3 Audible Alarm at Cabinet 5 0 4 Diagnostic Battery Test 0 5 5 Input AC Normal 12 6 Output AC Normal 12 7 12 VDC 8 Gnd 9 Overtemp 5 0 10 Spare 5 0 11 Battery Operation 12 12 Battery Low Charge 12 13 No connection 14 ...

Page 124: ...SECTION 4 OPERATION 114 THIS PAGE INTENTIONALLY BLANK ...

Page 125: ...SECTION 4 OPERATION 115 THIS PAGE INTENTIONALLY BLANK ...

Page 126: ...ful when servicing the equipment particularly when attempting to solve an application type problem The following procedure is recommended to be performed at 3 month intervals MAINTENANCE PROCEDURE Refer to Table 5 1 STEP 1 Record cabinet input data by pressing the INPUT then f1 and f2 keys on the front panel display STEP 2 Record cabinet output data by pressing the OUTPUT then f1 and f2 keys on th...

Page 127: ..._______ DATE ____ ____ ____ TECHNICIAN ____________________________ INPUT DATA I1 INPUT V ____ ____ ____ ____ ____ ____ ___NORMAL A _________ _________ _________ kW _________ _________ _________ FREQ ________ kVA _________ _________ _________ I2 INPUT Bus BATT BATT LVPS _____VDC ______ADC _____VDC _____VDC ______ADC _____VDC _______kW ...

Page 128: ... ____ ____ ____ ____ ____ ____ OUTPUT I PEAK _______ _______ _______ kVA _______ _______ _______ FREQ _____ kW _______ _______ _______ O3 SYSTEM V ____ ____ ____ ____ ____ ____ SUMMARY A _________ _________ _________ OUTPUT kW _________ _________ _________ FREQ ______ kVA _________ _________ _________ O4 REMOTE V ____ ____ ____ ____ ____ ____ OUTPUT A _________ _________ _________ kW _________ ___...

Page 129: ..._________________ DIAGNOSTIC INFORMATION D2 DIAGNOSTIC TEMPERATURE DATA XFMR _____ DEG C INV _____ D4 Port 2 Port 3 Port 4 Port 5 PWR ________ ________ ________ ________ EMER ________ ________ ________ ________ NOW ________ ________ ________ ________ COMMENTS APPEARANCE ______________________________________________________ ______________________________________________________ ___________________...

Page 130: ... are fully charged before performing a test Press the INPUT then f2 keys on the front panel display Both BATT amps must be 2 ADC or less but not negative STEP 3 Record the last battery test information by pressing the DIAG then f3 keys on the front panel display STEP 4 Press f3 key again then f2 and f4 keys together within 5 seconds to perform a new battery test The battery test is now in progress...

Page 131: ...The conditions contribute to battery death STEP 8 If none of the conditions in step 6 are true check for a single bad battery While the batteries are recharging after a battery test measure the voltage across each battery of the NOT OK battery string Mark any batteries which are 1 volt or greater than the average battery voltage WARNING BATTERIES ARE AT LETHAL POTENTIALS WEAR SAFETY GLASSES WHEN T...

Page 132: ...SECTION 5 MAINTENANCE 122 THIS PAGE INTENTIONALLY BLANK ...

Page 133: ...e If additional time is needed perform another battery test STEP 10 Any battery which was greater than 1 volt of the average battery voltage during charging and less than 1 volt of the average battery voltage during discharge has high internal impedance and should replaced Any battery which was less than 2 volts of the average battery voltage during discharge may have a shorted cell and should be ...

Page 134: ...BATTERY TEST D3 DIAGNOSTIC BATT ________ _______V LAST BATTERY _____ OK ________A TEST PRESS f3 BATT ________ _______V FOR NEW TEST _____ OK ________A NEW BATTERY TEST D3 DIAGNOSTIC BATT ________ _______V LAST BATTERY _____ OK ________A TEST PRESS f3 BATT ________ _______V FOR NEW TEST _____ OK ________A COMMENTS ____________________________________________________________ ________________________...

Page 135: ...SECTION 5 MAINTENANCE 125 THIS PAGE INTENTIONALLY BLANK ...

Page 136: ...ilter capacitors etc are considered replaceable components This section is organized as follows Para 6 1 Provides a brief description of each assembly Para 6 2 Provides the theory of operation required to troubleshoot the system Para 6 3 Provides step by step troubleshooting procedures Para 6 4 Provides procedures for replacing defective assemblies Para 6 5 Provides procedures for replacing defect...

Page 137: ...0 There are 2 Regulator PCB Assemblies One for the positive power supply and one for the negative power supply This PCB drives 6 SCRs to generate regulated voltage for the inverter assemblies and charging the batteries 3 DISCHARGE PCB ASSEMBLY P N 126075 This PCB assembly contains a transistor switch which is used to switch a load into the high voltage DC supply This switch is active during shutdo...

Page 138: ...SECTION 6 SERVICE 128 THIS PAGE INTENTIONALLY BLANK ...

Page 139: ...t Breaker Optional P N 716048 CT1 2 Battery Current sensors P N 703120 CT11 13 Input CT s P N 731029 F1 3 Input Fuses 1A for 480 VAC Input P N 712043 1 A for 380 VAC Input P N 712045 2A for 240 or 208 VAC Input P N 712044 F4 6 Utility Inverter Fuses P N 712025 F10 and F11 DC fuses P N 712042 L1 6 SCR Filter Inductors P N 530025 R1 3 Slow turn on resistors P N 769990 037 R4 and R5 Discharge Resisto...

Page 140: ...SECTION 6 SERVICE 130 FIGURE 6 1 1 MAINFRAME ...

Page 141: ...ferenced oscillator The output is a digitally synthesized sinewave 2 MODULATOR PCB ASSEMBLY P N 126071 This PCB assembly receives the output of the oscillator and produces the signals required to drive the inverter assemblies 3 DISPLAY PCB ASSEMBLY P N 126572 This PCB assembly is mounted to the front panel and contains a CPU which drives an LCD for metering status diagnostics alarms and the RSP IV...

Page 142: ...SECTION 6 SERVICE 132 FIGURE 6 1 2 CONTROL MODULE ...

Page 143: ...e inverter assembly is housed in a metal case This inverter assembly has been designed to reduce RFI EMI 2 DRIVER PCB ASSEMBLY P N 126270 This PCB assembly receives control signals from the modulator provides isolation and then drives the power transistors This PCB is a subassembly of the inverter assembly 3 SNUBBER PCB ASSEMBLY P N 126272 This PCB assembly is used to snub voltage spikes on the po...

Page 144: ...SECTION 6 SERVICE 134 FIGURE 6 1 3 INVERTER ...

Page 145: ...rol Term Definitions Ref Para 6 2 1 1 Power Conversion Circuits Ref Para 6 2 2 2 System Control Circuits Ref Para 6 2 3 3 DC Power Supply Circuits Ref Para 6 2 4 4 Metering and Display Circuits Ref Para 6 2 5 5 Paralleling Circuits Ref Para 6 2 6 Each of the circuits is discussed in detail in each of the above referenced paragraphs When the DIAG then f4 keys are pressed the digital inputs to the D...

Page 146: ...on C0 Control mode 0 C2 Control mode 2 DISCHARGE True if S3 CLOSE COMM and S7 CLOSE COMM is false EMER OFF SW True when switch is pressed Momentary contact panel switch with integral lamp EMER OFF LAMP Is lit whenever Q6 is true ERROR IN Error signal to the modulator ERROR OUT Error signal from the modulator ERROR System Error signal from the master modulator EXT EMER OFF External Emergency Off in...

Page 147: ...M and MXEN is true and INV TST OK is false Possible shorted transistor INV TST OK Inverter test OK indicates that the Inverters 2 per phase are switching at approximately 30 khz and no fuses are blown Does not test the quality of the sinewave being produced and does not care if inverter is in current limit INV VOLTS Inverter output voltage Inverter side of the output contactor INV AMPS Inverter ou...

Page 148: ...it if Q6 S3 CLOSE COMM and S7 CLOSE COMM is false ON LAMP Is lit if S5 CLOSE COMM is true OSC IN Oscillator signal OVER FREQUENCY OF Condition exists if output frequency is greater than preset limit Limit is set by the ALARM KEY OVER VOLTAGE OV Condition exists if output voltage is greater than preset limit Limit is set by the ALARM KEY OVERTEMP Either INV OVERTEMP or XFMR OVERTEMP is true POLARIT...

Page 149: ... relay S4 CLOSE COMM to close S5 CLOSE COMM S7 CLOSE COMM SLAVE LAMP Is lit whenever the FREQUENCY SELECT switch is in the SLAVE position STANDBY LAMP Is lit if S3 CLOSE COMM or S7 CLOSE COMM is true and S5 CLOSE COMM is false START RESET SW True when switch is pressed Momentary contact SUSTAINED O L Inverter is in current limit for more than 50 duty cycle for longer than 20 seconds SYSTEM AMPS To...

Page 150: ...GE UV Condition exists if output voltage is less than preset limit Limit is set by the ALARM KEY VDC 160 Term goes true when both BUSES are greater than 180 VDC Term goes false when either Bus goes below 160 VDC VDC 240 True when either Bus voltage exceeds 240 VDC XFMR OVERTEMP Input Transformer has overheated XFMR TEMP Analog signal from embedded thermocouple in input transformer ...

Page 151: ...4 enables or disables and selects local or remote operation of AGC When the FREQUENCY SELECT SWITCH is in the EXT or SLAVE positions all outputs of the oscillator are disabled and will be 0 VAC The oscillator output is fed into the modulator PCB The modulator takes the signal and creates a pulse width modulated digital signal required by the inverter assemblies The modulator also receives six curr...

Page 152: ...n will allow normal operation Rotating the MODE SELECT switch to STANDBY and then pressing START RESET will turn on S7 the Slow Turn On Contactor Resistors R1 R2 and R3 limit the inrush current during transformer turn on At this point the MXEN signal is high allowing the inverter to operate 200 milliseconds later S3 closes and the Regulator PCB is enabled The Regulator turns on the SCRs and charge...

Page 153: ...r PCB SCRs capacitors and DC fuses make up the main DC Power Supply Circuits The main DC Power Supply is a bipolar supply which produces 200 VDC This supply is regulated and current limited to charge the batteries The battery contactor S4 closes as required to directly connect the batteries to the 200 VDC Power Supplies It is actually two independent 200 VDC supplies which are stacked on top of ea...

Page 154: ...SECTION 6 SERVICE 144 THIS PAGE INTENTIONALLY BLANK ...

Page 155: ... dividers to scale down system voltages to a low level These system voltages are sent to the Control PCB The Control PCB provides all input signals analog and digital except input amps to the Display PCB CT11 CT13 provides the input current terms required by the Display PCB Figure 6 2 5 is the block diagram for the meter and display portion of the 3060 UMS power source The 2 serial ports and the R...

Page 156: ...SECTION 6 SERVICE 146 FIGURE 6 2 5 BLOCK DIAGRAM DISPLAY CIRCUITS ...

Page 157: ...ing connectors Tying pin 18 and pin 19 together with isolated external contacts shall cause an external emergency off of the system If a cabinet is a master and in an EMER OFF state it will cause all cabinets to be in an EMER OFF state The master EMER OFF must be cleared first then all slave s EMER OFF may be cleared When all slave cabinets have no EMER OFF and the mode select switch is in the ON ...

Page 158: ...wer Do not use any of these procedures unless instructed to do so by the performance check flow chart The procedures make use of flow charts along with explanatory text This will lead the technician to the defective component or assembly PCB assemblies and power assemblies are assumed to be replacement items No attempt is made to troubleshoot these assemblies to the component level WARNING ALWAYS ...

Page 159: ...ould be displayed If ABNORMAL is displayed this indicates input power is not acceptable and the machine will not start Check the nameplate at the rear of the machine for proper input voltages and that all three phases are present 4 The EMER OFF lamp should be off If you suspect the lamp it s self is bad press the EMER OFF button This will cause the EMER OFF lamp to light Pressing START RESET shoul...

Page 160: ...SECTION 6 SERVICE 150 FIGURE 6 3 1 PERFORMANCE CHECK FLOW CHART ...

Page 161: ...nced step 1 If the machine is dead check F1 F2 and F3 If the fuses are not good check for shorts then replace the fuses At least 2 fuses must be ok for the LVPS to operate 2 Check for 16 VAC from P60 8 to P60 1 P60 8 to P60 5 and P60 8 to P60 13 of the LVPS PCB If input voltage is present on the primary of T2 but not on the secondary replace T2 3 If 16 VAC voltage is present check for 18 VDC from ...

Page 162: ...SECTION 6 SERVICE 152 FIGURE 6 3 2 LVPS FLOW CHART ...

Page 163: ...se LVPS voltages are required for the Display PCB to operate C1 and C54 are near the two heatsinks Reset the Display PCB by simultaneously pressing INPUT OUTPUT and HELP keys If this does not cause a reset remove input power from the machine and reapply input power If this does not reset the Display PCB replace the Display PCB 2 Pressing the INPUT then f2 keys causes the LCD to display LVPS voltag...

Page 164: ...SECTION 6 SERVICE 154 FIGURE 6 3 3 DISPLAY FLOW CHART ...

Page 165: ...ayed press the f4 KEY to determine which bit s would cause an EMER OFF If a bit is true 1 for an Emergency OFF condition on the NOW line this could be the cause Reference section 4 4 1 4 MASTER EMERGENCY OFF indicates that the master of the system was is in an EMER OFF state Reset the Master s EMER OFF SUSTAINED OVERLOAD indicates the machine was in an overload condition for an extended period of ...

Page 166: ...SECTION 6 SERVICE 156 THIS PAGE INTENTIONALLY BLANK ...

Page 167: ...EMP indicates one of the inverters has overheated A fan may have failed LVPS FAULT indicates the regulated 12 VDC on a control modulator or driver PCB s has failed Bus VOLTAGE 240 VDC indicates one of the Regulator PCBs has failed Replace the Regulator PCB EXTERNAL EMERGENCY OFF pin 19 of the paralleling connector has positive voltage applied NO MASTER ON LINE one and only one cabinet must be a ma...

Page 168: ...SECTION 6 SERVICE 158 FIGURE 6 3 4 EMER OFF FLOW CHART ...

Page 169: ...Regulator PCB that is not producing voltage 3 If the Input Contactor S3 is open try to close it by rotating the MODE SELECT to STANDBY and press START RESET This should cause the Slow Turn on Contactor S7 then the main Input Contactor S3 and last the Battery Contactor S4 to close Check for 115 VAC on the coils of these contactors during the turn on sequence If 115 VAC is present on the coil and th...

Page 170: ...SECTION 6 SERVICE 160 FIGURE 6 3 5 NO INVERTER VOLTS FLOW CHART ...

Page 171: ... Contactor S5 is not closed check for 115 VAC on the coil If 115 VAC is present on the coil and the contactor does not close replace the contactor If no voltage is present on the coil and the ON lamp is on replace the control PCB 3 Pressing the OUTPUT then f2 KEYS displays the system load in percentages I PEAK kVA and kW Verify that the machine is not overloaded all six fields are less than 100 If...

Page 172: ...SECTION 6 SERVICE 162 FIGURE 6 3 6 ABNORMAL VOLTS FLOW CHART ...

Page 173: ...R TO ATTEMPTING ANY SERVICE TO THE EQUIPMENT LETHAL VOLTAGES ARE PRESENT WITHIN THE MAINFRAME WHEN INPUT OR BATTERY VOLTAGE IS APPLIED TO THE INPUT TERMINALS LETHAL VOLTAGES ARE PRESENT WITHIN THE MAINFRAME WHEN RED LEDS ARE LIT ON THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS THE SERVICE PROCEDURES OUTLINED IN THIS MANUAL ARE INTENDED FOR USE ONLY BY...

Page 174: ...Y VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS WARNING Verify the red LEDs on the discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 Remove five screws from the top of the keyboard subpanel Fold down the keyboard subpanel Disconnect ribbon cables from Modulator PCB STEP 5 Remove Bus bars from the front of the inverters Be careful not to spin the s...

Page 175: ...erter assembly STEP 7 Replace Bus bars on the front of the inverters Be careful not to spin the studs Reconnect P33 the fan wires STEP 8 Reconnect ribbon cables from Modulator PCB Fold up the keyboard subpanel Replace five screws from the top of the keyboard subpanel STEP 9 Replace fuses F10 and F11 if needed STEP 10 Replace subpanels Replace front covers ...

Page 176: ...Remove five screws from the top of the keyboard subpanel Fold down the keyboard subpanel STEP 5 Disconnect all cables from Control PCB Remove nine nuts holding the Control PCB Remove Control PCB assembly STEP 6 Install Control PCB assembly Install nine nuts holding the Control PCB Install all cables to the Control PCB STEP 7 Fold up the keyboard subpanel Replace five screws from the top of the key...

Page 177: ...covers STEP 3 Remove five screws from the top of the keyboard subpanel Fold down the keyboard subpanel STEP 4 Disconnect all cables from the Modulator PCB Remove ten nuts holding the Modulator PCB Remove the Modulator PCB assembly STEP 5 Install Modulator PCB assembly Install the nuts holding the Modulator PCB Install all cables to the Modulator PCB STEP 6 Fold up the keyboard subpanel Replace fiv...

Page 178: ...om the top of the keyboard subpanel Fold down the keyboard subpanel STEP 4 Disconnect all cables from Display PCB Remove nine nuts holding the Display PCB STEP 5 Lift up Display PCB and remove keyboard connector Remove Display PCB assembly STEP 6 Install keyboard connector Install Display PCB assembly Install nine nuts holding the Display PCB Install all cables to the Display PCB STEP 7 Fold up th...

Page 179: ...ve front covers STEP 3 Remove five screws from the top of the keyboard subpanel Fold down the keyboard subpanel STEP 4 Disconnect all cables from the LVPS PCB Remove four nuts holding the LVPS PCB Remove the LVPS PCB assembly STEP 5 Install LVPS PCB assembly Install four nuts holding the LVPS PCB Install all cables to the LVPS PCB STEP 6 Fold up the keyboard subpanel Replace five screws from the t...

Page 180: ...ON THE DISCHARGE PCB WHEN RED LEDS ARE LIT ON THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS WARNING Verify the red LEDs on the discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 Disconnect all cables Remove four nuts holding the Discharge PCB Remove the Discharge PCB assembly STEP 5 Install Discharge P...

Page 181: ... STEP 2 Remove all screws holding the top screen and side covers Remove top screen and side covers STEP 3 Disconnect all cables Remove six nuts holding the Driver PCB Remove the Driver PCB assembly STEP 4 Install Driver PCB assembly Install six nuts holding the Driver PCB Install all cables to the Driver PCB STEP 5 Install top screen and side covers Install all screws holding the top screen and si...

Page 182: ...ve all screws holding the top screen and side covers Remove top screen and side covers STEP 3 Un solder and mark all resistor wires Remove four nuts holding the Snubber PCB Remove the Snubber PCB assembly STEP 4 Install Snubber PCB assembly Install four nuts holding the Snubber PCB Solder resistor wires to the Snubber PCB STEP 5 Install top screen and side covers Install all screws holding the top...

Page 183: ... discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 Disconnect ribbon cables P1 and P2 Disconnect G1 G2 wires Disconnect transformer sense wires AC1 AC2 AC3 Disconnect current transducer plug P3 Remove nine nuts holding the Regulator PCB Remove the Regulator PCB 126670 or 126671 assembly STEP 5 Install new Regulator PCB 126671 assembly Install nine...

Page 184: ...rotect YOU from being injured or KILLED Warnings are conditions that are hazardous to user personnel All warnings throughout this procedure will be formatted as shown below A condition that is hazardous to both personnel and equipment will be issued as a WARNING WARNING THIS EQUIPMENT CONTAINS HIGH ENERGY LOW IMPEDANCE CIRCUITS LETHAL POTENTIALS ARE CONTAINED WITHIN THE SYSTEM WARNING WARNING THE ...

Page 185: ...F SHORTING THROUGH THE JEWELRY AND CAUSING BURNS TO THE OPERATOR 2 WEAR SAFETY GLASSES WHEN SERVICING THIS EQUIPMENT TO PREVENT EYE INJURY DUE TO FLYING PARTICLES CAUSED BY ACCIDENTAL SHORT CIRCUIT CONDITIONS WARNING Caution statements indicate a dangerous situation that may damage the equipment but is not a threat to life or limb Cautions will assume the format shown All cautions must be rigorous...

Page 186: ...s open 3 The positive and the negative Regulator PCBs are installed into the 3060UMS Set the BATTERY AMPS jumper as shown middle set of pins not used Note If the battery jumpers are incorrectly positioned the 3060 UMS will operate correctly However the battery test will fail and the battery current indication on the display panel will indicate incorrectly on the incorrectly positioned jumper Conne...

Page 187: ...50Hz Check the REF VOLTAGE U22 7 it should be 0V Check the CURRENT LIMIT VOLTAGE U23 7 it should be about 2 8VDC Check the ERROR VOLTAGE U22 1 it should be about 12VDC 5 2 FULL LOAD TESTS DC BUS VOLTAGE ADJUSTMENTS Switch the MODE SELECT SWITCH to STANDBY then press START RESET The DC BUS should charge up in about second The following adjustments use the Neutral Buss as the ground reference The DM...

Page 188: ... set the MODE SELECT SWITCH to STANDBY and observe the battery charging current does not exceed 10A As the batteries charge observe the DC voltage rising and peaks at 212 1 0VDC until battery charging current drops to under 5A then the DC voltage drops back to 204VDC Adjust the DC BUS voltage to 212VDC peak using R280 may need to run the battery test a few times to make this adjustment Set the loa...

Page 189: ...SECTION 6 SERVICE 173G Rev B THIS PAGE INTENTIONALLY BLANK ...

Page 190: ...LTAGES ARE PRESENT ON THE DC Bus WHEN RED LEDS ARE LIT ON THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS WARNING Verify the red LEDs on the Discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 If possible remove the rear cover and go to step 8 This is easier than removing the Output Inverters STEP 5 Remov...

Page 191: ... lbs CAUTION STEP 7 With the Output Inverters removed you can access the Utility Inverter down through the holes left by the Output Inverters The Utility Inverter is behind the Power Supply Panel STEP 8 Disconnect J1 and J2 from the Utility Inverter Assembly STEP 9 Remove the six screws holding the Utility Inverter Assembly to the Power Supply Panel and remove the assembly STEP 10 Using six screws...

Page 192: ...into the mainframe Reinstall three screws at the bottom of each Output Inverter assembly STEP 15 Replace the Bus bars on the front of the Output Inverters Be careful not to spin the studs Reconnect P33 the fan wires STEP 16 Reconnect ribbon cables from Modulator PCB Fold up the keyboard subpanel Replace five screws from the top of the keyboard subpanel STEP 17 Replace Subpanels Replace Front Cover...

Page 193: ...BATTERY POWER FROM THE MAINFRAME PRIOR TO ATTEMPTING ANY SERVICE TO THE EQUIPMENT LETHAL VOLTAGES ARE PRESENT WITHIN THE MAINFRAME WHEN INPUT OR BATTERY VOLTAGE IS APPLIED TO THE INPUT TERMINALS LETHAL VOLTAGES ARE PRESENT WITHIN THE MAINFRAME WHEN RED LEDS ARE LIT ON THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS THE SERVICE PROCEDURES OUTLINED IN THI...

Page 194: ...N THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS WARNING Verify the red LEDs on the discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 Remove the panel holding CB1 if needed and support it in front of the machine STEP 5 Disconnect the AC wires as needed Remove screws as needed Remove defective component...

Page 195: ... WHEN RED LEDS ARE LIT ON THE DISCHARGE PCB EVEN IF THE INPUT OR BATTERY VOLTAGE IS NOT APPLIED TO THE INPUT TERMINALS WARNING Verify the red LEDs on the discharge PCB are off With a DC voltmeter verify less than 5 VDC from each Bus bar to chassis STEP 4 Disconnect cables to the discharge PCB Disconnect output cables to the Inverters Disconnect battery cables Remove the panel holding the discharge...

Page 196: ...component Replace screws as needed Reconnect the AC wires as needed Replace Bus bars as needed STEP 7 Reinstall the panel holding the discharge PCB Reconnect output cables to the Inverters Reconnect cables to the discharge PCB Reconnect battery cables STEP 8 Replace subpanels Replace front covers ...

Page 197: ...move top screen and side covers STEP 3 Remove the Snubber PCB assembly if needed as described in section 6 4 8 STEP 4 Disconnect wires as needed Remove screws as needed Remove defective component STEP 5 Replace defective component Replace screws as needed Reconnect wires as needed STEP 6 Install the Snubber PCB assembly if needed as described in section 6 4 8 STEP 7 Install top screen and side cov...

Page 198: ... assembly came from and a description of the service required 3 Pack the equipment in the original carton or crate if available PACK CAREFULLY TO AVOID EQUIPMENT DAMAGE IN TRANSIT PACIFIC POWER SOURCE CORPORATION SHALL NOT BE RESPONSIBLE FOR REPAIR OF DAMAGE DUE TO IMPROPER PACKAGING AND HANDLING If the equipment to be serviced is under warranty Pacific Power Source Corporation will repair and ret...

Page 199: ... batteries which carry the warranty of their original manufacturer if applicable Within this warranty period Pacific Power Source Corporation will service repair or replace any defective part when examination shows that fault has not occurred because of misuse abnormal operation or user modification The unit must be returned by the original purchaser to the Huntington Beach California factory or t...

Page 200: ...VICE 184 6 7 BLOCK AND SCHEMATIC DIAGRAMS This section contains D Size drawings of an overall system block diagram figure 6 7 1 schematic diagrams for the Mainframe figure 6 7 2 and Inverter assemblies figure 6 7 3 ...

Page 201: ...SECTION 6 SERVICE 185 THIS PAGE INTENTIONALLY BLANK ...

Page 202: ......

Page 203: ...SECTION 6 SERVICE 187 INSERT D SIZE FIGURE 6 7 1 HERE FIGURE 6 7 1 SYSTEM BLOCK DIAGRAM ...

Page 204: ...SECTION 6 SERVICE 188 THIS PAGE INTENTIONALLY BLANK ...

Page 205: ...SECTION 6 SERVICE 189 INSERT D SIZE FIGURE 6 7 2 HERE FIGURE 6 7 2 MAINFRAME SCHEMATIC ...

Page 206: ...SECTION 6 SERVICE 190 THIS PAGE INTENTIONALLY BLANK ...

Page 207: ...SECTION 6 SERVICE 191 INSERT D SIZE FIGURE 6 7 3 HERE FIGURE 6 7 3 INVERTER SCHEMATIC ...

Page 208: ...SECTION 6 SERVICE 192 THIS PAGE INTENTIONALLY BLANK ...

Page 209: ...193 SECTION 7 MODIFICATIONS 7 MODIFICATIONS Any modifications or changes to the UPS will be included in this section ...

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