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Title

Callisto 5PX G2 Service Manual

Checked

Rev:

Approved

Confidential

Page 12 of 60

This specification is the property of Eaton Corp. and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission

3 Interconnection diagram of products by
power rating.

Goal: To know the interconnections and connectors between the boards for

different power ratings

of products.

3.1 UPS interconnection diagram

EPO

BOARD

COMM

BOARD

PSDR BOARD

Internal Battery

LCD

CNTL BOARD

IP-L

IP-N

FAN

USB

RS232

Segment

Input

Socket

EBM

Output

Socket

CARD

Box

RJ45

OP-L

OP-N

Segment

EPO & Dry in

Dry out

For Internal Lithium battery
communication

NTC BAT

NTC HS

Main

Fig3.1: 1000~1500VA (230V) interconnection Block

Содержание Callisto 5PX RT G2

Страница 1: ...Rev Approved Confidential Page 1 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permiss...

Страница 2: ...3 14 5PX2000IRT2UAUG2 APAC 2000VA 2000W RT 240V 9210 73040 15 5PX2200IRT2UAUG2 APAC 2200VA 2200W RT 240V 9210 73042 16 5PX2200IRT3UAUG2 APAC 2200VA 2200W RT 240V 9210 73041 17 5PX3000IRT2UAUG2 APAC 30...

Страница 3: ...Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission Rev Date Notes Updater name Approved 00 2021 7 5 Original Chase Fang 00 2...

Страница 4: ...rconnection diagram of products by power rating 12 3 1 UPS interconnection diagram 12 3 2 UPS interconnection Actual 15 3 3 EBM interconnection diagram 21 4 Diagrams showing the location of each princ...

Страница 5: ...ment This service manual will guide technicians to diagnose troubleshoot and repair UPS products Depending on the countries the extent of the repair of the product can be to find the failed item or th...

Страница 6: ...specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 1 2 Analysis process Global process showi...

Страница 7: ...he property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 1 3 Schematic of the UPS Goal Identify the Board references...

Страница 8: ...Checked Rev Approved Confidential Page 8 of 60 s specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Страница 9: ...Checked Rev Approved Confidential Page 9 of 60 s specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Страница 10: ...product unless an authorized person is present There is a risk of presence of AC voltage even if the mains power is no longer connected Switch off and disconnect the UPS from the mains power before re...

Страница 11: ...d or used as the basis for manufacture or sale of apparatus without permission Please check the insulation of all wires connectors and screws after opening the UPS Before restarting the UPS o Check th...

Страница 12: ...ing Goal To know the interconnections and connectors between the boards for different power ratings of products 3 1 UPS interconnection diagram EPO BOARD COMM BOARD PSDR BOARD Internal Battery LCD CNT...

Страница 13: ...EPO Dry in Dry out For Internal Lithium battery communication 1 2 3 4 5 6 8 9 7 10 11 12 13 14 15 17 18 19 20 21 NTC BAT NTC HS 22 23 Main 5A 6A 6B 6C 7A 8A Fig3 2 1000 1500VA 120V interconnection Bl...

Страница 14: ...ut permission I O BOARD EPO BOARD COMM BOARD PSDR BOARD Internal Battery LCD CNTL BOARD IP L IP N FAN1 USB RS232 Segment 1 Segment 2 Input Socket EBM Output Socket CARD Box RJ45 OP L OP N EPO Dry in D...

Страница 15: ...proved Confidential Page 15 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 3...

Страница 16: ...nual Checked Rev Approved Confidential Page 16 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Страница 17: ...nual Checked Rev Approved Confidential Page 17 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Страница 18: ...l Checked Rev Approved Confidential Page 18 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus witho...

Страница 19: ...nual Checked Rev Approved Confidential Page 19 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Страница 20: ...nual Checked Rev Approved Confidential Page 20 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Страница 21: ...p and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 3 3 EBM interconnection diagram BAT1 BAT2 BAT3 BAT4 BATTERY PACK1 BAT1 BAT2 BAT3 BA...

Страница 22: ...98 20149 XX 744 20146 3K 710 20149 XX 098 20149 XX 744 20149 PSDR LV 1K 710 20141 XX 098 20140 XX NA 1 5K 710 20143 XX 098 20140 XX NA 2K 710 20145 XX 098 20149 XX NA 3K 710 20150 XX 098 20149 XX NA I...

Страница 23: ...e of apparatus without permission 4 2 PSDR and IO schematic Functions designed on this board are the following Push Pull DC DC converter and the PWM driver LF DC AC inverter with the PWM driver Bat mo...

Страница 24: ...ed Rev Approved Confidential Page 24 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without perm...

Страница 25: ...ked Rev Approved Confidential Page 25 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Страница 26: ...cked Rev Approved Confidential Page 26 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Страница 27: ...hecked Rev Approved Confidential Page 27 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without...

Страница 28: ...Rev Approved Confidential Page 28 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permiss...

Страница 29: ...ked Rev Approved Confidential Page 29 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Страница 30: ...ked Rev Approved Confidential Page 30 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Страница 31: ...ecked Rev Approved Confidential Page 31 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without p...

Страница 32: ...Checked Rev Approved Confidential Page 32 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without...

Страница 33: ...ed Rev Approved Confidential Page 33 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without perm...

Страница 34: ...Confidential Page 34 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 4 2 1 PS...

Страница 35: ...d as the basis for manufacture or sale of apparatus without permission 4 3 CNTL Functions designed on this board are the following DSP digital control for DC DC converter DC AC inverter AVR control DC...

Страница 36: ...y of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 4 4 COMM EPO Functions designed on this board are the following HMI R...

Страница 37: ...e Manual Checked Rev Approved Confidential Page 37 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatu...

Страница 38: ...rmal or Safety relay is failure Please refer below flow chart Fault 002 0x004 UPS Temp High UPS internal temperature is high over fault point Please refer below flow chart Fault 004 0x007 Fan Lock Ven...

Страница 39: ...transfer to Fault mode Please refer below flow chart Fault 809 0x80A Capacitive overload Capacitive overload occurred transfer to Fault mode Please refer below flow chart Fault 80A 5 3 Location of the...

Страница 40: ...ernal fault Start Line mode Bat mode Whether the Output voltage is exceeds the output voltage range spec Y N Whether the safety relay is stuck END Y Whether the Driver circuit of safety relay is Damag...

Страница 41: ...e room temperature Y UPS temperature fault End N UPS surrounding temperature is high N Y Remove heat source Y UPS temperature fault N End Confirm outtake airflow on rear panel is block N Clear dust or...

Страница 42: ...ermission Fault 007 Fan Lock Start Fans is connected rightly Connect them 1 1 5 front panel FAN 2 3K front and rear panel FAN N Restart UPS and no alarm End N Fans on rear and front panel are rotating...

Страница 43: ...nel is block N Clear dust or object Y Y UPS AVR too hot fault End N Check Fan is rolling normally Clear dust or object UPS AVR too hot fault End N Y End Client Environment UPS Check CNTL CNTL Replace...

Страница 44: ...ire and live wire are reversely connected Y Y Connect L N wire rightly Y Restart UPS and no alarm N End Replace PSDR Y Restart UPS and no alarm N Replace UPS End UPS PSDR End Repair detection circuit...

Страница 45: ...without permission Fault 500 Fault 502 Fault 503 Charger Fault Charger Too High Charger Too Low Start PSDR End Over Replace UPS Check whether charger output voltage is right Charger Fault N Check CNTL...

Страница 46: ...No Battery Start End Check battery Volt UPS EBM Y End End Replace UPS Check battery wires and cables N No battery End N Y Replace Battery N Battery Fault N Y Battery Fault N Connect them Check CNTL Re...

Страница 47: ...or sale of apparatus without permission Fault 804 Imbalance Load Start Imbalance load alarm Remove Imbalance load End N Switch off UPS and disconnect loads UPS Y Check PSDR Battery detection Repair d...

Страница 48: ...ion Fault 805 Short Circuit Start loads are short circuit Remove damaged load Short circuit fault End Y N Y UPS Switch off UPS and disconnect loads Client load Output cables are short circuit Replace...

Страница 49: ...ale of apparatus without permission Fault 808 Overload fault Start End Check grid voltage Customer load Y End End Check load value N overload End N Y Check electrical grid N overload N Y overload N Re...

Страница 50: ...Fault 809 80A Inductive overload Capacitive overload Start Inductive Capacitive overload Decrease Load Replace load End N Switch off UPS and disconnect loads UPS Y Check PSDR UPS output waveform is r...

Страница 51: ...should not make the user call the Eaton service no red led no continuous buzzer sound The alarm message is displayed on status screen top row If the defect or incident cause disappears then the alarm...

Страница 52: ...connectors identify their connections on the boards Board references and names This permits the reassembly of the UPS and at the same time prevents any errors of inverted wiring which could cause the...

Страница 53: ...ev Approved Confidential Page 53 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permissi...

Страница 54: ...60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission Step 3 Remove the battery pack f...

Страница 55: ...v Approved Confidential Page 55 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permissio...

Страница 56: ...rvice Manual Checked Rev Approved Confidential Page 56 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of appa...

Страница 57: ...12 ZT 136 12V16A 240V 1C 092 00153 Main Relay RY4 RLY HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 RY4 RLY HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 30A 250...

Страница 58: ...40A 277 V 1C 092 01095 RY6 RY7 RLY SON 832HA 1C F V 12Vdc 40A 277 V 1C 092 01095 PSDR 2000HV 3000HV DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 F3 30A 250Vac 102 01708 DCDC MOS Q1 Q2 Q3 Q4 Q5 Q6 Trans...

Страница 59: ...HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 RY4A RY4B RLY 12Vdc 16A 250VACSON 79 3 P 1C 092 00991 DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 30A 250Vac 102 01708 DCDC MOS Q13 Q14 Q15 Q1 6 Q17 Q18 MOSF...

Страница 60: ...ON 832HA 1C F V 12Vdc 40A 277 V 1C 092 01095 PSDR 2000LV 3000LV DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 F3 30A 250Vac 102 01708 DCDC MOS Q1 Q2 Q3 Q4 Q5 Q6 Trans MOSFET N CH 250V 59A TO 3PN 088 2007...

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