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Service Manual
English
APC Smart-UPS® RT
3,000VA 10,000VA 200-240 Vac Tower/Rack Mount Uninterruptible Power Supply
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
1
Table of Contents
1 2 Safety Precautions........................................................................................................................................... 3 Introduction to SURT...................................................................................................................................... 4 2.1 Key Points ........................................................................................................................................... 4 2.2 One-Line Diagram .............................................................................................................................. 4 2.3 Main Circuit Components ................................................................................................................... 4 2.4 Functional Description ........................................................................................................................ 5 2.5 Power Train Operation........................................................................................................................ 5 2.6 Transistor-Level Diagrams ................................................................................................................. 6 User Interface ................................................................................................................................................ 11 3.1 Front Panel Display and Control Buttons ......................................................................................... 11 3.2 Terminal Mode.................................................................................................................................. 13 3.3 SmartSlot Accessories (Webcard)..................................................................................................... 15 Installation..................................................................................................................................................... 16 Component Replacements............................................................................................................................. 16 Troubleshooting ............................................................................................................................................ 17 6.1 Unit Setup ......................................................................................................................................... 17 6.2 Required Tools .................................................................................................................................. 17 6.3 Visual Inspections ............................................................................................................................. 17 6.4 Troubleshooting Flowchart ............................................................................................................... 18 6.5 Diode Checks .................................................................................................................................... 20 6.6 Documenting Failures ....................................................................................................................... 25 ECO's ............................................................................................................................................................ 25 Test After ECO's ........................................................................................................................................... 26 Appendix A. Fault codes on LED display & stored in EEPROM .................................................................... 28 Appendix B. ECO list as of October, 2005....................................................................................................... 33
3
4 5 6
7 8
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
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1
Safety Precautions
Read and adhere to the following warnings when installing or servicing a UPS and/or battery packs. Failure to observe these warnings may result in serious injury, death or damage to the equipment.
WARNINGS
·
Do not attempt to install or service external batteries alone. A qualified electrician should perform the installation and servicing of external batteries. Disconnect charging source(s) BEFORE connecting or disconnecting battery terminals. External batteries may retain lethal voltages after power has been disconnected and all switches are off. Use extreme caution when making terminal connections. Do not allow cables to touch anything except the intended terminal. · · · Goggles or face shields Acid-resistant, insulated gloves Protective aprons
· · ·
PRACTICES
Always wear:
· Protective overshoes or rubber boots Always use: · · · Insulated tools Rubber mats to cover batteries during servicing Rubber mats or rubber stands on the floor
· Adequate lifting devices Remove: · Watches, rings, and other metal objects from your body
PRECAUTIONS ·
· ·
To avoid static build-up, service personnel should establish a grounding contact prior working on batteries. Do not lay tools or metal parts on top of batteries. Lead-acid batteries contain hazardous, toxic materials. § Do not open, alter or mutilate batteries. Internal materials may be harmful to the skin and eyes. § Do not dispose of batteries in a fire. There is danger of explosion. Handle, transport and recycle batteries in accordance with local codes and regulations.
·
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
3
2
2.1
· · · · · · ·
Introduction to SURT
Key Points
Double-conversion online topology Inverter voltage is selectable through communication only: 200V, 208V, 220V, 230V, 240V. Bypass "acceptable voltage" window changes with Inverter voltage setting. Batteries must be connected to start UPS. After startup, batteries can be safely removed and replaced without interruption to the output. Lynx2 (3kVA 6kVA) has single battery (192V nominal) referenced to output Neutral. Lynx3 (7.5kVA 10kVA) has two battery strings (+192V and -192V nominal) managed independently and charged with separate chargers. Lynx3 (7.5kVA 10kVA) can accept single-phase or three-phase input voltage. In both cases, Bypass is only single-phase ("L1" and "N" inputs) so the input wiring must be sized to handle full-load current as singlephase.
2.2
One-Line Diagram
160 -284 VAC Input
Input Filter Section
Rectifier & PFC
+/- DC Bus
Inverter Output Section
Bypass Switch
240 VAC Output
Battery Charger
192 VDC Battery
2.3
Main Circuit Components
The primary sections of the UPS are: · Input disconnect and filter stage · Input Power Factor Correction (PFC) power stage · Energy storage stage (dc bus capacitor bank) · Output power stage (inverter) · Bypass · Battery charger · Battery: 1 or 2 strings each connected to output Neutral
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
4
2.4
Functional Description
The control of power module and fault detection logic is uP based. The input filter stage contains input backfeed relays, input EMI filter, transient suppression, and battery select transfer relays. Input PFC power stage contains non-isolated power factor correcting AC/DC converters. PFC converter is split in two power sections positive and negative boost stage while operating on-line and in positive boost and buck boost power stage while operating on battery. This converter is capable of full power operation from 160 to 280 VAC line to neutral or from a nominal DC battery voltage of 192VDC. The output from this stage is a +/-395V center tapped dc bus. The energy storage stage is split DC bus capacitor handling seamless transitions from battery to line and vice versa as well as the low and high frequency power stages ripple. The inverter stage operates directly from +/- 395VDC bus and produces an AC output voltage of 200/208/220/230/240Vac (for NAM and EMEA) or 200Vac (for Japan). The output of the UPS is either connected through a pair of relays either to the inverter or to the input filtered line. The UPS contains 1 or 2 battery chargers, each rated 400W.
2.5
Power Train Operation
When operating on line, the input voltage is first rectified so two half wave rectified voltage waveforms are produced in reference to the Neutral. Positive line rectified signal is fed to positive boost PFC stage. This stage is a boost type converter which converts positive half rectified input signal into DC positive bus voltage of +395V, drawing the input current in phase with positive half cycle of the line current. The boost stage consists of an input choke, high frequency IGBT switch, high frequency soft recovery diode and the output electrolytic capacitor. The positive boost stage is bypassed by a low power diode which serves as the boost converter protection in the case of sudden line overshoots and overvoltages or any other condition which causes input line peak voltage to be higher than DC bus capacitor voltage. The negative line rectified signal is fed to negative PFC stage. This stage is also boost type converter and operates in the same manner as the positive PFC boost stage. This stage converts negative line half rectified voltage to negative DC bus voltage of -395V. The bottom line is that when operating on line both PFC stages are operating as boost converters each processing half of the total output power per phase. When operating on battery, the transfer relays connect the PFC to a DC voltage from the battery. The battery voltage is fed through a filter and inrush stage to both positive and negative PFC stages. The battery filter consists of chokes and two electrolytic capacitors. The function of the filter is to prevent high frequency ripple from PFC stage going back to battery and to provide differential mode filter for high frequency noise emanating from battery buses or cables (in case of external battery packs). The inrush stage as its name says during startup limits the battery inrush current. When the battery is connected to the input of the PFC stage, the battery filter capacitor and positive DC bus capacitor charging current is limited through two 50 ohm PTC resistors. When capacitors are charged to battery voltage inrush relays are switched into closed position bypassing the PTC resistors. The positive PFC stage operates as a DC/DC boost converter and converts battery voltage to DC bus voltage. The operation in this mode is the same as operation on line as described above, except that current drawn from battery is now DC current. The negative PFC stage operates as buck boost stage and converts battery voltage to negative DC bus voltage. The output stage of the UPS consists of inverter with output filter and bypass relays. This stage is a DC/AC converter which function is to convert DC bus voltages into regulated output sine wave voltage. The inverter uses a neutral point clamp topology and consists of the top and bottom section. The top section converts positive DC bus voltage of 395V into positive half wave sine voltage and bottom portion converts negative DC bus voltage into negative half sinewave voltage. The PWM control of inverter regulates the frequency and amplitude of the output AC voltage. The output filter consists of a smoothing choke and a filter capacitor. The filtered voltage is fed through a NO relay contact to the UPS output.
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
5
2.6
Transistor-Level Diagrams Lynx2: 3kVA 6kVA
D22
Input 160-280Vac
LINE
BATTERY L101
K3
L8 D14 Q11
BATTERY 192V
50 OHM
50 OHM Q2//Q3
Q12//Q13 C12//C13
D23 K1
L4+L5+L6
C27//C28 C6//C8
Q14//Q15 D24
Q6//Q7
Q4//Q5
Q16 L7 D15
BATTERY
LINE
K4
D19
Lynx II POWER TRAIN
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
6
SURT 3kVA-10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
7
Lynx3: 7.5kVA 10kVA (interleaved PFC)
Bypass
Input 160-280Vac 50/60Hz
LINE
BATTERY BATTERY +192V 50 OHM
50 OHM
Inverter output 200-240Vac 50/60Hz
NEUTRAL
BATTERY -192V
BATTERY
LINE
Lynx3 POWER TRAIN
SURT 3kVA-10kVA Service Manual
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Lynx3 PFC power board, 640-0761 Circuit locations
SURT 3kVA-10kVA Service Manual
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9
Lynx3 INVERTER power board, 640-0762
SURT 3kVA-10kVA Service Manual
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3
3.1
User Interface
Front Panel Display and Control Buttons
The front panel contains status and diagnostic LEDs and two control buttons. Several of the LEDs comprise bar graphs that display status and diagnostic information according to the table below. Load Smart-UPS RT Front Display Battery Charge
Indicator
Online On Battery Bypass
Description
The Online LED illuminates when the UPS is drawing utility power and performing double conversion to supply power to connected equipment. The UPS is supplying battery power to the connected equipment. The Bypass LED illuminates indicating that the UPS is in bypass mode. Utility power is sent directly to connected equipment during bypass mode operation. Bypass mode operation is the result of an internal UPS fault, an overload condition or a user initiated command either through an accessory or the manual bypass switch. Battery operation is not available while the UPS is in bypass mode. Refer to Troubleshooting in this manual. The UPS detects an internal fault. Refer to Troubleshooting in this manual. An overload condition exists. See Troubleshooting. The battery is disconnected or must be replaced. See Troubleshooting.
Fault Overload Replace Battery
Table 1. Front Panel LEDs.
SURT 3kVA 10kVA Service Manual
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Feature
Power On Power Off Cold Start
Function
Press this button to turn on the UPS. (See below for additional capabilities.) Press this button to turn off the UPS.
Self-Test
When there is no utility power and the UPS is off, press and hold the button to power up the UPS and connected equipment. The UPS will emit two beeps. During the second beep, release the button. Automatic: The UPS performs a self-test automatically when turned on, and every two weeks thereafter (by default). During the self-test, the UPS briefly operates the connected equipment on battery. Manual: Press and hold the test. button for a few seconds to initiate the self-
Table 2. Front Panel Control Pushbuttons.
Diagnostic Utility Voltage
The UPS has a diagnostic feature that displays the utility voltage applied to the UPS. The UPS starts a self-test as part of this procedure. The selftest does not affect the voltage display. Press and hold the button to view the utility voltage bar graph display. After a few seconds the five-LED, Battery Charge display on the right of the front panel shows the utility input voltage. Refer to the figure at left for the voltage reading (values are not listed on the UPS). The display indicates the voltage is between the displayed value on the list and the next higher value.
Table 3. Front Panel Bar Graphs.
SURT 3kVA 10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
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3.2
Terminal Mode
SURT can be configured in a number of ways: Network Management Card web interface, PowerChute ® Software, Terminal Mode, or UPS-Link commands. To access Terminal Mode, you will need: - A computer with an RS-232 serial port - A terminal application such as Hyperterminal - An APC black cable 940-0024C (included with the UPS)
Make sure that no SmartSlot accessory is installed in the SmartSlot bay of the UPS. The SmartSlot prevents access to certain UPS communication features such as the Terminal Mode.
Using a standard APC serial cable (APC part number 940-0024C), connect the computer serial port to the back of the UPS. Open a terminal program. Hyperterminal example: From the Desktop, go to Start => Programs => Accessories => Communication =>HyperTerminal.
The "Connection Description" dialog box appears. Enter a name for this connection and select any icon for it. Click [OK]
The "Connect To" dialog box appears. In the "Connect using" drop-down list select the COM port you're going to use to communicate with the UPS. If you get a message that this port is used by another application then either use a different COM port or close the application using the intended port. Click [OK]
SURT 3kVA 10kVA Service Manual
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In the communication settings dialog box, select the following settings: Bits per second: 2400 Data bits: 8 Parity: Note Stop bits: 1 Flow control: None
Click [OK]
Press the Enter key. The root terminal mode menu will appear, similar to the following:
To configure the UPS, press the 1 key. The UPS will chirp and the "UPS Settings" menu will appear.
SURT 3kVA 10kVA Service Manual
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To change a setting, press the corresponding key (not case-sensitive) and follow the instructions. Please note that if no key is pressed for approximately 5 minutes, the Terminal Mode session will time out and you'll have to press Enter and start from the root menu again.
3.3
SmartSlot Accessories (Webcard)
SURT models include a standard SmartSlot that is compatible with accessories used in other APC products. Notes on "event log" entries in the AP9619 (NMC or "webcard"): · Almost all internal UPS faults are recorded as "Bad output voltage" regardless of whether or not the detected fault is related to the Inverter or Bypass. The NMC is not able to differentiate between the different UPS failure codes. · "Battery charger failure" could be a momentary battery overvoltage condition -- see if this alarm is cleared within 2 seconds in the log.
SURT 3kVA 10kVA Service Manual
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4
Installation
See User Manual included with the UPS for installation precautions and instructions. Installation troubleshooting: Make sure: · each battery string is above 175V (there are two battery modules per string) · all battery modules are securely connected · input AC is connected correctly, input phase_select switch set correctly to 1 or 3 (if exists) · input breaker closed (if exists) · output breakers on (if exist)
5
Component Replacements
Replacement boards:
SKU Power Board 0P7510 0P7510 0P7516 PFC power 0P7611 0P7611 0P7611 Control Board 0P7603 0P7600 0P7606 Inverter power 0P7621 0P7621 0P7621 Main Control 0P7507 0P7608 0P7501 Aux Control 0P7631 0P7631 0P7631 Bias & I/O 0P7641 0P7641 0P7641
SURT3000 SURT5000 SURT6000
SKU
SURT7500 SURT8000 SURT10000
Battery modules (RBC44?) one for Lynx2, two for Lynx3? Bezels w/ stickers Display PCB/bezel assemblies Fan for Lynx2 Fan for Lynx3 Battery fuses: (515-1030A) See ??? for optional PDU's including H/W kit for Lynx2 output
SURT 3kVA 10kVA Service Manual
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16
6
Troubleshooting
Safety: Remove jewelry, pendants and wrist watches. 6.1 Unit Setup
Unpack the UPS and put it on a flat even surface (mind OSHA regulations). Check the packaging for any signs of damage.
Lynx2
Net Weight Shipping Weight 120.00 lbs. ( 54.55 kg) 140.00 lbs. ( 63.64 kg)
Note: Follow all environmental regulations. Discard old batteries in an environmentally friendly way. Be sure to deliver spent batteries to a recycling facility or ship to the manufacturer in the replacement battery packing material. 6.2
· · · · · · ·
Required Tools
Digital multimeter (for example, Fluke 87) Power resistor to discharge capacitors Serial communication cable (RS-232) Communication software (for example, laptop and "Hyperterminal" software in Windows) Phillips screwdriver AC power supply Load
6.3
Visual Inspections
Visual inspection is often overlooked but is one of the most important steps in diagnosing a problem. It can also save a lot of time.
Exterior
Check the packaging and exterior of the UPS for any physical damage 1. Plastic bezels 2. Fan guard & blades 3. Bent sheet metal 4. PDU breakers
Interior
Check all wiring, connections, and PCB components 1. Wire insulation broken 2. Burned components and/or burned marks on PCB 3. Daughter PCBs not tight in sockets 4. Components touching chassis or other components (esp. small heatsinks, power resistor leads) 5. Leads not clipped properly, solder-bridges (solder-side of PCB)
SURT 3kVA 10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
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6.4
Troubleshooting Flowchart
Start
Visual inspection (exterior)
Make sure all battery packs disconnected
Each Battery pack >84V?
Yes
No
Replace battery pack(s)
Remove top panel, Discharge all caps
Visual inspection (interior)
Diode checks OK?
Yes
No
Repair & record failed parts
Connect Battery, Push ON-Switch Lynx 2: Check D781, D782, D776, D777, D778, D779, Q712 Lynx 3: Check D704, D705, D706, D707, D714, D718, D722, Q704
Brains on? (Fan on)
No
Troubleshoot LPS
Yes
(next page)
SURT 3kVA 10kVA Service Manual
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(continued)
Fault displayed?
Yes
Disconnect SNMP cable from ctrl bd. Send Y Send 1...1 Send CTRL-U
Evaluate CTRL-U response and LED display. See "SURT Faults Table"
SURT Faults Table
No
Does unit cold start?
No
Check PFC: Lynx 2: D716-k to J712: +400V D715-a to J712: -400V Lynx 3: PGND to +400V PGND to -400V
+/-400V bus voltages OK?
Yes
No
Troubleshoot PFC
Yes
Apply AC input voltage Troubleshoot Inverter Troubleshoot input voltage sense and transfer relays Lynx 2: Check Q705, Q706, Q715, Q716, Q717, Q718, D750, D751 Lynx 3: Check IC1403, IC1404, IC1407, IC1408 collector-emitter and gate-emitter Lynx2: Check Q708, Q709, Q710, Q711, Q726, Q727, D748, D749, D723 Lynx3: Check IC903, IC904
Does unit go on-line ?
No
Yes
Does unit stay on with all batteries disconnected?
Yes
No
Troubleshoot Charger
Re-connect batteries
Lynx 2: Check Q730, Q731, F703, F704, D736, D737, D738, D739. Lynx 3: Check Q1407, Q1408, F1401, F1402, D1406, D1407, D1408, D1409
Does unit hold load on battery?
Yes
No
SURT Faults Table
Apply ECO's
Calibrate and Test unit
Record failure type, list all failed parts along with part markings
Done
SURT 3kVA 10kVA Service Manual
©2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2
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6.5
Diode Checks
The following "good value" measurements were made with a functional board and a Fluke 87 DMM. These measurements are approximate and will vary depending on the meter used. See the power board diagram on the next page for Test Point locations.
Lynx2: 3kVA - 6kVA
+ Probe
Fuse BATT +VIN VMID PFC -400V -VIN -VIN INV_OUT Inverter INV_OUT VMID -400V Charger output VMID
CHGR_SEC
- Probe
BATTF +400V +VIN -VIN B+ VMID +400V VMID INV_OUT INV_OUT
CHGR_SEC CHGR_L
Good Value
zero 0.4V 0.45V 0.4V 0.45V zero 0.8V charges > 2V charges > 2V 0.8V 0.45V 0.45V 0.45V 0.55V 0.5V 0.5V 0.6V 0.85V
Components checked
F701, F702 (battery fuses) D716, D748 Q709, Q710, D706 D715, D723 Q726, Q727, D707 RY704-normally closed Q706, Q715, Q716 D751, Q718, Q717 D750, Q715, Q716 Q705, Q718, Q717 D738, D739 D736, D737 D735 Q712 D782 D781 D731, TH701, TH702 Q728
If open
Both fuses bad, PFC probably has problem
If short
OK at least 1 part bad
all parts bad all parts bad all parts bad RY704 bad at least 1 part bad if < 2V, Q718 or Q717 bad if < 2V, Q715 or Q716 bad at least 1 part bad
at least 1 part bad at least 1 part bad at least 1 part bad OK Q706 and Q715/Q716 bad At least D751 and 1 IGBT bad At least D750 and 1 IGBT bad Q705 and Q718/Q717 bad
at least 1 part bad at least 1 part bad D735 bad Q712 bad, check F705, Q729, D714, and output diodes D782 bad, check Q712, F705, Q729, D715 D781 bad, check Q712, F705, Q729, D714 D731 bad, check TH701, TH702 Q728 bad, check MV703, GDT701
CHGR_L VMID VMID VMID
ZEROOFF_FET ZEROOFF_FET
BATTF LPS_FET +24V_SW +15V_SW B+ BATTF
Zero off
Bias Supply
SURT 3kVA 10kVA Service Manual
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SURT 3kVA 10kVA Service Manual
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Lynx3: 7.5kVA through 10kVA
+ Probe
Fuses +BATT -BATT +VIN_P1 +VIN_P2 -400V PFC -400V PGND PGND -VIN_N1 -VIN_N2 -400V Inverter INV_OUT INV_OUT Charger +Charger Out -400V
- Probe
+BATTF -BATTF +400V +400V -VIN_N1 -VIN_N2 +VIN_P1 +VIN_P2 PGND PGND INV_OUT +400V PGND +400V -Charger Out
Good Value
zero zero 0.35V 0.35V 0.35V 0.35V 0.4V 0.4V 0.4V 0.4V 0.35V
Components checked
F1403, F1404, F1405, F1406 D903, IC903 (at least) D905, IC904 (at least) D902, IC903 (at least) D904, IC904 (at least) IC903 (at least) IC904 (at least)
If open
Fuses bad, +PFC probably has problem Fuses bad, -PFC probably has problem
If short
OK OK
D903, D905, IC903, and/or IC904 bad
D902, D904, IC903, and/or IC904 bad
IC903 and/or IC904 bad IC903 (at least) IC904 (at least)
IC1407, IC1408 0.35V Open 0.55V 0.55V IC1403, IC1404 Q1407, F1402 Q1408, F1401
IC1407 and/or IC1408
IC1403 and/or IC1404 bad F1402 open, Q1407 probably bad F1401 open, Q1408 probably bad Q1407 bad Q1408 bad
SURT 3kVA 10kVA Service Manual
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Lynx3 PFC power board, 640-0761
IC903, IC904 = SURT 3kVA 10kVA Service Manual
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23
Lynx3 INVERTER power board, 640-0762
IC1403, IC1404 = SURT 3kVA 10kVA Service Manual
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IC1407, IC408 =.
24
Notes: Cold boot the unit and get the diagnostic information from the serial port before it gets cleared out. If the unit fails right away, read the display LED pattern and the failure code.
Initial power up (brains up) with batteries only Check calibration of batteries (both strings), DC buses, firmware version, model #, serial number, etc. Check fault history (^U command) Cold-boot check calibration of DC buses, output AC voltage, etc. AC-input check calibration of AC input voltage disconnect batteries to see if unit shuts down (indicates charger failure) ON & OFF buttons, BYPASS switch, etc. Startup with AC-input Load: add/remove/calibration of watts & VA AC input: add/remove with load HF-OFF check · · · · Bypass switch 3phase input switch selection Lynx3 Battery voltage commands: ^J for +battery, ^K for battery in PROG mode Once failed part is identified, try to determine if there were any manufacturing defects that might have caused the part to fail: Insufficient torque on mounting screw, leads not clipped, solder-bridge, parts touching other components, etc. In Terminal Mode, if Model = "??", the EEPROM has probably become cleared or corrupted. "Overload" fault (ctrl-u = 02) is stored during factory testing (during production). Seeing this fault stored in a field unit does not necessarily mean the overload timeout happened at the customer's site. "EQ charge" is normal in later versions of Lynx2 & Lynx3 firmware. If the battery voltage ever drops below 200V, the charger will go up to 235V for at least 5 minutes before settling back down to 218V. EQ charge is also performed about once every 4 weeks.l
· · ·
6.6
Documenting Failures
Int'l Stars, SIEBEL, or local spreadsheets. Make sure to record all relevant information about the diagnosis: · Reference designators of failed parts with date codes and vendor marks · PCB revisions, firmware revisions, accessories added, etc. · Recommend Corrective Actions and/or PCB revisions as needed.
7
ECO's
See ECO RMA database. For list as of this revision, see Appendix B. · Need table showing which PCB revision combinations can be used together (examples: 762x requires 763x or later, 1kVA change) · Need list of PCB revisions that are ok to ECO and send back to customers · Need table showing which PCB revisions need which ECO's
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8
Test After ECO's
(Final test fixture) All calibration Cold-boot AC input: add/remove Add load, check calibration of Voutput, Wout, VAout, DC buses, Vbatt, ... AC input: add/remove With AC input, disconnect batteries HF-OFF check
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Failure Analysis Report & Corrective Action Plan
Customer Customer location Report date Model Unit s/n RMA number RMA date PCB1 s/n PCB2 s/n Accessory1 s/n Yes ___ ___ ___ ___ ___ ___ ___ ___ No ___ ___ ___ ___ ___ ___ ___ ___ Additional Information
Rev Rev Rev
Initial Assessment
Does the unit cold boot? Does the unit indicate a fault? Does unit operate online with no faults? Is there any output? Does unit switch to bypass? Do all display leds work? ("A" in SM) Does unit operate under 100% load? Unit shut off after 9 min on battery standby?
Physical damage (deformed metal or plastic, loose connections, cut insulation, poor crimps, etc.)
Voltages: Command: Displays Measured Voltages Measured
Pos Bus
Ctrl G*
Neg Bus
Ctrl H*
Vin
Shift L
Vout
Shift O
Charger (no batt)
Shift B or ^J / ^K*
f/w rev
b
Fault History
Ctrl U*
n/a 5V 12V -12V -15V 15V 24V
n/a
Vbat (list packs separately)
Action Taken to Repair
Repaired Unit - Measured and Calibrated Voltages
Voltages Command Displays Measured Pos Bus
Ctrl G*
Neg Bus
Ctrl H*
Vin
Shift L
Vout
Shift O
Charger (batteries disconnected)
Shift B or Shift J / K* (Lynx 3)
Fault History
Ctrl U*
n/a
Corrective Actions to be Taken
Additional Notes
*in programming mode
2/14/2005
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Appendix A. Fault codes on LED display & stored in EEPROM
Display LEDs show "1" for LED ON and "0" for LED OFF in the Battery capacity bar graph. For example, the following display indicates "Battery Capacitor Soft Start Fault".
Notes All values provided in UPS-Link terms. Overload test uses % power (watts) or % VA, whichever is greater. The last fault(s) detected can be retrieved by sending the "Ctrl-U" command in Programming mode. CtrlAuto-Recover from Display Fault Action Taken U FAILURE_BYPASS? LEDs
Repair suggestion Confirm battery voltage(s) above 165V and that +/-400V buses rise to within 15V(9V) of the battery bus(es) within 12 seconds and. If they don't, check voltage after softstart PTCs, relay and relay drives.
Related ECOs
Battery Capacitor Soft Start Fault
The unit immediately changes state to UPS_FAILURE (less than 1ms)
0 1 1 0 0
11
Can't be in FAILURE_BYPASS
Lynx2: TH701. TH702, RY702, Q701, Q728, F701, F702. Lynx 3: TH1401, TH1402, TH1403, TH1404, RY1403, RY1404, RY1405, RY1406, RY1407, RY1408, Q1402, F1403, F1404, F1405, F1406
BM934
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Battery <-> Line (PFC Input) Relay Weld fault
No immediate action taken. State change will take place in the next AC line cycle (9ms @50Hz or 7ms @60Hz) The UPS will transfer to FAILURE_BYPASS or UPS_FAILURE state (See State Diagram.)
1 0 0 0 1
0D
NO
Bypass Relay Fault (Bypass relay is closed) Bypass Relay Fault (Output is off)
No immediate action is taken. Unit will change the state to UPS_FAILURE a half of an AC cycle later (10ms @ 50Hz or 8ms @ 60Hz)
0 1 0 0 1
0F
Can't be in FAILURE_BYPASS
Lynx3: Confirm customer wiring to input terminal block (hardwired). Input wires might be connected to Output terminal block by mistake. Check Bypass contactor and drive Lynx 2: Check Q727, Q728, F703, F704, D736, D737, D738, D739, Q730, Q731
Battery Charger Fault(descent method)
Battery Charger Fault (hard limit)
No immediate action taken. State change will take place in the next AC line cycle (13.3ms @50Hz or 11.1ms @60Hz) The UPS will transfer to FAILURE_BYPASS or UPS_FAILURE state (See State Diagram.)
0 1 0 1 0
12
NO Lynx 3: Check Q1407, Q1408, F1401, F1402, D1406, D1407, D1408, D1409
DC Bus Overvoltage Fault
DC Bus Overvoltage Fault will immediately turn-off the Inverter in hardware. The PFC will be turned off upon detection of this fault. Case 1 (Inverter relay is closed): The Inverter will be commanded off and new state will be set: UPS_FAILURE or FAILURE_BYPASS. Should UPS transfer to FAILURE_BYPASS, output Relay will be commanded to open and Bypass Relay will be commanded to close immediately. Case 2 (Inverter relay is open): UPS will transfer to UPS_FAILURE state at the closest AC line phase angle of 67.5 degrees (or in less than 18msec @50Hz or 15msec @60Hz.)
0 1 0 0 0
08
YES
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Fan Fault
State transitions in the next AC line cycle (4ms @50Hz 3ms @60Hz) Note: The UPS still tries to control the high/low speed mode selection for the fan. The UPS commands an immediate turn off of the Inverter, the PFC and the Charger. Next, the unit will enter either a FAILURE_BYPASS or UPS_FAILURE state (See State Diagram.) Upon setting the FAILURE_BYPASS state the UPS will command the Bypass and the Backfeed relays to close. Upon setting UPS_FAILURE state the UPS will command the Bypass and Backfeed relays to open. For either state the unit commands the Output Relay to open.Note: Normal UPS_FAILURE/ FAILURE_BYPASS procedure timings can not be applied in this case. The rest of hardware control operations (e.g. PFC input relay control) will take place in the next AC line cycle. So, the timings specified will start from phase angle 0. No immediate action is taken. All state transitions are taking place in the next AC cycle. (20msec @50Hz, 17msec @60Hz)
0 0 1 1 0
10
YES
Check: Fan connections to control board (Lynx2 uses J5 only), fan guard is not pushed in, no foreign objects stuck in fan blades, fan frame not broken
Lynx 2: Check Q705, Q706, Q715, Q716, Q717, Q718, D750, D751 0 0 0 0 1 06 NO Lynx 3: Check IC1403, IC1404, IC1407, IC1408 collector-emitter and gate-emitter
Inverter Fault (Hardware fault)
Inverter Fault (Output voltage test)
0B
Same as above
Logic Power Supply Fault
Immediately switches in UPS_FAILURE state. (See Normal Behavior for UPS_FAILURE State.)
1 1 0 0 0
01
Can't be in FAILURE_BYPASS
R544, R545 should be 10k
TA107
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High Output Voltage
High Output Voltage (Extreme Overvoltage) Output Relay Fault (bypass relay is closed) Output Relay Fault (Transferring to inverter-on state) Output Relay Fault (Inverter is on) Overload (Percent LoadInverter is on) Overload (Low output voltage) Overload (Percent Load Bypass Relay is closed)
No immediate action is taken. The UPS will transfer to UPS_FAILURE or FAILURE_BYPASS state (see State Diagram) in the next AC line cycle. (19msec @50Hz or 16ms @60Hz)
0 0 0 1 1
09
NO
No immediate action is taken. The UPS will transfer into UPS_FAILURE state in the next AC cycle (8ms @50Hz or 6ms @60Hz.)
0 0 1 0 1
0E
Can't be in FAILURE_BYPASS
02 No immediate action is taken. All state transitions are taking place in the next AC cycle (19msec @ 50Hz or 16msec @60Hz.)The UPS will sound the beeper as long as the fault conditions are present.
This fault is stored in `Ctrl-U' during factory testing. It is not cleared before shipment.
Overload LED
05
YES
03
Overtemperature
No immediate action is taken. All state transitions are taking place in the next AC cycle (4msec @50Hz or 3msec @60Hz.) The UPS will transfer to FAILURE_BYPASS or UPS_FAILURE (see State Diagram.)
1 0 0 0 0
07
YES
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PFC Failure (Inverter on, hard limit detection) PFC Failure (Inverter on, delta detection) PFC Failure (Inverter off)
No immediate action is taken. The UPS will transfer to FAILURE_BYPASS or UPS_FAILURE state (see State Diagram.) State transitions will take place at the closest phase angle of 67.5 degrees of AC line cycle. Upon detection of this fault, the PFC is turned off immediately, state transitions are taking place in the next AC cycle (8msec @50Hz or 6msec @60Hz.) The UPS will transfer into FAILURE_BYPASS or UPS_FAILURE state (see State Diagram.) Upon detection of this fault, the UPS will immediately enter UPS_FAILURE state. 0 0 1 0 0 0A YES
Lynx2: Q708, Q709, Q710, Q711, Q726, Q727, D748, D749, D723, DC bus and battery voltage feedback resistors, esp. R856, R857 Lynx3: IC903, IC904, DC bus and battery voltage feedback resistors
PFC Failure (Charging up DC Buses)
PFC Failure (cold-boot)
Short Circuit
Same as overload above.
Overload LED
04
Can't be in FAILURE_BYPASS
Backfeed Relay Weld
No immediate action is taken. All state transitions are taking place in the next AC cycle. (8msec @50Hz or 6msec @60Hz) The UPS will transfer to FAILURE_BYPASS or UPS_FAILURE (see State Diagram.)
0 0 0 1 0
0C
NO
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Appendix B. ECO list as of October, 2005 Lynx2 modifications (Control board) mirrored 180 degrees
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Lynx3 modifications (Control board, top side)
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Lynx3 modifications continued (Control board, bottom side) mirrored 180 degrees
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