Service manual

Always On UPS Systems Inc
Table of Contents
1. SAFETY INSTRUCTIONS......................................................................................................................... 1
2. GENERAL BLOCK DIAGRAM................................................................................................................ 2
3. 6 PULSE RECTIFIER TOPOLOGY DRAWING.................................................................................... 3
4. 12 PULSE RECTIFIER TOPOLOGY DRAWING.................................................................................. 4
5. RECTIFIER.................................................................................................................................................. 5
6. INVERTER................................................................................................................................................... 7
7. STATIC SWITCH ....................................................................................................................................... 9
8. INTER-PCB DIAGRAM........................................................................................................................... 11
9. PCB MODULE........................................................................................................................................... 12
10. AUXILARY POWER SUPPLY ...........................................................................................................13
11. STARTUP PROCEDURES .................................................................................................................. 14
11.1. System start up (from complete shutdown)..................................................................................................................................... 14
11.2. From Manual Bypass To Inverter Procedure................................................................................................................................ 15
12. UPS SHUTDOWN PROCEDURES..................................................................................................... 17
12.1. Complete UPS shut down procedure .............................................................................................................................................. 17
12.2. From Inverter To Manual Bypass Procedure ................................................................................................................................ 17
13. LCD DISPLAY AND LED DESCRIPTION....................................................................................... 19
14. THE LCD DISPLAY............................................................................................................................. 24
14.1. Menu 0 – Main Menu...................................................................................................................................................................... 24
14.2. Menu 1 – Select Menu..................................................................................................................................................................... 25
14.3. Menu 2 – Status Warning Menu..................................................................................................................................................... 26
14.4. Menu 3 – Real Time Data Menu..................................................................................................................................................... 27
14.5. Menu 4 – Historical Event Menu.................................................................................................................................................... 28
14.6. Menu 5 – Parameter Setting Menu................................................................................................................................................. 29
14.7. Menu 6 – Rectifier Data Menu ....................................................................................................................................................... 30
14.8. Menu 7 – Reserve Data Menu......................................................................................................................................................... 30
14.9. Menu 8 – Output Data Menu .......................................................................................................................................................... 31
14.10. Menu 9 – Other Data Menu...................................................................................................................................................... 31
14.11. Menu 10 – Boost Charge Setting Menu ................................................................................................................................... 32
14.12. Menu 11 – Data Time Setting Menu......................................................................................................................................... 34
14.13. Menu 12 – Other Setting Menu ................................................................................................................................................ 34
15. STATUS INDICATOR TABLE........................................................................................................... 35
16. BOARD LED INDICATION TABLE ................................................................................................. 36
17. BOARD FAULT DIAGRAMS ............................................................................................................. 37
18. BATTERY CABINET........................................................................................................................... 45
18.1. Battery Runtime Charts................................................................................................................................................................... 53
19. MAIN CONTROL (3A PCB)................................................................................................................ 54
20. POWER SUPPLY (3B PCB)................................................................................................................. 57
21. RECTIFIER CONTROL CIRCUIT (3C PCB) .................................................................................. 59
22. INVERTER PHASE CONTROL (3T PCB)........................................................................................ 61
23. COMMUNICATIONS INTERFACE (3R PCB) ................................................................................ 63
24. WARNING LED’S AND SWITCHES (3W PCB).............................................................................. 65
25. LCD DISPLAY ...................................................................................................................................... 65
26. MIMIC DIAGRAM (3L PCB).............................................................................................................. 65
27. STATUS LED’S AND AUDIBLE ALARM (3AG PCB).................................................................... 65
28. RECTIFIER MODULE ........................................................................................................................ 66
29. INVERTER MODULE ......................................................................................................................... 70
30. STATIC SWITCH................................................................................................................................. 74
31. AUXILIARY POWER SUPPLY..........................................................................................................78
Section A SINGLE LINE DRAWINGS........................................................................................................... 91
Section B PARTS LIST FOR ALL SYSTEMS............................................................................................... 94
32. CONTACT INFORMATION............................................................................................................... 95
32.1. Additional Purchases or Upgrades ................................................................................................................................................. 95
32.2. QA / Warranty Questions ................................................................................................................................................................ 95
32.3. Software Questions .......................................................................................................................................................................... 95