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AEC IST5 Series Service Manual

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AEC IST5 SERIE SERVICE
MANUAL
10-15-20-30-40-60-80-100-120-160-200-300 KVA
10-15-20-30-40 KVA
60-80-100-120-160-200-300 KVA
1

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  • Page 1 AEC IST5 SERIE SERVICE MANUAL 10-15-20-30-40-60-80-100-120-160-200-300 KVA 10-15-20-30-40 KVA 60-80-100-120-160-200-300 KVA...
  • Page 2 SERVICE MANUAL 10-15-20-30-40-60-80-100-120-160-200-300 KVA...

  • Page 3: About The Manual

    About the Manual This Manual is prepared for the users of IST5 Ups Series10-15-20-30-40-60-80-100-120-160- 200-300 kVA. Companion Manuals For more info about this device and its options, please visit www.aecups.com Updates Visit www.aecups.com for updates. Always use the latest manual.

  • Page 4: Safety And Warnings

    Batteries must not be thrown into fire. The damaged batteries and batteries with completed life cycle must not be thrown to nature. For the collection and disposal batteries must delivered to AEC authorized technicians or to the foundations which are authorized for collecting waste batteries by the Ministry of Environment.
  • Page 5 1.2 Clearance and Access Clearance There is no any air inlet or outlet grill on the left or right sides of our 10-20 kVA UPS. All air goes in to UPS from the front and is evacuated from the rear through fans. There must be spaces at least 1 meter for UPS's front side and 1,2 meter at the back side.

  • Page 6: Product Description

    2 PRODUCT DESCRIPTION 2.1 General View  10-15-20-30-40KVA...
  • Page 7  60-80KVA...
  • Page 8  100-120-160-200-300 KVA...

  • Page 9: Front View

    2.2 Front View  10-15-20-30-40KVA 320*240 LCD DISPLAY FRESH AIR GRIDS EPO BUTTON MENU KEYS MIMIC DIAGRAM...
  • Page 10  60-80-100-120-160-200KVA 320*240 LCD DISPLAY FRESH AIR GRIDS EPO BUTTON MENU KEYS MIMIC DIAGRAM...

  • Page 11: Front Panel View

    2.3 Front Panel View  60-80-100-120-160-200-300 KVA RECTIFIER/CHARGE-INVERTER COOLING FANS DC BAS RAMPING UP BUTTON MAINS SWITCH MAINTENANCE BYPASS SWITCH BYPASS TERMINALS MAIN CONNECTION TERMINALS OUTPUT CONNECTORS TERMINALS GROUND CONNECTION BATTERY FAST FUSES AND CONNECTION TERMINALS EXTERNAL BYPASS SWITCH OUTPUT BREAKER...
  • Page 12 BARTTERY START-UP SWITCHES RS232 TERMINAL FOR COMMUNICATION SOFTWARE CONNECTION TERMINALS FOR EXTERNAL BATTERY TEMPERATURE READING RS232 TERMINAL FOR COMMUNICATION SOFTWARE 2.4 Front Interior View  60-80-100-120-160-200-300 KVA MAINS SWITCH MAINTENANCE BYPASS SWITCH MAIN CONNECTION TERMINALS OUTPUT CONNECTORS TERMINALS GROUND CONNECTION OUTPUT FUSES BATTERY FAST FUSES AND CONNECTION TERMINALS...
  • Page 13 2.5 Side Interior View  10-15-20-30-40KVA...

  • Page 14: Rear View

    2.6 Rear View  10-15-20-30-40KVA HOT AIR EVACUATION CHANNEL DC BAS RAMPING UP BUTTON EXTERNAL BYPASS SWITCH MAINTENANCE BYPASS SWITCH MAINS SWITCH MAINS CONNECTION TERMINALS GROUND CONNECTION ETERNAL BYPASS TERMINALS OUTPUT CONNECTORS TERMINALS BATTERY FAST FUSES AND CONNCECTION TERMINALS...
  • Page 15 BATTERY START-UP SWITCHES OUTPUT BREAKER THYRISTOR HOT AIR DISCHARGE CHANNEL RS232 TERMINAL FOR COMMUNICATION SOFTWARE OPTIONAL CARD SLOTS OPTIONAL PARALLEL PORT TERMINAL  80-100-120-160-200-300 KVA PARALLEL PORT TERMINAL RECTIFIER, CHARGER, INVERTER HOT AIR EVACUATION CHANNEL WIRING HOT AIR EVACUATION CHANNEL...
  • Page 16 2.7 Electrical Connections...

  • Page 17: General Information

    2.8 General Information General operation topology of AEC IST5 Series UPS can be recognizing as follows: IST5 SERIES ELECTRICAL TOPOLOGY The UPS is connected to the mains voltage through the CB1 breaker. As DC bus is ramped up, the rectifier starts to operate. Rectifier converts the AC mains to DC voltage and charges the batteries.

  • Page 18: Static Transfer Switch

    In the external battery cabinets the battery temperature is measured and detected by ‘’temperature sensor’’. UPS adjusts battery charge parameters according to the detected temperature. 2.9 UPS’s Operation Modes IST5 series is on-line double conversion device. Our products operate in the following modes:  Online Mode ...
  • Page 19 2.9.1 Normal (Online) Mode In this mode, UPS feeds the load through the inverters. Rectifier unit is fed by the AC mains power. Inverter and battery charge units are fed by DC supply generated by rectifier unit. 2.9.2 Battery (Stored) Mode When the mains voltage is bad the UPS runs on battery mode.
  • Page 20 In this case, UPS continues to operates in normal (online) mode as long as the mains values are in desired criterions. For IST5 Series UPS, this feature is not activated in the initial factory set-up.
  • Page 21 2.9.5 Maintenance Mode On the maintenance mode loads are switched to the maintenance bypass line with a breaker, so that the UPS can be serviced without cutting off the power to loads. The breaker is in full conformity with capacity of loads. 2.10 Battery Management Lead- acid batteries are used with UPSs.

  • Page 22: Deep Discharge Protection

    Deep Discharge Protection While the system is operating in the battery mode, if battery voltage has dropped below the discharge level UPS shuts down and stops taking energy from the batteries. This value varies between 1.6-1.75 V/cell for Lead-Acid batteries, and between 0.9-1.1 V / cell for Ni-Cd batteries. Low Battery Warning While the system operates on battery (stored) mode, according to actual loads, if the battery capacity drops below 40% of its value, device will give audible and visible alarms.
  • Page 23 2.11 User Panel User panel consists of mimic diagram, LCD screen, EPO button and menu keys. The UPS can be controlled via this panel. Rectifier indicator LED Flashes while the DC bus is ramping up. Illuminates when Rectifier works AC/DC module (Rectifier) Battery discharge LED Illuminates on battery mode.
  • Page 24 Menu Flow Chart MAIN SCREEN Manufacturer – Device Name Control Menu Date - Time Status Menu Load Status as Percent Setup Menu Battery Charge Status as Percent Logging Menu Remaining Back up (Autonomy) Time Service Menu UPS Mode – Actual Alarms Main Menu Titles LOGGING STATUS...

  • Page 25: Opening Screen

    2.11.1 Opening Screen When the front panel monitor is turned on, firstly opening screen is observed. Manufacturer – Device Name, Date – Time, Load Status as Percent, Battery Charge Status as Percent, Remaining Back up (Autonomy) Time, UPS Mode – Actual Alarms, Main Menu Titles can be observed here.

  • Page 26: Password-Protected Menus

    2.11.4 Password-protected menus Some menus such as the control menu are password protected. Press to set each digit and press ENTER to confirm. 2.11.5 Control Menu Within the control menu, you can do one of the following:  Start Start the UPS ...
  • Page 27 If “Stop Battery Test” command is chosen, UPS cancels the battery test and returns the previous operating mode. 2.11.6 Status Menu On this menu you can see information about the mains, output, bypass line, battery, temperature, inverter and alarms. Mains UP, I, F, UL Voltage, current and frequency of each phase (phase-neutral) S, P, PF...
  • Page 28 Device Information ____ -____-___-___ Inverter, rectifier, CPLD, front panel software version ------------------- UPS serial no KVA, V/Hz Apparent power, instantaneous output voltage (phase-neutral), instantaneous output frequency _x__ , Ah Parallel battery arm number x Serial battery arm number Battery capacity adjusted in UPS 2.11.7 Setup Menu Setup menu consists of the following: Date &...

  • Page 29: Auto Restart

    Auto restart In battery mode, the device turns off at the end of battery discharge. Auto-restart can be used to restart the UPS automatically when the mains are restored. Turn on auto-restart and set the time to define when the device will be started after the normal values of the mains are restored.
  • Page 30 Language Set the menu language. Communication Set the protocol for the RS232 connection. The options are SEC and TELNET...

  • Page 31: Logging Menu

    2.11.8 Logging Menu Last 500 events of the device can be seen in the logging menu. When viewing a log, press e nter to see detailed info about the UPS. All recorded data for that particular event (status, setup etc.) can be seen on the menu.

  • Page 32: Single Module Installation

    Additionally, you will find here important information about the UPS cabins transportation, positioning and connections. 3.1.1 Warnings The UPS must be installed by a certified electrician of AEC. The warranty is valid only for the UPS installed by a certified electrician of AEC.
  • Page 33 3.1.3.1 Positioning the UPS In the IST5 Series, fresh air enters the device from the front and goes out from the fans on the rear side of the device. Care must be taken in order not to cover the air entrance and exit spots.

  • Page 34: External Battery Configuration

    Especially, for the external cabinet batteries system of UPS, fuses must definitely be used. These fuses must be mounted as close as possible to the batteries. This closeness will increase the electrical operation safety. THE TABLE OF IST5 SERIES EXTERNAL BATERY USAGE DEVİCE RATING(KVA) 10KVA 15KVA 20KVA 30KVA 40KVA 60KVA 80KVA 100KVA 120KVA BATTERİES IS SERIES...

  • Page 37: Internal Battery Configuration

    3.1.3.3 Internal Battery Configuration The internal battery configuration is valid for the 10-15-20-30-40 kVA UPS only, it can be configured by 62 paces 4,5 Ah, 7 Ah or 9Ah standard as following. IST5 SERIS INTERNAL BATTERY USAGE TABLE UPS POWER (KVA) 10KVA 15KVA 20KVA 30KVA 40KVA BATTERIES IN SERIES NUMBER OF PARALLEL ARMS...

  • Page 38: Transportation Type Of Cabinets

    UPS as rarely as possible. 3.1.5 Mains, Load and Battery Connections AEC strictly recommends a distribution board for the UPS output. Proper fuses and breakers must be used in such distribution board. Additionally variable speedy fuses may be needed according to load. A-B type fuses or magnetic breakers are recommended if the load is suitable.

  • Page 39: Cable And Fuse Configuration

    3.1.7 Cable and Fuse Configuration Cable designs must be compatible to current and voltage values stated herein, additionally local instructions must be obeyed about these topics RATED CURRENTS (A) INPUT CURRENTS@MAX OUTPUT CURRENTS @100% RATİNG CHARGE CURRENT (3P+N) LOAD (3P+N) (KVA) 380V 400V...
  • Page 40 3.1.5.3 Cable connections ATTENTION! 3 pole-circuit breakers (switch) are used for the input and output of UPS, Neutral line must not be interrupted. 3.1.5.3.1 for IST5 10-15-20-30-40 KVA 10-15-20KVA 30-40KVA...
  • Page 41 Read the following steps to connect the cables properly. 1. Turn OFF all the distribution board breakers (both input and output distribution boards) to make sure that the load and mains are completely disconnected from any cable. 10-15-20KVA 30-40KVA...
  • Page 42 2. Unscrew and remove the metal board on the rear side of the device. 3. Connect the ground cable. 10-15-20KVA 30-40KVA...
  • Page 43 4. Make sure that the circuit breakers are off. The use of these circuit breakers is explained on the operation section. 5. Connect the input cables.  R to INPUT L1,  S to INPUT L2,  T to INPUT L3, ...
  • Page 44 Use the cable clips to stabilize the cables when the connections are done. WARNING: Make sure that the loads are isolated from the UPS output if they are not ready to be connected. WARNING: Make sure that the cables are connected properly before UPS is started.
  • Page 45 1. Turn OFF all the distribution board breakers (both input and output distribution boards) to make sure that the load and mains are completely disconnected from any cable. INPUT STATIC BYPASS MECANICAL BYPASS OUTPUT BATTERY 2. Connect the ground cable. Unscrew and remove the metal board on the rear side of the device.
  • Page 46 3. Make sure that the circuit breakers are off. The uses of these circuit breakers are explained on the operation section. 4. Connect the input cables.  R to INPUT L1,  S to INPUT L2,  T to INPUT L3, ...

  • Page 47: Battery Installation Procedure

    5. Check the phase sequence. 6. Repeat steps 4-5 for output cables. 7. Replace the rear board and tighten the screws Use the cable clips to stabilize the cables when the connections are done. WARNING: Make sure that the loads are isolated from the UPS output if they are not ready to be connected.

  • Page 48: Battery Temperature Monitoring

    1. Remove the battery fuse. 2. Make sure that the batteries are connected properly in series and parallel. 3. Reach the –BAT labeled cable inside the UPS and connect it to the negative battery terminal. 4. Reach the +BAT labeled cable inside the UPS and connect it to the positive battery terminal. 5.
  • Page 49 Avoid short circuiting batteries. Short circuit the batteries can damage you and your environment! Battery terminal may rise up to 450 Vdc! 1. Switch “CB4”breaker OFF on UPS. 2. If there is breaker on battery cabinet, Switch it “OFF” . 3.
  • Page 50 11. If there is breaker on battery cabinet, switch it “ON”. 12. Check if there is appropriate battery voltages to the battery input terminals by proper measuring device. External battery cable selection is determined by application. Fuses which are recommended for UPS and battery cabinet are given.
  • Page 51 30-40KVA 60-80-100-120-160-200-300 KVA...
  • Page 52 3.1.5.5 Control and Communication Cable Connections AEC UPS have standard or optional connections of advanced external battery cabinet, environmental monitoring, control panels and various intelligent monitoring. 3.1.5.5.1 for AEC IST5 10-15-20 KVA; Connections on the rear side of UPS: ...

  • Page 53: Parallel Installation

    Parallel application should be made by authorized personal of AEC! In case of need for redundancy or more power, IST5 series can be operated in parallel up to quantity 8 (eight). A schematic diagram which shows two UPS connected in parallel can be seen below.

  • Page 55: Parallel Settings

    3.2.1 Parallel Settings 3.2.1.1 10-15-20 KVA; Connect the parallel cable as shown in figure below. Only use the cables provided by AEC. Software settings on the user panel should be made by authorized personnel.
  • Page 56 3.2.1.2 30-40 KVA; Connect the parallel cable as shown in figure below. Only use the cables provided by AEC. Software settings on the user panel should be made by authorized personnel.
  • Page 57 3.2.1.3 60-80 KVA; Connect the parallel cable as shown in figure below. Only use the cables provided by AEC. Software settings on the user panel should be made by authorized personnel.
  • Page 58 3.2.1.4 100-120 KVA; Connect the parallel cable as shown in figure below. Only use the cables provided by AEC. Software settings on the user panel should be made by authorized personnel.

  • Page 59: Making The Electrical Connections

    3.2.2 Parallel Connection Procedure Please read the following instructions before you use the devices in parallel mode. 3.2.2.1 Check if the devices can be used in parallel mode. 1. Be sure that all devices are from the same series and rated the same power. 2.
  • Page 60 6. First turn the maintenance switches OFF and sees if the inputs of the devices are connected to each other. 7. Then turn the maintenance switch ON and check the connection between the input of the first device and the output of the second device. 8.
  • Page 61 3.2.2.4 Set the software for parallel operation In parallel operation, IST5 series UPS use the Master/Slave configuration. Master authorization is temporary for a UPS; one of the slaves may become the master depending on the conditions. 1. Go to the Service menu and enter the Parallel Operation screen.

  • Page 62: Parallel Start-Up

    Open the status menu to see if any device is a master or a slave. The letter on the lower left corner of the LCD screen is “M” or “S” in parallel mode. 3.2.3.1 Parallel start-up Read the following to start the parallel system. ...
  • Page 63  The loads will be equally distributed on all devices. 3.2.3.2 Switching to static bypass  If any one of the devices is manually switched to static bypass mode, the others will automatically switch to static bypass mode.  To switch all the devices to online mode, select switch to UPS on any device. 3.2.3.3 Stopping/Removing a single UPS In a parallel Challenger system, any one of the devices can be removed off the system without affecting the others.
  • Page 64  Turn off the UPS input breaker (CB1)  Turn off the UPS output breaker (CB3) and the maintenance breaker (CB2)  Turn off the UPS breakers on the distribution board. 3.2.3.4 Stopping all UPS To stop all the UPS in a parallel system, go to Setup >Service Menu >Control >Stop All UPS. Note: Pressing the EPO button on any UPS will stop all UPS...

  • Page 65: Operation Procedure

    4 OPERATION 4.1 Operation Procedure You can find information’s about circuit breaker, first start-up, types of UPS operation tests, turning UPS off, EPO and RS232 serial communication system in this section. 4.1.1 Circuit Breakers There are four circuit breakers on the rear side of the device. These are used for the AC input, maintenance bypass, output and the battery connections respectively.

  • Page 66: First Start-Up

    4.1.2 First start-up WARNING: Wait for at least 5 seconds between each step. 1. Turn all circuit breakers OFF. 2. Push the soft start button (SW1) at least for 10 sec. 3. Turn input circuit breaker (CB1) ON. If there is an external bypass input, put the external bypass switch (CB5) to position closed circuit (ON) 10-15-20 KVA 30-40KVA...
  • Page 67 60-80-100-120KVA 4. Start the UPS using the front panel. Main menu> Control > Password > Start 5. Check the UPS has switched to normal operation mode, via mimic diagram LEDs and LCD panel.
  • Page 68 6. Turn battery circuit braker (CB4) ON. 7. Turn output circuit braker (CB3) ON. 10-15-20 KVA 30-40 KVA...

  • Page 69: Switching From Online Mode To Battery Mode

    60-80-100-120KVA 8. The loads which are connected to UPS can be turned on. After all these steps, check that load is fed through inverter static switches via mimic diagram. In a contrary situation, check UPS total and phase loads. The UPS gives audio alerts in an overload condition, without feeding critical AC loads.
  • Page 70 NOTE: UPS will not switch to bypass mode if the inverter voltage is out of limits or there is an overload or over temperature situation. 4.1.3.3 Switching from Static Bypass Mode to Online Use the front panel to switch the device to online mode. Check the mimic panel to make sure that the device has switched to online mode.
  • Page 71 1. Turn CB2 ON. 10-15-20KVA 30-40KVA...
  • Page 72 60-80-100-120KVA 2. Stop the UPS using the user front panel. Main menu > Control > Stop...
  • Page 73 3. Turn CB1, CB3 and CB4 OFF. 10-15-20KVA 30-40KVA...
  • Page 74 60-80-100-120KVA WARNING: Wait at least 5 minutes before opening up the device after it is completely turned off, for safety. 4.1.4 Performing a Complete Shutdown 1. Turn off the loads connected to the device. Use the front panel to turn the device OFF Main Menu>...
  • Page 75 3. Check if the UPS has switched to bypass mode, via mimic diagram LEDs and LCD panel. 4. Turn OFF respectively the output (CB3), battery (CB4), outer battery (CB5) and input (CB1). WARNING: Make sure that there are no critical loads on the UPS output before performing a complete shutdown.
  • Page 76 4.1.6 RS232 Serial Communication Installation and Investigation IST5 series has an RS-232 interface which supports SEC and TELNET protocol as standard. This interface is fully isolated and safe. UPS can be monitored remotely via a computer (PC) or SNMP by using this protocol. This connection works with all kinds of options.

  • Page 77: Electronic Boards

    5 ELECTRONIC BOARDS 5.1 High Voltage DC to DC SMPS High voltage coming from HF3-R302E card goes to J3 socket and leaves as 48VDC from J1 and High Voltage DC to DC SMPS High Voltage Input Test Instruction:  PURPOSE Board should be tested by functionality.

  • Page 78: Electrical Tests

     Testing Board Physically: Circuit components and PCB should be tested by physically and microscope and IPC-A-610D CLASS II criteria and assembly directions should be validated. Bar-coding order should be controlled and validated.  Electrical Tests: 1. DC 0-900V supply is connected to J3 2.
  • Page 79 11. DC supply is increased by 20 in V steps. Current is not withdrawn from DC supply, output voltage is increasing gradually. 12. Signals can be observed in the oscilloscope. The signals in the channel 2 are stable, signals in the channel 1 can be seen as increased gradually in the following picture. 13.
  • Page 80 15. J1 socket can be loaded with 100Ω 23W (0,5A) resistance. Signals in the oscilloscope can be seen in the following picture. 16. Please pay attention that voltage spikes should not be happened on the signals. The peak signal in the channel 1 should not pass 20V, the peak signal in the channel 2 should not pass 600V.
  • Page 81 20. Input voltage is set to 700V. It is loaded by resistance 24Ω 100W (2A) from J1 socket. Output voltage should be observed as 48V±%2 and above. 21. Wait for a moment as DC supply is turned off. After unloading the capacitors in the circuits, DC supply and remove the components in the board.
  • Page 82 5.2 Main Board Power Supply This board provides 48VDC which supplies the main board and current transformers. Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 83  Testing Board Physically: Circuit components and PCB should be tested by physically and microscope and IPC-A-610D CLASS II criteria and assembly directions should be validated. Bar-coding order should be controlled and validated.  Electrical Tests: 1. Power supply is set to series mode. Each channel is set to +24V and as a total of 48V. 2.
  • Page 84 21. If number 3-4 and number 8 of J59 socket are loaded as 3,5Ω 14W, DC 7V±%3 can be measured. 22. The fuse is inserted in F5 fuse holder as definer in GENERAL MATERIAL LIST. 23. Number 2 of F7 fuse is applied to DC +24V from 0-24V point of power supply. After the procedure, D22 LED is ON.

  • Page 85: Main Board

    5.2 Main Board This board controls all the operations of the UPS. Not only the basic function like start/stop, it also monitors the changes that occur in UPS operational modes, evaluation of the sampled parameters of the UPS and according to that produces various control signals changing the UPS parameters.
  • Page 86 ***Type of IST5 main boards A13-1.V1 MAIN BOARD 3L Control board A13-1.V2 MAIN BOARD 3L 10KVA A13-1.V3 MAIN BOARD 3L 15KVA A13-1.V4 MAIN BOARD 3L 20KVA A13-1.V5 MAIN BOARD 3L 30KVA A13-1.V6 MAIN BOARD 3L 40KVA A13-1.V7 MAIN BOARD 3L 60KVA A13-1.V8 MAIN BOARD 3L 80KVA...
  • Page 87  Electrical Tests: 1. Main board which is connected to testing board can be seen in the following picture. 2. Main board and testing board connections can be seen in the following picture.
  • Page 88 3. Should install the testing software for testing the main board.  Program is downloaded via J48, j49 and DSP1, DSP2 connections.  J20 and J21 jumpers should connect for install the software.
  • Page 89 4. Computer interface for installing the software from J48 and J49 connections as below. 5. Selected the DSP1Project.hex and install the software from J49 to DSP1. 6. IST5_CPId.hex software installed to J48...
  • Page 90 7. Cut off the energy and take out J20-J21 jumpers and then energised again. Should seen the flashing of D56 LED. 8. Cut off the energy again then connect J20-J21 jumper. 9. Emulator is connected to J32 as following picture.
  • Page 91 10. Energised again and delete the DSP2 software from the following computer interface picture. 11. Select IST5_CPId.hex via Open Code File and Open Password File 12. Click the ERASE FLASH 13. After that cut off the energy and then install DSP2Project.hex software from J48...
  • Page 92 14. J48 and J49 connected each other and take out the J21 jumper. 15. Energised the circuit and open the following computer interface. 16. Chose serial connection values as following picture. 17. Read the main boards barcode and chose boards type. In that way completed main board pre test procedure.
  • Page 93 19. If board is reliable than software will accepted the board as following picture. 20. After completing the test by running all the functions, the board should be labelled and stored in available conditions.
  • Page 94 5.4 By-pass Board By-pass board is controlled by the main board. This is the board that drives by-pass thyristor and by-pass inverter thyristor. By-pass voltage and current and also inverter voltage and current readings can be done by the by-pass board. 10-60KVA 80-300KVA...
  • Page 95 Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 96 Picture 1 3) In the beginning, function generator and power supply should be OFF. Power supply always turned on first and then function generator is turned on. For switching off, vice versa should be applied, function generator is first and then power supply. Note: Function generator should not be switched on/off from power switch.
  • Page 97 Picture 2 11) The signal should be seen as below in the number 2 of Q2 transistor. (See Picture 3) Picture 3 12) The signals should be measured in the order of J3 and J4. Pin 1 of sockets are negative(-) and pin 2 of sockets are positive.
  • Page 98 15) D7 LED is ON after these steps. 16) The signal should be seen in the number 8 of U1 integration as above. (against GND) (See Picture 2) 17) The signal should be seen in the number 2 of Q4 transistor as above. (See Picture 3) 18) The signals should be measured in the order of J9 and J10.
  • Page 99 34) The signal should be seen in the number 8 of the U3 integration. (against GND) (See Picture 2) 35) The signal should be seen in the number 2 of Q13 transistor as above.(against GND) (See Picture 3) 36) The signals should be measured in the order of J27 and J26. Pin 1 of sockets are negative(-) and pin 2 of sockets are positive.
  • Page 100 Signal Flow Diagram IY z ole trafo means isolated transformer...
  • Page 101 5.5 IGBT Driver Board The Pulse Width Modulation signals obtained from the main controller board unit are transmitted to this board. These transmitted signals are transformed to suitable pulse width modulation signals for IGBTs. In order to protect the IGBTs against over current fast monitoring and control is provided. This is accomplished by IGBT control logic available inside the hybrids over this board.
  • Page 102 20-30KVA IGBT Driver 40KVA IGBT Driver...

  • Page 103: Required Test Equipments

    60-80KVA IGBT Driver Up side view Side view 100-120KVA IGBT Driver Up side view Side view Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 104  Adjusted DUTY ratio function generator  Thermal camera(preferably able to transfer image to the computers  Preparation before the Test: Required thyristor and connection cables should be there for gate outputs  Testing Board Physically: Circuit components and PCB should be tested by physically and microscope and IPC-A-610D CLASS II criteria and assembly directions should be validated.
  • Page 105 4. C09-1.V4 board J2 socket connection should be performed as in the following table. GND-Pwm PWM-1 PWM-2 GND-Pwm +15Vdc GND-Power Table 1 5. C09-2.V1 board should be assembled into C09-1.V4 and not be affected from vibration by strengthening the connection. 6.
  • Page 106 9. The signal should be seen as follows at the pin4 of the U4 and U6 integration.(against GND-Power ) 10. The signals at the pin 5 and pin 6 in the transformer T1. 11. Pin 3 of the U1 integration should be +15.5Vdc, pin 2 should be observed as 19.5Vdc. (against GND-High) 12.
  • Page 107 Giriş Voltajı 14.2V Çıkış On/Off Durumu After completing the test by running all the functions, the board should be labeled and stored in available conditions. GND AREAS Signal Flow Diagram...
  • Page 108 5.6 Relay Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 109 5.7 EPO Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 110 5.8 Bridge Rectifier Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 111 5.9 DC Bus Feeding Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 112 5.10 Dry Contact Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 113 5.11 EMI Filter Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 114 5.12 PFC Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 115 5.13 Relay Board Test Instruction:  PURPOSE Board should be tested by functionality.  EXECUTION Before the test, precaution should be performed for electrostatic protection. Without defined direction IPC-A-610D article 3(Protecting the Assembly-EOS/ESD and Other Handling Considerations) taken as a reference, ESD safety requirements should be provided.
  • Page 116 Batt. Capacity (Ah) Akü kapasitesi Batt. Paral. Arms Akü paralel kol sayısı Current Offset Lmt. ENTER ‘OK’ 1) Make all the circuit breakers of UPS off. Drain DC bus energy. 2) There are four notches on SW2 switch. The switch 1 must be on, in the shown group in Picture 2.The PWM sockets of J36-J37 will be unplugged on the main board as shown in Picture 2.
  • Page 117 Picture 04. Picture 05. 6) Check the DSP version no,it can be either 332 or 335.For example:F28335PGFA.
  • Page 118 Picture 06. 7) C2000 prog asks for password on first programming; PASS: IST52014 Picture 07 8) Main board requires energy for the software update. There are two methods for energising main board at Boxer model. External power supply is the first method for energising. The second method is to unplug all NH fuses.
  • Page 119 Picture .08 10) Plug in external power supply socket instead of J2 socket.External power supply consists of L1 and L3 phases. 11) Input and battery fuses are unplugged as shown in Picture 9-10 if there isn’t enough equipment for the external power supply Picture .09 12) To ensure safe operation, do pay attention to DC bus voltage after NH fuses were unplugged.
  • Page 120 Picture .11 14) C2000 prog software indicates that the programming is successful, click OK. 15) After the installation is completed, turn UPS’s input breaker (CB1) off position and see UPS de-energised. Turn SW2 notch 1 off again. 16) Turn UPS’s input breaker (CB1)on again and see the main board is energised again. Check that the correct version is to set in the control panel.
  • Page 121 6.4 RS335 Dry Contact Installation Installation The module is installed on the left side slot on the rear side of the machine. 1. Unscrew and remove the left hand side slot cover, reach the female CAN socket. (attached to the slot cover) 2.
  • Page 122 3. Carefully insert the module into the slot, and screw to make sure that it is stable. 4. Insert the signal cables into the sockets while pressing on the connector with a screwdriver. Operation  Relay outputs are isolated from the UPS and ground. ...

  • Page 123: Pin Functionality

     Operating voltage for the isolated inputs is between 3.3 – 24 Volts and the input impedance is 3 kohms.  Polarity must be checked before applying any voltage to the inputs.  The 12V/150mA power supply on the module is also isolated from the UPS. Relay info Rated Switching NO 5A 250VAC...
  • Page 124 12 Vdc Out (-) Output-2(battery mode) COM Input-1(start) (+) Output-2(battery mode) NC Input-1(start) (-) Output-3(bypass mode) NO Input-2(stop) (+) Output-3(bypass mode) COM Input-2(stop) (-) Output-3(bypass mode) NC Input-3(bypass mod) (+) Output-4(common fault) NO Input-3(bypass mod) (-) Output-4(common fault) COM Input-4(ups mode) (+) Output-4(common fault) NC Input-4(ups mode) (-) Output-5(battery fault) NO...

  • Page 125: Connection Examples

    Connection examples Output relays can be connected in various ways to meet with control necessities. “AND” and “OR” configurations can be set with the relays by connecting them in series or parallel as seen in the figure above.

  • Page 126: Explanations Of Logging

    7. EXPLANATIONS of LOGGING UPS will beep when any problem is detected. You can see the first information about the situation on the front monitor panel. This may not be enough most of the time. In this case, you can see the following warnings by using log screen. Event Explanations RS232 Start...
  • Page 127 Bypass voltage value is out of limit while UPS was operating on the bypass Bypass Voltage Bad mode.UPS will switch to normal mode if temperature and load status are normal.If not ,UPS will stop. Bypass frequency value is out of limit while UPS was operating on the bypass Bypass Freq.
  • Page 128 UPS Thyr.L3 Open UPS has detected that inverter L3 thyristor can not be activated.Load will be transferred to bypass line. BYP Thyr.L1 Open UPS has detected that bypass L1 thyristor can not be activated.Load will be transferred to inverter line. BYP Thyr.L2 Open UPS has detected that bypass L2 thyristor can not be activated.Load will be transferred to inverter line.
  • Page 129 No P.CAN Bus Slave UPS which is operating in paralel mode can’t reach to master UPS from Comm. CAN bus.If UPS is operating,will be shut down. Ext. Start UPS which is operating in paralel mode has been given a command to start up Command by another (master) UPS.

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