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Tripp Lite SU60KX Manual

3-phase ups hardware introduction and troubleshooting su series
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SU-Series 3-Phase UPS Hardware:
Introduction and Troubleshooting
1111 W. 35th Street, Chicago, IL 60609 USA
+1.773.869.1234 • www.tripplite.com
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Summary of Contents for Tripp Lite SU60KX

  • Page 1 SU-Series 3-Phase UPS Hardware: Introduction and Troubleshooting 1111 W. 35th Street, Chicago, IL 60609 USA +1.773.869.1234 • www.tripplite.com...

  • Page 2: Table Of Contents

    Table of Contents 1 Basic Operation 1.1 Technical Specifi cations KX Models K and KTV Models SU80K Model 1.2 Features 1.2.1 Advanced Features 1.2.2 Control Panel Features 1.2.3 Front and Rear Panel Features 1.3 Operating Principles 1.3.1 System Layout 1.3.2 Internal Battery Layout 1.3.3 Power Module Layout 1.4 Opening and Closing the Unit 1.5 Operating Modes...

  • Page 3: Basic Operation

    32° F ~ 104° F (0° C ~ 40° C) 65 dBA Width 520 mm Depth 850 mm Height 1165 mm 267 kg* SU40KX SU60KX SU80KX (40kVA/32kW) (60kVA/48kW) (80kVA/64kW) 68 dBA 70 dBA 70 dBA 412 kg* 210 kg 244 kg...

  • Page 4: K And Ktv Models

    Basic Operation (continued) 1.1 Technical Specifi cations (continued) K and KTV Models: Input Input Voltage Voltage Regulation Harmonic Distortion PFC (Full Load) Frequency Frequency Tolerance Output Output Voltage Output Frequency Total Harmonic (Linear Load) Voltage Regulation Frequency Regulation Overload Audible Warning Battery Backup UPS Abnormal Display...

  • Page 5: Su80K Model

    Basic Operation (continued) 1.1 Technical Specifi cations (continued) SU80K Model: Input Input Voltage Voltage Regulation Harmonic Distortion PFC (Full Load) Frequency Frequency Tolerance Output Output Voltage Output Frequency Total Harmonic (Linear Load) Voltage Regulation Frequency Regulation Overload Audible Warning Battery Backup UPS Abnormal Display Interface...

  • Page 6: Features

    Basic Operation (continued) 1.2 Features 1.2.1 Advanced Features: • True on-line double conversion with superior IGBT inverter technology • Low input current THD allows 1:1 generator sizing for maximum effi ciency and cost savings • Internal N+1 power module redundancy (except for SU20KX model) •...

  • Page 7: Front And Rear Panel Features

    20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy in SU40KX, SU60KX and SU80KX models.
  • Page 8 Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call +1 773 869 1234 for more information about the SNMPWEBCARD accessory.
  • Page 9 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary from diagrams. Unit shown with front bezels removed. • Control Panel: The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.) •...
  • Page 10 Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for more information about the SNMPWEBCARD accessory.
  • Page 11 Basic Operation (continued) 1.2 Features (continued) Note: Individual models may vary from diagrams. Unit shown with front bezels removed. • Control Panel: The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.) •...
  • Page 12 Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for more information about the SNMPWEBCARD accessory.

  • Page 13: Operating Principles

    Basic Operation (continued) 1.3 Operating Principles 1.3.1 System Layout Manual Bypass Circuit Breaker Bypass Input Circuit Breaker Main Input MAIN Circuit Breaker BATTERY Manual Bypass Circuit Breaker MAIN Bypass Input Circuit Breaker BATTERY The SU-Series 3-Phase UPS is confi gured with 3-phase 20kVA power modules that can be paralleled for redundancy or capacity upgrades. Each KX- (Figure 1.3.1a), K- , and KTV-series (Figure 1.3.1b) UPS includes three key functions: 1) A central bypass static switch, which causes a critical load to automatically bypass any overload or fault conditions that occur.

  • Page 14: Power Module Layout

    Basic Operation (continued) 1.3 Operating Principles (continued) 1.3.3 Power Module Layout INPUT BATTERY The SU-Series 3-Phase UPS double-conversion power modules consist of three components (Figure 1.3.3a): 1) An AC/DC converter 2) An AC/DC inverter 3) A charger The power module’s 3-phase, 4-wire input runs A/C current through the AC/DC converter to generate regulative dual DC bus (±370Vdc). During backup mode, this current is provided by battery power.

  • Page 15: Operating Modes

    Basic Operation (continued) 1.5 Operating Modes This section provides a basic description of the UPS system’s operating modes. For more information about switching between operating modes, refer to Section 1.6 – Start-Up, Shutdown and Bypass. 1.5.1 Online (Normal) Mode (Single UPS) In online (normal) mode, the UPS system’s rectifier converts incoming AC utility power to DC power that charges the batteries and supplies the inverter.

  • Page 16: Online Mode (Parallel Ups)

    Basic Operation (continued) 1.5 Operating Modes (continued) 1.5.5 Online Mode (Parallel UPS) Parallel redundancy (1+1) provides UPS system redundancy or increased total capacity. Under parallel redundancy, the total load is shared by two UPS systems. If one of the UPS systems malfunctions, the total connected equipment load is supported by the remaining UPS system.

  • Page 17: Manual Bypass Mode (Parallel Ups)

    Basic Operation (continued) 1.5 Operating Modes (continued) 1.5.8 Manual Bypass Mode (Parallel UPS) Similar to manual bypass mode for a single UPS system (Section 1.5.4), except with parallel (1+1) UPS systems. Note: Both UPS systems must be switched into manual bypass mode. 1.5.9 Hot Standby Mode (Parallel UPS) For added fault-tolerance, the redundant UPS system acts as the bypass (reserve) power source for the main UPS system.

  • Page 18: Start-Up, Shutdown And Bypass

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass Warning: The UPS system’s output voltage is set at 220/380V by default. If you require output voltage of 230/400V or 240/415V, you must change the UPS system’s output voltage by accessing the output setup menu described in Section 10-9 of the owner’s manual. You must place the UPS system in bypass mode before changing the output voltage.

  • Page 19: Battery Start-Up Procedure (Single Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.3 Standard Start-Up Procedure (Single UPS) (continued) • Switch on the output circuit breaker switch circuit breaker switch . After a brief initialization process, the LCD screen will show “ON AUTO BYPASS”, the “BYPASS” LED will illuminate and UPS system output will be supplied by the bypass (reserve) power source.

  • Page 20: Manual Bypass Procedure (Single Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.5 Manual Bypass Procedure (Single UPS) Warning: Placing the UPS system in manual bypass will disable the inverter and power all loads from the manual bypass (reserve) source, but the UPS system will still be energized. Before performing maintenance or repair on the UPS system, shut down and de-energize the UPS system completely by following the steps in Section 1.6.6.

  • Page 21: Preliminary Checklist (Parallel Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.6 Shutdown Procedure (Single UPS) (continued) • Confirm that the UPS system is off and that all main output circuits are off. If the UPS system is connected to an external battery cabinet, turn off the external battery cabinet circuit breaker switch •...

  • Page 22: Shutdown Procedure (Parallel Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.8 Start-Up Procedure (Parallel UPS) (continued) • Switch on the bypass input circuit breaker switch UPS system. After a brief initialization process, the LCD screen will show “ON AUTO BYPASS” and the “BYPASS” LED will illuminate.

  • Page 23: Manual Bypass Procedure (Parallel Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.9 Shutdown Procedure (Parallel UPS) (continued) • For the UPS system you wish to shut down, switch off the bypass input circuit breaker switch • When the UPS system is completely shut down, the LCD screen will be completely off.

  • Page 24: Switching From Manual Bypass To Normal Mode (Parallel Ups)

    Basic Operation (continued) 1.6 Start-Up, Shutdown and Bypass (continued) 1.6.10 Manual Bypass Procedure (Parallel UPS) (continued) • If the UPS systems have external battery cabinets connected, switch off the external battery cabinet circuit breaker switch battery pack. • In this mode, only the output circuit breaker switch terminal block contain hazardous voltage, allowing qualified service personnel to perform maintenance or repair.

  • Page 25: Printed Circuit Boards (Pcb)

    Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) Table 1.7a lists the printed circuit boards present in each UPS system: SU80KX SU80K SU60KX SU40KX SU80KTV SU60K SU40K SU20KX V (2pcs) V (2pcs) V (2pcs) V (2pcs) V (2pcs) V (2pcs)

  • Page 26: Pcb Location (System)

    Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.1 PCB Location (System) 1.7.1.1 KX Models SU20KX and SU40KX: O/P CT FA (BYP) FA (MAIN) BYPASS SCR LA and LB...
  • Page 27 Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.1 KX Models (continued) SU60KX and SU80KX: F1 (BYP) F1 (MAIN) F2 (BYP) F2 (MAIN) O/P CT LA, LB, LC, LD...

  • Page 28: K Models

    Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models SU40K: LA, LB FA (BYP) FA (MAIN) Transfer Transfer Bypas SCR O/P CT...
  • Page 29 Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models (continued) SU60K: I/P Tx F1 (BYP) F1 (MAIN) F2 (MAIN) O/P Tx F2 (BYP) Bypas SCR O/P CT LA, LB, LC...
  • Page 30 Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.1 PCB Location (System) (continued) 1.7.1.2 K Models (continued) SU80K: O/P Tx I/P Tx F1(BYP) F1(MAIN) F2(BYP) F2(MAIN) Bypass SCR O/P CT LA, LB, LC, LD...

  • Page 31: Pcb Power Module

    Basic Operation (continued) 1.7 Printed Circuit Boards (PCB) (continued) 1.7.2 PCB Location (Power Module) PCB Board Name Description NH-PM-A Rectifi er of Phase R and S, Inductance and Switching Devices of DC-DC Converter, Bus Capacitors and Battery SCR circuit NH-PM-K Rectifi...

  • Page 32: Block And Wiring Diagrams

    Basic Operation (continued) 1.8 Block and Wiring Diagrams (continued) 1.8.1 KX Models Input: 3-phase 4-wire 230/380Vac Output: 3-phase 4-wire 230/380Vac The SU20KX (Figure 1.8.1a) has a model rating of 20kVA UPS and contains one power module and 40 internal batteries (which can be increased to 80, if necessary).

  • Page 33: Theory Of Operation

    Theory of Operation (continued) 2.2 DC Auxiliary Power Circuit (continued) Located at NH-SYS-M board (System MCU and Control Circuit) RM 42 RM 43 K-ON CM 24 (a) The input of DC auxiliary power circuit is from positive battery. (b) MCU detects the “on” key (on LCD board) status through KEY-ON(21) (c) When AC auxiliary power circuit is activated and battery is present, AUXON (64) is high and DC auxiliary power circuit will be on.

  • Page 34: Output Current Detection

    Theory of Operation (continued) 2.4 Output Current Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) CNP11 (W18) CNP12 (W19) CNP13 (W20) Located at NH-SYS-M board (System MCU and Control Circuit) RM 25 IoutR RM 33 CM 22 (a) Connectors CNP11, CNP12 and CNP13 connect to 3 Output CT individually.

  • Page 35: Input Voltage Detection

    Theory of Operation (continued) 2.5 Input Voltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) RP161 RP162 BYP/R RP167 RP168 CNP7 IP/R BYP/N IP/S IP/T IP/N CNP8 BYP/R RP177 BYP/S BYP/S BYP/T BYP/N RP185 BYP/T Located at NH-SYS-M board (System MCU and Control Circuit)

  • Page 36: Output Voltage Detection

    Theory of Operation (continued) 2.6 Output Voltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) CNP9 OP/R OP/S OP/T OP/N Located at NH-SYS-M board (System MCU and Control Circuit) RM 29 DM 4 VoutR RM 32 (a) MCU detects RMS value of 3-phase output voltage via Vout_R (95), Vout_S (97) and Vout_T (99).

  • Page 37: Battery Voltage Detection

    Theory of Operation (continued) 2.7 Battery Voltage Detection Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) RP94 RP99 BAT+ RP108 BAT- RP114 Located at NH-SYS-M board (System MCU and Control Circuit) Vbatt+ RM 49 RM 55 CM 28 (a) MCU detects battery voltage via Vbatt_+ (98) and Vbatt_- (100).

  • Page 38: Bypass Scr Short-Circuit Detection

    Theory of Operation (continued) 2.8 Bypass SCR Short-Circuit Detection Located at NH-SYS-FB board (Circuit for Bypass Back-Feed Detect) CFA22 CFA18 CFA12 Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) BKFD_S BKFD_T Located at NH-SYS-M board (System MCU and Control Circuit) SCRST_R (a) During backup mode, bypass 3 SCRs should be off and zero current should be running through CTFB1, CTFB2 and CTFB3.

  • Page 39: Bypass Scr Driver

    Theory of Operation (continued) 2.9 Bypass SCR Driver Located at NH-SYS-S or NH-SYS-SA board (Driver Circuit for Bypass SCR) +12VS RSA1 QSA7 BYPSTS1 Located at NH-SYS-M board (System MCU and Control Circuit) BYPSTS RM 75 BYPSTS2 (70) CENTRAL_OK RM 78 RM 82 CM 50 RM 91...

  • Page 40: Watchdog For System Mcu

    Theory of Operation (continued) 2.9 Bypass SCR Driver (continued) (a) The bypass SCR driver signal “BYPSTS1” is controlled by MCU or “TOBYP_J” according to the signal “CENTRAL_OK.” (b) “CENTRAL_OK” is the output of MCU watchdog. If MCU is operating normally, “CENTRAL_OK” will be high and the bypass SCR driver signal will be controlled by “BYPSTS”...

  • Page 41: Lcd Panel Control Circuit

    Theory of Operation (continued) 2.11 LCD Panel Control Circuit Located at NH-SYS-M board (System MCU and Control Circuit) TO LCD CNM 5 VLED LED0 LED2 LED4 DOWN CONTRAST LcdWR LcdD0 (32) LcdD2 (34) LcdD4 (36) LcdD6 (38) CM 72 CM 73 CM 74 CM 75 RM 126...

  • Page 42: Fan Control Circuit

    Theory of Operation (continued) 2.12 Fan Control Circuit Located on NH-SYS-M board (System MCU and Control Circuit) +12VS UM 8A FAN-C (17) FANLOCK_A RM 163 RM 166 FAN_ON Located on NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current) Located on NH-SYS-S or NH-SYS-SA board (Driver Circuit for Bypass SCR) +12VS CSA16...

  • Page 43: Bypass Scr Temperature Detection

    Theory of Operation (continued) 2.13 Bypass SCR Temperature Detection Located on NH-SYS-M board (System MCU and Control Circuit) STS_TH- Located on NH-SYS-S or NH-SYS-SA board (Driver Circuit for Bypass SCR) (a) Temperature sensor (NTC) is screwed onto the heat-sink of bypass SCR and connected to CNSA6 on the NH-SYS-S or SA board. (b) MCU detects the temperature via HS_TEMP (105).

  • Page 44: Communication Circuit For Slots

    Theory of Operation (continued) 2.15 Communication Circuit for Slots RR26 #TX_232 RR33 RR37 CR27 RR43 #RX_232 Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) RR51 +12VSF UR25 #TX_Slot1...

  • Page 45: Communication Circuit For Output Dry Contact

    Theory of Operation (continued) 2.16 Communication Circuit for Output Dry Contact Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) CNR8 Located on NH-SYS-M board (System MCU and Control Circuit) (a) System MCU sends out dry contact signal to the relays via DRY_A (65), DRY_B (66), DRY_C (67), DRY_D (68), DRY_E (83) and DRY_F (84).

  • Page 46: Communication Circuit For Input Dry Contact And Repo

    Theory of Operation (continued) 2.17 Communication Circuit for Input Dry Contact and REPO Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) CNX4 CNX5 Located on NH-SYS-M board (System MCU and Control Circuit) (a) System MCU will detect input dry contact via DRY_1 (79) and DRY_2 (80) (b) REPO (Remote Emergency Power Off) can be detected via R_EPO (86) by system MCU (high active).

  • Page 47: External Battery Cabinet Temperature Detection

    Theory of Operation (continued) 2.18 External Battery Cabinet Temperature Detection Located on NH-SYS-X board (Circuit for REPO, Input Dry Contact and Circuit for sense External Battery Cabinet Temperature) 10VSF_REF +12VSF UX5A CNX6 EXTB_TEMP1 RX13 RX18 10VSF_REF CNX7 CX11 RX24 EXTB_TEMP2 CX12 RX29 RX33...

  • Page 48: Detection Circuit For Manual Bypass Switch

    Theory of Operation (continued) 2.19 Detection Circuit for Manual Bypass Switch Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) TO Manual Bypass Breaker Located on NH-SYS-M board (System MCU and Control Circuit) (a) CNR13 connects to the auxiliary contact of the manual bypass switch.

  • Page 49: Control Circuit For Power Module

    Theory of Operation (continued) 2.21 Control Circuit for Power Module Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) CENTRAL_OK RR111 +12VSF DR13 BYPOK QR14 Located on NH-SYS-M board (System MCU and Control Circuit) (70) (a) VS is the voltage source for the parallel signal bus.
  • Page 50 Theory of Operation (continued) 2.21 Control Circuit for Power Module (continued) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) TO PM1 TO PM2 CNR20 CNR21 ID1OK ID2OK CI33(V)-4P...
  • Page 51 Theory of Operation (continued) 2.21 Control Circuit for Power Module (continued) Located on NH-SYS-M board (System MCU and Control Circuit) RR54 #DATA_TX RR61 #DATA_RX #TOBYP_O #TOBYP_I #TOINV_O #TOINV_I Located on NH-SYS-M board (System MCU and Control Circuit) RM 136 DATA_TX (120) RM 142 DATA_RX...
  • Page 52 Theory of Operation (continued) 2.21 Control Circuit for Power Module (continued) Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots) 5VSF CANH-M RR17 CANL-M Located on NH-SYS-M board (System MCU and Control Circuit) (g) CAN bus is the communication bus for load sharing, as well as the synchronization of signals between the system and its power modules.

  • Page 53: Transformer Over Temperature Detection

    (c) The thermal switch sensor will be open when the transformer coil’s temperature exceeds 150. MCU can detect the temperature status through IPRT_Temp (51) and OTRT_Temp (61). Note: For international models (SU20KX, SU40KX, SU60KX and SU80KX), short-pins must be inserted into CNM10 and CNM11. RM 4...

  • Page 54: Communication

    Communication Warning: Do not use the paralleling cable that came with the UPS system for these procedures. Use a RS232 cable. 3.01 RS232 Port The UPS provides a RS232 port in one D-sub 9 female connector. This RS232 port performs the following functions: 3.1) Sets EEPROM on the NH-M board 3.2) Sets Output Dry Contact status 3.3) Upgrades the system board’s fi...
  • Page 55 Communication (continued) Remote Emergency Power Off (REPO) The Remote Emergency Power Off (REPO) input connection (P1 in Figure 3.02b) allows you to connect the UPS system to your facility’s EPO circuit — enabling remote emergency shutdown of the UPS system’s output. Connect EPO input to a user-supplied remote switch using the circuit diagram (Figure 3.02c).

  • Page 56: Setting Eeprom On The Nh-M Board

    Communication (continued) 3.1 Setting EEPROM on the NH-M Board 3.1.1 Polling and Updating EEPROM WARNING: This procedure must be performed in bypass mode (see section 1.6). Instructions for polling and updating the EEPROM are as follows (Figure 3.1.1a): a) Link the UPS with a PC via the RS232 port b) Run the program “NH_SYS_V1_3B1030.exe”...

  • Page 57: Calibrating Eeprom Gain

    Communication (continued) 3.1 Setting EEPROM on the NH-M Board (continued) 3.1.2 Calibrating EEPROM Gain WARNING: This procedure must be performed in bypass mode (see section 1.6). Instructions for calibrating the EEPROM gain of the UPS parameters are as follows: (For polling procedure, please refer to section 3.1.1) a) Click the “Gain”...

  • Page 58: Setting Output Dry Contact Status

    Communication (continued) 3.2 Setting Output Dry Contact Status The UPS provides six output dry contact closures. The status of each output dry contact closure can be programmed from 19 status events: 1. Load on inverter (Default) 2. Load on auto bypass (Default) 3.

  • Page 59: Upgrading Firmware For The System Board

    Communication (continued) 3.3 Upgrading Firmware for the System Board WARNING: Make sure that the UPS is in bypass mode and that all power modules have been completely de-energized. WARNING: When the system is in manual bypass mode, bypass power is still present in the output terminal block.
  • Page 60 Communication (continued) 3.3 Upgrading Firmware for the System Board (continued) To upgrade the system’s fi rmware: a) Confi rm that the Main Input Breaker (Q1) and Output Breaker (Q4) are both OFF, and that Bypass Input Breaker (Q2) and Manual Bypass Breaker (Q3) are both ON (Figure 3.3b).
  • Page 61 Communication (continued) 3.3 Upgrading Firmware for the System Board (continued) b) Select “System Firmware Upgrade” using the LCD panel (Figure 3.3c). (Maintenance Firmware Upgrade Login (Administrator) System Firmware) & & Fig 3.3c...
  • Page 62 Communication (continued) 3.3 Upgrading Firmware for the System Board (continued) c) After confi rming the command, wait for the LCD to display “READY TO DOWNLOAD FIRMWARE!” (Figure 3.3d). Note 1: Once you confi rm the command, the system will go into “system fi rmware upgrade” mode. If you want to cancel the upgrade command before programming, the BYPASS input breaker (Q2) must be turned off.
  • Page 63 Communication (continued) 3.3 Upgrading Firmware for the System Board (continued) e) Run the program “FSL 3.75.exe” (Figure 3.3e). f) Select the PC COM Port and Click “Open.” Fig 3.3e g) Disable “Reading Comparison” (Figure 3.3f). Fig 3.3f...

  • Page 64: Upgrading Firmware For The Power Module

    Communication (continued) 3.3 Upgrading Firmware for the System Board (continued) h) Load the new fi rmware fi le and click “Upgrade” (Figure 3.3g). i) Once the system fi nished upgrading its fi rmware, it will auto-reset into manual bypass mode (Figure 3.4h). LOAD UNPROTECTED LOAD UNPROTECTED ON MANUAL BYPASS...
  • Page 65 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) Before upgrading your fi rmware, please verify the fi rmware version using the control panel (Fig 3.4a). (Maintenance Others SN & FW Version) To upgrade the power module’s fi rmware: a) Confi...
  • Page 66 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) Note: Confi rm that you’ve turned on the breaker for the external battery cabinet or internal battery. b) Select “Power Module Firmware Upgrade” using the LCD panel. (Figure 3.4c) (Maintenance tor) Power Module Firmware) &...
  • Page 67 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) c) Select “ON” to upgrade the power module’s fi rmware and press “ DOWNLOAD FIRMWARE!” (Figure 3.4d). Note 1: Once you confi rm the command, the system will go into “system fi rmware upgrade” mode. If you want to cancel the upgrade command before programming, the BYPASS input breaker (Q2) must be turned off.
  • Page 68 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) e) Run the program “NH_PM_V1_4B1207.exe” (Figure 3.4e). f) Click the “Firmware Upgrade” icon, select PC COM Port and click “Open COM Port.” Fig 3.4e g) Select the PFC DSP chip or INV DSP chip, along with power modules 1-4 (Figure 3.4f). Fig 3.4f...
  • Page 69 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) h) Load the new fi rmware fi le for the PFC (or Inverter) and click “Upgrade” (Figure 3.4g). Fig 3.4g...
  • Page 70 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) Fig 3.4h Note 1: During programming, the status indicator is red. When upgrade is complete, the status indicator will turn green (Figure 3.4h). Fig 3.4i Note 2: When one power module upgrade is complete, the system will automatically begin upgrading the next power module (Figure 3.4i).
  • Page 71 Communication (continued) 3.4 Upgrading Firmware for the Power Module (continued) Note 3: Once all power modules are complete, the status indicators will all turn green (Figure 3.4j). i) Once all fi rmware upgrades are complete, select “OFF” to disable the power module fi rmware upgrade. (Figure 3.4k) Note: When you disable the power module’s fi...

  • Page 72: Downloading The Event Log

    Communication (continued) 3.5 Downloading the Event Log To download the UPS event log: a) Link the UPS with a PC via the RS232 port. b) Run the program “NH-EventLog v1.0b1115.exe” (Figure 3.5a). c) Select PC COM Port and click “Open COM Port.” d) Click “Get UPS Event Log”...

  • Page 73: Internal Battery

    Internal Battery The SU20KX, SU40KX and SU40K models all use a +/-240Vdc (480V) DC internal battery system. An internal battery pack (number of packs vary by model) supplies the UPS system with battery backup power. Each internal battery pack consists of 40 12Vdc VRLA batteries arranged in two strings: one string of 20 positive batteries (black cable) and one string of 20 negative batteries (red cable).

  • Page 74: Installing And Removing Internal Batteries

    Internal Battery (continued) 4.1 Installing and Removing Internal Batteries • Place the UPS system in bypass (or turn it completely off) and turn off the internal battery circuit breaker switch, located on the rear of the UPS system. • Remove the battery access bezels, located on the front of the UPS system.
  • Page 75 Internal Battery (continued) 4.1 Installing and Removing Internal Batteries (continued) • Slide a battery string with a red cable into an empty slot within the battery compartment. Make sure the battery string is oriented as shown in the diagram. Note: Start with the empty slots at the bottom of the battery compartment and work toward the empty slots at the top of the battery compartment.
  • Page 76 220V and 280V DC (nominal 240V DC). If several voltmeter tests yield results outside the acceptable DC voltage range, contact Tripp Lite for assistance in determining the possible causes of the incorrect voltage reading before proceeding.

  • Page 77: Battery Cabinet

    Internal Battery (continued) 4.2 Battery Cabinet The standard battery cabinet includes two models: BP480V26B (Figure 4.2a) and BP480V40C (Figure 4.2b). (See Table 4.2a for battery cabinet weight and fl oor loading) Table 4.2a Weight Floor Loading Battery Capacity Voltage Amp/Hour Battery Type Fig 4.2a BP480V26B Fig 4.2b BP480V40C...
  • Page 78 Internal Battery (continued) 4.2 Battery Cabinet (continued) Both battery cabinet models have a Q board installed on the rear (Figure 4.2c). Fig 4.2c Q board functions include: • Battery temperature detection: The UPS detects the temperature of the battery cabinet and compensates the battery voltage. •...
  • Page 79 Internal Battery (continued) 4.2 Battery Cabinet (continued) To connect the external battery cabinet to its UPS system, use the W1 and W2 cables (Figure 4.2d) to connect the Q boards (Figure 4.2e) using the ports illustrated (Figure 4.2f). Temperature sensor Battery Cabinet (for standard B/C type) Fig 4.2d W1 and W2 Cables Fig 4.2e Connection between UPS and Battery Cabinet...

  • Page 80: Troubleshooting

    Troubleshooting 5.1 Alarm Messages Alarm messages are displayed on the LCD control panel. Press the “UP” and “DOWN” buttons to scroll through all alarm messages. Table 5.1a Warning Message List Warning Message MAIN VOLT/FREQ NOK MAIN SEQUENCE NOK BYPASS VOLT/REQ NOK BYPASS SEQUENCE NOK BYPASS STATIC SWITCH OVER TEMPERATURE BYPASS STATIC SWITCH FAULT...
  • Page 81 Troubleshooting (continued) 5.1 Alarm Messages (continued) Alarm messages are displayed on the LCD control panel. Press the “UP” and “DOWN” buttons to scroll through all alarm messages. Table 5.1b Power Module Warning Message List Warning Message PWR MODULE #n PFC FUSE OPEN PWR MODULE #n INVERTER FUSE OPEN PWR MODULE #n GENERAL FAULT PWR MODULE #n CHARGER FAILURE...

  • Page 82: Troubleshooting Flow Charts

    Note (1): For SU20KX, SU40KX and SU40K models, wire #1 is connected between the P board (CNP7) and FA (CNA9) for main input. (See chap- ter 1.5.) For SU60KX, SU80KX, SU60K, SU80K, SU60KTV and SU80KTV, wire #1 is connected between the P board (CNP7) and F1 (CNF15) for main input.

  • Page 83: Main Sequence Nok

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.2 “MAIN SEQUENCE NOK” This may occur during startup or if the customer changes their charger generation or main input source improperly. input external wiring input phase sequence Start Is the main correct? Is the main Correct phase rotation...

  • Page 84: Bypass Volt/Freq Nok

    Note (1): For SU20KX, SU40KX and SU40K models, wire #11 is connected between P board (CNP8) and FA (CNA9) for bypass input. (See chapter 1.5.) For SU60KX, SU80KX, SU60K, SU80K, SU60KTV and SU80KTV, wire #11 is connected between P board (CNP8) and F1 (CNF15) for bypass input.

  • Page 85: Bypass Sequence Nok

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.4 “BYPASS SEQUENCE NOK” 5.2.5 “BYPASS STATIC SWITCH OVER TEMPERATURE” Start Is the UPS loading too high? Reduce loading Note (1): The fans are installed at the heat-sink of the bypass static switch. (See section 1.5) Note (2): The NTC is mounted on the heat-sink of bypass static switch (Figure 5.2.5b).

  • Page 86: Bypass Static Switch Fault

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.6 “BYPASS STATIC SWITCH FAULT” Note (1): Use a multimeter to measure the pins of bypass SCRs. If the ohm value is close to zero, it indicates that the SCR has failed. (For the location of bypass SCRs, turn to section 1.5) Note (2): For the location of the NHS-SYS-M board, turn to section 1.5.

  • Page 87: Ups Internal Comm Abnormal

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.8 “UPS INTERNAL COMM ABNORMAL” Start Has the communication wire slipped ? Re-insert communication wire and try again Note (1): Check W2A, W2B, W2C, W2D, W4A, W4B and W6 (Fig 5.2.8b). Note (2): Remove wires W61A, W65A and W68A. Remove power connection of power module #1 Still getting the...

  • Page 88: Battery Test Fail

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.9 “BATTERY TEST FAIL” Note (1): To learn about EEPROM parameter settings and calibration, turn to section 3.2. Note (2): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM chip from the old NHS-SYS-M board and insert it into the new one.

  • Page 89: Battery Bad

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.11 “BATTERY BAD” Start the battery circuit breaker turned on ? Is the external wiring correct? Are the actual value and LCD value the same ? Battery broken Replace battery Note (1): Wire #31 connects CNP10 on the NH-SYS-P board to CNB7 on the NH-SYS-B board (Figure 5.2.11b). Note (2): To learn about EEPROM parameter settings and calibration, turn to section 3.2.

  • Page 90: Bypass Fan Failure

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.12 “BYPASS FAN FAILURE” Start Is the UPS in bypass mode? fan A spinning? Replace the S board or M board Note (1): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM chip from the old NHS-SYS-M board and insert it into the new one.

  • Page 91: Transformer Overheat

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.13 “TRANSFORMER OVERHEAT” Start Is the UPS loading too high? Reduce loading Note (1): Models with C–cabinets are: SU40K, SU60K, SU80K, SU60KTV and SU80KTV. Note (2): See Figure 5.2.13b for location. Note (3): For the location of the NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM chip from the old NHS-SYS-M board and insert it into the new one.

  • Page 92: Ps Output Volt Nok

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.14 “PS OUTPUT VOLT NOK” Start Is the output wire connection Are the Actual value and LCD value the same ? Check if any power module output voltages are out of range Note (1): Wire #10 connects CNP9 on the NH-SYS-P board with CNFC20 on the NH-SYS-FC board (Figure 5.2.14b). Note (2): To learn about EEPROM parameter setting and calibration, refer to section 3.2.

  • Page 93: Ps Ext Parallel Comm Abnormal

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.15 “PS EXT PARALLEL COMM ABNORMAL” Check firmware first, follow firmware procedure Has the parallel wire slipped? Re-insert the parallel wire and try again Note (1): The external parallel wire is located on the rear panel (Figure 5.2.15b). Start Parallel communication failed Replace the R board...

  • Page 94: Parallel Failure

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.16 “PARALLEL FAILURE” Note (1): Figure 5.2.16b shows the EEPROM’s power rating settings (Rating VA). To learn about EEPROM parameter settings, turn to section 3.2. Note (2): Access parallel ID settings using the LCD control panel (bypass mode only). (UPS SETUP Start Are both Make sure the units...

  • Page 95: Redundancy Loss

    Troubleshooting (continued) 5.2 Troubleshooting Flow Charts (continued) 5.2.17 “REDUNDANCY LOSS” Note (1): Access the redundancy setting using the LCD control panel (only in bypass mode). (UPS SETUP Select the power module’s redundancy number. EX: 40kVA UPS, load < 20kVA, redundancy number =1. If one power module proves abnormal, another power module will continue to supply the load without interruption.

  • Page 96: Power Module

    Power Module 6.1 Failure Power Module Identify WARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it continues to supply power to the critical load (the critical load is supported directly by utility power). These instructions will help you diagnose which power modules have failed and which are protected.
  • Page 97 Power Module (continued) 6.1 Failure Power Module Identify (continued) 3) Check the information of DC BUS voltage. (Figure 6.1c) (Maintenance the DC BUS voltage of a power module is about +/- 370Vdc. Use this number to confi rm which power module is abnormal. 4) Check the Output of Power modules.
  • Page 98 Power Module (continued) 6.1 Failure Power Module Identify (continued) 5) (Use this step to shut down the UPS with load protection) Set UPS to manual bypass mode. If the UPS is on normal mode, press the “OFF” button to enter bypass mode. Then turn on the manual bypass circuit breaker (Q3) and turn off the output circuit breaker (Q4).

  • Page 99: Power Module Replacement

    Power Module (continued) 6.2 Power Module Replacement WARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it continues to supply power to the critical load (the critical load is supported directly by utility power). WARNING: Make sure that the UPS unit is shut down completely.
  • Page 100 Power Module (continued) 6.2 Power Module Replacement (continued) b) Disconnect the power module (Figures 6.2c and 6.2d). AC INPUT +12V Rev. – DC INPUT Fig 6.2c W65A W61A W68A W66B W62B W69B W63C W67C W70C W36D W64D W71D Fig 6.2d ID Detect Comm.
  • Page 101 Power Module (continued) 6.2 Power Module Replacement (continued) c) Unscrew the rear panel of the power module (Figure 6.2e). d) Remove the corner bezels of the power module from the front side (Figure 6.2f). e) Unscrew the front bezel (Figure 6.2g). Remove the front bezel.
  • Page 102 Power Module (continued) 6.2 Power Module Replacement (continued) g) Unscrew the front of the power module (Figure 6.2h). Fig 6.2h h) Remove the power module (Figure 6.2i). Fig 6.2i...

  • Page 103: Preventive Maintenance

    Preventive Maintenance 7.1 Safety Overview Hazardous voltages and currents are present in this equipment! Hazardous energy is stored and will still be present even when the equipment is turned off and removed from power mains! Personal protective equipment is required when working on this equipment. This includes safety glasses, insulated gloves, and insulating blankets to prevent shorts or accidental contact with live circuits.

  • Page 104: Internal Battery Procedure

    Preventive Maintenance (continued) 7.3 UPS Procedure (continued) 7.3.5 Measure Ø to Ø and Ø to Neutral output voltage and output current as above and enter the values on the form. Compare the readings to the LCD display. If the voltage readings are within +/- 1% and the current readings are within +/- 1 ampere, check output metering OK on the form. If there is a greater discrepancy, enter that in NOTES.

  • Page 105: Appendix A Service Equipment And Tools

    Preventive Maintenance (continued) 7.4 Internal Battery Procedure c) Use the infrared thermometer to measure the ambient temperature near the battery module and the internal temperature of the battery module. Note that the best place to read ambient temperature is on the fl oor immediately behind the battery module. Battery module internal temperature should be taken at one of the jars on a top tier.

  • Page 106: Appendix B Torque Table

    Appendix B Torque Table KX Models Tables B.1 and B.2 list the torque for terminal block connection. (For TB locations, see Figure B.a.) Table B.1 Input TB Bypass TB Battery TB OUTPUT TB Ground Input TB Bypass TB Battery TB OUTPUT TB Ground SU20KX...
  • Page 107 Battery TB OUTPUT TB Ground Input TB Battery TB OUTPUT TB Ground Input Bar Battery TB OUTPUT Bar Ground SU60KX Torque lb-in (kgf-cm) 50 (57.6) 50 (57.6) 50 (57.6) 50 (57.6) 130.2 (150) SU80KX 50 (57.6) 50 (57.6) 50 (57.6) 50 (57.6)
  • Page 108 Appendix B Torque Table (continued) K Models Fig B.b. Fig B.c.
  • Page 109 Appendix B Torque Table (continued) KTV Models Table B.4 lists the torque for terminal block connection. (For TB locations, see Figure B.d.) Table B.4 Input TB Battery TB OUTPUT TB Ground Input TB Battery TB OUTPUT TB Ground SU60KTV Torque lb-in (kgf-cm) 50 (57.6) 50 (57.6) 50 (57.6)

  • Page 110: Appendix C Pcb And Test Point

    Appendix C PCB and Test Point NH-SYS-P Board TPP1: Reference ground (GND) of control circuit power TPP2: +12V of control circuit power TPP4: -12V of control circuit power NH-SYS-R Board TPR1: Reference ground (GND) of control circuit power TPR2: Synchronous signal TPR3: Reference ground (GND) of communication circuit power TPR4: +5V of communication circuit power TPR5: +12V of communication circuit power...

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