Page 3 UNINTERRUPTIBLE AC POWER SOURCE INSTALLATION AND OPERATION MANUAL THE INFORMATION CONTAINED IN THIS MANUAL IS PROPRIETARY TO PACIFIC POWER SOURCE INC THIS MANUAL MAY NOT BE COPIED OR REPRINTED WITHOUT THE EXPRESSED WRITTEN CONSENT. PACIFIC POWER SOURCE, INC 17692 FITCH IRVINE, CA.
Page 4 REVISION CONTROL PAGE Revision Date Pages Approved Per EO5696 10/20/04 Title Page/ Revision Control Page, 173 Rev B – 173G Rev B...
Page 5: Table Of Contents
INPUT POWER ....... 2.1.2 BATTERY POWER ......2.1.3 OUTPUT POWER ......MECHANICAL SPECIFICATIONS ...... 2.2.1 3060-UMS ........2.2.2 BATTERY CABINET ......INSTALLATION ........PLANNING THE JOB ....... MOVING, UNCRATING, AND INSPECTION ....CHANGING INPUT VOLTAGE ......SETTING THE CABINET INTO PLACE ....
Page 6: Title
TABLE OF CONTENTS Para. Title Page OPERATION ........... INSPECTION OF INSTALLATION ..... INSTALLATION RECORD ......OPERATING PROCEDURES ......4.3.1 FIRST TIME OPERATION ...... 4.3.2 PARALLEL CABINET OPERATION ....4.3.3 NORMAL SHUTDOWN PROCEDURE ....4.3.4 EMERGENCY SHUTDOWN PROCEDURE ....4.3.5 MODES OF OPERATION ......DESCRIPTION OF CONTROLS AND INDICATORS ..
Page 7 TABLE OF CONTENTS Para. Title Page MAINTENANCE ......... 115 POWER SOURCE MAINTENANCE SCHEDULE ....115 BATTERY MAINTENANCE AND TESTING ....119 SERVICE ..........125 DESCRIPTION ........126 6.1.1 MAINFRAME DESCRIPTION ..... 126 6.1.2 CONTROL MODULE DESCRIPTION ....130 6.1.3 INVERTER DESCRIPTION ...... 132 THEORY OF OPERATION ......
Page 8 FIGURE 1.3 UPS FUNCTIONAL BLOCK DIAGRAM ..... FIGURE 1.6 GROUNDING ........FIGURE 2.1.2 BATTERY SUPPORT TIME ......FIGURE 2.2.1 3060-UMS OUTLINE DRAWING ......FIGURE 2.2.2 BATTERY CABINET OUTLINE DRAWING ....FIGURE 3.1 ENVIRONMENTAL SURVEY CHECKLIST ....FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING ....
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Page 11: Scope
SCOPE MANUAL DESCRIPTION This manual written provide information required 3060-UMS Uninterruptible Power Source effectively. This manual is an Operations Manual. Installation, operation and maintenance are principal subjects of this manual. 1.1.1 USING THIS MANUAL This manual primarily covers installation and operation.
Page 12: Figure 1.1 3060-Ums
SECTION 1 GENERAL FIGURE 1.1 3060-UMS...
Page 13: Safety Notices
SECTION 1 GENERAL SAFETY NOTICES 3060-UMS capable transferring very large amounts of electrical energy very quickly. This basic quality fundamental high-performance power source. The batteries are connected in series to produce ± 200VDC at several hundred amps. The warnings and cautions listed below should be observed at all times.
Page 14 SECTION 1 GENERAL SAFETY NOTICES (Cont) WARNING DO NOT REMOVE ANY PANEL OR COVER WITHOUT FIRST REMOVING INPUT SERVICE OPENING ALL CIRCUIT BREAKERS. SERVICE OTHER THAN EXTERNAL CLEANING SHOULD REFERRED PERSONNEL AUTHORIZED BY THE FACTORY TO SERVICE THIS EQUIPMENT. WARNING CAUTION READ SECTIONS 3 AND 4 OF THIS MANUAL BEFORE INSTALLING OR OPERATING THIS EQUIPMENT.
Page 15: General Product Description
50 - 400 Hz. The basic 62.5 kVA / 50 kW unit is designated as the model 3060-UMS. Up to 10 units are paralleled to provide 625 kVA / 500 kW. The 3060-UMS functions as a double conversion Power Source.
Page 16: Figure 1.3 Ups Functional Block Diagram
SECTION 1 GENERAL FIGURE 1.3 UPS FUNCTIONAL BLOCK DIAGRAM...
Page 17: Major Component Description
SECTION 1 GENERAL MAJOR COMPONENT DESCRIPTION paragraphs below provide descriptions major components used in the 3060-UMS. 1.4.1 UNINTERRUPTIBLE POWER SOURCE (UPS) components within Cabinet separate battery cabinet which function as a system to provide continuous, conditioned AC power to the load.
Page 18: Rectifier/Charger
SECTION 1 GENERAL 1.4.4 RECTIFIER/CHARGER component that contains equipment controls necessary to convert the input AC power to regulated DC power for the inverter and to charge the batteries. rectifier/charger unit solid-state device designed to provide direct current to the inverter unit and charge the batteries.
Page 19: Inverter
SECTION 1 GENERAL 1.4.5 INVERTER The inverter unit is a solid-state device that derives its power from the output of the rectifier/charger or batteries provide rated output within specified limits. A high frequency pulse-width modulated switcher. The output frequency of the inverter is controlled by a digital oscillator with fixed frequencies of 50, 60 and 400 Hz.
Page 20: Utility Inverter
A system may be from one to ten cabinets in parallel. Cabinets may be paralleled together for higher power systems. Each 3060-UMS is capable of operating as either a SLAVE or MASTER in multi-cabinet paralleled system. The Mean Time Between Failure of a single cabinet 3060- UMS is quite high (approx.
Page 21: Figure 1.6 Grounding
SECTION 1 GENERAL FIGURE 1.6 GROUNDING...
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Page 23: Specifications
SPECIFICATIONS SPECIFICATIONS This section states electrical mechanical specifications for one 3060-UMS Uninterruptible AC Power Source. For paralleled systems the output amps and power will increase by the number of cabinets on line. ELECTRICAL SPECIFICATIONS 2.1.1 INPUT POWER Voltage Range 480, 380, 240 or 208 VAC ±15%.
Page 24 SECTION 2 SPECIFICATIONS 2.1.1 INPUT POWER (cont) Turn-on Surge 100% normal full load input inrush current, maximum. Power Factor 0.8 lagging at full load. Current 8% THD maximum. Distortion Input Controls Input contactors provide input ON- OFF controls. In addition, an input circuit breaker provided...
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Page 26: Battery Power
SECTION 2 SPECIFICATIONS 2.1.2 BATTERY POWER Type 12 volt, Sealed, non-venting lead acid. Quantity Two series strings of 15 batteries each for a total of 30 batteries. Capacity 120 AH. Weight 82 pounds each. Charge current 14 amps max. Charge voltage A two step charge voltage is used faster recharging.
Page 27: Figure 2.1.2 Battery Support Time
SECTION 2 SPECIFICATIONS FIGURE 2.1.2 BATTERY SUPPORT TIME...
Page 28: Output Power
SECTION 2 SPECIFICATIONS 2.1.3 OUTPUT POWER Power 50 kW. Volt-Amps 62.5 kVA. 120/208 3 φ WYE May be loaded WYE or Voltage DELTA. 0-132 VAC Adjustment Range. Other voltages available options. Output adjustable by front panel controls. Voltage Regulation ±1% of output voltage regardless 0-100% Load Step load unbalance,...
Page 29 SECTION 2 SPECIFICATIONS 2.1.3 OUTPUT POWER (cont) Frequency Range Selectable, crystal based frequencies at 50, 60, 400 Hz. A variable frequency oscillator included, covering the range 47-500 Hz. In addition, provision is made for an External Oscillator input. Frequency ±0.01% for fixed frequencies. Accuracy and Stability Power Factor...
Page 30: Mechanical Specifications
SECTION 2 SPECIFICATIONS MECHANICAL SPECIFICATIONS 2.2.1 3060-UMS Weight 1200 LBS Height 72" Width 36" Depth 30" Air Flow 1200 CFM bottom intake, top exhaust Noise level 65dbA at 3 feet Installation 36" front cabinet service, Clearance 12" top, 0" side and rear Operating 0 to 40 °...
Page 31: Figure 2.2.1 3060-Ums Outline Drawing
SECTION 2 SPECIFICATIONS FIGURE 2.2.1 3060-UMS OUTLINE DRAWING...
Page 32: Battery Cabinet
SECTION 2 SPECIFICATIONS 2.2.2 BATTERY CABINET Weight 2800 LBS including batteries. Height 60" Width 40" Depth 35.5" Installation 36" front cabinet service, Clearance 0" top and sides, 12" rear. 20 to 30 ° C. Ambient Temperature Relative 0 to 95% non-condensing Humidity Elevation 0 - 6500 Ft.
Page 33: Figure 2.2.2 Battery Cabinet Outline Drawing
SECTION 2 SPECIFICATIONS 40" 32.5" TRIPLE KNOCKOUTS: 1 3/32" x 1 31/32" x 3" 4 PLCS EACH SIDE 60" SIDE FRONT VENTILATION SLOTS 1 1/2" SINGLE KNOCKOUTS 6 PLCS BOTTOM BACK FIGURE 2.2.2 BATTERY CABINET OUTLINE DRAWING...
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Page 35 SECTION 3 INSTALLATION INSTALLATION This section describes the installation of a 3060-UMS Uninterruptible Power Source. information required to properly install UPS equipment is provided this section. thorough understanding this material is mandatory. Should a question arise regarding the installation of...
Page 36: Planning The Job
SECTION 3 INSTALLATION PLANNING THE JOB The main objective in planning the job is to determine hardware required install UPS. Proper consideration items below will allow installation to proceed in an orderly manner. The first step in planning the job is to determine the size of power source required to service the load.
Page 37: Figure 3.1 Environmental Survey Checklist
SECTION 3 INSTALLATION CHECK AT RIGHT WHEN CONFIRMED Ambient temperature between 20-30 degrees Centigrade. _____ Temperatures over the range 0-40 degrees are allowed with a decrease in battery life and capacity. Cooling and air exchange rates adequate to support _____ the heat load.
Page 38: Moving, Uncrating, And Inspection
SECTION 3 INSTALLATION MOVING, UNCRATING, AND INSPECTION Unless specified otherwise, all Pacific 3060-UMS UPS systems will be shipped in three separate wooden crates. Crate Number 1 contains the UPS Cabinet, with a crated weight between 1200-1300 lbs. depending upon the model selected.
Page 39: Figure 3.2 Crating And Moving Outline Drawing
SECTION 3 INSTALLATION FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING...
Page 40: Changing Input Voltage
SECTION 3 INSTALLATION CHANGING INPUT VOLTAGE This paragraph states the procedure to be used when changing input voltage. All voltages are line to line. Configure the machine for the correct input voltage prior to installing. To change input voltage, the input circuit breaker and fuses must be changed.
Page 41 SECTION 3 INSTALLATION CHANGING INPUT VOLTAGE (cont) WARNING OPENING INPUT CONTACTOR DOES NOT REMOVE INPUT VOLTAGE FROM INPUT TRANSFORMER. OPEN THE INPUT CIRCUIT BREAKER. WARNING STEP 1: Verify no input or battery power is connected. Open Input Circuit Breaker. STEP 2: Remove front covers.
Page 42: Figure 3.3.1 480 V Input Configuration
SECTION 3 INSTALLATION FIGURE 3.3.1 480 V INPUT CONFIGURATION...
Page 43: Figure 3.3.2 380 V Input Configuration
SECTION 3 INSTALLATION FIGURE 3.3.2 380 V INPUT CONFIGURATION...
Page 44: Figure 3.3.3 240 V Input Configuration
SECTION 3 INSTALLATION FIGURE 3.3.3 240 V INPUT CONFIGURATION...
Page 45: Figure 3.3.4 208 V Input Configuration
SECTION 3 INSTALLATION FIGURE 3.3.4 208 V INPUT CONFIGURATION...
Page 46: Setting The Cabinet Into Place
SECTION 3 INSTALLATION SETTING THE CABINET INTO PLACE Depending on the site, it may be advisable to rough-in the input and output wiring prior to moving the UPS into place. This is best evaluated by the installation team they should proceed appropriately.
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Page 48: Figure 3.4A System Interconnect Wiring
SECTION 3 INSTALLATION BATTERY CABINET FIGURE 3.4A SYSTEM INTERCONNECT WIRING...
Page 49: Figure 3.4B System Interconnect Wiring
SECTION 3 INSTALLATION FIGURE 3.4B SYSTEM INTERCONNECT WIRING...
Page 50: Connecting The Input Service
50-60 Hz, 100 Amp. 3 φ Delta, input service standard for the 3060-UMS. Check the name plate on the rear of the machine for input voltage. If a different input voltage required, machine must reconfigured.
Page 51 SECTION 3 INSTALLATION CAUTION...
Page 52: Figure 3.5 Input Terminal Detail
SECTION 3 INSTALLATION FIGURE 3.5 INPUT TERMINAL DETAIL...
Page 53: Connecting The Output Service
The standard output form of the 3060-UMS is 120/208Y, 50, 60, 400 Hz or Variable frequency. Phase sequence of the output is ABC. Maximum continuous output current is 175A. 370A is available into a short.
Page 54: Figure 3.6 Output Terminal Detail
SECTION 3 INSTALLATION FIGURE 3.6 OUTPUT TERMINAL DETAIL...
Page 55: Battery Installation
SECTION 3 INSTALLATION BATTERY INSTALLATION This paragraph describes the procedure to be used to install the battery cabinet assembly. Paragraph 3.7.1 deals with installing battery cabinet assembly. Paragraph 3.7.2 discusses electrical connections from the battery cabinet to the UPS cabinet. Paragraph 3.7.3 deals...
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Page 57: Battery Cabinet Installation
SECTION 3 INSTALLATION 3.7.1 BATTERY CABINET INSTALLATION This subsection describes the procedure to be used to set the battery cabinet into place. Figure 3.7.1 shows battery cabinet service clearances. The design of the cabinet allows it to be mounted with zero rear clearance.
Page 58: Figure 3.7.1 Battery Cabinet Service Clearances
SECTION 3 INSTALLATION FIGURE 3.7.1 BATTERY CABINET SERVICE CLEARANCES...
Page 59: Ups Cabinet To Battery Cabinet Connections
SECTION 3 INSTALLATION 3.7.2 UPS CABINET TO BATTERY CABINET CONNECTIONS This subsection discusses requirements wiring between the battery cabinet and UPS Cabinet. After battery cabinet place, wiring between the battery cabinet and the UPS cabinet is installed. The batteries are already installed in the cabinet at this time.
Page 60: Figure 3.7.2 Ups Cabinet Battery Terminal Detail
SECTION 3 INSTALLATION FIGURE 3.7.2 UPS CABINET BATTERY TERMINAL DETAIL...
Page 61 SECTION 3 INSTALLATION 3.7.3 BATTERY ORIENTATION AND WIRING The batteries are pre-wired at the factory. This section is for information purposes only. WARNING WHEN FOUR OR MORE BATTERIES ARE CONNECTED IN SERIES, LETHAL POTENTIALS EXIST. WEAR SAFETY GLASSES WHEN MAKING CONNECTIONS TO BATTERIES.
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Page 63: Battery Orientation And Wiring
SECTION 3 INSTALLATION 3.7.3 BATTERY ORIENTATION AND WIRING (cont) Inside the battery cabinet there are ten (10) batteries on each shelf. (See figure 3.7.3.) Be sure to note the polarity of the batteries, negative forward and positive back when doing maintenance or replacing batteries. The short jumper cables, from battery to battery, are installed using...
Page 64: Figure 3.7.3 Battery Orientation And Wiring
SECTION 3 INSTALLATION FIGURE 3.7.3 BATTERY ORIENTATION AND WIRING...
Page 65: Multiple Cabinet System
SECTION 3 INSTALLATION MULTIPLE CABINET SYSTEM This paragraph states the procedure to be used when connecting the two or more cabinets in parallel to make a Multiple Cabinet System. Proceed with installation of each cabinet as single cabinet power sources. Place each cabinet next to each other.
Page 66: Figure 3.8.1 Multiple Cabinet System Outline
SECTION 3 INSTALLATION FIGURE 3.8.1 MULTIPLE CABINET SYSTEM OUTLINE...
Page 67: Figure 3.8.2 Multiple Cabinet System One-Line Diagram
SECTION 3 INSTALLATION FIGURE 3.8.2 MULTIPLE CABINET SYSTEM ONE-LINE DIAGRAM...
Page 68: Rsp Iv Installation
SECTION 3 INSTALLATION RSP IV INSTALLATION This paragraph states the procedure to be used when connecting the RSP IV. The RSP IV connects to the 3060-UMS via J9 which is a DA15S connector machine. DA15P supplied for mating to this connector.
Page 69: Electrical Survey
INSTALLATION 3.10 ELECTRICAL SURVEY This paragraph provides a comprehensive checklist to be performed prior to first time power-up of the 3060-UMS Power Source. All work must be performed in accordance with applicable local, state, and national electrical codes. In the...
Page 70: Figure 3.10 Electrical Survey Checklist
SECTION 3 INSTALLATION CHECK AT RIGHT WHEN CONFIRMED In the Battery Cabinet, measure the voltage from the _____ neutral terminal block to the positive fuse. Verify the voltage is between +200 and +215 VDC. If the voltage is much less than +200 VDC a battery may be installed backward or mis-wired.
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Page 72: Operation
3060-UMS Uninterruptible AC Power Source. INSPECTION OF INSTALLATION Inspection of the installation is a very important step in the operation of the 3060-UMS Uninterruptible AC Power Source. This done safety measure prevent injury to personnel or damage to equipment.
Page 73: Installation Record
SECTION 4 OPERATION INSTALLATION RECORD During first time operation, Power Source Installation Record, Table 4.2, should be completed. This information will record initial operating parameters as well as providing the beginning of the maintenance and service record. Model, Serial and Modification Numbers may be found on a name plate at the upper rear of the cabinet.
Page 74 SECTION 4 OPERATION TABLE 4.2 INSTALLATION RECORD Cabinet and Site Information Model Number __________ Serial Number __________ Modification Numbers ___________________________ Customer Name ___________________________ ___________________________ Technical Contact ____________ ____________ Name Title Phone Number ________________ Ext. _____ Site Address ___________________________ ___________________________ Test Technician ___________________________ Date ___/___/___...
Page 75 SECTION 4 OPERATION TABLE 4.2 INSTALLATION RECORD (cont.) Technical Record Parameter Phase A Phase B Phase C Input Voltage (L-L) _______ _______ _______ Input Current _______ _______ _______ Output Voltage (L-N)_______ _______ _______ Output Current _______ _______ _______ Output kVA _______ _______ _______...
Page 76: Operating Procedures
Power Source operational states. Operation of the 3060-UMS Power Source has been designed to be simple and straightforward. This is done for several reasons the primary reason being safety. The addition of an Emergency Off Switch allows for quick action in the case of an emergency.
Page 77: First Time Operation
SECTION 4 OPERATION 4.3.1 FIRST TIME OPERATION This procedure is to be used to turn on a one Cabinet Power Source for the first time, or when service has been performed. Proceed as follows: STEP 1: Verify the AUTO RE-START option has been disabled by switching S14-1 OFF (refer to Section 4.5.2, figure 4.5.2.) Rotate the MODE SELECT switch to the OFF position.
Page 78 SECTION 4 OPERATION 4.3.1 FIRST TIME OPERATION (cont.) STEP 5: Place the cabinet in the STANDBY state by rotating the Mode Select Switch to STANDBY and pressing the START/RESET button. STANDBY lamp will illuminate. The high voltage power supplies are now energized, batteries charging...
Page 79: Parallel Cabinet Operation
SECTION 4 OPERATION 4.3.2 PARALLEL CABINET OPERATION This procedure is to be used to turn on the Paralleled Cabinet System for the first time, or when service has been performed on a cabinet. Proceed as follows: STEP 1: Inspect the installation. Verify that the wiring is correct (refer to Section 3.8, figure 3.8.2).
Page 80 SECTION 4 OPERATION 4.3.2 PARALLEL CABINET OPERATION (cont) STEP 6: On the MASTER, turn the Volts Adjust down to 0 VAC. Rotate the MODE SELECT to ON and press START/RESET. Select one and only one SLAVE. Rotate it's MODE SELECT to ON, and press START/RESET. Verify the MASTER and SLAVE output currents are less than 10 amps.
Page 81: Normal Shutdown Procedure
SECTION 4 OPERATION 4.3.3 NORMAL SHUTDOWN PROCEDURE This procedure describes how to place the Power Source into the normal Off state. One of two conditions may be desired when turning off the Power Source: Secure power from the Power Source. Turn off high voltage power supplies, inverters and output to the load.
Page 82: Emergency Shutdown Procedure
SECTION 4 OPERATION 4.3.4 EMERGENCY SHUTDOWN PROCEDURE Emergency shutdown is accomplished by depressing the EMER OFF Switch at any time. The principle function of the Emergency Off state is to open the input and output contactors in the event of internal Power Source failure.
Page 83: Modes Of Operation
SECTION 4 OPERATION 4.3.5 MODES OF OPERATION There are six possible modes of operation: Off State Stand By State On State Emergency Off State Slave State Auto Re-Start These states are achieved as described below: OFF STATE The OFF state is achieved by rotating the Mode Select Switch to Off.
Page 84 SECTION 4 OPERATION 4.3.5 MODES OF OPERATION (cont) STANDBY STATE STANDBY is when the input and/or battery contactor is closed and the machine is ready to deliver power to a load but the output contactor is open. The batteries are charging if input power is ok.
Page 85 SECTION 4 OPERATION 4.3.5 MODES OF OPERATION (cont) EMER OFF STATE EMER OFF causes the machine to be dead except for the low voltage power supply. The EMER OFF push button shall be lit. The following shall cause an EMER OFF: EMER OFF BUTTON, the EMER OFF push button has been pressed.
Page 86 SECTION 4 OPERATION 4.3.5 MODES OF OPERATION (cont) SLAVE STATE SLAVE causes the machine to act as a slave in a multi cabinet system. The machine is a SLAVE if the FREQUENCY SELECT switch is rotated to SLAVE, and a MASTER if in any other position.
Page 87: Description Of Controls And Indicators
SECTION 4 OPERATION DESCRIPTION OF CONTROLS AND INDICATORS The controls and indicators for the 3060-UMS are located on the front panel of the Power Source cabinet. As shown in figure 4.4 the Front Panel is divided into 3 basic regions: LCD and Interrogation Section.
Page 88: Figure 4.4 3060-Ums Front Panel
SECTION 4 OPERATION FIGURE 4.4 3060-UMS FRONT PANEL...
Page 89: Figure 4.4.1 Lcd And Interrogation Switches
SECTION 4 OPERATION FIGURE 4.4.1 LCD AND INTERROGATION SWITCHES...
Page 90: Lcd And Interrogation Switches
SECTION 4 OPERATION 4.4.1 LCD AND INTERROGATION SWITCHES This paragraph provides a detailed description of each Power Source message, how it is obtained, and it's meaning. four line, character Liquid Crystal display provides the communication interface between the Power Source and the operator. 4.4.1.1 INPUT KEY The INPUT Key is used to display the current status of...
Page 91 SECTION 4 OPERATION 4.4.1.2 OUTPUT KEY The OUTPUT Key is used to display the current status of all Power Source output power parameters. It may be pressed at any time power is applied to the cabinet. When the OUTPUT then f1 keys are depressed, message O1 will be displayed showing Single Cabinet Efficiency and output Frequency.
Page 92: Output Key
SECTION 4 OPERATION 4.4.1.2 OUTPUT KEY (cont) When the OUTPUT then f4 keys are depressed, message O4 will be displayed showing Remotely Sense signals from Remote Metering connector Remote Sense frequency, output volts (Phase to Neutral and Phase to Phase,) Amps, kW and kVA information are displayed for each phase.
Page 93 SECTION 4 OPERATION 4.4.1.3 STATUS KEY (cont) Displayed when the Power Source is in the Normal ON state. The ON lamp shall be lit. Output Frequency and %LOAD (the highest of any percent load as described in the Output O2 message) is displayed. Single Cabinet output volts (Phase to Neutral and Phase to Phase,) Amps information is displayed for each phase.
Page 94 SECTION 4 OPERATION 4.4.1.3 STATUS KEY (cont) Displayed when the Power Source is in an Alarm condition caused by an OUTPUT OVER VOLTAGE. S8: CAB IS ON - WARNING OVER VOLTAGE XXX/XXX XXX/XXX XXX/XXX FREQ=XXX.X %LOAD Displayed when the Power Source is in an Alarm condition caused by an OUTPUT UNDER FREQUENCY.
Page 95: Diagnostic Key
SECTION 4 OPERATION 4.4.1.4 DIAGNOSTIC KEY The Diagnostic (DIAG) key is dual purpose. First, by saving the cause of the Emergency Off state, an audit trail is provided for trouble shooting purposes. Second, technical operating parameters displayed recorded determining Power Source operational status.
Page 96 SECTION 4 OPERATION 4.4.1.4 DIAGNOSTIC KEY (cont) When the DIAG then f3 keys are pressed the results of the last battery test are displayed. BATT XXX % is the percentage of current delivered by the batteries as compared to calculated current. OK is displayed if the percentage is >...
Page 97 SECTION 4 OPERATION 4.4.1.4 DIAGNOSTIC KEY (cont) When the DIAG then f4 keys are pressed the digital inputs to the Display PCB are displayed. PORT # 2 PORT # 3 PORT # 4 PORT # 5 XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX EMER XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX XXXXXXXX This display shows the status of all of the 32 digital...
Page 98: Help Key
SECTION 4 OPERATION 4.4.1.5 HELP KEY The HELP key is provided to direct the operator with the proper course of action to turn on and operate the machine. Six different help messages are available for display. If the HELP key is pressed the first applicable message, H1 through H6, is displayed.
Page 99 SECTION 4 OPERATION 4.4.1.5 HELP KEY (cont) Displayed when the cabinet is in the Standby State. The cabinet is ready to deliver output power but the output contactor is open. Instructs the user to rotate the MODE SELECT switch to the ON position to turn on the output contactor.
Page 100: Alarm Key
SECTION 4 OPERATION 4.4.1.6 ALARM KEY Whenever ALARM is pressed message A1 appears. It remains displayed until some other button is pressed. Pressing ALARM momentarily there after has no effect. Pressing and holding ALARM for 2+ seconds shall cause the ALARM buzzer to change state between ENABLED and DISABLED (display text changes accordingly).
Page 101: Special Key Combinations
SECTION 4 OPERATION 4.4.1.7 SPECIAL KEY COMBINATIONS INPUT/STATUS/HELP: Pressed simultaneously shall cause software reset display CPU. OUTPUT/DIAG/ALARM: Pressed simultaneously shall clear the RAM.
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Page 103: Mode Select, Emergency Off, And On-Reset Switches
Power Source. 4.4.2.1 MODE SELECT SWITCH During normal operation of the 3060-UMS, control of the cabinet is through the MODE SELECT switch. The design of the switch is such that only one Mode Position can occur at any time.
Page 104: Figure 4.4.2 Mode Select, Emer Off, And Start/Reset
SECTION 4 OPERATION FIGURE 4.4.2 MODE SELECT, EMER OFF, AND START/RESET...
Page 105: Emergency Off And Start/Reset Switches
SECTION 4 OPERATION 4.4.2.2 EMERGENCY OFF AND START/RESET SWITCHES During normal operation of the Power Source, return to the OFF state is accomplished through the use of the Mode Select Switch. In the event of an emergency, the EMER button used cause immediate...
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Page 107: Frequency Select Switch And Volts Adjust
SECTION 4 OPERATION 4.4.3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST These switches also control the operation of the Power Source. The operator must be fully familiar with these switches and their function prior to operating the Power Source. 4.4.3.1 FREQUENCY SELECT SWITCH The primary of the Frequency Select Switch is to control the internal Oscillator.
Page 108: Figure 4.4.3 Frequency Select And Volts Adjust
SECTION 4 OPERATION FIGURE 4.4.3 FREQUENCY SELECT AND VOLTS ADJUST...
Page 109: Setup Switches
OPERATION SETUP SWITCHES This paragraph describes the PC mounted dip switches contained within the 3060-UMS AC Power Source, their purpose and location. Every effort has been made to simplify the Power Source design and it's maintenance. To this end, many common components are used throughout the product family.
Page 110: Figure 4.5 Cabinet Assembly
SECTION 4 OPERATION FIGURE 4.5 CABINET ASSEMBLY...
Page 111: Display Pcb
SECTION 4 OPERATION 4.5.1 DISPLAY PCB Refer to figure 4.5.1, Display PCB, part number 126572. Two switches are located on this assembly. Switch S42 is for testing and future use. Switch S41 provides the following configuration information to the Power Source: S41-1 S41-2 Machine Size...
Page 112: Figure 4.5.1 Display Pcb, Part Number 126572
SECTION 4 OPERATION FIGURE 4.5.1 DISPLAY PCB, PART NUMBER 126572...
Page 113: Control Pcb
SECTION 4 OPERATION 4.5.2 CONTROL PCB Refer to figure 4.5.2, Control PCB, part number 126572. One switch is located on this assembly. Switch S14 provides for enabling of the auto restart option and local or remote AGC (automatic gain control.) Switch S14 assignments are as follows: S14-1Auto Restart S14-2Undefined...
Page 114: Figure 4.5.2 Control Pcb, Part Number 126570
SECTION 4 OPERATION FIGURE 4.5.2 CONTROL PCB, PART NUMBER 126570...
Page 115: Feature Connectors
FEATURE CONNECTORS This paragraph describes Feature Connectors contained within the 3060-UMS AC Power Source, their purpose, location, and pin numbers. The use of these connectors is optional. Refer to figure 4.6 for location of these connectors. 4.6.1 P1, P2 PARALLELING These are used for Paralleling cabinets in multiple cabinet systems.
Page 116: Figure 4.6 Feature Connector Detail
SECTION 4 OPERATION FIGURE 4.6 FEATURE CONNECTOR DETAIL...
Page 117: J3 And J4 Serial I/O
J3 AND J4 SERIAL I/O This paragraph describes the Serial Ports available on the 3060-UMS Power Source. The 3060-UMS Power Source is provided with Dual Serial Communication Ports designated COM A and COM B. These output are RS-232-C Ports with bi-directional logic.
Page 118 Serial Port design is such that no "Handshaking" is required in hardware or software. Due to this fact, data transmitted 3060-UMS must limited characters per second. Data bursts are sent from the 3060-UMS in approximately 200ms increments. Refer Table 4.6.2. Hardware handshaking signals, (i.e.
Page 119 With the serial port, it is possible to obtain all Front Panel Display information described in section 4.4.1. This paragraph provides syntax brief description of all 3060-UMS recognized commands. Section 4.4.1 should be reviewed for detailed descriptions of returned messages. Command Command Type Information Type I1 <RET>...
Page 120 SECTION 4 OPERATION 4.6.2 J3 AND J4 SERIAL I/O (cont) Command Command Type Information Type D1 <RET> Diag. Screen #1 Cause of Emergency Off. D2 <RET> Diag. Screen #2 Temperature Data D3 <RET> Diag. Screen #3 DIAGNOSTIC BATTERY TEST, display prompts for display D5.
Page 121: J6 External Oscillator
SECTION 4 OPERATION 4.6.3 J6 EXTERNAL OSCILLATOR This is an External Oscillator Input. This connector is a DA15S type. If the Frequency Select Switch is rotated position cabinet inputs applied to J6 are amplified 25 times at the output terminals. Example: 4.80 VAC, 60 Hz input at J6 equals 120 VAC, 60 Hz at the output contactor.
Page 122: J8 Remote Metering Inputs
SECTION 4 OPERATION 4.6.5 J8 REMOTE METERING INPUTS J8 is a Remote Metering Input signal connector. Remote Volts are divided down by 100 to 1 and sent to this connector. Remote Amps are divided down by 400 to 1 and sent to this connector.
Page 123: J9 Auxiliary Alarm And Rsp Iv Outputs
SECTION 4 OPERATION 4.6.6 J9 AUXILIARY ALARM AND RSP IV OUTPUTS This connector alerts the user to conditions that cause alarm status in the cabinet and/or drives the Remote Status Panel (RSP IV.) Some of these are digital 0 to +5 VDC outputs designed to operate small relays which the user may utilize to operate remote lights and buzzers.
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Page 126: Maintenance
SECTION 5 MAINTENANCE MAINTENANCE The 3060-UMS has been designed so that maintenance is kept to an absolute minimum. This section describes the maintenance requirements of this equipment. Paragraph 5.1 describes the maintenance required by the Power Source. Paragraph 5.1 describes the maintenance required by the batteries.
Page 127 SECTION 5 MAINTENANCE TABLE 5.1 3060-UMS MAINTENANCE LOG EQUIPMENT MODEL NO. ____________________ EQUIPMENT SERIAL NO. ____________________ DATE: ____/____/____ TECHNICIAN: ____________________________ INPUT DATA I1: INPUT ____/____ ____/____ ____/____ ___NORMAL _________ _________ _________ _________ _________ _________ FREQ=________ _________ _________ _________ I2: INPUT...
Page 128 SECTION 5 MAINTENANCE TABLE 5.1 3060-UMS MAINTENANCE LOG (cont) OUTPUT DATA O1: CABINET ____/____ ____/____ ____/____ OUTPUT _________ _________ _________ EFF=____% _________ _________ _________ FREQ=______ _________ _________ _________ O2: CABINET ____/____ ____/____ ____/____ OUTPUT %I-PEAK _______ _______ _______ %kVA _______...
Page 129 SECTION 5 MAINTENANCE TABLE 5.1 3060-UMS MAINTENANCE LOG (cont) STATUS INFORMATION S__: CAB _____________________________________________ _______________________________________________________ _______________________________________________________ _______________________________________________________ DIAGNOSTIC INFORMATION D2: DIAGNOSTIC TEMPERATURE DATA XFMR: _____ DEG C INV: _____ Port # 2 Port # 3 Port # 4 Port # 5...
Page 130: Battery Maintenance And Testing
SECTION 5 MAINTENANCE BATTERY MAINTENANCE AND TESTING The UPS battery maintenance requirements are as stated below. The procedure should be performed at 3 month intervals. This test works best high loads becomes more inaccurate at light loads. The primary reason for this test is to monitor the batteries and to be able to detect and replace a weak battery.
Page 131 SECTION 5 MAINTENANCE BATTERY MAINTENANCE AND TESTING (cont) STEP 6: If both battery strings indicate OK, this concludes battery maintenance testing. either battery string indicates NOT OK, further testing is needed, continue to step 7. STEP 7: Consider replacing all of the batteries if any or all of the following are true: Batteries have been in service for several years.
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Page 133 SECTION 5 MAINTENANCE BATTERY MAINTENANCE AND TESTING (cont) STEP 9: This step should done quickly. Perform another battery test, steps 3 and 4 above. During the battery test measure the voltage across each battery and mark any batteries which are 1 volt or less than the average battery voltage.
Page 134 SECTION 5 MAINTENANCE TABLE 5.2 BATTERY MAINTENANCE LOG DATE: ____/____/____ TECHNICIAN: ____________________________ BATTERY STATUS I2: INPUT Bus/BATT BATT LVPS +_____VDC ______ADC +_____VDC +_____VDC ______ADC -_____VDC _______kW LAST BATTERY TEST D3: DIAGNOSTIC +BATT ________ % +_______V LAST BATTERY _____ OK ________A TEST.
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Page 136: Service
SECTION 6 SERVICE SERVICE 3060-UMS been designed using subassembly concept. This design feature allows for service via the assembly exchange approach. service procedures described in this section will isolate a problem to the replaceable assembly or component level as appropriate.
Page 137: Description
SECTION 6 SERVICE DESCRIPTION 6.1.1 MAINFRAME DESCRIPTION This paragraph describes various assemblies components Mainframe. Each assembly's component's function is described below. The numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.1 for the location of the assemblies and components listed below.
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Page 139 SECTION 6 SERVICE 6.1.1 MAINFRAME DESCRIPTION (cont) MAINFRAME COMPONENTS BR1-6, SCR Bridges (P/N 742008) C10-15, Filter Caps (P/N 720096-10) C30-39, Power Supply Caps (P/N 720219-12) CB1, Input Circuit Breaker 100A for 480 VAC Input (P/N 716049) 125A for 380 VAC Input (P/N 716056) 200A for 240 VAC Input (P/N 716057) 225A for 208 VAC Input (P/N 716032) CB2, Output Circuit Breaker Optional (P/N 716048)
Page 140: Figure 6.1.1 Mainframe
SECTION 6 SERVICE FIGURE 6.1.1 MAINFRAME...
Page 141: Control Module Description
SECTION 6 SERVICE 6.1.2 CONTROL MODULE DESCRIPTION This paragraph describes various assemblies components of the Control Module. Each assembly's and component's function is described below. The numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.2 for the location of the assemblies and components listed below.
Page 142: Figure 6.1.2 Control Module
SECTION 6 SERVICE FIGURE 6.1.2 CONTROL MODULE...
Page 143: Inverter Description
SECTION 6 SERVICE 6.1.3 INVERTER DESCRIPTION This paragraph describes various assemblies components of the Inverter assembly. Each assembly's and component's function is described below. The numbers listed are to be used when ordering spare assemblies and components. Refer to Figure 6.1.3 for the location of the assemblies and components listed below.
Page 144: Figure 6.1.3 Inverter
SECTION 6 SERVICE FIGURE 6.1.3 INVERTER...
Page 145: Theory Of Operation
SECTION 6 SERVICE THEORY OF OPERATION This paragraph describes the basic theory of operation for the 3060-UMS Uninterruptible AC Power Source. The information which follows provided technical reference to aid troubleshooting of the equipment. The system consists of five basic subsystems which are as follows: Control Term Definitions.
Page 146: Control Term Definitions
SECTION 6 SERVICE 6.2.1 CONTROL TERM DEFINITIONS 3 PHASE PRESENT True when all three input phases are present. Automatic Gain Control, provides better steady state regulation of the output voltage. AUTO RESTART PULSE Same as POWER ON RESET if selected. Battery Low Charge.
Page 147 SECTION 6 SERVICE 6.2.1 CONTROL TERM DEFINITIONS (cont) Input AC Normal. INPUT VOLTS Line to neutral input voltage. INPUT LINE FAULT True when Input voltage less than 80 % of nominal or greater than 120 % of nominal or 3 PHASE PRESENT is false.
Page 148 SECTION 6 SERVICE 6.2.1 CONTROL TERM DEFINITIONS (cont) MASTER LAMP whenever FREQUENCY SELECT switch is not in the SLAVE position. MASTER EMER OFF The master cabinet is in an EMER OFF state. Master line, least Cabinet is a Master. MOD ENABLE Modulator enable.
Page 149 SECTION 6 SERVICE 6.2.1 CONTROL TERM DEFINITIONS (cont) Remote mode 0. Remote mode 2. REMOTE VOLTS Remote line to neutral voltage. REMOTE SENSE Voltage and current metering from a remote location. selected to regulate to this point. REMOTE START True if the master is starting. REMOTE AMPS Remote amps...
Page 150 SECTION 6 SERVICE 6.2.1 CONTROL TERM DEFINITIONS (cont) UNDER FREQUENCY UF Condition exists output frequency less than preset limit. Limit is set by the ALARM KEY. UNDER VOLTAGE Condition exists output voltage is less than preset limit. Limit is set by the ALARM KEY. VDC >...
Page 151: Theory Of Operation - Power Conversion Circuits
SECTION 6 SERVICE 6.2.2 THEORY OF OPERATION - POWER CONVERSION CIRCUITS The power conversion circuits of the 3060-UMS power source consist of the following assemblies: Control PCB which contains the Oscillator Modulator PCB Inverter Assemblies (3 each) Figure 6.7.2 is a schematic of the mainframe. Figure 6.7.3 is a schematic of the inverter assembly.
Page 152: Theory Of Operation - Control Circuits
The Control PCB is mounted to the rear of the keyboard subpanel. The Control PCB assembly is central to the system control 3060-UMS mainframe. This monitors key system parameters and either allows or prohibits operation accordingly. Figure 6.7.1 is a block diagram of the system.
Page 153: Theory Of Operation - Dc Power Supply
SECTION 6 SERVICE 6.2.4 THEORY OF OPERATION - DC POWER SUPPLY The low voltage power supply transformer, T2, generates 3 phase 16/28 VAC for the low voltage DC power supplies and 3 phase 115 VAC for input contactor coils. The LVPS PCB generates a regulated ±...
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Page 155: Theory Of Operation - Display Circuits
Display PCB. CT11-CT13 provides the input current terms required by the Display PCB. Figure 6.2.5 is the block diagram for the meter and display portion of the 3060-UMS power source. The 2 serial ports and the RSP IV are controlled by the Display PCB.
Page 156: Figure 6.2.5 Block Diagram Display Circuits
SECTION 6 SERVICE FIGURE 6.2.5 BLOCK DIAGRAM DISPLAY CIRCUITS...
Page 157: Theory Of Operation - Paralleling Circuits
SECTION 6 SERVICE 6.2.6 THEORY OF OPERATION - PARALLELING CIRCUITS The paralleling circuits are located on the Control PCB. The Control PCB is mounted to the rear of the keyboard subpanel. The Master Cabinet's Control PCB assembly is central system control Multi-Cabinet paralleled...
Page 158: Troubleshooting Procedure
This paragraph outlines detailed troubleshooting procedure for the 3060-UMS. Read and understand section 4 of this manual prior to troubleshooting. These procedures apply to a single cabinet system or the master cabinet of a paralleled cabinet system with all slave...
Page 159: Performance Check
SECTION 6 SERVICE 6.3.1 PERFORMANCE CHECK The purpose of this paragraph is to provide a quick, yet thorough procedure that allows the user to verify that the UPS is operating properly. Always start with the performance check flow chart. The numbered comments below correspond to the circled numbers figure 6.3.1...
Page 160: Figure 6.3.1 Performance Check Flow Chart
SECTION 6 SERVICE FIGURE 6.3.1 PERFORMANCE CHECK FLOW CHART...
Page 161: Lvps Service Procedure
Low Voltage Power Supply of the 3060-UMS power source. Directions are given which locate a fault to the PCB level or component level as appropriate. Do not use this procedure unless instructed to do so by the performance check flow chart.
Page 162: Figure 6.3.2 Lvps Flow Chart
SECTION 6 SERVICE FIGURE 6.3.2 LVPS FLOW CHART...
Page 163: Display Service Procedure
Display Circuits 3060-UMS power source. Directions are given which locate a fault to the PCB level or component level as appropriate. Do not use this procedure unless instructed to do so by the performance check flow chart.
Page 164: Figure 6.3.3 Display Flow Chart
SECTION 6 SERVICE FIGURE 6.3.3 DISPLAY FLOW CHART...
Page 165: Emer Off Service Procedure
SECTION 6 SERVICE 6.3.4 EMER OFF SERVICE PROCEDURE troubleshooting procedure contained this paragraph is to be used to locate the cause of an EMER OFF condition. Directions are given which locate a fault to the PCB level or component level as appropriate. Do not use this procedure unless instructed to do so by the performance check flow chart.
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Page 167 SECTION 6 SERVICE 6.3.4 EMER OFF SERVICE PROCEDURE (cont) TRANSFORMER OVERTEMP indicates the input transformer has overheated. Allow to cool by leaving the fans on. This may take several hours. INVERTER TEMP indicates inverters overheated. A fan may have failed. LVPS FAULT indicates...
Page 168: Figure 6.3.4 Emer Off Flow Chart
SECTION 6 SERVICE FIGURE 6.3.4 EMER OFF FLOW CHART...
Page 169: No Inverter Volts Service Procedure
6.3.5 NO INVERTER VOLTS SERVICE PROCEDURE The troubleshooting procedure contained in this paragraph is to be used to locate a problem within the Inverter circuits 3060-UMS power source. Directions given which locate a fault to the PCB level or component level as appropriate.
Page 170: Figure 6.3.5 No Inverter Volts Flow Chart
SECTION 6 SERVICE FIGURE 6.3.5 NO INVERTER VOLTS FLOW CHART...
Page 171: Abnormal Voltage Service Procedure
Inverter circuits 3060-UMS power source. Directions are given which locate a fault to the PCB level or component level as appropriate. Do not use this procedure unless instructed to do so by the performance check flow chart.
Page 172: Figure 6.3.6 Abnormal Volts Flow Chart
SECTION 6 SERVICE FIGURE 6.3.6 ABNORMAL VOLTS FLOW CHART...
Page 173: Assembly Replacement Procedures
SECTION 6 SERVICE ASSEMBLY REPLACEMENT PROCEDURES This paragraph describes the various procedures to be used to replace assemblies contained in the 3060-UMS mainframe. WARNING ALWAYS REMOVE ALL INPUT AND BATTERY POWER FROM THE MAINFRAME PRIOR TO ATTEMPTING ANY SERVICE TO THE EQUIPMENT.
Page 174: Inverter Assembly Replacement
SECTION 6 SERVICE 6.4.1 INVERTER ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Inverter Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.1. STEP 1: Remove input and battery power. STEP 2: Remove front covers.
Page 175 SECTION 6 SERVICE 6.4.1 INVERTER ASSEMBLY REPLACEMENT (cont) STEP 6: Slide Inverter assembly into mainframe. Reinstall three screws bottom Inverter assembly. STEP 7: Replace Bus bars on the front of the inverters. Be careful not to spin the studs. Reconnect P33, the fan wires. STEP 8: Reconnect ribbon cables from Modulator PCB.
Page 176: Control Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.2 CONTROL PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Control PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.2. STEP 1: Remove input and battery power.
Page 177: Modulator Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.3 MODULATOR PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Modulator PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.2. STEP 1: Remove input and battery power.
Page 178: Display Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.4 DISPLAY PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Display PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.2. STEP 1: Remove input and battery power.
Page 179: Lvps Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.5 LVPS PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS LVPS Assembly. Input power MUST removed before attempting this procedure. See figure 6.1.2. STEP 1: Remove input and battery power. STEP 2: Remove front covers.
Page 180: Discharge Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.6 DISCHARGE PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Discharge PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.1. STEP 1: Remove input and battery power.
Page 181: Driver Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.7 DRIVER PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Driver PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.3. STEP 1: Remove Inverter assembly described section 6.4.1.
Page 182: Snubber Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.8 SNUBBER PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Snubber PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.3. STEP 1: Remove Inverter assembly described section 6.4.1.
Page 183: Regulator Pcb Assembly Replacement
SECTION 6 SERVICE 6.4.9 REGULATOR PCB ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Regulator PCB Assembly. Input power MUST be removed before attempting this procedure. See figure 6.1.1. STEP 1: Remove input and battery power.
Page 184 SECTION 6 SERVICE G2 Lead G1 Lead G1 / G2 Lead Positions STEP 6: Perform the following FIELD CALIBRATION procedure: 6.4.9. 6.1 SCOPE The purpose of this procedure is to establish a method to calibrate the UMS REGULATOR PCB at the client premises.
Page 185 SECTION 6 SERVICE 6.4.9. 6.2 SAFETY NOTICES (cont.) WARNING CARE MUST BE EXERCISED WHEN SERVICING THIS EQUIPMENT IN ORDER TO PREVENT SERIOUS INJURY TO THE OPERATOR OR EQUIPMENT DAMAGE. OBSERVE THE FOLLOWING WHEN SERVICE AND MAINTENANCE ARE REQUIRED: REMOVE ALL JEWELRY FROM ARMS AND NECK WHEN SERVICING THIS EQUIPMENT.
Page 186 SECTION 6 SERVICE 6.4.9. 6.3 TEST EQUIPMENT REQUIREMENTS 1) Digital voltmeter (Fluke 8010A or equivalent). 2) 50kW LOAD capable of 10kW steps (Cannon Load Banks Model L-69-80 or equivalent). 6.4.9. 6.4 TEST SETUP The test setup assumes the following: 1) Input power to the 3060UMS is disconnected. 2) The battery cabinet circuit breaker is open.
Page 187 SECTION 6 SERVICE 6.4.9. 6.5 PERFORMANCE TESTS The purpose of these load tests is to verify that the REGULATOR PCB shall perform as required. INITIAL CHECKS The following checks use the heat sink of the +12VDC regulator at U1 as ground reference. Apply input power to the 3060UMS with the MODE SELECT SWITCH set to OFF.
Page 188 SECTION 6 SERVICE While the battery test is running adjust the DC BUS voltage to 175VDC using R282. Allow the battery test to complete normally. At the end of the battery test turn the MODE SELECT SWITCH to STANDBY. Connect the battery cabinet to the DC BUSS by engaging the battery cabinet circuit breaker.
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Page 190: Utility Inverter Assembly Replacement
SECTION 6 SERVICE 6.4.10 UTILITY INVERTER ASSEMBLY REPLACEMENT This procedure is to be used to replace a 3060-UMS Utility Inverter Assembly. Input Power MUST removed before attempting this procedure. figure 6.1.1. STEP 1: Remove Input and Battery Power. STEP 2: Remove front covers.
Page 191 SECTION 6 SERVICE 6.4.10 UTILITY INVERTER ASSEMBLY REPLACEMENT (cont) STEP 6: Remove bars from front Output Inverters. Be careful not to spin the studs. Disconnect P33, the fan wires. Remove three screws at the bottom of the Output Inverter assembly. Slide three Output...
Page 192 SECTION 6 SERVICE 6.4.10 UTILITY INVERTER ASSEMBLY REPLACEMENT (cont) STEP 13: If you removed the Output Inverters continue to step 14. If you removed the rear panel skip to step 17. STEP 14: Slide the Output Inverter Assemblies back into the mainframe.
Page 193: Component Replacement Procedures
SECTION 6 SERVICE COMPONENT REPLACEMENT PROCEDURES This procedure provides procedures which allow the user to replace various components. The following paragraphs detail the order of disassembly/assembly for particular portions of the system. WARNING ALWAYS REMOVE ALL INPUT AND BATTERY POWER FROM THE MAINFRAME PRIOR TO ATTEMPTING ANY SERVICE TO THE EQUIPMENT.
Page 194: Input Power Panel Component Replacement
SECTION 6 SERVICE 6.5.1 INPUT POWER PANEL COMPONENT REPLACEMENT This procedure is used to replace components located on the Input Power Panel. Input power MUST be removed before attempting this procedure. STEP 1: Remove input and battery power. STEP 2: Remove front covers.
Page 195: Dc Power Supply Component Replacement
SECTION 6 SERVICE 6.5.2 DC POWER SUPPLY COMPONENT REPLACEMENT This procedure is used to replace components located on the Power Supply Panel assembly. Input power MUST be removed before attempting this procedure. STEP 1: Remove input and battery power. STEP 2: Remove front covers.
Page 196 SECTION 6 SERVICE 6.5.2 DC POWER SUPPLY COMPONENT REPLACEMENT (cont) STEP 6: Replace defective component. Replace screws as needed. Reconnect the AC wires as needed. Replace Bus bars as needed. STEP 7: Reinstall the panel holding the discharge PCB. Reconnect output cables to the Inverters. Reconnect cables to the discharge PCB.
Page 197: Inverter Component Replacement
SECTION 6 SERVICE 6.5.3 INVERTER COMPONENT REPLACEMENT This procedure is used to replace components located on Inverter assembly. Input power MUST removed before attempting this procedure. STEP 1: Remove Inverter assembly as described in section 6.4.1. STEP 2: Remove all screws holding the top screen and side covers.
Page 198: Returning Assemblies For Repair
DAMAGE IN TRANSIT. PACIFIC POWER SOURCE CORPORATION SHALL NOT BE RESPONSIBLE FOR REPAIR OF DAMAGE DUE TO IMPROPER PACKAGING AND HANDLING. If the equipment to be serviced is under warranty, Pacific Power Source Corporation will repair and return equipment, freight collect, original purchaser.
Page 199 SERVICE RETURNING ASSEMBLIES FOR REPAIR (cont) WARRANTY PROVISIONS Pacific Power Source Corporation warrants each unit to be free of defects in material and workmanship for a period of one year beginning with the date of shipment to the original purchaser. Excepted from this warranty are fuses and batteries which carry the warranty of their original manufacturer if applicable.
Page 200: Block And Schematic Diagrams
SECTION 6 SERVICE BLOCK AND SCHEMATIC DIAGRAMS This section contains D-Size drawings of an overall system block diagram figure 6.7.1, schematic diagrams for the Mainframe figure 6.7.2 and Inverter assemblies figure 6.7.3.
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Page 203: Figure 6.7.1 System Block Diagram
SECTION 6 SERVICE INSERT D SIZE FIGURE 6.7.1 HERE FIGURE 6.7.1 SYSTEM BLOCK DIAGRAM...
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Page 205: Figure 6.7.2 Mainframe Schematic
SECTION 6 SERVICE INSERT D SIZE FIGURE 6.7.2 HERE FIGURE 6.7.2 MAINFRAME SCHEMATIC...
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Page 207: Figure 6.7.3 Inverter Schematic
SECTION 6 SERVICE INSERT D SIZE FIGURE 6.7.3 HERE FIGURE 6.7.3 INVERTER SCHEMATIC...
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Page 209: Modifications
SECTION 7 MODIFICATIONS MODIFICATIONS Any modifications or changes to the UPS will be included in this section.