Page 1 100kW Power Conditioning System (PCS) Maintenance Manual Version: 1.0.0...
Page 2 Delta may modify or update the Manual from time to time without any notice. Delta will do its best to keep the Manual updated and maintain the accuracy of the Manual. Delta disclaims any kinds or forms of warranty, guarantee or undertaking, either expressly or implicitly, including but not limited to the completeness, accuracy, non-infringement, merchantability or fitness for particular purpose or usage.
Page 3: Table Of Contents
Maintenance ..........17 Powering off the PCS100 ......18 Front Door .
Page 4 LCD Plate ......... . 58 LCD Module .
Page 5 Air Intake Filter ........154 Ventilation Fan Module-IGBT .
Page 6 Conventions General Conventions The following conventions are used in this manual: Note: Indicates additional information that is relevant to the current process or procedure. WARNING! Warning information appears before the body of text indicting a hazardous situation, which if not avoided, could result in death or serious injury. CAUTION! AUTIONS APPEAR BEFORE THE TEXT IT REFERENCES AUTIONS APPEAR IN CAPITAL LETTERS TO...
Page 7 About to this Manual Version Control Table 1: Version Control Rev. Change Description Date 1.0.0 Maintenance Manual...
Page 8 Purpose This manual provides includes safety guidelines, detailed instructions for the maintenance and troubleshooting of the Delta PCS100. Target Audience This manual is intended for customers intending to maintain and troubleshoot these products. Installers should be certified technicians or electricians.
Page 9 Maintenance Flowchart Start Turn off PCS100 via host server Turn off the AC/DC disconnect switch on the front panel Service the front cabinet Open the Open the front panel rear panel Follow the Maintenance Manual to service PCS Follow the Maintenance...
Page 10 Store the charge handle in the dock to prevent unnecessary exposure to contamination or moisture. WARNING! Stop using and do not use the PCS100 if it is defective, appears cracked, frayed, broken, or otherwise damaged, or fails to operate. WARNING! Do not attempt to disassemble, repair, tamper with, or modify the PCS100.
Page 11 Do not touch the PCS100's end terminals with fingers or sharp metallic objects, such as wire, tools, or needles. WARNING! Do not forcefully fold or apply pressure to any part of the PCS100 or damage it with sharp objects. WARNING! Do not insert foreign objects into any part of the PCS100.
Page 12 Do not obstruct the airflow, air intakes/exhaust to prevent the risk of overheating and fire. Preventing Fire and Explosion Hazards Maintenance or servicing the PCS100 may produce sparks. For this reason, the PCS100 should only be installed in an environment free of flammable material or gases. These areas may exclude locations that house gasoline-powered machinery, fuel tanks, and battery compartments.
Page 13: Hardware Introduction
In addition, the PCS100 can operate by local or remote control. The local access is enabled through the display panel and remote control access is performed through commands from a computer connected to the PCS100 through an RS485 communication link using Modbus protocols.
Page 14: Enclosure Front And Side Sections
Hardware Introduction Enclosure Front and Side Sections This section describes the physical characteristics of the PCS100. These converters are housed in IP55 enclosures. To better describe all of the components, the respective location are divided as follows: Front Side Locations, Access Door Locations, Front Compartment Locations (Internal), Rear Compartment Locations (Internal), and Rear Side Locations.
Page 15 Hardware Introduction Left Side Locations Figure 3. Left Side View Table 3: Left Side View Description Description Side base cover  Provides access for forklift  Provides access for front side cable routing Maintenance Manual...
Page 16 When a control switch is turned to the OFF (default) position the respective contactor is opened and immediately shuts down the corresponding section of the PCS100. WARNING! The control switches turn off the PCS100. However, live power still exists in both the DC and AC sections within the enclosure. Maintenance Manual...
Page 17: Internal Enclosure Views
Hardware Introduction Internal Enclosure Views Open Front Door The front door houses a number of components and also provides access to the internal sections of the enclosure as it also serves as the front door way. The following figure illustrates the serviceable components as seen from an open access door.
Page 18 Hardware Introduction Front Compartment Locations The Front Compartment is composed of two internal areas accessible after opening the front door of the cabinet. The initial area includes the Safety Cover and for this guide’s purpose is named the Front Protective Cover area. The second area, Internal Compartment, is the section which houses the main bulk of the internal components and is accessible only after opening the Safety Cover and Control Box cover.
Page 19 Hardware Introduction Cable Access Glands All power cables and wiring can be routed through the bottom-front or bottom-rear floor locations in the enclosure. DC Cable Glands (+/-, x3 sets) AC Cable Glands (L1, L2, L3, 2 cables for each) Communication and I/O Glands Grounding Cable Glands (x2)
Page 20 Hardware Introduction Internal Compartment The internal compartment houses the components only accessible after opening the cabinet’s internal protective cover. Figure 8. Front View of Components in an Open Compartment Table 7: Front View of Components in an Open Compartment Description Description DC main relay DC softstart relay...
Page 21: Control Box
Hardware Introduction Control Box The control box includes a front cover, which acts as a door to access the interior. Once the cover is opened, the front view any installed components on this side are visible. By swinging open the front cover on the control box, you can gain access to the components on the rear side of the control box.
Page 22 Hardware Introduction Rear of Control Box Cover The following figure illustrates the rear view of an open control box cover. When the cover is closed it is situated directly in front of the interior of the cabinet. Figure 10. Components in Rear of Open Control Box Cover Table 9: Components in Rear of Open Control Box Cover Description Description...
Page 23 Hardware Introduction Cabinet Interior Figure 11. Components within Interior of Top Cabinet Table 10: Components within Interior of Top Cabinet Description Description DC cap board (D Board) Copper bar and hall (IGBT to D board) IGBT driver adapter board (A board) IGBT driver board (B board) Maintenance Manual...
Page 24: Enclosure Rear Section
Hardware Introduction Enclosure Rear Section This section describes the physical characteristics of the rear sections for the PCS100. Rear Access Door Locations Figure 12. Rear View of Closed (Left) and Opened (Right) Cabinet Table 11: Rear View of Closed and Opened Cabinet...
Page 25: Rear Compartment Locations
Hardware Introduction Rear Compartment Locations Figure 13. Open Compartment, Rear View Table 12: Open Compartment, Rear View Description Description Ventilation fan module-IGBT (IGBT fan IGBT HSK cover module) AC filter module (C Board) (Visible) Inverter module (IGBT HSK) Maintenance Manual...
Page 26: Preventive Maintenance
General Overview It is important to keep in mind that the PCS100 is designed to supply power in the event of a power failure from the power utility grid. The internal components of the PCS100 are unsafe until the DC power source is disconnected and the capacitors are discharged.
Page 27 Daily Maintenance The following items should be performed on a daily basis:  Inspect the area around the PCS100. Make sure the area is clean and access to the PCS100 is not hampered.  Ensure the system operating normally. If a status LED indicates an error or fault, make sure to contact an authorized service technician.
Page 28: Guidelines For Cleaning And General Inspection
Preventive Maintenance Guidelines for Cleaning and General Inspection The PCS100 should be cleaned from the interior first by blowing low pressure compressed air into the bottom of the unit first then continue by moving upwards. By maintaining the PCS100 in good electrical condition, many hazards stemming from disrepair can be avoided.
Page 29: Guidelines For General Maintenance
Due to the complexity of the PCS100, it is highly recommended that all repairs be performed by a qualified power supply technician. Before attempting any service procedures, the technician should be familiar with the system and the operation design.
Page 30: Powering Off The Pcs100
Maintenance Powering off the PCS100 To power off the system, see the following guidelines: 1. Check the system status on the front display panel to ensure that the system is not in a SoftS- tart or Run state. 2. If the system is in SoftStart or Run state, push the PCS OFF button on PCS HMI Tool to switch the PCS system to Standby mode.
Page 31: Front Door
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 32 Maintenance Opening a Front Door The AC and DC disconnects have an interlock mechanism to prevent the front door from being opened if they are not in the OFF position. After turning the disconnects to the OFF (horizontal) position, wait at least five minutes before opening the front door.
Page 33 Maintenance 3. Insert the key and turn it to retract the lock. Figure 18. Unlocking a Front Door 4. Release the door handle then rotate it to open the door. Figure 19. Opening a Door Handle 5. Open the front door open and swing it open until it locks in place. Figure 20.
Page 34 Maintenance Make sure the locking mechanisms at the bottom of the door engages in the track to keep the front door from closing accidentally. Figure 21. Locking a Front Door in a Cabinet The front door locks in place when it is fully extended. Closing a Front Door 1.
Page 35 Maintenance 4. Maintain pressure on the door while rotating the door handle to the closed position. Figure 23. Closing a Door Handle Note: To ensure a closed front door, make sure there is no gap between the front door and the cabinet.
Page 36: Rear Door
Maintenance 6. Slide the keyhole cover down to complete securing the handle. STANDBY FAULT Figure 25. Securing a Keyhole Slot 7. Rotate the switch handles to the ON position to engage the AC and DC inputs. DC DISCONNECT AC DISCONNECT DC DISCONNECT AC DISCONNECT Figure 26.
Page 37 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 38 Maintenance 2. Insert the key and turn it to retract the lock. Figure 28. Unlocking a Rear Door 3. Release the door handle then rotate it to open the door. Figure 29. Opening a Door Handle Maintenance Manual...
Page 39 Maintenance 4. Open the rear door open and swing it open until it locks in place. Figure 30. Opening a Rear Door Maintenance Manual...
Page 40 Maintenance Closing a Rear Door Before you close a door, make sure there are no obstructions hindering the door from closing correctly. 1. Maintain pressure on the door while rotating the door handle to lock the rear door to the cabinet. Figure 31.
Page 41 Maintenance 3. Insert the key and rotate it to engage the lock. Once the lock is engaged, remove the key. Figure 33. Locking a Front Door 4. Slide the keyhole cover down to complete securing the handle. Figure 34. Securing a Keyhole Slot Maintenance Manual...
Page 42: Control Box
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 43 Maintenance Opening a Control Box The control box swings open to reveal the components on the rear side and the top internal section of the cabinet. 1. Open the front door. See “Opening a Front Door” on page 20. 2. Loosen the captive screws securing the control box. 3.
Page 44 Maintenance Opening a Control Box Cover 1. Open the front door. See “Opening a Front Door” on page 20. 2. Slide in the release latches to open the control box cover. PWB Box Figure 37. Opening a Control Box Cover Closing a Control Box Cover 1.
Page 45: Safety Cover
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 46 Maintenance Removing a Safety Cover 1. Open the front door. See “Opening a Front Door” on page 20. 2. The securing stoppers are held in place by the screws. Once the screws are removed, the stop- pers fall off. Start on one side and remove the screws from the securing stopper. 3.
Page 47 Maintenance 5. Slide the safety cover until the slits in the cover are flush with the extension rods. The extension rods must have access to pass through the slits without interference. CAUTION! HEN SERVICING THE AFETY OVER MAKE SURE TO KEEP AWARENESS OF THE XTENSION AUTION IS RECOMMENDED TO AVOID INJURY OR DAMAGE WHEN THE XTENSION...
Page 48 Maintenance 7. Locate the safety cover bracket on the left side of the cabinet, see the following figure. 8. Remove the screws securing the safety cover bracket. 9. Remove the bracket. Figure 42. Removing a Safety Cover Bracket 10. Starting with the AC extension rod, locate the hex screw on the side of the extension rod, see the following figure.
Page 49 Maintenance 14. Locate the DC extension rod and the hex screw on the side of the extension rod, see the follow- ing figure. 15. Insert a hex-key wrench and remove the hexagon screw. This allows the extension rod to be free from the securing slot.
Page 50 Maintenance 1. Continue with the AC extension rod, align the base of the rod to the socket. The base of the rod is design to fit on the socket in a specific alignment. 2. Insert the hexagonal screw in the screw hole on the rod and turn it to thread it in place. 3.
Page 51 Maintenance 6. Align the safety cover in the cavity. Make sure the extension rods are able to pass through the designed slits. 7. Install the safety cover into the cabinet and slide it to the right until the screw holes on the cover bracket and safety cover are aligned.
Page 52: Emergency Stop Switch
Maintenance 9. Starting with one side, align one half of the extension rod stopper on the safety cover and align it with the screw holes. 10. Once aligned, insert the screws and secure the stopper in place. 11. Continue with the remaining half of the stopper. Figure 50.
Page 53 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 54 Maintenance 3. The rear side of the switch is accessible from the open panel. Locate the connecting wires on the switch. 4. The wires are secured by the screws. Loosen the captive screws to disconnect the wires. 5. Pull out the connecting wires. Figure 52.
Page 55 Maintenance Installing an Emergency Stop Switch 1. Open the front door if it isn’t open already. See “Opening a Front Door” on page 20. To install an emergency stop switch, you will need to access the front and rear side of the front door. 2.
Page 56 Maintenance 5. Position yourself to view the inner side of the front door. From this angle the bottom side of the plunger mechanism is visible. 6. Inspect the mechanism to make sure it is inserted correctly. The screw threads on the barrel should all be visible if the mechanism is seated correctly.
Page 57: Ac And Dc Switch Handles
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 58 Maintenance Removing AC and DC Switch Handles 1. Open the front door. See “Opening a Front Door” on page 20. 2. Locate the switch handle base located on the inner bottom side of the front door. There are two base locations, one for the AC switch and the other for the DC switch handle. 3.
Page 59 Maintenance Installing AC and DC Switch Handles 1. Open the front door. See “Opening a Front Door” on page 20. 2. Starting from the exterior side of the front door, locate the socket housing for the handles and align the handles to match the housing orientation. 3.
Page 60: Ventilation Fan For Dc-Side
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 61 Maintenance Removing a DC-Side Fan Module The fan module is located on the DC side of the enclosure. In order to reach the fan assembly, you must first open the safety cover. 1. Open the front door. See “Opening a Front Door” on page 20. 2.
Page 62 Maintenance 6. Pull the cable leading to the fan module out of the tray channels. 7. Remove the nuts securing the fan assembly. 8. Remove the fan assembly. Figure 64. Removing a DC-side Fan Assembly 9. Locate the rear of the fan module and insert a screw driver through each hole to remove the screws securing the fan module.
Page 63 Maintenance Installing a DC-Side Fan Module 1. Face the fan module so that it’s sticker label is visible through the opening in the fan bracket. Position the fan cable so that it protrudes through the side facing the cable bracket. 2.
Page 64 Maintenance 8. Hold the cable attached to the fan module and insert it in the channels of the cable tray. Make sure the head of the cable sits in the middle of the cable tray. 9. Locate the remaining cable end and connect it to the cable already inserted in the channel. 10.
Page 65: Heat Exchanger
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 66 Maintenance Removing a Heat Exchanger 1. Open the front door. See “Opening a Front Door” on page 20. Make sure the front door is fully opened to allow for unrestricted access to the heat exchanger. 2. Take off the grounding wire by removing the screw securing one end of it. 3.
Page 67 Maintenance 5. Locate the data cables on the heat exchanger and loosen the captive screws securing them. 6. Pull the cables out to disconnect them. Heat Exchager - 4 8 - 4 8 Figure 71. Disconnecting the Cables 7. Locate the hexagonal nuts on the parameter of the heat exchanger. Begin with the nuts on the bottom of the exchanger and move upwards to remove all the hexagonal nuts.
Page 68 Maintenance 8. Hold the bottom and top of the heat exchanger and lift it up slightly. 9. Once the heat exchanger is off the bolts, remove it off the front door. Figure 73. Removing a Heat Exchanger 10. Place the heat exchanger on a clean work surface. Installing a Heat Exchanger 1.
Page 69 Maintenance 4. Continue to hold the housing in place and insert a hexagonal nut at the top of the housing and tighten it halfway. This prevents the heat exchanger from falling off. 5. Once in place, continue from the bottom of the housing and inserting the remaining nuts. 6.
Page 70: Lcd Plate
Maintenance 9. Insert the grounding wire into the bolt on the exchanger cabinet. 10. Insert a screw through the one end of the grounding wire and align it with the grounding hole located on the front of the heat exchanger frame. Turn the screw to secure the wire in place. 11.
Page 71 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 72: Lcd Module
Maintenance Installing an L Plate The following procedure assumes that the LCD assembly, see “LCD Module” on page 60, is already installed on the L plate. 1. Locate the front side of the L plate assembly to expose the LCD module. 2.
Page 73 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 74: Auxiliary Heat Exchanger Power Board (G Board)
Maintenance Installing a LCD Module 1. Situate the LCD module over the L plate. Take note of the terminal block socket and connector. 2. Install the bolts and LCD module. 3. Secure the LCD module with screws. Figure 81. Installing an LCD Module 4.
Page 75 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 76: Switch Indicator For Door State (Door Sensor)
Maintenance Installing a G Board 1. Align the posts on the front door with the keyholes on the G board. 2. Slide the G board to lock in place. 3. Secure the G board with screws. 4. Connect the cables to the L board. Figure 83.
Page 77 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 78 Maintenance 5. Remove the door sensor. Figure 85. Removing a Door Sensor Installing a Door Sensor 1. Align the door sensor with the holes on the top of chassis. 2. Secure the door sensor with screws. Figure 86. Installing a Door Sensor Maintenance Manual...
Page 79: Dc Fuse
Maintenance 3. Align one end of the wires to the holes on door sensor. 4. Secure the wires with washers and screws. Figure 87. Installing the Wires 5. Close the front door. See “Closing a Front Door” on page 22. DC Fuse WARNING! Read the “Safety Instructions”...
Page 80 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 81: Ac Fuse
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 82 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 83 Maintenance Installing an AC Fuse 1. Align the AC fuse and secure the AC fuse with screws. Figure 92. Installing an AC Fuse 2. Close the control box. See “Closing a Control Box Cover” on page 32. 3. Align the AC fuse and cable (only available for the bottom of AC fuse) with the holes on the chassis.
Page 84: Fuse For Ac Surge Protection (Ac Spd Fuse)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 85 Maintenance Removing an AC SPD Fuse 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Remove the screws securing the AC SPD fuse and the wires. 4.
Page 86 Maintenance Installing an AC SPD Fuse 1. Position the rear of the AC SPD fuse directly in front of the SPD rail. Make sure the top of the AC SPD fuse hooks over the top of the SPD rail. 2. Once the AC SPD fuse is seated correctly in the SPD rail clip, press the front of the AC SPD fuse to rotate the AC SPD fuse down and into the release tab on the AC SPD fuse.
Page 87: Ac Surge Protector (Ac Spd)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 88 Maintenance Removing an AC SPD 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Loosen the captive screws securing the wires. 4. Pull out the wires from the AC SPD. SPD 1 Figure 98.
Page 89 Maintenance Installing an AC SPD 1. Position the rear of the AC SPD directly in front of the rail. Make sure the top of the AC SPD hooks over the top of the rail. 2. Once the AC SPD is seated correctly in the rail clip, press the front of the AC SPD to rotate the AC SPD down and into the release tab on the AC SPD.
Page 90: Dc Emi Filter Board (F Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 91 Maintenance Removing an F Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Remove the screws securing the F board. 4. Remove the F board. F BD Figure 102.
Page 92: Ac Emi Filter Board (E Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 93 Maintenance Removing an E Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Remove the screws securing the E board and the wires. 4.
Page 94: Interface Board (J Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 95 Maintenance Removing a J Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Disconnect the cables from the J board. Figure 106. Disconnecting J Board Cables 4.
Page 96 Maintenance Installing a J Board 1. Align the posts on the chassis with the keyholes on the J board. 2. Slide the J board to lock in place. 3. Secure the J board with screws. Figure 108. Installing a J Board 4.
Page 97: Dc Surge Protector (Dc Spd)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 98 Maintenance Removing a DC SPD 1. Open the front door. See “Opening a Front Door” on page 20. 2. Remove the safety cover. See “Removing a Safety Cover” on page 34. 3. Locate the DC SPD. SPD 2 Figure 110. DC SPD Location 4.
Page 99 Maintenance 6. Push down on the top of the DC SPD release tab with your finger. As the DC SPD releases, lift the bottom of the DC SPD. 7. Remove the DC SPD from the rail. Figure 112. Removing a DC SPD Installing a DC SPD 1.
Page 100: Ac Switch
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 101 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 102 Maintenance 6. Remove the nuts securing the AC protection glass. 7. Remove the AC protection glass. Figure 117. Removing an AC Protection Glass 8. Remove the screws securing the wires, washers and brackets. 9. Remove the nuts securing the wires. 10.
Page 103 Maintenance 11. Remove the screws securing the wires, washers and brackets. 12. Remove the wires, washers and brackets. Figure 119. Removing the Wires, Washers and Brackets 13. Remove the screws securing the AC switch. 14. Remove the AC switch. Figure 120. Removing an AC Switch Maintenance Manual...
Page 104 Maintenance Installing an AC Switch 1. Align the holes on the AC switch with the posts on the chassis. 2. Secure the AC switch with screws. Figure 121. Installing an AC Switch 3. Align the wires, washers and brackets with the holes on the AC switch. 4.
Page 105 Maintenance 5. Align the wires, washers and brackets with the holes on the AC switch. 6. Secure the wires, washers and brackets with screws. 7. Secure the wires and the washers with nuts. Figure 123. Installing the Wires, Washers and Brackets 8.
Page 106: Dc Switch
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 107 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 108 Maintenance 6. Remove the nuts securing the DC protection glass. 7. Remove the DC protection glass. Figure 128. Removing a DC Protection Glass 8. Remove the screws securing the wires, washers and brackets. 9. Remove the nuts securing the wires. 10.
Page 109 Maintenance 11. Remove the screws securing the wires, washers and brackets. 12. Remove the wires, washers and brackets. Figure 130. Removing the Wires, Washers and Brackets 13. Remove the screws securing the DC switch. 14. Remove the DC switch. Figure 131. Removing a DC Switch Maintenance Manual...
Page 110 Maintenance Installing a DC Switch 1. Align the holes on the DC switch with the posts on the chassis. 2. Secure the DC switch with screws. Figure 132. Installing a DC Switch 3. Align the wires, washers and brackets with the holes on the DC switch. 4.
Page 111 Maintenance 5. Align the wires, washers and brackets with the holes on the DC switch. 6. Secure the wires, washers and brackets with screws. 7. Secure the wires and washers with nuts. Figure 134. Installing the Wires, Washers and Brackets 8.
Page 112: Ac Main Contactor
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 113 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 114 Maintenance 6. Remove the screws securing the AC main contactor. Figure 139. Removing the Screws 7. Remove the screws securing the wires. 8. Remove the wires. Figure 140. Disconnecting the Wires Maintenance Manual...
Page 115 Maintenance 9. Remove the screws securing the L-brackets. 10. Remove the L-brackets. Figure 141. Removing the L-brackets 11. Remove the screws securing the AC main contactor. 12. Remove the AC main contactor. Figure 142. Removing an AC Main Contactor Maintenance Manual...
Page 116 Maintenance Installing an AC Main Contactor 1. Align the holes on the AC main contactor with the holes on the chassis 2. Secure the AC main contactor with screws. Figure 143. Installing an AC Main Contactor 3. Align the holes on the L-brackets with the holes on the chassis. 4.
Page 117 Maintenance 5. Align the holes on the wires with the holes on the L-brackets. 6. Secure the L-brackets and wires with screws. Figure 145. Connecting the Wires 7. Secure the AC main contactor and L-brackets with screws. Figure 146. Securing the Screws Maintenance Manual...
Page 118: Ac Softstart Contactor
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 119 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 120 Maintenance 6. Remove the screws securing the AC softstart contactor and the wires. 7. Remove the AC softstart contactor and the wires. Figure 150. Disconnecting the Wires 8. Remove the screws securing the AC softstart contactor assembly. 9. Remove the AC softstart contactor assembly. Figure 151.
Page 121 Maintenance Installing an AC Softstart Contactor 1. Align the holes on the AC softstart contactor with the holes on the AC softstart contactor bracket. 2. Secure the AC softstart contactor and AC softstart contactor bracket with screws. Figure 153. Installing an AC Softstart Contactor 3.
Page 122: Dc Main Relay
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 123 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 124 Maintenance 6. Remove the screws securing the DC main relay. 7. Remove the DC main relay. Figure 159. Removing a DC Main Relay Installing a DC Main Relay 1. Align the holes on the DC main relay with the holes on the chassis. 2.
Page 125 Maintenance 3. Align the hole on the wire with the post on the DC main relay. 4. Align the hole on the bracket with the post on the DC main relay. 5. Secure the wire and the bracket with nuts. Figure 161.
Page 126: Dc Softstart Relay
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 127 Maintenance 4. Remove the screws securing the wires. 5. Remove the wires. Figure 164. Removing the Wires 6. Remove the screws securing the DC softstart relay. 7. Remove the DC softstart relay. Figure 165. Removing a DC Softstart Relay Installing a DC Softstart Relay 1.
Page 128: Igbt Driver Board (B Board)
Maintenance 3. Align the hole on the wires with the holes on the DC softstart relay. 4. Secure the wires with screws. Figure 167. Installing the Wires 5. Connect the cable. Figure 168. Connecting the Cable 6. Installing a safety cover. See “Installing a Safety Cover” on page 37. 7.
Page 129 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 130 Maintenance 4. Disconnect the cables from the B board. Figure 170. Disconnecting the Cables 5. Remove the screws securing the B board. 6. Remove the B board. Figure 171. Removing a B Board Installing a B board 1. Align the holes on the B board with the holes on the chassis. 2.
Page 131: Igbt Driver Adapter Board (A Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 132 Maintenance Removing an A Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box. See “Opening a Control Box” on page 31. 3. Locate the A board. A BD Figure 174. A Board Location 4.
Page 133 Maintenance 5. Remove the nuts securing the B board assembly. 6. Slide and remove the B board assembly. Figure 176. Removing a B Board Assembly 7. Remove the screws securing the A board. Figure 177. Removing the Screws 8. Release the hooks locking the A board. 9.
Page 134 Maintenance Installing an A Board 1. Align the holes on the A board with the holes on the chassis. 2. Install the A board. Make sure the hooks are locked in place as following illustration. Figure 179. Installing an A Board 3.
Page 135: Dc Cap Board (D Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 136 Maintenance Removing a D Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box. See “Opening a Control Box” on page 31. 3. Locate the D board. D BD Figure 183. D Board Location 4.
Page 137 Maintenance 6. Remove the screws securing the D board. Figure 185. Removing the Screws 7. Loosen the captive screws securing the D board. Figure 186. Loosening the Captive Screws Maintenance Manual...
Page 138 Maintenance 8. Slide and remove the D board. Figure 187. Removing a D Board Installing a D Board 1. Align the holes on the D board with the captive screws on the chassis. 2. Slide to lock the D board in place as the following illustration. Figure 188.
Page 139 Maintenance 3. Secure the D board with captive screws. Figure 189. Securing the Captive Screws 4. Securing the D board with screws Figure 190. Securing the Screws Maintenance Manual...
Page 140: Module Control Board (M Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 141 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 142 Maintenance 5. Remove the screws securing the M board. 6. Remove the M board Figure 194. Removing a M Board Installing a M Board 1. Locate the M board. H BD R BD S BD M BD Figure 195. M Board Location Maintenance Manual...
Page 143 Maintenance 2. Align the holes on the M board with the holes on the control box. 3. Secure the M board and the control box with screws. Figure 196. Installing a M Board 4. Connect the cables to the M board. Figure 197.
Page 144: System Control Board (S Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 145 Maintenance Removing an S Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box door. See “Opening a Control Box Cover” on page 32. 3. Locate the S board. H BD R BD S BD M BD...
Page 146 Maintenance 5. Remove the screws securing the S board. 6. Remove the S board Figure 200. Removing the Screws 7. Slide and remove the S board. Figure 201. Removing an S Board Maintenance Manual...
Page 147 Maintenance Installing an S Board 1. Locate the S board. H BD R BD S BD M BD Figure 202. S Board Location 2. Align the holes on the S board with the captive screws on the chassis. 3. Slide to lock the S board in place as the following illustration. Figure 203.
Page 148 Maintenance 4. Align the holes on the S board with the holes on the control box. 5. Secure the S board and the control box with screws. Figure 204. Installing the Screws 6. Connect the cables to the S board. Figure 205.
Page 149: Module Sampling Board (R Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 150 Maintenance Removing a R Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box door. See “Opening a Control Box Cover” on page 32. 3. Locate the R board. H BD R BD S BD M BD...
Page 151 Maintenance 5. Remove the screws securing the R board. 6. Remove the R board Figure 208. Removing a R Board Installing a R Board 1. Locate the R board. H BD R BD S BD M BD Figure 209. R Board Location Maintenance Manual...
Page 152: System Sampling Board (H Board)
Maintenance 2. Align the holes on the R board with the holes on the control box. 3. Secure the R board and the control box with screws. Figure 210. Installing a R Board 4. Connect the cables to the R board. Figure 211.
Page 153 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 154 Maintenance 4. Disconnect the cables from the H board. Figure 213. Disconnecting the Cables 5. Remove the screws securing the H board. 6. Remove the H board Figure 214. Removing a H Board Maintenance Manual...
Page 155 Maintenance Installing a H Board 1. Locate the H board. H BD R BD S BD M BD Figure 215. H Board Location 2. Align the holes on the H board with the holes on the control box. 3. Secure the H board and the control box with screws. Figure 216.
Page 156: Ventilation Fan For Auxiliary Power
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 157 Maintenance Removing an Auxiliary Power Fan Module 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box door. See “Opening a Control Box Cover” on page 32. 3. Disconnect the cable from the fan assembly. 4.
Page 158 Maintenance Installing an Auxiliary Power Fan Module 1. Install the auxiliary power fan module into the fan bracket. 2. Secure the auxiliary power fan module with screws. Figure 220. Installing an Auxiliary Power Fan Module 3. Align the fan assembly with the holes on the control box. 4.
Page 159: Auxiliary Power Board (P Board)
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 160 Maintenance Removing a P Board 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box door. See “Opening a Control Box Cover” on page 32. 3. Locate the P board. Module Aux Power BD System Aux Power BD Figure 222.
Page 161 Maintenance 5. Remove the screws securing the P board. Figure 225. Removing the Screws 6. Slide and remove the P board. Figure 226. Removing a P Board Maintenance Manual...
Page 162 Maintenance Installing a P Board 1. Locate the P board. Module Aux Power BD System Aux Power BD Figure 227. P Board Location 2. Align the holes on the P board with the captive screws on the chassis. 3. Slide to lock the P board in place as the following illustration. Figure 228.
Page 163 Maintenance 4. Secure the P board and the control box with screws. Figure 229. Installing the Screws 5. Connect the cables to the P board. Figure 230. Connecting the Cables to the Top P Board Figure 231. Connecting the Cables to the Bottom P Board 6.
Page 164: Auxiliary Transformer
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 165 Maintenance Removing an Auxiliary Transformer 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box door. See “Opening a Control Box Cover” on page 32. 3. Locate the auxiliary transformer. 4. Remove the screws securing the auxiliary transformer. 5.
Page 166: Air Intake Filter
Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 167 Maintenance Before attempting any work around the PCS100, observe the following precautions:  Remove any watches, rings, or other metallic accessories.  Only use tools with insulated handles.  Wear rubber gloves and boots.  Do not lay tools or metal parts on top of the cabinet.
Page 168 Maintenance 4. Use a vacuum cleaner with an antistatic hose and nozzle to clean the filter. A normal vacuum cleaner creates static discharges. The filter can also be cleaned with water. Make sure the filter is completely dried before reusing it in the system.
Page 169: Ventilation Fan Module-Igbt
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 170 Maintenance Removing an IGBT Fan Module 1. Open the rear door. See “Opening a Rear Door” on page 25. 2. Locate the fan module assembly. A temperature sensor cable is secured on the assembly. Remove the screw attaching the sensor cable to the assembly. 3.
Page 171 Maintenance 8. Once the IGBT HSK cover is removed, the screws securing the IGBT fan module are exposed. Locate the nuts above the fan module assembly, see the following figure, and remove them. 9. There are thumb screws below the nuts, which were just removed. Loosen the thumb screws 10.
Page 172 Maintenance Installing an IGBT Fan Module 1. Align the parameter of the IGBT fan module with the bolts on the chassis. 2. Insert the IGBT fan module in the chassis. Make sure that each bolt passes through the holes on the fan module.
Page 173 Maintenance 5. Insert the IGBT HSK cover in the cabinet. Make sure the holes on the cover align with the bolts on the cabinet. 6. Securing the IGBT HSK cover with screws. 7. Secure the IGBT HSK cover with hexagonal nuts. Figure 242.
Page 174: Ventilation Fan Module-Choke
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 175 Maintenance 3. Remove the screws securing the choker fan module. 4. Remove the choker fan module. Figure 245. Removing a Choker Fan Module Installing a Choker Fan Module 1. Align the choker fan module with the holes on the chassis. 2.
Page 176: B Board Assembly
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 177 Maintenance Removing a B Board Assembly Two individuals are recommended for this procedure. 1. Open the front door. See “Opening a Front Door” on page 20. 2. Open the control box. See “Opening a Control Box” on page 31. 3. Directly behind the control box, the location of the B board is found. B BD Figure 248.
Page 178 Maintenance 5. Locate the nuts securing the B board to the chassis and remove them. 6. Slide and remove the B board assembly, which includes the fixed plate. Figure 250. Removing a B Board Assembly Installing a B Board Assembly Installing the B board assembly requires angling the assembly at different angles.
Page 179: A Board Assembly
OR HARDWARE DAMAGE CAN RESULT IF CAUTION IS NOT TAKEN Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 180: Ac Filter Module (C Board)
Maintenance Removing an A Board Assembly 1. Remove the screws securing the IGBT HSK. Figure 253. Removing screws from a Board Installing an A Board Assembly 1. Securing the IGBT HSK cover with screws. Figure 254. Securing the Screws AC Filter Module (C Board) WARNING! Read the “Safety Instructions”...
Page 181 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 182 Maintenance 4. Remove the screws securing the C board assembly. 5. Remove the C board assembly from the chassis. Figure 256. Releasing the C Board Assembly 6. Remove the nut and screw securing the cable, see the following illustration. Figure 257. Releasing the Cable Maintenance Manual...
Page 183 Maintenance 7. Releasing the casing from the cable, see the following illustration. Figure 258. Releasing the Casing 8. Open the C board Assembly. Figure 259. Opening the C Board Assembly Maintenance Manual...
Page 184 Maintenance 9. Disconnect the cables from the connectors on the C board. 10. Remove the screws securing the cables to the cover and disconnect the cables. Figure 260. Disconnecting the Cables and Wires 11. Take off the wire by removing the screw securing one end of it. Figure 261.
Page 185 Maintenance 12. Remove the screws securing the C board. There are standoffs located on the C board to hold it in place. Figure 262. Removing the Screws from the C Board Assembly 13. Slide the C board upwards to clear the posts from the key holes and pull it off to remove it. Figure 263.
Page 186 Maintenance Installing a C Board 1. Align the holes on the C board to the posts on the C board cage. Make sure the connectors are facing front. 2. Insert the C board over the posts. Slide the C board down until the posts are secured in the key holes.
Page 187 Maintenance 4. Insert a screw through one end of the wire and align it with the hole located on the top of the C board. 5. Tighten the screw to secure the wire in place. Figure 266. Connecting a Wire 6.
Page 188 Maintenance 8. Close the C board assembly. Figure 268. Closing the C Board Assembly 9. Insert the casing and rotate to securing the casing, see the following illustration. Figure 269. Securing the Casing Maintenance Manual...
Page 189 Maintenance 10. Insert a screw through the end of the cable and align it with the hole located on the bottom of the chassis. 11. Tighten the nut to secure the cable in place. Figure 270. Securing the Cable 12. Align the C board assembly with the chassis. 13.
Page 190: Igbt Heatsink (Hsk)
Maintenance 14. Install the cover into the cabinet. 15. Secure the cover with nuts. Figure 272. Installing the C Board Cover 16. Close the rear door. See “Closing a Rear Door” on page 28. IGBT Heatsink (HSK) WARNING! Read the “Safety Instructions” on page ix on the first at the beginning of this manual before performing any service on the components.
Page 191 Maintenance Important Safety Instructions It is important to remember that the PCS100 is designed to supply power even when it is disconnected from the power grid. The interior of the PCS100 is unsafe until the DC power source is disconnected and the AC/DC inputs are disengaged.
Page 192 Maintenance 5. Remove the screws securing the IGBT HSK. Figure 274. Removing the Screws 6. Remove the nuts securing the IGBT HSK. 7. Remove the IGBT HSK. Figure 275. Removing an IGBT HSK Maintenance Manual...
Page 193 Maintenance Installing an IGBT Heatsink (HSK) 1. Align the IGBT HSK with the posts on the chassis. 2. Secure the IGBT HSK and the chassis with nuts. Figure 276. Installing an IGBT HSK 3. Securing the IGBT HSK and chassis with screw. Figure 277.
Page 194 Maintenance 4. Insert the IGBT HSK cover into the bolt on the chassis. 5. Securing the IGBT HSK cover with screws. 6. Secure the IGBT HSK cover with hexagonal nuts. Figure 278. Installing an IGBT HSK Cover 7. Close the rear door. See “Closing a Rear Door” on page 28. Maintenance Manual...

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