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ARTronic ARTon Plus series Service Training Manual

10-15-20-30-40 kva
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ARTon Plus
SERİSİ
UPS
10-15-20-30-40 kVA
3 Faz Giriş - 3 Faz Çıkış
SERVICE TRAINING NOTES

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  • Page 1 ARTon Plus SERİSİ 10-15-20-30-40 kVA 3 Faz Giriş - 3 Faz Çıkış SERVICE TRAINING NOTES...

  • Page 3: Table Of Contents

    CONTENTS SAFETY..........................1 GENERAL DESCRIPTION....................2 1.1 Introduction ........................2 1.2 Design Concept......................3 1.2.1 Operating modes of UPS..................4 1.3 Technical specifications....................7 1.4 ARTonPlus Series UPS Basic Diagrams ..............8 1.5 ARTonPlus Series UPS Electronic Boards..............12 1.5.1 PCB Locations....................13 1.5.2 PFC3P-R1 IGBT Rectifier Controller Board............15 1.5.3 IPMD Intelligent Power Module (IPM) Driver Board ..........18 1.5.4 P3MC-R5 UPS Main Controller Board..............20 1.5.5 ADVS01-R1 DC-3 Phase AC Voltage Sample Board .........25...
  • Page 4 V. OPERATING INSTRUCTIONS .....................59 5.1. Introduction........................59 5.2 Operating Instruction for a single UPS unit (online operation) ........59 5.2.1 Procedure for turning on the UPS to supply the load from a complete Power-off condition......................59 5.2.2 Power off ......................59 5.2.3 Switching into Maintenance Bypass Mode.............60 5.2.4 Switching from Maintenance Bypass into normal Operation........60 5.3 Operating Instruction for Parallel connected UPSs............60 5.3.1 Procedure for turning on the UPS (First Installation)..........60...

  • Page 5: Safety

    SAFETY IMPORTANT NOTICES 1. Read instructions carefully before installing and starting the UPS 2. All warnings in the manual should be adhered to. 3. All operating instructions should be followed. 4. The unit should be supplied by a grounded outlet. Do not operate the unit without a ground source. 5.

  • Page 6: General Description

    I. GENERAL DESCRIPTION 1.1 Introduction ARTonPlus Series Uninterruptible Power Supplies are double-conversion, on-line UPS’s manufactured with the latest IGBT and PWM technology, to produce an uninterruptible, microprocessor controlled pure sine wave output to critical loads. ARTonPlus Series units are 3-phase in/3-phase out devices, and they are installed between a three phase critical load, and a 3-phase+N mains supply The advantages of using ARTonPlus Series UPS: ...

  • Page 7: Design Concept

     RS232 port multiplexer (Optional)  MODBUS adapter (Optional)  Diagnostic and adjustment via PC.  Input and/or output isolation transformers (optional) 1.2 Design Concept Maintenance Bypass Switch (F4-F5-F6) Static Bypass 3 PHASE 3 PHASE AC Output ̃ MAINS I/P ̃...

  • Page 8: Operating Modes Of Ups

    INVERTER: It is manufactured by using the latest IGBT technology and Pulse width Modulation (PWM) technique. The Inverter converts the DC BUS voltage supplied by the IGBT Rectifier and / or the batteries into a well regulated 3-phase AC voltage with fixed voltage and frequency. The output of the inverter is used to supply the critical loads connected to the UPS output.
  • Page 9 ( RS232 / SNMP ) Communication Select Switch RS232 Battery circuit Emergency Line Failure Battery Low By-Pass Communication Port breaker Input Stop Relay Relay Relay (DB9 Female) Dry Relay Output Contacts Parallel Com. Ports. Manual Bypass Switch ON / OFF Switch (AC Input, F1-F2-F3) (Battery Input, F10-F11-F12)
  • Page 10 Battery circuit Emergency Line Failure Battery Low By-Pass breaker Input Stop Relay Relay Relay Dry Relay Output Contacts ( RS232 / SNMP ) Communication Masaüstünü Göster.scf Select Switch Parallel Com. Ports. RS232 Communication Port (DB9 Female) Manual Bypass Switch ON / OFF Switch (AC Input, F1-F2-F3) (Battery Input, F10-F11-F12)

  • Page 11: Technical Specifications

    Technical Specifications MODEL Output (KVA) Output (KW) Output Power Factor INPUT Number of Phases 3 Phase + Neutral Input Voltage 220/380 Vac , 230/400Vac or 240/415Vac 3phase+N Input Voltage Tolerance +20%,-25% (+15% , -30% for 240/415Vac) Input Power Factor (PF) 0,98 - 0,99 (at full load) Input THDI ≤...

  • Page 12: Artonplus Series Ups Basic Diagrams

    ARTonPlus Series UPS Basic Diagrams...
  • Page 13 Figure 1.4.2 IGBT Rectifier...
  • Page 14 Figure 1.4.3 Transformerless 3-Phase Inverter...
  • Page 15 Figure 1.4.4 ARTonPlus series UPS Basic Diagram...

  • Page 16: Artonplus Series Ups Electronic Boards

    ARTonPlus SERIES UPS ELECTRONIC CONTROL BOARDS You will find below a list of PCBs used in 3 Phase in / 3 Phase out UPSs : ARTonPlus Series PFC3P-R1 3 PHASE POWER FACTOR CORRECTION BOARD  (IGBT RECTIFIER CONTROLLER BOARD) IPMD3P (2 pieces) ...

  • Page 17: Pcb Locations

    1.5.1 PCB LOCATIONS ITF3-R2 P3MC-R5 IPMD3P LEFT VIEW FRONT VIEW STP01-R1 STM01 CPC01-R2 PFC3P-R1 IPMD3P ADVS01-R1 OPS3 SDXC300-R1 RS330-R1 RIGHT VIEW TOP VIEW Figure 1.5.1 10-15-20 kVA...
  • Page 18 IPMD3P ITF3-R2 P3MC-R5 STP01-R1 OPS3 ADVS01-R1 IPMD3P PFC3P-R1 FRONT VIEW LEFT VIEW SDXC300-R1 STM01 CPC01-R2 RS330-R1 TOP VIEW Figure 1.5.2 30-40 kVA RIGHT VIEW...

  • Page 19: Pfc3P-R1 Igbt Rectifier Controller Board

    1.5.2 PFC3P-R1 IGBT RECTIFIER CONTROLLER BOARD: This electronic controller board is used to control the 3-Phase IGBT Rectifier at the input stage of the ARTonPlus Series tansformerless Uninterruptible Power Supplies. By using an IGBT rectifier and this control board, the nput power factor of the UPS is corrected (to 0.99 at full load) and the input current THD is improved (less than 5% at full load).
  • Page 20 B) Adjustments of PFC3P-R1 IGBT Rectifier Controller Board: -AR1 : Rectifier output voltage with only R-phase operation, (increases CW) -AR2 ‘’ ‘’ ‘’ ‘’ “ S-phase ‘’ ‘’ -AR3 : Positive (+) battery group boost charge voltage, (increases CW) -AR4 : Negative (-) ‘’...
  • Page 21 Figure 1.5.3 PFC3P-R1 Board...

  • Page 22: Ipmd Intelligent Power Module (Ipm) Driver Board

    1.5.3 IPMD3P INTELLIGENT POWER MODULE (IPM) DRIVER BOARD This driver board is used to drive the Intelligent Power Modules which are used in the IGBT rectifier and the Inverter stages of ARTonPlus Series UPSs ranging from 10kVA to 40kVa. Basic functions of IPMD3P 1.
  • Page 23 Figure 1.5.4 IPMD3P Board...

  • Page 24: P3Mc-R5 Ups Main Controller Board

    1.5.4 P3MC-R5 UPS MAIN CONTROLLER BOARD This board is used to control the Inverter operation and general UPS functions. Various analog and digital data related to the operation of the UPS are collected by this microprocessor controlled board and necessary control signals are generated and sent to other electronic boards A) Basic functions of P3MC-R5 1.
  • Page 25 - CN5 : It is connected to CN3 of the RS330-R1 board Pin1-Pin3 0volt (GND) Pin5-Pin7 +5V supply Pin2 --------- Pin4 --------- Pin6 Com1 RX input Pin8 Com1 TX output - CN6 : Cabinet temperature measurement sensor is connected to this socket. Pin1 0volt Pin2...
  • Page 26 1. Inverter Output Voltage Adjustment - When the inverter is running, connect an AC voltmeter to the inverter outputs (TP3, TP4 and TP5 on ADVS01-R1 board). - Keeping VR2, VR4, and V6 at approximately their mid-position, adjust the output voltages (roughly) to their nominal value using VR7.
  • Page 27 Additional Test Points: -REF1 : +2.5V reference zener diode voltage -U10-Pin7 : 11V DC -U10-Pin6 : 2.5V DC -U10-Pin1 : 0V DC -U16-Pin11 :0V DC -U38-Pin10 : 19200Hz square wave -U39-Pin3 : 50Hz square wave -U39-Pin14 : 50Hz square wave P3MC-R5 Board ‘’jumper’’...
  • Page 28 Figure 1.5.5 P3MC-R5 Board...

  • Page 29: Advs01-R1 Dc-3 Phase Ac Voltage Sample Board

    1.5.5 ADVS01-R1 DC-3 PHASE AC VOLTAGE SAMPLE BOARD This board accepts the inverter output voltages and bypass input voltages of the UPS and sends suitable AC and DC feedback signals to the main controller (P3MC-R5) board for measurement and control. A) Basic Functions of ADVS01-R1 1.
  • Page 30 B) ADVS01-R1 Board Test Points -TP1 : Inverter output Neutral -TP2 : Bypass (Line) Neutral -TP3 : Inverter output T-Phase (220-230VAC) -TP4 : Inverter output S-Phase ( ‘’ -TP5 : Inverter output R-Phase ( ‘’ -TP6 : Bypass input T-Phase ‘’...
  • Page 31 Figure 1.5.6 ADVS01-R1 Board...

  • Page 32: Sdxc300-R1 Bypass And Inverter Scr Driver Board

    1.5.6 SDXC300-R1 BYPASS AND INVERTER SCR DRIVER BOARD This board is used to drive six pairs of SCRs which are used as AC switches for transferring the load between the inverter output and the bypass supply. A) Basic Functions of SDXC300-R1 Board 1.
  • Page 33 Figure 1.5.7 SDXC300-R1 Board...

  • Page 34: Stp01-R2 Switching Power Supply Board

    1.5.7 STP01-R2 SWITCHING POWER SUPPLY BOARD This board generates the HF supply signals for the operation of all the electronic boards used in a ARTonPlus Series UPS. A) Basic Functions of STP01-R2 Board 1. It uses the AC (200-240V) or DC (280-432V) voltage coming to its CN1 socket to produce HF (high frequency) supply signals for the operation of electronic control boards of the UPS.

  • Page 35: Itf3-R2 3Ph/3Ph Ups Interface Board

    1.5.8 ITF3-R2 3Ph/3Ph UPS INTERFACE BOARD This board contains dry relay contact outputs and inputs for alarm interfacing of the UPS. Power supply sense input are also on this board and if there is no supply voltage, an alarm is produced and the UPS doesn’t start.
  • Page 36 Figure 1.5.9 ITF3-R2 Board...

  • Page 37: Stm01 Output Monitoring Board

    1.5.9 STM01 OUTPUT MONITORING BOARD This board monitors the UPS output voltages. It accepts the 3-Phase AC output voltages at the UPS output and generates a fault signal if there is a voltage or alternance loss in the outgoing sinusoidal waveforms. A) STM01 Board Connectors - CN1 : The 3-phase and Neutral of UPS output voltages (the output of the SCR switches) are connected to this socket.

  • Page 38: Ops3 3Ph Voltage And Current Sample Board

    1.5.10 OPS3 3 PH VOLTAGE AND CURRENT SAMPLE BOARD This board accepts IGBT rectifier input voltage and current samples and sends to the main controller board for measurement purposes. A) Basic Functions of OPS3 Board 1. IGBT rectifier AC input voltages (phase-neutral) are connected to CN1. These voltages are stepped down to a suitable level by the transformers T1, T2, T3 and then sent to the main controller board P3MC-R5 through CN7 of the OPS3 board.
  • Page 39 Figure 1.5.11 OPS3 Board...

  • Page 43: Ups Installation

    II. UPS INSTALLATION 2.1 Introduction WARNING!!!  Do not apply electrical power to the UPS equipment before the arrival of authorized service personnel.  The UPS equipment should be installed only by qualified service personnel.  The connection of the batteries and the maintenance should be done by qualified service personnel. ...

  • Page 44: Safety Earth

    The connection of the electrical panel should be supplied by a grounded outlet. Otherwise, the UPS and the load connected to the output will be left ungrounded. The grounding system must be checked, and must be strengthen if required. Potential difference between ground and neutral must be less than 3V AC.

  • Page 45: Description Of Connection Terminals Of The Ups

    2.4.3 Description of connection terminals of the UPS : By-Pass UPS Outputs Rectifier Inputs Inputs (3 Phase+N) Battery (3 Phase+N) Battery (3 Phase+N) Group Group Figure 2.1 10-15-20 kVA Cable Connections Maintenance Bypass Switch By-Pass UPS Outputs Rectifier Inputs Inputs (3 Phase+N) (3 Phase+N) Battery...

  • Page 46: Battery Installation

     As shown on the power connection label of the UPS, U1, V1 and W1 phase of the incoming 3 phase supply are used as the bypass inputs under normal conditions, if there is not a separate bypass supply (split bypass). ...
  • Page 47 ( 0 ) ( 0 ) ( - ) ( + ) 360V 360V Nominal Nominal 30x12V Batteries 30x12V Batteries Figure 2.3 External Battery Connections (60x12V)
  • Page 48 K2-K2 Figure 2.3 ARTonPlus series, 10-15-20 KVA Internal Battery Connections (2x30=60x12V 7Ah)

  • Page 50: Front Panel

    III. FRONT PANEL 3.1 Introduction The front panel of UPS, consisting of a 2 lines alphanumeric display, 7 status lamps, plus 5 function keys, allows the complete monitoring of the UPS status. The mimic flow diagram helps to comprehend the operating status of the UPS.

  • Page 51: Measures Menu Items

    3.2.1 MEASURES Menu Items In this menu you can see all measured values. Use (↑) and (↓) keys for moving on submenu items. Submenu item Function 1 LD%: 060 074 080 Output load percentage 2 OPV: 220 221 220 Output voltages 3 FREQU: 50.0 Hz Output frequency 4 IPV: 240 235 220...

  • Page 52: Adjust Menu Items

    3.2.4 ADJUST Menu Items: Only service personnel can use this menu ,the incorrect use of this menu can cause damage to the UPS. Submenu item Function Service password input (-) key 100, UP key 10, (+) key 1 changes PASSWORD : XXX after you write the password on screen press ENTER key ,if the password is wrong the is no action.

  • Page 53: Command Menu Items

    3.2.6 COMMAND Menu Items This menu is used to give various commands, to the UPS or to perform some tests on it. . Submenu items Function Used for turning on/off the audible alarm. If you press ENTER key the option will change (push ON, push OFF) 1 SOUND : ON/OFF If the OFF option is selected, audible alarm is turned off but in case of a new alarm, UPS changes the option to ON state.

  • Page 54: Time Menu Items

    3.2.7 TIME Menu Items You can see date and time of RTC (real time clock) on UPS. And you can adjust date and time. Submenu item Function TIME : 23 :15 time DATE : 11-10-2006 date SET HOURS: 11 (+) and (-) adjust hours (0-23) SET MINS : 38 (+) and (-) adjust minutes (0-59) SET DAY : 21...

  • Page 55: Shutdown Messages

    FAULT STATUS: In some cases controller checks events but can not find solutions, in this case controller decide to stop the system. For restarting the user must turn off the ON/OFF switch and turn it on again. WARNING STATUS: Some events recorded to log event file stays on LCD PANEL but UPS continues to work, these messages named as warning messages, user can clear this messages by pressing ENTER key for 3 seconds.
  • Page 56 ALARM DESCRIPTION A9 OVERLOAD UPS loaded more than 100% of nominal power rating. This state is may be continous or temporary. When this alarm is continous Possible Causes: check the loads connected to the UPS output. A10 LINE FAILURE Line failure. Possible Causes: 1) Mains may be off.
  • Page 57 ALARM DESCRIPTION A28 P.FAILURE 21 Parallel controller board failure A29 P.TEST MODE Parallel controller is in test mode A30 P FAILURE 23 Parallel controller board failure A31 DUBL UPS NR. Same UPS number is used for two UPS in the parallel system. Possible Causes: 1) Change number(s) in OPTIONS Menu.

  • Page 58: Parallel Operation

    IV. PARALLEL OPERATION 4.1 Introduction Two (or more) identical ARTonPlus Series UPSs can be interconnected for parallel operation. The main purposes for parallel use of ARTonPlus Series UPSs are: -Redundancy for Increased Reliability -Power Increase Although recent UPS designs are perfect and have high MTBF figures, a second (or more) UPS can be used in parallel with the first one, for supplying the critical load in case of any possible failure of the first UPS.

  • Page 59: Parallel Operation Modes Of Artonplus Series Upss

    The AC inputs of all UPSs in the parallel system are connected to the same mains, and all the AC outputs are connected to each other. Each UPS has its own battery group. The critical load is connected to the common output of the parallel system.

  • Page 60: N+1 Redundant Mode

    In REDUNDANT parallel mode, the total VA rating of the parallel system is equal to the VA rating of a single UPS used in the system. Only after all the UPS units in the system fail and are isolated from the system, the critical load is transferred to Bypass supply without interruption.
  • Page 61 Parallel Parallel Parallel Parallel Parallel Parallel Port 2 Port 1 Port 2 Port 2 Port 1 Port 1 Figure 4.2.b 3 units in parallel Note: One purpose-built signal cable (DB25) is provided for each UPS unit in the parallel system. Parallel signal cables are interconnected between the UPS units to form a loop, as shown in figure 4.2, for having higher reliability against any possible signal cable failures.
  • Page 62 MAIN AC INPUT BYPASS AC INPUT UPS1 UPS2 UPS3 BATTERIES BATTERIES AC OUTPUT1 AC OUTPUT3 AC OUTPUT2 BATTERIES K12 K13 K14 K12 K13 K14 K12 K13 K14 U V W N U V W N U V W N FUSES FUSES FUSES AC OUTPUT...

  • Page 63: Operating Instructions

    V. OPERATING INSTRUCTIONS INTRODUCTION After completing the installation of the unit, and connecting all the power cables with all switches and fuses in “OFF” position, 1. Check the battery polarities. : + V (+360V Nominal, +405V under float charge) K2 - K2 : 0 Volts (connected to the midpoint of the 60 blocks battery string) : - V (-360V Nominal, -405V under float charge) 2.

  • Page 64: Switching Into Maintenance Bypass Mode

    5.2.3 Switching into Maintenance Bypass Mode 1. Use “DOWN” button to choose COMMAND MENU and press ENTER. Use “DOWN” button again to reach ENTER <BYPASS> message. Press ENTER, the UPS will switch into bypass mode. “MANUAL BYPASS” and “A52 MANUA. BYPASS” messages will appear on the screen. 2.

  • Page 65: Power Off

    Again using UP-DOWN and “+”, “-“ keys in the OPTIONS MENU enter a number (0 to 3) for each UPS. Turn off S7 (ON-OFF) and after a few seconds turn it on again. UPS wilt start running again. When “INVERTER START” message appears on the front panel turn on S5 (Battery) into “1”. Perform the same procedure given above for all UPS units.

  • Page 66: Maintenance

    VI. MAINTENANCE WARNING!!! DO NOT OPEN the covers of the UPS because there are no user serviceable parts inside. DO NOT TOUCH battery leads. There is high voltage even if the UPS is off. Therefore no one should open the covers of the UPS except authorized service personnel. Otherwise, serious injuries may occur.

  • Page 67: Annual Maintenance

    6.4 Annual maintenance To get reliable and efficient performance from the UPS, please call the qualified service personal at least once a year. 6.5 UPS Storage and transportation 1. Check the batteries charge by performing manual battery test before storage. If the charge is not enough then charge the batteries at least for 12 hours.

  • Page 68: Faults And Troubleshooting

    VII. FAULTS AND TROUBLESHOOTING 7.1 General Procedure For Fault Checking And Troubleshooting UPS contains complicated electronic control circuits. In order to locate any fault occurring circuits, an advanced knowledge about the circuitry and its operation principles must be known. The aim of this section is to give the knowledge required at the first intervention.

  • Page 69: Ups Remote Monitoring And Control

    VIII. UPS REMOTE MONITORING AND CONTROL Following external connections are available for ARTonPlus Series UPSs. Communication by serial port connection.   Dry contact (interface board) connections.  Remote monitoring panel. 8.1 Using Serial Port A standard Serial (RS232) communication port is installed to all ARTonPlus Series UPS. By using this port user can get all information about the UPS.

  • Page 70: Serial Communication Cable

    In “RS232” position of DIP switches, RS232 communication with an external device is performed through the standard DB9 socket shown above. If DIP switches are in “INTERNAL” position, communication through the standard socket is turned off and routed to an internally connected device. For example, if an ML100 Port Multiplexer has been installed in the UPS, standard DB9 socket is not used for RS232 communication, instead, the two ports, COM1 and COM2 on the ML100 can be used for external communication simultaneously.

  • Page 71: Modem Programming Procedure

    8.3.3 Modem programming procedure Smart modem (SM) is the one connected to PC, and NULL Modem (NM) is the one connected to the UPS. Standard Hayes AT programming language is the suitable language for modems. In usual applications a modem which uses AT command set should be selected. 8.3.3.1 SMART Modem Programming (PC modem) The connected modem to PC (smart modem) will be programmed from UPS control software (T-Mon) automatically.

  • Page 72: Remote Monitoring Panel

    Battery Circuit Emergency Stop Line Failure Battery Low Relay Breaker Input Relay NOTE: Emergency stop terminals (4 and 5) should be short circuited by an external EPO switch to apply an EMERGENCY POWER OFF to the UPS (No output voltage). Line Failure, Battery Low and Bypass relays are normally de-energized and they are energized only in case of an alarm.
  • Page 74 AGKK7080 01/2008...

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