Service Manual

Manual Registration
Manual Registration
S THIS MANUAL IS A CONTROLLED DOCUMENT AND WILL BE PERIODICALLY UPĆ

DATED.
S IN ORDER TO ENSURE THAT YOU RECEIVE ANY AMMENDMENT PLEASE REGĆ
ISTER THIS MANUAL WITH THE TECHNICAL SUPPORT DEPARTMENT BY REĆ
TURNING A COPY OF THIS FORM TO:
Manual Registration
Number
Name of Registered Holder
Address of
Company
Holder
Name/Building
Street/Road
Area/region
Town/City
County/State
Post/Zip Code
Country
Telephone Number
FAX Number
E Mail Address
3x3 UPS Preliminary Pages Prelim Page i

Issue 2 - November 2001
Amendment Record
Amendment Record
Service Manual
Manual Serial Please enter the Manual Serial Nº
Number: for future record
Issue Issue
Amendment Amended By Date
Nº Date
1 Initial issue ć ć
Service Manual
Amendment Record
This Service manual contains information concerning the installation operation and service of the folĆ
lowing UPS
EQUIPMENT PART NUMBER

With battery Without battery
10 kVA UPS
15 kVA UPS
20 kVA UPS
30 kVA UPS
3x3 UPS Preliminary Pages Prelim Page iii

Service Manual
Limitations of Use
Limitations of Use
ELECTROMAGNETIC COMPATABILITY
The equipment covered by this manual complies with the requirements of the EMC DirecĆ
tive 89/336/EEC and the published technical standards. Continued compliance requires
installation in accordance with these instructions and use of manufacturer approved accesĆ
sories only.
WARNING The UPS is a Class A product.

When used in a domestic environment a unit may cause radio interference,
If this is the case the user may be required to take additional measures
WARNING HIGH EARTH LEAKAGE CURRENT.

Earth connection is essential before connecting the utility supply.
This equipment must be earthed in accordance with local electrical codes.
WARNING This UPS does not incorporate automatic backĆfeed protection. A warning label must be
fitted to all external primary power isolators stating:
ISOLATE THE UNINTERRUPTIBLE POWER SYSTEM BEFORE WORKING ON THIS CIRCUIT.
UTILITY The UPS should not be supplied from electrical power systems of the ÌT'
SUPPLY (Impédance à Terre) type.
(IEC 364 Ć ELECTRICAL INSTALLATION OF BUILDINGS)
WARNING Note: Where use on ÌT' systems is required an optional input isolation transformer should
be fitted.
CAUTION This equipment is fitted with RFI suppression filters

Earth leakage exceeds 3.5mA but is less than 300mA.
Transient and steadyĆstate earth leakage currents, which occur when starting the equipĆ
ment, should be taken into account when selecting instantaneous RCCB or RCCD devices.
Note also that the earth leakage currents of the load will be carried by this RCCB or RCCD.
PLEASE These products are intended for Commercial/Industrial use only, and are not suitable for
NOTE use in any life support applications.
Prelim Page iv 3x3 UPS Preliminary Pages

Service Manual
Important Instructions for safe use
Important Instructions for safe use
GENERAL The UPS must be approved engineer before it is put into serĆ
vice. Failure to observe this condition will invalidate any implied warranty.
In common with other types of high power equipment, dangerous voltages are present with
the UPS and battery enclosure. The risk of contact with these voltages is minimised as the
live component parts are housed behind a hinged lockable door.
Further internal safety screens make the equipment protected to IP20 standards.
No risk exists to any personnel when operating the equipment in the normal manner, followĆ
ing the recommended operating procedures.
All equipment maintenance and servicing procedures involving internal access, should be
carried out by trained personnel.
The UPS is for indoor use only. It must be protected from rain or excessive moisture and
installed in a clean environment, free from flammable liquids, gasses, or corrosive subĆ
stances. Do not put drinks, plants, or any other containers holding liquids, on top of the unit.
BATTERIES Battery manufacturers supply details of the necessary precautions to be observed when
working on, or in the vicinity of, a large bank of battery cells. These precautions should be
followed at all times.
Particular attention should be paid to the recommendations concerning local environĆ
mental conditions and the provision of protective clothing, first aid and fireĆfighting facilities.
TEST EQUIPMENT
When the battery is under charge it is earthĆreferenced about its midĆpoint e.g. if the battery
is being charged at 460V the battery extremities will be =230V and Ć230V with respect to
neutral (earth). When using mains powered test equipment such as oscilloscopes in the
UPS high voltage area, always use a differential mode of operation to avoid the need to disĆ
connect the oscilloscope frame earth.
PERSONNEL
When working inside the UPS (trained personnel only) is recommended that protection be
worn to prevent eye damage, should an electric arc be struck by mishandling or severe
electrical fault.
Some of the power components are very heavy. If their removal is necessary ensure that
sufficient manpower is available, otherwise use adequate mechanical handling equipment.
When working in the general area of the UPS where high voltages are present, a second
person should be standingĆby to assist and summon help in case of accident.
3x3 UPS Preliminary Pages Prelim Page v

Service Manual
Personnel Categorisation
Personnel Categorisation
The following definitions are given to categorise the scope, and use of this service
manual:
Operator/User
This service manual is outside the scope for use by personnel who have received instrucĆ
tion on the correct operation of the UPS controls; limited to operation of the unit circuit
breakers and the Front Control Panel; operator/users are not permitted to remove any panĆ
els which are retained by screws.
Service Personnel
This Service manual is designed for use by engineers who have received the relevant
etraining and are password authorised.
Important Symbols
The warning triangle shown above indicate personal safety instructions.

Follow these instructions carefully to avoid injury.
Competent Personnel
The Troubleshooting section, and Service procedures contained in this manual are norĆ
mally outside the scope of personnel categorised competent; though they may be aware
of the dangers appropriate to working with hazardous voltages. A Competent engineer is
deemed to have sufficient technical skills/training to make electrical connections, install
batteries, close and open circuit breakers/fuses etc. (i.e. a qualified electrician) he is not
categorised as service personnel.
Prelim Page vi 3x3 UPS Preliminary Pages

Service Manual
Specification
Specification
10kVA 15kVA 20kVA 30kVA

Input Data
Nominal Input Voltage 400V 3 phase, neutral and earth
Input Voltage Range 300 ć 480Vac (330 ć 480Vac full charging capability)
Nominal Input Frequency 50/60Hz
Input Frequency Range 40 ć 70Hz
Maximum Input Current at Nominal Input Voltage 18.5A 25.3A 31.7A 45.0A
Input Current Harmonic Distortion (THD) <30% (without filter)
Input Power Factor 0.95 (over specified load and voltage ranges)
Output Data
Nominal Output Voltage 380, 400 or 415Vac selectable
Output Voltage Adjustment Range 360 ć 415Vac
Output Voltage Stability

Static Balanced Load ±1%
Static 50% Unbalanced Load ±3%
Static 100% Unbalanced Load ±5%
Dynamic 50% Load Step ±3%
Dynamic 100% Load Step ±5%
Output Voltage Transient Recovery Time <30ms (to 3% RMS)
Output Voltage Distortion (THD)

Linear Load <3%
Non Linear Load (100% 3:1 Crest Factor Load) <5%
Output Voltage Phase Displacement

Balanced Load 120° ±1%
100% Unbalanced Load 120° ±3%
Nominal Output Frequency 50 or 60Hz
Output Frequency Regulation

Synchronised With Input ±1% or ±4%, selectable
Free Running ±0.005%
Maximum Slew Rate 1Hz/sec
Nominal Output Power Rating

kVA 10 15 20 30
kW 8 12 16 24
Output Nominal Power Factor 0.8
Overload Capability on Inverter (Load Will Transfer to

125% for 10 minutes, 150% for 10 seconds
Static Bypass if Times are Exceeded)
Output Short Circuit Current 300% of nominal current for 100ms
Maximum Load Crest Factor 3:1 (at full load without deĆrating)
UPS Preliminary Pages Prelim Page vii

Service Manual
Specification

Intermediate DC Circuit Data
Internal Battery Type valve regulated, sealed, lead acid cells
Number of Battery Cells 192
Nominal Battery Voltage 384Vdc
Internal Battery Rating 7.2Ahr 2 x 7.2Ahr 2 x 7.2Ahr 3 x 7.2Ahr
Full Load Autonomy Time With Standard Internal Battery

(For part load and battery configuration Autonomy times 6 minutes 9 minutes 6 minutes 6 minutes
refer to the table on page Ćxiii)
DC Bus Overvoltage Trip 500Vdc
End of Battery Discharge Voltage 320Vdc
Battery PreĆalarm Discharge Voltage Level 350Vdc
Battery Charger Nominal Float Voltage at 20°C 432Vdc
Battery Charger Voltage Stability ±1%
Battery Charger Output Voltage Ripple <1%
Maximum Battery Recharging Current 1, 3, 5 or 7A (Selectable)
Automatic Battery Test 12, 24 or 48 hour impedance test
System Data
True OnĆline double conversion, high frequency,
Topology
transformerless design
Power Upgrade Yes ć up to a maximum rating of 30kVA
StartĆup On Battery Yes
System Efficiency (Excluding Battery Charging)

50% Linear Load 88% 88% 89% 90%
100% Linear Load 90% 90% 91% 91%
Full Load Inverter Efficiency 94% 94% 94% 94%
Operating Temperature Range 0° Ć 40°C (20°C for optimal battery lifetime)
Storage Temperature Range Ć20° to 70°C (excluding battery)
Operating Relative Humidity Range <95% (nonĆcondensing)
Maximum Altitude Above Sea Level 1000m before deĆrating
Audible Noise Level At 1 Metre <52dBA
Relay Communications Card DB9 connector Internal Terminals

Alarm Contacts On Battery On Battery
Low Battery Low Battery
On Bypass
UPS On
Remote Stop Contacts Open to disable inverter and static bypass
Cable Entry Bottom entry at rear of unit
Prelim Page viii UPS Preliminary Pages

Service Manual
Specification

Bypass Data
Input Voltage Range For Bypass Switching Nominal ±10%
Overload Capability on Static Bypass 150% for 30 minutes, 1000% for 100 m seconds
Mechanical Data
Unit Dimensions (w x h x d) 530 x 1220 x 950 mm
Unit Weight Without Battery 185kg
Unit Weight With Standard Battery 275kg 365kg 365kg 455kg
Shipping Dimensions (w x h x d) 545 x 1260 x 965 mm
Unit Shipping Weight Without Battery 215kg
Unit Shipping Weight With Standard Battery 305kg 395Kg 395kg 485kg
Enclosure Rating IP20
RAL 7035 Metal Covers

Colour
RAL 7042 Plastic Door
Design Standards
Safety EN50091Ć1Ć1
Radio Frequency Interference (RFI)
Electromagnetic Compatibility (EMC) EN50091Ć2 Class A
European Directive
Quality CE marked compliance LVD / EMC
ISO9001
UPS Preliminary Pages Prelim Page ix

Service Manual
Specification
BATTERY AUTONOMY TIMES

Approximate Autonomy Time in Minutes at
Configuration Part N
Nº Stated Load and 25°C
100% 75% 50% 25% 10%
3 Phase 10kVA
UPS with 1 internal set of batteries
6 9 17 35 115
(Standard configuration)
UPS with 2 internal sets of batteries 17 24 40 82 282

+ 1 x BATT

+ 2 x BATT

+ 3 BATT
3 Phase 15kVA
UPS with 2 internal sets of batteries
9 14 24 55 157

+ 1 x BATT

+ 2 x BATT
3 Phase 20kVA
6 9 17 39 108

+ 1 x BATT

+ 2 xBATT
3 Phase 30kVA
6 9 17 40 110

+ 1 x BATT
Prelim Page x UPS Preliminary Pages

Service Manual
Table of Contents
Table of Contents
Manual Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Amendment Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Limitations of Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Important Instructions for safe use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Personnel Categorisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
Chapter 1 - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 - Equipment Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
1.2.1 - Principle of operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
1.2.2 - UPS Power Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
1.2.3 - Battery fuses switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Chapter 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 - Installation (Mechanical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 - Preliminary Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 - Installation (Electrical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.2.1 - Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.2.2 - Power Cable connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
2.2.3 - Safety Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.2.4 - Protective devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
2.3 - Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.1 - Battery Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.2 - Battery Installation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.3 - Installing the Battery Upgrade Kit (BATTCABLE) .............. 2-9
2.4 - Setting Standard Relay Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
2.4.1 - Setting Options on the standard Relay Interface . . . . . . . . . . . . . . . . . 2 - 12
2.4.2 - Relay Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
2.4.3 - Remote EPO (Emergency Power Off) . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
2.4.4 - Emergency Power Off (E.P.O.) pushĆbutton connection . . . . . . . . . . . 2 - 14
2.4.5 - Connection to Personal Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
2.4.6 - UPS Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
Chapter 3 - Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 - PreĆpower Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 - Validating the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.1 - Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2.2 - Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 - Setting UPS Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.1 - Control Logic PCB CS0072. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.2 - Driver Interface PCB CS0071 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3.3 - Auxiliary DC-DC PSU Converter PCB CS0070 Settings . . . . . . . . . . 3-3
3.3.4 - Battery Charger PCB CS0074 Setting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.5 - LCD Display Monitor Board CS0077 Settings . . . . . . . . . . . . . . . . . . . 3-3
3x3 UPS Preliminary Pages Prelim Page i
Issue 1 - May 2001
Service Manual
Table of Contents
3.4 - Initial UPS Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.4.1 - Converter and Inverter Output Calibration. . . . . . . . . . . . . . . . . . . . . . . 3-4
3.4.2 - Inverter to Bypass Synchronisation Check. . . . . . . . . . . . . . . . . . . . . . 3-6
3.4.3 - Battery Charger Output Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.5 - Power Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.1 - Bupass Failure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.2 - Mains Failure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5.3 - Test Transfer to the Reserve Line (Automatic Bypass). . . . . . . . . . . . . 3-8
3.5.4 - Manual Bypass Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.5.5 - Local EPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.5.6 - External EPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
3.6 - Normal UPS Start-Up Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
3.6.1 - LCD Messages and LED status after starting the UPS. . . . . . . . . . . . 3 - 12
3.7 - Normal Shutdown to Manual Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.8 - Setting Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
3.8.1 - Setting options on the Relay card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
Chapter 4 - Operation and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 - Operator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Chapter 5 - Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 - Control Logic PCB CS0072 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 - Potentiometer adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 - Link and Jumper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 - Auxiliary Supply PCB CS0070 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.2.1 - Battery Threshold settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 - Driver Interface PCB CS007I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1 - Bypass Voltage Threshold Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 - Link and Jumper functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 - Battery Charger CS0074 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
5.4.1 - Battery Charger Voltage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
5.4.2 - Link and Jumper Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4
5.4.3 - Battery test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.5 - UPS monitor board PCB CS0077 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.6 - Relay Interface PCB CS0082 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.1 - EPO Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.6.2 - Optional Second Relay Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.7 - LCD MIMIC DISPLAY CS0075 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.7.1 - Control panel indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Chapter 6 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 - Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.1.1 - Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.1.2 - Weekly Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
6.1.3 - Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 2
6.2 - Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.1 - Factors Effecting Battery Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.2 - Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Prelim Page ii UPS Preliminary Pages
Issue 1 - May 2001
Service Manual
Table of Contents
6.2.3 - Battery capacity testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 - Battery Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.4 - UPS Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Chapter 7 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.1.1 - General Fault Identification Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 - Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 - Removing the UPS Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 - Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 - Fault Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7.6 - Typical Voltage Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 11
7.7 - Fuse Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
7.8 - Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 13
7.8.1 - DC Bus Discharge Routine, Shutdown to Maintenance Bypass. . . . 7 - 13
7.8.2 - DC offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 15
7.8.3 - IGBT Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
7.8.4 - IGBT testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 19
7.8.5 - SCR Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 22
7.8.6 - Inverter Drive Signal Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 26
7.8.7 - Checking power circuit capacitors. . . . . . . . . . . . . . . . . . . . . 7 - 27
7.9 - PCB Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 28
7.9.1 - Auxiliary DC Ć DC Converter Part Nº OSDE0070 (PCB Label: CS0070 Exx) 7 - 28
7.9.2 - LCD UPS Monitor Board OSDE0077 (PCB Label: CS0077 Exx) . . . . 7 - 29
7.9.3 - Inverter Driver/Feedback Interface Part Nº OSDE0071 . . . . . . . . . . . . 7 - 30
7.9.4 - 3ph TL Control Logic Part Nº OSDE0072 * (PCB Label: CS0072 Exx) . . . 7 - 32
7.9.5 - Battery Charger Part Nº OSDE0074 (PCB Label: CS0074) . . . . . . . . 7 - 34
7.9.6 - Input Filter Part Nº OSDE0079 (PCB Label: CS0079 Exx) . . . . . . . . . 7 - 36
7.9.7 - Operator Control Panel (LDC) Part Nº OSDE0075 (PCB Label: CS0075 Exx)7 - 36
Chapter 8 - Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 - Second Relay card (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 - Remote Alarm Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2.1 - Remote Alarm Panel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.3 - Upgrade Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.4 - Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.5 - Internal Extended Battery Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.6 - Battery Connecting Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Chapter 9 - Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Chapter 10 - Schematic Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - 1
3x3 UPS Preliminary Pages Prelim Page iii

Issue 1 - May 2001
Chapter 1 - Overview
1.1 - Introduction
The aim of this chapter is to give a general overview of the, control principles and construction of the
series onĆline Uninterruptible Power Supply (UPS).
The UPS is a standĆalone, single module, system designed to furnish a well regulated 3 phase
power supply to a critical load, such as a computer, under all rated load and input supply conditions.
The unit is of a category known as an ònĆline' UPS and is therefore permanently connected between
the utility 3Ćphase supply and the load equipment and operational at all times
A battery provides the standĆby power source for the UPS when the input utility supply fails.
The system offers the user the following advantages:
Increased power quality. The UPS has its own internal voltage and frequency regulator circuits
which ensure that its output is maintained within close tolerances independent of voltage and frequency
variations on the utility power lines.
Increased noise rejection. By rectifying the input AC power to DC power, and then converting it
back to AC, any electrical noise present on the input utility supply line is effectively isolated from the UPS
output, therefore the critical load sees only clean power.
Powewr blackout protection. If the utility power fails, the UPS continues to power the critical load
from its backĆup battery source, leaving the load immune from power disturbances ć even complete
power blackouts.
1.2 - Equipment Construction

The equipment is constructed around a steel frame with removable panels. The door which can be seĆ
cured with a key is opened to give easy access to the input, bypass, output, reserve line circuit breakers
and battery C.B. fused switch, protecting them from accidental operation.
A string LED and control panel on the front of the cabinet permits the operator to monitor the UPS.
The cabinet houses both the power components and the batteries.
It is carried on four wheels. Jacking feet help to support the UPS, and also prevent it from moving once
it has been wheeled into its final position. These feet are also used to secure the equipment to its shipĆ
ping pallet during transit.
Cooling is by internal fan. Air is drawn in from beneath the UPS and exhausted through ventilation grills
of the front panel. These areas must be kept free of anything that may avoid the air flow into and out of
the unit.
Operator
control
panel
Lockable
Door
1220
530
Figure 1-1 Front view of cabinet.

3x3 UPS Overview 1-1
Chapter 1 - Overview Service Manual
Equipment Construction
1.2.1 - Principle of operation
Normal operation
During normal operation, i.e. when the UPS input supply is present and within specification, both the
converter and inverter sections are active and the automatic byĆpass is turned on to connect the inverter
output to the critical load terminals. The battery fuseĆholder switch is also closed and the battery is thereĆ
fore permanently float charged at the d.c. terminals voltage level.
Mains Failure
If the mains has a failure or is out of tolerance the converter will be supplied from the battery, while the
Inverter will continue to operate for a period of time which depends on the load and the capacity of the
battery. If the mains supply has not returned within this time, the Inverter will go off automatically and
an alarm condition will appear on the UPS operator control panel.
Critical load will not be interrupted in the event of a drop or return of the AC power mains.
Return of power mains

When the mains returns within the required tolerance, the converter will be automatically supplied from
mains, supplying power to the Inverter and recharging the battery at the same time. There will be no
interruption of the critical load.
UPS fault
In the event of an inverter failure, the automatic byĆpass will automatically transfer the load onto the
mains with no interruption. In such an event, request qualified technical assistance.
The load will be transferred with no interruption if the inverter is synchronised with the mains; if this is
not the case, there will be an interruption of some milliseconds.
The intervention of the automatic byĆpass line is shown on the front panel by the yellow led on.
WARNING CAUTION: When the load is being supplied from the bypass line through the automatic byĆ
pass, it is connected directly to the mains supply and is therefore no longer protected
against mains faults.
Maintenance Bypass
A second bypass circuit contained in the UPS cabinet, identified as the 'Maintenance Bypass' line is
included to enable the reserve supply to be made available to the load while facilitating a safe working
environment for carrying out scheduled UPS system maintenance or trouble shooting. The circuit is
manually selected by the Manual Bypass Switch (3) which can be padlocked in the OFF position.
WARNING CAUTION CAUTION: If an automatic circuit breaker device is not present in the input disĆ
tribution panel, there remains a dangerous voltage at the output terminals and also on the
input terminals of the UPS module that is switched off.
Note: The load is not protected from mains aberrations when operating on the
maintenance bypass mode.
1-2 3x3 UPS Overview

Service Manual Chapter 1 - Overview
Equipment Construction
Figure 1-2 Split Bypass" configuration
UPS Split
Bypass
Input
Link
UPS
Output
Battery UPS
1.2.2 - UPS Power Configuration
Common Bypass
The UPS is factory set to operate in the Common Bypass" configuration. Split Bypass links shown
in Figure 1-2 connect the Input Mains supply to the Reserve Input (Bypass) line creating a common
input. A separate Reserve Input is therefore not required.
Split Bypass
To configure the with a Split Bypass input, the Split Bypass links shown in Figure 1-2 are removed
by the commissioning engineer. In the Split Bypass" configuration the static bypass line is connected
by a separate power switch to a dedicated `bypass' power source which also feeds the maintenance
bypass line. Where a separate power source is not available the Reserve and Converter input supply
connections would be linked together.
With the exception of the maintenance bypass switch (3), all the isolators shown must be closed during
normal UPS operation.
1.2.3 - Battery fuses switch

The battery is connected to the d.c. bus through a battery fuses switch (5) fitted inside the UPS cabinet
3x3 UPS Overview 1-3

Chapter 2 - Installation
2.1 - Installation (Mechanical)
2.1.1 - Preliminary Checks

Before installing the UPS hardware the following preliminary checks must be carried out:
1. Verify that the UPS room satisfies the environmental conditions stipulated in the equipment
specification, paying particular attention to the ambient temperature and air exchange
system.
Material admittance
1. Remove any packaging debris, then visually examine the UPS and battery equipment for
transit damage, both internally and externally.
Report any such damage to the shipper immediately.
2. Ascertain that the material supplied corresponds with that on the freight bill.
Identification
The equipment supplied is provided with an adhesive identification label placed on the UPS rear panel
reporting type of UPS model and power.
The cases used to transport the equipment must be unpacked as specified by the procedure stated
below.
Packing material removal

During this operation observe the indications (FRAGILE, UP) printed on the case to avoid damaging the
UPS
To remove the packing material proceed in the following manner:
1. Place the equipment on the floor as instructed on the outer case (UP, DOWN).
2. Cut the tape and open the flaps at the top of the cardĆboard box.
3. Remove the extruded elements used as protective packing.
4. Position the forks of the lifting truck under the UPS taking care not to damage the UPS
castors and lift it a few centimetres from the floor. Back up the forklift and position the UPS.
Lower to the floor.
Hinet is provided with wheels to allow ease of movement.
5. Retain the packing material.
The original transit packing should be used if the equipment is be returned to the
maintenance centre, or moved to another position.
6. Check that the equipment has not been damaged.
Any damage should immediately be reported to the Sales Representative.
7. Locate the four battery fuses. Do not fit at this point.
8. Locate the door key and panel bolt spanner secured on the rear of the UPS. Retain for future
use.
9. The operator manual and communication cable are located behind the hinged front door.
Moving the cabinets
WARNING Ensure that any lifting equipment used for moving the UPS cabinet has sufficient lifting caĆ
pacity.
Ensure that the UPS weight is within the designated surface weight loading (Kg/cm2) of any
handling equipment. See the UPS specification for weight details.
The UPS can be lifted using a fork lift. Take care when using either method not to damage
the UPS castors located on the bottom of the unit.
3x3 UPS Installation 2-1

Chapter 2 - Installation Service Manual
Installation (Mechanical)
Locating the unit in the operating position

The UPS cabinets are fitted with castors on the base to allow ease of movement and positioning. When
the equipment has been finally positioned ensure the adjustable feet are set so that the UPS will remain
stationary and stable
Ensure the following considerations are observed when locating the equipment:
a) Easy connection.
b) Enough space to ensure good access when servicing the UPS.
c) Exchange of air sufficient enough to dispel heat produced by UPS.
d) Protection against atmospheric agents.
e) Protection against excessive humidity and very high heat sources.
f) Protection against dust.
g) Compliance with the current fire prevention regulations.
h) Operating environment temperature is within +20° C and +25° C.
The batteries are at maximum efficiency in this temperature range.
Clearances
Cooling air enters the module through ventilation grills located at the bottom of the cabinet and is exĆ
hausted through the fan grills located on the front panel; you must therefore allow for a minimum gap
of 170 mm behind the unit to allow adequate air flow. Clearance around the front of the equipment
should be sufficient to enable free passage of personnel with the door fully opened.
Raised floor installation

If the equipment is to be located on a raised floor it must be mounted on a pedestal suitably designed
to accept the equipment point loading.
Refer to the base view to design this pedestal.
Cable entry
Cables enter the UPS cabinet from the rear.
UPS Mechanical Characteristics
Rated power kVA 10 15 20 30

Height mm 1220
Width mm 530
Depth mm 950
Weight:
Hinet cabinet 185
with 1 battery strings 275

K
Kg
Ventilation Ć forced
Airflow full speed 600

m3/h
Air flow half speed 300
Protection grade Ć IP 20
Cable entry Ć Bottom
2-2 3x3 UPS Installation

Service Manual Chapter 2 - Installation
Installation (Electrical)
2.2 - Installation (Electrical)
The UPS requires connection of the power cables once it has been mechanically installed. All auxiliary
cables, whether screened or not, should be run separate from the power cables in metal conduits, or
metal ducts electrically bonded to the cabinet metalwork to which they are connected.
2.2.1 - Power Cabling
WARNING BEFORE CABLINGĆUP THE UPS, ENSURE THAT YOU ARE AWARE OF THE LOCATION AND
OPERATION OF THE EXTERNAL ISOLATORS THAT CONNECT THE UPS INPUT/BYPASS
SUPPLY TO THE MAINS DISTRIBUTION PANEL.
CHECK THAT THESE SUPPLIES ARE ELECTRICALLY ISOLATED, AND POST ANY NECESSĆ
ARY WARNING SIGNS TO PREVENT THEIR INADVERTENT OPERATION.
2.2.2 - Power Cable connections
The cable connection terminal block shown in Figure 2Ć1 is located at the rear of the cabinet.
1. Prepare the power cable ends and locate in the lower terminals of the terminal block.
2. Connect Input Mains to terminals 14 (U1), 15 (V1), 16 (W1) & 17 (N1).
Caution When preparing the power cables for connection, provide sufficient spare cable to allow
the UPS to be moved if necessary from it's normal operating position for servicing access.
Spare cable can be coiled beneath the unit.
3. Tighten the terminal block lower securing screws and check that each cable is secure.
4. Connected the UPS Output power cables to terminals 1 (U2), 2 (V2), 3 (W2) & 4 (N2) as
shown in Figure 2Ć1.
5. Secure the cables to the cable securing bar adjacent to the terminal block using appropriate
cable clamps.
Note: If connecting a battery to the External Battery input connections ensure

that connections are made with the correct polarity.
Split Bypass Configuration

If the UPS is to operate with a separate Reserve Input (Bypass) supply.
1. Connect the power connections for the Bypass to terminals 10 (U3), 11 (V3), 12 (W3) & 13
(N3)
2. Connect the Input Mains to terminals to 14 (U1), 15 (V1), 16 (W1) & 17 (N1) as shown in
Figure 2Ć1.
Caution When the UPS is to be operated in the Split Bypass" configuration, the Split Bypass shortĆ
ing links must first be removed by the Commissioning Engineer before Power is applied
to the unit.
Note: The maximum cable size that can be connected to the UPS power
terminal block is 25mm 2

Figure 2-1 Connections to distribution Terminal Block.
PE U2 V2 W2 N2 + + ć ć U3 V3 W3 N3 U1 V1 W1 N1 PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Ground Ground
UPS Output Ext. Battery Input Reserve Input (Bypass) Input Mains
1.. Ground (ground lead for load connection) 2.. Input reserve (Bypass) phase U3
3.. Output phase U2 4.. Input reserve (Bypass) phase V3
5.. Output phase V2 6.. Input reserve (Bypass) phase W3
7.. Output phase W2 8.. Input Reserve (Bypass) Neutral N3
9.. Output Neutral N2 10.. Input Mains phase U1
11.. Battery Positive (ext. Battery input) 12.. Input Mains phase V1
13.. Battery Positive (ext. Battery input) 14.. Input Mains phase W1
15.. Battery Negative (ext. Battery input) 16.. Input Mains Neutral N1
17.. Battery Negative (ext. Battery input) 18.. Ground (Incoming ground wire from UPS
input mains connected to this terminal)
Figure 2-2 Cable Securing Bar
Cable Securing Bar

2.2.3 - Safety Earth

The safety earth busĆbar is located near the UPS output terminals. The safety earth cable must be conĆ
nected to the earth terminal and bonded to each cabinet in the system.
All cabinets and cable trunking must be earthed in accordance with local regulations.
WARNING FAILURE TO FOLLOW ADEQUATE EARTHING PROCEDURES CAN RESULT IN ELECTRIC

SHOCK HAZARD TO PERSONNEL, OR THE RISK OF FIRE, SHOULD AN EARTH FAULT
OCCUR.
BEFORE ANY OTHER CABLE CONNECTION THE PE SAFETY CONDUCTOR SHALL BE
CONNECTED
2.2.4 - Protective devices
Protection against earth faults (RCD devices):

In the event of a differential (RCD) device being installed upstream of the input supply, the transient and
steady state earth leakage currents that are produced during startĆup of the UPS must be taken into acĆ
count.
The presence of an RFI suppression filter inside the UPS, determines a residual earth current no greater
than 500 mA.
Residual current circuit breakers (RCCB) must be sensitive to d.c. unidirectional pulse (class A) in the
mains and insensitive to transient current pulses.

Battery Installation
2.3 - Battery Installation
All UPS models are normally shipped with an internal battery fitted, therefore a thorough check
of the battery installation is required before applying power to the unit. The battery capacity, number of
cells and installation is dependent on the unit power rating and autonomy option ordered. A full break
down of the different battery configurations can be found in the Specification on preliminary page Ćxiii.
In addition to the standard battery fitted to the UPS extra strings may be added (to a maximum of 4) to
upgrade the battery autonomy. Full fitting instructions for the battery upgrade are included with each
kit, however this information has been also included in this section of the manual for continuity.
The UPS may also have an extended battery option to be fitted either in a separate or atĆ
tached cabinet, therefore the same basic checks apply.
Before
2.3.1 - Battery Safety
WARNING THE BATTERY CHAIN IS A HIGH VOLTAGE ENERGY SOURCE. WHICH CAN BE VERY DANĆ
GEROUS GIVING A POTENTIAL RISK OF SHOCK OR BURNS.
GREAT CARE SHOULD BE EXERCISED AT ALL TIMES WHEN WORKING WITH BATTERIES.
S Special care should be taken when working with the batteries associated with this
equipment.
S When connected together, the battery terminal voltage will exceed 380Vdc and is
potentially lethal.
S Eye protection should be worn to prevent injury from accidental electrical arcs.
S If a battery leaks electrolyte, or is otherwise physically damaged, it should be
placed in a container resistant to sulphuric acid and disposed of in accordance with
local regulations.
S If electrolyte comes into contact with the skin the affected area should be washed
immediately.
2.3.2 - Battery Installation Check

1. Gain access to the battery safety cover by first opening the front hinged door.
a) Disconnect the Earth bonding cable from the safety cover.
b) Remove the two top M6 retaining bolts.
c) Release the two bottom retaining bolts and lift the cover from the UPS.
2. Remove the Main Switch Cover held by four M6 retaining bolts.
3. Carefully ease the cover away from the control switches.
Note: Each battery string are held in 3 trays positioned as

shown in Figure 2Ć3, up to four strings can be fitted dependent on model.
4. Check the battery security in each tray.

5. Check that the FastĆon connecters to each battery are secure and that each connector is
correctly positioned on the battery terminals.
6. Check that the battery linking connectors are correct for each tray.
7. Check that the +ve cable from lower battery tray connector is connected to the correct
battery fuse, as shown in Figure 2Ć4
8. Check that the ćve battery from the top battery tray connector is secured to the common
battery ćve connection bar.

Figure 2-3 Battery Tray Installation for one battery string
Battery Fuses (shown removed)
Battery Earth Bar
Battery String Voltage Check
Note: Battery fuses are removed for transit and should only be fitted by the
commissioning engineer. The fuses can be found with the User manual, in
the document pocket on the battery safety cover.
Battery String Voltage check
1. Ensure the battery fuses are removed from the switched fuse holders.
Warning Do not fit the battery fuses into the fuse holders or close the fuse holders.
2. With a DVM set to a DC range of above 450V, check for each individual battery string
voltage. This voltage for a serviceable battery should be between +385V and +416V DC.
3. Measure the battery string voltage from the lower connecting screw of the appropriate fuse
holder and the battery ćve connection bar. As shown in Figure 2-3
4. If a voltage of less than +385V is recorded reĆcheck the battery connections and reĆtest the
string voltage.
Note: A measured voltage substantially less then +385V DC may point to a

defective battery block this can be further isolated by disconnecting each
individual tray and carry out a further check of each tray voltage. This
should be grater than 132V for trays of 11 battery blocks and 120V for 10
blocks.

Figure 2-4 Battery Cable Connections for one string
F1 F2 F3 F4
Battery Fuses
Battery ćve Connection Bar

CN1
Battery String 3 Top Battery Tray (10)

CN2
Battery String 3 Middle Battery Tray (11)

CN3
Battery String 3 Bottom Battery Tray (11)
CN1
Battery String 1 Top Battery Tray (10)

CN2
Battery String 1 Middle Battery Tray (11)

CN3
Battery String 1 Bottom Battery Tray (11)

Note: Battery strings 1 & 3 shown connected

2.3.3 - Installing the Battery Upgrade Kit

Note: Installation of a battery upgrade kit must only be carried out by a suitably
qualified, manufacturer approved engineer.
Kit Contents
Prior to installing the battery upgrade kit thoroughly check the items for damage and ensure that they
are in a serviceable condition.
Check that the battery kit contains the following items:
Item Description Part Nº Quantity

Mylar insulating sheet CM 0319 3
Battery tray CM 0470 3
Battery retaining bracket CM 0743 3
Lexan protection CM 0101 3
Battery cable harness OS 001 1
Adhesive foam strip ? ć
Cable holder self adhesive ? 9
Label `High Voltage' ? 3
Note: The 32 battery blocks are not included in the upgrade kit Part Nº
BATTCABLE, but are supplied separately as Battery Kit Part Nº
INTBATT.
Figure 2-5 Battery Tray Assembly
Lexan protection strip Battery Blocks

(links fitted)
Cable Holder
Battery Cable
Foam Strip
Retaining
Bracket
Battery Tray Mylar Insulating Sheet

Cable Holder
Lexan protection strip

Retaining Bracket
Battery Cable Connector

(Secure to retaining
Mylar Insulating Sheet
bracket with cable tie)
(fold to fit batteries)
Battery Tray

Battery Tray Assembly

1. Place the Mylar insulation strip on to the battery tray.
2. With a DVM check each individual battery block terminal voltage is within 12.5V to 13.0V.
Voltages measured below this may indicate a defective battery block. Refer to `Battery
Maintenance' on Page 6Ć5 Chapter 6 `Maintenance' for information on battery testing.
3. Fold the mylar insulation to fit the batteries and place the 11 battery blocks on to the battery
tray, as shown in Figure 2-5
(Note 10 battery blocks are fitted to the top battery tray.
4. Stick the adhesive foam strip to the battery fixing bracket.
5. Screw the battery retaining bracket to the battery tray.
Connect the batteries using the short battery interconnecting links.
6. Fit the lexan protection to the battery fixing bracket.
7. Place the three adhesive cable retaining clips to the lexan insulating strip, one in the middle
and one at each end.
8. Identify the cable Anderson type connecter supplied with a red and black interconnecting
cable and connect the red cable to the remaining +ve battery connection and the black
cable to the ćve battery connection.
9. Secure the cables in the cable retaining clips.
10. Secure the red cable to the battery retaining bracket at the rear of the assembled battery tray
using a cable tie supplied.
11. Stick the `High Voltage' label to the lexan insulating strip.
Repeat the above procedure for the remaining two battery trays.
Note: The upper battery tray is fitted with 10 batteries.
Battery String Connection

1. Ensure that the UPS has been powered down.
Note: When positioning the battery trays in the UPS, slight downward pressure
may be required on the front of the tray to clear the chassis metalwork at
the rear.
2. Fit the lower battery tray of 11 batteries to the lower position and secure using the battery
tray retaining bolt.
3. Fit the second battery tray of 11 batteries to the middle position and secure using the battery
tray retaining bolt.
4. Fit the upper battery tray of 10 batteries to the top position and secure using the battery tray
retaining bolt.
5. Refer to the schematic diagram (Figure ) locate the battery string interconnecting links from
the battery cable set.
6. Thread the Red +ve wire of the lower Anderson type cable connector through the
appropriate access hole and connect it to the battery fuse lower cable terminal.
Note: Fuse F1 is used for the first battery string, F2 for the second etc.
7. Thread the Black ćve wire of the top Anderson type cable connector through the appropriate
access hole and connect it to the ćve battery connection bar cable stud.
8. Connect the wiring harness connectors to the battery tray Anderson connectors.
a) CN1 to the top battery tray.
b) CN2 to the middle battery tray.
c) CN3 to the lower battery tray.
9. Secure the Anderson type battery connectors to the battery retaining bracket using the cable
ties supplied with the kit.
2 - 10 3x3 UPS Installation

Battery String Voltage Check

1. Ensure the battery fuses are removed from the switched fuse holders.
Warning Do not fit the battery fuses into the fuse holders or close the fuse holders.
2. With a DVM set to a DC range of above 450V, check for each individual battery string
voltage. This voltage for a serviceable battery should be between +385V and +416V DC.
3. Measure the battery string voltage from the lower connecting screw of the appropriate fuse
holder and the battery ćve connection bar. As shown in Figure 2-3
4. If a voltage of less than +385V is recorded reĆcheck the battery connections and reĆtest the
string voltage.
Note: A measured voltage substantially less then +385V DC may point to a

defective battery block this can be further isolated by disconnecting each
individual tray and carry out a further check of each tray voltage. This
should be greater than 132V for trays of 11 battery blocks and 120V for 10
blocks.
3x3 UPS Installation 2 - 11

Setting Standard Relay Interface PCB
2.4 - Setting Standard Relay Interface PCB
The preĆsettings required are only those which concern the interfaces wiring to any external devices,
i.e., personal computer, safety switch, remote panel.
2.4.1 - Setting Options on the standard Relay Interface
A standard Relay Card is situated on the left side of the rear panel. This card is typically supĆ
plied and is factory preĆset to operate with the PC.
When the operation is through the remote indication panel, the factory will deliver the card already preset
to operate with the remote panel.
Figure 2-6 Setting options on the standard Relay Board
FUNCTION JUMPER CLOSED JUMPER OPEN

Use With PC JP4 JP5
Use With Remote Panel JP5 JP4
EPO Enabled ć JP6
EPO Disabled JP6 ć
Note: If an optional second relay interface PCB is to be fitted Refer to the `Relay
Interface PCB CS0082' on Page 5Ć7 Chapter 5 `Functional Description'
for further information on Link settings.

2.4.2 - Relay Interface Connections
The relay interface PCB provides two sets of volt free contacts rated at 50V 1A the PCB receives the UPS
status signals from the Display Control Logic PCB Part Nº CS0073 and is connected to CN1.
Output signals from the relay interface are made to the terminal block M1 shown in Figure 2Ć7, or from
the RS232 DB9 connector P1 (fitted to later equipment only).
Figure 2-7 Relay Interface Outputs

2.4.3 - Remote EPO (Emergency Power Off)

A connection is provided for a switch, which can be located remotely from the UPS, and which has the
same function as the internal EPO switch. When it is operated it shuts down the inverter, and inhibits the
static switch so that power is removed from the load.
WARNING Pressing the Remote EPO push button will turn the inverter off and remove power from the
load.
The mains input, bypass input and battery terminals still carry lethal voltages after pressing
the EPO switch. Do not remove cover from these parts.
Only competent personnel must remove protection panel held in place with screws.
2.4.4 - Emergency Power Off (E.P.O.) pushĆbutton connection

Refer to Figure 2-6 and Figure Figure 2-7 to make a pushĆbutton connection to the standard Relay
Card.
1. Obtain a suitable length (not more than 100 m.) twoĆwire cable (0.6 sq. mm cross section)
2. Connect one end of the cable to the N.C. pins of a fire preventing button.
3. Connect the other end to the standard Relay Card connector M2.
2.4.5 - Connection to Personal Computer

The UPS contains a standard DB9 Female connector located on the rear of the UPS.
Several signals are provided on this port and assigned as follow:
PIN Description
1 Low Battery (N.O.)
2 T.B.D.
3 T.B.D.
4 N.C.
5 Common
6 N.C.
7 Low Battery (N.O.)
8 Mains Fail (N.O.)
9 Mains Fail (N.O.)

2.4.6 - UPS Monitoring

The UPS has the capability of being monitored with stand alone computers, network workstations,
network servers, or UNIx hosts via the DBĆ9 female connector (1) located on the rear of the UPS.
The capability is used in applications requiring the UPS to provide status and power monitoring informaĆ
tion to the computer system. For example, during a mains power failure, the information can be used
by the computer's operating system or application program to automatically save information in buffers,
to close files, and shutdown operations prior to battery capacity depletion.
Monitoring of the UPS via a computer system is easily made with a Liebert Multilink Software and a
special cable (2) shipped with the Unit.
Figure 2-8 UPS Monitoring cable connection

Chapter 3 - Commissioning
3.1 - PreĆpower Checks
WARNING The UPS must be commissioned by a suitably qualified, and manufacturer approved enĆ
gineer.
Failure to ensure proper commissioning may invalidate any implied warranty.
WARNING During the commissioning procedure the UPS output terminals will become live.
If any load equipment is connected to the UPS output terminals, fully isolate it from the UPS
to ensure that no damage is caused in the extremely unlikely event of a UPS failure
WARNING During the commissioning procedure it may be necessary to power up the unit with the side
or top covers removed, in this situation exposure to potentially lethal voltages is possible
even with the input utility supply switched off.
Take great care at all times to minimise the risk of contact with live voltages, especially when
working around the battery or the dc busbar.
3.2 - Validating the Installation

Before carrying out the following checks, refer to the Ìnstallation Manual' supplied with the equipment
or the information contained in Chapter installation in this manual.
3.2.1 - Positioning
1. Check that the UPS has been correctly positioned with at least 150mm clear space at the
rear.
2. Check that there is sufficient space at the sides of the unit to gain access.
If no access is available the UPS input and output cabling must be of sufficient length to
allow the unit to be moved forward.
3.2.2 - Preliminary checks

1. Ensure that all the UPS isolators, including he fused battery switch, are open (i.e. OFF or in
position `0').
2. Check the voltage of the input mains supply.
3. Check that the cable connections to the distribution terminal block are correct. Refer to
Figure 2Ć1 on page 2Ć4.
4. Check that the internal battery connections are secure and any external battery connected to
the Ext.Battery Input terminals are connected in the correct polarity. Refer to the `Battery
Installation' procedure on page 2Ć6.
Input mains voltage checks

1. Apply mains voltage to input terminals 14 (U1), 15 (V1), 16 (W1) & 17 (N1).
2. Measure line to line voltage of all three phases and ensure that the values are within ±10% of
nominal rating.
3. Ensure correct phase rotation clockwise R, S, T using an oscilloscope or phase rotation
meter
Note: If a split bypass is fitted, apply bypass mains voltage to the bypass
terminals 10 (U3), 11 (V3), 12 (W3) & 13 (N3) and duplicate the check for
the Input Mains.
3x3 UPS Commissioning 3-1

Chapter 3 - Commissioning Service Manual
Validating the Installation
3.3 - Setting UPS Parameters

Check that the following factory set parameters are correct for the normal operating Conditions of the UPS.
Standard link positions are shown in bold text.
3.3.1 - Control Logic PCB CS0072.
General Operation:
LINK POSITION FUNCTION
OPEN Eco mode operation (bypass line preferred)
J1
CLOSED Normal operation (inverter line preferred)
OPEN Bypass frequency window 4%
J2
CLOSED Bypass frequency window 1%
OPEN Inverter output frequency 60Hz
J3
CLOSED Inverter output frequency 50Hz
Output voltage selection:

Link 380Vac 400Vac 415Vac
J4 Open Closed Open
J5 Closed Open Open
The following link position set the UPS overload level relative to the UPS kVA rating. (As shown
on the factory rating plate)
Link 10kVA 20kVA 30kVA
J6 Open Closed Open
J7 Closed Open Closed
J8 Closed Closed Open
The following link position set the inverter and converter peak current limits which is dependent
on the UPS kVA rating. (as shown in the factory rating plate). Ensure that these links are set
according to the following table:
Link 10kVA 20kVA 30kVA
J9 Open Open Open
J10 Open Open Open
J11 Closed Closed Closed
J12 Closed Closed Closed
3.3.2 - Driver Interface PCB CS0071 Settings
Bypass value setting

Link 380Vac 400Vac 415Vac
J1A Closed Open Open
J2A Open Closed Open
J3A Open Open Closed
Service / test mode for the secondary DC bus voltage

DC V/Link J4A J5A
375 Vdc Closed Closed
750Vdc Open Open
3-2 3x3 UPS Commissioning

Service Manual Chapter 3 - Commissioning
3.3.3 - Auxiliary DC-DC PSU Converter PCB CS0070 Settings

No link setting are required.
3.3.4 - Battery Charger PCB CS0074 Setting
Set the correct battery current limit according to the following link chart.
Link/Ampere 1Amp 3Amps 5Amps
JP1 Open Open Closed
JP2 Open Closed Open
We recommed to used the following battery current limint setting:

Battery size 7.5 Ah 2x7.5Ah 3x7.5Ah 4x7.5Ah
Battery current 1Amp 1Amp 3Amps 3Amps
Link Position Function

Open Boost recharge disable
JP3
Closed Boost recharge enable
Open Battery charger temperature compensation disable
JP4
Closed Battery charger temperature compensation enable
Battery test settings
Links JP5 to JP10 set the capacity of the standard battery, check the battery Ah to set the corĆ
rect value as shown in the table below
Link JP10 JP9 JP8 JP7 JP6 JP5
Ah 7.2Ah 2x7.2Ah 3x7.2Ah 4x7.2Ah 38Ah 65Ah
JP11 SHOULD BE ALWAYS CLOSED
Set the automatic battery test interval referring to the table below (it is recommanded to use
48h)
Link J4 J5 J6
Time 12Hours 24Hours 48Hours
3.3.5 - LCD Display Monitor Board CS0077 Settings
Used for PCB testing porposes only.

Link Position Funktion
JP1 1–2 close for normal operation.
JP3 2–3 close for normal operation.
Note: THE SILKSCREEN IDENT (JP1/JPS) IS NEXT TO PIN NUMBER 3.
LINK JP2 ( External EPO ):
JP2 is used to enable the operation of the optional external EPO.

Link Ext EPO fitted Ext EPO not fitted
JP2 Open Close

3.4 - Initial UPS Start-up.

The following procedure describes the start-up and calibration of the UPS at the initial Start-up.
Figure 3-1 Operator Control Panel
2 1 a b
3 4 c
Note: The following instructions refer to the controls on the UPS OPERATOR PANEL
(shown above). The user interface consits of 4 status indicator LEDs (labled 1-4),
a LCD panel and 4 control push buttons (labled a-d).
3.4.1 - Converter and Inverter Output Calibration.

The Secondary DC bus and Inverter Output settings will be automatically set by the Voltage parameters set on the
UPS Control Boards (see Setting UPS Parameter Section for more details).
The following table shows the correct levels of the Inverter AC volts and the Secondary DC Bus volts, depending
on the Voltage Parameters:
Voltage Parameter/ Secondary DC Bus Voltage.
Inverter AC (L–L) Voltage.
380Vac 715Vdc
400Vac 750Vdc
415Vac 800Vdc
Before starting the UPS connect a DVM set to DC volts to the UPS Secondary DC bus as shown below:
Figure 3-2 DC Bus Voltage check
F2
F3
Check Secondary DC bus

between Fuse F3 & F2
765V DC

1. Close the MAINS INPUT MCB (I1).

2. Close the UPS OUTPUT MCB (I4).
3. Wait approx. 20 seconds and check that the following sequence occurs:
D The Operator display Panel LCD energises (if required adjust Language settings as described in
chapter 4).
D The Red ÀLARM' (2) LED illuminates.
D The Alarm Buzzer sounds.
D The Secondary DC Bus has risen to approx. 650Vdc (shown on the DVM).
4. Start the Inverter using the following procedure:
a) Press the `MENU' push button (a) on the FRONT PANEL.
b) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.
c) Confirm the `COMMAND' menu selection by pressing the `BACK' and `NEXT' push-buttons at the same
time (i.e. ENTER).
d) Select the ÌNVERTER ON- OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.
e) To start Inverter, press `BACK' and `NEXT' at the same time.
D A *CONFIRMED* message will be displayed.
D The Inverter Section will now be started and be brought on-line.
f) Press `CLEAR' (d) twice to return to the main menu.
5. Wait 20 seconds and confirm that:
D The Green `LOAD on INV' LED has illuminated.
D Using the DVM check that the Secondary DC has risen to within 1% of the appropriate level shown in the
table above (e.g. 750Vdc for a 400Vac installation).
If required the level of the secondary DC bus can be adjusted using the Potentiometer P2 on the 3 Phase Control
Logic PCB (CS0072).
Note: Turn P2 Counter-Clock Wise (CCW) to increase the Secondary DC Bus.
6. Remove the DVM from the DC bus, set it to AC Volts and reconnect to the UPS output terminals (2 and 3) to
give a Line to Line voltage measurement. As shown below:
Figure 3-3 Connections to distribution Terminal Block
PE U2 V2 W2 N2 + + ć ć U3 V3 W3 N3 U1 V1 W1 N1 PE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Ground Ground
UPS Output Ext. Battery Input Reserve Input (Bypass) Input Mains
7. Check that the Inverter Output Voltage has risen to within 1% of the appropriate level (e.g. 400Vac).
If required the level of the Inverter AC can be adjusted using the Potentiometer P1 on the 3 Phase Control Logic
PCB (CS0072).
Note: Turn P1 Counter-Clock Wise (CCW) to increase the Inverter Output Voltage.

3.4.2 - Inverter to Bypass Synchronisation Check.

The following procedure describes the checking of the Inverter Phase-lock-loop circuit.
1. Using an appropriate oscilloscope connect:
Probe 1 to the Reserve Mains Ù' phase voltage (termial 10).
Probe 2 to the UPS Output Ù' phase voltage (terminal 2).
Note:Note: Use the Reserve Mains Neutral (termial 13) should be used a common
reference, therefore the scope channels should be set to differential mode.
2. Close the RESERVE MAINS MCB (I2).

3. Ensure that:
D The LCD shows the message:
BYPASS LINE WITHIN LIMITS
D The Zero crossings of the Inverter and Bypass sinewaves are synchronised.
3.4.3 - Battery Charger Output Calibration.

The following procedure describes the calibration of the UPS's Battery charger output.
Connect a DVM set to DC Volts to the UPS's External Battery terminals (+ve at terminals 6 or 7 and ćve at terminals
8 or 9).
Ensure that:
D The DC value at the battery terminals is at 432Vdc +/-1%.
If required the Battery Charger voltage can be adjusted using the potentiometer P1 on the Battery Charger Board
(CS0070).
Note: Turn P1 Counter-Clock Wise (CCW) to increase the Battery Charger Output Voltage.
Insert the appropriate number of fuses into the INTERNAL BATTERY Fused Switch (I5) and Close.
Ensure that:
The red ÀLARM' LED extinguishes.
The green `NORMAL' LED illuminates.
The LCD shows a `- UPS in Operation ć` heading.
THE START UP AND CALIBRATION OF THE UPS IS NOW COMPLETE.

3.5 - Power Checks
Once the initial start up and commissioning have been completed the UPS should be functionally checked and
before connecting to the critical load.
The following procedure describes the recommended functional checks:
3.5.1 - Bypass failure test.
3.5.2 - Mains failure checks.
3.5.3 - Load Transfer Test
3.5.4 - Maintenance bypass check.
3.5.5 - Internal EPO check.
3.5.6 - External EPO (if required).
3.5.1 Bupass Failure Test

The purpose of this test is to ensure that the UPS correctly recognises a Bypass failure (simulated by opening the
Reserve MCB) and that the Inverter remains stable.
1. Open the `RESERVE INPUT' MCB. ( I2 ).
2. On the LCD ensure that the following alarms are displayed:
D UPS ALARM ć (heading)
D MAINS WITHIN LIMITS.
D BATTERY VOLTAGE WITHIN LIMITS.
D INVERTER OPERATING.
D LOAD ON INVERTER.
D BYPASS LINE OUT OF LIMITS.
D The green `NORMAL' LED ( 1 ) will extinguish.
D The red ÀLARM' LED ( 2 ) will illuminate.
D The green `LOAD on INV' LED ( 3 ) remains illuminated.
D The alarm buzzer should sound, press `CLEAR' (d) push button to silence the alarm.
3. Using a DVM check that the output Voltage and frequency at output terminals is correct (e.g. 400Vac and
50Hz).
4. Close the `RESERVE INPUT' MCB. ( I2 )
5. The UPS should now return to normal Operation.
Ensure that:
D The `ć UPS in Operation ć` returns to the LCD.
D The green `NORMAL' LED ( 1 ) has illuminated,
D The red ÀLARM' LED ( 2 ) has extinguished,
D The yellow `BYPASS ON' LED ( 4 ) has extinguished
D The green `LOAD-on-INV' LED ( 3 ) has illuminated.
3.5.2 Mains Failure Checks

The purpose of this test is to ensure that the UPS correctly recognises a Mains Failure (Simulated by opening the
MAINS INPUT MCB) and is able to operate from the internal Battery.
1. Open the `MAINS INPUT' MCB. ( I1 )
2. On the LCD ensure that the following alarm are displayed:
D UPS ALARM ć (heading)
D MAINS OUT OF LIMITS.
D BYPASS LINE WITHIN LIMITS.
D INVERTER-BYPASS LINE SYNCHRONIZED.
D LOAD ON INVERTER.
D The green `NORMAL' LED ( 1 ) has extinguished.
D The red ÀLARM' LED ( 2 ) has illuminated.
D The green `LOAD on INV' LED ( 3 ) remains illuminated.
D The Alarm buzzer should sound, press `CLEAR' (d) push button to silence the alarm.

3. Using a DVM check that the output Voltage and frequency at output Terminals is correct (e.g. 400Vac and
50Hz).
Using a DVM check that the Battery Voltage at the battery Terminals is correct (405V +/- 10V).
4. Close the `MAINS INPUT' MCB (I1).
The UPS should now return to normal Operation.
Ensure that:
D The `ć UPS in Operation ć` returns to the LCD.
D The green `NORMAL' LED ( 1 ) has illuminated,
D The red ÀLARM' LED ( 2 ) has extinguished,
D The yellow `BYPASS ON' LED ( 4 ) has extinguished
3.5.3 Test Transfer to the Reserve Line (Automatic Bypass).

Testing the transfer to the reserve bypass line, is carried out by forcing the automatic By-pass circuit to switch and
then checking that the load is still being powered.
If no other alarms occur, the UPS will automatically re-transfer back to inverter operation after 20 seconds on
completion of the test.
1. Press the `MENU' push button (a) on the FRONT PANEL.
a) Select the `COMMAND' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.
b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER).
c) Select the `SWITCH LOAD' function by pressing either `BACK' or `NEXT'.
d) Confirm `SWITCH LOAD' function by pressing `BACK' and `NEXT' at the same time.
D A ***CONFIRMED*** message will be displayed
2. Press `CLEAR' (d) twice to return to the main menu.
The follow change over sequence will should occur:
D The yellow `BYPASS ON' LED ( 4 ) will be illuminated (UPS ON BYPASS)
D After 20 seconds the yellow `BYPASS ON' LED ( 4 ) will turn off and the load will be re-transferred back
to inverter.
D The green `LOAD on INV' LED ( 3 ) will illuminate (UPS ON INVERTER).

3.5.4 Manual Bypass Operation Check

The manual bypass allows the UPS to be switched OFF while the critical load is maintained.
The following procedure describe the confirmation of this function.
The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:
D The yellow `BYPASS ON' LED ( 4 ) is illuminated
D The green `LOAD on INV' LED is extinguished.
3. To turn off the Inverter follow the procedure below:
c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same time (i.e. ENTER).
d) Select the ÌNVERTER ON-OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.
e) Confirm ÌNVERTER OFF' function by pressing `BACK' and `NEXT' at the same time.
f) Press `CLEAR' twice to return at the main screen.
4. The follow sequence should occur:
D The Alarm buzzer is activated.
D The Red general ÀLARM' red LED ( 2 ) will illuminate.
D The Yellow `BYPASS ON' LED ( 4 ) will illuminate.
D The Green `NORMAL' LED will extinguish.
D The LCD will display the following messages:
`LOAD ON BYPASS' and
ÌNVERTER OFF'.
5. Remove the Mechanical Lock from the MANUAL BYPASS MCB ( I3 )
6. Close the. MANUAL BYPASS MCB ( I3 )
7. Open the ÙPS OUTPUT' MCB ( I4 ).
8. Open the `MAINS INPUT' MCB ( I1 ).
9. Open the `RESERVE INPUT' MCB ( I2 ).
10. Open the ÌNTERNAL BATTERY' fused switch ( I5 ).
11. Check that the load continues to be powered from the Maintenance Bypass Mains supply while the UPS is
off.
RETURN FROM MANUAL BYPASS TO NORMAL OPERATION

D wait until the fan is running, indicating that the output voltage is present.
2. Close the `MAINS INPUT' MCB. ( I1)
Wait until the Operator panel shows the following indications:
D LCD is energize and
D The alarm buzzer sounds.
D The red ÀLARM'LED ( 2 )
D The yellow `BYPASS ON' LED will illuminate.
3. Close the ÌNTERNAL BATTERY' fused switch. ( I5 ).
4. Close the ÙPS OUTPUT' MCB. ( I4 ).
5. Open the `MANUAL BYPASS' MCB. ( I3 ).
6. Start the inverter as follow:

e) Confirm ÌNVERTER ON' function by pressing `BACK' and `NEXT' at the same time.
f) Press `CLEAR' (d) twice to return at the main screen.
7. Within approximately 20 sec. and the follow sequence should occur:
D The green `NORMAL' LED ( 1 ) has illuminated.
D The red ÀLARM' LED ( 2 ) has extinguished.
D The yellow `BYPASS ON' LED ( 4 ) has extinguished.
Place the mechanical lock, onto the `MANUAL BYPASS' MCB.
The UPS is now in the normal operating condition with the Inverter supplying the load.
3.5.5 Local EPO

The following procedure describes the testing of the UPS's Emergency Power Off (EPO) functions.
The activation of the EPO circuit will shutdown all UPS functions, causing the disconnection of the Critical Load.
Ensure that it is safe to carry out this test before proceeding.
1. Press the front panel EPO push button and hold it for at least 3 seconds to confirm it.
2. All UPS functions will stop and UPS will disconnect the critical load.
Check that the following indications are seen:
D The Alarm buzzer sounds.
D The red ÀLARM' LED has illuminated.
D The green `NORMAL' LED has extinguished
D The green `LOAD-on-INV' has extinguished.
D The LCD shows the alarm ÈMERGENCY POWER OFF'.
To restart the UPS after an EPO, carry out the following procedure:
1. Open the ÙPS OUTPUT' MCB. ( I4)
2. Open the ÌNTERNAL BATTERY' fused switch. ( I5 )
3. Open the `RESERVE INPUT' MCB. ( I2 )
D Wait until the display has de-energized.
5. Restart the UPS by following the start up procedure in chapter 3.4.
3.5.6 External EPO

The following procedure describes the testing of the UPS's Emergency Power Off (EPO) functions.
The activation of the EPO circuit will shutdown all UPS functions, causing the disconnection of the Critical Load.
Ensure that it is safe to carry out this test before proceeding.
1. Press the External EPO push button and hold it for at least 3 seconds to confirm it.
2. All UPS functions will stop and UPS will disconnect the critical load.
Check that the following indications are seen:
D The Alarm buzzer sounds.
D The red ÀLARM' LED has illuminated.
D The green `NORMAL' LED has extinguished
D The green `LOAD-on-INV' has extinguished.
D The LCD shows the alarm ÈMERGENCY POWER OFF'.
To restart the UPS after an EPO, carry out the following procedure:
3. Open the ÙPS OUTPUT' MCB. ( I4)
4. Open the ÌNTERNAL BATTERY' fused switch. ( I5 )
5. Open the `RESERVE INPUT' MCB. ( I2 )
D Wait until the display has de-energized.
7. Restart the UPS by following the start up procedure in chapter 3.4.
3 - 10 3x3 UPS Commissioning

3.6 - Normal UPS Start-Up Instructions
After calibration the following procedure can be used to activate the UPS:
Figure 3-4 ups power switches
I1 I2 I3 I4 I5
MAINS INPUT MCB RESERVE INPUT MCB MANUAL BYPASS MCB UPS OUTPUT MCB INTERNAL BATTERY
FUSED SWITCH
1. Close the RESERVE INPUT MCB (Miniature Circuit Breaker) (I2).

2. Close the UPS OUTPUT MCB (I4).
D Wait until the fan is running, indicating that the output voltage is present.
3. Close the MAINS INPUT MCB (I1).
D The display will energize, the `BYPASS ON' (4) and the ÀLARM' (2) LEDs will illuminate (see figure 3-3).
D The Alarm Buzzer will sound.
4. Fit the battery fuses into the fused battery switch. (The fuses are removed for transit and can be found with
the User manual in the document pocket on the battery safety cover).
5. Close the ÌNTERNAL BATTERY' fused switch. (I5).
6. Check the status of the UPS Operator Panel:
D The Amber `BYPASS ON' ( 4 ) LED will be illuminated
D The red ÀLARM' (2) led will be illuminated.
MAINS WITHIN LIMITS;
BY-PASS LINE WITHIN LIMITS;
BATTERY VOLTAGE WITHIN LIMITS;
LOAD ON BY-PASS and
INVERTER OFF.
7. To Silence the buzzer press the`CLEAR' (d) push button.
8. To Start the Inverter carry out the following instructions:
c) Confirm the `COMMAND' menu selection by pressing the `BACK' and `NEXT' push-buttons at the same
time (i.e. ENTER).
e) To start Inverter press `BACK' and `NEXT' at the same time.
D A *CONFIRMED* message will be displayed.
D The Inverter Section will now be started and be brought on-line.
f) Press `CLEAR' (d) twice to return to the main menu.
9. After 20 seconds:
D The Amber `BYPASS ON' LED ( 4 ) will extinguish.
D The Green `LOAD on INV'LED will illuminate.
D the Green `NORMAL' LED will illumunate.
THE UPS IS NOW IN THE NORMAL OPERATING CONDITION.

3x3 UPS Commissioning 3 - 11
3.6.1 - LCD Messages and LED status after starting the UPS.
During the Normal Operation of the UPS LCD panel will show the following messages:
D MAINS WITHIN LIMITS.
D BYPASS LINE WITHIN LIMITS.
D BATTERY VOLTAGE WITHIN LIMITS.
D INVERTER-BYPASS LINE SYNCHRONIZED.
D LOAD ON INVERTER.
D The `NORMAL' green LED ( 1 )and the `LOAD on INV' green LED ( 3 ) are illuminate. The buzzer alarm is off.
Note:Note: for a full explanation of the control panel LCD and LED function refere to
chapter 4.
3.7 - Normal Shutdown to Manual Bypass
After calibration the following procedure can be used to shutdown the UPS to a Manual bypass condition, and then
to normal operation:
c) Select the `SWITCH LOAD'function by pressing either `BACK' or `NEXT'.
D A *CONFIRMED* message will be displayed
The following change-over sequence should occur, indicating that the load has been transfer to the bypass line:
D The green`LOAD on INV' LED is extinguished.
d) Select the ÌNVERTER ON-OFF' screen by pressing either the `BACK' (c) or `NEXT' (b) push button.
D A **CONFIRMED** message will be displayed
a) The Alarm buzzeris activated.
b) the Red general ÀLARM' red LED ( 2 ) will illuminate.
c) the Yellow `BYPASS ON' LED ( 4 ) will illuminate.
d) the Green `NORMAL' LED will extingaquish.
e) The LCD will display the following messages:
`LOAD ON BYPASS' and ÌNVERTER OFF'.
11. Check that the load continues to be powered from the Maintenance Bypass Mains supply while the UPS is
off.


f) Press `CLEAR' (d) twice to return at the main screen.
7. Within approximately 20 sec. and the follow sequence should occour:
D the red ÀLARM' LED ( 2 ) has extinguished.
D the yellow `BYPASS ON' LED ( 4 ) has extinguished.
D the green `LOAD-on-INV' LED ( 3 ) has illuminated.
8. Place the mechanical lock, onto the `MANUAL BYPASS' MCB, or secure with a Pad-lock.

Setting Options
3.8 - Setting Options

The preĆsetting checks required are to the relay interfaces PCB links and wiring, to any fitted external
devices, i.e. personal computer, EPO switch, remote panel.
3.8.1 - Setting options on the Relay card

The relay card is supplied as an option at the customers request. If supplied the card shall have to be
preset according to specific Customer requirements.
The link configuration required for the application with a PC or with the remote indication panel is deĆ
scribed in the following table. Output signals from the relay interface are used for the control of customer
peripheral computer equipment and connections are made to the terminal block M1 shown in Figure
3Ć6, or from the RS232 DB9 connector P1 (fitted to later equipment only).
Figure 3-5 Setting options on the Relay card
Table 3-1 Relay Interface PCB Output
Link
Relay UPS Function Signal Function
JP4 JP5
Mains NOT OK Closed Open
RL1 MAINS STATUS
Mains OK Open Closed
RL2 BYĆPASS ON
RL3 UPS Ć RUN No associated link
RL4 PREĆALARM
Links fitted to the PCB allow the input mains status to be set and the serial port P1 to be enabled as shown
in Table 3-2. These signals are generated on the display control logic PCB and connected to the relay
PCB at connector CN4.

Setting Options
Table 3-2 Serial Port P1 DB9 Connector Connections
Pin Link
F
Function
ti R l
Relay
Nº JP1 JP2 JP3 JP4 JP5
5 COMMON N/A Closed ć ć
3 UPS RX N/A ć Closed ć ć
2 UPS TX N/A ć ć Closed
8 MAINS MainsĆ
RL1 ć MainsĆOK
9 STATUS NOK
1
PRE ALARM RL4 ć
7

Chapter 4 - Operation and control
4.1 - Operator Control Panel
Introduction
On the front of the UPS there is a control panel, from which it is possible to easily verify the status of the UPS, battery
and alarms. The operator control panel consists in a LCD display that indicates the operational and alarm status of
the UPS and the EPO push-button that is located at the left side.
The LCD Display Panel displays textual messages and operating parameters on a LCD screen capable of showing
4 rows of 20 characters.
The displayed screen is organized in a multi-level menu system and selected by using push button located to the
right of the screen
Figure 4-1 UPS Operator control panel
LCD control panel

Figure 4-2 LCD Display make-up
3x3 UPS Operation and control 4-1

Chapter 4 - Operation and control Service Manual
Operator Control Panel
Control panel indicator LEDs

The Table 4-1 shows that the menu contains three levels. The main level is the State and Alarm Menu.
In this menu it is possible to see the state and operative condition of the UPS, the CLEAR Button is used to scroll
through the different windows of this menu.
From the main menu the User may have access to different menu pressing the MENU Button (second level).
Once in this level the first row will show < menu choice > and the NEXT and BACK push Button enable the User
to move from one menu level to another.
Pressing both NEXT and BACK push button at the same time the ENTER command is selected and the next lower
level will be reached, while CLEAR take you back to the previous level. To verify the acquisition of ENTER a Beep
will be heard and CONFIRMED will appeared on the Display.
The NEXT/BACK selector keys are used to scroll through different windows in the same menu.
Table 4-1 LCD Display Main Menu Path

CLEAR CLEAR CLEAR
CLEAR BATTERY VOLTAGE INVERTER OPERATING INVERTER – BYPASS
WITHIN LIMITS SYNCRONISED
BYPASS LINE CLEAR

CLEAR LOAD ON INVERTER
WITHIN LIMITS
MAIN WITHIN CLEAR CLEAR

LIMTTS
STATUS ALARM MENU LOAD ON BYPASS
MENU CLEAR
CLEAR
ENTER
COMMAND MODE BATTERY TEST
NEXT BACK
NEXT BACK CLEAR
SWITCH LOAD
CLEAR
NEXT BACK
ENTER
DISPLAY EVENTS EVENT HISTORY CLEAR
INVERTER ON–OFF
NEXT BACK
NEXT
CLEAR
DELETE EVENTS NEXT BACK
NEXT
CLEAR
ENTER
OPERATING LANGUAGE ITALIAN
NEXT BACK
NEXT BACK CLEAR
ENGLISH
NEXT BACK
CLEAR
CLEAR FRENCH
ENTER NEXT BACK

DATE CLOCK CLEAR
NEXT BACK GERMAN
CLEAR NEXT BACK NEXT BACK
HOUR
CLEAR
SPANISH
NEXT
NEXT
CLEAR
ENTER
UPS CONFIGURATION SERIAL NUMBER
NEXT BACK
NEXT CLEAR
PHONE NUMBER
NEXT BACK
CLEAR
BATTERY CAPACITY
NEXT BACK
CLEAR
CALIBRATION
NEXT
4-2 3x3 UPS Operation and control

Service Manual Chapter 4 - Operation and control
From the main menu (STATUS ALARMS MENU) the User may have also access to the Input/Output measured paraĆ
meters and the internal parameters as well as the UPS temperature and the battery back-up time.
To scroll through these parameters use Next and Back Push Buttons. (see Table 4-2)
Table 4-2 Input/Output Parameters Menu

BACK BACK
INPUT CURRENT OUTPUT CURRENT BATTERY
Ir , Is , It NEXT NEXT
Ir , Is , It V, I , Autonomy: %
BACK NEXT BACK NEXT
OUTPUT VOLTAGE FREQUENCY

Phase/Phase Vrs,Vst,Vtr fin, fout
BACK NEXT NEXT BACK
OUTPUT VOLTAGE UPS TEMPERATURE

Phase/Neutral Vrn,Vsn,Vtn t emp.
BACK NEXT NEXT BACK
INPUT VOLTAGE OUTPUT POWER

Phase/Phase Vrs,Vst,Vtr kW , kVA, cos
BACK NEXT NEXT BACK
NEXT NEXT
INPUT VOLTAGE UPS SETTING
Phase/Neutral Vrn,Vsn,Vtn BACK STATUS ALARM MENU BACK fout, Vout
STATUS ALARM MENU

This menu is characterized by the first raw of the message that can be UPS IN OPERATION or UPS ALARM, depenĆ
ding whether the status of the UPS is in normal operation or an alarm condition has been detected. The meaning
of the message given are the following.
UPS in Operation
MESSAGE INTERPRETATION
The Main Input Line is present and the voltage is in
MAIN WITHIN LIMITS
the specified range
The Input Bypass Supply Line is present and the volĆ
BYPASS LINE WITHIN LIMITS
tage is within the specified tolerance
BATTERY VOLTAGE WITHIN LIMITS The Battery voltage is within specifications limits
The inverter is turned-on and behave with regularity
INVERTER OPERATING
operation
Indication of regular synchronism state between inverĆ
INVERTER ć BYPASS SYNCRONISED
ter and bypass line
LOAD ON INVERTER The load is supplied from the inverter
The load is supplied from the bypass line. This can be a
LOAD ON BYPASS temporary condition lasting for 20 sec when a fast overĆ
load occurs.
UPS in Alarm
In case of a failure in the UPS, the default screen will be replaced by the Alarm Screen. In this display the User will
have an overview on the type of malfunction occurred .A buzzer will be activated and can be cleared by pressing
CLEAR button. In this screen by pressing ENTER it will be shown a list of instruction to guide the Operator to underĆ
stand the meaning of the Alarm. The CLEAR push button allow to scroll through different messages As the alarm
condition is removed the current default screen will be displayed.
UPS ALARM ENTER CAUSE OF THE ALARM

ACTIONS
TYPE OF ALARM
ENTER

The List of possible Alarm and the associate help messages is displayed below.
ALARM MESSAGE CAUSE ACTION
Initial Start Up
Start the Inverter
INVERTER OFF Permanent Overload has been deĆ
Check Output
tected
Check Output Load and Restart
Continuos Overload on UPS OutĆ
INVERTER OVERLOAD Inverter
put
Check for Output Short-Circuit
High Transient Loads on UPS OutĆ
Check Output Load and Restart
BYPASS SWITCH LOCKED put. Inrush Load Current
Inverter
After 3 times
Check Battery
BATTERY FAILURE Battery Test not OK
Check Battery fuses
INVERTER SHUT-DOWN Battery almost flat, next to Make shut-down to the connecĆ
IMMINENT Shut-Down of inverter ted Loads
Check SCR of Bypass
One or more Phases in the Output
BYPASS SWITCH FAILURE Check Bypass external connecĆ
are missing
tions
MANUAL BYPASS ON UPS on Maintenance
Breaker is Open Check Main line Voltage and
MAIN OUT OF LIMITS
Main Input is missing Breaker position
The input phase rotation is not corĆ
BYPASS LINE OUT OF Check Bypass line Voltage
rect
LIMITS Check Phase Rotation
Input Voltage Missing
Restart the UPS
Fully switch-off the Breakers and
The Command EPO has been seĆ
EMERGENCY POWER OFF the Battery Fuse, wait till the LCD
lected
is complete switch-off then restart
the UPS
Battery Switch Open
BATTERY NOT CONNECTED
Battery Test Failed
Call Service Office, to replace the
BATTERY CHARGER FAULT
Battery Charger
Call Service Office, to replace the
HIGH BATTERY VOLTAGE LEVEL Battery Charger in Fault
Battery Charger
END OF BATTERY DISCHARGE Main is missing for long time
COMMAND MODE MENU
In this menu is possible to give some operative command to the UPS.

MESSAGE INTERPRETATION
With this message displayed by pressing ENTER an automatic test on the
BATTERY TEST
Battery will be performed instantaneously
With this message displayed by pressing ENTER the load is switched from
inverter to the Bypass Line. This command is also used for reset the alarm
conditions on the bypass line. For instance when the Alarm Bypass Switch
SWITCH LOAD
Locked is present because for three consecutive times the load has been
connected to Bypass for transient overload. To reconnect the load on inverter
is necessary to activate this command by ENTER
With this message displayed by pressing ENTER the User can Turn-on or
Turn-off the Inverter in a permanent way and connect it to the Load.
INVERTER ON/OFF
It is necessary Turn-on the Inverter at the start-up and after a permanent
overload.

Service Manual Chapter 4 - Operation and control
EVENT HISTORY MENU

In this menu the user may scroll through the past n°512 Alarm occurrences in chronological order.
The Event Log display can be opened from the menu EVENT HISTORY by pressing ENTER twice. The Log screen
will display Date and Time of the last EVENT occurred. The Back push button will be used to scroll Date and Time
of the previous EVENTS and the Next push button will be used to scroll other statements and Alarm Messages conĆ
nected to the same EVENT.
In any position of the EVENT List by pressing Menu the Display Screen will go back in the last EVENT occurred.
ENTER NEXT NEXT NEXT

DATE & TIME ALARM & STATE ALARM & STATE ALARM & STATE
DISPLAY EVENTS CLEAR LAST EVENT LAST EVENT LAST EVENT NEXT
LAST EVENT
BACK MESSAGE 1 BACK MESSAGE 2 BACK MESSAGE M
BACK NEXT
NEXT ALARM & STATE NEXT ALARM & STATE NEXT ALARM & STATE
DATE & TIME
MENU PREV. EVENT N–1 PREV. EVENT N–1 PREV.EVENT N–1
PREVIOUS EVENT
LAST–1 BACK MESSAGE 1 BACK MESSAGE 2 BACK MESSAGE M
BACK
NEXT
DATE & TIME PREV. EVENT N–2 PREV. EVENT N–2 PREV.EVENT N–2
MENU PREVIOUS EVENT
LAST–2 BACK MESSAGE 1 BACK MESSAGE 2 BACK MESSAGE M
BACK
NEXT
MENU DATE & TIME FIRST EVENT FIRST EVENT FIRST EVENT
FIRST EVENT
BACK MESSAGE 1 BACK MESSAGE 2 BACK MESSAGE M
BACK NEXT
To delete all unwanted EVENT first move in the DELETE EVENTS display, then press ENTER.
ENTER ENTER
DATE & TIME ENTER
EVENT HISTORY DELETE EVENTS EVENT
CLEAR CLEAR LAST EVENT CANCELLED
BACK CLEAR
DATE & TIME ENTER

MENU EVENT
PREVIOUS EVENT CANCELLED
N–1
BACK CLEAR
ENTER
DATE & TIME EVENT
MENU PREVIOUS EVENT CANCELLED
N–2

OPERATING LANGUAGE MENU

Up to five language are available in this menu. To select one language first move into the OPERATING LANGUAGE
display press ENTER and scroll the different languages up the desired one using NEXT button, than press ENTER
to confirm.
CLOCK MENU
This menu allows User to change the Date and Time setting on Hinet. To select Date or Time press first ENTER from
CLOCK menu then NEXT. When the Date or TIME are displayed the cursor will be over the last right character. To
scroll consecutive numbers use BACK and NEXT buttons, to move on the left use MENU button. Then type the whole
Date and press ENTER to confirm. If something is wrong in the Date or Time the message ERROR will be displayed
and the setting restart.
UPS CONFIGURATION MENU

It is strongly recommended that only trained people can have access to this menu.
In this menu the following parameters can be adjusted:
D Serial Number of the Unit
D Telephone number of Service Dept.
D Battery Capacity (Battery Ah at the C10 rate)
D Calibration'. Display calibration of the following parameters:
1. Input Current and Voltage. Calibration of measured Values
2. Output Current and Voltage. Calibration of measured Values
3. Battery Current and Voltage. Calibration of measured Values
To enter in one of these menu follow the procedure below:
a) Press the `MENU' push button (A) on the FRONT PANEL.
b) Select the ÙPS Configuration' screen by pressing either the `BACK' ( C ) or `NEXT' ( B ) push button.
c) Confirm the ÙPS Configuration' menu selection by pressing the `BACK' and `NEXT' push-buttons at the
same time (i.e. ENTER).
d) Select one of the following parameters (Serial Number, Service Phone Number, Battery capacity, Calibration)
by pressing either `BACK' ( C ) or `NEXT' ( B ) push button.
e) Confirm the selection by pressing and hold for at least 20 seconds `BACK' and `NEXT' push button at the
same time.
f) Select the correct value by pressing either `BACK' ( C ) or `NEXT' ( B ) push button.
g) Confirm the correct value by pressing `MENU' push button.
h) Press the `CLEAR' key to return to the main menu.
Note: These parameters are factory set and it is not recommanded to adjust them during
commissioning.

Chapter 5 - Functional description
This chapter describes the principal PCB `s fitted to the UPS, there function, and configuration of the
potentiometers, test points and jumpers.
Abbreviations
The following abbreviations are used throughout.
P = potentiometer
TP = test point
JP = Jumper
5.1 - Control Logic PCB CS0072
The Control logic PCB integrates all the UPS'S functions, converter, inverter, static bypass. The control
is accomplished with programmable logic IC's fitted to the PCB. Their use significantly reduces the disĆ
crete components required, thus keeping any faults or problems to a minimum.
The principal circuit functions of the control logic are:
a) Feedback circuits (inverter voltage, converter voltage, static bypass voltage, inverter
output current).
b) Peak limit current detector circuits (inverter current and converter current).
c) Control logic power supply detector.
d) Overload detector.
e) UPS status and alarms generated by the UPS's PCB's.
5.1.1 - Potentiometer adjustment

a) P1 = adjust the inverter output voltage.
b) P2 = adjust the converter DC voltage.
c) P3 = adjust the UPS output threshold at ± 15%.
5.1.2 - Link and Jumper functions

a) J1ĆJ2ĆJ3 define the UPS characteristics.
Link Close Open

J1 OnĆLine OffĆline
J2 Freq. Tolerance 1% Freq. Tolerance 4%
J3 50Hz 60Hz
b) J4ĆJ5 define the parameters of the inverter output voltage and DC Bus voltage.
Output V/Link J4 J5
Service close close
380 open close
400 close open
415 open open
3x3 UPS Functional description 5-1

Chapter 5 - Functional description Service Manual
Auxiliary Supply PCB CS0070
c) J6ĆJ7ĆJ8 define the overload level related to the UPS ratings
Link 10K 20K 30K

J6 open close open
J7 close open close
J8 close close open
d) J9ĆJ10ĆJ12 defines the inverter peak current limit for the appropriate UPS output rating.
Link 10K 20K 30K

J9 open close open
J10 open open close
J12 open open open
e) J11 define the converter peak current limit. (normally closed for all UPS output ratings).
5.2 - Auxiliary Supply PCB CS0070
The auxiliary power supply is based on a flyĆback converter circuit, the source supply being the 750 volt
DC Bus. Secondary windings of the power supply transformer provide the control logic and the power
component gate drive circuits.
The auxiliary power supply generates a regulated 7. 5Vdc and l5Vdc voltage.
Adjustments to the battery threshold voltage are made from the auxiliary power supply by setting the
potientiometers P1, P2 and P3.
5.2.1 - Battery Threshold settings
a) Maximum voltage (500 Vdc) adjusted with P1.

b) Minimum voltage (320 Vdc) adjusted with P2.
c) PreĆalarm voltage (350 Vdc) adjusted with P3.
5-2 3x3 UPS Functional description

Service Manual Chapter 5 - Functional description
Driver Interface PCB CS007I
5.3 - Driver Interface PCB CS007I
The principle circuit functions of the driver interface PCB are:

a) Inverter and converter IGBT gate drives (connectors JI IĆJ9ĆJ12 for the inverter, J14 for
the converter)
b) Static bypass thyristors and inverter gate drives (connectors J3ĆJ4ĆJ5 for the inverter, JI
J2ĆJ5 J6 for the static bypass)
c) Input thyristor driver (J16)
d) Converter DC feedback (+DC, ĆDC)
e) Inverter feedback
f) Bypass supply circuit and bypass threshold (P1 and P2)
g) DC Bus unbalanced sensing (SI reset).
5.3.1 - Bypass Voltage Threshold Adjustment

a) P1 = adjusts the maximum bypass voltage threshold (+10%)
b) P2 = adjusts the minimum bypass voltage threshold (Ć10%)
5.3.2 - Link and Jumper functions

a) J4AĆJ5A sets the DC Bus voltage.
DC V/Link J4A J5A

375V (service maintenance mode) close close
750V (normal operation.) open open
b) JIAĆJ2AĆJ3A sets the UPS nominal bypass voltage;
Link 380V 400V 415V

J1A close open open
J2A open close open
J3A open open close

Battery Charger CS0074
5.4 - Battery Charger CS0074

The battery charger used in the UPS is a PWM controlled `Buck/Boost' DCĆDC converter which
produces a battery recharge float voltage of 230 Vdc.
The principals circuit components are:
a) Power section (PD1Ć2, LI, Q1, Dl, L2).
b) Supply section (+l5Vdc, Ć 6.2 Vdc).
c) PWM generation and feedback section (U10 Ć U3).
d) The battery test section (U4).
The input mains voltage is rectified by the diode bridge PD1 and PD2, steppedĆdown by the main power
components L1, D1, L2 with the voltage stabilised by the switching of IGBT Q2 the PWM gate drive signal
generated by U10. This configuration produces a stable battery recharging float voltage of 432 Vdc.
5.4.1 - Battery Charger Voltage Adjustment

a) P1 = adjusts the float voltage level to 432 Vdc
b) P2 = adjusts the boost voltage level. This setting is dependant on the type of battery
fitted.
c) P3 = adjusts the float voltage when the temperature compensation option is enabled.
5.4.2 - Link and Jumper Functions

a) JPI ĆJP2 sets the recharging current.
Link/Amper
IA 3A 5A
e
JPI open open close
JP2 open close open
b) JP3 enable/disables the boost charge.
Link Boost Disable Boost Enable

JP3 open close
c) JP4 enable/disables the temperature compensation circuit.
Th Comp. Th. Comp.

Link
Disable Enable
JP4 open close
d) Jumpers JP5 to JPI0 set the capacity for the installed battery, this is used for the battery
test function.

2x 3x 4x
7.2Ah 38Ah 65Ah
7.2Ah 7.2Ah 7.2Ah
e) JP11 when selected open inhibits the battery test regime.
Note: JP11 is always set closed.
f) J4ĆJ5ĆJ6 set the automatic battery test interval
Link J4 J5 J6
Time 12 Hours 24 Hours 48 Hours

Battery Charger CS0074
5.4.3 - Battery test

The battery test circuit will automatically initiate at the time interval selected by the links J4, J5 and J6.
The test duration is set at 10 seconds, during this period the battery charger logic switches off the mains
power by opening the input test relay K1 which shuts down the charger circuit. The terminal voltage of
the battery is then monitored to verify the battery status, if this is correct and stable over a 20 seconds
period, the battery charger will restart and continue to charge the battery.
If the battery check fails detecting a parameters different from the expected value, the control logic initiĆ
ates a battery fault alarm. The fault will give a flashing red LED on the front mimic panel. If the battery
test is satisfactory the green battery LED will illuminate indicating that the battery is OK.
5.5 - UPS monitor board PCB CS0077
The function of UPS monitor board is to interface the UPS control and status alarm signals with the OperĆ
ator LCD Control panel Part Nº CS0075 , the Relay Interface PCB Part Nº CS0082 and the SNMP
adapter.
UPS CONTROL LOGIC

P/N CS0072
Inverter Driver &

Feedback
J6 J2 CS0071
LCD MIMIC
DISPLAY J1 UPS MONITOR
BOARD CS0077 J3 RELAY
P/N CS0075 INTERFACE
J5 P/N CS0082
J7
OPTIONAL RELAY
INTERFACE
P/N CS0082
SNMP CARD
This board has a microprocessor that manage and control the serial port, the SNMP adapter, the LCD
messages and UPS menu.
The LCD Display Panel displays textual messages and operating parameters on a LCD screen capable
of showing 4 rows of 20 characters.
The displayed screen is organized in a multi-level menu system and selected by using push button
located to the right of the screen.
LD1 illuminated indicates that the monitor board is failed and must be replaced.
BT2 is an hardware and software reset.
Links setting:
JP1 1-2 close and JP3 2-3 close are factory setting.
JP2 close disable the second remote EPO, JP2 open enable the second remote EPO.

Relay Interface PCB CS0082
5.6 - Relay Interface PCB CS0082

The relay interface PCB provides two sets of volt free contacts rated at 50V 1A which enable the UPS
functions listed below in Table 5-1 to be monitored externally. The relay interface PCB receives the UPS
status signals from the Display Control Logic PCB Part Nº CS0073 and is connected to CN1.
Output signals from the relay interface are used for the control of customer peripheral computer equipĆ
ment and connections are made to the terminal block M1 shown in Figure 5Ć2, or from the RS232 DB9
connector P1 (fitted to later equipment only).
Table 5-1 Relay Interface PCB Output
Link
Relay UPS Function Signal Function
JP4 JP5
Mains NOT OK Closed Open
RL1 MAINS STATUS
Mains OK Open Closed
RL2 BYĆPASS ON
RL3 UPS Ć RUN No associated link
RL4 PREĆALARM
Links fitted to the PCB allow the input mains status to be set and the serial port P1 to be enabled as shown
in Table 5-2. These signals are generated on the display control logic PCB and connected to the relay
PCB at connector CN4.
Table 5-2 Serial Port P1 DB9 Connector Connections
Pin Link
F nction
Function Rela
Relay
Nº JP1 JP2 JP3 JP4 JP5
5 COMMON N/A Closed ć ć
3 UPS RX N/A ć Closed ć ć
2 UPS TX N/A ć ć Closed
8 MAINS MainsĆ
RL1 ć MainsĆOK
9 STATUS NOK
1
PRE ALARM RL4 ć
7
5.6.1 - EPO Connections.

Provision has been made on the relay interface PCB to connect an external Èmergency Power Off'
switch, to allow remote shut down of the UPS to be implemented.
Connection for the EPO is provided by the terminal block M2.
Caution When connecting an EPO switch to the relay PCB the Link JP6 must be opened.
5.6.2 - Optional Second Relay Interface PCB

If a second set of outputs is required, an optional relay interface PCB can be connected to CN3 on the
display control logic PCB.
Caution With two relay PCB's connected. Link JP1 on the display logic PCB must be opened in
addition to JP6 on the optional relay PCB, to allow the use of a Second EPO switch.


5.7 - LCD MIMIC DISPLAY CS0075
LCD control panel
5.7.1 - Control panel indicator LEDs

The menu contains three levels. The main level is the State and Alarm Menu.
In this menu it is possible to see the state and operative condition of the UPS, the CLEAR Button is used
to scroll through the different windows of this menu.
From the main menu the User may have access to different menu pressing the MENU Button (second
level).
Once in this level the first row will show < menu choice > and the NEXT and BACK push Button enable
the User to move from one menu level to another.
Pressing both NEXT and BACK push button at the same time the ENTER command is selected and the
next lower level will be reached, while CLEAR take you back to the previous level. To verify the acquisition
of ENTER a Beep will be heard and CONFIRMED will appeared on the Display.
The NEXT/BACK selector keys are used to scroll through different windows in the same menu.
(See Chapter 4)

Chapter 6 - Maintenance
This section contains the procedures necessary to effect general maintenance of the UPS and battery.
Certain procedures entail gaining internal access to the UPS, and should be undertaken only by a comĆ
petent engineer who is familiar with the operation and layout of the equipment and is fully conversant
with the areas of potential hazard. If there are any doubts concerning safety, or the method of carrying
out any procedure then contact an approved service agent for assistance or advice.
Safety The equipment contains live voltages at ALL Swiss unless externally isolated from the mains
Precautions supply, bypass supply and batteries.
When working on the UPS it is essential that the safety and precautionary notes in this manĆ
ual are read and FULLY UNDERSTOOD before touching any UPS internal component part.
6.1 - Scheduled Maintenance
The UPS utilises solidĆstate components not subjected to wear, with the only moving part the cooling
fan. Scheduled maintenance requirements, beyond ensuring that the environmental conditions remain
suitably cool and clean, are therefore minimal. However, a well documented periodic program of inspecĆ
tion and preventive maintenance, as suggested below; will ensure optimum equipment performance
and serve to detect minor malfunctions prior to them developing into a major fault.
6.1.1 - Daily Checks

Carry out a daily walkĆby inspection of the UPS, checking the following points:
1. Carry out a spot check of the Operator Control Panel; ensuring that all mimic LED
indications are normal and no alarm messages are present.
2. Check for obvious signs of overheating.
3. Check for continuous exit air flow from the extractor fans on the front door.
4. Ensure that the ventilation grills around the UPS are unobstructed.
5. If possible, log the results of the inspection, noting any discrepancies from the norm.
6.1.2 - Weekly Checks

Perform the following checks and log the results:
1. Measure and record the battery charge voltage.
2. Measure and record the battery charge current.
3. Measure and record the UPS output voltage on all three phases.
4. Measure and record the UPS output line currents.
If there are significant differences from the values previously recorded, note the size, type and location
of any additional load connected to the UPS supply since the previous inspection. This type of informaĆ
tion could prove useful to the troubleshooting engineer should a problem occur.
If any of the above indications differ greatly from the previously logged values for no apparent reason
you should contact the Customer Service & Support Department at the address given at the front of this
manual for advice.
3x3 UPS Maintenance 6-1

Chapter 6 - Maintenance Service Manual
Scheduled Maintenance
6.1.3 - Annual Maintenance
Caution We strongly recommend that the annual maintenance is carried out by a manufacturerĆ
trained engineer who is fully aware of the hazards concerned and will carry out this proĆ
cedure, where necessary with the load connected to the maintenance bypass supply
WARNING LETHAL VOLTAGES ARE PRESENT IN THE UPS UNIT EVEN IF THE UNIT HAS BEEN
SWITCHED OFF AND ISOLATED
The following procedure is intended as a guide to carrying out an annual preventative maintenance
schedule. It is assumed that the engineer carrying out this procedure has been trained in the operation
of the UPS and is able to operate the unit in the `Maintenance Mode'.
Preliminary checks
1. Visually inspect the outside of the UPS and determine that the operating environment is
correct.
2. Carry out the checks detailed in `Weekly Checks'.
3. Determine if any abnormal faults have been previously recorded.
4. Confirm with the load user that it is safe to transfer the unit to maintenance bypass before
proceeding.
Transfer to the Maintenance Bypass

The manual bypass allows the UPS to be switched OFF while the critical load is maintained.
To transfer the load to Maintenance Bypass:
1. Press the `MENU' push button ( A ) on the FRONT PANEL.
a) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push
button.
b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same
time (i.e. ENTER).
2. Press `CLEAR' ( d ) twice to return to the main menu.
The following change-over sequence should occur, indicating that the load has been transfer to the
bypass line:
a) Press the `MENU' push button ( A ) on the FRONT PANEL.
b) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push
button.
c) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same
time (i.e. ENTER).
d) Select the ÌNVERTER ON-OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (B)
push button.
D The Alarm buzzer is activated.
D The Red general ÀLARM' red LED ( 2 ) will illuminate.
6-2 3x3 UPS Maintenance

Service Manual Chapter 6 - Maintenance
D The Yellow `BYPASS ON' LED ( 4 ) will illuminate.

D The Green `NORMAL' LED will extinguish.
ÌNVERTER OFF'.
11. Check that the load continues to be powered from the Maintenance Bypass Mains supply
while the UPS is off.
12. Wait a minimum of 10 minutes before proceeding to allow the DC bus voltage to discharge.
WARNING THE DC BUS VOLTAGE OF 750VDC MAY TAKE SEVERAL MINUTES TO DISCHARGE TO A
SAFE LEVEL.
13. Remove the top cover of the UPS to gain internal access to the unit.

The following procedure describe how to start the ups and transfer the load from the maintenance byĆ
pass to the ups inverter.
button.
time (i.e. ENTER).
d) Select the ÌNVERTER ON- OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (
b ) push button.
f) Press `CLEAR' ( d ) twice to return at the main screen.
7. Within approximately 20 sec. and the follow sequence should occur:
D The red ÀLARM' LED ( 2 ) has extinguished.
D The yellow `BYPASS ON' LED ( 4 ) has extinguished.
Place the mechanical lock, onto the `MANUAL BYPASS' MCB.

Mechanical inspection
1. Carry out the weekly checks detailed above
2. Ensure that the UPS is totally powered down.
a) Check for input AC voltage at the rectifier input connections SKD 82/12 terminals 14, 15
& 16
b) Check for Battery voltage at the battery connection terminals 6 & 7 ćve, 8 & 9 +ve.
c) Check for AC voltage at the output terminal connections 2, 3 & 4.
d) Check for an AC voltage at the Reserve Bypass input terminal connections 10, 11 & 12.
Note: Refer to Figure 2Ć1 on page 2Ć4 for terminal connection detail.
3. Gain access to the UPS interior by removing the top cover panel.
4. Carry out a thorough examination of the UPS power components and subĆassemblies,
paying particular attention to the following:
a) Electrolytic capacitors Ċ check for signs of leakage, distortion etc.
b) Magnetic components Ċ check for signs of overheating, security of fixture and
deĆlamination.
c) Cables and connections Ċ check cables for signs of overheating.
d) Check that all printed circuit board connectors are secure.
e) Printed circuit boards Ċ check the cleanliness and integrity of the PCB's and replace if
any signs of deterioration are found.
5. Thoroughly clean inside the equipment enclosure using a vacuum cleaner and low pressure
air to remove any foreign debris.
6. Reconnect the UPS input mains power.
Power checks
1. Start the UPS following the appropriate operating procedure.
2. Carry out a calibration of the DC Bus Voltage and Inverter output voltage.
3. Connect a DVM set to DC volts to the DC bus and a second DVM set to AC volts to the UPS
output.
4. Select I1 (Input mains) to ON
a) The DC voltage will increase slowly up to 650 Vdc.
b) After 10 sec. the converter and the inverter will start regulating respectively
The DC Bus voltage to 750 Vdc ± 1%
The output inverter voltage to 400 Vac ± 1% (Assuming the UPS is set for an output of
400 Vac)
5. If the measured values are incorrect, reĆadjustment of the voltage settings can be carried out
using the potentiometers on the UPS control logic PCB Part Nº CS0072.
Note: Turning P1 Inverter feedback potentiometer CCW will increase the

voltage.
Turning P2 Converter feedback potentiometer CCW will increase the
voltage.

Table 6-1 Output Voltage PCB Link Settings
Link PCB Part Nº 38OVac 400Vac 4l5Vac

J4 CS0072 open close open
J5 CS0072 close open open
JIA CSOO7I close open open
J2A CSOQ7I open close open
J3A CSOO71 open open close
lnverter Bypass Phase Lock check

1. Using a dual trace oscilloscope operating in the differential mode (insulated from mains) on
the inverter driver interface PCB (CSOO7I) connect:
a) Probe 1 to the bypass `R' phase voltage terminal stud N9.
b) Probe 2 to the inverter output phase `R' voltage terminal stud N 7.
2. Check both sine waves are perfectly in phase.
The phase adjustment is fixed and is determined by R23 on the driver interface CSOO7I (1
Mohm).
The check of the CONVERTER and INVERTER section is now complete.
Battery charger checks

Float voltage adjustment and battery reĆcharging current
1. Connect a DVM set to DC volts to the battery DC bus terminal connecting block (terminal 6Ć7
positive, 8Ć9 negative).
2. Open the battery power fuses F1 to F4.
3. Check that the value at the battery DC bus terminal connections is 432 Vdc ± 1%.
If the measured value is different it is possible to reĆadjust using the potentiometer P1 on the
battery charger PCB C50074.Ć
Note: Turning P1 CCW will increase the float voltage
4. Refit the battery fuses.

5. Check the battery reĆcharging current with a DC clamp meter.

Battery Maintenance
6.2 - Battery Maintenance
The batteries fitted within the UPS are valve regulated and require very little maintenance.
It is wrong to describe them as completely `maintenance free', because the batteries still require a mainĆ
tenance check, but at a significantly greater interval than the unsealed type.
The removal of the need to continually top up batteries, is a major advantage, but by removing access,
a visual examination of the cell plates, and electrolyte is impossible.
Battery condition and capacity can therefore only be determined as a complete 12V battery block.
The battery is an important component in the UPS system, as the UPS function relies on the battery
power, on failure of the input AC supply To ensure that the battery will support the UPS operation it should
be checked annually for performance.
6.2.1 - Factors Effecting Battery Use

The following factors affect the overall operation and ultimately the useful life of the UPS battery. These
considerations must be taken into account when deciding the serviceability of a battery.
Service life
Temperature is the major factor in determining the effective life of a battery if the battery is operating
above 200 C it will reduce the battery life. It is also important that the charge voltage is within limits. TypiĆ
cally a 5 year life battery will start to decline after 3 years in service, therefore the need for regular checks
is important.
Charge voltage
The nominal charge voltage is normally 2.25 volts per cell, multiplied by the number of cells in series.
Operation at voltages below 2.2 volts per cell, will lead to a undercharge and sulphation. Operation at
2.3 volts per cell and above, will cause overcharge and rapid positive plate corrosion. Positive plate corĆ
rosion is known to be the major life limiting component in all batteries, therefore for optimum life, battery
cell voltages must be within the range of 2.25 to 2.3 volts per cell.
The UPS has 32 x 12V batteries and is designed to operate with a float charge voltage of 432 V
DC.
Battery capacity
Battery capacity is used to define endĆofĆlife of the battery for example if the battery cannot supply 80%
it is deemed to be at the end of its effective life. For some applications 80% may be decreased to 50%
to mark the end of the batteries effective life.
Battery capacity from manufacture, usually increases slightly after 2 or 3 discharges and will be enĆ
hanced by high temperature and reduced by low temperature.
As the battery ages beyond 12 months the battery capacity will fall at a rate determined by the operating
temperature and the charge voltage. These adverse factors, will cause accelerate erosion to the positive
plate grid, reducing the effective battery capacity The life of the battery will then depend on the requireĆ
ments of the system, if the capacity of the UPS has been oversized then the load may only need 50%
of the normal duty.
In most applications, the battery is essentially on continuous float charge, and rarely will experience a
input supply failure longer than the end of the battery autonomy.
Therefore a battery in poor condition may well continue to support the load for short autonomies, but
will fail if the loss of the input AC supply exceeds 30 seconds.
It is therefore highly recommended that a battery autonomy test, is carried out as part of a regular mainĆ
tenance program.
Open circuit voltages

Measurement of the battery open circuit voltage is not a good indicator of the available capacity of the
battery It may apply to batteries on the shelf but not to batteries that have been on charge, up to 72 hours
prior to measurement. The terminal voltage of batteries that have been on charge, have an actual cell
voltage, plus a polarization voltage.
6-6 UPS Maintenance

Battery Maintenance
The polarization voltage will disappear once loaded, but can lead to misleading terminal voltage
measurements.
To use the open circuit voltage of a battery as a guide to its capacity it must have been disconnected
for at least 72 hours. This measurement is taken off load and can only be used as a guide, it will not indiĆ
cate a battery with high internal resistance.
Float voltage
The float voltage of each battery connected in a series string, is determined by its impedance, relative
to other batteries. The voltage measured at each battery while on charge can give an indication to its
serviceability A battery on charge taking above the minimum float current, will have a different voltage
distribution to one that is fully charged. This measurement can therefore give an indication of the charge
of the battery however a valid voltage reading can only be obtained if the battery has been on float
charge for at least 48 hours.
For maintenance purposes, the ideal is to check the float voltage of each battery before shutting the UPS
down, if the test is carried out after shut down, the reading will not be valid until the float current normalĆ
izes back to its original level, prior to shut down.
It is recommended that a float voltage check is carried out on the unit if a battery problem is suspected,
a defective battery will normally give an abnormal terminal voltage.
6.2.2 - Battery Testing

When working on batteries, regardless of size, remember they have considerable energy content under
short circuit conditions.
They cannot be switched off or isolated as is normal in electric circuits.
WARNING RISK OF DEATH, SHOCK OR BURN. WHEN THIS BATTERY IS ASSEMBLED, IT IS A SOURCE
OF 390 VOLTS.
Caution Use extreme care to ensure that batteries are not accidentally short circuited by tools, rings,
watch straps etc.
Use insulated hand tools.
Wear eye protection during handling of batteries.
Before tightening or making connections on battery strings, ensure the battery is isolated
from the UPS circuit and is earth free.
In the event of a battery breakage occurring, dispose of in a container resistant to sulphuric

acid.
Should electrolyte contact the skin, wash the affected area immediately
Site testing
It is not normally possible to check the float voltage of the battery string prior to turning the UPS off, but
the float voltage may need to be checked subsequently.
Float voltage test

Batteries on float below 13.0 V per I2V battery will ultimately sulphate.
Batteries above 13.8 V will have a short service life, and indicates a deteriorating cell.
Investigate the serviceability of batteries with a float voltage below 13.4 V and above 13.98 V If the averĆ
age float voltage is at the correct level, check and replace if necessary any batteries that fall outside the
float voltage parameters.
Visual examination
1. After shutdown examine the batteries for the following:

Battery Maintenance
a) White deposits around the terminal seals which indicate seal failure.
Replace any batteries found.
2. Check the security of the terminal connections. Examine for signs of corrosion or
overheating.
3. Inspect battery cases for distortion, splits or bulges.
a) Batteries near the end of their effective life, will exhibit bulges in the case, due to
increasing pressure of the positive plates as they grow in size.
b) Severe distortion may also be apparent, caused by the higher resistance of the corroded
plates, which tends to generate heat during charge and discharge. In turn the plastic of
the case will creep and failure of a single cell will cause the side of that cell to bulge.
c) Total end of life condition will normally cause all cells to bulge or distort.
6.2.3 - Battery capacity testing.

There are generally two ways in which the capacity of a battery can be tested by impedance measureĆ
ment, or by load testing.
Impedance measurement
Measurement of the battery AC impedance requires special test equipment, but gives a measure of how
the battery impedance has changed since new. Any battery that has been on continuous float charge
prior to the test, should not exhibit more than twice the new battery value.
Values in excess of this, indicate the battery is nearing the end of its effective life, while batteries exhibitĆ
ing 4 or more Swiss the new value, need immediate replacement.
This test will only look at the battery level and not the individual cell level, therefore, a cell with above
normal impedance to the others, will not be indicated.
Discharge test
The more common method of determining the capacity and serviceability of the batteries, is to carry out
a discharge test.
A suitable resistor designed to draw a current equal to the Ah size of the battery is placed across the
battery terminals. The battery terminal voltage is then monitored.
A fairly large wattage, 5 W resistor capable of taking 11A is connected across the battery terminals. After
10 minutes discharge, the battery terminal voltage should not fall below 11.2 V indicating the 50% capacĆ
ity level.
If a battery has high internal resistance and reduced capacity the terminal voltage will fall quickly.
Batteries with a capacity above 50% may continue to be used, but will reduce the autonomy of the sysĆ
tem. It is recommended that they be replaced, however batteries below 50%, should always be reĆ
placed.
Note: A higher resistance value, discharge resistor may be used to discharge

the battery. The terminal voltage measured will then give an indication of
the serviceability of the battery, but is not an accurate measure of the
battery capacity.

Battery Replacement
6.3 - Battery Replacement
When deciding to replace a battery the following must be considered, and a decision taken, to mix old
or new batteries in the series string. Adding new batteries to a series string that has been in use for more
than 18 months, may induce problems due to the difference in capacity A new undercharged battery
placed into a fully charged old string, may fail to achieve full charge. The other batteries in the string may
limit the charge current, as the older batteries may only require a charge current of some milliamps, this
may then cause the new battery to sulphate. If a new battery is fully charged before inclusion, the probĆ
lem should not arise, however the effective life of the new battery is limited to that of the originals. The
new battery may also have a higher terminal float voltage.
Replacing more than one battery may cause redistribution of the float voltages, causing over and underĆ
charging. Attempts to equalize the string by using a top charge of 2.4 volt per cell, may cause temporary
overheating and the test should only be carried out with continual monitoring.
Applying a top charge, (equalization) to a battery of unknown quality can lead to rapid overheating and
the possible release of acid fumes. Equalization on a long series string has not shown to be of any beneĆ
fit, due to the ability of the batteries to absorb the excess charge over a large number of cells. However~
equalization of a single battery introduced into a string, is effective.
Since a site visits to replace a single battery is a costly process, a point will be reached where it is more
cost effective to replace an entire battery string than to properly asses the battery condition, and carry
out single or multiple replacements. This decision has the additional advantage of enhancing the reliaĆ
bility of the system, and has the benefit of a 12 month warranty on the new battery.
6.4 - UPS Storage
If the UPS is to be transported, or stored in a powered down condition for any length of time, the internal
battery may discharge below the minimum battery voltage.
To prevent this condition occurring, remove the battery fuses and retain with the unit.
For periods of storage in excess of 12 weeks, the batteries will exceed their shelf life.
This can be prevented by operating the UPS and allowing them to reĆcharge for 24 hours.
Battery recharging is done by:
1. Connect the UPS to an input AC supply
2. Fit the battery fuses.
3. Power up the UPS and allow it to operate for 24 hours.

Chapter 7 - Troubleshooting
7.1 - Introduction
The UPS contain complex electronic control circuits which require a firm understanding,
in order to carry out comprehensive fault diagnosis and repair of the equipment. The aim of the informaĆ
tion contained in this chapter is to provide sufficient guidance to the trained service engineer, to enable
successful fault location to printed circuit board level. Once a faulty circuit board or component has been
identified, it should be replaced or returned to the nearest service centre for repair.
The troubleshooting information has been divided into the following main areas:
a) Component location and identification.
b) Diagnostic information.
c) Troubleshooting procedures.
d) Test procedures.
Note: When following the procedures cross referencing is inevitable, therefore

it is recommended that this chapter is read in its' entirety, before
commencing work on the equipment.
There is no practical way of detecting an impending UPS malfunction, as most problems do not emerge
as a gradual performance degradation. Generally the UPS will either work correctly or shut down with
or without a warning indication.
In the event of a UPS malfunction troubleshooting should be carried out methodically along the following
guide lines.
7.1.1 - General Fault Identification Procedure

When first summoned to a UPS fault the immediate action should be to observe and record the LED
indication displayed on the unit operator panel.
1. Determine the UPS power Status.
2. Note the control switch configuration, and also the warning horn sequence if it is operating.
WARNING During troubleshooting it will be necessary to power up the unit with the side or top covers
removed, in this situation exposure to potentially lethal voltages is possible even with the
input utility supply switched off.
Take great care at all Swiss to minimise the risk of contact with live voltages, especially when
working around the battery or the DC bus.
3. Power down the unit, and ensure that the DC Bus Safety discharge check is carried out.
4. Gain access to the internal components follow the procedure for removing the UPS covers.
5. Check the serviceability of the UPS Fuses refer to the check list on page 7Ć12.
6. Apply power and analyse PCB LED indications.
7. Refer to the common fault identification chart on page 7Ć9 to identify possible fault
conditions.
8. Check DC converter power components. Refer to the procedures on page 7Ć19.
9. Check Inverter power components. Refer to the procedure on page 7Ć19.
Note: When checking signal levels refer to the table of typical normal values on
page 7Ć11 for comparison.
3x3 UPS Troubleshooting 7-1

Chapter 7 - Troubleshooting Service Manual
Special Tools
7.2 - Special Tools.
No special tools are required to service the UPS, a normal electricians tool kit will be adequate.
However, to carry out the check procedures contained in this chapter the following test equipment will
be required.
Oscilloscope.
A dual beam oscilloscope, which has the ability to sum the two channels, allowing differential voltage
measurements to be made.
For the measures points that it is needed to check it is very important to have the oscilloscope insulated
from the supply with a transformer.
A storage facility is useful but not essential.
WARNING ENSURE THAT ANY OSCILLOSCOPE USED IS RATED FOR USE ON 1000 V AND IS FITTED
WITH APROPRIATE 1000 V LEADS AND TEST PROBES.
Digital volt meter (DVM).

The voltages quoted in this manual assume that a true RMS reading AC voltmeter is used. A meter that
also has the ability to test electronic components such as diode's and similar electronic devices is reĆ
quired.
WARNING ENSURE THAT ANY DVM USED IS RATED FOR USE ON 1000 V AND IS FITTED WITH
APROPRIATE 1000 V LEADS AND TEST PROBES.
7-2 3x3 UPS Troubleshooting

Service Manual Chapter 7 - Troubleshooting
Removing the UPS Covers
7.3 - Removing the UPS Covers
To gain access to the UPS components the following covers must first be removed.
Figure 7-1 UPS Cover Removal

Top Heatsink Cover
Top Cover
Right Side Cover
Main Switch Cover

Covers Removed
Lockable Front Door Battery Safety Cover
1. Front Door Panel

a) To gain access to the power switches and battery compartment the front door panel is
first unlocked and hinged forward.
2. Battery Safety Cover
a) Disconnect the Earth bonding cable.
b) Remove the two top M6 retaining bolts.
c) Release the two bottom retaining bolts and lift the cover from the UPS.
Note: The battery safety cover has slots on the lower edge for easy removal and
repositioning.
3. Main Switch Cover
a) Remove the four M6 retaining bolts.
b) Carefully ease the cover away from the control switches.
4. Heatsink Cover
a) Remove the four M6 retaining bolts.
a) Carefully ease the cover away from the front of the UPS.
5. Top Cover.
WARNING DANGER OF SEVERE SHOCK OR BURNS. 800V DC IS EXPOSED WHEN TOP COVER IS
REMOVED DO NOT REMOVE THE COVER UNLESS THE UPS HAS BEEN COMPLETELY
POWERED DOWN AND THE DC BUS ALLOWED TO DISCHARGE FOR 10 MINITUES

Removing the UPS Covers
a) Ensure that the UPS has been correctly switched off and the battery fuse switches are
opened.
b) Wait for at least 10 minutes to allow the DC bus to fully discharge.
a) Carefully lift the cover from the retaining ball studs.
6. Side Panels
a) Remove the three M6 retaining screws securing each side panel at the rear of the UPS.
b) Disconnect the earth cable fitted to the top rear of each side panel, from the UPS chassis
by removing the M6 earthing bolt.
c) Push the panel forward to disengage the front locating studs and lift the panel from the
UPS.
Rear Cover Removal
7. Power Distribution Terminal Block Cover.
a) Remove the six M6 retaining screws from the terminal block cover and lift from the UPS.
Refer to Figure 7Ć2.
Figure 7-2 Rear Cover Removal
Rear Side Cover Earth Cables
Side Cover
Retaining Bolts
Rear Covers Fitted Distribution Terminal Block Cover

Removed

Component Location
7.4 - Component Location
Before starting to repair or service the UPS models, correct identification of the main compoĆ
nents and their location is required. All the main power component are mounted on the power heatsink
under the driver interface board.
The following information is primarily to furnish the repair engineer with a quick reference to the basic
component identification and location. A detailed breakdown of the equipment components and spare
parts kits available can be found in Chapter 9 Spare Parts.
Figure 7-3 Main PCB Location
3Ph TL Control Logic PCB Inverter Driver/Feedback PCB

Part Nº 0SDE0072 Part Nº 0SDE0071
Battery Charger PCB

Part Nº 0SDE0074
Fan PCB
Part Nº 0SDE0078
Auxiliary DCĆDC Converter PCB UPS Monitor PCB

Part Nº 0SDE0070 Part Nº 0SDE0077
Input Filter PCB

Part Nº 0SDE0079
Battery Charger PCB

Part Nº 0SDE0074

Component Location
Figure 7-4 Semiconductor Components
Bypass SCR's (3)

91A (S2 S4 S6)
Part Nº 0CASR212391
Inverter SCR's (x 3)
91A (S1 S3 S5)
Part Nº 0CASR212391
Snubber Diodes
30A (CD4 CD5)
Part Nº 0CADR210230
Inverter IGBT's 150A

150A (Q1 Q2 Q3)
Part Nº 0CATRCM150BU24F
Transfer Diode Transfer Diode

60A (CD1) 60A (CD2)
Part Nº 0CSDRFBYT261P12 Part Nº 0CSDRFBYT261P12
Converter IGBT Snubber Diode

200A (Q4) 30A (CD3)
Part Nº 0CATD212420 Part Nº 0CADRFBYT231
Input SCR
Input SCR 132A (S8)
132A (S7) Part Nº 0CSSX212413
Part Nº 0CSSX212413
Input Bridge (PD1)

Part Nº 0CADTSSKD82/12

Component Location
Figure 7-5 Passive components
Thermostat
55oC (ST2)
Thermostat Part Nº 0CEX50CLSD
85oC (ST1)
Part Nº 0CEX-SONDA
Inverter CT's Inv Snubber Capacitors

1/1000 (TA1 TA2 TA3) 2.5ìF (C9 C10)
Part Nº 0CEMC316610M019 Part Nº 0CPCPP525850
Sec. DC Bus Filter Caps

Sec. DC Bus Filter Caps 4400ìF (x 3 of 6)
4400ìF (x 3 of 6) Part Nº 0CPA08440400
Part Nº 0CPA08440400
DC Bus Fuse DC Bus Fuse

125A (F3) 125A (F3)
Part Nº 0CEFXV412 Part Nº 0CEFXV412
Output Filter Caps (x 6)

Capacitor
60ìF (C1 C2 C3 C4 C5 C6)
15ìF (C8)
Pt. Nº 0CPCPA06600450
Part Nº 0CPCPP615400
Capacitor
5ìF (C5) Capacitor
Part Nº 0CPCPP505700 15ìF (C7)
Saturable Inductor
Saturable Inductor
(L4)
(L3)
Part Nº 0CEXE3206203F3 (E)
Part Nº 0CEXE3206203F3 (E)
Part Nº 0CEXEPLT322033F3 (I)
Part Nº 0CEXEPLT322033F3 (I)
Converter Current Transformer Inductors Capacitor

1/100 (TA4) (L2 L1) 0.47ìF (C4 C3)
Part Nº 0CEMC316410M006 Part Nº 0CEMI316313M073 Part Nº 0CPCPP4471200
Primary DC Bus Fuse Primary DC Bus Fuse

125A (F4) 125A (F1)
Part Nº 0CEFXV412 Part Nº 0CEFXV412
Primary DC Bus Cap

15ìF (C2) Primary DC Bus Cap
Part Nº 0CPCPP615400 15ìF (C1)
UPS Troubleshooting 7-7

Component Location
Figure 7-6 Miscellaneous Component Location
Battery Charger PCB

Part Nº 0SDE0074
LCD Display PCB Power Circuit Breakers Battery Fuses

Part Nº 0SDE0075 63A (I1 I2 I3 I4) 32A (FS1 FS2 FS3 FS4)
Part Nº 0CESO4063 Part Nº 0CEFNC332
Relay PCB
Part Nº 0SDE0082
Cooling Fan (accessed from side)

VT1
Part Nº 0CEVTM2200800
Output Current Transformers

1/1000 (TA1 TA2 TA3)
Part Nº 0CEMC316610M019
Fan PCB
Part Nº 0SDE0078

Fault Identification
7.5 - Fault Identification
The following table lists all alarm conditions shown on the Operator panel LCD, the cause of the alarm,
what checks should be carried out and possible solutions.
The activation of any alarm condition will illuminate the Red ALARM LED on the OPERATOR PANEL.
Table 7-1 General Fault Identification Check List
LCD MESSAGE CAUSE CHECKS SOLUTIONS
The inverter is OFF.

Check for other active alarm
messages.
Check the output current on each Reduce the load to acceptable level.
If no other alarm indications are
INVERTER OFF phase. Re start Inverter via the Operator
seen:
Attempt to re-start the Inverter. Panel.
At the initial inverter start up an
overload has been detected
(>125%).
Continuos Overload on UPS Reduce the load to acceptable level.

INVERTER OVERLOAD Check the output current of each
Output (between 100% and Re-start Inverter via the Operator
phase.
125%). Panel.
High Transient Loads on UPS

Output.
During initial closure of the
STATIC SWITCH Check Output Load and Restart Reduce the load to acceptable level.
Bypass Static Switch an over
LOCKED UPS. Re start UPS.
Load Current is detected. After 3
attempts the Bypass Static Switch
will be blocked.
Replace defective battery

The automatic Battery Test has Check condition of Battery.
BATTERY FAILURE (see paragraph 6.3 on page6-8)
failed. Check Battery fuses (F1-4).
Replace Battery fuses.
This indication warns that the

battery is approaching its
BATTERY end-of-discharge voltage. Confirm the alarm is genuine by If the alarm is not genuine replace
PRE-ALARM This alarm is Normally seen measuring the battery voltage. the Auxiliary DC-DC Converter.
during an extended Mains
Failure.
Upon closing the Internal Static
STATIC SWITCH Check SCR of Bypass. Replace the faulty devices as
Switch one or more phases are
FAILURE Check Bypass external connections. necessary.
missing at the UPS Output.
If the indicated circuit breaker status

does not agree with the actual
Manual bypass MCB (I3) is
MANUAL BYPASS ON Check the status of the MCB. position then carry out a check of the
closed.
auxiliary contact monitoring circuit
and rectify as required.
If the MAINS INPUT MCB I1 has

Check the status of the MAINS opened, secure load to the bypass
INPUT MCB I1. supply and shutdown the UPS.
The Mains input voltage (supply Check that the input voltage is Check the input rectifier/converter
MAINS OUT OF LIMITS
to I1) is out of tolerance. present, and within tolerances devices for fault before attempting to
(+/-10% of nominal). restart unit.
Reconnect the Mains Supply to
module.
If the RESERVE INPUT MCB I2 has

opened, secure load to the bypass
The Bypass input voltage (supply Check the status of the RESERVE
supply and shutdown the UPS.
to I2) is out of tolerance. INPUT MCB I2.
Check the bypass devices for fault
This condition is detected by the Check that the Bypass (reserve)
BYPASS LINE OUT OF before attempting to restart unit.
Inverter Driver & Feedback Board input voltage is within tolerances
LIMITS Reconnect the Mains Supply to
(Voltage detection or phase (+/-10% of nominal).
module.
rotation detector circuits are Check the phase rotation of the
If the alarm continues replace the
active). Bypass supply.
Inverter Driver and Feedback Board
(P/N OSDE0071).

Fault Identification
LCD MESSAGE CAUSE CHECKS SOLUTIONS
Check the integrity of the internal

EMERGENCY POWER The front panel EMERGENCY EPO push button contact (Normally If the alarm is genuine then check the
OFF (+INVERTER OFF push button or the External open) and the external EPO push reason for the EPO circuit activation
+ STATIC SWITCH Emergency Power Off circuit has button circuit (at the customer and rectify as necessary.
FAILURE) been activated. connection terminal block, Normally Restart UPS.
closed) to ensure alarm is genuine.
Check the battery fuses in the
This alarm is activated if the
BATTERY BREAKER INTERNAL BATTERY fused breaker
Battery is not connected or if the Replace defective fuses or battery.
OFF and check Battery for open or short
Battery Test Fails.
circuit cell.
Check integrity of Battery Fuses

BATTERY CHARGER This alarm is activated if a failure in (F1-F5). Change battery charger if
FAILURE the Battery Charger is detected. Check IGBT Q1 on the battery necessary.
charger board
Check fuses F1-F5 on Battery

This alarm is activated by the
HIGH BATTERY Charger Board.. Change battery charger if
detection of a High Battery
VOLTAGE LEVEL Check IGBT Q1 on the Battery necessary.
Voltage/Charger Output.
Charger Board
This alarm is activated when the

battery voltage is below the ènd
of discharge' level (set on the Check the level of the battery If the alarm is not genuine
END DISCHARGE Auxiliary DC-DC Power Supply voltage. (i.e. Battery level is correct) replace
BATTERY VOLTAGE Board). If level is low check function of the the auxiliary DC-DC power supply
This alarm is Normally seen Battery Charger Board. board.
during an extended mains
Failure.
7 - 10 3x3 UPS Troubleshooting

Typical Voltage Values
7.6 - Typical Voltage Values
The following table of values have been taken from a serviceable UPS and are intended to give a typical
reference when carrying out fault diagnosis.
Table 7-2 Typical Measured Voltage Values and LED indications
PCB Test Point/LED Indication Normal Value Comment

3Ph TL Control Logic SE0072
TP2 (+ve) to TP3 (Ćve) 4.27V dc Inverter feedback signal to U8 Level adjusted by P1.
TP4 (+ve) to TP5 (Ćve) 4.31V dc Converter feedback signal to U9 Level adjusted by P2.
TP6 (+ve) to TP7 (Ćve) 4.28V dc Static Switch feedback signal to U8 Level adjusted by P3.
TP9 Logic Low NO MAINS OK signal from U12A.
TP10 2.49 Ć 2.29V dc MAINS FREQ signal from U12B.
TP11 5.48V dc TEMP ALARM signal from U14C (Active Low).
TP12 0.021V dc MANĆBYP signal from U12D.
TP14 0.37V dc MAINS PRESENT signal from U12F.
TP15 0.025V dc NO BATTERY HIGH signal from U13A.
TP16 5.01V dc BATTERY LOW signal from U13B.
TP17 0.016V dc NO BATTERY PREALARM signal from U13C.
LED LD1 (green) UPS Normal (OFF indicates an over temperature ST1, a DC offset
ON condition or PCB power failure)
Auxiliary DCĆDC Converter SE0070

U2A pin 1 8.88V dc Battery voltage monitor.
R36 5.59V dc VMAX level adjustment (P1) sets battery high level 500V.
R37 7.89V dc VMIN level adjustment (P2) sets battery low level 320V.
R39 7.53V dc PREALARM level adjustment (P3) 350V.
Molex Connector PM2 Pin 1 16.83V dc +15V supply to Inv. driver feedback PCB.
Molex Connector PM2 Pin 2 7.68V dc +7.5V supply to Inv. driver feedback PCB.
Molex Connector PM2 Pin 3 0V Ground.
Molex Connector PM2 Pin 4 15.33V dc Battery high output to Inv. driver feedback PCB.
Molex Connector PM2 Pin 5 0.616V dc Battery low output to Inv. driver feedback PCB.
Molex Connector PM2 Pin 6 15.47V dc Battery Prealarm output to Inv. driver feedback PCB.
Inverter Driver Feedback SE0071
R66 6.43V dc Reserve Bypass Vmin level adjustment (P2)
R69 5.54V dc Reserve Bypass Vmax level adjustment (P1)
R149 9.53V dc Temperature alarm reference adjustment (P3)
LED LD1 OFF ON indicates incorrect phase rotation.
LED LD2 OFF ON indicates DC Offset unbalanced load.
Battery Charger SE0074

Note: No voltage measurements can be carried out safely on this PCB.
LED LD1 FLASHING FLASHING indication when float charging battery.
3x3 UPS Troubleshooting 7 - 11

Fuse Check List
7.7 - Fuse Check List
Prior to any fault diagnosis, a serviceability check of the fuses is recommended. Failure of a fuse
can give an indication of a defective power device or component.
1. Using the list shown in Table 7Ć3 check each fuse for serviceability.
2. Determine the serviceability of any related component or PCB and repair or replace as
required.
3. Replace the fuse with a serviceable item.
4. Continue with any required fault diagnosis.
Table 7-3 Fuses
Fuse Value Function Location
F1 32A Battery Bank 1

Batte Fuses
Battery F e F
Front
o tSSwitch
itch Pa
Panel
el
F1 125A Primary DC bus +ve

U
Upper Power
P Section
S ti SeeS Figure
Fi 7Ć5
75
F4 125A Primary DC bus ćve
F2 125A Secondary DC bus +ve

U
Upper Power
P Section
S ti SeeS Figure
Fi 7Ć5
75
F3 125A Secondary DC bus ćve
F1 1A DC+ Input
A ilia DC
Auxiliary DCĆDC
DC Co
Converter
e te PCB
F2 1A DCć Input
F1 10A Input Phase R
F2 10A Input Phase S
F3 10A Input Phase T Battery

y Charger
g PCB
F4 10A Battery +
F5 10A Battery ć
F1 1A Cooling Fan Protection Fan PCB
7 - 12 3x3 UPS Troubleshooting

Service Manual
Test Procedures
7.8 - Test Procedures
7.8.1 - DC Bus Discharge Routine, Shutdown to Maintenance Bypass.

After calibration the following procedure can be used to shutdown the UPS to a Manual bypass condiĆ
tion, and then to normal operation:
1. Press the `MENU' push button ( A ) on the FRONT PANEL.
a) Select the `COMMAND' screen by pressing either the `BACK' ( C ) or `NEXT' ( b ) push
button.
b) Confirm the `COMMAND' menu selection by pressing `BACK' and `NEXT' at the same
time (i.e. ENTER).
D A *CONFIRMED* message will be displayed
2. Press `CLEAR' ( d ) twice to return to the main menu.
The following change-over sequence should occur, indicating that the load has been transfer to the
bypass line:
button.
time (i.e. ENTER).
d) Select the ÌNVERTER ON-OFF' screen by pressing either the `BACK' ( C ) or `NEXT' (B)
push button.
a) The Alarm buzzer is activated.
b) the Red general ÀLARM' red LED ( 2 ) will illuminate.
c) the Yellow `BYPASS ON' LED ( 4 ) will illuminate.
d) the Green `NORMAL' LED will extinguish.
e) The LCD will display the following messages:
ÌNVERTER OFF'.
11. Check that the load continues to be powered from the Maintenance Bypass Mains supply
while the UPS is off.
WARNING Wait at least 10 minutes after Shutting Down the UPS before proceeding with a StartĆ
Up procedure. to allow the DC bus to fully discharge
Note: To completely isolate the UPS from the input AC supplies, the main
external input power isolator must be opened.
On the primary input utility supply distribution panel post a label advising
personnel that the UPS circuit is under maintenance.
3x3 UPS 7 - 13
Service Manual
Test Procedures
Primary and Secondary DC Bus Voltage Check (refer to Figure 7Ć7)

1. Remove the UPS top cover.
2. With a DVM check the secondary DC bus across F3 and F2 has fallen less than 20V dc.
3. With a DVM check the primary DC bus across F1 and F4 has fallen less than 20V dc.
The UPS is now safe to carry out further investigation.
Note: The half DC bus level can also be monitored if required by connecting the
DVM across the +ve or Ćve fuse and the DC common (neutral) bus bar as
shown in Figure 7Ć7.
Figure 7-7 DC Bus Voltage check
F2
F3
Check Secondary DC
bus between Fuse F3
& F2
765V DC
To Check Half Secondary DC bus Voltage check for 382V DC between Fuse
F3 and Neutral Bus. (a similar check can be carried out from F2)
7 - 14 3x3 UPS
Service Manual
Test Procedures
7.8.2 - DC offset
Fault indication
The output of the UPS is monitored by the Inverter Driver Feedback PCB for any DC component on the
output waveform. If the level of DC exceeds the limit of 400mV, a signal is generated and switched to
the control logic PCB. This signal is switched through the thermostat ST1 as shown below in Figure 7Ć8.
Figure 7-8 DC Offset Alarm Signal
The UPS will transfer to the bypass and the red LED LD 2 on the inverter driver/feedback PCB Part Nº
OSDE0071, will illuminate. The red LED D11 on the 3ph TL control logic PCB Part Nº OSDE0072 will
extinguish. The UPS will remain on bypass until the alarm condition is reset using the Reset push switch
S1 on the PCB, or the UPS is completely powered down and restarted.
Figure 7-9 Typical output current waveforms with DC offset.
DC Offset
0 0
Normal output current waveform

Output current waveform showing DC Offset
DC Offset
Effect on the Output current

0 waveform with unbalanced non linear
load
DC Offset Condition
The most likely cause of a `DC OFFSET' condition could be:
1. The UPS is supplying an unbalanced non linear load, this could be on any phase.
2. The load is drawing DC current.
A common reason for this is an input bridge rectifier on a computer power supply is
defective and only half wave rectifying its input power.
3. An inverter gate drive circuit is defective.
This could cause the inverter EIGHT's switching to be out of balance.
3x3 UPS 7 - 15
Service Manual
Test Procedures
Action
1. To determine if the DC offset problem is load related.
Replace the normal load temporarily with a resistive load and monitor the alarm condition, if
it disappears then the problem lies with the load.
2. To measure the level of DC offset present, connect the test circuit shown in Figure 7Ć9 to the
output of the UPS.
Figure 7-10 DC offset test circuit.
C1 C3
U3 R1 N3 R1 W3
C2
All R = 120kÙ 2Watt
All C = 1ìF 250V R1
DC checked across each

Meter
capacitor normal level
50mV V3
3. Measure the DC mV across each phase capacitor the nominal level should be 50mV the
maximum 400mV.
a) Measure the DC offset level with the load connected if it is out of limits then the problem
is load related.
b) Check again with no load if the DC offset level is out of limits then the problem may lie
with the UPS.
4. If the DC Offset appears to be generated by the UPS, check the voltage across D94 and D89
on the inverter driver/feedback PCB Part Nº OSDE0071.
The voltage should be equal.
5. If an unequal voltage is measured then the fault is likely to be in either the inverter gate drive
or IGBT's.
Check that the IGBT drive circuit is correct and the IGBT devices are serviceable.
6. If the circuit and IGBT checks are OK the problem points to a defective monitoring circuit in
the inverter driver/feedback PCB.
Replace the inverter driver/feedback PCB.
7. Reconnect all cables and fit any covers removed.
8. Restore the UPS to its normal running condition.
7 - 16 3x3 UPS
Service Manual
Test Procedures
7.8.3 - IGBT Replacement
General Fitting Information.

When fitting heatsink mounted devices the following factors must be observed.
1. Ensure that when handling devices correct anti static precautions are taken and the handler
is connected to earth using a antistatic wrist band.
2. Take care when handling devices. Do not fit any device that may have been dropped or
damaged.
3. Spread a thin film of heatsink compound Part Nº 04010340 over the whole of the base area.
Ensure there are no gaps and the base and heatsink are free of foreign material before
fitting.
4. Position the device on the heat sink and insert the correct length screws listed in Table 7Ć4
5. Tighten the screws to finger tightness, ensuring that the threaded holes are not damaged.
6. Tighten screws alternately part way before applying the full torque to individual screws, to
prevent unnecessary strain being applied to the device substrate.
7. Use the tightening sequence shown in Figure 7Ć10.
Figure 7-11 Screw tightening sequence.
1 4
3 2
8. Finally tighten the screws to the appropriate torque shown in Table 7Ć4.
Torque Nm
Pan head
Ci
Circuit
it R
Ref.
f P t Nº
Part Sems Heatsink Terminal
Bridge PD1 0CADTSSKD82/12 M4 X 12FL 2 2
Diode CD1 CD2 0CSDRFBYT261P12 3.5 3.5
Diode CD4 CD5 0CADR210230 2 2
Diode CD3 0CADRFBYT231 2 2
SCR S7 S8 0CASR212132 M5 X 16FL 3 3
SCR S1, 2, 3, 4, 5 & S6 0CASR212391 M5 X 16FL 3 3
M4 Ć 2
IGBT Q1, Q2, Q3 (Inverter) 0CATR210415 M5 X 13FL 3 M5 Ć 3
IGBT Q4 (Converter) 0CATD212420 M5 X 16FL 2.5 2
Table 7-5 Torque settings for Hinet devices.
Inverter IGBT (Q1 Q2 Q3) Removal

1. Power down the UPS and carry out the DC bus discharge routine.
2. Gain access to the UPS power section by removing the top and side covers.
3. Disconnect and remove the Inverter driver/feedback PCB Part NºOSDE0071. Follow the
procedure on page 7Ć32.
4. Disconnect fuse F2 and F3.
5. Remove capacitors C9 and C10
6. Remove the Inverter bus bar retaining screws from the IGBT's and lift off the bus bars.
3x3 UPS 7 - 17
Service Manual
Test Procedures
7. Disconnect the cables attached to current transformer TA1 TA2 and TA3 IGBT connection
extension pillars and lift off the CT's.
Note: An inĆsitu test for a short circuit IGBT can be carried out at this point
before the devices are removed.
8. Disconnect the gate drive fastĆon connectors from the IGBT's and note their position for
reĆassembly.
9. Remove the four retaining IGBT securing Allen screws from each IGBT and remove each
IGBT.
10. Test each IGBT for serviceability follow the IGBT test procedure on page 7Ć20.
11. Replace any components found defective.
IGBT fitting is the reverse of the removal procedure refer to Table 7-6 for correct IGBT gate drive conĆ
nector location.
Table 7-6 Inverter IGBT Gate Drive Connectors
IGBT Gate Lead Terminal

IGBT Connector
4 5 7 6
Q1 J11 Red Black Black Red
Q2 J9 Blue Black Black Blue
Q3 J11 Red Black Black Red
Converter IGBT (Q4) Removal

4. Remove the converter bus bar retaining screws from IGBT Terminal 2 and 4.
5. Remove capacitors C9 and C10 from the bus bars.
6. Remover the connecting screws from diodes CD4 and CD5
7. Remove the bus bar retaining screws from the insulated pillar.
8. Slacken the converter current transformer (TA4) mounting bolt securing the CT and bus bar,
and reposition to gain access to Q4.
Note: An inĆsitu test for a short circuit IGBT can be carried out at this point
before the devices are removed.
9. Disconnect the gate drive fastĆon connectors from the IGBT and note their position for
reĆassembly.
10. Remove the four retaining IGBT securing Allen screws and remove from IGBT from the
heatsink.
11. Carry out a test of the IGBT for serviceability follow the IGBT test procedure on page 7Ć20.
12. Replace IGBT if found defective.
IGBT fitting is the reverse of the removal procedure refer to Table 7-7 for correct IGBT gate drive conĆ
nector location.
Table 7-7 Converter IGBT Gate Drive Connectors
IGBT Gate Lead Terminal

IGBT
3 5
Q4 Red Black
7 - 18 3x3 UPS
Service Manual
Test Procedures
7.8.4 - IGBT testing

Two types of IGBT are used on the series UPS.
a) Twin pack devices used in the inverter section.
b) A single pack devices used on the converter.
All the devices currently used on the , are the latest àdvanced second' or `third' generation type,
these have a higher gate emitter impedance. Difficulty can be experienced testing this type of IGBT
using a standard DVM, as they lack the battery power to switch on the device.
This difficulty can give rise to an incorrect diagnosis and a perfectly serviceable IGBT may be marked
as defective.
As a normal DVM cannot produce a high enough voltage to switch on a advanced second or third generĆ
ation IGBT, it is recommended that the functional test is carried out with the use of an external dc power
supply.
Note: A 9V PP3 battery can successfully be used as the external voltage source.
Hinet Third Generation IGBT's
Circuit Ref. IGBT Type Liebert Hiross Part Nº
IGBT Q1, Q2, Q3 EUPEC BSM150GB120DN2 Twin 0CATR210415
IGBT Q4 EUPEC BSM200GA120DN2 (6) Single 0CATD212420
Table 7-8 Third generation IGBT usage
Testing the IGBT

1. Power down the UPS and gain access to the power sections by following the procedure on
page 7Ć3.
2. Ensure that the power sections have been completely isolated, check using a DVM.
3. Locate the IGBT to be tested and totally isolate it by disconnecting its gate drive lead from
the inverter drivers and feedback PCB, and the power leads from the screwed terminals.
4. Test the IGBT using a DVM and a 9V dc power source.
Follow the procedure shown in Table 7Ć6. Refer to Figure 7Ć11 for the IGBT internal circuit.
5. Replace the IGBT if required.
Ensure the correct fitting procedure is used. Refer to Table 7Ć4 for correct torque values.
6. Reconnect the IGBT gate drive and power connections.
7. Carry out a test of the Inverter or Converter.
8. Replace all panels removed and restore the UPS to its normal working condition.
3x3 UPS 7 - 19
Service Manual
Test Procedures
Table 7-9 Functional check of power IGBT's
DVM/Battery Lead DVM

Action Connection Indication Interpretation
(mV)
+ve to: Ćve to: IGBT
Connect DVM across the emitter cathode 1 2Ć7

junction. OL IGBT switched off a serviceable condition.
[1] [2 Ć 5]
Reverse DVM leads to check internal 2Ć7 1

diode. 0.355 Diode forward resistance.
[2 Ć 5] [1]
ReĆconnect DVM leads across emitter cathĆ 1 2Ć7

ode. OL
[1] [2 Ć 5]
Connect the 9V power supply (battery) 2Ć7

negative Ćve OL
[2 Ć 5]
6 2Ć7
Touch the +ve Battery lead to gate (base). 0.345 This will switch on the device.
[3] [2 Ć 5]
1 2Ć7 Low mV reading indicates IGBT has

ReĆcheck the emitter cathode junction. 0.345 switched on and is serviceable.
[1] [2 Ć 5]
Disconnect the battery +ve and Ćve leads. ć ć 0.345
Turn off the device by shorting B2(G2) and 1 2Ć7

E2. OL High resistance indicates the IGBT is off.
[1] [2 Ć 5]
Note: Terminal connections for single pack IGBT are shown in [square brackets]
Testing the second IGBT
Connect DVM across the emitter cathode

junction. 3 1 OL IGBT switched off a serviceable condition.
Reverse DVM leads to check internal

diode. 1 3 0.336 Diode forward resistance.
ReĆconnect DVM leads across emitter cathĆ

ode. 3 1 OL
Connect the 9V power supply (battery)

negative Ćve 1 OL
Touch the +ve Battery lead to gate (base). 4 1 0.345 This will switch on the device.
Disconnect the battery +ve and Ćve leads. ć ć 0.345
Low mV reading indicates IGBT has

ReĆcheck the emitter cathode junction. 3 1 0.345 switched on and is serviceable.
Turn off the device by shorting B1 and E1. 3 1 OL High resistance indicates the IGBT is off
Note: The DVM readings shown in the above table are typical they will vary
slightly from device to device and with the type of meter used.
7 - 20 3x3 UPS
Service Manual
Test Procedures
Figure 7-12 IGBT internal circuit and external connections.
Twin pack IGBT (Part Nº OCATR210415)
Single pack IGBT (Part Nº OCATD212420)
3x3 UPS 7 - 21
Service Manual
Test Procedures
7.8.5 - SCR Testing

The UPS use two types of SCR devices, one to switch the reserve bypass and inverter output
to the load. The second type to connect the battery to the primary DC bus in the event of failure of the
utility supply.
The two different types of device used to perform these functions are both of twin pack construction howĆ
ever S7 and S8 have a single SCR and Diode. arrangement.
Table 7-10 SCR
Circuit Ref. SCR Type Part Nº
SCR S1 S2 S3 S4 S5
S6 SEMIKRON SKKT 92/12E 91A Twin Pack 0CASR212420
132A combined SCR &

SCR S7 S8 SEMIKRON SKKH132/12E Diode Pack 0CASR212132
Failure of a static switch or battery SCR will initiate the appropriate indication on the LED display and
will normally fail open circuit O/C or short circuit S/C. If a faulty device is suspected it can be checked
using a DVM. A short circuit across the anode cathode junction will be quickly apparent, however an
open circuit cannot so easily be diagnosed as the high resistance indicated is the normal state of the
device when turned off.
The Gate Cathode resistance can also be measured and should be in the range of 10 to 20 ohms for
a serviceable SCR, a high resistance would indicate an open circuit.
It is therefore recommended that a functional test of the SCR is carried out using the simple test circuits
shown in Figure 7Ć12 and Figure 7Ć14.
Twin Pack SCR Replacement (S1 S2 S3 S4 S5 S6)
4. Remove the two SCR gate drive leads from terminals 4 and 6 from each SCR and note their
position.
Note: Note SCR S6 has the gate drive leads reversed blue to 4 red to 6.
5. Remove the terminal standoffs and screws to release the bus bars from SCR terminals 1. 2
and 3.
6. Disconnect the second gate drive leads from SCR terminals 1 and 2.
Table 7-11 SCR Gate Drive Lead Connection
Gate Drive Terminal

SCR
4 6 1 2
S1 Blue Red Black Brown
S2 Red Blue Brown Black
S4 Red Blue Brown Black
7. Remove the two SCR Allen retaining screws from each SCR and lift from the Heatsink
8. Carry out the following functional test on each SCR and replace if required.
SCR fitting is the reverse of the removal procedure refer to 12. for correct SCR gate drive connector locaĆ
tion.
7 - 22 3x3 UPS
Service Manual
Test Procedures
Figure 7-13 Testing the twin pack SCR
9 volt power
source Test lamp
Twin pack SCR

9 volt power
Test lamp source
ćve +ve
+ve ćve
+ve ćve
+ve
ćve
9 volt power source 9 volt power source

and switch and switch
To functionally test a twin pack SCR as shown in Figure 7Ć12 a DC power source and test lamp is reĆ
quired, typically a 9V PP3 battery and 12V bulb.
1. Connect the bulb and battery to SCR1 as shown, connect the +ve to the anode (1) and ćve
to the cathode (2) terminal.
2. Using a second power source or link from the battery connect the +ve lead to SCR1 gate
terminal 4 and the ćve lead gate terminal 5.
3. Switch on the SCR by briefly making the gate circuit, use a switch if available.
The SCR will fire and the bulb will light and remain on. The bulb provides a current source
for the SCR and it will continue to fire.
4. Remove the +ve connection from terminal 1.
The bulb will extinguish an the SCR will switch off.
5. Repeat the test for SCR2.
3x3 UPS 7 - 23
Service Manual
Test Procedures
Single SCR and Diode Pack Replacement. (S7 S8)

3. To gain access to the SCR's disconnect and remove the Input Filter PCB Part NºOSDE0079.
Follow the procedure on page 7Ć38.
SCR S7
4. Disconnect the Red and Black gate drive Connectors from 4Q1 (red) and 5K1 (black).
5. Disconnect the Battery negative bus bar from SCR terminal 2.
6. Disconnect Fuse F4 bus bar from SCR terminal 1.
7. Disconnect black leads from R2 to SCR terminal 1 and 2.
8. Remove red leads from SCR terminal 1 and 2 which connect to the fast on connectors F12
(SCR 1) and F11 (SCR 2) on the Inverter driver/feedback PCB.
Note: There is no connection to SCR terminal 3.

9. Remove the two SCR Allen retaining screws from the SCR and lift from the Heatsink.
Note: There is a deĆcoupling capacitor linking the heatsink from SCR mounting
screw to the neutral bus bar.
SCR S8
10. Disconnect the battery +ve cable from SCR terminal 3.
11. Disconnect red leads from R1 to SCR terminal 1 and 2.
12. Remove fuse F1 bus bar from SCR terminal 2.
13. Remove the input bridge bus bar from SCR terminal 1.
14. Remove red leads from SCR terminal 1 and 2 which connect to the fast on connectors F13
(SCR 1) and F14 (SCR 2) on the Inverter driver/feedback PCB.
15. Carry out the following functional test on each SCR and replace if required.
SCR fitting is the reverse of the removal procedure.
Figure 7-14 Single SCR Test.
9 volt power
Test lamp source
Single SCR & Diode pack
+ve ćve
+ve ćve
9 volt power source

and switch
7 - 24 3x3 UPS
Service Manual
Test Procedures
To functionally test a single SCR and diode pack as shown in Figure 7Ć12 a DC power source and test
lamp is required, typically a 9V PP3 battery and 12V bulb.
1. Connect the bulb and battery to the SCR as shown, connect the +ve to the anode (1) and
ćve to the cathode (2) terminal.
2. Using a second power source or link from the battery connect the +ve lead to the SCR gate
terminal 4 and the ćve lead gate terminal 5.
3. Switch on the SCR by briefly making the gate circuit, use a switch if available.
The SCR will fire and the bulb will light and remain on. The bulb provides a current source
for the SCR and it will continue to fire.
4. Remove the +ve connection from terminal 1.
The bulb will extinguish an the SCR will switch off.
5. Using a DVM set to the diode range check the individual diode between SCR terminal 1 and
3 for the forward and revers conditions.
3x3 UPS 7 - 25
Service Manual
Test Procedures
7.8.6 - Inverter Drive Signal Testing

Equipment required
a) (DC) Power Supply greater than 350Volts (Battery string)
b) Oscilloscope (Isolated or in Differential mode)
c) Linking Wire.
d) Cable with 8 Pin Amphinol style connector or two compatible insulated connectors
To carry out test.
1. Turn of unit and wait for the DC Bus Voltage to decay
2. Select a battery string and remove the wire from the output side of it's fuse holder.
3. Insulate the end of this wire.
4. Remove connector PM1 from the Auxiliary Converter board Part Nº OSDE0070.
5. Connect the test cable positive to the Battery Fuse holder selected.
6. Connect the test cable negative to the battery common negative rail.
7. Remove the remaining fuses from the other battery fuse holders if fitted.
8. Connect the test lead Amphinol connector to PM1 on the Auxiliary Converter PCB Connect
the Negative to the rearmost pin and positive to the front most pin.
9. Close links J5 & J4 on the Control Logic PCB Part Nº OSDE0072.
10. Fit a wire link from Test Point TP30 to capacitor C30 (side nearest to IC U12.) on the Control
Logic PCB (This forces a mains OK signal)
11. Close the selected battery fuse.
12. Wait for the UPS to initialise.
13. Press the inverter ONĆOFF push button.
14. Check the inverter IGBT gate drive PWM signals at the appropriate connectors J9, J11 and
J12, on the Inverter Driver/Feedback PCB Part Nº OSDE0071.
15. On completion of the test press the inverter ONĆOFF push button to stop the inverter.
16. Open the battery fuse allow the DC bus to discharge.
17. Remove all test links and cables, and restore all the original connections.
18. Return the machine to normal operating condition.
Figure 7-15 Test Lead connection
Amphenol Connector
connect to PM1 Rear Pin
Test cable +ve

Battery Fuse
Holders
Front Pin
Test cable ćve
Auxiliary Converter board Part Nº OSDE0070
6mm Ring Tab
To Battery String Battery ćve common
7 - 26 3x3 UPS
Service Manual
Test Procedures
7.8.7 - Checking the Hinet power circuit capacitors.

Failure of one or more capacitors in the power circuits, can normally be determined by a visual
inspection. A defective capacitor will normally have distortion to the top of the capacitor can, the terĆ
minals may have splayed apart and in extreme circumstances the cooling oil may leak from the conĆ
tainer.
The primary and secondary DC bus capacitors C1 & C2; C7 & C8; should have a thorough visual examĆ
ination.
If the capacitors show no external signs of damage each capacitor may be checked individually for an
internal open or short circuit.
Capacitor short circuit checks
1. Transfer the load to the Maintenance Bypass supply.
2. Totally powerĆdown the UPS.
3. Allow sufficient time for the capacitors to fully discharge, verify with DC voltmeter (DVM) that:
a) DC bus capacitors are safe to touch.
b) Half bridge capacitors are safe to touch.
4. Isolate each capacitor by disconnecting each terminal connection.
5. Using an ohmmeter (DVM on Resistance range) check the following:
a) Connect the ohmmeter between the capacitor terminals and verify that the capacitor
charges up (eventually the meter will indicate OL).
b) Measure the resistance between each capacitor terminal and ground (capacitor body
earth) ć this should indicate open circuit in each case.
6. Replace any capacitor that fails the above checks.
Capacitor open circuit checks
1. Transfer the load to the Maintenance Bypass supply.
2. Totally powerĆdown the UPS.
3. Allow sufficient time for the capacitors to fully discharge, verify with DC voltmeter (DVM) that:
a) DC bus capacitors are safe to touch.
b) Half bridge capacitors are safe to touch.
4. Isolate each capacitor by disconnecting each terminal connection.
5. Connect a shorting link across both capacitor terminals, and at the same time connect an
ohmmeter (DVM) across the shorted terminals (i.e. meter should indicate 0 Ohms ć
shortĆcircuit).
6. Remove the shorting link and note the time taken by the meter indication to rise from 0
Ohms to OL as the capacitor charges up to the meter voltage ć this should be of the order of
20 seconds on a suitable meter range.
7. Perform this check for the DC bus capacitors and compare the results. If any capacitor has a
seriously reduced time constant compared to the others then it should be replaced.
8. Repeat the check for any suspect capacitors.
3x3 UPS 7 - 27
Service Manual
PCB Replacement Procedures
7.9 - PCB Replacement Procedures
7.9.1 - Auxiliary DC Ć DC Converter Part Nº 0SDE0070 (PCB Label: CS0070 Exx)

R36 U2A pin1 R39
P1 (500Vdc) (See 13.) (See 13.) (See 13.)
F2 P2 (320Vdc)
(DC ćve Input 1A)
R37
(See 13.)
PM1
P3 (500Vdc)
F1
(DC +ve Input 1A)
PM2
PM2 pin 1 to 6
(See 13.)
3. Mark all connectors before removal.
4. Disconnect Connector PM1 and PM2.
5. Release the PCB StandĆOff mounts and remover the PCB from the Unit.
Replacing the PCB
1. Replace the DC Ć DC converter PCB using the opposite sequence to the removal.
Important All replacement PCB's leave the manufacturer pre calibrated therefore no adjustment
note should be necessary.
2. Refit all covers removed and return the UPS to its normal operating condition.
7 - 28 3x3 UPS
Service Manual
7.9.2 - LCD UPS Monitor Board 0SDE0077 (PCB Label: CS0077 Exx)
J3 J2 CN1
J5
Link
JP2
J7
J6
J4
Link
JP3
Link
JP1
J1
2. Gain access to the UPS power section by removing the top and side covers
4. Disconnect connectors J1; J2; J5; J6; J7 & CN1.
5. Release the PCB Stand-Off mounts and remove the PCB from the unit.
Replacing the PCB
1. Replace the UPS Monitor Board using the opposite sequence to the removal.
2. When fitting a replacement PCB the on board links must be checked to ensure they are in
the correct position.
Link and Jumper functions
Link Position Function

JP1 1-2 close for normal operation.
JP3 2-3 close for normal operation.
Note: THE SILKSCREEN IDENT (JP1/JPS) IS NEXT TO PIN NUMBER 3.
Link JP2 ( External EPO )
JP2 is used to enable the operation of the optional external EPO.
Link Ext EPO fitted Ext EPO not fitted

JP2 Open Close
3x3 UPS 7 - 29
Service Manual
7.9.3 - Inverter Driver/Feedback Interface Part Nº 0SDE0071 (PCB Label: CS0071 Exx)
Leave 2 Pins LINK J5A J4A

Clear on J21
J22 J21 J18 J13 J10 J7 J8
J17 N8
2 red wires
N12
black wire
LD2
DC Offset
N16
brown wire
J23 LD1
LINK J1A J2A J3A P1 P1 f Rotation
(bypass V +10%) (bypass V ć10%)
R69 R66 R149
(See 13.) (See 13.) (See 13.)
4. Disconnect connectors J19, J15 and J7.
5. Disconnect SCR driver connectors J1 to J6.
6. Disconnect the inverter IGBT gate drive connectors J9, J11 and J12.
7. Disconnect the converter IGBT gate drive lead J14.
8. Disconnect the input SCR gate drive connector J16.
9. Disconnect connectors J8, J10, J13 and J18.
10. Disconnect J21.
Note: J21 connector leaves the two rear pins free on the plug when reconnecting.
11. Remove secondary DC bus voltage feedback fastĆon connectors.

a) ćve feedback F1 & F15.
b) +ve feedback F2 & F16.
12. Remove Primary DC bus voltage feedback fastĆon connectors
a) ćve feedback F11.
b) +ve feedback F13.
13. Remove Input SCR output feedback fastĆon connectors.
a) ćve feedback F12.
b) +ve feedback F14.
7 - 30 3x3 UPS
Service Manual
14. Remove the terminal screws and wires from the static switch SCRs.
a) N7, N8 & N9 Note: N8 has two Red wires attached.
b) N11, N12 & N13 Note: N12 has a Black wire attached.
c) N15, N16 & N17 Note: N16 has a Brown wire attached.
15. Remove the PCB Earth terminal screw N20.
16. Remove the remaining PCB retaining screw from the mounting pillar and carefully lift the
PCB from the unit feeding the gate drive lead connectors through the PCB cutĆouts.
Replacing the PCB
1. Replace the Inverter Driver/Feedback PCB using the opposite sequence to the removal.
a) J4AĆJ5A sets the DC Bus voltage.
DC V/Link J4A J5A

375V (service maintenance mode) close close
750V (normal operation.) open open
b) JIAĆJ2AĆJ3A sets the UPS nominal bypass voltage;
Link 380V 400V 415V

J1A close open open
J2A open close open
J3A open open close
3. Carry out the Inverter and Converter functional test outlined on page 7-15.
Bypass Voltage Threshold Adjustment
a) P1 = adjusts the maximum bypass voltage threshold (+10%)
b) P2 = adjusts the minimum bypass voltage threshold (Ć10%)
3x3 UPS 7 - 31
Service Manual
7.9.4 - 3ph TL Control Logic Part Nº 0SDE0072 * (PCB Label: CS0072 Exx)
Link TP11 TP14 Link TP30 to C30 TP12 TP9 TP10
J8 J7 J6 (See 13.) (Ref. test on page 7-27) (See 13.)
CN1 CN1
Link
J1 to J5
CN1
LD1
AC Power ON
Link
J9 J10
U7
(EPROM)
Link
J11 J12
CN1
P2
(Conv. output V adj.)
TP15 TP16 TP17 P1 P3 TP2 TP4 TP6

(See 13.) (Inv. output V adj.) (UPS. output ±15%) (See 13.)
Note: * This PCB must be replaced with one of the same power rating as the UPS.
UPS Rating Replacement PCB Part Number: EPROM U7 Identification:

10kVA 0SDE0072-10 QSR-10
15kVA 0SDE0072-15 QSR-15
20kVA 0SDE0072-20 QSR-20
30kVA 0SDE0072-30 QSR-30
4. Note the position of the shorting links fitted to the PCB
5. Disconnect connectors CN2, CN4 and CN5.
6. Release the PCB StandĆOff mounts and remove the PCB from the Unit.
Replacing the PCB
1. Replace the Control Logic PCB using the opposite sequence to the removal.
7 - 32 3x3 UPS
Service Manual

a) J1ĆJ2ĆJ3 define the UPS characteristics.
Link Close Open
J1 OnĆLine OffĆline
J2 Freq. Tolerance 1% Freq. Tolerance 4%
J3 50Hz 60Hz
b) J4ĆJ5 define the parameters of the inverter output voltage and DC Bus voltage.
Output V/Link J4 J5
Service close close
380 open close
400 close open
415 open open
c) J6ĆJ7ĆJ8 define the overload level related to the UPS ratings
Link 10K 20K 30K
J6 open close open
J7 close open close
J8 close close open
d) J9ĆJ10ĆJ12 defines the inverter peak current limit for the appropriate UPS output rating.
Link 10K 20K 30K
J9 open close open
J10 open open close
J12 open open open
e) J11 define the converter peak current limit. (normally closed for all UPS output ratings).
3. Carry out the Inverter and Converter functional test outlined on page 7-15.
Potentiometer adjustment
4. It is unlikely that any potentiometer adjustment will be required on a replacement PCB
however the function is listed below.
a) P1 = adjust the inverter output voltage.
b) P2 = adjust the converter DC voltage.
c) P3 = adjust the UPS output threshold at ± 15%.
3x3 UPS 7 - 33
Service Manual
7.9.5 - Battery Charger Part Nº 0SDE0074 (PCB Label: CS0074)

Links Links P1 LD1 P2 P3
JP5 to JP10 J4 to J5 (float volts adj.) (float Charge) (boost volts adj.) (temp. comp float adj.)
CN2 CN1
F5
Battery ćve
CN3 C1 C11 & C12

C9
F4 Link Link Links Link Link Link F1 F2 F3
Battery+ve JP11 JP3 JP1 JP2 JP4 JP12 JP13 (Input fuses)
3. Gain access to the Battery charger PCB by removing the front Top Heatsink Cover. See
Figure 7-1 UPS Cover Removal on page 7-3.
WARNING Capacitors C1, C9, C11 & C12 will remain charged for a considerable period after power
is removed from UPS. Ensure that the following PCB discharge routine is carried out before
handling the PCB.
4. With a DVM check for a voltage across F4 and F5, C1 and C9.
5. If a voltage is detected, discharge the capacitors using a 1kÙ 4Watt Resistor or equivalent.
Connect the discharge resistor to the voltage test point. (Across F4, F5, C1 and C9).
7. Disconnect connectors CN1, CN2 and CN3.
8. Remove the ftwo Heatsink securing bolts.
9. Carefully lift the complete PCB and Heatsink assembly from the side of the unit.
10. Remove the two fixing screws and insulated washers from the front heatsink insulated
stand-off.
11. Remove the two rear fixing screws and insulated washers from the heatsink insulated
stand-off's.
12. Remove the two Allen terminal screws from diods PD1 and PD2.
13. Remove the four terminal screws from the battery charger IGBT Q1.
14. Remove the four terminal screws from the diode pack D1.
15. Note the position of the shorting links fitted to the PCB.
16. Carefully lift the PCB from the Heatsink.
Replacing the PCB
1. Replace the Battery Charger PCB using the opposite sequence to the removal.
7 - 34 3x3 UPS
Service Manual
a) JPI ĆJP2 sets the recharging current.
Link/Ampere IA 3A 5A
JPI open open close
JP2 open close open
b) JP3 enable/disables the boost charge.
Link Boost Disable Boost Enable

JP3 open close
c) JP4 enable/disables the temperature compensation circuit.
Link Th Comp. Disable Th. Comp. Enable

JP4 open close
d) Jumpers JP5 to JPI0 set the capacity for the installed battery, this is used for the battery
test function.

7.2Ah 2 x 7.2Ah 3 x 7.2Ah 4 x 7.2Ah 38Ah 65Ah
e) JP11 when selected open inhibits the battery test regime.
Note: JP11 JP12 and JP13 are always set closed.
f) J4ĆJ5ĆJ6 set the automatic battery test interval
Link J4 J5 J6
Time 12 Hours 24 Hours 48 Hours
Battery Charger Voltage Adjustment

3. It is unlikely that any potentiometer adjustment will be required on a replacement PCB
however the function is listed below.
a) P1 = adjusts the float voltage level to 432 Vdc
b) P2 = adjusts the boost voltage level. This setting is dependant on the type of battery
fitted.
c) P3 = adjusts the float voltage when the temperature compensation option is enabled.
3x3 UPS 7 - 35
Service Manual
7.9.6 - Input Filter Part Nº 0SDE0079 (PCB Label: CS0079 Exx)
3. Mark filter wiring before disconnection.
4. Remove the five retaining terminal screws and disconnect the filter wires.
a) Red wire from PW3 PHĆR.
b) Black wire from PW4 PHĆS.
c) Brown wire from PW5 PHĆT.
d) Blue wire from PW2 Neutral.
5. Carefully lift the PCB from the unit.
Replacing the PCB
1. Replace the Input Filter PCB using the opposite sequence to the removal.
7 - 36 3x3 UPS
Service Manual
7.9.7 - Operator Control Panel (LDC) Part Nº 0SDE0075 (PCB Label: CS0075 Exx)
CS0075 front CN1

(EPO Push botton)
J1
CS0075 rear
P1
LCD Contrast
Removing the Assembly:
1. Power down the UPS and carry out the DC bus Discharge routine.
2. Gain access to the rear of the UPS's Front door.
4. Disconnect connectors CN1 and J1.
5. Remove the Left and Right hand fixing bolts in order to remove the assembly.
Replacing the Assembly:

1. Replacing the Operator Control Panel assembly is the oppoite sequence to the removal.
Adjusting the LCD contrast:

If required the contrast of the LCD can be adjusted using the potentiometer P1 on the rear of the Operator Control
Panel assembly.
3x3 UPS 7 - 37
Chapter 8 - Optional Equipment
The following optional equipment is available for the UPS
DESCRIPTION PART NUMBER
Internal Extended Battery Kit BATT
Battery Connecting Kit BATTCABLE
Optional Communications Cards (Relays) RELAYCARD
Upgrade Kit 10 to 15kVA UPGRADE1015
Isolation Transformer 10kVA ISOLTX10
Isolation Transformer 30kVA in Cabinet ISOLTX30
Remote Panel
8.1 - Second Relay card (Optional)
A Relay card is supplied upon customer demand.

The Relay card functions are the same as the standard card, but the second relay card option provides
a tag block, allowing the duplication of the same signals as the DB9 plug. Therefore, any type of device
(e.g. buzzer alarms, lamps, remote indications, etc.) can be controlled.
The Relay card cannot be fitted with an additional EPO button. To connect several EPO buttons
first connect them in series and then connect to CN3 on the standard Relay card.
For Jumper configuration, please refer to Chapter 2 2. 4 `Setting Standard Relay Interface PCB' on page
2Ć12.
3x3 UPS Optional Equipment 8-1

Chapter 8 - Optional Equipment Service Manual
Remote Alarm Panel
8.2 - Remote Alarm Panel
The remote indication panel provides duplication of the main functions and operating status of the
UPS control panel LED's, at a distance from the main equipment.
8.2.1 - Remote Alarm Panel connection

The remote signalling panel is provided with its own power supply unit and a connection cable.
The connection is to the M1 tag block on the card and the remote signalling panel.
8.3 - Upgrade Kit
This Upgrade Kit allows the extension of the output power from the original rating value up to 30kVA by
changing some internal components.
Note: This upgrade must be carried out by a qualified ĆTrained

Engineer.
Additional components may be required (Batteries, Circuit Breakers etc.) depending on the actual inĆ
stallation & unit configuration.
8.4 - Isolation Transformer
The isolation transformer is a starĆstar configuration and can be connected either in the input or output
side.
This item must be fitted internally in the unit for power up to 20kVA and in an external cabinet for 30kVA.
Different sizes are provided for different power ratings.
8.5 - Internal Extended Battery Kit
The Kit includes:

1. The Battery (string of 32 batteries 12V eachĆ 7.2Ah) Lead Acid Valve Regulated
2. The electrical connections
3. The sustaining frame
8.6 - Battery Connecting Kit
Is the same as the Internal Extended Battery Kit without the Battery.
8-2 3x3 UPS Optional Equipment

Chapter 9 - Spare Parts
The following list describes the most commonly used part on the (3x3) UPS.
For additional parts and information on the parts location refer to the section 7-4 Component
Identification.
Note: In some case the re-order number for the PCBs and the PCB Label may
differ.
For example:
The label on the `silk-screen' of the UPS Monitor Board is CS0077, however the correct re-order
number OSDE0077.
Re–order Part Number Description
0CEFNC332 Fuse 32 A 400 V
0CEVTM2200800 Fan 2GDR35 133/190R
0CPCPA06600450 Capacitor 60mF 450 V
0CSDRFBYT261P12 Diode 60 A 1.200 V
0SDE0082 Relay Board
0SDE0070 Auxiliary Converter Board
0SDE0071 Driver & Feedback Interface
0SDE0072–10 Control Logic Board 10KVA
0SDE0077 UPS Monitor Board
0SDE1074 Battery Charger Assembly
0SDE0075 LCD display
0SDE0078 Fan Board
0SDE0079 Input filter
0SDE0080 EMC/RF Filter Board
0SDE1051 Subassembly Module
0CEFXV412 Fuse 120 A 660 V
0CPCPA08440400 Capacitor 4400 mF 400V
0CATRCM150BU24F IGBT 150 A 1.000 V (Double)
0CATD212420 IGBT 200 A 1.200 V (Single)
0CASR212391 SCR 91 A 1.200 V
0CSSX212413 SCR 132 A 1.200 V
0CADR210230 Diode 30 A 1.000 V BYT230
0CADRFBYT231 Diode 30 A 1.000 V BYT231
0CADTSSKD82/12 Bridge SKD 82/12
0CESO4063 Circuit Breaker 63A 4
0CBE1200 Sealed Battery 7,2 Ah 12 V
3x3 UPS Spare Parts 9-1


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3x3 UPS Preliminary Pages Prelim Page i

EQUIPMENT PART NUMBER

3x3 UPS Preliminary Pages Prelim Page iii

WARNING The UPS is a Class A product.

WARNING HIGH EARTH LEAKAGE CURRENT.

CAUTION This equipment is fitted with RFI suppression filters

Prelim Page iv 3x3 UPS Preliminary Pages

Important Instructions for safe use

3x3 UPS Preliminary Pages Prelim Page v

The warning triangle shown above indicate personal safety instructions.

Prelim Page vi 3x3 UPS Preliminary Pages

10kVA 15kVA 20kVA 30kVA

Nominal Input Frequency 50/60Hz

Input Frequency Range 40 ć 70Hz

Input Current Harmonic Distortion (THD) <30% (without filter)

Output Voltage Adjustment Range 360 ć 415Vac

Output Voltage Stability

Output Voltage Transient Recovery Time <30ms (to 3% RMS)

Output Voltage Distortion (THD)

Output Voltage Phase Displacement

Nominal Output Frequency 50 or 60Hz

Output Frequency Regulation

Maximum Slew Rate 1Hz/sec

Nominal Output Power Rating

Output Nominal Power Factor 0.8

Overload Capability on Inverter (Load Will Transfer to

Output Short Circuit Current 300% of nominal current for 100ms

UPS Preliminary Pages Prelim Page vii

10kVA 15kVA 20kVA 30kVA

Number of Battery Cells 192

Nominal Battery Voltage 384Vdc

Internal Battery Rating 7.2Ahr 2 x 7.2Ahr 2 x 7.2Ahr 3 x 7.2Ahr

Full Load Autonomy Time With Standard Internal Battery

DC Bus Overvoltage Trip 500Vdc

End of Battery Discharge Voltage 320Vdc

Battery PreĆalarm Discharge Voltage Level 350Vdc

Battery Charger Nominal Float Voltage at 20°C 432Vdc

Battery Charger Voltage Stability ±1%

Battery Charger Output Voltage Ripple <1%

Maximum Battery Recharging Current 1, 3, 5 or 7A (Selectable)

Automatic Battery Test 12, 24 or 48 hour impedance test

Power Upgrade Yes ć up to a maximum rating of 30kVA

StartĆup On Battery Yes

System Efficiency (Excluding Battery Charging)

Full Load Inverter Efficiency 94% 94% 94% 94%

Operating Temperature Range 0° Ć 40°C (20°C for optimal battery lifetime)

Storage Temperature Range Ć20° to 70°C (excluding battery)

Operating Relative Humidity Range <95% (nonĆcondensing)

Maximum Altitude Above Sea Level 1000m before deĆrating

Audible Noise Level At 1 Metre <52dBA

Relay Communications Card DB9 connector Internal Terminals

Remote Stop Contacts Open to disable inverter and static bypass

Cable Entry Bottom entry at rear of unit

Prelim Page viii UPS Preliminary Pages

10kVA 15kVA 20kVA 30kVA

Unit Weight Without Battery 185kg

Unit Weight With Standard Battery 275kg 365kg 365kg 455kg

Figure 1-2 Split Bypass" configuration