401985

Contents of JUE 401985UPS E-2001 Service Manual This Service Manual consists of the following documents: 1. 2. 3. 4. 5. 6. 7. 8. 9. SAFETY INSTRUCTIONS GENERAL SYSTEM DESCRIPTION INSTALLATION AND INITIAL START-UP OPERATION FRONT PANEL CONTROL LOGIC TROUBLESHOOTING TECHNICAL DATA PCBs SCHEMATICS Pag. “ “ “ “ “ “ “ “ 2 3 8 14 20 27 64 80 82 A Issued See rev. doc. JSE401923 22.12.98 05.11.98 F. Fabbri F. Fabbri G. Pisellini 22.12.98 A4 1 82 22.12.98 JUE401985 UPS E-2001 - Service Manual 1. Safety Instructions 1.1 SAFETY INSTRUCTIONS The unit must be used as intended. Follow the instructions given in the Operating Manual. Dangerous voltages are present inside the unit. Installation and use of this equipment must comply to all national and local regulations and procedures. To prevent overheating do not obstruct the flow of air for ventilation openings to the unit. The components inside the unit are not repairable by the user. The user must not open the equipment cabinets or remove any protective covers from inside the cabinets. This equipment must be installed and serviced by qualified personnel. To completely isolate the equipment, the input, putput and battery (if preset) switches must be switched off. Connect protective earth before power supply cables. Earth leakage protection: this device may have a high leakage current towards protective earthing. When setting the threshold of the earth leakage circuit breaker installed upstream from this equipment consider this amount of current and that due to the loads. JUE401985 2 UPS E-2001 - Service Manual 2. General System Description Chapters 1 UPS ASSEMBLY 1.1 1.2 1.3 1.4 1.5 1.6 1.7 Features UPS System Structure Rectifier/Battery Charger Battery (Accumulator) Inverter Static Switch Unit Maintenance Bypass 4 5 5 5 6 6 7 Pictures PIC. 1.1 UPS Block-Diagram PIC. 1.2 Rectifier Block-Diagram PIC. 1.3 Inverter Block-Diagram PIC. 1.4 Static Switch Block-Diagram 5 5 6 6 PIC. 1.5 Maintenance Bypass Block-Diagram 7 JUE401985 3 UPS E-2001 - Service Manual 2. General System Description 1 UPS ASSEMBLY 1.1 Features UPS Function The uninterruptible power supply (UPS) is connected between the consumer’s equipment or installations (the load) and supply mains. Its function is to guarantee a continuous and conditioned power supply to the load. Even in the case of a total black-out it will supply the load for a predetermined time (autonomy time). In addition, the UPS provides the following advantages in comparison with conventional supply systems (mains, motor generator sets, etc.): The UPS output voltage frequency and amplitude control guarantee consistent and stabilized output power. Mains voltage fluctuations and frequency changes that are usually present in electricity supply systems do not affect the UPS output voltage. By using double energy conversion from ac to dc and back to ac, all mains distortions are filtered out. Therefore, each unit connected to the UPS system is protected against mains distortions that are usually present in industrial electricity supply systems. This is especially important for sensitive electronic devices, e.g. computer systems. During long term or short term ac mains supply interruption, the UPS system guarantees continuous load supply by means of a battery. The battery is connected to the rectifier and the inverter of the UPS system. In normal operation the inverter (which feeds the load) is fed by the rectifier. In case of a mains failure, the battery feeds the inverter. Thus the load is supplied without interruption. However, the load can only be supplied by the battery for a certain time. If longer autonomy times are required, we recommend the use of a Diesel Generator Set. In this case the battery autonomy time only has to be sufficient for the time span between mains failure and full operating capacity of the Diesel-Generator-Set. Better Output Power Characteristics Uncoupling from Mains Distortion Complete Protection against Mains Failures JUE401985 4 3 Rectifier/Battery Charger The charger is a three phase/6 pulse rectifier that converts ac voltage to dc voltage. the block diagram Figure 1. An isolation transformer and a commutation choke is used at the input of the rectifier bridge. the load will be fed by the battery. This means that the recharging current limitation is accomplished by reduction of the dc voltage according to a specified curve. The number of cells within the battery depends on the battery type and may also vary due to specific customer requirements. The rectifier’s recharge characteristic is of the I/ U type. The battery is connected to the rectifier through a saturation choke which reduces ac ripple current to the battery. General System Description 1. The dc output of the rectifier feeds the inverter and the battery. thus increasing on the battery life.4 Battery (Accumulator) The battery supplies power in case of a short interruption or a total breakdown of the ac mains source. The rectifier is designed to feed both the inverter at maximum load conditions and simultaneously the battery with maximum charging current. JUE401985 5 .1 illustrates six essential functional components: • Rectifier/battery charger (6 pulse) (GR) • Battery (B) • Inverter (WR) • Static inverter switch (SW) • Static bypass (SB) • Maintenance bypass (QIBY) All components are located in a single housing.UPS E-2001 .2 UPS System Structure The basic E-2001 power supply unit is an ac/dc/ac converter. They are explained in detail on the following pages. The battery is only capable of feeding the load for a certain time (autonomy time). thus assuring that the batteries will not be damaged by excessive charging current values. In case of a rectifier failure (no dc voltage output). QIRP 1.Service Manual 2. depending on battery capacity and actual load. QIRA 1. By always actuating both switches together for a short period. the output voltage is kept constant.UPS E-2001 . The inverter output voltage is generated by pulse width modulation (PWM).). The use of a high clock rate for the PWM and a dedicated ac filter circuit consisting of the transformer and capacitor. The inverter control logic restricts the maximum output current to 150% of the nominal current in case of a short circuit... thus connecting the load to the inverter output.. output of another UPS system. diesel generator set.5 Inverter The inverter converts dc voltage supplied by the rectifier or battery to ac voltage of precisely stabilized amplitude and frequency that is suitable for power supply to most sophisticated electrical equipment. SW is closed and SB is open. However. providing power supply from a backup source (mains. 1. During overload or inverter failure conditions. an uninterrupted power supply during the switching is ensured.6 Static Switch Unit The block diagram illustrates the two static switch units that use thyristors as switching elements. General System Description 1. otherwise the UPS will switch to bypass operation for currents higher than 125% of the nominal current. JUE401985 6 . The inverter transistors are fully protected from severe short circuits by means of a saturation monitor or “electronic fuse”. For higher currents the output voltage is reduced. During normal UPS operation. this will only occur if the static bypass is not available. SW is switched off and SB is switched on. assure a very low distortion of the output voltage (THD<3%). In case of overload (up to 125% of the nominal current).Service Manual 2. This is an essential condition to reliably meet all power supply requirements for connected sensitive equipment. the UPS remains in bypass operation and signals an alarm. Switching Conditions. . With E-2001 series UPS systems.Bypass a) Voltage and frequency of the bypass line have to be within tolerance limits. c) After three unsuccessful attempts within 3 minutes to switch to inverter operation. QIRA JUE401985 7 .Service Manual 2. b) Under overload or inverter failure conditions. or .Inverter a) The UPS switches automatically back to inverter operation when inverter voltage and frequency are within tolerance limits and the inverter is synchronized with the bypass line. the UPS switches to bypass operation.pass c.UPS E-2001 . With the maintenance bypass on. the power supply system may be completely switched off. the UPS automatically tries again to switch back to inverter operation. Inverter . b) In the case of a remaining overload condition the inverter might not be able to take the load and the UPS will switch back to bypass operation.the inverter continues to operate with reduced output voltage under overload conditions. thus permitting maintenance work to be carried out safely ( there is only voltage at the input and output terminals and their connections to the by .the inverter stops under inverter failure conditions. switch QIBY. commutation from different operating modes to maintenance bypass will take place without interruption. General System Description Switching Conditions. and the inverter has to be synchronized with the bypass line.7 Maintenance Bypass The maintenance bypass function is to supply power directly to the connected load during UPS system failure or maintenance. switch). The bypass consists essentially of one make before break c.o. c) If the conditions under a) are not met. Bypass . d) After pressing RESET. 1.o. UPS E-2001 - Service Manual 3. Installation and Initial Start-Up Chapters 1 INSTALLATION 1.1 1.2 Mechanical Installation Electrical Installation 9 11 Pictures PIC. 1.1 - Moving the UPS PIC. 1.2 - UPS Floor space PIC. 1.2 - UPS Room size 9 10 10 11 2 INITIAL START - UP 2.1 Start Up Procedure 12 PIC. 1.2 - UPS connection diagram JUE401985 8 UPS E-2001 - Service Manual 3. Installation and Initial Start-Up 1 INSTALLATION 1.1 Mechanical Installation Equipment Delivery and Storage After delivery, check equipment for damages that may have occurred during shipment. If you do not wish to install the equipment immediately, please observe the following storage recommendations: • Store equipment in a vertical position in a well conditioned room, protected against humidity. Do not store the equipment in close proximity to frequently used passageways and keep it away from movable parts. • If the UPS system is already unpacked, please ensure storage in a clean environment protected from dust, away from heat sources. The UPS can be lifted and moved by means of a lifting truck or a fork lifter. Remove front side and rear side base sheets. The UPS can now be moved with a lifting fork. Caution : Secure equipment against being knocked over Handling the UPS System PIC. 1.1 - Moving the UPS Setting Up The UPS system should be installed in a dry, clean and lockable room. Provisions have to be made to remove heat created by the system. Under all installation conditions, the unrestricted flow of cooling air must be assured. JUE401985 9 UPS E-2001 - Service Manual 3. Installation and Initial Start-Up PIC. 1.2 - UPS floor space (base only - without side panels) PIC. 1.3 - UPS room size JUE401985 10 UPS E-2001 - Service Manual 3. Installation and Initial Start-Up 1.2 Electrical Installation This equipment must be installed by service personnel. Switch off QIRP, QIRA, QIB and put QIBY c.o. switch in normal position. All primary power switches installed remote from the UPS area will be fit with the following label: "Isolate uninterruptible power supply (UPS) before working on this circuit". General All electrical connections must be made in accordance with local standards and all input terminals must be protected by external fuse switch or circuit breaker. If possible, install battery cables separately from other power cables in order to avoid possible RF interference. Before wiring, open all system switches. QIRA PIC. 1.4 - UPS connection diagram JUE401985 11 • Check that all switches QIRP . • Wait until the Data Monitor Panel is illuminated (the panel automatically executes a self-test). • Make sure that the batteries have been installed according to the instructions in chapter 1. Preparation A: Rectifier Power Supply Check yes JUE401985 12 .3. X1. • Close QIRP. It must be carried out by specialized personnel. switch off the external mains supply and reconnect the three phases of the external mains supply to input terminals X1. X1. The installation of the UPS must have been carried out according to chapter 1.1. and the rectifier and inverter automatically start to operate. observing the phase rotation.1. a large screwdriver for the terminals and a small screwdriver for potentiometers. For carrying out the Start Up Procedure you need a 3 digit voltmeter with 1% accuracy. voltage. Should problems arise during the Start Up Procedure. X1.2. switch is in normal position • Switch on the external mains supply to the UPS. ? Is LED LSC on the RPD board continually illuminated? no • Open QIRP.o. • Check that the supply voltage at terminals X1. refer to section 5. X1.k. • Check that the ventilation system of the UPS room is ready to operate.1 Start Up Procedure General With the Start Up procedure the correct installation of the UPS according to chapter 1 is checked.UPS E-2001 .QIB are open • Check that QIBY c.QIRA . Installation and Initial Start-Up 2 INITIAL START-UP 2. For direct control of current.2. a DC clip-on ammeter.Service Manual 3. UPS output power and UPS operating status by the DATA MONITOR PANEL. Safety precautions according to the national safety standards must be applied. The rectifier supply voltage is o. • Return to A. call for service assistance.3 is within ±10% of the UPS rated voltage. switch is in normal position. yes C: Bypass Power Supply Check • Switch on the external supply for the bypass. yes JUE401985 13 .1 / XB-.UPS E-2001 . • Return to C. • Close QIB circuit breaker. Installation and Initial Start-Up • Measure the battery voltage in the battery terminals XB+. • Return to B. ? Is the green status LED "Emergency Line" on the operating panel on? no • Check the voltage of the static bypass supply.o.1: ? Does this voltage have a correct polarity? no • Open QIRP. wait for 2 minutes. • Close QIRA. • The start-up procedure has been successfully completed now. • Check that QIBY c.Service Manual 3. and then reconnect the battery cables at the terminals which lead to the switch(es) where the wrong polarity was detected. 2 2.3 Switching On Switching Off Manual by-pass 17 18 18 JUE401985 14 .2 1. Operating Modes Chapters 1 OPERATING MODES 1.3 1.3 PIC. 1.4 Pictures Normal Operation Battery Operation Bypass Operation Maintenance Bypass Operation 16 16 16 16 2 OPERATING INSTRUCTIONS 2.1 1.1 2. 1. 1.UPS E-2001 . 1.Service Manual 4.4 1.1 PIC.5 General Normal Operation Battery Operation Bypass Operation Maintenance Bypass Operation 15 16 16 16 16 PIC.2 PIC. Transitions between these operating modes are performed without interruption of the power supply to the load. JUE401985 15 .Service Manual 4. In both operating modes the UPS signals a failure condition (audible and visual alarm) to indicate that any additional failure bears the risk of interrupting the power supply to the load. • "Maintenance Bypass Operation" is used to supply the load directly from mains during maintenance or repair work.1 General The standard on-line UPS-system composes of four different operating modes to ensure the uninterrupted power supply of the load under various conditions. • in "Battery Operation" or "Bypass Operation" an additional failure may interrupt the power supply to the load. Safety concept • in "Normal Operation" any failure. depending on the kind of failure.UPS E-2001 . Operating Modes 1 OPERATING MODES 1. internal or external. will transfer the UPS system either to "battery operation" or to "bypass operation". • The inverter converts this dc power to ac power used to feed the connected load. • The static inverter switch SW opens automatically after the static bypass switch SB is closed.g.UPS E-2001 . • In this mode.3 Battery Operation The "Battery Operation" mode is activated by a mains failure or rectifier failure • The rectifier supplies no power. • The load is supplied directly from mains through the static bypass. Operating Modes 1. • Power will only be supplied to the load for a certain period of time depending on the battery capacity. QIRA 1. QIRA 1.switch QIBY. • The rectifier converts ac power to dc power which charges the batteries and feeds the inverter. • The battery supplies the required dc power to the inverter. the individual functional components are completely separated from the load (e.Service Manual 4.5 Maintenance Bypass Operation The "Maintenance Bypass Operation" mode is used to supply the load directly from mains during maintenance or repair work. for maintenance work).2 Normal Operation "Normal Operation" is the standard operating mode of the UPS • Mains power is present.o. • The inverter supplies ac power to the load as described above. • Power for the load is supplied directly from mains through c. QIRA 1. QIRA JUE401985 16 .4 Bypass Operation The "Bypass Operation" mode is activated by an inverter failure or overload • The rectifier supplies dc power only to the battery. • Close QIRP switch. • Wait until the front panel is illuminated. and all power switches are open. The UPS performs a self-test and the rectifier and inverter start automatically. Operating Modes 2 OPERATING INSTRUCTIONS 2. "UPS ON" and "EMERGENCY LINE" on the front panel must be illuminated. • Close QIRA switch. Final UPS Operating Mode: The UPS is now in normal operation mode. • Open the UPS front door. the load is not supplied.UPS E-2001 .1 Switching On Initial UPS Operating Mode: QIRA The UPS is switched off.Service Manual 4. • Close QIB switch. QIRA JUE401985 17 . as described in chapter 1. The green LEDs "LINE". Operating Steps: • Switch on the external mains supply for the UPS.2. JUE401985 18 . and the load is fed either through the inverter or the static bypass.3.UPS E-2001 . After opening the QIRP switch the display is only powered by the DC capacitors and will fade out within a few seconds. • Open QIRP switch. QIRA QIRA Now the load is only supplied by the maintenance bypass.3 Manual by-pass operation 2.1 From normal operation to manual by-pass Initial UPS Operating Mode: The UPS is in any operating mode described in chapter 1. • Open QIRA switch. • Move QIBY switch to I + II position The load is now supplied by the static bypass and the maintenance bypass in parallel.e.Service Manual 4. After opening the QIRP switch the display is only powered by the DC capacitors and will fade out within a few seconds. QIRA • Open QIRP switch. Operating Modes 2. Operating Steps: • Make sure that the green LED "EMERGENCY LINE" is illuminated (i. • Open QIB switch. Final UPS Operating Mode: The UPS is now shut down. • Open QIB switch.e. QIRA Operating Steps: • Make sure that the green LED "EMERGENCY LINE" is illuminated (i. The load is supplied directly from the mains supply via the maintenance bypass. 2.2 Switching Off Initial UPS Operating Mode: The UPS is in any operating mode described in chapter 1. the bypass supply voltage is ok). the bypass supply voltage is ok). All power switches are closed. and the load is fed either through the inverter or the static bypass. • Move QIBY switch to II position. All power switches are closed. The inverter stops and the UPS automatically transfers to bypass operation without interruption. 2 From manual by-pass to normal operation Initial UPS Operating Mode: The UPS is supplied via maintenance by pass.UPS E-2001 .2. • Move QIBY switch from II to I + II position Attention! Wait until the inverter is synchronized with the emergency line (Led LSOK on IWM-3 card must be lit on) • Move QIBY switch to I position. The UPS performs a self test and the rectifier and inverter start automatically. there is still voltage at QIRA. . QIB and at the respective terminals. QIRA Final UPS Operating Mode: The UPS is in normal operation as described in chapter 1.Service Manual 4. Operating Modes Attention! Although the load is no longer supplied by the UPS. 2. QIRA Operating Steps: • Close QIRP switch. • Wait until the front panel is illuminated • Close QIB switch. JUE401985 19 . the inputs of QIRP.3. UPS block diagram PIC.2 1.4 1.3 .Setting of SW1 PIC.2 . 1.3 .5 1.22 22 23 23 24 25 25 2 PANEL SETTINGS 2. 1. 2. 1.2 .6 1.Setting of SW2 PIC.UPS E-2001 .1 1.1 .Setting of SW3 21 . Front Panel DME/S Chapters 1 FUNCTIONS 1. 2. 1.METERS Display PIC.4 .E 2001 front panel DME/S PIC.1 .1 2.3 1.Alarm LEDs PIC. 2.2 DIP Switch Settings Measurement Adjustment 24 26 JUE401985 20 .Service Manual 5.7 General Measurements Protective Functions UPS Operating Mode Indication Alarm signalling AS 400 Interface Remote Monitoring 22 22 22 23 23 23 23 Pictures PIC. UPS E-2001 .Service Manual 5. 1. Front Panel DME/S 1 FUNCTIONS PIC.E 2001 Front Panel DME/S JUE401985 21 .1 . After resolving the problem. The static switch is blocked after three unsuccessful attempts to switch back to inverter operation. The red LED "BACK UP" lights up and the alarm buzzer beeps. • Measured values are shown in the “METERS” display. The various measurements can be selected by pressing the "PUSH" button in the "METERS" display.1 General The front panel DME/S is the user-interface of the UPS. • Remote monitoring options via RS232 and RS485 interface 1. Front Panel DME/S 1.Service Manual 5.3 Protective Functions BACK UP The "BACK UP" alarm indicates that only a certain time of the battery autonomy is left. The actual measurement is indicated by a green LED. the static switch can be reset by pressing the RESET push-button at the right side. It is a microprocessor controlled panel and it provides the following functions: • Alarms are indicated by red LEDs in the upper line of the display. • The UPS status (operating mode) is indicated by LEDs in the block diagram of the UPS. Static Switch Blocking JUE401985 22 . In this case there is either an inverter failure or an overload condition.2 Measurements The measurements are shown in the "METERS" display.UPS E-2001 . the red LED above the right RESET push-button is lit. The following values can be shown in the "METERS" display: • Battery voltage • Output voltage • Output current • UPS output load % • Output frequency 1. • UPS ON: The load is supplied by the inverter. • The integrated buzzer signals an alarm by beeping. JUE401985 23 .NOVELL .6 AS 400 Interface The front panel features an integrated UNIX . The provided messages are: • Load fed by inverter. • UPS output voltage OK.5 Alarm signalling Alarms are signalled by the front panel optically and acoustically: • One or more of the red alarm LEDs light up. The operating mode of the UPS is indicated with LEDs integrated into the block diagram: • LINE: Voltage and frequency of the mains supply are within tolerance limits. • Battery discharge: the battery is feeding the load (led flashing). • MANUAL BYPASS: The maintenance bypass switch QIBY in by-pass position 1. • Load fed by static bypass. • The buzzer can be muted by pressing the left RESET button at the front panel. when the battery autonomy time has almost expired the relevant led light-on • Inverter failure: the inverter output voltage is out of the tolerance limits. 1.4 UPS Operating Mode Indication On the front panel a block diagram of the UPS is shown. • Battery OK. • Mains supply OK.LAN AS 400 interface for remote signalling with voltage-free contacts. • EMERGENCY LINE: Voltage and frequency of the static bypass supply are within tolerance limits. • BYPASS: The load is supplied by the static bypass. With the RS232 and RS485 interfaces it is possible to transmit all the necessary data up to a distance of 400m (RS485). 1.UPS E-2001 . The available alarms are: • Mains failure: voltage and/or frequency of the mains supply are out of the tolerance limits. Front Panel DME/S 1.7 Remote Monitoring The front panel offers the possibility to communicate with a computer through RS232 and RS485 interfaces.Service Manual 5. 0. the operation parameters can be set according to actual conditions and desired functions. 5 kVA 10 kVA 15 kVA 20 kVA 25 kVA 30 kVA 40 kVA 50 kVA 60 kVA 80 kVA 100 kVA 120 kVA 150 kVA 200 kVA 250 kVA 300 kVA CURRENT TRANSFORMER • Current Transformer: The trasformation ratio of the UPS output current transformer Dip 5 0 1 0 1 DIP 7 0 1 DIP 8 0 1 Dip 6 0 0 1 1 100 200 400 600 • Output: For E-2001 UPS systems OUTPUT A.8 1 JUE401985 24 . 2.1 DIP Switch Settings With the DIP switches SW1 and SW2 and SW3 at the back of the front panel. 2. The setting of the DIP switches is explained in the tables FIG.3.1 to FIG. • Power Factor: Selectable for “UPS output load %” calculation in reference to the loads power factor. COS ϕ 0.Service Manual 5. The meaning of the various settings is explained below (shown for version 4. Front Panel DME/S 2 PANEL SETTINGS 2.UPS E-2001 . DIP Switch SW1 Dip 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Dip 2 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 Dip 3 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 Dip 4 0 0 0 0 0 0 0 0 1 0 1 1 1 1 1 1 NOMINAL POWER • Nominal Power: The nominal output power of the UPS in kVA. ONE PHASE THREE PHASE output has to be set to single phase.2 software).L. 6.Service Manual 5.off DIP 2 DIP 3 0 1 • Thermal figure: select seconds only for test DIP 4 0 1 DIP 5. Front Panel DME/S DIP Switch SW2 DIP 1 0 1 THERMAL FIGURE ON OFF NON INFLUENCE THERMAL FIGURE Minutes Seconds SEC PROTOCOL START UP/ SHUTDOWN OFF • Thermal figure inverter protection against overloads.UPS E-2001 . Attenction: the intervenction of thermal image cause the inverter cut . 7 0 1 0 1 0 1 0 1 0 0 1 1 0 0 1 1 DIP 8 0 1 0 0 0 0 1 1 1 1 ON NOMINAL INPUT VOLTAGE 415 200 525 480 440 400 380 208 NOMINAL INPUT FREQUENCY 50Hz 60Hz DIP Switch SW3 DIP 1 0 1 DIP2 0 1 PANEL TYPE • Panel type: for E2001 UPS system select “Engineering” Engineering Standard MANUFACTURER BORRI JUE401985 25 . Current Offset Adjustment Output Current Read-out Adjustment Output Voltage Read-out Adjustment Battery Voltage Read-out Adjustment JUE401985 26 .Service Manual 5. • If the voltage measured with the AC voltmeter does not correspond to the voltage shown in the METERS display. • Set switch 7 of SW2 to OFF (automatic measurement mode). adjust it by turning the potentiometer RV4 at the back of the front panel. • If the displayed current is not zero.2 Measurement Adjustment At the front panel. • Move QIBY to normal position • Apply nominal load to the UPS output • If the current measured with the AC clip-on ampmeter does not correspond to the displayed current. • Press the "PUSH"-button below the METERS display until the green LED corresponding to OUTPUT CURRENT lights up. • Connect an AC clip-on ampmeter to phase R (true RMS measurement). • Press the "PUSH"-button below the METERS display until the green LED corresponding to BATTERY VOLTAGE lights up. • Press the "PUSH"-button below the METERS display until the green LED corresponding to OUTPUT VOLTAGE lights up. • Switch on the UPS. • Set switch 7 of SW2 to ON (manual measurement mode). adjust the displayed voltage by turning the potentiometer RV3 at the back of the front panel. Front Panel DME/S 2. • Connect a DC voltmeter to the battery terminals between B+ and B-. the read-outs of the following measurements can be controlled and adjusted: • Battery voltage • UPS output voltage • UPS output current • UPS output current offset Preparation • Connect an AC voltmeter with 1% accuracy to the inverter output between phases R and N. adjust the displayed voltage by turning the potentiometer RV2 at the back of the front panel. • If the voltage measured with the DC voltmeter does not correspond to the voltage shown in the METERS display.UPS E-2001 . adjust it to zero by turning the potentiometer RV5 at the back of the front panel. 1 2.Block diagram (1 of 2) PICT.3 2.1 -Inverter subsystem . 3.RVR41773 Front vew PICT.Block diagram PICT.6 .3 Functional description RPD Card RVR41773 Card 28 32 35 Pictures PICT.Rectifier subsystem .1 3. 3.3 -IST .Block diagram (1 of 2) PICT.5 . 1.3 -SCLT Block diagram PICT.9 -IGD . 2. 2.Block diagram (2 of 2) PICT. 2. 3.Block diagram 3 STATIC SWITCH CONTROL LOGIC 3.2 -Static switch subsystem . 1. 3. 2.2 -Inverter subsystem . 2. 2.4 -IST .2 3. 3.1 -Static switch subsystem . 2.4 2.3 . 3.7 -IPS .block diagram (2 of 2) PICT.4 .2 2.Block diagram PICT.3 Functional Description SCLT Card SPT Card 54 58 61 PICT.RVR41773 Block diagram PICT. 1.6 -IWM-3 . 2.Front view PICT.Block diagram PICT.Block diagram PICT.Service Manual 6.4 -SCLT Front view PICT.RPD Block diagram 30 31 33 34 37 38 41 42 45 46 48 49 51 52 53 56 57 59 60 62 63 2 INVERTER CONTROL LOGIC 2.2 1.5 -SPT Block diagram PICT. 1.8 -IPS Front view PICT. Control Logic Chapters 1 RECTIFIER CONTROL LOGIC 1.UPS E-2001 .block diagram (1 of 2) PICT.RPD Front view PICT.1 1.Rectifier subsystem . 2.5 -IWM-3 .6 -SPT Front view JUE401985 27 . 1.Block diagram (2 of 2) PICT.1 .5 Functional description IST Card IWM-3 Card IPS Card IGD Card 39 43 47 50 53 PICT. 1.2 . processed by pulse transformers TR1÷TR6 of Rect. Mains voltage (R. the possible absence of one phase. through shunts SHR . JUE401985 28 . Therefore it is just VE which determines the conduction angle of the bridge SCR's under the control of relevant logic.m -IR and VU are taken from the output circuit.UPS E-2001 .GT are also sent to the logic generating the conduction angles. Signals GR .1. supplies signal 1 GPS. is controlled by startup consent signal 0CA suppled by RPD which. In addition. after being processed.T) reaches SCR's TH1÷TH6 of the rectifying bridge by closing switch QIRP through F1÷F3. after all. In case the first three checks specified are carried out successfully.1 Functional description of Rectifier With reference to the block diagram shown in pict. carried out on card RVR41773. in order to supply the startup consent to the rectifier and to generate +12V and +24Vservice voltage. Such SCR's are put into conduction by the control signals supplied by the SCR drive placed on card RPD. The outputs of diodes are finally used to carry out a number of controls on mains voltage. GT) where it is rectified by diodes D1÷D6. supplies the firing signals of the SCR's.T) reaches also card YY Sync & supply through cable W13 and it is reduced fro 380V to 22V by transformers TR1÷TR6 and sent through W5 to card RPD (GR.S. the "Startup Consent" logic generate signal 0CA which enables the operation of RVR 41773 and generates signal 1ROK which enables the formation of +24V to feed the loads. the voltage which should not be lower than 75% of rated value and the status of rectifying bridge fuse.Service Manual 6. tyr. Such signals are used on card RVR41773 to verify the rectifier output and. which generates the synchronism signals to calculate the SCR's conduction angle keeping signal VE into account. 1. firing card.S.2. GS. which represents the final result of all the processing carried out on card RVR41773 about voltage and current on rectifier output. following controls are carried out on RPD card: the cyclic sense of phases. Signals +IR.SHB and the resistive divider installed on RBP41773.1 .GS . Signal 1GPS blocks the SCR drive and therefore the rectifier in case of malfunction. the description of the rectifier system is specified as follows : . Control Logic 1 RECTIFIER CONTROL LOGIC 1. so that the bridge SCR's are put into conduction in the manner and time determined by the logic of RPD card. The functions controlled on RPD are monitored through the leds placed on the card front and through the alarms shown on the front panel DME/S. The next "SCR drive" block with the signal generated by the high frequency oscillator. The generation of error voltage VE.The three-phase voltage of the supply mains (R. to generate the signal VE which affects the conduction angle of the SCR's on the rectifying bridge. it is verified that output current is not exceeding the maximum value the rectifier is able to supply.RPD Card . At the end of this initial phase.RVR41773 Card JUE401985 29 . The management of recharge levels is completely automatic. gradually allows the rectifier output to reach the voltage and current rated value so as to avoid excessive stress on the various components of the system. when it is at level 1.UPS E-2001 . it is controlled by the "management of 2 levels" charge block where battery current relay handles the changeover from floating to boost charge and vice-versa.Service Manual 6. should conditions arise In order to prevent malfunctions on this sensor. The description is divideed as follows: . The block concerning "RECHARGE MANAGEMENT with EXTERNAL TIMERS" interface the control logic with the external recharge timers in case they are preset to control recharge time and modes (OPTIONAL). a safety timer with setting range from 4÷24h. Control Logic Such signal is sent to card RPD (on which. it block the H. Possible overload and failing rectifier conditions are displayed on the front panel DME/S. at the initial operation stage. forces the system to floating charge whenever the maximum recharge time tolerated by the battery is exceeded. The blocks concerning "4th LEVEL" and "RECHARGE BLOCK" force the rectifier to relevant output voltages in case relevant command arrives from the unit (OPTIONAL).F. oscillator and enables the mains failure sensor) and it starts the operation of card RVR41773 and basically of the whole rectifier by generating soft-start signal 1SSR. that output voltage is present and it is not exceeding the maximum value allowed. whereas voltage VE is sent to card RPD to choke te SCR's conduction angle. Such signal. value VE is determined by controlling output voltage and current on RVR41773. In case the 2 levels charge is set. Following hereunder are the detailed descriptions of the cards making up the Rectifier Control Logic. In particular. UPS E-2001 .Service Manual 6. Control Logic Pict.1 Rectifier subsystem .Block diagram ( 1 of 2 ) JUE401985 30 . 1. 1.Service Manual 6.UPS E-2001 .2 Rectifier subsystem .Block diagram ( 2 of 2 ) JUE401985 31 . Control Logic Pict. obtaining +24Vdc direct voltage.UPS E-2001 .S. S. present between TP1 and earth (TP3) and. alternatively (with J4 open).R. 1. JUE401985 32 . F • Section controlling the status of mains fuses F1. with potentiometer P2. S. Signal ROK is also taken to pin 7C by means of a relay which closes at earth when ROK shows the absence of alarm (led LROK steady). C. at the same time it operates relay BB which closes pin 13C 12C together. when it is high (led LGPS flashing). F2 and F3. after closing switch IA. D generates signal ROK with led LROK flashing in case of error coming from sections B. VCO is controlled through trimmer P1 when the rectifier operates in TEST mode. T. Signal 1GPS on pin 15C. which enables relay MV taking pin 5C to earth and making led LMV flash in case of alarm. C. synchronized with mains through signals R. whose detailed block diagram is shown in Pict. D • Section monitoring the supply voltage of logics PSP. through YY Sync & supply. D. direct voltage PSP corresponding to +12Vdc. which signals the interruption of one of the input fuses on the rectifier. and flashing led LMFin case of error. such signal is given by the flashing of led LFB and by taking pin 4C to earth through the operation of relay FB. G • Section generating the control signal of the rectifier SRC's. Control Logic 1. setting the alarm threshold. B • Section for cyclic sense monitoring (correct connection of mains phases R. E • Section controlling the ventilation failure of the heatsink. disables VCO output and blocks the high frequency oscillator. C • Section monitoring the failure of one or more phases. The simultaneous absence of error in sections B. present between TP2 and earth. The presence of such voltages lights leds LPSP1 and LPSP respectively. from pin 10C. includes: A • Rectifier section (3Ø) for three phases of mains voltages coming from the rectifier supply line.2 RPD Card The RPD card. P1 allows to modify Vdc on rectifier output with open loop (J2 closed).3.Service Manual 6. By closing J1 the system operates with closed loop and VCO is controlled by error signal VE coming from RVR41773. T on rectifier output) with flashing led LSC in case of error.T and which receives the choking command of the conduction angle "α" from VCO or. JUE401985 33 .Service Manual 6.With logic level 0. .3 RPD . Control Logic Pict. leds are on with fixed light and relays are not energized. 1.With logic level 1. leds flash and relays are energized (alarm).UPS E-2001 .Block diagram Attention! . - Red flashing led: placing sequence of phases R. T of incorrect mains - +12V Supply voltage switch - Red led on with fixed light: +24V supply voltage present +24V Test point Red led on with fixed light: input supply OK - Red led on with fixed light: generation of control pulses on rectifier SCR's OK +12V Test point Red led on with fixed light: +12V supply voltage present 0 V: earth terminal connected to the negative pole of the battery Red flashing led: phase failure on input voltage Red flashing led: failure of heatsink ventilation (heatsinks faults) - Potentiometer for variation of rectifier output voltage. with J1 open and J2 closed.4 RPD .UPS E-2001 .Service Manual 6. 1.Front view NOTE : Such operation is only possible when the UPS operates in TEST mode. JUE401985 34 . test points and leds of card RPD accessible on the front side. circuit breakers. with open loop (NOTE) Red flashing led: interrupted fuse on the rectifier Pict. S. Control Logic RPD Front view The picture shows potentiometers. includes: Control section for rectifier startup (soft start) which. D depending on the operating conditions of the system. Control section of the current delivered by the rectifier to the battery which. after turnng it from differential signal (±IR) into common mode signal (±IR) by means of a differential amplifier with adjustable offset through potentiometer P7. Control section of the current delivered by the rectifier which. the current control prevails over the voltage control. current to be delivered by the rectifier at its rated operating voltage.25 In) signals. allows to affect the rectifier voltage. Through an accurate setting on potentiometer P4 the voltage drop on rectifier output cables may be compensated in order for the rated voltage to be taken to the external battery terminals. voltage on rectifier output. starting from VU voltage signal (30C). Monitoring section of rectifier overload which. then the control the output voltage is taken by one of sections B. allows to fix the max. This is achieved by operating on potentiometer P8. which sets the limitation threhold f current above which. after being buffered. At the end of the procedure led LSS lights steadily .P5.3 RVR41773 Card A• The RVR41773 card. Finally we have the actual control of rectifier output voltage which. the rectifier starts with the soft start sequence of output voltage. Once the consents coming from pins 10A and 5A have arrived. the overload condition making led LOL flash and operating relay OL for signaling to SIR's. starting from the signal coming from the battery (±IB) into common mode signal (+IB).Service Manual 6. controlled by the action on the analogue OR bar by means of D16. through trimmers P2 . coming from card RPD and of the signal on pin 5A. prevailing over the other controls coming to the analogue OR bar. starting from the signal coming from the current shunt of the rectifier. reducing output voltage to keep output current constant on load variation. Therefore the recharging current of the battery cannot exceed the treshold set through potentiometer P9. after a delay ∆t.5. allows to limit the max. concerning an alarm contact due to the heating of the SCR heatsink. fixing its value through potentiometer P6. Control section of output voltage which. by operating n the analogue OR bar. whose detailed block diagram is shown in picture 1.UPS E-2001 . after receiving the consents.P3 . starting from current signal +IR delivered by the rectifier and comparing it with the treshold set by means of potentiometer P11 (usually 1. is turned into error signal VE set to card RPD through pin 21C. 0CA. by means of the differential amplifier with adjustable offset through potentiometer P14. Control Logic 1. with relevant flashing led LTS (in case of alarm) and relay TS operated due to the signal to the Front Panel (along with relay MV of RPD). transfers the control level to the bar of the analogue OR which. C. B• C• D• E• JUE401985 35 . Through potentiometer P1 it is also possible to affect the rectifier stability by subsequently varying the dynamic characteristics of the control loop. with relevant led LCA lighting steadily (flashing in case of alarm). commences the soft start. operated by the unit through the earthing of pin 17A. It blocks the system (under any charging condition) at the floating value (to be set through P3). It supplies a signal in case the recharging voltage is lower than the desired value adjustable through P13 and P12 (reset hysteresis) for a time longer than one set through SW2. M • Minimum voltage or insufficient floating relay. JUE401985 36 . H • 4th level. It blocks the system (under any charging condition) at the 4th level set through P2. In case the changeover from boost to floating charge does not occur within the maximum time allowed. I • Recharge block. in case of parameters out of the limits. Control Logic F • Monitoring section of voltage and current range on rectifier output which. In this case the system will remain blocked until the RESET push button is operated manually. It disconnects the rectifier in case output voltage exceeds the max. operated by the unit through the earthing of pin 24A.acceptable value set through P15.UPS E-2001 .Service Manual 6. signalling the failure to the recharge system. generates an alarm condition which makes NO DELIVERY led LME flash and causes the operation of relay ME. L • Max. N • Logic of external timers voltage. It interfaces RVR41773 with the external timers (OPTIONAL) in case the management of the battery recharge is performed by a programming and timing system. G • Management of 2 levels charge according to DIN41773. which is controlled by a current relay on which (through P10) the setting of the changeover level from floating charge to boost charge and vice-versa is carried out. which takes the earth to pin 23C. output voltage relay. a safety timer will bring the system back to floating charge. 5 RVR41773 .Service Manual 6. 1. Control Logic Pict.UPS E-2001 .Blocks diagram JUE401985 37 . protection voltage Red led on with fixed light: shows startup consent Red led flashing: overload condition Red led on with fixed light: commencement of soft start Red led on with fixed light: thermal protection Red led flashing: shows no delivery Reset push button for max. voltage protection - Push button for boost charge reset - Automatic charge / manual charge switch Pict. circuit breakers.UPS E-2001 . - Potentiometer to set floating charge Potentiometer for automatic floating charge Potentiometer for voltage drop comensation on rectifier output cables Potentiomer for automatic boost charge Potentiometer for battery current limitation Red led on with fixed light: shows manual charge Green led on with fixed light: shows floating charge Yellow led on with fixed light: shows boost charge Red led on with fixed light: shows max.6 RVR41773 . Control Logic RVR41773 Front view The picture shows potentiometers. test points and leds of card RVR41773 accessible on the front.Front view JUE401985 38 . 1.Service Manual 6. for simplicity. the signal +VUF) and LOV (current. we point out that the signal 0MR. generated by the IPS card is in order. The signal 0CA. is used to: • Energise the relay SOK which signals to the front operating panel when the inverter is synchronised. The IWM-3 card controls the inverter output voltage and limits the output current in case of an overload. The pulse width modulation may also be varied by the synchronisation control circuitry which will vary the phase and / or frequency of the inverter output voltage in order to maintain it phaselocked (or in synchronism) with the bypass line voltage coming from the bypass static switch section. Control Logic 2 INVERTER CONTROL LOGIC 2. If this occurs. converts the DC voltage delivered by the rectifier. the signal +CUF). or by the battery. Blinking implies not synchronised). This is carried out by the inverter power section which has been represented. into an AC voltage with low harmonic content. led LOL will flash and the relay OL will signal the overload condition to the front panel. Returning to the control performed on the presence of the bypass supply.1a and 2. which is the start-up consent of the inverter itself. In the case that the bypass supply is not present. These measurements are analog-ORed and compared with a reference voltage set with P2. whose block diagram is specified in figures 2.1b.UPS E-2001 . is generated by the IST card after it has verified: • the inverter electronic power supply voltage PSP. two IGBT bridge assemblies (maybe either half-bridge or full-bridge assemblies) and four IGD cards. which sets the necessary pulse modulation width in order to rmaintain the inverter output voltage at the desired level. fixed implies synchronised. which is compared with the sinusoidal modulating voltage. The resultant error voltage is sent to the "PWM generation" block.1 Functional Description The inverter system. together with the startup consent 0CA. The signal +CUF. which is a DC voltage proportional to the total current flowing in the inverter bridge(s). • Inform the bypass static switch control logic and the IST card (signal 0SOK) that the inverter is synchronised with the bypass supply (for interruption-free transfers between the two supplies). through the PLL and the dividers. can be trimmed using P3 and is compared with the threshold set by P4 in order to signal an overload if the nominal output current is exceeded. JUE401985 39 . The selector output. the mains tolerance frequency selector transfers the synchronisation control to the frequency generated by the 50 or 60Hz oscillator. The on/off control signals for the IGD cards are supplied by the IWM-3 card in order to perform the DC-AC conversion. The result of the comparison within the PWM generation circuitry determines the modulation width and therefore the conduction time of the transistors of the inverter bridge.Service Manual 6. with a capacitive filter on the input. generates the "F" signal used to generate a triangular wave signal. • light led LSOK (On. measured via the cards I/F-SG (voltage. the sensor "battery running down" generates a signal to the front operating panel. The control signals for the reed relays IOK and IFL. The descriptions are subdivided as follows: • IST Card • IWM-3 Card • IPS Card • IGD Card JUE401985 40 . • there is no inverter overtemperature or no fuse blown (see the section on the IST card) and • the correct operation of the power transistors and their relevant control (desaturation detection). informing the operator that the battery is about to end its rated autonomy. the signals ROK and 0BY. Control Logic • the presence of signal 0VIOK. +24V and +26V supply voltages as well as two AC voltages in order to supply the ITD-2 cards. The inverter output voltage is monitored on the IST card in order to ascertain whether it is within the required tolerance window. In the following sections.UPS E-2001 . which are supplied by the bypass static switch. Another output of this control logic block enables the pulse generating highfrequency oscillator. which signal to the front operating panel that the inverter is in order and the inverter output static switch is closed. which enables the firing of the inverter output static switch SCR's. respectively. The IPS card is the inverter electronic power supply and it generates the +12V.Service Manual 6. and the signal "INV. are included in the inverter control logic. Also. detailed descriptions of the cards making up the inverter control logic are given. Still on the IPS card. Such signals inform the inverter that the bypass line is in order in determining which source (inverter or bypass line) is to feed the load. also generated on the IPS card and determines whether the inverter input voltage is in tolerance.OK" which informs the bypass static switch control logic that the inverter is in order and therefore the inverter may feed the load are generated on the IST card. UPS E-2001 .Service Manual 6.Block diagram ( 1 of 2 ) JUE401985 41 . Control Logic Pict.1 Inverter subsystem . 2. 2. Control Logic Pict.Block diagram ( 2 of 2 ) JUE401985 42 .Service Manual 6.2 Inverter subsystem .UPS E-2001 . • The fuse monitoring circuit is connected at the input 13AC (a high level here indicates a blown fuse) and again in this case the startup consent for the inverter will not be given unless the fuses are in order. • The inverter transistors are monitored by a desaturation monitor coming from the IGD pcbs at 16AC. . the inverter start-up consent will be removed by pulling 1CA to a low level via D9. it will shutdown.The signal 0CC. The signal 1CA will then be high and this signal is sent to the IWM-3 card via the signal 0CA and output 30C in order to start the inverter. the inverter start-up consent will not be given due to D12 pulling the signal 1CA to a low level. the inverter start-up consent will be given when an ON command is present (the input 15AC is at a low level) and the relay ICA is energised. The start-up consent will not be given to the inverter (the signal 1CA) as this point will be pulled to a low level via D12 if an overtemperature occurs.3.UPS E-2001 . The LED LMV will flash only if an optional fan monitoring circuit is installed and one of the monitored fans fails. releasing the start-up consent to a high level.2 IST Card The IST card. PSP. includes: • The input signal 14AC is used to monitor the inverter heat sink and transformer temperature using thermal switches. A high level at this input will activate the desaturation control circuitry.Service Manual 6. The opening of one of the thermal switches will cause the input at 14AC to go to a high level at +12V and the LED LST will flash. The over and under voltage tolerances of the inverter output voltage are adjusted with P1 and P2 respectively. if this input goes to a high level. whose detailed block diagram is shown in figure 2. generated on the IPS pcb is monitored for set tolerances and if it is determined not to be in order. the following conditions are monitored: . This circuit may also be set into a "locked state" via the flip-flop set by the signal "1STOP" and must then be reset by switching the microswitch MSW first to the OFF position and then again to the ON position. • The inverter electronic power supply. • The input at 4C arrives from the IPS pcb and a low level at this input indicates that the inverter input voltage (or battery voltage) is in tolerance (i. which is enabled only if the inverter is synchronised (1SOK). 1CA. switching off the inverter by setting the inverter start-up consent. JUE401985 43 . coming from the input 12AC. The relay MV is used to signal the overtemperature condition to the front panel. Again. The desaturation circuitry may retry to connect the inverter to the load. Control Logic 2. Vin(min) < Vin < Vin(max)). The inputs 19AC and 18A are for the optional connection of fan monitoring circuits and are normally not connected.The command for a manual commutation to the bypass supply (or another inverter in a hot-standby or parallel/redundant system).The inverter output voltage is monitored via the input 4A which is a DC signal proportional to the output voltage. • If all the above listed conditions are in order. If the inverter was already running. • On starting the inverter.e. which is at a low level if a short circuit occurs on the inverter output or the inverter peak current limitation detector is active and . to a low level. The inverter output voltage must be within this window for the signal 1OK to go high. the following conditions must be true: . Control Logic If these 3 conditions are in order then the LED LVU will be lit.UPS E-2001 . the inverter voltage will go outside the tolerance window in order to limit the output current.the inverter output static switch of the second unit in a hot-standby or a parallel / redundant system must not be on. fixed. In this case. JUE401985 44 . in addition. Additionally. will allow the inverter output static switch to remain on if both are at a high level.the signal 0BY must not be at a low level indicating that the a command for the transfer to bypass supply is present and .The inverter start-up consent must be present and .Service Manual 6. the signals 0ROK (low if the bypass supply is in order) and 0I2OK (low if the second inverter in a hot-standby or parallel / redundant system is in order). the following conditions are met: .the signal 1CM must be true indication that on command to release the inverter firing (relay ICA) and the inverter output (relay 0CA) is present. the inverter static switch control logic will close the inverter output static switch if. If in the case of a short-circuit on the output. When the inverter is in order (0IOK and the output at 20A are at a low level). for the inverter to signal to the front operating panel that it is in order. 3 IST Control Pcb . Control Logic Pict. JUE401985 45 .UPS E-2001 .Blocks diagram Note: With logic level 1. With logic level 0. fixed and relays are not energised.Service Manual 6. led's are lit. 2. led's flash and relays are energised. 2. for the setting of the minimum threshold of the inverter output voltage (normal setting -10%. for the setting of the maximum threshold of the inverter output voltage (normal setting +10%.UPS E-2001 . . test points and leds on the IST card which are accessible from the front.Red led flashing: Blown fuse .Red led flashing: Inverter static switch open. switches. . . . Control Logic IST Front View The figure shows potentiometers. max 15%) Pict. . max -15%) .Pot. .Red led flashing: Inverter output not in order.Red led flashing: Overtemperature.Service Manual 6. Also used to reset the inverter after desaturation of a transistor.Microswitch to enable the inverter start-up.Red led flashing: Fan failure.4 IST .Pot.Changeover push button for test mode: manual changeover from inverter to the bypass line (enabled only when the bypass supply is in order). .Front view JUE401985 46 . reduces the output voltage through the diode analog OR as mentioned above. with the test (or manual) mode operation which allows to set the inverter output voltage manually in an open loop mode using the potentiometer P1.3 IWM-3 Card The IWM-3 card.the Led LCC will flash and the signal 0CC on pin 14C will go low. when the signal 0CA is at a low level. signalling the short-circuit to IST in order to commutate to the bypass supply if it is present. depending on whether the square wave of the bypass supply line is present on the pins 6C-5A. An analog OR using the diodes D12 and D10 determines whether the output shall be voltage or current controlled. coming from the IST card. slowly enables the control on output voltage in order to gradually rise the inverter output voltage. if it is available. Control Logic 2. When the phase lock loop (PLL) is locked. if the bypass supply is in order.Service Manual 6. synchronises the reference signal generated by the PWM circuitry with the bypass supply. . JUE401985 47 .UPS E-2001 . starting from the signal coming from the current transformers at pin 2A (+CU). the signalled is filtered and regulated by the output voltage regulator to the value set with the potentiometer P2 as long as the current remains below the current limitation value. • This closed loop operation may be replaced. This is normally adjusted in order to have 5. The control section for a load short circuit. in order to monitor the tolerance limits of inverter output voltage. or with the local crystal oscillator if the bypass supply is not available or out of the frequency tolerance limits. which is the inverter start-up consent. controls the inverter voltage during the short-circuit period in two ways: . fixed. when the signal CUF exceeds the set limit. includes: • The synchronisation selection switch. • The soft start section which. starting from the feedback signal proportional to the inverter output voltage (VU).1V dc at TP1. the led LSOK will be on. which based on the signal CUF.It temporarily stops the PWM by disabling the high frequency oscillator for the transistor output driver. By means of the output at pin 28A the same filtered signal (VU) is sent to the IST card. fixed and the relay SOK will be energised signalling to the front panel that the inverter is in synchronism with the bypass supply. This external signal arrives from the IPL card (for hot-standby and parallel / redundant systems only) and the jumpers J3 must be closed and J4 open in this case. • The control section of the inverter output voltage which.4. • The control section of the current delivered by the inverter which. the output LS of the phase detector goes high and. the led LBCC becomes lit. current limitation threshold using the potentiometer P3. on pin 30C. whose detailed block diagram is shown in figure 2. The potentiometer P5 sets the central point of the phase lock window with the nominal frequency desired (50 or 60Hz). or with an external synchronisation signal available on pin 7C. The current regulator. starting from signal 0CA on 29A. by closing J1 and opening J2. allows to set the max. generated on-board using the EPROM and digital-to-analog conversion. according to the amplitude of the signal from the diode analog OR.With logic level 0. fixed and relays are not energised. • The PWM generation section which. when the current exceeds the threshold set with the potentiometer P4. 2. which modulates this signal with a high frequency carrier (AF).5 IWM-3 . Pict. varies the modulation amplitude of the modulating sinewave. synchronised through the PLL using the signal "F". Leds are on. causes the led LOL to flash.Block diagram Note: .UPS E-2001 . operates the relay OL and sends a low level to pin 26A which signals the overload condition to the front operating panel. . Control Logic • The overload monitoring section which.With logic level 1. JUE401985 48 . coming from the oscillator AF (when it is enabled by the signals 1CA and 0CC) and controls the turn on and off pulses of the inverter power stage via the ITD-2 cards. The PWM signal is sent to the output drivers. The PWM is generated by comparing the generated sinusoid with a triangular carrier wave with fixed amplitude and frequency. Leds flash and relays are energised.Service Manual 6. Service Manual 6. .Red led flashing: inverter is overloaded. . fixed : inverter synchronised with the bypass supply.Front view JUE401985 49 . .1 Vdc.Red led flashing: inverter short-circuit or peak current limitation. common at TP16.6 IWM-3 .Red led on. test points and leds on the IWM3 card accessible from the front: . Adjust P5 for 5. . . .Potentiometer to adjust the inverter output voltage in test (or manual) mode. IPS card. .Potentiometer to set the inverter PLL centre frequency (at TP1).Red led on. fixed : Inverter start-up consent active.Test point: to set the inverter PLL centre frequency.Potentiometer to adjust the inverter output voltage. Pict. 2. Control Logic IWM-3 Front View The figure shows potentiometers.UPS E-2001 . signalling the failure to the IST card. JUE401985 50 . +24V on pin 5AC and +12V on pin 1AC. Control Logic 2. The DC to high-frequency AC converter part of the power supply generates an alternate voltage at a fixed frequency between pins 13AC and pin 3AC to supply the transistor driver cards IGD. generates a DC signal on pins 16AC-26AC. fixed if the voltage is in order).Service Manual 6. whose detailed block diagram is shown in figure 2. enables relay PFS. • The section starting from +B (inverter input voltage) monitors the voltage at the inverter input that it is within the upper and lower limits set through the trimmers P3 and P4 respectively.UPS E-2001 .4 IPS Card The IPS card. • Battery running down sensor which. all of them referred to the electronic common point. 32AC. The output voltage may be regulated through the trimmer P2 and led LFI. when the inverter input voltage (or battery voltage) drops below the set voltage level. If the voltage is outside this window. which signals the corresponding condition to the front operating panel. uses the battery voltage available between pins 27AC. includes: • The supply section which. on with a fixed light. 19AC and 31AC to generate the required inverter electronic supply voltages of +26V on pin 7AC (with LVU on. which is proportional to the inverter input voltage in order to prewarn the inverter of a voltage drop due to a load transient or dip in the mains supply of the connected rectifier. shows the correct operation of the regulation feed back.6. the LED LVI flashes and the signal 0VIOK on pin 11AC goes high. • The feed-forward section which from the inverter input voltage at +B and -B. The signal is sent to the the voltage control loop on the IWM-3 card. 7 IPS . LVI lit. JUE401985 51 . 2. alarm. OK.Block diagram Note: - LVU lit. OK. OK. off. LFI lit. alarm. alarm. Control Logic Pict. OK.UPS E-2001 . LAS lit. flashing.Service Manual 6. off. alarm. off. to set the upper limit of the inverter DC input voltage .Service Manual 6.ON / OFF Switch.Red led lit with fixed light: DC input supply voltage available - Test Test Test Test point point point point +12 V (PSP) electronic ground (0V) +26 V (PSP-1) +24 V (PSP . Inverter Eletronic Power Supply .Front view JUE401985 52 . Control Logic IPS Front View The figure shows potentiometers.Pot.A) . switches. . test points and leds on the IPS card accessible from the front: .Red led lit with fixed light: inverter electonic power supply OK.8 IPS .Jumper for test mode . . 2. to set the lower limit of the inverter DC input voltage Pict.Red led lit with fixed light: inverter DC input voltage within tolerance limits .Pot.Red led lit with fixed light: rectifier output voltage OK.UPS E-2001 . Service Manual 6. blocking the on-pulse and signalling the ICP pcb of a desaturation of an IGBT via an opto-coupled output.9 IGD Block Diagram.levels are generated from the high frequency alternating waveform coming from the IPS pcb. The switching waveform for each IGBT is generated on the ICT-2 pcb. The output of the pulse control circuit is fed directly to the driver stage. If this voltage exceeds a set value. the resistors R29 and R30 controlling the on and off times respectively. JUE401985 53 . The emitter-collector voltage VCE of each IGBT is continuously monitored during the on-state. This waveform is opto-coupled to the pulse control circuitry on the IGD pcb. IGBT Driver Circuit Desaturation Monitor FIG 2.5 IGD Card Power Supply Each pcb generates its own internal power supply to provide isolation from other modules. The V+ and V. the desaturation detector will be activated. Control Logic 2. The capacitor C12 controls the dead time.UPS E-2001 . The signal is also compared in the high/low voltage comparators for the UPS output voltage. the same signal (FR) is phase regulated and sent to the inverter as a reference signal for synchronisation. The signal SR is proportional to the bypass supply line voltage waveform and phase and is then converted into a square wave (FR) by the zero detector and used to monitor the bypass supply frequency. which is at a low level if the UPS output voltage is within the tolerance limits. after being filtered and rectified. Control Logic 3 STATIC SWITCH CONTROL LOGIC 3.. The UPS output voltage is sent to the SPT card via an auxiliary transformer on the SSV1F pcb. is rectified and filtered on the SPT pcb and is also used to redundantly generate the electronic supply voltages for the case where the bypass supply fails and the inverter is connected to the UPS output. JUE401985 54 . is the logic which continuously monitors the UPS output for set tolerances and includes the control and drivers of the bypass static switch thyristors. The control logic block following thereafter.1 Functional Description The bypass static switch control logic. In addition. Based on the signals 0COK and 0ROK. generates signal 0ROK which is at a low level if the bypass supply voltage is in order and the bypass supply frequency is within the set toerance window thereby generating the signal 1FROK. the SCLT card determines whether the load is to be supplied by the bypass or the inverter supplies via the bypass commutation decision logic block. PSP1 and PSPA on the SPT card. the inverter supply will feed the load and the signals 0COK and 0ROK will be at a low level.Service Manual 6. The signal IROKB is only used in case of Hot-standby and Parallel / redundant configurations. whose block diagram is shown in figures 3. In normal operating conditions (when the unit is not programmed in an off-line mode).1a. and 3. The bypass line voltage is sent to the SPT card via an auxiliary transformer on the SSV1F card and it is rectified and then used to generate the bypass electronic supply voltages PSP. which verifies if the bypass line voltage is within the desired tolerance limits. The result of this comparison and of the logic processing following thereafter is the signal 0COK.UPS E-2001 . The signal 0BY indicates that the load is supplied by the bypass supply when at a low level. the resultant voltage is sent to the high/low mains voltage comparators.1b. In addition. The 0ROK signal (IROKA) is then sent to the inverter control logic which enables the PLL to synchronise to the bypass supply line. In the following sections detailed functional descriptions of the electronic control cards (or Pcbs) composing the bypass static switch control logic are given. The manual bypass is open under normal operating conditions: it is closed only in case of maintenance or repair work on the UPS itself.UPS E-2001 . The descriptions are subdivided as follows: .2OK and S2OK if the unit is part of a hot-standby or parallel / redundant system) are used to illuminate the LEDs shown and to signal the UPS condition to the front operating panel. respectively.Service Manual 6.SPT Card .SCLT Card JUE401985 55 . Control Logic The SCLT card receives the signals INV. Through the control logic block following thereafter.1 OK and S1OK from the inverter when the inverter is in order and synchronised. these galvanically decoupled signals (along with INV. Service Manual 6.1 . 3.UPS E-2001 .Static switch subsystem .Block diagram (1 of 2 ) JUE401985 56 . Control Logic Pict. Block diagram (2 of 2 ) JUE401985 57 .Static switch subsystem . Control Logic Pict.UPS E-2001 .2 .Service Manual 6. 3. fixed and the relay RC is energised signalling to the front operating panel that the load is being fed by the bypass supply. preventing the closing of the inverter output static switch(es) of inverters 1 and 2 (for hot-standby and parallel / redundant configurations). taking it from pins 3C2C. signalling the condition the the front operating panel via the relay RPM and the Led LBR flashes. via the SCR drivers. If it is determined that the load must be supplied by the bypass supply line. The presence of a high level on 1IOK and 1SOK energises the respective relays IOK and SOK which signal the UPS status to the front operating panel. To prevent continuous retransfers under failure conditions. The high frequency oscillator is also enabled to in order to transfer the firing pulses to the SCR's of the bypass static switch.e. once the conditions have been verified. Control Logic 3. the control logic allows only 3 retransfer attempts within 1 minute and if more retranfers are attempted. the blocked condition must be reset as in the case when the microswitch MSWA is in the manual position. S2OK will flash if the respective condition is not true (with one inverter present only. the signal 0BY becomes low. With MSWA in position A (automatic). 9C-5C.2 SCLT Card The SCLT card whose detailed block diagram is shown in figure 3. or needs to be commutated to the bypass supply line. as well as the signals 0COK. LI2OK. 8C-2C and 6C-5C. In this case.Service Manual 5. S1OK. At the same time. a high level if the inverter-bypass supplies are synchronised for either inverter and the respective inverter is in order). receiving the signals 1IOK and 1SOK mentioned above. the reset for retransfer of the load to the inverter supply is only possible through the reset push button PR or through an external reset coming from pin 16C.2. JUE401985 58 .UPS E-2001 . by means of optocouplers and generating the signals 1I1OK (i. the reset for retransfer of the load to the inverter supply.e. the led LSS lights. and 0ROK. a high level if inverter 1 is OK) and 1SOK (i. determines whether the load is to be fed by the inverter. Leds LI1OK. consists of: • The input / interface sections between inverters 1 and 2 (only for hot-standby and parallel / redundant configurations) and the bypass control logic transfer the information "inverter OK" and "synchronism of inverter with the bypass supply" from the control logic of the respective inverter. based on the status for UPS output voltage in order and coming in at the pin 14C. LI2OK and S2OK flash continuously). based on the status of the bypass supply input voltage in order and coming in at the pin 13C (both coming from the SPT card). occurs automatically. • The section managing the load commutations between the inverter and the bypass supply operates in two modes depending on the status of microswitch MSWA. With MSWA in position M (manual). • The control section of the inverter output and bypass supply line status which. the automatic retransfer control becomes blocked. 3 SCLT .UPS E-2001 . Led LSS flashes when the load is fed by the inverter (normal operation) and becomes lit.Service Manual 6. Control Logic Pict.Block diagram Note: With logic level 1. fixed and relays are not energised. leds are lit. JUE401985 59 . fixed when the load is fed by the bypass supply line. With logic level 0. leds flash and relays are energised. 3. .Red led lit. . 3. JUE401985 60 .4 SCLT . fixed: Inverter 1 synchronised .Red led flashing: automatic retransfer of the load from the mains to inverter supply is blocked (Reset using pushbutton PR below). fixed: Inverter 1 OK . .UPS E-2001 . Control Logic SCLT Front View The figure shows potentiometers. switches and leds on the SCLT card accessible from the front.Front view * These leds are always flashing when inverter 2 is not present i.Pushbutton to reset after the retransfer of the load to the inverter is blocked.Red led lit.Red led flashing: Inverter 2 not OK* . when there is no hot-standby or parallel / redundant configuraton. Pict.Red led flashing: Bypass static switch open.e. in automatic mode it attempts 3 retransfers within 1 minute). .Microswitch for manual/automatic control when commutating between the inverter and bypass supplies (In manual mode the UPS does not attempt to retransfer.Red led flashing: Inverter 2 not synchronised* .Service Manual 6. The following leds light when the bypass supply frequency is not within the limits set: . generates the supply voltage for the bypass electronic power supply. after being rectified. whose detailed block diagram is shown in figure 3. The signal 0ROK will be at a low level and is sent to the SCLT card via the pins 8AC and the high level signals 1ROKA (to inverter 1) and 1ROKB (to inverter 2 for hot-standby and parallel / redundant systems) to pins 5AC and 3AC respectively. • The supply section which. For single-phase systems. is within set tolerance limits and. The relay BYS is also energised to signal the condition that the bypass electronic power supply is in order. feeds the DC power supply PSPA. will be at a JUE401985 61 .LFB if the frequency is lower than the minimum limit. After a fixed delay. available at TP3 (referred to the common for the bypass electronics at TP4) via the voltage regulator PVR when the microswitch MSWA is closed. which enables the inverter-bypass supply synchronisation.UPS E-2001 . . frequency tolerance limits. which is used for firing the bypass static switch thyristors. redundantly to that above. if the mains voltage amplitude is below the maximum threshold and the bypass line is not blocked externally via the relay 0BC coming from pins 7AC. PSP. after being rectified. the bypass electronic supply.3 SPT Card The SPT card. available on TP1 and on pin 15AC. consists of following sections: • Section for rectification and filtration of incoming bypass supply voltage which. • The control section of bypass supply line frequency where the frequency range to be set through the jumpers J3. starting from the non-regulated DC voltage PSPA. The signal 1FROK. fixed to show that the bypass supply line is in order. pole 5 closed. Control Logic 3. and max. by generating the signal 1PSOK. When the bypass supply voltage amplitude is above the minimum level. enables the DC supply PSP1. • Section for rectification and filtration of the incoming UPS output voltage which.Poles 1-4 open. • The control section of the bypass supply line voltage amplitude limits which allows to set the minimum and maximum value of the line voltage by means of potentiometers P1 and P2 respectively (nominal setting of ±10%). the led LROK will light. PSP. feeds the non-regulated DCpower supply PSPA. The bypass electronic supply monitor verifies that the bypass electronic supply voltage. PSP. Pole 5 inserts more filtration on the signal CR.Service Manual 6. The SPT card may be used with three phase or single phase systems. the signal 1RM becomes high. Otherwise the Leds are off. is in order (1PSOK) and the bypass frequency is on order (1FROK).4. J6 (50 / 60 Hz) and potentiometers P6 and P7 for the setting of the min. J5. J4. the DIP switch DSW1 is set as follows: .LFA if the frequency is higher than the maximum limit. leds are lit. . This section.UPS E-2001 . the led LCOK will flash and the signal 0COK at 31A will go to a high level. Control Logic high level if the bypass supply line frequency is within the set tolerance limits (LFA and LFB both off) and the level 1RM is high.Service Manual 6. starting from the signal CR. JUE401985 62 .With logic level 0. . Under these conditions the led 1FROK lights. If the UPS output voltage is out of the set tolerance limits. 3. fixed and relays are not energised.LFA and LFB are off and they light in case of alarm. fixed and a high level will be present on TP21. • The control section for the amplitude limits of the UPS output voltage which feeds the load (taken downstream of both static switches but before the output switch QIUG). leds flash and relays are energised. Pict.With logic level 1. through potentiometers P3 and P4 respectively.Block diagram Note: .5 SPT . allows to set the minimum and maximum thresholds. to adjust the upper threshold of the bypass line frequency.Service Manual 6. .6 SPT . test points and leds on the SPT card accessible from the front. after taking the voltage SR coming from the bypass supply input volatge from pins 28AC. . . . . and voltage of the bypass line in order. 3. .Adjustment of the upper limit of the UPS output voltage monitor.Red led lit. Bypass Electronic Power Supply . out of the tolerance limit. if enabled by the signal 1RM. . .Pot.Pot.Front view JUE401985 63 .Pot. fixed: bypass supply line in order. .Red led flashing: lower threshold of the bypass supply line freq.Test point +12 V (PSP) for the bypass electronic control. SPT Front View The figure shows potentiometers. .Red led lit. .Adjustment of the lower limit for the bypass input line voltage. to adjust the lower threshold of the bypass line frequency. The potentiometer P5 (phase regulator) allows to adjust the phase difference between the bypass supply and the inverter output supply for correct synchronisation. to adjust the upper threshold of the bypass line voltage. .Red led flashing: upper threshold of the bypass supply line freq.Pot. fixed: freq.Test point +28 V (PSPA).Test point common (0V) for the bypass control electronic.Adjustment of the lower limit of the UPS output voltage monitor. converts it into a square wave and.Red led lit. for adjustment of the phase difference between the inverter and bypass supplies. . Control Logic • The section for the generation of a square wave for the bypass inverter synchronisation which. Pict. . .Test point +24V (PSP1) for firing the bypass static switch SCRs. . transfers the square wave signal for the first and the second inverters (in case of hot-satndby and parallel / redundant configurations) to pins 10AC and 6AC respectively. fixed: UPS output voltage OK (adjustable with P3 and P4). out of the tolerance limit.UPS E-2001 . switches.ON / OFF Switch. RECTIFIER VOLT.1 Troubleshooting procedure 74 3 BLOWN FUSES 3.1 Troubleshooting procedures 70 12 MAINS FAULT 12.1 Troubleshooting procedures 71 13 LOAD FED BY MAINS 13. Troubleshooting Chapters 1 GENERAL DESCRIPTION 1.1 Troubleshooting procedure 77 5 MAX.UPS E-2001 .1 Troubleshooting procedures 68 11 STATIC SWITCH BLOCK RESET 11.VOLTAGE RESET 5.Service Manual 7.1 Troubleshooting procedures 67 10 OVERLOAD 10.1 Troubleshooting procedure 78 6 RECTIFIER MINIMUM VOLTAGE 6./ MAX.1 Troubleshooting procedure 73 2 MAINS OK LED OFF 2.1 1.2 Introduction Troubleshooting procedures 65 65 8 INVERTER ON 8.1 Troubleshooting procedure 79 7 SYSTEM TEST 7.1 Troubleshooting procedures 66 9 INVERTER FAULT 9.1 Troubleshooting procedures 72 JUE401985 64 .1 Troubleshooting procedure 76 4 RECTIFIER TROUBLE 4. The procedures do not take into account possible interruptions of tracks and wirings on various back panels and on the printed circuits of cards. 1. Troubleshooting 1 GENERAL DESCRIPTION 1. the technician is guided inside the system with the help of signals (leds) placed on the logics cards.1 Introduction This chapter contains the troubleshooting procedures for "E-2001" system.Service Manual 7. JUE401985 65 .UPS E-2001 . Starting from a particular alarm. Such procedures help the technician to locate the faulty part causing the malfunction.2 Troubleshooting The troubleshooting procedures mentioned hereunder result almost exclusively from fault symptoms shown by the lighting of relevant leds. • replace YY-SYNC.c. No: 2C: Is led "Phase failure" on card RPD flashing? No: Yes: 2D: Are the leds on card YY-SYNC. restore the cyclic sense R-S-T. JUE401985 66 .1 Trobleshooting procedure Mains OK led OFF! • Open the front panel of "E-2001" system and check the status of the leds installed on the internal p. OK ? Yes: Troubleshooting finished.& SUPPLY card. • check fuses F1-F2-F3 and replace them if needed. • replace RPD card.& SUPPLY lit? Yes: No: • replace RPD card . Troubleshooting 2 MAINS OK LED OFF 2.& SUPPLY card. • contine with 2B. boards. • Continue with 2C. OK ? No: replace YY-SYNC. • continue with 2D.UPS E-2001 .Service Manual 7. 2A: Is led "MAINS OK" on card RPD flashing? No: Yes: 2B: Is led "Phase sequence OK" on card RPD flashing? Yes: • The cyclic sense of mains is not correct for some reason. No: Supply mains is not correct. JUE401985 67 .UPS E-2001 .Service Manual 7.c.1 Troubleshooting procedure Blown fuses led on! • Open the front door of "E-2001" system and check the status of the leds installed on the internal p. boards. Troubleshooting 3 BLOWN FUSES 3. • check fuses F1-F2-F3 of rectifier bridge and replace the faulty one. 3A: Is led "Blown fuses" on card RPD lit? No: Yes: • replace RPD card. c. boards. No: 4E: Is led "MAX volt. OK ? Yes: Troubleshooting finished. • Read troubleshooting procedure 2 (MAINS OK led off). • Continue with 4E. • Read troubleshooting procedure 3 (Blown fuses) OK ? Yes: Troubleshooting finished No: Continue with 4C • replace RVR41773 card. 4D: Is led "Thermal Protection" on card RVR41773 flashing? Yes: • check the temperature on the rectifer bridge or the thermal sensor. • read troubleshooting procedure JUE401985 68 .UPS E-2001 .protection" flashing ? No: Yes: • replace RVR41773 card. • Continue with 4B. Troubleshooting 4 RECTIFIER FAULT 4.1 Troubeshooting procedure Rectifier trouble led on • Open the front door of "E-2001" system and check the status of the leds installed on the internal p.Service Manual 7. 4A: Is led "No Rectifier Output" on card RVR41773 flashing? No: Yes: 4B: Is led "Blown fuses" on card RPD flashing? No: Yes: • Continue with 4C. No: Continue with 4D. 4C: Is led "Mains OK" on card RPD flashing? No: Yes: • Continue with 4D. 4E. OK? Yes: Troubleshooting procedure finished. JUE401985 69 .4D .Service Manual 7.UPS E-2001 . Troubleshooting 4F: Is led "STARTUP CONSENT" on card RVR41773 flashing? No: Yes: • replace RVR41773 card. No: replace RPD card. • continue with points 4B .4C . boards. RECT VOLTAGE . Troubleshooting 5 MAX. JUE401985 70 .max.1 Troubleshooting prcedure Max. VOLTAGE RESET 5.voltage reset button led ON! • Open the front door of "E-2001" system and check the status of the leds installed on the internal p.UPS E-2001 . rect. voltage .MAX. 5A: Is led "MAX.Service Manual 7.c. VOLTAGE protection due to a serious failure on the control electronics.PROTECTION" on card RVR41773 flashing? No: Yes: • replace RVR41773 card. Call for service in order to carry out a general checkup and restore the system. • the rectifier has set to MAX. VOLT. • continue with 6C. • replace RVR41773 card. JUE401985 71 . • replace RVR41773 card. • replace RVR41773 card. • continue with 6B. Call for service in order to carry out a general checkup on E 2001 system.UPS E-2001 .1 Troubleshooting procedure RECTIFIER MINIMUM VOLTAGE led on! • Open the front door of "E-2001" system. remove the front panel of control cards and check the status of the leds installed on the internal cards. 6A: Is the yellow led "L MIN" on? No: Yes: 6B: Is Vdc voltage on rectifier output at the nominal vaue of the charge in progress ( ± 5% )? No: Yes: 6C: Is battery recharging current still > 0. Troubleshooting 6 RECTIFIER MINIMUM VOLTAGE 6.1 C10? No: Yes: 6D: Is the red led "LCG" on card RVR41773? No: Yes: • replace RVR41773 card.Service Manual 7. • there's a failure on the recharging system or on the battery. • continue with 6D. OK? Yes: Successful testing. 7A: Led FLOATING CHARGE on RVR41773 shall go off and led BOOST CHARGE on RVR41773 shall light.Service Manual 7.UPS E-2001 . No: Continue with 7C. • continue with 7B and following points.FLOATING"? No: Yes: 7D: Wait for the recharging cycle to end and check what specified in point 7C.1 Test procedure to assess operational efficiency • Open the front door of "E-2001" system (only in case of systems with no optional "RECHARGE TEST" push button) and press button PRC. OK? No: replace RVR41773 card. 7C: Is the current absorbed by the battery exceeding the changeover level "BOOST CHARGE . JUE401985 72 . OK? Yes: Test and recharge ended successfuly. Yes: continue with 7B. Continue with 7D. No: continue with 7E. Ok? No: replace RVR41773 card. Troubleshooting 7 SYSTEM TEST 7. Yes: Wait 30" for charge and make sure the system is switched back to floating (Floating Charge on and Boost Charge off). 7E: Has the red led LGC on RVR41773 lit? No: Yes: • replace RVR41773 card. 7B: Make sure output voltage sets to the boost charge value. • the battery was flat. • replace RVR41773 card. 1 Troubleshooting Procedure Inverter ON led OFF! • Open the front door of the "E-2001" system and check the status of leds placed on the internal cards. Troubleshooting 8 INVERTER ON LED OFF 8. 8A: Is led LOSS flashing on card IST? No: Yes: 8B: Is led INVERTER OK on the panel OFF.UPS E-2001 . • Replace IST card.Service Manual 7. • Replace IST card. OK? Yes: End ! No: Replace SCLT card. • continue with 8B. JUE401985 73 . too? Yes: No: • See troubleshooting procedure for INVERTER FAULT. Service Manual 7. Proceed with 9F . No: Replace the fuse. Ok? Yes: After ascertaining environmetal conditions meet the installation specifications. 9A: Is led LVU on card IST flashing? No: • Replace IST card. Ok? Yes: Replace the faulty fan. Is led LAS on card IPS ON? Yes: Proceed with 9B. Yes: Continue with following procedure. 9B: Are also leds LVU. Yes: Is switch MSW on card IST on ON? No: Set MSW to ON. Yes: Continue with following procedure. Is the switch on the front panel ON? No: Set the switch on ON. • Proceed with 9D. switch the inverter OFF. No: Proceed with 9C. • Check fans efficiency. Troubleshooting 9 INVERTER FAULT 9. JUE401985 74 . LFI and LVI on card IPS lit with steady light? No: Yes: 9C: Is switch MSW on card IPS positioned on ON? No: Yes: 9D: Is led LST on card IST flashing? No: Yes: • Proceed with 9E. • Replace the fuse.1 Troubleshooting Procedure Inverter fault led ON! • Open the front door of the "E-2001" system and check the status of the leds placed on the internal cards. let the system cool and switch the inverter ON again (with rated load).UPS E-2001 . No: Check the fuse integrity. • Set MSW on ON. • Replace IPS card. 3. THEY ARE ALL FLASHING • Replace IWM-3 card. The inverter has started operating again. Ok? Yes: End! No: Replace the card. No: 1. 9F: Is the alarm occurring again? No: Yes: • End! • Check the efficiency of the thermostat installed on transformer TR1 and of the transformer itself. Is the led still flashing? No: A protection has tripped due to unidentified causes. Troubleshooting 9E: Are leds LFT on cards ITD-2 all lit with fixed light ? Yes: • Replace card IST. THEY ARE ALL OFF • Replace fuse F1 on the logic back panel. 2.Service Manual 7. Yes: Replace relevant IGD card. ONE LED IS FLASHING • Switch the inverter OFF and then ON.UPS E-2001 . No: Replace the failing component. Ok? Yes: End! No: Check the integrity of the output filter components and of the capacitive filter on inverter input. All Ok? Yes: Check the integrity of transformer TR1. Ok? Yes: End! No: Replace relevant PTM module. JUE401985 75 . Troubleshooting 10 OVERLOAD 10.Service Manual 7. JUE401985 76 .UPS E-2001 . • Make sure the load be within the nominal values specified in the technical data of the system.1 Troubleshooting Procedure Overload led ON! Is led LOL on card IWM-3 flashing? No: Yes: • Replace IWM-3 card. Yes: JUE401985 77 . or press push button PR on card SCLT. Ok? Yes: End! No: The fault is located on the inverter power part.1 Troubleshooting Procedure Led Static switch block RESET ON! • Press the RESET push button for static switch block when the red luminous signal inside the push button flashes. Troubleshooting 11 STATIC SWITCH BLOCK RESET 11. See paragraph 2. • Replace SCLT card.Service Manual 7.UPS E-2001 . Is the alarm occurring again? No: • End! Repeated overcurrents on the load had occurred within a short time. JUE401985 78 . Is mains voltage present on the system input? No: Restore mains voltage on system input.Service Manual 7. Troubleshooting 12 LED MAINS FAULT ON 12. No: Replace SPT card.1 Troubleshooting Led MAINS FAULT ON! • Open the front door of the "E-2001" system and check the status of the leds placed on the internal cards.UPS E-2001 . Is led LROK on card SPT flashing? Yes: Make sure mains voltage be within the nominal values specified in the technical data of the system. 2. Is Led MAINS OK on the front panel OFF? 1. Yes: Check the status of lamp MAINS OK on the front panel. 1 Troubleshooting Led LOAD FED BY MAINS ON! • Open the door of the front panel of the "E-2001" system and check the status of the leds placed on the internal cards. JUE401985 79 .UPS E-2001 . Troubleshooting 13 LOAD FED BY MAINS 13.Service Manual 7. Is led LSS on card SCLT flashing? No: • Check the other alarms in progress and follow relevant troubleshooting procedures. Yes: • Replace SCLT card. 2 88 83 IP20 0°C ± 40° 0°C ± 85° ≤ 95% ≤ 2000 msl RAL 7032 27.5 15 22.3 45.9 94 383 90.3 7.4 93 280 66.85 92 96 22.7 15.6 88 82 18. Technical Data 1.2 23 93 5 10 15 20 30 40 50 380 Vac ( ±10%) 3ph 50 Hz 110 Vdc 192 45.5 95 Rectifier Input Power (kVA) Efficiency (%) Battery capacity (Ah) (30 min autonomy) Battery charging current (A) Input voltage (Vdc) Output voltage (Vac) 37 / 50 75 / 100 125 150 / 200 250 400 400 / 500 Battery 7.5 30 95 .6 86 79 9.165 45 60 75 115 (110-120) or 230 (220-240) Inverter Nominal output current (A) 230V/115V Input Power (kW) Efficiency (%) Overall efficiency Protection degree 17 / 34 35 / 70 52 / 104 69 / 138 104 / 208 139 / 278 174 / 348 4.1 Technical data SIZE (kVA) Input Voltage Vdc Voltage Rectifier output current (A) Rectifier input current (A) 48 11.6 31.6 62.UPS E-2001 .7 94 479 113.2 87 81 13.2 88 83 36 89 84 45 89 84 Operation Temperature Storage Temperature Relative Humidity Altitude Painting colour Dimensions (mm) Weight (Kg) W H D 1200 1800 800 450 1200 1800 800 500 1200 1800 800 600 1200 1800 800 650 1800 1800 800 820 1800 1800 800 900 1800 1800 800 1000 Table 1.1 Technical Data JUE401985 80 .7 93 140 33.4 78.Service Manual 8. 2 93 140 65.8 92 86 43.5 15.3 94 232 108.5 11.Service Manual 8.25 15 22.5 176 .UPS E-2001 .8 93 88 86 93 88 Operation Temperature Storage Temperature Relative Humidity Altitude Painting colour Dimensions (mm) Weight (Kg) W H D 1200 1800 800 450 1200 1800 800 500 1200 1800 800 600 1200 1800 800 650 0°C ± 40° 0°C ± 85° ≤ 95% ≤ 2000 msl RAL 7032 1200 1800 800 750 1200* 1800 800 830 1400 1800 800 920 1800 1800 800 1050 1800 1800 800 1140 1800 1800 800 1300 Table 1.6 93 72 33.3 7.8 75.6 62.2 Technical Data NOTE : * 1400 if 110Vac output JUE401985 81 .1 92 86 IP20 34.5 88 81 9 89 83 13. Technical Data SIZE (kVA) Input Voltage Vdc Voltage Rectifier output current (A) Rectifier input current (A) 5 10 15 20 30 40 50 60 80 100 380 Vac ( ±10%) 3ph 50 Hz 220 Vdc 24 11.1 31.8 155.6 124.7 27.325 30 37.5 92 87 51.75 7.2 93 88 68.4 94 192 75.5 45 60 75 115 (110-120) or 230 (220-240) Inverter Nominal output current (A) 230V/115V Input Power (kW) Efficiency (%) Overall efficiency Protection degree 17 / 34 35 / 70 52 / 104 69 / 138 104 / 208 130 / 260 174 / 348 208 / 416 278 / 556 348 / 696 4.3 93 96 45.6 95 Rectifier Input Power (kVA) Efficiency (%) Battery capacity (Ah) (30 min autonomy) Battery charging current (A) Input voltage (Vdc) Output voltage (Vac) 25 37 / 50 75 75 / 100 125 150 / 200 200 250 400 400 / 500 Battery 3.3 95 280 131.8 92 48 22.6 45.2 91 85 17.5 91 95 383 179.3 92 85 26.3 95 479 224. TYR. TYR. & SUPPLY : I/F .Service Manual 9. FIRING 6P SGV02C: RBP41773: IBMU / IGBT: SBTR: RVR41773: RPD: IWM .UPS E-2001 .3: IPS 120: IPS 208: IST: IPL: SCLT : SPT: IGD/N50/I DATA MONITOR PANEL DME/S: ORA-8 / ORA-14: SA/IF IBM38 AS400 JUE 300636 JUE 300242 JUE 300011 JUE 300689 SE 053B116 SE 053B112 JUE 300257 JRE 300550 JUE 302158 SE 032B003D JRE 300528 SE 013B004 JUE 300195 SE1663 SE 023A027A SE 023A002 SE 23B006 SE 033AA003 SE 033A001 JUE 300349 JUE 302039 JUE 302200 / JUE 302209 (Optional) SE053B108B (Optional) JUE401985 82 JUE 300351 JUE 300197 JRE 300530 A PRINTED CIRCUIT JUE 300638 JUE 300244 JUE 300013 JUE 300691 . PCBs Schematics WIRING DIAGRAM YY SYNC.1F: RECT. FIRING CPSII-CP RECT.SG : SSV1F : ST .