i4 ups module.xa.yimg.com/.../13724245/1943176420/name/hi-rel-10+… · · 2010-03-17i4 ups...

HI-REL Electronics LTD . I4 UPS module Operation Manual. Doc # 985UUALL01 (Rev 1) . page # 1

Operation manual.

Uninterruptible Power Supply System.

I4 UPS Module. (For Parallel redundant configurations)

Contents


1. Safety -- 3 2. Introduction 2.1 The I4 UPS module. -- 4 2.2 Technical Specifications. -- 6 3. Operation . 3.1 Location reference. -- 7 3.2 Energization. -- 9 3.3 Start / Stop. -- 10 3.4 Isolating a module. -- 11 3.5 Re-connecting a module. -- 12 4. Monitoring & Control. 4.1 LED Mimic -- 13 4.2 Monitoring & Control software. -- 13 4.3 Program navigation. -- 14 4.3.1 Alarms -- 15 4.3.2 Metering -- 16 4.3.3 System status -- 17 4.3.4 Alarm Log -- 18 4.3.5 Fault Log -- 19 4.3.6 Clock -- 20 4.3.7 Control -- 21 5. Dealing with Faults & Alarms. 5.1 Alarms -- 22 5.2 Faults -- 24 5.3 Service calls. -- 25 6. Maintenance. 6.1 Cleaning -- 26 6.2 Preventive Checks -- 26 6.3 Service contracts -- 27 7. Spares. -- 28

1. Safety


• For the purpose of this manual and the product the following symbols are used.

SYMBOL DESCRIPTION

Alerts a person that high voltage is present which could result in severe bodily injury or loss of life. Relevant instructions & electrical safety measures must be adopted.

Alerts a person that if procedures are not followed, damage to or destruction of the equipment could result.

Qualified person - who is formally trained by Gujarat Hi-Rel Controls LTD to perform the specific job.

• This product contains high voltage supplies connected. DO NOT touch the internal parts when the front door is open.

• DO NOT attempt to bypass the instructions given in this manual. Always consult HI-REL incase of doubt, BEFORE proceeding with other actions not included in this manual.

NOTE Calls for attention to the information that is especially significant in understanding

the operation.

NOTE The following sections of this manual describe various operational aspects of a Single UPS module. These are equally applicable to the redundant UPS module.

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2. Introduction


2.1 I4 UPS module (for Parallel redundant Configuration)

FIG 1

FIG 1 Rectifier - Converts the AC mains to regulated DC power. - Supplies DC power to the Inverter - Charges the Battery when mains is present. Inverter - Converts DC into Frequency & Voltage controlled AC supply Battery (separate module) - Stores energy while mains supply is present. - Delivers energy (DC supply) to the Inverter when mains supply is absent. Static Switch A bi-directional, solid-state transfers switch. - Normally connects the Inverter output to the load - Automatically transfers the load to an Alternate supply if Inverter fails or overloads. - Automatically re-transfers the load from the Alternate supply to the Inverter, once the Inverter is healthy or the overload condition has ceased.

2. Introduction


2.1 I4 UPS module (for Parallel redundant Configuration) cont.... Major components CBI Mains input Isolator CBA Alternate input Isolator CBB Battery isolating circuit breaker MIS Module Isolator switch FD DC link fuse LD DC Filter choke CD DC link filter capacitors - multiple units CO Output AC filter capacitors – multiple units T2 Output isolation Transformer Control section • System Manager (H1) The system manager is basically a high-level user interface unit. It employs a powerful microcontroller based circuitry along with a non-volatile memory. It controls the LCD-Keypad as well as the LED mimic for status reporting as well as programming the parameters of the UPS module. • LCD-Keypad The LCD-Keypad is used to View & Control various parameters of the I4 UPS module. An LED mimic is also provided alongside the LCD-Keypad to provide a snapshot information of the UPS module status. A detailed explanation of the LCD-Keypad & the LED mimic is provided in section 3 of this manual. • System control (H2) The system control card is the heart of the I4 UPS module. It employs an advanced, microprocessor based, digital control for the Inverter & the Static switch. It monitors the performance of the UPS module & communicates the status to the system manager card. It also receives operational commands from the system manager & control the UPS module accordingly. • Rectifier control (H3) I4 UPS module uses a 6 pulse, phase controlled, thyristorised rectifier. The rectifier control generates the required firing pulses so as to maintain a regulated DC o/p. The rectifier also performs the function of battery charging. The Battery charging current is monitored by the rectifier control & will operate the rectifier so as to limit the charging current of the battery to a preset value. • SMPS (H4) Redundant Switch Mode Power supplies generate the control power supplies for the Control of I4 UPS module (Inverter, Static switch, etc). This power supply receives input from the Battery, Input mains as well as the Alternate supply lines, enabling it to operate under all eventualities. • Gate Drivers. (H5) The main function of the gate driver is to drive the Inverter IGBT power devices. The gate driver employs a sophisticated hybrid circuit in order to drive as well as protect the IGBT’s. It derives its power supply directly from the DC link & acts on the PWM signals generated by the system control. • System F/B. (H6) The system f/b (feedback) assy. taps all the required information (voltages, currents, etc) from various parts of the I4 UPS module as provides the feedback to the system control. • Paralleling Control. (H11)

2. Introduction


The Paralleling control card provides the necessary signals & interconnections for Parallel operation with the redundant UPS module 2.2. Technical specifications of the I4 UPS module. Model I4 - 7.5 10 15 20 30 40 50/60 INPUT Mains Voltage 300V AC min. - 415 V AC nom. – 470V AC max. Frequency 50Hz, +/- 6%

Feeder KVA 12 15 23 30 45 60 75/90 Alternate Voltage VAC 1 Phase 230 V AC +/-10% Freq. Hz 50Hz, +/- 6% Battery Voltage VDC 210V min. – 240V nom – 270V max. OUTPUT Rectifier Voltage. 270V DC Float Inverter Voltage

1 Ph 230 VAC +/- 1%. Steady state loading (0 –100%) +/- 5%. Step loading <1 cycle recovery to steady state.

Frequency 50Hz +/- 0.1% - Free running +/- 6 % - Alt sync ( S =1,2,3,4,5,6 settable)

Waveform Sinusoidal - THD < 3% - Linear loading - THD < 5% - Nonlinear loading @ CF 2.5

KVA 7.5 10 15 25 30 40 50/60 kW 6 8 12 20 24 32 40/48

Overload 150% - 10 sec. 125% - 600 sec. Fuse clearing 30 % rated type (GSG).

Installation Information. Dimensions Height - mm 1700 2215 2215 2215 2215 2215 2215 (230 V o/p) Width - mm 800 800 800 800 800 800 800 Depth - mm 800 800 800 800 800 800 800 Protection. IP Class. 30 41 41 41 41 41 41 Cable Entry. / Panel Mounting Bottom / Floor mounted (stationary application).Clearance. Front - mm 1000 1000 1000 1000 1000 1000 1000Recommended Sides. - mm 500 500 500 500 500 500 500 Back. - mm 1000 1000 1000 1000 1000 1000 1000 Top. - mm 500 500 500 500 500 500 500 Audible noise at 1m (dB) 60 60 60 60 60 65 65 Operating Conditions Ambient Temperature. -10 to 50 deg C.- no derating required. Altitude. 2000 Mts. max. From MSL. Humidity. 95 % RH - non-condensing. Atmosphere. Non corrosive, dust free, free air - ventilated. Thermal (Typical) Efficiency @ 100% Load AC-AC 86 87 88 88 88 88 88Efficiency @ 50% Load AC-AC 81 82 83 83 83 85 85

NOTE Above mentioned specifications are for std models. Refer to the purchase contract for specific details / custom specifications.

3. Operation


3.1 Location reference.

FIG 3.1

3. Operation


3.1 Location reference. contd. ...

FIG 3.2

No. Des. Description No. Des. Description 01 TA1 Power Terminals 02 TA2 Pot. Free terminals &

aux. Term 03 CBA/

CBI Alternate and input circuit breaker/isolator.

04 CBB Battery circuit breaker

05 MBS Manual Bypass switch 06 CTD DC current sensor 12 H2 Inv. Control Card 13 H3 Charger Control card 16 H16 Rect. Sharing card 17 H10 Parallel Buffer Card 19 H9 Rev. Polarity protection card 06 CTO Output Current CT ** - Used to isolate a Parallel connected Rectifier/Charger (applicable only for configurations with Parallel Chargers).

3. Operation


3.2 Energization.

• Energization of a module shall be done after the necessary installation checks. • This is NOT a routine operation. I is recommended that the UPS system

ramin in ON condition ALWAYS and should NOT be switched OFF in the evenings or during holidays, unless absolutely necessary.

Preconditions Input (Mains) supply CBI OFF Alternate (Bypass) supply CBA OFF Battery isolator CBB OFF Maintenance bypass switch MIS NORMAL Mains, Alt [Aux. ON] & Batt. supply at terminals - Available

• Follow the energization procedure in steps & in the sequence mentioned in the procedure.

• Non compliance to the procedure can result in serious injury to the personnel as well as damage to the equipment.

The UPS module has High voltage supplies connected to the Input / Output terminals. Don’t open the safety shrouds or touch metallic parts , wires , PC cards , etc. without ensuring that there are NO voltages present.

Energization should to be performed by qualified personnel ONLY. Who have specifically practiced the above procedure during training.

Procedure (Sequenced) 1. Switch CBI (Input breaker/isolator) to ON position. Wait for 1 minute. 2. Switch CBB (battery breaker/isolator) to ON position. 3. Switch CBA (alternate breaker/isolator) to ON position. 4. Switch MIS (Module Isolator switch) to ON position. 5. Close the front door. -Energization complete! Module ready to start. 6. Give Start command from the front door Red Key pad

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3. Operation


3.3 Start / Stop. The UPS module inverter can be started or stopped using the START / STOP key. This key works

to toggle the state of the UPS inverter.

NOTE • The START / STOP key must be kept depressed for aprox. 3 sec’s in order to initiate the action.

(This is incorporated to disregard unintentional stopping of the Inverter.)

NOTE • The UPS inverter is designed for continuos operation as such start / stop operation may not be required.

• It is recommended that the UPS be left ON as far as possible.

• Stopping both the UPS inverters in redundant configuration may cause a transfer to the Alternate supply (if available & synchronized). High voltage supply will still be available at the terminals & at the LOAD.

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3. Operation


3.4 Isolating a UPS module.

• Isolation is required to repair / maintain a Faulty module ONLY. • This is NOT a routine operation. Applying this procedure to a healthy module

may lead to discontinuity of power to the load.

Preconditions

Module Faulty (Pending Faults displayed on LCD) Fault - - - - - - - - -

• Follow the isolation & de-energization procedure in steps & in the sequence mentioned in the procedure.


• Capacitors inside the UPS module can store charge for a long time. Before touching such parts ensure that these have completely discharged and NO harmful voltage is present.

Isolation & De-energization should to be performed by qualified personnel ONLY. Who have specifically practiced the above procedure during training.

Procedure (Sequenced) 1. Give the stop command from front door Red Key pad 2. Open the Front door. 3. Switch MIS to OFF position. 4. Switch CBA to OFF position. 5. Switch CBB to OFF position . 6. Switch CBI to OFF position. 7. Wait for 5 minutes. 8. Close the front door. - Module Isolation complete!

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3. Operation


3.5 Re-connecting a UPS module.

• Re-connecting of a module, to the common AC bus, is done after completing the necessary repairs / maintenance of Faulty module.

• This is NOT a routine operation.

Preconditions Input (Mains) supply CBI OFF Alternate (Bypass) supply CBA OFF Battery isolator CBB OFF Maintenance bypass switch MIS OFF Mains, Alt & Batt supply at terminals - Available

• Follow the energization procedure in steps & in the sequence mentioned in the procedure.


The UPS module has High voltage supplies connected to the Input / Output terminals. Don’t open the safety shrouds or touch metallic parts, wires, PC cards, etc. without ensuring that there are NO voltages present.

Energizing & re-connecting should to be performed by qualified personnel ONLY. Who have specifically practiced the above procedure during training.

Procedure (Sequenced) 1. Switch CBI to ON position. 2. Wait for 1 minute. 3. Switch CBB to ON position. 4. Switch CBA to ON position. 5. Switch MIS to ON position 6. Give the start command from the front door Red Key pad 7. Check the front panel LCD for any pending Faults. Incase of

pending Fault - DONOT proceed - Consult HI-REL. 8. Close the front door. - Re-connection complete!

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5. Dealing with Faults & Alarms


4.1 LED Mimic The LED Mimic provides a one shot overview of the UPS module. 4.2 Monitoring & Control software. The monitoring & control software of the I4 UPS module has been divided into two modes - 1) User Mode (unrestricted access) Provides monitoring / control of - → Metering parameters like voltage, current, frequency, etc at various points. → Alarms that may arise & require attention. Up to 10 pending alarms can be viewed.

NOTE - The Alarm menu is active only if there are pending alarms. Otherwise the display will show < HI-REL UPS! > In place of the Alarm menu.

NOTE An ALARM is a violation of the specified operating conditions on which the UPS module has no direct control. (E.g. Input over voltage).

→ Alarm Log - All alarms are logged in a nonvolatile memory along with a date-time stamp. The Alarm log holds information on the last 10 Alarms & works on FIFO basis.

→ Fault Log - All faults are logged in a nonvolatile memory along with a date-time stamp. The Alarm log holds information on the last 10 Alarms & works on FIFO basis.

NOTE A FAULT is a violation of the preset parameters, which the UPS module should have controlled but did not, in favor of other priorities. (e.g. IGBT limb fault - in favor of protecting the IGBTs from an overload / short-circuit on the load side)

→ System status parameters like Battery charging mode, Phase lock with Alt supply, etc. → Real time clock - dates & times setting. Control - Manual initiation of Battery boost charging & Static switch transfer / re-transfer. 2) Service Mode (restricted access - not available to the general user)

Charger ON Green Indicates that the rectifier / charger is ON & the battery bank (if connected) is being charged.

Battery ON Green Indicates that the battery is connected with the UPS. CBB and Battery fuse are in healthy condition

Float/Boost Green/Red Indicates whether the charger/ rectifier is charging the battery in float mode or in boost mode.

Alternate ON Green Indicates that the Alternate supply is ON. Inverter ON Green Indicates that the Inverter output is ON. Static switch Position Normal

Green Indicates that the static switch position is normal & the load is connected to the inverter output.

Alarm RED (flashing)

Indicates that there is a FAULT or an ALARM pending. (details of which are available on the LCD display)



• The service mode allows access to vital settings, calibrations, etc. Tampering with these can result in serious damage to the equipment.

• DO NOT attempt to gain forced access to this mode.

4.3 Program Navigation (User mode).

POWER ON

POWER ON SELF TEST

<ALARM> ALARM SUBMENU

<METERING> METERING SUBMENU

<SYSTEM STATUS> SYS STATUS SUBMENU

<ALARM LOG> ALARM LOG SUBMENU

<FAULT LOG> FAULT LOG SUBMENU

<CLOCK> CLOCK SUBMENU

! CAUTION



<CONTROL> CONTROL SUBMENU

4.3.1 Alarms. → A pending Alarm is displayed in the submenu along. → A total of 10, currently pending alarms can be displayed. → The following alarms are monitored -

• Input - Over voltage, Under voltage. • Battery - Discharging, End of discharge • Inverter - Under voltage, Overload • Alternate - Over voltage, Under voltage, Frequency out of sync limits. • Static switch - Transfer to alternate. • System - Over temperature, Service mode accessed.

Alarm menu navigation

ALARM SUBMENU

<ALARM> NO #1 <ALARM NAME>

NO #2 Return to Alarm menu <ALARM NAME>

NO #10 Return to Alarm menu <ALARM NAME>

Display example (Alternate supply Under voltage)



NO #1

# ALT UV similarly for other alarms.

.3.2 Metering.

→ Up to 3 meters (max), related to one parameter are displayed in a submenu. NOTE The meter readings displayed are accurate within +/- 2% with reference to the

nominal values and are for general indicative purposes only. For more precise measurements, dedicated instruments are recommended.

→ The following parameters are metered. • Voltage - Alternate, Input (3ph), Inverter, Load • Current - Alternate, Inverter, Load • Frequency - Alternate / (Bypass), Inverter, Load

Metering menu navigation METERING SUBMENU

<METERING> IN R xxx . xx V

IN Y xxx . xx V Return to Metering menu

LOAD xxx.xx V xxx.xx A xx.xx Hz

Display example (Input YB line)

IN Y 415. 00 V



similarly for other meters.

4.3.3 System Status.

→ Monitoring the status of the static switch & rectifier / charger. → Load on Inv. / Alt - shows the current position of the static switch (also indicated by the LED

mimic) → Battery charging / discharging mode. → Charger mode Boost (available for Ni-Cd & LATB batteries only). → Status of the phase lock between Inverter & Alternate.

SYS STATUS SUBMENU

<SYSTEM STATUS> LOAD ON INV

BATTERY Return to SYS Status menu CHARGING

PHASE LOCK Return to SYS Status menu ON

4.3.4 Alarm Log.

→ All alarms (currently pending as well as those that have been cleared) are logged. → The log stores a max of 10 alarms along with the date-time stamp of occurrence.



→ The log works on a FIFO (First In First Out) basis, as such will display the last 10 alarms that have occurred.

ALARM LOG SUBMENU

<ALARM LOG> LOG #1 <ALARM NAME> dd:mm:yy hh:mm

LOG #2 <ALARM NAME> Return to Alarm Log menu dd:mm:yy hh:mm

LOG #10 <ALARM NAME>Return to Alarm Log menu dd:mm:yy hh:mm Display example (Inverter Under voltage)

LOG #10 INV UV 01:01:96 19:05

similarly for other meters.

4.3.5 Fault Log.

→ All faults (currently pending as well as those that have been cleared) are logged. → The log stores a max of 10 faults along with the date-time stamp of occurrence.



→ The log works on a FIFO (First In First Out) basis, as such will display the last 10 faults that have occurred.

→ The following faults are monitored & logged - • DC - Over voltage. • Inverter - Over voltage, Overload (trip), Limb1 & 2 -SAT (trips) • Control - CPU fault.

FAULT LOG SUBMENU

<FAULT LOG> LOG #1 <FAULT NAME> dd:mm:yy hh:mm

LOG #2 <FAULT NAME> Return to Fault Log menu dd:mm:yy hh:mm

LOG #10 <FAULT NAME> Return to Fault Log menu dd:mm:yy hh:mm

Display example (Inverter Over voltage)

LOG #10 INV OV 01:01:96 17:05

Similarly for other meters.

4.3.6 Clock.

→ A real time clock provides the basis for date-time stamping of logged events such as Alarms & Faults.



→ The clock will remain active as long as the UPS module is energized. → Setting of the clock parameters may be necessary after each energization. It is also

recommended to check / set the clock at regular intervals (aprox 2 weeks). CLOCK SUBMENU

<CLOCK> TIME hh.mm . ss

DATE Return to Clock menu dd . mm . yy

Clock setting

Procedure To change the Time / Date parameters in the Clock submenu 1. Press to activate a flashing cursor under the parameter. 2. Use scroll keys to increase or to decrease the value 3. Press to record the new value. 4. Use scroll keys to move the flashing cursor to the next

parameter. 5. Repeat steps 2 & 3 to record new value. 6. Press once again to complete recording of the new values in the

submenu.

4.3.7 Control.

→ Allows manually initiated transfer / re-transfer’s of the load via the static switch for Bypass & Return from Bypass operations (refer sec 3)



CONTROL SUBMENU

LOAD TRANS TO Return to Control menu INV

Procedure To change the parameters in the Control submenu 1. Press to activate a flashing cursor under the parameter. 2. Use scroll keys or to toggle the setting. 3. Press to record the new setting. 4. Press once again to complete recording of the new settings in the

submenu.

NOTE The I4 UPS module has a large number of control parameters. All other

parameters are available in the “Service mode” only. Setting of these parameters requires considerable understanding / training on the I4 UPS module.

5. Dealing with Faults & Alarms 5.1 Alarms

NOTE • A pending alarm is indicated by the summary alarm LED on the LED mimic.



• Details of the alarm are available on the LC display. Alarm Possible cause Actions Input Under voltage 1. Mains Failure / supply

problem 2 .Calibration error

1. If the condition is persistent you may have to install an additional step-up transformer Consult HI-REL. 2. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Input Over voltage 1. Mains supply problem 2. Calibration error

1. If the condition is persistent you may have to install an additional step down transformer Consult HI-REL. 2. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Battery discharging 1. Mains supply voltage is too low or has failed. 2. Charger Failure.

1. Power is being drawn from the reserve (battery) unless the mains supply resumes. Check the backup time available / ordered & initiate load shutdown action accordingly.

End of discharge 1 Reserve (battery) power has been nearly exhausted.

1. You only have aprox 5 minutes of battery backup left - Initiate load shutdown IMMEDIATELY.

Inverter Under voltage 1. The inverter output is overloaded & Alt supply is not available for transfer. 2. Calibration error.

1. Remove excess load. 2. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Inverter Overload 1. The inverter output is overloaded & Alt supply is not available for transfer. 2. Calibration error.

1. Remove excess load IMMEDIATELY or else the inverter may trip. 2. Measure actual value with a multi meter & if found to be in specified limits - Try starting the inverter & if unsuccessful Call for service support.

5.1 Alarms contd. ... Alarm Possible cause Actions



Alternate supply Under voltage

1. Alternate supply problem. 2. Auxiliary module (stabilizer) problem - if incorporated. 3. Calibration error.

1. If the condition is persistent you may have to install an auxiliary module (stabilizer) 2. If you have a stabilizer in the Alt supply line it has developed a fault. - See the operation manual of the Auxiliary module (stabilizer) - consult HI-REL. 3. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Alternate supply Over voltage

1. Alternate supply problem. 2. Auxiliary module (stabilizer) problem - if incorporated. 3. Calibration error.

1. If the condition is persistent you may have to install an auxiliary module (stabilizer) 2. If you have a stabilizer in the Alt supply line it has developed a fault. - See the operation manual of the Auxiliary module (stabilizer) - consult HI-REL. 3. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Alternate supply frequency out of sync limits.

1. Alternate supply problem. 1. If the condition persists - - Check the acceptable frequency range for your load. (Default setting = 50Hz +/- 2%) - The I4 UPS module can synchronize with an alternate frequency up to 50Hz +/- 6%. - Contact HI-REL if you need to get the frequency range extended.

Static switch transfer to Alternate.

1. Inverter is overloaded 2. Inverter has tripped 3. Manual transfer has been Initiated.

1. Remove excess load 2. Check Fault log - if the inverter has tripped - consult HI-REL. 3. Manual transfer.- re-transfer the load back to the inverter. (see section - )

MCB trip CBALT CBM CBF1--

- Control transformer failure - Control transformer failure - Fan failure

- - Consult HI-REL -

Service mode accessed

1. The service mode software has been accessed.

1. Ensure that this is being done by an authorized person.

5.2 Faults.

NOTE • A fault is also indicated by the summary alarm LED on the LED mimic. • Details of the fault are available in the Fault log - the LC display.



Fault Possible cause Actions DC Over voltage. 1. Rectifier control problem.

2 .Calibration error 1. Call for service support. 2. Call for service support.

Inverter Overvoltage 1. Inverter control problem 2. Calibration error

1. Call for service support. 2. Measure actual value with a multi meter & if found to be in specified limits - Call for service support.

Inverter Overload trip. (This trip is inverse time acting -i.e.: more the overload faster the trip.)

1. The inverter output was overloaded & Alt supply was not available for transfer. 2. Calibration error.

1. Remove excess load. 2. - Try starting the inverter & measure actual value with a multi meter & if found to be in specified limits or & if unsuccessful - Call for service support.

Inverter Limb 1 or Limb2 fault - trip.

1. The inverter output was severely overloaded & Alt supply was not available for transfer.

1. Check load side for overload / short circuit - Remove fault. 2. - Try starting the inverter & if unsuccessful - Call for service support.

CPU fault - trip. 1. Control system failure. 2. Serial link between System manager & System control failure

1. Call for service support. 2. Call for service support.

Over temperature trip

1. Cooling fan failure. 2. Excess load. 3. Ambient temperature above specified limits.

1. Call for service support. 2. Reduce load & try to start the unit - if unsuccessful -Call for service support. 3. Measure the ambient temperature at aprx 1mt from the unit - if found in excess of specified limits - take actions to reduce it (room ventilation, a/c, etc.) - wait for aprox 20 min. to allow cooling & try to start the unit - if unsuccessful -Call for service support.

5.3 Service calls. • Accurate & timely information greatly helps us in preparing for a service call. In turn the

service rendered is of a better quality, reducing the down time. • You may place a service call at any of the HI-REL support offices.

NOTE • Please check the terms & conditions of your service contract with us.



The following information (at the minimum) should be communicated. 1. Unit Serial number & KVA rating. 2. LC display - ALL 10 logs in the ALARM LOG along with date & time stamp. 3. LC display - ALL 10 logs in the FAULT LOG along with date & time stamp. 4. LC display - ALL 10 pending alarms in the ALARM menu. 5. LED mimic status. 6. A brief description of the nature of problem. 7. All actions taken at your end before issuing the service call. • A service call may be placed by fax / phone.

6. Maintenance


6.1Cleaning.

NOTE • It is presumed that the UPS module is installed & maintained in a room with conditions complying with those specified in the Technical specifications. (refer section 2.2 of this manual)

• To Clean the UPS module from outside (door closed).

→ Use a clean, soft piece of cloth. → Slightly dampen the cloth with water. → Wipe the panels gently.

• DO NOT use corrosive chemicals or soap to clean the panels. • DO NOT open the front door or side covers while cleaning. • DO NOT attempt cleaning the UPS module from inside. • This requires de-Energization and will be done during scheduled

maintenance visits by authorized service persons. 6.2 Preventive checks.

NOTE • It is advisable to maintain a log book for recording the results of preventive checks & report abnormal behavior to seek service support.

Check Action / Remark Daily Weekly Monthly

Key pad - LCD - LED LED Mimic Record status yes - - Clock setting Record - reset if required - yes - Alarm log Record - report - correct yes - - Fault log Record - report - correct - yes - Environmental conditions General cleanliness . Ensure that the room / space is clean. - yes Ambient temperature Record in the afternoon using a

mercury thermometer in the 1m vicinity of the UPS module

- yes -

Inside the UPS module Burning smell , Visual damage, rattling sound.

Open the front door, do not touch any parts.

- - yes

Corrosion, arcing at terminals

Open the front door, do not touch any parts.

- - yes

The UPS module has High voltage supplies connected. Don’t touch metallic parts , wires , PC cards , etc. when the front door is open.

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DANGER

6. Maintenance


6.3 Service contracts.

• In case of problems, seek service support from Hi-Rel sources only. • DO NOT try to repair / replace components on your own.

• It is advisable to enter into a Maintenance / Service contract upon expiry of the warranty period. • It is recommended that the UPS module be serviced by a qualified person once a year. The

necessary shutdown / de-Energization should be planned accordingly. • Please refer to your service contract agreement with us or contact your nearest HI- REL support

office.

! CAUTIO

7. Spares


7.1 Recommended spares. The concept of replace instead of repair reduces down time & increases availability of the equipment. Stocking of spares is recommended to ensure minimum down time.

NOTE • The spares & quantity recommended is based upon our acessment & experience. They are by no means exhaustive & may not be sufficient to take care of ALL eventualities.

Item description. Primary

Designator Recommended Quantity per module - KVA

7.5 10 15 20 30 40 50/60

System Control card♦ H2 1 1 1 1 1 1 1 System Manager card♦ H1 1 1 1 1 1 1 1 Rectifier control card♦ H3 1 1 1 1 1 1 1 IGBT gate driver card♦ H5 1 1 1 2 2 2 2 Switch mode power supply H4 1 1 1 1 1 1 1 Heat sink cooling fan 6” FAN 2 2 2 2 2 2 2 Inverter IGBT♦ TR 2 2 2 2 4 4 4 Thyristor module 56A TS / TC 3 3 - - - - - Thyristor module 91A TS / TC - - 3 3 - - - Thyristor module 131A TS / TC - - - - 3 2 2 Thyristor module 161A TS / TC - - - - - 1 1 Fuse 110A FA,FD 3 3 3 3 - - - Fuse 150A FA,FD - - - - 3 3 3 Fuse 300A FA,FD - - - - 3 3 DC filter capacitor CD 2 2 2 2 2 4 4 AC filter capacitor CO 2 2 2 2 2 4 4 Metal oxide Varistor RV 3 3 3 3 3 3 3

• Parts marked “♦” are STATIC sensitive. • DO NOT remove them prom the packing. • Store the spares in a cool & dry place along with the packing. • DO NOT subject them to any inspection / test except visual.

! CAUTIO

i4 ups module.xa.yimg.com/.../13724245/1943176420/name/hi-rel-10+… · · 2010-03-17i4 ups...

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