Sect 11

Section 11: Troubleshooting & Repair
Chapter 1 - Basic Troubleshooting Procedure

1.1 About Troubleshooting ........................................................................... 11-1
1.1.1 Introduction ................................................................................ 11-1
1.1.2 Troubleshooting aids .................................................................. 11-1
1.2 Basic troubleshooting (from Operator Control Panel metering) ............ 11-1
1.3 General troubleshooting procedure ........................................................ 11-2
1.3.1 Test equipment ........................................................................... 11-2
Chapter 2 - Fault diagnosis
2.1 Introduction ............................................................................................ 11-5
2.2 Interpreting the Operator Control Panel indications .............................. 11-5
Chapter 3 - Board Replacement & Calibration Procedures
3.1 Rectifier Logic Board replacement (Part N 4520074A) ..................... 11-27
3.2 Inverter Logic Board replacement (Part N 4530025T) ....................... 11-29
3.3 UPS Logic Board replacement (Part N 4550007H) ............................ 11-33
3.4 Operator Logic Board replacement (Part N 4550005F) ...................... 11-34
3.5 Static Switch Driver Board replacement (Part N 4542043Z) ............. 11-35
3.6 High Voltage Interface Board replacement (Part N 4590054O) ......... 11-36
3.7 DC DC Power Supply Board replacement (Part N 4503028K) ....... 11-37
3.8 AC DC Power Supply Board replacement (Part N 4503030M) ...... 11-38
3.9 Parallel Logic Board replacement (Part N 452007H) ......................... 11-39
Chapter 4 - Functional Check Procedures
4.1 Introduction .......................................................................................... 11-41
4.2 How to check the rectifier power components ..................................... 11-41
4.2.1 Short-circuit rectifier SCR ....................................................... 11-41
4.2.2 Open-circuit rectifier SCR ....................................................... 11-42
4.2.3 Shorted DC filter capacitor ...................................................... 11-42
4.2.4 Open-circuit DC filter capacitor .............................................. 11-43
4.3 How to check the inverter power components ..................................... 11-44
4.3.1 Short-circuit and Open-circuit IGBT ....................................... 11-44
4.3.2 How to check the inverter IGBTs ............................................ 11-45
4.3.3 Shorted AC filter capacitor checks .......................................... 11-47
4.3.4 Open-circuit AC filter capacitor checks .................................. 11-48
4.4 How to check the Static Bypass power components ............................ 11-49
4.4.1 Short-circuit bypass SCR checks ............................................. 11-49
S-10.FM5 - Issue 2 Dated 21/08/97
SECTION 11 - Troubleshooting & Repair
7200 Series UPS Service Manual
4.4.2 Open-circuit bypass SCR ......................................................... 11-50

4.4.3 Output contactor failure ........................................................... 11-51
ii
S-10.FM5 - Issue 2 Dated 21/08/97
Section 11:
Chapter 1 - Basic Troubleshooting Procedure
1.1
About Troubleshooting
1.1.1
Introduction
The UPS equipment contains complex electronic control circuits which require a
firm understanding, and often specialist microprocessor monitoring test equipment, in order to carry out comprehensive fault diagnosis and repair. The troubleshooting information contained in this chapter therefore aims to provide sufficient
guidance to assist a trained engineer to locate and replace a faulty major component, or printed circuit board. All faulty circuit boards should be returned to the
nearest service centre for repair.
1.1.2
Troubleshooting aids
The UPS contains numerous indicators to assist in fault diagnosis. These take the
form of:
Operator Control Panel metering
provides indication of battery (DC Bus) voltage and charge/discharge current; and output voltage, current and frequency.
Operator Control alarm messages
provides various alarm and status information.
Operator Control module status leds
provides an indication of the operational status of the module isolators and
functionality of the major assemblies.
Circuit board mounted leds
indicates the status of various internal control logic signals
CAUTION
1.2
It is necessary to gain internal access to the UPS to observe circuit board mounted indicators; this should be undertaken only by trained personnel.
Basic troubleshooting (from Operator Control Panel metering)

Most UPS problems do not emerge as a gradual performance degradation; generally the UPS either works correctly or it will shut down - and transfer the load to
the bypass supply if applicable. However, it is important to maintain a regular
record of the UPS meter indications, as suggested in the maintenance instructions,
in order that any change in the system or load characteristics are readily identified.
In general, the output voltage on all three phases should be within 2% of nominal,
and the output line currents should not normally differ by more than 20%. If a
greater difference is noted, the load is likely to be unbalanced and should be redistributed more equally if possible.
Where the UPS has not operated on battery power within the previous ten hours
the battery charge current should typically be less than 10A.
If any meter indication differs significantly from normal the cause should be investigated.
S10-C1.FM5 - Issue 2 Dated 21/08/97
11-1
SECTION 11 - Troubleshooting
CHAPTER 1 - Basic Troubleshooting Procedure
Information concerning prevailing load conditions can prove useful when discussing problems with the service agent: for example, details of any particular
load being started or shed at the time of the fault occurrence.
1.3
General troubleshooting procedure

Troubleshooting should be carried out methodically along the following guidelines:
Fault Identification
When first summoned to the scene of a UPS fault, the immediate action should be
to observe and record the Operator Control Panel status and alarm messages, led
indications, meter indications and power isolator switch configuration. This
should be completed before touching ANY switch.
Corrective Action
When the mimic panel leds and meter indications have been noted, the next step
is to determine whether any led condition is abnormal. If an abnormal indication
exists then refer to the troubleshooting charts - beginning at the TOP LEVEL
chart.
If the mimic panel messages and led indications appear normal, but the meter display shows one or more of the operating parameters to be incorrect (for example,
incorrect output voltage), then refer to the calibration procedures and carry out
the appropriate PCB adjustment.
If the mimic panel messages, led and meter indications all appear normal but a
problem still exists (for example the UPS is emitting unusual noises), then contact
the nearest service centre for advice or assistance.
Fault Reporting
Irrespective of whether fault rectification is successful or not, please report all

fault occurrences to the nearest service centre who will then forward details to the
manufacturer. This type of user feedback is an important factor in maintaining
high product reliability.
1.3.1
Test equipment
As mentioned above, some of the microprocessor-base control boards require
specialist test equipment to analyse on-board problems, and is unlikely to be
available during standard site troubleshooting exercises. In order to carry out general troubleshooting to board-replacement level, and undertake the check procedures contained later in this section, the following test equipment will be
required:Oscilloscope
A dual-beam oscilloscope is essential as is the ability to sum the two channels for
making differential voltage measurements. A storage facility is useful but not essential.
DVM
The a.c. voltages quoted in the check procedures assume that a true r.m.s. reading a.c. voltmeter is used.
11-2
Frequency meter
If a digital frequency meter is not available an oscilloscope may be used to measure waveform periods, although this is obviously less accurate.
Logic Probe
A general TTL / CMOS logic probe will be useful in detecting LF pulses etc.
Current meter
An AC/DC current meter is useful for checking internal current readings. Unbalanced, or incorrect, readings can assist in isolating faulty components and UPS
power section, and is especially useful for identifying faulty filter capacitors. An
appropriate current outlet to the oscilloscope is also beneficial.
WARNING
Some of the instructions in the charts at the end of this chapter involve checking
internal fuses. This should be undertaken (after the equipment has been shut
down) only by a trained electrician who is familiar with the layout and operation of
the equipment and fully conversant with the areas of potential hazard.
Caution
The following diagnostic charts are designed for 'first aid' trouble shooting only. If
a problem cannot be resolved by taking the actions given then fully trained assistance should be sought immediately.
Do not under any circumstances make internal circuit adjustments or interfere
with the circuit boards in any other way.
11-3
11-4
Section 11:
Chapter 2 - Fault diagnosis
2.1
Introduction
This chapter provides information necessary for carrying out initial fault diagnosis through the correct interpretation of the Operator Control Panel LED indicators and alarm messages.
Detailed troubleshooting charts are not provided at this stage; but appropriate
cross-references are made to the following text and procedures in order to further
trace the cause of an abnormal condition:
Circuit board replacement procedures (chapter 3)
Functional check procedures (chapter 3)
Detailed circuit operation and adjustment information (earlier sections)
2.2
Interpreting the Operator Control Panel indications

LED Indicators
The Operator Control Panel LED indicators are shown in Figure 11-1 and described in detail in Table 11-1, on the following page.
Figure 11-1: Operator Control Panel LED indications
Display panel message interpretation
The messages displayed on the 7200 can be categorised into two types:
a) ALARM messages - are messages which need urgent attention and warn
of a UPS shutdown or imminent shutdown - the load would normally
transfer to the bypass supply if it is available. All alarm messages are
accompanied by an audible warning.
b) WARNING messages - these are messages generated to warn or confirm
to the operator of actions taken (i.e. if the rectifier a.c. input supply power
switch was opened the Warning message would read - RECTIF. SWITCH
OPEN).
Table 11-2 lists the various messages displayed on the Operator Control Panel together with a description of their interpretation
s10-c2.fm5 - Issue 2 Dated 21/08/97
11-5
Table 11-1: Operator Control Panel LED indication
(Sheet 1 of 2)
Normal
State
ON
If this green led is OFF it signifies a problem with the bypass input a.c.
mains supply.
Check the following:

a) Bypass input power switch Q2 is closed.
b) Input supply voltage is within 20% of nominal.
c) Power supply fuses are OK - LS1, LS2 on the a.c. Power Supply
board will extinguish if either fuse is ruptured.
If the above checks prove unsatisfactory then seek qualified assistance.
ON
If this green led is OFF it signifies that the inverter is not producing its
correct output voltage.

a) If [OVER TEMPERATURE] OR [OVERLOAD] alarm messages
are active then (after allowing the UPS to cool, checking that the
load current on the bypass line is not excessive) press the reset
switch (S1) on the UPS Logic Board.
b) If the d.c. busbar is below 320V d.c. for 380 V a.c. system, 330V
d.c. for 400 V a.c. system or 340 V d.c. for a 415 V a.c. system
then do the checks as per Rectifier Block'- input failure items
15,16,17 & 18 in Table 11-2.
c) If the inverter works OK when mains is available but not when
mains is unavailable then check the battery power fuse F13.
If the above checks prove unsatisfactory then seek qualified assistance.
OFF
If this yellow led is ON (flashing) then it signifies that the load has been
transferred to the static bypass supply.
If this is an automatic change over it will be accompanied by a fault

warning on the display panel, take the appropriate actions for the display
indication (See Table 11-2).
OFF
If this yellow led is on it signifies that the battery is not available. This
could be due either to, the battery circuit breaker being open or that the
d.c. busbar voltage is below the figures stated in (2) above.
The battery circuit breaker will open automatically if the d.c. voltage falls
below these levels.

a) Battery circuit breaker is closed.
b) DC busbar voltage - if not above 320V then carry out checks as
per 1 (mains failure) above. If the d.c. busbar voltage is greater
than 320V but you are unable to close the battery circuit breaker
then seek qualified assistance.
c) If the battery circuit breaker trips as soon as mains power is disconnected then check the battery power fuse (F13).
Interpretation
Continuously ON = DC undervoltage
Flashing = CBB open or Battery fuse failure
Diagnostic - Action
Item
Number
CHAPTER 2 - Alarms & Indications
11-6
Item
Number
Normal
State
N/A
This is a bar graph indicating the% of the total load that is being applied
to the system. Under normal running conditions several of these LEDs
would be ON i.e. the LEDs indicate in 20% steps the current drawn
from the greatest loaded phase.
N/A
This is a bar graph indicating the battery charge state and would normally have four or five of the LEDs ON. When the unit runs on battery,
this bargraph changes to give an indication of the time remaining on battery as a percentage of the total autonomy time.
When charging, each segment indicates 20% available capacity. When
discharging each segment indicates 2 minutes autonomy remaining
with all 5 segments being illuminated if the autonomy time is above
10minutes.
Interpretation
OFF
If this yellow led is ON it signifies that the applied load has exceeded the
maximum. It will be accompanied by all five load bargraph LEDs being
ON (item 5), the Alarm warning indication flashing RED (item 9) and an
OVERLOAD message on the visual display. This will be accompanied by
an audible warning.
OFF
If this yellow led is ON it signifies that the battery voltage is low and that
the end of battery discharge is near (normally two minutes). This will be
OFF
This red LED indicates that the UPS has detected a fault, and will be
accompanied by a message on the display panel. Take the required
actions for the display panel message (See Table 11-2). This will be
Continuously ON = ALARM message
Flashing = WARNING message
None
During battery charge, examine the % Battery Charge state using the
MEASURMENT menu on the Operator Control Panel. The number of

illuminated segments should approximate to the displayed valued.
During battery discharge, the autonomy time remaining should automatically be displayed on the DEFAULT menu screen
Reduce the load immediately.

The overload algorithm follows an inverse time/load characteristic and, if
exceeded, the load is transferred to the bypass and the overload latch is
triggered. Reset the latch by means of the RESET switch on the UPS
Logic Board.
11-7
Diagnostic - Action
Table 11-1: Operator Control Panel LED indication (Continued) (Sheet 2 of 2)
CODE
Display Alarm Messages

(Correct Meaning)
01
[ NORMAL OPERATION ]
02
[ BYPASS SWITCH OPEN ]
03
[ OUTPUT SWITCH OPEN ]
04
[ RECTIF. SWITCH OPEN ]
05
[ BATTERY SWITCH OPEN ]
06
[ MANUAL BYPASS CLOSED ]

(maintenance bypass
breaker closed)
Details
Rectification
The state of the Circuit Breakers is sensed by monitoring their

auxiliary contacts, which in all cases are closed when the
associated circuit breaker is closed.
1. If the indicated circuit breaker status does not agree with the
true position then carry out a check of the auxiliary contact
monitoring circuit and rectify as required.
The sense signal route passes from the circuit breakers,

through the HVIB (see paragraph 2.3.7 on page 7-8), to the
UPSLB, where they are buffered by D2 (see paragraph
3.3.11.2 on page 7-39) and D1 (see paragraph 3.3.11.3 on
page 7-40).
The resulting digital sense signals are processed by the micro
which then passes the alarm data to the Operator Logic Board
and then on to the LCD Display.
2. If a fault is found on the HVIB then replace it (see paragraph 3.6 on page 11-36).
3. If the inputs are correct to the UPSLB buffers then replace
the UPSLB (see paragraph 3.3 on page 11-33).
11-8
Table 11-2: Alarm messages
NOTES:
If [#02] is active it disables [#10], [#11], [#12], [#13] and [#16]

If [#04] is active it disables [#22]
If [#05] is active it disables [#52], [#53], [#56], & initiates the
mimic display battery fault LED4 to flash

(Correct Meaning)
10
[ BYP: ABSENT ]
(bypass supply <50Vac)
11
[ BYP: OVERVOLTAGE ]
(bypass supply over voltage)
12
[ BYP: UNDERVOLTAGE ]
(bypass supply under voltage)
Details
Rectification
These alarms are enabled only if the bypass circuit breaker is

closed (see alarm #2) and indicates a voltage error on the
bypass supply.
1. First verify that the bypass voltage presented to the module

is within the selected voltage range, and rectify the external
supply if it is found to be faulty.
The alarms are triggered by a bypass voltage monitoring function of the UPSLBs micro (see paragraph 3.3.14.1 on page 759) which senses the three-phase bypass supply via buffered
attenuators the HVIB (see paragraph 2.3.6 on page 7-8).
2. Verify that the input MAX. and MIN values programmed in

the SETUP/VOLTAGE menu screen are appropriate and reprogram if necessary.
The alarm thresholds are programmable via the SETUP/

VOLTAGE menu screen (+10% -15% default setting) (see paragraph 2.4.5 on page 2-33).
In addition to controlling these alarms, the monitoring function
also controls the bypass supply LED (green) on the mimic
display.
13
[ BYP: FREQUENCY ERROR ]

(bypass supply is
over/under freq)
The alarm window threshold is programmable via the SETUP/

FREQUENCY menu screen (2% default setting)
(see paragraph 2.4.5 on page 2-33).
In addition to controlling the alarm, the monitoring function also
controls the bypass supply LED (green) on the mimic display.
The alarm is disabled if the bypass supply isolator is opened.
1. First verify that the bypass voltage presented to the module

is within the selected frequency range.
2. Verify that the SYNC WINDOW value programmed in the
SETUP/FREQUENCY menu screen is appropriate and reprogram if necessary.
3. If step 1 & 2 are OK then measure the R-phase sense signal
to the UPSLB. If this is correct then replace the UPSLB (see
paragraph 3.3 on page 11-33); if the monitored voltage is
incorrect then check wiring/connections to HVIB and if this is
correct replace the HVIB (see paragraph 3.6 on page 11-36).
11-9
This alarm is triggered by a bypass frequency monitoring function of the UPSLBs micro (see paragraph 3.3.13 on page 755) which senses the bypass supply R-phase via the same
signals used by the Input Voltage monitoring alarms described
in alarms #10 - #12 above (see page 7-59).
3. If step 1 & 2 are OK then measure the sense signals to the

UPSLB. If these are correct then replace the UPSLB (see paragraph 3.3 on page 11-33); if the monitored voltages are incorrect then check the wiring/connections to HVIB and if this is
correct then replace the HVIB (see paragraph 3.6 on page 1136).
CODE
14

(Correct Meaning)
[ BYP: PHASE ROT. ERROR ]
(bypass phase rotation error)
Details
Rectification
This alarm is triggered by a detection circuit on the UPSLB

which monitors the R and S phase bypass voltages and signals an error to the micro control system (see page 7-60). The
sensed voltages are the same as those used by the Input Voltage monitoring alarms (see page 7-59).
1. First verify that the rotation of the bypass supply presented

to the module is correct, and rectify if found to be in error.
The alarm threshold is fixed by component values.

In addition to controlling the alarm, the monitoring function also
controls the bypass supply LED (green) on the mimic display.
This alarm also enables alarm [#16].
15
[ BYP: SCR FAILURE ]

(bypass scr open cct)
This latched alarm is triggered by a detection circuit on the

UPSLB which monitors the voltage drop across the bypass
SCRs (see page 7-31). It monitors both the 3-phase bypass
voltage and UPS output voltage (see page 7-63).
Analogue circuits on the UPSLB process the sense voltages
via attenuator circuits on the HVIB (see paragraph 2.3.4 on
page 7-7) and also (see paragraph 2.3.6 on page 7-8).
[ BYP:HARDWARE BLOCK ]
(bypass supply blocked)
3. If the R-phase or S-phase sense signal to the UPSLB is

missing there will be other active alarms concerning the
bypass voltage. If no such alarm is present then the problem is
with the UPSLB phase-rotation monitor circuit.
4. Check-out the monitor circuit (see page 7-60) or replace the
UPSLB (see paragraph 3.3 on page 11-33).
1. Attempt to reset the alarm using S1 on the UPSLB.
2. With the module shut-down (maintenance bypass). Check
the bypass SCR for open circuit ((see paragraph 4.4 on page
11-49)). Also check the gate drive connections.
3. If the SCRs are OK then check the bypass voltage and output voltage sense inputs to UPSLB via the HVIB, and repair/
replace as necessary.
4. If the signals to the UPSLB are OK then replace the SSDB
(see paragraph 3.5 on page 11-35).
This alarm is triggered by i.c. D22 on the UPSLB (see paragraph 3.3.7 on page 7-29) which, via the micro, inhibits the
static bypass circuit (BLK_MNS) in response to the presence
of various fault conditions.
The alarm is inhibited when the bypass power isolator is open
i.e. when [#02] is active.
1. Check the following (any one instigates this alarm) and carry
out the associated rectification:
a) Manual inhibit switch S1 is open (OFF) on the UPSLB.
b) Emergency Stop active (alarm #63).
c) Open Bypass SCR (alarm #15).
d) Incorrect bypass phase rotation (alarm #14).
When [#16] is active it disables [#17]
2. If no fault is found with the above checks then replace the

16
2. check for cross-wiring of R & S on the HVIB connector X6.
11-10
CODE
17

(Correct Meaning)
[ BYP:OFF VIA DISPLAY ]
(bypass blocked via operator
menu)
Details
This alarm is triggered by the micro on the UPSLB when the
Static Bypass has been inhibited manually, either from the
Operator Control Panel or remotely from the External Alarms
Interface Board (optional).
This alarm is enabled only if [#16] is inactive.
18
[ LOAD ON BYPASS ]
Rectification
1. Verify that the bypass has not been selected off via the
FUNCTION/NEXT_PAGE/LINE menu screen return the
selection to [ ON ] if required.
2. Verify that a remote bypass inhibit is not being applied via
the Alarm Interface Board 4590055P
If this alarm is active it will also activate [#16]
3. If neither of the above is calling for the bypass inhibit then

replace the UPSLB (see paragraph 3.3 on page 11-33).
This is a status alarm generated by the UPSLBs micro when

the load is transferred to the static bypass supply either intentionally or due to an inverter fault. It also causes the bypass led
(amber) on the mimic panel to be flashing. If ON continuously,
then the load is being held on bypass due to the UPS being
in the manual retransfer operating mode
1. Tend to any other active alarm that might be the cause of a

load transfer and rectify as necessary.
CODE
2. If no other fault alarm is present and the inverter is working

correctly but the load has not automatically transferred back to
the inverter the UPSLB might be configured in the manual
retransfer mode check the position of link X26 on the
UPLSB (See Table 7-8).
3. If no fault found then suspect faulty transfer control logic.
Replace the UPSLB (see paragraph 3.3 on page 11-33).
[ BYP: OVERTEMPERATURE ]
(static bypass
overtemperature)
This alarm is triggered by the UPSLBs micro in response to a

temperature monitoring thermostat on the Static Switch heatsink passed via the SSDB. This facility is not normally used.
If the alarm is active, check that link X11 on the Static Switch
Driver Board is made 1-2.
Note: 1 minute after the alarm is activated the static bypass is

stopped and alarm[#62] is latched on.
20
[ RECT: SOFTWARE BLOCK ]

(software block via the micro)
This alarm is triggered by a UPSLB software routine concerned with rectifier control, and is present when the input to
D23 pin 14 (REC-ON) is active (low) (See Figure 7-7) and
also (see page 7-33). This signal also triggers alarm #22.
11-11
Check the following conditions (any one of which instigates

this alarm) and carry out the necessary rectification:
1. Is the rectifier selected ON on the Operator Control Panel?
2. Is the Rectifier Fuse Fail alarm [#25] active?
3. Is the Rectifier Block active on the RLB (e.g. H7 = Power
supply fail; H8 = Ph. rotation error; H9 = input undervolts)? (If
problem then check out RLB and replace if necessary).
4. Is H10 lit on RLB only? (If so then problem is on the UPSLB
- replace if necessary).
19
21

(Correct Meaning)
[ RECT: OFF VIA DISPL. ]
(rectifier blocked via
operator menu)
Details
This alarm is triggered by the micro on the UPSLB when the
Rectifier has been inhibited manually, either from the Operator
Control Panel or remotely from the External Alarms Interface
Board (optional).
This alarm is disabled if alarm [#22] is active.
If this alarm is active then alarm [#22] is blocked.
Rectification
1. Verify that the rectifier has not been selected off via the
FUNCTION/NEXT_PAGE/RECTIFIER menu screen

return the selection to [ ON ] if required.
2. Verify that a remote rectifier inhibit is not being applied via
the Alarms Interface Board 4590055P
3. If neither of the above is calling for the rectifier inhibit then
replace the UPSLB (see paragraph 3.3 on page 11-33).
22
[ RECT: HARDWARE BLOCK ]

(hardware block via the
UPSLB)
This latched alarm is triggered by a UPSLB rectifier control

logic, and is present when the output from D23 pin 19
(ON_REC) is in its blocking state (low) (See Figure 7-7).
This output is affected by several rectifier inhibit signals (see
page 7-33).
This alarm is disabled if alarm [#21] is active.
If this alarm is active then alarm [#21] is blocked.
1. Check the following (any one instigates this alarm) and carry
out the associated rectification:
a) Manual inhibit switch S3 is open (OFF) on the UPSLB.
b) Emergency Stop active (alarm #63).
c) Fast/Slow DC Overvoltage (alarm #58 or #55).
d) Software rectifier inhibit (alarm #20).
e) Circuit Board power supply failure
11-12
CODE
2. If no fault is found with the above checks then replace the

23
This alarm is triggered by the UPSLBs micro in response to an

input current limit fault signal generated on the RLB. The operating threshold is calibrated by R17 on the RLB and led H6 illuminates on the RLB when an overload is detected (see
paragraph 2.3.4.2 on page 4-29).
1. If there is a genuine overload check out the rectifier SCRs,

DC filter caps, shorted battery, shorted inverter leg.AC filter
capacitors (see paragraph 4.3.3 on page 11-47).
2. If no genuine overload but H6 is illuminated, check out/
replace RLB (see paragraph 3.1 on page 11-27).
3. If H6 is extinguished the problem is likely to be either the
RLB issuing an erroneous fault signal (see page 4-29) or the
UPSLB is faulty: repair/replace as necessary.
[ RECT: CURRENT LIMIT ]

(rectifier input current limit)

(Correct Meaning)
Details
Rectification
24
[ RECT: OVERTEMPERAT. ]
(rectifier overtemperature)

temperature monitoring thermostat on the rectifier heatsink
passed via the RLB. The alarm can be overridden by fitting a
jumper link to X10 pins 2-3 on the RLB. This facility is not normally used
Note: 1 minute after the alarm is activated the rectifier is
stopped and alarm[#62] is latched on.
1. A genuine overtemperature condition may be due to:

a) Increased ambient air temp.
b) Restricted cooling air flow.
c) Prolonged rectifier overload under raised ambient temp.
d) Fan failure.
2. If not a genuine overtemp condition then check out wiring of
thermostats (n/c) through RGDBs and RLB to UPSLB.
25
[ RECT: FUSE FAIL ]

failure of a rectifier input fuse. This facility is reserved for larger
UPS modules and is not normally used for modules up to
60kVA. When not used, the facility is disabled by fitting a
jumper link to X17 pins 1-2.
As a genuine fuse fail condition is not normally monitored, any

activation of this alarm channel is usually caused by a false
alarm. If the alarm activates:
a) check the signal path from the HVI X17 pins 1-2 to the
UPSLB.
b) Replace the UPS Logic Board
30
[ INV: SOFTWARE BLOCK ]

(software block via the micro)
This alarm is triggered by the UPSLBs software routine and is

present when the input to D23 pin 6 [INV_ON> is active (low)
(See Chart 7-3).
Check the following (any one of which instigates this alarm)

and carry out any necessary rectification:
31
[ INV: OFF VIA DISPLAY ]

(inverter blocked via operator
menu)
a) Is the DC Bus is within its permissible range?

b) Is the inverter selected ON on the Operator Control Panel?
c) Is there an inverter block signal active on the Inverter Logic
Board (H11 = PCB power supply fail; H13 = Base drive lead
disconnected; H5-H10 = Desaturation detector active, investigate reason on ILB.
d) Is H12 (only) lit on the ILB? If so then replace the UPSLB.
e) Are any external blocks being applied to the UPS?
11-13
This alarm is triggered by the UPSLB when the inverter has

been inhibited manually; either from the Operator Control
Panel or remotely from the external Alarms Interface Board.
1. Verify that the inverter has not been selected OFF via the
FUNCTION/NEXT_PAGE/INVERTER menu screen return
the selection to [ON] if required.
This alarm is disabled if alarm #30 is active.
2. Verify that a remote inhibit is not being applied via the

Alarms Interface board (See Section 9 Chapter 1).
3. If neither of the above are commanding the inverter OFF
then replace the UPSLB.
When this alarm is present is disables alarm #31 and enables

alarm #32.
CODE
32

(Correct Meaning)
[ INV: HARDWARE BLOCK ]
(hardware block via UPSLB)
Details
Rectification
This alarm is triggered by the UPSLB inverter control logic and

is present when the output from D23 pin 15 [ON_INV> is in its
blocking state (low) This output is affected by several inverter
inhibit signals (see paragraph 3.3.7 on page 7-29).
Check the following (any one of which instigates this alarm)

and carry out any necessary rectification:
a) Is the manual inhibit switch (S2) open (OFF) on the UPSLB?
b) Is the Emergency Stop line active (alarm #63)?
c) Is the Fast/Slow Overvolts alarm active (alarms #58 & #55)?
d) Is the software calling for an inverter inhibit (alarm #30)?
e) Has the PCB power supply failed?
This alarm is disabled if alarm #31 is active.

33
34
[ INV: CURRENT LIMIT ]

(inverter current limit)
[ INV: OVERTEMPERATURE ]
(inverter overtemperature)
1. Check for a genuine reason for the fault indication by examining for shorts/burns etc. in the:
a) output transformer and associated cabling.
b) output filter capacitors and associated wiring.
c) inverter power stacks and associated cabling.
Note: the IGBT PWM pattern is limited appropriately to reduce

the inverter output voltage. This may lead to an increase in
pulsed current in the output transformer which causes an
increased audible noise.
2. If no reason for genuine alarm is apparent then:

a) if H14 is illuminated on the ILB determine the cause of the
erroneous overload detection and repair/replace as necessary.
b) if H14 is extinguished then replace the UPSLB.
This alarm is triggered by the UPSLBs micro in response to

the opening of a thermostat on one of the inverter power stack
heatsinks. This is designed to occur if the power stack reaches
90C the inverter is shut down (Alarm #62) if the condition
prevails for 1 minute following the alarm activation.
1. If overtemperature is genuine then check for and rectify:

a) any increase of ambient air temperature.
b) restricted cooling air flow.
c) fan failure.
d) prolonged inverter overload.
2. If overtemperature is not genuine then check continuity (n/c)
of thermostats and wiring through HVI to UPSLB. Replace/
repair cause of any open-circuit found. If no open-circuit is
found then replace UPSLB.
3. Verify that jumper X12 0-1 on the ILB is open (standard).
This alarm is triggered by the UPSLBs micro in response to an

inverter >150% current limit fault signal generated on the ILB.
The operating threshold is calibrated by R246 on the ILB and
LED H14 illuminates on the ILB when the threshold has been
exceeded, and the current limit is therefore active.
11-14
CODE
35

(Correct Meaning)
[ INV: UNSYNCHRONIZED ]
(inverter unsynchronised to
bypass)
Details
This alarm is triggered by a UPSLBs software routine which
detects when the inverter and bypass waveforms are misaligned by more than 9. The alarm resets automatically
when this condition is no longer true.
Rectification
1. If non-sync condition is genuine then check for and rectify:
a) bypass breaker open (alarm #02)
b) bypass supply error (alarms #10, #11, #12, #13, #14)
1. If non-sync condition is not genuine then check for and rectify:
a) recalibrate inverter phase displacement (R247 on the ILB)
b) increase the inverter slew-rate by use of the SPEED
selection in the SETUP menu.
c) Replace the UPS Logic Board.
d) Replace the Inverter Logic Board
36
[ INV: OVERVOLTAGE]
(inverter overvoltage warning)

detects when the inverter voltage goes above a maximum
level which is set by the % UPPER LIMIT menu selection on
the Operator Control Panel.
Note: if the load is on-bypass the inverter is given 10 seconds
to recover, otherwise the inverter is latched off. Use the reset
button to restart the inverter. If the bypass is available when
the fault occurs the load is transferred to bypass by the critical
bus monitor (alarm #39).
1. If the alarm operation is genuine:

a) verify that the programmed % UPPER LIMIT on the Operator Control Panel is suitable.
b) check the inverter feedback to the ILB voltage control loop
on the ILB at X9-1, X9-2, X9-3. If the voltage feedback signal is
missing then trace the open circuit via X5 on the HVI board;
ribbon cable W8 to the UPSLB; ribbon cable W5 to ILB.
Replace faulty component as applicable.
[ INV: UNDERVOLTAGE ]
(inverter undervoltage warning)

detects when the inverter voltage goes below a minimum level
which is set by the % LOWER LIMIT menu selection on the
Operator Control Panel.
Note: if the load is on-bypass the inverter is given 10 seconds
to recover, otherwise the inverter is latched off. Use the reset
button to restart the inverter. If the bypass is available when
the fault occurs the load is transfered to bypass by the critical
bus monitor (alarm #39).

a) verify that the programmed % LOWER LIMIT on the Operator Control Panel is suitable.
b) check for an open-circuit output filter capacitor and associated wiring to the output contactor.
c) replace the ILB
2. If there is no genuine reason for the alarm condition then
replace the UPSLB.
11-15

replace the UPSLB.
37
CODE

(Correct Meaning)
38
39
Details
Rectification
[ INV: FUSE FAIL ]
This alarm is triggered by the UPSLB micro in response to an

inverter fuse failure.
This facility is reserved for larger UPS modules and is not normally used in models up to 60kVA. It is disabled by fitting a link
to jumper X16 pins 1-2 on the HVI.
As a genuine fuse fail condition is not normally monitored, any

activation of this alarm channel is usually caused by a false
alarm. If the alarm activates:
a) check the signal path from the HVI X16 pins 1-2 to the
UPSLB.
b) replace the UPS Logic Board
[ OUTPUT: OVERVOLTAGE ]
(critical bus overvoltage trip)

detects when the critical bus voltage goes above a maximum
level which is set by the % UPPER LIMIT menu selection on
Note: when the load is on-inverter; if the bypass is available
when the fault occurs the load is transferred to bypass. If the
bypass is unavailable then the output contactor K1 will be
opened and the load powered-down.

a) verify that the programmed % UPPER LIMIT on the Operator Control Panel is suitable.
b) check the critical bus feedback to the UPSLB voltage control loop. If the voltage feedback signal is missing then trace
the open circuit via X4 on the HVI board; ribbon cable W8 to
the UPSLB. Replace faulty component as applicable.
11-16
CODE

replace the UPSLB.
40
[ OUTPUT: NO VOLTAGE ]
(UPS in off-line mode)

detects when the critical bus voltage goes below a minimum
level which is set by the % LOWER LIMIT menu selection on
Note: when the load is on-inverter; if the bypass is available
when the fault occurs the load is transferred to bypass. If the
bypass is unavailable then the output contactor K1 will be
opened and the load powered-down.

a) verify that the programmed % LOWER LIMIT on the Operator Control Panel is suitable.
b) check for an open-circuit output filter capacitor and associated wiring to the output contactor.
c) replace the ILB
This alarm is triggered by the UPSLB if the inverter is running

at nominal output voltage but the output contactor (K1) is
open.
1. Check that the unit is selected to Auto mode by ensuring

that jumper X26 pin 1-2 is not linked (standard) on the UPSLB.

replace the UPSLB.
2. Check the control wiring to the output contactor coil via the
Static Switch Trigger Board at X8, X9, X10. Check contactor
coil resistance for open-circuit or short-circuit.
3. If no genuine reason can be found for the alarm then
replace the UPSLB.
41
[ OUTPUT UNDERVOLTAGE ]
(critical bus undervoltage trip)
42

(Correct Meaning)
[ OUTPUT: WAVEFORM ERR.]
(low inverter peak volts)
Details
This alarm is triggered by a UPSLB software routine which
monitors the peak voltage waveform of each output voltage
envelope.
Rectification
Check to see if the alarm is genuine by monitoring each output
waveform with an oscilloscope.
1. If the problem is genuine:
a) check the output filter capacitors for correct function.
b) check for open circuit wiring between the inverter output and
the output contactor (K1)
c) check the inverter feedback to the ILB voltage control loop
on the ILB at X9-1, X9-2, X9-3. If the voltage feedback signal is
missing then trace the open circuit via X5 on the HVI board;
ribbon cable W8 to the UPSLB,; ribbon cable W5 to ILB.
Replace faulty component as applicable.
CODE
2. If the problem is not genuine then replace the UPSLB.

43
[ INV: FREQUENCY ERROR ]

(inverter frequency error)

detects when the inverter frequency is outside its window limits. This is automatically set at twice the bypass frequency window limits set via the Operator Control Panel menuing system.
Check the true inverter frequency to determine if the alarm is

genuine.
2. If the alarm is not genuine then replace the UPSLB.

44
[ INV: PARALLEL ERROR ]

(inverter selected off)
This alarm is triggered in a 1+1 configured system if the Parallel Logic Boards selective shutdown circuit is active.
If fault is genuine then led H1 should be illuminated on the Parallel Logic Board.
Attempt to reset using the reset switch on the UPS Logic
Board. If this does not solve the problem then investigate
cause for any load current sharing problem.
45
[ CONTACTOR ERROR ]
11-17
This alarm is triggered if the state of the monitored auxiliary

contacts do not agree with the output contactor control status
e.g. contacts indicate that the contactor is open when it should
be closed
Check the operation of the contactor power poles and auxillary

contacts
Check contactor control logic on Static Switch Driver Board
and state of auxiliary contacts/wiring.
Check the impedence of the contactor coil is wthin the range
30-38k (see paragraph 4.4.3 on page 11-51)
1. If the alarm is genuine:

a) check that the mimic display nominal operating frequency is
entered correctly (e.g. 50Hz).
b) recalibrate/replace the ILB and necessary.

(Correct Meaning)
50
[ BATTERY: UNDER TEST ]
This warning is triggered by a UPSLB software routine in

response to a user-initiated BATTERY TEST selected via the
Operator Control Panel menuing system.
Check the mimic display window under BATTERY TEST, and

reset the warning if necessary. Otherwise replace the UPSLB.
51
[ BATTERY: TEST FAILED ]
This latched alarm is activated by a UPSLB software routine in

response to the results of the BATTERY TEST routine.
1. Press the reset button (S1) on the UPSLB to unlatch the

alarm.
Details
Rectification
2. If the alarm fails to reset then check the battery test parameters indicated on the Operator Control Panel display screen.
If the parameters are correct then replace the UPSLB; if the
parameters are faulty then check the battery for a genuine
fault.
52
[ BATTERY: DISCHARGING ]
(battery is discharging)
This alarm is triggered by a UPSLB software routine and is

enabled only when the battery breaker is closed. The battery
current must be negative (discharging) for longer than 10 seconds before the alarm is activated.
11-18
CODE
Confirm the alarm is genuine by measuring the battery discharge current.

1. If the alarm is genuine check the rectifier function and float
voltage level. Also observe the instructions appropriate to any
other active alarms.
2. If the alarm is not genuine:

a) check the battery discharge current from the Operator Control Panel MEASUREMENT screen.
b) ensure that the battery parameters are correctly set: i.e. NO
OF BATT. EL.; CAPACITY etc., under the appropriate display
menu screen.
c) check the rectifier float voltage.
d) Replace the UPSLB.
53

(Correct Meaning)
[ BATTERY: E.O.D. ]
(battery end_of_discharge trip)
Details
Rectification

trips the battery breaker at the appropriate low battery disconnect voltage (i.e. when the battery discharges to its end-ofdischarge voltage.
Note 1: the exact trip level is programmable via the display
menu screen.
Note 2: If the load is less than 15% of nominal rating, the
E.O.D. trip level is automatically increased by 10%.
Confirm the alarm is genuine by measuring the battery voltage,

and check the battery circuit breaker trip status.
a) reset the UPS system by carrying out a re-start.
b) Check the rectifier float voltage level and observe the
instructions appropriate to any other active alarms.
a) check that the END DIS. trip level programmed via the
Operator Control Panel SETUP menu is correct.
b) replace the UPSLB.
54
[ BOOST: TIME EXPIRED ]
This latched alarm is triggered by a UPSLB software routine if

the Boost Charge timer has been exceeded. At some time previously, the unit has automatically entered its Boost Charge
regime and continued to boost the batteries for the programmed number of hours.
Confirm that the alarm is genuine by checking that the AUTOMATIC boost facility is enabled, and that the boost parameters are correctly selected (See Figure 2-17).
a) check the battery string for faulty cells.
b) press the reset button (S1) on the UPSLB to clear the alarm.
[ DC BUS: SLOW OVERVOL. ]

(dc overvoltage warning)

the DC Bus voltage rises above the programmed MAX. level.
(See Figure 2-16)
When activated, the rectifier and inverter are turned off.
Confirm that the alarm is genuine by checking that the DC Bus

voltage does not exceed the programmed overvoltage level.
a) check the rectifier float voltage level and observe the
b) check that the DC Bus filter capacitors are healthy.
c) check the DC Bus voltage feedback path to the RLB for an
open-circuit fault.
11-19

a) verify that the DC Bus MAX. parameter is correctly set in
the display menu screen.
3. If the alarm is not genuine, replace the UPSLB.

55
CODE
56

(Correct Meaning)
[ DC BUS: UNDERVOLTAGE ]
(low battery warning)
Details
Rectification

the DC Bus voltage falls below the low voltage ( BATT. LOW)
warning level (See Figure 2-16).
This is a warning that the battery is approaching its end-of-discharge voltage, and does not in itself affect the inverter/load
operation.
Confirm that the alarm is genuine by checking that the DC Bus

voltage is not below the programmed undervoltage level.
1. If the alarm is genuine, check the rectifier float charge and
recalibrate/replace the RLB as necessary. Also, observe the
a) verify that the DC Bus BAT. LOW. parameter is correctly
set in the display menu screen.
57
[ BATTERY: FUSE FAIL ]
The battery fuse condition (F13) is monitored by a normallyopen micro-switch which is connected to the fuse. If the fuse
ruptures, a mechanical pin is released which operates (closes)
the micro-switch.
The resulting digital low signal is processed by the UPSLB
micro which then passes the alarm data via the Operator Logic
to the LCD Display.
Confirm that the alarm is genuine by checking the state of the

mechanical pin on the fuse body and then carry out a continuity check of the fuse itself using an ohmmeter.
11-20
CODE

a) investigate the battery string for faulty (short-circuit) cells.
b) check incorrect operation of the battery circuit breaker (e.g.
attempted closure when the rectifier is OFF).

a) check the micro-switch for correct operation.
b) check the wiring from the micro-switch back to the HVI
board and UPSLB (and associated ribbon cables).
c) replace the UPSLB and/or HVI board as required.
58

(Correct Meaning)
[ DC BUS: FAST OVERVOL. ]
(fast dc overvoltage)
Details
This latched alarm is triggered by a UPSLB software routine
which detects the DC Bus voltage rising above 620Vdc. This
instantaneously shuts down the rectifier and inverter; and also
trips the battery breaker.
The 620V threshold is fixed by hardware.
The load will be transferred to the bypass if it is available
Rectification
1. Transfer the load to the maintenance bypass; open the
static bypass breaker; and block the inverter by closing Q2
on the UPSLB.
2. Start the rectifier and record the DC Bus float voltage.
a) if the float voltage is correct then check for a shorted static
bypass SCR (using 3. below).
b) if the DC Bus voltage rises to the fast overvoltage threshold then there is a fault in the rectifier voltage regulation loop:
check the DC Bus voltage feedback path to the RLB for an
open circuit fault (X2 on HVI; ribbon cable W8 to UPSLB; ribbon cable W6 to RLB). Note that on the RLB, test point X1 pins
1-3 should equal 3Vdc at nominal 432Vdc on the DC Bus.
60
[ BYP: XFER COUNT BLOCK ]

which counts the number of transfers between the inverter and
bypass. If the count exceeds 8 within 1 minute, the load is
latched onto the bypass-side. The alarm must be reset by the
reset switch (S1) on the UPSLB.
The transfer-count and time is not variable.
Confirm that the alarm is genuine by resetting the UPS and

check for transfer recurrences.
a) check for open circuit power wiring between the inverter output and the critical bus e.g. via the output transformer and
output contactor.
b) check for open circuit control wiring to X5 on the HVI board
and X10 on the Static Switch Driver Board.
11-21
2. If the alarm is not genuine than replace the UPSLB.
3. If the rectifier is OK, start the inverter and check for no voltage at Q2 bypass isolator. If the inverter voltage is present, a
shorted bypass SCR exists. If no voltage is present then the
alarm is not genuine and the UPSLB should be replaced.
Note: a shorted bypass SCR can also be detected by turning
off the inverter and static bypass section using Q1 and Q2 on
the UPSLB, then closing the static bypass breaker and checking for voltage on the UPS output terminals.
CODE

(Correct Meaning)
61
[ CUT-OFF: OVERLOAD ]
Details
Rectification

which detects if an overload condition is present for longer
than the permissible inverse-time characteristic:
e.g. 110% for 1 hour; 125% for 10 minutes 150% for 1 minute.
The alarm must be reset by the reset switch (S1) on the
UPSLB.
Confirm that the alarm is genuine by checking the amber led of

the appropriate % bargraph or check for % load indicated on
the Display menu Measurement screen. If an overload is indicated then check the load, and investigate any additional load
connected prior to the alarm (if applicable).
Note 1: If the overload timer is active then alarm #66 should

also be active as the load is above nominal.
Note 2: When the timer has counted-out, the output contactor
(K1) is opened and the load transferred to bypass, but the
inverter is not switched off.
Note 3: The activation of alarm #66 and the time-out period are
factory set and not adjustable.
62
[ CUT-OFF: OVERTEMPER. ]

a) check the load equipment and rectify as necessary.
a) verify that the correct UPS kVA rating has been entered via
the Display menu SET UP screen.
b) verify that the correct CT burden resistance is selected on
the HVI board, and ensure that there is no open circuit via X19,
X20, X21 on the HVI board.
c) replace the UPSLB.
Confirm that the alarm is genuine by checking for a temperature increase using the appropriate Display menu MEASUREMENT screen.
Note 1: The alarm will occur only upon receipt of alarm #19,
#24 or #34.

a) check the appropriate rectification under alarms #19, #24 or
#34, as applicable.
Note 2: The 1 minute time-out period is factory set and not

adjustable.

a) check for restricted air flow and fan failure

which detects if an overtemperature fault has been registered
for longer than 1 minute. When this is true, the rectifier and
inverter are turned off.
UPSLB.
11-22
CODE

(Correct Meaning)
63
[ CUT-OFF: EMERGENCY ]
Details
This latched alarm is triggered by a UPSLB software routine in
response to the operation of the External Emergency Power
Off (Emergency Stop) circuit. The external circuit should complete a closed circuit between pins 10 & 11 of the Customer
Terminal Block (X3).
UPSLB.
Rectification
Confirm that the alarm is genuine by checking the integrity of
the external EPO circuit at the customer terminal block (X3)
pins 10-11.
1. If the alarm is genuine then check the reason for the EPO
circuit activation and repair as necessary.
a) check for normally closed connection to HVI board X8
between pins 6 and 7.
66
[ OVERLOAD PRESENT ]
This alarm is triggered by the UPSLB micro once the load current rises above the UPS 100% nominal rating. The overload
timer is started, as described in alarm #61.
Note 1: the operating level is factory set and not adjustable.
67
[ CUT-OFF: OVERLOAD ]
Confirm that the alarm is genuine by verifying that the amber

overload LED is activated on the % load bargraph; and check
the Display menu MEASUREMENT screen to determine
which phase is being overloaded. Then measure the actual
output current to verify that the indications are valid.
a) verify that the correct UPS kVA rating has been entered via
the Display menu SET UP screen.
b) verify that the correct CT burden resistance is selected on
the HVI board, and ensure that there is no open circuit via X19,
X20, X21 on the HVI board.
c) replace the UPSLB.
11-23
Note 2: the alarm automatically resets once the overload condition is removed.
CODE

(Correct Meaning)
70
[ BAD EEPROM PROGRAM. ]
Details
Rectification
This alarm is triggered by the UPSLB micro if there is an error

during writing the UPS parameters into the EEPROM (D20)
during initialisation.
1. Verify that the correct UPS kVA rating has been entered via
the Display menu SET UP screen. Turn the UPS off for 5
seconds and then back on again to reinitialise the software.
Note: the rectifier, inverter and bypass are all disabled if this
alarm is active.
2. Try to RELOAD the UPS data via the appropriate display

Menu FUNCTION screen. Turn the UPS off for 5 seconds
and then back on again to reinitialise the software, re-enter the
modules KVA value.
3. Replace the UPSLB.
71
[ ERR0R LRC PAR. PAG 1 ]
72
[ ERROR LRC PAR. PAG 2 ]
73
[ ERROR LRC PAR. PAG 3 ]
[ ERROR LRC ALARM HIS. ]
75
[ ERROR LRC EVENT HIS. ]
76
[ INTERNAL BATTERY LOW ]
80
[ ERROR LRC TABLE ]
81
[ ERROR LRC PANEL ]
82
[ MODEM WRONG CONFIG. ]
83
[ ERROR LRC ALARM MEM. ]
84
[ MODEM NO RESPONSE ]
85
[ MODEM FALSE COMMAND ]
86
[ MODEM TIMEOUT TRASM. ]
87
[ CAN BUS NO RESPONSE ]
Note: the rectifier, inverter and bypass are all disabled if either
of these alarms are active.
1. Try to RELOAD the UPS data via the appropriate display

Menu FUNCTION screen. Turn the UPS off for 5 seconds
and then back on again to reinitialise the software, re-enter the
modules KVA value.
2. Replace the UPSLB.
74
These alarms are triggered by the UPSLB micro if there is an

error with the operating parameters during the software initialisation routines.
11-24
CODE
90
89
[ AUTONOMY XXXX min ]

(battery autonomy time)
88
Rectification
Details
(Correct Meaning)
CODE
11-25
11-26
Section 11:
Chapter 3 - Board Replacement & Calibration Procedures
Important Note:
Throughout these procedures, reference is made to switches Q1, Q2 and Q3 on

the UPS Logic Board which are used to manually enable/inhibit the Static Bypass,
Inverter and Rectifier power sections respectively.
When instructed to close a switch this should be interpreted as apply the inhibit
(or block the power section) e.g. turn off the rectifier by closing Q3. Similarly,
opening a switch enables the relevant power section.
3.1
Rectifier Logic Board replacement (Part N 4520074A)

1.
Using the correct power switching sequence, transfer the load to the Maintenance Bypass (see Operators Manual if required).
2.
Totally power down the UPS (see Operators Manual if required).
3.
Remove the faulty Rectifier Logic Board.
4.
Note and record the position of the jumper X links on the removed board.
5.
Ensure the jumper X links on the replacement Board are positioned identically to those on the board being replaced.
Note: For further details of the jumper functions, refer to Table 4-5 (on page
4-37) if necessary.
6.
Fit the replacement Rectifier Logic Board.
7.
Block all the power sections by closing the inhibit switches Q1, Q2 and Q3
on the UPS Logic Board.
8.
Close the UPS Input Power Isolator Q1.

a) The control power supply will energise.
b) The UPS Logic Board will carry out a self-test and then display associated alarms on the Operator Control Panel LCD display screen.
3.1.1
Calibration
Rectifier input current limit
1.
Connect a DVM between test point X8 pin 7 and the 0V rail (X12/X13).
2.
Adjust R17 (clockwise to increase) to obtain the following indication:

a) 30kVA = -0.8Vdc
b) 40kVA = -1.2Vdc
c) 60kVA = -1.6Vdc
Battery current limit
3.
11-27
CHAPTER 3 - Board Replacement & Calibration
4.
Adjust R18 (clockwise to increase) to obtain the following indication:

a) 30kVA = 0.1Vdc per Amp for the required battery current limit.
b) 40kVA = 0.1Vdc per Amp for the required battery current limit.
c) 60kVA = 0.1Vdc per Amp for the required battery current limit.
Battery temperature compensation
5.
6.
Adjust R121 to obtain an indication of 2.98Vdc (equivalent to 25C).

Note: this sets the temperature above which the DC bus voltage will
decrease by 1Vdc for every 1 C rise in battery temperature. For a different
threshold temperature setting the value is adjusted linearly.
DC float voltage settings (range = 200 to 500 volts)
7.
Connect a DVM (500V range) to the UPS +ve and ve battery connections.
8.
Open the inhibit switch Q3 on the UPS Logic Board to remove the manual
inhibit on the rectifier.
9.
The rectifier should start in a controlled manner and the DC busbar should
ramp up to the battery float charge voltage.
10. On the Rectifier Logic Board:

a) LED H3 (green) should illuminate.
b) Adjust R21 to obtain an indication of 2.25V/cell i.e. 2.25V x the total
number of cells contained in the battery blocks (clockwise to increase).
DC manual voltage setting (range = 0 to 600V volts)
11. Using standard screen navigation techniques, gain access to the charge mode
selection screen via the FUNCTION NEXT PAGE ON/OFF UPS BLOCK
menu path (see figure 2-28 on page 2-67).
12. Scroll through the menu options and select manual charge mode (MAN).
a) Ensure led H4 (yellow) illuminates (H3 extinguishes).
b) Adjust R22 to obtain an indicated charge voltage appropriate to forming open vented cells (if applicable). If sealed cells are used then set this
voltage to equal the float voltage set previously (2.25V/cell) (clockwise
to increase).
DC boost voltage setting (Range = 200 to 550 volts)
14. With the MANUAL charge mode still selected from the previous test;
on the Rectifier Logic Board:
a) Fit a jumper link X9 pin 02 (to initiate the BOOST mode).
b) Ensure that the LED H2 (green) illuminates.
c) Adjust R20 to obtain an indicated DVM voltage appropriate to the
required battery boost charge voltage (clockwise to increase). If sealed
11-28
cells are used then set this voltage to equal the float voltage set previously (2.25V/cell).
DC test voltage setting (Range 0 - 600Volts)
15. This setting is used to reference the rectifier voltage during a battery autonomy test. It should be set at 20V below the battery fail voltage as selected by
the BATTERY TEST software screen during the FUNCTION setup (see figure
2-23 on page 2-52) e.g. if the battery fail value is set at 1.9V/cell this
value should be set at 1.8V/cell.
a) Fit a jumper link to X9 pins 01 (leave jumper on 02).
b) Ensure that LED H1 (amber) illuminates.
c) Adjust R19 to obtain an indicated voltage on the DVM equivalent to the
desired battery Test Fail voltage (e.g. 1.8V/cell).
17. Using standard screen navigation techniques, gain access to the charge mode
selection screen via the FUNCTION NEXT PAGE ON/OFF UPS BLOCK
menu path (see figure 2-28 on page 2-67).
18. Scroll through the menu options and select float charge mode (FLO).
a) Remove the jumper links from X9 0-1 & 0-2
b) Ensure led H3 (green) illuminates.
c) Verify that the battery voltage returns to the float charge value.
3.1.2
3.2
Returning the UPS to service

1.
Open the UPS Input Power Isolator Q1 & Bypass Power Isolator Q2.
2.
On the UPS Logic Board open Q1, Q2 and Q3 to enable the inverter, rectifier and static switch power sections.
3.
Disconnect and remove all test equipment.
4.
Refit any other connections and/or components disturbed during the above
procedure.
5.
Start the UPS following the standard operating procedure contained in the
Operators Manual and verify that the UPS parameters are correct during the
start-up sequence.
6.
Return the faulty Rectifier Logic Board to the nearest Liebert Service Centre
for repair.
Inverter Logic Board replacement (Part N 4530025T)

1.
2.
3.
Remove the faulty Inverter Logic Board.
4.
11-29
5.
Ensure the jumper X links on the replacement Board are positioned identically to those on the board being replaced.
Note: For further details of the jumper functions, refer to Table 5-4 (on page
5-53) if necessary.
6.
Fit the replacement Inverter Logic Board.
7.
8.

b) The UPS Logic Board will carry out a self-test and then display associated alarms on the Operator Control Panel LCD display screen.
9.
3.2.1
Open the inhibit switch Q3 on the UPS Logic Board to enable the rectifier
allow sufficient time for the DC busbar to rise and stabilise at the float
charge voltage.
Calibration
Inverter current limit
1.
2.
Adjust R248 (clockwise to increase) to obtain an indication of 0.6Vdc on

the DVM this is equivalent to 150%.
Inverter PWM reference tri-wave.
Note: Adjust the triangular waveform shown below only if necessary.

Figure 11-2: Inverter PWM reference tri-wave
+2 volts
0
2 volts
3.
On the Inverter Logic Board:

a) Connect an oscilloscope to the right hand side of resistor R27 (use X17/
X18 for 0V reference).
b) If necessary, adjust potentiometer R241 to obtain a triangular waveform
of 4 volts peak to peak, as shown above.
Inverter starting
4.
Open the inhibit switch Q2 on the UPS Logic Board to enable the inverter.
a) The inverter should ramp up to nominal voltage.
b) The output contactor (K1) should close.
5.
Close the Bypass Power Isolator Q2.

a) The inverter should synchronise to the bypass supply.
11-30
b) Verify that the INVERTER UNSYNCHRONISED alarm is no longer shown on

the Operator Panel LCD display.
6.
Ensure that the inhibit switch Q1 on the UPS Logic Board remains closed to
disable the static bypass.
Inverter output voltage adjustment.

R242 simultaneously adjusts all three output L-N voltages while R244, R245
and R246 independently adjusts all three phases non-linearly.
Ensure that R242 is adjusted first to set all three line voltages before
making the final line to neutral adjustments.
Important Note:
7.
Connect a DVM to the inverter output terminals R and N.
8.
Adjust potentiometer R246 (clockwise to increase) to obtain the required

output L-N voltage, as indicated by the appropriate operating mode i.e. led
H1= 220V, H2=230V, H3=240V.
9.
Connect the DVM to the inverter S and N terminals.
10. Adjust potentiometer R244 (clockwise to increase) to obtain the required

output L-N voltage as indicated by the appropriate operating mode i.e. led
H1= 220V, H2=230V, H3=240V.
11. Connect the DVM to the Inverter T and N terminals.
12. Adjust potentiometer R245 (clockwise to increase) to obtain the required
output L-N voltage, as indicated by the appropriate operating mode i.e. led
H1= 220V, H2=230V, H3=240V.
Inverter bypass phase lock adjustment
13. Connect a dual channel oscilloscope probe 1 to monitor the bypass R

phase voltage and probe 2 the inverter output phase R voltage (use the
chassis earth for 0V reference).
14. Adjust potentiometer R247 until both sine waves are perfectly in phase.
Inverter manual voltage adjustment (range = 0 to 500 volts AC)
Note: this mode is used for inverter testing only so adjust only if required.
15. Turn off the inverter by closing the inhibit switch Q2 on the UPS Logic
Board.
16. On the Inverter Logic Board
a) Turn R243 fully clockwise this is equivalent to 0V output.
b) Fit jumper links to X12, 0-3 and 0-4.
a) Verify that the amber LED H4 is illuminated (indicating manual mode).
17. Connect a DVM (500Vac) between the inverter output R and S phases.
18. Enable the inverter by opening the inhibit switch Q2 on the UPS Logic
Board.
19. On the Inverter Logic Board
a) Slowly turn R243 anti-clockwise until the inverter just starts to generate
an output AC voltage.
11-31
b) Continue adjusting R243 until the nominal output voltage is reached

the output contactor (K1) should closed.
Do not run the inverter on low voltage for extended periods as it may
adversely affect the cooling fans operation.
Important Note:
Inverter overvoltage test
20. Using R243, continue to (slowly) increase the inverter voltage above its
nominal value and verify the following output overvoltage actions:
a) At 110% nominal voltage the INV: OVERVOLTAGE alarm (#36) should
annunciate on the Operator Control Panel LCD display panel.
Note: Equivalent to 418V/440V/457V for 380V/400V/415V systems.
b) At 112% nominal output voltage the OUTPUT: OVERVOLTAGE alarm (#39)
should annunciate on the Operator Control Panel LCD display panel.,
and the output contactor K1 should open.
Note: Equivalent to 426V/448V/465V for 380V/400V/415V.
Inverter undervoltage test
21. Using R243, decrease the inverter output voltage and verify the following
output undervoltage actions (note that contactor K1 should re-energise as
the voltage is reduced):
a) At 90% nominal output voltage, INV: UNDERVOLTAGE alarm (#37) should
annunciate on the Operator Control Panel LCD display panel.
b) At 88% nominal output voltage, the OUTPUT: UNDERVOLTAGE alarm (#40)
should annunciate on the Operator Control Panel LCD display panel, and
the output contactor K1 should open.
22. Using R243, increase the inverter output to nominal voltage once again
(note that contactor K1 should re-energise as the voltage is increased):
3.2.2

1.
Open the UPS Input Power Isolator Q1 and Bypass Power Isolator Q2.
2.
On the UPS Logic Board:

a) Open the inhibit Q1, Q2 & Q3 to enable the UPS power sections.
b) Remove the jumper links fitted to X12 pins 0-3 & 0-4.
11-32
3.
4.
procedure.
5.
start-up sequence.
6.
Return the faulty Inverter Logic Board to the nearest Liebert Service Centre
for repair.
3.3
UPS Logic Board replacement (Part N 4550007H)

1.
2.
3.
Remove the faulty UPS Logic Board.
4.
5.
Ensure the jumper X links on the replacement Board are positioned identically to those on the board being replaced. Note: For further details of the
jumper functions, refer to Table 7-8 (on page 7-72) if necessary.
6.
Fit the replacement UPS Logic Board.
7.
8.

b) The UPS Logic Board will carry out a self-test and then display associated alarms on the Operator Control Panel LCD display screen note
that the ERROR HISTORY alarms will be active as no settings have yet
been installed in the NVRAM.
3.3.1
Calibration
Power supplies
1.
Connect the internal battery by fitting a jumper link to X32 LED H8 may
illuminate to indicate that the internal battery charger is active.
2.
Connect a DVM between X20 pin 1 and the 0V rail (X18-8), and adjust
potentiometer R209 to obtain a DVM indication of 5.00Vdc.
3.
Connect a DVM to diode V45 anode and the 0V rail (X18-8), and adjust
potentiometer R212 to obtain a DVM indication of 2.50Vdc.
Software set-up
In order to reset the ERROR HISTORY alarm it is necessary to re-program the nonvolatile RAM (NVRAM).
4.
Ensure that the unit kVA is set. (see paragraph 2.4.5.1 on page 2-34)
5.
Carry out the following software commissioning procedures:

a) Ensure that link X26 7-8 is closed. This will overide the password security system.
b) Language selection (if necessary) (see paragraph 2.4.4 on page 2-31)
Note: This procedure includes details for setting the PASSWORD.
c) UPS Setup parameters (see paragraph 2.4.5 on page 2-33). This includes
the following: Basic UPS Configuration and kVA vcalue (see paragraph 2.4.5.1 on
page 2-34).
UPS Working voltage parameters (see paragraph 2.4.5.2 on page 2-34)
11-33
UPS Frequency parameters (see paragraph 2.4.5.3 on page 2-35).

Battery Parameters (see paragraph 2.4.5.4 on page 2-36).
d) MAINTENANCE Data entry (see paragraph 2.4.6 on page 2-39).
6.
3.3.2
3.4
The ERROR HISTORY alarm will not reset until the UPS is powered down and
restarted the internal battery will maintain the re-programmed parameters.

1.
Open the UPS Input Power Isolator Q1 and the Bypass Power Isolator Q2.
2.
On the UPS Logic Board, close the inhibit switches Q1, Q2 and Q3 to enable the rectifier, inverter and static switch power sections.
3.
4.
procedure.
5.
start-up sequence.
6.
Return the faulty UPS Logic Board to the nearest Liebert Service Centre for
repair.
Operator Logic Board replacement (Part N 4550005F)

1.
2.
3.
Remove the faulty Operator Logic Board.
4.
5.
6.
Fit the replacement Operator Logic Board.
7.
8.

b) The UPS Logic Board will carry out its self-test and the associated
alarms will be shown on the LCD display screen.
3.4.1
Calibration
11-34
1.
Ensure that the internal power supply is active i.e. LED H1 is illuminated.
2.
Adjust potentiometer R21 to give the appropriate contrast on the display

LCD screen.
3.4.2
3.5

1.
2.
On the UPS Logic Board, open the inhibit switches Q1, Q2 and Q3 to enable the rectifier, inverter and static switch power sections.
3.
procedure.
4.
start-up sequence.
5.
Return the faulty Operator Logic Board to the nearest Liebert Service Centre for repair.
Static Switch Driver Board replacement (Part N 4542043Z)

1.
2.
Full DC busbar (battery) voltage is present on the Static Switch Driver Board during normal operation. Wait for at least 2 minutes then ensure that the DC capacitors have fully discharged before proceeding
Caution
3.
Remove the faulty Static Switch Driver Board.
4.
5.
6.
Fit the replacement Static Switch Driver Board.
7.
8.

3.5.1
Calibration
There is no calibration necessary on the Static Switch Board, however the board
should be functionally checked by carrying out a load transfer in both directions
between the inverter and bypass supply.
1.
Open the inhibit switches Q1, Q2 and Q3 on the UPS Logic Board this
will energise the rectifier, inverter and static bypass sections.
2.
The UPS will power-up normally and display MANUAL BYPASS CLOSED on
the default screen.
11-35
3.5.2
3.6
3.
Turn off the inverter by closing the inhibit switch Q2 on the UPS Logic
Board.
4.
Verify that the Load on Bypass amber LED is flashing on the Operator
Control Panel mimic display.
5.
Restart the inverter by opening Q2 on the UPS Logic Board.
6.
Verify that the inverter output ramps up to nominal voltage and the output
contactor K1 closes.
7.
Verify that the Load on Inverter green LED is illuminated on the Operator
Control Panel mimic display.

1.
2.
On the UPS Logic Board, ensure that the inhibit switches Q1, Q2 and Q3 are
open to enable the rectifier, inverter and static switch power sections.
3.
procedure.
4.
start-up sequence.
5.
Return the faulty Static Switch Driver Board to the nearest Liebert Service
Centre for repair.
High Voltage Interface Board replacement (Part N 4590054O)
Caution
1.
2.
Full DC busbar (battery) voltage is present on the High Voltage Interface Board
during normal operation. Wait for at least 2 minutes then ensure that the DC capacitors have fully discharged before proceeding.
3.
Remove the faulty High Voltage Interface Board.
4.
5.
6.
Fit the replacement High Voltage Interface Board.
7.
8.

11-36
3.6.1
Calibration
No calibration is necessary on the High Voltage Interface Board; however, some
of its functions may be checked by verification of the metered parameters on the
Operator Control Panel.
3.6.2
3.7
1.
Open the inhibit Q1, Q2 and Q3 on the UPS Logic Board to energise the
Rectifier, Inverter and Bypass sections the UPS will power-up normally
and display MANUAL BYPASS CLOSED on the default screen.
2.
Press the ENTER button to display the main menu screen and then select
MEASUREMENT.
3.
Check the expected nominal parameters using the MEASURMENT menu map
(see figure 2-21 on page 2-48).

1.
Open the UPS Input Power Isolator Q1.
2.
procedure.
3.
start-up sequence.
4.
Return the faulty High Voltage Interface Board to the nearest Liebert Service Centre for repair.
DC DC Power Supply Board replacement (Part N 4503028K)

1.
2.
Full DC busbar (battery) voltage is present on the DC-DC Power Supply Board
during normal operation. Wait for at least 2 minutes then ensure that the DC capacitors have fully discharged before proceeding
Caution
3.
Remove the faulty DC-DC Power Supply Board.
4.
Ensure that the soldered links CV1 & CV2 are made on the replacement
board.
5.
Fit the replacement DC-DC Power Supply Board.
6.
7.

3.7.1
Calibration
1.
Ensure that LS1 and LS2 are illuminated on the DC DC Power Supply
11-37
Board.
2.
Connect a DVM to the Inverter Logic Board (Part N 4530025T) to check

the DC voltage levels as follows:
Note: 0V DC ground can be found at test point X18.
a) V14 anode = 12.2Vdc.
Adjust using potentiometer TM1 on the DC DC Power Supply Board.
b) V15 cathode = -12.2Vdc.
3.
3.7.2
3.8
Open the inhibit switches Q1, Q2 and Q3 on the UPS Logic Board to energise the Rectifier, Inverter and Bypass sections the UPS should power-up
normally and display MANUAL BYPASS CLOSED on the default screen.

1.
2.
procedure.
3.
start-up sequence.
4.
Return the faulty DC-DC Power Supply Board to the nearest Liebert Service
Centre for repair.
AC DC Power Supply Board replacement (Part N 4503030M)

1.
2.
Full AC bus voltage is present on the AC-DC Power Supply Board during normal
operation. Wait for at least 2 minutes then ensure that the power at the input fuses
has fully discharged before proceeding
Caution
3.
Remove the faulty AC-DC Power Supply Board.
4.
Fit the replacement DC-DC Power Supply Board (There are no configuration links fitted to the replacement board).
5.
6.

3.8.1
Calibration
1.
11-38
Ensure that power supply LEDs LS1 and LS2 are illuminated on the AC
DC Power Supply Board.
2.
Connect a DVM to the Rectifier Logic Board (Part N 4520074A) to check

the voltage levels as follows.:
Note: 0V DC ground can be found at test point X13.
a) V46 cathode = 12.1V dc.
Adjust using potentiometer TM2 on the AC DC Power Supply Board.
b) V45 anode = 12.1V dc.
Adjust using TM1 on the AC DC Power Supply Board.
3.
3.8.2
3.9
Open the inhibit switches Q1, Q2 and Q3 on the UPS Logic Board to energise the Rectifier, Inverter and Bypass sections the UPS should power-up
normally and display MANUAL BYPASS CLOSED on the default screen.

1.
2.
procedure.
3.
start-up sequence.
4.
Return the faulty AC-DC Power Supply Board to the nearest Liebert Service
Centre for repair.
Parallel Logic Board replacement (Part N 452007H)

1.
2.
3.
Remove the faulty Parallel Logic Board.
4.
Note and record the position of the jumper links on the removed board.
5.
Ensure the jumper links on the replacement board are positioned identically
to those on the board being replaced. Note: For further details of the jumper
functions, refer to Table 2-10 on page 2-26 if necessary.
6.
Fit the replacement Parallel Logic Board.
7.
8.

3.9.1
Calibration
1. Ensure that switches Q1, Q2, Q3 on the UPS Logic Board are selected OFF
i.e. to disable the rectifier, inverter, and bypass operation.
11-39
2. Ensure that all power isolators on both module are OPEN, take particular
care that the bypass isolator Q2 is OPEN.
3. Close the rectifier power isolator Q1 to energise the control electronics.
4. Connect a DVM to X8 pin 1 and check that the level is high (+5V) to ensure
that the G.V.C.O. is free running (0V is available at TP10).
5. Adjust R18 to obtain a 50Hz square wave at X8 pin 2. Note: for 60Hz operation connect jumper X7 to 1-2 and adjust R18 for 60.00Hz @ X8 pin 2.
6. Connect a DVM to the lower end of R68.
7. Adjust R19 to obtain the appropriate voltage for the expected nominal output
current as shown in Table 11-3.
Table 11-3:
3.9.2
UPS Rated Voltage
R68 Lower End Value
220/380V
5.90V
230/400V
6.20V
240/415V
6.45V
11-40
1.
2.
On the UPS Logic Board, ensure that the inhibit switches Q1, Q2 and Q3 are
open to enable the rectifier, inverter and static switch power sections.
3.
procedure.
4.
start-up sequence.
5.
Return the faulty Parallel Logic Board to the nearest Liebert Service Centre
for repair.
Section 11:
Chapter 4 - Functional Check Procedures
4.1
Introduction
This chapter contains detailed procedures intended to be used in conjunction with
the troubleshooting tables in chapter 3. Sample oscilloscope waveforms are provided in Volume 2 (Drawings).
4.2
How to check the rectifier power components

Most rectifier power problems can be due to faulty SCRs or DC filter capacitors
as detailed in table below and the following check procedures.
Table 11-4: Power rectifier component checks

Symptoms
4.2.1
Possible cause
Input fuse failure
Short-circuit rectifier SCR

Short-circuit DC filter capacitor
Tripped input supply distribution circuit breaker

Unbalanced input current.
Open-circuit rectifier SCR
Increased DC ripple voltage the degree of

ripple reduces as the load increases above 30%.

Open-circuit DC filter capacitor
Unexpected decrease in battery autonomy

performance; with possible shortened life.

Unexplained DC filter capacitor failure.
Intermittent inverter saturation detected on

different power poles attenuated when the
inverter is on load for a period of time.

Rectifier runs continuously in its input currentlimit mode.

1. Transfer the load to the Maintenance Bypass supply.
2. Totally power-down the UPS.
3. Ensure that the DC Filter capacitors have fully discharged.
4. Using a DVM set to measure resistance, check each rectifier SCR device for a
short-circuit between its anode and cathode.
5. Replace any faulty device.
S10-c4.fm5 - Issue 2 Dated 21/08/97
11-41
CHAPTER 4 - Functional Check Procedures
4.2.2

1. With the rectifier running, check for a balanced input current. A lower current
indication on one of the input phases would indicate an open-circuit SCR.
2. Scope the input current on all three phases and interpret the results according
to Figure 11-3 below. The upper illustration shows that the input current
waveform normally consists of two peaks during both the positive half and
negative half voltage waveforms, occurring as the SCRs in the other two
phases are turned on. If an SCR is open-circuit (or not receiving a gate drive
signal) its current peak will disappear from the current waveform, as shown
in the lower diagram (which shows the effect of a missing S+ SCR on the Rphase current waveform).
Figure 11-3: Illustration of input current waveforms
S+ current
T+ current
R+
S+
T+
R (load)
R+ Volts
S- current
T- current
R- Volts
S+ current missing
T+ current
R+
S+
T+
R (load)
R+
S- current
T- current
3. If a non-conducting SCR is found, it could be due to it being open-circuit or

not receiving a gate drive current. Using a suitable current clamp, measure
the current in the yellow wire connected to the SCR gates. A current of
200mA or more is satisfactory.
4.2.3
Shorted DC filter capacitor

3. Allow sufficient time for the DC filter capacitors to fully discharge verify
with DC voltmeter (DVM) that the capacitors are safe to touch.
4. Isolate each capacitor by disconnecting their positive and negative DC Busbar connections.
5. Using an ohmmeter (DVM):
a) Measure the resistance between the capacitor positive (+) and negative (-)
terminals the capacitor should charge up due to the meter voltage to
eventually indicate overload (OL).
11-42
b) Measure the resistance between the (+) terminal and ground this should
indicate open circuit (note the capacitor case is grounded via the threads of
its base mounting stud).
c) Measure the resistance between the (-) terminal and ground this should
indicate open circuit (note the capacitor case is grounded via the threads of
its base mounting stud).
6. Replace any capacitor whose resistance indications fail the above checks.
4.2.4

with DC voltmeter (DVM) that the captors are safe to touch.
Check Method 1
2. Connect a shorting link between the capacitor positive (+) and negative (-)
terminals, and at the same time connect an ohmmeter (DVM) across the
shorted terminals (i.e. meter should indicate 0 Ohms short-circuit).
3. Remove the shorting link and note the time taken by the meter indication to
rise from 0 Ohms to OL as the capacitor charges up to the meter voltage this
should be of the order of 20 seconds on a suitable meter range.
4. Perform this check on all the DC filter capacitors and compare the results. If
any capacitor has a seriously reduced time constant compared to the others
then it should be replaced.
Check Method 2
2. Individually charge each capacitor to a low dc voltage (e.g. to 12Vdc from a
single battery) ensure that the charging source is connected with the correct
polarity.
3. Disconnect the charging source once the capacitors are charged to the applied
voltage.
4. Measure and record the initial capacitor terminal voltage.
5. Wait 15-30 minutes then repeat the capacitor voltage measurements and compare the result with the initial values. If any capacitor has a greatly reduced
voltage when compared with the others then it is unable to hold its charge and
should be replaced.
11-43
4.3
How to check the inverter power components

Most inverter power problems are due to faulty IGBTs or AC Filter Capacitors.
An overview of these problems is given in the following table.
Table 11-5: Inverter power component problems
Symptoms
4.3.1
Possible cause
Continuous inverter current limit and/or

intermittent Vsat failure.
Short-circuited AC filter capacitor or

shorted output transformer.
Bad/incorrect inverter sine-wave output,

becoming more pronounced as load is
increased.
Open-circuited output AC filter capacitor.

Open-circuit base drive lead.
Continuous Vsat on the same power pole

on each attempt at starting the inverter.
Sort-circuited IGBT (80%)

Open-circuited IGBT (10%)
Faulty Base Driver Board (10%)
Intermittent Vsat on different power pole

on each attempt at starting the inverter.
Faulty DC Hall-effect CT on output

transformer.
Faulty DC filter capacitor
Faulty rectifier SCR
Faulty DC-DC Power Supply Board
Faulty Inverter Logic Board
Short-circuit and Open-circuit IGBT

It is difficult to check for an open-circuit IGBT with the device in-situ. To this
end, it is convenient to check the Vsat detection indication (H5 - H12) on the Inverter Logic Board before proceeding.
The Vsat detector (one for each power IGBT on each Base Driver) attempts to
measure the voltage drop across the IGBT when it is turned ON. It therefore indicates the following latched conditions:
a) Shorted IGBT on this device (80% chance).
b) Open IGBT on this power pole but not this device (10% chance).
c) Faulty power supply/device fets on this Base Driver Board (10% chance).
Figure 11-4: Vsat example

Positive Bus
R+
R-
Vsat = LS2 OFF on Base Drive Board

H5 ON on Inverter Logic Board
Vsat = LS2 OFF on Base Drive Board

H6 ON on Inverter Logic Board
Negative Bus
11-44

with DC voltmeter (DVM) that the captors are safe to touch.
4. Check the impedance across R+ IGBT terminals (See paragraph 4.3.2).
a) If a short circuit is found then replace the R+ IGBT
b) If no short circuit is found then it is likely that the R- IGBT is open-circuit.
therefore replace the R- IGBT.
5. Restart the UPS following the Start procedure in the Users Manual. and allow
the rectifier to run up to float voltage.
a) The DC-DC Power Supply should now energise each of the Base Drive
Boards.
b) Check the intensity of all six green Power Supply leds on the Base Drive
Boards. A low intensity would indicate a poor Base Drive Board, which
should be replaced.
4.3.2
How to check the inverter IGBTs

In the event of an inverter failure it is possible that the power IGBTs might have
been damaged. It is therefore expedient to test the devices following any form of
inverter fault.
Two types of IGBT devices may be fitted to the inverter heatsink, as shown
below: dual-pack devices, containing two transistors are fitted to 30kVA models; and single-pack devices are used in 40/60kVA models.
Figure 11-5: IGBT Layout and internal circuit
C2/E1
E2
C1
G2
E2
G2
E2
C1
C2/E1
E2
E1
G1
E1
G1
Dual-Pack Device
E
E
Single-Pack Device
11-45
When testing an IGBT, the measured values may vary slightly from those given
below.
Check Procedure
1. Ensure the power rectifier is shut-down and battery circuit breaker is open.
2. Wait 2 minutes to allow the DC Busbar capacitors time to discharge: verify
that the bus voltage is zero before proceeding.
3. Disconnect the cables from the IGBT to be tested.
4. With reference to Table 11-7 and Figure 11-5; carry out a check of the impedances across the IGBT terminals using a DVM set to the Diode range.
Note: Table 11-7 describes the method of checking the two IGBTs in a Dual
Pack device independently.
5. If the indicated values are different those shown, or if the device fails to
switch ON/OFF then it must be regarded as unserviceable and replaced.
Caution
When replacing an IGBT ensure that the new component is of the correct type
and part number (do not mix IGBTs in an inverter section). Smear the mating
surface of the replacement part with suitable heat-sink compound before fitting.
Table 11-6: Single-Pack device checks

DVM
+ve
Lead
DVM
-ve
Lead
DVM
Indication
(mV)
Connect DVM across the emitter-collector

junction
OL
reverse DVM leads to check internal diode
0.388
Reconnect DVM to original polarity
OL
Touch the +ve DVM lead to the gate
Recheck the Emitter-Collector junction
0.445
Turn the device OFF by shorting G and E
OL
Action
11-46
Interpretation
IGBT switched off in a
serviceable condition
Diode Forward Resistance
The device should turn ON

This low reading indicates
that the device is turned on
(Note it will remain ON
under the present
circumstances due to its
internal Cge capacitance
High resistance indicates
that the device is OFF
Table 11-7: Dual-Pack device checks

DVM
+ve
Lead
DVM
-ve
Lead
DVM
Indication
(mV)

junction
C2 E1
E2
OL
E2
C2 E1
0.388
C2 E1
E2
OL
G2
E2
C2 E1
E2
0.445
Turn the device OFF by shorting G2 and E2
C2 E1
E2
OL


junction
E2
C1
OL

E2
C1
0.388
E2
C1
OL
G1
E1
E2
C1
0.445
Turn the device OFF by shorting G1 and E1
E2
C1
OL
Action
Interpretation
Checking IGBT2

under the present
Checking IGBT1
4.3.3

under the present
Shorted AC filter capacitor checks

with DC voltmeter (DVM) that the DC filter capacitors are safe to touch.
4. Verify with DC voltmeter (DVM) that the AC filter capacitors are safe to
touch.
5. Isolate each capacitor by disconnecting each terminal connection.
6. Using an ohmmeter (DVM on Resistance range) check the following:
11-47
a) Connect the ohmmeter between the capacitor terminals and verify that the
capacitor charges up (eventually the meter will indicate OL).
b) Measure the resistance between each capacitor terminal and ground
(capacitor body earth) this should indicate open circuit in each case.
7. Replace any capacitor that fails the above checks.
4.3.4
Open-circuit AC filter capacitor checks

4. Verify with DC voltmeter (DVM) that the AC filter capacitors are safe to
touch.
Check method 1
1. Isolate each capacitor by disconnecting each terminal connection.

2. Connect a shorting link across both capacitor terminals, and at the same time
connect an ohmmeter (DVM) across the shorted terminals (i.e. meter should
indicate 0 Ohms short-circuit).
3. Remove the shorting link and note the time taken by the meter indication to
rise from 0 Ohms to OL as the capacitor charges up to the meter voltage this
should be of the order of 20 seconds on a suitable meter range.
4. Perform this check on all the AC filter capacitors and compare the results. If
any capacitor has a seriously reduced time constant compared to the others
then it should be replaced.
Check method 2
The expected filter current on each delta-connected main power wire with the inverter running on no-load is approximately 80% of the units nominal kVA rating
e.g. on a 60kVA unit wires 9, 10, 11 should carry approximately 48A.
1. If possible, run the inverter (following the standard start-up procedure
described in the Users Manual).
2. Measure the filter current on all three phases and verify that the spread is balanced to within 80%. An unbalanced, or low, indication indicates an open circuit capacitor on the appropriate filter leg replace as necessary.
3. If the inverter cannot be started, it is possible to connect the filters delta
power wires directly to the 3 phase mains supply using appropriate fusing
(e.g. rectifier fuses) and check for a balanced current as described above.
11-48
4.4
How to check the Static Bypass power components

Most static bypass power problems are likely to be due too faulty bypass SCRs,
as detailed in the table below.
Figure 11-6: Static Bypass power component checks
Symptoms
4.4.1
Possible causes
Inverter overload or high DC bus

overvoltage upon taking over the load
from the bypass.
Short-circuit bypass SCR
Load failure when load transferred to

bypass.
Alarm #15 [BYP: SCR FAILURE]
annunciated
Open-circuit bypass SCR
Bypass-to-inverter transfer count exceed.

Alarm #60 [BYP: XFER COUNT
BLOCK] annunciated
Output contactor K1 failure
Short-circuit bypass SCR checks

When the UPS is started, the load is initially connected to the static bypass. Once
the inverter has run-up to full voltage (approximately 5 seconds), the preferred
action is to close the output contactor (K1) and open the bypass SCRs. However,
if a bypass SCR is short-circuited (or slow to turn off), the mains will back-feed
through the inverter to the DC bus in an uncontrolled manner (the inverter changes the mains to DC). This will cause the DC bus voltage to either decrease (causing DC undervoltage trip or inverter overloading), or increase (causing DC
overvoltage trip).
1. Transfer the load to the Maintenance Bypass supply and open the output isolator.
2. Turn the Inverter OFF and the Static Bypass ON using Q2 & Q1 on the UPS
Logic Board.
3. Using a dual-channel oscilloscope, monitor the output lines ahead of the output isolator i.e. on the inverter/static switch side of the output isolator. That
is, monitor the three output phases in pairs to compare their waveforms.
4. Using Q1 on the UPS Logic Board, turn OFF the bypass SCRs and check that
the traces on the oscilloscope indicate an instantaneous cut-off of the mains
voltage when the bypass SCRs cease their conduction see the waveforms
illustrated below.
5. From the following waveforms, determine the SCRs status and replace if
necessary, after first powering down the UPS.
11-49
Figure 11-7: Output voltage waveforms
Good blocking characteristics
Slow/lazy SCR on negative side

Replace the faulty device
Shorted SCR on negative side

Replace the faulty device
4.4.2
Open-circuit bypass SCR

An open-circuit bypass SCR will only be recognised by the electronics when the
load is on bypass. The voltage drop across the device is monitored when it is conducting, and if the voltage rises above 50V (approx.) the bypass is latched off after
a few cycles. Alarm #15 [BYP: SCR FAILURE] is annunciated.
1. Transfer the load to the Maintenance Bypass supply and open the output isolator.
2. Turn the Inverter OFF and the Static Bypass ON using Q2 & Q1 on the UPS
Logic Board.
3. Using a dual-channel oscilloscope, monitor the output lines ahead of the output isolator i.e. on the inverter/static switch side of the output isolator. That
is, monitor the three output phases in pairs to compare their waveforms.
4. Run the inverter and check the output for a true three-phase ac sinewave.
5. Using Q2 on the UPS Logic Board, turn OFF the inverter and check that the
traces on the oscilloscope indicate a true three-phase ac sinewave from the
bypass mains. If any SCR is open-circuit it will fail to conduct and the missing half-wave will be instantly recognisable from the output waveform.
6. If a faulty SCR is identified, replace it after first powering down the UPS.
11-50
4.4.3
Output contactor failure

If it is not possible to energise, and therefore close, the output contactor (K1), the
transfer control logic will attempt to, by repeatedly transferring between inverter
and bypass, as described below.
1. The inverter voltage monitor will detect that the inverter voltage is valid and
initiate a load transfer by closing K1 and opening the static bypass SCRs.
2. If K1 fails to close, the critical bus (output) voltage monitor will sense a lack
of voltage due to the non-closure of K1 and immediately re-energise the
bypass SCRs.
3. The inverter voltage monitor still sees a valid inverter voltage and will
attempt to energise K1 again after a delay of 5 seconds.
4. Once again, if K1 fails to close, the critical bus (output) voltage monitor will
sense a lack of voltage due to the non-closure of K1 and immediately re-energise the bypass SCRs.
As you can see, this cycle is repetitive and would lead to 12 transfer attempts over
a one minute period. However, this exceeds the transfer lock-out circuits maximum of 8 transfers in one minute, and will cause the circuit to latch out and annunciate alarm #60 [BYP: XFER COUNT BLOCK]. Note that this condition must
be reset by pressing PS1 on the UPS Logic Board.

4. Using a DVM, check the resistance of the output contactors coil (440V).
This should be approximately 30-38kOhms. Replace the coil if found faulty.
5. Check the connections from the Static Switch Driver Board to the contactor
coil (wires 37/38), also wires 39/40 from the Static Switch Driver Board to
the DC Bus.
6. If the above checks prove satisfactory, start the inverter in the usual manner
but open the static bypass input isolator. This forces the electronics to select
load-on-inverter, and attempt to close K1 (if the inverter voltage is valid).
7. Carefully, measure the DC voltage across K1 coil at terminals A1-A2. This
should equal the DC Busbar float voltage. If this voltage is not present then
replace the Static Switch Driver Board.
11-51
11-52

Sect 11

Uploaded by

Copyright:

Available Formats

Sect 11

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Sect 11

Uploaded by

Copyright:

Available Formats

Section 11: Troubleshooting & Repair

Chapter 1 - Basic Troubleshooting Procedure

S-10.FM5 - Issue 2 Dated 21/08/97

SECTION 11 - Troubleshooting & Repair

7200 Series UPS Service Manual

4.4.2 Open-circuit bypass SCR ......................................................... 11-50

S-10.FM5 - Issue 2 Dated 21/08/97

Chapter 1 - Basic Troubleshooting Procedure

Basic troubleshooting (from Operator Control Panel metering)

S10-C1.FM5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

General troubleshooting procedure

Irrespective of whether fault rectification is successful or not, please report all

S10-C1.FM5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

S10-C1.FM5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

S10-C1.FM5 - Issue 2 Dated 21/08/97

Chapter 2 - Fault diagnosis

Interpreting the Operator Control Panel indications

Display panel message interpretation

s10-c2.fm5 - Issue 2 Dated 21/08/97

Table 11-1: Operator Control Panel LED indication

Check the following:

Check the following:

If this is an automatic change over it will be accompanied by a fault

Check the following:

7200 Series UPS Service Manual

s10-c2.fm5 - Issue 2 Dated 21/08/97

MEASURMENT menu on the Operator Control Panel. The number of

Reduce the load immediately.

7200 Series UPS Service Manual

s10-c2.fm5 - Issue 2 Dated 21/08/97

Table 11-1: Operator Control Panel LED indication (Continued) (Sheet 2 of 2)

Display Alarm Messages

[ BYPASS SWITCH OPEN ]

[ OUTPUT SWITCH OPEN ]

[ RECTIF. SWITCH OPEN ]

[ BATTERY SWITCH OPEN ]

[ MANUAL BYPASS CLOSED ]

The state of the Circuit Breakers is sensed by monitoring their

The sense signal route passes from the circuit breakers,

Table 11-2: Alarm messages

7200 Series UPS Service Manual

s10-c2.fm5 - Issue 2 Dated 21/08/97

If [#02] is active it disables [#10], [#11], [#12], [#13] and [#16]

Display Alarm Messages

These alarms are enabled only if the bypass circuit breaker is

1. First verify that the bypass voltage presented to the module

2. Verify that the input MAX. and MIN values programmed in

The alarm thresholds are programmable via the SETUP/

[ BYP: FREQUENCY ERROR ]

The alarm window threshold is programmable via the SETUP/

1. First verify that the bypass voltage presented to the module

3. If step 1 & 2 are OK then measure the sense signals to the

7200 Series UPS Service Manual

s10-c2.fm5 - Issue 2 Dated 21/08/97

Display Alarm Messages