Manual 9x55
Manual 9x55
Manual 9x55
TABLE OF CONTENT
Parts lists
El module (8 – 10kVA) “N” model 10 22 593
El module (8 – 10kVA) “S” model 10 22 595
El module (10 – 15kVA) “N” model 10 22 594
Chokes (8 – 10kVA) 10 22 592
Chokes (12 – 15kVA) 10 22 982
Fan module 10 22 818
SET Mechanics (8 – 10kVA) 10 22 205
SET Mechanics (12 – 15kVA) 10 22 983
Stands and wheels 10 22 599
Cable set 10 21 790
5. POWER BOARD
7. I / O - BOARD
Layout 10 21 596
Circuit diagram 10 21 595
Parts list 10 22 453
8. CONTROL BOARD
Layout 10 21 281
Circuit diagram 10 21 280
Parts list 10 21 278
9. DISPLAY MODULE
Display board
Layout 10 21 650
Circuit diagram 10 21 649
Parts list 10 21 647
10. OPTIONS
Communications
ConnectUPS – X web SNMP adapter user’s guide *
Modbus user’s guide *
Modem Installation instructions 10 19 019
Functional description 10 19 139
Layout 10 18 687
Multi server card user’s guide *
Relay card Description 10 18 947
Circuit diagram 10 18 345
Connection cable 10 02 001
RS 232 single port user’s guide
Communication port connections
Power options
Battery module (BM) and cabinet assemblies, diagrams
Single battery cabinet for EM 10 22 569
Double battery cabinet for EM 10 22 571
Double battery cabinet stand alone 10 22 573
Triple battery cabinet stand alone 10 22 576
2 stand alone BM + cover assembly 10 22 574
3 stand alone BM + cover assembly 10 22 577
Single battery cabinet + EM assembly 10 22 579
Double battery cabinet + EM assembly 10 22 580
1 BM + EM and cover assembly 10 22 581
2 BM + EM and cover assembly 10 22 582
Stand alone BM circuit breaker assembly 10 22 223
Stand alone BM circuit breaker connection diagram 10 22 583
Warning!
Operations inside the UPS must be performed by a service engineer from the
manufacturer or from an agent authorised by the manufacturer.
Do not ever service inside the UPS when mains power is applied or the UPS is in battery mode.
Use the optional mechanical bypass if installed to the system. Remember to open battery
breaker. Always ensure by measuring with a multi-meter that no dangerous voltages are
present.
Audience
The intended audiences of this manual are people who plan the installation, install,
commission, and use or service the UPS. The manual provides guidelines to check delivery,
installing and commissioning of the UPS.
The reader is expected to know the fundamentals of electricity, wiring, electrical components
and electrical schematic symbols. This manual is written for a global reader.
Note!
Read the manual before operating or working on the UPS.
CE marking
The product has the CE marking in compliance with the following European directives:
• LV Directive (Safety) 72/23/CEE and 93/68/CEE
• EMC Directive 89/336/EEC and 93/68/EEC
Declaration of conformity with UPS harmonised standards and directives EN 62040-1-1
(Safety) and EN 50091-2 (EMC) are available on the web site (http://www.powerware.com).
User precautions
The only user operations permitted are:
• Start up and shut down of the UPS, excluding the commissioning start-up.
• Use of the LCD control panel and Maintenance Bypass Switch (MBS)
• Use of optional connectivity modules and their software
The user must follow the precautions and only perform the described operations. Any deviations
from the instructions could be dangerous to the user or cause accidental load loss.
Environment
The UPS must be installed according to the recommendations in this manual. Under no
circumstances the UPS should be installed in an airtight room, in the presence of flammable
gases, or in an environment exceeding the specification.
Excessive amount of dust in the operating environment of UPS may cause damage or lead to
malfunction. The UPS should be always protected from the outside weather and sunshine. The
recommended operating temperature is from +15 to +25 Celsius degrees.
Inquiries
Address any inquiries about the UPS and battery cabinet to the local office or agent authorised
by the manufacturer. Please quote the type code and the serial number of the equipment.
Delivery check
The UPS is delivered with the following items:
• Plastic bag containing:
Quick Installation Guide, paper format, multilingual (coming later)
User’s Guide, paper format, multilingual
User’s Guide, CD-ROM format, multilingual (coming later)
Residual voltage warning stickers
Software Suite, CD-ROM format, English language
RS-232 serial cable for the Software Suite
• Delivery documents
Note!
A claim for shipping damage must be filed immediately and the carrier must be
informed within 7 days of receipt of the equipment. The packing materials should be
stored for further investigation.
Unpack the equipment by removing the packing and shipping materials. Make a visual
inspection and check that the inside ‘Drop&Tell’ indicator is intact. Make sure that the floor
surface is solid and suitable for the wheeling and heavy weight, twist the levelling feets of the
unit to up position and remove the equipment from the pallet.
It is required to arrange ventilation of the UPS room. Sufficient amount of air cooling is needed
to keep the max. room temperature rise at desired level:
• Temperature rise of max. +5°C requires the airflow of 600 m3 per 1 kW of losses.
• Temperature rise of max. +10°C requires the airflow of 300 m3 per 1 kW of losses.
An ambient temperature of 15 to 25 Celsius degrees is recommended to achieve a long life of
the UPS and batteries. The cooling air entering the UPS must not exceed +40 °C. Avoid high
ambient temperature, moisture and humidity.
The floor material should be non-flammable and strong enough to support the heavy load. The
UPS has (4) leveling feet that should be used when finalising the installation. The diameter of a
single leveling foot is 1 inch (25.4 mm).
The UPS family has several alternative battery cabinets and configurations depending on the
selected back-up time and quality of batteries.
Please fix the mechanical bypass switch (MBS) to the wall (din rail) or to the back of the UPS
as shown below.
The overtemperature sensor cable is connected to the control input (X45 or X44) of the UPS,
see the next drawing. In the factory installed systems this cable is ready-made for use.
Figure 10. Wiring diagram of the UPS and the external transformer option.
Warning!
The UPS contains high DC voltages. A qualified person must do the connections between
the UPS and the external battery cabinet(s). The battery cabinet is connected electrically
in parallel with the internal batteries of the UPS.
Battery racks
External battery racks shall be sized to take the voltage drop in the cable into account. To
obtain support and help contact the local office or agent authorised by the manufacturer.
Warning!
Physical injury or death may follow, or damage may occur to the UPS, or the load
equipment if these instructions are ignored.
Note!
The rectifier requires a Neutral to operate. It’s connected internally from the bypass
terminal to the rectifier, see wiring diagram.
Table 14. Cable and fuse ratings for the different UPS ratings
(*With optional limited charging feature at low input and high kW load, see User Settings)
Wiring procedure
The power cable terminals are located in the back of the UPS unit. The service personnel is
responsible for the correct electrical installation. They must be authorised by the manufacturer.
The installation procedure:
1. Remove the cover(s) of the terminal box of the power cables with a screwdriver.
Refer to the dimensional drawing for the correct location at the back of the unit.
2. Slide the cables through the grommets of the connection box.
3. Connect the conductors of the rectifier and bypass input cables to the proper terminals.
With single phase unit it is recommended to use the same phases for rectifier and bypass
inputs.
4. Connect the conductors of the load cable to the proper terminals.
5. Connect the conductors of an external battery cabinet cable to the external battery +, -
and PE terminals. Check for the correct polarity.
See External Battery Cabinet (EBC) installation procedure.
Warning!
If available, the internal battery has to be disconnected first because the external battery
terminals are hazardous due to the parallel battery string.
Figure 21. Wiring diagram of UPS S-model (1-ph rectifier) with integral MBS, (Norway)
Note!
Site wiring fault must be
disabled from LCD
User Settings menu.
Note!
Do not place EBC on the UPS unit.
2. The required minimum distance for UPS unit and EBC is ten millimeters, which is also
required distance between two EBCs.
3. Turn F1 battery breaker from the UPS unit in OFF position.
4. Check that the circuit breaker F3 of the EBC is in the OFF position. To minimise safety risk
remove one of the cable (+ or -) from battery string to break a battery circuit.
Battery cables can be accessed by removing a plastic front cover and a metal hatch behind
the plastic cover. Do not remove the safety wire of the circuit breaker before all the wires
are connected and the installation of the whole system is ready. Remove plate A on the
rear side of the EBC to connect cables to EBC’s terminal block X6. Bring cables outside
from the EBC by removing the cover plate B. Place the plate A back to the original position
and connect the cable clamp to the place of the cover plate B.
5. If the system consists two or more EBC connect first the EBCs parallel as follows:
a) Connect the cables to second EBC in the same way as guided in point four (4)
of this installation procedure.
b) Remove the cover plate C of the first EBC and connect cables to terminal block X6.
Connect the cable clamp to the place of the cover plate C.
6. When all the EBCs are connected parallel, disconnect one of the cables (+ or -) from UPS
cabinets internal battery string in the same way as guided with EBC in point four (4) of
this installation procedure before connecting cables to terminal block X3 of the UPS unit.
Otherwise the terminal block X3 is live.
7. After installation connect disconnected battery cables to strings, check that the removed
plates on right positions remove safety wires from circuit breakers and turn breakers of
EBCs and the UPS on.
8. Finally change the Number of 32 pcs. battery strings from User Settings. SETTINGS ->
USER SETTINGS -> NUMBER OF BATTERY STRINGS.
Note!
It is not allowed to feed the load simultaneously from mains (bypass) and inverter(s) of
the UPS unit(s). While turning the switch, where the bypass is connected, ON/OFF, UPS
should be on static bypass mode or shut down.
Note!
The maximum load supported by the system is limited to size of one UPS if there are
two UPSs and bypass connected to SPM.
Terminals of the SPM have two-wire connection (L1 and N) and ground terminals. The upper
ground terminal is for a load cable and the lower ground terminal is for UPSs. The wiring shall
be done according to the following wiring diagrams. The terminals and cable routing is shown
in Figure Cable routing of the SPM. See also Table 14 for cable and fuse ratings for the different
UPS ratings.
Figure 29. SPM9155 wiring diagram with two UPSs and bypass connected
Communication cables
It is recommended that the control cables and power cables be installed on separate trays.
Where control cables will cross power cables make sure they are arranged at an angle as near to
90 degrees as possible.
All control cables shall preferably be shielded. If the shield is grounded, this shall take place on
only one end of the cable.
The procedure for connecting the control cables is the following:
1. Remove the front cover by lifting the cover from the bottom outwards by releasing the
retaining clip. It’s located in the bottom part of the bezel.
2. Locate the control terminal or X-slot module where you want to install the
communications cable.
LanSafe software
The LanSafe software shuts down computers and whole networks in case of an extended power
failure. It provides basic monitoring, data logging, notification and event actions for a single
UPS solution. The software is bundled free of charge in Software Suite CD.
The connection procedure for the RS-232 interface port is following:
1. Connect the RS-232 communication cable to the computer.
2. Connect the RS-232 communication cable to the serial interface on the UPS.
3. Run the UPS software installation disk (Software Suite CD) on the computer.
Note!
If communication does not work choose the correct baud rate from the LCD display
Please refer to the optional software manuals for appropriate baud rate settings.
Note!
Pay attention to proper polarity if one is using a semiconductor switch type. A relay or
other mechanical control is a preferred method.
Note!
EPO does not necessarily disconnect supply to load when unit is on internal or external
bypass. Quaranteed disconnection of bypass supply has to be through a separate
disconnect switch located in the supplying switchgear cabinet.
In order to have the UPS running again pins 1 and 2 of connector X52 have to be reconnected
and the UPS started manually. The pins must be shorted in order to keep the UPS running.
Maximum resistance is 10 ohm. The EPO shall not be galvanically connected to any mains
connected circuits. Reinforced insulation to the mains is required.
If the use of normally open EPO operation is desired, the loop on X52 has to be retained and
the normally open EPO switch connected to X12. Operation is as above.
Warning!
The relay contacts must not be directly connected to mains related circuits. Reinforced
insulation to the mains is required.
Note!
Please note the polarity of the inputs as indicated in the external control connections if
used with a polarity control.
The default and programmable settings for the signal inputs are
a) Disable Bypass Operation
If active the automatic transfer to the static bypass is prevented.
b) Charger off
If active the batteries charging is disabled. In case of mains power outage the discharge of
batteries is supported.
c) Remote ON/OFF
If active the UPS output turns off regardless of mode of operation. Auxiliary power, fan,
communications and rectifier/battery charger shall remain functional. Restart initiated
immediately when inactive.
d) Request Bypass
If active the UPS transfers to bypass if bypass voltage, frequency and synchronisation are ok.
e) Request Normal
If active the UPS transfers to inverter operation if not prohibited by EPO or alarm condition.
f) Force Bypass
If active the UPS is forced to static bypass operation regardless of the bypass status.
g) External Battery Breaker Status
If active the UPS knows that the batteries are disconnected.
h) Building alarm 1-6
These can be activated separately or at the same time with other building alarms.
i) Not in use (default)
j) Shutdown
If active the UPS will shutdown immediately.
k) Delayed Shutdown
If active the UPS will shutdown after user configurable delay time. Restart initiated
immediately when inactive.
l) Normal/Bypass
If active the UPS transfers to bypass if ok. If inactive the UPS transfers to inverter when
possible.
The UPS supports two serial communication devices according to the table below.
Independent Multiplexed
Configuration X-slot #1 X-slot #2 Std. RS-232 port
Default #1 Any X-slot Module Any X-slot Module Not in use
Default #2 Any X-slot Module Relay Module Available
Default #3 Any X-slot Module Not in use Available
Table 34. Typical X-slot configurations for UPS communication.
Display functions
As default and after 15 minutes of inactivity the UPS is showing the selectable start screen:
1. Logo screen
2. Mimic screen (See User Settings on LCD screen)
The screen backlit has automatic shutdown after long period of inactivity. It will light up once a
button is pushed. The right side button will initiate the text to the screen. The scrolling
through the menu structure is done with buttons indicated by the ↑ ↓images of the LCD
screen. The menu structure is shown in the table below.
Changing language
Pressing and holding down the first button on the left for about 5 seconds selects the language
menu. This action is possible from any LCD menu screen.
The default firmware has four main languages: English, Spanish, French and German. Other
local language packages including Chinese, Greek and Russian can be requested from the local
service representative.
Select Maximum charging current from User Settings menu. Default setting is 3.0 Amps and it
is changeable up to 20 Amps. Minimum step is 0.1 A.
Note!
Maximum charging current is dependent on output load and power rate of the UPS. If the
UPS is supporting maximum output load the highest level of Maximum charging current is
3.0 A, which is also the default setting. As a thumb rule, 1 kW decrease in the load provides
extra 2.0 A charging capacity. For example, the charging capacity is 5 Amps at 8 kW load,
and 7 A at 7 kW load.
Battery start-up
UPS will start on battery if mains is not available. Note that the UPS behavior may be slightly
different from the normal start-ups.
Shutdown
The procedure to shutdown from LCD is following:
1. Push any key of the control panel to enable the functions of the LCD screen
2. Select “TURN UPS OFF” from the LCD menu (see: Display Functions)
3. Press and hold ↵ button for 5 sec. There shall be an indication sound during the hold.
4. UPS shall do a shutdown routine.
5. Turn the battery and input circuit breakers to OFF position to finalise the shutdown procedure.
Note!
The behaviour is different if UPS is turned off from the programmable input or through
communication cards. If battery and input circuit breakers are left ON, UPS will enter a
stand-by mode and starts to charge batteries with a cooling fan operational. Output is
without the voltage in the stand-by mode.
Scrapping
Before scrapping UPS or its battery cabinet, the battery bank must be removed. Local
requirements must be followed in battery recycling or discard. The removal of batteries is
allowed only by authorised service personnel due to high energy and voltage.
Regular service/intervals
The UPS requires very little maintenance if installed in an appropriate environment.
Maintentenance Interval
Batteries change ~ 3-5 years / service
Batteries test ~ 18 months / service
Cooling fan change ~ 5 years / service
Table 42. Routine maintenance intervals recommended by the manufacturer.
Batteries
The condition of the batteries is crucial for operation. The UPS will indicate by audible and
visual alarms if the capacity of the battery bank has decreased. The UPS units are provided with
the automatic battery test and ABM management function to continuously monitor the
condition of the battery bank.
Note!
Do not dispose of batteries in a fire. The batteries may explode.
Do not open or mutilate batteries. Released electrolyte is harmful to the skin and eyes. It
may be toxic.
Cooling fan
The cooling fan lifespan of the UPS unit is about 60 000 operating hours. The actual lifespan
depends on the environment and ambient temperature.
Fan failure can be predicted by increasing noise from the fan bearings. The fan replacement is
recommended once this symptom starts appearing.
Do not use other than manufacturer’s specified spare parts.
LED Indicators
The UPS unit has (4) LEDs to indicate the status.
Note!
The MBS consist of three switches and failure to understand the correct sequence may
drop the critical load.
Figure 42. The normal (UPS supplying the load) positions of the three MBS switches.
OFF ON ON
2. Use LCD to turn the UPS on internal static bypass mode. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
ON OFF
ON
ON OFF OFF
9. Remount the locking plate of the S1-3 switches to the position to prevent the use of them.
Figure 46. The service (bypass supplying the load) positions of the three MBS switches.
ON OFF OFF
ON OFF
ON
5. Use LCD to “Turn UPS on” and wait until fully started.
- Make sure the UPS is not displaying alarms or notices alarm with the green LED lit.
- You may verify the output voltage from the meters screen of the LCD.
6. Use LCD to transfer the UPS to internal static bypass. Remember to verify the transfer
before proceeding the next step.
ON
ON ON
OFF ON ON
10. Remount the locking plate of the S1-3 swiches to the position to prevent the use of them.
Figure 48. UPS models with (1) and (2) battery bottom sections.
Figure 49. UPS models with (1) and (2) battery bottom sections plus integrated MBS.
Figure 51. UPS models with middle battery and bottom transformer sections.
Environment
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Amb. temperature 0 to +40°C (electronics), 15 to +25°C (batteries)
Relative humidity 0 to 95%, no condensation allowed
Altitude <1000 m above sea level at +40°C
Vibration IEC 68-2-6; max. 0.3 mm (2 to 9 Hz), max. 1 m/s2 (9 to 200 Hz) sinusoidal
Mechanical configuration
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Dimensions
- Width 305 mm
- Depth 702 mm
- Height 817 mm (32 bat) or 1214 mm (2x32 bat)
Weight
- no battery 65 kg 70 kg
- 32 battery 155 kg 160 kg
- 64 battery 265 kg 270 kg
- 32 battery and transformer 270 kg 275 kg
- MBS +15 kg
Colour RAL 9011 black
Characteristics
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Efficiency
Up to 92% Up to 93% Up to 92% Up to 93%
- nominal load
Heat losses <580 W <720 W <870 W <1050 W
Backup time 10 min (32 bat 7 Ah) 6 min (32 bat 7 Ah)
15 min (32 bat 9 Ah) 10 min (32 bat 9 Ah) 8 min (32 bat 9 Ah) 5 min (32 bat 9 Ah)
- load pf 0.7
28 min (64 bat 7 Ah) 20 min (64 bat 7 Ah) 15 min (64 bat 7 Ah) 10 min (64 bat 7 Ah)
(+25°C amb.) 33 min (64 bat 9 Ah) 25 min (64 bat 9 Ah) 20 min (64 bat 9 Ah) 15 min (64 bat 9 Ah)
Noise (ISO 7779) 50 - 53 dB(A) depending on the load
DC circuit
AC output
UPS 8 kVA 10 kVA 12 kVA 15 kVA
Active power 7,2 kW 9 kW 10,8 kW 13.5 kW
Nro. of phases 1-phase
Frequency 50 Hz or 60 Hz, user selectable
Voltage 220, 230 or 240 Volts, user selectable
Short circuit
100 A, < 300 ms 144 A, < 300 ms
capability
10 min >100-110% load
1 min > 110-125% load
Overload capability
5 sec >125-150% load
300 ms >150% load
Technical Specifications
General Rating 8-15 kVA 0.9 p.f.
Efficiency 92% at nominal load
Audible noise <50 dB (A) Environmental Monitoring Probe
Powerware®, Advanced Battery Management, LanSafe, PowerVision and FORESEER are trademark(s) of Powerware Corporation. © 2004 Powerware Corporation
GERMANY RUSSIA
Tel: +49 7841 6660 Tel: +7 095 787 2890
[email protected] [email protected]
9X55 HV CAA Code Chart
CAA = Configuration After Assembly
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
HW Options HW Options
Product HW kVA Rating Application Input Output No. of Batt. Batt. Type Future Use Future Use Future Use Generation
1 (Future) 2 (Future)
K = 9X55 1 = 1in/1out 08 = 8kVA 1 = RT 1 = 230V 1 = 230V 0 = None 0 = None 0 = None 0 = None 0 = None 0 = None 0 = None P=
10kVA (Single UPS) Prototype
A = 3in/3out 15 = 15kVA 3 = 9 Ah
15kVA
B = 3in/3out 30 = 30kVA
30kVA
Digit 1: Product indentification, always K for 9X55. (OEM PRODUCTS MAY VARY)
Digit 2: Hardware indentification, single or three phase input/output, power range
Digit 3: First digit of kVA rating
Digit 4: Second digit of kVA rating
Digit 5: Application such as single or parallel operation, frequency converter, stand-by etc.
Digit 6: Input voltage selection, 400V for three phase, 230V for single phase input. May have other options in future.
Digit 7: Output voltage selection. 400V for three phase, 230V for single phase output. May have other options in future.
Digit 8: Number of battery strings ( battery compartments ) in a UPS.
Digit 9: Type of installed batteries in a UPS.
Digit 10: Hardware Options 1 for future use.
Digit 11: Hardware Options 2 for future use.
Digit 12: For possible future use.
Digit 13: For possible future use.
Digit 14: For possible future use.
Digit 15: Generation, 1 = First release.
The UPS must be installed and serviced only by a service personnel from the manufacturer or
from an agent authorised by the manufacturer.
The UPS must be used as intended. Follow the instructions given in the User’s and Installation
manual.
Installation and use of the UPS must comply with all national and local safety regulations and
procedures.
To prevent overheating do not obstruct the flow of air for ventilation opening to the unit.
The UPS contains Lead-Acid batteries, which must be disposed of correctly in compliance with the
local regulations.
High leakage current; connect protective earth before power supply cables.
All primary power switches installed downstream of the UPS must be labelled as follows:
ISOLATE UPS ( Uninterrupted Power Supply ) before working on this circuit.
There is dangerous voltage inside the unit due to the internal batteries. Turn the battery breaker
off in order to isolate the batteries during service work.
Note: This trouble shooting guide is a preliminary issue, based on information of our R&D. It will
periodically be updated and distributed to service engineers attending the PW9155 training,
also to be found on the service web.
Note: Display - and fan module can be exchanged while the unit remains in normal operation
(refer to document 1022755).
1. Save the alarm log and label the file with the serial number of the unit (refer to service software
description……..chapter ……).
2. Analyse the problem with the help of the 9155 alarm table (refer to pages 2 – 6).
3. If necessary, inform the customer, that the load has to be transferred to bypass (refer to steps 2 - 7)
4. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30. Note: If there
is no mechanical bypass (optional) assembled to the unit, inform the customer of the fact, that
the load has to be switched off for the time of servicing the UPS !
5. Shut down the UPS -> refer to the user’s guide 1022403, page 27 !
6. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off .
Note: The depleting of the DC bus takes about 5 minutes.
7. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
8. Unscrew the fixing bolts of the hood -> eight (8) at front, ten (10) at the back of the unit. Lift the
hood off the unit.
9. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
10. Replace the faulty component by referring to the appropriate replacement instruction and
re-assemble the unit.
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 1 (6)
9155
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 2 (6)
9155
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 3 (6)
9155
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 4 (6)
9155
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 5 (6)
9155
POWERWARE Approved
Finland Checked PK No 1022754 Rev A
Issued RR 24.5.2004 Page 6 (6)
9155
Part numbers of :
Front panel 10 22 878
Fan assembly 10 22 818
Input/output choke(s), L3 – L8 10 21 865
Battery choke(s), L1 – L2 10 22 276
Note: Before replacing any part, save the alarm log and label the file with the serial number
of the unit (refer to service software description……..chapter ……). If necessary,
inform the customer, that the load has to be transferred to bypass.
1. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
2. Unscrew the two (2) fixing bolts of the front panel and pull it towards you (refer to front panel
assembly drawing 1022170, section “DISPLAY” of service manual).
5. Check the display firmware for it’s revision and if necessary update it (refer to service software
description ….. chapter …..)
1. Transfer the load via display to static bypass, refer to display description …
2. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
3. Unscrew the four (4) fixing bolts of the fan assembly and pull it’s upper edge towards you. (refer
to “El-step 4” assembly drawing 1022405, section “MAIN CIRCUIT” of service manual, -> for
details refer to “fan” assembly drawing, 1022171).
5. Re-assemble the new fan module and transfer the load via display back to “normal operation”.
C) Replacement of choke(s)
1. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30 !
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
2. Shut down the UPS -> refer to the user’s guide 1022403, page 27 ! Turn rectifier input circuit
breaker F2 and battery circuit breaker F1 off..
Note: The depleting of the DC bus takes about 5 minutes.
3. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
4. Unscrew the fixing bolts of the hood -> eight (8) at front, ten (10) at the back of the unit. Lift the
hood off the unit.
5. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
6. Disconnect the cables of the chokes to be replaced, after having made sure, that they are labelled
correctly. To do so, slide the bushing sidewise out of the frame an gently spread it to get the cables
pulled out (refer to assembly drawings 1022282 and 1022174, chapter “MAIN CIRCUIT” of the
service manual).
7. Remove the top plate of the choke assembly and replace the choke(s) referring to dwg. 1022282.
8. After having re-assembled the top plate tighten both nuts evenly to the level that the bolts to the
back plate can fitted.
9. Reconnect the cables of the replaced choke(s) and check once more mechanics and connections
to be correct.
10. Put the UPS back into normal operation referring to instructions of the user’s guide, pages 27
and 31.
11. Measure the voltage(s) before and after the replaced choke(s) for correct level.
*** Note: Do not touch the contacts of the IGBT module(s). Be aware, that according manufacturer’s
specification, the spring loaded contacts of an IGBT do not guarantee for good connection
after being more than three (3) times re-assembled !
1. Save the alarm log and label the file with the serial number of the unit (refer to service software
description……..chapter ……). Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30 !
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
3. Shut down the UPS -> refer to the user’s guide 1022403, page 27 !
4. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
Note: The depleting of the DC bus takes about 5 minutes.
5. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
6. Unscrew the fixing bolts of the hood -> eight (8) at front, ten (10) at the back of the unit. Lift the
hood off the unit.
7. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
10. Remove the X-slot bays after their ribbon cables to X55 and X56 of the power board have been
disconnected. Squeeze the bay gently by it’s height and lift it off.
11. Remove the sockets of the EPO and remote indications/alarms, X44, X45, X12 X52 and X57 and
disconnect the cable of the RS232 port X53.
13. Remove the three (3) fixing bolts at the front edge of the power board, squeeze the retainer tongues
of the six (6) plastic supports and lift the board towards the back of the unit.
14. Check the on board contacts to the IGBT for burn marks and damaged tracks.
a) If the board shows physical damage, replace it by proceeding with step 12.
b) If the board seems to be “OK”, but one or more IGBTs damaged, proceed with step 13.
c) If neither board nor IGBTs seems to be faulty, re-assemble the power board.
15. After having checked the cables to the power board for correct labelling, disconnect them, and lift
the board out of the unit.
16. Use a thin bladed knife to remove the faulty IGBT from the heat sink, by gently lifting off it’s front
edge.
17. Clean the surface of the heat sink from the heat conducting paste.
Note: Make sure, that the surface of the heat sink is clean and smooth (no scratches), before
assembling the new IGBT.
18. Place an even, thin layer of heat conducting paste to the base (copper) of the new IGBT and place
it on the top of the lower edge of the heat sink frames respective cut out. To keep the IGBTs in
place make temporary use of their fixing bolt (without cover plate).
Note: Remember, do not touch the contacts of the IGBT module(s).
19. While re-assembling the power board, make sure, that the IGBTs will be positioned correctly by
their centre and upper left pivots.
20. Re-assemble the power board’s fixing bolts, but DO NOT YET tighten them.
21. Remove the centre bolts of the IGBTs and re-assemble them with the IGBTs cover plates, torque
shall be 2 – 2,5 nm.
22. Finish the re-assembling of the power board by tightening all screws, reconnecting cables and
sockets of peripherals. Recheck bolts and cables once more.
24. Calibrate the DC bus voltages, the DC offsets and the batt. voltage 2 backup according calibration
instructions …….and service bulletins regarding firmware updates.
1. Save the alarm log and label the file with the serial number of the unit (refer to service software
description……..chapter ……). Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30 !
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
3. Shut down the UPS -> refer to the user’s guide 1022403, page 27 !
4. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
Note: The depleting of the DC bus takes about 5 minutes.
5. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
6. Unscrew the fixing bolts of the hood -> eight (8) at front, ten (10) at the back of the unit. Lift the
hood off the unit.
7. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
8. Disconnect all cables from the I/O board, after you have made sure, that their labelling is correct.
9. Remove the four (4) earthing bolts as well as the fixing bolts of the static switch thyristors and
squeeze the retainer tongues of the four (4) plastic supports to lift the board out of the unit.
10. Replace the board and re-check for correct assembling and connections.
11. If necessary update the firmware and re-calibrate according calibration instructions 1022759.
POWERWARE Approved
Finland Checked MT No 1022757 Rev A
Issued RR 16.4.2003 Page 1 (1)
9155
1. Save the alarm log label the file with the serial number of the unit (refer to service software
description……..chapter …). Inform the customer, that the load has to be transferred to bypass.
2. Transfer the load to mechanical bypass -> refer to the user’s guide 1022403, page 30 !
Note: If there is no mechanical bypass (optional) assembled to the unit, inform the customer of
the fact, that the load has to be switched off for the time of servicing the UPS !
3. Shut down the UPS -> refer to the user’s guide 1022403, page 27 !
4. Turn rectifier input circuit breaker F2 and battery circuit breaker F1 off.
Note: The depleting of the DC bus takes about 5 minutes.
5. Remove the (black) front cover by pulling at the middle of the lower edge and lifting it upwards.
6. Unscrew the fixing bolts of the hood -> eight (89 at front, ten (10) at the back of the unit. Lift the
hood off the unit.
7. To be on the save side, check with a DMM between the power board terminals X24 and X15, DC
bus positive, and terminals X24 and X11, DC bus negative, the voltages to be less than 50V (for
terminal locations refer to board layout 1021592).
8. Disconnect the ribbon cable X6 and the display cable X17 (RJ 45) from the power board.
9. Squeeze the retainer tongue of the 3 plastic supports and lift the near by edge of the control
board slightly up. Press both thumbs against the power board and pull the control board out of
it’s sockets.
Note: The control board shall not be bent, since otherwise SMD components soldering points
might suffer by getting cracked.
10. Check the spare board’s firmware revision and if necessary update it -> refer to step 12.
11. Assemble the spare board to the unit and reconnect the cables to X6 and X17 to the power board.
12. Make sure, that all tools are removed from the unit, thereafter turn input and / or battery circuit
breaker on. Do NOT yet start up the unit!
Note: If the firmware has to be updated do it now -> refer to calibration instructions ….. and
service bulletins regarding firmware updates.
13. Calibrate the unit according calibration instruction … (only control board related values).
POWERWARE Approved
Finland Checked MT No 1022758 Rev A
Issued RR 16.4.2003 Page 1 (2)
9155
14. Check, if the displays selection still shows “TURN UPS ON” and press “ENTER”
15. Once the unit is in operation, execute several transfers from inverter to bypass and vice versa.
Check the output voltages of the UPS with a DMM and compares them to the respective
readings at the display.
17. Transfer the load (from bypass) back to the UPS -> refer to user’s guide, page 31.
POWERWARE Approved
Finland Checked MT No 1022758 Rev A
Issued RR 16.4.2003 Page 2 (2)
9155 / 9355
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 1 (12)
9155 / 9355
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 2 (12)
9155 / 9355
The formula typically used to adjust any 10 000 based (linear) calibration factor is as follows:
All the offset factors are 10 000 by default. The analog channels can be often “auto-zeroed” by the firmware
and correct values written to corresponding offset EEPs. The spare parts are factory calibrated. Need for
field calibration is limited.
At the low end of the measuring range the offset has the biggest influence to error and as measured values
increase, effect of the scale factors increase. When the metering is calibrated, first the offset has to be
adjusted up or down to make the metered value zero when actual value is zero. This matches the “starting
points” of the curves.
Next step is to adjust the scale factors so that the formula gain equals the gain of the analog circuit i.e. both
curves have the same angular coefficient.
Now the metered value matches actual value throughout the measuring range.
When the offset is adjusted with RMS calculation (AC measurements), the metering doesn’t get negative
values since the samples are squared. Both negative and positive offset in signal will make the metered value
to increase. During the calibration one has to find the “bottom” of the V-curve. Minimum value may not
reach zero due noise on the signal.
The UPS has rectifier supplies connected and logic power on but UPS is not turned on (output is off). Prior
applying power for the rectifier input, jumpers have been installed inside UPS to zero metering signals. For
detailed instructions see 1.3 Calibration procedures.
Calibration value found from this location is 10000.
Meter value as seen by the XCP Service Tool (and DSP) shows 1.6Vac.
Meter value as seen by a calibrated DMM shows 0.1Vac.
Adjust the DSP EEP 3011 from 10000 with step of 10 increments to either direction. If metered value
increases, adjust to opposite direction. Adjust EEP value until a minimum value is achieved. To get best
possible result it may be necessary to use smaller steps than 10 increments.
This means that meter calibration factor must be decreased by 1.43% to a new EEP value of 9857 (98.57%).
Value 10000 in DSP EEP 3040 is replaced with a value of 9857. The metered value now seen by UPS
should be 227.7Vac, a true representation of the actual voltage measurement.
• NOTE#1: Exact EEP values for meter calibration factors may have to be altered slightly from
calculated result in able to achieve exact meter values desired.
• NOTE#2: When a metering is used as a controller’s feedback, like inverter voltage or DC link,
the value seen by the UPS does not change since the controller will adjust it’s own output to
match the feedback with the reference (target) level. In this case the correct calibration has to
be verified from DMM i.e. to adjust the output to the desired level.
The same techniques just illustrated above are used for calibrating meter values and display values as they
relate to current and power values.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 4 (12)
9155 / 9355
AC Voltage Measurements
EEP Measurement Test Point Reference
3010 Output Volts L1-N Scale X2 L1 N
3026 Bypass Volts L1-N Scale X1 L1 N
3040 Utility Volts L1-N Scale F2 L1 N
To
3042 Utility Volts L2-N Scale F2 L2 N
3044 Utility Volts L3-N Scale F2 L3 N
3056 Inverter Volts L1-N Scale A2, F1 N
3070 Output DC Volts L1-N Scale --- ---
AC Current Measurements
EEP Measurement Test Wire From / To
3032 Output Current L1 Scale
3046 Utility Current L1 Scale
3048 Utility Current L2 Scale To
3050 Utility Current L3 Scale
3062 Inverter Current L1 Scale
DC Voltage Measurements
EEP Measurement Test Point Reference
3018 Battery Volts Scale F1 + F1 -
To
3020 DC Link Positive Scale A1, X15 N
3022 DC Link Negative Scale A1, X1 N
DC Current Measurements
EEP Measurement Test Wire From / To
3052 Battery Amps Scale To
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 5 (12)
9155 / 9355
1.2.3 OFFSETS
AC Voltage Measurements
EEP Measurement Jumper From/ To
3011 Output Volts L1-N Offset A2, J40
3027 Bypass Volts L1-N Offset A2, X19
3041 Utility Volts L1-N Offset ---
3043 Utility Volts L2-N Offset ---
TO A2, J54
3045 Utility Volts L3-N Offset ---
3057 Inverter Volts L1-N Offset A2, J38 or F1
3069 Chassis Volts Offset ---
3071 Output DC Volts L1-N Offset (A2, J40)
AC Current Measurements
EEP Measurement
3033 Output Current L1 Offset --- ---
3047 Utility Current L1 Offset --- ---
3049 Utility Current L2 Offset --- ---
3051 Utility Current L3 Offset --- ---
3063 Inverter Current L1 Offset --- ---
DC Voltage Measurements
EEP Measurement Jumper From/To
3019 Battery Volts Offset A2, R124(L)
3021 DC Link Positive Offset A1, X15 TO A2, J54
3023 DC Link Negative Offset A2, R216(L)
DC Current Measurements
EEP Measurement
3053 Battery Amps Offset --- ---
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 6 (12)
9155 / 9355
If customer’s loads are supplied by the UPS, all the calibrations are preferred to do while in Maintenance
Bypass whenever possible. Otherwise load may have to be disconnected for some of the calibrations.
• NOTE: The Internal Maintenance Bypass disconnects the NEUTRAL from the UPS. The
neutral is required whenever the UPS is operating from mains supplies. This applies also for
the logic power supplies. Closing the bypass switch may be needed to provide a neutral for
the UPS even the calibration wouldn’t require it.
The Auto-Standby function can be enabled and disabled via XCP Service Tool Options screen. The UPS
logic power has to be recycled for changes to take effect. Spare PCBAS Control boards should have Auto-
Standby disabled (firmware’s default setting). After the calibrations the Auto-Standby should be enabled for
UPS normal operation unless otherwise instructed.
If at any time during this procedure an alarm condition prevents the continued execution of the following
steps, please verify the issued alarm to determine and correct the cause of the event annunciation.
The current offset calibrations have to be verified after a board replacement since part of the analog circuits
of current measurements locates on IO-Board. Those may have to be performed manually for each offset
calibration according the instructions in this document.
The voltage offset calibrations needs to be adjusted on field only in rare occasions. The instructions how to
perform voltage offset calibrations are provided in this document. The procedure for the voltage offset
calibrations requires carefulness and should not be done unless instructions fully understood. These
calibartion steps like any other calibrations are meant to be done by trained and authorized personnel only.
The UPS must be restored to normal condition after the calibrations or any other service procedures.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 7 (12)
9155 / 9355
1. Begin with all power removed from UPS, input and battery breaker open.
If using a MBS, make sure the maintenance isolation switch is open.
2. Remove the covers of the UPS if not done so yet.
3. Place jumpers inside UPS,
FROM: UDC+, Power Board X15-1
UDC-, IO Board R216(L)
TO: N, IO Board J54
NOTE: Connect the jumpers to instructed locations or damage to the unit may occur.
Proceed with steps 4 – 10 only if voltage offset need to be calibrated. Not required for
a factory calibrated (spare) control board.
4. Close battery breaker and wait for logic power, disable Auto-Standby with XCP Service Tool
if enabled.
5. Open battery breaker and make sure the UPS is isolated from all power sources.
6. Place jumpers inside UPS,
FROM: UDC+, Power Board X15-1
UDC-, IO Board R216(L)
Battery +, IO Board R124(L)
Bypass, IO Board X19
Output, IO Board J40
Inverter, IO Board J38 (or F1)
TO: N, IO Board J54
(L) refers to left side or end of the component.
NOTE: Connect the jumpers to instructed locations or damage to the unit may occur and
calibrations may fail.
7. Close rectifier input breaker. Neutral is required to enable logic power supplies. NOTE:
Bypass isolation breaker of the MBS may be closed for this, but if Auto-Standby is not
disabled, severe damege to unit may occur if bypass supply voltage is connected.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 8 (12)
9155 / 9355
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 9 (12)
9155 / 9355
1. Begin with rectifier input power connected. Bypass supplies may be required to provide a
neutral for the UPS.
2. Calibrate Utility Volts:
a) Measure Utility Input Voltage from Input Breaker (F2) L1 to N
b) Adjust EEP 3040 until Uutil L1 voltage meter matches DMM
c) Measure Utility Input Voltage from Input Breaker L2 to N
d) Adjust EEP 3042 until Uutil L2 voltage meter matches DMM
e) Measure Utility Input Voltage from Input Breaker L3 to N
f) Adjust EEP 3044 until Uutil L3 voltage meter matches DMM
• NOTE: In case of a single phase input model, use Input Breaker L1 also in steps c) and e).
3. Calibration completed.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 10 (12)
9155 / 9355
1. Begin with all input power removed from UPS, rectifier and battery breaker open.
If using a MBS, make sure the maintenance isolation switch is open.
2. Remove the covers of the UPS if not done so yet.
3. Apply rectifier input power, UPS in STANDBY mode (Auto-Standby enabled). Bypass
supplies may be required to provide a neutral for the UPS.
4. Calibrate DC Link Positive Volts:
a) Measure DC Link Positive Voltage from Power Board X15-1 to X22-1 (N).
b) Adjust EEP 3020 until DC Bus POS voltage meter matches DMM
5. Calibrate DC Link Negative Volts:
a) Measure DC Link Negative Voltage from Power Board X1-1 to X22-1 (N).
b) Adjust EEP 3022 until DC Bus NEG voltage meter matches DMM
NOTE: This calibration effects also the Battery Voltage metering!
6. Verify correct battery voltage metering.
Note: Battery Volts Scale Factor has to be calibrated according 1.3.1.
7. Calibration completed.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 11 (12)
9155 / 9355
1. Begin with UPS bypass and rectifier supplies connected, STANDBY mode (Auto-Standby
enabled).
2. Calibrate Bypass Volts:
a) Measure Bypass Input Voltage from X1 L1 to N
b) Adjust EEP 3026 until Ubyp L1 voltage meter matches DMM
3. Calibration completed.
1. Begin with UPS in NORMAL mode. If in Maintenance Bypass, make sure the maintenance
isolatation switch is open before starting the UPS.
2. Calibrate Output Volts:
a) Measure UPS Output Voltage from X2 L1 to N.
b) Adjust EEP 3010 until Uout L1 voltage meter matches DMM
3. Calibration completed.
1.4 Warning
This document provides additional information about 9155 / 9355 for a service purposes. Service should not
be performed anyone else except trained and authorized service personnel.
This document is not to be used with any other product than 9155 / 9355. Doing so, may cause severe
damage to the equipment.
Title
9155 / 9355 Calibration instruction for Field Serrvice
EATON Powerware Approved PK
Finland Checked RR No 10 22759 Rev A
Issued JP 15.11.2004 Page 12 (12)
Powerware
This Preventative Maintenance Instruction is for use with the preventative maintenance work of the
Powerware UPS products. The products which this instruction concerns are listed in this document in
chapter Measurements and Calibrations. This document describes the maintenance activities that are
common to all the UPS products of the above mentioned list. The instructions for maintenance tasks
that are unique to specific UPS products are described in attached documents. See chapter
Measurements and Calibrations.
Long life batteries under maintenance contract or under extended warranty time shall be handled
according to instruction Annual Preventative Maintenance Instructions for Batteries Under
Preventative Maintenance Contract, 1005611.
SAFETY PRECAUTIONS
This instruction and the attached documents for specific products are for use of the qualified personnel
only. A qualified person in this case means a person who has completed Powerware service training for
the specific product type the maintenance work is to be performed.
Many components inside the UPS - and battery cabinets carry high AC- or DC- voltages. To touch them
may prove fatal. All maintenance and repair work must be performed with extreme caution.
The following general safety precautions must be observed when performing maintenance to
Powerware UPS'.
1: No repair or maintenance activity shall be performed unless repair/maintenance personnel
fully understand and carry out the necessary repair or maintenance procedures.
2: When a UPS unit is shut down for maintenance work the DC-voltage will occur several
minutes inside the cabinet. Before performing any maintenance work the discharge of the
DC-capacitor bank MUST be measured.
3: Test equipment such as an oscilloscope etc. MUST be isolated from the commercial ground.
The chassis of an oscilloscope MUST NOT be in touch with the chassis of the UPS. Only one
ground lead of an oscilloscope can be used.
4: The battery bank carries high voltage also when the unit is shut down and must therefore be
handled extremely carefully. The batteries include corrosive materials that can be harmful for
eyes, skin and clothing. Any leakage must be cleaned carefully.
5: Any metal articles such as watches, rings, chains etc. must not be worn.
6: Use common sense to avoid hazards.
GENERAL INSTRUCTIONS
If repairs are needed they shall be carried out for units under contract and costs will be borne by
Powerware or customer depending on the maintenance level of the contract. For units not under
contract repairs shall be proposed to the customer and carried out at customers expense after approval
from customer.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 1 (6)
Powerware
CUSTOMER INFORMATION
Fill in correct customer name and contact person responsible for maintenance of system. Check other
customer data on FSR and make changes if incorrect.
UNIT INFORMATION
Fill in unit type number and serial number from type plate located inside the door.
SITE CONDITIONS
Room Temp
Measure room temperature using an electronic thermometer. Room temperature shall
normally between +18 and +25°C, (O- +40°C is maximum according to specification). If
temperature is outside normal values then the customer shall be advised. If temperature is
significantly outside normal values customer actions shall be proposed. Service contracts
are only valid if temperature is kept below 40°C.
The ambient temperature requirements can alter by the battery brand. Refer to the
specification and warranty terms of the battery manufacturer.
Humidity
Check that site location is dry and non-condensing and give status in report: dry, acceptable
or wet. If acceptable or wet customer actions shall be proposed
Cleanliness
Check that site location is clean and free from dust and dirt and give status in report: clean,
acceptable or dirty. If acceptable or dirty customer actions shall be proposed.
INSTALLED OPTIONS
Identify up what options the customer has bought with the system and make notes in report: product
type and serial number for standard options.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 2 (6)
Powerware
CLEANING
Before commencing cleaning, put the UPS to manual bypass and switch it off, disconnect possible
external battery circuit breaker and make sure that the unit is "dead". Be careful with battery voltage.
Inspect DC connections
Check that all DC connections are free from oxide, clean and well greased, if not clean and
grease.
TECHNICAL UPDATES
Installed bulletins
For the units under contract install all actual bulletins from bulletin list and note in report
number of bulletins installed. For the units not under contract customers should be offered to
have bulletins installed according to Service Bulletin price list.
SAFETY GROUNDING
UPS - battery cabinet
Check the ground connection between the UPS and the battery cabinets for tightness and
good connection. Measure also the voltage between battery cabinet and UPS cabinet. The
voltage shall be zero, if not follow up and fix the grounding arrangement.
VISUAL CHECKS
Electrical modules
Check that all electrical modules are securely fitted, free from damage and other visible
weaknesses.
Internal connections
Check that all internal connectors are securely connected and free from damage and other
visual weaknesses. All screw and nut connections shall be tightened.
Electrolytic capacitors
Check all electrolytic capacitors for visual leakage.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 3 (6)
Powerware
Cooling fans
Check mechanical status of cooling fans, test that they are running smoothly without
abnormal vibrations or noise.
Batteries
Check the battery bank for visual leakage or other damages.
Battery connections
Check and tighten all external connections to UPS, battery and load. Check that mains and
distribution fuses are correct according to cable area and load power. Check the tightening
torque of some battery terminals according to the battery manufacturers data.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 4 (6)
Powerware
RMS current
Measure the RMS current using a power meter or DMM with current clamp and note in
report the value.
Peak current
Measure the peak current using an oscilloscope and note in report the value. Check that actual
peak current is within UPS specification, if not give warning note and suggest corrective
actions to customer.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 5 (6)
Powerware
BATTERY TEST
The following activities will mainly be performed with voltage on. Ensure all activities are performed
safely.
Date installed
Check date of installation of battery from maintenance log or check manufacturing date on
batteries and note in report.
Battery size
Check and note battery data: manufacturer, quantity and type.
Back-up time
Measure the actual battery back-up time. Refer to attached document for details of procedure
relevant to specific UPS type.
Battery status
Based on the result of the above measurement give status in report from the following
categories: OK, WEAK or NO GOOD. Give comments in report.
NOTES
Give special notes related to items above using a number marker in "Note" column.
POWERWARE Approved
Finland Checked PK No 1003671 Rev F
Issued RR 23.03.04 Page 6 (6)
9155 / 9355
Purpose.........................................................................................................................................3
Audience ......................................................................................................................................3
Definitions....................................................................................................................................3
#004 BYPASS_AC_UNDER_VOLTAGE..................................................................................4
#010 OUTPUT_AC_UNDER_VOLTAGE .................................................................................4
#012 REMOTE_EMERGENCY_POWER_OFF.........................................................................5
#014…19 BUILDING_ALARM_6…1 .......................................................................................5
#021 CHARGER_OVER_TEMPERATURE ..............................................................................5
#024 INVERTER_OVER_TEMPERATURE .............................................................................6
#025 OUTPUT_OVERLOAD .....................................................................................................6
#026 RECTIFIER_INPUT_OVER_CURRENT..........................................................................7
#027 INVERTER_OUTPUT_OVER_CURRENT ......................................................................7
#028 DC_LINK_OVER_VOLTAGE ..........................................................................................7
#029 DC_LINK_UNDER_VOLTAGE .......................................................................................8
#030 RECTIFIER_FAILED.........................................................................................................8
#033 BYPASS_BREAKER_FAIL ..............................................................................................9
#042 DC_VOLTAGE_UNCALIBRATED..................................................................................9
#047 BATTERY_CURRENT_LIMIT.........................................................................................9
#048 INVERTER_STARTUP_FAILURE.................................................................................10
#055 SHUTDOWN_IMMINENT..............................................................................................10
#056 BATTERY_LOW .............................................................................................................11
#057 UTILITY_FAIL ................................................................................................................11
#059 UTILITY_NOT_PRESENT..............................................................................................11
#068 BATTERY_DC_OVER_VOLTAGE ...............................................................................12
#071 POWER_SUPPLY_5_VOLT_FAULT.............................................................................12
#072 POWER_SUPPLY_12_VOLT_FAULT...........................................................................13
#074 HEATSINK_TEMPERATURE_SENSOR_FAILED.......................................................13
#094 TO_BYPASS_COMMAND .............................................................................................13
#105 BYPASS_NOT_AVAILABLE.........................................................................................14
#107 BATTERY_CONTACTOR_OPEN..................................................................................14
#143 ON_MANUAL_MAINTENANCE_BYPASS..................................................................15
#149 BATTERY_NEEDS_SERVICE .......................................................................................15
#159…161 LEVEL_2_OVERLOAD_PHASE_A/B/C..............................................................15
#162…164 LEVEL_3_OVERLOAD_PHASE_A/B/C..............................................................16
#165…167 LEVEL_4_OVERLOAD_PHASE_A/B/C..............................................................16
#168 UPS_ON_BATTERY .......................................................................................................17
#169 UPS_ON_BYPASS...........................................................................................................17
#174 LOW_BATTERY_SHUTDOWN.....................................................................................17
#176 SOFTWARE_INCOMPATIBILITY_DETECTED..........................................................18
#188 BYPASS_FAILURE .........................................................................................................18
#191 BATTERY_TEST_FAILED.............................................................................................19
#192 FUSE_FAILURE ..............................................................................................................19
#194 SITE_WIRING_FAULT...................................................................................................19
#199 BATTERIES_DISCONNECTED.....................................................................................20
#201 TRANSFORMER_OVERTEMPERATURE....................................................................20
Purpose
This document contains 9155 / 9355 notices and alarms. Each event has a short description with
reason, consequence, and possibly appropriate remedy. Not all descriptions are complete.
This document does not contain descriptions of any status information.
Audience
This document is an aid for product support and field service. This document shall not be directly
distributed to customers.
Definitions
XCP Al. #
XCP knows only a subset of the alarms. In other words, several display alarms share the same XCP
alarm.
Level
There are three information levels like: Alarm, Notice and Status.
Alarms need immediate attention and most likely action, since the load might be in danger to be lost.
A notice on the other hand is primarily a user information,
A status reflects the operation mode of the UPS and is saved to the event log. Status information is
not described within this document.
Horn
The horn has 3 different sound levels to indicate alarms: Hi, medium, low, none.
Horn intervals:
• Hi: 0.5s on, 0.5s off.
• Med.: 0.5s on, 1s off.
• Low: 0.5s on, 5s off
• None: no sound.
Call
You can set a call bit for any alarm, you want to initiate a phone call (service settings). Up to 31
alarms may initiate a phone call. For phone calls connect a modem to the UPS and configure the port
for the modem and the modem commands. (service settings). By default no alarm will cause phone
call.
Relay
The unit has one built-in signal output relay. Up to 8 additional relays can be added via X-Slot cards.
The standard relay configuration is:
• Alarm-1 (built-in): UPS ok
• X-SLOT1-1: on bypass
• X-SLOT1-2: UPS ok
• X-SLOT1-3: battery low
• X-SLOT1-4: on battery
• X-SLOT2-1: on bypass
• X-SLOT2-2: UPS ok
• X-SLOT2-3: battery low
• X-SLOT2-4: on battery
#004 BYPASS_AC_UNDER_VOLTAGE
Reason
Bypass voltage is below Bypass voltage deviation low limit.
Consequence
Bypass is not available. Battery test is not possible.
Remedy
#010 OUTPUT_AC_UNDER_VOLTAGE
Reason
Output voltage is below Bypass voltage deviation low limit.
Consequence
The UPS does not start. The UPS shuts down and drops the load.
Remedy
#012 REMOTE_EMERGENCY_POWER_OFF
Reason
Remote emergency power off input active: X12
Consequence
The UPS does not start. The UPS shuts down and drops the load.
Remedy
#014…19 BUILDING_ALARM_6…1
Reason
Input signal X44, X45, or X-Slot RX-Break signal active.
Consequence
Signal function for this signal is active. See Signal Inputs, in User Settings
Remedy
Check Signal Input settings, and X-Slot Signal input activation delay in User Settings.
Inactivate the input, reconfigure the input signal function, or reconfigure the alarm settings
#021 CHARGER_OVER_TEMPERATURE
Reason
Battery temperature is above limit: 10 kVA type: 75º C, 15 kVA type: 95º C.
Consequence
Remedy
#024 INVERTER_OVER_TEMPERATURE
Reason
Inverter temperature is above limit: 10 kVA type: 75º C, 15 kVA type: 95º C.
Consequence
Remedy
#025 OUTPUT_OVERLOAD
Reason
Load is above 102% of nominal Output Power.
Consequence
The UPS transfers to bypass after 5s. If Bypass is not present, the UPS shuts down in 10min.
Remedy
#026 RECTIFIER_INPUT_OVER_CURRENT
Reason
Rectifier current is above hardware limit.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#027 INVERTER_OUTPUT_OVER_CURRENT
Reason
Inverter current is above hardware limit.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#028 DC_LINK_OVER_VOLTAGE
Reason
DC link voltage is above absolute limit.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down. The UPS
does not start.
Remedy
#029 DC_LINK_UNDER_VOLTAGE
Reason
DC link voltage is below absolute limit.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#030 RECTIFIER_FAILED
Reason
Rectifier did not start as expected.
Consequence
UPS won’t start
Remedy
#033 BYPASS_BREAKER_FAIL
Reason
Backfeed relay does not work as expected.
Consequence
UPS won’t start
Remedy
#042 DC_VOLTAGE_UNCALIBRATED
Reason
Calibration required flag required in EEPROM is set.
Consequence
UPS won’t start
Remedy
Clear Calibration required flag: EEPROM 3001
#047 BATTERY_CURRENT_LIMIT
Reason
Battery current is above hardware limit.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#048 INVERTER_STARTUP_FAILURE
Reason
Inverter did not start as expected. Inverter fuses failed. Unexpected Voltage at inverter output.
Inverter SCR voltages out of limits.
Consequence
UPS won’t start
Remedy
#055 SHUTDOWN_IMMINENT
Reason
A running timer shuts the UPS down in less than a minute.
Consequence
Load is dropped.
Remedy
Minute timers (XCP commands 0x91, 0x93): Set the timers to 0.
Second timer (XCP command 0x8A): shortly push the OFF button.
#056 BATTERY_LOW
Reason
Battery voltage is below configured Alarm level (Parameter 25, service settings).
Consequence
UPS will support the load for a limited time only.
Remedy
#057 UTILITY_FAIL
Reason
Utility voltage is out of limits, too high, too low, or not present.
Consequence
UPS transfers to bypass or to battery.
Remedy
#059 UTILITY_NOT_PRESENT
Reason
Rectifier input voltages are out of hardware limits.
Consequence
UPS transfers to bypass or to battery.
Remedy
#068 BATTERY_DC_OVER_VOLTAGE
Reason
Battery voltage is above charge target voltage + battery overvoltage offset (5VPC) for at least 60s.
Consequence
Batteries circuit breaker gets tripped (forced rest mode).
Remedy
#071 POWER_SUPPLY_5_VOLT_FAULT
Reason
5 volts power supply is not OK (hardware sensor).
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#072 POWER_SUPPLY_12_VOLT_FAULT
Reason
12 volts power supply is not OK (hardware sensor).
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down.
Remedy
#074 HEATSINK_TEMPERATURE_SENSOR_FAILED
Reason
Heatsink temperature values are unreasonable. Suspicion for heatsink temperature sensor failure.
Consequence
The UPS transfers to bypass immediately.
Remedy
#094 TO_BYPASS_COMMAND
Reason
A User action, or active signal input commands the UPS to bypass
Consequence
UPS transfers to bypass.
Remedy
Transfer the UPS to inverter over display.
#105 BYPASS_NOT_AVAILABLE
Reason
Bypass failed, or bypass voltage out of limits, or bypass disabled by user or signal input.
Consequence
UPS stays on inverter.
Remedy
#107 BATTERY_CONTACTOR_OPEN
Reason
Input signal function "ext. battery breaker" is active
Consequence
Battery charging disabled.
Remedy
Check signal input.
#143 ON_MANUAL_MAINTENANCE_BYPASS
Reason
Signal input “Force bypass” is active.
Consequence
The UPS transfers to bypass.
Remedy
Check signal input (User settings).
#149 BATTERY_NEEDS_SERVICE
Reason
Battery voltage is negative during UPS start (< -100V).
Consequence
UPS trips battery breaker.
Remedy
#159…161 LEVEL_2_OVERLOAD_PHASE_A/B/C
Reason
Load is above 111% of nominal output power.
Consequence
The UPS transfers to bypass after 5s. If bypass is not present, the UPS shuts down in 60s.
Remedy
#162…164 LEVEL_3_OVERLOAD_PHASE_A/B/C
Reason
Load is above 126% of nominal output power.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down in 5s.
Remedy
#165…167 LEVEL_4_OVERLOAD_PHASE_A/B/C
Reason
Load is above 151% of nominal output power.
Consequence
The UPS transfers to bypass immediately. If bypass is not present, the UPS shuts down in 300ms.
Remedy
#168 UPS_ON_BATTERY
Reason
UPS has been on battery at least 5 seconds continuously, (Parameter 17, service settings).
Consequence
Battery gets discharged. A new ABM cycle will start when UPS goes off battery. Delayed shutdown
and restart timer may start, if configured, “Automatic on battery shutdown delay” > -1s.
XCP monitoring PC-software starts to shut down PCs, if this alarm gets active.
Remedy
#169 UPS_ON_BYPASS
Reason
UPS is in Bypass state (Bypass controller signal).
Consequence
Remedy
#174 LOW_BATTERY_SHUTDOWN
Reason
Battery voltage is below shutdown limit.
Consequence
UPS drops load after 60s. If battery is worse, the UPS drops the load in 1s.
Low battery shutdown alarm stays active until rectifier is running or system is on bypass.
Remedy
#176 SOFTWARE_INCOMPATIBILITY_DETECTED
Reason
Hardware is incompatible to DSP firmware, PLD version is incompatible to DSP firmware version.
Consequence
UPS won’t start.
Remedy
Chose right firmware. Update all processors and PLDs to the latest release.
#188 BYPASS_FAILURE
Reason
Bypass processor did not execute last command (timeout).
Consequence
Bypass not available.
Remedy
#191 BATTERY_TEST_FAILED
Reason
Battery charge failure. Assumption: bad batteries.
Consequence
Battery operation is not reliable.
Remedy
#192 FUSE_FAILURE
Reason
Inverter output voltage not OK. Assumption: fuse failure
Consequence
Load is not powered.
Remedy
#194 SITE_WIRING_FAULT
Reason
UPS chassis voltage potential is above 100V.
Consequence
Remedy
#199 BATTERIES_DISCONNECTED
Reason
Batteries are disconnected (also when built-in battery breaker is open).
Consequence
ABM resting, batteries not being charged, new charging cycle will start.
Remedy
Connect batteries. Close the battery breaker
#201 TRANSFORMER_OVERTEMPERATURE
Reason
Transformer overtemperature signal input is active (user settings).
Consequence
Load dump within delayed off ROM time (User settings)
Remedy
#202 AMBIENT_UNDERTEMPERATURE
Reason
Temperature is below 0º C
Consequence
Remedy
#203 AMBIENT_OVERTEMPERATURE
Reason
Temperature is above 45º C
Consequence
Remedy
#206 AUTOMATIC_SHUTDOWN_PENDING
Reason
shutdown in < 1 minute due to output transformer overtemperature (input signal).
Consequence
Load dump in less than 1 minute.
Remedy
#211 MODEM_FAILED
Reason
Modem did not react on reset command.
Consequence
Modem is not available.
Remedy
Check the modem, connect it to correct port. If using X-SLOT 2, check that the communication is not
locked to service port (service setting)
#212 INCOMING_MODEM_CALL_STARTED
Reason
UPS detected data over the modem cable.
Consequence
UPS assumes an ongoing telephone call.
Remedy
End the call via normal modem operation or reset the modem (service setting).
Check modem connected port number (service setting).
#213 OUTGOING_MODEM_CALL_STARTED
Reason
An active alarm is configured to make a phone call and starts the call.
Consequence
A phone call is initiated.
Remedy
End the call via normal modem operation or reset the modem (service setting)
#214 MODEM_CONNECTION_ESTABLISHED
Reason
Modem connection was established. Line is open.
Consequence
Line will be closed down in 5 minutes in case of no activity.
Remedy
End the call via normal modem operation or reset the modem (service setting)
#216 MODEM_CALL_COMPLETION_FAILED
Reason
Modem call attempt could not be completed, connection not established
Consequence
Modem call will be re-attempted later if all the retries are not yet done
Remedy
Wait for modem call reattempt or reset the modem (service setting)
#222 ABNORMAL_OUTPUT_VOLTAGE_AT_STARTUP
Reason
Significant voltage at UPS output detected, although Inverter and bypass are inactive.
Consequence
Remedy
#223 RECTIFIER_OVERTEMPERATURE
Reason
Rectifier temperature is above warning limit: 10 kVA-types: 75º C, 15 kVA-types: 95º C.
Consequence
UPS stays on bypass, if on bypass.
Remedy
#224 CONFIGURATION_ERROR
Reason
Start check routine has reset part of EEPROM to default, or copied from backup EEPROM
Consequence
UPS won’t start
Remedy
Check settings of UPS and restart the UPS.
#229 SUMMARY_ALARM
Reason
Active when the UPS is ON and there is an active alarm (Summary Alarm), inactive when UPS OK
(see #258).
Consequence
Remedy
#238 EEPROM_FAULT
Reason
UPS could not access EEPROM.
Consequence
UPS won’t start
Remedy
Reset EEPROM. Replace faulty EEPROM.
#240 BATTERY_TEST_FAILED_OCV
Reason
Battery open cell voltage dropped below the monitoring level during the first 10 days in rest mode.
Consequence
Automatic battery support tests will not be done while the alarm is active
Remedy
#241 BATTERY_TEST_FAILED_CHRG
Reason
UPS could not completely charge batteries during the charge cycle.
Consequence
Automatic battery support tests will not be done while the alarm is active.
Remedy
#243 BATTERY_CHARGING_DISABLED
Reason
Input signal function "charger off" is active.
Consequence
Batteries are forced to rest, no charging.
Remedy
Deactivate or reconfigure the input signal (User settings).
#244 ILLEGAL_OPERATION_TRAP
Reason
Control board hardware fault.
Consequence
UPS behaves unpredictably.
Remedy
Change control board. Update all firmware to latest release.
#245 POWER_NMI
Reason
Control board hardware fault.
Consequence
UPS behaves unpredictably.
Remedy
Change control board. Update all firmware to latest release.
#246 WATCHDOG_TRIP
Reason
Control board hardware fault.
Consequence
UPS behaves unpredictably.
Remedy
Change control board. Update all firmware to latest release.
#247 EXTERNAL_WATCHDOG_FAILURE
Reason
Control board hardware fault.
Consequence
UPS behaves unpredictably.
Remedy
Change control board. Update all firmware to latest release.
#248 RECTIFIER_OVERTEMPERATURE_SD
Reason
Temperature is above shutdown limit: 10 kVA type: 85º C, 15 kVA type: 105º C. Also active, if
sensor fails.
Consequence
UPS shuts down.
Remedy
#249 CHARGER_OVERTEMPERATURE_SD
Reason
Battery temperature is above shutdown limit: 10 kVA type: 85º C, 15 kVA type: 105º C. Also active,
if sensor fails.
Consequence
Batteries are forced to rest, no charging. Battery start impossible.
Remedy
#250 INVERTER_OVERTEMPERATURE_SD
Reason
Temperature is above shutdown limit: 10 kVA type: 85º C, 15 kVA type: 105º C. Also active, if
sensor fails.
Consequence
UPS transfers to bypass, or shuts down. UPS won’t start.
Remedy
#251 POWER24V_STARTUP_FAIL
Reason
24 Volts power supply for control board is not OK.
Consequence
UPS won’t start.
Remedy
#252 UNIT_IS_NOT_9155/9355
Reason
The Control board hardware does not fit to this firmware.
Consequence
UPS won’t start.
Remedy
#253 INCOMPATIBLE_PLD_VERSION
Reason
DSP firmware is too old for the control board’s PLDs.
Consequence
UPS won’t start.
Remedy
Update all firmware to the latest release.
#254 POWER_SUPPLY_24_VOLT_AD_FAULT
Reason
24 Volts power supply for control board is not OK (analog sensor).
Consequence
UPS won’t start.
Remedy
#255 POWER_SUPPLY_24_VOLT_DIGITAL_FAULT
Reason
24 Volts power supply for control board is not OK (digital sensor).
Consequence
UPS won’t start.
Remedy
#257 OUTPUT_KW_OVERLOAD
Reason
Output KW are above maximum.
Consequence
See alarm #195…167.
Remedy
#258 UPS_OK
Reason
Normally active when UPS is on and OK, inactivates when any alarm is active (Summary Alarm) (see
#229).
Consequence
Relays get active.
Remedy
#259 NEUTRAL_FAULT
Reason
Neutral fault is triggered when chassis voltage is over 30V and either DC bus
voltage is over 450V. Neutral fault can be disabled by a user settable parameter.
Consequence
Neutral fault causes transfer on battery. PW9155 can not reliably detect neutral fault while on battery;
thus UPS tries to transfer back from battery on line after one minute. The UPS does not clear the
neutral fault alarm until Neutral is OK for at least one more minute.
Utility voltage and bypass voltage alarms are disabled. Utility fail (#57) and bypass not available”
(#105) alarms are activated.
Remedy
#260 BYP_SCR_FAILED
Reason
Output voltage is not OK while UPS is on bypass or voltage at bypass while bypass is off.
Consequence
Bypass is not available. UPS may shut down.
Remedy
#261 DCCHARGER_FAILED
Reason
UPS failed to charge DC-bus to desired voltage level at UPS start.
Consequence
UPS won’t start.
Remedy
#262 BALANCER_RLY_FAILED
Reason
UPS failed to charge the DC-bus positive, and negative rail symmetrically at start.
Consequence
UPS won’t start.
Remedy
#263 FAST_MODE_TRIP
Reason
Rectifier was too long in “fast mode” (timeout).
Consequence
UPS transfers to bypass. UPS may shut down.
Remedy
Parameter settings
Parameter 0, (U)*
Start screen Default : 0, Powerware logo.
Option : 1, mimic screen.
Parameter 1, (U)*
Language selection Default : 0, first language in the language pack, English.
Options: 1- 3 (attached)
Parameter 2, (U)*
User password Default : 0, password for user settings disabled.
Option : 1, password for user settings, "USER" enabled.
Parameter 3, (U)*
Audible alarms Default : 1, audible alarms are enabled.
Option : 0, UPS stays permanently silent.
Parameter 4, (U)*
Behavior on input break Default : 1, prefer bypass.
Option : 0. prefer battery.
Parameter 5, (U)*
Transfer to bypass when overload Default : 0, transfer immediately.
Option : 1, transfer after a load dependent delay (refers to
overload levels, tech. spec., user guide.
Parameter 6, (U)*
Transfers to bypass Default : 0, unsynchronized transfers to bypass
Option : 1, synchronized transfers to bypass.
Parameter 7, (U)*
Synchronization Default : 0, enabled.
Option : 1, disabled, inverter free running
Parameter 8, (U)*
Bypass operation Default : 0, enabled.
Option : 1, transfer to bypass disabled
Parameter 9, (U)*
Site wiring fault notice Default : 0, notice enabled.
Option : 1, disabled,
Alarm # 194, "site wiring fault", and alarm # 259, "neutral fault"
are suppressed. If conditions leading to these alarms are present
during start up, the "UPS on" command is the suppressed and the
start up discontinued.
Parameter 10,
EPO Default : 0, EPO is enabled.
Option 1, EPO input X52 is ignored and X12 disabled.
Parameter 15,
Temperature compensat. charging Default : 0, temperature charging enabled
Option : 1, temperature compensation disabled.
Parameter 16,
Modem installed Default : 0, no modem installed:
Options: 1: modem connected to X-slot 1.
2: modem connected to X-slot 2/service port.
Parameter 17,
Battery operation Default : 5
Option : 0 - 99, sets the delay in seconds alarm # 168 is displayed
while the unit is in battery operation, can be set in steps of 1 second.
Parameter 18,
Start up delay (auto standby) Default : 0, no delay
Options : 1s - 9h in steps of 1second
-1, Remote start up only, via X44, X45, X-SLOTS
and/or XCP-service tool.
Parameter 19,
Battery operation shut down delay Default : -1, disabled.
Option : 0 - 10800 . Positive numbers indicate the shut down delay
in seconds, which can be set steps of 1 second. Meaning, that any
other value than "-1" leads to a predetermined shut down regardless
of the available battery back up capacity. The UPS restarts, once the
utility is available within the specified tolerance.
Parameter 26,
Constant float charge voltage Default : 2.270 V/cell.
Option : 2,150 - 2,335 V/cell.
This is the target battery charge voltage (refers to 25°C), if the
ABM is disabled, while the charger is permanently in operation.
Parameter 33,
Utility synchronization window Default : +/- 1.0Hz.
Option : 0,5 - 3,0Hz in steps of 0,1Hz .
Parameter 37,
Rectifier input current limit Default : 60 A for 8 - 10kVA units single phase input
20 A for 8 - 10kVA units three phase input
29 A for all 12 - 15kVA units
Parameter 38,
Reset modem Default : 0.
Option : 1, the UPS sends a reset command to the modem. The
modem ends communications and resets modem related errors.
Parameter 39,
Clear event log Default : 0.
Option : 1 The UPS clears the memory's event history.
Parameter 41,
Lock RS232 RX to service port Default : 0, X-slot 2 RX (receive) enabled.
Option : 1, only service port communication to UPS possible.
- but only -
Parameters 0 - 10, 14, 15 and 41 can be set via XCP - service tool.
UPDATE INSTRUCTION
If a unit's firmware shall be updated, refer to the instructions within this document. Service
bulletins will inform periodically about the availability and "update urgency" of new firmware,
which can be downloaded from the service web as a complete package including LangLoader.
1. Langloader
User: Customers, service engineer (main (DSP) firmware + display firmware)
DSP
The DSP is the main firmware, located in the main processor D1 of the control board (refer to
figure 1). Next to the control functions and the communication services, it includes a package
of 2- 4 languages. Available DSP firmware are:
9155 9355
Note: Each LangLoader package includes the DSP and the display firmware.
Figure 1
The LangLoader is easy to use, and allows therefore the user to update and/or change the
display language package according the following instruction:
• Connect the laptop to the RS232 port X53 of the UPS and start up the LangLoader
Shortcut to langLoader.exe.lnk
From the pull down menu you can select the COM port, or let "autodetect" find it.
Note:
• Do NOT keep service software tools within the "START UP" menu, otherwise the
COM port(s) of your PC might be blocked.
• Before you confirm the selection of the COM port, by clicking onto "Next>>", make sure,
that the "Power Options" of your PC are set to minimum:
Select <Start - Settings - Control Panel - Power Options - Power Schemes>
Turn off monitor after 10 min (or longer)
Turn off hard disk after 10 min (or longer)
System stand by after 10 min (or longer)
If the "Power Options" for hard disk and/or system stand by are set to a shorter time, you might
risk, that during the data transfer to the UPS, the PC will go to sleep mode and therefore will
reduce the baud rate automatically. As a result, the download requires more time or is stopped
completely.
Note: If however the window "Could not find any supported UPS..." is displayed, check the
baud rate of the serial port of the UPS. Select from the display: <Settings - User Settings - Serial
Port Config. - XSlot-2/Serv.> and set the baud rate to 19200. Make also sure, that parameter 12
(User settings - Contr. commands X-SLOT2/SERV) is set to "allowed" !
• Select from the pull down menu the most suitable language, "Revision info" informs about
the DSP and display revisions going to be downloaded.
• From the display submenu "Control" select "Go to Bypass Mode". The bypass operation is
confirmed by the yellow LED (third from top) of the front panel being lit. If no bypass is
available, inform the customer, that the load has to be switched off. Select from the display
"Turn UPS off" and press "Enter" for 5 seconds. KEEP THE CIRCUIT BREAKERS "F1"
AND "F2" CLOSED !
Note: If you forget to do so, the UPS will remind you once more by displaying the following
window:
If you confirm by clicking "Yes" but still didn't perform the action, the UPS will then
automatically switch to bypass mode, or switch itself off and start to download of the selected
firmware after the confirmation by clicking "Yes", or the displayed time within the following
window:
After the firmware has been downloaded, the following windows will appear:
• Confirm by clicking "OK", and proceed as instructed within the following window:
Note: The help folder (use pull down menu) within the above widow includes the file
"Quick-start guide (F1). In case, you encounter difficulties to download the firmware, read
this document before taking further actions.
2. Flash
User: Service engineer (Tool to download all firmware except "Bypass", 1022770)
Pwflas~3.exe
On top of the "Flash PROM Loader" the following window shall appear:
Note: If the communication settings are incorrect, the "Flash" software will inform:
If all communication settings are "OK", the following window shall appear.
• Select from the tool bar the "FOLDER" icon and within the folder the firmware you'd like
to flash. Refer to figure 1, at page 1 of this document.
• "Open" the firmware. As a result the 5th icon (from the left) of the "Flash PROM Loader"
window toolbar turn from gray to red.
• Click this icon to start the download. Within the following window it will be confirmed by
text: "Programming started"
Note: If the UPS for some reason still would be in normal mode (inverter operation) the
following window will appear and the "Flash PROM Loader" window turns from green
to red:
Once the programming has been completed the firmware is verified. The last action of the
download is, the reset command to the UPS, which will put it few seconds later automatically
back into normal operation.
CODE DESCRIPTION
| | | System normal
| | - Power: xxx %
| | |
| | |
| | | |
| | | UPS on battery |
| | - Runtime: 25 min -
| | | |
| | | |
| |
| Battery resting
|
|
|
Notice #10
EVENT LOG Inverter AC under
-- 11/ 03/ 2003
08: 25: 07
| | |
| | Output current A
| | 16.7 15.8 17.1
| |
| | |
| | Output frequency Hz
| | 50.0
| |
| | |
Output
| | power kW
| |
| | 3.5
| | |
| | |
| | Output power pf
| | xxx
| |
| | |
| | |
| | Battery current A
| | 23.8
| |
| | |
Battery
| | runtime min
| |
| | 25
| | |
| | |
| |
| | Input current A
| | 16.7 15.8 17.1
| | |
| | Input frequency Hz
| | 50.0
| |
| | |
| |
| Bypass current A
| 16.7 15.8 17.1
|
| |
| Bypass frequency Hz
| 50.0
|
| |
| |
|
Set year
SETTINGS USER SETTINGS PASSWORD: AAAA SET DATE AND TIME Date: 2003 / 10 / 31
-- -- -- --
Time: 14 : 25
| | |
| | |
| | CHANGE LANGUAGE Select Language:
| | -- <US ENGLISH >
| |
| | |
| | |
Signal: INPUT 1
| | SIGNAL INPUTS < shutdown >
| | --
| | Logic: 0 Filter: 1
| | |
| | |
| | Start screen
| | <Powerware logo >
| |
| | |
| | User password
| | <disabled >
| |
| | |
| | Audible alarms
| | <normal sound >
| |
| | |
Advanced battery
| | management
| |
| | <enabled >
| | |
Automatic battery
| | support tests
| |
| | <enabled >
| | |
| | Number of battery
| | strings
| | < 1 >
| | |
| | Battery size
| | < 50 W/cell>
| |
| | |
Battery low alarm
| | level
| |
| | < 1.800 V/cell>
| | |
Maximum charging
| | current
| |
| | < 10 A>
| | |
Nominal output
| | voltage
| |
| | < 230 V>
| | |
Bypass voltage high
| | limit
| |
| | <230V +10 %>
| | |
Bypass voltage low
| | limit
| |
| | <230V -10 %>
| | |
Nominal output
| | frequency
| |
| | < 50 Hz>
| | |
| | Synchronization
| | < enabled >
| |
| | |
Synchronization
| | window
| |
| | < 0.5 Hz>
| | |
Unsynchronized
| | transfers to bypass
| |
| | < allowed >
| | |
Output frequency
| | slew rate
| |
| | < 0.7 Hz/s>
| | |
| | |
| | Usage of bypass
| | < enabled >
| |
| | |
Behaviour on
| | input break
| |
| | <prefer battery >
| | |
Transfer to bypass
| | when overload
| |
| | <immediately >
| | |
Automatic restart
| | delay
| |
| | < 10 s>
| | |
Automatic on battery
| | shutdown delay
| |
| | < 40 s>
| | |
Control commands
| | from X-SLOT1
| |
| | <allowed >
| | |
| |
| | Control commands
| | from X-SLOT2
<allowed >
| | |
X-SLOT signal inp.
| | activation delay
| |
| | < 5 s>
| | |
Input signal delayed
| | shutdown delay
| |
| | < 120 s>
| | |
| |
| |
| |
| |
| |
Notice #191
| ADJUST EVENTS Battery test failed
| --
| Log all Horn: 2
| |
RESET CUSTOM
| EVENT SETTINGS
|
| Total: 1 / 32
| |
| CLEAR EVENT LOG
| Total events: 35
|
IDENTIFICATION Type:
-- POWERWARE 9155
| |
Part:
| 000000000000
|
| 00000000000
| |
Serial:
| 000000000000
|
| 00000000000
| |
Revisions
| Firmware: A
|
| Display: 0.12
TURN UPS ON
PDF/NB
POWERWARE OY
BILL OF MATERIAL FOR PRODUCT 1022769 a
SUBAS 9155 DISPLAY PANEL
PART NUMBER DESCRIPTION QUANTITY DESIGNATOR
Select the COM-port, the country where the UPS is located, set flow control to
none and the communication speed to 1200 bps (this communication speed is
recommended if standard FORS modem setup is used, traditionally UPSCode
units have had this speed).
Run ”Initialize modem” (this may take a while).
b) Configure the UPS built-in serial port settings. The required settings are: serial
port communication speed 9600, UPSCode enabled, control command enabled.
Save the changes.
c) Configure the modem settings and activate the X-Slot number where the
modem is installed. Save the changes.
Example: ATX3DT0,123456
This AT-command is: do not wait for a dial tone, dial a zero (0) for outline, dial
phone number 123456
Close the terminal or terminal emulation software and remove the serial
communication cable from the UPS serial port. Configuration is now done.
XSLOT Modem is made for UPS remote monitoring purpose. It is installed to UPS XSLOT extension place and it
offers one RJ-11 phone-jack connector for telephone network connection and four LEDs to indicate its status on
its face plate. There are also onboard RS-232 port and DC-socket for the configuration purpose (which are not
available when Modem is installed in UPS).
XSLOT Modem is based on Conexant SocketModem (or Multitech ModemModule) chip. SocketModem is fully
functional modem which needs only +5 VDC and some external components for interfaces to operate. In the
following are explained functional parts of the modem board.
Functional parts:
Fully functional modem chip. There are two alternative manufacturers, Conexant and Multitech.
With these jumpers are set modem behaviour in terms of hardware signals. In the Assembly
picture is explained how to assemble these jumpers. By default, hardware signals are not used.
POWERWARE
Checked LM No 1019139 Rev A
Approved RAK Page 1 (2)
Telephone network interface consist of RJ-11 connector and overvoltage- (V9) and overcurrent
(F1) surge arresters.
Indicator LEDs shows modem status. There are four LEDs: Receiving (RX), Sending (TX), Data
Carrier Detect i.e. modem is off-hook (DCD) and Data Terminal Ready i.e. modem is ready
(DTR), which will lit nearly always.
RS-232 interface consist of 9-pin RS-232 port and MAX3232 voltage level conversion IC (D1).
This port is for configuration purposes. Modem should be configured before it is assembled in
UPS.
6. +5V DC-DC converter (C1 - C3, C10, L1, N1, R1, V5, V8)
This part of circuit will make operating voltage to modem board. It will convert 8 - 25 V input DC-
voltage offered by XSLOT +V to +5 VDC. DC-DC converter is based on National Simple
Switcher IC (N1).
Current limiter is situated between XSLOT +V (8-25 VDC) output and +5V DC-DC converter
input. It protects UPS power supplies from overloading. Current is limited to under 550 mA with
transistor circuitry. Shortcircuit protection is implemented with fusible resistors R3 and R4.
8. DC-socket (X4)
This DC-socket is for configuration purposes. Via this connector is supplied 9 - 25 VDC when
modem board is configured.
Face plate of the modem board is attached through these terminals. There is no any electrical
connection between modem circuitry and terminals (and face plate).
Modem draws its power and communicates with UPS through XSLOT connector when modem
is assembled into UPS.
POWERWARE
Checked LM No 1019139 Rev A
Approved RAK Page 2 (2)
Relay Interface Card for Powerware X-Slot
General
This Relay Interface Card (p/n 1018460) provides potential free true relay interface for AS/400 and other
relay connected computers and industrial applications. This relay interface uses a 15-pin D-sub connector as
well as wiring connections and this Relay Interface Card is installed in the X-Slot of the UPS.
Installation
The UPS does not have to be shut down when installing this Relay Interface Card.
1. Remove the cover on the X-slot of UPS to install the Relay Interface Card.
2. Put the Relay Interface Card into the slot and attach it to UPS´s panel by using screws.
1018947 Rev. B
1/2
Table 1. Bypass relay information is not supported by the Powerware 5115 and 5125 UPSes. UPS
Alarm/OK relay information is supported only by the Powerware 9340 UPS.
Table 1
Table 2
* Normally closed (NC) /open (NO) connection state when the Relay Interface Card is not powered.
** The shutdown pin (15) needs minimum of 5 seconds high level signal (connection to +12VDC) to
perform the UPS shutdown.
NOTICE: The relay contacts must not be galvanically connected to any mains connected circuits. Do not use
+12VCD (Pin13) of the Relay Interface Card for any power supply purposes for external devices. Reinforced
insulation to the mains is required for equipment and cables connected to these connections.
The relay contacts are rated for maximum 1A/30VAC or 200mA/60VDC. All relay outputs are galvanically
isolated from the other circuits of the UPS (IEC 950, EN 50091-1, FCC Class A).
1018947 Rev. B
2/2
1018345A.sch-1 - Fri Mar 12 09:17:29 2004
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POWERWARE OY
BILL OF MATERIAL FOR PRODUCT 1022584 a1
SUBAS 9155 battery cabinet 32x0Ah (no batt. incl.)
PART NUMBER DESCRIPTION QUANTITY DESIGNATOR