Always On GES-103NX, Service Manual

Page 1: ...M0704_NX_Series_Service_Manual V2 17 2012 06 12 NX Series Three Phase UPS System GES 103NX GES 1603NX 10 kVA 160 kVA Service Manual...

Page 2: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 i...

Page 3: ...enu 28 14 6 Menu 5 Parameter Setting Menu 29 14 7 Menu 6 Rectifier Data Menu 30 14 8 Menu 7 Reserve Data Menu 30 14 9 Menu 8 Output Data Menu 31 14 10 Menu 9 Other Data Menu 31 14 11 Menu 10 Boost Cha...

Page 4: ...rnal wrap around bypass mode before work is started This manual is designed as an aid tool in diagnosing problems that may arise Always On does not assume responsibility if information causes injuries...

Page 5: ...ll simultaneously supply power to the inverter and the battery charger to replenish the batteries Reserve Mode If the inverter is placed into an abnormal condition such as over temperature short circu...

Page 6: ...Figure 3 1 Always On UPS Systems Topology 3 Phase UPS 6 Pulse Rectifier Input 3PH 4W Output 3PH 4W Zero Degrees Phase Shift INPUT FIL N T S INPUT R BAT NEG BAT POS FILTER AUTO TRANS RECV RECTIFIER FIL...

Page 7: ...igure 4 1 Always On UPS Systems Topology 3 Phase UPS 12 Pulse Rectifier Input 3PH 4W Output 3PH 4W Zero Degrees Phase Shift N T S OUTPUT R 12 PULSE RECTIFIER RESV R T N FIL S INPUT INPUT BAT NEG BAT P...

Page 8: ...is added to improve reliability and to shutdown the rectifier in the event of abnormal conditions The DC bus is adjustable to allow for different types and capacities of batteries The power components...

Page 9: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 6 Figure 5 2 Detailed drawing of Rectifier...

Page 10: ...non linear loads are connected The system is designed and incorporates an independent inverter per phase These inverters are totally independent of each other preventing the possibility of cascading...

Page 11: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 8 Figure 6 2 Detailed drawing of one phase of the Inverter S t...

Page 12: ...rent a dead short requires the static switch will not transfer to reserve preventing the tripping of the reserve breaker Overload condition The UPS will transfer the load to reserve utility path The s...

Page 13: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 10 Figure 7 2 Detailed drawing of one phase of the Static Switch System...

Page 14: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 11 8 INTER PCB DIAGRAM Figure 8 1 Connection diagram for the PCB Module Inverter Rectifier and Static Switch...

Page 15: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 12 9 PCB MODULE Figure 9 1 Detailed drawing of PCB...

Page 16: ...SSPS 17 Vac ST9632 120Vac POWER SUPPLY 3J 250 Vac 0 Vac 120Vac STFAN 6 ST9632 120Vac 30Vac UPPER FAN LOWER FAN 4A 4A L1 OUTPUT 4A ACPS 180Vac POWER SUPPLY 3B 4 8 7 DC BUSS BATT V SNMP 3 1 2 5 6 1 5 CO...

Page 17: ...s up displays general information about the UPS Status LEDs indicate status of sub systems many alarm indicators will be illuminated as the rectifier does not yet have AC power applied and the DC buss...

Page 18: ...tors will show backup mode operation UPS will be beeping Rectifier AC Fail Rotation Error Reserve AC Fail Reserve Freq Fail k Rectifier restart Turn Input breaker to ON position Rectifier will ramp up...

Page 19: ...nerated by the rectifier g Turn Inverter ON push buttons on front panel Inverter will ramp up over a 7 second period and then supply power to the output of the UPS Fans will start output voltage will...

Page 20: ...he DC bus will start to drop slowly until it reaches a save level of approximately 20VDC WARNING Completing the next step will turn off the power to the loads Make sure all loads have been turned off...

Page 21: ...ing When the maintenance bypass breaker is closed power will flow through the bypass loop instead of the reserve loop because the impedance of the bypass loop is lower e Open the Reserve breaker You c...

Page 22: ...rm service or maintenance record the readings and all the LED s that are illuminated on the Front Panel Status Report Log This will aid in identifying the status of the UPS system prior to shutdown Be...

Page 23: ...window This is related to the supply voltage out of range the phase rotation is incorrect or the rectifier has been shutdown refer to C Status LED s RESERVE FAIL supply to the reserve is outside of t...

Page 24: ...D load connected to the output is over 110 of the UPS rating 125 LOAD load connected to the output is over 125 of the UPS rating 150 LOAD load connected to the output is over 150 of the UPS rating RES...

Page 25: ...ly HIGH DC SHUTDOWN beep continuously BYPASS ON STOP beep continuously EMERGENCY STOP beep continuously The buzzer will beep once every time the inverter is switched on or off This will allow for the...

Page 26: ...items are being selected or changes the number character forward when data or parameters of the UPS are being set N Down key This is an LCD control key It moves the cursor one field downward when ite...

Page 27: ...ut rating and output rating of the UPS The serial no is set by the factory for the convenience of maintenance personnel who may need to refer to the serial number for the correct spare parts and testi...

Page 28: ...into a screen that will prompt the user for a password See the figure below The numbers are changed by pressing the UP or the DOWN key respectively and is confirmed by the ENTER key When the four digi...

Page 29: ...ing conditions that can be displayed they are arranged in order of priority starting with the highest priority 1st row BYPASS ON Output is being supplied by the reserve RECT AC FAIL AC utility source...

Page 30: ...UP or DOWN key has no function in this menu The screen will go back to MENU 1 when ENTER is pressed 14 4 Menu 3 Real Time Data Menu MENU 3 is reached by selecting REAL TIME DATA on MENU 1 The cursor i...

Page 31: ...l they re overwritten by the 78th or the 155th events The three most recent records are displayed at one time on the view screen The displayed records will move one record upward when the UP key is pr...

Page 32: ...f the inverter press the UP or the DOWN key and confirm selection by pressing the ENTER key INVERTER ON will be displayed if ON is selected or INVERTER OFF will be displayed if OFF is selected To cont...

Page 33: ...serve Data Menu MENU 7 is reached by selecting RESERVE DATA on MENU 3 The information provided on this menu is the real time readings of the reserve input RESERVE FREQUENCY R N S N T N VOLTAGE for wye...

Page 34: ...the UPS system is operating in normal mode the last line on MENU 9 will read CHARGE CURRENT and will represent the amount of current being supplied to the batteries When the system changes to back up...

Page 35: ...s that the system will be boost charged after the system has reached a low battery condition This boost charging recharges the batteries at a faster rate and will improve the conditioning of the batte...

Page 36: ...e via the UP and DOWN keys Once the level of charge has been selected confirm with the ENTER key The CHARGE CURRENT can be roughly selected by the simple rule listed below CHARGE CURRENT SETTING 10 30...

Page 37: ...to a 30day month HOUR 0 23 MINUTE 0 59 DAY OF THE WEEK MON TUE WED THU FRI SAT SUN The values selected value is flashing are increased by the UP key and can be decreased by the DOWN key and confirmed...

Page 38: ...x x x x 110 LOAD 0 0 0 0 0 x 125 LOAD 0 0 0 0 0 x 150 LOAD 0 0 0 0 0 x RESERVE AC FAIL 0 0 0 0 1 RESERVE FREQ FAIL 0 0 0 0 1 BATTERY LOW 1 0 0 0 x BATTERY LOW SHUTDOWN 0 0 0 0 x REC AC FAIL 1 0 0 0 1...

Page 39: ...no input power or input power outside of operating parameters Ensure cable connections are secure and correctly attached Check the input power Replace the board LED C2 C3 12VDC All Yes PCB has power...

Page 40: ...Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 37 17 BOARD FAULT DIAGRAMS 3A Board Fault UPS will not start up Once Reserve Breaker is closed all LED s on front display light up and LCD is n...

Page 41: ...lways On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 38 3B Board Fault UPS will not start up Once Reserve Breaker is closed all LED s on front display light up and LCD is non functiona...

Page 42: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 39 3CC Board Fault UPS will not start up Rectifer disabled No DC Buss...

Page 43: ...ystems M0704_NX_Series_Service_Manual V2 17 2012 06 12 40 3R Board Fault No front panel display and no communications UPS starts up as per normal operation and inverter and rectifier function as per n...

Page 44: ...2012 06 12 41 3T Board Fault A UPS system initializes ok Once inverter attempts to assume load system beeps Inv Fail Shutdown LED turns on Fault LED turns on and Load LED flashes System remains in Sta...

Page 45: ...X_Series_Service_Manual V2 17 2012 06 12 42 3T Board Fault B UPS system initializes ok Once inverter attempts to assume load system beeps Inv Fail Shutdown LED turns on and Fault LED turns on System r...

Page 46: ...04_NX_Series_Service_Manual V2 17 2012 06 12 43 Inverter Module Fault UPS system initializes ok When DC Buss is established Fuse Temp fault LED turns on Inverter can not be turned on System operates i...

Page 47: ...On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 44 Static Switch Module Fault UPS starts up to full operation When inverter is turned off UPS output shuts down because of faulty static...

Page 48: ...with the same style and appearance as the UPS cabinet for ease of installation and cosmetic value Re enforcement has been added to strengthen the cabinet for the additional weight and transportation...

Page 49: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 46 Figure 18 2 SC and SE Cabinet Mechanical Drawing...

Page 50: ...HAS ONLY 7 BATTERIES TOP TRAY Always On UPS Systems BATTERY CAB A BATTERY TRAY WIRING LAYOUT VERSION V1 0 DATE 050112 FILE BATTERY CAB A 0001 PROJECT BATTERY CAB A Kelowna B C alwaysonups com PH 877...

Page 51: ...L 348VDC 60A FILE BATTERY CAB A 0002 DATE 050112 BATTERY CAB A BATTERY INTERCONNECT WIRING CONFIG Always On UPS Systems VERSION V1 0 PROJECT BATTERY CAB A DESIGNED BY AA DRAWN BY XT Reproduction and o...

Page 52: ...ER NEG 125A BREAKER VERSION V1 0 BATTERY CAB B BATTERY INTERCONNECT WIRING CONFIG Always On UPS Systems FILE BATTERY CAB B 0001 DATE 050112 PROJECT BATTERY CAB B Kelowna B C alwaysonups com PH 877 259...

Page 53: ...TRAY HAVE ONLY 7 BATTERIES EACH TRAY 4 TRAY 5 BATTERY CAB B BATTERY TRAY WIRING LAYOUT VERSION V1 0 Always On UPS Systems FILE BATTERY CAB B 0002 DATE 050112 PROJECT BATTERY CAB B Kelowna B C alwayson...

Page 54: ...sonups com PH 877 259 2976 Reproduction and or use without express permission is prohibited by law DATE 050112 FILE BATTERY CAB C 0001 PROJECT BATTERY CAB C DRAWN BY XT DESIGNED BY AA BATTERY CAB C 29...

Page 55: ...sonups com PH 877 259 2976 Reproduction and or use without express permission is prohibited by law DATE 041228 FILE BATTERY CAB E 0001 PROJECT BATTERY CAB E DRAWN BY XT DESIGNED BY AA BATTERY CAB E 29...

Page 56: ...ns 24 mins 2 x NX ALW 160 2 108 mins 92 mins 72 mins 38 mins Load 100 000VA 120 000VA 160 000VA 200 000VA 250 000VA 300 000VA Model NX ALW 85 3 NX ALW 110 3 8 mins 5 mins NX ALW 160 3 13 mins 10 mins...

Page 57: ...nitors and controls all the major components within the UPS system Through the various monitoring devices and PCB s mentioned later in this manual it provides all the control signals synchronizing sig...

Page 58: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 55 LED A1 LED A2 LED A3 LED A4 LED A5 LED A6 Picture 19 1 3A PCB Main Control...

Page 59: ...rd LED A2 No 3S S phase working Yes S phase failure and UPS shutdown Check 3T S phase ensuring cable connections are secure and correctly attached Replace the board LED A3 No 3T T phase working Yes T...

Page 60: ...main power supply for the PCB and is the interface between the Main Control PCB and the Battery supply It provides battery condition information to the Main Control PCB to control the Rectifier Charg...

Page 61: ...ted Description 3B Power Supply PCB Module LED B1 B2 B3 B4 All Yes PCB has power All No All LED s of PCB extinguished Check fuse set behind PCB holder and ensure cable connections are secure and corre...

Page 62: ...he Main Control PCB and the Rectifier Module It relays the control signals from the Main Control PCB to the Rectifier Driver 3S PCB within the Rectifier Module It also monitors all aspects of the Rect...

Page 63: ...f 12 pulse PCB Module LED C1 Yes Rectifier Enabled No PCB has no input power or input power outside of operating parameters Ensure cable connections are secure and correctly attached Check the input p...

Page 64: ...phase of the Inverter Module It relays the control signals and inverter drive waveforms from the Main Control PCB to the Inverter Driver 3G PCB within each phase of the Inverter Module It also monito...

Page 65: ...CB LED LED Illumination Description LED Illumination Description 3T Inverter Phase Control PCB Module LED T1 T2 All Yes PCB has power All No R S or T phase lost output LED on the front panel mimic dia...

Page 66: ...t panel Operator interface by utilizing information from the Main Control PCB and translating and sending that to the front panel display PCB s Also receives the local Operator commands from front pan...

Page 67: ...LOCATION NORMAL ABNORMAL SOLUTION PCB LED LED Illumination Description LED Illumination Description 3R Communication Interface PCB Module LED R1 Yes PCB has power No Interface communication failure En...

Page 68: ...7 2012 06 12 65 24 WARNING LED S AND SWITCHES 3W PCB 25 LCD DISPLAY 26 MIMIC DIAGRAM 3L PCB 27 STATUS LED S AND AUDIBLE ALARM 3AG PCB These PCBs make up the local operator display and control interfac...

Page 69: ...m the AC utility to regulated and conditioned DC power which is used to charge the batteries and supply the DC Bus The rectifier can be configured as a 6 pulse or 12 pulse rectifier system The rectifi...

Page 70: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 67 Figure 28 2 Location of Rectifier Module in the 80kVA to 160kVA UPS RECTIFIER MODULE...

Page 71: ...PS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 68 6 pulse Rectifier Static Switch R Phase S Phase T Phase Picture 28 1 Picture of Rectifier and Static Switch Module for the 10kVA to 60kVA...

Page 72: ...ption 3S Rectifier Drive Rectifier Module If DC bus can not be stabilized the AC output is transferred to the reserve automatically Ensure cable connections are secure and correctly attached The expec...

Page 73: ...ces for the inverter The inverter converts the power from the DC Bus to regulated and conditioned AC power One phase of the inverter is comprised of an Inverter Driver PCB 3G PCB high powered IGBTs a...

Page 74: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 71 Figure 29 2 Location of Inverter Modules in the 10kVA to 60kVA UPS system T INVERTER MODULE S INVERTER MODULE R INVERTER MODULE...

Page 75: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 72 LED G1 S phase T phase R phase Picture 29 1 Picture of the Inverter Module from a 10kVA to 60kVA UPS system...

Page 76: ...ION LOCATION NORMAL ABNORMAL SOLUTION PCB LED LED Illumination Description LED Illumination Description 3G Inverter Driver RST Inverter Module LED G1 Yes Inverter working No Inverter failure Ensure ca...

Page 77: ...tput If a condition occurs inverter shutdown or problem condition it will transfer the output from the inverter to the reserve path automatically When the condition has been cleared the static switch...

Page 78: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 75 Figure 30 2 Location of Static Switch Module in the 80kVA to 160kVA UPS system STATIC SWITCH MODULE...

Page 79: ...ems M0704_NX_Series_Service_Manual V2 17 2012 06 12 76 6 pulse Rectifier Static Switch R Phase S Phase T Phase Picture 30 1 Picture of Static Switch and Rectifier Module for the 10kVA to 60kVA UPS sys...

Page 80: ...LED Illumination Description 3P Static Switch Driver R S T Static Switch Module LED P1 Yes Inverter output is within normal parameters No Inverter operating transfer from inverter has failed Replace...

Page 81: ...esigned as a secondary and redundant power supply to the one located within the UPS module The main function of the auxiliary power supply is to provide power to the fans and an alternate supply for t...

Page 82: ...i ng ForInstallation Firs t Ti me S tartup P lea s e S e S t artup P roc edure S hutdown Procedure Inverter to Manual B ypass P rocedure Manual Bypass to InverterPP roc edure 1 Turn off theINV E R T E...

Page 83: ...7 M IM IC P A N E L LC D P A N E L S W ITC H E S LE D P A N E L W A R N IN G C N B 5 C N B 7 B E E P E R LE D P A N E L S TA TU S C N B 6 M O D U LE TO S S BLU W H T R E D TO IN V 3B 3C 3A 3T TO R E...

Page 84: ...es_Service_Manual V2 17 2012 06 12 81 A C O P S S O P O P P S LO W E R F A N P S R S T C A P C A P C A P O S IR IN IT IS O R B O T O N B Figure 31 5 Front view of system with door open PCB Module full...

Page 85: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 82 Figure 31 6 Exploded view of system behind the PCB Module...

Page 86: ..._Manual V2 17 2012 06 12 83 Figure 31 7 Layout view of the left side of the system with the panel off Figure 31 8 Layout view of the back of the system with the panel off Figure 31 9 Layout view of th...

Page 87: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 84 Figure 31 10 Front view of system with door closed...

Page 88: ...ACIT OR INS IDE TODIS CHAR GE 5 OPEN THERES E RV E B REA KE R 6 LOCK T HE DOOR START PROCEDURE 1 CLOSE THERES ER VE B RE AK ER 2 CLOSE THEREC TIF IERBRE AK ER 3 WA I T30sec FORDC V OLTAGERISEUP 4 CLOS...

Page 89: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 86 Figure 31 12 Front view of system with door open and PCB Module door open...

Page 90: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 87 Figure 31 13 Front view of system with door open PCB Module fully open and terminal strip cover off...

Page 91: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 88 Figure 31 14 Exploded view of system behind the PCB Module...

Page 92: ...S Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 89 Figure 31 15 Layout view of the left side of the system with the panel off Figure 31 16 Layout view of the right side of the system with th...

Page 93: ...Always On UPS Systems M0704_NX_Series_Service_Manual V2 17 2012 06 12 90 Figure 31 17 Layout view of the back of the system with the panel off...

Page 94: ...Always On UPS Systems Section A SINGLE LINE DRAWINGS...

Page 95: ...40KVA 160 175 70 70 56 60 50KVA 200 200 90 90 70 70 60KVA 250 250 110 110 90 90 80KVA 330 350 145 150 115 125 100KVA 415 450 180 200 145 150 120KVA 500 500 220 225 175 175 160KVA 660 700 290 300 230...

Page 96: ...tems Always On UPS Systems Single line drawing of UPS System and External Bypass System Generic NFB 3P 4W G RECT BATS INV S S TO LOAD PANEL 3PH 4W G S S BYPASS RES RECT N G BONDED UPS INPUT UPS OUTPUT...

Page 97: ...il sales alwaysonups com Website www alwaysonups com 32 2 QA Warranty Questions Always On UPS Systems Inc Bldg 1 150 Campion Road Kelowna BC Canada V1X 7S8 Phone 250 491 9777 Ext 209 Fax 250 491 9775...