Eaton Callisto 5PX RT G2, Service Manual

Page 1: ...Rev Approved Confidential Page 1 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permiss...

Page 2: ...3 14 5PX2000IRT2UAUG2 APAC 2000VA 2000W RT 240V 9210 73040 15 5PX2200IRT2UAUG2 APAC 2200VA 2200W RT 240V 9210 73042 16 5PX2200IRT3UAUG2 APAC 2200VA 2200W RT 240V 9210 73041 17 5PX3000IRT2UAUG2 APAC 30...

Page 3: ...Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission Rev Date Notes Updater name Approved 00 2021 7 5 Original Chase Fang 00 2...

Page 4: ...rconnection diagram of products by power rating 12 3 1 UPS interconnection diagram 12 3 2 UPS interconnection Actual 15 3 3 EBM interconnection diagram 21 4 Diagrams showing the location of each princ...

Page 5: ...ment This service manual will guide technicians to diagnose troubleshoot and repair UPS products Depending on the countries the extent of the repair of the product can be to find the failed item or th...

Page 6: ...specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 1 2 Analysis process Global process showi...

Page 7: ...he property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 1 3 Schematic of the UPS Goal Identify the Board references...

Page 8: ...Checked Rev Approved Confidential Page 8 of 60 s specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Page 9: ...Checked Rev Approved Confidential Page 9 of 60 s specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Page 10: ...product unless an authorized person is present There is a risk of presence of AC voltage even if the mains power is no longer connected Switch off and disconnect the UPS from the mains power before re...

Page 11: ...d or used as the basis for manufacture or sale of apparatus without permission Please check the insulation of all wires connectors and screws after opening the UPS Before restarting the UPS o Check th...

Page 12: ...ing Goal To know the interconnections and connectors between the boards for different power ratings of products 3 1 UPS interconnection diagram EPO BOARD COMM BOARD PSDR BOARD Internal Battery LCD CNT...

Page 13: ...EPO Dry in Dry out For Internal Lithium battery communication 1 2 3 4 5 6 8 9 7 10 11 12 13 14 15 17 18 19 20 21 NTC BAT NTC HS 22 23 Main 5A 6A 6B 6C 7A 8A Fig3 2 1000 1500VA 120V interconnection Bl...

Page 14: ...ut permission I O BOARD EPO BOARD COMM BOARD PSDR BOARD Internal Battery LCD CNTL BOARD IP L IP N FAN1 USB RS232 Segment 1 Segment 2 Input Socket EBM Output Socket CARD Box RJ45 OP L OP N EPO Dry in D...

Page 15: ...proved Confidential Page 15 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 3...

Page 16: ...nual Checked Rev Approved Confidential Page 16 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Page 17: ...nual Checked Rev Approved Confidential Page 17 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Page 18: ...l Checked Rev Approved Confidential Page 18 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus witho...

Page 19: ...nual Checked Rev Approved Confidential Page 19 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Page 20: ...nual Checked Rev Approved Confidential Page 20 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus wi...

Page 21: ...p and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 3 3 EBM interconnection diagram BAT1 BAT2 BAT3 BAT4 BATTERY PACK1 BAT1 BAT2 BAT3 BA...

Page 22: ...98 20149 XX 744 20146 3K 710 20149 XX 098 20149 XX 744 20149 PSDR LV 1K 710 20141 XX 098 20140 XX NA 1 5K 710 20143 XX 098 20140 XX NA 2K 710 20145 XX 098 20149 XX NA 3K 710 20150 XX 098 20149 XX NA I...

Page 23: ...e of apparatus without permission 4 2 PSDR and IO schematic Functions designed on this board are the following Push Pull DC DC converter and the PWM driver LF DC AC inverter with the PWM driver Bat mo...

Page 24: ...ed Rev Approved Confidential Page 24 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without perm...

Page 25: ...ked Rev Approved Confidential Page 25 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Page 26: ...cked Rev Approved Confidential Page 26 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without pe...

Page 27: ...hecked Rev Approved Confidential Page 27 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without...

Page 28: ...Rev Approved Confidential Page 28 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permiss...

Page 29: ...ked Rev Approved Confidential Page 29 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Page 30: ...ked Rev Approved Confidential Page 30 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without per...

Page 31: ...ecked Rev Approved Confidential Page 31 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without p...

Page 32: ...Checked Rev Approved Confidential Page 32 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without...

Page 33: ...ed Rev Approved Confidential Page 33 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without perm...

Page 34: ...Confidential Page 34 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 4 2 1 PS...

Page 35: ...d as the basis for manufacture or sale of apparatus without permission 4 3 CNTL Functions designed on this board are the following DSP digital control for DC DC converter DC AC inverter AVR control DC...

Page 36: ...y of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission 4 4 COMM EPO Functions designed on this board are the following HMI R...

Page 37: ...e Manual Checked Rev Approved Confidential Page 37 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatu...

Page 38: ...rmal or Safety relay is failure Please refer below flow chart Fault 002 0x004 UPS Temp High UPS internal temperature is high over fault point Please refer below flow chart Fault 004 0x007 Fan Lock Ven...

Page 39: ...transfer to Fault mode Please refer below flow chart Fault 809 0x80A Capacitive overload Capacitive overload occurred transfer to Fault mode Please refer below flow chart Fault 80A 5 3 Location of the...

Page 40: ...ernal fault Start Line mode Bat mode Whether the Output voltage is exceeds the output voltage range spec Y N Whether the safety relay is stuck END Y Whether the Driver circuit of safety relay is Damag...

Page 41: ...e room temperature Y UPS temperature fault End N UPS surrounding temperature is high N Y Remove heat source Y UPS temperature fault N End Confirm outtake airflow on rear panel is block N Clear dust or...

Page 42: ...ermission Fault 007 Fan Lock Start Fans is connected rightly Connect them 1 1 5 front panel FAN 2 3K front and rear panel FAN N Restart UPS and no alarm End N Fans on rear and front panel are rotating...

Page 43: ...nel is block N Clear dust or object Y Y UPS AVR too hot fault End N Check Fan is rolling normally Clear dust or object UPS AVR too hot fault End N Y End Client Environment UPS Check CNTL CNTL Replace...

Page 44: ...ire and live wire are reversely connected Y Y Connect L N wire rightly Y Restart UPS and no alarm N End Replace PSDR Y Restart UPS and no alarm N Replace UPS End UPS PSDR End Repair detection circuit...

Page 45: ...without permission Fault 500 Fault 502 Fault 503 Charger Fault Charger Too High Charger Too Low Start PSDR End Over Replace UPS Check whether charger output voltage is right Charger Fault N Check CNTL...

Page 46: ...No Battery Start End Check battery Volt UPS EBM Y End End Replace UPS Check battery wires and cables N No battery End N Y Replace Battery N Battery Fault N Y Battery Fault N Connect them Check CNTL Re...

Page 47: ...or sale of apparatus without permission Fault 804 Imbalance Load Start Imbalance load alarm Remove Imbalance load End N Switch off UPS and disconnect loads UPS Y Check PSDR Battery detection Repair d...

Page 48: ...ion Fault 805 Short Circuit Start loads are short circuit Remove damaged load Short circuit fault End Y N Y UPS Switch off UPS and disconnect loads Client load Output cables are short circuit Replace...

Page 49: ...ale of apparatus without permission Fault 808 Overload fault Start End Check grid voltage Customer load Y End End Check load value N overload End N Y Check electrical grid N overload N Y overload N Re...

Page 50: ...Fault 809 80A Inductive overload Capacitive overload Start Inductive Capacitive overload Decrease Load Replace load End N Switch off UPS and disconnect loads UPS Y Check PSDR UPS output waveform is r...

Page 51: ...should not make the user call the Eaton service no red led no continuous buzzer sound The alarm message is displayed on status screen top row If the defect or incident cause disappears then the alarm...

Page 52: ...connectors identify their connections on the boards Board references and names This permits the reassembly of the UPS and at the same time prevents any errors of inverted wiring which could cause the...

Page 53: ...ev Approved Confidential Page 53 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permissi...

Page 54: ...60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission Step 3 Remove the battery pack f...

Page 55: ...v Approved Confidential Page 55 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permissio...

Page 56: ...rvice Manual Checked Rev Approved Confidential Page 56 of 60 This specification is the property of Eaton Corp and shall not be reproduced or copied or used as the basis for manufacture or sale of appa...

Page 57: ...12 ZT 136 12V16A 240V 1C 092 00153 Main Relay RY4 RLY HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 RY4 RLY HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 30A 250...

Page 58: ...40A 277 V 1C 092 01095 RY6 RY7 RLY SON 832HA 1C F V 12Vdc 40A 277 V 1C 092 01095 PSDR 2000HV 3000HV DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 F3 30A 250Vac 102 01708 DCDC MOS Q1 Q2 Q3 Q4 Q5 Q6 Trans...

Page 59: ...HF 140FF 012 2ZTF 12V 12A 277V 2C 092 09037 RY4A RY4B RLY 12Vdc 16A 250VACSON 79 3 P 1C 092 00991 DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 30A 250Vac 102 01708 DCDC MOS Q13 Q14 Q15 Q1 6 Q17 Q18 MOSF...

Page 60: ...ON 832HA 1C F V 12Vdc 40A 277 V 1C 092 01095 PSDR 2000LV 3000LV DCDC fuse F1 F2 30A 250Vac 102 01708 F1 F2 F3 30A 250Vac 102 01708 DCDC MOS Q1 Q2 Q3 Q4 Q5 Q6 Trans MOSFET N CH 250V 59A TO 3PN 088 2007...