HP R12000 XR, Maintenance And Service Manual

Page 1: ...HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 26 02 2 15 PM HP UPS R12000 XR Models Maintenance and Service Guide Part Number 221273 001 July 2002 First Edition ...

Page 2: ...herein The information in this document is provided as is without warranty of any kind and is subject to change without notice The warranties for HP products are set forth in the express limited warranty statements accompanying such products Nothing herein should be construed as constituting an additional warranty HP UPS R12000 XR Models Maintenance and Service Guide July 2002 First Edition Part N...

Page 3: ...cation Ports 1 2 Batteries and Extended Runtime Modules 1 2 Remote Emergency Power Off 1 4 Chapter 2 Illustrated Spare Parts List UPS Exploded View of Spare Parts Front 2 2 UPS Exploded View of Spare Parts Rear 2 4 ERM Exploded View of Spare Parts 2 5 Chapter 3 Identifying Components Front Components 3 1 Front Panel Views 3 1 Control Buttons 3 3 LED Indicators 3 4 Modes of Operation 3 5 Rear Compo...

Page 4: ...he Control Bezel 4 4 Removing and Replacing the Supervisory Bezel 4 5 Removing and Replacing a Front Bezel 4 6 Battery Module 4 7 Removing and Replacing the Battery Module 4 8 Disposing of Used Batteries 4 8 Testing the New Battery Module 4 9 Electronics Module 4 10 Removing and Replacing the Electronics Module 4 11 Supervisory Board 4 13 Removing and Replacing the Supervisory Board 4 14 Chapter 5...

Page 5: ...on of UPSs Symbols on Equipment The following symbols may be placed on equipment to indicate the presence of potentially hazardous conditions WARNING This symbol in conjunction with any of the following symbols indicates the presence of a potential hazard The potential for injury exists if warnings are not observed Consult your documentation for specific details This symbol indicates the presence ...

Page 6: ...roubleshooting and repair procedures are detailed to allow only subassembly module level repair Because of the complexity of the individual boards and subassemblies no one should attempt to make repairs at the component level or to make modifications to any printed wiring board Improper repairs can create a safety hazard WARNING To prevent personal injury from electric shock and hazardous energy l...

Page 7: ...x7 4 hour response 3 year on site coverage 171255 002 FM US724 36 Hardware installation 171256 002 FM USINS IN Where to Go for Additional Help In addition to this guide the following information sources are available User documentation Service Quick Reference Guide Service training guides Service advisories and bulletins QuickFind information services Power management software Telephone Numbers Fo...

Page 8: ... energy levels installation or service procedures must be performed by an HP authorized service technician who is knowledgeable about the procedures precautions and hazards associated with AC power products Rack WARNING To prevent personal injury verify that the rack containing the UPS is stable The following conditions must be met The leveling feet are extended to the floor The full weight of the...

Page 9: ...lied with the UPS to connect the communications port to the host computer Batteries and Extended Runtime Modules Observe these precautions when handling or connecting batteries and Extended Runtime Modules ERMs WARNING To prevent personal injury or damage to equipment take the following precautions The maintenance and replacement of batteries and ERMs must be carried out by an HP authorized servic...

Page 10: ...ample date The date on your carton may be different THIS PRODUCT CONTAINS A NONSPILLABLE BATTERY Next Recharge Date Please refer to Maintenance Section of Owner s Manual enclosed inside 05 MAR 07 Figure 1 1 Checking the battery recharge date label IMPORTANT Because of the short shelf life of the battery avoid storing a battery spare as a backup Do not maintain an inventory of spare batteries on si...

Page 11: ...output receptacles to be switched off from a remote location Local or national wiring regulations may require REPO capabilities WARNING To prevent personal injury or damage to equipment take the following precautions The REPO port must be wired by a qualified electrician The main breaker switch must be in the off position before wiring the REPO port Remote circuits connected to the REPO port must ...

Page 12: ...Sierra Part Number 221273 001 Last Saved On 7 31 02 8 58 AM 2 Illustrated Spare Parts List This chapter provides the illustrated parts breakdown and spare parts list for the UPS and ERM Refer to Table 2 1 Table 2 2 and Table 2 3 for the names and descriptions of referenced spare parts ...

Page 13: ... 2 HP UPS R12000 XR Models Maintenance and Service Guide HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 7 31 02 8 58 AM UPS Exploded View of Spare Parts Front 3 3 4 2 1 5 6 4 Figure 2 1 UPS exploded front view ...

Page 14: ...are Part 1 SPS BEZEL UPS SPRVSRY 228286 001 2 SPS BEZEL UPS 12 KVA 228287 001 3 SPS BATTERY UPS 12 KVA 228288 001 4 SPS MODULE ELECT UPS 12 KVA 228289 001 5 SPS BD UPS 12 KVA SPRV 228290 001 6 SPS CHASSIS UPS 12 KVA 228285 001 7 SPS RETURN KIT UPS 228293 001 8 SPS RETURN KIT BATTRY 228294 001 9 SPS RETURN KIT ELCT MD 228295 001 10 SPS PDU 40 A 200 240 V WW 212430 001 11 SPS CA MPUPS SRVRINTFC X 12...

Page 15: ...Part Number 221273 001 Last Saved On 7 31 02 8 58 AM UPS Exploded View of Spare Parts Rear 3 2 1 2 2 1 1 Figure 2 2 UPS exploded rear view Table 2 2 UPS Spare Parts List rear Reference Description Spare Part 1 SPS HRDW MOUNT UPS 12 KVA 228292 001 2 SPS PANEL UPS ERM W HRDW 252048 001 3 SPS CHASSIS UPS 12 KVA 228285 001 ...

Page 16: ...pare Parts 4 1 2 3 Figure 2 3 ERM exploded view Table 2 3 ERM Spare Parts List Reference Description Spare Part 1 SPS PANEL UPS ERM W HRDW 252048 001 2 SPS BEZEL ACCESSORY ERM 252049 001 3 SPS BATTERY 12 KVA 1 SET ERM 252050 001 4 SPS MODULE EXTD RUN 228291 001 5 SPS RAIL KIT ADJUST FIXED 332578 001 6 SPS RETURN KIT BTRY 12 KVA ERM 252051 001 7 SPS RETURN KIT ERM 228296 001 Not shown in figure ...

Page 17: ...nformation in this chapter to locate and identify these components This UPS also contains an LCD menu for unit configuration The functions on the LCD menu are explained in detail at the end of the chapter Front Components Use the following illustrations to locate and identify the front components of the UPS Front Panel Views The overall front panel view of the UPS is shown in Figure 3 1 and Figure...

Page 18: ...221273 001 Last Saved On 7 31 02 8 58 AM Figure 3 2 UPS indicators and control buttons 1 UPS control buttons 2 LED indicators of UPS status 3 LCD status and configuration screen 4 LCD configuration control buttons For more information on using the LCD refer to the section Configuring the UPS Using the LCD Menu in this chapter ...

Page 19: ...nd Figure 3 4 Figure 3 3 Front panel control buttons Item Description Function 1 On Starts the UPS power up of the load 2 Standby Places the UPS in Standby mode 3 Test Alarm Reset Resets alarms or initiates self tests 4 Escape Navigates and deselects options in the LCD menu structure 5 Center Is a large four way rocking button that controls navigation through the LCD menu structure up down left an...

Page 20: ...Solid Amber UPS is in Bypass mode Flashing Amber Bypass not available 4 Alarm Solid Red One or more alarms may be present or active 5 Redundant Solid Green Redundant mode one or more redundant electronics modules operating in system Flashing Green Battery self test initiated Off Nonredundant not Redundant mode NOTE Upon first powering up the time required for the UPS to reach Standby mode ranges f...

Page 21: ... and charges batteries if required Bypass Mode The Utility LED 1 and Battery LED 2 are off The Bypass LED 3 is solid amber and an audible alarm is active The Alarm LED 4 is solid red The utility is bypassing the unit and going directly to the load The UPS monitors and charges batteries if required Battery Mode The Battery LED 2 is solid amber The Alarm LED 4 is solid red Utility power is not prese...

Page 22: ...uide HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 7 31 02 8 58 AM Rear Components Use the following illustrations to locate and identify the rear components of the UPS 1 2 2 1 Figure 3 5 Rear panel 1 Terminal block wiring punch out points 2 Bypass switch ...

Page 23: ...FIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 7 31 02 8 58 AM 10 Compaq SNMP Serial Port Card 1 2 4 5 3 Figure 3 6 Rear panel components 1 Option slot for future expansion 2 Ground bonding screw 3 REPO port 4 Serial communication ports 2 5 Option slot for future expansion ...

Page 24: ...he operating range update the UPS configuration to match NOTE When you set the voltage through the LCD panel as described in the Setting the Voltage section of this chapter you are setting the UPS output voltage Table 3 1 Voltage Ranges VAC Nominal Utility Voltage Level Normal Utility Voltage Range UPS Output Voltage 200 166 240 200 208 166 248 208 220 176 264 220 230 default 184 276 230 240 192 2...

Page 25: ...Part Number 221273 001 Last Saved On 7 31 02 8 58 AM Module Locations Use the LCD menus to configure either the main module or one of the electronics modules 1 2 3 4 5 Figure 3 7 UPS electronics modules numbered 1 Main Module MM includes all four electronics modules 2 Module M1 3 Module M2 4 Module M3 5 Module M4 ...

Page 26: ...nduct an LCD display test and change the system setup The LCD display and control buttons are shown in Figure 3 3 Initial Power Up Display When the UPS is powered up the LCD displays the Main Menu COMPAQ R12000 XR Main Menu Top Level Main Menu After pressing the Enter button Main Menu appears on the top line of the display Use the Center button to scroll through the choices displayed on the lower ...

Page 27: ... Supporting Load Meters Main Module MM Module M 1 through 4 Input Volts Output Volts Input Frequency Output Frequency Output Power Battery Volts Input Current Battery Data Battery Charge Set Time Set Date Firmware Vers MM Control Vers MM Comm Version M1 M4 Versions Display Module Display Test System Setup Enter Password Comm Setup Set Voltage Set HW Config Serial Port 1 Serial Port 2 Set Language ...

Page 28: ...attery DC Over Voltage Level 3 Overload Phase A Battery Low Level 4 Overload Phase A Battery n Needs Service Loss of Redundancy Battery Not Charged Loss of Sync Bus Battery n Test Failed Low Battery Shutdown Bypass Not Available Non volatile Memory Checksum Fail Calibration Failed On Manual Bypass DC Link Over Voltage Output AC Over Voltage Fan Failure Output AC Under Voltage Fuse Failure Output O...

Page 29: ...ms are present The variable x indicates the number of alarms Table 3 3 Main Module Status Options LCD Display Explanation Load Power Off The UPS is in Standby mode and is not supporting the load System Normal 0 Alarms The UPS is operating normally from utility and is protecting the load No alarms are present Load Power On x Alarms The UPS is operating from utility and is protecting the load On Bat...

Page 30: ...ering the load Electronics Modules M1 M4 Status and Alarms Select Module Mx to display Status and Alarms for an electronics module The variable x indicates one of the electronics modules Module M1 M4 Table 3 4 lists the possible status options For a descriptive list of alarm causes and solutions refer to the section LCD Alarm Troubleshooting in Chapter 5 Status Select Module Mx Table 3 4 Electroni...

Page 31: ...ead the message Press the Enter button to view selections Table 3 5 lists the options under the Meters menu Table 3 5 Main Module and Electronics Modules M1 M4 Meter Options LCD Display Explanation Input Volts The utility voltage Output Volts The voltage available at the UPS output receptacles Input Frequency The utility frequency in Hertz Output Frequency The frequency in Hertz available at the U...

Page 32: ...lowing LCD is displayed Battery Charge 1h The remaining battery energy is shown where the tag 1h means that each block represents one hour For example this LCD shows three hours of remaining battery time Possible tags are listed in Table 3 6 Table 3 6 Possible Tags Tag Time 1m 1 minute per block 5m 5 minutes per block 10m 10 minutes per block 30m 30 minutes per block 1h 1 hour per block Setting th...

Page 33: ...are Vers Table 3 7 Firmware Version Options LCD Display Explanation MM Control Vers xxx Version of firmware that the control board is running MM Comm Version xxx Version of firmware that the communication board is running M1 M4 Versions xxx xxx xxx xxx Version of firmware in each electronics module Display Module xxx Version of display firmware that the UPS is running Testing the LCD Display Selec...

Page 34: ...ct the first digit using the up and down arrow keys on the Center button 2 Press the right arrow key on the Center button to move to the next digit 3 To change a digit use the left arrow key on the Center button to go back 4 After entering the entire password press the Enter button IMPORTANT Record your password After 30 minutes with no key presses security is automatically restored and the displa...

Page 35: ...e current configuration The options for voltage are 200 208 220 230 default and 240 System Setup Set Voltage NOTE This option is only available when the UPS is in Standby mode or Manual Bypass mode Otherwise the LCD panel indicates Not Available Setting the Hardware Configuration Select Set HW Config from the System Setup menu to set the hardware configuration for the UPS System Setup Set HW Confi...

Page 36: ...ederlands and Italiano An asterisk indicates the current configuration System Setup Set Language Setting the Password Select Set Password from the System Setup menu to set the password System Setup Set Password To access some of the more critical UPS operations you must have a password Use the Center and Enter buttons to select the six digits for the password 0 9 and A Z NOTE The password must be ...

Page 37: ...wn the UPS After you complete all necessary removal and replacement procedures power up the UPS to verify that all components are operating properly Shutting Down the System To shut down the system 1 Place the UPS in Standby mode by pressing the Standby button for three seconds The load relays open and the Utility LED begins to flash slowly For more information on the control buttons refer to the ...

Page 38: ...eplaceable parts Bezels Battery modules Electronics modules Supervisory board Chassis Tools Required To service the UPS you will need the following tools Torque wrench Medium flat bladed screwdriver 1 Philips screwdriver bit 3 Philips screwdriver bit Metric tools 7 mm 8 mm 10 mm Sheetmetal hole punch tools up to 44 45 mm 1 inches in diameter The following items are supplied with the rack Screws Ca...

Page 39: ...rocedures HP UPS R12000 XR Models Maintenance and Service Guide 4 3 HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 7 02 3 45 PM Bezels Figure 4 1 Bezels 1 Supervisory bezel 2 Control bezel 3 Front bezel ...

Page 40: ...73 001 Last Saved On 8 7 02 3 45 PM Removing and Replacing the Control Bezel To remove the control bezel 1 Pull both ends of the control bezel and lift it off the chassis 1 2 Disconnect the LCD cable from the connector on the control bezel 2 2 1 Figure 4 2 Removing the control bezel 3 To replace the control bezel reverse the preceding steps ...

Page 41: ...sory Bezel To remove the supervisory bezel 1 Remove the control bezel For more information refer to the section Removing and Replacing the Control Bezel in this chapter 2 Remove the screw from each end of the supervisory bezel 1 3 Press both ends of the supervisory bezel and pull it off the chassis 2 2 1 1 Figure 4 3 Removing the supervisory bezel 4 To replace the supervisory bezel reverse the pre...

Page 42: ...ed On 8 7 02 3 45 PM Removing and Replacing a Front Bezel To remove a front bezel 1 Pull in on each end of the bezel and pull it off the chassis 2 Repeat for the remaining bezels you want to remove Figure 4 4 Removing a front bezel 3 To replace a front bezel reverse the preceding steps NOTE Verify that the ventilation holes are over the electronics modules ...

Page 43: ...and Replacement Procedures HP UPS R12000 XR Models Maintenance and Service Guide 4 7 HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 7 02 3 45 PM Battery Module Figure 4 5 Battery module ...

Page 44: ... to the section Removing and Replacing a Front Bezel in this chapter 2 Remove the two screws that secure the battery module in place 1 and slide out the battery module 2 2 1 Figure 4 6 Removing the battery module 3 Set aside the used battery module for proper disposal 4 To replace the battery module reverse the preceding steps Disposing of Used Batteries The spare battery kit includes the instruct...

Page 45: ...cing the Battery Module section of this chapter and check the battery terminal connections If the Alarm LED is still red refer to the section LCD Alarm Troubleshooting in Chapter 5 for more information on the cause of the alarm IMPORTANT The batteries charge to 80 percent of their capacity within approximately three hours Charge the batteries for at least 24 hours before you use the UPS to supply ...

Page 46: ...Replacement Procedures 4 10 HP UPS R12000 XR Models Maintenance and Service Guide HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 7 02 3 45 PM Electronics Module Figure 4 7 Electronics module ...

Page 47: ...le To remove the electronics module 1 Remove the front bezel at the location of the electronics module you want to remove For more information refer to the section Removing and Replacing a Front Bezel in this chapter 2 Loosen the security screw in the front of the electronics module 1 slide the security panel upward 2 and pull the hook latch all the way down 3 3 2 1 Figure 4 8 Preparing to remove ...

Page 48: ...intenance and Service Guide HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 7 02 3 45 PM 3 Slide the electronics module out of the chassis Figure 4 9 Removing the electronics module 4 To replace the electronics module reverse the preceding steps ...

Page 49: ...Replacement Procedures HP UPS R12000 XR Models Maintenance and Service Guide 4 13 HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 8 7 02 3 45 PM Supervisory Board Figure 4 10 Supervisory board ...

Page 50: ... Supervisory Board To remove the supervisory board 1 Remove the control bezel and the supervisory bezel For more information refer to the sections Removing and Replacing the Control Bezel and Removing and Replacing the Supervisory Bezel in this chapter 2 Pull the supervisory board out of the chassis Figure 4 11 Removing the supervisory board 3 To replace the supervisory board reverse the preceding...

Page 51: ... alarms An audible alarm may also sound For each alarm listed in the table an explanation of the cause is provided as well as a recommended action to take to resolve the problem As shown in Table 5 1 x Alarms on the first line of the LCD display means that one or more alarms are present with the variable x indicating the number of alarms The type of alarm is displayed on the second line of the LCD...

Page 52: ...Not enough battery modules are installed to support the current load levels Remove bezels and check that each battery module is firmly seated in its slot Verify that the load does not exceed 12 kW If necessary replace the faulty battery module x Alarms Battery DC Over Voltage At least one electronics module detects that battery voltage is abnormally high while operating in Battery mode Switch to M...

Page 53: ...autocalibration process fails to complete successfully This could be the result of an interruption from an operating mode transition or because of UPS load changes occurring while autocalibration was in progress The autocalibration process reschedules and automatically restarts when the UPS conditions are conducive for the operation to complete If the condition persists locate and replace the faul...

Page 54: ...ately transitions to Battery mode until valid utility returns If this occurs before a system has entered an online state its startup sequence does not complete and the system shuts down until valid utility returns If the condition persists contact an electrician x Alarms Input AC Under Voltage The UPS detects that the input utility voltage is below the minimum operating range of about 172 V 160 V ...

Page 55: ...enu Scroll through and examine the additional alarms related to the failed electronics module for details on handling this condition x Alarms Inverter Fault At least one electronics module detects a hardware failure in its inverter generates this alarm and subsequently shuts down The UPS may have transitioned into Automatic Bypass mode due to the failure depending on the load levels present at the...

Page 56: ...ge in the chassis If the problem persists replace the module x Alarms Inverter Uncalibrated At least one electronics module has not been calibrated with others as a set which is required for efficient load sharing operations An autocalibration is required and the UPS automatically schedules the autocalibration process on detection of this condition Switch to Manual Bypass mode Replace the faulty m...

Page 57: ... that would provide redundant protection to the electronics modules The system continues to operate but is no longer in Redundant mode The load could be at risk if an electronics module fails If you still want redundant operation reduce the load until the alarm clears x Alarms Loss of Sync Bus The UPS detects that its electronics modules are having trouble synchronizing with the input utility sour...

Page 58: ...ty to the load This is a normal operation x Alarms Output AC Over Voltage The UPS detects that its output voltage is higher than its configured operational range The UPS immediately initiates a transfer to Bypass mode if that mode is available If Bypass mode is not available at the time of this failure the UPS shuts down immediately to protect the load This problem could be caused by a hardware co...

Page 59: ...uts down to protect itself from damage The UPS may have transitioned into Automatic Bypass mode due to the failure depending on the load levels present at the time of the failure and the number of modules affected This problem could be caused by a hardware failure Switch to Manual Bypass mode Locate and replace the faulty module x Alarms Remote Emergency Power Off The UPS detects a Remote Emergenc...

Page 60: ...ormally low that the UPS classifies it as not being present Verify the utility power If the problem persists contact an electrician Problems During Startup If problems occur when starting the UPS refer to Table 5 2 for possible causes and suggested actions Table 5 2 Troubleshooting Problems During UPS Startup Symptom Possible Cause Actions to Take UPS will not start There is no utility power Unit ...

Page 61: ...ty LED is flashing slowly and all other LEDs are off Utility power is within acceptable range The UPS is operating normally and is in Standby mode Press the On button to assume the load Utility LED is flashing rapidly The full UPS or an electronics module is in the process of starting up Wait for a continuous Utility or Battery LED light or slowly flashing Utility LED All LEDs flash on and off tog...

Page 62: ... LCD menu to view current alarms Use the power management software to view the alarm history to determine the reason for the transfer to Battery mode UPS frequently switches between utility and battery power The utility voltage is frequently outside the UPS operating range Update the configuration Utility LED and Redundant LED are lit UPS is on utility The UPS is operating normally The system is c...

Page 63: ...ice Guide 5 13 HP CONFIDENTIAL Codename Sierra Part Number 221273 001 Last Saved On 7 31 02 8 59 AM Repairing the UPS Repairs to the UPS must be carried out by an HP authorized service technician Other than battery replacement there are no user serviceable parts ...

Page 64: ...untime estimates and environmental requirements when operating the UPS Physical Specifications Table 6 1 Physical Specifications Feature Metric U S Dimensions Width 44 45 cm 17 50 in Height 44 45 cm 17 50 in Depth 72 64 cm 28 60 in Weight 189 kg 420 lb Input Specifications Table 6 2 Input Specifications UPS Model Utility Voltage Frequency Hz Default Settings Nominal Voltage VAC Range Available Set...

Page 65: ...00 208 220 230 or 240 Source of Power Regulation Output Utility power normal range 3 of nominal output voltage rating within the guidelines of the Computer Business Equipment Manufacturers Association Battery power 3 of nominal output voltage rating Feature Specification Other features Online efficiency 83 Voltage wave shape Sine wave 3 THD with typical PFC load Surge suppression High energy 6500 ...

Page 66: ...48 hours The UPS recharges in three hours to 80 usable capacity ERMs recharge in less than eight hours to 80 usable capacity Battery Runtime Table 6 5 Estimated Battery Runtime Load percent Estimated Battery Runtime minutes UPS with ERM Runtime minutes 20 43 69 50 14 28 80 7 15 100 5 11 Environmental Specifications Table 6 6 Environmental Specifications Feature Specification Operating temperature ...

Page 67: ...M port 1 2 LCD cable 4 4 CarePaq services vii Center button 3 3 Comm Setup menu option 3 18 commissioning test for batteries 4 9 communication board firmware version displaying 3 17 communication ports 1 2 component level repairs vi configuration LCD menus 3 10 control bezel 3 1 4 3 location 3 1 photograph of 4 3 removing replacing 4 4 control board firmware version displaying 3 17 control buttons...

Page 68: ...f 3 5 LEDs 3 4 operation modes 3 5 output specifications 6 2 output voltage setting 3 8 overcurrent protection 6 2 P Parallel mode 3 19 passwords 3 18 3 20 physical specifications 6 1 ports communication 1 2 power up display initial 3 10 R racks attachment equipment 4 2 spare parts list 2 4 warnings 1 1 1 2 rails spare parts list 2 5 rear components 2 4 3 6 3 7 rear panel 3 6 Redundancy LED 3 4 Re...

Page 69: ...ng startup 5 10 U UPS uninterruptible power system components 3 1 configuration menus 3 10 general product information 1 1 packaged service options vii removing replacing components 4 1 safety 1 1 spare parts exploded front view 2 2 spare parts exploded rear view 2 4 spare parts list 2 3 2 4 specifications 6 1 troubleshooting 5 1 weight warning 1 2 UPS battery charge data displaying 3 16 UPS firmw...