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Su 60 KX
Su 60 KX
A RY
I N
E L IM
P R
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3.02 Emergency Power Off (EPO) 72
1.5.1 Online (Normal) Mode (Single UPS) 15 3.1 Setting EEPROM on the NH-M Board 74
1.5.2 Battery Backup Mode (Single UPS)
1.5.3 Auto Bypass Mode (Single UPS)
1.5.4 Manual Bypass Mode (Single UPS)
15
15
15
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3.1.1 Polling and Updating EEPROM
A
3.1.2 Calibrating EEPROM Gain
N
3.2 Setting Output Dry Contact Status
74
75
76
I
1.5.5 Online Mode (Parallel UPS) 16 3.3 Upgrading Firmware for the System Board 77
1.5.6 Battery Backup Mode (Parallel UPS) 16 3.4 Upgrading Firmware for the Power Module 82
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1.5.7 Auto Bypass Mode (Parallel UPS) 16 3.5 Downloading the Event Log 90
1.5.8 Manual Bypass Mode (Parallel UPS) 17
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4 Internal Battery 91
1.5.9 Hot Standby Mode (Parallel UPS) 17 4.1 Installing and Removing Internal Batteries 92
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1.6 Start-Up, Shutdown and Bypass
1.6.1 Control Panel and Breaker Diagrams
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1.6.2 Preliminary Checklist (Single UPS)
1.6.3 Standard Start-Up Procedure (Single UPS)
1.6.4 Battery Start-Up Procedure (Single UPS)
1.6.5 Manual Bypass Procedure (Single UPS)
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18
18
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19
20
4.2 Battery Cabinet
5 Troubleshooting
5.1 Alarm Messages
5.2 Troubleshooting Flow Charts
5.2.1 “MAIN VOLT/FREQ NOK”
5.2.2 “MAIN SEQUENCE NOK”
95
98
98
100
100
101
1.6.6 Shutdown Procedure (Single UPS) 20 5.2.3 “BYPASS VOLT/FREQ NOK” 102
1.6.7 Preliminary Checklist (Parallel UPS) 21 5.2.4 “BYPASS SEQUENCE NOK” 103
1.6.8 Start-Up Procedure (Parallel UPS) 21 5.2.5 “BYPASS STATIC SWITCH OVER TEMPERATURE” 103
1.6.9 Shutdown Procedure (Parallel UPS) 22 5.2.6 “BYPASS STATIC SWITCH FAULT” 104
1.6.10 Manual Bypass Procedure (Parallel UPS) 23 5.2.7 “BYPASS STATIC SWITCH OVERLOAD” 104
1.6.11 Switching from Manual Bypass to Normal Mode 5.2.8 “UPS INTERNAL COMM ABNORMAL” 105
(Parallel UPS) 24 5.2.9 “BATTERY TEST FAIL” 106
1.7 Printed Circuit Boards (PCB) 25 5.2.10 “BATTERY OVER CHARGE” 106
1.7.1 PCB Location (System) 26 5.2.11 “BATTERY BAD” 107
1.7.1.1 KX Models 26 5.2.12 “BYPASS FAN FAILURE” 108
1.7.1.2 K Models 28 5.2.13 “TRANSFORMER OVERHEAT” 109
1.7.1.3 KTV Models 32 5.2.14 “PS OUTPUT VOLT NOK” 110
1.7.2 PCB Power Module 33 5.2.15 “PS EXT PARALLEL COMM ABNORMAL” 111
1.8 Block and Wiring Diagrams 34 5.2.16 “PARALLEL FAILURE” 112
1.8.1 KX Models 34 5.2.17 “REDUNDANCY LOSS” 113
1.8.2 K Models 40 6 Power Module 114
1.8.3 KTV Models 45 6.1 Failure Power Module Identify 114
2 Theory of Operation 48 6.2 Power Module Replacement 117
2.1 AC Auxiliary Power Circuit 48 7 Preventive Maintenance 121
2.2 DC Auxiliary Power Circuit 51 7.1 Safety Overview 121
2.3 Auxiliary Power Failure Detection 51 7.2 Suggested tools and supplies 121
2.4 Output Current Detection 52 7.3 UPS Procedure 121
2.5 Input Voltage Detection 53 7.4 Internal Battery Procedure 122
2.6 Output Voltage Detection 54 Appendix A Service Equipment and Tools 123
2.7 Battery Voltage Detection 55 Appendix B Torque Table 124
2.8 Bypass SCR Short-Circuit Detection 56 Appendix C PCB and Test Point 128
2.9 Bypass SCR Driver 57
2.10 Watchdog for System MCU 58
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1 Basic Operation
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Total Harmonic (Linear Load)
R
Voltage Regulation Static ±1%
A
Dynamic ±7% (10% ~ 90% Linear Load)
Frequency Regulation Interior Oscillator ±0.05 Hz
Overload
I
Synchronized ±5%
N
≤125% : 10 minutes; ≤150% : 1 minute
IM
Audible Warning Battery Backup Intermittent
L
UPS Abnormal Continuous
E
Display LED UPS Status: Normal • Bypass • Backup • Fault
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LCD Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage
UPS abnormal messages with intelligent self-diagnosis.
PInterface
Others
Standard
Optional
Parallel Redundancy
EPO
SRAM Event Log
RS-232, Dry Contact
SNMPWEBCARD
Yes (1+1 for 2 UPS systems of the same type and capacity only.)
Standard (Local and Remote)
500 Records
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 94%
ECO 97%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 65 dBA 68 dBA 70 dBA 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 850 mm
Height 1165 mm
Weight (Power Module) 267 kg* 412 kg* 210 kg 244 kg
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1 Basic Operation (continued)
Y
Output Frequency 50 / 60 Hz
≤3%
R
Total Harmonic (Linear Load)
Voltage Regulation Static ±1%
Frequency Regulation Dynamic
Interior Oscillator
Synchronized
I
±0.05 Hz
±5%
A
±7% (10% ~ 90% Linear Load)
N
IM
Overload ≤125% : 10 minutes; ≤150% : 1 minute
Audible Warning Battery Backup Intermittent
Display LED
R
LCD
E L
UPS Abnormal Continuous
UPS Status: Normal • Bypass • Backup • Fault
Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage
P
UPS abnormal messages with intelligent self-diagnosis.
Interface Standard RS-232, Dry Contact
Optional SNMPWEBCARD
Others Parallel Redundancy Yes (1+1 for 2 UPS systems of the same type and capacity only.)
EPO Standard (Local and Remote)
SRAM Event Log 500 Records
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 92%
ECO 96%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 65 dBA 68 dBA 70 dBA 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 850 mm 950 mm 850 mm
Height 1696 mm
Weight (Power Module) 682 kg* 534 kg 534 kg 584 kg
* With internal batteries.
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1 Basic Operation (continued)
Frequency Regulation
Dynamic
Interior Oscillator
Synchronized
±0.05 Hz
±5%
A Y
±7% (10% ~ 90% Linear Load)
R
N
Overload ≤125% : 10 minutes; ≤150% : 1 minute
Audible Warning
Display
Battery Backup
UPS Abnormal
LED
IM I Intermittent
Continuous
UPS Status: Normal • Bypass • Backup • Fault
L
LCD Input/Output • Bypass • Inverter • Frequency • Loading • Battery Voltage
E
UPS abnormal messages with intelligent self-diagnosis.
Interface
R
Standard RS-232, Dry Contact
P
Optional SNMPWEBCARD
Others Parallel Redundancy Yes (1+1 for 2 UPS systems of the same type and capacity only.)
EPO Standard (Local and Remote)
SRAM Event Log 500 Records
Parameter Configuration Yes
Hot Standby Installation Optional
Battery Temperature Compensation Optional
Battery Cold-Start Standard
Overall Efficiency Normal 92%
ECO 96%
Transfer Time 0 ms
Temperature 32° F ~ 104° F (0° C ~ 40° C)
Humidity (non-condensing) 90%
Noise (1 m) 70 dBA
Dimensions (Power Module) Width 520 mm
Depth 1026 mm
Height 1696 mm
Weight (Power Module) 655 kg
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1 Basic Operation (continued)
1.2 Features
1.2.1 Advanced Features:
• True on-line double conversion with superior IGBT inverter technology
• Low input current THD allows 1:1 generator sizing for maximum efficiency and cost savings
• Internal N+1 power module redundancy (except for SU20KX model)
• Built-in parallel redundancy (1+1) capability for increased capacity or fault-tolerance
• Up to 80kVA capacity in a compact footprint; up to 160kVA in parallel redundancy (1+1) configuration
• High input power factor and high efficiency with low thermal loss and low noise
• Simplified, easy-to-repair, long-life, high-availability system design
• Redundant auxiliary power and control circuits
• Dual input design with separated rectifier and bypass input (SU20K, SU40K, SU60K, SU80K only)
• All models support external battery cabinets for extended battery backup runtime
• High-resolution LCD status screen simplifies operation and delivers detailed operational information, including system block diagrams
A
F
RYG H I J K
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•A
P R
“NORMAL” LED: This green light illuminates to indicate that the UPS system is in online (normal) mode. The primary AC input supply is
present and within standard operating parameters.
•B “BATTERY” LED: This amber light illuminates when the UPS system is in battery backup mode, discharging the batteries to provide power
to connected equipment. An audible alarm will also sound.
•C “BYPASS” LED: This amber light illuminates when the UPS system is in bypass mode (auto bypass or manual bypass). Battery backup
power will not be available to connected equipment while the UPS system is in bypass mode, but connected equipment loads will be
supported by the bypass (reserve) power source.
•D “FAULT” LED: This red light illuminates when any UPS system or input power fault occurs. Available diagnostic information will be
displayed on the LCD screen.
•E LCD Status Screen: This illuminated LCD status screen displays text and graphics to indicate a wide range of UPS system operating
conditions and diagnostic data. Note: The LCD backlight will turn off after 10 minutes of inactivity. Turn on the backlight by momentarily
pressing the ON button or one of the scroll buttons.
•F “ESC” (Escape) Button: Press this button to return to the previous page or menu.
•G Scroll Buttons ( and ): Press these buttons to move the cursor up or down and navigate the control panel menus and screens. These
buttons are also used for data entry in several screens.
•H Enter Button ( ): Press this button to select a menu item or confirm a setting change.
•I ON Button: Press and hold this button for 3 seconds to turn the UPS system’s inverter ON.
•J OFF Button: Press and hold this button for 3 seconds to turn the UPS system’s inverter OFF. If the UPS system is in online (normal) mode,
it will switch to auto bypass mode. Note: If the UPS system remains off for an extended period of time, the batteries should be recharged
periodically. The UPS system should be turned on and the batteries should be recharged at least one uninterrupted 24-hour period every
3 months. Failure to recharge the batteries periodically may cause irreversible battery damage.
•K “EPO” (Emergency Power Off) Button: Press this button to turn the UPS system’s output OFF and also disable bypass output.
If the UPS system is in battery backup mode when the EPO button is activated:
• Main output and bypass output are turned off, the alarm sounds, fans shut down after approximately one minute, and control circuitry
remains active.
• Releasing the EPO button (by pressing it again) turns off the UPS system completely, including the alarm and control circuit. Press the
ON button for 3 seconds to restart the UPS system.
If the UPS system is in online (normal) mode when the EPO button is activated:
• Main output and bypass output are turned off, the alarm sounds, fans and control circuitry remain active.
• Releasing the EPO button (by pressing it again) turns off the alarm and places the UPS system in auto bypass mode. Press the ON button
for 3 seconds to return the UPS system to online (normal) mode.
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1 Basic Operation (continued)
Y
C
NA R
I
E F
D G
E L H IM H
P R I
Fig 1.2.3a SU40KX front
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
•A
•B
I
Control Panel: The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.)
Internal Power Modules: 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The
number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy in SU40KX, SU60KX and
SU80KX models.
•C Internal Battery Pack Compartment (SU20KX and SU40KX only; shown without batteries): Internal batteries must be connected by a
qualified electrician. (See section 4 for more information.)
•D Output Circuit Breaker Switch (Q4): Controls AC output power.
•E Manual Bypass Circuit Breaker Switch (Q3): Controls AC input power to the UPS system during manual bypass operation.
•F Bypass Input Circuit Breaker Switch (Q2): Controls AC input power to the UPS system during auto bypass operation.
•G Main Input Circuit Breaker Switch (Q1): Controls AC input power to the UPS system during online (normal) operation.
•H Levelers: The levelers provide long-term support for the UPS system.
•I Casters: The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
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1 Basic Operation (continued)
L M
K
N
A RY
N
P
IM I
L
H H
E
I I
R
Fig 1.2.3b SU40KX rear
•H
•I
•J
P
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
Levelers: The levelers provide long-term support for the UPS system.
Casters: The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an
Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call +1 773 869 1234 for
more information about the SNMPWEBCARD accessory.
•K RS-232 Serial Communications Port: This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic
shutdown during extended blackouts and monitoring of operating and power conditions.
•L Parallel Redundancy Port: This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel
redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
•M Input Dry Contact Interface: This interface receives dry contact signals that allow the UPS system to receive commands and monitor
external battery conditions.
•N Output Dry Contact Interface: This interface allows the UPS system to send information via dry contact communications. (See section 3.3
for more information.)
•O Internal Battery Circuit Breaker Switch (SU20KX and SU40KX only): Controls the input/output power of the UPS system’s internal
batteries.
•P Terminal Block Cover: Remove the terminal block cover to access the UPS system’s input, bypass input, external battery cabinet, output and
grounding connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. (See section 1.8 for more
information, including a detailed diagram of the terminal block.)
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1 Basic Operation (continued)
A RY
E
D
I N F
G
E L IM
P R
H I H
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1 Basic Operation (continued)
J
M
L
K
N
A RY
N
P
IM I
R E L
P I
H H
Fig 1.2.3d SU40K rear
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
•H Levelers: The levelers provide long-term support for the UPS system.
•I Casters: The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
•J Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an
Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for
more information about the SNMPWEBCARD accessory.
•K RS-232 Serial Communications Port: This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic
shutdown during extended blackouts and monitoring of operating and power conditions.
•L Parallel Redundancy Port: This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel
redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
•M Input Dry Contact Interface: This interface receives dry contact signals that allow the UPS system to receive commands and monitor
external battery conditions.
•N Output Dry Contact Interface: This interface allows the UPS system to send information via dry contact communications. (See section 3.3
for more information.)
•O Internal Battery Circuit Breaker Switch (SU40K only): Controls the input/output power of the UPS system’s internal batteries.
•P Terminal Block Cover: Remove the terminal block cover to access the UPS system’s input, external battery cabinet, output and grounding
connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. (See section 1.8 for more information,
including a detailed diagram of the terminal block.)
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1 Basic Operation (continued)
A RY
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IM
C
R E L
P
D D
E
Fig 1.2.3e SU80K front
Note: Individual models may vary from diagrams. Unit shown with front bezels removed.
•A Control Panel: The control panel allows the operator to monitor and control the UPS system. (See section 1.2.2 for more information.)
•B Internal Power Modules: 20kVA internal power modules can be replaced in the field without powering down connected equipment loads. The
number of internal power modules varies by model. The internal power modules are capable of N+1 redundancy.
•C Main Input Circuit Breaker Switch (Q1): Controls AC input power to the UPS system during online (normal) operation.
•D Levelers: The levelers provide long-term support for the UPS system.
•E Casters: The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
11
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1 Basic Operation (continued)
F
I
H G
J
A RY
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IM
L M N
R E L
P K
D E D
Fig 1.2.3f SU80K rear
Note: Individual models may vary from diagrams. Unit shown with breaker guard removed.
•D Levelers: The levelers provide long-term support for the UPS system.
•E Casters: The casters are designed for small position adjustments within the final installation location only; they are not designed for moving
the UPS system over longer distances. The casters are not designed to provide long-term support for the UPS system after final installation.
Use the levelers to provide long-term support.
•F Accessory Slot: Remove the cover panel to install a Tripp Lite SNMPWEBCARD accessory. The SNMPWEBCARD accessory provides an
Ethernet interface for the UPS system and enables remote monitoring and control via SNMP, Web browser or telnet. Call (773) 869-1234 for
more information about the SNMPWEBCARD accessory.
•G RS-232 Serial Communications Port: This DB9 port connects the UPS system to compatible workstations or servers, enabling automatic
shutdown during extended blackouts and monitoring of operating and power conditions.
•H Parallel Redundancy Port: This DB9 port connects the UPS system to another UPS system of identical type and capacity for use in a parallel
redundancy (1+1) configuration. (See sections 1.5 and 1.8 for more information.)
•I Input Dry Contact Interface: This interface receives dry contact signals that allow the UPS system to receive commands and monitor
external battery conditions.
•J Output Dry Contact Interface: This interface allows the UPS system to send information via dry contact communications. (See section 3.3
for more information.)
•K Terminal Block Cover: Remove the terminal block cover to access the UPS system’s input, external battery cabinet, output and grounding
connection terminals. Wiring conduits pass through the circular knockouts in the terminal block cover. The UPS system includes alternate
circular knockouts in the bottom panel. (See section 1.8 for more information, including a detailed diagram of the terminal block.)
•L Bypass Input Circuit Breaker Switch (Q2): Controls AC input power to the UPS system during auto bypass operation.
•M Manual Bypass Circuit Breaker Switch (Q3): Controls AC input power to the UPS system during manual bypass operation.
•N Output Circuit Breaker Switch (Q4): Controls AC output power.
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1 Basic Operation (continued)
Bypass Input
Q2
Bypass Input
Circuit Breaker STS
Main
Q1 20kVA/3U POWER MODULE Q4 LOAD
MAIN Main Input Output
Circuit Breaker Circuit Breaker
20kVA/3U POWER MODULE
RY
20kVA/3U POWER MODULE
A
20kVA/3U POWER MODULE
BATTERY
I N
Fig 1.3.1a System Block Diagram for KX models
IM
Q3
L
Manual Bypass
Circuit Breaker
E
Manual Input
P R MAIN Q2 XFMR
Bypass Input
Q1
Main Input
Circuit Breaker Circuit Breaker
Bypass Input
XFMR
Q4
Output
LOAD
BATTERY
Fig 1.3.1b System Block Diagram for K and KTV models
The SU-Series 3-Phase UPS is configured with 3-phase 20kVA power modules that can be paralleled for redundancy or capacity upgrades. Each
KX- (Figure 1.3.1a), K- , and KTV-series (Figure 1.3.1b) UPS includes three key functions:
1) A central bypass static switch, which causes a critical load to automatically bypass any overload or fault conditions that occur.
2) A maintenance bypass switch, which eliminates UPS faults by supplying a critical load.
3) A matched transformer, which increases and decreases the input/output voltage
An internal battery pack (number of packs vary by model) supplies the UPS system with battery backup power. Each internal battery pack consists
of 40 12Vdc VRLA batteries arranged in two strings: one string of 20 positive batteries (black cable) and one string of 20 negative batteries (red
cable). The two strings are connected by a neutral (N) point (Figure 1.3.2a).
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1 Basic Operation (continued)
BATTERY Charger
The SU-Series 3-Phase UPS double-conversion power modules consist of three components (Figure 1.3.3a):
1) An AC/DC converter
Y
2) An AC/DC inverter
R
3) A charger
A
The power module’s 3-phase, 4-wire input runs A/C current through the AC/DC converter to generate regulative dual DC bus (±370Vdc). During
N
backup mode, this current is provided by battery power.
I
The dual DC bus then runs through the AC/DC inverter to generate a pure sine wave of AC power (3-phase, 4-wire). The DC bus also charges the
dual battery strings by running current through the charger. Each power module has a maximum charge current of 5 A.
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1.4 Opening and Closing the Unit
[PENDING]
E IM
P R
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1 Basic Operation (continued)
Y
1.5.2 Battery Backup Mode (Single UPS)
R
When a blackout or other extreme power event occurs, the UPS system
automatically switches from normal mode to battery backup mode. The
UPS system’s batteries (internal and/or external) provide emergency DC
power to the inverter. The inverter transforms the DC power to precision-
I
regulated, pure sine wave AC power that supports the operation of
connected equipment.
NA
E L
1.5.3 Auto Bypass Mode (Single UPS) IM
P R
If the inverter malfunctions due to excessive temperature, overload,
output short circuit, abnormal voltage or battery problems, the inverter
will shut down. If the UPS system detects a bypass (reserve) power
source that conforms to normal parameters, then the UPS system
automatically switches to auto bypass mode to continue supplying power
to connected equipment. When all problems are eliminated, the UPS
system switches back to online (normal) mode automatically.
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1 Basic Operation (continued)
A RY
I N
IM
1.5.6 Battery Backup Mode (Parallel UPS)
Similar to on battery backup mode for a single UPS system (Section
L
1.5.2), except the total connected equipment load is shared by the parallel
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(1+1) UPS systems.
P R
1.5.7 Auto Bypass Mode (Parallel UPS)
Similar to auto bypass mode for a single UPS system (Section 1.5.3),
except with parallel (1+1) UPS systems.
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1 Basic Operation (continued)
A RY
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IM
1.5.9 Hot Standby Mode (Parallel UPS)
For added fault-tolerance, the redundant UPS system acts as the bypass
R E L
(reserve) power source for the main UPS system.
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1 Basic Operation (continued)
•C “BYPASS” LED B
G
•D “FAULT” LED C
Y
•F “ESC” (Escape) Button H J
1
R
•G Scroll Buttons ( and )
Control Panel
A
•H Enter Button ( )
N
•I ON Button
•J
•K
•L
OFF Button
“EPO” (Emergency Power Off) Button
Output Circuit Breaker Switch
IM I L M N O
•M
•N
R E L
Manual Bypass Circuit Breaker Switch
Bypass Input Circuit Breaker Switch 2
Output Manual
Bypass
Bypass
Input
Main
Input
P
•O Main Input Circuit Breaker Switch Circuit Breaker Switches (UPS System Front Panel)
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1 Basic Operation (continued)
A RY A
I 4
N
Output Manual
Bypass
Bypass
Input
Main
Input
IM
•5 Press the ON button A for 3 seconds (until you hear a beep), then
A
release the button. The inverter will activate and synchronize with
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the bypass source, then automatically switch from auto bypass
E
(reserve) mode to online (normal) mode. The “BYPASS” LED will
darken and the “NORMAL” LED will illuminate.
P R
1.6.4 Battery Start-Up Procedure (Single UPS)
5
Note: The battery must be at least partially charged for this operation to succeed.
•1 If there is an external battery cabinet connected, switch on the
circuit breaker A of the external battery cabinet.
3
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1 Basic Operation (continued)
Y
1
R
•2 Switch on the manual bypass circuit breaker switch A , then switch
A
off the output circuit breaker switch B .
I
B
N A
E L IM 2
Output Manual
Bypass
Bypass
Input
Main
Input
R
1.6.6 Shutdown Procedure (Single UPS)
P
Warning: The UPS system shutdown procedure will eliminate the AC power output for all loads. Before shutdown, confirm that all loads
are turned off or place the UPS system in manual bypass mode to keep loads powered by the reserve (bypass) power source.
•1 Press the OFF button A for 3 seconds (until you hear a beep), then
release the button. If the UPS system is in online (normal) mode, it
will switch to bypass mode. If the UPS system is in battery backup
mode, the inverter will shut down and AC output power will be
interrupted.
1 A
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1 Basic Operation (continued)
Y
Note: If the UPS system remains off for an extended period of time, it
A
should be turned on periodically to allow the batteries to recharge. The
UPS system should be turned on and the batteries should be recharged
at least one uninterrupted 24-hour period every 3 months. Failure
to recharge the batteries periodically may cause irreversible battery
NA R
Output Manual Bypass Main
I
damage. 5 Bypass Input Input
IM
1.6.7 Preliminary Checklist (Parallel UPS)
L
Warning: Parallel redundancy requires exactly two UPS systems (1+1 redundancy ). Do not attempt to link more than two UPS systems
via parallel redundancy. The UPS systems must have the same rating and capacity for parallel redundancy installation. Attempting to link
E
dissimilar UPS systems will damage the UPS systems and create a serious risk of personal injury and property damage.
R
• All circuit breaker switches should be off, including the breakers of the external battery cabinets.
P
• Confirm that no voltage potential exists between Neutral and Ground.
• Confirm that the input power source matches the rating (voltage, frequency and phase) of the UPS systems.
• You must use the control panel to set the parallel ID numbers of the UPS systems to be 1 and 2. See section 10-11 of the owner’s
manual for information about setting the parallel ID numbers.
Note: After start-up, the UPS systems will perform a brief self-test and display the results on the LCD screen. After a successful self-test, the UPS
systems will provide AC power to the connected equipment load.
B A
1
•2 If the UPS systems have external battery cabinets connected, switch
on the external battery cabinet circuit breaker switch A of each
battery pack.
A
21
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1 Basic Operation (continued)
A RY A
N
Output Manual Bypass Main
I
Bypass Input Input
4
IM
•5 Press the ON button A of one of the UPS systems for 3 seconds A
(until you hear a beep), then release the button. The inverter will
L
activate and synchronize with the bypass source. Press the ON
E
button for the other UPS system for 3 seconds (until you hear a
beep), then release the button. When the inverter of each UPS
R
system is operating normally, they will automatically switch from
P
auto bypass (reserve) mode to online (normal) mode at the same
time. The “BYPASS” LED will darken and the “NORMAL” LED
will illuminate. 5
•6 Check the output voltage of each UPS system. The phase deviation
between each UPS system should be less than 5V. If the phase
deviation is within the acceptable range, switch on the output
circuit breaker switch A of each UPS system. Note: For more A
information on checking the output voltage of each UPS system,
see section 10-6 of the owner’s manual.
22
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1 Basic Operation (continued)
A RY
I
to recharge the batteries periodically may cause irreversible battery
damage.
4
N
IM
1.6.10 Manual Bypass Procedure (Parallel UPS)
L
Warning: When the UPS system is in manual bypass, the inverter shuts down. Connected equipment loads are powered by the bypass
(reserve) power source and will not receive battery backup during a utility power failure.
•1
P E
For the first UPS system you wish to shut down, press the OFF
R
button A for 3 seconds (until you hear a beep), then release
the button. If the other UPS system can support the connected
equipment loads alone, the UPS system that was turned off will
shut down its inverter and its LCD screen will read “LOAD NOT
POWERED”. The other UPS system’s LCD screen will read
“ONLINE MODE”. If the total connected equipment load is too
large to be handled by a single UPS system, both UPS systems
will shut down their inverters and switch to bypass mode, and their 1 A
LCD screens will read “ON AUTO BYPASS”. Repeat step 1 for
the second UPS system you wish to shut down.
•2 Switch off the main input circuit breaker switch A of each UPS
system. A
23
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1 Basic Operation (continued)
5
•6 In this mode, only the output circuit breaker switch A and the
terminal block B contain hazardous voltage, allowing qualified
service personnel to perform maintenance or repair. Note:
B
Y
Qualified service personnel may prefer to de-energize the UPS
systems completely, depending on local codes and the nature of the A
maintenance or repair.
NA R
1.6.11 Switching from Manual Bypass to Normal Mode (Parallel UPS)
IM
•1 If the UPS systems have external battery cabinets connected, switchI 6
battery pack.
R L
off the external battery cabinet circuit breaker switch A of each
E
A
•2
P
Switch on the bypass input circuit breaker switch A and the output
circuit breaker switch B of each UPS system.
1
B A
•3 Confirm that both UPS systems are shut down, then switch off the Output Manual Bypass Main
manual bypass input circuit breaker switch A of each UPS system. 2 Bypass Input Input
24
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1 Basic Operation (continued)
SU80KX
SU80K SU60KX SU40KX
SU80KTV SU60K SU40K SU20KX PCB name P/N Description
TOP
V V V V NH-SYS-LCD 16-5505001323 Circuit for LCM, Circuit for LED and Function Key
V V V V NH-SYS-R 16-5505001327 Circuit for RS232, Output Dry Contact, Parallel Port,
Connector to connect with each Power Module, Circuit for
2 Slots
V V V V NH-SYS-X 16-5505001319 Circuit for REPO, Input Dry Contact and Circuit for sense
External Battery Cabinet Temperature
V V V V NH-SYS-M 16-5505001321 System MCU and Control Circuit
V
V
V
V
V
V
V
V
NH-SYS-P
NH-SYS-B
16-5505001325
16-5505001317
Y
Auxiliary Power for System, Detect Circuit for Voltage and
R
Current
A
EMI Filter for Battery Input
N
V V V V NH-SYS-LA 16-5505001322 Input EMI Filter for each Power Module
V
V
V
V
V
V
I
NH-SYS-LB
IM
NH-SYS-LC
NH-SYS-LD
16-5505001353
16-5505001354
16-5505001355
Input EMI Filter for each Power Module
Input EMI Filter for each Power Module
Input EMI Filter for each Power Module
R E L
V
V V NH-SYS-SA
NH-SYS-S
BOTTOM
16-5505001370
16-5505001326
Driver Circuit for Bypass SCR
Driver Circuit for Bypass SCR
P V
V (2pcs)
V (2pcs)
V
V
V
V (2pcs)
V (2pcs)
V
V
V V NH-SYS-FC
NH-SYS-F1(BYP)
NH-SYS-F1(MAIN)
NH-SYS-F2(MAIN)
NH-SYS-F2(BYP)
16-5505001349
16-5505001371
16-5505001371
16-5505001373
16-5505001374
Output EMI Filter
Input EMI Filter for Bypass
Input EMI Filter for Main
Input EMI Filter for Bypass
Input EMI Filter for Main
V V NH-SYS-F3 16-5505001372 Circuit for Surge suppress
V (2pcs) V (2pcs) NH-SYS-FA 16-5505001347 Input EMI Filter
V V V V NH-SYS-FB 16-5505001346 Circuit for Bypass Back-feed Detect
Table 1.7a
25
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1 Basic Operation (continued)
X LA and LB
FA (BYP)
FB M
P
A RY
I N B
E L IM
P R FA (MAIN)
SA
LCD
26
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1 Basic Operation (continued)
F1 (BYP)
F3 FB
A R
M
PY
I N
E L IM B
O/P CT S
PC
27
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1 Basic Operation (continued)
X LA, LB
FA (BYP) FA (MAIN) FB
A RY
I N
E L IM
P R O/P
Transfer
I/P
Transfer P LCD
B
SA
Bypas SCR FC
O/P CT
28
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1 Basic Operation (continued)
A RY
N
P
IM I
F1 (BYP) F3 FB
R E L
P I/P Tx
F1 (MAIN)
O/P Tx
F2 (MAIN)
F2 (BYP)
LCD B
Bypas SCR S
O/P CT FC
29
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1 Basic Operation (continued)
M
F1(BYP) F2 FB P
A RY
I N
E L IM
P R O/P Tx
I/P Tx
F1(MAIN) F2(BYP)
Bypass SCR
F2(MAIN)
S
LCD
O/P CT FC
30
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1 Basic Operation (continued)
Y
NH-PM-B Switching Devices of Inverter (Phase T) and Bus Capacitors
R
NH-PM-D Switching Devices of Inverter (Phase R and S) and Bus Capacitors
A
NH-PM-L LC Filter of Inverter, Current Sensor and Static Switch Circuit of Inverter
N
NH-PM-N Control Circuit for Inverter
I
NH-PM-DSP(INV) DSP Chip (Assemble on NH-PM-N Board)
IM
NH-PM-H1 External Connector of Power Module AC Input
NH-PM-H2 External Connector of Power Module Battery Input
L
NH-PM-H3 External Connector of Power Module AC Output
P R E N
H3
H2
H1
L
Fig 1.7.2a
A
M
Fig 1.7.2b
33
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1 Basic Operation (continued)
1.8.1 KX Models
Input: 3-phase 4-wire 230/380Vac
Output: 3-phase 4-wire 230/380Vac
The SU20KX (Figure 1.8.1a) has a model rating of 20kVA UPS and contains one power module and 40 internal batteries (which can be increased to
80, if necessary). (See Figure 1.8.1b for wiring.)
Q3
Manual Bypass
Circuit Breaker
Manual Input
Bypass Input
Q2
Bypass Input
Y
STS
Circuit Breaker
R
MAIN Main
INPUT Q1 20kVA/3U POWER MODULE Q4 LOAD
A
Main Input Output
Circuit Breaker
N
Circuit Breaker
I
EXTERNAL EMPTY
BATTERY
IM
12V, 9AH, 10PCS 12V, 9AH, 10PCS
Q5
L
12V, 9AH, 10PCS 12V, 9AH, 10PCS
E
EMPTY EMPTY
R
EMPTY EMPTY
P
(See Figure 1.8.1d for wiring.)
Q3
Manual Bypass
Circuit Breaker
Fig 1.8.1a SU20KX Block Diagram
The SU40KX (Figure 1.8.1c) has a model rating of 40kVA UPS and contains two power modules and 80 internal batteries.
Manual Input
Bypass Input
Q2
Bypass Input
STS
Circuit Breaker
MAIN Main
INPUT 20kVA/3U POWER MODULE Q4 LOAD
Q1
Main Input Output
Circuit Breaker Circuit Breaker
EXTERNAL 20kVA/3U POWER MODULE
BATTERY
34
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2 Theory of Operation (continued)
RM42 RM22
5VS RM43 AUXON AUX-ON
A RY
When AC auxiliary power circuit is activated and battery is present, AUXON (64) is high and DC auxiliary power circuit will be on.
I N
IM
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
L
DP11
RP20
E
+12VS
R
RP18
+12VB
QP8
P
ZDP5
RP19 AUX-FAIL
G1 DP12
RP23
+12VS
RP21 QP10
+12VP QP9 RP24
ZDP6
RP22
G1 G1
RM34
5VS RM35
AUX-FAIL AUXFAIL
CM23 (71)
G1
+12VP is from AC auxiliary power and +12VB is from DC auxiliary power. During AC mode, +12VP and +12VB should both be live. If one or
both of them fails, MCU can detect auxiliary power failure through AUXFAIL (71) (low active).
51
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2 Theory of Operation (continued)
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
CP25
RP119
RP120 CP26
OPCT_R- -12VS G1
RP121 RP122
11
CNP11
1 OPCT_R+ 2
(W18) 2 OPCT_R-
1
IoutR
3
RP125 RP124 CP89 UP19A
RP126
4
RP130 CP90
OPCT_R+ +12VS G1
G1
RP135
Y
CP91
OPCT_S- RP136
R
RP137 RP138
CNP12
A
1 OPCT_S+ 9
(W19) 2 OPCT_S- 8 IoutS
10
N
RP140 CP92 UP19C
I
RP141
RP142
RP146
OPCT_S+
IM
G1
L
RP147 CP93
OPCT_T-
E
RP148
RP150 RP151
CNP13
R
1 OPCT_T+ 13
(W20) 14
P
2 OPCT_T- 12 IoutT
G1
G1 G1 G1
52
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2 Theory of Operation (continued)
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
CP78 CP83
RP159 RP160
Y
1 BYP/R
2 RP177 RP178 RP179 9 UP18C RP180 RP181 RP182 9 UP20C
3 BYP/S BYP/S 8 IP/S 8
R
4 10 VbypS 10 VinS
5 BYP/T
6
A
7 BYP/N CP82 CP88
N
RP183 RP184
I
RP185 RP186 RP187 13 UP18D RP188 RP189 RP190 13 UP20D
BYP/T 14 IP/T 14
VbypT VinT
IM
12 12
L
Located at NH-SYS-M board (System MCU and Control Circuit)
P R E VbypR
5VS
DM1
RM27
5VS
RM23
RM30
QM1
BYPZO_R
(12)
VinR
5VS
DM2
RM28
5VS
RM24
RM31
QM2
INPZO_R
(14)
2
G1 G1
G1 G1 G1 G1
(a) MCU detects RMS value of bypass 3-phase voltage via Vbyp_R (89), Vbyp_S (91) and Vbyp_T (93).
(b) MCU detects RMS value of main input 3-phase voltage via Vin_R (92), Vin_S (94) and Vin_T (96).
(c) MCU detects the bypass frequency and zero crossing via BYPZO_R (12) at falling edge.
(d) MCU detects the main input frequency and zero crossing via INPZO_R (14) at falling edge.
53
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2 Theory of Operation (continued)
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
CP73
RP123
RP134
CNP9 OP/R
Y
1 CP72
2 G1
R
3 OP/S CP76
4
A
5 OP/T
6 RP139
N
7
I
OP/N RP143 RP144 RP145 9 UP17C
OP/S
8 VoutS
IM
10
L
CP77
P R E OP/T
12
UP17D
RP149
14
VoutT
G1 G1 G1
(a) MCU detects RMS value of 3-phase output voltage via Vout_R (95), Vout_S (97) and Vout_T (99).
54
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2 Theory of Operation (continued)
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
CP57
RP90
-12VS CP79
G1
4
RP94 RP95 RP96 2 UP10A
1
RP99 RP100 RP101 Vbatt+
BAT+ 3
Y
CP58
R
8
RP102 CP80
+12VS
I
G1
NA CP59
G1
IM
RP106
L
RP108 RP109 RP110 6 UP10B
BAT-
7
E
RP114 RP115 RP116 Vbatt-
5
P R
Located at NH-SYS-M board (System MCU and Control Circuit)
RP118
G1
CP60
5VS 5VS
Vbatt-
2
Vbatt+
RM49 RM62
DM10 DM15
3 3
Vbatt_+ Vbatt_-
(98) (100)
RM55 CM28 RM70 CM32
1
G1 G1
(a) MCU detects battery voltage via Vbatt_+ (98) and Vbatt_- (100).
55
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2 Theory of Operation (continued)
RFB1 BKFD_R
CTFB1
QFB1
R RFB2
CTFB2
S RFB3 BKFD_S
QFB2
RFB4
CFA18 SCCT_S+
Y
CNFB13 DFB2
CFB19 RFB8
R
1 BKFD_R
2 BKFD_S
3 BKFD_T
A
4
N
CTFB3
I
RFB5
T BKFD_T
QFB3
RFB6
IM
CFA12 SCCT_T+
DFB3
L
CFB20 RFB9
N
R E
Located at NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
P +12VS
RP34 RP33
-12VS
CP63
G1
SCRST_R
11
2 UP18A DP13
1 RP35
QP13
BKFD_R 3
4
RP88 RP87
CP84 G1
-12VS
G1 SCRST_S
11
2 UP20A DP15
BKFD_S RP89
1 QP15
3
4
CP68 RP92
RP93
CP67 +12VS
RP98 CP85 G1
+12VS
RP103 CP74 G1
RP104 -12VS
G1 SCRST_T
11
2 UP17A DP46
BKFD_T RP105
1 QP17
3
4
CP71 RP111
RP112
CP70 +12VS
RP117 CP75 G1
G1
G1 G1 G1
(a) During backup mode, bypass 3 SCRs should be off and zero current should be running through CTFB1, CTFB2 and CTFB3. If current is
running through CTFB1, CTFB2 or CTFB3, then STShort_R (5), STShort_S (129) or STShort_T (128) will be low. The UPS will turn off its
inverter to prevent back-feed voltage.
56
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2 Theory of Operation (continued)
Y
7
RSA8 G RSA13 4
QSA5 3 DSA6
RSA18 3
S 9
R
2 K1
CSA6
1 G1
RSA9 CSA13
DSA4
A
4 10
2803402000
G1
N
G1
CSA3
I
+12VS
TSA3
G1
+12VS DSA8
2 6 RSA19
IM
CSA9 CNSA3
RSA5
QSA3 CSA14 6 G2
D
5 K2
7
RSA10 G RSA14 4
QSA6 3 DSA9
L
RSA20 3
S 9
2 K1
CSA8 1 G1
RSA11
E
CSA15
DSA7
4 10
R
2803402000
G1
G1
P
Located at NH-SYS-M board (System MCU and Control Circuit)
(1)
BYPSTS 5VS
RM75
TOBYP-J
DM27
DM28 DM29
CM92
#TOBYP_O
(70) CENTRAL_OK DM21 DM22 RM141 G1
DM19
QM4 RM83 G1
RM82
+12VS
G1
RM94 RM95
5VS
RM93 BYPASS Static Transfer Switch Control CKT.
CM50 RM91 RM92 8 5
BYPSTS1
DM25
UM6C 10 UM6B 4 RM97
G1 BYPSTS2 9 6 QM7
UM9 CM54
8
4 3
R Q RM101 RM98 DM30 QM8 RM100
RM96 G1 5VS
VCC
2 7 QM6
TRIG DIS CM122
5VS
5VS G1 DM26 G1
5 6
RM99 12 DM31 FAN_ON
RM2
14 + -
CVolt THR
UM6D
GND1
1 11
UM6A 3 13
RM90
CM52 CM53 RM102 TOBYP-J
2
DM39 CM51
RM103
G1 G1 G1
G1
Located at NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module, Circuit for 2 Slots)
RR1 RR2 QR1
5VS VS TOBYP
CR8
CR4
G1 5VS UR3
1 4
14
ZR1
#TOBYP_O 1 2 2 3
UR4A RR6
CR7
7
G1 G4
RR8 DR16 RR9 RR10
5VS +12VSF
UR6
#TOBYP_I 4 1
CR10 CR9
3 2
G1
57
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2 Theory of Operation (continued)
(a) The bypass SCR driver signal “BYPSTS1” is controlled by MCU or “TOBYP_J” according to the signal “CENTRAL_OK.”
(b) “CENTRAL_OK” is the output of MCU watchdog. If MCU is operating normally, “CENTRAL_OK” will be high and the bypass SCR driver
signal will be controlled by “BYPSTS” (1) (high active). If MCU is not operating normally, “CENTRAL_OK” will be low and the bypass SCR
driver signal will be controlled by “TOBYP_J” (high active).
(c) UM9 is a 45 kHz self-oscillator that can provide pulse signal for driver bypass SCR.
(d) The “TOBYP_J” signal is limited by “#TOBYP_I.”
Y
5VS
CM36
5VS
LEDM1
LED(GRN)
NA R
I
G1
RM71
8
IM RM72
RM1
4 R Q 3 CENTRAL_OK
(70)
VCC
L
CM39 2
TRIG DIS
7
SYS_RDY
E
(4) QM3 5 6
CVolt THR
RM81
R
GND1
UM3
P
CM45 TLC555C
1 RM86 CM46
2 G1
DM24
RM89 RM88
CNM2 5VS
2.5X2P QM5
G1
(a) SYS_RDY (4) will send out a pulse to reset CM46. CM46 will then be recharged by 5V through RM88. “CENTRAL_OK” will maintain a high
level. If SYS_RDY (4) does not send out a pulse during a specific period (for example, during an MCU crash), then “CENTRAL_OK” will be
low.
(b) Test JUMP (CNM2): If CNM2 is shorted, then “CENTRAL_OK” will be low. If CNM2 is opened, “CENTRAL_OK” will stay high during
normal operation.
58
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2 Theory of Operation (continued)
Y
G1 RM121
U-LcdCS
(49) LcdCS
R
UM5
RM126 KEY_ESC 8 9 CM80
ESC KEY_ESC G1 GND COM ZDM2
(8)
A
U-LED0 7 10
CM85 (73) 7B 7C LED0
RM127 (74)
U-LED1 6 6B 6C 11 LED1
U-LED2 5 12
N
(75) U-LED3 4 5B 5C 13 LED2 G1
(76) 4B 4C LED3 RM132
I
U-LED4 3 14 U-LcdWR
G1 (77) U-LED5 2 3B 3C 15 LED4 (63) LcdWR
(78) CENTRAL_OK 1 2B 2C 16 LED5
RM133 KEY_DOWN (70) 1B 1C BYP_OK CM90 ZDM3
IM
DOWN KEY_DOWN
(9)
CM91 RM135 RM134
+12VS BKLIT G1
L
HSM1
U-LcmBL RM137 RM138
G1 (62) 1
E
RM140 KEY_OFF RM139 QM9 HS
OFF KEY_OFF
R
(22) UM10
CM96 RM143 +12VS VLED
RM158
P
1 3
G1 G1 Vin +5V
RM144
G1
5VS CM121
GND
CM118 CM119
RM147 KEY_UP RM148 EPO CM120
2
UP KEY_UP NO+
(10) (85)
CM103 RM149 CM104
G1
G1
G1
RM152 KEY_ENT
ENT KEY_ENT
+12VS G1
RM154(7) CM113
CM110
4
2
1 1 CONTRAST
(2) U-LcmCA RM155 3
G1
CM112 UM7A
LM324AD
11
G1 G1
(a) MCU detects the status of EPO button (on LCD display panel) via “EPO” (85) (low active). When the EPO button is activated, UPS will shut
down the output and turn off the inverter. When the EPO button is released, UPS will stay in bypass mode.
(b) MCU can control the LCD backlight via “U-lcmBL” (62).
(c) MCU can adjust the contrast of LCD by PWM control via “U-lcmCA” (2).
59
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2 Theory of Operation (continued)
9
UM8A
FAN-C 1 16 FAN-SPEED-C (18) RM6 FANLOCK_C
(17) 10K
CM136
104
8
G1 CM124
RM161 5VS G1 RM162 G1
5VS +12VS
14
1 UM8E
(143) FAN_A UM12A 3 4 13 5 12
+ -
FAN_SPEED_A
FAN_ON
2 4081 UM8D
FANLOCK_A (19)
ULN2003A ULN2003A
7
RM163 RM164
5VS DM32 G1 5VS
DM34 DM33
Y
(48) FANLOCK_B FAN_LOCK_B
RM166
R
5VS FAN_LOCK_A
RM168 RM167
+12VS
5
A
UM12B 4 8 UM8G
6 4081 UM12C 10 6 11 7 10
FAN_ON FAN_SPEED_B
4081
N
9
G1 UM8F ULN2003A
CM127 ULN2003A
Located on NH-SYS-P board (Auxiliary Power for System, Detect Circuit for Voltage and Current)
IM
+12VS
I DP5 CNP16
L
1
E
CP96 RP194 2
3
P R FAN_SPEED_C
G1
D
S
QP14
DP6
FANLOCK_C
TO FAN
FAN_LOCK_A FAN_LOCK_B
G1 D G1 D
QSA9 QSA8
G G
FAN_SPEED_A S FAN_SPEED_B S
G1 G1
(a) Fan C is located at the rear panel of the power module’s input EMI filter. Fan A and Fan B are both located at the heat-sink for bypass SCR.
(b) MCU controls fan C via FAN-C (17).
(c) MCU detects a fan C failure via (18).
(d) When in bypass mode, FAN_A (143) will be high to control fan A; fan B will be off. If fan A experiences a failure, fan B will turn on.
(e) MCU detects a fan A failure via FANLOCK_A (19).
(f) MCU detects a fan B failure via FANLOCK_B (48).
60
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2 Theory of Operation (continued)
RM76 RM77
RM79
5VS
2
+12VS
DM23
4
UM7B
6
7 RM84 3
5 2 HS_TEMP
STS_TH- (105)
CM48
RM87
11
CM49
Y
G1
1
R
G1 G1
I CNSA6
NA
E L IM 1
2
CON2(2.54)
5VREF
STS_TH-
R
(a) Temperature sensor (NTC) is screwed onto the heat-sink of bypass SCR and connected to CNSA6 on the NH-SYS-S or SA board.
P
(b) MCU detects the temperature via HS_TEMP (105).
8
7
UR15 RR31
2 6
#TX_232 +12VSF
QR4 3 5
-12VSF
D 5
RR33 RR118 9
4
G
G4 4
S 8
RR37 CR27 RR38 3
G1 5VS +12VSF 232_TX
7
G1 2
7
8
G
S RR47
G4
TX_232 RM107
(23) #TX_232
CM58
RX_232 RM111 G1
(24) #RX_232
CM62
(a) System MCU TX_232 (23) transmits data via RS232 port. G1
(b) System MCU RX_232 (24) receives data via RS232 port.
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2 Theory of Operation (continued)
RR26 CR21
5VS +12VSF G4
232_RX
8
7
UR15 RR31
2 6
#TX_232 +12VSF
QR4 3 5
-12VSF
D 5
RR33 4 RR118 9
G
G4 4
S 8
RR37 CR27 RR38 3
G1 5VS +12VSF 232_TX
7
G1 2
7
8
1
RR43 UR20 232_RX
5VS 6 2 232_TX 6
1
5 3 RR44
D CNR6
#RX_232
Y
G1 QR5
RS232 Port
4
R
S RR47
G4
I
Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module,
Circuit for 2 Slots)
NA
IM
RR51 CR36
5VS +12VSF G4
L
SLOT1_RX
1
8
7
UR25 RR55
2 6
E
#TX_Slot1 +12VSF
QR6 3 5
-12VSF
R
D
RR58 RR121
4
P RR65
S
RR66
To Slot 1
CR42
G1 5VS +12VSF
CNR2 +12VSF
G1 CR3
7
8
RR67 UR29 G4 1 2
6 2
5VS SLOT1_TX SLOT1_TX 3 4 SLOT1_RX
5 6 CR5
5 3 RR69 7 8
D
#RX_Slot1 G1 QR8 9 10
4
G G4
S RR73
G4
RR76 CR52
5VS +12VSF G4
SLOT2_RX
To Slot 2
1
8
7
UR34 RR77
#TX_Slot2 2 6 +12VSF CNR7 +12VSF
CR11
G4 1 2
QR9 3 5
D -12VSF SLOT2_TX 3 4 SLOT2_RX
RR123 5 6 CR13
RR80
4
G 7 8
S 9 10
RR84 CR59 RR85 G4
G1 5VS +12VSF
G1
7
8
RR87 UR38
5VS 6 2 SLOT2_TX
5 3 RR93
D
#RX_Slot2 G1 QR10
4
G
S RR95
G4
G1 G1
(a) System MCU communicates with Slot 1 via TX_Slot1 (117) and RX_Slot1 (118).
(b) System MCU communicates with Slot2 via TX_Slot2 (122) and RX_Slot2 (121).
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2 Theory of Operation (continued)
1
RLR1 DR1
UR13F
11 6
OP_DRYA DRYA
2
CR24
COMM_B +12VS
1
RLR2 DR3
G1 UR13E
12 5
OP_DRYB DRYB
2
CR28
COMM_C +12VS
Y
3
1
RLR3 DR4
M4 G1 UR13D
R
CNR8 13 4
OP_DRYC DRYC
2
A
1 OP_DRYA CR33
2 COMM_A COMM_D +12VS
3 OP_DRYB
3
N
1
RLR4 DR6
4 COMM_B
G1 UR13C
I
5 OP_DRYC
6 COMM_C
14 3
7 OP_DRYD OP_DRYD DRYD
2
IM
8 COMM_D
CR40
9 OP_DRYE COMM_E +12VS
10 COMM_E
3
1
11 OP_DRYF RLR5 DR8
G1 UR13B
L
12 COMM_F
15 2
E
OP_DRYE DRYE
4
2 CR44
R
G1
COMM_F +12VS +12VS
P
3
RLR6 DR10 G1
9
CR87 UR13A
16 1
OP_DRYF DRYF
4
8 CR49
G1 G1
Located on NH-SYS-M board (System MCU and Control Circuit)
DRY_F RM104
(84) DRYF
200 CM55
103
DRY_E RM108 G1
(83) DRYE
200 CM59
103
DRY_D RM112 G1
(68) DRYD
200 CM63
103
DRY_C RM117 G1
(67) DRYC
200 CM68
103
DRY_B RM122 G1
(66) DRYB
200 CM81
103
DRY_A RM128 G1
(65) DRYA
200 CM86
103
G1
(a) System MCU sends out dry contact signal to the relays via DRY_A (65), DRY_B (66), DRY_C (67), DRY_D (68), DRY_E (83) and DRY_F
(84).
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2 Theory of Operation (continued)
Y
3 +12VSF G1
4 IP_DRYB RX44 RX42
5VS
R
4
UX13 1 RX45
DRY2 IP_DRYB
A
CX22 3 2
N
G4
G1
(86)
IM
R_EPO
I RM118
#R_EPO
L
CM69
P R E (79)
(80)
DRY_1
DRY_2
RM123 G1
RM129 G1
DRY1
CM82
DRY2
CM87
G1
(a) System MCU will detect input dry contact via DRY_1 (79) and DRY_2 (80)
(b) REPO (Remote Emergency Power Off) can be detected via R_EPO (86) by system MCU (high active).
(c) When REPO has activated, System MCU will shut down the output. After the REPO release, the unit will stay in bypass mode.
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2 Theory of Operation (continued)
RX1 CX1
10VSF_REF +12VSF G4 UX1
CX2
1 8 10VS_REF
UX5A G4 N/C RX4
4
CNX6
3
1 RX5
2 1 2 N/C 7 G1 RX6
CX4 2
RX9 +12VS RX8 UX6B
11
+12VSF 3 6 UX6A 6
2 7
11
RX11 #EXTB_TEMP1
G4 1 5
EXTB_TEMP1 G4 4 5 3
CX5 CX6
RX14
CX8
4
RX16
RX13 +12VS RX17 CX9
G1 G1
G1
RX18 UX2 G1
10VSF_REF CX10
G4
Y
1 8 10VS_REF
CNX7 G4 N/C RX20
5
R
1 7 RX21 2 7 RX22
2 N/C
CX11 6 UX5B UX6C
RX24 +12VS RX23
A
3 6 UX6D 9
+12VSF 13 8
RX27 #EXTB_TEMP2
N
14 10
EXTB_TEMP2 G4 4 5 12
I
CX12 CX13
RX30
RX31
RX29 RX32 CX15
IM
G1
G1
RX33 UX3 G1
L
10VSF_REF G4 CX16
G4 1 N/C 8 10VS_REF
RX36
E
CNX8 UX5C
1 10
8 RX38 2 7 G1 RX39
2 N/C
R
CX18 9
RX41 +12VS 11 RX40 UX7B
3 6 UX7A 6
P
+12VSF
2 7 #EXTB_TEMP3
1 RX43 5
EXTB_TEMP3 G4 4 5 3
CX19 CX20
RX47
CX21
4
RX48 RX49
RX46 +12VS CX23
G1 G1
G1
RX50 UX4 G1
10VSF_REF CX24
G4
1 8 10VS_REF
UX5D G4 N/C RX51
CNX11
12
1 RX52
2 14 2 N/C 7 RX53
CX27 13 UX7C
RX55 +12VS RX54
3 6 UX7D 9
+12VSF 13 8
RX58 #EXTB_TEMP4
CX28 14 10
EXTB_TEMP4 G4 4 5 12
CX32
RX60
RX62
RX59 RX63 CX34
G1
G1
G1
G4
G1 G1 G1 G1
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2 Theory of Operation (continued)
DR15
RR102 RR103
+12VSF 5VS
UR43
1 4 #TOMBYP_I
RR107 2 3 CR65
CR66
TOMBYP G1
CNR13 CR73
1
TO Manual Bypass Breaker 2
A RY
(6)
TOMBYP_I
I
RM146
#TOMBYP_I
N
IM
CM102
R E L
(a) CNR13 connects to the auxiliary contact of the manual bypass switch.
G1
P
(b) System MCU detects the status of the manual bypass switch via TOMBYP_I (6). Manual bypass switch will stay in the OFF position and
TOMBYO_I (6) will be high.
+12VSF
RR75 RR74
5VS
UR33
1 4 #OPCBAUX_I
CR54 RR79 2 3 CR53
G1
CNR10
CR58
1
2
G4
Located on NH-SYS-M board (System MCU and Control Circuit)
OPCBAUX_I RM151
(72) #OPCBAUX_I
CM108
G1
(a) CNR10 connects to the auxiliary contact of the output breaker.
(b) System MCU detects the status of the output breaker via OPCBAUX_I (72). Output breaker stays in the OFF position and OPCBAUX_I (72)
will be high.
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2 Theory of Operation (continued)
5VS UR42
RR105 1 4 RR106
2 3
QR11
CENTRAL_OK G4
VS
QR12
RR108
RR111
Y
G1
+12VSF
NA R
BYPOK
DR13
IM I +12VSF
4
UR35
1
RR78
+12VS
L
RR138
3 2 CR56 RR81
E
QR14
RR137
P R G4
UM5
G1 8 GND COM 9
U-LED0 7 10
(73) U-LED1 6 7B 7C 11 LED0
(74) U-LED2 5 6B 6C 12 LED1
(75) U-LED3 4 5B 5C 13 LED2
(76) U-LED4 3 4B 4C 14 LED3
(77) 3B 3C LED4
U-LED5 2 2B 2C 15 LED5
(78) CENTRAL_OK 1 16
(70) 1B 1C BYP_OK
ULN2003A
(a) VS is the voltage source for the parallel signal bus. CENTRAL_OK signal is controlled by the system MCU’s watchdog circuit.
(b) The BYPOK signal indicates that the system MCU is functioning properly.
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2 Theory of Operation (continued)
RR126
365
RR132
365
RR127
681
RR133
681
RR128
1K1
RR134
1K21
RR129
1K65
RR135
1K82
RR130
2K61
RR136
2K61
G4 G4 G4 G4 G4 G4
RR25
10K RR52
RR29 5VS RR53 5VS
2K 1 UR14 4 2K 1 UR26 4 10K
+12VSF #ID1_OK +12VSF #ID4_OK
2 3 CR23 2 3 CR41
104 104
TLP421(GRL) TLP421(GRL)
Y
DR2 ID1OK DR9 ID4OK
1N4148 G1 RR34 1N4148 G1 RR59
R
RR36 5VS RR64 5VS
2K 1 UR18 4 10K 2K 1 UR28 4 10K
A
+12VSF #ID2_OK +12VSF #ID5_OK
2 3 CR29 2 3 CR48
N
TLP421(GRL) 104 TLP421(GRL) 104
DR5 ID2OK DR11 ID5OK
I
1N4148 G1 RR45 1N4148 G1 RR71
RR46 5VS RR72 5VS
IM
2K 1 UR22 4 10K 2K 1 UR32 4 10K
+12VSF #ID3_OK +12VSF #ID6_OK
2 3 CR34 2 3 CR51
104 104
L
TLP421(GRL) TLP421(GRL)
DR7 ID3OK DR12 ID6OK
1N4148 G1 1N4148 G1
P R E
Located on NH-SYS-M board (System MCU and Control Circuit)
+12VSF
RR96
ON
4
3
UR41
1
2
RR97
ON1
+12VS
(c) System MCU can detect the status of the power module DSP chip via ID1_OK (28), ID2_OK (29), ID3_OK (30), ID4_OK (31), ID5_OK
(40) and ID6_OK (41). “Logic Low” means that the power module DSP chip is functioning properly. (ID5_OK and ID6_OK are not used for
reserve.)
(d) ON is connected to the relay driver of the auxiliary power supply inside the power module. If POWER_ON (42) is “Logic H,” then the auxiliary
power supply inside the power module is on.
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2 Theory of Operation (continued)
8
7
2 6
5VS
UR4D 3 5 ZR4
#DATA_TX 9 8 QR7
RR56
4
5VS G4
RR61 G1 RR62 RR63
5VS CR43 +12VSF
7
8
1
#DATA_RX 6 2
CR46
CR47 5 3
UR30
4
Y
G1
G1
5VS
CR8
RR1
5VS UR3
VS
RR2
CR4
NA R QR1
TOBYP
I
1 4
14
ZR1
1 2 2 3
#TOBYP_O
IM
UR4A RR6
CR7
7
G1 G4
L
RR8 DR16 RR9 RR10
5VS +12VSF
UR6
E
4 1
#TOBYP_I
CR9
CR10
R
3 2
P
RR12 G1 RR13 QR2
5VS VS TOINV
UR7 CR15
1 4
UR4B
ZR2
3 4 2 3
#TOINV_O
RR16 CR16
G4
RR18 DR17 RR19 RR20
5VS +12VSF
UR10
#TOINV_I 4 1
CR18
CR19 3 2
G1
DATA_RX RM142 G1 G1 G1
(119) #DATA_RX TOINV_O RM145
#TOBYP_O (46) #TOINV_O
CM98
CM92 CM101
G1
G1 G1
(e) DATA_BUS is the communication bus between the system and its power modules. This signal also connects to the external parallel port.
(f) TOBYP and TOINV are used to control the bypass or inverter transfer. The system frame and power module determine these signals together.
These signals also connect to the external parallel port.
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2 Theory of Operation (continued)
2
G4 RR14
RR15 UR9
8 1
7 2
VCC
GND
CANH-M 7 1 6 3
CANH TXD CANM_TX
5 4
RR17 4 5VSF SHIELD
RXD CR17
G4
6 5
CANL-M CANL Rs Vref 5VS
RR21
UR11 RR22 G1
UR8
8
1 8
2 7
3 6
G4 4 5 CANM_RX
Y
SHIELD
G1
(134)
CANM_TX
(135)
CANM_RX
NA R
I
CM106 CM109
IM
G1 G1
L
(g) CAN bus is the communication bus for load sharing, as well as the synchronization of signals between the system and its power modules.
P R E
Control Circuit for External Parallel
Located on NH-SYS-R board (Circuit for RS232, Output Dry Contact, Parallel Port, Connector to connect with each Power Module,
Circuit for 2 Slots)
Parallel Port
5VSF
CR1
G4 CR2
5VSF 5VS
3
G4 RR3
RR4 UR2
1 TOMBYP 8 1
6 7 2
VCC
GND
SYNC_BUS CANH-S
2 7 1 6 3
CNR14 7 TOINV CANH TXD 5 4 CANS_TX
3 RR5 4 5VSF SHIELD
TOBYP RXD CR6
8 G4
4 6 5
CANH-S CANL-S CANL Vref 5VS
Rs
9 RR7
5 CANL-S UR1 UR5 RR11 G1
8
1 8
2 7
G4 3 6
CANS_RX
G4 4 5
SHIELD
G1
DR15
RR102 RR103
+12VSF 5VS
UR43
1 4 #TOMBYP_I
RR107 2 3 CR65
CR66
TOMBYP G1
CNR13 CR73
1
2
G4
Located on NH-SYS-M board (System MCU and Control Circuit)
G1 G1
CANS_RX
(137)
CM100
G1
(h) CAN bus is the communication bus for load sharing, and also synchronizes signals between the two systems.
(i) TOMBYP is the status of the manual bypass switch on the system frame. When the manual bypass switch turns on, MCU can detect its status
via TOMBYP_I(6) and auto-transfer to bypass the mode and its alarm.
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2 Theory of Operation (continued)
RM4
1K
CNM10 OPRT Temp (61)
RM175
TO OUTPUT XFMR 2
1 392 CM137 ZD4
CON2 104 5V1
G1
5VS
TO INPUT XFMR
CNM11
2
1
RM8
1K
RM176
392
N
CM138 ZD5
5V1
I
CON2 104
IM
G1
L
(a) CNM10 connects to the output transformer, CNM11 connects to the input transformer.
E
(b) Thermal switch sensors are mounted on the coils of the transformer.
R
(c) The thermal switch sensor will be open when the transformer coil’s temperature exceeds 150. MCU can detect the temperature status through
IPRT_Temp (51) and OTRT_Temp (61).
P
Note: For international models (SU20KX, SU40KX, SU60KX and SU80KX), short-pins must be inserted into CNM10 and CNM11.
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3 Communication
Warning: Do not use the paralleling cable that came with the UPS system for these procedures.
Use a RS232 cable.
A RY
I N
E L IM
Figure 3.01a RS232 Pin Assignment
R
Pin 2: PC receives line RS-232 data from UPS.
P
Pin 3: PC transmits line RS-232 data to UPS.
Pin 5: Signal ground.
The EPO button on the front control panel (Figure 3.02a) turns the UPS system’s output OFF and also disables its bypass output.
If the UPS system is in battery backup mode when the EPO button is activated:
• Main output and bypass output are turned off, the alarm sounds, fans shut down after approximately one minute, and control circuitry remains
active.
• Pressing the EPO button again turns off the UPS system completely, including the alarm and control circuit. Press the ON button for three sec-
onds to restart the UPS system.
If the UPS system is in online (normal) mode when the EPO button is activated:
• Main output and bypass output are turned off, the alarm sounds, fans and control circuitry remain active.
• Pressing the EPO button again turns off the alarm and places the UPS system in auto bypass mode. Press the ON button for three seconds to
return the UPS system to online (normal) mode.
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3 Communication (continued)
A RY
I N
E L IM Fig 3.02b
P R 4 1
UPS
12Vdc
2
1
Note: This contact is normally open.
3 2
G4
Fig 3.02c
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3 Communication (continued)
WARNING: This procedure must be performed in bypass mode (see section 1.6).
Instructions for polling and updating the EEPROM are as follows (Figure 3.1.1a):
a) Link the UPS with a PC via the RS232 port
b) Run the program “NH_SYS_V1_3B1030.exe”
c) Click the “EEPROM” icon
d) Select the PC COM Port and click “Open COM Port”
Y
e) Click “Polling” to download the EEPROM data from the UPS.
R
f) Save the file to ensure that you have the values in case they are needed later
A
g) After setting the data, click “Update All” and wait for the procedure to complete itself
EEPROM
I N
E L IM
P R
Fig 3.1.1a
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3 Communication (continued)
WARNING: This procedure must be performed in bypass mode (see section 1.6).
Instructions for calibrating the EEPROM gain of the UPS parameters are as follows:
(For polling procedure, please refer to section 3.1.1)
a) Click the “Gain” tab (Figure 3.1.2a)
A RY
I N
E L IM
P R
Fig 3.1.2a
b) Select the parameter you want to calibrate and click its gain icon
c) Key in the actual value to the “Actual Measured:” column of the dialogue box
d) Key in the LCD value to the “UPS Detected:” column of the dialogue box
e) Click the “Calculate” icon (the New Gain Value will auto-calculate)
f) Click the “OK” icon (the dialogue box will close)
g) After calibrating the gain, click “Update All” and wait for the procedure to complete itself
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3 Communication (continued)
A RY
14. Battery cabinet over temperature warning/shutdown
15. Output voltage abnormal
I N
IM
16. Battery need replace
L
17. Bypass over temperature warning/shutdown
E
18. Battery ground fault
R
19. Bypass static switch fault
Fig 3.2a
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3 Communication (continued)
WARNING: Make sure that the UPS is in bypass mode and that all power modules have been completely
de-energized.
WARNING: When the system is in manual bypass mode, bypass power is still present in the output
terminal block.
Before upgrading your firmware, please verify the firmware version using the control panel (Figure 3.3a).
(Maintenance Others SN & FW Version)
M E A S U R E
U P S S E T U P
M A I N T E N A N C E
A RY
I N
IM
M A I N T E N A N C E
L
S T A T I S T I C
E
E V E N T L O G
M A N U A L S E T U P & T E S T
P R F I R M W A R E
O T H E R S
U P G R A D E
O T H E R S
S N & F W V E R S I O N
S Y S T E M T I M E
M O D U L E D C B U S V O L T
Fig 3.3a
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3 Communication (continued)
Q4 Q3 Q2 Q1
Y
Output Manual Bypass Main
Bypass Input Input
NA R
IM I Q1: Input Circuit Breaker
Q2: Bypass Input Circuit Breaker
P Fig 3.3b
78
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3 Communication (continued)
M E A S U R E
U P S S E T U P
M A I N T E N A N C E
M A I N T E N A N C E
S T A T I S T I C
A RY
N
E V E N T L O G
I
M A N U A L S E T U P & T E S T
F I R M W A R E U P G R A D E
IM
O T H E R S
R E L
P L O G I N
A D M I N I S T R A T O R
U S E R
F I R M W A R E U P G R A D E
S Y S T E M
P O W E R M O D U L E
Fig 3.3c
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3 Communication (continued)
S Y S T E M F W U P G R A D E
N O T E : S E T T I N G A L L O W E D
O N L Y W H E N A T M A N U A L
B Y P A S S M O D E
A R E Y O U S U R E ?
Y E S
S Y S T E M
W A I T I N G …
F W U P G R A D E
A RY
I N
E L IM
P R S Y S T E M
R E A D Y T O
F I R M W A R E !
F W U P G R A D E
D O W N L O A D
Fig 3.3d
Note 1: Once you confirm the command, the system will go into “system firmware upgrade” mode. If you want to cancel the upgrade command
before programming, the BYPASS input breaker (Q2) must be turned off.
Note 2: The Firmware Upgrade setting is only allowed in manual bypass mode.
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3 Communication (continued)
A RY
I N
E L IM
P R
g) Disable “Reading Comparison” (Figure 3.3f).
Fig 3.3e
Fig 3.3f
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3 Communication (continued)
A RY
I N
E L IM
P R Fig 3.3g
i) Once the system finished upgrading its firmware, it will auto-reset into manual bypass mode (Figure 3.4h).
LOAD UNPROTECTED
ON MANUAL BYPASS
BYPA.
MAINS
!
Fig 3.3h
WARNING: Make sure that the UPS is in bypass mode and that all power modules have been completely
de-energized.
WARNING: When the system is in manual bypass mode, bypass power is still present in the output
terminal block.
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3 Communication (continued)
M A I N T E N A N C E
S T A T I S T I C
E V E N T L O G
A RY
M A N U A L
I
F I R M W A R E
S E T U P
N
U P G R A D E
& T E S T
IM
O T H E R S
R E L
P
O T H E R S
S N & F W V E R S I O N
S Y S T E M T I M E
M O D U L E D C B U S V O L T
Fig 3.4a
To upgrade the power module’s firmware:
a) Confirm that the Main Input Breaker (Q1) and Output Breaker (Q4) are both OFF, and that the Bypass Input Breaker (Q2) and Manual Bypass
Breaker (Q3) are both ON. (Figure 3.4b)
PM1 Q4 Q3 Q2 Q1
PM3
PM4
Fig 3.4b
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3 Communication (continued)
M A I N T E N A N C E
S T A T I S T I C
A RY
E V E N T
M A N U A L
I
L O G
S E T U P &
N
T E S T
IM
F I R M W A R E U P G R A D E
O T H E R S
R E L
P L O G I N
A D M I N I S T R A T O R
U S E R
F I R M W A R E U P G R A D E
S Y S T E M
P O W E R M O D U L E
Fig 3.4c
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3 Communication (continued)
P W R M O D F W U P G R A D E
O N
O F F
N O T E : S E T T I N G A L L O W E D
O N L Y W H E N A T M A N U A L
B Y P A S S M O D E
A R E Y O U S U R E ?
Y E S
P W R
O N
O F F
M O D F W
RY
U P G R A D E
A
I
W A I T I N G …
N
E L IM
P R P W R
O N
O F F
R E A D Y
M O D
T O
F I R M W A R E !
F W U P G R A D E
D O W N L O A D
Fig 3.4d
Note 1: Once you confirm the command, the system will go into “system firmware upgrade” mode. If you want to cancel the upgrade command
before programming, the BYPASS input breaker (Q2) must be turned off.
Note 2: The Firmware Upgrade setting is only allowed in manual bypass mode.
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3 Communication (continued)
A RY
I N
E L IM
P R Fig 3.4e
g) Select the PFC DSP chip or INV DSP chip, along with power modules 1-4 (Figure 3.4f).
Fig 3.4f
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3 Communication (continued)
A RY
I N
E L IM
P R Fig 3.4g
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3 Communication (continued)
A RY
I N
E L IM
P R Fig 3.4h
Note 1: During programming, the status indicator is red. When upgrade is complete, the status indicator will turn green (Figure 3.4h).
Fig 3.4i
Note 2: When one power module upgrade is complete, the system will automatically begin upgrading the next power module (Figure 3.4i).
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3 Communication (continued)
A RY
I N
E L IM
P R Fig 3.4j
Note 3: Once all power modules are complete, the status indicators will all turn green (Figure 3.4j).
i) Once all firmware upgrades are complete, select “OFF” to disable the power module firmware upgrade. (Figure 3.4k)
P W R M O D F W U P G R A D E
O N
O F F
N O T E : S E T T I N G A L L O W E D
O N L Y W H E N A T M A N U A L
B Y P A S S M O D E
A R E Y O U S U R E ?
Y E S
Fig 3.4k
Note: When you disable the power module’s firmware upgrade, the power module will reset and shut down.
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3 Communication (continued)
A RY
N
Fig 3.5a
IM I
R E L
P
Fig 3.5b
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4 Internal Battery
The SU20KX, SU40KX and SU40K models all use a +/-240Vdc (480V) DC internal battery system. An internal battery pack (number of packs
vary by model) supplies the UPS system with battery backup power. Each internal battery pack consists of 40 12Vdc VRLA batteries arranged in
two strings: one string of 20 positive batteries (black cable) and one string of 20 negative batteries (red cable). The two strings are connected by a
neutral (N) point (See Figure 4a).
B+ N B-
All other KX, K and KTV models are designed with an external battery cabinet.
Y
Both the SU20KX and SU40KX model’s internal battery space (Figure 4b) can hold eight battery packs. Each battery pack contains 10 batteries
(9AH, 12Vdc, VRLA), giving them a maximum capacity of 80 batteries.
NA R
IM I
R E L
P
Fig 4b Front View of SU20KX and SU40KX Fig 4c Front View of SU40K
The SU20KX model’s standard battery quantity is 40, with a discharge time of about 5.5 minutes on full load. Upgrading to 80 batteries results in a
discharge time of about 13 minutes on full load.
The SU40KX and SU40K (Figure 4c) model’s standard battery quantity is 80, with a discharge time of about 5.5 minutes on full load.
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4 Internal Battery (continued)
1
•2 Remove the battery access bezels, located on the front of the UPS
system.
A RY
I N
•3
E L
Remove the battery cartridge fuses from each fuse block.
IM 2
P R
3
•4 Disconnect the blue and white jumper cables attached to each fuse
block. Warning: When disconnecting the jumper cables, pull
them straight away from the fuse block with even force. Do not
wiggle them side-to-side, as this may damage the connector.
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4 Internal Battery (continued)
•6 Slide a battery string with a red cable into an empty slot within
TERMINALS
the battery compartment. Make sure the battery string is oriented
as shown in the diagram. Note: Start with the empty slots at the
bottom of the battery compartment and work toward the empty
slots at the top of the battery compartment.
SIDE VIEW
Y
•7 Slide a battery string with a black cable into an empty slot within TERMINALS
R
the battery compartment, next to the battery string that you inserted
in step 6. Make sure the battery string is oriented as shown in the
diagram. Repeat steps 6 and 7 as needed until all the battery strings
have been inserted into the empty battery slots.
I NA
IM
SIDE VIEW
R E L
P
7
•8 Reconnect the fuse block bracket. (The letters on the fuse block
bracket should be upright when it is in the correct orientation.)
•9 Connect the blue and white jumper cables on each internal battery
pack to the corresponding fuse block. The labeling next to the fuse
block identifies the correct fuse block for each cable.
•10 Insert the battery cartridge fuses into each fuse block. The fuses are
interchangeable. Make sure the fuses are firmly snapped into place.
Warning: Battery cartridge fuses must be inserted last due to
potential arcing of connectors. Blown fuses must be replaced
by a qualified electrician. Replace only with fuses of the same
type and rating.
10
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4 Internal Battery (continued)
11
•12 Connect the black cable for each internal battery pack to the
Y
nearest black connector located inside the UPS system’s battery
R
compartment. Connect the red cable for each internal battery
pack to the nearest red connector located inside the UPS system’s
A
battery compartment. Warning: Observe proper polarity by
N
connecting negative to negative (black to black) and positive
I
to positive (red to red). Failure to observe proper polarity will
damage the UPS system and create a serious risk of personal
IM
injury and property damage.
L
12
E
•13 Replace the battery access bezels.
P R
13
•14 Turn on the internal battery circuit breaker switch. If you placed
the UPS system in bypass, return it to the previous operating mode.
If you turned the UPS system off, turn it on.
Note: If you need to remove or replace internal battery packs, modify
steps 6 and 7 by removing and/or replacing the existing internal battery
packs, as required.
14
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4 Internal Battery (continued)
A RY
I
Fig 4.2a BP480V26B
N
E L IM
P R
Table 4.2a
BP480V26B BP480V40C
Weight 470 kg 700 kg
Floor Loading 1064 kg/m^2 1575 kg/m^2
Battery Capacity 40 40
Voltage 12V DC 12 V DC
Amp/Hour 26AH 40AH
Battery Type VRLA VRLA
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4 Internal Battery (continued)
A RY
I N
E L IM
P R Fig 4.2c
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4 Internal Battery (continued)
A RY
N
To connect the external battery cabinet to its UPS system, use the W1 and W2 cables (Figure 4.2d) to connect the Q boards (Figure 4.2e) using the
I
ports illustrated (Figure 4.2f).
E L IM
P R
Fig 4.2e Connection between UPS and Battery Cabinet
W1
P7
1 1
Q board 2 2
3 3
4 4
Temperature 5 5
sensor
P6
P5
W2 P4
Battery Cabinet (for standard B/C type)
P3
UPS
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5 Troubleshooting
Y
BYPASS STATIC SWITCH OVER TEMPERATURE Bypass STS temperature over 80 degree C 5.2.5
R
BYPASS STATIC SWITCH FAULT Bypass STS open/short 5.2.6
BYPASS STATIC SWITCH OVERLOAD Bypass loading over 175% 5.2.7
UPS INTERNAL COMM ABNORMAL 1.CAN BUS loss
2.SCI loss
I NA
3.Power module internal communication loss
5.2.8
IM
BAT TEST FAIL Battery Capacity too low 5.2.9
BAT OVER CHARGE Battery voltage more than 296V 5.2.10
BATTERY BAD
BYPASS FAN FAILURE
TRANSFORMER OVERHEAT
P
UPS OUTPUT VOLT NOK
5.2.15
5.2.16
5.2.17
BAT LOW WARNING Battery voltage under 220V and above 200V
BAT LOW SHUTDOWN Battery voltage under 200V
BAT REPLACE REQUIRED Battery package out of date
INVERTER OVERLOAD WARNING Loading over 105%
INVERTER OVERLOAD SHUTDOWN Loading over 105%~125% 10min.
Loading over 125%~150% 1min.
Loading over 150% 1sec.
INVERTER OVER CURRENT Output current over 80A/phase
EMERGENCY POWER OFF ACTIVED E.P.O./ Remote E.P.O. ON
OUTPUT BREAKER OFF Output breaker not turn on
BYPASS LOAD OVER 104% the load over 104% when UPS is on bypass
BAT CABINET OVER TEMPERATURE Battery cabinet over 35 degree C
EXT BAT BREAKER OFF If support external battery and the breaker ont turn on
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5 Troubleshooting (continued)
Y
PWR MODULE #n INVERTER WARNING OVER TEMPERATURE Power module #n INV temperature over 60 degree C
R
PWR MODULE #n INVERTER SHUTDOWN OVER TEMPERATURE Power module #n INV temperature over 65 degree C
A
PWR MODULE #n INVERTER VOLT NOK Power module #n INV voltage over rating ( 220V/230V/240V ) +/-1%
N
PWR MODULE #n INVERTER SHORT CIRCUIT UPS output short circuit
I
PWR MODULE #n STATIC SWITCH FAULT Power module #n STS open/short
IM
PWR MODULE #n DC BUS ABNORMAL Power module #n DC BUS over 430V / under 300V
L
Note: #n indicates the ID of the power module. (Ex.: #1 is power module 1)
E
Note: In the event of power module failure, refer to chapter 6.1.
P R
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5 Troubleshooting (continued)
Start
Is the main N
Turn on the main
input circuit breaker END
input circuit breaker
(Q1) turned on?
Are the
actual value and LCD
value the same?
N
Is the LCD value zero?
Y
A RY
Is the Wire #1(1)
connection OK?
I
N
N Y
IM
Replace P board or M
Is the main input Y board (3)
L
voltage or frequency Calibrate parameter on
EEPROM(2 )
E
out of range?
P R N
END
Fig 5.2.1a
Note (1): For SU20KX, SU40KX and SU40K models, wire #1 is connected between the P board (CNP7) and FA (CNA9) for main input. (See chap-
ter 1.5.) For SU60KX, SU80KX, SU60K, SU80K, SU60KTV and SU80KTV, wire #1 is connected between the P board (CNP7) and F1 (CNF15) for
main input. (See section 1.5.)
Note (2): To learn about EEPROM parameter settings and calibration, turn to section 3.2.
Note (3): For the location of the NHS-SYS-P and NHS-SYS-M boards, turn to section 1.5. To replace the NHS-SYS-M board, simply remove the
EEPROM chip from an old NHS-SYS-M board and insert it into the new one.
Fig 5.2.1b
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5 Troubleshooting (continued)
Start
Is the main N
input external wiring Correct the wiring
correct?
Y
Y
Is the main
input phase sequence
N
A R
Correct phase
N
I
rotation
correct?
IM
Y
R E L END
P
Fig 5.2.2a
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5 Troubleshooting (continued)
Start
Are the
the main or bypass N Turn on the main or
input circuit breaker bypass input END
(Q1 and Q2) circuit breaker
turned on?
Fix the connection
Y
N
Are the
actual value and LCD
value the same?
N
Is the LCD value zero?
Y
A RY
Is the Wire #11 (1)
connection OK?
I N
N Y
IM
Replace P board or M
board (3)
L
Is the main input Y
voltage or frequency Calibrate parameter on
E
out of range? EEPROM(2 )
P R N
END
Fig 5.2.3a
Note (1): For SU20KX, SU40KX and SU40K models, wire #11 is connected between P board (CNP8) and FA (CNA9) for bypass input. (See chapter
1.5.) For SU60KX, SU80KX, SU60K, SU80K, SU60KTV and SU80KTV, wire #11 is connected between P board (CNP8) and F1 (CNF15) for bypass
input. (For locations, see chapter 1.7)
Note (2): To learn about EEPROM parameter settings and calibration, turn to chapter 3.2.
Note (3): For the location of the NHS-SYS-P and NHS-SYS-M boards, turn to chapter 1.5. To replace the NHS-SYS-M board, simply remove the
EEPROM chip from an old NHS-SYS-M board and insert it into the new one.
Fig 5.2.3b
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5 Troubleshooting (continued)
Is the bypass N
input external wiring Correct the wiring
correct?
A RY
I END
N
IM
Fig 5.2.4a
L
5.2.5 “BYPASS STATIC SWITCH OVER TEMPERATURE”
P R E Start
Y
Y
END
Fig 5.2.5a
Note (1): The fans are installed at the heat-sink of the bypass static switch. (See section 1.5)
Note (2): The NTC is mounted on the heat-sink of bypass static switch (Figure 5.2.5b). Remove wire #35 and unscrew the NTC.
Fig 5.2.5b
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5 Troubleshooting (continued)
Are the N
bypass SCRs Replace the SCR
functioning? (1)
Does the
fault still occur w/ UPS
N
A RY
N
in bypass mode?
IM I
L
Replace the S or SA board (3)
P R E END
Fig 5.2.6a
Note (1): Use a multimeter to measure the pins of bypass SCRs. If the ohm value is close to zero, it indicates that the SCR has failed. (For the
location of bypass SCRs, turn to section 1.5)
Note (2): For the location of the NHS-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM chip from the old
NHS-SYS-M board and insert it into the new one.
Note (3): For the location of the NHS-SYS-S board (for 60kVA and 80kVA) or the NHS-SYS-SA board (for 20kVA and 40kVA), turn to section 1.5.
Start
N Is the load CT N
Is the UPS loading
too high? functioning? (1)
Y Y
END
Fig 5.2.7a
Note (1): Use a multimeter to measure OIP CT resistance. If the value is about 35ohm, the OIP CT is good.
Note (2): To learn about EEPROM parameter settings and calibration, turn to section 3.2.
Note (3): To learn the location of the NHS-SYS-P and NHS-SYS-M boards, turn to section 1.5. To replace the NHS-SYS-M board, remove the
EEPROM chip from the old NHS-SYS-M board and insert it into the new one.
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5 Troubleshooting (continued)
Start
Has the N
Remove power connection
communication wire
of power module #1 (2)
slipped?(1)
Re-insert power connection
of previous power module
Y and remove the next power
module’s connection
Y
Re-insert communication
wire and try again Still getting the Y
R
same fault message?
I
N
NA
IM
Replace the power module
R E L END
P
Fig 5.2.8a
Note (1): Check W2A, W2B, W2C, W2D, W4A, W4B and W6 (Fig 5.2.8b).
Note (2): Remove wires W61A, W65A and W68A.
W3A
W2A W4A
W5 W6
W61A W65A
W68A
W2B
W5 W6
W5 W6
W62B W66B
W69B
W2C
W5 W6
W5 W6
W63C W67C
W70C
W2D
W5 W6
W2B W4B
W64D W36D
W71D
Fig 5.2.8b
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5 Troubleshooting (continued)
Y
Battery voltage < +/-256Vdc
Check battery bank and
Y
consider replacing the
R
battery
END
I Fig 5.2.9a
NA
IM
Note (1): To learn about EEPROM parameter settings and calibration, turn to section 3.2.
L
Note (2): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM
chip from the old NHS-SYS-M board and insert it into the new one.
R E
5.2.10 “BATTERY OVER CHARGE”
P
Start
Is the
N
neutral (N) of the battery Correct the wiring
external wiring
correct? (1)
END
Fig 5.2.10a
Note (1): The midpoint of the battery string must be connected to the neutral (N) of the battery terminal block.
Note (2): To learn about EEPROM parameter settings and calibration, turn to section 3.2.
Note (3): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM
chip from the old NHS-SYS-M board and insert it into the new one.
Note (4): Check the battery voltage of each power module one at a time. If it is normal, check the next one.
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5 Troubleshooting (continued)
Start
Is
the battery N Turn on battery
circuit breaker circuit breaker
turned on?
Is the external
wiring correct?
N
A RY
Correct the wiring
IM
N
R E L Are the
actual value
and LCD value the
same?
N Is the
LCD value zero?
Y Is the Wire #31(1)
connection OK?
P Y
Battery broken
Replace battery
N
Replace P board or M
board
(3)
Calibrate parameter
Y
END
Fig 5.2.11a
Note (1): Wire #31 connects CNP10 on the NH-SYS-P board to CNB7 on the NH-SYS-B board (Figure 5.2.11b).
Note (2): To learn about EEPROM parameter settings and calibration, turn to section 3.2.
Note (3): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM
chip from the old NHS-SYS-M board and insert it into the new one.
Fig 5.2.11b
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5 Troubleshooting (continued)
Start
N N
Is the UPS Is Fan C failed
in bypass mode? fan C spinning? Replace fan C (4)
N Does fan C Y
Replace the P board or work normally after
Y
Y M board (1) restarting UPS?
NA R
Is
fan A spinning?
N
IM I Is
fan B spinning?
N
Fan A and B failed
Replace fan A (2) and
fan B (3)
R E L Y
Fan A failed
P
Y Replace fan A (2 )
N Do fans
Replace the S board work normally after
or M board (1) restarting UPS?
END
Fig 5.2.12a
Note (1): For the location of the NH-SYS-P and/or NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM
chip from the old NHS-SYS-M board and insert it into the new one.
Note (2): Fan A is the main fan for the bypass static switch (Figure 5.2.12b).
Note (3): Fan B is the redundancy fan for the bypass static switch (Figure 5-16).
Note (4): Fan C is the main fan for the filter (Figure 5.2.12c).
Start
N Is it a N Are short-pins N
Is the UPS loading in CNM10 and
too high? C-Cabinet model? (1)
CNM11? (2)
Y Y Y Plug in short-pins
Reduce loading
Y
Are the
W38 plug in CNM11
R
(3)
Replace M board
and W39 plug in
A
(2)
CNM10?
I N
IM
Plug in these wires
R E L END
Fig 5.2.13a
P
Note (1): Models with C–cabinets are: SU40K, SU60K, SU80K, SU60KTV and SU80KTV.
Note (2): See Figure 5.2.13b for location.
Note (3): For the location of the NH-SYS-M board, turn to section 1.5. To replace the NHS-SYS-M board, remove the EEPROM chip from the old
NHS-SYS-M board and insert it into the new one.
Fig 5.2.13b
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5 Troubleshooting (continued)
Start
Is the output N
wire connection Fix the connection END
OK?
Y
N
R
Are the Is the
Actual value Is the Y
A
(1)
N Wire #10
and LCD value LCD value connection
N
the same? zero?
OK?
IM I N Y
L
Replace P board or M
board (3)
E
Check if any power
Calibrate parameter on
module output voltages
EEPROM(2)
R
(4)
are out of range
P END
Fig 5.2.14a
Note (1): Wire #10 connects CNP9 on the NH-SYS-P board with CNFC20 on the NH-SYS-FC board (Figure 5.2.14b).
Note (2): To learn about EEPROM parameter setting and calibration, refer to section 3.2.
Note (3): For the location of the NH-SYS-P board and NH-SYS-M boards, turn to section 1.5. To replace the NHS-SYS-M board, remove the
EEPROM chip from the old NHS-SYS-M board and insert it into the new one.
Note (4): Check the output voltage of each power module one at a time. If normal, check the next power module.
Fig 5.2.14b
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5 Troubleshooting (continued)
Start
Check
firmware first,
follow firmware
procedure
Has the
parallel wire
N
A RY
Parallel communication failed
END
N
Replace the R board
slipped? (1)
IM I
R E L Re-insert the parallel
wire and try again
P END
Fig 5.2.15a
Note (1): The external parallel wire is located on the rear panel (Figure 5.2.15b).
Fig 5.2.15b
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5 Troubleshooting (continued)
Start
A RY
I N
IM
END
L
Fig 5.2.16a
E
Note (1): Figure 5.2.16b shows the EEPROM’s power rating settings (Rating VA). To learn about EEPROM parameter settings, turn to section 3.2.
R
Note (2): Access parallel ID settings using the LCD control panel (bypass mode only). (UPS SETUP
P
LOCAL SETUP PARALLEL ID)
Fig 5.2.16b
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5 Troubleshooting (continued)
Start
Y
Reduce loading
END
NA R
IM I Fig 5.2.17a
Note (1): Access the redundancy setting using the LCD control panel (only in bypass mode). (UPS SETUP REDUNDANCY SETUP)
L
Select the power module’s redundancy number.
E
EX: 40kVA UPS, load < 20kVA, redundancy number =1.
R
If one power module proves abnormal, another power module will continue to supply the load without interruption.
P
40kVA UPS, load > 20kVA, redundancy number =1.
LCD panel displays “REDUNDANCY LOSS” message.
If one power module is abnormal, another power module will be overloaded and shut down to bypass.
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6 Power Module
WARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it
continues to supply power to the critical load (the critical load is supported directly by utility power).
These instructions will help you diagnose which power modules have failed and which are protected.
1) Check the warning messages by pressing the “ ” or “ ” button on the main page of the control panel. (Figure 6.1a) (Table 5.1b lists the
conditions for each power module warning message)
2) Check the event log message. (Figure 6.1b) (Maintenance Event Log Read)
P W R M O D U L E # 1
P F C F U S E O P E N
● P W R
◆ S E R V I C E
M O D D U L E # 1
R E Q U I R E D
O F F
A RY
I Fig 6.1a
N
E L U P S
IM
M E A S U R E
S E T U P
R
M A I N T E N A N C E
P M A I N T E N A N C E
S T A T I S T I C
E V E N T L O G
M A N U A L S E T U P & T E S T
F I R M W A R E U P G R A D E
O T H E R S
E V E N T L O G
R E A D
E R A S E
EVENT LOG
07-07-03 13:17:00
UPS State:Load on Inverter
07-07-03 13:15:57
Input Voltage Normal
07-07-03 13:15:57
Input Frequency Normal
07-07-02 13:15:54
UPS State: Load on Bypass
07-07-02 13:15:53
Input Frequency Abnormal
07-07-02 13:10:16
Input Voltage Abnormal
Fig 6.1b
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6 Power Module (continued)
M E A S U R E
U P S S E T U P
M A I N T E N A N C E
M A I N T E N A N C E
S T A T I S T I C
A RY
E V E N T
M A N U A L
L O G
S E T U P &
I
T E S T
N
IM
F I R M W A R E U P G R A D E
O T H E R S
R E L
P O T H E R S
S N &
S Y S T E M
M O D U L E
F W V E R S I O N
T I M E
D C B U S V O L T
L O G I N M E A S U R E
A D M I N I S T R A T O R U P S S E T U P
U S E R M A I N T E N A N C E
D C B U S V O L T A G E P O W E R M O D U L E # 3
I N V E R T E R O U T P U T
# 1 : + 3 7 2 . 6 V / - 3 6 8 . 4 V R : 2 2 0 . 0 V / 1 2 . 5 A
# 2 : + 3 7 2 . 6 V / - 3 6 8 . 4 V S : 2 2 0 . 0 V / 1 2 . 5 A
# 3 : + 3 7 2 . 6 V / - 3 6 8 . 4 V T : 2 2 0 . 0 V / 1 2 . 5 A
# 4 : + 3 7 2 . 6 V / - 3 6 8 . 4 V
F R E Q U E N C Y
5 0 . 0 H z
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6 Power Module (continued)
Q4 Q3 Q2
A RY Q1
I
Output Manual
Bypass
N
Bypass
Input
Main
Input
E L IM
P R Q1: Input Circuit Breaker
Q2: Bypass Input Circuit Breaker
Q3: Manual Bypass Circuit Breaker
Q4: Output Circuit Breaker
Fig 6.1e
Ultimately, normal power modules will shut down (with fans inactive), while faulty power modules will still be pending (no discharge, fans still
active).
Finally, turn off the battery switch to force the power modules to shut down. At this point, faulty power modules have either failed or are being
protected.
6) Turn on the main input circuit breaker. Then, once the fan is active, turn off the main input circuit breaker. Normal power modules will shut
down instantly, while faulty power module will discharge DC BUS voltage.
Failed power modules can be identified by the following:
• Inactive fans
• Alarm message on LCD
If neither of these occur, follow step 7 to ascertain that the faulty power modules are protected.
7) Turn on the main input circuit breaker and observe whether the power module’s DC BUS voltage (Figure 6.1c) ever reaches +/- 370Vdc. If it
does not, or you receive an alarm message, the power module has failed.
Turn off the main input circuit breaker and monitor the output message for each power module (Figure 6.1d). If the output voltage is abnormal or
you receive an alarm message, the power module has failed.
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6 Power Module (continued)
WARNING: Before opening the unit, please make sure that the UPS is in Manual Bypass mode so that it
continues to supply power to the critical load (the critical load is supported directly by utility power).
WARNING: Make sure that the UPS unit is shut down completely. (Main Input circuit breaker (Q1), Bypass
Input circuit breaker (Q2) and Output circuit breaker (Q4) must be OFF (see Figure 6.2a).)
Q4 Q3 Q2 Q1
Output
A RY
Manual
Bypass
Bypass
Input
Main
Input
I N
E L IM Q1: Input Circuit Breaker
Q2: Bypass Input Circuit Breaker
Fig 6.2a
Fig 6.2b
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6 Power Module (continued)
ID Detect
+12V
Comm. Port
Rev. Comm. Port
R +
S N N
T – T
N S
R
A RY
I N
E L W61A
IMW65A
W2A
W5
W3A
W4A
W6
W68A
R
W2B
W6
P
W5
W5 W6
W62B W66B
W69B
W2C
W5 W6
W5 W6
W63C W67C
W70C
W2D
W5 W6
W2B W4B
W64D W36D
W71D
Fig 6.2d
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6 Power Module (continued)
Fig 6.2e
A RY
N
d) Remove the corner bezels of the power module from the front side (Figure 6.2f).
IM I
R E L
P
Fig 6.2f
Fig 6.2g
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6 Power Module (continued)
A RY
I N
IM
Fig 6.2h
h) Remove the power module (Figure 6.2i).
R E L
P
Fig 6.2i
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7 Preventive Maintenance
Y
7.2 Suggested tools and supplies
• Insulated tools:
Torque wrench
NA R
I
Socket set, ratchet
Screwdrivers (Philips and common)
IM
Magnetic Philips screw driver
Needle-nose pliers
L
Diagonal wire cutters
E
• Oscilloscope—199 Fluke Scope meter or equivalent
R
• Digital Multi-meter—189 Fluke or equivalent true RMS with diode scale
P
• Clamp-on Ammeter—AC/DC; true RMS
• Non-contact infra-red thermometer
• TIF tester (for battery module)
• Small soldering iron and rosin-core solder
• Insulated gloves
• ESD protective equipment (grounded pad, wrist strap)
• Insulating blanket
• Electrical tape
• Heat sink thermal compound
• Plastic ties
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7 Preventive Maintenance (continued)
Y
Perform the visual battery inspection. Note any problems. Then take an infrared reading of ambient temperature and the inside of the battery
R
compartment and enter that information on the form. Note on the form if battery temperature exceeds 95O F, or 32O F above ambient. What steps
should be followed to address this issue? Is this an information only step?
A
N
7.3.9
7.3.10
IM I
If the battery PM is to be performed, it should be done at this time. See section 7.4 for the internal battery procedure.
When inspection is complete, replace the rear, side, top and front covers of the UPS.
7.3.11
E L
When you turn on manual bypass under the following situation :
R
1. Replace the failure power module with a new one.
P
2. Replace the failure board/components in the system
Please follow the regular turn-on procedure. Turn on the bypass input, output and main input breaker. Verify the static switch is load on the bypass,
turn off the manual bypass breaker.
7.3.12
Check the LCD display to verify DC BUS voltages are present, and then press the “ON” key. Verify that the inverter starts and operates correctly
per the LED panel and LCD display.
7.3.13
Summarize the results of the inspection with the customer representative on site. Be sure to note any items that will require service or customer
action.
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7 Preventive Maintenance (continued)
A RY
Recommended Equipment and Tools
I N
IM
• Laptop: with series COM port
• Multi-Meter
•
•
•
Oscilloscope
E L
Clamp Meter: for measurement of current
R
Screwdriver: Phillips-head and slotted
•
•
•
P Hex Wrench: 5mm and 6mm
Socket Wrench: 13mm and 17mm
Diagonal Cutters
Software Tools
• NH_SYS_V1_3B1030.exe: For system EEPROM parameter settings and calibration.
• FSL 3.75.exe: For upgrading the system MCU’s firmware on a NH-SYS-M board.
• NH_PM_V1_4B1207.exe: For upgrading the power module’s firmware.
• NH-Dry-Contact v1.0b1024.exe: For output dry contact status setting.
• NH-EventLog v1.0b1115.exe: For downloading the UPS event log.
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Appendix B Torque Table
KX Models
Tables B.1 and B.2 list the torque for terminal block connection. (For TB locations, see Figure B.a.)
Table B.1
SU20KX
Torque lb-in (kgf-cm) Screwdriver
Input TB 15.6 (18) Slotted Screwdriver
Bypass TB 15.6 (18) Slotted Screwdriver
Battery TB 15.6 (18) Slotted Screwdriver
OUTPUT TB 15.6 (18) Slotted Screwdriver
Ground 130.2 (150) 13mm Socket Wrench
SU40KX
Y
Input TB 30.4 (35) Slotted Screwdriver
R
Bypass TB 30.4 (35) Slotted Screwdriver
A
Battery TB 30.4 (35) Slotted Screwdriver
N
OUTPUT TB 30.4 (35) Slotted Screwdriver
Ground
R E L
P
Fig B.a.
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Appendix B Torque Table (continued)
KX Models (continued)
Table B.2
SU60KX
Torque lb-in (kgf-cm) Screwdriver
Input TB 50 (57.6) Slotted Screwdriver
Bypass TB 50 (57.6) Slotted Screwdriver
Battery TB 50 (57.6) Slotted Screwdriver
OUTPUT TB 50 (57.6) Slotted Screwdriver
Ground 130.2 (150) 13mm Socket Wrench
SU80KX
Input TB 50 (57.6) Slotted Screwdriver
Y
Bypass TB 50 (57.6) Slotted Screwdriver
Battery TB 50 (57.6) 5mm Hex Wrench
OUTPUT TB
Ground
50 (57.6)
130.2 (150)
NA R Slotted Screwdriver
13mm Socket Wrench
K Models
IM I
L
Table B.3 lists the torque for terminal block connection. (For SU40K and SU60K TB locations, see Figure B.b.) (For SU80K TB locations, see
Figure B.c.)
Table B.3
P R E Input TB
Battery TB
SU40K
Torque lb-in (kgf-cm)
50 (57.6)
50 (57.6)
Screwdriver
5mm Hex Wrench
Slotted Screwdriver
OUTPUT TB 50 (57.6) 5mm Hex Wrench
Ground 217 (250) 17mm Socket Wrench
SU60K
Input TB 90 (130.7) 6mm Hex Wrench
Battery TB 50 (57.6) Slotted Screwdriver
OUTPUT TB 90 (130.7) 6mm Hex Wrench
Ground 217 (250) 17mm Socket Wrench
SU80K
Input Bar 217 (250) 17mm Open End Wrench & Socket Wrench
Battery TB 50 (57.6) 5mm Hex Wrench
OUTPUT Bar 217 (250) 17mm Open End Wrench & Socket
Wrench
Ground 217 (250) 17mm Socket Wrench
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Appendix B Torque Table (continued)
K Models
A RY
I N
E L IM
Fig B.b.
P R
Fig B.c.
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Appendix B Torque Table (continued)
KTV Models
Table B.4 lists the torque for terminal block connection. (For TB locations, see Figure B.d.)
Table B.4
SU60KTV
Torque lb-in (kgf-cm) Screwdriver
Input TB 50 (57.6) Slotted Screwdriver
Battery TB 50 (57.6) Slotted Screwdriver
OUTPUT TB 50 (57.6) Slotted Screwdriver
Ground 217 (250) 17mm Socket Wrench
SU80KTV
Input TB 50 (57.6) 5mm Hex Wrench
Battery TB
OUTPUT TB
Ground
50 (57.6)
50 (57.6)
217 (250)
I N
E L IM
P R
Fig B.d.
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Appendix C PCB and Test Point
NH-SYS-P Board
TPP1: Reference ground (GND) of control circuit power
TPP2: +12V of control circuit power
TPP4: -12V of control circuit power
A RY
I N
IM
NH-SYS-R Board
L
TPR1: Reference ground (GND) of control circuit power
TPR2: Synchronous signal
P R E
TPR3: Reference ground (GND) of communication circuit power
TPR4: +5V of communication circuit power
TPR5: +12V of communication circuit power
TPR6: -12V of communication circuit power
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