Tripp Lite SU60KX manual Preventive Maintenance, Safety Overview, Suggested tools and supplies

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7 Preventive Maintenance

7.1 Safety Overview

Hazardous voltages and currents are present in this equipment! Hazardous energy is stored and will still be present even when the equipment is turned off and removed from power mains!

Personal protective equipment is required when working on this equipment. This includes safety glasses, insulated gloves, and insulating blankets to prevent shorts or accidental contact with live circuits.

LOTO (Lockout-Tagout) procedures should be used when service cannot be completed in one visit.

Insulated tools are required for service inside power modules or battery cabinets when working hot.

Use a voltmeter to verify that voltage has been removed before servicing any module.

Use a voltmeter to determine that voltages and polarities are correct before re-connecting any batteries or battery cabinets.

If you are working with someone else, be certain that you know what the other person is doing at all times AND that the other person knows what you are doing!

7.2Suggested tools and supplies

•Insulated tools:

Torque wrench Socket set, ratchet Screwdrivers (Philips and common) Magnetic Philips screw driver Needle-nose pliers

Diagonal wire cutters

•Oscilloscope—199 Fluke Scope meter or equivalent

•Digital Multi-meter—189 Fluke or equivalent true RMS with diode scale

•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

7.3UPS Procedure

7.3.1

Check the LCD display and the LED panel for status and alarms. If the unit is operating normally and no alarms are present, or if the unit has an active alarm, download the event log and failure power module identify (Please refer to chapter 3 and chapter 6 of “owner’s manual”).

7.3.2

Remove the rear, side, top and front covers. Perform an infrared scan on input and bypass breakers, cables and wire connections (terminal blocks, internal connect, etc.), and other assemblies. What are we looking for? What temperature limits can not be exceeded?

7.3.3

Visually inspect cables for signs of overheated or damaged insulation. Visually inspect modules for damage and inspect bypass STS snubbers for damage.

7.3.4

Measure Ø to Ø and Ø to Neutral main input voltage, bypass input voltage and enter those on the form. Note that phases R, S, T correspond to A, B, C on the form. Compare the meter readings with the LCD display readings. If the voltage readings are correct within +/- 1%, check input metering OK on the form. If there is a greater discrepancy, enter that in NOTES. Then what do we do? Is there a troubleshooting tree to reference in the service manual?

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Contents Th Street, Chicago, IL 60609 USA Table of Contents Technical Specifications Basic OperationKX Models SU40K SU60K SU60KTV SU80KTV KTV ModelsModel Capacity SU80K 80kVA/64kW SU80K ModelAdvanced Features FeaturesControl Panel Features 3a SU40KX front Front and Rear Panel Features3b SU40KX rear 3c SU40K front 3d SU40K rear 3e SU80K front 3f SU80K rear Operating Principles Internal Battery LayoutSystem Layout 3a Power Module Block Diagram Power Module LayoutOpening and Closing the Unit Manual Bypass Mode Single UPS Online Normal Mode Single UPSBattery Backup Mode Single UPS Auto Bypass Mode Single UPSBattery Backup Mode Parallel UPS Online Mode Parallel UPSAuto Bypass Mode Parallel UPS Hot Standby Mode Parallel UPS Manual Bypass Mode Parallel UPSStandard Start-Up Procedure Single UPS Control Panel and Breaker DiagramsNormal LED Battery LED Bypass LED Fault LED Preliminary Checklist Single UPSBattery Start-Up Procedure Single UPS Shutdown Procedure Single UPS Manual Bypass Procedure Single UPSStart-Up Procedure Parallel UPS Preliminary Checklist Parallel UPSShutdown Procedure Parallel UPS Manual Bypass Procedure Parallel UPS Switching from Manual Bypass to Normal Mode Parallel UPS SU80KX SU60KX SU40KX SU80KTV SU20KX Printed Circuit Boards PCBPCB Location System F3 FB M LA, LB, LC, LD Models LA, LB, LC LA, LB, LC, LD F1BYP F1MAIN F2BYP F2MAIN LCD PCB Board Name Description PCB Location Power ModuleKX Models Block and Wiring Diagrams1a SU20KX Block Diagram 1c SU40KX Block DiagramAuxiliary Power Failure Detection DC Auxiliary Power CircuitTheory of Operation W18 Output Current DetectionLocated at NH-SYS-M board System MCU and Control Circuit Input Voltage DetectionLocated at NH-SYS-M board System MCU and Control Circuit Output Voltage DetectionUP10B Battery Voltage DetectionScrst R Bypass SCR Short-Circuit DetectionTSA1 Bypass SCR DriverWatchdog for System MCU To LCD LCD Panel Control CircuitLocated on NH-SYS-M board System MCU and Control Circuit Fan Control CircuitCommunication Circuit for RS232 Bypass SCR Temperature DetectionCommunication Circuit for Slots RS232 PortOutput DRY Contact Communication Circuit for Output Dry ContactInput DRY Contact Communication Circuit for Input Dry Contact and RepoEXTBTEMP1 External Battery Cabinet Temperature DetectionDetection Circuit for Output Breaker Detection Circuit for Manual Bypass SwitchCentralok Control Circuit for Power ModuleTo PM1 to PM2 CM93 Control Circuit for External Parallel CM106 CM109Theory of Operation 02a Front Control Panel Emergency Power Off EPOCommunication 01 RS232 Port02b Remote Emergency Power Off Repo02c Polling and Updating Eeprom Setting Eeprom on the NH-M BoardCalibrating Eeprom Gain Setting Output Dry Contact Status Upgrading Firmware for the System Board Output Manual Bypass Main Input N C S T G R G I N G R a D E Communication Upgrading Firmware for the Power Module PM1 U P S T G R G I N Link the UPS to a PC via the RS232 port Communication Communication Communication T I N G L O W E D Downloading the Event Log Battery Strings Internal BatteryFront View of SU20KX and SU40KX Installing and Removing Internal Batteries Terminals Injury and property damage Battery compartment. Warning Observe proper polarity byConnecting negative to negative black to black and positive Damage the UPS system and create a serious risk of personal2a BP480V26B 2b BP480V40C Battery CabinetInternal Battery 2f Wiring between UPS and Battery Cabinet 2e Connection between UPS and Battery Cabinet2d W1 and W2 Cables Alarm Messages Troubleshooting1a Warning Message List Condition 1b Power Module Warning Message ListMain VOLT/FREQ NOK Troubleshooting Flow ChartsMain Sequence NOK Bypass VOLT/FREQ NOK Bypass Sequence NOK Bypass Static Switch Over TemperatureBypass Static Switch Overload Bypass Static Switch FaultUPS Internal Comm Abnormal Same fault message? Replace the power moduleBattery Over Charge Battery Test Fail10a 11a 11b Battery BAD12a 12b 12c Bypass FAN Failure13a 13b Transformer Overheat14a 14b PS Output Volt NOK15a 15b PS EXT Parallel Comm Abnormal16a 16b Parallel Failure17a Redundancy LossFailure Power Module Identify Power Module115 116 Power Module Replacement AC Input DC Input Output 119 120 Suggested tools and supplies Preventive MaintenanceSafety Overview UPS ProcedureInternal Battery Procedure Multi-Meter Oscilloscope Appendix a Service Equipment and ToolsRecommended Equipment and Tools Software ToolsFig B.a Appendix B Torque TableKX Models Table B.1Table B.2 ModelsTable B.3 Fig B.b Fig B.c Table B.4 KTV ModelsFig B.d NH-SYS-P Board Appendix C PCB and Test PointNH-SYS-R Board
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