Tripp Lite SU60KX manual Table of Contents

Page 2

Table of Contents

1

Basic Operation

3

 

1.1

Technical Specifications

3

 

 

KX Models

3

 

 

K and KTV Models

4

 

 

SU80K Model

5

 

1.2

Features

6

 

 

1.2.1 Advanced Features

6

 

 

1.2.2 Control Panel Features

6

 

 

1.2.3 Front and Rear Panel Features

7

 

1.3

Operating Principles

13

 

 

1.3.1 System Layout

13

 

 

1.3.2 Internal Battery Layout

13

 

 

1.3.3 Power Module Layout

14

 

1.4

Opening and Closing the Unit

14

 

1.5

Operating Modes

15

 

 

1.5.1 Online (Normal) Mode (Single UPS)

15

 

 

1.5.2 Battery Backup Mode (Single UPS)

15

 

 

1.5.3 Auto Bypass Mode (Single UPS)

15

 

 

1.5.4 Manual Bypass Mode (Single UPS)

15

 

 

1.5.5 Online Mode (Parallel UPS)

16

 

 

1.5.6 Battery Backup Mode (Parallel UPS)

16

 

 

1.5.7 Auto Bypass Mode (Parallel UPS)

16

 

 

1.5.8 Manual Bypass Mode (Parallel UPS)

17

 

 

1.5.9 Hot Standby Mode (Parallel UPS)

17

 

1.6

Start-Up, Shutdown and Bypass

18

 

 

1.6.1 Control Panel and Breaker Diagrams

18

 

 

1.6.2 Preliminary Checklist (Single UPS)

18

 

 

1.6.3 Standard Start-Up Procedure (Single UPS)

18

 

 

1.6.4 Battery Start-Up Procedure (Single UPS)

19

 

 

1.6.5 Manual Bypass Procedure (Single UPS)

20

 

 

1.6.6 Shutdown Procedure (Single UPS)

20

 

 

1.6.7 Preliminary Checklist (Parallel UPS)

21

 

 

1.6.8 Start-Up Procedure (Parallel UPS)

21

 

 

1.6.9 Shutdown Procedure (Parallel UPS)

22

 

 

1.6.10 Manual Bypass Procedure (Parallel UPS)

23

 

 

1.6.11 Switching from Manual Bypass to Normal Mode

 

 

 

(Parallel UPS)

24

 

1.7

Printed Circuit Boards (PCB)

25

 

 

1.7.1 PCB Location (System)

26

 

 

1.7.1.1 KX Models

26

 

 

1.7.1.2 K Models

28

 

 

1.7.1.3 KTV Models

32

 

 

1.7.2 PCB Power Module

33

 

1.8

Block and Wiring Diagrams

34

 

 

1.8.1 KX Models

34

 

 

1.8.2 K Models

40

 

 

1.8.3 KTV Models

45

2

Theory of Operation

48

 

2.1 AC Auxiliary Power Circuit

48

 

2.2

DC Auxiliary Power Circuit

51

 

2.3 Auxiliary Power Failure Detection

51

 

2.4

Output Current Detection

52

 

2.5

Input Voltage Detection

53

 

2.6

Output Voltage Detection

54

 

2.7

Battery Voltage Detection

55

 

2.8

Bypass SCR Short-Circuit Detection

56

 

2.9

Bypass SCR Driver

57

 

2.10 Watchdog for System MCU

58

 

2.11

LCD Panel Control Circuit

59

 

2.12

Fan Control Circuit

60

 

2.13

Bypass SCR Temperature Detection

61

 

2.14

Communication Circuit for RS232

61

 

2.15

Communication Circuit for Slots

62

 

2.16

Communication Circuit for Output Dry Contact

63

 

2.17

Communication Circuit for Input Dry Contact and REPO

64

 

2.18

External Battery Cabinet Temperature Detection

65

 

2.19

Detection Circuit for Manual Bypass Switch

66

 

2.20

Detection Circuit for Output Breaker

66

 

2.21

Control Circuit for Power Module

67

 

2.22 Transformer Over Temperature Detection

71

3 Communication

72

 

3.01

RS232 Port

72

 

3.02

Emergency Power Off (EPO)

72

 

3.1 Setting EEPROM on the NH-M Board

74

 

 

3.1.1 Polling and Updating EEPROM

74

 

 

3.1.2 Calibrating EEPROM Gain

75

 

3.2

Setting Output Dry Contact Status

76

 

3.3

Upgrading Firmware for the System Board

77

 

3.4

Upgrading Firmware for the Power Module

82

 

3.5

Downloading the Event Log

90

4

Internal Battery

91

 

4.1

Installing and Removing Internal Batteries

92

 

4.2

Battery Cabinet

95

5

Troubleshooting

98

 

5.1 Alarm Messages

98

 

5.2 Troubleshooting Flow Charts

100

 

 

5.2.1 “MAIN VOLT/FREQ NOK”

100

 

 

5.2.2 “MAIN SEQUENCE NOK”

101

 

 

5.2.3 “BYPASS VOLT/FREQ NOK”

102

 

 

5.2.4 “BYPASS SEQUENCE NOK”

103

 

 

5.2.5 “BYPASS STATIC SWITCH OVER TEMPERATURE”

103

 

 

5.2.6 “BYPASS STATIC SWITCH FAULT”

104

 

 

5.2.7 “BYPASS STATIC SWITCH OVERLOAD”

104

 

 

5.2.8 “UPS INTERNAL COMM ABNORMAL”

105

 

 

5.2.9 “BATTERY TEST FAIL”

106

 

 

5.2.10 “BATTERY OVER CHARGE”

106

 

 

5.2.11 “BATTERY BAD”

107

 

 

5.2.12 “BYPASS FAN FAILURE”

108

 

 

5.2.13 “TRANSFORMER OVERHEAT”

109

 

 

5.2.14 “PS OUTPUT VOLT NOK”

110

 

 

5.2.15 “PS EXT PARALLEL COMM ABNORMAL”

111

 

 

5.2.16 “PARALLEL FAILURE”

112

 

 

5.2.17 “REDUNDANCY LOSS”

113

6 Power Module

114

 

6.1

Failure Power Module Identify

114

 

6.2

Power Module Replacement

117

7

Preventive Maintenance

121

 

7.1

Safety Overview

121

 

7.2

Suggested tools and supplies

121

 

7.3

UPS Procedure

121

 

7.4

Internal Battery Procedure

122

Appendix A Service Equipment and Tools

123

Appendix B Torque Table

124

Appendix C PCB and Test Point

128

2

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Contents Th Street, Chicago, IL 60609 USA Table of Contents KX Models Basic OperationTechnical Specifications KTV Models SU40K SU60K SU60KTV SU80KTVSU80K Model Model Capacity SU80K 80kVA/64kWControl Panel Features FeaturesAdvanced Features Front and Rear Panel Features 3a SU40KX front3b SU40KX rear 3c SU40K front 3d SU40K rear 3e SU80K front 3f SU80K rear System Layout Internal Battery LayoutOperating Principles Opening and Closing the Unit Power Module Layout3a Power Module Block Diagram Auto Bypass Mode Single UPS Online Normal Mode Single UPSBattery Backup Mode Single UPS Manual Bypass Mode Single UPSAuto Bypass Mode Parallel UPS Online Mode Parallel UPSBattery Backup Mode Parallel UPS Manual Bypass Mode Parallel UPS Hot Standby Mode Parallel UPSPreliminary Checklist Single UPS Control Panel and Breaker DiagramsNormal LED Battery LED Bypass LED Fault LED Standard Start-Up Procedure Single UPSBattery Start-Up Procedure Single UPS Manual Bypass Procedure Single UPS Shutdown Procedure Single UPSPreliminary Checklist Parallel UPS Start-Up Procedure Parallel UPSShutdown Procedure Parallel UPS Manual Bypass Procedure Parallel UPS Switching from Manual Bypass to Normal Mode Parallel UPS Printed Circuit Boards PCB SU80KX SU60KX SU40KX SU80KTV SU20KXPCB Location System F3 FB M LA, LB, LC, LD Models LA, LB, LC LA, LB, LC, LD F1BYP F1MAIN F2BYP F2MAIN LCD PCB Location Power Module PCB Board Name Description1c SU40KX Block Diagram Block and Wiring Diagrams1a SU20KX Block Diagram KX ModelsTheory of Operation DC Auxiliary Power CircuitAuxiliary Power Failure Detection Output Current Detection W18Input Voltage Detection Located at NH-SYS-M board System MCU and Control CircuitOutput Voltage Detection Located at NH-SYS-M board System MCU and Control CircuitBattery Voltage Detection UP10BBypass SCR Short-Circuit Detection Scrst RBypass SCR Driver TSA1Watchdog for System MCU LCD Panel Control Circuit To LCDFan Control Circuit Located on NH-SYS-M board System MCU and Control CircuitBypass SCR Temperature Detection Communication Circuit for RS232RS232 Port Communication Circuit for SlotsCommunication Circuit for Output Dry Contact Output DRY ContactCommunication Circuit for Input Dry Contact and Repo Input DRY ContactExternal Battery Cabinet Temperature Detection EXTBTEMP1Detection Circuit for Manual Bypass Switch Detection Circuit for Output BreakerControl Circuit for Power Module CentralokTo PM1 to PM2 CM93 CM106 CM109 Control Circuit for External ParallelTheory of Operation 01 RS232 Port Emergency Power Off EPOCommunication 02a Front Control Panel02c Remote Emergency Power Off Repo02b Setting Eeprom on the NH-M Board Polling and Updating EepromCalibrating 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 Front View of SU20KX and SU40KX Internal BatteryBattery Strings Installing and Removing Internal Batteries Terminals Damage the UPS system and create a serious risk of personal Battery compartment. Warning Observe proper polarity byConnecting negative to negative black to black and positive Injury and property damageBattery Cabinet 2a BP480V26B 2b BP480V40CInternal Battery 2d W1 and W2 Cables 2e Connection between UPS and Battery Cabinet2f Wiring between UPS and Battery Cabinet 1a Warning Message List TroubleshootingAlarm Messages 1b Power Module Warning Message List ConditionTroubleshooting Flow Charts Main VOLT/FREQ NOKMain Sequence NOK Bypass VOLT/FREQ NOK Bypass Static Switch Over Temperature Bypass Sequence NOKBypass Static Switch Fault Bypass Static Switch OverloadSame fault message? Replace the power module UPS Internal Comm Abnormal10a Battery Test FailBattery Over Charge Battery BAD 11a 11bBypass FAN Failure 12a 12b 12cTransformer Overheat 13a 13bPS Output Volt NOK 14a 14bPS EXT Parallel Comm Abnormal 15a 15bParallel Failure 16a 16bRedundancy Loss 17aPower Module Failure Power Module Identify115 116 Power Module Replacement AC Input DC Input Output 119 120 UPS Procedure Preventive MaintenanceSafety Overview Suggested tools and suppliesInternal Battery Procedure Software Tools Appendix a Service Equipment and ToolsRecommended Equipment and Tools Multi-Meter OscilloscopeTable B.1 Appendix B Torque TableKX Models Fig B.aTable B.3 ModelsTable B.2 Fig B.b Fig B.c Fig B.d KTV ModelsTable B.4 NH-SYS-R Board Appendix C PCB and Test PointNH-SYS-P Board