Always "On" UPS NX-Series Service Manual

Always “On” UPS Systems Inc. Bldg 1 - 150 Campion Road, Kelowna, BC, Canada, V1X 7S8 Phone: (250) 491-9777 Ext. 451, Fax: (250) 491-9775, Email: sale

Always On UPS Systems Inc 7 6. INVERTER The inverter is composed of IGBT’s, inductors, capacitors, highly efficient filters, contr

Always On UPS Systems Inc 8 Figure 6.2 Detailed drawing of one phase of the Inverter System

Always On UPS Systems Inc 9 7. STATIC SWITCH The static switch is composed of two pairs of back to back naturally commutated SCR’s,

Always On UPS Systems Inc 10 Figure 7.2 Detailed drawing of one phase of the Static Switch System

Always On UPS Systems Inc 11 8. INTER-PCB DIAGRAM Figure 8.1 Connection diagram for the PCB Module, Inverter, Rectifier and Static Switch

Always On UPS Systems Inc 12 9. PCB MODULE Figure 9.1 Detailed drawing of PCB Module

Always On UPS Systems Inc 13 10. AUXILARY POWER SUPPLYRESERVE 8A SSPS 17 VacST9632120VacPOWER SUPPLY 3J 250 Vac0 Vac120VacSTFAN6 ST9632120Vac

Always On UPS Systems Inc 14 11. STARTUP PROCEDURES Using the following procedure below start up the UPS, or use “manual bypass to inverter pro

Always On UPS Systems Inc 15  Fans will start, output voltage will be present.  Indicators will show normal inverter operation of the system.

Always On UPS Systems Inc 16 - Status LEDs indicate status of sub-systems – many alarm indicators will be illuminated as the rectifier does not

Always On UPS Systems Inc

Always On UPS Systems Inc 17 - Indicators will show normal rectifier and inverter operation of the system. Record UPS status o Out of servi

Always On UPS Systems Inc 18 d. Close the Bypass breaker – The reserve breaker and reserve static switch are still conducting. When the mainten

Always On UPS Systems Inc 19 13. LCD DISPLAY AND LED DESCRIPTION Before powering down the system to perform service or maintenance, record the

Always On UPS Systems Inc 20 The front panel is located behind the glass window on the front door. It displays the real time information, UPS S

Always On UPS Systems Inc 21 • SHORT CIRCUIT – UPS output is in a short circuit state. • FUSE/OVER TEMP SD – inverter has shutdown due to inve

Always On UPS Systems Inc 22 >125%, beep once / second >150%, beep twice / second • BACK-UP >320VDC, beep once / 3 seconds <

Always On UPS Systems Inc 23 M. Up key: This is an LCD control key. It moves the cursor one field upward when items are being selected or chan

Always On UPS Systems Inc 24 14. THE LCD DISPLAY The LCD displays Real Time information as to the status and operation characteristics of the

Always On UPS Systems Inc 25 14.2. Menu 1 – Select Menu MENU 1 is reached by pressing any button on the opening screen and is also the defau

Always On UPS Systems Inc 26 14.3. Menu 2 – Status Warning Menu The Status/Warning menu is accessed through MENU 1 by selecting STATUS WARNIN

Always On UPS Systems Inc Table of Contents 1. SAFETY INSTRUCTIONS...

Always On UPS Systems Inc 27 Listed below are all the fault conditions that can be displayed: 1st row: HIGH DC SHUTDOWN – DC Bus voltage out

Always On UPS Systems Inc 28 14.5. Menu 4 – Historical Event Menu MENU 4 is reached by selecting HISTORICAL DATA on MENU 1. All abnormal eve

Always On UPS Systems Inc 29 14.6. Menu 5 – Parameter Setting Menu MENU 5 is reached by selecting PARAMETER SET on MENU 1 and access is onl

Always On UPS Systems Inc 30 14.7. Menu 6 – Rectifier Data Menu MENU 6 is reached by selecting RECTIFIER DATA on MENU 3. The information pr

Always On UPS Systems Inc 31 14.9. Menu 8 – Output Data Menu MENU 8 is reached by selecting OUTPUT DATA on MENU 3. The information provided

Always On UPS Systems Inc 32 14.11. Menu 10 – Boost Charge Setting Menu Warning! These settings have been preset by the factory to optimize th

Always On UPS Systems Inc 33 CHARGE CURRENT increases the amount of charge current the rectifier/charge supplies the battery bank. There are

Always On UPS Systems Inc 34 14.12. Menu 11 – Data Time Setting Menu MENU 11 is reached by selecting DATE/TIME on MENU 5. This menu all

Always On UPS Systems Inc 35 15. STATUS INDICATOR TABLE Indicators: 1=On, 0=Off, R=Red, G=Green, x=On

Always On UPS Systems Inc 36 16. BOARD LED INDICATION TABLE NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LED LED IlluminatedDescription LED Illum

Always On UPS Systems Inc 1 1. SAFETY INSTRUCTIONS This Safety Notice is addressed to the Always “On” customer engineers who perform maintenance

Always On UPS Systems Inc 37 17. BOARD FAULT DIAGRAMS 3A Board Fault UPS will not start up. Once

Always On UPS Systems Inc 38 3B Board Fault UPS will not start up. Once Reserve Breaker is closed

Always On UPS Systems Inc 39 3CC Board Fault UPS will not start-up. Rectifer disabled. No DC Bus

Always On UPS Systems Inc 40 3R Board Fault No front panel display and no communications. UPS star

Always On UPS Systems Inc 41 3T Board Fault AUPS system initializes ok. Once inverter attempts to

Always On UPS Systems Inc 42 3T Board Fault B UPS system initializes ok. Once inverter attempts to

Always On UPS Systems Inc 43 Inverter Module Fault UPS system initializes ok. When DC Buss is esta

Always On UPS Systems Inc 44 Static Switch Module Fault UPS starts up to full operation. When inve

Always On UPS Systems Inc 45 18. BATTERY CABINET The battery cabinets have been designed with the same style and appearance as the UPS cabine

Always On UPS Systems Inc 46 Figure 18.2 SC and SE Cabinet Mechanical Drawing

Always On UPS Systems Inc 2 2. GENERAL BLOCK DIAGRAMNormal Operation: The rectifier/charger converts the supplied AC power into DC (bus) power,

Always On UPS Systems Inc 47 ++++++++++++++LOWER THREE TRAYS(NOTE: BOTTOM TRAYHAS ONLY 7 BATTERIES)TOP TRAYAlways "On" UPS SystemsBA

Always On UPS Systems Inc 48 ++++POS NEG125ABREAKERTOTAL: 348VDC / 60AFILE: BATTERY CAB A - 0002DATE: 050112BATTERY CAB A BATTERY INTERCONNECT

Always On UPS Systems Inc 49 TOTAL: 348VDC / 250A+++++++POS125ABREAKERNEG125ABREAKER+VERSION: V1.0BATTERY CAB B BATTERY INTERCONNECT WIRING C

Always On UPS Systems Inc 50 ++++++++++++++TRAYS 2,3,6,7NOTE: TRAY 1 (BOTTOM TRAY) & TRAY 8 (TOP TRAY)HAVE ONLY 7 BATTERIES EACHTRAY 4 &a

Always On UPS Systems Inc 51 Always "On" UPS SystemsKelowna B.C.alwaysonups.comPH:877-259-2976Reproduction and/or use without expre

Always On UPS Systems Inc 52 Always "On" UPS SystemsKelowna B.C.alwaysonups.comPH:877-259-2976Reproduction and/or use without expres

Always On UPS Systems Inc 53 18.1. Battery Runtime Charts Load 5000VA 10,000VA 15,000VA 20,000VA 30,000VAModel NX-ALW-9-1 25

Always On UPS Systems Inc 54 19. MAIN CONTROL (3A PCB) The Main Control PCB monitors and controls all the major components within the UPS syst

Always On UPS Systems Inc 55 LED A1 LED A2 LED A3 LED A4 LED A5 LED A6 Picture 19.1 3A PCB (Main Control)

Always On UPS Systems Inc 56 Table 19.1 LED Operation for the 3A PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LEDLED IlluminatedDescription LE

Always On UPS Systems Inc 3 3. 6 PULSE RECTIFIER TOPOLOGY DRAWING Figure 3.1 Always “On” UPS Systems Topology - 3 Phase UPS 6 Pulse Rectifier

Always On UPS Systems Inc 57 20. POWER SUPPLY (3B PCB) This is the main power supply for the PCB and is the interface between the Main Control

Always On UPS Systems Inc 58 Table 20.1 LED Operation for the 3B PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LEDLED Ill

Always On UPS Systems Inc 59 21. RECTIFIER CONTROL CIRCUIT (3C PCB) This PCB acts as the interface between the Main Control PCB and the Recti

Always On UPS Systems Inc 60 Table 21.1 LED Operation for the 3C PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LED LED Il

Always On UPS Systems Inc 61 22. INVERTER PHASE CONTROL (3T PCB) This PCB acts as the interface between the Main Control PCB and each phase of

Always On UPS Systems Inc 62 Table 22.1 LED Operation for the 3T PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LEDLED Ill

Always On UPS Systems Inc 63 23. COMMUNICATIONS INTERFACE (3R PCB) This is the local and remote Operator interface for the entire UPS system.

Always On UPS Systems Inc 64 Table 23.1 LED Operation for the 3T PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LEDLED Ill

Always On UPS Systems Inc 65 24. WARNING LED’S AND SWITCHES (3W PCB) 25. LCD DISPLAY 26. MIMIC DIAGRAM (3L PCB) 27. STATUS LED’S AND AUDIB

Always On UPS Systems Inc 66 28. RECTIFIER MODULE This is a pluggable module which contains the high power devices for the rectifier / charger.

Always On UPS Systems Inc 4 4. 12 PULSE RECTIFIER TOPOLOGY DRAWING Figure 4.1 Always “On” UPS Systems Topology - 3 Phase UPS 12 Pulse Rectifie

Always On UPS Systems Inc 67 Figure 28.2 Location of Rectifier Module in the 80kVA to 160kVA UPS RECTIFIER MODULE

Always On UPS Systems Inc 68 6-pulse Rectifier Static Switch R Phase S Phase T Phase Picture 28.1 Picture of Rectifi

Always On UPS Systems Inc 69 Table 28.1 Operation for the 3S PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LED LED Illumination DescriptionLED I

Always On UPS Systems Inc 70 29. INVERTER MODULE This is a pluggable module which contains the high power devices for the inverter. The invert

Always On UPS Systems Inc 71 Figure 29.2 Location of Inverter Modules in the 10kVA to 60kVA UPS system T INVERTER MODULE S INVERTER MODULE R

Always On UPS Systems Inc 72 LED G1 S phase T phase R phase Picture 29.1 Picture of the Inverter Module from a 10k

Always On UPS Systems Inc 73 Table 29.1 LED Operation for the 3G PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LEDLED Illumination Description L

Always On UPS Systems Inc 74 30. STATIC SWITCH This is a pluggable module, which is either part of the Rectifier Module (for the 10kVA to 60kVA

Always On UPS Systems Inc 75 Figure 30.2 Location of Static Switch Module in the 80kVA to 160kVA UPS STATIC SWITCH MODULE

Always On UPS Systems Inc 76 6-pulse Rectifier Static Switch R Phase S Phase T Phase Picture 30.1 Picture of Static Switch and Rectifier Module

Always On UPS Systems Inc 5 5. RECTIFIER The main function of a rectifier is to convert the AC input power to DC power. The DC power is then us

Always On UPS Systems Inc 77 Table 30.1 LED Operation for the 3P PCB NORMAL ABNORMAL PCB FUNCTION LOCATION PCB LED LED IlluminationDescription L

Always On UPS Systems Inc 78 31. AUXILIARY POWER SUPPLY Designed as a secondary and redundant power supply to the one located within the UPS m

Always On UPS Systems Inc 79 Figure 31.2 Front view of system with door closedFigure 31.3 Front view of system with door open 1. Turn o

Always On UPS Systems Inc 80 CNT2CNA11CNB6CNA7CNT3 GCNT4 R CNT3 CNT4 R G CNT3CNT5CNT5CNA4CNT1CNA10CNA9CNT2CNT1CNT2CNT1CNA8CNC3 CNC4CNC1CNB2CNB1C

Always On UPS Systems Inc 81 ACO/PSS O/P O/PPSLOWER FANPS R S TCAPCAPCAPOSIRIN ITIS OR B+OT ON B-Figure 31.5 Front view of system with door open

Always On UPS Systems Inc 82 Figure 31.6 Exploded view of system behind the PCB Module

Always On UPS Systems Inc 83 Figure 31.7 Layo

Always On UPS Systems Inc 84 Figure 31.10 Front view of system with door closed

Always On UPS Systems Inc 85 FROM INVERTER T O BYPASS PROCEDURE: 1. PUSH T HE INVERTER OFF SWITCH (RIGHT & MIDD LE OF IN VERT ER

Always On UPS Systems Inc 86 Figure 31.12 Front view of system with door open and PCB Module door open

Always On UPS Systems Inc 6 Figure 5.2 Detailed drawing of Rectifier System

Always On UPS Systems Inc 87 Figure 31.13 Front view of system with door open, PCB Module fully open and terminal strip cover off

Always On UPS Systems Inc 88 Figure 31.14 Exploded view of system behind the PCB Module

Always On UPS Systems Inc 89 Figure 31.15 Layout view of the left side of the system with the panel off Figure 31.16 Layout view of the right s

Always On UPS Systems Inc 90 Figure 31.17 Layout view of the back of the system with the panel off

Always On UPS Systems Inc Section A SINGLE LINE DRAWINGS

Always On UPS Systems Inc Always “On” UPS Systems Single line drawing of UPS System “NX” Series (Generic) UPS Imax (A) / NFB (A) Rating

Always On UPS Systems Inc Always “On” UPS Systems Single line drawing of UPS System and External Bypass System (Generic) NFB - 3P 4W+GRECTBAT

Always On UPS Systems Inc Section B PARTS LIST FOR ALL SYSTEMS Recommended Spare Parts for the NX Series UPS Systems Item Part No. Name

Always On UPS Systems Inc 32. CONTACT INFORMATION 32.1. Additional Purchases or Upgrades Always “On” UPS Systems Inc. Bldg 1 – 150 Campion