Always On NX-Series User manual

M0704_NX_Series_Service_Manual V2.17 2012-06-12
NX-Series
Three Phase UPS System
GES-103NX – GES-1603NX
10 kVA – 160 kVA
Service Manual

Always On UPS Systems
M0704_NX_Series_Service_Manual V2.17 2012-06-12 i

Always On UPS Systems
M0704_NX_Series_Service_Manual V2.17 2012-06-12 ii
Table of Contents
1. SAFETY INSTRUCTIONS..................................................................................................................... 1
2. GENERAL BLOCK DIAGRAM ............................................................................................................ 2
3. 6 PULSE RECTIFIER TOPOLOGY DRAWING ................................................................................ 3
4. 12 PULSE RECTIFIER TOPOLOGY DRAWING.............................................................................. 4
5. RECTIFIER .............................................................................................................................................. 5
6. INVERTER............................................................................................................................................... 7
7. STATIC SWITCH.................................................................................................................................... 9
8. INTER-PCB DIAGRAM........................................................................................................................ 11
9. PCB MODULE....................................................................................................................................... 12
10. AUXILARY POWER SUPPLY............................................................................................................ 13
11. STARTUP PROCEDURES ................................................................................................................. 14
11.1. System start up (from complete shutdown)....................................................................................................................14
11.2. From Manual Bypass To Inverter Procedure..................................................................................................................15
12. UPS SHUTDOWN PROCEDURES ................................................................................................... 17
12.1. Complete UPS shut down procedure................................................................................................................................17
12.2. From Inverter To Manual Bypass Procedure..................................................................................................................17
13. LCD DISPLAY AND LED DESCRIPTION........................................................................................ 19
14. THE LCD DISPLAY.............................................................................................................................. 24
14.1. Menu 0 – Main Menu ..............................................................................................................................................................24
14.2. Menu 1 – Select Menu............................................................................................................................................................25
14.3. Menu 2 – Status Warning Menu..........................................................................................................................................26
14.4. Menu 3 – Real Time Data Menu...........................................................................................................................................27
14.5. Menu 4 – Historical Event Menu.........................................................................................................................................28
14.6. Menu 5 – Parameter Setting Menu.....................................................................................................................................29
14.7. Menu 6 – Rectifier Data Menu..............................................................................................................................................30
14.8. Menu 7 – Reserve Data Menu..............................................................................................................................................30
14.9. Menu 8 – Output Data Menu ................................................................................................................................................31
14.10. Menu 9 – Other Data Menu...................................................................................................................................................31
14.11. Menu 10 – Boost Charge Setting Menu............................................................................................................................32
14.12. Menu 11 – Data Time Setting Menu...................................................................................................................................34
14.13. Menu 12 – Other Setting Menu............................................................................................................................................34
15. STATUS INDICATOR TABLE............................................................................................................ 35
16. BOARD LED INDICATION TABLE................................................................................................... 36
17. BOARD FAULT DIAGRAMS.............................................................................................................. 37
18. BATTERY CABINET............................................................................................................................ 45
18.1. Battery Runtime Charts.........................................................................................................................................................53
19. MAIN CONTROL (3A PCB)................................................................................................................ 54
20. POWER SUPPLY (3B PCB)............................................................................................................... 57
21. RECTIFIER CONTROL CIRCUIT (3C PCB).................................................................................... 59
22. INVERTER PHASE CONTROL (3T PCB)........................................................................................ 61
23. COMMUNICATIONS INTERFACE (3R PCB).................................................................................. 63
24. WARNING LED’S AND SWITCHES (3W PCB).............................................................................. 65
25. LCD DISPLAY....................................................................................................................................... 65
26. MIMIC DIAGRAM (3L PCB)................................................................................................................ 65
27. STATUS LED’S AND AUDIBLE ALARM (3AG PCB)................................................................... 65
28. RECTIFIER MODULE.......................................................................................................................... 66
29. INVERTER MODULE........................................................................................................................... 70
30. STATIC SWITCH.................................................................................................................................. 74
31. AUXILIARY POWER SUPPLY........................................................................................................... 78
Section A SINGLE LINE DRAWINGS.......................................................................................................... 91
32. CONTACT INFORMATION................................................................................................................. 94
32.1. Additional Purchases or Upgrades ...................................................................................................................................94
32.2. QA / Warranty Questions......................................................................................................................................................94
32.3. Software Questions................................................................................................................................................................94

M0704_NX_Series_Service_Manual V2.17 2012-06-12 1
1. SAFETY INSTRUCTIONS
This Safety Notice is addressed to the Always On customer engineers who
perform maintenance of the Uninterruptible Power Supply (UPS) systems.
Electrical Safety
•Maintenance work to be preformed by factory trained customer engineers or
qualified personnel. Extremely dangerous voltage levels can exist within the
UPS system; extreme caution must be used.
•Ensure system is in maintenance bypass mode or external wrap-around bypass
mode before work is started.
•This manual is designed as an aid tool in diagnosing problems that may arise.
Always On does not assume responsibility if information causes injuries.
•Apart from the front door, do not open any other part of the UPS without
consulting the factory first. Before removing the protection screens, be sure that
the unit is completely powered off.
•Be aware that dangerous voltage can be supplied by the internal battery or
electrolytic capacitors.
•When system is in bypass mode and all fuses have been opened, dangerous
voltages may exist within the UPS system. Use extreme caution when
exchanging boards and working inside the unit.

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2. GENERAL BLOCK DIAGRAM
Normal Operation: The rectifier/charger converts the supplied AC power into DC (bus) power, which is then supplied to the
inverter and the battery charger. The DC to AC inverter then supplies continuous, noise free AC power to the critical loads. The
inverter output is synchronized with the bypass AC power source provided that the bypass AC power source is within the specified
frequency range.
Back-up Mode: As the batteries are connected to the DC bus they supply energy to the inverter via this DC bus, the AC power will
remain constant and continuous without interruption to the loads when the AC fails or falls out side of the operating parameters.
Upon return of the supplied AC input power the UPS the rectifier will automatically assume the DC load (charger, inverter) from the
batteries. The UPS will simultaneously supply power to the inverter and the battery charger to replenish the batteries.
Reserve Mode: If the inverter is placed into an abnormal condition, such as over temperature, short circuit, abnormal output voltage
or is overloaded for a period which exceeds the inverter’s limits, the inverter will automatically shutdown in order to protect itself. If
the AC utility power is within the normal parameters, the static switch will automatically transfer the load to the reserve (utility)
source without interruption of the AC output.
Maintenance Bypass Mode: During UPS maintenance procedures or battery replacement, the loads cannot be interrupted, and as
such the technician needs to turn off the inverter switch, close the bypass breaker and then open the rectifier and reserve (utility)
breakers. The UPS is now running in Maintenance By-pass mode supplying utility AC to the loads. The AC output will not be
interrupted during the manual bypass transfer procedure because the maintenance bypass switch is designed to supply continuous
power to the loads.
Figure 2.1
General Block Diagram

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3. 6 PULSE RECTIFIER TOPOLOGY DRAWING
Figure 3.1
Always On UPS Systems
Topology - 3 Phase UPS 6 Pulse Rectifier
Input: 3PH-4W Output: 3PH-4W
Zero Degrees Phase Shift
INPUT
FIL
N
T
S
INPUT
R
BAT. NEG.
BAT. POS.
FILTER
AUTO-TRANS
RECV
RECTIFIER FILTER
RESV
P.S.
RESERVE
BYPASS
R
STATIC SWITCH
INVERTER
6 PULSE RECTIFIER
FIL
OPV
N
T
S
STATIC SWITCH
OUTPUT
P.S.

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4. 12 PULSE RECTIFIER TOPOLOGY DRAWING
Figure 4.1
Always On UPS Systems
Topology - 3 Phase UPS 12 Pulse Rectifier
Input: 3PH-4W Output: 3PH-4W
Zero Degrees Phase Shift
N
T
S
OUTPUT
R
12 PULSE RECTIFIER
RESV
R
T
N
FIL
S
INPUT
INPUT
BAT. NEG.
BAT. POS.
FILTER RECV
AUTO-TRANS
FILTER
RECTIFIER
RESERVE P.S.
BYPASS
STATIC SWITCH
INVERTER
FIL
OPV
STATIC SWITCH
P.S.

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5. RECTIFIER
The main function of a rectifier is to convert the AC input power to DC power. The DC
power is then used to charge the batteries, supply the DC bus, which in turn supplies
the inverter.
The rectifier design used in the 10kVA to 60kVA UPS’s include a 6-pulse full controlled
rectifier. Power Factor Correction (PFC) has been added to maintain a high input power
factor, independent of the load power factor. This 6 pulse rectifier smoothes the current
waveform and reduces the harmonic content reflected back to the utility. The control
circuit regulates the DC bus to within 1% of the nominal voltage. Soft walk-in circuitry
(approximately 20 seconds) and current limiting circuitry are used to prevent over
current or surge currents from affecting any part of the UPS system.
Additionally, over and under-voltage protection is added to improve reliability and to
shutdown the rectifier in the event of abnormal conditions. The DC bus is adjustable to
allow for different types and capacities of batteries. The power components used within
the rectifier are specially designed and selected to handle extreme ranges of high
voltage and high current (–25% to +25%).
In order to further improve the power factor and reduce harmonic current drawn by the
rectifier, Always On UPS’s above 80kVA incorporate a 12-pulse full controlled rectifier
(also available as an option on the 10 to 60kVA UPS’s) to reduce the total harmonic
current to less than 12%. A phase shift transformer is added with input inductors to
achieve this higher level of performance while maintaining our high input power factor.
An optional 5th harmonic filter can be added to further reduce the total harmonic
distortion current to less than 9%.
The total harmonic current can be decreased to less than 7% with the inclusion of the
18-pulse full controlled rectifier. This option is recommended for the larger (80kVA and
up) UPS systems.
Figure 5.1
Rectifier Block Dia
g
ram

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Figure 5.2
Detailed drawin
g
of Rectifier

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6. INVERTER
The inverter is composed of IGBT’s, inductors, capacitors, highly efficient filters, control
circuitry and protection circuitry. This inverter inverts the DC power received on the DC
bus to isolated, noise-free AC power, which is then supplied to the critical loads. Our
PWM wave generator is switching at a higher frequency well above the human audible
range.
The Voltage regulating circuitry limits the output voltage variation to within 1% of the
nominal voltage and special compensation circuitry has been added to eliminate output
distortion. Every component is oversized to accept a wide DC input range (from 285 to
420VDC), allowing the output waveform to remain sinusoidal throughout the entire
range. With the aid of dynamic feedback loop circuits the inverter maintains a true sine
wave output, even if non-linear loads are connected.
The system is designed and incorporates an independent inverter per phase. These
inverters are totally independent of each other preventing the possibility of cascading
failures while allowing the user to connect loads to adjacent inverters without affecting
the other inverters. This connectivity provides high-end voltage regulation under a 100%
unbalanced load situation.
The IGBT is operated in its optimal condition to obtain maximum efficiency, keeping
electrical costs to a minimum.
Usually, most UPS failures are a result of inverter failures. To prevent this occurrence,
Always On has included redundant protection circuitry to protect the inverter and
increase its reliability. To enhance this protection we have also added a high efficiency
filter designed to suppress the spikes and noise that can be reflected from the attached
loads back into the UPS system. Specifying oversized and high quality components,
additional semi-conductor fuses and allowing for good ventilation systems within further
increase reliability.
Figure 6.1
Inverter La
y
out