Eaton Callisto 5PX RT G2 User manual

Title
Callisto 5PX G2 Service Manual
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Standard service
manual
5PX Callisto RT

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Item
Catalog Nb
Region
Power Rating
Type
Voltage
default
PQNA PN
1
5PX1000IRT2UG2
EMEA
1000VA/1000W
RT
230V
9210-53050
2
5PX1500IRT2UG2
EMEA
1500VA/1500W
RT
230V
9210-63060
3
5PX2200IRT2UG2
EMEA
2200VA/2200W
RT
230V
9210-73043
4
5PX2200IRT3UG2
EMEA
2200VA/2200W
RT
230V
9210-73037
5
5PX3000IRT2UG2
EMEA
3000VA/3000W
RT
230V
9210-83120
6
5PX3000IRT3UG2
EMEA
3000VA/3000W
RT
230V
9210-83121
7
5PXEBM48RT2UG2
EMEA
48V*9AH
RT
230V
9000-1426
8
5PXEBM72RT2UG2
EMEA
72V*9AH
RT
230V
9000-1427
9
5PXEBM72RT3UG2
EMEA
72V*9AH
RT
230V
9000-1428
10
5PX1500IRT2UTHG2
APAC
1500VA/1500W
RT
230V
9210-63062
11
5PX2200IRT2UTHG2
APAC
2200VA/2200W
RT
230V
9210-73039
12
5PX3000IRT2UTHG2
APAC
3000VA/3000W
RT
230V
9210-83123
13
5PX1500IRT2UAUG2
APAC
1500VA/1500W
RT
240V
9210-63063
14
5PX2000IRT2UAUG2
APAC
2000VA/2000W
RT
240V
9210-73040
15
5PX2200IRT2UAUG2
APAC
2200VA/2200W
RT
240V
9210-73042
16
5PX2200IRT3UAUG2
APAC
2200VA/2200W
RT
240V
9210-73041
17
5PX3000IRT2UAUG2
APAC
3000VA/3000W
RT
240V
9210-83124
18
5PX3000IRT3UAUG2
APAC
3000VA/3000W
RT
240V
9210-83125
19
5PX1500HRTG2
AMER
1500VA/1500W
RT
208V
9210-6502
20
5PX2200HRTG2
AMER
2200VA/2200W
RT
208V
9210-7504
21
5PX3000HRTG2
AMER
3000VA/3000W
RT
208V
9210-8512
22
5PX3000HRTNG2
AMER
3000VA/3000W
RT
208V
9210-8513
23
5PX1000RTG2
AMER
1000VA/1000W
RT
120V
9210-5170
24
5PX1000RTNG2
AMER
1000VA/1000W
RT
120V
9210-5171
25
5PX1500RTG2
AMER
1440VA/1440W
RT
120V
9210-6173
26
5PX1500RTNG2
AMER
1440VA/1440W
RT
120V
9210-6174
27
5PX2000RTG2
AMER
1950VA/1950W
RT
120V
9210-7135
28
5PX2000RTNG2
AMER
1950VA/1950W
RT
120V
9210-7136
28
5PX2000RT3UNG2
AMER
1950VA/1950W
RT
120V
9210-7137
30
5PX3000RTG2
AMER
3000VA/3000W
RT
120V
9210-8137
31
5PX3000RTNG2
AMER
3000VA/3000W
RT
120V
9210-8138
32
5PX3000RT3UNG2
AMER
3000VA/3000W
RT
120V
9210-8139
33
5PXEBM48RTG2
AMER
48V*9AH
RT
120V
9000-1429
34
5PXEBM72RTG2
AMER
72V*9AH
RT
120V
9000-1430
35
5PXEBM72RT3UAG2
AMER
72V*9AH
RT
120V
9000-1431
Note: BSMI Model are integrated into US LV model

Title
Callisto 5PX G2 Service Manual
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Rev
Date
Notes
Updater name
Approved
00
2021-7-5
Original
Chase Fang
00
2021-7-12
Update electrical data
Legeng Xu
00
2021-7-13
Update disassembly part
Chase Fang
01
2021-8-27
Update
Chase Fang

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Summary
1 Introduction...................................................................5
1.1 Purpose of the document.................................................................................. 5
1.2 Analysis process............................................................................................... 6
1.3 Schematic of the UPS........................................................................................ 7
2 Security........................................................................10
3 Interconnection diagram of products by power
rating...............................................................................12
3.1 UPS interconnection diagram..........................................................................12
3.2 UPS interconnection Actual.............................................................................15
3.3 EBM interconnection diagram.........................................................................21
4 Diagrams showing the location of each principle
function on the circuit and the assembled board .......22
4.1 PCBA list ...........................................................................................................22
4.2 PSDR and IO schematic...................................................................................23
4.2.1 PSDR and IO board ............................................................................ 34
4.3 CNTL..................................................................................................................35
4.4 COMM & EPO....................................................................................................36
4.5 LCD ....................................................................................................................37
5 Failure analysis...........................................................38
5.1 Alarms ...............................................................................................................38
5.2 Fault...................................................................................................................38
5.3 Location of the faulty function or component................................................39
5.4 LCD Fault and Alarm messages......................................................................51
6 Disassembly................................................................52
7 Component level Tests by function and by board...57

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1 Introduction
1.1 Purpose of the document
This service manual will guide technicians to diagnose, troubleshoot and
repair UPS products.
Depending on the countries, the extent of the repair of the product can be to
find the failed item or the failed component. This can reduce repair costs.
This template allows the definition of the content of a service manual.
It allows R&D to provide a manual that meets the expectations of users who
include:
- Technical support
- Technician after sales
- Production( repair station)
- Repair personnel
- …

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1.2 Analysis process
Global process showing the flow from the broken product to the test and repair
steps and back to the customer

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1.3 Schematic of the UPS
Goal: Identify the Board references by product model / rating
1.3.1 UPS System Block Diagram
1000~1500VA Block Diagram
2000~3000VA Block Diagram

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1.3.2 1000~1500VA Topology

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1.3.3 2000~3000VA Topology

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2 Security
Goal : To protect against electrical hazards
•Do not make adjustments to the product unless an authorized person is
present.
•There is a risk of presence of AC voltage even if the mains power is no longer
connected.
•Switch off and disconnect the UPS from the mains power before removing the
cover(s).
•Disconnect EBM and the internal batteries before removing the cover(s)
•To avoid injury, do not touch any connections or components when the UPS is
turned on.
•Discharge battery input capacitors with discharge tool as below figure before
disassembling PSDR or any internal connection wires
Discharge
Bat
capacitor
W1 W2

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•Please check the insulation of all wires, connectors and screws after opening
the UPS
•Before restarting the UPS :
oCheck the input (voltage and frequency) before commissioning.
oCheck the polarity of the battery connections and the state of all internal
wiring and connectors.
oClose all cover(s)

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3 Interconnection diagram of products by
power rating.
Goal: To know the interconnections and connectors between the boards for
different power ratings of products.
3.1 UPS interconnection diagram
EPO
BOARD
COMM
BOARD
PSDR BOARD
Internal Battery
LCD CNTL BOARD
IP-L
IP-N
FAN USB
RS232
Segment
1
Segment
2
Input
Socket
EBM
Output
Socket
CARD
Box
RJ45
OP-L
OP-N
Segment
+
-
+
-
EPO & Dry in
Dry out
+
-For Internal Lithium battery
communication
1
2
3
4
5
6
8
9
7
10
11
12
13
14
15
17
18
19
20
21
NTC BAT
NTC HS
22
23
Main
Fig3.1: 1000~1500VA (230V) interconnection Block

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EPO
BOARD
COMM
BOARD
PSDR BOARD
Internal Battery
LCD CNTL BOARD
IP-L
IP-N
FAN USB
RS232
Segment
1
Segment
2
Input
Socket
EBM
Output
Socket
CARD
Box
RJ45
OP-L
OP-N
Segment
+
-
+
-
EPO &Dry in
Dry out
+
-For Internal Lithium battery
communication
1
23
4
5
6
8
9
7
10
11
12
13
14
15
17
18
19
20
21
NTC BAT
NTC HS
22
23
Main
5A
6A
6B
6C
7A
8A
Fig3.2: 1000~1500VA (120V) interconnection Block
I/O
BOARD
EPO
BOARD
COMM
BOARD
PSDR BOARD
Internal Battery
LCD CNTL BOARD
IP-L
IP-N
FAN1
USB
RS232
Segment 1
Segment 2
Input
Socket
EBM
Output
Socket
CARD
Box
RJ45
OP-L
OP-N
+
-
+
-
EPO &Dry in
Dry out
+
-For Internal Lithium battery
communication
1
2
3
4
5
6
8
9
7
10
11
12
13
14
15
17
18
19
20
21
NTC BAT
NTC HS
22
23
INV Output
Charger Input
24
25
26
28
FAN2
27
Segment Main
C19
Fig3.3: 2000~3000VA (230V) interconnection Block

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I/O
BOARD
EPO
BOARD
COMM
BOARD
PSDR BOARD
Internal Battery
LCD CNTL BOARD
IP-L
IP-N
FAN1
USB
RS232
Segment 1
Segment 2
Input
Socket
EBM
Output
Socket
CARD
Box
RJ45
OP-L
OP-N
+
-
+
-
EPO &Dry in
Dry out
+
-For Internal Lithium battery
communication
1
2
3
4
5
6
8 97
10
11
12
13
14
15
17
18
19
20
21
NTC BAT
NTC HS
22
23
INV Output
Charger Input
24
25
26
28
FAN2
27
Segment
Main
5A
8A
7A
Fig3.4: 2000~3000VA (120V) interconnection Block

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3.2 UPS interconnection Actual
HV models:
1000-1500VA

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2000-3000VA 2U

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2200-3000VA 3U

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LV models:
1000-1500VA

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2000-3000VA 2U

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2000-3000VA 3U