Eaton POWERWARE Plus 18 User manual

.._ ~.. . .,

Table of Contents
chapter 1
.............................................................
System Overview
....................................................
‘;-:
1.1 SYSTEM DESCRIFTION
......... ...............................
1.2 MODES OF OPERATION
l-l
....................................... l-2
1.3 MODES OF OPBRAl’ION/ALARMs
.............................. l-3
NormalMode
........................ .......................... l-3
GnBatteryMode..
............................................. l-3
overload . ................................ .....................
1-3
Bypass Mode
.................................................. l-3
Emergency Power Off@PO)
.................. ................... l-3
1.4 SPECIFICATIONS
......................................... .... l-8
1.4.1 Ratings
................................................. l-8
1.4.2
Input
................................................... l-8
1.4.3 system Output
........................................... l-8
1.4.4 Bnvimnmental
........... ................................ l-9
1.45 Battery
................................................
l-10
1.4.6 Dimensions
....... ..................................... l-10
Chapter 2
Safety
............................................................. 2-l
..............................................................
2.1 GENERAL SAFEIY CONSIDERATIONS’
2-l
.......................... 2-l
2.1.1
......
2- 1
2.1.2 Tools, Equipment and Expendable Field Service Supplies GuxxalSafetyRules
...............
2.2ENvfRoNMENrALsAFErY..
.................... 2-l
.............. .................... 2-l
2.3ELECTRICALSAFEI’Y..
.............. ......................... 2-2
2.4 MECHANIW MFJ3Y . ...................................... 2-3
2sEYBsAFETY
.; .......... .. ................................... 2-3
2.6 UPS SAFElY
................................................. 2-4
2.6.1 Qxrating l5wironmknt
.................................... 2-4
2.6.2 NcmalOpmuion
........................................ 24
2.6.3 Maintmancc/service ...................................... 24
2.6.4 Battaies
................................................ 2-5
2.7SlTBSAFBTY.. ........ .......................................
2-5
2.8 SUMMARY
................................................... 2-6
t$u2~llt.rol Pmcedure
............................................
2-7
.......................................................... 2-7
2.9 ELBCTROSTATIC DISCHARGE @SD) PROCEDURE AND EQUIPMENT
REQ- .
............ ..... ............. .... ........... 2-7
2.9.1 Purpose............:.:..........; .......................
2-7
2.9.2 scope .................................................. 2-7
2.9.3 Responsibility
. ............................. ............. 2-7

Table of Contents Plus 18
2.9.4
Applicable Documents and Materials . 2-7
2.9.5 IWinitionS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._ 2-7
2.9.6 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-g
2.9.7 Removal of Boards . . . . . . . ..I..........................
2-9
2.9.8 PackagingofBoards . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . 2-9
2.10 GENERAL GUIDELINES FOR ESD PROTECTION . . ., . . . . . . . . . 2-10
Cbapter3
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“;:
Installation and Intial Startup
.d.......................................
3.1 UNPACIUNG lNSl’RLJCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-l
3.2 INSTALLATION (CABINET JOWING) . . . . . . . . . . . . . . . . . . . . . _ . . . _ .
3-l
3.3 INSTALLATION OF OPTIONS (lF APPLICABLE) . . . . . . . . . . . . . . . . .
3-2
3.4CONNJXTIONOFUPS .:. ..:~..;.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.5 SYSTEM START-UP AND SITE ACCEPTANCE PROCEDURE . _ . . . _ . .
3-3
3.5 SYSTEM START-UP AND SlTE ACCEPTANCE CHECK SHEEI’ . . . . 3-4
Chapter4
System Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-l
4.1 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-l
4.1.1 OpenuiugGmtroLl . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-l
4.1.2~~~Lights............................................ 4-l
4.2FRONTPANELDISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3EXPLANKI’IONOFMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3.1 UI’SStatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3.2 MetersMenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3.3 AlarmQueue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3.4 ActiveAlarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.3.5 PaSWord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.3.6 SystemSet-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37
4.3.7 SelectType.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37
4.3.8 H.W.Mod&s
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.3.9 SynCRange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-37
4.3.10 . ..AdjOutVolts . . . . . .-..: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.3.11
commsetup....;.................................... 4-38
4.3.12 Relay Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.3.13 SetLaIlguage . . .i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.3.14 Set TmeJDate . .
..,:..................................
4-38
4.3.15 ConfrastAdjust
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-38
4.3.16 HornVolume
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
4.3,17 Clear Alarm Queue
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.3.18
SetUscrFw......................................... 4-39
4.3.19 BaaayTypc.........:............................... 4-39
4.4SETTYPE(FULLFEATLJRE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4.5 SYSTEM START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-40
4.6 SYSTEM SHUT-DOWN (WITHOUT BYPASS) . . . . . . . . . . . . . . . . . . . .
440
ii
EXIDE ELECTRONICS CONFIDENTIAL

PIUS 18
Table of Conrenrs
4.7 SYSTEM SHUT-DOWN (WlTH BYPASS)
........................
4.8MAINTENANCEBYPASS 4-40
.....................................
4-40
chapter 5 ... ..... ..: ..................................................
Functional Description
...............................................
5.1REClmERFRu
“;-:
................................ .............
5.2lNvERTERFRu..
5-l
............................................. 5-l
5.3 POWER CONVERSION
Circuit Board Descriptions
........................................ 5-2
............................................
5.4AlAZANDAZA2GATEDRIVEBOARD
5-4
..........................
5-4
5.5 AlA POWER SUPPLY BOARD
................................. 5-5
5.6 A8Al BYPASS CONTROL BOARD
............................... 5-6
5.7A3A2FuLLFEAmRE
FRONT PANEL BOARD
..................... 5-8
5.7.1 Front Panel Interface Board
.... ............................. 5-a
5.7.1.1 Relay Driven
......................................... 5-8
5.7.1.2 DB-25 Co~ector
.....................................
5-8
5.7.1.3 RJ-11 Interface
....................................... 5-9
5.7.1.4 Power consumption
.................................... 5-9
5.7.2 Daughterboard
............................................ 5-9
5.7.2.1 Isolated Power Supply
.................................. 5-9
5.7.2.2 Relay Drivers
........................................ 5-10
5.7.2.3 26-Pin Header Comector
.......... .................... 5-10
5.7.3 Front Control Panel Interface
..............................
.5-11
5.8 EXFANDER INTERFACE BOARD
............................... 5-12
5.8.1 Isolated Power Supply
....................................
5-12
5.8.2 Relay Drivers
...........................................
5-13
5.8.3 RS-232 Sigials
.........................................
5-13
5.8.4 AMOOExpansion .
’ .......................................
5-13
5.8.5 26-Pin Header cOM&tk
................................. 5-14
5.8.6 Front Control Paqel Iatedak (Expander Intedce)
.............
5- 14
5.8.6.1PowerComumption..
................................. 5-14
5.9 AlAl REcTlFIw CONTROL BOARD
........................... 5-16
5.10A2Al SINGLE AND THREE PHASE INVERTER CONTROL BOARD 5-16
Chapter6
options
............................................................. 6-l
............................................................ 6-l
6.1OPTIONS ..... ................................................. 6-l
6.1.1
Extended Battery Cabinets
.................................. 6-l
6.1.2 Output Power Distribution
.................................. 6-2
6.1.3 Communications Intedacc
.................................. 6-5
6.1.4 L.ocal Emergency Power Off
..... . .......................... 6-5
6.1.5 Remote Emergency Power Off
...
............................ 6-5
6.1.6 LAN Relay Interface .
communications
.....................................
....................................................
6.2 RS-232 OPTION
22
............................................... 6-6
EXIDE ELECTRONICS CONFIDENTIAL
iii

Table of Contents Plus 18
6.2.1 Inmxiuction
............................................. 6-6
6.2.2 Communications Setup
....................................
6-6
6.2.3 TerminalMode
......................
6.23.1Met&Saecn.:.
.................... 6-10
...........
.
......................... 6-10
6.2.3.2 Active Alam&
.................... .................... 6-10
6.2.3.3 Alarm/bent Queue
............... .................... 6-10
6.2.3.4BatteryData..
....................................... 6-10
6.2.3.5 Mimic Screen
........................................ 6-10
6.2.3.6SetTmeandDate
.................................... 6-10
6.2.4 Printer Mode
...........................................
.6-11
6.2.4.1 Options Mode.
.......................................
.6-11
6.25ConfgurationScre-m
.....................................
..&I 1
6.25.1 Meters Screen.
........................................6-11
6.2.5.2AaiveAlarmsScreen
..................................
6-11
6.25.3 Alarm/Event Him-y Screen
........................... ..6-11
6.2.6 LosginsMode
..........................................
6-12
6.3 ASCII COMPUTER MODE
.....................................
6-14
6.3.1
DataBlockFormat..
......... ............................
6-15
6.3.1.1 JD Block (Sl)
........................................ 6-16
6.3.1.2 Alarm History Block (S2)
.............................. 6-16
6.3.1.3 Status Block (S3)
.....................................
6-16
6.3.1.4 Meter Block (S4)
.....................................
6-17
6.3.1.5AlamBlock(S5).
....................................
6-17
6.3.2 Binary Mode
...........................................
6-17
6.3.3 DateFormat
.........................................
6-18
6.3.4
TieFormat
.........................................
6-20
6.3.5 Ul’S to CPU Communications . .
......................... 620
6.3.6Da&BlockDesaiptions
....................................
6-21
6.3.6.1 ID Block
............................................
6-21
6.3.6.2hfcterMap
.......................................... 6-22
6.3.6.3AlmmMap..
.........................................
6-25
6.3.6.4 Alann Hiatmy Block
..................................
6-31
6.3.6.5 Stahu Biock
.........................................
6-32
6.3.7 Meter Block
................ ............................
6-33
6.3.7.1 Alarm Block
............ .........................
.,
636
6.4 RELAYSETUP
...........................................
6.4.1 Introduction . . .........................................
I
z:
6.4.2 MainRelayMamScnen.. .............................
6-38
iv
EXIDE ELECTRONICS CONFIDENTIAL

Plus 18 Figures
Figure 8-5 Output Panel “B”
...............................................
8-5
Figure 8-6 Output Panel “E”
...............................................
8-6
Figure%7OutputPanel“F”.
........................................ ......
8-7
Figure 8-8 output Panel "G"
...............................................
8-8
Figure 8-9 Output Panel “J”
...............................................
8-9
Figure 8-10 Output Panel "K"
.............................................
8-10
Figures-11OutputPanel“L”.
‘*’
.............. ...............................
8-11
Figure8-12OutputPanel”MM”and”~‘.
.................................
S-12
Figure 8-13 Output Panels “000”. “PPP”, and “QQQ”
........................
8-13
Figure 8-14 Top Assembly
...............................................
8-15
Figure 8-15 hverter Assembly
............................................
8-17
Figure 8-16 Inverter Assembly
............................................
8-18
Figure 8-17 Inverter Assembly
............................................
8-19
Figure 8-18 Inverter Assembly
............................................
8-21
Figure 8-19 Invertex Assembly .
..........................................
8-22
Figure 8-20 hater Assembly
............................................
8-23
Figure 8-21 Invertcr Assembly
...... -. . (.
.................................
8-24
Figure 8-22 I/O Assembly
................................................
8-26
Figme 8-23 I/O Assembly
................................................
8-27
Figure&24FullFeatureFrontPanelAssembly..
......................... ....
8-29
Figure 8-25 HV Transformer Cabinet Assembly
..............................
S-30
Figure 8-26 HV Transformer Cabinet Assembly
..............................
8-31
EXIDE ELECTRONICS CONFIDENTIAL
ix

Plus 18 Fiaures
a
a
I
a
Figure l-l Front View .................................................... 14
Figurel-2Rearwew ................. ...................................
l-5
Figurel-3TopView
..................................................... l-6
Figure1-4PowerFlow
................................................... l-7
Figure4-1FrontPanel ...................................................
4-3
Figure4-2MenuScreen-UPSStatus .......................................
w
Figure4-3MenuScreen-Meters..
.........................................
4-5
Figure4-4MenuSc.ree.n-AlarmQueue
..................................... 4-6
Figure4-5MenuScreen-ActiveAlarms ........... .........................
4-7
Figure4-6MenuScree.n-BatteryData
...................................... 4-8
Figure 4-7 Menu Scnxn - S.W. Versions
.....................................
es
Figure-4-8MenuScree.n-SystemSetup
....................................
4-10
Figure 4-9 Menu Screen - Select Type
.......................................
4-11
Figure4-lOMenuScreen-H.W.Modules
. ..I..
.............................
4-12
Figure4-llMenuScreen-SyncRange
.....................................
4-13
Figure4-12MenuScreen-Adj.OutVolts.. .................................
4-14
Figure4-13MenuScreen-CommSetup..
.................... .:
............
4-15
Figure4-14MemScreen-CommSetup-OutputMode ..
..................... 4-16
Figure4-15MenuScree.n-CommSetup-UOPortSetup
......................
4-17
Figure4-16MenuScreen-CommSetup-CustomizeUO ..
.................... 4-18
Figure 4-17 Menu Screen - Relay Setup ...................................
4-19
Figure4-18Menu~,~n-RelaySetup-Displaycurrentse.tup
................. 4-20
Figure4-19MenuScreen-RelaySetup-AS/400
............................ 4-21
Figure4-2OMenuScreen-Relay&up-NoveJl
............................. 4-22
Piie4-21MenuScxeen-RelaySetup-Default#l
.......................... 4-23
Figure4-22MenuStxeen-RelaySetup-Custom
............................ 4-24
Figure4-23MenuSm-RelaySetup-Custom -Relayl..
.................. 4-25
Figure4-24MmuScnxn-SetLanguage
................................... 4-26
Figure625MenuScretn-SetTie/Date..
.................................
4-27
Pigure4-26MenuScreen-ContrastAdj
.....................................
4-28
Figure 627 Menu Screen - Horn Volume
...................................
4-29
J3XIDEELECTRONICSCONFil.iE~ vii

Figures Plus 18
Figure4-28MenuScreen-ClearAhmQueue
.....
,
.........................
4-30
Figure4-29MenuScreen-SetUserPW.
...................................
4-31
Figure 4-30 Menu Screen - Battery Configuration
.............................
4-32
Fime 4-3 1 Menu Screen - Set Service PW.
.................................
4-33
Figure4-32MenuScreen-BattetyTiieCalibration
..........................
4-34
Figure4-33Me.nuScree.n-BattetyliuneF came.
............. ................
4-35
F&ore%lone-lineDiagram
... .:
.........................................
5-3
Figure 5-2 Gate Drive Board Block Diagram
..................................
54
Figure 5-3 Power Supply Board Block Diagram
...............................
5-5
Figure54AutoBypassControlBoardBlockDiagram..
........................ 5-7
Figure 6-l Output Panels ........... ......................................
6-3
Figure 6-2 Output Panels (continued)
........................... .............
64
Figure 6-3 Communications Menu Configurations
............................. 6-6
Figore64LocationofCommunicatiottConnector
............................. 6-7
Figure 6-5 Communications Pin Assignments
.................................
6-a
Figure64CommunicationsPinAssigntnen~
.................................
6-9
Figure 6-7 RMP Installation
........
.-ii> ..................................
6-47
Figure 6-8 High Voltage Transfcmnes Cabinet Installation.
......................
6-49
Figure 7-l Q5 (Battery SCR) Gate Signal ..... ................................
7-3
Figure 7-2 I/O Power Supply Board
......................................... 7-4
Figure 7-3 I/O Rectifier Control Board
.......... .............................
7-5
Figure74InvMerOutput
................................................
7-7
Figure 7-5 I/O Inverter Control Board
... ....................................
7-8
.Figure7-6I/OGate.DriveBourd
....... L..
...... .......................... 7-9
Figure 7-7 I/O FrontPanel Board ...........................................7-11
Figure. 7-8 I/O EPO Control Board
.........................................
7-13
Figure 7-9 I/O Bypass Control Board
.
:
.......................................
7-15
Figure 7-10 Rectifier FRU Connections
......................................
7-35
Figure 7-11 Inverter FRU Chmectia
........ ...............................
7-36
Figure 7-12 Switch Connections
........
;
....... ............................
7-37
Figure 8-1 Output Panel"C"
........................................ ....... 8-l
Figure8-2OutputPanel“H”.
.............................................. 8-2
Figure%3OutputPanel”A”.
...............................................
8-3
Figure8-4OutputPanel“D”.
.........................................
_, . 8-4
...
VIII
EXIDE ELECTRONICS CONFJDENTLU

0
a
)
6.5
6.6
6.4.2.1 Display Current Relay Configuration
..................... 6-39
6.4.2.2 AS/400 Configuration
......... I
........................
6-39
6.4.2.3 Novell Configuration
...... .:
..........................
6-41
6.4.2.4 AT &T/Default 1
.....................................
6-42
6.4.2.5 Custom Configuration
.................................
6-42
6.4.2.6 Relay Numbe.r Setup
..................................
6-43
REMOTE MONlTOR PANEL
................................
HIGH VOLTAGE TRANSFORMER CABINET 6-45
..................
: ‘;-:
chapter7 .......................
lhmbleshoohng and Main Ice
....
..........................................................................
7.1 RECTIFIER TROUBLESHOOTING
7.1.1 Power Supply Test .
...............................
7.1.2 Battery Voltage
......................................
7.1.3
...........................................
BatteqSCR
.................
7.1.4 IGBTs
............................
......................................
7.15 FanPower
..............
7.1.6 Tkmistar _
............................................
.............................................
7.2 DIVERTER ‘IROUBLESHOOTING
............
:
..........
7.2.1 IGBTs
........
.
.................................................
7.2.2 Fan Power
7.2.3
..............................................
Invertcr Sensing
Sync.. ...................... 7.2.4
........ ..‘...................~~~
.................
7.3 COMMUNI~ON TROUBLESHOOTING
.................
7.4 EPO OPTION
...........................
............. .
......................
7.5 BYPAW CONTROL TROUBLESHOOTING
.............
....
7.5.1 Relays.. ...........
;.;:.~ ..:.
....................
... .
..... .........
7.5.2
.............
“GO l-U BYPASS” and “GO TO
IlwEmzR” command
7.6FRUFAILUREDISPLAY.
.........
.. .
..................
7.7 RECTEER STAI-US LEDS
..................
........................
7.8INVERTERSTAlUSLEDS
..... .
..............
.....
7.9 MAINTENANCJZ MODE
...........................
7.10 FRU‘ISOLAITON . ........................................
7.11
......................
PHASE RELKI’IONSHE’ WITH VOLTMIXER
....................
7.12 BATIERY
TESTINFORMKI'ION
...................
....................
7.13 ALARM INFORMATION/ACTION rlEM LIST
..........
7.14 FRLJREPLACEMHNT
..................
..................................... ....
7.14.1 RectifkrFRURemovirl
.............
7.14.2 Redier FRU Rc@acunent
........................
.......
7.14.3 Invertcr FRU Removal
..........................
....
7.14.4 rmaterFRUReplacumlt
.................................
7.145 FrontPanelFRURcmovd.. .....................
7.14.6 Front Panel FRU Replacemint
::::::::::::::::::::::
7.14.7 J/O FRU Removal
..............................
.............................. .............
7-l
7-l
7-1
7-2
7-2
7-2
7-3
7-6
7-6
7-7
7-7
7-7
7-10
7-12
7-14
7-14
7-14
7-16
7-16
7-17
7-18
7-18
7-19
7-19
7-20
7-30
7-30
7-31
7-31
7-32
7-32
7-32
7-32
EXIDE ELECTRONICS CONFIDENTIAL
V

Table of Contents Pius 18
7.14.8 I/O FRU Replacement . . . .
7-33
chapter8 .............................................................
Parts Lit
...........................................................
“8::
-EZ
...........................................................................................................................
;::
Appendix A .........................................................
-
LockouUTagout Procedures
...........................................
2-i
A.1 LocKOIJT
...
.............................................
A-l
A2 TAGOUT
.................................................. A-l
A3 USE OF LOCKOUT AND TAGOUT DEVICES.
.................. A-2
A4 REMOVAL OF LOCKOUT OR TAGOUT DEVICES.
.............. A-2
A5 DOCUMENTATION.............................: ........... A-2
A6 INSPEcIlONS
............................................. A-3
Appendix B
.........................................................
Fluke 97 Scopemeter
.................................................
;::
B.l DESCRIPTION
............
.................................. B-l
B.2
MEl-ERFUNCIlONS
........................................ B-l
B.3 AC VOLTAGE
.............................................. B-l
B.4 FREQUENCY
.............................................. B-l
BJ DCVOLTAGE ..............................................
B-2
B.6 DIODE AND OHMIC CHECKS
............................... E-2
B.7 SCOPEFUNCTIONS .; .;. .. .
.................................
B-2
B.8 CALIBRM’ION
.....
: i
....
: ;
................................
B-2
B.9
AUTO SET ................................................
B-2
B.10 ZEROINGSCOPE ..
;
....................................... B-2
B.ll RECORDING AWAVEFORkd
.................................
B-2
B.12 VIEWlNGASTOREDWAVEFORM
...........................
B-3
B.13 POWERSYNC
............................................... B-3
B.14 MEASURINGTRANSFERS ._
................................ B-3
B.15 ZERO CROSSINGS
.........................................
B-3
8.16 UVTRANSFERS
...........................................
B-3
B.17 RECOMMENDED PARl?3
....................................
B-3
Appendix C .........................................................
Receptacles Chart
...................................................
:I:
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