Pacific Power Source MS SERIES User manual

MS SERIES
AC POWER SOURCE
OPERATIONS
MANUAL
PACIFIC
POWER SOURCE


Limited Warranty:
Pacific Power Source (PPS) warrants each unit to be free from defects in material and
workmanship. For the period of two (2) years from the date of shipment to the
purchaser, PPS will either repair or replace, at its sole discretion, any unit returned to its
factory in Irvine, California. Excepted from this warranty are fuses and batteries, which
carry the warranty of their original manufacturer if applicable. It does not cover damage
arising from misuse of the unit or attempted field modifications or repairs. This warranty
specifically excludes damage to other equipment connected to this unit.
Upon notice from the purchaser within thirty (30) days of shipment of units found to be
defective in material or workmanship, PPS will pay all shipping charges for the repair or
replacement. If notice is received more than thirty (30) days from shipment, all shipping
charges shall be paid by the purchaser. Units returned on debit memo will not be
accepted and will be returned without repair.
This warranty is exclusive of all other warranties, expressed or implied.
Service & Spare Parts Limited Warranty:
Pacific Power Source (PPS) warrants repair work to be free from defects in material and
workmanship for the period of ninety (90) days from the invoice date. This warranty
applies to replaced parts or subassemblies only. This warranty does not include
batteries. All shipping and packaging charges are the sole responsibility of the buyer.
Pacific Power Source will not accept debit memos for returned power sources or
subassemblies. Debit memos will cause return of power sources or assemblies without
repair.
This warranty is exclusive of all other warranties, expressed or implied.

3060-MS
SOLID-STATE
AC POWER SOURCE/FREQUENCY CONVERTER
INSTALLATION AND OPERATION MANUAL
THE INFORMATION CONTAINED IN THIS MANUAL
IS PROPRIETARY TO PACIFIC POWER SOURCE, INC.
THIS MANUAL MAY NOT BE COPIED OR REPRINTED
WITHOUT THE EXPRESSED WRITTEN CONSENT
OF PACIFIC POWER SOURCE, INC..
PACIFIC POWER SOURCE, INC.
17692 FITCH
IRVINE, CA., U.S.A. 92614
PHONE: [phone]
FAX: [phone]
February 2013
MANUAL PART NO. 126050
Revision E
DWG NO. 126050-10e

THIS PAGE INTENTIONALLY BLANK

TABLE OF CONTENTS
Section Description Page
Pacific Power Source ©2013 v Document # 126050-10 Rev E
1.0 GENERAL DESCRIPTION................................................................................1-1
1.1 MANUAL DESCRIPTION.......................................................................................................1-1
1.2 USING THIS MANUAL...........................................................................................................1-1
1.3 SAFETY NOTICES.................................................................................................................1-1
1.4 GENERAL PRODUCT DESCRIPTION..................................................................................1-3
1.5 DEFINITIONS.........................................................................................................................1-4
1.6 DETAILED DESCRIPTION ....................................................................................................1-5
1.6.1 3060-MS CABINET..........................................................................................................1-5
1.6.2 RECTIFIER CIRCUIT.......................................................................................................1-5
1.6.3 INVERTER MODULE.......................................................................................................1-6
1.6.4 MULTI-CABINET PARALLELED SYSTEM .....................................................................1-6
2.0 SPECIFICATIONS ............................................................................................2-1
2.1 ELECTRICAL SPECIFICATIONS ..........................................................................................2-1
2.1.1 INPUT POWER................................................................................................................2-1
2.1.2 OUTPUT POWER............................................................................................................2-2
2.2 MECHANICAL SPECIFICATIONS.........................................................................................2-3
2.3 ENVIRONMENTAL SPECIFICATIONS .................................................................................2-3
3.0 INSTALLATION ................................................................................................3-1
3.1 PLANNING THE JOB.............................................................................................................3-1
3.2 MOVING, UNCRATING, AND INSPECTION.........................................................................3-4
3.3 CHANGING INPUT VOLTAGE ..............................................................................................3-6
3.4 SETTING THE CABINET INTO PLACE...............................................................................3-12
3.5 SAFETY GROUNDING / EARTHING ..................................................................................3-12
3.6 CONNECTING THE INPUT SERVICE ................................................................................3-12
3.7 CONNECTING THE OUTPUT SERVICE ............................................................................3-15
3.8 MULTIPLE CABINET SYSTEM............................................................................................3-18
3.9 ELECTRICAL SURVEY CHECKLIST ..................................................................................3-21

TABLE OF CONTENTS
Section Description Page
Pacific Power Source ©2013 vi Document # 126050-10 Rev E
4.0 OPERATION.....................................................................................................4-1
4.1 INSPECTION OF INSTALLATION.........................................................................................4-1
4.2 INSTALLATION RECORD .....................................................................................................4-1
4.3 DESCRIPTION OF CONTROLS AND INDICATORS............................................................4-4
4.3.1 LCD AND INTERROGATION SWITCHES......................................................................4-5
4.3.1.1 INPUT KEY.................................................................................................................4-6
4.3.1.2 OUTPUT KEY.............................................................................................................4-6
4.3.1.3 STATUS KEY .............................................................................................................4-8
4.3.1.4 DIAGNOSTIC KEY...................................................................................................4-10
4.3.1.5 HELP KEY................................................................................................................4-11
4.3.1.6 ALARM KEY.............................................................................................................4-13
4.3.1.7 SPECIAL KEY COMBINATIONS .............................................................................4-14
4.3.2 MODE SELECT, EMERGENCY OFF, AND ON-RESET SWITCHES..........................4-14
4.3.2.1 MODE SELECT SWITCH.........................................................................................4-14
4.3.2.2 EMERGENCY OFF AND START/RESET SWITCHES ...........................................4-15
4.3.3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST..............................................4-16
4.3.3.1 FREQUENCY SELECT SWITCH.............................................................................4-16
4.3.3.2 VOLTAGE ADJUST CONTROLS ............................................................................4-16
4.4 OPERATING PROCEDURES..............................................................................................4-17
4.4.1 MODES OF OPERATION..............................................................................................4-18
4.4.2 FIRST TIME OPERATION.............................................................................................4-21
4.4.3 PARALLEL CABINET OPERATION..............................................................................4-22
4.4.4 NORMAL SHUTDOWN PROCEDURE .........................................................................4-23
4.4.5 EMERGENCY SHUTDOWN PROCEDURE .................................................................4-23
4.5 SETUP SWITCHES..............................................................................................................4-24
4.5.1 DISPLAY PCB (126072 or 126172)...............................................................................4-26
4.5.2 CONTROL PCB (126070 or 126079) ............................................................................4-28
4.6 FEATURE CONNECTORS..................................................................................................4-30
4.6.1 P1, P2 PARALLELING...................................................................................................4-30
4.6.2 J3 AND J4 SERIAL I/O ..................................................................................................4-32
4.6.3 J6 EXTERNAL OSCILLATOR .......................................................................................4-35
4.6.4 J5 AND J7 SYSTEM METERING OUTPUTS................................................................4-35
4.6.5 J8 REMOTE METERING INPUTS.................................................................................4-36
4.6.6 J9 AUXILIARY ALARM OUTPUTS................................................................................4-36
5.0 MAINTENANCE................................................................................................5-1
5.1 MAINTENANCE SCHEDULE.................................................................................................5-1

TABLE OF CONTENTS
Section Description Page
Pacific Power Source ©2013 vii Document # 126050-10 Rev E
6.0 SERVICE...........................................................................................................6-1
6.1 DESCRIPTION.......................................................................................................................6-1
6.1.1 MAINFRAME DESCRIPTION..........................................................................................6-1
6.1.2 CONTROL MODULE DESCRIPTION .............................................................................6-4
6.1.3 INVERTER DESCRIPTION .............................................................................................6-6
6.2 THEORY OF OPERATION ....................................................................................................6-8
6.2.1 THEORY OF OPERATION - POWER CONVERSION CIRCUITS ...............................6-11
6.2.2 THEORY OF OPERATION - CONTROL CIRCUITS.....................................................6-13
6.2.3 THEORY OF OPERATION - DC POWER SUPPLY .....................................................6-15
6.2.4 THEORY OF OPERATION - DISPLAY CIRCUITS .......................................................6-17
6.2.5 THEORY OF OPERATION - PARALLELING CIRCUITS..............................................6-18
6.3 TROUBLESHOOTING PROCEDURE .................................................................................6-20
6.3.1 PERFORMANCE CHECK .............................................................................................6-21
6.3.2 LVPS SERVICE PROCEDURE.....................................................................................6-23
6.3.3 DISPLAY SERVICE PROCEDURE...............................................................................6-24
6.3.4 EMER OFF SERVICE PROCEDURE............................................................................6-26
6.3.5 NO-INVERTER-VOLTS SERVICE PROCEDURE ........................................................6-28
6.3.6 ABNORMAL VOLTAGE SERVICE PROCEDURE........................................................6-30
6.4 SCHEMATIC DIAGRAMS....................................................................................................6-32
6.5 ASSEMBLY REPLACEMENT PROCEDURES....................................................................6-35
6.5.1 INVERTER ASSEMBLY REPLACEMENT ....................................................................6-36
6.5.2 CONTROL PCB ASSEMBLY REPLACEMENT ............................................................6-37
6.5.3 MODULATOR PCB ASSEMBLY REPLACEMENT.......................................................6-38
6.5.4 DISPLAY PCB ASSEMBLY REPLACEMENT...............................................................6-38
6.5.5 LVPS PCB ASSEMBLY REPLACEMENT.....................................................................6-39
6.5.6 DISCHARGE PCB ASSEMBLY REPLACEMENT.........................................................6-40
6.5.7 DRIVER PCB ASSEMBLY REPLACEMENT ................................................................6-41
6.5.8 SNUBBER PCB ASSEMBLY REPLACEMENT.............................................................6-42
6.6 COMPONENT REPLACEMENT PROCEDURES................................................................6-42
6.6.1 INPUT POWER PANEL COMPONENT REPLACEMENT............................................6-43
6.6.2 DC POWER SUPPLY COMPONENT REPLACEMENT ...............................................6-44
6.6.3 INVERTER COMPONENT REPLACEMENT ................................................................6-45
6.7 RETURNING ASSEMBLIES FOR REPAIR .........................................................................6-46

TABLE OF CONTENTS
Figure Description Page
Pacific Power Source ©2013 viii Document # 126050-10 Rev E
List of ILLUSTRATIONS and TABLES
FIGURE 2.1.1 INPUT RATINGS................................................................................2-1
FIGURE 2.1.3 OUTPUT RATINGS............................................................................2-2
FIGURE 2.2 OUTLINE DRAWING...........................................................................2-4
FIGURE 3.1 INSTALLATION DETAIL –(MECHANICAL CLEARANCES)...............3-2
TABLE 3.1 ENVIRONMENTAL SURVEY CHECKLIST.............................................3-3
FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING..................................3-5
FIGURE 3.3.1 480 VINPUT CONFIGURATION........................................................3-8
FIGURE 3.3.2 380 VINPUT CONFIGURATION........................................................3-9
FIGURE 3.3.3 240 VINPUT CONFIGURATION......................................................3-10
FIGURE 3.3.4 208 VINPUT CONFIGURATION......................................................3-11
TABLE 3.6.1 INSTALLATION WIRING...................................................................3-13
FIGURE 3.6 INPUT TERMINAL DETAIL...............................................................3-13
FIGURE 3.6.1 CUSTOMER INPUTWIRING DETAIL..............................................3-14
FIGURE 3.7 OUTPUT TERMINAL DETAIL ...........................................................3-16
FIGURE 3.7.1 OUTPUT CONTACTOR....................................................................3-17
(CUSTOMER LOADWIRING DETAIL) ......................................................................3-17
FIGURE 3.7.2 OPTIONAL OUTPUT CIRCUIT BREAKER.......................................3-17
(CUSTOMER LOADWIRING DETAIL) ......................................................................3-17
FIGURE 3.8.1 MULTIPLE CABINET SYSTEM OUTLINE........................................3-19
FIGURE 3.8.2 MULTIPLE CABINET SYSTEMWIRING ..........................................3-20
FIGURE 3.9 ELECTRICAL SURVEY CHECKLIST.....................................................3-21
TABLE 4.2 INSTALLATION RECORD..........................................................................4-2
FIGURE 4.3.1 LCD AND INTERROGATION SWITCHES..........................................4-5
FIGURE 4.3.2 MODE SELECT, EMER OFF, AND START/RESET.........................4-15
FIGURE 4.3.3 FREQUENCY SELECT AND VOLTS ADJUST.................................4-16
FIGURE 4.4.1 SLAVE CONTROL MODE ................................................................4-20
FIGURE 4.5 CABINET ASSEMBLY.......................................................................4-25
FIGURE 4.5.1ADISPLAY PCB ASSY., 126072 .......................................................4-27
FIGURE 4.5.1BDISPLAY PCB ASSY., 126172 .......................................................4-27
FIGURE 4.5.2 CONTROL PCB ASSY., 126070 AND 126079....................................4-29
FIGURE 4.6 CABINET TOP VIEW -FEATURE CONNECTOR DETAIL................4-31
TABLE 5.1.1 6MONTH MAINTENANCE CYCLE.....................................................5-1
FIGURE 5.1.1 REAR OF MS-SERIES CABINET –BACK PANEL REMOVED.............5-2
FIGURE 5.1.2 UNDERSIDE OF MS-SERIES INVERTERS..........................................5-2
TABLE 5.1.2 4-6WEEK MAINTENANCE CYCLE....................................................5-3
FIGURE 5.1.3 FIRESCREEN LOCATION FOR CLEANING.........................................5-3
FIGURE 5.1.4 MS-SERIES MAINTENANCE LOG.....................................................5-4
FIGURE 6.1.1 MAINFRAME......................................................................................6-3
FIGURE 6.1.2 CONTROL MODULE..........................................................................6-5
FIGURE 6.1.3 INVERTER..........................................................................................6-7
FIGURE 6.2.1 BLOCK DIAGRAM POWER CONVERSION CIRCUITS ...................6-12

TABLE OF CONTENTS
Figure Description Page
Pacific Power Source ©2013 ix Document # 126050-10 Rev E
List of ILLUSTRATIONS and TABLES (continued)
FIGURE 6.2.2 BLOCK DIAGRAM SYSTEM CONTROL CIRCUITS.........................6-14
FIGURE 6.2.3 BLOCK DIAGRAM DC POWER SUPPLY.........................................6-16
FIGURE 6.2.4 BLOCK DIAGRAM DISPLAY CIRCUITS...........................................6-17
FIGURE 6.2.5 BLOCK DIAGRAM PARALLELING CIRCUITS.................................6-19
FIGURE 6.3.1 PERFORMANCE CHECK FLOW CHART ........................................6-22
FIGURE 6.3.2 LVPS FLOW CHART........................................................................6-23
FIGURE 6.3.3 DISPLAY FLOW CHART ..................................................................6-25
FIGURE 6.3.4 EMER OFF FLOW CHART...............................................................6-27
FIGURE 6.3.5 NO-INVERTER-VOLTAGE FLOW CHART.......................................6-29
FIGURE 6.3.6 ABNORMAL VOLTS FLOW CHART.................................................6-31
FIGURE 6.4.1 LVPS SCHEMATIC...........................................................................6-32
FIGURE 6.4.2 INPUT POWER SCHEMATIC...........................................................6-33
FIGURE 6.4.3 DC POWER SUPPLY SCHEMATIC .................................................6-34
FIGURE A.1 3060-MS MAINFRAME MAINTENANCE/SERVICEABLE PARTS A-1
FIGURE A.2 3060-MS INVERTER ASSEMBLY MAINTENANCE/SERVICEABLE
PARTS A-2
FIGURE B.1 MS3060 SYSTEM SCHEMATIC B-1

SECTION 1 GENERAL
Pacific Power Source ©2013 1-1 Document # 126050-10 Rev E
1.0 GENERAL DESCRIPTION
1.1 MANUAL DESCRIPTION
This manual is written to provide the information required to use the MS-Series
AC Power Source effectively. This Operations Manual describes proper
installation, operation and maintenance of the MS series power source units.
1.2 USING THIS MANUAL
This manual primarily covers installation and operation. It is very important that
the user reads Section 3, INSTALLATION and Section 4, OPERATION, prior to
installing this equipment. A thorough understanding of these two sections is
required to operate this equipment properly.
If questions arise while reading this manual, the user is encouraged to call Pacific
Power Source Inc. Pacific maintains a toll-free number which is 1-800-854-2433
(949-251-1800 Outside the USA), Fax [phone] or contact us through our
website: www.pacificpopwer.com
Section 5 discusses maintenance, Section 6 is for service. These sections need
to be read only when such activities are required to be performed.
1.3 SAFETY NOTICES
MS-Series equipment is capable of transferring very large amounts of electrical
energy very quickly. This basic quality is fundamental to any high-performance
power source. The warnings and cautions listed below should be observed at all
times.
Warnings indicate potentially hazardous situations which, if not avoided, could
result in death or serious injury. All warnings throughout this manual will appear
as shown below.