Pacific Power Source 3060-UMS User manual

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3060-UMS
UNINTERRUPTIBLE AC POWER SOURCE
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.
PACIFIC POWER SOURCE, INC
17692 FITCH
IRVINE, CA. 92614
PHONE [phone]
FAX [phone]
May 2001
MANUAL PART NO. 126550
MANUAL DWG NO. 126550 REV. B
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REVISION CONTROL PAGE
Revision Date Pages Approved
B 10/20/04
Per EO5696
Title Page/ Revision Control
Page, 173 Rev B – 173G Rev B DRH
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i
TABLE OF CONTENTS
Para. Title Page
1 SCOPE ............................................... 1
1.1 MANUAL DESCRIPTION ............................. 1
1.1.1 USING THIS MANUAL......................... 1
1.2 SAFETY NOTICES ................................. 3
1.3 GENERAL PRODUCT DESCRIPTION .................... 5
1.4 MAJOR COMPONENT DESCRIPTION .................... 7
1.4.1 UNINTERRUPTIBLE POWER SOURCE (UPS)........ 7
1.4.2 CABINET................................... 7
1.4.3 BATTERY CABINET........................... 7
1.4.4 RECTIFIER/CHARGER......................... 8
1.4.5 INVERTER.................................. 9
1.4.6 UTILITY INVERTER.......................... 10
1.4.7 SYSTEM.................................... 10
1.4.8 LOW VOLTAGE POWER SUPPLY (LVPS)........... 10
1.5 ON-LINE BATTERY TEST ........................... 10
1.6 GROUNDING ...................................... 10
2 SPECIFICATIONS ...................................... 13
2.1 ELECTRICAL SPECIFICATIONS ...................... 13
2.1.1 INPUT POWER............................... 13
2.1.2 BATTERY POWER............................. 16
2.1.3 OUTPUT POWER.............................. 18
2.2 MECHANICAL SPECIFICATIONS ...................... 20
2.2.1 3060-UMS.................................. 20
2.2.2 BATTERY CABINET........................... 22
3 INSTALLATION ........................................ 25
3.1 PLANNING THE JOB ............................... 26
3.2 MOVING, UNCRATING, AND INSPECTION .............. 28
3.3 CHANGING INPUT VOLTAGE ......................... 30
3.4 SETTING THE CABINET INTO PLACE ................. 36
3.5 CONNECTING THE INPUT SERVICE ................... 40
3.6 CONNECTING THE OUTPUT SERVICE .................. 42
3.7 BATTERY INSTALLATION ........................... 44
3.7.1 BATTERY CABINET INSTALLATION.............. 46
3.7.2 UPS CABINET TO BATTERY CABINET
CONNECTIONS............................... 48
3.7.3 BATTERY ORIENTATION AND WIRING............ 50
3.8 MULTIPLE CABINET SYSTEM ........................ 54
3.9 RSP IV INSTALLATION ............................ 57
3.10 ELECTRICAL SURVEY .............................. 58
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ii
TABLE OF CONTENTS
Para. Title Page
4 OPERATION ........................................... 61
4.1 INSPECTION OF INSTALLATION ..................... 61
4.2 INSTALLATION RECORD ............................ 62
4.3 OPERATING PROCEDURES ........................... 65
4.3.1 FIRST TIME OPERATION...................... 66
4.3.2 PARALLEL CABINET OPERATION................ 68
4.3.3 NORMAL SHUTDOWN PROCEDURE................. 70
4.3.4 EMERGENCY SHUTDOWN PROCEDURE.............. 71
4.3.5 MODES OF OPERATION........................ 72
4.4 DESCRIPTION OF CONTROLS AND INDICATORS ......... 76
4.4.1 LCD AND INTERROGATION SWITCHES............ 79
4.4.1.1 INPUT KEY............................ 79
4.4.1.2 OUTPUT KEY........................... 80
4.4.1.3 STATUS KEY........................... 81
4.4.1.4 DIAGNOSTIC KEY....................... 84
4.4.1.5 HELP KEY............................. 87
4.4.1.6 ALARM KEY............................ 89
4.4.1.7 SPECIAL KEY COMBINATIONS............. 90
4.4.2 MODE SELECT, EMERGENCY OFF, AND ON-RESET
SWITCHES.................................. 92
4.4.2.1 MODE SELECT SWITCH................... 92
4.4.2.2 EMERGENCY OFF AND START/RESET
SWITCHES............................. 94
4.4.3 FREQUENCY SELECT SWITCH AND VOLTS ADJUST.. 96
4.4.3.1 FREQUENCY SELECT SWITCH.............. 96
4.4.3.1 VOLTAGE ADJUST CONTROLS.............. 96
4.5 SETUP SWITCHES ................................. 98
4.5.1 DISPLAY PCB............................... 100
4.5.2 CONTROL PCB............................... 102
4.6 FEATURE CONNECTORS ............................. 104
4.6.1 P1, P2 PARALLELING........................ 104
4.6.2 J3 AND J4 SERIAL I/O...................... 106
4.6.3 J6 EXTERNAL OSCILLATOR.................... 110
4.6.4 J5 AND J7 SYSTEM METERING OUTPUTS......... 110
4.6.5 J8 REMOTE METERING INPUTS................. 111
4.6.6 J9 AUXILIARY ALARM AND RSP IV OUTPUTS..... 112
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iii
TABLE OF CONTENTS
Para. Title Page
5 MAINTENANCE ......................................... 115
5.1 POWER SOURCE MAINTENANCE SCHEDULE .............. 115
5.2 BATTERY MAINTENANCE AND TESTING ................ 119
6 SERVICE ............................................. 125
6.1 DESCRIPTION .................................... 126
6.1.1 MAINFRAME DESCRIPTION..................... 126
6.1.2 CONTROL MODULE DESCRIPTION................ 130
6.1.3 INVERTER DESCRIPTION...................... 132
6.2 THEORY OF OPERATION ............................ 134
6.2.1 CONTROL TERM DEFINITIONS.................. 135
6.2.2 THEORY OF OPERATION - POWER CONVERSION
CIRCUITS.................................. 140
6.2.3 THEORY OF OPERATION - CONTROL CIRCUITS.... 141
6.2.4 THEORY OF OPERATION - DC POWER SUPPLY..... 142
6.2.5 THEORY OF OPERATION - DISPLAY CIRCUITS.... 144
6.2.6 THEORY OF OPERATION - PARALLELING
CIRCUITS.................................. 146
6.3 TROUBLESHOOTING PROCEDURE ...................... 147
6.3.1 PERFORMANCE CHECK......................... 148
6.3.2 LVPS SERVICE PROCEDURE.................... 150
6.3.3 DISPLAY SERVICE PROCEDURE................. 152
6.3.4 EMER OFF SERVICE PROCEDURE................ 154
6.3.5 NO INVERTER VOLTS SERVICE PROCEDURE....... 158
6.3.6 ABNORMAL VOLTAGE SERVICE PROCEDURE........ 160
6.4 ASSEMBLY REPLACEMENT PROCEDURES ................ 162
6.4.1 INVERTER ASSEMBLY REPLACEMENT............. 163
6.4.2 CONTROL PCB ASSEMBLY REPLACEMENT.......... 165
6.4.3 MODULATOR PCB ASSEMBLY REPLACEMENT........ 166
6.4.4 DISPLAY PCB ASSEMBLY REPLACEMENT.......... 167
6.4.5 LVPS PCB ASSEMBLY REPLACEMENT............. 168
6.4.6 DISCHARGE PCB ASSEMBLY REPLACEMENT........ 169
6.4.7 DRIVER PCB ASSEMBLY REPLACEMENT........... 170
6.4.8 SNUBBER PCB ASSEMBLY REPLACEMENT.......... 171
6.4.9 REGULATOR PCB ASSEMBLY REPLACEMENT........ 172
6.4.10 UTILITY INVERTER ASSEMBLY REPLACEMENT..... 173
6.5 COMPONENT REPLACEMENT PROCEDURES ............... 176
6.5.1 INPUT POWER PANEL COMPONENT REPLACEMENT... 177
6.5.2 DC POWER SUPPLY COMPONENT REPLACEMENT..... 178
6.5.3 INVERTER COMPONENT REPLACEMENT............ 180
6.6 RETURNING ASSEMBLIES FOR REPAIR ................ 181
6.7 BLOCK AND SCHEMATIC DIAGRAMS ................... 183
7 MODIFICATIONS ....................................... 191
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iv
List of Illustrations
FIGURE 1.1 3060-UMS ......................................... 2
FIGURE 1.3 UPS FUNCTIONAL BLOCK DIAGRAM ..................... 6
FIGURE 1.6 GROUNDING ........................................ 11
FIGURE 2.1.2 BATTERY SUPPORT TIME ............................. 17
FIGURE 2.2.1 3060-UMS OUTLINE DRAWING ......................... 21
FIGURE 2.2.2 BATTERY CABINET OUTLINE DRAWING .................. 23
FIGURE 3.1 ENVIRONMENTAL SURVEY CHECKLIST ................... 27
FIGURE 3.2 CRATING AND MOVING OUTLINE DRAWING ............... 29
FIGURE 3.3.1 480 V INPUT CONFIGURATION ........................ 32
FIGURE 3.3.2 380 V INPUT CONFIGURATION ........................ 33
FIGURE 3.3.3 240 V INPUT CONFIGURATION ........................ 34
FIGURE 3.3.4 208 V INPUT CONFIGURATION ........................ 35
FIGURE 3.4A SYSTEM INTERCONNECT WIRING ....................... 38
FIGURE 3.4B SYSTEM INTERCONNECT WIRING ....................... 39
FIGURE 3.5 INPUT TERMINAL DETAIL ............................ 41
FIGURE 3.6 OUTPUT TERMINAL DETAIL ........................... 43
FIGURE 3.7.1 BATTERY CABINET SERVICE CLEARANCES ............... 47
FIGURE 3.7.2 UPS CABINET BATTERY TERMINAL DETAIL .............. 49
FIGURE 3.7.3 BATTERY ORIENTATION AND WIRING ................... 53
FIGURE 3.8.1 MULTIPLE CABINET SYSTEM OUTLINE .................. 55
FIGURE 3.8.2 MULTIPLE CABINET SYSTEM ONE-LINE DIAGRAM ......... 56
FIGURE 3.9 RSP IV CONNECTIONS ............................... 57
FIGURE 3.10 ELECTRICAL SURVEY CHECKLIST ...................... 59
TABLE 4.2 INSTALLATION RECORD .............................. 63
FIGURE 4.4 3060-UMS FRONT PANEL ............................. 77
FIGURE 4.4.1 LCD AND INTERROGATION SWITCHES ................... 78
FIGURE 4.4.2 MODE SELECT, EMER OFF, AND START/RESET ........... 93
FIGURE 4.4.3 FREQUENCY SELECT AND VOLTS ADJUST ................ 97
FIGURE 4.5 CABINET ASSEMBLY ................................. 99
FIGURE 4.5.1 DISPLAY PCB, PART NUMBER 126572 .................. 101
FIGURE 4.5.2 CONTROL PCB, PART NUMBER 126570 .................. 103
FIGURE 4.6 FEATURE CONNECTOR DETAIL ......................... 105
TABLE 4.6.2 SERIAL I/O CONNECTIONS ........................... 107
TABLE 5.1 3060-UMS MAINTENANCE LOG ......................... 116
TABLE 5.2 BATTERY MAINTENANCE LOG .......................... 123
FIGURE 6.1.1 MAINFRAME ........................................ 129
FIGURE 6.1.2 CONTROL MODULE ................................... 131
FIGURE 6.1.3 INVERTER ......................................... 133
FIGURE 6.2.5 BLOCK DIAGRAM DISPLAY CIRCUITS ................... 145
FIGURE 6.3.1 PERFORMANCE CHECK FLOW CHART ..................... 149
FIGURE 6.3.2 LVPS FLOW CHART .................................. 151
FIGURE 6.3.3 DISPLAY FLOW CHART ............................... 153
FIGURE 6.3.4 EMER OFF FLOW CHART .............................. 157
FIGURE 6.3.5 NO INVERTER VOLTS FLOW CHART ..................... 159
FIGURE 6.3.6 ABNORMAL VOLTS FLOW CHART ........................ 161
FIGURE 6.7.1 SYSTEM BLOCK DIAGRAM ............................. 185
FIGURE 6.7.2 MAINFRAME SCHEMATIC .............................. 187
FIGURE 6.7.3 INVERTER SCHEMATIC ............................... 189
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1
SECTION 1
GENERAL
1 SCOPE
1.1 MANUAL DESCRIPTION
This manual is written to provide the information
required to use the 3060-UMS Uninterruptible Power
Source effectively. This manual is an Operations Manual.
Installation, operation and maintenance are principal
subjects of this manual.
1.1.1 USING THIS MANUAL
This manual primarily covers installation and operation.
It is very important that the user reads sections 3 and
4 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 the Pacific Power Source
Corporation. Pacific maintains a toll-free number which
is 1-800-854-2433 (1-800-472-8465 inside California),
FAX [phone].
Section 5 discusses maintenance. This section needs to
be read only when such activities are required to be
performed.
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SECTION 1 GENERAL
2
FIGURE 1.1 3060-UMS
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SECTION 1 GENERAL
3
1.2 SAFETY NOTICES
The 3060-UMS is capable of transferring very large
amounts of electrical energy very quickly. This basic
quality is fundamental to a high-performance power
source. The batteries are connected in series to produce
± 200VDC at several hundred amps. The warnings and
cautions listed below should be observed at all times.
Warnings are conditions which are hazardous to user
personnel. All warnings throughout this manual will be
formatted as shown below. A condition which is hazardous
to both personnel and equipment will be issued as a
warning.
Caution statements indicate a dangerous situation which
may damage the equipment but is not a threat to life or
limb. Cautions will assume the format shown on the
following page. All cautions should be rigorously
observed.
* * * * * * * WARNING * * * * * * *
* THIS EQUIPMENT CONTAINS HIGH ENERGY, LOW
IMPEDANCE CIRCUITS !! LETHAL POTENTIALS ARE
CONTAINED WITHIN THE CABINET.
* CARE MUST BE EXERCISED WHEN SERVICING THIS
EQUIPMENT IN ORDER TO PREVENT SERIOUS OPERATOR
INJURY OR EQUIPMENT DAMAGE.
* OBSERVE THE FOLLOWING WHEN SERVICE AND
MAINTENANCE ARE REQUIRED:
1) REMOVE ALL JEWELRY FROM ARMS AND NECK
WHEN SERVICING THIS EQUIPMENT. THIS
PREVENTS THE POSSIBILITY OF SHORTING
THROUGH THE JEWELRY AND CAUSING BURNS TO
THE OPERATOR.
2) WEAR SAFETY GLASSES WHEN SERVICING THIS
EQUIPMENT TO PREVENT EYE INJURY DUE TO
FLYING PARTICLES CAUSED BY ACCIDENTAL
SHORT CIRCUIT CONDITIONS.
* * * * * * * WARNING * * * * * * *
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SECTION 1 GENERAL
4
1.2 SAFETY NOTICES (Cont)
* * * * * * * WARNING * * * * * * *
* 3) DO NOT REMOVE ANY PANEL OR COVER WITHOUT
FIRST REMOVING THE INPUT SERVICE BY
OPENING ALL CIRCUIT BREAKERS.
4) SERVICE OTHER THAN EXTERNAL CLEANING
SHOULD BE REFERRED TO PERSONNEL
AUTHORIZED BY THE FACTORY TO SERVICE THIS
EQUIPMENT.
* * * * * * * WARNING * * * * * * *
- - - - - - - CAUTION - - - - - - -
- READ SECTIONS 3 AND 4 OF THIS MANUAL BEFORE
INSTALLING OR OPERATING THIS EQUIPMENT.
- - - - - - - CAUTION - - - - - - -
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SECTION 1 GENERAL
5
1.3 GENERAL PRODUCT DESCRIPTION
Pacific UMS Series of equipment is a family of
Uninterruptible AC Power Sources covering the power
range 62.5 to 625 kVA (50 - 500 kW), at power
frequencies of 50 - 400 Hz. The basic 62.5 kVA / 50 kW
unit is designated as the model 3060-UMS. Up to 10 units
are paralleled to provide 625 kVA / 500 kW.
The 3060-UMS functions as a double conversion Power
Source. Input AC Power is rectified to DC by a special
power supply that provides low input current distortion
and charges the batteries. The DC is then converted back
to AC by a high frequency pulse-width modulated
switcher, under the control of a highly stable digital
oscillator. Batteries provide power if the input line
fails.
The 3060-UMS unit is designed to provide high quality
output power. Output regulation and total harmonic
distortion are of the order of 1% at 50 or 60Hz and 2%
at 400Hz. Response time to a 100% step load change is
300 microseconds. The machine is therefore capable of
delivering very high pulse current loads.
The fast response time and excellent regulation of the
3060-UMS is extremely important in applications where
mixed or switched loads may cause power interference and
load "Cross talk".
3060-UMS equipment is designed for long term, continuous
operation in a sheltered (no rain) environment. The
equipment is efficient circulates little cooling air and
is relatively tolerant of high dust environments.
Cabinet operation is controlled by simple, highly
reliable digital logic. A microprocessor provides
internal diagnostics and communicates with the operator
via a 160 character Liquid Crystal Display.
The 3060-UMS is easy to install and even easier to
operate. Turn-on, start up, shutdown and other
operations are guided by the front panel communications
center. The equipment is fail-safe and provides for both
local and remote status information.
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SECTION 1 GENERAL
6
FIGURE 1.3 UPS FUNCTIONAL BLOCK DIAGRAM
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SECTION 1 GENERAL
7
1.4 MAJOR COMPONENT DESCRIPTION
The paragraphs below provide descriptions of major
components used in the 3060-UMS.
1.4.1 UNINTERRUPTIBLE POWER SOURCE (UPS)
All components within the UPS Cabinet and separate
battery cabinet which function as a system to provide
continuous, conditioned AC power to the load.
1.4.2 CABINET
An enclosure that contains the rectifier, charger,
inverter, and controls required to provide the specified
AC power to the load.
1.4.3 BATTERY CABINET
A cabinet that contains maintenance-free sealed
batteries sufficient to maintain UPS output in
accordance with the specifications.
The Battery Cabinet contains a battery disconnect
contactor and fuses. The contactor is mounted in the
battery cabinet and when open, allows no battery voltage
to be present in the UPS cabinet.
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SECTION 1 GENERAL
8
1.4.4 RECTIFIER/CHARGER
The UPS component that contains the equipment and
controls necessary to convert the input AC power to
regulated DC power for the inverter and to charge the
batteries.
The rectifier/charger unit is a solid-state device
designed to provide direct current to the inverter unit
and charge the batteries.
A 12 pulse input rectifier is used. This reduces current
distortion into the input AC line to no more than 8%.
The rectifier also improves the input power factor so
that it remains above 0.75 lagging at full load.
A dry type power transformer is used for the
rectifier/charger unit. The transformer's hottest spot
winding temperature is monitored by the Diagnostic
System to ensure that the transformer temperature does
not exceed design limits.
The rectifier/charger unit provides a soft start-up
feature whereby when the AC power is first applied, the
total initial power drawn at the input terminals will
not exceed 100% of rated input power. If the output
power is in excess of 100% then the input power may
increase over 100%.
Nominal float voltage is 204 VDC. Voltage will increase
to 212 VDC during recharge of the batteries. Voltage
will decrease to 175 VDC during a battery test.
DC overvoltage protection is provided so that if the DC
Bus voltage rises above the 240 VDC, the UPS will shut
down automatically.
DC undervoltage protection is provided so that if the DC
Bus voltage drops below 160 VDC, the UPS will shut down
automatically and prevent battery damage from over-
discharging.
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SECTION 1 GENERAL
9
1.4.5 INVERTER
The inverter unit is a solid-state device that derives
its power from the output of the rectifier/charger or
batteries to provide the rated AC output within
specified limits. A high frequency pulse-width modulated
switcher.
The output frequency of the inverter is controlled by a
digital oscillator with fixed frequencies of 50, 60 and
400 Hz. The oscillator is adjustable over the range of
47 to 500Hz in the VAR position.
In the fixed frequency positions, the oscillator is also
designed to hold the inverter output frequency to ±0.01%
for both steady state and transient conditions. Drift
will not exceed ±0.01% during a 24-hour period. Total
frequency deviation, including short time fluctuations
and drift, is limited to ±0.01% from the specified
frequency.
The inverter is capable of supporting transient
overloads up to 150%, or any load within its rating,
without reducing the output voltage. Overloads will
cause the machine to overheat and shutdown. Loads
greater than 150% may cause a reduction of the output
voltage.
The inverter will current limit at 150% of rated
current. The inverter is capable of supplying at least
210% of rated RMS current for short circuit conditions.
If the short circuit is sustained, the inverter will
shut down and disconnect automatically from the output
in approx. 20 seconds.
Each inverter output phase is independently regulated to
±0.5%, with Automatic Gain Control enabled, such that
unbalanced loading will not cause the output voltage to
go outside the specified voltage unbalance.
A four pole inductor capacitor low pass filter, is
incorporated in the inverter unit. The filter reduces
the inverter output sine wave voltage harmonics to less
than 1% total and single harmonics to less than 0.5% for
linear loads at 50-60Hz.
Insulated Gate Bipolar Transistors in the inverter unit
are fused with fast acting fuses, so that loss of any
one transistor will not cause cascading failures.
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SECTION 1 GENERAL
10
1.4.6 UTILITY INVERTER
The UPS component that contains the equipment and
controls necessary to convert DC power from the
rectifier or batteries to 110 VAC, 60 Hz required by the
UPS such as fans and contactors. A high frequency pulse-
width modulated switcher.
1.4.7 SYSTEM
A system may be from one to ten cabinets in parallel.
Cabinets may be paralleled together for higher power
systems. Each 3060-UMS is capable of operating as either
a SLAVE or MASTER in multi-cabinet paralleled system.
The Mean Time Between Failure of a single cabinet 3060-
UMS is quite high (approx. 5 years). Parallel system
architecture is such that a failed slave unit
automatically drops off-line.
A failed MASTER turns the entire system off. In this
event an operator can select any other paralleled unit
as the MASTER from a front panel control and restore
system operation.
1.4.8 LOW VOLTAGE POWER SUPPLY (LVPS)
A ±18 VDC power supply to power all low voltage
circuits.
1.5 ON-LINE BATTERY TEST
The UPS is provided with an "On-Line" battery test
capability that tests the UPS battery and battery
connections under actual operating load. Initiation of
battery test will not disturb the UPS output in case of
a failed battery or battery connection. Refer to section
5, Maintenance for a full description of the battery
test feature.
1.6 GROUNDING
The input power is fully isolated from the output power
with exception of three, 1 megohm voltage sense
resistors. The chassis of the UPS Cabinet must be tied
to ground. Output neutral is tied to chassis. Battery
neutral is tied to chassis.
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