APC SURT service manual RMA rev2

Service Manual

APC Smart-UPS

®

RT

3,000VA – 10,000VA 200-240 Vac

Tower/Rack Mount

Uninterruptible Power Supply

English

SURT 3kVA-10kVA Service Manual



2005 American Power Conversion. All rights reserved. No part of this publication may be used, reproduced, photocopied, transmitted, or stored in any retrieval system of any nature, without the written permission of the copyright owner. www.apc.com Rev 2005-2

1

Table of Contents

1 Safety Precautions........................................................................................................................................... 3

2 Introduction to SURT...................................................................................................................................... 4

2.1

2.2

Key Points ........................................................................................................................................... 4

One-Line Diagram .............................................................................................................................. 4

2.3

2.4

2.5

Main Circuit Components ................................................................................................................... 4

Functional Description ........................................................................................................................ 5

Power Train Operation ........................................................................................................................ 5

2.6 Transistor-Level Diagrams ................................................................................................................. 6

3 User Interface ................................................................................................................................................ 11

3.1 Front Panel Display and Control Buttons ......................................................................................... 11

3.2

3.3

Terminal Mode.................................................................................................................................. 13

SmartSlot Accessories (Webcard)..................................................................................................... 15

4 Installation..................................................................................................................................................... 16

5 Component Replacements............................................................................................................................. 16

6 Troubleshooting ............................................................................................................................................ 17

6.1 Unit Setup ......................................................................................................................................... 17

6.2 Required Tools .................................................................................................................................. 17

6.3

6.4

6.5

Visual Inspections ............................................................................................................................. 17

Troubleshooting Flowchart ............................................................................................................... 18

Diode Checks .................................................................................................................................... 20

6.6 Documenting Failures ....................................................................................................................... 25

7 ECO's ............................................................................................................................................................ 25

8 Test After ECO's ........................................................................................................................................... 26

Appendix A. Fault codes on LED display & stored in EEPROM .................................................................... 28

Appendix B. ECO list as of October, 2005....................................................................................................... 33


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2

1 Safety Precautions

Read and adhere to the following warnings when installing or servicing a UPS and/or battery packs.

Failure to observe these warnings may result in serious injury, death or damage to the equipment.

W ARNINGS

•

Do not attempt to install or service external batteries alone. A qualified electrician should perform the installation and servicing of external

batteries.

•

Disconnect charging source(s) BEFORE connecting or disconnecting battery terminals.

•

External batteries may retain lethal voltages after power has been disconnected and all switches are off.

•

Use extreme caution when making terminal connections. Do not allow cables to touch anything except the intended terminal.

P RACTICES Always wear:

•

Goggles or face shields

•

Acid-resistant, insulated gloves

•

Protective aprons

•

Protective overshoes or rubber boots

Always use:

•

Insulated tools

•

Rubber mats to cover batteries during servicing

•

Rubber mats or rubber stands on the floor

•

Adequate lifting devices

Remove:

•

Watches, rings, and other metal objects from your body

P RECAUTIONS

•

To avoid static build-up, service personnel should establish a grounding contact prior working on batteries.

•

Do not lay tools or metal parts on top of batteries.

•

Lead-acid batteries contain hazardous, toxic materials.

§ Do not open, alter or mutilate batteries. Internal materials may be harmful to the skin and eyes.

§ Do not dispose of batteries in a fire. There is danger of explosion.

•

Handle, transport and recycle batteries in accordance with local codes and regulations.


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3

2 Introduction to SURT

2.1 Key Points

•

Double-conversion online topology

•

Inverter voltage is selectable through communication only: 200V, 208V, 220V, 230V, 240V.

•

Bypass “acceptable voltage” window changes with Inverter voltage setting.

•

Batteries must be connected to start UPS. After startup, batteries can be safely removed and replaced without interruption to the output.

•

Lynx2 (3kVA – 6kVA) has single battery (192V nominal) referenced to output Neutral.

•

Lynx3 (7.5kVA – 10kVA) has two battery strings (+192V and -192V nominal) managed independently and charged with separate chargers.

•

Lynx3 (7.5kVA – 10kVA) can accept single-phase or three-phase input voltage. In both cases, Bypass is only single-phase (“L1” and “N” inputs) so the input wiring must be sized to handle full-load current as singlephase.

2.2 One-Line Diagram

160 -284

VAC Input

Input

Filter

Section

Rectifier &

PFC

+/- DC Bus

Inverter

Output

Section

Bypass

Switch

Battery

Charger

240 VAC

Output

192 VDC

Battery

2.3 Main Circuit Components

The primary sections of the UPS are:

•

Input disconnect and filter stage

•

Input Power Factor Correction (PFC) power stage

•

Energy storage stage (dc bus capacitor bank)

•

Output power stage (inverter)

•

Bypass

•

Battery charger

•

Battery: 1 or 2 strings each connected to output Neutral


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4

2.4 Functional Description

The control of power module and fault detection logic is uP based. The input filter stage contains input backfeed relays, input EMI filter, transient suppression, and battery select transfer relays. Input PFC power stage contains non-isolated power factor correcting AC/DC converters. PFC converter is split in two power sections – positive and negative boost stage – while operating on-line and in positive boost and buck boost power stage while operating on battery. This converter is capable of full power operation from 160 to 280 VAC line to neutral or from a nominal DC battery voltage of

192VDC. The output from this stage is a +/-395V center tapped dc bus. The energy storage stage is split DC bus capacitor handling seamless transitions from battery to line and vice versa as well as the low and high frequency power stages ripple. The inverter stage operates directly from +/- 395VDC bus and produces an AC output voltage of

200/208/220/230/240Vac (for NAM and EMEA) or 200Vac (for Japan). The output of the UPS is either connected through a pair of relays either to the inverter or to the input filtered line. The UPS contains 1 or 2 battery chargers, each rated

400W.

2.5 Power Train Operation

When operating on line, the input voltage is first rectified so two half wave rectified voltage waveforms are produced in reference to the Neutral. Positive line rectified signal is fed to positive boost PFC stage. This stage is a boost type converter which converts positive half rectified input signal into DC positive bus voltage of +395V, drawing the input current in phase with positive half cycle of the line current. The boost stage consists of an input choke, high frequency

IGBT switch, high frequency soft recovery diode and the output electrolytic capacitor. The positive boost stage is bypassed by a low power diode which serves as the boost converter protection in the case of sudden line overshoots and overvoltages or any other condition which causes input line peak voltage to be higher than DC bus capacitor voltage. The negative line rectified signal is fed to negative PFC stage. This stage is also boost type converter and operates in the same manner as the positive PFC boost stage. This stage converts negative line half rectified voltage to negative DC bus voltage of -395V. The bottom line is that when operating on line both PFC stages are operating as boost converters each processing half of the total output power per phase.

When operating on battery, the transfer relays connect the PFC to a DC voltage from the battery. The battery voltage is fed through a filter and inrush stage to both positive and negative PFC stages. The battery filter consists of chokes and two electrolytic capacitors. The function of the filter is to prevent high frequency ripple from PFC stage going back to battery and to provide differential mode filter for high frequency noise emanating from battery buses or cables (in case of external battery packs). The inrush stage as its name says during startup limits the battery inrush current. When the battery is connected to the input of the PFC stage, the battery filter capacitor and positive DC bus capacitor charging current is limited through two 50 ohm PTC resistors. When capacitors are charged to battery voltage inrush relays are switched into closed position bypassing the PTC resistors. The positive PFC stage operates as a DC/DC boost converter and converts battery voltage to DC bus voltage. The operation in this mode is the same as operation on line as described above, except that current drawn from battery is now DC current. The negative PFC stage operates as buck boost stage and converts battery voltage to negative DC bus voltage.

The output stage of the UPS consists of inverter with output filter and bypass relays. This stage is a DC/AC converter which function is to convert DC bus voltages into regulated output sine wave voltage. The inverter uses a neutral point clamp topology and consists of the top and bottom section. The top section converts positive DC bus voltage of 395V into positive half wave sine voltage and bottom portion converts negative DC bus voltage into negative half sinewave voltage.

The PWM control of inverter regulates the frequency and amplitude of the output AC voltage. The output filter consists of a smoothing choke and a filter capacitor. The filtered voltage is fed through a NO relay contact to the UPS output.


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2.6 Transistor-Level Diagrams

Lynx2: 3kVA – 6kVA

Input 160-280Vac

BATTERY 192V

D22

L101

50 OHM

50 OHM

K1

LINE

BATTERY

K3 L8

D14

Q11

C6//C8

Q2//Q3

C12//C13

D23

Q12//Q13

L4+L5+L6

C27//C28

BATTERY

LINE

K4

Q6//Q7

L7

D19

Q4//Q5

D15


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D24

Q14//Q15

Q16

6

Lynx II POWER TRAIN


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7

Lynx3: 7.5kVA – 10kVA (interleaved PFC)

Input 160-280Vac

50/60Hz

BATTERY

+192V

LINE

50 OHM

50 OHM

BATTERY

NEUTRAL

BATTERY

-192V

LINE

BATTERY


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8

Bypass

Inverter output

200-240Vac

50/60Hz

Lynx3 POWER TRAIN

Lynx3 PFC power board, 640-0761 – Circuit locations


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9

Lynx3 INVERTER power board, 640-0762


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10

3 User Interface

3.1 Front Panel Display and Control Buttons

The front panel contains status and diagnostic LEDs and two control buttons. Several of the LEDs comprise bar graphs that display status and diagnostic information according to the table below.

Load Smart-UPS RT Front Display Battery Charge

Indicator Description

Online The Online LED illuminates when the UPS is drawing utility power and performing double conversion to supply power to connected equipment.

On Battery The UPS is supplying battery power to the connected equipment.

Bypass

Fault

Overload

The Bypass LED illuminates indicating that the UPS is in bypass mode.

Utility power is sent directly to connected equipment during bypass mode operation. Bypass mode operation is the result of an internal UPS fault, an overload condition or a user initiated command either through an accessory or the manual bypass switch. Battery operation is not available while the

UPS is in bypass mode. Refer to Troubleshooting in this manual.

The UPS detects an internal fault.

Refer to Troubleshooting in this manual.

An overload condition exists. See Troubleshooting.

Replace

Battery

The battery is disconnected or must be replaced. See Troubleshooting.

Table 1. Front Panel LEDs.

SURT 3kVA – 10kVA Service Manual

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11

Feature Function

Power On Press this button to turn on the UPS. (See below for additional capabilities.)

Power Off Press this button to turn off the UPS.

Cold Start

Self-Test

When there is no utility power and the UPS is off, press and hold the button to power up the UPS and connected equipment.

The UPS will emit two beeps. During the second beep, release the button.

Automatic: The UPS performs a self-test automatically when turned on, and every two weeks thereafter (by default). During the self-test, the UPS briefly operates the connected equipment on battery.

Manual: Press and hold the button for a few seconds to initiate the selftest.

Table 2. Front Panel Control Pushbuttons.

Diagnostic Utility

Voltage

The UPS has a diagnostic feature that displays the utility voltage applied to the UPS.

The UPS starts a self-test as part of this procedure. The selftest does not affect the voltage display.

Press and hold the button to view the utility voltage bar graph display. After a few seconds the five-LED, Battery Charge

display on the right of the front panel shows the utility input voltage.

Refer to the figure at left for the voltage reading (values are not listed on the UPS).

The display indicates the voltage is between the displayed value on the list and the next higher value.

Table 3. Front Panel Bar Graphs.


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12

3.2 Terminal Mode

SURT can be configured in a number of ways: Network Management Card web interface, PowerChute ® Software,

Terminal Mode, or UPS-Link commands.

To access Terminal Mode, you will need:

- A computer with an RS-232 serial port

- A terminal application such as Hyperterminal

- An APC black cable 940-0024C (included with the UPS)

Make sure that no SmartSlot accessory is installed in the SmartSlot bay of the UPS. The SmartSlot prevents access to certain UPS communication features such as the Terminal Mode.

Using a standard APC serial cable (APC part number 940-0024C), connect the computer serial port to the back of the UPS.

Open a terminal program. Hyperterminal example:

From the Desktop, go to Start => Programs => Accessories => Communication

=>HyperTerminal.

The “Connection Description” dialog box appears. Enter a name for this connection and select any icon for it.

Click [OK]

The “Connect To” dialog box appears. In the “Connect using” drop-down list select the COM port you’re going to use to communicate with the UPS.

If you get a message that this port is used by another application then either use a different COM port or close the application using the intended port.

Click [OK]


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13

In the communication settings dialog box, select the following settings:

Bits per second: 2400

Data bits: 8

Parity: Note

Stop bits: 1

Flow control: None

Click [OK]

Press the Enter key. The root terminal mode menu will appear, similar to the following:

To configure the UPS, press the 1 key. The UPS will chirp and the “UPS Settings” menu will appear.


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14

To change a setting, press the corresponding key (not case-sensitive) and follow the instructions.

Please note that if no key is pressed for approximately 5 minutes, the Terminal Mode session will time out and you’ll have to press Enter and start from the root menu again.

3.3 SmartSlot Accessories (Webcard)

SURT models include a standard SmartSlot that is compatible with accessories used in other APC products.

Notes on “event log” entries in the AP9619 (NMC or “webcard”):

•

Almost all internal UPS faults are recorded as "Bad output voltage" regardless of whether or not the detected fault is related to the Inverter or Bypass. The NMC is not able to differentiate between the different UPS failure codes.

•

"Battery charger failure" could be a momentary battery overvoltage condition -- see if this alarm is cleared within 2 seconds in the log.


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4 Installation

See User Manual included with the UPS for installation precautions and instructions.

Installation troubleshooting: Make sure:

• each battery string is above 175V (there are two battery modules per string)

• all battery modules are securely connected

• input AC is connected correctly, input phase_select switch set correctly to 1 or 3 (if exists)

• input breaker closed (if exists)

• output breakers on (if exist)

5 Component Replacements

Replacement boards:

SKU Power Board Control Board

SURT3000 0P7510 0P7603

SURT5000

SURT6000

SKU

SURT7500

0P7510

0P7516

0P7600

0P7606

PFC power Inverter power Main Control Aux Control Bias & I/O

0P7611 0P7621 0P7507

SURT8000 0P7611 0P7621 0P7608

SURT10000 0P7611 0P7621 0P7501

Battery modules (RBC44?) – one for Lynx2, two for Lynx3?

Bezels w/ stickers

Display PCB/bezel assemblies

Fan for Lynx2

Fan for Lynx3

Battery fuses: (515-1030A)

See ??? for optional PDU’s including H/W kit for Lynx2 output

0P7631

0P7631

0P7631

0P7641

0P7641

0P7641


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16

6 Troubleshooting

Safety: Remove jewelry, pendants and wrist watches.

6.1 Unit Setup

Unpack the UPS and put it on a flat even surface (mind OSHA regulations). Check the packaging for any signs of damage.

Lynx2

Net Weight 120.00 lbs. ( 54.55 kg)

Shipping Weight 140.00 lbs. ( 63.64 kg)

Note:

Follow all environmental regulations. Discard old batteries in an environmentally friendly way. Be sure to deliver spent batteries to a recycling facility or ship to the manufacturer in the replacement battery packing material

.

6.2 Required Tools

•

Digital multimeter (for example, Fluke 87)

•

Power resistor to discharge capacitors

•

Serial communication cable (RS-232)

•

Communication software (for example, laptop and “Hyperterminal” software in Windows)

•

Phillips screwdriver

•

AC power supply

•

Load

6.3 Visual Inspections

Visual inspection is often overlooked but is one of the most important steps in diagnosing a problem. It can also save a lot of time.

Exterior

Check the packaging and exterior of the UPS for any physical damage

1. Plastic bezels

2. Fan guard & blades

3. Bent sheet metal

4. PDU breakers

Interior

Check all wiring, connections, and PCB components

1. Wire insulation broken

2. Burned components and/or burned marks on PCB

3. Daughter PCBs not tight in sockets

4. Components touching chassis or other components (esp. small heatsinks, power resistor leads)

5. Leads not clipped properly, solder-bridges (solder-side of PCB)


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17

6.4 Troubleshooting Flowchart

Start

Visual inspection

(exterior)

Make sure all battery packs disconnected

Each

Battery pack

>84V?

Yes

No

Remove top panel,

Discharge all caps

Replace battery pack(s)

Visual inspection

(interior)

Diode checks OK?

No

Yes

Connect Battery,

Push ON-Switch

Repair & record failed parts

Brains on?

(Fan on)

Yes

No

(next page)

Troubleshoot

LPS

Lynx 2: Check

D781, D782, D776, D777,

D778, D779, Q712

Lynx 3: Check D704, D705,

D706, D707, D714, D718,

D722, Q704


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18

(continued)

Fault displayed?

Yes

No

Disconnect SNMP cable from ctrl bd.

Send Y <SM>

Send 1...1 <PROG>

Send CTRL-U

Does unit cold start?

No

Yes

Apply AC input voltage

Check PFC:

Lynx 2: D716-k to J712: +400V

D715-a to J712: -400V

Lynx 3: PGND to +400V

PGND to -400V

Evaluate CTRL-U response and LED display.

See "SURT Faults Table"

+/-400V bus voltages OK?

No

Yes

Troubleshoot

PFC

Does unit go on-line ?

Yes

No

Troubleshoot input voltage sense and transfer relays

Troubleshoot

Inverter

Lynx2: Check Q708,

Q709, Q710, Q711,

Q726, Q727, D748,

D749, D723

Lynx3: Check IC903,

IC904

SURT

Faults

Table

Does unit stay on with all batteries disconnected?

Yes

No Troubleshoot

Charger

Lynx 2: Check Q705,

Q706, Q715, Q716,

Q717, Q718, D750,

D751

Lynx 3: Check

IC1403, IC1404,

IC1407, IC1408 collector-emitter and gate-emitter

Re-connect batteries

Lynx 2: Check Q730, Q731, F703,

F704, D736, D737, D738, D739.

Lynx 3: Check Q1407, Q1408,

F1401, F1402, D1406, D1407,

D1408, D1409

Does unit hold load on battery?

Yes

No

Apply ECO's

SURT

Faults

Table

Calibrate and Test unit

Record failure type, list all failed parts along with part markings

Done


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19

6.5 Diode Checks

The following “good value” measurements were made with a functional board and a Fluke 87 DMM. These measurements are approximate and will vary depending on the meter used. See the power board diagram on the next page for Test Point locations.

Lynx2: 3kVA - 6kVA

+ Probe - Probe

Good

Value

Components checked If open If short

BATT BATTF zero

F701, F702 (battery fuses)

Both fuses bad, PFC probably has problem

OK

+VIN +400V 0.4V D716, D748 at least 1 part bad

VMID

-400V

-VIN

-VIN

INV_OUT

INV_OUT

VMID

-400V

+400V

VMID

INV_OUT

INV_OUT

0.8V charges

> 2V charges

> 2V

0.8V

Q706, Q715, Q716

D751, Q718, Q717

D750, Q715, Q716

Q705, Q718, Q717

VMID

+VIN

-VIN

B+

VMID

CHGR_SEC

0.45V Q709, Q710, D706

0.4V D715, D723

0.45V Q726, Q727, D707 zero RY704-normally closed

0.45V D738, D739 all parts bad all parts bad at least 1 part bad at least 1 part bad all parts bad at least 1 part bad

RY704 bad at least 1 part bad if < 2V, Q718 or Q717 bad if < 2V, Q715 or Q716 bad at least 1 part bad

OK

Q706 and

Q715/Q716 bad

At least D751 and 1

IGBT bad

At least D750 and 1

IGBT bad

Q705 and

Q718/Q717 bad at least 1 part bad

CHGR_SEC CHGR_L

CHGR_L

VMID

BATTF

LPS_FET

VMID +24V_SW

VMID

ZERO-

OFF_FET

ZERO-

OFF_FET

+15V_SW

B+

BATTF

0.45V D736, D737

0.45V D735

0.55V Q712

0.5V D782

0.5V D781

0.6V D731, TH701, TH702

0.85V Q728 at least 1 part bad

D735 bad

Q712 bad, check F705, Q729, D714, and output diodes

D782 bad, check Q712, F705, Q729, D715

D781 bad, check Q712, F705, Q729, D714

D731 bad, check TH701, TH702

Q728 bad, check MV703, GDT701


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21

Lynx3: 7.5kVA through 10kVA

+ Probe - Probe

+BATT

-BATT

+VIN_P1

+VIN_P2

+BATTF

-BATTF

+400V

+400V

Good

Value

zero zero

Components checked

F1403, F1404,

F1405, F1406

If open

Fuses bad, +PFC probably has problem

Fuses bad, -PFC probably has problem

0.35V D903, IC903 (at least)

0.35V D905, IC904 (at least)

If short

D903, D905,

IC903, and/or IC904 bad

OK

OK

-400V

-400V

PGND

PGND

-VIN_N1

-VIN_N1

-VIN_N2

+VIN_P1

+VIN_P2

PGND

0.35V D902, IC903 (at least)

0.35V D904, IC904 (at least)

0.4V

0.4V

0.4V

IC903 (at least)

IC904 (at least)

IC903 (at least)

D902, D904,

IC903, and/or IC904 bad

IC903 and/or IC904 bad

-VIN_N2 PGND

-400V INV_OUT

INV_OUT +400V

INV_OUT

+Charger

Out

-400V

PGND

+400V

-Charger

Out

0.4V IC904 (at least)

0.35V

IC1407, IC1408

0.35V

Open IC1403, IC1404

0.55V Q1407, F1402

0.55V Q1408, F1401

IC1407 and/or IC1408

IC1403 and/or IC1404 bad

F1402 open, Q1407 probably bad

F1401 open, Q1408 probably bad

Q1407 bad

Q1408 bad


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22

Lynx3 PFC power board, 640-0761


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23

IC903, IC904 =

Lynx3 INVERTER power board, 640-0762

IC1403, IC1404 =


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24

IC1407, IC408 =.

Notes:

Cold boot the unit and get the diagnostic information from the serial port before it gets cleared out. If the unit fails right away, read the display LED pattern and the failure code.

Initial power up (brains up) with batteries only

Check calibration of batteries (both strings), DC buses, firmware version, model #, serial number, etc.

Check fault history (^U command)

Cold-boot check calibration of DC buses, output AC voltage, etc.

AC-input check calibration of AC input voltage disconnect batteries to see if unit shuts down (indicates charger failure)

ON & OFF buttons, BYPASS switch, etc.

Startup with AC-input

Load: add/remove/calibration of watts & VA

AC input: add/remove with load

HF-OFF check

• Bypass switch

• 3phase input switch selection

• Lynx3 Battery voltage commands: ^J for +battery, ^K for –battery in PROG mode

• Once failed part is identified, try to determine if there were any manufacturing defects that might have caused the part to fail: Insufficient torque on mounting screw, leads not clipped, solder-bridge, parts touching other components, etc.

• In Terminal Mode, if Model = “??”, the EEPROM has probably become cleared or corrupted.

• “Overload” fault (ctrl-u = 02) is stored during factory testing (during production). Seeing this fault stored in a field unit does not necessarily mean the overload timeout happened at the customer’s site.

• “EQ charge” is normal in later versions of Lynx2 & Lynx3 firmware. If the battery voltage ever drops below 200V, the charger will go up to 235V for at least 5 minutes before settling back down to 218V.

EQ charge is also performed about once every 4 weeks.l

6.6 Documenting Failures

Int'l Stars, SIEBEL, or local spreadsheets. Make sure to record all relevant information about the diagnosis:

•

Reference designators of failed parts with date codes and vendor marks

•

PCB revisions, firmware revisions, accessories added, etc.

•

Recommend Corrective Actions and/or PCB revisions as needed.

7 ECO's

See ECO RMA database. For list as of this revision, see Appendix B.

•

Need table showing which PCB revision combinations can be used together (examples: 762x requires 763x or later, 1kVA change)

•

Need list of PCB revisions that are ok to ECO and send back to customers

•

Need table showing which PCB revisions need which ECO’s


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25

8 Test After ECO's

(Final test fixture)

All calibration

Cold-boot

AC input: add/remove

Add load, check calibration of Voutput, Wout, VAout, DC buses, Vbatt, ...

AC input: add/remove

With AC input, disconnect batteries

HF-OFF check


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26

Failure Analysis Report

& Corrective Action Plan

Customer

Customer location

Report date

Model

Unit s/n

Action Taken to Repair

RMA number

RMA date

PCB1 s/n

PCB2 s/n

Accessory1 s/n

Rev

Rev

Rev

Initial Assessment

Does the unit cold boot?

Does the unit indicate a fault?

Does unit operate online with no faults?

Is there any output?

Does unit switch to bypass?

Do all display leds work? ("A" in SM)

Does unit operate under 100% load?

Unit shut off after 9 min on battery standby?

Yes

___

___

___

___

___

___

___

___

No

___

___

___

___

___

___

___

___

Additional Information

Physical damage (deformed metal or plastic, loose connections, cut insulation, poor crimps, etc.)

Voltages: Pos Bus Neg Bus Vin Vout Charger (no batt) f/w rev

Command: Ctrl G*

Displays

Measured

Voltages

Measured

5V

Ctrl H*

12V

Shift L

-12V

Shift O

-15V

Shift B or ^J / ^K*

15V 24V b

Fault History

Ctrl U* n/a n/a

Vbat (list packs separately)

Repaired Unit - Measured and Calibrated Voltages

Voltages Pos Bus Neg Bus Vin Vout Charger (batteries disconnected)

Command Ctrl G* Ctrl H* Shift L Shift O Shift B or Shift J / K* (Lynx 3)

Displays

Measured

Corrective Actions to be Taken

Additional Notes

*in programming mode

Fault History

Ctrl U* n/a

2/14/2005


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27

Appendix A. Fault codes on LED display & stored in EEPROM

Display LEDs show "1" for LED ON and "0" for LED OFF in the Battery capacity bar graph. For example, the following display indicates "Battery Capacitor

Soft Start Fault".

Notes

All values provided in UPS-Link terms. Overload test uses % power (watts) or % VA, whichever is greater.

The last fault(s) detected can be retrieved by sending the "Ctrl-U" command in Programming mode.

Fault Action Taken

Display

LEDs

Ctrl-

U

Auto-Recover from

FAILURE_BYPASS?

Battery Capacitor

Soft Start Fault

The unit immediately changes state to

UPS_FAILURE (less than 1ms)

0

1

1

0

0

11

Can't be in

FAILURE_BYPASS

Repair suggestion

Confirm battery voltage(s) above

165V and that +/-400V buses rise to within 15V(9V) of the battery bus(es) within 12 seconds and. If they don’t, check voltage after softstart PTCs, relay and relay drives.

Lynx2: TH701. TH702, RY702,

Q701, Q728, F701, F702.

Lynx 3: TH1401, TH1402,

TH1403, TH1404, RY1403,

RY1404, RY1405, RY1406,

RY1407, RY1408, Q1402, F1403,

F1404, F1405, F1406

Related

ECOs

BM934


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28

Battery <-> Line

(PFC Input) Relay

Weld fault

No immediate action taken. State change will take place in the next AC line cycle (9ms @50Hz or 7ms @60Hz)

The UPS will transfer to

FAILURE_BYPASS or UPS_FAILURE state (See State Diagram.)

1

0

0

0

1

0D NO

Bypass Relay Fault

(Bypass relay is closed)

Bypass Relay Fault

(Output is off)

No immediate action is taken. Unit will change the state to UPS_FAILURE a half of an AC cycle later (10ms @ 50Hz or 8ms @ 60Hz)

0

1

0

0

1

Battery Charger

Fault(descent method)

No immediate action taken. State change will take place in the next AC line cycle (13.3ms @50Hz or 11.1ms

@60Hz) The UPS will transfer to

FAILURE_BYPASS or UPS_FAILURE state (See State Diagram.)

Battery Charger Fault

(hard limit)

0

1

0

1

0

DC Bus Overvoltage

Fault

DC Bus Overvoltage Fault will immediately turn-off the Inverter in hardware. The PFC will be turned off upon detection of this fault.

Case 1 (Inverter relay is closed): The

Inverter will be commanded off and new state will be set: UPS_FAILURE or

FAILURE_BYPASS. Should UPS transfer to FAILURE_BYPASS, output

Relay will be commanded to open and

Bypass Relay will be commanded to close immediately.

Case 2 (Inverter relay is open): UPS will transfer to UPS_FAILURE state at the closest AC line phase angle of 67.5 degrees (or in less than 18msec

@50Hz or 15msec @60Hz.)

0

1

0

0

0





0F

12

Can't be in

FAILURE_BYPASS

NO

Lynx3:

Confirm customer wiring to input terminal block (hardwired).

Input wires might be connected to Output terminal block by mistake.

Check Bypass contactor and drive

Lynx 2:

Check Q727, Q728, F703, F704,

D736, D737, D738, D739, Q730,

Q731

Lynx 3:

Check Q1407, Q1408, F1401,

F1402, D1406, D1407, D1408,

D1409

08

29

YES

Fan Fault

State transitions in the next AC line cycle (4ms @50Hz 3ms @60Hz)

Note: The UPS still tries to control the high/low speed mode selection for the fan.

Inverter Fault

(Hardware fault)

Inverter Fault

(Output voltage test)

The UPS commands an immediate turn off of the Inverter, the PFC and the

Charger. Next, the unit will enter either a FAILURE_BYPASS or

UPS_FAILURE state (See State

Diagram.) Upon setting the

FAILURE_BYPASS state the UPS will command the Bypass and the Backfeed relays to close. Upon setting

UPS_FAILURE state the UPS will command the Bypass and Backfeed relays to open. For either state the unit commands the Output Relay to open.Note: Normal UPS_FAILURE/

FAILURE_BYPASS procedure timings can not be applied in this case. The rest of hardware control operations (e.g.

PFC input relay control) will take place in the next AC line cycle. So, the timings specified will start from phase angle 0.

No immediate action is taken. All state transitions are taking place in the next

AC cycle. (20msec @50Hz, 17msec

@60Hz)

Logic Power Supply

Fault

Immediately switches in UPS_FAILURE state. (See Normal Behavior for

UPS_FAILURE State.)

0

0

1

1

0

0

0

0

0

1

1

1

0

0

0

10

06

0B

YES

NO

Check: Fan connections to control board (Lynx2 uses J5 only), fan guard is not pushed in, no foreign objects stuck in fan blades, fan frame not broken

Lynx 2: Check Q705, Q706, Q715,

Q716, Q717, Q718, D750, D751

Lynx 3: Check IC1403, IC1404,

IC1407, IC1408 collector-emitter and gate-emitter

Same as above

01

Can't be in

FAILURE_BYPASS

R544, R545 should be 10k TA107


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30

High Output Voltage

High Output Voltage

(Extreme Overvoltage)

No immediate action is taken. The UPS will transfer to UPS_FAILURE or

FAILURE_BYPASS state (see State

Diagram) in the next AC line cycle.

(19msec @50Hz or 16ms @60Hz)

Output Relay Fault

(bypass relay is closed)

Output Relay Fault

(Transferring to inverter-on state)

Output Relay Fault

(Inverter is on)

Overload (Percent

LoadInverter is on)

No immediate action is taken. The UPS will transfer into UPS_FAILURE state in the next AC cycle (8ms @50Hz or 6ms

@60Hz.)

Overload

(Low output voltage)

Overload

(Percent Load

Bypass Relay is closed)


AC cycle (19msec @ 50Hz or 16msec

@60Hz.)The UPS will sound the beeper as long as the fault conditions are present.

Overtemperature


AC cycle (4msec @50Hz or 3msec

@60Hz.) The UPS will transfer to

FAILURE_BYPASS or UPS_FAILURE

(see State Diagram.)

1

0

0

0

0

0

0

1

0

1

0

0

0

1

1

Overload

LED

09 NO

0E

Can't be in

FAILURE_BYPASS

02

05

03

07

YES

YES

This fault is stored in ‘Ctrl-U’ during factory testing. It is not cleared before shipment.


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31

PFC Failure

(Inverter on, hard limit detection)

PFC Failure

(Inverter on, delta detection)

PFC Failure

(Inverter off)

PFC Failure

(Charging up DC

Buses)

PFC Failure

(cold-boot)

No immediate action is taken. The UPS will transfer to FAILURE_BYPASS or

UPS_FAILURE state (see State

Diagram.) State transitions will take place at the closest phase angle of 67.5 degrees of AC line cycle.

Upon detection of this fault, the PFC is turned off immediately, state transitions are taking place in the next AC cycle

(8msec @50Hz or 6msec @60Hz.) The

UPS will transfer into

FAILURE_BYPASS or UPS_FAILURE state (see State Diagram.)

Upon detection of this fault, the UPS will immediately enter UPS_FAILURE state.

Short Circuit Same as overload above.

0

0

1

0

0

0A YES

Overload

LED

04

Can't be in

FAILURE_BYPASS

Lynx2:

Q708, Q709, Q710, Q711, Q726,

Q727, D748, D749, D723, DC bus and battery voltage feedback resistors, esp. R856, R857

Lynx3:

IC903, IC904, DC bus and battery voltage feedback resistors

Backfeed Relay Weld


AC cycle. (8msec @50Hz or 6msec

@60Hz) The UPS will transfer to

FAILURE_BYPASS or UPS_FAILURE

(see State Diagram.)

0

0

0

1

0

0C NO


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32

Appendix B. ECO list as of October, 2005

Lynx2 modifications (Control board) – mirrored 180 degrees





33

Lynx3 modifications (Control board, top side)


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34

Lynx3 modifications continued (Control board, bottom side) – mirrored 180 degrees


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35

APC SURT service manual RMA rev2

Service Manual

APC Smart-UPS

®

RT

3,000VA – 10,000VA 200-240 Vac

Tower/Rack Mount

Uninterruptible Power Supply

English

Table of Contents

1 Safety Precautions

2 Introduction to SURT

2.1 Key Points

2.2 One-Line Diagram

2.3 Main Circuit Components

2.4 Functional Description

2.5 Power Train Operation

2.6 Transistor-Level Diagrams

3 User Interface

3.1 Front Panel Display and Control Buttons

3.2 Terminal Mode

Make sure that no SmartSlot accessory is installed in the SmartSlot bay of the UPS. The SmartSlot prevents access to certain UPS communication features such as the Terminal Mode.

3.3 SmartSlot Accessories (Webcard)

4 Installation

5 Component Replacements

6 Troubleshooting

Safety: Remove jewelry, pendants and wrist watches.

6.1 Unit Setup

Note:

.

6.2 Required Tools

6.3 Visual Inspections

Exterior

Interior

6.4 Troubleshooting Flowchart

6.5 Diode Checks

Lynx2: 3kVA - 6kVA

+ Probe - Probe

Good

Value

Components checked If open If short

Lynx3: 7.5kVA through 10kVA

+ Probe - Probe

Good

Value

Components checked

If open

If short

Notes:

Cold boot the unit and get the diagnostic information from the serial port before it gets cleared out. If the unit fails right away, read the display LED pattern and the failure code.

6.6 Documenting Failures

7 ECO's

8 Test After ECO's

Failure Analysis Report

& Corrective Action Plan

Action Taken to Repair

Initial Assessment

Repaired Unit - Measured and Calibrated Voltages

Corrective Actions to be Taken

Additional Notes

Appendix A. Fault codes on LED display & stored in EEPROM

Appendix B. ECO list as of October, 2005

Lynx2 modifications (Control board) – mirrored 180 degrees

Lynx3 modifications (Control board, top side)

Lynx3 modifications continued (Control board, bottom side) – mirrored 180 degrees

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