ON / OFF LINE – PREVENTIVE MAINTENANCE

(7200, 7400M, Hipulse, Hipulse E & Hipulse-EX)

Summary of the OFF Line Preventive Maintenance report:-

1) Customer, UPS and batteries details

2) Methods of cleaning of UPS
3) Methods of physical connection checks
4) Sizing of cable used & its observations
5) PCB Jumper settings checks
6) Control Parameters & windows checks
7) Power parameters & windows checks
8) AC / DC Capacitor health checkups
9) Battery health checks & cleaning
10) Thermal Imaging
11) Site and Environmental conditions
12) Important Note
13) Remarks & Recommendations

Page 1
 1) Customer, UPS and battery details
1.1 Customer Details

Customer Name :

Customer Address

Contact Person :

Contact No :
Email ID :
1.2 UPS Details
Hipulse -
UPS Model & Capacity 7200 7400M Hipulse Hipulse -E
EX

UPS Sr. No

UPS output Phase 3 Phases 1Phases

Hot
Configuration Single Parallel LBS
Standby

LBS Details Indigenous Imported

MSDA
LBS Model Supplied Single Parallel LBS ELBS
panel

Ext.TRF Input Output

Bypass Status Enabled Disabled

Source of Bypass Common Split UPS TRF SVR

Output Neutral Status Ground Ungrounded Multiple Ground

PE & NE Earthing conductor Separated Common

1.3 Battery Details

Battery Make Exide G&Y Amararaja HBL Quanta Panasonic
Battery Type SME VRLA Ni -Cad LATB
Battery Nominal Voltage 12V 2V 1.2V
No. of Battery / Cell / Bank
No. of Bank / UPS
No. of Battery rack / Cabinet

Page 2
Battery racks Earthing Grounded Ungrounded

2) Methods Of cleaning of UPS systems

Sr. No Activity UPS 1 UPS 2
2.1 Ensure all the alarm downloading complete before shutdown
2.2 Switch OFF inverter toggle switch in ULB ( Q2 in down position)
2.3 Switch OFF bypass toggle switch in ULB ( Q1 in down position)
2.4 Switch OFF rectifier toggle switch in ULB (Q3 in down position)
2.5 Switch OFF battery breaker in the enclosure box (BCBE)
2.6 Switch OFF Q1 input breaker
2.7 Switch OFF Q2 bypass breaker
2.8 Switch OFF Q4 output breaker
2.9 Wait for 10Min to ensure that DC voltage in the capacitor drops
2.10 Make sure no power supply in any of the power terminal in UPS
2.11 Ensure internal & external input breaker is switched OFF
2.12 Switch OFF internal & external Bypass breaker (Split Bypass)
2.13 Open all doors & covers in front side
2.14 Open all doors & covers in back side
2.15 Perform a thorough inspection of all cabinet for foreign objects
2.16 Perform a thorough dusting & vacuuming of all cabinets
interiors
2.17 Use industrial Air blower for cleaning the entire UPS systems
2.18 Clean all PCB by air blower & ensure no dust accumulation in
between the component in the PCB
2.19 If required use “Electronics cleaning compound” for PCB cleaning
in the components level cleaning if required
2.20 Make sure that dust removed near & on the power component
(IGBT, SCR, AC / DC Capacitor, between the winding of
Transformer & etc)

Page 3
3) Methods of physical connection checks
Sr. No Power Section tightness checks UPS 1 UPS 2
3.1 Rectifier Section
3.2 Inverter Section
3.3 Static Switch Section
3.4 DC Filter Section
3.5 AC Filter Section
3.6 Transformer Terminal Connection
3.7 Transformer Bases & Core
3.8 Series chokes & other wire compound
3.9 Other power cables
3.10 Input termination (R, Y, B, N, PE)
3.11 Output Termination (R, Y, B, N, NE)
3.12 Bypass termination (R, Y, B, N)
3.13 Battery termination (+ve & -Ve)
3.14 All isolator termination

Sr. No Control Section tightness checks UPS 1 UPS 2

3.15 RLB (X3 Connector) - Specific
3.16 ILB (X5 Connector) - Specific
3.17 AC/DC card (CN1 connector) - Specific
3.18 DC / DC Card (CN1 Connector) - Specific
3.19 ULB (X4 & X6 Connectors) - Specific
3.20 OLB (X9 & X2) - Specific
3.21 Firing Pulse wire of IGBT, SCR - Specific
3.22 All Flat ribbon cables (Specifically IGBT, SCR) - Specific
3.23 UPS end (X3 – Pin 2,3,4,5,6) - Specific
3.24 UPS end (X4 – Pin 1 to 12) - Specific
3.25 BCBE end - Specific
3.26 CT control cables
3.26 Other control cables in all PCB’s

Page 4
4) Sizing of cable used & its observations
Sr. No Cables size & runs UPS 1 UPS 2
4.1 Input conductors

4.2 Bypass conductors

4.3 Neutral Conductors

4.4 Output Cables size & runs

Neutral Earthing
4.6
conductors

4.7 PE Conductors

4.8 Battery Cables & runs

Page 5
 5) PCB Jumper settings checks
Rectifier Logic Board
Plug Position Function UPS 1 UPS 2
1-2 Disable Battery Temperature/Voltage Compensation (Standard) Ok
X5
2-3 Enable Battery Temperature/Voltage Compensation
1-2 Fast DC Regulation Speed for ALL UNITS Ok
X6
2-3 Decreased DC Regulation Speed- NOT USED
1-2 Fast Walk-In
X7
2-3 Slow Walk-In: 10 Seconds+ (Standard) Ok
1-2 Disable Temperature Monitor (6P Rectifier)
X9
2-3 Enable Temperature Monitor (12P Rectifier) Ok
1-2 Enable Rectifier Temperature Monitor (12P Rectifier)
X10
2-3 Disable Rectifier Temperature Monitor (6P Rectifier) Ok

Inverter Logic Board

Plug Position Function UPS 1 UPS 2
Open Not Used
0-1
Closed Standard Ok
Open Enable Ribbon Cable Detector Ok
0-2
Closed Disable Ribbon Cable Detector
Voltage Select Override Open
0-3 Manual Inverter Volts Adjust R243
Closed
0-4 Test Only; Open = Standard
X12 Frequency Select Override Open
0-5 Closed
Test Only; Open = Standard
Force Inverter ON -> Ignore All Blocks Open
0-6 Closed
Test Only; Open = Standard
Open Failed Contactor Enabled (Standard 7200)
0-7
Closed Failed Contactor Disabled (Standard Hipulse) Ok
Open Enable Bypass Matching Circuit (Standard 7200)
0-8
Closed Enable Bypass Matching Circuit (Standard Hipulse) Ok
0-1 2400 Hz Switching Frequency (Standard) Closed
0-2 4800 Hz Switching Frequency Open
X15 0-1 Open
9600 Hz Switching Frequency
0-2
0-5 1200 Hz Switching Frequency Open
0-1 Open
6P Inverter Current Feedback (Standard)
X16 0-2
0-3 12P Inverter Current Feedback Closed

Page 6
 UPS Logic Board
Plug Position Function UPS 1 UPS 2
Open for Parallel Operation
1-2
X12 Closed for Single-Module Operation
3-4 Open (Standard)
1-2 EPROM Enabled
X13
2-3 RAM Enabled (Standard) Closed
1-2 Open
3-4 Open
X14 Not Required; PCB Testing Only; Normally Open
5-6 Open

7-8 Open

1-2 PLL Option with

X15
2-3 PLL Option with Closed

Open CANbus Display Disabled

X16
1-2 CANbus Display Enabled (Standard) Closed
1-2 ALE Enable Data Save
X17
2-3 Power Supply Fail Enable Data Save (Standard) Closed
1-2 EPROM II Enable (Not Required) Open
X19
2-3 RAM II Enable (Not Required) Open
1-2 +5V PCB Enables Micro Ref for VA Calculations (Standard) Closed
X20
2-3 V Ref Enables Micro Ref for VA Calculations
1-2 Not Required
X21
2-3 RAM Enable (Standard) Closed
1-2 EPROM Enable (Standard) Closed
X22
2-3 Not Required
1-2 Not Required
2-3 EPROM Enable (Standard) Closed
X23
3-4 Not Required
4-5 Not Required
1-2 RAM Enable (Standard) Closed
2-3 EPROM Enable (Not Required)
X24
3-4 RAM Enable (Standard) Closed
4-5 EPROM Enable (Not Required)
1-2 Manual Reset Output Buffers
X25
2-3 Micro Reset Output Buffers (Standard) Closed
Inverter Oper Manual Mode (Bypass Preferred) = Closed
X26 1-2
Inverter Oper Auto Mode (Inverter Preferred) = Open (Standard)

Page 7
 Inverter Bad Voltage for 10 Seconds Closed
3-4 OFF Latch Enabled = Closed (Standard)
OFF Latch Disabled = Open
5-6 Not Required
Security Password Override Closed
7-8 Closed = Override Security Password
Open = Enable Security Password (Standard)
Open Internal Battery Disabled
X31
1-2 Internal Battery Installed and Charger Enabled (Standard) Closed
Open RS485 Port Disabled
X32
1-2 RS485 Port Enabled (Standard) Closed
1-2 Calendar IC Supply from VRAM (Standard) Closed
X33
2-3 Calendar IC Supply from Internal Battery
1-2 G.V.C.O. to Inverter Logic (Parallel Module Operation) Closed
X34
2-3 Micro V.C.O. to Inverter Logic (Single Module Operation)
1-2 Manual Reset Output Buffers Closed
X35
2-3 Micro Reset Output Buffers (Standard)
1-2 Separate Battery Per Module (1 for each Rectifier) Closed
X36
2-3 Common Battery (Parallel Rectifiers)
1-2 No Function
X37
2-3 No Function (Standard) Closed
1-2 Close for 7200 (30 kVA–60 kVA)
X38
2-3 Close for Hipulse (80 kVA) Closed

Page 8
 Operator Logic Board
Plug Position Function UPS 1 UPS 2
Open +5V Enable Main CPU (Standard)
X11
Closed ALE Enable Main CPU
0-1 Enable INV ON-OFF Push Button
0-2
0-3
0-4
X12
0-5 Open (Standard)
0-6
0-7
0-8
1-2 Inhibit Buzzer
X23
2-3 Enable Buzzer (Standard)
1-2 CAN bus Terminated (Standard)
X24
2-3 CAN bus not Terminated
1-2 RS232 Terminated (Standard)
X25
2-3 RS232 not Terminated
1-2 RS485 GND Connected to Board 0V
X26
2-3 RS485 GND not Connected to Board 0V (Standard)
X27 Open Standard (Test Only)

Page 9
 Static Switch Driver Board
Plug Position Function UPS 1 UPS 2
0-1 Inhibit Temp Sensor (Standard)
X15 0-2 Open
0-3 Close

High Voltage Interface Board

kVA X25 X29 X24 X26 (6 PULSE) X26 (6 PULSE)
80 0-1,0-3,0-5 0-1,0-2,0-3,0-4,0-5,0-6 0-2 0-1,0-2 0-3,0-6
120 0-2,0-4,0-6 0-1,0-3 0-1
160 0-1,0-3,0-5 0-1,0-2,0-3,0-4,0-5,0-6 0-2 0-1,0-2 0-3,0-6
200 0-2,0-4,0-6 0-1,0-2,0-3,0-4,0-5,0-6 0-3 0-2,0-4,0-5,0-7 0-2,0-7
250 0-1,0-2,0-3,0-4,0-5,0-6 0-2,0-4,0-6 0-3 0-1,0-4,0-5 0-1,0-2,0-7,0-8
300 0-2,0-4,0-6 0-1,0-3,0-5 0-1 0-2,0-4,0-5,0-7 0-2,0-7
400 0-1,0-3,0-5 0-2 0-1,0-2,0-4,0-5,0-7,0- 8 0-1,0-2,0-7,0-8
500
600 0-1,0-2,0-3,0-4,0-5,0-6 0-1,,0-3,0-5 0-1,0-3
800 0-1,0-2,0-3,0-4,0-5,0-6 0-1,,0-3,0-5 0-1,0-2,0-3 0-1, 0-2, 0-7, 0-8

X23 0-2, 0-4, 0-6

Page 10
 Parallel Logic Board
Plug Position Function UPS 1 UPS 2
0-1
0-2
X4 0-3 Links are Closed to give a Fixed Ref Voltage to the Circuit
0-4
0-5
All Open
X5 No Links
Ref Signal is o_n_inv from the Parallel Connectors Board
Open Common Battery for all UPS Modules
0-2 Closed Separate Battery for each UPS Module
(Standard)
Open (Standard)
0-3
Closed Disable Open Parallel Cable Shutdown
X6
0-5 Open No Function
0-6 Open No Function
0-7 Open No Function
Open Normal Operation (Standard)
0-8
Closed Test Mode Active
1-2 60 Hz
X7
2-3 50 Hz (Standard)
X11 1-2 Board Test Only (Open = Standard)
1-2 Parallel Cable Screen Earthed
X13
2-3 Parallel Cable Screen NOT Earthed (Standard)
0-1, 0-2 Open Slow Slew Rate (0.1 Hz/Sec) Selected
X14
0-1, 0-2 Closed Fast Slew Rate (0.5 Hz/Sec) Selected

Parallel Interface Board

Plug Position Function UPS 1 UPS 2
0-1
0-2
X4 0-3 Closed for 1+1 Operation
0-4
0-5
0-1
X5 0-2 Closed for Normal Operation

0-3

Page 11
 High Voltage Interface Board (7200 / 7400M)
Shunt Plug Link Position Function UPS 1 UPS 2
- 0-1 30 kVA CT burden
selection
x31 0-2
x31 : x32 : x33 : x34 : x35 : x37 : x38 : x39 : x40 0-3
- 0-1 40 kVA CT burden
selection
x31 : x32 : x33 : x34 0-2
x35 : x36 : x37 : x38 : x39 : x40 0-3
- 0-1 60 kVA CT burden
selection
- 0-2
x31: x32 : x33 : x34 : x35 : x36 : x37 : x38 : x39 : 0-3
x40

Bypass Static Switch (7200 / 7400M)

Shunt Plug x Link Position Function UPS 1 UPS 2
x11 0-1 open Inverter Static Switch
0-2 open ---------
0-3 Closed Bypass Static Switch (Std)
0-4 N/A ----------
0-5 closed Closed (Std)

Inverter Static Switch (7200 / 7400M)

Shunt Plug x Link Position Function UPS 1 UPS 2
x11 0-1 Closed Inverter Static Switch (Std)
0-2 open ---------
0-3 Closed Bypass Static Switch
0-4 N/A ----------
0-5 closed Closed (Std)

12 Pulse Rectifier Logic Board

Shunt Plug x Link Position Function UPS 1 UPS 2
J1 0–3 Open ---------------
CN1 0–5 Open ----------------

Replacement of RANGSON make IGBT Driver Boards

Page 12
 6) Control Parameters & windows checks
CARD SETTINGS

Rectifier Logic Board - (GND - X12 or X 13)

TEST
SI.NO CHECK MIN MAX UPS 1 UPS 2
POINT
1 CPS +12V V46 - K +12.95 +13.10
2 CPS --12V V45 - A -13.00 -13.05
3 DC Voltage reference X8 - 6 3.3 3.3
4 Rectifier Current Limit X8 - 7 -1.6 -1.6
Battery Current Limit.
5 X8 - 8 59mV / A 59mV / A
Ref. as per battery .Ah

Inverter Logic Board – (GND - X17 or X 18)

SI.NO CHECK TEST POINT MIN MAX UPS 1 UPS 2

1 CPS +12V V14 - K
+13.30 +13.50

2 CPS --12V V15 - A

-13.50 -13.55

3 150% Current Limit X 10 - 4

0.6 0.65

4 Peak to Peak X7–4&5

36VAC 36VAC

UPS Logic Board – (GND - X18 – 8)

SI.NO CHECK TEST POINT MIN MAX UPS 1 UPS 2

1 5 V reference by R209 X20 - 1
5.00 5.00

2 2.5 V reference by R212 V 45 - A

2.5 2.5

Page 13
 Parallel Logic Board – (GND – X10)

SI.NO CHECK TEST POINT MIN MAX UPS 1 UPS 2

1 CPS +12 V DC X25 - 5
+12.65 +12.75

2 G.V.C.O ref Voltage X8 - 3

4.00 4.00

3 G.V.C.O. Freq. By R18 X8 - 2

50.10 50.10
220 / 380V –
220 / 380V –
5.15V
5.15V
230 / 400V –
4 Selective Shutdown by R19 R68 Lower 5.56V
230 / 400V –
5.56V
240 / 415V –
240 / 415V –
5.86V
5.86V

SOFTWARE SETTINGS
SI.NO CHECK UPS 3 UPS 4
1 Configuration
2 UPS capacity
3 NUM. OF. INVERTER OK Selection
4 Rated Output Voltage
5 Voltage Window (Upper / Lower – Input & Output)
6 Sync. Window
7 Slew Rate
8 Battery Capacity
9 No. Of Cell
10 Date and Time Set
11 Communication - Local / Remote / IGMNET / JBUS

Page 14
 7) Power parameters & windows checks
Output Parameters
Sr. No Parameters
R phase Y phase B Phase
Voltage
Current
kW
UPS 1
kVA
PF
Frequency

Output Parameters
Sr. No Parameters
R phase Y phase B Phase
Voltage
Current
kW
UPS 2
kVA
PF
Frequency

Inverter Transformer parameters

TRF. Primary DC
TRF. Primary AC TRF. Secondary AC
Current Output Load Current
Current current
(Including Polarity)
Sr. No

R Y B R Y B R Y B R Y B
Phase Phase Phase Phase Phase Phase Phase Phase Phase Phase Phase Phase

UPS 1

UPS 2

UPS 3

Page 15
 8) AC / DC Capacitor health checkups
AC and DC Capacitors Bank
Sr. DC Capacitors AC Capacitors
Parameters
No

1 Capacitor Voltage

2 Capacitor Current

3 Any Leakage

5 Ambient Temp.

6 Capacitor Temp.

7 Physical Condition

8 DC Voltage Sharing
Charging current
9
with Battery
10 Ripple Current

Page 16
9) Battery health checks & cleaning
UPS 1 UPS 2
Sr. No Float Discharge Float Discharge
Batch Code Batch Code
Voltage Voltage Voltage Voltage
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

Page 17
Battery health checkups
Sr. No Activity UPS 1 UPS 2
1 Cleaning of battery container
2 Terminal Tightness
3 Leakage on container
4 Physical damages if any

10) Thermal Images

Input Transformer (Max 100 Deg Centigrade) DC Capacitors (Max 60 Deg Centigrade)

Inverter Transformer (Max 100 Deg Centigrade) AC Capacitors (Max 50 Deg Centigrade)

Page 18
 Rectifier Heatsink (Max 60 Deg Centigrade) IGBT Heatsink (Max 70 Deg Centigrade)

11) Site and Environmental Conditions

Page 19
12) Important Note:
a) Do not connect OC web card in online.
b) Do not connect AS400 card in online.
c) Do not disconnect PLB in online.
d) Do not disconnect PLB until DC voltage drop completely Zero.
e) Do not disconnect PLB without convert it to single mode.
f) Do not forget to change the setup in the display when disconnected PLB.

13) Remarks & Recommendations

Customer Signature & Seal ENPI Engineer Signature

Page 20