Operating Signals, Check-List For Possible Faults and Troubleshooting (Ups Safepower Evo Ug..)

OPERATING
PROCEDURE
TRAINING
Check‐List faults and troubleshooting (Safepower evo UG..)
OPERATING SIGNALS, CHECK-LIST

FOR POSSIBLE FAULTS AND TROUBLESHOOTING
(UPS SAFEPOWER EVO UG..)
REV. Date Prepared by Checked by Issued by ID: NUMBER

Issue/000 2014-06-20 A. Mazza E. Rusconi P. Baggi PO-DT-F001E
1 of 11+ FR
Proprietà riservata - A termini di legge è rigorosamente vietato riprodurre o rendere noto a terzi il contenuto del presente documento
This is a propriety of Siel - Do not reproduce and transmit the content of this document to third parties
OPERATING PROCEDURE
TRAINING
CONTENTS PAGE
1. PREMISE................................................................................................................................................................... 3
2. SIGNALS................................................................................................................................................................... 3
1) Rectifier on ............................................................................................................................................................ 3
2) Battery on float charge .......................................................................................................................................... 3
3) Battery on boost charge ......................................................................................................................................... 3
4) Battery voltage ok.................................................................................................................................................. 3
5) Inverter on ............................................................................................................................................................. 3
6) Inverter-Reserve in Synchronism .......................................................................................................................... 4
7) Ups master ............................................................................................................................................................. 4
8) Load on inverter .................................................................................................................................................... 4
9) Reserve ok ............................................................................................................................................................. 4
10) Load on reserve ................................................................................................................................................. 4
3. ALARMS ................................................................................................................................................................... 5
1) Rectifier off ........................................................................................................................................................... 5
2) Rectifier blocked ................................................................................................................................................... 5
3) Rectifier overheating ............................................................................................................................................. 5
4) Battery pre-alarm ................................................................................................................................................... 6
5) Battery voltage not ok............................................................................................................................................ 6
6) Battery Fault .......................................................................................................................................................... 6
7) Max battery temperature ........................................................................................................................................ 6
8) Battery temperature probe fault ............................................................................................................................. 7
9) Inverter overload ................................................................................................................................................... 7
10) Over current ...................................................................................................................................................... 7
11) Inverter overheating .......................................................................................................................................... 7
12) Magnetic overheating ........................................................................................................................................ 8
13) Inverter blocking ............................................................................................................................................... 8
14) Inverter not synchronised .................................................................................................................................. 8
15) Switching blocked ............................................................................................................................................. 9
16) Static switch fault .............................................................................................................................................. 9
17) UPS emergency on ............................................................................................................................................ 9
18) Back feed protection........................................................................................................................................ 10
19) Max ambient temperature................................................................................................................................ 10
20) Highly distorted load ....................................................................................................................................... 10
21) Preventive maintenance recommended ........................................................................................................... 10
22) Missing Isolation ............................................................................................................................................. 10
23) Filter fault ........................................................................................................................................................ 11

2 of 11+ FR
OPERATING PROCEDURE
TRAINING
1. PREMISE
This document provides essential information on the signals and alarms displayed on the
front UPS LCD monitor.
Specifically, as for signals, an explanation is provided to better understand UPS conditions
while the reason for which an alarm is triggered and a series of checks the operator can
run to better identify the cause are provided for each alarm.
Essential operations to be run to remove the fault found.
2. SIGNALS
1) Rectifier on
Comment on the signal:

The rectifier is running since both power voltage and frequency are within the technical
specification limit values.
Status: Normally included.
2) Battery on float charge

The rectifier is running and distributes power to keep the buffer battery charged.
3) Battery on boost charge

The rectifier is running and distributes current to charge the battery after it died following a
blackout or rectifier fault.
Status: Normally absent.
Included after a blackout.
4) Battery voltage ok

Indicates that the battery voltage is suited to power the inverter (the VBatt min and VBatt
max values are indicated in the technical specifications).
If battery voltage is not suitable, the inverter stops. It automatically restarts when voltage
returns within admitted limits.
5) Inverter on

The inverter is running, distributes voltage equal to rated voltage and thus is able to
charge.

3 of 11+ FR
OPERATING PROCEDURE
TRAINING
6) Inverter-Reserve in Synchronism

Inverter voltage is in phase with reserve line voltage. This is possible provided that reserve
voltage frequency is suited to power the load.
Admitted tolerance can be selected at the following values:
a) ± 1% rated frequency
b) ± 4% rated frequency
7) Ups master

For a UPS in parallel, this signal indicates that the machine provides synchronisation to
the other UPS.
Status: It must be included on at least one of the UPS in parallel.
Checks: Continuous transmission of the “master” signal from one UPS to another is a
symptom of parallel system fault.
Reset: The most probable cause is a partial signal interruption on optic fibres due to
crushing or abnormal bend in the fibre. It may also be due to a control board fault.
8) Load on inverter

The inverter is running and powers the load.
9) Reserve ok

Indicates that reserve voltage is suited to power the load. This signal is transmitted when
voltage is within ±10% of rated voltage.
10) Load on reserve

The signal is normal when both inverters are off or during mains switching (intentional or
due to overload).
Status: Normally absent.

4 of 11+ FR
OPERATING PROCEDURE
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3. ALARMS
1) Rectifier off
Comment on the alarm:

power outage
Causes:
Cause 1: Power outage of mains switch opened upstream from the UPS
Check 1: Check mains input voltage
2) Rectifier blocked

Caused by rectifier stop.
Causes:
Cause 1: Mains input voltage under 20% Vnom
Cause 2: No input voltage phase

Cause 3: Incorrect mains input voltage cycle direction

Check 3: Check mains input voltage connections
Reset 3: Reverse the two mains input voltage phases
Cause 4: Input fuse triggered

Check 4: Check input fuses
Reset 4: Replace input fuses
Cause 5: Rectifier board transformer fault

Check 5: Check the transformer and relevant protection fuses
Cause 6: Rectifier board fault (control and power logic)

Check 6: Check concerned board power.
3) Rectifier overheating

Indicates rectifier overheating.
Causes:
Cause 1: Fan fault
Reset 1: Replace fan
Cause 2: Air vents clogged

Reset 2: Remove air vent clog
Cause 3: Thermo-resistance fault (open contact)

Reset 3: Replace the thermo-resistance

5 of 11+ FR
OPERATING PROCEDURE
TRAINING
4) Battery pre-alarm

It should be considered normal in the event of prolonged power outage (indicates that the
battery is low), otherwise see alarms 2) and 3).
5) Battery voltage not ok

Indicates that inverter input DC voltage is not within the inverter operating range.
Causes:
Cause 1: The rectifier is in soft start phase and has not yet reached rated VDC.
Reset 1: Reset is automatic when rectifier start has completed.
Cause 2: The machine is restarting after a stop due to dead battery.

Reset 2: Reset is automatic as soon as the battery is 70% charged.
Cause 3: Rectifier fault.

Check 3: Check whether the rectifier fault persists (alarm 2) even if input voltage is regular.
Cause 4: Converter DC/AC board fault (CS007 or CS228 board)

Check 4: Check chopper trigger on concerned board.
Reset 4: Replace the CS007 or CS228 board.
Cause 5: CS221 inverter logic board fault

Check 5: Check the ”Battery OK” signal on the CS221 board
Reset 5: Replace the CS221 board
6) Battery Fault

Period battery test failed or charge timed out (12 h standard).
Cause:
Battery fault
7) Max battery temperature

The battery temperature sensor read a room temperature over 35°C.
Cause:
Room air ventilation fault or clog.
Reset:
Restore correct room ventilation.

6 of 11+ FR
OPERATING PROCEDURE
TRAINING
8) Battery temperature probe fault

Signals a temperature check circuit fault in the battery cabinet
Causes:
Cause 1: Probe signal cable disconnected.
Check 1: Check signal cable continuity.
Reset 1: Restore signal continuity.
Cause 2: Probe fault.

Reset 2: Replace the faulty probe.
9) Inverter overload

The load is switched to the backup line.
Cause:
Load over rated value.
Check:
Check load absorption.
Reset:
Reduce load absorption. The load must be re-powered by the inverter.
10) Over current

IGBT electronic protection triggered.
Causes:
Cause 1: Accidental peak over current.
Check 1: Check instant load absorption.
Reset 1: Restart the inverter.
Cause 2: Parallel regulation fault.

Check 2: Make sure there is no current recirculation between parallel UPS.
Cause 3: Inverter stage fault

Check 3: Check IGBT and driver board.
11) Inverter overheating

Indicates inverter overheating.
Causes:
Cause 1: Fan fault

7 of 11+ FR
OPERATING PROCEDURE
TRAINING
Cause 3: Faulty thermo-resistance (open contact)

12) Magnetic overheating

Indicates inverter transformer overheating.
Causes:
Cause 1: Fan fault

Cause 3: Faulty thermo-resistance (open contact)

13) Inverter blocking

The alarm signals the fact that the inverter is stopped.
Cause 1:
The inverter was turned off using the buttons on the front.
Reset 1:
Restart the inverter.
Other causes:
The cause is specified when one of the alarms described in points 5), 9), 10), 11) or 12)
appears.
(see single points)
14) Inverter not synchronised

This alarm is triggered whenever the inverter cannot remain synchronised with the
emergency mains.
Causes:
Cause 1: Reserve/Static by pass frequency is out of the inverter connection range.
Check 1: Check G.E. frequency.
Reset 1: Return G.E. frequency within the limits.
Cause 2: G.E. frequency variation speed is excessive.

Check 2: Check whether G.E. changes frequency.
Reset 2: Restore correct G.E. frequency stability.

8 of 11+ FR
OPERATING PROCEDURE
TRAINING
15) Switching blocked

The switching blocking alarm is triggered when load power is forced on the mains.
Cause:
“Forced” switch on one or more UPS in position “ON”.
Check:
Check whether one or more switch is forced “ON”.
Reset:
Turn all forced switches to “OFF”.
16) Static switch fault

Static switch fault
Cause:
Cause 1: one or more thyristor short circuits
Check 1: Ohm test thyristors
Cause 1: Control logic or power board fault

Check 1: Replace the above boards one at a time
17) UPS emergency on

Indicates EPO (Emergency Power OFF) triggered. The alarm is not on the display. The
UPS does not distribute output voltage and displays rectifier, backup and inverter block
alarms. Leds are all off except the LED (suitable backup)
Causes:
Cause 1: Emergency Power Off button pressed.
Check 1: Check button conditions.
Reset 1: After turning off the button, follow the instructions in the manual to restore UPS
operations.
Cause 2: Signal cables to EPO button interrupted.

Check 2: Check EPO circuit connection integrity.
Reset 2: After restoring circuit integrity, follow the instructions in the manual to restore
UPS operations.

9 of 11+ FR
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18) Back feed protection

The alarm signals a severe static switch fault.
Causes:
Cause 1: one or more thyristor short circuits
Check 1: Ohm test thyristors
Cause 2: NRE CS144 board fault

Check 2: Check the power supply of CS144 board
19) Max ambient temperature

The room temperature sensor measured temperature near maximum UPS operating
temperature.
Cause:
Room air ventilation fault or clog.
Reset:
Restore correct room ventilation.
20) Highly distorted load

Load current harmonic distortion exceeds admissible UPS distortion. Consequently the
output voltage waveform is out of rated limits; this may cause load switching on the mains
in more severe cases.
Reset:
Remove the more distorting loads (or increase UPS power).
21) Preventive maintenance recommended
Comment on the alarm: Normally off. If on, the alarm is triggered 1 year from activation
date. Warns the customer that preventive maintenance is recommended.
22) Missing Isolation

Normally disabled. If enabled, the alarm detects the lack of load cut-off.
Causes:
Cause 1: Load current dispersion to grounding of one or more UPS output phases.
Check 1: Where possible, open load switches one at a time until the fault is found.
Reset 1: Restore normal system operations (from UPS) and cut off the faulty load.
Cause 2: Grounding phase on distribution cables between UPS and loads.

10 of 11+ FR
OPERATING PROCEDURE
TRAINING
Check 2: Perform check 1. If the signal does not disappear opening distribution switches,
this means that the dispersion is on UPS output connection cables and load switch.
Cause 3: Grounding phase in one of the two UPS.

Check 3: Proceed as with check 2. If the relevant signal does not disappear when a UPS
output switch is opened, this means that dispersion is inside the UPS. Check output wires
and switch.
Cause 5: Cut-off control board fault.

Check 5: Check CS144 board power.
Reset 5: Replace the faulty board.
23) Filter fault

The AC filter temperature sensor detected cubic condenser overheating.
Causes:
Cause 1: AC filter cubic condenser fault.
Check 1: Check the probe with the open contact
Reset 1: Replace the cubic condensers with the new cylinder condenser kit (shatter proof)
Cause 2: Probe connection cables disconnected

Check 2: Check the connection on board CS223 or CS270. Check the jumper connection
where temperature probes are not installed.
Cause 3: (CS221) inverter logic board fault.

Reset 3: Replace the board
Note: The alarm may also be triggered when new cylinder condensers are installed
(temperature sensors not included) since the filter fault circuit is still on board CS221.

11 of 11+ FR
Data
Rev.
Modifica
Descrizione modifica Compilato Verificato Emesso
000 2014-06-20 - Prima Emissione A. Mazza E. Rusconi P. Baggi
ID:NUMBER
STATO DELLE REVISIONI PO-DT-F001E
Check‐List guasti e ricerca guasti (Safepower evo UG..) MD111 Rev00 Page. FR1 of FR1

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OPERATING

OPERATING SIGNALS, CHECK-LIST

REV. Date Prepared by Checked by Issued by ID: NUMBER

REV. Date Prepared by Checked by Issued by ID: NUMBER

Comment on the signal:

2) Battery on float charge

Comment on the signal:

3) Battery on boost charge

Comment on the signal:

Comment on the signal:

Comment on the signal:

REV. Date Prepared by Checked by Issued by ID: NUMBER

Comment on the signal:

Comment on the signal:

Comment on the signal:

Comment on the signal:

10) Load on reserve

Comment on the signal:

REV. Date Prepared by Checked by Issued by ID: NUMBER

Comment on the alarm:

Comment on the alarm:

Cause 2: No input voltage phase

Cause 3: Incorrect mains input voltage cycle direction

Cause 4: Input fuse triggered

Cause 5: Rectifier board transformer fault

Cause 6: Rectifier board fault (control and power logic)

Comment on the alarm:

Cause 2: Air vents clogged

Cause 3: Thermo-resistance fault (open contact)

REV. Date Prepared by Checked by Issued by ID: NUMBER

Comment on the alarm:

5) Battery voltage not ok

Comment on the alarm:

Cause 2: The machine is restarting after a stop due to dead battery.

Cause 3: Rectifier fault.

Cause 4: Converter DC/AC board fault (CS007 or CS228 board)

Cause 5: CS221 inverter logic board fault

Comment on the alarm:

7) Max battery temperature

Comment on the alarm:

REV. Date Prepared by Checked by Issued by ID: NUMBER

8) Battery temperature probe fault

Comment on the alarm:

Cause 2: Probe fault.

Comment on the alarm:

10) Over current

Comment on the alarm:

Cause 2: Parallel regulation fault.

Cause 3: Inverter stage fault

11) Inverter overheating

Comment on the alarm:

Cause 2: Air vents clogged

Cause 3: Faulty thermo-resistance (open contact)

12) Magnetic overheating

Comment on the alarm:

Cause 2: Air vents clogged

Cause 3: Faulty thermo-resistance (open contact)