UG-18 UPS Support System Operations and Service Manual...ug-18 ups support system operations and service manual manual #114550-e the information contained, proprietary to pacific power

PACIFIC POWER SOURCE

UG-18 UPS SUPPORT SYSTEM

OPERATIONS AND SERVICE MANUAL

MANUAL #114550-E

THE INFORMATION CONTAINED, PROPRIETARY TO

PACIFIC POWER SOURCE CORPORATION, MAY NOT BE COPIED OR

REPRINTED WITHOUT ITS EXPRESS WRITTEN CONSENT.

PACIFIC POWER SOURCE CORPORATION 17. I

, CALIFORNIA 92549 PHONE <714) 898-2591

NOVEMBER, 1985

SIXTH EDITION

THIS MANUAL IS ASSIGNED TO EQUIPMENT SERIAL NUMBER:

vi

herman.vaneijkelenbu

Text Box

Pacific Power Source, Inc. 17692 Fitch, Irvine, CA 92614 (949) 251-1800 www.pacificpower.com

herman.vaneijkelenbu

Text Box

SECTION

1.0

2.0

3.0

4.0

5.0

CONTENTS

TITLE

SUMMARY DESCRIPTION 1-1

1.1 UG UPS System 1-2 1.2 UG-18 Battery Support Cabinet 1-3

ELECTRICAL SPECIFICATIONS

2. 1 2.2 2.3

Input Power Output Power Battery Recovery,Time

MECHANICAL SPECIFICATIONS

3. 1 3.2

Size Weight

INSTALLATION

4. 1 4.2 4.3 4.4 4.5 4.6

Crating, Uncrating and Moving Clearances Floor Loading Battery Installation Procedure Interconnections Charger Module Removal and Installation

OPERATION

5.1 5.2 5.3 5.4 5.5

First Time Operation UG-CM18 Charger Module Batteries Maintenance Calibration

v

2-1

2-1 2-1 2-1

3-1

3-1 3-1

4-1

4-1 4-3 4-3 4-5 4-21

4-24

5-1

5-1 5-3 5-7 5-9 5-10

n,M;f';M 0.-.woY' ~'"'"'"" rnl"ni"IY'.:!tinn - Huntinoton Beach. California 92649 (714) 898-2691

SECTION

6.0

7.0

8.0

9.0

10.0

TITLE

UG-18 MAIN FRAME DETAILED DESCRIPTION

6.1 Description 6.2 Servicing

UG-CM18 CHARGER MODULE DETAILED DESCRIPTION

7.1 7.2 7.3 7.4

Description Theory of Operation Servicing Calibration

UG-BA18 BATTERY ADAPTOR DETAILED DESCRIPTION

8.1 Description 8.2 Theory of Operation 8.3 Servicing 8.4 Calibration

FAN DRIVER DETAILED DESCRIPTION

9. 1 9.2 9.3 9.4


4024 REMOTE STATUS PANEL DETAILED DESCRIPTION <OPTION>

10. 1 10.2 10.3 10.4


iv

6-1

6-1 6-4

7-1

7-1 7-14 7-15 7-16

8-1

8-1 8-9 8-9 8-10

9-1

9-1 9-5 9-5 9-G

10-1

10-1 10-12 10-14 10-14

FIGURE

1-1 1-2 1-3 2-1 3-1

4-1 4-2 4-3 4-4

4-5 4-6 5-1

6-1 7-1 7-2 7-3 7-4 7-5 7-6 7-7 8-1 8-2 8-3 8-4 9-1 9-2

10-1 10-2 10-3 10-4

LIST OF ILLUSTRATIONS

DESCRIPTION

390-UGC System Detail UG-18 Battery Support Cabinet Detail UG-BA18 Battery Adaptor Mtg. Detail Battery Discharge Curve UG-18 Battery Support Cabinet Outline Drawing Crating Detail Battery Tray Wiring Diagram Battery Terminal Numbering Drawing Battery Tray & Terminal Location Drawing Battery Placement Detail UG-18 Systems Interconnection Detail UG-CM18 Charger Module Control Location Detail UG-18 Main Frame Assembly UG-CM18 Chassis Assembly Control Card Schematic Control Card Assembly UG-CM18 Charger Module Schematic Power Supply Board Schematic Power Supply Board Assembly Battery Voltage Sensor Test Set-Up UG-BA18 Battery Adaptor Assembly UG-BA18 Battery Adaptor Schematic Battery Switch Card Assembly Battery Switch Card Schematic Fan Driver Assembly Fan Driver Schematic

Function Assmbly

6-2, 7-2,

4024 Remote Status Panel 4024 Remote Status Panel 4024 Remote Status Panel 4024 Remote Status Panel

PCB Assembly Schematic

iii

o~~ifi~ o~wa~ ~~~~~rP r.o~ooration- HuntinQton Beach, California 92&49 (714) 898-2&91

PAGE

1-2 1-4 1-6 2-2

3-2 4-2 4-6 4-8

4-10 4-12 4-22

5-4 6-3 7-3 7-5 7-6 7-10 7-12 7-13 7-18 8-2 8-3 8-4 8-5 9-2 9-3

10-2 10-4 10-6 10-7

This page intentionally left blank.

ii

This page intentionally le£t blank.

i

Para.

1.0 1.1 1.2

Fig.

1-1 1-2 1-3

SECTION .1.

SUMMARY DESCRIPTION

TABLE OF CONTENTS

Title

Summary Description UG UPS System UG-18 Battery Support Cabinet


Title

390-UGC System Detail UG-18 Battery Support Cabinet Detail UGBA-18 Battery Adaptor Mtg. Detail

1-0

Page

1-1 1-1 1-3

Page

1-2 1-4 1-6

P.::~rifir 01'\WPY' SnurrP r.ornnr.<tion- Hunti!'lllton Beach. California 92649 (714) 898-2691

MODEL UG-18 SECTION 1

1. 0

1.1

SUMMARY DESCRIPTION

UG UPS SYSTEM

The UG-18 Battery Support Cabinet is a single cabinet containing batteries and battery charger plus interface circuits which allow the cabinet to be connected to any standard PPSC G-Series AC power source. When connected, the power source and UPS Support Cabinet become a full on-line, high quality uninterruptible power source <UPS>. <See Figure 1-1>

The UG-18 Battery Support Cabinet is designed to interface with Pacific's G-Series power sources only, and cannot interface with any other. However, it will interface with any G-Series machine, single or three phase, small or large unit, up to 18 KVA.

The UG-18 Battery Support Cabinet and G-Series power source, comprising the complete UPS system, operate from AC input power to produce high quality AC output power at operator selected voltage and frequency. When AC input fails either momentarily or permanently, control circuits connect the UG Batteries to the power source instantaneously. Transfer is "glitchless" because load equipment experiences no detectable disturbance in output power.

When AC input power resumes, the power source automa-tically transfers to line operation, and the UG-18 Battery Support Cabinet starts recharging its batteries. Again, retransfer is "glitchless".

If AC line input power is not resumed, the UPS will operate until 80-90% of battery capacity is used and activates a "LOW CHARGE" alarm. When 100% of useful battery energy is used, the UPS system turns off and system output is finally interrupted. The system cannot thereafter be turned on again until AC line power is available.

An optional 4024 REMOTE STATUS PANEL is available which indicates full status of the UPS system including; charger operation, charge status, line status, etc., This panel is specifically designed for those applications where the UPS is located remotely from the operator station.

1-1

0

U G 18 BATTERY SUPPOR,T CABINET

I

~ l--!1 "' --.+-1---- C TYPE CONTROL

MODULE

I ' .

rr _._.:;:;.··-·-·'--·-·- , J : -~.-+nn_._' -dH-T-UG MAINFRAME L~~l- ____ ·uu 1 ADAPTOR

390-GC

(MNTD TO REAR PLANE)

INTERCONNECT CABLES

FIGURE 1-1

MODEL 390-UGC SYSTEM DETAIL

1-2


1.2 UG-18 BATTERY SUPPORT CABINET

The complete UG-18 Battery Support System consists of:

A UG-18 Battery Support Cabinet (ref. Figure 1.2), consisting of 6 trays of sealed Gel Cell batteries, each tray housing eight batteries, 12 Volts @ 40 Ampere-hour capacity each. The batteries in each tray are connected in series to produce a 100 VDC string. The six trays are interconnected to produce three isolated supplies, each of ~ 100 VDC. An interconnection strip in front of each battery tray connects the batteries in series. This strip also provides convenient terminals for the user to monitor battery voltages. Batteries are conveniently loaded or exchanged from the front.

The UPS Support Cabinet also houses a charger module containing three isolated chargers, one for each of the ~ 100 VDC battery supplies.

The charger module also contains sensitive voltage comparators to indicate battery charge status and to trip the main battery DC circuit breaker at the battery End-of-Life point. The main battery DC Circuit Breaker (6 pole>, and DC and AC instrumentation circuits are also contained in the charger module.

1-3

I

1111111 B~l71 <i 0 0 - -. . - - '-._: .

~ "" . j..:..:.J L..._ 1---l ··-==

4 --

:..___.! L- :..___.! L-

• = I I 1---l L..._ 1---J L_ I

I

0 = a

~-==~· L..._ 1---1 L.:_ v )

- -- -

1-==1 L.:. 1---l L_

0

~ '-- '---! '-- ' . . . . . .

II I I II

FIGURE 1-2

MODEL UG-18 BATTERY SUPPORT · CABINET DETAIL

1-4

1/

l

~

v

CHARGE-R MODU!,I;S

BAlTf:RY TRAY.


1. 2 UG-18 BATTERY SUPPORT CABINET <con't)

The UG Mainframe Adaptor unit is physically located on the rear surface of the Power Source cabinet <Ref. Figure 1-3). It contains the sensors, which determine the presence or absence of AC line power, and the logic to transfer to battery power. It also contains the battery switches and wiring into the power source cabinet.

Fan drivers are placed in multiple locations throughout the power source cabinet. They are required in each power module to guarantee adequate cooling during battery-only operation.

The 4024 Remote Status Panel (optional) is a small unit which can be located hundreds of cable-feet away from the UPS system to give the operator system status information.

1-5

POWER SOURCE 7

MAINFRAME ADAPTOR

-

1\

'

"-.../. _________ '.::.7 u ______ .u

FIGURE 1-3

MODEL UGBA-18 BATTERY ADAPTOR MTG. DETAIL

1-6

REAR


- THIS PAGE INTENTIONALLY LEFT BLANK -

1-7

Para.

2.0 2.1 2.2 2.3

Fig.

2-1

SECTION 2


TABLE OF CONTENTS

Title

Electrical Specifications Input Power Output Power Battery Recovery Time


Title

Battery Discharge Curve

2-0

Page

2-1 2-1 2-1 2-1

Page

2-2


2.0

2. 1


INPUT POWER

The UG-18 Battery Support Cabinet requires 115VAC, 47-63 Hz at 10 Amps maximum input current during charging. When the batteries are fully charged the input current should reduce to less than 2 Amps.

It is important that the "Charger On" lamp, (blue), is on at all times. If the input power is removed for a long period of time, permanent battery damage may occur due to battery self-discharge.

The Battery Cabinet may be connected into the outlet located on the UG Mainframe Adaptor mounted on the rear of the Power Source. The charger may also be connected into any standard outlet during storage.

Refer to the Power Source Manual for the Power Source's Input Power requirements.

2.2 OUTPUT POWER

2.3

The UG-18 Battery Support Cabinet comes standard with 40 A-H batteries. This rating is given for a 20 hour 2 Amp discharge rate. As the discharge current increases the the A-H rating decreases <See Figure 2-1>. The Battery Capacity will also decrease with lower temperature.

Refer to the Power Source Manual for the Power Source's Output Power specifications.

BATTERY RECOVERY TIME

Fully discharged batteries will recover to full charge in 24 hours. However, they are capable of operation for 1/2 the time intervals shown in Figure 2-1 in JUSt 12 hours of recharging.

2-1

24

18

SYSTEM OUTPUT 12

(KVA) @ 120V

6

0

I ·-~

I I

\

\ I I I \ I

"" I I

~ -'---- --"--...__ I

--r------ I

I i

0 20 40 60 80 100 120 140 160 180

6ATTE.RY OPERATION T I M E ( f\\11' J) @ 2 5° c

FIGURE 2-1

BATTERY DISCHARGE CURVE <STANDARD 40 A-H BATTERIES>

2-2



2-3

Para.

3.0 3.1 3.2

Fig.

3-1

SECTION 3


TABLE OF CONTENTS

Title

Mechanical Specifications Dimensions Weight


Title

UG-18 Battery Support Cabinet Outline Dwg.

3-0

Page

3-1 3-1 3-1

Page

3-2

Pacific Power Source Corporation- Huntington Beach, California 92&49 (714) 898-2&91


3.0

3.1

3.2


DIMENSIONS

Figure 3-1 is an outline drawing of the UG Battery Support Cabinet.

The UG-BA18 Battery Adaptor is a 19-inch wide rack mount unit, 5 1/4 inches high and 8 inches deep. The UG-BA18 Battery Adaptor will add 6.5 inches to the overall depth of the Power Source.

Refer to the Power Source Service and Operation Manual for the dimensions of the Power Source.

WEIGHT

The UG-18 Battery Support Cabinet will weigh approximately 1,800 pounds. The center of gravity is located as shown in Figure 3-1. Care should be taken to keep it upright.

Refer to the Power Source Service and Operation Manual for the weight of the Power Source.

3-1

P.:~ri fir PnwPr ~llf'rP r.nf'nnf".:~tior, - Huntinoton Beach. California 92&49 (714) 898-2&91

- SHOCK MOUNT (OPT)

r-24.11 -r~=--· _.;..____ 3 8. 8 ---+--1 1-o------ 3'4.3 -----....-l

DOE] !PJJUAkl 0 0 • 0 0

0 (

0 E

tG ~ c

lo c

~12 ~ [

~-----.---

71.0

73.5

FIGURE 3-1

UG-18 BATTERY SUPPORT CABINET OUTLINE DRAWING

3-2

tG I

33

SHOCK MOUNTS (OPT)



3-3

Para.

4.0 4. 1 4.2 4.3 4.4 4.5 4.6

Fig.

4-1 4-2 4-3 4-4 4-5 4-6

SECTION 4

INSTALLATION

TABLE OF CONTENTS

Title

Installation Crating, Uncrating and Moving Clearances Floor Loading Battery Installation Interconnections Charger Module Removal & Installation


Title

Crating Detail Battery Tray Wiring Diagram Battery Terminal Numbering Dwg. Battery Tray and Terminal Location Dwg. Battery Placement Detail UG-18 System Interconnection Detail

4-0

Page

4-1 4-1 4-3 4-3 4-5 4-21 4-24

Page

4-2 4-6 4-8 4-10 4-12 4-22

n,n;i';n Dr.WCY' Gr~IIY'I'CI rnY'MY'.":Itir,y, - l·hmt.inntrm Beaeh. California 92549 (714) 898-2591


4.0 INSTALLATION

4. 1 CRATING, UNCRATING and MOVING

Crating Notice: It is the customer's responsibility to insure that cabinets are adequately crated when they are sent to a different site or returned for repair. Heavy wooden crates with fork lift bases and shock absorbing material under the base and on all sides to reduce shock and vibration are recommended. The crate should be securely fastened or banded together. Units are to be crated, shipped and handled in the VERTICAL POSITION ONLY.

C A U T I 0 N

* DO NOT PERMIT SHIPMENT OF UNITS ON THEIR SIDE. STRUCTURAL DAMAGE MAY RESULT.

* THE MANUFACTURER'S WARRANTY IS VOID FOR UNITS IMPROPERLY CRATED OR SHIPPED ON ANY OF THE FOUR SIDE SURFACES OR UPSIDE DOWN.

Uncrating: Pacific "G" Series power sources are shipped in wooden crates with a shock absorbing padding on all sides. While crated, they can be moved with a fork lift or hand truck. Uncrating instructions are attached to the outside of the crate and should be adhered to.

Moving:: The UG-18 Battery Support Cabinet is equipped with a fork lift base. Therefore, a fork lift will be required to move the unit. Care should be taken when moving the unit, because the unit has a relatively high center of gravity and it may tip over. Refer to the Power Source's Manual for the Power Source's crating, uncrating and moving.

4-1


I

\ l\ I\

I I (I

\ I 1\\~~r

FIGURE 4-1

MODEL UG-18 CRATING DETAIL

4-2

/STRAPS

PALLET

I

, MODEL UG-18 SECTION 4

4.2 CLEARANCES

The equipment should be given at least two feet clearance, front and rear, to access the equipment for maintenance. Refer to the Power Source's manual for the Power Source's clearance specifications. No side clearance is required for this equipment.

FLOOR LOADING

The base comes standard with a fork lift base to reduce the unit load per square inch. Casters are available but not recommended because the unit load per square inch may be as high as 500 lbs. per square inch. Refer to the Power Source's Manual for the Power Source's floor loading.

4-3



4-4

• " • • "'-----'- n'>r 1.o nit.\ AQA-;:lkG1

·MODEL UG-18 SECTION 4

4.4 BATTERY INSTALLATION

This procedure is to be used to install or remove batteries in Pacific Power Source's model UG-18 Battery Support Cabinet.

You will be connecting (8), 12 VDC batteries per tray in series to produce 100 VDC at each of the 6 battery trays. (See Figure 4.2). Two battery trays will be connected in series to produce ~ 100 VDC or a total of 200 VDC. Each pair of ~ 100 VDC battery trays will be used to power one phase of the Power Source. The phase A ~ 100 VDC battery trays are totally isolated from the phase B and C ~ 100 VDC battery trays and chassis. The phase A, B, and C commons are NOT to be connected together or to chassis.

Safety Notice

* W A R N I N G * * THIS BATTERY CABINET CONTAINS 6 TRAYS OF 8 BATTERIES PER TRAY.

THE BATTERIES ARE CONNECTED IN SERIES TO PROVIDE ~ 100 VDC. A POTENTIAL OF 200 VDC EXISTS BETWEEN THE ~ BATTERY TRAYS.

* !!!!!!!!!!THESE VOLTAGES ARE A LETHAL SHOCK HAZARD !!!!!!!!!!

* THE BATTERIES CAN DELIVER UP TO 1000 AMPS EACH. REMOVE ALL WATCHES RINGS OR OTHER JEWELRY BEFORE DOING ANY SERVICE TO THIS EQUIPMENT BECAUSE RINGS OR WATCHES CAN CAUSE SEVERE BURNS ON YOUR SKIN IF SHORTED ACROSS THE BATTERY.

* USE EXTREME CARE IN NOT SHORTING THE BATTERY .WITH TOOLS.

* DO NOT SHORT THE BATTERY WITH THE BATTERY CABLES.

*

4-5

12VOC

~T 12VOC

l2VDC

12VOC

12VOC

12 voc

12VOC

12VOC

BATTERY TRAY INTERNAL CONNECTIONS TYPICAL OF SIX TRAYS

·'

100 voc

FIGURE 4-2

BATTERY TRAY WIRING DIAGRAM

4-5

UPPER BATTERY

TRAY

LOWER BATTERY

TRAY

I - - - -- 1 TBl-25

I ltlllt~ +lOOVDCTO . I I - - C/J A INVERTER

I I TBl-1 ·~ COM TO 0A L ____ _

r------, ' C I I I I I , I ' Tr2-25 I I . L ___ _:_~

INVERTER

-100 VOC TO C/J A INVERTER

r - - - - - -, TB3-25 I I I It It ~ +lOOVDC TO I I TB3~1 C/J 8 INVERTER

L_----

r------, COM TO 0 8 INVERTER

: clllilli ; L _____ _j TE:S -100 VDC TO

T84-l 0 8 INVERTER

r - - -. _,_ - I TB5~25

1 _

1----lllllll~

I . I TB5-l L_____ .

r------, 1 r-' ltlllt I I I L -·--- _::J ~ TB6-l

BATTERY TRAY EXTERNAL CONNECTIONS

+lOOVDC TO 0 C INVERTER

COM TO 0 C INVERTER

-lOOVDC TO 0-C INVERTER

· MODEL UG-18 SECTION 4

BATTERY INSTALLATION <con't)

* Disconnect all AC power to the unit.

* Turn OFF the "Battery Output" Circuit Breaker.

* Turn OFF the "Charger" switch.

BATTERY CABLES: Inspect each battery cable set and make sure they have protective covers on the ends opposite the ring lugs. Then attach one cable set to each battery by connecting the red wire of each cable set to the positive side of each battery and the black wire of each cable set to the negative side of each battery.

BATTERY NUMBERING: The battery becomes numbered when the battery cable is installed. (See Figure 4-3)

4-7


BAT. 11 BAT. 45

II

1-24 1-22

j LTERM. NO. (TYP)

. TERM. BLOCK NO. (TYP)

45- 45+

4-12 \ 4-10

\~BAT. POLARITY

FIGURE 4-3

BATTERY NO.-1ST DIG IT INDICATES

TRAY. 2ND DIGIT INDICATES

BATTERY POSITION ON TRAY.

BATTERY TERMINAL NUMBERING DRAWING

4-8

' MODEL UG-18 SECTION 4

4.4 BATTERY INSTALLATION <con~t>

REMOVING HARDWARE: Remove the front panel. Remove the front battery restraints on Battery Trays #1-5 and loosen, but DO NOT remove the front battery restraint on Battery Tray #6.

Remove all wires and JUmpers to the terminal blocks, then remove the terminal block bracket. <See Figure 4-4)

4-9


JUMPER (14 AW PINS 1,2

G)_/

TYP TBl-6

JUMPERS(lOAWG) PINS 3-25

_II TYP TBl-6

o 0 0 jl IJ c ld+!+hl0° o DO 0 c TERMINAL

BLOCK NO.

I I I - T81 (1-25)

tl'f.J I

~ I I I

"J-u· -, - TB2(1-25)

I I I I -TB 3{1-25)

I

l l I - TB 4(1-25}

T ~I

I I I - TB 5(1-25)

J- J

I I l - TB 6(1=25)

II 'T ...... ~ .- ~ ... ~~ I

II _II u Jl

FIGURE 4-4

BATTERY TRAY AND TERMINAL LOCATION DRAWING

4-10

BATTERY TRAY NO.

1 (A+)

2 (A-)

3 ( B+)

4 (B-)

5 (C+)

6 (C-)


4a4 BATTERY INSTALLATION <con't)

INSTALL BATTERIES: Start with Battery Tray #6 by installing Battery #64 and #65, then #63 and #66, next #62 and #67, and finally #61 and #68.

Next on Battery Tray #5, install Battery #54 and #55, then #53 and #56, next #52 and #57, and finally #51 and #58.

Next en Battery Tray #4, install Battery #44 and #45, then #43 and #46, next #42 and #47, and finally #41 and #48.

Next on Battery Tray #3, install Battery #34 and #35, then #33 and #36, next #32 and #37, and finally #31 and #38.

Next on Battery Tray #2, install Battery #24, and #25, then #23 and #26, next #22 and #27, and finally #21 and #28.

Last on Battery Tray #1, install Battery #14 and #15, then #13 and #16, next #12 and #17, and finally #11 and #18. <See Figure 4-5)

4-11

~ODEL UG-18 SECTION 4

-

p fl!i~bhp,j 0 ~ Jt 0 1/ 0

P DO 0

I IL Jl IL

UG 18 FRONT VIEW

j

BATTERY NO:s

ll-18

21-28

31-38

41-48

51-58

61-68

FIGURE 4-5

X4 xs

x:s X6

X2 X7

Xl X8

BATTERY POSITION

NUMBERING SEQUENCE TYP 6 TRAYS

(X INDICATES TRAY NO.)

BATTERY PLACEMENT DETAIL

4-12

" • · • · '"'---~ r~li+~~v.i" Q~I=.4Q (714\ 898-2591

FRONT


4.4 BATTERY INSTALLATION <con't)

REINSTALL HARDWARE: Reinstall the front battery restraints and Terminal Block Bracket on all of the Battery Trays.

WIRE BATTERIES: * Disconnect all AC power to the unit.

* Turn OFF the "Battery Circuit Breaker".

* Turn OFF the "Charger ON" switch.

* Do NOT install the solid wire JUmpers at this time.

Install wiring as follows:

FROM BATTERY # TO TERMINAL BLOCK # WIRE COLOR

11+ 1-4 RED 11- 1-2 BLK 12+ 1-7 RED 12- 1-5 BLK 13+ 1-10 RED 13- 1-8 BLK 14+ 1-13 RED 14- 1-11 BLK 15+ 1-16 RED 15- 1-14 BLK 16+ 1-19 RED 16- 1-17 BLK 17+ 1-22 RED 17- 1-20 BLK 18+ 1-25 RED 18- 1-23 BLK 21+ 2-4 RED 21- 2-2 BLK 22+ 2-7 RED 22- 2-5 BLK 23+ 2-10 RED 23- 2-8 BLK 24+ 2-13 RED 24- 2-11 BLK 25+ 2-16 RED 25- 2-14 BLK

4-13



26+ 2-19 RED 26- 2-17 BLK 27+ 2-22 RED 27- 2-20 BLK 28+ 2-25 RED 28- 2-23 BLK 31+ 3-4 RED 31- 3-2 BLK 32+ 3-7 RED 32- 3-5 BLK 33+ 3-10 RED 33- 3-8 BLK 34+ 3-13 RED 34- 3-11 BLK 35+ 3-16 RED 35- 3-14 BLK 36+ 3-19 RED 36- 3-17 BLK 37+ 3-22 RED 37- 3-20 BLK 38+ 3-25 RED 38- 3-23 BLK 41+ 4-4 RED 41- 4-2 BLK 42+ 4-7 RED

'~ ;·~ 42- 4-5 BLK 43+ 4-10 RED 43- 4-8 BLK 44+ 4-13 RED 44- 4-11 BLK 45+ 4-16 RED 45- 4-14 BLK 46+ 4-19 RED 46- 4-17 BLK 47+ 4-22 RED 47- 4-20 BLK 48+ 4-25 RED 48- 4-23 BLK 51+ 5-4 RED 51- 5-2 BLK 52+ 5-7 RED 52- 5-5 BLK 53+ 5-10 RED 53- 5-8 BLK 54+ 5-13 RED 54- 5-11 BLK

4-14

·MODEL UG-18 SECTION 4


55+ 5-16 RED 55- 5-14 BLK 56+ 5-19 RED 56- 5-17 BLK 57+ 5-22 RED 57- 5-20 BLK 58+ 5-25 RED 58- 5-23 BLK 61+ 6-4 RED 61- 6-2 BLK 52+ 6-7 RED 62- 6-5 BLK 63+ 6-10 RED 63- 6-8 BLK 64+ 6-13 RED 64- 6-11 BLK 65+ 6-16 RED 65- 6-14 BLK 66+ 6-19 RED 66- 6-17 BLK 67+ 6-22 RED 67- 6-20 BLK 68+ 6-25 RED 68- 6-23 BLK

FROM TERMINAL BLOCK # TO TERMINAL BLOCK # WIRE COLOR

1-1 2-25 #B AWG BLK 3-1 4-25 #8 AWG BLK 5-1 G-25 #B AWG BLK

FROM CABLE # TO TERMINAL BLOCK # WIRE rrru no \.JUL.rUl\.

Phase A 1-1 BLK Phase A 1-25 RED Phase A 2-1 WHT Phase B 3-1 BLK Phase B 3-25 RED Phase B 4-1 WHT Phase c 5-1 BLK Phase c 5-25 RED Phase c 6-1 WHT

4-15

"--''"- n-···-~ c-.. ~MM r'"'"'"'wdim-.- l-111r.tinnt:nn Beach. California 92649 (7141 898-2&91

!10DEL UG-18 SECTION 4

FROM CABLE # TO CHASSIS WIRE COLOR

Phase A Chassis GRN Phase B Chassis GRN Phase c Chassis GRN

NOTE: CHASSIS CONNECTIONS NORMALLY SHIPPED CONNECTED, LISTED FOR REFERENCE.

Install Jumpers as follows:

FROM TERMINAL BLOCK # TO TERMINAL BLOCK # BUSS WIRE AWG

1-1 1-2 #14 1-4 1-5 #10 1-7 1-8 #10 1-10 1-11 #10 1-13 1-14 #10 1-16 1-17 #10 1-19 1-20 #10 2-1 2-2 #14 2-4 2-5 #10 2-7 2-8 #10 2-10 2-11 #10 2-13 2-14 #10 2-16 2-17 #10 2-19 2-20 #10 3-1 3-2 #14 3-4 3-5 #10 3-7 3-8 #10 3-10 3-11 #10 3-13 3-14 #10 3-16 3-17 #10 3-19 3-20 #10 4--1 4-2 #i4 4-4 4-5 #10 4-7 4-8 #10 4-10 4-11 #10 4-13 4-14 #10 4-16 4-17 #10 4-19 4-20 #10 5-1 5-2 #14 5-4 5-5 #10 5-7 5-8 #10 5-10 5-11 #10

4-16

o~,..;f;,.. Dnwc,... ~"""'"P r.nY'nnriltion- Huntinoton Beach. California 9254'3 (714) 8'38-2591

,MODEL UG-18 SECTION 4

FROM TERMINAL BLOCK # TO TERMINAL BLOCK # BUSS WIRE AWG

5-13 5-14 #10 5-16 5-17 #10 5-19 5-20 #10 6-1 6-2 #14 6-4 6-5 #10 6-7 6-8 #10 6-10 6-11 #10 6-13 6-14 #10 6-16 6-17 #10 6-19 6-20 #10

4-17

'MODEL UG-18 SECTION 4


INSTALL JUMPERS Install solid wire JUmpers as shown by the legend on the battery terminal bracket. DO NOT install from TBx-22 to TBx-23 at this time. This JUmper will be installed after a wiring check has been performed.

TESTING::

WIRING CHECK: Install a 10K Ohm 2 Watt resistor from Terminal Block 1-22 to Terminal Block 1-23, then measure the voltage across the resistor. If the voltage is less than 2 volts, remove the resistor and install a #10 AWG Jumper in place of the resistor. If the voltage is over 2 volts, recheck the wiring and troubleshoot.

Repeat the above procedure for Terminal Blocks 2-6.

REVERSE BATTERY TEST:: After all trays are fully connected rotate the "Battery Condition Meter Select Switch" and read the voltage on each of the Battery Trays. All of the voltages should be 96 VDC to 104 VDC. If one or more battery trays are below 96 VDC a battery may be installed backwards or a defective battery may exist.

Using a DC voltmeter place the (-) lead on the #1 terminal of the terminal block, and the + lead on the #25 terminal of the terminal block in question. The voltage should be + 96 VDC to + 104 VDC. If not, check each battery.

Place the (-) lead of the DC voltmeter on terminal #2 and the (+) lead on terminal #4. The voltage should be +12.0 VDC to +13.0 VDC.


4-18



REVERSE BATTERY TEST: (con't) Place the (-) lead of the DC voltmeter on terminal #8 and the (+) lead on terminal #10. The voltage should be +12.0 VDC to +13.0 VDC.






Upon location of the improper Battery voltage inspect wiring and correct the wiring error. If no wiring error appears to exist, remove the battery in question and measure the battery voltage directly at the battery terminals. Battery voltage must be in the range of 11.00 to 13.8 volts. If outside this range, the battery is defective and must be replaced.

4-19

" '• • - "---L l".l:.C •.••• ,_ l'l'>l:/,Q Iii/,\ llCill-?£:.Q1



4-20


4.5 INTERCONNECTIONS

In normal configuration the UG-18 Battery Cabinet will be supplied with a set of four interconnect cables. <Interconnect cable set PPSC P/N 114616). One end of the cable set will connect to the rear of the charger module. The other end of the cable set will connect to the UG-BA18 Battery Adaptor <Ref. Fig. 4.6).

The three large cables <SO 8-4) are the Battery Cables which connect the DC from the VG-18 Battery Support Cabinet to the DC Power Supplies in the power source.

The single cable is a signal cable used for control purposes.

Connect the phase A battery cable and the phase A receptacle on the CM-18 to the phase A receptacle on the Mainframe Adaptor. Connect the phase B and C Battery Cables to their proper receptacles.

Connect the small signal cable from J4 on the battery adaptor to the signal cable receptacle on the rear of the charger module.

Connect the 115 VAC Power Cord to the convenience outlet on the adaptor box.

4-21

IJ.=~rifir IJnwPr SourcE> Corooration- Huntinoton Beach, California 92649 (714) 898-2691

MAINFRAME ADAPTOR --+H-t~

SIGNAL CABLE CONNECTOR

VIEW 8

VIEW 8

I II I I

lUI~ POWER SOURCE UG-18 BATTERY SUPPORT

CABINET

08 0C 0 0 1

OUTPUT AJSE

115$Ac 1SASr:£.N

VIEW AA FIGURE 4-E.

'- UG C/c, BLE SET (ASSY. NO. 114GTG') INPUT PCWER CORD

UG-18 SYSTEM INTERCONNECTION DETAIL

4-22


4.5 INTERCONNECTIONS (con't>

A cable may connect to JlO for the optional remote status panel.

C A U T I 0 N

SOME CABLES MAY NOT BE KEYED AND CONNECTION TO THE WRONG MATING CONNECTOR MAY BE POSSIBLE. BE SURE TO LOOK AT THE CONNECTOR LABEL AND VERIFY EACH CABLE CONNECTS TO ITS PROPER CONNECTOR. IMPROPER CONNECTION WILL RESULT IN IMPROPER SYSTEM OPERATION AND MAY ALSO RESULT IN EQUIPMENT DAMAGE.

4-23

o~~ifi~ Dnw~r ~n11rrp r.n~no~rition- Huntincton Beach. California 92649 (714) 898-2691


4.6 CHARGER MODULE -REMOVAL & INSTALLATION

The charger module is removable to allow for easy sparing. To remove the charger module follow the procedure listed below.

* Make sure the system is not operating on the batteries. Battery operation is indicated by the Amber Battery Operation Light.

* Switch the "Battery Output" breaker Off.

* Disconnect all cables from the rear of the charger module. Disconnect power cord from outlet on adaptor box. Remove P9.

* * * w A R N I N G * * Although the ends of the connectors are protected, lethal voltage may be present on some connectors. Refer to Paragraph 4. 4, Safety Notice.

* * * * * * * * * *

* Remove the four screws securing the front of the charger module to the cabinet and remove the charger module, by pulling the module forward.

* *

* For installation of the charger module, reverse the above steps.

4-24

*

*



4-25

o~rifir Omo~Pr ~n11rrE Corooration - Huntin!lton Beach, California 92549 (714) 898-2591

Para.

5.0 5. 1 5.2 5. 3 5. 4 5.5

Fig.

5-1

SECTION 5

OPERATION

TABLE OF CONTENTS

Title

Operation First Time Operation UG-CM18 Charger Module Batteries Maintenance Calibration


Title

UG-CM18 Charger Module Control Location Detail

5-0

Page

5-1 5-1 5-3 5-7 5-9 5-10

Page

5-4

P~rific Power Source CorPOration- Huntington Beach, California 92649 (714) 898-2691


5.0

5. 1

OPERATION

FIRST TIME OPERATION

C A U T I 0 N

BEFORE TURNING ANYTHING ON, READ THROUGH SECTION 5 OF THIS MANUAL COMPLETELY.

Refer to the Power Source Manual and check aut the operation of the Power Source by itself.

Install the batteries as per Section 4.4 of this manual.

Turn on the charger. The Blue light should came an. Leave the charger an and allow the batteries to charge until the charge current drops below 2 Amps.

Make all interconnections as per Section 4.5 of this manual.

Turn an the Battery Circuit Breaker. The Battery Circuit Breaker cannot be turned an if the interconnections are nat made properly or the Power Source is nat on. The Green Battery at Full Charge light should illuminate indicating that the system is ready far UPS operation.

Turn off the Input Circuit Breaker at the Power Source. The Green light should go aut and the Yellow Battery Operation light should came an indicating that the batteries are being discharged. The Power Source should continue to operate.

Turn on the Input Circuit Breaker at the Power Source and allow the batteries to charge. Always leave the Charger ON. Permanent battery damage will result if the batteries are left in a discharged state for a lang period of time.

5-1

Pacific Power Source Corporation- Huntington Beach, California 92649 (714) 898-2691



5-2

Pacific Power Source Corporation - Huntington Beach, California 92649 (714) 898-2691


5.2 UG-CM1B CHARGER MODULE -

The numbered triangles below correspond to the numbered triangles on Figure 5-1 and describe the function of the controls and indicators.

BATTERY OUTPUT CIRCUIT BREAKER: This circuit breaker engages or disengages the batteries to the power source. This circuit breaker may not be turned on unless all connections between the Power Source and the UG-18 Battery Support Cabinet are connected properly and the Power Source is on.

CHARGER ON LAMP: This lamp will light when the charger is on. This lamp should be lit at all times except when there is no input power.

CHARGER CURRENT AMMETER: This meter indicates the magnitude of the battery charging current. This ammeter should drop to less than 2 Amps after 24 hours of charging.

CHARGER ON-OFF SWITCH: This switch engages or disengages the input power to the UG-CM18 Charger Module. This switch should be left ON to prevent battery damage due to self discharge.

WARNING LOW CHARGE LAMP: This lamp will light when the batteries have been discharged to less than 107. of their capacity. The system will shut down very soon.

BATTERY OPERATION LAMP: This lamp will light when the batteries are being discharged by the Power Source.

BATTERY @ FULL CHARGE LAMP: This lamp will light when all the batteries are fully charged and all the connections are made between the UG-18 Battery Support Cabinet and the Power Source. The system is ready for UPS operation when lit.

5-3

-0

0

@

@

'J3ATTERY OUTPUT

ON @ @

@ @ OFF

@

J ···:· ·; . . ; '

\AJARN!NG LOW CHARGE

'·.·;]]·········.·.-.-· .. BLU RED

ON SYSTEM SHUT

10

0

CURRENT

DOWN IMMINENT

-BATTERY ·oPERATION

' !'

BATTERY CONDITION

0

BATTERY VOLTAGE

··~

J

~~l ===:::::=:==::::====~] ~~ ~F~~=rc=::R=~E =I===I=====I=======!Jj

FIGURE 5-1

UG-CM18 CHARGER MODULE CONTROL LOCATION DETAIL

5-4

0

0


5.2 UG-CM18 CHARGER MODULE

BATTERY CONDITION VOLTMETER: This meter measures the voltage across the battery trays and indicates the general state of the batteries. Normally it should read in the Full Charge Region at all times. However, when the batteries are being charged or discharged, the meter will read in the Partial Charge region.

METER SELECT SWITCH: This switch selects which one of the six battery trays the meter is monitoring. This switch should be left in the OFF position when not in use to prevent battery discharge.

5-5

.MODEL UG-18 SECTION 5


5-6

Pacific Power Source Corporation - Huntington Beach, California 92649 {714) 898-2691


5.3 BATTERIES

5.3.1 NOTICE

To insure that the batteries are ready for use when needed follow the instructions that are printed on the front panel and reprinted below:

FOR BEST BATTERY LIFE AND TO PREVENT BATTERY DAMAGE

KEEP CABINET ON AT ALL TIMES - EVEN WHEN SYSTEM IS NOT IN USE - TO MAINTAIN BATTERY CHARGE.

OPERATE SYSTEM ON BATTERY POWER AT LEAST ONCE EVERY FOUR MONTHS.

CHECK BATTERY VOLTMETER FREQUENTLY - VOLTAGE TO BE IN FULL-CHARGE REGION AT ALL TIMES.

CHARGE CURRENT SHOULD REDUCE TO 2 AMPS OR LESS WHEN FULLY CHARGED.

In normal use the charger and the Battery Circuit Breaker should be left in the ON position. This will insure that the batteries are maintained in a fully charged state and ready to supply standby power.

5.3.2 CHARGING

When recharging discharged batteries, the Charge Current Ammeter will read about 10 Amps and drop off as the batteries become fully charged. After 24 hours of charging the meter should read 2 Amps or less.

When the batteries are fully charged the battery voltage should be in the green Full Charge Region and remain there until discharged again.

NOTE: The batteries will charge with the Battery Circuit Breaker in the OFF position.

5-7

P~rific Power Source Corooration -Huntington Beach, California 92649 (714) 898-2691


5=3.3 BATTERY CONDITION

This UPS utilizes solid electrolyte gel-cell type batteries and requires none of the maintenance normally associated with lead-acid batteries, such as water level and hydrometer check. However, it is EXTREMELY important that the batteries are kept fully charged. If the batteries are left in a discharged state, they will almost certainly be permanently damaged. Visually inspect the batteries for signs of leakage.

Observe the voltage of each tray to be in the full-charge region of the Battery Voltage meter. Use the Battery Monitor Switch to select the battery trays. If one battery tray is 2 Volts or more lower than the other battery trays, this would indicate the presence of one bad battery in the tray being measured. If so indicated, that battery should be replaced.

5a3.4 BATTERY REPLACEMENT

* W A R N I N G

NOT ONLY ARE LETHAL VOLTAGES PRESENT THROUGHOUT THE SYSTEM WHEN IT IS OPERATING, BUT DC VOLTAGES ARE PRESENT WITH LARGE AMOUNTS OF ENERGY AVAILABLE, EVEN WITH ALL CIRCUIT BREAKERS OFF. RINGS AND WATCHES SHOULD BE REMOVED WHEN SERVICING THE EQUUIPMENT AND THE GREATEST CAUTION SHOULD BE EXERCISED, PARTICULARLY WHEN HANDLING BATTERIES.

Read through Section 4.4 of this manual COMPELETLY before attempting to replace any batteries. Remove the defective battery from the tray and replace with a new one.

5-8



5.4 MAINTENANCE

5.4.1 MAINTENANCE REQUIREMENTS

Pacific recommends that a maintenance schedule be set up for a visual inspection to be done on a monthly basis and periodic exercising of the system performed once every four months. Pacific also recommends that all maintenance activities are logged on a form similar to pages 5-10 and 5-11 of this manual.

5.4.2 MONTHLY VISUAL INSPECTION

Check Charger Current Ammeter to be less than 2 Amps.

Check the Battery Voltmeter to be within the full-charge region on all six trays.

The green and blue lights on the front panel of the charger module should be ON and both the red and yellow lights should be OFF. The intensity of the blue lamp is proportional to the charge current.

NOTE: If the battery cabinet is not connected to a power source the green light will not illuminate, but the meters should read the same as above.

5.4.3 PERIODIC SYSTEM TEST

The only absolute guarantee that a UPS is functioning properly is to simulate a power loss and test it. Pacific recommends scheduling a period every four months where any critical loads can be shut down or put in a stand-by mode so as not to lose any data, or cause a life-threatening situation.

As a preliminary check, perform the visual inspection of Section 5.4.2 above to insure that everything appears to be in proper order. This check should be made with the system running and delivering power to a load.

5-9

Pacific Power Source Corporation - Huntington Beach, California 92&49 (714) 898-2&91


5.4.3 PERIODIC SYSTEM TEST <con't>

5.5

Turn OFF the AC Line circuit breaker while starting a stop-watch or timer. The system AC output meter should not change and should remain steady until the batteries are approaching a fully discharged state. When the batteries reach their low limit the system will turn itself off to prevent overdischarging of the batteries. This ends the UPS time and the time should be recorded.

This test determines the overall condition of the batteries. Figure 2-1 is a chart which shows ~ne expected UPS time at various load levels. This curve is a level of performance offered by good batteries. When performing this test, the UPS must be in excess of the time indicated on the chart for a given load.

If it would be inconvenient to allow the machine to trip off, an abbreviated test can be run until illumination of the "Low Charge Warning Lamp".

After the test is completed turn the AC line breaker on, the batteries will recharge.

CALIBRATION

Pacific Power Source Corporation recommends a periodic system test at four month intervals. If the unit is out of calibration or has undergone maJor repairs, it should be re-calibrated per Section 7.4, 8.4, 9.4 or 10.4.

5-10

Pacific Power Source Corporation- Huntington Beach, California 92649 <714) 898-2691


PERIODIC SYSTEM TEST REPORT

Power Source serial number

UG-18 UPS Support Cabinet serial number

Date installed

Signed Todays date

ITEM CHECK POWER SOURCE

1. Normalized Input Voltmeter

2. Clean Air Filters

3. Fans Start & Rotate Freely

4. Abnormal Module Current

5. Module Failure Lights

6. Output Volts Phase A

7. Output Volts Phase B

8. Output Volts Phase c

9. Repairs Required

ITEM CHECK UG-18 UPS SUPPORT CABINET

1. Charge Current

2. Battery Voltmeter A+

3. Battery Voltmeter A-

4. Battery Voltmeter B+

5. Battery Voltmeter B-

6. Battery Voltmeter C+

7. Battery Voltmeter c-

Page 1 of 2

_!_!_

RECORD

90-110%

OK

RECORD

OK

NONE

NONE

OK

OK

OK

Less than 2 A

106-112 VDC*

106-112 VDC*

106-112 VDC*

106-112 VDC*

106-112 VDC*

106-112 VDC*

* These Battery Voltages should be + or - 2 V of each other.

5-11



PERIODIC SYSTEM TEST REPORT Page 2 of 2

ITEM CHECK UG-18 UPS SUPPORT CABINET (continued) RECORD

B. Blue Light ON

9. Green Light ON

The Green light will not be on if the UG-18 UPS Support Cabinet is not connected to a Power Source.

10. Yellow Light OFF

11. Red Light OFF

12. Repairs Required

ITEM

1.

2.

3.

4.

5.

UG-18 UPS SYSTEM BATTERY DISCHARGE TEST

Output KVA

Take the largest Phase KVA

and multiply by 3 to find

the total KV A.

Turn off the Power Source Input Circuit Breaker and record the time.

Record the t.l.me when the red "Low Charge Warning" lamp turns on.

Record the time when the 6 pole DC Circuit breaker trips off. This is when the UPS SHUTS DOWN.

Subtract item 2 from item 4 and record this as the total UPS time. Compare this time to Figure 2.1.

Phase A

Phase B

Phase C

total

5-12

RECORD

___ KVA

___ KVA

___ KVA

___ KVA

___ TIME

TIME

TIME

___ TIME




5-13

P~rifir PowPr Source Corooration- Huntinnton Beach, California 92&49 (714) 896-2&91

Para.

6.0 6. 1 6.2

Fig.

6-1(a) 6-l(b)

Title

SECTION 6

UG-18 MAINFRAME DETAILED DESCRIPTION

TABLE OF CONTENTS

UG-18 Mainframe Detailed Description Description Servicing


Title

UG-18 Mainframe Assy. Dwg. <Sht.1) UG-18 Mainframe Assy. Dwg. <Sht.2l

6-0

Page

6-1 6-1 6-4

Page

6-2 6-3


6.0 UG-18 MAINFRAME DETAILED DESCRIPTION

6.1 DESCRIPTION

The Mainframe consists of the cabinet, input power transformer, Charger Module and battery trays. Refer to Figure 6-1.

ITEM

1 2 5 9 11 13 15 17 19 59

MATERIAL LIST UG-18 MAINFRAME

DESCRIPTION

Cabinet, UG Battery Support Bracket, UG Battery Terminal Block Manual, UG UPS Service and Operation Transformer, Input Power UG Charger Label, System ID Batt. Restraint Short Batt. Restraint Long Connector, 10 Pin Male <not shown) Term. Block, 5 Terminal label, UPS Operation

6-1

PPSC PIN

114601 114602-A 114650-E 531192 114209 109343-A 109344-A 714069 705009 580043

c JL

B

JL

~~A C SEE SH 2

p DOD c I lft!R!R!R!R!~I 0 0 I I I

I

I

I I

0 0 0 c

f-J .~. y _[o o o o[o o o ojo o o Ojo o o ¢jo o o ol

J ' -1 ' L --- _j

r ~ I I . I I I

J I

p ~ I I I I I

J I

-~ ~ I I I I I

j I

~ ~ I I I I I

J I

r ~ I I I 1 I

j I

I I I

FRONT VIEW FRONT PANEL OMITTED

l y

I

l y

I

l ~

I

l l-j

I

~

y I

l I

I I I

I I

I

I I

I I

_l

B SEE SH 2

_l

~

~L----® . Q

I[ D v~ f- I

0 0

lj L_l I I

~ f-.! f-.! I

l I 0 0

L---® 0 0

l~__j II ~ f-.! 1--J

~ ' I

0 0 0 0

j~ I _j 1--1 1--1 I

I

I 0 0 0 0

I · _ _j I! _j 1--1 1--1

l ~ 0

0 0

I II I

~ ~ f-.! f-.! I

Dl I 0 0 0 0

I! D~ q~ i--J 1--1 f-.! li FIGURE S-l(a)

II l oj1 MODEL UG-18 ~ MAINFRAME ASSY.

f-

I 6-2

SECTION A A

J ~

I_ - + -

\ I 2 3 4 "

® (§) @) (§)

~ ~(--j-

VIEW C C

VIEW 0 0 TYP 6 PL TERMINAL BRACKET

XFMR /CHARGER MODULE TRAY/ BRACKET

L +- +

2. I 2.2. 23 21 2.5

@@@@

5 PL

(DREF

2

13 2 PL

VIEW 8 B TYP 6 PLS

SATTE RY TRAYS ~ CABINET BASE

FIGURE 6-l(b)

MODEL UG-18 MAINFRAME ASSY.

S-3


6.2 SERVICING

Due to the modular design of the UG-18 UPS Support Cabinet, service to the mainframe is, for the most part, module exchange or battery maintenance. Refer to Section 4.4 for battery testing and replacement. Refer to Section 7 for information regarding the service of the charger module.

6-4

"---'- "-' ,., ___ ,, O'JC/,Q 171h.\ AQA-:>l=.Q1



6-5

Para.

7.0 7.1 7.2 7.3 7.4

F'ig.

7-1(a) 7-1(b) 7-2 7-3 7-4 7-5 7-6 7-7

SECTION 7

UG-CM18 CHARGER MODULE DETAILED DESCRIPTION

TABLE OF CONTENTS

Title

UG-CM18 Detailed Description Description Theory of Operation Service Calibration


Title

UG-CM18 Chassis Assy. <Sht. 1)

UG-CM18 Chassis Assy. <Sht. 2) Control Card Schematic Control Card Assy. UG-CM18 Charger Module Schematic Power Supply Board Schematic Power Supply Board Assy. Battery Voltage Sensor Test Set-up

7-0

Page

7-1 7-1 7-14 7-15 7-16

Page

7-2 7-3 7-5 7-6 7-10 7-12 7-13 7-18


7.0 MODEL UG-CMlB CHARGER MODULE-DETAILED DESCRIPTION

7.1 DESCRIPTION

The UG-CM18 Charger Module is located in the top of the mainframe. It contains an SCR type battery charger, indicators for the battery condition and circuits to trip the Battery Circuit Breaker. The circuit breaker will trip if the interconnections are not properly made or at the end of a discharge cycle. Refer to Figure 7-1.

MATERIAL LIST UG-CM18 CHARGER MODULE

ITEM

3 5 7 9 11 13 15 17 19 23 25 26 29 31 33 35 37 39 41 43 45 46 47 51 53 55

DESCRIPTION

Chassis Front Panel Ammeter, 0-10 Amps Ckt Bkr, 65 A, 6 pole DC Voltmeter, Battery Charge Level Inductor, 8/4/2 mH @ 6/6/12 A Transformer, Current Relay, 3PDT 10 A @ 120 VAG 110 VDC Coil Connector, 10Pin Female Switch, Toggle DPST 15A @ 125 VAG Switch, Rotary 12 POS 2 Pole 0.5A Knob, 1 1/4 OD Blk Plastic W/Indic. Receptacle, Box Mounting 19 Pin Female Lampholder, Snap-in 3/4 Square Lens, Blue 0.75 Square Lens, Green 0.75 Square Lens, Amber 0.75 Square Lens, Red 0.75 Square Lamp, Incandescent 28V .04A T-1 3/4 Bridge, 1 Phase Full Wave 25 V 600 V Receptacle, 7 Pin Male Receptacle, 4 Pin Male Receptacle, 17 Pin Male Connector, 15 Pin Female Crimp Terminal, 5 A Tin Plated Power Cord, 16 AWG 3 Cond, 12 Ft

7-1

PPSC P/N

114630-C 114620-A 500016 716030 500031 730001 731001 717003 714074 710005 510025 702034 714057 701010 701018 701020 701019 701017 701004 743005 714058 714085 714075 714008 714006 775015

n~Mi+iM D"w""' C:moi"''D rnl"MV';Ihi'W\ - Huntinnton Beach. California 92649 (714) 898-2691

~ 3

Pe-. ~8R3 TYI': =®I

t.'_l

'-l I

N

~~@!:1 BR2

k~BR1

kM77t7, LUI'?iDE

hY?tDE Vie-w

> (J)C:: (J)Gi M I ::lCC"l ., o:l::lC I:"" I-'

1-1 --<():) en -.C"l c:: (J)::t: ::t1 ::r> rn t+(J) . (,f)

H -....! I-' (.f) I

1-' ...... Ill ._,

(~-----

<:== TOP

~ "-../

QPL.TYF'

63 .____./ ~

4PL-.1YP

@

[Qj

0

u JJ

FRONT

5

@

[1§1 0

ij~ ~~ [~

0

9

1:: U ? II ·:C>•

CHA77t7 RE-Ar If.J7t[/£ ViEW

PP5C A55Y ""H 4.010

19

{r UIO TOP

@~)

~~TYP 7 PL

~

65

@ ~

~ ~

~ 0

I

Q]

,{7;)2Pl. I '-.__/ TYP.

!~ I

'2Pl.. 15 )lYP.

~ •?· ,.{' 1.~

PLI 1-'L~ .. ~1 ., 1 n 112£

\ FROf.J'f PANEL

[tJ7iC>£ Vi£W

13

~

em

II}

TQf'=;>

CHA-?717, Ri&HI7ivE

[N<?ir?E Vie:w

~

PPSC ASSY NO. 114673

0 0 0

0 0

0 0

@ @ @

0 0

@ @ @

'-----0 ___ _j COVER- BOTTOM VIEW

PPSC ASSY NO. 114672

FIGURE 7-i(b)

UG-CM18 CHASSIS ASSEMBLY <Sht. 2>

7-3


MATERIAL LIST (con't) UG-CM18 CHARGER MODULE

ITEM

57 59 61 63 65 67 71 95 97 109 135 139 141 143 145 153 160

DESCRIPTION

Resistor, 150 OHM 1W 5XCC Diode, Silicon Rect. 600 V PIV 1 Amp Handle, 5/160D 3.00L MTG Black Oxide Ferrule, 5/16 Rack Handle Black Oxide Strain Relief Circuit Breaker, 15A Resistor, 510K 1/8W 1X Resistor, 270 OHM 1W 5XCC Connector Polarizing Key Transformer, 35VCT@ .5A Resistor, 2.2K 2W 5XCC Connector, 15 Pin Male Connector, Female 15 Pin Connector Pin, Male .093 Dia Connector Pin, Female .093 Mounting Tab Tie Mount

7-4

PPSC P/N

760041-15 741001 702059 702060 778093 716031 760213-510 760041-27 714013 731007 760052-22 714004 714005 714003 714002 779138 779131

TO J8..J.

REH FIG. ·tr4

TOr _,

PS OR

P6 OR

P7 REF FIG. 7~4

115VAC {

KEY

115VAC

T METER{

CHARGE{ AC

CHARGER ON LITE

COM

h ~ p I/"'\ ,0 I~ I~

~ l\...:..-1 1'5' I~ lv VJij p

'"' ~ '8' i'-=-'

h ~

'"' ,0

lt? 10

~ ~

P12

R12 Tl 8

¥oo 1 (6 1(7 I 3

·~ 5 SCR 2 ,,. ~ T2~ 1'\ 6 II'S

,0'5 ,0'5 VAC ) r. 4 '\ SCR I T2 soov 'SOOV AVo

1 1 I

I 2 4

7 5

P13

Pl9 (I METER 2.2K

--

EJ. ~~" e, ~ R'l 1------1 K Rl3 RISA IVCR8 120K

+ < 4.7 K 1= Cl CHG Cl3 750K

K

50 R5 CUR 1 =f'~& c~ 25V IK R8 H IOK v-4'1:2_" cw Tf4 ~~~ t~~ c .. Rs feR? IOK R6 .. ..

IIOK,I% CRIG ~61 ~~ c .. R 6 1/4W .. (3

Rl I < R 18 CW > 1K < 2.2K

R2 R7 2W 10 K DCHG , 2.2 K v's C8

>2w +cz

r,cs 1

R9 ~

Rl6 5 t> > 120K 300VDC > 1,8K "'cR 9 1% 1N751A

c !' 12 Jl' c!' 14

CR 13

-.. CRI5 .,.,

Zl 3 ~ 7812 CRI~ P20

7SOK 2 4 8

2 6 Z2

555 • 7

~~p, Cll + Cl2 I 200

R22 C9 C10 t;,?K

~h1 ,01

II ~ TP 1

T -,-£2 BATT -~~~--------------------------------------------- BATTERY VOLTAGE SENSOR

CHARGED['-J I 0 A I I WARN IN G:lr---,

c;!~E{I([~---------------------------------------------------, COIL IG:: L_ _____________________ ___, I I

r----9 1 _AR I 0 I R I 04 0TP105 L_ __________________ ----, I I +IOOVDC f l 1)-.o- ~~ T~ \..::.-- 2.2K 2 2K !

2 W 2'w I Lol P123 R;oi3KO < I 0 8

47 ._ __ __J V4W R 131 < C111 + d T?P1.09 lOG d r -}-.,.. MJE340 IJ4W r-1-..... MJE340

0 c SAME AS

0A

l I I

I

I l CR104 <;>~~~~ CR !$_l_Ql Ill > ~g~,19fo 10K LV Q101 ~~~ 1% l V 1Q102 I SAM0EAAS I

r'?'P107 4.7K ~~ c1~ 109 I P6 I P7 R109 Rll2 +------1-----, ~ lrCRI07 ;~ •

5242 R201-R234 R301- R334-

r'- 10K 3.3M 1C1103 +LOW ?

4 11

K (+BAT 6 I2V C201- C212 C301 -C 312 AS + II l---i~---.---_._ __ ___. _ _._-+----'\.fV<v---1r-"VVv-l------1 : ~ I C 10 5 CHARGED - ZIO 14 C 10 7

\..__/ +[ CI09 TPlll v ~5v 3 HARGE -L 1 T);ll 5 + 114 _05 I Cf\201- CR210 I CR301 -CR310

..-~ ~7 l RIO? cw 6 +WIOI 2 T8J3 I R128 Rl32 500V 0201- Q202 Q301 -Q302 > C101 '-~ lOK J +TRIP 1/4 Rll7 1 Rll9 Rl25 ';....o~-+-AJ v K201---- K 301 -----

R 10 2 1 CR102 ~ VOLTS 4 Ll2_-l---. IOK ')44--._---A,/\/\r-4------../\/V'v-~ lOK CW IOK 10M CRI"" I TP 201 - TP204 I TP30 I - TP304

I

I

I

I

COM

AS-

I< EY

-100 VDC

120K IN751A 1 cw IOK 10M IV:: -

~~~--~~--~~~4-----------4-4-~--~-------------i-~-t---~-----------i---+-i----1~~UJ TP101 + CliO R108 RIIO Rll3 Ril8 cw -LOW~ Rl26

1'12' f'--J

ir---,

10

~ 1'15 ~

47 Cl02 't> JOK J~J- ·~. ~·" IOK n---c-HARGE - .,.102 I IOK cw -BAT~H_ I 1 'r-c-R103 10 K 3.3M " .~.CHARGED ZIO 14

5 ro---+--t--' r-----..-+';-il/1 + I '4 Rl03 1N751A cw 3 1 L 7 CI06 /' \. CRIIO 120K<' TPII2 -TRIP + ZIO 2 CI04 0 >RI20 Rl22 f 1 TPIIG .t- IN5242 I

l VOLTS - 1/4 1 TP114 > :;;· -

J 1 nTPllO ..q::_;--- 12 > IOK 101\A ( 12V 0TP108 I TP102 TPI03 Rl~9 Rl33 Cl08

·v OS c112 RIOS CRJ05 IOK IOM o ·5oov I

147 r 4.7K .j~ TPI04

Rill 'V

2,2K 2W

Rll4 V' 2.2 K 2W

Rll5

1 >IIOK,I% 1 1/4 w

< R 127 < IIOK,l 'Yo

I/4W

I

I

I

5 IC's 101,102,201,202,301,302 ARE UA339.

4. l% RESISTORS ARE 1/8 W.

3. DIODES ARE IN 400 5.

2. CAPACITOR VALUES IN MFD's, 50V

I, RESISTOR VALUES IN OHMS :± 5%,1/4 W.

NOTES: UNLESS OTHERWISE SPECIFIED

FIGURE 7-2

CONTROL CARD SCHEMATIC

7-5

0

0

0

0

0

0

0

0

0

0

0

0

0

0

~u t}lco

0

0

0

0

0

.0

0

0

0

0

0

0

:r: lJ)

N

7'. (>J 0

SCRI -c ~ lJ) ~=;!-===--~g

CR307

CD

3H

. I o· o:: ~ ~~ <r: cr> 3;: z <( UJ - lf) (l_ 0::

R214 R 211

0

0

0

FIGURE 7-3

CONTROL CARD ASSEMBLY

7-6


MATERIAL LIST CONTROL CARD

CKT SYMBOL

DIODES

CR1-CR8 CR9 CR10-CR16 CR102, CR103 CR104-CR108 CR109, CRllO CR204-CR208 CR209, CR210 CR304-CR308 CR309, CR310

DESCRIPTION

Diode, 1 Amp Diode, Zener Diode, 1 Amp Diode, Zener Diode, 1 Amp Diode, Zener Diode, 1 Amp Diode, Zener Diode, 1 Amp Diode, Zener

600 PIV 5.1 v 0.5 w 600 PIV 5.1 v 0.5 w 600 PIV 12 v 0.5 w 600 PIV 12 v 0.5 w 600 PIV 12 v 0.5 w

SILICON CONTROLLED RECTIFIERS <SCR's)

PPSC P/N

741001 741006 741001 741006 741001 741003 741001 741003 741001 741003

SCR1, SCR2 SCR, 300 V 55 A 1/4 Stud Mount 742001

TRANSISTORS

Q101, Q102, Q201, Q202, Q301, Q302

Transistor, NPN 300V 0.5A T0-126

INTERGRATED CIRCUITS

A1,A2 Z1 Z2 Z101, Z102,

2201, 7?n? ____ ,

Z301, Z302

CAPACITORS

C1

C2

C3-C5

C6, C7 C8, C9

C10

OP-Amp T0-5 Package Voltage Regulator +12 V T0-220 Monolithic Timer 8-Pin DIP Quad Comparator

Capacitor, 50 uf @ 25 v Alum Electrolytic

Capacitor, 5 uf @ 300 v Alum Electrolytic

Capacitor, 1 uf @ 50 v Monolithic

Capacitor, 0.05 uf @ 500 V Disc Capacitor, 1 uf @ 50 v

Monolithic Capacitor, 0.01 uf @ 200 V Film

7-7

740008

746012 746003 746002 746019

720226-50

720245-50

720045-10

720023-50 720045-10

720183-10


CKT SYMBOL DESCRIPTION PPSC PIN

CAPACITORS <can't)

Cll Capacitor, 1 uf @ 50 v 720045-10 Monolithic

C12 Capacitor, 200 uf @ 50 v 720237-20 Alum Electrolytic

C101, C102 Capacitor, 0.05 uf@ 500 V Disc 720023-50 C103-C106 Capacitor, 1 uf @ 50 v 720045-10

Monolithic C107, C108 Capacitor, 0.05 uf @ 500 V Disc 720023-50 C109-C112 Capacitor, 47 uf @ 35 V Tantulm 720336-47 C201, C202 Capacitor, 0.05 uf @ 500 V Disc 720023-50 C203-C206 Capacitor, 1 uf @ 50 v 720045-10

Monolithic C207, C208 Capacitor, 0.05 uf @ 500 V Disc 720023-50 C209-C212 Capacitor, 47 uf @ 35 V Tantulm 720336-47 C301, C302 Capacitor, 0.05 uf @ 500 V Disc 720023-50 C303-C306 Capacitor, 1 uf @ 50 v 720045-10

Monolithic C307, C308 Capacitor, u.u::> uf @ 500 V Disc 720023-50 C309-C312 Capacitor, 47 uf @ 35 V Tantulm 720336-47

RESISTORS <Unless stated otherwise resistance is in ohms. )

R1,R2 Resistor, 2. 2K, 2W 5%CC 760052-22 R4, R5 Trim Pot, 1K, 10 turn 769990-005 R6 Resistor, llOK l/4W 1% 760323-110 R7 Trim Pot, lOK, 10 turn 769990-006 R8 Resistor, 10K 1/4W 5'XCC 760023-10 R9 Resistor, 1. 82K 1/8W 1% 760211-182 Rll Resistor, 120K 1/4W 5%CC 760024-12 R12 Resistor, 100 OHM 1/4W 5%CC 760021-10 R13 Resistor, 4.7K 1/4W 5%CC 760022-47 R14 Resistor, 10K l/4W 5%CC 760023-10 R15 Resistor, 750K 1/4W 5%CC 760024-75 R16 Resistor, 120K 1/411' 5'XCC 760024-12 R17 Resistor, lK 1/10W 1% 760211-100 R18 Resistor, 1K 1/4W 5%CC 760022-10 R19 Resistor, 2 ~" • L:l\ 1/4W t::•l f""r""

..Jt.vlt 760022-22 R20 Resistor, 750K 1/4W 5%CC 760024-75 R21 Resistor, 120K 1/4W 5%CC 760024-12


MATERIAL LIST <con't> CONTROL CARD

CKT SYMBOL DESCRIPTION

RESISTORS (can't) R22 Resistor, 4.7K 1/4W 57.CC R101 Resistor, 2.2K 2W 57.CC R102, R103 Resistor, 120K 1/4W 5%CC R104 Resistor, 2.2K 2W 57.CC R105, R106 Resistor, 4.7K 1/4W 5%CC R107, R108 Trim Pot, lOK, 10 turn R109, RllO Resistor, lOK 1/4W 57.CC Rlll Resistor, 2.2K 2W 5Y.CC R112, R113 Resistor, 3.3M 1/4W 5%CC R114 Resistor, 2.2K 2W 5%CC R115, R116 Resistor, 110K 1/4W 1% R117, R118 Trim Pot, lOK, 10 turn R119, R120 Resistor, 10K 1/4W 5/.CC R121, R122 Resistor, 10M 1/4W 5/.CC R123 Resistor, lOK 1/4W 5/.CC R124 Resistor, 4.7K 1/4W 5/.CC R125, R126 Trim Pot, 10K, 10 turn R127 Resistor, 110K 1/4W 1/. R128-R130 Resistor, lOK 1/4W 5/.CC R131 Resistor, 4.7K 1/4W 5'l.CC R132, R133 Resistor, 10M 1/4W 5/.CC R201 Resistor, 2.2K 2W 5'l.CC R202, R203 Resistor, 120K 1/4W 5/.CC R204 Resistor, 2.2K 2W 5'l.CC R205, R206 Resistor, 4.7K 1/4W 5'l.CC R207, R208 Trim Pot, lOK, 10 turn R209, R210 Resistor, 10K 1/4W 5/.CC R211 Resistor, 2.2K 2W 5/.CC R212, R213 Resistor, 3.3M 1/4W 5'l.CC R214 Resistor, 2.2K 5%CC R215, R216 Resistor, 110K 1/4W 1'l. R217, R218 Trim Pot, 10K, 10 turn R219, R220 Resistor, lOK 1/4W 5/.CC R221, R222 Resistor, 10M 1/4W 5%CC R223 Resistor, 10K 1/4W 5'l.CC R224 Resistor, 4.7K 1/4W 5%CC R225, R226 Trim Pot, 10K, 10 turn R227 Resistor, llOK 1/4W 1% R228-R230 Resistor, 10K 1/4W 5/.CC R231 Resistor, 4.7K l/4W 5Y.CC R232, R233 R301 R302, R303

Resistor, 10M 1/4W 5Y.CC Resistor, 2.2K 2W 5Y.CC Resistor, 120K 1/4W 5%CC

7-8

PPSC PIN

760022-47 760052-22 760024-12 760052-22 760022-47 769990-006 760023-10 760052-22 760025-33 760052-22 760323-110 769990-006 760023-10 760026-10 760023-10 760022-47 769990-006 760323-110 760023-10 760022-47 760026-10 760052-22 760024-12 760052-22 760022-47 769990-006 760023-10 760052-22 760025-33 760052-22 760323-110 769990-006 760023-10 760026-10 760023-10 760022-47 769990-006 760323-110 760023-10 ·760022-47 760026-10 760052-22 760024-12

"--""- "-···"~ c,., .. ........, rnV'MV'.:>tirm- Huntinnton Beach. California 92649 (714) 898-2691

,, !;


MATERIAL LIST (con't> CONTROL CARD


RESISTORS (can't}

R304 R305, R305 R307, R308 R309, R310 R311 R312, R313 R314 R315, R315 R317, R318 R319, R320 R321, R322 R323 R324 R325, R325 R327 R328-R330 R331 R332, R333

MISCELLANEOUS

T1 T2 HS1, HS2 P5-P8 K101, K201,

K301

Resistor, 2.2K 2W 5%CC Resistor, 4.7K 1/4W 5Y.CC Trim Pot, 10K, 10 turn Resistor, 10K 1/4W 5Y.CC Resistor. 2.2K 2W 5Y.CC Resistor, 3.3M 1/4\11 5Y.CC Resistor, 2.2K 2W 5Y.CC Resistor, 110K 1/4\11 1% Trim Pot, 10K, 10 turn Resistor, 10K 1/4W 5Y.CC Resistor, 10M 1/4W 5Y.CC Resistor, 10K 1/4\11 5Y.CC Resistor, 4.7K 1/4W 5Y.CC Trim Pot, 10K, 10 turn Resistor, 110K 1/4\11 1% Resistor, 10K 114\11 5/.CC Resistor, 4.7K 1/4\11 5Y.CC Resistor, 10M 1/4\11 5/.CC

Transformer, 30 VCT@ 0.15A Transformer, Audio lOmW Heatsink, 1" Finger Connector, 15 Pin Male Relay, SPST 3.5 A

120 VAG 24 VDC coil

7-9

PPSC P/N

760052-22 760022-47 769990-006 760023-10 750052-22 760026-10 760052-22 750323-110 769990-006 760023-10 750026-10 760023-10 760022-47 769990-005 760323-110 760023-10 760022-47 760026-10

731003 731004 703013 714011 717001

(P9)

r1 J9 BLK r--

Gl r----1>- BLK

' f----8RN 4

1>- WHT ?

i: BRN b

RFn 1

1?- RED WHT B

1?- prn q

ORG 10 >- ORG WHT 11 >- OFG 1::<

-

I

>f1, ~II(~ ~~ 3

L1 2

IC CT l ., 1 2 J:-' 3

r TO RSP Jll

REF FIG.l0-7

NOTES: UNLESS OTHERWISE SPECIFIED

~ ,---------------------------------------------------------------------------------------------~AC1 ® I b2 ,S2

0~ R4

,-------+-1-+--H--q 'A" J~S-~ 1:\ o·\·vvv ,...---1-1-1-1-f----. ~

r-+-+-+-+-+-+----D-"6 o7 I C\s::-----4-----,

~------------------------------------------------------~ I L~~

4 I

'3 I 6

(j) t:(Y

B 9

~-, 10

11 1.:\s 1~ A~~k~uE-RbN"

1;>

14

1'3 '--

I I

I I

L_ __

JIO + 35 voc 'A

3S VAC AC OP B f..-- f-BAT OP c

BAT CHARGED 0 BAT CHARGIN(· E: f..--

eAT LOW F CHS G

~ H J

:,!GNAL COM \': POWEn COM l

M N p R

rA s OUTPUT '/J 8 'T ~5 VAC ¢ C u

10 v '--

I ,.-----L-~-~-~=L---.L ____ _r_J -

J1~1 1 3 13 14 15 (Pll) ~. . . J . ____ _j _____ L __ :·~~ 6.flJ

~tlOOVDC::c .::.lOOVDC-1 +35VOC-2 -35VOC-1 COM 35VAC-I . -Gr:tlfi:_L l J 35VAc-z~ uLJJ

~ : L-..-....- AC1 ® 1-----1--+1-+-+ ~-+--..Z:-''2 1 I R s

H--f--H-----<:: 3 1 ?10 kh

L----! Ac~ e r---.'------+----+-+-.>-+-+-t-++-o ·· .. J.JL L- ~ 80'-,j

J c CHS.

171 L...

~~;! ~ R3

0 7~8 '3ATT E ld 27 ':)CJ 1

OI'ERATI•)N 1 W

A . ,B ·::_________. __ -:; I 9 L..--~,.- ([)c;--..c...o

'-".JPL'Z K? ~ B * CR7 - 'l-A~_____._-~

J4(Ui~Jr) - -.r-- .

L.,....... A A.S. +

L.............- B A.S. -·

c B.S. +

D B.S.

E C.S. t-

F C.S -

~A1.

0B POWER SOURCE BAT. ADAPTOR

TO

A- A+ 0 0

B+o 2 l 3

B-04

oS c+ 6 7 8

0 0 0 C- OFF N/A

..2?.... POSITION FUNCTION

BAT. ADAPTOR P4 REF FIG. 8-2

REF FIG. 7-5 FD-2~YIY1 12

·f!ODv'IX-1 -/OOVDC-2 FD-1 UiND-1 c;N~----_j I L_=:J=.:----

J K L....-----------1 : 1 RELAY DRIVE

----- 1--...r--·~~m~o~v~v~c-----~m~o~vD~c---ouT GND

rA-1/ DRIVE/?

5,A.T REF

FIG. 9-2

L

------4 M 0C I

j'-1-.....;....----1 >·· 0A 1\l VB

1t35 VAC OUT

~-------1\-\ 10

~================~Jr~2- 3~ VAC IN

COMMON

_______ FIGURE 7-4

UG-18 CHARGER MODULE SCHEMATIC

7-10


MATERIAL LIST POWER SUPPLY CARD

CKT SYMBOL

DIODES

CR1-CR4

CAPACITORS

Cl, C2

RESISTORS

Rl, R2 R3

MISCELLANEOUS

F1

DESCRIPTION

Diode, 1 Amp 600 PIV

Capacitor, 80 uf @ 150 VDC Alum. Elect.

Resistor, 3.3K 5W 5% Resistor, 47K 2W 5%

Fuse, 1/2A @ 125 VAG

7-11

PPSC P/N

741001

720236-80

760282-33 760053-47

712005

Pacific Power Source Corporation - Huntington Beach, California 92£49 (714) 898-2691

+ 100 VDC -1

- 100 VDC -1

REF FIG. 7-4

35 VAC -1

35 VAC -2

+C2 + 100 VDC -2

R3 R2 - 80MFD 47K 3.3 K 150 VDC 2W 5W -1

GND -2

Rl + c 1 3 .. 3K T 80 MFD 5W 150 V DC

-100 VDC -2

.-----------...__-0 + 35 v 0 c - 1 .

Fl .5A

+35VDC-2

COM

o-------J

REF FIG. 7-4

FIGURE 7-5

POWER SUPPLY BOARD SCHEMATIC

7-12

©

(\j

0::

35VDC-1 0

35VDC-2 o

© COM o

-1 -2 0 0

+lOOVDC

+

(\J

u

§

0 -1

~

GND

~

-1 -2 0 0

-lOOVDC

u

+

0 -2

35VAC-2 0

~ ~ 0

35VAC-1

@

F0-2 0

0

FD-1

@ FIGURE 7-5

POWER SUPPLY BOARD ASSEMBLY

7-13


7.2 THEORY of OPERATION

Refer to Figure 7-4 for the UG-CM18 Charger Module schematic and Figure 7-2 for the Control Card schematic.

SCR 1 and SCR 2 <Fig. 7-2> phase modulate the input 115 VAC power to T1 <Fig. 7-4). BR1-BR3 rectify the modulated 115 VAC to produce a regulated 110 VDC at the battery trays. A1 <Fig. 7-2) compares the charge voltage, which is adJusted by R7, to the reference voltage created by CR9. 22 <Fig. 7-2) resets at each zero crossing of the input power and times out according to the voltage out of A1. With higher voltage at pin 5 of 22 <Fig. 7-2) the SCR's turn on later during each half cycle and deliver less voltage to T1 <Fig. 7-4).

There are three battery voltage sensors, one for each phase. As+ and As- are DC power supply sense voltages which come from the power source. They feed into a comparator and trip the Battery Circuit Breaker when the voltage drops too low. R107 and R108 adJusts the trip voltage.

R117 and R118 determine when the Red, Low Charge Warning, lamp will light. R125 and R126 adJust when the Green, Battery @ Full Charge lamp will light. The phase B sense components are refrenced by "200" numbers and phase C by "300" numbers.

7-14

n,M;f;~ Dnwa~ ~n~~~~P r.n~no~ation - Huntinoton Beach, California 92G49 (714) 898-2G91


7.3 SERVICE

* W A R N I N G

THESE SERVICING INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL ONLY. TO AVOID PERSONAL INJURY, DO NOT PERFORM ANY SERVICING UNLESS YOU HAVE BEEN QUALIFIED TO DO SO.

If the Charger ON lamp does not light, check the light bulb and Fl. Next check for 115 VAC from pin 6 to pin 4 of JB or PB. Next check for 90-115 VAC from pin 1 or 2 to pin 6 of J8 or PB. If.there is no voltage check 22 for a variable duty cycle square wave output feeding T2 and triggering SCR 1 and SCR 2.

If the batteries are being overcharged, check for a shorted SCR or misadJustment of R7.

If one of the battery condition lights does not light when it should, make sure the Battery Circuit Breaker is ON. Next check the Fan Driver and measure 35 VDC from pins 14 to 15 on Jll or Pll. Now check the relay or relays that drive the light. Finally, check the comparator circuit and output transistor.

7-15

O:o"a;,.. Oi'\wo"' c:" .. ,..."., r",...nn,....-tinn - HuntiYI!lton Beach. California 92649 (714) 898-2691


7.4 UG CONTROL CARD CALIBRATION

Pacific Power Source Corporation recommends a Periodic System Test at four month intervals. If the unit is out of calibration or has undergone maJor repairs, it should be recalibrated.

TEST EQUIPMENT REQUIRED

DVM: Data Precision model 1351 or equivalent.

Clamp On Ammeter: Amprobe model RS-1000 or equivalent.

MATERIAL REQUIRED

Resistors: 2 each 110K 1/4W 1%, 5.11K 1/8W 1%.

Molex Connector: 2 each

Molex Pins: 30 each

Potentiometer: 2 each 5K OHM 5W

CALIBRATION of the BATTERY VOLTMETER

Switch the Battery Voltmeter to the A+ position and using a DVM measure the Battery Voltage from TB1-1 to TB1-25, then adJust the S.A.T. resistor across the meter so that it reads the same as the DVM + or - 1 VDC.

CALIBRATION of FULL CHARGE VOLTAGE

With the batteries fully charged, the charge current less than 2 Amps, and the Charger ON, adJust R7 so that all of the Battery Trays read 108-110 VDC.

CALIBRATION of the CHARGE CURRENT LIMIT

While the Battery Voltmeter is in the partial charge region and the Batteries are recharging, use a clamp on ammeter to measure the input current. Then, adJUSt the input current to 10 Amps using R5.

7-16

O~rifir OnwPr Snurrp Corooration - Huntincton Beach, California 92649 (714) 898-2691


7.4 UG CONTROL CARD CALIBRATION <con't>

CALIBRATION of the CHARGE CURRENT AMMETER

While the Battery Voltages are in the partial charge region and the Batteries are recharging use a clamp-on ammeter to measure the input current of the charger module. Then, adJust R4 so that the Charge Current Ammeter reads the same as the clamp-on ammeter.

BATTERY VOLTAGE SENSOR TEST SET-UP:

Turn off all Input Power and Battery Power. Connect P5 of the Control Card and J5 of the wiring harness to the test set-up as shown in figure 7-7.

7-17


0 ®

TO ® J5 (j)

OR ® J6 cw OR

J7 9

@ ®

KEY

R+

110 K 1%

FIGURE 7--7

BATTERY VOLTAGE SENSOR TEST SET-UP

7-18

® ® ® 0 ®

TO PS OR

P6 OR

P7


7.4 UG CONTROL CARD CALIBRATION <con't)

TRIP VOLTAGE SENSOR CALIBRATION:

Turn on all power supply and DC Circuit Breaker. AdJust R- fully clockwise. Set the voltage, from TP101 to TP105, to +82 VDC using R+.

Slowly turn R107 until TP102 changes state.

AdJust R+ fully clockwise. Set the voltage, from TP101 to TP106, to -82 VDC using R-.

Slowly turn R108 until TP102 changes state.

WARNING LOW CHARGE VOLTAGE SENSOR CALIBRATION:

AdJust R- fully clockwise. Set the voltage from TP101 to TP105, to +90 VDC using R+.

Slowly adJust R117 until TP103 changes state.

AdJust R+ fully clockwise. Set the voltage, from TP101 to TP106, to -90 VDC using R-.

Slowly adJust R118 until TP103 changes state.

7-19

o~~;f;~ Dnwa~ ~n~~~~a rn~nn~~t.inn - Huntinoton Beach. California 92&49 (714) 898-2&91


BATTERY CHARGED VOLTAGE SENSOR CALIBRATION:

AdJUSt R- fully clockwise. Set the voltage from TP101 to TP105, to +106 VDC using R+.

AdJUSt R125 until TP104 changes state.

AdJUSt R+ fully clockwise. Set the voltage from TP101 to TP106, to -106 VDC using R-.

AdJUSt R126 until TP104 changes state.

The calibration of the comparator trip points are for Phase A only. These procedures must be repeated for Phases B and C in order to complete the calibration process. P5 and the "100" series reference designators relate to Phase A. P6 and the "200" series reference designators relate to Phase B. P7 and the "300" series reference designators relate to Phase C.

7-20




7-21

Pririfir PnwPr ~ourrP r.nrnnrrition - Huntinoton Beach. California 92649 (714) 898-2691

Para.

8.0 8.1 8.2 8.3 8.4

Fig.

8-1 8-2 8-3 8-4

Title

SECTION 8

UG-BA18 BATTERY ADAPTOR DETAILED DESCRIPTION

TABLE OF CONTENTS

UG-BA18 Battery Adaptor Detailed Description Description Theory of Operation Service Calibration


Title

UG-BA18 Battery Adaptor Assembly UG-BA18 Battery Adaptor Schematic Battery Switch Card Assembly Battery Switch Card Schematic

8-0

Page

8-1 8-1 8-9 8-9 8-10

Page

8-2 8-3 8-4 8-5


8.0 UG-BA18 BATTERY ADAPTOR DETAILED DESCRIPTION

8.1 DESCRIPTION

The UG-BA18 Battery Adaptor attaches to the back of the Power Source Mainframe and interfaces the Battery Cabinet with the Power Source. <See fig. 8.1)

MATERIAL LIST UG-BA18 BATTERY ADAPTOR

ITEM

1 3 7 9 11 19 21 23 63 64 65 66 67 68 69 70 71

DESCRIPTION

Chassis, UG-BA18 Battery Adaptor UG-BA18 Battery Switch Card Assembly Contactor, 3 Pole 50A @ 120 VAC 717008 Receptacle, Box Mounting 7 Pin Male Receptacle, Box Mounting 17 Pin Female Circuit Breaker, 5A 250VAC Single Pole Receptacle, Single Side Wired 15A Label, "Danger High Voltage" Potential Transformer 8 Pin Female with Lock Ramp Connector, 15 Pin Male Crimp Terminal 5A Connector, Female 15 Pin 6A Connector Pin, Male .093 Dia Connector Pin, Female .093 Dia Picofuse, 1/8A @ 125 VAG Terminal Strip, Solder Lug

8-1

PPSC P/N

114690-A 114671-A

714058 714075 716031 714022 704001 531195 714007 714004 714006 714005 714003 714002 712004 705008

0

SPL.. fYP.

0

2 Pt.. TYP

-8

TSl TYP. we.

0 TS2

0 J 0 B

Pl

@ @ ® @ @

FIGURe-c.. 8-1

UG-BA18 BATTERY ASSEMBLY ADAPTOR

8-2

CHARGER MODULE

REF. FIG. 7-4

/

'A. FlAT + A.S. +

A. COM

f/JA l A.S.+ A. BAT-

CHS

{

B. BAT+ B.S.+

B. COM ¢ B B.S.+

B. BAT-CHS

r·H c.s. + ¢ C C. COM

c.s. + C. BAT-

CHS

A.S. + A.S.-B.S.+ B.S.-c. s.+ c.s.-

RELAY { DRIVE

35 VAC 1/JC OUT 35VACI/J80UT 35 VAC 1/JA OUT 35 VAC 11/J OUT 35 VAC IN

CONMON

<E-- A 1----------- ---- ---------------E--- 8 1 o-----L-------E--- c _"\ o.---:::4--------1---. 4------- 0 ~----- ______ A__2" I o----'6'---------1---- ,_

~- E

<0-L_G_ -~~ fl ~ Iii

P2 1 2 ------E---- A f-----------+--~~ -, __4 := ~ f--------1 --1 -E---- 0 ~--- E f------+---+-1-4-4--~~-~ ~- G

5., o---L-A_

8, -~ K6

..,____ -E-----E----

-E----

-E----

-E------

-E----

-E-------<'-----E-----E----

-E-----E----

-E-----+------E---

<E----

TB3

- t-t-t-t-t-t---l-1---l 1

2

1 ------------------ E2 3

10"'- A. s· AT+ [",, "-+-+-+-+--t---c~---j 4 ~'- AY. S.+ [7/ ..--

L-J-1-+-----'E::-<4:<'--1 A. BAT - A. P . .S. - ~* >------- 5 L....H~-1--l-+---E'=-'<S (- 8. BAT + 8. P. S. + t-+-+-+-~~----1 6

L--J--l-+------'E"<Rf--1 B. BAT- 8 P S :_,)E7 7

~ A B c o~ L---J--l-+---'E"-"9; f--1 C. bAT + ' . . El 0

Ell C. P. S. + f-'?n>-=-El:.c_Z __ _j 8

E

G --

P4 -

A B c D

~--+--+--+---+-+-l----~-1-+---'·-.Y/ C. BAT- CPS -,~ - .. - f-7~.:.~~------+--+-+-+----l 9

P7/J7 (V"'

l.....----------l-+--1 1 1- A. s_ + ~--+-+--+---~-------l-+--j 3 1- A. S. -

L----------1--1---1 4 f-- B.s. + ~---+--+---------------1---1~ 6 f-- B.s.-

BATTERY SWITCH

CARD A. COM B. COM C. COM

Al A2

P7/J7

~~ --3

CHS '---

Tl ,---

E- ~--------------+-1--l?f--- C.S.+ ~-----------------1---1~ 9 f-- c. s. -~----------------1--l>--113f-- KG-B

~--------------J.-- 151- K6-A

!--------4 Al t-------------~A2

A3 - 5 f---------jA3 F G H

-

J

81-6 81

82-7 82 83-8 83

PB/JB

POWER SOURCE OUTPUT

~115-1 CBl 15A ,--- 115-2

'----

POWER SOURCE DC POWER SUPPLY

POWER SOURCE INPUT TRANSFORMER

FIGURE 8-2

UG-BA18 BATTERY ADAPTOR SCHEMATIC

8-3

AS-~ 0 [[[]

SCR-2

§~SCR2K~

0

0

~~ u 0l

+

0

SCR4-K

SCR6-K 0

ITiTI 85-

~ES HS4

cs-

,@,Ell

r--,. I '

< ) \ I '- ___/

SCR-6

I@IE12

(0 ACOM o

I I (]IT] I I __ J L ___

~ ( I N

I T2 Vll ll{) I

" l~~l IJ w

I I C I I C

l~ J B COM

f.;\ I I

0

I I __ _j L ___

~ ( 1 N

I I VJ I T3 I l{)

,. l~~l l__j w

I I 0 I 1

L~ D

J COCOM

N

T4

AS+~ 0 ~ @P

El~ ~--,

/ '> \ / '-----'

CRI4 E 0 CC) ~(~ ~L

C8

.-----~ ~ [email protected]~I + ~ L..._ --------l TP 1 @

(\j

u

0 SCRl-G

~ KErB

0

+ C9

~-----------~ SCR -1 I (7:\ I E2 0 K~-A 8

[8)9]

0

SCRl-K 0 Q2

E5~ + ~

~--\ < )

\ I

\_ ___ _/

<..')

'<1 ~ 0~ u ~

SCR-3

E6~ 03 0 ~

0

cs+

\ I \.__.../

SCR-5

E9j@l

SCR3-K

0

C10

CR 5 CC)

~~ ~ ~I Cl I

I El4

~ El3

F TP3

@ I f0\ II r: AS2 ~·@ ~@ ~ ~ ~_) f(2;l U3 lQJ l0 ~ ~ ©J ~ WElOO 5

8

I - F SCRS-K ! ~ 1o o o 0 0 0 o o I

IWA __ SJN __ _ FjN ____ REV_ l~ J PS

CRIMP SIDE

P7 TO P7 TO

A.s. + c.s.-

B.S.+ B COM

B.S.-C.S.+ C COM

* *

* KS-8

*NOT USED

WIRING DIAGRAM

E

FIGURE 8-3

BATTERY SWITCH CARD ASSEMBLY

8-4

TO CHARGEF< MODULE FIG. 7-4

TO BATT

ADAPTOR FIG. 8-2

r~· 0A COM

A.S.-

[B.S.< 0B COM

B.S.-

[ c.s.• 0C COM

c.s.-

P7 1

2 3 4

5 6 7 8 g

10 11 12

E2 A,P.S. + <E-_,.__,._ __ ___... ____ _.__._...j A. P.S.- ~E::.:..::· 3::e-~

IIOK,I% I/4W

llOK,1% 1/4 W Rl3 . 5.111<,1 ~0

1101<,1% 1!4W

Rl8 lKG·A 13

CONTACTORS 141 '----~..---__/\

· KG·B 151

P8

2 3 r INPUT FROM

. XFMR SEC. 4

(5) 6 7

6

8. KEY PIN 5 OF P2

7. 1% RESISTORS ARE 1/8 W.

6. lC11S 746019 5.ALL DIODES AKE 74100.1 4.C2-7 VALUES ARE 200UF, 50V. 3.CAOCITANCE VAI.l£SARE MICRO FARADS. 2. SCR'S 1-6 ARE 742001 l.RESISlffiS ARE 114W,SI'o.

NOTF~d Nl FSS OTHFWISE SPECIFIED.

R 19

1101(,1% I/4W

5.111<,1%

CR2

CR 3

C R15

CR16

CR17

E10 C.P.S+~~--+------+-------_.--~

c. P.S.-~E1~l-~

E13 G TP3

R1 110 K

1% I/4W

R2 IOK

R23 1.82K(t>

Cl 1%

.15 200

TP4 CR4 714006

R3 7.5 K 5W

R4 lOK

CB 5 300V

R24 470K 10 K 4,3K

R2G

R2S JR27 I 0 K

--~~~~~~~_.--~v~~

CRI2

CIO 8

IOOVDC

0 TP2

Ql 740000

R29 75

02 540129

1 CRI4 Cll 714004 .05

'YXJV

~EI4 FIGURE 8-4

BATTERY SWITCH CARD SCHEMATIC

8-5


MATERIAL LIST BATTERY SWITCH CARD

CKT SYMBOL DESCRIPTION PPSC P/N

RESISTORS

R1 Resistor, llOK 1/4W 1% 760323-110 R2 Trim Pot, 10K 769990-006 R3 Resistor, 7.5K 5W 54 760292-75 R4 Resistor, 10K 1/4W 5%CC 760023-10 oc; Resistor, 75 OHM 1/4W 5%CC 760020-75 '"'"' R6 Resistor, 110K 1/4W 1% 760323-110 R7, R8 Resistor, 5. 1K 1/8W 1Y. 760211-511 R9 Resistor, 110K 1/4W 1Y. 760323-110 R10, R11 Resistor, 75 OHM 1/4W 5Y.CC 760020-75 R12 Resistor, 110K 1/4W 1X 760323-110 R13 Resistor, 5. llK 1/8W 1Y. 760211-511 R15 Resistor, llOK 1/4W 1% 760323-110 R16, R17 Resistor, 75 OHM 1/4W 5Y.CC 760020-75 R18 Resistor, llOK 1/4W 1X 760323-110 R19, R20 Resistor, 5. llK 1/8W !X 760211-511 R21 Resistor, llOK 1/4W 1% 760323-110 R22 Resistor, 75 OHM 1/4W 5Y.CC 760020-75 R23 Resistor, 1. 82K 1/8W 1X 760211-182 R24 Resistor, 470K 1/4W 5Y.CC 760024-47 R25, R26 Resistor, 10K 1/4W 5Y.CC 760023-10 R27 Resistor, 4.3K 1/4W 5r.cc 760022-43 R28 Resistor, 390 OHM 1/4WCC 760021-39 R29 Resistor, 75 OHM 1/4W 5Y.CC 760020-75 R30, R35 Resistor, 22 OHM 1/4W 5Y.CC 760020-22 R36 Resistor, 4.3K 1/4W 5Y.CC 760022-43 R37 Resistor, 22 OHM 1/4W 5Y.CC 760020-22

MISCELLANEOUS

Tl, T2 Transformer, 12.6 V@ 0.35 A 731010 P7 Connector, 15 Pin Female 714005 P8 Connector, 8 Pin Male PC Mount 714010

Connector, Pin Male .093 Dia. 714003

8-7



8-8


8.2 THEORY of OPERATION

Refer to Figure 8-2 for the UG-BA18 Battery Adaptor schematic and Figure 8-4 for the Battery Switch Card schematic.

SCRl-SCRG (Fig. 8-4) turn on as soon as the Power Source AG Input drops too low for normal operation. This action connects the batteries to the Power Source DC Power Supply. Contactors KG and K7 <Fig. 8-2) then close to continue to deliver power from the batteries to the Power Source DC Power Supply.

CR1-CR3, and CR15-CR17, <Fig. 8-4), rectify the input voltage, which is adJusted by R2, <Fig. 8-4), and is compared to the reference voltage created by CR5 <Fig. 8-4) to enable the battery switch when required.

SERVICE

W A R N I N G

THESE SERVICING INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL ONLY. TO AVOID PERSONAL INJURY, DO NOT PERFORM ANY SERVICING UNLESS YOU ARE QUALIFIED TO DO SO.

If the charger delivers full charge current continuously and one or more battery trays do not fully charge, check for a shorted SCR.

If the Power Source will not operate on battery power, make sure the battery output circuit breaker is closed. Next, check to see if KG and K7 <Fig. 8-2> close when input power is removed from the power source. Finally, check the comparator circuits for normal operation.

8-9

\

n __ ,.,,_ n~··-- c~•Mnn r~~""'"'"H"""'- ~untir~nt.nn F!P;.!rh. California 92649 (714) 898-2691


8.4 CALIBRATION

Pacific Power Source Corporation recommends a periodic System test at four month intervals. If the unit is out of calibration or has undergone maJor repairs, it should be re-calibrated.

TEST EQUIPMENT REQUIRED:

Oscilloscope: Tektronix Model T922 or equivalent

DVM: Data Precision Model 1351 or equivalent

DC Power Supply: 0-110 VDC variable at 1 AMP

Clip lead.

TEST SET UP

Turn off the Power Source and the Battery Cabinet.

Using the clip lead connect the cathode of CR1 to the cathode of CR4. (See figures 8.3 and 8.4.)

Turn off the DC power supply and turn it down to zero output. Connect the + of the 110 VDC power supply to the clip lead and the common to Phase A common.

TESTING THE SENSE CIRCUIT

Turn on the DC power supply and adJust it to + 90 VDC.

Turn R2 fully counterclockwise.

Reference the oscilloscope to phase A common and look at pin 1 of IC1. It should be sitting at zero VDC. If not, wait 5 seconds.

Turn R2 clockwise until pin 1 of IC1 JUSt goes to 2.5 VDC.

8-10


TESTING THE SENSE CIRCUIT <can't>

AdJust the DC power supply to + 95 VDC and pin 1 of IC1 should return to zero in about 5 seconds.

Slowly reduce the DC power supply voltage. Pin 1 of IC1 should go to 2.5 VDC as the DC power supply voltage goes through 90 VDC.

Turn off the DC Power Supply. Remove the clip lead. Remove the DC power supply.

8-11

. -. ..... ,.,,.. ,...,~J., nnn ~C.Oi



8-12



8-13

1'"1 ·-------1...! -·~

Para.

9.0 9. 1 9.2 9.3 9.4

Fig.

9-1 9-2

SECTION 9

FAN DRIVER DETAILED DESCRIPTION

TABLE OF CONTENTS

Title

Fan driver Detailed Description Description Theory of Operation Servicing Calibration


Title

Fan Driver Assy. Fan Driver Schematic

9-0

Page

9-1 9-1 9-5 9-5 9-6

Page

9-2 9-3

"··-'-'--'-~~ o ... ~ .... h r.2lifnl"nia 92&49 (714) 898-2691


9.0 FAN DRIVER DETAILED DESCRIPTION

9. 1 DESCRIPTION

Fan Drivers are located in the Charge Module, Control Module and each Power Module. The Fan Driver provides 60 Hz AC from the DC Power Supply to operate the lights in the Charger Module. The same applies to the fans in the Control Module and Power Modules. (See Fig. 9-1)

MATERIAL LIST FAN DRIVER

CKT SYMBOL

DIODES

CR1, CR2 CR3-CR5

TRANSISTORS

Ql Q2, Q3 Q4 QS, Q6

DESCRIPTION

Diode, Zener 12 V 0.5W Diode, 1 Amp 600 PIV

Transistor, PNP 300 v Transistor, NPN 300 v Transistor, PNP 300 v Transistor, NPN Power

1 A 0.5 1 A

Apprvd Alt. Part:

A

PPSC PIN

741003 741001

760006 760008 740006 540132 540129-5

INTERGRATED CIRCUITS

A1

CAPACITORS

C1 C2

C3

C4, C5 C6

OP-AMP T0-5 Case 746012

Capacitor, 0.68UF@ 50 V Film 720304-68 Capacitor, 1.0UF @ 50 V 720045-10

Monolithic Capacitor, 1.0UF@ 300 VDC 720245-10

Alum Elect Capacitor, O.OSUF@ 500 V Disc 720023-50 Capacitor, 10UF @ 135 VAC 720366-10

<continued on page 9-4>

9-1

"'-----·--'-•~~- u.,,Hnntnn Rr>a.ch. California 92649 (714) 898-2691

IWA# S/N

@ Cl

FIGURE '3-1

FAN DRIVER ASSEMBLY

9-2

L4 I ,Oi5pf = 500V

Q6 ?W1:Z'l-5

rI

' ,_

' 1-=?

Cl\'1-74100\

CRS 74\001

r;< 1A

C6 (INSTALLED AI TIME- OF TEST) 10 f.J~ 135 VAC

0 UTF UT - - - ----i 1----

aROUIJD

E C B METAL TAB (FARSI DE)

Q2,Q3

Ql 'Q4

(BOT TOM VIEW)

c (CASE)

0

8 E

o+o

0

Q5 ~ Q6

(BOTTOM VIEW)

FIGURE 9-2

FAN DRIVER SCHEMATIC

9-3


MATERIAL LIST (con't> FAN DRIVER


RESISTORS

R1, R2 Resistor, 110K 1/4W 1Y. R4, R5 Resistor, 22K 2W 57.CC R6 Resistor, 10K 1/4W 5Y.CC R7 Resistor, 22K 1/2W 5Y.CC R8 Resistor, 330 OHM 1/4W 5Y.CC R9 Resistor, 47K 2W 5Y.CC R10 Resistor, 47 OHM 1/4W 5Y.CC Rll Resistor, 330 OHM 1/4W 5Y.CC R12, R13 Resistor, 47 OHM 1/4W 5Y.CC R14 Resistor, 1K 1/4W 5Y.CC

MISCELLANEOUS

Fl, F2 Pica Fuse, 1. 0 A @ 125 VAG

9-4

PPSC P/N

760323-110 760053-22 760023-10 760033-22 760021-33 760053-47 760020-47 760021-33 760020-47 760022-10

712001

·.HODEL UG-18 SECTION 9

9.2

9.3

THEORY of OPERATION

Refer to Figure 9-2 for a schematic of the Fan Driver.

The Fan Driver is basically a 60 Hz power Oscillator. It switches between +100 V and -100 V to produce a 200 Vp-p square wave which drives the fans. R1-R3 and C1 are the timing components of the circuit. The triangle wave across C1 is compared with the square wave across R3. The output of A1 drives Q1. Q1 drives Q2 which in turn drives Q3 and Q5, or Q2 and Q4.

SERVICING

W A R N I N G

THESE SERVICING INSTRUCTIONS ARE FOR USE BY QUALIFIED PERSONNEL ONLY. TO AVOID PERSONAL INJURY, DO NOT PERFORM ANY SERVICING UNLESS YOU ARE QUALIFIED TO DO SO.

In most cases, when a fan driver has failed the probable cause will be a shorted output device<s>, Q3-6. This condition is indicated when either F1 or F2 is open. The defctive devices can her located using a VOM. If the fuses are not open and the fan driver is not operational, replace A1.

9-5


9. 4 CALIBRATION

Pacific Power Source Corporation recommends calibration checks at 1 year intervals. If the unit is out of calibration or has undergone maJor repairs, it should be re-calibrated.

Calibration of the fan driver consists of adJusting the output frequency and verifying that the output is correct.

TEST EQUIPMENT REQUIRED

Oscilloscope: Tektronix model T922 or equivalent.

Frequency Counter: H.P. model 5302A or equivalent.

TESTING

The output should be a clean squarewave comming within 2 V of the power supply.

To calibrate the frequency, select a value for R3 which will provide an output frequency of 60 (~ 0.5) Hz.

9-6



9-7

Para.

10.0 10.1 10.2 10.3 10.4

Fig.

10-1 10-2 10-3 10-4

Title

SECTION .10

4024 REMOTE STATUS PANEL DETAILED DESCRIPTION <OPTION>

TABLE OF CONTENTS

Model 4024 Detailed Description Description Theory of Operation Servicing Calibration


Title

4024 Remote Status Panel Function 4024 Remote Status Panel Assembly 4024 Remote Status Panel PCB Assembly 4024 Remote Status Panel Schematic

10-0

Page

10-1 10-2 10-10 10-12 10-12

Page

10-2 10-4 10-6 10-7

"-----·--.. ' ~- - u .... H ... nh-."' Rl>r~rh. California 92649 (714) 898-2691


10.1 Description

;{:\ , __ )

The 4024 Remote Status Panel informs the user of the condition of the UPS, including batteries, from a remote location.

The following numbered triangles correspond to the numbered triangles in fig. 10.1. This will give a complete description of each indicator.

4024 REMOTE STATUS PANEL FUNCTION

BATTERIES CHARGING LAMP:

This blue lamp illuminates when the Battery Charger is delivering current to the batteries and will extinguish when the batteries are charged or if the Battery Charger is turned off.

BATTERIES CHARGED LAMP:

This green lamp illuminates when the batteries are charged, the Battery Circuit Breaker is closed and all interconnections are made to the Power Source. This lamp must light after 24 hours of continuous charging.

BATTERY OPERATION LAMP:

This yellow lamp illuminates when the Power Source is discharging the batteries. Should this condition exist longer than 20 seconds, the Audible Alarm will enunciate in a steady tone.

WARNING LOW CHARGE LAMP:

This red lamp flashes when less than 10% of Battery Power is remaining. The Audible Alarm will enunciate in an interrupted tone in order to alert the operator of imminent shutdown.

AC LINE OPERATION LAMP:

This green lamp illuminates when the AC line is If the AC input fails, the lamp will extinguish Audible Alarm will enunciate in a steady tone. AC input is excessive, this lamp will flash and will enunciate in a steady tone.

10 - 1

present. and the If the the Alarm

l

\ !

I

PACIFIC HUNTINGTON BEACH rnmm• CALIFORNIA 92649

WARNING-LOW CHARGE SHUTDOWN IMMINENT

BATTERIES CHARGING

~ ~ BATTERY

OPERATION

BATTERIES CHARGED MUST LIGHT AFTER 24 HRS OF CONTINUOUS CHARGING

ALARM RESET

PRESS TO

SILENCE ALARM

TEST LAMP/ALARM

:• PI·C-EL MODEL 4024 M UPS REMOTE STATUS PANEL

AC LINE OUTPUT OPERATION ON

[:J N & POWER

CONVERTER

0

v ~

~ N

1$!1 A B

LOAD

c

A-B METER SELECT

8-C C-A

& ACVOLTS

\9 ALARM WILL SOUND A STEADY TONE FOR

IIIIJ SYSTEM OPERATING ON BATTERY POWER

1111J BATTERIES LOW AND CHARGER NOT WORKING

1111J EXCESSIVE AC INPUT VOLTAGE

1111J CONVERTER AC OUTPUT IS OFf

~

ALARM WILL SOUND INTERMITTENT TONE Wt-EN BATTERY CHARGE NEARING DEPLETION AND SYSTEM SHUTDOWN IS IMMINENT

FIG 10-1 4024 REMOTE STATUS PANEL

FUNCTION

10 - 2


4024 REMOTE STATUS PANEL FUNCTION <continued>

OUTPUT ON LAMP:

This green lamp illuminates when the output of the Power Source is present. If the output fails, the lamp will extinguish and the Audible Alarm will enunciate in a steady tone.

AUDIBLE ALARM:

The Audible Alarm will enunciate as stated above or if both the Charger Charging and the Battery Charged Small lamps are extinguished. This alarm will also sound off when the Test LAMP/ALARM switch is depressed. To silence the alarm depress the ALARM RESET SWITCH CAPS.

ALARM RESET SWITCH:

This switch must be depressed to silence the Alarm each time the Alarm is activated.

TEST LAMP/ALARM SWITCH:

This button illuminates all lamps and activates the Audible Alarm.

OUTPUT VOLTMETER:

This meter measures the Power Source output voltage as indicated by the Meter Select Switch.

OUTPUT FREQUENCY METER:

This meter measures the Power Source Output Frequency as indicated by the Meter Select Switch.

METER SELECT SWITCH:

This switch selects which primary output the meters will monitor.

POWER CONVERTER:

This represents the Power Source which converts AC input line, or Battery power, to regulated AC power delivered to the load.

10 - 3

ALARM

~ ALAI<:v< R'EE£.1 --rD oiL.~ N-AR'M I

0

TE:ST 1rM S2

M1

~ D.LAR M Will. 'SOUND 6. '?IT=t.OY \ONe FOR = ?Y 5 TE:!v\ OYf:i:<./':>.T iNS, oN eATIE:RY PcWER a C:.\-\ARGi8< NCJI W 01<)(\N!:q b.ND BAJTE::Rt£:> ARE- LDW a EXC-~IVE AC... IWR..JT VD[..TA~ • ~-rE'I'I; Ac... C>\.:fTFU'I 6 Of"F

.I>LARIVI Wi~L ~D i\..!$"""-11UTI<.UT TDI-lE \1-Jf\El...l =nl:':K'Y ~ I-J66.Ri~ ~Tle!J AUDG$[EM ~IJ I~ I..,MiiJE'-1\

0

@ ~---@

Jl3 <FAR SIDE>

FIG 10-2 4024 REMOTE STATUS PANEL ASSEMBLY

10 - 4


ITEM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 25

MATERIAL LIST 4024 REMOTE STATUS PANEL

DESCRIPTION

Chassis, 4024 Remote Status Panel Cover, 4024 Remote Status Panel PCB Assy, 4024 Remote Status Panel Voltmeter AC output Meter, Vibrating Reed 60, 400 Hz Sonalert, 1900Hz 10-48V Lampholder, Snap-In 3/4 Square Lens, Red 0.75 Square Lens, Green 0.75 Square Lens, Amber 0.75 Square Lens, Blue 0.75 Square Switch, Rotary 12 POS 2 Pole Knob, 1 1/40D Blk Plastic W/Indic. Lamp, Incandescent 28V .04A T-1 3/4 Receptacle, Box Mounting 19 Pin Female Switch, Rocker 2PDT Snap-In Mount

10-5

PPSC PART NUMBER

114692 114693 114697-A 500011 700004 702089 701010 701017 701020 701019 701018 710013 702034 701004 714057 710016

©

SWAGE INTO PLACE,

JUMPERS A-RE 22 AW6 BUSS WIRE WITH 20AW6 SLEEVING.

A=f>1 (£ill) @W @liD (!@

(§) @][) (ill[) (Kill>

~ @ID

& IDENTtfY BOARD WITH PART NO.., SER NO., REV LTR AND IWA NO.,

£1

REMOVE PIN 14 OF Pl3.

ZiS REMOVE PIN 15 OF Pl2.

NOTEs: UNLESS OTHERWISE SPECIFIED

ITITJ (]10 @]

[fJD

@I] [§ill

mo ITID

31 4 TYPE. PLS

© (@ill

~ !('@]) @) <mill)

©§]) @ill) @]) @ID

P13

©

y

SECT A A

FIG 10-3 REMOTE STATUS PANEL

PRINTED CIRCUIT BOARD ASSEMBLY

10 6

TO CHARGER MODULE (JlO) REF FIG. 7-4

+35VOC 35VAC OP BATT OP

6AT CHARGED

SAT CHARGING

BAT LOW CHS

SIGNAL COM

POWER COM

{

0A 35 VAC ~ 8 OUTPUT 91 C

I~

PC BOARD~

I I

'' --f J--~ '~"'' ~I I "" " I

r-P---Ec::~J ~~~. -- r----------------------~------~~~~~~8-----~R-20 __________ -_-_-_-_-_=====--~-~ 10K I

+ QB R47

II IOKT?29 :(N~~-455tC4 ~~ I t~ IM ~-7·-";/\R:A:~,-+-",..rv-t~';: r---r-:i~--os·o"+_5 __ R-53_7_,_2h E=_=_=_=_=======;-1

I j ,o j'.o fceJo J..c,~o R72 ,-~-Pic-/ 12 '----......, --P;-;-]Jl3 ~ ~~ L--~-..__..._ __ _. ___ _.l_N_75_l_A ~-6~4'NK'r<1"'~ R56 Q5 R23 ~.-

A 1-+H-------------/ I 1 '--- -o R64 C150 ; ~.9 ,., 1 R48 ~.ii' 1M ~~ R38 C>"+-t--.--'11101/K-r--<t-l-i-----.j I I f---+-4-+-------

8 2 2 f--------~f--...--~1111-... CIG~ ,.,._,2

'-",v...,..J~J~10M1 4 C 1-- 130K,I% CR26 !.OJ 3

1 _ Rl 2 -o CR49 lOOK lOOK CR39 ~

1-- r--------------1 < 2 2 f---t-+-4f-'A'-I VGRN ACO lpl

~ 1-l-J : ~ 1---._j ~ ~ -GR11 1 ?.lJ ~08~ lOK fc0'K C2G R46 CR34 c;:45 3 3 f- ACO F f- 6 6 \----------, ~- 3 CR35 l.O 300K CR40

G I"J, ~ 7 1----------- C~-c ~---__.,-3_0-'\.~i\:i\~~..:.;-:o~ r;,;- l'7-J.1:~:~9v---,..,Rl:-;K2,.--)-t----t-!=R=I7~~=~=::i!======::l=~ r--!--~-C~R>f-4_6 __ 4 4 f---+-j...tl~ K h 8 ~66 ~ c7,9 1-...---l~..--~-wn~ I .PH 5 s f---L E.Bf.Q.a '3 9 R67 86.6K 1.0 47.5K CR27-r G4,9K lOK J;Rl~•>"'C..:.---{ Q9 10K R27 R35 R88 CR41 ~

B M2 10 10 1--:.:..:==-----'l...:. l% J:C18 R65 ._ __ -J.-'~'J/-...c:;,;; '] lQK lOOK lOOK 6 6 f----j...t\AGRN B I3

11 11 1-------~ T'o 130K (22 vC-----1-!c R BAT

s 1--..-----4 T 1--+-,._-.J-.< u 1--+-!-..·-l-l-0

3 4 2 't3' I.J

1>---12 12

1------ CR\8 ' 1% l.O - c,",i7 C 47 7 7 f--- CHARGED

r-- 13 13 1-------. ,----1-+----.j ~~IK CR42 _!\~

A o

100

14 ~ CR\9 -o ~,j~K 8 8 1-----"l '\:./BAT LOW OW

~KEY R68 C~R2~l rJI~ l ,:~ Cl.204r..-'C::.;;:.::3c:34--i---..J kR38 CR43 A~I5 ~ 130K CS .','a ---1 R ~ 9 9 e------"<BLU CHARGING

JO.t. 1.0 Cl Cl9 R84>-ol-'2'-'l/\14tv-!-+-"1 R32 VOLTS C~21 l.Of l.O lOK IOK 2 R45 lOOK -- I I R?f 3 lOOK 00 CR44 0 ~

-o: 40.2K,I% ~l _ ...... ~ :___} 1 !Of-------"<~ OLJi'ON

AB 0

oCA

;;_]_ NONEHCLATURE

CR221 R74 R51 R30 ~ R22 t 53

'--JRI/61/9v--<~ir',-O-<t-~CR~2j-'9 jf:~~ llOM lOOK ~~~3K ~-------__)!OK L!-+-f---f----._j 11 11 1------'A'-o-'-~ 113~K 1.0 Cl_4l C20 R85'-"'2--"'RA15A-l~~ t---- R5 r-r--- 12 12 f------~ RESET

l.O'j= \,0 \OK !OK 4 -c ~1 12::: CR23 I R79 3 R41 R24 8 ALARM lOOK !OK

R 70 C 12 130 K 1.0

~ r-rCRI-2 ~-~·K-1NS239

t-- -~---

40.2K,1% 1 r--+-t:-:-:--!--~f---;-1 CR48

c:::o~-+---64;.;~9;...:5;;_,1~- 1 ,::2 ~ ~~7l~· 2 ~~ J C15 C 21 2 RIG 11 10 K [C:'_.'G ;-,Y..-+--.j"l I 0 1.0 RSG l]tR:.: .. . ' Q2 ,..... ...... - 2

CR25' RBO IOK IOK ~''3 ::... ~~;s ~~~g

40.2K,l% ALARM SET/ RESET ~6~

R52 IM

R63 R44 lOOK

-=?

CR32

QlO

ALL COMPONENTS WITHIN DASHED LINES ARE MOUNTED ON PC BOARD,

CRU CRI'i Q6

7. ALL PNP TRANSISTORS ARE 2N2905. R2G 6. All NPN TRANSISTORS ARE 2N221'3., R60

IM !OK

I

I

______ j 5. 4. 3. 2, I.

ALL COMPARATORS ARE LM339.

ALL 1% RESISTORS AR£ 1/8 W.

ALL RESISTORS ARE !/4 W, 5%.

ALl CAPS ARE MICROFARADS, SOVDC.

ALL DIODES ARE 1N4005.

NOTEs: UNLESS OTHERWISE SPECIFIED

CRJG RGI IM

FIG 10-4 REMOTE STATUS PANEL SCHEMATIC

10 - 7


MATERIAL LIST 4024 REMOTE STATUS PANEL PCB

CIRCUIT SYMBOL DESCRIPTION PPSC PART NUMBER

DIODES CRl, CR2 CRS, CR6 CRlO CRll

TRANSISTORS Ql Q2-Q7 Q8-Qll

Diode, Zener 9.1V O.SW Diode, Zener 15V O.SW Diode, Zener 5.1V O.SW Diode, 1 Amp 600 PIV

Transistor, NPN Power Transistor, NPN Signal Transistor, PNP Signal

INTERGRATED CIRCUITS AR1-AR3 Quad Comparator

CAPACITORS Cl, C2 C3-C10, C12-C30

RESISTORS R1 R2-R7 R8 R9-R28, R88 R29-R33 R35-R39 R41-R45 R46 R47-R53 R54-R63 R64, R65 R66p R67 R68-70 R71 R72-R76 R77 R78-80 R81 R82-R86 R87

Capacitor, SOUF @ SOV Alum Elect Capacitor, lUF @ SOV Monolithic

Resistor, 75 Ohm l/4W SXCC Resistor, lK 1/4W SXCC Resistor, 5.6K 1/4W SY.CC Resistor, lOK 1/4W 5%CC Resistor, lOOK 1/4W 5XCC Resistor, lOOK 1/4W 5XCC Resistor, lOOK l/4W 5XCC Resistor, 300K 1/4W 5Y.CC Resistor, 10M 1/4W 5%CC Resistor, 1M 1/4W 5XCC Resistor, 130K l/8W lX Resistor, 86.6K 1/8W 17. Resistor, 130K 1/8W lX Resistor, 20K 1/8W 1% Resistor, 64.9K 18W 1X Resistor, 47.5K 1/8W 1% Resistor, 40.2 1/8W 1% Trim Pot, 100 Ohm 10 turn Trim Pot, 10K 10 turn Resistor, 30.1 1/8W 17.

10-8

741002 741004 741006 741001

540129-5 740001 740002

746019

720236-50 720045-10

760020-75 760022-10 760022-56 760023-10 760024-10 760024-10 760024-10 760024-30 750026-10 760025-10 760213-130 760212-866 760213-130 760212-200 760212-649 760212-475 760212-402 769990-004 769990-006 760212-301


CIRCUIT SYMBOL

MISCELLANEOUS HSl Pl2-Pl3

DESCRIPTION

Heatsink, 1" Finger Connector, 15 Pin Hale

10-9

PPSC PART NUMBER

703013 714011

n,M;f;,., nr.....,,. q,...IIY'rP r.orooration - HuntingtOYt Beach, California 92649 (714) 898-2691


10.2 Theory of Operation

Ref. Fig. 10.4 for a schematic of the 4024 Remote Status Panel.

J11 is the input for the 4024 Remote Status Panel. To the left of J11 you will find a brief description of what each input line is for. J11-A is the power supply input of 45-28 VDG. Q8, GR5, GR6 and Q1 form a regulated power supply of approximately 28 VDG. GR10 forms a ref. 5 VDG for the input comparators.

The 35 VAG OP (J11-B) is a scaled down version of the Input Voltage to the Power Source. This is rectified and fed into AR2-2 and compared to the ref. 5 VDC. When the AC input is high enough AR2-2 allows Q4 and Q5 and the green AC Operation light to turn on. If the AC input is too high, AR 2-1 allows AR 2-3 to oscillate causing the AC Operation light to flash.

The Battery OP (J11-C> input will go to ground when the Batteries are being discharged. This turns on the Battery OP light and starts a 20 second time delay <AR 2-4> before triggering the audio alarm. This time delay is to prevent nuisance trips of the audio alarm during occasional low line inputs.

The Battery Charged (J11-D) input will go to ground when the Batteries are at full charge and all the interconnections are made for the Battery Cabinet to the Power Source. This indicates the system is ready for UPS operation.

The Battery Charging (J11-E> input is a signal proportional to the charge current. This signal is rectified and compared to the ref. 5 VDC by AR 1-1 which goes low, turning on Q9 and the blue Batteries Charging light, when the charge current is high enough.

The Battery Low (J11-F) input goes low when the Batteries are at a low charge condition. This signal turns on Q11 which allows AR 3-3 to oscillate causing the red Battery Low Charge light to blink.

10-10


10.2 Theory of Operation (continued)

The 35 VAC Output, (J11-S, T, U, V>, is a scaled down version of the output voltage from the Power Source. These signals are rectified and fed into AR 1-2, AR 1-3, and AR 1-4 and compared to the ref. 5 VDC. When the AC Output Voltage is high enough on phase A, B, and C or 1 Phase, AR 1-2, AR 1-3 and AR 1-4 allow Q2, Q3 and the Green Output On light to turn on.

Some of the functions described above also pulse the Alarm Set/Reset line low causing the latch AR 3-1 output to go high. This allows Q6, Q7 and the Alarm to turn on. Pushing the Alarm Reset button pulses the Alarm Set/Reset line high causing the Alarm to turn off.

To test the lamps simply push the lamp TEST LAMP/ALARM button. ·All the lamps should light. When the button is released the Alarm should sound, then press Alarm Reset to silence the Alarm.

10-11


10.3 Servicing

* * * * * * * * * * WARNING * * * * * * * * * * * THESE SERVICING INSTRUCTIONS ARE FOR USE BY * * QUALIFIED PERSONNEL ONLY. TO AVOID PERSONAL * * INJURY, DO NOT PERFORM ANY SERVICING UNLESS * * YOU HAVE BEEN QUALIFIED TO DO SO. * * * * * * * * * * * * * * * * * * * * * * * * * * * * *

If the Status Panel is not operating properly, check the input signals on J11 and the associated signals in the circuits as per sections 10.2.

10.4 Calibration

Pacific Power Source Corporation recommends calibration checks at four month intervals. If the unit is out of calibration or has undergone maJor repairs, it should be re-calibrated.

10.4.1 Calibration of the AC LINE OPERATION LAMP

Disconnect the input to T2 (fig. 8.2), the black wires in the Adaptor. Apply 104 VAG, 60 Hz to the input of T2 then adJust R82 (fig. 10.4> so that the green AC OPERATION lamp JUst lights. Next, apply 126 VAG, 60Hz to the input of T2 and adJust R83 (fig. 10.4> so that the green AC Operation lamp JUSt starts to flash. Reconnect T2 as per fig. 8.2.

10.4.2 Calibration of the OUTPUT ON LAMP

Place the Power Source in the 1 Phase mode and adJust the Output Voltage to 105 VAG or the customer specified low line voltage. Take two clip leads and tie the cathode of CR 29 and CR 30 (fig. 10.4) to the +28 VDC power supply then adJust R84 (fig. 10.4>

10.4.3 CALIBRATION VOLTMETER

Place the Power Source in the 1 Phase mode and switch the voltmeter to the 1 Phase position. Connect a DVM to the 1 Phase Output of the Power Source. AdJust R81 so that the voltmeter agrees with the DVM.

10-12

o~~ifi~ DnwP~ ~~~~ r.ornordtion- Huntinoton Beach, California 92649 (714) 898-2691

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UG-18 UPS Support System Operations and Service Manual...ug-18 ups support system operations and service manual manual #114550-e the information contained, proprietary to pacific power