PREVENTIVE MAINTENANCE CHECKLIST FOR

SERIES 7400 UPS

CUSTOMER NAME & ADDRESS
M/S.

SERVICE ENGINEER

DATE :

Unit Identification
Field Service Report Number
Serial Number
KVA
Output Voltage
Battery Type & AH Capacity
No. Of Cells
Battery Breaker Details
DC filter Capacitors
No
1
2
3
4

Spects:
Spects:

Description
Physical Inspection of UPS
UPS Cleaning.
Tightness of all FRC connections
Tightness of power connections Rectifier Section
Inverter Section
DC Filter Section
St. Sw. Section
O/P Filter Section.
Functioning and Direction of
Rotation of Cooling Fans

CSEs Remark :

Make :
Make/Nos :
Module I

Module II

CSEs Remark :

R37 & R38 (100R) are bridging across R15(100R). R39 & R40 (100R) are bridging across
R19(100R).Resistors R41 & R42 (100R) are bridging R23 (100R). R43 & R44 (12R) are
bridging across R27 (12R). R45 & R46 (12R) are bridging across R31 (12R)
UPS Interface Board For 1 Phase ( HVI PCB No. 0126600063 / 0126600064 )
KVA
Resistors to be removed & CV to closed
Selection
For 110 volts
For 230 volts
10
From R37 to R46 CV : Nil
From R37 to R46 & R 19,23.
connect 300 ohms across R15
CV : Nil
15
From R37 to R42 &R45,46
From R37 to R42 , R23,45,46
CV : 2
CV : Nil
25
From R23,41,42,45,46.
From R39 to R42 & R45,46
CV : 2,4,8
CV : 8
40
From R37 to R40 & R43-R46 From R37 to R40 & R43-R46
CV : 2,4,7,8
CV : 2,4,7,8
50
R 39 to 42 & R44
R 39 to 42 & R44
Connect 12 ohms across R27
connect 12 ohms across R27
CV : 2,7,8
CV : 2,7,8
60/65 From R39 to R46 CV : 2,7
From R39 to R46 CV : 2,7
80
From R37 to R40 & R43- 46
From R39 to R46 CV : 7,8
CV : 2,4,7,8
Note : Resistors R37 & R38 (100R) are bridging across R15(100R). R39 & R40 (100R) are
bridging across R19(100R).Resistors R41 & R42 (100R) are bridging R23 (100R). R43 &
R44 (12R) are bridging across R27 (12R). R45 & R46 (12R) are bridging across R31 (12R).

CSEs Remark :

Shunt Links Selections

TTINGS
Rectifier logic board
PCB No.7452004902
No.
1
2
3
4
5
6
7
8
9
10
11

Description
CPS + 12 V & ripple
CPS - 12 V & ripple
CPS + 5 V & ripple
CPS -5 V & ripple
Gain setting by TM4
Boost timer set for hrs.
Change over current by TM3
Battery current limit byTM1
Rectifier current limitTM2
I.P.V. F.B.with osc. V pk-pk
Rectifier SCR Conduction

Test point
TP1-16
TP1-15
TP4-13
TP1-11
TP4-2
S1
R39 upper
R4 upper
R9 upper
TP2-1,2,3
Input R,S,T

Mod. I

Mod.II

Inverter Logic Board

( PCB No.7453001914/2217 for 3 ph & 0126600062 / 70 for 1 ph)
1
2
3
4
5
6
7
8
9
10
11

CPS +12V & ripple

TP1
CPS -12V & ripple
TP3
CPS +5V & ripple
TP4
CPS - 5V & ripple
TP5
Internal Clock Frequency
TP12
Inv. F.B.with osc. V pk-pk
TP22,23,24
150% Current Limit
TP29
Synchro. Signal
TP6
Ref. Sine Waveform V pk-pk TP19,20,21
Verify Base drive FRC continuity trip
PWM Base firing
TP35 to 49

CSEs Remark :

CARD SETTINGS
Parallel Logic Board
( PCB No.7459007023 for 3 ph & 0126600072 for 1 ph.)
No
1
2
3
4
5
6
7
8

Description
CPS + 12 V
CPS - 12 V
CPS + 5 V
CPS - 5 V
Voltage regulator TM4
GVCO frequency TM3
Reverse current detector
Verify cable continuity trip

Test point
D13 anode
D1 anode
D20 anode
D1 cathode
TP1-1
TP1-3
R 50 RHS
Remove CN8

Mod. I

Mod.II

UPS Logic Board

PCB No. 7452006922
1
2
3
4
5
6
7
8
9
10
11
12
13

CPS + 12 volts
CPS - 12 volts
CPS + 5 volts
DC Feed back + 3 volts
DC OV instantaneous by TM4
DC OV steady by TM3
Low Batt Warning TM2-LS13 ON
Low Batt Trip TM1-LS14 &15 ON
Shunt Trip to Battery Breaker
Low Battery Warning reset
Overtemperature Check (2 mins.)
Reset Push Button PS1
Check by oscilloscope
Invert V. Feed Bck TP1: 1,2,3
Byp. V.F.B. TP2 :1,2,3
Output V.F.B. TP3 : 1,2,3
Inverter I. F.B. TP4 : 1,2,3

Fuse F1
Fuse F2
D8 Anode
TP5 - 2
R62
R60 & 61
R58 & 59
R56 & 57
LS15 ON
LS13 OFF
LS7
PS1
V Pk-Pk - Module I
*

Sign * indicates Not Applicable For Single Phase UPS

CSEs Remark :

V Pk-Pk - Module II

CARD SETTINGS
Static Switch Logic Board
( PCB No. 7454006821 for 3 ph & 0126600060 for 1 ph )
No
1
2
3
4
5
6
7
8
9
10
11
12
13

Description
St. Sw. CPS +12 V
St. Sw. CPS -12V
St. Sw. CPS +5 V
St. Sw. CPS -5 V
St. Sw. CPS -7 V
System Nominal TM1
101% Overload
UPS Output Voltage
UPS Output Voltage
Mains Under Voltage
Mains Over Voltage
Max. Inv. Voltage-LS5
Min. Inv. Voltage-LS4

Test Pts.
TP5-1
TP5-5
TP6-1
TP6-5
TP7-1
TP1-3
TP4-3
I2 Pole 1
I2 Pole 2
I2 Pole3
I2 Pole 4
I2 Pole 5
I2 Pole 6

Mod. I

Mod.II

Phase Locking Test

1
2
3
4
5

Window adjustment on inverter

logic board TM1
Bypass frequency window on
parallel logic board TM2
Inverter/ bypass phase lock TM2 on
inverter logic board
Ph.Lock MonitorTM3 on SSLB
Sync OK LS6,TM2 on SSLB
(ILB-TM2 first)

TP 9 &
TP7
TP2-1 &
TP2-3
R Byp. &
R Inverter
TP2-3 vs
TP2-2
TP3-1

Note : Pl. Ensure that ripple voltage in all +12, -12V supplies should be < 100mv. And
ILB power supply (+12V, -12V ) should be more than that of RLB by 0.3 V
(i.e. if RLB is 12.25, ILB should be 12.55V. )

CSEs Remark :

POWER SETTINGS

DC bus Voltage Settings

No.
1
2
3
4
5
6
7
8
9
10
11
12

Description
DC Ripple without Battery
Low Batt. Trip ( TM1-ULB )
Low Batt.Warn. (TM2-ULB )
DC O/V Steady ( TM3-ULB)
DC O/V Inst. (TM4 -ULB)
Float Voltage (TM7- RLB)
Boost Voltage ( TM6 RLB)
Bat. I Limit ( TM1 - RLB)
Ripple I. with Batt charging
Ripple I. with Batt. On float
V. balance acc. DC Filter Caps.
Change over I (TM3 RLB )

Module I
V Pk-Pk
LS14,15 ON at
Vdc
LS 13 ON at
Vdc
LS 12 ON at
Vdc
LS 12 ON at
Vdc
LS7 ON
Vdc
LS6 ON
Vdc
LS1 ON
Amp.
Amp.
Amp.

Module II
V Pk- Pk
LS14,15 ON at
Vdc
LS 13 ON at
Vdc
LS 12 ON at
Vdc
LS 12 ON at
Vdc
LS7 ON
Vdc
LS6 ON
Vdc
LS1 ON
Amp.
Amp.
Amp.

LS3 ON

LS3 ON

Amp.

Amp.

AC Bus Voltage Settings

1
2
3
4
5
6
7

Inv. U/V. LS4 SSLB

Inv. O/V LS3 SSLB
Volts - L-L( TM9 -ILB )
Volts - L-N (TM 5,6,7- ILB)
V drop a/c Inv St.Sw.SCR
V Drop a/c Byp. St.Sw. SCR
Trap Filter Current

*
*
*
*
*

*
*
*
*
*

*
*
*
*
*

*
*
*
*
*

Voltage, Current & Frequency Measurements On Actual Load.

1
2
3
4
5
6

Input Voltage
Input Current
Output Voltage
Output Currents
Output Frequency
DC Voltage w/o Battery

*
*

*
*
Hz
V

Sign * indicates Not Applicable For Single Phase UPS

CSEs Remark :

*
*

*
*
Hz
V

Transfer & Redundancy Check

Test
1
2
3
4
5
6

Description
Module I to Module II
Module II to Module I
Module I to Bypass Transfer
Module II to Bypass Transfer
Bypass to Module Transfer
Transfer to Main. Byp. Without Break

Remarks

Verification of LCD Calibrations,Mimic & Alarms

Checks
1

Description
Membrane Sw Vo

Module I
Vrs/Vo Vst*
Vtr*

Module II
Vrs/Vo Vst*
Vtr*

Membrane Sw Io

Ir/Io

Ir/Io

3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
20
21

Membrane Sw B
Membrane Sw f
Membrane Sw (*) (Reset )
Verification of Mimic
Emergency Stop
Bypass Off Or Failed
Input CB Open
Output CB Open
Battery CB Open
Bypass CB Open
Load on Bypass
Rectifier Off or Failed
Inverter Off or Failed
Over Temperature
UPS on Maintenance Byp.
Inverter Unsynchronised
Battery Earth Fault
Normal Operation

Vb
Hz

Is*

It*

In*

Ib

Vb
Hz

Is*

It*
Ib

Control Function Operations

Sr. No.
1
2

Control Functions
Inverter On-Off Push Button
Emergency Push Button

ModuleI

Module II

In*

Sign * indicates Not Applicable For Single Phase UPS

CSEs Remark :