invensys fault finding

Technical Manual No. 1029230A

INVENSYS

ENERGY SYSTEMS

TELECOMMUNICATIONS POWER SUPPLY SYSTEM

WS2100-101 & 102

Fault Finding Handbook

1HEALTH AND SAFETY31.1BATTERY HANDLING PROCEDURE31.2SAFETY INSTRUCTIONS - BEFORE LIFTING BATTERIES31.3BEFORE INSERTING/CLOSING BATTERY PROTECTION DEVICES32INTRODUCTION32.1General Description32.2Approvals and Standards33FAULT FINDING AND REPLACEMENT PROCEDURES33.1Safety Precautions33.2Fault Finding and Replacement Procedures33.3System Faults33.4Power-i Fault Finding and Repair Procedures33.5SMR Faults34REPLACEMENT OF PARTS IN THE RACK34.1Replacing the Power-i Controller (LC2-00)34.2Replacing a Faulty SMR From the Rack34.3DC Loads (Distribution) MCBs34.4Rectifier AC Supply 10A MCBs34.5Rectifier DC Output 40A MCBs34.6Battery 100A MCBs34.7Low Voltage Disconnect Contactor3

1 HEALTH AND SAFETY

WARNING:This apparatus must be installed by a professional installer.

WARNING:IT is MaNDATORY TO FIX THIS EQUIPMENT TO THE BUILDING.

WARNING:When installed, a protective earth must be provided for safety, in accordance with BS6701:1994: (WHICH REFERS TO THE IEE WIRING REGULATIONS BS7671). THE PROTECTIVE EARTH CONNECTION MUST BE HARD WIRED.

WARNING:THE CABINET OPERATES FROM A MAINS VOLTAGE POWER SUPPLY. ISOLATE FROM SUPPLY BEFORE REMOVING COVERS FOR MAINTENANCE ACCESSES.

WARNING:A Three pole disconnect device MUST BE PROVIDED IN THE BUILDING INSTALLATION. ensure mains supply NEUTRAL conductor is identIFIED PRIOR TO CONNECTION

WARNING:high LEAKAGE CURRENT. earth connection essential before connecting supply.

WARNING:WHILE WORKING ON THIS EQUIPMENT, UNSAFE VOLTAGE AND ENERGY SOURCES MAY BE EXPOSED, AND ONLY TRAINED, APPROVED INSTALLATION AND MAINTENANCE ENGINEERS SHOULD INSTALL, TEST AND REPAIR THESE UNITS. NO PERSON OTHER THAN THOSE TRAINED TO WORK ON LIVE EQUIPMENT MUST BE PRESENT IN THE WORKING AREA DURING INSTALLATION OR MAINTENANCE UNLESS UNDER DIRECT SUPERVISION OF A COMPETENT PERSON.

WARNING:TAKE NOTE OF ALL WARNING LABELS.

WARNING:TAKE NOTE OF the installation instructions supplied separately with the rectifier units.

CAUTION:ENSURE THAT THE SUPPLY VOLTAGE INDICATED ON THE CABINET IDENTIFICATION/DATA PLATE IS CORRECT FOR THIS INSTALLATION.

CAUTION:ALL STAGES WHICH INVOLVE HANDLING OF ASSEMBLIES FITTED WITH ANY SEMICONDUCTOR COMPONENTS SHOULD CONTAIN PROTECTION AGAINST THE POSSIBILITY OF STATIC INDUCED DAMAGE. THE PRINTED CIRCUIT CARDS SHOULD ONLY BE REMOVED FROM THEIR PROTECTIVE CARRIERS IN STATIC-SAFE HANDLING AREAS BY PERSONS WEARING STATIC PROTECTION SUCH AS WRIST STRAPS.

1.1 BATTERY HANDLING PROCEDURE

Batteries present two main hazards:

Electrical energy - SEE BELOW

Weight - SEE "SAFETY INSTRUCTIONS - BEFORE LIFTING BATTERIES" ON THE FOLLOWING PAGES.

BEFORE REMOVING COVERS OR MAKING ELECTRICAL CONNECTIONS:

1REMOVE WATCHES, JEWELLERY AND OTHER METAL OBJECTS

2REMOVE OR COVER ALL RINGS

3READ AND FOLLOW - "SAFETY INSTRUCTIONS - BEFORE LIFTING BATTERIES", BEFORE INSERTING/CLOSING BATTERY PROTECTION DEVICES, AND "BEFORE CONNECTING RECTIFIERS TO A SYSTEM WITH BATTERIES AND/OR RECTIFIERS ALREADY CONNECTED" ON THE FOLLOWING PAGES

4USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS. SHAFTS OF SCREWDRIVERS, ETC., SHOULD BE INSULATED.

5USE ONLY ISOLATED INSTRUMENTS AND SOLDERING IRONS

DANGER OF DEATH OR SERIOUS INJURY EXISTS IF THESE PRECAUTIONS ARE NOT FOLLOWED.

BATTERY DISPOSAL

WARNING:CONTACT THE BATTERY MANUFACTURER FOR INSTRUCTIONS ON THE DISPOSAL OF BATTERIES. THE MANUFACTURERS ADDRESS IS LABELLED ON EACH BATTERY.

1.2 SAFETY INSTRUCTIONS - BEFORE LIFTING BATTERIESThe Manual Handling of Loads Regulations, 1993, require that all persons are familiar with the Regulations, that they take care to minimise risk of injury to themselves and others, that they are properly trained, and that the correct equipment is used.

1Before lifting batteries, stand as close as possible to the battery.

2Keep the back straight and as vertical as possible.

3Use the leg muscles to lift in preference to the arms.

4Minimise twisting, stretching and stooping.

5 Batteries should be withdrawn/inserted evenly, without jerking, maintaining the load level and balanced, with adequate support.

The limits on lifting imposed by the Regulations are:

NOTE: The diagram shows recommended limits for men. The weights should be reduced by 30% for the average woman. If twisting is involved, the weights should be reduced by 20%. For further details, refer to the Manual Handling of Loads Regulations, 1993.

1.3 BEFORE INSERTING/CLOSING BATTERY PROTECTION DEVICES(PROTECTION DEVICES MAY BE FUSES, LINKS, MCBs OR MCCBs)

1 Read and follow the safety instructions

2Read and follow the user instructions

3If a fault is found, do not proceed further without clearing the fault

4Check polarity of battery connections

5Check sequence of battery connections

6Measure the voltage between the common return and each battery protection device

7Check that the battery voltages are correct according to the user instructions

8Check that the battery polarities are correct according to the user instructions

9Check that the battery voltages differ from each other by no more than 2V

10With load isolated, connect Rectifiers and switch on, following the user instructions. See also Note 1 below.

11Check the system voltage and polarity against the value given in the user instructions

12Check that the voltage measured across the first battery protection device is less than 6V.

13If the voltage measured in 11 above is satisfactory, insert/close the protection device

14Repeat (12) and (13) for each battery in turn

Note 1:Where parallel systems (e.g. Master/slave) are used, the system must be powered down and the above procedure followed as though the whole system were one cabinet. Failure to power down the system would amount to `live working' as defined by the Electricity at Work Act, 1989.BEFORE CONNECTING RECTIFIERS TO A SYSTEM WITH BATTERIES AND/OR RECTIFIERS ALREADY CONNECTED:1 Check that AC input circuit breaker for the appropriate rectifier is off/open.

2Insert the rectifier into its slot. Do not use excessive force. Connect the Rectifier input and output connectors. Make sure the DC connector clip is secure.

3Tighten captive screw at base of rectifier front panel.

4Close the AC circuit breaker.

2 INTRODUCTION

The purpose of this document is to provide the information necessary to deal with alarms generated by the controller and rectify minor faults on the Invensys Energy Systems cabinet types WS2100-101 & WS2100-102 systems.

Installation, servicing and repairs to these units must only be performed by authorised and qualified engineering staff; and strictly in accordance with the information provided in this manual.

Invensys Energy Systems cannot accept responsibility for safety, reliability and performance if modifications or repairs are carried out by unauthorised personnel. Invensys Energy Systems specified replacement parts must be used. Replacement parts must be of the same type and rating to ensure continued protection against risk of fire. This applies particularly to fuses and circuit breakers.

Note: as with all Invensys Energy Systems products, this equipment is subject to continuous development and improvement and consequently may incorporate minor changes from the information in this manual.

2.1 General Description

The Power Supply System detailed in this manual consists of up to seven rectifier units connected in parallel to provide a 48V DC supply. A microprocessor based management system is installed in the system for control and alarm monitoring purposes.

Protection is provided by means of MCBs as follows:

(a) In the AC supply input to each rectifier rated at 10A.

(b) In the positive (WS2100-101) or negative (WS2100-102) supply of the rectifier DC output rated at 40A.

(c) In the positive (WS2100-101) or negative (WS2100-102) negative supply to each battery string rated at 100A.

(d) In the positive (WS2100-101) or negative (WS2100-102) negative supply to each load connection (various ratings).

Protection is provided by means of fuses as follows:

(a) In the positive and negative supply to the Low Volt Disconnect Contactor coil circuit located on the LA-IB201 Interface PCB on the shelf below the rectifiers, labeled 'F68' and F69 respectively, both rated at 2A (Littlefuse type 215002).(b) In the positive and negative supply to the PMS - located on the LA-IB201 Interface PCB on the shelf below the rectifiers, labeled 'F53' and F46 respectively, both rated at 2A (Littlefuse type 215002).(c) In the positive and negative sense to the PMS - located on the LA-IB201 Interface PCB on the shelf below the rectifiers, labeled 'F63' and F49 respectively, both rated at 2A (Littlefuse type 215002).

(d) In the +15V and 15V connection to external current measuring devices located on the LA-IB201 Interface PCB on the shelf below the rectifiers, labeled 'F4' and F5 respectively, both rated at 500mA (Bussman type S500 (SPN31)).

(e) In the +27V (WS2100-101) or -48V (WS2100-102) supply to the MCB Trip PCBs located behind the top distribution panel next to the rectifier DC output circuit breakers, labeled FS1 and rated at 2A (Littlefuse type 314002).

(f) In the -48V (WS2100-102 only) supply to the Non Priority Disconnect Contactor located behind the top distribution panel next to the rectifier AC Input circuit breakers labeled FS2 and rated at 2A (Littlefuse type 314002).

(g) In each battery monitoring sense lead connected to each battery cell rated at 500mA (Littlefuse type 251.500 or Bel MQ 500).

Figure 1 WS2100-101/102 Cabinet Assembly

2.2 Approvals and Standards

The Invensys Power Supply System cabinet type WS2100-102 has invoked the LVD and EMC directives 73/23/EEC and 89/336/EEC respectively, by invoking EN60950, EN50081-1 and EN50082-2 as amended by the "CE Marking Directive" 96/68/EEC.

This Telecommunications Power Supply System complies with or exceeds the following Standards:

EN60950 Safety of information technology equipment, including electrical business equipment. Low Voltage Directive

EN50081-1 Electromagnetic Compatibility Generic Emission Standard (Commercial Environment).

EN50082-2 Generic Immunity Standard (Industrial Environment).

This Telecommunications Power Supply System output is classed as SELV at a hazardous energy level.

3 FAULT FINDING AND REPLACEMENT PROCEDURES

3.1 Safety Precautions

BEFORE REMOVING COVERS OR MAKING ELECTRICAL CONNECTIONS:

1REMOVE WATCHES, JEWELLERY AND OTHER METAL OBJECTS

2REMOVE OR COVER ALL RINGS

3READ AND FOLLOW - "SAFETY INSTRUCTIONS - BEFORE LIFTING BATTERIES", BEFORE INSERTING/CLOSING BATTERY PROTECTION DEVICES, AND "BEFORE CONNECTING RECTIFIERS TO A SYSTEM WITH BATTERIES AND/OR RECTIFIERS ALREADY CONNECTED" IN SECTION 1 HEALTH AND SAFETY.4USE ONLY SINGLE-ENDED, FULLY INSULATED TOOLS. SHAFTS OF SCREWDRIVERS, ETC., SHOULD BE INSULATED.

5USE ONLY ISOLATED INSTRUMENTS AND SOLDERING IRONS

6REPLACEMENT PARTS MUST BE OF THE SAME TYPE AND RATING TO ENSURE CONTINUED PROTECTION AGAINST RISK OF FIRE.

DANGER OF DEATH OR SERIOUS INJURY EXISTS IF THESE PRECAUTIONS ARE NOT FOLLOWED.

REFER TO SECTION 1 HEALTH AND SAFETY BEFORE PROCEEDING.3.2 Fault Finding and Replacement Procedures

This section describes in some detail the cause of alarms that may occur from time to time and the procedures that should be followed to clear the alarms and more importantly, redress the problem or cause of the alarm.

It is assumed here that the most that a field maintenance person will do is change a complete assembly. It is normally impractical to attempt to repair a particular PCB without test equipment, which is normally only available at an Invensys Service Department.

The recommendation is that the supplied spare complete sub-assemblies are kept on site. This includes a complete Switch Mode Rectifier (SMR), a Power-i unit, and a LA-IB201 PCB.

The following tables outline suggested procedures to be followed if it is assumed that no PCB swapping will be attempted. It is assumed instead that only front panel adjustments and unit replacement will be performed.

3.3 System Faults

Alarm ConditionPossible CauseAction Suggested

System Voltage High

Float voltage setting too highCheck and adjust float voltage setting

Equalise / boost charge in progressNo Action required

Faulty SMRReplace SMR

Faulty Power iReplace Power I

System Voltage LowFloat voltage setting too lowCheck and adjust float voltage setting

AC failed and system running from batteriesRestore AC Input


Faulty Power iReplace Power I

Battery Temperature HighAmbient temperature around batteries is too highReduce air temperature

Sensor is in contact with a localised source of heatCheck and reposition sensor if required

Temperature Sensor FailSensor has become disconnectedCheck and reconnect sensor (LA-IB201 connector X17)

Faulty SensorReplace Sensor

Batt Switch Open (Battery MCB)Load current exceeds capacity of battery breakers when AC failsDecrease load requirements.

Faulty Battery StringReplace Battery String

Fault in wiring to breaker monitor pcbCheck connection of battery MCB monitor pcb (LA-IB201 X23)

Faulty Battery MCBReplace Battery MCB

Accidental mechanical opening of MCBReset MCB


CB Trip (Load / Rectifier MCB)Load current exceeds capacity of breakerDecrease load requirements.

Faulty MCBReplace MCB

Fault in wiring to breaker monitor pcbCheck connection of MCB monitor pcb (LA-IB201 X22)


Accidental mechanical opening of MCBReset MCB

System voltage reduced to below the preset level after a mains failNo Action required

LVDS Open (LV Contactor)

Low Voltage Differential Signaling.

A low noise, low power, low amplitude method for high-speed (gigabits per second) data transmission over copper wire. Fault in wiring to LVD control pcbCheck connection of LVD Aux. contact (LA-IB201 X64) and LVD coil (LA-IB201 X65)

Faulty ContactorReplace Contactor

Battery Cell Voltage HighFloat voltage set too highCheck and adjust float voltage setting

Faulty battery cellCheck and replace if necessary

Fault in wiring to Battery Monitor boardCheck wiring from the battery strings to LA-IB204 and from LA-IB204 to LA-IC204

Battery Cell Voltage Low

Float voltage set too lowCheck and adjust float voltage setting



Battery Cell Deviation High

Deviation threshold set too lowCheck and adjust setting



Battery Cell Deviation Low

Deviation threshold set too lowCheck and adjust setting



Batt Discharge Test Fail



EEPROM FailFaulty Power iReplace Power I

Non Priority Disconnect ContactorSystem voltage reduced to below the preset level after a mains failNo Action required

Fault in wiring to contactor control pcbCheck connection of contactor, LA-IB201 X2 to pins 26-29 of 37way D connector

Faulty ContactorReplace Contactor

Note

1. A faulty Power I can give rise to any of the above alarms.

2. A fault in the cabling from the Power i to the LA-IB201 pcb or LA-IC204 pcb can give rise to any of the above alarms.

3.4 Power-i Fault Finding and Repair Procedures

In addition to performing a supervisory function by monitoring output voltage and current and the various system alarms, the Power-i also performs a voltage control function in order to achieve battery charging current control and active current sharing.

To control current to the lowest battery voltage, the Power-i has the ability to suppress the SMR output voltage to a value lower than the minimum battery voltage.

It therefore follows that it is possible for a Power-i fault to occur which can suppress the SMR voltage to that low level and thus cause a battery discharge, despite the precautions that have been taken to ensure that this does not happen.In such a situation disconnecting the 4-way cable, which connects the SMRs to the Power-i, will remove the voltage suppressing PWM control signal and thus avoid the batteries discharging. Without the Power-i connected, the SMRs will revert to their pre-set Float voltage and passive current sharing.

The Power-i can then be changed to resolve the problem.

There are virtually no electronic components on the LA-IB201 except for the Remote alarm and control relays, and some fuse links, but there are many connectors. It is worth checking for poor connections when a Power-i system problem is being investigated.

3.5 SMR Faults


SMR OvervoltageThreshold level set incorrectlyCheck and adjust threshold level


SMR AC Input FailAC connector not fitted correctlyCheck & reposition AC input connector

AC Input breaker failedReset breaker. Note a failed SMR may cause the breaker to open hence it may not be possible to reset the breaker.


SMR DC Output FailFaulty SMRReplace SMR

SMR Current LimitCurrent share not adjusting SMR correctlyCheck & reposition output connector

Check current share in Power I

Faulty Power I (replace)

Load & Battery current exceeds current capacity of system.Decrease load & / or battery requirements.


As a general rule any SMR, which has a different set of active alarms, compared to the other SMRs in the rack probably requires attention.

One exception is when one SMR gives the Current Limit alarm message. This may be a temporary condition arising during battery recharging.

One alarm, which will always warrant changing the associated unit, is HVSD.

Note

1. An alarm on more than one rectifier will give an Urgent Alarm.

2. A fault in the cabling from the SMRs to the LA-IC204 pcb or from LA-IC204 to the Power I can give rise to any of the above alarms.

4 REPLACEMENT OF PARTS IN THE RACK

4.1 Replacing the Power-i Controller (LC2-00)

To replace a Power-i the following procedure should be followed:

1. Remove the screws holding the front escutcheon plate to the rack and remove it.

2. Gently pull the LC2-00 unit forward, and hold it in a horizontal position until the back is just clear of the rack.

3. Unplug the 34-way cable first (removes all power) and then the other cables. The SMRs will now be working in passive current sharing mode and current sharing may not be as good as previously. The output voltage will also rise to the value pre-set in the SMRs.

4. Bring the replacement LC2-00 to its position in the rack and plug in all the cables making sure that the 34-way cable is connected last;

5. Gently push unit into rack and secure the escutcheon with screws supplied.6. Check operating parameters.4.2 Replacing a Faulty SMR From the Rack

4.2.1 Removing an SMR

1. Switch off AC input and DC output circuit breakers.

2. Disconnect the Rectifier input and output connectors.

3. Loosen the Rectifier front panel Dzus fasteners.

4. Withdraw the Rectifier.

4.2.2 Installing an SMR

1. Tighten the Rectifier front panel Dzus fasteners.

2. Connect the Rectifier input and output connectors. Make sure the DC connector clip is secure. Position the Rectifier in its bay.

3. Switch on AC input and DC output circuit breakers.

4. Check that the status LEDs are indicating the same as for the other Rectifiers.

4.3 DC Loads (Distribution) MCBs

4.3.1 Removal.

1. Switch off the relevant circuit breaker.

2. Remove the four fixing screws from the distribution circuit breaker covering panel.

3. Release the top cable fixing screw. Withdraw the load cable and sense wire and tape the ends.

4. Release the circuit breaker bottom busbar fixing screw.

5. Withdraw clip securing the circuit breaker to the DIN rail and lift off the circuit breaker.

4.3.2 Re-fitting.

1. Check that the replacement breaker is switched off before fitting it.

2. Fit the circuit breaker to the DIN rail and secure with its clip.

3. Tighten the circuit breaker bottom busbar fixing screw to a torque setting of 2.2 Nm.

4. Remove the tape from the load cable and sense wire and position it in the top receptacle on the breaker. Tighten the top cable fixing screw to a torque setting of 2.2 Nm.

5. Fit the circuit breaker covering panel and secure with the four fixing screws.

4.4 Rectifier AC Supply 10A MCBs

4.4.1 Removal.

1. Isolate the dual AC supplies external to the cabinet.

2. This unit can be removed with the system remaining on DC standby power. Switch off the relevant circuit breaker.

3. Release the four fixing screws from the circuit breaker covering panel.

4. Release the top cable/linking bar fixing screw. Withdraw the cable and tape the end.

5. Release the bottom cable fixing screw. Carefully withdraw the cable without touching anything and tape the end.


4.4.2 Re-fitting.

1. Check that the AC supply external to the cabinet is still isolated. Check that the replacement breaker is switched off before fitting it.

2. Fit the circuit breaker to the DIN rail and secure with its clip.

3. Remove the tape from the bottom end cable and position it in its receptacle on the breaker. Tighten the bottom cable fixing screw to a torque setting of 2.2 Nm.

4. Remove the tape from the top end cable and position it in its receptacle on the breaker. Tighten the top cable fixing screw to a torque setting of 2.2 Nm.


4.5 Rectifier DC Output 40A MCBs

4.5.1 Removal.

THE SYSTEM MUST BE SHUT DOWN FOR THIS PROCEDURE.

1. Switch off the relevant circuit breaker.

2. Switch off the Battery circuit breakers.

3. Switch off the Rectifier AC Supply breakers.


5. Release the top busbar fixing screw.



4.5.2 Re-fitting.


2. Fit the circuit breaker to the DIN rail ensuring that the busbar 'finger' enters the top breaker receptacle and secure with its clip.

3. Tighten the top busbar fixing screw to a torque setting of 2.2 Nm.



4.6 Battery 100A MCBs

4.6.1 Removal.


2. Release the top busbar fixing screw.



4.6.2 Re-fitting.


2. Fit the circuit breaker to the DIN rail ensuring that the busbar 'finger' enters the top breaker receptacle and secure with its clip.

3. Tighten the top busbar fixing screw to a torque setting of 2.2 Nm.



6. Replace plastic cover, tighten fixing screws.

4.7 Low Voltage Disconnect Contactor

4.7.1 Removal.

THE SYSTEM MUST BE SHUT DOWN FOR THIS PROCEDURE

1. Switch off the Battery circuit breakers.

2. Switch off the Rectifier AC Input and DC Output breakers.

3. Release the four fixing screws from the distribution covering panel and remove.

4. Remove the two M8 nuts and washers from the contactor.

5. Note the polarity of the wires across the fastons, so that the correct polarity can be maintained when re-connecting. Release the cables for the contactor coil and auxiliary switch one at a time and tape them.

6. Remove the two contactor mounting bracket to panel fixing screws.

7. Move contactor down and then pull away from the panel.

4.7.2 Re-fitting.

1. Fit and secure the contactor with its fixing screws.

2. Replace the two M8 nuts and washers and tighten.

3. Remove the tape and refit the fastons, noting the colours of the wires.

4. Fit the distribution covering panel and secure with the four fixing screws.

5. Switch on the Rectifier AC input and DC output breakers.

6. Switch on the Battery circuit breakers.

EMBED Word.Picture.8

EMBED Word.Document.8 \s

EMBED AutoCAD.Drawing.15

Rectifier AC Input Circuit Breakers

Battery String Circuit Breakers

LR 24-50-03 or LR 48-28-04 Rectifier

Battery Compartment

DC Load Output Circuit Breakers

Rectifier DC Output Circuit Breakers

Dummy Rectifier

Power Management System - PMS

Author: Peter AlmondPage 12Date: 2/22/2013

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