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UNINTERRUPIBLE POWER SYSTEMS
SERVICE MANUAL
PCM Vanguard
5/6KVA
P/N : XXX-XXXX-XXX
2004/08/31
PCM Vanguard
5/6KVA SERVICE MANUAL
I. INTRODUCTION
II. PRINCIPLE OF OPERATION
III. POWER STAGE (PSDR)
i. DC POWER SUPPLY SUB-SYSTEM :
ii. INVERTER SUB-SYSTEM :
iii. OUTPUT SUB-SYSTEM :
iv. UNIT POWER FACTOR CORRECTION SUB-SYSTEM:
IV. MAIN CONTROL PCB ASSEMBLIES (CNTL)
i. REGULATION & CONTROL SUB-SYSTEM :
ii. PROTECTION SUB-SYSTEM :
iii. SIGNALING SUB-SYSTEM :
V. FRONT PANEL :
i. switch button :
ii. LED display :
iii. LCD display :
VI. ALIGNMENTS
VII. TROUBLE SHOOTING
1. OVERVIEW:
2. P.F. CORRECTION:
3. DC/AC INVERTER:
4. DC POWER SUPPLY:
5. AC/DC CHARGER :
VI. APPENDIX I : SCHEMATICS
Figure 1a：Wiring diagram for 5/6KVA
Figure 1b：Wiring diagram for 5/6KVA with output ISO transformer
Figure 2a：Sub-assembly location for 5/6KVA
Figure 2b：Sub-assembly location for 5/6KVA with output ISO
transformer
Figure 3：block diagram for 5/6K
Figure 4：DC power supply circuit for 5/6K
Figure 5：Inverter circuit for 5/6K
Figure 6：Unit power factor correction circuit for 5/6K
Figure 7：Charger circuit for 5/6K
VII. APPENDIX II : COMMUNICATION
i. RS232
ii. AS400 (option)
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PCM Vanguard
5/6KVA SERVICE MANUAL
WARNING
(For qualified service personnel only)
1. DO NOT perform any internal service or adjustment of this product unless another
person is capable of rendering first aid and resuscitation is present.
2. Dangerous voltage exists at several points in this product. To avoid personal injury, don't
touch any exposed connections or components while power is on.
3. Turn off the UPS and disconnect input power cord and two battery cables before
removing outside protective cover.
4. AC voltage is always present if the input AC power is still available.
5. Dangerous electric charge may be stroed in DC capacitors and associated circuit, after
turning off the UPS and disconnect input power cord. Please test before touching.
6. Verify input source (voltage and frequency) before service.
7. For the air flow smoothly, please cover the cover to test after you repaired.
CAUTION
1. After opening the cover, please always check the tightness of all wires, connectors, and
screws first. Then check if there is any decolored components inside.
2. DO NOT make internal batteries short-circuited.
3. If find that the battery wire in the UPS is disconnected, be sure that the battery cabinet is
disconnected and the input power cord is unplugged before re-connect the battery wire.
4. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.
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PCM Vanguard
I.
5/6KVA SERVICE MANUAL
INTRODUCTION
For all series of Vanguard UPS, they are strictly tested and carefully designed. We
always do our best to make our products more reliable and safer, this is also the goal of our
company. However, due to the lifetime of electrical components and some unpredictable
reasons, there will be unavoidable failures of this UPS. If this situation occurs, service of
qualified person is needed. This service manual will guide the technicians to repair and
adjust a problematic UPS. If the UPS still does not work properly, please contact with us
and we will be glad to solve any problems you met.
This UPS is very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.
This service manual consists of 4 major parts:
1. Introduction.
2. Principle of operation：It describes the functions and principles of each part.
3. Alignments：It describes the locations and methods needed to adjust this UPS.
4. Trouble shooting：This part describes the possible failure conditions and procedures
to repair it.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and
safe operation.
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PCM Vanguard
5/6KVA SERVICE MANUAL
II. PRINCIPLE OF OPERATION
This 5/6VA high input power factor UPS system contains some PCB assemblies. They are
including :
5/6KVA
1.Panel
contains LCD and LED display, UPS configuration and meter
2.PSDR
contains major parts of (1) DC power supply, (2) inverter (3) output and (4)
unit power factor correction circuits
3.Charger
contains major parts of charger circuits, ABM circuits and Battery test circuit
4.CNTL
contains major parts of protection, signaling circuits, regulation and control
circuits of inverter
The simplified schematics in figure 1 shows how the major circuits are connected and
illustrates the overall system functions. The locations of these assemblies in this machine
are shown in figure 2.
The block diagram in figure 3, shows the UPS at normal operation from left to right.
When a protection circuit is triggered or a fault condition occurs, the output supply is
transferred immediately from inverter to AC mains by a bypass relay. The operation
principle will be explained in later section.
Basically, these Vanguard UPS system utilizes high frequency PWM techniques to
achieve high efficient performance. This UPS can deliver a clean, regulated sine-wave
output at any load under full load. The sub-systems are described as below:
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5/6KVA SERVICE MANUAL
III. POWER STAGE (PSDR)
The power stage consists of unit power factor correction, DC power supply and inverter
circuits.
i. DC POWER SUPPLY SUB-SYSTEM:
The input of the DC power supply is connected to the battery bus, i.e., the output of the
charger. The output of DC power supplies provid +24/+12/+5Vdc for the bias supply of
IC's working voltage and the fan(s) voltage and other requirement. The DC power supply
works only when the 12 Vdc regulator supplies Vcc to its control IC. To have proper
operation of 12 Vdc regulator, its input power is controlled by the switch as indicated in
figure 4.
ii.INVERTER SUB-SYSTEM :
The UPS transfers ＋,－ DC bus voltages to the AC output voltage through an inverter
of half bridge configuration at normal operation. The schematic diagram of inverter is
shown in figure 5.
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching
signals from PWM generation circuit through a pair of photo-couplers to trigger the upper
IGBT and the lower IGBT alternately. The output of IGBT's is filtered by an LC circuit to
reduce the o/p voltage harmonics distortion.
iii.OUTPUT SUB-SYSTEM :
The bypass relay receives signal from control circuit to switch the output of the UPS
from bypass to inverter, and vice versa. The output noise filter circuit blocks EMI noise to
the loads.
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PCM Vanguard
5/6KVA SERVICE MANUAL
iv.UNIT POWER FACTOR CORRECTION SUB-SYSTEM :
The purpose of power factor correction (P.F.C.) circuit is to make the input current and
voltage in phase and therefore achieve a high input power factor. The schematic is
indicated in figure 6.
When the input AC power cord is plugged in and switch on, the AC power goes
through noise filter to the charger and to the line detector, the P.F.C. circuit is enabled and
the DC buses are regulated at ＋/－365Vdc.
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PCM Vanguard
5/6KVA SERVICE MANUAL
IV. MAIN CONTROL PCB ASSEMBLIES (CNTL)
These assemblies are the control center of UPS. It is composed of three major circuits
as following.
(1) Regulation & control
(2) Protection
(3) Signaling
i.REGULATION & CONTROL SUB-SYSTEM :
This portion can be seen as brain of the UPS. It provides the control pulses to the
switching elements which deliver power to the output. The sub-system also regulates the
output to ensure that the UPS is delivering constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a
reference signal from sine wave generator. The difference of these two signals (error
signal) alter the pulse widths of PWM signals which control the duty cycles of switching
elements to regulate the output voltage within specification.
In order to avoid un-wanted surge current at the transfer of bypass relay, the bypass
signal activates the tracking circuit. It matches the inverter voltage with the line voltage by
having the amplitude of the reference signal following the variation of line voltage.
When the mains in the acceptable range is applied and the switch is turned on, the UPS
operates at battery mode to charge the buses voltage and inverter on. As soon as the phase
lock and amplitude are completed. If the battery is weak, the UPS transfers to bypass mode
about 3 seconds when switch turns on, then transfer to inverter mode and as soon as the
phase lock and amplitude are completed.
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5/6KVA SERVICE MANUAL
ii.PROTECTION SUB-SYSTEM :
The UPS provides the following protection circuits :
1. Overload protection
The load detector senses the load current. i.e. the inverter current, and sends the
signal by two paths. In battery mode, the UPS will go to failure mode if overload
condition happened. The panel will indicate the fault condition.
A. The UPS collects the continuous overload signals through CPU switches the
bypass relay. If the output load is higher than 110% and lower than 125% of
rated load(VA ,or Wattage) the UPS keeps running on inverter mode for 1
minute. If the output load is higher than 125% and lower than 150% of rated
load, the UPS transfers to bypass after 10 seconds. If the output load is higher
than 150%, the UPS transfers to bypass at once.
B. When output loads sink a high surge current , a high inverter current is
detected and the inverter switches, i.e. the IGBT's, are turned off pulse by pulse
to protect themselves from thermal runaway. The bypass relay stays at inverter
output position unless a continuous overload is detected or an abnormal
inverter operation occurs
.
2. Battery over or under shut down
Upon the battery voltage declines to battery-under level, a signal is generated to cut
off the power supply of the whole system, The buzzer becomes silent and all the
LED's extinguish. When the utility is coming, the UPS will start up automatically.In
case of the battery voltage(chargeing voltage) exceeds the acceptable high-limit
voltage (15V/per Battery), the UPS will discharge the battery capacity by way of
battery mode to ensure the battery life. The panel will display the fault condition.
3. Inverter output abnormal protection
The inverter failure signal shuts down the inverter immediately, makes the buzzer
continuous beep, and the "FAULT" LED light. The panel will display the fault
condition." The failure signal is latched unless the UPS is turned off or the battery is
empty".
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PCM Vanguard
5/6KVA SERVICE MANUAL
4. Over temperature protection
The thermal switch detect the temperature of the heatsink of the inverter on the
PSDR. The thermal switches are electrically connected to the CPU. While the
temperature is higher than the switch’s specification, the thermal switch is opened
and the CPU can’t detect the 5V. The CPU will think the condition as high internal
temperature, The panel will display the fault condition.
5. Bus overvoltage protection
To protect the BUS voltage from being overvoltage condition, especially for the
half-bridge load. The panel will display the fault condition.
iii.SIGNALING SUB-SYSTEM :
When the AC line is unable to supply, the batteries release stored energy to supply the
inverter immediately. At the same time, the utility failure relay is activated and the buzzer
beeps every five seconds.
Upon the batteries are discharged to battery-low level, the battery-low signal is
activated and the buzzer two beeps every five seconds.
Remote shutdown signal is enabled only when the line fails. The signal is connected to
the battery detector. It generates battery-under signal to cut off the bias power supply of the
UPS system. The EPO signal is enabled at any mode, when the EPO is enable, the unit
shut off the output power.
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PCM Vanguard
V.
5/6KVA SERVICE MANUAL
FRONT PANEL :
The front panel consists 3 parts: switch button, LED and LCD display.
i. switch button
There are five switch buttons：(1)“ON/OFF” button, it can turn on and off UPS,
(2)”FUNC” button, it can configure fifteen functions of UPS, (3)”ENTER” button, it can
enter、enable or confirm the function that you want, (4) ”ESCAPE” button, it can return to
main display, (5) ”STATUS” button, it can display fourteen contents of UPS. For example,
it can display the input voltage, frequency, output voltage, frequency, load,….etc.
ii. LED display
The five LEDs indicate “UPS ON”, “LINE MODE”, “BATTERY MODE”, “BYPASS
MODE” and “FAULT”.
iii. LCD display
The LCD display UPS any conditions.
Besides, when the system works abnormally, the fault LED will light up and the buzzer
will beep continuously. In this situation, the LCD will display the fault condition, for
example: High output voltage, High temperature,….,etc.
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PCM Vanguard
5/6KVA SERVICE MANUAL
VI. ALIGNMENTS
The Vanguard series are auto-regulation the bus voltage, bus balance and charger
voltage, when the CNTL or PSDR is modified, the engineer must rectify them according to
the following steps:
(1). Connect the computer to the rectified unit.
(2). Execute the “service program”.
(3). Measure the temperature, charge voltage, and output voltage.
(4). Import the measured temperature, charger voltage, and output voltage.
The CPU will auto-regulate the charger voltage, temperature, and output voltage.
Note: The charger voltage will be changed according to the temperature at the Vanguard
series, it is 13.8V/pcs at 25 degree C.
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PCM Vanguard
5/6KVA SERVICE MANUAL
VII. TROUBLE SHOOTING
For the reason of safety, you must unplug the power cord and disconnect the batteries
from UPS.
Check the components listed below to confirm which block is out of order and follow
the procedures listed on the following pages to repair them.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components.
5/6KVA
1. OVERVIEW :
Circuit Block
FUSE
P.F. Correction
Inverter
Charger
DC Power Supply
Components to be checked
Fail condition
F1,F2
open
U4,U6,D6,D29,Q4,Q5,Q11,Q12,Q35,Q36 short or open
Q6,Q7,Q8,Q13,Q14,Q15,D11,D36
D-S short or open
Q102,Q103
D-S short or open
Q211
D-S short or open
2. P.F. CORRECTION:
Step
Checked components
*Instrument Reference Failed condition
function
Value
short
open
Ω
1
F1
2
Q4,Q5,Q11,Q12,Q35,Q36 (D,S)
DIODE
2.8
short or open
3
D6,D29
DIODE
0.37
short or open
4
R16,R18,R293,R77,R85,R296
Ω
47
5
CBUS＋,CBUS－
Ω
open
short
open or value
change
deformed
visual
* The instrument is D.M. ( digital multimeter )
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PCM Vanguard
5/6KVA SERVICE MANUAL
3.DC/AC INVERTER:
Step
Checked components
*Instrument Reference Failed condition
function
Value
DIODE
0.37
short or open
1.
Q6,Q7,Q8,Q13,Q14,Q15 (D,S)
2.
D11,D36
DIODE
0.37
short or open
3.
R23,R25,R27,R90,R95,R99
Ω
22Ω
open
4.DC POWER SUPPLY :
Step
Checked components
1
2
3
4
Reference
Value
0.48
Failed condition
Q211 (D,S)
*Instrument
function
DIODE
R234
R243
Ω
Ω
47
0.68Ω/2W
open
open
too low
Ω
47.6K
38.1K
4.05K
51.7K
Reference
Value
0.49
Failed condition
47
0.167Ω/2W
open
open
47.6K
38.1K
4.05K
51.7K
0.49
open
too low
U11 (3845) PIN
5-6
5-7
5-8
6-8
short or open
5.AC/DC CHARGER :
Step
Checked components
1
Q102,Q103
*Instrument
function
DIODE
2
3
R132,R150
R123,R125,R131
Ω
Ω
4
U401 (3843) PIN 5-6
5-7
5-8
6-8
BR101(＋,~,~,－)
C101
5
6
Ω
DIODE
Ω
visual
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short or open
short or open
short
deformed
PCM Vanguard
5/6KVA SERVICE MANUAL
After you have replaced all defect components on power stage (PSDR), connect with
control board. Supply DC voltage (3Amp limited current) with DC power supply via
battery cable(＋) and cable(－). Turn on the switch on panel, you will see "current limit"
on the DC power supply for about 2 seconds (If not, there are some defective components
you have not found).
When everything seems good, turn off the switch on panel and remove DC power
supply. Plug in the power cord and supply UPS with the mains. Test the output of charger
( battery cable(＋),(－) ). Check the charger voltage OK or not? The fan will also active. If
there is no problem in charger, connect to the batteries.
Finally, turn on the switch on panel again and follow the procedure listed in part IV
(Alignment) to rectify the charger voltage and temperature, and measure voltage on DC
bus, output voltage.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components
14
B70
Terminal Block
15
O/L
O/N
O/G
I/L2
I/N2
I/G2
B54
B55
B53
B54
B55
B53
B69
Jumper
B65
I/L1
B66
I/N1
I/G1 B53
6-L
2-N
7-L
3-N
MB
5-L
1-N
E36
E37
E33
E34
Bypass EMI
113-V3K0-810
P1-L
P5-L
P2-L
P7-N
P3-N
P8-N
D89
I/P EMI
L
113-UIFI-610 N
P106-N
P107-L
610-BRN
P102-CHGR+
P101-BATP104-CHGR-
B60
O/P EMI
L O/P L
L
L D85
N NFB N B61 N 113-UOFI-610 N D88
L I/P L B56 L
B57
N NFB N
N
P103
P108
CN310
CHGR
115-V6K0-810
CN11
B58
B59
P1-L
P2-N
CN205
CN206
P14-L
CN2
404
USB
119-0VGD-010
PSDR
112-V6K0-810
CN201 CN202 CN203
612-WHT
612-RED
P6
P3
P5
P4
B+
B-
140-RED B+
140-BLK B-
B71
A61
P12 612-BLK
P11
P10
CN6
Panel
114-V6K0-810
CN1
CN2
045
405
CN404A
CN201
CNTL
111-V6K0-810
CN402 CN403 CN405
CN407
020
SNMP
Slot
5&6 403 CN206
O/P RY
1
4 B64 P13-L
P216-N
FAN
FAN
B67
610-BLU
611-RED
611-WHT
611-BLK
402
CN408
EPO
686
P7-BAT+
P3A-BATP8-CHGR-
Internal
Battery
External
Battery
Connector
PCM Vanguard
5/6KVA SERVICE MANUAL
APPENDIX I：SCHEMATICS
Figure 1a：Wiring diagram for 5/6KVA
transformer
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B70
B70
B74
B75
B53
O/L1
O/N1
O/L2
O/N2
B53
O/G
I/L2
I/N2
I/G2
B79
Jumper
B65
I/L1
B66
I/N1
B53
I/G1
110
220
0 O/P 0
110 ISO
0
6-L
2-N
7-L
3-N
MB
5-L
1-N
E38
E39
E33
E34
Bypass EMI
113-V3K0-810
P1-L
P5-L
P2-L
P7-N
P3-N
P8-N
E35
I/P EMI
113-UIFI-610
L
N
P106-N
P107-L
610-BRN
P102-CHGR+
P101-BATP104-CHGR-
O/P EMI
L O/P L B56 L
L D85
N NFB N B57 N 113-UOFI-610 N D88
L I/P L B56 L
B57
N NFB N
N
P103
P108
CN310
CHGR
115-V6K0-810
CN11
B58
B59
P1-L
P2-N
CN205
CN206
P14-L
CN2
404
USB
119-0VGD-010
PSDR
112-V6K0-810
CN201 CN202 CN203
612-WHT
612-RED
P6
P3
B+
B-
B+
B-
140-RED
140-BLK
B71
P5
P4 A61
P12 612-BLK
P11
P10
CN6
Panel
114-V6K0-810
CN1
CN2
045
405
CN404A
CN201
CNTL
111-V6K0-810
CN402 CN403 CN405
CN407
020
SNMP
Slot
5&6 403 CN206
O/P RY
B64
1
4
P13-L
P216-N
FAN
FAN
B67
610-BLU
611-RED
611-WHT
611-BLK
402
CN408
EPO
686
P7-BAT+
P3A-BATP8-CHGR-
Internal
Battery
External
Battery
Connector
PCM Vanguard
5/6KVA SERVICE MANUAL
Figure 1b：Wiring diagram for 5/6KVA with output ISO
Terminal Block
PCM Vanguard
14
15 19 12
8
9
10
5
7
4
5/6KVA SERVICE MANUAL
2
1
16 20
18
3
11 17
6
13
Figure 2a：Sub-assembly location for 5/6KVA
11
14 15 19 12
8 9
13
10
4
2
16
1
20
3
18
6
5
7
17
21
Figure 2b：Sub-assembly location for 5/6KVA with output ISO transformer
Item Name
1 Panel PCB
2 PSDR PCB
3 Charger PCB
4 CNTL PCB
5 Bypass Filter
6 Input Filter
7 Output Filter
8 TVSS PCB
9 EXT. BATT. CON.
10 FAN (12cm)
11 INTERFACE (option)
Quantity Item Name
Quantity
1
12 USB (option)
1
1
13 Terminal Block
1
1
14 Input NFB
1
1
15 Output NFB
1
1
16 Battery
20
1
17 Manual Bypass
1
1
18 BUS Cap.
2
1
19 EPO
1
1
20 INV. Relay
1
2
21 Output ISO
1
1
17
PCM Vanguard
CHGR
I/P
I/P NFB
PFC
BAT
INV
BYPASS
INV RY
STS
O/P NFB
Manual
Bypass
O/P
5/6KVA SERVICE MANUAL
Figure 3：block diagram for 5/6K
18
5V
GND
5/6KVA SERVICE MANUAL
GND
0
GND
0
CHGR
CHGR
1
a1
7812
b1
2
1
a1
7805
b1
2
12V
24V
PCM Vanguard
Figure 4：DC power supply circuit for 5/6K
19
PCM Vanguard
O/P L
O/P N
5/6KVA SERVICE MANUAL
L.C
L.C
C.L
Figure 5：Inverter circuit for 5/6K
20
GND
BUS
INV
BUS
INV
C.L
PCM Vanguard
I/P L
I/P N
PFC
PFC
BUS
BUS
GND
5/6KVA SERVICE MANUAL
Figure 6：Unit power factor correction circuit for 5/6K
21
CHGR
5/6KVA SERVICE MANUAL
I/P N
I/P L
CHGR
BAT
CHGR
PCM Vanguard
Figure 7：Charger circuit for 5/6K
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5/6KVA SERVICE MANUAL
APPENDIX II：COMMUNICATION
i. RS232
The RS232 provides proprietary command sequence for the computer to monitor the
line and UPS stat us and to control the UPS. The data format is listed as following:
PIN TYPE
：female
BAUD RATE
：2400 bps
DATA LENGTH
：8 bits
STOP BIT
：1 bit
PARITY
：NONE
The pin assignment and description are listed in the following table and the interface
configuration is indicated in the following figure I. Note that, the computer will control
information exchange by a ASCII command. UPS will respond with ASCII information or
action. UPS data will be provided at 2400 baud rate and consist of 8 data bits, 1 stop bit,
and no parity bit. All the information is provided in Binary format.
PIN #
1
Description
No connection
I/O type
------
2
RS232 TxD output
Output
3
RS232 RxD/Inverter Off input
Input
4
No connection
------
5
common
------
6
Line Fail
Output
7
No connection
------
8
Battery Low
Output
9
12Vdc
Output
Table I : RS232 connection
Figure I : RS232 connection
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5/6KVA SERVICE MANUAL
ii. AS400 (option)
a. AS 400 provides dry contact closure signal open or close.
b. AS 400 provides the remote shutdown function,while the shorter connector on the CN2
is removed, the UPS will be forced to get into bypass mode.
c. The pin assignment and description are listed as following.
PIN #
Description
1
UPS fail, relay contact, normally open active close.
2
Summary alarm, relay contact, normally open, active close.
One of the following conditions activate this signal
. UPS fail
. Bypass active
. Battery low
. Utility fail
. Inveter out of order
3
GND for secondary
4
Remote shutdown
5
Common
6
7
8
9
Bypass active, normally open, active close
Battery low, normally open, active close
Battery mode shutdown
Utility fail, normally open, active close
I/O type
output
output
input
output
output
input
output
Other AS400 card definition:
PIN #
Description
1--3 Utility fail, normally open, active close
4--6 Battery low, normally open, active close
7--9 Summary alarm, relay contact, normally open, active close.
One of the following conditions activate this signal
. UPS fail
. Bypass active
. Battery low
. Utility fail
. Inveter out of order
10--12 Bypass active, normally open, active close
I/O type
output
output
output
output
13
14
15
GND for secondary
Remote shutdown
output
input
24