UPSB220 Uninterruptible Power Supply Caterpillar

Troubleshooting

Usage:

The UPS provides the following tools to aid in troubleshooting the unit:

General alarms and messages that are related to specific events of the UPS are shown on the display.
Detailed status and fault messages that are associated with operation of the UPS can be accessed by using the UPS Tuner interface.

Before the UPS is taken out of service, gather information from the following sources:

Status logs
Fault logs
Personalization
Measurements logs
Board Status logs

General Operation

Table 1 lists the possible causes or corrective actions for problems that are associated with the general operation of the UPS.

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Table 1
Problem	Possible Causes or Corrective Actions
Input switch trips	Faulty rectifier SCR Faulty phase rotation Faulty component or device Faulty SCR gate drive PCA Faulty local or remote EPO signal
Rectifier does not start	Input source out of tolerance Open input power fuse Faulty voltage acquisition Open DC sensing fuse or fault wire Loose ribbon cable or control harness
DC regulation is unstable	Faulty rectifier SCR Faulty SCR gate drive PCA Faulty rectifier control PCA Loose ribbon cable or control harness
High AC ripple on the DC bus	Open or faulty battery/batteries Open or faulty DC capacitors DC regulation is unstable. Refer to the above problem "DC regulation is unstable".
Inverter does not start	Faulty power supply to ALBZ Faulty ALBZ PCA Loose ribbon cable or control harness Faulty inverter modules Open inverter output fuse
Inverter starts, inverter voltage = 0, no current limitation	Faulty inverter AC sensing Faulty inverter acquisition Faulty inverter AC capacitors
Inverter starts, inverter voltage = 0, inverter goes into current limitation	Faulty inverter AC capacitors Faulty inverter module Faulty inverter LEM Open primary winding on inverter transformer Shorted/faulty inverter transformer
Inverter starts, AC voltage is normal, goes into current limitation	Faulty (open/shorted) inverter power connection (refer to preceding problem) Shorted inverter static switch SCR
Inverter reports current limit during and after transfer	Shorted inverter or mains 2 static switch SCR
Inverter will not forward transfer once synchronized	Faulty acquisition or calibration - check inverter and mains 2 acquisition and calibration Perform full logic power reset Faulty component or device
Inverter stops after forward transfer	Faulty component or device Faulty acquisition or calibration - check inverter and mains 2 acquisition and calibration
Inverter forward transfer with 800 msec break	Faulty acquisition or calibration - check inverter and mains 2 acquisition and calibration Faulty inverter static switch
Mains 2 Q4S does not close	Faulty mains 2 sensing to/on K4S control PCA Faulty K4S control PCA or pilot relay Faulty local or remote EPO signal Faulty K4S contractor

Display Panel

Table 2 lists the possible causes or corrective actions for problems that are associated with display panel operation.

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Table 2
Problem	Possible Causes or Corrective Actions
No display, UPS is inoperable	Faulty mains 2 acquisition Faulty mains 1 acquisition Faulty voltage-select PCA Faulty power supply PCA
No display, UPS is operational	Contrast set incorrectly Loose ribbon cable or control harness Faulty display panel PCA Faulty power supply PCA
Display metered values inaccurate	Incorrect voltage or power applied to unit Faulty personalization or calibration Loose ribbon cable or control harness Faulty circuit board Faulty sensing or a damaged wire
Button on Display inoperative	Faulty display assembly
LED on Display Panel inoperative	Verify LED operation. Using LED lamps, test for a bad LED. Faulty display assembly
Abnormal error message present	Refer to list of operation messages and the descriptions found in Operation and Maintenance Manual, SEBU8274
Indication of invalid faults or status conditions	Conditions appeared and disappeared for a valid condition Personalization parameters are incorrect Faulty sensing or a damaged wire Faulty component or device

I/O Card Abnormalities

Table 3 lists the possible causes or corrective actions for problems that are associated with I/O card operation.

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Table 3
Information from 66061 JBus/Modbus PCA intermittent or not displayed on SCADA or BMS	Faulty configuration switch settings on PCA Faulty soft settings on PCA Faulty RS485 wiring connections at DB9 connector Faulty RS485 wiring connections between host data acquisition device and DB9 connector at PCA Missing or too many termination resistors installed on vendor RS485 wiring Duplicate addresses exist on the communications line
Output contacts do not change in association with designated alarms	Faulty configuration switch settings on PCA Faulty wiring connections at terminal block for PCA Faulty wiring connections between host and terminal block for PCA Core controller fails to recognize presence of PCA
SNMP PCA not accessible via customer network or is not operating properly	A faulty setup of network parameters for Ethernet port A faulty setup of reports configuration Faulty SNMP PCA