MBF COMPANY CONFIDENTIAL FIELD INFORMATION BULLETIN SERVICE GROUP(S): MICRO,MINI,LARGE MFG: ALL NACS TYPE(S): N022 MFG. MODEL(S): UPS, MISC CATEGORY: LINE CONDITIONER DESC: A/C POWER CONDITIONER *** TABLE OF CONTENTS AS OF 02/01/91 *** FIB 00001.TOPAZ UPS for MAI/Basic Four - General Information..........07/09/90 FIB 00002.TOPAZ UPS - Voltage Adjustments............................06/24/86 FIB 00003.UPS information for the Basic Four 2000 and 3000 systems....07/07/87 FIB 00004.TOPAZ UPS Battery Testing/Replacement - Revised 3/26/90.....03/26/90 FIB 00005.Deleted.....................................................03/21/90 FIB 00006.Power Conditioning Devices..................................08/09/89 FIB 00007.Topaz UPS Covers no Longer Refurbished, Use Customer's......09/08/89 FIB 00008.Testing.for UPS batteries with 'open' cells - revised 2/14/902/14/90 FIB 00009.Battery Connections for Topaz Model 84130-01AA..............03/06/90 FIB 00010.Spare Batteries Won't Fit In All Models of Topaz UPS........07/06/90 FIB 00011.Wiring of Line-Conditioner PCBA on -54 Units................07/09/90 FIB 00012.Line Fuse Part Numbers for 115 Volt UPS Models..............07/16/90 FIB 00013.Exide UPS...................................................01/07/91 LINE CONDITIONER-ALL-UPS, MISC----------------------Table Of Contents Pg01 of 01 FIB 00001 07/09/90 *** TOPAZ UPS for MAI/Basic Four - General Information *** MAI/Basic Four is selling Topaz UPS (Uninterruptible Power Supplies) of two capacities with some Systems as an optional feature. The purpose of the Topaz UPS is to provide AC power back-up to the Systems during a power failure for 10 to 20 minutes. This period of time will allow the customer to stop operating and properly shutdown the system. The UPS provides AC back-up when the commercial AC power is interrupted. The UPS includes 2 maintenance-free batteries, a battery charger and a static inverter to convert battery power to AC power. When the commercial AC power is available, it powers the load directly and maintains the battery in a charged state. When the commercial AC power fails, the inverter is automatically turned on to supply power to the load. INSTALLATION: The UPS should be connected to the power line for at least 16 hours prior to system installation to recharge the batteries. The internal charger operates only when the UPS power switch is set to the ON position. Plug ONLY the following 2 units to the UPS output receptacles: o 1 System Cabinet (SPx, PCx, GPx 2xx-3xx-4xx) o 1 Basic Four Console Terminal (4309, 4310, 4312, 4313, 4314, etc) The unit should provide at least 10 minutes of back-up power with above load. Do not plug any more units to the UPS to prevent overload during inverter operation. The Topaz UPS is not of sufficient capacity to provide backup power for MPx or GPx Sr. Other larger UPS units will offered. MAINTENANCE: Field Maintenance is limited to: o Recharge the batteries o Replace the batteries (may/may not be covered by Maintenance Agreement) o Replace the complete unit (without the batteries) Most of the problems in the field are caused by discharged or defective batteries. An attempt should be made to recharge the batteries during 16 or more hours, or to replace the batteries before replacing the complete unit. The internal charger will not operate when the batteries are totally discharged. When this condition exists, replace the batteries or use an external charger. NOTE: If the UPS is connected to an AC outlet which is switched through a timer or otherwise disconnected from AC line when the System is not in use, the UPS must also be switched OFF during those periods of AC power interruption. The UPS will otherwise switch to power-fail operation and discharge its batteries in approximately 30 minutes, even though no load (System) is actually operating. This will shorten battery life, and cause the batteries to require complete re-charging after each period of AC loss. The available backup capacity is very limited during the first 8 to 10 hours of the re-charge process. LINE CONDITIONER-ALL-UPS, MISC----------------------FIB001 Pg001 Spare Parts: Description ICN Vendor P/N ---------------------------------------------------- -------- ------------- UPS 1350 VA without line cond., without batteries MM535076 84130-01A UPS 1350 VA with line conditioner, without batteries MM536076 84130-54 UPS 400 VA without line cond., without batteries MM533071 84462-01 UPS 400 VA with line conditioner, without batteries MM536071 84462-54 Battery, 12 volts, 30 Amp-hours Gell type MM533080 PS12300 SPECIFICATIONS: 117 VOLT 60 HZ MODELS 220/240 VOLT 50 HZ MODELS Input Voltage Range: + 20% -15% (144-102 volts) (264-187)or(288-204) Volts Output Voltage: 120V, +/- 3.5V at 60 Hz. Nominal +/- 7.0 Volts TRANSFER VOLTAGE Line to Inverter: 96 Vac +/- 1 Vac 176 Vac or 196 Vac +/- 2 Vac Inverter to Line: 101 Vac maximum 190 Vac or 209 Vac maximum Output Capacity: 400 Volt-Amperes, (current limits at 550 Volt-Amperes) 1350 Volt-Amperes, (11.25 Amps at 120 Volts) Batteries: Type: Lead-acid, gel-type, maintenance free. Voltage: 24 volts (nominal). 2 batteries (12 volts each) connected in series. Time required to re-charge the batteries: 16 hours to recharge 90%. 48 hours to recharge 100%. Power Cord: 6 foot power cord with NEMA plug type 5-15P (standard plug) Output Receptacle: 4 output receptacles NEMA type 5-15R (standard receptacle) Above power cord/receptacle info refers to 117 Vac 60 Hz models only Automatic shutdown: when batteries discharge to 19.0 +/- .5 V. when current limiting continuously, after exceeding 550 Volt-Amperes (4.5 A @ 120V) (400 VA) or 1625 Watts (1350VA) Unit Weight: 66.5 lb (30.2 kg.) (400 VA) 90.0 lb (40.8 kg ) (1350 VA) Storage: Units should be connected to the power line, with the power switch on, for 48 hours prior to storage to fully recharge the batteries. They should be removed from storage and recharged every 90 days. CONTROLS AND INDICATORS. Power switch With the power switch in the ON position, power will be present at the output receptacles delivered from either the power line or the inverter, depending on the input voltage. When the power switch is operated from OFF to ON, power will be initially delivered to the output by the inverter. If the line voltage is normal, transfer to line will take place within about 3 seconds. The power switch is also used to restore operation when the inverter has shut down because of a continuous overload. When this occurs, switching to OFF and then to ON will restart the inverter. Indicator Light The indicator light on the power switch is on when the power is present at the output receptacles. LINE CONDITIONER-ALL-UPS, MISC----------------------FIB001 Pg002 Audible Alarm A beeper sounds, once every 8 seconds, when the system is operating from battery power. If the outage persists until the batteries are discharged, the beeper will continue to sound until the power switch has been turned off. ORIGINATOR: JAVIER VAN OORDT Revised by J. VanderHeyden MODIFIED BY: Norm Jones LINE CONDITIONER-ALL-UPS, MISC----------------------FIB001 Pg003 FIB 00002 06/24/86 *** TOPAZ UPS - Voltage Adjustments *** CAUTION: * The batteries in the U.P.S have a very high short circuit current capacity! Personal injury can result during service by unqualified personal. * High Voltages can be present inside this unit with or without A.C.power connected, The red indicator will light whenever the output recepttcle is energized. ADJUSTMENT COMPONENT LIMITS 60HZ LIMITS 50HZ --------------------------------------------------------------------------- Low A.C. line R31 102 +or- 1 VAC 187 +or- 2 VAC(220) Transfer: 195 +or- 2 VAC(230) 204 +or- 2 VAC(240) --------------------------------------------------------------------------- Inverter Output Voltage (no load): R89 120 +or- 1 VAC 220-240 +or- 2 VAC --------------------------------------------------------------------------- Battery Check Voltage: R85 27.6 +or- 0.1 VDC 27.6 +or- 0.1 VDC --------------------------------------------------------------------------- Inverter Frequency: R13 60 +or- 0.5 HZ 50 +or- 0.5 HZ --------------------------------------------------------------------------- No attempt should be made by the field engineer to adjust R85 or R13. These resisters are factory adjusted for optimum operation. Maladjustment of these resisters can result in sever damage to the unit. To adjust R89: (All units disconnected from the U.P.S.) 1. Set On/Off switch to Off. 2. Unplug U.P.S. from the power line. 3. Remove the four screws that secure the top cover from the sides of the U.P.S. 4. Connect a voltmeter between the Hot and Neutral terminals at the output receptacle. Do not use the Ground terminal. 5. Set the On/Off switch to On. 6. While observing the inverter output on the voltmeter, set the voltage adjust pot. R89. For 120VAC operation - set R89 for 120VAC. For 240VAC operation - set R89 for 240VAC. There should not be any load connected to the U.P.S. during this adjustment. To adjust R31: (Batteries must be connected) NOTE: There is a normal time delay between varying R31, and any observed result. 1. This adjustment normally requires an output adjustable trans- former. 2. Adjust this transformer for the lower limit at which the LINE CONDITIONER-ALL-UPS, MISC----------------------FIB002 Pg001 switch to battery should occur, i.e.: For 120VAC operation - limit is at 102VAC, +or- 1 volt: For 240VAC operation - limit is 204VAC, +or- 2 volts. 3. If it is necessary to adjust R31 and no adjustable transformer is available, wait until the time of day when electricity usage is at its peak. This will assure you that the adjustment will be made at some level below the normal voltage supply. (During time of peak usage, voltage supply levels can easily reach 110VAC.) Procedure: 1. Wait until peak- usage period or install varible transformer. 2. Turn R31 fully clockwise. Wait until transfer to line occurs. (Fan stops turning) 3. Slowly adjust R31 counter-clockwise until transfer to Inverter occurs. (Fan starts turning) 4. If an adjustable transformer was used during the above adjustment disconect it - you are finished. Proceed to step 5 only if an adjustable transformer was NOT used. 5. Slowly turn R31 clockwise until transfer to line reoccurs. (Fan stops turning) Preforming step 5 will assure operation down to just above the level of peak usage. Remember, the higher R31's thershold of adjustment is, the more sensitive the U.P.S. will become during times of peak electricity usage. ORIGINATOR: Pete Koehler LINE CONDITIONER-ALL-UPS, MISC----------------------FIB002 Pg002 FIB 00003 07/07/87 *** UPS information for the Basic Four 2000 and 3000 systems *** The UPS (Uninterruptible Power Supply) that MAI Basic Four sells for the MAI 2000/3000 system is not a Line Conditioner. The UPS is a Battery Backup Unit. The purpose of the UPS is to allow you to do a proper shutdown, in the case of a power outtage without loosing any critical files. The MAI 2000 and the MAI 3000 do not use the same kind of UPS. Listed below are the Uninterruptable Power Supplies available for both systems. For the MAI 2000 system o Part Numbers: 400578-003 120v /60 Hz 400 VA MM533070 400578-004 220v /50 Hz 400 VA 400578-006 230v /50 Hz 400 VA 400578-007 240v /50 Hz 400 VA For the MAI 3000 system o Part Numbers: 400651-001 120v /60 Hz 1300 VA MM535075 400651-002 220v /50 Hz 1300 VA 400651-003 230v /50 Hz 1300 VA 400651-004 240v /50 Hz 1300 VA Note: If you want to use a Line Conditioner, it is recomended to put the line conditioner first followed by the UPS and last the CPU. Power Line Outlet Cond. UPS CPU ____ ____ ____ ____ | | | | | | | | | |-------| |-------| |-------| | |____| |____| |____| |____| ORIGINATOR: C. Figueroa LINE CONDITIONER-ALL-UPS, MISC----------------------FIB003 Pg001 FIB 00004 03/26/90 *** TOPAZ UPS Battery Testing/Replacement - Revised 3/26/90 *** Reference: MM533071/400578 UPS, Topaz 400 VA w/o batteries. MM535076/400651 UPS, Topaz 1300 VA w/o batteries. MM533080/105-00002 Battery, Topaz UPS, 12 VDC The Topaz UPS is no longer available with batteries, this FIB addresses field battery troubleshooting and replacement procedures. The batteries should be considered first when the inverter fails to turn on or when the inverter shuts down automatically after running only briefly. Two 12-volt batteries connected in series provide 24-volt DC power to the inverter. Normal batteries being discharged by an operating inverter eventually reach the 19-volt automatic shutdown level. The discharge rate when operating in power-fail mode is approximately 80 - 100 Amps. The batteries are rated at 30 Amp/hours. The internal charger (27.6 volts output) will trickle charge partially discharged batteries until they reach full charge --this takes approximately 16 hours. The charger will not attempt to charge fully discharged batteries (below 19 volts.) Batteries fully discharged may be removed and recharged externally using a 12-volt automotive battery charger as indicated elsewhere in this FIB, or replaced if defective. NOTE: It is important to review the procedures in this FIB prior to performing . battery replacements. Also it is important to place the UPS in a good work environment (sufficient lighting & space) prior to working on it. ***** REQUIRED HARDWARE ***** 1. Battery load tester 100 Amp. Automotive Battery Tester - DAYTON type 4Z581B - purchase locally from W. W. GRAINGER - price approximately $60.00 - or substitute equivalent . load tester from mail-order automotive parts/accessory outlet (J. C. WHITNEY catalog number 13-5467A is equivalent at a similar price if you are not in a location convenient to W. W. GRAINGER.) 2. Capacitor charge/discharge resistor 100 ohm 10 watt resistor, 16 AWG wire, and alligator clips 3. Replacement battery terminal bolts - 4 required per battery set 1/4" carriage bolts - 1/4 20 threads, 3/4" long 4. Automotive 12V battery charger, MAXIMUM CHARGING RATE OF 6 AMPS LINE CONDITIONER-ALL-UPS, MISC----------------------FIB004 Pg001 These hardware items will have to be purchased locally. Possible sources are: 100 ohm resistor.....Radio Shack wire.................Radio Shack alligator clips......Radio Shack 6 AMP 12V charger....Sears/auto parts store 1/4" carriage bolts..hardware store ***** TESTING THE BATTERIES BACKUP POWER ***** The best test for the batteries is to force the UPS inverter into operation under normal load and measure the backup time available. Proceed as follows: o Recharge the batteries on the internal charger for at least 16 hours before testing. o Verify load of the devices connected to the UPS. Do not exceed recommended maximum: - 400VA UPS, maximum load: 325W, typical load: 1 2000 CCA and 1 terminal. - 1300VA UPS, maximum load: 1000W, typical load: 1 3000 CCA and 1 terminal. NOTE: IF THE SYSTEM IS A MULTI-USER UNIX/UNOS ENVIRONMENT (SPx, GPx, etc), ENSURE THAT IT IS 'SHUTDOWN' PRIOR TO THIS TEST. o Remove AC power cord to simulate a power failure condition and measure backup time available: - 400VA UPS, minimum backup time: 20 minutes at maximum load. - 1300VA UPS, minimum backup time: 8 minutes at maximum load. Replace the batteries if the backup power available is below the minimum or if the UPS fails to go into inverter mode. Useful general information: Average operating time on fully-charged batteries with NO LOAD is 30 minutes. If the UPS is to be attached to an AC circuit that will be interrupted by a timer or manually turned OFF when the UPS-attached system is also turned OFF, the UPS itself must also be turned OFF to prevent it from discharging its batteries during these normal periods of power-interruption. ***** REMOVING THE BATTERIES FROM UPS ***** 1. Turn the UPS ON/OFF switch to OFF, unplug the A.C. cord from wall receptacle, and remove the cover. ****************** WARNING *********************** High voltages can be present inside the UPS with or without the AC input cord connected. ****************** WARNING *********************** The batteries have a high short-circuit capacity. Mistakes in connecting or disconnecting can cause severe burns. Eye protection and rubber gloves should always be worn when working with batteries. Remove all jewelry from your hands. ******* SPECIAL WARNING FOR THE 1300 VA UPS ******* When replacing the cover, position the paper insulator LINE CONDITIONER-ALL-UPS, MISC----------------------FIB004 Pg002 over the terminals on the large cables near the regulator to prevent a short circuit between terminals and cover. To remove the batteries, follow the following instructions, DO NOT follow the instructions affixed to the UPS cover. UPS Top View _________________________ | | | | | | Rear | + - | + - | Front | 1 2 | 3 4 | |____________|____________| Figure 1. Battery Posts NOTE: Model 84130-54 (and possibly other models with surge suppression) with surge suppression PCBA has this PCBA mounted in the battery tray area, and it must be removed prior to battery removal. Remove the two PCBA mounting screws, tag and remove the five wires attached to the PCBA, remove PCBA and position wires out of the way of the batteries. Follow the following disconnect sequence: 1. Disconnect post # 1 and insulate the wire that was removed from this post. 2. Disconnect post # 2 and slide left battery out. 3. Disconnect post # 3 and slide right battery out. Post 4 can be disconnected after the battery is removed. To prevent arcing while working on the unit and when reinstalling the wires: 1. Discharge filter capacitors using a 100 ohm, 5 watt resistor by touching the battery output leads that were connected to posts 2 and 3. 2. Recharge capacitors before reconnecting the last wire (post # 1) by connecting the 100 ohm resistor in series between the wire and the battery post. ***** TESTING THE BATTERIES REMOVED FROM UPS ***** This section is divided in 2 parts. Part 1 is to test the batteries before recharging to eliminate defective batteries. Part 2 is to test the batteries after recharging. PART 1- TESTING BATTERIES BEFORE RECHARGING: 1. Allow the batteries to stabilize for at least 30 minutes before taking voltage measurement. 2. Measure individual battery voltage without a load using a Digital Voltmeter: o If voltage is less than 11.95 volts, the battery has been discharged beyond a safe level and is probably defective. It should be replaced. o If voltage is greater than 11.95 volts, the battery may be recharged and tested under load. Recharging may be able to restore normal operation. PART 2 - TESTING THE BATTERIES AFTER RECHARGING: LINE CONDITIONER-ALL-UPS, MISC----------------------FIB004 Pg003 1. Recharge the batteries for 16 hours using the internal UPS charger or using an external charger as indicated elsewhere on this FIB. 2. INDIVIDUAL batteries should be tested under load to obtain reliable results. Use the Automotive Battery Load Tester (Item 1 of Required Hardware above). 3. Observing polarity, connect Tester across the battery. Observe the meter on the Tester. The indicated Voltage should be well into the green range marked "GOOD". 4. Transfer the momentary-switch on the Tester to connect the load accross the battery. Hold the switch transferred for about 3 seconds after it stops bouncing. It should remain steady during this period. Observe the reading. Do not exceed ten (10) seconds of continuous load-testing during any sixty (60) second period. Re-test only as needed to ensure that the clips are making good contact with the battery terminals. o If voltage indicated is below the Green 'GOOD' range, the battery is defective. It should be replaced. o If voltage indicated is in the Green 'GOOD' range, the battery is fully charged and capable of 100 Amps discharge rate. It should operate correctly in the UPS. ***** RECHARGING THE BATTERIES ***** The batteries may be recharged using the UPS internal battery charger or may be removed and recharged externally using a 12-volt automotive battery charger as indicated elsewhere in this FIB. Recharging with the internal battery charger: -------------------------------------------- o Remove all the loads from the UPS output receptacle. o Plug the UPS to the AC power line, and turn the UPS ON/OFF switch to ON. o The red indicator light should illuminate when the charger is working. o Time required to recharge the batteries: - 16 hours to recharge 90% (minimum required). - 48 hours to recharge 100% o If the indicator will not light, the charger is not working probably due to very low battery voltage. The practical solution is to replace the batteries or recharge them externally. Recharging the batteries with an external charger: ------------------------------------------------- o Batteries should be removed from the UPS to be charged individually. o Use a 12-volt automotive battery charger rated at 6 Amps or less to recharge the batteries for about 10 hours, or follow manufacturers recommendations concerning the time required to recharge the batteries. o Do not use battery chargers with a capacity larger than 6 Amps because larger currents may cause battery explosion. +++ CHARGING CURRENT MUST NOT EXCEED 6 AMPS. +++ +++ CHARGING VOLTAGE MUST NOT EXCEED 14.4 VOLTS +++ LINE CONDITIONER-ALL-UPS, MISC----------------------FIB004 Pg004 ***** RECONNECTING BATTERIES ***** The 1/4" carriage bolts (1/4-20 threads, 3/4" long) should be used to replace the 3/4" long, 1/4-20 bolts used for connecting the wires to the battery posts. Insert the carriage bolts from the inside of the battery cavity in the UPS. This will allow easy handling of the wires, flat washer, and nut from the outside of the battery cavity and the carriage bolts will not spin as the nuts are tightened. UPS Top View _________________________ | | | | | | Rear | + - | + - | Front | 1 2 | 3 4 | |____________|____________| Figure 2. Battery Posts Follow the following reconnect procedure: 1. Reconnect the wire removed from post 4 prior to installing in the UPS. 2. Insert the batteries in the UPS. 3. Connect battery posts 3, and 2. 4. To prevent a spark, connect the 100 ohm resistor between battery post 1 and the wire, wait 10 seconds, then connect the wire to post 1. 5. If the surge suppression PCBA was removed, reconnect wires, remount PCBA. ORIGINATOR: JAVIER VAN OORDT MODIFIED by: Norm Jones/John Tank/John VanderHeyden LINE CONDITIONER-ALL-UPS, MISC----------------------FIB004 Pg005 FIB 00005 03/21/90 *** Deleted *** ORIGINATOR: N. Jones LINE CONDITIONER-ALL-UPS, MISC----------------------FIB005 Pg001 FIB 00006 08/09/89 *** Power Conditioning Devices *** This Field Information Bulletin addresses Power Conditioning devices in a manner consistent with the MBF marketing approach. However prior to discussing Power Conditioning devices, the need for correct wiring and grounds must be addressed. These devices do a good job but they are not magic, they must have correct wiring and grounding for them to work properly. If the input wiring and grounding is not correct the Power Conditioning Devices may in fact make matters worse. The input AC wiring should be verified according to ENVIRONMENTAL HANDBOOK FIB 12 (Building Wiring Verification) prior to installing any Power Conditioning Device. THE ABCs OF POWER PROTECTION ---------------------------- AC power conditioning devices can be grouped into five categories. These categories will be referred to as A, B, C, D, & E throughout this FIB. These are: [ A ] Surge Protector: Shields computer equipment from high intensity impulses, or spikes greater than 250V (above or below ground potential). These devices may use a variety of components such as MOVs (Metal Oxide Varisters), Silicon Avalanche Diodes (frequently referred to as Transorbs), and Gas Tubes. [ B ] Isolation Transformer: Establishes a new neutral-to-ground reference, therefore eliminates neutral-to-ground noise (frequently referred to as 'COMMON MODE NOISE'). [ C ] Power Line Filter: Reduces oscillatory noise such as transients or hash which are of a higher frequency than the 60HZ AC sine wave. [ D ] Voltage Regulator: Brings varying input AC voltage into specification. The switch mode power supplies in MBF 1200 systems through the Advanced Series systems will tolerate a wide voltage range, and a [ D ] should not be necessary. These may be Ferroresonant Transformers or Tap Switching devices. [ E ] Battery Backup: Provides a source of standby power in the event of a black-out or severe brown-out. These include Standby UPS (switches to battery backup after AC loss sensed), On-Line UPS (battery supplies AC power at all times), and RUPS (battery powered motor generator) A "COMPLETE" power conditioning system would include all of these components ([A], [B], [C], [D], and [E]). The components may be separate or have several of them combined into a single package. LINE CONDITIONER-ALL-UPS, MISC----------------------FIB006 Pg001 An example of combining packages is the Power Protection Pak offered by MBF for the SPx and DSxx systems which consists of: 1) a Power Conditioner: [A] [B] [C] device 2) a UPS: [A] [E] device 3) the switching power supply: [D] device combined they form: [A] [B] [C] [D] [E] DESCRIPTION OF MBF POWER PROTECTION PRODUCTS -------------------------------------------- UNINTERRUPTABLE POWER SUPPLIES (STAND-BY UPS) [A] AND [E] MBF offers two UPS models, a 325W and a 1000W UPS. These cover systems ranging from the MAI 1200 to the MAI 4000. They are NOT rated for use on MPx or Advanced Series systems. These stand-by UPS units contain spike protection (the original models sold did not contain spike protection) as well as battery back-up. Some system configurations may require multiple UPSs (such as a 4000 system). MARKET CODE DESCRIPTION ----------- ----------------------------------- ZA034AA UPS w/Spike Suppression, 325W ZA035AA UPS w/Spike Suppression, 1000W POWER CONDITIONERS [A], [B], and [C] MBF offers three power conditioner models; 4 AMP (.48 KVA), 8.3 AMP (1 KVA), and 13 AMP (1.5 KVA) These units combine a surge protector [A], an isolation transformer [B], and a power line filter [C] in a single package. MARKET CODE DESCRIPTION ----------- ----------------------------------- ZA041AA Power Conditioner, 4A ZA042AA Power Conditioner, 8.3A ZA043AA Power Conditioner, 13A SURGE PROTECTORS FOR WORKSTATIONS AND PERIPHERALS [A] MBF offers eight different surge protector models. These are recommended for use only with workstations (DS 500, 1200) and peripherals. Surge protectors: MARKET CODE DESCRIPTION .----------- ----------------------------------------------------------------- QN016AA CL6 Clip Strip - six outlet strip with surge protection, master on/off switch and 6' cord QN021AA DS2 Surge Sentry - two outlet wall unit with surge protection, and status light QN022AA DS4 Surge Sentry - four outlet surge protector with master on/off switch, 6' cord, resettable circuit breaker and status light LINE CONDITIONER-ALL-UPS, MISC----------------------FIB006 Pg002 QN023AA DS6 Surge Sentry - six outlet surge protector with master on/off switch, 6' cord, resettable circuit breaker and status light QN006AA DSD Surge Sentry & Dropout Protector - Four outlet protector with master on/off switch, resettable circuit breaker, surge protection status light, and status indicator light. In the event of a voltage drop, the unit keeps power off until the user restores it by pressing the reset button. This manual restore requirement prevents damage to equipment as a result of surges or spikes that occur when power is automatically restored after a blackout or brownout. QN014AA DSLP Surge Sentry FAX Protector - One outlet surge protector with two additional RJ11 jacks to protect data lines from damage. Includes status indicator light and 6' cord. QN015AA DS4LP Surge Sentry Modem Protector - Four outlet surge protector with 2 additional RJ11 jacks to protect data lines from damage. Includes status indicator light and 6' cord. QN012AA DSDLP Surge Sentry Disk and Modem Protector - Four outlet surge protector with 2 RJ11 jacks and dropout protection for MAI 1200 class disk drives. Includes surge protection status light, 6' cord, and resetable circuit breaker. SELECTING A MBF STAND-BY UPS OR POWER CONDITIONER FOR A SYSTEM -------------------------------------------------------------- This table shows the size and quantity of UPS and Power Conditioners for the various MBF systems. (2) denotes 2 units required. CCA OR PERIPHERAL UPS POWER CONDITIONER ------------------------------- --------- ----------------- MPx or Advanced Series CPU................N/A............13A Chassis (not doublewide) Advanced Series doublewide................N/A.........(2) 13A CPU chassis Fixed Disk module (tall cabinet,..........N/A.............13A MPx or Advanced Series) Fixed Disk module (short cabinet,.........N/A............8.3A MPx or Advanced Series) MAI 4000 CPU chassis (2)............(2) 1000W........(2) 8.3A MAI 3000 CPU chassis....................1000W............8.3A MAI 2500 CPU chassis....................1000W............8.3A MAI 2000 CPU chassis.....................325W............4.0A MAI 1800 CPU chassis.....................325W............4.0A MAI 1500 CPU chassis.....................325W............4.0A MAI 1200 CPU chassis.....................325W............4.0A DS500 Workstation........................325W............4.0A LINE CONDITIONER-ALL-UPS, MISC----------------------FIB006 Pg003 PERIPHERAL POWER RATINGS ------------------------ The chart below shows the power consumption in watts for various peripherals. This can be used to calculate which UPS and/or power conditioner a customer may need. Up to four of these devices can be plugged into any UPS or power conditioner as long as it does not exceed it's rated capacity. NOTE: Printers must NEVER be plugged into the same UPS/Power Conditioner a CPU or Disk is connected to. Printers are notorious noise generators and MUST be kept seperate from CPUs and Disks. Peripheral Power Rating ----------------- ------------ PT-4201 Printer..................800W PT-4214 Printer..................200W PT-4215 Printer..................150W PT-4216 Printer...................60W PT-4217 Printer...................35W PT-4218 Printer...................35W PT-4220 Printer..................630W PT-4221 Printer.................1400W PT-4222 Printer..................140W PT-4223 Printer..................720W DT-4313 Terminal.................100W DT-4314 Terminal.................100W External 60MB MCS................325W External 120 MB MCS..............325W 1/2" MTS.........................325W 1/2" GCR.........................600W UPS or Power Conditioner Power Rating ------------------------ ------------ 325W UPS.........................325W 1000W UPS.......................1000W 4A Power Conditioner.............480W 8.3A Power Conditioner..........1000W 13A Power Conditioner...........1500W CONFIGURING POWER PROTECTION PRODUCTS ------------------------------------- When installing a Power Conditioner and a UPS on the same device the Power Conditioner should be placed ahead of the UPS (on the AC input side). The reason for this arrangement is that there is some power loss in the Power Conditioner and this will impact the UPS's back-up time. ___________________ _____ _____ | | | | | | AC-----| Power Conditioner |-----| UPS |-----| CPU | |___________________| |_____| |_____| MAINTENANCE ON THE POWER CONDITIONING DEVICES --------------------------------------------- NACS will service all of the Power Conditioning Devices. LINE CONDITIONER-ALL-UPS, MISC----------------------FIB006 Pg004 The Power Conditioners and Surge Protectors will be replaced as whole units. Both of these come with a five year warranty, units returned to MBF will be returned to the manufacturer for new ones. The Power Conditioners and Surge Protectors may be tested as follows: 1. Observe the units for physical damage as they may suffer damage in the process of diverting the energy if there is a lightning strike nearby. 2. Use an ECOS 7106 to test the Power Conditioner, all tests except the Neutral to Ground short test should pass, the Neutral to Ground short test should indicate a Neutral to Ground short on a good unit. The reason for this indication is the isolation transformer included in the Power Conditioner has a Neutral to Ground bond inside. 3. If steps 1 and 2 do not indicate a failure but the unit is suspected of not working properly replace it. The stand-by UPSs are already maintained by NACS and the adjustment procedures, battery testing, and battery replacement procedures are covered in FIBs in this FIB group. Battery replacement is not included in the UPS maintenance agreement, they are a customer responsibility and should be replaced every two years. Additionally the UPS should be tested during every system PM. MARKET CODE DESCRIPTION ----------- ----------------------------------- ZA050AA UPS Replacement Batteries ORIGINATOR: N. Jones LINE CONDITIONER-ALL-UPS, MISC----------------------FIB006 Pg005 FIB 00007 09/08/89 *** Topaz UPS Covers no Longer Refurbished, Use Customer's *** The Topaz UPS covers will no longer be refurbished at the Repair Center, they will only be cleaned. The customer's original covers should be reused and the covers from the spare placed on the defective UPS for protection during shipment back to the Repair Center. As these covers which are used for protection during shipment will get a great deal of wear and tear, they may become unsightly. It is a good idea to remove the covers before taking to the customer location. The customer may be distressed to see the repaired unit in less than new appearance. ORIGINATOR: Norm Jones LINE CONDITIONER-ALL-UPS, MISC----------------------FIB007 Pg001 FIB 00008 02/14/90 *** Testing for UPS batteries with 'open' cells - revised 2/14/90 *** SYMPTOM: Batteries meter good unloaded, but UPS does not operate. PROBLEM DETERMINATION: Measure battery voltage while UPS is attempting to start 'power-fail' operation. FIX: Replace battery showing voltage-drop when loaded. The following text and procedure aids in determining whether the UPS is the cause of apparent failure, or if one (or both) of the batteries may be showing the 'open-cell' failure-mode common to lead-acid or 'gel-cell' batteries. It is assumed that the batteries in question have already been measured under no- load conditions, and that the Voltage present is that of a fully-charged unit. Unless the batteries have been tested with an Automotive-type 100 Amp load- tester according to FIB 0004, the following symptoms may still apply: - The 'open-cell' failure is really a high-resistance connection between the internal cells of a storage battery. When only a minimal load is present (such as a meter or lamp), the Voltage is normal or even slightly high if recently charged. - When connected to a 'quick-charger' capable of several Amps capacity, the battery 'draws' little or no current relative to a normal discharged battery, but the Voltage rises almost immediately to the charger 'float' Voltage. - In a no-load state, the Voltage remains at the fully-charged level, but when loaded to relatively high current demand, the Voltage drops far below that of the nominal Voltage level of a charged unit. The TOPAZ UPS has a 'battery-saver' circuit which senses when the nominal 24 Volt battery level drops below 19 Volts, at which time it shuts off the power- conversion circuits to prevent 'deep-discharging' the batteries - a state from which they may not recover. This 'battery-saver' circuit reacts so fast that the drop in Voltage across an 'open-cell' battery can only be observed for a half-second or so. This quick responce may cause difficulty in observing it with a DVM due to the slow sample rate of the DVM, an analog meter (Triplet 310) or an oscilloscope in auto sync mode may be required to see it. The process in FIB 0004 calls for a 100-Amp load-tester to test for this condition, but the following procedure can be used if the tester is not available immediately: 1. Unplug and open the UPS and attach a meter across each battery. Set the meter to 15 or 20 Volts full-scale. If you have only one meter available, repeat the test process twice with the meter across each battery in turn. 2. Connect the UPS to an AC outlet and turn it ON. It should start up the power-conversion circuit for 2 to 3 seconds before switching to stand-by (trickle-charge) mode. If it does, verify that each battery now reads 12.5 to 14.0 Volts and proceed to step 3. If the UPS does not start, observe the meter(s) while turning it OFF and back ON. If the voltage reading of either battery is observed dropping to less than 8.0 Volts, or if the combined Voltage drops below 19.0 Volts, one or both of the batteries has an 'open-cell' or a battery cable connection is loose. LINE CONDITIONER-ALL-UPS, MISC----------------------FIB008 Pg001 3. If the UPS functioned correctly in step 2, observe the meter(s) while performing a 'power-fail' by unplugging the UPS from the AC outlet. The UPS should immediately turn on the power-conversion circuits and the fan. It should 'beep' after about 30 seconds, and every 30 seconds thereafter. Battery voltage should be approximately 10.5 to 11.5 Volts. If instead, the output of either battery drops below 8.0 Volts when the power-converter attempts to start, the 'battery-saver' will shut off the converter before any other visible evidence of the converter is seen. If both batteries appear to maintain normal Voltage at the time the AC is removed, but the UPS does not start, it is probably defective. ORIGINATOR: J. VanderHeyden LINE CONDITIONER-ALL-UPS, MISC----------------------FIB008 Pg002 FIB 00009 03/06/90 *** Battery Connections for Topaz Model 84130-01AA *** The Topaz model 84130-01AA UPS without batteries may come from spares with four wires in the battery cavity for connection to the batteries rather than the normal Topaz UPS configuration of two wires for battery connection. The wires can be connected in one of the following ways: NOTE: The wire from E2 to battery 1 minus (-) may connect via a terminal labeled E on a transistor block on some units. As long as there is a connection from terminal E2 to battery 1 minus (-) this is okay. Method 1 - This wiring method uses the wires in the battery cavity as they came from spares and requires no rewiring but the connection scheme is somewhat illogical. BAT 2 BAT 1 +| | - 125A +| | - E1---O---| | | |---o~~o---| | | |---E2 ^ | | ^ | | | | | | LARGE TERMINAL FUSE F2 JUST DOWN FROM E1 Method 2 - This wiring method requires some rewiring using the existing battery connection wires, however it is a more logical wiring scheme. BAT 2 BAT 1 125A +| | - +| | - E1---O---o~~o---| | | |-----| | | |---E2 ^ ^ | | | | | | | FUSE F2 | LARGE TERMINAL JUST DOWN FROM E1 ORIGINATOR: Norm Jones LINE CONDITIONER-ALL-UPS, MISC----------------------FIB009 Pg001 FIB 00010 07/06/90 *** Spare Batteries Won't Fit In All Models of Topaz UPS *** SYMPTOM/TEXT: MBF is now supplying batteries made by Panasonic, PN LCL12V33P. Due to their construction they are too wide to fit in the Model 84130-01AA Topaz UPS. FIX: Remove the plastic insulating strip on the right side of the unit to gain additional width. Batteries will now slide in. Save plastic strip by taping it inside unit, if ever needed in future. ORIGINATOR: John Tank LINE CONDITIONER-ALL-UPS, MISC----------------------FIB010 Pg001 FIB 00011 07/09/90 *** Wiring of Line-Conditioner PCBA on -54 Units *** SYMPTOM: Blows line fuse after battery installation. PROBLEM DETERMINATION: Wiring of Line-Conditioner PCBA incorrect. The Tustin Repair Center reports several UPS units were returned with the main input fuse blown due to mis-wiring of the Line-Conditioner PCBA after it was removed for battery installation. The cause seems to be an extra FASTON lug for the Ground circuit on one end of the PCBA (normally unused on 115 Volt units), and the fact that TOPAZ sometimes mounts the Line-Conditioner PCBA inverted (upside-down) from the illustration below. The fuse is being blown due to the LINE INPUT wire being plugged erroneously on the extra G terminal. The correct wiring for the Line-Conditioner PCBA is: NEUTRAL OUT (WHITE WIRE # 55) ------------------. | LINE OUT (BLACK WIRE #54) .-------|------. GREEN/YELLOW WIRE FROM FRAME ----------------|-[]L []N []G|-------------------- | ===== ===== | | ===== | | ##### ##### | | ##### ##### | | ##### ##### | FROM LINE FUSE | ### ### | LINE IN (BLACK WIRE #53) | | ----------------|-[]L []N []G| NO WIRE TO THIS (G) TERMINAL FROM LINE CORD |______|_______| NEUTRAL IN (WHITE WIRE NO #) | -----------------------' Please note that the orientation of the PCBA is not critical, and it may be inverted from this illustration. It is only important to keep the input and output circuits grouped at each end of the PCBA and the LINE and NEUTRAL wires. on the correct terminals: WHITE = NEUTRAL (CENTER 'N' TERMINAL), BLACK = LINE (OUTSIDE 'L' TERMINAL), GREEN/YELLOW = FRAME GROUND ('G' TERMINAL). The PCBA silk-screened labeling 'INPUT' and 'OUTPUT' should not be considered as being critical, since it functions in either orientation, and has been used both ways by the manufacturer. ORIGINATOR: J. VanderHeyden LINE CONDITIONER-ALL-UPS, MISC----------------------FIB011 Pg001 FIB 00012 07/16/90 *** Line Fuse Part Numbers for 115 Volt UPS Models *** In the event of a blown line fuse, please use the correct type as replacements whenever possible, as the UPS requires a Slo-Blo (Time-Delay) fuse. The MBF Inventory Control Numbers are shown below. UPS SIZE LINE FUSE TYPE MBF ICN USPS DESCRIPTION -------- ------------------------ -------- ---------------------- 450 VA BUSSMAN MDA-10 YY005846 FUSE 10A 250V SB or LITTLEFUSE 3AB/326 10Amp 1350 VA BUSSMAN MDA-15 YY019822 FUSE 15A 250V/MDA-15 or LITTLEFUSE 3AB/326 15Amp These may be purchased locally if desired. Avoid Code A orders on these items. ORIGINATOR: J. VanderHeyden LINE CONDITIONER-ALL-UPS, MISC----------------------FIB012 Pg001 FIB 00013 01/07/91 *** Exide UPS *** MAI is now shipping Exide 'UPS'. Exide has not given MAI the authorization to install or service these units. The standard warranty is: 2 years - mail-in only - 1 KVA units 2 years parts, 90 days labor- 3 KVA and 5 KVA units MAI is still negotiating details with Exide on service. In the interim, DO NOT attempt to install any Exide 'UPS' and DO NOT open any of the units up - THIS WILL VOID OUR WARRANTY! The 1 KVA units are user installable and should be shipped to Exide for repair. The 3 KVA and 5 KVA units are not user-installable. Most customers will purchase a start-up package which includes an Exide rep installing the unit. The start-up package increases the labor warranty from 90-days to 1 year. FE's should only have to co-ordinate with Exide for the start-up package if they originally sold the UPS. Otherwise, SDC or the account rep is supposed to make the arrangements. If an FE is requested to install a UPS, or for any other questions, they should call one of the 800 numbers provided from Exide for MAI: WESTERN REGION: 1 (800) 333-9433 CENTRAL REGION: 1 (800) 733-9433 EASTERN REGION: 1 (800) 678-2111 More specifics will be forwarded when available. ORIGINATOR: Susan Peacock LINE CONDITIONER-ALL-UPS, MISC----------------------FIB013 Pg001