Blackout Buster operation and service manual
Contents
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4. Hinweise sorgfaltig durch Heben Sie diese Anleitung f r den sp teren Gebrauch auf Vor jedem Reinigen ist das Ger t vom Stromnetz zu trennen Verwenden Sie Keine Fl ssig order Aerosolreiniger Am besten dient ein angefeuchtestes Tuch sur Reinigung Um eine Besch digung des Ger es zu vermeiden sollten Sie nur Zubeh rteile verwenden die vom Hersteller zurgelassen sind Das Ger t ist vor Feuchtikeit zu sch tzen Bei der Aufstellung des Ger tes ist auf sicheren Stand zu achten Ein Kippen oder Fallen K nnte Verletzungen hervorrufen Verwenden Sie nur sichere Standorte und beachten Sie die Aufstellhinweise des Herstellers Die Bel ftungs ffnungen dienen zur Luftzirkuation die das Ger t vor bertizung sch tst Sorgen Sie daf r da diese ffnungen nicht abgedeckt werden Beachten Sie beim Anschlu aus Grn den der elektrischen Sicherheit einen Schutzleiterkontakt haben Verlegen Sie die Netzanschluleitung so da niemand dar ber fallen kann Es sollte auch nichts auf der Leitung abgestellt werden Alle Hinweise und Warnungen die sich am Ger ten befinden sind zu beachten Durch die L ftungs fnungen d rfen niemals Gegenst nde oder Fl ssigkeiten in das Cer t gelangen Dies K nnte eien Brand bzw Elektrischen Schlag ausl sen Offenen Sie niemals das Ger t Das Ger t darf aus Gr nden der elektrischen Sicherheit nur non authorisiertem Servicepersonal ge ffnet werden Wenn folgende Situationen auftreten is
5. or charger fault connect a RMS root mean square voltmeter to the output of BOB Power up in battery mode The voltmeter should read 230Vac If the reading is low below 205 V or if BOB will not startup in battery mode DC Mode the inverter is faulty Change the main circuit board Revised on 3111198 _ a RTT PAPAE RES e TT Cor PTT oam SONTRONIC GmbH Zur Deutschen Einheit 3 B D 81929 M nchen Tel 08999301160Fax 089937342 f Surge Protection Symptom Input fuse blown After replacing the input fuse and applying input power to BOB the fuse blows again The most probable cause would be a faulty Metal Oxide Varistor MOV BOB has one MOV for AC power protection and three for Modem I OBaseT protection Replace the MOV as shown below Modem 10BaseT The MOVs are rated as a for AC input 300V 4500A 76Joules x 1 piece b for Modem l OBaseT 130V 1200A 9 5Joules x pieces 4 Servicing amp Maintaining PowerPack Fault Diagnosis The PowerPack PP does not have a voltage regulator it uses the regulated output of BOB Its main components are Battery inverter charger board and output transformer Some test described here requires that BOB stays connected to PP a Battery Low or Weak Field Test DT ee TE ee EEE EEE TEE nie de SONTRONIC GmbH Zur Oeutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089937343 To test a PP battery you need a custom made connectio
6. 5 990262 UK Ad Asia Fax 606677 1811 Malaysia 00240774 Step by step guide Installing the BlackoutBuster is as easy as following the steps shown Skip steps 4 and 5 if you do not need Internet network protection Keep the Internet line cable provided for future use BlackoutBuster and accessories The BiackoutBuster package comes with the following items BlackoutBuster Unit Power Cable Internet Line Cable Installation Guide User s Guide Warranty Card Warranty Statement Envelope Connecting power to the BlackoutBuster Ensure all power switches are aff Remove the power cable at the back of your computer and plug it into the socket marked Power In at the back of the BlackoutBuster Connecting the BlackoutBuster to your computer Use the power cable supplied to connect BlackoutBuster to your computer Plug one end of the cable to the socket marked Power Out at the back of the BlackoutBuster and plug the other end to the power input at the back of the computer as shown optional Connecting the BlackoutBuster to Internet 10 Base T If Internet is used then unplug the cable at the back of the modem and plug it into the Internet in socket at the back of the BiackoutBuster For 10 Base T network the procedure is the same optional Connecting the BlackoutBuster to Internet modem After step 4 use the Internet l
7. SONTRONIC JINOH LNOS BLACKOUT BUSTER OPERATION UND SERVICE MANUAL PK Electronics Blackout Buster 1 System Description Please refer to BlackoutBuster s Technical Specifications amp Product Description Manual 2 General Safety Considerations Please observe the following guidelines e Do not work alone in any potentially hazardous conditions e Always inform your co workers of hazardous voltages or conditions that pose a threat to yours and or their safety e Always be on the lookout for possible hazards such as worn out insulation moisture non grounded power source faulty or poorly maintain electrical safety device such as circuit breakers and residual current breakers etc Do not operate UPS without their safety covers e Before starting the UPS ensure that all personnel are not exposed to any potentially hazardous voltages e Do not remove or bypass any safety device Fuses amp Circuit Breakers etc are designed into the system for safety reasons e Never assume that once power has been removed from a circuit it is safe to work Always check with a test pen or voltmeter Always think about safety With good housekeeping and preventive practices we can keep our workplace safe Care for our Environment 3 Servicing amp Maintaining BlackoutBuster The Servicing and maintenance of Blackout Buster BOB PowerPack and accessories is done at the board level The only componen
8. bly is similar to BOB gS SONTRONIC GmbH Zur Deutschen Einheit 3 8 D 81929 M nchen Tel 089993011 60 Fax 089 937343 ANNEX B How to use SmartPack to control BlackoutBuster 1 Connect SmartPack Power Pack and BlackoutBuster BOB as shown Turn ON BOB BOB amp Ribbon Cable RS232 Communication Input Output 2 Starts the SEC software SmartMon Set Reboot with Duration to 30 seconds Executes the set command 3 Turns BOB OFF after waiting for approximately 10 seconds if using Win 3 1X or the Safe to shutdown your computer message appears if using Win 95 or NT 4 Now BOB is under the control of SmartPack SmartPack will turn in approximately 30 seconds 5 You can then set any schedule to automatically turn or OFF BOB SmartPack will startup and shutdown BOB as scheduled 6 If you need to turn ON BOB while BOB is in the scheduled OFF mode just press the ON button on BOB 7 Likewise if you need to switch OFF BOB while it is in the scheduled ON mode you have 2 options SONTRONIC GmbH Zur Deutschen Einheit 3 B D 81929 M nchen 089 99301160 Fax 089 937343 a Issues a OFF command Shutdown after Delay from SmartMon or b Remove the ribbon cable connecting BOB and SmartPack Note 7 To have SmartPack controls BOB again you need to perform the above steps 1 to 4 2 SmartMon will not register any load
9. d email to Techsupport pkworld com sq SONTRONIC GmbH ZurDeutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089 937 343 ANNEX A Pictorial Guide on Disassemblv of BlackoutBuster Place BOB on a flat surface Remove two legs to access the screws Remove the screws as shown SONTRONIC GmbH Zur Oeutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089 937343 Carefully push open the front cover latch using a flat blade screwdriver Push the latch inwards towards the top of BOB It is a plastic latch do not use too much force or it will snap View of Blackout Buster with the front cover and side cover removed Unscrew the battery tray screws 3 and remove the battery tray to reveal the main printed circuit board nm 6 _ _ ee ee ea GET eee SONTRONIC GmbH Zur Deutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089 937343 Overview of components of BOB Under side view of the PCB SONTRONICGmbH Zur Deutschen Einheit3 B D 81929 M nchen Tel 08999301160 Fax 089 937343 Close up view of the transformer Note PowerPack disassem
10. dle all the power problems that affect your computer This all in one power protection product has been designed to handle even the most powerful desk top computers EMERGENCY BACKUP BATTERY Sudden interruptions to the power supply can lead to the loss of your computer files BlackoutBuster s long life rechargeable battery will give you time to safely shutdown your system and prevent the loss of valuable work or personal files POWER SURGE GUARD The most commonly known cause of power surge or spike is lightning When lightning strikes a power line it can send a spike of high voltage electricity through your computer destroying key components BlackoutBuster suppresses these major variations in power protecting your computer and data from damage VOLTAGE PROTECTION Variations in the voltage of the power supply can even be caused by common electrical appliances in the same building BlackoutBuster will protect your files and hardware against damage caused by these voltage variations INTERNET LINE PROTECTION Just as lightning can strike a power line it can also strike the Internet or network line and send a spike into your computer damaging or destroying the modem BlackoutBuster provides protection for your modem or 10 Base T network adaptor against such spikes Using your BlackoutBuster The BlackoutBuster is designed for ease of operation The ON OFF button conveniently located on top of the module allows the computer
11. e next few minutes If thare is no change at all replace the battery with a good battery and repeat the test If the voltage does not climb upwards the charger is faulty Change the main circuit board Note The rate of voltage rise when charging depends on the state of battery under charge Battery Fuse Two 30A fuses protect BOB s battery The only know possible condition that could causes this fuse to blow is an overload of BOB in Battery Mode DC Mode Should this occi please contact PK Electronics Customer Service Center listed on the back ofthis manual d Voltage Regulator Symptom BOB keeps going into battery backup mode when utility power is still within specifications 170 270 The regulate LED does not light up You will need a variable transforrrer to do this test Connect the output of the variable transformer to the input o BOB Connect the probes of a voltmeter to the output of BOB Set the variable transformer to 23OVac Power on BOB Monitor the reading of the voltmeter It should show 230Vac Now trim down the variable transformer to about 200V and monitor the voltmeter reading As you trim up down the variable transformer the output of BOB will fluctuate between 205 V and 245 V If it is outside this range the voltage regulator is faulty Change the main circuit board e Inverter Output Symptom When utility power fails BOB shutdown immediately After you have confirmed that this is not due to a battery fault
12. ine cable supplied to connect the BlackoutBuster to the modem Plug one end of the Internet line cable to the Internet Out socket at the back of the BlackoutBuster and plug the other end to the modem cable input socket as shown For a 10 Base T connection you will need to obtain a network cable suitable for this connection as the cable suppliec with the BlackoutBuster is for Internet use only 1 a 25 O your computer Turn your computer power switch on and leave it in this position Use the switch at the front of the ee eee ee PERE RE E F k BlackoutBuster to control the ON OFF of the system 2 Switching the power on s b KO 4 STE a Position the BlackoutBuster in a convenient location beside BLACKOUT BUSTI ER EC Testing the BlackoutBuster You may test the functioning of the BlackoutBuster by 4 i switching off the power supply while the whole system is switched on The coinputer system should continue to 1 function as long as the BlackoutBuster s battery is not depleted Once you are satisfied with the test switch the power supply back on to the BlackoutBuster How fo get your Blackoutpdster instafied on your computer r more information please contact Electronics 226 00240775 BlackoutBuster BlackoutBuster Specifications Troubleshoo
13. n cable Refer to Annex C Custom Made Cable for Testing PowerPack Connect the cable between BOB amp PP Do not forget to connect the Data Cable between BOB and PP Connect a 100 watt lamp to the output of PP Simulate a utility power failure BOB and PP should go into battery mode DC Mode Time the battery backup duration For a fully charged PP 100 watt discharge you should get at least 10 to 15 minutes of backup time For backup times of 5 minutes or less the battery is suspect to be bad b Battery low or weak Bench Top Test Refer to section 3 1 b c Charger Refer to section 3 1 c Note The PP gets its input power through BOB s Voltage Regulator The charge LED will only light up when connected to BOB and BOB is turned on For testing you could connect the input power directly to PP d Inverter Symptom When utility power fails BOB shutdown immediately or there is a continuos beep from BOB To test a PP inverter you need to custom make a connection cable Refer to Annex C Custom Made Cable for Testing PowerPack Connect the cable between BOB amp PP Next connect a 100 watt lamp to the output of PP In parallel to this lamp connect a RMS root mean square voltmeter Do not forget to connect the Data Cable between BOB and PP Power up BOB in battery mode PP should also power up The voltmeter should read 230VAC If the reading is low below 205 V or if BOB will not startup in battery mode DC Mode the inverte
14. nutes consumption and may Acermate Pentium 100 16 minutes 32 minutes overload the Most Other Pentium PC 15 20 minutes 30 40 minutes BlackoutBuster n IBM PC Server 520 25 minutes BlackoutBuster beeps at Overload Reduce load connected HP NetServer 5 166LS 20 minutes to the BlackoutBuster The BlackoutBuster will recharge its internal battery when the incoming supply is available leave it to power up for a day to recover its charge If problem persists although above actions have been taken replace battery fast pace soon after power failure Battery not charged Battery weak BlackoutBuster shuts down Overload soon after power failure Battery not charged Battery weak Same remedy as above Compaq Prosignia Most Pentium Servers More PowerPacks up to a maximum of five per system can be added to extend backup time 32 minutes 20 30 minutes Backup time is for reference only Actual duration may very depending on temperature battery condition and peripherals added Using your BlackoutBuster Safely IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This User s Guide and the Installation Guide contain important instructions for the BlackoutBuster that should be followed during installation and maintenance of the UPS and batteries To avoid personal injury or electric shocks please take note of and observe strictly the following precautions To reduce the risk of electric shock
15. r is faulty Change the main circuit board 5 Servicing amp Maintaining SmartPack SmartPack contains no serviceable part within The fuse is rated 5A slow blow In most cases it is treated as a disposable accessory However depending on conditions the main circuit board may be replaceable Please check with PK Electronics Customer Care Center as listed on the back of this manual a Testing SmartPack Connect SmartPack as in Annex B How to use SmartPack to control BlackoutBuster Revised on 20 10 98 SONTRONIC GmbH Zur Deutschen Einheit3 B D 81929 M nchen Tel 08999301160 Fax 089 937343 If you are unable to establish communications with SmartPack and you are certain that the serial port of the PC you are using is working correctly then it is safe to assume that SmartPack has cease to function 6 Servicing amp Maintaining MicroPack The MicroPack contains no serviceable parts within To test that the MicroPack is functioning correctly carry out the following procedure Connect MicroPack to a PC that you know has run PowerMon 11 without problems If PowerMON II reports that BOB has a battery low signal but BOB is operating in Utility Power Mode AC Mode then we can assume that MicroPack has ceased to function 7 Summary For the information on servicing the BlackoutBuster PowerPack and accessory please contact PK Electronics Customer Service Cenfers listed on the back of this manual Alternatively you coul
16. readings if the load is connected to output socket other than SmartPack 3 For software version 7 3 it allows BOB to start automatically after power failure shutdown SmartPack is still in control Revised on 20 10 98 Ry ee SONTRONIC GmbH Zur Deutschen Einheit 3JB D 81929 M nchen Tel 089 99301160 Fax 089937342 ANNEX C Custom Made Cable for Testing PowerPac BOB communicates with PowerPack via the ribbon cable and the electrical earth connection of the IEC type sockets To make the test cable get 1 x IEC 320 plug male and 1 x IEC 320 plug female Wire ONLY the EARTH DO not wire the Live and Neutral Refer to picture below Wire IEC 320 Male connector IEC 320 Female connector _ SONTRONIC GmbH Zur Oeutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089 937343 ANNEX D_ BlackoutBuster Block Diagram PLUG 10 WIR CLUS 9 CPUSE DUTPUT SOCKET wy CA Tee sur P CE VOLTAGE VOLTAGE REGULATION F FEEDBACK CHASSIS GND iui 7 CONTROL j Y Ea mW me 8PIN E CUNTROL Eme L 7 Fic M cc ERTER k 4 Po c 10 PIN oo 7 gt INTERFACE FRONT PANEL SWITCH j BATT FUSE lev BATT RE ERENCE DESCGNA PTS BLACK TU BUSTER
17. s install in a temperature and humidity controlled indoor area free of conductive contaminants To reduce the risk of electric shocks do not remove cover No user serviceable parts inside Refer servicing to qualified service personnel Risk of electric shocks Battery circuit is not isolated from AC input Hazardous voltage may exist between battery terminals and ground Test before touching Risk of electric shocks Hazardous live parts inside this UPS are energized from battery supply even when the input AC power is disconnected All power cables used must be suitable and in accordance with the total load requirement Servicing of batteries should be performed or supervised by personnel knowledgeable in batteries and the required precautions Keep unauthorised personnel away from batteries When replacing batteries replace only with batteries of the same type and rating Do not dispose of batteries through burning or in a fire The batteries may explode Do not open or mutilate the batteries Electrolyte is harmful to skin and eyes It may be toxic The following additional precautions should be observed when working with batteries a Remove watches rings or other metal objects as they may accidentally short the battery terminals b Use tools with insulated handles Wear rubber gloves and boots d Do not lay tools or metal parts on top of batteries WICHITIGE SICHERHEITSHINWEISE Bitte lesen Sie diese
18. suitable for laser printer The power requirement for this type of printer is higher than the rating of BlackoutBuster output voltage
19. system to be switched ON or OFF at the touch of a button Visual indicators and an audible alarm system have been built in to indicate the state of operation In normal operation the Power Charge and Regulate LEDs will light up In case of power failure or input power is out of operating range BlackoutBuster will immediately switch to its internal battery operation and the Power and Backup LEDs will light up The audible alarm will sound at a regular interval When the internal battery is near depletion the audible alarm will beep continuously indicating the need for file saving and system shutdown When input power is restored BlackoutBuster will start up automatically ON OFF SWITCH DATA PORT Switch the Accessories may be BlackoutBuster ON or added through this port OFF by depressing for communication with the button the PC or for axpansion of backup power capacity POWER Remove protective cover to indicates that access to this port for there is output from expansion purposes ae INTERNET MODEM PACKUP RARE the internet Indicates that the Network BlackoutBuster is nie a operating on internal battery POWER SOCKETS IN is for connecti CHARGE into the unit and OUT is for Indicates that supplying power to the PC the BlackoutBuster is charging its FUSE internal battery For protecting the unit against overload REGULATE indicates that POWER SOCKET the BlackoutBuster is Additional power outlet for regulating its peripheral Not
20. t das Ger t vom Stromnetz zu trennen und von einer qualifizierten Servicestelle zu berpr fen a Netzkabel oder Netzstecker sind besch digt b Fl ssigkeit ist in das Ger t war eingedrungen c Das Ger t war Feuchtigkeit ausgesetzt d Wenn das Ger t nicht der Bedienungsanleitung entsprechend funktioniert oder Sie mit Hilfe dieser Anleitung keine Verbesserung erzielen Das Ger t ist gefallen und oder das Geh use ist besch digt f Wenn das Ger t deutliche Anzeichen eines Defektes aufweist Bei Reparaturen d fen nur Orginalersatzteile bzw Den Orginalteilen entsprechende Teile Verwendet werden Der Einsatz von ungeeigneten Ersatzteilen kann eine weitere Besch digung hervorrufen Wenden Sie sich mit allen Fragen die Service und Reparatur betreffen an Ihren Servicepartner Servicepartner Somit stellen Sie Betriebssicherheit des Ger tes sicher Der Arbeitsplatzbezogene Schalidruckkpegel nach DIN 45 635 betr gt 70dB A oder weniger The sound pressure level at the operators position according to TEC 704 1 1982 is equal or less than 70dB A Um ein Umkippen dieses Ger tes zu verhindern sind mit der Installation dieses Ger tes die zus tzlichen S tzen an der Unterseite dieses Ger tes anzubringen How the BlackoutBuster protects your computer and your files BlackoutBuster delivers a new way to ensure the smooth running of your computer system BlackoutBuster s extensive features will han
21. ting POSSIBLE CAUSE Specifications BlackoutBuster PROBLEM System will not power up REMEDY Turn the relevant B10E A B BlackoutBuster Model B10PE PowerPack Stand Alone When Connected power switch not ON Computer power switch not ON BlackoutBuster beeper sounds even when AC loose power is available Wall switch not ON Fuse blown Power cord connection switches to ON position Plug cord securely into wall socket Switch to ON position Fuse to be replaced by qualified personnel Plug into ancther wall socket or have wall socket repaired Wall socket faulty BlackoutBuster beeper sounds occasionally but system operates normally AC power fluctuating beyond the operating range of the BlackoutBuster No action required BlackoutBuster will go into backup mode when input voltage exceeds limit Install an extra voltage regulator Plug into another BlackoutBuster beeper sounds frequently but system operates AC power fluctuating widely and frequently AC power line is heavily 50Hz 60Hz 2 2A 2 3A To B10E A B 230V 220 AC normally loaded wail socket that is not affected Blow fuse Overload Dn A BlackoutBuster with one PowerPack BlackoutBuster Devices IBM Aptiva Pentium 166 14 minutes 28 minutes like laser printers have HP Vectra Pentium 166 15 minutes 30 minutes very heavy power Compaq Deskpro Pentium 133 19 minutes 38 mi
22. ts that are replaceable are the surge protector Metal Oxide Varistor MOV battery and fuses For service and warranty policy please consult PK Electronics Customer Service Center for your country region te ee SONTRONIC GmbH Zur Deutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089 9373113 3 1 Fault Diagnosis a Battery Low or Weak Field Test Leave BOB charging for at least 6 hours The Charge and Regulate Light Emitting Diodes LED green must be on If BOB keeps going into battery mode for short duration it could be that the supply voltage or frequency falls outside specifications When BOB is fully charged connect the output to a 100 watts lamp Simulate a power failure by cutting power to BOB Time the battery backup duration For a fully charged BOB 100 watt discharge you should get at least 10 to 15 minutes of backup time For backup times of 5 minutes or less the battery is suspect to be bad b Battery low or weak Bench Top Test Remove the battery and charge it via an external 12V DC charger You could use the automotive type battery charger After about 6 hours connect a 50 watt battery cell load tester to the battery for 10 minutes Connect a voltmeter in parallel to the lamp amp battery to measure the battery voltage while discharging At the end of 10 minutes if the battery voltage drops below 11 5 volts the battery should be replaced Notes If a load cell tester is not a
23. vailable you could use a 12V halogen lamp or an automotive lamp of similar wattage Some battery may display an open terminal voltage of 12 5 V or so but when under load the voltage drops to below 17 5 V A load test is the best indicator of a battery s health If the battery under test shows signs of physical defect such as bulging or depressed side walls corroded terminals sealed vent caps that have vented or any indication of acid leakage the battery should be considered defective and should be replaced Please re cycle all used batteries and help save the environment M M Me e SONTRONIC GmbH Zur Deutschen Einheit 3 B D 81929 M nchen Tel 089 99301160 Fax 089937343 Battery Charger Battery Fuse Symptom Battery or dead battery Example while simulating a power failure BOB shutdown immediately or battery backup time is very short Note a faulty charger if not corrected may damage the battery over time To test charger we need to connect a voltmeter across the battery and monitor a rise in voltage when input power is supplied Open BOB Refer to Annex A Pictorial Guide on Disassembling BlackoutBuster Next connect the input power cord but do not energize turn power on Place your voltmeter probes across the battery terminals A good battery should indicate a reading of about 12 5 volts Next supply input power to BOB The charge LED should come on Monitor the voltmeter readings it should rise over th
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