Service Manual
Contents
1. Gently pull out the battery Disconnect the two wires connecting the battery to the UPS Connect the wires to the new battery making sure that the red wire is connected to the red battery terminal and the black wire is connected to the black battery terminal Push the new battery into place Close the cover and replace the screws back to the cover 5 2 Replacement Procedure for IMP IMD 1025 2000AP ONO Pe oa gez rss 10 Remove the screws on the battery cover Pull and open the cover Remove the screws of the battery retaining plate Pull out the battery Disconnect the two wires connecting the battery pack to the UPS Connect the wires to the new battery pack making sure that the red wire is connected to the red battery terminal and the black wire is connected to the black battery terminal Push the new battery into place Reposition the battery retaining plate and tighten the screws Slide the front panel back into place Tighten the two small screws on the bottom of the front panel 6 Disassembly Procedure 6 1 Disassembly procedure for IMP IMD 425 1000AP 6 1 1 Top Cover Removal Turn the UPS off and unplug it from the utility line Remove the 6 screws on the bottom Open the top cover 6 1 2 Remove the battery wire Remove the black wire from PCB to battery 6 1 3 Removal the PCB and Transformer Take off all the wires on the PCB Remove all the screws on the PCB Take off the PC2. Test amp Adjustment Procedure This Procedure outlines the steps to functionally test the IMP IMD 425AP 2000AP models The functional test is broken down into several sections to test each different function of the UPS 7 1 Charger Voltage Test Plug the UPS into an AC power source and turn the UPS on Disconnect positive red battery wire Using a multi meter verify the B to B voltage is at 13 4V 14 0V IMP IMD 425 1000AP or 26 8V 27 8V IMP IMD 1025 2000AP If not adjust VR1 7 2 Over Load Test Set the AC power source to the rating voltage Plug the UPS into an AC power source and turn the UPS on Connect a true RMS power meter to the output of the UPS Connect the SPS load to the output Add the SPS load slowly till the UPS over load alarm Use the following chart to verify the power handling capabilities of the UPS Load Product Name Overload Alarm AC Mode SPS IMP IMD 425AP IMP IMD 525AP IMP IMD 625AP IMP IMD 825AP IMP IMD 1000AP IMP IMD 1025AP IMP IMD 1200AP IMP IMD 1500AP IMP IMD 2000AP 425VA 510VA 525VA 630VA 625VA 750VA 825VA 990VA 1000 VA 1200VA 1025 VA 1230VA 1200 VA 1440VA 1500 VA 1800VA 2000 VA 2400VA 7 3 Transfer Point Test Using a variac set the output for the rated UPS s voltage Slowly reduce the variac output while monitoring the UPS s input voltage The UPS should transfer to Boost when the voltage drops to the level given in the follow
3. B Take off the transformer 6 1 4 Remove the rear panel Remove the 4 screws on the real panel Take off the rear panel IMD 425 1000A AP Wiring Diagram O U IPS2 V1 0 IN9GIA GA oll vio IP D 6 2 Disassembly procedure for IMP IMD 1025 2000AP 6 2 1 Top Cover Removal Remove the 8 screws on the bottom and rear panel Take off the top cover 6 2 2 Batter Removal Turn the UPS off and unplug it from the utility line Remove the front panel and disconnect the LED wire Remove the battery cover Pull the battery out from the chassis 6 2 3 Removal the PCB and Transformer Take off all the wires on the PCB Remove the 5 screws on the PCB Take off the PCB Remove the 4 screws on the transformer Take off the transformer IMD 1025 2000A AP Distribution Diagram TRANSFORMER BLU BLU BATTERY BACKUPOP 3116 TO EXTRA BATTERY RED LGpyN RED E H 1 3 t Ye s i G mx 3 cw 177 BLK RED 31l PEO BLK BLK __ _xp wos BATTERY 12V7AH 2 KPW n IPD4 TEA H B E 2 PCB E NA py ca on 4 Co 1 1 T EE ES BNT 808 812 PCB LA N NI LI 73N D050 154 4 Coun MZ SURGE 4 PROTECTION ENI BNT 806 PCB 13 T
4. Service Manual Imperial Series Model IMP 425 525 625 825 1000AP IMD 425 525 625 825 1000AP IMP 1025 1200 1500 2000AP IMD 1025 1200 1500 2000AP Contents of Service Manual 1 Safety Precautions 2 1 1 Service Warnings 2 1 2 Important Safety Instructions 2 2 General Information 3 2 1 Outline 3 2 2 Features 2 022 922 2002 2 3 3 SPECIFICATIONS 5 3 1 Electrical Specifications 5 3 2 Mechanical Specifications 7 3 3 Environmental Specifications 7 4 Communications Interface 8 5 Battery Replace Procedure 10 5 1 Replacement Procedure for IMP IMD 425 1000AP 10 5 2 Replacement Procedure for IMP IMD 1025 2000AP 11 6 Disassembly Procedure 12 6 1 Disassembly proce
5. dure for IMP IMD 425 1000AP 12 6 2 Disassembly procedure for IMP IMD 1025 2000AP 13 7 Test amp Adjustment Procedure 14 7 1 Charger Voltage Test 14 7 2 Backup Capacity Test 14 7 3 Transfer Point Test 15 7 4 Startup On Battery 15 7 5 Communications Port Test 15 8 Function Block Diagram 16 8 1 Main structure 16 8 2 Control circuit 16 9 Troubleshooting 17 1 Safety Precautions 1 1 Service Warnings The UPS contains voltages what are potentially hazardous All repairs should be performed by qualified service person The UPS has its own internal energy source battery The output receptacles may be alive even when the UPS is not connected to an AC supply No modification of any circuit should be attempted Service work should only be performed after you are thoroughly familiar with a
6. ice PCB failure Replace PCB Buzzer continuous Overload Replace PCB beeping
7. ime Battery Specifications IMP D IMP D IMP D IMP D IMP D 1000AP 1025AP 1200AP 1500AP 2000AP DC voltage Type 3 2 3 3 Mechanical Specifications ie Qt TO E Ummwen wns I oe o immer omes ce o9 MP IMD 1025AP 13 4 14 8 MP IMD 1200AP 13 4 14 8 Environmental Specifications 0 40 C 32 104 F 20 60 C 4 140 F Humidity 0 95 non condensing 0 95 non condensing Altitude 3 000 m 10 000 ft Max 12 000 m 40 000 ft Max 4 Communications Interface The communication port on the rear panel of the UPS allows for connection to a host computer When used with UPSMON communication software you will have access to important operating information From your computer screen you can monitor input output voltage AC frequency battery voltage etc and analyze power problems UPSMON will also initiate automatic graceful shutdowns during extended power failures If UPSMON and a communication cable are not included in your UPS package purchase it from your local dealer The following are some of the parameters you can monitor Input Voltage Indicates the actual input voltage to the UPS when AC power is present Output Voltage Indicates the actual output voltage of the UPS Input Frequency Indicates the actual Input frequency of the UPS Output Frequency Indicates the actual output frequency of the UPS Battery Voltage Indicates the actual o
8. ing Transfer Point Chart Repeat this procedure to ensure accurate results While the UPS is in Boost mode continue to slowly reduce the variac output until the UPS transfers to battery mode The UPS should transfer to battery when the voltage drops lo the level given in the following Transfer Point Chart Slowly increase the variac output until the UPS goes back to on line operation Continue to increase the variac output until the UPS transfers to Buck when the voltage increases to the level shown in the Transfer Point Chart Repeat this procedure to ensure accurate results While the UPS is in Buck mode continue to slowly increase the variac output until the UPS transfers to battery mode Check the output voltage for each step according to the Transfer Point Chart Load ii ea 134 141 140 147 130 136 135 143 117 123 122 129 113 120 118 125 88 94 101 108 106 113 194 207 202 216 211 226 INV Low recover 76 82 91 98 167 180 175 189 182 197 Low to INV 72 78 86 94 158 172 166 179 173 187 91 97 100 107 104 112 109 116 200 213 209 223 218 233 7 4 Startup On Battery Unplug the UPS from the variac and press the front panel On Off button for three seconds and the UPS should turn on 7 5 Communications Port Test Plug the UPS into the variac and turn on the UPS Connect the USB or 9 pin communication cable 721 9266 dd8 between the computer com port and UPS com port Start the UPSMON Monitor amp Manage
9. ioning via both buck step down voltage and boost step up voltage functions For example if your normal voltage is 120V and the voltage fluctuates up to 131V the buck function in your UPS will step it down so that your equipment receives approximately 120V If the voltage fluctuates down to 109V the boost function will step it up so that your equipment receives approximately 120V This provides your equipment with excellent voltage regulation with less possibility for the UPS to drain its internal battery User Replaceable Battery Design The battery is the most critical part in a UPS The average lifetime of a battery is between 3 and 5 years The special user replaceable battery design of this UPS provides significant savings and gives the UPS an almost unlimited life You can replace the battery very easily and without turning off your UPS or the equipment it is protecting Advanced Interface to Communicate with Computer Many UPS s provide only a basic power failure warning These models together with UPSMON also provide you with important operating information From your computer screen you can know input output voltage and current frequency battery voltage etc and analyze power problems If software is not part of your UPS package you can purchase it from your local dealer Schedule Shutdown amp Startup Using software you can locally or remotely control the shutdown and startup of equipment connected to the UPS A cus
10. ll of the following safety checks and servicing guidelines Safe and continuous operation of the UPS depends partially on the care taken by users Please observe the following precautions 1 Do not attempt to power the UPS from any receptacle except a 2 pole 3 wire grounded receptacle 2 Do not place the UPS near water or in environments of excessive humidity 3 Do not allow liquid or any foreign objects to get inside the UPS 4 Do not plug appliances such as hair dryers into the UPS receptacles 5 Do not place the UPS under direct sunshine or close to heat emitting sources 6 This UPS is intended for installation in a temperature controlled indoor area free of conductive contaminants 1 2 Important Safety Instructions This manual contains important safety instructions Keep this manual handy for reference For continued protection against the risk of fire replace with the same type rating of fuses While testing the UPS to determine the problem always use a DC power supply in place of the batter A battery can be present a risk of electrical shock burns from high short circuit current fire of explosion from vented cases Observe proper precautions When replacing batteries use the same number and the following type batteries sealed lead acid maintenance free Proper disposal of batteries is required Refer to your local codes for disposal requirements There are special components used in this UPS what are important for safety
11. myn These parts are identified by the international symbol on the schematic diagram and on the replacement parts list It is essential to replace these critical parts with manufactures specified parts to prevent shock fire or other hazards 2 General Information 2 1 Outline The Imperial Series are advanced line interactive simulated sine wave uninterruptible power systems UPS designed to prevent spikes surges sags transients and blackouts from reaching your sensitive equipment Your equipment may include such items as computers and computerized instruments to telecommunication systems When AC power is present the UPS filters and conditions the power continuously When AC power fails the unit employs its internal maintenance free battery to supply back up power without interruption TRAN SFER SWIC H ARTLNE gt ONDITD NER EMIRFI NOBE FLIER TO IO AD ie your equpm ent AC SOURCE DCAC NVERTER VOLTAGE TRAN SFO RM ER 2 2 Features Frequency Auto Sensing The Imperial series UPS can operate in either a 50 or 60 Hz environment When you plug the UPS into an AC outlet and turn it on it will automatically detect the incoming line frequency and configure itself to match that frequency Smart Buck and Boost Line Conditioning The voltage from your AC power source can fluctuate above and below the standard rating This microprocessor controlled UPS provides line condit
12. r programs and verify the information is displayed correctly Model Voltage Frequency Configuration Input Output etc UPSMON will also initiate automatic graceful shutdowns during extended power failures If UPSMON and a communication cable are not included in your UPS package you can purchase it from your local dealer 15 8 Function Block Diagram 8 1 Main structure 8 2 Control circuit I P V Detector UP F Detector i Relay Driver MCU 68HC805JL3 A aa ee at V Detector ENT Load Current Buzzer Controller Detector LED controller CHARGER Controller O P V Detector PCB POWER 9 Troubleshooting Problem Possible Cause Action to take UPS can t turn on LED not light Switch on the display board fail Replace the display PCB Per Battery voltage less than 9V Recharge the ups at least 8 hours or change the battery PCB failure Replace the PCB UPS can t turn on Battery failure Replace the battery LED light PCB failure Replace the PCB Transformer failure Replace the transformer UPS always at battery mode AC Fuse or breaker open Replace the AC fuse in inlet or reset the circuit breaker PCB Failure Replace PCB Transformer failure Replace the transformer Back up time too Battery not fully charged Recharge the UPS at least 8 hours short Battery too old Replace Battery call for serv
13. tomized schedule can be developed to meet your specific requirements Data Line Surge Protection The built in data line surge suppression on the rear panel completes your system protection It provides an easy way to protect a network RJ45 or modem single line phone connection from hazardous spikes 3 SPECIFICATIONS 3 1 Electrical Specifications Battery output rating Product Name Frequency Rated Voltage Capacity Hz v W 100 110 115 120V IMP IMD 425AP 50 60 255W 220 230 240V 100 110 115 120V IMP IMD 525AP 50 60 315W 220 230 240V 100 110 115 120V IMP IMD 625AP 50 60 220 230 240V 100 110 115 120V IMP IMD 825AP 50 60 495W 220 230 240V 100 110 115 120V IMP IMD 1000AP 50 60 550W 220 230 240V 100 110 115 120V IMP IMD 1025AP 50 60 615W 220 230 240V 100 110 115 120V IMP IMD 1200AP 50 60 720W 220 230 240V 100 110 115 120V IMP IMD 1500AP 50 60 900W 220 230 240V 100 110 115 120V IMP IMD 2000AP 50 60 1200W 220 230 240V Input Voltage Range Input Output Frequency Input AC mode 45Hz 55 Hz 55 Hz 65 Hz Output Inverter mode 50 Hz 60 Hz 1 Hz Wave Form Transfer time Power Failure AC gt Inverter 4 ms typical Spike Surge protection Audible Alarm Battery and Charger Battery type Maintenance free sealed lead acid Recharge time 6 to 8 hours typical from total discharge The UPS may be used immediately after discharge but will provide shorter backup t
14. utput DC voltage of the UPS battery Load Percent Indicates the percentage of UPS Voltage Ampere VA capacity being utilized by your equipment The Imperial Series also supports software which relies on basic contact closure signals such as the built in UPS Service in Windows NT you will need to purchase a special cable for this type of application The major functions of this type of software normally include the following To broadcast a warning when power fails To close any open files before the battery rescues are exhausted To turn off the UPS Note You can connect your computer to your UPS without also connecting to the communication port In this case your UPS warns you of a power failure by beeping but you have to manually shut down your UPS and computer Dsub9 Pin assignments RS 232 Signal Contact Closure Signal Tx UPS gt Computer Rd Computer gt UPS Shut Down 12V Computer gt UPS GND GND AC failure 12V Computer gt UPS Tx Short with pin2 5 Battery Replace Procedure Changing the batteries in your UPS is a safe and easy procedure Since the battery is not isolated from the AC input you must power off your UPS and unplug the power cord before proceeding the following procedure 5 1 Replacement Procedure for IMP IMD 425 1000AP Optional function 1 E 27 IS A Remove the two screws on the battery cover Pull and open the cover as the following illustrations
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