UPS R3000 XR Maintenance and Service Guide First Edition (September 2000) Part Number 221891-001 Spare Part Number 223932-001 Compaq Computer Corporation
Notice © 2000 Compaq Computer Corporation COMPAQ, the Compaq logo, Compaq Insight Manager, and SmartStart Registered in U.S. Patent and Trademark Office. All other product names mentioned herein may be trademarks of their respective companies. Compaq shall not be liable for technical or editorial errors or omissions contained herein. The information in this document is subject to change without notice. THE INFORMATION IN THIS PUBLICATION IS PROVIDED “AS IS” WITHOUT WARRANTY OF ANY KIND.
Contents About This Guide Symbols in Text .......................................................................................................... v Compaq Technician Notes .........................................................................................vi Where to Go for Additional Help ...............................................................................vi Telephone Numbers ...........................................................................................
iv Compaq UPS R3000 XR Maintenance and Service Guide Removal and Replacement Procedures continued Replacing the UPS Battery Pack ..............................................................................3-8 Disposing of Used Batteries ............................................................................3-10 Replacing the Electronics Module..........................................................................3-11 Replacing an Option or Communication Board ...................................
About This Guide This Maintenance and Service Guide is a troubleshooting guide that can be used for reference when servicing Compaq R3000 XR series of Uninterruptible Power Systems (UPSs). WARNING: To reduce the risk of personal injury from electrical shock and hazardous energy levels, only authorized service technicians should attempt to repair this equipment. Improper repairs could create conditions that are hazardous.
vi Compaq UPS R3000 XR Maintenance and Service Guide Compaq Technician Notes WARNING: Only authorized technicians trained by Compaq should attempt to repair this equipment. All troubleshooting and repair procedures are detailed to allow only subassembly/module level repair. Because of the complexity of the individual boards and subassemblies, no one should attempt to make repairs at the component level or to make modifications to any printed wiring board. Improper repairs can create a safety hazard.
About This Guide Telephone Numbers For the name of your nearest Compaq Authorized Reseller: ■ In the United States, call 1-800-345-1518 ■ In Canada, call 1-800-263-5868 For Compaq technical support: ■ In the United States and Canada, call 1-800-386-2172 ■ For Compaq technical support phone numbers outside the United States and Canada, visit the Compaq website at http://www.compaq.
Chapter 1 Before You Begin Safety and Product Information WARNING: The Compaq Uninterruptible Power System (UPS) R3000 XR contains hazardous voltage levels and energy circuits. There is a risk of personal injury from electrical shock and hazardous energy levels. Persons performing installation or service procedures must be Trained Service Technicians, knowledgeable about the procedures, precautions, and hazards associated with AC Power Products.
1-2 Compaq UPS R3000 XR Maintenance and Service Guide Technician Notes WARNING: To reduce the risk of personal injury from electrical shock and hazardous energy levels: Only authorized technicians trained by Compaq should attempt to repair this equipment. The installation of options and routine maintenance and service of this product must be performed by Trained Service Technicians who are knowledgeable about the procedures, precautions, and hazards associated with AC Power Products.
Before You Begin Communication Ports CAUTION: To reduce the risk of damage to the equipment, only use the DE9 UPS/Computer Interface cable supplied by Compaq (part number 201092-00X) to connect the communications port to the host computer. Do not use standard RS-232 cables. This UPS/Computer Interface Cable carries power and is specifically designed for UPS communications. Extended Runtime Modules and Batteries Observe these precautions when handling or connecting batteries and Extended Runtime Modules.
1-4 Compaq UPS R3000 XR Maintenance and Service Guide THIS PRODUCT CONTAINS A NONSPILLABLE BATTERY Next Recharge Date: 14-DEC-01 Please refer to Maintenance Section of Owner's Manual enclosed inside Figure 1-1. Checking the battery recharge date label IMPORTANT: Do not use the batteries if the recharge date has passed (Figure 1-1). If the date on the Battery Recharge Date Label has passed without the batteries being recharged, contact an Authorized Compaq Service Representative.
Chapter 2 Illustrated Parts List This chapter provides the illustrated parts breakdown and a spare parts list for the Compaq UPS R3000 XR. See Table 2-1 for the names of referenced spare parts.
2-2 Compaq UPS R3000 XR Maintenance and Service Guide Exploded View 6 5 2 1 3 4 Figure 2-1.
Illustrated Parts List Table 2-1 UPS Spares Parts List Ref Description Spares Part # 1 UPS Chassis ** 2 Front Bezel 204507-001 3 Electronics Module (low voltage) 204506-001 Electronics Module (high voltage) 216097-001* 4 UPS Battery Pack 204503-001 5 Battery Bracket ** 6 X-Slot Serial Board 204514-001 7 UPS L530-NA 222383-001* UPS L530-JP 222383-291* UPS 620H-NA 222384-001* UPS DTC-INTL 222385-002* UPS 309-EURO 222386-021* 8 Cord Retention Clip 204505-001* 9 Front and
2-4 Compaq UPS R3000 XR Maintenance and Service Guide 15 15 16 17 14 14 Figure 2-2.
Illustrated Parts List Table 2-2 Extended Runtime Module Spares Parts List Ref Description Spares Part # r Battery Packs 204503-001 t Battery Brackets ** y Front Bezel 204511-001 u Chassis for Extended Runtime Module ** i Extended Runtime Module 204510-001* o Front and Rear Mounting Brackets 204504-001* p Mounting Rail 322578-002* ERM to UPS Cable 216092-001* Cables a * Not shown ** No spare available 2-5
Chapter 3 Removal and Replacement Procedures This chapter provides guidance for removing and replacing spare parts in the Compaq UPS R3000 XR. Before You Begin WARNING: The Compaq UPS R3000 XR is a high-energy product. There is a risk of personal injury from electrical shock and hazardous energy levels. Persons performing installation or service procedures must be Trained Service Technicians, knowledgeable about the procedures, precautions, and hazards associated with high-energy AC Power Products.
3-2 Compaq UPS R3000 XR Maintenance and Service Guide Tools Required To service a UPS R3000 XR, you need one or more of the following: ■ #2 Phillips screwdriver ■ ¼-inch driver ■ Compaq Power Management Utility (from the Compaq SmartStart Software CD) ■ Voltmeter to verify the nominal voltages to ensure proper configuration TM and Support Identifying Components Use the following illustrations to locate and identify the components of the UPS R3000 XR. Front Panel 1 2 3 Figure 3-1.
Removal and Replacement Procedures Front Panel Controls and LED Display The UPS front panel contains four control buttons and ten LEDs that create the interface for setup, configuration, load control, and status monitoring. 1 2 3 4 5 15 6 7 8 9 14 10 13 12 11 Figure 3-2.
3-4 Compaq UPS R3000 XR Maintenance and Service Guide Table 3-2 Front Panel Controls and LED Display continued Item Name Function 8 51% to 75% load Indicates that the UPS is approximately 51% to 75% of the maximum power available when green 9 26% to 50% load Indicates that the UPS is approximately 26% to 50% of the maximum power available when green - 0% to 25% load Indicates that the UPS is approximately 0% to 25% of the maximum power available when green q Configure mode on LED Indicates t
Removal and Replacement Procedures 1 2 11 3 4 5 10 6 9 Figure 3-4.
3-6 Compaq UPS R3000 XR Maintenance and Service Guide Modes of Operation The UPS has four modes of operation: Standby, Operate, Configure, and Auto-Bypass. Standby Mode Place the UPS in Standby mode by pressing the STANDBY button on the front panel. During Standby mode: ■ No power is available at the UPS output receptacles. ■ The UPS charges the batteries as necessary. Operate Mode Place the UPS in Operate mode by pressing the ON button on the front panel.
Removal and Replacement Procedures Powering Down the UPS To completely remove power from the UPS: 1. Power down all equipment being supported by the UPS (attached loads). 2. Place the UPS in Standby mode by pressing the STANDBY button on the front panel. 3. Disconnect the UPS from utility power. 4. Wait at least 60 seconds for the UPS internal circuitry to discharge.
3-8 Compaq UPS R3000 XR Maintenance and Service Guide Replacing the UPS Battery Pack When the Bad Battery/Low Battery LED 1 turns red, the battery pack will need to be replaced within 30 to 60 days. 1 100% 1 25% Figure 3-5. Bad Battery/Low Battery LED Verify that battery replacement is required by initiating a UPS self-test (press the TEST/ALARM RESET button). If the red LED is still flashing after the test, replace the batteries.
Removal and Replacement Procedures To replace the battery pack: 1. Obtain access to the battery pack by pulling on both ends of the front bezel 1 to remove it. 2. Locate the two screws 2 on the metal battery bracket 3. 3 1 2 Figure 3-6. Removing the front bezel 3. Remove the two screws 1 and lift off the metal battery bracket 2. 1 2 1 Figure 3-7.
3-10 Compaq UPS R3000 XR Maintenance and Service Guide 4. Pull out the battery pack. Set aside the used battery pack for proper disposal. See “Disposing of Used Batteries,” in this chapter. Figure 3-8. Removing the battery pack WARNING: The UPS R3000 XR battery pack weighs 42 lb (19 kg). Prepare the area and observe all materials handling procedures for removing the battery pack. 5. Slide the new battery pack into the chassis. 6. Replace the metal battery bracket and secure the two screws. 7.
Removal and Replacement Procedures Replacing the Electronics Module NOTE: The electronics module can be replaced (hot-swapped) without powering off the UPS. To replace the electronics module with the UPS power off, follow the procedure in “Powering Down the UPS,” in this chapter. CAUTION: To avoid dropping the load while hot-swapping the electronics module, hold down the TEST/ALARM RESET button while sliding the new electronics module into the chassis.
3-12 Compaq UPS R3000 XR Maintenance and Service Guide 2. Obtain access to the electronics module by pulling on both ends of the front bezel 1 to remove it. 3. Locate the two screws 2 on the electronics module 3. 2 3 1 Figure 3-10. Removing the front bezel 4. Remove the two screws 1 and pull out the electronics module 2. 2 1 Figure 3-11.
Removal and Replacement Procedures CAUTION: To avoid dropping the load while hot-swapping the electronics module, hold down the TEST/ALARM RESET button while sliding the new electronics module into the chassis. 3. Hold down the TEST/ALARM RESET button 1 on the front panel of the new electronics module and slide the electronics module into the chassis 2.
3-14 Compaq UPS R3000 XR Maintenance and Service Guide Replacing an Option or Communication Board NOTE: The option or communication board can be replaced (hot-swapped) without powering off the UPS. To replace the option or communication board with the UPS power off, follow the procedure in “Powering Down the UPS,” in this chapter. To remove an option or communication board: 1. Disconnect the external cable from the board. Figure 3-13. Disconnecting option board cables 2.
Removal and Replacement Procedures 3. Remove the screws securing the board to the UPS. 4. Pull the board out of the unit. Figure 3-14. Removing an option board 5. Slide the new board into the UPS. 6. Tighten the screws that secure the board to the UPS. 7. If the UPS is powered down, proceed to step 8. If hot-swapping the board, replace the electronics module. See steps 5 through 7 in “Replacing the Electronics Module.
3-16 Compaq UPS R3000 XR Maintenance and Service Guide Replacing the UPS Unit To replace the UPS: 1. Power down the UPS. Follow the procedure in “Powering Down the UPS,” in this chapter. 2. Turn all battery circuit breakers on the ERMs (one circuit breaker each) to the Off position. Figure 3-15. Switching the circuit breaker to the Off position 3. Unplug the UPS power cable. 4. Unplug connected devices and remove the retention clips that secure device cables to the UPS. 5.
Removal and Replacement Procedures 6. Remove the UPS front bezel. 7. Remove the screws that secure the UPS to the front of the rack. 8. Remove the UPS from the rack. 9. To replace the UPS, place the new unit in the rack and reverse steps 1 through 7. Extended Runtime Modules Extended Runtime Modules (ERMs) are supported by the Compaq UPS R3000 XR. The UPS rear panel provides a power receptacle where the module is attached.
3-18 Compaq UPS R3000 XR Maintenance and Service Guide 2. Obtain access to the battery packs by pulling on both ends of the ERM front bezel to remove it. Figure 3-18. Removing the ERM front bezel 3. Remove two screws 1 from each metal battery bracket and lift off the battery brackets 2. 1 2 1 Figure 3-19.
Removal and Replacement Procedures 4. Pull out the battery packs. Set aside the used battery packs for proper disposal. See “Disposing of Used Batteries,” in this chapter. Figure 3-20. Removing the battery packs 5. To replace the battery packs, reverse steps 1 through 4. NOTE: The right battery pack is inserted upside down. NOTE: To increase the useful life of the replacement battery, replace all batteries in the UPS and connected ERMs at the same time.
3-20 Compaq UPS R3000 XR Maintenance and Service Guide Replacing an ERM To replace an ERM: 1. Turn all battery circuit breakers on all attached ERMs (one circuit breaker each) to the Off position. 2. Unplug the ERM from the back of the UPS. Figure 3-21. Unplugging the Extended Runtime Module 4. Remove the front bezel from the ERM you want to replace. 5. Remove the screws that secure the ERM to the front of the rack. 6. Remove the ERM from the rack. 7.
Chapter 4 Troubleshooting This chapter provides information on the following topics: ■ Troubleshooting problems that occur during UPS start ■ Troubleshooting problems that occur after UPS start Troubleshooting During Start If problems occur when starting the Compaq UPS R3000 XR models, select the appropriate symptom for possible causes and suggested actions.
4-2 Compaq UPS R3000 XR Maintenance and Service Guide Table 4-1 Troubleshooting Guide (UPS Start) continued Symptom Possible Cause Suggested Action Bad Battery/Low Battery LED is flashing red Battery voltage is low because the UPS has been out-of-service for a long period. Allow the UPS to charge the batteries for 24 hours. Initiate a self-test. If the LED does not turn off, replace the batteries. The battery test failed. Allow the UPS to charge the batteries for 24 hours. Initiate a self-test.
Troubleshooting Table 4-2 Troubleshooting Guide (After Start) continued Symptom Possible Cause Suggested Action Utility LED and On Battery LED are flashing red The utility frequency is out of tolerance. Contact a qualified electrician to ensure that utility power is suitable for the UPS. Utility LED is flashing red The utility input voltage is outside the ±12% nominal range. If this happens repeatedly, check the input voltage and reconfigure the unit.
4-4 Compaq UPS R3000 XR Maintenance and Service Guide Table 4-2 Troubleshooting Guide (After Start) continued Symptom Possible Cause Suggested Action Utility LED is flashing red and the unit is in Auto-Bypass mode A potential for overload exists. Reduce the load. An over-temperature condition may exist. Ensure that there is no blockage of airflow to the front bezel and rear panel. The electronics module may have failed. Replace the electronics module.
Chapter 5 Specifications This chapter provides specifications that apply to all Compaq UPS R3000 XR models: ! Physical specifications ! Input specifications ! Output specifications ! Overcurrent protection ! Battery specifications ! Battery runtime ! Environmental specifications Physical Specifications Table 5-1 Physical Characteristics Feature Dimensions Weight U.S. Metric Width 19.0 in 483 mm Height 3.5 in 89 mm Depth 24.
5-2 Compaq UPS R3000 XR Maintenance and Service Guide Input Specifications Table 5-2 Input Specifications UPS Model Utility Voltage Default Settings Available Settings Power Cord Supplied Frequency Nominal Voltage Utility Voltage (VAC) (Hz) (VAC) R3000 XR-NA 50/60 120 100, 110, 120, 127 Non-detachable power cord with NEMA L5-30 plug R3000j XR-JPN 50/60 100 100, 110, 120, 127 Non-detachable power cord with NEMA L5-30 plug R3000h XR-NA 50/60 208 200, 220, 230, 240 Non-detachable power cord w
Specifications Output Specifications Table 5-3 Output Specifications UPS Model R3000 XR-NA R3000j XR-JPN R3000h XR-NA R3000h XR-JPN R3000e XR-INT R3000i XR-EURO; R3000i XR-SCHUKO; R3000i XR-SA Effective VA Nominal Power Rating (W) Load Segment # Output Receptacles 2880 2700 1 2 x 5-15R 1 x L5-30R 2 2 x 5-15R 3 2 x 5-15R 1 2 x 5-15R 1 x L5-30R 2 2 x 5-15R 3 2 x 5-15R 1 3 x IEC-320, C13 1 x L6-20R 2 3 x IEC-320, C13 3 3 x IEC-320, C13 1 3 x IEC-320, C13 1 x L6-20R 2 3 x IEC-3
5-4 Compaq UPS R3000 XR Maintenance and Service Guide Table 5-4 Output Specifications Characteristics Configuration Setting (VAC) Available Nominal Output Voltage (VAC) Voltage 100 100 110 110 120 120 127 127 200 200 208 208 230 230 240 240 Source of Power Regulation Utility power (normal range) -10% to +6% of nominal output voltage rating (within the guidelines of the Computer Business Equipment Manufacturers Association) Battery power ±5% of nominal output voltage rating Output
Specifications Overcurrent Protection Table 5-5 Overcurrent Protection Per Model UPS Model Input Protection R3000 XR-NA Circuit protector for each load segment R3000j XR-JPN Circuit protector for each load segment R3000h XR-NA Circuit protector for each load segment R3000h XR-JPN Circuit protector for each load segment R3000e XR-INT Circuit protector for each load segment R3000i XR-EURO Circuit protector for each load segment R3000i XR-SCHUKO Circuit protector for each load segment R3000i X
5-6 Compaq UPS R3000 XR Maintenance and Service Guide Environmental Specifications Table 5-8 Environmental Specifications Feature Specification Operating temperature 10 C to 40 C (50 F to 104 F) o o o o o o UL-tested at 25 C (77 F) Relative humidity 0% to 95%; non-condensing Operating altitude Up to 2,000 m (6,562 ft) above sea level* Audible noise Less than 45 dBA Transit temperature -25 C to +55 C (-13 F to 131 F) Transit altitude 15,000 m (49,212 ft) above sea level o o o o *Due
Index A adapters, removing 3-14 alarms general 3-3 responding to 4-2 silencing 3-4 troubleshooting 4-1 altitude, operating 5-6 audible noise specifications 5-6 Auto-Bypass mode 3-6 B backup time 5-5 Bad Battery/Low Battery LED 3-3, 4-4 batteries accessing 3-8 charging 5-5 disposing of 3-10 estimated backup time 5-5 part numbers 2-3, 2-5 precautions 1-3 replacing 3-8, 3-17 specifications 5-5 storing 1-4 testing 3-8 type supported 5-5 weight warning 1-2 when to change 3-8 battery compartment 3-2 bezels, fro
2 Compaq UPS R3000 XR Maintenance and Service Guide emergency shutdown procedures 3-7 environmental specifications 5-6 ERM batteries part number 2-5 replacing 3-17 description 3-17 exploded view 2-4 front bezel part number 2-5 removing 3-18 part number 2-5 replacing 3-20 unplugging 3-16 warnings 1-2, 1-3 exploded view ERM 2-4 UPS 2-2 Extended Runtime Module See ERM F frequency, input 5-2 front bezels part numbers 2-3, 2-5 removing 3-9, 3-18 front panel buttons 3-2, 3-3 components 3-2 LEDs 3-2, 3-3 G gen
Index removing front bezels 3-9, 3-18 UPS power 3-7 replacing adapters 3-14 batteries 3-8, 3-17 electronics modules 3-11 ERM 3-20 option boards 3-14 UPS 3-16 REPO port 3-5, 3-7 retention clip, cord 2-3, 3-5 S safety 1-1, 3-1 self-test, initiating 3-4, 3-8 servicable parts list 3-1 silencing alarms 3-4 Site Wiring Fault Indicator 3-3 SmartStart and Support Software CD 3-2 spare parts list 2-3, 2-5 specifications battery 5-5 environmental 5-6 input 5-2 overcurrent protection 5-5 overview 5-1 UPS audible noi
