Okinawa Service Report.pdf

POC: Jeff Stinson Facility Operations Specialist/Data Center Facility Manager MCIPAC G-6 Camp S.D. Butler Okinawa, Japan JPN Cellular: 080-8592-9517GFE Mobile: (724) 496-2301 Report Reviewed By: Bryant Colino, P.E.

ESM Engineers

Preventive Maintenance & Service Report

Liebert 750 KVA UPS:

(2) UDA63750A36AD50

ESM SERVICE REPORT

EXECUTIVE SUMMARY

ESM Engineers was selected as the service contractor to perform emergency repairs of two discontinued Liebert AP600 750KVA UPS systems. Initial inspection found UPS A online with a fan/failure alarm and UPS B offline, in bypass, due to a Hardware Shutdown fault and associated alarms. Prior to service, ESM reviewed the history files of both UPS systems’ logs which date back to August 2017.

UPS B – ESM identified a bad power supply with +24 VDC signal out of tolerance, control signals which were out of calibration, and the output filter amperage readings were unbalanced with a delta of 90 amps. 60% of the AC capacitors were replaced and all critical control power voltages we calibrated to manufacturer’s specifications. Upon completion of service, ESM identified a noisy failing blower fan on UPS B due to bearings; to avoid loud rubbing, and inevitable equipment failure, ESM bypassed the blower fan. This was possible due to the minimal load on UPS B and proper cooling in the space.

UPS A – ESM identified a blown inverter fan and blown fuse on the fuse monitor board, out of calibration control signals. The output filter amperage readings were unbalanced with a delta of 60 amps due to open AC capacitors. Several DC capacitors were leaking and contributed to unbalanced amperage readings. A full DC cap changeout was performed to improve equipment reliability and avoid future fault transfers to bypass.

60% of the AC Capacitors in the output filter assembly were replaced, and the DC control power voltages were calibrated to manufacturer’s specifications. Upon completion of service, UPS A was left online with no active alarms.

Both systems have (2) cabinets of (40) Deka Unigy 31HR5000 batteries. The system was designed with (5) battery cabinets per UPS. ESM has been notified the batteries have been ordered and will need to be installed. It is imperative that the new batteries be installed per manufacturer recommendations for equipment to perform at optimum levels; ESM would be happy to assist you with the installation.

ESM organized and itemized the existing parts found onsite (Attachment 1) and provided a recommended parts list as requested (Attachment 2). It is our mission to maintain 100% equipment reliability with proactive refurbishments and proper preventative maintenance.

As a professional courtesy we have included instruction to transfer the UPS off internal bypass in the unlikely event of a transfer to bypass. If you do not feel comfortable operating the equipment, please feel free to give us a call. Our goal is to be the firm you come to for all UPS needs.

Preventative Maintenance Values

Date: 10/24/2019

Camp Foster Kitamae, Building 480, Data Center

Chatan Cho Okinawa, JP 904-0117

UPS A

INPUT

Phase L-L Volts L-N Volts Amps

A 477 275 133 B 477 275 121 C 479 277 130

BYPASS

Phase L-L Volts L-N Volts Amps

A 477 275 0 B 476 275 0 C 479 277 0

OUTPUT

Phase L-L Volts L-N Volts Amps

A 483 279 79 B 482 278 81 C 482 278 85

LOAD

Phase KW KVA %

A 18 22 8.81% B 18 23 9.02% C 19 24 9.46%

BATTERY

Voltage Charge Runtime

540 98% N/A

NOTES:

UPS A was left online – All parts were replaced, no active alarms present.

12.9

13.1

13.2

13.3

13.4

13.5

13.6

13.7

13.8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

UPS A Battery Cabinet # 1

Camp Foster Kitamae, Building 480, Data Center

Chatan Cho Okinawa, JP 904-0117

Battery Model Number: DEKA 31HR5000 Date Code: 09/2017 DC BUS Voltage: 540 VDC

13.1

13.2

13.3

13.4

13.5

13.6

13.7

13.8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

UPS A Battery Cabinet # 2

Camp Foster Kitamae, Building 480, Data Center

Battery Model Number: DEKA 31HR5000 Date Code: 09/2017 DC BUS Voltage: 540 VDC

Preventative Maintenance Values Date: 10/24/2019

Camp Foster Kitamae, Building 480, Data Center

Chatan Cho Okinawa, JP 904-0117

UPS B

INPUT

Phase L-L Volts L-N Volts Amps

A 478 276 116 B 475 274 111 C 478 276 112

BYPASS

Phase L-L Volts L-N Volts Amps

A 478 276 0 B 476 275 0 C 479 277 0

OUTPUT

Phase L-L Volts L-N Volts Amps

A 482 279 77 B 480 277 73 C 483 279 82

LOAD

Phase KW KVA %

A 17 21 8.57% B 16 20 8.09% C 18 23 9.15%

BATTERY

Voltage Charge Runtime

541 98% N/A

NOTES:

UPS B was left online with a blower fan bypassed. No further issues to report.

13.25

13.3

13.35

13.4

13.45

13.5

13.55

13.6

13.65

13.7

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

UPS B Battery Cabinet # 1

Camp Foster Kitamae, Building 480, Data Center

Battery Model Number: DEKA 31HR5000 Date Code: 9/2017 DC BUS Voltage: 540 VDC

13.2

13.3

13.4

13.5

13.6

13.7

13.8

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

UPS B Battery Cabinet # 2

Camp Foster Kitamae, Building 480, Data Center

Battery Model Number: DEKA 31HR5000 Date Code: 9/2017 DC BUS Voltage: 540 VDC

ATTACHMENT 1

ON-HAND PARTS LIST

DESCRIPTION PART NUMBER QNTY DETAILS

POWER SUPPLY 02-790843-00; P/L 6, REV 3 USED - +24VDC out of tolerance - found @20.66

02-790843-00 USED - 4/19 (original Power Supply)

DC REGULATOR BOARD 02-790879-00; P/L 8, REV 1 --

02-790821-10; P/L 11, REV 3 DATE 11/2001

INTERFACE ASSY 02-790831-69; P/L 2, REV 2 DATE 07/2002

03-790831-57; P/L 0, REV 0 DATE 12/2002

IGBT GATE DRIVER 02-791970-07; P/L 6, REV 10 DATE 09/2003

02-791970-07; P/L 1, REV 7 DATE 05/1999

FAN FUSE MONITOR ASSEMBLY 02-791946-02; P/L 4, REV 3 DATE 06/2001

02-791946-03; P/L 4, REV 3 DATE 09/2003

LOGIC BOARD 02-790811-69; P/L 4, REV 6 1 DATE 09/2003

GATE DRIVE STATIC SWITCH 02-790802-00; P/L 2, REV C 1 DATE 08/2003

V&I CONDITIONER 02-790889-03; P/L 1. REV 4 1 DATE 09/2003

FUSE MONITOR BOARD 02-790875-15; P/L 2, REV 1 1 DATE 09/2003

TRANSFER RELAY 02-790858-00; P/L 1, REV 2 1 DATE 10/2003

DC SENSOR ASSEMBLY 02-790886-00; P/L 5, REV 2 1 DATE 09/2003

DC FUSE MONITOR BOARD 02-790875-40; P/L 3, REV 2 1 DATE 10/2003

PWA RLI 02-790868-00; P/L 2, REV A 1 DATE 09/2003

IFM 12-749043-10 USED

12-749043-16 USED

SNUBBER BOARD 02-779857-23; P/L 2, REV 4 1 DATE 07/2003

SUBER RECTIFIER 02-790743-76; P/L 4, REV 3 1 DATE 10/2003

INVERTER FANS 12-796524-01L 3 NEW

FAN AXIAL 12-714150-00 8 NEW

AC CAPACITORS 12-817416-00 40 NEW

DC TRAP ASSEMBLIES 02-796340-50 3 NEW

630A-700V 170M4416 3 TESTED

500A-700V 170M3672 2 TESTED

315A-700V 170M1472 13 TESTED

60A-500V FWH-600A 5 TESTED

12-749351-05 1 NEW

12-79351-05 1 NEW

2A 12749437-00 1 NEW

ON-HAND FUSES

ON-HAND PARTS

ATTACHMENT 2

RECOMMENDED PARTS LIST

RECOMMENDED PARTS

DESCRIPTION PART NUMBER QNTY DETAILS

BLOWER FANS 12-776825-20 3 (1) WILL REPLACE BAD FAN FOUND IN UPS B

INVERTER FANS 12-796524-01L 8 RECOMMENDED TO HAVE ON-HAND

AIR-FILTER 11.8 X 26.3 X 1 6 BOX OF AIR FILTERS

Maintenance Bypass Load Transfers

Upon future transfers to bypass due to a fault in the system it is recommended to manually transfer the load between UPS internal bypass and Maintenance Bypass. Do not transfer the load between Maintenance Bypass and the UPS system (module inverters) output if no UPS has no active faults.

If the load is on internal UPS Bypass, transferring to maintenance bypass:

a) If the maintenance bypass cabinet or switchboard has an optional 2-key interlock system,

b) press the button on the maintenance bypass cabinet to remove the key from the solenoid.

c) If using a key interlock system, insert the key into the lock for the Maintenance Bypass

d) Breaker (MBB) to enable it to be closed.

e) Close the Maintenance Bypass Breaker (MBB).

f) Verify closure of the MBB.

a. Verify load has been reduced to ½.

g) Open the Maintenance Isolation Breaker (MIB). The UPS

h) system is now isolated from the critical load and the load is now on Maintenance

i) Bypass.

j) If using a key interlock system, remove the key from the lock for the Maintenance Isolation

k) Breaker (MIB) to lock it open.

l) If the maintenance bypass cabinet or switchboard has an optional 2-key interlock system,

m) replace the key into the solenoid.

n) If UPS bypass shutdown is required, open the Bypass Input Breaker (BIB).

If the load is on Maintenance Bypass, returning to UPS bypass:

a) Close the Bypass Input Breaker (BIB) or verify BIB is closed. Note that UPS System Bypass

b) circuit breaker (motorized) must also be closed. Refer to 3.4.1 - SCC Start-Up Procedure.

c) If the maintenance bypass cabinet or switchboard has an optional 2-key interlock system,

d) press the button on the maintenance bypass cabinet to remove the key from the solenoid.

e) If using a key interlock system, insert the key into the lock for the Maintenance Isolation

f) Breaker (MIB) to enable it to be closed.

g) Close the Maintenance Isolation Breaker (MIB).

h) Verify closure of the MIB.

a. Verify load is on the system prior to proceeding to next step.

i) Then open the Maintenance Bypass Breaker (MBB). Load is now

j) on UPS Internal Bypass.

a. Verify load has doubled by opening the MBB.

k) If using a key interlock system, remove the key from the lock for the Maintenance Bypass

l) Breaker (MBB) to lock it open.

m) If the maintenance bypass cabinet or switchboard has an optional 2-key interlock system,

n) replace the key into the solenoid.

! CAUTION

Make sure you understand the proper sequence before operating any circuit breaker.

Operating a Maintenance Bypass circuit breaker out of sequence could cut off power to the critical load.

! CAUTION

The UPS system (SCC) must be on internal bypass before performing the following procedures and operating MIB or MBB or damage to the UPS may occur and the critical load may be lost.

NOTE

If the maintenance bypass cabinet or switchboard has any other type of custom interlock, follow the specific instructions for that interlock system to remove the key.