MAINTENANCE

of
UPS SYSTEM, Type: PEW / PDW

TABLE OF CONTENTS:
1. Maintenance of the UPS System
1.1 Monthly checks
1.2 Semiannual checks
1.3 Annual checks

2. Maintenance of the Battery

2.1 Monthly checks
2.2 Annual checks
2.3 Battery capacity test

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 MAINTENANCE
Due to the critical intended purpose and to ensure the safe and reliable operation of the equipment,
inspection and preventive maintenance are essential.

To perform a proper maintenance on GUTOR UPS systems it is adivisable to have participated on a

GUTOR training course. GUTOR also provides global service contracts to guarantuee a maximum
availability of the system therefore please refer to the description 7RA9092GB «Servce-
Training-Contact Addresses».

For the checks listed below a brief report/checklist shall be issued where all findings are
documented. These records must be available in case of a warranty claim.

Please read the «Safety regulations» 7RA9020GB thoroughly before

performing any manipulations on the installation.

1. MAINTENANCE OF THE UPS SYSTEM

1.1 MONTHLY CHECKS
The following checks should be made monthly:

1. Check the inverter output voltage by means of a measuring instrument.

2. Check the DC voltage by means of a measuring instrument.

3. Check the inverter output current by means of a measuring instrument.

4. Persisting alarm indications or incorrect operating statuses must be recorded. Subsequently,

reset the alarms by pressing the button and make sure that the UPS operates

correctly and no alarm of the «Alarm indications» is any longer pending.

5. Press the button S3 «LAMP TEST». All operating status and alarm indications must
illuminate as long as the button is pressed.

1.2 SEMIANNUAL CHECKS

The following checks should be made semi-annually:

1. Monthly checks as above.

2. Read out the event log and analyse it. In case of irregularities which can not be explained,
kindly contact the GUTOR support.

3. Only for systems with filter mats: Check whether the filter mats are dirty.

4. Job preparations for annual maintenance depending on the findings.

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1.3 ANNUAL CHECKS
1. Monthly & semiannual checks as above.

2. Check tightness of all connections. Check the screws and nuts in the device (in volt-free
condition — system isolated).

3. In case of strong contamination clean the system from dust.

Switch off the entire system according to the description

7RA9118GB «Starting — Switching over — Stopping» (7RA9119GB for
redundant systems).

Don’t use any liquid for cleaning — only vacuum cleaner !

4. Only for systems with filter mats:

Check whether the filter mats are dirty. In the case of strong contamination the filter mats
must be replaced. (A strong contamination results in a reduction of velocity of air, necessary
for the ventilation of the system, and thus sufficient cooling is no longer ensured).

5. Only for systems with bypass stabilizer:

Check in accordance with the maintenance instructions of description 7RA9069GB.

6. Recommendations of OEM (Original Equipment Manufacturer) shall be followed regarding

annual maintenance.

7. Functional check of the entire system shall be performed.

2. MAINTENANCE OF THE BATTERY

During operation the battery capacity and the life-span can be influenced by several processes as:
♦ Corrosion
♦ Grid growth
♦ Ripple effects
♦ Sulphation
♦ Passivation
♦ Short circuit
♦ none or excessive cycling
♦ Deep discharge
♦ Wrong battery room temperature
♦ Operation with low electrolyte
♦ Gradual changes in active material
♦ Normal aging
This only to name a few influencing factors.

Detailed corresponding data for the maintenance of the battery see the information given by
the battery manufacturer in «Battery documentation».

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 MAINTENANCE
2.1 MONTHLY CHECKS
The following checks should be performed at the same time as the monthly checks of the
UPS system:

1. Check the battery voltage at the battery.

2. Check all wet battery cells on the liquid level and if necessary refill ( see «Battery
documentation»).

3. Check the voltage of each individual cell (in the case of wet battery cells additionally the
specific gravity) of the «pilot cells» ( see «Battery documentation»).

2.2 ANNUAL CHECKS

1. Annually the cell covers must be cleaned and if necessary the poles and links must also be
cleaned (possible corrosion) and slightly greased.

2. Check the starting torque of the pole screws.

3. Check the battery with the rectifier switched on. Measure and record the voltage of each cell.
In the case of wet cells additionally the specific gravity must be checked and recorded.

4. Perform a nominal battery discharge test according to the manufacturer’s recommendation

( see «Battery documentation»). The discharge test records should at least contain:
All cell voltages, discharge current, overall battery voltage, ambient temperature and
discharge time. If wet cells are used it would also include the specific gravity as well as the
electrolyte temperature of pilot cells.

2.3 BATTERY CAPACITY TEST

The battery capacity test gives an information about how long the battery backup time is at actual
load. The performance of a battery capacity test only make sense, when the batteries are fully
charged and the rectifier is running in float charge.

At the end of this check the capacity of the battery is low. If at this time a mains
failure occurs, it will have a direct influence on the emergency current time
(autonomy time). Therefore, this check must be co-ordinated with the personnel
(e.g. operator of the connected load). Nevertheless, the test should not be
foregone because it provides the best information on the condition of the batteries.

1. Start with fully charged batteries, i.e. if the system has been in normal operation for longer
than 8 hours.

2. For testing the battery capacity from the foil key board proceed as follows: push and

step inside the stack with the cursor key or until:

is shown on the display, where «xxx» is the back-up time of the last test — if not performed
before or if the test has been aborted, «???» is shown.

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 MAINTENANCE

3. Push to abort or to continue. The display shows: ,

where «time > …min.» is only shown if option «Advanced battery monitor» is installed.

4. Wait until the display shows: and a short alarm has been activated.

5. Push and until the display shows , where «xxx» is the

actual back-up time in minutes.

6. Push or wait 30secs until the display shows: .

If during the test a mains fault occurs, the test will immediately be aborted and no test result will be
obtained. When reading out data of the battery capacity test in the display after a test has been
aborted, «???» is shown, i.e. that no result was obtained

Please note that after a battery capacity test it will take about 8...24 hours before the battery is
recharged and the full back-up time is available again.

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 REPLACEMENT OF COMPONENTS & PARTS
UPS SYSTEM, Type: PEW / PDW

As a minimum GUTOR specifies that the following components and parts in the UPS systems are
replaced according to the time periods indicated:

Reference Normal NPP Replacement

Part Designator Scope Scope Cycle
Fan Sub-assembly E0.. X X 5 years
Battery Bank — X X Note 1 + 2
Backup RAM with Lithium Battery A070 (D098) X X 9 years
DC Capacitor Module CB02 X X 9 years
AC Capacitor Module CB03 X X 9 years
Air Filter — X X Note 3

Normal scope: Stationary on-shore installation with non-seismic requirements

NPP scope: Installation in Nuclear Power Plants, seismic requirements, off-shore- or mobile application

These values refer to a maximum ambient temperature of 40° Celsius and a maximum load of 70%.
If one of these values is continuously exceeded, the items mentioned must be replaced 1 year
earlier.

Note 1: See battery specification of the battery manufacturer.

Note 2: With enabled battery monitor (option) the battery is automatically monitored.
In the case of a faulty battery an alarm is generated.

Note 3: The air filters must be checked at least every 6 months. Dependent on the contamination
they must be replaced immediately.

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 REPLACEMENT OF COMPONENTS & PARTS

10year extended Replacement Schedule

Reference Normal NPP Replace

Part Designator Scope Scope Cycle Remarks
Main Controller with Chipset A070 X X 10 years
Master Logic A701 X X 10 years if applicable
SC-Controller A072 X X 10 years
Display-Unit (Frontpanel) A073 X X 10 years
External Connection Board A025 X 10 years
PSU AC A202 X X 10 years
PSU DC A201 X X 10 years
Parallel Controller Board A024 X X 10 years parallel operation
Rectifier Module A030 X 10 years
12-pulse Rectifier Module A031 X 10 years if applicable
Static Switch Module EN A035 X 10 years
Static Switch Module EA A036 X 10 years if applicable
Inverter Power Module A032 X 10 years
Inverter Power Module A033 X 10 years if applicable
Inverter Power Module A034 X 10 years if applicable
DC Current Sensor P007 X 10 years
DC Current Sensor P009 X 10 years

Options

Normal NPP Replace

Part Scope Scope Cycle Remarks
Harmonic Filters X X 10 years
Static Transfer Switch X X 10 years
TDS X X 10 years according specific instructions
AC/DC Converter X X 10 years
DC/DC Converter X X 10 years

Replacement cycle intervals may be shorter and the scope may need to be
extended if the system is exposed to harsh environmental conditions
(vibration, climate, air-pollution).

Consult GUTOR for an appropriate schedule in this case.

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 SERVICE — TRAINING — CONTACT
ADDRESSES

UPS SYSTEM, Type: PEW / PDW

TABLE OF CONTENTS:
1. Service/Repairs
1.1 Call for After Sales Service and Return of Parts
1.2 Installation and Commissioning
1.3 Maintenance

2. Spare Parts

3. Training
3.1 Level 1: Operation
3.2 Level 2: Maintenance
3.3 Level 3: Service
3.4 Training for Design Engineers
3.5 Training for Installation Supervisors

4. Contact Addresses

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1. SERVICE/REPAIRS
1.1 CALL FOR AFTER SALES SERVICE AND RETURN OF PARTS
LABEL «RETURN OF PARTS»:

This label contains all necessary information for the return of parts or for contacting our service
department. It is adhered behind the front door near the name plate.

The necessary information to call for service action are mentioned on the name plate.
885-3854

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 SERVICE — TRAINING — CONTACT ADDRESSES
1.2 INSTALLATION AND COMMISSIONING
Upon completion of all tests at GUTOR’s test bay the systems are shipped to the customer site by
ship, air and or land transport. On site, GUTOR-trained and licensed field service engineers (FSE)
perform numerous services such as:

♦ System unpacking and inspection after transportation

♦ Installation and, or installation supervision, to ensure that the assembly and installation of the
system is performed in a professional manner and according OEM requirements
♦ Mechanical and electrical commissioning checks on the isolated system
♦ Mechanical and electrical tests on the energised system
♦ Initial battery charging, or battery refreshing charge
♦ Battery discharge test including dummy load bank
♦ Complete functional test on the entire system
♦ Acceptance test with customer and authorities

GUTOR‘s Installation, commissioning and testing services are designed according to customer
needs to ensure best possible operational condition and to guarantee highest possible system
availability and reliability.

1.3 MAINTENANCE
Maintenance covers several important aspects which have a deep impact on the availability and
reliability of the entire system and the plant it services. The aspects of maintenance are divided in:

Preventive Maintenance
The concept of preventive maintenance comprises planned maintenance tasks. Their purpose is to
minimize breakdowns, excessive depreciation of the system and to maximize availability and
reliability during the entire life span. The individual preventive maintenance jobs are performed
according to the system maintenance manual and the OEM maintenance checklist. Preventive
maintenance requires adequately-trained and experienced manpower, replacements of those parts
with limited lifetime, tools and instruments to perform the respective work.

Corrective Maintenance
Preventive maintenance cannot prevent a breakdown that is caused by external influences,
operational error or a part failure. If an unexpected breakdown occurs it is important that the system
is repaired, tested and brought back to operation immediately.

Spare part Stocking

The successful performance of corrective maintenance requires the availability of critical parts and
components.

Hard and software updates

During the life of a system new features are being developed. Their implementation, or the
replacements of outdated parts make older systems more reliable.

Response time for Services and Material

Adequate response time is an important factor when it comes to remedial services.

Hotline Services
For operational questions, remote advice, or the request of a field service engineer (FSE).

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 SERVICE — TRAINING — CONTACT ADDRESSES
1.3.1 TAILORED MAINTENANCE PACKAGES
We have bundled above maintenance aspects into three professional packages to cover individual
customer requirements ranging from minimum service, to absolute peace of mind. You choose the
package that suits your requirements.

Pro-Life
This comprehensive package provides customers with an all-inclusive service, and total peace of
mind from day one. GUTOR takes care of:
♦ All regular preventive maintenance including material and tools
♦ Software & hardware updates
♦ All corrective maintenance including material and tools
♦ Guaranteed service response time
♦ Guaranteed product response time
♦ Extended warranty for as long as the package contract lasts
♦ 24 hours, 7 days a week hotline

Pro-Partner
With this package GUTOR caters for customers who maintain a GUTOR trained, own maintenance
force capable of performing regular minor preventive works, and minor corrective jobs on all the
systems by themselves. GUTOR take care of major preventive works and respond to unexpected
major technical failures. The package includes:
♦ Major preventive maintenance including material and tools
♦ Software & hardware updates
♦ Major corrective maintenance including material and tools
♦ Guaranteed service response time
♦ Guaranteed product response time
♦ Extended warranty for as long as the package contract lasts
♦ 24 hours, 7 days a week hotline

Pro-Flex
In cases where customers require fast and in-depth expertise to solve unexpected major failures
GUTOR guarantee quick and reliable help as and when required. This package guarantees:
♦ Major preventive maintenance including material and tools
♦ Software updates
♦ Service and material response time
♦ 24 hours, 7 days a week hotline

Pro-Basic
For customers who want to have organized an easy way to standardize the maintenance of their
systems. GUTOR takes care of standard preventive checks and responds to unexpected major
technical failures. The package includes:
♦ 1 standard preventive maintenance job per system & year
♦ Software updates
♦ Service and material response time
♦ 24 hours, 7 days a week hotline

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 SERVICE — TRAINING — CONTACT ADDRESSES
Pro-Light
For customers who want to have an easy access to service & support at any time. GUTOR takes
care of updating the Software. The package includes:
♦ Software updates
♦ Service and material Response time
♦ 24 hours, 7 days a week hotline

2. SPARE PARTS
Spare parts are differentiated according to the various plant requirements:
♦ Spares for commissioning
♦ Spares for preventive maintenance
♦ Spares for corrective maintenance as strategic stock
The selection of the correct spare parts is crucial. We gladly support you in defining the spare parts
needed taking in consideration of your installed GUTOR systems and requirements.

3. TRAINING
Uninterruptible Power Supply (UPS) systems from GUTOR are designed according to individual
customer needs. Technical staff servicing and maintaining these systems therefore receive
customized training based on specific requirements in relation to those particular systems installed
on-site.

GUTOR offers three different training levels concerning operation, maintenance, and service
respectively. Each training course, as well as the documentation, are individually tailored based on
the customer's installed fleet. All levels are appropriate for the operation and maintenance
requirements of the GUTOR systems.

3.1 LEVEL 1: OPERATION

This course is composed of two parts. The first theoretical part introduces the participants to the
various system operating modes, and provides information on how the system is built. In the
second practical part, the training instructor demonstrates to the participants how to operate the
system in a safe and confident manner.
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 SERVICE — TRAINING — CONTACT ADDRESSES
We recommend Level 1 training to all personnel working with (and in-charge of) GUTOR systems.
We also recommend clients having a «Pro-Life» maintenance contract to attend this course.

Requirements:
The participants should have a basic education in electronics. Special UPS knowledge is not
necessary.

3.2 LEVEL 2: MAINTENANCE

This course builds on the information provided during Level 1. Participants learn the
important functions of the major UPS components. They also receive information
regarding maintenance work and maintenance intervals. Upon completion of this course,
participants are capable of resolving simple system errors.

We recommend Level 2 training to clients having at least a «Pro Partner» maintenance

contract.

Requirements:
Level 1 is a prerequisite for Level 2, and shall be completed first. The participants should
have a solid education in electronics.

3.3 LEVEL 3: SERVICE

In Level 3 training participants learn how to analyze and repair system errors. In addition,
the training instructor explains how the system can be calibrated. Upon completion of this
course, participants are capable of performing most repair and maintenance work by
themselves.

We recommend Level 3 training to clients having as a minimum a «Pro Light»

maintenance contract.

Requirements:
Level 1 and Level 2 are prerequisites for Level 3, and shall be completed first. The
participants should have a solid education in electronics.

3.4 TRAINING FOR DESIGN ENGINEERS

This training course conveys valuable system solution know-how about UPS systems,
intended for Design Engineers. This knowledge is useful when evaluation new systems
and/or expanding existing systems. Participants learn in detail about functions and
characteristics of the system, as well as the various standard system configurations.

An explanation of the important aspects of system options and basic battery rules are also
included.

Requirements:
The participants should have a solid education in electronics.

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3.5 TRAINING FOR INSTALLATION SUPERVISORS

This training course mainly focuses on the installation of a GUTOR system and its batteries. The
Installation Supervisors learn how to perform proper mechanical checks on the system.
Furthermore, they discover the climactic conditions for which the life-span of the system can be
optimized.

Requirements:
The participants should have a solid education in electronics.

For detailed description please contact our customer service

4. CONTACT ADDRESSES
GUTOR Electronic LLC
Hardstrasse 72-74

5430 - Wettingen / Switzerland

Internet : www.gutor-service.com
E-Mail : gutor.customerservice@apcc.com
Phone: ++ 41 56 437 34 34
Fax: ++ 41 56 437 34 21

Malaysia's contact address:

GUTOR Electronic Asia Pacific Sdn. Bhd.

No. 19, Jalan Juruukur U1/19,
Seksyen U1 Hicom Glenmarie Industrial Park
40150 Shah Alam, Selangor, Malaysia.

Phone : +(6) 03 55690331

Fax : +(6) 03 55690332

Further Offices in: China, Brazil, Germany, India, Japan, Mexico, Nigeria, Qatar, Russia, U.S.A.,
U.A.E.

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