T Service Manual

8/10/2019 T Service Manual

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1.2 Operation Instructions

1.2.1 System Start-up Procedure

Please check the following noticed items before UPS start-up:

1. All circuit breakers and isolators are in OFF position and battery fuse is out.

2. Ensure that neutral line and grounding are the same voltage level.

3. Apply power to the AC input cables and check that input voltage, frequency and

phase order are with in the machine specifications.

When UPS comply with the above mentioned conditions, start-up UPS according to the

following procedures:

1. Close MANUAL BYPASS breaker, at the same time LCD display LOAD ON

BYPASS .

2. Close AC INPUT and RECTIFIER INPUT breakerwait 1520 seconds until

BATT LOW LED behind the door is off.

3. Close RESERVED INPUT breaker, at the same time LCD display LOAD ON

RESERVE .

4. Close UPS OUTPUT breaker.

5. Open MANUAL BYPASS breaker.

6. Close BATTERY FUSE ISOLATOR in battery cabinet.

7. Press the inverter ON & button simultaneously, the load will be transferred

from reserve to inverter automatically, at the same time LCD display LOAD ON

INVERTER .

Note: It must never turn on manual bypass circuit breaker when the

inverter is turned on. It will damage the UPS owing to utility power

parallel with inverter output.

1.2.2 Maintenance Manual Bypass Procedure

This procedures leave the critical load undisturbed and the UPS batteries will still be

charged. The operating procedures are as follows:

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1. Check MAIN FREQ ABNORMAL RES MAINS FAIL LEDS behind the door are

all off.

2. Press inverter OFF & button simultaneously. Check that INV ON LED

behind the door is off.

3. Close MANUAL BYPASS breaker.

4. Open UPS OUTPUT breaker.

5. Open RESERVE INPUT breaker.

1.2.3 Return from Bypass to Normal Mode

This operating procedures will transfer load from bypass to normal mode as follows:

1. Check that INV ON LED behind the door is off.

2. Close RESERVE INPUT breaker.

3. Close UPS OUTPUT breaker.4. Open MANUAL BYPASS breaker.

5. Press the inverter ON & button simultaneously.

6. The load will be transferred from reserve to inverter automatically.

1.2.4 System Shutdown Procedure

This operating procedure can turn off power supply to UPS, please first confirm the load

has been shutdown, the procedures as follows

1. Press inverter OFF & button simultaneouslyCheck that INV ON LED

behind the door is off.

2. Close MANUAL BYPASS breaker.

3. Open BATTERY FUSE ISOLATOR in battery cabinet.

4. Open RECTIFIER INPUT breaker.

5. Open RESERVE INPUT breaker.

6. Open UPS OUTPUT breaker.

7. Wait 5 mins for DC CAP to discharge.

8. Open AC INPUT & MANUAL BYPASS breaker.

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1.3 Technical Specifications

1.3.1 Rectif ier Input Characterist ics

(a) 380/220 Input

3 input3 output 3 input1 output

Power rating KVA (P.F.0.8) 10 15 20 30 40 50 60 80 100 120 150 10 15 20 30 40 50

(1) Nominal voltage V 220/380() 220/380()

(2) Voltage range % 20 20

(3) Nominal frequency Hz 50 / 60 50 / 60

(4) Frequency range % 5 5

(5) Nominal input power

(with charged battery)KVA Power rating120% Power rating120%

(6) Input power factor cosq 0.7 0.7

(7) Maximum input power

(with battery under charge)KVA Power rating 135% Power rating 135%

(8) Range input current A 18 28 37 55 73 90 108 144 180 215 270 18 28 37 55 73 90

(9) Maximum input current A 26 39 52 78 103 127 152 203 253 304 376 26 39 52 78 103 127

(10) Start-up time sec 20 20

(11) Efficiency % 96 96

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(b) 208/120 Input



1) Nominal voltage V 208/120() 208/120()

2) Voltage range % 15 15

3) Nominal frequency Hz 50 / 60 50 / 60

4) Frequency range % 5 5

5) Nominal input power

(with charged battery)KVA Power rating120% Power rating120%

6) Input power factor cosq 0.7 0.7

7) Maximum input power

(with battery undercharge)

KVA Power rating 135% Power rating 135%

8) Range input current A 33 51 68 101 134 165 198 264 330 394 495 33 51 68 101 134 165

9) Maximum input current A 48 72 95 143 189 233 279 372 464 557 689 48 72 95 143 189 233

10) Start-up time sec 20 20

11) Efficiency % 96 96

() The different voltage specification is available.

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Item Spec.


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1.3.2 Rectif ier Output Characteristics



(1) DC voltage range V 300420 300420

(2) Output voltage

(with Ni-Cd battery)

---float charge V 393 393

---boost charge V 415 415

(3) output voltage (with

sealed lead acid battery)

---float charge V 393 393

---boost charge V 405 405

(4) Voltage stability

(for input voltage and

output current change

simultaneously)

% 1 1

(5) DC voltage ripple

(Vrms/Vb100)% 2 2

(6) Nominal current Adc 22 34 45 67 89 110 131 175 219 263 324 22 34 45 67 89 110

(7) Maximum output current Adc 32 47 63 95 126 155 185 247 309 371 459 32 47 63 95 126 155

(8) Maximum charge current Adc 7 10 13 19 25 31 37 49 62 74 92 7 10 13 19 25 31

(9) Adjustable charging

current

Yes Yes

(10) Battery charging system DIN 41773 DIN 41773

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1.3.5 Inverter Output Characteristics

(a) 380/220 Output



(1) Nominal voltage V 220/380() 220()

(2) Nominal current A 15 23 30 45 61 76 91 121 152 182 227 45 68 91 136 182 227

(3) Nominal voltage

adjustment range

% 10 10

(4) Waveform Sinusoid Sinusoid

(5) T.H.D.(with linear load) % 3 3

(6) Output voltage

regulation (for input

voltage and output loadchange simultaneously)

% 1 1

(7) Output voltage dynamic

regulation for 0100%

load variations% 5 5

(8) Voltage symmetry with

balanced load

% 1 1

(9) Voltage symmetry with

100% unbalanced load % 1 1

(10) Displacement angle

between three phases1203 NA

(11) Output frequency Hz 50 / 60 50 / 60

(12) Phase lock range Hz 3 3

(13) Frequency stability

with internal oscillator

with mains synchronize

%

%

0.01

1

0.01

1

(14) Overload

110%15 minutes

125%10minutes

150%1minutes200%

110%15 minutes

125%10minutes

150%1minutes200%

(15) Inverter efficiency % 88 90 91 92 93 94 94 94 94 94 94 88 90 91 92 93 94


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ItemSpec.


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(b) 208/120 Output



1) Nominal voltage V208/120(

) 110(

)

2) Nominal current A 28 42 55 83 112 139 167 222 279 334 417 91 136 182 273 364 455

3) Nominal voltage

adjustment range

% 10 10

4) Waveform Sinusoid Sinusoid

5) T.H.D.(with linear load) % 3 3

6) Output voltage regulation

(for input voltage and

output load change

simultaneously)

% 1 1

7) Output voltage dynamic

regulation for 0100%

load variations% 5 5

8) Voltage symmetry with

balanced load

% 1 1

9) Voltage symmetry with

100% unbalanced load % 1 1

10) Displacement angle

between three phases1203 NA

11) Output frequency Hz 50 / 60 50 / 60

12) Phase lock range Hz 3 3

13) Frequency stability

- with internal oscillator

- with mains

synchronize

%

%

0.01

1

0.01

1

14) Overload

110%15 minutes

125%10minutes

150%1minutes200%

110%15 minutes

125%10minutes

150%1minutes200%

15) Inverter efficiency % 86 87 88 89 90 90 90 91 91 91 91 87 88 89 90 91 91


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1.3.6 Static Switch Input / Output Characteristics

(a) 380/220 Input / Output



(1) Input / Output voltage V 380 220

(2) Input / Output frequency Hz 4565 4565

(3) Overload current

--- 30 minutes

--- 10 seconds

--- 30 milliseconds

%

%

%

120

500

1000

120

500

1000

(4) Maximum transfer time

- From inverter to reserve

(a) inverter failure

(b) inverter overload or

manual operation

- From reserve to inverter

manual operation or

automatic return

msec

msec

msec

1

0

0

1

0

0

(5) Efficiency (at nominal

load)

% 99.5 99.5

(6) High / Low AC voltage

transfer rate

% 20 20

(7) Slew rate Hz / sec 1 1

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(b) 208/120 Input / Output



1) Input / Output voltage V 208 120

2) Input / Output frequency Hz 4565 4565

3) Overload current

--- 30 minutes

--- 10 seconds

--- 30 milliseconds

%

%

%

120

500

1000

120

500

1000

4) Maximum transfer time

- From inverter to reserve

a) inverter failure

b) inverter overload or

manual operation

- From reserve to inverter

manual operation or

automatic return

msec

msec

msec

1

0

0

1

0

0

5) Efficiency (at nominal

load)

% 99.5 99.5

6) High / Low AC voltage

transfer rate

% 20 20

7) slew rate Hz / sec 1 1

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1.3.7 General Specif icat ion

(a) 380/220 Input / Output

Item Spec. 3 input3 output 3 input1 o

Power rating KVA (P.F.0.8) 10 15 20 30 40 50 60 80 100 120 150 10 15 20 30

(1) ACAC efficiency

---nominal load % 86 88 89 90 91 92 92 92 92 92 92 86 88 89 90

---75 % 84 86 87 88 89 90 90 90 90 90 90 84 86 87 88

---50 % 81 82 83 84 85 86 86 86 86 86 86 81 82 83 84

---25 % 73 74 75 77 79 81 82 82 82 82 82 73 74 75 77

(2) Maximum dissipated

power at nominal load kw 1.30 1.63 1.98 2.67 3.16 3.48 4.17 5.57 6.95 8.35 10.4 1.30 1.63 1.98 2.67

(3) Audible noise(at a

distance of 1.5 m)

dB 60 65 60

(4) Ambient temperature 040 040

(5) Relative humidity % 90 90

(6) Dimensions:

--- Depth mm 800 800

--- Width mm600 600 600 600 600 800 800 1200 1200 1200 1200 600

--- Height mm 1700 1700

(7) Weight kg 480 380 420 490 550 670 750 900 1050 1200 1400 460 350 390 450

(8) Grade of protection IP20 IP20

(9) Control cabinet color DELTA COOL GREY DELTA COOL

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(b) 208/120 Input / Output

Item Spec. 3 input3 output 3 input1 o

Power rating KVA (P.F.0.8)

10 15 20 30 40 50 60 80 100 120

150

10 15 20 30

(1) ACAC efficiency

---nominal load % 85 86 87 88 89 90 90 90 90 90 90 85 86 87 88

---75 % 83 84 85 86 87 88 88 88 88 88 88 83 84 85 86

---50 % 80 81 81 82 83 84 84 84 84 84 84 80 81 81 82

---25 % 71 72 73 75 77 79 80 80 80 80 80 71 72 73 75

(2) Maximum dissipated

power at nominal load kw 1.41 1.95 2.39 3.27 3.96 4.44 5.33 7.11 8.89 10.7 13.4 1.41 1.95 2.39 3.27

(3) Audible noise(at a

distance of 1.5 m)

dB 60 65 60

(4) Ambient temperature 040 040

(5) Relative humidity % 90 90

(6) Dimensions:

--- Depth mm 800 800

--- Width mm 540 450 490 590 650 780 870 1050 1200 1400 1600 600

--- Height mm 1700 1700

(7) Weight kg 480 380 420 490 550 670 750 900 1050 1200 1400 540 420 460 540

(8) Grade of protection IP20 IP20

(9) Control cabinet color DELTA COOL GREY DELTA COOL

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2. Introduction to PCB Function

2.1 A Board (Inverter Control Board)

A. Function:

a. Generate three-phase sine-wave reference signal and triangle-wave which are transmitte

to T board.

b. Detect reserve AC voltage and frequency whether they are normal or not.

c. Produce high frequency square-wave signals, P1 and P2 signals are transmitted to B

board, SW+ and SW- signals to T board, and HF signals to P board.

d. When the inverter short circuit, heatsink over temperature or fuse fail, the LED will show

malfunction.

e. Dip switch (SWA1) function setting are as follows:

1 2 3 4 5 6 7 8

OTFS OTFP OTFGT OTFGS SEL1 SEL2 D/Y

(1) OTFS (Rectifier heatsink over temperature): When switch on, disable ove

temperature function.

(2) OTFP (Static switch heatsink over temperature): When switch on, disable ovetemperature function.

(3) OTGT (Inverter heatsink over temperature, T phase): When switch on, disable ove


(4) OTGS (Inverter heatsink over temperature, S phase): When switch on, disable ove


(5) SEL1 and SEL2 are used to set Boost charge time, as following table:

SEL1 SEL2 HRS

OFF OFF 4

OFF ON 8

ON OFF 16

ON ON 32

(6) D/Y : If AC input is Y connection, setting the dip switch to ON, and if Dconnectio

setting to OFF.

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f. If the UPS loading is greater than 70%, the CPU will send control signal to B board focooling fan speed control.

g. Press SWA2 push button switch that will reset BOOST CHARGE function, if the rectifier i

in boost charge mode.

B. Test and adjustment

a. VRA1-----Amplitude adjustment of the triangle wave(6V).

b. VRA2-----Amplitude adjustment of the reserve AC source(2.5V).

c. VRA3----- phase-lock adjustment of the reserve AC source frequency.

d. TPA2,3---The 30 kHz constant frequency square waves are transmitted to B and T board

for switching signals.

e. TPA4,5---Reserve AC source frequency (square wave) and amplitude test points.

f. TPA6,7---Triangle wave signals test points, TPA6 and TPA7 are 180 phase shift.

C. Troubleshooting:

a. Confirm that CPU board and EPROM are inserted in right direction.

b. Confirm that three-phase sine reference signals are normal.

c. Confirm that amplitude and frequency of triangle wave are normal.d. Confirm that dip switch setting is correct.

e. Confirm that +16VA, +12VA, +5VA and all wire connections are correct.

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2.2 B Board (Power Supply Board)

A. Function:

a. Transfer AC main power from 200 VA transformer or DC bus voltage into 16VA, 16VB

and +8VR, for the usage of other PCB.

b. Battery ground fault detection.

c. Control relay to drive cooling fan in high or low speed operation.d. Battery charge current limitation.

e. High DC bus voltage detection.

f. Battery current sensing.

B. Test and adjustment:

a. VRB1-----Adjustment of the battery charge current limitation. The following are the prese

values.

KVA 10 15 20 30 40 50 60 80 100 120 150

A 3 5 7 10 14 17 20 22 25 30 36

b. VRB2----- Adjustment of the High DC shutdown voltage level.

c. TPB2,3---PWM drive signals for DC/DC converter, TPB2 and TPB3 are 180 phase shift.

C. Troubleshooting:

a. Confirm that TPB2, TPB3 are 30 kHz square waves, and indicators LEDB2~LEDB5 are

emitted.

b. When UPS loading over 70% rated power, confirm that FAN signal from A board is set highand relay is close correctly.

c. After battery supplies power for a period of time and utility power is recovered, confirm tha

battery charge current within tolerance(< 0.2C).

d. Confirm that HIGH DC SHUTDOWN is set on correct level and function normally.

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2.3 C Board (Rectifier Control Board)

A. Function:

a. Utility power low voltage level (-20%) detection.

b. Rectifier over current.

c. Shutdown protection of high DC bus voltage.d. Float charge and boost charge status setting.

e. Three-phase input power phase sequence detection.

f. Rectifier soft-start function.

g. 12-pulse rectifier configuration with rectifier output current sharing .

h. Battery temperature compensation and battery test function.

B. Test and adjustment

a. VRC1-----Adjustment of the utility power low voltage level.

b. VRC2-----Float charge voltage adjustment, when battery in floating(393Vdc), LEDC3 will b

lit.

c. VRC3-----Boost charge voltage adjustment, when battery in boost(405Vdc), LEDC4 will b

lit.

d. VRC4-----Level adjustment of rectifier over current protection.

e. VRC5-----Battery test rectifier output voltage adjustment, when battery in test mode, the

rectifier will output constant voltage (335Vdc), LED5 will be lit.

f. VRC6-----Battery temperature compensation voltage adjustment, If the battery temperatur

is grater than 35, the rectifier output voltage will be reduced 5V(i.e. 388V in floatin

charge).

g. TPC17(RECT INH)---When utility power and rectifier operation are normal, this detectio

point is low voltage level, the contrast is high and blocks rectifier.

h. TPC8~TPC13---SCR trigger signals, transmitted to rectifier drive board (S board).

i. TPC1~TPC3--- R, S, T phase sequence of the utility power.

j. TPC16 (DC E/A OUT)---DC error voltage output, control SCR fire angle.

C. Troubleshooting:

a. RECT MAINS FAIL:

(1) Confirm whether the utility power is normal or not. (Test point TPC17)

(2) Confirm whether the utility phase sequence is normal or not. (Test point TPC1~TPC3)

b. HIGH DC SHUTDOWN:

(1) Confirm whether the DC capacitors are correct or not.

(2) Confirm whether the HIGH DC SHUTDOWN adjustment (B board VRB22) is se

correctly or not.

(3) Confirm that rectifier over current protection is correct.

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2-6

TPC3

R-SQ

TPC1

S-SQ

TPC2

T-SQ

TPC5

R-RAMP

TPC6

S-RAMP

TPC7

T-RAMP


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2-7

TPC9

S-

TPC12

T+

TPC11

T-

TPC8

R+

TPC13

R-

TPC10

S+


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2.4 E Board and AA Board (IGBT Snubber Board)

A. Function:

a. Suppress and absorb the transient voltage and current produced by IGBT switching.

b. Connected to E board when using single IGBT module, and AA board when using paralleIGBT.

B. Troubleshooting:

a. Confirm whether the capacitors are fluid leakage or destructive.

b. Confirm whether the diodes, resistors, and capacitors are normal or not.

2.5 G Board (Inverter Drive Board)

A. Function:

a. System automatic shutdown protection when IGBT is over temperature( heatsin

temperature greater than 70).

b. Isolate and amplify the PWM signals generated by T board to drive IGBT.

c. DC bus voltage level detection to determine the IGBT fuse fail.


a. TPG1~4-----Inverter drive signal connected to terminals of IGBT module.

b. SW+, SW- -----Generated from A board, as the power source control signals for IGBT

driving.

C. Troubleshooting:

a. IGBT drive abnormal:

(1) Confirm that IGBTs and fuses are normal.

(2) Confirm that PWM waveforms are normal(TPG1 and TPG2 are 180phase shift, TPG

and TPG4 are 180phase shift.)

b. PWM waveform abnormal:(1) Confirm that PWM waveforms generated from T board are correct.

(2) Confirm power supply (SW+, SW-) generated from A board is correct.

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2-9

TPG1PWM

TPG2

PWM

TPG1

PWM

TPG2

PWM


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2.6 H Board (Alarm Switch Board)

A. Function:

a. LED displays 4 status of alarm signals for users reference.

b. Press SELECT key for LCD item inquiring.

c. Press ENTER key for confirmation.

B. Troubleshooting:

a. Confirm that LEDs are not destroyed and buttons are in good contact.

b. Confirm that connector are in good contact with lead.

2.7 J Board and M Board (MOV Board)

A. Function:

a. Absorb high voltage surge from input terminal of the UPS.b. When input power is Dconnection using J board, and when Y connection using M Board.

B. Troubleshooting:

a. Confirm that the wiring is in good contact and tighten adequately.

b. Confirm that MOV is not destroyed and choosing the correct MOV type.

2.8 L Board (System LED Board)

A. Function:

a. Transfer twelveUPS status into system diagram and four LEDs driving signals.

b. Transfer R board series in signals into parallel out signals by IC 74HC164 to drive LEDs.

c. When pressing ON & CTRL key simultaneously, there is +5V voltage between them (INV

ON).

d. When pressing OFF & CTRL key simultaneously, there is +5V voltage between them

(INV OFF).

B. Troubleshooting:a.Confirm that LEDs are not destroyed and buttons are in good contact.

b.Confirm that +5V power supply and IC 74H164 whether they are correct or no

destroyed.

c.If the LEDS are all lit, confirm that R board or EPROM on CPU board are correct.

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2.9 N Board (Remote Panel Board) and Y Board (Switch Board)

A. Function:

a. Communicated with UPS for remote monitoring.

b. Monitoring three sets of UPS at same time via RS485 interface.c. With 120V or 220V receptacles depends on UPS output.

d. By communication, user can set inverter ON/OFF and alarm ON/OFF.

e. Power supply:

(1) +12V: Supplied to buzzer and LCD CCF.

(2) -5V: Supplied to CPU board and RS485 Interface.

(3) -12V: Supplied to LCD bias (contrast adjustment).

f. The dip switch SWN1 setting is the same as SWR1 on R board, according to the input

output voltage and KVA rating.

B. Troubleshooting:

a. Confirm whether the power supply and signals are normal or not.

b. Confirm whether the LCD and push button are normal or not.

2.10 P Board (Static Switch Board)

A. Function:

a. Generate SCR trigger signals for static switch transferring between Reserve and Inverte

mode.

b. Inverter output voltage abnormal detection. If the UPS output voltage is over or under 20%

of nominal voltage, the SSOP fault signal will be generated and sent to A board.


a. VRP1, TPP3-----High voltage level adjustment of inverter output.

b. VRP2, TPP2-----Low voltage level adjustment of inverter output. The following are th

different nominal output voltage and VRP1, VRP2 preset values.Nominal voltage 380/220 400/230 415/240

TPP3 5.1V 5.3V 5.6V

TPP2 2.7V 2.9V 3.0V

c. TPP4---------------When transfer signal (transmitted from A board) is from low going to

high level, it means UPS is transferred from Reserve mode to Inverter

mode, at the same time.

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C. Troubleshooting:

a. Confirm that all wire terminals and static switches are connected correctly.

b. Confirm whether VRP1 and VRP2 are adjusted correctly(When Inverter output voltage i

abnormal, SSOP signal is low level).

c. Confirm that reserve and inverter SCR, only one set is triggered at any time.

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ZDP5

(+)

ZDP3

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2.11 Q Board (Dry Contact Board)

A. Function:

Generate four sets of dry contact signals output as follows:

a. Load on inverter (P1,P2 are closed at that time).

b. Load on reserve(P3,P4 are closed at that time).c. Warning Message ( RES MAINS FAIL, RES FREQ ABNORMAL, RECT MAINS

FAIL, BATT LOW,INV OVERLOAD, BATT LOW STOP, Load on bypass) (P5,P6 ar

closed at that time).

d. Fault Messages ( RECT HI DC STOP, OVERTEMP/FUSE FAULT, BATT GND

FAULT, INV FAULT) (P7,P8 are closed at that time).

B. Troubleshooting:

a. Confirm that +12V power supply and relay are normal.

b. Confirm that signals transmitted from R board are all normal.

2.12 R Board (Display Board)

A. Function:

a. Transfer the signals from A board into twelve UPS status for LED display, and to fron

panel for users reference.

b. Display the Input / Output voltage, current, and frequency, battery voltage and curren

and loading percentage, by feedback voltage and current signals to CPU.

c. Provide RS485 interface.

d. The power supply of LCD lamp is provided from R board INVR1 (DC/AC

12V30KHz/250V), and the character contrast is controlled by -12.6V supply.

e. According to Input / Output voltage and KVA rating, the dip switch SWR1 must be set a

follows:

SWR1-1 SWR1-2 I / P Voltage O / P Voltage

ON ON 3f4W 3f4W

OFF ON 1f3W 1f3W

ON OFF 3f4W 1f2W

OFF OFF

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SWR1-3 SWR1-4 KVA-1 KVA-2 KVA-3 KVA-4

ON ON 5 30 70 120

OFF ON 10 40 80 150

ON OFF 15 50 90

OFF OFF 20 60 100

f. The 12 LEDs on R board (from left to right), status explanations are as follows:

(1) RECT MAINS FAIL: When utility power is under voltage (less than 20% rating), th

LED will be lit.

(2) RECT HI DC STOP: When DC bus voltage is too high, the LED will be lit.

(3) OVERTEMP/FUSE FAIL: When the heatsink is over temperature or fuse fail, the LED

will be lit.

(4) BATT LOW/STOP: When UPS in back-up mode and DC bus voltage below 330V, th

LED will flash, and when DC bus voltage below 300V, the LED will be lit.

(5) LOAD LEVEL: When UPS in normal mode, the LED will flash, and the flashing ratdepends on loading percentage.

(6) BATT GND FAULT: When the battery is shorted with ground, the LED will be lit.

(7) INV ON: When the load is supply by inverter output, the LED will be lit.

(8) INV OVERLOAD: When UPS is loaded over rated capacity, the LED will be lit.

(9) INV FAULT: When Inverter is abnormal, the LED will be lit.

(10) LOAD ON RES: When the load is supplied by reserve source, the LED will be lit.

(11) RES MAINS FAIL: When the voltage amplitude of reserve input is abnormal, the LED

will be lit.

(12) RES FREQ ABNORMAL: When the frequency of reserve input is abnormal, the LE

will be lit.

A. Test and adjustment:

a. VRR1~VRR3------Adjustment LCD display of output current.

b. VRR5----------------Adjustment LCD display of battery voltage.

c. VRR6~VRR11----Adjustment LCD display of input / output voltage.

d. VRR7~VRR14----Adjustment LCD display of input current (optional).

e. VRR15-------------- Adjustment LCD display of battery charge current.f. VRR16-------------- Adjustment LCD display of battery discharge current.

B. Troubleshooting:

a. Confirm that all signals and power lines are correctly connected with R board.

b. Confirm that CPU board is inserted correctly, and the EPROM is function correct.

c. Confirm that all LEDs status display normally.

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2.13 S Board (Rectifier Drive Board)

A. Function:

a. Transmitting trigger signals generated from C board through isolation pulse transformer t

trigger thyristors.

b. When SCRs are switching, Snubber will absorb and suppress transient surge to protecfrom destroyed.

B. Troubleshooting:

a. Confirm that SCRs are normal.

b. Confirm that all connectors and wiring are connected properly.

c. Confirm that trigger signals transmitted from C board are correct.

d. Check pulse transformers and Zener diodes are normal.

e. Check components of the Snubber(resistors and capacitors) are not burnout.

2.14 T Board (Inverter Phase Board)

A. Function:

a. Short circuit protection of inverter output.

b. Feedback UPS output voltage to generate error voltage and error sine-wave signal.

c. Compare the error sine-wave signal and triangle wave to generate PWM trigger signal

that will be transmitted to G board to drive IGBT.


a. VRT1-------Adjustment of output voltage amplitude.

b. VRT2-------Adjustment inverter over current protection level.

c. TPT5-------Feedback O/P current signals and compared with over current protecting

point (setting by VRT2), to generate output short circuit signals transmitted

to A board.

d. TPT7,8-----When UPS is single phase output, TPT7 and TPT8 are the detecting point

of current feedback signals on the secondary and primary of the outputtransformer for DC offset compensation to prevent transformer saturation.

TPT7 and TPT13 (DSINE) must be the same phase, TPT8 and TPT13 ant

phase .

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31/65

e. TPT23,24---Triangle signals transmitted from A board, TPT23 and TPT24 are 180

phase shift.

f. TPT15~22---PWM trigger signals transmitted to G board for triggering IGBT,TPT15

and TPT16, TPT17 and TPT18,TPT19 and TPT20,TPT21 and TPT22 are

anti-phase.

C. Troubleshooting:

a. Over current protection abnormal:

(1). Confirm that detecting CT for protection is connected correctly.

(2). Confirm that O/P transformer and Inverter Choke both are not saturated.

(3). Confirm that VRT2 setting level for over current protection is correct.

b. PWM waveform abnormal:

(1). Confirm that triangle and error sine wave are correct.

(2). Confirm INV ON signal is normal.

(3). Confirm the dead time setting is correct. (Check the component specifications o

DT18~21, RT95~98, and CT4~7 are correct.)

2-16

TPT22

S1

TPT20

S2


32/65

2-17

TPT22

S1

TPT20

S2

TPT13

DSINE

TPT14

ERROR

VOLTAGE


33/65

2-18

TPT3

INVFB

TPT4

SINE

TPT3INVFB

TPT4

SINE


34/65


35/65


36/65


37/65

D

transfer to INV

false

false

?

false

?

false?

false

?

KEY

?

No

No

No

No

SOPFAULT

Yes

SCFAULT

Yes

OTFAULT

Yes

HIDCFAULT

Yes

OFFAULT

Yes

F

E

No

3-3


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F

check

check

reset key

check

time check

check

BATFAULT

Main Loop

OVLFAULT

Check overload %

Time out

?

No

No

Yes

Yes

3-4


39/65

SOPFAULT

false

SINEWAVE O/P OFF

false

false

?

Transfer to RES

Ture

?

Transfer to RES

Ture

wait 7 sec

SINEWAVE O/P ON

No

Yes

Yes

No

RE-START

3-5


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41/65

OTFAULT

false

SINEWAVE O/P OFF

false false

?

Transfer to RES

Ture

?

Transfer to RES

Ture

wait 20 sec

SINEWAVE O/P ON

No

Yes

disappear

?No

Yes

No

LED ON

Yes

RE-START

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43/65

OFFAULT

false

SINEWAVE O/P OFF

false

false

?

Transfer to RES

Ture

KEY

?

UPS on mode

SINEWAVE O/P ON

Yes

NoNo

KEY

?

No

Yes

UPS on normal mode

RE-START

Yes

3-9


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45/65

OVLFAULT

false

SINEWAVE O/P OFF

false

false

?

Transfer to RES

Ture

?

Transfer to RES

Ture

wait 20 sec

SINEWAVE O/P ON

No

Yes

?

Yes

No

RE-START

Yes

No

OFFAULT

cancel

re-start

?

No

Yes

3-11


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3.2 Flow Chart for System Display

START

INITIALI/O_PIN

ALLSYS_LED=

TESTLCM:DELTA

ALLSYS_LED=

/TESTLCM:Sys. Diag.

MAIN

INITIAL RAM

SET_UPRS232/TIMER

INT1/EI

CALLINI_LCM

OR MODE

GRAPHIC ON

SET CURSOR

GRAPHAREA

HOMEADDRESS

DATA AUTOWRITE MODE

INI_LCM

RET

3-12


47/65

MAIN

CALL

INI_LCM

CALL

STSLED

STSLCM

READ

UPS

STATUS

KEYNM>9

CLEAR

MAIN

Measure

TRUE_POWER

Vrms X Irms

UPDATE

R/S/T_V R/S/T_i

VRMS

CLEAR

SQUARE

BUFFER

RMSVI

RET

CALL

RMSVI

LCM

DISPLAY

3-13


48/65

TIMER/500us

INTERRUPT

ENT RY SCAN MODERD AN0-3 ->

BUFCR0_3

4502 AN_SW

AV ERAG EBAT_V,BAT_i

4502 AN_SW

SQ R/S/T_V,i

SQ R-S-T_V

MEM V n, In

4502 AN_SW

SCANED

UP/DO WN_ K

TIM:20MS

LEDSIO

BUZZER

TIME:2SEC

TIME_OUT->

RS232/CHK_S

CALL

UART _ T RX

RET I

R ET

INTTM1

UART_TRX

txbgn.f

FSR.f

PASER

RX_BUF

error

IN C

TRX_INDEX

CLEAR

CHECK_SUM

TRX_INDEX

SETUP

TX_FRAME

TXBGN.F

TRX_INDEX

BUF.FULL

NO YES

R ET R ET

R ETYE S

FST.f

NO

NO

UART X

UART X

R ET

PASER

TRX_INDEX

EN D

NO

YE S

TXB


49/65

INT1

AC_SYNC

I_FREQ =

N_FC - O_FC

UPDATE->

O_FC=N_FC

I_FREQ

? =

F_BUF

FREQCT = 0

UPDATE

AC_CYC

INC.

FREQCT

FREQCT

> 5

CLEAR

FREQCT

F_BUF=I_FREQ

RETI

RETI

YES

NO

YES

NO

3-15


50/65

4. Troubleshooting

4.1 Test Procedures of The System

1. Check PCB all connectors are connected correctly and the right wiring.

2. Check all Breakers in OFF position and make sure the correct input power (Dtype U, V, Wor Y type R, S, T, N) by meter, when UPS is connected to power and battery cabinet.

3. Check all screws of the UPS are tightened.

4. Turn on BYPASS breaker and then measure PCB power supply.

5. If LEDA1 and LEDA2 on A board are lit that represents 12V in normal function. If LEDB2

LEDB3, LEDB4, and LEDB5 on B board are lit that represents 16V in normal function

Measure TPB12 and TPB13 on B board whether 8V is normal or not. If LEDC1 an

LEDC2 on C board, LEDT1 and LEDT2 on T board are all lit, that represents 12V in norma

function.

6. Turn A board dip switch (DSWA1) and R board dip switch (DSWR1) into moderate position.

7. Triangular amplitude adjustment: Turn on BYPASS breaker, and connect CH1 and CH

with oscilloscope probes to A board TPA6 and TPA7. Adjust varistor (VRA1) to make th

amplitude of triangular waveform to 6V, and check its frequency whether equals to 7.8KHzand TPA6, TPA7 with 180 phase shift.

4-1


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8. High-low limit adjustment of INV output voltage: Turn on BYPASS breaker, then adjust th

varistor (VRP2) to make TPP2 (Low Ref.) to 2.5V and adjust the VRP3 to make TPP3 (High

Ref.) to 4.5V.

9. Driving signal test of power board: Turn on BYPASS breaker, and connect CH1 and CH

with oscilloscope probes to B board TPB2 and TPB3. Check the amplitude of squar

waveform equals to +12V, frequency to 30 kHz, TPB2 and TPB3 with 180 phase shift.

10. Test of reference sine wave: Turn on BYPASS breaker, then press ON and OFF buttons o

the front panel simultaneously. Check reference sine wave signals (top of RA70-R phase

top of RA68-S phase, top of RA69-T phase) are 120 phase shift.

11. Test of IGBT driving signals: Turn on BYPASS breaker, then press ON and OFF button

simultaneously. Check the amplitudes of PWM waveform on G board (S1, S2), (S1, S2

(S3, S4), and (S3, S4) are +14V/-5V, and the dead time is about 3.5 ~ 5 us.

4-2


52/65

12. Adjustment of reserve input detection: Turn on BYPASS and RESERVE breakers, the

connect CH1 of oscilloscope probe to TPA5 and adjust varistor VRA2 to the amplitude abou

2.3~2.5V.

13. Test of rectifier driving signals: Pull out CNC4 connector on C board, turn off BYPASS an

RECT breakers, and connect CH1 and CH2 with oscilloscope probes to TPC8/TPC13

TPC9/TPC10, TPC11/TPC12. Check whether TPC8 and TPC13, TPC9 and TPC10, TPC1

and TPC12 are 180 phase shift.

14. Adjustment of DC bus voltage: Connect back the CNC4 connector on C board, adjust VRC

clockwise to end, and turn on BYPASS and RECT breakers, the LEDC3 on C board will be l

Adjust VRC2 counterclockwise slowly until the DC bus voltage equals to 393V. Then, tur

off RECT breaker waiting for DC bus voltage down to zero.

15. Adjustment of HIGH DC SHUTDOWN voltage: Turn on BYPASS and RECT breakerwaiting until DC bus voltage reaches 393V. Adjust VRC2 counterclockwise till DC bu

voltage equals to 415V. Then, adjust VRB2 on B board clockwise until buzzer is beep, an

HI DC SHUTDOWN LED on R board is lit at the same time. Finally, adjust DC bus voltag

back to 393V.

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16. Adjustment of BOOST CHARGE voltage: Turn on BYPASS and RECT breakers waitin

until DC bus voltage attains to 393V, and short C board JPC3 with short pin, then LEDC4 wi

be lit at that time. Adjust VRC3 until DC bus voltage reaches 405V, then take out short pin

and DC bus voltage will down to 393V automatically.

17. INV ON test: Turn on BYPASS and RECT breakers until DC BUS voltage is about 30V~40Vthen turn off RECT breaker. Connect CH1 and CH2 with oscilloscope probes to T boar

TPT3 and TPT4, then press ON and OFF buttons simultaneously and check the waveform

should be anti-phase.

18. INV ON test: Turn on BYPASS and RECT breakers, then adjust VRC2 until DC bus voltag

attains to 393V. Connect CH1 and CH2 with oscilloscope probes to T board TPT3 an

TPT4, press ON and OFF buttons simultaneously. Using voltage meter to check the

phase output voltage whether they are coincidence with the specifications or not. If no

adjust VRT1 on T board to meet the specifications.

19. Phase-lock adjustment: Turn on BYPASS and RECT breakers until DC bus voltage attain

to 393V, then turn on RESERVE and O/P breakers, turn off BYPASS breaker, press ON an

OFF buttons simultaneously (the above procedures means transferring UPS to INV outpu

mode). Connect CH1 and CH2 with oscilloscope probes to static switch SCR, then chec

reserve power and INV output whether they are phase-lock or not. If no, adjust A boar

VRA3 till phase-lock.

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20. Adjustment of the LCD display: Transfer UPS to INV output mode, adjust VRR5~VRR11 o

R board for the LCD display of I/P, O/P, and DC bus voltage and current to meet the actua

value.

21. Adjustment of 200% Ipeak protection level: Connect CH1 with an oscilloscope probe to T

board TPT5, take on resistive load and check whether there is an waveform on the scope

If yes, change to computer load, and adjust T board VRT2 counter-clockwise to 200% Ipea

protection point.

4-5


55/65

22. BATT GND FAULT test: Connect one terminal of wire to UPS GND, the other side to touc

with battery terminal, then R board LEDR6 will be lit, and alarm will beep.

23. High-low transfer voltage test: Transfer UPS to INV output mode, connect battery cabine

and shut off AC input power. Then, using autotransformer to change AC input voltage tUPS, adjust C board VRC1 for rectifier input low-level transfer point (nominal voltage -15%)

and VRP1, VRP2 on P board for reserve input high-level and low-level transfer poin

(nominal voltage 20%).

24. OVERTEMP/FUSE FAULT test: Transfer UPS to INV output mode, pull out CNP

connector on P board or CNG6 connector on G board, the alarm will beep and LEDR3 on R

board will be lit at that time.

25. Cooling fan test: Transfer UPS to INV output mode and take on 70% loading. Check th

cooling fan whether rotate faster or not.

26. Overload test: Transfer UPS to INV output mode and take on 110% loading. The R boar

LEDR8 will be lit and buzzer will beep at the same time. 15 minutes later, INV output mod

will be transferred to RES output mode automatically and INV OVERLOAD LED on R board

will be lit. If take off the over loading, after 20 seconds, RES mode will be transferred bac

to INV mode again automatically.

27. 125% overload test: The test procedures are similar to Item 26, but the loading leve

changes to 125% and overload time to 5 minutes.

28. 150% overload test: The test procedure are similar to Item 26, but the loading leve

changes to 150% and overload time to 30 seconds.

29. BATT LOW & BATT LOW STOP test: Transfer UPS to INV output mode, connect batter

cabinet, take on nominal load, and shut off AC input power. When DC bus voltage goe

down to 330V, the LEDR4 on R board will flash and buzzer will beep faster. When DC bu

voltage goes down to 300V, LEDR4 will be lit and shutdown UPS.

30. Adjustment of the battery charge current: Continuously from Item 29 last step, turn on th

AC input power to UPS and connect current probe to battery + terminal, then adjust B boar

VRB3 for battery charge current (< 0.2C).

4-6


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57/65

2. RESERVE FREQUENCY ABNORMAL

R

board

LED12

lit

Rboard

RESMAINSFF

="LO"(RR26)

Aboard

RESS-W

(TPA4)OK

RESFreq.

OK

CheckRESI/P

&50/60Hzsetting

END

ReplaceRboard

ReplaceCPUboard

onAboard

ReplaceAboard

NO

NO

NO

YES

YES

YES

4-8


58/65

3. RESERVE MAINS FAIL

RboardLEDR11lit

Rboard

RESMAINSFF

="LO"(UR31.1)

Aboard

RESMAG

=2.3~2.5V

(TPA5)

AboardRESvoltage

detect

OK

CheckUPSwiring

END

ReplaceRboard

Replace

CPU board

onAboard

Aboard

RES amplitude

settingOK

Adjust

A

board

VRA2

ReplaceAboard

NO

NO

NO

YES

YES

YES

NO

YES

4-9


59/65

4. INVERTER FAULT

R board LEDR9 lit

R board

INV SC="HI"

(UR31.5)

A board

SCR,SCS,SCT

= "HI"

Ipeak level

setting OK

(TPT6)

Check Ipeak CT OK

END

Replace R board

Replace A board

Adjust T board

VRT2

NO

NO

Yes

No

YES

YES

4-10


60/65

5.INVERTER OVERLOAD

R board LEDR8 lit

R boardINV OL= "LO"

(UR31.6)

A board

LOAD(CNA6.20)Freq. OK

R boardPIOBL(UR30.2)

Freq. OK

Overload

CT OK

Check UPS wiring

END

Replace R board

Replace CPU boardon A board

Replace A board

Replace R board

NO

NO

NO

NO

YES

YES

YES

YES

4-11


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6. BATTERY GROUND FAULT

R board LEDR6 lit

R board

BGF= "LO"

(UR32.2)

BATT wiring

correct

Correct BATT Wiring& replace bad BATT

END

Replace R board

Replace B board

NO

NO

YES

YES

4-12


62/65

7. BATTERY LOW / STOP

R board LEDR5 lit

Replace R board

R board

PIOSD="LO"

(UR31.1)

DC BUS 330V

Replace C board& check RECT SCR

END

Replace CPU board

on R board

NO

NO

YES

YES

4-13


63/65

8888.... OVERTEMPERATURE / FUSE FAIL

R board LEDR3 lit

R board

OTF ="LO"

(UR31.3)

A board

OTFG,OTFP,

OTFS= "LO"

Check thermal switchon heatsink

END

Replace R board

Replace A board

NO

NO

YES

YES

4-14


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9. RECTIFIER HIGH DC STOP

RboardLEDR2lit

Rboard

HDCSDR="LO"

(UR32.1)

DCBUS415V

Cboard

TPC8.9.10,11,

12.13OK

ReplaceCboard

CheckRECTSCR

wiring

ReplaceRboard

END

ReplaceBboard

Bboard

VRB2setting

correct

AdjustBboardVRB2

NO

NO

NO

YES

YES

YES

NO

YES

4-15


65/65

10. RECTIFIER MAINS FAIL

R board LEDR1 lit

R board

RMF= "LO"(UR31.4)

A boardRMF5= "LO"(CNA46.22)

C board

(TPC1~TPC3)OK

Check I/P powerphase & wiring

END

C board VRC1

setting OK

Replace Rboard

Replace A

board

Adjust C board VRC1

Replace C

board

NO

NO

NO NO

YES YES

YES

YES

T Service Manual

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