Service Manual: 1-1.5KVA Model
Service Manual: 1-1.5KVA Model
Service Manual: 1-1.5KVA Model
1-1.5KVA model
General Information
Getting start
This service manual uses the following conventions to alert you some important information for
safe operation and quick working.
Information and Tips: There are some tips and skills after this symbol. During
service operations, these skills are provided by our design
engineers which may help you quickly finish your work.
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Important Safety Instructions
STOP
2. DO NOT perform any internal service or adjustment of this product unless another person is
capable of rendering first aid and resuscitation is present.
3. Dangerous voltage exists at several points in this product. To avoid personal injury, don't
touch any exposed connections or components while UPS is active.
4. Turn off the UPS and disconnect input power cord before removing outside protective cover.
6. High voltage may present at DC capacitors. Before opening the outside cover, wait for at
least five minutes after turning off the UPS.
2. If the battery connectors (P5, P8) are disconnected, be sure to plug in the input power cord
and the input power is available before re-connect the battery connectors.
3. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.
After opening the cover, please always check the tightness of all wires, connectors,
and screws first. Then check if there is any de-colored components inside
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STEPS TO OPEN THE CASE
There are two types of the mechanical structure,Tower and RACK.To open the outside case,
please follow steps and figures below:
1. Remove related screws on STEP 1 figure.
2. Slide outside cover in the direction shown in STEP 2.
3. Done.
TOWER RACK
STEP1
STEP2
3
STEP3
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I. INTRODUCTION
For all series of UPS, they are strictly tested and carefully designed. We always do our best to
make our products more reliable and safer, this is also the goal of our company. However, due
to the lifetime of electrical components and some unpredictable reasons, there will be
unavoidable failures of this UPS. If this situation occurs, service of qualified person is needed.
This service manual will guide the technicians to repair and adjust a problematic UPS. If the
UPS still does not work properly, please contact with us and we will be glad to solve any
problems you met.
Because of the following unique features of this series UPS (Uninterruptible Power System), it
is very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and safe
operation.
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II. PRINCIPLE OF OPERATION
This 1KVA high input power factor UPS system contains two major PCB assemblies. They are
including:
1. PSDR: contains major parts of (1) charger, (2) DC power supply, (3) unit power factor
correction, (4) DC-DC converter, (5) inverter and (6) output circuits.
2. CNTL : contains major parts of protection, signaling circuits, regulation and control
circuits of inverter
The simplified schematics in figure 1 shows how the major circuits are connected and illustrates
the overall system functions.
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Front Panel Function Display
Key Board
Programmble
Battery
Power Board
Control Board
Basically, this ON-LINE UPS system utilizes high frequency PWM techniques to achieve high
efficient performance. This UPS can deliver a clean, regulated sine-wave output at any load
under full load. The sub-systems are described as below:
O/P
I/P PFC
RY
N.F. AC/DC DC/AC N.F.
RY
DC/DC
CHARGER
BATTERY
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching signals
from PWM generation circuit through a pair of photo-couplers to trigger the upper IGBT and
the lower IGBT alternately. The output of IGBT's is filtered by an LC circuit to reduce the o/p
voltage harmonics distortion.
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Figure 6: Schematics for inverter
This portion can be seen as brain of the UPS. It provides the control pulses to the switching
elements which deliver power to the output. The sub-system also regulates the output to
ensure that the UPS is delivering constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a reference
signal from sine wave generator. The difference of these two signals (error signal) alter the
pulse widths of PWM signals which control the duty cycles of switching elements to regulate
the output voltage within specification.
In order to avoid un-wanted surge current at the transfer of bypass relay, the bypass signal
activates the tracking circuit. It matches the inverter voltage with the line voltage by having
the amplitude of the reference signal following the variation of line voltage.
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When the main is applied and the switch is turned on, a 10-second timer is triggered. The
bypass relay stays at bypass position in this time period. At the end of this period, the bypass
signal is removed and the relay transfers to inverter output.
a. Overload Protection: The UPS collects the continuous overload signals through CPU
switch the bypass relay. If the output load is lower than 110% of rated load (VA ,or
Wattage) the UPS keeps running on inverter running and warnning. If the output load is
between 110% and 130% of rated load (VA ,or Wattage) the UPS transfers to bypass
after 12s. If the output load is higher than 130% of rated load, the UPS transfers to
bypass after 1.5s immediately.
b. Cycle by Cycle Current Limit: When output loads sink a high surge current for a
short time, a high inverter current is detected and the inverter switches, i.e. the IGBT's,
are turned off pulse by pulse to protect themselves from thermal runaway. The output
relay stays at inverter output position unless a continuous overload is detected or an
abnormal inverter operation occurs.
In case of the battery voltage is high voltage, the UPS will warning and the LCD will
display the fault code.
3. Inverter output abnormal protection
The inverter failure signal shuts down the inverter immediately, makes the buzzer a
continuous alarm, and the LCD displays the fault code.
" The failure signal latches itself unless SW off or battery is empty".
4. Over temperature protection
The thermal switch detects the temperature of PSDR heat sink. The thermal switch is
electrically connected to the CPU. An opened thermal switch is thought as temperature
failure by the UPS. The LCD will display the fault code.
5. Bus over/under/unbalance-voltage protection
To protect any BUS over/under/unbalance -voltage condition especially for the half-bridge
load. The LCD will display the fault code.
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Upon the batteries are discharged to battery-low level, the battery-low signal is activated
and the buzzer beeps every 1 second.
3. Front Panel:
The front panel consists 2 parts: push button and display LCD set.The push button is used to
turn on and off the UPS. LCD display indicates the load level,the battery voltage level and
operation status of the UPS.Besides, when the system works abnormally, The LCD will
display the fault code.
Button Function
Turn on the UPS: Press and hold ON/Mute button for at least 2
seconds to turn on the UPS.
Mute the alarm: After the UPS is turned on, press and hold this button
ON/Mute Button for at least 5 seconds to disable the alarm system. But it’s not applied
to the situations when warnings or errors occur.
Down key: Press this button to display previous selection in UPS
setting mode.
Turn off the UPS: Press and hold this button at least 2 seconds to turn
off the UPS in battery mode. UPS will be in standby mode under
power normal or transfer to Bypass mode if the Bypass enable setting
OFF/Enter Button
by pressing this button.
Confirm selection key: Press this button to confirm selection in UPS
setting mode.
Switch LCD message: Press this button to change the LCD message
for input voltage, input frequency, battery voltage, output voltage and
output frequency. It will return back to default display when pausing
Select Button for 10 seconds.
Setting mode: Press and hold this button for 5 seconds to enter UPS
setting mode when UPS is off.
Up key: Press this button to display next selection in UPS setting
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mode.
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IV. ALIGNMENTS
List below are some test points and procedures when a qualified service person wants to check
whether EUT (Equipment Under Test) will works properly. Before beginning following
procedures, please make sure that EUT is OFF and disconnected from Utility.
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Figure 9 : Circuit for test output balance
V. TROUBLE SHOOTING
Due to careful design and strict tests of our products, fail of UPS seldom occurs. However,
once they do fail in some situations, please check them according to Trouble Shooting Chart,
that will help you solve the most problems on UPS.
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Trouble Shooting Chart
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Display Function
Backup time information
Indicates the backup time in pie chart.
Indicates the backup time in numbers.
H: hours, M: minute, S: second
Fault information
Indicates that the warning and fault occurs.
Indicates the warning and fault codes, and the codes are listed in
details in 3-5 section.
Mute operation
Indicates that the UPS alarm is disabled.
Output & Battery voltage information
Indicates the output voltage, frequency or battery voltage.
Vac: output voltage, Vdc: battery voltage, Hz: frequency
Load information
Indicates the load level by 0-25%, 26-50%, 51-75%, and 76-
100%.
Indicates overload.
Indicates the load or the UPS output is short circuit.
Programmable outlets information
Indicates that programmable management outlets are working.
Mode operation information
Indicates the UPS connects to the mains.
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Indicates the bypass circuit is working.
Battery information
Indicates the Battery level by 0-25%, 26-50%, 51-75%, and 76-
100%.
UPS Setting
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There are three parameters to set up the
Parameter 1
UPS.
Parameter 1: It’s for program
alternatives. There are 8 programs to set
up: output voltage setting, frequency
converter enable/disable, output
frequency setting, ECO enable/disable,
ECO voltage range setting, Bypass
enable/disable, Bypass voltage range
setting, programmable outlets
enable/disable, programmable outlets
Parameter 2 Parameter 3
setting and exit.
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Standby mode UPS is powered off and no output
supply power, but still can charge
batteries.
Warning indicator
Warning Icon (flashing) Alarm
Low Battery Sounding every second
Overload Sounding twice every second
Battery is not connected Sounding every second
Sounding every second
Over Charge
Failure Diagnosis
1. OVERVIEW :
Circuit Block Components to be checked Fail condition
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Charger Q3 D-S short or open
D3,D5 short or open
DC Power Supply Q2 D-S short or open
2. U.P.F. CORRECTION:
Step Checked components Instrument Reference Value Failed condition
function
1 F1 Ω short open
4.DC/AC INVERTER:
Step Checked components Instrument Reference Value Failed condition
function
1 F1,F2,F3 Ω short open
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4 Ω >1M too low
U1 (3845) PIN : 5-6
>1M
5-7
3.5k
5-8
>1M
6-8
6. AC/DC CHARGER :
Step Checked components Instrument Reference Value Failed condition
function
1 Q3(D,S) DIODE 0.49 short or open
2 R6 Ω 47 open
3 R37 Ω 0.5Ω open
After you have replaced all defect components on power stage ( PSDR ) , connect with
control board. Supply DC voltage36Vdc/2Amp (limited current) with DC power supply via
P5+ and P8-. Turn on the switch on panel, you will see "current limit" on the DC power supply
for about 2 seconds (If not, there are some defective components you have not found).
When everything seems good, turn off the switch on panel and remove DC power supply.
Plug in the power cord and supply UPS with the mains. Test the output of charger( P5+,P6- ).
Is it 41.2Vdc.The fan will also active. If there is no problem in charger, connect the batteries
via P5, P8.
Finally, turn on the switch on panel again and follow the procedure listed in part Ⅲ
(Alignment) to adjust the DC offset, and measure voltage on DC bus, output voltage.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have replaced
all defective components
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Line low comeback 175 VAC; 5%(Full Load)
Line high transfer 300 VAC; 5%
Line high comeback 285 VAC; 5%
Start-up Voltage with Output 110 VAC to 300 VAC; 5%
Power
Ratings (at nominal input voltage) 1000/1500 5A/8A
earth leakage 3.5 mA, maximum (UPS only)
Input power factor > 0.95
Input frequency 40 Hz to 70 Hz
Input protection type circuit protector
O/P Specification
O/P Power
Power (VA) 1000 / 1500
Power (Watts) 800 / 1200
Output Power Factor Rating 0.8
Load Power Factor Range 0.5 lagging to 1.0 (unity)
Output Voltage 208/220/230/240
Waveform Sinusoidal
Nominal Voltage 230 VAC
Line Mode Voltage Regulation 3% of nominal; no load to full load, resistive &
RCD loads
Battery Mode Voltage Regulation 3% of nominal; no load to full load, resistive &
RCD loads
Transient Response 0%-100%-0%; 9% max.
(line mode) 20%-100%-20%; 6 % max.
1. RS232 PORT
The RS232 provides proprietary command sequence for the computer to monitor the line and
UPS status and to control the UPS. The data format is listed as following:
PIN TYPE ...................: female
BAUD RATE .............. : 2400 bps
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DATA LENGTH ......... : 8 bits
STOP BIT ................... : 1 bit
PARITY ...................... : NONE
The pin assignment and description are listed in the following table and the interface
configuration is indicated in figure VI-1. Note that, the computer will control information
exchange by a query followed by <cr> (Character Return). UPS will respond with information
followed by a <cr> or action. UPS data will be provided at 2400 baud rate and consist of 8 data
bits, 1 stop bit, and no parity bit. All the information is provided in ASCII format.
2.USB PORT
The USB is compatible to USB1.1 specification, and implemented for HID device and bus-
powered.
The USB connector is "B" receptacles, seeing the following figure . The following table is signal
definition of USB interface.
PIN# SIGNAL
1 VBUS
2 D-
3 D+
4 GND
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