9SX 15-20K UPS Service Manual - 20200318 (Ingles)

Sirius 15-20K UPS
Service manual
Title Sirius 15-20K Service Manual

Checked : Rev:1.0
Approved : Confidential Page 1 of 58
This specification is the property of Eaton Corp. and shall not be reproduced or copied or used as the basis for manufacture or sale of apparatus without permission
Summary
1 Introduction .................................................................... 3
1.1 Purpose of the document ........................................................................................ 3
1.2 Analysis process ...................................................................................................... 4
1.3 Schematic of the UPS .............................................................................................. 5
2 Security ........................................................................... 7
3 Interconnection diagram of products ........................... 9
4 Introduction of each principle function and the
assembled board ............................................................. 12
4.1 Functional Block of The Product .......................................................................... 12
4.2 Operating Principle Of The Major Functional Block ............................................ 14
4.3 PCBA board in the UPS ......................................................................................... 18
5 Operation by service tools .......................................... 22

6 Failure analysis ............................................................ 25
6.1 LCD Panel Display.................................................................................................. 25
6.2 Primary Diagnosis with LCD Information ............................................................. 28
6.3 Failure Diagnosis by Static Checking .................................................................. 29
6.4 Trouble shooting .................................................................................................... 31
7 Disassembly ................................................................. 46
8 Component level Tests by function and by board..... 55

Checked : Rev:1.0
1 Introduction
1.1 Purpose of the document
This service manual will guide technicians to diagnose, troubleshoot and repair UPS
products.
Depending on the countries, the extent of the repair of the product can be to find the failed
item or the failed component. This can reduce repair costs.
It allows R&D to provide a manual that meets the expectations of users who include:
- Technical support
- Technician after sales
- Repair personnel
- etc

Checked : Rev:1.0
1.2 Analysis process
Global process showing the flow from the broken product to the test and repair steps and
back to the customer
CUSTOMER
UPS failed at customer Diagnostic’s help
REPAIRS
Reception of the
product and Replacement of Product repaired
verification of broken and ready to be
visual and components sent
electrical aspects
Tests with and

without power to End of repair test
localize the failure
Process at the customer
Repair process

Checked : Rev:1.0
1.3 Schematic of the UPS
Goal: Identify the Board references by product model / rating
Main power block

Bypass Input Internal
Bypass
Main Input Output

IP EMI PFC INV OP EMI
Charger
Batteries
Fig. 1.3.1 15K-20K main power block

Checked : Rev:1.0
Signal and communication block
Signal and power supply connection
LCD
Main
Intelligent slot SPS
Communication PFC board FAN
board
USB/RS232/RS485 Control board
communication Charger
EPO/
Dry in/Dry out/
MBP&EBM detection Slave
SPS
INV-ESS
INV board
board
Parallel board
Fig. 1.3.2 10K-20K signal and communication block
PCB board PN :
STK 15KS STK 20KS
ETN 15KS ETN 20KS
9106- 9106-
9106-52225 9106-52216
52226 52217
126-00317 126-00317EN1
LCD
(744-A4645) (744-A4646)
712-00616 712-00617
CNTL
(744-00616) (744-00617)
710-07794
PFC
(744-07794)
710-07803 710-07795 710-07803 710-07795
INV-ESS
(744-07803) (744-07795) (744-07803) (744-07795)
710-07796
INV
(744-07796)
710-07800
PARA
(744-07800)
710-07801
COMM
(744-07801)
710-07799
EBM detect
(744-07799)
710-07857
MBP detect
(744-07857)

Checked : Rev:1.0
Contains major parts of protection, signaling circuits, regulation
CNTL board
and control circuits, and supports LCD interface.
PFC board Contains input EMI, PFC, charger circuit and main SPS circuit.
Contains output EMI, inverter circuit, bypass circuit and slave SPS
INV-ESS board
circuit.
INV board Contains inverter circuit
Parallel board Contains parallel communication interface.

Communication board Contains RS485/RS232/USB/SLOT communication interface.
2 Security
Goal : To protect against electrical hazards
• Do not make adjustments to the product unless an authorized person is present.

• There is a risk of presence of AC voltage even if the mains power is no longer
connected.
• Switch off and disconnect the UPS from the mains power before removing the cover(s).
• Remove the batteries because battery voltage is always present on the power boards,
even after the product is switched off.
• To avoid injury, do not touch any connectors or components when the UPS is turned
on.
• Charged capacitors can deliver high voltage.
o Before opening the cover, wait at least five minutes after turning off the UPS.
• After opening the UPS, always check the insulation of all wires, connectors and
screws.
• Before restarting the UPS :
o Check the input (voltage and frequency) before commissioning.
o Check the polarity of the battery connections and the state of all internal wiring and
connectors.
o Close/Cover the product
Indicate symbol in this service manual :

Checked : Rev:1.0
STOP
Warning: Denotes a procedure or operation, which, if not perform correctly, may result in
personal injury. Be sure not to continue operation until indicated conditions are fully understood
and met.
1. For qualified service personnel only.
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, and wait until the UPS shuts down completely
before removing outside protective cover.
5. AC voltage is always present if the input AC power is still available.
6. High voltage may present at DC capacitors. Before opening the outside cover, wait for at least five
minutes after turning off the UPS. Discharge the remaining energy at DC capacitors with resistor
before disassembling the power board.
7. Verify input source (voltage and frequency) is within the maximum range before service.
!
Caution: Denotes a procedure or operation, which, if not perform correctly, may cause damage
to the UPS. Be sure not to continue operation until indicated conditions are fully understood and
met.
1. DO NOT short-circuit internal batteries

2. After service, verify the polarity of batteries, fasten all screws and connectors before restarting the UPS.
Information and Tips: There are some tips and skills after this symbol. During service
operations, these skills may help you quickly finish your work.
1. After opening the cover, please always check the tightness of all wires, connectors, and screws first.
Then check if there are any de-colored components inside.
2. TO DISCHARGE the residue energy on bus capacitors and charger capacitors.

Checked : Rev:1.0
3 Interconnection diagram of products
Goal: To know the interconnections and connectors between the boards for different
power ratings of products.
This is demonstrated by showing all the boards and their interconnections including:
- Input
- Output
- COM Cards
- Batteries (internal and external)
- LCD
- Fans
- etc

Checked : Rev:1.0
Checked : Rev:1.0
Sirius 15-20K UPS internal wiring diagram
SIRIUS UPS INTERNAL WIRING DIAGRAM
W14 W13 W12

T.BYS S.BYS R.BYS
BYP-L3
R.CHOKE W7 P1 R
BYP-L2
BYP-L1
W18
OP-L3 GND-N.OP
W19
S.CHOKE W8 P2 S
OP-L2
OP-L1 W15 R.OP-L INV-ESS INV

OP-N
W16 S.OP-L
T.CHOKE W9 P3 T
OP-N
W17 T.OP-L
N W10 P5 N
N W11 P4 N BUS- W4
W2
GND-N
CN1 CN2 W3
CN3 CN1
BUS+ W1
CN4
PARA
CN1 CN2
CN7 CN8
CN6
CN12
LCD
CN5
CNTL/710-07793
CN4
CN2 CN3 CN10 CN9
CN6 CN5
CNRJ1
CN1
CN3 COMM
CN8
SLOT
BUS+ BAR1
CN4 CN3
W1
BAT+ BAT+ BAR3
GND-N
BAT-N
BAR2
BAT-N
W6
N
SPS
W7
BUS- BAR4
BAT- W9
BAT-
CN6
PFC
W11
IP-N W12 IP-N
IP-N
W13 IP-R
IP-L1 CN8
IP-L2 W14 IP-S
IP-L3
W15 IP-T
CN9

Checked : Rev:1.0
4 Introduction of each principle function and the
assembled board
Goal : To know each function and all Boards.
4.1 Functional Block of The Product
As a true online UPS, the product employ a double conversion topology, comprise
following functional blocks, as shown in Figure 4.1.1
Bypass Input Internal

Bypass
Main Input Output

IP EMI PFC INV OP EMI
Charger
Main SPS Controller LCD
Slave SPS Communication Parallel

Batteries
Figure 4.1.1 Function block Diagram
Controller:
Control the operation of the whole UPS. The controller block also provides communication
interface for receiving and executing command from user via the panel or a preset
protocol.
Rectifier:
Also called PFC, belongs to input stage of the UPS. The converter block converts the AC
mains input power into a pair of stable DC power storing on the DC-BUS. In means time,
Power Factor Correction is performed, the input current tracking the input voltage
waveform, and the input power factor can be close to 1, achieve maximum efficiency and
product lowest power pollution to the power supply system.

Checked : Rev:1.0
At battery mode the converter is reused to convert the low level DC power into higher level
and more stable DC power, storing on the DC-BUS also.
Inverter:
The block belongs to the output stage of the UPS, used to convert the DC power from the
DC-BUS into clean, stable AC output power.
When the mains line is within the spec, the converter works; In case the mains line supply
is out of spec, due to either the voltage or the frequency, the UPS will transfer to battery
mode. The controller can detect the interruption of input mains supply in very short time,
the output power will be sustained by energy stored in the DC-BUS capacitor, the
interruption will never appear on output.
Charger:
The battery charger converts the DC-BUS voltage into lower DC voltage to recharge the
Battery. The max capacitor of charger can be up to 13A. (the default charging current is
2A).
EMI:
The input EMI filter and output EMI filter are used for two purpose, the first one is to
prevent the UPS being interfered by external electronic/magnetic noise which generated
by the other electronic system, the second is to prevent the other system being interfered
by the noise which generated by UPS system.
Internal bypass:
The internal Bypass provides an alternative path in case the power conversion stage
become out of order, to maintain the continuity of output supply.
SPS:
The Power supply generates low voltage DC power which supply to the control and
operation circuit. Two SPS is designed for redundancy. Main SPS located in REC board
provides all power supply in normal statute. Slave UPS located in INV-ESS board provides
part power supply for bypass operation and communication.
LCD and communication:

The LCD, Communication card are the interface for user. They could supply the
information about UPS through LCD panel, computer, internet etc.

Checked : Rev:1.0
4.2 Operating Principle Of The Major Functional Block
PFC Converter
The purpose of PFC converter is to generate a stable bipolar DC BUS for inverter first. It’s
another very important task is to make the input current track input voltage waveform,
therefore to achieve a high input power factor. That is why we call it PFC (Power Factor
Correction) converter. Figure 4.2.1 showed the topology implement the PFC converter(just
one phase is showed, other two phase are similar).
BAT+ BUS+
LINE-R
N
BAT-
BUS-
Figure 4.2.1 PFC converter
While AC mains is in normal condition, input switch is on. The global controller outputs
PWM (Pulse Width Modulation) signal, the PWM signal will be isolated, amplified and used
to drive switching component, the IGBT. When The IGBT is turned on, the current flow
through the PFC chock increase, the chock is energized; when the IGBT is turned off, the
chock de-energize and charge the DC-BUS capacitor. By controlling the Duty Cycle of the
PWM signal, the energy charging the DC-BUS capacitor can be controlled, therefore the
voltage of the DC BUS can be controlled, at the same time the waveform of the current
can also be controlled to track the input voltage waveform, implement the power factor
correction.
In case the AC mains interrupt or being out of tolerance range, the BAT relay would be on,
so the battery is the input of the converter. Similarly the converter converts the DC power
from the battery to maintain the DC-BUS voltage.
The DC BUS voltage, will be regulated at ±350 Vdc to ±390 Vdc.
Inverter
The inverter converts the DC power from DC BUS into the AC output to supply the load. A
three level half bridge topology is employed, Figure 4.2.3 shows a diagram of inverter. (just
one phase is showed, other two phase are similar)
Checked : Rev:1.0
+BUS
INV OUTPUT
-BUS
Figure 4.2.3 Inverter converter
The three level half bridge inverter comprise four switching devices - IGBT with co-pack
diode, two clamp diodes, the driving circuits for each IGBT, a LC filter.
When the two positive IGBT is turned on, The output of half bridge is equal to Positive DC-
BUS voltage, when the first positive IGBT is turned off and the second positive IGBT is
turned on, either the positive clamp diode is active or the negative clamp diode is active,
the output of the switching leg is Neutral. So by changing the duty cycle, average of output
of the switching leg can vary from +BUS voltage to Neutral. It is the same that control the
two negative IGBT to achieve –Bus voltage to Neutral. Then the output of the switching leg
filtered by a LC filter to get clean and stable sine wave voltage.
Global Controller：
The CPU can be regarded as the brains of the UPS, which is in the charge of signal
detecting, measurement, processing, timing control, protection, communication. The
Global Controller of UPS is composed of following major circuits as following:
1. CPU Central Processor Unit
2. Signal detecting circuit
3. Regulation & Protection circuit
4. Output buffering circuit
5. Communication interface circuit
The global controller implements following protection function:
1. Overload Protection
2. Cycle by Cycle Current Limitation
3. Battery over or under voltage protection
4. Inverter output abnormal protection
5. Over temperature protection
6. Bus over or under voltage protection
Checked : Rev:1.0
7. Fans lock protection
Due to the high level integration, the global controller is not desired to maintenance or
repair out of manufacture factory. There are two methods to identify the status of global
controller. The first one is to test it with test fixture; the second is to test the global
controller on one piece PSDR(PFC and INV) which has been verified OK.
13A Charger
Refer to Fig. 4.2.4; the battery charger is employed dual BUCK topology. The global
controller outputs PWM (Pulse Width Modulation) signal, the PWM signal will be isolated,
amplified and used to drive switching component, the IGBT. When IGBT turns on, the
current in the inductor will increase, and a certain amount of energy is stored in the
inductor. When IGBT turns off, the energy stored in the inductor will start to release to load
side and charge the output capacitor. By controlling the duty cycle, energy transfers to
load side and the output voltage can be controlled.
BAT+
BUS+
N N
BUS-
BAT-
Fig. 4.2.4 13A charger
Auxiliary Power Supply (SPS)

The Auxiliary Power Supply (SPS) module supplies DC power for UPS operation. The
main SPS module is located in rectifier board and slave SPS is intergrated in INV-ESS
board. The input of the main SPS is the battery, or DC BUS or AC line. The input of slave
SPS is bypass AC input.
The SPS module output +12 Vdc, +15Vdc, -15 Vdc.
+12 Vdc mainly uses for Relay driving, IGBT driver power, SCR driver power, Fans supply
and generates ELV power supply for communication board.+12Vdc also generates +5Vdc.
+15Vdc, -15 Vdc use for signal amplifiers, comparators, HCT power.
+5 Vdc uses for LCD power and generate +3.3 Vdc and +1.65 Vdc power supply for the
CPU.

Checked : Rev:1.0
LCD, LED and button
The front panel consist 3 parts: ON/OFF push buttons, LCD and LEDs.
ON/OFF button : turn on and off the UPS. Start main SPS when just battery is available.
All UPS information including the input, the output, the battery, the load and the status of
UPS are displayed on the LCD screen. The detailed illumination of LCD display can be
found in user manual.
When UPS is out of order, the fault information will be displayed and the buzzer will beep
continuously. The detailed definition of the warning or fault code can be found in section 5.
Communication Interface
The communication interface provides a means for using computer to manage the UPS,
on the rear panel of the UPS, a standard RS232 serial interface, USB, RS485 port and an
intelligent slot are provided.
With dedicated software, output voltage, frequency can be set via the serial interface port;
also status of the UPS can be monitored.
The intelligent slot can accept NMC, AS400, MODBUS etc., for more flexible application
solution.
The communication interface circuit provides isolation and voltage level transfer function
for communication; the communication protocol is implemented by the CPU.
Emergence Power Off

The Emergence Power Off interface provides an emergence power off function. When the
EPO function is enabled and configured to NC status, once the EPO port is open, the UPS
would shut off the output and enter into EPO mode, and the UPS would not respond
anything command unless the port is closed. In additional, EPO function can be configured
to NO status.
Ventilation And Chassis

Ventilation system of the UPS consist of air flow guiding insulation paper and fans, The
ventilation system keeps the temperature of component of the UPS in safe range, so it is
very important for the UPS, To achieve lowest acoustic noise and longest life time of the
fans, fans driver and intelligent fans speed control algorithm is employed.
The chassis of the UPS provide a strong construction accommodate all the electrical parts,
shield for EMC, and safety guard for operator.
Basically, the chassis comprise a base plant, an internal support plant, a front support
plant, an outside cover, a rear panel, and a front panel.

Checked : Rev:1.0
4.3 PCBA board in the UPS
Sirius UPS contains two big parts, one is base that PFC board is located, another one is
cover that INV board/INV-ESS board/CNTL board/Communication board/PARA board is
located. Fig4.4.1 and Fig 4.4.2 show the internal structure of UPS.
Fig. 4.3.1 Structure Diagram
Fig. 4.3.2 Exploded View
Next,the PCBA board of UPS are introduced. Fig. 4.3.3 shows the CNTL board. CNTL
board is assembled in INV-ESS board, and is connected to PFC board/Communication
board and LCD through signal wiring. Also parts SELV port was located in CNTL board.

Checked : Rev:1.0
Fig. 4.3.3 CNTL board
Fig.4.3.4 shows the PFC board. PFC board has signal connectors which are connected to
CNTL board. PFC has power connection from line/battery to INV board. PFC board
contains input EMI/PFC/charger and SPS.
Fig. 4.3.4 PFC board
Fig.4.3.5 shows the INV board.INV board has signal connectors which are connected to
INV-ESS board. INV has power connection from PFC board to INV-ESS board. INV board
contains part of INV circuit.

Checked : Rev:1.0
Fig. 4.3.5 INV board
Fig.4.3.6 shows the INV-ESS board.INV-ESS board has signal connectors which are
connected to INV board/CNTL board/PARA board. INV-ESS has power connection from
INV board or bypass input to output. INV board contains part of INV circuit, bypass,output
EMI and slave UPS.
Fig. 4.3.6 INV-ESS board
Fig.4.3.7 shows the communication board and parallel board.Communication board

contains sps for SELV power and communicaiton ports. Parallel board provide parallel port.

Checked : Rev:1.0
Fig. 4.3.7 Communicaiton board and PARA
Fig.4.3.8 shows the other boards which are inserted in above boards. SPS and RLY DRV
board are in PFC board. IGBT DRV board are used for PFC and INV board.SCR DRV and
5V power board are located in INV-ESS board.
Fig. 4.3.8 Other board

Checked : Rev:1.0
5 Operation by service tools
We can get UPS information，real time meters, events and logs from service tool.
Service tool also provide control and calibration.
5.1 UPS information
Item
SN
UPS Type
UPS Name
Firmware Version
Nominal Output Watt
Nominal Output VA
Nominal Output Volt
Nominal Output Freq
5.2 UPS Meters
Input Bypass Output Battery Other

Working Mode Working Mode Working Mode Positive Battery Volt UPS Temp.
Input Phase Bypass Phase Output Phase Negative Battery Volt
Input Volt R Bypass Volt R Output Volt R Battery Capacity
Input Volt S Bypass Volt S Output Volt S Remaining Time
Input Volt T Bypass Volt T Output Volt T Battery Number
Checked : Rev:1.0
Input Freq Bypass Freq Output Current R
Output Current S
Output Current T
Output Freq
Output Watt R
Output Watt S
Output Watt T
Output VA R
Output VA S
Output VA T
Output Percent R
Output Percent S
Output Percent T
5.3 UPS Setting
Item
Line Volt R Calibration
Inverter Volt R Calibration
Bypass Volt R Calibration
Battery Volt Calibration
Charger Output Volt Calibration
Output Current R Calibration
Setting Command

Checked : Rev:1.0
5.4 UPS Control
Item
Turn On
Turn Off
Battery Test for 10 Seconds
Battery Test for n Minutes
Battery Test Till Battery Low
Cancel Battery Test
Reset Factory
Clear Log
Note : “Clear fault ” function is not supported in this tool.
5.5 Events and Logs
Item
Current Event
Export Event Log(Max 100 lines)

Checked : Rev:1.0
6 Failure analysis
Despite of careful design and strict tests, in case UPS become out of order. Basically,
designer suggest following service procedure:
1．Check the UPS status and record by LCD panel display, or listen to the end user
description
2. Identify the failure part/boards with the help of failure identify flowchart.
3. Observe the failure board, Static checking
4. Replace the failure components with OK parts
5. Static checking
6. Power up checking
7. Test after repair.
Following section will help service person to solve the most problems.
6.1 LCD Panel Display
Table.6.1.1 The button

The Button Funtion Illustration
When the unit is no power and has connected with battery, press this button
Power on
for >100ms&<1s to power on
When the unit is powered on and is in Bypass mode, press this button for
Turn on
>1s to turn on
Turn off When the unit has been turned on, press this button for >3s to turn off
When the unit is in fault mode, press this button for >1s to stop alarm and
Clear fault
clear fault

Checked : Rev:1.0
Scroll up
Press this button for >100ms&<1s to scroll up the menu option
Scroll down Press this button for >100ms&<1s to scroll down the menu option
Enter next Press this button for >100ms&<1s to select the present menu option, or
menu tree enter next menu, but do not change any setting
Select one Press this button for >100ms&<1s to select the present menu option, or
menu option enter next menu, but do not change any setting
Confirm the
Press this button for >1s to confirm the edited options and change the
present
setting
setting
Press this button for > 100ms & < 2s to exit the present menu to default
Exit main
system status display menu or the higher level menu without executing a
menu
command or changing a setting
Press this button for > 2s to mute the buzzer temporarily, once new warning
Mute buzzer /fault is active or UPS reenters into bypass mode or battery mode, buzzer
will work again.
LED display information
UPS leds LED

on STATUS
Ups mode sub mode line battery bypass fault
Power
   
on/shutdown
Standby no Bypass output   ⚫  flash
BYPASS   ⚫  continuous
ON LINE ⚫    continuous
BATTERY  ⚫   continuous
HE ⚫  ⚫  continuous
Converter ⚫    continuous
lights for 1sec in
UPS start ⚫ ⚫ ⚫ ⚫
turn
lights for 1sec in
battery test ⚫ ⚫ ⚫ ⚫
turn
warning    ⚫ flashing for 1sec
Fault    ⚫ continuous

Checked : Rev:1.0
Buzzer information
Priority UPS condition Buzzer

1 UPS fault and failure Continuous
2 Normal mode No beep
One beep per 4 sec
3 Battery/battery test mode
(One beep per 1s when battery low)
4 Bypass mode One beep per 2 minutes
5 Overload One beep per 500ms
6 Other alarm One beep per 1s
In the event log menu all the old event, alarm and fault have been recorded here. The
information includes the illustration, the event code, and the operating time of UPS when
the event happened.
Event log
0001:03:02:25
Alarm #A083
Amb. Temp. alarm
1/100
0001:03:01:25
Event #E061
Online mode
2/100
0001:03:01:06
Alarm #A042
Inverter overload
3/100
0001:02:01:00
Alarm #A031
Out. Short circuit
100/100

Checked : Rev:1.0
6.2 Primary Diagnosis with LCD Information
If the UPS system does not operate correctly, and you could get the failure information on
the LCD display, here are some possible causes and remedies in the table below.
6.2.1 Trouble Shooting According To Warning Indication
Warning: these are “minor” problems which do not cause the lock of the UPS but reduce
performance or prevent certain functions from being used.
CODE DESCRIPTION
A004 Input bad wiring: Phase Neutral inversion on every UPS or GND no connect
No battery: Battery not present (or some elements of the battery are
A011
disconnected)
A012 Bat low: battery voltage is low
A014 Over Charge: Recharge battery voltage is too high
A015 Charger fault: Any hardware fault that cause charger malfunction
A01F Low Charge: charger output voltage is low
A027 Rectif. fuse fault : rectifier fuse is broken
A041 Power overload : (default > 105% Load ,it can be set from 50% to 105% )
A072 Maintain bypass: (force to bypass by manual operation）
A081 UPS temp. warning: the heat sink temperature is high
A082 Amb. temp. alarm: Ambient temperature is higher than 50°C
Amb. temp. alarm: Ambient temperature is higher than 100°C or lower
A083
than -10°C or NTC is open
A085 Fan fault: the fan have no connect or block
A094 BP device fault: bypass output device is sticked
A0E3 Para. cable lost: male cable terminal is open.
A0E4 Para. cable lost: female cable terminal is open.
A0E6 Para. Inconsistent : Parallel UPS battery connection status is different
A0E7 Para. inconsistent : Parallel UPS line input status is different
A0E9 Para. inconsistent : Parallel UPS Work mode is different
A0EA Para. not compatib. : Parallel UPS power rating different
A0EB Para. not compatib. : Parallel UPS work in wrong operation mode
A0EE Para. not compatib. : Parallel UPS ID are the same

Checked : Rev:1.0
6.2.2 Trouble Shooting According To Fault Indication
Faults: these are more critical problems than anomalies because, if they persist, they
could cause the UPS to lock in a very short time.
CODE DESCRIPTION
F016 Bat. num. error: battery voltage or pieces is not right
DC bus too high: bus voltage over 500V for 60ms or bus voltage
F021
accumulation of over 450V is more than 200V
F022 DC bus too low: bus voltage lower than 280V for 200ms
F023 DC bus unbalanced: bus voltage deviation is more than 100V for 200ms
F024 DC bus short circ.: DC bus is short
Rectifier fault: bus soft start fail, the rectifier could not rise the Bus voltage to
F025
350v in 60 seconds during startup process
F031 Out. short circuit : inverter output is short
F032 Inv over voltage: inverter voltage over 270V for 200ms
F033 Inv under voltage: inverter voltage lower than 140V for 200ms
Inv. device fault: inverter soft start fail, inverter voltage cannot reach the
F034
setting voltage in 60s during the startup process
F035 Inv. device fault: inverter capacity is broken
F042 Inverter overload: inverter output is overloaded
F043 Bypass overload: bypass output is overloaded
F071 Emergency Off: emergency power off
F081 UPS temp. fault: the heat sink temperature is too high
F093 BP device fault: back feeder is active
F095 INV Fault: inverter output device is broken
F0E1 Negative power: Negative power
F0E2 Para. cable lost: communication loss or abnormal
6.3 Failure Diagnosis by Static Checking
Goal:
This part of the manual is focused on the localization of the function(s), or the part(s),
which are faulty, from the fault shown on the display (LCD).
This type of flowchart applies to all types of faults to determine the faulty functions of the
UPS such as the rectifier, battery charger etc.

Checked : Rev:1.0
How To Start
Suggest following service procedure:
1. Check the UPS status and record by LCD panel display, or listen to the end user
description
2. Identify the failure part/boards with the help of failure identify flowchart.
3. Observe the failure board, Static checking
4. Replace the failure components with OK parts
5. Static checking
6. Power up checking
7. Test after repair.
Trouble shooting start

point selection begin
Is there any Trouble

Yes No
information
Check
Can the product
with power Yes
power up?
on
Visual Inspection
Apply Power
supply to the UPS
No
Sign of Burn, damage,
Can the UPS be contaminate on the
Yes
turned on? outlet, sockets,
Yes connectors
No
Does the problem

Yes
still exist?
Impedance
measurement
Does LCD give

Following instruction:
abnormal
6.5 Trouble shooting
Yes message? Short-circuit at battery
Yes connector, input mains
socket, output socket
Follow the LCD message No
explanation and solution
table:
Start PCB board static
6.3 Primary Diagnosis
checking process:
with LCD information 6.4 Failure Diagnosis Check
by static checking with power
on
Trouble shooting start

point selection end

Checked : Rev:1.0
6.4 Trouble shooting
F093 → BP device fault

Checked : Rev:1.0
F034 /F035/F095 → Inverter Failure

Checked : Rev:1.0
F032 → Inv over voltage, F033 → Inv under voltage

Checked : Rev:1.0
F0E1 → Negative power

Checked : Rev:1.0
F031 → output short circuit

Checked : Rev:1.0
F023→ DC bus unbalanced

Checked : Rev:1.0
F021 → BUS over voltage F022 → BUS under voltage

Checked : Rev:1.0
F025 → Rectifier fault

Checked : Rev:1.0
F042 → Inverter overload, F043 →Bypass overload

Checked : Rev:1.0
F081 → UPS temp. fault

Checked : Rev:1.0
LCD Panel Display
UPS Status Summary screen is shown below.
The UPS Status Summary screen is composed of four sections：

Battery Section:
1. Battery icon, it is composed of five bars and each one represent 20% battery level;
2. Battery value, it will be battery remaining time when UPS is working in battery mode
and the function of battery remaining time is enabled. Otherwise it will be battery level
instead.
Load Section:
1. Load icon, it is composed of five bars and each one represent 20% load level;
2. Load level value shows real-time load information;
UPS Status Section:

The icon on this section demonstrates ups working status; the following table describes the
status information.
Operation status Cause Description

Standby mode The UPS is Off. UPS is operating without output.

Checked : Rev:1.0
Online mode The UPS is The UPS is powering and protecting the equipment.
operating normally.
Battery mode A utility failure has The UPS is powering the equipment with the battery power.
occurred and the Prepare your equipment for shutdown.
UPS is on Battery
mode.
Battery low The UPS is on When Battery voltage low, the battery icon would flash.
Battery mode and
the battery is
running low.
High Efficiency mode The UPS is Once the mains is loss or abnormal, the UPS would transfer to
operating on High Line mode or Battery mode and the load is supplied continuously.
Efficiency mode. 1. The function could be enabled through the LCD setting or the
software (Winpower, etc.)
2. It is attention that the transfer time of UPS output from HE mode
to battery mode is about 10ms. But it is still too long for some
sensitive load.
Bypass mode An overload or a Equipment is powered but not protected by the UPS.
fault has occurred,
or a command has
been received, and
the UPS is in
Bypass mode.
Converter mode The UPS is In converter mode, the UPS would free run with fixed output
operating on frequency (50Hz or 60Hz). Once the mains is loss or abnormal,
converter mode. the UPS would transfer to battery mode and the load is supplied
continuously.
1. The function could be enabled through the LCD setting or the
software (Winpower, etc.).
2. The load should be derating to 60% in converter mode.
Warning There are some The UPS continues working, but the problems should be paid
abnormal problems attention to, or the UPS may fail.
during the operation
of UPS. Normally
Fault the problems
Some fatal are The UPS would directly cut off the output or transfer to bypass,
not fatal happened
problems and keep alarming.

Checked : Rev:1.0
Overload The load exceeds Some unnecessary loads should be get rid of one by one to
the capacity of the decrease the loads connected to the UPS.
UPS
Battery test UPS is executing a Test the battery

battery test
Battery fail The UPS detects The symbol of battery failure would be shown and UPS would
bad battery or alarm.
battery
disconnected
UPS Parallel Using two or three Two or three UPS operation in parallel
UPS for heavy load
or redundancy
Input/Output Section:
This Section shows input and output information (Voltage and Frequency) alternatively
each 4 seconds. Screen will return to the UPS Status Summary screen automatically when
none button is pushed in 15 minutes.
Notice/alarm screen
Press the Down button during the main menu, present alarm/ fault menu will show on the
screen. These alarm screens are visible only when alarms are active, including faults and
warnings. Events are not visible in UPS status screens; they are shown only in the event
log. There is a separate screen shown for each active alarm between main status and
battery status screens. If there is no alarm active, the message “No Active Alarms”
appears in the first screen before the Battery Status.
When a new alarm is active, the LCD menu will jump to the latest active alarm screen.
When the alarm is cleared, the alarm screen will automatically clear the alarm and show
the next active alarm or if no other alarms are active, the LCD will show the message “No
Active Alarms”.

Checked : Rev:1.0
Location of the faulty function or component
Irregular UPS operation is most likely not an indication of a fault but due to simple
problems or distraction. It is therefore advisable to consult the table below carefully as it
summarises information which is useful for solving the most common problems.
PROBLEM POSSIBLE CAUSE SOLUTION

Close the input switch located on the back of
INPUT SWITCH OPEN
the UPS.
MAIN CONNECTION Check that the power cable is connected
CABLE MISSING correctly.
THE DISPLAY DOES NOT Check that the power reaches the socket
NO MAINS VOLTAGE
LIGHT UP where the UPS is connected (try it with a
(BLACKOUT)
table lamp, for example).
Reset the thermal protection.
UPSTREAM THERMAL
PROTECTION TRIP CAUTION: Check that there is no output
overload to the UPS.
THE UPS IS IN STAND- Press the “ON” button on the front panel to
BY MODE power the loads.
It is necessary to change mode.
THE DISPLAY IS ON BUT THE THE STAND-BY OFF The STAND-BY OFF (emergency power
LOAD IS NOT POWERED MODE IS SELECTED supply) mode, in fact, only powers the loads
in the event of a blackout.
NO CONNECTION TO
Check the connection to the load.
THE LOAD
THE INPUT VOLTAGE
IS OUTSIDE THE Problem with the mains. Wait until the input
PERMITTED mains voltage returns within the tolerance
THE UPS IS OPERATING TOLERANCE RANGE range. The UPS will automatically return to
FROM THE BATTERY DESPITE FOR MAINS mains operation.
THE PRESENCE OF MAINS OPERATION
VOLTAGE
Reset the thermal protection.
UPSTREAM THERMAL
PROTECTION TRIP CAUTION: Check that there is no output
overload to the UPS.
THE BUZZER SOUNDS Reduce the load to within the threshold of
CONTINUOUSLY AND THE THE LOAD APPLIED 100%. If the display shows a lock:
DISPLAY SHOWS ONE OF THE TO THE UPS IS TOO
FOLLOWING CODES: HIGH remove the load and switch the UPS off and
A041,F042, F043 back on again.
BATTERIES MISSING On the versions with an additional battery
THE DISPLAY SHOWS THE OR BATTERY BOX charger in place of the batteries, check that
FOLLOW CODE: A011 MISSING OR NOT the Battery Box is inserted and connected to
CONNECTED the UPS correctly.
THE BUZZER SOUNDS
THE TEMPERATURE
CONTINUOUSLY AND THE Check that the temperature of the
OF THE DISSIPATORS
DISPLAY SHOWS ONE OF THE environment in which the UPS is located
INSIDE THE UPS IS
FOLLOWING CODES: A082, does not exceed 50°C or the NTC is open
TOO HIGH
A083
THE BUZZER SOUNDS If possible, disconnect the power to the load,
CONTINUOUSLY AND THE THE UPS IS switch the UPS off and back on again; if the
DISPLAY SHOWS ONE OF THE MALFUNCTIONING problem occurs again, call the support
FOLLOWING CODES: centre.

Checked : Rev:1.0
Check the parallel battery /line connection is
THE DISPLAY SHOWS ONE OF
PARALLEL OK and the work mode is consistent. if the
THE FOLLOWING CODES:
MALFUNCTIONING problem occurs again, call the support
A0E6,A0E7,A0E9
centre.
THE DISPLAY SHOWS ONE OF Check the capacity is consistent and HE
PARALLEL
THE FOLLOWING CODES: mode is set. if the problem occurs again, call
MALFUNCTIONING
A0EA,A0EB,A0EE the support centre.
If possible, disconnect the power supply,
THE DISPLAY SHOWS ONE OF
PARALLEL and repower the UPS after shutdown
THE FOLLOWING CODES:
MALFUNCTIONING completely. If the problem occurs again, call
A0EE
the support centre.

Checked : Rev:1.0
7 Disassembly
This section defines the exact method to disassemble the UPS.Please cut off all input
power of UPS and check the voltage of terminal block before disasemble the UPS.
Losen the 2 pcs screws in front panel and move the panel right.
Disconnect the signal wire to LCD.
Remove the 6 pcs screws in front plate and move right.

Checked : Rev:1.0
Check the BUS voltage. Need discharge the BUS capacitor power if the voltage is not safe.
Then disconnect the FAN wires and BUS wires.
Remove the screws and then remove the cover for terminal block.

Checked : Rev:1.0
Disconnect the wires which are used in single source mode to connect main input and
bypass input, remove the screws in rear panel.
Push back the upper parts and rotate it.

Checked : Rev:1.0
Disconnect the signal wires which connect PFC board and control board.
Remove the screws in left panel of lower parts.

Checked : Rev:1.0
Remove the 9 pcs screws in terminal block which are used to connect to PFC board.
Remove the 16 pcs screws in PFC board. Remove the 16 pcs plastic screws in heatsink to
get the air channel paper.

Checked : Rev:1.0
Remove the plastic screws and air channel paper in INV board. Disconnect the power and
signal wire between INV board and ESS board. Then remove the 13pcs screws which are
used to fix INV board.
Remove EPO and Dry in/out terminal and losen the screw in rear panel which is used to fix
CNTL board.

Checked : Rev:1.0
Disconnect LCD/COMM signal wires, Remove the 2 screws which are used to fix CNTL
board. Then take CNTL board.
Remove RS232 screws and the screw in rear panel which is used to fix COMM board.
Disconnect signal wires to SLOT, disconnect signal wires to CNTL board if CNTL board
doesn’t need to disassemble. Then take COMM board.

Checked : Rev:1.0
Remove the screws in PARA cover.
Remove the screws in plastic bracket which are used to fix PARA board. Disconnect the
signal wire to INV-ESS board and then take PARA board.

Checked : Rev:1.0
Disconnect the power wire to terminal block from INV-ESS board, disconnect the power
and signal wire to INV board. Remove 10 pcs screws which are used to fix INV-ESS board.
Then take INV-ESS board. CNTL board/COMM board/PARA board and SLOT box should
be removed at first if need disassemble INV-ESS board.

Checked : Rev:1.0
8 Component level Tests by function and by board
Goal: Find failure through component level testing on the boards, the function or failed
component.
Before any detail check of UPS, please check the components listed in the following table.
This action could help you find problem quickly and make following debug procedures go
smoothly.
Fuse position:
Related Circuit Block Fuses to be checked Component Type Fail condition

PFC board
F9,F10,F13,F14,F17,F18
I/P Fuse Fuse Open
F1,F8,F2,F11,F3,F12,F4,F15,
BAT Fuse Fuse Open
F5,F16,F6,F19
Charger fuse F1,F8,F2,F11 Fuse Open
Main SPS F34,F7,F24 Fuse Open
INV board
Slave SPS F1 Fuse Open
EBM
Fuse board F5, F6 Fuse Open
!
If the fuse is open, replacing fuse only DOES NOT mean you have solved the
problem. In most case, open of fuse is caused by other failure of components; therefore,
before restart that UPS, you must find the real failed components and replace them!
AC/DC Converter Analysis:
In this section, some components you could check to see if failure occurs to PFC
Converter. General speaking, open of I/P fuse indicates failure of this block. Please
replace all failed components before testing UPS.
m Checked Instrument Reference Type Failed
components function Value condition
1 Diode Voltage 0.35 IGBT Short or open
Q8,Q9,Q12,Q14,Q16,Q18 Drop (E→C)
(C→E) Diode / IGBT Short
Voltage Droop
Checked : Rev:1.0
2 D28,D35,D41,D48,D53,D60 Diode Voltage 0.35 Diode Short or open
Drop
3 BR1,BR2,BR3,BR4,BR5,BR6 Diode Voltage 0.43 Diode Short or open
Drop
4 R134,R142,R166,R174,R196 Ω 10 Resistance Short or open or value
,R204 change
5 R138,R143,R170,R175,R199 Ω 47 Resistance Short or open or value
,R206 change
DC/AC Inverter Analysis:

1 Q2,Q1,Q6,Q5,Q10,Q9 Diode Voltage 0.35 IGBT Short or open
Drop (E→C)
Voltage Droop
2 Q3,Q4,Q7,Q8,Q11,Q12 Diode Voltage 0.39 IGBT Short or open
Drop (E→C)
Voltage Droop
4 D1,D2,D7,D8,D13,D14 Diode Voltage 0.35 Diode Short or open
Drop
5 R12,R11,R13,R15,R34,R33 Ω 10 Resistance Short or open or value
,R35,R37,R56,R55,R57,R5 change
9
6 R9,R10,R31,R32,R53,R54 Ω 47 Resistance Short or open or value
change
7 R7,R8,R29,R30,R51,R52 Ω 100(parallel Resistance Short or open or value
with 121Ω ) change
8 R88,R89,R94,R92,R96,R97 Ω 121(parallel Resistance Short or open or value
with 100Ω ) change
Charger Analysis
Checked : Rev:1.0
1 Q2,Q3 Diode Voltage 0.39 IGBT Short or open
Drop (E→C)
Voltage Droop
2 D6,D7 Diode Voltage 0.35 Diode Short or open
Drop
3 R20,R24 Ω 47 Resistance Short or open or value
change
Test after repairing

After repairing all failed components or PCB board, the next check and test procedure
should be followed.
1. Check the internal wiring connection.
2. Fix the side and top cover.
3. Connect the external wiring. PE must be connected.
4. Check all switch status is right.
5. Take on the battery power.
Note: It is suggested to use DC power which has current limit function as the battery
power. It can protect the UPS in case there is still some failure part. The limit current
should be 3A.
6. Turn on the UPS. And then check the voltage and UPS status. If turn on failed, please
check the fault code.
7. Turn off UPS. Take on the input AC power.
8. Turn on the UPS again. And then check the voltage and UPS status. If turn on failed,
please check the fault code.
9. If possible, take on full load test after finish before test. Then return UPS to end user.
If every step is ok, Congratulation, you have finish the maintenance/ repair work.

Checked : Rev:1.0
Typical voltage
TEST ITEM TEST POINT EXPECTED RESULT

+DC Bus Voltage BAR1 and BAR3 on PFC +350VDC to +390VDC
board
-DC Bus Voltage BAR4 and BAR2 on PFC -350VDC to -390VDC
board
O/P voltage O/P terminal block 230Vac (or 220Vac, etc according
to the setting)
O/P DC offset O/P terminal block 100mV max.
DC Offset Measurement Fixture: A RC net shown in below picture can be used to measure
output voltage DC offset.
From O/P
To DVM
terminal
block C C
R=100Kohm/2W
C=10uF/250V

Checked : Rev:1.0

9SX 15-20K UPS Service Manual - 20200318 (Ingles)

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Sirius 15-20K UPS

Title Sirius 15-20K Service Manual

5 Operation by service tools .......................................... 22

Title Sirius 15-20K Service Manual

Title Sirius 15-20K Service Manual

UPS failed at customer Diagnostic’s help

Tests with and

Process at the customer

Title Sirius 15-20K Service Manual

Goal: Identify the Board references by product model / rating

Main power block

Main Input Output

Fig. 1.3.1 15K-20K main power block

Title Sirius 15-20K Service Manual

Fig. 1.3.2 10K-20K signal and communication block

Title Sirius 15-20K Service Manual

INV board Contains inverter circuit

Parallel board Contains parallel communication interface.

• Do not make adjustments to the product unless an authorized person is present.

Indicate symbol in this service manual :

Title Sirius 15-20K Service Manual

1. DO NOT short-circuit internal batteries

Title Sirius 15-20K Service Manual

Title Sirius 15-20K Service Manual

SIRIUS UPS INTERNAL WIRING DIAGRAM

W14 W13 W12

OP-L1 W15 R.OP-L INV-ESS INV

IP-L2 W14 IP-S

Title Sirius 15-20K Service Manual

4.1 Functional Block of The Product

Bypass Input Internal

Main Input Output

Slave SPS Communication Parallel

Figure 4.1.1 Function block Diagram

Title Sirius 15-20K Service Manual

LCD and communication:

Title Sirius 15-20K Service Manual

Fig. 4.2.4 13A charger

Auxiliary Power Supply (SPS)

Title Sirius 15-20K Service Manual

Emergence Power Off

Ventilation And Chassis

Title Sirius 15-20K Service Manual

Fig. 4.3.1 Structure Diagram

Fig. 4.3.2 Exploded View

Title Sirius 15-20K Service Manual

Fig. 4.3.4 PFC board

Title Sirius 15-20K Service Manual

Fig. 4.3.6 INV-ESS board

Fig.4.3.7 shows the communication board and parallel board.Communication board

Title Sirius 15-20K Service Manual

Fig. 4.3.8 Other board

Title Sirius 15-20K Service Manual

5.1 UPS information

5.2 UPS Meters

Input Bypass Output Battery Other

5.3 UPS Setting

Title Sirius 15-20K Service Manual

5.5 Events and Logs