Service-Handbuch
GRAFENTHAL
USV PTR-10000
GRAFENTHAL GmbH • von-Monschaw-Straße 3 • 47574 Goch • info@grafenthal.de • www.grafenthal.de
Copyright © 2016 GRAFENTHAL GmbH, Alle Rechte vorbehalten. GRAFENTHAL ist eine eingetragene Marke der GRAFENTHAL GmbH.
CONTENT
1. GENERAL INFORMATION ....................................................................................................................................... 4
1.1 GETTING START ........................................................................................................................................................ 4
1.2 IMPORTANT SAFETY INSTRUCTIONS ........................................................................................................................ 4
2. ELECTRIC SPECIFICATIONS .................................................................................................................................. 5
3. FUNCTIONAL BLOCK ............................................................................................................................................... 7
4. WORKING PRINCIPLE OF THE MAJOR FUNCTIONAL BLOCK ..................................................................... 9
4.1 SWITCH POWER SUPPLY ......................................................................................................................................... 9
4.2 PFC/BOOSTER ........................................................................................................................................................ 9
4.3 INVERTER ................................................................................................................................................................. 9
4.4 CHARGER ............................................................................................................................................................... 10
4.5 EMI BOARD ............................................................................................................................................................ 10
5. FUNCTION EXPLANATIONS FOR EACH PCB .................................................................................................. 11
5.1 SPS-CHARGER BOARD (POWER STAGE BOARD) ................................................................................................. 11
5.2 CNTL BOARD (CONTROL BOARD) ......................................................................................................................... 11
5.3 COMMUNICATION BOARD ....................................................................................................................................... 11
5.4 EMI BOARD ............................................................................................................................................................ 11
5.5 MAIN POWER BOARD ............................................................................................................................................. 11
5.6 PARA(A) AND PARA(B) BOARD............................................................................................................................... 11
5.7 O/P RELAY BOARD ................................................................................................................................................. 12
6. INTERFACE ............................................................................................................................................................... 13
6.1 LED DISPLAY ......................................................................................................................................................... 13
6.2 LCD DISPLAY ......................................................................................................................................................... 13
6.3 LCD DISPLAY ICON ................................................................................................................................................ 13
7. TROUBLE SHOOTING ............................................................................................................................................ 16
7.1 LCD PANEL DISPLAY PATTERN DEFINITION .......................................................................................................... 16
7.1.1 Trouble shooting for warning icon in LCD display ......................................................................................... 16
7.1.2 Trouble shooting for fault codes in LCD display ............................................................................................. 17
7.1.3 Trouble shooting .............................................................................................................................................. 18
7.2 REPAIR ................................................................................................................................................................... 18
7.2.1 Basic Instruments and tools............................................................................................................................. 19
7.2.2 Configuration of the Model Port on the Control Board .................................................................................. 19
7.2.3 Configuration of the charger current on the charger Board ........................................................................... 19
7.2.4 Configuration of the charge voltage on the charger Board ........................................................................... 19
7.2.5 Regulation of the system .................................................................................................................................. 20
7.2.6 Quick Start ....................................................................................................................................................... 21
8. TEST STEP ................................................................................................................................................................ 23
9. APPENDIX ................................................................................................................................................................. 24
9.1 REFERENCE WAVEFORM ....................................................................................................................................... 24
2
9.2 BASIC COMMUNICATION COMMAND........................................................................................................................ 26
9.2.1 QGS ................................................................................................................................................................. 26
9.2.2 V<n> ............................................................................................................................................................... 27
9.2.3 V±<n> ............................................................................................................................................................. 27
9.2.4 BUSP±<n>...................................................................................................................................................... 27
9. 2.5 BUSN±<n> .................................................................................................................................................... 28
9. 2.6 VB±<n> ......................................................................................................................................................... 28
9.2.7 QVFW .............................................................................................................................................................. 28
9.2.8 OC±<n> .......................................................................................................................................................... 28
3
1. General Information
1.1 Getting start
This manual is for Galleon II 6K(L)/10K(L) tower UPS. It can help service person perform the basic
maintenance and repair service.
This manual only focuses on the service section, so you should get the basic operation of the UPS from
the user manual, and make sure you had read and understood the user manual before reading the
manual.
The manual include 9 sections:
● General Information, this section shows you the general information of the service manual.
● Electric Specifications, this section shows you the basic electric specification of the UPS.
● Functional block, this section shows you the major functional block of the UPS.
● Working Principle of the Major Functional Block, this section shows you the working principle of
the major functional block.
● Function explanations for each PCB, this section explains you all the PCBs of the UPS system.
● Interface, this section shows you the LCD interface, including display and setting.
● Trouble Shooting, this section gives you the way to find the problems.
● Test Step, this section tells you how to test the UPS after you repair the unit.
● Appendix, this section shows you the basic waveforms for reference and the basic communication
commands.
1.2 Important Safety Instructions
For qualified service person only.
DO NOT perform any internal service or adjustment of this product unless the technical person is
well trained and experienced. .
Dangerous voltage exists at several points in this product. To avoid personal injury, don't touch
any exposed connections or components while UPS is on.
Turn off the UPS and switch off the input breaker before removing protective case.
AC voltage is always present if the input AC power is still available.
High voltage may exist at DC capacitors. Before removing the protective case, wait for at least
five minutes after turning off the UPS.
Verify input source (voltage and frequency) is within the maximum range before service.
4
2. Electric Specifications
MODEL
SPECIFICATION
6K
6KL
10K
10KL
Input
176~300 VAC @ Full Load
Input Voltage
110 VAC @ Half Load
46~54 Hz for 50Hz system
Input Frequency
56~64 Hz for 60Hz system
Input Power Factor
≥0.99
Input THD
<4%
Generator
Support
Output
Output Power (VA/Watt)
6000/6000( 20 pieces battery)
10000/10000( 20 pieces battery)
6000/5400( 18~19 pieces battery)
10000/9000(18~19 pieces battery)
6000/4800(16~17 pieces battery)
10000/8000(16~17 pieces battery)
Nominal Output Voltage
208/220/230/240VAC
Voltage Regulation
±1%
Follows Bypass Frequency in Line Mode
Output Frequency
(50/60+0.1) Hz in Battery Mode
≤6% @ Full Nonlinear Load
Voltage Distortion
≤2% @ Full Linear Load
Current Crest Ratio
3:1
0ms @ Line  Battery
0ms @ Inverter  Bypass
Transfer Time
<10ms @ Inverter  ECO
Short Circuit Protection
Yes
Battery
Nominal Battery Voltage
240 VDC
Nominal Battery Quantity
20 pcs
Acceptable Battery Quantity
18~20 pcs
Type/Capacity
12V/7.2Ah
12V/9Ah
Backup Time
≥6minutes@full load
≥4minutes@full load
Efficiency
To Line Mode
>93%
To Battery Mode
>91%
To ECO Mode
>96%
Overload Protection
100%~110%
110%~130%
Over 130%
Alarm and Transfer To Bypass after 10min @ Line mode
Alarm and Cut Off Output after 30s @ Battery mode
Alarm and Transfer To Bypass after 1min @ Line mode
Alarm and Cut Off Output after 10s @ Battery mode
Alarm and Transfer To Bypass after 1s @ Line mode
Alarm and Cut Off Output after 1s @ Battery mode
5
Alarm and Cut Off Output after 1min @ Bypass mode
Auto Retransfer
Yes
Interface
RS232
Yes
USB 1.1
Yes
EPO
Yes
Environment
0 ℃ to 40℃
OperatingTemperature
Humidity
Acoustic Noise
<95% (No condensing)
≤55dB
≤58dB
Standard
ESD
IEC 61000-4-2 Level 4
RS
IEC 61000-4-3 Level 3
EFT
IEC 61000-4-4 Level 4
Surge
IEC 61000-4-5 Level 4
Conduction
IEC/EN 62040-2 Category C3
Radiation
Safety
IEC62040-1-1
Drop
ASTM D5276-94
Vibration
ASTM D4728-87
Mechanical
Inlet
Terminal Block
Outlet
Terminal Block and Receptacle
6
3. Functional Block
As a true online UPS, the product applies a double conversion topology, comprising functional blocks as
shown in Figure 3.1
Figure 3.1 Function block Diagram
The CNTL block controls the action of the UPS system. It also provides the communication interface for
receiving and executing command from users via the panel or other communication protocol. When the
UPS becomes abnormal, in most case, the CNTL can provide basic information indicating the status of
the UPS.
The Rectifier and PFC blocks are the input stage of the UPS. The blocks convert AC input power into
two stable DC power stored in the BUS capacitor. In the meantime, PFC (Power Factor Correction) will
be executed and allows input current tracking the input voltage waveform. Therefore, the input power
factor will be corrected to 1 to achieve maximum efficiency and produce lowest power pollution to the
utility.
The PFC block in battery mode, also called Booster, is used to convert the low voltage DC power to
higher voltage with stable DC power, stored in the BUS capacitor.
The Inverter block is the output stage of the UPS and used to convert DC power from the BUS capacitor
to sine waveform output power.
When the utility is within the acceptable range, the UPS will provide power directly from the utility input
and the Rectifier and PFC will be executed at the same time. When the utility is outside of the acceptable
range, no matter it’s because of input voltage or input frequency, the UPS will shut down the Rectifier
and PFC functions and turn on the Battery Booster. In case of sudden interruption from input utility, the
controller can detect the interruption in very short time. During the short interval of detecting the
interruption, the output power will be provided by the power stored in the BUS capacitor. In this way,
there is no any interruption on output power.
The charger charges the battery when the UPS system is in online model. You can set the current from
1A to 4A by changing the jumper. And you also can choose a different voltage corresponding to different
battery pieces by changing the jumper on the CNTL board and the charger board.
The Input EMI section provides EMI filter function. The input EMI filters can prevent the UPS from being
interference by external electronic/magnetic noise which is generated by other electronic system and
7
prevent other systems from the noise generated inside the UPS system.
The SPS generates DC power supply needed by operation of the circuit of the UPS itself. The Bypass
provides a path that utility can power the output directly when the Inverter is not executed. The
Maintenance Bypass provides another path that utility can power the output directly when UPS is in
maintenance status.
8
4. Working Principle of the Major Functional Block
4.1 Switch Power Supply
The Switch Power Supply (SPS) supplies DC power for UPS operation. The input source of the SPS is
the grid when the grid voltage is higher than 110V . Or the input source of the SPS is the battery.
Figure 4.1 Basic circuit of power supply
Figure 4.1 is a flyback converter. When Q1 is on, all rectifier diodes (D1/D2/D3) are on open status and
all output capacitors (C1/C2/C3) supply currents to the load. The primary coil of the transformer will
become a pure inductor and the primary current will linearly increase to store energy in the coil. When
Q1 is off, primary current will stop and all rectifier diodes (D1/D2/D3) will turn to “close” status. It will
release the stored energy from the primary coil of the transformer to the secondary coil to supply loads.
At the same time, it will charge output capacitors including 15V, +12V, +5V, +12V(Fan), and HFPW.
The power of 12V, +5V supplies stable voltage to all kinds of ICs and other devices such as HCT. The
+12V (Fan) is supplied to fans and relays. The HFPW supplies a high frequency power for the switch
(SCR/IGBT) driver and some other drive boards.
4.2 PFC/Booster
L1
D1
Q3
UBUS+
Q5
Q1
C1
Utility
N
N
Q4
Battery
C2
Q2
D2
UBUS-
L2
Figure 4.2 PFC/Booster
As shown in the Figure 4.2, when Q1/Q2 is on and D1/D2 is off, the current will increase to store energy
in choke(L1/L2). When the Q1/Q2 is off and D1/D2 is on, the choke will release energy. Therefore, we
can control the current in chokes (input current) by regulating the time of Q1/Q2 on and off.
4.3 Inverter
The input of the three level inverter topology is two DC voltages, and the output is an AC voltage, as
shown in the Figure 4.3. When Q1/Q2 is on and Q/Q3 is off, the voltage of the bridge midpoint is +BUS.
When Q1/Q2 is off and Q3/Q4 is on, the voltage of the midpoint bridge is –BUS. We can get any voltage
waveform between ±BUS voltage from LC filter output by regulating the duty cycle of Q1/Q2/Q3/Q4,
including sine wave form.
9
Figure 4.3 Three level inverter bridge
4.4 Charger
The function of charger is to charge and maintain the batteries at fully charged condition. The charger
charges the batteries with a constant current at initial stage. At the same time, the battery voltage keeps
increasing until reaching the constant charge voltage point. Then, the charge current will decrease
accordingly, now it’s in second stage. After one hour of constant voltage charging, the charge voltage will
change to floating charge voltage, in general, the charger will control the output voltage at a constant
level (13.65V±1% per battery) to optimize battery recharge time and prolong the lifetime of batteries
without overcharging.
Figure 4.4 Topology of the charger
Note: There are two kinds of chargers for standard model UPS and long-run model UPS. They both
apply the same principle, but there is on difference in charger output capacity.
4.5 EMI Board
Input EMI board is connected between utility and the input of rectifier.
CY
Common
Choke
CY
CX
CX
Input
Output
CY
CY
Figure 4.5 Topology of the EMI
10
5. Function explanations for each PCB
Table 5.1 PCB information of Galleon 6~10k
Item
PCB Name
PCB serial number
Quantity
Remark
1
SPS-Charger
6k
71-302390-XXG
1
For 6kVA model
10k
71-301757-XXG
1
For 10kVA model
2
CNTL
71-301569-XXG
1
3
Communication
71-302389-XXG
1
4
EMI
6K
71-302448-XXG
1
For 6kVA model
10K
71-302408-XXG
1
For 10kVA model
5
Main Power
6K
71-302114-XXG
1
For 6kVA model
10K
71-301756-XXG
1
For 10kVA model
Para(A)
71-302096-XXG
1
Para(B)
71-302097-XXG
1
O/P Relay
71-300026-XXG
1
6
7
Note: “XX” in the serial number is the version of the PCB. It may be modified according to releasing
version in the future.
5.1 SPS-Charger board (Power Stage Board)
The PSDR board consists of SPS. It gives the whole UPS system power supply.
You can set the current from 1A to 4A by changing the jumper. And you also can choose a different
voltage corresponding to different battery pieces by changing the jumper on the CNTL board and the
Charger-Charger board. The charge voltage is controlled by CNTL board.
5.2 CNTL board (Control Board)
The CNTL board is the core of the UPS system. It controls the actions of the semiconductors and other
mechanical switches, the display of the LED/LCD, the sound of the buzzer, the communication with the
computer, and other important tasks.
5.3 Communication board
The Communication board provides RS232/USB interface to the users, and it also provide one EPO port
to cut off the output immediately.
5.4 EMI board
The EMI board can prevent the UPS from external electronic/magnetic noise generated by other
electronic systems, and also prevent other systems from the noise generated inside of the UPS system.
And the MOV is also on the EMI board which can absorb the surge to protect the UPS system.
5.5 Main Power board
The Main Power board is the most expensive and biggest PCB in the UPS. It converts the AC/DC power
to a pure sine waveform. And then it converts the DC/AC power. There are many semiconductors and
easy-failure components on the board, so it’s required to pay more attention when UPS is abnormal.
5.6 Para(A) and Para(B) board
The Para(A) board and Para(B) board is used for parallel communication when the UPS system is
11
running in parallel mode.
5.7 O/P Relay board
The O/P Relay board should be installed for parallel system. For single system, it can be removed.
The board can disconnect the UPS from the output (parallel system).
12
6. Interface
6.1 LED Display
Table 6.1 LED Display
Mode
LED
UPS Startup
No Output mode
Bypass mode
AC mode
Battery mode
CVCF mode
Battery Test
ECO mode
Fault
Note:
Bypass
Line
Battery
Fault
●
●
●
●
○
○
○
○
●
○
○
○
○
●
○
○
○
○
●
○
○
●
○
○
●
●
●
○
●
●
○
○
○
○
○
●
● means LED is lighting, and ○ means LED is faded.
6.2 LCD Display
Figure 6.1 LCD Display
6.3 LCD Display Icon
Display
Function
13
Backup time information
Indicates the backup time in pie chart.
● Indicates the backup time in numbers.
H: hours, M: minutes, S: seconds
● When UPS is in Bypass mode, these two numbers indicating the power
capacity; 06 for 6K model and 10 for 10K model.
Fault information
Indicates that the warning and fault occurs.
Indicates the fault codes, and the codes are listed in details in section 7-1.
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 output is short.
Programmable output information
Indicates that the programmable outputs are working.
Mode operation information
Indicates the UPS connects to the utility.
Indicates the battery is working.
Indicates the bypass circuit is working.
Indicates the ECO mode is enabled.
Indicates the Inverter circuit is working.
Indicates the output is working.
Battery information
Indicates the Battery capacity by 0-25%, 26-50%, 51-75%, and 76-100%.
Indicates the battery is fault.
Indicates low battery level and low battery voltage.
Input & Battery voltage information
14
Indicates the input voltage or frequency or battery voltage.
Vac: Input voltage, Vdc: battery voltage, Hz: input frequency
15
7. Trouble Shooting
This section describes how to find the troubles when UPS is abnormal. We suggest you to follow the
service procedure below:
1. Check the UPS status via LED and LCD display, the sound of the buzzer, or listen to the
description of end users.
2. Inspect failure board for static checking.
3. Replace failure components.
4. Static checking.
5. Power-on checking.
6. Test after repair.
Following section will help service person to solve the most problems.
7.1 LCD Panel Display Pattern Definition
7.1.1 Trouble shooting for warning icon in LCD display
Any warning display implies some abnormity happened to the UPS, indicating that some situation that
may endanger the reliability of the UPS has occurred, but these situations don’t immediately lead to
interruption of power supply.
LCD icon (Flashing)
Alarm
Possible cause
Action
1 Beeping / second
Low battery
Check the battery voltage
2 Beeping / second
Over load
Check the loads
1 Beeping / second
Battery disconnected
Check the battery wiring
1 Beeping / second
Battery/Charger voltage too high
1 Beeping / second
EPO plug or cable not connected
Check the EPO plug and EPO cable
Fan
Check the fans, loads, ventilation,
1 Beeping / second
1 Beeping / second
failure,
or
high
internal
temperature
Check the output voltage of the
battery and the charger
ambient temperature
Charger broken or
low output
voltage
Check the charger
1 Beeping / second
I/P fuse broken
Check the I/P fuse
1 Beeping / second
Overload 3 times in 30min
Check the loads
Note: When the UPS alarms, the UPS is still working on the original mode.
16
7.1.2 Trouble shooting for fault codes in LCD display
When the UPS is fault, it will transfer to Fault mode.
Code
01
02
03
LCD
icon
None
None
None
04
None
05
None
11
None
12
13
None
None
Fault Event
BUS
soft
failure
BUS voltage high
BUS voltage low
BUS
voltage
unbalance
BUS
short
circuited
INV
soft
start
failure
None
21
None
When the bus voltage can’t
reach the setting value in
30s, the fault signal will be
displayed.
When one of the following
conditions occurs, the fault
signal will be displayed.
1. +Bus voltage keeps
higher than 450V or
the –BUS voltage keeps
lower than –450V for more
than 50 ms.
2. +Bus voltage keeps
higher than 400V or
the –BUS voltage keeps
lower than –400V for more
than 1.5s.
When +Bus voltage keeps
lower
than
230V
or
the –BUS voltage keeps
higher than –230V for more
than 200ms, the fault signal
will be displayed.
When
the
difference
between the ±Bus voltage
absolute value keeps more
than 40V for 2 minutes, the
fault signal will be sent.
When bus voltage drops to
32V in a period and the
situation occurs for more
than two periods, the fault
signal will be displayed.
Check if power components such as IGBT and
SCR for the PFC and the utility power SCR are
well. Meanwhile, check if the components on
the drive circuit are well.
Inverter voltage can’t reach
the setting value in 30s.
INV voltage high
INV voltage low
When INV voltage keeps
lower than 140V for 128
ms, the fault signal will be
displayed.
short
circuited
1A
Action
When INV voltage keeps
higher than 276V for 128
ms, the fault signal will be
displayed.
Output
14
start
Description
Negative
power
fault
Battery SCR short
circuited
When INV output voltage
keeps lower than 50V and
output current keeps lower
than 20A for over 3 periods,
the fault signal will be
displayed.
When the output power on
the INV terminal is over
-800W, the fault signal will
be displayed.
When battery voltage is
more than 310V, the fault
signal will be displayed.
17
Maybe the PSDR board is damaged;
Check if power components such as IGBT and
SCR for the PFC and the utility power SCR are
well. Meanwhile, check if components on the
drive circuit are well.
Maybe the PSDR board is damaged.
Check if power components such as IGBT and
SCR for the PFC and the utility power SCR are
well. Meanwhile, check if components on the
drive circuit are well.
Maybe the PSDR board is damaged.
Check if power components such as IGBT and
SCR for the PFC and the utility power SCR are
well. Meanwhile, check if components on the
drive circuit are well.
Check all the components on power board.
Check the inverter drive circuit.
Check if power components in power INV and
on the drive circuit are normal. Check if IGBT
protective circuit and some PFC components
are normal.
Maybe the PSDR board is damaged;
Check if power components in power INV and
on the drive circuit are normal. Check if IGBT
protective circuit and some PFC components
are normal.
Remove all the loads. Turn off the UPS. Check
whether the output of UPS and loads are short
circuited. Make sure the short circuit is
removed, and the UPS has no internal faults
before turning on again.
Check if input and output connections are
correct. And then check if INV relay RY5 or
STS(Q13, Q14, Q20,Q25 and their driver
circuits) are OK.
It is probably the charger or PSDR board
damaged.
Check if the battery SCR(Q21)or the battery
relay (RY3, RY4) on the PSDR board are well. If
PSDR board is ensured ok after checking, it
may indicate there is something wrong with
charger output.
Check if components for the battery drive
signals are normal. Check circuit of the utility
power SCR part.
24
None
35
None
36
None
INV
relay
short
circuited
Parallel
cable
failure
Current un-sharing
41
None
over temperature
42
None
Internal fault
43
After
Bus
soft
start
completes and INV PWM is
off, more than 50V INV
voltage is detected, the
fault
signal
will
be
displayed.
When
the
parallel
communication
between
the UPSs is interrupted, the
fault
signal
will
be
displayed.
When sharing current is
greater than 5A and sharing
current is greater than
5*ILoad or the share
current less than 5A and
greater than the ILoad+4A
in UPS parallel system, the
fault
signal
will
be
displayed.
Check if INV relay RY5 on PSDR board is OK.
Check the parallel cables between the UPSs
are normal, and the cable between the parallel
board and the control board are normal.
Check the share current cable are normal, and
make sure the output be connected together.
Check if UPS is overloaded, air vents are
blocked, and ambient temperature is over 40℃.
After overload or block is removed, please keep
UPS cool down for 10 minutes before turning on
again.
It is not recommended to operate the UPS
under over 40°C temperature environment.
CPU
can
not
build
communication and the
control board is damaged.
Replace the CNTL board.
Check the loads and remove some non-critical
loads.
Check whether some loads are failed.
Overload
7.1.3 Trouble shooting
Problem
Possible cause
Action
Battery not yet been fully charged.
Battery backup time is
shorten
The UPS cannot power
on after pressing the
button
UPS overload.
Battery aged.
Charger fails
The button is not pressed and hold
long enough
Battery is not connected or battery
voltage is too low, or charger fails.
UPS failure.
Keep UPS connected to utility power persistently
for more than 10 hours to recharge the batteries.
Check the loads and remove some non-critical
loads.
Replace the batteries.
Replace the charger.
Press the button continuously for more than 0.5s.
Check the charger and battery.
Repair the UPS.
7.2 Repair
In this section, some debug skills are listed to help you finding the failed components and problems as
soon as possible. Before proceeding the following steps, we strongly suggest to read previous section
for trouble shooting first. Then check the components listed in section 7.2.4 to find out which block fails.
18
7.2.1 Basic Instruments and tools
1、 One computer with RS232 port and one standard RS232 cable;
2、 Wire cutters and clamps;
3、 One electric soldering iron;
4、 One multimeter;
5、 One oscilloscope(voltage and current probe needed);
6、 Diagonal pliers, snipe nose pliers, cross screwdrivers (150mm/75mm length), flat screwdrivers
(75mm length) and PVC insulating tapes etc;
7、 Make-self tools including Balance voltage test equipments, current limiting resistors, tubes and
clamp terminals with different specifications;
7.2.2 Configuration of the Model Port on the Control Board
The Model Port (JP1) on the CNTL board should be configured as follows:
Table 6.1 Model Port Setting List
Model Type
pin1&pin2
pin3&pin4
Battery Number
pin5&pin6
pin7&pin8
pin5&pin6
6K
0
1
16
1
0
0
6KL
0
0
17
0
1
1
10K
1
1
18
0
1
0
10KL
1
0
19
0
0
1
20
0
0
0
Note:“1” indicates that the jumper is connected;
“0”indicates that nothing is connected
7.2.3 Configuration of the charger current on the charger Board
The Model Port on the Charger board should be configured as follows:
Table 7.3 Charger current Setting List
Charge current (A)
1A
JP06
JP07
JP08
0
0
1
2A
0
1
0
3A
1
0
0
4A
0
0
0
Note:“1” indicates that the jumper is connected;
“0”indicates that nothing is connected
7.2.4 Configuration of the charge voltage on the charger Board
Modify charger voltage according to below table to meet the setting number in control board. There are
jumpers on the charger board. Please refer to the below table to modify charger voltage.
Table 7.4 Charge Voltage Setting List
Battery Number
in series
16
Charge
voltage (V)
JP01
JP02
JP03
JP04
JP05
218
0
0
0
1
0
17
232
0
0
1
0
0
18
245
0
1
0
0
0
19
19
259
1
0
0
0
0
20
273
0
0
0
0
0
Note:“1” indicates that the jumper is connected;
“0”indicates that nothing is connected
7.2.5 Regulation of the system
Parameter Setting Method:
1. Connect the RS232 port of the UPS to the RS232 port of the computer with RS232 cable.
Choose the “Start>>Program>>Accessory>>Communication>>Hyper terminal” and start Hyper
terminal application. Set the COM port for “COM1” and the other setting as Figure 7.1.
Communication protocol setting
Display setting
Figure 7.1 Hyper terminal setting
20
2. After completing the setting, you can type the command in the command area.
3. +BUS voltage regulation: Type “BUSP+/- XX” command (XX is two digits from 00 to 99). Then
press the “ENTER” key, and +BUS voltage will rise (drop) about X.XV.
4. -BUS voltage regulation: Type “BUSN+/- XX” command (XX is two digits from 00 to 99). Then
press the “ENTER” key, and -BUS voltage will rise (drop) about X.XV.
5. INV output voltage regulation: Type “V+/- XX” command (XXis a digit from 00 to 99) Then press
the “ENTER” key, and output voltage will rise (drop) about X.XV.
6. INV output voltage setting: Type “VXXX” command (XXX is 208/220/230/240). Then press the
“ENTER” key, and INV output voltage will be set to 208V/220V/230V/240V.
7. Output current regulation: Type “OC+/-XX” command (XX is two digits from 00 to 99). Then
press the “ENTER” key, and output current will rise (drop) about X.X A.
Regulation Process for Single UPS
1. BUS voltage regulation: When the UPS run into AC mode, measure ±BUS voltage with the
multimeter, and then regulate ±BUS voltages to 360±0.5V by using BUS regulation command.
(BUS voltage can be regulated about 0.1V every point by using BUS regulation command).
2. INV output voltage regulation: When the UPS run into the Inverter mode, measure the output
voltage with the multimeter, and regulate the output voltage to 230±0.5V by using output
voltage regulation command. (INV output voltage can be regulated about 0.1V every point by
using output voltage regulation command).
3. Output current regulation: When the UPS run into the Inverter mode with full R load, measure
the output current, and regulate the output current which we can read from QGS command to
measure value±0.2A by using output current regulation command. (Output current can be
regulated about 0.1A every point by using output voltage regulation command).
Notes:
1. Make sure the ground of the UPS connects to earth safely during parameter regulation.
2. New assembly UPS must be regulated.
3. UPS which have been replaced CNTL/PSDR must be regulated again.
4. All the commands use capital letters.
5. All the above parameter regulation cannot be accumulated.
6. All the regulation will be saved in the flash memory of the CNTL when UPS shutdown with
battery connected.
7.2.6 Quick Start
Before any detail check for UPS, please check the components listed in the following table. This action
could help you find problem quickly and make debug procedures go smoothly.
Note: Make sure that the capacitor voltage is lower than the safety voltage before disassembling any
parts to do checking procedure.
10k Main Power Section
Circuit Block
Checked components
Component Type
Failure condition
DC FUSE
F3, F4
Fuse
Open
Rectifier
Q27, Q18, Q21
SCR
A-K Short or open
D33, D35
Diode
Short or open
Q22, Q23, Q24, Q25
IGBT
C-E short or open
D52, D62
Diode
Short or open
PFC
INV
21
STS
Q7, Q8, Q9, Q10, Q12, Q15
IGBT
C-E short or open
Q13, Q14, Q20, Q46
SCR
A-K Short or open
6k Main Power Section
Circuit Block
Checked components
Component Type
Failure condition
AC FUSE
F3,F4
Fuse
Open
Rectifier
Q17, Q18, Q21
SCR
A-K Short or open
D33, D35
Diode
Short or open
Q22, Q23
IGBT
C-E short or open
D62, D52
Diode
Short or open
Q7, Q8, Q9, Q10
IGBT
C-E short or open
Q1, Q2, Q3, Q4
SCR
A-K Short or open
PFC
INV
STS
SPS-Charger Section
Circuit Block
Power
Semiconductor
Others
Checked components
Component Type
Failure condition
D2, D3, D7, D8, D11
Diode
Short or open
Q1, Q2
MOSFET
D-S short or open
IC1
Power IC
I-O short or open
Q28
MOSFET
D-S short or open
F1
Fuse
Open
REC1
Rectifier Bridge
Short or open
Q6, Q15, Q28
MOSFET
D-S short or open
D8, D16, D13, D7, D17, D18 ,D33
Power Diode
Short or open
U1, U4
Power IC
I-O short or open
U9, U10
Power Control IC
Vcc short to GND
Note: If the fuse is in “open” status, don’t replace the fuse only. In most of cases, open fuse is caused by
other failed components. Therefore, before restarting the UPS, you must find all failed components and
replace them.
22
8. Test Step
After replacing all defected components,
following testing steps can be adopted to verify
the repair result and the reliability of the UPS.
1. Install all of boards/cable/connector.
2. Check the wiring, pay more attention to
the charger control cable(3Pin).
3. Apply DC Power from power source with
current limitation function to the battery
terminal.
4. Press the ON button on the panel for
less than 0.5s, the LCD will be lit and
the Fan will rotates, If not, please check
the input voltage of the SPS, if the
voltage is the DC source output voltage,
please repair the SPS again.
5. Press the ON button on the panel for
more than 0.5s until you hear the note
ringing and loosen the button, you will
see "current limit" for a short time on the
DC source for about only 2 seconds,
then UPS should be DC started, If UPS
does not start successfully, please
repair the PFC or CNTL again.
6. If UPS does not start up for several
trying or DC source is on current-limit
state continuously, there must be some
defected components exists. Please
follow trouble-shooting chart to debug
again.
7. Turn off the UPS, connect utility to the
UPS, turn on the UPS, if fail you may
have start one new round of trouble
shooting.
8. Check and adjust charge voltage.
9. Check the output voltage waveform and
DC-offset voltage, at no-load and full
load condition.
Repair the UPS
according to the
trouble shooting
1. Cable from LCD to
CNTL disconnected.
2. Cable from LCD to
PSDR disconnected.
3. SPS failure
Connect the DC
source and press ON
button less than 0.5s
Check the wiring and
correct it
Yes
LCD light and fan
rotates?
No
DC voltage on the
SPS is OK?
No
Yes
Information of the
LCD display OK?
No
CNTL failure and
repair it
No
Booster/CNTL failure
and repair it
No
INV/CNTL failure and
repair it
No
Charger failure and
repair it
No
Rectifier/CNTL
failure and repair it
No
CNTL failure and
repair it
Yes
Press ON button
more than 0.5s
Yes
BUS voltage rise to
360V?
Yes
INV voltage rise to
230V?
Yes
Shutdown and turn
on the IP breaker
without DC source
and battery
LCD light and fan
rotates?
Yes
BUS voltage rise to
311V?
Yes
Press ON button
more than 0.5s
BUS voltage rise to
360V and INV
voltage rise to 230V?
Yes
END
23
9. Appendix
9.1 Reference Waveform
. Below are some waveform charts to show normal UPS operation. It’s a very useful reference to verify
the test result in section 8.
CH1: IP SCR driver
CH2: IP voltage
CH3: -BUS voltage
CH4: +BUS voltage
Figure 9.1 Switch on the input breaker without turn on
CH1: INV voltage
CH2: IP voltage
CH3: -BUS voltage
CH4: +BUS voltage
CH1: INV voltage
CH2: Battery voltage
CH3: -BUS voltage
CH4: +BUS voltage
AC mode (transfer from Bypass mode)
Battery mode
Figure 9.2 Turn on the UPS
24
CH1: IP voltage
CH3: VGE-(PFC PWM-)
CH4: VGE+(PFC PWM+)
CH1: INV voltage
CH2: Battery voltage
CH3: VGE-(PFC PWM-)
CH4: VGE+(PFC PWM+)
AC mode
Battery mode
Figure 9.3 PFC PWM
CH1: INV voltage
CH2: IP voltage
CH3: VGE-(INV PWM-)
CH4: VGE+(INV PWM+)
Figure 9.4 INV PWM
25
9.2 Basic communication command
In this section, we will show you some basic communication commands that will help you debug or
regulate the UPS system.
9.2.1 QGS
QGS means to request general status parameters of the system. The command format is:
Computer:QGS<cr>
UPS: (MMM.M HH.H LLL.L NN.N
b9b8b7b6b5b4b3b2b1b0a0a1<cr>
QQQ.Q
DDD
KKK.K
VVV.V
SSS.S
XXX.X
TTT.T
Data
Description
Notes
a
(
Start byte
b
MMM.M
Input voltage
M is an Integer number 0 to 9. The units is V.
c
HH.H
Input frequency
H is an Integer number 0 to 9. The units is Hz.
d
LLL.L
Output voltage
L is an Integer number 0 to 9. The units is V.
e
NN.N
Output frequency
N is an Integer number from 0 to 9. The units is Hz.
g
QQQ.Q
Output current
Q is an Integer number from 0 to 9. The units is A.
h
DDD
Output load percent
For Off-line UPS: DDD is a percent of maximum VA,
not an absolute value.
For On-line UPS: DDD is Maximum of W% or VA%.
VA% is a percent of maximum VA.
W% is a percent of maximum real power.
j
KKK.K
Positive BUS voltage
K is an Integer ranging from 0 to 9. The units is V.
k
VVV.V
Negative BUS voltage
V is an Integer ranging from 0 to 9. The units is V.
l
SSS.S
P Battery voltage
S is an Integer ranging from 0 to 9. The units is V.
m
XXX.X
N Battery voltage
X is an Integer ranging from 0 to 9. The units is V.
n
TTT.T
Max Temperature of the
detecting pointers
T is an integer ranging from 0 to 9. The units is °C
o
b9b8b7b6
b5b4b3b2
b1b0
a0a1
Ups status
B9,b8:
00: standy;
01: line-interactive;
10: on-line.
B7: Utility Fail
b6: Battery Low
b5: Bypass/Boost Active
b4: UPS Failed
b3: EPO
b2: Test in Progress
b1: Shutdown Active
b0: bat silence
a0: Bat test fail
a1: Bat test OK
Example:
26
Computer: QGS<cr>
UPS: (220.2 50.0 220.0 50.0 027.0 100 345.8 344.9 241.0 241.5 045.0 100011000000<cr>
Means:
I/P voltage is 220.2V.
I/P frequency is 50.0Hz
O/P voltage is 220.0V
O/P frequency is 50.0Hz.
O/P current is 27.0A
O/P load 100%
Positive BUS voltage is 345.8V
Negative BUS voltage is 344.9V
P Battery voltage is 241.0V.
N Battery voltage is 241.5V.
Temperature is 45.0 degrees of centigrade.
On-line mode, Utility OK, Bypass Active, UPS failed.
9.2.2 V<n>
This command is to set the nominal output voltage. The format is:
Computer: V<n><Enter>
UPS: (ACK or (NAK*
*: If UPS accepts this command, responds ACK. Otherwise, responds NAK
Output Voltage: <n>. n is 208,220,230,240.
Default status: Nominal output voltage 220V. (It can be set only in bypass mode)
For example:
Computer: V230<Enter>
UPS: (ACK
Meanings: set output nominal voltage to 230V.
9.2.3 V±<n>
This command is to adjust the nominal inverter voltage. The format is:
Computer: V±<n><Enter>
UPS: (ACK or (NAK*
*: If UPS accepts this command, responds ACK. Otherwise, responds NAK
Voltage adjust step: <n>. n=00, 01……, 99.
For example:
Computer: V+01<Enter>
UPS: (ACK
Meanings: Inverter voltage will increase about 0.1Volt.
9.2.4 BUSP±<n>
This command is to adjust the positive BUS voltage, the format is:
Computer: BUSP±<n><Enter>
27
UPS: (ACK or (NAK*
*: If UPS accepts this command, responds ACK. Otherwise, responds NAK
Voltage adjustment step: <n>. n=00, 01……, 99.
For example:
Computer: BUSP-01<Enter>
UPS: (ACK
Meanings: Positive BUS voltage will decrease about 0.1Volt.
9. 2.5 BUSN±<n>
This command is to adjust the negative BUS voltage, the format is:
Computer: BUSN±<n><Enter>
UPS: (ACK or (NAK*
*: If UPS accepts this command, responds ACK. Otherwise, responds NAK
Voltage adjustment step: <n>. n=00, 01……, 99.
For example:
Computer: BUSN+01<Enter>
UPS: (ACK
Meanings: Negative BUS voltage will increase about 0.1 Volt.
9. 2.6 VB±<n>
This command is to adjust the battery voltage sampling value. You can adjust the parameter to the
sampling voltage displayed on LCD and the real battery voltage. The format is:
Computer: VB±<n><Enter>
UPS: (ACK or (NAK*
*: If UPS accepts this command, responds ACK. Otherwise, responds NAK
Voltage adjustment step: <n>. n=00, 01……, 99.
For example:
Computer: VB-01<Enter>
UPS: (ACK
Meanings: Battery sampling voltage will decrease about 0.1Volt.
9.2.7 QVFW
QVFM means to request the version of the firmware. The command format is:
Computer: QVFM<Enter>
UPS: (VERFW: <NNNNN.NN>
<N> is a HEX number from 0...9 or A…F.
Example:
Computer: QVFW<Enter>
UPS: (VERFW: <00123.01>
Meanings: 00123 is the firmware series number and 01 is the version.
9.2.8 OC±<n>
This command is to adjust the output current sampling value. The format is:
28
Computer: OC+<n>< Enter >
UPS: (ACK<cr> if UPS accepts this command, otherwise, responds (NAK<cr>
Computer: OC-<n>< Enter >
UPS: (ACK<cr> if UPS accepts this command, otherwise, responds (NAK<cr>
<n> is a number which ranging from 00, 01…… to99. 99 means 9.9A
For example:
Computer: OC-01<Enter>
UPS: (ACK
Meanings: Output current sampling value will decrease about 0.1A.
29
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