1KVA UPS Service Manual Guide
1KVA UPS Service Manual Guide
SERVICE MANUAL
1KVA model
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.
                                                 1
                    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
                                                      2
                      STEPS TO OPEN THE CASE
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.
STEP 1
STEP 2
STEP 3
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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.
                                                 4
                         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 schematic in figure 1 shows how the major circuits are connected and illustrates
the overall system functions.
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:
                                                6
                                                                                      O/P
 I/P
                    RY               PFC
          N.F.                      AC/DC                   DC/AC             N.F.
                                                                     RY
                                                    DC/DC
                            CHARGER
BATTERY
                                                7
                                Figure 4: Charger Circuit Diagram
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.
                                               8
                               Figure 6: Schematics for inverter
                                             9
 The major function of the UPS is to deliver accurate AC power to the loads connected to it
 whenever the AC line is correct or fails. In this system, the batteries release the stored
 energy to supply inverter immediately upon AC line fails.
 Refer to figure 8, the battery voltage is transformed through a push-pull DC-DC converter to
 ±360Vd as DC buses for inverter. When the line fails, the ±360Vdc DC sources are caught up
 to supply the power needed by the inverter immediately.
 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.
 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.
                                                 10
2-2 PROTECTION SUB-SYSTEM:
The UPS provides the following protection circuits:
  1. Overload protection
The load detector senses the load current. I.e. the inverter current, and sends the signal by
two paths. In battery mode, the UPS will go to failure mode if overload condition happened.
The panel will indicate the fault condition. There are two kinds of protection in our UPS:
  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 warning. If the output load is
     between 110% and 130% of rated load (VA, or Wattage) the UPS transfers to bypass
     after 30s. 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.
  Upon the batteries are discharged to battery-low level, the battery-low signal is activated
  and the buzzer beeps every 1 second.
                                               11
    Remote shutdown signal is enabled only when the line fails.
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
                   for 10 seconds.
  Select Button
                  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
                   mode.
ON/Mute + Select  Switch to bypass mode: When the main power is normal, press
     Button        ON/Mute and Select buttons simultaneously for 5 seconds. Then UPS
                                               12
                     will enter to bypass mode. This action will be ineffective when the
                     input voltage is out of acceptable range.
                    Switch to UPS self-test mode: Press ON/Mute and OFF/Enter buttons
  ON/Mute +
                     simultaneously for 5 seconds to enter UPS self-testing while in AC
OFF/Enter Button
                     mode, ECO mode, or converter mode.
                             IV. ALIGNMENTS
                                             13
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.
V. TROUBLE SHOOTING
                                                 14
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, which
will help you solve the most problems on UPS.
                                                15
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.
Mode operation information
                         Indicates the UPS connects to the mains.
                                                   16
                          Indicates the ECO mode is enabled.
Battery information
                          Indicates the Battery level by 0-25%, 26-50%, 51-75%, and 76-
                          100%.
UPS Setting
                                                   17
                                                     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, Backup time setting for outlets.
    Parameter 2            Parameter 3
                                                18
                                You may set the initial frequency on battery mode:
                                BAT 50: presents output frequency is 50Hz
                                BAT 60: presents output frequency is 60Hz
                                If converter mode enable, you may choose the following
                                output frequency:
                                CF 50: presents output frequency is 50Hz
                                CF 60: presents output frequency is 60Hz
 04: ECO enable/disable
 Interface                      Setting
                                ENA: ECO mode enable
                                DIS: ECO mode disable
                                              19
                                 For 100/110/115/120/127 VAC models:
                                 120-132: setting the high voltage point from 120Vac to
                                 132Vac
                                 85-115: setting the low voltage point from 85Vac to
                                 115Vac
   08: Backup time setting for outlets
Interface                            Setting
                                     Parameter 3: Set up backup time on battery mode for
                                     general outlets.
                                     0-999: setting the backup time in minutes from 0-999 for
                                     general outlets on battery mode.
                                     0: When setting as “0”, the backup time will be only 10
                                     seconds.
                                     999: When setting as “999”, the backup time setting will
                                     be disabled.
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
                                                   21
FUSE                            F1,F2,F3                        short or open
U.P.F. CORRECTION               D10, D11,REC1,Q1                short or open
Push-Pull Booster               Q2,Q3,Q4,Q6                     D-S short or open
                                D15,D16, D17, D18               short or open
Inverter                        Q7,Q8                           D-S short or open
Charger                         Q3,                             D-S short or open
                                Q301,Q306
                                D2,D3,D5,                       short or open
                                D300,D302,D305,D306
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
                                               22
  1    Q2(D,S)                       DIODE            0.47              short or open
  2    R18                           Ω                22                open
  3    R104                          Ω                0.22              open
6. AC/DC CHARGER :
Step       Checked components            Instrument   Reference Value    Failed condition
                                           function
  1    Q3,                           DIODE            0.49              short or open
       Q301,Q306 (D,S)
  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 voltage 36Vdc/2Amp (limited current) with DC power supply via P5+ and
                                              23
  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+, P7-).
  Is it 41.2Vdc.The fan will also active. If there is no problem in charger, connect the batteries
  via P11, 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
                                                 24
        Acceptable Input Voltage                            0-300 VAC
            Low line transfer                       160VAC;  5% (Full Load)
           Line low comeback                        168 VAC;  5%(Full Load)
            Line high transfer                           300 VAC;  5%
          Line high comeback                             290 VAC;  5%
      Start-up Voltage with Output                  110 VAC to 300 VAC;  5%
                  Power
    Ratings (at nominal input voltage)                          5A
              earth leakage                       3.5 mA, maximum (UPS only)
           Input power factor                                 > 0.99
             Input frequency                              40 Hz to 70 Hz
          Input protection type                          circuit protector
O/P Specification
               O/P Power
               Power (VA)                                      1000
             Power (Watts)                                     800
       Output Power Factor Rating                               0.8
        Load Power Factor Range                      0.5 lagging to 1.0 (unity)
             Output Voltage                           200//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:
                                               25
      PIN TYPE ...................: female
      BAUD RATE .............. : 2400 bps
      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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