SERVICE MANUAL

ELIPSE SERIES
EL-1.5K/EL-3K 110V
FORZA POWER TECHNOLOGIES
 CONTENT
1. GENERAL INFORMATION OF THIS DOCUMENT....................................................... 4
1.1 GETTING STARTED ........................................................................ 4
1.2 CONVENTIONS ............................................................................ 4
1.3 IMPORTANT SAFETY INSTRUCTIONS .................................................... 5
2. CHARACTERISTICS OF THE PRODUCT ........................................................................ 6
3.1 FUNCTIONAL BLOCK OF THE PRODUCT ................................................. 7
3.2 OPERATING PRINCIPLE OF THE MAJOR FUNCTIONAL BLOCK ......................... 9
3.2.1 AC/DC converter (PFC)..............................................................................................9
3.2.2 DC/DC converter (Battery Booster) .....................................................................11
3.2.3 Inverter .......................................................................................................................12
3.2.4 Global Controller .......................................................................................................12
3.2.5 Charger .......................................................................................................................13
3.2.6 DC Power Supply (SPS)...........................................................................................14
3.2.7 User Interface............................................................................................................15
3.2.8 Ventilation and Chassis ...........................................................................................16
4. TROUBLE-SHOOTING....................................................................................................... 18
4.1 LED PANEL DISPLAY PATTERN DEFINITION........................................... 18
Problem..................................................................................................................................20
4. 2 TROUBLE SHOOTING PROCEDURES ................................................... 21
4.2.1 How to Start...............................................................................................................21
4.2.2 Find out the Problem Quickly.................................................................................22
4.3 FAILURE DIAGNOSIS .................................................................... 22
4.3.2 P.F.C Converter Analysis: ........................................................................................25
4.3.3 Push-Pull DC-DC Converter Analysis....................................................................26
4.3.4 DC/AC Inverter Analysis .........................................................................................27
4.3.5 DC Power supply .......................................................................................................27
4.3.6 AC/DC charger...........................................................................................................28
4.3.7 Others..........................................................................................................................29
5. TEST AND FINISH .......................................................................... 30
APPENDIX.................................................................................................................................. 32

3
1. General Information of This Document

1.1 Getting started

This is the service manual for the Elipse Series 110V UPS, intended to help service
personnel perform maintenance and repair service.

If you want to know:

• What is special for this UPS from service point of view; please refer to
section “characteristics of the product”.
• Construction of the product; how many pieces of PCB make up the product,
please refer to “construction of the product”.
• Functional block of the UPS, and operating principle, please refer to
“Principles of Operation”.
• What’s wrong with the UPS and How to solve the problem, please refer
to “Trouble-Shooting”.
• Basic information about the product, install and operation instruction,
please refer to the USER MANUAL

1.2 Conventions

This service manual uses the following conventions to alert you of important
information for safe operation.

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.


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.

Information and Tips: There are some tips and information after this symbol.
During service operations, these tips may help you quickly finish your work.

4
 1.3 Important Safety Instructions

STOP

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 before removing outside
protective cover.

5. AC voltage is always present if the input AC power is still available.

6. High voltage may be present at DC capacitors. Before opening the outside cover,
wait at least five minutes after turning off the UPS.

7. Verify input source (voltage and frequency) is within the maximum range before
service.

1. DO NOT short-circuit internal batteries

2. If the battery connectors [BAT (+), BAT (-)] are disconnected, be sure to plug in
the input power cord and the input power is available before re-connecting the
battery connectors.

3. After service, verify the polarity of batteries, fasten 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 are any discolored components
inside.

5
2. Characteristics of the Product

All UPS in this series are carefully designed and strictly tested. 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 unexpected failures that may occur to the
product; in this case, qualified service 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 may
encounter.

Because of the following unique features, this series UPS (Uninterruptible Power
System) is very easy to maintain and service.

All major power components are put on PCB.

Minimum numbers of PCB sub-assembly.

Major parts are simply connected with flexible insulated wires and plugs.

All PCBs are interconnected with connectors.

Most functional sub-circuit become modular, easy to identify the problem

and repair by replacing the appropriate module

6
3. PRINCIPLES OF OPERATION
3.1 Functional Block of the Product

As a true online UPS, the product employ a double conversion topology, comprised of
the following functional blocks:

Figure 3.1 Function block Diagram of the product

7
 2
-
+
43

3
2

1
3
3

1
2
1

3
2

Fig3.2 PSDR functional diagram

In which:

The controller block controls 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.

The AC/DC module, called also PFC/rectifier, belongs to the input stage of the UPS. The
AC/DC converter block converts the AC mains input power into a pair of stable DC
power storing on the DC-BUS. In the mean time, Power Factor Correction is performed,
the input current tracking the input voltage waveform, and the input power factor can
be very close to 1, achieving maximum efficiency and producing lowest power pollution
to the power supply system.

The DC/DC module, called also Battery Booster, is another part of input stage, used to
converts the low level DC power into higher level and more stable DC power, storing on
the DC-BUS also.

The DC/AC module, also called an inverter, belongs to the output stage of the UPS,
used to convert the DC power from the DC-BUS into clean, stable AC output power.

8
When the mains line is within the tolerance range, the UPS uses the mains input, at this
time, the AC/DC converter work; In case the mains line supply is outside the tolerance
range, due to either the voltage or the frequency, the UPS will stop the AC/DC
converter working and start the DC/DC module. In case the input mains supply
interrupts suddenly, the controller can detect the interruption in very short time, and in
the interval before detecting the interruption, the output power will be maintained by
energy stored in the DC-BUS capacitor, there will never be appear interruption on
output.

The battery charger module converts the AC mains input into DC power for recharging
the Battery. Two type of charger can be available, one is for the standard model, and
another is for long backup time model that connects external battery.

The input EMI filter and output EMI filter are used for two purpose, the first one is to
prevent the UPS being interference by external electronic/magnetic noise which is
generated by the other electronic systems, the second is to prevent the noise
generated inside the UPS system to interfere with other systems.

The Power supply block generates DC power supply needed by operation of the circuit
of the UPS itself.

The internal Bypass provides an alternative path in case the power conversion stage
become out of order, to maintain the continuity of output supply.

3.2 Operating Principle of the Major Functional Block

3.2.1 AC/DC converter (PFC)

The purpose of AC/DC converter is to generate a stable bipolar DC BUS for inverter,
another very important task of AC/DC converter is to make the input current track
input voltage waveform therefore achieving a high input power factor close to 1,
performing PFC (Power Factor Correction), That is why we also call the AC/DC
converter PFC converter.

9
 1K:L9 1K:D10
1.5K:L2 1.5K:D18
2K&3K:L06 2K&3K:D16
Line_R +DC BUS

1
1K&1.5K:REC1
2K&3K:REC02
C
2 - + 4 1K:D11
1.5K:D13
2K&3K:D17

3
Neutral

1K&1.5K:Q14
2K&3K:Q09 C

-DC BUS

Figure 3.3 showed the topology the PFC converter

When the input AC power cord is plugged in, the AC relay is activated and the AC power
goes through the noise filter to the charger and to the line detector. Both DC Buses
present Voltages at about 1.4 times of input RMA voltage. When the “ON” switch is
pressed, the PFC circuit is enabled and the DC BUS is regulated at for 110VAC serried.

The PFC converter is comprised of several sub-circuits, the first one is the modified
BOOST power topology, the second one is the driving circuit, the third one is the PFC
controller, which can further divided into signal sensor, feedback circuit and the
actuator.

When AC mains is in normal condition, after receiving the turn on command, the global
controller turns on the AC relay and enables PFC converter to work, the PFC controller
outputs PWM (Pulse Width Modulation) signal, the PWM signal will be isolated,
amplified and used to drive the switching component, the IGBT. When the IGBT is
turned on, the current flow through the PFC chock is increased, the chock is energized;
when the IGBT is turned off, the chock is de-energized and charges 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, implementing the power factor correction.

10
 3.2.2 DC/DC converter (Battery Booster)

In case the AC mains interrupt or go out of tolerance range, the global controller stops
the PFC converter and starts the DC/DC converter to converts the DC power from the
battery to maintain the DC-BUS voltage, therefore maintaining the output power
supply to the load.

+DC BUS
1K:D14
1.5K:D24
3K&2K:D05
1K:C13
1.5K:C51&C68
1K&1.5K:Q4 1K:D12 2K&3K:C36&C38
2K&3K:Q04 1K&1.5K:TX1 1.5K:D23
2K&3K:TX02 2K&3K:D06
1K&1.5K:Q6
2K&3K:Q05

BATTERY

Neutral

1K:C12
1K&1.5K:Q10 1K:D15 1.5K:C52&C73
2K&3K:Q06 1.5K:D11 2K&3K:C37&C40
2K&3K:D07
1K&1.5K:Q11
2K&3K:Q07

-DC BUS
1K:D13
1.5K:D12
2K&3K:D08

Figure 3.4 DC/DC Converter

The DC/DC converter employes a push-pull power topology, the driving circuit, and the
controller. The controller is majorly comprised of ASIC UC3525 and auxiliary circuit.

The DC/DC converter controller drive a pair of switching component, MOSFET used
here, turns on in turns, the switch frequency goes above 40kHz. Either of the MOSFET
is turned on, there will be power from the Battery transfer to the secondary side of the
transformer to charging the DC-BUS. The MOSFETs turn on /off in turn, can prevent the
saturation of the transformer and damage of the circuit.

11
 3.2.3 Inverter

The inverter converts the DC power from the DC BUS into the AC output to supply the
load. A half bridge topology is employed,

+BUS

1K&1.5K:Q13
1K:C13 2K&3K:Q13&Q14
1.5K:C51&C68 +
2K&3K:C36&C38

CHOCK

OUTPUT

C
1K&1.5K:Q12
1K:C12 2K&3K:Q15&Q16
+
1.5K:C52&C73
2K&3K:C37&C40

-BUS

Figure 3.7 Schematics for inverter

The input of the half-bridge inverter topology is in DC Voltage, and the output is in AC
voltage. The half bridge inverter is composed of a pair of complementing switching
devices, IGBT, a free wheel diode parallel with each IGBT forming a switching leg, a
driving circuit for each IGBT, an LC filter, and the controller. In the real circuit, an IGBT
with co-pack diode is used to simplify circuit and achieve minimize stray parameters.

When the positive IGBT is turned on, The output of half bridge is equal to the positive
DC-BUS voltage, when the positive IGBT is turned off, either the negative IGBT is
turned on or the negative free-wheel diode is active, the output of the switching leg is
negative DC-BUS, so by changing the duty cycle, the average of output of the switching
leg can vary from +BUS voltage to –BUS voltage, the output of the switching leg is
filtered by an LC filter to get clean and stable sine wave output voltage.

3.2.4 Global Controller

The Global Controller of the UPS is composed of the following major circuits:

(1) CPU Central Processor Unit

(2) Signal conditioning circuit

(3) Regulation & Protection circuit

12
 (4) Output buffering circuit

(5) Communication interface

The CPU can be regarded as the brains of the UPS, in charge of signal detecting,
measurement, processing, timing control, inverter operating control, protection,
and communication.

To control the UPS, the status of the UPS must be monitored. Different kinds of
sensors are widely used in the UPS, due to the pure condition of the signal given by
the sensors; Signal conditioning circuits are used to attenuate / amplify / filter the
signals given so they can become suitable to be processed by the CPU.

The regulation network of the inverter, forming a close loop controller, enables the
inverter to run stable, and get the desired performance, such as less distortion, good
dynamic response performance, etc.

The global controllers also implement the following protection functions:

1. Overload Protection

2. Cycle by Cycle Current Limitation

3. Battery over or under voltage shut down

4. Inverter output abnormal protection

5. Over temperature protection

6. Bus over-voltage protection

7. Fans lock protection

Due to the high level of integration, the global controller is not designed to be
maintained or repaired outside of the manufacturer. There are two methods to
identify the status of the global controller. The first one is to test with test fixture;
the second is to test the global controller on a PSDR that has been verified to be OK.

3.2.5 Charger

The purpose of the charger is to recharge and to maintain the batteries at fully
charged condition. It charges the battery with a constant current at initial stage, as
the battery voltage keeps increasing, the charge current decreases accordingly, and
the voltage until the floating recharge voltage, and the charger will control the
output at a constant level (41.4VDc/1K, 54.9Vdc/1.5K,110Vdc/2k&3k). In this way,

13
 to make the battery fully recharged but not over-charged. This protects and
prolongs the lifetime of charged batteries.

- - -
3

Fig.3.8 Topology of the charger

The battery charger employes a Flyback topology, the switching component
MosFET turn on /off, when the MOSFET is turned on, the current in the transformer
increases, and a certain amount of energy is stored in the transformer, when the
MOSFET turns off, the energy stored in the transformer starts to release from the
secondary side of the transformer and charges the output capacitor, by controlling
the duty cycle, energy transfer to secondary side of the Flyback circuit can be
controlled, and so can the output voltage.

3.2.6 DC Power Supply (SPS)

The Power Supply (SPS) supplies DC power for UPS operation. The input of the SPS is
the battery, or the output of the charger.

Fig.3.9 Topology of the DC Power Supply

This is a Flyback converter topology. When the MOSFET is on, all rectifier diodes are

14
reverse-based and all output capacitors supply currents to the load. The primary wire
acts like a pure inductor and load current builds up linearly in it to a peak lp. When the
MOSFET is off, the primary stored energy is delivered to the secondary to supply load
current and replenish the charge on output capacitors that they had lost when the
MOSFET was on. The SPS module output +15Vdc and a High frequency low level AC
power, called H.F power+/ -, +12Cdc mainly used for Relay driving, Signal amplifier,
Fans supply, and generate +5V DC power supply for the CPU, And the. H.F.power+/ -
is not only the source of IGBT gate drive power but also the source of the isolated
power supply for communication ports on the CNTL board. The SPS module works only
when the +15 Vdc regulator supplies Vcc to its control IC.

3.2.7 User Interface

3.2.7.1 LED Display

1) LED icon description

Display Function

AC INPUT LED The green LINE LED lights up if mains voltage is applied to the UPS
input.
LINE LED flashes when the phase and neutral conductor have been
reversed at the input of the UPS system.
If LINE LED and BATTERY-LED light up, the mains power supply is
out of tolerance.
BATTERY LED The orange-coloured BATTERY-LED lights up when the mains power

15
 has failed and the inverter is being powered by the batteries.
BYPASS LED The orange-coloured BYPASS LED lights up when the UPS system is
supplying voltage provided by the mains power via the bypass.

UPS ON LED The green-coloured INVERTER LED lights up if the UPS system is
supplying voltage provided by the mains power via the inverter.
FAULT LED The red FAULT LED lights up and an acoustic warning signal is
issued every second when the UPS system is in fault condition.
Press the Standby switch to turn off the warning tone.
Load and These LEDs show the load of the UPS system if the mains power is
battery available (normal operation):
capacity LED 6th LED 1% -35 % 5th LED 36% -55 %
4th LED 56% -75 % 3rd LED 76%-95 %
2nd LED 96%-105 %.
In the battery operation, the LEDs indicate the capacity of the
batteries:
2nd LED 1 % -35 % 3rd LED 36% -55 %
4th LED 56% -75 % 5th LED 76% -95 %
6th LED 96% -100 %.

3.2.7.2 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 port and an
intelligent slot are provided.
With dedicated software, output voltage, frequency can be set via the RS232
port; also status of the UPS can be monitor.
The intelligent slot can accept SMNP, AS400, USB adaptor card, for more
flexible application solution.
The communication interface circuit is mainly located on the global controller
board; the circuit provides isolation and voltage level transforms function for
communication; the communication protocol is implemented by the CPU.

3.2.8 Ventilation and Chassis

Ventilation system of the UPS consists of air flow guiding insulation paper and
fans. The ventilation system keeps the temperature of component of the UPS in

16
safe range, so it is very important for the UPS. To achieve lowest acoustic noise
and longest life time of the fans, a fans driver and intelligent fans speed control
algorithm is employed.
The chassis of the UPS provides a strong construction to accommodate all the
electrical part, shield for EMC, and safe guard for operator.
Basically, the chassis is comprised of a base plant, an internal support plant,
a front support plant, an outside cover, a rear panel, and a front panel.

17
4. TROUBLE-SHOOTING

Despite of careful design and strict tests, the UPS can malfunction. The designer
suggests the following service procedures:
1. Check the UPS status by LED 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.

4.1 LED Panel Display Pattern Definition

4.1.1 Trouble shooting according to warning indication

If there is a warning display given it means some abnormity happened in 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.

Display Function

AC INPUT LED LINE LED flashes when the phase and neutral conductor have been
reversed at the input of the UPS system.
If LINE LED and BATTERY-LED light up, the mains power supply is
out of tolerance.
FAULT LED The red FAULT LED lights up and an acoustic warning signal is
issued every second when the UPS system is in fault condition.
Press the Standby switch to turn off the warning tone.
Load and These LEDs show the load of the UPS system if the mains power is
battery available (normal operation):
capacity LED 6th LED 1% -35 % 5th LED 36% -55 %
4th LED 56% -75 % 3rd LED 76%-95 %
2nd LED 96%-105 %.
In the battery operation, the LEDs indicate the capacity of the
batteries:
2nd LED 1 % -35 % 3rd LED 36% -55 %

18
 4th LED 56% -75 % 5th LED 76% -95 %
6th LED 96% -100 %.

Note 1: When the UPS warning, the UPS is still working on the original mode with the
original display.
Note 2: At any time, only one normal operating mode or fault mode is presented. But
the warning, even several warnings could appear in a certain normal operating mode at
one time. And the normal operating mode code and the warning code would be shown
circularly.
4.1.2 Trouble shooting according to fault indication

When the UPS is at fault, the UPS will transfer to Fault Mode. Beware that there may
sill output voltage that can endanger the operator’s safety, due to the Bypass.

Possible
Display Action
cause
1. Check the IGBT power components for the PFC
converter and DC/DC circuit are well.
#1,#4 bus fault
2. Check the components on the drive circuit are
well.
1. Check the power components for power INV and
on the drive circuit are normal
#1,#3 Internal fault
2. Check the IGBT protective circuit and some PFC
converter or DC/DC components.
1. Check the loads and remove some non-critical
Overload
#1,#6 loads.
fault
2. Check whether some loads are failed.
Check whether the UPS is overloaded, the air vents
are blocked, and the ambient temperature is over
40 .
Internal over
If the overload or block is removed, please make the
#1,#2 temperature
UPS cool down for 10 minutes before turning on
fault
again.
It is not recommended the UPS is operated at the
ambient temperature of over 40 .
Battery over Check the power components for power CHGR
#1,#5
charge
#1 Charger fault Check the power components for power CHGR

Note 1: At any time, only one normal operating mode or fault mode is presented. Once
one fault is come forth, then all previous warnings would not be shown again, only the

19
fault code wil be presented.
Note 2: when the load or the UPS output is short and the UPS is in inverter fault mode,
then “short” would be shown in the display block of the load;
4.1.3 Trouble shooting in other cases

Problem Possible cause Action

Battery not yet

Keep UPS connected to utility power persistently for
been fully
Battery more than 10 hours to recharge the batteries.
charged.
discharging
time UPS overloaded. Check the loads and remove some non-critical loads.

diminishes Battery aged. Replace the batteries.

Charger failed Check the charger.

No indication
or warning
tone though
NO input voltage Check building wiring socket outlet and input cable
the system is
connected to
mains

The button is
pressed too Press the button continuously for more than 2 seconds.
The UPS
briefly.
cannot power
Battery is not
on after
connected or
pressing the
battery voltage is Check the charger and battery.
button
too low, or
Charger failed.

20
 4. 2 Trouble Shooting Procedures

4.2.1 How to Start

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 LED give

Following instruction
: Test
abnormal
after repair
No message? Yes Short- circuit at battery
Yes connector, input mains
socket, output socket
Follow the LED
Find the problem and solution message explanation
according to function circuit and solution table
introduction and possible
problem and solution
Start PCB board Check
static checking with power
process on

Trouble shooting start

point selection end

21
 4.2.2 Find out the Problem Quickly

Begin

If the panel LED NO

If DC start works
light and fan No
properly?
rotates?

Yes

If the panel LED Change CNTL SUB

-
No Yes
display normally? ASSY

Yes No

If I/ P relay PFC or charger

If DC start works
continuouly open Yes Yes fail, refer to relative
properly?
and close? analysis

No

Turn- off and Restart DC/ DC fail, refer to

the UPS DC/ DC fail analysis

Can the UPS be

Yes Terminated
properly start?

No

Read panel LED to

get the information of
UPS on next page

4.3 Failure Diagnosis

In this section, some debug skills are listed to help you find the failing components and
problems as soon as possible. Before continuing with the following steps listed, we
suggest that you should read the problem shooting chart in previous section and then
check the components listed in Quick Start to find out which block is out of order, in
order to shorten the service time.

For the reason of safety, please follow safety instruction to begin your work

22
STOP

High Voltage Danger: Some components contain residue charge and remain
dangerous high voltage even if the external power supply is cut off. Operator
should follow instructions strictly to avoid risk of electrical shock.

1.Unplug the power cord from the utility.

2.Open outside case shown in the beginning of this manual
3.Remove connectors from battery, for long backup time model, unplug battery
cabinet connector to UPS.
4.Discharge energy in BUS CAPACITORS, and CHARGER CAPACITORS
5.Disassemble cable from connectors, if required.
6.Disassemble PCB if required.

Before starting service, some tools are necessary, at least: A DMM (Digital
Multifunction Meter) meter, screwdrivers and discharge resistor (100Ω/10W
recommended). A DC power supply with current limiting (over current
protection) function (120VDC/3A at least) is recommended for fast and safe
diagnosis.

TO DISCHARGE the residue charge on bus capacitor,

For 1k(s) model contact BAT (-) terminal and upper lead of R4 with a
300Ω/10W resistor to discharge +BUS capacitor, contact BAT (-) terminal and
upper lead of R1 with a 300Ω/10W resistor to discharge +BUS capacitor.

For 1.5K(S) model contact BAT (-) terminal and upper lead of R58 with a
300Ω/10W resistor to discharge +BUS capacitor, contact BAT (-) terminal and
upper lead of R53 with a 300Ω/10W resistor to discharge +BUS capacitor.

For 2k(s)/3k(s) model, contact BAT (-) terminal and upper lead of R104 with a
300Ω/10W resistor to discharge +BUS capacitor, contact BAT (-) terminal and
R118 (2k/3k) upper lead with a 300Ω/10W resistor to discharge +BUS
capacitor

TO DISCHARGE the energy of charger capacitor, after disconnect the

battery from PSDR/Charger, you can use a 300Ω/10W resistor contact BAT
(+) terminal and BAT (-) terminal for discharge battery filter capacitor

23
 
DO NOT power up UPS with the mains unless you are sure that you have
replaced all defective components.

4.3.1 Quick Start

Before any detail check of UPS, please check the components listed in the following
table. This action could help you find the problem quickly and make debug procedures
go smoothly.
Related Circuit Components to be Component Fail condition
Block checked Type
BAT FUSE F1/F2 Fuse Open
I/P FUSE (on PSDR) F3 Fuse Open
1K:D10, D11, REC1

1.5K REC1 D18 D13
Diode Short or open

REC02
D16
D17

PFC converter
3K

3K:Q09, 1K/1.5K:Q14 IGBT C-E short or open

1K/1.5K:Q4.Q6,Q10,Q11
MOSFET D-S short or open
3K:Q04, Q05,Q06, Q07
1K:D12, D13, D14, D15
Push-Pull Booster 1.5K:D11,D12,D23.D24.D
2.D3 Power Diode Short or open
3K:D05.D06.D07.D08.D0
4.D09
3K: Q13, Q14, Q15, Q16
Inverter IGBT C-E short or open
1K/1.5K:Q12, Q13
1K/1.5K:Q8
MOSFET D-S short or open
3K: Q10
Charger 1K:D1 D4

1.5K: D5,D6 Power Diode Short or open

3K: D27
1K: Q601
DC Power Supply 1.5K: Q2 MOSFET D-S short or open
3K: Q01

24
 Related Circuit Components to be Component Fail condition
Block checked Type

1K: D603 D604 D605

1.5K: D33.D32.D20 Power Diode Short or open

3K: D03.D02.D21.D22


If the fuse is open, replacing fuse only DOES NOT mean you have solved the
problem. In most cases, open of fuse is caused by other component failures;
therefore, before restarting that UPS, you must find the real failure components
and replace them!

4.3.2 P.F.C Converter Analysis:

In this section, some components you could check to see if failure occured to P.F.C
Converter. General speaking, OPEN of fuse F3 indicates failure of this block. Please
replace all fail to check components then utility can be connected to your UPS.

Ite Checked components Instrument Reference Failed condition

m function Value
1 F3 Ω Short Open
2 2K/3K:Q09 Diode Voltage Infinite Short or open
1K/1.5K:Q14 (SD) Droop
3 2K/3K:D16, D17 ,D20 Diode Voltage 0.44 Short or open
1K: D10, D11 Droop
1.5K:D13.D18
4 2K/3K:R66,R208 Ω 47.0 Open or value
1K:R68 change
1.5K: R52
5 2K/3K:REC02 Diode Voltage 0.46 Short or open
1K/1.5K:REC1 Droop

 
(+, ),( ,-)

6 1.5K: Diode Voltage Infinite Short or open

D39.D40.D41.D42.D45. Droop
D43D44.D47

25
Ite Checked components Instrument Reference Failed condition
m function Value
2K/3K:
D35.D36.D37.D38

If all components listed above are in normal condition and UPS does not work, try
to change PFC control module and IGBT driver module

4.3.3 Push-Pull DC-DC Converter Analysis

General speaking, the most obvious phenomenon of failure on the section is open of F1
and F2. Knowing this will be very helpful to repair them.

Instrument Reference
Item Checked components Failed Condition
function Value
1 F1, F2 Ω 0Ω Open
2 2K/3K:Q04~Q07 (SD) Diode Voltage 0.42V Short or open
1K/1.5K:Q4, Q6, Q10, Droop
Q11 (SD)
3 1K:R7, R73, R76, R77 Ω 10Ω Open
1.5K:R32,R11,R33.R39.R
40
4 2K/3K:D05,D06,D07, D08 Diode Voltage 0.41V Short or open
1K:D12, D13, D14, D15 Droop
1.5K:D11,D12,D23,D24
5 2K/3K:D09,D04,D12,D13 Diode Voltage 0.41V Short or open
,D14,D15,D26 Droop
1.5K:D28,D29,D30,D31
1K;D16,D17
6 1.5K: R6.R7.R8.R9 Resistance(Ω) 49.9K Short or open
2K/3K:R32.R30.R40.R35


BE SURE TO use fuse with same spec as original ones to replace failure ones,
otherwise, unpredictable danger could happen.

26
 If all components listed above are in normal condition and UPS still can’t be DC
started, try to change DC/DC module.

4.3.4 DC/AC Inverter Analysis

Ite Checked components Instrument Reference Failed Condition

m function Value
1 F3, F2, F1, F4 Ω Short Open
2 2K/3k:Q14,Q13,Q16,Q15 Diode Voltage infinite Short or open
(SD) Droop
1K/1.5K:Q14, Q13, Q16, Q15
(SD)
3 2K/3k:R107, R109, R116, R120 Ω 47.0 Open
1.5K: R56,R50 10.0
1k: R40, R54 47.0
4 1.5K: D37,D35 Diode Voltage infinite Short or open
2K/3K:D30,D31,D32,D33,D40, Droop
D41

If fail condition stated in item 3 occurs, it is very possible that the corresponding
IGBT driver module is damaged, so please try to change the IGBT driver
module.

4.3.5 DC Power supply

Item Checked components Instrument Reference Failed condition

function Value
1 1K:Q601 (S, D) Diode Voltage 0.42V Short or open
2K/3K:Q01(S.D) Droop
1.5K:Q2(S.D)
2 1K: R607 Ω 47 Open
2K/3K: R05
1.5K; R18

27
Item Checked components Instrument Reference Failed condition
function Value
3 1K:R601 Ω 0.50 Open
2K/3K: R08
4 2K/3K: F5 Ω Short Open
5 2K/3K: Diode Voltage infinite Short or open
D01.D22.D21.D02.D03 Droop
1.5K:
D33.D32.D20.D19.
D10.D1

4.3.6 AC/DC charger

Item Checked components Instrument Reference Failed condition

function Value
1 1K/1.5K:Q8 (S, D) Diode Voltage 0.45V Short or open
2K/3K:Q10(S.D) Droop
2 1K:R502 Ω 47.00 Open
2K/3K:R75
1.5K: R42
3 1K;R3 Ω 0.75 Open
1.5K: R45.R45A
4 1K;D1.D4, D20, D3, Diode Voltage 0.45 Short or open
2K/3K:D27,D28.D29 Droop
1.5K:
D5.D6.D14.D48.D25.D2
7
5 2K/3K: Diode Voltage 0.46 Short or open

 
REC01(+, ),( ,-) Droop

1.5K:REC2(+, ),( ,-)


DO NOT let the charger work with full load when the outside cover is removed,
without the airflow path forming with cover, it can cause over-heat of TX3, and
therefore the other related components will fail again.

28
 On the Super charger, adjust the value of VR1 can adjust the output voltage of
the charger.

4.3.7 Others

In previous sections, we pay attention to the components on PSDR, in this section,

we are trying to list some possible failure phenomenons not stated before and on
control PCB sub-assembly. They are the following:
problem Phenomenon Action
Bus over-voltage 1.Bus over-voltage fault alarm and Check PFC IGBT and Driver module
display occur
2.Bus voltage doesn’t meet spec.
Inverter Softstart Inverter fault alarm and display occur. Check INV IGBT and Driver module
fail
UPS can’t start, but It is active randomly or abnormally. Replace CNTL
not the problem
stated before.
Start-up 1.UPS is bypass after the mains is on. 1. Check PSDR IGBT
2.No response after press ON button. 2. Replace CNTL

O/P DC balance O/P DC balance is out of spec. 1. Check IGBT and Driver module
on PSDR
2. Replace CNTL

For O/P DC balance problem, it is almost always caused by incorrect bus voltage.
If this indeed happened, please try to find in which mode the problem arose. For
example, if it happens under Line mode, you must measure bus voltages to see
if they are correct. After doing this, debug the corresponding circuit. If
unfortunately, both modes are incorrect, two possible circuits should be
checked: Bus feedback loop (on PSDR) and auto-balance circuit (on CNTL).

29
5. Test and Finish

After replacing all defective components on power stage (PSDR), the following
test steps can be performed to verify the repair results and the reliability of the UPS.

1. Connect all boards, cables, and connectors.

2. Check the Wiring

3. Apply DC Power from power source with current limitation function to the BAT
terminal on the PSDR, the voltage of DC power should be 96-110Vdc/3 Amp

(limited current) for 2/3K UPS, 36~41Vdc/3Amp for 1K UPS, 48 54Vdc/3

Amp;

4. Press the ON-switch on front panel for 2 seconds, you will see "current limit" for
a short time on the DC power supply for about only 2 seconds, and then UPS
should be DC started, If UPS does not start successfully, please try diagnosing
procedure again.

5. If UPS does not start up for several tries or DC power supply is on current-limit
state continuously, there must still be some defective components present.
Please follow trouble-shooting chart to debug again.

6. Stop the UPS; apply AC mains to the UPS module. Try on the UPS. If it fails you
may have start one new round of trouble shooting

7. Check and adjust Charging Voltage

8. Check the output voltage waveform and DC-offset voltage, at no-load and full
load condition.

9. In most case result of step 7 and 8 can represent whether product is in normal
condition. If possible, however, for better reliability, perform a quick check
using th procedures in the table below.

30
 TEST ITEM TEST POINT TEST AND ADJUSTMENT SEQUENCE EXPECTED RESULT
Charger Voltage BAT (+) 1. Disconnect BAT (+) and BAT (-) wires from 1. Cooling fans on
BAT (-) pins respectively. back panel begin to
2. Connect DVM (Set to measure DC) to test rotate.
points and plug input power cord to utility. 2.2K/3K
Adjust VR1 slowly to expected value. 110Vdc±0.4V
3. 1K 41.2Vdc±0.3V
4.1.5K
54.9Vdc±0.4V
+DC Bus Voltage @ 2K/3K:R104Top (+) and 1. Connect DVM (Set to measure DC Volt) to +170VDC±10V
Line Mode GND test point.
1K: R4 Top (+) and GND 2. Plug input power cord to utility.
1.5K: R58 Top(+) and 3. Press ON bottom for 2 seconds to turn the
GND UPS on.
-DC Bus Voltage @ 2K/3K:R118 Top (+) and 4. Waiting for 10 seconds to make sure the -170VDC±10V
Line Mode GND Inverter LED lights.
1K: R1 Top (+) and GND Check measurement result on DVM
1.5K: R53 Top (+) and
GND
O/P DC Balance @ O/P socket 1. Keeping UPS on @ Line mode. 200mV max.
Line Mode 2. Connect DC measurement fixture to O/P
socket.
3. Check reading on DVM.
+/-DC Bus Voltage 2K/2K:R104Top (+) and 1. Disconnect Input power cord from utility +/-170VDC 10V 
@ Backup Mode GND and press OFF bottom for 2 seconds to
1K: R4 Top (+) and GND turn UPS off.
2K/3K:R118 Top (+) and 2. Connect DVM (Set to measure DC) to test
GND point.
1K: R1 Top (+) and GND 3. Plug input power cord to utility.
4. Press ON bottom for 2 seconds to turn
EUT on.
5. Waiting for 10 seconds to make sure the
Inverter LED lights.
6. Check reading on DVM

8.If possible, do a burn-in test on repaired UPS before return it to customer… the longer
the better. If every step is ok, congratulations, you have finished the
maintenance/ repair work.

31
Appendix

I. DC Offset Measurement Fixture


   
  

 
 

Fig.A.I.1 DC Offset Measurement Fixture

32
33