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Ladis G31 Series Service Manual

Tower model
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UNINTERRUPTIBLE POWER SYSTEM
SERVICE MANUAL
G31 10K~30KVA Tower Model
REVISION
DESCRIPTION
Rev. 1.0
Formal Release
Rev. 2.0
Rev. 3.0
Add 30KVA unit content
Rev. 4.0
Add 30KVA safe start section
Shenzhen LADS Technology Co.,Ltd.
Date
2010/4/28
2012/8/9
2013/9/4
2013/12/27

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Summary of Contents for Ladis G31 Series

  • Page 1 UNINTERRUPTIBLE POWER SYSTEM SERVICE MANUAL G31 10K~30KVA Tower Model REVISION DESCRIPTION Date Rev. 1.0 Formal Release 2010/4/28 Rev. 2.0 2012/8/9 Rev. 3.0 Add 30KVA unit content 2013/9/4 Rev. 4.0 2013/12/27 Add 30KVA safe start section Shenzhen LADS Technology Co.,Ltd.

  • Page 2: Table Of Contents

    CONTENT 1. GENERAL INFORMATION ............................... 4 1.1 G ................................4 ETTING START 1.2 I ..........................4 MPORTANT AFETY NSTRUCTIONS 2. ELECTRIC SPECIFICATIONS ............................5 3. FUNCTIONAL BLOCK ............................... 7 4. WORKING PRINCIPLE OF THE MAJOR FUNCTIONAL BLOCK ................9 4.1 S ..............................
  • Page 3 8.HOW TO START UPS SAFELY AFTER REPAIRING OR REPLACING PSDR BOARD ........36 8.1 S 10K(L) 20K(L) ........................36 TART UNIT SAFELY 8.2 S 30K(L) ............................50 TART UNIT SAFELY they 8.2.1 est Charger to make sure could work fine....................50 Turn on the UPS with DC source ( the charger work as a current limitation DC source) 8.2.2 ..

  • Page 4: General Information

    1. General Information 1.1 Getting start This manual is for Galleon 10K(L)~30K(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.

  • Page 5: Electric Specifications

    2. Electric Specifications CAPACITY* 10000VA / 8000W 15000VA / 12000W 20000VA / 16000W 30000VA / 24000W INPUT 110 VAC(L-N) ± 3 % at 50% Load Low Line Loss 176 VAC(L-N) ± 3 % at 100% Load Voltage Low Line Comeback Low Line Loss Voltage + 10V Range 300 VAC(L-N) ±...
  • Page 6 **If the UPS is installed or used in a place where the altitude is above than 1000m, the output power must be derated one percent per 100m. ***Product specifications are subject to change without further notice.

  • Page 7: Functional Block

    3. Functional Block As a true online UPS, the product applies a double conversion topology, comprising functional blocks as shown in Figure 3.1 Maintain Bypass Output Receptacle Bypass BPS STS Output Terminal P1 Relay Input INV Relay I/P EMI Rectifier Inverter OP EMI P1 Output Terminal...
  • Page 8 power for recharging the battery. Two types of chargers will be available, one is for the standard model, and the other is for long-run model that connects to external batteries. The Input and Output EMI section provides EMI filter function. The input and output EMI filters can prevent the UPS from being interference by external electronic/magnetic noise which is generated by other electronic system and prevent other systems from the noise generated inside the UPS system.

  • Page 9: Working Principle Of The Major Functional Block

    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 battery, or the output of the charger. 7812 +12V Output 7815 Battery +15V Output...

  • Page 10: Charger

    The Bypass output power is supplied by R phase, and there is BYP.STS and INV.STS for the transfer time requires. R Phase BUS+ BYP.STS INV.RLY INV.STS BUS- Figure 4.3 Half-bridge inverter 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.
  • Page 11 IP/R OP/R OP/S IP/S OP/T IP/T OP/N IP/N Figure 4.6 Topology of the input EMI...

  • Page 12: Function Explanations For Each Pcb

    5. Function explanations for each PCB Table 5.1 PCB information of Galleon 3-1 10~20k Item PCB Name PCB serial number Quantity Remark 10kVA mode, just 16-300076-XXG S(L2)&T(L3) phase PFC 15k/20k 16-300032-XXG For 15K/20KVA model For 10kVA model, include 16-300000-XXG R(L1) phase PFC 15k/20k 16-300033-XXG For 15K/20KVA model...

  • Page 13: Pfc Board (Power Factor Correct Board)

    Optional,for30Kparallel O/P Relay 71-300043- XXG model Communication 71-300621- XXG Parallel 71-300609- XXG Optional, for parallel model Panel 71-300211- XXG Line I/P 71-300034- XXG BAT I/P 71-300044- XXG 16-300036-XXG 71-300048- XXG Note: “XX” in the serial number is the version of the PCB. It may be modified according to releasing version in the future.

  • Page 14: Mov Board

    electronic systems, and also prevent other systems from the noise generated inside of the UPS system. 5.12 MOV board The MOV board can absorb the surge to protect the UPS system.

  • Page 15: Interface

    6. Interface 6.1 LED Display Table 6.1 LED Display Bypass Line Battery Fault MODE UPS Startup ● ● ● ● No output ○ ○ ○ ○ Bypass mode ● ○ ○ ○ Line mode ○ ● ○ ○ Battery mode ○...
  • Page 16 Indicates that the warning and fault occurs. Indicates the fault codes, and the codes are listed in details in section 3-9. 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%.

  • Page 17: Trouble Shooting

    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 and get the warning or fault code via the RS232 if possible, otherwise listen to the description of end users.
  • Page 18 1 Beeping / second Input Neutral loss Check the input wiring 1 Beeping / second Input phase abnormal Check the input wiring Line input status different parallel 1 Beeping / second Check the R/S/T input system Bypass status is different 1 Beeping / second Check R phase input in parallel system...

  • Page 19: Trouble Shooting For Fault Codes In Lcd Display

    7.1.2 Trouble shooting for fault codes in LCD display When the UPS is fault, it will transfer to Fault mode. 7.1.2.1 Fault code for 10k~20k Code Fault Event Description Action icon When the bus voltage can’t Check if power components such as IGBT and soft start reach the setting value in...
  • Page 20 power SCR part. After soft start completes and INV PWM is relay short off, more than 50V INV Check if INV relay RY5(for 20KVA,check RY5 None voltage is detected, the and RY6) on INV board is OK. circuited fault signal will displayed.
  • Page 21 –BUS voltage keeps and SCR for the PFC and the utility power higher than -300Vfor more SCR are well. Meanwhile, check if than 200ms, the fault components on the drive circuit are well. signal will be displayed. When the difference Maybe the PFC board is damaged.
  • Page 22 When the output power on the INV 2 terminal is over Check if input and output connections are Inverter 2 output correct. And then check if INV relay RY5 or -3000W(for STS(Q19, Q20, Q21,Q22 and their driver -1500W) for more than negative power circuits) are OK.

  • Page 23: Trouble Shooting

    Check if UPS is overloaded, air vents are blocked, and ambient temperature is over 40℃. The temperature of sink is After overload or block is removed, please over temperature None over the protection setting. keep UPS cool down for 10 minutes before turning on again.
  • Page 24 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.

  • Page 25: Basic Instruments And Tools

    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;...

  • Page 26: Regulation Of The System

    The Model Port (JP1) on the Charger board should be configured as follows: Table 7.3 Charger current Setting List Charger Current(A) Pin1&pin2 Pin2&pin3 Note：“1” indicates that the jumper is connected; “0”indicates that nothing is connected 7.2.4 Regulation of the system Parameter Setting Method: 1.

  • Page 27: Quick Start

    multimeter, and then regulate ±BUS voltages to 370±0.1V 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±0.2V by using output voltage regulation command.
  • Page 28 D33, D35, D34, D36,D45,D43,D49,D44,D54,D52 Diode Short or open D53,D58, Q22, Q23,Q59,Q60,Q32,Q43,Q61,Q62,Q57,Q52 IGBT C-E short or open Q63,Q64 30k PFC Phase R&S Section Circuit Block Checked components Component Type Failure condition Rectifier Q17,Q18,Q24,Q25,Q21,Q26,Q27,Q49 A-K Short or open D33,D35,D43,D45,D34,D36,D44,D49 Diode Short or open Q22,Q23,Q29,Q32,Q37,Q38,Q42,Q43,Q44,Q45, IGBT C-E short or open...
  • Page 29 30K INV 1&2 Section Circuit Block Checked components Component Type Failure condition D17, D18,D34,D32 Diode Short or open Q8,Q9,Q10,Q11,Q45,Q46,Q42,Q43 IGBT C-E short or open Q13, Q14, Q17, Q18,Q19,Q20,Q21,Q22 A-K Short or open Fuse Open Q6, U14,U15 MOSFET D-S short or open D3, D4, D5, D6, D7, D8,D9 Power Diode Short or open...
  • Page 30 7.2.5.1 Major parameters of Rectifier and PFC section The most likely problems occur on the Rectifier and PFC section including: open fuse, broken IGBT, broken Diode, broken SCR, and broken IGBT/SCR driver resistor. When checking PFC section, directly check the IGBT with Resistance probe or the Diode Voltage Droop probe with multimeter. 10K S&T PFC Section Reference Failed...
  • Page 31 TVS1, TVS2, TVS3, TVS4, TVS5, TVS6 0.53V TVS7, TVS8, TVS9, TVS10, TVS11, TVS12 Diode Voltage Droop Short or open TVS13, TVS14, TVS15, TVS16, TVS17, TVS18 30K PFC Phase R&S Section Reference Failed Checked components Instrument function Value condition 6MΩ (A, K) Resistance Short Q17, Q18, Q24,Q25...
  • Page 32 the corresponding driver is damaged, so please try to change the IGBT driver component. 7.2.5.2 Major parameters of Inverter and STS section The most likely problems occur on the INV section including broken IGBT, broken Diode, broken SCR, damaged IGBT/SCR driver resistor, damaged relative snubber circuit with broken IGBT/SCR, and stuck output relay.
  • Page 33 1.4V Q42,Q43,Q45,Q46 (E, G) Diode Voltage Droop Short or open 25.5KΩ (G, E) Resistance Short or open D22, D23, D24, D25 0.61V D26,.D27,.D28,.D31 Diode Voltage Droop Short or open (need be removed from PCB) R45, R46, R52, R53, Resistance 22Ω Infinite or value change R131,R137,R124,R127 R47, R48, R54, R55...
  • Page 34 47Ω Resistance Infinite or value change 0.53V Diode Voltage Droop Short or open D3, D4, D5, D6, D7, D8, D21 282KΩ (D, S) Resistance Short 1KΩ (G, S) Resistance Short 0.6V U2, U3, U4, U5 Diode Voltage Droop Short 76.4KΩ Resistance Short 15K/20K SPS Section...
  • Page 35 0.61V Diode Voltage Droop Short or open (need be removed from PCB) 0.43V (S, D) Diode Voltage Droop Short or open 0.67V (G, S) Diode Voltage Droop Short or open 1.0V (S, G) Diode Voltage Droop 1.1V (G, D) Diode Voltage Droop 10KΩ...

  • Page 36: How To Start Ups Safely After Repairing Or Replacing Psdr Board

    How To Start UPS Safely After Repairing or Replacing PSDR Board When the PCBA board is reinstalled after repairing or replacing a new one, it is more secure for UPS that input source, no matter DC source or Ac source, has some protection function such as current limitation or power limitation in case the board is damaged again if it still has some potential defects.
  • Page 38 Step2: Install PSDR board repaired or completely new spare part and connect related wires, although some wires are not necessary for charger testing here, but doing it at this section is in order to be easy for later section testing 10K/10KL：...
  • Page 39 20K/20KL：Install the PFC board Disconnect Battery - cables and Packed with tape Disconnect Battery + cables and Packed with tape Step4: Disconnect utility input with PSDR, but connect charger input with utility L1/ N outside PSDR board and pack with tape in case of electricity risk as below; 10K/10KL Input “I/P L”...
  • Page 40 Step5: Turn on input breaker 10K/10KL：Input L1/N connected Only 20K/20KL: Input L1/N connected Only Input breaker Input breaker Utility input N Utility input N Utility input L1 Utility input L1 Step6: If normal, Charger fan rotates and charger’s output voltage is about 245V DC. If not, please check the charger 10KL:4A Charger 10K：1A Charger...
  • Page 41 Section 2：To make sure all of supplement power supply are fine, it is very important for control board, please test SPS as the following procedure: 1. Turning off input breaker, connecting charger output with SPS input and plugged fan power wires into The corresponding terminal, then Turning on input breaker, Check if the SPS input is about 245V DC, if not, please check if the SPS input cable is plugged tight 2.
  • Page 42 Step3: Measuring critical voltage signal as below 10K/10KL U5: -15V (the upper leg) U4: +15V (the upper leg) U3: GND (the heat sink) GND (the heat sink) U3: +5V (the right leg) 20K/20KL U9: -15V (the right leg) GND (the heat sink) U13: +5V (the right U13: GND (the heat sink) leg)
  • Page 43 Step1: Install the upper PSDR board and screw some cables to PSDR board, for 20k/20KL, please skip this step and goto step2 directly. 10K/10KL Plugged Screw “BAT-“ Screw “N” of charger output to “BAT-“ of the Screw copper cylinders tight to PSDR board upper PSDR board and plug 2pin wires into and heat sinks “CN2”...
  • Page 44 20K/20KL Screw “R BAT-/S BAT-/T BAT-“ Screw “R BAT+/S BAT+/T BAT+“ Step3: Install control board and communication board 10K/10KL Plug this wire between two boards Install control board Install COMMU board 20K/20KL Plugged Install control board Install COMMU board Plugged this 2pin wires which is from bypass switch into “CN9”...
  • Page 45 Step4：Do not connect this three pins cable which is from control board to charger board 10KL: 4A Charger 10K：1A Charger Do not plug this cable Do not plug this cable 20KL Do not plug this cable Do not plug this cable Step5：turn on input breaker and turn on the UPS.
  • Page 46 10K：For 10K standard model, as the 1A charger only can provide about 240w power, so you should unplug fans power wire to make sure ups could be started up successfully. If 10K standard model is still installed with 4A charger inside, then you don’t need to unplug these wires here.
  • Page 47 Step 8：Measuring output voltage, if the voltage is not 230V, please check detection circuit of INV voltage on PSDR. 10K/10KL Put the probe on output L terminal Output voltage 230V 50HZ Put the probe on Output N terminal 20K/20KL Put the probe on output L terminal Put the probe on Output N terminal...
  • Page 48 “I/N” of the bottom PSDR board and screw “S LINE” and “T LINE” of the upper PSDR board. Then, re-assemble the upper PSDR board and the control board and the communication board, and connecting related cables finally. 20K/20KL Screw Input “R I/P”&“S I/P”&“T I/P”&“N” Screw Bypass Step 2: Plug this 3 pins control wire to charger board...
  • Page 49 Step 3: Turn on input breaker 10K/10KL 20K/20KL Input breaker Input breaker Input L1/L2/L3/N Input L1/L2/L3/N Connect utility input L1/L2/L3/N with input Connect utility input L1/L2/L3/N with input terminal and then turn on input breaker terminal and then turn on input breaker Step 4：Turn on the UPS.

  • Page 50: Start 30K(L) Unit Safely

    8.2 Start 30K(L) unit safely Before starting any operation, please disconnect battery input no matter for standard or long run model due to its potential electricity risk. The following pictures showing how to disconnect inside batteries for 30K unit. Left view Right view 8.2.1 T est Chargers to make sure they could work fine.
  • Page 51 b. 30KL Step2: Remove 3PIN charger control cable. a. Remove 3PIN charger control cable from the CN2 in the charger of 30K unit: b. Remove 3PIN charger control cable from the CN2 in charger1 of 30KL unit:...
  • Page 52 Step3: Remove the wire that connect to P103 on INV-R&S board, becareful the terminal should be protected by insulating tap after remove from the board. Step4: For 30K unit, there are 4 electronic capacitors, 2 for positive BUS, and 2 for negative BUS; but one 4 A charger can not offer enough energy for these capacitors, so we need to change the BUS capacitors connection to start the unit with a 4A charger.
  • Page 53 b. Unscrew the screws that marked in the pincture below: Then protect the two ends of the copper bar for neutral with insulating tape (or other insulating material) to disconnect the capacitor with the neutral completely, then we will get two electronic capacitors for BUS, one for positive, the other for negative.

  • Page 54: Turn On The Ups With Dc Source ( The Charger Work As A Current Limitation Dc Source)

    8.2.2 Turn on the UPS with DC source ( the charger work as a current limitation DC source) Step1: Check the SPS:Press the ON button on the keyboard of the UPS after check the ouput voltage of the charger according 8.2.1, then you will see the LCD lighted,and the fan of the UPS working, UPS will enter to power on mode, otherwise please check the SPS on INV 1&2.

  • Page 55: Turn On The Ups With Utility Power

    8.2.3 Turn on the UPS with utility power Step1: Shut down the UPS by press OFF on the keyboard ,open the input breaker. Wait until the voltage of the bus capacitors below 10VDC, assemble the fuses (HC10AR30 )back to the input EMI board, connect the wire that removed at step3 of 8.2.1 to P103 on INVR&S board,connect the 3PIN cable back to CN2 on charger1.

  • Page 56: Appendix

    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 CH1: INV voltage...
  • Page 57 CH1: IP voltage CH1: INV voltage CH3: V -(PFC PWM-) CH2: Battery voltage CH4: V +(PFC PWM+) CH3: V -(PFC PWM-) CH4: V +(PFC PWM+) AC mode Battery mode Figure 9.3 PFC PWM CH1: INV voltage CH2: IP voltage CH3: V -(INV PWM-) CH4: V +(INV PWM+)

  • Page 58: Basic Communication Command

    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<Enter>...

  • Page 59: V

    I/P voltage = 225.2V. I/P frequency = 50.0Hz O/P voltage = 220.0V O/P frequency = 50.0Hz. O/P current = 27.0A O/P load = 73% Positive BUS voltage = 360.8V Negative BUS voltage = 359.9V P Battery voltage = 241.0V. N Battery voltage is ---.-V. It means it is a single battery-type UPS. The negative battery voltage does not exist. Temperature = 45.0 degrees of centigrade.

  • Page 60: Busn±

    For example: Computer: BUSP-01<Enter> UPS: (ACK Meanings: Positive BUS voltage will decrease about 0.1V. 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>.

  • Page 61: Qfs

    relevant bit will set 0. Warning Battery disconnected Input Neutral loss Reserved Input phase abnormal Reserved Reserved Battery over charge Low battery Overload Fan failure EPO active Reserved Over temperature Charger failure Reserved L1 IP fuse broken a16-a49 Reserved Locked in bypass after overload 3 times in 30min Converter current unbalance Battery fuse broken Inverter inter-current unbalance...
  • Page 62 EE.E Output Frequency when fail Q is an Integer number from 0 to 9. The units is Hz. LLL is Maximum of W% or VA%. Output load percent when fail VA% is a percent of power. W% is a percent of maximum active power. CCC.C Output current when fail C is an Integer ranging from 0 to 9.

This manual is also suitable for:

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