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Forza Elipse Series Service Manual

Tower ups
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SERVICE MANUAL
EL 6~10K
Forza
1

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Summary of Contents for Forza Elipse Series

  • Page 1 SERVICE MANUAL EL 6~10K Forza...

  • Page 2: Table Of Contents

    CONTENT 1. GENERAL INFORMATION OF THIS DOCUMENT ..............4 1.1 G ........................4 ETTING TART 1.2 S ......................5 AFETY NSTRUCTIONS 2. CHARACTERISTIC OF THE PRODUCT ..................6 3. CONSTRUCTION OF THE PRODUCT ..................7 3.1 O ...................... 7 UTSIDE OVER 4.
  • Page 3 5.3.2 Parallel Maintenance Operation .................. 29 5.4 T ....................... 35 ROUBLE HOOTING 5.4.1 How To Start ........................ 37 5.4.2 Fault code definition and possible points ..............38 5.4.3 Quick Problem Identification process................41 5.4.4 Static Impedance Characteristic Of PCB board............42 5.5 C ....................

  • Page 4: General Information Of This Document

    1. General Information of This Document 1.1 Getting Start This is a service manual for Elipse Series Tower UPS, intend to help service technician 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 - characteristic of the product.

  • Page 5: Safety Instructions

    1.2 Safety Instructions For qualified service personnel only. DO NOT performs any internal service or adjustment unless another person is capable of rendering first aid and resuscitation is present. Dangerous voltage exists at different points in this product. To prevent electrical shock, don't touch any exposed connections or components inside the UPS while UPS is active.

  • Page 6: Characteristic Of The Product

    2. Characteristic of the Product For all UPS of this series, they are carefully designed and strictly tested. We always do our best to make our products more reliable and safe; 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 may occur to the product;...

  • Page 7: Construction Of The Product

    3. Construction of the Product 3.1 Open The Outside Cover To open the outside cover, please follow steps and figures below: STEP 1: Remove all the screws; including those on the opposite side of the case, refer to Figure 3.1 STEP 2: move the top cover and side cover upward, as shown in Figure 3.2.

  • Page 8: Operation Principle Of The Ups

    4. OPERATION PRINCIPLE OF THE UPS The EL 6~10K UPS is a true online UPS employing a double conversion topology. Figure 4.1.1 shows the function block diagram of the UPS system. 4.1 Functional Block Of The UPS Bypass Inverter Rectifier Booster O/P EMI I/ P EMI...

  • Page 9: Operation Of The Functional Blocks

    4.2 Operation Of The Functional blocks Here after, operation and behaviors of each function block of the UPS will be described: 4.2.1 The Input/Output connector/terminal block The part provides electrical connection of the input mains and battery power input to the UPS and the output to users load.

  • Page 10: The Inverter Module

    The Output of the voltage Booster, i.e. the BUS voltage, keeps stable in difference operating mode, regardless input voltage. 4.2.5 The inverter module The inverter module converses the DC voltage from DC BUS into the AC output of pure sine wave voltage.

  • Page 11: The Battery Switch

    4.2.8 The battery switch The battery switch connects the battery input to the voltage booster to provide power supply for supporting the operation of the UPS and maintains the inverter output power when the mains input is out of order. The battery switch disconnects the battery bank from input of the voltage booster when the mains input is recover to normal condition, and the UPS transfer from battery mode to line mode.

  • Page 12: The Ventilation Module

    converse into a group of low voltage power supplying to each part of the UPS itself. The output of the Auxiliary power supply (SPS) includes: +5Vdc, +/-15Vdc, +12Vdc, and a square wave high frequency power supply +/-H.F.PW2.1.12 The communication interface As stated before the communication interface of the UPS is a bridge between the UPS and human or between the UPS and UPS.

  • Page 13: The Pcb Boards

    4.3.The PCB Boards The UPS comprise different PCB board and each PCB may contain more than one function block, or one functional block need more than 1 piece of PCB to implement. hereafter is explanation of the PCB. 4.3.1 Control Board Control board contains circuit implemented of the controller of the UPS.

  • Page 14: Led Panel

    Figure4.3.2.1 The PSDR board 4.3.3 LED PANEL As part of User interface, the LED Panel provides comprehensive information of the UPS, Figure 3.3.1 is a photo of a LED panel 4.3.4 O/P EMI board & I/P EMI board O/P EMI Board and I/P EMI Board is the EMI filter local in input and output end of the UPS respectively.

  • Page 15: Charger Board

    Figure 4.3.4.3 EL 10K(s) O/P EMI 4.3.5 Charger Board Charger board contain the charger circuit, Use for charging the bat Figure 4.3.5.2 Charger of standard model Figure 4.3.5.2Charger of long-backup-time model...

  • Page 16: Parallel Board

    4.3.6 Parallel Board Parallel board is a dedicated board comprises parallel communication circuit. Figure 3.6 Figure 4.3.6.3 Para board of 6/10K...

  • Page 17: Simplified System Topology & Wiring Diagram

    4.4 Simplified system topology & wiring diagram Figure 4.4 shows simplified system topology and wiring diagram; For helping understand the electrical construction of the UPS system. For more detail of the circuit and wiring connection of all PCB, please refer to maintenance schematic and detail wiring diagram. Figure 4.4 EL6K/EL10K UPS configuration diagram...
  • Page 18 Figure 4.5 EL6KS/EL10KS UPS configuration diagram...

  • Page 19: Maintenance

    5. Maintenance 5.1 Maintenance Tools/Equipments A computer with a serial port and a standard RS232 cable; A multimeter and a current meter (clamper); If possible, an oscilloscope with appropriate probes or other kinds waveform displayer can provide great help to the maintenance task in most case.
  • Page 20 Configure the COM1 or COM2 properties as figure 5.2.1.1.b: figure 5.2.1.1.b 1、 Change the ASCII setup as figure 3: figure 5.2.1.1.C...
  • Page 21 After you finished the setting, you can see the following interface like figure 5.2.1.1.d. Figure 5.2.1.1.d You can type command on the hyper terminal. Normally, after type a command, the acknowledge of the UPS will be displayed on the next row, For example, UPSID setting command response with a OK on the next row represent action to set the ID of the UPS have been executed and valid.
  • Page 22 Set Ups ID command: UPSID Computer send: UPSID YYMMDDPPSSS <CR> UPS reply : OK <CR> Means: Ups product date < YY >/< MM >/< DD > (year/month/day), lot number < PP > ranging from 01 to 31 and serial number < SSS > ranging from 000 to 511 Notes: “UPSID”...
  • Page 23 digit number, ranges from 0 to 6, .1 represents about 1V. INV output rated voltage setting command Command Format: VXXX < CR > UPS reply: XXXV Means: set inverter output rated voltage. Fault history query command Command Format: QF < CR > reply: FF.F EE.E...
  • Page 24 (g) Load percentage before fault: LLL LLL is maximum of W% or VA%. VA% is a percent of maximum VA. W% is a percent of maximum real power. (h) O/P current before fault: CCC CCC is a percent of maximum current. (i) Positive Bus voltage before fault: PPP P is an integer number ranging from 0 to 9.

  • Page 25: Calibration

    5.2.2 Calibration In most case, The UPS works in good condition and the output and internal parameter are as precise as the specification definition. However, due to PCB or part replacement or firmware or hardware update executed. The UPS need to be calibration to achieve most precision. Following are the common procedure to calibrate a UPS, Major parameter need to calibrate includes: Positive Bus voltage, Negative Bus voltage, and Inverter output voltage.
  • Page 26 Increase the -BUS voltage with BUSN+xx, or decrease the -BUS voltage with NBUS-xx command according to real situation need. 1 represent about 0.5V. 11. Measure the voltage between JP2 and I/P neutral; the voltage is the inverter output voltage. 12. if the output of inverter need to calibrate, reset the calibration with send a V+0, and then increase inverter output voltage with V+x command or decrease inverter output with V-x command according to real situation need, 1 represent about 1voltage here.

  • Page 27: System Maintenance

    5.3 System Maintenance 5.3.1 Unitary Maintenance Operation 5.3.1.1 Routine inspection a) Check the wiring /circuit breaker/connector All the wiring, cable, connector should no sign of loose, burnt, or bad contact, and the diameter of the wire should match the current it carries. b) Check the Output voltage The output voltage is 230V+/-1%, and the output is stable either in voltage or frequency, the waveform is clean, no noise, less distortion (THDv%<2 @ linear load).
  • Page 28 Corrosion can be found at the PIN of the components and the copper track on the PCB. If obvious corrosion sign found, recommend replacing the PCB to avoid potential failure. b) Internal Wiring /connector Internal Wiring/connector should be checked; any wire/cable should be replace with new one.

  • Page 29: Parallel Maintenance Operation

    11. Check the wiring and test the UPS. 5.3.1.4 Firmware update Check the Firmware version with hyper terminal and Q7 command, detail of set the hyper terminal and method to set a command please refer to previous section, if it is not the version expected.
  • Page 30 5.3.2.1 Operating procedure of installation a new parallel system 1. Prepare the input and output cables, the input/output breaker (switch) and the parallel cable for all UPS to be connected in parallel. 2. Make sure power supply to the parallel system has been cut and without dangerous for the operator 3.
  • Page 31 the voltage between the JP1 and JP2 on the terminal block of each UPS to check if the voltage is less than 1V. Or measure the impedance value between JP1 and JP2 to check if the resistor is short circuit. If the voltage difference is more than 1V, the output relay of the UPS may have problem and can not be closed.
  • Page 32 7. Turn on the mains input breaker of the new UPS; Measure the voltage difference between the output line wires in the new UPS and the parallel system. If the difference is more than 1V, check if the wirings are abnormal. If the difference is less than 1v, the output breaker of the new UPS can be turn on.
  • Page 33 5.3.2.3 Remove a UPS from the parallel system 1. If you need to remove the UPS in normal running, press on “OFF” button of the UPS to be removed twice in succession to turn off the UPS and the UPS will cut off its output;...
  • Page 34 2. Make sure that the maintenance switches of all UPSs (including new unit) are in the same positions (either in the positions of “UPS” or “BPS”) when the UPS parallel system is going to be in INV mode 3. Normally, when maintenance bypass switch is open, the UPS will transfer to bypass automatically, and the maintenance bypass switch can be operated, but for most safety, check the status of the UPS from LED display, make sure the UPS is on bypass mode before operate maintenance bypass.

  • Page 35: Trouble Shooting

    5.4 Trouble Shooting When abnormal occurs to the UPS system, trouble shoot is needed. Here after, general trouble shooting guidance will be provided. Basically, we can divide the trouble shooting into three difference levels, to have clear idea how to carry out the service and increase service efficiency, technician can consider selecting before start action basing on the service policy, available time and real situation: System level...
  • Page 36 Humidity Dust or Salt Vibration? 3. Event before the problem occurs 4. Record of fault or warning message. After get possible information, choose a start point and direction of finding the problem according the information got. Section 5.4.1 provides a general guidance to selection the start point.

  • Page 37: How To Start

    5.4.1 How To Start Trouble shooting start point selection begin Is there any Trouble information Check Can the product with power power up? Visual Inspection Apply Power supply to the UPS Sign of Burn, damage, Can the UPS be contaminate on the turned on? outlet, sockets, connectors...

  • Page 38: Fault Code Definition And Possible Points

    5.4.2 Fault code definition and possible points Possible failure point displa Buzzer Fault Name Definition PCB Board Component/Circuit The DC BUS voltage higher or Mainly check that the IGBT and SCR etc power components for Keep The PSDR board or control board #1,#4 Bus abnormal lower than the predetermined...
  • Page 39 The UPS detected voltage at #1,#4, Keep INV relay sticked inverter output even the inverter PSDR INV relay RY1 & RY2 on the PSDR board is in well condition. Beeping stop working. #1,#5, Reserved Check that the battery SCR（Q305）or the battery relay (RY3、RY4) on the PSDR board Check that the components for the battery switch driving Battery over charged, battery...
  • Page 40 Beeps #1,#3, every IP Fuse Open I/P Mains fuse open PSDR Check the IP fuse. second NOTE; LED indicators: Bypass LED (orange LED): Whenever the bypass LED is turned on, it shows that the loading current is supplied directly from the utility power. Utility power LED (green LED): Whenever the utility power LED is turned on, it shows that the utility power is normal.

  • Page 41: Quick Problem Identification Process

    5.4.3 Quick Problem Identification process Figure 5.4.3.1 Quick problem identification process.

  • Page 42: Static Impedance Characteristic Of Pcb Board

    5.4.4 Static Impedance Characteristic Of PCB board. After find out the failure board, to find out the broken component, you can measure the impedance of the major components with multimeter. Following tables record Static Impedance Characteristic Of PCB board for reference. 5.4.4.1 PSDR Board a.
  • Page 43 Q203,Q204 Ω Ω (G, E) short or open 23.5k ≈0.36V D201, D202, D203.D204 DIODE Ω Ω R201, R202, R208, R209 open Ω Ω R203, R204, R210,R211 open D210, D211, D212.D213 DIODE open 46Ω 5.4.4.2 Charger of standard model Fail Item Checked components DVM function Reference Value Condition...

  • Page 44: Component Level Repair

    5.5 Component Level Repair After find out broken component, replace with a new one. The designation & part number of the component can be found in the spare part list in the appendix. Generally, A driver or driving circuit is adopted for each power semiconductor. If the power semiconductor broken, measure the driver resistor (listed in the table in section 5.4), if the driving resistor failure, the driver is very like broken, so replace the driving module.
  • Page 45 In most case result of step7, 8 can represent whether product in normal condition, If possible, however, for more reliability, perform quick check follow procedure shows in table would help in know the UPS situation in detail. If possible, do a burn-in test on repaired UPS before return it to customer, the longer the better.
  • Page 46 load to the output of the UPS 2. THDV%<6% Non-linear full load 8. Test with over 1. On line mode, Apply load The UPS transfer to load 130%~150% of rated power to the output of bypass mode in 1s after the UPS over load apply.

  • Page 47: Appendix

    Appendix I. Electrical Specification MODEL EL-6K EL-6KS* EL-10K EL-10KS* 6000 VA / 4200W 10000 VA / 7000W CAPACITY VA/W Voltage INPUT Range Line Low Transfer 176 ± 3%VAC Line Low Comeback 185 ± 3% VAC Line High Transfer 276 ± 3% VAC Line High Comeback 266 ±...
  • Page 48 DIMENSION Tower Case (DxWxH)mm 655x300x830 WEIGHT Tower Case (kgs) 135 kgs 80 kgs 165 kgs 101 kgs Rack Case (kgs) ENVIRONMENT Operating Environment 0-40° C 20-95% (NON-CONDENSING) Relative Humidity Noise Level <55dB @ 1 meter INTERFACE Smart RS-232 Software supports Windows 98/NT/2000/XP/2003/ME, Linux, Sun Solaris, IBM Aix, Compaq True64, SGI IRIX, FreeBSD, HP-UX, and MAC SNMP (option)

  • Page 49: Model Pin Configuration

    II. Model Pin Configuration To detection and control difference model of UPS, The controller need correct model pin configuration for recognizing the UPS model. The MODEL PORT （JP01）of the second version(710-01902-02) or the later version CNTL board should be configured as follows： Note：“1”...

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