Related Manuals for Forza ELIPSE Series
Summary of Contents for Forza ELIPSE Series
- Page 1 SERVICE MANUAL ELIPSE SERIES EL-6K/EL-6KS/EL-10K/EL-10KS FORZA POWER TECHNOLOGIES...
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Page 2: Table Of Contents
CONTENT 1. GENERAL INFORMATION OF THIS DOCUMENT ...............4 1.1 G ........................4 ETTING TARTED 1.2 S ........................5 AFETY NSTRUCTIONS 2. CHARACTERISTICS OF THE PRODUCT ..................6 3. CONSTRUCTION OF THE PRODUCT..................7 3.1 O ......................7 UTSIDE OVER 4. OPERATION PRINCIPLE OF THE UPS..................8 4.1 F UPS....................8 UNCTIONAL... - 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 ......................44 OMPONENT EVEL...
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Page 4: General Information Of This Document
1. General Information of This Document 1.1 Getting Started This is a service manual for the Elipse Series Tower UPS, intended to help service technicians perform maintenance and repair services. If you want to know: What is special for this UPS from service point of view; please refer to section –... -
Page 5: Safety Instructions
1.2 Safety Instructions For qualified service personnel only. DO NOT perform 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: Characteristics Of The Product
2. Characteristics 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 " $ I # 9 9 H @ ¡... -
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 different operating modes, regardless of input voltage. 4.2.5 The inverter module The inverter module converts 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 recovered to normal condition, and the UPS transfer from battery mode to line mode. -
Page 12: The Auxiliary Power Supply
4.2.11 The auxiliary power supply The Auxiliary power supply (SPS) takes energy from the battery or the charger output, converts it 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... -
Page 13: The Pcb Boards
4.3.The PCB Boards The UPS comprises of different PCB boards and each PCB may contain more than one function block, or one functional block may need more than 1 piece of PCB to implement. hereafter is explanation of the PCB. 4.3.1 Control Board Control board contains circuits 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 I/P EMI board & O/P EMI board I/P EMI Board and O/P EMI Board is the EMI filter local in the 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 dfor charging the battery Figure 4.3.5.2 Charger of standard model Figure 4.3.5.2Charger of long-backup-time model (s) -
Page 16: Parallel Board
4.3.6 Parallel Board Parallel board is a dedicated board that has the parallel communication circuit. Figure 3.6 Figure 4.3.6.3 Para board of 6/10K... -
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 of waveform displayers that 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 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 acknowledgement of the UPS will be displayed on the next row, For example, UPSID setting command response with an OK on the next row represent the action to set the ID of the UPS has been executed and is 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: PPP 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.
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Page 25: Calibration
5.2.2 Calibration In most cases, The UPS works in good condition and the output and internal parameter are as precise as the defined specification. However, due to PCB / part replacement / firmware or hardware updates. The UPS needs to be calibrated to achieve the best precision. Following are the common procedure to calibrate a UPS, Major parameters that need to be calibrated include: Positive Bus voltage, Negative Bus voltage, and Inverter output voltage. - Page 26 the -BUS voltage with BUSN+xx, or decrease the -BUS voltage with NBUS-xx command accordingly. 1 unit represents 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 needs to be calibrated, reset the calibration by sending a V+0, and then increase inverter output voltage with V+x command or decrease inverter output with V-x command accordingly, 1 unit represents about 1voltage.
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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 show 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 should be stable in eithe voltage or frequency, the waveform should be clean, with no noise, and minimum distortion (THDv%<2... - Page 28 Corrosion can usually be found at the PIN of the components and the copper track on the PCB. If obvious corrosion signs are found, we 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 a new one.
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Page 29: Parallel Maintenance Operation
10. Check the wiring and test the UPS. 5.3.1.4 Firmware update Check the Firmware version with hyper terminal and Q7 command. For details on how to set the hyper terminal and methods on setting the commands please refer to previous section, if it is not the version expected. - Page 30 5.3.2.1 Operating procedure of installating 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 feed to the parallel system has been cut. 3.
- Page 31 the resistor has a short circuit. If the voltage difference is more than 1V, the output relay of the UPS may have problem and can not be closed. 11. Measure the voltage between JP2s of each UPS (JP2 of Unit I-JP2 of Unit II, and so on) to check if the voltage value is less than 5V (Generally 2V).
- Page 32 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. 8. Turn on the mains input breakers of all of the UPSs (including the new UPS) and the battery breaker in the parallel system.
- Page 33 5.3.2.3 Removing a UPS from the parallel system 1. If you need to remove the UPS in normal running mode, press the “OFF” button of the UPS to be removed twice in succession to turn off the UPS and the UPS will also 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 cover is opened, the UPS will transfer to bypass automatically, and the maintenance bypass switch can be operated, but for safety reasons, check the status of the UPS from LED display, make sure the UPS is on bypass mode before operating maintenance bypass.
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Page 35: Trouble Shooting
5.4 Trouble Shooting When the UPS is malfunctioning or an abnormality occurs, troubleshooting 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 service and increase service efficiency. - Page 36 Humidity Dust or Salt Vibration? 3. Event before the problem occurs 4. Record of fault or warning message. After getting this information, choose a starting point and direction for finding the problem according the information obtained. Section 5.4.1 provides a general guidance for selecting a guidance point In most case, from the fault /warning code presented on the display, the problem can be identified with the help of fault code definition and possible cause table provided in section...
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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 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 finding out the failure board, to find the broken component, you can measure the impedance of the major components with a multimeter. Following tables record Static Impedance Characteristic Of PCB board for reference. 5.4.4.1 PSDR Board a. - Page 43 (E, C) short Ω ≈100k Ω Q201, Q202, Q203,Q204 (G, E) short or open 23.5k Ω Ω D201, D202, D203.D204 DIODE ≈0.36V R201, R202, R208, R209 open Ω Ω R203, R204, R210,R211 open Ω Ω D210, D211, D212.D213 DIODE 46Ω open 5.4.4.2 Charger of standard model Fail...
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Page 44: Component Level Repair
5.5 Component Level Repair After finding a 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 is broken, measure the driver resistor (listed in the table in section 5.4), if the driving resistor fails, the driver is very likely broken, so replace the driving module. - Page 45 In most cases result of step 7 and 8 can represent whether a product is in normal condition, If possible, however, for more reliability, perform quick check following procedures show in the table below. 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.
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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 INPUT Voltage 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)
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Page 49: Model Pin Configuration
II. Model Pin Configuration To detect and control different model of UPSs, The controller needs the correct model pin configuration to recognize 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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