Forza Atlas 2-3KVA Service Manual
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Forza Atlas 2-3KVA Service Manual

Power inverter/ups system
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Service Manual
Atlas 2-3KVA Model
Power Inverter/UPS System

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Summary of Contents for Forza Atlas 2-3KVA

  • Page 1 Service Manual Atlas 2-3KVA Model Power Inverter/UPS System...

  • Page 2: Important Safety Instructions

    General Information Getting started · Overview and UPS features · Replacing the battery · Steps to Open the Case · Principles of Operation · Alignments · Trouble Shooting · Electrical Specifications Conventions The following conventions are used in this manual to provide important information for a quick and safe operation of the UPS.
  • Page 3 High voltage may be present at DC capacitors. Before opening the external cover, wait for at least five minutes after turning off the UPS. Verify the input source (voltage and frequency) before performing service work. DO NOT short circuit the batteries. If the battery connectors (P6, P8) are disconnected, plug in the input power cord and verify that that there is input power available before re-connecting the battery...
  • Page 4 Step 2 Step 3...
  • Page 5 I. INTRODUCTION All the UPS series are strictly tested and carefully designed. We always do our best to make our products more reliable and safer. However, due to the lifetime of electrical components and some unpredictable reasons, malfunctioning may occur. If this happens, consult with qualified and trained personnel.

  • Page 6: Principle Of Operation

    II. PRINCIPLE OF OPERATION This 3KVA (2KVA) high input power factor UPS system contains two major PCB assemblies. They are: Includes (1) a charger, (2) a DC power supply, (3) a power 1. PSDR factor correction, (4) a DC-DC converter, (5) an inverter and (6) output circuits.
  • Page 7 The location of the assemblies in the machine are shown in picture 2. The location of the assemblies in the machine are shown in picture 2.
  • Page 8 Picture 2 : Sub-assembly location The block diagram in picture 3 shows the UPS at normal operation from left to right. When a protection circuit is triggered or a fault condition occurs, the output supply is transferred immediately from the inverter to the AC mains by a bypass relay.
  • Page 9 1.POWER STAGE (PSDR) As shown in picture 1, the power stage consists of a charger, a power factor correction unit, a DC power supply, a DC-DC converter, an inverter and output circuits. 1-1 Charger Sub-System: The purpose of the charger is to provide power to keep the batteries full, (Refer to picture 4).
  • Page 10 Picture 6: Schematics for inverter 1-4 Output Sub-System: The bypass relay receives a signal from the control circuit to switch the output of the UPS from bypass to inverter, and vice versa. The output noise filter circuit blocks the EMI noise to the loads. 1-5 Input Power Factor Correction Sub-System: The purpose of the power factor correction (PFC.) system is to ensure that the level of the input current is less than 1,...
  • Page 11 Refer to picture 8, the battery voltage is transformed through a full bridge DC-DC converter to ±360Vdc as DC buses for inverter. When the line fails, the ±360Vdc DC sources are caught up to supply the power needed by the inverter immediately.
  • Page 12 Overload Protection: The UPS collects the continuous overload signals through the CPU switch, the bypass relay. If the output load is lower than 110% of rated load (VA or Wattage), the UPS keeps running on inverter mode, showing the warning status. If the output load is between 110% and 130% of rated load (VA or Wattage) the UPS transfers to bypass after 12s.
  • Page 13 2-3 Signaling Sub-System: When the AC line is unable to supply, the batteries release energy inside to supply the inverter immediately. At the same time, the buzzer beeps every 4 seconds. When the batteries are depleted, the battery-low signal will be activated and the buzzer will beep every 1 second.
  • Page 14 Button Function Turning the UPS on: Press and hold the ON/Mute button for at least 2 seconds to turn on the UPS. Muting the alarm: After the UPS is turned on, press and hold this button ON/Mute for at least 5 seconds to disable the alarm system. This does not apply Button when warnings or errors occur.
  • Page 15 TEST ITEM TEST POINT TEST AND ADJUSTMENT EXPECTED SEQUENCE RESULT 1. Disconnect P5(+) and P8(-) 1. Cooling fans wires from pins respectively. on back panel P5/P6/P9, +- . Charger Voltage 2. Connect DVM (set to measure begin P7/P8P10(-) DC) to test pins and plug input rotate.

  • Page 16: Troubleshooting Chart

    V. TROUBLE SHOOTING Our products are carefully designed and strictly tested to prevent malfunctioning. However, if failure occurs, refer to the following Trouble Shooting Chart. Trouble Shooting Chart Begin If the panel If DC start works LCD light and properly? fan rotates? If the panel Change CNTL...
  • Page 17 Panel LCD Display Explanation Display Function Backup time information Indicates the remaining backup time in pie chart Indicates the remaining backup time in numbers H: hours, M: minute, S: second Fault information Indicates a warning or a malfunction. Warning and fault code indicators. The meaning of the codes is listed in the section below.

  • Page 18: Lcd Display Wordings Index

    LCD display wordings index Abbreviation Display content Meaning Enable Disable Escape High loss Low loss Battery Converter Temperature Charger UPS Setting There are three parameters to set up the UPS. Parameter 1 Parameter 1: It’s for program alternatives. There are 8 programs to set up: output voltage setting, frequency converter enable/ disable, output frequency setting, ECO enable/disable, ECO voltage range setting,...
  • Page 19 02: Frequency Converter enable/disable Interface Setting CF ENA: converter mode enabled CF DIS: converter mode disabled 03: Output frequency setting Interface Setting The initial frequency may be set on battery mode: BAT 50: current output frequency is 50Hz BAT 60: current output frequency is 60Hz If the converter mode is enabled, you may choose the following output frequency: CF 50: current output frequency is 50Hz...
  • Page 20 06: Bypass mode enable/disable Interface Setting ENA: Bypass mode enabled DIS: Bypass mode disabled 07: Bypass voltage range setting Interface Setting Press the Down key or Up key to set the acceptable high voltage point and acceptable low voltage point: HLS: Bypass high voltage point LLS: Bypass low voltage point For 208/220/230/240 VAC models:...
  • Page 21 Operating Mode Description Operating mode Description LCD display When the input voltage is within an acceptable range, the UPS will provide pure Online mode and stable AC power to output. The battery is also charged when the online mode is set. Energy saving mode: When the input voltage is within voltage regulation...

  • Page 22: Faults Reference Code

    Faults Reference Code Fault event Fault code Icon Fault event Fault code Icon Bus start fail Inverter voltage Low Bus over Inverter output short Bus under Battery voltage too high Bus unbalance Battery voltage too low Inverter soft start fail Over temperature Inverter voltage high Over load...
  • Page 23 2. U.P.F. CORRECTION: Step Checked components Instrument function Reference Value Failed condition Ω short open Q1(D,S) DIODE 0.46 short or open D10, D11 DIODE 0.44 short or open Ω 47.00 open or value change REC1 (+,~),(~,-) short or open DIODE 0.46 3.
  • Page 24 After replacing all defective components on the power stage (PSDR), proceed to make the connection on the control board. Supply the DC voltage 36V dc/2Amp (limited current) with the DC power supply via P6+ and P8-. Turn on the switch on the panel. After doing that, the message Current limit will be displayed on the DC power supply for about 2 seconds.

  • Page 25: Appendix I: Engineering Spec

    APPENDIX I: ENGINEERING SPEC. I/P Specification Cold Start Yes, default frequency = 50 Hz Acceptable Input Voltage 110-300 VAC Low line transfer 160VAC; ± 5% (Full Load) Line low comeback 175 VAC; ± 5%(Full Load) Line high transfer 300 VAC; ± 5% Line high comeback 285 VAC;...

  • Page 26: Appendix Ii: Communication

    APPENDIX II: COMMUNICATION 1. RS232 PORT The RS232 provides proprietary command sequence for the computer to monitor the line and UPS status and to control the UPS. The data format is listed as following: PIN TYPE ....: female BAUD RATE ....: 2400 bps DATA LENGTH ..

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