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CDP UPO11-3RT Service Manual

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SERVICE MANUAL
UPO11-3RT model

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  • Page 1 SERVICE MANUAL UPO11-3RT model...

  • Page 2: General Information

    General Information Getting start If you want to know: ? Overview and what special for this UPS, refer to section Introduction. ? Replacing Battery Pack, refer to Replacing the Battery Pack. ? Open external case; refer to Steps to Open the Case. ? Electrical function and principle, refer to Principle of Operation.

  • Page 3: Important Safety Instructions

    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.
  • Page 4 STEPS TO OPEN THE CASE To open the outside case, please follow steps and figures 3KVA as below: 1. Remove the front Panel as shown in STEP1-3 figure. 2. Remove related screws on STEP4 figure. 3. Slide outside cover in the direction shown in STEP5 figure. 4.
  • Page 8 INTRODUCTION For all series of UPS, they are strictly tested and carefully designed. 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 unavoidable failures of this UPS.

  • Page 9: Principle Of Operation

    II. PRINCIPLE OF OPERATION This 1KVA&1.5KVA&2KVA high input power factor UPS system contains two major PCB assemblies. They are including: 1. PSDR: Contains major parts of (1) DC power supply (2) DC-DC converter, (3) inverter (4) Input and output circuits. 2.
  • Page 10 Figure 1: Circuit connection for 3KVA The locations of these assemblies are shown in figure 2.1...
  • Page 11 Output Input USB+RS232 Mini Solt Extend battery Input & Output PFC PCB Battery Pack 1A charger Control board Power PCB Figure 2.1: Sub-assembly location Figure 2.2: The Real Panel 1. Programmable outlets: connect to non-critical loads. 2. Output receptacles: connect to mission-critical loads. 3.
  • Page 12 Basically, this ON-LINE UPS system utilizes high frequency PWM techniques to achieve high efficient performance. This UPS can deliver a clean, regulated sine-wave output at any kinds of loads. The sub-systems are described as below: N.F. N.F. AC/DC DC/AC DC/DC CHARGER BATTERY Figure 3: Block Diagram for UPS.
  • Page 13 The UPS transfers positive(＋) and negative(－) DC bus voltages to the AC output voltage through an inverter of half bridge configuration at normal operation. The schematic diagram of inverter is shown in figure 6. To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching signals from PWM generation circuit through a pair of photo-couplers to trigger the upper IGBT and the lower IGBT alternately.
  • Page 14 Figure 7: I/P PFC configuration 1-6 DC-DC Converter Sub-System: The major function of the UPS is to deliver accurate AC power to the loads connected to it whenever the AC line presents or fails. In this system, the batteries release the stored energy to supply inverter immediately upon AC line failure.
  • Page 15 This portion can be seen as brain of the UPS. It provides the control pulses to the switching elements which deliver power to the output. The sub-system also regulates the output to ensure that the UPS is delivering constant AC voltage to the loads. The inverter signal is sensed directly by resistor division.
  • Page 16 " The failure signal latches itself unless UPS is off or battery is empty".

  • Page 17: Front Panel

    4. Over-temperature protection The thermal switch detects the temperature of PSDR heat sink. The thermal switch is electrically connected to the CPU. An opened thermal switch is identified as temperature failure by the UPS. The LCD will display the fault code. 5.
  • Page 18 Button Function  Turn on the UPS: Press and hold ON/Mute button for at least 2 seconds to turn on the UPS.  Mute the alarm: After the UPS is turned on in battery mode, press and hold this button for at least 5 seconds to disable or enable the alarm system.
  • Page 19 IV. ALIGNMENTS List below are some testing points and procedures when a qualified service person wants to check whether EUT (Equipment under Test) will work properly. Before beginning below procedures, please make sure that EUT is OFF and disconnected from the mains. TEST ITEM TEST POINT TEST AND ADJUSTMENT...
  • Page 20 Figure 9 : Circuit for test output balance V. TROUBLE SHOOTING Due to careful design and strict tests of our products, UPS failure seldom occurs. However, once failure occurs, please check it out according to Trouble Shooting Chart, that will help you solve the most problems on UPS.

  • Page 21: Troubleshooting Chart

    Trouble Shooting Chart Begin If the panel If DC start works LCD light and properly? fan rotates? If the panel Change CNTL LCD display SUB-ASSY normally? If I/P relay PFC or charger fail, If DC start works continuouly open refer to relative properly ? and close? analysis...
  • Page 22 Tower: Display Function...

  • Page 23: Backup Time Information

    Backup time information Indicates the backup time in pie chart. Indicates the backup time in numbers. H: hours, M: minute Warning & Fault information Indicates that the warning and fault occurs. Indicates the warning and fault codes, and the codes are listed in details in 3-5 section.

  • Page 24: Lcd Display Wordings Index

    LCD display wordings index Abbreviation Display content Meaning Enable Disable Escape Rack display Tower display Low Battery Over Load Battery is not connected Over Charger Site Fault Over Temperature Charger Failure Battery Fault Bypass Frequency Unstable Bypass Out Range UPS Setting There are two parameters to set up Parameter 2 the UPS.
  • Page 25 01: Output voltage setting  Interface Setting For 208/220/230/240 VAC models, you may choose the following output voltage: 208: presents output voltage is 208Vac 220: presents output voltage is 220Vac 230: presents output voltage is 230Vac 240: presents output voltage is 240Vac For 110/150/120/127 VAC models, you may choose the following output voltage: 110: presents output voltage is 110Vac...
  • Page 26 05: AECO enable/disable  Interface Setting ENA: Advanced ECO mode enable DIS: Advanced ECO mode disable 06: Bypass mode enable/disable  Interface Setting ENA: Bypass mode enable DIS: Bypass mode disable 07: Programmable outlets enable/disable  Interface Setting ENA: Programmable outlets enable DIS: Programmable outlets disable 08: Programmable outlets setting ...
  • Page 27 09: LCD display direction setting  Interface Setting RAC: the LCD display is horizontal. TOE: the LCD display is vertical. 10: Acceptable input voltage range setting  Interface Setting 110/300 alternating flashing: acceptable input voltage range is from 110V to 300V; 160/260 alternating flashing: acceptable input voltage range is 160V to 260V;...

  • Page 28: Warning Indicator

    Frequency When input frequency is within 40 Hz Converter to 70 Hz, the UPS can be set at a mode constant output frequency, 50 Hz or （Rack） 60 Hz. The UPS will still charge battery under this mode. Battery When the input voltage is beyond the mode acceptable range or power failure and alarm is sounding every 4...

  • Page 29: Failure Diagnosis

    Low Battery Sounding every second Overload Sounding twice every second Battery is not connected Sounding every second Overcharge Sounding every second Site wiring fault Sounding every second EPO enable Sounding every second Over temperature Sounding every second Charger failure Sounding every second Battery Fault Sounding every second Bypass Out Range...
  • Page 30 Ω F2,F3,F4 short open Q2,Q4,Q5,Q6,Q9,Q10,Q11, DIODE 0.47 short or open Q12 (D,S) Ω R31, R54, R41, R42, R50, open R49, R47, R48 D15,D16, D17, D18 DIODE 0.41 short or open 4. DC/AC INVERTER: Step Checked components Instrument Reference Value Failed condition function Q7,Q8, Q13,Q14, (D,S) DIODE...
  • Page 31 Ω C1, C2 open short deformed visual After you have replaced all defect components on power stage (PSDR), charger, please supply normal DC voltage (72V) with limited current 2Amp via P5+ and P8- points. Then, turn on the UPS, you will find “current limit” on the DC power supply for about 2 seconds. When everything seems good, turn off turn off UPS and and remove DC power supply.

  • Page 32: Appendix I: Engineering Spec

    APPENDIX I: ENGINEERING SPEC. I/P Specification Cold Start Yes, default frequency = 50 Hz Acceptable Input Voltage 100-300 VAC 160VAC;  5% (Full Load) Low line transfer 170 VAC;  5%(Full Load) Line low comeback 300 VAC;  5% Line high transfer 290 VAC;...

  • Page 33: 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 ..: 8 bits STOP BIT ....: 1 bit PARITY ......: NONE...

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