User Guide - USE 2Ky3K
User Guide - USE 2Ky3K
2KVA model
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.
? Whether UPS works properly, refer to Alignments.
? What happened to the UPS, refer to Trouble Shooting.
? Electrical performance, refer to Electrical Spec.
Conventions
This service manual uses the following conventions to alert you some important information for
safe operation and quick working.
Information and Tips: There are some tips and skills after this symbol. During
service operations, these skills are provided by our design
engineers which may help you quickly finish your work.
Important Safety Instructions
STOP
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.
4. Turn off the UPS and disconnect input power cord before removing outside protective cover.
6. High voltage may present at DC capacitors. Before opening the outside cover, wait for at
least five minutes after turning off the UPS.
2. If the battery connectors (P6, P8) are disconnected, be sure to plug in the input power cord
and the input power is available before re-connect the battery connectors.
3. After service, verify the polarity of batteries, the tightness of all screws and connectors before
restarting the UPS.
After opening the cover, please always check the tightness of all wires, connectors,
and screws first. Then check if there is any de-colored components inside
STEPS TO OPEN THE CASE
To open the outside case, please follow steps and figures below:
1. Remove related screws on STEP 1 figure.
2. Slide outside cover in the direction shown in STEP 2.
3. Done.
STEP 1
STEP 2
STEP 3
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. If this situation occurs, service of qualified person is needed.
This service manual will guide the technicians to repair and adjust a problematic UPS. If the UPS
still does not work properly, please contact with us and we will be glad to solve any problems you
met.
Because of the following unique features of this series UPS (Uninterruptible Power System), it is
very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.
This service manual consists of 4 major parts:
1. Introduction.
2. Principle of operation: It describes the functions and principles of each part.
3. Alignments: It describes the locations and methods needed to adjust this UPS.
4. Trouble shooting: This part describes the possible failure conditions and procedures to
repair it.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and safe
operation.
II. PRINCIPLE OF OPERATION
This 2KVA high input power factor UPS system contains two major PCB assemblies. They are
including:
1.mainbord: Contains major parts of (1) DC power supply, (2) unit power factor correction,
(3) input filter, (4) inverter (6) output filter, (6) charger, (7) DC-DC converter.
2. CNTL: Contains major parts of protection, signaling circuits, regulation and control
circuits of inverter.
The simplified schematic in figure1 shows how the major circuits are connected and illustrates
the overall system functions. .
DC/DC
CHARGER
BATTERY
The load detector senses the load current, i.e. the inverter current, and sends the signal by
two paths. In battery mode, the UPS will go to failure mode if overload condition happened.
The panel will indicate the fault condition. There are two kinds of protection in our UPS:
a. Overload Protection: The UPS collects the continuous overload signals through CPU
switch the bypass relay. If the output load is between 105% and 110% of rated load (VA,
or Wattage) the UPS transfers to bypass after 10min when ambient temperature lower
than 350C. If the output load is between 110% and 130% of rated load (VA, or Wattage)
the UPS transfers to bypass after 1min when ambient temperature lower than 35 0C. If
the output load is higher than 130% of rated load, the UPS transfers to bypass after 3s
immediately when ambient temperature lower than 350C.
b. Cycle by Cycle Current Limit: When output loads sink a high surge current for a short
time, a high inverter current is detected and the inverter switches, i.e. the IGBT's, are
turned off pulse by pulse to protect themselves from thermal runaway. The output relay
stays at inverter output position unless a continuous overload is detected or an
abnormal inverter operation occurs.
2. Battery voltage over or under shut down
Upon the battery voltage declines to battery-under/over level, the UPS will warning and the
LCD will display the fault code, then shut down.
In case of the battery voltage is high voltage, the UPS will warning and the LCD will display
the fault code.
3. Inverter output abnormal protection
The inverter failure signal shuts down the inverter immediately, makes the buzzer a
continuous alarm, and the LCD displays the fault code. “The failure signal latches itself
unless SW off or battery is empty".
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 thought as temperature
failure by the UPS. The LCD will display the fault code.
5. Bus over/under/unbalance-voltage protection
To protect any BUS over/under/unbalance -voltage condition especially for the half-bridge
load. The LCD will display the fault code.
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.
Upon the batteries are discharged to battery-low level, the battery-low signal is activated
and the buzzer beeps every 1 second.
Remote shutdown signal is enabled only when the line fails.
3. Front Panel:
The front panel consists 2 parts: push button and display LCD set.
The push button is used to turn on and off the UPS. LCD display indicates the load level, the
battery voltage level and operation status of the UPS.
Besides, when the system works abnormally, The LCD will display the fault code.
LCD Screen
Se
Select Button
Button
Button Function
Turn on the UPS: Press and hold ON/Mute button for at least 2 seconds
ON/Mute Button
to turn on the UPS.
Mute the alarm: When the UPS is on battery mode, press and hold this
button for at least 5 seconds to disable or enable the alarm system. But
it’s not applied to the situations when warnings or errors occur.
Up key: Press this button to display previous selection in UPS setting
mode.
Switch to UPS self-test mode: Press and hold ON/Mute button for 5
seconds to enter UPS self-testing while in AC mode, ECO mode, or
converter mode.
Turn off the UPS: Press and hold this button at least 2 seconds to turn
off the UPS in battery mode. UPS will be in standby mode under power
normal or transfer to Bypass mode if the Bypass enable setting by
OFF/Enter Button pressing this button.
Confirm selection key: Press this button to confirm selection in UPS
setting mode.
Switch LCD message: Press this button to change the LCD message for
input voltage, input frequency, battery voltage, output voltage and
output frequency. It will return back to default display when pausing for
10 seconds.
Select Button
Setting mode: Press and hold this button for 5 seconds to enter UPS
setting mode when UPS is in standby mode or bypass mode.
Down key: Press this button to display next selection in UPS setting
mode.
Begin
No
If the panel NO
If DC start works
LCD light and
properly?
fan rotates?
Yes
Yes No
No
No
Display Function
Backup time information
Indicates the backup time in pie chart.
Indicates the backup time in numbers.
H: hours, M: minute, S: second
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.
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%.
Indicates overload.
Indicates the load or the UPS output is short circuit.
Mode operation information
Indicates the UPS connects to the mains.
Battery information
Indicates the Battery level by 0-25%, 26-50%, 51-75%, and
76-100%.
UPS Setting
There are three parameters to set up the
Parameter 1 UPS.
Parameter 1: It’s for program
alternatives. There are 8 programs to set
up. Refer to below table.
Parameter 2 and parameter 3 are the
setting options or values for each
program.
Parameter 2 Parameter 3
01: Output voltage setting
Interface Setting
For 200/208/220/230/240 VAC models, you may choose
the following output voltage:
200: presents output voltage is 200Vac
208: presents output voltage is 208Vac
220: presents output voltage is 220Vac
230: presents output voltage is 230Vac(Default)
240: presents output voltage is 240Vac
For 100/110/115/120/127 VAC models, you may choose
the following output voltage:
100: presents output voltage is 100Vac
110: presents output voltage is 110Vac
115: presents output voltage is 115Vac
120: presents output voltage is 120Vac(Default)
127: presents output voltage is 127Vac
02: Frequency Converter enable/disable
Interface Setting
CF ENA: converter mode enable
CF DIS: converter mode disable(Default)
Over Charge
5. DC POWER SUPPLY:
Step Checked components Instrument Reference Failed condition
function Value
1 Q3(D,S) DIODE 0.47 short or open
2 R54 Ω 22 open
3 R105 Ω 0.22 open
4 U1 (3845) PIN : 5-6 Ω >1M too low
5-7 >1M
5-8 3.5k
6-8 >1M
6. AC/DC 1A CHARGER:
Step Checked components Instrument Reference Value Failed condition
function
1 Q3(D,S) DIODE 0.49 short or open
2 R6 Ω 47 open
3 R37 Ω 0.3Ω open
4 U3(3845) PIN : 5-6 45k too low
5-7 Ω >1M
5-8 3.5k
6-8 53.5k
5 D2, D3, D5 DIODE 0.57 short or open
6 C1, C2 Ω open short
visual deformed
After you have replaced all defect components on power stage (PSDR), connect with control
board. Supply DC voltage 48Vdc(4BAT)/3Amp (limited current) with DC power supply via
P1/2+ and P7/8-. Turn on the switch on panel, you will see "current limit" on the DC power
supply for about 2 seconds (If not, there are some defective components you have not found).
When everything seems good, turn off the switch on panel and remove DC power supply. Plug
in the power cord and supply UPS with the mains. Test the output of charger P1/2+, P8-). Is it
54.8Vdc(4BAT).The fan will also active. If there is no problem in charger, connect the
batteries viaP1/2、P8.
Finally, turn on the switch on panel again and follow the procedure listed in part Ⅲ
(Alignment) to adjust the DC offset, and measure voltage on DC bus, output voltage.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have replaced all
defective components.
APPENDIX I: ENGINEERING SPEC.
I/P Specification
Cold Start Yes, default frequency = 50 Hz(60 Hz)
Acceptable Input Voltage 0-300 VAC(0-150 VAC)
Low line transfer 160VAC; 5% (Full Load)
(85VAC; 5% (Full Load))
Line low comeback 168 VAC; 5%(Full Load)
(95VAC; 5% (Full Load))
Line high transfer 300 VAC; 5%
(150VAC 5%)
Line high comeback 290 VAC 5%
(145 VAC 5%)
Start-up Voltage with Output 110 VAC to 300 VAC 5%
Power (55VAC to 150VAC) 5%
Ratings (at nominal input voltage) 5A(10A)
earth leakage 3.5 mA, maximum (UPS only)
Input power factor > 0.99
Input frequency 40 Hz to 70 Hz
Input protection type circuit protector
O/P Specification
O/P Power
Power (VA) 2000
Power (Watts) 1800
Output Power Factor Rating 0.9
Load Power Factor Range 0.5 lagging to 1.0 (unity)
Output Voltage 200/208/220/230/240VAC
(100/110/115/120/127VAC)
Waveform Sinusoidal
Nominal Voltage 230 VAC(120V)
Line Mode Voltage Regulation 1% of nominal; no load to full load, resistive &
RCD loads
Battery Mode Voltage Regulation 1% of nominal; no load to full load, resistive &
RCD loads
Transient Response 0%-100%-0%; 9% max.
(line mode) 20%-100%-20%; 6 % max.
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
The pin assignment and description are listed in the following table and the interface
configuration is indicated in figure VI-1. Note that, the computer will control information exchange
by a query followed by <cr> (Character Return). UPS will respond with information followed by a
<cr> or action. UPS data will be provided at 2400 baud rate and consist of 8 data bits, 1 stop bit,
and no parity bit. All the information is provided in ASCII format.
PIN # Description I/O type
1,4,6,7,8,9 not connected
3 UPS RS232 receiver Rx from computer. input
2 UPS RS232 transmitter to computer output
5 GND
2. USB PORT
The USB is compatible to USB1.1 specification, and implemented for HID device and
bus-powered.
The USB connector is "B" receptacles, seeing the following figure. The following table is signal
definition of USB interface.
PIN# SIGNAL
1 VBUS
2 D-
3 D+
4 GND