T5 UPS service manual 10kVA - 60kVA
Contents
1. 1 15 4 2 Each board DIE Switch 15 4 2 1 Display control board DIP switch 4 422 15 4 2 2 Main control board DIP switch setting eese ceres eere eerte eere eerte nnne 17 4 2 3 Rectifier control board DIP switch setting eee 18 4 3 Each board potential function introduction 40 2222 4 19 Ee Deler 19 45352 haute nt 19 43 3 SEWM Lt pe 20 4 3 41015 20 a3 Bowenboard ee EM 21 4 4 Main control board indicate light introduce 2 ecce eee eere eren neret 21 5 Some familiar symptoms and diagnosis eere eee cree eerte esten esten setenta setae senno 23 5 1 symptom 1 After close the power breaker or bypass breaker the panel PHASE light is on and the buzzer beep Continuallly ccecsccsscscseccscecsccssscesescscecsecsonscscscsessseseccsescsesecsces 23 5 2 Symptom 2 The panel rectifier light is off LCD display that rectifier is abnormal and the buzzer beep Intermittent cccssccssssssoesscsonssocscecenssosecssoceesecscsenscsvocsssecsssensoss 24 EX DETIENE B E E 24 5 22 Program e LEE 24 5 3 Symptom 3 The UPS power breaker jump when it operation normally 40 5 4 Sym2. 55 6 22 VOR LTE 56 7 Paralleled system trouble shooting program ecce 56 7 1 Two units paralleled system trouble shooting program ecce eere ener 56 RE MET EEN UNICI DIUI UE 56 20 57 7 2 Three or more units paralleled system diagnosis program 60 Appendix ST5100 series UPS spare 2 62 1 System overview ST5100 series UPS adopt advanced DSP control technique it has a easy viewing and easy operating interface and a strong communication function the structure design of the product is easy to maintenance and it so has excellent EMC design these make the product to be a high reliability UPS The series have eight models Single model ST5100 10KVA ST5100 60K VA and parallel model ST5100 10KVA ST5100 60KVA the technical specification is shown in the table below TAB 2 1 ST5100 SERIES TECHNICAL SPECIFICATION MODEL SPECIFICATION 10KVA 20KVA 30KVA 40KVA 50KVA 60KVA Voltage range Vac 380 25 Frequency range Hz 40 65 Synchronous range Hz 50 5 input Phase 3p 4W GND Battery voltage VDC 12V 29 348 10 20 Charge current A 10 15 15 20 10 60 OUTPUT Rated power KVA 20 30 40 50 Phase 30 4W GND Voltage Vac
3. HESE WEE EE SNE Figure 5 14 PWM board sine signal test and wave shape D Test left pin of R113 R115 R104 R107 of the three PWM board the wave is 35 SPWM wave its Vp p is 12 1V as shown in figure 5 15 It can be tested with a multimeter the value is 6 2 0 2Vac 6 2 0 2VDC Yp p 12V PWM wave shape Figure 5 15 PWM board SPWM signal test and wave shape E Test inverter driver board four SPWM driver signal between each G and E with a oscillograph as shown in figure 5 16 It can be tested with a multimeter the value is 10 8 0 2Vac 5 2 0 2VDC 36 Figure 5 16 Inverter driver board SPWM driver signal Turn off the UPS Turn off the power breaker test the signal of V21 V32 of the main board the ground line connect to R37 down pin Close the power breaker the voltage V21 tested will be about 5VDC the voltage V32 tested will be OVDC turn on the UPS 30 seconds later its protection will enable buzzer beep continually Turn off the UPS Put on the CN12 of power backup and transfer board put on 09 of the main board install three 5A fuse between the place the three inverter fuse uninstalled before H Close the power breaker test the voltage between CN1 1P and 3P it should have a rise period and stabilize at about 30Vac as shown in figure 5 18 Test the voltage between any two upper pins of the bypass breaker with a multimeter the
4. the Rectifier Is End A Rectifier control board utility sampling transformer and fuse test Close the power breaker test the voltage between both sides of the fuse and N of CN6 on the board with a multimeter the value should be about 220 Vac else the fuse should be damage Test the voltage between cathode of V01 V02 V03 on 28 the board GND left pin of C64A the value should be about 30Vac as shown in figure 5 6 If the value is wrong the transformer should be damage replace the rectifier control board V01 V03 Figure 5 6 Utility sample voltage test B Diagnosis of rectifier over voltage Turn off the power or bypass breaker close the power breaker test the rectifier output voltage with a multimeter as shown in figure 5 5 If the voltage raise to 415VDC and panel RETIFIER light off FAULT light on buzzer beep intermittently and the rectifier output voltage descend it means that the rectifier output is over voltage it may caused by the damage of rectifier output voltage sampling hall of fans control board or damage of rectifier control board Replace the rectifier control board or fans control board C Diagnosis of rectifier over heat When the UPS over heat protection enable test the voltage between R75 with a multimeter if the value is OVDC then it should be rectifier over heat it will be 5VDC normally The problem may caused by temperature relay connect line contacting badly tempera
5. 016 U15 U16 U15 JEA U16 U15 U16 U15 2 Panel 50 60 2 system identify DIP switch setting As shown the figure below when U15 second switch switch to ON the 50Hz identify system will be selected else the 60 Hz identify system will be selected ON 015 50Hz system ON U15 60Hz system 4 2 2 Main control board DIP switch setting Main board has two DIP switch SW1 SW2 it can be used for parallel single unit system setting and output 50 60Hz setting D Parallel single unit setting As shown in the figure below ON SW2 Parallel unit setting ON SW2 Single unit setting 2 Output 50 60Hz setting ON 5 1 50Hz output system ON LITIY SW1 60Hz output system 4 2 3 Rectifier control board DIP switch setting SW1 setting SW1 1 SW1 2 SW1 3 Charge current ST5100 ST5100 40 60KVA 10 30KVA OFF OFF OFF 40A 20A Appearance 30A 15A ON ON OFF 20A 10A 4 3 Each board potential function introduction 4 3 1 Rectifier control board SWI Figure 4 1 Rectifier board potential and DIP switch RP6 Adjust float charge voltage it should be adjusted to 394 4VDC RP8 Adjust boost charge voltage it should be adjust to 405 5VDC 4 3 2 Main control board SW2 Figure 4
6. 7 Paralleled system trouble shooting program 7 1 Two units paralleled system trouble shooting program 7 1 1 Diagnosis program Abnormal phenomenon Over load output Reduce the load or check TES the output wire ie ihe tility Saba N Check the utility voltage frequency and phase normal Confirm that if the battery is Is the battery fully charge is bad or is connected correctly correct it UPS is failure 56 Single unit exit program Single unit diagnosis Parallel system launching 7 1 2 Program describe Single unit exit program in the paralleled system A Turn off the load of the UPS press off key on the panel to turn off the two paralleled UPS B Turn off the power bypass and battery breaker of the two UPS and turn off paralleled output breaker of the failure UPS C Remove the paralleled wire set the SW2 switch of the main board of two UPS to make them in single mode as shown in 4 2 2 in the manual D Close the power bypass breaker of the normal UPS close the battery breaker when the rectifier start normal press on key on the panel to turn on the UPS 2 Paralleled system launching program A Turn off the load of the UPS Turn off the paralleled output breaker of the normal UPS B Press on key on the panel to turn on two UPS C Turn off the power bypass and battery breaker of the two UPS D Connect the two UPS with the para
7. LA N gt gt gt gt N e e 00 c A UJ UJ gt 50 a UJ UJ Wi 602 UB3320 01 gt 602 UB3330 01 um Contactor LPIK DC contactor 0910MD Universal It is different for 20 and 30 KVA It is different for 20 and 30 KVA Universal Universal Universal Universal Universal It is different for 20 and 30 KVA It is different for 20 and 30 KVA 515100 Fuse 40 60 K VA Fuse RGS17 100A 600V ST5100 40 60 K VA IGBT LCD display board an 607 UT3320 00 Universal ST5100 LCD di PY ST5100 20KVA 40 60 board Display control Display control ST5100 board 606 BT3340 00 board 40 60 K VA ST5100P40K VA ST5100 BLF300 S7 266 308S70 AA 7 Universal 40 60 KVA ST5100 Hall LT308 S7 266 300570 Universal 40 60 KVA Rectifier SCR Rectifier SCR driver ST5100 driver board board 605 UK3350 10 Universal 40 60 KVA ST5100 50K VA ST5100 Fan AA1752HB AW 4 350 A17251 50 3 Universal 40 60 KVA ST5100 Fan TDP201A 2123HBT 40 60 K VA 220V 0 125A Resistance RX27 4H 40W 10Q 201 D01100 XJ Universal ST5100 Buffer 40 60 K VA resistance J ST5100 SCR 247 16212E 00 3 40 60 K VA SKKT162 12E ST5100 SCR 247 09212E 00 2 40 60 K VA SKKT92 12E Main board Main board It is different for FR UK3340T 601 BT3340 00 ST5100 40 and 50 KVA 40 60 KVA Main board Main board PH CPU It is
8. sampling hall should be bad 5 5 Symptom 5 In utility mode UPS is normal but the battery breaker will jump off when it is turned on in battery mode Abnormal symptom Diagnosis ready program Replace DC contactor Does the battery breaker Replace the battery breaker System recover program Program describe System recover program 1 Close the power bypass output breaker Turn the maintenance switch to UPS mode 3 Close the battery breaker 43 after the panel BAT LOW indicate light is off 4 Press panel key to turn on the UPS 5 6 Symptom 6 In utility mode UPS is normal but the UPS battery low protection enable when battery breaker is turned on in battery mode and the panel BAT LOW light on and the buzzer beep continually 5 6 1 Diagnosis program Abnormal symptom Replace the DC buffer resistance 5 6 2 Program describe Act as program 5 4 1 Test the DC resistance test the resistance of the DC resistance that is locked upon the fan control boar with a multimeter as shown in figure 5 22 44 ai E ET 5 E n Bi DC buffer resistance Figure 5 22 Replace the DC buffer resistance 45 5 7 Symptom 7 The UPS switch to bypass panel FAULT indicate light on and buzzer beeps continually Abnormal symptom Check the main board indicate light confirm that which protection the UPS is in Output over voltage Inve
9. L N 220 L L 380 Frequency Hz Trace the mains when it is normal else 50 60 0 2 Voltage stability 2 permit three phase output load 100 unbalance Wave form Linear load THD lt 3 Switch time ms Efficiency 90 OTHER Overload 125 of rated load last for 15min 150 of rated load last for 1min Maintenance bypass Available DC start Available LCD display Input voltage Frequency Output voltage Battery voltage Load DC current etc LED display Operation status Alarm function Overload AC input abnormal Low battery Failure Over temperature Communication function RS232 RS485 dry connection communication signal Battery test function Available Protect function Low battery Overload Overheat Output short circuit Output over voltage EMC Meets GB T 7260 3 2003 standard Noise dB lt 65 Cooling mode Fans Working temperature E 07 40 CC Relative humidity 07 9595 no condensation Dimension W X D X H 500X800 X 1180 mm Weight Kg 250 300 320 350 450 460 2 Working principle 2 1 Working Principle Drawing AC source 0 5 ka Utility ance bypass Tbe O Load 5 2 2 Working mode When the utility is normal the rectifier convert the AC input to DC power it supply the inverter and charge the battery at the same time Through the proce
10. the wave Vp p should be 23 2V frequency should be 9 00 0 05KHz The oscillograph ground line can be connected to R37 down pin as shown in figure 5 12 The signal can be tested with a multimeter the value should be 11 10 0 2 0 2 0 1VDC 33 TE 3 23 42V f 9 00 0 O5kHz E Figure 5 14 board 9KHz square wave signal test and wave shape B Test the PWM board 3 board IC3 1P 7P signal with a oscillograph the wave should be two anti phase 9KHz triangle wave as shown in figure 5 13 It can be tested with a multimeter the value tested should be 2 1 0 2 0 1 0 1 0 GND connect to right pin of R54 34 OV DER ACE LEES RENS AES SEC Ede ble cin 13 5 0 9 00 0 O5kHz Figure 5 13 Triangle wave signal test and wave shape C Press ON key to turn on the UPS test the three phase PWM board IC9 1P the wave shape should be sine wave and there is a slow start period the phase differ between any two of the three sine wave of PWM board should be 120 It can be tested with a multimeter the value should be 1 0 0 2 0 15 0 1VDC GND connect to right pin of R54 Sara dee eee ae ei ey at Wee festa Le ov
11. value should be 20 30Vac else the bypass SCR or its control board should be damaged Figure 5 18 Inverter output sampling voltage test 37 Turn off the UPS Turn off the power breaker discharge the rectifier capacitor until its voltage reduce to OVDC install the inverter fuse again close the bypass breaker turn the maintenance switch to UPS mode put on the CN15 of main board UPS function test A Close the power breaker the panel BAT LOW indicate light and RECTIFIER indicate light on close the bypass and output breaker the panel BYPASS indicate light on and buzzer beep continually 205 later the rectifier start normally the BAT LOW indicate light off buzzer stop beeping close the battery breaker Turn on the UPS the inverter start to work the panel rectifier indicate light on 30s later the inverter output SCR is turned on and the bypass SCR is turned off the panel BYPASS indicate light off the inverter supply to output B Switch function test Turn off and turn on the UPS AC input power breaker of the power cabinet test the UPS output voltage on the terminal it should be uninterruptible as shown in figure 5 21 C Charge function test Turn off the battery breaker test voltage between the UPS battery breaker upper connector and BAT of the terminal the value should be 395 3VDC as shown in figure 5 20 38 Figure 5 20 Charge voltage test D Operation with load function test Turn on and turn off loa
12. 2 Rectifier board potential and DIP switch Adjust output B phase voltage RP7 Adjust synchronous accuracy RP8 Adjust output A phase voltage RP9 Adjust output C phase voltage R35 Adjust synchronous accuracy 4 3 3 SPWM board Figure 4 3 SPWM board potential RP1 Adjust triangle wave voltage RP2 Adjust sine wave voltage RP4 Handle equilibrium adjust 4 3 4 Display control board R24 U16 U15 R26 Figure 4 4 Display control board potential R23 Battery voltage display value adjust R24 A phase output current display value adjust R25 B phase output current display value adjust R26 C 20 phase output current display value adjust R40 A phase output voltage display value adjust R42 B phase output voltage display value adjust R41 C phase output voltage display value adjust RP1 CPU 5V power adjust 4 3 5 Power board RP6 5 4 RP2 RP3 RP7 Figure 4 5 Power board potential RP1 Adjust parallel board power 12V RP2 Adjust SCR driver power 12V Adjust main control board power 12V 4 Adjust main control board power 12V RP5 Adjust DSP power 5V RP6 Adjust LCD power 5V RP7 Adjust parallel board power 12V 4 4 Main control board indicate light introduce Figure 4 6 Main control board indicate light 21 LED1 red When system appears inverter output over voltage protection IGBT over current protection o
13. 515100 series Maintenance Manual 10 60K VA www allis com tw I I EI PII e IE OI EIU EI 4 GE TU Re ULT ee 5 2 1 Working DEU 5 MME 6 2 3 T heselectricab connecte drawing 7 SsliheistructurelolU BS 8 Sa Kl ERUPTIONE Ee EE ERES 8 SZ 0 E 9 Bessemer rte Kee BEE tee 12 4 12 4 1 1 Rectifier control board function 12 4 1 2 Main control board function 13 4 1 3 PWM board function 14 44A Display poard US Wee 14 4 1 5 Rectifier driver board Rectifier driver signal isolate and enlarge 15 4 1 6 Inverter driver board Inverter driver signal isolate and enlarge 15 4 1 7 Bypass inverter static switch driver board Bypass inverter output SCR driver isolate and ele 15 4 1 8 Power board Supply 12VDC 12VDC 30VDC 5VDC 24VDC power to UE 15 4 1 9 Power backup and transfer board Power transfer ees 15 4 510 Eans controliboard ee 15 4 1 11 Parallel board Parallel control
14. 7 Universal 10 30 75100 Hall LT308 S7 266 300S70 AU Universal 10 30 Rectifier SCR Rectifier SCR driver ST5100 driver board board 605 UK3350 10 Universal 10 30 KVA ST5100 Fan AA1752HB AW 350 17251 50 Universal 10 30 KVA ST5100 Fan TDP201A 2123HBT 350 A12038 5B 10 30 K VA 220V 0 125A 62 a ON LA w N T ST5100 50KVA 875100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 K VA ST5100 10 30 K VA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA ST5100 10 30 KVA Buffer resistance SCR SKKT92 12E Main board Main board DSP FR UK3350 Rectifier control board DSP FR UK3350 Capacitor Fan control Fan control board board ST5100P 50KVA Capacitor CBB65 70u 450V J Inverter driver Inverter driver board board ST5100 50KVA SCR control SCR control board board ST5100 50KVA Rectifier control board Rectifier control board Resistance RX27 4H 40W 10Q J Main board ST5100P 20K VA Main board ST5100P 30KVA TMS320F240PQA TMS320F240PQA CD135 3300 u 450V Rectifier control board ST5100 20KVA Rectifier control board ST5100 30KVA 201 D01100 XJ 247 09212E 00 00 a fon e e e S S LA LA LA UJ UJ UJ UJ UJ UJ UJ
15. G System recover program Paralleled line failure diagnosis program A In single system the problem may be caused by main board DIP switch setting mistake it can be reset according to 4 2 2 mentioned in the manual B It should be paralleled line poor contact or bad turn off the UPS and connect it again or replace it 5 8 Symptom 8 Close the bypass power breaker turn on the UPS and protection enable as soon as the inverter start Diagnosis program D Turn off the load Turn off the bypass breaker turn off the UPS 2 Turn on the UPS again if the symptom still exist it should be inverter failure Act as 5 6 mentioned in the manual 3 If the UPS start normally test the voltage between CN2 1P and 3P on the PWM board the value has a low start progress then it should be inverter output SCR SCR driver board failure 4 Proceed UPS diagnosis ready program 5 Replace the inverter output SCR SCR driver board 6 Proceed system recover program 52 7 UPS function test 5 9 Symptom 9 The protection enable as soon as the UPS switch to inverter output after it is turned on about 30 seconds Diagnosis program D Tum offthe load of the UPS Turn off the bypass breaker turn off the UPS 2 If the problem still exist it should be inverter failure act as 5 6 mentioned in the manual 3 If it start normally test the voltage between any two pins of the bypass breaker upper pins the value should b
16. N12 of power backup and transfer board close the power breaker again test the rectifier output voltage with a multimeter the value tested will rise slowly and stabilize at 394 4VDC at last 5 The rectifier symptom that caused by inverter diagnosis program A Turn the maintenance switch to BYPASS Turn off the power bypass and battery breaker discharge the rectifier capacitors with a 3KQ 10W resistance until its voltage reduce to OVDC B Remove the inverter DC fuse test the resistance between C1 and E2 of IGBT as shown in figure 5 12 the value should be more than 10KO else it should be IGBT or its filter board damage IGBT test Test the E1C2 to C1 E2 to E1C2 of IGBT with a multimeter in diode mode the first one tested with red pen the value should 0 3 0 6 test it contrary the value should be oo Test G1 to E1 G2 to E2 of the IGBT with a multimeter in capacitor mode the value tested should 30 40nF as shown in figure 5 13 32 Dismantle the fuse before test Figure 5 13 IGBT test IGBT filter board test Remove the board test the resistance between C1 and E2 on the board the value should be more than 10 else it should be damage Replace it Inverter test Remove the inverter fuse pull out CN11 CN12 of power backup and transfer board pull out CN9 CN15 of main board A Close the power breaker test J1 of main board with a oscillograph the wave shape will be 9KHz square wave
17. PS and close the battery breaker after the rectifier start normally turn on all UPS from the panel After the UPS start normally test the voltage between two UPS output with same phase the value should be less than 10Vac as shown in figure 7 1 Turn off the output breaker test the voltage between two output breaker upper three pins A1 and A2 B1 and B2 C1 and C2 Close the two output breaker without load test the three live lines output current and the value should be less than as shown in figure 7 2 Turn off the utility cabinet power breaker test the voltage two UPS output should be 50Hz and the voltage should be 220Vac test the output current should less than 3A Close the cabinet power breaker add the UPS load and test the two UPS output current the difference should less than 596 of 61 nominal output current Appendix ST5100 series UPS spare part Damage grade 1 The easiest damage component 2 Easier damage component 3 Possible damage component 4 Not easy damage component Damage Model Part Part model Code Note m grade ST5100 Fuse 302 011630 00 10 30 K VA Fuse RGS4 63A 660V ST5100 2 1150 060 251 150060 00 10 30 LCD display board 607 UT3320 00 Universal ST5100 LCD display ST5100 20KVA 10 30 board Display control CPU program is Display control ST5100 board board ST5100P 20K VA different 10 30 KVA ST5100 Hall BLF300 S7 266 308570
18. VERE ccce N S eo N La Le Lc N LA Le lt N La Le N Le icio Eel E amp OUTPUT GNPUT GND E amp OUTPUT NPUT GNDu T lo battery cabinet Input utility Output breaker Power cabinet No Lio 120 Lan D load Figure 7 3 Paralleled system connect drawing 7 2 Three or more units paralleled system diagnosis program Three or more units paralleled system diagnosis program is similar to two units paralleled system the difference is single unit exit program and paralleled system recover program D Single unit exit program 60 A Turn off all UPS from panel B Turn off the failure UPS bypass power battery and output breaker C Pull out the failure UPS paralleled line set the UPS to single unit act as 4 2 2 in the manual D Turn on the other UPS from the panel if the load is bigger than one unit output nominal load the load should be turned off or reduced 2 Paralleled system recover program A Turn off the load turn off all the UPS from the panel and turn off their output breaker B Turn off the bypass power and battery breaker of all the UPS C Connect the paralleled line and set the UPS that used to be failure to paralleled mode D Close power bypass breaker of all the U
19. breakers of the UPS discharge DC capacitor and replace the paralleled board and paralleled average current sampling transformer C If it is IGBT over current carry out diagnosis ready program act as 5 1 2 mentioned in the manual 50 Replace the IGBT current sampling hall test IGBT and replace the bad one E Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board 5 Inverter overload or output phase unequal diagnosis A Expel the problem of the load first if there is short circuit or overload in it B Test the current three phase output as shown in figure 5 25 2 m A Figure 5 25 Output current test Calculate the actual load by Pn Un In 1 3 and compare to the load displayed in panel LCD if the difference is too much over 50 the UPS output current sampling hall should be bad C For output phase unequal fault the UPS will operation normally without load the difference amount three phase output voltages should enlarge with small load and the UPS protection will enable with large load Test the voltage between three DC fuse with a multimeter to confirm that if the fuse is bad 51 D Proceed diagnosis ready program Test IGBT F Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board
20. d test the voltage between any line of the three live lines and the neutral of the terminal with a multimeter the value should be 220Vac 2 as shown in 5 19 Figure 5 21 Output voltage test E Bypass function test Press OFF key to turn off the UPS the RECTIFIER indicate light on 30 seconds later it will switch from bypass to inverter output and the BYPASS light off during the switch test the UPS output with a multimeter it should be uninterruptible F Display function test During the test program concerned previously the UPS panel LED LCD should display correctly 39 5 3 Symptom 3 The UPS power breaker jump when it operation normally Abnormal symptom Diagnosis ready program Pull out the line on the rectifier driver board that is connected to SCR turn on the power breaker again 40 Will the UPS power Replace the rectifier control board rectifier driver board Replace the rectifier SCR Put on the driver board connect line turn on the power breaker Will the UPS power Y Replace the UPS power breaker Inverter test UPS function test Some step of the program has been described before 5 4 Symptom 4 When the utility is failure the UPS shutdown output and the panel BAT LOW indicate light is on 5 4 1 Diagnosis program Abnormal symptom Is the UPS turned on or Turn on the UPS or reduce the load Check the battery cabinet breaker Is th
21. different for ST5100 50KVA 601 BT3350 00 ST5100 40 and 50 KVA 40 60 K VA Main board TMS320F240PQA DSP S 602 UK3350 20 Universal ST5100 ST5100 50KV 10 30 64 Rectifier TMS320F240PQA control board DSP 602 UK3350 10 Universal ST5100 ST5100 50KV 10 30 135 4700 u 875100 213 513470 0 40 60 Capacitor 450V ST5100 CBB65 70 u 450V 216 4J1700 0J 40 60 K VA Capacitor Rectifier Rectifier control Rar Itis different for control board board 602 UB3340 01 ST5100 STS100P 40K VA 40 and 50 KVA 40 60 KVA Rectifier Rectifier control It is different for control board board 602 UB3350 01 ST5100 ST5100P 50KVA 40 and 50 KVA 40 60 K VA SC 0 G 220V 20A ST5100 40 60 K VA DC contactor X6 65
22. e 20 30Vac else the bypass SCR SCR driver board or main board should be bad 4 Proceed UPS diagnosis ready program 5 Replace bypass SCR SCR driver board or main board 6 Proceed system recover program 7 Proceed UPS function test 6 Series Connection Hot Standby System diagnosis program 6 1 The standby UPS of series connection hot standby system diagnosis program D Press off key of the panel to turn off the UPS Turn off the standby UPS utility and bypass breaker Turn off the main UPS bypass breaker Operation as single unit trouble shooting program 4 When the standby UPS is normal close the utility and bypass breaker press key to turn on the UPS close the battery breaker when the rectifier start normally and close the bypass breaker of the main UPS 53 54 6 2 The main UPS of series connection hot standby system trouble shooting program 6 2 1 Diagnosis program Abnormal phenomenon Y Over load output Reduce the load or check the output wire N us heck the utili Is the utility input N frequency phase lose or normal not in order Y N Confirm that if the battery is Is the battery full charge is bad or is connected correctly correct it Turn off the load and go to abnormal UPS test program 55 Check the UPS function 6 2 2 Program describe The program has been described before in the manual
23. e battery connected battery connect line and UPS battery breaker The utility long time failure cause the battery low when the utility Is the battery low i recover recharge the battery for 10 hours and it will be normal Replace the battery Is the battery bad Y Replace the DC contactor Is the DC contactor Is th tifi It Replace the fan control board Replace the main board Inverter test 5 4 2 Program describe It is very possible that the symptom caused by battery bad especially for the UPS that has been used for more than three years D Battery test The UPS has battery test function in the panel LCD there is a battery test function menu there are three items in it as shown in figure below Choose the GENERAL TEST or DEEP TEST the UPS will discharge the battery and test it if the battery is bad the panel LCD will display alarm message MANUAL TEST BATTERY MANAGEMENT STATUS OFF gt MANUAL TEST gt ABOART TEST BOOST CHARGE GENERAL TEST DEEP TEST 2 Test the DC contactor Test the voltage between the two control pins of the DC contactor with a multimeter the value should 197 2 and the voltage between two contact pin should be 0 else the DC contactor should be damage 3 Test the rectifier voltage sampling hall Check the rectifier voltage that panel LCD display if the value is much smaller than it is tested in fact so the rectifier voltage
24. er capacitor Note High voltage exists in the UPS the programs should be carried out before the parts are replaced 3 Inverter fault diagnosis The inverter fault diagnosis Remove the inverter DC fuse as shown in figure 5 4 Close the power breaker if the rectifier start normally and the panel rectifier light is on test the voltage between the battery breaker upper part to of the terminal with a multimeter confirm that the battery breaker is Turn off as shown in figure 5 5 If the voltage is 39427 4VDC then the rectifier is normal the fault should be caused by the inverter CZe pC fuse screw Figure 5 4 Remove the three phase DC fuse 26 Figure 5 5 Test the rectifier voltage Rectifier fault diagnosis program and describe Abnormal symptom Is 01 sampling transformer Replace A01 rectifier or fuse damage Is rectifier Replace rectifier control board or fan control board Temperature relay or its Is rectifier over connect line SCR or its connect line Replace the damage Y rectifier output current Is rectifier over sampling hall charge current current sampling hall rectifier SCR or rectifier N capacitor Y Is the SCR connect Line the SCR again line contact good ensure that it is contact good N Y Replace the rectifier Is the rectifier driver control board and rectifier driver board
25. igure 5 23 Power backup and transfer board Inverter output capacitor Figure 5 23 Replace the power backup and transfer board inverter output capacitor E Inverter test system recover program act as 5 1 2 and 5 4 mentioned in the manual 3 Inverter output low voltage diagnosis program A Turn off the UPS test the voltage between inverter DC fuse if the value is not zero the fuse should be bad B Diagnosis ready program act as 5 1 2 mentioned in the manual C Test IGBT Test the E1C2 to C1 E2 to E1C2 of IGBT with a multimeter in diode mode the first one tested with red pen the value should be 0 3 0 6 test it contrary the value should be co Test G1 to E1 G2 to E2 of the IGBT 49 with a multimeter in capacitor mode the value tested should be 30 40 1 2 E 2 C Figure 5 24 IGBT test D Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board E System recover program 4 IGBT over current paralleled over current diagnosis A Exit the paralleled system act as paralleled system exit program described in the manual B Turn on the failure UPS again check the main board indicate light that if the IGBT over current or paralleled over current light is on the light is on means that it is IGBT over current else it should be paralleled over current turn off the UPS Turn off all the
26. lleled wire set the SW2 switch of the main board of two UPS to make them in two unit paralleled system mode Close the power bypass breaker of the two UPS close the battery breaker when the rectifier start normally press key on the panel to turn on the UPS After the UPS start normally test the voltage between two UPS output with same phase the value should be less than 10Vac as shown in figure 7 1 Close the two 57 output breaker without load test the three live lines output current and the value should be less than as shown in figure 7 2 Turn off the utility cabinet power breaker test the voltage two UPS output should be 50Hz and the voltage should be 220Vac test the output current should less than 3A Close the cabinet power breaker add the UPS load and test the two UPS output current the difference should less than 5 of nominal output current 58 Paralleled line Figure 7 1 Test the difference between two paralleled UPS output 59 Figure 7 2 Output current test Paralleled system connect drawing UPS1 UPS2 GND GND OUTPUT ANPUT ut ATTERY OUTPUT up GATTERY SSS PT eeng
27. off LCD display that rectifier is abnormal and the buzzer beep Intermittently 5 2 1 Diagnosis program UPS will shutdown rectifier Is AC input voltage when the AC input is 2 frequency abnormal abnormal it will recover when the AC input recover N Diagnosis ready program The rectifier fault that is Is inverter failure caused by inverter diagnosis N Rectifier fault diagnosis Inverter test UPS function test 5 2 2 Program describe D Utility voltage and frequency abnormal distinguish When the input utility voltage or frequency is abnormal close the power breaker the panel rectifier light will be on fault light will be off and the buzzer will beep intermittently Test the voltage between the input three phase live line 24 to neutral line the value should 165 275Vac and the frequency should be 40 65Hz as shown in figure 5 1 else it should be utility voltage or frequency abnormal Figure 5 1 The input utility test 2 Diagnosis ready program A Press the panel OFF key to turn off the UPS B Close the maintenance bypass switch or turn it to BYPASS as shown in figure 5 2 25 Figure 5 2 Maintenance bypass switch operation C Turn off the power bypass battery and output breaker D Discharge the rectifier capacitor with a resistance of 3XO 10W until the voltage of capacitor reduce to 0 VDC as shown in figure 5 3 Figure 5 3 Discharge the rectifi
28. ptom 4 When the utility is fail the UPS shut down output and the panel Geier Ee 41 EE BIETEN EI 41 5 4 2 NOUR LTE 42 5 5 Symptom 5 In utility mode UPS is normal but the battery breaker will jump off when it is turned on in battery MOE ccsccssscsssecscseonssecsoseneseseccessosesenccescssesscseseessssesees 43 5 6 Symptom 6 In utility mode UPS is normal but the UPS battery low protection enable when battery breaker is turned on in battery mode and the panel BAT LOW light on and the buzzer beep continually ccscccsssccscsccscsccscsccssscsssssscsccssscscsssssssnssees 44 5 6 1 Diagnosis programi EE 44 56 2 Program 44 5 7 Symptom 7 UPS switch to bypass panel FAULT indicate light and buzzer beeps Gont ul 46 5 8 Symptom 8 Close the bypass power breaker turn on the UPS and protection enable as soon as the inverter Start lt csccecscssessssecseseosscanscssensecnessvoosessoncesnessoocsesscnssensses 52 5 9 Symptom 9 protection enable as soon as the UPS switch to inverter output after IGIS turned OM ADOUESOSCCONGS eere ENEMIES 53 6 Series Connection Hot Standby System diagnosis 53 6 1 The standby UPS of series connection hot standby system diagnosis program 53 6 2 The main UPS of series connection hot standby system trouble shooting program EECHER 55 62 1 DTA SMOSIS PROSTAME ceret
29. r over current protection between two parallel units it will light Pressing the panel OFF key can clear the protection LED2 red Inverter output low voltage fault light LED3 red Inverter over heat indicate light LED4 red Inverter output over voltage indicate light LEDS red It will light when the inverter does not work LED6 red When the system appear 200 rated overload output phase unbalance output over voltage or low voltage software protection the light will light The protection can be cleared when the power bypass battery breaker are turn offed and closed again LED7 red Battery low indicate light it lights when battery low or the moment rectifier start LED8 red Parallel line fault indicate light LED9 green It will light when the system become synchronous 22 5 Some familiar symptoms and diagnosis 5 1 symptom 1 After close the power breaker or bypass breaker the panel PHASE light is on and the buzzer beep continually This is caused by the input AC power phase lose or phase wrong turn off the power breaker or bypass breaker test the voltage between terminal AC input three phase LA LB LC to N if one or two phase voltage is abnormal it should be input phase lose check the AC input line else it should be input phase wrong exchange any two lines of the three phase line and close the power breaker or bypass breaker 23 5 2 Symptom 2 The panel rectifier light is
30. rter output over voltage diagnosis program Inverter low output Inverter output low voltage diagnosis program Inverter over Inverter over temperature diagnosis program IGBT over current or IGBT over current or paralleled over current norallalad narrar aurrant 2 diagnosis program Inverter output overload Inverter output overload or phase unequal diagnosis program 47 i i Paralleled line failure Paralleled line failure diagnosis program UPS function test _ Program describe Confirm that which protection the UPS is in according to main board LED display Panel indicate light has been described before in the manual 2 Inverter output over voltage diagnosis program A Press panel off key to turn off the UPS test the voltage between CN2 1P and 3P on the PWM board as shown in figure 5 18 press panel on key to turn on the UPS the voltage tested should rise and stabilize at about 30Vac at last during the start process 48 If the voltage is too small is zero then the inverter output voltage sampling transformer on the power backup and transfer board should be bad if the value that voltage and frequency tested is variable then the inverter output capacitor should be bad C Diagnosis ready program act as 5 1 2 mentioned in the manual D Replace the bad power backup and transfer board or inverter output capacitor as shown in f
31. ss of AC power changed to DC power the inverter can supply more reliable and pure power to load as the rectifier can dispel the problems of the portent noise unstable frequency and so on When the utility is abnormal the battery connected to DC BUS will supply power to inverter to protect load from AC power interrupting when the inverter is failure such as over temperature short circuit output voltage abnormity overload and so on the inverter should shut off automatically If the utility is normal at this moment the switch will switch to bypass power to supply power to load When you are maintaining and the power must not be interrupted you can shut off the inverter and turn on the maintenance switch then turn off the rectifier and bypass breaker At this mode AC power goes through maintenance switch to supply power to load And at this time there will be no any electricity in the UPS inside and the maintenance person can work without any danger e 2 a E Ey 5 XN o E E T EH d d 3 The structure of UPS 3 1 Shape AA 3 1 ST5100 series 10 60KVA shape 3 2 Display panel LPs Shiva COVA IIT 200v COlL UPS 60KVA MODEL 60K VA INPUT 398V 50Hz OUTPUT 398V 50Hz Figure 3 3 Display panel mm Figure descripe Display UPS working parame
32. ter choke zs jm ER Figure 3 4 UPS terminal breaker 11 Parallel port Battery breaker Bypass breaker Three phase PWM board Main control board Main control board DSP Rectifier filter capacitor Main transformer output current sampling hall Inverter main transformer Inverter output capacitor Parallel average current sampling transformer Main transformer output current sampling hall Inverter main transformer Inverter driver board DC fuse IGBT filter board IGBT Rectifier SCR Figure 3 5 Structure of the UPS 4 Function describe 4 1 Function of system main parts 4 1 1 Rectifier control board function introduce Power supply board Power backup and transfer board Maintenance switch Utility power sampling transformer Bypass power sampling transformer Fans power sampling transformer Inverter bypass output SCR driver board Display control board LCD display board Rectifier SCR driver board Rectifier output current sampling hall AC input phase wrong lose test When AC input phase wrong or lose the rectifier shutdown 2 AC input voltage test When the AC input voltage beyond the range setting before the rectifier shutdown 3 Bypass input phase wrong lose test When bypass input phase wrong or 12 lose the DSP of the rectifier control board will conclude that the bypass is failure and send a bypass fault signal to inverter
33. ters and status 1 LCD 2 ON Press ON key for 1s will start inverter 3 OFF Press OFF key for 1s will shutdown inverter 4 Phase indicate light red It will light when AC input is phase lose or phase wrong 5 Rectifier indicate light green It will light when the rectifier works normally 6 Inverter indicate light green It will light when the inverter works normally 7 Bypass indicate light red It will light when the bypass output 8 Battery low indicate light red It will light when the battery low 9 Overload indicate light red It will light when the UPS is overload 10 Fault indicate light red It will light when the UPS is fault 11 Page up This key is display upward parameter setting function repeat 12 Enter Push this key to confirm the function 13 Back Push this key to back to previous page 14 Page down Push this key mean display downward parameter setting 15 left Push this key to check the item LCD display or turn on background light 3 3 Terminal and breaker Maintenance switch Output breaker Power breaker Terminal Terminal describe 3 4 Structure Parallel board IGBT current sampling hall Rectifier control board Rectifier control board DSP Fans control board DC buffer contactor Battery current sampling hall AC input fil
34. then the bypass will be prohibited 4 Bypass input voltage test When bypass input voltage beyond the range setting before the DSP of the rectifier control board will conclude that the bypass is failure and send a bypass fault signal to inverter then the bypass will be prohibited 5 Rectifier output over voltage current test When the rectifier output voltage or current beyond the range setting it will shutdown Charger over current protect When the charge current beyond the value setting the rectifier will shutdown Boost charge float charge voltage small adjust The charge voltage can be adjusted by adjusting potential RP6 RP8 of rectifier control board the float charge voltage can be adjusted from 390VDC to 400VDC the boost charge voltage can be adjusted from 400VDC to 410VDC Charge current setting Setting SW1 of rectifier control board can change charge current Rectifier over heat protection Rectifier will shutdown when it is over heat Rectifier six pulse driver signal control 4 1 2 Main control board function introduce DSP voltage stability control 2 Output frequency 50Hz 60Hz synchronous frequency range setting output voltage phase synchronous tiny adjust function 3 Inverter protect function over temperature over load output over voltage low voltage battery low switch control bus over current etc UPS failure appearances indicate 4 1 3 PWM board function introduce Three phase in
35. ture relay 29 being bad fans being bad or rectifier SCR being bad etc D Diagnosis of rectifier over heat When the rectifier over current protection enable test the voltage between U9A 1P U12 1P or V8 and GND C64A left pin if the value is about 5 VDC it should be rectifier over current or over charge protection as shown in figure 5 8 It may caused by rectifier output current sampling hall charge current sampling hall rectifier capacitor or rectifier SCR being bad Figure 5 8 Rectifier over current or charge over current protection test E Rectifier driver signal test Turn off the power breaker pull out CN12 of power backup and transfer board as shown in figure 5 9 Close the power breaker again test left pin of R98 R99 right pin of R100 R101 R102 upper pin of R103 to GND left pin of C64A as shown in figure 5 8 on the rectifier control board with a oscillograph the signal wave shape tested should be 50Hz pulse group as shown in figure 5 10 It can be tested with a multimeter the value should be 1 07 0 2VDC 1 4 0 2 30 CN12 Figure 5 10 Rectifier driver signal test and wave shape F SCR test test the SCR any two pin between each of the pin 1 2 3 with a multimeter the resistance tested should not be short circuit test pin 4 to 5 pin 6 to 7 the resistance should be 10 1000 as shown in figure 3 17 31 Figure 5 11 SCR test G Rectifier test Turn off the power breaker put on the C
36. verter signal produce Automatic equilibrium control 3 Current feedback and current limit protection 4 1 4 Display board function Some parameter value display 2 Battery test charge control 3 System alarm signal display 4 1 5 Rectifier driver board Rectifier driver signal isolate and enlarge 4 1 6 Inverter driver board Inverter driver signal isolate and enlarge 4 1 7 Bypass inverter static switch driver board Bypass inverter output SCR driver isolate and enlarge 4 1 8 Power board Supply 12VDC 12VDC 30 0 5VDC 24VDC power to the system 4 1 9 Power backup and transfer board Power transfer 4 1 10 Fans control board Fans speed control full speed half speed stop 2 DC buffer 3 DC voltage isolate and sample DC current isolate sample 4 1 11 Parallel board Parallel control function 4 2 Each board DIP switch setting 4 2 1 Display control board DIP switch setting Communication ID code setting There are 16 ID codes the value and the DIP switch setting is shown in the table below ID code DIP switch ID code DIP switch E U16 U15 U16 U15 016 015 016 015 11 11417114 016 015 016 015 12 LILIT U16 U15 U16 U15 TEAD U16 U15 U16 U15 PEEL U16 U15 U16 U15 SEIT
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