HPM3300 (10-300kVA) Series Principle & Maintenance Manual - V01

HPM 3300 (10-300kVA)
Series UPS Principle & maintenance
Shenzhen KSTAR Science & Technology Co., Ltd

V01
Contents
Contents ..................................................................................................................................... I
Figure Contents ........................................................................................................................ III
Table contents ........................................................................................................................... V
1. Product introduction ......................................................................................................... 1
1.1. Summary ............................................................................................................. 1
1.2. Appearance......................................................................................................... 1
1.3. Features .............................................................................................................. 2
1.4. Operating panel .................................................................................................. 5
2. System electrical diagram ................................................................................................. 8
2.1. Cabinet block diagram ........................................................................................ 8
2.2. Module block diagram ........................................................................................ 9
2.3. Power modue AC/DC & DC/DC principle circuit diagram................................. 10
2.4. Inverter DC/AC principle................................................................................... 10
2.5. Charging principle ............................................................................................. 11
3. Parameters ...................................................................................................................... 11
3.1. UPS specification .............................................................................................. 11
4. UPS internal structure ..................................................................................................... 14
4.1. UPS cabinet internal structure ......................................................................... 14
4.2. Power module internal structure ..................................................................... 27
5. Each PCB board and its interface signals ......................................................................... 30
5.1. PFC inductor board ........................................................................................... 30
5.2. PFC drive board ................................................................................................ 33
5.3. PFC power board .............................................................................................. 34
5.4. INV. Inductor board .......................................................................................... 35
5.5. Inverter power board ....................................................................................... 37
5.6. DSP board ......................................................................................................... 39
5.7. Parallel adapter board ...................................................................................... 41
6. Inspection before installation.......................................................................................... 42

I
V01
6.1. Room environment inspection ......................................................................... 42
6.2. UPS location inspection .................................................................................... 42
6.3. UPS visual inspection ........................................................................................ 43
6.4. External cables and switch capacity inspection................................................ 43
6.5. External auto switching and generator power distribution inspection............ 44
6.6. Battery inspection ............................................................................................ 44
7. UPS maintenance ............................................................................................................ 45
7.1. Guidelines for good service .............................................................................. 45
7.2. Security conditions ........................................................................................... 45
7.3. Shutdown-disassembly/reassembly UPS.......................................................... 46
7.4. Troubleshooting ............................................................................................... 47
7.4.1. Fault analysis .................................................................................................... 47
7.4.2. Troubleshooting ............................................................................................... 48
7.5. Battery replacement ......................................................................................... 52
7.5.1. Standard battery string..................................................................................... 52
7.5.2. Single Battery cabinet:...................................................................................... 53
7.6. PCB replacement .............................................................................................. 53
7.6.1. General instruction ........................................................................................... 53
7.6.2. EMI board replacement .................................................................................... 53
7.6.3. Replace DSP board............................................................................................ 54
7.6.4. Replace PFC inductor board ............................................................................. 54
7.6.5. Replace PFC power board................................................................................. 54
7.6.6. Replace INV inductor board.............................................................................. 55
7.6.7. Replace INV power board ................................................................................. 55
7.6.8. LCD on front panel ............................................................................................ 55
7.7. Replace fan ....................................................................................................... 56
7.8. PCB static maintenance .................................................................................... 56
7.8.1. PFC inductor board ........................................................................................... 56
7.8.2. PFC power board .............................................................................................. 56
7.8.3. INV inductor board ........................................................................................... 57
II
V01
7.8.4. INV power board .............................................................................................. 57
8. Single cabinet commissioning ......................................................................................... 57
8.1. Startup steps..................................................................................................... 57
8.2. Shutdown steps ................................................................................................ 58
8.3. Emergency shutdown instructions: .................................................................. 59
9. Parallel system commissioning........................................................................................ 59
9.1. Startup steps..................................................................................................... 59
9.2. Shutdown steps ................................................................................................ 59
9.3. Emergency shutdown ....................................................................................... 59
10. Software upgrade ............................................................................................. 60
10.1. Use XDS100V3 emulator to upgrade ................................................................ 60
10.2. Use 485 communication to upgrade ................................................................ 60
10.2.1. Note .......................................................................................................... 60
10.2.2. Software updating procedure ................................................................... 60
Appendix A Power module Jumpper cap configuration.......................................................... 67
Appendix B Power module fault judgement ........................................................................... 68
Appendix C Display query on reaons of no-transfer to inverter mode ................................... 72
Figure Contents
Figure 1. Appearance (stand-alone UPS)................................................................................... 1
Figure 2. Appearance (power module) ...................................................................................... 2
Figure 3. Operation panel ......................................................................................................... 5
Figure 4. Monitoring module operating interface ..................................................................... 5
Figure 5. Power module operating interface ............................................................................. 6
Figure 6. UPS Cabinet block diagram ........................................................................................ 8
Figure 7. Module block diagram ............................................................................................... 9
Figure 8. Power module AC/DC & DC/DC principle ................................................................. 10
Figure 9. Power module Bypass and inverter principle ........................................................... 10
Figure 10. Charging principle .................................................................................................. 11
Figure 11. 200/300K UPS cabinet Right view .......................................................................... 14
Figure 12. 200/300K UPS cabinet Left view ............................................................................ 15
Figure 13. 60/90/100/150K UPS cabinet Right view ............................................................... 16
Figure 14. 60/90/100/150K cabinet Left view......................................................................... 16
Figure 15. 300K UPS cabinet Monitoring module, bypass inductor board .............................. 17
III
V01
Figure 16. 200K UPS cabinet Monitoring module, bypass inductor board .............................. 17
Figure 17. 60/90/100/150K cabinet Monitoring module, Breaker .......................................... 18
Figure 18. 60/90/100/150K UPS Cabinet bypass inductor and battery fuse module .............. 18
Figure 19. Monitoring module internal view ........................................................................... 19
Figure 20. 300K UPS cabinet bypass inductor module Rear view............................................ 19
Figure 21. 300K UPS cabinet bypass inductor module internal view ...................................... 19
Figure 22. 200K UPS cabinet bypass inductor module Rear view............................................ 20
Figure 23. 200K UPS cabinet bypass inductor module Internal view ...................................... 20
Figure 24. 90K/150K UPS Cabinet bypass inductor and fuse module ..................................... 20
Figure 25. 90K/150K UPS Cabinet bypass inductor and battery fuse module internal view ... 21
Figure 26 . 60K/100K UPS Cabinet bypass infuctor and battery fuse module ......................... 21
Figure 27. 60K/100K UPS Cabinet bypass inductor and battery fuse module internal view ... 21
Figure 28. 300K UPS Cabinet powr distribution and parts internal view ................................ 22
Figure 29. 200K UPS Cabinet power distribution and part invernal view................................ 22
Figure 30. 60/90/100/150K UPS Cabinet, Status detection switch of Module hot-swappatble
......................................................................................................................................... 22
Figure 31. 200/300K UPS Cabinet EMI .................................................................................... 23
Figure 32. 60/90/100/150K UPS Cabinet EMI ......................................................................... 23
Figure 33. 200/300K UPS Cabinet rear view 1......................................................................... 24
Fiureg 34. 200/300K UPS cabinet rear view 2 ......................................................................... 24
Figure 37. 200/300K UPS Cabinet rear view5 ......................................................................... 26
Figure 38. 60/90/100/150K UPS Cabiner SPD and filter capacitor ......................................... 26
Figure 39. Front door display PCB transfer wiring and transfer PCB ....................................... 26
Figure 40. Touchable LCD on the front door ............................................................................ 27
Figure 41. Rear view of monitoring module ............................................................................ 27
Figure 42. Power module front side view ................................................................................ 27
Figure 43. Power morel back sideview .................................................................................... 28
Figure 44. PFC drive board ...................................................................................................... 28
Figure 45. PFC inductor board ................................................................................................. 28
Figure 46. PFC power board .................................................................................................... 29
Figure 47. Inverter inductor board .......................................................................................... 29
Figure 48. INV. Power board.................................................................................................... 29
Figure 49. Control detection board ......................................................................................... 29
Figure 50. PFC inductor board ................................................................................................. 30
Figure 51. PFC drive board interface ....................................................................................... 33
Figure 52. PFC power board .................................................................................................... 35
Figure 53. Inv. Inductor board ................................................................................................. 36
Figure 54 Inverter power board .............................................................................................. 38
Figure 55. DSP board ............................................................................................................... 39
Figure 56. Parallel adapter board interface ............................................................................ 41
Figure 57. Module ID (for example)......................................................................................... 58
Figure 58 Module front panel screw ....................................................................................... 61
IV
V01
Figure 59. Module mains switch ............................................................................................. 61
Figure 60. Prg2800_33.exe software ...................................................................................... 61
Figure 61. Software settings.................................................................................................... 62
Figure 62. comport .................................................................................................................. 62
Figure 63 communication port ................................................................................................ 63
Figure 64 Definition of port ..................................................................................................... 63
Figure 65. Updating command................................................................................................ 64
Figure 66 Ready for Updating ................................................................................................. 64
Figure 67 Command procesing................................................................................................ 65
Figure 68. Updating successful................................................................................................ 65
Figure 69. Close device ............................................................................................................ 66
Figure 70. Updating acomplish ............................................................................................... 66
Table contents
Tabel 1. LED decription .............................................................................................................. 6
Table 2. Button function ............................................................................................................ 7
Table 3. Power module LED description .................................................................................... 7
Table 4. Power module button function .................................................................................... 7
Table 5. HPM data sheet ......................................................................................................... 11
Table 6. PFC inductor board interface ..................................................................................... 30
Table 7. PFC drive board interface ........................................................................................... 33
Table 8. PFC power board interface......................................................................................... 35
Table 9. Inv. Inductor board interface ...................................................................................... 36
Table 10. Inv. Power board interface ....................................................................................... 38
Table 11. DSP board interface ................................................................................................. 39
Table 12 Parallel adapter board interface ............................................................................... 41
Table 13 Common fault troubleshooting ................................................................................. 49
Table 14 PFC inductor board ................................................................................................... 56
Table 15 PFC power board ....................................................................................................... 56
Table 16 INV inductor board.................................................................................................... 57
Table 17 INV power board ....................................................................................................... 57
V
V01
HPM 33 series UPS Principle and Maintenance

1. Product introduction
1.1. Summary
HPM33 Series is a kind of high-frequency online intelligent UPS and adopts double DSP control chips,
advanced control technology and double conversion topology. It eliminates various interference of
the grid and makes the output a stable and pure sine wave power with low noise, no interfence and
low distortion. With strong load capacity, good load compatibility, wide input voltage and frequency
range, excellent generator compatibility and zero transfer time, it greatly meets the requirement of
variety of applications. Comprehensive protection enhances the stability and reliability of the
system. It supports perfect monitoring function via the RS232 and RS485. Large LCD is provided with
both English and Chinese operation. The monitoring components can monitor the UPS running
staturs, send out instructions and keep the history record about fault. Intelligent battery
management, equalized and floating charging auto conversion, battery discharge time prediction
and battery self-test can extend the battery life. It can be used in advanced network systems.
★ power range: 10KVA-300KVA, up to 4 cabinets can be parallel

★ Working mode: High frequency intelligent online (3-phase in to 3-phase out)
★ Application: Work station, large network server, and large-scale computer rooms and data center
1.2. Appearance
Figure 1. Appearance (stand-alone UPS)
1 / 79
V01
Figure 2. Appearance (power module)
1.3. Features
◆ Three-phase in to three-phase out UPS
This series is three-phase in to three-phase out UPS with large capacity, the input current of three
phase is balanced which can balance the load of each phase.
◆ Digital control
Digital control is used for all parts of the UPS, which makes the performance indicators very
excellent and the system more stable. It not only has self-protection and fault diagnosis, but also can
avoid risks of analog device failure, which allows the control system more reliable.
◆ 19-inch standard cabinet
HPM33 series UPS adopts 19-inch standard cabinet, which looks nice and can perfectly match with
the applications and save the space as well. According to the user’s requirement, 1.4m and 2m
height cabinet can be provided.
◆ Modularized design
HPM33 series take the modularized design, the power of module is 25KVA/30KVA. The whole UPS
comprises 1-10 modules in parallel, which can reach 300KVA. The user can gradually increase the
module numbers according to the load. Hot swap technology is used between module and cabinet,
which can realize adding or removing the module online. Therefore, “zero” maintenance time is
achieved.
◆ High power-density design
The height of the single module of HPM33 series is 3U, a standard 1.4m cabinet can hold 5 pieces of
modules (the max power of single module can reach 30KVA), so the whole capacity of each 1.4M
cabinet can reach 150KVA; a standard 2M cabinet for 10 modules(30KVA for each module) can reach
max. 300KVA.
◆ N+X parallel redundancy
The HPM33 series UPS adopts N+X parallel redundancy design, user can set different redundancy
according to the importance of the load. While the redundancy modules are set more than two, the
availability of UPS system will achieve 99.999%, the MTBF (Meantime before Failure) is up to
250,000 hours. They can fully satisfy the required reliability of the critical load connected. Through
LCD display setting, you may configure the required quantity of the redundancy unit. When the load
connected is over the number of the redundancy, the UPS will alert right away.
2 / 79
V01
◆ The flexible parallel redundant setting
This series can set the number of redundancy modules. When the load exceeds the redundancy
setting, UPS can still work normally and simultaneously send out corresponding warning as long as
the load doesn’t exceed the total capacity of modules.
◆ Parallel Redundant control system
Each module of HPM33 series UPS has its independent control system. The module is separately
controlled base on the sharing information. The fault module will immediately exit from the system,
which will not do any harm to the system. With hot swap technology, it is easy to remove the fault
module for repair.
◆ Optimizing distributed convergence for the cabinet
HPM33 series UPS improved modular layout and brought in distribution convergence concept,
which protect the security of the parallel system.
◆ Separated Bypass
HPM series UPS is powered by separate bypass. Each module has built-in auto bypass switch and
bypass current sharing inductor, which provides a good current sharing of the system bypass.
◆ Common Battery when parallel
HPM33 series UPS can be paralleled with shared battery pack. The battery number has nothing with
the parallel units, which greatly reduces the number of battery configuration. The user can
configure the battery according to the backup time.
◆ Selectable external battery number(32-40pcs optional)
The external battery number can be selected from 32/34/36/38/40pcs according to the user’s
requirement.
◆ Settable charging current
By setting the battery capacity configured by user in the LCD, the reasonable charging current can
be automatically allocated. The proper charging current can be also set in LCD. Constant voltage
charging mode, constant current charging mode and floating charging mode can auto-switch
smoothly.
◆ Intelligent charging method
Advanced two-way, three-stage charging method is adopted. At the first stage, fast recharge with
constant large current to 90% capacity; at the second stage, constant voltage charge can activate the
battery characteristics and make the battery full; at the third stage, floating mode operates. This
method can provide a balance between the fast charge and extended the battery life, which saves
the battery investment.
◆ Touch-screen Super-large LCD display
HPM33 series UPS adopts super large LCD (320*240 dots) display with both English and Chinese
languages. It provides rich UPS status, warning and fault messages. The user can easily operate LCD
3 / 79
V01
with the menu-driven way. The setting can be realized by touching the LCD without pressing the
button.
◆ Each module with indiviaul LCD display
Each module of HPM33 series UPS has both LCD and LED display, which allows user a better
understanding of module status and running parameters such as input/output voltage and
frequency, load capacity, battery capacity, internal temperature and ect.
◆ Intelligent monitoring function
The remote monitoring to UPS can be realized with SNMP card.
◆ Build a small and medium-sized distribution system
HPM33 series UPS provides a rich option. User can select isolation transformer, distribution panel,
SNMP card, relay card to form a small and medium-sized distribution system.
◆ Easy maintenance
HPM33 series UPS provides maintenance bypass function. When emergency occurs, it can transfer
to maintenance bypass to power the load, and the personnel can safely do the maintenance at the
same time.
The UPS provides
◆ Short downtime
If the number of faulty module is no more than redundant module, it is possible to replace the
faulty module online without affecting the other module. The downtime for repair is zero in this
case. If the number of faulty module is more than redundant module, the downtime will not exceed
5min due to the module replacement.
◆ Centralized monitoring module
HPM33 series UPS provides the centralized monitoring module, which supports the hot-swapped
function. When pull out the monitoring module, the system can still work normally.
◆ EPO function
An EPO (emergency power off) button is embedded in the panel of monitoring unit. Press the EPO
function in case of emergency, the UPS will shutdown. A transparent cover is provided for EPO
button to avoid misuse. It also has remote emergency power off (REPO) function.
4 / 79
V01
1.4. Operating panel
LCD touch Exit

screen
Arrow
Enter
Figure 3. Operation panel
Monitoring
unit switch
Fault LED Inverter power-on

EPO button
Bypass LED
Rectifier LED Fault clear Mute button
Battery LED
Inverter shutdown
Inverter LED Output LED

Figure 4. Monitoring module operating interface
5 / 79
V01
Status LED
Cycle button
1. Fault alarm
2. Bypass
OFF button
3. Battery
4. Mains output
LCD display ON button
Figure 5. Power module operating interface
The operating panel is divided into three parts
◆ LCD display and four buttons are above the front door
Enter the different menu from LCD by touching menu or arrow, exit, enter buttons to check the
various data, information and set the parameters.
◆ Running status LED and relevant buttons in the monitoring module
“Power on/off”button in the monitoring module can turn on/off the monitoring unit.
Running status LED can indicate the UPS status.
Control button can control the UPS status.
Tabel 1. LED decription
Name Status Description

Rectifier LED Green on Rectifier normal
Green off Mains fail, rectifier not work
Bypass LED Green on Bupass output
Yellow flash Bypass power abnormal or out of range, or bypass switch fail
Green off Bypass ok, no output
Battery LED Green on Battery output
Green flash Battery discharge termination notice
Yellow flash Battery abnormal(no battery or battery fail)
Inverter LED Green on Inverter output
Green off NO inverter output
6 / 79
V01
Output LED Green on UPS output OK
Green flash UPS output overload
Green off UPS no output
Fault LED Red on UPS fault alarm
Red flash UPS normal
Table 2. Button function
Button Function
EPO CUT OFF OUTPUT, RECTIFIER, INVERTER, STATIC BYPASS AND BATTERY STOP
WORKING
Note: “EPO” will cause power down for load
INVERTER ON INVERTER ON
INVERTER OFF INVERTER OFF
FAULT CLEAR CLEAR GENERAL FAULT ALARM
SILENCE ON/OFF ON/OFF BUZZER
◆ Running status LED, LCD and relevant buttons
The LCD and LED in the power module only show the status of this module. The button is also only
available for this module
Table 3. Power module LED description
NAME STATUS DESCRIPTION

Red on UPS module fault alarm
Fault alarm LED
Red flash UPS module ok
Green on UPS module bypass output
Bypass LED Green flash Bypass power abnormal or out of range, or bypass switch fail
Green off Bypass ok, no bypass output
Green on UPS module is powered by battery
Battery LED Green flash UPS module battery discharge termination notice
Green off Battery anbormal(no battery or battery fail)
Green on UPS module mains output
Mains output LED
Green off UPS module no mains output
Table 4. Power module button function
BUTTON FUNCTION
Cycle Enter power module menu to check the UPS running status and data
ON INVERTER ON
Turn off inverter and transfer to bypass output in line mode (bypass normal)
OFF Turn off inverter in battey mode, power module power down
Battery cold start under the shutdown condition
7 / 79
V01
2. System electrical diagram
2.1. Cabinet block diagram
LCD display Communication
Centralized monitoring module
UPS module 10#
UPS module 9#
Input
Output
Switch
Battery
UPS module 2#
Output
UPS module 1#
Bypass inductor
BYPASS
Maint bypass breaker
Figure 6. UPS Cabinet block diagram
As shown above, for HPM3330-300KVA UPS, the main road and bypass is separated. The bypass
power goes to each module via the bypass inductor to realize the separate bypass output. The
mains and battery powers each module via the copper bar. The 10 modules share one output switch.
In maintenance bypass mode, the bypass outputs directly via the maint switch.
8 / 79
V01
2.2. Module block diagram
Bps
Bp break
Bps EMI
EMI
Main EMI DC/AC

AC/DC
Breaker DC/DC Output
INV
FUSE
Battery
CHARGER
FUSE
Figure 7. Module block diagram
As shown above, each power module has bypass air-switch and main air-switch. When close the
bypass air-switch, the bypass power of the cabinet will go into the UPS module. When one module
is powered, it will compete with other moduls to be a host. The module detects the cabinet output
air-switch and bypass voltage, frequency, phase sequence. If output air-switch is closed and bypass
votage and frequency is in the range, the UPS will send out bypass output command, all the
matching modules will output from bypass while bypass LEDs will be on.
Close the main switch, if the mains voltage, frequency and phase sequence are in the range, UPS will
soft start. When bus voltage rises around 310V, PFC boost begins to work and the bus voltage will be
up to about 370V. Inverter starts. When all the power inverters are ready, the host will send out
command to transfer to inverter. If bypass voltage, frequency and phase sequence are normal, the
inverter voltage will track the bypass power and switch to inverter output without interruption, or
the module will transfer to inverter intermittently. Inverter LED on and bypass LED off, the inverter
will provide power. If the battery is normal, the module will activate the charger to charge the
battery.
The module supports hot-swapped. When loose the fixing screw at the top right corner, the module
will exit and can be pulled out for maintenance or replacement. If there is only one module, it will
not exit to avoid power down. Only fix the screw well when insert the new module, it wil begin to
work. At the moment, if the host is in inverter mode, module will not enter the bypass status and
directly output from inverter when inverter is ready instead.
UPS module detects maintenance air-switch at any time. When remove the baffle of the switch,
module will transfer to bypass status. Now close the maintenance air-switch for supplying power
from bypass. When finish maintenance, the air-switch cannot be open until the module is in bypass,
or it will cause the power down of load.
9 / 79
V01
2.3. Power modue AC/DC & DC/DC principle circuit diagram
A B C
Figure 8. Power module AC/DC & DC/DC principle
As shown above, Part A (yellow box) shows the rectifier circuit, Part B (blue box) shows the battery
input circuit, Part C (other part) shows the boost circuit. A and C form the PFC rectifier circuit while
The battery boost circuit is composed by Part B and Part C.
2.4. Inverter DC/AC principle
Figure 9. Power module Bypass and inverter principle
10 / 79
V01
As shown above, A (yellow box) represents bypass circuit of power module, B (blue box) shows the
inverter circuit, which converts the Bus voltage into the AC output.
2.5. Charging principle
Battery
Charging fuse
Figure 10. Charging principle
As shown above, charger reduces the Bus voltage to a suitable voltage to charge the battery.
3. Parameters
3.1. UPS specification
Table 5. HPM data sheet
Model 60KVA 100KVA 200KVA

10~60kVA 10~100kVA 10~200kVA
UPS Cabinet
Capacity 9~54kW 9~90kW 9~180kW
UPS Module 10kVA/9kW; 15kVA/13.5kW; 20kVA/18kW
Phase 3 Phase 4 Wires and Ground
Rated Voltage 380/400/415Vac
Voltage Range 208~478Vac
Frequency Range 40Hz-70Hz
Power Factor ≥0.99
Current THDi ≤3%(100% nonlinear load)
Input
380V: +25 %( optional +10%, +15%, +20%)
400V: +20 %( optional +10%, +15%)
Bypass Voltage Range 415V: +15 %( optional +10%)
Min. voltage: -45% (optional -20%, -30%)
Frequency protection range: ±10%
Generator Input Support
Output
11 / 79
V01
Power Factor 0.9
Voltage Regulation ±1%
Utility Mode ±1%, ±2%, ±4%, ±5%, ±10% of the rated frequency (optional)
Frequency
Battery Mode (50/60±0.2%)Hz
Crest Factor 3:1

≤2% with linear load
THD
≤5% with non linear load
Efficiency 95.5% at normal mode
Voltage ±192V\±204V\±216V\±228V\±240V DC; battery quantity (optional)
UPS Cabinet 18A Max. 30A Max. 60A Max.
Battery Charging
UPS Module 6A Max.
Current
charge current can be set according to battery capacity installed
Transfer Time Utility to Battery : 0ms; Utility to bypass: 0ms
Load≤110%, last 60min; ≤125%, last 10min, ≤150%, last 1min;
AC Mode
≥150% turn to bypass mode immediately;
Protection Overload
Load≤110%, last 10min; ≤125%, last 1min;
Bat. Mode
≤150%, last 1S; ≥150% shut down UPS immediately.
Communication Interface RS232, RS485, Intelligent slot x 2, Dry Contact
Operating Temperature 0℃～40℃
Storage Temperature -25℃～55℃
Environment
Humidity 0～95% non condensing
Altitude < 1500m
Unit UPS Cabinet 840x600x1400mm 1100x600x2000mm
Dimensions
UPS Module 580x443x131mm
(D*W*H)
Other
UPS Cabinet 149 152 290
Weight (Kg)
UPS Module 10kVA:26;15kVA:30;20kVA:31
Safety IEC/EN62040-1,IEC/EN60950-1
STANDARDS IEC/EN62040-2,IEC61000-4-2,IEC61000-4-3,IEC61000-4-4,IEC61000-
EMC
4-5,IEC61000-4-6,IEC61000-4-8
Model 90KVA 150KVA 300KVA

25~90kVA 25~150kVA 25~300kVA
UPS Cabinet
Capacity 22.5~81kW 22.5~135kW 22.5~270kW
UPS Module 25kVA/22.5kW; 30kVA/27kW
Input Voltage Range 208~478Vac
Frequency Range 40Hz-70Hz
Power Factor ≥0.99
12 / 79
V01
Current THDi ≤3% (100% nonlinear load)
380V: +25 % (optional +10%, +15%, +20%)
400V: +20 % (optional +10%, +15%)
Bypass Voltage Range 415V: +15 % (optional +10%)
Min. voltage: -45% (optional -20%, -30%)
Frequency protection range: ±10%
Generator Input Support
Power Factor 0.9
Voltage Regulation ±1%
Utility Mode ±1%,±2%,±4%,±5%,±10% of the rated frequency(optional)

Output
Frequency
Battery
(50/60±0.2%)Hz
Mode
Crest Factor 3:1
≤2% with linear load
THD
≤5% with non linear load
Efficiency 95.5% at normal mode
Voltage ±192V\±204V\±216V\±228V\±240V DC; battery quantity(optional)
UPS Cabinet 30A Max. 50A Max. 100A Max.

Battery Charging
UPS Module 25kVA: 6A Max. ; 30kVA: 10A Max.
Current
charge current can be set according to battery capacity installed
Transfer Time Utility to Battery : 0ms; Utility to bypass: 0ms
Load≤110%, last 60min; ≤125%, last 10min; ≤150%: last 1min;
AC Mode
≥150% turn to bypass mode immediately.
Protection Overload
Load≤110%, last 10min; ≤125%, last 1min; ≤150%, Last 1S; ≥150%
Bat. Mode
shut down UPS immediately.
Communication Interface RS232, RS485, Intelligent slot x 2, Dry Contact
Operating Temperature 0℃～40℃
Storage Temperature -25℃～55℃
Environment
Humidity 0～95% non condensing
Altitude < 1500m
Unit Dimensions UPS Cabinet 840x600x1400mm 1100x600x2000mm
(D*W*H) UPS Module 580x443x131mm

Other
UPS Cabinet 158 170 307
Weight (Kg)
UPS Module 25kVA:32;30kVA:33.5
Safety IEC/EN62040-1,IEC/EN60950-1
STANDARDS IEC/EN62040-2,IEC61000-4-2,IEC61000-4-3,IEC61000-4-4,IEC6100
EMC
0-4-5,IEC61000-4-6,IEC61000-4-8
13 / 79
V01
4. UPS internal structure
4.1. UPS cabinet internal structure
Power moduel
Input EMI board,
from bottom to top: Power moduel
1, 2…, 10 parallel adapter
board, from bottom
to top: 1, 2…, 10
Figure 11. 200/300K UPS cabinet Right view
14 / 79
V01
Figure 12. 200/300K UPS cabinet Left view
15 / 79
V01
Input PDU: Mains

input and bypass
Power moduel input, from
parallel adapter bottom to top, 1,
board, from bottom
to top: 1, 2…, 5
Detection cable of
power module
plugin signal,
from bottom to
top, 1, 2…, 5
Figure 133. 60/90/100/150K UPS cabinet Right view
Output PDU:
Ouput & battery
cable, from bottom
to top, 1, 2…, 5
Figure 144. 60/90/100/150K cabinet Left view
16 / 79
V01
Monitoring module
Bypass inductor module
Output Switch Maintain Bypass switch and baffle
Figure 155. 300K UPS cabinet Monitoring module, bypass inductor board
Monitoring
module
Bypass
inductor
module
Aids Output air-switch

Mains switch
& baffle
Figure 166. 200K UPS cabinet Monitoring module, bypass inductor board
17 / 79
V01
Output Switch
Maintain Bypass Battery Switch

switch and baffle
Figure 177. 60/90/100/150K cabinet Monitoring module, Breaker
Bypass inductor &

battery fuse module,
from left to right, 1,
2…, 5
Figure 188. 60/90/100/150K UPS Cabinet bypass inductor and battery fuse module
18 / 79
V01
Connection
terminals
Dry contact board LED board
Communication
adapter board Monitoring board
Relay slot
SNMP card
Power board
Figure 199. Monitoring module internal view
Connection terminals
Figure 200. 300K UPS cabinet bypass inductor module Rear view
Bypass fuse board
Bypass Fuse PCB
Bypass inducotor
board
Bypass
inductor PCB
Figure 211. 300K UPS cabinet bypass inductor module internal view
19 / 79
V01
Figure 222. 200K UPS cabinet bypass inductor module Rear view
Bypas fuse PCB
Bypass
inductor PCB
Figure 233. 200K UPS cabinet bypass inductor module Internal view
Figure 244. 90K/150K UPS Cabinet bypass inductor and fuse module
20 / 79
V01
Battery fuse Bypass inductor PCB Bypass fuse PCB
Figure 255. 90K/150K UPS Cabinet bypass inductor and battery fuse module internal view
Figure 26 . 60K/100K UPS Cabinet bypass infuctor and battery fuse module
Battery Fuse Bypass inductor PCB Bypass Fuse PCB
Figure 2727. 60K/100K UPS Cabinet bypass inductor and battery fuse module internal view
21 / 79
V01
Monitoring unit
hot-swappable Status detection switch of
terminal Module hot-swappatble
Bypass inductor
module hot-swappable
terminal
Distriution unit
copper bar &
wiring
Figure 28. 300K UPS Cabinet powr distribution and parts internal view
Monitoring unit
hot-swappable
terminal
Bypass inductor
module
hot-swappable
terminal
Figure 299. 200K UPS Cabinet power distribution and part invernal view
Status detection switch of

Module hot-swappatble
Figure 30. 60/90/100/150K UPS Cabinet, Status detection switch of Module hot-swappatble
22 / 79
V01
Input EMI PCB

Output EMI PCB
Figure 31. 200/300K UPS Cabinet EMI
Output EMI PCB Input EMI PCB
Figure 3232. 60/90/100/150K UPS Cabinet EMI
23 / 79
V01
Output wiring
copper bar
Mains input
filter
capacitor
Mains input
Bypass input wiring filter capacitor
copper bar switch
Mains input SPD
Figure 333. 200/300K UPS Cabinet rear view 1
Mains input
wiring copper
bar
Battery “N”
wiring
copper bar
Fiureg 34. 200/300K UPS cabinet rear view 2
24 / 79
V01
Output EMI
Capacitor
Bypass input
EMI capacitor
Bypass input EMI Output EMI Capacitor

capacitor switch switch
BAT “-“wiring
copper bar
BAT “-“Fuse
BAT “+“Fuse
BAT “+“wiring
copper bar
25 / 79
V01
Figure 377. 200/300K UPS Cabinet rear view5
Output EMI
Capacitor
Bypass input
Output EMI EMI capacitor
Capacitor switch
switch
Mains input EMI
Bypass input capacitor
EMI capacitor
Mains input SPD
Mains input EMI
capacitor switch
Figure 388. 60/90/100/150K UPS Cabiner SPD and filter capacitor
Figure 39. Front door display PCB transfer wiring and transfer PCB
26 / 79
V01
Button board
Terminal to
monitor module
Touch sreen board
Adapter
board
Figure 40. Touchable LCD on the front door

Communication port
Signal
Intelligent
hot-swappable port
card (left)
Dry contact port SNMP (right)
EPO port
LCD port
Figure 411. Rear view of monitoring module
4.2. Power module internal structure
Input EMI
Magnetic ring
PFC inductor PCB 风扇
PFC driver PCB
LCD
Battery fuse
Switch
Inverter inductor
Fan
PCB
Output EMI
Magnetic ring
Figure 422. Power module front side view
27 / 79
V01
INV. Powe
Fan PCB
DSP control
Switch
detection PCB
Fan
PFC Power PCB
Figure 433. Power morel back sideview
Figure 444. PFC drive board
2pcs charging
inductors 6pcs PFC inductors
Bypass relay+SCR
Figure 455. PFC inductor board
28 / 79
V01
Charging fuse IGBT drive

board
Figure 466. PFC power board
BUS capacitor
3pcs inverter
SCR drive board
6pcs inv. inductors

3pcs inverter
fuse
6pcs inv.
capacitor
Figure 477. Inverter inductor board
Auxiliary power heatsink
Figure 488. INV. Power board
Figure 499. Control detection board
29 / 79
V01
5. Each PCB board and its interface signals
5.1. PFC inductor board
Function overview
 Mains rectifier
 Battery input circuit
 Bypass static switch
 Boost inductor circuit
 Charging inductor circuit
Figure 50. PFC inductor board
Table 6. PFC inductor board interface
No. Definition Specification Name Description

Name: blade terminal
BAT- BAT-
P8 Description: UHTWSZ Wiring copper bar II BAT- input
BAT- input
welded assemblies plated bright nickel
BPS_A Name: blade terminal
Bps A phase
P11 Bps A phase Description: 4PIN 10A M4 screw hole straight leg BPS_A
output
output 8*8.4*11.1mm T0.8mm tinned copper
BPS_B Name: blade terminal
Bps B phase
P13 Bps B phase Description: 4PIN 10A M4 screw hole straight leg BPS_B
output
Assistant Name: neilsbed Assistant
P6 power Description: 1121S-2P P=3.96mm 180° single row power 15V+
15V+ square PIN white
PFC drive Name: neilsbed PFC drive board
J1
board signal Description: 1121S-6P P=3.96mm 180° single row signal
30 / 79
V01
square PIN white
BPS_C Name: blade terminal
Bps C phase
P17 Bps C phase Description: 4PIN 10A M4 screw hole straight leg BPS_C
output
Name: neilsbed
relay/SCR drive relay/SCR drive
P15 Description: 301S-10P P=2.54mm 180° two rows
signal signal
square PIN black
BAT+
P5 Description: UHTWSZ Wiring copper bar II BAT+ BAT+ input
BAT+ input
BPS_A_IN Bps A phase
P10 Description: 4PIN 10A M4screw hole straight leg BPS_A_IN
Bps A phase input input
8*8.4*11.1mm T0.8mm tinned copper
CHARGE+
Name: neilsbed
CHARGE- CHARGE+ Charging voltage
P21 Description: 1121S-3P P=3.96mm 180° single row
Charging CHARGE- sampling
square PIN white
voltage sample
N N
P25 Description: UHTWSZ Wiring copper bar II Neutral
Neutral
BPS_B_IN BPS_B_IN Bps B phase
P12 Description: 4PIN 10A M4 screw hole straight leg
Bps B phase input input
BPS_C_IN
P14 Description: 4PIN 10A M4 screw hole straight leg BPS_C_IN Bps C phase input
Bps C phase input
A Name: blade terminal
Main A phase
J2 Main A phase Description: 4PIN 10A M4 screw hole straight leg A
input
input 8*8.4*11.1mm T0.8mm tinned copper
B Name: blade terminal
Main B phase
J13 Main B phase Description: 4PIN 10A M4 screw hole straight leg B
input
C Name: blade terminal
Main C phase
J14 Main C phase Description: 4PIN 10A M4 screw hole straight leg C
input
A Name: neilsbed
Main A phase
J23 Main A phase Description: 1121S-3P P=3.96mm 180° single row A
input sampling
input sampling square PIN white
B&C
Name: neilsbed Main B&C
Main B&C
J24 Description: 1121S-3P P=3.96mm 180° single row B&C phase input
phase input
square PIN white sampling
sampling
J3 positive Name: neilsbed CHRG_SCR+ positive
31 / 79
V01
charger SCR drive Description: 2001S-2P P=2.54mm 180° single row charger SCR drive
square PIN white
Name: neilsbed
Negative Negative
J4 Description: 2001S-2P P=2.54mm 180° single row CHRG_SCR-
charger SCR drive charger SCR drive
square PIN white
Negative Name: neilsbed Negative
J9 battery SCR drive Description: 2001S-2P P=2.54mm 180° single row BAT1-SCR1 battery SCR drive
1 square PIN white 1
Name: neilsbed
Bypass SCR Bypass SCR
P18 Description: 2001S-2P P=2.54mm 180° single row BPS_B_RLY
drive signal drive signal
square PIN white
Positive Name: neilsbed Positive
J8 battery SCR drive Description: 1121S-2P P=3.96mm 180° single row BAT1+SCR battery SCR drive
A phase Name: neilsbed
A phase bypass
J22 bypass SCR1 Description: 1121S-2P P=3.96mm 180° single row BPS_A_SCR1
SCR1 drive
drive square PIN white
A phase Name: neilsbed
A phase bypass
J25 bypass SCR2 Description: 1121S-2P P=3.96mm 180° single row BPS_A_SCR2
SCR2 drive
B phase Name: neilsbed
B phase bypass
J26 bypass SCR1 Description: 1121S-2P P=3.96mm 180° single row BPS_B_SCR1
SCR1 drive
B phase Name: neilsbed
B phase bypass
J27 bypass SCR2 Description: 1121S-2P P=3.96mm 180° single row BPS_B_SCR2
SCR2 drive
C phase Name: neilsbed
C phase bypass
J28 bypass SCR Description: 1121S-2P P=3.96mm 180° single row BPS_C_SCR1
SCR1 drive
drive1 square PIN white
C phase Name: neilsbed C phase bypass
J29 BPS_C_SCR2
bypass SCR Description: 1121S-2P P=3.96mm 180° single row SCR2 drive
32 / 79
V01
drive2 square PIN white
5.2. PFC drive board

Function overview:
 Bypass SCR drive circuit
 Battery SCR drive circuit
 Charging SCR drive circuit
Figure 51152. PFC drive board interface
Table 7. PFC drive board interface

Name: neilsbed
PFC drive board PFC drive board
J1 Description: 1121S-6P P=3.96mm 180° single row
signal signal
square PIN white
Name: neilsbed
positive charger positive charger
J13 Description: 2001S-2P P=2.54mm 180° single row CHRG_SCR+
SCR drive SCR drive
square PIN white
Name: neilsbed negative
negative charger
J14 Description: 2001S-2P P=2.54mm 180° single row CHRG_SCR- charger SCR
SCR drive
square PIN white drive
negative battery
J9 Description: 2001S-2P P=2.54mm 180° single row BAT1-SCR1 battery SCR
SCR drive1
square PIN white drive1
negative battery
SCR drive2
33 / 79
V01
negative battery
SCR drive3
Name: neilsbed
bypass SCR drive bypass SCR
J23 Description: 2001S-2P P=2.54mm 180° single row BPS_B_RLY
signal drive signal
square PIN white
Name: neilsbed
positive battery positive battery
J6 Description: 1121S-2P P=3.96mm 180° single row BAT1+SCR
SCR drive1 SCR drive1
square PIN white
Name: neilsbed
square PIN white
Name: neilsbed
square PIN white
Name: neilsbed
A phase bypass A phase bypass
J2 Description: 1121S-2P P=3.96mm 180° single row BPS_A_SCR1
SCR1 drive SCR1 drive
square PIN white
Name: neilsbed
A phase bypass A phase bypass
J3 Description: 1121S-2P P=3.96mm 180° single row BPS_A_SCR2
square PIN white
Name: neilsbed
B phase bypass B phase bypass
J4 Description: 1121S-2P P=3.96mm 180° single row BPS_B_SCR1
square PIN white
Name: neilsbed
B phase bypass B phase bypass
J5 Description: 1121S-2P P=3.96mm 180° single row BPS_B_SCR2
square PIN white
Name: neilsbed
C phase bypass C phase bypass
J10 Description: 1121S-2P P=3.96mm 180° single row BPS_C_SCR1
SCR drive1 SCR1 drive
square PIN white
Name: neilsbed
C phase bypass C phase bypass
J20 Description: 1121S-2P P=3.96mm 180° single row BPS_C_SCR2
SCR drive2 SCR2 drive
square PIN white
5.3. PFC power board

Function overview:
 Boost circuit IGBT
 Charging circuit MOSFET
 Battery soft start resistor
34 / 79
V01
Figure 53. 54PFC power board
Table 8. PFC power board interface

Name: neilsbed
Assistant Assistant
P6 Description: 1121S-2P P=3.96mm 180° single row 15V+
power 15V+ power
square PIN white
P9 BUS+ Description: 4PIN 10A M4 screw hole straight leg BUS+ BUS+
P10 BUS- Description: 4PIN 10A M4 screw hole straight leg BUS- BUS-
PFC/charger drive 301S-30P P=2.54mm 180° two rows square PIN PFC/charger
P14
signal black horn drive signal
Assistant Name: neilsbed
Assistant
P20 power Description: 1121S-2P P=3.96mm 180° single row 15V+
power
15V+ square PIN white
BAT+/BAT- Name: neilsbed
battery cold
P22 battery cold start Description: 1121S-3P P=3.96mm 180° single row BAT+/BAT-
start power
power square PIN white
BUS+/BUS- Name: neilsbed BUS+/BUS-
J18 BUS+/BUS- Description: 1121S-3P P=3.96mm 180° single row BUS+/BUS- Voltage
Voltage detection square PIN white detection
BAT+/BAT- Name: neilsbed BAT+/BAT-
J25 BAT+/BAT- Description: 1121S-3P P=3.96mm 180° single row BAT+/BAT- Voltage
Voltage detection square PIN white detection
5.4. INV. Inductor board

Function overview:
 INV LC filter
 Output current detection
 Inv. inductor current detection
35 / 79
V01
Figure 553. Inv. Inductor board
Table 9. Inv. Inductor board interface

VOUT_A
P2 Description: 4PIN 10A M4screw hole straight VOUT_A Output A phase
Output A phase
leg 8*8.4*11.1mm T0.8mm tinned copper
BPS_A Name: blade terminal
Bypass A phase
P3 Bypass A phase Description: 4PIN 10A M4screw hole straight BPS_A
Output
Output leg 8*8.4*11.1mm T0.8mm tinned copper
BPS_B Name: blade terminal
Bypass B phase
P5 Bypass B phase Description: 4PIN 10A M4screw hole straight BPS_B
Output
VOUT_B
P6 Description: 4PIN 10A M4screw hole straight VOUT_B Output B phase
Output B phase
BPS_C Name: blade terminal
Bypass C phase
P8 Bypass C phase Description: 4PIN 10A M4screw hole straight BPS_C
Output
VOUT_C
P9 Description: 4PIN 10A M4screw hole straight VOUT_C Output C phase
Output C phase
N
P12 Description: UHTWSZ Wiring copper bar II N Neutral
Neutral
N
Neutral
36 / 79
V01
N
Neutral
Name: blade terminal PH2_INV_FUS
PH2_INV_FUSE-P2
P40 Description: UHTWSZ Wiring copper bar II E-P2 B phase inv.fuse
B phase inv.fuse
PH3_INV_FUSE-P2
P42 Description: UHTWSZ Wiring copper bar II E-P2 C phase inv.fuse
C phase inv.fuse
PH1_INV_FUSE-P2
P44 Description: UHTWSZ Wiring copper bar II E-P2 A phase inv.fuse
A phase inv.fuse
PH1_INV_Q_C1E2&V
OUT_A PH1_INV_Q_ A phase inv.DC
Name: neilsbed
A phase inv.DC C1E2&VOUT_ component and
J1 Description: 1121S-4P P=3.96mm 180°
component and A Output voltage
single row square PIN white
Output voltage sampling
sampling
PH2_INV_Q_C1E2&V
OUT_B PH2_INV_Q_ B phase inv.DC
Name: neilsbed
B phase inv.DC C1E2&VOUT_ component and
component and B Output voltage
sampling
PH3_INV_Q_C1E2&V
OUT_C PH3_INV_Q_ C phase inv.DC
Name: neilsbed
C phase inv.DC C1E2&VOUT_ component and
component and C Output voltage
sampling
INV SCR
INV SCR drive/output Name: neilsbed
drive/output
J4 current detection Description: 301S-26P P=2.54mm 180° two
current
signal rows square PIN black horn
detection signal
5.5. Inverter power board

Function overview:
 Auxiliary power
 Half-bridge inverter circuit
 Fan speed regulation circuit
37 / 79
V01
Figure 564 Inverter power board
Table 100. Inv. Power board interface

+DCBUS
P9 Description: 4PIN 10A M4 screw hole straight leg +DCBUS +BUS voltage
+BUS voltage
-DCBUS Name: blade terminal
P10 -BUS voltage Description: 4PIN 10A M4 screw hole straight leg -DCBUS -BUS voltage
+15V/-15V Name: neilsbed
ASSISTANT
P13 ASSISTANT Description: 1121S-2P P=3.96mm 180° single row +15V/-15V
POWER
POWER square PIN white
+24V_FAN Name: neilsbed
P28 Fan power Description: 1121S-2P P=3.96mm 180° single row +24V_FAN Fan power
square PIN white
VBPS_A/BAT+/VIN
V_A Name: neilsbed VBPS_A/BAT+ Supply power
J4 Supply power Description: 1121S-5P P=3.96mm 180° single row /VINV_A from auxiliary
from auxiliary square PIN white (remove 2 4PIN) power
power
REC_THERMAL_S
Name: neilsbed REC_THERMA REC
WITCH
J5 Description: 2001S-2P P=2.54mm 180° single row L_SWITCH temperature
REC temperature
square PIN white detection
detection
upper half bridge Name: neilsbed upper half
J6 INV drive Description: 301S-12P P=2.54mm 180° two rows bridge INV drive
signal square PIN black horn signal
ASSISTANT Name: neilsbed ASSISTANT
J7 POWER Description: 1121S-4P P=3.96mm 180° single row POWER +15V/-15V
+15V/-15V square PIN white
ON Name: neilsbed Start up signal
J8 ON
Start up signal Description: 2001S-2P P=2.54mm 180° single row button
38 / 79
V01
button square PIN white
REC_THERMAL_S
Name: neilsbed REC_THERMA REC
WITCH
J9 Description: 2001S-2P P=2.54mm 180° single row L_SWITCH temperature
REC temperature
square PIN white detection
detection
lower half bridge Name: neilsbed lower half
J10 INV drive Description: 301S-10P P=2.54mm 180° two rows bridge INV drive
signal square PIN black horn signal
+24_CSU Name: neilsbed
monitoring
J18 monitoring unit Description: 1121S-2P P=3.96mm 180° single row +24_CSU
unit POWER
5.6. DSP board

Function overview:
 UPS control
 Communication circuit
 Parallel circuit
 Display circuit
Figure 575. 58DSP board
Table 111. DSP board interface

+15V/-15V Name: neilsbed
ASSISTANT
P13 ASSISTANT Description: 1121S-2P P=3.96mm 180° single row +15V/-15V
POWER
ASSISTANT Name: neilsbed
ASSISTANT
J7 POWER Description: 1121S-4P P=3.96mm 180° single row +15V/-15V
POWER
+15V/-15V square PIN white
A phase INV A phase INV
Name: neilsbed
voltage/output Vinv_A/Vout voltage/output
voltage sampling _A voltage
square PIN white
signal sampling signal
J2 B phase INV Name: neilsbed Vinv_B/Vout B phase INV
39 / 79
V01
voltage/output Description: 1121S-5P P=3.96mm 180° single row _B voltage/output
voltage sampling square PIN white voltage
C phase INV C phase INV
Name: neilsbed
voltage/output Vinv_C/Vout voltage/output
voltage sampling _C voltage
square PIN white
Assistant power Name: neilsbed
Assistant
P20 15V+ Description: 1121S-2P P=3.96mm 180° single row 15V+
power
square PIN white
Name: neilsbed charging
charging voltage
P21 Description: 1121S-3P P=3.96mm 180° single row CHARGE+/- voltage
sampling
square PIN white sampling
Name: neilsbed
input voltage input voltage
J23 Description: 1121S-3P P=3.96mm 180° single row Vin_A/Vin_N
sampling sampling
square PIN white
Name: neilsbed
input voltage input voltage
J24 Description: 1121S-4P P=3.96mm 180° single row Vin_B/Vin_C
sampling sampling
square PIN white
Name: neilsbed Vbps_A/Vibp bypass
bypass voltage
J12 Description: 1121S-8P P=3.96mm 180° single row s_N/ Vbps_B/ voltage
sampling
square PIN white Vbps_C sampling
Name: neilsbed
battery voltage battery voltage
J25 Description: 1121S-3P P=3.96mm 180° single row Vbat+/Vbat-
sampling sampling
square PIN white
Name: neilsbed
BUS voltage BUS voltage
J18 Description: 1121S-3P P=3.96mm 180° single row Vbus+/Vbus-
sampling sampling
square PIN white
Name: neilsbed
J17 parallelsignal1 Description: 2001S-13P P=2.54mm 180° single row parallelsignal1
square PIN white
Name: neilsbed
J19 parallelsignal2 Description: 2001S-13P P=2.54mm 180° single row parallelsignal2
square PIN white
monitor& Name: neilsbed monitor&
J12 communication Description: 2001S-12P P=2.54mm 180° single row communication
signal square PIN white signal
Name: neilsbed
LCD display
CN3 LCD display signal Description: 302NS-16P P=2.54mm 180° two rows
signal
square PIN black
Name: neilsbed
P14 PFC drive signal Description: 301S-30P P=2.54mm 180° two rows PFC drive signal
square PIN black horn
40 / 79
V01
PFC inductor
PFC inductor board Name: neilsbed
board
P15 relay/SCR drive Description: 301S-10P P=2.54mm 180° two rows
relay/SCR drive
signal square PIN black horn
signal
INV. inductor
INV. inductor board INV. SCR
Name: neilsbed
board INV. SCR drive/output
J4 Description: 301S-26P P=2.54mm 180° two rows
drive/output current current
square PIN black horn
detection signal detection
signal
Name: neilsbed upper half
upper half bridge
J6 Description: 301S-12P P=2.54mm 180° two rows bridge INV
INV drive signal
square PIN black horn drive signal
Name: neilsbed lower half
lower half bridge
J10 Description: 301S-10P P=2.54mm 180° two rows bridge INV
INV drive signal
square PIN black horn drive signal
5.7. Parallel adapter board

Function overview:
 Parallel circuits connection among the power modules
 Connection between power module and monitoring module
Figure 596. Parallel adapter board interface
Table 122 Parallel adapter board interface
41 / 79
V01
Connector No. Signal Remark Corresponding interface
1 485-B Building a database module
2 485-A
3 GND_485
J12
4 EPO
5 GND_485
6 NC
1 24V power
J11 2 Monitoring module
3 GND2
1 24V power Power module
J9
2 GND2
J5 1 Parallel signal Power module
J6 1 parallel signal Power module
J15 1 parallel signal Last parallel connection board
J10 1 parallel signal Next parallel connection board
J14 1 parallel signal Last parallel connection board
J16 1 parallel signal Next parallel connection board
Maintenance air-switch
J13 1 Maintenance air-switch
signal
J8/J19 1 Output air-switch signal Output air-switch
J7 1 Module insert signal Module insert switch board
6. Inspection before installation

6.1. Room environment inspection
◆ UPS room:
UPS should be installed in a cool, dry, clean and well-ventilated environment, such as the room
temperature should be < 40℃, the humidity≤95% when 20℃, not obvious dust on the floor,
especially without any conductive powder. The roon air cannot contain acid mist or other
conductive medium. For detail, please refer to the users’ manual and other specifications.
◆ Battery room:
The battery should be also placed in a cool, dry, clean and well-ventilated environment. The
available temperature is 15℃-25℃, typically is 20℃. The place where the battery located should
keep the constant temperature and far away from heat and vents.
6.2. UPS location inspection
The users’ manual offers the detailed installation instruction which can be referred for installation.
◆ Check if enough space is left for maintenance operation, ensure that the operator can still pass
through freely when the door is fully opened.
42 / 79
V01
◆ There is no obstruction in the front, above and below of UPS. Enough space should be left for
ventilation.
◆ Air is primarily comes from front door, so check if the front door leave enough air inlet space.
6.3. UPS visual inspection
Particularly important: it is necessary to have a comprehensive inspection of internal and external of

UPS
a. Check the external power cable connection (include input /Output phase sequence battery
polarity, fasten bolt and ect.)
b. Check if the parallel cables are connected well? If they are routed separately from power
cables?
c. Check if the external signal of the battery box and LBS (when needed) connections are good or
correct?
d. Check if the internal signal cable is connected well, if the cable is loosed by shaking it gently;
e. Check if the internal boards or components are inconnected or damaged?
6.4. External cables and switch capacity inspection
◆ For power cable selection and connection method, please refer to the user manual and related
specification.
◆ Check if the breakers rated capacity of UPS input, Output and distributjion cabinet are appropriate.
◆ Pay attention to the Neutral and Ground protection inspection:
If the Neutral and Ground cable size meets the requirement?
Neutral has separate input and output, connect to the same Neutral is not allowed.
Check and confirm all the cabinets and cable ducts have been grounded according to the local
provisions.
◆ If the bypass has different power source, please check if the short copperbar of the internal mains
and bypass has been removed, do the connection correctly according to the users’ manual.
◆ If the battery breaker box is provided, check if the connection of it is correct.
◆ Check if the UPS input/output wiring is reasonable and the cable is not in contact with any sharp
edges of objects.
◆ If the user install the remote contact to realize the EPO function, make sure that the EPO cable is
not interference by other main power signals to avoid UPS misfunction. About how to realize the EPO
function by remote contat, please refer to user’s manual.
◆ About other control cables connction, please refer to the relevant Chapters of the user’s manual.
43 / 79
V01
6.5. External auto switching and generator power distribution
inspection
◆ Confirm that the ATS at the input side is three level switch, that is the Neutral cannot be cut off; if it
is four level, confirm that when transfer between two sources, neutal should meet on-befor-off principle.
◆ If the AC and generator can be selected at the input side, please confirm the proper connction
between Neutral and Ground according to the relevant specifications.
◆ If the generator has dry contact, it is necessary to connect it to the generator dry contact of the
monitor board.
6.6. Battery inspection

The important security guidance when operating battey:
a. Battery exists danger of short-circuit and possibly causes burning due to the short-circuit
current.
b. The voltage may reach 200VDC when battery connted in series, which has deadly danger. So
keep in mind to prevent electric shock.
c. The installation and operation of the battery must be carried out by professionals.
d. Note of eye protection to avoid accidental arc damage.
e. Remove all rings, watched, necklaces, bracelets and other metal objects.
f. The tools must be used with insulated handles.
g. Wear rubber gloves and protective aporns when do the battery operation.
h. If the battery has liquid leakage or housing damaged, place it in the ant-acid container and
deal it according to the local regulations.
i. If the electrolyte touches your skin, immediately wash it with a plenty of water.
j. The battery must be handled with reference to local environmental regulations.
Focus on the following aspects:
a. If the battery surface is clean, the appearance is damaged, deformed and leakage;
b. Check if the connection among battery is reliable, if the screws are tightened, if there is
corrosion and confirm that all battery terminals are coated with insulating material;
c. Check if there at least 10mm interval between the vertical side of the battery to ensure the
free flow of the air around the battery;
d. At least 150mm space should be left between battery top and upper frame for monitoring and
maintenance of the battery;
e. Check if the battery cabint or battery rack installed realiably, if there is good grounded. One
cable must be individually connected between battery breaker box and UPS;
f. About connections between battery pack and UPS, battery and battery, battery pack and
battery pack and rated capacity of breaker, please refer to the user’s manual and relevant
relevant specifications;
g. Check if the wiring is reasonalble and the cable is not in contact with any sharp edges of
objects;
h. If the battery cabinet is installed on a raised floor, the battery power cable and breaker
44 / 79
V01
controlled cable can route through the floor; if the battery cabinets are side-by-side and
installed on a solid floor, cables can go into the outlet holes at the bottom of the cabinet side
to connect the battery cabinets;
i. Check and confirm that the cables are correctly and safely conncted to the battery termainal
blocks of the UPS. Don’t reverse the battery. About the terminal block diagram, please refer to
the user’s manual.
j. Make sure that the battery breaker box is switched off.
7. UPS maintenance
7.1. Guidelines for good service
◆ The UPS is almost maintenance-free and is designed to have a failure rate less than 1% a year.
Periodical service is only needed for the fans; the UPS has a low heat generation.
A battery change after 3-6 years can be expected and, apart from the service to the fan, it
should normally be the only service done to the unit.
◆ Due to the size of the UPS and the highly complex of the PCB, board level repair is not
recommended, take the following measures instead:
Improve the reliability of the design;
Replace the PCBA;
7.2. Security conditions
Warning: When the UPS is operating, all the electronic parts connected directly to the power supply
and all internal components including the battery exist high voltage. Even disconnected from the
power supply, all internal parts including the battery still have dangerous voltage (except the
communication output).
◆ Only authorized professionals with relevant knowledge can open the machine, the others
cannot open it for maintenance.
For authorized service personnel:
Do not work alone, a second person should be standing by to assist and render help in case of
accident.
Danger may occur only during the installation and maintenance. Any person operating in a normal
manner is safe.
◆ If the UPS is in need of repair, the process A operation is recommended (This is completely
safe): Disconnect all input power supply and battery. Load is allowed to turn off for process A. The
specific steps can be seen in Chapter 7.3.
◆ If the load is not allowed to turn off, please enter the maintenance bypass mode for
maintenance. Follow the process B (refer to Chapter 7.3 for specific information). Please note that
the do the maintenance in maintenance bypass mode is not absolutely safe, Part of circuits are still
45 / 79
V01
at work.
◆ In maintenance mode, the load is directly connected to the power via the bypass, so the UPS
will not provide any protection.
◆ To avoid electrostatic discharge damage, ensure that the maintenance is under the ESD safe
conditions
- work on an anti-static mat;
- ground yourself and the unit when it is opened.
◆ Be careful when disconnect the battery:
- Do not wear metal bracelets and etc.
- do not short circuit the batteries
◆ If the UPS must be repaired during the operation such as measurement, Make sure that the
power supply is isolated. In this case, a transformer can be used between the UPS and power.
Before maintenance, this manual should be entirely read.
7.3. Shutdown-disassembly/reassembly UPS
Warning: when UPS works, a large amount of energy is stored in the internal BUS capacitor, no
electricity cannot be guaranteed inside the UPS with mains isolation, so it needs extra attention
when maintenance. Disconnect all external input power of the fault machine for maintenance, after
opening the casing, use the bleed resistor to release the energy stored in BUS capacitor to avoid
injury to person.
◆ Please refer to the user’s manual on UPS installation content;
◆ First read Chapter 7. 2 “Security conditions”
◆ If the UPS is in need of repair, the process A operation is recommended (This is completely
safe): Disconnect all input power supply and battery. Load is allowed to turn off for process A.
The specific steps can be seen in Chapter 7.3.
◆ If the load is not allowed to turn off, please enter the maintenance bypass mode for
maintenance. Follow the process B (refer to Chapter 7.3 for specific information). Please note that
the do the maintenance in maintenance bypass mode is not absolutely safe, part of circuits are still
at work.
◆ In maintenance mode, the load is directly connected to the power via the bypass, so the UPS
will not provide any protection.
★Process A: the load may be closed

a. Turn off the load, disconnect all input power supply and battery;
b. Open the front door, put the input/output/battery air-switches to OFF;
c. Remove the 4 screws of the power module, pull out the module;
d. Insert good power module;
e. Tighten the four screws;
46 / 79
V01
f. Connect the mains/battery/load, switch on the battery switch, press the start key to start the
unit
g. If UPS has no fault, it will has output when output air-switch is switched on.
h. Switch-on the input -air-switch, the UPS will transfer to mains, and charge the battery.
i. Close the front door.
★ Step B: The load may not be closed.

a. Open the front door, remove the maintenance screws and baffles to check whether the
machine enter the maintenance bypass mode
b. If the UPS goes to the maintenance bypass mode, switch on the maintenance bypass switch,
otherwise do the maintenance in accordance with the process A;
c. Remove the 4 screws of the power module, and then pull the power module;
d. Insert the good power module;
e. Tighten the four screws, the unit goes into the maintenance bypass mode;
f. Switch off the maintenance switch, install baffles and screws, the unit goes to the bypass
mode;
g. If both the mains and battery are normal, the unit goes into the line mode and charging after
a period of time;
h. Close the front door.
7.4. Troubleshooting
This Chapter provides information that can help you to locate faults in UPS.
Some data may have to be measured to fix the fault. If it needs to be measured during the operation,
the device should be isolated from the mains. In this case, a transformer can be used between
device and the power. It also applies to the bypass input.
Warning: when UPS works, a large amount of energy is stored in the internal BUS capacitor, it
cannot be guaranteed that there is no electricity inside the UPS with mains isolation, so it needs
extra attention when maintenance. Disconnect all external input power of the fault machine for
maintenance. After opening the case, use the bleed resistor to release the energy stored in BUS
capacitor to avoid injury to person.
Before maintenance, please confirm the related reliable cable connection.
For the UPS fault, please record the software version and PCB version correctly.
!!! Warnings and precautions:

When fault occurs, make a note of the display (refer to code table) as the reference for maintenance.
Note: the UPS mains input switch cannot be OFF arbitrarily to avoid electricity interruption.
7.4.1. Fault analysis

Record the status of display, then fix the reason in accordance with the following questions.
a. if the input supply is abnormal?(over/under voltage)
b. If load changes?( capacity or type)
c. If fire?
47 / 79
V01
d. If smelly odor?
e. If abnormal noise?
f. If bad environment?(dust or moisture)
g. High temperature of UPS or ambient environment?
7.4.2. Troubleshooting
Failure view:
Please ensure the safe conditions before starting the maintenance. Please read Chapter 7.2
“Security conditions” and Chapter 7.3 “shutdown-disassembly/reassembly UPS”;
After remove the case, checking the following items:
a. If the CONNECTOR or terminals loose?
b. If the transformer or other parts burst or discoloration especially the power
components on the heat sink?
c. Is capacitor rupture or leak?
d. If any parts serious blow up especially power components on heat sink?
Solutions:
a. If the unit fails, due to higher probability damage of the INV-POWER board, replace the
power board is ok.
b. If any power component on the power board is founded to blow up, replace it
according to the “replace PCB”;
c. If fan doesn’t work with mains input, confirm that if the auxiliary power of the
INV-POWER board is damaged and needs to be replaced
d. Charger shows abnormal, check if the charging circuit in the PFC power board is
damaged and need to be replaced.
7.4.1 The display has no light and response when connected mains
48 / 79
V01
No light and response for LCD
Refer to chapter 2 and chapter

3 for operation
Check if the ± 15V in YES

Replace DSP
INV-POWER board is normal
NO
Check If the fuse of NO Replace the fuse

INV-POWER board is good
YES
NO
Replace INV-power board If repaired
YES
END
7.4.2 Common fault troubleshooting
Table 133 Common fault troubleshooting
The board may be damaged (1 shows the max.

Errrr code UPS alarm Buzz LED Probability, 2 shows the less probability)
1 2 3
control
PFC power PFC inductor
1 Rectifier fault long beep Fault ON detection
board board
board
control
Inv. fault(include INV power INV inductor
2 long beep Fault ON detection
Inv. Bridge arm ) board board
board
control
INV inductor
3 Inv. SCR short long beep Fault ON detection
board
board
control
INV inductor
4 Inv. SCR break long beep Fault ON detection
board
board
49 / 79
V01
control
PFC inductor
5 Bypass SCR short long beep Fault ON detection
board
board
control
PFC inductor
6 Bypass SCR break long beep Fault ON detection
board
board
INV inductor
7 Fuse broken long beep Fault ON
board
control
8 Paralle Relay fault long beep Fault ON
detection board
INV power
9 Fan fault long beep Fault ON fan
board
10 Reserve long beep Fault ON
control
Auxiliary power INV power
fault board
board
Power initialization control
12 long beep Fault ON
fault detection board
control
Positive battery PFC power PFC inductor
Charge fault board board
board
control
Negative battery PFC power PFC inductor
Charge fault board board
board
control
15 Bus over-voltage long beep Fault ON detection
board board
board
control
16 Bus under-voltage long beep Fault ON detection
board board
board
control
Large difference PFC power PFC inductor
between ±Bus board board
board
control
18 Soft start fail long beep Fault ON detection
board board
board
Rectifier PFC power
19 twice/s Fault ON fan
over-temperature board
Inv. INV power
20 twice/s Fault ON fan
Over-temperature board
connection
21 Input neutral loss twice/s Fault ON
wrong
50 / 79
V01
control
connection
22 Battery reverse twice/s Fault ON detection
wrong
board
Parallel cable control
Parallel connection
23 twice/s Fault ON not connected detection
fault
well board
Setting parallel
CAN control
mode but only
24 communication twice/s Fault ON detection
single UPS
fault board
working
control
Share current when Parallel cable
25 twice/s Fault ON detection
parallel fault problem
board
control
Battery high PFC power
26 once/s Fault flash battery fault detection
voltage board
board
Input phase connection
27 once/s Fault flash
sequence reverse wrong
connection
28 Bypass reverse once/s Fault flash
wrong
29 Output short circuit once/s Fault flash output short
control
Rectifier PFC power
30 once/s Fault flash detection
over-current board
board
Bypass bypass output
31 once/s BPS flash
over-current overload
INV or BPS
32 Over load once/s output overload
flash
BATTERY battery battery voltage
33 No battery once/s
flash disconnected abnormal
BATTERY Low battery and
34 Battery voltage low once/s
flash shutdown
Low battery BATTERY Battery low and
35 once/s
pre-alarm flash pre-alarm
Internal
control
36 communication once/2s Fault flash
detection board
error
control
INV inductor
37 Inv. DC excessive once/2s INV flash detection
board
board
Redundancy control
38 Overload in parallel once/2s INV flash output overload number setting detection
is improper board
51 / 79
V01
Mains voltage BATTERY Input voltage
39 once/2s
abnormal ON abnormal
Mains frequency BATTERY Input frequency
40 once/2s
abnormal ON abnormal
Bypass ultra
41 BPS flash bypass abnormal
protection
Bypass ultra
42 BPS flash bypass abnormal
tracking
Inverter cannot
43 Start invalid be started due
to some faults
Check the
The conditions
relative switch
Module screws of screw on
44 and singnal
unlocked module front
wiring of the
panel
screw
The inverter not
start after 2min
45 Inverter not on
without any
alarm
Output signal
Output switch not Detect output in the
46 Once per 3s
ON switch detection
board is wrong
7.5. Battery replacement

a. Refer to the user’s manual for battery installation operation;
b. Ensure the safe conditions before any operation. Please read Chapter 7.2 <Security
conditions> and Chapter 7.3 <shutdown-disassembly/reassembly UPS> carefully. Be
careful when disconnecting the battery. Short circuit will damage the battery or wiring.
Note:
The battery with the same brand/type/date of manufacture is recommended to ensure a
long battery life. The voltage difference among the batteries should not more than ±150
mV.
We recommended to measure the voltage of each battey during discharge to ensure the
voltage differences no more than ±150 mV.The battery pack capacity will be affected if
there is one or more battery voltages differ too much. In the worst case, it will damage the
other battery.
The voltage difference should be reduced after a long period of charging.
7.5.1. Standard battery string

a. Switch off the battery switch (if any), remove the middle baffle;
b. Pull out the battery drawer, remove the screws, take out the battery, and replace with
new battery;
52 / 79
V01
c. Replace the remaining three drawer of battery;
d. Thoroughly check if all the connections are correct;
e. Re-install the battery drawer;
f. Measure the total voltage of the battery;
g. Install all screws, baffles, switch on the battery switch (if any).
7.5.2. Single Battery cabinet:

h. Close the battery switch (if any);
i. Disconnect the connection between the UPS and the battery cabinet;
j. Replace the battery according to the battery cabinet user’s manual;
k. Thoroughly check if all the connections are correct;
l. Measure the total voltage of the battery;
m. Open the battery switch (if any)
7.6. PCB replacement

Warning: when UPS works, a large amount of energy is stored in the internal BUS capacitor,
it cannot be guaranteed that there is no electricity inside the UPS with mains isolation, so it
needs extra attention when maintenance. Disconnect all external input power of the fault
machine for maintenance. After opening the case, use the bleed resistor to release the
energy stored in BUS capacitor to avoid injury to person.
7.6.1. General instruction

The internal voltage of the module is high enough to cause serious personal injury or death.
a. Ensure the safe conditions before any operation. Please read Chapter 7.2<Security
conditions>and Chapter 7.3<shutdown-disassembly/reassembly UPS>carefully. Be
careful when disconnecting the battery. Short circuit will damage the battery or wiring.
b. ESD (electrostatic discharge) precautions: The PCB is very sensitive to electrostatic.
When pick and place the board, ensure that the operating personnel and equipment
are grounded well.
The new board is taken out from the anti-static packaging only when necessary, the old
board removed from the UPS should be immediately placed in anti-static packaging.
c. Shut down the UPS according to the process A or B in Chapter 7.3.
d. When disconnect any connectors, hold the male while pulling the female(sometimes
need to press the connector snaps), otherwise, it will make the connector or PCB
bending.
Mark it before disconnecting in order to facilitate the re-assembly connector.
e. Ensure the compatibility between the new board and old board before replacement.
f. When re-install the connector, the male and female should be aligned, or the PCB or
UPS will be damaged.
g. Confirm if the connection is correct after replacing PCB.
7.6.2. EMI board replacement

n. Ensure the safe conditions before any operation. Please read Chapter 7.2<Security
conditions>and Chapter 7.3<shutdown-disassembly/reassembly UPS>carefully.
53 / 79
V01
o. Operate according to the Step a-c of process A or Step a-c of process B in Chapter 7.3;
p. Remove the upper cover screws of the bad power module, remove the cover, use the
bleeder resistor to release the energy stored in the Bus capacitor;
q. Remove all the cables of the EMI board;
r. Remove all the screws of the EMI board;
s. Replace the PCB, package the old PCB;
t. Install the screws and cables;
u. Install the upper cover and the screws of the power module;
v. Continue with the Step d-h in process A or d-i in process B in Chapter 7.3;
7.6.3. Replace DSP board

a. Ensure the safe conditions before any operation. Please read Chapter 7.2 <Security
conditions>and Chapter 7. 3 <shutdown-disassembly/reassembly UPS> carefully.
b. Operate as per Step a-c of Process A or Step a-c of Process B in Chapter 7.3;
c. Remove the lower cover screws of the bad power module, remove the cover, use the
d. Remove all the cables of the DSP board;
e. Remove all the screws of the DSP board;
f. Replace the PCB, package the old PCB;
g. Install the screws and cables;
h. Install the lower cover and screws of the power module;
i. Continue with the Step d-h in process A or d-i in process B in Chapter 7.3;
7.6.4. Replace PFC inductor board

b. Operate according to the Step a-c of process A or Step a-c of process B in Chapter 7.3;
c. Remove the upper cover screws of the bad power module, remove the cover, use the
d. Remove all the cables of the PFC inductor board;
e. Remove all the nuts and screws of the PFC inductor board;
g. Install the nuts, screws and cables;
h. Install the upper cover and screws of the PFC inductor module;
7.6.5. Replace PFC power board

d. Remove all the cables of the PFC power board
e. Remove all the screws of the PFC power board;
54 / 79
V01
7.6.6. Replace INV inductor board

c. Remove the upper cover screws of the bad power module, remove the cover, use the
d. Remove all the cables of the INV inductor board
e. Remove all the screws and nuts of the INV inductor board;
g. Install the nuts, screws and cables;
h. Install the upper cover and screws of the power module;
7.6.7. Replace INV power board

d. Remove all the cables of the INV-POWER board
e. Remove all the screws of the INV power board;
7.6.8. LCD on front panel

c. Open the front panel, remove 4pcs of nuts of the rear panel and then remove the rear
panel;
d. Remove all the cables of the PCB
e. Remove all the screws of the PCB;
h. Install the rear panel and nuts;
i. Continue with the Step d-i in process A or d-h in process B in Chapter 7.3;
55 / 79
V01
7.7. Replace fan

Four fans are provided
a. Ensure the safe conditions before any operation. Please read Chapter 7.2 <Security
conditions>and Chapter 7.3 <shutdown-disassembly/reassembly UPS>carefully.
b. Operate according to the Steps a-c of process A or Steps a-c of process B in Chapter
7.3;
c. Remove the upper and lower cover screws of the bad power module, remove the cover,
use the bleeder resistor to release the energy stored in the Bus capacitor;
d. Remove the fan cables of the INV power board;
e. Remove all the screws of the fan;
f. Replace with a new fan;
h. Install the upper and lower covers, screws of the power module;
i. Continue with the Steps d-i in process A or Steps d-h in process B in Chapter7.3;
7.8. PCB static maintenance
7.8.1. PFC inductor board
Table 144 PFC inductor board
Detect Meter
1
NO. Description Type Checked components Pin stall Normal Abnormal
1 AC rectify Diode D1,D3,D6,D11,D14,D16 A/K diode 0.36V open or short
2 mains input Relay K1,K2,K6 4/5 Ω open short
3 Battery input SCR D7,D9,D18,D19,D20,D21 A/K Ω open Short
4 Battery input SCR D7,D9,D18,D19,D20,D21 G/K Ω ≈10Ω open or short
5 Charge SCR Q70, Q71 A/K Ω open Short
QJ1,QJ4,QJ5,QJ6,
6 Charge SCR QJ7,QJ8,QJ3,QJ12 G/K Ω ≈10Ω open or short
QJ1,QJ4,QJ5,QJ6,
7 Bypass SCR QJ7,QJ8,QJ3,QJ12 A/K Ω open Short
8 Bypass SCR K7,K8,K9 G/K Ω ≈10Ω open or short
9 Bypass Relay K3, K4, K5 1/3 Ω open short
7.8.2. PFC power board
Table 155 PFC power board
Checked Detect
2
NO. Description Type components Pin Meter stall Normal abnormal
1 BOOST Diode D7-D12 A/K diode 0.36V open or short
56 / 79
V01
2 BOOST IGBT Q1-12 E->C diode ≈0.4V open or short
3 BOOST IGBT Q1-12 G/E Ω ≈10KΩ open or short
4 Charge FUSE F3-4 Ω 0Ω open
5 Charge MOSFET Q13-14 S->D diode ≈0.46V open or short
6 Charge MOSFET Q13-14 G/S Ω ≈20KΩ open or short
7.8.3. INV inductor board
Table 166 INV inductor board
Checked Detect Meter

3
NO. Description Type components Pin stall Normal abnormal
1 INV FUSE F1-3 Ω 0Ω open
2 INV SCR SCR1-6 A/K Ω Open Short
3 INV SCR SCR1-6 G/K Ω 20~40Ω open or short
4 INV Relay RLY1-3 1/3 Ω open short
7.8.4. INV power board
Table 177 INV power board
Checked Detect
4
NO. Description Type components Pin Meter stall Normal abnormal
1 INV IGBT Q1-12 E->C diode ≈0.4V open or short
2 INV IGBT Q1-12 G/E Ω ≈10KΩ open or short
3 Auxiliary power FUSE F1 Ω 0Ω open

4 Auxiliary power MOSFET Q14-15 S->D diode ≈0.46V open or short
5 Auxiliary power MOSFET Q14-15 G/S Ω ≈10KΩ open or short
8. Single cabinet commissioning

Warning: When UPS is working, the internal Bus capacitor stores a lot of energy. But isolated
with mains cannot guarantee completely no electricity inside the UPS and need extra attention
when do the maintenance. When cut off all the external input power supplied for maintenance,
use the bleed resistor to release the energy stored in Bus capacitor after open the case firstly
to avoid causing injury to persons.
Please refer to the “UPS repair/maintenance”, especially the “Security maintenance conditions”
and “Close-Disassembly/Reassembly UPS”.
The stand-alone commissioning requires intact power module.
8.1. Startup steps

a. Before startup, confirm that the input/output connection is correct, measure the
positive and negative battery voltage, battery breaker is temporarily open;
b. Check if the switch of monitoring module power is closed. The default is closed
57 / 79
V01
c. Close the output switch of power distribution module on the front door;
d. Close input switches of all the power modules. Close the external main input switch to
start by AC;
e. After start, check the LCD of each module to see if the display of working mode,
maching ID number, the VA of UPS, output voltage level and the frequency is the same
with the actual values.( refer to the following pictures). If not the same, immediately
disconnect the mains to check or cal lthe customer service hotline;
f.
Cabinet ID
Module ID
Figure 607. Module ID (for example)
Note: For cabinet ID,-shows cabinet 1,= shows cabinet 2, and so on, cabinet 4 can be
displayed at most;
g. Further to see the LCD dipaly to check the power on status, output voltage, frequency
level, working mode (stand-alone or parallel), cabinet ID and if parallel modules and
total VA are the same with the actural values. Enter each module LCD to check the
display (the interface can be referred to the following). If different, cut off the mains
and check UPS or call the sevice hotline;
h. Close the external battery breaker, check if the charge current on the LCD is normal;
i. Simulate mains power failure test: Disconnect external main input breaker and check if
the UPS can transfer to battery inv. Mode and the output is uninterruptable. Then close
the external mains breaker to confirm the UPS enter the line mode. At last, check if the
charge and output are normal.
8.2. Shutdown steps

a. Open the front door, turn off all the output switches of power modules;
b. Press the “inv OFF” button on the monitoring module panel and keep for no less than
2s, UPS inverter LED is off;
c. Open the battery breaker;
d. Open the back door of UPS, turn off all the input switches of power modules, UPS shut
down;
e. To completely isolate the AC power supply, the external grid input switch should be
open. The main input distribution board is usually away from the UPS. It is necessary to
inform the service personnel that the UPS is in repair by posting a lable on it.
58 / 79
V01
8.3. Emergency shutdown instructions:

a. Open the front door, an emergency power off (EPO) button is emboded next to the
SNMP card. In case of emergency, press EPO button for 3s, the UPS shutdown can be
achieved.
b. EPO button is designed with protection. It is coverer by transparent cover to avoid
misuse. When the emergency shutdown is required, open the transparent cover and
press the red button for more than 3s, the UPS will shutdown.
9. Parallel system commissioning

Warning: When UPS is working, the internal Bus capacitor stores a lot of energy. But
isolated with mains cannot guarantee completely no electricity inside the UPS and need
extra attention when do the maintenance. When cut off all the external input power
supplied for maintenance, use the bleed resistor to release the energy stored in Bus
capacitor after open the case firstly to avoid causing injury to persons.
Please refer to the “UPS repair/maintenance”, especially the “Security maintenance
conditions” and “Close-Disassembly/Reassembly UPS”.
Parallel system should be commissioning when the stand-alone are all intact.
9.1. Startup steps

a. According to the stand-alone startup steps, set up the ID of each cabinet. The ID must be
different for each unit. Up to four units can be paralleled.
b. Properly connect the parallel cables (refer to the users’ manual), input/output cables,
battery cables.
c. Measure the positive and negative battery pack voltage, battery breaker is temporarily
opened.Each single UPS need to have a separate battery cabinet.
d. Confirm if the switch of monitoring module is closed. The default is close
e. Close the output switch of the power distribution module.
f. Close all input switches of power modules at the back door. Close external input switch to
start UPS from AC.
g. After startup, check the ID of parallel cabinet, check if the VA is the same with actual
value. If not the same, please cut off mains for check or call the service hotline.
h. Close all external battery breakers of all cabinets. Check if the charge current displayed in
LCD is normal.
9.2. Shutdown steps

a. Confirm the load information to avoid overload when turn off single unit;
b. Shut down each UPS according to the stand-alone UPS shutdown steps.
9.3. Emergency shutdown

According to the stand-alone emergency shutdown steps, select any one unit can shut
59 / 79
V01
down all the outputs of UPS in the parallel system.
10. Software upgrade

There are two methods for software upgrade.
10.1. Use XDS100V3 emulator to upgrade

When shutdown the UPS, remove the right panel of UPS, burn the DSP in control detection
board separately to upgrade. For detailed steps, please refer to the XDS100V3 simulator
instruction.
10.2. Use 485 communication to upgrade
10.2.1. Note
1. In order to make the program update more reliable, the best way of software update is one
module by one module, Means if update one module; the others push out of the solts;
2. Must pull out the monitor module before update;
3. This file provides description of the software update methods and steps;
4. Update the REC firmware before INV firmare updating;
5. When burning is finished, the other DSP or module cannot be burned until the DSP buzz. (When
finish burning the REC, the next burning can be executed after about 20s).
6. If it fails during the REC burning, it will show “Program was unsuccessful”. Switch off the UPS
and then restart, click “Update” to re-burn.
7. If it fails during the INV burning, it will show “Program was unsuccessful”. Switch off the UPS and
then restart, remove the module with ID1, and modify the ID number to 1 in the software. Close
the serial port and then open it, click “Re-Update” to start the re-burning.
8. During the burning, it repeats a frame data which goes into an infinite loop. Restart the UPS and
Prg2800_33 and check if the communication connection is ok. Then re-burn can be operated. If
it is the REC burning, please refer to the item b, if INV burning, please refer to item c.
9. If both the REC and INV burning fail, the INV burning (Re-Update) has to be operated firstly. Cut
off the mains and then power on the UPS, then the REC burning (Update) can be executed.
10.2.2. Software updating procedure

1． Remove the panel of the maintenance breaker; turn on the breaker so that the UPS goes to
maintenance bypass mode.
2． Remove the screws of all the module’s panels, left one module in the solt, and take out the
other modules.
60 / 79
V01
Figure 618 Module front panel screw
3． Switch off Battery switch (OFF) ;

4． Switch off monitoring module (OFF) ;
5． Switch off the mains switch of the module to be udpatd (OFF);
Figure 629. Module mains switch
6． Turn on the UPS with bypass input (mains switch open, no battery input). Open the serial
program software Prg2800_33.exe
Figure 63. Prg2800_33.exe software
7． Follow the settings in figure 61

“1” is to choose serial port that the computer uses;
“2” choose speed 9600;
“3” choose RS232;
“4” is to choose the ID number for the module that we are programmed.
4.1 Programmed ID number=Parallel ID*10 +module ID (DSP version is no communication ID)
4.2 Programmed ID number= Com ID*10 + module ID (DSP can set communication ID)
4.3 When parallel ID or communication ID is 1, programmed can use module ID (eg: ID=1,
module ID=2, programmed ID=2)
“5” for laptop, pls set the value ≥5; for desktop computer, can set the value <5;
“6” choose 07;
“7” choose INV for the program, because we are going to update the inverter program;
“8” is default value, no need to change;
“10” is for the target software “3302-304E_HPM3320-RM_INV33_20K_400.out”that we are
going to program. Please click “11” to choose target upgrade file.
8． After the setting done, pls click “Open device” as shown in Figure 61.
61 / 79
V01
Figure 64. Software settings
9． After the above steps, it shows below Figure 62, pls click the “OK” button.
Figure 652. comport
10． Update must user RS232/USB-RS485 convertor, RS232/USB connected to the computer’s
serial port, RS485 connected to a DB9 (SCI UPDATE) terminal and link to the UPS update port (at
the rear of the UPS), make sure the communication between them is good.
62 / 79
V01
Figure 663 communication port
Figure 674 Definition of port
11． After set up the communication between UPS and computer, make sure monitor module
pull out, and the just wait one minute before update (before update the REC or INV) , then click
“Update” as shown in Figure 65;
63 / 79
V01
Figure 685. Updating command
12． Figure 66 Shows the chip is preparing for the program.
Figure 696 Ready for Updating
13． Figure 67 shows the program work is preceding.
64 / 79
V01
Figure 70 Command procesing
14． Follow below Figure 68/69/70 to finish and exit.

If need go on the programming, pls return to step 3.
If finish and stop the programming pls turn OFF the maintenance switch and put on the
maintenance cover, screw the screws of the modules
Figure 71. Updating successful
65 / 79
V01
Figure 72. Close device
Figure 73. Updating acomplish
66 / 79
Appendix A Power module Jumpper cap configuration
HPM3320High
HPM3310 HPM3315 HPM3320 HPM3325 HPM3330
Item PART efficiency
10KVA 15KVA 20KVA 25KVA 30KVA
Control detection
PCB jumper cap J102/104/106/107/1 J102/104/106/107/ J102/104/106/107/ J101/103/105/110/11 J101/103/105/109/110/11
1 J107
HPM3300-RM 09 108/109 108/109 1/112/113/114/115 1/112/113/114/115
module PF0.9
install output
2 isolation J118 J118 J118 J118 J118 J118
transformer
Control detection
J101/103/105/110/11
PCB jumper cap J102/104/106/107/1 J102/104/106/107/ J102/104/106/107/ J101/103/105/109/110/11
3 J107/116 1/112/113/114/115/1
HPM3300-RM 09/116 108/109/116 108/109/116 1/112/113/114/115/116
16
module PF1.0
Remarks: J101/103/105/102/104/106 are invertercurrent limitation option; J110/111/112/113/114/115 are PFC sampling resistor parallel option;
4 J107/108/109/116(TEST1)/117(TEST2)/118/119are model option; J20/J30/J31are SAmodel CAN resistor option; P4/P11are output switch and maintenance switch
condition option;
67 / 79
Appendix B Power module fault judgement
Software judgment
NO. UPS Alarm Buzz LED
Condition 1 Condition 2 Condition 3 Condition 4
long
1 Rectifier fault DC BUS over-voltage DC BUS under-voltage Large bus difference Fault ON
beep
Inv. fault(include Inv. Bridge The absolute value of the output voltage ＞112.5% of rated Bridge arm midpoint voltage( Inv. voltage) last 500ms＞1.1 long
2 Fault ON
arm ) output voltage, last 500ms time of rated peak value 360vfor230 344for220 376for240 beep
long
3 Inv. SCR short Fault ON
beep
(in parallel, X phase load rate<6.3%) &&(parallel X phase total load rate＞50%) &&(large loop current||in bypass mode) last time long
4 Inv. SCR break Fault ON
2S beep
long
5 Bypass SCR short (X phase Output voltage>60% of rated) &&(the absolute values of other phases voltage＜5% of rated voltage) last 2s Fault ON
beep
((in parallel, X phase load rate <6.3%) &&(parallel X phase total load rate＞50%) &&(large loop current|| in Bypass mode) ) ||(X long
6 Bypass SCR break Fault ON
phase current＜10% of rated&&X phase Output voltage＜50% of the Bypass voltage) last 2S beep
long
7 Fuse broken Hardware signal low available Fault ON
beep
long
8 Parallel Relay fault ( Inv. Status & Relay open) ||(no Inv. Status && parallel Relay close) last 20ms Fault ON
beep
Hardware signal low long

9 Fan fault Fault ON
available for 5s beep
long
10 Reserve Fault ON
beep
Hardware signal low long

11 Auxiliary power fault Fault ON
available for 3ms beep
1) Rec.DSP read IIC self-test, until 15s power on) Inv. DSP read IIC self-test, until 15s delay unit not obtain valid parameter from long
12 Power initialization fault Fault ON
E2PROM, jumper error, jumper type is not defined, DSP internal RAM self-test error(MCU cannot completely modify RAM) beep
68 / 79
Software judgment
long
13 Positive battery Charge fault Fault ON
beep
long
14 Negative battery Charge fault Fault ON
beep
+bus voltage＞470V -bus voltage＞470V long

15 Bus over-voltage Fault ON
Last time: 20ms Last time: 20ms beep
Bus voltage ＜280V Bus voltage is 10V lower than setting value long
16 Bus under-voltage Fault ON
time:120ms Time: 2min beep
30V difference between long

17 Large difference between ±Bus Fault ON
±bus beep
10s later, soft start bus During the soft start, ±bus voltage ＜1.2 times of input long
18 Soft start fail Fault ON
voltage is lower than 300V voltage for 120ms beep
Last 0.2s＞77℃ show PFC

19 Rectifier over-temperature twice/s Fault ON
over temperature
Last 0.2s＞77℃ show

20 Inv. Over-temperature twice/s Fault ON
inverter over temperature
21 Input neutral loss twice/s Fault ON
22 Battery reverse +battery voltage＜ -50V -battery voltage ＞+50V twice/s Fault ON
Parallel cable fault under

23 Parallel connection fault twice/s Fault ON
the parallel : 10ms
Parallel number more than 1 for single unit and powered UPS is
24 CAN communication fault twice/s Fault ON
no more than 1 unit
25 Share current when parallel fault twice/s Fault ON
26 Battery high voltage Setting Charge voltage +20V once/s Fault flash
27 Input phase sequence reverse Obtain by algorithm once/s Fault flash

28 Bypass reverse Obtain by algorithm once/s Fault flash
29 Output short circuit X phase Output voltage is lower than rated 30%&&X phase Output current is 70% of rated current once/s Fault flash
69 / 79
Software judgment
30 Rectifier over-current once/s Fault flash
31 Bypass over-current X phase Bypass Output current greater than the rated 125% once/s BPS flash
INV or BPS
32 Over load X phase load rate( Inv. or Bypass) greater than rated 105% once/s
flash
BATTERY
33 No battery Battery voltage lower than 50V once/s
flash
BATTERY
34 Battery voltage low Battery voltage lower (EOD voltage*6*battery pcs) once/s
flash
BATTERY
35 Low battery pre-alarm Battery EOD voltage+(battery pcs *6(SetJarNum) *1.5) once/s
flash
Comm. Error between

36 Internal communication error once/2s Fault flash
Rectifier and Inv.
37 Inv. DC excessive DC component average value is more than 2V last 2S once/2s INV flash
38 Overload in parallel X phase load rate is more than total load rate of parallel system: 400ms once/2s INV flash
BATTERY
39 Mains voltage abnormal Higher than 270V Lower than 182V once/2s
ON
BATTERY
40 Mains frequency abnormal Higher than 70Hz Lower than 38Hz once/2s
ON
41 Bypass ultra protection Bypass power down and not available BPS flash
42 Bypass ultra tracking Bypass abnormal but powered, and bypass instantaneous normal, then change the Bypass to ultra tracking BPS flash
1) rectifier not start completely or start fault
a) over-temperature
b) fan fault
43 Start invalid c) SCR fault and shutdown
d) bridge arm short and shutdown
e) power board fault
f) software fail
70 / 79
Software judgment
g) battery reverse and shutdown

h) User operation fault (maint. Bypass close)
i) Auxiliary power power down and shutdown
2) manually start invalid
44 Module not inserted Module access signal is not set
45 Inverter not on
Once per
46 Output switch not ON 3
seconds
71 / 79
Appendix C Display query on reaons of no-transfer to inverter mode
bi
Segment Why Rectifier Turn off Why Inverter Turn off 1 Why Inverter turn off 2 Segment why no transfer
t
Bypass breaker
T1 1 No auxiliary power Overload time out Module is removed T1
off
Rectifier
T2 2 Output Prohibited Output Breaker off T2
over-temperature
No power supply from Bypass
T3 4 DC bus abnormal EOD T3
Mains and battery abnormal
Shutdown set from
T4 5 Fan out of order Inverter out of order T4 Phase Unlock
LCD Display
CAN Communication DC Component
T5 6 EPO EPO T5
Setting Abnormal
Parallel Modules in
Inverter SCR short
T6 7 Inverter IGBT short circuit the frame Turn off T6 Force to Bypass
circuit
simultaneously
Under parallel mode,
one module is
Inverter Output Breaker
T7 3 IGBT out of order impacted by another T7
Over-temperature off
module, so the DC
bus is in over-voltage.
Power supply out of Parallel Relay out of Inverter is not
T8 9 Turn on Manually T8
order order in standby
The inverter is
parallel system
No fault code when
T9 10 Rectifier soft-start failure Bypass SCR short circuit T9 is not
start-up
synchronized
to bypass
72 / 79
The system is
Battery Polarity on
T10 12 Output short circuit T10 on inverter
reverse
output mode.
Inverter Peak
T11 13 Module is removed Inverter relay is stuck T11 Voltage is not
locked
Not
T12 14 Input Over-current Auto Start is prohibited T12 synchronized
to Master
T13 15 Rectifier is on Turn off manually T13
Maintenance
T14 11 Maintenance Bypass On Maintenance Bypass On T14 Bypass Breaker
On
Inverter
Operation
T15 0 Rectifier out of order Force to Bypass T15 Soft-start is not
Fault(reserved)
finished yet
T16 8 Battery Mode Battery Mode T16
Display type:
Display
sections to
show the root
cause
73 / 79

HPM3300 (10-300kVA) Series Principle & Maintenance Manual - V01

Uploaded by

Copyright:

Available Formats

HPM3300 (10-300kVA) Series Principle & Maintenance Manual - V01

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HPM3300 (10-300kVA) Series Principle & Maintenance Manual - V01

Uploaded by

Copyright:

Available Formats

HPM 3300 (10-300kVA)

Series UPS Principle & maintenance

Shenzhen KSTAR Science & Technology Co., Ltd

Figure Contents ........................................................................................................................ III

Table contents ........................................................................................................................... V

1. Product introduction ......................................................................................................... 1

1.1. Summary ............................................................................................................. 1

1.3. Features .............................................................................................................. 2

1.4. Operating panel .................................................................................................. 5

2. System electrical diagram ................................................................................................. 8

2.1. Cabinet block diagram ........................................................................................ 8

2.2. Module block diagram ........................................................................................ 9

2.3. Power modue AC/DC & DC/DC principle circuit diagram................................. 10

2.4. Inverter DC/AC principle................................................................................... 10

2.5. Charging principle ............................................................................................. 11

3.1. UPS specification .............................................................................................. 11

4. UPS internal structure ..................................................................................................... 14

4.1. UPS cabinet internal structure ......................................................................... 14

4.2. Power module internal structure ..................................................................... 27

5. Each PCB board and its interface signals ......................................................................... 30

5.1. PFC inductor board ........................................................................................... 30

5.2. PFC drive board ................................................................................................ 33

5.3. PFC power board .............................................................................................. 34

5.4. INV. Inductor board .......................................................................................... 35

5.5. Inverter power board ....................................................................................... 37

5.6. DSP board ......................................................................................................... 39

5.7. Parallel adapter board ...................................................................................... 41

6. Inspection before installation.......................................................................................... 42

6.2. UPS location inspection .................................................................................... 42

6.3. UPS visual inspection ........................................................................................ 43

6.4. External cables and switch capacity inspection................................................ 43

6.5. External auto switching and generator power distribution inspection............ 44

6.6. Battery inspection ............................................................................................ 44

7. UPS maintenance ............................................................................................................ 45

7.1. Guidelines for good service .............................................................................. 45

7.2. Security conditions ........................................................................................... 45

7.3. Shutdown-disassembly/reassembly UPS.......................................................... 46

7.4. Troubleshooting ............................................................................................... 47

7.4.1. Fault analysis .................................................................................................... 47

7.4.2. Troubleshooting ............................................................................................... 48

7.5. Battery replacement ......................................................................................... 52

7.5.1. Standard battery string..................................................................................... 52

7.5.2. Single Battery cabinet:...................................................................................... 53

7.6. PCB replacement .............................................................................................. 53

7.6.1. General instruction ........................................................................................... 53

7.6.2. EMI board replacement .................................................................................... 53

7.6.3. Replace DSP board............................................................................................ 54

7.6.4. Replace PFC inductor board ............................................................................. 54

7.6.5. Replace PFC power board................................................................................. 54

7.6.6. Replace INV inductor board.............................................................................. 55

7.6.7. Replace INV power board ................................................................................. 55

7.6.8. LCD on front panel ............................................................................................ 55

7.7. Replace fan ....................................................................................................... 56

7.8. PCB static maintenance .................................................................................... 56

7.8.1. PFC inductor board ........................................................................................... 56

7.8.2. PFC power board .............................................................................................. 56

7.8.3. INV inductor board ........................................................................................... 57

8. Single cabinet commissioning ......................................................................................... 57