MP II 1-3KVA 220V Service Manual

Author: Wang Shi Jie

Checker: Yang Wen Tao
doc. number:
revision: A0
doc. date: 2014-10-16

Product Introduction ............................................................................................... 1

1.1

Front Panel Explanation .....................................................................................1

1.1.1
LCD Explanation ......................................................................... 1
1.1.2

Button function ............................................................................... 1

1.1.3

Error code Explanation ...............................................................2

1.2

Rear Panel Explanation ......................................................................................3

1.3

Customer Options Slot ....................................................................................4

1.3.1
RS232 and USB Communication Ports RS232 and USB ............................4
1.3.2

Installation and Operation ..................................................................................... 8

2.1

Operation Mode ...................................................................................................8

2.1.1
AC mode ...................................................................................... 8

2.2

Battery mode .......................................................................................................8

2.2.1
Bypass mode .................................................................................. 9

2.3

2.2.2

ECO mode ECO ................................................................................... 9

2.2.3

fault mode.................................................................................... 9

UPS on and off UPS .......................................................................................10

2.3.1
start up operation ........................................................................... 10
2.3.2

Turn off operation .......................................................................... 11

2.3.3

Manual self-test, mute test operation ....................................11

System Block Diagram and Wiring Diagram ...............................................12

3.1

System Block Diagram ...................................................................................12

3.2

Wiring Diagram
................................................................................................13
3.2.1
1KVAS UPS is mainly coRTosed of the following PCBs:......................................13
3.2.2

Electrical Characteristics ......................................................................................16

4.1.1
Battery Charging Voltage (25) 25....................................16
4.1.2

4.2

Test points and standards ...........................................................16

COMPONENT VERIFICATION .........................................................................17

4.2.1
POWER FACTOR CORRECTION:.................................................................18
4.2.2

DC-DC CONVERTER: - ..........................................................19

4.2.3

DC/AC INVERTER: /..............................................................19

4.2.4

CHARGER: ................................................................................... 20

Customer Options Slots ...................................................................................... 20

5.1

2/3KVAS UPS is mainly coRTosed of the following PCBs:....................................14

Unit Test and Calibration Setting ..............................................................16

4.1

Emergency Power-off .................................................................6

DCE (Dry Contact) card DCE .......................................................................20

5.2
SNMP card SNMP .......................................................................................................21
Troubleshooting Guide .................................................................................. 21
6.1

Error Code BUS Fault........................................................................................................21

6.2

Error Code inv Fault.........................................................................................................22

6.3

Error Code Over Heat........................................................................................................23

6.4

Error Code INV Short........................................................................................................25

6.5
Error Code Over load.........................................................................................................25
Technical Specifications ............................................................................... 26

Appendix ................................................................................................................ 30
8.1

PCB Layout PCB ..................................................................................................30

8.2

PCB Placement PCB ..............................................................................................33

8.2.1
1KVA/1.5KVA Input filter plate 1KVA/1.5KVA .....................................33
8.2.2

1KVA/1.5KVA power board 1K/1.5K ....................................................34

8.2.3

2KVA/3KVA power board 2KVA/3KVA .................................................35

8.2.4

2KVA/3KVA Input filter Board 2KVA/3KVA ....................................36

8.2.5

control board .................................................................................. 36

8.2.6

charging board ................................................................................ 37

8.2.7

USB and RS232 board USB RS232 .........................................................39

8.2.8

SPS board SPS ...................................................................................... 40

1 Product Introduction

1.1 Front Panel Explanation

1.1.1

LCD Explanation

UPS Control Panel UPS

Indicator

Description
On

Red

Yellow

Yellow
Green

The UPS has an active alarm or fault. UPS

On The UPS is in Bypass mode. UPS

The UPS is operating normally on bypass during
High efficiency operation.
UPS
On The UPS is in Battery mode. UPS
On The UPS is operating normally. UPS

NOTE When power on or startup , these indicators will turn on and of

sequentially.
NOTE On diferent operation modes , these indicators will indicate
diferently. Refer to Table 7.
,
, 7
1.1.2 Button function
Button
Start up
combination
+

turn of

Function description
Press and hold this key for more than half a second
to turn on the UPS.
UPS .
Press and hold this key for more than half a second
1

combination
+

Battery test/Mute
combination
+
/

Scroll

or

Setting entry

1.1.3

to turn of the UPS.

UPS
Press and hold the key for more than 1 second in
Line mode or economic(ECO) mode: UPS runs self-test
function.
Press and hold the key for more than 1 second in
battery mode: UPS runs mute function.
ECO 1 UPS
.
1 UPS
Non-function setting mode:

Press and hold the key for more than half a second
(less than 2 seconds): Indicate the items of the LCD
item section orderly.
Press and hold this key for more than 2 seconds:
Circularly and orderly display the items every 2
seconds, when press and hold the key for some time
again, it will turn to output status.
Function setting mode:
Press and hold the key for more than half a second
(less than 2 seconds): Select the set option.
2 : LCD
2 2

:
2 :
Non-function setting mode:
Press and hold the key for more than 2 seconds:
Function setting interface.
Function setting mode:
Press and hold the key for more than half a second
(less than 2 seconds): Affirm the set option.
Press and hold the key for more than 2 seconds, exit
from this function setting interface.
2 :

2
2 :

Error code Explanation

Fault Kind

Fault type

Bus Fault

P Bus High
N Bug High

Byp
Mode

Operating Mode before fault

Line
Bat
BatTest
Mode
Mode
Mode
05
01
40
25
21
41

P Bus Low
N Bus Low

35
55
2

31
51

70
71

Eco
Mode
80
81
90
91

Bus
unbalance
Soft fail

82

83

84

85

04
14

24
34

42
52

86
96

06

08

43

53

16

02

44

73

36

03
28

09
38

45
46

65
66

07

17

27

11

12

13

62

High
Low
Inv Fault

Over
Heat
INV short
OverLoad
Fan Fault
Charger
Fault
Bat Over

Soft fail
Bus
discharge
fail

63
61
33

1.2 Rear Panel Explanation

1KVA

2/3KVA

1.Emergency Power Of (EPO)

2.RS232 and USB Port

RS232 and USB
3.RJ45 Port
RJ45
4.Communication Card Options Slot

5.External Battery Connector

6.AC power connection socket

AC
7.Two programmable outlets

8.Breaker

9.High current Outlets

1.3 Customer Options Slot

The UPS is equipped with EPO dry contacts input, true RS232 and USB
Communication port as standard to provide communication with bundled UPS
monitoring software for remote monitoring of UPS status via PC.
There are 4 other optional interface cards available to meet various
communication needs, i.e. dry contact relay card and SNRT/WEB card
UPS EPO , RS232 USB
UPS UPS
, SNRT /
All the communication ports (including optional cards) can be active & use
simultaneously to monitor the UPS status. However only 1 communication
interface at any one time with the highest priority has the ability to command
&
control the UPS. The priority of these communication interfaces are as follow:
4

Highest Priority (in descending order),

() UPS
UPS:
(),
1) EPO input port
EPO
2) Optional Interface card
3) USB
4) RS232
1.3.1

RS232 and USB Communication Ports RS232 and USB

The UPS has serial communication capabilities through the USB
and RS232 communication ports or through a connectivity card
in the available communication bay. The UPS supports two
serial communication devices according to the following table:
USB RS232 UPS
UPS :

NOTEThe communication speed of the RS232 port is fixed at

2400 bps.
RS232 2400bps.
To establish communication between the UPS and a computer,
connect your computer to one of the UPS communication
ports using an appropriate communication cable (not
supplied). See Figure 18 for the communication port locations.
UPS ,()
UPS 18
When the communication cable is installed, power
management software can exchange data with the UPS. The
software polls the UPS for detailed information on the status
of the power environment. If a power emergency occurs, the
software initiates the saving of all data and an orderly
shutdown of the equipment. The cable pins for the RS-232
communication port are identified in Figure 19, and the pin
functions are described in Table 9.
, UPS
UPS ,
RS - 232 19
, 9

RS-232 Communication Port (DB-9 Connector)

RS-232 (DB-9 )

Table 1 . RS-232 Communication Port Pin Assignment

1 RS-232
Pin Number

146789

Fu n c t i o n
D e fi n i t i o n
N

RD(Transmit to external
device)
RD()
TxD(Receive from external
3
device)
TxD()
GND(Signal
5
common)
GND()
Emergency Power-off
2

1.3.2

Direction from the

UPS
-Out

In

- -

EPO is used to shut down the UPS from a distance. This feature can be used
for shutting down the load and the UPS by thermal relay, for instance in the
event of room over teRTerature. When EPO is activated, the UPS shuts down
the output and all its power converters immediately. The UPS remains on to
alarm the fault.
EPO UPS
UPS EPO ,UPS UPS
WARNING
The EPO circuit is an IEC 60950 safety extra low voltage
(SELV)
circuit. This circuit must be separated from any
hazardous voltage circuits by reinforced insulation.
EPO IEC60950 SELV
()

CAUTION
The EPO must not be connected to any utility connected
6

circuits. Reinforced insulation to the utility is required. The

EPO switch must have a minimum rating of 24 Vdc and 20 mA
and be a dedicated latching-type switch not tied into another
circuit. The EPO signal must remain active for at least 250 ms
for proper operation.
EPO
EPO 24Vdc 20mA
EPO
250ms
To ensure the UPS stops supplying power to the load during
any mode of operation, the input power must be disconnected
from the UPS when the emergency power-of function is
activated.
UPS
UPS
NOTE For Europe, the emergency switch requirements are
detailed in Harmonized document HD-384-48 S1, Electrical
Installation of the Buildings, Part 4: Protection for Safety
Chapter 46: Isolation and Switching.

HD-384 - 48 S1
,, 4 : 46
EPO Connections
EPO
Wire
Terminal
Wire
Size
Suggested
Function
Rating
Wire Size

EPO L1
40.32
mm2
(1222 0.82 mm2 (18
L2
AWG)
AWG)

NOTE Leave the EPO connector installed onto the EPO port of
the UPS even if the EPO function is not needed.
EPO EPO UPS EPO
EPO Connections EPO

You can set the EPO polarity..

EPO

EPO

NOTE Depending on user configuration, the pins must be

shorted or opened to keep the UPS running. To restart the UPS,
reconnect (re-open) the EPO connector pins and turn on the UPS
manually. Maximum resistance in the shorted loop is 10 ohm.
NOTE Always test the EPO function before applying your critical
load to avoid accidental load loss.
, UPS UPS,
EPO UPS 10
7


EPO

2 Installation and Operation

2.1 Operation Mode

2.1.1

AC mode

LED indications in line mode are as follows: the inverter green LED is on.
LED LED

When input AC mains is in line with the working conditions, UPS will work in
line mode.
UPS will monitor and charge batteries and protect your
equipment
UPS UPS UPS

2.2 Battery mode

LED indications in battery mode are as follows: both the inverter green LED
and battery yellow LED are on, the buzzer beeps once every 4 seconds. The
warning red LED is on when beeping.
LED LED LED
LED

When the mains power down or instable, The UPS will turn to battery mode at
once.
When recovering the mains power, UPS will turn to line mode and charge
batteries.
If low battery volume in battery mode, indications flash. Audible alarm beeps
every 1 second and LCD flash.
UPS
UPS
LCD

If battery voltage is approaching to power-of point, UPS will be turned of .
OFF points are varied with the loads.
UPS
Note: UPS power time depends on the EBP numbers and load. The estimated
time displaying on the LCD is similar with the actual stop time, but may have
obvious diference.
UPS EBP LCD
9


When mains power resumes for low battery voltage, UPS will auto-restart.
UPS
2.2.1

Bypass mode

LED indications in bypass mode are as follows:

LED

By-pass yellow LED is on, the buzzer beeps once every 2 minutes. The
warning red LED is on when beeping. LCD displays are according to the exact
load and battery capacity.
LED , LED LCD

By-pass input range can be set on the front panel. Please refer to manual.

UPS can transfer to bypass mode in below conditions:

UPS
Users can active bypass mode by front panel.
UPS is of when the line power is on and bypass output is active. UPS

Overload in line mode or ECO mode. ECO

Note: When UPS is working in by-pass mode, it has no backup function.

2.2.2

ECO mode ECO

LED indications in ECO mode are as follows: both the inverter green LED and
bypass yellow LED are on.
ECO LED LED LED

When the input mains meets the input range of the ECO mode and start the
ECO function, the UPS will works in ECO mode. If input AC mains exceeds the
range of ECO several times in a row in a minute but stays in inverting input
range, UPS will work on inverting mode automatically.
ECO ECO UPS ECO
1 ECO

ECO range can be set on the front panel. Refer to manual.

ECO
2.2.3

fault mode

LED indications in fault mode are as follows: warning red LED is on.
LED LED
10

Fault mode(LCD interface displaying fault code )

( LCD )
When UPS is fault , the LED light is on and the buzzer beeps. UPS will turn to
fault mode when overload, inverting fault, Over-temperature fault etc., UPS
cuts of the output and LCD displays fault codes. At this moment, you can
press the mute key to make the buzzer stop beeping temporarily to wait for
maintenance. You can also press the ON/OFF key to shut down the UPS when
confirm that there is no serious fault.
UPS UPS
UPS LCD

2.3 UPS on and of UPS

2.3.1

start up operation

Turn on the UPS in AC mode . UPS

. Once mains power is plugged in, the UPS will charge the batteries. LCD
shows output voltage is 0, which means UPS has no output voltage at that
moment. If it is expected to have output of bypass, you can set bPS "ON" by
LCD setting menu.
.UPS LCD 0 UPS
bPS ON
.Press and hold the ON/OFF combination key for more than half a second to
start the UPS, then it will start the inverter.
.
.Once started, the UPS will perform a self-test function.The LED will turn on
and of sequentially. After finishing self-test, it will come to line mode. The
corresponding LED lights and UPS will work in AC mode.
. UPS LED ,
LED UPS
UPS Turn on the UPS by DC without mains power
.When main power is disconnected, press and hold the ON/OFF key for more
than half a second to start UPS.
UPS
11

.The operation of UPS in the process of start is almost the same as when
mains power is in. After finishing the self-test, the corresponding LED lights
and UPS is working in battery mode.
UPS LED UPS

2.3.2

Turn off operation

Turn of the UPS in line mode. UPS

Press and hold the ON/OFF key for more than half a second to turn of the
UPS and inverter.

After UPS shutting down, LED go out and there is no output. If out put is
needed, you can set bPS "ON" by LCD setting menu.
LED bPS ON
Turn of the UPS by DC without mains power. UPS
Press and hold the ON/OFF key for more than half a second to turn of the
UPS.

When turning of the UPS, it will do self-testing firstly. LED will turn on and
of sequentially until there is no display on the panel.
UPS LED ,
2.3.3

Manual self-test, mute test operation

When UPS is in line mode, press and hold the self- test/ mute key for more
than 1 second, LED light will turn on and of sequentially. UPS comes to selftest mode and tests its status. It will exit automatically after finishing testing,
LED resume.
UPS / 1 LED
,UPS UPS LED
When UPS is in battery mode, press and hold the self- test/ mute key for
more than 1 second, the buzzer stops beeping. If you press and hold the selftest/ mute key for more than 1 second, it will restart to beep again.
UPS / 1
/ 1

12

3 System Block Diagram and Wiring Diagram

3.1 System Block Diagram

1.Bypass

2. AC Input To provide the AC source to the PFC and charger circuits of the
UPS.
PFC
3.Breaker: Input Breaker
:
4. Input EMI Filter: To eliminate magnetic interference from AC source or UPS
Rectifier.
EMI
5.PFC:
.
6.Inverter:

7.Output EMI Filter:

UPS .
8.Output (Load)
UPS
9.Auxiliary Power:

10.DC/DC:
DC DC
11.Battery:

12. Control:

13.Charger:

14.LCD Display:
LCD
15.USB and RS232
USB RS232
16.SNMP:
SNMP
17.EPO:

18.RJ45:
RJ45

3.2 Wiring Diagram

3.2.1

1KVAS UPS is mainly coRTosed of the following PCBs:

1KVAS UPS PCB :
13

3.2.2

2/3KVAS UPS is mainly composed of the following PCBs:

2/3KVAS UPS PCB :

14

15

4 Unit Test and Calibration Setting

4.1 Electrical Characteristics

4.1.1

Battery Charging Voltage (25) 25

Setting
Battery Charging Voltage
Point Model

1KVA
27.5Vdc
1KVAH-B
27.5Vdc
1KVAH
41.25Vdc
4.1.2
Test points
and
standards

2KVA
55Vdc

2KVAH-B
55Vdc
PCB
TEST 2KVAH
TEST POINT 82.5Vdc
EXPECTED RESULT
PSDR DC(+)BU
C13
or
BATTERY-,R104
for
360V20V
for 220V output
3KVA
82.5Vdc
S 3KVAH-B
1KVA C139/C138/C136
or
82.5Vdc
BATTERY-,R304 for 2KVA/3KVA
3KVAH
110Vdc
DC(-)BUS
C12 or BATTERY-,R101 for
-360V20V for 220V output
1KVA C137/C140/C141 or
BATTERY-,R318 for 2KVA/3KVA
CHG
R

CHARGE
R

27.50.5V /41.250.6V for 1KVA

550.6V/82.50.6V for 2KVA
82.50.6V/1101V for 3KVA

BAT+, BAT-, for

1KVA/2KVA/3KVA

4.2 COMPONENT VERIFICATION

For the reason of safety, you must disconnect UPS to the mains and disconnect battery
connector. Check the components listed below to confirm which block is out of order and
follow the procedures listed on the following pages to repair them.
, UPS

CAUTION:
DO NOT supply UPS with the mains unless you are sure that you have replaced all defective
components.
: UPS
Circuit Block
Components to be checked
Fail condition
FUSE

PFC

DC/DC MOS

F1,F2,F3 for 1KVA

for 2KVA/3KVA

F1,F2,F3

Q1/Q1A for 1KVA

Q9 for 2kVA/3KVA
D11,D10,CD1 for 1KVA
D116,D117,REC02 for 2KKVA/3KVA
Q2,Q3,Q4,Q10 for 1KVA
Q4,Q5,Q6,Q7 for 2KKVA/3KVA
16

open
C-E short or open
short or open
D-S short or open

Inverter
IGBT

Q12,Q13 for 1KVA

Q13,Q14,Q15,Q16 for 2kVA/3KVA

4.2.1

C-E short or open

POWER FACTOR CORRECTION:

Step

Checked components

*Instrument
function

Reference
Value

Failed
condition

F3 for 1KVA
F3 for 2KVA/3KVA

short

open

Q1/Q1A for 1KVA

Q9 for 2kVA/3KVA

(C,E)
DIODE
(G,E)

0.5V
47K

short or open
short or open
or value
change

D11,D10 for 1KVA

D116,D117 for 2KKVA/3KVA

DIODE

0.5V

short or open

R168,R169 for 1KVA

R408,R266,R267 for
2KVA/3KVA

36,10for
1KVA/1.5KVA
36,47,22fo
r2KVA/3KVA

open or value
change

CD1 for 1KVA

REC02 for 2KKVA/3KVA

DIODE

0.5V

short or open

4.2.2

Step

DC-DC CONVERTER: -

Checked components

F1,F2 for 1KVA

Q2,Q3,Q4,Q10 for1KVA
Q4,Q5,Q6,Q7 for 2KVA/3KVA

4.2.3

2KVA/3KVA

*Instrument
function

Referenc
e
Value

Failed
condition

short

open

(D,S)DIODE
(G,S)

0.5V
23.5K

short or open
short or open or
value change

DC/AC INVERTER: /

Step

Checked components

Instrument
function

Q12,Q13 for 1KVA

Q13,Q14,Q15,Q16 for
2kVA/3KVA

(C,E):
DIODE
(G,E):

R138,R140,R154,R155for1KV
A
R303,R307,R314,R308,R311,
R316,R322,R320for2KVA/3KV
A

4.2.4
Step

Reference
Value
0.5V
20K for
1KVA/1.5KVA,
23.5K for
2KVA/3KVA
36,10for 1KVA
10,27for
2KVA/3KVA

Failed
condition
short or open
short or open or
value change

value change or
open

CHARGER:

Checked components

*Instrument
function
17

Reference
Value

Failed
condition

D1,D2,D3,D4 for
1KVA/2KVA/3KVA

DIODE

0.5V

Q1 for 1KVA/2KVA/3KVA

(S,D)
(D,S)
(G,S)

0.5V

50K

D6 for 1KVA/2KVA/3KVA

DIODE

0.5V

Short or open
Short or open
Short
short or open or
value change
Short or open

5 Customer Options Slots

5.1 DCE (Dry Contact) card DCE

For installation, please refer to the users manual attached with the card.

Installation Position: Optional Slot

5.2 SNMP card SNMP

For installation, please refer to the users manual attached with the card.

Installation Position: Optional Slot

6 Troubleshooting Guide

6.1 Error Code BUS Fault

SymptomIt means Bus voltage fault. The LED light is on and the buzzer
beeps. UPS will turn to fault mode, cuts of the output and LCD
18

displays fault codes.

Note: Fault code in detail see 1.1.3 (Error code Explanation)

Troubleshooting Chart

6.2 Error Code inv Fault

SymptomIt means the UPS inverter is abnormal. The LED light is on and the
buzzer beeps. UPS will turn to fault mode, cuts of the output and
LCD displays fault codes.
Note: Fault code in detail see 1.1.3 (Error code Explanation)

Troubleshooting Chart

19

6.3 Error Code Over Heat

SymptomIt means there is overheat protection occurred in the UPS. The LED
light is on and the buzzer beeps. UPS will turn to fault mode, cuts of
the output and LCD displays fault codes.
Note: Fault code in detail see 1.1.3 (Error code Explanation)
20

Troubleshooting Chart

6.4 Error Code INV Short

Symptom It means UPS is short circuit. The LED light is on and the buzzer
beeps. UPS will turn to fault mode, cuts of the output and LCD
displays fault codes.
Note: Fault code in detail see 1.1.3 (Error code Explanation)
21

Troubleshooting Chart

6.5 Error Code Over load

SymptomIt means there is overload protection occurred in the output of the
Inverter of the UPS. The LED light is on and the buzzer beeps. UPS
will turn to fault mode, cuts of the output and LCD displays fault
codes.
Note: Fault code in detail see 1.1.3 (Error code Explanation)

Troubleshooting Chart

22

23

7 Technical Specifications

24

8 Appendix

8.1 PCB Layout PCB

25

8.2 PCB Placement PCB

8.2.1

1KVA/1.5KVA Input filter plate 1KVA/1.5KVA

26

8.2.2

1KVA/1.5KVA power board 1K/1.5K

27

8.2.3

2KVA/3KVA power board 2KVA/3KVA

28

8.2.4

2KVA/3KVA Input filter Board

8.2.5

control board

29

2KVA/3KVA

8.2.6

charging board

Fly back transformer

Fly back
Mosfet

R
ECTIFIER

30

8.2.7

USB and RS232 board USB RS232

31

8.2.8

SPS board SPS

Fly back
transformer

Mosfe
t

32