Service Manual - PHD Powerhouse
Contents
1. GPO S GB GO GBP BB NIL b Le N LAT le Lo Tl T N LA ls te N ta LE itc DO iM H OUTPUT iA INPUT GND Faith BATT fi OUTPUT 5 A INPUT GNDI Hi it BATT Ol BELA a a APACHE No Lio Lz0 L30 um B R GR Diagram 7 paralleled system of the s 3 units connect line diagram 7 2 Three or more units paralleled system diagnosis program Three or more units paralleled system diagnosis program is similar to two units paralleled system the difference is single unit exit program and paralleled system recover program D Single unit exit program A Turn off all UPS from panel B Turn off the failure UPS bypass power battery and output breaker C Pull out the failure UPS paralleled line set the UPS to single unit act as 4 2 2 in the manual D Turn on the other UPS from the panel if the load is bigger than one unit output nominal load the load should be turned off or reduced Paralleled system recover program A Turn off the load turn off all the UPS from the panel and turn off their output breaker B Turn off the bypass power and battery breaker of all the UPS C Connect the paralleled line and set the UPS that used to be failure to paralleled mode D Turn on power bypass breaker of all the UPS and turn on the battery breaker after the rectifier start normally turn on all UPS from the panel 502. 3 6 4W GND Battery voltage VDC Charge current A 12V X 29 348V Voltage Vac L N 220 L L 380 Mains input normal automaticly synchronize the mains Mains failure 50 Frequency Hz ae Three line 100 load imbalance lt 2 allow 100 imbalance Sd stabilization linear load THD lt 3 125 rated load 15 minute 150 rated load 1 minute E Capacity KVA Maintain bypass Provide no transfer time maintain bypass switch Start up function Support DC start up function Three phase input voltage input frequency three phase output voltage load LCD displa si battery voltage battery charge and discharge current and so on LED display UPS working status and failure indication Alarm function Input abnormal battery low over load failure Communication provide stem point communication and RS232 RS485 achieve UPS function aptitude supervise Battery testing detail see in LCD display working battery testing control page function introduction output short circuit over load over temperature battery low output over Protection voltage low voltage Meets standard GB T 7260 3 2003 Noise dB Cooling mode Ventilator Working 0 40 temperature CC Relative humidity 0 95 95 No condensation condensation Dimension wide X length xX 1200 X 800 X 1600 height mm Weight Ko 1180 1300 The index fluctuation forgives a not another line to notify Tab 2 2 Techni
3. ese OV EE ER H i ULC Von p 23 2V 9 005 OSkHz EE N basal eel Pe ee i mr Ma SD re EE EK i RARE Inti i lola i eed reni 3 The square wave signal of diagram 5 14 main board 9 KHzseses measure and its wave 30 B Test the PWM board 3 board IC3 1P 7P signal with a oscillograph the wave should be two anti phase 9KHz triangle wave as shown in figure 5 13 It can be tested with a multimeter the value tested should be 2 1 0 2Vac 0 1 0 1VDC GND connect to right pin of R54 T1 Vp p 13 5 0 3 V f 9 00 0 OB kHz Picture 5 13 Triangle wave signal test and waveform C Press ON key to turn on the UPS test the three phase PWM board IC9 1P the waveform should be sine wave and there is a slow start period the phase differ between any two of the three sine wave of PWM board should be 120 It can be tested with a multimeter the value should be 1 0 0 2Vac 0 1 0 IVDC GND connect to right pin of R54 a a i H p 31 i ARE oe ia EE EE EE N N EER EN N EEUE Fr Ja re A alas siii Figure 5 14 PWM board sine signal test and waveform D Test left pin of R113 R115 R104 R107 of the three PWM board the waveform is SPWM wave its Vp p is 12 1V as shown in figure 5 15 It can be tested with a multimeter the value is 6 2 0 2Vac 6 2 0 2VDC YVp p l1l2Yy A 9KHx PRE TE JE Figure 5 15 PWM board SPWM signal test and waveform E Test inverter driver board four SPWM driv
4. Is the battery bad Replace the battery Y Replace the DC contactor Is the DC contactor bad Y Is the rectifier voltage Replace the fan control board sampling hall bad Replace the main board Inverter test i end 37 5 4 2 Program describe It is very possible that the symptom caused by battery bad especially for the UPS that has been used for more than three years Battery test The UPS has battery test function in the panel LCD there is a battery test function menu there are three items in it as shown in figure below Choose the GENERAL TEST or DEEP TEST the UPS will discharge the battery and test it if the battery is bad the panel LCD will display alarm message HANUAL TEST BATTERY MANAGEMENT STATUS OFF gt HANUAL TEST gt ABOART TEST BOOST CHARGE GENERAL TEST DEEP TEST Test the DC contactor Test the voltage between the two control pins of the DC contactor with a multimeter the value should be 197 2VDC and the voltage between two contact pin should be 0 else the DC contactor should be damage Test the rectifier voltage sampling hall Check the rectifier voltage that panel LCD display if the value is much smaller than it is tested in fact the rectifier voltage sampling hall should be bad 5 5 Symptom 5 In utility mode UPS is normal but the battery breaker will trip when it is turned on in battery mode Abnormal symptom Diagnosis ready program Replace DC conta
5. 17 42 2 main board DIP SWitCh Seting arr 18 4 2 3 rectifier control board DIP switch setting oro 19 4 3 Potennal iumetion intfoduciloni scorci lele i ata 19 4 TE ONO board Eee 19 SOZZI ille lia 19 APA M 010 110 ERE ME 20 ER ES DE K controll na SE tele rel Ao taht ee rela aaa eaa Aes eae 20 LODO clelia 21 4 4 Main board indicate light introduce ese ee nenna ena RR Ee E ee ee ee ee ee ee ee ee ee ee ee 21 5 Some familiar symptoms and diagnosis program ee ee ee ennen ennen eee e ener eee ener reeeee 22 SMP ONLINE 22 After turn on the power breaker or bypass breaker the panel PHASE light is on and the buzzer Deep Oh vvs 22 NPD 22 Daas DNS OT NNN 23 POSE 23 5 3 Symptom 3 The UPS power breaker trip when it operation normally rrrrrrrrrrrrrrnn 36 5 4 Symptom 4 When the utility is failure the UPS shutdown output and the panel BAT LOW i dicate e ER 37 DENN 37 DA PN Ne 38 5 5 Symptom 5 In utility mode UPS is normal but the battery breaker will trip when it is Cured on i battery Mode HP 38 5 6 Symptom 6 In utility mode UPS is normal but the UPS battery low protection enable when battery breaker is turned on in battery mode and the panel BAT LOW light on and the puzzer bee sella 39 Sue DENS TOT ON Fer 39 STEN 39 5 7 Symptom 7 The UPS switch to bypass panel FAULT indicate light on and buzzer beeps Conumualle sc ee eee eee eli 40 S L1 Diagnosis propra ie iS N alee aed GE lille ila 41
6. 312 PO ON rail 42 5 8 Symptom 8 Turn on the bypass power breaker turn on the UPS and protection enable as s mas hemmer 44 5 9 Symptom 9 The protection enable as soon as the UPS switch to inverter output after it is red bout 0 ae 44 6 Series Connection Hot Standby System diagnosis program i 45 6 1 The standby UPS of series connection hot standby system diagnosis program 45 6 2 The main UPS of series connection hot standby system diagnosis program 46 62 TDAI PN PR 46 0 22 POR aM COSC US eee 46 Paralleled system didsnosis prosrani cui bia 47 7 1 Two units paralleled system diagnosis programi iii 47 ide DE SI DOEL EEE ER 47 EV Prom 48 7 2 Three or more units paralleled system diagnosis program iii 50 1 Brief introduction The ST5100 series UPS adopt advanced DSP control technique they have a simple operation interface and strong communication function the module design is easy to maintenance and it have good EMC design which makes it become a excellent and high performance UPS Its technique specification is shown in the table below Tab 2 1 Technique specification en N ST5100 Specification EE CE 515100 100K ST5100 120K 515100 160K Rectifier structure Three line phase control rectifier Voltage range Vac 380 25 Rectifier frequency range 40 65 Hz Synchronization frequency range 50 15 Hz
7. mistake it can be reset according to 4 2 2 mentioned in the manual B It should be paralleled line poor contact or bad turn off the UPS and connect it again or replace it 5 8 Symptom 8 Turn on the bypass power breaker turn on the UPS and protection enable as soon as the inverter start Diagnosis program 1 Turn off the load Turn off the bypass breaker and turn off the UPS Turn on the UPS again if the symptom still exist it should be inverter failure Act as 5 6 mentioned in the manual 8 If the UPS start normally test the voltage between CN2 1P and 3P on the PWM board the value has a low start progress then it should be inverter output SCR SCR driver board failure 4 Proceed UPS diagnosis ready program Replace the inverter output SCR SCR driver board 6 Proceed system recover program 7 UPS function test 5 9 Symptom 9 The protection enable as soon as the UPS switch to inverter output after it is turned on about 30 seconds Diagnosis program 1 Turn off the load of the UPS Turn off the bypass breaker turn off the UPS 2 If the problem still exist it should be inverter failure act as 5 6 mentioned in the manual 8 If it start normally test the voltage between any two pins of the bypass breaker upper 44 pins the value should be 20 30Vac else the bypass SCR SCR driver board or main board should be bad 4 Proceed UPS diagnosis ready program Replace bypass SCR S
8. parallel parallel Rectifier Inverter Main Output Battery current current input output transformer current current equal sample inductor inductor sample sample inductor transformer hall hall picture 3 10 ST5100 80 160K back sight right sight picture 3 4 2 inverter radiator module IGBT snubber Inverter DC board IGBT current is below it sampling hall DC fuse Inverter IGBT current samping hall IGBT ST5100 80 160K three modules Picture 3 11 inverter radiator module 14 3 4 3 rectifier and SCR radiator module SCR snubber beer Beard output SCR Bypass SER SCR Inverter output and bypass SCR driving board Rectifier output current Rectifier i sampling hall SCR driving mr 5 board Mn s1 oS Rectifier gt re lt Ls f a SCR A i 7 si mre a Ed Rectifier A E Af ui ad SCR snubber board ST5100 80 160K rectifier SCR radiator picture 3 12 rectifier bypass SCR radiator module 4 Function description 4 1 Function of system main parts 4 1 1 Rectifier control board function 1 AC input phase sequence wrong or phase lose test When AC input phase sequence wrong or phase lose rectifier will stop working Q Input voltage test When the AC input voltage is out of permited value rectifier will not work 8 Bypass input phase sequence wrong or phase lose test When bypass input phase sequence wrong or phase lose rectifier control board DSP think that bypass
9. CR driver board or main board 6 Proceed system recover program 7 Proceed UPS function test 6 Series Connection Hot Standby System diagnosis program 6 1 The standby UPS of series connection hot standby system diagnosis program 1 Press off key of the panel to turn off the UPS Turn off the standby UPS utility and bypass breaker Q Turn off the main UPS bypass breaker Operation as single unit trouble shooting program 4 When the standby UPS is normal turn on the utility and bypass breaker press on key to turn on the UPS turn on the battery breaker when the rectifier start normally and turn on the bypass breaker of the main UPS 45 6 2 The main UPS of series connection hot standby system diagnosis program 6 2 1 Diagnosis program Abnormal phenomenon Over load output Reduce the load or short circuit check the output wire sa 18 Hi I Is the utility input Check the utility voltage h l normal frequency phase lose or not in order Confirm that if the battery is full charge is bad or is connected correctly correct it Turn off the load and go to abnormal UPS test program Check the UPS function End 6 2 2 Program describe The program has been described before in the manual 46 7 Paralleled system diagnosis program 7 1 Two units paralleled system diagnosis program 7 1 1 Diagnosis program Abnormal phenomenon Over load output Reduce the load or check
10. E After the UPS start normally test the voltage between two UPS output with same phase the value should be less than 10Vac as shown in figure 7 1 Turn off the output breaker test the voltage between two output breaker upper three pins Al and A2 Bl and B2 Cl and C2 Turn on the two output breaker without load test the three live lines output current and the value should be less than 3A as shown in figure 7 2 Turn off the utility cabinet power breaker test the voltage two UPS output should be 50Hz and the voltage should be 220Vac test the output current should less than 3A Turn on the cabinet power breaker add the UPS load and test the two UPS output current the difference should less than 5 of nominal output current 51
11. ER indicate light on 30 seconds later it will switch from bypass to inverter output and the BYPASS light off during the switch test the UPS output with a multimeter it should be uninterruptible F Display function test During the test program concerned previously the UPS panel LED LCD should display correctly 33 5 3 Symptom 3 The UPS power breaker trip when it operation normally Pull out the line on the rectifier driver board Abnormal symptom Diagnosis ready program that is connected to SCR turn on the power breaker again Will the UPS power Replace the rectifier breaker jump again control board rectifier driver board Replace the rectifier SCR Put on the driver board connect line turn on the power breaker Will the UPS power breaker jump again X Replace the UPS power breaker Inverter test UPS function test 36 5 4 Symptom 4 When the utility is failure the UPS shutdown output and the panel BAT LOW indicate light is on 5 4 1 Diagnosis program Abnormal symptom Is the UPS turned on or Turn on the UPS or reduce the load lt output overload Check the battery cabinet breaker Is the battery connected Hy battery connect line and UPS normally battery breaker The utility long time faluree cause Is the battery low the battery low when the utility recover recharge the battery for 10 hours and it will be normal
12. INDEX E BierkmnbodiioliessGsge a 3 gt Vors 6 Did VE NENNE Ne 6 NE oi ER alia hd palesi alp leleine ERNE FEER ERE REE AE RER En Vi 2 3 TheWUPS eleetrical connceton diapram ecieie a leda 7 URTI UT O aa IAA 9 iaia 9 3 1 1 ST5100 80 160KVA shape and dimension uren ennen ene renerne 9 30 1c 2 15100 200 10001 shape and diens TOR EE EE cues 9 2 Parel NR 10 25 Terminal and bek EE SE AAS Sn 11 ENN 11 NN ENN 11 DA 2 Inverter FO Mode EE EE EE Ge 14 3 4 3 rectifier and SCR radiator DIE ns 15 A URCHONSGESCL Pto Ne OR AE OR OE AR EE EE EE OE N 15 A Futetioiol system mal PN nei eerie ees 15 4 1 1 Rectifier control board Tune ss ss se ee ER ee Ee Se SE Me De Ge ceo 15 412 Main board TG ON ONSE sigilli 16 41 PM Bod FUNC ELON OE eee el 16 A4 JA Display board Ene ON ae 16 4 1 6 Inverter driver board Inverter driver signal isolate and enlarge 16 4 1 7 Bypass inverter output SCR driving board Bypass inverter output SCR diivei isolate sd Eee lana eee 16 4 1 8 Power board Supply 12VDC 12VDC 30VDC 5VDC 24VDC power to the SEE SR EE EE ORE EE REED PIER AIR IERI ON EE EIN EP aes 16 4 1 9 Power backup and transfer board Power transfer iii 16 AO PLN 16 4 1 11 Parallel board Parallel control function iii 17 42 DIP switchsetting or each board ella beth 17 4 2 1 display control board board DIPswitch setup ennen en eeeeeere
13. UPS function aptitude supervise Battery Detail see in the LCD display working battery testing control page testing function introduction Output short circuit over load over temperature battery low voltage output Protection over voltage low voltage Meets standard GB T 7260 3 2003 Noise dB Cooling mode Ventilator Working temperature CC Relative 0 95 No condensation humidity Dimension wide X length X 1200 Xx 800 X 1600 height mm mm uni de ia iu ai 2 Working principle 2 1 Working principle diagram gt lt NED a Maintenance switch Bale 5 Bypass breaker AC SOURCE O LOAD An BTG AC DC peace 9 Power breaker A Transformer N Battery FE 2 2 Working mode When the utility is normal the rectifier convert the AC input to DC power it supply the inverter and charge the battery at the same time Through the process of AC power changed to DC power the inverter can supply more reliable and pure power to load as the rectifier can dispel the problems of the portent noise unstable frequency and so on When the utility is abnormal the battery connected to DC BUS will supply power to inverter to protect load from AC power interrupting when the inverter is failure such as over temperature short circuit output voltage abnormity overload and so on the inverter should shut off automatically If the utility is normal at this moment the switch will switch to bypass power t
14. ctor Does the battery breaker Replace the battery jump after it is turn breaker System recover program 38 Program describe System recover program 1 Turn on the power bypass output breaker Turn the maintenance switch to UPS mode 8 Turn on the battery breaker after the panel BAT LOW indicate light is off 4 Press panel on key to turn on the UPS 5 6 Symptom 6 In utility mode UPS is normal but the UPS battery low protection enable when battery breaker is turned on in battery mode and the panel BAT LOW light on and the buzzer beep continually 5 6 1 Diagnosis program Abnormal symptom Diagnosis ready program Replace the DC buffer resistance System recover program End 5 6 2 Program describe Test the DC resistance test the resistance of the DC resistance that is locked upon the fan 39 control boar with a multimeter as shown in figure 5 22 direct current Picture 5 22 Replace the DC buffer resistance 5 7 Symptom 7 The UPS switch to bypass panel FAULT indicate light on and buzzer beeps continually 40 5 7 1 Diagnosis program Abnormal symptom Check the main board indicate light confirm that which protection the UPS is in Inverter output over voltage Output over voltage diagnosis program low Inverter output low Inverter output voltage voltage diagnosis program Inverter Inverter over temperature
15. d output over voltage low voltage battery low switch control bus over current etc 4 PS failure appearances indicate d 1 3 PWM board function introduce 1 Three phase inverter signal produce 2 Automatic equilibrium control Current feedback and current limit protection 4 1 4 Display board function D Some parameter value display Battery test charge control System alarm signal display 4 1 5 Rectifier driver board Rectifier driver signal isolate and enlarge 4 1 6 Inverter driver board Inverter driver signal isolate and enlarge 4 1 7 Bypass inverter output SCR driving board Bypass inverter output SCR driver isolate and enlarge 4 1 8 Power board Supply 12VDC 12VDC 80VDC 5VDC 24VDC power to the system 4 1 9 Power backup and transfer board Power transfer 4 1 10 Fans control board D Fans speed control full speed half speed stop 16 DC buffer 8 DC voltage isolate and sample 4 DC current isolate sample 4 1 11 Parallel board Parallel control function 4 2 DIP switch setting of each board 4 2 1 display control board board DIPswitch setup ID code setting We can set the UPS ID code through display control board DIP switch setting it can be set according to the table below For the UPS produced after 2007 01 01 the DIP switch is cancel and it can be set from panel LCD directly Setting picture Setting picture H Panel 50 60Hz system identify se
16. e put on the CN15 of main board function test A Turn on the power breaker the panel BAT LOW indicate light and RECTIFIER indicate light on turn on the bypass and output breaker the panel BYPASS indicate light on and buzzer beep continually 20s later the rectifier start normally the BAT LOW indicate light off buzzer stop beeping turn on the battery breaker Turn on the UPS the inverter start to work the panel rectifier indicate light on 30s later the inverter output SCR is turned on and the bypass SCR is turned off the panel BYPASS indicate light off the inverter supply to output B Switch function test Turn off and turn on the UPS AC input power breaker of the power cabinet test the UPS output voltage on the terminal it should be uninterruptible as shown in figure 5 21 C Charge function test Turn off the battery breaker test voltage between the UPS batterybreaker upper connector and BAT of the terminal the value should be 395 3VDC as shown in figure 5 20 PIERROT in hm ie AD 7 N Yel f y_ 0000 Picture 5 20 measure of charge voltage D Operation with load function test Turn on and turn off load test the 34 voltage between any line of the three live lines and the neutral of the terminal with a multimeter the value should be 220Vact2 as shown in 5 19 The diagram 5 21 output voltage measure E Bypass function test Press OFF key to turn off the UPS the RECTIFI
17. eaker of the two UPS turn on the battery breaker when the rectifier start normally press on key on the panel to turn on the UPS F After the UPS start normally test the voltage between two UPS output with same phase the value should be less than 10Vac as shown in figure 7 1 Turn on the two output breaker without load test the three live lines output current and the value should be less than 3A as shown in figure 7 2 Turn off the utility cabinet power breaker test the voltage two UPS output should be 50Hz and the voltage should be 220Vac test the output current should less than 3A Turn on the cabinet power breaker add the UPS load and test the two UPS output current the difference should less than 5 of nominal output current 48 Diagram 7 paralleled output of the s 1 units press bad of measure Diagram 7 the s 2 output the current measure The units paralleled system connects line diagram 49 UPS1 UPS2 v JH GND Hi GND it OUTPUT i INPUT Hi BATTERY YAH OUTPUT f l INPUT Hi BATTERY PERE M TN ORE A HEN GO EIE GB IE OB OG GB EIS GN GP GPO OG GO
18. ectifier over sampling hall charge 9 a current sampling hall rectifier SCR or rectifier capacitor Is the SCR connect Line the SCR again line contact good ensure that it is contact good Is the rectifier driver Replace the rectifier signal normal control board and SCR rectifier driver board damage replace it rectifier driver board Is the Rectifier normal End 26 A Rectifier control board utility sampling transformer and fuse test Turn on the power breaker test the voltage between both sides of the fuse and N of CN6 on the board with a multimeter the value should be about 220 Vac else the fuse should be damage Test the voltage between cathode of V01 V02 V03 on the board and GND left pin of C64A the value should be about 30Vac as shown in picture 5 6 If the value is wrong the transformer should be damage replace the rectifier control board V01 V03 ess en ee Ar EF F n ip meet etree SPE at HAY Ur picture 5 6 utility samping voltage test B Diagnosis of rectifier over voltage Turn off the power or bypass breaker turn on the power breaker test the rectifier output voltage with a multimeter as shown in figure 5 5 If the voltage raise to 415VDC and panel RETIFIER light off FAULT light on buzzer beep intermittently and the rectifier output voltage descend it means that the rectifier output is over voltage it may caused by the damage of rectifier output
19. er C If it is IGBT over current carry out diagnosis ready program act as 5 1 2 mentioned in the manual D Replace the IGBT current sampling hall test IGBT and replace the bad one E Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board Picture 5 25 output current measure Inverter overload or output phase unequal diagnosis A Expel the problem of the load first if there is short circuit or overload 43 1 TE B Test the current three phase output as shown in figure 5 25 Calculate the actual load by Pn Un In n 1 3 and compare to the load displayed in panel LCD if the difference is too much over 50 the UPS output current sampling hall should be bad C For output phase unequal fault the UPS will operation normally without load the difference amount three phase output voltages should enlarge with small load and the UPS protection will enable with large load Test the voltage between three DC fuse with a multimeter to confirm that if the fuse is bad D Proceed diagnosis ready program E Test IGBT Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board G System recover program Paralleled line failure diagnosis program A In single system the problem may be caused by main board DIP switch setting
20. er signal between each G and E with a oscillograph as shown in figure 5 16 It can be tested with a multimeter the value is 10 840 2Vac 5 20 2VDC 32 Figure 5 16 Inverter driver board SPWM driver signal F Turn off the UPS turn off the power breaker test the signal of V21 V32 of the main board the ground line connect to R37 down pin Turn on the power breaker the voltage V21 tested will be about 5VDC the voltage V32 tested will be OVDC turn on the UPS 30 seconds later its protection will enable buzzer beep continually Turn off the UPS G Put on the CNI2 of power backup and transfer board put on CN09 of the main board install three 5A fuse between the place the three inverter fuse uninstalled before Small insurance MP z i atter d i Picture 5 17 ascend the small insurance tube try inverter 33 H Turn on the power breaker test the voltage between CN1 1P and 3P it should have a rise period and stabilize at about 30Vac as shown in figure 5 18 Test the voltage between any two upper pins of the bypass breaker with a multimeter the value should be 30 40Vac else the bypass SCR or its control board should be damaged Picture 5 18 Measure the inverter feedback voltage DUPS I Turn off the UPS Turn off the power breaker discharge the rectifier capacitor until its voltage reduce to OVDC install the inverter fuse again turn on the bypass breaker turn the maintenance switch to UPS mod
21. ht bright U Phase indicates light red When the rectifier input bypass input phase sequence wrong or phase lose the light bright 3 3 Terminal and breakers 80 160KVA Input and output N BAT BAT 200 400KVA Picture 3 5 Terminal and breakers 3 4 Inside structure 3 4 1 UPS inside structure D Main PCB 11 Power distribution Paralleled board board Rectifier control board i Display board Main board Display control board PWM board Power board _ Ei Fan control board Power distribution board Rectifier control board Display board Main board PWM board Display control board l i Power board 200 400KVA Picture 3 6 machine main electrocircuit board 2 Radiator module 12 Inverter Rectifier Bypass and output Picture 3 7 ST5100 80 160K inverter module Picture 3 8 ST5100 80 160K rectifier module bypass and output SCR module Bypass and inverter output IGBT and its SCR filter board Rectifier SCR Picture 3 9 200 400K VA inverter module rectifier module bypass and output SCR module As above diagram when we need to be replaced a component on the damage radiator module we can remove the two screws fix on top and bottom of the radiator and pull out the connect line of the radiator module turn off the line box pull out lines insided then pull out the radiator module 8 Main circuit inductor transformer Hall 13
22. ht while mains input is normal C Rectifier indicate light green it bright when the rectifier working normal D Page up key This key is display upward parameter setting function repeat E Back page key left Push this key to check the item LCD display or turn on background light F Turn over page key downward Push this key mean display downward Parameter setting G Switch on key Match with a usage with H while switch on H Confirm key Push this key to confirm the function I Shut down key Match with a usage with H while shut down J Confirm key Usage while checking to seek the contents of LCD display K Return to key Usage while checking to seek the contents of LCD display L The battery indicate light green When battery power supply it bright M The inverter indicate light green When the inverter working normally the light is bright N Output indicate light green The light is bright while there is output voltage O Bypass indicate light green Bypass power supply the light is bright P Maintenance bypass indicate light green When power is supplied by maintainance bypass the light bright Q Failure indicate light red Rectifier inverter and bypass failure the light be bright R Overload indicate light red The light bright when UPS is overload S Battery low indicate light red The light bright when battery low 10 T Bypass indicates light red Bypass output the lig
23. in board indicate light introduce jas Sj N sapa rel di LED9 Wai 7 i Li dy DR LED Figure 4 6 Main control board indicate light LEDI red When system appears inverter output over voltage protection IGBT over current protection or over current protection between two parallel units it will light Pressing the panel OFF key can clear the protection LED2 red Inverter output low voltage fault light LED3 red Inverter over temperature indicate light LED4 red Inverter output over voltage indicate light LEDS red It will light when the inverter does not work LED6 red When the system appear 200 rated overload output phase unbalance 21 output over voltage or low voltage software protection the light will light The protection can be cleared when the power bypass battery breaker are turned off and then turned on again LED7 red Battery low indicate light it lights when battery low or the moment rectifier start LED8 red Parallel line fault indicate light LED9 green It will light when the system become synchronous 5 Some familiar symptoms and diagnosis program 5 1 symptom 1 After turn on the power breaker or bypass breaker the panel PHASE light is on and the buzzer beep continually This is caused by the input AC power phase lose or phase wrong turn off the power breaker or bypass breaker test the voltage between terminal AC input three phase LA LB LC to N if one o
24. is failure at this time and send out a bypass failure signal to the inverter and request inverter not allow bypass output 4 Bypass input voltage test When the bypass input voltage is out os the permited range rectifier control board DSP think that bypass is failure at this time and send out a bypass failure signal to the inverter and request inverter not allow bypass output 15 Output over voltage over current protection When the voltage current of the rectifier output exceeds permited range rectifier will be shut down 6 Charge current too big protection When the charge current exceeds an enactment value the rectifier automaticly stops working 7 Boost charge float Charge voltage tiny adjust Through adjust rectifier control board RP6 and RP8 potential we can adjust the float charge voltage and boost charge voltage Float Charge voltage adjust range is 390 400 VDC and boost charge voltage range is 400 410 VDC The charge current setting The rectifier control board SW1 DIP can be used to set charge current 9 The rectifier over temperature protection The rectifier will stop working when the temperature is too high Rectifier six pulse control signal produce 4 1 2 Main board function introduce 1 DSP voltage stability control Output frequency 50Hz 60Hz synchronous frequency range setting output voltage phase synchronous tiny adjust function Inverter protect function over temperature over loa
25. ld be 1 0 0 2VDC 1 4 0 2Vac SZ TE qie Se FT m ee ai ETE ME GE wa EE neo a das bl tere Hi HM to os ad lt la rd 3 Oe i ae kHz ee sA es LER FE ee ee ee ne ee ee ee AN ee ee EE ee ee eee AE EEN ee eee ee eee EE ee ee ee EN EE EE ee ee AE DE EEN eee AAN eee eee EN eee eee AN EEN a picture 5 10 rectifier driving sign test wave 28 F SCR test test the SCR any two pin between each of the pin 1 2 3 with a multimeter the resistance tested should not be short circuit test pin 4 to 5 pin 6 to 7 the resistance should be 10 100 2 as shown in figure 3 17 4 Three dots of control 5 silcon 7 6 picture 5 11SCR test G Rectifier test Turn off the power breaker put on the CN12 of power backup and transfer board turn on the power breaker again test the rectifier output voltage with a multimeter the value tested will rise slowly and stabilize at 394 4VDC at last The rectifier symptom that caused by inverter diagnosis program A Turn the maintenance switch to BYPASS Turn off the power bypass and battery breaker discharge the rectifier capacitors with a 3KQ 10W resistance until its voltage reduce to OVDC B Remove the inverter DC fuse test the resistance between C1 and E2 of IGBT as shown in figure 5 12 the value should be more than 10K Q else it should be IGBT or its filter board damage IGBT test Test
26. o supply power to load when you are maintaining and the power must not be interrupted you can shut off the inverter and turn on the maintenance switch then turn off the rectifier and bypass breaker At this mode AC power goes through maintenance switch to supply power to load And at this time there will be no any electricity in the UPS inside and the maintenance person can work without any danger 2 3 The UPS electrical connection diagram d SE I FS 3 UPS structure 3 1 Shape 3 1 1 ST5100 80 160KVA shape and dimension Ft ER EET ES picture 3 1 ST5100 80 160K shape 3 1 2 ST5100 200 400KVA shape and dimension 2200 800 I l l i 2 I UA OT TEE CO aa I fung HITTER SITT NN 2140 784 picture 3 3 ST5100 300 400KVA shape and dimension 3 2 Panel introduction D SOC PHASE Ne F DOC BYPASS mg a SA A DOC BATT x Pd DOC LOAD NG NAZ n DOC FAULT TEN MAINTENANCE OE INPUT2 BYPASS AN gt 2x 5 ae x od 5 6 6 4 D Picture 3 4 Display panel pp A LCD display display UPS operation parameter and status such as voltage current amount of load etc B Mains indicate light green it brig
27. pacitance and transfer board Picture 5 23 inverter the output filter replace of an electric capacity Inverter output low voltage diagnosis program A Turn off the UPS test the voltage between two side of inverter DC fuse if the value is not zero the fuse should be bad B Diagnosis ready program act as 5 1 2 mentioned in the manual C Test IGBT Test the EIC2 to CI E2 to E1C2 of IGBT with a multimeter in diode mode the first one tested with red pen the value should be 0 3 0 6 test it contrary the value should be Test Gl to El G2 to E2 of the IGBT with a multimeter in capacitor mode the value tested should be 30 40nF 42 _ G2 a RZ El Gl Picture 5 24 IGBT examine D Inverter test act as 5 1 2 mentioned in the manual if a board signal is abnormal turn of the UPS discharge the DC capacitor and replace the board E System recover program 4 IGBT over current paralleled over current diagnosis A Exit the paralleled system act as paralleled system exit program described in the manual B Turn on the failure UPS again check the main board indicate light that if the IGBT over current or paralleled over current light is on the light is on means that it is IGBT over current else it should be paralleled over current turn off the UPS Turn off all the breakers of the UPS discharge DC capacitor and replace the paralleled board and paralleled average current sampling transform
28. que specifications ST5100 P 80K ST5100 P 100K ST5100 P 120K ST5100 P 160K Three line phase control rectifier Rectifier configuration Voltage range Vac Rectifier inpu 380 25 frequency range 40 65 Hz Synchronization frequency 50 5 range Hz 3 4AW GND Battery voltage VDC 12V X 29 348V Refresh electric 30 40 40 current A 304W Voltage Vac L N 220 L L 380 Frequency Hz Mains input normal automaticly synchronize the mains Mains failure 50 0 2 Three line 100 load imbalance i 2 allow 100 imbalance voltage stabilization Parallel mode parellel mode with equal current output and without principal and subordinate Output current unequalization 5 when units are paralleled Wave distortion linear load THD lt 3 Transient bypass transfer time ms System ss efficiency dd NER MR 125 rated load 15 minute 150 rated load 1 minut capacity 6 rated load minute 6 rated load 1 minute Maintain bypass Provide no transfer time maintain bypass switch Start up function Support DC start up function ioni Three phase input voltage input frequency three phase output voltage load ispla pe battery voltage battery charge and discharge current and so on LED display UPS working status and failure indication Alarm function Input abnormal battery low over load failure Communication provide stem point communication and RS232 RS485 achieve
29. r two phase voltage is abnormal it should be input phase lose check the AC input line else it should be input phase wrong exchange any two lines of the three phase line and turn on the power breaker or bypass breaker 5 2 Symptom 2 The panel rectifier light is off LCD display that rectifier is abnormal and the buzzer beep Intermittently 22 5 2 1 Diagnosis program UPS will shutdown rectifier Keen when the AC input is 9 frequency abnormal abnormal it will recover when the AC input recover N Diagnosis ready program Is failure The rectifier fault that is s inverter failure caused by inverter diagnosis N Rectifier fault diagnosis Inverter test UPS function test 5 2 2 Program description Utility voltage and frequency abnormal distinguish When the input utility voltage or frequency is abnormal turn on the power breaker the panel rectifier light will be on fault light will be off and the buzzer will beep intermittently Test the voltage between the input three phase live line to neutral line the value should be 165 275Vac and the frequency should be 40 65Hz as shown in figure 5 1 else it should be utility voltage or frequency abnormal 23 SRI DELE AT LAT TE OUTPUT Tora Picture 5 1 utility input measure Diagnosis ready program A Press the panel OFF key to turn off the UPS B Turn on the maintenance bypass switch or turn it to BYPASS a
30. s shown in figure 5 2 C Turn off the power bypass battery and output breaker D Discharge the rectifier capacitor with a resistance of 3KQ 10W until the voltage of capacitor reduce to 0 VDC as shown in picture 5 3 Picture 5 3 rectifiers filters turn on electricity of an electrolysis electric capacity AN Note High voltage exists in the UPS the programs should be carried out before the parts are replaced 8 Inverter fault diagnosis The inverter fault diagnosis Remove the inverter DC fuse as shown in picture 5 4 Turn on the power breaker if the rectifier start normally and the panel rectifier light is on test the voltage between the battery breaker upper part to BAT of the terminal with a multimeter confirm that the battery breaker is Turn off as shown in picture 5 5 If the voltage is 394 4VDC then the rectifier is normal the fault should be caused by the inverter 24 Mas ha ad ad haa eee Ml Picture 5 4 Remove DC fuse Picture 5 5 Test the rectifier voltage 25 Rectifier fault diagnosis program and describe Abnormal symptom Y i Is A01 sampling transformer Replace A01 rectifier or fuse damage control board N le tasie over x Replace rectifier control voltage board or fan control board N y Temperature relay or its Is heat rectifier over connect line SCR or its connect line Replace the damage rectifier output current Is r
31. short circuit the output wire Is the utility input N Check the utility voltage normal frequency and phase Confirm that if the battery is Is the battery fully charge is bad or is normal connected correctly correct it UPS is failure Single unit exit program in the paralleled system Single unit diagnosis program Parallel system launching program 47 7 1 2 Program describe DSingle unit exit program in the paralleled system A Turn off the load of the UPS press off key on the panel to turn off the two paralleled UPS B Turn off the power bypass and battery breaker of the two UPS and turn off paralleled output breaker of the failure UPS C Remove the paralleled wire set the SW2 switch of the main board of two UPS to make them in single mode as shown in 4 2 2 in the manual D Turn on the power bypass breaker of the normal UPS turn on the battery breaker when the rectifier start normal press on key on the panel to turn on the UPS Paralleled system launching program A Turn off the load of the UPS Turn off the paralleled output breaker of the normal UPS B Press on key on the panel to turn on two UPS C Turn off the power bypass and battery breaker of the two UPS D Connect the two UPS with the paralleled wire set the SW2 switch of the main board of two UPS to make them in two unit paralleled system mode E Turn on the power bypass br
32. temperature diagnosis program IGBT over current or IGBT over current or paralleled over current paralleled over current diagnosis program N Y Inverter output overload Inverter output overload or phase unequal diagnosis or phase unequal program N Y Paralleled line failure Paralleled line failure diagnosis program UPS function test End 41 5 7 2 Program introduction D Confirm that which protection the UPS is in according to main board LED display Panel indicate light has been described before in the manual Q Inverter output over voltage diagnosis program A Press panel off key to turn off the UPS test the voltage between CN2 1P and 3P on the PWM board as shown in figure 5 18 press panel on key to turn on the UPS the voltage tested should rise and stabilize at about 30Vac at last during the start process If the voltage is too small or is zero then the inverter output voltage sampling transformer on the power backup and transfer board should be bad if the value that voltage and frequency tested is variable then the inverter output capacitor should be bad Diagnosis ready program act as 5 1 2 mentioned in the manual Replace the bad power backup and transfer board or inverter output capacitor as shown in figure 5 23 Inverter test system recover program act as 5 1 2 and 5 4 mentioned in the manual inverter E i output I L filter elf ca
33. the E1C2 to C1 E2 to E1C2 of IGBT with a multimeter in diode mode the first one tested with red pen the value should be 0 3 0 6 test it contrary the value should be co Test G1 to El G2 to E2 of the IGBT with a multimeter in capacitor mode the value tested should be 30 40nF as shown in figure 5 13 picture 5 12 inverter radiator board test resistance 29 G2 E1C2 ag El E2 C1 Gl Picture 5 13 IGBT measure IGBT filter board test Remove the board test the resistance between Cl and E2 on the board the value should be more than 10 K 2 else it should be damage Replace it Inverter test Remove the inverter fuse pull out CN11 CN12 of power backup and transfer board pull out CN9 CN15 of main board A Turn on the power breaker test Jl of main board with a oscillograph the waveform will be 9KHz square wave the wave Vp p should be 23 2V frequency should be 9 00 0 05KHz The oscillograph ground line can be connected to R37 down pin as shown in figure 5 12 The signal can be tested with a multimeter the value should be 11 10 0 2Vac 0 2 0 1VDC BON er f e id mm i DiE R Ne F i i ife ner Ladd KAAS KLARES RAMA LIZA pur ora ILL agli IFRS d mer bd bed FILIALI e I gt og RS pa N VERVET Ed SON Chi tS gt na AY No a RA AA kl ORAAL Re ICI PI VINE MT AS n GA ONE VIGEN Gr ry rev TTI sent mm tk MT SEK ee TEL o aas ee te eterni Life Li ii et mM Abbe
34. tting It is shown in the picture below when the DIP switch SWI second pin as is turned to ON then it is set to 50Hz identify system if it is turned to OFF then it is set to 17 60Hz identify system For the UPS produced after 2007 01 01 the SW1 is cancel and the frequency identify system can be set from the panel LCD ON SUN SWI 50Hz system ON HU SWI 60Hz system 4 2 2 main board DIP switch setting Main board has two DIP switch SW1 SW2 it can be used for parallel single unit system setting and output 50 60Hz setting Parallel single unit setting As shown in the figure below ON SWZ Parallel unit setting ON SW2 Single unit setting d 50 60Hz output system setup It can beset according to the picture below For the UPS produced after 2007 01 01 it just need to be set from the panel LCD ON SWI 50Hz output system setup ON SWI 60Hz output system setup 4 2 3 rectifier control board DIP switch setting The UPS charge current canbe set through rectifier control board SW1 it is shown in the table below setting ST5100 P 80 160K OFF OFF OFF 40A Status OFF OFF 30A For the 80 160KVA UPS produced after 2007 01 01 and 200 400KVA the charge current can be set from panel LCD for 80 160KVA the charge current setting range is 5 40A for 200 400KVA charge current setting range is 5 80A 4 3 Potential function introduction 4 3 1 rectifier control board RP8 SWI pict
35. ure 4 1 rectifier control board electrical organ position RP6 Adjust float charge voltage it should be adjusted to 394 4VDC RP8 Adjust boost charge voltage it should be adjust to 405 5VDC 4 3 2 main board SWI Figure 4 2 Rectifier board potential and DIP switch RP6 Adjust output B phase voltage RP7 Adjust synchronous accuracy 19 RP8 Adjust output A phase voltage RP9 Adjust output C phase voltage R35 Adjust synchronous accuracy 4 3 3 PWM board RP2 RP3 RP4 RP1 Figure 4 3 PWM board potential RP1 Adjust triangle wave voltage RP2 RP3 Adjust sine wave voltage RP4 Handle equilibrium adjust 4 3 4 display control board RPI RP2 RP4 RP3 SW3 SWI Fed Display control board potential R23 Battery voltage display value adjust R24 A phase output current display value adjust R25 B phase output current display value adjust R26 C phase output current display value adjust R40 phase output voltage display value adjust R42 B phase output voltage display value adjust R41 C phase output voltage display value adjust RP1 CPU 5V power adjusts 20 4 3 5 power board RP7 RPI RP2 RP3 RP4 RPS RP6 Figure 4 5 Power board potential RP1 Adjust parallel board power 12V RP2 Adjust SCR driver power 12V RP3 Adjust main control board power 12V RP4 Adjust main control board power 12V RP5 Adjust DSP power 5V RP6 Adjust LCD power 5V RP7 Adjust parallel board power 12V 4 4 Ma
36. voltage sampling hall of fans control board or damage of rectifier control board Replace the rectifier control board or fans control board C Diagnosis of rectifier over heat When the UPS over heat protection enable test the voltage between R75 with a multimeter if the value is OVDC then it should be rectifier over heat it will be SVDC normally The problem may caused by temperature relay connect line contacting badly temperature relay being bad fans being bad or rectifier SCR being bad etc D Diagnosis of rectifier over heat When the rectifier over current protection enable test the voltage between U9A 1P U12 1P or V8 and GND C64A left pin if the value is about 5 VDC it should be rectifier over current or over charge protection as shown in figure 5 8 It may caused by rectifier output current sampling hall charge current sampling hall rectifier capacitor or rectifier SCR being bad 27 Picture 5 8 rectifier over current or charge over current protective test E Rectifier driver signal test Turn off the power breaker pull out CN12 of power backup and transfer board as shown in figure 5 9 Turn on the power breaker again test left pin of R98 R99 right pin of R100 R101 R102 upper pin of R103 to GND left pin of C64A as shown in figure 5 8 on the rectifier control board with a oscillograph the signal waveform tested should be 50Hz pulse group as shown in figure 5 10 It can be tested with a multimeter the value shou
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