SERVICE MANUAL

1K(S)/2K (S)/3K (S)

General Information
Getting start
If you want to know:
? Overview and what special for this UPS, refer to section Introduction.
? Replacing Battery Pack, refer to Steps to replacing The Battery Pack.
? Open external case; refer to Steps to Open the Case.
? Electrical function and principle refer to Principle of Operation.
? Whether UPS works properly, refer to Alignments.
? What happened to the UPS, refer to Trouble Shooting.
? Electrical performance, refer to Electrical Spec.

Conventions
This service manual uses the following conventions to alert you some important information for safe
operation and quick working.

STOP

Warning: Denotes a procedure or operation, which, if not perform correctly, may

result in personal injury. Be sure not to continue operation until indicated
conditions are fully understood and met.

!
Caution: Denotes a procedure or operation, which, if not perform correctly, may
cause damage to the UPS. Be sure not to continue operation until indicated
conditions are fully understood and met.

Information and Tips: There are some tips and skills after this symbol. During service
operations, these skills are provided by our design engineers who may help you
quickly finish your work.
 Important Safety Instructions
STOP

1. For qualified service personnel only.

2. DO NOT performs any internal service or adjustment of this product unless another
person is capable of rendering first aid and resuscitation is present.

3. Dangerous voltage exists at several points in this product. To avoid personal injury, don't
touch any exposed connections or components while UPS is active.

4. Turn off the UPS and disconnect input power cord before removing outside protective
cover.

5. AC voltage is always present if the input AC power is still available.

6. High voltage may present at DC capacitors. Before opening the outside cover, wait for at
least five minutes after turning off the UPS.

7. Verify input source (voltage and frequency) before service.

1. DO NOT makes internal batteries short-circuited.

2. If the battery connectors [BAT(+), BAT(-)] are disconnected, be sure to plug in the
input power cord and the input power is available before re-connect the battery
connectors.

3. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.

After opening the cover, please always check the tightness of all wires, connectors, and
screws first. Then check if there are any de-colored components inside
 INTRODUCTION
For all UPS of this series, they are strictly tested and carefully designed. We always do our best to
make our products more reliable and safer, this is also the goal of our company. However, due to the
lifetime of electrical components and some unpredictable reasons, there will be unavoidable failures of
this UPS. If this situation occurs, service of qualified person is needed. This service manual will guide
the technicians to repair and adjust a problematic UPS. If the UPS still does not work properly, please
contact with us and we will be glad to solve any problems you met.
Because of the following unique features of this series UPS (Uninterruptible Power System), it is
very easy to maintain and service.
z All major power components are put on PCB.
z Minimum numbers of PCB sub-assembly.
z Major parts are simply connected with flexible insulated wires and plugs.
z All PCBs are interconnected with connectors.
 STEPS TO OPEN THE CASE
To open the outside case, please follow steps and figures below:
1.Remove related screws on STEP 1 figure.
2.Remove another related screws in STEP 2.
3.Slide outside cover in the direction shown in STEP3.

STEP 1

STEP 2

STEP 3
 COMPONENTS LOCATION
The main components location of the UPS is shown below:

STOP

Warning: Any further operation of service, e.g. removing PSDR PCB, please disconnect at least
one of the short battery connection cables shown above to make sure safety of operation.

1K PSDR PCB

2K PSDR PCB
3K PSDR PCB

1K PSDR MODULE LOCATION

 2K/3K PSDR MODULE LOCATION

No. Module Name Part No. Quantity Remark

1. Charger Module 710-61201 1 1053
710-61200 1 1073/1083
2. Fan Driver 710-61000 1 1053(S)
710-61001 1 1073(S)/1083(S)
3. CNTL Pcb 710-01771 1
4. IGBT Driver 710-61800 3
5. PFC Control Module 710-62800 1 1073(S)
6. SPS Module 710-61400 1 1073(S)/1083(S)
710-61401 1 1053(S)
7. DCDC Driver Module 710-62200 1 1073S/1083S

NOTE: S MODEL UPS PSDR Charger Module is NC, Battery is recharged by 8A super charger.
 PRINCIPLE OF OPERATION
INTRODUCTION
This UPS system contains two major PCB assemblies. They are including:
1. PSDR: Contains major parts of (1) charger, (2) DC power supply, (3) unit power factor
correction, (4) DC-DC converter, (5) inverter and (6) output circuits.
2. CNTL: Contains major parts of protection, signaling circuits, regulation and control circuits of
inverter.
Note: PSDR contains major module of (1) charger module, (2) DCDC module, (3) PFC( power factor
correction) module, (4) Fan driver module, (5) IGBT driver module (6) SPS(switching power
supply )module

The simplified schematics in and figure11 shows how the major circuits are connected and illustrates the
overall system functions. .

Figure 1: Circuit connection

1
P/N listed in figure 1 are different from customer’s request.
Basically, this ON-LINE UPS system utilizes high frequency PWM techniques to achieve high efficient
performance. This UPS can deliver a clean, regulated sine-wave output at any load under full load. Each
sub-system are described as below:

Figure2: Block Diagram for UPS

The block diagram in figure 2 shows the UPS at normal operation from left to right. When a protection
circuit is triggered or a fault condition occurs, the output supply is transferred immediately from inverter to
AC mains by a bypass relay. The operation principle will be explained in later section

POWER STAGE (PSDR)

As shown in figure2, the power stage consists of charger, unit power factor correction, DC power
supply, DC-DC converter, inverter and output circuits.

Charger Sub-System:
The purpose of charger is to charge and to maintain the batteries at fully charged condition. Refer to
figure 3, the voltage flyback switching power supply provides a constant DC voltage (2k/3k 110.4
Vdc,1k just 41.2Vdc) for batteries. Besides providing constant voltage, the power supply also limits the
current flowing into batteries and therefore protects and prolongs the lifetime of charged batteries.

Figure 3: Charger circuit diagram

 VR1 in figure 3, which is used to adjust the output voltage of the charger.

About the charger, standard model UPS and s model UPS is different, the standard model have a
charger module building in the board of PSDR, the outline are described in the figure4,and the s
model is a super charger module with 8A charge current separating and connecting the board with
wires.

41.2V CHARGER MODULE 110V CHARGER MODULE

FIGURE4 CHARGER MODULE

DC Power Supply Sub-System:

The DC power of UPS is supplied by SPS module. The input of the SPS module is connected to the
battery bus, i.e. the output of the charger. The output of DC power supplies provide +12 Vdc and
h.f.power+/h.f.power-, +12Cdc for the coil of relay, +12 Vdc for the bias supply of IC's working voltage
and the fan(s) voltage. and +5V via the IC7805 in the board of cntl. And the h.f.power+/h,f.power- is
not only the source of driver IGBT voltage+15V and –5V via IGBT driver module, but also the source
of the power converter in the CNTL board. The SPS module works only when the +12 Vdc
regulator supplies Vcc to its control IC. The power system of UPS as indicated in figure 5,The SPS
module outline as figure 6

Figure 5: Schematic for DC power supply

 2k/3k SPS 1K SPS
Figure 6: Out line of SPS module

Inverter Sub-System:
The UPS converters ＋,－ DC bus voltages to the AC output voltage through an inverter of half
bridge configuration. The schematic diagram of inverter is shown in figure 7.
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching signals from
PWM generation circuit through a pair of photo-couplers to trigger the upper IGBT and the lower IGBT
alternately. The output of IGBTs is filtered by a LC circuit to reduce the o/p voltage harmonics
distortion.

Figure 7: Schematics for inverter

Output Sub-System:
The bypass relay receives signal from control circuit to switch the output of the UPS from bypass to
inverter, and vice versa. The output noise filter circuit blocks EMI noise to the loads.

Input Power Factor Correction Sub-System:

The purpose of power factor correction (P.F.C.) circuit is to make the input current and voltage in
phase and therefore achieve a high input power factor near to 1. The schematic is indicated in figure 8.
Here the PFC module and the IGBT driver module is used.

When the input AC power cord is plugged in, the AC relay is activated and the AC power goes
through noise filter to the charger and to the line detector. Both DC buses present voltages at about 1.4
times of input RMS voltage. When the "on" switch is pressed, the P.F.C. circuit is enabled and the DC
buses are regulated at ±350 Vdc(220Vac).

Figure 8: I/P PFC configuration

DC-DC Converter Sub-System:

The major function of the UPS is to deliver accurate AC power to the loads connected to it
whenever the AC line exists or not. In this system, the batteries release the stored energy to supply
inverter immediately once AC line lose detected.
Refer to figure 9, the battery voltage is transformed through a push-pull DC-DC converter to ±
350Vdc(220Vac) as DC buses for inverter. When the line fails, the ±350Vdc DC sources are caught
up to supply the power needed by the inverter immediately. Here the converter pwm is controlled by
DCDC module
 Figure 9: Schematics for DC/DC Booster(2K/3K)

MAIN CONTROL PCB ASSEMBLIES (CNTL)

These assemblies are the control center of UPS. It is composed of three major circuits as following.
(1) Regulation & control
(2) Protection
(3) Signaling

REGULATION & CONTROL SUB-SYSTEM:

This portion can be seen as brain of the UPS. It provides the control pulses to the switching
elements, which deliver power to the output. The sub-system also regulates the output to ensure that the
UPS is delivering constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a reference signal
from sine wave generator. The difference of these two signals (error signal) alter the pulse widths of
PWM signals which control the duty cycles of switching elements to regulate the output voltage within
specification.
In order to avoid unwanted surge current at the transfer of bypass relay, the bypass signal activates
the tracking circuit. It matches the inverter voltage with the line voltage by having the amplitude of the
reference signal following the variation of line voltage.
When the main is applied and the switch is turned on, a 10-second timer is triggered. The bypass
relay stays at bypass position in this time period. At the end of this period, the bypass signal is removed
and the relay transfers to inverter output.

PROTECTION SUB-SYSTEM:
The UPS provides the following protection circuits:

1. Overload protection
The load detector senses the load current, i.e. the inverter current, and sends the signal by two paths.
In battery mode, the UPS will go to failure mode if overload condition happened. The panel will
indicate the fault condition. There are two kinds of protection in our UPS:
a. Overload Protection: The UPS collects the continuous overload signals through CPU switch the
bypass relay. If the output load is 110% of rated load (VA, or Wattage) the UPS keeps running on
inverter running for 30seconds. If the output load is higher than 130% of rated load, the UPS
transfers to bypass immediately.
b. Cycle by Cycle Current Limit: When output loads sink a high surge current for a short time, a
high inverter current is detected and the inverter switches, i.e. the IGBT's, are turned off pulse by
pulse to protect themselves from thermal runaway. The output relay stays at inverter output
position unless a continuous overload is detected or an abnormal inverter operation occurs.

2. Battery over or under shut down

Upon the battery voltage declines to battery-under level, a signal is generated to cut off the power
supply of the whole system; the buzzer becomes silent and all the LED's extinguish. When the utility is
coming, the UPS will start up automatically.
In case of the battery voltage is high voltage, the UPS will discharge the battery capacity by way of
DC-DC converter to ensure the battery life. The panel will indicate the fault condition.

3. Inverter output abnormal protection

The inverter failure signal shuts down the inverter immediately, makes the buzzer a continuous
alarm, and lights "FAULT" LED. The panel will indicate the fault condition.
" The failure signal latches itself unless SW off or battery is empty".

4. Over temperature protection

The thermal switch detects the temperature of PSDR heat sink. The thermal switch is electrically
connected to the CPU. An opened thermal switch is thought as temperature failure by the UPS. The
panel will indicate the fault condition.

5. Bus over-voltage protection

To protect any BUS over-voltage condition especially for the half-bridge load. The panel will
indicate the fault condition.

6. Fan block protection

To avoid the ups is damage after the fan have been fault or been blocked ,. The function will be
awoke user the fan is fault;
Signaling Sub-System:
When the AC line is unable to supply, the batteries release energy inside to supply the inverter
immediately. At the same time, the utility failure relay is activated and the buzzer beeps every 4
seconds.
Upon the batteries are discharged to battery-low level, the battery-low signal is activated and the
buzzer beeps every 1 second.
Remote shutdown signal is enabled only when the line fails. The signal is connected to the battery
detector. It generates battery-under signal to cut off the bias power supply of the UPS system.

Front Panel:
The front panel consists 2 parts: push bottom and display LED set.
The push bottom is used to turn on and off the UPS. LED display indicates the load level (battery
mode indicates the battery voltage level) and operation status of the UPS. AC INPUT LED indicates
AC line is normal. If the line LED flash, it warns the power source is site fault. BYPASS LED indicates
bypass is active. UPS ON LED indicates inverter is working and BATTERY LED indicates the UPS is
in battery mode condition.
Besides, when the system works abnormally, the fault LED will light up and the buzzer will beep
continuously. In this situation, the panel LED will indicate which part inside the UPS is out of order.
The representations of fault conditions are listed as following:
 ALIGNMENTS
List below are some test points and procedures when a qualified service person wants to check
whether EUT (Equipment Under Test) will works properly. Before beginning following procedures,
please make sure that EUT is OFF and disconnected from Utility.

TEST ITEM TEST POINT TEST AND ADJUSTMENT EXPECTED

SEQUENCE RESULT
Charger Voltage BAT (+) 1.Disconnect BAT (+) and BAT(-) 1.Cooling fans on
BAT (-) wires from pins respectively. back panel begin to
2.Connect DVM (Set to measure DC) rotate.
to test points and plug input power 2. 2K/3K 110 Vdc±
cord to utility. 0.4V
3.Adjust VR1 slowly to expected 1K 41.2Vdc+0.3V
value.

+DC Bus Voltage @ Line 2K/2K:R104Top (+) and 1.Connect DVM (Set to measure DC) +350VDC±10V
Mode GND to test point.
1K: :R4Top (+) and GND 2.Plug input power cord to utility.
3.Press ON bottom for 2 seconds to
-DC Bus Voltage @ Line Mode 2K/3K:R118 Top (+) and turn EUT on. -350VDC±10V
GND 4.Waiting for 10 seconds to make sure
1K: R1 Top (+) and GND the Inverter2 LED lights.
Check reading on DVM
O/P DC Balance @ Line Mode O/P socket 1.Keeping UPS on @ Line mode. 100mV max.
2.Connect DC measurement tool 3 to
O/P socket.
3.Check reading on DVM.

+DC Bus Voltage @ Backup 2K/2K:R104Top (+) and 1.Disconnect I/P power cord from +350VDC±10V
Mode GND utility and press OFF bottom for 2
1K: :R4Top (+) and GND seconds to turn UPS off.
2.Connect DVM (Set to measure DC)
to test point.
3.Plug input power cord to utility.
4.Press ON bottom for 2 seconds to
turn EUT on.
5.Waiting for 10 seconds to make sure
the Inverter4 LED lights.
Check reading on DVM
-DC Bus Voltage @ Backup 2K/3K:R118 Top (+) and Same as previous -350VDC±10V
Mode GND
1K: R1 Top (+) and GND

2
For some models, Inverter LED could be labeled as UPS ON.
3
DC measurement tool is a low-pass filter. Its schematics is shown on next page
4
For some models, Inverter LED could be labeled as UPS ON.
 R

From O/P To DVM

Socket
C C

R=100Kohm/2W
C=10uF/250V

Measurement Tools Schematic for Measuring O/P DC Balance

TROUBLE SHOOTING
Due to careful design and strict tests of our products, fail of UPS seldom occurs. However, once
they do fail in some situations, please check them according to Trouble Shooting Chart, which will
help you solve the most problems on UPS.

Trouble Shooting Chart

Begin

If the panel LED NO

If DC start
light and fan No
works properly?
rotates ?

Yes

If the panel LED Change CNTL

display No
SUB-ASSY
Yes
normally?

Yes No

If I/P relay
PFC or charger
continuouly If DC start
Yes Yes fail,refer to relative
open and works properly?
analysis
close ?
No

Turn-off and DC/DC fail,refer to

Restart the UPS DC/DC fail analysis

Can the UPS

be properly Yes Terminated
start?

No

Read panel LED to

get the information
of UPS on next
page

Panel LED Display Explanation

Bypass Due to Output Overload
Cause: O/P load is larger than rated load in VA or in Wattage.
Strategy: Removed or reduce load connected to O/P socket. On line mode, the UPS will restart
automatically. On battery mode, UPS must be OFF in advance and ON again.

Bypass Due to Over-temperature

Cause 1:Ambient Temperature is higher than allowed operation temperature.
Strategy: Reduce ambient temperature or O/P load.
Cause 2: Thermal detection circuit failed.
Strategy: Refer to the thermal detection problem strategy on later pages.

Bypass Due to DC Bus Over-voltage

Cause 1: Some non-fatal misbehavior of UPS.
Strategy: Turn off UPS then Turn it on.
Cause 2: PFC circuit fails.
Strategy: Refer to PFC circuit failure analysis.
Cause 3: DC/DC circuit fails. (In this situation, AC INPUT LED will not light)
Strategy: Refer to DC/DC circuit failure analysis.
Cause 3: Bus voltage feedback circuit problem.
Strategy: Refer to bus feedback loop problem.

Bypass Due to Inverter Failure

Cause 1: O/P short circuit. (In this situation, no power will be transfer to O/P socket.)
Strategy: Remove short circuit condition, turn off the UPS then turn on again.
Cause 2: Inverter circuit failed.
Strategy: Refer to Inverter Circuit failure analysis.

Fault Due to Battery Over-Voltage

Cause: Charger circuit fail
Strategy: Refer to charger circuit analysis.
 Failure Diagnosis
In this section, some debug skills are listed to help you finding the fail components and problems as soon
as possible. Before continuing the following steps listed, we suggest that you should read problem shooting
chart in previous section then check the components listed in Quick Start to confirm which block is out of
order and obey the procedures listed on the following pages to repair them. However, for the reason of
safety, please obey following procedures to begin your work

STOP

High Voltage Danger: Some components inside with high voltage are dangerous,
please obey following steps strictly.

1.Unplug the power cord from the utility.

2.Open outside case shown in the beginning of this manual
3.Remove connectors from battery (For some models, unplug battery cabinet connector to UPS)
4.Discharge energy in BUS CAPACITORS5, and CHARGER CAPACITORS6
5.Remove all connectors (if required).
6.Remove PCB assembly (if required).

Before starting service, some tools are necessary, including: A DMM (Digital
Multifunction Meter) meter, screwdrivers and discharge resistor (100Ω/10W
recommended). A DC power supply (120VDC/3A at least) is recommended for fast
and safe diagnosis.

TO DISCHARGE the energy of bus voltage, you can use a 100Ω/10W resistor to
contact P01 flange of upper lead of R104(2k/3k) for +BUS capacitor energy and
R118(2k/3k) upper lead for -BUS capacitor energy.

TO DISCHARGE the energy of charger capacitor, you can use a 100Ω/10W resistor
contact flange of BAT(+) and BAT(-) for charger capacitor energy, the method is
almost same as previous but the discharge points.

5
Capacitor numbered as 2K/3K:C36, C37, C38, C401K:C12,C13 删除的内容: ,
6
Capacitor numbered as 2K/3K:C63, 1K: C19
 !
DO NOT supply UPS with the mains unless you are sure that you have replaced all
defective components.

Quick Start
Before any detail check of UPS, please check the components listed in the following table. This action
could help you find problem quickly and make following debug procedures go smoothly.
Related Circuit Block Components to be checked Component Type Fail condition
BAT FUSE 1K/3K:F1/F2;2K:F1 Fuse Open
I/P FUSE (on PSDR) F3, Fuse Open
U.P.F. Correction 2K/3K:D16, D17, REC02 Diode Short or open
1K:D10, D11, REC1
2K/3K:Q09,1K:Q14 IGBT C-E short or open
Push-Pull Booster 2K/3K:Q04, Q05, Q06Q07 MOSFET D-S short or open
1K:Q4, Q6, Q10Q11
2K/3K:D05, D06, D07, D08 Power Diode Short or open
1K:D12, D13, D14, D15
Inverter 2K/3K:Q13, Q14, Q15, Q16 IGBT C-E short or open
1K:Q12, Q13

Charger module Q2 MOSFET D-S short or open

D10,D11,D12,D13D15 Power Diode Short or open
SPS module Q201 MOSFET D-S short or open
D202,D203 Power Diode Short or open

!
If the fuse is open, replacing fuse only DOES NOT mean you have solved the
problem. For most situations, open of fuse is caused by other failure of components;
therefore, before restart that UPS, you must find the real failure components and
replace them!

P.F.C Analysis:
In this section, some components you could check to see if failure occurs on U.P.F Correction circuit are
shown. BE SURE TO KEEP IN MIND is that, failure of F3(OPEN) indicates failure of this block. Please
replace all fail to check components then utility can be connected to your UPS.
 Step Checked components Instrument Reference Value Failed condition
function
1 F3 Ω Short Open
2 2K/3K:Q09,1K:Q14(SD) DIODE 0.46 Short or open
3 2K/3K:D16,D17 1K:D10,D11 DIODE 0.44 Short or open
4 2K/3K:R66, R208 1K:R68 Ω 47.0/36.0/36.0 Open or value change
5 2K/3K:REC02/1K:REC1 DIODE 0.46 Short or open
(+,～),(～,-)

If all above list components are replaced and UPS still can’t work, try to change PFC
module and IGBT driver module

Push-Pull DC-DC Converter Analysis

General speaking, the most distinct phenomenon of failure on the section is open of F1 and F2. Knowing
this will be very helpful to repair them.

Step Checked components Instrument Reference Failed condition

function Value
1 F1,F2 Ω short open
2 2K/3K:Q04~Q07 (S,D) DIODE 0.42 short or open
1K:Q4,Q6,Q10,Q11(S.D)
3 2K/3K:R31,R33,R34,R36 Ω 2K:10.0 3K:5.0 open
1K:R7,R73,R76,R77 1K:10.0
4 2K/3K:D05,D06,D07,D08 DIODE 0.41 short or open
1K:D12,D13,D14,D15

!
BE SURE TO use DC fuse with same spec as original ones to replace failure ones,
otherwise, unpredictable danger could happen.

If all above list components are replaced and UPS still can’t be DC started, try to
change DCDC module.
 DC/AC Inverter Analysis
Step Checked components Instrument Reference Failed condition
function Value
1 F3, F2, F1 Ω Short Open
2 2k/3k:Q14,Q13,Q16,Q15 (S,D) DIODE 0.4 Short or open
1k:Q14,Q13,Q16,Q15 (S,D)
3 2k/3kR110, R106, R117, R119 Ω 2K/3K:47K Open
2k/3kR53,R37 1K:20K
4 2k/3k:R107,R109,R116,R120 Ω 27.0 Open
R114,R103,R111,R122 10.0
1k: R40,R54 36.0

If fail condition stated in item 3 occurs, it is very possible that the corresponding photo
couplers are damaged, so please try to change the IGBT driver module .

SPS Module Analysis

Step Checked components Instrument Reference Failed condition
function Value
1 Q201(S,D) DIODE 0.42 Short or open
2 R206,R206A Ω 47 Open
3 R209 Ω 0.10 Open
4 R207 Ω 1K Open
5 U01 (3845) PIN 5-6 Ω 46.7K Too low
PIN 5-7 38K
PIN 5-8 4.31K
PIN 6-8 50.9K

1A Charger Module Analysis

Step Checked components Instrument Reference Failed condition
function Value
1 Q2(S,D) DIODE 0.45 Short or open
2 R40 Ω 47.00 Open
3 R38 Ω 0.50 Open
4 U07 (3845) PIN 5-6 47K Too low
PIN 5-7 Ω 20K
PIN 4-8 7.48K
5 D10.D11,D12,D13,D15 DIODE 0.45 Short or open
 !
DO NOT make the charger be active when the case is open, this will cause
over-heated of TX1, and therefore the other related components will fail again.

As usual, the most possible fail component is Q2, if this indeed happens; please replace
not only that component but also R40, R38, D15, R37and U1. Since failure of Q2 will
cause the other components list above fail.

IGBT Driver Module Analysis

Step Checked components Instrument Reference Failed condition
function Value
1 U701.PIN2/PIN3 DIODE 0.54 Short or open
2 R707 Ω 10.00 Open or too high
3 R708,R709 Ω 20.00 Open
4 Q702(E.B,E.C) DIODE 0.64,1.00 Short or open
Q703(B.E,C.E)

As usual, the most possible fail component is IGBT, if this indeed happens; please replace not only
that component but also R708, R709, Q702, Q703and U701. Since failure of IGBT will cause the other
components list above fail

Others
For previous sections, we pay attention to the components on PSDR, however in this section, we are
trying to list some possible failure phenomenon not stated before and on control PCB sub-assembly.
They are list as following.
Fail for Phenomenon Possible components Comment
Bus over-voltage 1.Bus over-voltage fault alarm and PFC IGBT Driver
display occur module, 2k/3k:Q09,
2.Bus voltage doesn’t meet spec. 1k:Q14
Inverter Inverter fault alarm and display occur. 1.Components listed in
previous section.
2.U8, U9, U10, U11 2. This IC’s are
on CNTL PCB
UPS can’t start, but 1.LED’s light, but are active randomly U18 (CPU on CNTL)
not the problem or abnormally.
stated before. 2.Buzzer beeps abnormally.
Audible problem Buzzer does not beep at start-up or for Q5, BZ1 On CNTL PCB
alarm.
 Fail for Phenomenon Possible components Comment
Start-up 1.UPS is bypass after the mains is on. 1.SPS Module Q201 1.on PSDR
2.No response after press ON button. 2.U13 2.on CNTL PCB
O/P DC balance O/P DC balance is out of spec. 1.PFC IGBT Driver 1.Bus feedback
module, Q09 or Q14 loop.
(on PSDR)
2.U22 (on CNTL) 2.Auto-balance
circuit.

For O/P DC balance problem, it is almost caused by incorrect bus voltage. If this
indeed happen, please try to find which mode the problem arise. For example, if it
happens under Line mode, you must measure bus voltages to see if they are correct.
After doing this, debug the corresponding circuit. If unfortunately, both modes are
incorrect, two possible circuits should be check: Bus feedback loop (on PSDR) and
auto-balance circuit (on CNTL).

Finish and Test

After you have replaced all defect components on power stage (PSDR), please follow the steps
below.
1.Connect with control board.
2.Connect cable to panel and plug wires of fan into FAN1 and FAN2.
3.Supply DC voltage (96-110Vdc/3 Amp (limited current),36~41Vdc/3Amp for 1k) with DC power
supply via BAT(+) and BAT(-). Press the switch on front panel for 2 seconds, you will see
"current limit" for a short time on the DC power supply for about only 2 seconds, then UPS
should be DC started (If UPS does not start successfully, and All display LED’s extinguish,
please try above procedure again). If UPS does not start up for several trying or DC power
supply is on current-limit state continuously, there must be some defective components exists.
Please follow trouble-shooting chart to debug again.
4.When everything seems good, press the off switch on panel and remove DC power supply.
5.Plug in the power cord and supply UPS with the mains. Buzzer should beep continuously in the
mean time. Measure voltage of the charger output (BAT(+), BAT(-)), it should be 110V.(2k/3k) or
41V for 1k, If not, adjust VR01 to the desired voltage. The fan will rotate also. If there is no
apparent problem at this time, connect the batteries via BAT(+), BAT(-), unplug input power cord.
6.After fan stops rotating, plug the input power cord again.
7.Turn on the switch on panel again and follow the procedure listed in Alignment part to adjust the
DC offset, and measure voltage on DC bus, output voltage.
8.Re-assembly the UPS
9.GOOD LUCK!
WAVEFORM OF THE KEY POINT:

U801 PIN1 DCDC module U801 PIN2 DCDC module

U801 PIN4 DCDC module U801 PIN5 DCDC module

U801 PIN6 DCDC module U801 PIN7 DCDC module

U801 PIN8 DCDC module U801 PIN9 DCDC module

U801 PIN11 DCDC module U801 PIN16 DCDC module

U04-UC3854 PIN2 U04-UC3854 PIN3

U04-UC3854 PIN6 U04-UC3854 PIN7

U04-UC3854 PIN8 U04-UC3854 PIN9

U04-UC3854 PIN11 U04-UC3854 PIN14

U04-UC3854 PIN16 U01-UC3845 PIN1

U01-UC3845 PIN2 U01-UC3845 PIN3

U01-UC3845 PIN4 U01-UC3845 PIN6

 CLOCK INV L2

SINE.PWM SIGNAL U8-TL074 PIN6

U8-TL074 PIN8 U8-TL074 PIN14 SIGNAL

LNV120 (U22-TL074 PIN8) LNVZERO (U10-IC339 PIN13)