EP Series _10-80KVA_ Service Manual

CONTENTS EP Series UPS operating principle ..................................................................................... 3 1 Product introduction .......................................................................................................... 4 1.1 Introduction .............................................................................................................. 4 1.2 Control panel ........................................................................................................... 4 2 System electrical connection diagram............................................................................... 5 2.1 Electrical connection schematic diagram................................................................. 5 2.2 System block diagram ............................................................................................. 6 3 EP series UPS specifications............................................................................................ 7 4 EP series UPS internal structure..................................................................................... 10 4.1 Inside picture for 10~40KVA .................................................................................. 10 4.2 Inside picture for 60-80KVA ................................................................................... 13 5 EP series UPS principle introduction .............................................................................. 16 5.1 Rectifier module..................................................................................................... 16 5.2 Inverter module...................................................................................................... 17 6 PCB interface signals...................................................................................................... 18 6.1 Rectifier driver board (CS12772E)......................................................................... 18 6.2 Rectifier control board............................................................................................ 21 6.3 Inverter driver board (CS12083F) .......................................................................... 25 6.4 Inverter control board (CS12190C)........................................................................ 27 6.5 Auxiliary power board (NF12200C)........................................................................ 31 6.6 SCR bypass board (NF12345C) ............................................................................ 34 6.7 Interface board ...................................................................................................... 36 6.8 System control board (OCSA2196A01) ................................................................. 40 6.9 Power configuration board (NF12223B) ................................................................ 46 6.10 Output sampling board (NF12310C).................................................................... 48 6.11 Inverter current sampling board (NF12494B)....................................................... 51 7 Parameter regualtion potentiometer................................................................................ 53 8 Indicator signification of PCB status................................................................................ 53 1. Indicator signification of system board status ............................................................. 53 2. Indicator signification of invert control board status.................................................... 53 3. Indicator signification of parallel board status............................................................. 54 9 UPS parameter and function setting command code (press key 3→5 on display panel) 54 10 PCB difference between EP series different power UPS .............................................. 55 1. Rectifier driver board (CS12772E) ............................................................................. 55 2. Inverter driver board (CS12083F) .............................................................................. 55 3. Inverter current sampling board (CS12494C)............................................................. 55 4. Power configuration board (CS12223B)..................................................................... 55 EP Series UPS maintenance.............................................................................................. 57 1 Introduction ..................................................................................................................... 59 1

2 Fault analysis and maintenance...................................................................................... 60 3 Failure code and inquiry.................................................................................................. 64 TABLE OF MEMORIZED INTERNAL CODE / TABELLA CODICI INTERNI ........ 64 4 Parallel maintenance ...................................................................................................... 69 5 Instructions of EP Series singe unit into parallel units:.................................................... 70 Start up ................................................................................................................................. 79

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EP Series UPS Operating Principle

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1 1.1

Product introduction Introduction

EP series on-line intelligent UPS adopts double-conversion design to eliminate various interference of the power system. UPS outputs a pure sine wave power with stabilizing voltage, filtering out noise, low distortion and being not interferenced by the fluctuation of power system. And it has strong load ability, good load compatibility, wide range of input voltage and frequency, excellent generator compatibility, non-switching time of output and so on, extremely satisfy the requirement of various application environments; Perfect protection system improves the stability and reliability of system operation; Friendly LCD design makes human-machine communication easier; Use a RS232 between UPS and PC to get work history, monitor the parameters, start up / shut down automatically, realize unattended and remote monitoring function (by SNMP-Adapter). It applies to advanced network system. ★Power range: 10KVA-80KVA ★Operation mode: intelligent on-line (3 phases in 3 phases out) ★Application range: work stations, large-scale network servers, computer room and large data center

1.2

Control panel

LCD Display Button

“IN” utility input indicator (Green: lighting indicates normal utility, blinking indicates abnormal utility) “BY” bypass output indicator (Yellow: lighting indicates normal bypass output, blinking indicates abnormal bypass output) “OUT” inverter output indicator (Green: lighting indicates normal inverter output, blinking indicates output is overload) “BATT” battery discharging indicator (Orange: lighting indicates the battery is discharging, blinking indicates battery is not connected)

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2 2.1

System electrical connection diagram Electrical connection schematic diagram

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2.2

System block diagram SWMB

BYP

SWBY

TLBY

DC

AC DC

AC SWOUT

SWIN

TLBATT

TLI

FBATT

Figure 2-1 EP Series UPS electrical principle diagram

Shown on Fig 2.1, close SWBY and SWOUT, UPS checks the phase sequence. If it is correct, the bypass contactor will close immediately. Bypass powers the load (orange line) and system PCB operating power begins to set up; Then close SWIN, the rectifier begins to work, when the BUS voltage is up to 360VDC, the inverter will start up. UPS enters the self-check, if the utility is in the range of synchronous tracking and there is no internal fault, the output contactor will close and bypass contactor will open, and UPS switches to inverter mode; The battery pack is directly connected to DC BUS, once close battery switch, UPS begins to charge the battery (red line); Green line in Fig 2.1 represents maintenance bypass. When the UPS is abnormal and needs maintenance, close SWMB, the utility powers the load directly. open SWBY, SWIN, SWOUT, and discharge the voltage of capacitance to zero. Then you can change the board and carry out maintenance. As the orange line shown on Fig 2.1, when one of the following situations happens, UPS will switch to bypass mode: 1) Utility is on, close SWBY and SWOUT, SWIN is off; 2) Close SWIN, UPS is in soft start process; 3) Switch to bypass mode through operating command on the control panel; 4) Overload; 5) Inverter fault; 6) UPS overtemperature protection.

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3

EP series UPS specifications

System Rated power [KVA] Power factor range

10

15

100 % load 100~80%load 80% load 70% load 80%load Efficiency（%） Full load Half load Loss power with nominal load and battery charge kW / kcal / B.T.U.

THREE-PHASE OUTPUT 20 30 40

60

80

0.5~0.8 inductive load 0.8~1.0 inductive load 1.0~0.8 capacitive load 0.5~0.8 capacitive load computer load 91 91 92 89 89 90 1.58 2.37 2.78 1400 2000 2400 5560 7940 9500 868 1240 1488

90 90 92 92 88 88 91 91 0.89 1.33 4.17 5.57 800 1100 3600 4800 4367 4400 14000 19000 Flow rate allowing (for room installation) 496 682 2232 2976 (*)[mc/h] Max leakage current [mA] 100 MTBF: 200,000 hours Remote signal three contact signals (battery low, battery discharging, bypass/fault); output 12Vdc 80mA Computer interface RS232/C Operating temperature 0 ± 40 °C Maximum relative hunmidity 95 % (without condensate) Maximum operating altitude 1000m at rated power An (-1% An for each 100m) max 4000m Cooling forced ventilation (fan speed function of the load) Acoustic noise, as measured at 1m from front of equipment (depend on load and 48 ~ 54 53 ~ 60 53 ~ 62 temperature) dBA Degree of protection IP20

Rectifier input (Standard UPS) THREE-PHASE OUTPUT

Rated power [KVA] Rated voltage Phase Voltage range Rated frequency Frequency range Soft start Max input current [A] Current distortion Power factor

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15

18

28

20

30 40 380V 3 phases 3 ± 20 % 50 / 60 Hz auto learning 45 ~ 65 (1+10%) 0 - 100% 10 Sec 37 55 72 30 % 0.8

60

80

108

130

60

80

Rectifier input (UPS with harmonic reduction filter) Rated power [KVA] Rated voltage Phase

10

15

7

THREE-PHASE OUTPUT 20 30 40 380V 3 phases 3

Voltage range Rated frequency Frequency range Soft start Max input current [A] Total harmonic distortion and power factor, vary with the output load (nominal input Voltage) : Total harmonic distortion and power factor, vary with the input voltage (load 100%) :

16 24 load 100% 50% 30% 0% Vinput 100% 86% 114%

± 20 % 50 / 60 Hz auto learning 45 ~ 65 0 ~ 100% 10 Sec 33 50 65 distortion 8% p.f. 12% 25% 30% distortion 8% p.f. 5% 11%

97 0.9 0.94 0.96 1 0.9 0.94 0.84

117

Rectifier output THREE-PHASE OUTPUT Rated power [KVA] 10 15 20 30 40 60 80 Maintenance voltage (20°C) Battery type 1 and 2 : V =435Vdc (2.26 x el.) type 3 : V =424Vdc (2.2 x el.) type 0 : default values are equal to type 1 and 2. Value adjustable V =400~460Vdc Charge voltage Battery type 1 and 2 : V(% recharge 5, input the code: 467123. At this time you will see the UPS model "RT10, B" displays on control panel (if the UPS is EP10K). It means the parallel EP10K UPS units share the battery pack, and this UPS is defaulted as the Master UPS of all parallel UPS units. 3. Close SWIN and SWOUT of the first UPS unit, wait the UPS into normal operating mode (NOMAL OPERATION). 4. Close SWBY of the second UPS unit, you will see the UPS model "RT10, p" dispalys on control panel (if the UPS model is EP10K), it means the UPS unit is EP10K parallel, and this UPS is defaulted as the Slave UPS of all parallel UPS units. If the parallel UPS units share battery pack, you will see the UPS model “RT10, b” displays on control panel (if the UPS is EP10K). It means the parallel EP10KUPS units share the battery pack, and this UPS is defaulted as the Slave UPS of all parallel UPS units. Close SWIN of the second UPS unit, get into the control panel menu 2―>2 and wait till displaying I=220V. Close SWMB and then open, then all the started up UPS units switch to bypass mode. When the first UPS switches back to inverter mode, measure the voltage difference V1 of SWOUT upper and lower R, S, T phases on second UPS unit with multimeter AC posotion, if V1