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Training Manual 2
Training Manual 2
ON
SALIENT FEATURES OF
SERVICE MANUAL
DECEMBER 2008 - 09
1
CONTENTS
Page No.
¾ Inverter
¾ Off Line UPS
¾ Online UPS
¾ Home UPS
¾ Static UPS
¾ Square wave
¾ Sine Wave
¾ High Frequency Home UPS
¾ Inverter
¾ Off Line UPS
¾ Online UPS
¾ Home UPS
¾ Static UPS
¾ Square wave
¾ Sine Wave
¾ High Frequency Home UPS
¾ Online UPS
¾ Home UPS
2
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA
4) TESTING PROCEDURE
¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA
5) FAULT FINDING
¾ Online UPS
¾ Home UPS
3
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA
¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
High Frequency Home UPS
4
INTRODUCTION OF INVERTER & UPS
1.1 INVERTER
Inverter converts the battery power current into conventional A/C power. This power
can be used to run almost any AC appliance absolutely anywhere. They can run
items such as mobile phone chargers, lights, electrical appliances, power tools,
computers, faxes, TV sets, microwave ovens, battery chargers & motors.
1. SQUARE WAVE INVERTER - The square wave is the simplest and the least
expensive type, but now days it is practically not use because of low quality of
power.
2. MODIFIED SINE WAVE INVERTER - The modified sine wave topologies (which are
actually modified square wave) produce square wave with some dead spots
between positive & negative half-cycles. They are suitable for many electronic
loads & are the most popular low-cost inverter on the market today.
3. PURE SINE WAVE INVERTER - Pure sine wave inverters produce AC voltage with
low total harmonic distortion (typically below 3%). They are used when there is a
need for clean sine wave output for some sensitive devices such as medical
equipment laser printers stereos etc.
5
STATIC INVERTER/UPS
Static inverters have no moving parts and are used in a wide range of applications, from
small switching power supplies in computers, to large electric utility high-voltage direct
current applications that transport bulk power. Inverters are commonly used to supply AC
power from DC sources such as solar panels or batteries.
1.2 UPS
Survey indicates that 50% of the malfunctioning that happened during data
processing was caused by commercial power disturbance. This explains the
importance of configuration of a UPS together with a Computer system,
telecommunications, medical instrument, process control, security system, CNC
machine and all power sensitive equipment. The UPS is designed to protect
computer, telecommunication, medical instrument, process control, security
system, CNC machine and all power sensitive equipment against any power failure
or disturbance.
There are three different types of UPS that are suitable for different tasks and
supporting different types of load. These are:
b. Off-Line Stand by
c. Line Interactive
d. On-Line Double Conversion
a. Off-Line Stand by
During normal operation, the power flows straight through the unit and hence
only RFI filtering is usually provided. When the input voltage fails or fluctuates
outside of a pre-set tolerance window, the UPS detects this and a relay will close
allowing the UPS to start feeding battery power via the inverter.
b. Line Interactive
6
battery. The DC current flow is then fed through an inverter stage which
reconstructs the 230 V AC mains output.
7
2. BLOCK DIAGRAM OF UPS
INVERTER
MAINS LOAD
(I/P) INVERTER
(S/W) (O/P)
CHARGING DISHCHARGIN
BATTERY BANK
STATIC UPS
CHARGING DISHCHARGIN
BATTERY BANK
8
OFFLINE UPS
FILTER & SCR
MAINS LOAD
(I/P) INVERTER
(S/W) (O/P)
CHARGING DISHCHARGIN
BATTERY BANK
ONLINE UPS
FOR BY PASS
BATTERY BANK
9
3. WIRING DIAGRAM OF INVERTER & UPS
Wiring diagrams of inverters of various capacity are given as under:
10
diagram of 5 KVA/ 96 V inverter
11
Fig. 4 Wiring diagram of 5 KVA 120 V Static UPS
12
Fig. 6 Wiring diagram of 5 KVA/ 180 V On-Line UPS
13
Fig. 8 Wiring diagram of 10 KVA/ 192 V On-Line UPS
14
4. CIRCUIT DIAGRAM OF INVERTER
• CIRCUIT DIAGRAM 800 VA HF
• A
D7 +15V_LO
VCC-MAINS D48 STTH110A/STTH112A R69 10E_1W 1%
1N4007
C21 C22
Z6
C35 100uF/35V 104/25V
R20 10uF/63V 18V/1/2W
10K_1/4W 1% R123 D49
1K_1/4W 1% 1N4007
VCC Q22 TR1
D11 R18 BC857 3 D6 +15V_HI1
1N4007 68K_1/4W 1% STTH110A/STTH112A 0
Q13 65T,35SWG
BC847 +VE BATT.
4 R68 10E_1W 1%
6 Z5
R19 C26 C18 C19
6K8_1/4W 1% 1uF/63V 1 65T,38SWG 18V/1/2W
R1 100uF/35V 104/25V
C1 C2 1K_1W 1% 5
40T(20T+20T),30SWG 8
470uF/25V 0.22uF/25V D5 +15V_HI2
R170 2 65T,38SWG STTH110A/STTH112A FGND1
R164
1K_1W 1% 7
150K_1/2W 1% 10 R67 10E_1W 1%
D2 C15 C16 Z4
STTH110A/STTH112A 25T,30WG
100uF/35V 104/25V 18V/1/2W
9
C3
Z8 145T,35SWG
C5 27V_1/2W 0.01uF/100V
C4 FGND2
22uF/25V 0.1uF/25V CF138,EE COSMO,20 X10 X 5.5mm
D3 +5V
IC1 STTH310-DO-201ADC2/UF5408 L1
7
UC3843 R4 10K_1/4W 1%
3 8
VCC
1000PF/25V OUT 1
COMP C7
C9 R11
R7 103/25V 2200PF/25V Z1 6K2_1/4W 1%
5
R9 1K_1/4W 1% R5 15V/1/2W
1K_1/4W 1% 1K_1/4W 1%
4 IC2 1
C8 470PF/25V 3 2
PC817 R10
1K8_1/4W 1%
R6 T POINT R
TP4
100K_1/4W 1% R2 R3 D4 VCC-RELAY
1E_1/4W 1% 1E_1/4W 1% STTH110A/STTH112A R12
750E_1W 1%
C14
Z2
10uF/63V 33V/1/2W
• B
VCC
CN7 +5V +VE BATT. D50 1N4007
1
NOT ON PCB
BUZZER CN8
2 DR1B O/P PHASE TR5
3 DT1 +5V BUZ1 1 C90
4 PWMHIGH1 BUZZER D8 2 O/P SENSE
CN2
5 PWMLOW1 1N4007 CN4 3 0.1J/63V
6 PWMHIGH2 +5V 4 NEUTRAL 3Pin JST Male
7 PWMLOW2 3 1 SS-400V/23V-0V-23V
8 2
22Pin L-Type Burgstrip
INDUCTOR
R49 FGND2 C83 L2 MOV1
15K_1/8W 1% 4700PF/1KVA VCC-RELAY
CON1
OP2 C82
FGND1 C86 N
DC-SENSE 4uF/440V C84 470NF/440V~- X2 375V
4700PF/1KVA FILTER C25
FGND2 D9
t
F3
MANSE SENSE(ZEROCROSS1) TR2 I/P-L
POWER STAGE 0
C24 6A FUSE
0.1J/63V 35SWG
ZEROCROSS2(1.25Vref )
NOT ON PCB
D33 1N4007 31SWG
VCC-MAINS SS-400V/23V-0V-23V/0V-23V
R169 D32 1N4007
15
• C
+VeBATT.
Bolt Hex Hd, M6X16X2.8, Brass
F2 40A FUSE
SW KEY -SPST
C27 C28
STTH310-DO-201ADC2/UF5408
220uF/25V 104/25V Q2 Q3
85 DEG. R32 STP80NF55-08 R33 STP80NF55-08
STTH310-DO-201ADC2/UF5408
2 2 ST T H310-DO-201ADC2/UF5408 C41
1 V+ 10 DC-DC OFF (3525-SD) 14
V- SD R65 R66 0.1uF/630V
9 8 0.001E/2W 0.001E/2W 1 D24
R23 COMP CSS ST T H310-DO-201ADC2/UF5408
8K2_1/4W 1% C29 104/25V SG3525 C34 CF139(COSMO)/N87(SIMENS) R125
C31 C32 -VeBATT. 220uF/50V 220K_1/4W 1%
Bolt Hex Hd, M6X16X2.8, Brass
0.22uF/25V 104/25V
D15
R53 0
R21 10K_1/4W 1% Q4 Q5 R52
1K_1/4W 1% R34 STP80NF55-08 R35 STP80NF55-08 330K_1/4W 1%
2E2_1/8W 1% 2E2_1/8W 1%
R51
150K_1/4W 1%
R30
1K_1/8W 1%
VR2
220K
4 IC5 1
3 2
PC817
0
DC-DC SECTION
Kevin Power Solutions(P) Ltd.
Title
HFI800VA(K8HFIR6)
Size D o cu men t N u mb er R ev
B 1.6
DC - DC STAGE
D ate: Thursday , March 27, 2008 Sh eet 1 of 1
• D
+HTP
20K_5W NI
R173(EXTRA)
C42
20K_5W NI
R46 4700PF/2KVA
1M5_1/4W 1% 0
D18
R54
D23
D16 NA
R44 STTH110A/STTH112A
180K_1/4W 1%
R43 R47
75K_1/4W 1% 120K_1/4W 1%
TR4 R57
CORE SIZE = ETD-34-17-11 4E7/2W C47 4700PF/2KVA
C38 Z7 2 8
2
9 1 L3
1 TSW1 30uH/10AMP
C TOP249 0 3 10 D47 2
R45 STPS3060CW
X
S
F
D20 4 3
6.8E_1/4W 1% STTH102A/UF4007 11
5
C36 5 5 12
NA R58
C37 C48 1000PF/2KVA 51E/2W
6 13
100uF/35V +HTP D21
STTH102A/UF4007 7 14
VCC
0 R42 R172(EXTRA) C43 2200PF/2KVA
4K7_1/4W 1% 1.5M_1/4W 1% R55 0
R74 10E_1/4W 5% +VE BATT. R126
4K7_1/4W 1% 470K_1/8W 1%
RELAY /CHGARGER CUT 1 IC7 4
2 3
PC817 C44 C45 R62 R63
750E_1/8W 1% NA
0 100uF/50V NA
4 IC6 1 VR2
220K
0 3 2
PC817 R60 R59
470E_1/8W 1% 39K_1/8W 1%
Q14 CHARGER PWM
BC847
CHARGER SECTION Z3
8V2_1/4W
R61
NA JMP1 C49
JUMPER
100nF/25V
D31
JUMPER
16
• CIICUIT DIAGRAM 1400 VA
• A
DC(+)
20K_5W NI
20K_5W NI
C3
R3
1M5_1/4W 1% 4700PF/2KVA
D2
R1
R10
D1 P6KE200A D3
R5
390K_1/4W 1% P6KE200A P6KE200A
D9 0
UF4007 +12V
R4
180K_1/4W 1%
R7 R6
D15
TR1 R16 C13 1N4007 CN3
75K_1/4W 1% 120K_1/4W 1% CORE SIZE = ETD-34-17-11 4E7/2W 4700PF/2KVA
Z1 2 8 1
7
C5 6V8_1/4W 1 +VE BATT.(12V)
104/25V R31 2
D
9 1 L1 CN2 470E_1/8W 1% 2Pin Relimate Male(Fan)
1 TSW1 30uH/10AMP FAN Q2
C TOP249 0 3 10 D8 2 1 BD139
STPS3060CW
2
S
F
R8 D5 4 3
68E_1/4W 1% UF4007 11 2Pin JST Male(Fan) FAN
C15
4
C4 5 5 12
NA 1000uF/50V
C7 C12 R15
6 13
47uF/50V D4
DC(+) UF4007 7 14 1000PF/2KVA 51E/2W
-VE BATT.(24V)
0 R9 0 C10 2200PF/2KVA +VE BATT.(24V)
4K7_1/4W 1% R33(EXTRA) R2 SNAPON
10E_1/4W 5%
1.5M_1/4W 1% +VE BATT.(12V)
R14 R35(EXTRA)
4K7_1/4W 1% 100E/2W 1%
RELAY/CHGARGER CUT 1 IC2 4
C6 C8 R13
2 3 750E_1/8W 1%
PC817 100uF/50V NA
0 4 IC1 1 D7
1N4007 CN5
0 3 2
PC817 R12 1
CN1
470E_1/8W 1%
Q1 3 R23 2
Z2 BC847 2 CN4 470E_1/8W 1% 2Pin Relimate Male(Fan)
3V_1/4W 1 FAN Q3
3Pin Relimate Male 1 BD139
R11
NA JMP1 C11 2
JUMPER 2Pin JST Male(Fan) FAN
104/25V
JMP2
JUMPER
DC(+)
DC(+)
DC1(+)
20K_5W NI
20K_5W NI
SNAPON C2
C1 C16
0.1uF/630V R30
220uF/450V 1M5_1/4W 1% 4700PF/2KVA
DC1(-) D11
R17
R32
SNAPON
0 R19 P6KE200A P6KE200A
390K_1/4W 1% 0
D18
R20 UF4007
180K_1/4W 1%
R22 R21
9 1 L2
1 TSW2 30uH/10AMP +VE BATT.(24V)
C TOP249 0 3 10 D17 2
STPS3060CW
X
S
F
C17 5 5 12 1000uF/50V
NA
C23 C19 R28
6 13
47uF/50V DC(+) D13
UF4007 7 14 1000PF/2KVA 51E/2W
B
+VE BATT.(24V)
R175 +12V R163 SW1 +VeBATT.
2E2_2W 1% Q15 L7812 10E_1/4W 1%/JUMPER Bolt Hex Hd, M6X16X2.8, Brass
1 2 1 2
VIN VOUT F1 40A FUSE +VE BATT.(24V)
SW KEY -SPST
GND
+VE BATT.(24V)
R165 LED5 RED
Q2 Q3 D53
104/25V 220uF/25V STP140NF75 NA Q24
85 DEG. R32 R33 R172 STP140NF75
STTH310-DO-201ADC2
R26 7K5_1/4W 1% 8 TR3
2E2_1/8W 1% NA 2E2_1/8W 1% D14 D24
IC4
6 15 R24 2E2_1/8W 1% 7 9 DC(+)
5 RT VCC 13 STTH310-DO-201ADC2 SNAPON
R28 C30 4 CT COL 12 6
2K2_1/4W 1% 3300PF/25V R27 OSC GND C33 10 D25
51E_1/4W 1% 7 14 D12 1N4148 220uF/63V R36
DISC OUTB R25 220E/2W 5 11
11 R29 2E2_1/8W 1% 1K_1/8W 1% STTH310-DO-201ADC2 JMP2 +HTP
16 OUTA 4 JUMPER
C85 VREF C86 C50 C39 12
R37 D26
R22 104/25V R31 D13 1N4148 -VE BATT.(24V) 4700uF/50V 0.1uF/63V 4700uF/50V 220E/2W 3 13 0
5K1_1/4W 1% 3 10K_1/4W 1% R124
SY NC
STTH310-DO-201ADC2
2 2 STTH310-DO-201ADC2 220K_1/4W 1%
1 V+ 10 DC-DC OFF (3525-SD) SNAPON 14 C40 C95 C41
V- SD R65 R66 R174 D27
220uF/450V
220uF/450V
0.1uF/630V
R52
330K_1/4W 1%
R30
1K_1/8W 1%
R51
150K_1/4W 1%
VR2
220K
4 IC5 1
3 2
PC817
0 Kevin Power Solutions(P) Ltd.
DC-DC SECTION Title
HFI1400VA(K14HFIR4)
Size D o cu men t N umb er R ev
Custom 1.4
DC - DC STAGE
D ate: Tuesday , Nov ember 18, 2008 Sh eet 1 of 1
17
C.
VCC
CN5 +5V
1 BUZZER
2 DR1B
3 DT1
4 PWMHIGH1
5 PWMLOW1
6 PWMHIGH2
7 PWMLOW2
8
22Pin L-Type Burgstrip
COM
9 C81 104/6V
10 +5V
11 FAN FAN R119 470E_1/8W 1%
12 RELAY /CHGARGER CUT RELAY /CHGARGER CUT
13 DC-DC OFF (3525-SD)
14 CHARGER PWM R158 100K_1/8W 1%
15 TEMP.-SENSE Q16
16 DC-SENSE +5V BC847 R121 470E_1/8W 1%
17 O/P SENSE
18 ZEROCROSS2(1.25Vref )
19 MANSE SENSE(ZEROCROSS1)
20 SHUNT R161 R157 R122
21
3
TRIP-DRV 100K_1/8W 1% 4K7_1/8W 1% +5V NA
22 ZEROCROSS1 5
+
2 CN6
4
- 1
+5V +5V +5V C87 D41 D22 IC21B GPIOD3/TMS/LED1[MAINS ON(GREEN)]
LM339 2 SCLK/LED2[INV ON(Y ELLOW)]
3
12
220PF/6V 1N4148 1N4148 GPIOD0/TDI/LED3[BATT. LOW(RED)]/CHARGER FAN
R134 4 MOSI/LED4[OL/SC(RED)]
R139 R148 6K8_1/8W 1% 5
2K2_1/4W 1% 3K3_1/4W 1% 6 TDO/INV/UPS SWITCH R117 470E_1/8W 1%
7
R129 100K_1/8W 1% 8 ON/OFF SWITCH
R147 R133 9 TCK/BUZZER
D30 1N4148 10E_1/4W 1% 10K_1/8W 1% +5V 10
10Pin JST Male +5V
Q17 R116
BC847 C73
TEMP. SENSE 10K_1/8W 1%
R146 R162 R128
3
470PF/25V/COG(NPO)
Q21 R120
BC847 IC20
16 21
O/P VOLTAGE SENSE 470E_1/8W 1% ZEROCROSS(+Ve) 19 RESET/GPIOA7 GPIOB0/SCLK/SCL 1 FAN-BASE
ZEROCROSS(-Ve) 3 GPIOB4/T0/CLKO GPIOB1/SS/SDA 18 RELAY 1(CO)
CHG-CRNT 4 GPIOB5/T1/FAULT3 GPIOB2/MISO/T2 17
D46 1N4007 O/P-CRNT 5 ANB0/GPIOC4 GPIOB3/MOSI/T3
ANB1/GPIOC5 29
MAINS-SENSE PWM0(LOW) 28 TDI/GPIOD0 31
PWM1(HIGH) 27 GPIOA0/PWM0 TDO/GPIOD1 15
D45 1N4007 R138 PWM2(CHARGER) 23 GPIOA1/PWM1 TCK/GPIOD2 30
4K7_1/8W 1% PWM4(LOW) 22 GPIOA2/PWM2 TMS/GPIOD3
R137 PWM5(HIGH) 20 GPIOA4/PWM4/FAULT1/T2
680E_1/8W 1% GPIOA5/PWM5/FAULT2/T3 2 DT1
GPIOB7/TXD/SCL 32
MAINS SENSE GPIOB6/RXD/SDA/CLKIN
+3.3V R111 330E_1/8W 1%
O/P CRNT R149 1K_1/8W 1%
CHG CRNT R150 1K_1/8W 1% DC-DC(3525-SD) 6 25 C63
PWMTRIPB PWMTRIPB 7 ANB2/VREFL/GPIOC6 VDD_IO
DC SENSE R154 1K_1/8W 1% DC-SENSE 13 ANB3/GPIOC7 C76 1000PF/6V/COG(NPO)
TEMP.- SENSE R153 1K_1/8W 1% TEMP. SENSE 12 ANA0/GPIOC0
O/P SENSE R152 1K_1/8W 1% O/P-SENSE 11 ANA1/GPIOC1 26 104/6V
MAINS SENSE R151 1K_1/8W 1% MAINS-SENSE 10 ANA2/VREFH/GPIOC2 VSS_IO 14
+3.3V ANA3/GPIOC3 VSS_IO
8 24
O/P CURRENT +5V +5V C67 C68 C69 C70 C66 C65 C64 9 VDDA
VSSA
VCAP
C77 C74
104/6V
104/6V
104/6V
104/6V
NA
NA
R160 220PF/6V
1K8_1/8W 1% R143 33K_1/8W 1% 104/6V 4.7uF/63V
R141 R140
10K_1/8W 1% 4K7_1/8W 1%
R142 DSP CONTROL
15K_1/8W 1%
12
4
470PF/25V/COG(NPO)
8
+5V C79
C78
104/6V SUPPLY
104/6V
R156
10K_1/8W 1%
R127
12
100nF/6V/COG(NPO) +5V
8
+5V 1000PF/6V/COG(NPO)
CHG-CRNT
18
D.
VCC R126 1
CN7 R64 470K_1/8W 1%
2
NEUTRAL O/P SENSE
470E_1/8W 1%
1 BUZZER Q11 2Pin Relimate Male(Fan)
2 DR1B BC847 FAN Q10
3 DT1 +5V BD139
4 PWMHIGH1 CN2
5 PWMLOW1
6 4 FAN
3Pin Relimate Male(Charger)
PWMHIGH2 +5V
7 PWMLOW2 3 VR2
8 COM 2 220K
9 COM 1
10 +5V 4Pin JST Male
11 FAN CN8
12 RELAY /CHGARGER CUT RELAY/CHGARGER CUT
13 DC-DC OFF (3525-SD) CHARGER PWM 1
14 CHARGER PWM R59 2
15 TEMP.-SENSE 39K_1/8W 1% 3
16 DC-SENSE 1 CN3
17 O/P SENSE 2
18 ZEROCROSS2(1.25Vref ) 2Pin JST Male(Temp. Sense)
19
20
MANSE SENSE(ZEROCROSS1) CHARGER CONTROL
SHUNT
21 TRIP-DRV
22 CONTROL INDUCTOR(L4)
VALUE=800mH(+/-10mH),21SWG,125 TRUN
+VE BATT.(24V) +HTP CORE MAKE=HONEYWELL
STGW30NC120HD
OP3 O/P
R39 Q7 R41 Q9 SNAPON SNAPON
R49 GATE-HI1 STGW30NC120HD GATE-HI2
22K_1/8W 1% RL1
4E7_1/8W 1% OP1 4E7_1/8W 1% NTC1 2E/7.5A Coil 12V DC, Contact 250 AC / 30A / (SPDT)
O/P-L
DC-SENSE SNAPON L4X4
t
INDUCTOR
FGND2 C83 L2 MOV1
R50 4700PF/1KVA VCC-RELAY
2K_1/8W 1% OP2 C82
FGND1 C86X2 CON1
N
SNAPON 4uF/440V C84 470NF/440V~- X2 375V
4700PF/1KVA FILTER C25
FGND2 D9
t
N 100uF/50V 1N4148
BATTERY SENSE 85 DEG.
NTC2 2E/7.5A
FGND2 OPTIONAL RELAY /CHGARGER CUT
R38 Q6 R40 Q8
STGW30NC120HD
POWER STAGE 0
F3
MANSE SENSE(ZEROCROSS1) TR2 I/P-L
C24 6A FUSE
0.1J/63V 35SWG
ZEROCROSS2(1.25Vref )
NOT ON PCB
D33 1N4007 31SWG
VCC-MAINS SS-400V/23V-0V-23V/0V-23V
R169 D32 1N4007
NOT ON PCB
19
E.
D7 +15V_LO
VCC-MAINS D48 +12V STTH110A/STTH112A R69 10E_1W 1%
1N4007 D49
C21 C22
1N4007 Z6
C35 100uF/35V 104/25V
R20 10uF/63V 18V/1/2W
10K_1/4W 1% R123
1K_1/4W 1%
VCC Q22 TR1
D11 R18 BC857 3 D6 +15V_HI1
1N4007 68K_1/4W 1% STTH110A/STTH112A 0
Q13 65T,35SWG
BC847 +VE BATT.(24V)
4 R68 10E_1W 1%
6 Z5
R19 C26 C18 C19
6K8_1/4W 1% 1uF/63V 1 65T,38SWG 18V/1/2W
R1 100uF/35V 104/25V
C1 C2 1K_1W 1% 5
40T(20T+20T),30SWG 8
470uF/50V 0.22uF/25V D5 +15V_HI2
R170 2 65T,38SWG STTH110A/STTH112A FGND1
R164
1K_1W 1% 7
150K_1/2W 1% 10 R67 10E_1W 1%
D2 C15 C16 Z4
STTH110A/STTH112A 25T,30WG
100uF/35V 104/25V 18V/1/2W
9
C3
Z8 145T,35SWG
C5 27V_1/2W 0.01uF/63V D3 +5V
C4 STTH310-DO-201ADC2 FGND2 L1
22uF/25V 104/25V CF138,EE COSMO,20 X10 X 5.5mm
UC3843 R4 10K_1/4W 1%
3 8 100uF/35V 104/25V 470uF/25V
VCC
2 ISEN VREF 4 R8
C6 VFB RT/CT 10E_1/4W 1% Q1
6 IRFZ44N
GND
TP4
VCC-RELAY
D4
R6 STTH110A/STTH112A R12
100K_1/4W 1% R2 R3
1E_1/4W 1% 1E_1/4W 1%
C14 750E_1W 1%
10uF/63V Z2
33V/1/2W
5. TESTING PROCEDURE
20
◄ TESTING PROCEDURE
(Online)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing Fuse & wire(between choke
and DC capacitor))
• Then remove connection of the port CN1, CN2, CN3 of charger card
and port CN1, CN16, CN15 of mother card.
• Put the mains MCB (Zig) ON and then put mains MCB of the system,
then check the voltage on blue wires of 6-pin female connector (black
wire is ground) it must be 15V.
• Now OFF all MCB’s and put the connection of CN1 port.
• Now put the CRO’s ground probe on the heat sink of IC1 and main lead
body of the Q1 and check the amplitude of pulse it must be 2.5v and see
the formation of the teeth; it must be very smooth.
• Then with the same process as above done check Q2, voltage must be
15v and frequency must be up to 1 kHz.
• Now check voltage on port CN3 it must be 15v.
• Now check port CN2,it having 4pins;from right to left 1st pin is ground
put CRO ground probe to 1st pin and check 2nd pin it will show sine
wave now on 3rd pin it will so spicks and 4th pin will show it’s
modulation.
• Now connect the connector CN2&CN3, and check smooth DC
formation.
• Make choke to DC capacitor wire connection.
• Now putt all connections of charger card and mother card except CN1.
• Now make DC by using pot P1 (variable resistance) as per specification.
• Now OFF all MCBs and put the connection CN1.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Now OFF the AC MCB and connect Fuse.
• Now ON AC MCB and check the fan; if it’s running then OK and if it
shows SHORT CIRCUIT then check the IGBT driver.
• Put the communication wire into the mother board.
• Now open testing tool (communication) in computer.
21
• Now check the LCD and Parameters and also O/P waveform.(it must be
pure sine wave )
22
◄ TESTING PROCEDURE
HKva For higher
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing DC CAPACITOR)
• Then ON the battery MCB of zig.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Now OFF the DC MCB and connect DC CAPACITOR.
• Now ON battery MCB and check the fan; if it’s running then OK and if
it shows SHORT CIRCUIT then check the IGBT driver.
• Put the communication wire into the mother board.
• Now open testing tool (communication) in computer and tune battery
voltage as per the system specification.
• Now check the LCD and Parameters and also O/P waveform.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & tune it in between 220 to 230.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 60% & check fan.
• If it’s OK then put the load 100% & tune.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.(mains must be
230v)
• System will show Mains MCB Trip.
• Then ON Mains MCB & tune mains voltage according to I/P voltage.
• Then tune Charging current as per instruction.
• Tune CT current as per instructions.
• OFF Mains & Battery MCB of the system and zig.
• Remove communication and connect normal/ups connector.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON. Check voltage
& zero crossing. If OK then system OK; if not OK then interchange the
drain wires & then again check zero crossing. If all is right then system
is done.
23
◄ TESTING PROCEDURE
(3-PHASE INVERTER/LUPS)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing +ve(red) terminal of DC
CAPACITOR)
• Remove all connection from DC-DC card.
• Then ON the battery MCB of zig.
• Now check the voltage at the CN1 female port it must be same as I/P
DC supply.
• Now off the DC MCB and connect the female connector to the male
CN1 port.
• Now ON DC MCB and check voltage at the port CN3 to CN10, it must
be 15v and at port CN7, voltage should be 5v.
• Now OFF DC MCB & connect all connection of DC-DC card.
• Now ON DC MCB of zig as well as system.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Apply the short ckt.Test.
• Now OFF the DC MCB and connect DC CAPACITOR.
• Now ON battery MCB and check the fan; if it’s running then OK and if
it shows SHORT CIRCUIT then check the IGBT driver.
• Now match DC by using preset (variable resistance) in control card, it
must be same as DC I/P supply (on LCD).
• Now check the sequence of O/P voltage by using Sequence Meter.
• Now check the LCD and Parameters and also O/P waveform.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & tune it in between 220 to 230,by using preset
on control card.(PN)
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 60% & check fan.
• If it’s OK then put the load 100% & tune it as pre specification by using
preset placed on Control card.
24
TESTING PROCEDURE
(1400VA)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper
position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.(24V)
• Then ON the battery MCB of zig...
• Now check the LCD and Parameters.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & no load o/p current.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 50% & check fan.
• If it’s OK then put the load 100%.
• Check full load battery current.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.
• System will show Mains fuse Trip.if mains fuse not ableble.
• Then connect the fuse.
• Check mains voltage.
• Now check normal & high charging current.
• Now check BOOST voltage.
• Now check high cut, low cut & recovery voltage.(UPS/normal
mode)
• OFF Mains & Battery MCB of the system and zig.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON.
• Check voltage & zero crossing. If OK then system OK; if not OK
then interchange the drain wires & then again check zero crossing.
If all is right then system is done.
25
TESTING PROCEDURE
(800VA)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper
position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.(12V)
• Then ON the battery MCB of zig...
• Now check the LCD and Parameters.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & no load o/p current.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 50% & check fan.
• If it’s OK then put the load 100%.
• Check full load battery current.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.
• System will show Mains fuse Trip.
• Then connect the fuse.
• Check mains voltage.
• Now check normal & high charging current.
• Now check BOOST voltage.
• Now check high cut, low cut & recovery voltage.(UPS/normal
mode)
• OFF Mains & Battery MCB of the system and zig.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON.
• Check voltage & zero crossing. If OK then system OK; if not OK
then interchange the drain wires & then again check zero crossing.
If all is right then system is done.
26
TESTING PROCEDURE
(PCB Power card 800)
STEPS:
• Visual inspection of the 800va Power Card.
• Connect to dc regulator power supply (12V).
• Then connect LCD & ON & OFF switch.
• Check the voltage (4.8V-5.1V) between Ground & diode D3,it
must be OK.
• Check the voltage (4.8V-5.1V) between Ground & pin no.1 of
CN6 connector, it must be OK.
• Check voltage (10V -22V) between Ground & Zener Z2,it must be
OK.
• Check voltage 15±3V between Zener Z 4, Z5, Z6& Capacitor C16,
C19, C22, they must be OK.
• Check voltage 15±3V between Capacitor C16, C19, C22& diode
D1, D28, D37, D39 they must be OK.
• Then short jumper J3 & tune the DC- DC voltage between 335V-
340V.by using preset VR2.
• Then discharge capacitor C40 &joint DC to DC section & power
section.
• Then connect PCB to testing Jig with all connections.
• Then put the communication wire with power card.
• Then open the testing tool in computer.
• Then tune Battery voltage according to DC voltmeter.
• Then check the LCD.
• Then O/P voltage tune 220V.
• Then put load 50% check fan it must be running then put load
100% and tune.
• Apply the short ckt.Test.
• Then reduce load & apply main from the Jig, then tune mains
according to voltmeter.
• Then tune charging current.(9V+0.5V)
• OFF mains & battery MCB of Jig.
• Remove communication & connect normal /UPS connector.
• Then check high charging current.(13V±1V)
• Check UPS/INV switch & display then apply mains ON.
• OFF mains & battery MCB of the Jig.
• Then remove the all connection.
27
TESTING PROCEDURE
(PCB Power card 1400VA)
STEPS:
• Visual inspection of the 1400va Power Card.
• Connect to dc regulator power supply (24V).
• Then connect LCD & ON & OFF switch.
• Check the voltage (4.8V-5.1V) between Ground & diode D3,it
must be OK.
• Check the voltage (4.8V-5.1V) between Ground & pin no.1 of
CN6 connector, it must be OK.
• Check voltage (10V -22V) between Ground & Zener Z2,it must be
OK.
• Check voltage 15±3V between Zener Z 4, Z5, Z6& Capacitor C16,
C19, C22, they must be OK.
• Check voltage 15±3V between Capacitor C16, C19, C22& diode
D1, D28, D37, D39 they must be OK.
• Then short jumper J3 & tune the DC- DC voltage between 345V-
350V.by using preset VR2.
• Then discharge capacitor C40 &joint DC to DC section & power
section.
• Then connect PCB to testing Jig with all connections.
• Then put the communication wire with power card.
• Then open the testing tool in computer.
• Then tune Battery voltage according to DC voltmeter.
• Then check the LCD.
• Then O/P voltage tune 220V.
• Then put load 50% check fan it must be running then put load
100% and tune.
• Apply the short ckt.Test.
• Then reduce load & apply main from the Jig, then tune mains
according to voltmeter.
• Then tune charging current.(9V+0.5V)
• OFF mains & battery MCB of Jig.
• Remove communication & connect normal /UPS connector.
• Then check high charging current.(13V±1V)
• Check UPS/INV switch & display then apply mains ON.
• OFF mains & battery MCB of the Jig.
• Then remove the all connection.
28
6. FAULT FINDING OF INVERTER
29
Troubleshooting chart (2.5/3 KVA STATIC UPS)
OUT PUT REVERSE 1.SCR LICKEY 1. CHECK SCR IF FAULTY
PROBLEM
COMING ONAND
IN PUT SIDE POSSIABLE
2.SCR CASE
DRIVER FAULTY SOLUTIONS
REPLACE.
SYMPTONS 3.WIRING BETWEEN CN5AND 2. SCR SRIVER FAULTY.
UPS DEAD 1.DC FUSE BLOW
SCR DRIVER PCB CN1 1.DC FUSECONNECTOR
3. CHECK 40 AMP CHANGE
CN5(ON
2.LOOSE BATTERY 2.DO TIGHT
MOTHER BATTERY
BOARD) AND CN1(ON
CONNECTION/DISCHARGE CONNECTION
SCR DRIVER)
3. CONNECTOR CN 7 LOOSE 3. CHECK BATTERY VOLTAGE
4.MOTHER CARD FAULTY ON CONNECTOR CN7 IF OK THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND RE-
MASSAGE COMING ON SIDE START
LCD DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN PCB
3.CONNECTOR LOOSE 3.CHECK CONNECTOR ON DSP
4. LOGIC CARD FAULTY BOARD
4.REPLACE THE LOGIC CARD
BATTERY MODE BUT NO 1.BATTERY IN LOW 1. CHECK DISPLAY IF BATTERY
OUT PUT CONDITION LOW COMING ON DISPLAY THEN
DISPLAY SHOW 2.BATTERY CONNECTION CHARGE THE BATTERY WHEN
PROTECTION BATTERY LOOSE/RUSTY TERMINAL MAINS RESUME.
LOW 2. CHACK LOOSE CONNECTION
/RUSTY TERMINAL.
BATTERY MODE BUT NO 1.SHORT CIRCUIT ON OUT 1.CHECK SHORTING ON OUT PUT
OUT PUT PUT SIDE SIDE
DISPLAY SHOW SHORT 2.TOO MUCH LOAD 2. REMOVE LOAD OF OUT PUT
CIRCUIT 3.MOTHER CARD FAULTY SIDE AND RE START
3.CHECK MOTHER CARD AND
REPLACE
COMPUTERS RESTART 1.UPS RUNNING ON 1.SELECT SWITCH TO UPS MODE
WHEN MAINS FAIL INVERTER MODE
DISPLAY SHOW MAINS 1.CHECK MAINS MCB FOR 1. TURN ON THE MAINS MCB.
MCB TRIP TRIP 2.CHECK SCR/SCR DRIVER
2. SCR/SCR DRIVER FAULTY 3.CHECK CN5
3.CONNECTOR CN5 ON
MOTHER CARD
DISPLAY SHOW SWICH 1.SWITCH CHECK
OFF WHILE FRONT PROBLEM,CONNECTOR SWITCH,INTERNALWIRING OF
SWITCH ON /WIRE LOOSE SWITCH
UPS NOT RUNNING ON 1.MAINS OUT OF RANGE 1. CHECK MAINS FOR NORMAL.
MAINS MODE WHILE 2.LOOSE CONNECTION ON 2. CHECK LOOSE CONNECTION
MAINS PRESENT I/P TERMINAL BLOCK ON I/P TERMINAL BLOCK.
3.LOGIC CARD FAULTY 3. REPLACE THE LOGIC CARD.
30
Troubleshooting chart (2.5/3 KVA INVERTER)
PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS
INVERTER DEAD 1.DC FUSE BLOW 1.DC FUSE 40 AMP CHANGE
2.LOOSE BATTERY 2.DO TIGHT BATTERY
CONNECTION/DISCHARGE CONNECTION
3. CONNECTOR CN 7 LOOSE 3. CHECK BATTERY
4.MOTHER CARD FAULTY VOLTAGE ON CONNECTOR
CN7 IF OK THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND
MASSAGE COMING ON LCD SIDE RE-START
DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN
3.CONNECTOR LOOSE PCB
4. LOGIC CARD FAULTY 3.CHECK CONNECTOR ON
DSP BOARD
4.REPLACE THE LOGIC
CARD
BATTERY MODE BUT NO 1.BATTERY IN LOW 1. CHECK DISPLAY IF
OUT PUT CONDITION BATTERY LOW COMING ON
DISPLAY SHOW 2.BATTERY CONNECTION DISPLAY THEN CHARGE
PROTECTION BATTERY LOW LOOSE/RUSTY TERMINAL THE BATTERY WHEN MAINS
RESUME.
2. CHACK LOOSE
CONNECTION /RUSTY
TERMINAL.
BATTERY MODE BUT NO 1.SHORT CIRCUIT ON OUT 1.CHECK SHORTING ON OUT
OUT PUT PUT SIDE PUT SIDE
DISPLAY SHOW SHORT 2.TOO MUCH LOAD 2. REMOVE LOAD OF OUT
CIRCUIT 3.MOTHER CARD FAULTY PUT SIDE AND RE START
3.CHECK MOTHER CARD
AND REPLACE
DISPLAY SHOW SWICH OFF 1.SWITCH CHECK
WHILE FRONT SWITCH ON PROBLEM,CONNECTOR SWITCH,INTERNALWIRING
/WIRE LOOSE OF SWITCH
INVERTER NOT RUNNING 1.MAINS OUT OF RANGE 1. CHECK MAINS FOR
ON MAINS MODE WHILE 2.LOOSE CONNECTION ON NORMAL.
MAINS PRESENT I/P TERMINAL BLOCK 2. CHECK LOOSE
3.LOGIC CARD FAULTY CONNECTION ON I/P
TERMINAL BLOCK.
3. REPLACE THE LOGIC
CARD.
INVERTER WORKING BUT 1.DISPLAY PROBLEM 1.CHANGE DISPLAY
JUNK DISPLAY 2.CONNECTOR PROBLEM 2. CHECK CONNECTOR.
3.MOTHER BOARD 3. MOTHER BOARD FAULTY
PROBLEM
DISPLAY SHOW MAINS MCB 1.CHECK MAINS MCB FOR 1. TURN ON THE MAINS
TRIP TRIP MCB.
2. SCR/SCR DRIVER FAULTY 2.CHECK SCR/SCR DRIVER
3.CONNECTOR CN5 ON 3.CHECK CN5
MOTHER CARD
OUT PUT COMING ON IN PUT REALY PROBLEM CHECK REALY
31
2.5KVA/3KVA/48VOLT STATIC/INVERTER
MOTHER BOARD
HS1 11
HS2 HS3 10
8
7
12 6
15
13
CN2 CN7
14 C CN3 CN5 CN6
1 2 3 4 5
32
SCR DRIVER CARD
1 2
1
2
4
5
33
2.5KVA/3KVA/48VOLT STATIC/INVERTER
MOTHER BOARD
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PIN 1 PIN 2 PIN 3 PIN4 REMARKS
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PIN 1 PIN 2 PIN 3 PIN4 REMARKS
34
Troubleshooting chart
(5KV/6KVA/7.5KVA/10KVA/96V/120V/180V STATIC/INVERTER)
(1$ IN-1$ OUT)
PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS
UPS DEAD 1.DC MCB AND MAINS MCB 1.TURN ON DC MCB THEN
OFF MAINS MCB
2.LOOSE BATTERY 2.DO TIGHT BATTERY
CONNECTION/DISCHARGE CONNECTION
3. CONNECTOR CN 1 LOOSE 3.CHECK BATTERY VOLTAGE
4.MOTHER CARD FAULTY ON CONNECTOR CN IF OK
THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND
MASSAGE COMING ON LCD SIDE RE-START
DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN
3.CONNECTOR LOOSE PCB
4. MOTHER CARD FAULTY 3.CHECK CONNECTOR ON
5.IGBT/DRIVER CARD DSP BOARD
FAULTY 4.REPLACE THE LOGIC CARD
BATTERY MODE BUT NO SHORT CIRCUIT ON OUT CHECK DISPLAY IF SHORT
OUT PUT PUT SIDE/ CIRCUIT COMMING ON
DISPLAY SHOW SHORT PROBLEM IN DRIVER DISPLAY THEN REMOVE OUT
CIRCUIT CARD/IGBT/CANTROL CARD PUT AND RESTART THE UPS
.IF UPS GIVING OUT PUT
THEN PROBLEM WITH OUT
PUT SIDE .IF DISPLAY SHOW
AGAIN SHORT CIRCUIT THEN
PROBLEM IN LOGIC CARD
/DRIVER CARD/IGBT.
COMPUTERS RESTART UPS RUNNING ON INVERTER SELECT SWITCH TO UPS
WHEN MAINS FAIL MODE MODE
DISPLAY SHOW MAINS CHECK MAINS MCB FOR SWITCH ON THE MAINS
MCB TRIP TRIP/CHECK SCR MCB/REPLACE THE SCR
DRIVER/WIRING DRIVER/CHECK WIRING
UPS NOT RUNNING ON MAINS LOW/VERY CHECK MAINS FOR
MAINS MODE WHILE HIGH,MAINS SENCE TRF / NORMAL,IF OK THEN CHECK
MAINS PRESENT WIRE FAULTY, MAINS WIRE AND VOLTAGE
LOGIC CARD, ON I/P TERMINAL
INTERNAL WIRING BLOCK,REPLACE LOGIC
CARD,CHECK INTERNAL
WIRING
DISPLAY SHOW SWICH OFF SWITCH CHECK
WHILE FRONT SWITCH IS PROBLEM,CONNECTOR SWITCH,INTERNALWIRING
ON /WIRE LOOSE OF SWITCH
35
5KVA—12KVA STATIC/INVERTER
MOTHER BOARD
1 2 3 4 5 6 7 8 9
LS1 TRF
TS1
CN14
CN10
TRF
CN9
CN12
CN1
10 11 12 13 14 15 16 17 18 19 20 21
36
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PI PIN PIN 3 PIN4 PIN5 PIN6 REMARKS
N1 2
CN4-7 15 VOLT +15 FOR DRIVER
-
CN19 DC TO SWITCH
NORMAL
/UPS
CN18 DRIVE TO IGBT
DRIVER
CN17 DRIVE TO IGBT
DRIVER
CN16 DC CR. DC DENCE
+ - SENCE CHARGING
CURRENT
CN15 AC 230 0 MAIN SENCE
CN1 DC + NC - FOR SMPS
CN20 DC/DATA FOR
DIPLAY/ON/OFF
SWITCH
CN9 AC FROM CT
CN12 AC 230 0 OUT PUT F.B.
CN14 DC TO SCR
DRIVE/RELAY
37
Troubleshooting chart
38
3KVA—10KVA ON-LINE UPS
MOTHER BOARD
1 2 3 4 5 6 7 8 9
LS1 TRF
TS1
CN14
CN10
TRF
CN9
CN12
CN1
10 11 12 13 14 15 16 17 18 19 20 21
39
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PI PIN PIN 3 PIN4 PIN5 PIN6 REMARKS
N1 2
CN4-7 15 VOLT +15 FOR DRIVER
-
CN19 NOT IN USE
40
7. INSTALLATION PROCEDURE & PRECAUTIONS
INSTALLATION
Inverter/ Static UPS are sophisticated devices and must be treated accordingly.
Keep the inverter/ static UPS in non-condensing, well ventilated environment,
ensuring that there are no ingresses of moisture of foreign material. Inverter/ Static
UPS should be kept as close as possible to the battery in order to keep the battery
cables short. However, do not locate the inverter/ static UPS in the same
compartment as non-sealed batteries. Batteries generate gases, which are very
corrosive to electrical equipment and everything else.
An independent circuit breaker (MCB) is suggested for input & out put according to the
inv/ups capacity.
For in put, out put, battery wire thickness refers to table below.
1) UN pack the ups and examines carefully to make sure the out look of the
ups/inv/lift ups is in good condition.
2) Select a proper environment; keep at least 1feet clearance between inv/ups/lift ups
rear panel and the wall.
3) Keep smooth air flow to the ventilation hole of the ups.
4) Avoid over heating or excessive moisture.
Installation notice:
41
2) Error phase wiring of input &out put will prohibit system operation.
3) Casters are designed for smooth floor displacement only. Ramped floor
displacement is not allowed and against warranty condition.
4) In case the out put wires get short, the ups/inv get tripped in short circuit please
check the out put wires to rectify the short case and restart inv/ups
Installation instruction:
OPERATION INSTRUCTION:
INV SWITCH: OFF I/P VOLTAGE: 000VOLT O/P VOLTAGE: 000 VOLT
MAINS NOT OK I/P FREQ : 00 HZ O/P FREQ : 00 HZ
42
5) Check load current/status.
An independent circuit breaker (MCB) is suggested for input & out put according to
the online-ups capacity.
For in put, out put, battery wire thickness refers to table below.
UPS/INV(KVA) MAX I/P AMP IN PUT I/P WIRE O/P WIRE BATTERY
AT LOW I/P PROCETION THICKNESS THICKNESS WIRE
VOLTAGE MCB(AMP) (MMS) (MMS) (MMS)
1KVA/168VOLT(1P-1P) 6 AMP 10AMP 1.5 1.5 2.5
43
1) UN pack the ups and examines carefully to make sure the out look of the ups/inv/lift
ups is in good condition.
2) Select a proper environment; keep at least 1feet clearance between on line ups rear
panel and the wall.
Installation notice:
2) Error phase wiring of input &out put will prohibit system operation.
3) Casters are designed for smooth floor displacement only. Ramped floor
displacement is not allowed and against warranty condition.
4)In case the out put wires get short, the ups/inv get tripped in short circuit please
check the out put wires to rectify the short case and restart inv/ups
5) Never put on battery MCB first.
Installation instruction:
44
INSTALLATION CHECK LIST:
FOR EXAMPLE: IF ON LINE UPS CAPACITY IS 5 KVA AND LIGHT/OTHER LOAD IS 5 KVA THEN WE
REQUIRED 15 KVA GOOD WORKING DG SET.
OPERATION INSTRUCTION:
1) Turn on mains mcb.(wait some time …)
On-line Ups will be energized and get start, LCD will display.
45
Display status:
status On display Alarm
On-line ups running on I/P …..XXX VOLT no
mains
o/p……xxx volt
I/P freq……..xx Hz
o/p freq……..xx Hz
battery charging
mains ok
load %
Over load
I/P mcb trip i/p mcb trip beeping
Installation Procedures
Inverter/ Static UPS are sophisticated devices and must be treated accordingly.
Keep the inverter/ static UPS in non-condensing, well ventilated environment,
ensuring that there are no ingresses of moisture of foreign material. Inverter/ Static
UPS should be kept as close as possible to the battery in order to keep the battery
cables short. However, do not locate the inverter/ static UPS in the same
compartment as non-sealed batteries. Batteries generate gases, which are very
corrosive to electrical equipment and everything else.
46
Operation
Once the AC & DC wiring have been installed and connected, take a moment to re-
examine all the connections and make sure they are secured and in the proper
terminals. Check to see that the inverter/ static UPS are turned off, and then apply
battery DC power to it. Ensure that all wiring has been installed properly. Turn on the
battery bank DC disconnect or connect the proper Fuse/ MCB in line to the battery
to complete the battery circuit. Put ON/ OFF switch to the ON position. The inverter/
static UPS should run a load without AC input (battery only). Place a load on the
inverter/ static UPS and make sure that it works. To change the batteries, connect
AC power to the inverter/ static UPS by plugging in the AC power and turning on the
MAIN line. This shows that charger is working properly. Any AC load powered by the
inverter/ static UPS should also work at this point since a protection of the AC
power is passed through the inverter/ static UPS to power the loads. The delay
before connecting is provided within acceptable frequency and voltage limits.
Disconnect the AC power. The inverter/ static UPS should transfer to inverter/ static
UPS mode immediately. This will be indicated by a clicking sound as the internal
transfer relay changes position. The inverter/ static UPS will begin to take power
from the batteries and use it to power the load and the load continues to operate
uninterrupted.
1) Make sure that the MCB’s on the rear panel are OFF
2) Connect in-put mains wires according to the indication of (N-L-E)/ (R-Y-B) on the
terminals block
3) Connect out-put wires according to the indication of (N-L-E)/ (R-Y-B-N) on the
terminal block
4) Ready battery bank as on-line UPS battery voltage rating. Connect battery
positive and negative wires in inverter/ UPS according to the indication on rear
panel.
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Precautions
General Precautions:
Before using the Three Sixty DSP Sine Wave Inverter/ Static UPS, read all the
instructions and caution marking on the inverter/ static UPS, the batteries, all
appropriate sections of this Instruction Manual.
Do not expose Three Sixty DSP Sine Wave Inverter/ Static UPS to any type of
chemicals
Do not assemble the Three Sixty DSP Sine Wave Inverter/ Static UPS. Take it to
a qualified Three Sixty Engineering Service Centre when service or repair is
required. Opening by unqualified person can lead electrical shock or fire hazard
To reduce risks of electrical shock, disconnect all wiring before cleaning
Warning: Avoid exposing the inverter/ static UPS or batteries to any type of
explosive gases (in the vicinity, as batteries generate explosive gases during
normal operation), provide ventilation to outdoors from the battery
compartments. The battery enclosures should be designed to prevent
accumulation and concentration by hydrogen gas in “POCKET” at the top of the
compartment. Vent the battery compartment from the highest point. A sloped
lid can also be used to direct the flow to the vent opening location. To reduce the
risk or the battery explosion, follow all the instruction of battery supplier or any
equipment you intend to use in the vicinity of the batteries
Use the correct tolls to make AC/ DC wiring connections
Do not install this Three Sixty DSP Sine Wave Inverter/ Static UPS on or near
flammable materials like plywood, chemicals, gasoline etc.)
CAUTION: The Three Sixty DSP Sine Wave Inverter/ Static UPS should be
connected to grounded, permanent wiring systems
Personal Precautions
Someone should be within the range of your voice to come to you aid when you
work near batteries
Keep plenty of fresh water and soap nearby in the event that battery acid
contact skin, clothing or eyes
Wear complete eye protection and clothing protection
Avoid touching eyes while working near batteries; wash your hands with soap,
when done
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If battery acid comes in contact with skin or clothing, wash immediately with
soap and water. If acid enters eyes, immediately flood eyes with running cool
water for at least 15 minutes and get medical attention immediately
Baking soda neutralizes battery electrolyte. Keep a supply in the battery area
handy.
NEVER smoke or allow spark or a flame in the vicinity of the battery
Be extra cautious when working with metal tools on and around batteries. It
could short circuit the batteries or other electrical parts producing a spark that
could cause an explosion
Remove personal metal items such as rings, bracelet, necklace and watches
when working with the battery. Battery can produce a short circuit current high
enough to cause severe burns
Never attempt to charge a frozen battery
Before touching the battery terminal make sure that the inverter/ static UPS
front switch is OFF and AC mains to the inverter/ static UPS is also OFF
f it is necessary to remove any battery, always remove the grounded terminal
from the battery first. Make sure that all the accessories are OFF, so as not to
cause arcing
Be sure that the area around the battery is well ventilated
Clean battery terminals. Be careful not to allow corrosion to come in contact
with the eyes
Study all the battery manufacturer’s specific precautions and recommended
rates of charge.
Add only distilled water in each cell until battery acid reaches level specified by
battery manufacturer. This helps purge excessive gas from cells. Do not overfill.
For a battery without caps carefully follow manufacturer’s recharging
instructions
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