Download DS-I 6-20KVA maintenance manual

DS-I 11 6-20KVA maintenance manual V1.0
0. foreword
This manual must be used together with “user manual”, “DS-I11 and 31 series panel
operation guide” or “UPS power monitor users manual”, “wiring diagram”.
DS-I Series 6-20K
user manual.pdf
DS-I Series 6-10K DS-I 11and 31 Series
UPS Power
Wiring Diagram.pdf UPS Panel Operating Guide.pdf
Monitor.pdf
DS-I Series 6-10K
Wiring Diagram.pdf
1. Introduction about DS-I11 and DS-I31 series
1.1 boards
There are 9 types of boards for DS-I11 series:
Model
description
1
SNT_PCB_PS1103_ZK
DSP controlled board. Also used in DS-I31
2
PCB_PS1103_DR9
Rectifier power board. Include SCR rectifier, discharge
circuit, PFC and DC bus
SCH_PS1103_DR9.pd
f
3
SNT_PCB_PS110310_FG
Inverter power board. Include DC bus, inverter, bypass
SNT_SCH_PS110310_
FG.pdf
4
SNT_PCB_PS1103_DY
Power supply board. Output 12Vdc supply for whole system
SNT_SCH_PS1103_DY
.pdf
5
SNT_PCB_PS1103_CD
Charger board. 1pcs for standard model, 2pcs for long
backup model. Max charge voltage is 220Vdc.
SNT_SCH_PS1103_CD
.pdf
6
SNT_PCB_PS110310_CR
Input EMI board. Include input filter, battery fuse.
7
SNT_PCB_PS110310_FR
Output EMI board. Include output filter, output optional
relay.
8
PCB_PS1103_DR8
IGBT driver board. Assembled on power board.
SCH_PS1103_DR8.pd
f
9
SNT_PCB_PS1103_JP
Keyboard. Include keyboard and LCD.
There are 11 types of boards for DS-I31 series:
Model
description
1
SNT_PCB_PS1103_ZK
DSP controlled board. Also used in DS-I 31
2
PCB_PS1103_DR10
PFC power board. Include discharge circuit, PFC and DCbus.
There are 2 PFC power board in 20KVA.
SCH_PS1103_DR10.p
df
3
SNT_PCB_PS110310_FG
Inverter power board. Include DC bus, inverter, bypass.
There are 2 PFC power board in 20KVA
SNT_SCH_PS110310_
FG.pdf
4
SNT_PCB_PS1103_DY
(10KVA)
Power supply board. Output 12Vdc supply for whole system
SNT_SCH_PS1103_DY
.pdf
SNT_PCB_PS1103_PW1
(20KVA)
SNT_SCH_PS1103_PW
1.pdf
5
SNT_PCB_PS1103_CD
Charger board. 1pcs for standard model, 2pcs for long
backup model. Max charge voltage is 220Vdc.
SNT_SCH_PS1103_CD
.pdf
6
SNT_PCB_PS1103_EM1
Input EMI board. Include input filter, battery fuse.
7
SNT_PCB_PS1103_EM2
Output EMI board. Include output filter, output optional
relay.
8
PCB_PS1103_DR8
IGBT driver board. Assembled on power board.
SCH_PS1103_DR8.pd
f
9
PCB_PS1103_EM3
Battery EMI board.
10
SNT_PCB_PS1103_JP
Keyboard. Include keyboard and LCD.
11
SNT_PCB_PS1103_DR2
Rectifier board. Include SCR rectifier.
SNT_SCH_PS1103_DR
2.pdf
Optional boards:
There are 3 types of optional boards:
Model
1
SNT_PCB_PS1103_DR3
description
ECO board. If choose ECO board, must choose ECO board. It
can be fast assembled on SNT_PCB_PS110310_FG
2
SNT_PCB_PS1103_BJ
Parallel board. If choose parallel mode, the UPS must be
assembled with parallel board yet
3
PCB_PS1103_TF1
Dry contact board. It can offer many function signals to
user
NOTE: All board may be upgraded continuously, including function, model and so on. For
optional kits assemble, please refer to the assembling operation manual.
1.2 cables
Fig.1.2 cable design
One cable in UPS includes cable, connectors, cable number label, direction label shown as
fig.1.2
Routing direction label indicates that where is this connector connected to, such as CD1-J2
means connect to socket J2 on SNT_PCB_PS1103_CD board 1#.
Every cable has one and only cable number.
Wiring direction of DS-I 11 and DS-I 31 are shown as below:
6-10KVA Wiring.pdf
DS-I 3110
Wiring.pdf
DS-I 3120
Wiring.pdf
User can see where is one cable connected to.
1.3 main components
1).
Input circuit breaker: assembled at rear panel
Input fuses, battery fuses: assembled on input EMI board
Rectifier SCRs:
DS-I 11: assembled on SNT_PCB_PS110310_FG as fig.1.3.1
Fig.1.3.1 DS-I 11 series rectifier power board
DS-I 31: assembled on SNT_PCB_PS1103_DR2 as fig.1.3.2
Fig.1.3.2 DS-I 31 series SCR board
PFC IGBTs, PFC Diodes, discharge relay(no for 6KVA), discharge SCR
DS-I 11: assembled on PCB_PS1103_DR9 as fig.1.3.1
DS-I 31: assembled on PCB_PS1103_DR10 as fig.1.3.3
Fig.1.3.3 DS-I 31 series PFC power board
2). Failure mode of main component
FUSE:
normal- resistor is near zero
broken- resistor is very large
SCR:
normal- resistor is about xx Kohms~xxx Kohms
broken- shorted, resistor is near zero
DIODE:
normal- voltage from Anode to Cathode is about 0.7V
broken- shorted, voltage is near zero; opened, voltage can’t be tested
IGBT(internal anti-parallel diode):
normal- voltage from E node to C node (Vec) is about 0.7V, resistor (Rce) is about xx Kohms,
capacitor between G and E (Cge) is about xx nf
broken- shorted, Vec is about zero, Rce is about zero, and probably Cge is about 0; opened,
Vec can’t be tested. Probably devices near gate of IGBT may also be destroyed, such as driver
resistors, TVS and so on
2. To get the fault or warn information
a). UPS is continuous beeping, some LEDs are steady red, fault alarm(something are broken)
b). UPS is sounded once per second, some LEDs are red flicker, warn alarm(something are
wrong)
c). Press
to see the higtory log, it tells what have happened
d).Choose
then press RIGHT button to get S-code information
Note: S-code scrolls like as S0-S1-A0-A1-A2-A3-A4-A5, please record them all, or you can
downlowd the S-code according to power monitor software.
Fig.2.1 Panel
3. To get the failure point
According the history log and S-code, we can judge what have happened.
See the S-code as fig.2.2
1
16
Fig.2.2 S-code
Every number of S-code indicates one warn or fault. If the number is set to be “1”, it means
something has happened.
Description of every code has been listed in user manual.
3.1 Solution for faults
S-code
Cause
Solution
A0-1
1). Bypass voltage is out of
synchronous range
2). Bypass voltage changed too
fast to be tracked by inverter
Check if bypass voltage on LCD and through
testing utility are same, if yes, it is probably that
utility is abnormal
A0-2
Main input is abnormal
Check if utility is abnormal
A0-3
Rectifier fault
It’s a composited fault, it maybe for rectifier
over temperature, soft start failure, DCbus over
voltage or else
A0-4
Inverter fault
It’s a composited fault, it maybe for inverter
over temperature, inverter voltage abnormal,
DCbus over voltage or else
A0-13
Input phase A over current. As
DS-I 11 series, it means input
over current.
A0-14
Input phase B over current.
Reserved in DS-I 11 series.
A0-15
Input phase C over current.
Reserved in DS-I 11 series.
1). Check if PFC IGBT is broken, if yes, please
replace it.
2). Check if DC bus is shorted, if yes, please
replace all DC capacitors and check again
3). Check if IGBT drivers are lost, if yes, please
replace IGBT drivers and check if some cables
are not connected correctly
4). Input voltage is too low when load big loads
5). Check if PFC current transformer is broken, if
yes, please replace it
A0-16
Inverter voltage fault
1). Check if inverter IGBT is broken, if yes,
please replace it.
2). Check if inverter IGBT driver is lost, if yes,
please replace it
3). Check if cable from DSP board to inverter
power board is not connected correctly
A1-9
Input voltage fault
1). Check if input voltage is out of range
2). Check if voltage display on LCD is same as
tested input voltage
A1-10
Input frequency fault
Check if input frequency is out of range
A1-11
Input sequence fault
Check if input wires connection or input voltage
sequence is wrong
A1-15
Rectifier over temperature
1). Check if environmental temperature is over
40℃
2). Check if fans are abnormal
A1-16
Positive bus over voltage
1) Check if some half-wave loads are
connected to UPS , if yes, please remove
them
2) Check if maintenance bypass switch is
mistaken closed, if yes, please open it
3) Please contact with manufacturer or
distributer
A2-1
Negative bus over voltage
1) Check if some half-wave loads are
connected to UPS , if yes, please remove
them
2) Check if maintenance bypass switch is
mistaken closed, if yes, please open it
3) Please contact with manufacturer or
distributer
A2-2
Fan fault
1). Find out that which fan is stopped or rotates
slowly and then replace it with same model
2). Check if fan wires connection is loosen
3). Check if the short jumper is disappeared
near reserved fan power socket
A2-5
Positive DC bus under voltage
A2-6
Negative DC bus under voltage
1). Check if PFC IGBTs are broken, if yes, please
replace it
2). Check if PFC IGBT drivers are broken, if yes,
please replace it
A2-7
Battery reversed
Check if battery connection is reversed, please
connect if correctly
A2-13
Battery over temperature
1) Check if battery temperature is too high,
please locate batteries at temperature from
20~25℃.
2) Battery life is over, please replace all
batteries with same type of batteries.
A3-1
Battery voltage is low
Alarm, battery backup time is near ZERO, please
resume utility or loads will be shutdown
A3-3
Battery EOD
Battery voltage is under the end of discharge,
UPS will shutdown and has no output
A3-7
Bypass voltage fault
Check if bypass input voltage is normal
A3-8
Bypass SCR or relay is failure
Open input breaker, and UPS works in battery
mode, check if input voltage is same as output
voltage, if yes, please replace bypass SCR or
relays
A3-11
Bypass
frequency
synchronous
Check bypass frequency is out of range
A3-14
Overload time out
Please remove some loads and UPS will transfer
back to inverter
A4-1
Manual shutdown
Someone has shutdown the UPS manually
A4-2
Inverter protect
A4-3
Transfer times over limit
over
Transfer times between inverter and bypass is
over 5times in one hour
A4-8
Inverter over temperature
Check if environmental temp is over 40℃, or
fans are abnormal
A4-11
Over load
Please check load level and remove
non-essential load to make sure load percent is
under 95%
A4-12
Inver relay or fuse fault
Check if inverter relay is shorted or opened
A4-14
Parallel communication fault
1). Check if one parallel communication cable is
disconnected
2). Check if working mode is “P(parallel)” for
single UPS, if yes, please set it as “S(single)”
A5-2
Output shorted
Shutdown UPS and open output breaker, check
if load is effective or short, if yes, please
remove the load. Check if output connection is
short, is yes, please connect it correctly
A5-3
Battery test
Normal
A5-4
Battery maintenance
Normal
3.2 How to transfer to maintenance bypass
Maintenance bypass kit can be chosen with DS-I 11 and DS-I 31 series.
If need to maintenance UPS without interruption, please operate as below:
(1). Press “ON/OFF”, and then choose “OFF” to transfer to bypass mode
(2). Open battery breaker
(3). Close maintenance bypass switch or breaker
(4). Open main input breaker
3.3 how to replace or assemble boards
(1) replace power board
Replace rec and inv
board for DS-I.docx
(2) assemble output relay
DS-I output relay
assemble.docx
(3) assemble dry contact board
a). assemble dry contact board to UPS as fig.3.3.1
Fig.3.3.1
b). connect signal cable from DSP board to dry contact board as fig.3.3.2
Fig. 3.3.2