Forza Atlas 2-3KVA User manual

2 Year
Warranty
Atlas 2-3KVA Model
Power Inverter/UPS System
Service Manual

· Overview and UPS features
· Replacing the battery
· Steps to Open the Case
· Principles of Operation
· Alignments
· Trouble Shooting
· Electrical Specifications
General Information
Important Safety Instructions
Getting started
Conventions
The following conventions are used in this manual to provide
important information for a quick and safe operation of the
UPS.
For qualified personnel only:
AVOID performing any internal service or adjustment to
this product unless there is qualified personnel who can
perform first aid or CPR.
AVOID touching any exposed connections or
components while the UPS is working since there is
dangerous voltage at several points in this product.
Turn off the UPS and disconnect the input power cable
before removing the external protective cover.
AC voltage may be present when AC power is being
supplied.
1.
2.
3.
4.
5.
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.
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.
This symbol means that there are
some tips or actions recommended by our design
engineers during service operations as a way to
help you finish your job.
Warning:
Caution:
Information and Tips:
STOP
STOP

Steps to open the case
Step 1
High voltage may be present at DC capacitors. Before
opening the external cover, wait for at least five minutes
after turning off the UPS.
Verify the input source (voltage and frequency) before
performing service work.
DO NOT short circuit the batteries.
If the battery connectors (P6, P8) are disconnected,
plug in the input power cord and verify that that there is
input power available before re-connecting the battery
connectors.
After servicing the UPS and before restarting it, perform
a polarity test on the batteries, and make sure the screws
and connectors are tight.
After opening the cover, always make sure that all wires,
connectors, and screws are tight. Then, check if any
components inside are discolored.
Remove related screws as shown in STEP 1.
Slide external cover in the direction shown in STEP 2.
You will see the internal panel.
To open the external case, follow the illustrations below:
6.
7.
1.
2.
3.
4.
1.
2.
3.

Step 2
Step 3

I. INTRODUCTION
All the UPS series are strictly tested and carefully
designed. We always do our best to make our products
more reliable and safer. However, due to the lifetime of
electrical components and some unpredictable reasons,
malfunctioning may occur. If this happens, consult with
qualified and trained personnel. This service manual will
help technicians repair and adjust any trouble that you may
find in your UPS. If the UPS still does not work properly,
contact us and we will gladly solve any problems that you
may have encountered.
Due to the unique features of this UPS series
(Uninterruptible Power System), this unit is very easy to
maintain and service.
The PBC has all the major power components.
All PCBs are interconnected.
Major parts are connected with flexible insulated wires
and plugs.
·
·
·
This service manual consists of 4 major parts:
For a correct and safe operation, make sure to read this
manual carefully before servicing the UPS.
Introduction.
Principle of operation: This section describes the
functions and principles of each part.
Alignments: This section describes the locations and
methods needed to adjust this UPS.
Troubleshooting: This section describes the possible
failure conditions and procedures to repair it.
1.
2.
3.
4.

II. PRINCIPLE OF OPERATION
This 3KVA (2KVA) high input power factor UPS system
contains two major PCB assemblies. They are:
Picture 1 shows how the major circuits are connected and
how the entire system works.
Picture 1 shows how the major circuits are connected and
how the entire system works.
Picture 1: Circuit connection for 2-3KVA.
Includes (1) a charger, (2) a DC power supply, (3) a power
factor correction, (4) a DC-DC converter, (5) an inverter
and (6) output circuits.
Includes protection parts, signaling circuits, regulation
and inverter control circuits.
1. PSDR
2. CNTL

The location of the assemblies in the machine are shown in
picture 2.
The location of the assemblies in the machine are shown in
picture 2.

Picture 2 : Sub-assembly location
Picture 3: Block Diagram for UPS
The block diagram in picture 3 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 the inverter to the AC mains
by a bypass relay. This operation will be explained in
another section.
This ON-LINE UPS system resorts to high frequency
PWM techniques to achieve high efficient performance.
When the Full mode is on, the UPS can deliver a clean,
regulated sine-wave output at any load. Each sub-system
is described as follows:
N.F.
CHARGER DC/DC
N.F.
DC/AC
PFC
AC/DC
RY
BATTERY
I/P
O/P
RY

Picture 4: Charger Circuit Diagram
1.POWER STAGE (PSDR)
As shown in picture 1, the power stage consists of a
charger, a power factor correction unit, a DC power supply,
a DC-DC converter, an inverter and output circuits.
The purpose of the charger is to provide power to keep
the batteries full, (Refer to picture 4). The voltage flyback
switching power supply delivers a constant DC voltage
(83.8 VDC) to the batteries. Apart from providing constant
voltage, the power supply also limits the current going into
the batteries thus, protecting and extending their life.
1-1 Charger Sub-System:
Picture 5: Schematic for DC power supply

Picture 6: Schematics for inverter
Picture 7: I/P PFC configuration
1-4 Output Sub-System:
1-5 Input Power Factor Correction Sub-System:
1-6 DC-DC Converter Sub-System:
The bypass relay receives a signal from the control circuit
to switch the output of the UPS from bypass to inverter,
and vice versa. The output noise filter circuit blocks the
EMI noise to the loads.
The purpose of the power factor correction (PFC.) system
is to ensure that the level of the input current is less than 1,
as shown in picture 7.
The primary role of a UPS is to deliver accurate AC power
to the loads connected to it whether the AC line exists or
not. The batteries in the UPS release the stored energy to
start supplying the inverter once the loss in the AC line is
detected.
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 have
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 ±360 Vdc.

Picture 8: Schematics for DC/DC Booster
2-1 REGULATION & CONTROL SUB-SYSTEM:
2-2 PROTECTION SUB-SYSTEM:
Refer to picture 8, the battery voltage is transformed
through a full bridge DC-DC converter to ±360Vdc as DC
buses for inverter. When the line fails, the ±360Vdc DC
sources are caught up to supply the power needed by the
inverter immediately.
The UPS is controlled by the PCB assemblies which are
composed of three mayor circuits:
This section can be considered the 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.
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.
The UPS provides the following protection circuits:
1. Overload protection
The load detector identifies the load current, i.e. the inverter
current, and sends the signal through two paths. When the
battery mode is on, the UPS will go onto failure mode if the
overload occurs.
The overload status will be indicated on the UPS panel.
There are two kinds of protection provided by our UPS:
(1) Regulation & control
(2) Protection
(3) Signaling
Q1
Q2
Q3
Q4
Bat D1 D2
D3 D4
L1
L2
C2
C3
C1
TX1
+BUS
-BUS
2. MAIN CONTROL PCB ASSEMBLIES (CNTL)

Overload Protection: The UPS collects the continuous
overload signals through the CPU switch, the bypass
relay. If the output load is lower than 110% of rated load
(VA or Wattage), the UPS keeps running on inverter mode,
showing the warning status. If the output load is between
110% and 130% of rated load (VA or Wattage)
the UPS transfers to bypass after 12s. If the output load
is higher than 130% of rated load, the UPS immediately
transfers to bypass after 1.5 seconds.
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
3. Inverter output abnormal protection
4. Over temperature protection
5. Bus over/under/unbalance-voltage protection
When the battery voltage is under or over the level, the
UPS will activate a warning signal which will turn off later.
After that, the fault code will be displayed on the LCD.
When there is a failure signal, the inverter shuts down
immediately. When this happens, the alarm continues
buzzing and the LCD displays the following fault code. "The
failure signal remains on latching mode until it is switched
off or until the battery depletes".
The thermal switch detects the temperature of PSDR
heat sink. The thermal switch is electrically connected
to the CPU. An opened thermal switch is considered as
temperature failure by the UPS. The LCD will display the
fault code.
To protect any BUS over/under/unbalance -voltage
condition especially for the half-bridge load. The LCD will
display the fault code.
a.
b.

When the AC line is unable to supply, the batteries release
energy inside to supply the inverter immediately. At the
same time, the buzzer beeps every 4 seconds.
When the batteries are depleted, the battery-low signal will
be activated and the buzzer will beep every 1 second.
Remote shutdown signal is enabled only when the line fails.
The front panel consists 2 parts: push button and display
LCD set.
The push button is used to turn on and off the UPS. LCD
display indicates the load level,the battery voltage level and
operation status of the UPS.
When the system is not working properly, the LCD will
display the fault code.
2-3 Signaling Sub-System:
3. Front Panel:

Button
ON/Mute
Button
OFF/Enter
Button
Select
Button
ON/Mute + Select
Button
ON/Mute +
OFF/Enter
Button
Function
Turning the UPS on: Press and hold the ON/Mute button for at least 2
seconds to turn on the UPS.
Muting the alarm: After the UPS is turned on, press and hold this button
for at least 5 seconds to disable the alarm system. This does not apply
when warnings or errors occur.
Down key: Press this button to display previous selection on the UPS
setting mode.
Turning the UPS off: Press and hold the OFF/Enter button for at least 2
seconds to turn off the UPS on Battery mode. The UPS will be on Stand-
by mode under normal power or will switch to Bypass mode.
Muting the alarm: After the UPS is turned on, press and hold this button
for at least 5 seconds to disable the alarm system. This does not apply
when warnings or errors occur.
Down key: Press this button to display previous selection on the UPS
setting mode.
Switching the LCD messages: Press this button to display the following
messages showing values related to input voltage, input frequency,
battery voltage, output voltage and output frequency. The default values
will be restored after pressing it for 10 seconds.
Setting mode: After pressing and holding this button for 5 seconds, if
the UPS is off, it will go onto setting mode.
Up key: Press this button to display the next selection on the UPS
setting mode.
Switching to bypass mode: When the main power is normal, press the
ON/Mute and the Select buttons simultaneously for 5 seconds. The UPS
will then go onto Bypass mode. This action will be ineffective when the
input voltage is beyond the acceptable range.
Switching to UPS self-test mode: Press the ON/Mute and OFF/Enter
buttons simultaneously for 5 seconds to go onto UPS self-testing mode
while on AC mode, ECO mode, or Converter mode.
IV. ALIGNMENTS
Below, there is a list of the tests to be performed by
qualified personnel to ensure the EUT is working properly.
Before beginning, make sure that the device is OFF and
disconnected from the utility line.

TEST ITEM TEST POINT TEST AND ADJUSTMENT
SEQUENCE
EXPECTED
RESULT
Charger VoltageP5/P6/P9,+-.
P7/P8P10(-)
1. Disconnect P5(+) and P8(-)
wires from pins respectively.
2.
Connect DVM (set to measure
DC) to test pins and plug input
power cord to utility.
1.
Cooling fans
on back panel
begin to
rotate.
2. 82.8Vdc±1.8V
+DC Bus
Voltage @ Line
Mode
JP16/JP17(+).
JP48/JP49/JP50
(GND)
+360VDC±10V
-DC Bus
Voltage @ Line
Mode
JP18/JP19(+).
JP48/JP49/JP50
(GND)
1.
2.
3.
4.
5.
Connect DVM (Set to
measure DC) to test point.
Plug input power cord to
utility.
Press “ON”button for 2
seconds to turn EUT on.
Waiting for 10 seconds to
make sure the
EUT work in
line mode according to the
LCD display.
Check reading on DVM.
-360VDC±10V
+DC Bus
Voltage @
Baterry Mode
JP16/JP17(+).
JP48/JP49/JP50
(GND)
+360VDC±10V
-DC Bus
Voltage @
Baterry Mode
JP18/JP19(+).
JP48/JP49/JP50
(GND)
1.
2.
3.
Disconnect I/P power cord
from utility and press “ON
”
button for 2 seconds to turn
the EUT ON.
Connect DVM (Set to
measure DC) to test point.
Waiting for 4
seconds to make
sure the
ETU word in baterry
mode.
-360VDC±10V
O/P DC
Balance @
Line Mode
O/P socket
1.
2.
3.
Keeping UPS on @ Line
mode.
Connect DC measurement
tool1to O/P socket.
Check reading on DVM.
100mV max.
Picture 9 : Circuit for test output balance

V. TROUBLE SHOOTING
Our products are carefully designed and strictly tested to
prevent malfunctioning. However, if failure occurs, refer to
the following Trouble Shooting Chart.
Trouble Shooting Chart
Begin
If the panel
LCD light and
fan rotates?
If the panel
LCD display
normally?
If I/P relay
continuouly open
and close?
If D/C start works
properly?
Change CNTL
SUB-ASSY
If DC start works
properly?
DC/DC fail, refer
to DC/DC fail
analysis
Turn-off and
Restart the UPS
Can the UPS
be started
properly?
Read panel LCD to
get the information of
UPS on next page
Yes
Yes
Yes
Yes Yes
Yes Terminated
No
No
No
No
No
No

Panel LCD Display Explanation
Display Function
Backup time information
Indicates the remaining backup time in pie chart
Indicates a warning or a malfunction.
Indicates that the UPS alarm is disabled
Overload indicator
Indicates the load or the UPS output is short circuited
Indicates that programmable management outlets are working
Indicates the UPS is connecting to the mains
Indicates the battery is working
Indicates the bypass circuit is working
Indicates the ECO mode is enabled
Indicates the Inverter circuit is working
Indicates the output receptacle is working
Battery level indicator at 0-25%, 26-50%, 51-75%, and 76-100%
of its capacity
Battery fault indicator
Low battery level and low voltage indicator
Input voltage or frequency or battery voltage indicator.
VAC: Input voltage, VDC: battery voltage, Hz: input frequency
Indicates the remaining backup time in numbers
H: hours, M: minute, S: second
Warning and fault code indicators. The meaning of the codes
is listed in the section below.
Output voltage, frequency or battery voltage.
VAC: output voltage VDC: battery voltage Hz: frequency
Load level indicator at 0-25%, 26-50%, 51-75%, and 76-100%
of its capacity
Fault information
Mute operation
Output & Battery voltage information
Load information
Programmable outlets information
M
Battery information
Input & Battery voltage information
ode operation information

LCD display wordings index
UPS Setting
Abbreviation Display content Meaning
ENA Enable
DIS Disable
ESC Escape
HLS High loss
LLS Low loss
BAT Battery
CF Converter
EP EPO
FA Fan
TP Temperature
CH Charger
Parameter 1
Parameter 2
Parameter 3
There are three parameters to set up the UPS.
Parameter 1: It’s for program alternatives.
There are 8 programs to set up: output
voltage setting, frequency converter enable/
disable, output frequency setting, ECO
enable/disable, ECO voltage range setting,
Bypass enable/disable, Bypass voltage range
setting, programmable outlets enable/disable,
programmable outlets setting and exit.
Setting
For 208/220/230/240 VAC models, you may
choose the following output voltage:
208: current output voltage is 208Vac
220: current output voltage is 220Vac
230: current output voltage is 230Vac
240: current output voltage is 240Vac
For 110/150/120/127 VAC models, you may
choose the following output voltage:
110: current output voltage is 110Vac
115: current output voltage is 115Vac
120: current output voltage is 120Vac
127: current output voltage is 127Vac
01: Output voltage setting Interface

Setting
CF ENA: converter mode enabled
CF DIS: converter mode disabled
Setting
ENA: ECO mode enabled
DIS: ECO mode disabled
Setting
The initial frequency may be set on battery
mode:
BAT 50: current output frequency is 50Hz
BAT 60: current output frequency is 60Hz
If the converter mode is enabled, you may
choose the following output frequency:
CF 50: current output frequency is 50Hz
CF 60: current output frequency is 60Hz
Setting
Press the Down key or Up key to set the
acceptable high voltage point and acceptable
low voltage point:
HLS: High loss voltage in ECO mode (For
208/220/230/240 VAC models, the setting
range is from +7V to -24V of the nominal
voltage. For 110/115/120/127 VAC models,
the setting range is from +3V to -12V of the
nominal voltage). LLS: Low loss voltage
in ECO mode (For 208/220/230/240 VAC
models, the setting range is from -7V to -24V
of the nominal voltage. For 110/115/120/127
VAC models, the setting voltage is from +3V
to -12V of the nominal voltage)
02: Frequency Converter enable/disable Interface
03: Output frequency setting Interface
04: ECO enable/disable Interface
05: ECO voltage range setting Interface

Setting
ENA: Bypass mode enabled
DIS: Bypass mode disabled
Setting
ENA: Programmable outlets enabled
DIS: Programmable outlets disabled
Setting
0-999: setting the backup time limits in minutes
from 0-999 for programmable outlets which
connect to non-critical devices on battery
mode.
Setting
Press the Down key or Up key to set the
acceptable high voltage point and acceptable
low voltage point:
HLS: Bypass high voltage point
LLS: Bypass low voltage point
For 208/220/230/240 VAC models:
230-264: setting the high voltage point from
220Vac to 264Vac
170-220: setting the low voltage point from
170Vac to 220Vac
For 110/115/120/127 VAC models:
120-132: setting the high voltage point from
120Vac to 140Vac
85-115: setting the low voltage point from
85Vac to 115Vac
06: Bypass mode enable/disable Interface
07: Bypass voltage range setting Interface
08: Programmable outlets enable/disable Interface
09: Programmable outlets setting Interface
00: Exit setting