Forza Elipse Series User manual

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SERVICE MANUAL
EL 6~10K
Forza

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CONTENT
1. GENERAL INFORMATION OF THIS DOCUMENT.....................................................................4
1.1 GETTING START........................................................................................................................4
1.2 SAFETY INSTRUCTIONS .............................................................................................................5
2. CHARACTERISTIC OF THE PRODUCT ....................................................................................6
3. CONSTRUCTION OF THE PRODUCT .......................................................................................7
3.1 OPEN THE OUTSIDE COVER ......................................................................................................7
4. OPERATION PRINCIPLE OF THE UPS......................................................................................8
4.1 FUNCTIONAL BLOCK OF THE UPS ............................................................................................8
4.2 OPERATION OF THE FUNCTIONAL BLOCKS.................................................................................9
4.2.1 The Input/Output connector/terminal block ....................................................................9
4.2.2 The Input EMI filter & the Output EMI filter ....................................................................9
4.2.3 The rectifier module .......................................................................................................9
4.2.4 The voltage Booster module..........................................................................................9
4.2.5 The inverter module.....................................................................................................10
4.2.6 The automatic UPS switch...........................................................................................10
4.2.7.The maintenance bypass switch..................................................................................10
4.2.8 The battery switch........................................................................................................11
4.2.9 The battery charger ..................................................................................................... 11
4.2.10 The controller............................................................................................................. 11
4.2.11 The auxiliary power supply......................................................................................... 11
4.2.12 The ventilation module...............................................................................................12
4.2.13 The chassis ...............................................................................................................12
4.3.THE PCB BOARDS.................................................................................................................13
4.3.1 Control Board ..............................................................................................................13
4.3.2 PSDR board ................................................................................................................13
4.3.3 LED PANEL .................................................................................................................14
4.3.4 O/P EMI board & I/P EMI board...................................................................................14
4.3.5 Charger Board .............................................................................................................15
4.3.6 Parallel Board ..............................................................................................................16
4.4 SIMPLIFIED SYSTEM TOPOLOGY &WIRING DIAGRAM..................................................................17
5. MAINTENANCE.........................................................................................................................19
5.1 MAINTENANCE TOOLS/EQUIPMENTS........................................................................................19
5.2 COMMON OPERATION USED IN MAINTENANCE..........................................................................19
5.2.1 Query & Setting the UPS status With Hyper Terminal .................................................19
5.2.2 Calibration ...................................................................................................................25
5.3 SYSTEM MAINTENANCE...........................................................................................................27
5.3.1 Unitary Maintenance Operation ...................................................................................27

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5.3.2 Parallel Maintenance Operation ..................................................................................29
5.4 TROUBLE SHOOTING...............................................................................................................35
5.4.1 How To Start ................................................................................................................37
5.4.2 Fault code definition and possible points .....................................................................38
5.4.3 Quick Problem Identification process...........................................................................41
5.4.4 Static Impedance Characteristic Of PCB board. ..........................................................42
5.5 COMPONENT LEVEL REPAIR....................................................................................................44
5.6 TEST AFTER REPAIR...............................................................................................................44
APPENDIX.....................................................................................................................................47
I. ELECTRICAL SPECIFICATION.......................................................................................................47
II. MODEL PIN CONFIGURATION .....................................................................................................49

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1. General Information of This Document
1.1 Getting Start
This is a service manual for Elipse Series Tower UPS, intend to help service technician perform
maintenance and repair service.
If you want to know:
? What is special for this UPS from service point of view; please refer to section - characteristic
of the product.
? Construction of the product; how many pieces of PCB do the product make up, please refer to
construction of the product
? Functional block of the UPS please refer to Principle of Operation.
? What’s wrong with the UPS and How to solve the problem, please refer to Trouble Shooting.
? Basic information about the product, install and operation instruction, you may please refer
to USER MANUAL

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1.2 Safety Instructions
1. For qualified service personnel only.
2. DO NOT performs any internal service or adjustment unless another person is capable of
rendering first aid and resuscitation is present.
3. Dangerous voltage exists at different points in this product. To prevent electrical shock, don't
touch any exposed connections or components inside the UPS while UPS is active.
4. For most safety, turn off the UPS and disconnect input power cord before removing outside
protective cover.
5. Verify input source (voltage and frequency) is within the maximum range before installation or
any service action.
6. Prevent short-circuit of internal batteries or external battery bank.
7. After service, check all the wiring, fasten all screws and connectors, verify the polarity of
batteries, polarity of the DC-BUS Cap have been correctly connected, before applying power
supply to the UPS and restarting the UPS.
8. High voltage may present at DC-BUS capacitors, Battery input filter capacitor, Even if all power
supply to the ups have been cut off. Before disassembly or touch any parts of in side the UPS,
use discharge fixture to discharge the residue charge on DC-BUS capacitors & battery
capacitor.
TO DISCHARGE the residue charge on bus capacitor, a discharge resistor of 1kΩ/10W can be
used to discharge the DC-BUS cap after all the power supply to the UPS have been cut off.
TO DISCHARGE the energy of charger capacitor ，after disconnect the battery from
PSDR/Charger, you can use a 300Ω/10W resistor contact BAT (+) terminal and BAT (-)
terminal for discharge battery filter capacitor

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2. Characteristic of the Product
For all UPS of this series, they are carefully designed and strictly tested. We always do our
best to make our products more reliable and safe; this is also the goal of our company. However,
due to the lifetime of electrical components and some unpredictable reasons, there will be
unexpected failures may occur to the product; in this case, qualified service 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 help in solving any
problems you met.
Because of the following unique features, this series UPS (Uninterruptible Power System) is
very easy to maintain and service.
zFully digital control, the intelligent controller provides most comprehensive information
for maintenance.
zGreatly simplified control circuit; avoid a lot time for tuning the analog controller.
zModular designed, some identical circuit, such driver, detector are designed as a
module,
zHigh power density, the space is limited. Need carefully assembly

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3. Construction of the Product
3.1 Open The Outside Cover
To open the outside cover, please follow steps and figures below:
STEP 1: Remove all the screws; including those on the opposite side of the case, refer to
Figure 3.1
STEP 2: move the top cover and side cover upward, as shown in Figure 3.2.
STEP 3: Done, as shown in Figure 3.3.
Figure 3.1 Figure 3.2
Figure 3.3

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4. OPERATION PRINCIPLE OF THE UPS
The EL 6~10K UPS is a true online UPS employing a double conversion topology. Figure 4.1.1
shows the function block diagram of the UPS system.
4.1 Functional Block Of The UPS
Inverter
I/ P EMI
FILTER AC
DC
AC I/P AC O/P
Battery
Battery SW
(Relay & SCR)
Booster
DC
DC
Rectifier
AC
DC
PFC
Battery
Charger
Battery
Charger
DC BUS CAP
Bypass
SCR
O/P EMI
FILTER
MB SW
Controller
Power Supply
(SPS)
Communication
Interface
Ventilation
&
Chassis
Figure 4.1.1 Functional block diagram
*The dashed indicates the interconnection of long backup time model
From logical point of view, the system comprises: An Input/output connector/terminal block, an input
EMI filter, an output EMI filter, a rectifier, a battery switch, a voltage booster, an inverter, an automatic
UPS switch, a maintenance bypass switch, a battery charger, a controller, an auxiliary power supply,
a communication interface, a ventilation module and the chassis.

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4.2 Operation Of The Functional blocks
Here after, operation and behaviors of each function block of the UPS will be described:
4.2.1 The Input/Output connector/terminal block
The part provides electrical connection of the input mains and battery power input to the UPS
and the output to users load.
4.2.2 The Input EMI filter & the Output EMI filter
The EMI filter filters out the EMI (Electric & Magnetic Interference) noise from the input/output of the
UPS, prevents the UPS being interfered by the external EMI noise or the noise generated inside the
UPS to interference the user’s load.
4.2.3 The rectifier module
When Mains input is in normal condition, the UPS works on Line mode, the Rectifier module
rectifies the AC mains input into DC power of half waveform.
The rectifier remains in off state under battery mode.
4.2.4 The voltage Booster module
In line mode, the voltage Booster boost the output of the rectifier into a positive BUS voltage and
a Negative BUS voltage, the Positive BUS voltage and negative bus voltage are +/-345Vdc (+/-360V
for 230V output system), respect to the Neutral.
The Rectifier and the voltage Booster form a PFC (Power factor Correction) Module, which
make the input current track the input voltage, and the Power factor of the UPS close to 1, which help
to minimize the power pollution and reduce the reactive power and save energy for the user.
On battery mode the voltage booster receive power from the battery via the battery switch, and
boost the battery voltage of around 240V up to +/-BUS voltage of +/-345Vdc (+/-360V for 230V output
system), respect to the Neutral

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The Output of the voltage Booster, i.e. the BUS voltage, keeps stable in difference operating
mode, regardless input voltage.
4.2.5 The inverter module
The inverter module converses the DC voltage from DC BUS into the AC output of pure sine
wave voltage.
The inverter keeps working after the UPS turn on either line mode or battery mode. Which
make sure the power supply to the load is clean and stable enough.
4.2.6 The automatic UPS switch
The automatic UPS switch comprises a relay and a pair of SCRs, the switch select the inverter
output to supply the load when the UPS in normal condition. And select the bypass output when the
UPS become overload, or out of normal condition and can’t no more supply the load with inverter
output.
Combination of the SCR and the mechanical relay make the transfer between bypass and
inverter output without any interruption (zero transfer time).
4.2.7.The maintenance bypass switch
The Maintenance Bypass switch is a mechanical rotary switch, In normal condition the
maintenance bypass switch stay on “UPS” state, the inverter output or automatic bypass output will
pass through the maintenance bypass switch to supply the user’s load; when Maintenance Bypass
Switch is turn to “BPS” state manually, all of the power conversion parts and automatic bypass are
bypassed by the mechanical bypass wiring, to enable maintenance operation.
*******************************************************************************************************
Due to construction of the maintenance-bypass-switch.
On EL 6k and 10k UPS (single phase input and single phase Output model), Turn the
Maintenance Bypass switch to Maintenance bypass state (BPS), and After switching off the
I/P mains switch on the rear panel of the UPS and cutting off battery input, the PCBs or
parts of the UPS can be disassembled follow safety instruction without interruption of output
power supply.
*******************************************************************************************************

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4.2.8 The battery switch
The battery switch connects the battery input to the voltage booster to provide power supply for
supporting the operation of the UPS and maintains the inverter output power when the mains input is
out of order.
The battery switch disconnects the battery bank from input of the voltage booster when the
mains input is recover to normal condition, and the UPS transfer from battery mode to line mode.
4.2.9 The battery charger
The battery charger is a converter energy from mains into power to re-charge the battery, in
order to keep battery full energized and provide as long as possible backup time incase mains input is
out of normal condition and the UPS transfer to battery operating mode.
4.2.10 The controller
The controller is the brain of the UPS, controls all of action of the UPS, response and feedback
to the query or action command of the communication interface.
Basically, the controller includes the CPU (Central Processing Unit), which collects and
processes the information necessary for control of the UPS, and output control action according the
predetermined algorithm.
Secondary, the controller includes feedback signal conditioning circuit, process the signal come
from sensors to detecting the difference parameter. The feedback signal include the analog signal
and digital signal
The third, the controller includes also output buffer circuit to buffer the output signal of the CPU
and driving the Power stage.
Due to high degree integration, to diagnose the failure on the controller takes long time not
match the value of the controller itself, so we recommend not to repair the controller at component
level.
4.2.11 The auxiliary power supply
The Auxiliary power supply (SPS) takes energy from the battery or the charger output,

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converse into a group of low voltage power supplying to each part of the UPS itself.
The output of the Auxiliary power supply (SPS) includes: +5Vdc, +/-15Vdc, +12Vdc, and a
square wave high frequency power supply +/-H.F.PW2.1.12 The communication interface
As stated before the communication interface of the UPS is a bridge between the UPS and
human or between the UPS and UPS.
The communication interface carries parallel operation control signal and common
communication signal.
4.2.12 The ventilation module
To keep the UPS safely running, the ventilation system comprises fans , fans driver, and airflow
guiding parts keeps the parts of UPS cool enough, make the temperature of the components stays
within the safe operation range.
The ventilation module is as essential as rest part of electrical parts of the UPS, such as
controller.
4.2.13 The chassis
The chassis is the case mounting all the parts of UPS in.

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4.3.The PCB Boards
The UPS comprise different PCB board and each PCB may contain more than one function block,
or one functional block need more than 1 piece of PCB to implement. hereafter is explanation of the
PCB.
4.3.1 Control Board
Control board contains circuit implemented of the controller of the UPS. Figure4.3.1.1 is a photo of
the Control board
Figure4.3.1.1 The Control board.
4.3.2 PSDR board
The PSDR board comprises major power conversion circuit of the UPS: the SPS, the PFC Module,
the Inverter Module battery switch, INV relay and bypass SCR.

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Figure4.3.2.1 The PSDR board
4.3.3 LED PANEL
As part of User interface, the LED Panel provides comprehensive information of the UPS, Figure
3.3.1 is a photo of a LED panel
4.3.4 O/P EMI board & I/P EMI board
O/P EMI Board and I/P EMI Board is the EMI filter local in input and output end of the UPS
respectively.
Figure 4.3.4.1 EL 6/10K(s) I/P EMI Figure 4.3.4.2 EL 6K(s) O/P EMI

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Figure 4.3.4.3 EL 10K(s) O/P EMI
4.3.5 Charger Board
Charger board contain the charger circuit, Use for charging the bat
Figure 4.3.5.2 Charger of standard model Figure 4.3.5.2Charger of long-backup-time model

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4.3.6 Parallel Board
Parallel board is a dedicated board comprises parallel communication circuit. Figure 3.6
Figure 4.3.6.3 Para board of 6/10K

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4.4 Simplified system topology & wiring diagram
Figure 4.4 shows simplified system topology and wiring diagram; For helping understand the electrical construction of the UPS system. For more
detail of the circuit and wiring connection of all PCB, please refer to maintenance schematic and detail wiring diagram.
Figure 4.4 EL6K/EL10K UPS configuration diagram

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Figure 4.5 EL6KS/EL10KS UPS configuration diagram

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5. Maintenance
5.1 Maintenance Tools/Equipments
1. A computer with a serial port and a standard RS232 cable;
2. A multimeter and a current meter (clamper); If possible, an oscilloscope with appropriate
probes or other kinds waveform displayer can provide great help to the maintenance task
in most case.
3. An Output DC balance (DC-offset) test fixture, a discharge resistors for discharger
residual charge on the CAPs inside the UPS.
4. A tool box include: Wire cutters and clamps of different shape, Cross screwdrivers
Straight screw drivers, sleeve spanner of difference diameter, solder iron, and solder
sucker, PVC insulating tapes etc.
5. Boxes or cases for carrying spare board or parts.
5.2 Common Operation used in Maintenance
5.2.1 Query & Setting the UPS status With Hyper Terminal
5.2.1.1 Setup of Hyper terminal:
Run the Hyper terminal by clicking” Start/Program/Accessory/Communication/Hyper terminal” :
and create a new connection using COM1 or COM2 as figure 5.2.1.1.a:
Figure 5.2.1.1.a

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Configure the COM1 or COM2 properties as figure 5.2.1.1.b:
figure 5.2.1.1.b
1、Change the ASCII setup as figure 3:
figure 5.2.1.1.C