EA990G5 10-30kVA (3/3)

Maintenance Manual

Prepared by Wu Zhifei / 20220830

Checked by Luo Changsheng / 20220831

Approved by Yang Lin / 20220831

EAST GROUP CO., LTD.

 Preface
General
This document provides maintenance requirement for high frequency three-input single-output
6-20KVA products, including safety precautions for maintenance, product description, description
on internal structure, description on composition of single boards, main components of single
boards, description on main functions, fault removal flow, replacement of single boards,
maintenance of single boards, and commissioning after maintenance, etc., to help an engineer to
provide technical support and maintenance service for three-input single-output 6-20K products.

User of document
This document (manual) is mainly applicable for the following engineers:
Technical support engineer
Maintenance engineer

Revision history
The revision history provides description on each document upgrade. The latest version of
document includes the upgraded content of all previous versions.
Document version: V01 (15 AUG 2014)
Formally issued for first time

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 Content
Preface.................................................................................................................................................. i
1 Safety precautions............................................................................................................................1
1.1 Hazards.................................................................................................................................... 1
1.2 Warning....................................................................................................................................1
2 Description of model........................................................................................................................2
2.1 Description of EA990G5 10-30kVA serial model...................................................................2
2.2 Appearance introduction of EA990G5 10-30kVA series model..............................................3
2.3 The operation control LCD panel introduction of EA990G5 10-30kVA................................ 6
3 Internal Introduction.................................................................................................................... 23
3.1 System Configuration............................................................................................................23
3.2 System Block Diagram..........................................................................................................26
3.3 Introduction to Internal Boards............................................................................................. 27
4 Troubleshooting............................................................................................................................. 28
4.1 Repair tool List...................................................................................................................... 28
4.2 Troubleshooting process........................................................................................................28
4.3 Alarm information collection................................................................................................ 30
4.4 Common faults and troubleshooting methods.......................................................................30
4.5 Alarm detailed explanation and handling suggestions.......................................................... 30
5 Board replacement........................................................................................................................ 35
5.1 Board replacement of 10kVA model..................................................................................... 35
5.2 Board replacement of 15kVA model..................................................................................... 37
5.3 Board replacement of 20kVA model..................................................................................... 40
5.4 Board replacement of 30kVA model..................................................................................... 42
6 Board maintenance........................................................................................................................45
6.1 Maintenance of power board................................................................................................. 45
6.2 Maintenance of IP/OP board................................................................................................. 58
6.3 Maintenance of Bypass board............................................................................................... 66
7 Test.................................................................................................................................................. 72
7.1 Boards installation................................................................................................................. 72
7.2 Preparation before power-on................................................................................................. 72
7.3 Power-on and testing............................................................................................................. 72
1 Safety precautions
1.1 Hazards
1.As dangerous voltage exists in the UPS and the battery holder, installation and maintenance are only
completed by a professional engineer holding professional electrician qualification of the company or authorized
by the company.
2.Operators and maintainers, and professional technicians should receive full training on safe use and
equipment maintenance and work on the equipment after enough precautionary measures are taken and personal
safety equipment is used.
3.As the UPS is connected with the battery, voltage may exist on its output end even if it is not connected
with AC mains supply.
4.When the UPS is moved or rewired, the inputs, such as mains supply, the battery, etc., must be
disconnected, corresponding operation may be performed after the UPS powers down fully (more than 10min),
and otherwise the voltage may exist on its output end.
5.Before use, the UPS is reliably earthed to ensure personal safety and the normal use of the UPS.
6.When the UPS is maintained, the maintainer must wear insulated shoes and use insulated tools.
7.If temperature and humidity exceeds the limit value specified in the user manual, do not operate the
equipment.
8.Before maintenance of the UPS, all inputs and outputs of the UPS (including battery input) must be
disconnected.
9.Do not place the battery in fire to avoid explosion and endangering personal safety.
10.Do not stop the protector and ignore warnings, cautions and precautionary measures provided in the
manual and equipment nameplate.

1.2 Warning
1.Do not open the battery cover or damage the battery. If you are exposed to electrolyte, immediately wash
with plenty of clear water and seek medical advice.
2.Remove watch, ring and other metal article, wear insulating gloves and use the tools with insulated handle
during work on the battery.
3.During equipment operation, make sure that all sides and internal panels are securely fixed and front door
is closed.

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2 Description of model
2.1 Description of EA990G5 10-30kVA serial model
Our EA990G5 10-30kVA series models are divided into tower type and rack type. The power level is
10/15/20/30KVA and the output power factor is 1.0. It can realize parallel operation of up to 4 units, provide
redundant power supply, and provide stable and reliable power supply for customer loads.

Table 2-1 EA990G5 10-30kVA serial model

Component Model Specification Note

UPS 10kH 10kVA Long-delay Mode(Tower)
UPS 10kS 10kVA Standard Mode(Tower) with ±10 12V/7AH internal
UPS 10kHRT 10kVA Long-delay Mode(Rack)
UPS 15kH 15kVA Long-delay Mode(Tower)
UPS 15kS 15kVA Standard Mode(Tower) with ±20 12V/7AH internal
UPS 15kHRT 15kVA Long-delay Mode(Rack)
UPS 20kH 20kVA Long-delay Mode(Tower)
UPS 20kS 20kVA Standard Mode(Tower) with ±20 12V/7AH internal
UPS 20kHRT 20kVA Long-delay Mode(Rack)
UPS 30kH 30kVA Long-delay Mode(Tower)
UPS 30kS 30kVA Standard Mode(Tower) with two string ±15 12V/7AH internal
UPS 30kHRT 30kVA Long-delay Mode(Rack)
Table 2-2 Accessories of EA990G5 10-30kVA serial model

SNMP card/protocol
Remote network monitoring can be realized (RJ45 interface, as a
conversion
iDA-ST200P protocol conversion card, an adapter cable is required)
card(including
The built-in card is directly inserted into the card slot;
packaging materials)
SNMP card/protocol
Remote network monitoring can be realized (RJ45 interface, as a
conversion
iDA-ST200P protocol conversion card, an adapter cable is required)
card(excluding
The built-in card is directly inserted into the card slot;
packaging materials)
This device needs to be used with an SNMP card;
When the SNMP card detects that the UPS has an alarm, the SNMP
card can control the SMS modem to send the alarm content to the
SMS cat iDM-MDM200E mobile phone of the designated user;
It does not contain a SIM card and needs to be purchased separately.
At the same time, it only applies to standard SIM cards of China
Mobile and China Unicom.
The alarm information of the UPS can be automatically sent to the
mobile phone of the designated user;
SMS alarm iDM-ALM200P It does not contain a SIM card and needs to be purchased separately.
At the same time, it only applies to standard SIM cards of China
Mobile and China Unicom.
WIFI--glue stick antenna; you can connect the WIFIF module
WIFI module iDM-SPW202P through a mobile phone or computer to check the running status and
parameters of the UPS.
GPRS module iDM-SPG203P GPRS - glue stick antenna; you can connect the GPRS module

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(external, DB9) through a mobile phone or computer to check the running status and
parameters of the UPS.

2.2 Appearance introduction of EA990G5 10-30kVA series model

The overall appearance is shown in Figures 2-1 to 2-7 below.

Fig.2-1 The front pannel of 10-30kVA series UPS (Tower)

Fig.2-2 The front pannel of 10-30kVA series UPS (Rack)

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Fig.2-3 The rear pannel of 10kVA, 15kVA, 20kVA long-delay UPS (Tower)

Fig.2-4 The rear pannel of 10kVA, 15kVA, 20kVA standard UPS (Tower)

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 Fig.2-5 The rear pannel of 30kVA UPS (Tower)

Fig.2-6 The rear pannel of 10kVA, 15kVA, 20kVA UPS (Rack)

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 Fig.2-7 The rear pannel of 30kVA UPS (Rack)

Table 2-3 The introduction of front and rear pannel

NO. Part name

1 LCD screen
2 LED
3 Smart card slot
4 Cold start button
5 RS232 port
6 RS485 port
7 USB port
8 EPO
9 Parallel port
10 Dry contact port
11 Maintenance Bypass Assembly
12 Bypass breaker
13 Output breaker
14 Input breaker
15 Terminal block and cover
16 PE
17 Battery breaker

2.3 The operation control LCD panel introduction of EA990G5 10-30kVA

This chapter introduces the functions and operator instructions of the operator control and display panel in
detail, and provides LCD display information, including LCD display types, detailed menu information, prompt
window information and UPS alarm information.
2.3.1 LCD panel for Cabinet
The structure of operator control and display panel for cabinet is shown in Fig.4-1. The operation control
panel of UPS is located on the front panel of the case. By operating the LCD, the ups can be operated, controlled,
and checked for all its parameters, operating status, and alarm information.

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 Fig.2-8 Control and display panel

LED Indicator
There are 2 LEDs on the panel to indicate the operating status and fault.The description of indicators is
shown in table 2-4。

Table 2-4 Status description of indicators

Indicators State Description

Steady red UPS fault
red
Flashing red UPS alarming
green Steady green Power supply mode (mains mode, bypass mode, ECO mode, etc.)
No None Standby status or no starting

Alarm
There are two different types of audible alarm during UPS operation, as shown in table 2-5

Table 2-5 Description of audible alarm

Alarm Description
Intermittent alarm when system has general alarm (for example: AC fault),
Continuous alarm When system has serious faults (for example: hardware fault)

LCD Menu structure

The menu structure of the monitoring display interface is shown in Fig.2-9

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 Fig.2-9 Menu

2.3.2 Home page

After the monitoring system starts self-test, the system enters the home page, following the
welcome window. The home page is divided into three parts, including main menu, energy flow
diagram, status bar. The home page is shown in Fig. 2-10.

Fig. 2-10 Home page

Table 2-6 Function description of interface area

No. Area Function description

1 Main menu Level 1 menu, including home page, system, alarm, control,
settings, password login. The control and the settings are
displayed in gray before login by password.

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 No. Area Function description
2 Energy flow diagram Display the energy flow state of the cabinet. Click the
corresponding work interface to view the status information.
3 Status bar Display operation status, system time, buzzer status, alarm
status, HMI and monitoring communication status, USB status
of the cabinet.
4 Cold start Start the UPS in battery mode. The icon will be hidden after two
minutes.

Table 2-7 Description of icons in status bar

Icon Function description

Buzzer status, which becomes lit to indicate the buzzer enabled, and off to indicate the
buzzer disabled
Alarm status, which becomes lit to indicate an alarm, and off to indicate no alarm

Password login/logout key. After clicking, enter user password or advanced password
by the keyboard. The screen will be locked automatically.

Table 2-8 Description of password permissions

Password Default Function description

permissions
User password 123456 Unlock On and OFF control right and the right of common
settings and communication settings.
It can be changed in "settings - common settings - user
password".
Advanced Not opened Unlock all control and setting rights.
password It can be used by qualified electricians only.

2.3.3 System
In the "System" information interface, the "Mains ", "Bypass ", "Battery ", "Output", "Other", "Statistics" and
"About " information of the system can be inquired in the secondary menu at the left side.

Mains
The menu interface of the mains input is shown in Fig. 2-11, and displays information on three phases ABC
from left to right. The interface description is shown in Table 2-9.

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 Fig. 2-11 Input interface

Table 2-9 Description of input interface

Display item Description

Voltage (V) Mains input phase voltage
Current (A) Mains input phase current
Frequency (Hz) Mains input frequency
PF Mains input Power factor

Bypass
The menu interface of the bypass input is shown in Fig. 2-12, and the interface description is shown in Table
2-10.

Fig. 2-12 Bypass interface

Table 2-10 Description of bypass interface

Display item Description

Voltage (V) Bypass input phase voltage

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 Display item Description
Current (A) Bypass input phase current
Frequency (Hz) Bypass input frequency
PF Bypass input Power factor

Battery
The interface menu of battery input is shown in Fig. 2-13, and the interface description is shown in Table
2-11.

Fig. 2-13 Battery interface

Table 2-11 Description of battery interface

Display item Description

Battery voltage Battery voltage
(V)
Battery Current Battery current
(A)
Battery status Current battery status: idle, discharge, boost charge, floating charge, None
Temperature Current operating temperature of battery (optional battery temperature sensor,
(℃) display "NA" if not connected)
Backup time Estimated discharge time of the battery at the current load
(min)
Remaining cap. Current remaining capacity of battery
(%)

Output
The interface of output menu is shown in Fig. 2-14, and the interface description is shown in Table 2-12.

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 Fig. 2-14 Output interface

Table 2-12 Description of output interface

Display item Description

Voltage (V) AC output phase voltage.
Current (A) AC output phase current.
Frequency (Hz) AC output frequency.
Load ratio (%) Load rate of each phase of the machine
Active power (kW) Output active power of each phase of the UPS unit
Appa. pow. (kVA) Output apparent power of each phase of the UPS unit
Reactive power(kVA) Output reactive power of each phase of the UPS unit
PF Output power factor of each phase of the UPS unit

Other
The interface of other menu is shown in Fig. 2-15, and the interface description is shown in Table 2-13.

Fig. 2-15 Other interface

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 Table 2-13 Description of other interface

Display item Description

PFC temperature Rectifier temperature
INV temperature Inverter temperature
Environmental Environmental temperature(optional battery temperature sensor,
temperature display "NA" if not connected)

Statistics
The interface of statistics menu is shown in Fig. 2-16, and the interface description is shown in Table 2-14.

Fig. 2-16 Statistics interface

Table 2-14 Description of statistics interface

Display item Description

Bypass runtime (min) Accumulative operation time of UPS in bypass output status
Inv. Runtime (min) Accumulative operation time of UPS in inverter output status
Last discharge Date of previous discharge status of UPS
Batt. expire time When the system time exceeds the warranty period, the status bar will
prompt the warranty information of battery.
UPS expire time When the system time exceeds the warranty period, the status bar will
prompt the warranty information of main machine.

About
The interface of “About” menu is shown in Fig. 2-17, and the interface description is shown in Table 2-15.

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 Fig. 2-17 About interface

Table 2-15 Description of Interface

Display item Description

S/N Production serial number of this machine.
TEL Contact information of after-sales service providers.
Manufacturer Manufacturer of this machine.
Website Website of manufacturer of this unit.
HMI version Program version of HMI display system.
PFC1 version Program version of power rectifier system
Inv.1 version Program version of power inverter system

2.3.4 Alarm
In the "Alarms" information interface, you can view "Active alarm"and"Fault record "from the secondary
menu in the lower left corner. Click to select the type of alarm you want to view. The interface of alarm menu is
shown in Fig. 2-18.

Fig. 2-18 Alarm menu interface

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 Active alarm
The active alarm interface displays the relevant information of the current warning of UPS system, The
interface description is shown in Table 2.16.

Table 2-16 Description of active alarm interface

Display item Description

No. Alarm number
Location Display the cabinet number and module number of the current alarm
source.
ID Alarm code for program analysis.
Information Current alarm name
Time The current alarm is the current alarm information without time
display.

History records
The "history record" is divided into "Location ID ", "Information " and "Tine ", as shown in Fig.2-19, The
interface description is shown in Table 2-17.

Fig.2-19

Table 2-17 Description of history record interface

Display item Description

No. Record number, which is listed in reverse order, that is to say the latest
record is in the front.

Location Displays the module number of the current record source.

ID List code of fault, status or operation information for program analysis
Information Current record name and record state (occurrence, disappearance).
Time Record the time of occurrence or disappearance.

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4.2.6 Control
In the "Control " information interface, you can select relevant operation from the left secondary menu,
which contains "On-Off "and "Maintain".
On-Off
The interface of the On-Off menu is shown in Fig. 2-20, and the interface description is shown in Table 2-18.

Fig. 2-20 On-Off interface

Table 2-18 Description of On-Off interface

Control item Description

System on-off Including “Inv.On”, “Shut to bypass” and “Shutdown”. It is gray
when clicking is invalid.
Manual to bypass Including “On” and “Off”. It is gray when clicking is invalid.
If the bypass is abnormal, switching to bypass fails.

Maintenance
The interface of maintenance menu is shown in Fig. 2-21, and the interface description is shown in Table
2-19.

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 Fig. 2-21 Maintenance interface

Table 2-19 Description of maintenance interface

Control item Description

Mute Mute the buzzer
Clear history Clear history
Faults Clear Clear the fault
Bat Test1 UPS transfer to battery discharge mode to test if the battery is normal. Bypass
must be in normal condition, the battery capacity should be above 25%.
Bat Test2 This test will lead to the battery being partly discharged to activate battery
until battery voltage is low. Bypass must be in normal condition, the battery
capacity should be above 25%.
Stop Bat Test Manually Stop the test including maintenance test, capacity test

2.3.6 Settings
Common settings
The interface of common settings menu is shown in Fig. 2-22, and the interface description is shown in Table
2-20.

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 Fig. 2-22 Common setting interface

Table 2-20 Description of common setting interface

Setting item Default Options Description

Language English English Display in English.
YYYY-MM-DD 2016-01-01 2000-01-01~2099-12-31 Set the current date.
Time 00:00:00 00:00:00~23:59:59 Set the current time.
Support 3 formats: Y-M-D, M-D-Y,
Date format Y-M-D Y-M-D, M-D-Y, D-M-Y
D-M-Y.
Adjust backlight brightness by
Brightness 100% 0% ~ 100%
moving the slider.
Set screen time out. 0 is set to keep
Auto-lock 5 min 0 ~ 30 min
the screen on.
The user can change the password,
User password 123456 0 ~ 99999999
which can be set to 1-8 digits.

Communication settings
The interface of the communication setting menu is shown in Fig. 2-23, and the interface description is
shown in Table 2-21.

Fig. 2-23 Communication settings interface

Setting item Default Options Description

MODBUS_U, Settings such as Protocol, Address and Parity are set
R&D for serial ports, including USB interface, RS232
Protocol MODBUS_U
MODBUS, interface and RS485 interface. Users can make the
MEGATEC corresponding settings according to the setting
requirements of the monitoring software used, but
ensure that the setting value in the monitoring
Address 0 0~ 247 software must be consistent with the value in the
UPS communication settings.

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 Table 2-21 Description of communication settings interface

Dry contact settings

The interface of dry contact setting menu is shown in Fig. 2-24, and the interface description is shown in
Table 2-22.

Fig. 2-24 Dry contact setting interface

Table 2-22 Description of dry contact setting interface

INTERFACE Name Function

D.G.mode Connection status of generator, Select IN_DRY1_NC
EPO EPO , Select IN_DRY1_NC
BCB online BCB on-line input (normally open), Select IN_DRY2/3_NO
BCB contact status, connect with the normally open signal of
BCB status
BCB. Select IN_DRY2/3_NO.
Input Dry
INV Transfer from the bypass to inverter
Contact
Bypass Transfer from the inverter to bypass
DI_1 ~ DI_3
Fault clear Fault clear
Batt over
The battery is over charging, the ups will shutdown the charger
charge
The battery voltage is low, the ups will get ready to shutdown or
Low batt.volt.
recharge
Grid Fault Grid Fault warning
Low.Bat.vol The battery voltage is low
Load on
The UPS is in bypass mode
bypass
Output Dry Load on INV The UPS is in INV mode
Contact
Battery Mode The UPS is in battery mode
DO_1~ DO_3
General Alarm General Alarm
Output over
Output over load
load
BCB drive BCB contact drive, need +15V voltage，20mA drive signal

Rate parameters
The interface of the rate parameters menu is shown in Fig. 2-25, and the interface description is shown in
Table 2-23.

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 Fig. 2-25 Bypass parameters interface

Table 2-23 Description of bypass parameters interface

Setting item Default Options Description

Battery type: VRLA battery and Lithium battery,
Lithium/VRL
Batt.Type VRLA The supported lithium battery type is 3.2 V
A
lithium iron phosphate battery.
Rate output freq 50 50/60 Rate output frequence
Rate output 208/220/230/2
220 Rate output voltage
voltage 40
Rate input freq 50 50/60 Rate input frequence
208/220/230/2
Rate input voltage 220 Rate input voltage
40

Advanced parameters
The interface of advanced parameters menu is shown in Fig. 2-26, and the interface description is shown in
Table 2-24.

Fig. 2-26 Advanced parameters interface

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 Table 2-24 Description of advanced parameters interface

Setting item Default Options Description

Select the corresponding working mode
Normal/ECO/Self-ag
Working mode Normal according to user needs. It is normal
e/ Parallel mode
working mode in general.
Set according to the actual frame numbers
Parallel Number 1 1~4
of the UPS system installed by the user.
Dev ID 1 1 ~ 16 Set device parallel ID
Output voltage Fine tune the output voltage according to
0 -5.0 ~ 5.0
adjust the customer's field power distribution.
Freq track limit ±3Hz ±0.5Hz ~ ±5Hz Settable, ±0.5Hz ~ ±5Hz, default ±3Hz
Self-age curr It is percentage of output current in rated
80 30 ~ 100
precent (%) output current in self-aging mode.
Transformer coil
1 settable Set the output transformer coil turns ratio.
turns ratio
+10%, +15%, +20%, Upper limit: +10%, +15%, +20%, +25%
Byp volt up limt +15%
+25%
Byp volt down -10%, -15%, -20%, Lower limit: -10%, -15%, -20%, -30%,
-20%
limt -30%, -40% -40%
Note that the bypass frequency range
±1.0/±2.0/±3.0/±4.0/±
bypass frq range ±5.0 cannot be less than the ECO frequency
5.0/±6.0
range.

Battery parameters
The interface of battery parameters menu is shown in Fig. 2-27, and the interface description is shown in
Table 2-25.

Fig. 2-27 Battery parameters interface

Table 2-25 Description of battery parameters interface

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Setting item Default Options Description
et according to the total number of battery cells connected
Battery to the UPS system, each conventional lead-acid battery
40 settable
number has 6 battery cells, for example, 32 batteries × 6=192
battery cells.
Battery
capacity 18 settable Single battery capacity connected to the UPS system.
(Ah)
Charge
curr.limit(A 1 10 Set according to the needs，20% * UPS capacity limited.
)
Boost time
2 1-48 Set according to the needs.
limit
Cell float Charging voltage of single cells under floating charge
2.25 2.10 ~ 2.35
voltage condition.
Cell boost Charging voltage of single cells under boost charge
2.25 2.20~2.45
voltage condition.
Cell EOD
voltage for 1.65 1.6~1.85 Set according to the needs.
0.6C
Cell EOD
voltage for 1.75 1.65~1.9 Set according to the needs.
0.15C
Boost cycle 1440 1~3000h Set according to the needs.
This test will lead to the battery being partly discharged
Batt auto
to activate battery until battery voltage is low. Bypass
mainten 2880 720~30000h
must be in normal condition, the battery capacity should
cycle
be above 25%.
Batt volt
low 1.1 1.05~1.25 Set according to the needs.
coefficent
Batt
Set according to the actual battery replacement time for
mainten 3000 0-3000d
the users.
cycle

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3 Internal Introduction
3.1 System Configuration
The Tower UPS is configured by the following part: Rectifier, Charger, Inverter, Static Switch and Manual
Bypass Switch. One or several battery strings should be installed to provide backup energy once the utility fails.
The UPS structure is shown in Fig. 3-1.

Fig.3-1 UPS Configuration

3.1.1 Operation Mode

The UPS is an on-line, double-conversion UPS that permits operation in the following modes:Normal mode、
Battery mode、Bypass mode、Maintenance mode (manual bypass)、ECO mode、Auto-restart mode、Frequency
Converter mode、Self Aging Mode

Normal Mode
The inverter of power modules continuously supply the critical AC load. The rectifier/charger derives power
from the AC mains input source and supplies DC power to the inverter while simultaneously FLOAT or BOOST
charging its associated backup battery.

Fig 3-2 Normal mode operation diagram

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 Battery Mode
Upon failure of the AC mains input power, the inverter of power modules, which obtain power from the
battery, supply the critical AC load. There is no interruption in power to the critical load upon failure. After
restoration of the AC mains input power, the “Normal mode” operation will continue automatically without the
necessity of user intervention.

Fig 3-3 Battery mode operation diagram

Bypass Mode
If the inverter overload capacity is exceeded under Normal mode, or if the inverter becomes unavailable for
any reason, the static transfer switch will perform a transfer of the load from the inverter to the bypass source,
with no interruption in power to the critical AC load. Should the inverter be asynchronous with the bypass, the
static switch will perform a transfer of the load from the inverter to the bypass with power interruption to the load.
This is to avoid large cross currents due to the paralleling of unsynchronized AC sources. This interruption is
programmable but typically set to be less than 3/4 of an electrical cycle, e.g., less than 15ms (50Hz) or less than
12.5ms (60Hz). The action of transfer/re-transfer can also be done by the command through monitor.

Fig. 2-4 Bypass mode operation diagram

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 Maintenance Mode (Manual Bypass)
A manual bypass switch is available to ensure continuity of supply to the critical load when the UPS becomes
unavailable e.g. during a maintenance procedure. (As shown in Fig.3-5).

Fig .3-5 Maintenance mode operation diagram

Danger
During Maintenance mode, dangerous voltages are present on the terminal of input, output and neutral, even
with the LCD turned off.

ECO Mode
To improve system efficiency, UPS rack system works in Bypass mode at normal time, and inverter is
standby. When the utility fails, The UPS transfers to Battery Mode and the inverter powers the loads.

Fig.3-6 ECO Mode operation diagram

Note
There is a short interruption time (less than 10ms) when transfer from ECO mode to battery mode, it must be
sure that the interruption has no effect on loads.

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 Auto-restart Mode
The battery may become exhausted following an extended AC mains failure. The inverter shuts down when
the battery reaches the End of Discharge Voltage (EOD). The UPS may be programmed to “System Auto Start
Mode after EOD”. The system starts after a delay time when the AC mains input recovers. The mode and the
delay time are programmed by the commissioning engineer.
Frequency Converter Mode
By setting the UPS to Frequency Converter mode, the UPS could present a stable output of fixed frequency
(50 or 60Hz), and the bypass static switch is not available.
Self Aging Mode
If users want to burn in UPS without load, could set the UPS as Self Aging Mode, in this mode, the current
flow through rectifier, inverter, and back to input through bypass. It needs only 5% loss to burn in UPS with 100%
load.

Fig.3-7 self aging operation diagram

3.2 System Block Diagram

The system block diagram of EA990G5 10-30kVA is shown as Fig.3-8.

Fig.3-8 System Block Diagram

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3.3 Introduction to Internal Boards
Table 3-1 Internal Boards introduction of EA990G5 10-30kVA

No. Board name PCBA Code Introduction Remark

Including input filter circuit, mains
10kVA IP/OP
1 12-202700-00 soft-start circuit, output filter circuit,
board
auxiliary power supply and charger
10kVA Power Contains PFC boost circuit, inverter
2 12-202600-00
board circuit and Fan circuit
10k Byapss
3 12-208600-00 Bypass output circiut
board
Including input filter circuit, mains
15kVA IP/OP
4 12-207800-00 soft-start circuit, output filter circuit,
board
auxiliary power supply and charger
15kVA Power Contains PFC boost circuit, inverter
5 12-202601-00
board circuit and Fan circuit
Including input filter circuit, mains
20kVA IP/OP
6 12-192000-00 soft-start circuit, output filter circuit,
board
auxiliary power supply and charger
20kVA Power Contains PFC boost circuit, inverter
7 12-192100-00
board circuit and Fan circuit
20k Byapss 15K and 20K share
8 12-192200-00 Bypass output circiut
board board
Including input filter circuit, mains
30kVA IP/OP
9 12-201100-00 soft-start circuit, output filter circuit,
board
auxiliary power supply and charger
30kVA Inductor Inverter inductor and inverter current
10 12-201300-00
Board sample
30kVA Power Contains PFC boost circuit, inverter
11 12-201200-00
board circuit and Fan circuit
30kVA Bypass
12 12-192201-00 Bypass output circiut
board
Dry Contact External interface, realize the function
13 12-205000-00 Universal board
board of input and output dry contact;
External interface to realize parallel
14 Parallel board 12-205100-00 Universal board
communication;
Communication External interface, realize
15 12-202200-01 Universal board
interface board RS232/RS485/USB/EPO function;
LCD Driver
16 12-202500-00 LCD Driver Universal board
board
17 Cold start board 12-192500-00 Battery cold start Universal board
18 Filter board 1 12-192300-00 Filter Universal board
19 Filter board 4 12-212100-00 Filter Universal board
Various types of external
Monitoring
20 12-192501-00 communication interface signal Universal board
board
conversion;

27
4 Troubleshooting
This chapter mainly introduces all the alarm information of the system, the meaning of the alarm, the
possible cause of the alarm, and the processing method.

4.1 Repair tool List

Table 4-1 Repair tool list

Tools Number Remark

Oscilloscope 1 Measurement waveforms
Measure voltage and resistance,
Multimeter 1
etc.
Isolated probe Some Measuring voltage signals
Provides a current-limited DC
DC Source 1
power supply
Provides current-limited AC
AC Source 1
power
Screwdrivers, Needle-nose Pliers, Disassembly and assembly of
1 Set
Diagonal Pliers, etc. machines and PCB board
Soldering iron, solder wire, etc. 1 Set Repair welding use
Use after machine maintenance
AC Load 1
and debugging

4.2 Troubleshooting process

The troubleshooting process is shown as Fig.4-1.

Fig.4-1 Troubleshooting process

28
 1. Fault record of UPS: The first on-site information of the fault is very important. According to these
information, the fault point and the cause of the fault can be roughly judged, and the correct solution can be
formulated. Therefore, the first thing for engineers to arrive at the site is to record all the conditions of the power
system, mainly recording the following:
1) The status of the UPS system (panel and monitoring information): the information of each display
interface of the LCD screen when a fault occurs, and the display status of the UPS on the monitoring side;
2) History download: use IServiceTool II software to download and save the running history of the UPS;Or
take pictures page by page of the LCD screen history page.
3) Actual input, output and battery parameters of the UPS system: When a fault occurs, the parameters
displayed on the panel may not the real parameters of the power supply. You can use a multimeter to measure the
actual parameters on the terminals and record them, including: input voltage, output voltage, battery voltage;
4) The position of each switch of the power system;
5) Environmental records: The surrounding environment is also very important to the work of the power
system. After completing the above records, the surrounding working environment should be recorded:
1> How is the ventilation; 2> Ambient temperature; 3> Whether the surrounding installation distance meets
the requirements; 4> Is the surrounding environment bad (such as dust or humidity); 5> How is the input and
output battery wiring? Does the wire diameter meet the requirements? Is the electrical insulation damaged? Are
the terminals loose? 6> The name, type, rated power, etc. of the load (you can consult the customer).
2. Fault type identification: After recording all indications, refer to the following fault information
description table to check the abnormal indicator lights. In most cases, the fault is caused by external reasons of
the UPS, so follow the principle of "outside first and then inside", locate and eliminate external faults according to
the fault information table.
Common external failure reasons:
1> Overload
2>Input, output over, under voltage
3>The mains air switch is disconnected or the mains is abnormal
4> Output short circuit
5>The battery voltage is lower than the low voltage point.
3. If the fault may be reported due to the internal reasons of the power supply, an implementation plan shall
be made according to the fault location. Each key step in the implementation of the plan should be recorded so
that the unresolved problems can be referenced when the plan is re-developed.
4. If the above methods still cannot solve the fault of UPS system, the recorded information will be fed back
to the technical support engineer for coordination and resolution.

29
4.3 Alarm information collection
4.3.1 LCD screen alarm information collection
When the maintenance personnel arrive at the scene for the first time, the alarm information needs to be
collected as soon as possible in order to obtain an effective basis for fault analysis. Record the display conditions
of the LCD panel (mainly fault codes) in detail, and record the working conditions of the LED indicators.
According to the fault code of the machine and the indication of the LED light, we can preliminarily determine the
fault category, which is convenient for locating the fault point.
4.3.2 Monitoring and alarm information collection
If the customer's power system is connected with monitoring software, maintenance personnel can download
and export the current alarm information and all data through the monitoring software for analysis. For details,
please refer to the user manual of the corresponding network management software.

4.4 Common faults and troubleshooting methods

The troubleshooting methods for common faulty machines are shown in table 4-2.

Table 4-2 The troubleshooting methods for common faulty

No. Fault Description Analysis of possible causes Approach

1 UPS triggers overload alarm Overload Remove non-critical loads
Please turn off the UPS
UPS makes abnormal noise or immediately, cut off the input
2 UPS internal fault
smells power, and contact the postsale
engineer for technical support.
Power on by battery, and it The battery voltage is too low Please charge the battery in time
3
automatically shut down soon after or the battery is damaged or replace it with a new one
The battery discharge time is
The battery is not fully charged Please charge the battery in time
4 significantly lower than the
or the battery is damaged or replace it with a new one
standard value

4.5 Alarm detailed explanation and handling suggestions

Alarm detailed explanation and handling suggestions are shown in table 4-3.

Table 4-3 Alarm detailed explanation and handling suggestions table

ID Faults and alarms Description suggestion

Default 1.1 times EOD voltage (can
230 Battery voltage low (DOD) Check if the charger is abnormal
be set)
Battery end of discharge The default cell voltage is 1.65~1.75V,
231 No processing required
(EOD) which can be set

1. Check whether the bypass board

SCR is damaged;
232 Bypass fail Bypass SCR is open or shorted 2. Check whether the signal cable
from the bypass board to the input and
output board is normal;
233 Fan fail Fan fault signal trigger Replace the Fan;

30
 1. Check whether the mains input air
The effective value of the three-phase switch is disconnected;
243 Grid input breaker open
input voltage is lower than 35% 2. Check whether the mains input
insurance is damaged;
UPS maintenance breaker Maintenance bypass closed signal Check whether the maintenance
245
close trigger bypass cover is loose;

The effective value of the three-phase Check whether the bypass air circuit
246 UPS bypass breaker open
bypass voltage is lower than 35% breaker is disconnected;

Please check whether the addresses of

Same address of multiple
337 Parallel addresses are the same each UPS in the parallel system are
inverter
duplicated
Frequency beyond tracing The bypass frequency exceeds the set Check whether the bypass voltage is
366
range tracking range abnormal
Check whether the bypass voltage is
368 Bypass phase overvoltage Bypass voltage out of set range
abnormal
Check whether the bypass voltage is
369 Bypass phase undervoltage Bypass voltage is lower than set range
abnormal
Check whether the bypass voltage is
370 Bypass overfrequence Bypass frequency out of set range
abnormal
Check whether the bypass voltage is
371 Bypass underfrequence Bypass frequency out of set range
abnormal
Check whether the bypass phase
372 Bypass phase sequence error Bypass reversed
sequence is reversed
Check whether the bypass voltage is
373 Bypass phase loss Bypass missing 1 or 2 phases
abnormal
Bypass voltage is not 120 degree Check whether the bypass voltage is
374 Bypass phase volt imbalance
symmetrical abnormal
Bypass instantaneous voltage is higher
Bypass voltage rapid Check whether the bypass voltage is
375 than 1.25 times or lower than 0.8
inspection abnormal abnormal
times rated voltage
Battery maintenance Battery maintenance reminder time is Maintaining Batteries: Perform
418
reminder up Battery Test 2
There is an abnormal PFC alarm
423 Battery self check fail Please replace the power board
during the battery test
Check whether the mains input
464 Input overvoltage Input voltage higher than 280V
voltage is abnormal
Check whether the mains input
465 Input undervoltage Input voltage below 132V
voltage is abnormal
Check whether the mains input
466 Input overfrequence Input frequency higher than 70Hz
voltage is abnormal
Check whether the mains input
467 Input underfrequence Input frequency below 40Hz
voltage is abnormal

31
 Check whether the phase sequence of
468 Input phase sequence error input reversed
the mains input voltage is reversed

Check whether the mains input

469 Input phase loss Input missing 1 or 2 phases
voltage is abnormal

The difference between the maximum Check whether the mains input
470 Input voltage imbalance
and the lowest input voltage is 17V voltage is abnormal

The instantaneous value of the input

input voltage rapid Check whether the mains input
471 voltage is higher than 1.35 times rated
inspection abnormal voltage is abnormal
or lower than 0.45 times rated
Input current is higher than 1.35 times
472 Input overcurrent Check if the input voltage is too low
rated current

The difference between the maximum

473 Input current imbalance and minimum input current is 0.25 Please replace the power board
times the rated current

Abnormal three-phase input voltage Please check whether the input neutral
474 Input null wire loss
DC line is connected normally;
Frequent switching between Mains and battery switching over 5 Check whether the mains input
477
grid and battery times within 1 hour voltage is abnormal
Please check if the battery is
480 Battery disconnect battery is not connected
connected;
There is an abnormal PFC alarm
482 Battery self check fail Please replace the power board
during the battery test
The battery voltage is 10V higher than Please check whether the battery
483 Battrey overvoltage
the equalizing voltage voltage is abnormal;
When the battery voltage is lower than
Please check whether the battery
484 Battery undervoltage DOD 1.1 times the EOD voltage, it can be
voltage is abnormal;
set
The battery current is 1.1 times greater
489 Battery charging overcurrent Please replace the I/O board
than the limit current
Open circuit of battery fuse/
491 Charger switch open Please replace the I/O board
charger switch
492 Charger switch short circuit Charger switch short circuit Please replace the I/O board
Please check whether the battery is
494 Reverse battery connection battery reversed
connected properly;
The busbar soft-start stage does not
521 PFC sofe start fail Please replace the power board
reach the set voltage
Rectifier IGBT module Rectification temperature is higher Please check whether the fan is
528
overtemperature than 80 degrees abnormal;
Rectifier E2PROM Rectifier E2PROM read and write
529 Please replace the I/O board
read-write failure failed
The charger voltage soft start does not
546 Charger sofe start fail Please replace the I/O board
reach the battery voltage

32
 The charger voltage is 10V higher
547 Charger overvoltage Please replace the I/O board
than the equalizing voltage
Charger voltage is lower than 80% of
549 Charger undervoltage Please replace the I/O board
battery voltage
The bus voltage continuously drops
592 Bus-bar short circuit Please replace the power board
more than 150V in 3ms
594 Bus-bar overvoltage Bus voltage higher than 450V Please replace the power board
595 Bus-bar undervoltage Bus voltage below 286V Please replace the power board
The difference between the positive
596 Bus-bar voltage imbalance Please replace the power board
and negative bus voltage is 40V
Inverter voltage is 1.05 times higher
608 Inverter overvoltage Please replace the power board
than rated
Inverter voltage is 0.95 times lower
609 Inverter undervoltage Please replace the power board
than rated
Inverter module 105% Inverter overload 105 and more than 1
612 Please remove non-critical loads
overload hour
Inverter module 110% Inverter overload 110% and more than
613 Please remove non-critical loads
overload 1 hour
Inverter module 125% Inverter overload 125% and more than
614 Please remove non-critical loads
overload 10 minutes
Inverter module 150% Inverter overload 150% and more than
615 Please remove non-critical loads
overload 1 minute
Short circuit of inverter Remove the load and check for a short
616 Inverter short circuit exceeds 200ms
output circuit
Inverter module overload
617 Inverter overload 100% Please remove non-critical loads
alarm
Bypass overload 125% for more than
626 BYP 125% overload Please remove non-critical loads
10 minutes
Bypass overload 135% for more than
627 BYP 135% overload Please remove non-critical loads
1 minute
Bypass overload 150% for more than
628 BYP 150% overload Please remove non-critical loads
1 second
Bypass overload 200% for more than
629 BYP 200% overload Please remove non-critical loads
20ms
630 Bypass overload alarm Bypass overload 100% Please remove non-critical loads

The inverter soft start voltage does not

640 nverter sofe start fail Please replace the power board
reach 0.9 times the rated voltage

Frequent switching between Bypass and inverter switching over 5

642 Manually clear faults
bypass and inverter times within 1 hour
The difference between the maximum
Parallel operation current and minimum load rates between Please check whether the parallel
644
imbalance parallel UPS systems is more than communication is abnormal
30%

33
 1. Check whether the parallel cable
Parallel operation wire
648 Parallel operation wire abnormal connection is normal;
abnormal
2. Replace the parallel line;
Inverter radiator Inverter temperature is higher than 80 Please check whether the fan is
656
overtemperature degrees abnormal;
Inverter E2PROM operation Inverter E2PROM read and write
657 Please replace the I/O board
failure failed
Inverter DSP and monitor The communication of the clock chip
658 Please replace the I/O board
communication failure is abnormal
Please check whether the EPO
663 Emergency shutdown Emergency shutdown
terminal is loose;
672 Inverter relay open circuit Inverter relay open circuit Please replace the I/O board
673 Inverter relay short circuit Inverter relay short circuit Please replace the I/O board
SPI communication failure SPI communication failure between
676 Please replace the I/O board
between rectifier and inverter rectifier and inverter

34
5 Board replacement
5.1 Board replacement of 10kVA model
The 10kVA model includes the following boards: power board, IP/OP board, bypass board, monitoring board,
cold start board, parallel interface board, communication interface board, dry contact board; the specific locations
are shown in Fig.5-1 to 5-5.

Fig.5-1 The right side board of 10kVA long-delay model (Tower)

Fig.5-2 The left side board of 10kVA long-delay model (Tower)

35
Fig.5-3 The right side board of 10kVA standard model (Tower)

Fig.5-4 The left side board of 10kVA standard model (Tower)

36
 Fig.5-5 The board of 10kVA model (Rack)

5.2 Board replacement of 15kVA model

The 15kVA model includes the following boards: power board, IP/OP board, bypass board, monitoring board,
cold start board, parallel interface board, communication interface board, dry contact board; the specific locations
are shown in Fig.5-6 to 5-10.

Fig.5-6 The right side board of 15kVA long-delay model (Tower)

37
Fig.5-7 The left side board of 15kVA long-delay model (Tower)

Fig.5-8 The right side board of 15kVA standard model (Tower)

38
Fig.5-9 The left side board of 15kVA standard model (Tower)

Fig.5-10 The board of 15kVA model (Rack)

39
5.3 Board replacement of 20kVA model
The 20kVA model includes the following boards: power board, IP/OP board, bypass board, monitoring board,
cold start board, parallel interface board, communication interface board, dry contact board; the specific locations
are shown in Fig.5-11 to 5-15.

Fig.5-11 The right side board of 20kVA long-delay model (Tower)

Fig.5-12 The left side board of 20kVA long-delay model (Tower)

40
Fig.5-13 The right side board of 20kVA standard model (Tower)

Fig.5-14 The lest side board of 20kVA standard model (Tower)

41
 Fig.5-15 The board of 20kVA model (Rack)

5.4 Board replacement of 30kVA model

The 30kVA model includes the following boards: power board, IP/OP board, Inductor board, bypass board,
monitoring board, cold start board, parallel interface board, communication interface board, dry contact board; the
specific locations are shown in Fig.5-16 to 5-20.

Fig.5-16 The right side board of 30kVA long-delay model (Tower)

42
Fig.5-17 The left side board of 30kVA long-delay model (Tower)

Fig.5-18 The right side board of 30kVA standard model (Tower)

43
Fig.5-19 The left side board of 30kVA standard model (Tower)

44
6 Board maintenance
Maintenance of EA990 G5 10-30kVA series UPS requires maintenance engineer having basic circuit theory,
power electronics related knowledge, and knowledge of related circuit topology. In addition, the improvement of
maintenance skills requires the accumulation of long-term maintenance experience. Please keep a good record of
maintenance notes during the maintenance process. The maintenance notes are convenient for future maintenance,
which can help maintenance engineer quickly locate problem points, quickly solve problems, and improve his
maintenance efficiency.
According to the actual use, the EA990 G5 10-30kVA vulnerable parts are the main power board, input and
output board, bypass board, monitoring board and cold start board. The following will explain the maintenance of
these boards of the whole series of UPS.

6.1 Maintenance of power board

6.1.1 Maintenance of 10kVA power board
The 10kVA power board is mainly divided into a rectifier booster part and an inverter part. Among them, the
fragile components are shown in Table 6-1, and the position of the board is shown in Fig. 6-1.

Table 6-1 The fragile componments of 10kVA power board

Components Tag Number Specifications Alternative

specification
Diode of input retifier D11,D12,D13,D14,D15,D16 RHRP30120 MM30FU120K
Battery SCR S7,S8,S9,S10,S11,S12 VS-50TPS12L-M3 CLA50E1200HB
Battery SCR driver
PCB11
module
Boost IGBT Q1,Q2,Q3,Q4,Q5,Q6 IKW50N65H5 MM75G5U65BX
Inverter outer bridge
Q7,Q8,Q11,Q12,Q15,Q16 IKW25N120T2 MM40G3U120BX
IGBT
Inverter inner bridge
Q9,Q10,Q13,Q14,Q17,Q18 IKW30N65EL5 JT050N065WED
IGBT
PCB1,PCB2,PCB3,PCB4,PCB5,
IGBT driver module
PCB6,PCB7,PCB8,PCB9
ZD6,ZD7,ZD8,ZD9,ZD10,ZD11,
ZD12,ZD13,ZD14,ZD15,ZD16,
ZD17,ZD18,ZD19,ZD20,ZD21,
Zenner diode of IGBT
ZD22,ZD23,ZD24,ZD25,ZD26, ZMM18
driver
ZD27,ZD28,ZD29,ZD30,ZD31,
ZD32,ZD33,ZD34,ZD35,ZD36,
ZD37,ZD38,ZD39,ZD40,ZD41
Boost diode D1,D2,D3,D4,D5,D6 RHRP3060 MM30FU60K

45
 Fig.6-1 Key components identification of 10kVA power board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the whole power board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire power board for obvious burns or cracks, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the boost
IGBT and the inverter outer/inner bridge IGBT. If the multimeter shows that the voltage drop is too low (less than
0.1V), you need to replace the corresponding IGBT.
Note: When replacing the IGBT, it is necessary to apply heat dissipation paste on the back of the IGBT. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it should also be replaced
together.
Step 4: Use the multimeter diode gear to detect the Zenner diode of IGBT driver. If the multimeter shows that
the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the input rectifier diode and Boost diode. If the forward
voltage drop is too low (less than 0.1V) or there is also a reverse voltage drop, the diode may be damaged and
needs to be replaced.
Step 6: Measure the resistance of the battery thyristor (SCR) with a multimeter in the ohm range. The normal
resistance should be around 20Ω. If not, it needs to be replaced.

46
 After completing the inspection work in steps 1-6, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-2. Connection method Connect the main power board to the input and
output board (only connect the signal cable, not the copper bus), and carry out the drive test. The test waveforms
of each key device are shown in Table 6-2.

Fig.6-2 The connection of drive test circuit of 10kVA power board

Table 6-2 The driver test description of 10kVA power board

Component and its tag number Waveform Remark

High level
+15V±1V；

Boost IGBT Low level

Q1,Q2,Q3,Q4,Q5,Q6 -8V±1V；

Frequency
40KHz；

High level
+15V±1V；

Inverter outer bridge IGBT Low level

Q7,Q8,Q11,Q12,Q15,Q16 -8V±1V；

Frequency
20KHz；

47
 High level
+15V±1V；

Inverter inner bridge IGBT Low level

Q9,Q10,Q13,Q14,Q17,Q18 -8V±1V；

Frequency
20KHz；

High level
1V-1.5V；
Battery SCR
S7,S8,S9,S10,S11,S12
Low level
0V；

If it is found that the individual IGBT or SCR drive is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.
6.1.2 Maintenance of 15kVA power board
The 15kVA power board is mainly divided into a rectifier booster part and an inverter part. Among them, the
fragile components are shown in Table 6-3, and the position of the board is shown in Fig. 6-3.

Table 6-3 The fragile componments of 15kVA power board

Components Tag Number Specifications Alternative

specification
Diode of input retifier D11,D12,D13,D14,D15,D16 RHRP30120 MM30FU120K
Battery SCR S7,S8,S9,S10,S11,S12 VS-50TPS12L-M3 CLA50E1200HB
Battery SCR driver
PCB11
module
Boost IGBT Q1,Q2,Q3,Q4,Q5,Q6 IKW50N65H5 MM75G5U65BX
Inverter outer bridge
Q7,Q8,Q11,Q12,Q15,Q16 IKW25N120T2 MM40G3U120BX
IGBT
Inverter inner bridge
Q9,Q10,Q13,Q14,Q17,Q18 IKW30N65EL5 JT050N065WED
IGBT
PCB1,PCB2,PCB3,PCB4,PCB5,
IGBT driver module
PCB6,PCB7,PCB8,PCB9
Zenner diode of IGBT ZD6,ZD7,ZD8,ZD9,ZD10,ZD11,
ZMM18
driver ZD12,ZD13,ZD14,ZD15,ZD16,

48
 ZD17,ZD18,ZD19,ZD20,ZD21,
ZD22,ZD23,ZD24,ZD25,ZD26,
ZD27,ZD28,ZD29,ZD30,ZD31,
ZD32,ZD33,ZD34,ZD35,ZD36,
ZD37,ZD38,ZD39,ZD40,ZD41
Boost diode D1,D2,D3,D4,D5,D6 RHRP3060 MM30FU60K

Fig.6-3 Key components identification of 15kVA power board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the whole power board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire power board for obvious burns or cracks, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the boost
IGBT and the inverter outer/inner bridge IGBT. If the multimeter shows that the voltage drop is too low (less than
0.1V), you need to replace the corresponding IGBT.
Note: When replacing the IGBT, it is necessary to apply heat dissipation paste on the back of the IGBT. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it should also be replaced
together.
Step 4: Use the multimeter diode gear to detect the Zenner diode of IGBT driver. If the multimeter shows that
the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.

49
 Step 5: Use the diode gear of the multimeter to test the input rectifier diode and Boost diode. If the forward
voltage drop is too low (less than 0.1V) or there is also a reverse voltage drop, the diode may be damaged and
needs to be replaced.
Step 6: Measure the resistance of the battery thyristor (SCR) with a multimeter in the ohm range. The normal
resistance should be around 20Ω. If not, it needs to be replaced.
After completing the inspection work in steps 1-6, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-4. Connection method Connect the main power board to the input and
output board (only connect the signal cable, not the copper bus), and carry out the drive test. The test waveforms
of each key device are shown in Table 6-4.

Fig.6-4 The connection of drive test circuit of 15kVA power board

Table 6-4 The driver test description of 15kVA power board

Component and its tag number Waveform Remark

High level
+15V±1V；

Boost IGBT Low level

Q1,Q2,Q3,Q4,Q5,Q6 -8V±1V；

Frequency
40KHz；

50
 High level
+15V±1V；

Inverter outer bridge IGBT Low level

Q7,Q8,Q11,Q12,Q15,Q16 -8V±1V；

Frequency
20KHz；

High level
+15V±1V；

Inverter inner bridge IGBT Low level

Q9,Q10,Q13,Q14,Q17,Q18 -8V±1V；

Frequency
20KHz；

High level
1V-1.5V；
Battery SCR
S7,S8,S9,S10,S11,S12
Low level
0V；

If it is found that the individual IGBT or SCR drive is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.

6.1.3 Maintenance of 20kVA power board

The 20kVA power board is mainly divided into a rectifier booster part and an inverter part. Among them, the
fragile components are shown in Table 6-5, and the position of the board is shown in Fig. 6-5.

51
 Table 6-5 The fragile componments of 20kVA power board

Components Tag Number Specifications Alternative

specification
S1,S2,S3,S4,S5,S6,S7,S8,S9,S10,S11,
Battery SCR VS-50TPS12L-M3 CLA50E1200HB
S12
Battery SCR driver
PCB10,PCB11
module
Boost IGBT Q1,Q2,Q3,Q4,Q5,Q6 IKW50N65H5 MM75G5U65BX
Inverter outer bridge
Q7,Q8,Q11,Q12,Q15,Q16 IKW40N120CS6 MM40G3U120BX
IGBT
Inverter inner bridge
Q9,Q10,Q13,Q14,Q17,Q18 IKW30N65EL5 JT050N065WED
IGBT
PCB1,PCB2,PCB3,PCB4,PCB5,PCB
IGBT driver module
6,PCB7,PCB8,PCB9
ZD6,ZD7,ZD8,ZD9,ZD10,ZD11,
ZD12,ZD13,ZD14,ZD15,ZD16,
ZD17,ZD18,ZD19,ZD20,ZD21,
Zenner diode of IGBT
ZD22,ZD23,ZD24,ZD25,ZD26, ZMM18
driver
ZD27,ZD28,ZD29,ZD30,ZD31,
ZD32,ZD33,ZD34,ZD35,ZD36,
ZD37,ZD38,ZD39,ZD40,ZD41
Boost diode D1,D2,D3,D4,D5,D6 APT75DQ60BG MM75FU60B

Fig.6-5 Key components identification of 20kVA power board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the whole power board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire power board for obvious burns or cracks, and replace if necessary.

52
 Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the boost
IGBT and the inverter outer/inner bridge IGBT. If the multimeter shows that the voltage drop is too low (less than
0.1V), you need to replace the corresponding IGBT.
Note: When replacing the IGBT, it is necessary to apply heat dissipation paste on the back of the IGBT. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it should also be replaced
together.
Step 4: Use the multimeter diode gear to detect the Zenner diode of IGBT driver. If the multimeter shows that
the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the input rectifier diode and Boost diode. If the forward
voltage drop is too low (less than 0.1V) or there is also a reverse voltage drop, the diode may be damaged and
needs to be replaced.
Step 6: Measure the resistance of the battery thyristor (SCR) with a multimeter in the ohm range. The normal
resistance should be around 20Ω. If not, it needs to be replaced.
After completing the inspection work in steps 1-6, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-6. Connection method Connect the main power board to the input and
output board (only connect the signal cable, not the copper bus), and carry out the drive test. The test waveforms
of each key device are shown in Table 6-6.

Fig.6-4 The connection of drive test circuit of 20kVA power board

Table 6-4 The driver test description of 20kVA power board

Component and its tag number Waveform Remark

53
 High level
+15V±1V；

Boost IGBT Low level

Q1,Q2,Q3,Q4,Q5,Q6 -8V±1V；

Frequency
40KHz；

High level
+15V±1V；

Inverter outer bridge IGBT Low level

Q7,Q8,Q11,Q12,Q15,Q16 -8V±1V；

Frequency
20KHz；

High level
+15V±1V；

Inverter inner bridge IGBT Low level

Q9,Q10,Q13,Q14,Q17,Q18 -8V±1V；

Frequency
20KHz；

54
 High level
Main and battery SCR 1V-1.5V；
S1,S2,S3,S4,S5,S6,S7,S8,S9,S1
0,S11,S12 Low level
0V；

If it is found that the individual IGBT or SCR drive is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.

6.1.4 Board replacement of 30kVA model

The 20kVA power board is mainly divided into a rectifier booster part and an inverter part. Among them, the
fragile components are shown in Table 6-7, and the position of the board is shown in Fig. 6-7.

Table 6-7 The fragile componments of 30kVA power board

Components Tag Number Specifications Alternative

specification
S1,S2,S3,S4,S5,S6,S7,S8,S9,S10,S11,
Battery SCR VS-70TPSPBF
S12
Battery SCR driver
PCB10,PCB11
module
Boost IGBT Q1,Q2,Q3,Q4,Q5,Q6 IKW75N65EH5 NCE80TD65BT
Inverter outer bridge SGTP75V65SDS1P
Q7,Q8,Q11,Q12,Q15,Q16 IKW75N65ES5
IGBT 7
Inverter inner bridge
Q9,Q10,Q13,Q14,Q17,Q18 IKW75N65EL5 NCE80TD65BT
IGBT
PCB1,PCB2,PCB3,PCB4,PCB5,PCB
IGBT driver module
6,PCB7,PCB8,PCB9
ZD6,ZD7,ZD8,ZD9,ZD10,ZD11,
ZD12,ZD13,ZD14,ZD15,ZD16,
ZD17,ZD18,ZD19,ZD20,ZD21,
Zenner diode of IGBT
ZD22,ZD23,ZD24,ZD25,ZD26, ZMM18
driver
ZD27,ZD28,ZD29,ZD30,ZD31,
ZD32,ZD33,ZD34,ZD35,ZD36,
ZD37,ZD38,ZD39,ZD40,ZD41
Boost diode D1,D2,D3,D4,D5,D6 FFH70H60S MM75FU60B

55
 Fig.6-7 Key components identification of 30kVA power board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the whole power board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire power board for obvious burns or cracks, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the boost
IGBT and the inverter outer/inner bridge IGBT. If the multimeter shows that the voltage drop is too low (less than
0.1V), you need to replace the corresponding IGBT.
Note: When replacing the IGBT, it is necessary to apply heat dissipation paste on the back of the IGBT. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it should also be replaced
together.
Step 4: Use the multimeter diode gear to detect the Zenner diode of IGBT driver. If the multimeter shows that
the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the input rectifier diode and Boost diode. If the forward
voltage drop is too low (less than 0.1V) or there is also a reverse voltage drop, the diode may be damaged and
needs to be replaced.
Step 6: Measure the resistance of the battery thyristor (SCR) with a multimeter in the ohm range. The normal
resistance should be around 20Ω. If not, it needs to be replaced.

56
 After completing the inspection work in steps 1-6, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-8. Connection method Connect the main power board to the input and
output board (only connect the signal cable, not the copper bus), and carry out the drive test. The test waveforms
of each key device are shown in Table 6-8.

Fig.6-8 The connection of drive test circuit of 30kVA power board

Table 6-8 The driver test description of 30kVA power board

Component and its tag number Waveform Remark

High level
+15V±1V；

Boost IGBT Low level

Q1,Q2,Q3,Q4,Q5,Q6 -8V±1V；

Frequency
40KHz；

High level
+15V±1V；

Inverter outer bridge IGBT Low level

Q7,Q8,Q11,Q12,Q15,Q16 -8V±1V；

Frequency
20KHz；

57
 High level
+15V±1V；

Inverter inner bridge IGBT Low level

Q9,Q10,Q13,Q14,Q17,Q18 -8V±1V；

Frequency
20KHz；

High level
Main and battery SCR 1V-1.5V；
S1,S2,S3,S4,S5,S6,S7,S8,S9,S1
0,S11,S12 Low level
0V；

If it is found that the individual IGBT or SCR drive is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.

6.2 Maintenance of IP/OP board

6.2.1 Maintenance of 10kVA IP/OP board
10kVA IP/OP board mainly includes auxiliary power supply, charger, input filter, output filter and mains soft
start circuit. Among them, the fragile components are shown in Table 6-9, and the position of the board is shown
in Fig 6-9.

Table 6-9 The frogile components of 10kVA IP/OP board

Alternative
Components Tag Number Specifications
specification
Input/Output Fuse F1,F3,F5,F8,F10,F12 324-0324030
Battery Fuse F15,F16 100A/690V
Charger Fuse F13,F14 10A/250V
Charger IGBT Q23,Q24 IKW30N65H5 JT050N065WED
Charger Diode D9,D10,D33,D34 RHRP3060 MM30FU60K

58
 Fig.6-9 The key components identification of 10kVA IP/OP board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the
charger IGBT. If the multimeter shows that the voltage drop is too low (less than 0.1V), you need to Replace the
corresponding IGBT.
Step 4: Use the multimeter diode gear to detect the driving Zener diode corresponding to the IGBT. If the
multimeter shows that the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be
replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the diode of the charger. If the forward voltage drop is too
low (less than 0.1V) or there is a voltage drop in the reverse direction, the diode may be damaged and needs to be
replaced.
Note: When replacing IGBT, diodes and SCR, it is necessary to smear heat dissipation paste on the back of
the devices. If the corresponding insulating gaskets are blackened, burned, burned through, burned, etc., they also
need to be replaced together.
After completing the inspection work in steps 1-5, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,

59
and then follow the steps shown in Figure 6-10. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-10.

Fig.6-10 The connection of drive test circuit of 10kVA IP/OP board

Table 6-10 The driver test description of 10kVA IP/OP board

Component and its tag number Waveform Remark

High level
+15V±1V；

Charger IGBT Low level

Q23,Q24 -8V±1V；

Frequency
40KHz；

If it is found that the individual IGBT drive wareform is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.
6.2.2 Maintenance of 15kVA IP/OP board
15kVA IP/OP board mainly includes auxiliary power supply, charger, input filter, output filter and mains soft
start circuit. Among them, the fragile components are shown in Table 6-11, and the position of the board is shown
in Fig 6-11.

Table 6-11 The frogile components of 15kVA IP/OP board

Alternative
Components Tag Number Specifications
specification
Input/Output Fuse F1,F3,F5,F8,F10,F12 324-0324030
Battery Fuse F15,F16 100A/690V
Charger Fuse F13,F14 10A/250V
Charger IGBT Q23,Q24 IKW30N65H5 JT050N065WED
Charger Diode D9,D10,D43,D44 RHRP3060 MM30FU60K

60
 Fig.6-11 The key components identification of 15kVA IP/OP board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the
charger IGBT. If the multimeter shows that the voltage drop is too low (less than 0.1V), you need to Replace the
corresponding IGBT.
Step 4: Use the multimeter diode gear to detect the driving Zener diode corresponding to the IGBT. If the
multimeter shows that the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be
replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the diode of the charger. If the forward voltage drop is too
low (less than 0.1V) or there is a voltage drop in the reverse direction, the diode may be damaged and needs to be
replaced.
Note: When replacing IGBT, diodes and SCR, it is necessary to smear heat dissipation paste on the back of
the devices. If the corresponding insulating gaskets are blackened, burned, burned through, burned, etc., they also
need to be replaced together.
After completing the inspection work in steps 1-5, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,

61
and then follow the steps shown in Figure 6-12. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-12.

Fig.6-12 The connection of drive test circuit of 15kVA IP/OP board

Table 6-12 The driver test description of 15kVA IP/OP board

Component and its tag number Waveform Remark

High level
+15V±1V；

Charger IGBT Low level

Q23,Q24 -8V±1V；

Frequency
40KHz；

If it is found that the individual IGBT drive wareform is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.
6.2.3 Maintenance of 20kVA IP/OP board
20kVA IP/OP board mainly includes auxiliary power supply, charger, input filter and output filter. Among
them, the fragile components are shown in Table 6-13, and the position of the board is shown in Fig 6-13.

Table 6-13 The frogile components of 20kVA IP/OP board

Alternative
Components Tag Number Specifications
specification
F1,F2,F3,F4,F5,F6,F8,F9,F10,F11,F1
Input/Output Fuse 324-0324030
2,F13
Battery Fuse F15,F16 100A/690V
Charger Fuse F13,F14 10A/250V
Charger IGBT Q23,Q24 IKW30N65H5 JT050N065WED
Charger Diode D9,D10,D43,D44 RHRP3060 MM30FU60K

62
 Fig.6-13 The key components identification of 20kVA IP/OP board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the
charger IGBT. If the multimeter shows that the voltage drop is too low (less than 0.1V), you need to Replace the
corresponding IGBT.
Step 4: Use the multimeter diode gear to detect the driving Zener diode corresponding to the IGBT. If the
multimeter shows that the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be
replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the diode of the charger. If the forward voltage drop is too
low (less than 0.1V) or there is a voltage drop in the reverse direction, the diode may be damaged and needs to be
replaced.
Note: When replacing IGBT, diodes and SCR, it is necessary to smear heat dissipation paste on the back of
the devices. If the corresponding insulating gaskets are blackened, burned, burned through, burned, etc., they also
need to be replaced together.
After completing the inspection work in steps 1-5, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,

63
and then follow the steps shown in Figure 6-14. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-14.

Fig.6-14 The connection of drive test circuit of 20kVA IP/OP board

Table 6-14 The driver test description of 20kVA IP/OP board

Component and its tag number Waveform Remark

High level
+15V±1V；

Charger IGBT Low level

Q23,Q24 -8V±1V；

Frequency
40KHz；

If it is found that the individual IGBT drive wareform is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.
6.2.4 Maintenance of 30kVA IP/OP board
30kVA IP/OP board mainly includes auxiliary power supply, charger, input filter and output filter. Among
them, the fragile components are shown in Table 6-15, and the position of the board is shown in Fig 6-15.

Table 6-15 The frogile components of 30kVA IP/OP board

Alternative
Components Tag Number Specifications
specification
Input/Output Fuse F4,F5,F6,F25,F26,F27 100A/690V
Battery Fuse F13,F14 10A/250V
Charger Fuse Q19,Q20 IKW40N65H5 JT050N065WED
Charger IGBT D9,D10,D6,D7 RHRP3060 MM30FU60K

64
 Fig.6-15 The key components identification of 30kVA IP/OP board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Use the diode gear of the multimeter to detect the PIN1(+)-PIN3(-) and PIN2(+)-PIN3(-) of the
charger IGBT. If the multimeter shows that the voltage drop is too low (less than 0.1V), you need to Replace the
corresponding IGBT.
Step 4: Use the multimeter diode gear to detect the driving Zener diode corresponding to the IGBT. If the
multimeter shows that the voltage drop is too low (less than 0.1V), the corresponding Zener diode needs to be
replaced.
Note: If the IGBT is found to be damaged in step 3, the corresponding driving Zener diode will also be
damaged.
Step 5: Use the diode gear of the multimeter to test the diode of the charger. If the forward voltage drop is too
low (less than 0.1V) or there is a voltage drop in the reverse direction, the diode may be damaged and needs to be
replaced.
Note: When replacing IGBT, diodes and SCR, it is necessary to smear heat dissipation paste on the back of
the devices. If the corresponding insulating gaskets are blackened, burned, burned through, burned, etc., they also
need to be replaced together.
After completing the inspection work in steps 1-5, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,

65
and then follow the steps shown in Figure 6-16. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-16.

Fig.6-16 The connection of drive test circuit of 30kVA IP/OP board

Component and its tag number Waveform Remark

High level
+15V±1V；

Charger IGBT Low level

Q19,Q20 -8V±1V；

Frequency
40KHz；

Table 6-16 The driver test description of 30kVA IP/OP board

If it is found that the individual IGBT drive wareform is abnormal during the drive test, please re-check
whether the device is replaced, and check whether the corresponding drive module is damaged.

6.3 Maintenance of Bypass board

6.3.1 Maintenance of 10kVA bypass board
The 10kVA bypass board mainly includes bypass output circuit and output current sampling circuit. Tthe
frogile component of bypass board is bypass SCR, which are shown in Table 6-17, and its position in the board is
shown in Figure 6-17.

Table 6-17 The frogile components of 10kVA bypass board

Alternative
Components Tag Number Specifications
specification
Bypass SCR Q1,Q2,Q3,Q4,Q5,Q6 VS-40TPS12A-M3 BT155W-1200T

66
 Fig.6-17 The key components identification of 10kVA bypass board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Measure the resistance of the bypass thyristor (SCR) with the ohm gear of the multimeter. The normal
resistance should be around 20Ω. If not, it needs to be replaced.
Note: When replacing the SCR, it is necessary to apply thermal paste on the back of the device. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it needs to be replaced
together.
After completing the inspection work in steps 1-3, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-18. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-18.

Fig.6-18 The connection of drive test circuit of 10kVA bypass board

67
 Table 6-18 The driver test description of 10kVA bypass board

Component and its tag number Waveform Remark

High level
1V-1.5V；
Bypass SCR
Q1,Q2,Q3,Q4,Q5,Q6
Low level
0V；

If it is found that the individual SCR is abnormally driven during the drive test, please re-check whether the
device is replaced, and check whether the corresponding drive module is damaged.
6.3.2 Maintenance of 15kVA/20kVA bypass board.
The 15kVA and 20kVA model share the bypass board, and the board mainly includes the bypass output
circuit and the output current sampling circuit. Among them, the frogile components have bypass SCR, which are
shown in Table 6-19, and its position in the board is shown in Figure 6-19.

Table 6-19 The forgile components 15/20kVA bypass board

Alternative
Components Tag Number Specifications
specification
Bypass SCR Q1,Q2,Q3,Q4,Q5,Q6 VS-50TPS12A BT155W-1200T

Fig.6-19 The key components identification of 15/20kVA bypass board

The detailed maintenance steps are as follows:

68
 Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Measure the resistance of the bypass thyristor (SCR) with the ohm gear of the multimeter. The normal
resistance should be around 20Ω. If not, it needs to be replaced.
Note: When replacing the SCR, it is necessary to apply thermal paste on the back of the device. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it needs to be replaced
together.
After completing the inspection work in steps 1-3, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-20. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-20.

Fig.6-20 The connection of drive test circuit of 15/20kVA bypass board

Table 6-20 The driver test description of 15/20kVA bypass board

Component and its tag number Waveform Remark

High level
1V-1.5V；
Bypass SCR
Q1,Q2,Q3,Q4,Q5,Q6
Low level
0V；

If it is found that the individual SCR is abnormally driven during the drive test, please re-check whether the
device is replaced, and check whether the corresponding drive module is damaged.
6.3.3 Maintenance of 30kVA bypass board
The 30kVA bypass board mainly includes bypass output circuit and output current sampling circuit. Among
them, the forgile component is bypass SCR, which is shown in Table 6-21, and its position in the board is shown
in Fig.6-21.

69
 Table 6-21 The frogile component of 30kVA bypass board

Alternative
Components Tag Number Specifications
specification
Bypass SCR Q1,Q2,Q3,Q4,Q5,Q6 VS-70TPSPBF

Fig.6-21 The key components identification of 30kVA bypass board

The detailed maintenance steps are as follows:

Step 1: Check whether the copper foil is corroded and rusted on the entire I/O board. You can use a
multimeter to assist in the inspection. If there is corrosion, the copper foil needs to be re-soldered.
Step 2: Visually inspect the entire I/O board for obvious burns or explosions, and replace if necessary.
Step 3: Measure the resistance of the bypass thyristor (SCR) with the ohm gear of the multimeter. The normal
resistance should be around 20Ω. If not, it needs to be replaced.
Note: When replacing the SCR, it is necessary to apply thermal paste on the back of the device. If the
corresponding insulating gasket is blackened, burned, burned through, burned, etc., it needs to be replaced
together.
After completing the inspection work in steps 1-3, replace the damaged device; after replacing the device,
use the shorting cap to short-circuit J2 of the rectifier control board CT1 and J2 of the inverter control board CT2,
and then follow the steps shown in Figure 6-20. Connection method for drive test. The test waveforms of each key
device are shown in Table 6-20.

Fig.6-20 The connection of drive test circuit of 30kVA bypass board

70
 Table 6-20 The driver test description of 30kVA bypass board

Component and its tag number Waveform Remark

High level
1V-1.5V；
Bypass SCR
Q1,Q2,Q3,Q4,Q5,Q6
Low level
0V；

If it is found that the individual SCR is abnormally driven during the drive test, please re-check whether the
device is replaced, and check whether the corresponding drive module is damaged.

71
7 Test
This chapter mainly introduces how to test the UPS after maintenance.

7.1 Boards installation

After the maintenance of the abnormal board is completed, it needs to be installed on the whole machine for
debugging to confirm whether the single board is fixed.
Please install the repaired board on the whole machine according to the content in Chapter 5, and ensure that
the installed position is correct and the wiring is correct.

7.2 Preparation before power-on

1>Check and confirm that the veneer inside the machine is well installed.
2>Check and confirm that the internal wiring of the machine is correct.
3>Check whether the connection of the cable is tight.
4>Check that the polarity and sequence of the DC source input cables are correct.
5>Check whether all wiring is neat, whether there is looseness, and whether the binding of cables meets the
process specifications.
6>Check whether the grounding is reliable.
7>The operator must wear insulating shoes.

7.3 Power-on and testing

Step 1: Set the output voltage of the AC source to the rated input of the machine (220V/50Hz or 60Hz) and
limit the output current to 10A.
Step 2: Close the bypass circuit breaker, and after the UPS is powered on and the display screen is lit, use the
IServiceTool II monitoring software to check whether the parameters on the "parameter display" and "parameter
setting" interfaces are normal; (if it is a rack-mounted machine, skip this step)
Step 3: Close the main circuit input breaker of the machine, wait for the UPS to automatically start the
rectifier and inverter, and run in the mains inverter mode. If it is a rack-mounted machine, check the parameters of
the "parameter display" and "parameter setting" interface in this step.
Step 4: Close the positive and negative battery breaker, connect the battery pack to the UPS, and check
whether the battery voltage displayed by the UPS is normal at this time. After waiting for two minutes, measure
the battery current through the LCD panel to check whether the positive and negative battery packs start to charge;
Step 5: Click "Control" -> "Maintenance" -> "Battery Test 1" on the screen (password login is required) to
test the battery self-test mode. After the test is completed, the UPS will switch back to the mains inverter mode.
Then, click "Control" on the screen -> "Switch" -> "Disconnect output", turn off the UPS; and open the main
circuit input circuit breaker, bypass circuit breaker and battery pack circuit breaker respectively.

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 Step 6: 5 minutes after the UPS is completely powered off, re-close the battery pack air switch; press the cold
start switch until the LCD screen of the UPS lights up (about 3seconds), and then click the "cold start" button on
the screen to start the battery cold start. The UPS operates in battery inverter mode.
Note: If the machine can work normally in battery mode, mains mode, and battery self-check mode, it means
that the UPS has been repaired, and you can proceed to the next step. If the above operations are performed and
the machine works abnormally, it is necessary to further find the problem and repair it.
Step 7: Close the main circuit input circuit breaker and bypass circuit breaker, and wait for the UPS to switch
to the mains inverter mode. In the "mains inverter mode" and "battery self-test mode", the output load is 50%, and
check whether the input and output voltage and current of the UPS are normal. If the UPS can work normally, the
UPS has been repaired. If it is not working properly, then the problem needs to be further investigated and
repaired.
Reminder: If possible, try to use an oscilloscope and a isolated probe to measure the waveforms of ﹢BUS,
-BUS, INV voltage, output current, etc. during the above operation. This is more helpful to judge whether the UPS
is repaired or not.

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