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Maintenance Manual for Power Lead 2

3P Series 10-20KVA

Version 1.0
In February 2019

Shenzhen EverExceed Corporation Ltd

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Important Safety Instructions

This manual contains important safety instructions. Read all safety and operating
instructions before operating the uninterruptible power system (UPS). Adhere to all
warnings on the unit and in this manual. Follow all operating and user instructions.
This equipment can be operated by individuals without previous training.
This product designed for commercial/industrial use only. It is intended for using with
lift support and other designated “critical” devices. Maximum load must not exceed
that shown on the UPS rating label. The UPS is designed for data processing
equipment. If uncertain, consult your dealer or local representative.

WARNING OF BATTERY

The battery can present a risk of electrical shook and high short circuit current.
Following precautions should be observed before replace the battery or maintain
standard UPS.
Wear rubber gloves and boots.
Remove rings, watches and other metal objects.
Use tools with insulated handles.
Do not lay tools or other metal objects on the batteries.
If the battery is damaged in any way or shows signs of leakage, contact your
local representative immediately.
Do not dispose batteries in a fire. The batteries may explode.
Handle, transport and recycle batteries in accordance with local representative.

WARNING

Although UPS has been designed and manufactured to ensure personal safety,
improper use also can result in electrical shock or fire. To ensure safety, observe the
following precautions:
Turn off and unplug the UPS before cleaning it.
Clean the UPS with a dry cloth. Do not use liquid or aerosol cleaners.
Never block or insert any objects into the ventilation holes or other openings of
the UPS.
Do not place the UPS power cord where it might be damaged.
If there is a fire, please use the dry powder extinguisher. If you use
liquid extinguisher, there may get an electric shock risk.
Before turning on the ups, please check that whether the cable and the polarity
of the batteries are correct.

Important Tips：
When you need to replace board, please turn off ups, disconnect the main switch
and battery switch (built-in battery, please unplug at least one battery cable), wait for
10 minutes.

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Contents
1. Product Structure ............................................................... 4
1.1 Outlook ................................................................................... 4
1.2 Panel instruction ........................................................................ 6
2. Topology and System Description ............................................ 10
2.1 Topology ................................................................................10
2.2 System description ....................................................................11
3. Alarm Code ...................................................................... 13
4. Hardware Detection ............................................................ 15
4.1 Inner structure .........................................................................15
4.2 Rectifier failure ........................................................................20
4.3 Inverter failure and inverter protection ............................................21
4.4 Bypass failure ..........................................................................22
4.5 Charger failure and battery issue ...................................................22
4.6 Utility abnormal........................................................................23
4.7 Bypass voltage abnormal .............................................................23
4.8 Output overload or overload timeout...............................................24

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1. Product Structure

1.1 Outlook
Available models are shown as Table1-1:
Table 1- 1: Models
Model Nominal Power Model Nominal Power
10K long backup 10000VA/10000W 15K long backup 15000VA/15000W
20K long backup 20000VA/20000W

10KVA 15K/20KVA

Fig 1.1 Front view

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EPO
USB(option )

Parallel
(option)
RS232
Cold
start
Intelligent
button
slot
Fan

Reserved

Ground
Bypass
breaker

Input
breaker

Terminal
cover
Cable
protector

10KVA

EPO
Parallel
RS232 (option)
Cold
USB(option) start
button
Intelligent
slot
Fan
Reserved

Bypass
breaker
Input
Ground
breaker

Terminal
cover

Cable
protector

15/20KVA
Fig 1.2 Rear view

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OUT_ BYP_
PE OUT_L BAT+ BAT- IN_L1 IN_L2 IN_L3 IN_N
N L

10KVA
BYP_
IN_L1 IN_L2 IN_L3 IN_N
L

OUT_
PE BAT+ BAT- OUT_L
N
15/20KVA
Fig 1.3 Connection terminals

As shown in Fig 1.2, the rear panel provides the following components and function:
⚫ USB: B type, used to connect monitoring software
⚫ EPO: NC
⚫ Parallel port: option
⚫ Reserved: reserved for customer function, such as manual bypass, battery breaker, socket and
so on
⚫ Terminal cover
⚫ Input breaker: surge protection
⚫ Bypass breaker: surge protection
⚫ Cable protector: cable entry, fix cables, safety
⚫ Cold start: start UPS from battery
⚫ Fans: intelligent fan speed control

1.2 Panel instruction

Operation of LCD panel is very important for maintenance personnel to quickly master the UPS.
This step will greatly improve the efficiency of UPS maintenance.
Fig 1.5 is the front panel, and the panel is easy to operate UPS.

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LCD

LED indicators Button

Fig 1.5 Control and display panel

Table 1-1 showing the descriptions of controls on the control and display panel.
Table 1-1 Descriptions of controls
Controls Description
1. Press ON/OFF to start inverter when rectifier is OK
NOTE:
Not available when UPS is set in automatically start mode
ON/OFF 2. Press ON/OFF to shutdown inverter and transfer to bypass
3.Press ON/OFF to shutdown UPS completely when UPS is in
battery mode
4.Press ON/OFF to confirm setting when in setting mode
Functional button:
1. Press FUNC to page down to see LCD menu
2. Press FUNC for 2.5s at the page 1 to mute off, press again to mute
FUNC
on
3. Press FUNC and ON/OFF together for 2.5s to enter in setting mode
4.Press FUNC for 2.5s at the page 4 to clear fault
Indicators Description
Rectifier indicator: green--rectifier is normal, green flicker--rectifier is
REC
starting, dark--rectifier is not working
Inverter indicator: green--inverter is normal, green flicker--inverter is
INV starting or tracking with bypass(ECO), dark--inverter is not working
Bypass indicator: yellow—bypass is normal, yellow flicker--bypass
BYP
alarm ,dark--UPS is in normal mode and bypass is normal
Battery indicator: yellow--battery discharged, yellow flicker--No
BAT
battery or battery alarm, dark--battery is connected

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Here is the homepage of the UPS screen.

Fig 1.6 Homepage

The description of LCD menu is shown in Table 1-2.

Table 1-2 Description of LCD menu

Menu Information
Main input: voltage VAC, current A, Frequency Hz
Input information Bypass input(bypass “B” flicks): voltage VAC, current A, frequency Hz
Battery: voltage VDC, discharge/charge current A, remained capacity
Battery information
percent, battery low alarm
Output information Output information: voltage, current, frequency
: mute on/off
Alarm OVER LOAD: overload alarm
SHORT: output shorted
ECO: working in economic mode
Load: active load KW, apparent load KVA, load percent %
VER: firmware version
Load/Version/Code MODE: system mode, S—single mode, P—parallel mode, E-ECO mode,
A—self aging mode
: warning code, refer to “3. Alarm Code” to get detailed code list

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B: bypass input menu

Ohters SETTING: LCD is in setting mode
BYPASS: bypass conversion

Press FUNC to check menu:

Table 1-3 Descriptions of page
Page Description
Page 1:
Input voltage: 234VAC
Output voltage: 220VAC
Battery voltage: 259VDC
Load percent: 13%
Load percent (%), active power (KW), apparent power
(KVA) are displayed in turn
Press “FUNC” for 2.5s in this page to mute off
Page 2:
Input frequency: 50Hz
Output frequency: 50Hz
Remained battery capacity: 0%(no battery)
System MODE: S—single mode

Page 3:
Input current: 0.8A
Output current: 0.1A
Battery current: 0.0A (downward arrow—charge, upward
arrow—discharge, no arrow—no battery)
Firmware version: V0.17(17.0)

Page 4:
“B”: flicks, bypass input menu now
Bypass input voltage: 220VAC
Alarm code: 07
Press “FUNC” for 2.5s to manually clear fault

Parameters setting:
If you want to set rated parameters, press ON/OFF and FUNC buttons together for 2.5s to enter
in setting mode, “SETTING” on the bottom of LCD present and all LEDs flicks. Press the
FUNC to change the parameters, and press the ON/OFF to transfer to another parameter setting.

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2. Topology and System Description

2.1 Topology
The topology is shown in following figures.

Fig 2.1 Topology of Power Lead 2 3P Series10KVA

Fig 2.2 Topology of Power Lead 2 3P Series15/20KVA

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2.2 System description

Fig 2.3 UPS system

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(1) Transient Voltage Surge Suppression (TVSS) and EMI/FRI Filters

These UPS components provide surge protection and filter both electromagnetic interference
(EMI) and radio frequency interference (RFI). They minimize any surge or interference present
in the utility line and keep the sensitive equipment protected.

(2) Rectifier/Power Factor Correction (PFC) Circuit

In normal operation, the rectifier/power factor correction (PFC) circuit converts utility AC
power to regulated DC power for use by the inverter while ensuring that the waveform of the
input current used by the UPS is near ideal. Extracting this sinewave input current achieves two
objects:
The utility power is used as efficiency as possible by the UPS.
The amount of distortion reflected on the utility is reduced.
This results in cleaner power being available to other devices in the building not being protected
by the UPS.

(3) Inverter
In normal operation, the inverter utilize the DC output of the power factor correction circuit and
inverters it into precise, regulated sine wave AC power. Upon a utility power failure, the inverter
receives its required energy from the battery through the DC-to-DC converter. In both modes of
operation, the UPS inverter is on-line and continuously generating clean, precise, regulated AC
output power.

(4) Battery Charger

The battery charger utilizes energy from the DC bus and precisely regulates it to continuously
charge the batteries. The batteries are being charged whenever the UPS is connected to utility
power.

(5) DC-to-DC Converter

The DC-to-DC converter utilizes energy from the battery system and raises the DC voltage to
the optimum operating voltage for the inverter. The converter includes boost circuit which is
also used as PFC.

(6) Battery
If input power is failure when in normal mode, UPS will transfer to battery mode. In this mode, the
battery provide power to inverter.

(7) Static Bypass

The UPS provides an alternate path for utility power to the connected load in the unlikely event
of a UPS malfunction. If the UPS have an overload, over temperature or any other failure
condition, the UPS automatically transfers the connected load to bypass. Bypass operation is
indicated by an audible alarm and illuminated amber bypass LED. To manually transfer the
connected load from the inverter to bypass.

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3. Alarm Code
This chapter describes how to check the UPS’s status. This section also indicates various UPS
symptoms a user may encounter and provides a trouble shooting guide in the event when the
UPS appear a problem. Use following information to determine whether external factors caused
the problem and how to solve the situation.
If the UPS alarm and buzzer sound, please press “FUCC” to get alarm code on the menu of
alarm code ) on LCD. And press “FUNC” for 2.5s when at page 4 to manually clear fault.
If alarm is still existing, please refer to the Table 3-1 to solve the problem.

Table 3-1 the alarm code

Code Cause Solution
Check if the battery cables are connected correctly.
7 No battery Check if battery breaker or fuses are opened.
Check if batteries are damaged.
Manual bypass is closed, the UPS will transfer to bypass
8 Manual bypass on
and be forbidden to transfer back to inverter.
Check if EPO is closed correctly.
10 EPO
Check if EPO is activated manually.
UPS main input is abnormal.
Check if main input is normal.
Check if main input voltage and frequency is over the
working range.
16 Utility abnormal Check if main input breaker or external input breaker is
opened.
Check if the input phase sequence against.
Please recover main input power, otherwise output will be
shutdown if battery is discharged to EOD.
Check if bypass input power is abnormal.
Check if bypass input breaker is opened.
20 Bypass abnormal
Please recover bypass input power, otherwise there will be
no backup circuit when UPS is faulty.
Bypass SCR is opened or shorted, please contact with local
22 Bypass faulty
dealer.
Check the load and remove some non-critical load until the
24 Bypass overload
load is below 95%.
26 Bypass overload timeout Bypass overload and timeout, UPS will shutdown output.
Bypass voltage or frequency is over tracking range. There
28 Over synchronization could be a interruption if manually transfer to bypass or
inverter is faulty.
Main and battery or inverter and bypass transfer for 5 times
30 Over transfer times
in 1 hour.
Load is abnormal or output breaker is shorted.
Check if load is abnormal and the faulty load is shutdown.
32 Output shorted Check if output breaker is faulty.
If the faulty load is removed, please manually clear fault to
restart UPS.
DC bus over voltage, low voltage, shorted or IGBT opened.
47 Rectifier fault Please manually clear the fault and if the fault is still exist,
please contact with local dealer.
Inverter voltage is abnormal, or inverter IGBT opened.
49 Inverter fault Please manually clear the fault and if the fault is sill exist,
please contact with local dealer.

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Rectifier heat sink is over temperature or the temperature

sensor is not connected correctly.
Check if fans are working normally.
51 Rectifier over temperature
Check if anything block ventilation.
Check if the sensor is connected correctly.
Check if the environmental temp is over the range of UPS.
One or more fans are faulty or blocked.
53 Fan fault Check if all fans working normally.
Check if something blocks fan.
Inverter is overload. Please remove numbers of non-critical
55 Overload
loads, or else UPS could transfer to bypass.
UPS will transfer to bypass and if bypass overload, output
could be shutdown because of bypass overload timeout.
57 Over load timeout
Please remove numbers of loads and the UPS will transfer
back to inverter.
Inverter heat sink is over temperature or the temperature
senor is not connected correctly.
Check if fans are working normally.
59 Inverter over temperature Check if any thing block ventilation.
Check if the sensor if connected correctly.
Check if the environmental temperature is over the range of
UPS.
If bypass is over synchronization range, output could be
63 Manual transfer to bypass
interrupted if manually transfer to bypass.
65 Battery low Remained battery capacity is low when in battery mode.
Check if battery cables are connected correctly.
67 Battery reversed Check if inverter cables of battery packs are connected
correctly.
Inverter voltage abnormal or DC bus is over voltage. UPS
69 Inverter protect will clear fault automatically. If not, please contact with local
dealer.
Check if all parallel communication cables are connected
78 Parallel cables error correctly.
Charger is faulty or is not disconnected. Please contact with
81 Charger fail
local dealer.
119 Relay opened Inverter relay is opened. Please contact with local dealer.
121 Relay closed Inverter relay is closed. Please contact with local dealer.

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4. Hardware Detection
4.1 Inner structure
The Power Lead 2 3P Series10KL/S and the Power Lead 2 3P Series 20KL/S are similar in
structure. Consisting of following parts: control board, power board, charger board, bus
capacitor board, battery fuse board and EMI board, SCR board and so on. The aux power
board is welded to the power board or power transfer board. The inner structure is shown in
following figures.

Fig 4.1 Right structure of Power Lead 2 3P 10KL

Fig 4.2 Left structure of Power Lead 2 3P 10KL

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Fig 4.3 Right structure of Power Lead 2 3P 15/20KL

Fig 4.4 Left structure of Power Lead 2 3P 15/20KL

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Fig 4.5 Power board of Power Lead 2 3P 10KL

Fig 4.6 Power board of Power Lead 2 3P 15/20KL

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Fig 4.7 Control board

Fig 4.8 SCR board

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4.2 Rectifier failure

Table 4-1 Methods of detecting components
Model Components Serial number Methods of detection
Measure the resistor between pin 1
and pin 3, if the value is between
10K A phase: S1,S4 20~70Ω, it’s ok. And measure the
Rectifier SCR B phase: S2,S5 resistor between pin 2 and other
two pins, if not shorted, it’s normal,
15/20K C phase: S3,S6 and the value is usually several KΩ
or MΩ.
A phase: Q73,Q74
Using the diode measure function
10K B phase: Q71,Q72 of multimeter to measure the
voltage between pin 2 and pin 3, if
C phase: Q5,Q7
Rectifier IGBT the voltage is near 0.5V, if’s ok. If
A phase: Q1,Q2,Q3,Q4 shorted or opened, it’s broken.
Check every two pins, if
15/20K B phase: Q5,Q6,Q7,Q8
shorted, it’s broken.
C phase: Q9,Q10,Q11,Q12
A phase: R439,R423,R442,R421
10K B phase: R440,R418,R441,R425
Check the resistor value, if it is in
IGBT driver C phase: R443,R419,R444,R424
range of +/-5% of rated value, it’s
resistor
A phase: R198,R199,R202,R203 ok.
15/20K B phase: R185,R204,R196,R197
C phase: R186,R189,R185,R204
A phase: D121,D122,D131,D132
10K B phase: D123,D124,D127,D129
C phase: D125,D126,D128,D130
A phase: D46,D45,D80,D79,D51, Using the diode measure function
IGBT driver of multimeter to measure the
Zener D52,D47,D48 Zener, if voltage is near 0.7V, it’s
B phase: D71,D72,D77,D78,D83, ok. Or else, it’s broken.
15/20K
D84,D50,D49
C phase: D75,D76,D82,D81,D74,
D73,D86,D85
A phase: D134,D139
10K B phase: D135,D138 Using the diode measure function
of multimeter to measure the
C phase: D136,D137
PFC Diode voltage between pin 1 and pin 2, if
A phase: D1,D2 the voltage is near 0.7V, it’s ok. If
it’s shorted or opened, it’s broken.
15/20K B phase: D3,D4
C phase: D5,D6

Check if the sampling resistors for bus voltages are ok.

The following figure shows the sampling resistors for bus voltages.

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Fig 4.8 Power Lead 2 3P 10KL Sampling resistors for bus voltages

4.3 Inverter failure and inverter protection

Table 4-2 Methods for detecting components
Model Components Serial number Methods of detection
Using the diode measure function of
10K Q58,Q59,Q60,Q61,Q66,Q67 multimeter to measure the voltage
between pin 2 and pin 3, if the voltage
Inverter IGBT is near 0.5V, if’s ok. If shorted or
Q13,Q14,Q15,Q16,Q17,Q18, opened, it’s broken.
15/20K Check every two pins, if shorted,
Q19,Q20 it’s broken.
R329,R300,R331,R293,
10K R330,R299,R332,R292,
R333,R301,R334,R296
IGBT driver Check the resistor value, if it is in range
resistor R265,R256,R264,R257, of +/-5% of rated value, it’s ok.
R267,R258,R266,R259,
15/20K
R269,R260,R268,R261,
R271,R262,R270,R263
D8,D26,D16,D17,D14,D15,
10K
D18,D19,D9,D27,D7,D25 Using the diode measure function of
IGBT drive multimeter to measure the Zener, if
Zener D53,D54,D55,D56,D61, voltage is near 0.7V, it’s ok. Or else, it’s
15/20K D62D63,D64,D57,D58, broken.

D59,D60,D65,D66,D67,D68

Check if the sampling resistors for bus voltages are ok.

The following figure shows the sampling resistors for inverter voltage.

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Fig 4.10 Power Lead 2 3P 10KL Sampling resistors for inverter voltage

4.4 Bypass failure

Table 4-3 Methods for detecting components
Model Components Serial number Methods of detection
Measure the resistor between pin 1 and
10K Q9,Q10 pin 3, if the value is between 20~70Ω,
it’s ok. And measure the resistor
BYP SCR
between pin 2 and other two pins, if not
shorted, it’s normal, and the value is
15/20k Q21,Q22
usually several KΩ or MΩ.

Check if the sampling resistors for bypass input voltage are ok.
The following figure shows the sampling resistors for bypass input voltage.

Fig 4.11 Power Lead 2 3P 10KL Sampling resistors for bypass input voltage

4.5 Charger failure and battery issue

Table 4-4 Methods for detecting components
Model Components Serial number Methods of detection
10K F1 Measure the resistor of fuse, if near 0Ω,
Battery
15/20K fuse F1,F2 it’s ok. If opened, it’s broken.
Measure the resistor between pin 3 and
10K pin 1, if the value is between 20~70Ω,
Battery it’s ok. And measure the resistor
S7,S8,S9,S10,S11,S12 between pin 2
SCR
15/20K and pin 3, not shorted circuit is normal,
the value is usually several KΩ or MΩ.
Using the diode measure function of
10K multimeter to measure the voltage
Charger between pin 3 and pin 2, if the voltage
Q10,Q11
IGBT is near 0.5V, it’s ok. If shorted or
15/20K opened, it’s broken. Check every two
pins, if shorted, it’s broken.
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Model Components Serial number Methods of detection

10K Using the diode measure function of
multimeter to measure the voltage
Diode D9,D10 between pin 2 and pin 1, if the voltage
15/20K is near 0.7V, it’ ok. If it’s shorted or
opened, it’s broken.

Check if the sampling resistors for battery voltages are ok.

The following figure shows the sampling resistors for battery voltage.

Fig 4.12 Power Lead 2 3P 10KL Sampling resistors for battery voltage

4.6 Utility abnormal

Check if the sampling resistors for main input are ok.
The following figure shows the sampling resistors for input side.

Fig 4.13 Power Lead 2 3P 10KL Sampling resistors for main input voltage

4.7 Bypass voltage abnormal

Check if the sampling resistors for bypass are ok.
The following figure shows the sampling resistors for bypass.

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Fig 4.14 Power Lead 2 3P 10KL Sampling resistors for bypass input voltage

4.8 Output overload or overload timeout

Check if the sampling resistors for output are ok.
The following figure shows the sampling resistors for output.

Fig 4.15 Power Lead 2 3P 10KL Sampling resistors for output voltage

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