East EA990G5, Maintenance Manual

Page 1: ...EAST GROUP CO LTD EA990G5 10 30kVA 3 3 Maintenance Manual Prepared by Wu Zhifei 20220830 Checked by Luo Changsheng 20220831 Approved by Yang Lin 20220831...

Page 2: ...ingle 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...

Page 3: ...oduction 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 Alar...

Page 4: ...7 1 Boards installation 72 7 2 Preparation before power on 72 7 3 Power on and testing 72...

Page 5: ...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 tool...

Page 6: ...etwork monitoring can be realized RJ45 interface as a protocol conversion card an adapter cable is required The built in card is directly inserted into the card slot SNMP card protocol conversion card...

Page 7: ...ning 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 seri...

Page 8: ...4 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...

Page 9: ...5 Fig 2 5 The rear pannel of 30kVA UPS Tower Fig 2 6 The rear pannel of 10kVA 15kVA 20kVA UPS Rack...

Page 10: ...nel 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...

Page 11: ...een 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...

Page 12: ...to 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...

Page 13: ...gout 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 permissions Default Func...

Page 14: ...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 Ta...

Page 15: ...item Description Battery voltage V Battery voltage Battery Current A Battery current Battery status Current battery status idle discharge boost charge floating charge None Temperature Current operatin...

Page 16: ...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 powe...

Page 17: ...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 st...

Page 18: ...nufacturer 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 t...

Page 19: ...arm 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...

Page 20: ...n 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 inv...

Page 21: ...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...

Page 22: ...9999999 The user can change the password 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 sho...

Page 23: ...Select IN_DRY2 3_NO INV Transfer from the bypass to inverter Bypass Transfer from the inverter to bypass Fault clear Fault clear Batt over charge The battery is over charging the ups will shutdown the...

Page 24: ...ry type is 3 2 V lithium iron phosphate battery Rate output freq 50 50 60 Rate output frequence Rate output voltage 220 208 220 230 2 40 Rate output voltage Rate input freq 50 50 60 Rate input frequen...

Page 25: ...limit 3Hz 0 5Hz 5Hz Settable 0 5Hz 5Hz default 3Hz Self age curr precent 80 30 100 It is percentage of output current in rated output current in self aging mode Transformer coil turns ratio 1 settabl...

Page 26: ...single cells under floating charge condition Cell boost voltage 2 25 2 20 2 45 Charging voltage of single cells under boost charge condition Cell EOD voltage for 0 6C 1 65 1 6 1 85 Set according to th...

Page 27: ...eration 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 Fr...

Page 28: ...ailable 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 b...

Page 29: ...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...

Page 30: ...r 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 M...

Page 31: ...12 192200 00 Bypass output circiut 15K and 20K share board 9 30kVA IP OP board 12 201100 00 Including input filter circuit mains soft start circuit output filter circuit auxiliary power supply and cha...

Page 32: ...voltage and resistance etc Isolated probe Some Measuring voltage signals DC Source 1 Provides a current limited DC power supply AC Source 1 Provides current limited AC power Screwdrivers Needle nose P...

Page 33: ...t 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...

Page 34: ...ossible causes Approach 1 UPS triggers overload alarm Overload Remove non critical loads 2 UPS makes abnormal noise or smells UPS internal fault Please turn off the UPS immediately cut off the input p...

Page 35: ...the bypass voltage is abnormal 371 Bypass underfrequence Bypass frequency out of set range Check whether the bypass voltage is abnormal 372 Bypass phase sequence error Bypass reversed Check whether t...

Page 36: ...nnected Please check if the battery is connected 482 Battery self check fail There is an abnormal PFC alarm during the battery test Please replace the power board 483 Battrey overvoltage The battery v...

Page 37: ...and more than 10 minutes Please remove non critical loads 615 Inverter module 150 overload Inverter overload 150 and more than 1 minute Please remove non critical loads 616 Short circuit of inverter...

Page 38: ...replace the I O board 658 Inverter DSP and monitor communication failure The communication of the clock chip is abnormal Please replace the I O board 663 Emergency shutdown Emergency shutdown Please c...

Page 39: ...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 Th...

Page 40: ...36 Fig 5 3 The right side board of 10kVA standard model Tower Fig 5 4 The left side board of 10kVA standard model Tower...

Page 41: ...del 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...

Page 42: ...38 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...

Page 43: ...39 Fig 5 9 The left side board of 15kVA standard model Tower Fig 5 10 The board of 15kVA model Rack...

Page 44: ...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 s...

Page 45: ...41 Fig 5 13 The right side board of 20kVA standard model Tower Fig 5 14 The lest side board of 20kVA standard model Tower...

Page 46: ...udes 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 lo...

Page 47: ...43 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...

Page 48: ...44 Fig 5 19 The left side board of 30kVA standard model Tower...

Page 49: ...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 a...

Page 50: ...cessary 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...

Page 51: ...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...

Page 52: ...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 specificati...

Page 53: ...p 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...

Page 54: ...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...

Page 55: ...1 5V 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...

Page 56: ...B 6 PCB7 PCB8 PCB9 Zenner diode of IGBT driver ZD6 ZD7 ZD8 ZD9 ZD10 ZD11 ZD12 ZD13 ZD14 ZD15 ZD16 ZD17 ZD18 ZD19 ZD20 ZD21 ZD22 ZD23 ZD24 ZD25 ZD26 ZD27 ZD28 ZD29 ZD30 ZD31 ZD32 ZD33 ZD34 ZD35 ZD36 ZD...

Page 57: ...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 repl...

Page 58: ...el 15V 1V Low level 8V 1V Frequency 40KHz Inverter outer bridge IGBT Q7 Q8 Q11 Q12 Q15 Q16 High level 15V 1V Low level 8V 1V Frequency 20KHz Inverter inner bridge IGBT Q9 Q10 Q13 Q14 Q17 Q18 High leve...

Page 59: ...he fragile componments of 30kVA power board Components Tag Number Specifications Alternative specification Battery SCR S1 S2 S3 S4 S5 S6 S7 S8 S9 S10 S11 S12 VS 70TPSPBF Battery SCR driver module PCB1...

Page 60: ...cessary 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...

Page 61: ...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...

Page 62: ...e 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...

Page 63: ...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 Z...

Page 64: ...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...

Page 65: ...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...

Page 66: ...e 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 charg...

Page 67: ...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...

Page 68: ...ring 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...

Page 69: ...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...

Page 70: ...responding 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 circ...

Page 71: ...normal resistance should be around 20 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 gaske...

Page 72: ...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 h...

Page 73: ...acing 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 f...

Page 74: ...e resistance of the bypass thyristor SCR with the ohm gear of the multimeter The normal resistance should be around 20 If not it needs to be replaced Note When replacing the SCR it is necessary to app...

Page 75: ...ts tag number Waveform Remark Bypass SCR Q1 Q2 Q3 Q4 Q5 Q6 High level 1V 1 5V Low level 0V If it is found that the individual SCR is abnormally driven during the drive test please re check whether the...

Page 76: ...t 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 parame...

Page 77: ...bnormally 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...