Ladis G31 10K, Service Manual

Page 1: ...VICE MANUAL G31 10K 30KVA Tower Model REVISION DESCRIPTION Date Rev 1 0 Formal Release 2010 4 28 Rev 2 0 2012 8 9 Rev 3 0 Add 30KVA unit content 2013 9 4 Rev 4 0 Add 30KVA safe start section 2013 12 27 Shenzhen LADS Technology Co Ltd ...

Page 2: ... 5 6 O P RELAY BOARD 13 5 7 POWER RELAY BOARD 13 5 8 COMMUNICATION BOARD 13 5 9 PARALLEL BOARD 13 5 10 PANEL BOARD 13 5 11 EMI BOARD 13 5 12 MOV BOARD 14 6 INTERFACE 15 6 1 LED DISPLAY 15 6 2 LCD DISPLAY 15 6 3 LCD DISPLAY ICON 15 7 TROUBLE SHOOTING 17 7 1 LCD PANEL DISPLAY PATTERN DEFINITION 17 7 1 1 Trouble shooting for warning icon in LCD display 17 7 1 2 Trouble shooting for fault codes in LCD...

Page 3: ...make sure they could work fine 50 8 2 2 Turn on the UPS with DC source the charger work as a current limitation DC source 54 8 2 3 Turn on the UPS with utility power 55 9 APPENDIX 56 9 1 REFERENCE WAVEFORM 56 9 2 BASIC COMMUNICATION COMMAND 58 9 2 1 QGS 58 9 2 2 V n 59 9 2 3 V n 59 9 2 4 BUSP n 59 9 2 5 BUSN n 60 9 2 6 VB n 60 9 2 7 QVFW 60 9 2 8 QWS 60 9 2 9 QFS 61 ...

Page 4: ...the UPS system Interface this section shows you the LCD interface including display and setting Trouble Shooting this section gives you the way to find the problems Test Step this section tells you how to test the UPS after you repair the unit Appendix this section shows you the basic waveforms for reference and the basic communication commands 1 2 Important Safety Instructions For qualified servi...

Page 5: ...9 Ah x 20 12 V 9 Ah x 40 12 V 9 Ah x 40 12 V 9 Ah x 60 Recharge Time 9 hours recover to 90 capacity Charging Current 1 0 A 10 max 2 0 A 10 max 2 0 A 10 max 4 0 A 10 max Charging Voltage 13 65V 1 Long run Model Type Depending on applications Numbers 18 20 Charging Current 4 0 A 10 max 8 0 A 10 max 8 0 A 10 max 12 0 A 10 max Charging Voltage 13 65 1 PHYSICAL Model 10K 10KL 15K 15KL 20K 20KL 30K 30 L...

Page 6: ...If the UPS is installed or used in a place where the altitude is above than 1000m the output power must be derated one percent per 100m Product specifications are subject to change without further notice ...

Page 7: ...s convert AC input power into two stable DC power stored in the BUS capacitor In the meantime PFC Power Factor Correction will be executed and allows input current tracking the input voltage waveform Therefore the input power factor will be corrected to 1 to achieve maximum efficiency and produce lowest power pollution to the utility The PFC block in battery mode also called Booster is used to con...

Page 8: ...oise which is generated by other electronic system and prevent other systems from the noise generated inside the UPS system The SPS generates DC power supply needed by operation of the circuit of the UPS itself The Bypass provides a path that utility can power the output directly when the Inverter is not executed The Maintenance Bypass provides another path that utility can power the output direct...

Page 9: ...stable voltage to all kinds of ICs and other devices such as HCT The 12V Fan is supplied to fans and relays The HFPW supplies a high frequency power for the switch SCR IGBT driver and some other drive boards 4 2 PFC Booster N Q1 Q2 UBUS UBUS R S T Battery L1 D2 D1 C1 C2 N L2 Q3 Q4 Q5 Q6 Figure 4 2 PFC Booster As shown in the Figure 4 2 when Q1 Q2 is on and D1 D2 is off the current will increase to...

Page 10: ...he charger will control the output voltage at a constant level 13 65V 1 per battery to optimize battery recharge time and prolong the lifetime of batteries without overcharging As shown in the Figure 4 4 the battery charger applies same flyback topology as the SPS Cp C1 RS D1 Q1 DC Output TX R Phase REC Figure 4 4 Topology of the charger Note There are two kinds of chargers for standard model UPS ...

Page 11: ...11 Cx Cx Cx Cy Cy Cy Cy Cy Cy Cy Cy Cy Cy Cy IP R IP S IP T IP N OP R OP S OP T OP N L1 F1 F2 F3 Figure 4 6 Topology of the input EMI ...

Page 12: ...or 10kVA model 13 15k 20k 16 300047 XXG 1 For 15k 20kVA model 14 Communication 16 300245 XXG 1 Only one of them installed on UPS 15 16 300045 XXG 1 16 Parallel 16 300059 XXG 1 Optional for parallel model 17 Panel 16 300006 XXG 1 18 EMI Line I P 16 300077 XXG 1 For 10KVA model 19 16 300034 XXG 1 For 15k 20KVA model 20 BAT I P 16 300044 XXG 1 For 15k 20KVA model 21 O P 16 300009 XXG 1 For 10KVA mode...

Page 13: ...Communication Board The COMM board is charged of display of the LED LCD the control of the buzzer the communication with the computer and other important tasks 5 5 Charger board There are two kinds of chargers one is for standard model with 1A charge current and the other is for long run model with 4A charge current But you can set the current to 2A or 1A by changing the jumper JP1 short pin1 pin2...

Page 14: ...14 electronic systems and also prevent other systems from the noise generated inside of the UPS system 5 12 MOV board The MOV board can absorb the surge to protect the UPS system ...

Page 15: ...e mode Battery mode Battery test ECO mode CVCF mode Fault mode means LED is lighting means LED is faded 6 2 LCD Display Figure 6 1 LCD Display 6 3 LCD Display Icon Display Function Backup time information Indicates the backup time in pie chart Indicates the backup time in numbers H hours M minutes S seconds Fault information ...

Page 16: ...ort Programmable output information Indicates that the programmable outputs are working Mode operation information Indicates the UPS connects to the mains Indicates the battery is working Indicates the bypass circuit is working Indicates the ECO mode is enabled Indicates the Inverter circuit is working Indicates the output is working Battery information Indicates the Battery capacity by 0 25 26 50...

Page 17: ...ppened to the UPS indicating that some situation that may endanger the reliability of the UPS has occurred but these situations don t immediately lead to interruption of power supply LCD icon Flashing Code Alarm Possible cause Action 01 1 Beeping second Battery disconnected Check the battery wiring 07 1 Beeping second Battery Charger voltage too high Check the output voltage of the battery and the...

Page 18: ... the Battery fuse 36 1 Beeping second Inverter inter current unbalance Check the inverter 3A 1 Beeping second Cover of the maintain switch is open Check the cover of the maintain switch or 2 pin black black cable to the CN2 in 16 300076 XXG for 10K CN9 in 16 300033 XXG for 20K 3B 1 Beeping second Phase auto adapt failure Please check if phase sequence between three phase is correct 3C 1 Beeping se...

Page 19: ... the utility power SCR are well Meanwhile check if components on the drive circuit are well 11 None INV soft start failure Inverter voltage can t reach the setting value in 40s Check the inverter drive circuit 12 None INV voltage high When INV voltage keeps higher than 276V for 400 ms the fault signal will be displayed Check if power components in power INV and on the drive circuit are normal Chec...

Page 20: ...mperature is over 40 After overload or block is removed please keep UPS cool down for 10 minutes before turning on again It is not recommended to operate the UPS under over 40 C temperature environment 43 Overload The load is over the settings for certain time Check the loads and remove some non critical loads Check whether some loads are failed 46 None Incorrect UPS setting The UPS can not identi...

Page 21: ... 140V for 400 ms the fault signal will be displayed Maybe the INV board is damaged Check if power components in power INV and on the drive circuit are normal Check if IGBT protective circuit and some PFC components are normal 14 Inverter 1 Line to Neutral Output short circuit When INV 1 output voltage keeps lower than 50V and output current keeps higher than 30A for 10K is 20A for over 4 periods t...

Page 22: ... Q21 Q27 Q26 Q49 Q46 Q58 If PFC board is ensured ok after checking it may indicate there is something wrong with charger output Check if components for the battery drive signals are normal Check circuit of the utility power SCR part 24 None INV relay short circuited After Bus soft start completes and INV PWM is off more than 50V INV voltage is detected the fault signal will be displayed Check if I...

Page 23: ...al will be displayed Check if the cable between the INV control board and the COMM board is normal 48 None Two DSP firmware versions are incompatible When these two DSP firmware versions are incompatible the fault signal will be displayed Contact the distributor or service people to replace the control board with compatible version 49 None Input and output phases are incpmpatible When the UPS was ...

Page 24: ...oon as possible Before proceeding the following steps we strongly suggest to read previous section for trouble shooting first Then check the components listed in section 7 2 4 to find out which block fails ...

Page 25: ... pin2 Pin3 pin4 Pin5 pin6 Pin7 pin8 10K 1 0 0 0 0 1 10KL 1 0 0 0 0 0 15K 0 1 0 0 0 1 15KL 0 1 0 0 0 0 20K 0 0 1 0 0 1 20kL 0 0 1 0 0 0 30K 0 0 0 1 1 1 30kL 0 0 0 1 1 0 Table 7 2 Battery Number Setting List Battery Number JS3 Pin1 pin2 Pin3 pin4 Pin5 pin6 Pin7 pin8 18 1 0 0 0 19 0 1 0 0 20 0 0 1 0 Note 1 indicates that the jumper is connected 0 indicates that nothing is connected For long run model...

Page 26: ...gure 7 1 Hyper terminal setting 2 After completing the setting you can type the command in the command area 3 BUS voltage regulation Type BUSP XX command XX is two digits from 00 to 99 Then press the ENTER key and BUS voltage will rise drop about 0 1V 4 BUS voltage regulation Type BUSN XX command XX is two digits from 00 to 99 Then press the ENTER key and BUS voltage will rise drop about 0 1V 5 IN...

Page 27: ... and make debug procedures go smoothly Note Make sure that the capacitor voltage is lower than the safety voltage before disassembling any parts to do checking procedure 10k R PFC INV Section Circuit Block Checked components Component Type Failure condition DC FUSE F4 Fuse Open AC FUSE F2 Fuse Open Rectifier Q17 Q18 Q21 SCR A K Short or open R PFC D33 D35 D34 D36 Diode Short or open Q24 Q25 IGBT C...

Page 28: ... or open PFC D43 D45 D44 D49 Diode Short or open Q32 Q43 Q44 Q45 Q46 Q47 IGBT C E short or open 15k 20k INV Section Circuit Block Checked components Component Type Failure condition INV D17 D18 D34 D32 Diode Short or open Q8 Q9 Q10 Q11 Q45 Q46 Q42 Q43 IGBT C E short or open STS Q13 Q14 Q17 Q18 BYPASS SCR G K short or open for normal condition A K is 0ohm G K is around 40 ohm Q19 Q20 Q21 Q22 ECO SC...

Page 29: ...s Component Type Failure condition Line I P EMI F1 F2 F3 F4 F5 F6 Fuse Open BAT I P EMI F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 Fuse Open 30K EMI Section Circuit Block Checked components Component Type Failure condition Line I P EMI F1 F2 F3 F4 F5 F6 Fuse Open BAT I P EMI F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 Fuse Open 1A 4A Charger Section Circuit Block Checked components Component Type Failure c...

Page 30: ...Infinite or value change R164 R163 R222 R198 Resistance 2 2Ω D45 D43 D52 D54 Diode Voltage Droop 0 38V Short or open D49 D44 D53 D58 Diode Voltage Droop 0 38V Short or open D68 D69 D62 D67 Diode Voltage Droop 0 38V Short or open TVS7 TVS8 TVS9 TVS10 TVS11 TVS12 TVS13 TVS14 TVS15 TVS16 TVS17 TVS18 Diode Voltage Droop 0 53V Short or open 15K 20K PFC Section Checked components Instrument function Ref...

Page 31: ...6 D44 D49 Diode Voltage Droop 0 38V Short or open D69 D70 D71 D72 Diode Voltage Droop 0 38V Short or open TVS1 TVS2 TVS3 TVS4 TVS5 TVS6 TVS7 TVS8 TVS9 TVS10 TVS11 TVS12 Diode Voltage Droop 0 53V Short or open 30k PFC Phase T Section Checked components Instrument function Reference Value Failed condition Q24 Q25 A K Resistance 6MΩ Short G K Resistance 33Ω Short Q26 Q49 A K Resistance 10MΩ Short G K...

Page 32: ...ce 2 2Ω D33 D35 Diode Voltage Droop 0 38V Short or open D34 D36 Diode Voltage Droop 0 38V Short or open D49 D50 Diode Voltage Droop 0 38V Short or open TVS1 TVS2 TVS3 TVS4 TVS5 TVS6 Diode Voltage Droop 0 53V Short or open Q7 Q8 Q9 Q10 E C Diode Voltage Droop 0 38V Short or open E G Diode Voltage Droop 1 4V Short or open G E Resistance 25 5KΩ Short or open D22 D23 D24 D25 need be removed from PCB D...

Page 33: ...be removed from PCB Diode Voltage Droop 0 61V Short or open R45 R46 R52 R53 R131 R137 R124 R127 Resistance 22Ω Infinite or value change R47 R48 R54 R55 R125 R130 R123 R129 Resistance 62Ω Infinite or value change D17 D18 D32 D34 Diode Voltage Droop 0 38V Short or open Q13 Q14 Q17 Q18 A K Resistance 0 Short by the INV RLY G K Resistance 33Ω Short Q19 Q20 Q21 Q22 A K Resistance 6MΩ Short G K Resistan...

Page 34: ...Reference Value Failed Condition F6 Resistance 0 5 Ω Open Q6 S D Diode Voltage Droop 0 53V Short or open S G Diode Voltage Droop 0 68V Short or open G S Resistance 47 5KΩ Short or open R25 Resistance 47Ω Infinite or value change D4 D5 D6 D7 D8 D9 Diode Voltage Droop 0 53V Short or open U14 U15 D S Resistance 282KΩ Short G S Resistance 500Ω Short U5 U6 U9 U13 Diode Voltage Droop 0 6V Short U11 Resi...

Page 35: ...oken MOSFET Checked components Instrument function Reference Value Failed condition F1 F2 F3 F4 Resistance 0 5Ω Open Q13 Q14 S D Diode Voltage Droop 0 46V Short or open G S Diode Voltage Droop 1 7V Short or open S G Diode Voltage Droop 1 05V Short or open G D Diode Voltage Droop 2 1V Short or open G S Resistance 23 5KΩ Short or open R85 R87 Resistance 3Ω Infinite or value change D10 D11 need be re...

Page 36: ... 8 1 Start 10K L and 20K L unit safely Notes This operating SOP is made base on 10K standard model and 20KL long run model As Galleon 10K and 10KL almost have the same frame structure and cabinet so for 10KL long run model please refer this 10K standard model operating SOP By the same token for 20K standard model please refer 20KL long run model operating SOP also Before starting any operation ple...

Page 37: ...37 ...

Page 38: ...m PSDR board and connect some cables 20K 20KL Install the INV board Step3 Disconnect battery connection with PSDR board pack the battery cables with tape 10K 10KL Pack the battery cables with tape SPS input unplugged and packed with tape Lock output L Bypass unlock and pack with tape Disconnect Battery cables and Packed with tape Battery input terminal SPS input unplugged and packed with tape Plug...

Page 39: ...ith tape in case of electricity risk as below 10K 10KL 20K 20KL Utility input L1 and N are connected with charger input Packing with tape Input I P L and I P N terminals Utility input L3 Utility input L2 Disconnect Battery cables and Packed with tape Disconnect Battery cables and Packed with tape Packing with tape Input L1 Input N Input L3 Input L2 ...

Page 40: ...nd charger s output voltage is about 245V DC If not please check the charger 10K 1A Charger 10KL 4A Charger 20K 4A Charger 20KL 4A Charger 2 Parallel Utility input L1 Input breaker Output is about 245V DC Output is about 245V DC Utility input N Utility input N Utility input L1 Input breaker Output is about 245V DC Output is about 245V DC ...

Page 41: ...the Fans wouldn t rotate because the fan power needs a signal to drive from control board but control board was not installed in this step To confirm whether the SPS is fine or not please check if the following voltage is right for 10K 10KL U4 output should be 15V DC U5 output should be 15V DC U3 output should be 5V for 20K 20KL U5 output should be 15V DC U9 output should be 15V DC U13 output shou...

Page 42: ...ovide very limited power around 240W so please unplug the power wires of fans for PSDR board to make sure ups could be started up successfully For 10KL 20K 20KL it is unnecessary to unplug the fan power in this step 6 Turn on input breaker Press ON button for less than 0 5s the LCD will be lit confirm if the battery voltage displaying on LCD is same as actual value between 240 245V DC If everythin...

Page 43: ...R board and heat sinks Screw N of charger output to BAT of the upper PSDR board and plug 2pin wires into CN2 from bypass switch Make sure S LINE T LINE were disconnected with input L2 L3 Cover the upper PSDR board on the bottom PSDR board and Tighten the screws Step2 Screw battery input cables to PSDR board 10K 10KL Disconnect S LINE and T LINE Screw BAT Plugged Screw BAT BAT ...

Page 44: ...20K 20KL Plugged this 2pin wires which is from bypass switch into CN9 of INV board 20K 20KL Install control board Install COMMU board Plug this wire between two boards Install control board Install COMMU board Plugged Screw R BAT S BAT T BAT Screw R BAT S BAT T BAT ...

Page 45: ...0KL Step5 turn on input breaker and turn on the UPS 10K 10KL 20K 20KL Step6 unplug the fans power wires for 10K standard module with 1A charger inside but for 10KL 20K 20KL please ignore this step and goto step7 directly Do not plug this cable Do not plug this cable Do not plug this cable Press On button Do not plug this cable ...

Page 46: ...ould be started up successfully If 10K standard model is still installed with 4A charger inside then you don t need to unplug these wires here Step7 Measuring BUS voltage for 230V output if BUS voltage is not 370V please check detection circuit of BUS voltage on PSDR 10K 10KL 20K 20KL BUS 370V BUS 370V BUS 370V BUS 370V Unplug fans wire ...

Page 47: ...button for more than 0 5s the UPS is starting in line mode Measuring and checking BUS voltage output voltage as same as above Section 3 Step1 Connect back input L N cable to PSDR 10K 10KL In this step you have to disassemble the upper PSDR board before you disassemble the upper PSDR board please discharge BUS voltage first to screw input I P and Connect Bypass to PSDR board Put the probe on output...

Page 48: ...y 20K 20KL Step 2 Plug this 3 pins control wire to charger board 10K 1A Charger 10KL 4A Charger This 3 pin wire is from CN7 of contrl board This 3 pin wire is from CN7 of contrl board 20K 20KL This 3 pin wire is from CN7 of contrl board This 3 pin wire is from CN7 of contrl board Plug this 3 pin wire Screw Input R I P S I P T I P N Plug this 3 pin wire Screw Bypass Plug this 3 pin wire Plug this 3...

Page 49: ...4 Turn on the UPS 10K 10KL 20K 20KL When you turn on input breaker LCD will light automatically then you can press ON button to start ups Section 5 If UPS passes all of above testing that means the PSDR can work fine then please connect the battery back to UPS install related ventilation paper put cover back finally whole testing is over by now Input L1 L2 L3 N Input breaker Input L1 L2 L3 N Input...

Page 50: ...r for standard or long run model due to its potential electricity risk The following pictures showing how to disconnect inside batteries for 30K unit Left view Right view 8 2 1 Test Chargers to make sure they could work fine Step1 Remove all the fuses on the input EMI board and battery EMI board a 30K ...

Page 51: ...51 b 30KL Step2 Remove 3PIN charger control cable a Remove 3PIN charger control cable from the CN2 in the charger of 30K unit b Remove 3PIN charger control cable from the CN2 in charger1 of 30KL unit ...

Page 52: ...c capacitors 2 for positive BUS and 2 for negative BUS but one 4 A charger can not offer enough energy for these capacitors so we need to change the BUS capacitors connection to start the unit with a 4A charger Before the modify be sure the voltage of the capacitors dischaged completely a There are 2 electronic capacitors for positive BUS and 2 for negtive BUS please refer the picture below ...

Page 53: ... capacitors for BUS one for positive the other for negative Step5 Test the charger supply the charger with turn on the input breaker With the utility power connected the bypass breaker must be kept at OFF and then test the charger ouput voltage at the terminals on the battery EMI board the voltage is about 245V DC Otherwise please check the chargers Becareful the electricity on the Input EMI board...

Page 54: ...eaker wait a few seconds then put the battery fuses KLKD 30 back to the battery EMI board Turn on the input breaker Step3 Press the ON button to set up the power supply for the UPS UPS will enter to power on mode After initialization UPS will enter to No Output mode then Press and hold the ON button for 0 5s to turn on the UPS and the buzzer will beep once A few seconds later the UPS will be turne...

Page 55: ...rd connect the wire that removed at step3 of 8 2 1 to P103 on INVR S board connect the 3PIN cable back to CN2 on charger1 For 30K unit assemble the neutral cooper bar back to the capacitors terminals Step2 Close the input breaker and bypass breaker turn on the unit by press ON on the Keyboard Step3 If UPS passed all of above testing that means the UPS can work fine please connect the batteries bac...

Page 56: ... result in section 8 CH1 IP SCR driver CH2 IP voltage CH3 BUS voltage CH4 BUS voltage Figure 9 1 Switch on the input breaker without turn on CH1 INV voltage CH2 IP voltage CH3 BUS voltage CH4 BUS voltage CH1 INV voltage CH2 Battery voltage CH3 BUS voltage CH4 BUS voltage AC mode transfer from Bypass mode Battery mode Figure 9 2 Turn on the UPS ...

Page 57: ...H3 VGE PFC PWM CH4 VGE PFC PWM CH1 INV voltage CH2 Battery voltage CH3 VGE PFC PWM CH4 VGE PFC PWM AC mode Battery mode Figure 9 3 PFC PWM CH1 INV voltage CH2 IP voltage CH3 VGE INV PWM CH4 VGE INV PWM Figure 9 4 INV PWM ...

Page 58: ...r from 0 to 9 The units is A DDD Output load percent DDD is Maximum of W or VA VA is a percent of power W is a percent of maximum active power KKK K Positive BUS voltage K is an Integer ranging from 0 to 9 The units is V VVV V Negative BUS voltage V is an Integer ranging from 0 to 9 The units is V SSS S P Battery voltage S is an Integer ranging from 0 to 9 The units is V XXX X N Battery voltage X ...

Page 59: ...ACK Otherwise responds NAK Output Voltage n n is 208 220 230 240 Default status Nominal output voltage 220V It can be set only in bypass mode For example Computer V230 Enter UPS ACK Meanings set output nominal voltage to 230V 9 2 3 V n This command is to adjust the nominal output voltage The format is Computer V n Enter UPS ACK or NAK If UPS accepts this command responds ACK Otherwise responds NAK...

Page 60: ...d the real battery voltage The format is Computer VB n Enter UPS ACK or NAK If UPS accepts this command responds ACK Otherwise responds NAK Voltage adjustment step n n 00 01 99 For example Computer VB 01 Enter UPS ACK Meanings Battery sampling voltage will decrease about 0 1V 9 2 7 QVFW QVFW means to request the version of the firmware The command format is Computer QVFW Enter UPS VERFW NNNNN NN N...

Page 61: ...xample Computer QWS Enter UPS 1000000000000000000000000000000000000000000000000000000000000000 Meanings The battery of UPS disconnected 9 2 9 QFS QFS means to request the latest fault occurred of the UPS The command format is Computer QFS Enter If no UPS fail occurred UPS OK cr If UPS fail occurred UPS KK PPP P FF F OOO O EE E LLL CCC C HHH H NNN N BBB B TTT T b7b6b5b4b3b2b1b0 cr Data Description ...

Page 62: ...Temperature of the detecting pointers T is an integer ranging from 0 to 9 The units is C b7b6b5b4b 3b2b1b0 Ups status b7 DC to DC is on b6 AC to DC is on b5 Inverter is on b4 Reserved always 0 b3 Reserved always 0 b2 output relay is on b1 Reserved always 0 b0 Reserved always 0 Example Computer QWS Enter UPS 01 208 3 50 0 000 0 0 0 000 000 0 300 0 290 0 245 5 028 0 01000000 cr Meanings The fault is...