Smartbitt SBOL50KTIII-3, Service Manual

Page 1: ...UNINTERRUPTIBLE POWER SYSTEM SERVICE MANUAL Smartbitt SBOL50KTIII 3 SBOL60KTIII 3 SBOL90KTIII 3 Tower Model ...

Page 2: ...2 ...

Page 3: ...f 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 ser...

Page 4: ...i ng Recharge Time 7hours Charging Current 2 0 A 10 max Charging Voltage 13 65V 1 Long run Model Type Depending on applications Numbers 32 40 Charging Current 1 0 12 0A 10 Adjustable 1 0 18 0A 10 Adjustable 2 0 36 0A 10 Adjustable Each step 2A 3 0 54 0A 10 Adjustable Each step 3A Charging Voltage 13 65VDC 1 PHYSICAL Model 30K 30KL 60KL 100KL 120KL 180KL 200KL Outline Dimension D X W X H 815 x 300 ...

Page 5: ...to convert DC power from the BUS capacitor to sine waveform output power When the utility is within the acceptable range the UPS will provide power directly from the utility input and the Rectifier and PFC will be executed at the same time When the utility is outside of the acceptable range no matter it s because of input voltage or input frequency the UPS will shut down the Rectifier and PFC func...

Page 6: ...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 directly when UPS is in maintenance status ...

Page 7: ...e tube flyback converter When Q1 and Q2 are on rectifier diodes D11 D12 are on open status and output capacitors C6 C7 supply currents to the load The primary coil of the transformer will become a pure inductor and the primary current will linearly increase to store energy in the coil When Q1 and Q2 are off primary current will stop and rectifier diodes D11 D12 will turn to close status It will re...

Page 8: ...verter The input of the three level inverter topology is two DC voltages and the output is an AC voltage as shown in the Figure 4 3 When Q1 and Q2 are on Q3 and Q4 are off the voltage of the middle point bridge is BUS When Q1 and Q2 are off Q3 and Q4 are on the voltage of the middle point bridge is BUS We can get any voltage waveform between BUS voltage from LC filter output by regulating the duty...

Page 9: ... the 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 buck converter Figure 4 4 Topology of the charger 4 5 EMI Board Input EMI board is connected between utility and the input of rectifier Output EMI board is connected ...

Page 10: ...10 n 5 Picture of the UPS 30k picture single input dual input ...

Page 11: ...11 30k UPS inner picture 60K picture ...

Page 12: ...12 60K picture 60K unit inner picture ...

Page 13: ...13 Front panel Rear panel Left panel 100K 200K picture ...

Page 14: ...14 Right side panel Top side panel 100K 200K picture ...

Page 15: ...B Table 5 1 PCBA information of Smartbitt 3 3 10 80k Ite m Mode l Part number Function Picture 1 30K 31 531408 XXG INV board 2 30K 31 531407 XXG PFC board 3 30K 200K 72 300745 XXG INV Control board 4 30K 200K 72 300744 XXG PFC Control board ...

Page 16: ...EMI board 6 30K Rack 72 300820 XXG LCD Communicatio n board 30K 60K Towe r 72 300746 XXG LCD 60K 200K tower 72 300773 XXG Touch panel 7 30K 200K 31 531225 XXG Parallel board 8 30K 31 531366 XXG SPS board 9 60K 31 531025 01G R PFC board ...

Page 17: ...17 200K 31 531252 XXG ST PFC board 10 60K 200K 31 531026 XXG INV Board 11 60K 200K 31 531253 XXG AC IN Board 12 60K 200K 31 531254 XXG Bypass board ...

Page 18: ...18 13 60K 200K 31 531255 XXG Charger board 14 60K 200K 71 600400 XXG Charger fuse board 15 30K 200K 71 304252 XXG SNMP card power supply board 16 30K 200K 71 300194 XXG EMBS board ...

Page 19: ...K 200K 71 303357 XXG 71 304615 00G for advance communicatio n board Touch panel power board Note XX in the serial number is the version of the PCB It may be modified according to releasing version in the future ...

Page 20: ...ble 6 1 LED Display MODE LED Bypass Line Battery Fault UPS Startup No output Bypass mode Line mode Battery mode Battery test ECO mode CVCF mode Fault mode means LED is lighting means LED is faded 7 2 LCD Display Figure 6 1 LCD Display ...

Page 21: ...vel by 0 25 26 50 51 75 and 76 100 Indicates overload Indicates the load or the output is short 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 Indi...

Page 22: ...nch and 5 inch and 7 inch touch panel password The Primary password is 0000 this password can set UPS function The Factory password is XXXX this password can calibrate the parameter and change all parameter Only factory and after sales Service person have this password ...

Page 23: ...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 Open Check the battery wiring 02 1 Beeping second Input Neutral loss Check the input N wiring 04 1 Beeping second line phase error Check the input wires 05 1 Beeping second Bypa...

Page 24: ...e maintain switch is open Check the cover of the maintain switch or 2 pin black black cable to the CN12 in 16 302132 XXG for 30K 80K 3C 1 Beeping second Utility extremely unbalanced There are huge gap between L1 N and L2 N or L2 N and L3 N or L1 N and L3 N Please check input voltage 3D 1 Beeping second Bypass unstable Please check if bypass voltage is stable 3E 1 Beeping second Battery Voltage Hig...

Page 25: ...t are well 04 None BUS unbalance When the difference between the Bus voltage absolute value the fault signal will be sent Maybe the PFC board is damaged Check if power components such as IGBT and SCR for the PFC and the utility power SCR are well Meanwhile check if components on the drive circuit are well 06 None PFC over current When the current of PFC Boost is over current the fault signal will ...

Page 26: ...er L3L1 output short When INV phase L3 phase L1 Line to line voltage keeps lower and output current keeps higher than normal the fault signal will be displayed 1A None Inverter L1 negative power fault When the output power on the INV phase L1 terminal is overpower the fault signal will be displayed Remove all the loads Turn off the UPS Check whether the output of UPS and loads are short circuited ...

Page 27: ...UPS detect the charger current more than 1 5A when power on the UPS Check the charger HCT 46 None Model fault The UPS can not identify the right model Check the Model Pin of the Control board is inserted correctly 47 None DSP and MCU communication Failure When the communication between the INV control board and the COMM board is interrupted the fault signal will be displayed 1 for 30K 80K old vers...

Page 28: ...f UPS and loads are short circuited Make sure the short circuit is removed and the UPS has no internal faults before turning on again 69 None Inverter Relay short circuited There isn t signal drive the Inverter Relay close but inverter output voltage over normal Check the Inverter Relay circuited 6C None BUS voltage vary fast BUS voltage drop too fast in Inverter mode Remove all the loads Turn off...

Page 29: ...he button is not pressed and hold long enough Press the button continuously for more than 0 5s Battery is not connected or battery voltage is too low or charger fails Check the charger and battery UPS failure Repair the UPS 8 2 Repair In this section some debug skills are listed to help you finding the failed components and problems as soon as possible Before proceeding the following steps we stro...

Page 30: ... for battery configuration For long run model charger s part number is 71 303981 03G XXG xx means the version of charger normally the 60KL s default charging current is 8A for battery configuration and the 100KL 120KL s default charging current is 16A for battery configuration and the 180KL 200KL s default charging current is 24A for battery configuration 8 2 3 Regulation of the system Parameter S...

Page 31: ...oint by using output voltage regulation command Notes 1 Make sure the ground of the UPS connects to earth safely during parameter regulation 2 New assembly UPS must be regulated 3 UPS which have been replaced CNTL PFC INV must be regulated again 4 All the commands use capital letters 5 All the above parameter regulation cannot be accumulated 6 All the regulation will be saved in the flash memory o...

Page 32: ...n IGBT SCR driver resistor When checking PFC section directly check the IGBT with Resistance probe or the Diode Voltage Droop probe with multimeter 30K PFC Section Checked components Instrument function Reference Value Failed condition UC1 UC2 UC3 UC4 UC5 UC6 UC7 UC8UC9 UC10 UC11 UC12 A K Resistance infinite Short G K Resistance 20Ω Short R9 R10 R24 R25 R61 R62 R76 R77 R111 R112 R126 R127 Resistan...

Page 33: ...Short or open G S Diode Voltage Droop 1 399V Short or open G D Diode Voltage Droop 1 777V Short or open G S Resistance 10KΩ Short or open D3 D4 Diode Voltage Droop 0 375V Short or open UC1 UC2 A K Resistance 1 3MΩ Short or open G K Resistance 23Ω Short or open 8 2 4 3 30K Major parameters of SPS section 30K SPS Section Checked components Instrument function Reference Value Failed Condition F4 F5 F...

Page 34: ...0 200K BYPASS Section Circuit Block Checked components Component Type Failure condition SCR SCR1 SCR2 SCR3 SCR Short or Open RLY RLY10 RLY11 RLY12 RELAY Short or Open INV FUSE F1 F2 F3 FUSE Open Note If the fuse is in open status don t replace the fuse only In most of cases open fuse is caused by other failed components Therefore before restarting the UPS you must find all failed components and re...

Page 35: ...or open D75 Diode Voltage Droop 0 29V Short or open D74 Diode Voltage Droop 0 35V Short or open Q11 Q12 S D Diode Voltage Droop 0 31V Short or open S G Diode Voltage Droop infinite Short or open G S Resistance 20KΩ Short or open 60 200K PFC Section Checked components Instrument function Reference Value Failed condition UC1 UC2 UC3 UC4 UC5 UC 6 UC7 UC8 A K Resistance infinite Short G K Resistance 2...

Page 36: ...roop 0 375V Short or open D1 D9 Diode Voltage Droop 0 415V Short or open 60 200K INV Section Checked components Instrument function Reference Value Failed condition Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 Q9 Q10 Q11 Q12 E C Diode Voltage Droop 0 38V Short or open E G Diode Voltage Droop 1 0V Short or open G E Resistance 50KΩ Short or open D1 D2 D3 D4 Diode Voltage Droop 0 372V Short or open 60 200K BYPASS Section...

Page 37: ... D17 D18 D19 D20 D21 D22 D23 D24 D27 Diode Voltage Droop 0 59V Short or open D32 D35 D25 D26 Diode Voltage Droop 0 425V Short or open 8 2 5 Output DC offset value test method RC filter for test inverter offset DC balance check 50mV output DC value 50mV 9 How To Transfer the UPS from Online mode to Maintain Bypass mode 9 1 HV30KL LV15KL mode transfer to Maintain Bypass mode R C R C R 60K 5W C 20uF ...

Page 38: ...38 HV30KL LV15KL Single Input Mode ...

Page 39: ...ff the UPS to bypass mode 2 Removing the cover of the Maintain bypass then the UPS will force transfer to bypass mode and the warning 3A will alarm 3 Close the Maintain bypass switch 4 Turn off the Input Breaker and output breaker If your UPS is Dual Input mode please also turn off the bypass breaker 5 Disconnect the Input Neutral which locked on the SPS board ...

Page 40: ...ypass mode 2 Removing the cover of the Maintain bypass then the UPS will force transfer to bypass mode and the warning 3A will alarm 3 Close the Maintain bypass switch 4 Turn off the Input Breaker and output breaker If your UPS is Dual Input mode please also turn off the bypass breaker 5 Disconnect the Input Neutral which locked on the SPS board ...

Page 41: ...in online mode please turn off the UPS to bypass mode 2 Removing the cover of the Maintain bypass then the UPS will force transfer to bypass mode and the warning 3A will alarm 3 Close the Maintain bypass switch 4 Turn off the Input Breaker and output breaker If your UPS is Dual Input mode please also turn off the bypass breaker ...

Page 42: ...e unit with battery but don t start up the unit Then send the command Noted1 Enter the S009CHMC04 0 command and click Send UPS will return D006ACK when it accept The parameter settings will be saved only when UPS shuts down normally with battery connection Noted2 The range of charger current is from 1A to 4A for one charger board The ...

Page 43: ...click Send UPS will return D006ACK when it accept The parameter settings will be saved only when UPS shuts down normally with battery connection Noted2 The range of charger current is from 1A to 12A for one charger board The command is S009CHMC01 0 to S009CHMC12 0 Noted3 the newest 40K and 80K unit each charger board is 16A so for 40K can set to maximum 16A charger current and 80K can set to maxim...

Page 44: ...44 10 1 3 PF1 0 unit with touch panel set charger current Power on the unit with battery but don t start up the unit Then send the command ...

Page 45: ...45 This parameter setting is will be saved only when UPS shuts down normally with battery connection ...

Page 46: ...46 10 2 Dynamic Password Description ...

Page 47: ...suggested you use our DC source which has power limitation function to simulate DC source to start UPS if everything is fine and almost same with the following specific data then the board repaired or replaced is fine otherwise please recheck it according to some suggestion we provide as below 11 1 What is the DC Source The Smartbitt SBOL series Unit DC Source is made up by two chargers you can us...

Page 48: ... 8 8 for LV unit c if your unit s battery number is 10pcs 10 10 for LV unit you need to send the command S010SOUTTYPE0 to set the unit from LV to HV then the battery number will change to 20pcs 20 20 as HV unit after you self test unit ok please send the command S010SOUTTYPE1 to set the unit from HV to LV Then your unit s battery number will change to 10pcs 10 10 for LV unit d Battery pcs setting ...

Page 49: ... that when UPS occurs warning code 01 it s not able to save the change So if you change the battery pack firstly UPS maybe occur warning code 01 it will not able to save the change and it will be dangerous for that charging voltage does not match the actual battery Pcs e For example we use the USB cable to send the battery pcs setting command Open the communication Tool and you will see the follow...

Page 50: ...e the UPS is saving your new parameter to the system 11 3 Start 10K 15K 20K L 30K L 40K L 60K L 80K L unit safely with standard LCD Before starting any operation please disconnect battery input no matter for standard or long run model due to its potential electricity risk Figure 8 3 1 Figure 8 3 2 Step1 Connect the DC Source output to the battery connect figure 8 3 3 Start the DC Source figure 8 3...

Page 51: ...nt beyond the scope of DC source Don t worry this is a protection measures for our DC Source Please repeat the step2 and step3 again Good luck for you Note2 If the self checking program stop in a interface long time please record the self checking step and disconnect the DC Source then release the BUS cap energy with a high power resistance Please repair the PCBA again and check the wire connectio...

Page 52: ...above the standard LCD self test step for touch panel UPS self test it is need to press the POWER ON button to start up the SPS then you can refer below picture to do the self test step Settingàadvanceàpassword 0729 àUPS self testàStart ...

Page 53: ... relay PFC 8 Check the Bypass SCR circuit PFC 9 Check the Line Voltage detect circuit PFC 10 Check the PFC Current detect circuit PFC 11 Check the BUS voltage and Battery Voltage again INV 1 Check the INV Voltage detect circuit INV 2 Check the INV Current detevt circuit INV 3 Check the Output Voltage detect circuit INV 4 Check the Bypass Voltage detect circuit INV 5 Check the Bypass SCR circuit ag...

Page 54: ...eger number 0 to 9 The units is V HHH H Output Voltage T H is an Integer number 0 to 9 The units is V II I Output Frequency I is an Integer number 0 to 9 The units is Hz JJJ J Output Current R J is an Integer number from 0 to 9 The units is A KKK K Output Current S K is an Integer number from 0 to 9 The units is A LLL L Output Current T L is an Integer number from 0 to 9 The units is A MMM M Load ...

Page 55: ...BUS voltage the format is Computer C010BUSNV NNN 0x0d UPS ACK or NAK If UPS accepts this command responds ACK Otherwise responds NAK Voltage adjustment step nnn n 000 001 999 For example Computer C010BUSNV 001 0x0d UPS ACK Meanings Negative BUS voltage will increase about 0 1 12 1 4 C010BATPV NNN 0x0d This command is to adjust the positive battery voltage sampling value You can adjust the paramete...

Page 56: ...arning of the UPS The command format is Computer P004QWS 0x0d UPS a0a1 a62a63 cr a0 a63 is the warning status If the warning is happened the relevant bit will set 1 else the relevant bit will set 0 Bit Warning a0 Battery disconnected a1 Input Neutral loss a2 Reserved a3 Input phase abnormal a4 Reserved a5 Reserved a6 Battery over charge a7 Low battery a8 Overload a9 Fan failure a10 EPO active a11 ...

Page 57: ...57 UPS 1000000000000000000000000000000000000000000000000000000000000000 Meanings The battery of UPS disconnected ...