Grafenthal USV PTR-6000, Service Handbook

Page 1: ...AFENTHAL USV PTR 6000 GRAFENTHAL GmbH von Monschaw Straße 3 47574 Goch info grafenthal de www grafenthal de Copyright 2016 GRAFENTHAL GmbH Alle Rechte vorbehalten GRAFENTHAL ist eine eingetragene Marke der GRAFENTHAL GmbH ...

Page 2: ...D PARA B BOARD 11 5 7 O P RELAY BOARD 12 6 INTERFACE 13 6 1 LED DISPLAY 13 6 2 LCD DISPLAY 13 6 3 LCD DISPLAY ICON 13 7 TROUBLE SHOOTING 16 7 1 LCD PANEL DISPLAY PATTERN DEFINITION 16 7 1 1 Trouble shooting for warning icon in LCD display 16 7 1 2 Trouble shooting for fault codes in LCD display 17 7 1 3 Trouble shooting 18 7 2 REPAIR 18 7 2 1 Basic Instruments and tools 19 7 2 2 Configuration of t...

Page 3: ...3 9 2 BASIC COMMUNICATION COMMAND 26 9 2 1 QGS 26 9 2 2 V n 27 9 2 3 V n 27 9 2 4 BUSP n 27 9 2 5 BUSN n 28 9 2 6 VB n 28 9 2 7 QVFW 28 9 2 8 OC n 28 ...

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: ... in Battery Mode Voltage Distortion 6 Full Nonlinear Load 2 Full Linear Load Current Crest Ratio 3 1 Transfer Time 0ms Line Battery 0ms Inverter Bypass 10ms Inverter ECO Short Circuit Protection Yes Battery Nominal Battery Voltage 240 VDC Nominal Battery Quantity 20 pcs Acceptable Battery Quantity 18 20 pcs Type Capacity 12V 7 2Ah 12V 9Ah Backup Time 6minutes full load 4minutes full load Efficienc...

Page 6: ... 40 Humidity 95 No condensing Acoustic Noise 55dB 58dB Standard ESD IEC 61000 4 2 Level 4 RS IEC 61000 4 3 Level 3 EFT IEC 61000 4 4 Level 4 Surge IEC 61000 4 5 Level 4 Conduction IEC EN 62040 2 Category C3 Radiation Safety IEC62040 1 1 Drop ASTM D5276 94 Vibration ASTM D4728 87 Mechanical Inlet Terminal Block Outlet Terminal Block and Receptacle ...

Page 7: ...ck is the output stage of the UPS and used 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 UP...

Page 8: ... 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 directly when UPS is in maintenance status ...

Page 9: ...V 12V 5V 12V Fan and HFPW The power of 12V 5V supplies 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 Utility Battery L1 D2 D1 C1 C2 N L2 Q3 Q4 Q5 Figure 4 2 PFC Booster As shown in the Figure 4 2 when Q1 ...

Page 10: ...ltage charging the charge voltage will change to floating charge voltage in general 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 Figure 4 4 Topology of the charger Note There are two kinds of chargers for standard model UPS and long run model UPS They both apply the ...

Page 11: ... is controlled by CNTL board 5 2 CNTL board Control Board The CNTL board is the core of the UPS system It controls the actions of the semiconductors and other mechanical switches the display of the LED LCD the sound of the buzzer the communication with the computer and other important tasks 5 3 Communication board The Communication board provides RS232 USB interface to the users and it also provid...

Page 12: ...running in parallel mode 5 7 O P Relay board The O P Relay board should be installed for parallel system For single system it can be removed The board can disconnect the UPS from the output parallel system ...

Page 13: ...de LED Bypass Line Battery Fault UPS Startup No Output mode Bypass mode AC mode Battery mode CVCF mode Battery Test ECO mode Fault Note means LED is lighting and means LED is faded 6 2 LCD Display Figure 6 1 LCD Display 6 3 LCD Display Icon Display Function ...

Page 14: ...oltage Vac output voltage Vdc battery voltage Hz frequency Load information Indicates the load level 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 utility Indicates the battery is working Indicates the bypass ...

Page 15: ...15 Indicates the input voltage or frequency or battery voltage Vac Input voltage Vdc battery voltage Hz input frequency ...

Page 16: ...reliability of the UPS has occurred but these situations don t immediately lead to interruption of power supply LCD icon Flashing Alarm Possible cause Action 1 Beeping second Low battery Check the battery voltage 2 Beeping second Over load Check the loads 1 Beeping second Battery disconnected Check the battery wiring 1 Beeping second Battery Charger voltage too high Check the output voltage of the...

Page 17: ...d When bus voltage drops to 32V in a period and the situation occurs for more than two periods the fault signal will be displayed Check all the components on power board 11 None INV soft start failure Inverter voltage can t reach the setting value in 30s Check the inverter drive circuit 12 None INV voltage high When INV voltage keeps higher than 276V for 128 ms the fault signal will be displayed C...

Page 18: ... on again It is not recommended to operate the UPS under over 40 C temperature environment 42 None Internal fault CPU can not build communication and the control board is damaged Replace the CNTL board 43 Overload Check the loads and remove some non critical loads Check whether some loads are failed 7 1 3 Trouble shooting Problem Possible cause Action Battery backup time is shorten Battery not yet...

Page 19: ...n6 pin7 pin8 pin5 pin6 6K 0 1 16 1 0 0 6KL 0 0 17 0 1 1 10K 1 1 18 0 1 0 10KL 1 0 19 0 0 1 20 0 0 0 Note 1 indicates that the jumper is connected 0 indicates that nothing is connected 7 2 3 Configuration of the charger current on the charger Board The Model Port on the Charger board should be configured as follows Table 7 3 Charger current Setting List Charge current A JP06 JP07 JP08 1A 0 0 1 2A 0...

Page 20: ...arameter Setting Method 1 Connect the RS232 port of the UPS to the RS232 port of the computer with RS232 cable Choose the Start Program Accessory Communication Hyper terminal and start Hyper terminal application Set the COM port for COM1 and the other setting as Figure 7 1 Communication protocol setting Display setting Figure 7 1 Hyper terminal setting ...

Page 21: ... using output voltage regulation command INV output voltage can be regulated about 0 1V every point by using output voltage regulation command 3 Output current regulation When the UPS run into the Inverter mode with full R load measure the output current and regulate the output current which we can read from QGS command to measure value 0 2A by using output current regulation command Output curren...

Page 22: ...it Block Checked components Component Type Failure condition Power Semiconductor D2 D3 D7 D8 D11 Diode Short or open Q1 Q2 MOSFET D S short or open IC1 Power IC I O short or open Others Q28 MOSFET D S short or open F1 Fuse Open REC1 Rectifier Bridge Short or open Q6 Q15 Q28 MOSFET D S short or open D8 D16 D13 D7 D17 D18 D33 Power Diode Short or open U1 U4 Power IC I O short or open U9 U10 Power Co...

Page 23: ...be some defected components exists Please follow trouble shooting chart to debug again 7 Turn off the UPS connect utility to the UPS turn on the UPS if fail you may have start one new round of trouble shooting 8 Check and adjust charge voltage 9 Check the output voltage waveform and DC offset voltage at no load and full load condition Repair the UPS according to the trouble shooting Connect the DC...

Page 24: ... 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 25: ...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 26: ... number from 0 to 9 The units is A h DDD Output load percent For Off line UPS DDD is a percent of maximum VA not an absolute value For On line UPS DDD is Maximum of W or VA VA is a percent of maximum VA W is a percent of maximum real power j KKK K Positive BUS voltage K is an Integer ranging from 0 to 9 The units is V k VVV V Negative BUS voltage V is an Integer ranging from 0 to 9 The units is V ...

Page 27: ...ormat is Computer V n Enter UPS ACK or NAK If UPS accepts this command responds 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 inverter voltage The format is Computer V n En...

Page 28: ...mand is to adjust the battery voltage sampling value You can adjust the parameter to the sampling voltage displayed on LCD and 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 1...

Page 29: ...wise responds NAK cr Computer OC n Enter UPS ACK cr if UPS accepts this command otherwise responds NAK cr n is a number which ranging from 00 01 to99 99 means 9 9A For example Computer OC 01 Enter UPS ACK Meanings Output current sampling value will decrease about 0 1A ...