UPS USER MANUAL

F-20
LARGE ONLINE DOUBLE
CONVERSION UPS
20kVA / 30kVA / 40kVA


Safety Introduction

Please keep the safety sheet properly. No allowance for operation is permitted before the reading of
all the safety and operation introductions. All the warnings and operation introductions included in the
Customer Manual shall be strictly followed.

Installation Safety

1. This apparatus shall be installed by the professional maintenance personnel under the instruction of
the safety introduction,

2. The weight capacity of the floor to support the apparatus and the battery pack shall be considered
before installation.

3. Consult the specification list on page 20 for the specifications of wire and air switch.

Operation Safety
1. Leakage current. Put to earth connection before connecting to the power supply.

2. Warn: Electric shock danger

To avoid electric shock, dont open the cover board of the apparatus before cutting the mains supply input
switch, by-pass switch, and battery switch.

3. Warn: dont expose the accumulator to fire. It may explode.

4. Warn: dont open or break down the accumulator since the electrolyte released may damage eyes and skins, or
even cause poisoning.

5. Dont block or insert in the intake or other apertures with any things. Keep spacing intervals around the
UPS in installation in favor of the air circulation and heat rejection. Avoid of the direct sunlight.

6. Keep a clean working environment and avoid environments of humidity, flammable gas, liquid, or corrosive
materials.

7. Antistatic gloves must be worn on during any operation on PCB.

 Contents

Chapter One: About UPS.........................................................................................................................P5

1Electrical Specification......................................................................................................................P7
2Technical Performance and Feature...................................................................................................P9
3, UPS Framework and Appearance.......................................................................................................P10
4, Workings of UPS................................................................................................................................P13
5, Hardware Components and Functions.................................................................................................P16
6, Details of Link of Power Line, Data Line ...........................................................................................P17
7, Communication Interface and
Monitoring...............................................................................................................................................P19

Chapter Two: Installation........................................................................................................................P20

Part of Single Unit...................................................................................................................................P20

1, Inspection of the Accessories...............................................................................................................P21
2, Examination of the Installation
Environment............................................................................................................................................P21
3, Examination of the Environment for Pow distribution ............................................................................P22
4, line sewing, and installing..................................................................................................................P23
5, Startup debugging...............................................................................................................................P25
6, Setup and inquiry of UPS LCD.........................................................................................................P28

Part of parallel installation.....................................................................................................................P29

1, examination of the equipments and accessories................................................................................P30
2, confirmation of the installation environment...........................................................................................P30
3, lines connection.................................................................................................................................P30
4, startup debugging for the single unit..................................................................................................P30
5, connection of the parallel lines...........................................................................................................P31
6, examination of the input and output
connection................................................................................................................................................P31

Chapter Three: Repair and Maintenance

1, item number and amounts of the parts...............................................................................................P34

2fault code and warning code............................................................................................................P34
3Examination and repair standard for PCB..............................................................................................P40
4time-order list for the startup under mains..........................................................................................P42
5repair and maintenance of single UPS.............................................................................................P45
6Repair of the doubling UPS.............................................................................................................P49
Introduction
1, Electrical Specification (take 20K for example, the30K,40K series are of similar specifications)

model 3w3 IX 20K

rating capacity 20KVA / 16KW
Output waveform sine wave
Switching interval Zero interrupt
Input
distribution Twin-channel mains supply input
system
210 475 Vac
Startup voltage range
Three-phase four wire& earth connection
Standard voltage 380Vac

Bypass voltage range 323 Vac 437Vac

Frequency of standard
50Hz/60Hz
mains supply input
Input
Synchronizing
frequency range of 50/60 Hz 4Hz
mains supply

Input power factor >0.99

Inbuilt input
isolation none
transformer
45.67Amp (Max)
input electric current
130% overload, minimum input voltage )
voltage 380Vac / 220 Vac (3 4 4W)
power factor 0.8
Voltage
2%
stability
output Full-load
voltage <2% (R Load)
precision
Output voltage 200/208/220/230/240(At 200V and 208V, default 10%
adjustable de-rating)
 Current peak 3:1
coefficient
Unbalance load 100%(unbalance load available)
frequency (46~54)Hz / (56~64)Hz

(500.05 )Hz / (600.05)Hz (bat mode)

System ECO mode UP TO 98 %
efficiency Line mode: UP TO 93 %
Bat mode: UP TO 93%
Parallel redundancy Perfect parallel redundancy with maximum capacity of 8 parallels
DC startup DC startup is available both for single or parallel mode
Auto restart Auto restart when mains supply recovers
By-pass protection When UPS fault, overload, or battery exhaustion is occurred,
by-pass input is transformed automatically
Excess-temperature protection Fan s rotational speed sensor together with TDS to avoid excess
temperature

Output short protection Available

Overload capacity
Communication interface
Line mode Input turns to bypass mode and alarm signals
after 10 minutes of keeping110%<Load^
125%; Input turns to bypass mode and alarm
signals after 1 minute of keeping
125%<Load^150%; Input turns to bypass
mode and alarm signals after 0.5 S of keeping
Bat mode Load>150%
Input turns to bypass mode and alarm signals
after 10 minutes of keeping110%<Load^ 125%;
Input turns to bypass mode and alarm signals
after 1 minute of keeping 125%<Load^150%;
Input turns to bypass mode and alarm signals
after 0.5 S of keeping Load>150%
Standard RS-232 interface 1
Standard RS-485 interface 2
Standard AS-400 interface 1
SERIVICE interface 1
Intelligent slot 1

Software monitoring Download Winpower monitoring software from Reros website

freely or purchase the Webpower intelligent monitoring card for
intelligent management or integral and remote monitoring.
 Operation Working 0 40
environmen temperature
t Storing -25 55
temperature
Working humidity 5% 95%
Altitude 0-1000 meters above sea level (if altitude is above 1000 meters,
the output shall decrease in proportion to the increase of altitude
with 1% decrease to 100-meter rise)
noise <55dB (70% load, 1 meter right ahead)
Panel display LCD to display the operational parameters (auto set is available)
With Chinese and English as the working language; simple
operations
lightening proof grade Grade IV of IEC1000-4-5 Standard (the max level)
EMC Standard IEC61000-4-2(ESD) antistatic level Level 4
IEC61000-4-3(RS): radio-resistance level Level 3
IEC61000-4-4(EFT) power pulse interference resistance
Level 4
IEC61000-4-5(Surge) anti-lightening/surge level Level 4
IEC62040-2 C3

Bat Standard Bat 12V x (28/30/32 is only optional) in series

Parameter battery unit for yes
parallel use
Rated voltage 336/360/384Vdc
Charger s +/-216Vdc(32 batteries)
charging voltage
charging current 4.5A
pair to generator The pair to generator is acceptable. Collocate generator 2. 2
times above the UPS rated capacity; 5-10 times is advised.
Size (W x D x H)mm 633.5*420*956
Net Weight kg

2,Technical performances and features

2.1, Product Description
3W3 IX 20K-40K series are tower-structure online UPS aimed at the lower-end customer of
enterprise network, data room and most users in industrial fields. The series products are categorized into 20K,
30K, and 40K, which are the upgrade of the existing 3W3 IX 20K/30K / 40K products.
2.2 ,Product functions and features
> Chinese menu on LCD
> ECO function
> two- supply input
 > Intelligent Bat management including the capacity, optimum charging mode, enough charging
capacity and low voltage alarm.
> battery unit share for parallel use
> perfect output management and EPO
> direct parallel extension that does need no external parallel connection card and the max amount
is 8

3, UPS Framework and Appearance

3.1. internal routing
3.2. block diagram of system function

3.3. overall framework

3.4 . PSDR framework chart

3.5. CHGR framework chart

communication interface
 LCD and Operation panel

4, Working modes of UPS

4.1. Line Inversion Mode
This mode is the normal state of UPS operation in which UPS rectifies the input mains supply to
DC and boosts and inverts to AC for stable power output.
 The flow chart is as follows
BYPASS FOR MAINTAINCE

4 .1. Battery Inversion Mode

This mode refers to that when the input mains supply is abnormal and the main lines rectifier
SCR cuts, then the battery inputs through BAT SCR to booster and inverter for stable power output.
The flow chart is as follows
 BYPASS FOR MAINTAINCE

4.2. Bypass Mode

This mode is that when the UPS operation is abnormal while the bypass input is normal, the
main lines rectifier SCR cuts and the bypass inputs through STS to load
 supply. The flow chart is as follows
BYPASS FOR MAINTAINCE

4.3 Bypass for Maintenance Mode

This mode is that when fault is occurred to UPS, the mains supply through maintenance
switch for load, which enables the maintenance personnel carrying out repair and maintenance
under the condition of not cutting the load supply. The flow chart is as follows
4. 4 ECO Mode
 This mode is only used when the mains supply input and bypass input are both normal to increase the
overall efficiency. Under this mode, the rectifier, booster and inverter are all in work but the inverter does
not output. The flow chart is as follows
BYPASS FOR MAINTAINCE
7, Communication Interface and Monitoring
3W3 IX series have a multitude of communication interfaces including the external interfaces like RS232
RS485, Intelligent Slot, and AS400, among which the intelligent slot can be installed with WebPower card
(optional) and USB+RS232 card. These interfaces may help the user to monitor the UPS state with computer.
7.1 Standard RS232 interface, with an effective transmission distance of 15m, can be used with the graphic
WebPower monitoring software of Reros .
7.2 Standard RS485 interface, with an effective transmission distance of 1.2 km, can be used with WinPower
for remote or integral control of the UPS .
7.3 AS400 interface: use this interface on UPS to monitor the power supply
7.4 Intelligent Slot, together with WebPower card, enables you carry out the remote control and management
of UPS through Internet.
7.5 USB+RS232 card: an extension monitoring interface, through which the graphic Winpower software can
monitor the UPS.

Note: RS232 And RS485 use the same channel, that is, the two cannot be used in the same time; RS232 or
RS485 does not share the same channel with intelligent slot.
 Chapter Two Installation
(Single and Parallel)

Part of single unit

Operation Instruction:
A: 3 w3 IX series single installation SOP refers to the whole process from the installation engineer
arriving at the spot to finishing the filling of Startup Debugging Register List.
 B: The unpacking, electric power layout for the distribution box and the nose for lock line shall be done by the
dealer.
The installation of 3 w3 IX series UPS must be done by the installation engineer authorized by Reros Company.
basic procedure of the spot installation :

1, Check the Accessories

1 Check the appearance, if there is any improperness to the apparatus due to transportation and so
on, dont start the equipment and please contact the carrier and dealer.
2 Check the completeness of the accessories to the apparatus. The accessories include:
A: a WINPOWER disc

B a user s manual

2, Examination of the Installation Environment

1 whether the temperature and humidity excesses the technical specification or not (temperature: 0C
40C; RH: 20% 90%)
2. Whether the installation place is vibrating or susceptible to collision
3. Whether there is metallic powder, corrosive material, salt, or flammable gas
4. Whether there is direct sunshine
5 whether the altitude is above 1000m (if is, decrease the rate according to the following chart)

Altitude(M) 1000 1500 2000 2500 3000 3500 4000 4500 5000
Load 100% 95% 91% 86% 82% 78% 74% 70% 67%
Coefficient

6. keep the good ventilation for the installation of UPS. The space between the rear board of the
apparatus and the obstacle shall be at least 50 cm, and the space between the side boards and the
obstacles shall be at least 10 cm.
3, Examination of Power Distribution Environment
1. the following standard of wire layout is advised

Rated input fire wire Input zero line output fire output zero line Battery line Ground wire
model
power width width wire width width width width

20KVA/16 10AWG/6mm
3W3 IX 10AWG/6mm2 8AWG/10mm2 2 8AWG/10mm2 8AWG/10mm2 8AWG/10mm2
20KVA KW

30KVA/24 8AWG/10mm 6AWG/16mm2

3W3 IX 8AWG/10mm2 6AWG/16mm2 2 6AWG/16mm2 8AWG/10mm2
KW
30KVA

40KVA/32 6AWG/16mm 4AWG/25mm2

3W3 IX 6AWG/16mm2 4AWG/25mm2 2 4AWG/25mm2 8AWG/10mm2
40KVA KW

2.the following specification for air switch is advised

model Rated power mains supply bypass supply Output air switch Battery air switch
input air switch input air switch

20KVA/16K 3P63A/380VAC 3P100A/380VAC 3P100A/380VAC 3P125A/250VDC

W
3W3 IX 20KVA
30KVA/24K 3P80A/380VAC 3P100A/380VAC 3P100A/380VAC 3P150A/250VDC
W
3W3 IX 30KVA
40KVA/32K 3P100A/380VAC 3P100A/380VAC 3P100A/380VAC 3P200A/250VDC
3W3 IX 40KVA W

3. examination of i/o three-phase fire wire, zero line and ground line

3.1 confirmation of input three-phase fire wire, zero line and ground line

1) Generally, the ground line shall be led from the ground line block of distribution box, so the
resistance between ground line and the block of distribution box can be checked with the
 universal meter, and the resistance value shall approach to 0 ohm.
2) Zero line shall be led from the zero line block of distribution box.If the user dont made N and G short,
then the resistance value between N and G can be tested with the universal meter, and the value
fluctuates from 10 odd to 100 odd; or the voltage of three-phase line and zero line. The value of voltage
is about 220V, and the voltage of N and G generally shall be below 2 V.
3) The standard voltage between fire line is 380V, and the actual voltage is determined by the userpower
distribution. The phase order can be affirmed with the phase-order meter.
4) If the input three-phase fire line, zero line and ground line have been checked and examined,
please signal with corresponding marks.
3.2 confirmation of battery polarity and voltage
1) The polarity of battery can be judged with the universal meter. After the confirmation, make
marks for the positive and negative polar.
2) The voltage of battery can also be judged with the universal meter. Generally, the voltage of a
new 32-cell battery is between 410 and 420V. If the value checked to be too high or too low,
please find out the reason.
3) Judge the N line according to the voltage of battery. The line that the voltage between it and
other two lines is just half of the total voltage is the N line.
4) Check the number of battery, the width of battery line, and the connection.
5) Use the universal meter to check whether there is a short between the positive and the negative, N, and
the ground. If the battery is installed in two or more battery box, please notice the connection between
boxes.
4, line sewing, installing
1 Select the following connection modes according to the user s demand
(two-supply input, one supply input, single mode or parallel mode)
2. installation steps
2.1 Open the front door, and demount the terminal block cover board
1.1 UPS input wiring connection: confirm that the air switches of mains supply input, bypass supply input are
OFF in the distribution box, and then connect the two groups of wires marked with A B C N G with
the UPS mains supply input end and bypass input end correspondingly, then tighten the screws.
1.2 UPS output wiring connection: confirm that the distributions switches are OFF in the distribution box, and
then connect wires marked with A B C N G with the UPS correspondingly
1.3 Battery unit wiring connection: put the DC switch into OFF position, then connect the positive pole marked
+of the battery unit with the +terminal in the UPS terminal block, and the negative pole marked
- of the battery unit with the - terminal, and N pole with N mark of the battery unit with N terminal,
then tighten the screws.
2.2 After the confirmation of the right connections, fix all the wires with binding wire on the binding wire frame.
5. Startup debugging
2 confirmation before the startup
2.1 Put the battery air switch to the ON position, use the universal meter to re-affirm the battery polarity. Put the
air switch to the OFF position if there is no fault.
2.2 Use the phase-order meter to confirm the phase of input electricity (if any fault is occurred, please find out the
reason such as the lead wire fault, or mark mistake), then check the wire voltage (A-BA-CB-C), and phase
voltage (A-NB-NC-N) with universal meter(the wire voltage is about 380V, and the phase voltage is about
220V). If any fault is occurred, please find out the reason at once.
2.3 N, G voltage is generally below 2V (if N and G are of short circuit, then it shall be 0V, the resistance value
approaches to 0 ohm). If any abnormity is found, please figure out the reason.
2.4 If the above steps are correct, conduct the startup debugging.
 3 start and close the apparatus in DC condition
3.1 Push the battery air switch to ON position, then touch the ENTER on panel.At this time, the back lighting
lightens, fan rotates, and words like UPS Self-examination, please wait are displayed on the panel. If abnormity
is found, please figure out the reason immediately (whether the battery is connected, or the DC startup has been set
or not).
3.2 When the self examination is finished, choose Start on the panel and press the ENTER key for the choosing
of starting the machine with DC. Then words like DC starting, please wait. shall be displayed on the panel and
then the UPS enters into the battery mode for working. (Notice: DC startup shall be executed within 40 seconds after
the LCD self examination. If no action is conducted within 40 seconds, UPS will cut off power automatically.)When
the UPS enters into invert battery mode, the signal lamp of battery and inverter on the panel will lighten and the
buzzer will sing every 4 seconds.
3.3 Check whether the parameters on the panel are correct. Use the universal meter for the examination and
register the parameters like UPSs input voltage and frequency.
3.4 If the UPS works well under the battery mode, select turn off the machine on the panel and make sure, then
the UPS doesn't input, but the back light still lightens.
2. The back light of panel will go out about 1 minute after the turn-off of the battery, and the fan stops rotating.
When the fan stops rotating totally, push the air switch of battery to OFF position.
4 AC start and turnoff
4.1 Push the mains supply input air switch and bypass air switch to ON position, then the panel of UPS lightens,
and the fan rotates. Words like UPS IN SELF EXAMINATION, PLEASE WAIT will be displayed on
the panel.
4.2 Enter the startup menu three minutes later, press ESC to escape the menu and check the parameters under
bypass, and enter the SET for the setting of corresponding parameter according to the actual demand. When
the setting is finished, press ENTER and ESC to escape. Choose Start up on the panel and the LCD will
show Starting up, please wait . Several minutes later it will enter into the mains supply invert mode and
the panel displays right supply, no battery linked.
4.3 After the inversion, please check whether the input and output voltage of UPS is normal. Then push the
battery air switch to ON position, and the UPS does not alarm any more. Check the battery parameter on the
panel and you can see that the battery state shall be in charge and the charging current is determined by
the battery saturation. If there is anything wrong, please check the battery and the UPS state. Use the
universal meter to check the charging voltage (13.5V for each cell). If the value is not in the range, please
check on the panel whether the charging voltage setting is correct.
4.4 Check whether the parameters on the panel are correct, and use the universal meter to test and register the
output voltage, frequency, and charging voltage.
4.5 Shift between mains line mode and battery mode. UPS works normal under the mains supply mode, then
turn off the mains input switch, UPS turns to battery mode. Turn the mains supply input air switch of the
UPS ON, UPS turns back to mains supply inversion mode. Operate the shift for three times. After the shift
test, UPS keeps working in the mains supply inversion mode.
4.6 After the normal operation under no-load mains supply/ battery mode shift, carry out the loading test. (If
theres no condition for carrying out such a test, do not conduct this operation) Load on the UPS, and check
whether the parameters on the panel are correct. Use the universal meter to test the output voltage and
frequency of UPS.If the values are normal and the apparatus operates well will normal load 15 minutes later
everything is ok and register down the corresponding data
4.7 Turn off the machine in Mains supply mode. Execute the turnoff order on the panel, when enters into the
bypass and then turn off the mains supply switch. At this time, the back light of the panel still lights, and fan
rotates. One minute later, the back light goes out and fans stops rotating. Cut off the power supply switch when
the fan stops rotating totally.
4. 8 Start the UPS again to the mains supply inversion mode after the cutting off power.
4.9 Carry out basic training for the user, including how to start the UPS, turn off the machine, inquire
information on the panel, deal with the basic faults, maintain the battery, how to call for repair when faults
occurred.
4.10 Fill the registering list one by one according to the startup debugging. And ask the user to sign for
affirmation.
4.11 Put back the cover board of the terminal block on the UPS, lock the front door and clean up the spot.
 Note: explanation about the setting of AS400 card in the maintenance setting: the AS400 card of CATLE EX
series UPS can be reset according to users need. When in setting, PORT refers to the relayer 1-4 of AS 400,
which shall not be changed, the function number stands for the programmable contents can be chosen with the
corresponding function number. The number in the parenthese is the function number.

AS400 Contract
[1] UPS ON V 1.5

[2] 5: Battery mode ... V 1.5

[3] 6: Bypass on ... V 1.5

[4] 9: Shutdown active ... V 1.5

[5] 10: Fault... V 1.5

[6] 11: INV-Fault... V 1.5

[7] 12: Bypass-Fault ... V 1.5

[8] 13: Charge Fail ... V 1.5

[9] 15: Temp. Warning ... V 1.5

[10]16: Battery backup time below min.valueV 1.5

[11]18: Overload ... V 1.5

[12]20: Line Loss ... V 1.5

[13]21: Bypass Loss.. V 1.5

[14]22: Batt.Temperature ... V 1.5

[15]25: Battery 25 ... V 1.5

[16]26: Battery 50 ... V 1.5

[17]27: Battery 75 ... V 1.5

[18]28: Battery 100 ... V 1.5

[19]29: Load 25 ... V 1.5

[20]30: Load 50 ... V 1.5

[21]31: Load 75 ... V 1.5

[22]32: Load 100 ... V 1.5

[23]33: Load 105 ... V 1.5

[24]35: General Alarm ... V 1.6

Parallel Installation
3W3 IX series boast of perfect parallel function and the following characteristics:
a .maximum for six machines parallel
b.battery unit share for parallel mode
c .DC startup in parallel mode is available
d .start any one of the parallel unit, start all the machines under the parallel mode
e .Inbuilt parallel card
 1, Examination of the spot machine and accessories
After the arrival at the spot, check whether the single and accessories are complete or not
according to the single unit standard. The parallel mode needs parallel line.
2, Examine the installation environment according to the single unit requirement. The distribution
switch and the wiring width are determined by the actual amount of machines and load.
3, Make sure that all are in accordance with the specifications and link the wirings as follows.( Take
two machines for example. Notice that the input and output air switches are OFF, the N lines of
mains supply input and bypass input are linked together, the output N lines are linked together.)

4, Single Start Debugging

4.1 ,Test the single UPS according to the above-mentioned ways. If the single does not work normal,
do the parallel requirement test.
4.11 Invert voltage adjustment: use the universal meter to test whether the output invert voltage is
within 2200.5V or not at the input terminal. If it is in the range, theres no need for adjustment. If it is out of
the range, then readjust the invert voltage to the required range by the Inverter Voltage Adjustment in the
Balance Adjustment.
4.12 After the readjustment of the parameters, escape the set and turn off the machine. Then the
machine enters into bypass mode, push the line input air switch and bypass input air switch to OFF, the
machine is cut off power totally.
4.13 Register down all the data after the debugging.
4 2 ,Parallel setting ( all the UPS setting in the parallel system must be the same)
After the single debugging, conduct the parallel setting:
4. 21 UPS address setting: settingmaintenance codeother settingaddress setting. The range of
setting is 1-8, and the address shall not be the same in the parallel system
4. 22 Parallel mode setting: settinguser codeother settingparallel mode, and choose ON.
4. 23 ECO mode setting: Settinguser codeother settingECO, and choose OFF.
4. 24 Line Support Setting: settingmaintenance codeother settingline support, and choose OFF.
After the setting, push the UPSs line input air switch and bypass input air switch to OFF.

5, Parallel wire connection

Connect the parallel wire in a mesh as the following chart.
6, confirmation of the correctness of i/o connection wire:

6, 1 Input connection wire : push the UPSs input line air switch and bypass input air switch to ON
position(the total input air switch OFF), and use the universal meter to test the resistance value
between A-A B-B and C-C of line input and bypass input on the UPS terminal block. If the value
is below 1 ohm, it means that the connection is correct. After the confirmation, push back the air
switches to OFF. (Notice: the main line input or bypass line input shall come from the same source in
the parallel system)
62 Push the single input air switch of each UPS ON in the parallel system, use the universal meter to
test whether the resistance value between A-AB-Band C-C of line input and bypass input on the
UPS terminal block approaches 0 ohm. If it is, it stands for that the connection is right. After the
confirmation, push the air switches OFF.
6. 3 If the UPS is with input transformer or output transformer, the above-mention 2 steps are not
applicable. Push the line input air switch of UPS in the distribution box ON, bypass line input air
switch ON ( the line input and bypass input air switch on the UPS OFF), and use the universal meter to
test the voltage between A-AB-BC-C of line input and bypass input on the terminal block. If the
value tested is over 0.5%, please check for reasons.
7 , Push the UPSs line input air switch, bypass line input air switch, and battery air switch ON in the
parallel system, when the UPS enters into the bypass mode, use the universal meter to test the output
voltage of corresponding L line and make sure the voltage difference is within 2V.
8 , Push back the UPS input air switch, and choose any one of the parallel system to start the machine, the
whole system enters into the Line inv mode. Check the LCD panel of each UPS if normal in the system
and register down the corresponding data.

9 , After the registration of all parameters, choose any one of parallel system to turn off the machine in the
parallel mode and press ENTER, UPS will turn off and enter into the bypass mode if the bypass supply is
normal; if the bypass supply is abnormal, then it will enter into the STANDBY mode. Push the line input
and bypass line input air switches OFF, one minute later, the LCD panel and the fan stop working. Push
the battery air switch OFF, the UPS cuts off power totally.

10,After the test of start and turnoff, push the battery air switch, line input air switch, and bypass line air
switch to ON positive in succession. When the machine enters into the bypass mode, choose START on
the panel and the parallel system will come to work and enter into the line invert mode.
 Chapter Three Repair and Maintenance

One :Item code and used amount

 1 ,3w3 IX - 20K Overall Item Code 9106-5259-00P

number item code description amount

1 710-02168-00P CCB-SIGNAL 1
2 710-02167-00P CCB-POWER 1
3 710-02827-00P PSDR 3
4 710-02829-00P CAP 6
5 710-02830-00P INDUCTOR 3
6 710-02323-00P CHRG 1
7 710-02324-00P CHRG CNTL 1
8 710-02826-00P STS 1
9 710-02600-00P INTERFACE 1
10 710-02680-00P PARALLEL-INTERFACE 1
11 710-02620-00P KEY 1
12 710-02839-00P I/P EMI 1
13 710-02840-00P O/P EMI 1
14 710-02841-00P MAIN1-MOV
15 710-02842-00P O/P EMI1 1
16 710-83404-00P DIC 1
17 710-02151-00P LCD 1
18 710-02660-00P LED 1
19 102-01500-00 Mains supply input FUSE 2

20 102-01245-01 battery FUSE 2

21 102-01246-01 FUSE on the charger 2
22 102-01245-01 BUS FUSE 2

2, Fault code and warning code

1.definition of fault code The fault code is displayed through a decimal number. Please consult the
fault code list for judgment.
2. fault code and its comment
Number Fault Table Comment Explanation

1 cBusSoftTimeOut BUS soft time out Maximum time for Bus soft is 60S
2 cBusOver
BUS Over voltage Higher than 430V and then accumulate to

Fault 200V
3 cBusUnder BUS Under lower than 260 V

Sample Bus voltage drops over 50V in

5 cBusShort Bus Short
consecutive 2 times
6 cInvSoftTimeOut Inversion Soft Time 30S
Out
7 cInvVoltHigh Inversion Volt High higher than 252V

Fault Inversion Volt

8 cInvVoltLow lower than 150V
Low

R-phase Inv Volt

10 cRInvVoltShort
Short When the output voltage is below 70V in
consecutive 5S, and output current is higher
S-phase Inv Volt than 50A, UPS alarms for output short. If
11 cSInvVoltShort
the Inverter Output is 70-150 V and lasts for
Short
4S, it alarms
T-phase Inv Volt .
12 cTInvVoltShort
Short

RS phase Inv Volt

13 cRSInvVoltShort
Short
When the output voltage is higher than
ST phase Inv Volt 120V in consecutive 5S, and output current
14 cSTInvVoltShort
is higher than 50A,UPS alarms for output
Short
short.
TR phase Inv Volt
15 cTRInvVoltShort
Short
R-phase negative three-phase total negative power>2.5KW
17 cInvRNegPow
power fault in 2 period, and

S-phase negative
18 cInvSNegPow >1.25KW in 5 period
power fault

T-phase negative
19 cInvTNegPow
power fault
20 cTotalInvNegPow
Total inversion

negative power fault

21 cReact PowFault React power fault

React power over 1600W in consecutive 5

periods
22 cOverLoadFault Overload fault

23 cOver Temperature Over temperature

Then is excesses the temperature point, it is
fault
a fault. The temperature point is defaulted as

75 C. If the

fan fault is detected, the point decreased

for 10 degree; if LCD opens the

temperature protection, the point goes

down for 10 degrees. Restart the machine

when the temperature drops down to 10

degree below the temperature point.

24 cInvRlyOpenFault INV Rly open

RLY closes, the voltage of output and

inverter tested in consecutive 5ms has 50v

difference
25 cInvRlyStickFault INV Rly stick
under the bypass mode, the voltage

difference between inverter and output is

within 5V in consecutive 5ms

26 cLineSCRFault Line SCR Fault When the voltage difference between Line
SCR input terminal and battery is within
10V in 1/4 line period

29 cConverterFailFault Converter Fail It refers to PFC Fail (PFC module

 fails to supply energy to BUS), three-phase
Fault PFC Fail or 2-phase Fail and the sum of

three phase invert load is beyond 150%

CAN
Communication line loss, CAN
34 cCanFault communication line
information back
fault

Synchronized signal The signal line that transmits synchronized

35 cSynLine Fault
line fault signals in the parallel wires is not detected

In 250ms, the average value of power is

below 20V-4V or beyond

36 cPower Fault Power fault 12v2v,15v2v,-15v2v. Use the

universal meter to test TP1-TP5 of power

board to identify the voltage of each power

41 cADS7869Fault ADS 7869 fault 7869 is an ADC chip, sample fault

Op Breaker Off The output breaker loss in the parallel

43 cOp Breaker Off Fault
system
Relay Fault

R-phase BUS Fuse

44 cRBus Fuse Break
Break
That is the inverter short fault, the invert
S-phase BUS Fuse
45 cSBus Fuse Break voltage value varies in 2V in consecutive
Break 4ms
T-phase BUS Fuse
46 cTBus Fuse Break
Break
NTC is installed on the cooling fin of the
47 cNTCAbnormal NTC Abnormal power board, if the temperature is below -15
degree before the start,
 the start is forbidden and warned. If NTC
detects that the temperature is below -15
after the start, then the UPS fault
48 cEPOActiveFault EPO Active Fault Setting EPO on LCD. Only when the
setting is effective, pluck out the EPO
switch on the rear, UPS fault and cut of f
power soon.
49 cParaLineLoss Para Line Loss Setting single mode or parallel mode on
LCD. If single mode is set and the parallel
line is detected, or para mode is set but the
para line is unconnected, the start is
forbidden. If in the para mode, the para line
is disconnected after the start, then the
UPS will warn automatically. If the para
line is disconnected but the UPS works
well, then the fault will not be warned.

3,Warning Code
The displaying style of warning code is different from that of fault code. The warning code is divided
into present warning and historical warning.
3. 1 present warning
Transfer the decimal number displayed on the machine to binary, and correspond the
digit to fault.

1 2H
L
1 2
H L

3.2 historical warning

Explanation :the digit bit of Warning code ,from 0 to 15 ,is the low digit ,and written in the form of
WC*L ,and the digit from 16-31 in the form of WC*H.
 Code category: 0 stands for system warning
1 stands for Internal warning

3 . 3 Warning Code

WC1L System Warning WC1H System Warning

BIT0 Reserve BIT0 open maintenance bypass cover
BIT1 EPO Switch offno used) BIT1 Charger fault

BIT2 Module not lockno used) BIT2 physical place fault

BIT3 mains supply abnormal BIT3 non-satisfactory to start

BIT4 input line loss BIT4 Non- redundancy systemno used)

BIT5 mains supply phase order BIT5 Module is not insert tightno used)
fault
BIT6 reverse L and N BIT6 time for battery maintenance
BIT7 bypass abnormal BIT7 time for inspection
BIT8 bypass phase-order BIT8 time for overprotect maintenance
abnormal
BIT9 battery unconnected BIT9 NTC abnormal low temperature alarm
BIT10 battery low volt alarm BIT10 NTC high-temperature alarm

BIT11 battery overcharge BIT11 battery high temperature alarm

BIT12 battery invert connection BIT12 fan to the maintenance time

BIT13 overload precaution BIT13 BUS capacity maintenance time

BIT14 overload alarm BIT14 System capacity (no used)
BIT15 Fan fault BIT15 Reserv
WC2L Internal Warning WC2H Internal Warning
BIT0 R/W fault BIT0 Reserv
BIT1 BIT1 Reserv
BIT2 CAN-B communication BIT2 Reserv
abnormal
BIT3 BIT3 Reserv
BIT4 BIT4 aux charger off line
BIT5 BIT5 CAN A internal communication

BIT6 communication line BIT6 excessive low temperature

unconnected
BIT7 BIT7 excessive high temperature

BIT8 BIT8 parallel mode fault

BIT9 BIT9 battery abnormal
BIT10 R-phase positive PFC fault BIT10 parallel bypass abnormal
no used
BIT11 R-phase negative PFC BIT11 CHG&EXCHG
fault no used
Communication
disruption
BIT12 T-phase fan fault BIT12 Reserv
BIT13 R-phase fan unconnected BIT13 Reserv

BIT14 S-phase fan unconnected BIT14 Reserv

T-phase fan BIT15 BIT15 Reserv

unconnected
.

1, Time order graph of AC start

2, Time order graph of battery start

5, repair and maintenance of UPS single

The repair and maintenance of 3W3IX series UPS are done from the frontal part, including the PSDR
CCB-POWER CCB-SIGNAL, maintenance switch, line and bypass input switch, terminal block.
Theres no need for dismantling the side board. When repairing the STS, CHGR, O/P EMI, the top
board shall be opened.
1 steps for repair of the single unit
1. 1 Turn off the UPS to Bypass mode.
1. 2 Open the front door of the UPS.
1. 3 Twist the 2 screws on the left and right of the maintenance switch off, and the switch turns
from UPS position to BPS position. Notice: theres no position switch below the cover
board of maintenance switch, so make sure that the UPS is turned off and shifted to
bypass mode before the operation.
1. 4 Push the UPSs line input switch, bypass input switch OFF, battery air switch OFF.
1. 5 Dismantle the UPS airflow board, like the following graph
1 . 7 Use the discharge resistor to discharge the BUS voltage. When open the airflow board, you will find 2
BUS terminal on the left front of PSDR. Since the three-phase BUS is linked together, so you can
just discharge on the one-phase PSDR.
1 . 8 after the discharge of BUS, remove the linking line of corresponding components
according to the fault explanation. assembling and disassembling of PSDR
Just remove the 8 electrical lines and one 50PIN Data line and then you can draw out
the whole tray.

PSDR that is drawn out of the machine

1.8.1.1 Draw out the PSDR and remove the duct paper.
1.8.1.2 Dismantle the inductance board and capacitance board

inductance board capacitance board

1.8.1.3 Remove the 2 bearing poles that fix the capacitance board.
 1.8.1.4 Twist down the screws on PSDR, and then remove and replace the PSDR.
1.8.1.5 Restore the PSDR with the invert order of removing. disassembling and
assembling of CCB-POWER and CCB-SIGNAL
1.8.2.1 Disassembling and assembling of CCB-POWER
1.8.2.1. 1 Twist down the fix screws marked in the following graph

1.8.2.1.2 Draw out the PCB softly, during the drawing removing the wiring on the board
and draw the PCB out of the socket.
 1. 8.2.2 Disassembling and assembling of CCB-SIGNAL
1 .8.2.2.1 The disassembling and assembling of CCB-SIGNAL is similar to that of
CCB-POWER, the wiring connection is as follows :

1.8.3 Disassembling and assembling of CHGR and STS

1.8.3.1 The assembling and disassembling of CHGR and STS needs open the top board on the
machine. Open the front door, you will find 2 fix screws under the top board. Twist
down the 2 screws and rise the top cover board, and then push it back and draw the
cover board.
1.8.3.2 After the drawing of top cover board, you may find the CHGR, STS, and O/P-EMI
boards.
6, steps of repair for parallel mode
6.1 online joining of parallel machines
6.1.1 Join in the new machine or repaired machine according to the debugging steps and make
the corresponding settings.
6.1.2 Join the parallel line of the machine into the parallel system

6 . 1.3 Connect the output line of the newly-joined machine with the connecting line of
parallel system. Push the input air switch to ON position. Notice: make sure that the
parallel system is working under the line invert mode before new machines joining in.
If parallel system is working under the bypass mode, this operation is forbidden, and
must be shifted to maintenance bypass mode. When all the machines in the parallel
system enter into the bypass mode, shift the maintenance bypass mode to bypass mode,
and then start the system.
6 . 1.4 Push the battery air switch of newly-joined machine to ON position.
6 . 1.5 Connect the line and bypass input of the newly-joined machine with the corresponding
terminals of the parallel system.
6. 1.6 The newly-joined machine will start automatically and join into the parallel system.
6.2 online escape of parallel system
6.2.1 Make sure that the system load is redundancy mode (if the system is of capacity
extension mode, unload the load to redundancy at first and then conduct the following
actions. )
6.2.2 Enter into the LCD menu of the UPS that is going to escape the system, choose Single
Close and enter into the single unit turnoff mode.
6.2.3 When the machine turns off to waiting mode, turn OFF the UPSs input air switch,
battery air switch, line input air switch and bypass input air switch.
6.2.4 Pack the dismantled wirings with insulation tape.
6.2.5 Remove the parallel line after the total cutoff of power.
 6. 3 repair of parallel system
6.3.1 If fault occurred to UPS, it will escape from the parallel system automatically.
Escape the UPS that fails according to the above-mentioned way from the parallel
system, and shift the parallel mode to single mode before repairing. The repair is the
same to that of single unit.
6.3.2 adjustment of corresponding parameter after the repair of parallel system:
6.3.2.1 BUS Voltage Readjustment: under the bypass mode, enter into the
settingmaintenance codebalance adjustment, choose Yes, then UPS starts
into invert mode. Under the invert mode, use the universal meter to test whether
the voltage of positive and negative of BUS is 360 0.5V. If the voltage
difference is higher than the standard, readjust through the selections on the
LCD to the correct range. Notice: if the line voltage is under 250V, the
readjustment of BUS voltage shall be conducted under line supply. If the line
voltage is higher than 250V, the readjustment under battery mode.)
6.3.2.2 Output Voltage Readjustment: check whether the output voltage displayed on
LCD is 220 0.5V. If it is beyond the range, readjust to the correct range in the
item of output voltage readjustment under balance adjustment .
6.3.2.3 Invert voltage readjustment: use the universal meter to test whether the invert
output phase voltage of the single machine is in the range of 220 0.5V. If it is
in the range, then it' s unnecessary for readjustment. If it is beyond the range,
readjust to the correct range in the item of inverter voltage readjustment under
balance adjustment.
6.3.3 After the completion of readjustment of the parameters, escape and turn off the
machine. The machine turns to bypass mode, restart the parallel mode of the machine,
and push the line input air switch and bypass input air switch OFF, then the machine is
cut off power completely.
6.3.4 Join the UPS into the parallel system according to the above-mentioned way.

Note: After the replacement of LCD the parameters must be set again to ensure the parameters are all the same in
the system.