HIP33000 (10 80K) Maintenance Manual

KSTAR 高频产品线
HIP33000 10-160KVA
UPS Principle and
Maintenance
Contents
Contents ................................................................................................................................ I
Figure Contents ..................................................................................................................... II
Table contents ..................................................................................................................... III
一、 Product introduction .............................................................................................. 1
1. Summary.................................................................................................................... 1
2. Appearance ................................................................................................................ 1
3. Features ..................................................................................................................... 2
4. Operating panel ......................................................................................................... 2
二、 System block diagram ............................................................................................. 4
1. Cabinet block diagram ................................................................................................ 4
2. Power module block diagram ..................................................................................... 5
3. Power modue AC/DC & DC/DC principle circuit diagram ............................................. 6
4. Inverter DC/AC principle............................................................................................. 6
5. Charging principle ...................................................................................................... 7
三、 Parameters ............................................................................................................. 7
1. UPS specification ........................................................................................................ 7
四、 Internal structure ................................................................................................... 9
1. The whole appearance ............................................................................................... 9
2. Internal view of power module ................................................................................ 15
五、 PCB boards and their signals ................................................................................. 16
1. PFC inductor board................................................................................................... 17
2. PFC power board ...................................................................................................... 19
3. INV. Inductor board .................................................................................................. 20
4. Inverter power board ............................................................................................... 23
5. DSP board ................................................................................................................ 24
6. Parallel connection board ......................................................................................... 30
六、 Inspection before installation ............................................................................... 31
1. Room environment inspection ................................................................................. 31

I
2. UPS location inspection ............................................................................................ 31
3. UPS visual inspection................................................................................................ 32
4. External cables and switch capacity inspection ......................................................... 32
5. External auto switching and generator power distribution inspection ...................... 32
6. Battery inspection .................................................................................................... 33
七、 UPS maintenance ................................................................................................. 33
1. Guidelines for good service.......................................................................................... 33
2. Security conditions ...................................................................................................... 34
3. Shutdown-disassembly/reassembly UPS ...................................................................... 35
4. Troubleshooting .......................................................................................................... 36
5. Battery replacement.................................................................................................... 38
6. PCB replacement ......................................................................................................... 39
8. PCB static maintenance ............................................................................................ 42
八、Single cabinet commissioning ...................................................................................... 44
1. Startup steps ............................................................................................................ 44
2. Shutdown steps： .................................................................................................... 45
3. Emergency shutdown instructions ............................................................................ 45
9. Parallel system commissioning .................................................................................... 45
1. Startup steps ............................................................................................................ 45
2. Shutdown steps........................................................................................................ 46
3. Emergency shutdown ............................................................................................... 46
10. Software upgrade..................................................................................................... 46
1. Use C2000 emulator to upgrade ............................................................................... 46
2. Use 485 communication to upgrade ......................................................................... 46
Appendix A HIP33000 Series UPS difference .............................................................. 47
Appendix B Power module fault judgement ....................................................................... 49
Figure Contents
Fig. 2 Operating interface of power module ............................................................................. 3
Fig. 3 block diagram .................................................................................................................. 4
II
Fig. 4 Power module block diagram .......................................................................................... 5
Fig. 5 power module AC/DC & DC/DC principle......................................................................... 6
Fig. 6 Bypass and inverter principle........................................................................................ 7
Fig. 7. Charging principle........................................................................................................... 7
Fig. 8 HIP20K UPS front view.................................................................................................. 9
Fig. 9. HIP60-80KVA UPS front view ........................................................................................ 10
Fig. 10 Terminal block.............................................................................................................. 11
Fig. 11 HIP60-80KVA UPS left view....................................................................................... 11
Fig. 12 HIP60-80KVA right view............................................................................................... 12
Fig. 14 HIP20KVA bottom from rear view ......................................................................... 13
Fig. 16 The front of power module ....................................................................................... 15
Fig. 17 The back of power module ....................................................................................... 15
Fig. 18 PFC inductor board ................................................................................................... 16
Fig. 19 PFC power board ......................................................................................................... 16
Fig. 20. Inv. Inductor board...................................................................................................... 16
Fig. 21 Inv power board........................................................................................................ 16
F22. PFC inductor board .......................................................................................................... 17
Fig. 23 PFC power board ......................................................................................................... 19
Fig 24 Inv. Inductor board........................................................................................................ 21
Fig. 25 Inverter power board ................................................................................................... 23
Fig. 26 DSP board ................................................................................................................. 25
Fig. 27 parallel connection board......................................................................................... 30
Fig. 28 HIP settings ............................................................................................................... 44
Table contents
Table 1 Indicator descripiton ..................................................................................................... 3
Table 2 Button description......................................................................................................... 3
Table 3 HIP data sheet............................................................................................................ 7
Table 5 PFC power board interface.......................................................................................... 19
Table 6 Inv. Inductor board interface ............................................................................... 21
Table 7 Inv. Power board interface .......................................................................................... 23
Table 8 DSP board interface ................................................................................................. 25
Table 9 Parallel connection board interface ......................................................................... 30
III
HIP33000 10-160KVA UPS Principle and
Maintenance
一、 Product introduction
1. Summary
HIP Series is a kind of high-frequency online intelligent UPS and adopts double DSP
control chips, advanced control technology and double conversion topology. It
eliminates various interference of the grid and makes the output a stable and pure sine
wave power with low noise, no interfence and low distortion. With strong load capacity,
good load compatibility, wide input voltage and frequency range, excellent generator
compatibility and zero transfer time, it greatly meets the requirement of variety of
applications. Comprehensive protection enhances the stability and reliability of the
system. Intelligent battery management, equalized and floating charging auto
conversion, battery discharge time prediction and battery self-test can extend the
battery life. It can be used in advanced network systems.
★ power range：10KVA-160KVA, up to 4 units can be parallel，
★ Working mode：High frequency intelligent online (3-phase in to 3-phase out)
★ Application：Work station、network server、computer rooms and data center
2. Appearance
Fig. 1 Appearance（ 20KVA）
1
3. Features
◆Three-phase in to three-phase out UPS
This series is three-phase in to three-phase out UPS with large capacity，the input
current of three phase is balanced which can balance the load of each phase.
◆Digital control
Digital control is used for all parts of the UPS, which makes the performance indicators
very excellent and the system more stable. It not only has self-protection and fault
diagnosis, but also can avoid risks of analog device failure, whick allows the control
system more reliable.
◆Optional external battery quantity（32-40pcs optional）
The quantity of external battery can be optional according to the users ：
32/34/36/38/40pcs.
◆Settable charging current
By setting the battery capacity configured by user, the reasonable charging current can
be automatically allocated. Constant voltage charging mode, constant current charging
mode and floating charging mode can auto-switch smoothly.
◆Intelligent charging method
Advanced two-way, three-stage charging method is adopted. At the first stage, fast
recharge with constant large current to 90% capacity; at the second stage, constant
voltage charge can activate the battery characteristics and make the battery full; at the
third stage, floating mode operates. This method can provide a balance between the
fast charge and extended the battery life, which saves the battery investment.
◆LCD display
Both the LCD and LED display for the series allows the users a more intuitive
understanding of the UPS status and operating parameters such as input/output
voltage and frequency, load capacity, battery capacity,temperature and ect.. All the
operation are under the monitoring.
◆Intelligent monitoring function
When SNMP is selected with UPS, the remote monitoring can be achieved easily.
◆EPO function
An emergency power off(EPO) button interface Is embedded in the rear panel of the
UPS. The user can add the EPO button. In case of emergency, press the EPO button can
shut down the UPS. It also has remote emergency power off (REPO) function.
4. Operating panel
2
Status indicator
Cycle button
1. error alarm
2. bypass
OFF button
3.battery
4. mains input
LCD display ON button
Fig. 1 Operating interface of power module
 Status indicator on front panel、LCD and other buttons

LCD and indicator LED on front panel, cooperate with buttons, can view all the
data, information and set parameters.
Table 1 Indicator descripiton
Name Status Description

Alarm LED Red on UPS fault and alarm
Red off UPS normal
Bypass LED Green on UPS bypass output
Green flash Bypass abnormal or out of range，or bypass switch fail
Green off Bypass normal，no bypass output
Battery LED Green on Battery supply power
Green flash Battery discharge termination and pre-inform
Green off Battery abnormal（no battery or battery fail）
Mains output LED Green on mains output
Green off no mains output
Table 2 Button description

ButtonName Description
Cycle Enter the menu to view the UPS data and information
ON Start inverter
OFF Shut down inverter in Line mode and transfer to bypass（if bypass
normal）；
Shut down inverter under the battery mode，power module down；
Battery cold start when off status
3
二、 System block diagram
1. Cabinet block diagram
Comm LCD display

u
Power module 1
Batt Power module 2

eery Battery
池 switch
Output
switch
Input
Input Outp
switch Power module 7 ut
Power module 8
Maint switch
Fig. 2 block diagram
As shown above, the HIP33000 series UPS is composed of power modules. The power
of each power module is from 10 to 30KVA. The mains and battery power enter the
power modules via the air-switch. At the same time, the mains provide the output
directly via the maint air-switch. Each power module has internal battery bypass switch,
which disperses bypass output. All the power modules share a common output switch.
4
2. Power module block diagram
Byp switch
EMI
EMI
mains EMI DC/AC

AC/DC
DC/DC Module output
Output switch
Battery fuse
battery
CHARGER
fuse
Fig. 3 Power module block diagram
As shown above, each power module has bypass air-switch and main air-switch.
When close the bypass air-switch, the bypass power of the cabinet will go into the UPS
module. When one module is powered, it will compete with other moduls to be a host.
The module detects the cabinet output air-switch and bypass voltage, frequency, phase
sequence. If output air-switch is closed and bypass votage and frequency is in the range,
the UPS will send out bypass output command, all the matching modules will output
from bypass while bypass LEDs will be on.
Close the main switch, if the mains voltage, frequency and phase sequence are in
the range, UPS will soft start. When bus voltage rises around 310V, PFC boost begins to
work and the bus voltage will be up to about 370V. Inverter starts. When all the power
inverters are ready, the host will send out command to transfer to inverter. If bypass
voltage, frequency and phase sequence are normal, the inverter voltage will track the
bypass power and switch to inverter output without interruption, or the module will
transfer to inverter intermittently. Inverter LED on and bypass LED off, the inverter will
provide power. If the battery is normal, the module will activate the charger to charge
the battery.
The module supports hot-swapped. When loose the fixing screw at the top right
corner, the module will exit and can be pulled out for maintenance or replacement. If
there is only one module, it will not exit to avoid power down. Only fix the screw well
when insert the new module, it wil begin to work. At the moment, if the host is in
inverter mode, module will not enter the bypass status and directly output from
inverter when inverter is ready instead.
UPS module detects maintenance air-switch at any time. When remove the baffle
of the switch, module will transfer to bypass status. Now close the maintenance
air-switch for supplying power from bypass. When finish maintenance, the air-switch
cannot be open until the module is in bypass, or it will cause the power down of load.
5
3. Power modue AC/DC & DC/DC principle circuit diagram
A B C
Fig. 4 power module AC/DC & DC/DC principle
As shown above, A (yellow box) shows the rectifier circuit, B (blue box) shows the battery
input circuit, C (other part) shows the boost circuit. A and C form the PFC rectifier circuit while
B and C form the battery boost circuit.
4. Inverter DC/AC principle
6
Fig. 5 Bypass and inverter principle
As shown above, A (yellow box) represents bypass circuit of power module, B (blue box)
shows the inverter circuit, which converts the Bus voltage into the AC output.
5. Charging principle
battery
Charging fuse
Fig. 6. Charging principle
As shown above, charger reduces the Bus voltage to a suitable voltage to charge the
battery.
三、 Parameters
1. UPS specification
Table 3 HIP data sheet
Model HIP33010S/H HIP33015S/H HIP33020S/H HIP33030S/H HIP33040H HIP33060H HIP33080H
10KVA 15KVA 20KVA 30KVA 40KVA 60KVA 80KVA

Capacity
8KW 12KW 16KW 24KW 32KW 48KW 64KW
phase 3P4W+G
Rated voltage 380/400/415Vac
Voltage range 208~478Vac
Frequency range 40Hz-70Hz

Input
Power factor ≥0.99
Thdi ≤3%(100％ non-linear load)
Max.voltage：+15%（optional +5%、+10%、+25%）
Bypass range Min. voltage：-45%(optional-20%、-30%)
frequency protection range：±10%
Phase 3P4W+G
Rated voltage 380/400/415Vac

Outpu
Power factor 0.8
t
Regulation ±2%
lin
Frequency Synchronized with input；when exceeds ±10% （optional ±1%、±2%、±4%、±5%），output is Breaker Breaker 50×(±0.2)Hz
e
7
Model HIP33010S/H HIP33015S/H HIP33020S/H HIP33030S/H HIP33040H HIP33060H HIP33080H
Ba
(50/60±0.2%)Hz
tt.
Crest 3:1
≤2% linear load

THD
≤5% nonlinear load
Efficiency Normal ≥92%
voltage Standard: ±216V DC(36pcs); long time unit: ±192V\±204V\±216V\±228V\±240V DC (32 /34/ 36 /38 /40pcs)
Bat capacity(s) 12V/38AH
Charging current 5.7A(s) ；long time unit:6A max 12A max 18A max
Transfer time mains to bypass: 0ms(tracking)；mains to battery:0ms
Li
ne
m load≤110%，60min，≤125%， 10min，≤150% 1min，≥150% shut down
od
e
Ba
tt
Overload m Load ≤110%，10min，≤125%， 1min，≤150% 5S，≥150% shut down
Protec
od
tion
e
By
p
Breaker Breaker
m Breaker 20A Breaker 32A Breaker 40A Breaker 63A Breaker 80A
100A 125A
od
e
Overtemperature Normal mode: switch to bypass mode; battery mode: cut off output immediately
EPO Cut off the output immediately
Communication RS232，RS485，dry contact，parallel，SNMP card（option）
Working temp. 0℃～40℃
Enviro Humidity -25℃～55℃
nment Storage temp. 0～95% non-condensing
Altitude < 1500m
Dimension
600*780*1200
Physic (W*D*H)
al HIP33010S:622 HIP33015S:625 HIP33020S:626 HIP33030S:626

Weight （net）Kg 158 158 195
HIP33010H:123 HIP33015H:126 HIP33020H:127 HIP33030H:127
Standard CE,EN/IEC 62040-2,EN/IEC 62040-1-1,YD/T1095-2008
8
四、 Internal structure
1. The whole appearance
10-20KVA UPS only

has one power
module
SNMP card slot and

EPO switch
Communication
Switch interface
Baffle for
terminal block
Fig. 7 HIP20K UPS front view
9
60-80KVA UPS has 3
power modules,
marked as 1, 2, 3
from top to bottom
SNMP card slot and

EPO switch
Communication
Operation interface
switch
Baffle for
terminal block
Fig. 8. HIP60-80KVA UPS front view
10
Fig. 9 Terminal block
Parallel board
Battery EMI
board
Fig. 10 HIP60-80KVA UPS left view
11
Signal connection
board
Fig. 11 HIP60-80KVA right view
12
功率模块
Power module
Parallel
port
Fig.13 .HIP20KVA top from rear view
Cable
Fig. 12 HIP20KVA bottom from rear view
13
Baffle for
3 power parallel port
modules
Fig15 HIP60-80KV rear view
14
Output filter
magnetic ring
2. Internal view of power module
Inv inductor
board
Fan
EMI filter
board
PFC inductor
board
Fan
Input filter
Fig. 13 The front of power module magnetic ring
PFC power
board Fan
DSP 控制板
Fan
Inv. Power
board
Fig. 14 The back of power module
15
2 charging
inductors
Battery fuse 6 PFC

inductors
Fig. 15 PFC inductor board
散热器
Charging fuse radiator IGBT drive
board
Fig. 16 PFC power board
BUS capacitor
12 inv inductors 3 inv. fuse
6 inv capacitor
Fig. 17. Inv. Inductor board
radiator
Auxiliary
power board
Fig. 18 Inv power board
五、 PCB boards and their signals

16
1. PFC inductor board
Function overview
 Mains rectifier
 Battery input circuit
 Bypass static switch
 Boost inductor circuit
 Charging inductor circuit
F19. PFC inductor board
Input and output interface definition

Table 4 inductor board interface
No. Definition Specification Name Description
BAT- Name：blade terminal
BAT- input BAT-
P1 Description: UHTWSZ Wiring copper bar II welded BAT- input
assemblies plated bright nickel
BPS_A Name：blade terminal

Bps A phase
P3 Bps A phase output Description：4PIN 10A M4 screw hole straight leg BPS_A
output
8*8.4*11.1mm T0.8mm tinned copper
BPS_B Name：blade terminal

Bps B phase
P5 Bps B phase output Description：4PIN 10A M4 screw hole straight leg BPS_B
output
Assistant power Name：neilsbed

Assistant power
P6 15V+ Description：1121S-2P P=3.96mm 180° single row square 15V+
PIN white
BPS_A_IN
Name：neilsbed ASSISTANT POWER
ASSISTANT POWER BPS_A_IN
P7 Description：1121S-2P P=3.96mm 180° single row square Power from A
Power from A phase
PIN white phase bypass
bypass
P8 BPS_C Name：blade terminal BPS_C Bps C phase
17
Bps C phase output Description：4PIN 10A M4 screw hole straight leg output
BAT_SCR_TRIG_ Bat. Thyristor

ENA drive signal
BAT_RLY Bat. Relay signal
Charging thyristor
CHARGE_SCR
drive
Name：neilsbed BPS_SCR_TRIG_
Bps thyristor drive
P15 Description：301S-10P P=2.54mm 180° two rows square ENA
PIN black BPS_RLY Bps relay signal
RELAY_IN Main relay signal
+AC soft start

ACSOFT+
drive signal
-AC soft start drive

ACSOFT-
signal
BAT+ Name：blade terminal

P16 BAT+ input Description：UHTWSZ Wiring copper bar II welded BAT+ BAT+ input
BPS_A_IN Name：blade terminal

P20 Bps A phase input Description：4PIN 10A M4screw hole straight leg BPS_A_IN Bps A phase input
CHARGE+
Name：neilsbed
CHARGE- CHARGE+ Charging voltage
P21 Description：1121S-3P P=3.96mm 180° single row square
Charging voltage CHARGE- sampling
PIN white
sample
BATTERY+ Name：neilsbed
Battery voltage
P22 BATTERY- Description：1121S-3P P=3.96mm 180° single row square
sampling
Bat. voltage sample PIN white
N Name：blade terminal
N
P25 Neutral Description：UHTWSZ Wiring copper bar II welded Neutral
BPS_B_IN Name：blade terminal

BPS_B_IN
P27 Bps B phase input Description：4PIN 10A M4 screw hole straight leg Bps B phase input
BPS_C_IN Name：blade terminal

P43 Bps C phase input Description：4PIN 10A M4 screw hole straight leg BPS_C_IN Bps C phase input
A Name：blade terminal
Main A phase
J2 Main A phase input Description：4PIN 10A M4 screw hole straight leg A
input
B Name：blade terminal
Main B phase
J13 Main B phase input Description：4PIN 10A M4 screw hole straight leg B
input
18
C Name：blade terminal
Main C phase
J14 Main C phase input Description：4PIN 10A M4 screw hole straight leg C
input
A Name：neilsbed
Main A phase
J23 Main A phase input Description：1121S-3P P=3.96mm 180° single row square A
input sampling
sampling PIN white
B&C Name：neilsbed Main B&C

J24 Main B&C Description：1121S-3P P=3.96mm 180° single row square B&C phase input
phase input sampling PIN white sampling
2. PFC power board

Function overview：
 Boost circuit IGBT
 Charging circuit MOSFET
 Battery soft start resistor
Fig. 20 PFC power board

Table 4 PFC power board interface

P6 15V+ Description：1121S-2P P=3.96mm 180° single row Assistant power 15V+
squrePIN white
BUS+ Name：blade terminal

P9 Description：4PIN 10A M4 screw hole straight leg BUS+ BUS+
BUS- Name：blade terminal

BUS- BUS-
P10 Description：4PIN 10A M4 screw hole straight leg
A phase PFC
I+BST1Q_A+/
P14 301S-30P P=2.54mm 180° two rows squre PIN black horn inductor current
I-BST1Q_A+
detection
19
B phase PFC
I+BST2Q_A+/
inductor current
I-BST2Q_A+
detection
C phase PFC
I+BST3Q_A+/
inductor current
I-BST3Q_A+
detection
PWM_+BST_PH
1/ PFC power tube A
PWM_-BST_PH phase drive signal
1
PWM_+BST_PH
2/ PFC power tube B
2
PWM_+BST_PH
3/ PFC power tube C
3
PWM+_CHRG/ BUCK power tube

PWM-_CHRG drive signal
I_+CHRG_A+/ Charging current

I_-CHRG_A+ detection
COLD_START_S battery cold start

CR_TRIG SCR drive signal

P20 15V+ Description：1121S-2P P=3.96mm 180° single row squre Assistant power 15V+
PIN white
BAT+/BAT- Name：neilsbed
battery cold
P22 battery cold startpower Description：1121S-3P P=3.96mm 180° single row squre BAT+/BAT-
startpower
PIN white
BUS+/BUS- Name：neilsbed
BUS+/BUS- BUS+/BUS-
J18 BUS+/BUS- Description：1121S-3P P=3.96mm 180° single row
Voltage detection
Voltage detection squrePIN white
BAT+/BAT- Name：neilsbed
BAT+/BAT-
J25 BAT+/BAT- Description：1121S-3P P=3.96mm 180° single row BAT+/BAT-
Voltage detection
Voltage detection squrePIN white
3. INV. Inductor board

 INV LC filter
 Output current detection
 Inv. inductor current detection
20
Fig 21 Inv. Inductor board

Table 5 Inv. Inductor board interface
VOUT_A Name：blade terminal

P2 Output A phase Description：4PIN 10A M4screw hole straight leg VOUT_A Output A phase
BPS_A Name：blade terminal

Bypass A phase
P3 Bypass A phase Description：4PIN 10A M4screw hole straight leg BPS_A
Output
Output 8*8.4*11.1mm T0.8mm tinned copper
BPS_B Name：blade terminal

Bypass B phase
P5 Bypass B phase Output Description：4PIN 10A M4screw hole straight leg BPS_B
Output
VOUT_B Name：blade terminal

P6 Output B phase Description：4PIN 10A M4screw hole straight leg VOUT_B Output B phase
BPS_C Name：blade terminal

Bypass C phase
P8 Bypass C phase Description：4PIN 10A M4screw hole straight leg BPS_C
Output
Output 8*8.4*11.1mm T0.8mm tinned copper
VOUT_C Name：blade terminal

P9 Output C phase Description：4PIN 10A M4screw hole straight leg VOUT_C Output C phase
P12 Neutral Description：UHTWSZ Wiring copper bar II welded N Neutral
21
PH2_INV_FUSE-P2 Name：blade terminal PH2_INV_FUSE-

P40 B phase inv.fuse Description：UHTWSZ Wiring copper bar II welded P2 B phase inv.fuse

P42 C phase inv.fuse Description：UHTWSZ Wiring copper bar II welded P2 C phase inv.fuse

P44 A phase inv.fuse Description：UHTWSZ Wiring copper bar II welded P2 A phase inv.fuse
PH1_INV_Q_C1E2&VO
A phase inv.DC
UT_A Name：neilsbed PH1_INV_Q_C1
component and
J1 A phase inv.DC Description：1121S-4P P=3.96mm 180° single row E2&VOUT_A
Output voltage
component and Output squrePIN white
sampling
voltage sampling
PH2_INV_Q_C1E2&VO
B phase inv.DC
UT_B Name：neilsbed PH2_INV_Q_C1
component and
J2 B phase inv.DC Description：1121S-4P P=3.96mm 180° single row E2&VOUT_B
Output voltage
sampling
voltage sampling
PH3_INV_Q_C1E2&VO
C phase inv.DC
UT_C Name：neilsbed PH3_INV_Q_C1
component and
J3 C phase inv.DC Description：1121S-4P P=3.96mm 180° single row E2&VOUT_C
Output voltage
sampling
voltage sampling
A phase inv.
PH1_INV_IL inductor current
detection
B phase inv.
detection
C phase inv.
detection
301S-26P P=2.54mm 180° two rows squre PIN black
J4 ICIR_BUS_PH1/ Aphase circulation
horn
ICIR_DIFF_PH1 detection
ICIR_BUS_PH2/ Bphase circulation

ICIR_BUS_PH3/ Cphase circulation

AphaseOutput
IOCT-_PH1
current detection
BphaseOutput
IOCT-_PH2
current detection
22
CphaseOutput
IOCT-_PH3
current detection
INV_FUSE_BRO inv.fuse
KEN detection
INV_STS_TRIG_ Inv. SCR drive

ENA signal
Inv. Relay drive

INV_RLY_DRV
signal
4. Inverter power board

 Auxiliary power
 Half-bridge inverter circuit
 Fan speed regulation circuit
Fig. 22 Inverter power board

Table 6 Inv. Power board interface
+DCBUS
+BUS voltage
Name：blade terminal
P9 Description：4PIN 10A M4 screw hole straight leg +DCBUS +BUS voltage
-DCBUS Name：blade terminal

P10 -BUS voltage Description：4PIN 10A M4 screw hole straight leg -DCBUS -BUS voltage
+15V/-15V Name：neilsbed
ASSISTANT
P13 ASSISTANT Description：1121S-2P P=3.96mm 180° single row +15V/-15V
POWER
POWER squrePIN white
+24V_FAN Name：neilsbed
P28 +24V_FAN Fan power
Fan power Description：1121S-2P P=3.96mm 180° single row
23
squrePIN white
VBPS_A/BAT+/VINV_A Name：neilsbed VBPS_A/BAT+/V Supply power

J4 Supply power from Description：1121S-5P P=3.96mm 180° single row squre INV_A from auxiliary
auxiliary power PIN white (remove 2 4PIN) power
REC_THERMAL_SWITCH Name：neilsbed REC_THERMAL

REC temperature
J5 REC temperature Description：2001S-2P P=2.54mm 180° single row squre _SWITCH
detection
detection PIN white
PH1_INV_PWM Inv. A phase

+ +IGBT drive signal
PH2_INV_PWM Inv. B phase

+ + IGBT drive signal
301S-12P P=2.54mm 180° two rows squre PIN black PH3_INV_PWM Inv. C phase
J6
horn + +IGBT drive signal
FAN_FAULT Fan fault detection
PWM_FAN_SPD Fan speed control
DCPS_TRANSITI Auxiliary power to

ON_RLY relay signal
ASSISTANT Name：neilsbed ASSISTANT

J7 POWER Description：1121S-4P P=3.96mm 180° single row POWER +15V/-15V
+15V/-15V squrePIN white
ON Name：neilsbed
Start up signal
J8 Start up signal button Description：2001S-2P P=2.54mm 180° single row ON
button
squrePIN white
REC_THERMAL_SWITCH Name：neilsbed REC_THERMAL

REC temperature
J9 REC temperature Description：2001S-2P P=2.54mm 180° single row _SWITCH
detection
detection squrePIN white
SW_ON Start up signal
PH1_INV_PWM Inv. A phase

- –IGBTdrive signal
PH2_INV_PWM Inv. B phase
301S-10P P=2.54mm 180° two rows squre PIN black
J10 PH3_INV_PWM Inv. C phase
horn
Auxiliary
DCPS_SD
power-off signal
REC_THERMAL REC temperature

_SWITCH detection
+24_CSU Name：neilsbed
monitoring unit
J18 monitoring unit Description：1121S-2P P=3.96mm 180° single row squre +24_CSU
POWER
POWER PIN white
5. DSP board
24
 UPS control
 Communication circuit
 Parallel circuit
 Display circuit
Fig. 23 DSP board

Table 7 DSP board interface
Corresponding
Connector No. Signal Remark
interface
1 +15V Inv. power board
2 GND
J7
3 GND
4 -15V
Inv. Inductor
1 PH1_INV_Q_C1E2
board
2
J1
3 VOUT_A
4
5 PH1_INV_FUSE-P1
Inv. inductor
1 PH2_INV_Q_C1E2
board
2
J2
3 VOUT_B
4
5 PH2_INV_FUSE-P1
Inv. inductor
1 PH3_INV_Q_C1E2
board
2
J3
3 VOUT_C
4
5 PH3_INV_FUSE-P1
1 +15V PFC power board
P20
2 GND
25
Corresponding
interface
1 CHARGE+ PFC power board
P21 2
3 CHARGE-
mains PFC inductor
1 A
input board
J23 2
mains
3 N
input
mains PFC inductor
1 B
input board
2
J24
3
mains
4 C
input
Bypass parallel
1 VBP_A
input connection board
2
3 N_BP
J12 4
5 VBP_B
6
7
8 VBP_C
1 BAT+ PFC power board
J25 2
3 BAT-
1 BUS+ PFC power board
J18 2
3 BUS-
parallel
1 BPSIDE_HOLD_BC
connection board
2 ICIR_BUS_A
3 ICIR_BUS_B
4 ICIR_BUS_C
5 CANBUS_H
J17/J19
6 GND
7 CANBUS_L
8 INV_STATUS_BC
9 MASTER_SYN_BC
10 CONNECT_OK
11 SYSTEM_UNLOCK_BC
26
Corresponding
interface
12 RESERVED1_BC
13 RESERVED2_BC
parallel
1 485_A_INVSCIA
connection board
2 485_B_INVSCIA
3
4 EPO
5 MAINTAIN-AUXW+
J12 6 CONNECT_MODULE_IN
7 OUT_BREAKER
8 ID_1_IN
9 ID_2_IN
10 ID_3_IN
11 ID_4_IN
12 GND_485
parallel
1 LCD_LED1
connection board
2 LCD_LED2
3 LCD_LED3
4 LCD_LED4
5 LCD_RST
6 LCD_WR/SPIB_CLK
7 LCD_DATA/SPIB_SIMO
CN3 8 BLA
9 LCD_CS1
10 LCD_CS2
11 GND
12 LCD_TEST
13 3.3V
14 LCD_SELECT
15 KEY1 ON button
16 KEY2
PFC power board
1 I+BST1Q_A+
P14
2 I-BST2Q_A+
3 I+BST3Q_B+
P14 4 I-BST2Q_B+
5 I+BST4Q_C+
6 I-BST3Q_C+
7 PWM_+BST_PH1
8 PWM_-BST_PH1
27
Corresponding
interface
9 PWM_+BST_PH2
10 PWM_-BST_PH2
11 PWM_+BST_PH3
12 PWM_-BST_PH3
13 GND
14 GND
15 PWM+_CHRG
16 PWM-_CHRG
17 I_+CHRG_A+
18 I_-CHRG_A+
19 TEMP_BST_HS
20 COLD_START_SCR_TRIG
21 GND
22 GND
23 GND
24 GND
25 GND
26 GND
27 GND
28 GND
29 NC
30 NC
PFC inductor
1 BAT_SCR_TRIG_ENA
board P15
2 BAT_RLY
3 CHRG_SCR
4 BPS_STS_TRIG_ENA
P15 5 BPS_RLY
6 RELAY_IN
7 ACSOFT+
8 ACSOFT-
9 GND
10 GND
Inv. inductor
1 I_INVL_CT+_PH1
board J4
2 GND
3 I_INVL_CT+_PH2
J4
4 GND
5 I_INVL_CT+_PH3
6 GND
7 ICIR_BUS_PH1
28
Corresponding
interface
8 ICIR_DIFF_PH1
9 IOCT-_PH1
10 ICIR_BUS_PH2
11 ICIR_DIFF_PH2
12 IOCT-_PH2
13 ICIR_BUS_PH3
14 ICIR_DIFF_PH3
15 IOCT-_PH3
16 INV_FUSE_BROKEN
17 INV_STS_TRIG_ENA
18 INV_RLY_DRV
19 GND
20 GND
21 GND
22 GND
23 +15V
24 +15V
25 +15V
26 -15V
Inv. power
1 PWM_INV+_PH1
board J6
2
3 PWM_INV+_PH2
4
5 PWM_INV+_PH3
J6 6 FAN_FAULT
7 PWM_FAN_SPD_OUT
8 DCPS_TRANSITION_RLY
9
10 GND
11
12
Inv. power
1 NC
board J10
2 SW_ON
3 PWM_INV-_PH3
J10 4 DCPS_SD
5 PWM_INV-_PH2
6 TEMP_INV_HS
7 PWM_INV-_PH1
8 NC
29
Corresponding
interface
9 GND
10 GND
6. Parallel connection board

 Parallel circuits connection among the power modules
 Connection between power module and monitoring module
Fig. 24 parallel connection board

Table 8 Parallel connection board interface
Corresponding
interface
Building a database
1 485-B
module
2 485-A
J12 3 GND_485
4 EPO
5 GND_485
6 NC
1 24V power
J11 2 Monitoring module
3 GND2
1 24V power Power module
J9
2 GND2
30
Corresponding
interface
J5 1 Parallel signal Power module
J6 1 parallel signal Power module
Last parallel
J15 1 parallel signal
connection board
Next parallel
connection board
Last parallel
connection board
Next parallel
connection board
Maintenance Maintenance
J13 1
air-switch signal air-switch
Output
J8/J19 1 Output air-switch
air-switch signal
Module insert Module insert switch
J7 1
signal board
六、 Inspection before installation
1. Room environment inspection

 UPS room：
UPS should be installed in a cool, dry, clean and well-ventilated environment, such as the
room temperature should be < 40℃, the humidity≤95% when 20℃, not obvious dust on
the floor, especially without any conductive powder. The roon air cannot contain acid mist
or other conductive medium. For detail, please refer to the users’ manual and other
specifications.
 Battery room：
The battery should be also placed in a cool, dry, clean and well-ventilated environment. The
available temperature is 15℃-25℃, typically is 20℃. The place where the battery located
should keep the constant temperature and far away from heat and vents.
2. UPS location inspection

The users’ manual offers the detailed installation instruction, it can be referred for
installation.
 Check if enough space is left for maintenance operation, ensure that the operator can
still pass through freely when the door is fully opened.
 There is no obstruction in the front, above and below of UPS. Enough space should be
left for ventilation.
 Air is primarily comes from front door, so check if the front door leave enough air inlet
space.
31
3. UPS visual inspection
 Particularly important: it is necessary to have a comprehensive inspection of internal
and external of UPS
1. Check the external power cable connection（include input /Output phase sequence
battery polarity、fasten bolt and ect.）
2. Check if the parallel cables are connected well? If they are routed separately from
power cables?
3. Check if the external signal of the battery box and LBS (when needed) connections are
good or correct?
4. Check if the internal signal cable is connected well，if the cable is loosed by shaking it
gently
5. Check if the internal boards or components are inconnected or damaged?
4. External cables and switch capacity inspection

 For power cable selection and connection method, please refer to the user manual
and related specification.
 Check if the breakers rated capacity of UPS input、Output and distributjion cabinet are
appropriate.
 Pay attention to the Neutral and Ground protection inspection:
If the Neutral and Ground cable size meets the requirement?
Neutral has separate input and output，connect to the same Neutral is not
allowed.
Check and confirm all the cabinets and cable ducts have been grounded
according to the local provisions.
 If the bypass has different power source, please check if the short copperbar of the
internal mains and bypass has been removed, do the connection correctly according to
the users’ manual.
 If the battery breaker box is provided, check if the connection of it is correct.
 Check if the UPS input/output wiring is reasonable and the cable is not in contact with
any sharp edges of objects.
 If the user install the remote contact to realize the EPO function, make sure that the
EPO cable is not interference by other main power signals to avoid UPS misfunction.
About how to realize the EPO function by remote contat, please refer to user’s manual.
 About other control cables connction, please refer to the relevant chapters of the
user’s manual.
5. External auto switching and generator power distribution inspection

 Confirm that the ATS at the input side is three level switch, that is the Neutral cannot
be cut off; if it is four level, confirm that when transfer between two sources, neutal
should meet on-befor-off principle.
 If the AC and generator can be selected at the input side, please confirm the proper
connction between Neutral and Ground according to the relevant specifications.
 If the generator has dry contact, it is necessary to connect it to the generator dry
contact of the monitor board.
32
6. Battery inspection
The important security guidance when operating battey：
1) Battery exists danger of short-circuit and possibly causes burning due to the short-circuit
current.
2) The voltage may reach 200VDC when battery connted in series, which has deadly danger. So
keep in mind to prevent electric shock.
3) The installation and operation of the battery must be carried out by professionals.
4) Note of eye protection to avoid accidental arc damage.
5) Remove all rings, watched, necklaces, bracelets and other metal objects.
6) The tools must be used with insulated handles.
7) Wear rubber gloves and protective aporns when do the battery operation.
8) If the battery has liquid leakage or housing damaged, place it in the ant-acid container
and deal it according to the local regulations.
9) If the electrolyte touches your skin, immediately wash it with a plenty of water.
10) The battery must be handled with reference to local environmental regulations.
Focus on the following aspects：
1) If the battery surface is clean, the appearance is damaged, deformed and leakage;
2) Check if the connection among battery is reliable, if the screws are tightened, if there is
corrosion and confirm that all battery terminals are coated with insulating material；
3) Check if there at least 10mm interval between the vertical side of the battery to ensure the
free flow of the air around the battery；
4) At least 150mm space should be left between battery top and upper frame for monitoring
and maintenance of the battery;
5) Check if the battery cabint or battery rack installed realiably, if there is good grounded. One
cable must be individually connected between battery breaker box and UPS;
6) About connections between battery pack and UPS, battery and battery, battery pack and
battery pack and rated capacity of breaker, please refer to the user’s manual and relevant
relevant specifications;
7) Check if the wiring is reasonalble and the cable is not in contact with any sharp edges of
objects;
8) If the battery cabinet is installed on a raised floor, the battery power cable and breaker
controlled cable can route through the floor; if the battery cabinets are side-by-side and
installed on a solid floor, cables can go into the outlet holes at the bottom of the cabinet
side to connect the battery cabinets;
9) Check and confirm that the cables are correctly and safely conncted to the battery
termainal blocks of the UPS. Don’t reverse the battery. About the terminal block diagram,
please refer to the user’s manual.
10) Make sure that the battery breaker box is switched off.
七、 UPS maintenance
1. Guidelines for good service
1.1 The UPS is almost maintenance-free and is designed to have a failure rate less than 1% a
33
year.
Periodical service is only needed for the fans; the UPS has a low heat generation.
A battery change after 3-6 years can be expected and, apart from the service to the fan,
it should normally be the only service done to the unit.
1.2 Due to the size of the UPS and the highly complex of the PCB, board level repair is not
recommended, take the following measures instead:
Improve the reliability of the design；
Replace the PCBA；
2. Security conditions
Warning：When the UPS is operating, all the electronic parts connected directly to the
power supply and all internal components including the battery exist high voltage. Even
disconnected from the power supply, all internal parts including the battery still have
dangerous voltage （except the communication output）.
2.1 Only authorized professionals with relevant knowledge can open the machine, the
others cannot open it for maintenance.
For authorized service personnel：
Do not work alone，a second person should be standing by to assist and render help in
case of accident.
Danger may occur only during the installation and maintenance. Any person operating in
a normal manner is safe.
2.2 If the UPS is in need of repair, the process A operation is recommended（This is

completely safe）：Disconnect all input power supply and battery. Load is allowed to turn
off for process A. The specific steps can be seen in chapter 3.
If the load is not allowed to turn off, please enter the maintenance bypass mode for
maintenance. Follow the process B （refer to chapter III for specific information）. Please
note that the do the maintenance in maintenance bypass mode is not absolutely safe，
Part of circuits are still at work.
In maintenance mode, the load is directly connected to the power via the bypass, so the
UPS will not provide any protection.
2.3 To avoid electrostatic discharge damage，ensure that the maintenance is under the ESD
safe conditions
- work on an anti-static mat；
- ground yourself and the unit when it is opened.
2.4 Be careful when disconnect the battery：
- Do not wear metal bracelets and etc.
- do not short circuit the batteries
2.5 If the UPS must be repaired during the operation such as measurement，Make sure that
the power supply is isolated. In this case, a transformer can be used between the UPS
34
and power.
Before maintenance, this manual should be entirely read.
3. Shutdown-disassembly/reassembly UPS
Warning： when UPS works，a large amount of energy is stored in the internal BUS capacitor，
no electricity cannot be guaranteed inside the UPS with mains isolation, so it needs extra
attention when maintenance. Disconnect all external input power of the fault machine for
maintenance，After opening the case, use the bleed resistor to release the energy stored in
BUS capacitor to avoid injury to person.
3.1Please refer to the user’s manual on UPS installation content；

3.2 First read chapter 2 “Security conditions”
3.3 If the UPS is in need of repair, the process A operation is recommended（This is
completely safe）：Disconnect all input power supply and battery. Load is allowed to turn
off for process A. The specific steps can be seen in chapter 3.
If the load is not allowed to turn off, please enter the maintenance bypass mode for
maintenance. Follow the process B （refer to chapter III for specific information）. Please
note that the do the maintenance in maintenance bypass mode is not absolutely safe，
Part of circuits are still at work.
In maintenance mode, the load is directly connected to the power via the bypass, so the
UPS will not provide any protection.
Step A：the load may be closed

A1 Turn off the load，disconnect all input power supply and battery；
A2 Open the front door，put the input/output/battery air-switches to OFF；
A3 Remove the 4 screws of the power module，pull out the ；
A4 Insert good power module；
A5 Tighten the four screws；
A6 Connect the mains/battery/load, switch on the battery switch, press the start key to
start the unit
A7 If UPS has no fault, it will has output when output air-switch is switched on.
A8 Switch-on the input -air-switch, the UPS will transfer to mains, and charge the
battery.
A9 Close the front door.
Step B: The load may not be closed.

B1 Open the front door, remove the maintenance screws and baffles to check whether
the machine enter the maintenance bypass mode
B2 If the UPS goes to the maintenance bypass mode，switch on the maintenance bypass
switch，otherwise do the maintenance in accordance with the process A；
B3 Remove the 4 screws of the power module, and then pull the power module；
B4 Insert the good power module；
B5 Tighten the four screws，the unit goes into the maintenance bypass mode；
35
B6 Switch off the maintenance switch，install baffles and screws，the unit goes to the
bypass mode；
B7 If both the mains and battery are normal，the unit goes into the line mode and
charging after a period of time；
B8 Close the front door.
4. Troubleshooting
This chapter provides information that can help you to locate faults in HIP UPS.
Some data may have to be measured to fix the fault. If it needs to be measured during
the operation, the device should be isolated from the mains. In this case, a transformer
can be used between device and the power. It also applies to the bypass input.
Warning： when UPS works，a large amount of energy is stored in the internal BUS
capacitor， it cannot be guaranteed that there is no electricity inside the UPS with mains
isolation, so it needs extra attention when maintenance. Disconnect all external input
power of the fault machine for maintenance. After opening the case, use the bleed
resistor to release the energy stored in BUS capacitor to avoid injury to person.
Before maintenance, please confirm the related reliable cable connection.

For the UPS fault, please record the software version and PCB version correctly.
Warning s and precautions:

When fault occurs, make a note of the display (refer to code table) as the reference for
maintenance.
Note: the UPS mains input switch cannot be OFF arbitrarily to avoid electricity
interruption.
Fault analysis:
Record the status of display，then fix the reason in accordance with the following
questions.
1. if the input supply is abnormal？(over/under voltage)
2. If load changes？( capacity or type)
3. If fire？
4. If smelly odor？
5. If abnormal noise？
6. If bad environment？(dust or moisture)
7. High temperature of UPS or ambient environment？
Troubleshooting
Failure view:
Please ensure the safe conditions before starting the maintenance. Please read chapter
36
2 “Security conditions” and chapter 3 “shutdown-disassembly/reassembly UPS”；
After remove the case，checking the following items:
1. If the CONNECTOR or terminals loose？
2. If the transformer or other parts burst or discoloration especially the power
components on the heat sink?
3. Is capacitor rupture or leak？
4. If any parts serious blow up especially power components on heat sink？
Solutions:
1. If the unit fails，due to higher probability damage of the INV-POWER board，replace
the power board is ok.
2. If any power component on the power board is founded to blow up, replace it
according to the “replace PCB”；
3. If fan doesn’t work with mains input, confirm that if the auxiliary power of the
INV-POWER board is damaged and needs to be replaced
4. Charger shows abnormal, check if the charging circuit in the PFC power board is
damaged and need to be replaced.
4.1The display has no light and response when connected mains
37
No light and response for LCD
Refer to chapter 2 and chapter

3 for operation
Check if the ± 15V in YES

Replace DSP
INV-POWER board is normal
NO
Check If the fuse of NO Replace the fuse

INV-POWER board is good
YES
NO
Replace INV-power board If repaired
YES
END
5. Battery replacement
1. Refer to the user’s manual for battery installation operation；

2. Ensure the safe conditions before any operation. Please read chapter 2《Security
conditions》 and chapter 3《shutdown-disassembly/reassembly UPS》carefully. Be
careful when disconnecting the battery. Short circuit will damage the battery or
wiring.
Note：
The battery with the same brand/type/date of manufacture is recommended to ensure a
long battery life. The voltage difference among the batteries should not more than ±150
mV。
We recommended to measure the voltage of each battey during discharge to ensure the
voltage differences no more than ±150 mV。The battery pack capacity will be affected if
there is one or more battery voltages differ too much. In the worst case, it will damage
the other battery.
The voltage difference should be reduced after a long period of charging.
38
5.1 HIP standard battery string：
1. Switch of the battery switch（if have），remove the middle baffle；
2. Pull out the battery drawer，remove the screws，take out the battery，replace the new
battery；
3. Replace the remaining three drawer of battery；
4. Thoroughly check if all the connections are correct；
5. Re-install the battery drawer；
6. Measure the total voltage of the battery；
7. Install all screws、baffles，switch on the battery switch（if have）.
5.2 Single Battery cabinet：

1. Close the battery switch（if have）；
2. Disconnect the connection between the UPS and the battery cabinet；
3. Replace the battery according to the battery cabinet user’s manual；
4. Thoroughly check if all the connections are correct；
5. Measure the total voltage of the battery；
6. Open the battery switch（if have）
6. PCB replacement
Warning：when UPS works, a large amount of energy is stored in the internal BUS
capacitor, it cannot be guaranteed that there is no electricity inside the UPS with mains
isolation, so it needs extra attention when maintenance. Disconnect all external input
power of the fault machine for maintenance. After opening the case, use the bleed
resistor to release the energy stored in BUS capacitor to avoid injury to person.
6.1 General instruction
The internal voltage of the module is high enough to cause serious personal injury or
death。
conditions》 and chapter 3《shutdown-disassembly/reassembly UPS》carefully. Be
careful when disconnecting the battery. Short circuit will damage the battery or
wiring.
2. ESD（electrostatic discharge） precautions： The PCB is very sensitive to electrostatic.
When pick and place the board, ensure that the operating personnel and equipment
are grounded well.
The new board is taken out from the anti-static packaging only when necessary，the
old board removed from the UPS should be immediately placed in anti-static
packaging.
3. Shut down the UPS according to the process A or B in chapter 3.
4. When disconnect any connectors, hold the male while pulling the female
39
（sometimes need to press the connector snaps），otherwise, it will make the
connector or PCB bending.
Mark it before disconnecting in order to facilitate the re-assembly connector.
5. Ensure the compatibility between the new board and old board before replacement.
6. When re-install the connector, the male and female should be aligned，or the PCB or
UPS will be damaged.
7. Confirm if the connection is correct after replacing PCB.
EMI board replacement

conditions》 and chapter 3《shutdown-disassembly/reassembly UPS》carefully.
2. Operate according to the steps 1-3 of process A or steps 1-3 of process B in chapter
3；
3. Remove the upper cover screws of the bad power module，remove the cover，use
the bleeder resistor to release the energy stored in the Bus capacitor；
4. Remove all the cables of the EMI board；
5. Remove all the screws of the EMI board；
6. Replace the PCB，package the old PCB；
7. Install the screws and cables；
8. Install the upper cover and the screws of the power module；
9. Continue with the steps 4-9 in process A or 4-8 in process B in chapter 3;
Replace DSP board

3；
3. Remove the lower cover screws of the bad power module，remove the cover，use
4. Remove all the cables of the DSP board；
5. Remove all the screws of the DSP board；
8. Install the lower cover and screws of the power module；
Replace PFC inductor board

3；
40
4. Remove all the cables of the PFC inductor board；
5. Remove all the nuts and screws of the PFC inductor board；
7. Install the nuts, screws and cables；
8. Install the upper cover and screws of the PFC inductor module；
Replace PFC power board

3；
4. Remove all the cables of the PFC power board
5. Remove all the screws of the PFC power board；
Replace INV inductor board

3；
4. Remove all the cables of the INV inductor board
5. Remove all the screws and nuts of the INV inductor board；
7. Install the nuts, screws and cables；
8. Install the upper cover and screws of the power module；
Replace INV power board

3；
4. Remove all the cables of the INV-POWER board
41
5. Remove all the screws of the INV power board；
LCD on front panel

3；
3. Open the front panel，remove 4pcs of nuts of the rear panel and then remove the
rear panel；
4. Remove all the cables of the PCB
5. Remove all the screws of the PCB；
8. Install the rear panel and nuts；
7. Replace fan
Four fans are provided
2. Operate according to the steps 1-3 of process A or steps 1-3 of process B in chapter 3；
3. Remove the upper and lower cover screws of the bad power module，remove the cover，
use the bleeder resistor to release the energy stored in the Bus capacitor；
4. Remove the fan cables of the INV power board；
5. Remove all the screws of the fan；
6. Replace with a new fan；
8. Install the upper and lower covers, screws of the power module；
8. PCB static maintenance

PFC inductor board
42
1
NO. Description Type Checked components Detect Pin Meter stall Normal abnormal
1 AC rectify Diode D1-6 A/K diode 0.36V open or short
2 mains input Relay K6-8 4/5 Ω open short
3 Battery input Diode D7、D9、D18-21 A/K diode 0.36V open or short
4 Battery input FUSE F1、F2 Ω 0Ω open
5 Battery input Relay K1、K2 1/3 Ω open short
6 Charge SCR Q70、Q71 A/K Ω open Short
7 Charge SCR Q70、Q71 G/K Ω ≈10Ω open or short
8 Bypass SCR QJ2-3、QJ11-14 A/K Ω open Short
9 Bypass SCR QJ2-3、QJ11-14 G/K Ω ≈10Ω open or short
10 Bypass Relay K3、K4、K5 1/3 Ω open short
PFC power board

NO. Description2 Type Checked components Detect Pin Meter stall Normal abnormal
1 BOOST Diode D7-D12 A/K diode 0.36V open or short
2 BOOST IGBT Q1-12 E->C diode ≈0.4V open or short
3 BOOST IGBT Q1-12 G/E Ω ≈10KΩ open or short
4 Charge FUSE F3-4 Ω 0Ω open
5 Charge MOSFET Q13-14 S->D diode ≈0.46V open or short
6 Charge MOSFET Q13-14 G/S Ω ≈20KΩ open or short
INV inductor board

1 INV FUSE F1-3 Ω 0Ω open
2 INV SCR SCR1-6 A/K Ω Open Short
3 INV SCR SCR1-6 G/K Ω 20~40Ω open or short
4 INV Relay RLY1-3 1/3 Ω open short
INV power board

1 INV IGBT Q1-12 E->C diode ≈0.4V open or short
2 INV IGBT Q1-12 G/E Ω ≈10KΩ open or short
3 Auxiliary power FUSE F1 Ω 0Ω open
4 Auxiliary power MOSFET Q14-15 S->D diode ≈0.46V open or short
43
5 Auxiliary power MOSFET Q14-15 G/S Ω ≈10KΩ open or short
八、Single cabinet commissioning

Warning： When UPS is working, the internal Bus capacitor stores a lot of energy. But
isolated with mains cannot guarantee completely no electricity inside the UPS and need
extra attention when do the maintenance. When cut off all the external input power
supplied for maintenance, use the bleed resistor to release the energy stored in Bus
capacitor after open the case firstly to avoid causing injury to persons.
Please refer to the “UPS repair/maintenance”, especially the “Security maintenance
conditions” and “ Close-Disassembly/Reassembly UPS”.
The stand-alone commissioning requires intact power module.
1. Startup steps
1) Before startup, confirm that the input/output connection is correct, measure the positive
and negative battery voltage, battery breaker is temporarily open.
2) Close the UPS Output switch.
3) Close the UPS input switch. Close external input mains and start UPS by AC.
4) After AC start, check the LCD in the front door to see if the display of working mode,
maching ID number, the VA of UPS, output voltage level and the frequency is the same with
the actual values.( refer to the following pictures). If not the same, immediately disconnect
the mains to check or cal lthe customer service hotline.
Stand-alone mode
Fig. 25 HIP settings

5) Close the external battery breaker, check if the charge current on the LCD is normal
6) Simulate mains power failure test: Disconnect external main input breaker and check if the
UPS can transfer to battery inv. Mode and the output is uninterruptable. Then close the
44
external mains breaker to confirm the UPS enter the line mode. At last, check if the charge
and output are normal.
2. Shutdown steps：
1) Open the front door of UPS, open the output breaker
2) Press the OFF button the the LCD panel and keep it for no less than 2s，UPS Inv. LED is off
3) Open the battery breaker
4) Open the input breaker and UPS shutdown
5) To completely isolate the AC power supply, the external grid input switch should be open.
The main input distribution board is usually away from the UPS. It is necessary to inform the
service personnel that the UPS is in repair by posting a lable on it.
3. Emergency shutdown instructions

1) Open the front door, an emergency power off (EPO) button is emboded next to the SNMP
card. In case of emergency, press EPO button for 3s, the UPS shutdown can be achieved.
2) EPO button is designed with protection. It is coverer by transparent cover to avoid misuse.
When the emergency shutdown is required, open the transparent cover and press the red
button for more than 3s, the UPS will shutdown.
KSTAR technical service hotline：400-700-9662 / 800-830-9662
9. Parallel system commissioning

Warning： When UPS is working, the internal Bus capacitor stores a lot of energy. But
isolated with mains cannot guarantee completely no electricity inside the UPS and need
extra attention when do the maintenance. When cut off all the external input power
supplied for maintenance, use the bleed resistor to release the energy stored in Bus
capacitor after open the case firstly to avoid causing injury to persons.
Please refer to the “UPS repair/maintenance”, especially the “Security maintenance
conditions” and “ Close-Disassembly/Reassembly UPS”.
Parallel system should be commissioning when the stand-alone are all intact.
1. Startup steps
1) According to the stand-alone startup steps, set up the working mode, ID, output
voltage level, frequency level of each UPS. The ID must be different for each unit. Up
to four units can be paralleled.
2) Properly connect the parallel cables（refer to the users’ manual）、input/output cables、
battery cables.
3) Measure the positive and negative battery pack voltage，battery breaker is temporarily
opened。Each single UPS need to have a separate battery cabinet.
4) Close the output breaker.
45
5) Close the input breaker. Close the external input breaker and start from AC.
6) After startup, check the ID of parallel cabinet, check if the VA is the same with actual
value. If not the same, please cut off mains for check or call the service hotline.
7) Close all external battery breakers of all cabinets. Check if the charge current displayed
in LCD is normal.
2. Shutdown steps
1) Confirm the load information to avoid overload when turn off single unit；
2) Shut down each UPS according to the stand-alone UPS shutdown steps.
3. Emergency shutdown
According to the stand-alone emergency shutdown steps, select any one unit can shut
down all the outputs of UPS in the parallel system.
10. Software upgrade

There are two methods for software upgrade.
1. Use C2000 emulator to upgrade

For specific steps, please refer to the C2000 emulator description.
2. Use 485 communication to upgrade

The method requires the special tools and software, which is under the development now.
46
Appendix A HIP33000 Series UPS difference

N
NAME HIP33010 HIP33015 HIP33020 HIP33030 HIP33040H HIP33050H HIP33060H HIP33080H
O
S H S H S H S H
Output PF0.9 9KW 13.5KW 18KW 27KW 36KW 45KW 54KW 72KW
1 Power
PF0.8 8KW 12KW 16KW 24KW 32KW 48KW 64KW
factor
Module PF0.9 15KVA--2PCS 15KVA--3PCS 20KVA--3PCS

2 10KVA 15KVA 20KVA 20KVA--2PCS 30KVA--3PCS
power
PF0.8 30KVA--1PCS 30KVA--2PCS
J102/104/106/107/118/ J102/104/106/110/111/112/113/114/115/1
PF0.9 J107/116 J102/104/106/107/109/116 J102/104/106/107/108/109/116 J102/104/106/116 J102/104/106/109/116 J102/104/106/108/109/116
Short 116 07/109/118/116
circuiter
3 J102/104/106/110/111/112/113/114/115/1
PF0.8 J107 J102/104/106/107/109 J102/104/106/107/108/109 J102/104/106/110/111/112/113/114/115 J102/104/106/109 J102/104/106/108/109 J102/104/106/107/118/
（inside 07/109/118/
module）
Remark：J101/103/105/102/104/106: Inv. Current limiting selection；J110/111/112/113/114/115: PFC sampling resistor in parallel selection；J107/108/109/116(TEST1)/117(TEST2)/118/119: model selection
J23,J24,J25,J26,J27
（Remove the J26 and J27 when 3 UPSs in J25,J26,J27

Short
PF0.9 parallel （Remove the J26 and J27 when 3 UPSs in parallel
circuiter
Remove the J25,J26 and J27 when 4 UPSs in Remove the J25,J26 and J27 when 4 UPSs in parallel ）
(parallel
parallel ）
connection
J23,J24,J25,J26,J27
4 board J1/J2
UP J23,J24,J25,J26,J27 （Remove the J26 and J25,J26,J27
Can
S （Remove the J26 and J27 J27 when 3 UPSs in （Remove the J26 and J27 when 3 UPSs in
compatible
PF0.8 J1/J2 when 3 UPSs in parallel parallel parallel
with
Remove the J25,J26 and J27 Remove the J25,J26 and Remove the J25,J26 and J27 when 4 UPSs in
resistor)
when 4 UPSs in parallel ） J27 when 4 UPSs in parallel ）
parallel ）
Chassis PF0.9 A baffle is used for the bottom module place for 3 modules
different
Standard unit with battery tray；
5 English and Standard unit with battery tray； A baffle is used for the bottom A baffle is used for the
PF0.8 long time unit without battery tray place for 3 modules
Chinese silk long time unit without battery tray module bottom module
screen
Input、 PF0.9 63A(NDM1-125) 100A

6 Output 20A 32A 40A 80A 100A 125A
PF0.8 63A(NDM1-63)
breaker
PF0.9 NO
Battery Standard unit with 63A/2PIN battery breaker；
7 Standard has 63A/2PIN battery breaker；
breaker PF0.8 long time unit has no this breaker NO
long time unit has no this breaker
Maint PF0.9 125A 225A

8 63A 125A
breaker PF0.8 63A 225A
9 semi-finishe PF0.9 Stand unit with battery cable； 2 module wiring 3 module wiring(25mm wiring) 3 module wiring
47
d wire long time unti without battery cable Standard unit with battery cable; (35mm wiring)
PF0.8 2 module wiring 2 module wiring
long time unti has no
parallel PF0.9 2 big parallel connection board 3 big parallel connection board
10 connection Small parallel connection boardUHDBGST1CX02 Small parallel connection 2 big parallel connection 2 big parallel connection
PF0.8 3 big parallel connection board
board boardUHDBGST1CX02 board board
NO. Name HIP33010 HIP33015 HIP33020 HIP33030 HIP33040H HIP33050H HIP33060H HIP33080H
S H S H S H S H
Signal PF0.9 2PCS 3PCS

connection
11 1PCS
board PF0.8 1PCS 2PCS 2PCS 3PCS
UHTBJHT1CX02
PF0.9 2PCS 3PCS

12 Switch board NO
PF0.8 NO 2PCS 2PCS 3PCS
UPS
PF0.9 150A
13 Terminal 60A 150A 200A
PF0.8 75A
PF0.9 English
14 LCD display
PF0.8 Chinese
Package PF0.9 Pallet ---for standard unit with battery shipment ：2049-2320
15
material PF0.8 PF0.9 some customers requirement：module need to be individually packaged
HIP series module difference
For reference 2012-08-24
NO PCB HIP33010 HIP33015 HIP33020 HIP33030
10KVA 15KVA 20KVA 30KVA
6PCS IGBT： PFC---12 PCS IGBT：IKW40N120H3 PFC---12PCS MOSFET：SPW47N60C3

1 PFC power board
IKW40N120H3 Diode：RHRG75120 Diode：APT60DQ120BG
PFC inductor board（Diode

2 silica gel strip Ceramic gasket
Bare insulating sheet）
UPS
INV inductor board（BUS 10PCS 470U
- 3 16PCS 470U capactor 19PCS 470U capacitor 19PCS 680U capacitor
capacitor） capacitor
Module
4 INV power board（IGBT） 6PCS IGBT 12PCS IGBT
5 Semi-finished wire Max. 10AWG wire With 8AWG wire
Front 12025-0.75A
6 Fan Front and back 12038-0.5A
back 12038-0.8A
7 Short circuiter Refer to the corresponding jumper
48
Appendix B Power module fault judgement

Software judgement
NO. UPS Alarm
Condition 1 Condition 2 Condition 3 Condition 4 Buzz LED
long
1 Rectifier fault DC BUS over-voltage DC BUS under-voltage Large bus difference
beep Fault ON
Bridge arm midpoint voltage（ Inv. voltage） last 500ms＞

Inv. fault（include Inv. Bridge The absolute value of the output voltage ＞112.5% of rated
2 1.1 time of rated peak value 360vfor230 344for220 long
arm ） output voltage, last 500ms
376for240 beep Fault ON
long
3 Inv. SCR short
beep Fault ON
（in parallel, X phase load rate<6.3%）&&（parallel X phase total load rate＞50%）&&（large loop current||in bypass mode） long
4 Inv. SCR break
last time 2S beep Fault ON
long
5 Bypass SCR short （X phase Output voltage>60% of rated）&&（the absolute values of other phases voltage＜5% of rated voltage）last 2s
beep Fault ON
（（in parallel, X phase load rate <6.3%）&&（parallel X phase total load rate＞50%）&&(large loop current|| in Bypass mode）） long
6 Bypass SCR break
||（X phase current＜10% of rated&&X phase Output voltage＜50% of the Bypass voltage）last 2S beep Fault ON
long
7 Fuse broken Hardware signal low available
beep Fault ON
long
8 Paralle Relay fault （ Inv. status&&Relay open）||（no Inv. Status && parallel Relay close）last 20ms
beep Fault ON
Hardware signal low long

9 Fan fault
available for 5s beep Fault ON
long
10 Reserve
beep Fault ON
Hardware signal low long

11 Auxiliary power fault
available for 3ms beep Fault ON
1）Rec.DSP read IIC self-test，until 15s power on） Inv. DSP read IIC self-test，until 15s delay unit not obtain valid parameter from long
12 Power initialization fault
E2PROM, jumper error，jumper type is not defined, DSP internal RAM self-test error（MCU cannot completely modify RAM） beep Fault ON
49
Software judgement
NO. UPS Alarm
long
13 Positive battery Charge fault
beep Fault ON
long
14 Negative battery Charge fault
beep Fault ON
+bus voltage＞470V -bus voltage＞470V long

15 Bus over-voltage
Last time: 20ms Last time: 20ms beep Fault ON
Bus voltage ＜280V Bus voltage is 10V lower than setting value long
16 Bus under-voltage
time:120ms Time: 2min beep Fault ON
30V difference between ± long

17 Large difference between ±Bus
bus beep Fault ON
10s later, soft start bus During the soft start, ±bus voltage ＜1.2 times of input long
18 Soft start fail
voltage is lower than 300V voltage for 120ms beep Fault ON
Last 0.2s＞77℃ show PFC

19 Rectifier over-temperature
over temperature twice/s Fault ON
Last 0.2s＞77℃ show

20 Inv. Over-temperature
inverter over temperature twice/s Fault ON
21 Input missing Neutral twice/s Fault ON
22 Battery reverse +battery voltage＜ -50V -battery voltage ＞+50V twice/s Fault ON
Parallel cable fault under

23 Parallel connection fault
the parallel : 10ms twice/s Fault ON
Parallel module numbermore than 1 for single unit and

24 CAN communication fault
powered module is no more than 1 unit twice/s Fault ON
25 Share current when parallel fault twice/s Fault ON
26 Battery high voltage Setting Charge voltage +20V once/s Fault flash
27 Input phase sequence reverse Obtain by algorithm once/s Fault flash
28 Bypass reverse Obtain by algorithm once/s Fault flash
29 Output short circuit X phase Output voltage is lower than rated 30%&&X phase Output current is 70% of rated current once/s Fault flash
50
Software judgement
NO. UPS Alarm
30 Rectifier over-current once/s Fault flash
31 Bypass over-current X phase Bypass Output current greater than the rated 125% once/s BPS flash
INV or BPS
32 Over load X phase load rate（ Inv. or Bypass）greater than rated 105%
once/s flash
BATTERY
33 No battery Battery voltage lower than 50V
once/s flash
BATTERY
34 Battery voltage low Battery voltage lower （EOD voltage*6*battery pcs）
once/s flash
BATTERY
35 Low battery pre-alarm Battery EOD voltage+（battery pcs *6（SetJarNum）*1.5）
once/s flash
HIP module number is not the

Comm. Error between
36 Internal communication error CAN comm. Master/slaver detect cabinet and module ID fault same with modules powered
Rectifier and Inv.
on: 1S once/2s Fault flash
37 Inv. DC excessive DC component average valure is more than 2V last 2S once/2s INV flash
38 Overload in parallel X phase load rate is more than total load rate of parallel system: 400ms once/2s INV flash
BATTERY
39 Mains voltage abnormal Higher than 270V Lower than 182V
once/2s ON
BATTERY
40 Mains frequency abnormal Higher than 70Hz Lower than 38Hz
once/2s ON
41 Bypass ultra protection Bypass power down and not available BPS flash
42 Bypass ultra tracking Bypass abnormal but powered, and bypass instantaneous normal, then change the Bypass to ultra tracking BPS flash
1） rectifier not start completely or start fault

a) over-temperature
b) fan fault
43 Start invalid
c) SCR fault and shutdown
d) bridge arm short and shutdown
e) power board fault
51
Software judgement
NO. UPS Alarm
f) software fail
g) battery reverse and shutdown
h) remove module and shutdown
i) user operation fault(maint Bypass close)
j) Auxiliary power power down and shutdown
2） manually start invalid

44 Module not inserted Module access signal is not set
52

HIP33000 (10 80K) Maintenance Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

HIP33000 (10 80K) Maintenance Manual

Uploaded by

Copyright:

Available Formats

KSTAR 高频产品线

Figure Contents ..................................................................................................................... II

Table contents ..................................................................................................................... III

一、 Product introduction .............................................................................................. 1

4. Operating panel ......................................................................................................... 2

二、 System block diagram ............................................................................................. 4

1. Cabinet block diagram ................................................................................................ 4

2. Power module block diagram ..................................................................................... 5

3. Power modue AC/DC & DC/DC principle circuit diagram ............................................. 6

4. Inverter DC/AC principle............................................................................................. 6

5. Charging principle ...................................................................................................... 7

1. UPS specification ........................................................................................................ 7

四、 Internal structure ................................................................................................... 9

1. The whole appearance ............................................................................................... 9

2. Internal view of power module ................................................................................ 15

五、 PCB boards and their signals ................................................................................. 16

1. PFC inductor board................................................................................................... 17

2. PFC power board ...................................................................................................... 19

3. INV. Inductor board .................................................................................................. 20

4. Inverter power board ............................................................................................... 23

5. DSP board ................................................................................................................ 24

6. Parallel connection board ......................................................................................... 30

六、 Inspection before installation ............................................................................... 31

1. Room environment inspection ................................................................................. 31

3. UPS visual inspection................................................................................................ 32

4. External cables and switch capacity inspection ......................................................... 32

5. External auto switching and generator power distribution inspection ...................... 32

6. Battery inspection .................................................................................................... 33

七、 UPS maintenance ................................................................................................. 33

1. Guidelines for good service.......................................................................................... 33

2. Security conditions ...................................................................................................... 34

3. Shutdown-disassembly/reassembly UPS ...................................................................... 35

6. PCB replacement ......................................................................................................... 39

8. PCB static maintenance ............................................................................................ 42

八、Single cabinet commissioning ...................................................................................... 44

1. Startup steps ............................................................................................................ 44

2. Shutdown steps： .................................................................................................... 45

3. Emergency shutdown instructions ............................................................................ 45

9. Parallel system commissioning .................................................................................... 45

1. Startup steps ............................................................................................................ 45

3. Emergency shutdown ............................................................................................... 46

10. Software upgrade..................................................................................................... 46

1. Use C2000 emulator to upgrade ............................................................................... 46

2. Use 485 communication to upgrade ......................................................................... 46

Appendix A HIP33000 Series UPS difference .............................................................. 47

Appendix B Power module fault judgement ....................................................................... 49

Fig. 1 Appearance（ 20KVA）

LCD display ON button

Fig. 1 Operating interface of power module

 Status indicator on front panel、LCD and other buttons

Name Status Description

Table 2 Button description

1. Cabinet block diagram

Comm LCD display

Batt Power module 2

Fig. 2 block diagram

mains EMI DC/AC

Fig. 3 Power module block diagram

Fig. 4 power module AC/DC & DC/DC principle

4. Inverter DC/AC principle

Model HIP33010S/H HIP33015S/H HIP33020S/H HIP33030S/H HIP33040H HIP33060H HIP33080H

10KVA 15KVA 20KVA 30KVA 40KVA 60KVA 80KVA

Rated voltage 380/400/415Vac