TRAINING PROGRAMME

ON

SALIENT FEATURES OF
SERVICE MANUAL

DECEMBER 2008 - 09

KEVIN POWER SOLUTIONS LTD.

Khasra No. 275, Lakeshri Industrial Area,
Bhagwanpur, Roorkee - 247 667
Uttaranchal (INDIA)
Tel: (01332) 235216; Fax: (01332) 235217
Web-site: www.kevin solutions.net

1
 CONTENTS
Page No.

1) INTRODUCTION ABOUT INVERTER & UPS

¾ Inverter
¾ Off Line UPS
¾ Online UPS
¾ Home UPS
¾ Static UPS
¾ Square wave
¾ Sine Wave
¾ High Frequency Home UPS

1) BLOCK DIAGRAM & BRIEF WORKING

¾ Inverter
¾ Off Line UPS
¾ Online UPS
¾ Home UPS
¾ Static UPS
¾ Square wave
¾ Sine Wave
¾ High Frequency Home UPS

2) WIRING DIAGRAM & BRIEF WORKING

¾ Online UPS
¾ Home UPS

2
 ¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS

3) CIRCUIT DIAGRAM & BRIEF WORKING

¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA

4) TESTING PROCEDURE

¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA

5) FAULT FINDING

¾ Online UPS
¾ Home UPS

3
 ¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
¾ High Frequency Home UPS
o 800VA
o 1400VA

6) INSTALLATION PROCEDURE & PRECAUTIONS

¾ Online UPS
¾ Home UPS
¾ Static UPS
o 2.5 KVA to 3.5 KVA
o 5 KVA and Above
High Frequency Home UPS

4
 INTRODUCTION OF INVERTER & UPS

1.1 INVERTER

Inverter convert battery DC Power into AC Power

Inverter converts the battery power current into conventional A/C power. This power
can be used to run almost any AC appliance absolutely anywhere. They can run
items such as mobile phone chargers, lights, electrical appliances, power tools,
computers, faxes, TV sets, microwave ovens, battery chargers & motors.

There are three kinds of DC - AC inverter:

1. SQUARE WAVE INVERTER - The square wave is the simplest and the least
expensive type, but now days it is practically not use because of low quality of
power.

2. MODIFIED SINE WAVE INVERTER - The modified sine wave topologies (which are
actually modified square wave) produce square wave with some dead spots
between positive & negative half-cycles. They are suitable for many electronic
loads & are the most popular low-cost inverter on the market today.

3. PURE SINE WAVE INVERTER - Pure sine wave inverters produce AC voltage with
low total harmonic distortion (typically below 3%). They are used when there is a
need for clean sine wave output for some sensitive devices such as medical
equipment laser printers stereos etc.

5
STATIC INVERTER/UPS

Static inverters have no moving parts and are used in a wide range of applications, from
small switching power supplies in computers, to large electric utility high-voltage direct
current applications that transport bulk power. Inverters are commonly used to supply AC
power from DC sources such as solar panels or batteries.

1.2 UPS
Survey indicates that 50% of the malfunctioning that happened during data
processing was caused by commercial power disturbance. This explains the
importance of configuration of a UPS together with a Computer system,
telecommunications, medical instrument, process control, security system, CNC
machine and all power sensitive equipment. The UPS is designed to protect
computer, telecommunication, medical instrument, process control, security
system, CNC machine and all power sensitive equipment against any power failure
or disturbance.

There are three different types of UPS that are suitable for different tasks and
supporting different types of load. These are:

b. Off-Line Stand by
c. Line Interactive
d. On-Line Double Conversion

a. Off-Line Stand by

During normal operation, the power flows straight through the unit and hence
only RFI filtering is usually provided. When the input voltage fails or fluctuates
outside of a pre-set tolerance window, the UPS detects this and a relay will close
allowing the UPS to start feeding battery power via the inverter.

b. Line Interactive

A line interactive UPS operates in a very similar fashion to an off-line UPS,

except with the advantage of better filtering and output voltage boost/ reduce
features. Whilst not eliminating mains borne interference, line interactive
technologies reduce the impact of spikes, surges and sags by ‘clipping’ the
peaks and valleys, boosting power or switching to battery back-up.

c. Online Double Conversion

An uninterruptible power supply using true online double conversion technology

provides the highest level of power protection available. The UPS converts the
230 V input AC mains supply to DC power which is then used to charge the

6
 battery. The DC current flow is then fed through an inverter stage which
reconstructs the 230 V AC mains output.

Few major characteristics of On-Line UPS are:

a) Total solution for computer system, telecommunication, medical instrument,

process control, security system, CNC Machine and all power sensitive
equipments management.
b) DSP control intelligent system
c) Advanced IGBT Technology to deliver pure sine wave
d) Large LCD display board
e) Fully automatic by pass switch capable to sustain 200% rated current during
transfer
f) Smart over load & short circuit protection for both of utility & inverter mode
g) High in rush handling capability of inverter able to turn on UPS with load on
h) Better than 3:1 crash factor handling
i) True RS 232 communication port compatibility sec or valued UPS management
software
j) SNMP connectivity to operate network management system
k) Ergonomic & stylish design to match with OA environment

7
2. BLOCK DIAGRAM OF UPS

Block diagram of on-line UPS is given below:

INVERTER

MAINS LOAD
(I/P) INVERTER
(S/W) (O/P)

CHARGING DISHCHARGIN

BATTERY BANK

STATIC UPS

MAINS STATIC LOAD

(I/P) INVERTER
(S/W) (O/P)

CHARGING DISHCHARGIN

BATTERY BANK

8
 OFFLINE UPS
FILTER & SCR

MAINS LOAD
(I/P) INVERTER
(S/W) (O/P)

CHARGING DISHCHARGIN

BATTERY BANK

ONLINE UPS

FOR BY PASS

MAINS RECTIFIER INVERTER STATIC LOAD

(I/P) (AC-DC) (DC-AC) (S/W) (O/P)

BATTERY BANK

9
3. WIRING DIAGRAM OF INVERTER & UPS
Wiring diagrams of inverters of various capacity are given as under:

Fig. 1. Wiring diagram of 2.5 KVA/ 48 V Inverter

10
 diagram of 5 KVA/ 96 V inverter

Fig. 3 Wiring diagram of 2.5 KVA/ 48 V Static UPS

11
Fig. 4 Wiring diagram of 5 KVA 120 V Static UPS

Fig. 5 Wiring diagram of 6 KVA/ 180 V Static UPS

12
Fig. 6 Wiring diagram of 5 KVA/ 180 V On-Line UPS

Fig. 7 Wiring diagrams of 10 KVA/ 360 V On-line UPS

13
 Fig. 8 Wiring diagram of 10 KVA/ 192 V On-Line UPS

Fig. 9 Wiring diagram of 15 KVA/ 360 V 3 Phase-in; 3 Phase-out On-Line UPS

14
4. CIRCUIT DIAGRAM OF INVERTER
• CIRCUIT DIAGRAM 800 VA HF
• A
D7 +15V_LO
VCC-MAINS D48 STTH110A/STTH112A R69 10E_1W 1%
1N4007

C21 C22
Z6
C35 100uF/35V 104/25V
R20 10uF/63V 18V/1/2W
10K_1/4W 1% R123 D49
1K_1/4W 1% 1N4007
VCC Q22 TR1
D11 R18 BC857 3 D6 +15V_HI1
1N4007 68K_1/4W 1% STTH110A/STTH112A 0
Q13 65T,35SWG
BC847 +VE BATT.
4 R68 10E_1W 1%
6 Z5
R19 C26 C18 C19
6K8_1/4W 1% 1uF/63V 1 65T,38SWG 18V/1/2W
R1 100uF/35V 104/25V
C1 C2 1K_1W 1% 5
40T(20T+20T),30SWG 8
470uF/25V 0.22uF/25V D5 +15V_HI2
R170 2 65T,38SWG STTH110A/STTH112A FGND1
R164
1K_1W 1% 7
150K_1/2W 1% 10 R67 10E_1W 1%
D2 C15 C16 Z4
STTH110A/STTH112A 25T,30WG
100uF/35V 104/25V 18V/1/2W
9
C3
Z8 145T,35SWG
C5 27V_1/2W 0.01uF/100V
C4 FGND2
22uF/25V 0.1uF/25V CF138,EE COSMO,20 X10 X 5.5mm
D3 +5V
IC1 STTH310-DO-201ADC2/UF5408 L1
7

UC3843 R4 10K_1/4W 1%
3 8
VCC

2 ISEN VREF 4 R8 C10 C11 INDUCTOR C12

C6 VFB RT/CT 10E_1/4W 1% Q1
6 IRFZ44N 100uF/35V 104/25V 470uF/25V
GND

1000PF/25V OUT 1
COMP C7
C9 R11
R7 103/25V 2200PF/25V Z1 6K2_1/4W 1%
5

R9 1K_1/4W 1% R5 15V/1/2W
1K_1/4W 1% 1K_1/4W 1%
4 IC2 1

C8 470PF/25V 3 2
PC817 R10
1K8_1/4W 1%

R6 T POINT R
TP4
100K_1/4W 1% R2 R3 D4 VCC-RELAY
1E_1/4W 1% 1E_1/4W 1% STTH110A/STTH112A R12

750E_1W 1%
C14
Z2
10uF/63V 33V/1/2W

LOW POWER SUPPLY

Kevin Power Solutions(P) Ltd.
Title
HFI800VA(K8HFIR6)
Size D o cumen t N u mber R ev
B 1.6
LOW SMPS SUPPLY STAGE
D ate: Thursday , March 27, 2008 Sh eet 1 of 1

• B

VCC
CN7 +5V +VE BATT. D50 1N4007
1
NOT ON PCB
BUZZER CN8
2 DR1B O/P PHASE TR5
3 DT1 +5V BUZ1 1 C90
4 PWMHIGH1 BUZZER D8 2 O/P SENSE
CN2
5 PWMLOW1 1N4007 CN4 3 0.1J/63V
6 PWMHIGH2 +5V 4 NEUTRAL 3Pin JST Male
7 PWMLOW2 3 1 SS-400V/23V-0V-23V
8 2
22Pin L-Type Burgstrip

COM R64 D51 1N4007

9 COM 1 470E_1/8W 1% 2
10
11
+5V 4Pin JST Male Q11 2Pin Relimate Male(Fan) NEUTRAL O/P SENSE
FAN BC847 FAN Q10
12 RELAY /CHGARGER CUT BD139
13 DC-DC OFF (3525-SD)
14 CHARGER PWM
15
16
TEMP.-SENSE
1
FAN
DC-SENSE CN3
17 O/P SENSE 2
18 ZEROCROSS2(1.25Vref ) 2Pin JST Male(Temp. Sense)
19
20
MANSE SENSE(ZEROCROSS1) INDUCTOR(L4)
SHUNT
21 TRIP-DRV VALUE=800mH(+/-10mH),21SWG,125 TRUN
22 CONTROL
CORE MAKE=HONEYWELL
+HTP
STGW30NC120HD

R39 Q7 R41 Q9 OP3 O/P

+VE BATT. GATE-HI1 STGW30NC120HD GATE-HI2
RL1
4E7_1/8W 1% CON1
OP1 4E7_1/8W 1% NTC1 2.5E/5A Coil 12V DC, Contact 250 AC / 10A / (SPDT)
O/P-L
L4
t

INDUCTOR
R49 FGND2 C83 L2 MOV1
15K_1/8W 1% 4700PF/1KVA VCC-RELAY
CON1
OP2 C82
FGND1 C86 N
DC-SENSE 4uF/440V C84 470NF/440V~- X2 375V
4700PF/1KVA FILTER C25
FGND2 D9
t

R50 N 100uF/50V 1N4148

3K_1/8W 1% 85 DEG.
NTC2 2.5E/5A
FGND2 OPTIONAL RELAY /CHGARGER CUT
R38 Q6 R40 Q8 I/P-L
STGW30NC120HD

GATE-LO1 STGW30NC120HD GATE-LO2 OP4 I/P-L FUSE

BATTERY SENSE 4E7_1/8W 1% 4E7_1/8W 1%

F3
MANSE SENSE(ZEROCROSS1) TR2 I/P-L
POWER STAGE 0
C24 6A FUSE
0.1J/63V 35SWG
ZEROCROSS2(1.25Vref )
NOT ON PCB
D33 1N4007 31SWG

VCC-MAINS SS-400V/23V-0V-23V/0V-23V
R169 D32 1N4007

10E_1/4W 1% D34 1N4007

C91
47uF/50V
D35 1N4007

MAINS SENSE & I/P,O/PSECTION

Kevin Power Solutions(P) Ltd.

Title
HFI800VA(K8HFIR6)
Size D o cumen t N u mb er Rev
B 1.6
POWER STAGE
D ate: Thursday , March 27, 2008 Sh eet 1 of 1

15
 • C

+VeBATT.
Bolt Hex Hd, M6X16X2.8, Brass

F1 40A FUSE +VE BATT.

F2 40A FUSE

R165 LED5 RED

+VE BATT.
R163 SW1 VCC
10E_1/4W 1%/JUMPER 1K_1/8W 1% LED6 RED
1 2

SW KEY -SPST
C27 C28

STTH310-DO-201ADC2/UF5408
220uF/25V 104/25V Q2 Q3
85 DEG. R32 STP80NF55-08 R33 STP80NF55-08

R26 7K5_1/4W 1% 8 TR3 +HTP

2E2_1/8W 1% 2E2_1/8W 1% D14 D27
IC4 STTH310-DO-201ADC2/UF5408
6 15 R24 2E2_1/8W 1% 7 9
5 RT VCC 13
R28 C30 4 CT COL 12 6
2K2_1/4W 1% 3300PF/25V R27 OSC GND C33 10
51E_1/4W 1% 7 14 D12 1N4148 220uF/50V R36 D26 JMP2
DISC OUTB R25 220E/2W 5 11 JUMPER
11 R29 2E2_1/8W 1% 1K_1/8W 1% ST T H310-DO-201ADC2/UF5408
16 OUTA 4
C85 VREF C50 C39 12
R37 0 D25 C40
R22 104/25V R31 D13 1N4148 .1uF/63V 6800uF/25V 220E/2W 3 13 R124
5K1_1/4W 1% 3 10K_1/4W 1% 220uF/450V 220K_1/4W 1%
SY NC

STTH310-DO-201ADC2/UF5408
2 2 ST T H310-DO-201ADC2/UF5408 C41
1 V+ 10 DC-DC OFF (3525-SD) 14
V- SD R65 R66 0.1uF/630V
9 8 0.001E/2W 0.001E/2W 1 D24
R23 COMP CSS ST T H310-DO-201ADC2/UF5408
8K2_1/4W 1% C29 104/25V SG3525 C34 CF139(COSMO)/N87(SIMENS) R125
C31 C32 -VeBATT. 220uF/50V 220K_1/4W 1%
Bolt Hex Hd, M6X16X2.8, Brass
0.22uF/25V 104/25V
D15

R53 0
R21 10K_1/4W 1% Q4 Q5 R52
1K_1/4W 1% R34 STP80NF55-08 R35 STP80NF55-08 330K_1/4W 1%

2E2_1/8W 1% 2E2_1/8W 1%

R51
150K_1/4W 1%

R30
1K_1/8W 1%

VR2
220K

4 IC5 1

3 2
PC817
0

DC-DC SECTION
Kevin Power Solutions(P) Ltd.
Title
HFI800VA(K8HFIR6)
Size D o cu men t N u mb er R ev
B 1.6
DC - DC STAGE
D ate: Thursday , March 27, 2008 Sh eet 1 of 1

• D

+HTP
20K_5W NI

R173(EXTRA)

C42
20K_5W NI

R46 4700PF/2KVA
1M5_1/4W 1% 0
D18
R54

D17 BZW06-171/P6KE200A C46 NA

R48 BZW06-171/P6KE200A D19

390K_1/4W 1% BZW06-171/P6KE200A
R56 NA

D23
D16 NA
R44 STTH110A/STTH112A
180K_1/4W 1%

R43 R47
75K_1/4W 1% 120K_1/4W 1%

TR4 R57
CORE SIZE = ETD-34-17-11 4E7/2W C47 4700PF/2KVA
C38 Z7 2 8
2

104/25V 6V8_1/4W 1 +VE BATT.

L

9 1 L3
1 TSW1 30uH/10AMP
C TOP249 0 3 10 D47 2
R45 STPS3060CW
X

S
F

D20 4 3
6.8E_1/4W 1% STTH102A/UF4007 11
5

C36 5 5 12
NA R58
C37 C48 1000PF/2KVA 51E/2W
6 13
100uF/35V +HTP D21
STTH102A/UF4007 7 14
VCC
0 R42 R172(EXTRA) C43 2200PF/2KVA
4K7_1/4W 1% 1.5M_1/4W 1% R55 0
R74 10E_1/4W 5% +VE BATT. R126
4K7_1/4W 1% 470K_1/8W 1%
RELAY /CHGARGER CUT 1 IC7 4

2 3
PC817 C44 C45 R62 R63
750E_1/8W 1% NA
0 100uF/50V NA

4 IC6 1 VR2
220K
0 3 2
PC817 R60 R59
470E_1/8W 1% 39K_1/8W 1%
Q14 CHARGER PWM
BC847

CHARGER SECTION Z3
8V2_1/4W
R61
NA JMP1 C49
JUMPER
100nF/25V

D31
JUMPER

Kevin Power Solutions(P) Ltd.

Title
HFI800VA(K8HFIR6)
Size D ocu ment N u mb er R ev
B 1.6
CHARGER STAGE
D ate: Thursday , March 27, 2008 Sh eet 1 of 1

16
• CIICUIT DIAGRAM 1400 VA
• A
DC(+)

20K_5W NI

20K_5W NI
C3
R3
1M5_1/4W 1% 4700PF/2KVA

D2

R1

R10
D1 P6KE200A D3

R5
390K_1/4W 1% P6KE200A P6KE200A

D9 0
UF4007 +12V
R4
180K_1/4W 1%

R7 R6
D15
TR1 R16 C13 1N4007 CN3
75K_1/4W 1% 120K_1/4W 1% CORE SIZE = ETD-34-17-11 4E7/2W 4700PF/2KVA
Z1 2 8 1

7
C5 6V8_1/4W 1 +VE BATT.(12V)
104/25V R31 2

D
9 1 L1 CN2 470E_1/8W 1% 2Pin Relimate Male(Fan)
1 TSW1 30uH/10AMP FAN Q2
C TOP249 0 3 10 D8 2 1 BD139
STPS3060CW
2

S
F
R8 D5 4 3
68E_1/4W 1% UF4007 11 2Pin JST Male(Fan) FAN
C15

4
C4 5 5 12
NA 1000uF/50V
C7 C12 R15
6 13
47uF/50V D4
DC(+) UF4007 7 14 1000PF/2KVA 51E/2W
-VE BATT.(24V)
0 R9 0 C10 2200PF/2KVA +VE BATT.(24V)
4K7_1/4W 1% R33(EXTRA) R2 SNAPON
10E_1/4W 5%
1.5M_1/4W 1% +VE BATT.(12V)
R14 R35(EXTRA)
4K7_1/4W 1% 100E/2W 1%
RELAY/CHGARGER CUT 1 IC2 4
C6 C8 R13
2 3 750E_1/8W 1%
PC817 100uF/50V NA
0 4 IC1 1 D7
1N4007 CN5
0 3 2
PC817 R12 1
CN1
470E_1/8W 1%
Q1 3 R23 2
Z2 BC847 2 CN4 470E_1/8W 1% 2Pin Relimate Male(Fan)
3V_1/4W 1 FAN Q3
3Pin Relimate Male 1 BD139
R11
NA JMP1 C11 2
JUMPER 2Pin JST Male(Fan) FAN
104/25V
JMP2
JUMPER

DC(+)
DC(+)
DC1(+)
20K_5W NI

20K_5W NI

SNAPON C2
C1 C16
0.1uF/630V R30
220uF/450V 1M5_1/4W 1% 4700PF/2KVA
DC1(-) D11
R17

R32

D10 P6KE200A D12

SNAPON
0 R19 P6KE200A P6KE200A
390K_1/4W 1% 0

D18
R20 UF4007
180K_1/4W 1%

R22 R21

TR2 R29 C18

75K_1/4W 1% 120K_1/4W 1% CORE SIZE = ETD-34-17-11 4E7/2W 4700PF/2KVA
Z3 2 8
2

C20 6V8_1/4W 1 +VE BATT.(24V)

104/25V
L

9 1 L2
1 TSW2 30uH/10AMP +VE BATT.(24V)
C TOP249 0 3 10 D17 2
STPS3060CW
X

S
F

R24 D14 4 3 SNAPON

68E_1/4W 1% UF4007 11 C14
5

C17 5 5 12 1000uF/50V
NA
C23 C19 R28
6 13
47uF/50V DC(+) D13
UF4007 7 14 1000PF/2KVA 51E/2W

0 R25 R34(EXTRA) C22 2200PF/2KVA

4K7_1/4W 1% R18 0
1.5M_1/4W 1% 10E_1/4W 5%
+VE BATT.(24V)
R27
4K7_1/4W 1%
RELAY/CHGARGER CUT 1 IC4 4
C21 C24 R26
2 3 750E_1/8W 1%
PC817 100uF/50V NA
0 4 IC3 1
Kevin Power Solutions(P) Ltd.
Z4 Z5
0 3 2 Title
PC817 HFI1400VA(K14HFIR4)
8V2_1/4W 3V_1/4W
CHARGER SECTION Size
C
Do cu men t Nu mb er
CHARGER CARD
R ev
1.2

D ate: Tuesday , Nov ember 18, 2008 Sheet 1 of 1

B
+VE BATT.(24V)
R175 +12V R163 SW1 +VeBATT.
2E2_2W 1% Q15 L7812 10E_1/4W 1%/JUMPER Bolt Hex Hd, M6X16X2.8, Brass
1 2 1 2
VIN VOUT F1 40A FUSE +VE BATT.(24V)
SW KEY -SPST
GND

C90 C91 C92 C93

220uF/63V 104/50V 10uF/63V 104/25V F2 40A FUSE

3

+VE BATT.(24V)
R165 LED5 RED

VCC SNAPON DC(+)

1K_1/8W 1% LED6 RED
D52

C28 C27 STTH310-DO-201ADC2

STTH310-DO-201ADC2

Q2 Q3 D53
104/25V 220uF/25V STP140NF75 NA Q24
85 DEG. R32 R33 R172 STP140NF75
STTH310-DO-201ADC2
R26 7K5_1/4W 1% 8 TR3
2E2_1/8W 1% NA 2E2_1/8W 1% D14 D24
IC4
6 15 R24 2E2_1/8W 1% 7 9 DC(+)
5 RT VCC 13 STTH310-DO-201ADC2 SNAPON
R28 C30 4 CT COL 12 6
2K2_1/4W 1% 3300PF/25V R27 OSC GND C33 10 D25
51E_1/4W 1% 7 14 D12 1N4148 220uF/63V R36
DISC OUTB R25 220E/2W 5 11
11 R29 2E2_1/8W 1% 1K_1/8W 1% STTH310-DO-201ADC2 JMP2 +HTP
16 OUTA 4 JUMPER
C85 VREF C86 C50 C39 12
R37 D26
R22 104/25V R31 D13 1N4148 -VE BATT.(24V) 4700uF/50V 0.1uF/63V 4700uF/50V 220E/2W 3 13 0
5K1_1/4W 1% 3 10K_1/4W 1% R124
SY NC
STTH310-DO-201ADC2

2 2 STTH310-DO-201ADC2 220K_1/4W 1%
1 V+ 10 DC-DC OFF (3525-SD) SNAPON 14 C40 C95 C41
V- SD R65 R66 R174 D27
220uF/450V

220uF/450V

0.1uF/630V

9 8 0.001E/2W 0.001E/2W 0.001E/2W 1

R23 COMP CSS
8K2_1/4W 1% C29 104/25V SG3525 C34 CF139(COSMO)/N87(SIMENS) STTH310-DO-201ADC2 R125
C31 C32 -VeBATT. 220uF/63V 220K_1/4W 1%
Bolt Hex Hd, M6X16X2.8, Brass D54
0.22uF/25V 104/25V
D15
STTH310-DO-201ADC2
R53 Q5 DC(-)
R21 10K_1/4W 1% Q4 NA Q25 D55
1K_1/4W 1% R34 STP140NF75 R35 STP140NF75
SNAPON
STTH310-DO-201ADC2 0
2E2_1/8W 1% NA R173 2E2_1/8W 1%

R52
330K_1/4W 1%

R30
1K_1/8W 1%

R51
150K_1/4W 1%

VR2
220K

4 IC5 1

3 2
PC817
0 Kevin Power Solutions(P) Ltd.
DC-DC SECTION Title
HFI1400VA(K14HFIR4)
Size D o cu men t N umb er R ev
Custom 1.4
DC - DC STAGE
D ate: Tuesday , Nov ember 18, 2008 Sh eet 1 of 1

17
C.

VCC
CN5 +5V
1 BUZZER
2 DR1B
3 DT1
4 PWMHIGH1
5 PWMLOW1
6 PWMHIGH2
7 PWMLOW2
8
22Pin L-Type Burgstrip

COM
9 C81 104/6V
10 +5V
11 FAN FAN R119 470E_1/8W 1%
12 RELAY /CHGARGER CUT RELAY /CHGARGER CUT
13 DC-DC OFF (3525-SD)
14 CHARGER PWM R158 100K_1/8W 1%
15 TEMP.-SENSE Q16
16 DC-SENSE +5V BC847 R121 470E_1/8W 1%
17 O/P SENSE
18 ZEROCROSS2(1.25Vref )
19 MANSE SENSE(ZEROCROSS1)
20 SHUNT R161 R157 R122
21

3
TRIP-DRV 100K_1/8W 1% 4K7_1/8W 1% +5V NA
22 ZEROCROSS1 5
+
2 CN6
4
- 1
+5V +5V +5V C87 D41 D22 IC21B GPIOD3/TMS/LED1[MAINS ON(GREEN)]
LM339 2 SCLK/LED2[INV ON(Y ELLOW)]
3

12
220PF/6V 1N4148 1N4148 GPIOD0/TDI/LED3[BATT. LOW(RED)]/CHARGER FAN
R134 4 MOSI/LED4[OL/SC(RED)]
R139 R148 6K8_1/8W 1% 5
2K2_1/4W 1% 3K3_1/4W 1% 6 TDO/INV/UPS SWITCH R117 470E_1/8W 1%
7
R129 100K_1/8W 1% 8 ON/OFF SWITCH
R147 R133 9 TCK/BUZZER
D30 1N4148 10E_1/4W 1% 10K_1/8W 1% +5V 10
10Pin JST Male +5V
Q17 R116
BC847 C73
TEMP. SENSE 10K_1/8W 1%
R146 R162 R128

3
470PF/25V/COG(NPO)

NA 100K_1/8W 1% 4K7_1/8W 1% VCC

ZEROCROSS2 11 R118
+
13 47K_1/8W 1% R171
10 Q23 4.7ME_1/8W 1%
-
C88 D44 D43 IC21D BC847
R136 LM339
12
8K2_1/8W 1% 220PF/6V 1N4148 1N4148 C75 C89
R135
680E_1/8W 1% 104/6V 1uF/6V

Q21 R120
BC847 IC20
16 21
O/P VOLTAGE SENSE 470E_1/8W 1% ZEROCROSS(+Ve) 19 RESET/GPIOA7 GPIOB0/SCLK/SCL 1 FAN-BASE
ZEROCROSS(-Ve) 3 GPIOB4/T0/CLKO GPIOB1/SS/SDA 18 RELAY 1(CO)
CHG-CRNT 4 GPIOB5/T1/FAULT3 GPIOB2/MISO/T2 17
D46 1N4007 O/P-CRNT 5 ANB0/GPIOC4 GPIOB3/MOSI/T3
ANB1/GPIOC5 29
MAINS-SENSE PWM0(LOW) 28 TDI/GPIOD0 31
PWM1(HIGH) 27 GPIOA0/PWM0 TDO/GPIOD1 15
D45 1N4007 R138 PWM2(CHARGER) 23 GPIOA1/PWM1 TCK/GPIOD2 30
4K7_1/8W 1% PWM4(LOW) 22 GPIOA2/PWM2 TMS/GPIOD3
R137 PWM5(HIGH) 20 GPIOA4/PWM4/FAULT1/T2
680E_1/8W 1% GPIOA5/PWM5/FAULT2/T3 2 DT1
GPIOB7/TXD/SCL 32
MAINS SENSE GPIOB6/RXD/SDA/CLKIN
+3.3V R111 330E_1/8W 1%
O/P CRNT R149 1K_1/8W 1%
CHG CRNT R150 1K_1/8W 1% DC-DC(3525-SD) 6 25 C63
PWMTRIPB PWMTRIPB 7 ANB2/VREFL/GPIOC6 VDD_IO
DC SENSE R154 1K_1/8W 1% DC-SENSE 13 ANB3/GPIOC7 C76 1000PF/6V/COG(NPO)
TEMP.- SENSE R153 1K_1/8W 1% TEMP. SENSE 12 ANA0/GPIOC0
O/P SENSE R152 1K_1/8W 1% O/P-SENSE 11 ANA1/GPIOC1 26 104/6V
MAINS SENSE R151 1K_1/8W 1% MAINS-SENSE 10 ANA2/VREFH/GPIOC2 VSS_IO 14
+3.3V ANA3/GPIOC3 VSS_IO
8 24
O/P CURRENT +5V +5V C67 C68 C69 C70 C66 C65 C64 9 VDDA
VSSA
VCAP
C77 C74
104/6V

104/6V

104/6V

104/6V

NA

NA

R160 220PF/6V
1K8_1/8W 1% R143 33K_1/8W 1% 104/6V 4.7uF/63V
R141 R140
10K_1/8W 1% 4K7_1/8W 1%
R142 DSP CONTROL
15K_1/8W 1%
12
4

IC22A 6 - +5V Q18 +3.3V

2 - LM358 R159 10K_1/8W 1% 1 PWMTRIP AZ1117
R144 1 O/P-CRNT 7 + 3 2
3 IC21A VIN VOUT
+
C13 LM339
ADJ

330E_1/8W 1% C72 +5V +5V C17 C80

3

470PF/25V/COG(NPO)
8

220nF/6V/COG(NPO) 22uF/6V 104/6V

1

+5V C79
C78
104/6V SUPPLY
104/6V
R156
10K_1/8W 1%

R131 100K_1/8W 1% +5V

R155

R127
12

R145 R132 15K_1/8W 1% 2K2_1/8W 1%

4

68E_1/8W 1% 1K_1/8W 1% 8 - D29

6 - R130 14
7 9 +
5 + IC21C 1N4148
C71 IC22B 3K9_1/8W 1% LM339
LM358 C20
3

100nF/6V/COG(NPO) +5V
8

+5V 1000PF/6V/COG(NPO)

CHG-CRNT

CURRENT AMPLIFIER SECTION CHARGING CURRENT

14HFCK
Note:- C65,C66,R122,R146 Are not Solder(NA) Kevin Power Solutions(P) Ltd.
Title
HFI1400VA(K14HFIR4)
Size D o cu men t N umb er R ev
Custom 1.4
CONTROL STAGE
D ate: Tuesday , Nov ember 18, 2008 Sheet 1 of 1

18
D.

+5V +12V D50 1N4007

O/P PHASE TR5
C94
O/P SENSE
BUZ1 +5V 0.1J/63V
BUZZER D8 NEUTRAL
1N4007 CN4 SS-400V/23V-0V-23V D51 1N4007

VCC R126 1
CN7 R64 470K_1/8W 1%
2
NEUTRAL O/P SENSE
470E_1/8W 1%
1 BUZZER Q11 2Pin Relimate Male(Fan)
2 DR1B BC847 FAN Q10
3 DT1 +5V BD139
4 PWMHIGH1 CN2
5 PWMLOW1
6 4 FAN
3Pin Relimate Male(Charger)
PWMHIGH2 +5V
7 PWMLOW2 3 VR2
8 COM 2 220K
9 COM 1
10 +5V 4Pin JST Male
11 FAN CN8
12 RELAY /CHGARGER CUT RELAY/CHGARGER CUT
13 DC-DC OFF (3525-SD) CHARGER PWM 1
14 CHARGER PWM R59 2
15 TEMP.-SENSE 39K_1/8W 1% 3
16 DC-SENSE 1 CN3
17 O/P SENSE 2
18 ZEROCROSS2(1.25Vref ) 2Pin JST Male(Temp. Sense)
19
20
MANSE SENSE(ZEROCROSS1) CHARGER CONTROL
SHUNT
21 TRIP-DRV
22 CONTROL INDUCTOR(L4)
VALUE=800mH(+/-10mH),21SWG,125 TRUN
+VE BATT.(24V) +HTP CORE MAKE=HONEYWELL
STGW30NC120HD

OP3 O/P
R39 Q7 R41 Q9 SNAPON SNAPON
R49 GATE-HI1 STGW30NC120HD GATE-HI2
22K_1/8W 1% RL1
4E7_1/8W 1% OP1 4E7_1/8W 1% NTC1 2E/7.5A Coil 12V DC, Contact 250 AC / 30A / (SPDT)
O/P-L
DC-SENSE SNAPON L4X4

t
INDUCTOR
FGND2 C83 L2 MOV1
R50 4700PF/1KVA VCC-RELAY
2K_1/8W 1% OP2 C82
FGND1 C86X2 CON1
N
SNAPON 4uF/440V C84 470NF/440V~- X2 375V
4700PF/1KVA FILTER C25
FGND2 D9

t
N 100uF/50V 1N4148
BATTERY SENSE 85 DEG.
NTC2 2E/7.5A
FGND2 OPTIONAL RELAY /CHGARGER CUT
R38 Q6 R40 Q8
STGW30NC120HD

GATE-LO1 STGW30NC120HD GATE-LO2 OP4

SNAPON I/P-L
4E7_1/8W 1% 4E7_1/8W 1% SNAPON I/P-L FUSE
SNAPON

POWER STAGE 0
F3
MANSE SENSE(ZEROCROSS1) TR2 I/P-L

C24 6A FUSE
0.1J/63V 35SWG
ZEROCROSS2(1.25Vref )
NOT ON PCB
D33 1N4007 31SWG

VCC-MAINS SS-400V/23V-0V-23V/0V-23V
R169 D32 1N4007

10E_1/4W 1% D34 1N4007

C96
47uF/50V MAINS SENSE & I/P,O/PSECTION
D35 1N4007

NOT ON PCB

Kevin Power Solutions(P) Ltd.

Title
HFI1400VA(K14HFIR4)
Size D o cumen t N u mb er Rev
Custom 1.4
POWER STAGE
D ate: Tuesday , Nov ember 18, 2008 Sh eet 1 of 1

19
E.

D7 +15V_LO
VCC-MAINS D48 +12V STTH110A/STTH112A R69 10E_1W 1%
1N4007 D49

C21 C22
1N4007 Z6
C35 100uF/35V 104/25V
R20 10uF/63V 18V/1/2W
10K_1/4W 1% R123
1K_1/4W 1%
VCC Q22 TR1
D11 R18 BC857 3 D6 +15V_HI1
1N4007 68K_1/4W 1% STTH110A/STTH112A 0
Q13 65T,35SWG
BC847 +VE BATT.(24V)
4 R68 10E_1W 1%
6 Z5
R19 C26 C18 C19
6K8_1/4W 1% 1uF/63V 1 65T,38SWG 18V/1/2W
R1 100uF/35V 104/25V
C1 C2 1K_1W 1% 5
40T(20T+20T),30SWG 8
470uF/50V 0.22uF/25V D5 +15V_HI2
R170 2 65T,38SWG STTH110A/STTH112A FGND1
R164
1K_1W 1% 7
150K_1/2W 1% 10 R67 10E_1W 1%
D2 C15 C16 Z4
STTH110A/STTH112A 25T,30WG
100uF/35V 104/25V 18V/1/2W
9
C3
Z8 145T,35SWG
C5 27V_1/2W 0.01uF/63V D3 +5V
C4 STTH310-DO-201ADC2 FGND2 L1
22uF/25V 104/25V CF138,EE COSMO,20 X10 X 5.5mm

IC1 C10 C11 INDUCTOR C12

7

UC3843 R4 10K_1/4W 1%
3 8 100uF/35V 104/25V 470uF/25V
VCC

2 ISEN VREF 4 R8
C6 VFB RT/CT 10E_1/4W 1% Q1
6 IRFZ44N
GND

1000PF/25V OUT 1 R11

COMP C7 6K2_1/4W 1%
C9
R7 103/25V 2200PF/25V Z1
5

R9 1K_1/4W 1% R5 15V/1/2W 4 IC2 1

1K_1/4W 1% 1K_1/4W 1%
3 2
PC817 R10
C8 470PF/25V 1K8_1/4W 1%

TP4

VCC-RELAY
D4
R6 STTH110A/STTH112A R12
100K_1/4W 1% R2 R3
1E_1/4W 1% 1E_1/4W 1%
C14 750E_1W 1%

10uF/63V Z2
33V/1/2W

LOW POWER SUPPLY

Kevin Power Solutions(P) Ltd.
Title
HFI1400VA(K14HFIR4)
Size Document N umber Rev
Custom 1.4
LOW SMPS SUPPLY STAGE
D ate: Tuesday , Nov ember 18, 2008 Sh eet 1 of 1

• CIICUIT DIAGRAM 2.5/3 KVA

•

5. TESTING PROCEDURE

20
 ◄ TESTING PROCEDURE
(Online)

STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing Fuse & wire(between choke
and DC capacitor))
• Then remove connection of the port CN1, CN2, CN3 of charger card
and port CN1, CN16, CN15 of mother card.
• Put the mains MCB (Zig) ON and then put mains MCB of the system,
then check the voltage on blue wires of 6-pin female connector (black
wire is ground) it must be 15V.
• Now OFF all MCB’s and put the connection of CN1 port.
• Now put the CRO’s ground probe on the heat sink of IC1 and main lead
body of the Q1 and check the amplitude of pulse it must be 2.5v and see
the formation of the teeth; it must be very smooth.
• Then with the same process as above done check Q2, voltage must be
15v and frequency must be up to 1 kHz.
• Now check voltage on port CN3 it must be 15v.
• Now check port CN2,it having 4pins;from right to left 1st pin is ground
put CRO ground probe to 1st pin and check 2nd pin it will show sine
wave now on 3rd pin it will so spicks and 4th pin will show it’s
modulation.
• Now connect the connector CN2&CN3, and check smooth DC
formation.
• Make choke to DC capacitor wire connection.
• Now putt all connections of charger card and mother card except CN1.
• Now make DC by using pot P1 (variable resistance) as per specification.
• Now OFF all MCBs and put the connection CN1.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Now OFF the AC MCB and connect Fuse.
• Now ON AC MCB and check the fan; if it’s running then OK and if it
shows SHORT CIRCUIT then check the IGBT driver.
• Put the communication wire into the mother board.
• Now open testing tool (communication) in computer.

21
 • Now check the LCD and Parameters and also O/P waveform.(it must be
pure sine wave )

◄STATIC UPS TESTING PROCEDURE

(2.5/3/3.5 KVA)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper
position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• Then ON the battery MCB of zig.
• Check DC supply of the Mother card.
• Put the communication wire into the mother board.
• Now open testing tool (communication) in computer and tune
battery voltage as per the system specification.
• Now check the LCD and Parameters.
• Switch ON inverter switch. (from the front panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & tune it.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 60% & check fan.
• If it’s OK then put the load 100% & tune.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.
• System will show Mains MCB Trip.
• Then ON Mains MCB & tune mains voltage according to I/P
voltage.
• Then tune Charging current as per instruction.
• Tune CT current as per instructions.
• OFF Mains & Battery MCB of the system and zig.
• Remove communication and connect normal/ups connector.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON.
• Check voltage & zero crossing. If OK then system OK; if not OK
then interchange the drain wires & then again check zero crossing.
If all is right then system is done.

22
 ◄ TESTING PROCEDURE
HKva For higher
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing DC CAPACITOR)
• Then ON the battery MCB of zig.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Now OFF the DC MCB and connect DC CAPACITOR.
• Now ON battery MCB and check the fan; if it’s running then OK and if
it shows SHORT CIRCUIT then check the IGBT driver.
• Put the communication wire into the mother board.
• Now open testing tool (communication) in computer and tune battery
voltage as per the system specification.
• Now check the LCD and Parameters and also O/P waveform.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & tune it in between 220 to 230.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 60% & check fan.
• If it’s OK then put the load 100% & tune.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.(mains must be
230v)
• System will show Mains MCB Trip.
• Then ON Mains MCB & tune mains voltage according to I/P voltage.
• Then tune Charging current as per instruction.
• Tune CT current as per instructions.
• OFF Mains & Battery MCB of the system and zig.
• Remove communication and connect normal/ups connector.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON. Check voltage
& zero crossing. If OK then system OK; if not OK then interchange the
drain wires & then again check zero crossing. If all is right then system
is done.

23
 ◄ TESTING PROCEDURE
(3-PHASE INVERTER/LUPS)

STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.
• By pass the IGBT (system).(By removing +ve(red) terminal of DC
CAPACITOR)
• Remove all connection from DC-DC card.
• Then ON the battery MCB of zig.
• Now check the voltage at the CN1 female port it must be same as I/P
DC supply.
• Now off the DC MCB and connect the female connector to the male
CN1 port.
• Now ON DC MCB and check voltage at the port CN3 to CN10, it must
be 15v and at port CN7, voltage should be 5v.
• Now OFF DC MCB & connect all connection of DC-DC card.
• Now ON DC MCB of zig as well as system.
• Check IGBT Driver card by checking PWM on MOSFET one by one. It
must be 15v.
• Now charge DC capacitor on IGBT and ON the system and check the
fan. (If it’s moving then OK) and also check O/P sine waveform on
CRO.
• Apply the short ckt.Test.
• Now OFF the DC MCB and connect DC CAPACITOR.
• Now ON battery MCB and check the fan; if it’s running then OK and if
it shows SHORT CIRCUIT then check the IGBT driver.
• Now match DC by using preset (variable resistance) in control card, it
must be same as DC I/P supply (on LCD).
• Now check the sequence of O/P voltage by using Sequence Meter.
• Now check the LCD and Parameters and also O/P waveform.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & tune it in between 220 to 230,by using preset
on control card.(PN)
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 60% & check fan.
• If it’s OK then put the load 100% & tune it as pre specification by using
preset placed on Control card.

24
 TESTING PROCEDURE
(1400VA)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper
position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.(24V)
• Then ON the battery MCB of zig...
• Now check the LCD and Parameters.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & no load o/p current.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 50% & check fan.
• If it’s OK then put the load 100%.
• Check full load battery current.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.
• System will show Mains fuse Trip.if mains fuse not ableble.
• Then connect the fuse.
• Check mains voltage.
• Now check normal & high charging current.
• Now check BOOST voltage.
• Now check high cut, low cut & recovery voltage.(UPS/normal
mode)
• OFF Mains & Battery MCB of the system and zig.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON.
• Check voltage & zero crossing. If OK then system OK; if not OK
then interchange the drain wires & then again check zero crossing.
If all is right then system is done.

25
 TESTING PROCEDURE
(800VA)
STEPS:
• Visual inspection of the system.
• Check all connections; they must be in proper way and proper
position.
• Check all joints, they must be tight.
• Check all MCBs & switch OFF zig & the system must be OFF.
• Connect system with zig properly.(12V)
• Then ON the battery MCB of zig...
• Now check the LCD and Parameters.
• Switch ON inverter switch. (from the panel of the system )
• Check LCD; inv switch must be OK.
• Then check O/P voltage & no load o/p current.
• Check O/P frequency; it must be 50Hz & wave form on CRO.
• Now put the load of 50% & check fan.
• If it’s OK then put the load 100%.
• Check full load battery current.
• Apply the short ckt. Test.
• Now reduce the load and apply Mains from the zig.
• System will show Mains fuse Trip.
• Then connect the fuse.
• Check mains voltage.
• Now check normal & high charging current.
• Now check BOOST voltage.
• Now check high cut, low cut & recovery voltage.(UPS/normal
mode)
• OFF Mains & Battery MCB of the system and zig.
• ON battery MCB put 100% load.
• Check UPS/Inv.switch on display then apply Mains ON.
• Check voltage & zero crossing. If OK then system OK; if not OK
then interchange the drain wires & then again check zero crossing.
If all is right then system is done.

26
 TESTING PROCEDURE
(PCB Power card 800)
STEPS:
• Visual inspection of the 800va Power Card.
• Connect to dc regulator power supply (12V).
• Then connect LCD & ON & OFF switch.
• Check the voltage (4.8V-5.1V) between Ground & diode D3,it
must be OK.
• Check the voltage (4.8V-5.1V) between Ground & pin no.1 of
CN6 connector, it must be OK.
• Check voltage (10V -22V) between Ground & Zener Z2,it must be
OK.
• Check voltage 15±3V between Zener Z 4, Z5, Z6& Capacitor C16,
C19, C22, they must be OK.
• Check voltage 15±3V between Capacitor C16, C19, C22& diode
D1, D28, D37, D39 they must be OK.
• Then short jumper J3 & tune the DC- DC voltage between 335V-
340V.by using preset VR2.
• Then discharge capacitor C40 &joint DC to DC section & power
section.
• Then connect PCB to testing Jig with all connections.
• Then put the communication wire with power card.
• Then open the testing tool in computer.
• Then tune Battery voltage according to DC voltmeter.
• Then check the LCD.
• Then O/P voltage tune 220V.
• Then put load 50% check fan it must be running then put load
100% and tune.
• Apply the short ckt.Test.
• Then reduce load & apply main from the Jig, then tune mains
according to voltmeter.
• Then tune charging current.(9V+0.5V)
• OFF mains & battery MCB of Jig.
• Remove communication & connect normal /UPS connector.
• Then check high charging current.(13V±1V)
• Check UPS/INV switch & display then apply mains ON.
• OFF mains & battery MCB of the Jig.
• Then remove the all connection.

27
 TESTING PROCEDURE
(PCB Power card 1400VA)
STEPS:
• Visual inspection of the 1400va Power Card.
• Connect to dc regulator power supply (24V).
• Then connect LCD & ON & OFF switch.
• Check the voltage (4.8V-5.1V) between Ground & diode D3,it
must be OK.
• Check the voltage (4.8V-5.1V) between Ground & pin no.1 of
CN6 connector, it must be OK.
• Check voltage (10V -22V) between Ground & Zener Z2,it must be
OK.
• Check voltage 15±3V between Zener Z 4, Z5, Z6& Capacitor C16,
C19, C22, they must be OK.
• Check voltage 15±3V between Capacitor C16, C19, C22& diode
D1, D28, D37, D39 they must be OK.
• Then short jumper J3 & tune the DC- DC voltage between 345V-
350V.by using preset VR2.
• Then discharge capacitor C40 &joint DC to DC section & power
section.
• Then connect PCB to testing Jig with all connections.
• Then put the communication wire with power card.
• Then open the testing tool in computer.
• Then tune Battery voltage according to DC voltmeter.
• Then check the LCD.
• Then O/P voltage tune 220V.
• Then put load 50% check fan it must be running then put load
100% and tune.
• Apply the short ckt.Test.
• Then reduce load & apply main from the Jig, then tune mains
according to voltmeter.
• Then tune charging current.(9V+0.5V)
• OFF mains & battery MCB of Jig.
• Remove communication & connect normal /UPS connector.
• Then check high charging current.(13V±1V)
• Check UPS/INV switch & display then apply mains ON.
• OFF mains & battery MCB of the Jig.
• Then remove the all connection.

28
6. FAULT FINDING OF INVERTER

Troubleshooting chart (600VA/800VA/1400VA) H-UPS

PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS
NO OUT PUT VOLTAGE NO POOR BATTERY CONDITION OR CHECK BATTERY OR MAKE
INDICATOR ON BATTERY CONNECTION LOOSE PROPER CONNECTION
OVER LOAD/ SHORT CIRCUIT DISCONNECT THE EXCESSIVE
LOAD FROM THE H-UPS& GRT
NO OUT PUT VOLTAGE OVER THE HOUSE WIRING CHECKED
LOAD INDICATOR ON
NO OUT PUT VOLTAGE ALL THERMAL PROTECTION HEAT SINK OVER HEAT,MAY
INDICATORS BLINK BE FAN OR THERMISTOR
PROBLEM
MAINS INDICATOR BLINK WITH MAINS FUSE BLOW CHECK THE MAINS FUSE
BUZZER
BATTERY MODE BUT NO OUT BATTERY LOW/SHORT CIRCUIT CHECK DISPLAY IF BATTERY
PUT LOW INDICATOR ON THEN
CHARGE THE BATTERY WHEN
MAINS RESUME.
IF SHORT CIRCUIT INDICATOR
ON THEN REMOVE OUT PUT
AND RESTART THE UPS .IF UPS
GIVING OUT PUT
THEN PROBLEM WITH OUT PUT
SIDE IF INDICTOR STILL THEN
PROBLEM IN LOGIC CARD
COMPUTERS RESTART UPS RUNNING ON INVERTER SELECT SWITCH TO UPS MODE
MODE
BEEP SOUND COMING ON THAT IS WARNING BEEP BEEP SOUND WILL BE COME
BATTERY MODE THAT H-UPS RUNNING ON UPS ON BATTERY MODE WHEN
MODE SWITCH SELECTED ON UPS
MODE
H-UPS NOT GIVING POWER ON LOGIC CARD FAULTY CHECK LOGIC CARD IF SOME
BATTERY MODE AND NOT COMPONENT DAMAGE THEN
TAKING CHARGE REPLACE LOGIC CARD
H-UPS RUNNING ON MAINS PROBLEM IN LOGIC CARD CHECK INTERNAL WIRING IF
MODE BUT NO OUT PUT OK THEN REPLACE LOGIC
CARD
H-UPS NOT RUNNING ON MAINS LOW/VERY HIGH,MAINS CHECK MAINS FOR NORMAL,IF
MAINS MODE WHILE MAINS LEAD FAULTY, OK THEN CHECK MAINS
PRESENT LOGIC CARD, LEAD,REPLACE LOGIC
INTERNAL WIRING CARD,CHECK INTERNAL
WIRING
H-UPS SOME TIMES RUNNING MAINS LEAD , CHECK MAINS LEAD,AND
ON BATTERY MODE WHEN WIRING,LOGIC CARD FAULTY WIRING
MAINS RESUME IT TAKE TWO REPLACE LOGIC CARD
TO THREE TIMES TO SWITCH
OVER ON MAINS

29
 Troubleshooting chart (2.5/3 KVA STATIC UPS)
OUT PUT REVERSE 1.SCR LICKEY 1. CHECK SCR IF FAULTY
PROBLEM
COMING ONAND
IN PUT SIDE POSSIABLE
2.SCR CASE
DRIVER FAULTY SOLUTIONS
REPLACE.
SYMPTONS 3.WIRING BETWEEN CN5AND 2. SCR SRIVER FAULTY.
UPS DEAD 1.DC FUSE BLOW
SCR DRIVER PCB CN1 1.DC FUSECONNECTOR
3. CHECK 40 AMP CHANGE
CN5(ON
2.LOOSE BATTERY 2.DO TIGHT
MOTHER BATTERY
BOARD) AND CN1(ON
CONNECTION/DISCHARGE CONNECTION
SCR DRIVER)
3. CONNECTOR CN 7 LOOSE 3. CHECK BATTERY VOLTAGE
4.MOTHER CARD FAULTY ON CONNECTOR CN7 IF OK THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND RE-
MASSAGE COMING ON SIDE START
LCD DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN PCB
3.CONNECTOR LOOSE 3.CHECK CONNECTOR ON DSP
4. LOGIC CARD FAULTY BOARD
4.REPLACE THE LOGIC CARD
BATTERY MODE BUT NO 1.BATTERY IN LOW 1. CHECK DISPLAY IF BATTERY
OUT PUT CONDITION LOW COMING ON DISPLAY THEN
DISPLAY SHOW 2.BATTERY CONNECTION CHARGE THE BATTERY WHEN
PROTECTION BATTERY LOOSE/RUSTY TERMINAL MAINS RESUME.
LOW 2. CHACK LOOSE CONNECTION
/RUSTY TERMINAL.
BATTERY MODE BUT NO 1.SHORT CIRCUIT ON OUT 1.CHECK SHORTING ON OUT PUT
OUT PUT PUT SIDE SIDE
DISPLAY SHOW SHORT 2.TOO MUCH LOAD 2. REMOVE LOAD OF OUT PUT
CIRCUIT 3.MOTHER CARD FAULTY SIDE AND RE START
3.CHECK MOTHER CARD AND
REPLACE
COMPUTERS RESTART 1.UPS RUNNING ON 1.SELECT SWITCH TO UPS MODE
WHEN MAINS FAIL INVERTER MODE
DISPLAY SHOW MAINS 1.CHECK MAINS MCB FOR 1. TURN ON THE MAINS MCB.
MCB TRIP TRIP 2.CHECK SCR/SCR DRIVER
2. SCR/SCR DRIVER FAULTY 3.CHECK CN5
3.CONNECTOR CN5 ON
MOTHER CARD
DISPLAY SHOW SWICH 1.SWITCH CHECK
OFF WHILE FRONT PROBLEM,CONNECTOR SWITCH,INTERNALWIRING OF
SWITCH ON /WIRE LOOSE SWITCH
UPS NOT RUNNING ON 1.MAINS OUT OF RANGE 1. CHECK MAINS FOR NORMAL.
MAINS MODE WHILE 2.LOOSE CONNECTION ON 2. CHECK LOOSE CONNECTION
MAINS PRESENT I/P TERMINAL BLOCK ON I/P TERMINAL BLOCK.
3.LOGIC CARD FAULTY 3. REPLACE THE LOGIC CARD.

UPS WORKING BUT JUNK 1.DISPLAY PROBLEM 1.CHANGE DISPLAY

DISPLAY 2.CONNECTOR PROBLEM 2. CHECK CONNECTOR.
3.MOTHER BOARD 3. MOTHER BOARE FAULTY
PROBLEM

30
 Troubleshooting chart (2.5/3 KVA INVERTER)
PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS
INVERTER DEAD 1.DC FUSE BLOW 1.DC FUSE 40 AMP CHANGE
2.LOOSE BATTERY 2.DO TIGHT BATTERY
CONNECTION/DISCHARGE CONNECTION
3. CONNECTOR CN 7 LOOSE 3. CHECK BATTERY
4.MOTHER CARD FAULTY VOLTAGE ON CONNECTOR
CN7 IF OK THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND
MASSAGE COMING ON LCD SIDE RE-START
DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN
3.CONNECTOR LOOSE PCB
4. LOGIC CARD FAULTY 3.CHECK CONNECTOR ON
DSP BOARD
4.REPLACE THE LOGIC
CARD
BATTERY MODE BUT NO 1.BATTERY IN LOW 1. CHECK DISPLAY IF
OUT PUT CONDITION BATTERY LOW COMING ON
DISPLAY SHOW 2.BATTERY CONNECTION DISPLAY THEN CHARGE
PROTECTION BATTERY LOW LOOSE/RUSTY TERMINAL THE BATTERY WHEN MAINS
RESUME.
2. CHACK LOOSE
CONNECTION /RUSTY
TERMINAL.
BATTERY MODE BUT NO 1.SHORT CIRCUIT ON OUT 1.CHECK SHORTING ON OUT
OUT PUT PUT SIDE PUT SIDE
DISPLAY SHOW SHORT 2.TOO MUCH LOAD 2. REMOVE LOAD OF OUT
CIRCUIT 3.MOTHER CARD FAULTY PUT SIDE AND RE START
3.CHECK MOTHER CARD
AND REPLACE
DISPLAY SHOW SWICH OFF 1.SWITCH CHECK
WHILE FRONT SWITCH ON PROBLEM,CONNECTOR SWITCH,INTERNALWIRING
/WIRE LOOSE OF SWITCH
INVERTER NOT RUNNING 1.MAINS OUT OF RANGE 1. CHECK MAINS FOR
ON MAINS MODE WHILE 2.LOOSE CONNECTION ON NORMAL.
MAINS PRESENT I/P TERMINAL BLOCK 2. CHECK LOOSE
3.LOGIC CARD FAULTY CONNECTION ON I/P
TERMINAL BLOCK.
3. REPLACE THE LOGIC
CARD.
INVERTER WORKING BUT 1.DISPLAY PROBLEM 1.CHANGE DISPLAY
JUNK DISPLAY 2.CONNECTOR PROBLEM 2. CHECK CONNECTOR.
3.MOTHER BOARD 3. MOTHER BOARD FAULTY
PROBLEM
DISPLAY SHOW MAINS MCB 1.CHECK MAINS MCB FOR 1. TURN ON THE MAINS
TRIP TRIP MCB.
2. SCR/SCR DRIVER FAULTY 2.CHECK SCR/SCR DRIVER
3.CONNECTOR CN5 ON 3.CHECK CN5
MOTHER CARD
OUT PUT COMING ON IN PUT REALY PROBLEM CHECK REALY

31
 2.5KVA/3KVA/48VOLT STATIC/INVERTER
MOTHER BOARD

HS1 11

HS2 HS3 10

8
7
12 6
15

13
CN2 CN7
14 C CN3 CN5 CN6

1 2 3 4 5

32
 SCR DRIVER CARD

1 2

IGBT DRIVER CARD

1
2

4
5

33
 2.5KVA/3KVA/48VOLT STATIC/INVERTER
MOTHER BOARD

CONNECTOR DETAIL:
CONNECTOR VOLTAGE PIN 1 PIN 2 PIN 3 PIN4 REMARKS

CN2 AC MAINS INPUT

SENCE
CN3 AC OUT PUT
FEEDBACK
CN5 DC AND 14 GROUND DRIVE SIGNAL TO SCR
DRIVE VOLT
+
CN5 DC 14 GROUND GROUND APPREATING
VOLT VOLTAGE TO
+ REALY
CN6 DC 24/48 GROUND TO FAN
VOLT FOR 3 KVA 02
NOS OF 24 VOLT
FAN USED IN
SERIES AND IN
2.5KVA 24 VOLT
01 NOS FAN USE
1) I/P SENCE (230 VOLT AC/AS MAINS COMMING)
2) OUT PUT FEED BACK (230 VOLT AC)
3) TO SCR DEIVER IN STATIC UPS/TO REALY IN INVERTER
4) TO COOLING FAN (FOR 2.5 KVA 01 NO 24 VOLT AND FOR3 KVA 02 NOS 24 VOLT REQ.)
5) DC IN PUT (BATTERY VOLTAGE FOR SUPPLY)
6) NEGATIVE POINT BOLT (10 MM BLACK WIRE GOES TO DC CAPACITOR)
7) DC FUSE (40 AMP)
8) NEGATIVE POINT BOLT (10 MM WIRE COMES FROM BATTERY NEGATIVE
TERMINAL
9&10) HEAT SINKS (HS2 & HS3)
11) HEAT SINK (HS1)
12) REGULATOR 7805
13) MAIN SENCE TRANSFORMER
14) CONNECTOR (LOAD SENCING ON MAINS IN STATIC) AND ON OFF SWITCH
CONNECTOR FOR INVERTER
15) TO LCD DISPLAY

SCR DRIVER CARD

CONNECTOR DETAIL:
CONNECTOR VOLTAGE PIN 1 PIN 2 PIN 3 PIN4 REMARKS

1 DC 14 + GND DRIVE FROM CN5 OF

MOTHER BOARD
2 DRIVE DRIVE TO SCR

34
 Troubleshooting chart

(5KV/6KVA/7.5KVA/10KVA/96V/120V/180V STATIC/INVERTER)
(1$ IN-1$ OUT)
PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS
UPS DEAD 1.DC MCB AND MAINS MCB 1.TURN ON DC MCB THEN
OFF MAINS MCB
2.LOOSE BATTERY 2.DO TIGHT BATTERY
CONNECTION/DISCHARGE CONNECTION
3. CONNECTOR CN 1 LOOSE 3.CHECK BATTERY VOLTAGE
4.MOTHER CARD FAULTY ON CONNECTOR CN IF OK
THEN
4. REPLACE MOTHER CARD
WARNING OVER LOAD 1.OVER LOAD ON OUT PUT 1.REMOVE SOME LOAD AND
MASSAGE COMING ON LCD SIDE RE-START
DISPLAY 2.CT BURDEN OPEN 2.CHECK CT AND BURDEN
3.CONNECTOR LOOSE PCB
4. MOTHER CARD FAULTY 3.CHECK CONNECTOR ON
5.IGBT/DRIVER CARD DSP BOARD
FAULTY 4.REPLACE THE LOGIC CARD
BATTERY MODE BUT NO SHORT CIRCUIT ON OUT CHECK DISPLAY IF SHORT
OUT PUT PUT SIDE/ CIRCUIT COMMING ON
DISPLAY SHOW SHORT PROBLEM IN DRIVER DISPLAY THEN REMOVE OUT
CIRCUIT CARD/IGBT/CANTROL CARD PUT AND RESTART THE UPS
.IF UPS GIVING OUT PUT
THEN PROBLEM WITH OUT
PUT SIDE .IF DISPLAY SHOW
AGAIN SHORT CIRCUIT THEN
PROBLEM IN LOGIC CARD
/DRIVER CARD/IGBT.
COMPUTERS RESTART UPS RUNNING ON INVERTER SELECT SWITCH TO UPS
WHEN MAINS FAIL MODE MODE
DISPLAY SHOW MAINS CHECK MAINS MCB FOR SWITCH ON THE MAINS
MCB TRIP TRIP/CHECK SCR MCB/REPLACE THE SCR
DRIVER/WIRING DRIVER/CHECK WIRING
UPS NOT RUNNING ON MAINS LOW/VERY CHECK MAINS FOR
MAINS MODE WHILE HIGH,MAINS SENCE TRF / NORMAL,IF OK THEN CHECK
MAINS PRESENT WIRE FAULTY, MAINS WIRE AND VOLTAGE
LOGIC CARD, ON I/P TERMINAL
INTERNAL WIRING BLOCK,REPLACE LOGIC
CARD,CHECK INTERNAL
WIRING
DISPLAY SHOW SWICH OFF SWITCH CHECK
WHILE FRONT SWITCH IS PROBLEM,CONNECTOR SWITCH,INTERNALWIRING
ON /WIRE LOOSE OF SWITCH

35
 5KVA—12KVA STATIC/INVERTER
MOTHER BOARD

1 2 3 4 5 6 7 8 9

CN19 CN18 CN17 CN16 CN15

CN4 CN5 CN6 CN7
MAIN SENCE

LS1 TRF
TS1

CN14
CN10

SMPS OUT PUT SENCE

TRF

CN9

CN12

CN1

10 11 12 13 14 15 16 17 18 19 20 21

36
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PI PIN PIN 3 PIN4 PIN5 PIN6 REMARKS
N1 2
CN4-7 15 VOLT +15 FOR DRIVER
-
CN19 DC TO SWITCH
NORMAL
/UPS
CN18 DRIVE TO IGBT
DRIVER
CN17 DRIVE TO IGBT
DRIVER
CN16 DC CR. DC DENCE
+ - SENCE CHARGING
CURRENT
CN15 AC 230 0 MAIN SENCE
CN1 DC + NC - FOR SMPS
CN20 DC/DATA FOR
DIPLAY/ON/OFF
SWITCH
CN9 AC FROM CT
CN12 AC 230 0 OUT PUT F.B.
CN14 DC TO SCR
DRIVE/RELAY

1) CN4-15 VOLT SUPPLY TO IGBT DRIVR CARD

2) CN5-15 VOLT SUPPLY TO IGBT DRIVR CARD
3) CN6-15 VOLT SUPPLY TO IGBT DRIVR CARD
4) CN7-15 VOLT SUPPLY TO IGBT DRIVR CARD
5) CN19-UPS/NORMAL SWITCH
6) CN18-TO DRIVER CARD
7) CN17-TO DRIVER CARD
8) CN16-BATTERY VOLTAGE SENCE AND CURRENT
9) CN15-MAINS SENCE
10) TR1-SMPS TRANSFORMER
11) CN1- BATTERY VOLTAGE (FOR SMPS)
12) CN20-TO DISPLAY
13) CN10-TO MARK NO 15
14) CN9-LOAD SENCE ON MAINS
15) CONNECTION COMES FROM CN10
16) BZ1-BUZZER
17) TS1-TEMPTAURE SENCER
18) CN14-TO SCR DRIVER &TDR RELAY (IN UPS) OR
TO CHANGEOVER RELAY & TDR RELAY (IN INVERTER)
19) TR3- MAINS SENCE TRANSFORMER
20) TR2- OUT PUT FEED BACK TRANSFORMER
21) CN12-OUT PUT FEED BACK

37
 Troubleshooting chart

(3KVA/5KV/6KVA/7.5KVA/10KVA/180V/192VON –LINE UPS)

(1$ IN-1$ OUT)

PROBLEM AND SYMPTONS POSSIABLE CASE SOLUTIONS

38
 3KVA—10KVA ON-LINE UPS
MOTHER BOARD

1 2 3 4 5 6 7 8 9

CN19 CN18 CN17 CN16 CN15

CN4 CN5 CN6 CN7
MAIN SENCE

LS1 TRF
TS1

CN14
CN10

SMPS OUT PUT SENCE

TRF

CN9

CN12

CN1

10 11 12 13 14 15 16 17 18 19 20 21

39
CONNECTOR DETAIL:
CONNECTOR VOLTAGE PI PIN PIN 3 PIN4 PIN5 PIN6 REMARKS
N1 2
CN4-7 15 VOLT +15 FOR DRIVER
-
CN19 NOT IN USE

CN18 DRIVE TO IGBT

DRIVER
CN17 DRIVE TO IGBT
DRIVER
CN16 DC CR. DC DENCE
+ - SENCE CURRENT
CN15 AC 230 0 MAIN SENCE
CN1 DC + NC - FOR SMPS
CN20 DC/DATA FOR
DIPLAY/ON/OFF
SWITCH
CN9 NOT IN USE
CN12 AC 230 0 OUT PUT F.B.
CN14 DC CHARGING
CUT

1) CN4-15 VOLT SUPPLY TO IGBT DRIVR CARD

2) CN5-15 VOLT SUPPLY TO IGBT DRIVR CARD
3) CN6-15 VOLT SUPPLY TO IGBT DRIVR CARD
4) CN7-15 VOLT SUPPLY TO IGBT DRIVR CARD
5) N/C
6) CN18-TO DRIVER CARD
7) CN17-TO DRIVER CARD
8) CN16-BATTERY VOLTAGE SENCE AND CURRENT
9) CN15-MAINS SENCE
10) TR1-SMPS TRANSFORMER
11) CN1- BATTERY VOLTAGE (FOR SMPS)
12) CN20-TO DISPLAY
13) CN10-N/C
14) CN9-N/C
15) N/C
16) BZ1-BUZZER
17) TS1-TEMPTAURE SENCER
18) CN14- CHARGER CUT
19) TR3- MAINS SENCE TRANSFORMER
20) TR2- OUT PUT FEED BACK TRANSFORMER
21) CN12-OUT PUT FEED BACK

40
7. INSTALLATION PROCEDURE & PRECAUTIONS

INSTALLATION
Inverter/ Static UPS are sophisticated devices and must be treated accordingly.
Keep the inverter/ static UPS in non-condensing, well ventilated environment,
ensuring that there are no ingresses of moisture of foreign material. Inverter/ Static
UPS should be kept as close as possible to the battery in order to keep the battery
cables short. However, do not locate the inverter/ static UPS in the same
compartment as non-sealed batteries. Batteries generate gases, which are very
corrosive to electrical equipment and everything else.
An independent circuit breaker (MCB) is suggested for input & out put according to the
inv/ups capacity.
For in put, out put, battery wire thickness refers to table below.

UPS/INV(KVA) IN PUT I/P WIRE O/P WIRE BATTERY

PROCETION THICKNESS THICKNESS WIRE
MCB(AMP) (MMS) (MMS) (MMS)
2.5KVA/48VOLT 20 AMP 2.5 2.5 16
(1PH-1PH)

3KVA/48VOLT 20 AMP 2.5 2.5 16

5KVA/96/120/180VOLT 32 AMP 4/4/4 4/4/4 10/8/6

6KVA/96/120/180VOLT 40AMP 6/6/6 6/6/6 10/8/6

7.5KVA/120/180/192VOLT 63AMP 8/8/8 8/8/8 16/10/8

10KVA/180/192VOLT 63/AMP 10/10 10/10 16/16

12KVA/192VOLT 63AMP 10 10 16

Installation of Inv/static ups/lift ups:

Site selection:

1) UN pack the ups and examines carefully to make sure the out look of the
ups/inv/lift ups is in good condition.
2) Select a proper environment; keep at least 1feet clearance between inv/ups/lift ups
rear panel and the wall.
3) Keep smooth air flow to the ventilation hole of the ups.
4) Avoid over heating or excessive moisture.

Installation notice:

1) The installation must be conduct by qualified parson.

41
 2) Error phase wiring of input &out put will prohibit system operation.
3) Casters are designed for smooth floor displacement only. Ramped floor
displacement is not allowed and against warranty condition.
4) In case the out put wires get short, the ups/inv get tripped in short circuit please
check the out put wires to rectify the short case and restart inv/ups

Installation instruction:

1) Make sure the MCBs on the rear panel are off.

2) Connect in put mains wires according to the indication of N-L-E
On the terminal block.
3) Connect out put wires according to the indication of N-L-E on the terminal block.
4) Ready battery bank as inv/ups battery voltage rating. Connect battery positive and
negative wire in inv/ups according to the indication on rear panel.

INSTALLATION CHECK LIST:

1) The voltage of ac line input.

2) The phase of input &out put wires correct as requested.
3) All wiring terminals or connectors are as well fastened.
4) Earth must be connected.

OPERATION INSTRUCTION:

1) Turn on battery mcb.

Ups/inv will be energized and get start,LCD will display.

Kevin power Web:www.kevin DSP SINE WAVE

STATIC UPS 7.5 KVA
solutions p ltd Solutios.net

INV SWITCH: OFF I/P VOLTAGE: 000VOLT O/P VOLTAGE: 000 VOLT
MAINS NOT OK I/P FREQ : 00 HZ O/P FREQ : 00 HZ

BATTERY CHARGED UPS MODE: OFF

BATT VOLTAGE: 210 VOLT

2) Switch on inv/ups on off switch.

Inv/ups will get start and give out put 230 volt. LCD show….

Inv switch: on O/p voltage: 230 volt

Mains :not ok O/p freq : 50 Hz

3) Turn on mains input mcb.

Inv/ups turn on battery mode to mains mode and get start charging. LCD show….

I/p voltage: 220 volt Battery charging

I/p freq : 50 Hz Batt voltage: 190volt
4) Select rotary switch to ups/inv side.

42
 5) Check load current/status.

6) Turn off external mcb to check inv/ups on battery mode.

7) Select normal/ups switch as customer needs

(INSTALLATION OF ON LINE UPS)

ON LINE UPS (1/2/3/4/5/6/7/8/9/10/…………..100KVA/1PH/3PH)

An independent circuit breaker (MCB) is suggested for input & out put according to
the online-ups capacity.
For in put, out put, battery wire thickness refers to table below.

UPS/INV(KVA) MAX I/P AMP IN PUT I/P WIRE O/P WIRE BATTERY
AT LOW I/P PROCETION THICKNESS THICKNESS WIRE
VOLTAGE MCB(AMP) (MMS) (MMS) (MMS)
1KVA/168VOLT(1P-1P) 6 AMP 10AMP 1.5 1.5 2.5

2KVA/168VOLT(1P-1P) 12AMP 20 AMP 2.5 2.5 2.5

3KVA/180VOLT(1P-1P) 17AMP 32AMP 4 4 4

5KVA/180VOLT(1P-1P) 28AMP 40AMP 6 6 6

7.5KVA/180VOLT(1P-1P) 42AMP 63AMP(DP) 8 8 8

10KVA/192VOLT(1P-1P) 58AMP 63/AMP(DP) 10 10 16

10KVA/360VOLT(3P-1P) 20AMP/PH 40AMP(TPN) 6 10 8

15KVA/360 VOLT(3P-3P) 33AMP/PH 63AMP(TPN) 8 8 8

20KVA/360 VOLT(3P-3P) 45AMP/PH 100AMP 10 10 10
30KVA/360 VOLT(3P-3P) 16 16 25
40KVA/360 VOLT(3P-3P) 25 25 35
50KVA/360 VOLT(3P-3P) 35 35 50

Installation of online ups:

Site selection:

43
 1) UN pack the ups and examines carefully to make sure the out look of the ups/inv/lift
ups is in good condition.

2) Select a proper environment; keep at least 1feet clearance between on line ups rear
panel and the wall.

3) Keep smooth air flow to the ventilation hole of the ups.

4) Avoid over heating or excessive moisture.

Installation notice:

1) The installation must be conduct by qualified parson.

2) Error phase wiring of input &out put will prohibit system operation.

3) Casters are designed for smooth floor displacement only. Ramped floor
displacement is not allowed and against warranty condition.

4)In case the out put wires get short, the ups/inv get tripped in short circuit please
check the out put wires to rectify the short case and restart inv/ups
5) Never put on battery MCB first.

Installation instruction:

1) Make sure the MCBs on the rear panel are off.

2) Connect in-put mains wires according to the indication of (N-L-E)/(R-Y-B-N)
On the terminal block.
3) Connect out-put wires according to the indication of (N-L-E)/(R-Y-B-N) on the
terminal block.
4) Ready battery bank as inv/ups battery voltage rating. Connect battery positive and
negative wire in inv/ups according to the indication on rear panel.

44
INSTALLATION CHECK LIST:

1) The voltage of ac line input.

2) The phase of input &out put wires correct as requested.
3) All wiring terminals or connectors are as well fastened.
4) Earth must be connected.

5) CAPACITY OF DG SET: TWO TIMES FREE CAPACITY OF DG SET IS

REQUIRED FOR ON LINE UPS TO RUNNING ON DG SET SMOOTHLY.

FOR EXAMPLE: IF ON LINE UPS CAPACITY IS 5 KVA AND LIGHT/OTHER LOAD IS 5 KVA THEN WE
REQUIRED 15 KVA GOOD WORKING DG SET.

OPERATION INSTRUCTION:
1) Turn on mains mcb.(wait some time …)
On-line Ups will be energized and get start, LCD will display.

A) Kevin power solution p ltd.

B) Web: Kevinsolutions.net
C) Mains I/p voltage
D) Mains frequency
E) o/p voltage
F) o/p frequency
G) load %
H) battery voltage
I) SW on/off

2) Turn on battery Mcb.

3) Switch on on/off switch of ups of front panel.
4) UPS display show...

A) Out put voltage.

B) Out put frequency.
C) Battery charging/charged.

5) Turn on load external mcb.

6) Turn on mains external MCB for testing on battery mode.
7) Fill up all technical data in report.

45
Display status:
status On display Alarm
On-line ups running on I/P …..XXX VOLT no
mains
o/p……xxx volt

I/P freq……..xx Hz

o/p freq……..xx Hz

battery charging

battery ……xxx volt

mains ok

load %

Battery low Protection battery low beeping

Out put over load Warning beeping

Over load
I/P mcb trip i/p mcb trip beeping

O/P Short circuit Protection short circuit beeping

Ups on battery Mains not ok Beeping every 5 min.

Installation Procedures
Inverter/ Static UPS are sophisticated devices and must be treated accordingly.
Keep the inverter/ static UPS in non-condensing, well ventilated environment,
ensuring that there are no ingresses of moisture of foreign material. Inverter/ Static
UPS should be kept as close as possible to the battery in order to keep the battery
cables short. However, do not locate the inverter/ static UPS in the same
compartment as non-sealed batteries. Batteries generate gases, which are very
corrosive to electrical equipment and everything else.

46
Operation
Once the AC & DC wiring have been installed and connected, take a moment to re-
examine all the connections and make sure they are secured and in the proper
terminals. Check to see that the inverter/ static UPS are turned off, and then apply
battery DC power to it. Ensure that all wiring has been installed properly. Turn on the
battery bank DC disconnect or connect the proper Fuse/ MCB in line to the battery
to complete the battery circuit. Put ON/ OFF switch to the ON position. The inverter/
static UPS should run a load without AC input (battery only). Place a load on the
inverter/ static UPS and make sure that it works. To change the batteries, connect
AC power to the inverter/ static UPS by plugging in the AC power and turning on the
MAIN line. This shows that charger is working properly. Any AC load powered by the
inverter/ static UPS should also work at this point since a protection of the AC
power is passed through the inverter/ static UPS to power the loads. The delay
before connecting is provided within acceptable frequency and voltage limits.
Disconnect the AC power. The inverter/ static UPS should transfer to inverter/ static
UPS mode immediately. This will be indicated by a clicking sound as the internal
transfer relay changes position. The inverter/ static UPS will begin to take power
from the batteries and use it to power the load and the load continues to operate
uninterrupted.
1) Make sure that the MCB’s on the rear panel are OFF
2) Connect in-put mains wires according to the indication of (N-L-E)/ (R-Y-B) on the
terminals block
3) Connect out-put wires according to the indication of (N-L-E)/ (R-Y-B-N) on the
terminal block
4) Ready battery bank as on-line UPS battery voltage rating. Connect battery
positive and negative wires in inverter/ UPS according to the indication on rear
panel.

47
 Precautions

General Precautions:

Please read the general precautions carefully:

Before using the Three Sixty DSP Sine Wave Inverter/ Static UPS, read all the
instructions and caution marking on the inverter/ static UPS, the batteries, all
appropriate sections of this Instruction Manual.
Do not expose Three Sixty DSP Sine Wave Inverter/ Static UPS to any type of
chemicals
Do not assemble the Three Sixty DSP Sine Wave Inverter/ Static UPS. Take it to
a qualified Three Sixty Engineering Service Centre when service or repair is
required. Opening by unqualified person can lead electrical shock or fire hazard
To reduce risks of electrical shock, disconnect all wiring before cleaning
Warning: Avoid exposing the inverter/ static UPS or batteries to any type of
explosive gases (in the vicinity, as batteries generate explosive gases during
normal operation), provide ventilation to outdoors from the battery
compartments. The battery enclosures should be designed to prevent
accumulation and concentration by hydrogen gas in “POCKET” at the top of the
compartment. Vent the battery compartment from the highest point. A sloped
lid can also be used to direct the flow to the vent opening location. To reduce the
risk or the battery explosion, follow all the instruction of battery supplier or any
equipment you intend to use in the vicinity of the batteries
Use the correct tolls to make AC/ DC wiring connections
Do not install this Three Sixty DSP Sine Wave Inverter/ Static UPS on or near
flammable materials like plywood, chemicals, gasoline etc.)

CAUTION: The Three Sixty DSP Sine Wave Inverter/ Static UPS should be
connected to grounded, permanent wiring systems

Personal Precautions

Someone should be within the range of your voice to come to you aid when you
work near batteries
Keep plenty of fresh water and soap nearby in the event that battery acid
contact skin, clothing or eyes
Wear complete eye protection and clothing protection
Avoid touching eyes while working near batteries; wash your hands with soap,
when done

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If battery acid comes in contact with skin or clothing, wash immediately with
soap and water. If acid enters eyes, immediately flood eyes with running cool
water for at least 15 minutes and get medical attention immediately
Baking soda neutralizes battery electrolyte. Keep a supply in the battery area
handy.
NEVER smoke or allow spark or a flame in the vicinity of the battery
Be extra cautious when working with metal tools on and around batteries. It
could short circuit the batteries or other electrical parts producing a spark that
could cause an explosion
Remove personal metal items such as rings, bracelet, necklace and watches
when working with the battery. Battery can produce a short circuit current high
enough to cause severe burns
Never attempt to charge a frozen battery
Before touching the battery terminal make sure that the inverter/ static UPS
front switch is OFF and AC mains to the inverter/ static UPS is also OFF
f it is necessary to remove any battery, always remove the grounded terminal
from the battery first. Make sure that all the accessories are OFF, so as not to
cause arcing
Be sure that the area around the battery is well ventilated
Clean battery terminals. Be careful not to allow corrosion to come in contact
with the eyes
Study all the battery manufacturer’s specific precautions and recommended
rates of charge.
Add only distilled water in each cell until battery acid reaches level specified by
battery manufacturer. This helps purge excessive gas from cells. Do not overfill.
For a battery without caps carefully follow manufacturer’s recharging
instructions

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