5K/7K Test Program

The short pin position and function introduction

M Board :(FIG1:test pin location of control board)
Short pin introduction
JPM1: Short JPM1, the units change into repair mode
JPM6: Short JMP6: turn off inverter
Test pin introduction
TPM1: Grounding pin
TPM2: Triangle waveform of inverter controller(17kHZ)
TPM3: reference sine waveform
TPM4: Inverter H drive signal
TPM5: Inverter L drive signal

Power board (FIG2:test pin location of power board)

Short pin introduction
JPA1/JPA3: short JPA1/JPA3,turn off Battery SCR
CND4: short CND4,turn off charger
JPB1: short JPB1,turn off PFC
Test pin introduction
TPB1: PFC+ drive signal
TPB2: BUS+ voltage
TPB7: Grounding
TPB4: BUS- voltage
TPB5: PFC- drive signal
TPB8: Voltage feedback selection for PFC controller (BUS-)
TPB6: Voltage feedback selection for PFC controller (BUS+)
TPB9: Common battery MOSFET drive signal

PCB function introduction

Control board(PCB p/n: 2933301405 SCH p/n: 5505001436)
1. Inverter control
2. Communication circuit
3. Input & output detection
4. Battery & AC rectifier control signals
5. Input & output fuse detection
6. Other signals detection
Power board (PCB p/n: 2933301005 SCH p/n : 5505001264)
1. PFC control
2. main auxiliary power
3. PFC & Inverter circuit
4. AC & DC rectifier
EMI board (PCB p/n:2933301603 SCH p/n : 5505001446)
1. AC auxiliary power circuit
2. Bypass SCR & Inverter SCR control
3. I/P relay & HVP protection
 Test procedure
1. Check auxiliary power
1.1 Let ups enter to repair mode (short JPM1)

1.2 Disable battery rectifier (short JPA1,JPA3)

1.3 Connect battery cable

1.4 Press “on” key, but not power on ups, then the fan running and LCD show

“ups off waiting”.

1.5 Else please check the battery voltage on terminal CNA1 and CNA2,if

abnormal, you should check battery cable and battery module.

1.6 If battery voltage is ok, then check the fuse FUA2 and FUA3. if not, replace it

and press “on” key to check the fan and the LCD again. Else please replace the

power board.

2. Check battery rectifier

1.1: Disable inverter (short JPM6).
1.2: Disable PFC (short JPB1)
1.3: connect battery cable, press “on” key to start ups.
1.4: Then ups will show “DC BUS FAIL”
1.5: Measure the bus voltage, Normally, the voltage is half battery voltage.
1.6: If not, please check the critical components (table 1) on power board.
1.7: Else please disconnect the battery cable and replace the control board. Then
check again.
3. Check inverter
1.1: Disable inverter (short JPM6).
1.2: Disable PFC (short JPB1)
1.3: connect battery cable, press “on” key to start ups.
1.4: when the bus voltage up to half battery voltage, disconnect the battery cable.
1.5: enable the inverter (remove the short pin JPM6)
 1.6: Connect the battery cable, press “on” key, but not power on ups to discharge
the bus voltage, then the voltage of +bus/-bus will drop down rapidly.
1.7: If the bus voltage down slowly 1 by 1 volt. After the buss voltage less than 10
volts ,Please disconnect the battery cable and check the critical components
on power board.(table 2)
1.8: If the components is abnormal please replace the power board and check
again.

1.9: Else please replace the control board and check again.
4. Check PFC
1.1: Disable inverter (short JPM6)
1.2: Connect battery cable, input AC.
1.4: When the bus voltage up to about 370V, disconnect the battery cable.
1.5: Connect the battery cable, enable inverter (remove JPM6) and press “on” key
for about 1s to discharge BUS voltage.
1.6: If the bus voltage is abnormal, then disconnect the battery cable, enable
inverter(remove JPM6) and connect the battery cable .press “on” key for
about 1s to discharge the bus voltage.
1.7: Check the critical components of PFC circuit (Table 3). If ok, please replace
the control board. Else, replace the power board and check again.
5. Check AC rectifier
1.1: Disable inverter (short JPM6)
1.2: Disable PFC (short JPB1).
1.3: Connect battery cable, input ac .then the bus voltage will up to about 320V.
1.4: If abnormal, then the LCD will show “rectifier fail”. please cut off the ac
input, disconnect battery cable, enable the inverter (remove JPM6).
1.5: Connect the battery cable and press “on” key for about 1s to discharge BUS
voltage.
1.6: Check the critical components of AC rectifier circuit (Table 4). If ok, please
replace the control board , else replace the power board
1.7: Disable inverter (short JPM6), connect battery cable and input ac to check the
ac rectifier function again.

6. Check UPS Function

1.1: Remove all short pin
1.2: Connect battery .
1.3: Input AC, then ups will operating on bypass mode .
1.4: Else the LCD will show “bypass SCR fail”. Then you should check the critical
components of the bypass circuit.(Table 5)
1.5: If the critical components is ok ,please replace control board. Else please
replace the EMI board and input AC again.
1.6: After UPS operating on bypass mode, press “on” key for about 3s to start
UPS.
1.7: If any PCB have replaced, please check the difference between the value read
from LCD panel and actual measured. For more detail information please
reference to service manual page58 3-2-3 EEPROM parameter change.
FIG1(control board)
FIG2(Power board)
Table 1：Critical components of battery rectifier
Name Position
Rectifier SCR SCRA2,SCRA5,SCRB1
Boost IGBT QB9,QB10,QB11,QB12,QB20,QB21
Diode DB3,DB6
Driver Photo Couplers UA1,UA3

Table 2：Critical components of inverter on power board

Name Position
Inverter MOS QB2,QB3,QB4,QB7,QB16,QB17,QB18,QB19
RB3,RB19,RB20,RB21,RB45,RB46,RB47,RB34
Resistors
RB243,RB246
Zener diode ZDB7,ZDB8,ZDB5,ZDB6
Driver Photo Couplers UB4,UB22
Diode DB50,DB53

Table 3：Critical components of PFC

Name Position
PFC IGBT QB9,QB10,QB11,QB12,QB20,QB21
Resistors RB7,RB8,RB41,RB35,RB36,RB40,RB244,RB245
Zener diode ZDB1,ZDB2,ZDB10,ZDB4
Driver Photo Couplers UB2,UB21
Diode DB3,DB6,DB29
IC UB7,UB10,UB11

Table 4：Critical components of AC rectifier

Name Position
Rectifier SCR SCRA1,SCRA3
SCR driver QA1,TA1,DA14,DA15
Diode DB3,DB6,DB29
IC UB6
Table 5：Critical components of bypass control
Name Position
Bypass SCR SCRR1
MOS QR4
Transformer TRR1
Driver Photo Couplers UB2,UB21
Diode DR11,DR12