UNINTERRUPIBLE POWER SYSTEMS

SERVICE MANUAL

BEST 625/ PW 9120

700VA/1KVA/1.5KVA/2KVA/3KVA

P/N : 614-20197-0X 03,19,2001

BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

I. INTRODUCTION 3
II. PRINCIPLE OF OPERATION 4
1. INTRODUCTION 4
III. POWER STAGE (PSDR) 5
i. CHARGER SUB-SYSTEM: 5
ii. DC POWER SUPPLY SUB-SYSTEM: 5
iii. INVERTER SUB-SYSTEM : 5
iv. OUTPUT SUB-SYSTEM : 6
v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM : 6
vi. DC-DC CONVERTER SUB-SYSTEM : 6
1. MAIN CONTROL PCB ASSEMBLIES (CNTL) 7
i. REGULATION & CONTROL SUB-SYSTEM : 7
ii. PROTECTION SUB-SYSTEM : 8
iii. SIGNALING SUB-SYSTEM : 9
2. FRONT PANEL : 10
IV. ALIGNMENTS 11
V. TROUBLE SHOOTING 12---23
1. OVERVIEW :
2. U.P.F. CORRECTION:
3. PUSH-PULL DC-DC CONVERTER:
4. DC/AC INVERTER:
5. DC POWER SUPPLY :
6. AC/DC CHARGER :
VI. APPENDIX I : SCHEMATICS 24
VII. APPENDIX II : COMMUNICATION 33

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

WARNING
(For qualified service personnel only)
1. DO NOT perform any internal service or adjustment of this product unless another
person is capable of rendering first aid and resuscitation is present.
2. Dangerous voltage exists at several points in this product. To avoid personal injury, don't
touch any exposed connections or components while power is on.
3. Turn off the UPS and disconnect input power cord and two battery cables before
removing outside protective cover.
4. AC voltage is always present if the input AC power is still available.
5. Dangerous electric charge may be stroed in DC capacitors and associated circuit, after
turning off the UPS and disconnect input power cord. Please test before touching.
6. Verify input source (voltage and frequency) before service.

CAUTION

1. After opening the cover, please always check the tightness of all wires, connectors, and
screws first. Then check if there is any decolored components inside.
2. DO NOT make internal batteries short-circuited.
3. If find that the battery wire in the UPS is disconnected, be sure that the battery cabinet is
disconnected and the input power cord is unplugged before re-connect the battery wire.
4. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

I.INTRODUCTION
For all series of BEST625/PW9120 UPS, they are strictly tested and carefully designed.
We always do our best to make our products more reliable and safer, this is also the goal
of our company. However, due to the lifetime of electrical components and some
unpredictable reasons, there will be unavoidable failures of this UPS. If this situation
occurs, service of qualified person is needed. This service manual will guide the
technicians to repair and adjust a problematic UPS. If the UPS still does not work
properly, please contact with us and we will be glad to solve any problems you met.
Because of the following unique features of 1000NN series UPS (Uninterruptible
Power System), it is very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.

This service manual consists of 4 major parts:

1. Introduction.
2. Principle of operation: It describes the functions and principles of each part.
3. Alignments: It describes the locations and methods needed to adjust this UPS.
4. Trouble shooting: This part describes the possible failure conditions and procedures
to repair it.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and
safe operation.

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

II. PRINCIPLE OF OPERATION

1. INTRODUCTION

This 700VA--3KVA high input power factor UPS system contains two major pcb
assemblies. They are including :
1. PSDR: contains major parts of (1) charger, (2) DC power supply, (3) unit power
factor correction, (4) DC-DCconverter, (5) inverter and (6) output circuits.
2. CNTL : contains major parts of protection, signaling circuits, regulation and control
circuits of inverter

The simplified schematics in figure 1 (3K HV model) shows how the major circuits are
connected and illustrates the overall system functions. The locations of these assemblies in
this machine are shown in figure 2 (3K HV model) .

The block diagram in figure 3, shows the UPS at normal operation from left to right. When a
protection circuit is triggered or a fault condition occurs, the output supply is transferred
immediately from inverter to AC mains by a bypass relay. The operation principle will be
explained in later section.

Basically, these BEST625/PW9120 UPS system utilizes high frequency PWM techniques to
achieve high efficient performance. This UPS can deliver a clean, regulated sine-wave output
at any load under full load. The sub-systems are described as below:

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

III. POWER STAGE (PSDR)

The power stage consists of charger, unit power factor correction, DC power supply,
DC-DC converter, inverter and output circuits. figure 4 shows the block diagram of power
stage.

i.CHARGER SUB-SYSTEM:
The purpose of charger is to charge and to maintain the batteries at full charged
condition. Refer to figure 5 (3K HV model), the voltage flyback switching power supply
provides a constant DC voltage for batteries. Besides providing constant voltage, the
power supply also limits the current flowing into batteries and therefore protects and
prolongs the life time of charged batteries. The charger voltage is auot-regulated by CPU
according to the temperature.

ii. DC POWER SUPPLY SUB-SYSTEM:

The input of the DC power supply is connected to the battery bus, i.e., the output of the
charger. The output of DC power supplies provid +12 Vdc for the bias supply of IC's
working voltage and the fan(s) voltage and other requirement. 5V is used for CPU's
working voltage and made by control board through IC7805. The DC power supply works
only when the 12 Vdc regulator supplies Vcc to its control IC. To have proper operation of
12 Vdc regulator, its input power is controlled by the switch as indicated in figure 6 (3K
HV model).

iii.INVERTER SUB-SYSTEM :

The UPS transfers ＋,－ DC bus voltages to the AC output voltage through an inverter

of half bridge configuration at normal operation. The schematic diagram of inverter is

shown in figure 7 (3K HV model).
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching
signals from PWM generation circuit through a pair of photo-couplers to trigger the upper
IGBT and the lower IGBT alternately. The output of IGBT's is filtered by an LC circuit to
reduce the o/p voltage harmonics distortion.
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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

iv.OUTPUT SUB-SYSTEM :

The bypass relay receives signal from control circuit to switch the output of the UPS
from bypass to inverter, and vice versa. The output noise filter circuit blocks EMI noise to
the loads.

v.INPUT POWER FACTOR CORRECTION SUB-SYSTEM :

The purpose of power factor correction (P.F.C.) circuit is to make the input current and
voltage in phase and therefore achieve a high input power factor. The schematic is
indicated in figure 8 (3K HV model).

When the input AC power cord is plugged in and switch on, the AC power goes
through noise filter to the charger and to the line detector, the P.F.C. circuit is enabled and
the DC buses are regulated at 380Vdc for 230VAC series and 190V for 120VAC series,
the buses voltage are regulated according to the input voltage. When the input voltage is
160—200V, the bus voltage is 360V, 200—260V is 380V, 260—276V is 400V. And
120V series is divided two.

vi.DC-DC CONVERTER SUB-SYSTEM :

The major function of the UPS is to deliver accurate AC power to the loads connected
to it whenever the AC line is correct or fails. In this system, the batteries release the
stored energy to supply inverter immediately upon AC line fails.
Refer to figure 9 (3K HV model), the battery voltage is transformed through a push-
pull DC-DC converter to ± 400Vdc (± 200Vdc for 120V series) as DC buses for inverter.
When the line fails, the ± 400Vdc(± 200Vdc) DC sources are caught up to supply the
power needed by the inverter immediately.

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

1.MAIN CONTROL PCB ASSEMBLIES (CNTL)

These assemblies are the control center of UPS. It is composed of three major circuits
as following.
(1) Regulation & control
(2) Protection
(3) Signaling

i.REGULATION & CONTROL SUB-SYSTEM :

This portion can be seen as brain of the UPS. It provides the control pulses to the
switching elements which deliver power to the output. The sub-system also regulates the
output to ensure that the UPS is delivering constant AC voltage to the loads.

The inverter signal is sensed directly by resistor division. It is compared with a

reference signal from sine wave generator. The difference of these two signals (error
signal) alter the pulse widths of PWM signals which control the duty cycles of switching
elements to regulate the output voltage within specification.

In order to avoid un-wanted surge current at the transfer of bypass relay, the bypass
signal activates the tracking circuit. It matches the inverter voltage with the line voltage by
having the amplitude of the reference signal following the variation of line voltage.

When the mains in the acceptable range is applied and the switch is turned on, the UPS
operates at battery mode to charge the buses voltage and inverter on. As soon as the phase
lock and amplitude are completed. If the battery is weak, the UPS transfers to bypass
mode about 3 seconds when switch turns on, then transfer to inverter mode and as soon as
the phase lock and amplitude are completed.

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

ii.PROTECTION SUB-SYSTEM :

The UPS provides the following protection circuits :

1. Overload protection
The load detector senses the load current. i.e. the inverter current, and sends the signal
by two paths. In battery mode, the UPS will go to failure mode if overload condition
happened. The panel will indicate the fault condition.
A.The UPS collects the continuous overload signals through CPU switches the bypass
relay. If the output load is higher than 110% and lower than 125% of rated
load(VA ,or Wattage) the UPS keeps running on inverter running for 1 minute.
If the output load is higher than 125% and lower than 150%of rated load, the UPS
transfers to bypass after 10 seconds. If the output load is higher than 150%, the UPS
transfers to bypass at once.
B.When output loads sink a high surge current , a high inverter current is detected and
the inverter switches, i.e. the IGBT's, are turned off pulse by pulse to protect
themselves from thermal runaway. The bypass relay stays at inverter output position
unless a continuous overload is detected or an abnormal inverter operation occurs.

2. Battery over or under shut down

Upon the battery voltage declines to battery-under level, a signal is generated to cut off
the power supply of the whole system, The buzzer becomes silent and all the LED's
extinguish. When the utility is coming, the UPS will start up automatically.
In case of the battery voltage(chargeing voltage) exceeds the acceptable high-limit
voltage (15V/per Battery), the UPS will discharge the battery capacity by way of DC-DC
coverter to ensure the battery life. The panel will display the fault condition.

3. Inverter output abnormal protection

The inverter failure signal shuts down the inverter immediately, makes the buzzer
continuous beep, and the "FAULT" LED light. The panel will display the fault condition.
" The failure signal is latched unless the UPS is turned off or the battery is empty".

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

4. Over temperature protection

The thermal switch detect the temperature of the heatsink of the inverter on the PSDR.
The thermal switches are electrically connected to the CPU. While the temperature is
higher than the switch’s specification, the thermal switch is opened and the CPU can’t
detect the 5V. The CPU will think the condition as high internal temperature, The panel
will display the fault condition.

5. Bus overvoltage protection

To protect the BUS voltage from being overvoltage condition, especially for the half-
bridge load. The panel will display the fault condition.

iii.SIGNALING SUB-SYSTEM :

When the AC line is unable to supply, the batteries release stored energy to supply the
inverter immediately. At the same time, the utility failure relay is activated and the buzzer
beeps every five seconds.
Upon the batteries are discharged to battery-low level, the battery-low relay is activated
and the buzzer two beeps every five seconds.
Remote shutdown signal is enabled only when the line fails. The signal is connected to
the battery detector. It generates battery-under signal to cut off the bias power supply of
the UPS system. The EPO signal is enabled at any mode, when the EPO is enable, the unit
shut off the output power.

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

2.FRONT PANEL :

The front panel consists 3 parts: button switch, mode LED set and display LCD.
There are three button switched, one is to turn on and off the UPS, one is scroll button,
it can select the function of unit operation, another is enter button, it can display the unit
function, for example, it can display the input voltage, frequency, output voltage,
frequency, load,….etc. The three LEDs indicate “UPS ON”, “BATTERY MODE”, and
“FAULT”, PW9120 increase a LED to indicate “BYPASS MODE”. The LCD display
UPS any conditions.

2. Besides, when the system works abnormally, the fault LED will light up and the
buzzer will beep continuously. In this situation, the LCD will display the fault condition,
for example: High output voltage, High temperature,….,etc.

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

IV. ALIGNMENTS

The BEST625/PW9120 series are auto-regulation the bus voltage, bus balance and charger
voltage, when the CNTL or PSDR is modified, the engineer must rectify them according to
the following steps:
(1). Connect the computer to the rectified unit.
(2). Execute the “service program”.
(3). Import the part number and serial number.
(4). Measure the temperature and charge voltage.
(5). Import the measured temperature and charger voltage.
The CPU will auto-regulate the charger voltage and temperature.

Note: the charger voltage will be changed according to the temperature at the
BEST625/PW9120 series, at the 25 degree C, it is 14V/pcs.

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

V. TROUBLE SHOOTING
For the reason of safety, you must unplug the power cord and disconnect the batteries
from UPS.
Check the components listed below to confirm which block is out of order and follow
the procedures listed on the following pages to repair them.

CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components.

700VA
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE F1 short or open
P.F. Correction U9,D7,D8,Q9 short or open
Push-Pull Booster Q4,Q5,Q7,Q8 D-S short or open
D22,D23,D24,D25 short or open
D12,D13 short or open
Inverter Q10,Q11 D-S short or open
Charger Q18 D-S short or open
DC Power Supply Q21 D-S short or open

2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 Ω short open

2 Q9 (D,S) DIODE 0.41 short or open

3 D7,D8 DIODE 0.42 short or open
4 R46 Ω 47 open or value
change
R47 Ω 10 open or value
change
5 REC1(+,～),(～,-) DIODE 0.49 short or open

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
C40,C42 Ω open deformed
short
visual

3. PUSH-PULL DC-DC CONVERTER:

Step Checked components *Instrument Reference Failed condition
function Value
1 F2 Ω short open

2 Q4,Q8,Q7,Q5 (D,S) DIODE 0.48 short or open

R11,R14,R22,R31 Ω 10 open

3 D22,D25,D23,D24 DIODE 0.4 short or open

* The instrument is D.M. ( digital multimeter ).

4.DC/AC INVERTER:
Step Checked components *Instrument Reference Failed condition
function Value
1. Q10,Q11 (D,S) DIODE 0.416 short or open
2. R52,R59 Ω 47Ω open

5.DC POWER SUPPLY :

Step Checked components *Instrument Reference Failed condition
function Value
1 Q21 (D,S) DIODE 0.5 short or open
2 R27 Ω 47 open
3 R29 Ω 0.22Ω open
/2W
4 U5 (3845) PIN 5-6 49.9K too low
5-7 39K
5-8 Ω 4.2K
6-8 54.1K

6.AC/DC CHARGER :
Step Checked components *Instrument Reference Failed condition
function Value

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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
1 Q18 DIODE 0.5 short or open
2 R128 Ω 47 open
3 R130 (LV) Ω 0.5Ω /2W open
R130A(HV)
1.2Ω /2W
4 U13 (3843) PIN 5-6 49.9K too low
5-7 30.44K
5-8 Ω 4.13K
6-8 54K
5 D34,D35,D36, DIODE 0.564 short or open
D37
6 C48 Ω open short
deformed
visual
7 F3(HV) Ω short open

1KVA
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE F1 short or open
P.F. Correction U9,Q9,D7,D8 short or open
Q4,Q5,Q7,Q8 D-S short or open
Push-Pull Booster
D22,D23,D24,D25 short or open
Inverter Q10,Q11 D-S short or open
Q18 D-S short or open
Charger
D12,D28 short or open
DC Power Supply Q21 D-S short or open

2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 Ω short open

2 Q9(D,S) DIODE 0.4 short or open

3 D7,D8 DIODE 0.4 short or open
4 R46 Ω 47 open or value
change
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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
R47 Ω 10 open or value
change
5 REC1 DIODE 0.5 short or open
6 C40,C42 Ω Open deformed
short
visual

3. PUSH-PULL DC-DC CONVERTER:

Step Checked components *Instrument Reference Failed condition
function Value
1 F2,F3 Ω short open

2 Q4,Q5,Q7,Q8(D,S) DIODE 0.49 short or open

3 R11,R14,R22,R31 Ω 10 open

4 D22,D23,D24,D25 DIODE 0.4 short or open

* The instrument is D.M. ( digital multimeter ).

4.DC/AC INVERTER:
Step Checked components *Instrument Reference Failed condition
function Value
1 Q10,Q11 DIODE 0.38 short or open
2 R52,R59 Ω 47Ω open

5.DC POWER SUPPLY :

Step Checked components *Instrument Reference Failed condition
function Value
1 Q21(D,S) DIODE 0.53 short or open
2 R27 Ω 47 open
3 R29 Ω 0.5Ω /2W open

0.39Ω

/2W (LV)

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
4 U5 (3845) PIN 5-6 >1M too low
5-7 >1M
5-8 Ω 4K
6-8 >1M

6.AC/DC CHARGER :
Step Checked components *Instrument Reference Failed condition
function Value
1 Q18 DIODE 0.5 short or open
2 R128 Ω 47 open
3 R130(LV) Ω 0.5Ω /2W open
R130A(HV)
1Ω /2W
4 U13(3843) PIN 5-6 45K too low
5-7 >1M
5-8 Ω 3.5K
6-8 53.5K
5 D12,D28 DIODE 0.4 short or open
6 C48 Ω open short
deformed
visual
7 F4(HV) Ω Short open

1.5KVA
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE (1060NN) F1, FC2, FC3, F4 short or open
P.F. Correction D13,D12,REC1,Q3 short or open
Push-Pull Booster Q4,Q5,Q6,Q7,Q21,Q22 D-S short or open
D33,D34,D35,D36 short or open
Inverter Q1,Q2 D-S short or open
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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Charger Q16 D-S short or open
D21, D22,D23 short or open
DC Power Supply Q14 D-S short or open

2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 Ω short open

2 Q3 (D,S) DIODE 0.9 short or open

3 D13,D12 DIODE 0.44 short or open
4 R37(LV) Ω 20 open or value
change
R36(LV) Ω 47 open or value
change
R36(HV)
100
5 REC1(+,～),(～,-) DIODE 0.4 short or open

6 C68,C69,C70,C71 Ω open deformed

short
visual

3. PUSH-PULL DC-DC CONVERTER:

Step Checked components *Instrument Reference Failed condition
function Value
1 FC2,FC3 Ω short open

2 Q4,Q5,Q6,Q7,Q21,Q22 (D,S) DIODE 0.47 short or open

D33,D34,D35,D36 DIODE 0.39 short or open
3 R69,R83,R152,R62,R63,R154 Ω 10 open

* The instrument is D.M. ( digital multimeter ).

4.DC/AC INVERTER:
Step Checked components *Instrument Reference Failed condition
function Value
1 Q1,Q2 (D,S) DIODE 0.39 short or open

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
2 R18,R21 Ω 47Ω open

R19,R22(LV) Ω 20Ω open

R19,R22(HV) 10Ω

5.DC POWER SUPPLY :

Step Checked components *Instrument Reference Failed condition
function Value
1 Q14 (D,S) DIODE 0.54 short or open
2 R65 Ω 47 open
R57 Ω 0.5Ω /2W open

3 U6 (3845) PIN 5-6 >1M too low

5-7 >1M
5-8 Ω 3.5K
6-8 >1M

6.AC/DC CHARGER :
Step Checked components *Instrument Reference Failed condition
function Value
1 Q16(D,S) DIODE 0.49 short or open
2 R94 Ω 47 open
3 R97(LV) Ω 0.39Ω open
R97(HV)
/3W
0.5Ω /2W
4 U9 (3845) PIN 5-6 45k too low
5-7 >1M
5-8 Ω 3.5k
6-8 53.5k
F4 Ω short open
D24,D25,D26,D27 DIODE 0.57 short or open
6 C57 Ω open short
deformed
visual

2KVA
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BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE F1,F2,F3 short or open
U.P.F. Correction REC1,Q14,D23,D26 short or open
Push-Pull Booster Q10,Q11,Q12,Q13,Q22 D-S short or open
Q21
D33,D34,D36,D37 short or open
Inverter Q3,Q4 D-S short or open
D12,D13 short or open
Charger Q1 D-S short or open
D06 short or open
DC Power Supply Q401 D-S short or open

2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 Ω short open

2 Q14 (D,S) DIODE 0.914 short or open

3 D23,D26 DIODE 0.4 short or open
4 R119(LV) Ω 10 open or value
100 change
R120(HV)

5 REC1(+,～),(～,-) DIODE 0.485 short or open

6 C57,C58,C59,C60,C116 Ω open deformed

short
C117(LV)
visual
C18,C19,C58,C60(HV)

3. PUSH-PULL DC-DC CONVERTER:

Step Checked components *Instrument Reference Failed condition
function Value
1 F3 Ω short Open

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
2 Q10,Q11,Q12,Q13,Q21,Q22 DIODE 0.416 short or open
(D,S)(LV)
Q11,Q12,Q13,Q21(D,S)(HV)
3 R129,R131,R134,R136,R164 Ω 10 open
R166(LV)
R131,R134,R136,R164(HV)
4 D33,D34,D36,D37 DIODE 0.357 short or open
* The instrument is D.M. ( digital multimeter ).

4.DC/AC INVERTER:
Step Checked components *Instrument Reference Failed condition
function Value
1 F2 Ω short open

2 Q3,Q4(D,S) DIODE 0.356 short or open

3 R56,R63(LV) Ω 10Ω open

R60,R64(HV) 47Ω

5.DC POWER SUPPLY :

Step Checked components *Instrument Reference Failed condition
function Value
1 Q401(D,S) DIODE 0.5 short or open
2 R31 Ω 47 open
3 R34(LV) Ω 0.5Ω /2W open
R34(HV)
1Ω /2W
4 U09 (3845) PIN 5-6 47K too low
5-7 33K
5-8 Ω 4.2K
6-8 51K

6.AC/DC CHARGER :
Step Checked components *Instrument Reference Failed condition
function Value

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
1 Q1 DIODE 0.46 short or open
2 R09 Ω 47 open

3 R12(LV) Ω 0.22Ω open

R13(HV)
/2W
0.43Ω
/2W
4 U01 (3843) PIN 5-6 47K too low
5-7 30K
5-8 Ω 4K
6-8 51K
5 REC2 DIODE 0.487 short or open

6 C13 Ω open short

deformed
visual

3KVA
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE F1,F2,F3,F4 short or open
U.P.F. Correction REC2,Q15,Q16,D38,D39 short or open
Push-Pull Booster Q11,Q12,Q13,Q14,Q24 D-S short or open
Q25
D21,D22,D23,D24 short or open
Inverter Q5,Q6,Q7,Q8 D-S short or open
D12,D13 short or open
Charger Q02 D-S short or open
D06 short or open
DC Power Supply Q03 D-S short or open

2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 Ω short open

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700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
2 Q15,Q16 (D,S)(LV) DIODE 0.869 short or open
Q15(D,S)(HV)
3 D38,D39 DIODE 0.356 short or open
4 R117,R119(LV) Ω 10 open or value
change
R118(HV)
47

5 REC1(+,～),(～,-) DIODE 0.46 short or open

6 C70,C71,C72,C73,C106 Ω open deformed

short
C107(LV)
visual
C15,C16,C17,C18,C71,C73
(HV)

3. PUSH-PULL DC-DC CONVERTER:

Step Checked components *Instrument Reference Failed condition
function Value
1 F3,F4 Ω short Open

2 Q11,Q12,Q13,Q14,Q24,Q25 DIODE 0.409 short or open

(D,S)
3 R99,R104,R177,R101,R103 Ω 10 open
R179
4 D21,D22,D23,D24 DIODE 0.360 short or open
* The instrument is D.M. ( digital multimeter ).

4.DC/AC INVERTER:
Step Checked components *Instrument Reference Failed condition
function Value
1 F2 Ω short open

2 Q5,Q6,Q7,Q8(D,S) DIODE 0.34 short or open

3 R30,R32,R36,R39(LV) Ω 47Ω open

R33,R37,R40,R153(HV)

22
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

5.DC POWER SUPPLY :

Step Checked components *Instrument Reference Failed condition
function Value
1 Q03(D,S) DIODE 0.411 short or open
2 R78 Ω 47 open
3 R82(LV) Ω 0.5Ω /2W open
R82(HV)
1Ω /2W
4 U09 (3845) PIN 5-6 47K too low
(LV) 5-7 33K
5-8 Ω 4.2K
U06(3845)PIN 6-8 51K
(HV)

6.AC/DC CHARGER :
Step Checked components *Instrument Reference Failed condition
function Value
1 Q02 DIODE 0.468 short or open
2 R09 Ω 47 open

3 R23 Ω 0.22Ω open

/2W
4 U01 (3843) PIN 5-6 47K too low
(LV) 5-7 30K
U208 (3843) PIN 5-8 Ω 4K
(HV) 6-8 51K
5 REC1 DIODE 0.493 short or open

6 C13 Ω open short

deformed
visual

After you have replaced all defect components on power stage ( PSDR ) , connect with
control board. Supply DC voltage /3Amp (limited current) with DC power supply via
battery cable(+) and cable(-). Turn on the switch on panel, you will see "current limit" on
the DC power supply for about 2 seconds (If not, there are some defective components you
have not found).
23
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
When everything seems good, turn off the switch on panel and remove DC power
supply. Plug in the power cord and supply UPS with the mains. Test the output of charger
( battery cable(+),(-) ). Check the voltage OK or not? The fan will also active. If there is
no problem in charger, connect to the batteries.

Finally, turn on the switch on panel again and follow the procedure listed in part Ⅲ

(Alignment) to rectify the charger voltage and temperature, and measure voltage on DC
bus, output voltage.

CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components

VI. APPENDIX I : SCHEMATICS

24
 O/P
INLET Breaker

O/P-L
L I/P(L) O/P
I/P I/P FILTER
N O/P-N
FILTER Breaker
G I/P(N)

PSDR FAN1
P7
FAN2
BEST625 / PW9120

FAN
FUSE P5
CN1-
3 FAN

25
RS232
BAT.(-) BAT.(+) CN1-3

CN4 CNTL CN9

CN7

Figure 1 : System schematic diagram

BATTERY LCD
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

CABINET PANEL
OUTLET
INTERFACE
SLOT
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

Figure 2 : Sub-assembly location

26
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

O/P
N.F.
RY
DC/AC

BATTERY CABINET
DC/DC
AC/DC
PFC

CHARGER
RY
N.F.
I/P

Figure 3 : block diagram

27
 BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Bypass

I/P
Relay FUSE +BUS
CN--L CT &
I/P
EMI Rectifier
Filte PFC Choke
r for current
CN--N feedback + BUS
Capacitor

To 3854
-BUS
Capacitor

- + -BUS
PFC IC
3854

BUS
FEEDBACK
To CPU CIRCUIT

CPU

PWM
CONTROLLER

OP

VREF
=2.5V
BAT +

BAT- DC BUS(+)

PWM
SIGNAL
FROM
CONTROL
BOARD

PWM
CONTR CHOKE
OLLER
o/p
PWM
SIGNAL
FROM
CONTROL
BOARD

DC BUS(-)

28
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

Figure 4 : PSDR functional diagram

CPU
CN +
TO BATTERY

VREF
=2.5V
D12

OP
C13
D06

U02

TX2
Q02
CONTROLLER
PW
M
Cap.
REC1

CN--L

CN--N
INPUT

Figure 5 : Charger circuit

29
 EEL16
BAT(+)

+12V

Power for Inverter

D08 C38
BAT(-) IGBT +
0V

C39 5.1v

Q0 -5V

3
PW +12V

M
BEST625 / PW9120

CONTROLLER Power for Inverter

C40
D09
IGBT -
0V

30
System C41 5.1v
TX3
GND R82
-5V

Figure 6 : DC power supply circuit

700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

D10
12V

C42
 DC BUS(+)

PW
M Q05,Q06
C320etc. SIGNAL
FROM
CONTROL
BOARD
BEST625 / PW9120

L2,3,4
OUTPU
T

31
PW
M
C321etc. SIGNAL Q07,Q0
C25
FROM 8

Figure 7 : Inverter circuit

CONTROL
BOARD
OUTPU
T
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

DC BUS(-)
 I/P
Relay
RLY01 +BUS
CN16L CT &
EMI Rectifier
Filte PFC Choke
r FUSE L9,L10 for current D38
CN16N C71,
feedback
C15,
C16

To 3854
C73,
C17,
C18

- + D39 -BUS
REC2
PFC IC
3854
BEST625 / PW9120

Q15

32
BUS
FEEDBACK
To CPU CIRCUIT
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

Figure 8 : Input power factor correction circuit

 +BUS
D21

D22 C71,C15,C1
6

Q11,Q12,Q24 D23

TX1,TX4 D24
PW
M
CONTROLLER
BATTERY

System
GND

C73,C17,C1
8
BEST625 / PW9120

Q13,Q14,Q2
5

33
Figure 9 : DC -DC circuit
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

I.APPENDIX II : COMMUNICATION
i.1. RS232

The RS232 provides proprietary command sequence for the computer to

monitor the line and UPS status and to control the UPS. The data format is
listed as following:
PIN TYPE ...................: female
BAUD RATE .............. : 9600 bps
DATA LENGTH ......... : 8 bits
STOP BIT ................... : 1 bit
PARITY ...................... : NONE
The pin assignment and description are listed in the following table and the interface
configuration is indicated in figure VI-1. Note that, the computer will control information
exchange by a Binary command. UPS will respond with Binary information followed by a
checksum or action. UPS data will be provided at 9600 baud rate and consist of 8 data bits, 1
stop bit, and no parity bit. All the information is provided in Binary format.

PIN # Description I/O type

1 Low battery output Output
2 RS232 RxD output Output
3 RS232 TxD/Inverter Off input Input
4 DTR Input
5 common ------
6 (tied to pin 4) Output
7 No connection Input
8 AC fail output Output
9 12Vdc Output

Figure VI-1 : RS232 connection

34
BEST625 / PW9120
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL

ii.AS 400 (option)

a. AS 400 provides dry contact closure signal open or close.

b. AS 400 provides the remote shutdown function,while the shorter connector on the CN2
is removed, the UPS will be forced to get into bypass mode.
c. The pin assignment and description are listed as following.
PIN # Description I/O type
1 UPS fail, relay contact, normally open active close. output
2 Summary alarm, relay contact, normally open, active close. output
One of the following conditions activate this signal
. UPS fail
. Bypass active
. Battery low
. Utility fail
. Inveter out of order
3 GND for secondary
4 Remote shutdown input
5 Common
6 Bypass active, normally open, active close output
7 Battery low, normally open, active close output
8 Battery mode shutdown input
9 Utility fail, normally open, active close output

Other AS400 card definition:

PIN # Description I/O type
1--3 Utility fail, normally open, active close output
4--6 Battery low, normally open, active close output
7--9 Summary alarm, relay contact, normally open, active close. output
One of the following conditions activate this signal
. UPS fail
. Bypass active
. Battery low
. Utility fail
. Inveter out of order
10--12 Bypass active, normally open, active close output
13
14 GND for secondary output
15 Remote shutdown input

35