Download Service manual (VGD 700-3K)

UNINTERRUPIBLE POWER SYSTEMS
SERVICE MANUAL
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA
P/N : XXX-XXXX-XXX
2005/7/1
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
I. INTRODUCTION
II. PRINCIPLE OF OPERATION
1. INTRODUCTION
III. POWER STAGE (PSDR)
i. CHARGER SUB-SYSTEM:
ii. DC POWER SUPPLY SUB-SYSTEM:
iii. INVERTER SUB-SYSTEM :
iv. OUTPUT SUB-SYSTEM :
v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM :
vi. DC-DC CONVERTER SUB-SYSTEM :
1. MAIN CONTROL PCB ASSEMBLIES (CNTL)
i. REGULATION & CONTROL SUB-SYSTEM :
ii. PROTECTION SUB-SYSTEM :
iii. SIGNALING SUB-SYSTEM :
2. FRONT PANEL :
IV. ALIGNMENTS
V. TROUBLE SHOOTING
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
VII. APPENDIX II : COMMUNICATION
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4
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5
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6
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9
10
11
12---23
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PCM Vanguard
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.
7. For the air flow smoothly, please cover the cover to test after you repaired.
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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PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
I.INTRODUCTION
For all series of Vanguard 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.
This UPS 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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PCM Vanguard
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 Vanguard 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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PCM Vanguard
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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PCM Vanguard
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.
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 pushpull 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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PCM Vanguard
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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PCM Vanguard
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 DCDC 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.
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PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
" The failure signal is latched unless the UPS is turned off or the battery is empty".
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 halfbridge 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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PCM Vanguard
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 five LEDs indicate “UPS ON”, “LINE MODE”, “BATTERY
MODE”, “BYPASS MODE” and “FAULT”. 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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PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
IV. ALIGNMENTS
The Vanguard 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). Measure the temperature, charge voltage, and output voltage.
(4). Import the measured temperature, charger voltage, and output voltage.
The CPU will auto-regulate the charger voltage, temperature, and output voltage.
Note: the charger voltage will be changed according to the temperature at the Vanguard
series, at the 25 degree C, it is 13.8V/pcs.
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PCM Vanguard
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
FUSE
P.F. Correction
Push-Pull Booster
Inverter
Charger
DC Power Supply
Components to be
checked
F502,F201
U101,D105,D108,Q101
Q202,Q203,Q206,Q207
D201,D202,D203,D204
Q302,Q304
Q505
Q401
Fail condition
open
short or open
D-S short or open
short or open
D-S short or open
D-S short or open
D-S short or open
2. P.F. CORRECTION:
Step
Checked components
1
F502
*Instrument
function
Ω
2
Q101(D,S)
DIODE
0.4
short or open
3
D105,D108
DIODE
0.4
short or open
4
R116
Ω
47
R115
Ω
2.2
REC101(+,～),(～,-)
DIODE
0.4
open or value
change
open or value
change
short or open
5
12
Reference Failed condition
Value
short
open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
6
Ω
C105,C122
visual
open
short
deformed
3. PUSH-PULL DC-DC CONVERTER:
Step
Checked components
*Instrument Reference Failed condition
function
Value
short
open
Ω
1
F201
2
Q202,Q203,Q206,Q207 (D,S)
DIODE
0.4
short or open
3
R201,R202,R222,R213
Ω
10
open
4
D201,D202,D203,D204
DIODE
0.4
short or open
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
Step
Checked components
1.
Q302,Q304 (D,S)
2.
R304,R312
*Instrument Reference Failed condition
function
Value
DIODE
0.4
short or open
Ω
47Ω
open
5.DC POWER SUPPLY :
Step
Checked components
1
2
3
4
Reference
Value
0.5
Failed condition
Q401 (D,S)
*Instrument
function
DIODE
R404
R407
Ω
Ω
47
0.15Ω
/2W
49.9K
39K
4.2K
54.1K
open
open
U401 (3845) PIN
5-6
5-7
5-8
6-8
Ω
short or open
too low
6.AC/DC CHARGER :
Step
Checked components
Reference
Value
0.5
Failed condition
Q505
*Instrument
function
DIODE
1
2
R523
Ω
47
open
13
short or open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
3
4
5
6
R527 (LV)
R527(HV)
U503 (3843) PIN 5-6
5-7
5-8
6-8
D509,D510,D508,D514
C527
Ω
Ω
DIODE
Ω
0.5Ω/2W
1.2Ω/2W
49.9K
30.4K
4.1K
54K
0.5
open
visual
open
too low
short or open
short
deformed
1KVA
1. OVERVIEW :
Circuit Block
FUSE
P.F. Correction
Push-Pull Booster
Inverter
Charger
DC Power Supply
Components to be
checked
F101,FC2,FC3
D27,D28,REC501,Q11
Q07,Q08,Q09,Q04,Q05,Q
06
D21,D22,D23,D24
Q02,Q03
Q18
D19, D20,D29
Q10
Fail condition
open
short or open
D-S short or open
short or open
D-S short or open
D-S short or open
short or open
D-S short or open
2. P.F. CORRECTION:
Step
Checked components
1
F101
*Instrument
function
Ω
2
Q11 (D,S)
DIODE
0.4
short or open
3
D27,D28
DIODE
0.4
short or open
4
5
R52
Ω
100
REC501(+,～),(～,-)
DIODE
0.4
open or value
change
short or open
C32,C33
Ω
open
short
deformed
short
open
6
visual
1
Ω
F101
14
Reference Failed condition
Value
short
open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
3. PUSH-PULL DC-DC CONVERTER:
Step
Checked components
1
FC2,FC3
2
Q04,Q05,Q06,Q07,Q08,Q09
*Instrument Reference Failed condition
function
Value
short
open
Ω
DIODE
0.4
short or open
D21,D22,D23,D24
DIODE
0.4
short or open
R25,R27,R29,R31,R34,R38
Ω
10
open
(D,S)
3
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
Step
Checked components
1
Q02,Q03 (D,S)
2
R05,R18
*Instrument Reference Failed condition
function
Value
DIODE
0.4
short or open
Ω
47Ω
open
5.DC POWER SUPPLY :
Step
Checked components
Reference
Value
0.5
Failed condition
Q10 (D,S)
*Instrument
function
DIODE
1
2
R116
R36
Ω
Ω
open
open
3
U3 (3845) PIN 5-6
(Driver PCB)
5-7
5-8
6-8
47
0.5Ω
/2W(LV)
0.33Ω
/2W(HV)
>1M
>1M
3.5K
>1M
Ω
15
short or open
too low
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
6.AC/DC CHARGER :
Step
Checked components
1
Q18(D,S)
2
3
R90
R103(LV)
R103(HV)
4
U9 (3845) 5-6
(Driver PCB) 5-7
5-8
6-8
D19,D20,D29
C23
5
6
*Instrument
function
DIODE
Reference
Value
0.5
Failed condition
Ω
Ω
47
0.39Ω
/3W
1Ω/2W
45K
>1M
3.5K
53.5K
0.5
open
open
open
Ω
DIODE
Ω
visual
short or open
too low
short or open
short
deformed
1.5KVA
1. OVERVIEW :
Circuit Block
FUSE
P.F. Correction
Push-Pull Booster
Inverter
Charger
DC Power Supply
Components to be
checked
F101,FC2,FC3
D27,D28,REC501,Q11
Q07,Q08,Q09,Q04,Q05,Q
06
D21,D22,D23,D24
Q02,Q03
Q18
D19, D20,D29
Q10
Fail condition
open
short or open
D-S short or open
short or open
D-S short or open
D-S short or open
short or open
D-S short or open
2. P.F. CORRECTION:
Step
Checked components
1
F101
*Instrument
function
Ω
2
Q11 (D,S)
DIODE
0.9
short or open
3
D27,D28
DIODE
0.4
short or open
16
Reference Failed condition
Value
short
open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
4
R52
Ω
100
5
REC501(+,～),(～,-)
DIODE
0.4
6
C31,C32,C33,C34
Ω
open
short
visual
open or value
change
short or open
deformed
3. PUSH-PULL DC-DC CONVERTER:
Step
Checked components
1
FC2,FC3
2
Q04,Q05,Q06,Q07,Q08,Q09
*Instrument Reference Failed condition
function
Value
short
open
Ω
DIODE
0.4
short or open
D21,D22,D23,D24
DIODE
0.4
short or open
R25,R27,R29,R31,R34,R38
Ω
10
open
(D,S)
3
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
Step
Checked components
*Instrument Reference Failed condition
function
Value
DIODE
0.4
short or open
1
Q02,Q03 (D,S)
2
R05,R18
Ω
47Ω
open
R04,R17
Ω
10Ω
open
Reference
Value
0.5
Failed condition
47
0.5Ω
/2W(LV)
0.33Ω
/2W(HV)
open
open
5.DC POWER SUPPLY :
Step
Checked components
1
Q10 (D,S)
*Instrument
function
DIODE
2
R115
R36
Ω
Ω
17
short or open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
3
U3 (3845) PIN 5-6
(Driver PCB)
5-7
5-8
6-8
too low
Ω
>1M
>1M
3.5K
>1M
*Instrument
function
DIODE
Reference
Value
0.5
Failed condition
Ω
Ω
47
0.39Ω
/3W
0.5Ω/2W
45K
>1M
3.5K
53.5K
open
open
6.AC/DC CHARGER :
Step
Checked components
1
Q16(D,S)
2
3
R94
R97(LV)
R97(HV)
4
U9 (3845) 5-6
(Driver PCB) 5-7
5-8
6-8
Ω
D19,D20,D29
C23
DIODE
Ω
5
6
0.5
open
visual
short or open
too low
short or open
short
deformed
2KVA
1. OVERVIEW :
Circuit Block
FUSE
U.P.F. Correction
Push-Pull Booster
Inverter
Charger
DC Power Supply
Components to be
checked
F101,F401,F402
REC501,Q501,D504,D50
5
Q401,Q402,Q403,Q405,Q
406,Q407
D401,D402,D403,D404
Q301,Q302
Q102
D102,D103,D104,D105
D-S short or open
Q202
D-S short or open
2. P.F. CORRECTION:
18
Fail condition
open
short or open
short or open
D-S short or open
D-S short or open
short or open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Step
Checked components
1
F101
*Instrument
function
Ω
2
Q501(D,S)
DIODE
0.9
short or open
3
D504,D505
DIODE
0.4
short or open
4
R512(LV)
Ω
100
20
open or value
change
R512(HV)
Reference Failed condition
Value
short
open
5
REC501(+,～),(～,-)
DIODE
0.4
short or open
6
C307,C308,C501,C501A,C
Ω
deformed
502, C502A(LV)
visual
open
short
C307,C308,C501,C502(HV
)
3. PUSH-PULL DC-DC CONVERTER:
Step
Checked components
1
F401,F402
2
Q401,Q402,Q403,Q405,Q406,Q4
*Instrument Reference Failed condition
function
Value
short
Open
Ω
DIODE
0.4
short or open
Ω
10
open
DIODE
0.4
short or open
07
3
R406,R408,R410,R415,R417,R4
20
4
D401,D402,D403,D404
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
Step
Checked components
1
Q301,Q302(D,S)
2
R301,R309
*Instrument Reference Failed condition
function
Value
DIODE
0.4
short or open
Ω
R302,R308
19
22Ω
47Ω
open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
5.DC POWER SUPPLY :
Step
Checked components
Reference
Value
0.5
Failed condition
Q202(D,S)
*Instrument
function
DIODE
1
2
3
R206
R208
Ω
Ω
47
0.5Ω/2W
open
open
4
U09 (3845) PIN 5-6
5-7
5-8
6-8
too low
Ω
47K
33K
4.2K
51K
Reference
Value
0.4
Failed condition
short or open
6.AC/DC CHARGER :
Step
Checked components
1
Q102
*Instrument
function
DIODE
2
R122
Ω
47
open
3
R125(LV)
R125(HV)
Ω
open
4
5
U101 (3843) PIN 5-6
5-7
5-8
6-8
REC101
DIODE
0.82Ω
/2W
0.75Ω
/2W
47K
30K
4K
51K
0.5
6
C102
Ω
open
Ω
visual
short or open
too low
short or open
short
deformed
3KVA
1. OVERVIEW :
Circuit Block
FUSE
Components to be
checked
F1,F2,F3
20
Fail condition
open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
U.P.F. Correction
Push-Pull Booster
Inverter
Charger
REC501,Q501,Q502(LV
only),D506,D507
Q401,Q402,Q403,Q404,Q
405,Q406
D403,D404,D405,D406
Q301,Q302,Q303,Q304
Q103
D101,D102,D103,D108
DC Power Supply
short or open
D-S short or open
short or open
D-S short or open
D-S short or open
short or open
Q202
D-S short or open
2. P.F. CORRECTION:
Step
Checked components
1
F3
*Instrument
function
Ω
Reference Failed condition
Value
short
open
2
Q501,Q502 (D,S)(LV)
DIODE
0.9
short or open
Q501(D,S)(HV)
3
D506,D507
DIODE
0.4
short or open
4
R508,R516(LV)
Ω
47
open or value
change
20
0.4
R508(HV)
5
REC501(+,～),(～,-)
DIODE
6
C307,C308,C309,C310C50
Ω
1,C502,C510,C511(LV)
visual
open
short
short or open
deformed
C307,C308,C309,C310C50
1,C502(HV)
3. PUSH-PULL DC-DC CONVERTER:
Step
Checked components
1
F1,F2
2
Q401,Q402,Q403,Q404,Q405,Q4
*Instrument Reference Failed condition
function
Value
short
Open
Ω
DIODE
0.4
short or open
Ω
10
open
06 (D,S)
3
R418,R420,R422,R425,R428,R4
30
21
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
4
D403,D404,D405,D406
DIODE
0.360
short or open
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
Step
Checked components
1
Q301,Q302,Q303,Q304(D,S)
2
R302.R307,R311,R315
*Instrument Reference Failed condition
function
Value
DIODE
0.4
short or open
Ω
20Ω
open
5.DC POWER SUPPLY :
Step
Checked components
1
2
3
4
Reference
Value
0.4
Failed condition
Q202(D,S)
*Instrument
function
DIODE
R206
R205
Ω
Ω
47
0.5Ω/2W
open
open
too low
Ω
47K
33K
4.2K
51K
Reference
Value
0.468
Failed condition
U3 (3845) PIN
(Driver PCB)
5-6
5-7
5-8
6-8
short or open
6.AC/DC CHARGER :
Step
Checked components
1
Q103
*Instrument
function
DIODE
2
R123
Ω
47
open
3
R120
Ω
open
4
U9 (3845) 5-6
(Driver PCB) 5-7
5-8
6-8
REC101
0.39Ω
/2W(LV)
0.43Ω
/2W(HV)
47K
30K
4K
51K
0.5
5
Ω
DIODE
22
short or open
too low
short or open
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
6
Ω
C101
visual
open
short
deformed
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).
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
23
G
N
L
Figure 1 : System schematic diagram
24
BAT.(+)
FUSE
I/P
FILTER
BATTERY
CABINET
BAT.(-)
INLET
LCD
PANEL
I/P
Breaker
CN201
P407,408
P403,405
I/P(N)
I/P(L)
CNTL
CN1-3
CN13
PSDR
CN407
CN9
FAN2
FAN1
O/P-N
O/P-L
INTERFACE
SLOT
RS232
FAN
FAN
O/P
FILTER
OUTLET
O/P
Breaker
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
VI. APPENDIX I : SCHEMATICS
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Figure 2 : Sub-assembly location
25
PCM Vanguard
I/P
N.F.
RY
CHARGER
PFC
AC/DC
Figure 3 : block diagram
26
BATTERY CABINET
DC/DC
DC/AC
RY
N.F.
O/P
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Bypass
I/P Relay
I/P
CN--L
+BU
S
FUSE
EMI
Filter
CT &
Rectifier
for current
feedback
PFC Choke
+ BUS
Capacitor
To 3818
CN--N
-
-BUS
Capacitor
BUS
+
PFC IC
3818
To CPU
BU
S
FEEDBACK
CIRCUIT
CPU
PWM
CONTROLLER
OP
VREF
=2.5V
BAT +
BAT-
DC BUS(+)
PWM
SIGNAL
FROM
CONTROL
BOARD
PWM
CHOKE
CONTR
OLLER
o/p
PWM
SIGNAL
FROM
CONTROL
BOARD
DC BUS(-)
27
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Figure 4 : PSDR functional diagram
Q103
D102
C101
OP
D104
VREF
=2.5V
CN +
TO BATTERY
CPU
CN--N
INPUT
CN--L
REC1
Cap.
PW
M
CONTROLLER
TX101
Figure 5 : Charger circuit
28
BAT(-)
BAT(+)
System
GND
PW
M
CONTROLLER
R205
Q202
TX201
D206
C206
D204
D205
12V
C203
C202
C205
C204
5.1v
5.1v
-5V
0V
Power for Inverter
IGBT -
+12V
-5V
0V
Power for Inverter
IGBT +
+12V
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Figure 6 : DC power supply circuit
29
Figure 7 : Inverter circuit
30
DC BUS(-)
C308
C301
DC BUS(+)
PW
M
SIGNAL
FROM
CONTROL
BOARD
PW
M
SIGNAL
FROM
CONTROL
BOARD
Q303,Q304
Q301,Q302
L301,302,303
C312
OUTPU
T
OUTPU
T
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
PFC IC
3818
P101
N
EMI
Filter
I/P Relay
RLY101
FUSE
REC501
PFC Choke
L501,L502
+
CT &
Rectifier
for current
feedback
To 3818
P102
L
To CPU
Q501
BUS
FEEDBACK
CIRCUIT
D507
C307,C308,
C502
C309,C310
,C501
D506
BUS
+BU
S
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Figure 8 : Input power factor correction circuit
31
PW
CONTROLLE
M
R
Q404,Q405,Q406
Q401,Q402,Q403
BATTERY
TX401
D403
D404
D405
D406
C307,C308
,C502
C309,C310,
C501
+BUS
System
GND
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
Figure 9 : DC -DC circuit
32
PCM Vanguard
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 .............. : 2400 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 ASCII command. UPS will respond with ASCII information or action. UPS
data will be provided at 2400 baud rate and consist of 8 data bits, 1 stop bit, and no parity bit.
All the information is provided in Binary format.
PIN #
1
Description
No connection
I/O type
------
2
RS232 TxD output
Output
3
RS232 RxD/Inverter Off input
Input
4
No connection
------
5
common
------
6
Line Fail
Output
7
No connection
------
8
Battery Low
Output
9
12Vdc
Output
Figure VI-1 : RS232 connection
33
PCM Vanguard
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
1
UPS fail, relay contact, normally open active close.
2
Summary alarm, relay contact, normally open, active close.
One of the following conditions activate this signal
Output fault.
Bus fault.
Over temperature.
Overload.
Over Charging.
Battery test fail.
Charger failure.
3
GND for secondary
4
Remote shutdown
5
Common
6
7
8
9
Bypass active, normally open, active close
Battery low, normally open, active close
Battery mode shutdown
Utility fail, normally open, active close
I/O type
output
output
input
34
output
output
input
output