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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 1 3 4 4 5 5 5 5 6 6 6 7 7 8 9 10 11 12---23 24 33 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. 2 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. 3 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: 4 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. 5 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. 6 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. 7 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. 8 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. 9 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. 10 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. 11 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