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UNINTERRUPIBLE POWER SYSTEMS SERVICE MANUAL PCM Vanguard 8~20KVA V1.0 P/N : XXX-XXXX-XXX 2006/05/20 PCM Vanguard 8K-20KVA 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. 1 PCM Vanguard I. 8K-20KVA SERVICE MANUAL 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. 2 PCM Vanguard 8K-20KVA SERVICE MANUAL 二 .8K~20K VA 1. PRINCIPLE OF OPERATION 8K~20K VA without iso-transformer Wiring diagram in figure 4 , This 8K~20kVA high input power factor UPS system contains some PCB assemblies. They are including : >1.Panel : contains LCD display , UPS configuration and meter FORM A : 114 – V6K0 – 8xx FORM B : 114 – V6K0 – Bxx FORM A FORM B >2.Control Board : contains major parts of protection, signaling circuits, regulation and control circuits of inverter Part Number : 111 – V10K - 810 Parts Number : 111 – V12K – 8xx 3 PCM Vanguard 8K-20KVA SERVICE MANUAL >3.Main Board : 112 – V10K/12K/20K – xxx contains major parts of (1) dc power supply (2)output (3) unit power factor correction circuits >4.Snubber Board : 117 – V10K – Sxx contains i/p scr , bat scr , pfc igbt ,inverter igbt snubber circuits 4 PCM Vanguard 8K-20KVA SERVICE MANUAL >4.Snubber Board : 117 – V15K/20K – S10 contains i/p scr , bat scr , pfc igbt ,inverter igbt snubber circuits >4.Snubber Board : 117 – V20K – S11/SA1 contains i/p scr , bat scr , pfc igbt ,inverter igbt snubber circuits 5 PCM Vanguard 8K-20KVA SERVICE MANUAL >5.Rellay Board : 112 – V12S – 010 &112-V12R-010 contains (1) inverter current sensor (2) o/p current sensor (3) invert transfer to bypass or bypass transfer to inverter circuits 6 PCM Vanguard 8K-20KVA SERVICE MANUAL >5.Rellay Board : 112 – V20S – 010 &112-V20R-010 contains (1) inverter current sensor (2) o/p current sensor (3) invert transfer to bypass or bypass transfer to inverter circuits 7 PCM Vanguard 8K-20KVA SERVICE MANUAL >6.Input Emi Board : 113 – V10I – 612 single phase emi filter >6.Input Emi Board : 113 – V20K – 810 single phase emi filter 8 PCM Vanguard 8K-20KVA SERVICE MANUAL >7.Output Emi Board : 113 – V10S – 611 single fase emi filter >7.Output Emi Board : 113 – V20K – 811 single fase emi filter 9 PCM Vanguard 8K-20KVA SERVICE MANUAL >8 . Pfc transformer Board : 110 – V10K – CK2 >9.Inverter Transformer Board : 110 – V10K – CK0 >8 . Pfc transformer Board : 110 – V20K – CK2 10 PCM Vanguard 8K-20KVA SERVICE MANUAL >8 . Pfc transformer Board : 110 – V20K – CK3 11 PCM Vanguard 8K-20KVA SERVICE MANUAL >9.Inv transformer Board : 110 – V8K0 – CK0 & 110-V10K-CK0 12 PCM Vanguard 8K-20KVA SERVICE MANUAL >9.Inv transformer Board : 110 – V20K – CK0 & 110-V20K-CK1 13 PCM Vanguard 8K-20KVA SERVICE MANUAL >10.Charger Board : 115 – V6K0 – 812 AC 220Vac i/p , contains charger . ABM . battery test circuits >10.Charger Board : 115 – UCHG – 612 AC 220Vac i/p , contains charger . 14 PCM Vanguard 8K-20KVA SERVICE MANUAL 2. POWER STAGE ( PSDR ) 1 2 3 4 5 6 D D C14 C13 0. 01U/X2 0. 01U/X2 REC+ L INE T2 L1 T1 CT3 LBUS+ 3 1 2 4 CT COIL CN10-1 CN10-2 F1 F USE IBUS+ D8 1 2 1 R13 RURG 5060 W IRE PBUS+ 1 LI N E_ S CR1 D4 I RK T5 6 /1 2 C17 10U/275V F2 F USE R5 10/5W R3 56/5W 10/10W D3 R12 1 2 W IRE C D1 R2 56/5W R14 R15 C10 60K /5W 60K /5W 0. 022U/1K V R6 10/5W R1 56/5W Q 1/IG BT2 C? 4700UF 10/10W R6 10/5W RH R30120 C6 3A334M CN13-3 CM 200DY-12H D5 RH R30120 CN10-4 C1 3C473M NI C7 C3 CM 200DY-12H 3A334M R17 W IRE 1 RURG 5060 3 2 1 4 10/10W R19 R20 60K /5W 60K /5W C11 R9 10/5W REC- T4 T3 IBUS- 1 1 B W IRE RURG 5060 F3 F USE CN11-4 CT4 0. 01U/X2 A 3 1 CN11-1 C4 R10 10/5W F4 F USE 1 2 LBUS- R21 33/2W Q 2/IG BT2 CM 200DY-24H 2 D65 2 4 D? DIO DE 0. 022U/1K V PBUS- L2 CA R8 10/5W R16 10/10W COIL C5 D6 RH R30120 C? 4700UF D2 RH R30120 LI N E_ S CR2 IRKT56/12 R18 10/10W CT2 CT B W IRE 3A224M 1 D4 2 1 O /P L COIL C2 C16 10U/275V P F C_L- L3 1 2 3A224M Q 2/IG BT1 D? DIO DE CM 200DY-24H RURG 5060 Q 1/IG BT1 BAT + NI R4 56/5W R11 CT 1 10/10W RH R30120 CT1 1 1 4 P F C_L+ Q? SCR R29 22/2W 2 2 C15 0. 01U/X2 3 2 C12 0. 01U/X2 2 C 1 R28 33/2W CT 0. 01U/X2 >1.DC POWER SUPPLY SUB-SYSTEM : A Title THE DC POWER SUPPLY SUB-SYSTEM provide +27/+12/+5 VDC , Size Number Revis ion C Date: File: 1 2 3 4 5 9-Nov-2004 Sheet of D:\RD6\VGD10K\¾ã¾÷\V10K SNUBBER.DDB Drawn By: 6 The circuits place in main board (112 – V10K/12K/20K – xxx ),show in figure 1 >2.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 2. To construct a high frequency (19.2kHz) PWM inverter, the drivers circuit (place in 112-V10K/12K/20K-xxx)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 IGBT MODULE is filtered by an L , C circuit to reduce the o/p voltage harmonics distortion. 15 PCM Vanguard 8K-20KVA SERVICE MANUAL >3. OUTPUT SUB-SYSTEM : The bypass relay(112-V12S/V20S-010&112-V12R/V20R-010) 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. >4. UNIT POWER FACTOR CORRECTION SUB-SYSTEM : The purpose of power factor correction (P.F.C.) circuit(place in main board 112-V10K/12K/20K-xxx) is to make the input current and voltage in phase and therefore achieve a high input power factor. The schematic is indicated in figure 3. 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 +/-365Vdc. PS : (1) PFC igbt module (2) PFC CHOKE BOARD(3) LINE RECTIFIER SCR module 3. MAIN CONTROL PCB ASSEMBLIES 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. 16 PCM Vanguard 8K-20KVA SERVICE MANUAL 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. 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 mode 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 . 17 PCM Vanguard 8K-20KVA SERVICE MANUAL 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 battery mode 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". 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 signal is activated and the buzzer two beeps every five seconds. 18 PCM Vanguard 8K-20KVA SERVICE MANUAL 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. 19 PCM Vanguard 8K-20KVA SERVICE MANUAL 4. FRONT PANEL : The front panel consists 3 parts: switch button, LED and LCD display. i. switch button There are five switch buttons:(1)“ON/OFF” button, it can turn on and off UPS, (2)”FUNC” button, it can configure fifteen functions of UPS, (3)”ENTER” button, it can enter、enable or confirm the function that you want, (4) ”ESCAPE” button, it can return to main display, (5) ”STATUS” button, it can display fourteen contents of UPS. For example, it can display the input voltage, frequency, output voltage, frequency, load,….etc. ii. LED display The five LEDs indicate “UPS ON”, “LINE MODE”, “BATTERY MODE”, “BYPASS MODE” and “FAULT”. iii. LCD display The LCD display UPS any conditions. 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. 20 PCM Vanguard 8K-20KVA SERVICE MANUAL 5.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, it is 13.8V/pcs at 25 degree C. 21 PCM Vanguard 8K-20KVA SERVICE MANUAL 6.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. 8K~20KVA >1. OVERVIEW : Circuit Block Circuit Breaker P.F. Correction Inverter Charger DC Power Supply Components to be checked IELHK11-1IGBT MODULE IGBT MODULE Q102,Q103 Q5 >2.P.F. CORRECTION: Step Checked components Fail condition open C-E short or open C-E short or open D-S short or open D-S short or open *Instrument Reference Failed condition function Value 0.31 short or open DIODE 1 D8,D9 2 D3,D4 DIODE 0.31 short or open 3 R50,R59 Ω 22 4 D2,D7 Ω 30 5 R45,R48,R54,R57 Ω 10 6 CBUS+,CBUS- Ω open short open or value change open or value change open or value change deformed visual The instrument is D.M. ( digital multimeter ) 22 PCM Vanguard 8K-20KVA SERVICE MANUAL >3.DC/AC INVERTER: Step Checked components 1 D5,D6 2 R64,67,69,78,81,83 Ω 10 3 D1 Ω 55 4 F1,F2,F3,F4 Ω 0 >4.DC POWER SUPPLY : Step Checked components *Instrument Reference Failed condition function Value 0.34 short or open DIODE 1 Q5 (D,S) *Instrument function DIODE 2 3 R36 R38 Ω Ω 4 U3 (3845) PIN 5-6 5-7 5-8 6-8 >5.AC/DC CHARGER : Step Checked components Reference Value 0.48 Failed condition 47 0.75Ω/2W open open short or open too low Ω 1 Q102,Q103 *Instrument function DIODE 2 3 R132,R150 R123,R124,R125 Ω Ω 4 U401 (3843) PIN 5-6 5-7 5-8 6-8 BR101(+,~,~,-) C101 5 6 open or value change open or value change open or value change 47.6K 38.1K 4.05K 51.7K Reference Value 0.49 Failed condition 10 0.167Ω/2W open open short or open too low Ω DIODE Ω visual 23 23.46K 39.39K 6.26K 29.73K 0.49 open short or open short deformed PCM Vanguard 8K-20KVA SERVICE MANUAL 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 charger 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 3 (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 24 PCM Vanguard 8K-20KVA SERVICE MANUAL 7. COMMUNICATION i. RS232 The RS232 provides proprietary command sequence for the computer to monitor the line and UPS stat us 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 the following figure I. 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 Table I : RS232 connection Figure I : RS232 connection 25 PCM Vanguard ii. 8K-20KVA SERVICE MANUAL AS400 (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 . UPS fail . Bypass active . Battery low . Utility fail . Inveter out of order 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 output output input output Other AS400 card definition: PIN # Description 1--3 Utility fail, normally open, active close 4--6 Battery low, normally open, active close 7--9 Summary alarm, relay contact, normally open, active close. 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 I/O type output output output output 13 14 15 GND for secondary Remote shutdown output input 26 PCM Vanguard 8K-20KVA SERVICE MANUAL GND 5V GND 0 0 7805 CHGR CHGR 1 a1 7812 b1 2 1 a1 GND b1 2 12V 24V 8.SCHEMATICS Figure 1:DC power supply circuit for 8-20K 27 PCM Vanguard O/P L O/P N 8K-20KVA SERVICE MANUAL L.C L.C C.L Figure 2:Inverter circuit 28 GND BUS BUS INV INV C.L PCM Vanguard I/P L I/P N PFC PFC BUS BUS GND 8K-20KVA SERVICE MANUAL Figure 3:Unit power factor correction circuit 29 PCM Vanguard 8K-20KVA SERVICE MANUAL Figuer 4 30