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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.
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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.
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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
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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
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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
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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
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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
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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
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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
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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
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8K-20KVA SERVICE MANUAL
>8 . Pfc transformer Board : 110 – V20K – CK3
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8K-20KVA SERVICE MANUAL
>9.Inv transformer Board : 110 – V8K0 – CK0 & 110-V10K-CK0
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8K-20KVA SERVICE MANUAL
>9.Inv transformer Board : 110 – V20K – CK0 & 110-V20K-CK1
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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 .
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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.
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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.
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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
.
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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.
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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.
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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.
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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.
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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 )
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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
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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
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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
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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
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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
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8K-20KVA SERVICE MANUAL
Figuer 4
30