Centralion 400VA, Service Manual

Page 1: ...E POWER SYSTEM SERVICE MANUAL Blazer series 400VA 600VA and 800VA Model 400VA 400VA 115V 400VA 230V 600VA 600VA 115V 600VA 230V 800VA 800VA 115V 800VA 230V 115V 220V 230V 240V 50Hz 60Hz Prepared by Fulin April 9 2002 ...

Page 2: ... C Control Power Circuit D Battery Charger E Line And Zero Crossing Detection F Inverter Operation G Active Clamp H Microcontroller CPU Control Circuit I Displays Audio alarm and control button J Load Detection Circuit K Interface Circuit L Troubleshooting 3 ...

Page 3: ...S 5 CPU Circuit Figure S 6 Relay Circuit Figure S 7 Panel Circuit Figure S 8 Load Detecting Circuit Figure S 9 RS232 Circuit Waveform flowchart Figure W 1 Cold Start Figure W 2 Zero Crossing Figure W 3 Inverter Circuit 1 Figure W 4 Inverter Circuit 2 Figure W 5 Clamp Circuit Figure W 6 Relay speed up capacitor Figure W 7 Battery mode examination flowchart Figure W 8 Line mode examination flowchart...

Page 4: ...uce the UPS output voltage to 0 85 times its input voltage 3 50 60Hz Automatic Frequency Selection The output frequency will automatically match the input frequency 50 or 60Hz 4 Communication Port RS232 open collector Computer interface with RS232 communication and remote shutdown capacities 5 Data line telephone line protect The unit provides RJ11 receptacles to provide transient voltage surge su...

Page 5: ...r has three functions 1 Inverter Transformer Provides inverter voltage to UPS output It performs a push pull transformer when UPS at battery mode 2 Booster Buck Thus the output voltage at booster mode is given by Boost Relay ON VOUT V IN 1 18 The Buck relay is ON when the line voltage is over voltage It can reduce output voltage by VOUT 0 85 V IN 3 Charger The Main transformer has a charger coil T...

Page 6: ...4 2V g Inverter circuit The inverter circuit is based on a push pull circuitry to drive inverter transformer coil h Panel PCB The UPS display device contains one led and one switche l Batteries Acts as a power supply source while the UPS is at battery mode Different types of batteries are used for different models of UPS 600VA 12V7Ah 1 pc 400VA 6V4Ah 2pc 800VA 1245W 1pc 4 ...

Page 7: ...ly passes through U03 78L05 generating a 5 volt DC logic power supply And CPU send HI signal shutdown to sustain Q12 on 5 Figure W 1 shows the pulse on the C15 i e the base signal of Q12 during the cold start 2 Start with input AC power AC start 1 When we connected UPS with AC source AC voltage pass through fuse full wave rectifier D21 D22 D23 D24 and ZD02 Zenor diode turns on Q12 2 If on off swit...

Page 8: ...Figure S 1 Control Power circuit 6 ...

Page 9: ...CH1 C15 GND Figure W 1 Cold Start 7 ...

Page 10: ...s 1 1050 100 50 10 6 1050 14 4275 Volts If T 25 degree Rp 2000 4020 4990 2000 4020 4020 4990 4990 2000 1 05kohm By considering the voltage drop of D13 the actual charging voltage is given by 14 4275 0 7 13 7275 VDC To prevent the charger current from over charging and damaging the batteries R31 Q09 and associated components are used as the current limiter The current limiter process is described b...

Page 11: ...Figure S 2 Charger circuit 9 ...

Page 12: ...nverter voltage and the input line voltage while UPS is switching from battery mode to line mode If the phase difference is too large it can create a large amount of energy which may damage the internal passive components such as relays The Zero Crossing signal is get by the following ways 1 Use the voltage reduced from input line voltage by resistor R49 to drive Q14 2222ASM 2 The Zero Crossing si...

Page 13: ...Figure S 3 Line and Zero Crossing Detecting circuit 11 ...

Page 14: ...CH1 Line I P CH2 Q14 collector Figure W 2 Zero Crossing 12 ...

Page 15: ...ignal of output voltage please refer Charger circuit to get a stable output The gates of MOSFETs are driven by transistors Q20 Q24 Q23 Q25 which are controlled by the DS1 and DS2 from CPU pin 11 and 26 Figure W 4 shows the collector waveforms for transistor pairs Q20 Q24 Q23 Q25 while the system is at no load condition C24 and R83 are used to eliminate the inverter transformer energy spikes due to...

Page 16: ...Figure S 4 Inverter circuit 14 ...

Page 17: ...CH1 DS1 CH2 Output Voltage 1 200V Figure W 3 Inverter Circuit 1 15 ...

Page 18: ...CH1 DS2 CH2 Output Voltage 1 200 Figure W 4 Inverter Circuit 2 16 ...

Page 19: ...pin 27 of CPU goes to HI If either one of the two MOSFET sets turn on Q20 Q24 or Q023 Q25 the CLAMP OFF signals will remain HI When UPS at line mode the CLAMP OFF signal remains HI This turns on U07 to turn off Q22 At this time the Clamp circuitry is not active When the CLAMP OFF is LOW U07 turns OFF and Q22 turns on This pulls down output voltage to approximately zero at battery mode Figure W 8 i...

Page 20: ...CH1 CLAMP OFF signal CH2 output voltage 1 200V Figure W 5 Clamp circuit 18 ...

Page 21: ...n 14 buck relay control pin 15 mani relay control pin 16 LED1 control pin 17 shutdown pin 18 model selection pin 19 reset control pin20 Vpp via resistor R11 to ground pin 21 no use pin 22 oscillation circuit pin 23 oscillation circuit pin 24 ground pin 25 5Volts pin 26 inverter PWM signal DS2 pin 27 CLMP OFF control pin 28 charge off control pin 29 TXD pin 30 RXD To prohibit the CPU from power up ...

Page 22: ...he drive signal for RY02 booster relay When the input line source voltage falls below boost active threshold pin 12 sends a high signal to turn on Q05 2SC1815 This actives the RY02 and UPS goes into the Boost mode When the input line voltage goes above the boost disactive threshold the UPS returns to nominal mode by sends a LOW signal from pin 12 This forces RY02 to switch into its normal position...

Page 23: ...Figure S 5 CPU circuit 21 ...

Page 24: ...Figure S 6 Relay Circuit 22 ...

Page 25: ...CH1 C10 GND CH2 Output Voltage 1 200V Figure W 6 Relay speed up capacitor 23 ...

Page 26: ...HI signal passes through LED to turn on LED 2 Audio alarm The buzzer is controlled by pin 2 of CPU When CPU send a HI signal to buzzer from pin 2 buzzer is beeping And CPU send LOW signal to stop buzzer 3 Control button ON OFF Button Push to turn on UPS push again to turn off UPS Please refer Chapter C for cold start AC start 24 ...

Page 27: ...Figure S 7 Panel circuit 25 ...

Page 28: ...er the voltage signal divided by R34 R102 to get 0 5 Volts signal the CPU can get output current value of UPS 1 At line booster buck mode The current value multiplies output voltage to get output VA value 2 At battery mode Because the power factor of square wave is approximately equal 1 The current value multiplies 120V 230V output voltage to get output Watt value ZD03 is added for protection of r...

Page 29: ... RS232 series communication and plug play for Windows 95 The communication port is a D type 9 pin connector and its pin definition is pin1 N C pin2 RS232 transmit pin3 RS232 receive pin4 connect with pin 6 pin5 common pin6 connect with pin 4 pin7 connect PC pin8 N C pin9 N C Figure S 9 RS232 circuit 27 ...

Page 30: ...econnect the connectors of battery to prevent unwanted sparks Please depend on the following steps when you want to repair a problematic unit 1 Visual inspection This is the first step to check the UPS after opening its cover Be sure to do it it can help you to identify with most problems Major items that should be checked are listed below 1 Are there any connectors or terminals loosen 2 Are there...

Page 31: ... fuse F01 and F02 are open 6 Replace abnormal DC fuse 7 Check if there is a battery voltage on regulator 7805 input 8 Check Q11 MPS2907A Q12 2222ASM and replace them if abnormal 9 Check there is 12V on 7805 input 10 Replace abnormal Q11 11 Check there is 5V on U03 7805 12 Replace abnormal 7805 13 Replace PCB 14 Check if buzzer beeps and LED extinguished 15 Check if battery voltage is correct 16 Re...

Page 32: ...20V models 2 Check if input fuse is open 1 Replace fuse 4 1 Replace main relay 230 240V models 2 Turn to procedure 6 120V models 5 Check UPS if remains at line mode 1 Check if full bridge rectifier is short 2 Replace abnormal diode 3 Check Q14 2222ASM collector if there is zero crossing signal 4 Replace abnormal Q14 5 Replace PCB 6 Check if buzzer beeps continuously and fault LED lights 7 Check if...

Page 33: ...Figure W 7 Battery mode examination flowchart Figure W 8 Line mode examination flowchart 30 ...