Powertronix PTX2-A3, Service Manual

Page 1: ...Service Manual PTX2 A3 UPS 6kVA 10kVA 220VAC ...

Page 2: ...ng 2 3 Troubleshooting 3 3 1 Quick Start 3 3 2 PFC Analysis 4 3 3 Boost Analysis 5 3 4 Inverter Analysis 7 3 5 Charger Module Analysis 8 3 6 PFC Boost Inverter IGBT Driver Module Analysis 9 4 Final testing 10 5 Service Setting 13 5 1 How to adjust the output voltage and frequency on LED type UPS 13 5 2 How to replace the control card 16 ...

Page 3: ...2 Page 1 of total 19 August 2007 1 PSDR Introduction 1 1 6 10 kVA PSDR Right side c d e f 1 2 6 10 kVA PSDR Left side f e d 1 Bypass Mosfet Driver 2 Inverter IGBT Driver Module 3 Boost IGBT Driver Module 4 PFC IGBT Driver Module ...

Page 4: ...il 1 Inverter circuit failed 2 Inverter driver failed 3 PFC circuit failed 1 Replace the Inverter components or driver 2 Replace the PFC components or driver Fault Warning Normal y UPS in Normal Mode but battery capacity is low y The alarm beeps once every second for battery low AC OK BATT LOW Normal Mode 1 Charger may break down 1 Please replace charger board Fault Warning Normal y UPS stop worki...

Page 5: ...5 D307 Push Pull Boost D309 D311 D308 D310 Power Diode Short or open Q201 Q202 Q203 Q204 IGBT C E short or open D201 D202 D203 D204 D205 Inverter D210 D211 D212 D213 Power Diode Short or open Charger module standard Q907 Q908 IGBT D S short or open D901 D902 D903 Power Diode Short or open Q909 MOSFET A K Short or open IP SCR module Q3 Q4 Q5 Q6 MOSFET A K short or open For the 6 and 10kVA both of t...

Page 6: ...302 fuse open indicates failure of this block Please replace all faulty components before re start the UPS 6 10kVA PFC Right side 6 10kVA PFC Left side Step Checked components Instrument function Reference Value Failure Mode 1 F301 F302 Fuse 0 Open A K 1 2 M Short or open 2 Q301 Q302 G K 40 50 Short or open Action ltem If all above stated components are replaced well and UPS still can t work chang...

Page 7: ...ting 3 3 Boost Analysis 6 10kVA Boost Right side 6 10kVA Boost Left side Step Checked components Instrument function Reference Value Failure Mode E C 800k short 1 Q306 Q311 G E 23 8k short or open 2 D308 D310 D309 D311 DIODE 0 35V 0 V 3 D302 D304 D306 D303 D305 D307 12 open ...

Page 8: ...4 R325 R331 R334 R342 R337 R328 10 open 5 R390 R388 R389 R393 R392 R391 2 2 open 6 F303 F304 0 open A K 2 5M short 7 Q305 G K 43 6 short Action ltem If all above stated components are replaced well and UPS still can t be DC start change Boost IGBT Driver Module ...

Page 9: ...Checked components Instrument function Reference Value Failure Mode E C 100k Short 1 Q201 Q202 Q203 Q204 G E 47 6k Short or Open 2 D201 D202 D203 D204 Diode 0 36V 0V 3 D210 D211 D212 D213 Diode 46 Open 4 R201 R202 R208 R209 10 Open 5 R203 R204 R210 R211 36 Open Action ltem Make sure the DC fuses with same rating as original ones for replacement Otherwise unpredictable danger might happen ...

Page 10: ...nents Instrument function Reference Value Failure Mode 1 F1 0 open E C 1M Short 2 Q301 Q105 G E 10k Short or Open 3 D303 DIODE 0 4V 0V 4 D106 DIODE 0 4V 0V A K 1M Short 5 Q04 G K 12 Short Step Checked components Instrumen t function Reference Value Failure Mode 1 F901 F902 F903 F904 F905 F906 0 open S D 1 7M Short 2 Q907 Q908 G S 57 Short 3 D901 D902 D903 DIODE 0 4V 0V A K 20M Short 4 Q909 G K 54 ...

Page 11: ...st Inverter IGBT Driver Module Analysis 6 10kVA Boost Right side 6 10kVA Boost Left side Step Checked components Instrument function Reference Value Failure Mode ZD201 V 0 7V 0V Q201 Q202 V VBE 0625V VBC 0 625V 0V 1 RED R203 R205 10 Open D201 V 0 580V 0V 2 BLUE Q01 V VSD 0 5V VSG 2 225V 0V ...

Page 12: ...he switch on front panel for more than 3 seconds you will see current limit for a short time on the DC power supply for about only 2 seconds then UPS should be DC start If UPS does not start successfully and LCD display off replace the above procedure If UPS fails to start up for several times or DC power supply is on current limit state continuously there must be some defective components exist P...

Page 13: ...he UPS re start normally check the DC_BUS and output voltage For 6 10kVA DC_BUS 340 350 and 340 350VDC deviation between negative and positive voltage should be within 10VDC Output Voltage 220 230 240 2 DC BUS Voltage Positive DC_BUS 340 350VDC _ DC BUS Voltage Negative _ DC_BUS 340 350VDC ...

Page 14: ...power source then follow the step3 and step4 to check the DC_BUS and output voltage again Also the charger voltage need to be confirmed the charger voltage should be 274VDC 1 If UPS fails to start up for several times there must be some defective components exist Please follow section 3 trouble shooting to check again _ Charger Voltage 274VDC 1 ...

Page 15: ... original output voltage of PTX2 A3 LED type do not meet the local voltage because LED can not setting the voltage on LED panel Following the guide line to adjust the output voltage Step 1 UPS connect with computer via RS232 Step 2 UPS should be working on Bypass Mode and double click the ID setting software on computer for operation Æ Double Click ...

Page 16: ... 2 Page 14 of total 19 August 2007 5 Service Setting Step 3 Type 1 and for 1mins detection time between software and UPS Step 4 Type the and for showing the information on computer screen Step 5 Type the CTL and to setting mode ...

Page 17: ...al Rev 2 Page 15 of total 19 August 2007 5 Service Setting Step 6 Type the VXXX and for setting the output voltage XXX 220 230 240VAC Step 7 Type the CFXX and for setting the output Frequency XX 50 60 After Type ENTER key ...

Page 18: ...ugust 2007 5 Service Setting 5 2 How to replace the control card 6kVA Standard Step 1 For the safety of persons and product safety the battery should disconnect in advance Step 2 Adjust the Jumper on 6 10kVA control card Jumper between Pin 1 and Pin 2 ...

Page 19: ...PTX2 A3 Service Manual Rev 2 Page 17 of total 19 August 2007 5 Service Setting Step 3 Connect with 16 pin cable Step 4 Connect with cable 16 pin cable 10 pin cable 26 pin cable 2 pin cable ...

Page 20: ...oard Step 6 Connect with battery release the remnant of electric power in UPS by using the lamps or above 30ohm 100Watt resistance in advance then connect with UPS 10kVA Standard Only the Jumper is different other steps are following the 6kVA standard 1 6 Jumper between Pin 1 and Pin 2 Pin 11 and pin 12 ...

Page 21: ...7 5 Service Setting 6kVA Long backup type Only the Jumper is different other steps are following the 6kVA standard 1 6 No Jumper 10kVA Long backup type Only the Jumper is different other steps are following the 6kVA standard 1 6 Jumper between Pin 11 and pin 12 ...