SERVICE MANUAL Vista 1K(S) / 2K(S) / 3K(S) / Tower Centralion
CONTENT 1. GENERAL INFORMATION OF THIS DOCUMENT ...................................... 5 1.1 GETTING START ................................................................................................................. 5 1.2 CONVENTIONS.................................................................................................................... 5 1.3 IMPORTANT SAFETY INSTRUCTIONS ................................................................................. 6 2. CHARACTERISTIC OF THE PRODUCT ...
6.3.1 Quick Start................................................................................................................... 34 6.3.2 P.F.C Converter Analysis: ............................................................................................ 35 6.3.4 Push-Pull DC-DC Converter Analysis.......................................................................... 35 6.3.5 DC/AC Inverter Analysis.............................................................................................. 36 6.
1. General Information Of This Document 1.1 Getting start This is a service manual for Vista 1/2/3K(s), Tower UPS, intend to help service personal perform a maintenance and repair service. If you want to know: ? What is special for this UPS from service point of view; please refer to section characteristic of the product.
1.3 Important Safety Instructions STOP 1. For qualified service personnel only. 2. DO NOT performs any internal service or adjustment of this product unless another person is capable of rendering first aid and resuscitation is present. 3. Dangerous voltage exists at several points in this product. To avoid personal injury, don't touch any exposed connections or components while UPS is active. 4. Turn off the UPS and disconnect input power cord before removing outside protective cover. 5.
(2k/3k) upper lead with a 300Ω/10W resistor to discharge +BUS capacitor TO DISCHARGE the energy of charger capacitor, after disconnect the battery from PSDR/Charger, you can use a 300Ω/10W resistor contact BAT (+) terminal and BAT (-) terminal for discharge battery filter capacitor 7
2. Characteristic of the Product For all UPS of this series, they are carefully designed and strictly tested. 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 unexpected failures may occur to the product, in this case, qualified service is needed. This service manual will guide the technicians to repair and adjust a problematic UPS.
3. Construction Of The Product 3.1 Open The Outside Cover To open the outside cover, please follow steps and figures below: STEP 1: Remove all the screws, including those on the opposite side of the case, refer to Figure 3.1 STEP 2: Slide outside cover backward, as shown in Figure 3.2. STEP 3: Done, as shown in Figure 3.3.
3.2 Inside The Chassis STOP Warning: Before any further operation of service, touch any parts inside the chassis. Please make sure all power supply is cut off, either mains utility or DC power from external battery pack for standard model which contains internal battery, please disconnect at least one of battery connection cables and discharge the possible residue energy from energy storage component such as capacitor. 3.2.1 1K Fig. 3.2.1.1 1K PSDR & CNTL Fig. 3.2.1.
3.2.2 1KS Super Charger Fig. 3.2.2.1 1KS super charger 3.2.3 2K Fig. 3.2.3.
3.2.4 3K Fig. 3.2.4.1 3KS PSDR / CNTL I/P EMI Fig. 3.2.4.
3.2.5 2/3KS super charger Fig. 3.2.5.
4.COMPONENTS LOCATION Below Figures shows location of the main components / modules in the UPS: Fig.4.1 1K PSDR MODULE LOCATION Fig.4.
No. Module Name Part No. Quantity Remark 1. Charger Module 710-61201 1 1053 710-61200 1 1073/1083 710-61000 1 1053(S) 710-61001 1 1073(S)/1083(S) 2. Fan Driver 3. CNTL 710-01771 1 4. IGBT Driver 710-61800 3 5. PFC Control Module 710-62800 1 1073(S) 6. SPS Module 710-61400 1 1073(S)/1083(S) 710-61401 1 1053(S) 710-62200 1 1073S/1083S 7.
5. PRINCIPLE OF OPERATION 5.1 Functional Block of The Product As a true online UPS, the product employ a double conversion topology, comprise following functional blocks, as shown in Figure 5.1.1 Bypass PFC / Rectifier I/ P Mains Inverter DC AC I / P EMI FILTER DC O/P EMI FILTER AC DC O/P Controller DC Battery Charger Battery Booster Power Supply (SPS) User Interface Ventilation & Chassis Battery Figure 5.1.
The DC/AC module, call also inverter, belongs to the output stage of the UPS, used to converse the DC power from the DC-BUS into clean, stable AC output power. When the mains line is within the tolerance range, the UPS use the mains input, at this time, the AC/DC converter work; In case the mains line supply is output tolerance range, due to either the voltage or the frequency, the UPS will stop the AC/DC converter working and start the DC/DC module.
5.2 Operating Principle Of The Major Functional Block 5.2.1 AC/DC converter (PFC) The purpose of AC/DC converter is to generate a stable bipolar DC BUS for inverter, another very important task of AC/DC converter is to make the input current track input voltage waveform therefore achieve a high input power factor close to 1, performing PFC (Power Factor Correction), That is why we also call the AC/DC converter PFC converter. Figure 5.2.1.1 showed the topology implement the PFC converter. Figure 5.2.1.
DC-BUS capacitor can be controlled, therefore the voltage of the DC BUS can be controlled, at the same time the waveform of the current can also be controlled to track the input voltage waveform, implement the power factor correction. The P.F.C. output voltage, i.e. the DC BUS voltage, will be regulated at ±350 Vdc, ±360 Vdc, and ±370 Vdc when the UPS output voltage is set to 220Vac, 230V, and 240Vac respectively. 5.2.
The MOSFETs turn on /off in turn, can prevent the saturation of the transformer and damage of the circuit. Like the AC/DC converter, the DC/DC converter output regulated±350 Vdc, ±360 Vdc,±370 Vdc to the DC –BUS when the UPS output voltage is set to 220Vac, 230V, 240Vac respectively. 5.2.3 Inverter The inverter converse the DC power from DC BUS into the AC output to supply the load. A half bridge topology employed, Figure 5.2.3.1 shows a diagram of inverter in 1/2/3k product. Figure 5.2.3.
the output of the switching leg filtered by a LC filter to get clean and stable sine wave the output voltage. 5.2.4 Global Controller The Global Controller of UPS composed of following major circuits as following.
5.2.5 Standard Charger and Super Charger The utility of charger is to recharge and to maintain the batteries at fully charged condition. The charger the battery with a constant current at initial stage, as the battery voltage keep increasing, the charge current decrease accordingly, and the voltage until the floating recharge voltage, and the charger will control the output at a constant level (2k/3k 110.4 Vdc, 1k 41.2Vdc).
in the long backup time model UPS. Photos of super charger can be found in Fig. 3.2.2.1 & Fig. 3.2.5.1. 41.2V CHARGER MODULE 110V CHARGER MODULE Fig. 5.2.5.2 Standard 1A charger 5.2.6 Auxiliary Power Supply (SPS) The Auxiliary Power Supply (SPS) module supplies DC power for UPS operation. The input of the SPS is the battery, or the output of the charger. The SPS module output +12 Vdc and a High frequency low level AC power, called H.
5.2.7 User Interface 5.2.7.1 Front Panel The front panel consists 2 parts: push button and LCD indicator. The push button is used to turn on and off the UPS, or do some simple setting. Fig.5.2.7.1 LCD display panel All UPS information including the input, the output, the battery, the load and the status of UPS are displayed on the LCD screen. The detailed illumination of LCD display can be found in the user manual.
5.2.8 Ventilation and Chassis Ventilation system of the UPS consist of air flow guiding insulation paper and fans, The ventilation system keeps the temperature of component of the UPS in safe range, so it is very important for the UPS, To achieve lowest acoustic noise and longest life time of the fans, a fans driver and intelligent fans speed control algorithm is employed. The chassis of the UPS provide a strong construction accommodate all the electrical part, shield for EMC, and safety guard for operator.
5.3 PCBs of the UPS This UPS system contains two major PCB assemblies. They are including: 1.
5.4 Interconnection Of The PCBs The simplified schematics in and Fig.5.4.1 shows how the major circuits are connected and illustrates the overall system functions. . P/N shown in the Fig.5.4.1 may vary according to customer request. 126-00086 Fig.5.4.
6. TROUBLE SHOOTING Despite of careful design and strict tests, in case UPS become out of order. Basically, designer suggest following service procedure: 1. Check the UPS status by LCD panel display, or listen to the end user description 2. Identify the failure part/boards with the help of failure identify flowchart. 3. Observe the failure board, Static checking 4. Replace the failure components with OK parts 5. Static checking 6. Power up checking 7. Test after repair.
1. 05 19 BUS fault 11 20 Over charger 09 22 Line input site fault (L-N) 13 23 Battery / charger Fail 10 25 Fans fault Don’t let the UPS carry half-wave load, negative power load. Low PF inductive/capacitive load. 2. Don’t connect the UPS (inverter) output to the mains line. 3. Check the BUS voltage measurement Keep Buzzing circuit. 1. Check the battery Number. 2. Check the charging voltage measurement Keep Buzzing circuit. 1. Correct the wiring 2. Check the site-fault detection circuit 3.
Possible Cause 3: DC/DC circuit fails. Solution: Refer to DC/DC circuit failure analysis. Possible Cause 3: Bus voltage feedback circuit problem. Solution: Refer to bus feedback loop problem. Transfer to Bypass Due to Inverter Failure Possible Cause 1: O/P short circuit. (In this situation, no power will be transfer to O/P socket.) Solution: Remove short circuit condition, turn off the UPS then turn on again. Possible Cause 2: Inverter circuit failed. Solution: Refer to Inverter Circuit failure analysis.
6. 2 Trouble Shooting Procedures 6.2.
6.2.2 Find Out The Problem Quickly 6.3 Failure Diagnosis In this section, some debug skills are listed to help you finding the failure components and problems as soon as possible. Before continuing the following steps listed, we suggest that you should read problem shooting chart in previous section then check the components listed in Quick Start to find out which block is out of order, in order to shorten the service time.
For the reason of safety, please follow safety instruction to begin your work STOP High Voltage Danger: Some components contain residue charge and remain dangerous high voltage even if the external power supply is cut of, operator should follow following instruction strictly avoid risk of electrical shock. 1.Unplug the power cord from the utility. 2.Open outside case shown in the beginning of this manual 3.
6.3.1 Quick Start Before any detail check of UPS, please check the components listed in the following table. This action could help you find problem quickly and make following debug procedures go smoothly.
6.3.2 P.F.C Converter Analysis: In this section, some components you could check to see if failure occurs to P.F.C Converter. General speaking, OPEN of fuse F3 indicates failure of this block. Please replace all fail to check components then utility can be connected to your UPS. Item Checked components Instrument function Reference Value Ω Failed condition Short Open 2K/3K:Q09, 1K:Q14 (C E) Diode Voltage Droop Infinite Short or open 2K/3K:D16, D17 Diode Voltage Droop 0.
! BE SURE TO use fuse with same spec as original ones to replace failure ones, otherwise, unpredictable danger could happen. If all components listed above are in normal condition and UPS still can’t be DC started, try to change DCDC module. 6.3.5 DC/AC Inverter Analysis Item Checked components Instrument function Reference Value Failed Condition 1 F3, F2, F1 Ω Short Open 2 2k/3k:Q14, Q13, Q16, Q15 (E C) Diode Voltage Droop 0.
6.3.6 SPS Module Analysis Item Checked components Instrument function Reference Value Failed condition 1 Q201 (S, D) Diode Voltage Droop 0.42V Short or open 2 R206, R206A Ω 47 Open 3 R209 Ω 0.10 Open 4 R207 Ω 1K Open 5 U01 (3845) PIN 5-6 Ω 46.7K <10K PIN 5-7 38K PIN 5-8 4.31K PIN 6-8 50.9K 6.3.7 1A Charger Module Analysis Item Checked components Instrument function Reference Value Failed condition 1 Q2 (S, D) Diode Voltage Droop 0.45V Short or open 2 R40 Ω 47.
6.3.8 Super charger Item 1 Checked components 1k: F501 Instrument function Reference Value Failed condition Ω 0 Open Diode Voltage Droop 0.4V Open/Short Diode Voltage Droop 0.4V Open/Short 47K Short circuit/Open 2K/3K F801 2 1k: REC 501 (~ +)/(- ~) 2K/3K: REC 801 (~ +)/(- ~) 3 1K: Q501/Q502 (S D) 2K/3K: Q801/Q802 (S D) 4 1K:U502 2K/3K: U803 Ω 20K PIN 5-6 7.48K PIN 5-7 PIN 4-8 5 1K: D501, 504 Diode Voltage Droop 0.45 Short or open Ω 0.
or a whole driver module directly. 6.3.10 others In previous sections, we pay attention to the components on PSDR/Charger, in this section, we are trying to list some possible failure phenomenon not stated before and on control PCB sub-assembly. They are list as following. Fail for Phenomenon Possible Comment components Bus over-voltage 1.Bus over-voltage fault alarm and PFC module, display occur 2.Bus voltage doesn’t meet spec.
debug the corresponding circuit. If unfortunately, both modes are incorrect, two possible circuits should be check: Bus feedback loop (on PSDR) and auto-balance circuit (on CNTL). 6.4 Test And Finish After replace all defected components on power stage (PSDR), following test the steps can be adopt to verify the repair result and the reliability of the UPS. 1. Connect all of boards, cable, and connector right to place. 2. Check the Wiring 3.
TEST ITEM Charger Voltage TEST POINT TEST AND ADJUSTMENT SEQUENCE EXPECTED RESULT BAT (+) 1. Disconnect BAT (+) and BAT (-) wires from pins 1.Cooling fans on back BAT (-) respectively. panel begin to rotate. 2. Connect DVM (Set to measure DC) to test points 2. 2K/3K 110 Vdc±0.4V and plug input power cord to utility. 3. 1K 41.2Vdc+0.3V Adjust VR1 slowly to expected value. +DC Bus Voltage @ 2K/2K:R104Top (+) and GND 1. Line Mode 1K: R4 Top (+) and GND 2.
Appendix I. DC Offset Measurement Fixture R From O/P Socket To DVM C C R=100Kohm/2W C=10uF/250V Fig.A.I.
