SERVICE MANUAL ---------------------------------Linear Mk II 6/11 UNINTERRUPTIBLE POWER SYSTEM
I( INTRODUCTION………… ……………… ………… ………… ………… ………… ………… ………… ………… ………… ………… ………. ….
4
……………… ………… ………… ………… ………… ………… ………… ………… ………… ………. …... 1( INTRODUCTION…………
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II( PRINCIPLE O) OPERATION………… ……………… ………… ………… ………… ………… ………… ………… ………. …...
5
……………… ………… ………… ………… ………… ………… ………… ………… ………… ………… ………. …. 6 III(PCB )UNCTION………… 1( POWER STA*E +PSDR,
(1). (1). SOFT SOFT-ST -START SUB-S SUB-SYST YSTEM… EM………… ……………… ……………… ……………… ……………… …………. ….
6
(2). (2). CONTR CONTROL OL POWER POWER SUBSUB-SY SYSTE STEM…… M…………… ……………… ……………… ……………… ……….. ..
6
(3). (3). INPUT INPUT POWER POWER FAC FACTO TOR R CORRECT CORRECTION ION SUB-S SUB-SYST YSTEM… EM………… ………….. …..
6
(4). (4). BOOSTE BOOSTER R SUB-SY SUB-SYSTE STEM…… M…………… ……………… ……………… ……………… ……………… ………….. ….. 7 (5). (5). INVER INVERTE TER R SUB-SY SUB-SYSTE STEM…… M…………… ……………… ……………… ……………… ……………… …………. …. 7 "( MAIN CONTROL PCB ASSEMBLIES +CNTL,
(1). REULA REULAT TION ! CONTROL CONTROL SUB-SY SUB-SYSTEM… STEM………………… ………………………… ………… " (2). (2). PROTEC PROTECTIO TION N SUB-SY SUB-SYSTE STEM…… M…………… ……………… ……………… ……………… ……………… ……… # (3). SINALIN SINALIN SUB-SYSTE SUB-SYSTEM…………… M…………………………… ……………………………… ………………... ... 1$ ……………… ………… ………… ………… ………… ………… ………… ………… ……… … 11 #( OUTPUT SUB-SYSTEM………… 4( CHAR*ER+CH*R, ………… ……………… ………… ………… ………… ………… ………… ………… ………… ………… …….. .... 11
WARNIN* +)'r 23ai5ie% er7i8e 9er'nne 'n:, 1. O NOT '*+,* '*+,* %/ 0'*% 0'*% '*0' '*0' ,* %8 %8' ' ,+ 90 *,8 *,8 8' 8' %,9'* %,9'* '*, 0 %%:' ,+ *''*0& +0* %0 % *'80%0, 0 *''. 2. %&'*,8 %&'*,8 ,%&' ,%&' ';0 % ''*% ,0 ,0 0 90 *,8. *,8. T, %,0 %,0 '*,% '*,% 08*/< 08*/< ,= ,89 %/ ';,' ,'0, ,* ,,' >90' ,>'* 0 ,. 3. T8* ,++ 9' UPS % 08 NFB :'+,*' *',0& ,80' *,'0' ,'*. ,'*. 4. AC ,%&' ,%&' 0 %>%/ *'' *'' 0+ 9' 08 AC AC ,>'* 0 0 %%0%:'. %%0%:'. 5. ?0&9 ,%&' %/ *'' % C %%0,*. B'+,*' ,'0& 9' ,80' ,'*< >%0 +,* % '% +0' 08' %+'* 8*0& ,++ 9' UPS. 6. V'*0+/ 08 ,8*' ,8*' (,%&' % +*'@8'/ +*'@8'/)) :'+,*' '*0'.
CAUTION
STEPS TO OPEN THE CASE +MODEL LINEAR Mk II ON-LINE UPS,
------------------------------------APPLICABLE MODEL M'%e Linear Mk II 6/11 +""V/"#V/"4V /6H;, PLEASE )OLLOW THE STEPS TO OPEN THE CASE
F,* % UPS ,+ 90 '*0'< 9'/ %*' *0/ '' % %*'+8/ '0&'. W' %>%/ , ,8* :' , %' ,8* *,8 ,*' *'0%:' % %+'*< 90 0 %, 9' &,% ,+ ,8* ,%/. ?,>''*< 8' , 9' 0+'0' ,+ ''*0% ,,' % ,' 8*'0%:' *'%,< 9'*' >0 :' 8%,0%:' +%08*' ,+ 9' UPS. I+ 90 08%0, ,8*< '*0' ,+ @8%0+0' '*, 0 '''. T90 '*0' %8% >0 &80' 9' '900% , *'%0* % %8 9' *,:'%0 UPS. I+ 9' UPS 0 ,' , >,* *,'*/< '%' ,% >09 8 % >' >0 :' &% , ,' %/ *,:' /,8 '. B'%8' ,+ 9' +,,>0& 80@8' +'%8*' ,+ UPS (U0'**80:' P,>'* S/')< 0 0 '*/ '%/ , %0%0 % '*0'. A %,* ,>'* ,,' %*' 8 , PCB. M%,* %* %*' 0/ ,'' >09 +';0:' 08%' >0*' % 8&. A PCB %*' 0'*,'' >09 ,',*. T90 '*0' %8% ,0 ,+ 4 %,* %* 1. I*,80,. 2. P*00' ,+ ,'*%0, I '*0:' 9' +80, % *00' ,+ '%9 %*. 3. A0&' I '*0:' 9' ,%0, % '9, ''' , %8 9' UPS. 4. T*,8:' 9,,0& T90 %* '*0:' 9' ,0:' +%08*' ,00, % *,'8*' ,
1( INTRODUCTION T90 6DVA 90&9 08 ,>'* +%,* UPS /' ,%0 9*'' %,* : %':0'. T9'/ %*' 080& A. PSR ,%0 %,* %* ,+ (1) ,+-%*< (2) ,*, ,>'* 8/< (3) 80 ,>'* +%,* ,**'0,< (4) :,,'*< (5) 0'*'*< (6) *%+'* *'%/< S.T.S ,*, 0*80. B. CNTL ,%0 %,* %* ,+ *,'0,< 0&%0& 0*80< *'&8%0, % ,*, 0*80 ,+ 0'*'*. C. C?R ,%0 C-C *'&8%0, % ,*, 0*80. T9' 00+0' 9'%0 0 +0&8*' 1 9,> 9,> 9' %,* 0*80 %*' ,'' % 08*%' 9' ,'*% /' +80,. T9' ,%0, ,+ 9'' %':0' 0 90 %90' %*' 9,> 0 +0&8*' ". T9' :, 0%&*% 0 +0&8*' 2< 9,> 9' UPS % ,*% ,'*%0, +*, '+ , *0&9. W9' % *,'0, 0*80 0 *0&&'*' ,* % +%8 ,00, ,8*< 9' ,88 8/ 0 *%+'**' 0'0%'/ +*, 0'*'* , AC %0 :/ % S.T.S. T9' ,'*%0, *00' >0 :' ';%0' 0 %'* '0,.
1( PSDR+POWER STA*E, T9' ,>'* %&' ,0 ,+ ,+-%*< ,*, ,>'* 8/< 80 ,>'* +%,* ,**'0,< :,,'* % 0'*'*. T9' +0&8*' 3 9,> 9' :, 0%&*% ,+ ,>'* %&'. (1) SOFT-START SUB-SYSTEM T9' 8*,' ,+ ,+ %* 0*80 0 , 8*' 9' IP 0*89 8**'. (2) CONTROL POWER SUPPLY SUB-SYSTEM T9' 08 ,+ 9' ,*, ,>'* 8/ 0 ,'' , 9' :%'*/ :8< 0.'.< 9' ,88 ,+ 9' 9%*&'*. T9' ,88 ,+ ,*, ,>'* 80' *,0' G24V +,* 9' ,0 ,+ *'%/< G12V +,* 9' :0% 8/ ,+ IC= >,*0& ,%&' % 9' +%() ,%&'. 5V 0 8' +,* IC= >,*0& ,%&'. T9' ,*, ,>'* 8/ >,* ,/ >9' 9' 12V *'&8%,* 80' V , 0 ,*, IC. T, 9%' *,'* ,'*%0, ,+ 12V *'&8%,*< 0 08 ,>'* 0 ,*,' :/ 9' >09 % 00%' 0 +0&8*' 6. (3) INPUT POWER FACTOR CORRECTION SUB-SYSTEM T9' 8*,' ,+ ,>'* +%,* ,**'0, (PFC) 0*80 0 , %' 9' 08 8**' % ,%&' 0 9%' % 9'*'+,*' %90'' % 90&9 08 ,>'* +%,*. T9' 9'%0 0 00%' 0 +0&8*' 7.
T9' %,* +80, ,+ 9' UPS 0 , '0'* %8*%' AC ,>'* , 9' ,% ,'' , 0 >9'''* 9' AC 0' 0 8,**'' ,* +%0'. I 90 /'< 9' :%'*/ *''%' 9' ,*' ''*&/ , 8/ 0'*'* 0'0%'/ 8, AC 0' +%0. R'+'* , +0&8*' 7 < 9' :%'*/ ,%&' 0 *%+,*' 9*,8&9 % :,, C-C ,'*'* , 36$ ( :%'*/ V 2$$J273V ) % C :8' +,* 0'*'*. W9' 9' 0' +%0< 9' 36$V( :%'*/ V 2$$J273V) C ,8*' %*' %8&9 8 , 8/ 9' ,>'* ''' :/ 9' 0'*'* 0'0%'/. (5) INVERTER SUB-SYSTEM T9' UPS *%+'* +<-C :8 ,%&' , 9' AC ,88 ,%&' 9*,8&9 % 0'*' * ,+ 9%+ :*0&' ,+0&8*%0, % ,*% ,'*%0,. T9' 9'%0 0%&*% ,+ 0'*'* 0 9,> 0 +0&8*' 4. T, ,*8 % 90&9 +*'@8'/ (1#.2?) PWM 0'*'*< 9' *0'* *''0' >090& 0&% +*, PWM &''*%0, 0*80 9*,8&9 % %0* ,+ 9,,-,8'* , *0&&'* 9' 8'* IBT % 9' ,>'* IBT %'*%'/.
T9'' %':0' %*' 9' ,*, ''* ,+ UPS. I 0 ,,' ,+ 9*'' %,* 0*80 % +,,>0& (1) R'&8%0, ! ,*, (2) P*,'0, (3) S0&%0& (1) REULATION ! CONTROL SUB-SYSTEM T90 ,*0, % :' '' % :*%0 ,+ 9' UPS. I *,0' 9' ,*, 8' , 9' >090& ''' >909 '0'* ,>'* , 9' ,88. T9' 8:-/' %, *'&8%' 9' ,88 , '8*' 9% 9' UPS 0 '0'*0& ,% AC ,%&' , 9' ,%. T9' 0'*'* 0&% 0 '' 0*'/ :/ *'0,* 000,. I 0 ,%*' >09 % *'+'*'' 0&% +*, 0' >%' &''*%,*. T9' 0++'*'' ,+ 9'' >, 0&% ('**,* 0&%) %'* 9' 8' >09 ,+ PWM 0&% >909 ,*, 9' 8/ /' ,+ >090& ''' , *'&8%' 9' ,88 ,%&' >090 '0+0%0,. NOTE VR1 0 8' , %8 9' OP C ,%&' 8'* :%'*/ ,'.
(2) PROTECTION SUB-SYSTEM T9' UPS *,0' 9' +,,>0& *,'0, 0*80 A. O'*,% *,'0, T9' ,% '',* '' 9' ,% 8**'. 0.'. 9' 0'*'* 8**'< % ' 9' 0&% :/ >, %9. I :%'*/ ,'< 9' UPS >0 &, , +%08*' ,' 0+ ,'*,% ,00, 9%''. T9' %' >0 00%' 9' +%8 ,00,. T9'*' %*' >, 0 ,+ *,'0, 0 ,8* UPS +a,O7er'a% Pr'&e8&i'n T9' UPS ,' 9' ,08,8 ,'*,% 0&%
9*,8&9 CPU >09 9' :/% *'%/. ----
I+ 9' ,88 ,% 0 :'>'' 1$5K , 125K ,+ *%' ,% (VA< ,* W%%&')< 9' UPS '' *80& , 0'*'* *80& +,* 1 08'. A+'* 1 08' UPS *%+'* , :/% >909 0+ UPS 0 8'* 0' ,'. UPS *%+'* , +%08*' ,' >909 0+ UPS 0 8'* :%'*/ ,'.
----
I+ 9' ,88 ,% 0 :'>'' 126K , 15$K ,+ *%' ,%< 9' UPS '' *80& , 0'*'* *80& +,* 1$ ',. A+'* 1$ ', UPS *%+'* , :/% >909 0+ UPS 0 8'* 0' ,'.
C. I'*'* ,88 %:,*% *,'0, T9' 0'*'* +%08*' 0&% 98 ,> 9' 0'*'* 0'0%'/< %' 9' :8'* % ,08,8 %%*< % 0&9 HALARMH LE. T9' %' >0 00%' 9' +%8 ,00,. HT9' +%08*' 0&% %9' 0'+ 8' SW ,++ ,* :%'*/ 0 '/H. . O'* ''*%8*' *,'0, T9' 9'*% >09 ''' 9' ''*%8*' ,+ PSR 9'%-0. T9' 9'*% >09' 0 ''*0%/ ,'' , 9' CPU. A ,'' 9'*% >09 0 9,8&9 % ''*%8*' +%08*' :/ 9' UPS. T9' %' >0 00%' 9' +%8 ,00,. E. B8 ,'* ,%&' *,'0, T, *,' %/ BUS ,'* ,%&' ,00, ''0%/ +,* 9' 9%+-:*0&' ,%. T9' %' >0 00%' 9' +%8 ,00,.
P%&'1$
#( OUTPUT SUB-SYSTEM T9' ,88 ,+ IBT= 0 +0'*' :/ % LC 0*80 , *'8' 9' , ,%&' 9%*,0 0,*0,. T9' ,88 *'%/ % S.T.S *''0' 0&% +*, ,*, 0*80 , >09 9' ,88 ,+ 9' UPS +*, :/% , 0'*'*< % 0' '*%.
4( CHAR*ER +CH*R, T9' 8*,' ,+ 9%*&'* 0 , 9%*&' % , %0%0 9' :%'*0' % +8 9%*&' ,00,. R'+'* , +0&8*' 5< 9' ,%&' +/:% >090& ,>'* 8/ *,0' % ,% C ,%&' (273V) +,* :%'*0'. B'0' *,00& ,% ,%&'< 9' ,>'* 8/ %, 00 9' 8**' +,>0& 0, :%'*0' % 9'*'+,*' *,' % *,,& 9' 0+'0' ,+ 9%*&' :%'*0'.
P%&'11
( )RONT PANEL
O V E R L O A D
T9' 00%0,
OVERLOAD
T9'LE-9%0
LOAD
0 , >9' 9' UPS 0 ,'*,%'.
00%' 9' ,% %' ,+ 9' UPS.
L O A D
BYPASS T9' 00%0, >909 0 *,0' :/ 9' %0 0% 9' :/%.
0 ,< >9' 0' UPS 80' % ,%&'<
B Y P A S S IN V E R T E R
T9' 00%0,
INVERTER
0 ,< >9' 9' 0'*'* 0 0 ,'*%0,.
B A T T E R Y
T9'LE-9%0 (,*% ,'*%0,). T9' 00%0, 9' UPS 08.
L IN E ALARM
I
>
I
BATTERY
LINE
00%' 9' :%'*/= ,% %'
0 ,< >9' 9'*' 0 *'&8%* %0 ,%&' %
ALARM T9' 00%0, 0 ,< >9' 9' UPS 0 +%8/. S08%',8/< % %,80% 0&% 0 &0'< >909 >0 :' *'' >09 >090& ,++ 9' UPS.
T9' :8, >0 >09 0'*'* ,++ % :/% ,.
P%&'12
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P%&'13
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I'*'* M,' OP 9,*
P%&'14
IV( ALI*NMENTS PCB
TEST
PSR C(G) BUS
TEST
TEST AND AD?USTMENT
E0PECTED
POINT
SE@UENCE
RESULT
11
1.C,' VM (C) , ' ,0 %
12
8* , IP NFB< 9' 8* , 9' 36$5V >09.
13 C(-) BUS
1.C,' VM (C) , ' ,0 % 8* , IP NFB< 9' 8* , 9' -36$5V
12
>09. C?R
P#$5(G) C?ARER
1.
P#$7(-)
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2
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5
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9,* ,* ,'
T9' 0*8' 0 .M.M. ( 0&0% 80-''* ).
4(DC/AC INVERTER S&e9
1
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213<214<215<216
6( SO)T START S&e9
1
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.(CHAR*ER S&e9
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1
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2
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U211= 0 HIH< HOH 0+ 0 0 9,*. I+ 0 /'< *'%' 0. (:) V,%&' :'>'' C254 % N 0 12.5J12.$V. I+ 9' >%'+,* %:,*%< 9' *'9' ,0 5 ,+ PART V. () V,%&' :'>'' 232= %9,' % N 0 26J3$V.I+ 9' >%'+,* %:,*%< 9' *'9' ,0 5 ,+ PART V. Be5're 9r'
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
ATA LENT? ......... " :0 STOP BIT ................... 1 :0 PARITY ...................... NONE
T9' 0 %0&' % '*00, %*' 0' 0 9' +,,>0& %:' % 9' 0'*+%' ,+0&8*%0, 0 00%' 0 )i3re VI-1. N,' 9%< 9' ,8'* >0 ,*, 0+,*%0, ';9%&' :/ % @8'*/ +,,>' :/ * (C9%*%'* R'8*). UPS >0 *', >09 0+,*%0, +,,>' :/ % * ,* %0,. UPS %% >0 :' *,0' % 24$$ :%8 *%' % ,0 ,+ " %% :0< 1 , :0< % , %*0/ :0. A 9' 0+,*%0, 0 *,0' 0 ASCII +,*%. PIN
'*00,
IO /'
1<4<6<7<"<# , ,'' 3
UPS RS232 *''0'* R +*, ,8'*.
08
2
UPS RS232 *%0'* , ,8'*
,88
5
N
1
UPS +%0< *'%/ ,%< ,*%/ ,' %0' ,'.
,88
2
S8%*/ %%*< *'%/ ,%< ,*%/ ,'< %0' ,'.
,88
O' ,+ 9' +,,>0& ,00, %0%' 90 0&% . UPS +%0 . B/% %0' . B%'*/ ,> . U00/ +%0 . I'*'* ,8 ,+ ,*'* 3
N.C.
4
N.C.
5
C,,
6
B/% %0'< ,*%/ ,'< %0' ,'
,88
7
B%'*/ ,>< ,*%/ ,'< %0' ,'
,88
"
UPS ,< ,*%/ ,'< %0' ,'
,88
#
U00/ +%0< ,*%/ ,'< %0' ,'
,88
STS
I/P EMI-PCB
Line
AC/DC an% DC/DC B''6&C'n7er&er
DC/AC In7er&er
I/P N)B
O/P EMI-PCB
L'a%
O/P N)B Ba&&er: Bank
Carer
B,A 0%&*%
)i3re 1
MAINT BPS SW(
BYPASS
L210
D263
+BUS
BATSCR Q217
Q222
I/P NFB
I/P
BAT+
I/P
4
D G
D
2 1
S
G
S
L202
L201 4
G
S
L209
G D259
-BUS
CHGR O/P
I/P
PCB
6kVABLOCK DIAGRAM
)i3re "
2
D
Q223
S
8
RY2
D
EMI
MAINTBPSSW 6
C
1
O/P(L)
6 8
RY1
O/P(N)
O/P EMI
O/P NFB
O/P
20 21 9 12
3300uF/450V
3300uF/450V
C1
11
C2
13
+BUS
-BUS
N L210
BYPASS
D263
MAINTBPSSW
BATSCR
I/P
1P2W 220VAC
TB
I/P NFB N G
P2
P1
L
2 1
Q217
Q222
P3
2
3
PCB
BAT+
I/PEMI
4
I/PCHOKE
4
1
8
L
7
3
G
F204
N
10u/250V L1
PFCPWM
P212 BAT-
G
P213
P211
IGBTPWM
S
-
L202
L201
2
S
8
RY2
1
C*2pcs
G
6
O/PEMI P1 N
8
RY1
PARALELL
O/P(L)
6
O/P NFB
-PCB 2
4
14
1
3
15
30A/250V
16 17
G
PSDR
F202
CN202
CN203
CN201
WHT
CN20750PIN
NFB
+
EXTRABAT 240VDC
OUTLET FAN
G
FAN
BRN WHT GREEN
CN5
TOCNTL-PCBCN5
CONTROL CN116PIN
INTERNAL BATTERY 20PCS 7.0AH
+
P906 CHGRO/P -
P905
+
-
P907
P902 CHGRI/P
P904
+ -
PANNL
P903
6kVAWIRINGDIAGRAM
)i3re #
CN326PIN
P908 P901
CHARGER
CN250PIN
CN601 CN602
-
19
O/P TB 1P2W 220VAC 18 L N
O/P(N)
BLUE
P204
-
S
D259
BAT+ +
1
G
4
L209
N1
MOV-PCB
IGBTPWM
S
2
D
Q223
5
6
D
D
I/P(N)
P4
PFCPWM
I/P(L)
4
D
INTRFACE
+BUS IGBT*2PCS PARALELL
C1
SNUBBER
D
IGBTPWM+
G S
L202
L201
C2E1
INV_OUT
D
IGBTPWM-
G
SNUBBER S E2
-BUS
6kVAINVERTERBLOCKDIAGRAM )i3re 4
C
F901~903
+BUS P901+/P902+
D
D901
Q908
G S
TX901
P905+/P906+
D902
BAT+
CN201/CN202
PWM
C918
D
P907-/P908-
CONTROLLER Q907
CHGRON/OFF
BAT-
G S C928
D903
P903-/P904-
VR901
F904~906
-BUS
6kVACHARGER BLOCKDIAGRAM )i3re
D237 CHGR+
POW
1N5404 R236 619K*
TX201 EE25108*1
R436 100K*
C267
R341
103MP/1KV
R235
R290 100K*
619K*
22K/3W
D233 UF2006
R234
1
10
2
9
3
8
4
7
5
6
D232
D229
UF2006
MUR460
D223
619K* Q210
1N4937GI
PSA44 C280 47U/400V(18)
D ZD202 18V
Q211 2SK2608
G S
PWM CNTROLLER
R264 +24V
+24V
BAT-
R320 1
4
2.49K*
TLP
521
2
R319 C244
R289
470k
C266 104Z
C239
O A
C265 104Z
2200u/16v
Q209 TL431
HFPW+ GND
R322 10K*
1 2 R238 1.5K* R239 1K*
1 2
Q205 Q224
C1815
C2655 R240 10K*
6kVAPOWERDIAGRAM
)i3re 6
1N4007GI
+5V
IC7805 U211 7805
I
R321
470p
47.5K*
FANSP/F
D211 O
7812 A
U210 ICPS2561 3
+12V
IC7812 U212
I
CN202 JST-2P
JST-2P CN203
L210 1 2 3
RECT+
D263 4 5 6
700UH
1
+BUS
2
RHRG75120
v
V
u
U
CT100:1
C
IGBT DRIVER
LINE
SNUBBER
G IRG4PF50W
3300uF/450V
E
PFCCONTROLLER C
IGBT DRIVER
SNUBBER E
v
V
u
700UH
U
CT100:1
L209 4 5 6
1 2 3
D259 2
RHRG75120
FEEDBACK CIRCUIT
6KVAPFCBLOCKDIAGRAM )i3re .
3300uF/450V
G IRG4PF50W
RECT-
CURRENT SENSOR
1
-BUS