Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1. PCB And Wiring ........................................................................................................3 1.1 Power Module..................................................................................................6 1.1.1 Power Circuit ........................................................................................6 1.1.2 Control Circuit ......................................................................................9 (1) Driver Circuit of Rectifier SCR (SCRA1 & SCRA2)......................9 (2) Driver Circuit of Battery SCR........................................................10 (3) Driver Circuit of Inverter Output SCR........................................... 11 (4) Normal AC (Rectifier) Fuse Broken Detection..............................12 (5) Input Voltage Detection..................................................................13 (6) Input Frequency And Zero-Crossing Detection .............................14 (7) Inverter Voltage Detection..............................................................15 (8) Output Voltage Detection ...............................................................16 (9) Inverter Fuse Broken Detection .....................................................17 (10) Inverter Output Current Detection ...............................................18 (11) Inverter Control Circuit ................................................................19 (12) Output DC Offset Compensation Circuit .....................................20 (13) Inverter Ipk Protection Circuit .....................................................21 (14) DC-DC Control Circuit ................................................................22 (15) Driver Circuit for IGBT of DC-DC Converter.............................30 (16) Driver Circuit for IGBT of Inverter .............................................31 (17) Charger .........................................................................................32 (18) Auxiliary Power Circuit ...............................................................34 (19) Auxiliary Power For +/-5V ..........................................................35 (20) Watchdog for Power Module MCU .............................................36 (21) Communication Circuit ................................................................37 (22) Other Detection Circuit ................................................................39 1.2 System Frame.................................................................................................41 1.2.1 Power Circuit ......................................................................................41 1.2.2 Control Circuit ....................................................................................43 (1) Bypass SCR Short-Circuit Detection .............................................43 (2) Bypass SCR Driver ........................................................................44 (3) Output Current Detection ...............................................................46 (4) Input And Output Voltage Detection ..............................................47 (5) AC Auxiliary Power Circuit ...........................................................48 (6) DC Auxiliary Power Circuit...........................................................49 (7) Auxiliary Power Failure Detection.................................................50 (8) Battery Voltage Detection ..............................................................51 1
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (9) Battery Pack Detection...................................................................52 (10) Auxiliary Power For 5V ...............................................................53 (11) LCD And LED Driver ..................................................................54 (12) Watchdog For System MCU ........................................................55 (13) Communication Circuit for RS232 & USB..................................56 (14) Communication Circuit for Minislot............................................59 (15) Communication Circuit For Dry Contact.....................................61 (16) Communication For System and Power module..........................62 (17) EXB Detection Circuit (RJ45) And EPO Circuit (RJ12) .............65 (18) Other Detection Circuit ................................................................66 2. Troubleshooting .......................................................................................................67 2.1 Internal Fault..................................................................................................67 2.1.1 Alarm 34: CHARGER FAULT.............................................................67 2.1.2 Alarm 193: FAN FAULT......................................................................68 2.1.3 Alarm 004: UPS TEMPERATURE FAULT.........................................69 2.1.4 Alarm 701: INVERT FUSE BLOWN...................................................70 2.1.5 Alarm 100: NORM AC FUSE BLOWN...............................................71 2.1.6 Alarm 30: RECTIFIER FAULT ...........................................................72 2.1.7 Alarm 28: DC BUS +/- TOO HIGH/LOW ..........................................73 2.1.8 Alarm 31: INVERTER FAULT ............................................................74 2.1.9 Alarm 191: BATTERY FAULT.............................................................75 2.1.10 Alarm 36: AUTO BYPASS FAULT ....................................................76 2.1.11 Alarm 00A: DC POWER SUP FAULT..............................................77 2.1.12 Alarm 63: INTERNAL COM FAULT.................................................78 2.1.13 Alarm 006: COM FAULT BETW UPS ..............................................79
2
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1. PCB And Wiring Fig 1.1 B
LCD
A
WL1 #22 WL2 CNL2
M
WB2(P1)
6
WB4(P2)
5
CNA12(P2)
WB1(N1)
4
CNA10(N1) CNA11(P3)
WB3(P3)
3
WB6(BATT+)
2
WB9(B-)
1
CNB1
26p
CNA9(P1)
CNA4(BATT+) CNA5(B-)
34p
CNM1
#22
CNB4
20p CNM5
26p
21
WE6(O/L)
25
24 35
26p
G
CNP3
WG5 WG6 CNG4
32 31 22
CNG3(#10)
14p
CNP4
CNG1 (INV/L)
#18
CNG9 (O/L) CNG8 (N1)
CNG7 (IP/L)
WE3(B-) WE1(B+)
WE8(FG) CNE2(FCI) WE12(IP/L) WE5(IP/N)
CNG2(#10)
CNE1
CNV7
23
PDU
#10 EXTB-
EXTB+
12 13
CNG10 (IP/N)
20p CNV5
CNP9(B-)
CNP1(B+)
CNP8(B+)
CNP12(B-) CNP2 WP1(G3) WP2(+12VF) WP3(-12VF)
#22
10 11
30
P #10
8
WD11(ON) WD14(G3)
WD3(B+) WD4(B-) WD1(IP/L) WD2(IP/N) WD5(FG) WD6(O/L) CND2(FCI) WD7(O/N)
CNS12 CNS6 CNS10 CNS11
CNS1
7
E
CNV3
CNS8
WD10(+12VF)
CND1
#12 #12 #12 #12
V
S
#22
CNB5
CNA1
CNA6(O/N) CNA7(O/L) CNA3(IP/N) CNA2(IP/L)
15
CNS2
CNB3
CNB7(B-)
Minislot
CNP7
CNM3
CNB6(B+)
D
CNP14
CNB2
CNM4
Battery
efza
CNM2
EXT BAT
34
33
28 29
33
G N L OUTPUT
G N L INPUT
Terminal
3
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING WIRE LABEL
WIRE
COLOR
POSITION
1
AWG 10# BLACK B BOARD WB9 TO A BOARD CNA5
2
AWG 10#
3
AWG 10# BLACK B BOARD WB3 TO A BOARD CNA11
4
AWG 10# BLACK B BOARD WB1 TO A BOARD CNA10
5
AWG 10# BLACK B BOARD WB4 TO A BOARD CNA12
6
AWG 10# BLACK B BOARD WB2 TO A BOARD CNA9
7
AWG 10#
8
AWG 10# BLACK D BOARD WD4 TO B BOARD CNB7
10
AWG 10# BLACK D BOARD WD1 TO A BOARD CNA2
11
AWG 10# WHITE D BOARD WD2 TO A BOARD CNA3
12
AWG 10# BLACK D BOARD WD6 TO A BOARD CNA7
13
AWG 10# WHITE D BOARD WD7 TO A BOARD CNA6
15
AWG 10#
Y/G
D BOARD WD5 TO CASE G
21
AWG 10#
Y/G
E BOARD WE8 TO CASE G
22
AWG 10# BLACK E BOARD WE3 TO P BOARD CNP9
23
AWG 10#
24
AWG 10# BLACK E BOARD WE12 TO G BOARD CNG7
25
AWG 10# BLACK E BOARD WE6 TO G BOARD CNG1
28
G BOARD CNG3 TO TERMINAL BLOCK AWG 10# WHITE NORMAL AC SOURCE N
29
G BOARD CNG2 TO TERMINAL BLOCK AWG 10# BLACK NORMAL AC SOURCE L
30
AWG 18#
31
G BOARD CNG8 TO TERMINAL BLOCK AWG 10# WHITE OUTPUT N
32
G BOARD CNG9 TO TERMINAL BLOCK AWG 10# BLACK OUTPUT L
33
AWG 10#
RED
RED
RED
Y/G
B BOARD WB6 TO A BOARD CNA4
D BOARD WD3 TO B BOARD CNB6
E BOARD WE1 TO P BOARD CNP1
G BOARD WG7 TO P BOARD NUT
Y/G
TERMINAL BLOCK OUTPUT G TO CASE
33
AWG 10#
Y/G
TERMINAL BLOCK NORMAL AC SOURCE G TO CASE
34
AWG 10#
Y/G
BATTERY CONNECTOR 3PIN G TO CASE
35
AWG 10# WHITE E BOARD WE5 TO G BOARD CNG10
4
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING
5
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1.1 Power Module Power Module includes : A board: Input and Output EMI Filter, Rectifier, Inductance of DC-DC Converter, Inductance of Inverter, Output SCRs and Battery SCR Circuit B board: Switching Devices of DC-DC Converter, Bus Capacitors, Switching Devices of Inverter, Auxiliary Power and Charger M board: MCU of Power module and Control Circuit D board: External Connector of power module
1.1.1 Power Circuit The power circuit of power module is showed as Fig 1.2. The function of main components are described as below: CA1, LA1, LA2, CA6/CA7/CA8: Input EMI Filter FUA1: Normal AC (Rectifier) Fuse CTA1: Input (Rectifier) Current Feedback SCRA1, SCRA2: Rectifier DA3, DA6: Freewheeling Diode During Battery Mode LA8/LA9, LA10/LA11: Inductance of DC-DC Converter Q10/Q11/Q12, Q14/Q15/Q16: IGBT of DC-DC Converter DB1, DB2: Freewheeling Diode of DC-DC Converter C17/C19/C21/C23/C25/C27: DC BUS + Capacitors C18/C20/C22/C24/C26/C28: DC BUS – Capacitors QB18/QB19/QB20, QB22/QB23/QB24: IBGT of Half-Bridge Inverter CTB1: Inverter Inductance Current Feedback LA4/LA5/LA6/LA7: Inductance of Inverter FUA4: Inverter Fuse CA25/CA26: Output Capacitor of Inverter SCRA6/SCRA7: Output SCR of Inverter CTA3: Inverter Output Current Feedback CA34, LA3, CA27: Output EMI Filter QB47, QB50: MOSFET of Flyback Charger 6
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING DB41, DB42: Freewheeling diode of charger TB3: Charger Transformer DB44: Output Diode of Charger CB111: Output Capacitor of Charger DB46: Isolative Diode Between Charger and Battery FUB2: Output Fuse of Charger FUB3, FUB4: Battery Fuse CA18: Battery Capacitor SCRA3, SCRA4: Battery SCR RA12/RA13, SCRA5: Soft-Start Circuit During Cold Start CTA2: Battery Current Feedback TB1: Auxiliary Power Transformer QB44: MOSFET of Auxiliary Power RB191: Inductance Current Detection Resistor of Auxiliary Power RLB1, RB201, DB47: Start Circuit of Auxiliary Power
7
CNA7 (O/L)
CNA6 (O/N)
CNA3 (IP/N)
CNA2 (IP/L)
CA37
CA1
LA3
LA1
CTA3
CA34
LA2
CTA2
SCRA5
SINLA4/LA5/ LA6/LA7
LA10/LA11
DA6
DA3
LA8/LA9
SCRA4
CA18
SCRA3
SIN+
FUA4
RA12/RA 13
CA25/CA 26
A Board
SIN-
SIN+
SCRA7
SCRA6
SCRA2
CTA1
CA6/CA7/CA8
FUA1
SCRA1
CNA5 (B-)
CNA4 (BATT+)
CNA11 (P3)
CNA12 (P2)
CNA10 (N1)
CNA9 (P1)
WB9 (B-)
CNB7 (B-)
WB6 (BATT+)
WB3 (P3) CNB6 (B+)
WB4 (P2)
WB1 (N1)
WB2 (P1) BUS+
DB2
CB111
DB44
BATT+
BUS-
CB18/CB2 0/CB22/C B24/CB26/ CB28
CB17/CB1 9/CB21/C B23/CB25/ CB27
FUB2 DB46
FUB4
FUB3
QB14 /QB1 5/QB 16
QB10/ QB11/ QB12
DB1
DB42
BUS-
QB47
BUS+
BATT+
To UC3845P7
DB10
RB186
DB47
RB201
RLB1
DB41
QB50
RB191
QB44
DB48 NTCB1
B Board
TB3
QB22/QB 23/QB24
CTB1
QB18/QB 19/QB20
CNB5
BATT+
TB1
To -V1 To V3+/V3- (INV Driver)
To V6+/V6- (PFC Driver)
To V5+/V5- (PFC Driver) DB19
To V3 (Fan) TB2 DB18
To V1
20V to UC3854
DB24 To V4+/V4- (INV Driver)
DB23
DB14
DB12
DB4
DB13
DB20
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Fig 1.2
8
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1.1.2 Control Circuit (1) Driver Circuit of Rectifier SCR (SCRA1 & SCRA2) Located at A board TVSA1
SIN+
CA10 RA6
RA3
V3
6
2
1 2
G
4
RECT+'
SCRA1
DA2
RA7
DA4
A
JPA1
UA1
1
CA11 K
DA1
RA4
V3
JPA2
1 2
UA2
1
RA8 CA13
TVSA2 CA14
6
2
4
SCRA2
RECT-'
RA9
DA5
SIN-
Located at M board 8
(20)
RECT+
(21) (65) (66) (67)
RECTBATSOFT BATSCR1 BATSCR2
7 6 5 4 3 2 1
UM11 ULN2003A GND COM 7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
V1 9 10 11 12 13 14 15 16
RECT+' RECT-' Bs' Bon1' Bon2'
(a) SCRA1 will become a diode if RECT+’ becomes low (b) SCRA2 will become a diode if RECT-‘ becomes low (c) Test JUMP: JPA1: SCRA1 will become a diode no matter what RECT+’ is if JPA1 is shorted. JPA2: SCRA2 will become a diode no matter what RECT-‘ is if JPA2 is shorted.
9
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (2) Driver Circuit of Battery SCR Located at A board RA13
V3
TVSA4
K
RA18
DA10 1
JPA3 1 2
UA3
CA22
RA15
CA21
DA9
G
SCRA5
A
CA20
A
DA8
RA14
G
CA19
SCRA3
K
TVSA3
RA12
DA11
6
2
4
1
6
2
4
RA16 RA17
Bon1' V3
RA19
JPA4 12
Bs'
UA4
(a) During the soft-start process of cold start, Bs’ will be low to turn on SCRA5. The Bus capacitor will be charged by battery through RA12 and RA13. (b) After soft-start, Bs’ will be high to turn off SCRA5 and Bon1’ will be low to turn on SCRA3. Then the input of DC-DC converter will be supplied by battery through SCRA3. (c) Test JUMP: JPA3: SCRA3 will be off no matter what Bon1’ is if JPA3 is shorted JPA4: SCRA5 will be off no matter what Bs’ is if JPA4 is shorted
10
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (3) Driver Circuit of Inverter Output SCR Located at A board
DA15
TA1
SCRA7
CA31
SCRA6
QA1
37KHz
RA35
9
CA29
2 D
INVSTS'
V3
G
RA39
10
CA27
DA16
3
S
1
RA36
6
RA34
CA28
RA38
HSA1
4
CA30
RA37 7
DA14
Located at M board CM144
5V
3
5V
RM3 UM36A
UC33-3 5
2 2V5
4
INVSTS
LM339
12 11
UM15D CD4066B C IN
OUT
10
UC10-3
12
(32) -5V CM131 V1
UC10-3
7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
10 11 12 13 14 15 16
RM35
7 6 5 4 3 2 1
V1 9
RM34
8
UM10 ULN2003A GND COM
INVSTS'
(a) The driver signal is generated by MCU (Pin32). The frequency is 37Hz. (b) The output of driver signal is control by Watchdog (UC33-3). If Watchdog is active low, then UM15D is disable and inverter output SCR can’t be turned on. Refer to “Watchdog for Power Module MCU” for UC33-3 signal.
11
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (4) Normal AC (Rectifier) Fuse Broken Detection Located at A board FUA1 LA2
CTA1 2
1
4
3
1
2
*
DA18 DA17
RA44
RA28
RA45
FB
RA29 FA
Located at M board RM122 5V V1
CM148
RM235
3
RM124 RM117
RM212
QM25
*
IP_FUSE
5
FA
(4) 2
CM130
4
FB
RM170
12
RM64 CM149
UM3A LM339
DM24
ZDM2 5V
RM234
RM45 V1
(a) If fuse (FUA1) is not broken, then FA should be equal to FB and IP_Fuse (4) will be active high. (b) If fuse (FUA1) is broken, then FA > FB then IP_Fuse (4) will be active low.
12
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (5) Input Voltage Detection Located at A board RA1
Vi1
RA2
FUA1 LA2
CTA1 2
1
4
3
1
2
*
Located at B board CB41
RB65 DB25
RB67
-V1
RB68
11
Vi1
RB66
CB64
2
DB26
Vin 1
RB69
3
4
RB70 CB42
UB14A TL084 CB65
V1
Located at M board 5V DM2
Vin
RM115 CM9
RM177
VinR (81)
(a) Vin is full rectified sine wave (b) MCU detects the RMS voltage of input through VinR(81)
13
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (6) Input Frequency And Zero-Crossing Detection Located at A board
RA40
RA41 Vi2
FUA1 LA2
CTA1 2
1
4
3
1
2
*
Located at M board
Vi2 5V DM1 1N4148
RM87 10K
CM84 223
RM161 10K
QM13 MMMBT2222A
RM176 100K
RM141
INPZO (24)
1K CM91 102
(a) The waveform at INPZO (24) is square wave (b) MCU detection the zero-crossing through the falling edge of square wave
14
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (7) Inverter Voltage Detection Located at A board
CA26
FUA4
CA25
LA7
RA26
RA27
Vinv2
Located at M board CM90
Vinv2
RM104
RM147
13 RM193
RM194
(75) 14
RM103
12 CM89
RM146
Vinv_R
UM5D
2V5
(a) The waveform at Vinv_R (75) is full sine wave with 2V5 DC offset (b) MCU detects the RMS voltage of inverter output through Vinv_R (75)
15
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (8) Output Voltage Detection Located at A board CTo+RA32 CToLA3
CA34
1
2
RA33
4
3
CTA3 W2
RA30
RA31
Vout
Located at M board CM87 RM143
Vout RM94 9
RM191
UM5C 8
RM93
10
Vout_R
(78)
TL084
RM192 CM85
RM142 2V5
(a) The waveform of Vout_R (78) is the rescale of output voltage with 2V5 DC offset. (b) MCU detects the RMS value of output voltage through Vout_R (78)
16
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (9) Inverter Fuse Broken Detection Located at A board
Vinv3
RA47
RA48
CA26
FUA4
CA25
LA7
Located at M board
-V1 RM236 RM220 9 Vinv3
RM238
11
UM40C LM324 8
13
UM40D LM324 14
12
10 CM22
RM237
4
RM239 V1
5V RM233
DM25
RM221
ZDM1 3V9
QM24
OP_FUSE (11) CM25
CM24
RM232
(a) If inverter fuse (FUA4) is not broken, the waveform of Vinv3 is full sine wave. The line frequency signal can’t go through the high-pass filter (UM40D), so OP_FUSE (11) will be active high (b) If inverter fuse (FUA4) is broken, then the waveform of Vinv3 will be PWM waveform. This high frequency signal can go through high-pass filter (UM40D) and OP_FUSE (11) will be active low.
17
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (10) Inverter Output Current Detection Located at A board
CTo+RA32 CToLA3
RA33 CA34
1
2
SCRA7
4
3
CTA3 SCRA6
Located at M board 5V DM19 RM75
CM88 IOUT RM96
5V
CM60 11
-V1
RM158 6
CTo+
RM95 RM44
RM173
1
UM5B TL084
Iout_R
3
5 4
RM172 CM86
CTo-
RM61
7 RM43
RM62 RM131
2
UM5A TL084
(77)
V1
DM23
RM157
CM59
CM105
-5V
(a) The waveform of Iout_R (77) is rescale of inverter output current with 2V5 dc offset. (b) MCU detect the RMS value of inverter output current through Iout_R (77).
18
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (11) Inverter Control Circuit Located at A board LA7 RA24
RA25
Vinv1
CA26
FUA4
CA25
RA23
Located at M board (112) SPWM_R
CM114
CM116
RM186
9 RM205
RM200 RM97
UM6D 13
CM119
RM98
14
IN C
OUT
8 6
IOUT
IOUT
RM206
5V
UM15C CD4066B
RM179
RM199
12 RM187
CM101
TL084 CM117
UM36B 7 1 6
RM189 Vinv1
CM118
RM119
-V1 CM10
11
RM144
V1
1
TPM1 RM100
UM6A TL084
DM18
4 RM174
UM4A LM339
V1 CM75 RM188
3
1 2
CM79
INVCLK
-V1
-V1 V1 CM103 RM99
QM17
UM4B
UM6B TL084 6
RM155
6 1 7
RM101
7
14
INV-L
8 LM339
RM106
TPM2 RM121
9
5
CM69
INV-H
QM20
V1 TPM4
(33)
UM4D LM339
CM64
RM190 CM100
RM203
11 CM102
V1
RM120
13
RM102
2 5
4
DM17
QM16
10
3
DC OFFSET Compensator
CM63
(63)
RM154
2
RM202
DIS_DROOP
V1
CM65 -V1
CM95
12
RM162
JPM4
2V5
TPM3
RM204
17KHz
DM11
UM4C LM339
DM13
Inverter Ipk Protection
1 2 -V1
QM21
JPM1 -V1
(a) The waveform of UM6D-P14 is the reference sine wave generated by SPWM_R (112) through band-pass filter (UM6D) (b) Vinv1 is the feedback of inverter output (c) The waveform of UM6B-P7 is the triangle waveform generated by INVCLK (33) through integrator (UM6B) and the frequency is 17kHz (d) DIS_DROOP (63) is used to enable or disable the current feedback. DIS_DROOP (63) is high to disable the current feedback during standalone operation. DIS_DROOP (63) is low to enable the current feedback during parallel operation. (e) Test JUMP: JPM1: Inverter is disabled if JPM1 is shorted JPM4: DC offset compensation circuit is disable if JPM4 is shorted (f) Test Point: TPM4: Triangle wave TPM3: Inverter driver command (output of error amplifier) TPM1: Driver signal of top leg of half-bridge inverter TPM2: Driver signal of bottom leg of half-bridge inverter Refer to “Output DC Offset Compensator Circuit” for DC OFFSET Compensator signal. 19
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Refer to “Inverter Ipk Protection Circuit” for Inverter Ipk Protection signal (12) Output DC Offset Compensation Circuit Located at B board BUS+
QB18 CB27
WB3 P3
1
CTB1
RB36
P3
RB37
RB171 *
QB22
RB38
CB67
OS
TVSB4 P6KE18CA
CB28
BUS-
Located at M board 5V RM123 UM36C LM339 14
9
2V5
8
(5) OFFSET 5V
UM15B CD4066B
14
CM61
3
OUT
7
IN C
4 5 UM15A 13 1
CM15
C IN
-5V
CD4066B 2
OUT
CM115 CM113
OS
RM178
RM168
RM197 RM198
9 8
CM112
CM111
10
DC OFFSET Compensator
UM6C TL084 CM68
RM105
RM208 HOLD
-V1
RM207 HOLD
VRM1 HOLD
RM209
V1
HOLD
(a) The feedback signal is from the central point of inverter leg (P3). (b) UM6C is used to generate the output DC feedback signal by integral the signal OS. (c) OFFSET (5) is low to enable UM15B and UM15A to reset and disable the integral circuit (UM6C) while inverter is off.
20
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (13) Inverter Ipk Protection Circuit Located at B board BUS+
QB18 CB27
WB3 P3
1
CTB1
CTp+
BDB1
QB22
2
CB28
3
AC
+
AC
-
RB32 RB33 Hold
1 4
CTp-
BUS-
Located at M board Inverter Ipk Protection V1
6 UM3B LM339
V1 RM195
(29) INVIPK
RM222
DM9
D
(75) Vinv_R
9 14
S RM148
CM123
3V9 CM5
RM107
RM226 11
13
8 QM1
RM149
V1
RM196
RM164 DM14
QM18
ZDM8
2V5
RM181
3
RM224
G DM8
CM13
V1
CM72
RM159 RM223
INVEN (30)
1
DM12
DM10
RM108
7
RM163
10
CM70 RM175
12
UM3C LM339
CM92
RM225
UM3D LM339
2V5
RM201
CM74
CM73
CTP+ CM12
RM180
-V1 CTP-
CM71
(a) UM3D is used to disable Inverter during the start period of auxiliary power (b) If INVEN (30) is low then Inverter is disabled. (c) UM3C is used for inverter Ipk protection. CTP+ is the current feedback of inverter inductance. (d) There are two level for Ipk protection: 1st
level is
2nd level is
RM 107 ×V1 RM 159 + RM 107 ( RM 107 // RM 224) ×V1 RM 159 + ( RM 107 // RM 224)
(e) INVIPK (29) will be high to keep the Ipk to 1st level during the start of inverter (f) If Vinv_R (rescale of output voltage) is normal, then Ipk will keep at 1st level. If Vinv_R is lower than a specific level (for example, output short circuit) then the Ipk will change to 2nd level (g) The inverter output short circuit protection is about 100A.
21
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (14) DC-DC Control Circuit Enable/Disable Circuit Located at B board
CB49
9 2
3
4
5
7
11 15
16
20V
CB54
6
UB5 UC3854
8
RB80
V1
10 QB40
1
12
14
13
RB129
PFC
RB119 CB56 CB55
RB128
Located at M board
(34)
PFCEN
RM135 1K
PFC
(a) If PFCEN (32) is low then the controller of DC-DC converter is enabled. If PFCEN (32) is high, then the DC-DC converter is disabled.
22
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Bus voltage feedback circuit Located at B board Vselect 2
Vbus+
RB214
RB212
RB138
Hold
CB60 QB29
RB210 UB6D 10
OUT
RB122 CD4066B
V1
C IN
12 11
RB139
Vselect
RB136
CB52
RB134
8
C IN
RB145 BUS+
RB146
CB61
RB278
UB6C OUT
RB144
QB41
RB135
9
RB143
10
UB14C TL084
CB100 Hold
CB53
RB123
RB142
9
RB137
DB51
RB121
RB141
RB140
TPB5
6 8
CB128
UB17B LM339
TPB4 Q
6
CB130
1 Vselect
CD4066B
RB150
DB52
RB274
RB275
7
CB95 Hold
RB277
V1
CB129
RB151 RB276 CB51
RB148
Vselect 2
9 2
3
4
5
7
CB63
QB42 RB152
RB120
RB149
15 16
6
UB5
QB30
CB66
14
RB157
RB158
RB159
RB153
RB166 CB96
RB167
13
12
12
RB156
Vbus-
10 1
RB155
BUS-
12
RB211
8
RB154 13 14
UB14D TL084 RB147
Hold
RB213
11
RB215
CB97 V1
UB17A LM339
4
2
RB165
5
P
RB161
3
CB80 CB101
V1
RB163
Located at M board 5V
5V DM4
RM89
Vbus+
DM5
Vbus+' (88)
Vbus-
RM90
Vbus-' (100)
RM183
RM184
CM53
(35)
BUSEL
(9)
BUSEL2
(89)
CM54
RM114
Vselect Vselect2
RM139
(a) UB6C and UB6D are used to selectively feedback Bus+ or Bus- voltage to 23
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING UC3854 according to signal TPB5 and TPB4. (b) MCU detects DC Bus + voltage through Vbus+’ (88) and detects DC Bus- voltage through Vbus-‘ (89) (c) If BUSEL (35) is high, then DC bus +/- will increase to about +/-395Vdc (d) Net P & Q are used for Vpeak protection. The Vpeak is set at 420Vdc. Refer to “Positive And Negative Cycle Switching” for TPB5 and TPB4 signals Refer to “Output driver Signal” for P & Q signals. AC mode and backup mode switching Located at B board
V1
V1
RB73
RB91
AC
BC
RB88
backup
RB86 QB36 RB87
JPB2
QB35 RB169
1 2
Located at M board
(66) BATSCR1
RM136
backup
(a) If BATSCR1 (66) is high, then “AC” signal=low and “BC”=high, UPS is at backup mode. If BATSCR1 (66) is low, then “AC” signal=high and “BC”=low, UPS is at AC mode. (b) TEST JUMP: JPB2: Short JPB2 will change the DC-DC converter operating at backup mode
24
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Positive And Negative Cycle Switching Located at B board V1 Vi2
RB84
V1
RB82 RB133 HOLD
UB14B 6
RB34
7
QB38
V1
TPB4
RB35
RB93 QB39
TPB5
5
RB18
RB81 CB47 TL084
RB83 DB27
RB31
RB92
DB3
RB85
AC
RB89
p/n
DB30
DB29
RB90
QB37
BC
Located at A board
RA40
RA41 Vi2
FUA1 LA2
CTA1 2
1
4
3
1
2
*
Located at M board (52)
PFCSQR
RM138
p/n
(a) During positive half cycle, TPB4=low and TPB5=high. During negative half cycle, TPB4=high and TPB5=low. (b) During AC mode, the positive and negative half cycle are decided by input voltage (Vi2). (c) During backup mode, the positive and negative half cycle are controlled by PFCSQR (52). Refer to “AC mode and backup mode switching” for “AC” and “BC” signal 25
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Vrms and Iac Feedback Circuit Located at B board CB41
RB65 DB25
RB67
-V1
RB68
11
Vi1
RB66
CB64
2
DB26
Vin 1
RB69
3
BAT+
4
RB70 CB42
AC
UB14A TL084 CB65
RB74
RB72 CB44
V1
Vbatt
BC
V1
IN C
OUT
2
UB6A CD4066B UB6B 4 5
IN C
OUT
3
CD4066B
9 2
8
3
4
5
UB23A TL0721
16
RB76 4
8
RB118
10
-V1
RB79
1
12
14
RB124 Hold
6
UB5 UC3854
CB45
RB78
11 15
2
CB43
7
13
Hold
3
RB263
RB75
RB77
1 13
RB71
RB125 CB57
RB126 V1
RB127
CB58
CB46
Located at A board RA1
Vi1
RA2
FUA1 LA2
CTA1 2
1
4
3
1
2
*
(a) During AC mode, the feedback of Vrms (UC3854-P8) and Iac (UC3854-P6) is from Vin (b) During Backup mode, the feedback of Vrms (UC3854-P8) and Iac (UC3854-P6) is from Vbatt Refer to “AC mode and backup mode switching” for “AC” and “BC” signal
26
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Current Feedback Circuit Located at B board RB96
V1
RB97
DB33
V1
RB98
RB100
11 13
Ipeak
RB99 CTi-
RB115
RB101
10
RB113 UB17D LM339
RB112 DZONE
DB40
RB111 RB114 RB110
ZDB10
CB59
CB50 RB116 RB117 DB39
9 2
CB48
3
4
5
7
11 15
16
6
UB5
8 10 1
12
14
13
Located at A board
Battery Discharge Current CTA2
AC Input Current CTA1 4
DA7
CTi3
1
2
BDA1 RA5
3 2
AC AC
+
4
RA10 RA11 HOLD HOLD
-V1
CA17V3
1
Located at M board
(50) D-ZONE
RM33
DM16 DZONE
(a) CTi- is the combination signal of AC input current and Battery discharge current. 27
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING During AC mode, CTi- will feedback the AC input current. During backup mode, CTi- will feedback the battery discharge current. (b) During AC mode, D-ZONE (50)=low. During backup mode, D-ZONE (50) will provide 5V/550us pulse around zero crossing of inverter output voltage to disable the gate signal of DC-DC converter. This function is used to prevent battery short-circuit in common battery structure. Refer to “Output driver Signal” to Ipeak signal
28
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Output Driver Signal Located at B board RB104 DB31
UB8B D+
6
4071
RB94
D-
CB62
DB38
1
RB109
16
6
UB5 UC3854
8
13
RB95
11
RB108
12
JPB1
UB8D 4071
2 1
10
RB106
34KHz
1
12
14
13
DB37 RB103
BC
11 15
UB8C 4071
2
3
4071
RB105
8
DB32
P
UB8A
V1
7
10 V1
Q
TPB5 DB34
9
4 5
RB102
Ipeak
RB107
TPB4
DB36 DB35
(a) During positive half cycle, TPB5=H and TPB4=L During negative half cycle, TPB5=L and TPB4=H (b) During AC mode, BC=L During backup mode, BC=H (c) During positive half cycle of AC mode, D+ is PWM control and D-=L During negative half cycle of AC mode, D+=L and D- is PWM control During positive half cycle of backup mode, D+ is PWM control and D-=H During negative half cycle of backup mode, D+=H and D- is PWM control (d) Test JUMP JPB1: If JPB1 is shorted, then DC-DC converter is disabled. Refer to “AC mode and backup mode switching” for BC signal Refer to “Positive And Negative Cycle Switching” for TPB4 and TPB5 signals Refer to “Current Feedback Circuit” for Ipeak signal
29
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (15) Driver Circuit for IGBT of DC-DC Converter Located at B board V1
RB2
V5+
QB5
CB7 QB1
RB1
D+
RB5 CB5 UB1
1 2 3 4
RB62 TPB7
RB11 RB12
ZDB1 18V
8 7 6 5
QB10 QB6
QB48 RB6
D-
V1
V6+
CB6
RB3 1 2 3 4
TPB6
UB2
ZDB2 18V
CB8
V5-
RB4
RB13
RB9
TLP250
QB3
RB19
8 7 6 5
CB9 ZDB3 18V
QB7 RB14 RB15 RB20
RB7
RB16
RB10
RB63
QB8
TLP250 QB49 CB10RB8
QB14
ZDB4 18V
V6-
Refer to “Output Driver Signal of DC-DC Control Circuit” for D+ and D- signals
30
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (16) Driver Circuit for IGBT of Inverter Located at B board CB31 V3+
QB20
ZDB5 18V
RB47
QB25
CB33
RB39
RB45
RB44
RB43
UB3
8 7 6 5
RB46
1 2 3 4
INV-H
RB49
TLP250
QB26
ZDB9
RB48
-V1
ZDB6 18V
CB32
QB24
V3-
RB55 V4+
CB34 QB27 RB56
ZDB7 18V
RB59
RB57
CB36 RB58
RB51
QB28
8 7 6 5
UB4
TLP250 RB60
1 2 3 4
ZDB12 INV-L
RB50 -V1
ZDB8 18V CB35
V4-
Refer to “Inverter Control Circuit” for INV-H and INV-L signals
31
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (17) Charger Located at B board CB116
RB244
RB245
RB251 UB23B 6
RB162
RB130 D QB50
RB231
S
4
6 5
DB49 CB107
RB64
10 9
3
3 TB315,16 BUS-
5
CB40
10
1
GND
Vin
ZDB13
S
DB43
+15V
RB237
12,13 RB238
CB103
RB264 8
3
1 2
7
BUS-
RB183
2
RB182
3
CB104
1
VFB
4
VCC
2
3
COMP
70KHz RB185
CB105 BUS-
8
QB43
VREF
6
OUT
RB220
1
UB18
1 2
RB239
V1
B/T
NTCB2
4
CB113
2
RB17
UB22
3
VRB1
1 2
RB249
V1
B/C
RB267 RB242 Hold
UB20 R
4
BUS-
RB228
A
GND
RT/CT
3
ISEN
CB108 RB229 UC3845N
RB240 CB114
RB243
RB230
5
V1
4
UB16
1
RB235
RB221 CB106
UB19
K
CHi
UB24
RB181 4
4 3
JPB3
CB98
V1
UB9
F 4A/250V
CB111
D QB47
UB21
1
BATT+
FUB2
RB236
G
RB168
P6KE18CA UA7815K 2
CB38
RB232
TVSB2
BUSDB8
DB46
DB41
RB131
CB115
CB109
DB44
Vcharge
5
RB250
RB52
TVSB1 P6KE18CA
TB4
7
RB247
DB42
G
RB164
RB246
BUS+
2
3
C/O
BUS-
Located at M board
B/T QM2
RM6
(107) BTTEST
RM1 5V UM10 ULN2003A 8
(68) (96) (95)
CHRGI BCHG DCHG
7 6 5 4 3 2 1
DM6 V1 GND COM 7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
9 10 11 12 13 14 15 16
Vcharge CHi B/C C/O
RM91 RM185
Vchg (90)
CM55
(a) If DCHG (95)=H, then charger will be off (b) If BCHG (96)=H, then charger will go into boost charging mode. The charger voltage will increase to around 210Vdc (c) If BTTEST (107)=H, then charger voltage will decrease to around 160Vdc to perform battery test (d) If CHRGI (68) =L, then the charger current will be about 0,6A. If CHRGI (68)=H, then the charger current will increase to 2A. 32
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (e) MCU detects the charger voltage through Vchg (90) (f) Test JUMP: JPB3: NTCB2 is used to compensate the charger voltage according to ambient temperature. If JPB3 is shorted, the charger voltage should be 194,1Vdc by adjusting VRB1.
33
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (18) Auxiliary Power Circuit Located at B board RB203 RB132
CNB10
4
2
BAT+
RLB1
CB37
G3
CNB11
BAT+ 3
V1 20V
RB201
CB69
DB20
CB94
V3
RB202
RB40
4 Vx
CB74 CB71
7 2 1
1
4
CB70 2
RB197
3
DB11
70KHz
VREF
OUT
CB2
6
CB85
CB3
1 -12V
3
-V1
UB15 7912
D G
Vin
QB44
4
TB2
RT/CT
ISEN
5
CB92
DB23
RB192
3
RB262
RB258
10
CB77
V5+
DB18
V3+
2
CB86
RB191
CB76
RB268
10
S
RB190 GND
4
K
2
RB189
CB75
UB13
R
2
HSB5
COMP
RB188
CB79
RB199
7
DB14 VFB
CB112
6
RB179
UB7 UC3845N
RB187 8
CB78
CB82
CB84
CB72
RB196 RB198
CB83
CB73
3
UB12
V1
1
4
2
LB10 DB13
14
1
UB11
1
RB204
DB4
5
TVSB3 NTCB1
VCC
RB184
Poff
VFAN'
QB45
GND
DB48
G S
13
RB257
BATT+
D
CB99
DB10
RB186
G3
DB6
CB81
TB1
DB47 QB2 RB170
RB160
CB4
DB12
V1
RB266
BATT+ G3
V1
Fan'
DB61
3 2 1
DB21
1
CNB5
DB62
V1
+12VF
CB68
1 2 3
3 2 1
TO D
9
DB19 7
9
V3-
DB24
V5-
RB269 V6+
CB93
RB259
12 A
V4+ 6
CB87 11
V6-
V4-
Located at M board ZDM10
Fan'
5V(1/2W)"1206"
RM137
FAN
(54) UM10 ULN2003A
UM11 ULN2003A 8
(31)
(a) (b) (c) (d)
DAUX
7 6 5 4 3 2 1
V1 GND COM 7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
8
9 10 11 12 13 14 15 16
(51) Poff
VFAN
7 6 5 4 3 2 1
V1 GND COM 7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
9 10 11 12 13 14 15 16
VFAN'
If DAUX (31)=H, then the auxiliary power will be off The start of auxiliary power is controlled by System MCU through RLB1 VFAN (51) is PWM signal to control the speed of fans MCU detects the fan failure through FAN (54)
34
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (19) Auxiliary Power For +/-5V Located at M board QM19 V1
5V RM118
CM104
CM57
RM127
RM126
K
CM11
R
UM34 TL431(0.5%)
RM128 A
CM121
-V1
V1
-5V 3
RM145 DM7 CM122
CM39
2V5 K
UM14 79L05
-5V GND
CM58
Vin
1
2
CM4
R UM35 TL431(0.5%)
CM67
A
CM120
35
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (20) Watchdog for Power Module MCU Located at M board 5V POWER_RDY (10)
8
2 5
JPM3
R
VCC
4
TRIG CVolt
Q
THR
DM20 A
3 7
RM108
A RM215
CM13
5V
INVEN (30)
RM181
6 RM4 CM129
1
CM6 DM15
UM33 NE555
DIS GND
QM10
RM217
2 1
UC33-3
CM7
CM128
RM213
RM116
QM22 TPM5
(a) POWER_RDY (10) will send out pulse to reset CM129. And then CM129 will be charged again by 5V through RM215. UC33-3 will keep high level. If POWER_RDY (10) doesn’t send out pulse for a specific period (for example: MCU is crash) then UC33-3 will be low. (b) Test JUMP: JPM3: If JPM3 is shorted, then UC33-3 will be low or UC33-3 will keep high during normal operation.
36
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (21) Communication Circuit Part 1 Located at M board 5V 5V
RM240
RM218
TOMBYP
RM9 TOMBYP_I UC33-3 1 RM130
UM16
2
4
(16)
4
UM39
RM219
1
+12VF
RM231
CM150
ID1OK
3
2
CM18
3
QM26 RM17
QM7 G3 5V
+12VF
G3 RX
+12VF
RM8 QM23 RM10
(53)
4
SYS_RDY CM16
RM11 5V
UM17
1
3
2
CM17
1 RM46
RM230
UM18
4
2
3
RM12 INT_TX1 BYPOK
G3
RM14
QM3
(3) RM229
5V
+12VF
+12VF
RM18 RM76 (108) BYP_FAIL CM8
RM77 4 3
UM38
DM21
1 2
5V
RM22
RM13 4
INT_RX1 (2)
CM19
3
UM20
TX DM22
RM24 1 2
BYP-F QM15
G3
(a) If Power MCU is operating normally, power module will send out ID1OK signal (b) If System MCU is operating normally, SYS_RDY (53) will be low (c) Power MCU can detect AC utility failure through BYP_FAIL (108). BYP_F signal is send by System MCU. (d) Power MCU can detect the switching of manual bypass switch from TOMBYP_I (16). TOMBYP signal is the combination signal from auxiliary windings of manual bypass switch. (e) INT_TX1 (3) and INT_RX1 (2) are used to communicate with computer through RS232 port for firmware upgrade purpose. Refer to System Frame for RX and TX signals Refer to “Watchdog for Power Module MCU” for UC33-3 signal.
37
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Part 2 Located at M board 5V
VS
RM31
QM9 RM65
RM29
5V
1
UM37
RM30
4
QM14
RM67
UM12D 1
2
3
G3 VS
SYNC_O
RM28
UC33-3
9
8
ZDM6
4
2
3
5V RM69
CM35
(25) 5V
RM70
1
3
CM37
2
VS QM4
RM16
ZDM3
RM19
UM12B 1 4
UM25
4
SYNC_I
TOBYP
CM21
UM19
4
2
CM26
3 RM20
5V
5V RM21 4
TOBYP_I CM20
(17)
1
3
RM49 1 5
TOINV_0
6
2
INT_TX QM5
13
12
CM124
5 RM129
UM31
G3
4
2
CM33
3
CM97 5V
5V +12VF
UM12C
4
TOINV_I CM27
3
UM23
+12VF
RM132
2
6
INT_RX CM31
(59)
CM125
RM210
1
RM54
1
2
5
3 UM32
CM126
4
G3
RM48
RM125
RM58
7 8
5V
INT_DATA ZDM9
TOINV ZDM4
UM22
RM214 CM98
6
3
(60)
VS
CM29 RM53
(13)
2
UM12F CM23
RM52
5V
QM8 G3 1
UM21
VS
RM211
RM23
8 7
RM15
+12VF CM96
+12VF
G3
4
(12)
(18)
+12VF
G3 RM66
3
CM38
RM68
(26)
QM11 RM63
TOBYP_0
SYNC_BUS
CM36
UM24
(a) If Power MCU is operating normally, then VS is on. VS is the power source for communication circuit: TOBYP_O, TOINV_O, SYNC_O and INT_TX. If Power MCU is not operating normally (for example: MCU is crash), then VS is off to prevent the parallel bus is locked (b) TOBYP and TOINV signals are used to synchronize bypass mode and inverter mode transfer (c) SYNC_BUS signal is used synchronize the inverter and bypass voltage. (d) INT_DATA signal is used to transfer information between Power MCU and System MCU. Refer to “Watchdog for Power Module MCU” for UC33-3 signal.
38
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (22) Other Detection Circuit Located at M board 5V
5V
RM7
RM2
JPM2
CNM1 1 2
1 2
PWR_RELS CM145
REPAIR (1)
CM14
(19)
5V Vbatt
5V
V1 DM3
RM88
RM86 NTCM1
RM84
QM12 ZDM7
Vbat
(91)
TH2 CM62
RM182 CM52
RM85
TEMP
(93)
CM51
7V5 RM216
Located at B board BAT+
RB74 CB44
Vbatt
V1 8
RB75
UB23A TL0721
3
CB43
2
RB76 4
CB45 -V1
RB77
RB78
RB79 CB46
Located at B board
TH2
TH3
2 1
THB2
2 1
THB1
39
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Located at A board
WA2 #22 WA3 #22
TH3 1
1
(a) Power MCU detects the power module is released by PWR_RELS (19). CNM1 is the switch at the front of power module beside the fan. (b) MCU detects the battery voltage through Vbat (91) (c) MCU detects the temperature inside power module through TEMP (93). TH2 is connected to the thermal switches on B board and A board. THB2 is located on Heatsink HSB2 and THB1 is located at Heatsink HSB1. TH3 is located at HSA2. (d) Test JUMP: JPM2: If JPM2 is shorted, MCU will go into repair mode (e) CNM6 is used for programming the MCU by BDM (f) CNM9 can connect to specific LCD to show the information of power module
40
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1.2 System Frame System frame includes: G Board: Input EMI Filter and Bypass SCR P Board: Auxiliary power for system S Board: System MCU and control circuit. Circuit for RS-232, dry contact, RJ12 and RJ45. C Board: Extend board for S board V Board: Circuit for USB, Parallel port and minislot E Board: Connector to connect with power module
1.2.1 Power Circuit The power circuit of system frame is showed as Fig 1.3. The function of main components are described as below: CG1, LG1: Input EMI Filter CTG1: bypass SCR short-circuit detection and back-feed protection CTG2: Output Current detection CG4: Output EMI Filter LP2: EMI filter of AC auxiliary power circuit TP2: AC auxiliary power circuit. The input source is from AC utility. TP1: DC auxiliary power circuit. The input source is from battery source. DP23: Provide generated voltage from TP2 to TP1 input. With this diode, UPS can start without battery CNP14: On switch
41
L
N G INPUT
CNG10 (N1)
CG1
CNG1 (INV/L)
CNG8 (IP/N)
G Board
CG4
CTG2
CTG1
LG1
CNP9 (B-)
CNP12 (B-)
CNP1 4 1 2
CNP8 (B+)
CNP1 (B+)
1 2
FUP2
CNP3
RP15 4
RP15 5
DP8
FUP1
LP2
CP82
NTCP2
G2
G2
G2
RP160
DP27
CP148
DP23
CP147
DP22
To UC3845-P7 G2
DP28
P Board
RP179
QP12
RP2
RP1
RP180
QP22
CP146
NTCP3
To UC3845P7
DP14
G2
DP20 TP2
TP1
G2
CNG9 (INV/L)
CNG3
CNG2
CNG7 (IP/L)
WG6
WG5
CP15
CP12
CP7
CP13 DP7
DP3
DP32
CP88
CP86
DP31
DP15
DP5
DP33
CP89
CP90
DP34
DP17
G3
DP4
DP16
G1
DP1
DP18
G3
DP6
DP19
G1
DP2
To -12VF
RP39
To +12VF
To -12VS
G3
RP38
Vi Vo Adj
LM317
G1
LM7912 I O G
To +12VS
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Fig 1.3
L N G OUTPUT
42
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 1.2.2 Control Circuit (1) Bypass SCR Short-Circuit Detection Located at G board CTG1
CNG2
4
3
3 2
1
4
2
G1
1
1
1
WG1 #10 CT1
4
1
6
LG1
3
1
1
2
CG1
MOVG1
WG10 #10 *
DG2
2,3 1
1
SCR
CNG3
DG3
4,5 6
Located at S board
+12VS
RS234 9
US9C TL084
5VS DS4 8
CT1
QS4
RS227
RS235
(53) SCRSD
RS34
10 QS5
RS231 RS228
RS229 +12VS
DS2 CS127
CS128
RS230
CS129
RS84
G1
(a) During battery mode, bypass SCR should be off and CT1 should be zero. If there has current through CTG1 then SCRSD (53) will be Low. UPS will turn off the inverter to prevent back-feed voltage.
43
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING
WG8 #22
WG11 #22
1
1
(2) Bypass SCR Driver Located at G board SCR TG1 +12VS
2
THS1-1 QG1
CG9
DG3
4,5
THS1-1
G
RG15
9
DG2
2,3 1
RG1
CG6
D BYPSTS
DG1
3 S
10
6
DG5
RG17
RG18
6
RG16
CG10
CG7
RG19
CG8 4
G1
7 G1 5
DG4
Located at S board RS217
5VS THS1
(91) CPU-P91
RS67
RS162
CS24
RS163 QS24
G1
Located at S board 5VS +12VS
RS18
5VS
CS10 5VS RS11
US36 QS15
5
CVolt
RS17
RS2 5VS RS12
THR
US15B-P3
6
US5D 4081
G1
CS19
RS3
TO US36-P6
8
GND COM
7 6 5 4 3 2 1
7B 6B 5B 4B 3B 2B 1B
5VS
CS25
RS8 QS13 G1
RS74
TO US36-P4
(33) BYPSTS
BYPSTS
9 5VS CS32 1 US5A 2 4081
6
DS18 4
BYP_STS
B9
RS53
TOBYP_I
TO US36-P6 DS8
3
4
US5C 4081 (105) TOBYP_I
G1
RS118
5VS
US5B 4081
10
(49) TOBYP_O
3
G1
DS10
RS117
811
US15B-P3 G1
10 11 12 13 14 15 16
MM74HC14 US20B
DS11
G1 RS9
7C 6C 5C 4C 3C 2C 1C
ULN2003A G1
1
US4 TLC555C
DS13
RS47
RS19
3 7
13
DIS GND
TRIG
Q
CS41
R
2
12
VCC
4
G1
8
G1 5VS
+12VS 9
TOBYP_I (105)
RS114
B10 CS49
5 G1
44
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Located at V board RV48
VS
QV2 5VS
RV33
1
UV14
ZDV2
4 CV13
B9
2
CV16
3 RV50 G3 RV62
+12VF B10 G1
4 3
UV15
RV18
TO BYP
1 2
CV21
(a) THS1-1 is connected to the thermal switch located at heatsink of bypass SCR. If the thermal switch is open due to over-temperature, the driver will be off (b) MCU can detect over-temperature of bypass SCR through CPU-P91 (91) (c) The bypass SCR driver signal will come from MCU or US4 according to the signal “TO US36-P4”. (d) “TO US36-P4” is the output of MCU watchdog. If MCU is operating normally then “TO US36-P4” will be high and the bypass driver signal will come from BYPSTS (33). If MCU is not operating normally, “TO US36-P4” will be low and then the bypass driver signal will come from US4 (e) US4 is a 37kHz self-oscillator that can provide driver signal for bypass SCR. (f) RS47/DS13/CS41 is used to disable the output of US4 during initialization of auxiliary power (g) The output of driver signal from US4 is also limited by TOBYP_I (105) signal (h) US15B-P3 is the signal used to send out To bypass signal on parallel port no matter the bypass SCR is driven by MCU or US4 Refer to “Watchdog For System MCU” for “TO US36-P4” signal.
45
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (3) Output Current Detection Located at G board
1
SCR DG3
1
DG2
CNG10
N1 OP/CT+ OP/CTRG2
CG4
CG5 MOVG4
WG9 #10 1
2,3 1
WG10 #10
4,5 CTG2
MS-130125-2-01
6
CNG1 1
WG3 1 CG11 O/L
1
CNG9
TO T
Located at S board CS16 RS33
5VS
CS96 11
-12VS RS55
OP/CT-
G1
RS157
2 RS51
1
RS54 CS15
RS32 4
OP/CT+
(76) Iout_R
RS21
3 US9A TL084 CS97
+12VS
CS34 G1
G1 G1
(a) MCU detects output current through Iout_R (76). The output current could be bypass current or inverter current according to operation mode
46
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (4) Input And Output Voltage Detection Located at G board
1
CNG2 I/L
1
LG1 4
1
6
OP/CT+
RG2
OP/CT-
N1
MOVG1
CG4
3
1
2
CG1
CNG10
CTG2 1
CNG1
I/L
WG3
1
CNG3 RG3
RG7
RG11
RG4
RG8
RG12
I_N
O/L
1
O/L
I_L
1
RG5
RG9
RG13
RG6
RG10
RG14
CNG9
O_L O_N
Located at S board CS5
RS38
RS26
5VS 5VS
5VS
Vbyp_R
CS36 11 2
RS239
3
CS4
DS1
(25) BYPZO_R
RS169 O_L
US16A
CS20
RS172
O_N
G1
RS25 RS244
6 7
RS245
5
4
RS22
RS190
QS1
G1 1
CS2
Vout_R (77) CS29
RS173
(80)
-12VS
RS238
RS156 RS29
RS30
RS24
+12VS
CS1
US16B TL084
CS95 G1 G1
G1 CS56
I_L
5VS
RS100 RS240
13 14
RS241
RS102 RS101
12 CS17
RS99
G1
G1
5VS
I_N
VinR
RS192 (75)
RS196
INPZO_R
(24)
US16D DS3
RS195
QS3
CS18
RS191
G1
(a) MCU detects RMS value of output voltage through Vout_R (77) (b) MCU detects RMS value of bypass voltage through Vbyp_R (80) and RMS value of input voltage through VinR (75). (c) MCU detects the bypass frequency and zero crossing through BYPZO_R (25) at falling edge. MCU detects the input frequency and zero crossing through INPZO_R (24) at falling edge
47
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (5) AC Auxiliary Power Circuit Located at P board 1 2
NTCP3 I/L
CNP3
DP20
FUP2
CP2
RP161
2
3
2 G2
1
7 VFB COMP
G2
DP23 D
8
UP4
1
4
VREF
OUT
RP174
G2
4 CP103
RT/CT
GND
G2
6
ISEN
G
RP178
QP22 S G2
3
5
2
3
RP50
G1 CP20
12 DP33
45KHz
CP34 NC
11 CP89
6
DP19 -12V
UP6 LM317
DP6
G2 RP29
B+
CP92
7 DP5
B1
8 CP15
CP21
Vin
+Vout
+12VF 2 RP39
G3 CP22
RP184
RP94
3
CP12 CP147
CP10
4
G2 DP22
DP30
UP14
CP30
VCC
A
18V
G'
4 5
+12VS CP19
ADJ
ZDP2 G2 G2
VCC
CP90
1
CP78
LP2 I/N
G1
10
2 3
DP28
RP158
RP183
K
CP6
1
1
CP101
R UP2 TL431AC
DP2
+12VP CP146
CP100
CP5
RP26
DP34
I/N
RP27
RP25
TP2
RP157
RP28
RP181
+12VP
DP15 9
RP38
DP18 -12VF
RP180 UP5 UC3845
RP49 CP14
G3 G2
Located at S board
EPO CNS5 1 2 3 4 5 6
VCC G' NC
RJ12
(a) The input of AC auxiliary power circuit is from AC input. (b) Battery winding of TP2 is used to provide input voltage to DC auxiliary power circuit once battery pack is not connected. (c) If EPO is active (NC is released) through RJ12, then AC auxiliary power circuit is disabled.
48
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (6) DC Auxiliary Power Circuit Located at P board FUP1
B+ DP14
NTCP2
RP23
RP163
CNP14 CON(2.5)
UP10
1
4
2
K-ON
3
QP17
1 2
G1
BATTERY
ON_A ON_B
RP162
ON_B RP155
ON_A
RP24 CP82 TP1 1
RP160 DP8 ZDP1 18V
4
2
CP8
2 1
8 +12VS RP132
4
CP28
VREF
OUT
4
RT/CT
CP102 5
DAUX
A
QP21
RP21
6
ISEN UP3 UC3845
3
3
OUT
UP6 LM317
DP4
11 S
-12VS
3 G3
Vin
+Vout
QP12
+12VF 2 RP39
CP18
RP47
DP7 RP79
RP46
DP3
CP7 CP17
D G
RP171
3 RP131
R UP37 TL431
UP13
1 2
K
RP170
HSP1 45KHz
IN
UP1 LM7912CT
10
COMP
RP177
2 -12V
DP29
3
RP19 CP27
VFB
DP16
DP32 9
12
1
UP12
G1 CP16
6
1
1
RP145
RP182
VCC
CP9 RP175
CP4
CP88
7
CP87
RP2 +12VB
CP86
8
ADJ
CP79
CP29
GND
B1
+12VS
1
DP12
RP1
CP1
RP30
4 5
DP1
GND
RP154
ON_B
+12VB
DP31 7
2 3
DP27
CP13 DP17
CP11
-12VF
RP38
RP179
G1
G1
G3
G1
Located at S board 5VS RS164 RS139
K-ON
CS26
KEY_ON (4)
DAUX_BAT (31)
RS13
DAUX
G1
(a) B+ is the source from AC auxiliary power circuit (b) MCU detects the on key through KEY_ON (4) (c) If DAUX_BAT (31) is high during battery mode, DC auxiliary power will be off Refer to “AC Auxiliary Power Circuit” for B+ and B1 signals
49
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (7) Auxiliary Power Failure Detection Located at P board +12VB +12VS RP31 RP33 DP24 ZDP3
9V G1
RP37 QP1
+12VP
G1 +12VS
RP32 AUX-F RP35 DP25 ZDP4
9V G1
RP36
RP34
QP3 QP2 G1 G1
Located at S board
5VS RS10
AUX-F
RS138
(61) AUX_Fail
(a) +12VP is from AC auxiliary power and +12VB is from DC auxiliary power. During AC mode, +12VP and +12VB should be both alive. If one of them is fail, MCU can detect auxiliary power failure through AUX_Fail (Low active).
50
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (8) Battery Voltage Detection Located at P board
B+
RP7
RP8
RP9
RP10
RP11
RP12
BATTBATT+
Located at S board CS6 RS27 BATTBATT+
RS242
9
RS243
10
8
RS23
CS3
RS31
US16C TL084
Vbat
(87) CS28
RS15
G1 G1
(a) MCU detect the voltage through Vbat (87)
51
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (9) Battery Pack Detection Located at P board
INTBNO
D+ CP3 CNP7
1 2 RP22
D-
G1
Located at S board
5VS DS20
RS20 RS137
INTBNO
INTB_NO
(89) INTB_NO
CS31 DS21 G1 G1
(a) MCU detects the internal battery pack through A/D INTB_NO (89).
52
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (10) Auxiliary Power For 5V Located at S board +12VF RS155 QS19 +5VF RS150 RS153 CS7 1
Vin
Vout
K
3 R CS107
US6 TL431 0.5%
2
CS136
A
RS154
CS37
VLED GND
+12VS
US38
G1
RS151
CS8
G3
QS23 CS106 +12VS
5VS RS80 RS81
RS82
+12VS
RS160
QS22
5V8
CS33
RS158
CS35
CS12
R
US10
CS94 A
A
CS105
G1
(a) (b) (c) (d)
R
US26 RS83
RS161
K
K
G1
RS159
G1
5VS is the power source for MCU VLED is the power source for LCD and LEDs 5V8 is the power source for blue backlight of LCD +5VF is the power source for USB MCU and Minislot.
53
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (11) LCD And LED Driver Located at S board BKLIT VLED
CS85 VLED
16
11 10
SRCLK SRCLR
12 13
RCLK E
16
CS88
G1
15 1 2 3 4 5 6 7
LED0 LED1 LED2 LED3 LED4 LED5 LED6 LED7
LED_STB (64)
O0 O1 O2 O3 O4 O5 O6 O7
9
G1
Q7
VCC
VCC
14
SER
G1
SER SRCLK SRCLR RCLK E
G1 G1 CS84
16
VLED
15 1 2 3 4 5 6 7
Q7
G1 SER SRCLK SRCLR RCLK E
8
9
O0 O1 O2 O3 O4 O5 O6 O7
GND
LCD0 LCD1 LCD2 LCD3 LCD4 LCD5 LCD6 LCD7
VCC
US23 74HC595 LCD0 LCD1 LCD2 LCD3 LCD4 LCD5 LCD6 LCD7
14
RTCDO (7)
11 10
RTCSCK (8) LCD_STB (63)
12 13 G1
LCD7 LCD5 LCD3 LCD1 (20) LCDE (21) LCDRS
CS87 G1
LCD7
14 11 10
RS62 QS6
CS21 RS201 G1 RS128
ENT
KEY_ENT
G1
(97) KEY_ENT
RS143
(64) LED_STB
12 13
ESC
RS105
KEY_ESC
CS76
KEY_ESC (98)
RS142 CS65
G1 CS93
CS90
G1 G1 CNS8 LED0 LED2 LED4 LED6 LED8 LED10 LED12 DOWN ENT BKLIT
34 32 30 28 26 24 22 20 18 16 14 12 10 8 6 4 2
LCD5 LCD3 LCD1 LCDE LCDRS CS67
CS66
(62) LCD_BKLIT
RS70
(7) RTCDO (8) RTCSCK
8
CS89
(100) KEY_DOWN
CS91
GND
Q7
DOWN G1
US25 74HC595
8
9
O0 O1 O2 O3 O4 O5 O6 O7
GND
15 1 2 3 4 5 6 7
KEY_DOWN
RS35
G1 G1
US24 74HC595 LED8 LED9 LED10 LED11 LED12
CS86
VLED CS68
33 31 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1
G1 RS36 UP TO DISPLAY 5VS LED1 LED3 LED5 RS237 LED7 LED9 LED11 TEMP CS116 UP ESC G1 OFF LCD6 LCD4 LCD2 LCD0
KEY_UP RS71 (99) OFF
CS71 CS73
KEY_OFF
(5) KEY_OFF
CS23 G1
(88)
LCD6 LCD4 LCD2 LCD0 RS205
G1
G1 RS37
RS72
G1
5V8
CS70
CS69
KEY_UP CS22
VLED
CS72 RS206
-12VS
(61) G1
G1
(a) MCU detects the ambient temperature through TEMP (88). The thermal sensor is located on the LED board at the front panel. (b) LCD_BKLIT (62) can adjust the intensity of LCD backlight by PWM control
54
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (12) Watchdog For System MCU Located at S board 5VS 8
CS9 G1
5VS
R
RS7 2 5 SYS_RDY
CVolt
RS4 TO US36-P4
3 5VS
THR
7
RS1 CS27
6
CS14
CS11
G1 RS6
US3 TLC555C RS14
G1
G1
QS14
JS6 1 2
Q DIS
1
(29) SYS_RDY
TRIG GND
4
VCC
5VS
RS63
QS12 DS5 G1 G1
(a) SYS_RDY (29) will send out pulse to reset CS27. And then CS27 will be charged again by 5V through RS1. “TO US36-P4” will keep high level. If SYS_RDY (29) doesn’t send out pulse for a specific period (for example: MCU is crash) then “TO US36-P4” will be low. (b) Test JUMP: JPS6: If JPS6 is shorted, then “TO US36-P4” will be low or “TO US36-P4” will keep high during normal operation.
55
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (13) Communication Circuit for RS232 & USB Switching between RS232 and USB port Located at S board 5VS D_RS232
RS182 US27C C IN
OUT
2 RS232_RX
RXD
13 1
CD4066B RS177
(59) RS232_RX
6 8
(60) RS232_TX RS232_TX
US27A RS181
C IN
OUT
9
TXD
CD4066B US19A
US27D QS25
12 11
US27B 5 4
B2
RS178
G1
C IN
OUT
3
C IN CD4066B
OUT
10
1
2
B1
MM74HC14
CD4066B
Located at V board +12VF RV88
4
5VS
VBUS
UV24
1
3
D_RS232
2
RV85
RV86 QV11 RV87 G1 G3
(a) If D_RS232=high, MCU (RS232_RX, RS232_TX) will communicate with USB port (B1, B2). If D_RS232=low, MCU (RS232_RX, RS232_TX) will communicate with RS232 port (RXD, TXD). (b) VBUS is voltage of USB-P1 from computer. USB port has the higher priority than RS232 port
56
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Communication for USB port Located at V board +5VF CV42
+5VF
G3
CV8 5VS
CV1
G3
XTALV1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
UV3
8 7
1 2
6
3
RV16
+5VF CV7
4
5 G3 CV3
RV5
G3
G3
5VS
G1 +5VF
UV5
+5VF
1
7 8
RV6 6
5VS
2
RV4
RV27 5
B2
G3
CV10
UV7 CV6
B1
CV9 G3
+5VF RV2
3
CV11
VDD OSCOUT OSCIN VSS PC2/USBOE PC1/TDO PC0/RDI RESET NC PB7/AIN7/IT8 (10mA) PB6/AIN6/IT7 (10mA) Vpp/TEST PB5/AIN5/IT6 (10mA) PB4/AIN4/IT5 (10mA) PB3/AIN3 (10mA) PB2/AIN2 (10mA) PB1/AIN1 (10mA)
G3 VDDA USBVCC USBDM USBDP VSSA PA0/CPUCLK (25mA) PA1/SDA NC NC NC (25mA) PA2/SCL PA3/EXTCLK PA4/ICAP1/IT1 PA5/ICAP2/IT2 PA6/OCMP1/IT3 PA7/OCMP2/IT4 (10mA) PB0/AIN0
RV17
34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18
VBUS G3
RV34
4
G3
G3 G3 CV23 CV29
G RV89
CV12
RV26
G3
G3 QV12 RV32 CV46
CV44
C1- SHDN C1+ GND C2- VOUT C2+ VCC
G3
G3
8 7 6 5
RV9
CNV2
G3 UV2 1 2 3 4
RV80
CV2 VBUS
G3
CV43
CNV4 1 2 3 4
G3
CV17
+5VF +5VF
1 3 5 7 9
2 4 6 8 10
HEADER 5X2
RV10 DV5
G1
QV5 S
G3 DD+
D RV25
CV15
+5VF
G3 G3
RV28 RV8
CV45 QV1 G3
(a) UV2 is boost supply for self-programming purpose (b) CNV2 is used to USB chip programming
57
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Communication for RS232 Located at S board US19CTO TXD 6
5
TXD
MM74HC14
Located at C board +12VF +12VF +12VF CC4 RC21
RC19
G3
RC11 3
8 7
UC7A G3 LM393
RX
UC5
6
3
2 D
5
CC5
G
RC24
S
G3 4
TO TXD
CNS3-P2
1
QC3
4
1
RC22
2
CC6
+12VF 8
5VS
RC10 CC3 5VS
G3
RC12 -12VF RC18
G3
RXD
1
7 8
G1 UC6
6
2
RC20 5
TX
RC23
DC6
3 G3
RC13
4
G1
DC7
5VS
CC9
G3
D QC4
G S RC25
-12VF
QC5
CNS3-P6
CC8
CC7
Located at S board
RS232 +12VF CNS3
RS57
RS149
G3
TX CNS3-P2 CNS3-P6
5 9 4 8 3 7 2 6 1
(a) CNS3-P6 is used for plug & play function (b) RX and TX signals are also connected to power module for firmware upgrade purpose Refer to Power Module for RX and TX signals 58
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (14) Communication Circuit for Minislot Communication Circuit Located at S board US19B (58) DATA_TX DATA_TX
5VS (57) DATA_RX
DATA_RX
3
4
B3
RS127 RS133
B4
CS78
G1
Located at V board 5VS RV12
CV5
UV4
2
G3 RV42
8 7
1
RV3
B3
+12VF
+12VF
RV82
6
3
5 4
-12VF 5VS CV4
6
1 UV6
2
5
RV21
3 D
+12VF
RV7 G3
G1
G
4
B4
+5VF
CNV3
7 8
G1
S QV6
G3
RV41
INPUT 1 INPUT 2 G1 INPUT 3
1 3 5 7 9 11 13 15 17 19 21 23 25
2 4 6 8 10 12 14 16 18 20 22 24 26
CV14 CV33 G3
G3
INPUT 4 RSD INPUT 5
To Minislot
59
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Dry Contact Circuit Located at S board US36 8
G1
GND COM
7 6 5 4 3 2 1
(38) DRY A (37) DRY B (30) DRY C
7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
Bat fault
+12VS 9 10 11 12 13 14 15 16
ULN2003A
(95)
BAT-F
RS180 RS44
QS11
G1
Dry Contact
on line/backup low-batt load protect On bypass
G1 CNS4-P5 5VS CNS4-P3
BYPL DRY D
(103)
BYPL
RS73 QS18
RS87
(52) RMTSD
RS146
RS236
CNS4
5 9 4 8 3 7 2 6 1
RSD
G1
Located at C board CNS4-P3
RC16
RSD
4
1
3
2
RC17
CC2 G1 CNS4-P5 UC4
Located at V board +12VS
+12VS
load protect RV49 INPUT 1
QV19 on line/backup
RV45
INPUT 2
+12VS
INPUT 4
Bat fault RV46 INPUT 3
RV29 RV81
QV10
+12VS
RV39 RV79
RV30 QV13
RV40
RV61
On Bypass
+12VS RV14
RV11
RV20
low-batt QV20 INPUT 5
RV47
QV18
RV78
(a) INPUT 1: Load protected INPUT 2: Operation on battery INPUT 3: Battery fault INPUT 4: Operation on automatic-bypass INPUT 5: Low battery OUTPUT (RSD): Remote power off
60
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (15) Communication Circuit For Dry Contact Located at S board
Dry Contact US36 8
G1
GND COM
7 6 5 4 3 2 1
(38) DRY A (37) DRY B (30) DRY C
7B 6B 5B 4B 3B 2B 1B
CNS4-P5 CNS4-P9 CNS4-P4 CNS4-P8 CNS4-P3 CNS4-P7
+12VS 9 10 11 12 13 14 15 16
7C 6C 5C 4C 3C 2C 1C
CNS4-P6 on line/backup low-batt load protect On bypass
ULN2003A
DRY D
CNS4 DB9
5VS BYPL
(103)
5 9 4 8 3 7 2 6 1
BYPL RS73
QS18
RS87
(52) RMTSD
RS146
RS236
RSD
G1
Located at C board CNS4-P3
RC16
RSD
4
1
3
2
RC17
CC2 G1 CNS4-P5 UC4
+12VS
RLC10 +12VS
CNS4-P9 NO
NC
CNS4-P4
RLC11 NO
CNS4-P8 NC
DC3
DC1
+12VS
+12VS DC4
RLC12
RLC13 NO
CNS4-P7 NO
NC
DC2
low-batt
COM
load protect
COM
on line/backup
CNS4-P6 NC
DC5 COM
On bypass
COM CNS4-P5
(a) CNS4-P3: Remote power off CNS4-P5: Common CNS4-P7: Battery low CNS4-P9: On battery
CNS4-P4: On utility CNS4-P6: On bypass CNS4-P8: System (load) protected / UPS On
61
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (16) Communication For System and Power module Part 1 Located at V board +12VF RV55 RV38
5VS
UV20
1
B6
RV54
4
2
SYNC_BUS G3
3 G3
1 2
CNV6
QV9 VS
RV52
VS 5VS
RV36
1
UV18
2
B13
SYNC_BUS
QV3 ZDV4
CV19
4
RV48
VS
QV2
3
CV26
RV33
5VS
1
UV14
ZDV2
4 CV13
RV58
2
B9
CV16
3 RV50
G3 RV64
+12VF UV21
4
B14
G3
1
3
G1
RV22
+12VF CV27
2 VS +12VF
RV59 G3
8 7
1
UV10
CV30
RV35
1
UV16
2
ZDV3 CV20
3 RV53
RV60 4
G3 G3
6
UV11
+12VF
1
CV37
7 8
G1
RV66
+12VF
RV24
4
B12
2
5
3
G1
CV32
3
UV17
RV63
RV19 CV22
1 2
4
G1
TOINV QV4
CV18 4
5 5VS
B18
TO BYP
CV21
ZDV6
6
B11 B17
RV18
RV51
VS 5VS
RV62
1 2
CV31 INT_DATA
3
UV15
3
G1 QV8
CV38 2
4
B10
Located at S board US20C US19B 5
TOINV_O (50)
6
B11
(58) DATA_TX DATA_TX
RS89
5VS
5VS
RS116
TOINV_I (106)
3
B12
(57) DATA_RX
DATA_RX
4
B3
US15B-P3
3
US20B 4
RS127
B6
RS133
CS51
B4
CS78
G1
B9
To US36-P4
RS122
G1
RS94
QS20
US20F SYNC_O (27)
9
8
B13
13
INT_TX (3)
G1
12
B17
US20D 5VS SYNC_I (26)
RS90
5VS
RS119
B14
INT_RX (2)
RS91 RS120
B18 CS54
CS52 G1
G1
(a) If System MCU is operating normally, then VS is on. VS is the power source for communication circuit: US15B-P3 (B9), TOINV_O (B11), SYNC_O (B13) and INT_TX (B17). If System MCU is not operating normally (for example: MCU is crash), then VS is off to prevent the communication bus is locked 62
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (e) TOBYP and TOINV signals are used to synchronize bypass mode and inverter mode transfer (f) SYNC_BUS signal is used synchronize the inverter and bypass voltage (g) INT_DATA signal is used to transfer information between Power MCU and System MCU. Refer to “Watchdog for System Module MCU” for “TO US36-P4” signal. Refer to “Bypass SCR driver” for “US15B-P3” signal
63
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING Part 2 Located at V board 5VS
RV1
UV1
1
ON
RV31
4
2
3
+12VF
ON1 RV71
5VS 4
ID1_RDY CV39
UV22
1
3
RV72
+12VF
1 RV70
2
BYPOK 4
UV23
CV40 2
3
DV7
DV8
G3
ID1RDY G1
+12VF
BYP_OK
RV77
+12VF B8 G1
4
UV13
1
3
+12VF
RV43
2
TOMBYP(B) RV13
TOMBYP(N)
TOMBYP RV15
4
B7
UV12
1
3
QV14
2
RV74
QV15
RV37
5VS
B5
G3
RV83
RV84
RV75
RV76
QV17
QV16
G1 RV73
TOMBYP
RV44
1
BYP-F 4
UV19
2
3 G3
G3
Located at S board 5VS
ON
US36
QS2 G1
RS104
RS39 (34) POWER_ON
RS216
ID1_RDY (54)
CS43
TO US36-P4
G1 5VS
8 7 6 5 4 3 2 1
G1
GND COM 7B 6B 5B 4B 3B 2B 1B
7C 6C 5C 4C 3C 2C 1C
+12VS 9 10 11 12 13 14 15 16
BYP_OK
ULN2003A RS86
TOMBYP_B (104)
RS115
5VS B8
CS50
TOMBYP_N (35)
RS144
TOMBYP_N RS145
CS55 G1
B5
B7 BYP-Fail (22)
RS123 QS21 RS113
G1
G1
(a) If POWER_ON (34)=high, the auxiliary power of power module is powered on. ON1 is connected to power module. (b) If ID1_RDY (54)=Low, the Power MCU is operating normally (c) BYPOK is connected to power module to inform that System MCU is operating normally (d) TOMBYP(B) is connected to the bypass auxiliary winding of manual bypass switch. MCU detects that manual bypass switch is at bypass position by TOMBYP_B (104) (low active) (e) TOMBYP(N) is connected to the normal auxiliary winding of manual bypass switch. MCU detects that manual bypass switch is at normal position by TOMBYP_N (35) (low active) (f) BYP-F is connected to power module. If utility is fail, BYP-Fail (22) will be high. (g) TOMBYP is connected to power module to detect the switch of manual bypass switch. Refer to “Watchdog for System Module MCU” for “TO US36-P4” signal. 64
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (17) EXB Detection Circuit (RJ45) And EPO Circuit (RJ12) Located at S Board RS211
EXTBNO
EXTB_NO (90)
RS210
EMPO1
EPO (108) CNS9 CNS5
EXTBNO DS6
RS79
DS19
1 2 3 4 5 6 7 8
CS44 CNS9-P5 CNS9-P6 CNS9-P7 CNS9-P8
5VS G1
1 2 3 4 5 6
VCC
CNS5-P2
G' NC
CNS5-P4 CNS5-P5
EPO
EXT. BAT. DET.
Located at C board RC8 +12VF (1) BTEST
UC2
1
RC2
CNS9-P5 CNS9-P6 CNS9-P7 CNS9-P8
4
5VS 2
QC2
3
QC1
RC3
D G1
G3 2
RC6
5VS
G
3
1
RC4
4
S RC7
UC1 RC1 RC14
EMPO1 4 CC1 G1
3
UC3
1 2
G3 VCC
CNS5-P2
GND NC
CNS5-P4 CNS5-P5
RC15
(a) MCU detects the number of External battery cabinet by EXTB_NO (90) (b) Normal Close setup for EPO (RJ12): Short CNS5-P5 (NC) to CNS5-P4 (G’). If remove the short pin, EPO will be active (c) MCU detects EPO signal by EPO (108) (d) CNS9-P8 & CNS9-P7 is used to trip the circuit breaker (if the breaker has external trip function) on EXB when EPO is active. (e) CNS9-P5 & CNS9-P6 is used to disable the CLA during performing battery test
65
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING (18) Other Detection Circuit Located at S board
5VS RS167 CNS7 JS5 1 2
REPAIR (96)
BKGD BKGD(23)
BKGD
CS118
1 3 5
2 4 6
G1 /RES
(42) /RES
5VS
(BDM) G1 CNS6 #22
1
DS22
+12VS
CNS10 1
OL1
DS23 +12VS
1
#22 OUTLET1
(110) CPU-P110
QS16
G1 RS147
OL2
#22 OUTLET2
RS85
CNS11
QS17 RS136
(111) CPU-P111
G1
RS148
OUTLET2
OUTLET1
(a) If JS5 is shorted, UPS will go into test mode (b) CNS6, CNS10 and CNS11 are connected to outlet board for outlet control (c) CNS7 is used for MCU programming by BDM
66
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2. Troubleshooting 2.1 Internal Fault 2.1.1 Alarm 34: CHARGER FAULT START
Disconnect Battery And Check Charger Voltage 200Vdc
Y
Check Voltage at UB23-P7 On B Board 0V?
Y
Charger Detection Circuit On B Board Fail Replace B board
N END
Check Rectifier And PFC Circuit (refer to flow chart for alarm 305)
N Check Bus Voltage Around 375V/-375V?
Charger Detection Circuit On M Board Fail Replace M board
END Charger Circuit On B Board Fail Replace B Board
END
67
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.2 Alarm 193: FAN FAULT START
Fans At Front And Rear Of Power Module are rolling?
N
Fan Fail Replace Fan Which Is Not Rolling
Y
N
Fan Fail Detection Circuit On B Board Fail Replace B Board
Restart UPS and No AN FAULT ALARM
Y END
END
68
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.3 Alarm 004: UPS TEMPERATURE FAULT START
Remove Power Module and No Output At Bypass Mode?
Y
OTP At System Frame
N
OTP At Power Module
Output Load=0 And Output Is Recovered?
N
Check Wiring CNG4-P11 ~CNG4-P8 ~ CNP4-P8 ~ CNP2-P10~ CNS2-P10 OK?
Y
Temperature Detection Circuit On S Board Fail Replace S Board
N
Y
END Replace Fan
END
N
Turn On UPS And Check Fan Is Rolling Or Not?
Y
Turn On UPS Output Load=0 No OTP Alarm
Check Wiring CNA1-P13~CNA1-P22 ~CNB1-P22 ~ CNB3-P10 ~ CNM4-P9 OK?
Y
Y
Check the Ambient T < 40 C
Flat Cable Fail Change Flat Cable
END
END
1. Check Path of Air Flow And Clean Dust Or Barrier 2. Check the Ambient T<40 C
END
Temperature Detection Circuit On M Board Fail Replace M Board
END
N
Flat Cable Fail Change Flat Cable
END
69
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.4 Alarm 701: INVERT FUSE BLOWN START
Check FUA4 Is Open ?
Check Wiring CNA1-P11~CNB1-P11 ~CNB2-P15~CNM2~P16 OK?
N
Flat Cable Fail Replace Cable
END
Inverter Fuse Open Detection Circuit On M Board Fail Replace M Board
END
Y
Y
Check QB18/QB19/QB20 and QB22/QB23/QB24 Damaged ?
N
Y
Inverter Circuit On B Board Fail Replace B Board Replace FUA4
N Inverter Current Limit Circuit Fail Replace M Board Replace FUA4
Check Inverter Control Circuit On M Board TPM1 & TPM2 Ok?
N
Inverter Control Circuit On M Board Fail Replace M Board
Y END
END
END
70
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.5 Alarm 100: NORM AC FUSE BLOWN START
Check FUA1 Is Open ?
N
Check Wiring CNA1-P25~CNB1-P25 ~CNB2-P13~CNM2~P14 OK?
N
Flat Cable Fail Replace Cable
END
Flat Cable Fail Replace Cable
END
Rectifier Fuse Open Detection Circuit On M Board Fail Replace M Board
END
Y
Y
Check Wiring CNA1-P26~CNB1-P26 ~CNB2-P14~CNM2~P13 OK?
N
Y
Check QB10/QB11/QB12 And QB14/QB15/QB16 Damaged?
Y
PFC Circuit On B Board Fail Replace B Board Replace FUA1
END
Rectifier SCR Control Circuit On M Board Fail Replace M Board
END
N Check SCR Driver Signal On A Board (JPA1-P1 and JPA2-P1) OK?
N
Rectifier Circuit On A Board Fail Replace A Board
END
71
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.6 Alarm 30: RECTIFIER FAULT START
Short JPB1 And Input Voltage=230Vac Check Bus Voltage Around 300/-300Vdc ?
N
Y
Remove JPB1 And Turn On UPS Check Bus Voltage Around 375/-375V?
Check SCR Driver Signal On A Board (JPA1-P1 and JPA2-P1) OK?
N
Rectifier SCR Control Circuit On M Board Fail Replace M Board
END
Y
Y
Rectifier Circuit On A Board Fail Replace A Board
END
Bus Detection Circuit On M Board Fail Replace M Board
END
N
PFC Circuit On B Board Fail Replace B Board
END
72
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.7 Alarm 28: DC BUS +/- TOO HIGH/LOW START
Output Is Half-Wave Load
Y
Reduce The Load
END
N
Output Is Inductive Load (Ex. Transformer) And Short JPM4. No Alarm Again?
Y
DC Offset Compensation Circuit On M Board Fail Replace M Board
END
N
Short JPB1 And Input Voltage=230Vac Check Bus Voltage Around 300/-300Vdc ?
N
Check SCR Driver Signal On A Board (JPA1-P1 and JPA2-P1) OK?
N
Y
Y
Rectifier Circuit On A Board Fail Replace A Board
Remove JPB1 And Turn On UPS Check Bus Voltage Around 375/-375V?
N
PFC Circuit On B Board Fail Replace B Board
Rectifier SCR Control Circuit On M Board Fail Replace M Board
Y
Check Voltage At UB14-P8 Around 8Vdc?
END
N
BUS Voltage Detection Circuit On B Board Fail Replace B Board
END
N
BUS Voltage Detection Circuit On B Board Fail Replace B Board
END
Y
Check Voltage At UB14-P14 Around 8Vdc?
Y END BUS Voltage Detection Circuit On M Board Fail Replace M Board
END
73
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.8 Alarm 31: INVERTER FAULT START
Check Bus Voltage Around 375/-375Vdc?
Check Rectifier And PFC Circuit (Refer to Flow Chart For Alarm 305)
N
Y
Turn On UPS and Check Voltage On CA25 Preset Voltage (ex. 230Vac) ?
Check Wiring CNA1-P8~ CNB1-P8~ CNB2-8~ CNM2-P7 Ok?
Y
N
Flat Cable Fail Replace Flat Cable
Y
N
Inverter Voltage Detection Circuit On M Board Fail Replace M Board
END
END
Check Inverter Driver Signal On M Board (TPM1 & TPM2) Ok?
N
Inverter Control Circuit On M Board Fail Replace M Board
END
Inverter Circuit On B Board Fail Replace B Board
END
74
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.9 Alarm 191: BATTERY FAULT START
Switch On Top Chassis is showed Connected ?
N
Battery Is Not Connected Turn On The Switch
END
N
Battery End Of Its Life Replace With New Battery Tray
END
Fuse Is Broken Replace FUB3 & FUB4
END
Y
Measure The Battery Voltage Through EXB Connector >150Vdc
Y
Check FUB3 & FUB4 are Open ?
Y
Battery Voltage Detection Circuit On M Board Fail Replace M Board
END
75
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.10 Alarm 36: AUTO BYPASS FAULT START
Check SCR On G Board Is Shorted ?
Y
Bypass SCR Damaged Replace G Board
END
Flat Cable Fail Change Flat Cable
END
N
Check Wiring CNG4-P6 ~CNP4-P6 ~ CNP2-P4 ~CNS2-P4 Ok?
N
Bypass SCR Short Short Detection On S Board Fail Replace S Board
END
76
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.11 Alarm 00A: DC POWER SUP FAULT START
Check Voltage At CP86 On P Board Around +12Vdc ?
N
Battery Aux Power Fail Replace P Board
END
AC Aux Power Fail Replace P Board
END
Auxiliary Power Fail Detection Circuit On S Board Fail Replace S Board
END
Y
Check Voltage At CP90 On P Board Around +12Vdc ?
N
Y
Check QP3 C-E on P Board 0V?
N
Y Auxiliary Power Fail Detection Circuit On P Board Fail Replace P Board
END
77
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.12 Alarm 63: INTERNAL COM FAULT START
Check Wiring CND1-P3 ~ CNM5-P3 Ok?
N
Flat Cable Fail Replace Flat Cable
END
N
Flat Cable Fail Replace Flat Cable
END
Y
Check Wiring CNE1-P3 ~ CNV5-P3 Ok?
Communication Circuit On M Board Or S/V Board Fail Replace M Board Or Replace S/V Board
END
78
Powerware 9135 HARDWARE INTRODUCTION AND TROUBLESHOOTING 2.1.13 Alarm 006: COM FAULT BETW UPS START
Check Wiring DB15-P7 Of Two UPS Ok?
Parallel Cables Are Open Or PCB On ModularEasy Fail Replace Parallel Cable or PCB On Modular Easy
END
N
Flat Cable Fail Replace Flat Cable
END
N
Flat Cable Fail Replace Flat Cable
END
N
Y
Check Wiring CND1-P5~ CNM5-P5 Ok?
Y
Check Wiring CNE1-P5~ CNV5-P5 Ok?
Y Communication Circuit On M Board Or S/V Board Fail Replace M Board Or Replace S/V Board
END
79
