Powertronix PTX2-A3 Bedienungsanleitung

ServiceManual PTX2-A3 UPS

6kVA~10kVA 220VAC

PTX2-A3 Service Manual Rev.2

Content

1. PSDR Introduction............................................................................................................................ 1

1.1 6/10 kVA PSDR-Right side ...................................................................................................... 1

1.2 6/10 kVA PSDR-Left side ........................................................................................................ 1

2. Fault and Warning ............................................................................................................................ 2

3. Troubleshooting................................................................................................................................ 3

3.1 Quick Start............................................................................................................................... 3

3.2 PFC Analysis:.......................................................................................................................... 4

3.3 Boost Analysis......................................................................................................................... 5

3.4 Inverter Analysis...................................................................................................................... 7

3.5 Charger Module Analysis ........................................................................................................ 8

3.6 PFC / Boost / Inverter IGBT Driver Module Analysis ............................................................... 9

4. Final testing.................................................................................................................................... 10

5. Service Setting ............................................................................................................................... 13

5.1 How to adjust the output voltage and frequency on LED type UPS ...................................... 13

5.2 How to replace the control card............................................................................................. 16

PTX2-A3 Service Manual Rev.2

Page 1 of total 19 August 2007

1. PSDR Introduction

1.1 6/10 kVA PSDR-Right side

cdef

1.2 6/10 kVA PSDR-Left side

fed

1. Bypass Mosfet Driver

2. Inverter IGBT Driver Module

3. Boost IGBT Driver Module

4. PFC IGBT Driver Module

PTX2-A3 Service Manual Rev.2

Page 2 of total 19 August 2007

2. Fault and Warning

LCD & LED Status /

Audible Alarms Possible Cause Action

Fault Warning Normal

yUPS in Bypass Mode.

yThe alarm beeps continuously.

AC: OK BATT: OK

TEMP Fail

1. Fan fail.

2. Temperature is

higher than

allowed operation

temperature.

1. Replace the fan.

2. Reduce ambient

temperature or O/P load.

Fault Warning Normal

yUPS in Bypass Mode.

yFault LED lights up and the

alarm beeps continuously.

AC: OK BATT: OK

Inverter Fail

1. Inverter circuit

failed.

2. Inverter driver

failed.

3. PFC circuit failed.

1. Replace the Inverter

components or driver.

2. Replace the PFC

components or driver.

Fault Warning Normal

yUPS in Normal Mode, but

battery capacity is low.

yThe alarm beeps once every

second for battery low.

AC: OK BATT: LOW

Normal Mode

1. Charger may

break down.

1. Please replace charger

board.

Fault Warning Normal

yUPS stop working.

yThe alarm beeps continuously.

AC: OK BATT: OK

DC_BUS Fail

1. Boost circuit

failed.

2. Inverter circuit

failed

3. PFC circuit failed

4. BUS circuit failed.

1. Replace the Boost

components.

2. Replace the Inverter

components.

3. Replace the PFC

components.

4. Replace the BUS circuit

components.

PTX2-A3 Service Manual Rev.2

Page 3 of total 19 August 2007

3. Troubleshooting

3.1 Quick Start

Before any check of UPS, please check the components as listed in the following table. This action could help you find

problem quickly and make sure these components good or not first.

Possible Circuit Block Coded Components Description Failure Mode

BAT FUSE F303/F304 Fuse Open

I/P FUSE (on PSDR) F301/F302 Fuse Open

PFC Correction Q301, Q302 MOSFET A-K Short or open

Q306, Q307,Q308, Q309,

Q310, Q311

IGBT D-S short or open

D302, D304, D306, D303,

D305, D307

Push-Pull Boost

D309, D311, D308, D310

Power Diode Short or open

Q201, Q202, Q203, Q204 IGBT C-E short or open

D201, D202, D203, D204,

D205

Inverter

D210, D211, D212, D213

Power Diode Short or open

Charger module(standard) Q907, Q908 IGBT D-S short or open

D901,D902,D903 Power Diode Short or open

Q909 MOSFET A-K Short or open

IP SCR module Q3, Q4, Q5, Q6 MOSFET A-K short or open

For the 6 and 10kVA, both of the boards are the same size, only the some power components of

10kVA should be more than 6kVA.

If the fuse is open, replacing fuse only, DO NOT mean you have solved the problem. General

speaking, fuse open was caused by other failure of components; therefore, you must find the

real defective components and replace them, before restart the UPS.

PTX2-A3 Service Manual Rev.2

Page 4 of total 19 August 2007

3. Troubleshooting

3.2 PFC Analysis:

In this section, some components you could check to see if failure occurs on PFC Correction circuit as shown below. Be

aware of F301, F302 fuse open indicates failure of this block. Please replace all faulty components before re-start the UPS.

6/10kVA-PFC-Right side

6/10kVA-PFC-Left side

Step Checked components Instrument

function

Reference

Value

Failure Mode

1 F301, F302 (Fuse)  0  Open

(A, K)  1-2 M Short or open2 Q301

Q302 (G, K)  40-50  Short or open

Action ltem: If all above-stated components are replaced well and UPS still can’t work, change the PFC

IGBT driver module.

PTX2-A3 Service Manual Rev.2

Page 5 of total 19 August 2007

3. Troubleshooting

3.3 Boost Analysis

6/10kVA-Boost-Right side

6/10kVA-Boost-Left side

Step Checked components Instrument

function

Reference

Value

Failure Mode

(E,C)  800k short1 Q306~Q311

(G,E)  23.8k short or open

2 D308, D310, D309, D311 DIODE 0.35V 0 V

3 D302, D304, D306, D303,

D305, D307

 12 open

PTX2-A3 Service Manual Rev.2

Page 6 of total 19 August 2007

4 R325, R331, R334, R342,

R337, R328

 10 open

5 R390, R388, R389, R393,

R392, R391

 2.2 open

6 F303, F304  0 open

(A,K)  2.5M short7 Q305

(G,K)  43.6 short

Action ltem: If all above-stated components are replaced well and UPS still can’t be DC start, change Boost

IGBT Driver Module.

PTX2-A3 Service Manual Rev.2

Page 7 of total 19 August 2007

3. Troubleshooting

3.4 Inverter Analysis

6/10kVA-Inverter-Right side

6/10kVA-Inverter-Middle side

6/10kVA-Inverter-Left side

Step Checked components Instrument

function

Reference

Value

Failure Mode

(E,C)  100k Short1 Q201,Q202,

Q203,Q204 (G,E)  47.6k Short or Open

2 D201,D202,D203,D204 Diode 0.36V 0V

3 D210,D211,D212,D213 Diode 46 Open

4 R201,R202,R208,R209  10 Open

5 R203,R204,R210,R211  36 Open

Action ltem:Make sure the DC fuses with same rating as original ones for replacement. Otherwise,

unpredictable danger might happen.

PTX2-A3 Service Manual Rev.2

Page 8 of total 19 August 2007

3. Troubleshooting

3.5 Charger Module Analysis

6/10 kVA-Charger Module- Long back-up type

6/10 kVA- Charger Module- Standard type

Step Checked

components

Instrument

function

Reference

Value

Failure Mode

1 F1 :0

:open

(E,C) |1M:Short

2 Q301

Q105 (G,E) 10k:Short or Open

3 D303 DIODE |0.4V 0V

4 D106 DIODE |0.4V 0V

(A,K) |1M:Short

5 Q04

(G,K) |12:Short

Step Checked

components

Instrumen

t function

Reference

Value

Failure

Mode

1 F901,F902,F903,

F904,F905,F906,

open

(S, D) |1.7M

Short

2 Q907,Q908,

(G, S) 57

Short

3 D901,D902,

D903

DIODE |0.4V 0V

(A, K) |20M

Short

4 Q909

(G, K) |54

Short

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