Linear MK II 6kVA Service Manual
Linear MK II 6kVA Service Manual
MANUAL
---------------------------------Linear Mk II 6/11
UNINTERRUPTIBLE
POWER SYSTEM
CHLORIDE
---------------------------------614-10681-00
2001/03/29 Edition
I. INTRODUCTION. 4
1. INTRODUCTION..
III.PCB FUNCTION. 6
1. POWER STAGE (PSDR)
(1). SOFT-START SUB-SYSTEM.
12
IV. ALIGNMENTS..
15
V. TROUBLE SHOOTING.
16
1. OVERVIEW 16
2. U.P.F. CORRECTION 17
3. DC-DC CONVERTER 17
4. DC/AC INVERTER 17
5. CONTROL POWER SUPPLY
17
6. SOFT START..
18
7. CHGR... 18
8. DYNAMIC CHECK 19
VI. APPENDIX I : COMMUNICATION 20
Page1
WARNING
(For qualified service personnel only)
1. DO NOT perform any internal service or adjustment of this product unless another
person is capable of rendering first aid and resuscitation is present.
2. Dangerous voltage exists at several points in this product. To avoid personal injury,
don't touch any exposed connections or components while power is on.
3. Turn off the UPS and input NFB before removing outside protective cover.
4. AC voltage is always present if the input AC power is still available.
5. High voltage may present at DC capacitors. Before opening the outside cover, wait for
at least five minutes after turning off the UPS.
6. Verify input source (voltage and frequency) before service.
CAUTION
1. After opening the cover, please always check the tightness of all wires, connectors,
and screws first. Then check if there is any decolored components inside.
2. DO NOT make internal batteries short-circuited.
3. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.
Page2
------------------------------------APPLICABLE MODEL
Model: Linear Mk II 6/11 (220V/230V/240V 50/60Hz)
PLEASE FOLLOW THE STEPS TO OPEN THE CASE
Page3
I. INTRODUCTION
For all UPS of this series, they are strictly tested and carefully designed. 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 unavoidable failures of the UPS. If this situation occurs, service of qualified person is
needed. This service manual will guide the technicians to repair and adjust the problematic
UPS. If the UPS still does not work properly, please contact with us and we will be glad to
solve any problems you met.
Because of the following unique features of UPS (Uninterruptible Power System), it is
very easy to maintain and service.
* All major power components are put on PCB.
* Major parts are simply connected with flexible insulated wires and plugs.
* All PCBs are interconnected with connectors.
This service manual consists of 4 major parts:
1. Introduction.
2. Principle of operation: It describes the functions and principles of each part.
3. Alignments: It describes the locations and methods needed to adjust the UPS.
4. Trouble shooting: This part describes the possible failure conditions and procedures to
repair it.
Before starting to serve the UPS, be sure to read this manual carefully for a correct and
safe operation.
Page4
II.PRINCIPLE OF OPERATION
1. INTRODUCTION
This 6KVA high input power factor UPS system contains three major pcb assemblies.
They are including:
A. PSDR: contains major parts of (1) soft-start, (2) control power supply, (3) unit power
factor correction, (4) booster, (5) inverter, (6) transfer relay, S.T.S control circuits.
B. CNTL: contains major parts of protection, signaling circuits, regulation and control
circuits of inverter.
C. CHGR: contains DC-DC regulation and control circuits.
The simplified schematics in figure 1 shows how the major circuits are connected and
illustrated the overall system functions. The locations of these assemblies in this machine are
shown in figure 8.
The block diagram in figure 2, shows the UPS at normal operation from left to right.
When a protection circuit is triggered or a fault condition occurs, the output supply is
transferred immediately from inverter to AC mains by a S.T.S. The operation principle will be
explained in later section.
Basically, this ON-LINE UPS system utilizes high frequency PWM techniques to
achieve high efficient performance. The UPS can deliver a clean, regulated sine-wave output
at any load under full load. The sub-systems are described at next section:
Page5
III.PCB FUNCTION
1. PSDR(POWER STAGE)
The power stage consists of soft-start, control power supply, unit power factor
correction, booster and inverter. The figure 3 shows the block diagram of power stage.
(1) SOFT-START SUB-SYSTEM:
The purpose of soft start circuit is to suppress the I/P inrush current.
(2) CONTROL POWER SUPPLY SUB-SYSTEM:
The input of the control power supply is connected to the battery bus, i.e., the output of
the charger. The output of control power supplies provide +24Vdc for the coil of relay,
+12Vdc for the bias supply of IC's working voltage and the fan(s) voltage. 5Vdc is used
for IC's working voltage. The control power supply works only when the 12Vdc
regulator supplies Vcc to its control IC. To have proper operation of 12Vdc regulator, its
input power is controlled by the switch as indicated in figure 6.
(3) INPUT POWER FACTOR CORRECTION SUB-SYSTEM:
The purpose of power factor correction (PFC) circuit is to make the input current and
voltage in phase and therefore achieve a high input power factor. The schematic is
indicated in figure 7.
When the input NFB turn on, the AC power goes through noise filter to the line detector.
Both DC buses present voltages at about 1.4 times of input RMS voltage. When the "on"
switch is pressed, the P.F.C. circuit is enabled and the DC buses are regulated at 360Vdc
for 230Vrms series.
Page6
(4) BOOSTER SUB-SYSTEM:
The major function of the UPS is to deliver accurate AC power to the loads connected to
it whenever the AC line is uncorrected or failed. In this system, the battery release the
stored energy to supply inverter immediately upon AC line fails.
Refer to figure 7 , the battery voltage is transformed through a boost DC-DC converter
to 360dc ( battery V 200~273Vdc ) as DC buses for inverter. When the line fails, the
360Vdc( battery V 200~273Vdc) DC sources are caught up to supply the power needed
by the inverter immediately.
(5) INVERTER SUB-SYSTEM:
The UPS transfers ,DC bus voltages to the AC output voltage through an inverter of
half bridge configuration at normal operation. The schematic diagram of inverter is
shown in figure 4.
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching
signals from PWM generation circuit through a pair of photo-couplers to trigger the
upper IGBT and the lower IGBT alternately.
Page7
These assemblies are the control center of UPS. It is composed of three major circuits as
following:
(1) Regulation & control
(2) Protection
(3) Signaling
(1) REGULATION & CONTROL SUB-SYSTEM :
This portion can be seen as brain of the UPS. It provides the control pulses to the
switching elements which deliver power to the output. The sub-system also regulates the
output to ensure that the UPS is delivering constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a
reference signal from sine wave generator. The difference of these two signals (error
signal) alter the pulse widths of PWM signals which control the duty cycles of switching
elements to regulate the output voltage within specification.
NOTE: VR1 is used to adjust the O/P DC voltage under battery mode.
In order to avoid unwanted surge current at the transfer of bypass relay, the bypass
signal activates the tracking circuit. It matches the inverter voltage with the line voltage
by having the amplitude of the reference signal following the variation of line voltage.
When the main is applied and the switch is turned on, a 10-seconds timer is
triggered. The bypass relay stays at bypass position in this time period. At the end of this
period, the bypass signal is removed and the relay transfers to inverter output.
Page8
Page10
3. OUTPUT SUB-SYSTEM
The output of IGBT's is filtered by an LC circuit to reduce the o/p voltage harmonic
distortion.
The output relay and S.T.S receives signal from control circuit to switch the output of the
UPS from bypass to inverter, and vice versa.
4. CHARGER (CHGR)
The purpose of charger is to charge and to maintain the batteries at full charged
condition. Refer to figure 5, the voltage flyback switching power supply provides a
constant DC voltage (273Vdc) for batteries. Besides providing constant voltage, the
power supply also limits the current flowing into batteries and therefore protects and
prolongs the lifetime of charged batteries.
Page11
5. FRONT PANEL
O VER LO AD
The indication
OVERLOAD
The LED-chain
LOAD
LO AD
The indication
BYPASS
which is provided by the mains via the bypass.
BYPASS
IN V E R T E R
The indication
INVERTER
BATTERY
The LED-chain
(normal operation).
The indication
the UPS input.
L IN E
ALAR M
BATTERY
LINE
The indication
ALARM
is on, when the UPS is faulty. Simultaneously, an
acoustical signal is given, which will be reset with switching off the UPS.
The button will switch inverter off and bypass on.
The button will switch the inverter on and be silent in battery mode.
The front panel consists 2 parts: push bottom and display LED set. The push bottom is
used to turn on and off the UPS. LED display indicates the load level (battery mode
indicates the battery voltage level) and operation status of the UPS. Line LED indicates
AC line is normal. If the line LED flash, it warns the power source is bad. Bypass LED
indicates bypass is active. Inverter LED indicates inverter is working and Fault LED
indicates the UPS is in fault condition.
Besides, when the system works abnormally, the fault LED will light up and the buzzer
will beep continuously. In this situation, the panel LED will indicate which part inside
the UPS is out of order. The representations of fault conditions are listed as following:
Page12
Inverter Fault
Bus fault
Page13
EPO fault
Page14
IV. ALIGNMENTS
PCB
TEST
PSDR
EXPECTED
RESULT
DC(+) BUS
#11
#12
DC(-) BUS
#13
#12
CHARGER
P905(+)
P907(-)
current
balance
#R464
#R463
CHGR
CNTL
TEST
POINT
1.
100K/2W
from AC outlet
to DVM Meter
20uF/250V
Page15
V. TROUBLE SHOOTING
For the reason of safety, you must turn off I/P NFB and disconnect battery fuse. Check the
components listed below to confirm which block is out of order and follow the procedures
listed on the following pages to repair them.
CAUTION:
DO NOT supply UPS with the mains unless you are sure that you have replaced all
defective components.
1. OVERVIEW :
Circuit Block
Components to be checked
Fail condition
FUSE
F202,F204
open
I/P SCR
BAT SCR
Q222,2223
short or open
Q217
short or open
Booster
Q218,219,220,221
D259,263
short or open
Q213,Q214,Q215,Q216
Inverter
IGBT
D242,D243
short or open
Page16
2. P.F. CORRECTION:
Step
Checked components
*Instrument
function
Reference
Value
Failed
condition
F204
short
open
Q218,219,220,221 (C,E)
Q218,219,220,221 (G,E)
DIODE
2.69V
23.7K
short or open
short or open
D259,263
DIODE
0.35V
short or open
R401,402,407~411,413
10
open or value
change
D256,261
DIODE
0.39V
short or open
*Instrument
Reference
Failed
3. DC-DC CONVERTER:
Step
Checked components
function
Value
condition
F202
short
open
Q217(G,K)
10~16
short or open
*Instrument
function
Reference
Value
Failed
condition
4. DC/AC INVERTER:
Step
Checked components
Q213,214,215,216
(G,E)
(E,C)
DIODE
23.8K
0.36V
short or open
short or open
R360,363,364,380,381,389
10
R358,359,361,362
56
D242,243
DIODE
0.36V
short or open
D236,D248,D250
DIODE
0.36V
short or open
Page17
Checked components
*Instrument
function
Reference
Value
Failed
condition
Q211(D,S)
DIODE
0.47V
short or open
R264
open
R442
2.2
open
>1M
>1M
3.5k
>1M
too low
6. SOFT START :
Step
Checked components
*Instrument
function
Q222,223
(A,K)
(G,K)
Reference
Value
Failed
condition
>1M
20~60
short or open
short or open
7. CHARGER:
Step
Components
*Instrument
function
Reference
Value
Failed
condition
F901,902,903,904,905,906
short
open
Q909 (S,D)
(D,S)
DIODE
DIODE
0.5V
<0.4V
no open
D901,902,903
DIODE
0.43V
Short or open
Page18
8. DYNAMIC CHECK:
When all main components have been replaced, put PSDR board back and fix it then
plug all connector back. Check if all connectors and terminals are on correct location.
(1) Remove fuse F202 and F204, then connect battery jumper on battery.
(2) Turn on input breaker. Use oscilloscope to see those points :
(a) Voltage between C264 and GND (heat-sink of U212) is 5Vdc. If not, check
(3)
(4)
(5)
(6)
The pin assignment and description are listed in the following table and the interface
configuration is indicated in Figure VI-1. Note that, the computer will control
information exchange by a query followed by <cr> (Character Return). UPS will respond
with information followed by a <cr> or action. UPS data will be provided at 2400 baud
rate and consist of 8 data bits, 1 stop bit, and no parity bit. All the information is
provided in ASCII format.
PIN #
Description
I/O type
input
output
GND
RX
TX
3
4
5
6
7
8
9
2. AS400(option)
AS 400 provide dry contact closure signal open or close. The pin assignment and
description are listed as following.
PIN #
Description
I/O type
output
output
N.C.
N.C.
Common
output
output
output
output
Page21
STS
I/P
EMI-PCB
Line
AC/DC
and
DC/DC
Boost Converter
DC/AC
Inverter
I/P
NFB
O/P
EMI-PCB
Load
O/P
NFB
Battery
Bank
Charger
Block diagram
Figure 1
MAINT
BPS
SW.
BYPASS
L210
D263
+BUS
BATSCR
I/P
NFB
I/P
Q217
Q222
BAT+
I/P
EMI
D
Q223
G
D259
-BUS
CHGR
O/P
I/P
PCB
Figure 2
L202
L201
4
2
L209
4
2
MAINT BPS SW
6
8
RY2
O/P(L)
6
8
RY1
O/P(N)
O/P
EMI
O/P
NFB
O/P
20
21
9
12
3 00uF/450V
3300uF/450V
C1
11
I /P
1P2W
2 0VAC
13
+BUS
N
L210
C2
-BUS
BYPASS
D263
MAINT BPS SW
BATSCR
TB
L
2
1
N
G
I/P
NFB
I/P CHOKE
P3
PCB
P4
Q217
Q222
P2
P1
I/P EMI
BAT+
I/P(L)
D
PFCPWM
N
I/P(N)
10u/250V
L1
Q223
PFCPWM
BAT-
MOV-PCB
P213
P211
+
EXTRA BAT
240VDC
L202
L201
D
IGBTPWM
C*2pcs
PARALELL
D259
6
8
RY2
O/P(L)
RY1
30A/250V
O/P
NFB
-PCB
O/P EMI
P1
14
15
16
17
O/P(N)
CN202
P204
CN203
WHT
CN207 50PIN
CN201
NFB
FAN
OUTLET
FAN
BRN
WHT
GREEN
CONTROL
CN5
TO CNTL-PCB CN5
CN1 16PIN
INTERNAL
BATTERY
20PCS
7.0AH
+
-
P906
CHGR O/P
P907
CHARGER
P905
CN3 26PIN
CN601
CN602
P908
P901
P904
P902
CHGR I/P
+
-
PANNL
P903
Figure 3
CN2 50PIN
INTRFACE
19
18
O/P TB
1P2W
2 0VAC
L
N
G
BLUE
PSDR
F202
BAT+
L209
P212
N1
IGBTPWM
F204
+BUS
IGBT*2PCS
PARALELL
IGBTPWM+
C1
SNUBBER
G
S
L202
C2E1
IGBTPWM-
INV_OUT
SNUBBER
S
E2
-BUS
L201
F901~903
+BUS
P901+/P902+
D Q908
D901
G
TX901
CN201/CN202
CONTROLLER
PWM
G
C928
BAT+
C918
CHGR ON/OFF
P905+/P906+
D902
P907-/P908-
Q907
BAT-
D903
P903-/P904-
-BUS
VR901
F904~906
CHGR+
D237
POW
1N5404
R236
619K*
R436
100K*
R235
103MP/1KV
R290
100K*
619K*
22K/3W
R341
D233
UF2006
R234
619K*
TX201
EE25108*1
C267
10
D232
D229
UF2006
MUR460
D223
Q210
1N4937GI
PSA44
C280
47U/400V(18)
D
ZD202
18V
Q211
2SK2608
PWM
CNTROLLER
R264
+24V
+24V
BAT-
R320
4
TLP
521
U210
ICPS2561
R319
C244
2.49K*
R289
470k
C239
47.5K*
Q209
TL431
R238
1.5K*
1K*
Q224
C1815
C2655
10K*
Figure 6
1
2
Q205
R240
1N4007GI
IC7805
U211
I 7805
+5V
O
A
C265
104Z
GND
1
2
FANSP/F
D211
HFPW+
R322
10K*
R239
7812
2200u/16v
R321
470p
C266
104Z
+12V
IC7812
U212
CN202
JST-2P
JST-2P
CN203
L210
1
2
3
RECT+
D263
4
5
6
700UH
1
v
IGBT
DRIVER
LINE
CT100:1
+BUS
RHRG75120
IRG4PF50W
SNUBBER
3300uF/450V
PFC CONTROLLER
IGBT
DRIVER
IRG4PF50W
SNUBBER
RECT-
4
5
6
700UH
CT100:1
1
2
3
U
2
D259
RHRG75120
FEED BACK
CIRCUIT
3300uF/450V
L209
CURRENT
SENSOR
-BUS
Figure 8