AEC Star T3 User manual

ServiceManual STAR T3/T3R UPS
6kVA~10kVA 220VAC
www.allis.com.tw

ST3 6-10kVA Service Manual Rev.1
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 ............................................................. 10
4. Final testing.................................................................................................................................... 11

ST3 6-10kVA Service Manual Rev.1
Allis Electric Page 1 of total 13 September 2006
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

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Allis Electric Page 2 of total 12 September 2006
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.

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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.

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Allis Electric Page 4 of total 12 September 2006
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 Ω0 ΩOpen
(A, K) Ω2.6 MΩShort or open2 Q301
Q302 (G, K) Ω10 ΩShort or open
Action ltem: If all above-stated components are replaced well and UPS still can’t work, change the PFC
IGBT driver module.

ST3 6-10kVA Service Manual Rev.1
Allis Electric Page 5 of total 12 September 2006
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) Ω800kΩshort1 Q306~Q311
(G,E) Ω15.8kΩshort or open
2 D308, D310, D309, D311 DIODE 0.35V 0 V
3 D302, D304, D306, D303,
D305, D307
DIODE 12Ωopen

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4 R325, R331, R334, R342,
R337, R328
Ω10Ωopen
5 R390, R388, R389, R393,
R392, R391
Ω2.2Ωopen
6 F303, F304 Ω0Ωopen
(A,K) Ω2.5MΩshort7 Q305
(G,K) Ω10Ωshort
Action ltem: If all above-stated components are replaced well and UPS still can’t be DC start, change Boost
IGBT Driver Module.

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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) Ω100kΩShort1 Q201,Q202,
Q203,Q204 (G,E) Ω23.5kΩShort or Open
2 D201,D202,D203,D204,D205 Diode 0.36V 0V
3 D210,D211,D212,D213 Diode 46ΩOpen
4 R201,R202,R208,R209 Ω10ΩOpen
5 R203,R204,R210,R211 Ω36ΩOpen
Action ltem:Make sure the DC fuses with same rating as original ones for replacement. Otherwise,
unpredictable danger might happen.

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3. Troubleshooting
3.5 Charger Module Analysis
6/10 kVA-Charger Module- Long back-up type
Step Checked components Instrument
function Reference Value Failure Mode
1 F1 Ω0
Ωopen
(E,C) Ω≈1MΩ
2 Q301
Q105 (G,E) Ω10kΩ
3 D303 DIODE ≈0.4V 0V
4 R315 Ω10Ωopen
5 R319 Ω1kΩopen
6 D106 DIODE ≈0.4V 0V
7 R112,R159 Ω10Ωopen
(A,K) Ω≈1MΩ
8 Q04
(G,K) Ω≈12Ω
9 R320,R321,R322,R340,R339,
R341
Ω≈0.5/6 Ωopen

ST3 6-10kVA Service Manual Rev.1
Allis Electric Page 9 of total 12 September 2006
6/10 kVA- Charger Module- Standard type
Step Checked components Instrument
function Reference Value Failure Mode
1 F901,F902,F903,
F904,F905,F906,
Ω0 Ωopen
(S, D) Ω≈1.7MΩ
2 Q907,Q908,
(G, S) Ω32Ω
3 D901,D902,
D903
DIODE ≈0.4V 0V
(A, K) Ω≈20MΩ
4 Q909
(G, K) Ω≈42Ω

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3. Troubleshooting
3.6 PFC / Boost / Inverter IGBT Driver Module Analysis
6/10kVA-Boost-Right side
6/10kVA-Boost-Left side
Step Checked components Instrument
function Reference Value Failure Mode
ZD201 V 0.7V 0V
Q201,Q202 V VBE=0625V,
VBC=0.625V
0V
1(RED)
R203,R205 Ω10ΩOpen
D201 V 0.580V 0V2(BLUE)
Q01 V VSD=0.5V
VSG=2.225V
0V

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4. Final testing
After you have replaced all defective components on power stage (PSDR), please follow the steps as below.
Step 1. Install the PSDR board into UPS unit, but DO NOT connect with “Battery” and “Input source”.
Step 2. Supply DC voltage (270Vdc/3 Amp (limited current) for 6/10kVA) with DC power supply via BAT(+) and BAT(-).
Press the switch on front panel for more than 3 seconds, you will see "current limit" for a short time on the DC power
supply for about only 2 seconds, then UPS should be DC start (If UPS does not start successfully, and LCD display off,
replace the above procedure). If UPS fails to start up for several times or DC power supply is on current-limit state
continuously, there must be some defective components exist. Please follow the section 3 trouble shooting to check again.
- Before go to step 2, make sure all of the cable should be connected the right position.
- Do not connect with AC power source yet.

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4. Final testing
Step 3. If the UPS re-start normally, check the DC_BUS and output voltage.
- For 6/10kVA, DC_BUS: +340~350 and -340~350VDC, deviation between negative and positive voltage should be within
10VDC. Output Voltage: 220/230/240 +/-2%
DC-BUS Voltage: Positive
®
DC_BUS: + 340~350VDC
_
DC-BUS Voltage: Negative
_
DC_BUS: - 340~350VDC
®

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4. Final testing
Output Voltage
Output Voltage: 220/230/240 +/-2%
Step 5. Connect with AC power source, then follow the step3 and step4 to check the DC_BUS and output voltage again.
Also, the charger voltage need to be confirmed, the charger voltage should be 274VDC +/-1%. If UPS fails to start up for
several times, there must be some defective components exist. Please follow section 3 trouble shooting to check again.
_
Charger Voltage: 274VDC +/-1%
®