AEC Star T3 User manual

ServiceManual Star T3/T3R UPS
1kVA~3kVA 220VAC
www.allis.com.tw

ST3 1-3kVA Service Manual Rev.1
Content
1. PSDR Introduction............................................................................................................................ 1
1.1 1 kVA PSDR ............................................................................................................................ 1
1.2 2/3 kVA PSDR ......................................................................................................................... 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...................................................................................................................... 6
3.5 SPS Module Analysis .............................................................................................................. 7
3.6 1A Charger Module Analysis ................................................................................................... 8
3.7 IGBT Driver Module Analysis .................................................................................................. 9
4. Final testing.................................................................................................................................... 10

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 1 of total 12 September 2006
1. PSDR Introduction
1.1 1 kVA PSDR c
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1.2 2/3 kVA PSDR
idee
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1. Charger Module
2. Fan driver
3. Inverter IGBT Driver Module
4. PFC IGBT Driver Module
5. PFC Control Module
6. Boost IGBT Driver Module
7. SPS Module
8. Boost Control Module

ST3 1-3kVA Service Manual Rev.1
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.
4. Output shorted
1. Replace the Inverter
components or driver.
2. Replace the PFC
components or driver.
3. Remove the output
shorted.
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.

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 3 of total 12 September 2006
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 1K/3K:F1/F2;2K:F1 Fuse Open
I/P FUSE (on PSDR) F3, Fuse Open
2K/3K:D16, D17, REC02
1K:D10, D11, REC1
Diode Short or open
PFC Correction
2K/3K:Q09,1K:Q14 IGBT C-E short or open
2K/3K:Q04, Q05, Q06Q07
1K:Q4, Q6, Q10Q11
MOSFET D-S short or open
Push-Pull Booster
2K/3K:D05, D06, D07, D08
1K:D12, D13, D14, D15
Power Diode Short or open
Inverter 2K/3K:Q13, Q14, Q15, Q16
1K:Q12, Q13
IGBT C-E short or open
Charger module Q2 MOSFET D-S short or open
D10,D11,D12,D13D15 Power Diode Short or open
SPS module Q201 MOSFET D-S short or open
D202,D203 Power Diode Short or open
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.

ST3 1-3kVA Service Manual Rev.1
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 F3 fuse open indicates failure of this block. Please replace all faulty components before re-start the UPS.
1kVA-PFC
2/3kVA-PFC
Step Checked components Instrument
function Reference Value Failure Mode
1 F3 ΩShort Open
2 2K/3K:Q09(GS)
1K:Q14(GS)
Ω46.8kΩShort or open
3 2K/3K:D16,D17
1K:D10,D11
DIODE 0.418 Short or open
4 2K/3K:REC02 (+,〜),(〜,-)
1K:REC1 (+,〜),(〜,-)
DIODE 0.46 Short or open
Action ltem: If all above-stated components are replaced well and UPS still can’t work, change PFC Module
and PFC IGBT driver module.

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 5 of total 12 September 2006
3. Troubleshooting
3.3 Boost Analysis
General speaking, the most distinct phenomenon of failure on this section is F1 and F2. Open finding this will be very
helpful to repair them.
1kVA-Boost
2/3kVA-Boost
Step Checked components Instrument
function Reference
Value Failure Mode
1 F1,F2 Ωshort open
2 2K/3K:Q04~Q07 (G.S)
1K:Q4,Q6,Q10,Q11(G.S)
Ω23.49kΩshort or open
3 2K/3K:D05,D06,D07,D08
1K:D12,D13,D14,D15
DIODE 0.41 short or open
Action ltem:
(1) Make sure the DC fuses with same rating as original ones for replacement. Otherwise, unpredictable
danger might happen.
(2) If all above-stated components are replaced well and UPS still can’t be DC start, change Boost Control
Module.

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 6 of total 12 September 2006
3. Troubleshooting
3.4 Inverter Analysis
1kVA-Inverter
2/3kVA-Inverter
Step Checked components Instrument
function Reference Value Failure Mode
1 2k/3k:Q14,Q13,Q16,Q15 (G,S)
1k:Q12,Q13 (G,S)
Ω23.5kΩShort or open
2 2k/3k: D30,D31,D32,D33
1k: D21,D22
Ω70
46.6
Short or open
Action ltem: If fail condition stated in resistance R110, R106, R117 and R119 of 2/3kVA and R53 and R37 of
1kVA, there is high possibility that the corresponding photo couplers are damaged, change the Inverter IGBT
driver module

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 7 of total 12 September 2006
3. Troubleshooting
3.5 SPS Module Analysis
1 kVA-SPS Module
2/3 kVA-SPS Module
Step Checked components Instrument
function Reference Value Failure Mode
1 Q201(S,D) DIODE 0.42 Short or open
2 U01 (3845) PIN 5-6
PIN 5-7
PIN 5-8
PIN 6-8
Ω46.7K
38K
4.31K
50.9K
Too low
Action ltem: Even If the input source connected with UPS, the UPS still does not work. The high possible
cause is on SPS Module.

ST3 1-3kVA Service Manual Rev.1
Allis Electric Page 8 of total 12 September 2006
3. Troubleshooting
3.6 1A Charger Module Analysis
1 kVA-Charger Module
2/3 kVA-Charger Module
Step Checked components Instrument
function Reference Value Failure Mode
1 Q2(S,D) DIODE 0.45 Short or open
2 U07 (3845) PIN 5-6
PIN 5-7
PIN 4-8
Ω
47K
20K
7.48K
Too low
3 D10.D11,D12,D13,D15 DIODE 0.45 Short or open
Action ltem: UPS can work on bypass Mode normally when the input source connected, but it can not
start-up completely. The high possible cause is on Charger Module.