Powertronix Mizar-Alcor DT 0424 User manual

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POWERTRONIX
Mizar-Alcor
Service Manual
DT 0424
Document : DT0424 PTX English
Revision Date Checked Approved
00 14-03-2008 18-03-2008
Ghezzi R. 21-03-2008 Gorlani A.
01 19-05-2008 19-05-2008
Pirola G. 20-05-2008 Gorlani A.

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Index
1. GENERAL ITEMS ......................................................................................................4
1.1 INTRODUCTION...................................................................................................4
1.1.1 General Fault Identification Procedure .........................................................4
1.2 TOOLS..................................................................................................................5
1.2.1 Portable PC with software ............................................................................5
1.2.2 Oscilloscope.................................................................................................5
1.2.3 Digital multimeter( DSM)...............................................................................5
1.2.4 Discharging resistor......................................................................................5
2UPS COMPONENTS RECOGNIZING .......................................................................6
2.1 UPS CLOSED.......................................................................................................6
2.2 INNER VIEW WITH SAFETY COVER REMOVED...............................................7
2.3 REAR UPS DESCRIPTION..................................................................................8
2.4 MIZAR ELECTRONIC PARTS LAYOUT...............................................................9
2.5 ALCOR ELECTRONIC PARTS LAYOUT ...........................................................10
2.6 MIZAR BOARDS................................................................................................11
2.7 ALCOR BOARDS...............................................................................................11
2.8 BOARDS LAYOUT..............................................................................................12
2.8.1 CS0152 MIZAR Power Interface Board Component Layout.......................12
2.8.2 CS0151 ALCOR Power Interface Board Component Layout......................13
2.8.3 CS0150 MIZAR ALCOR Control Logic Board.............................................14
2.8.4 CS0153 MIZAR ALCOR Power Supply Board............................................15
2.8.5 CS0098 MIZAR ALCOR Relay & Communication Board ...........................16
2.8.6 MIZAR ALCOR SNMP Communication Board ...........................................16
2.8.7 CS0161 MIZAR ALCOR Terminal Blocks Board........................................17
3TROUBLESHOOTING .............................................................................................18
3.1 FUSE CHECK LIST ............................................................................................18
3.2 POWER FUSE....................................................................................................19
3.2.1 Mizar...........................................................................................................19
3.2.2 Alcor ...........................................................................................................20
3.3 CHECK ALL PFC & INVERTER OUT IGBTS. ....................................................21
3.3.1 Mizar...........................................................................................................21
3.3.2 Alcor ...........................................................................................................22
3.4 CS0153 MIZAR ALCOR POWER SUPPLY BOARD .........................................23
3.4.1 Check Auxiliary Power Supply Control Board.............................................24
3.5 CS0150 CONTROL LOGIC BOARD...................................................................25
3.5.1 LED Status .................................................................................................26
3.5.2 Check Control Board ..................................................................................27
3.5.3 Check Power Supply Voltage.....................................................................27
3.6 CS0152 POWER INTERFACE MIZAR BOARD ................................................28
3.7 CS0151 POWER INTERFACE ALCOR BOARD ................................................30
4PC BASED CHECKS AND SETTINGS....................................................................32
5ELECTRICAL DIAGRAM..........................................................................................40
5.1 PCB electrical diagram index..............................................................................40
5.1.1 DE1111 UPS general diagram Mizar..........................................................41
5.1.2 DE1112 UPS general diagram Alcor ..........................................................43

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5.1.3 DE0098 Relay & Communication Board.....................................................46
5.1.4 DE0138 Temperature sensor PCB.............................................................47
5.1.5 DE0143 Battery Fuse PCB (Battery 7.2-9Ah) / DE0157 Battery Fuse PCB
(Battery 4.5-5.2Ah)...................................................................................................47
5.1.6 DE0150 Control Logic.................................................................................48
5.1.7 DE0151 Inverter Driver & Feedback Alcor..................................................59
5.1.8 DE0152 Inverter Driver & Feedback Mizar.................................................65
5.1.9 DE0153 Power Supply Board.....................................................................69
5.1.10 DE0154 H-F Filter Mizar.............................................................................70
5.1.11 DE0155 LCD Mimic Display .......................................................................71
5.1.12 DE0161 H-F Filter Alcor..............................................................................72
5.1.13 DE1235 Battery String................................................................................73

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WARNING !
The following documentation requires the knowledge and the support of Mizar-Alcor
USER MANUAL .
1. GENERAL ITEMS
1.1 INTRODUCTION
The UPS contains complex electronic control circuits which require a firm understanding
in order to carry out comprehensive fault diagnosis and repair of the equipment.
The aim of the information contained in this chapter is to provide sufficient guidance to
the trained service engineer, to enable successful fault location to printed circuit board
level. When a faulty circuit board or component has been identified, it should be replaced
or returned to the nearest service centre to repair.
The troubleshooting information include the following items :
•Component location and identification
•Diagnostic information
•Troubleshooting procedures
•Test procedures
Note: when following the procedures cross referencing is inevitable, therefore
it is recommended that this chapter is read in its’ entirety, before commencing
work on the equipment.
There is no practical way detecting an impending UPS malfunction, as most problems do
not emerge as a gradual performance degradation. Generally the UPS will either work
correctly or shut down with or without a warning indication.
In the event of a UPS malfunction troubleshooting should be carried out methodically
along the following guide lines.
1.1.1 General Fault Identification Procedure
When first summoned to the UPS fault the immediate action should be to observe and
record the LED indication displayed on the unit operator panel.
a) Determine the UPS power status.
b) Note the control switch configuration, and also the warning horn sequence if it is
operating.
WARNING: during the troubleshooting it will be necessary to power up the
unit whit the side or top covers removed. In this situation exposure
to potentially lethal voltage is possible even whit the input utility
supply switched off.
Take great care at all switch to minimize the risk of contact whit live
voltage, especially when working around the battery or DC bus

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c) Power down the unit, and ensure that the DC Bus Safety discharge check is
carried out.
d) Gain access to the internal components follow the procedure for removing the UPS
covers.
e) Check the status of the UPS fuses refer to the check list on table 1,2,3
f) Apply power and analyse LCD indications
g) Refer troubleshooting chart to identify possible fault
h) Check PFC converter power components. Pag.20 for component location
i) Check inverter power components. Pag.20 for component location
1.2 TOOLS
Special mechanical tools aren’t required to service the UPS, a normal electricians tool kit
will be adequate. Are necessary insulating gloves and glasses for safety. However to
carry out the check procedures in this chapter the following test equipment will be
required.
1.2.1 Portable PC with software
POWERTRONIX UPS Maintenance UCT
See the chapter 4
is absolutely necessary for a skilled service engineer because every set point or UPS
logic status or regulation constant can be set or checked only via PC and
POWERTRONIX software
1.2.2 Oscilloscope
A dual trace oscilloscope, which has the ability to sum the two channel, allowing
differential voltage measurements to be made.
For the measure points that it is needed to check it is mandatory to have the
oscilloscope insulated from the supply whit a transformer or battery fed scope.
A storage facility is useful, but not essential.
1.2.3 Digital multimeter( DSM)
A standard digital multimeter is necessary to take essential measurements ; a reference
type could be the FLUKE 70 series multimeter or equivalent.
1.2.4 Discharging resistor
To discharge electrolytic capacitors bank in a short time it’s necessary use a discharging
resistor , ref. value 10K / 50W nom. Before using discharging resistor verify that
battery circuit breaker is open !

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2 UPS COMPONENTS RECOGNIZING
To do servicing it’s necessary to recognize UPS parts , so , before troubleshooting ,
some pictures of UPS and parts will be shown in the following pages . To check pictures
it’s necessary to follow the UPS general schematic diagram (DE1111 for Mizar and
DE1112 for Alcor) attached at the end of this document .
2.1 UPS CLOSED
Fig.1
*** WARNING !! Before removing safety covers after power disconnection , it’s
necessary to wait for 10 minutes to have discharged inner capacitors . In any case be
careful and never touch circuits or components before a voltage check
UPS Control Panel
UPS Side Cover panel
UPS Front Cover
BATTERY Front Cover
E:P:O: Command

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2.2 INNER VIEW WITH SAFETY COVER REMOVED
Fig.2
UPS Power Section
UPS Battery Location
BATTERY Connections
BATTERY String

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2.3 REAR UPS DESCRIPTION
Fig.3
Terminal Blocks
Power
Connection
Rotary Switch
Breaker
SNMP-Net Com
Slot location
RS232 & Status
Remote Control
Slot location
Output
Air window

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2.4 MIZAR ELECTRONIC PARTS LAYOUT
LEFT SIDE
Fig.4
RIGHT SIDE
Fig. 5
NEUTRAL BAR
Connection
DC Busbar
HEATSINK
FAN
Power Impedence
DC
Busbar
Power Impedence
CS0150
CS0153

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2.5 ALCOR ELECTRONIC PARTS LAYOUT
LEFT SIDE
Fig. 6
RIGHT SIDE
Fig. 7
NEUTRAL BAR
CONNECTION
DC Busbar
HEATSINK
Power Impedence
DC Busbar
Power Impendence
Fuse
Fuse
CS0153
CS0150

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2.6 MIZAR BOARDS
This paragraph describes the PCB 's fitted in the UPS,
Subassembly code Description Diagram Circuit code
0sde 0150 Control Logic 7-30KVA DE0150 CS0150
0sde 0152 Inverter Drivers&Feedback Mizar DE0152 CS0152
0sde 0153 Aux. Converter DE0153 CS0153
0sde 0155 LCD Mimic Display "4*20" DE0155 CS0155
0sde 0143 Fuse Holder x 7-9 Ah DE0143 CS0143
0sde 0157 Fuse Holder x 7-9 Ah DE0157 CS0157
0sde 0154 H-F Filter DE0154 CS0161
0sde 0162 Temperature Sensor SMT DE0138 CS0138
0sde 0098 Relay Board DE0098 CS0098
2.7 ALCOR BOARDS
This paragraph describes the PCB 's fitted in the UPS,
Subassembly code Description Diagram Circuit code
0sde 0150 Control Logic 7-30KVA DE0150 CS0150
0sde 0151 Inverter Drivers&Feedback Mizar DE0151 CS0151
0sde 0153 Aux. Converter DE0153 CS0153
0sde 0155 LCD Mimic Display "4*20" DE0155 CS0155
0sde 0143 Fuse Holder x 7-9 Ah DE0143 CS0143
0sde 0157 Fuse Holder x 7-9 Ah DE0157 CS0157
0sde 0161 H-F Filter DE0161 CS0161
0sde 0162 Temperature Sensor SMT DE0138 CS0138
0sde 0098 Relay Board DE0098 CS0098
0sde 0114 Fan Board DE0114 CS0114

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2.8 BOARDS LAYOUT
2.8.1 CS0152 MIZAR Power Interface Board Component Layout
Refer to Electrical Diagram :DE0152
Fig. 8
Input
Precharge
Relay
Negative
DC Capacitor
Fuse
Negative
DC Battery Fuse
RESERVE
Relay
Static Switch
Positive
DC Batter
y
Fuse Positive
DC Ca
p
acitor Fuse
IGBT
Input
Section
IGBT
Output
Section
INVERTER
Relay
Static Switch

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2.8.2 CS0151 ALCOR Power Interface Board Component Layout
Refer to Electrical Diagram :DE0151
Fig. 9
Input
Precharge
Thyristor
IGBT
INPUT
SECTION
RESERVE
Static Switch
Thyristor
IGBT
OUTPUT
SECTION INVERTER
Static Switch
Thyristor

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2.8.3 CS0150 MIZAR ALCOR Control Logic Board
Refer to Electrical Diagram :DE0150
Fig. 10
Fiber Optic
Connector
Parallel
Communicatio
LCD Mimic
Display Board
Connectors
LED BAR
UPS STATUS
LED BAR
Processor
STATUS
Battery
Keep Timer
Interface
Board
Connectors
Relay Board
Connectors
SNMP
Connector

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2.8.4 CS0153 MIZAR ALCOR Power Supply Board
Refer to Electrical Diagram :DE0153
Fig. 11
Input Mains
Connector
Input Reserve
Connector
DC Bus
Connector
Interface
Board
Connector
Power
Supply
status

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2.8.5 CS0098 MIZAR ALCOR Relay & Communication Board
Refer to Electrical Diagram :DE0098
Fig. 12
2.8.6 MIZAR ALCOR SNMP Communication Board
Fig. 13
DB9
RS232
Communication
Connector
E.P.O.
Terminal
Connection
Free voltage contacts
U
p
s status
Control
Logic
Connector
Control
Logic
Connection
Config Switch
NET RJ45 +
status led
CONNECTOR
Serial Comport
Aux
Input/Output
Dr
y
contact
Status Led
Error Link

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2.8.7 CS0161 MIZAR ALCOR Terminal Blocks Board
Refer to Electrical Diagram :DE0161
Fig. 14
BATTERY
Terminal
Blocks
OUTPUT
Terminal
Blocks
MAINS-INPUT
Terminal
Blocks
RESERVE-INPUT
Terminal
Blocks
BATTERY
FUSES OUTPUT FUSES
MAINS-INPUT
FUSES RESERVE-INPUT FUSES

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3 TROUBLESHOOTING
To identify a fault cause please refer to the following items.
Fig.15 MIZAR ALCOR TERMINAL BLOCKS BOARD
3.1 FUSE CHECK LIST
Prior to any fault diagnosis , a check of all UPS fuses is recommended.
Fault fuse can give an indication of a defective power device or component .
TAB.1
Fuse Value
MIZAR Value ALCOR Protection of Location
F1-F2-F3 32A
10X38mm 50A 14x51mm Mains Input EMC/RF FILTERS BOARD (CS0161)
Front high left corner
(DE0154 MIZAR) (DE0161 ALCOR)
F4-F5-F6 32A
10X38mm 50A 14x51mm Reserve Input EMC/RF FILTERS BOARD (CS0161)
Front high Centre left corner
(DE0154 MIZAR) (DE0161 ALCOR)
F7-F8 32A
10X38mm 50A 14x51mm External Battery EMC/RF FILTERS BOARD (CS0161)
Front high centre right corner
(DE0154 MIZAR) (DE0161 ALCOR)
F9-F10-F11 32A
10X38mm 50A 14x51mm Output UPS EMC/RF FILTERS BOARD (CS0161)
Front high right corner
(DE0154 MIZAR) (DE0161 ALCOR)
SCH.1
C9 0.47µF
275Vac
X2
PW34PW33
PW8
L3-R
C6 1µF
275Vac
X2 C7 0.47µF
275Vac
X2
F4
PW6
L1-R PW9 N-R
PW35
PW7
L2-R
F5 F6
C8 0.47µF
275Vac
X2 C12 0.47µF
275Vac
X2
C11 0.47µF
275Vac
X2
F7
PW11
- BATTERY
PW36
PW12
COMM.
PW10
+ BATTERY
F8
C10
1µF
275Vac
X2
PW37 PW40
F9
PW16
N-O
C14 0.47µF
275Vac
X2 C15 0.47µF
275Vac
X2
PW17
GROUND
PW14
L2-O
F10
PW13
L1-O
C13 0.47µF 275Vac
X2
PW39
F11
PW38
PW15
L3-O
C1
1µF
275Vac
X2
PW31
F3
PW30
F2
C2 1µF
275Vac
X2
PW3
L2-I
C3 0.47µF 275Vac
X2
PW4
L3-I PW5 N-I
F1
C4 0.47µF
275Vac
X2 C5 0.47µF
275Vac
X2
PW32
PW1
GROUND PW2 L1-I
HOLE 5.5mm
metal PlatedHOLE 5.5mm
metal Plated

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3.2 POWER FUSE
F1-F2: Positive and Negative DC BUS.
F3-F4: Positive and Negative BATTERY
3.2.1 Mizar
Refer to Electrical Diagram :DE0152
Refer to Fig.8 MIZAR Interface Board Component Layout
TAB.2
Fuse Value Protection of Location
F1-F2 32A
10x38mm Battery Input Power Interface BOARD (DE0152) MIZAR
F3-F4 32A
10x38mm DC BUS Power Interface BOARD (DE0152)
MIZAR
SCH.2
P+5
P+5
E1-T
16_+DC-BUS
G3-T
E4-B
G1-T G4-T
E5-B
G5-T
G2-B
E3-B G6-B
G4-BG1-B
E3-T E6-T
REF
16_-DC-BUS
G3-B
E5-T
G6-T
E2-B
G2-T
E6-B
G5-B
E4-T
E1-B
E2-T
AUX_CONV -DC
AUX_CONV +DC
FS6
L1
FS5
L2
FS22
L3
R183
100K 0.25W
R184
100K 0.25W
Q3
SK60GB128
28
613
27
2
1
24
125
23
F2
32A 10x38
1
23 4
C37
2.2µF PHB
850V
21
FS21
L2
Q6
SK60GB128
28
613
27
2
1
24
125
23
R180
150K 0.25W
R186
100K 0.25W
FS14
+ DC
R181
150K 0.25W
R188
150K 0.25W
C38
2.2µF PHB
850V
21
Q2
SK60GB128
28
613
27
2
1
24
125
23
C43
2.2µF PHB
850V
21
Q4
SK60GB128
28
613
27
2
1
24
125
23
R96
150K 0.25W
C40
2.2µF PHB
850V
21
R97
150K 0.25W
FS4
L3
C41
2.2µF PHB
850V
21
D42
1N4148
2 1
+
C62
10µF 16V
R187
100K 0.25W
F3
32A 10x38
1
23 4
Q1
SK60GB128
28
613
27
2
1
24
125
23
F1
32A 10x38
1
23 4
FS15
-DC
R185
100K 0.25W
F4
32A 10x38
1
23 4
D41
1N4148
2 1
R98
150K 0.25W
R99
6.8K
R100
6.8K
FS20
L1
R182
100K 0.25W
FS11
- BATTERY
R95
150K 0.25W
Q5
SK60GB128
28
613
27
2
1
24
125
23
FS10
+ BATTERY
CN3
DC BUS
1
2
3
4
C39
2.2µF PHB
850V
21
From Input Inductor
To Aux.
Converter
CS0153
OUTPUT INVERTER
To Inverter
Inductor
INPUT INVERTER
Note the location of fuse are different in Mizar compare to Alcor:

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3.2.2 Alcor
Refer to Fig.6/7 ALCOR LEFT/RIGHT SIDE electronic parts LAYOUT
TAB.3
Fuse Value Protection of Location
F1-F3 100A 690V
Positive Battery Input
Positive DC BUS Right side Heatsink (DE0152) ALCOR
F2-F4 100A 690V
Negative Battery Input
Negative DC BUS Left side Heatsink (DE0152) ALCOR
If you find one or more fuses blown, you have to check firstly
ALL the POWER semiconductors on the UPS