Powertronix Mizar-Alcor User manual

R&D
–
SERVICE MANUAL DT0489-E00
Powertronix spa reserves the right to modify this document without notice
POWERTRONIX
Mizar-Alcor
Service Manual
Document : DT0489 English PTX
Revision Date Checked Approved
00 07-09-2009 07-09-2009
Ghezzi R. 07-09-2009 Ghezzi R.

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 2 of 72
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 UPS-10-15KVA ELECTRONIC PARTS LAYOUT.................................................9
2.5 UPS-20-30KVA ELECTRONIC PARTS LAYOUT...............................................10
2.6 UPS-10-15KVA BOARDS..................................................................................11
2.7 UPS-20-30KVA BOARDS..................................................................................11
2.8 BOARDS LAYOUT..............................................................................................12
2.8.1 UPS-10-15KVA POWER INTERFACE BOARD COMPONENT LAYOUT..12
2.8.2 UPS-20-30KVA POWER INTERFACE BOARD COMPONENT LAYOUT..13
2.8.3 CS0150 UPS-10-15KVA UPS-20-30KVA CONTROL BOARD...................14
2.8.4 CS0153 UPS-10-15KVA UPS-20-30KVA POWER SUPPLY BOARD........15
2.8.5 CS0098 RELAY & COMUNICATION BOARD............................................16
2.8.6 SNMP COMUNICATION BOARD...............................................................16
2.8.7 TERMINAL BLOCKS..................................................................................17
3TROUBLESHOOTING.............................................................................................18
3.1 POWER FUSE....................................................................................................18
3.1.1 UPS-10-15KVA...........................................................................................18
3.1.2 UPS-20-30KVA...........................................................................................19
3.2 CHECK ALL PFC & INVERTER OUT IGBTS. ....................................................20
3.2.1 UPS-10-15KVA...........................................................................................20
3.2.2 UPS-20-30KVA...........................................................................................21
3.2.3 CHECK AUXILIARY POWER SUPPLY CONTROL BOARD......................23
3.2.4 LED STATUS .............................................................................................25
3.2.5 CHECK CONTROL BOARD.......................................................................26
3.2.6 CHECK POWER SUPPLY VOLTAGE........................................................26
3.3 POWER INTERFACE UPS-10-15KVA BOARD..................................................27
3.4 POWER INTERFACE UPS-20-30KVA BOARDS (CS0151)...............................29
4PC BASED CHECKS AND SETTINGS ...................................................................31
5ELECTRICAL DIAGRAM.........................................................................................40
5.1 PCB ELECTRICAL DIAGRAM INDEX................................................................40
5.1.1 DE1237 UPS 10-15KVA GENERAL DIAGRAM .........................................41
5.1.2 DE1112 UPS 20-30KVA GENERAL DIAGRAM .........................................43
5.1.3 DE0098 RELAY & COMMUNICATION BOARD.........................................46
5.1.4 DE0138 TEMPERATURE SENSOR PCB..................................................47

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 3 of 72
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 UPS 20-30KVA INVERTER DRIVER & FEEDBACK....................59
5.1.8 DE0152 UPS 10-15KVA INVERTER DRIVER & FEEDBACK....................65
5.1.9 DE0153 POWER SUPPLY BOARD ...........................................................69
5.1.10 DE0111 UPS 10-30KVA H-F FILTER.........................................................70
5.1.11 DE0155 LCD MIMIC DISPLAY...................................................................71
5.1.12 DE1235 BATTERY STRING.......................................................................72

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 4 of 72
WARNING !
The following documentation requires the knowledge and the support of
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 minimise the risk of contact whit live
voltage, especially when working around the battery or DC bus

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 5 of 72
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
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 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 !

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 6 of 72
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 (DE1244 and DE1245 )
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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 7 of 72
2.2 INNER VIEW WITH SAFETY COVER REMOVED
Fig.2
UPS Power Section
UPS Battery Location
BATTERY Connections
BATTERY String

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 8 of 72
2.3 REAR UPS DESCRIPTION
Fig.3
Breaker
SNMP-Net Com
Slot location
RS232 & Status
Remote Control
Slot location
Output
Air window
Tagblock

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 9 of 72
2.4 UPS-10-15KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 10 of 72
2.5 UPS-20-30KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 11 of 72
2.6 UPS-10-15KVA 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 UPS-20-30KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 12 of 72
2.8 BOARDS LAYOUT
2.8.1 UPS-10-15KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 13 of 72
2.8.2 UPS-20-30KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 14 of 72
2.8.3 CS0150 UPS-10-15KVA UPS-20-30KVA CONTROL BOARD
Refer to Electrical Diagram :DE0150
Fig. 10
Fiber Optic
Connector
Parallel
Comunication
LCD Mimic
Display Board
Connectors
LED BAR
UPS STATUS
LED BAR
Processor
STATUS
Battery
Keep Timer
Interface
Board
Connectors
Relay Board
Connectors
SNMP
Connector

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 15 of 72
2.8.4 CS0153 UPS-10-15KVA UPS-20-30KVA 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 16 of 72
2.8.5 CS0098 RELAY & COMUNICATION BOARD
Refer to Electrical Diagram :DE0098
Fig. 12
2.8.6 SNMP COMUNICATION BOARD
Fig. 13
DB9
RS232
Comunication
Connector
E.P.O.
Terminal
Connection
FREE VOLTAGE
CONTACTS
UPS 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

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 17 of 72
2.8.7 TERMINAL BLOCKS
Fig. 14

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 18 of 72
3 TROUBLESHOOTING
To identify a fault cause please refer to the following items.
3.1 POWER FUSE
F1-F2: Positive and Negative DC BUS.
F3-F4: Positive and Negative BATTERY
3.1.1 UPS-10-15KVA
Refer to Electrical Diagram :DE0152
Refer to Fig.8 UPS 10-15kVA Interface Board Component Layout
TAB.2
Fuse Value Protection of Location
F1-F2 32A
10x38mm Battery Input Power Interface BOARD (DE0152) UPS 10-15kVA
F3-F4 32A
10x38mm DC BUS Power Interface BOARD (DE0152)
UPS 10-15kVA
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 UPS 10-15kVA compare to UPS 20-30kVA

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 19 of 72
3.1.2 UPS-20-30KVA
Refer to Fig.6/7 UPS 20-30kVA 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 UPS 20-30kVA
F2-F4 100A 690V
Negative Battery Input
Negative DC BUS Left side Heatsink UPS 20-30kVA
If you find one or more fuses blown, you have to check firstly
ALL the POWER semiconductors on the UPS

R&D
–
SERVICE MANUAL DT0488
Powertronix spa reserves the right to modify this document without notice
Page. 20 of 72
3.2 CHECK ALL PFC & INVERTER OUT IGBTS.
well locked . If IGBT is damaged , remember that probably the driver circuitry could be
damaged , so the following parts on interface board.
3.2.1 UPS-10-15KVA
CS 0152 have to be tested.
The following diagram detail regards only the driver circuitry for PFC L1 , only to indicate
the part of circuit .
Obviously also PFC L2&L3 and INVERTER L1&L2&L3 driver has to be tested.
SCH.3
P+15
P+15
HF supply 1
HF supply 2
DRV_L1-TOP_ING
DRV_L1-BOTT_ING
G1-T
E1-T
G1-B
E1-B
R4
1.8K
R10
270
R28
270
R19
1.8K
D4
UF4007
2 1
Z4
15V
2 1
+
C7
100µF 35V
TP1
D10 1N4148
2 1
T1
VAC4721X004
1
6
3
2
4
5
+
C1
100µF 35V
D13
1N4148
21
+
C16
100µF 35V
+
-
Totem
ISO4
HCPL3120
2
3
6
5 8
7
R13
1K
+
C10
100µF 35V
+
-
Totem
ISO1
HCPL3120
2
3
6
5 8
7
TP10
R22 33
Z10
P6KE18CAC250
2 1
R7 33
C4
1µF
D1
1N4148
2 1 Z1
P6KE18CAC250
2 1
D7
UF4007
2 1
TP4
Z7
15V
21
R16
1K
R1 33
TP7
R25 33
D16
1N4148
2 1
C13
1µF
INVERTER_IN PHASE L1