Powertronix PTX2-A3 User manual

ServiceManual PTX2-A3 UPS
6kVA~10kVA 220VAC

PTX2-A3 Service Manual Rev.2
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 ............................................................... 9
4. Final testing.................................................................................................................................... 10
5. Service Setting ............................................................................................................................... 13
5.1 How to adjust the output voltage and frequency on LED type UPS ...................................... 13
5.2 How to replace the control card............................................................................................. 16

PTX2-A3 Service Manual Rev.2
Page 1 of total 19 August 2007
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

PTX2-A3 Service Manual Rev.2
Page 2 of total 19 August 2007
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.

PTX2-A3 Service Manual Rev.2
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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.

PTX2-A3 Service Manual Rev.2
Page 4 of total 19 August 2007
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 (Fuse)  0  Open
(A, K)  1-2 M Short or open2 Q301
Q302 (G, K)  40-50  Short or open
Action ltem: If all above-stated components are replaced well and UPS still can’t work, change the PFC
IGBT driver module.

PTX2-A3 Service Manual Rev.2
Page 5 of total 19 August 2007
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)  800k short1 Q306~Q311
(G,E)  23.8k short or open
2 D308, D310, D309, D311 DIODE 0.35V 0 V
3 D302, D304, D306, D303,
D305, D307
 12 open

PTX2-A3 Service Manual Rev.2
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4 R325, R331, R334, R342,
R337, R328
 10 open
5 R390, R388, R389, R393,
R392, R391
 2.2 open
6 F303, F304  0 open
(A,K)  2.5M short7 Q305
(G,K)  43.6 short
Action ltem: If all above-stated components are replaced well and UPS still can’t be DC start, change Boost
IGBT Driver Module.

PTX2-A3 Service Manual Rev.2
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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)  100k Short1 Q201,Q202,
Q203,Q204 (G,E)  47.6k Short or Open
2 D201,D202,D203,D204 Diode 0.36V 0V
3 D210,D211,D212,D213 Diode 46 Open
4 R201,R202,R208,R209  10 Open
5 R203,R204,R210,R211  36 Open
Action ltem:Make sure the DC fuses with same rating as original ones for replacement. Otherwise,
unpredictable danger might happen.

PTX2-A3 Service Manual Rev.2
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3. Troubleshooting
3.5 Charger Module Analysis
6/10 kVA-Charger Module- Long back-up type
6/10 kVA- Charger Module- Standard type
Step Checked
components
Instrument
function
Reference
Value
Failure Mode
1 F1 :0
:open
(E,C) |1M:Short
2 Q301
Q105 (G,E) 10k:Short or Open
3 D303 DIODE |0.4V 0V
4 D106 DIODE |0.4V 0V
(A,K) |1M:Short
5 Q04
(G,K) |12:Short
Step Checked
components
Instrumen
t function
Reference
Value
Failure
Mode
1 F901,F902,F903,
F904,F905,F906,
:
0
:
open
(S, D) |1.7M
:
Short
2 Q907,Q908,
(G, S) 57
:
Short
3 D901,D902,
D903
DIODE |0.4V 0V
(A, K) |20M
:
Short
4 Q909
(G, K) |54
:
Short

PTX2-A3 Service Manual Rev.2
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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  10 Open
D201 V 0.580V 0V2(BLUE)
Q01 V VSD=0.5V
VSG=2.225V
0V

PTX2-A3 Service Manual Rev.2
Page 10 of total 19 August 2007
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.

PTX2-A3 Service Manual Rev.2
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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
®

PTX2-A3 Service Manual Rev.2
Page 12 of total 19 August 2007
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%
®

PTX2-A3 Service Manual Rev.2
Page 13 of total 19 August 2007
5. Service Setting
5.1 How to adjust the output voltage and frequency on LED type UPS
The original output voltage of PTX2-A3 LED type do not meet the local voltage, because LED can not
setting the voltage on LED panel.
Following the guide-line to adjust the output voltage.
Step 1, UPS connect with computer via RS232.
Step 2, UPS should be working on Bypass Mode, and double click the “ID setting” software on computer for operation.
ÆDouble Click

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5. Service Setting
Step 3, Type “1” and “” for 1mins detection time between software and UPS.
Step 4, Type the “” and “” for showing the information on computer screen.
Step 5, Type the “CTL” and “” to setting mode.

PTX2-A3 Service Manual Rev.2
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5. Service Setting
Step 6, Type the “VXXX” and “” for setting the output voltage.
XXX: 220/230/240VAC
Step 7, Type the “CFXX” and “” for setting the output Frequency.
˄
XX: 50/60
˅
After Type ENTER key.

PTX2-A3 Service Manual Rev.2
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5. Service Setting
5.2 How to replace the control card
6kVA Standard
Step 1: For the safety of persons and product safety, the battery should disconnect in advance.
Step 2: Adjust the Jumper on 6-10kVA control card
Jumper between Pin 1 and Pin 2

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5. Service Setting
Step 3: Connect with 16 pin cable
Step 4: Connect with cable
16pincable 10pincable
26pincable 2pincable

PTX2-A3 Service Manual Rev.2
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5. Service Setting
Step 5: inset into PSDR board
Step 6: Connect with battery, release the remnant of electric power in UPS by using the lamps or above 30ohm/100Watt
resistance in advance, then connect with UPS.
10kVA Standard
Only the Jumper is different, other steps are following the 6kVA standard 1-6
Jumper between Pin 1 and Pin 2,
Pin 11 and pin 12