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Powertronix Mizar-Alcor Service Manual

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

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Summary of Contents for Powertronix Mizar-Alcor

  • Page 1 POWERTRONIX Mizar-Alcor Service Manual DT0489 English PTX Document : Revision Date Checked Approved 07-09-2009 07-09-2009 07-09-2009 Ghezzi R. Ghezzi R. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0489-E00...

  • Page 2: Table Of Contents

    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 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 2 of 72...
  • Page 3 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 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 3 of 72...

  • Page 4: General Items

    Take great care at all switch to minimise the risk of contact whit live voltage, especially when working around the battery or DC bus Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488...

  • Page 5: Tools

    , ref. value 10K / 50W nom. Before using discharging resistor verify that battery circuit breaker is open ! Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 5 of 72...

  • Page 6: Ups Components Recognizing

    10 minutes to have discharged inner capacitors . In any case be careful and never touch circuits or components before a voltage check Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488...

  • Page 7: Inner View With Safety Cover Removed

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

  • Page 8: Rear Ups Description

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

  • Page 9: Ups-10-15Kva Electronic Parts Layout

    LEFT SIDE Fig.4 CS0150 NEUTRAL BAR HEATSINK Connection DC Busbar Power Impedence RIGHT SIDE Fig. 5 CS0153 Busbar Power Impedence Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 9 of 72...

  • Page 10: Ups-20-30Kva Electronic Parts Layout

    NEUTRAL BAR CS0153 HEATSINK CONNECTION Fuse DC Busbar Power Impedence RIGHT SIDE Fig. 7 CS0150 Fuse DC Busbar Power Impendence Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 10 of 72...

  • Page 11: Ups-10-15Kva Boards

    CS0161 0sde 0162 Temperature Sensor SMT DE0138 CS0138 0sde 0098 Relay Board DE0098 CS0098 0sde 0114 Fan Board DE0114 CS0114 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 11 of 72...

  • Page 12: Boards Layout

    IGBT Output Input Section Section RESERVE Negative Negative Relay DC Capacitor Input DC Battery Fuse Static Switch Fuse Precharge Relay Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 12 of 72...

  • Page 13: Ups-20-30Kva Power Interface Board Component Layout

    Refer to Electrical Diagram :DE0151 Fig. 9 IGBT OUTPUT INVERTER SECTION Static Switch Thyristor IGBT RESERVE Input INPUT Static Switch Precharge SECTION Thyristor Thyristor Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 13 of 72...

  • Page 14: Cs0150 Ups-10-15Kva Ups-20-30Kva Control Board

    Comunication LCD Mimic Display Board Interface Connectors Board Connectors LED BAR UPS STATUS LED BAR Processor STATUS Battery Keep Timer Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 14 of 72...

  • Page 15: Cs0153 Ups-10-15Kva Ups-20-30Kva Power Supply Board

    Refer to Electrical Diagram :DE0153 Fig. 11 Power Interface Supply Board status Connector Input Mains Connector Input Reserve Connector DC Bus Connector Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 15 of 72...

  • Page 16: Cs0098 Relay & Comunication Board

    Fig. 13 NET RJ45 + Config Switch status led CONNECTOR Control Serial Comport Logic Connection Status Led Error Link Input/Output Drycontact Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 16 of 72...

  • Page 17: Terminal Blocks

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

  • Page 18: Troubleshooting

    32A 10x38 FS11 - BATTERY 32A 10x38 Note the location of fuse are different in UPS 10-15kVA compare to UPS 20-30kVA Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 18 of 72...

  • Page 19: Ups-20-30Kva

    If you find one or more fuses blown, you have to check firstly ALL the POWER semiconductors on the UPS Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 19 of 72...

  • Page 20: Check All Pfc & Inverter Out Igbts

    UF4007 VAC4721X004 HF supply 1 1N4148 HF supply 2 E1-B 1µF P+15 DRV_L1-BOTT_ING ISO4 1.8K G1-B Totem 1N4148 TP10 HCPL3120 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 20 of 72...

  • Page 21: Ups-20-30Kva

    UF4007 VAC4721X004 HF supply 1 1N4148 HF supply 2 E1-B 1µF DRV_L1-BOTT_ING P+15 ISO4 1.8K G1-B Totem 1N4148 TP10 HCPL3120 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 21 of 72...
  • Page 22 47 ohm Fig.15 R50-R51-R52 Input Mains AC L1-L2-L3 input 47 ohm Fig.15 R53-R54-R55 Reserve Input AC L1-L2-L3 input 47 ohm Fig.15 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 22 of 72...

  • Page 23: Check Auxiliary Power Supply Control Board

    , avoiding the deep discharge of the UPS battery . The dc/dc converter turns automatically on when mains or reserve ac voltages come back present . Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 23 of 72...
  • Page 24 DL3= Green ON when Power supply 12 Volt is inside the right parameters SW1=Push Button SW2=Push Button Upload STL Software Enable Function Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 24 of 72...

  • Page 25: Led Status

    Blinking No valid software found. Ready to receive the software "Application" Blinking µP update mode. Erasing internal application memory Blinking Blinking Blinking Blinking µP update mode. Receiving the software "Application" Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 25 of 72...

  • Page 26: Check Control Board

    RS232 interface communication board with a PC and follow the procedures described in chapter 4. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 26 of 72...

  • Page 27: Power Interface Ups-10-15Kva Board

    CN3 4-Pin Molex Connector “Feedback DC-BUS Voltage” DE0152-Pag.2 CN4 5-Pin Molex Connector “Reserve line to CS 0153” DE0152-Pag.3 F42 1A 250V Fuse protection for Fan DE0152-Pag.2 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 27 of 72...
  • Page 28 UPS-10-15KVA Component Layout Refer to Electrical Diagram :DE0152 Fig.17 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 28 of 72...

  • Page 29: Power Interface Ups-20-30Kva Boards (Cs0151)

    CN2 5-Pin Molex Connector “Mains line to CS 0153” DE0151-Pag.2 CN3 5-Pin Molex Connector “Reserve line to CS 0153” DE0151-Pag.4 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 29 of 72...
  • Page 30 UPS-20-30KVA Interface Boards Component Layout Refer to Electrical Diagram :DE0166 – DE0167 – DE0168 Fig.18 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 30 of 72...

  • Page 31: Pc Based Checks And Settings

    In most of cases it will be necessary to start the transmission between UPS and computer. To do this, the user must define the serial port number and transmission speed (usually 2400 bps), Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 31 of 72...
  • Page 32 UPS or the backup file, modify them (except firmware version) and write back to the UPS. press Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 32 of 72...
  • Page 33 This tab contains essential UPS parameters: parallel mode and batteries settings, output parameters (frequency, number of phases), and others. • Nominal values tab Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 33 of 72...
  • Page 34 "Idle read" control is activated (green colour). Otherwise, all the values in the window are not updated and becomes grey to indicate inactive state. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 34 of 72...
  • Page 35 When the Idle read mode is active, all the tab content is refreshed every second. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 35 of 72...
  • Page 36 Using this tab user can download event log content from the UPS. Updated log can be also saved to the file (button "Save to file" or File > Save UPS Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 36 of 72...
  • Page 37 To send the command to the UPS, the user should choose the command and click "Execute command". Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 37 of 72...
  • Page 38 If the file content is correct, the "Send update to UPS" button will be enabled and ready to use. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 38 of 72...
  • Page 39 (File > Save UPS backup option), saving Program Event Log, UPS History Log, changing the interface language, supervising the transmission, etc. Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 39 of 72...

  • Page 40: Electrical Diagram

    - DE0111 H-F Filter UPS 10-30kVA - DE0155 LCD Mimic Display - DE0157 Battery Fuse PCB gap22mm - DE1235 Battery String Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 40 of 72...

  • Page 41: De1237 Ups 10-15Kva General Diagram

    FS49 FS23 FS26 J7[1..20] FS50 J5[1..40] J5[1..40] J4[1..50] FS34 J4[1..50] FS38 FS42 FS35 FS39 FS51 FS36 FS40 FS41 UPS OUTPUT Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 41 of 72...
  • Page 42 735-3A-C-T SONG CHUAN Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 42 of 72...

  • Page 43: De1112 Ups 20-30Kva General Diagram

    59 - 60 - 61 65 - 66 PW27 FS10 J5[1..40] J4[1..40] FS12 J4[1..50] J1[1..50] J6[1..14] J2[1..14] FS13 FS14 FS15 UPS OUTPUT Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 43 of 72...
  • Page 44 INPUT MAINS TO PAGE 3 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 44 of 72...
  • Page 45 FROM PAGE 2 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 45 of 72...

  • Page 46: De0098 Relay & Communication Board

    5.1.3 DE0098 Relay & Communication Board Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 46 of 72...

  • Page 47: De0138 Temperature Sensor Pcb

    1uF 25V 5.1.5 DE0143 Battery Fuse PCB (Battery 7.2-9Ah) / DE0157 Battery Fuse PCB (Battery 4.5-5.2Ah) FASTON-F FASTON-F FASTON-F FASTON-F Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 47 of 72...

  • Page 48: De0150 Control Logic

    5.1.6 DE0150 Control Logic DEBUG_LED4 DEBUG_LED3 DEBUG_LED2 DEBUG_LED1 UPS-LD8 UPS-LD7 UPS-LD6 UPS-LD5 UPS-LD4 UPS-LD3 UPS-LD2 UPS-LD1 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 48 of 72...
  • Page 49 85TMP_ALL SPARE_1 BY-PASS_ON SPARE_2 Synchro-Front EPO-REM EPO_LOCAL CL_RESET PIO_0 SPARE_ULN FAST-FAN ENA _DC/DC BATT_LOW INVERTER_ON BYPASS_ON MAINS_NOK Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 49 of 72...
  • Page 50 TP28 TP19 TP36 TP20 000-A_MPX-0 000-B_MPX-0 000-C_MPX-0 000-D_MPX-0 000-A_MPX-1 000-B_MPX-1 000-C_MPX-1 000-D_MPX-1 TP37 TP21 000-INBT_-CS_0 000-SDATA_0 000-SCLK_0 000-INBT_-CS_1 000-SDATA_1 000-SCLK_1 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 50 of 72...
  • Page 51 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 51 of 72...
  • Page 52 SS-RELE_RES SS-RELE_INV SS-BY_HF1 SS-BY_HF0 SS-INV_HF1 SS-INV_HF0 Precharge-MAINS SCR_L3 SCR_L2 SCR_L1 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 52 of 72...
  • Page 53 Byte-Blaster FPGA programming Byte-Blaster EPCS1 programming TP42 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 53 of 72...
  • Page 54 BOTT1 BOTT2 BOTT3 BOTT4 LCD_RS LCD_RW LCD_E LCD_D7 LCD_D6 LCD_D5 LCD_D4 LCD_D3 LCD_D2 LCD_D1 LCD_D0 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 54 of 72...
  • Page 55 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 55 of 72...
  • Page 56 VCCINT VCCINT VCCINT VCCINT VCCIO1 VCCIO1 VCCIO1 VCCIO2 VCCIO2 VCCIO2 VCCIO3 VCCIO3 VCCIO3 VCCIO4 GNDA_PLL1 VCCIO4 GNDA_PLL2 VCCIO4 GNDG_PLL1 GNDG_PLL2 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 56 of 72...
  • Page 57 TP64 TP62 TP58 TP55 TP52 TP65 TP63 TP59 TP67 TP57 TP68 TP69 TP60 TP70 TP71 TP54 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 57 of 72...

  • Page 58: Powertronix Spa Reserves The Right To Modify This Document Without Notice

    16_+DC-BUS P+7.5 16_-DC-BUS 17_A-BATTERY C132 1µF CON40 24_MODULE_TEMP 25_INT-BATT_TEMP 26_EXT-BATT_TEMP CON50 Connettore DRIVER POWER Connettore DRIVER POWER Connettore ANALOG POWER Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 58 of 72...
  • Page 59 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V P6KE18CAC250 P6KE18CAC250 P6KE18CAC250 P6KE18CAC250 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 59 of 72...
  • Page 60 LEM DI BATTERIA 11_A-MAINS_L3 A-MAINS_POS E1-B G1-B G1-T E1-T E2-B G2-T G2-B E2-T E5-T G5-B G5-T E5-B E6-T G6-B G6-T E6-B Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 60 of 72...
  • Page 61 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 61 of 72...
  • Page 62 K-NEG_1 K-NEG_3 G-NEG_1 G-POS_3 K-POS_1 K-POS_3 12_V-OUT_L1 13_V-OUT_L2 14_V-OUT_L3 A-OUT_POS A-OUT_NEG 21_A-OUT_L1 10 0.25W 22_A-OUT_L2 10 0.25W 23_A-OUT_L3 10 0.25W Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 62 of 72...
  • Page 63 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 63 of 72...
  • Page 64 EXT BATTERY TEMP 26_EXT-BATT_TEMP ENABLE _DC/DC OVER-85TMP_ALL SPARE_1 P+15 P+7.5 P+5 AUX_BY -PASS_ON SPARE_2 TO CS0138 TEMPERATURE SENSOR FLAT 40VIE Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 64 of 72...

  • Page 65: De0152 Ups 10-15Kva Inverter Driver & Feedback

    100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V 100µF 35V P6KE18CAC250 P6KE18CAC250 P6KE18CAC250 P6KE18CAC250 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 65 of 72...
  • Page 66 Input INPUT MAINS LEM DI BATTERIA From Input Inductor Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 66 of 72...
  • Page 67 To page 4 A-INV_POS A-OUT_POS A-OUT_NEG 21_A-OUT_L1 10 0.25W 22_A-OUT_L2 10 0.25W 23_A-OUT_L3 10 0.25W To page 4 Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 67 of 72...
  • Page 68 TO CONTROL LOGIC TO CONTROL LOGIC Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 68 of 72...

  • Page 69: De0153 Power Supply Board

    1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 1N4007 PK-Curr PK-Curr BYT11-1000 BYT11-1000 DC BUS 1N4148 1N4148 TO INVERTER DRIVERS&FEEDBACK Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 69 of 72...

  • Page 70: De0111 Ups 10-30Kva H-F Filter

    5.1.10 DE0111 UPS 10-30kVA H-F Filter Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 70 of 72...

  • Page 71: De0155 Lcd Mimic Display

    5.1.11 DE0155 LCD Mimic Display Powertronix spa reserves the right to modify this document without notice R&D – SERVICE MANUAL DT0488 Page. 71 of 72...

  • Page 72: De1235 Battery String

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

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