Service Training Course For PSW7 Inverter Series

Feb 2010

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

Summary 1 Main Function˗ 2 General Specification˗ 3 Battery & Charger 4 Alarm & Indicators 5 Block Diagram 6 Key Part Of The Electrical Schematic 7 Inverter State Diagram 8 Trouble shooting 9 Something keep in mind 10 RMA record

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

1 Main Function          

Pure Sine-wave Combined Inverter & Charger. High Efficiency Using Line-Interactive Circuit Topology (Full Bridge Topology). 4-Step Progressive Charging & 7-Battery Type Selector. High Power, Multi-Stage Battery Charger. Bypass Function Without Battery (Option). Remote ControlǃRS232ǃUSB,SNMP Function (Option). Power Saver Function (Below Than 25Watt). LCD display option CE Safety. For more details pls contact with Power Star

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

2 General Specification

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

3 Battery & Charger

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

4.1 Indicator & Alarm Indicator on top cover Status

Line Mode

Invert Mode

Alarm Mode

LED on Remote control

INV ON

FAST CHARGE

FLOAT CHARGE

OVER TEMP TRIP

OVER LOAD TRIP

POWER SAVER ON

BATTER Y CHARGE R

INVERTE R

Alarm

Ĝ

h

Ĝ

h

h

h

h

Ĝ

h

h

h

CV

Ĝ

h

Ĝ, blink

h

h

h

h

Ĝ

h

h

h

Float

Ĝ

h

h

Ĝ

h

h

h

Ĝ

h

h

h

Standby

Ĝ

h

h

h

h

h

h

h

h

h

h

Inverter on

h

Ĝ

h

h

h

h

h

h

Ĝ

h

h

Power saver

h

h

h

h

h

h

Ĝ

h

h

h

h

Battery Low

h

Ĝ

h

h

h

h

h

h

Ĝ

Ĝ

beep 0.5s every 5s

Battery High

h

Ĝ

h

h

h

h

h

h

Ĝ

Ĝ

beep 0.5s every 1s

Overload on invert mode

h

Ĝ

h

h

h

Ĝ

h

h

Ĝ

Ĝ

Refer to “Audible alarm”

OverTem p on invert mode

h

Ĝ

h

h

Ĝ

h

h

h

Ĝ

Ĝ

Beep 0.5s every 1s

OverTem p on line mode

Ĝ

h

Ĝ

h

Ĝ

h

h

Ĝ

h

Ĝ

beep 0.5s every 1s

Over charge

Ĝ

h

Ĝ

h

h

h

h

Ĝ

h

Ĝ

beep 0.5s every 1s

Item

Utility POWER ON

CC

Buzzer

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

4.2 Indicator & Alarm Indicator on top cover Status

Fault Mode

LED on Remote control

INV ON

FAST CHARGE

FLOAT CHARGE

OVER TEMP TRIP

OVER LOAD TRIP

POWER SAVER ON

BATTER Y CHARGE R

INVERTE R

Alarm

h

h

h

h

h

h

h

h

h

h

beep continuous

Battery High

h

Ĝ

h

h

h

h

h

h

Ĝ

h

beep continuous

Inverter mode overload

h

h

h

h

h

Ĝ

h

h

h

h

beep continuous

OverTemp

h

h

h

h

Ĝ

h

h

h

h

h

beep continuous

Over charge

h

h

Ĝ

h

h

h

h

Ĝ

h

h

beep continuous

Back Feed Short

h

h

h

h

h

h

h

h

h

h

beep continuous

Item

Utility POWER ON

Fan lock

Buzzer

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

5  Block Diagram

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

6. 1 Key Part Of The Electrical Schematic 

PSDR Section˄Full Bridge˅

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

6. 2 Key Part Of The Electrical Schematic 

Driver Section

1/Driver of the Up Bridge;

2/Driver of the Down Bridge;

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

6. 3 Key Part Of The Electrical Schematic 

Line-Mode & Bat-Mode Transfer Section

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

7 Inverter State Diagram MCU POWER ON: 1.Mains Plug In 2.DC start

New SINE UPS STATE Diagram v0.01 STATIC MODE

Control Power Shut Off: 1.Mains too low to charge && battery low 2.Mains too low to charge && switch off

1.MCU has no power

Standby Alarm: 1.Fan Locked 2..Bat.Weak

Power On Mode 1. MCU is power on

1. 3 sec delay off

STANDBY 1.MCU is powered 2.UPS no in fault condition 3.Output has no power

UPS AutoReStart: Auto Start Delay Off && Mains OK && Not Bat.Low

UPS Stop: 1.Main SW Off 2.Schedule Off or Remote Off 3. battery under

1.UPS DC Start: Main SW On && Not Bat.Weak && Mains NG 2. UPS AC Start: Mains SW on && Mains OK 3. UPS first power on

Self Test Alarm: 1.Fan Locked 2.Over Loaded

Self Test Done && Mains OK (1. Inverter Fail 2.Battery Fail 3. Test time out)

SELFTEST MODE 1.DC start && Mains NG 2.! DC start && Mains NG

BATTERY MODE 1.UPS supplies the load power from Battery

Line Mode Test: 1.Test SW On && battery fully charged 2.Test Command Received && battery full charged

Standby Mode Fail: 1.Over Temperature 2.Fan Locked Timeout 3.Over charged

Battery Mode Fail: 1.Over Loaded Timeout 2.Over Temperature 3.Inverter Failure 4.Output Shorted 5.Fan Locked Timeout

LINE MODE 1.UPS supplies the load power from Utility

1.Mains Not OK 1.Mains OK

Battery Mode Alarm: 1.Battery Low 2.Over loaded 3.Fan Locked

UPS Stop: 1.Main SW Off 2.Schedule Off or Remote Off

UPS Stop: 1. first power on && selftest complete && main SW off 2. not first power on && Main SW Off 3.not first powre on && Schedule Off or Remote Off

Self Test Mode Fail: 1.Over Loaded Timeout 2.Over Temperature 3.Output Shorted 4.Fan Locked Timeout 5. first power on && inverter failed 6. first power on && battery bad

FAULT 1.UPS is fault condition 2.Ouput has no power

Line Mode Fail: 1.Over Loaded Timeout 2.Over Temperature 3.Output Shorted 4.Fan Locked Timeout

Line Alarm: 1.Fan Locked 2.Over Loaded 3.Bad Battery 4.Overcharged 5..Inverter failed

Fault Reset: 1. (Fanlock || Overcharged || Overtemperature) && ( main SW off || battery low) && no mains 2. ( !Fanlock && !Overcharged && !Overtemperature) && ( main SW off || battery low)

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

8 Trouble Shooting 

The most possible failure components are listed as following: 1 UPS fault at the battery mode (IGBT Damage Q1~Q24) INV Mode

IGBE Type

1012/1012E

IRF8113

1024/2024/3024/4024 1024E/2024E/3024E/4024E

IRF3205

3012/5024/6024 3012E/5024E/6024E

IRF1405

3048/3048E

IRF3710

4048/4048E/5048E/6048E

IRF4310

2 Driver Resistor ˄R5/R6/R7/R10… ;R8/R9/R11/R12…) R5/R6/R7/R10…..: 47Ohm 1/2W Dip type˗ R8/R9/R11/R12…: 20Kohm 1206 type˗ 3 Driver Circuit ˄Refer to Driver Section˅ Optocoupler U1/U2: IC TLP250˗ FET Q03/Q05/Q08/Q09 : 2SC2873 SMD˗

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

9 Something Keep In Mind High voltage, Do not open unless qualified to so;  Battery is very dangerous  After replacing the defective component or PCB and before re-plug the input power cord into the wall socket, make sure all power connections have been checked. 

Pinnacle Wholesalers 42 Gregory Street, Ballarat West, Victoria 3355 Ph 1800 214 334

10 RMA Record 

When you maintain the UPS, please record the below information and feedback to Power Star for further analysis and improvement.it’s important to make the maintenace record Model name Series number UPS failure description

Which component failed

01 PowerStar Inverter Service Manual.pdf

... Power Star. Pinnacle Wholesalers. 42 Gregory Street, Ballarat West, Victoria 3355. Ph 1800 214 334. Page 3 of 15. 01 PowerStar Inverter Service Manual.pdf.

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