Service Manual For PW9135

Powerware 9135 HARDWARE INTRODUCTION
AND TROUBLESHOOTING
1. PCB And Wiring ........................................................................................................3
1.1 Power Module..................................................................................................6
1.1.1 Power Circuit ........................................................................................6
1.1.2 Control Circuit ......................................................................................9
(1) Driver Circuit of Rectifier SCR (SCRA1 & SCRA2)......................9
(2) Driver Circuit of Battery SCR........................................................10
(3) Driver Circuit of Inverter Output SCR........................................... 11
(4) Normal AC (Rectifier) Fuse Broken Detection..............................12
(5) Input Voltage Detection..................................................................13
(6) Input Frequency And Zero-Crossing Detection .............................14
(7) Inverter Voltage Detection..............................................................15
(8) Output Voltage Detection ...............................................................16
(9) Inverter Fuse Broken Detection .....................................................17
(10) Inverter Output Current Detection ...............................................18
(11) Inverter Control Circuit ................................................................19
(12) Output DC Offset Compensation Circuit .....................................20
(13) Inverter Ipk Protection Circuit .....................................................21
(14) DC-DC Control Circuit ................................................................22
(15) Driver Circuit for IGBT of DC-DC Converter.............................30
(16) Driver Circuit for IGBT of Inverter .............................................31
(17) Charger .........................................................................................32
(18) Auxiliary Power Circuit ...............................................................34
(19) Auxiliary Power For +/-5V ..........................................................35
(20) Watchdog for Power Module MCU .............................................36
(21) Communication Circuit ................................................................37
(22) Other Detection Circuit ................................................................39
1.2 System Frame.................................................................................................41
1.2.1 Power Circuit ......................................................................................41
1.2.2 Control Circuit ....................................................................................43
(1) Bypass SCR Short-Circuit Detection .............................................43
(2) Bypass SCR Driver ........................................................................44
(3) Output Current Detection ...............................................................46
(4) Input And Output Voltage Detection ..............................................47
(5) AC Auxiliary Power Circuit ...........................................................48
(6) DC Auxiliary Power Circuit...........................................................49
(7) Auxiliary Power Failure Detection.................................................50
(8) Battery Voltage Detection ..............................................................51
1

AND TROUBLESHOOTING
(9) Battery Pack Detection...................................................................52
(10) Auxiliary Power For 5V ...............................................................53
(11) LCD And LED Driver ..................................................................54
(12) Watchdog For System MCU ........................................................55
(13) Communication Circuit for RS232 & USB..................................56
(14) Communication Circuit for Minislot............................................59
(15) Communication Circuit For Dry Contact.....................................61
(16) Communication For System and Power module..........................62
(17) EXB Detection Circuit (RJ45) And EPO Circuit (RJ12) .............65
(18) Other Detection Circuit ................................................................66
2. Troubleshooting .......................................................................................................67
2.1 Internal Fault..................................................................................................67
2.1.1 Alarm 34: CHARGER FAULT.............................................................67
2.1.2 Alarm 193: FAN FAULT......................................................................68
2.1.3 Alarm 004: UPS TEMPERATURE FAULT.........................................69
2.1.4 Alarm 701: INVERT FUSE BLOWN...................................................70
2.1.5 Alarm 100: NORM AC FUSE BLOWN...............................................71
2.1.6 Alarm 30: RECTIFIER FAULT ...........................................................72
2.1.7 Alarm 28: DC BUS +/- TOO HIGH/LOW ..........................................73
2.1.8 Alarm 31: INVERTER FAULT ............................................................74
2.1.9 Alarm 191: BATTERY FAULT.............................................................75
2.1.10 Alarm 36: AUTO BYPASS FAULT ....................................................76
2.1.11 Alarm 00A: DC POWER SUP FAULT..............................................77
2.1.12 Alarm 63: INTERNAL COM FAULT.................................................78
2.1.13 Alarm 006: COM FAULT BETW UPS ..............................................79

AND TROUBLESHOOTING
1. PCB And Wiring
Fig 1.1
B
LCD
WL1
#22 WL2
CNL2
WB2(P1)
WB4(P2)
CNA12(P2)
WB1(N1)
CNA10(N1)
CNA11(P3)
WB3(P3)
WB6(BATT+)
WB9(B-)
CNB1
26p
CNA9(P1)
CNA4(BATT+)
CNA5(B-)
34p
CNM1
#22
CNB4
20p CNM5
26p
21
WE6(O/L)
25
24
35
26p
CNP3
WG5
WG6
CNG4
32
31
22
CNG3(#10)
14p
CNP4
CNG1
(INV/L)
#18
CNG9 (O/L)
CNG8 (N1)
CNG7
(IP/L)
WE3(B-)
WE1(B+)
WE8(FG)
CNE2(FCI)
WE12(IP/L)
WE5(IP/N)
CNG2(#10)
CNE1
CNV7
23
PDU
#10
EXTB-
EXTB+
12
13
CNG10
(IP/N)
20p
CNV5
CNP9(B-)
CNP1(B+)
CNP8(B+)
CNP12(B-)
CNP2
WP1(G3)
WP2(+12VF)
WP3(-12VF)
#22
10
11
30
P
#10
WD11(ON)
WD14(G3)
WD3(B+)
WD4(B-)
WD1(IP/L)
WD2(IP/N)
WD5(FG)
WD6(O/L)
CND2(FCI) WD7(O/N)
CNS12
CNS6
CNS10
CNS11
CNS1
CNV3
CNS8
WD10(+12VF)
CND1
#12
#12
#12
#12
#22
CNB5
CNA1
CNA6(O/N)
CNA7(O/L)
CNA3(IP/N)
CNA2(IP/L)
15
CNS2
CNB3
CNB7(B-)
Minislot
CNP7
CNM3
CNB6(B+)
CNP14
CNB2
CNM4
Battery
efza
CNM2
EXT BAT
34
33
28
29
33
G N L
OUTPUT
G N L
INPUT
Terminal

AND TROUBLESHOOTING
WIRE LABEL
WIRE
COLOR
POSITION
AWG 10# BLACK B BOARD WB9 TO A BOARD CNA5
AWG 10#
AWG 10#
AWG 10# BLACK D BOARD WD4 TO B BOARD CNB7
10
AWG 10# BLACK D BOARD WD1 TO A BOARD CNA2
11
AWG 10# WHITE D BOARD WD2 TO A BOARD CNA3
12
AWG 10# BLACK D BOARD WD6 TO A BOARD CNA7
13
AWG 10# WHITE D BOARD WD7 TO A BOARD CNA6
15
AWG 10#
Y/G
D BOARD WD5 TO CASE G
21
AWG 10#
Y/G
E BOARD WE8 TO CASE G
22
AWG 10# BLACK E BOARD WE3 TO P BOARD CNP9
23
AWG 10#
24
AWG 10# BLACK E BOARD WE12 TO G BOARD CNG7
25
AWG 10# BLACK E BOARD WE6 TO G BOARD CNG1
28
G BOARD CNG3 TO TERMINAL BLOCK

AWG 10# WHITE NORMAL AC SOURCE N
29

AWG 10# BLACK NORMAL AC SOURCE L
30
AWG 18#
31

AWG 10# WHITE OUTPUT N
32

AWG 10# BLACK OUTPUT L
33
AWG 10#
RED
RED
RED
Y/G
B BOARD WB6 TO A BOARD CNA4
D BOARD WD3 TO B BOARD CNB6
E BOARD WE1 TO P BOARD CNP1
G BOARD WG7 TO P BOARD NUT
Y/G
TERMINAL BLOCK OUTPUT G TO CASE
33
AWG 10#
Y/G
TERMINAL BLOCK NORMAL AC SOURCE

G TO CASE
34
AWG 10#
Y/G
BATTERY CONNECTOR 3PIN G TO CASE
35
AWG 10# WHITE E BOARD WE5 TO G BOARD CNG10

AND TROUBLESHOOTING

AND TROUBLESHOOTING
1.1 Power Module
Power Module includes :
A board: Input and Output EMI Filter, Rectifier, Inductance of DC-DC Converter,
Inductance of Inverter, Output SCRs and Battery SCR Circuit
B board: Switching Devices of DC-DC Converter, Bus Capacitors, Switching Devices
of Inverter, Auxiliary Power and Charger
M board: MCU of Power module and Control Circuit
D board: External Connector of power module
1.1.1 Power Circuit

The power circuit of power module is showed as Fig 1.2. The function of main
components are described as below:
CA1, LA1, LA2, CA6/CA7/CA8: Input EMI Filter
FUA1: Normal AC (Rectifier) Fuse
CTA1: Input (Rectifier) Current Feedback
SCRA1, SCRA2: Rectifier
DA3, DA6: Freewheeling Diode During Battery Mode
LA8/LA9, LA10/LA11: Inductance of DC-DC Converter
Q10/Q11/Q12, Q14/Q15/Q16: IGBT of DC-DC Converter
DB1, DB2: Freewheeling Diode of DC-DC Converter
C17/C19/C21/C23/C25/C27: DC BUS + Capacitors
C18/C20/C22/C24/C26/C28: DC BUS Capacitors
QB18/QB19/QB20, QB22/QB23/QB24: IBGT of Half-Bridge Inverter
CTB1: Inverter Inductance Current Feedback
LA4/LA5/LA6/LA7: Inductance of Inverter
FUA4: Inverter Fuse
CA25/CA26: Output Capacitor of Inverter
SCRA6/SCRA7: Output SCR of Inverter
CTA3: Inverter Output Current Feedback
CA34, LA3, CA27: Output EMI Filter
QB47, QB50: MOSFET of Flyback Charger
6

AND TROUBLESHOOTING
DB41, DB42: Freewheeling diode of charger
TB3: Charger Transformer
DB44: Output Diode of Charger
CB111: Output Capacitor of Charger
DB46: Isolative Diode Between Charger and Battery
FUB2: Output Fuse of Charger
FUB3, FUB4: Battery Fuse
CA18: Battery Capacitor
SCRA3, SCRA4: Battery SCR
RA12/RA13, SCRA5: Soft-Start Circuit During Cold Start
CTA2: Battery Current Feedback
TB1: Auxiliary Power Transformer
QB44: MOSFET of Auxiliary Power
RB191: Inductance Current Detection Resistor of Auxiliary Power
RLB1, RB201, DB47: Start Circuit of Auxiliary Power
CNA7
(O/L)
CNA6
(O/N)
CNA3
(IP/N)
CNA2
(IP/L)
CA37
CA1
LA3
LA1
CTA3
CA34
LA2
CTA2
SCRA5
SINLA4/LA5/
LA6/LA7
LA10/LA11
DA6
DA3
LA8/LA9
SCRA4
CA18
SCRA3
SIN+
FUA4
RA12/RA
13
CA25/CA
26
A Board
SIN-
SIN+
SCRA7
SCRA6
SCRA2
CTA1
CA6/CA7/CA8
FUA1
SCRA1
CNA5
(B-)
CNA4
(BATT+)
CNA11
(P3)
CNA12
(P2)
CNA10
(N1)
CNA9
(P1)
WB9
(B-)
CNB7
(B-)
WB6
(BATT+)
WB3
(P3)
CNB6
(B+)
WB4
(P2)
WB1
(N1)
WB2
(P1)
BUS+
DB2
CB111
DB44
BATT+
BUS-
CB18/CB2
0/CB22/C
B24/CB26/
CB28
CB17/CB1
9/CB21/C
B23/CB25/
CB27
FUB2 DB46
FUB4
FUB3
QB14
/QB1
5/QB
16
QB10/
QB11/
QB12
DB1
DB42
BUS-
QB47
BUS+
BATT+
To UC3845P7
DB10
RB186
DB47
RB201
RLB1
DB41
QB50
RB191
QB44
DB48 NTCB1
B Board
TB3
QB22/QB
23/QB24
CTB1
QB18/QB
19/QB20
CNB5
BATT+
TB1
To -V1
To V3+/V3- (INV Driver)
To V6+/V6- (PFC
Driver)
To V5+/V5- (PFC
Driver)
DB19
To V3
(Fan)
TB2 DB18
To V1
20V to
UC3854
DB24 To V4+/V4- (INV Driver)
DB23
DB14
DB12
DB4
DB13
DB20

AND TROUBLESHOOTING
Fig 1.2

AND TROUBLESHOOTING
1.1.2 Control Circuit
(1) Driver Circuit of Rectifier SCR (SCRA1 & SCRA2)
Located at A board
TVSA1
SIN+
CA10 RA6
RA3
V3
1
2
RECT+'
SCRA1
DA2
RA7
DA4
JPA1
UA1
CA11
K
DA1
RA4
V3
JPA2
1
2
UA2
RA8
CA13
TVSA2
CA14
SCRA2
RECT-'
RA9
DA5
SIN-
Located at M board
8
(20)
RECT+
(21)
(65)
(66)
(67)
RECTBATSOFT
BATSCR1
BATSCR2
7
6
5
4
3
2
1
UM11
ULN2003A
GND COM
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
V1
9
10
11
12
13
14
15
16
RECT+'
RECT-'
Bs'
Bon1'
Bon2'
(a) SCRA1 will become a diode if RECT+ becomes low

(b) SCRA2 will become a diode if RECT- becomes low
(c) Test JUMP:
JPA1: SCRA1 will become a diode no matter what RECT+ is if JPA1 is shorted.
JPA2: SCRA2 will become a diode no matter what RECT- is if JPA2 is shorted.

AND TROUBLESHOOTING
(2) Driver Circuit of Battery SCR
Located at A board
RA13
V3
TVSA4
RA18
DA10
1
JPA3 1
2
UA3
CA22
RA15
CA21
DA9
SCRA5
CA20
DA8
RA14
CA19
SCRA3
TVSA3
RA12
DA11
RA16
RA17
Bon1'
V3
RA19
JPA4 12
Bs'
UA4
(a) During the soft-start process of cold start, Bs will be low to turn on SCRA5. The
Bus capacitor will be charged by battery through RA12 and RA13.
(b) After soft-start, Bs will be high to turn off SCRA5 and Bon1 will be low to turn
on SCRA3. Then the input of DC-DC converter will be supplied by battery
through SCRA3.
(c) Test JUMP:
JPA3: SCRA3 will be off no matter what Bon1 is if JPA3 is shorted
JPA4: SCRA5 will be off no matter what Bs is if JPA4 is shorted
10

AND TROUBLESHOOTING
(3) Driver Circuit of Inverter Output SCR
Located at A board
DA15
TA1
SCRA7
CA31
SCRA6
QA1
37KHz
RA35
CA29
2
D
INVSTS'
V3
RA39
10
CA27
DA16
RA36
RA34
CA28
RA38
HSA1
CA30
RA37
7
DA14
Located at M board
CM144
5V
5V
RM3
UM36A
UC33-3
5
2
2V5
INVSTS
LM339
12
11
UM15D
CD4066B
C
IN
OUT
10
UC10-3
12
(32)
-5V
CM131
V1
UC10-3
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
10
11
12
13
14
15
16
RM35
7
6
5
4
3
2
1
V1
9
RM34
UM10
ULN2003A
GND COM
INVSTS'
(a) The driver signal is generated by MCU (Pin32). The frequency is 37Hz.
(b) The output of driver signal is control by Watchdog (UC33-3). If Watchdog is
active low, then UM15D is disable and inverter output SCR cant be turned on.
Refer to Watchdog for Power Module MCU for UC33-3 signal.
11

AND TROUBLESHOOTING
(4) Normal AC (Rectifier) Fuse Broken Detection
Located at A board
FUA1
LA2
CTA1
2
DA18
DA17
RA44
RA28
RA45
FB
RA29
FA
Located at M board
RM122
5V
V1
CM148
RM235
RM124
RM117
RM212
QM25
IP_FUSE
FA
(4)
2
CM130
FB
RM170
12
RM64
CM149
UM3A
LM339
DM24
ZDM2
5V
RM234
RM45
V1
(a) If fuse (FUA1) is not broken, then FA should be equal to FB and IP_Fuse (4) will
be active high.
(b) If fuse (FUA1) is broken, then FA > FB then IP_Fuse (4) will be active low.
12

AND TROUBLESHOOTING
(5) Input Voltage Detection
Located at A board
RA1
Vi1
RA2
FUA1
LA2
CTA1
2
Located at B board
CB41
RB65
DB25
RB67
-V1
RB68
11
Vi1
RB66
CB64
DB26
Vin
1
RB69
RB70
CB42
UB14A
TL084
CB65
V1
Located at M board
5V
DM2
Vin
RM115
CM9
RM177
VinR
(81)
(a) Vin is full rectified sine wave

(b) MCU detects the RMS voltage of input through VinR(81)
13

AND TROUBLESHOOTING
(6) Input Frequency And Zero-Crossing Detection
Located at A board
RA40
RA41
Vi2
FUA1
LA2
CTA1
2
Located at M board
Vi2
5V
DM1
1N4148
RM87
10K
CM84
223
RM161
10K
QM13
MMMBT2222A
RM176
100K
RM141
INPZO
(24)
1K
CM91
102
(a) The waveform at INPZO (24) is square wave

(b) MCU detection the zero-crossing through the falling edge of square wave
14

AND TROUBLESHOOTING
(7) Inverter Voltage Detection
Located at A board
CA26
FUA4
CA25
LA7
RA26
RA27
Vinv2
Located at M board
CM90
Vinv2
RM104
RM147
13
RM193
RM194
(75)
14
RM103
12
CM89
RM146
Vinv_R
UM5D
2V5
(a) The waveform at Vinv_R (75) is full sine wave with 2V5 DC offset
(b) MCU detects the RMS voltage of inverter output through Vinv_R (75)
15

AND TROUBLESHOOTING
(8) Output Voltage Detection
Located at A board
CTo+RA32 CToLA3
CA34
RA33
CTA3
W2
RA30
RA31
Vout
Located at M board
CM87
RM143
Vout
RM94
9
RM191
UM5C
8
RM93
10
Vout_R
(78)
TL084
RM192
CM85
RM142
2V5
(a) The waveform of Vout_R (78) is the rescale of output voltage with 2V5 DC offset.
(b) MCU detects the RMS value of output voltage through Vout_R (78)
16

AND TROUBLESHOOTING
(9) Inverter Fuse Broken Detection
Located at A board
Vinv3
RA47
RA48
CA26
FUA4
CA25
LA7
Located at M board
-V1
RM236
RM220
9
Vinv3
RM238
11
UM40C
LM324
8
13
UM40D
LM324
14
12
10
CM22
RM237
RM239
V1
5V
RM233
DM25
RM221
ZDM1
3V9
QM24
OP_FUSE
(11)
CM25
CM24
RM232
(a) If inverter fuse (FUA4) is not broken, the waveform of Vinv3 is full sine wave.
The line frequency signal cant go through the high-pass filter (UM40D), so
OP_FUSE (11) will be active high
(b) If inverter fuse (FUA4) is broken, then the waveform of Vinv3 will be PWM
waveform. This high frequency signal can go through high-pass filter (UM40D)
and OP_FUSE (11) will be active low.
17

AND TROUBLESHOOTING
(10) Inverter Output Current Detection
Located at A board
CTo+RA32 CToLA3
RA33
CA34
SCRA7
CTA3
SCRA6
Located at M board
5V
DM19
RM75
CM88
IOUT
RM96
5V
CM60
11
-V1
RM158
6
CTo+
RM95
RM44
RM173
UM5B
TL084
Iout_R
5
4
RM172
CM86
CTo-
RM61
7
RM43
RM62
RM131
UM5A
TL084
(77)
V1
DM23
RM157
CM59
CM105
-5V
(a) The waveform of Iout_R (77) is rescale of inverter output current with 2V5 dc
offset.
(b) MCU detect the RMS value of inverter output current through Iout_R (77).
18

AND TROUBLESHOOTING
(11) Inverter Control Circuit
Located at A board
LA7
RA24
RA25
Vinv1
CA26
FUA4
CA25
RA23
Located at M board
(112)
SPWM_R
CM114
CM116
RM186
9
RM205
RM200
RM97
UM6D
13
CM119
RM98
14
IN
C
OUT
8
6
IOUT
IOUT
RM206
5V
UM15C
CD4066B
RM179
RM199
12
RM187
CM101
TL084
CM117
UM36B
7
1
6
RM189
Vinv1
CM118
RM119
-V1
CM10
11
RM144
V1
TPM1
RM100
UM6A
TL084
DM18
4
RM174
UM4A
LM339
V1
CM75
RM188
1
2
CM79
INVCLK
-V1
-V1
V1
CM103
RM99
QM17
UM4B
UM6B
TL084
6
RM155
6
1
7
RM101
14
INV-L
8
LM339
RM106
TPM2
RM121
CM69
INV-H
QM20
V1
TPM4
(33)
UM4D
LM339
CM64
RM190
CM100
RM203
11
CM102
V1
RM120
13
RM102
2
5
DM17
QM16
10
DC OFFSET Compensator
CM63
(63)
RM154
RM202
DIS_DROOP
V1
CM65 -V1
CM95
12
RM162
JPM4
2V5
TPM3
RM204
17KHz
DM11
UM4C
LM339
DM13
Inverter Ipk Protection
1
2
-V1
QM21
JPM1
-V1
(a) The waveform of UM6D-P14 is the reference sine wave generated by SPWM_R
(112) through band-pass filter (UM6D)
(b) Vinv1 is the feedback of inverter output
(c) The waveform of UM6B-P7 is the triangle waveform generated by INVCLK (33)
through integrator (UM6B) and the frequency is 17kHz
(d) DIS_DROOP (63) is used to enable or disable the current feedback. DIS_DROOP
(63) is high to disable the current feedback during standalone operation.
DIS_DROOP (63) is low to enable the current feedback during parallel operation.
(e) Test JUMP:
JPM1: Inverter is disabled if JPM1 is shorted
JPM4: DC offset compensation circuit is disable if JPM4 is shorted
(f) Test Point:
TPM4: Triangle wave
TPM3: Inverter driver command (output of error amplifier)
TPM1: Driver signal of top leg of half-bridge inverter
TPM2: Driver signal of bottom leg of half-bridge inverter
Refer to Output DC Offset Compensator Circuit for DC OFFSET Compensator
signal.
19

AND TROUBLESHOOTING
Refer to Inverter Ipk Protection Circuit for Inverter Ipk Protection signal
(12) Output DC Offset Compensation Circuit
Located at B board
BUS+
QB18
CB27
WB3
P3
CTB1
RB36
P3
RB37
RB171
*
QB22
RB38
CB67
OS
TVSB4
P6KE18CA
CB28
BUS-
Located at M board
5V
RM123
UM36C
LM339
14
2V5
(5) OFFSET
5V
UM15B
CD4066B
14
CM61
OUT
IN
C
4
5
UM15A
13
1
CM15
C
IN
-5V
CD4066B
2
OUT
CM115
CM113
OS
RM178
RM168
RM197
RM198
9
8
CM112
CM111
10
DC OFFSET Compensator
UM6C
TL084
CM68
RM105
RM208
HOLD
-V1
RM207
HOLD
VRM1
HOLD
RM209
V1
HOLD
(a) The feedback signal is from the central point of inverter leg (P3).
(b) UM6C is used to generate the output DC feedback signal by integral the signal
OS.
(c) OFFSET (5) is low to enable UM15B and UM15A to reset and disable the integral
circuit (UM6C) while inverter is off.
20

AND TROUBLESHOOTING
(13) Inverter Ipk Protection Circuit
Located at B board
BUS+
QB18
CB27
WB3
P3
CTB1
CTp+
BDB1
QB22
CB28
AC
AC
RB32 RB33
Hold
1
4
CTp-
BUS-
Located at M board
Inverter Ipk Protection
V1
6
UM3B
LM339
V1
RM195
(29)
INVIPK
RM222
DM9
(75)
Vinv_R
9
14
S
RM148
CM123
3V9
CM5
RM107
RM226
11
13
8
QM1
RM149
V1
RM196
RM164
DM14
QM18
ZDM8
2V5
RM181
RM224
G
DM8
CM13
V1
CM72
RM159
RM223
INVEN
(30)
DM12
DM10
RM108
RM163
10
CM70
RM175
12
UM3C
LM339
CM92
RM225
UM3D
LM339
2V5
RM201
CM74
CM73
CTP+
CM12
RM180
-V1
CTP-
CM71
(a) UM3D is used to disable Inverter during the start period of auxiliary power
(b) If INVEN (30) is low then Inverter is disabled.
(c) UM3C is used for inverter Ipk protection. CTP+ is the current feedback of
inverter inductance.
(d) There are two level for Ipk protection:
1st
level is
2nd level is
RM 107
V1
RM 159 + RM 107
( RM 107 // RM 224)
V1
RM 159 + ( RM 107 // RM 224)
(e) INVIPK (29) will be high to keep the Ipk to 1st level during the start of inverter
(f) If Vinv_R (rescale of output voltage) is normal, then Ipk will keep at 1st level. If
Vinv_R is lower than a specific level (for example, output short circuit) then the
Ipk will change to 2nd level
(g) The inverter output short circuit protection is about 100A.
21

AND TROUBLESHOOTING
(14) DC-DC Control Circuit
Enable/Disable Circuit
Located at B board
CB49
9 2
11
15
16
20V
CB54
UB5
UC3854
RB80
V1
10
QB40
12
14
13
RB129
PFC
RB119
CB56
CB55
RB128
Located at M board
(34)
PFCEN
RM135
1K
PFC
(a) If PFCEN (32) is low then the controller of DC-DC converter is enabled. If
PFCEN (32) is high, then the DC-DC converter is disabled.
22

AND TROUBLESHOOTING
Bus voltage feedback circuit
Located at B board
Vselect 2
Vbus+
RB214
RB212
RB138
Hold
CB60
QB29
RB210
UB6D
10
OUT
RB122
CD4066B
V1
C
IN
12
11
RB139
Vselect
RB136
CB52
RB134
C
IN
RB145
BUS+
RB146
CB61
RB278
UB6C
OUT
RB144
QB41
RB135
RB143
10
UB14C
TL084
CB100
Hold
CB53
RB123
RB142
RB137
DB51
RB121
RB141
RB140
TPB5
6
8
CB128
UB17B
LM339
TPB4
Q
CB130
1
Vselect
CD4066B
RB150
DB52
RB274
RB275
CB95
Hold
RB277
V1
CB129
RB151
RB276
CB51
RB148
Vselect 2
9 2
CB63
QB42
RB152
RB120
RB149
15
16
UB5
QB30
CB66
14
RB157
RB158
RB159
RB153
RB166
CB96
RB167
13
12
12
RB156
Vbus-
10
1
RB155
BUS-
12
RB211
RB154
13
14
UB14D
TL084
RB147
Hold
RB213
11
RB215
CB97
V1
UB17A
LM339
RB165
RB161
CB80
CB101
V1
RB163
Located at M board
5V
5V
DM4
RM89
Vbus+
DM5
Vbus+' (88)
Vbus-
RM90
Vbus-'
(100)
RM183
RM184
CM53
(35)
BUSEL
(9)
BUSEL2
(89)
CM54
RM114
Vselect
Vselect2
RM139
(a) UB6C and UB6D are used to selectively feedback Bus+ or Bus- voltage to
23

AND TROUBLESHOOTING
UC3854 according to signal TPB5 and TPB4.
(b) MCU detects DC Bus + voltage through Vbus+ (88) and detects DC Bus- voltage
through Vbus- (89)
(c) If BUSEL (35) is high, then DC bus +/- will increase to about +/-395Vdc
(d) Net P & Q are used for Vpeak protection. The Vpeak is set at 420Vdc.
Refer to Positive And Negative Cycle Switching for TPB5 and TPB4 signals
Refer to Output driver Signal for P & Q signals.
AC mode and backup mode switching
Located at B board
V1
V1
RB73
RB91
AC
BC
RB88
backup
RB86
QB36
RB87
JPB2
QB35
RB169
1
2
Located at M board
(66) BATSCR1
RM136
backup
(a) If BATSCR1 (66) is high, then AC signal=low and BC=high, UPS is at

backup mode. If BATSCR1 (66) is low, then AC signal=high and BC=low,
UPS is at AC mode.
(b) TEST JUMP:
JPB2: Short JPB2 will change the DC-DC converter operating at backup mode
24

AND TROUBLESHOOTING
Positive And Negative Cycle Switching
Located at B board
V1
Vi2
RB84
V1
RB82
RB133
HOLD
UB14B
6
RB34
QB38
V1
TPB4
RB35
RB93
QB39
TPB5
RB18
RB81 CB47
TL084
RB83
DB27
RB31
RB92
DB3
RB85
AC
RB89
p/n
DB30
DB29
RB90
QB37
BC
Located at A board
RA40
RA41
Vi2
FUA1
LA2
CTA1
2
Located at M board
(52)
PFCSQR
RM138
p/n
(a) During positive half cycle, TPB4=low and TPB5=high. During negative half cycle,
TPB4=high and TPB5=low.
(b) During AC mode, the positive and negative half cycle are decided by input voltage
(Vi2).
(c) During backup mode, the positive and negative half cycle are controlled by
PFCSQR (52).
Refer to AC mode and backup mode switching for AC and BC signal
25

AND TROUBLESHOOTING
Vrms and Iac Feedback Circuit
Located at B board
CB41
RB65
DB25
RB67
-V1
RB68
11
Vi1
RB66
CB64
DB26
Vin
1
RB69
BAT+
RB70
CB42
AC
UB14A
TL084
CB65
RB74
RB72
CB44
V1
Vbatt
BC
V1
IN
C
OUT
UB6A
CD4066B
UB6B
4
5
IN
C
OUT
CD4066B
9 2
UB23A
TL0721
16
RB76
4
RB118
10
-V1
RB79
12
14
RB124
Hold
UB5
UC3854
CB45
RB78
11
15
CB43
13
Hold
RB263
RB75
RB77
1
13
RB71
RB125
CB57
RB126
V1
RB127
CB58
CB46
Located at A board
RA1
Vi1
RA2
FUA1
LA2
CTA1
2
(a) During AC mode, the feedback of Vrms (UC3854-P8) and Iac (UC3854-P6) is
from Vin
(b) During Backup mode, the feedback of Vrms (UC3854-P8) and Iac (UC3854-P6)
is from Vbatt
Refer to AC mode and backup mode switching for AC and BC signal
26

AND TROUBLESHOOTING
Current Feedback Circuit
Located at B board
RB96
V1
RB97
DB33
V1
RB98
RB100
11
13
Ipeak
RB99
CTi-
RB115
RB101
10
RB113
UB17D
LM339
RB112
DZONE
DB40
RB111
RB114
RB110
ZDB10
CB59
CB50
RB116
RB117
DB39
9 2
CB48
11
15
16
UB5
8
10
1
12
14
13
Located at A board
Battery Discharge Current

CTA2
AC Input Current
CTA1
4
DA7
CTi3
BDA1
RA5
3
2
AC
AC
RA10 RA11
HOLD HOLD
-V1
CA17V3
Located at M board
(50)
D-ZONE
RM33
DM16
DZONE
(a) CTi- is the combination signal of AC input current and Battery discharge current.
27

AND TROUBLESHOOTING
During AC mode, CTi- will feedback the AC input current. During backup mode,
CTi- will feedback the battery discharge current.
(b) During AC mode, D-ZONE (50)=low. During backup mode, D-ZONE (50) will
provide 5V/550us pulse around zero crossing of inverter output voltage to disable
the gate signal of DC-DC converter. This function is used to prevent battery
short-circuit in common battery structure.
Refer to Output driver Signal to Ipeak signal
28

AND TROUBLESHOOTING
Output Driver Signal
Located at B board
RB104
DB31
UB8B
D+
4071
RB94
D-
CB62
DB38
RB109
16
UB5
UC3854
13
RB95
11
RB108
12
JPB1
UB8D
4071
2
1
10
RB106
34KHz
12
14
13
DB37
RB103
BC
11
15
UB8C
4071
4071
RB105
DB32
UB8A
V1
10
V1
TPB5
DB34
4
5
RB102
Ipeak
RB107
TPB4
DB36
DB35
(a) During positive half cycle, TPB5=H and TPB4=L

During negative half cycle, TPB5=L and TPB4=H
(b) During AC mode, BC=L
During backup mode, BC=H
(c) During positive half cycle of AC mode, D+ is PWM control and D-=L
During negative half cycle of AC mode, D+=L and D- is PWM control
During positive half cycle of backup mode, D+ is PWM control and D-=H
During negative half cycle of backup mode, D+=H and D- is PWM control
(d) Test JUMP
JPB1: If JPB1 is shorted, then DC-DC converter is disabled.
Refer to AC mode and backup mode switching for BC signal
Refer to Positive And Negative Cycle Switching for TPB4 and TPB5 signals
Refer to Current Feedback Circuit for Ipeak signal
29

AND TROUBLESHOOTING
(15) Driver Circuit for IGBT of DC-DC Converter
Located at B board
V1
RB2
V5+
QB5
CB7
QB1
RB1
D+
RB5
CB5
UB1
1
2
3
4
RB62
TPB7
RB11 RB12
ZDB1
18V
8
7
6
5
QB10
QB6
QB48
RB6
D-
V1
V6+
CB6
RB3
1
2
3
4
TPB6
UB2
ZDB2
18V
CB8
V5-
RB4
RB13
RB9
TLP250
QB3
RB19
8
7
6
5
CB9 ZDB3
18V
QB7
RB14 RB15 RB20
RB7
RB16
RB10
RB63
QB8
TLP250
QB49
CB10RB8
QB14
ZDB4
18V
V6-
Refer to Output Driver Signal of DC-DC Control Circuit for D+ and D- signals
30

AND TROUBLESHOOTING
(16) Driver Circuit for IGBT of Inverter
Located at B board
CB31
V3+
QB20
ZDB5
18V
RB47
QB25
CB33
RB39
RB45
RB44
RB43
UB3
8
7
6
5
RB46
1
2
3
4
INV-H
RB49
TLP250
QB26
ZDB9
RB48
-V1
ZDB6
18V
CB32
QB24
V3-
RB55
V4+
CB34
QB27
RB56
ZDB7
18V
RB59
RB57
CB36
RB58
RB51
QB28
8
7
6
5
UB4
TLP250
RB60
1
2
3
4
ZDB12
INV-L
RB50
-V1
ZDB8
18V
CB35
V4-
Refer to Inverter Control Circuit for INV-H and INV-L signals
31

AND TROUBLESHOOTING
(17) Charger
Located at B board
CB116
RB244
RB245
RB251
UB23B
6
RB162
RB130
D QB50
RB231
6
5
DB49
CB107
RB64
10
9
3 TB315,16
BUS-
CB40
10
GND
Vin
ZDB13
DB43
+15V
RB237
12,13
RB238
CB103
RB264
8
1
2
BUS-
RB183
RB182
CB104
VFB
VCC
COMP
70KHz
RB185
CB105
BUS-
QB43
VREF
OUT
RB220
UB18
1
2
RB239
V1
B/T
NTCB2
CB113
RB17
UB22
VRB1
1
2
RB249
V1
B/C
RB267 RB242
Hold
UB20
R
BUS-
RB228
GND
RT/CT
ISEN
CB108 RB229
UC3845N
RB240
CB114
RB243
RB230
V1
UB16
RB235
RB221
CB106
UB19
CHi
UB24
RB181
4
4
3
JPB3
CB98
V1
UB9
F 4A/250V
CB111
D QB47
UB21
BATT+
FUB2
RB236
RB168
P6KE18CA
UA7815K
2
CB38
RB232
TVSB2
BUSDB8
DB46
DB41
RB131
CB115
CB109
DB44
Vcharge
RB250
RB52
TVSB1
P6KE18CA
TB4
RB247
DB42
RB164
RB246
BUS+
C/O
BUS-
Located at M board
B/T
QM2
RM6
(107) BTTEST
RM1
5V
UM10
ULN2003A
8
(68)
(96)
(95)
CHRGI
BCHG
DCHG
7
6
5
4
3
2
1
DM6
V1
GND COM
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
9
10
11
12
13
14
15
16
Vcharge
CHi
B/C
C/O
RM91
RM185
Vchg
(90)
CM55
(a) If DCHG (95)=H, then charger will be off

(b) If BCHG (96)=H, then charger will go into boost charging mode. The charger
voltage will increase to around 210Vdc
(c) If BTTEST (107)=H, then charger voltage will decrease to around 160Vdc to
perform battery test
(d) If CHRGI (68) =L, then the charger current will be about 0,6A. If CHRGI (68)=H,
then the charger current will increase to 2A.
32

AND TROUBLESHOOTING
(e) MCU detects the charger voltage through Vchg (90)
(f) Test JUMP:
JPB3: NTCB2 is used to compensate the charger voltage according to ambient
temperature. If JPB3 is shorted, the charger voltage should be 194,1Vdc by
adjusting VRB1.
33

AND TROUBLESHOOTING
(18) Auxiliary Power Circuit
Located at B board
RB203
RB132
CNB10
BAT+
RLB1
CB37
G3
CNB11
BAT+
3
V1
20V
RB201
CB69
DB20
CB94
V3
RB202
RB40
4
Vx
CB74
CB71
7
2
1
CB70
2
RB197
DB11
70KHz
VREF
OUT
CB2
CB85
CB3
1
-12V
-V1
UB15
7912
D
G
Vin
QB44
TB2
RT/CT
ISEN
CB92
DB23
RB192
RB262
RB258
10
CB77
V5+
DB18
V3+
CB86
RB191
CB76
RB268
10
RB190
GND
RB189
CB75
UB13
HSB5
COMP
RB188
CB79
RB199
DB14
VFB
CB112
RB179
UB7
UC3845N
RB187
8
CB78
CB82
CB84
CB72
RB196
RB198
CB83
CB73
UB12
V1
LB10
DB13
14
UB11
RB204
DB4
TVSB3
NTCB1
VCC
RB184
Poff
VFAN'
QB45
GND
DB48
G
S
13
RB257
BATT+
CB99
DB10
RB186
G3
DB6
CB81
TB1
DB47
QB2
RB170
RB160
CB4
DB12
V1
RB266
BATT+
G3
V1
Fan'
DB61
3
2
1
DB21
CNB5
DB62
V1
+12VF
CB68
1
2
3
3
2
1
TO D
DB19
7
V3-
DB24
V5-
RB269
V6+
CB93
RB259
12
A
V4+
6
CB87
11
V6-
V4-
Located at M board
ZDM10
Fan'
5V(1/2W)"1206"
RM137
FAN
(54)
UM10
ULN2003A
UM11
ULN2003A
8
(31)
(a)
(b)
(c)
(d)
DAUX
7
6
5
4
3
2
1
V1
GND COM
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
9
10
11
12
13
14
15
16
(51)
Poff
VFAN
7
6
5
4
3
2
1
V1
GND COM
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
9
10
11
12
13
14
15
16
VFAN'
If DAUX (31)=H, then the auxiliary power will be off

The start of auxiliary power is controlled by System MCU through RLB1
VFAN (51) is PWM signal to control the speed of fans
MCU detects the fan failure through FAN (54)
34

AND TROUBLESHOOTING
(19) Auxiliary Power For +/-5V
Located at M board
QM19
V1
5V
RM118
CM104
CM57
RM127
RM126
CM11
UM34
TL431(0.5%)
RM128
A
CM121
-V1
V1
-5V
3
RM145
DM7
CM122
CM39
2V5
K
UM14
79L05
-5V
GND
CM58
Vin
CM4
R
UM35
TL431(0.5%)
CM67
CM120
35

AND TROUBLESHOOTING
(20) Watchdog for Power Module MCU
Located at M board
5V
POWER_RDY
(10)
2
5
JPM3
VCC
TRIG
CVolt
THR
DM20
A
3
7
RM108
A
RM215
CM13
5V
INVEN
(30)
RM181
6
RM4
CM129
CM6
DM15
UM33
NE555
DIS
GND
QM10
RM217
2
1
UC33-3
CM7
CM128
RM213
RM116
QM22
TPM5
(a) POWER_RDY (10) will send out pulse to reset CM129. And then CM129 will be
charged again by 5V through RM215. UC33-3 will keep high level. If
POWER_RDY (10) doesnt send out pulse for a specific period (for example:
MCU is crash) then UC33-3 will be low.
(b) Test JUMP:
JPM3: If JPM3 is shorted, then UC33-3 will be low or UC33-3 will keep high
during normal operation.
36

AND TROUBLESHOOTING
(21) Communication Circuit
Part 1
Located at M board
5V
5V
RM240
RM218
TOMBYP
RM9
TOMBYP_I
UC33-3
1
RM130
UM16
(16)
UM39
RM219
+12VF
RM231
CM150
ID1OK
CM18
QM26
RM17
QM7
G3
5V
+12VF
G3
RX
+12VF
RM8
QM23
RM10
(53)
SYS_RDY
CM16
RM11
5V
UM17
CM17
1
RM46
RM230
UM18
RM12
INT_TX1
BYPOK
G3
RM14
QM3
(3)
RM229
5V
+12VF
+12VF
RM18
RM76
(108)
BYP_FAIL
CM8
RM77
4
3
UM38
DM21
1
2
5V
RM22
RM13
4
INT_RX1
(2)
CM19
UM20
TX
DM22
RM24
1
2
BYP-F
QM15
G3
(a) If Power MCU is operating normally, power module will send out ID1OK signal
(b) If System MCU is operating normally, SYS_RDY (53) will be low
(c) Power MCU can detect AC utility failure through BYP_FAIL (108). BYP_F
signal is send by System MCU.
(d) Power MCU can detect the switching of manual bypass switch from TOMBYP_I
(16). TOMBYP signal is the combination signal from auxiliary windings of
manual bypass switch.
(e) INT_TX1 (3) and INT_RX1 (2) are used to communicate with computer through
RS232 port for firmware upgrade purpose.
Refer to System Frame for RX and TX signals
37

AND TROUBLESHOOTING
Part 2
Located at M board
5V
VS
RM31
QM9
RM65
RM29
5V
UM37
RM30
QM14
RM67
UM12D
1
G3
VS
SYNC_O
RM28
UC33-3
ZDM6
5V
RM69
CM35
(25)
5V
RM70
CM37
VS
QM4
RM16
ZDM3
RM19
UM12B
1
4
UM25
SYNC_I
TOBYP
CM21
UM19
CM26
3
RM20
5V
5V
RM21
4
TOBYP_I
CM20
(17)
RM49
1
5
TOINV_0
INT_TX
QM5
13
12
CM124
5
RM129
UM31
G3
CM33
CM97
5V
5V
+12VF
UM12C
TOINV_I
CM27
UM23
+12VF
RM132
INT_RX
CM31
(59)
CM125
RM210
RM54
3
UM32
CM126
G3
RM48
RM125
RM58
7
8
5V
INT_DATA
ZDM9
TOINV
ZDM4
UM22
RM214
CM98
(60)
VS
CM29 RM53
(13)
UM12F
CM23
RM52
5V
QM8
G3
1
UM21
VS
RM211
RM23
8
7
RM15
+12VF CM96
+12VF
G3
(12)
(18)
+12VF
G3
RM66
CM38
RM68
(26)
QM11
RM63
TOBYP_0
SYNC_BUS
CM36
UM24
(a) If Power MCU is operating normally, then VS is on. VS is the power source for
communication circuit: TOBYP_O, TOINV_O, SYNC_O and INT_TX. If Power
MCU is not operating normally (for example: MCU is crash), then VS is off to
prevent the parallel bus is locked
(b) TOBYP and TOINV signals are used to synchronize bypass mode and inverter
mode transfer
(c) SYNC_BUS signal is used synchronize the inverter and bypass voltage.
(d) INT_DATA signal is used to transfer information between Power MCU and
System MCU.
38

AND TROUBLESHOOTING
(22) Other Detection Circuit
Located at M board
5V
5V
RM7
RM2
JPM2
CNM1
1
2
1
2
PWR_RELS
CM145
REPAIR
(1)
CM14
(19)
5V
Vbatt
5V
V1
DM3
RM88
RM86
NTCM1
RM84
QM12
ZDM7
Vbat
(91)
TH2
CM62
RM182
CM52
RM85
TEMP
(93)
CM51
7V5
RM216
Located at B board
BAT+
RB74
CB44
Vbatt
V1
8
RB75
UB23A
TL0721
CB43
RB76
4
CB45
-V1
RB77
RB78
RB79
CB46
Located at B board
TH2
TH3
2
1
THB2
2
1
THB1
39

AND TROUBLESHOOTING
Located at A board
WA2
#22
WA3
#22
TH3
1
(a) Power MCU detects the power module is released by PWR_RELS (19). CNM1 is
the switch at the front of power module beside the fan.
(b) MCU detects the battery voltage through Vbat (91)
(c) MCU detects the temperature inside power module through TEMP (93). TH2 is
connected to the thermal switches on B board and A board. THB2 is located on
Heatsink HSB2 and THB1 is located at Heatsink HSB1. TH3 is located at HSA2.
(d) Test JUMP:
JPM2: If JPM2 is shorted, MCU will go into repair mode
(e) CNM6 is used for programming the MCU by BDM
(f) CNM9 can connect to specific LCD to show the information of power module
40

AND TROUBLESHOOTING
1.2 System Frame
System frame includes:
G Board: Input EMI Filter and Bypass SCR
P Board: Auxiliary power for system
S Board: System MCU and control circuit. Circuit for RS-232, dry contact, RJ12 and
RJ45.
C Board: Extend board for S board
V Board: Circuit for USB, Parallel port and minislot
E Board: Connector to connect with power module
1.2.1 Power Circuit

The power circuit of system frame is showed as Fig 1.3. The function of main
components are described as below:
CG1, LG1: Input EMI Filter
CTG1: bypass SCR short-circuit detection and back-feed protection
CTG2: Output Current detection
CG4: Output EMI Filter
LP2: EMI filter of AC auxiliary power circuit
TP2: AC auxiliary power circuit. The input source is from AC utility.
TP1: DC auxiliary power circuit. The input source is from battery source.
DP23: Provide generated voltage from TP2 to TP1 input. With this diode, UPS can
start without battery
CNP14: On switch
41
N
G
INPUT
CNG10
(N1)
CG1
CNG1
(INV/L)
CNG8
(IP/N)
G Board
CG4
CTG2
CTG1
LG1
CNP9
(B-)
CNP12
(B-)
CNP1
4
1
2
CNP8
(B+)
CNP1
(B+)
1
2
FUP2
CNP3
RP15
4
RP15
5
DP8
FUP1
LP2
CP82
NTCP2
G2
G2
G2
RP160
DP27
CP148
DP23
CP147
DP22
To UC3845-P7
G2
DP28
P Board
RP179
QP12
RP2
RP1
RP180
QP22
CP146
NTCP3
To UC3845P7
DP14
G2
DP20
TP2
TP1
G2
CNG9
(INV/L)
CNG3
CNG2
CNG7
(IP/L)
WG6
WG5
CP15
CP12
CP7
CP13
DP7
DP3
DP32
CP88
CP86
DP31
DP15
DP5
DP33
CP89
CP90
DP34
DP17
G3
DP4
DP16
G1
DP1
DP18
G3
DP6
DP19
G1
DP2
To -12VF
RP39
To
+12VF
To -12VS
G3
RP38
Vi Vo
Adj
LM317
G1
LM7912
I
O
G
To
+12VS

AND TROUBLESHOOTING
Fig 1.3
L N
G
OUTPUT
42

AND TROUBLESHOOTING
1.2.2 Control Circuit
(1) Bypass SCR Short-Circuit Detection
Located at G board
CTG1
CNG2
3
2
G1
WG1
#10
CT1
LG1
CG1
MOVG1
WG10
#10
*
DG2
2,3
1
SCR
CNG3
DG3
4,5
6
Located at S board
+12VS
RS234
9
US9C
TL084
5VS
DS4
8
CT1
QS4
RS227
RS235
(53)
SCRSD
RS34
10
QS5
RS231
RS228
RS229
+12VS
DS2
CS127
CS128
RS230
CS129
RS84
G1
(a) During battery mode, bypass SCR should be off and CT1 should be zero. If there
has current through CTG1 then SCRSD (53) will be Low. UPS will turn off the
inverter to prevent back-feed voltage.
43

AND TROUBLESHOOTING
WG8
#22
WG11
#22
(2) Bypass SCR Driver

Located at G board
SCR
TG1
+12VS
THS1-1
QG1
CG9
DG3
4,5
THS1-1
RG15
DG2
2,3
1
RG1
CG6
D
BYPSTS
DG1
3
S
10
DG5
RG17
RG18
RG16
CG10
CG7
RG19
CG8
4
G1
7
G1
5
DG4
Located at S board
RS217
5VS
THS1
(91)
CPU-P91
RS67
RS162
CS24
RS163 QS24
G1
Located at S board
5VS
+12VS
RS18
5VS
CS10 5VS RS11
US36
QS15
CVolt
RS17
RS2
5VS
RS12
THR
US15B-P3
US5D
4081
G1
CS19
RS3
TO US36-P6
GND COM
7
6
5
4
3
2
1
7B
6B
5B
4B
3B
2B
1B
5VS
CS25
RS8
QS13
G1
RS74
TO US36-P4
(33)
BYPSTS
BYPSTS
9
5VS
CS32
1
US5A
2
4081
DS18
4
BYP_STS
B9
RS53
TOBYP_I
TO US36-P6
DS8
US5C
4081
(105) TOBYP_I
G1
RS118
5VS
US5B
4081
10
(49) TOBYP_O
G1
DS10
RS117
811
US15B-P3
G1
10
11
12
13
14
15
16
MM74HC14
US20B
DS11
G1
RS9
7C
6C
5C
4C
3C
2C
1C
ULN2003A
G1
US4
TLC555C
DS13
RS47
RS19
3
7
13
DIS
GND
TRIG
CS41
12
VCC
G1
G1
5VS
+12VS
9
TOBYP_I
(105)
RS114
B10
CS49
5
G1
44

AND TROUBLESHOOTING
Located at V board
RV48
VS
QV2
5VS
RV33
UV14
ZDV2
4
CV13
B9
CV16
3
RV50
G3
RV62
+12VF
B10
G1
4
3
UV15
RV18
TO BYP
1
2
CV21
(a) THS1-1 is connected to the thermal switch located at heatsink of bypass SCR. If
the thermal switch is open due to over-temperature, the driver will be off
(b) MCU can detect over-temperature of bypass SCR through CPU-P91 (91)
(c) The bypass SCR driver signal will come from MCU or US4 according to the
signal TO US36-P4.
(d) TO US36-P4 is the output of MCU watchdog. If MCU is operating normally
then TO US36-P4 will be high and the bypass driver signal will come from
BYPSTS (33).
If MCU is not operating normally, TO US36-P4 will be low and then the bypass
driver signal will come from US4
(e) US4 is a 37kHz self-oscillator that can provide driver signal for bypass SCR.
(f) RS47/DS13/CS41 is used to disable the output of US4 during initialization of
auxiliary power
(g) The output of driver signal from US4 is also limited by TOBYP_I (105) signal
(h) US15B-P3 is the signal used to send out To bypass signal on parallel port no
matter the bypass SCR is driven by MCU or US4
Refer to Watchdog For System MCU for TO US36-P4 signal.
45

AND TROUBLESHOOTING
(3) Output Current Detection
Located at G board
SCR
DG3
DG2
CNG10
N1
OP/CT+
OP/CTRG2
CG4
CG5
MOVG4
WG9
#10
1
2,3
1
WG10
#10
4,5
CTG2
MS-130125-2-01
CNG1
1
WG3
1
CG11
O/L
CNG9
TO T
Located at S board
CS16
RS33
5VS
CS96
11
-12VS
RS55
OP/CT-
G1
RS157
2
RS51
RS54
CS15
RS32
4
OP/CT+
(76)
Iout_R
RS21
3
US9A
TL084
CS97
+12VS
CS34
G1
G1
G1
(a) MCU detects output current through Iout_R (76). The output current could be
bypass current or inverter current according to operation mode
46

AND TROUBLESHOOTING
(4) Input And Output Voltage Detection
Located at G board
CNG2
I/L
LG1
4
OP/CT+
RG2
OP/CT-
N1
MOVG1
CG4
CG1
CNG10
CTG2
1
CNG1
I/L
WG3
CNG3
RG3
RG7
RG11
RG4
RG8
RG12
I_N
O/L
O/L
I_L
RG5
RG9
RG13
RG6
RG10
RG14
CNG9
O_L
O_N
Located at S board
CS5
RS38
RS26
5VS
5VS
5VS
Vbyp_R
CS36
11
2
RS239
CS4
DS1
(25)
BYPZO_R
RS169
O_L
US16A
CS20
RS172
O_N
G1
RS25
RS244
6
7
RS245
RS22
RS190
QS1
G1
1
CS2
Vout_R
(77)
CS29
RS173
(80)
-12VS
RS238
RS156
RS29
RS30
RS24
+12VS
CS1
US16B
TL084
CS95 G1
G1
G1
CS56
I_L
5VS
RS100
RS240
13
14
RS241
RS102
RS101
12
CS17
RS99
G1
G1
5VS
I_N
VinR
RS192
(75)
RS196
INPZO_R
(24)
US16D
DS3
RS195
QS3
CS18
RS191
G1
(a) MCU detects RMS value of output voltage through Vout_R (77)
(b) MCU detects RMS value of bypass voltage through Vbyp_R (80) and RMS value
of input voltage through VinR (75).
(c) MCU detects the bypass frequency and zero crossing through BYPZO_R (25) at
falling edge. MCU detects the input frequency and zero crossing through
INPZO_R (24) at falling edge
47

AND TROUBLESHOOTING
(5) AC Auxiliary Power Circuit
Located at P board
1
2
NTCP3
I/L
CNP3
DP20
FUP2
CP2
RP161
2
G2
7
VFB
COMP
G2
DP23
D
UP4
VREF
OUT
RP174
G2
4
CP103
RT/CT
GND
G2
ISEN
RP178
QP22 S
G2
RP50
G1
CP20
12
DP33
45KHz
CP34
NC
11
CP89
DP19
-12V
UP6
LM317
DP6
G2
RP29
B+
CP92
7
DP5
B1
8
CP15
CP21
Vin
+Vout
+12VF
2
RP39
G3
CP22
RP184
RP94
CP12
CP147
CP10
G2
DP22
DP30
UP14
CP30
VCC
18V
G'
4
5
+12VS
CP19
ADJ
ZDP2 G2
G2
VCC
CP90
CP78
LP2
I/N
G1
10
2
3
DP28
RP158
RP183
CP6
CP101
R
UP2
TL431AC
DP2
+12VP
CP146
CP100
CP5
RP26
DP34
I/N
RP27
RP25
TP2
RP157
RP28
RP181
+12VP
DP15
9
RP38
DP18
-12VF
RP180
UP5
UC3845
RP49
CP14
G3
G2
Located at S board
EPO
CNS5
1
2
3
4
5
6
VCC
G'
NC
RJ12
(a) The input of AC auxiliary power circuit is from AC input.

(b) Battery winding of TP2 is used to provide input voltage to DC auxiliary power
circuit once battery pack is not connected.
(c) If EPO is active (NC is released) through RJ12, then AC auxiliary power circuit is
disabled.
48

AND TROUBLESHOOTING
(6) DC Auxiliary Power Circuit
Located at P board
FUP1
B+ DP14
NTCP2
RP23
RP163
CNP14
CON(2.5)
UP10
K-ON
QP17
1
2
G1
BATTERY
ON_A
ON_B
RP162
ON_B
RP155
ON_A
RP24
CP82
TP1
1
RP160
DP8
ZDP1
18V
CP8
2
1
8
+12VS
RP132
CP28
VREF
OUT
RT/CT
CP102
5
DAUX
QP21
RP21
ISEN
UP3
UC3845
OUT
UP6
LM317
DP4
11
S
-12VS
3
G3
Vin
+Vout
QP12
+12VF
2
RP39
CP18
RP47
DP7
RP79
RP46
DP3
CP7
CP17
D
G
RP171
3
RP131
R
UP37
TL431
UP13
1
2
RP170
HSP1
45KHz
IN
UP1
LM7912CT
10
COMP
RP177
2
-12V
DP29
RP19
CP27
VFB
DP16
DP32
9
12
UP12
G1
CP16
RP145
RP182
VCC
CP9
RP175
CP4
CP88
CP87
RP2
+12VB
CP86
ADJ
CP79
CP29
GND
B1
+12VS
DP12
RP1
CP1
RP30
4
5
DP1
GND
RP154
ON_B
+12VB
DP31
7
2
3
DP27
CP13
DP17
CP11
-12VF
RP38
RP179
G1
G1
G3
G1
Located at S board
5VS
RS164
RS139
K-ON
CS26
KEY_ON
(4)
DAUX_BAT
(31)
RS13
DAUX
G1
(a) B+ is the source from AC auxiliary power circuit

(b) MCU detects the on key through KEY_ON (4)
(c) If DAUX_BAT (31) is high during battery mode, DC auxiliary power will be off
Refer to AC Auxiliary Power Circuit for B+ and B1 signals
49

AND TROUBLESHOOTING
(7) Auxiliary Power Failure Detection
Located at P board
+12VB
+12VS
RP31
RP33
DP24
ZDP3
9V
G1
RP37
QP1
+12VP
G1
+12VS
RP32
AUX-F
RP35
DP25
ZDP4
9V
G1
RP36
RP34
QP3
QP2
G1
G1
Located at S board
5VS
RS10
AUX-F
RS138
(61)
AUX_Fail
(a) +12VP is from AC auxiliary power and +12VB is from DC auxiliary power.
During AC mode, +12VP and +12VB should be both alive. If one of them is fail,
MCU can detect auxiliary power failure through AUX_Fail (Low active).
50

AND TROUBLESHOOTING
(8) Battery Voltage Detection
Located at P board
B+
RP7
RP8
RP9
RP10
RP11
RP12
BATTBATT+
Located at S board
CS6
RS27
BATTBATT+
RS242
RS243
10
RS23
CS3
RS31
US16C
TL084
Vbat
(87)
CS28
RS15
G1
G1
(a) MCU detect the voltage through Vbat (87)
51

AND TROUBLESHOOTING
(9) Battery Pack Detection
Located at P board
INTBNO
D+
CP3
CNP7
1
2
RP22
D-
G1
Located at S board
5VS
DS20
RS20
RS137
INTBNO
INTB_NO
(89)
INTB_NO
CS31
DS21
G1
G1
(a) MCU detects the internal battery pack through A/D INTB_NO (89).
52

AND TROUBLESHOOTING
(10) Auxiliary Power For 5V
Located at S board
+12VF
RS155
QS19
+5VF
RS150
RS153
CS7
1
Vin
Vout
3
R
CS107
US6
TL431 0.5%
CS136
RS154
CS37
VLED
GND
+12VS
US38
G1
RS151
CS8
G3
QS23
CS106
+12VS
5VS
RS80 RS81
RS82
+12VS
RS160
QS22
5V8
CS33
RS158
CS35
CS12
US10
CS94
A
CS105
G1
(a)
(b)
(c)
(d)
US26
RS83
RS161
G1
RS159
G1
5VS is the power source for MCU

VLED is the power source for LCD and LEDs
5V8 is the power source for blue backlight of LCD
+5VF is the power source for USB MCU and Minislot.
53

AND TROUBLESHOOTING
(11) LCD And LED Driver
Located at S board
BKLIT
VLED
CS85
VLED
16
11
10
SRCLK
SRCLR
12
13
RCLK
E
16
CS88
G1
15
1
2
3
4
5
6
7
LED0
LED1
LED2
LED3
LED4
LED5
LED6
LED7
LED_STB
(64)
O0
O1
O2
O3
O4
O5
O6
O7
G1
Q7
VCC
VCC
14
SER
G1
SER
SRCLK
SRCLR
RCLK
E
G1
G1
CS84
16
VLED
15
1
2
3
4
5
6
7
Q7
G1
SER
SRCLK
SRCLR
RCLK
E
O0
O1
O2
O3
O4
O5
O6
O7
GND
LCD0
LCD1
LCD2
LCD3
LCD4
LCD5
LCD6
LCD7
VCC
US23
74HC595
LCD0
LCD1
LCD2
LCD3
LCD4
LCD5
LCD6
LCD7
14
RTCDO (7)
11
10
RTCSCK (8)
LCD_STB (63)
12
13
G1
LCD7
LCD5
LCD3
LCD1
(20) LCDE
(21) LCDRS
CS87
G1
LCD7
14
11
10
RS62
QS6
CS21
RS201
G1
RS128
ENT
KEY_ENT
G1
(97)
KEY_ENT
RS143
(64)
LED_STB
12
13
ESC
RS105
KEY_ESC
CS76
KEY_ESC (98)
RS142
CS65
G1
CS93
CS90
G1
G1
CNS8
LED0
LED2
LED4
LED6
LED8
LED10
LED12
DOWN
ENT
BKLIT
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
LCD5
LCD3
LCD1
LCDE
LCDRS
CS67
CS66
(62)
LCD_BKLIT
RS70
(7)
RTCDO
(8)
RTCSCK
CS89
(100)
KEY_DOWN
CS91
GND
Q7
DOWN
G1
US25
74HC595
O0
O1
O2
O3
O4
O5
O6
O7
GND
15
1
2
3
4
5
6
7
KEY_DOWN
RS35
G1
G1
US24
74HC595
LED8
LED9
LED10
LED11
LED12
CS86
VLED
CS68
33
31
29
27
25
23
21
19
17
15
13
11
9
7
5
3
1
G1
RS36
UP
TO DISPLAY
5VS
LED1
LED3
LED5
RS237
LED7
LED9
LED11
TEMP
CS116
UP
ESC
G1
OFF
LCD6
LCD4
LCD2
LCD0
KEY_UP
RS71 (99) OFF
CS71
CS73
KEY_OFF
(5)
KEY_OFF
CS23
G1
(88)
LCD6
LCD4
LCD2
LCD0
RS205
G1
G1
RS37
RS72
G1
5V8
CS70
CS69
KEY_UP
CS22
VLED
CS72
RS206
-12VS
(61)
G1
G1
(a) MCU detects the ambient temperature through TEMP (88). The thermal sensor is
located on the LED board at the front panel.
(b) LCD_BKLIT (62) can adjust the intensity of LCD backlight by PWM control
54

AND TROUBLESHOOTING
(12) Watchdog For System MCU
Located at S board
5VS
8
CS9
G1
5VS
RS7
2
5
SYS_RDY
CVolt
RS4
TO US36-P4
3
5VS
THR
RS1
CS27
CS14
CS11
G1
RS6
US3
TLC555C
RS14
G1
G1
QS14
JS6
1
2
Q
DIS
(29)
SYS_RDY
TRIG
GND
VCC
5VS
RS63
QS12
DS5
G1
G1
(a) SYS_RDY (29) will send out pulse to reset CS27. And then CS27 will be charged
again by 5V through RS1. TO US36-P4 will keep high level. If SYS_RDY (29)
doesnt send out pulse for a specific period (for example: MCU is crash) then TO
US36-P4 will be low.
(b) Test JUMP:
JPS6: If JPS6 is shorted, then TO US36-P4 will be low or TO US36-P4 will
keep high during normal operation.
55

AND TROUBLESHOOTING
(13) Communication Circuit for RS232 & USB
Switching between RS232 and USB port
Located at S board
5VS
D_RS232
RS182
US27C
C
IN
OUT
2
RS232_RX
RXD
13
1
CD4066B
RS177
(59)
RS232_RX
6
8
(60)
RS232_TX
RS232_TX
US27A
RS181
C
IN
OUT
TXD
CD4066B
US19A
US27D
QS25
12
11
US27B
5
4
B2
RS178
G1
C
IN
OUT
C
IN
CD4066B
OUT
10
B1
MM74HC14
CD4066B
Located at V board
+12VF
RV88
5VS
VBUS
UV24
D_RS232
RV85
RV86
QV11
RV87
G1
G3
(a) If D_RS232=high, MCU (RS232_RX, RS232_TX) will communicate with USB

port (B1, B2).
If D_RS232=low, MCU (RS232_RX, RS232_TX) will communicate with RS232
port (RXD, TXD).
(b) VBUS is voltage of USB-P1 from computer. USB port has the higher priority than
RS232 port
56

AND TROUBLESHOOTING
Communication for USB port
Located at V board
+5VF
CV42
+5VF
G3
CV8
5VS
CV1
G3
XTALV1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
UV3
8
7
1
2
RV16
+5VF
CV7
5
G3
CV3
RV5
G3
G3
5VS
G1
+5VF
UV5
+5VF
7
8
RV6
6
5VS
RV4
RV27
5
B2
G3
CV10
UV7
CV6
B1
CV9
G3
+5VF
RV2
CV11
VDD
OSCOUT
OSCIN
VSS
PC2/USBOE
PC1/TDO
PC0/RDI
RESET
NC
PB7/AIN7/IT8 (10mA)
PB6/AIN6/IT7 (10mA)
Vpp/TEST
PB5/AIN5/IT6 (10mA)
PB4/AIN4/IT5 (10mA)
PB3/AIN3 (10mA)
PB2/AIN2 (10mA)
PB1/AIN1 (10mA)
G3
VDDA
USBVCC
USBDM
USBDP
VSSA
PA0/CPUCLK
(25mA) PA1/SDA
NC
NC
NC
(25mA) PA2/SCL
PA3/EXTCLK
PA4/ICAP1/IT1
PA5/ICAP2/IT2
PA6/OCMP1/IT3
PA7/OCMP2/IT4
(10mA) PB0/AIN0
RV17
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
VBUS
G3
RV34
G3
G3 G3
CV23 CV29
G
RV89
CV12
RV26
G3
G3
QV12
RV32
CV46
CV44
C1- SHDN
C1+ GND
C2- VOUT
C2+ VCC
G3
G3
8
7
6
5
RV9
CNV2
G3
UV2
1
2
3
4
RV80
CV2
VBUS
G3
CV43
CNV4
1
2
3
4
G3
CV17
+5VF
+5VF
1
3
5
7
9
2
4
6
8
10
HEADER 5X2
RV10
DV5
G1
QV5
S
G3
DD+
D
RV25
CV15
+5VF
G3
G3
RV28 RV8
CV45
QV1
G3
(a) UV2 is boost supply for self-programming purpose

(b) CNV2 is used to USB chip programming
57

AND TROUBLESHOOTING
Communication for RS232
Located at S board
US19CTO TXD
6
TXD
MM74HC14
Located at C board
+12VF
+12VF
+12VF
CC4
RC21
RC19
G3
RC11
3
8
7
UC7A G3
LM393
RX
UC5
2
D
CC5
RC24
G3
4
TO TXD
CNS3-P2
QC3
RC22
CC6
+12VF
8
5VS
RC10
CC3 5VS
G3
RC12
-12VF
RC18
G3
RXD
7
8
G1
UC6
RC20 5
TX
RC23
DC6
3
G3
RC13
G1
DC7
5VS
CC9
G3
D
QC4
G
S RC25
-12VF
QC5
CNS3-P6
CC8
CC7
Located at S board
RS232
+12VF
CNS3
RS57
RS149
G3
TX
CNS3-P2
CNS3-P6
5
9
4
8
3
7
2
6
1
(a) CNS3-P6 is used for plug & play function

(b) RX and TX signals are also connected to power module for firmware upgrade
purpose
Refer to Power Module for RX and TX signals
58

AND TROUBLESHOOTING
(14) Communication Circuit for Minislot
Communication Circuit
Located at S board
US19B
(58)
DATA_TX
DATA_TX
5VS
(57)
DATA_RX
DATA_RX
B3
RS127
RS133
B4
CS78
G1
Located at V board
5VS
RV12
CV5
UV4
G3
RV42
8
7
RV3
B3
+12VF
+12VF
RV82
5
4
-12VF
5VS
CV4
1
UV6
RV21
3
D
+12VF
RV7
G3
G1
B4
+5VF
CNV3
7
8
G1
S
QV6
G3
RV41
INPUT 1
INPUT 2
G1
INPUT 3
1
3
5
7
9
11
13
15
17
19
21
23
25
2
4
6
8
10
12
14
16
18
20
22
24
26
CV14
CV33 G3
G3
INPUT 4
RSD
INPUT 5
To Minislot
59

AND TROUBLESHOOTING
Dry Contact Circuit
Located at S board
US36
8
G1
GND COM
7
6
5
4
3
2
1
(38) DRY A
(37) DRY B
(30) DRY C
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
Bat fault
+12VS
9
10
11
12
13
14
15
16
ULN2003A
(95)
BAT-F
RS180
RS44
QS11
G1
Dry Contact
on line/backup
low-batt
load protect
On bypass
G1 CNS4-P5
5VS
CNS4-P3
BYPL
DRY D
(103)
BYPL
RS73
QS18
RS87
(52)
RMTSD
RS146
RS236
CNS4
5
9
4
8
3
7
2
6
1
RSD
G1
Located at C board
CNS4-P3
RC16
RSD
RC17
CC2
G1
CNS4-P5
UC4
Located at V board
+12VS
+12VS
load protect
RV49
INPUT 1
QV19
on line/backup
RV45
INPUT 2
+12VS
INPUT 4
Bat fault
RV46
INPUT 3
RV29
RV81
QV10
+12VS
RV39
RV79
RV30
QV13
RV40
RV61
On Bypass
+12VS
RV14
RV11
RV20
low-batt
QV20
INPUT 5
RV47
QV18
RV78
(a) INPUT 1: Load protected

INPUT 2: Operation on battery
INPUT 3: Battery fault
INPUT 4: Operation on automatic-bypass
INPUT 5: Low battery
OUTPUT (RSD): Remote power off
60

AND TROUBLESHOOTING
(15) Communication Circuit For Dry Contact
Located at S board
Dry Contact
US36
8
G1
GND COM
7
6
5
4
3
2
1
(38) DRY A
(37) DRY B
(30) DRY C
7B
6B
5B
4B
3B
2B
1B
CNS4-P5
CNS4-P9
CNS4-P4
CNS4-P8
CNS4-P3
CNS4-P7
+12VS
9
10
11
12
13
14
15
16
7C
6C
5C
4C
3C
2C
1C
CNS4-P6
on line/backup
low-batt
load protect
On bypass
ULN2003A
DRY D
CNS4
DB9
5VS
BYPL
(103)
5
9
4
8
3
7
2
6
1
BYPL
RS73
QS18
RS87
(52)
RMTSD
RS146
RS236
RSD
G1
Located at C board
CNS4-P3
RC16
RSD
RC17
CC2
G1
CNS4-P5
UC4
+12VS
RLC10
+12VS
CNS4-P9
NO
NC
CNS4-P4
RLC11
NO
CNS4-P8
NC
DC3
DC1
+12VS
+12VS DC4
RLC12
RLC13
NO
CNS4-P7
NO
NC
DC2
low-batt
COM
load protect
COM
on line/backup
CNS4-P6
NC
DC5
COM
On bypass
COM
CNS4-P5
(a) CNS4-P3: Remote power off

CNS4-P5: Common
CNS4-P7: Battery low
CNS4-P9: On battery
CNS4-P4: On utility
CNS4-P6: On bypass
CNS4-P8: System (load) protected / UPS On
61

AND TROUBLESHOOTING
(16) Communication For System and Power module
Part 1
Located at V board
+12VF
RV55
RV38
5VS
UV20
B6
RV54
SYNC_BUS
G3
3
G3
1
2
CNV6
QV9
VS
RV52
VS
5VS
RV36
UV18
B13
SYNC_BUS
QV3
ZDV4
CV19
RV48
VS
QV2
CV26
RV33
5VS
UV14
ZDV2
4
CV13
RV58
B9
CV16
3
RV50
G3
RV64
+12VF
UV21
B14
G3
G1
RV22
+12VF
CV27
2
VS
+12VF
RV59
G3
8
7
UV10
CV30
RV35
UV16
ZDV3
CV20
3
RV53
RV60
4
G3
G3
UV11
+12VF
CV37
7
8
G1
RV66
+12VF
RV24
B12
G1
CV32
UV17
RV63
RV19
CV22
1
2
G1
TOINV
QV4
CV18
4
5
5VS
B18
TO BYP
CV21
ZDV6
B11
B17
RV18
RV51
VS
5VS
RV62
1
2
CV31
INT_DATA
UV15
G1
QV8
CV38
2
B10
Located at S board
US20C
US19B
5
TOINV_O
(50)
B11
(58)
DATA_TX DATA_TX
RS89
5VS
5VS
RS116
TOINV_I
(106)
B12
(57)
DATA_RX
DATA_RX
B3
US15B-P3
US20B
4
RS127
B6
RS133
CS51
B4
CS78
G1
B9
To US36-P4
RS122
G1
RS94
QS20
US20F
SYNC_O
(27)
B13
13
INT_TX
(3)
G1
12
B17
US20D
5VS
SYNC_I
(26)
RS90
5VS
RS119
B14
INT_RX
(2)
RS91
RS120
B18
CS54
CS52
G1
G1
(a) If System MCU is operating normally, then VS is on. VS is the power source for
communication circuit: US15B-P3 (B9), TOINV_O (B11), SYNC_O (B13) and
INT_TX (B17). If System MCU is not operating normally (for example: MCU is
crash), then VS is off to prevent the communication bus is locked
62

AND TROUBLESHOOTING
(e) TOBYP and TOINV signals are used to synchronize bypass mode and inverter
mode transfer
(f) SYNC_BUS signal is used synchronize the inverter and bypass voltage
(g) INT_DATA signal is used to transfer information between Power MCU and
System MCU.
Refer to Watchdog for System Module MCU for TO US36-P4 signal.
Refer to Bypass SCR driver for US15B-P3 signal
63

AND TROUBLESHOOTING
Part 2
Located at V board
5VS
RV1
UV1
ON
RV31
+12VF
ON1
RV71
5VS
4
ID1_RDY
CV39
UV22
RV72
+12VF
1
RV70
BYPOK
4
UV23
CV40 2
DV7
DV8
G3
ID1RDY
G1
+12VF
BYP_OK
RV77
+12VF
B8
G1
UV13
+12VF
RV43
TOMBYP(B)
RV13
TOMBYP(N)
TOMBYP
RV15
B7
UV12
QV14
RV74
QV15
RV37
5VS
B5
G3
RV83
RV84
RV75
RV76
QV17
QV16
G1
RV73
TOMBYP
RV44
BYP-F
4
UV19
3
G3
G3
Located at S board
5VS
ON
US36
QS2
G1
RS104
RS39
(34)
POWER_ON
RS216
ID1_RDY
(54)
CS43
TO US36-P4
G1
5VS
8
7
6
5
4
3
2
1
G1
GND COM
7B
6B
5B
4B
3B
2B
1B
7C
6C
5C
4C
3C
2C
1C
+12VS
9
10
11
12
13
14
15
16
BYP_OK
ULN2003A
RS86
TOMBYP_B
(104)
RS115
5VS
B8
CS50
TOMBYP_N
(35)
RS144
TOMBYP_N RS145
CS55
G1
B5
B7
BYP-Fail
(22)
RS123
QS21
RS113
G1
G1
(a) If POWER_ON (34)=high, the auxiliary power of power module is powered on.
ON1 is connected to power module.
(b) If ID1_RDY (54)=Low, the Power MCU is operating normally
(c) BYPOK is connected to power module to inform that System MCU is operating
normally
(d) TOMBYP(B) is connected to the bypass auxiliary winding of manual bypass
switch. MCU detects that manual bypass switch is at bypass position by
TOMBYP_B (104) (low active)
(e) TOMBYP(N) is connected to the normal auxiliary winding of manual bypass
switch. MCU detects that manual bypass switch is at normal position by
TOMBYP_N (35) (low active)
(f) BYP-F is connected to power module. If utility is fail, BYP-Fail (22) will be high.
(g) TOMBYP is connected to power module to detect the switch of manual bypass
switch.
Refer to Watchdog for System Module MCU for TO US36-P4 signal.
64

AND TROUBLESHOOTING
(17) EXB Detection Circuit (RJ45) And EPO Circuit (RJ12)
Located at S Board
RS211
EXTBNO
EXTB_NO
(90)
RS210
EMPO1
EPO
(108)
CNS9
CNS5
EXTBNO
DS6
RS79
DS19
1
2
3
4
5
6
7
8
CS44
CNS9-P5
CNS9-P6
CNS9-P7
CNS9-P8
5VS
G1
1
2
3
4
5
6
VCC
CNS5-P2
G'
NC
CNS5-P4
CNS5-P5
EPO
EXT. BAT. DET.
Located at C board
RC8
+12VF
(1)
BTEST
UC2
RC2
CNS9-P5
CNS9-P6
CNS9-P7
CNS9-P8
5VS
2
QC2
QC1
RC3
D
G1
G3
2
RC6
5VS
RC4
S
RC7
UC1
RC1
RC14
EMPO1
4
CC1
G1
UC3
1
2
G3
VCC
CNS5-P2
GND
NC
CNS5-P4
CNS5-P5
RC15
(a) MCU detects the number of External battery cabinet by EXTB_NO (90)
(b) Normal Close setup for EPO (RJ12): Short CNS5-P5 (NC) to CNS5-P4 (G). If
remove the short pin, EPO will be active
(c) MCU detects EPO signal by EPO (108)
(d) CNS9-P8 & CNS9-P7 is used to trip the circuit breaker (if the breaker has external
trip function) on EXB when EPO is active.
(e) CNS9-P5 & CNS9-P6 is used to disable the CLA during performing battery test
65

AND TROUBLESHOOTING
(18) Other Detection Circuit
Located at S board
5VS
RS167
CNS7
JS5
1
2
REPAIR
(96)
BKGD
BKGD(23)
BKGD
CS118
1
3
5
2
4
6
G1
/RES
(42)
/RES
5VS
(BDM)
G1
CNS6
#22
DS22
+12VS
CNS10
1
OL1
DS23
+12VS
#22
OUTLET1
(110) CPU-P110
QS16
G1
RS147
OL2
#22
OUTLET2
RS85
CNS11
QS17
RS136
(111) CPU-P111
G1
RS148
OUTLET2
OUTLET1
(a) If JS5 is shorted, UPS will go into test mode

(b) CNS6, CNS10 and CNS11 are connected to outlet board for outlet control
(c) CNS7 is used for MCU programming by BDM
66

AND TROUBLESHOOTING
2. Troubleshooting
2.1 Internal Fault
2.1.1 Alarm 34: CHARGER FAULT
START
Disconnect Battery
And Check Charger Voltage
200Vdc<Vbat<214Vdc
?
N
Check Voltage at
UB23-P7 On B Board
0V?
Charger Detection Circuit

On B Board Fail
Replace B board
N
END
Check Rectifier
And PFC Circuit
(refer to flow chart for
alarm 305)
N
Check Bus Voltage
Around 375V/-375V?
Charger Detection Circuit

On M Board Fail
Replace M board
END
Charger Circuit On B
Board Fail
Replace B Board
END
67

AND TROUBLESHOOTING
2.1.2 Alarm 193: FAN FAULT
START
Fans At Front And Rear Of

Power Module are rolling?
Fan Fail
Replace Fan Which Is Not
Rolling
Fan Fail Detection Circuit

On B Board Fail
Replace B Board
Restart UPS and No

AN FAULT ALARM
Y
END
END
68

AND TROUBLESHOOTING
2.1.3 Alarm 004: UPS TEMPERATURE FAULT
START
Remove Power
Module and
No Output At Bypass
Mode?
OTP At System Frame
OTP
At Power Module
Output Load=0 And

Output Is Recovered?
Check Wiring
CNG4-P11 ~CNG4-P8 ~
CNP4-P8 ~ CNP2-P10~
CNS2-P10
OK?
Temperature Detection
Circuit On S Board Fail
Replace S Board
END
Replace Fan
END
Turn On UPS
And Check Fan Is Rolling
Or Not?
Turn On UPS
Output Load=0
No OTP Alarm
Check Wiring
CNA1-P13~CNA1-P22
~CNB1-P22 ~ CNB3-P10 ~
CNM4-P9
OK?
Check the Ambient

T < 40 C
Flat Cable Fail

Change Flat Cable
END
END
1. Check Path of Air Flow

And Clean Dust Or Barrier
2. Check the Ambient
T<40 C
END
Temperature Detection
Circuit On M Board Fail
Replace M Board
END
Flat Cable Fail

Change Flat Cable
END
69

AND TROUBLESHOOTING
2.1.4 Alarm 701: INVERT FUSE BLOWN
START
Check FUA4
Is Open ?
Check Wiring
CNA1-P11~CNB1-P11
~CNB2-P15~CNM2~P16
OK?
Flat Cable Fail

Replace Cable
END
Inverter Fuse Open

Detection Circuit On M
Board Fail
Replace M Board
END
Check
QB18/QB19/QB20
and QB22/QB23/QB24
Damaged ?
Inverter Circuit On B
Board Fail
Replace B Board
Replace FUA4
N
Inverter Current Limit
Circuit Fail
Replace M Board
Replace FUA4
Check Inverter
Control Circuit On M Board
TPM1 & TPM2
Ok?
Inverter Control Circuit On

M Board Fail
Replace M Board
Y
END
END
END
70

AND TROUBLESHOOTING
2.1.5 Alarm 100: NORM AC FUSE BLOWN
START
Check FUA1 Is Open ?
Check Wiring
CNA1-P25~CNB1-P25
~CNB2-P13~CNM2~P14
OK?
Flat Cable Fail

Replace Cable
END
Flat Cable Fail

Replace Cable
END
Rectifier Fuse Open

Detection Circuit On M
Board Fail
Replace M Board
END
Check Wiring
CNA1-P26~CNB1-P26
~CNB2-P14~CNM2~P13
OK?
Check
QB10/QB11/QB12
And QB14/QB15/QB16
Damaged?
PFC Circuit On B Board

Fail
Replace B Board
Replace FUA1
END
Rectifier SCR Control

Replace M Board
END
N
Check
SCR Driver Signal
On A Board (JPA1-P1 and
JPA2-P1)
OK?
Rectifier Circuit On A
Board Fail
Replace A Board
END
71

AND TROUBLESHOOTING
2.1.6 Alarm 30: RECTIFIER FAULT
START
Short JPB1
And Input Voltage=230Vac
Check Bus Voltage Around
300/-300Vdc ?
Remove JPB1
And Turn On UPS Check
Bus Voltage Around
375/-375V?
Check
SCR Driver Signal
JPA2-P1)
OK?

Replace M Board
END
Board Fail
Replace A Board
END
Bus Detection Circuit On

M Board Fail
Replace M Board
END

Fail
Replace B Board
END
72

AND TROUBLESHOOTING
2.1.7 Alarm 28: DC BUS +/- TOO HIGH/LOW
START
Output Is
Half-Wave Load
Reduce The Load
END
Output Is
Inductive Load (Ex.
Transformer) And Short
JPM4. No Alarm
Again?
DC Offset Compensation
Replace M Board
END
Short JPB1
And Input Voltage=230Vac
Check Bus Voltage Around
300/-300Vdc ?
Check
SCR Driver Signal
JPA2-P1)
OK?
Board Fail
Replace A Board
Remove JPB1
And Turn On UPS Check
Bus Voltage Around
375/-375V?

Fail
Replace B Board

Replace M Board
Check Voltage
At UB14-P8
Around 8Vdc?
END
BUS Voltage Detection

Circuit On B Board Fail
Replace B Board
END

Circuit On B Board Fail
Replace B Board
END
Check Voltage
At UB14-P14
Around 8Vdc?
Y
END
Replace M Board
END
73

AND TROUBLESHOOTING
2.1.8 Alarm 31: INVERTER FAULT
START
Check Bus Voltage

Around 375/-375Vdc?
Check Rectifier And PFC

Circuit
(Refer to Flow Chart For
Alarm 305)
Turn On UPS and

Check Voltage On CA25
Preset Voltage
(ex. 230Vac) ?
Check Wiring
CNA1-P8~ CNB1-P8~
CNB2-8~ CNM2-P7
Ok?
Flat Cable Fail

Replace Flat Cable
Inverter Voltage Detection

Replace M Board
END
END
Check Inverter
Driver Signal On M Board
(TPM1 & TPM2)
Ok?
Inverter Control Circuit On

M Board Fail
Replace M Board
END
Inverter Circuit On B
Board Fail
Replace B Board
END
74

AND TROUBLESHOOTING
2.1.9 Alarm 191: BATTERY FAULT
START
Switch On
Top Chassis is showed
Connected ?
Battery Is Not Connected

Turn On The Switch
END
Battery End Of Its Life

Replace With New Battery
Tray
END
Fuse Is Broken
Replace FUB3 & FUB4
END
Measure The
Battery Voltage Through
EXB Connector
>150Vdc
Check FUB3 & FUB4 are

Open ?
Battery Voltage Detection

Replace M Board
END
75

AND TROUBLESHOOTING
2.1.10 Alarm 36: AUTO BYPASS FAULT
START
Check SCR On G Board Is

Shorted ?
Bypass SCR Damaged

Replace G Board
END
Flat Cable Fail

Change Flat Cable
END
Check Wiring
CNG4-P6 ~CNP4-P6 ~
CNP2-P4 ~CNS2-P4
Ok?
Bypass SCR Short Short

Detection On S Board Fail
Replace S Board
END
76

AND TROUBLESHOOTING
2.1.11 Alarm 00A: DC POWER SUP FAULT
START
Check Voltage
At CP86 On P Board
Around +12Vdc ?
Battery Aux Power Fail

Replace P Board
END
AC Aux Power Fail

Replace P Board
END
Auxiliary Power Fail

Detection Circuit On S
Board Fail
Replace S Board
END
Check Voltage
At CP90 On P Board
Around +12Vdc ?
Check
QP3 C-E on P Board
0V?
Y
Auxiliary Power Fail
Detection Circuit On P
Board Fail
Replace P Board
END
77

AND TROUBLESHOOTING
2.1.12 Alarm 63: INTERNAL COM FAULT
START
Check Wiring
CND1-P3 ~ CNM5-P3
Ok?
Flat Cable Fail

Replace Flat Cable
END
Flat Cable Fail

Replace Flat Cable
END
Check Wiring
CNE1-P3 ~ CNV5-P3
Ok?
Communication Circuit On
M Board Or S/V Board
Fail
Replace M Board Or
Replace S/V Board
END
78

AND TROUBLESHOOTING
2.1.13 Alarm 006: COM FAULT BETW UPS
START
Check Wiring
DB15-P7 Of Two UPS
Ok?
Parallel Cables Are Open

Or PCB On ModularEasy
Fail
Replace Parallel Cable or
PCB On Modular Easy
END
Flat Cable Fail

Replace Flat Cable
END
Flat Cable Fail

Replace Flat Cable
END
Check Wiring
CND1-P5~ CNM5-P5
Ok?
Check Wiring
CNE1-P5~ CNV5-P5
Ok?
Y
Communication Circuit On
M Board Or S/V Board
Fail
Replace M Board Or
Replace S/V Board
END
79

Service Manual For PW9135

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Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

AWG 10# BLACK B BOARD WB9 TO A BOARD CNA5

AWG 10# BLACK B BOARD WB3 TO A BOARD CNA11

AWG 10# BLACK B BOARD WB1 TO A BOARD CNA10

AWG 10# BLACK B BOARD WB4 TO A BOARD CNA12

AWG 10# BLACK B BOARD WB2 TO A BOARD CNA9

AWG 10# BLACK D BOARD WD4 TO B BOARD CNB7

AWG 10# BLACK D BOARD WD1 TO A BOARD CNA2

AWG 10# WHITE D BOARD WD2 TO A BOARD CNA3

AWG 10# BLACK D BOARD WD6 TO A BOARD CNA7

AWG 10# WHITE D BOARD WD7 TO A BOARD CNA6

D BOARD WD5 TO CASE G

E BOARD WE8 TO CASE G

AWG 10# BLACK E BOARD WE3 TO P BOARD CNP9

AWG 10# BLACK E BOARD WE12 TO G BOARD CNG7

AWG 10# BLACK E BOARD WE6 TO G BOARD CNG1

G BOARD CNG3 TO TERMINAL BLOCK

G BOARD CNG2 TO TERMINAL BLOCK

G BOARD CNG8 TO TERMINAL BLOCK

G BOARD CNG9 TO TERMINAL BLOCK

B BOARD WB6 TO A BOARD CNA4

D BOARD WD3 TO B BOARD CNB6

E BOARD WE1 TO P BOARD CNP1

G BOARD WG7 TO P BOARD NUT

TERMINAL BLOCK OUTPUT G TO CASE

TERMINAL BLOCK NORMAL AC SOURCE

BATTERY CONNECTOR 3PIN G TO CASE

AWG 10# WHITE E BOARD WE5 TO G BOARD CNG10

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

1.1.1 Power Circuit

Powerware 9135 HARDWARE INTRODUCTION

DB24 To V4+/V4- (INV Driver)

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

(a) SCRA1 will become a diode if RECT+ becomes low

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

(a) Vin is full rectified sine wave

Powerware 9135 HARDWARE INTRODUCTION

(a) The waveform at INPZO (24) is square wave

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Inverter Ipk Protection

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

(a) If BATSCR1 (66) is high, then AC signal=low and BC=high, UPS is at

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Powerware 9135 HARDWARE INTRODUCTION

Battery Discharge Current

Powerware 9135 HARDWARE INTRODUCTION