Service Manual (VGD 700-3K) 20050701

UNINTERRUPIBLE POWER SYSTEMS
SERVICE MANUAL
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA
P/N : XXX-XXXX-XXX
2005/7/1
PCM Vanguard
700VA/1KVA/1.5KVA/2KVA/3KVA SERVICE MANUAL
I. INTRODUCTION 3
II. PRINCIPLE OF OPERATION 4
1. INTRODUCTION 4
III. POWER STAGE (PSDR) 5
i. CHARGER SUB-SYSTEM: 5
ii. DC POWER SUPPLY SUB-SYSTEM: 5
iii. INVERTER SUB-SYSTEM : 5
iv. OUTPUT SUB-SYSTEM : 6
v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM : 6
vi. DC-DC CONVERTER SUB-SYSTEM : 6
1. MAIN CONTROL PCB ASSEMBLIES (CNTL) 7
i. REGULATION & CONTROL SUB-SYSTEM : 7
ii. PROTECTION SUB-SYSTEM : 8
iii. SIGNALING SUB-SYSTEM : 9
2. FRONT PANEL : 10
IV. ALIGNMENTS 11
V. TROUBLE SHOOTING 12---23
1. OVERVIEW :
2. U.P.F. CORRECTION:
3. PUSH-PULL DC-DC CONVERTER:
4. DC/AC INVERTER:
5. DC POWER SUPPLY :
6. AC/DC CHARGER :
VI. APPENDIX I : SCHEMATICS 24
VII. APPENDIX II : COMMUNICATION 33
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WARNING
(For qualified service personnel only)
1. DO NOT perform any internal service or adjustment of this product unless another person
is capable of rendering first aid and resuscitation is present.
2. Dangerous voltage exists at several points in this product. To avoid personal injury, don't
touch any exposed connections or components while power is on.
3. Turn off the UPS and disconnect input power cord and two battery cables before
removing outside protective cover.
4. AC voltage is always present if the input AC power is still available.
5. Dangerous electric charge may be stroed in DC capacitors and associated circuit, after
turning off the UPS and disconnect input power cord. Please test before touching.
6. Verify input source (voltage and frequency) before service.
7. For the air flow smoothly, please cover the cover to test after you repaired.
CAUTION
1. After opening the cover, please always check the tightness of all wires, connectors, and
screws first. Then check if there is any decolored components inside.
2. DO NOT make internal batteries short-circuited.
3. If find that the battery wire in the UPS is disconnected, be sure that the battery cabinet is
disconnected and the input power cord is unplugged before re-connect the battery wire.
4. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.
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I.INTRODUCTION
For all series of Vanguard UPS, they are strictly tested and carefully designed. We
always do our best to make our products more reliable and safer, this is also the goal of our
company. However, due to the lifetime of electrical components and some unpredictable
reasons, there will be unavoidable failures of this UPS. If this situation occurs, service of
qualified person is needed. This service manual will guide the technicians to repair and
adjust a problematic UPS. If the UPS still does not work properly, please contact with us
and we will be glad to solve any problems you met.
This UPS is very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.
This service manual consists of 4 major parts:

1. Introduction.
2. Principle of operation: It describes the functions and principles of each part.
3. Alignments: It describes the locations and methods needed to adjust this UPS.
4. Trouble shooting: This part describes the possible failure conditions and procedures
to repair it.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and
safe operation.
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II. PRINCIPLE OF OPERATION
1. INTRODUCTION
This 700VA--3KVA high input power factor UPS system contains two major PCB
assemblies. They are including :
1. PSDR: contains major parts of (1) charger, (2) DC power supply, (3) unit power
factor correction, (4) DC-DCconverter, (5) inverter and (6) output circuits.
2. CNTL : contains major parts of protection, signaling circuits, regulation and control
circuits of inverter
The simplified schematics in figure 1 (3K HV model) shows how the major circuits are
connected and illustrates the overall system functions. The locations of these assemblies in this
machine are shown in figure 2 (3K HV model) .
The block diagram in figure 3, shows the UPS at normal operation from left to right. When a
protection circuit is triggered or a fault condition occurs, the output supply is transferred
immediately from inverter to AC mains by a bypass relay. The operation principle will be
explained in later section.
Basically, these Vanguard UPS system utilizes high frequency PWM techniques to achieve
high efficient performance. This UPS can deliver a clean, regulated sine-wave output at any
load under full load. The sub-systems are described as below:
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III. POWER STAGE (PSDR)
The power stage consists of charger, unit power factor correction, DC power supply,
DC-DC converter, inverter and output circuits. figure 4 shows the block diagram of power
stage.
i. CHARGER SUB-SYSTEM:
The purpose of charger is to charge and to maintain the batteries at full charged
condition. Refer to figure 5 (3K HV model), the voltage flyback switching power supply
provides a constant DC voltage for batteries. Besides providing constant voltage, the power
supply also limits the current flowing into batteries and therefore protects and prolongs the
life time of charged batteries. The charger voltage is auot-regulated by CPU according to
the temperature.
ii. DC POWER SUPPLY SUB-SYSTEM:
The input of the DC power supply is connected to the battery bus, i.e., the output of the
charger. The output of DC power supplies provid +12 Vdc for the bias supply of IC's
working voltage and the fan(s) voltage and other requirement. 5V is used for CPU's
working voltage and made by control board through IC7805. The DC power supply works
only when the 12 Vdc regulator supplies Vcc to its control IC. To have proper operation of
12 Vdc regulator, its input power is controlled by the switch as indicated in figure 6 (3K
HV model).
iii. INVERTER SUB-SYSTEM :
The UPS transfers ＋,－ DC bus voltages to the AC output voltage through an inverter
of half bridge configuration at normal operation. The schematic diagram of inverter is
shown in figure 7 (3K HV model).
To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching
signals from PWM generation circuit through a pair of photo-couplers to trigger the upper
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IGBT and the lower IGBT alternately. The output of IGBT's is filtered by an LC circuit to
reduce the o/p voltage harmonics distortion.
iv. OUTPUT SUB-SYSTEM :
The bypass relay receives signal from control circuit to switch the output of the UPS
from bypass to inverter, and vice versa. The output noise filter circuit blocks EMI noise to
the loads.
v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM :
The purpose of power factor correction (P.F.C.) circuit is to make the input current and
voltage in phase and therefore achieve a high input power factor. The schematic is indicated
in figure 8 (3K HV model).
When the input AC power cord is plugged in and switch on, the AC power goes through
noise filter to the charger and to the line detector, the P.F.C. circuit is enabled and the DC
buses are regulated at 380Vdc for 230VAC series and 190V for 120VAC series.
vi. DC-DC CONVERTER SUB-SYSTEM :
The major function of the UPS is to deliver accurate AC power to the loads connected
to it whenever the AC line is correct or fails. In this system, the batteries release the stored
energy to supply inverter immediately upon AC line fails.
Refer to figure 9 (3K HV model), the battery voltage is transformed through a push-
pull DC-DC converter to ± 400Vdc (± 200Vdc for 120V series) as DC buses for inverter.
When the line fails, the ± 400Vdc(± 200Vdc) DC sources are caught up to supply the
power needed by the inverter immediately.
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1. MAIN CONTROL PCB ASSEMBLIES (CNTL)
These assemblies are the control center of UPS. It is composed of three major circuits as
following.
(1) Regulation & control
(2) Protection
(3) Signaling
i. REGULATION & CONTROL SUB-SYSTEM :
This portion can be seen as brain of the UPS. It provides the control pulses to the
switching elements which deliver power to the output. The sub-system also regulates the
output to ensure that the UPS is delivering constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a reference
signal from sine wave generator. The difference of these two signals (error signal) alter the
pulse widths of PWM signals which control the duty cycles of switching elements to
regulate the output voltage within specification.
In order to avoid un-wanted surge current at the transfer of bypass relay, the bypass
signal activates the tracking circuit. It matches the inverter voltage with the line voltage by
having the amplitude of the reference signal following the variation of line voltage.
When the mains in the acceptable range is applied and the switch is turned on, the UPS
operates at battery mode to charge the buses voltage and inverter on. As soon as the phase
lock and amplitude are completed. If the battery is weak, the UPS transfers to bypass mode
about 3 seconds when switch turns on, then transfer to inverter mode and as soon as the
phase lock and amplitude are completed.
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ii. PROTECTION SUB-SYSTEM :
The UPS provides the following protection circuits :

1. Overload protection
The load detector senses the load current. i.e. the inverter current, and sends the signal
by two paths. In battery mode, the UPS will go to failure mode if overload condition
happened. The panel will indicate the fault condition.
A.The UPS collects the continuous overload signals through CPU switches the bypass
relay. If the output load is higher than 110% and lower than 125% of rated
load(VA ,or Wattage) the UPS keeps running on inverter running for 1 minute.
If the output load is higher than 125% and lower than 150%of rated load, the UPS
transfers to bypass after 10 seconds. If the output load is higher than 150%, the UPS
transfers to bypass at once.
B.When output loads sink a high surge current , a high inverter current is detected and
the inverter switches, i.e. the IGBT's, are turned off pulse by pulse to protect
themselves from thermal runaway. The bypass relay stays at inverter output position
unless a continuous overload is detected or an abnormal inverter operation occurs.
2. Battery over or under shut down

Upon the battery voltage declines to battery-under level, a signal is generated to cut off
the power supply of the whole system, The buzzer becomes silent and all the LED's
extinguish. When the utility is coming, the UPS will start up automatically.
In case of the battery voltage(chargeing voltage) exceeds the acceptable high-limit
voltage (15V/per Battery), the UPS will discharge the battery capacity by way of DC-DC
coverter to ensure the battery life. The panel will display the fault condition.
3. Inverter output abnormal protection

The inverter failure signal shuts down the inverter immediately, makes the buzzer
continuous beep, and the "FAULT" LED light. The panel will display the fault condition.
" The failure signal is latched unless the UPS is turned off or the battery is empty".
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4. Over temperature protection

The thermal switch detect the temperature of the heatsink of the inverter on the PSDR.
The thermal switches are electrically connected to the CPU. While the temperature is
higher than the switch’s specification, the thermal switch is opened and the CPU can’t
detect the 5V. The CPU will think the condition as high internal temperature, The panel
will display the fault condition.
5. Bus overvoltage protection

To protect the BUS voltage from being overvoltage condition, especially for the half-
bridge load. The panel will display the fault condition.
iii. SIGNALING SUB-SYSTEM :
When the AC line is unable to supply, the batteries release stored energy to supply the
inverter immediately. At the same time, the utility failure relay is activated and the buzzer
beeps every five seconds.
Upon the batteries are discharged to battery-low level, the battery-low relay is activated
and the buzzer two beeps every five seconds.
Remote shutdown signal is enabled only when the line fails. The signal is connected to
the battery detector. It generates battery-under signal to cut off the bias power supply of
the UPS system. The EPO signal is enabled at any mode, when the EPO is enable, the unit
shut off the output power.
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2. FRONT PANEL :
The front panel consists 3 parts: button switch, mode LED set and display LCD.
There are three button switched, one is to turn on and off the UPS, one is scroll button,
it can select the function of unit operation, another is enter button, it can display the unit
function, for example, it can display the input voltage, frequency, output voltage,
frequency, load,….etc. The five LEDs indicate “UPS ON”, “LINE MODE”, “BATTERY
MODE”, “BYPASS MODE” and “FAULT”. The LCD display UPS any conditions.
2. Besides, when the system works abnormally, the fault LED will light up and the
buzzer will beep continuously. In this situation, the LCD will display the fault condition, for
example: High output voltage, High temperature,….,etc.
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IV. ALIGNMENTS
The Vanguard series are auto-regulation the bus voltage, bus balance and charger voltage,
when the CNTL or PSDR is modified, the engineer must rectify them according to the
following steps:
(1). Connect the computer to the rectified unit.
(2). Execute the “service program”.
(3). Measure the temperature, charge voltage, and output voltage.
(4). Import the measured temperature, charger voltage, and output voltage.
The CPU will auto-regulate the charger voltage, temperature, and output voltage.
Note: the charger voltage will be changed according to the temperature at the Vanguard
series, at the 25 degree C, it is 13.8V/pcs.
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V. TROUBLE SHOOTING
For the reason of safety, you must unplug the power cord and disconnect the batteries
from UPS.
Check the components listed below to confirm which block is out of order and follow
the procedures listed on the following pages to repair them.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components.
700VA
1. OVERVIEW :
Circuit Block Components to be Fail condition
checked
FUSE F502,F201 open
P.F. Correction U101,D105,D108,Q101 short or open
Push-Pull Booster Q202,Q203,Q206,Q207 D-S short or open
D201,D202,D203,D204 short or open
Inverter Q302,Q304 D-S short or open
Charger Q505 D-S short or open
DC Power Supply Q401 D-S short or open
2. P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F502 Ω short open
2 Q101(D,S) DIODE 0.4 short or open

3 D105,D108 DIODE 0.4 short or open
4 R116 Ω 47 open or value
change
R115 Ω 2.2 open or value
change
5 REC101(+,～),(～,-) DIODE 0.4 short or open
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6 C105,C122 Ω open deformed
short
visual

function Value
2 Q202,Q203,Q206,Q207 (D,S) DIODE 0.4 short or open

3 R201,R202,R222,R213 Ω 10 open
4 D201,D202,D203,D204 DIODE 0.4 short or open

* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
function Value
1. Q302,Q304 (D,S) DIODE 0.4 short or open
2. R304,R312 Ω 47Ω open
5.DC POWER SUPPLY :

function Value
1 Q401 (D,S) DIODE 0.5 short or open
2 R404 Ω 47 open
3 R407 Ω 0.15Ω open
/2W
4 U401 (3845) PIN 5-6 49.9K too low
5-7 39K
Ω
5-8 4.2K
6-8 54.1K
6.AC/DC CHARGER :
function Value
1 Q505 DIODE 0.5 short or open
2 R523 Ω 47 open
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3 R527 (LV) Ω 0.5Ω/2W open
R527(HV) 1.2Ω/2W
4 U503 (3843) PIN 5-6 49.9K too low
5-7 30.4K
Ω
5-8 4.1K
6-8 54K
6 C527 Ω open short
deformed
visual
1KVA
1. OVERVIEW :
checked
FUSE F101,FC2,FC3 open
P.F. Correction D27,D28,REC501,Q11 short or open
Push-Pull Booster Q07,Q08,Q09,Q04,Q05,Q D-S short or open
06
D19, D20,D29 short or open
2. P.F. CORRECTION:
function Value

5 change
REC501(+,～),(～,-) DIODE 0.4 short or open
6 C32,C33 Ω open deformed

short
visual
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function Value
1 FC2,FC3 Ω short open
2 Q04,Q05,Q06,Q07,Q08,Q09 DIODE 0.4 short or open

(D,S)
D21,D22,D23,D24 DIODE 0.4 short or open
3 R25,R27,R29,R31,R34,R38 Ω 10 open
4.DC/AC INVERTER:
function Value
1 Q02,Q03 (D,S) DIODE 0.4 short or open
2 R05,R18 Ω 47Ω open
5.DC POWER SUPPLY :

function Value
2 R116 Ω 47 open
R36 Ω 0.5Ω open
/2W(LV)
0.33Ω
/2W(HV)
3 U3 (3845) PIN 5-6 >1M too low
(Driver PCB) 5-7 >1M
Ω
5-8 3.5K
6-8 >1M
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6.AC/DC CHARGER :
function Value
2 R90 Ω 47 open
3 R103(LV) Ω 0.39Ω open
R103(HV) /3W
1Ω/2W
4 U9 (3845) 5-6 45K too low
Ω
5-8 3.5K
6-8 53.5K
5 D19,D20,D29 DIODE 0.5 short or open
6 C23 Ω open short
deformed
visual
1.5KVA
1. OVERVIEW :
checked
FUSE F101,FC2,FC3 open
P.F. Correction D27,D28,REC501,Q11 short or open
Push-Pull Booster Q07,Q08,Q09,Q04,Q05,Q D-S short or open
06
D19, D20,D29 short or open
2. P.F. CORRECTION:
function Value
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change
6 C31,C32,C33,C34 Ω open deformed

short
visual

function Value
1 FC2,FC3 Ω short open

(D,S)
D21,D22,D23,D24 DIODE 0.4 short or open
3 R25,R27,R29,R31,R34,R38 Ω 10 open
4.DC/AC INVERTER:
function Value
1 Q02,Q03 (D,S) DIODE 0.4 short or open
2 R05,R18 Ω 47Ω open
R04,R17 Ω 10Ω open
5.DC POWER SUPPLY :

function Value
2 R115 Ω 47 open
R36 Ω 0.5Ω open
/2W(LV)
0.33Ω
/2W(HV)
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3 U3 (3845) PIN 5-6 >1M too low
Ω
5-8 3.5K
6-8 >1M
6.AC/DC CHARGER :
function Value
2 R94 Ω 47 open
3 R97(LV) Ω 0.39Ω open
R97(HV) /3W
0.5Ω/2W
4 U9 (3845) 5-6 45K too low
Ω
5-8 3.5K
6-8 53.5K
5 D19,D20,D29 DIODE 0.5 short or open
6 C23 Ω open short
deformed
visual
2KVA
1. OVERVIEW :
checked
FUSE F101,F401,F402 open
U.P.F. Correction REC501,Q501,D504,D50 short or open
5
Push-Pull Booster Q401,Q402,Q403,Q405, D-S short or open
Q406,Q407
2. P.F. CORRECTION:
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function Value

4 R512(LV) Ω 100 open or value
20 change
R512(HV)
6 C307,C308,C501,C501A,C Ω open deformed

short
502, C502A(LV) visual
C307,C308,C501,C502(HV
)

function Value
1 F401,F402 Ω short Open

07
3 R406,R408,R410,R415,R417,R4 Ω 10 open
20
4.DC/AC INVERTER:
function Value
1 Q301,Q302(D,S) DIODE 0.4 short or open
2 R301,R309 Ω 22Ω open

R302,R308 47Ω
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5.DC POWER SUPPLY :

function Value
2 R206 Ω 47 open
3 R208 Ω 0.5Ω/2W open
4 U09 (3845) PIN 5-6 47K too low

5-7 33K
Ω
5-8 4.2K
6-8 51K
6.AC/DC CHARGER :
function Value
2 R122 Ω 47 open
3 R125(LV) Ω 0.82Ω open

R125(HV) /2W
0.75Ω
/2W
4 U101 (3843) PIN 5-6 47K too low
5-7 30K
Ω
5-8 4K
6-8 51K
5 REC101 DIODE 0.5 short or open

deformed
visual
3KVA
1. OVERVIEW :
checked
FUSE F1,F2,F3 open
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U.P.F. Correction REC501,Q501,Q502(LV short or open
only),D506,D507
Push-Pull Booster Q401,Q402,Q403,Q404, D-S short or open
Q405,Q406
Inverter Q301,Q302,Q303,Q304 D-S short or open
2. P.F. CORRECTION:
function Value
1 F3 Ω short open
2 Q501,Q502 (D,S)(LV) DIODE 0.9 short or open

Q501(D,S)(HV)
4 R508,R516(LV) Ω 47 open or value
change
R508(HV)
20
6 C307,C308,C309,C310C50 Ω open deformed

short
1,C502,C510,C511(LV) visual
C307,C308,C309,C310C50
1,C502(HV)

function Value
1 F1,F2 Ω short Open

06 (D,S)
3 R418,R420,R422,R425,R428,R4 Ω 10 open
30
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4.DC/AC INVERTER:
function Value
1 Q301,Q302,Q303,Q304(D,S) DIODE 0.4 short or open
2 R302.R307,R311,R315 Ω 20Ω open
5.DC POWER SUPPLY :

function Value
2 R206 Ω 47 open
3 R205 Ω 0.5Ω/2W open
4 U3 (3845) PIN 5-6 47K too low

(Driver PCB) 5-7 33K
Ω
5-8 4.2K
6-8 51K
6.AC/DC CHARGER :
function Value
2 R123 Ω 47 open
3 R120 Ω 0.39Ω open

/2W(LV)
0.43Ω
/2W(HV)
4 U9 (3845) 5-6 47K too low
(Driver PCB) 5-7 30K
Ω
5-8 4K
6-8 51K
5 REC101 DIODE 0.5 short or open
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deformed
visual
After you have replaced all defect components on power stage ( PSDR ) , connect with
control board. Supply DC voltage /3Amp (limited current) with DC power supply via
battery cable(+) and cable(-). Turn on the switch on panel, you will see "current limit" on
the DC power supply for about 2 seconds (If not, there are some defective components you
have not found).
When everything seems good, turn off the switch on panel and remove DC power
supply. Plug in the power cord and supply UPS with the mains. Test the output of charger
( battery cable(+),(-) ). Check the voltage OK or not? The fan will also active. If there is no
problem in charger, connect to the batteries.
Finally, turn on the switch on panel again and follow the procedure listed in part Ⅲ
(Alignment) to rectify the charger voltage and temperature, and measure voltage on DC
bus, output voltage.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components
23
O/P
INLET Breaker
O/P-L
L I/P(L) O/P
I/P I/P FILTER
N O/P-N
FILTER Breaker
G I/P(N)
PSDR FAN1
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P403,405
FAN2
FAN
FUSE P407,408
CN1-
3 FAN
24
RS232
BAT.(-) BAT.(+) CN1-3
VI. APPENDIX I : SCHEMATICS
CN201 CNTL CN9
CN407
Figure 1 : System schematic diagram

BATTERY LCD
CABINET PANEL
OUTLET
INTERFACE
SLOT
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Figure 2 : Sub-assembly location
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O/P
N.F.
RY
DC/AC
BATTERY CABINET
DC/DC
AC/DC
PFC
CHARGER
RY
N.F.
I/P
Figure 3 : block diagram
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Bypass
I/P Relay +BU

FUSE
S
CN--L CT &
EMI
I/P Filter PFC Choke Rectifier
for current
CN--N feedback + BUS
Capacitor
To 3818
-BUS
Capacitor
- + -
BUS
PFC IC
3818
BU
S
FEEDBACK
To CPU CIRCUIT
CPU
PWM
CONTROLLER
OP
VREF
=2.5V
BAT +
BAT- DC BUS(+)
PWM
SIGNAL
FROM
CONTROL
BOARD
PWM
CONTR CHOKE
OLLER
o/p
PWM
SIGNAL
FROM
CONTROL
BOARD
DC BUS(-)
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Figure 4 : PSDR functional diagram
CPU
CN +
TO BATTERY
=2.5V
VREF
D104
OP
C101
D102
Q103
TX101
CONTROLLER
PW
M
Cap.
REC1
CN--L
INPUT
CN--N
Figure 5 : Charger circuit
28
BAT(+)
+12V
D205 C204
Power for Inverter
BAT(-) IGBT +
0V
C205 5.1v
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-5V
Q202
PW +12V
M
CONTROLLER C202 Power for Inverter
D204
IGBT -
0V
29
System C203 5.1v
R205 TX201
GND -5V
Figure 6 : DC power supply circuit

D206
12V
C206
DC BUS(+)
PW
M Q301,Q302
C301 SIGNAL
FROM
CONTROL
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BOARD
L301,302,303
OUTPU
T
30
PW
M Q303,Q304
C308 SIGNAL
C312
Figure 7 : Inverter circuit

FROM
CONTROL
BOARD
OUTPU
T
DC BUS(-)
I/P Relay +BU
RLY101 S
P102
CT &
L EMI
PFC Choke Rectifier
Filter for current D506
P101 FUSE L501,L502
N feedback
C309,C310
,C501
To 3818
C307,C308,
C502
+ D507 -
- REC501 BUS
PFC IC
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3818
Q501
31
BUS
FEEDBACK
To CPU CIRCUIT
Figure 8 : Input power factor correction circuit

+BUS
D406
C309,C310,
D405 C501
Q401,Q402,Q403
D404
TX401 D403
PW
CONTROLLE
M
R BATTERY
System
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GND
C307,C308
,C502
Q404,Q405,Q406
32
Figure 9 : DC -DC circuit
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I.APPENDIX II : COMMUNICATION
i. 1. RS232
The RS232 provides proprietary command sequence for the computer to

monitor the line and UPS status and to control the UPS. The data format is
listed as following:
PIN TYPE ...................: female
BAUD RATE .............. : 2400 bps
DATA LENGTH ......... : 8 bits
STOP BIT ................... : 1 bit
PARITY ...................... : NONE
The pin assignment and description are listed in the following table and the interface
configuration is indicated in figure VI-1. Note that, the computer will control information
exchange by a ASCII command. UPS will respond with ASCII information or action. UPS
data will be provided at 2400 baud rate and consist of 8 data bits, 1 stop bit, and no parity bit.
All the information is provided in Binary format.
PIN # Description I/O type

1 No connection ------
2 RS232 TxD output Output
3 RS232 RxD/Inverter Off input Input
5 common ------
6 Line Fail Output
8 Battery Low Output
9 12Vdc Output
Figure VI-1 : RS232 connection
33
PCM Vanguard
ii. AS 400 (option)
a. AS 400 provides dry contact closure signal open or close.

b. AS 400 provides the remote shutdown function,while the shorter connector on the CN2
is removed, the UPS will be forced to get into bypass mode.
c. The pin assignment and description are listed as following.
PIN # Description I/O type
1 UPS fail, relay contact, normally open active close. output
2 Summary alarm, relay contact, normally open, active close. output
One of the following conditions activate this signal
Output fault.
Bus fault.
Over temperature.
Overload.
Over Charging.
Battery test fail.
Charger failure.
3 GND for secondary
4 Remote shutdown input
5 Common
6 Bypass active, normally open, active close output
7 Battery low, normally open, active close output
8 Battery mode shutdown input
9 Utility fail, normally open, active close output
34

Service Manual (VGD 700-3K) 20050701

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Service Manual (VGD 700-3K) 20050701

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UNINTERRUPIBLE POWER SYSTEMS

This service manual consists of 4 major parts:

II. PRINCIPLE OF OPERATION

III. POWER STAGE (PSDR)

ii. DC POWER SUPPLY SUB-SYSTEM:

iii. INVERTER SUB-SYSTEM :

iv. OUTPUT SUB-SYSTEM :

v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM :

vi. DC-DC CONVERTER SUB-SYSTEM :

1. MAIN CONTROL PCB ASSEMBLIES (CNTL)

i. REGULATION & CONTROL SUB-SYSTEM :

ii. PROTECTION SUB-SYSTEM :

The UPS provides the following protection circuits :

2. Battery over or under shut down

3. Inverter output abnormal protection

4. Over temperature protection

5. Bus overvoltage protection

iii. SIGNALING SUB-SYSTEM :

2 Q101(D,S) DIODE 0.4 short or open

3. PUSH-PULL DC-DC CONVERTER:

2 Q202,Q203,Q206,Q207 (D,S) DIODE 0.4 short or open

4 D201,D202,D203,D204 DIODE 0.4 short or open

5.DC POWER SUPPLY :

2 Q11 (D,S) DIODE 0.4 short or open

6 C32,C33 Ω open deformed

3. PUSH-PULL DC-DC CONVERTER:

2 Q04,Q05,Q06,Q07,Q08,Q09 DIODE 0.4 short or open

* The instrument is D.M. ( digital multimeter ).

5.DC POWER SUPPLY :

2 Q11 (D,S) DIODE 0.9 short or open

6 C31,C32,C33,C34 Ω open deformed

3. PUSH-PULL DC-DC CONVERTER:

2 Q04,Q05,Q06,Q07,Q08,Q09 DIODE 0.4 short or open

* The instrument is D.M. ( digital multimeter ).

R04,R17 Ω 10Ω open

5.DC POWER SUPPLY :

2 Q501(D,S) DIODE 0.9 short or open

5 REC501(+,～),(～,-) DIODE 0.4 short or open

6 C307,C308,C501,C501A,C Ω open deformed

3. PUSH-PULL DC-DC CONVERTER:

2 Q401,Q402,Q403,Q405,Q406,Q4 DIODE 0.4 short or open

2 R301,R309 Ω 22Ω open

5.DC POWER SUPPLY :

4 U09 (3845) PIN 5-6 47K too low

3 R125(LV) Ω 0.82Ω open

6 C102 Ω open short

2 Q501,Q502 (D,S)(LV) DIODE 0.9 short or open

6 C307,C308,C309,C310C50 Ω open deformed

3. PUSH-PULL DC-DC CONVERTER:

2 Q401,Q402,Q403,Q404,Q405,Q4 DIODE 0.4 short or open

2 R302.R307,R311,R315 Ω 20Ω open

5.DC POWER SUPPLY :

4 U3 (3845) PIN 5-6 47K too low

3 R120 Ω 0.39Ω open

CN201 CNTL CN9

Figure 1 : System schematic diagram

Figure 2 : Sub-assembly location

Figure 3 : block diagram

I/P Relay +BU

Figure 4 : PSDR functional diagram

Figure 5 : Charger circuit

Figure 6 : DC power supply circuit

Figure 7 : Inverter circuit

Figure 8 : Input power factor correction circuit