Service Manual - PC/MPC Series Inverter & Charger

Inverter & Charger

PC/ MPC 2-3KVA
Service Manual
 Service Manual - PC/MPC Series Inverter & Charger

Contents

1. General Information.....................................................................................................................1
1.1 Brief Introduction........................................................................................................................1
1.2 Basic Topology Introduction.....................................................................................................1
2. Fault and Troubleshooting..........................................................................................................1
3. Steps to Repair............................................................................................................................ 2
3.1 Battery Working Mode Test......................................................................................................2
3.1.1 Check DC FUSE and Capacitance..................................................................................... 2
3.1.2 DC/DC Boost Module............................................................................................................ 2
3.1.3 Divers....................................................................................................................................... 3
3.2 To Check BUS Module..............................................................................................................4
3.2.1 Rectifier Diode........................................................................................................................ 4
3.3 To Check Full-Bridge Invert Circuit.........................................................................................4
3.3.1 Power Parts.............................................................................................................................4
3.3.2 To Check Drivers.................................................................................................................... 5
3.4 Check output circuit...................................................................................................................6
3.5 Check the BUS circuit...............................................................................................................6
3.6 To Check Power Circuit............................................................................................................ 7
3.7 To Check MOSFETS for Reversed Protection on DC Terminal........................................ 8
3.8 To Check NTC Circuit............................................................................................................... 9
3.8.1 NTC in position of HS3 plugs in position of SW1 on main board.................................. 9
3.8.2 NTC1 under Transformer......................................................................................................9
3.8.3 NTC in CNHS4..................................................................................................................... 10
3.9 To Check Fan Drive Circuit....................................................................................................10
4.0 To Check AC Charging Circuit...............................................................................................11
4.1 To Check Power Components...............................................................................................11
4.1.1 Drivers.................................................................................................................................... 11
4.2 To Check Rectifier Circuit.......................................................................................................12
4.2.1 Charging Circuit....................................................................................................................12
 Service Manual - PC/MPC Series Inverter & Charger
1. General Information
1.1 Brief Introduction
This manual is used as a tool of inspection and repairing guidance for PC/MPC 2-3KVA,
as well as instructions of assembling and testing. It is best to have some electrical or
electronic background knowledge. With this guidance, hope it will help you to check and
inspect the inverter/charger first by yourself.

1.2 Basic Topology Introduction

The topology for 2KVA/3KVA shows as below:

2. Fault and Troubleshooting

First to test battery volt to check whether it is in range
No LCD of 22V-26V;
display If it is in the range, to switch the inverter one to check
when whether the unit starts. If the unit does not run yet,
inverter please disconnect all connections and open the
turns surface panel, take out the main board, then to check
on and repair according to 3.6 and 3.7. If problems
remains, the CPU is broken, replace the main board.
Fan is locked when First to replace the fan, to check whether it is ok; if
Fault 01 inverter is off. NO, please
inspect the main board and repair according to 3.9
Over temperature Please to check the main board and repair according
Fault 02
to 3.8
Battery voltage is Please to check first and then to repair the main
Fault 03 too high board according
to 3.1, 3.6 and 3.7
Battery voltage is Please check the battery’s voltage. If voltage is too
Fault 04
too low low, please charge it.
Output short circuit
or over temperature First to start up the inverter by only connecting
Fault 05 is detected by battery, if the fault is still on, please inspect the main
internal converter board following 3.3 and 3.4.
components.
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 Service Manual - PC/MPC Series Inverter & Charger
Output voltage is
abnormal. (For First to start up the inverter by only connecting
Fault 06 1K/2K/3K) battery, if the fault is still on, please inspect the main
Output voltage is too board following 3.3.
high. (For 4K/5K)
Overload time out Please turn off the loads, and restart the inverter
Fault 07
again.
Bus voltage is too Please check the BUS circuit of the main board
Fault 08
high according to 3.5.
Bus soft start failed To check the main board following 3.1.2, 3.2.1, 4.1
Fault 09
and 4.2 and to repair accordingly
Fault 11 Main relay failed Please check the relay whether work.

3. Steps to Repair
3.1 Battery Working Mode Test
3.1.1 Check DC FUSE and Capacitance
F1-F6: Fuse, F40A/32VDC UL

Positioning Attribute Reference Value Failure Status

F1-F6 Resistor 0 ohm Open

C19,C20,C39,C40: Electrolytic Capacitor, 4200uF 35V M RAD 7.5mm 105℃

If the capacitors explode, they need to be replaced.

3.1.2 DC/DC Boost Module
TR MOSEFET IRFB4110PBF 180A 100V TO-220

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 Service Manual - PC/MPC Series Inverter & Charger

Positioning Attribute Reference Value Failure Status

SD:0.44V Short Circuit
All MOSFET, 8pcs Diode
DS:OL Or Explosion
Note If one or more than one of them were broken, please replace all of them.
For 2K, the main board has just 6pcs MOSFETS.

3.1.3 Divers
Note: when there are power devices or components are damaged, Divers are usually
required to check.
The reference resistors listed as below.
R373,R7,R8,R9,R10,R11,R12,R13,R14,R79,R257
All the resistors are RES CHIP TF 1/4W 20 F(1206)

To use Multi-meter to measure each resistors till to find out the broken ones and to replace
them, no need to change all the resistors.

Positioning Attribute Reference Value Failure Status

R373,R7,R8,R9,R10,R11,
Short Circuit
R12,R13,R14,R79,R257 Resistor 20 omh
Or Explosion
If resistors are need to replace, please check the diver transistors and controlling IC.

UC2,UC4: Plug-in Transistor TOSHIBA/2SC2655-Y 2A 50V

UC1,UC3: Plug-in Transistor TOSHIBA/2SA1020-Y 2A 50V

Positioning Attribute Reference Value Failure Status

BE:0.58V
UC2,UC4 Diode BC:0.57V
CE:0.9V Short Circuit
BE:0.58V Or Burnt
UC1,UC3 Diode BC:1.17V
CE:0.9V

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 Service Manual - PC/MPC Series Inverter & Charger

U3: IC LINEAR FAIRCHILD/KA3525A

Positioning Attribute Reference Value Failure Status

Pin11-Pin12:5M
Short Circuit
U3 Resistor Pin13-Pin12: 3.7K
Or Burnt
Pin14-Pin12: 5M
If unable to make sure which components, we would like to suggest to replacing them all.

3.2 To Check BUS Module

3.2.1 Rectifier Diode
Rectifier Diode: D17,D18,D19,D20

D17,D18,D19,D20: FAIR./RHRP1560_NL 15A 600V

Positioning Attribute Reference Value Failure Status
+to-: 0.37V Short Circuit
D17,D18,D19,D20 Diode
-to+: OL Or Broken
Note: If there is one or more than one components broken, please replace them all.

3.3 To Check Full-Bridge Invert Circuit

3.3.1 Power Parts
Q16,Q17,Q18,Q19: IGBT 富士 FGW50N60HD 50A600V TO-247

Positioning Attribute Reference Value Failure Status

EC: 0.388V Short Circuit
Q16,Q17,Q18,Q19 Diode
CE: OL or Broken

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3.3.2 To Check Drivers
INV IGBT: Q16,Q17,Q18,Q19

R53,R55,R60,R63: SMD Resistor CHIP TF 1/4W 4.7 F(1206)

R54,R56,R61,R64: SMD Resistor CHIP TF 1/4W 100 F(1206)
ZD2,ZD3: ZD PANJIT/DL4745 16V SMD
D10,D12: SMD Diode ROHS D PANJIT/IN4148W 0.15A 75V SMD
U24,U25,U26,U27: IC PHO AVAGO/T350-560E DIP-8 8/300 MIL SMD

Positioning Attribute Reference Value Failure Status

R53,R55,R60,R63 Resistor 4.7ohm Open Circuit
R54,R56,R61,R64 Resistor 100 ohm or Other Value
+ to -: 0.22V
ZD2,ZD3 Diode
- to +: OL Short Circuit
+ to -: 0.22V or Broken
D10,D12 Diode
- to +: OL
Pin2-Pin3: 2K
U24,U25,U26,U27 Resistor Short Circuit or Broken
Pin5-Pin7: 49K

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 Service Manual - PC/MPC Series Inverter & Charger
C150/C151: SMD Capacitors CER MT 10nF 50V J NPO 103 (0805)

Positioning Attribute Reference Value Failure Status

Short Circuit
C150/C151 Capacitors 10nF
or Broken

3.4 Check output circuit

R303,R304,R305,R306,R307,R308: SMD Resistor CHIP TF 1/4W 270K(1206)

C86: Capacitors WH MKP82 350VAC 10uF J

Reference
Positioning Attribute Failure Status
Value
R303,R304,R305,R306,R307,R308 Resistor 270K Short Circuit
C86 Capacitors 10uF or Broken

3.5 Check the BUS circuit

R287,R288,R289,R292,R281,R282,R283,R286: SMD Resistor CHIP TF 392K(0805)

R284,R285,R290,R291: SMD Resistor CHIP TF 442K(0805)
R269,R270,R271,R272: SMD Resistor CHIP TF 100K(1206)
C70/C76: Capacitor, 470uF 500V M RAD 105℃

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 Service Manual - PC/MPC Series Inverter & Charger
Reference Failure
Positioning Attribute
Value Status
R287,R288,R289,R292,R281,R282,R283,R286 Resistor 392K
R284,R285,R290,R291 Resistor 442K Short
Circuit
R269,R270,R271,R272 Resistor 100K or Broken
C70/C76 Capacitors 470uF
3.6 To Check Power Circuit
Q1: Plug-in Transistor MOSFET IR/IRF640NPBF18A 200V
R1: Plug-in Resistor 3WS 0.15 J Rack F4
U2: IC PWM ON/UC3845BD1R2G L-1 SMD SOP-8

CE6: Electrolytic Capacitor 470uF 25V M 105℃

If the capacitor appears burst, please replace it.
R31: SMD Resistor CHIP TF 1/4W 2.2 F (1206)
D1: Plug-in Diode PAJIT/UF204 2A 400V ULTRAFAST AXI
ZD4: SMD Diode 16VCSM
U11: IC ON/MC78M05CDTG DPAK-3 SMD
U15: MC79L12

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 Service Manual - PC/MPC Series Inverter & Charger

R94: SMD Resistor CHIP TF 1/4W 4.7 F (1206)

R90: SMD Resistor CHIP TF 1/4W 20 F(1206)
ZD12: SMD Diode 18VCSM/C

R99: SMD Resistor CHIP TF 1W 2.2 F (1206)

D34: SMD Diode ROHS D PANJIT/IN4148W 0.15A 75V SMD

Positioning Attribute Reference Value Failure Status

Q1 Diode SD: 0.5V ; DS: OL
D1 Diode + to -: 0.45V ; - to +: OL
ZD4 Diode + to -:0.35V ; - to +:OL Short Circuit or Broken
ZD12 Diode + to -:0.35V ; - to +: OL
D34 Diode + to -: 0.40V ; - to +: OL
U11 Resistor I to O to A: OL
R99 Resistor 2.2omh
R1 Resistor 0.15omh
Open Circuit or other value
R31 Resistor 2.2omh
R94 Resistor 4.7omh
R90 Resistor 20omh
U15 Resistor O-I: 350K; O-G: 8.7K Short Circuit or Open Circuit

3.7 To Check MOSFETS for Reversed Protection on DC Terminal

Please open the cover and measure as follows.

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 Service Manual - PC/MPC Series Inverter & Charger
Positioning Attribute Reference Value Failure Status
PV – to BAT - Resistor >10K Short Circuit

If in Short Circuit, Please replace MOSFET in Main Board.

Q12, Q13, Q14, Q40: MOSFET IR/IRFB7434PBF 195A 40V N BULK TO-220

3.8 To Check NTC Circuit

On Main Board, there are three NTC, one is in DC-DC Boost Heat Sink, one is under
boost transformer and one is in inverting heat sink.
When 02 fault code appears, it requires to check this step, please kindly note.
3.8.1 NTC in position of HS3 plugs in position of SW1 on main board.

SW1

SW1: Thermistor KI66-120B5 120℃ KW

Positioning Attribute Reference Value Failure Status
SW1 Resistor 0.1 ohm Open Circuit
If it is not possible to check functioning, please make NTC short-circuit and test the
inverter again; if the fault disappears, it means the NTC is wrong.

3.8.2 NTC1 under Transformer

NTC1: Thermistor NTC 47K 240mW SMD 0805

Positioning Attribute Reference Value Failure Status

NTC1 Resistor 5.6K ohm Short Circuit or Open Circuit

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3.8.3 NTC in CNHS4
NTC_CNHS4: Thermistor NTC 15K 2.5mA KW

Positioning Attribute Reference Value Failure Status

NTC_CNHS4 Resistor 12.4K ohm Short Circuit or Open Circuit
If it is not possible to check functioning, please make NTC short-circuit and test the
inverter again; if the fault disappears, it means the NTC is wrong.

3.9 To Check Fan Drive Circuit

Positioning Attribute Reference Value Failure Status

R319/R329 100K ohm
Short Circuit or
R321/R325/R326/R331 Resistor 10K ohm
Other Value
R320/R330 100 ohm
D62/D65 + to - : 0.6V; - to +: OL Short Circuit or
Diode
Q34/Q35 SD: 0.5V; DS: OL Burst

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 Service Manual - PC/MPC Series Inverter & Charger
4.0 To Check AC Charging Circuit
4.1 To Check Power Components
Q20,Q21,Q22: MOSFET SLW/SVF3878PN 9A 900V(士兰微)

Positioning Attribute Reference Value Failure Status

EC: 0.38V Short Circuit
Q20,Q21,Q22 Diode
CE: OL or Broken
Note: If there is one or more than one components broken, please replace them all.
4.1.1 Drivers
R259,R261,R263: SMD Resistor CHIP TF 1/4W 10 F(1206)
R258,R260,R262: SMD Resistor CHIP TF 1/4W 100 F (1206)
D56/D57/D58: SMD Diode ROHS D PANJIT/IN4148W 0.15A 75V SMD

Positioning Attribute Reference Value Failure Status

R259,R261,R263 Resistor 10 ohm Open Circuit
R258,R260,R262 Resistor 100 ohm or Other Value
EC: 0.6V Short Circuit
D56/D57/D58 Diode
CE: OL or Broken
Note: When test diodes, please remove R259, R261, R263, otherwise the test result is
not right.

UC3843: U28

Positioning Attribute Reference Value Failure Status

Pin7-Pin5: 42K ; Short Circuit
U28(UC3843) Resistor
Pin6-Pin5: 30K or Broken

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 Service Manual - PC/MPC Series Inverter & Charger
4.2 To Check Rectifier Circuit
4.2.1 Charging Circuit
D21/D22/D23: Plug-in Diode ON/MBR30200C 30A 200V SCKY RAD BULK

REC1: D.GI/GBUM8M 8A 1000V BRIDGE

Positioning Attribute Reference Value Failure Status

D21/D22/D23 Diode P to N: 0.44V ; N to P: OL
Short Circuit
～ to +: 0.50V ; + to ～: OL
REC1 Diode or Broken
- to ～: 0.50; ～ to -: OL

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