Gamatronic

Mega Power Module old

hardware Troubleshoot

Rev.1

Introduction and Power Module layout

1011AC OUT

+FEEDBACK

1014PFC

controller

1012DC\DC

IGBT 1021

1013controller

1015INV

controller1010AC INDC I.O.

+MEASURE

098 fan

1019LED’sPanel

1024A

ParallelComm.1027

PFC INV

1022 IGBT

1024BDriver

098 fan

Mega Power Module Boards layout

Driver

Mega Power Module

Mega Power Module

PC1013, power module main controller

PC1012, power module main DC/DC unit

Mega Power Module

Inverter

Power – IGBT and Drivers

LC – Filter and out relays

PWM controller

Mega Power Module

PFC

Power – IGBT and Drivers,Inverter DC fuses

LC – Filter and input relays

PFC - controller

Fuses and IGBT Check

DC fuses

Inverter DC fuses

Battery DC fuses

Fuses and IGBT Check

Rectifier IGBT – PC1022

Adjust Fluke to measure Diode

Fluke back probe to positive on PC1022

Fluke red probe to phase T on PC1022

Fluke red probe to phase S on PC1022

Fluke red probe to phase R on PC1022

Fluke red probe to negative on PC1022

Fluke black probe to phase T on PC1022

Fluke black probe to phase S on PC1022

Fluke black probe to phase R on PC1022

Fuses and IGBT Check

Inverter IGBT – PC1021

Adjust Fluke to measure Diode

Fluke back probe to positive on PC1021

Fluke red probe to phase T on PC1021

Fluke red probe to phase S on PC1021

Fluke red probe to phase R on PC1021

Fluke red probe to negative on PC1022

Fluke black probe to phase T on PC1021

Fluke black probe to phase S on PC1021

Fluke black probe to phase R on PC1021

If the check result is positive, NO faults found then move to electric test.

Fuses and IGBT Check

If the check result is negative, replace the relevant parts and move to eclectic test

Inverter block PC1021

Rectifier block PC1022

Connect the module either to system or testing jig

Electric test

And power on

Connect DC voltage meter on positive and negative

Switch the controller to technician level

Startup steps

STEP 1

Immediately upon turning on the module the DC/DC turns on.

We will see the three LEDs turn on.

LEDs“ON”

If LEDs turn on, skip this slide

Are PC1013 LEDS

on?

Check LED board flat cable

that connected to PC1013

Replace it, or connect it back

Disconnected, or have a problem?

Yes

Yes

Works well done

Check Ac voltage on P1 of

PC1012, pin 5 is N, pin1, 3, 6 are

the phases

Voltage is

correct – 230V

Replace PC1012

Yes

No

No

No

Check input phases and neutral via

PC1010 and input C.B

Start

Pre Charge Relay “on”The DC/DC turns on the

microprocessor on the PCB 1013

Which give the order to close

the pre charge relay

STEP 2

Pre Charge Relay

PC1013 gives the command to turn the relay on. so the problem should be in:

1. PC1013 - to replace this board

2. Problem with input voltage measurements, a.PC1010b.PC1013c. Communication between PC1013 and PC1010.there is no direct flat cable between PC1013 and PC1010, the flat cable from PC1013 pass thru PC1014 to reach PC1010 – to check: flat of Pxx on PC1013 flat of Pxx on PC1014

If Rectifier Relay is “on”, skip this slide

The module starts pre-charging, DC starts increase smoothly on POSTIVE and NEGATIVE

STEP 2

DC meter is connected to the DC bus

DC voltage pre charge issue – if the unit pre charging normally, skip this slide

DC voltage

is between 0 to 40V

A. Check flat between1. PC1010 P1 and 1014 P7 2. PC1014 P3 and PC1013 P1B. replace PC1014

Is rectifier relay “on“ on LCD

Yes

Yes

Works well done

DC voltage doesn’t reach to 270VDC

Replace PC1012 or Q6 on PC1012

No

No

A. Replace CR26 on PC1010

B. Check there is no damage DC cap

Click here for troubleshooting

Is there 24Vdc on

K11 coil on PC1010

Check and replace:1.K11 on PC1010

2.CR26 and CR24 on PC10103. Check 1K gold pre charge resistor that connected to P9 on PC1010

YesNo

NegativePositive

Are the fans

turning on and off

Yes

A. Replace CR24 on PC1010

B. Check there is no damage DC cap

No

Start

DC rises rapidly to more than 250V, and input C.B might trip

Input relays likely are stuck – replace relays on PC1010

Yes

No

STEP 3

The DC is around

+280 V and -280 V

PCB 1013 sends command to close input

relay

Input Relay “on”

Input Relay

Input relay “on”

STEP 4

Immediately!!

PCB 1013 sends command

To PCB 1014 to start the

BOOST

Start BOOST

PC1013 gives the command to turn the relay on. so the problem should be in:

1. PC1013 - to replace this board

2. Problem with input voltage measurements, a.PC1010b.PC1013c. Communication between PC1013 and PC1010.there is no direct flat cable between PC1013 and PC1010, the flat cable from PC1013 pass thru PC1014 to reach PC1010 – to check: flat of Pxx on PC1013 flat of Pxx on PC1014

If PFC “on”, skip this slide

The module starts boost and DC increases from 270VDC to 405VDC on POSTIVE and NEGATIVE

STEP 4

DC meter is connected to the DC bus

If PFC is ok and DC reach 400V, skip this slide

DC voltage is ±300V

A. Check flat between1. PC1010 P1 and 1014 P7 2. PC1014 P3 and PC1013 P1

B. replace PC1014C. replace PC1012

Is PFC “on” on LCD

Yes

Yes

Works well done

No

No

A. Check flats on PC1014

B. Make sure that batt test is not in process on controller - required volt 810v

C. Check flats on PC1024B – IGBT driver

D. Check replace PC1024B by operate boards one by one – disconnect their flats on PC1014

E. Replace PC1014

Click here for troubleshooting

Is there 24Vdc on K11 coil on PC1010

Check and replace:1.K11 on PC10102.CR26 and CR24 on PC10103. Check 1K gold pre charge resistor that connected to P9 on PC1010

YesNoBurn PC1013

with up to date version

DC voltage stuck lower than 380 on “+” or “-” or both

No – stuck at 380V

Yes

Is PFC temperature

switch between “ok”

and “fault” or it is solid “fault”

on LCD

No

A. Check neutral connection and voltage between N and G is less than 2

B. Check and replace flats and PC1024B (3 boards)

Yes

Start

STEP 6

When +/- DC reaches about 380 V

PCB 1013 sends a command to the

Inverter to turn onand fans start

Inverter ON

STEP 6

Inverter isn’t turned on - skip this slide if inverter turns “on”

Yes

Works well done

No

A. Check IC40 well inserted, or replace it on PC1015

B. Check the flat cables in between PC1015 and IGBT drivers PC1024A

C. Check PC1024A one by one and replace the faulty PC1024A ones or its corresponding IGBT – refer to the procedure

D. Make sure DC voltage is not getting high

E. Replace PC1015

Is inverter temperature

switch between “ok”

and “fault” or it is sold “fault”

on LCD

A. Make sure DC measurement is correct

B. Check PC1013 flat cables C. Reprogram PC1013 without

programming the EEPROM, refer to the procedure

D. Replace PC1013

Start

STEP 7

Inverter is on

And the measured output voltage is ok

choose Master/Slave

Close output relay

And DC relay

STEP 7

Inverter is turned on, but output voltage is out of range, fans issue, or DC and output relays stay “off” – skip this slide if inverter works normally and

relays are closed

Fans are “on?”

Yes

No

A. Replace PC1015

B. Replace PC1013

Yes

A. Check output caps and coils on PC1011

B. Replace PC1011

C. Replace PC1013

Actual voltage

is 230V?

Calibrate the output voltage measurement to 230V regardless the actual voltage to get the output relays close – refer to the procedure

Yes

Received calibration and output relay is “on ”

Adjust output voltage - refer to procedure.

Receive voltage

adjustment

No

No Yes

No

Fan “fault”

on LCD?

Start

Works well done

Yes

Output relays are “on”

A. Replace PC1012

B. Check flats between PC1014 and both PC098

Yes

No

No

A. Replace this board

B. Make sure all white fans wires are well connected

C. Make sure jumper is in place on empty fan connector

Output voltage on LCD is “0”

or any other value

Other value

0

Before placing the repaired module into a system

1. Perform DC, battery and AC calibrations2. Perform output voltage and frequency configuration (230V, 240V, 50/60Hz

and so on)3. Perform output voltage adjust4. Make sure DC relays are not stuck – you should not be able to measure

DC voltage on module’s DC Anderson plugs during pre-charge 5. Make sure there is no abnormal noise from module during operation 6. Make sure there is no loose Anderson pins inside the module’s plugs

* Refer to the relevant procedure for the above

Testing the repaired module in the system

1. Make sure the module is getting the correct address 2. Make sure the module can work as “Master” and “Slave”3. Make sure there is no circulation current between modules without load4. Make sure input and output current measurements are correct5. Make sure the module shares the load and input current equally with the

other modules 6. Make sure the module can backup the load from batteries7. Make sure DC voltage is stable and balanced8. Make sure module can cold start from batteries9. Make sure the module react to battery test – drops and after the test

recovers the DC voltage

* Refer to the relevant procedure for the above

Finally

Well Done, the modules is working, please be in touch with Gamatronic

support and update us about the modules, please include the serial

number and fault discovered