Microsine 1000/1500/2000 service manual

Microsine
1000/1500/2000
SERVICE MANUAL

110/120/220/230/240 MODEL

LINE INTERACTIVE
UNINTERRUPTIBLE POWER SYSTEM

Ver Date Modification Prepared By Approved By

name visa name visa
Liufeng
00 2014-4-20 Original release

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 Microsine 1000/1500/2000 service manual

SUMMARY

1. INTRODUCTION 3

2. BLOCK DIAGRAM 4

3. CONTROL POWER CIRCUIT 6

4. BATTERY CHARGER 8

5. INPUT （OUTPUT ）VOLTAGE AND ZERO-CROSSING DETECTION 9

6. INVERTER OPERATION 11

7. ACTIVE CLAMP 13

8. MICROPROCESSOR (CPU) CONTROL CIRCUIT 13

9. RELAY CIRCUIT 15

10. DISPLAYS, AUDIO ALARM AND CONTROL BUTTON 17

11. LOAD DETECTION CIRCUIT 18

12. INTERFACE CIRCUIT 19

13. TROUBLESHOOTING 20

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1 Introduction
Microsine series is an off-line power system that has a sine wave output. It prevents
impulse, surge, sag and power outage situations. It provides the UPS output load with a
reliable source. It has the following functions:

1.1 Boost:
If the utility voltage drops to line boost activated point, the AVR will be activated and
increase the output voltage by 1.18 times of incoming utility voltage.
Boost activated point
110 VAC 120 VAC 220 VAC 230 VAC 240 VAC
99 VAC 108 VAC 198 VAC 207 VAC 216 VAC

1.2 Buck:
If the utility voltage reaches to line buck activated point, the AVR will be activated and
decrease the output voltage by 0.85 times of incoming utility voltage.
Buck activated point
110 VAC 120 VAC 220 VAC 230 VAC 240 VAC
121 VAC 132VAC 242 VAC 253 VAC 264VAC

1.3 50/60Hz Automatic Frequency Selection:

The output frequency will automatically match the input frequency (50 or 60Hz).

1.4 Communication Port (USB):

It provides remote shutdown capability via communication port for connected
computers.

1.5 Data line/telephone line protection:

The unit provides RJ11 port to provide transient voltage surge suppression (TVSS) for
data line or telephone line.

1.6 Cold start (DC start):

The UPS is equipped with DC start function to turn on the UPS without input source.

This manual contains block diagram, principle of operation, system outline and troubleshooting.

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2 Block Diagram
The Block diagram (Figure 1-1) of Microsine series is divided into the following parts:

2.1 Main Relay (MAIN-RY):

It’s to switch the UPS between line mode and battery mode.

2.2 Boost Relay (BOOST-RY):

At line mode, this is a switch used to increase UPS output voltage 18% when
the utility input voltage is under line boost activated point.
Relay OFF: line voltage is normal
Relay ON: line voltage is under line boost activated point.

2.3 Buck Relay:

At line mode, this is a switch used to reduce UPS output voltage 15% when
the utility input voltage is over line buck activated point.
Relay OFF: line voltage is normal
Relay ON: line voltage is over line buck activated point

2.4 Main Transformer (MAIN TX):

The Main transformer has three functions:
2.4.1 Inverter Transformer：
It provides voltage to UPS output and performs a full-bridge transformer when UPS is
at battery mode.
2.4.2 Boost/Buck：
The Boost relay is ON when the utility voltage is lower than line boost activated point.It
can improve 15% of input voltage:V OUT = V IN * 1.18
The Buck relay is ON when the utility voltage is beyond line buck activated point. It can
lower 15% of input voltage:V OUT = V IN * 0.85
2.4.3 Charger：
The battery is charged by the mains through transformer and a boost circuit.

2.5 Line Sense

The MCU detect the mains by input voltage and frequency signals converted from
the amplifier.

2.6 CPU (FREESCALE SEMICONDUCTOR/ MC9S08AC60)：

The Central Process Unit.

2.7 Electricity Switch：

It controls and Provide +5Vdc (generated from 7805 regulator) ±6Vdc and ±12Vdc
power supply.

2.8 Charger:
The source for the Charger comes from the mains through the transformer and
a boost circuit. The charger is controlled with high frequency technology and
the acceptable charging voltage is 27.1~28.1V.

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2.9 Inverter Circuit:

The inverter circuit is based on a full-bridge circuitry.

2.10 Interface Circuit:

The UPS display device contains three LEDs (six-LEDs as option) and one switch.

2.11 Batteries:
Acts as a power supply source while the UPS is on battery mode. Different types
of batteries are used for different models of UPS:

1500VA: 12V9Ah *2 pcs or equal capability 2000VA: 12V9Ah *2 pcs or equal capability

Main Relay
I/P-N
O/P-N

EMI Buck Relay

I/P-L O/P Relay
Filter
Boost Relay

O/P-L

Line Transformer O/P / Load

Sense Sense

Inverter/Charger

Battery

CPU

Figure 2-1 Block Diagram

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3 Control power circuit

The control power (+5Vdc，±6Vdc and ±12Vdc) comes from the following sources
(Figure 3-1).

3.1 Start without input AC power (Cold start):

A “Cold start “is described as follows:
3.1.1 When “ON/OFF” switch (SW/P9) is pressed, a positive battery current flows
through SW to charge C1.
3.1.2 Q7 base receives a HI pulse and turn on (signal bypass C1 at t=0, and charge C1
at t>0).
3.1.3 When Q7 turns on, the Q7 collector will drop to LOW and turn on Q6 (2907).
3.1.4 When Q6 turns on, the positive battery voltage via Q6 collector—R43—D7—U1
（3845）, establishes a +24Vdc power supply. Then 3845 start to work ，and
the Control Power circuit （a small switch Power supply） output ±12V，±6V，
+5V（+12V though 78L05）.
3.1.5 Figure 3-2 shows the pulse on the C1 during the cold start.
3.1.6 Figure 3-3 shows the Control PWM on Q9（IRF630）of the small switch Power
supply,the frequence of the PWM is about 52.4KHZ，the Voltage of the PWM is
about 12V .

3.2 Start with input AC power (AC start):

3.2.1 When we connect UPS to the utility, Full-wave rectifier will activate Q7 through
D11&D12& D13&D14, Z2, and R69，See figure 3-4.
3.2.2 If “ON/OFF” switch is pressed, Q6 turns on and establishes a ±12V，±6V，+5V
power supply similar to “Cold start”.
3.2.3 The SHUTDOWN network, triggered by pin 60 of the CPU, is used to shutdown
the UPS on battery mode. When a battery is in low battery voltage status,
the CPU sends a “High” signal to turn off the output of UC3845 by the signal of
SD . This causes the UPS system to be turned off and isolates the control
power from batteries.
3.2.4 Figure 3-5 shows the pulse on Q8 during the Shutdown.

Figure 3-1 Control Power Circuit

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Figure 3-2 CH1: C1 negative  GND Figure 3-3 Control PWM

Figure 3-4

Figure 3-5

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4 Battery Charger
The flow chart of charger is described as follows: (Figure 4-1)

4.1 When UPS is connected to the utility, the control power (+5Vdc) will be established and
the CPU will start to work.

4.2 When CPU turns on Main Relay (RY1 、 RY2), the AC power flows into Main
Transformer.

4.3 Charging current will be generated from the inverter coil of the Main Transformer.

4.4 A PWM IC 3843 is used to adjust the charging voltage and charging current. (Refer to
Figure 4-1) The charging voltage can be set by changing the value of R115 and R109.
The charging current can be set by changing the value of R22.

Figure 4-1 Charger Control Circuit

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5 Input （Output ）Voltage and Zero-Crossing Detection

Please refer Figure 5-1.

5.1 Input （Output ）Voltage Detection

The input（output） voltage is fully rectified and generates a signal. The signal LINE.V
（INV.V） will be sent to pin 34（35） of CPU. By monitoring this rectified sinusoidal voltage,
the CPU can identify if the utility is normal or abnormal. There are two methods to evaluate if
line voltage is abnormal.
5.1.1 Waveform detection:
If the mains breakout occurs, the CPU is able to immediately detect it and transfers
to battery mode. The waveform detection has a short response time.
5.1.2 RMS value detection:
CPU calculates input RMS value every cycle. If RMS value is not in acceptable range
for 3 cycles, UPS will transfer to battery mode. Compared to waveform detection,
although it will take longer response time, the RMS value can be accurately detected.

5.2 Zero Crossing Detection

Zero Crossing Detection is used to minimize the phase difference between
the Inverter voltage and the input line voltage while UPS is switched from battery mode to line
mode. If the phase difference is too large, it will generate excess energy which
may damage the internal passive components such as relays.
The Zero Crossing signal is generated by the following conditions:
5.2.1 The signal of LINE.V（INV.V） is full-bridge rectified waveform from line input.
The voltage of Pin 7（14） of LM324 drive Q4（Q5） (2222) on or off.
5.2.2 The Zero Crossing signal comes from the collector of Q4（Q5） and goes
through MCU pin 4（6）.
5.2.3 Refer to Figure 5-2 It shows the waveform of LINE.ZERO（INV.ZERO）from Q4
（Q5）collector and LINE.V（INV.V）.

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Figure 5-1 Line and Zero Crossing Detecting Circuit

Figure 5-2 Line-I/P &Zero Crossing

CH1: I/P-N（O/P-N） CH2: I/P-L（O/P-L） CH3: LINE.V（INV.V） CH4: LINE.ZERO
（INV.ZERO）

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6 Inverter Operation
The Inverter circuit (Figure 6-1) and PWM control are only active under Battery mode.
The Inverter circuit of Microsine is based on a full-Bridge circuitry and its output is driven by
a Half-Brridge Driver IC(IR2104) which is controlled by CPU.
Refer to the Inverter circuit diagram, the PWM1 and PWM2 signals are generated and
Produced by CPU and many relativity component.
Figure 6-2 illustrates the waveforms of PWM1 and PWM2 while the system is at no load
condition. The duty cycles of PWM1 and PWM2 signals are controlled by returned signal of
output voltage (Please refer to Charger circuit) to get a stable output.
The gates of MOSFETs are driven by two Half-Brridge Driver IC(IR2104), which are
controlled by the PWM1 and PWM2.
These inverter transistors are turned on and off alternately to transfer DC voltage of battery to
an AC sinewave output voltage, and then magnifies through the transformer to generate
a stable 230VAC output.
In full-bridge circuit, unlike push-pull circuitry having isolated CLAMP circuitry and driven
signal, the CLAMP signals are included in inverter drive logic.
Refer to Figure 6-2、Figure 6-3、Figure 6-4，It shows the waveform of Q12（G-S）、 Q15
（G-S）、Q21（G-S）、Q18（G-S）.

Figure 6-1

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Figure 6-2 CH1:Q12（G-S） CH2:Q15（G-S） CH3:Q21（G-S） CH4:Q18（G-S）

Figure 6-3 CH1:Q12（G-S） CH2:Q15（G-S） CH3:Q21（G-S） CH4:Q18（G-S）

Figure 6-4 CH1:Q12（G-S） CH2:Q15（G-S） CH3:Q21（G-S） CH4:Q18（G-S）

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7 Active Clamp
The purpose of Clamp is to pull down the output voltage while two sets
of Inverter MOSFET are OFF. The Clamp effect is active during the period of 0Vac
at battery mode. CLAMP principle is shown in the last paragraph of Chapter.

8 Microprocessor(CPU) Control Circuit

Please refer Figure 8-2.
The CPU is supplied by +5Vdc power supply to pin 22 with ground pin at pin 21. An
extra oscillation circuitry consisting of C29, C32, and crystal XL1 is connected to pin 57 &58.
The Microsine series is using FREESCALE SEMICONDUCTOR/ MC9S08AC60 CPU.
The pin definition is listed below(Figure 8-1):

PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION

1 MAIN.SW 17 BUCK.RLY 33 49 INV1.OFF
2 18 BST.RLY 34 LINE.V 50 INV2.OFF
3 RESET 19 OP.RLY 35 INV.V 51 INV3.OFF
4 LINE.ZERO 20 MAIN.RLY 36 BAT.V 52
5 CURR.ZERO 21 VSS 37 TEMP1.V 53
6 INV.ZERO 22 VDD 38 CURR.V 54
7 23 STS.ON 39 MODEL0 55
8 SINE.PWM 24 DATA 40 MODEL1 56
9 CHG.ON 25 CS/DATA.CLK 41 MODEL2 57
10 CHG.COST 26 WR/DATA.EN 42 MODEL3 58
11 TRIA.CLK 27 43 TEMP2.V 59 VSS
12 CONVER.OFF 28 44 60 SD
13 TXD1 29 45 61 FUN1.RLY
14 RXD1 30 46 BATMODE 62 FUN2.RLY
15 31 47 BATLOW 63 PNP
16 32 48 REMOTE.SD 64

Figure 8-1

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Figure 8-2 CPU Control Circuit

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9 Relay Circuit
Figure 9-1 is the relay circuit.
The RY1&RY2 (main relay) is used to switch between line and battery modes. When
the UPS is changing from battery to line mode, CPU pin 20 is set to HI to turn on Q1&Q10
(MMBT2222A) and activates RY1&RY2.
Alternatively, if the UPS is changing from line mode to battery mode, CPU pin 20 is set
to LOW and turn off Q1&Q10. This causes RY1&RY2 to be OFF and return to its normal state.
Q1, Q10, Z1 and Z3 are used to speed up the relay transfer action, so
the power failure time can be shorten to minimum. When UPS transfers to line mode, C2 is
charged by the +12 Volts. After the main relay makes contact, C2 provides instantaneous
power to the relay coils. This will increase the magnetic force and shorten the transfer
time from battery mode to line mode by switching the relay.
See Figure 9-2 for voltage changes on C2, during transfer time from line to BAT mode.
CPU pin 18 is used to the drive signal for RY3 (boost relay). When the mains
input voltage is low as within boost activated point, pin 18 sends a high signal to turn on Q3
(2222A). This will activate the RY3, and UPS will transfer to the Boost mode. When the mains
input voltage increases back to reach inactivated boost point, the UPS will return to normal
mode by sending a LOW signal from pin 18. This forces RY3 to switch to its normal position
(OFF). At battery mode, pin 18 is always set to LOW and RY3 is disabled.
Buck situation is the similar process. CPU pin 17 is used to drive signal for RY4
(buck relay). When the mains input voltage rises beyond buck activated point, CPU pin 17
sends a high signal to turn on RY4. When the mains input voltage decreases below
the inactivated buck point, the UPS returns back to normal mode by sending a LOW
signal from pin 9.

Figure 9-1 Relay Circuit

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Figure 9-2 Output waveform vs voltage change for relay speed-up circuitry
CH1 : C10(+)  GND CH2 : Output Voltage (1/200V)

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10 Displays, Audio Alarm and Control Button

10.1 Control button

ON/OFF Button: Push it to turn on UPS, and push again to turn off UPS.

10.2 Audio alarm

The buzzer is controlled by pin 7 of CPU. When CPU sends a HI signal to buzzer from
pin 7, buzzer is beeping. And CPU sends LOW signal to stop buzzer.

10.3 Display (Figure 10-1、Figure 10-2)

There are 3 LEDs or 6 LEDs on front panel.While control button is turned on, CPU
sends a HI signal to turn on LED.

Figure 10-1 3 LEDs Display Circuit

Figure 10-2 6 LEDs Display Circuit

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11 Load Detection Circuit

Load detection circuit is shown on Figure 11-1.
The output current is detected by current transformer CT1. It lowers 1000 times of
output current for CPU detection. The current signal generated from CT1 flows through
R13&R14&16&17 to convert to a voltage signal. Then CPU can receive output current value of
the UPS.

11.1 At line/boost/buck mode:

The current value multiplies output voltage to get output VA value.

11.2 At battery mode:

Because the power factor of sine wave is approximately equal to 1,
the current value multiplies 230V output voltage to get output Watt value.

Figure 11-1 Load Detection Circuit

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12 Interface Circuit
The interface circuit (refer to Figure 12-1) ： USB communication, and plug &
play for Windows 95/98/2000/XP/NT.

Figure 12-1 USB Interface Circuit

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13 Troubleshooting

WARNING
13.1 Troubleshooting can be done by qualified engineer or technician only.

13.2 Use isolated AC source for your oscilloscope to prevent floating voltage
problem between UPS chassis ground and system reference ground.

13.3 Before opening the cover, turn off the main switch and unplug the input
power cord.

13.4 Because hazardous voltage may remain in the DC capacitors, wait for at
least 5 minutes after turning off the UPS and disconnecting the power
cord before open its cover.

13.5 Do NOT plug in the input power cord before you reconnect the connectors
of battery to prevent unwanted sparks.

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Please follow the sines below when you want to repair a problematic unit:

1 Visual inspection
This is the first sine to check the UPS after opening its cover. Be sure to do the visual
inspection because it can help you to identify most problems.

Major items that should be checked are listed below:

1.1 Are there any connectors or terminals loose?

1.2 Are there any components burn-out or discolored?

1.3 Especially the power components on the heat sink?

1.4 Are there any capacitors broken or leakage? Check all the components listed
above and replace which is abnormal.

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2 Troubleshooting flowchart
To prevent from hurting yourself and damaging the UPS, be sure to obey the sequences
of flowchart listed below.

2.1 Battery mode examination (please refer to Figure 13-1)

1. Replace batteries by DC power supply and turn on it. Check if there is
current limit phenomenon for DC power supply.
2. One or more MOSFETs（Q12,Q13,Q15,Q16,Q18,Q19,Q21,Q22）is D-S
short. Check and replace it. If MOSFETs have been replaced
once, replace the PCB.
3. Check if both buzzer beeps and LED flash for once.
4. Check if +5Vdc on CPU pin 22 is normal.
5. Check if clock signals on CPU pin 57 and 58 are correct.
6. Replace the CPU. But if the CPU has been replaced once, replace the PCB.
7. Replace abnormal crystal XL1.
8. Check if Q12,Q13,Q15,Q16,Q18,Q19,Q21,Q22 are OK.
9. Replace abnormal Q12,Q13,Q15,Q16,Q18,Q19,Q21,Q22.
10. Check if there is a PWM signal on Q9（G-S）.
11. Check Q9 (IRF630), U1 (3845) and replace them if abnormal.
12. Check there is +12Vdc on 7805 input.
13. Replace abnormal U6.
14. Check there is +5Vdc on U03 (7805)
15. Replace abnormal 7805.
16. Replace PCB
17. Check if buzzer beeps and LED extinguished.
18. Check if battery voltage is correct.
19. Replace abnormal batteries.
20. Check if R46 is normal.
21. Replace abnormal R46.
22. Replace PCB.
23. Buzzer beeps and LED flash.
24. Check if fault LED lights and buzzer beeps continuously.
25. Check if CPU is shorted.
26. Replace abnormal CPU.
27. Check if the value（22R） of R85、R86、R90、R91、R99、R100、R104
、R105 are correct.
28. Replace R85、R86、R90、R91、R99、R100、R104、R105.
29. Check if Q11,Q14,Q17,Q20,U7,U8 are ok.
30. Replace Q11,Q14,Q17,Q20,U7,U8.
31. Replace PCB.

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Figure 13-1 Battery Mode Examination Flowchart

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2.2 Line mode examination (please refer to flowchart Figure 13-2)

If battery mode examination is OK, then do the line mode examination as below.
1. Plug in input power cord at right voltage range. Check if main relay RY1&RY2
is active.
2. Replace main relay.
3. Check if full-bridge rectifier is short.
4. Replace abnormal diode
5. Check Q4 (2222ASM collector) if there is zero crossing signal.
6. Replace abnormal Q4. Check if UPS remains on line mode.
7. Replace PCB.
8. Check if buzzer beeps continuously and fault LED lights.
9. Check if Buck/Boost relays (RY3, RY4) are bad.
10. Replace abnormal Buck/Boost relays (RY3, RY4).
11. Replace PCB.

Figure 13-2 Line Mode Examination Flowchart

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