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
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