1. Gamatronic Mega Power Module old hardware Troubleshoot Rev.1

2. Introduction and Power Module layout

3. 1011 AC OUT + FEEDBACK 1014 PFC controller 1012 DC\DC IGBT 1021 1013 controller 1015 INV controller 1010 AC IN DC I.O. + MEASURE 098 fan 1019 LEDs Panel 1024A Parallel Comm. 1027 PFCINV 1022 IGBT 1024BDriver 098 fan Mega Power Module Boards layout Driver

4. Mega Power Module

5. PC1013, power module main controller PC1012, power module main DC/DC unit

6. Mega Power Module Inverter Power – IGBT and Drivers LC – Filter and out relays PWM controller

7. Mega Power Module PFC Power – IGBT and Drivers,Inverter DC fuses LC – Filter and input relays PFC - controller

8. Fuses and IGBT Check DC fuses Inverter DC fuses Battery DC fuses

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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 Disconnec ted, or have a problem? 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 Check input phases and neutral via PC1010 and input C.B Start

15. 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

16. 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.PC1010 b.PC1013 c. 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

17. The module starts pre-charging, DC starts increase smoothly on POSTIVE and NEGATIVE STEP 2 DC meter is connected to the DC bus

18. DC voltage pre charge issue – if the unit pre charging normally, skip this slide DC voltage is between 0 to 40V A. Check flat between 1. PC1010 P1 and 1014 P7 2. PC1014 P3 and PC1013 P1 B. replace PC1014 Is rectifier relay on on LCD Yes Works well done DC voltage doesnt reach to 270VDC Replace PC1012 or Q6 on PC1012 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 PC1010 3. 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

19. 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

20. STEP 4 Immediately!! PCB 1013 sends command To PCB 1014 to start the BOOST Start BOOST

21. 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.PC1010 b.PC1013 c. 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

22. 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

23. If PFC is ok and DC reach 400V, skip this slide DC voltage is ±300V A.Check flat between 1. PC1010 P1 and 1014 P7 2. PC1014 P3 and PC1013 P1 B.replace PC1014 C.replace PC1012 Is PFC on on LCD Yes Works well done 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 PC1010 2.CR26 and CR24 on PC1010 3. Check 1K gold pre charge resistor that connected to P9 on PC1010 YesNo Burn 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

24. STEP 6 When +/- DC reaches about 380 V PCB 1013 sends a command to the Inverter to turn on and fans start Inverter ON

25. STEP 6

26. Inverter isnt 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

27. STEP 7 Inverter is on And the measured output voltage is ok choose Master/Slave Close output relay And DC relay

28. STEP 7

29. 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 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 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

30. Before placing the repaired module into a system 1.Perform DC, battery and AC calibrations 2.Perform output voltage and frequency configuration (230V, 240V, 50/60Hz and so on) 3.Perform output voltage adjust 4.Make sure DC relays are not stuck – you should not be able to measure DC voltage on modules 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 modules plugs * Refer to the relevant procedure for the above

31. 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 load 4.Make sure input and output current measurements are correct 5.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 batteries 7.Make sure DC voltage is stable and balanced 8.Make sure module can cold start from batteries 9.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

32. 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