gxt2-10000t230 service manual

SERVICE MANUAL ----------------------------

GXT2-10000T230

UNINTERRUPTIBLE

POWER

SYSTEM

LIEBERT

----------------------------

614-XXXXX-00 2006/4/6 Edition

2

INDEX,

T I T L E PAGE

STEPS TO OPEN THE 5 COMPONENTS 6

I. 7 II. PRINCIPLE OF 8 III. PCB 11 1. POWER STAGE (PSDR) 11 (1) SOFT-START SUB-SYSTEM--------------------------------------------- 11 (2) CONTROL POWER SUB-SYSTEM------------------------------------- 12 (3) INPUT POWER FACTOR CORRECTION SUB-SYSTEM-------- 13 (4) BOOSTER 14 (5) INVERTER SUB-SYSTEM------------------------------------------------- 14 2. MAIN CONTROL PCB ASSEMBLIES (CNTL)--------------------------- 15 (1) REGULATION & CONTROL SUB-SYSTEM------------------------- 15 (2) PROTECTION SUB-SYSTEM-------------------------------------------- 15 (A) Overload 15 (B) Battery over or under shut 16 (C) Inverter output abnormal 17 (D) Over temperature 17 (E) Bus over-voltage 17 (3) SIGNALING 17 3. OUTPUT 17 4. CHARGER (CHGR) 17 5. FRONT 17

T I T L E PAGE

IV. ALIGNMENTS 22

LIEBERT GXT2-10000T230

SERVICE MANUAL

2

V. TROUBLE SHOOTING 23 1. BEFORE FAILURE DIAGNOSIS 23 2. COMPONENTS 24 (1) PSDR PCB 24 (A) PFC / BOOSTER 24 (B) DC-DC CONVERTER 25 (C) DC/AC INVERTER 25 (E) CONTORL POWER SUPPLY 25 (2) CHARGER PCB 26 (3) I/P SCR PCB 26 (4) FUSE PCB 26 (5) MOV PCB 26 3.DYNAMIC CHECK 27 VI. APPENDIX I : 28

LIST OF FIGURES FIGURE T I T L E PAGE


SERVICE MANUAL

3

1 STEPS TO OPEN THE CASE 5

2 COMPONENTS LOCATION 6 3 BLOCK DIAGRAM 9 4 WIRING DIAGRAM 10 5 SOFT-START DIAGRAM 11 6 CONTROL POWER DIAGRAM 12 7 PFC BLOCK DIAGRAM 13 8 INVERTER BLOCK DIAGRAM 14 9 CHARGER BLOCK DIAGRAM 18

10 FRONT PANEL 19 11 FAULT DISPLAY 20 12 RS232 CONNECTION 28

WARNING


SERVICE MANUAL

4

(For qualified service personnel only) 1. DO NOT perform any internal service or adjustment of this product unless another

person is capable of rendering first aid and resuscitation is present. 2. Dangerous voltage exists at several points in this product. To avoid personal injury,

don't touch any exposed connections or components while power is on. 3. Turn off the UPS and input NFB before removing outside protective cover. 4. AC voltage is always present if the input AC power is still available. 5. High voltage may present at DC capacitors. Before opening the outside cover, wait for

at least five minutes after turning off the UPS. 6. Verify input source (voltage and frequency) before service.

CAUTION

1. After opening the cover, please always check the tightness of all wires, connectors, and screws first. Then check if there is any decolored components inside.

2. DO NOT make internal batteries short-circuited. 3. After service, verify the polarity of batteries, the tightness of all screws and connectors

before restarting the UPS.


SERVICE MANUAL

5

STEPS TO OPEN THE CASE To open the outside case, please follow steps and figures below:

1.Remove related screws on Figure 1.

APPLICABLE MODEL Model: GXT2-10000T230 (220V/230V/240V 50/60Hz) PLEASE FOLLOW THE STEPS TO OPEN THE CASE

Figure 1.

7

Figure 2. COMPONENTS LOCATION DIAGRAM

8

COMPONENTS LOCATION The main components’s location of the UPS is shown in Figure 2 as above :

STOP

Warning: Any further operation of service, e.g. removing PSDR PCB, please

disconnect at least one of the short battery connection cables shown above to make sure

safety of operation.

This service manual consists of 4 major parts: 1. Introduction. 2. Principle of operation: It describes the functions and principles of each part. 3. Alignments: It describes the locations and methods needed to adjust the UPS. 4. Trouble shooting: This part describes the possible failure conditions and procedures

to repair it. Before starting to serve the UPS, be sure to read this manual carefully for a correct and safe operation.

I. INTRODUCTION

For all UPS of this series, they are strictly tested and carefully designed. We always do

our best to make our products more reliable and safer, this is also the goal of our company.

However, due to the lifetime of electrical components and some unpredictable reasons,

there will be unavoidable failures of the UPS. If this situation occurs, service of qualified

person is needed. This service manual will guide the technicians to repair and adjust the

problematic UPS. If the UPS still does not work properly, please contact with us and we

will be glad to solve any problems you met.

Because of the following unique features of this series UPS (Uninterruptible Power

System), it is very easy to maintain and service.

All major power components are put on PCB.

Major parts are simply connected with flexible insulated wires and plugs.

All PCBs are interconnected with connectors.

9

II. PRINCIPLE OF OPERATION The high input power factor of 10KVA UPS system contains three major PCB

assemblies.

They are including:

1.PSDR PCB

contains major parts : (1) soft-start, (2) DC power supply, (3) unit

power factor correction, (4) converter, (5) inverter, (6)parallel relay

control.

2.CNTL PCB contains major parts : protection, signaling circuits, regulation and

control circuits of inverter.

3.CHGR. PCB contains DC-DC regulation and control circuits.

The simplified schematics in Figure 3 shows how the major circuits are connected and

illustrated the overall system functions.

The wiring diagram in Figure 4 shows the UPS at normal operation from left to right.

When a protection circuit is triggered or a fault condition occurs, the output supply is

transferred immediately from inverter to AC mains by S.T.S (Static Transfer Switch) and

inverter relay. The operation principle will be explained in later section.

Basically, the on-line UPS system utilizes high frequency PWM techniques to achieve

high efficient performance. The UPS can deliver a clean, regulated sine-wave output at any

load under full load. The sub-systems are described at next section.

10

Figure 3. BLOCK DIAGRAM

11

Figure 4. Wiring DIAGRAM


SERVICE MANUAL

12

III.PCB FUNCTION 1. PSDR (POWER STAGE)

The power stage which show in Figure 4 consists of soft-start, control power supply, unit power factor correction, boost converter and half bridge inverter.

(1) SOFT-START SUB-SYSTEM: The purpose of soft start circuit is to suppress the I/P inrush current.


SERVICE MANUAL

13

(2) CONTROL POWER SUPPLY SUB-SYSTEM:

The input of the control power supply is connected to the battery and output of the charger. The output of control power supplies provide +5Vdc for the bias supply of IC's working voltage and +12Vdc for the coil of relay, and the fan(s) voltage. +15Vdc is used for Logic IC's working voltage in DSP which are indicated in Figure 5.

Figure 5. CONTROL POWER DIAGRAM


SERVICE MANUAL

14

(3) INPUT POWER FACTOR CORRECTION SUB-SYSTEM: The purpose of power factor correction (PFC) circuit is to make the input current and

voltage in phase and therefore achieve a high input power factor. The schematic is indicated in Figure 6.

When the input NFB turn on, the AC power goes through noise filter to the line detector. Both DC buses present voltages at about 1.4 times of input RMS voltage. When the "on" switch is pressed, the PFC circuit is enabled and the DC buses are regulated at 360Vdc for 230Vrms series.

Figure 6. PFC BLOCK DIAGRAM


SERVICE MANUAL

15

(4) BOOSTER SUB-SYSTEM: The major function of the UPS is to deliver accurate AC power to the loads connected

to it whenever the AC line is uncorrected or failed. In this system, the batteries release the stored energy to supply inverter immediately upon AC line fails.

Refer to Figure 6,the battery voltage is transformed through a boost DC-DC converter to 360Vdc (battery V: 200~276Vdc) as DC buses for inverter. When the line fails, the 360Vdc (battery V: 200~276Vdc) DC sources are caught up to supply the power needed by the inverter immediately.

(5) INVERTER SUB-SYSTEM: The UPS transfers＋,－DC bus voltages to the AC output voltage through an inverter

of half bridge configuration at normal operation. The schematic diagram of inverter is shown in Figure 7.

To construct a high frequency (19.2kHz) PWM inverter, the drivers receive switching signals from PWM generation circuit through a pair of photo-couplers to trigger the upper IGBT and the lower IGBT alternately.


SERVICE MANUAL

16

Figure 7. INVERTER BLOCK DIAGRAM

2. MAIN CONTROL PCB ASSEMBLIES (DSP & Interface CNTL)

These assemblies are the control center of UPS. It is composed of three major circuits as

following.

(1) Regulation & control

(2) Protection

(3) Signaling

(1) REGULATION & CONTROL SUB-SYSTEM

This portion can be seen as brain of the UPS. It provides the control pulses to the

switching elements which deliver power to the output. The sub-system also regulates the

output to ensure that the UPS delivering constant AC voltage to the loads.

The inverter signal is sensed directly by resistor division. It is compared with a

reference signal from sine wave generator. The difference of these two signals (error

signal) alter the pulse widths of PWM signals which control the duty cycles of switching

elements to regulate the output voltage within specification.


SERVICE MANUAL

17

In order to avoid unwanted surge current at the transfer of bypass relay, the bypass

signal activates the tracking circuit. It matches the inverter voltage with the line voltage by

having the amplitude of the reference signal following the variation of line voltage.

When the main2 is applied, the bypass relay stays at bypass position and also have the

output of Main2 input voltage.

(2) PROTECTION SUB-SYSTEM: The UPS provides the following protection circuits:

A. Overload protection

The load detector senses the load current, i.e. the inverter current, and sends the

signal by two paths. In battery mode, the UPS will go to failure mode if overload

condition happened. The panel will indicate the fault condition. There are two

kinds of protection in our UPS:

(a)Overload Protection: The UPS collects the continuous overload signals through

CPU switch the bypass relay.

---- If the output load is between 105% to 125% of rated load (VA, or Wattage),

the UPS keeps running on inverter running for 1 minute.

After 1 minute: UPS transfer to bypass which if UPS is under line mode.

UPS transfer to overload fault mode and shut down which if

UPS is under battery mode.

---- If the output load is between 126% to 150% of rated load, the UPS keeps

running on inverter running for 10 seconds.

After 10 seconds: UPS transfer to bypass which if UPS is under line mode.



---- If the output load is higher than 150% of rated load, the UPS transfers to

bypass immediately for 2 seconds.


SERVICE MANUAL

18

After 2 seconds: UPS transfer to bypass which if UPS is under line mode.



(b)Cycle by Cycle Current Limit: When output loads sink a high surge current, a

high inverter current is detected and the inverter switches, i.e. the IGBTs, are

turned off pulse by pulse to protect themselves from thermal runaway. The

output relay stays at inverter output position unless a continuous overload is

detected or an abnormal inverter operation occurs.

B. Battery over or under shut down

Upon the battery voltage declines to battery-under level, a signal is generated to cut

off the power supply of the whole system, The buzzer becomes silent and all the

LEDs extinguish. When the utility is coming, the UPS will start up automatically.

In case of the battery voltage is high voltage, the UPS will discharge the battery

capacity to ensure the battery life. The LCD panel will indicate the fault condition.

C. Inverter output abnormal protection

The inverter failure signal shuts down the inverter immediately, makes the buzzer a

continuous alarm, and lights "FAULT" LED. The LCD panel will indicate the fault

condition. " The failure signal latches itself unless SW off or battery is empty".

D. Over temperature protection

The thermal switch detects the temperature of PSDR heat-sink. The thermal switch is

electrically connected to the CPU. The LCD panel will indicate the fault condition.

E. Bus over-voltage protection

To protect any BUS over-voltage condition especially for the half-bridge load. The

LCD panel will indicate the fault condition.

(3) Signaling Sub-System:


SERVICE MANUAL

19

When the AC line is unable to supply, the batteries release energy inside to supply the

inverter immediately. At the same time, the utility failure display is activated.

Upon the batteries are discharged to battery-low level, the battery-low signal is activated.

Remote shutdown signal is enabled only when the line fails. It generates battery-under

signal to cut off the bias power supply of the UPS system.

3. OUTPUT SUB-SYSTEM

The output of Inverter is filtered by a LC circuit to reduce the output voltage harmonic

distortion. The output relay and S.T.S. receives signal from control circuit to switch the

output of the UPS from bypass to inverter, and vice versa.

4. CHARGER (CHGR)


SERVICE MANUAL

20

The purpose of charger is to charge and to maintain the batteries at full charged

condition. Refer to Figure 8, the voltage flyback switching power supply provides a

constant DC voltage (276Vdc) for batteries. Besides providing constant voltage, the

power supply also limits the current flowing into batteries and therefore protects and

prolongs the lifetime of charged batteries.

Figure 8. CHARGER BLOCK DIAGRAM

4. LCD PANEL


SERVICE MANUAL

21

Figure 9. LCD PANEL

The LCD panel consists 3 parts: select bottom, display LED set, and LCD display.

The select bottom is used to turn on and off the UPS. LED display indicates the UPS

mode status and LCD display show operation status of the UPS. “BATT” LED

indicates battery mode is normal. If the line LED flash, it warns the power source is bad.

“Bypass” LED indicates bypass is active. “ON” LED indicates inverter is working and

“Fault” LED indicates the UPS is in fault condition. Besides, when the system works

abnormally, the fault LED will light up and the buzzer will beep continuously. In this

situation, the LCD will indicate which part inside the UPS is out of order. The

representations of fault conditions are listed as following:

Figure 10. FAULT DISPLAY :


SERVICE MANUAL

22

Fault Before fault

UPS mode

Condition After fault

UPS mode

1.Voltage > 450V

2.Voltage > 400V

3.+-BUS unbalance over 40V

Line,

BatteryTest

4.Voltage < 230V

Bypass

1.Voltage > 450V

2.Voltage > 400V

3.+-BUS unbalance over 40V

1. BUS fault

Battery

4.Voltage < 230V

No output

Bypass to

Line

1.soft start fail

1.Voltage > 276V Line,

batteryTest 2.Voltage < 140V

Bypass

1.Voltage > 276V

2. Inverter fault

Battery

2.Voltage < 140V

No output

Bypass, Line,

BatteryTest

Temperature over>90 degree C Bypass 3. Overheat fault

Battery Temperature over>90 degree C No output

4. Battery over

voltage fault

Bypass, Line Voltage > 292V Bypass

1.Load >105%

2.Load >125%

5. Battery mode,

overload fault

Battery,

BatteryTest

3.Load >150%

No output

1.Voltage <50V & Current

>20A

Line,

BatteryTest

No output 6. Inverter mode,

output

short-circuit

fault Battery 1.Voltage <50V & Current

>20A

No output


SERVICE MANUAL

23

7. INV relay short Bypass to

Line

before soft start check

inv voltage > 50V

Bypass

1.Voltage < 185 V Bypass,Line,

BatteryTest 2.Voltage < 185 V

Bypass,

1.Voltage < 185 V

2.Voltage < 185 V

No output Battery

Back:

8. Battery fault /

battery

disconnected

Voltage > 240 V

9. Charger Fault Line,Bypass 1.Charger On, but battery <240V Bypass

10. EPO activated Any mode EPO hardware active No output

11. Parallel(Option

) Error

Any mode Parallel communication CAN bus

loss

No output

12. Communicatio

n error

Any mode DSP with H8 communication error Bypass or No

output

13. Output failure Line,Battery Output actual power <-800W Bypass


SERVICE MANUAL

24

IV. ALIGNMENTS List below are some test points and procedures when a qualified service person wants to

check UPS.

TEST ITEM TEST

POINT TEST AND ADJUSTMENT SEQUENCE EXPECTED

RESULT

+DC Bus Voltage @ Line Mode

LABEL #+BUS

#18

+360Vdc±0.5V @O/P 230Vrms/ +330Vdc±0.5V @O/P 208Vrms

-DC Bus Voltage @ Line Mode

LABEL #-BUS

#18

1.Connect DVM (Set to measure DC) to test point. 2.I/P Main1& Main2 NFB ON, turn on UPS. 3.Waiting several seconds to make sure the “ON” LED

lights. Then Check reading on DVM. Terminal command for +BUS voltage adjustment (0.5V/div): BUSPS+02 or BUSPS-02( mean +BUS +/-1V) Terminal command for -BUS voltage adjustment (0.5V/div): BUSNS+02 or BUSNS-02( mean -BUS +/-1V)

-360Vdc±0.5V @O/P 230Vrms/ -330Vdc±0.5V @O/P 208Vrms

O/P Voltage @Line mode

O/P 1.Connect DVM (Set to measure AC) to Output. 3.Make sure UPS is on Line mode. Terminal command for output voltage adjustment: V+1 or V-1( mean output voltage +/-1V) V+2 or V-2( mean output voltage +/-1V)

230±1Vrms

208±1Vrms


SERVICE MANUAL

25

V.TROUBLE SHOOTING In this section, some debug skills are listed to help you finding the fail components and

problems shortly possible. Before continuing the following steps listed, we suggest that

you should read “Before Failure Diagnosis” and obey the procedures listed below. Then

the next chart “Components Check” and “Dynamic Check” will help you to confirm

which block is out of order and repair them. However, for the reason of safety, please obey

following procedures to begin your work.

1.BEFORE FAILURE DIAGNOSIS:

Before starting service, some tools are necessary, including: A DMM (Digital

Multifunction Meter) meter, screw drivers and discharge resistor(40Ω/80W

recommended). A DC power supply (300Vdc/3A at least) is recommended for fast and

safe diagnosis.

(1) Record panel LCD display, state of input and output.

(2) Reference APPENDIX II-FAULT TABLE to find what happened.

(3) Press “Menu” switch, UPS turn to bypass, rotate “MAINT. SW” to BPS.

※If UPS is not on bypass, you can’t rotate “MAINT. SW”.

※If UPS can’t turn to bypass, you must turn off the output NFB and input NFB.

If customer still needs power then rotate “MAINT. SW” to BPS.

(4) Input NFB OFF, Output NFB OFF.

(5) Open outside case shown in the beginning of this manual.

(6) disconnect the battery wires from batteries.

(7) Discharge the energy of BUS capacitors.(please use a 40Ω/80W resistor or more

large)

(8) Press ON switch to discharge the energy on PSDR PCB. Then, you can start to

maintenance safely.


SERVICE MANUAL

26

2.COMPONENTS CHECK:

Before any detail check of the UPS, please check the components listed in the

following table. This action could help you find problem quickly and make following

debug procedures go smoothly.

(1) PSDR PCB:

(A) PFC / BOOSTER:

Item Checked Components

DVM

Switch

position

Reference

value Fail condition

Component

Type

1 Q222(G,K)

(A,K) Ω

8~40Ω

≒ ∞

Short or open

Short

SCR

40TPS12

2 Q221,225,218 (C,E)

(G,E)

Ω

Ω

>100KΩ

15.8KΩ Short or open

IGBT

IRG4PF50W

D

3 TVS1,2,3 Ω ≒ ∞ Short TVS

1.5KE220A

4 D263 DIODE 0.36V Short or open RHRG75120

5 Q223(G,K)

(A,K) Ω

8~40Ω

≒ ∞

Short or open

Short

SCR

40TPS12

6 Q220,224,219(C,E)

(G,E)

Ω

Ω

>100KΩ


IGBT

IRG4PF50W

D

7 TVS4,5,6 Ω ≒ ∞ Short TVS

1.5KE220A

8 FC203,204 Ω 0Ω Open BLN 30

250V AC


SERVICE MANUAL

27

(B) DC-DC CONVERTER: (Related Circuit Block: PSDR)


DVM

Switch

position

Reference


Component

Type

1 FC201,202 Ω 0Ω Open KLKD30

/600V AC/DC

2 Q217(G,K)

(A,K)

Ω

Ω

8~40Ω

≒ ∞

Short or open

Short

SCR

40TPS12

(C) DC/AC INVERTER: (Related Circuit Block: PSDR)


DVM

Switch

position

Reference


Component

Type

1 Q213,215(C,E)

(G,E)

Ω

Ω

>100KΩ


IGBT

IRGPS40B12

0U


3 Q214,216 (C,E)

(G,E)

Ω

Ω

>100KΩ


IGBT

IRGPS40B12

0U


(D) CONTORL POWER SUPPLY: (Related Circuit Block: PSDR)


SERVICE MANUAL

28


DVM

Switch

position

Reference


Component

Type

1 Q03(D,S) DIODE 0.47V Short or open 2SK2611

(2) CHARGER PCB:


DVM

Switch

position

Reference


Component

Type

1 F601~602 Ω 0Ω Open 250VAC/6.3A

2 Q601,613,614 (S,D)

(D,S)

DIODE

DIODE

0.47V

≒ ∞

Short <0.4V

No open 2SK2611

(3) I/P SCR PCB:


DVM

Switch

position

Reference


Component

Type

1 F1,F2 Ω 0Ω Open BLN 30

250V AC

(4) EXT.BAT FUSE PCB:


DVM

Switch

position

Reference


Component

Type

1 F1,F2 Ω 1Ω Open KLKD30

/600V AC/DC

(5). MOV PCB:


SERVICE MANUAL

29


DVM

Switch

position

Reference


Component

Type

1 TC1~9 Ω 0Ω Open 115FUSE

2 MOV 1~MOV18 Ω ≒ ∞ Short 20N471K

3.DYNAMIC CHECK:

After finish components check and replace good components, we can check other

point listed below:

(1) PSDR control power check:

If the panel LED is light and fan is still working when UPS fault, then control power

is OK.

(2) !

If the fuse is open, and you only replace fuse that DOES NOT mean you have

solved the problem completely. For most situations, opened fuse is caused by other

failure of components, therefore, before restart that UPS, you must find the real

failure components and replace them!

(3) When all main components have been replaced, puts PSDR board back and fix it then

plug all connectors back. Check if all connectors and terminals are on correct

location.

(4) Don’t connect battery wire, please use external power supply to turn on UPS.

(220Vdc~276Vdc/3A limit)

(5) Observe BUS voltage, output voltage. If OK, then test battery mode and line mode

transforming. (Don’t connect load.)

(6) Turn off UPS. Take off external power supply. If UPS is OK, then connect battery

wires. Turn on UPS. Adjust +/-BUS and O/P voltage according to Chapter IV

ALIGNMENTS.

(7) Re-assembly the UPS.


SERVICE MANUAL

30

VI.APPENDIX I: COMMUNICATION 1. RS232

The RS232 provides proprietary command sequence for the computer to monitor

the line and UPS status and to control the UPS. The data format is listed as following:

PIN TYPE ...................: female

BAUD RATE .............. : 2400 bps

DATA LENGTH ......... : 8 bits

STOP BIT ................... : 1 bit

PARITY ...................... : NONE

PIN # Description I/O type 1,4,6,7,8,9 not connected

3 UPS RS232 receiver RX from computer. output 2 UPS RS232 transmitter to computer Input 5 GND


SERVICE MANUAL

31

1

2

3

4

5

6

7

8

9

TX

RX

Figure 12. RS232 connection

2. Relay Contacts

TX

RX


SERVICE MANUAL

32

gxt2-10000t230 service manual

Documents