SERVICE MANUAL

---------------------------GXT2-10000T230 UNINTERRUPTIBLE POWER SYSTEM

LIEBERT

---------------------------614-XXXXX-00 2006/4/6 Edition

INDEX,
TITLE
STEPS TO OPEN THE COMPONENTS I. II. PRINCIPLE OF III. PCB 1. POWER STAGE (PSDR)

PAGE
5 6 7 8 11

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 15 15 15 15 16 17 17 17 17 17 17 17

2. MAIN CONTROL PCB ASSEMBLIES (CNTL)--------------------------(1) REGULATION & CONTROL SUB-SYSTEM------------------------(2) PROTECTION SUB-SYSTEM-------------------------------------------(A) Overload (B) Battery over or under shut (C) Inverter output abnormal (D) Over temperature (E) Bus over-voltage (3) SIGNALING 3. OUTPUT 4. CHARGER (CHGR) 5. FRONT

TITLE
IV. ALIGNMENTS

PAGE
22
2

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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

23 23 24 24 24 25 25 25 26 26 26 26 27 28

LIST OF FIGURES
FIGURE TITLE PAGE

LIEBERT

GXT2-10000T230 SERVICE MANUAL

1 2 3 4 5 6 7 8 9 10 11 12

STEPS TO OPEN THE CASE COMPONENTS LOCATION BLOCK DIAGRAM WIRING DIAGRAM SOFT-START DIAGRAM CONTROL POWER DIAGRAM PFC BLOCK DIAGRAM INVERTER BLOCK DIAGRAM CHARGER BLOCK DIAGRAM FRONT PANEL FAULT DISPLAY RS232 CONNECTION

5 6 9 10 11 12 13 14 18 19 20 28

WARNING

LIEBERT

GXT2-10000T230 SERVICE MANUAL

1. 2. 3. 4. 5. 6.

(For qualified service personnel only) DO NOT perform any internal service or adjustment of this product unless another person is capable of rendering first aid and resuscitation is present. 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. Turn off the UPS and input NFB before removing outside protective cover. AC voltage is always present if the input AC power is still available. High voltage may present at DC capacitors. Before opening the outside cover, wait for at least five minutes after turning off the UPS. 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.

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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.

Figure 2. COMPONENTS LOCATION DIAGRAM

COMPONENTS LOCATION
The main componentss 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.

II. PRINCIPLE OF OPERATION

The high input power factor of 10KVA UPS system contains three major PCB assemblies. They are including: contains major parts : (1) soft-start, (2) DC power supply, (3) unit 1.PSDR PCB power factor correction, (4) converter, (5) inverter, (6)parallel relay control. contains major parts : protection, signaling circuits, regulation and 2.CNTL PCB 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.

Figure 3. BLOCK DIAGRAM

10

Figure 4. Wiring DIAGRAM

11

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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.

12

LIEBERT

GXT2-10000T230 SERVICE MANUAL

(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

13

LIEBERT

GXT2-10000T230 SERVICE MANUAL

(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

14

LIEBERT

GXT2-10000T230 SERVICE MANUAL

(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.

15

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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.
16

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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. UPS transfer to overload fault mode and shut down which if UPS is under battery mode. ---- If the output load is higher than 150% of rated load, the UPS transfers to bypass immediately for 2 seconds.

17

LIEBERT

GXT2-10000T230 SERVICE MANUAL

After 2 seconds: 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.

(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:

18

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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)

19

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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
20

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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 :

21

LIEBERT

GXT2-10000T230 SERVICE MANUAL

Fault

Before

fault

Condition

After

fault

UPS mode 1. BUS fault Line, BatteryTest 1.Voltage > 450V 2.Voltage > 400V 3.+-BUS unbalance over 40V 4.Voltage < 230V Battery 1.Voltage > 450V 2.Voltage > 400V 3.+-BUS unbalance over 40V 4.Voltage < 230V 2. Inverter fault Bypass Line Line, batteryTest Battery 1.Voltage > 276V 2.Voltage < 140V 1.Voltage > 276V 2.Voltage < 140V 3. Overheat fault Bypass, Line, BatteryTest Battery 4. Battery over Bypass, Line to 1.soft start fail

UPS mode Bypass

No output

Bypass

No output

Temperature over>90 degree C Bypass Temperature over>90 degree C No output Voltage > 292V Bypass

voltage fault 5. Battery mode, Battery, overload fault BatteryTest 1.Load >105% 2.Load >125% 3.Load >150% 6. Inverter mode, Line, output short-circuit fault Battery 1.Voltage >20A
22

No output

1.Voltage >20A

<50V

&

Current No output

BatteryTest

<50V

&

Current No output

LIEBERT

GXT2-10000T230 SERVICE MANUAL

7.

INV relay short Bypass Line

to before soft start check inv voltage > 50V 1.Voltage < 185 V 2.Voltage < 185 V 1.Voltage < 185 V 2.Voltage < 185 V Back: Voltage > 240 V

Bypass

8.

Battery fault / Bypass,Line, battery disconnected BatteryTest Battery

Bypass, No output

9.

Charger Fault

Line,Bypass

1.Charger On, but battery <240V Bypass EPO hardware active No output

10. EPO activated Any mode 11. Parallel(Option Any mode ) Error 12. Communicatio Any mode n error 13. Output failure Line,Battery

Parallel communication CAN bus No output loss DSP with H8 communication error Bypass or No output Output actual power <-800W Bypass

23

LIEBERT

GXT2-10000T230 SERVICE MANUAL

IV. ALIGNMENTS
List below are some test points and procedures when a qualified service person wants to check UPS. TEST ITEM TEST POINT LABEL #+BUS #18 TEST AND ADJUSTMENT SEQUENCE 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) 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) EXPECTED RESULT +360Vdc0.5V @O/P 230Vrms/ +330Vdc0.5V @O/P 208Vrms -360Vdc0.5V @O/P 230Vrms/ -330Vdc0.5V @O/P 208Vrms

+DC Bus Voltage @ Line Mode

-DC Bus Voltage @ Line Mode O/P Voltage @Line mode

LABEL #-BUS #18 O/P

2301Vrms 2081Vrms

24

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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(40/80W

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 cant rotate MAINT. SW. If UPS cant 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 40/80W resistor or more large) (8) Press ON switch to discharge the energy on PSDR PCB. Then, you can start to maintenance safely.

25

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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: DVM Item Checked Components Switch position Q222(G,K) (A,K) DIODE Reference value 8~40 >100K 15.8K 0.36V 8~40 >100K 15.8K 0 Short or open D Short TVS 1.5KE220A BLN 30 250V AC Short or open D Short Short or open Short or open Short TVS 1.5KE220A RHRG75120 SCR 40TPS12 IGBT IRG4PF50W Short or open Short Component Type

Fail condition

SCR 40TPS12 IGBT IRG4PF50W

Q221,225,218 (C,E) (G,E)

3 4

TVS1,2,3 D263 Q223(G,K) (A,K)

Q220,224,219(C,E) (G,E)

TVS4,5,6

FC203,204

Open

26

LIEBERT

GXT2-10000T230 SERVICE MANUAL

(B) DC-DC CONVERTER: (Related Circuit Block: PSDR) DVM Item Checked Components Switch position 1 FC201,202 Reference value 0 8~40 Component Type KLKD30 /600V AC/DC SCR 40TPS12

Fail condition

Open

Q217(G,K) (A,K)

Short or open Short

(C) DC/AC INVERTER: (Related Circuit Block: PSDR) DVM Item Checked Components Switch position Q213,215(C,E) (G,E) D242 Q214,216 (C,E) (G,E) D243 DIODE DIODE Reference value >100K 15.8K 0.38V >100K 15.8K 0.38V Short or open 0U Short or open RHRG75120 Short or open 0U Short or open RHRG75120 IGBT IRGPS40B12 Component Type IGBT IRGPS40B12

Fail condition

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

27

LIEBERT

GXT2-10000T230 SERVICE MANUAL

DVM Item Checked Components Switch position 1 Q03(D,S) DIODE

Reference value 0.47V

Fail condition

Component Type 2SK2611

Short or open

(2) CHARGER PCB: DVM Item Checked Components Switch position 1 F601~602 Q601,613,614 (S,D) (D,S) DIODE DIODE Reference value 0 0.47V Component Type 250VAC/6.3A

Fail condition

Open Short <0.4V No open

2SK2611

(3) I/P SCR PCB: DVM Item Checked Components Switch position 1 F1,F2 Reference value 0 Component Type BLN 30 250V AC

Fail condition

Open

(4) EXT.BAT FUSE PCB: DVM Item Checked Components Switch position 1 F1,F2 Reference value 1 Component Type KLKD30 /600V AC/DC

Fail condition

Open

(5). MOV PCB:

28

LIEBERT

GXT2-10000T230 SERVICE MANUAL

DVM Item Checked Components Switch position 1 2 TC1~9 MOV 1~MOV18

Reference value 0

Fail condition

Component Type 115FUSE 20N471K

Open Short

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) Dont 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. (Dont 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.

29

LIEBERT

GXT2-10000T230 SERVICE MANUAL

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 1,4,6,7,8,9 not connected 3 UPS RS232 receiver RX from computer. 2 5 UPS RS232 transmitter to computer GND

I/O type output Input

30

LIEBERT

GXT2-10000T230 SERVICE MANUAL

TX TX RX RX

2 3 4 5

6 7 8 9

Figure 12. RS232 connection

2. Relay Contacts

31

LIEBERT

GXT2-10000T230 SERVICE MANUAL

32