Professional Documents
Culture Documents
Liebert - gxt2-10000t230 - SERVICE MANUAL PDF
Liebert - gxt2-10000t230 - SERVICE MANUAL PDF
MANUAL
----------------------------
GXT2-10000T230
UNINTERRUPTIBLE
POWER
SYSTEM
LIEBERT
----------------------------
614-XXXXX-00
2006/4/6 Edition
INDEX,
TITLE PAGE
I. 7
II. PRINCIPLE OF 8
III. PCB 11
3. OUTPUT 17
4. CHARGER (CHGR) 17
5. FRONT 17
TITLE PAGE
IV. ALIGNMENTS 22
2
LIEBERT GXT2-10000T230
SERVICE MANUAL
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 TITLE PAGE
2
LIEBERT GXT2-10000T230
SERVICE MANUAL
WARNING
3
LIEBERT GXT2-10000T230
SERVICE MANUAL
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.
4
LIEBERT GXT2-10000T230
SERVICE MANUAL
APPLICABLE MODEL
Model: GXT2-10000T230 (220V/230V/240V 50/60Hz)
PLEASE FOLLOW THE STEPS TO OPEN THE CASE
Figure 1.
5
6
Figure 2. COMPONENTS LOCATION DIAGRAM
7
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.
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.
8
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.
9
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.
12
LIEBERT GXT2-10000T230
SERVICE MANUAL
13
LIEBERT GXT2-10000T230
SERVICE MANUAL
14
LIEBERT GXT2-10000T230
SERVICE MANUAL
15
LIEBERT GXT2-10000T230
SERVICE MANUAL
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.
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.
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.
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".
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.
To protect any BUS over-voltage condition especially for the half-bridge load. The
LCD panel will indicate the fault condition.
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.
4. LCD PANEL
20
LIEBERT GXT2-10000T230
SERVICE MANUAL
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:
21
LIEBERT GXT2-10000T230
SERVICE MANUAL
22
LIEBERT GXT2-10000T230
SERVICE MANUAL
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 EXPECTED
TEST ITEM TEST AND ADJUSTMENT SEQUENCE
POINT RESULT
1.Connect DVM (Set to measure DC) to test point. +360Vdc±0.5V
LABEL 2.I/P Main1& Main2 NFB ON, turn on UPS.
+DC Bus Voltage @O/P 230Vrms/
#+BUS 3.Waiting several seconds to make sure the “ON” LED
@ Line Mode +330Vdc±0.5V
#18 lights. Then Check reading on DVM.
Terminal command for +BUS voltage adjustment @O/P 208Vrms
(0.5V/div): -360Vdc±0.5V
LABEL BUSPS+02 or BUSPS-02( mean +BUS +/-1V)
-DC Bus Voltage @O/P 230Vrms/
#-BUS Terminal command for -BUS voltage adjustment
@ Line Mode -330Vdc±0.5V
#18 (0.5V/div):
BUSNS+02 or BUSNS-02( mean -BUS +/-1V) @O/P 208Vrms
O/P Voltage O/P 1.Connect DVM (Set to measure AC) to Output.
@Line mode 3.Make sure UPS is on Line mode.
Terminal command for output voltage adjustment: 230±1Vrms
V+1 or V-1( mean output voltage +/-1V)
V+2 or V-2( mean output voltage +/-1V) 208±1Vrms
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.
※If UPS can’t turn to bypass, you must turn off the output NFB and input NFB.
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
Reference Component
Item Checked Components Switch Fail condition
value Type
position
8~40Ω
Q222(G,K) SCR
1 Ω Short or open
(A,K) ≒ ∞ 40TPS12
Short
Ω >100KΩ IGBT
Q221,225,218 (C,E)
2 Short or open IRG4PF50W
(G,E) Ω 15.8KΩ
D
TVS
3 TVS1,2,3 Ω ≒ ∞ Short
1.5KE220A
4 D263 DIODE 0.36V Short or open RHRG75120
8~40Ω
Q223(G,K) Short or open SCR
5 Ω
(A,K) ≒ ∞ Short 40TPS12
Ω >100KΩ IGBT
Q220,224,219(C,E)
6 Short or open IRG4PF50W
(G,E) Ω 15.8KΩ
D
TVS
7 TVS4,5,6 Ω ≒ ∞ Short
1.5KE220A
BLN 30
8 FC203,204 Ω 0Ω Open
250V AC
26
LIEBERT GXT2-10000T230
SERVICE MANUAL
Ω 8~40Ω
Q217(G,K) Short or open SCR
2
(A,K) Ω ≒ ∞ Short 40TPS12
Ω >100KΩ IGBT
Q213,215(C,E)
1 Short or open IRGPS40B12
(G,E) Ω 15.8KΩ
0U
2 D242 DIODE 0.38V Short or open RHRG75120
Ω >100KΩ IGBT
Q214,216 (C,E)
3 Short or open IRGPS40B12
(G,E) Ω 15.8KΩ
0U
4 D243 DIODE 0.38V Short or open RHRG75120
27
LIEBERT GXT2-10000T230
SERVICE MANUAL
DVM
Reference Component
Item Checked Components Switch Fail condition
value Type
position
1 Q03(D,S) DIODE 0.47V Short or open 2SK2611
28
LIEBERT GXT2-10000T230
SERVICE MANUAL
DVM
Reference Component
Item Checked Components Switch Fail condition
value Type
position
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.
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
30
LIEBERT GXT2-10000T230
SERVICE MANUAL
1
6
TX TX 2
7
RX RX 3
8
4
9
5
2. Relay Contacts
31
LIEBERT GXT2-10000T230
SERVICE MANUAL
32