SERVICE

MANUAL
----------------------------

GXT2-10000T230
UNINTERRUPTIBLE
POWER
SYSTEM

LIEBERT

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

614-XXXXX-00
2006/4/6 Edition
 INDEX,
TITLE PAGE

 STEPS TO OPEN THE 5

 COMPONENTS 6

I. 7

II. PRINCIPLE OF 8

III. PCB 11

1. POWER
POWER STAGE PSDR
PSDR 11
1 SOFT-START
SOFT-START SUB-SYSTEM------
SUB-SYSTEM-----------------
----------------------
----------------------
-----------------
------ 11
2 CONTROL
CONTROL POWER
POWER SUB-SYSTEM------
SUB-SYSTEM-----------------
----------------------
--------------------
--------- 12
3 INPUT POWER
POWER FACTOR CORRECTION
CORRECTION SUB-SYSTEM-------
SUB-SYSTEM--------- 13
4 BOOSTE
BOOSTER
R 14
5 INVERTER
INVERTER SUB-SYSTEM------
SUB-SYSTEM-----------------
----------------------
----------------------
---------------------
---------- 14

2. MAIN CONTROL
CONTROL PCB ASSEMBLIES CNTL --------------------
---------------------------
------- 15
1 REGULA
REGULATION
TION & CONTROL
CONTROL SUB-SYSTEM---------
SUB-SYSTEM-------------------
----------------
------ 15
2 PROTECTIO
PROTECTION
N SUB-SYSTEM----
SUB-SYSTEM---------------
----------------------
----------------------
------------------
------- 15
 A Over l oad 15
B Batte
Batterr over
over or unde
under shut
shut 16
C Inverte
nverterr out ut abnorma
bnormall 17
D Over
ver tem
tem eratur
raturee 17
E Bus
Bus ove
over-vo
r-volta
lta e 17
3 SIGN
SIGNALING
ALING 17

3. OUTPUT 17
4. CHARGER
CHARGER CHGR
CHGR 17
5. FRONT 17
TITLE PAGE

IV. A L IGNMENTS 22

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SERVICE MANUAL
MANUA L

V. TROUBLE
TROUBL E SHOOTING 23
1. B EFORE FA IL URE DIA GNOSIS 23
2. COMPONENTS 24
1 PSDR
PSDR PCB
PCB 24
 A PFC / BOOSTER 24
B DC-DC
DC-DC CONVER
CONVERTER
TER 25
C DC/AC
DC/AC INVERT
INVERTER
ER 25
E CONTOR
CONTORL
L POWER
POWER SUPPLY
SUPPLY 25
2 CHARGE
CHARGER
R PCB
PCB 26
3 I/P
I/P SCR
SCR PCB
PCB 26
4 FUSE
FUSE PCB
PCB 26
5 MOV
MOV PCB
PCB 26
3.DYNAMIC CHECK 27
VI. APPENDIX I : 28

LIST OF FIGURES
FIGURE TITLE PAGE

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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

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(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 prese nt.
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.

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 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

Figur e 1.

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(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.

Figu re 6. PFC BLOCK DIAGRAM

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(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.

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Figu re 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.

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

DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

KLKD30
1 FC201,202 Ω 0Ω Open
/600V AC/DC

Ω 8~40Ω
Q217(G,K) Short or open SCR
2
(A,K) Ω ≒ ∞ Short 40TPS12

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

DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

Ω >100K Ω 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 >100K Ω 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

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

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DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

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

(2) CHARGER PCB:

DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

1 F601~602 Ω 0Ω Open 250VAC/6.3A

Q601,613,614 (S,D) DIODE 0.47V Short <0.4V

2 2SK2611
(D,S) DIODE ≒ ∞  No open

(3) I/P SCR PCB:

DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

BLN 30
1 F1,F2 Ω 0Ω Open
250V AC

(4) EXT.BAT FUSE PCB:

DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

KLKD30
1 F1,F2 Ω 1Ω Open
/600V AC/DC

(5). MOV PCB:

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DVM
Reference Component
Checked Components Switch Fail condition
value Type
position

1 TC1~9 Ω 0Ω Open 115℃FUSE

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.

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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

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1
6
TX TX 2
7
RX RX 3
8
4
9
5

Figur e 12. RS232 conn ection

2. Relay Contacts

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