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 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
TITLE PAGE

IV. ALIGNMENTS 22

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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

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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 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.

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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

Figure 1.

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6
Figure 2. COMPONENTS LOCATION DIAGRAM

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 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.

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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.

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Figure 3. BLOCK DIAGRAM

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Figure 4. Wiring DIAGRAM

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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.

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(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

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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.

Figure 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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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.

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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.

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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:

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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)

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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

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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 :

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Fault Before fault Condition After fault

UPS mode UPS mode
1. BUS fault Line, 1.Voltage > 450V Bypass
BatteryTest 2.Voltage > 400V
3.+-BUS unbalance over 40V
4.Voltage < 230V
Battery 1.Voltage > 450V No output
2.Voltage > 400V
3.+-BUS unbalance over 40V
4.Voltage < 230V
2. Inverter fault Bypass to 1.soft start fail Bypass
Line
Line, 1.Voltage > 276V
batteryTest 2.Voltage < 140V
Battery 1.Voltage > 276V No output
2.Voltage < 140V
3. Overheat fault Bypass, Line, Temperature over>90 degree C Bypass
BatteryTest
Battery Temperature over>90 degree C No output
4. Battery over Bypass, Line Voltage > 292V Bypass
voltage fault
5. Battery mode, Battery, 1.Load >105% No output
overload fault BatteryTest 2.Load >125%
3.Load >150%
6. Inverter mode, Line, 1.Voltage <50V & Current No output
output BatteryTest >20A
short-circuit
fault Battery 1.Voltage <50V & Current No output
>20A

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7. INV relay short Bypass to before soft start check Bypass

Line inv voltage > 50V
8. Battery fault / Bypass,Line, 1.Voltage < 185 V Bypass,
battery BatteryTest 2.Voltage < 185 V
disconnected Battery 1.Voltage < 185 V No output
2.Voltage < 185 V
Back:
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 Any mode Parallel communication CAN bus No output
) Error loss
12. Communicatio Any mode DSP with H8 communication error Bypass or No
n error output
13. Output failure Line,Battery Output actual power <-800W Bypass

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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

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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.

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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

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

DVM
Reference Component
Item 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
Item Checked Components Switch Fail condition
value Type
position

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

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

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DVM
Reference Component
Item 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
Item 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
Item 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
Item 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
Item 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

Figure 12. RS232 connection

2. Relay Contacts

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