UNINTERRUPTIBLE POWER SYSTEM
SERVICE MANUAL GXT MT+ 10K~20KVA Tower Model
REVISION
DESCRIPTION
Date
Rev. 1.0
Formal Release
2015/8/5
CONTENT 1. GENERAL INFORMATION ......................................................................................................................................... 4 1.1 GETTING START ........................................................................................................................................................ 4 1.2 IMPORTANT SAFETY INSTRUCTIONS .......................................................................................................................... 4 2. ELECTRIC SPECIFICATIONS ................................................................................................................................... 5 3. FUNCTIONAL BLOCK ................................................................................................................................................ 6 4.1 SWITCH POWER SUPPLY........................................................................................................................................... 7 4.2 PFC/BOOSTER ......................................................................................................................................................... 7 4.3 INVERTER.................................................................................................................................................................. 7 4.4 CHARGER ................................................................................................................................................................. 8 4.5 EMI BOARD .............................................................................................................................................................. 8 5. FUNCTION EXPLANATIONS FOR EACH PCB ..................................................................................................... 10 5.1 PFC BOARD (POWER FACTOR CORRECT BOARD)................................................................................................... 10 5.2 INV BOARD (INVERTER BOARD) .............................................................................................................................. 10 5.3 CNTL BOARD (CONTROL BOARD) ........................................................................................................................... 10 5.4 COMM BOARD (COMMUNICATION BOARD) ............................................................................................................. 10 5.5 CHARGER BOARD .................................................................................................................................................... 11 5.6 O/P RELAY BOARD .................................................................................................................................................. 11 5.7 COMMUNICATION BOARD ......................................................................................................................................... 11 5.8 PARALLEL BOARD .................................................................................................................................................... 11 5.9 PANEL BOARD ......................................................................................................................................................... 11 5.10 EMI BOARD........................................................................................................................................................... 11 5.11 MOV BOARD ......................................................................................................................................................... 11 6. INTERFACE ............................................................................................................................................................... 12 6.1 LED DISPLAY.......................................................................................................................................................... 12 6.2 LCD DISPLAY ......................................................................................................................................................... 12 7. TROUBLE SHOOTING ............................................................................................................................................. 14 7.1 LCD PANEL DISPLAY PATTERN DEFINITION ............................................................................................................. 14 7.1.1 Trouble shooting for warning icon in LCD display ............................................................................................ 14 7.1.2 Trouble shooting for fault codes in LCD display ................................................................................................ 16 7.1.3 Trouble shooting ............................................................................................................................................... 17 7.2 REPAIR ................................................................................................................................................................... 17 7.2.1 Basic Instruments and tools .............................................................................................................................. 18 7.2.2 Configuration of the Model pin and Battery number on the Control Board ......................................................... 18 7.2.3 Configuration of the charger current on the charger Board................................................................................ 18 7.2.4 Regulation of the system ................................................................................................................................... 19 7.2.5 Quick Start ....................................................................................................................................................... 20 8.HOW TO START UPS SAFELY AFTER REPAIRING OR REPLACING PSDR BOARD ..................................... 25 8.1 START 10KL AND 20KL UNIT SAFELY....................................................................................................................... 26 8.2.2 Turn on the UPS with DC source ( the charger work as a current limitation DC source).................................. 39 2
8.2.3 Turn on the UPS with utility power ................................................................................................................. 40 9. APPENDIX.................................................................................................................................................................. 41 9.1 REFERENCE WAVEFORM ......................................................................................................................................... 41 9.2 BASIC COMMUNICATION COMMAND .......................................................................................................................... 43 9.2.1 QGS ................................................................................................................................................................. 43 9.2.2 V ............................................................................................................................................................... 44 9.2.3 V± ............................................................................................................................................................. 44 9.2.4 BUSP± ...................................................................................................................................................... 44 9. 2.5 BUSN± ..................................................................................................................................................... 45 9. 2.6 VB± .......................................................................................................................................................... 45 9.2.7 QVFW .............................................................................................................................................................. 45 9.2.8 QWS ................................................................................................................................................................. 45 9.2.9 QFS.................................................................................................................................................................. 46
3
1. General Information 1.1 Getting start This manual is for GXT MT+ 10K~20KVA tower UPS. It can help service person perform the basic maintenance and repair service. This manual only focuses on the service section, so you should get the basic operation of the UPS from the user manual, and make sure you had read and understood the user manual before reading the manual. The manual includes 9 sections: ● General Information, this section shows you the general information of the service manual. ● Electric Specifications, this section shows you the basic electric specification of the UPS. ● Functional block, this section shows you the major functional block of the UPS. ● Working Principle of the Major Functional Block, this section shows you the working principle of the major functional block. ● Function explanations for each PCB, this section explains you all the PCBs of the UPS system. ● Interface, this section shows you the LCD interface, including display and setting. ● Trouble Shooting, this section gives you the way to find the problems. ● Test Step, this section tells you how to test the UPS after you repair the unit. ● Appendix, this section shows you the basic waveforms for reference and the basic communication commands.
1.2 Important Safety Instructions For qualified service person only. DO NOT perform any internal service or adjustment of this product unless the technical person is well trained and experienced. . Dangerous voltage exists at several points in this product. To avoid personal injury, don't touch any exposed connections or components while UPS is on. Turn off the UPS and switch off the input breaker before removing protective case. AC voltage is always present if the input AC power is still available. High voltage may exist at DC capacitors. Before removing the protective case, wait for at least five minutes after turning off the UPS. Verify input source (voltage and frequency) is within the maximum range before service.
4
2. Electric Specifications CAPACITY* INPUT
10000VA / 9000W
110 VAC(L-N) ± 3 % at 50% Load 176 VAC(L-N) ± 3 % at 100% Load Low Line Loss Voltage + 10V 300 VAC(L-N) ± 3 %t 50% Load 276 VAC(L-N) ± 3 % at 100% Load High Line Loss Voltage - 10V 46Hz ~ 54 Hz @ 50Hz system 56Hz ~ 64 Hz @ 60Hz system Three phase with ground ≧ 0.99 at 100% Load
Low Line Loss Low Line Comeback
Voltage Range
High Line Loss High Line Comeback
Frequency Range Phase Power Factor OUTPUT Output voltage AC Voltage Regulation Frequency Range (Synchronized Range) Frequency Range (Batt. Mode) AC mode Overload Battery mode Current Crest Ratio Harmonic Distortion Line Battery Transfer Inverter Bypass Time Inverter ECO EFFICIENCY AC mode Battery Mode BATTERY Type Numbers Long-run Model Charging Current Charging Voltage PHYSICAL Dimension, D X W X H Outline Net Weight (kgs) Dimension, D X W X H Packaging Net Weight (kgs) ENVIRONMENT Operation Temperature Operation Humidity Operation Altitude** Acoustic Noise Level MANAGEMENT Smart RS-232 or USB Optional SNMP
20000VA / 18000W
208/220/230/240VAC ± 1% 46Hz ~ 54 Hz @ 50Hz system 56Hz ~ 64 Hz @ 60Hz system 50 Hz ± 0.1 Hz or 60Hz ± 0.1 Hz 100%~110%: 10min 110%~130%: 1min >130% : 1sec 100%~110%: 30sec 110%~130%: 10sec >130% : 1sec 3:1 max ≦ 2 % @ 100% Linear Load; ≦ 5 % @ 100% Non-linear Load 0 ms 0 ms 92% > 90% Depending on applications 18 - 20 12.0 A ± 10% (max.)
12.0 A ± 10% (max.) 13.65± 1%
592X250X576 30 690X370X670 33
592*250*826 42 700*385*1071 45
0 ~ 40°C (the battery life will down when > 25°C) Program>>Accessory>>Communication>>Hyper terminal” and start Hyper terminal application. Set the COM port for “COM1” and the other setting as Figure 7.1.
Communication protocol setting
Display setting
Figure 7.1 Hyper terminal setting 2. After completing the setting, you can type the command in the command area. 3. +BUS voltage regulation: Type “BUSP+/- XX” command (XX is two digits from 00 to 99). Then press the “ENTER” key, and +BUS voltage will rise (drop) about 0.1V. 4. -BUS voltage regulation: Type “BUSN+/- XX” command (XX is two digits from 00 to 99). Then press the “ENTER” key, and -BUS voltage will rise (drop) about 0.1V. 5. INV output voltage regulation: Type “V+/- XX” command (X is two digit from 00 to 99) Then press the “ENTER” key, and output voltage will rise (drop) about 0.2V. 6. INV output voltage setting: Type “VXXX” command (XXX is 208/220/230/240). Then press the “ENTER” key, and INV output voltage will be set to 208V/220V/230V/240V. Regulation Process for Single UPS 1. BUS voltage regulation: When the UPS run into AC mode, measure ±BUS voltage with the multimeter, and then regulate ±BUS voltages to 370±0.1V by using BUS regulation command. (BUS voltage can be regulated about 0.1V every point by using BUS regulation command). 2. INV output voltage regulation: When the UPS run into the Inverter mode, measure the output voltage with the multimeter, and regulate the output voltage to 230±0.2V by using output voltage regulation command. (INV output voltage can be regulated about 0.2V every point by using output voltage regulation command). Notes: 19
1. 2. 3. 4. 5. 6.
Make sure the ground of the UPS connects to earth safely during parameter regulation. New assembly UPS must be regulated. UPS which have been replaced CNTL/PFC/INV must be regulated again. All the commands use capital letters. All the above parameter regulation cannot be accumulated. All the regulation will be saved in the flash memory of the CNTL when UPS shutdown with battery connected. 7.2.5 Quick Start Before any detail check for UPS, please check the components listed in the following table. This action could help you find problem quickly and make debug procedures go smoothly. Note: Make sure that the capacitor voltage is lower than the safety voltage before disassembling any parts to do checking procedure. 10k R-PFC&INV Section Circuit Block
Checked components
Component Type
Failure condition
DC FUSE
F4
Fuse
Open
AC FUSE
F2
Fuse
Open
Rectifier
Q17, Q18, Q21
SCR
A-K Short or open
D33, D35, D34, D36
Diode
Short or open
Q24, Q25
IGBT
C-E short or open
D15, D16, D17, D18
Diode
Short or open
Q7, Q8, Q9, Q10
IGBT
C-E short or open
Q13, Q14, Q20, Q31
SCR
A-K Short or open
F6
Fuse
Open
Q6, Q44
MOSFET
D-S short or open
D3, D4, D5, D6, D7, D8, D21
Power Diode
Short or open
U2, U3, U4, U5
Power IC
I-O short or open
U1
Power Control IC
Vcc short to GND
Q1, Q2, Q11, Q12, Q29, Q30, Q32, Q43
MOSFET
D-S short or open
R-PFC
INV STS
SPS
Others
10k S&T PFC Section Circuit Block
Checked components
Component Type
Failure condition
DC FUSE
F4,F5,F6,F7,F8
Fuse
Open
AC FUSE
F2,F3
Fuse
Open
Rectifier
Q24,Q25,Q26,Q44,Q45,Q46,Q49,Q58,Q59
SCR
A-K Short or open
D43,D44,D45,D49, D52, D53,D54,D58
Diode
Short or open
Q32, Q52,Q43,Q55
IGBT
C-E short or open
Component Type
Failure condition
SCR
A-K Short or open
Diode
Short or open
IGBT
C-E short or open
PFC
15k/20k PFC Section Circuit Block Rectifier
Checked components Q17,Q18,Q21,Q27,Q24,Q25,Q26,Q49,Q44,Q45, Q46,Q58 D33, D35, D34, D36,D45,D43,D49,D44,D54,D52
PFC
D53,D58, Q22, Q23,Q59,Q60,Q32,Q43,Q61,Q62,Q57,Q52 Q63,Q64
20k INV Section 20
Circuit Block INV
Checked components
Component Type
Failure condition
D17, D18,D34,D32
Diode
Short or open
Q8,Q9,Q10,Q11,Q45,Q46,Q42,Q43
IGBT
C-E short or open G-K short or open（for normal condition，A-K
Q13, Q14, Q17, Q18
BYPASS SCR is 0ohm，G-K is around 40 ohm ） G-K short or open or
STS
A-K
is
short
（ for
normal condition，A-K Q19, Q20, Q21, Q22
ECO SCR is around 440K ohm， G-K
is
around
40
ohm ）
SPS
Others
F6
Fuse
Open
Q6, U14,U15
MOSFET
D-S short or open
D3, D4, D5, D6, D7, D8,D9
Power Diode
Short or open
U5, U6, U9, U13
Power IC
I-O short or open
U11
Power Control IC
Vcc short to GND
MOSFET
D-S short or open
Q16, Q52, Q12, Q31,Q33,Q30,Q32, Q34 Q3,Q4,Q1,Q2,Q5,Q6
4A Charger Section Circuit Block
Checked components
Component Type
Failure condition
DC FUSE
F2, F3, F4
Fuse
Open
AC FUSE
F1
Fuse
Open
REC1, REC2
Rectifier Bridge
Short or open
Power
D3, D4, D5, D7, D8
Diode
Short or open
Semiconductor
Q8, Q14
MOSFET
D-S short or open
U10
Power IC
I-O short or open
Q11
MOSFET
D-S short or open
Q15, Q16, Q7, Q10
Transistor
C-E short or open
U1
Power Control IC
Vcc short to GND
Others
Note: If the fuse is in “open” status, don’t replace the fuse only. In most of cases, open fuse is caused by other failed components. Therefore, before restarting the UPS, you must find all failed components and replace them. 21
7.2.5.1 Major parameters of Rectifier and PFC section The most likely problems occur on the Rectifier and PFC section including: open fuse, broken IGBT, broken Diode, broken SCR, and broken IGBT/SCR driver resistor. When checking PFC section, directly check the IGBT with Resistance probe or the Diode Voltage Droop probe with multimeter. 10K S&T PFC Section Reference
Failed
Value
condition
Resistance
< 0.5 Ω
Open
(A, K)
Resistance
6MΩ
Short
(G, K)
Resistance
33Ω
Short
(A, K)
Resistance
10MΩ
Short
(G, K)
Resistance
33Ω
Short
Resistance
39Ω
Value change
(E, C)
Diode Voltage Droop
0.38V
Short or open
(E, G)
Diode Voltage Droop
1.4V
Short or open
(G, E)
Resistance
47.5KΩ
Short or open
Diode Voltage Droop
0.61V
Short or open
R210,R197,R122,R129
Resistance
10Ω
Infinite or value
R164,R163,R222,R198
Resistance
2.2Ω
change
D45,D43,D52,D54
Diode Voltage Droop
0.38V
Short or open
D49,D44,D53,D58
Diode Voltage Droop
0.38V
Short or open
D68,D69,D62,D67
Diode Voltage Droop
0.38V
Short or open
Diode Voltage Droop
0.53V
Short or open
Reference
Failed
Value
condition
Checked components
Instrument function
F2, F3, F4,F5,F6,F7,F8 Q24,Q25, Q44,Q45
Q26,Q46,Q49,Q58,Q59
R181, R178, R185,R205,R229,R226,R233,R248
Q32,Q43,Q52,Q57
D30, D31,D60,D61 (need be removed from PCB)
TVS7, TVS8, TVS9, TVS10, TVS11, TVS12 TVS13, TVS14, TVS15, TVS16, TVS17, TVS18
20K PFC Section Checked components
Instrument function (A, K)
Resistance
6MΩ
Short
(G, K)
Resistance
33Ω
Short
(A, K)
Resistance
10MΩ
Short
(G, K)
Resistance
33Ω
Short
Resistance
39Ω
Value change
(E, C)
Diode Voltage Droop
0.38V
Short or open
(E, G)
Diode Voltage Droop
1.4V
Short or open
(G, E)
Resistance
25.5KΩ
Short or open
Resistance
2.2Ω
D33, D35,D43,D45,D52,D54
Diode Voltage Droop
0.38V
Short or open
D34, D36,D44,D49,D53,D58
Diode Voltage Droop
0.38V
Short or open
D69,D70,D71,D72,D73,D74
Diode Voltage Droop
0.38V
Short or open
Q17, Q18, Q24,Q25,Q44,Q45
Q21,Q27, Q26,Q49, Q46,Q58
R102, R105, R116,R158,R181,R178 R185, R205, R226,R229,R233,R248 Q22,Q23,Q59,Q60,Q32,Q43, Q61,Q62,Q57,Q52,Q63,Q64
R118, R120, R122, R129,R197,R210, R251, R254, R258, R260,R264,R275
22
Infinite or value change
TVS1, TVS2, TVS3, TVS4, TVS5, TVS6 TVS7, TVS8, TVS9, TVS10, TVS11, TVS12
Diode Voltage Droop
Short or open
0.53V
TVS13, TVS14, TVS15, TVS16, TVS17, TVS18
Note: If IGBT/SCR is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. 7.2.5.2 Major parameters of Inverter and STS section The most likely problems occur on the INV section including broken IGBT, broken Diode, broken SCR, damaged IGBT/SCR driver resistor, damaged relative snubber circuit with broken IGBT/SCR, and stuck output relay. 10K R-PFC&INV Section Checked components
Instrument function
Reference Value
Failed Condition
F2, F4
Resistance
< 0.5 Ω
Open
(A, K)
Resistance
6MΩ
(G, K)
Resistance
33Ω
(A, K)
Resistance
10MΩ
(G, K)
Resistance
33Ω
Resistance
39Ω
Value change
(E, C)
Diode Voltage Droop
0.38V
(E, G)
Diode Voltage Droop
1.4V
(G, E)
Resistance
47.5KΩ
Diode Voltage Droop
0.61V
Short or open
R122, R126
Resistance
10Ω
R159, R163
Resistance
2.2Ω
D33, D35
Diode Voltage Droop
0.38V
Short or open
D34, D36
Diode Voltage Droop
0.38V
Short or open
D49, D50
Diode Voltage Droop
0.38V
Short or open
Diode Voltage Droop
0.53V
Short or open
(E, C)
Diode Voltage Droop
0.38V
Short or open
(E, G)
Diode Voltage Droop
1.4V
Short or open
(G, E)
Resistance
25.5KΩ
Short or open
Diode Voltage Droop
0.61V
Short or open
Q17, Q18,
Q19 R103, R111, R116
Q24, Q25
D29, D30 (need be removed from PCB)
TVS1, TVS2, TVS3, TVS4, TVS5, TVS6
Q7, Q8, Q9, Q10
D22, D23, D24, D25 (need be removed from PCB) R45, R46, R52, R53
Resistance
R47, R48, R54, R55
Resistance
22Ω for 40N120 IGBT 10Ω for 40B120U IGBT 62Ω for 40N120 IGBT 36Ω for 40B120U IGBT
Infinite or value change
Infinite or value change
Infinite or value change Short or open
D15, D16
Diode Voltage Droop
0.38V
Not install when use 40N120 IGBT
Diode Voltage Droop
0.38V
Short or open
(A, K)
Resistance
0(Short by the INV.RLY)
---
(G, K)
Resistance
33Ω
Short
D17, D18 Q13, Q14
23
Q20, Q31
(A, K)
Resistance
6MΩ
Short
(G, K)
Resistance
33Ω
Short
20K INV Section Checked components Q9, Q10,Q11,Q12, Q42,Q43,Q45,Q46
Instrument function
Reference Value
Failed Condition
(E, C)
Diode Voltage Droop
0.38V
Short or open
(E, G)
Diode Voltage Droop
1.4V
Short or open
(G, E)
Resistance
25.5KΩ
Short or open
Diode Voltage Droop
0.61V
Short or open
Resistance
22Ω
Infinite or value change
Resistance
62Ω
Infinite or value change
Diode Voltage Droop
0.38V
Short or open
(A, K)
Resistance
0(Short by the INV.RLY)
----
(G, K)
Resistance
33Ω
Short
(A, K)
Resistance
6MΩ
Short
(G, K)
Resistance
33Ω
Short
D22, D23, D24, D25 D26,.D27,.D28,.D31 (need be removed from PCB) R45, R46, R52, R53, R131,R137,R124,R127 R47, R48, R54, R55 R125,R130,R123,R129 D17, D18,D32,D34 Q13, Q14,Q17,Q18
Q19,Q20,Q21,Q22
Note: If IGBT/SCR is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. 7.2.5.3 Major parameters of SPS section The most likely problems occur on the SPS section including open fuse, broken MOSFET, broken Diode, damaged relative driver resistor with broken MOSFET. 10K SPS Section Checked components
Instrument function
Reference Value
Failed Condition
F6
Resistance
< 0.5 Ω
Open
(S, D)
Diode Voltage Droop
0.53V
Short or open
(S, G)
Diode Voltage Droop
0.68V
Short or open
(G, S)
Resistance
47.5KΩ
Short or open
R25
Resistance
47Ω
Infinite or value change
D3, D4, D5, D6, D7, D8, D21
Diode Voltage Droop
0.53V
Short or open
(D, S)
Resistance
282KΩ
Short
(G, S)
Resistance
1KΩ
Short
U2, U3, U4, U5
Diode Voltage Droop
0.6V
Short
U1
Resistance
76.4KΩ
Short
Q6
Q44
20K SPS Section Checked components
Instrument function
Reference Value
Failed Condition
F6
Resistance
< 0.5 Ω
Open
(S, D)
Diode Voltage Droop
0.53V
Short or open
(S, G)
Diode Voltage Droop
0.68V
Short or open
Q6
24
(G, S)
Resistance
47.5KΩ
Short or open
R25
Resistance
47Ω
Infinite or value change
D4, D5, D6, D7, D8, D9
Diode Voltage Droop
0.53V
Short or open
(D, S)
Resistance
282KΩ
Short
(G, S)
Resistance
500Ω
Short
U5, U6, U9, U13
Diode Voltage Droop
0.6V
Short
U11
Resistance
76.4KΩ
Short
U14,U15
7.2.5.4 Major parameters of 4A Charger The most likely problems occur on the Charger section including open fuse, broken MOSFET, broken Diode, damaged relative driver resistor with broken MOSFET. Checked components
Instrument function
Reference Value
Failed condition
F1.F2.F3.F4
Resistance
