Gtec ZP120N TOWER Service Manual
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- User manual (126 pages)
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Summary of Contents for Gtec ZP120N TOWER
- Page 1 GTEC UPS MODEL: ZP120N TOWER 6 K(KS) / 10K(KS) 1ph in / 1ph out SERVICE MANUAL www.gtec-power.eu...
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Page 2: Table Of Contents
CONTENT 1. GENERAL INFORMATION OF THIS DOCUMENT ..............3 1.1 G ........................3 ETTING TART 1.2 C .......................... 3 ONVENTIONS 1.3 I ................... 4 MPORTANT AFETY NSTRUCTIONS 2. CHARACTERISTIC OF THE PRODUCT ..................5 3. CONSTRUCTION OF THE PRODUCT ..................6 3.1 O ...................... -
Page 3: General Information Of This Document
1. General Information Of This Document 1.1 Getting Start This is a service manual for ZP120N 6/10K(s), Tower UPS, intend to help service personal perform maintenance and repair service. If you want to know: ? What is special for this UPS from service point of view; please refer to section characteristic of the product. -
Page 4: Important Safety Instructions
1.3 Important Safety Instructions STOP For qualified service personnel only. DO NOT performs 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 UPS is active. -
Page 5: Characteristic Of The Product
2. Characteristic of The Product For all UPS of this series, they are carefully designed and strictly tested. We always do our best to make our products more reliable and safe. This is also the goal of our company. However, due to the lifetime of electrical components and some unpredictable reasons, there will be unexpected failures may occur to the product. -
Page 6: Construction Of The Product
3. Construction of the Product 3.1 Open The Outside Cover To open the outside cover, please follow steps and figures below: STEP 1: Remove all the screws, including those on the opposite side of the case, refer to Figure 3.1 Fig. -
Page 7: Inside The Chassis
3.2 Inside The Chassis STOP Warning Before any further operation of service, touch any parts inside the chassis. Please make sure all power supply is cut off, either mains utility or DC power from external battery pack, and discharge the possible residue energy from energy storage component such as capacitor. - Page 8 Control board PSDR board I/P EMI board Battery I/P terminal Fig. 3.2.1 6K PSDR side USB&EPO board Dry contact board Bus board Parallel board O/P EMI board 1.4A Charger board O/P RLY board BAT RLY board Maintain Bypass I/P breaker Fig.
- Page 9 Control board PSDR board I/P EMI board Battery I/P terminal Fig. 3.2.310K PSDR side USB&EPO board Dry contact board Bus board O/P EMI board 1.4A Charger board O/P RLY board BAT RLY board Maintain Bypass I/P breaker Fig. 3.2.4 10K Charger side...
- Page 10 4A Charger board Fig. 3.2.4 6KS/10KS Charger side...
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Page 11: The Interconnection Of The Pcbs
3.3 The interconnection of the PCBs Main power wiring Charger Battery BAT Relay Bus Board Board Breaker Maintain Switch INPUT I/P EMI Bus+ I/P_N Bus- Bat+ Bat- Board I/P_L O/P_L O/P EMI Main Power Board Board O/P_N Bypass O/P Relay Board Terminal OUTPUT... -
Page 12: Modules Location
4. Modules Location Below Figures shows location of the main components / modules in the UPS: Fig.4.1 6K PSDR MODULE LOCATION Fig.4.2 10K PSDR MODULE LOCATION... - Page 13 Module Name Part No. Quantity IGBT Driver 710-61813 SCR Driver 710-61805 SPS Module 710-61443 Global Controller 710-03907...
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Page 14: Principle Of Operation
5. Principle of Operation 5.1 Functional Block Of The Product As a true online UPS, the product employ a double conversion topology, comprise following functional blocks, as shown in Figure 5.1.1 Maintain Bypass UPS Output PSDR Internal Bypass Mains Input O/P Relay Breaker I/P EMI... -
Page 15: Operating Principle Of The Major Functional Block
the AC/DC converter and start the DC/DC converter. The controller can detect the interruption of input mains supply in very short time, the output power will be maintained by energy stored in the DC-BUS capacitor, the interruption will never appear on output. The battery charger converse the AC mains input into DC power for recharging the Battery. -
Page 16: Dc/Dc Converter (Battery Booster)
While AC mains is in normal condition, after receiving the turn on command, the input relay RY1 is on I/P_L side and BAT Relay is open, so the AC mains is the input of the converter. The global controller outputs PWM (Pulse Width Modulation) signal, the PWM signal will be isolated, amplified and use to drive switching component, the IGBT. -
Page 17: Global Controller
IGBT gate 6K: Q12 driver 10K: Q1 Q12 Bypass Bus+ SCR gate driver IGBT gate 6K: Q2 driver 10K: Q2 Q13 Output 6K: Q3 IGBT gate 10K: Q3 Q23 Bus- driver 6K: Q24 IGBT gate 10K: Q4 Q24 driver Figure 5.2.3.1 Schematics for inverter The three level half bridge inverter comprise four switching devices - IGBT with co-pack diode, two clamp diodes, the driving circuits for each IGBT, a LC filter. -
Page 18: Standard Charger And Super Charger
The CPU can be regarded as the brains of the UPS, which is in the charge of signal detecting, measurement, processing, timing control, protection, communication. The global controller implements following protection function: 1. Overload Protection 2. Cycle by Cycle Current Limitation 3. -
Page 19: Auxiliary Power Supply (Sps)
Fig. 5.2.5.1 Topology of the standards and supper charger There are two kinds of chargers for standard model UPS and long backup time model UPS. Both operate in the samilar principle, but difference output capacity. The one for standard model UPS is maximum 1.4A charging current. A super charger for long back up time model is maximum 4A charging current. -
Page 20: Ventilation And Chassis
The push button is used to turn on and off the UPS, and do the setting. Fig.5.2.7.1 LCD display panel All UPS information including the input, the output, the battery, the load and the status of UPS are displayed on the LCD screen. The detailed illumination of LCD display can be found in user manual. - Page 21 very important for the UPS, To achieve lowest acoustic noise and longest life time of the fans, a fans driver and intelligent fans speed control algorithm is employed. The chassis of the UPS provide a strong construction accommodate all the electrical parts, shield for EMC, and safety guard for operator.
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Page 22: Trouble Shooting
6. Trouble Shooting Despite of careful design and strict tests, in case UPS become out of order. Basically, designer suggest following service procedure: 1. Check the UPS status and record by LCD panel display, or listen to the end user description 2. - Page 23 Scroll down Press this button for >0.1s&<1s to scroll down the menu option Enter next Press this button for >0.1s&<1s to select the present menu option, or enter menu tree next menu, but do not change any setting Select Press this button for >0.1s&<1s to select the present menu option, or enter menu option next menu, but do not change any setting Confirm the...
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Page 25: How To Start
6. 2 How To Start Trouble shooting start point selection begin Is there any Trouble information Check Can the product with power power up? Visual Inspection Apply Power supply to the UPS Sign of Burn, damage, Can the UPS be contaminate on the turned on? outlet, sockets,... -
Page 26: Primary Diagnosis With Lcd Information
6.3 Primary Diagnosis with LCD Information If the UPS system does not operate correctly, and you could get the failure information on the LCD display, here are some possible causes and remedies in the table below. 6.3.1 Trouble Shooting According To Warning Indication Problem Displayed Possible cause Remedy... -
Page 27: Trouble Shooting According To Fault Indication
Para Work Mode Differ There are different power The UPSs with different power strategy setting in parallel strategy setting (Ex. one Line mode system and one Converter mode) are forbidden to parallel. Para Rate Power Differ There are different UPSs The UPSs with different capacity (Ex. -
Page 28: Trouble Shooting In Else Cases
Bus Unbalance UPS internal fault Consult dealer. Bus short UPS internal fault Consult dealer. Bus Softstart Fail UPS internal fault Consult dealer. Inv Over Voltage UPS internal fault Consult dealer. Inv Under Voltage UPS internal fault Consult dealer. Inv Softstart Fail UPS internal fault Consult dealer. - Page 29 For long backup time model, disconnected UPS from battery cabinet. Open outside case shown in the beginning of this manual. Disconnected internal battery. Discharge energy in BUS capacitors, and Charger capacitors. Disassemble cable from PCB if required. Disassemble PCB if required. Before starting service, some tools are necessary, at least: A DMM (Digital Multifunction Meter) meter, screwdrivers and discharge resistor (300/10W recommended).
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Page 30: Quick Start
6.4.1 Quick Start Before any detail check of 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. Related Circuit Block Components to be checked Component Type Fail condition On I/P EMI board F7, F8... -
Page 31: Ac/Dc And Dc/Dc Converter Analysis
If the fuse is open, replacing fuse only DOES NOT mean you have solved the problem. In most case, open of fuse is caused by other failure of components; therefore, before restart that UPS, you must find the real failed components and replace them! 6.4.2 AC/DC and DC/DC Converter Analysis: In this section, some components you could check to see if failure occurs to PFC Converter. -
Page 32: Bypass Analysis
Item Checked components Instrument Reference Value Failed Condition function D1, D2 Diode Voltage Drop 0.44 Short or open Ω R29, R13, R19, R176 / 10.0/39.0 Short or open or R35, R9, R7, R177 value change 10K: R29, R17, R74, R13, R173, R19, R176, R15 / R35, R5, R162, R9, R174, R7, R177, R10... -
Page 33: Charger Analysis
6.4.6 4A Charger Analysis Item Checked components Instrument function Reference Value Failed condition Ω F1, F2, F3, F4 Open REC1 (~→+)/(-→~) Diode Voltage Droop 0.4V Short or open Q7, Q8, Q3 (S→D) Diode Voltage Droop 0.4V Short or open D2, D35, D41 Diode Voltage Droop 0.45 Short or open... - Page 34 12. If every step is ok, Congratulation, you have finish the maintenance/ repair work. TEST ITEM TEST POINT EXPECTED RESULT +DC Bus Voltage P4 and P1 on Bus board +350VDC to +390VDC -DC Bus Voltage P3 and P1 on Bus board -350VDC to -390VDC 220Vac (or 230Vac, etc O/P voltage...
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