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Gtec ZP120N Service Manual

20 k 3ph in / 1ph out
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GTEC UPS MODEL:
ZP120N 20 K
3ph in / 1ph out
SERVICE MANUAL
www.gtec-power.eu

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  • Page 1 GTEC UPS MODEL: ZP120N 20 K 3ph in / 1ph out SERVICE MANUAL www.gtec-power.eu...

  • Page 2: Table Of Contents

    1. Safety ..................................1 1.1 General Safety Considerations ......................... 1 1.2 Environmental Safety............................1 1.3 Electrical Safety ..............................2 1.4 Mechanical Safety ............................... 3 1.5 Eye Safety ................................3 1.6 UPS Safety ................................3 1.7 Site Safety ................................5 1.8 Summary ................................6 1.9 Electrostatic Discharge (ESD) Procedure and Equipment Requirements ..........

  • Page 3: Safety

    1. Safety 1.1 General Safety Considerations 1.1.1 Tools, Equipment, and Expendable Field Service Supplies. When performing service equipment, the following rules must be observed. These rules pertain to tools, testers, solvents, adhesives, and lubricants. • Ensure that electrical hand tools, such as power drills, are inspected regularly •...

  • Page 4: Electrical Safety

    11. Place removed UPS covers in a safe place while servicing the UPS. Reinstall the covers before returning the UPS to the customer. 12. Reinstall all safety devices, such as guards, shields, and ground wires. Replace worn or defective safety devices. Remember the safety devices protect personnel from a hazard.

  • Page 5: Mechanical Safety

    Do not touch live electric circuits with the surface of a dental mirror. The handle of the mirror is conductive and can cause equipment damage and/or personal injury. If an electrical accident occurs: • Use caution; do not become a victim. Switch off the power. •...
  • Page 6 4. Operating environment should be within parameters listed in the Installation & Operation Manual(s). 1.6.2 Normal Operation 1. Keep equipment doors closed to ensure proper cooling air flow, and to protect from dangerous voltages within the unit. 2. Ensure all conduit knockouts and/or unnecessary openings are sealed. 3.

  • Page 7: Site Safety

    • Contact with skin: – Wash immediately with soap and water – Contact a physician if any burn results • If acid splashes in eyes: – Wash for 20 minutes under running water –Contact a physician 1.7 Site Safety UPS personnel are aware of the presence of potentially lethal voltages within the UPS. Observe the following precautions to ensure personnel safety and continued equipment operation.

  • Page 8: Summary

    • An unsafe change or attachment installed in the UPS • An engineering change or a sales change installed incorrectly • A defective part • Potentially unsafe UPS because the unit is old or operated in an extreme environment 1.8 Summary Prevention is the key to electrical safety.
  • Page 9 1.9.2 Packaging of Boards NOTICE Note:Packaging of boards, unless otherwise specified, will be packaged in egg-crate type cartons, separating each board with partitions.

  • Page 10: System Overview

    Figure 1-1 2.2 Single Module Systems The ZP120N 20kva is a true online, continuous-duty, transformer less, double-conversion, solid-state, three-one phase systems that provide conditioned and uninterruptible AC power to the UPS system output protecting the customer’s load from power problems. The UPS module may be configured for stand alone operation or multi-module (parallel redundant “PR”...
  • Page 11 Figure 1-2 2.2.2 Modes of Operation - Single Module The ZP120N 20KVA will support a critical load in three different modes of operation: Normal mode, Battery mode, and Bypass mode. The UPS can automatically use all three modes, as required, without operator intervention. Sophisticated detection and control logic is used to ensure any change in operating mode is automatic and transparent to the load while internal monitoring systems indicate the current mode of operation.
  • Page 12 Figure 2-1 PFC Figure 2-2 INV 2.2.4 Battery Mode See Figure 2-3, Battery Mode. The UPS automatically transitions to Battery mode during a utility power failure or if the input power to the rectifier is out of specifications (refer to input specifications). During a utility power failure, the rectifier no longer has an AC utility source to supply the DC output power required to support the inverter.
  • Page 13 minute adjustments to maintain a regulated output. The UPS will remain in this Operating mode until the input power to the rectifier is again within specifications (refer to input specifications). If the input power fails to return or is not within specification for normal operation, the battery will continue discharging until a DC voltage level is reached where the inverter output can no longer support the connected loads.
  • Page 14 2.2.5 Bypass Mode See Figure 2-4, Bypass Mode. In Bypass Mode, the output of the system is provided with single-phase AC power directly from the system input. While in this mode, the output of the system is not protected from voltage or frequency fluctuations or power outages from the source.

  • Page 15: Parallel Redundant Or Capacity

    2.2.6 Maintain switch mode The CSE has the ability to put the load in the bypass, and than change the load to maintain switch，after you change the load to the maintain switch，CSE can shut down the UPS without interruptible the load。Figure 2-5, maintenance mode. This procedure is make-before-break to ensure the customer’s load remains supported.
  • Page 16 The ZP120N 20KVA can also be configured for either Parallel Redundant or Parallel Capacity operation; Just use the parallel line, the output of one UPS can be tied together with the output of other UPS to support a common output. UPS configured in this manner are considered to be part of a “parallel system.”...
  • Page 17 ZP120N Parallel Systems (Redundant and Capacity) will support a critical load in three different modes of operation: Normal mode, Battery mode, and Bypass mode. The system automatically uses all three modes, as required, without operator intervention.
  • Page 18 2.3.6 BYPASS Mode - Parallel In Bypass mode, the output of the system is provided with single-phase AC power directly from the bypass input. The output of the system is not protected from fluctuations, spikes, or power outages from the source. No power filtering, conditioning, or battery support is available to the output of the system in the Bypass mode of operation.

  • Page 19: Power Model Functional Descriptions

    3. Power Model Functional Descriptions This chapter provides a functional description for the ZP120N 20kVA power train and the printed circuit boards. 3.1 Power Module 3.1.1 Power PCB ZP120N 20kVA include follow PCB and main components 1.PFC: Contains AC/DC&DC/DC converter and necessary sub-circuit for...

  • Page 20: Pfc Board Function

    3.2 PFC board function PFC circuit of power module is showed as Fig 3.1. The function of main components is described as below: +BUS SCR1 SCR2 -BUS Fig 3.1（a） PFC Fig 3.1(b) Drive 1. PFC up board R phase include L1 HCT1 Current Feedback, Q3 and Q4 SCR (Rectifier) , CN1 SCR DRIVER;...

  • Page 21: Inv Board Function

    this we add a DC/DC PFC after rectifier and correct the input current as a sine wave to make the input power factor is close to 1.As shown in the Fig 3.1 diagram, when the IGBT is on and the DIODE is off, the CHOKE will store energy and the current crossing the choke will increase gradually.
  • Page 22 Fig 3.2（a）INV Fig 3.2（b）driver wave Fig 3.2 （c）part of driver Three level bridge include IGBT Q1 Q5 and Q9 CN1 IGBT driver Q2 Q6 and Q10 CN2 IGBT driver Q3 Q7 and Q11 CN3 IGBT driver Q4 Q8 and Q12 CN4 IGBT driver L1 L2 Converter Inductance HCT1 HCT2 C1 C52 C36 C53 Converter Capacitors D1 D17 and D2 D18 are freewheeling Diode C28/C35/C29/C11/C27: DC BUS + Capacitors...

  • Page 23: Chgr Board Function

    level half bridge inverter comprise four switching device, IGBT, a free wheel diode parallel with each IGBT, two clamp diodes, forming a switching leg, a driving circuit for each IGBT, a LC filter, and the driver. In the real circuit, an IGBT with co-pack diode is used to simplify circuit and achieve minimize stray parameter, When the two positive IGBT is turned on, The output of half bridge is equal to Positive DC-BUS voltage, when the first positive IGBT is turned off and the second positive IGBT is turned on, either the positive clamp diode is...

  • Page 24: Sps Board Function

    负 载 Fig 3.3 3.5 SPS board function SPS circuit of power module is showed as Fig 3.4. The function of main components is described as below: Fig 3.4 The Power Supply (SPS) module supplies DC power for UPS operation. The input of the SPS is the charger input or the battery.

  • Page 25: General Connection Views

    To control the UPS, the status of the UPS must be monitored, Difference kinds of sensor are widely used in the UPS, due the pure condition of the signal given by the sensors, so, Signal conditioning circuit is use to attenuate / amplify / filter the signal given by the sensor, so that it is suitable to be processed by the DSP.
  • Page 26 3.7.2 Signal connection views Signal connection views...

  • Page 27: Periphery Systems

    4. Periphery systems 4.1 Front Panel The front panel consists 2 parts: push button and LCD indicator. The push button is used to turn on and off and control the UPS. When UPS is out of order, the LCD will display fault or warning information and the buzzer will beep continuously.

  • Page 28: Operation Of Ups

    5 Operation Of UPS 5.1 Display Panel The UPS has a four-button graphical LCD with dual color backlight. Standard back-light is used to light up the display with white text and a blue background. When the UPS has a critical alarm, the backlight changes the text to dark amber and the background to amber.
  • Page 29 than one second To select an option: 1. When scrolling through the settings, the present setting displays for each selection. 2. Press and release the button to select the option. The current setting for the option flashes when selected 3. Use the buttons to select the available options.

  • Page 30: Display Functions

    ○ ○ ○ ○ Battest mode ● ↑ Fault mode ★ ↑ ↑ ↑ Warning ○ ○ ○ ○ UPS turning on (circulating until turn on OK) △ △ △ △ UPS change setting (circulating only once) Note： ●: Lightened constantly ○: #1-#4Lightened circularly △: #1-#4 Lightened circularly only once ★: Flashing...

  • Page 31: Turning On The Ups

    The UPS status provides separate screens for the following information: ⚫ Status summary, including mode and load ⚫ Notice or alarm status, if any are present ⚫ Battery status, including status and charge level See Table 2 for examples of the UPS status summary screens. The status icon in the middle of each status summary screen conveys the UPS status or mode.

  • Page 32: Turning Off The Ups

    5.3.2. Turn on the UPS with no utility power supplied (in Battery mode) 1) Check the breaker of the battery pack is in “ON” position (this step only for long backup time model). 2) Press button continuously for more than 1 second to power on the UPS, and the buzzer will beep for 1s, UPS starts to turn on.

  • Page 33: Set Up The Operation

    5.4.2 Turn off the UPS with no utility power supplied (in Battery mode) 1) To power off the UPS by pressing the button continuously for more than 3 second, and the buzzer will beep once. 2) When being powered off, the UPS will turn into Standby mode (Fig. 4-6). Finally not any display is shown on the display panel and no voltage is available from the UPS output.

  • Page 34: User Password

    button and choose “Settings” (Fig. 4-8). 2). Press Settings Fig. 4-8 3). Press button and LCD displays as Fig. 4-9. Enter the user password（default value is “AAAA”） Password: **** Fig. 4-9 4). After entering the password, press button. LCD will display the submenu of “Settings”...

  • Page 35: Output Voltage

    5.5.1.2 User password After you access the “Settings” submenu, LCD displays as Fig. 4-10. The value of “User password” will be “<enabled>” or “<disabled>”. And “<enabled>” means you can change the values of “Settings” submenu items. “<disabled>” means you can’t. It depends on whether you have entered the right password and the UPS status (we are not allowed to change the values of “Settings”...

  • Page 36: Audio Alarms

    value will be saved. The UPS output frequency will follow this value when the UPS turns on at next time. 5.5.1.5 Set up of “Audio Alarms” button to choose “Audio Alarms” (Fig. 4-13). Press 1). Press button or and the cursor will flash on “< enable >”. button Audio Alarms <enable>...
  • Page 37 LCD contrast -5~+5 5.5.2 Set up of “Control” 1). The main menu includes 6 items: UPS Status, Event Log, Measurements, Control, Identification, and Settings. button to choose “Control” (Fig. 4-14). Press button or Control Fig. 4-14 button and enter the submenu of “Control” (Fig. 4-15). 2).

  • Page 38: Start Battery Test

    1). Start System Battery Test The first item of the submenu of “Control” is Start System Battery Test (Fig. 4-15). Press button and LCD displays as Fig. 4-16. Status: Battery test Result unknown System bat test: No Fig. 4-16 button and the cursor will flash on “No”. Press Press button or button...
  • Page 39 choose “Single bat test” as “No” or “Yes”. Choose “Yes” and press button for less than 1 second. The Single Battery Test will start. The UPS self’s battery will be checked. 5.5.2.2 Single UPS turn off. In the UPS parallel system, single UPS can be turned off by this menu. button to access “Single UPS turn off”...
  • Page 40 Fig. 4-21 5.5.4 Submenus of “Measurements” Enter the “Measurements” menu, press button, LCD displays as Fig. 4-22. Output 850W 1130VA Fig. 4-22 The “Measurements” menu includes 8 submenu items: output power, output current, output voltage, input voltage, bypass, battery, DC bus and temperature. Press button button, LCD will display one item.
  • Page 41 Fig. 4-24 “Fault logging” menu also has two submenus (Fig.4-25). Press button or button, LCD will display one of them. Fault # 1/5 code: 15 Fault # x/5 code: xx Over temperature xxxxxxxxxx 0Day 0H 12M 12S xxDay xxH xxM xxS Fig.

  • Page 42: Power Up Behavior

    6 POWER UP behavior 6 .1 BYPASS MODE When you close the bypass switch (M2), no matter you connect the batteries or not, output terminal will be applies by M2 power, than charger, SPS, CNTL will be work , and at the same time LCD will be light up and the fan work too.

  • Page 43: Troubleshooting And Maintenance

    7 Troubleshooting and Maintenance 7.1 Parallel Troubleshooting Procedures How to install a new parallel UPS system: 1) Before installing a new parallel UPS system, user need to prepare the input and output wires, the output breaker, and the parallel cable. 2) Turn off the input breaker and output breaker, Remove the front panel and open the battery pack DC connectors each UPS.
  • Page 44 How to join a new UPS: 1) Before joining a new UPS, user need to prepare the input and output wires, the output breaker, and the parallel cable. 2) Turn off the input breaker and output breaker, Remove the front panel and open the battery pack DC connectors of the new unit.

  • Page 45: Combine Machine Warning

    parallel kit are normal. 12) Turn off each UPS in turn and after all of them transfer to the Bypass mode, remove the maintenance cover plate of each UPS and set the maintenance switch from “BPS” to “UPS” and screw the maintenance cover plate back again. 13) Turn on the UPSs in the Line mode to perform the parallel operation.

  • Page 46: Single System Troubleshooting Procedures

    output breaker must at the “OFF” position. 3) When UPS combine system work at inverter model, please do not operate any UPS maintain switch. 7.2 Single system Troubleshooting Procedures Despite of careful design and strict tests, in case UPS become out of order. Basically, designer suggest following service procedure: 1.
  • Page 47 1. Check the fan is connection and running. 2. Check the fan is ok! Fan Lock Fan abnormal 3. Check and replace the fan driver module on SPS. 1. Check the EPO jumper is connection. EPO function is Epo Active 2.

  • Page 48: Fault

    1. The battery capacity is low, and the UPS would Battery The battery voltage is shut down soon. The battery should be recharged. ModelNo 1. Check the Model pin set is right Model pin set wrong Fail Note 1: When the UPS warning, the UPS is still working on the original mode with the original display.
  • Page 49 1. Check whether the UPS is overloaded, the air vents are blocked, and the ambient temperature is over 45℃. Over Internal over 2. Check fan is ok. Temp. temperature 3. still fault after without load? 4. Check the NTC and the thermal detecting circuit. 1.

  • Page 50: Trouble Shooting In Else Cases

    7.5 Trouble shooting in else cases Problem Possible cause Action Keep UPS connected to utility power Battery not yet persistently for more than 10 hours to been fully recharge the batteries. charged. Battery Check the loads and remove some discharging time UPS overloaded.

  • Page 51: Failure Diagnosis

    7.6 Failure Diagnosis 7.6.1 Failure checks procedure. Fig 7.6.1 General Guidance to start a trouble shooting process In this section, some debug skills are listed to help you finding the failure components and problems as soon as possible. Before continuing the following steps listed, we suggest that you should read problem shooting chart in previous section then check the components listed in Quick Start to find out which block is out of order, in order to shorten the service time.
  • Page 52 For the reason of safety, please follow safety instruction to begin your work STOP High Voltage Danger: Some components contain residue charge and remain dangerous high voltage even if the external power supply is cut off, operator should follow following instruction strictly avoid risk of electrical shock. 1.Unplug the power cord from the utility.
  • Page 53 Quick Check...
  • Page 54 Related Circuit Components to be Component Fail condition Block checked Type BAT FUSE Fuse Open I/P FUSE F1 F2 F3 Fuse Open (on EMI board) Short or open P-N D1,D7,D5,D6,D11,D12 Power Diode (nearly 0.4V) Short open Q3,Q4,Q9,Q10 G-E( nearly PFC converter ohm) C-E short or open nearly...

  • Page 55: Test And Finish

    8. Test and Finish After replace all defected components on power stage (PSDR), following test the steps can be adopted to verify the repair result and the reliability of the UPS. Connect all of boards, cable, and connector right to place. Check the Wiring.

  • Page 56: Appendix

    9 Appendix 1 Tab TEST TEST POINT TEST AND ADJUSTMENT SEQUENCE EXPECTED ITEM RESULT +/-DC Bus Anode and Cathode of 1. Connect DVM (Set to measure DC) to +360VDC Voltage @ the +BUS test point. Backup Anode and Cathode of 2.
  • Page 57 3 Model Pin Configurations To detection and control difference model of UPS, The controller need correct model pin configuration for recognizing the UPS model. The MODEL PORT on the CCB board should be configured as follows： Note：“1” indicates that the jumper is connected; “0”indicates that nothing is connected;...
  • Page 58 5 Bat mode BUS soft start view Fig 9.3 BUS soft start in Bat mode...

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