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Gtec ZP120N 10K-31C Service Manual

Tower 10 k va compact model 3ph in / 1ph out
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GTEC UPS MODEL:
ZP120N 10K-31C & ZP120N 10K-31C-KS
(Tower 10 k VA compact model)
3ph in / 1ph out
SERVICE MANUAL
www.gtec-power.eu

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Summary of Contents for Gtec ZP120N 10K-31C

  • Page 1 GTEC UPS MODEL: ZP120N 10K-31C & ZP120N 10K-31C-KS (Tower 10 k VA compact model) 3ph in / 1ph out SERVICE MANUAL www.gtec-power.eu...
  • Page 2 7.1 Parallel Troubleshooting Procedures ......................36 7.2 Single system Troubleshooting Procedures ....................38 7.3 warning ................................39 7.4 Fault ..................................40 7.5 Trouble shooting in else cases ........................42 7.6 Failure Diagnosis ............................... 43 8. Test and Finish............................... 46 9 Appendix ................................... 47 www.gtec-power.eu...
  • Page 3 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 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 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 • 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 • A damaged UPS due to shipping • 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 6. All CSEs are required to use a portable static controlled field service kit when handling static sensitive material. 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 2. System Overview 2.1 System view See Figure 1-1 UPS Front View (left) and back view(right). Figure 1-1 2.2 Single Module Systems The ZP120N-31C 10KVA compact model 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.
  • Page 11 Figure 1-2 2.2.2 Modes of Operation - Single Module The ZP120N-31C 10KVA compact model 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 Line Mode PFC Figure 2-2 Line Mode 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 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 filtering and spike protection is provided to the load, but no active power conditioning or battery support is available to the output of the system in the bypass mode of operation. The internal bypass comprises two relay and a static switch (STS) and a back feed protection equipment.
  • Page 15 • No maintenance can be performed on maintain switch. • Dangerous voltages remain present in the maintain switch terminal. Figure 2-5, maintenance mode 2.3 Parallel Redundant or Capacity. 2.3.1 Multi-Module Parallel Systems See Figure3-1, Parallel systems Figure3-1, Parallel systems N+X is currently the most reliable power supply structure. N represents the minimum UPS number that the total load needs, X represents the redundant UPS number, i.e.
  • Page 16 3. Power Model Functional Descriptions This chapter provides a functional description for the ZP120N-10K-31C 10KVA compact model power train and the printed circuit boards. 3.1 Power Module 3.1.1 Power PCB ZP120N-31C 10KVA compact model include follow PCB and main components 1.PFC: Contains AC/DC&DC/DC converter and necessary sub-circuit for complement and supporting the converter which have been modular,...
  • Page 17 +BUS SCR1 SCR2 -BUS Fig 3.1 PFC 1. PFC up board(710-03995-00P) R phase include L1 HCT1 Current Feedback, Q3 and Q5 SCR (Rectifier) , CN1 SCR DRIVER; Q2 and Q4 IGBT, CN3 CN4 IGBT DRIVER D2and D9 Freewheeling DIODE use for R phase AC/DC and DC/DC. 2.
  • Page 18 ATTENTIONCE: F1、 F2、 F3 : Normal AC (Rectifier) Fuse in EMI board and the F1 、F2on the PFC down board is battery fuse. 3.3 INV board function INV circuit of power module is showed as Fig 3.2. The function of main components is described as below: Fig 3.2（a）INV...
  • Page 19 Fig 3.2（b）driver wave Three level bridge include IGBT Q1 Q5 ，CN1 IGBT driver ；Q2 Q6， CN2 IGBT driver ； Q3 Q7，CN3 IGBT driver； Q4 Q8，CN4 IGBT driver； L1 Converter Inductance HCT1， C53 Converter Capacitors D1 and D2 are freewheeling Diode C11/C27: DC BUS + Capacitors C33/C30: DC BUS –...
  • Page 20 3.4 CHGR board function Charger circuit of power module is showed as Fig 3.3. The utility of charger is to recharge and to maintain the batteries at fully charged condition. It charges the battery with a constant current at initial stage. While the battery voltage keeps increasing, the charging current will decrease accordingly.
  • Page 21 ） 3.5 SPS board function（ Integrated in the PFC UP board 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 output or the battery.
  • Page 22 The global controller also implements following protection function: 1. Overload Protection 2. Cycle by Cycle Current Limitation 3. Battery over or under voltage shut down 4. Inverter output abnormal protection 5. Over temperature protection 6. Bus over-voltage protection 7. Fans lock protection Due to the high level integration, the global controller is not desired to maintenance or repair out of manufacture factory.
  • Page 23 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 24 5 Operation Of UPS 5.1 Display Panel The UPS has a four-button graphical LCD with dual color screens (Blue/Amber). The Blue screen gives white text on LCD display during normal operating. The LCD display will change the text to dark amber and color amber instead of blue on the screen when the UPS has a critical alarm.
  • Page 25 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. 4.
  • Page 26 ● ↑ 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 ↑: Depended on the fault/warning status 5.2 Display functions...
  • Page 27 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 28 3) A few seconds later, the UPS turns into Battery mode (Fig. 4-4). Fig. 4-4 5.4 Turning off the UPS 5.4.1 Turn off the UPS with utility power supplied (in Line mode) 1) To turn off the inverter of UPS by pressing the button continuously for more than 3 seconds and the buzzer will beep for 3s.
  • Page 29 Fig. 4-6 Suggestions: Please turn off the connected loads before turning on the UPS and turn on the loads one by one after the UPS is working in INV mode. Turn off all of the connected loads before turning off the UPS. 5.5 Set up the operation When the UPS is in “Standby Mode”...
  • Page 30 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” (Fig. 4-10). User password <enabled> Fig. 4-10 The submenu of “Settings”...
  • Page 31 Output voltage <220v> Fig. 4-11 2). Press button or button to choose output voltage value. The value can be set as 208V, 220V, 230V or 240V. Press button for longer than1 second, the output voltage value will be saved. The UPS output voltage will follow this value when the UPS turns on at next time. 5.5.1.4 Set up of “Output frequency”...
  • Page 32 2). Press button or button to choose “Audio Alarms” as “< enable >” or “<disable >”. button for longer than1 second to save “Audio Alarms” value. Press 5.5.1.6 Set up of the others submenu items of “Settings” The others submenu items of “Settings” can be set up by the similar method above (4.5.1.3~4.5.1.5).
  • Page 33 button and enter the submenu of “Control” (Fig. 4-15). 2). Press Start System Battery Test Fig. 4-15 The submenu of “Control” includes 8 items: Start System Battery Test, Start Battery Test, Cancel Battery Test, Clear Fault, Clear EPO Active Status, Buzzer Mute, Restore factory settings and Single UPS turn off.
  • Page 34 2). Start Battery Test button to access “Start Battery Test” menu (Fig. 4-17). Press Start Battery Test Fig. 4-17 Press button and LCD displays as Fig. 4-18. Status: Battery test Result unknown Single bat test: No Fig. 4-18 button and the cursor will flash on “No”. Press Press button or button to...
  • Page 35 Fig. 4-20 button and the cursor will flash on “No”. Press Press button or button to choose “Single UPS turn off” as “No” or “Yes”. Choose “Yes” and press button for less than 1 second. The single UPS will be turned off.
  • Page 36 Warning logging Fig. 4-23 button or button, LCD will display “Fault logging”. Press “Warning logging” menu has two submenus (Fig.4-24). Press button or button, LCD will display one of them. Warning # 1/10 Warning # x/10 Battery Low xxxxxxxxxx 0Day 0H 12M 12S xxDay xxH xxM xxS Fig.
  • Page 37 6 POWER UP behavior 6 .1 BYPASS MODE When you close the input switch (4 port)，no matter you connect the batteries or not, output terminal will be applies by the line power, then charger, SPS, CNTL will be work , and at the same time LCD will be light up and the fan work too.
  • Page 38 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 39 3) Turn off the UPS systems that are running. After all of the running UPSs transfer to the Bypass mode, remove the maintenance cover plate of each UPS ,then turn the maintenance switch in the “ON” position, and turn the output switch in the “OFF” position.
  • Page 40 How to remove a single UPS from the parallel system: 1) If you need to remove one UPS of the UPSs parallel system which is on normal running, press the OFF button of the UPS that is confirmed to be removed twice continuously and the UPS will cut off its output immediately.
  • Page 41 2. turn the ups to the maintain mode if necessary, and shutdown system by the procedure, and remember before taking further action, discharge BUS voltage first! (Attention: this mode is not protection, when outage the is happen, load will be drop too.) 3.
  • Page 42 1. Check the battery bank is connected to the The battery bank UPS. Bat Open have not been 2. Check BAT FUSE is ok connected 3. Check the detecting circuit on the PSDR board. The battery different 1. For parallel UPS, any two ups battery connect Bat Differ in the parallel system different...
  • Page 43 1. Check if output is short. INV Soft INV is short 2. Check load is ok! Fail 3. Check the INV board is ok. 1. Check input voltage is normal BUS voltage is voltage 2. Check if the load is inductive or too large. more than 440V over 3.
  • Page 44 1. Check the parallel cable be connected tighten. PARA 2. Check and replace the parallel card. Communic Parallel cable ation abnormal 3. Check wiring in the UPS. LOSS Note 1: At any time, only one normal operating mode or fault mode is presented. Once one fault is come forth, then all previous warnings would not be shown again but only the fault code is presented.
  • Page 45 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 46 Attention: site maintain (for uninterruptable power maintain) must applies the load to the maintain mode first, and than show down the systems. Before starting service, some tools are necessary, at least: A DMM (Digital Multifunction Meter) meter, screwdrivers and discharge resistor (300/10W recommended).
  • Page 47 Related Circuit Components to be Component Fail condition Block checked Type BAT FUSE F1、F2 Fuse Open I/P FUSE F1、 F2、 F3 Fuse Open (on EMI board) Short or open P-N D2,D9,D5,D6,D11,D12 Power Diode (nearly 0.4V) Short or open Q3,Q4,Q5,Q9,Q10 G-E( nearly 25 PFC converter ohm) C-E short or open...
  • Page 48 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 49 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 50 3 Line mode BUS soft start view Fig 9.2 BUS soft start in line mode...

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