GXT2 U700 To 1 K 5 Service Liebert

UNINTERRUPTIBLE POWER SYSTEM
SERVICE MANUAL
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Liebert UPStation GXT2-700/1000/1500RT-230

SERIES
Liebert Hiross
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LIEBERT UPStation GXT2 700VA, 1KVA, 1.5KVA/230V
SERVICE MANUAL
I. INTRODUCTION 4
II. PRINCIPLE OF OPERATION 5
1. INTRODUCTION 5
III. POWER STAGE (PSDR) 6
i. CHARGER SUB-SYSTEM: 6
ii. DC POWER SUPPLY SUB-SYSTEM: 6
iii. INVERTER SUB-SYSTEM : 6
iv. OUTPUT SUB-SYSTEM : 6
v. INPUT POWER FACTOR CORRECTION SUB-SYSTEM : 7
vi. DC-DC CONVERTER SUB-SYSTEM : 7
1. MAIN CONTROL PCB ASSEMBLIES (CNTL) 8
i. REGULATION & CONTROL SUB-SYSTEM : 8
ii. PROTECTION SUB-SYSTEM : 8
iii. SIGNALING SUB-SYSTEM : 10
2. FRONT PANEL : 11
IV. ALIGNMENTS 12
V. TROUBLE SHOOTING 13
1. OVERVIEW : 13
2. U.P.F. CORRECTION: 14
3. PUSH-PULL DC-DC CONVERTER: 14
4. DC/AC INVERTER: 14
5. DC POWER SUPPLY : 15
6. AC/DC CHARGER : 15
VI. APPENDIX I : SCHEMATICS 17
VII. APPENDIX II : COMMUNICATION 26
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SERVICE MANUAL
WARNING
(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 disconnect input power cord 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. If the battery connectors (P4, P8 for 700/1KVAor P5, P8 for 1.5KVA) are disconnected,
be sure to plug in the input power cord and the input power is available before re-
connect the battery connectors.
4. After service, verify the polarity of batteries, the tightness of all screws and connectors
before restarting the UPS.
DISCLAIMER
This document is provided as-is, with no expressed or implied warranty of any kind. The
information may be subject to change without notice.
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SERVICE MANUAL
STEPS TO REPLACE BATTERY PACK

& TO OPEN THE CASE
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SERVICE MANUAL
I. INTRODUCTION
For all series of LIEBERT HIROSS UPS, 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 this UPS. If this
situation occurs, service of qualified person is needed. This service manual will guide the
technicians to repair and adjust a 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 the UPS (Uninterruptible Power System),
it is very easy to maintain and service.
* All major power components are put on PCB.
* All PCBs are interconnected with connectors.
* Major parts are simply connected with flexible insulated wires and plugs.
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 this UPS.
4. Trouble shooting: This part describes the possible failure conditions and procedures
to repair it.
Before starting to serve this UPS, be sure to read this manual carefully for a correct and
safe operation.
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II. PRINCIPLE OF OPERATION
1. INTRODUCTION
This 1.5KVA/1KVA/700VA high input power factor UPS system contains two major pcb
assemblies. They are including :
1. PSDR: contains major parts of (1) charger, (2) DC power supply, (3) unit power
factor correction, (4) DC-DCconverter, (5) inverter and (6) output circuits.
2. CNTL : contains major parts of protection, signaling circuits, regulation and control
circuits of inverter
The simplified schematics in figure 1 shows how the major circuits are connected and
illustrates the overall system functions. The locations of these assemblies in this machine are
shown in figure 2. .
The block diagram in figure 3, 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 a bypass relay. The operation principle will be
explained in later section.
Basically, this ON-LINE UPS system utilizes high frequency PWM techniques to achieve
high efficient performance. This UPS can deliver a clean, regulated sine-wave output at any
load under full load. The sub-systems are described as below:
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III. POWER STAGE (PSDR)
The power stage consists of charger, unit power factor correction, DC power supply,
DC-DC converter, inverter and output circuits. Figure 4 shows the block diagram of
power stage.
i.CHARGER SUB-SYSTEM:
The purpose of charger is to charge and to maintain the batteries at fully charged
condition. Refer to figure 5, the voltage flyback switching power supply provides a
constant DC voltage (55.2V) for batteries. Besides providing constant voltage, the power
supply also limits the current flowing into batteries and therefore protects and prolongs
the life time of charged batteries.
ii. DC POWER SUPPLY SUB-SYSTEM:
The input of the DC power supply is connected to the battery bus, i.e., the output of the
charger. The output of DC power supply provides +12 Vdc for the bias supply of IC's
working voltage,the coil of relay and the fan(s) voltage. The DC power supply works only
when the 12 Vdc regulator supplies Vcc to its control IC. To have proper operation of 12
Vdc regulator, its input power is controlled by the switch as indicated in figure 6.
iii.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. The output of IGBT's is filtered by an LC circuit to
reduce the o/p voltage harmonics distortion.
iv.OUTPUT SUB-SYSTEM :
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The bypass relay receives signal from control circuit to switch the output of the UPS
from bypass to inverter, and vice versa. The output noise filter circuit blocks EMI noise to
the loads.
v.INPUT POWER FACTOR CORRECTION SUB-SYSTEM :
The purpose of power factor correction (P.F.C.) 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 8.
When the input AC power cord is plugged in, the AC power goes through noise filter
to the charger and to the line detector. Both DC buses present voltage at about 400Vdc.
When the "on" switch is pressed, the P.F.C. circuit is enabled and the DC buses are
regulated at 380V for 230VAC series.
vi.DC-DC CONVERTER 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 correct or failed. In this system, the batteries release the
stored energy to supply inverter immediately upon AC line fails.
Refer to figure 9, the battery voltage is transformed through a push-pull DC-DC
converter to ± 400Vdc as DC buses for inverter. When the line fails, the ± 200Vdc DC
sources are caught up to supply the power needed by the inverter immediately.
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SERVICE MANUAL
1.MAIN CONTROL PCB ASSEMBLIES (CNTL)
These assemblies are the control center of UPS. It is composed of three major circuits
as follows,
(1) Regulation & control
(2) Protection
(3) Signaling
i.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 is 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.
In order to avoid un-wanted 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 main is applied and the switch is turned on, a 10 second timer is triggered.
The bypass relay stays at bypass position in this time period. At the end of this period, the
bypass signal is removed and the relay transfers to inverter output.
ii.PROTECTION SUB-SYSTEM :
The UPS provides the following protection circuits :

1. 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
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SERVICE MANUAL
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 110% of rated load(VA ,or Wattage)
the UPS keeps running on inverter running for 10 seconds. If the output load is
higher than 130% of rated load, the UPS transfers to bypass immediately.
B.Cycle by Cycle Current Limit: When output loads sink a high surge current for a
short time, a high inverter current is detected and the inverter switches, i.e. the
IGBT's, 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.
2. 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 LED's
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 by way of DC-DC coverter to ensure the battery life. The panel will indicate the
fault condition.
3. Inverter output abnormal protection

The inverter failure signal shuts down the inverter immediately, makes the buzzer a
continuous alarm, and lights "FAULT" LED. The panel will indicated the fault condition.
" The failure signal latches itself unless SW off or battery is empty".
4. Over temperature protection

The thermal switch detects the temperature of PSDR heatsink. The thermal switch is
electrically connected to the CPU. An opened thermal switch is thought as temperature
failure by the UPS. The panel will indicated the fault condition.
5. Bus overvoltage protection
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SERVICE MANUAL
To protect any BUS overvoltage condition especially for the half-bridge load. The
panel will indicated the fault condition.
iii.SIGNALING SUB-SYSTEM :
When the AC line is unable to supply, the batteries release stored energy to supply the
inverter immediately. At the same time, the utility failure relay is activated and the buzzer
beeps every ten seconds.
Upon the batteries are discharged to battery-low level, the battery-low signal is
activated and the buzzer beeps twice every 5 second.
Remote shutdown signal is enabled only when the line fails. The signal is connected to
the battery detector. It generates battery-under signal to cut off the bias power supply of
the UPS system.
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2.FRONT PANEL :
The front panel consists 2 parts: push bottom and display LED set.
The push bottom is used to turn on and off the UPS. LED display indicates the load
level (battery mode indicates the battery voltage level) and operation status of the UPS.
AC INPUT LED indicates AC line is normal.If the line LED flash, it warns the power
source is site fault. BYPASS LED indicates bypass is active. UPS ON LED indicates
inverter is working and BATTERY LED indicates the UPS is in battery mode condition.
Besides, when the system works abnormally, the fault LED will light up and the buzzer
will beep continuously. In this situation, the panel LED will indicate which part inside the
UPS is out of order. The representations of fault conditions are listed as follows:
0%-25% 26%-50% 51%-75% 76%-100% > 100%

A B C D E Fault
All. On bypass due to output overload (0.5 second beep, re-occurring every 0.5 seconds)
A.On bypass due to over temperature condition (1 second beep, re-occurring every four
seconds)
B.On bypass due to DC bus overvoltage (1 second beep, re-occurring every four seconds)
C.On bypass due to control power supply failure (1 second beep, re-occurring every four
seconds)
D.On bypass due to PFC failure (1 second beep, re-occurring every four seconds)
E. On bypass due to inverter failure (1 second beep, re-occurring every four seconds)
A&C.UPS failed battery test (2 second beep, re-occurring every sixty (60) seconds)
C&E.UPS shutdown due to command from communication (RS232 or SNMP) port (no
audible)
The fault indicators will be illuminated indefinitely when the battery charger is operational
or for a maximum of 5 minutes when the battery charger is not operational.
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IV. ALIGNMENTS
PCB TEST TEST POINT TEST AND ADJUSTMENT EXPECTED RESULT
SEQUENCE
PSDR DC(+) BUS 700,1K R118 1.Connect DVM (DC) to test points and 10X3:
1.5K R51 connect I/P ac power cord, then turn on +380VDC±15V
Bat (-) (GND) the switch. 10X0:
+190VDC±15V
DC(-) BUS 700,1K R108 1.Connect DVM (DC) to test points and 10X3:
1.5K R45 connect I/P ac power cord, then turn on -380VDC±15V
Bat (-) (GND) the switch. 10X0:
-190VDC±15V
CHARGER External 1.Disconnect P4(+),P8(-) connectors for 55.2 3%
Battery 700,1KVA. ( P5(+),P8(-) connectors for
connector 1.5KVA)
2.Connect DVM (DC) to test points and
connect I/P AC power cord.
Figure IV-1 : Circuit for test output balance
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SERVICE MANUAL
V. TROUBLE SHOOTING
For the reason of safety, you must unplug the power cord and disconnect the batteries
from UPS (unplug int Bat(+),and int Bat(-)).
Check the components listed below to confirm which block is out of order and follow
the procedures listed on the following pages to repair them.
CAUTION: DO NOT supply UPS with the mains unless you are sure that you have
replaced all defective components.
700,1KVA:
1. OVERVIEW :
Circuit Block Components to be checked Fail condition
FUSE F1,F2 short or open
U.P.F. Correction D37,D36,REC1,Q05 short or open
Push-Pull Booster Q7,Q6 G-S open or value changes
D21,D22,D25,D26 short or open
Inverter Q08,Q09 G-S open or value changes
Charger Q02 G-S open or value changes
D03, D04,D05,D06,D11,D10 short or open
DC Power Supply Q10 G-S open or value changes
2. U.P.F. CORRECTION:
Step Checked components *Instrument Reference Failed condition
function Value
1 F1 short open
2 Q05 (G,S) 47K open or value changes
3 D36,D37 DIODE 0.44 short or open
4 R77 47 open or value changes
5 REC1( ,+),(-, ) DIODE 0.46 short or open
6 C31,C32 for 700 open Short
C30,C31,C32,C33 for Visual deformed
1K
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SERVICE MANUAL
3. PUSH-PULL DC-DC CONVERTER:
function Value
1 F2 short open
2 Q06,Q07 (G,S) 47K open or value changes
3 R92,R100 10 open
4 D21,D22,D25,D26 DIODE 0.40 short or open
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
function Value
1 F1,F2 Short open
3 R109,R115 62 open
5.DC POWER SUPPLY :

function Value
1 Q10 47K open or value changes
2 R102 47 open
3 R107 0.5 open
4 U9 (3845) PIN 5-6 47K too low
7-1 >1M
5-1 >1M
6-8 51.3K
6.AC/DC CHARGER :
function Value
2 R23 47 open
3 R24 0.5 open
4 U1 (3843) PIN 5-6 47K too low
7-1 >1M
5-1 >1M
6-8 50.7K
6 C2 open short
visual deformed
7 D11,D10 DIODE 0.36,0.45 short or open
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SERVICE MANUAL
1.5KVA:
1. OVERVIEW :
Circuit Block Components to be checked Fail condition
FUSE F1A,F2A,F2 short or open
U.P.F. Correction D22,D35,REC1,Q7 short or open
Push-Pull Booster Q8,Q9,Q10,Q11 G-S open or value changes
D23,D24,D25,D26 short or open
Inverter Q5,Q6 G-S open or value changes
Charger Q2 G-S open or value changes
D10,D11,D12,D13,D15,D16 short or open
DC Power Supply Q14 G-S open or value changes
2. U.P.F. CORRECTION:
Step Checked *Instrument Reference Failed condition
components function Value
1 F2 Short open
2 Q7 (G,S) 47K open or value changes
3 D22,D35 DIODE 0.39 short or open
4 R53 47 open or value changes
5 REC1( ,+),(-, ) DIODE 0.48 short or open
6 C47,C48,C49,C50 Open Short
visual deformed
3. PUSH-PULL DC-DC CONVERTER:

function Value
1 F1A,F2A short open
2 Q8,Q9,Q10,Q11(G,S) 47K open or value changes
3 R86,R96,R109,R106 10 open
* The instrument is D.M. ( digital multimeter ).
4.DC/AC INVERTER:
function Value
1 F1A,F2A,F2 short open
3 R42,R48 47 open
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SERVICE MANUAL
5.DC POWER SUPPLY :
function Value
2 R92 47 open
3 R88 0.5 open
4 U06 (3845) PIN 5-6 47K too low
7-1 >1M
5-1 >1M
6-8 51.3K
6.AC/DC CHARGER :
function Value
2 R40 47 open
3 R38 0.5 open
4 U10 (3843) PIN 5-6 47K too low
7-1 >1M
5-1 >1M
6-8 50.7K
6 C68 open short
visual deformed
7 D15,D16 DIODE 0.47,0.46 short or open
After you have replaced all defected components on power stage (PSDR),connect it to
control board. Supply DC voltage 48Vdc/2Amp (limited current) with DC power supply
via int Bat(+),and int Bat(-). Turn on the switch on panel,and then you will see "current
limit" on the DC power supply for about 2 seconds.(If not,it means that there are still
some defective components not being found yet).
When everything seems good, turn off the switch on panel and remove DC power
supply. Plug in the power cord and supply UPS with the mains. Test the output of charger
(int Bat(+),int Bat(-)) to see if it is 55.2Vdc. The fan will also active. If there is no
problem in charger, connect the batteries via int Bat(+),and int Bat(-).
Finally, turn on the switch on panel again and follow the procedure listed in part IV
(Alignment) to measure the voltage on DC bus,and output voltage.
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VI. APPENDIX I : SCHEMATICS
Figure1 :System schematic diagram
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700VA UPS
1KVA UPS
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SERVICE MANUAL
1.5KVA UPS
Figure 2 : The main components location of the UPS – NOTE: These are Liebert Hiross
internal codes and should not be used for ordering Spare Parts. Contact your
Liebert Hiross representative for correct codes.
D y n a m ic
B yp a s s
R e c tifie r /P F C In v e r te r
TVSS OUTPUT
IN P U T and
E M I/R F I
F ilte r s
D C to D C
C o n v e rte r
B a tte ry B a tte ry
C h a rg e r
N
G
Figure 3 : Block diagram for UPS
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Figure 4 : PSDR functional diagram
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Figure 5 : Charger circuit
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Figure 6 : DC power supply circuit
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Figure 7 : Inverter circuit
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Figure 8 : Input power factor correction circuit
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Figure 9 : DC -DC circuit for 1000 series
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SERVICE MANUAL
VII. APPENDIX II : COMMUNICATION
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
The pin out configuration of the DB9F connector will be:
Pin Assignment Description

1 Low Battery (open collector)
2 UPS TxD
3 UPS RxD
4 Remote Shutdown (5-12V); on battery operation
5 Common
6 Remote Shutdown (short to pin 5); any mode operation
7 Low Battery (open emitter)
8 AC Fail (open emitter)
9 AC Fail (open collector)
The remote any mode shutdown function (shorting pin 6 to pin 5) will operate in the
following manner. When shorted (via a relay or switch) the UPS output is shut off no matter
what operating condition the UPS is in at the time and when the short is removed the UPS
output will be enabled again, since the UPS itself never shutdown completely. The duration
of the shorting (contact closure) of pins 5 to 6 will be at least 750 msec for the UPS to
recognize this as a command to shut off the output power.
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SERVICE MANUAL
Optional communications (Intellislot™)

The UPS will contain one communication port, called “Intellislot™ “, to allow the operator
to field install optional communication cards. These optional cards will allow the UPS to
communicate via either Ethernet SNMP, connected directly to the LAN; or AS400
communication card. Once the SNMP card is installed, the serial communications will be
disabled in the DB9F connector; however the photo-coupler signals (on battery, low battery,
remote “any mode” shutdown, and remote “on battery” shutdown) will remain active.
The Intellislot™ communication port will be designed to provide simple installation where
all electrical connections are made via a 26-pin edge card connector. The pin out
configuration of the Intellislot™ edge connector will be:
P1 P3 P5 P7 P9 P11 P13 P15 P17 P19 P21 P23 P25

I I I I I I I I I I I I I
I I I I I I I I I I I I I
P2 P4 P6 P8 P10 P12 P14 P16 P18 P20 P22 P24 P26
The pin out definition of the Intellislot™ edge connector will be:
Pin Description Pin Description

1 Ground (common for pins 1-10) 2 SNMP Power; +7 to +10 VDC, 500 mA max.
3 RxD from UPS to SNMP card 4 TxD from UPS to SNMP card
5 TxD to PC from SNMP card 6 RxD from PC to SNMP card
7 -Vdd; RS232 level, -8 to -12 V 8 SNMP Interface card detection pin
9 Ground (common for pins 1-10) 10 +Vdd; RS232 level, 11 to 14 V, 100 mA max.
11 reserved 12 reserved
17 Shutdown in battery mode, active close 18 Shutdown in any mode, active close
19 Summary alarm signal, active high 20 On bypass signal, active high
21 On battery signal, active high 22 UPS Fault signal, active high
23 Common for pins 17-26 24 Low battery signal; active high
25 Vpp1; + 19 to +28 VDC 26 Vpp2; + 11 V to +14 VDC
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SERVICE MANUAL
SPARES LIST
Part Number Description

Power Boards
740-01603 MAIN POWER BOARD GXT2-700RT
740-01638 MAIN POWER BOARD GXT2-3000RT A
740-12047 MAIN POWER BOARD GXT2-3000RT B
Control Boards
740-01660 CONTROL BOARD GXT2 700 TO 1500
740-12121 CONTROL BOARD GXT2 2000, 3000
28

GXT2 U700 To 1 K 5 Service Liebert

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UNINTERRUPTIBLE POWER SYSTEM

Liebert UPStation GXT2-700/1000/1500RT-230

STEPS TO REPLACE BATTERY PACK

This service manual consists of 4 major parts:

II. PRINCIPLE OF OPERATION

III. POWER STAGE (PSDR)

ii. DC POWER SUPPLY SUB-SYSTEM:

v.INPUT POWER FACTOR CORRECTION SUB-SYSTEM :

vi.DC-DC CONVERTER SUB-SYSTEM :

i.REGULATION & CONTROL SUB-SYSTEM :

The inverter signal is sensed directly by resistor division. It is compared with a

The UPS provides the following protection circuits :

2. Battery over or under shut down

3. Inverter output abnormal protection

4. Over temperature protection

5. Bus overvoltage protection

0%-25% 26%-50% 51%-75% 76%-100% > 100%

Figure IV-1 : Circuit for test output balance

* The instrument is D.M. ( digital multimeter ).

5.DC POWER SUPPLY :

3. PUSH-PULL DC-DC CONVERTER:

* The instrument is D.M. ( digital multimeter ).

VI. APPENDIX I : SCHEMATICS

Figure1 :System schematic diagram

Figure 3 : Block diagram for UPS

Figure 4 : PSDR functional diagram

Figure 5 : Charger circuit

Figure 6 : DC power supply circuit

Figure 7 : Inverter circuit

Figure 8 : Input power factor correction circuit

Figure 9 : DC -DC circuit for 1000 series

VII. APPENDIX II : COMMUNICATION

Pin Assignment Description

Optional communications (Intellislot™)

P1 P3 P5 P7 P9 P11 P13 P15 P17 P19 P21 P23 P25

Pin Description Pin Description

Part Number Description

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