Upstation GXT Series 230V Models Upstation GXT Series 230V Models

UPStation GXT Series
230V Models
Service Manual
Manual Part Nº04577451-1

GXT-230 Repair Manual Manual Registration
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Issue -1- 12/08/98

GXT-230 Repair Manual Manual Registration
Issue -1- 12/08/98

Table of Contents
CHAPTER 1 - Functional Description 1
1.1 Introduction 1
1.2 Principles of operation 2
1.2.1 Block diagram 2
1.3 Basic operation 4
1.4 Major component connection details 5
1.5 Control Panel description 7
1.5.1 Control Panel push-buttons 7
1.5.2 System Status indicators 7
1.5.3 Bargraph Led 8
CHAPTER 2 - Power Board 9

2.1 Battery Charger 10
2.1.1 Introduction 10
2.1.2 Circuit description 10
2.2 DC Power Supply 13
2.3 PFC Rectifier 15
2.3.2 PFC Principles of operation 15
2.3.3 The practical PFC power circuit 18
2.3.4 PFC Control circuit operation 19
2.4 DC-DC Converter 21
2.5 PWM Inverter 22
2.5.2 Power circuit description 22
2.5.3 Control circuit description 22
2.6 Input relay control 23
CHAPTER 3 - Control Board 25

3.1 Control system operation 25
3.1.2 Control Board power supplies 28
3.1.3 Micro-controller analogue inputs 29
3.1.4 Micro-controller digital inputs 31
3.1.5 Micro-controller digital outputs 34
3.1.6 PWM Pattern Generator 36
3.1.7 9-Pin Communications Interface Port 37
3.1.8 UPS INTELLISLOT™ Communications 39
CHAPTER 4 - Operating Procedures 41

4.1 Start-up procedure 41
4.2 Manual battery test 41
4.3 Shutdown procedure 41
Issue -1- 01/10/98 i

CHAPTER 5 - Maintenance & Repair Procedures 43
5.1 Maintenance 43
5.2 Repair Procedures 44
5.2.1 Important Safety Considerations 44
5.3 Gaining internal access to the UPS components (all *230RT models) 45
5.3.1 Removing the Top and Front bezel: 45
5.3.2 Removing the left and right side covers 45
5.4 Disconnecting, replacing / servicing the Batteries (all *230RT Models) 46
5.5 Replacing the Power Board & Control Board 47
5.6 Functional check procedures 48
5.6.1 Preliminary information 48
5.6.2 Battery Charger calibration 48
5.6.3 Bypass check 49
5.6.4 UPS switch ON check 49
5.6.5 DC Busbar voltage checks 50
5.6.6 Output voltage offset check 51
CHAPTER 6 - Troubleshooting Procedures 53

6.1 Introduction 53
6.2 Operating problems 54
700VA/1000VA/1500VA Model Checks
6.3 Quick Start (for 2000/3000VA models see Paragraph 6.11) 57
6.4 PFC Rectifier check procedure (for 2000/3000VA models see Paragraph 6.12) 58
6.5 DC-DC Converter check procedure (for 2000/3000VA models see Paragraph 6.13) 60
6.6 DC Power Supply check procedure (for 2000/3000VA models see Paragraph 6.14) 62
6.7 Battery Charger check procedure (for 2000/3000VA models see Paragraph 6.15) 64
6.8 Inverter check procedure (for 2000/3000VA models see Paragraph 6.16) 66
6.9 Overtemperature checks 68
6.10 DC Voltage Feedback loop checks (for 2000/3000VA models see Paragraph 6.18) 69
2000VA/3000VA Model Checks
6.11 Quick Start (for 700/100/1500VA models see Paragraph 6.3) 70
6.12 PFC Rectifier check procedure (for 700/100/1500VA models see Paragraph 6.4) 72
6.13 DC-DC Converter check procedure (for 700/100/1500VA models see Paragraph 6.5) 74
6.14 DC Power Supply check procedure (for 700/100/1500VA models see Paragraph 6.6) 76
6.15 Battery Charger check procedure (for 700/100/1500VA models see Paragraph 6.7) 78
6.16 Inverter check procedure (for 700/100/1500VA models see Paragraph 6.8) 80
6.17 Overtemperature checks 82
6.18 DC Voltage Feedback loop checks (for 700/100/1500VA models see Paragraph 6.10) 83
CHAPTER 7 - Spare Parts 85

7.1 Spare Parts Kits 85
7.2 GXT700MT-230 BILL OF MATERIALS 87
7.3 GXT1000MT-230 BILL OF MATERIAL 99
7.4 GXT1500RT-120 BILL OF MATERIAL 111
7.5 GXT3000RT-230 BILL OF MATERIAL 124
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GXT-230 Repair Manual
CHAPTER 8 - Specification 137
CHAPTER 9 - Drawings 139
Issue -1- 01/10/98 iii

GXT-230 Repair Manual
iv Issue -1- 01/10/98

General Information
Read this manual carefully before working on this UPS equipment
Conventions
This service manual uses the following conventions to alert you to important information for safe operation and
quick working.
WARNING:
Denotes a procedure or operation which, if not perform correctly, may result in personal injury. Be sure not to
continue operation until indicated conditions are fully understood and met.
Caution:
Denotes a procedure or operation which, if not perform correctly, may cause damage to the UPS. Be sure not to
continue operation until indicated conditions are fully understood and met.
Important Safety Instructions

1. The procedures detailed in this manual are intended for qualified service personnel only.
2. DO NOT perform any internal service or adjustment of this product unless a second person, capable of
rendering first aid and resuscitation, is present.
3. Dangerous voltage exists at several points in this product. To avoid personal injury, do not touch any exposed
connections or components while UPS is powered.
4. Turn off the UPS and disconnect the input power cable before removing the outer covers.
5. AC voltage is always present within the equipment when the connected input AC power is live.
6. High voltage may present at the DC bus capacitors. After turning off the UPS wait for at least five minutes
before removing the UPS cover.
7. DO NOT short-circuit the internal batteries.
8. If the battery is disconnected, be sure to ‘pre-charge’ the DC bus by powering-up the UPS input mains supply
before reconnecting the battery – failure to carry out this action may result in rupturing the battery fuses when
the battery is reconnected.
9. After service, verify the polarity of the battery connections and the tightness of all screws and connectors before
restarting the UPS.
GXT-230 Repair Manual Preliminary Information

GXT-230 Repair Manual Preliminary Information
vi Issue -1- 01/10/98

CHAPTER 1 - Functional Description
1.1 Introduction
There are six 230V models in the Liebert GXT UPS range:
Description Rating (kVA/kW) Case Style
GXT700MT-230 700 /490 Mini Tower

GXT1000MT-230 1000 / 700 Mini Tower
GXT1000RT-230 1000 / 700 Full Tower / Rack
All six models employ the same principles of operation, but for reasons of clarity the component annotations and
illustrations shown in this chapter refer to the 1500RT-230 unit. Details of the other models are provided elsewhere
in this manual.
The GXT product falls into the category generally described as an “On-Line” UPS system – i.e. under normal
circumstances the UPS batteries are being float charged and the UPS inverter is operative and providing processed
load power at all times. In the event of a mains supply failure the inverter will continue to provide processed load
power while operating from the internal battery, until the battery becomes fully discharged – whereupon the UPS
shuts down. The duration for which the batteries can sustain the load power under these conditions is known as the
autonomy time and depends upon the battery Ah capacity and the value of the demanded load current. Typically,
the battery is sized to offer 5-10 minutes of back-up at full load but this can be increased by connecting additional
battery-packs to the system. Purpose-designed external battery cabinets are available as optional equipment to
extend the autonomy time – for example a 50 minute back-up time can be achieved with the addition of a further
two cabinets.
If the UPS develops an internal fault which prevents it from producing its specified output supply, it will
immediately invoke an alternative ‘bypass’ supply line which connects the load directly to the UPS input (mains)
supply. Such a load transfer takes place without interrupting the load power; but when the UPS is ‘On-Bypass’ the
load is being supplied with unprocessed power which is not immune from supply aberrations or total loss.
The following design features help make this model easy to maintain and service:
• A minimum number of Printed Circuit Boards (PCBs) and sub-assemblies have been employed
– thus simplifying fault detection by substitution.
• All major power components are PCB-mounted.
• All major parts are connected with flexible insulated wires and plugs.
• All PCBs are interconnected with connectors – no soldering.
• Easily replaceable battery pack.
GXT-230 Repair Manual Functional Description

1.2 Principles of operation

Figure 1.1 - Basic block diagram
Figure 1.1 illustrates a basic block diagram of the UPS power sections. With the exception of the Input Filter and
Output Filter all the blocks shown are contained on the Power Board – which is one of two major boards contained
in the UPS. The functional description of the block diagram provided immediately below, is followed by a more
detailed description of each of the power sections shown.
1.2.1 Block diagram
Input/Output filter
These are simple low-pass filters designed to prevent mains-borne RFI entering the UPS control system and also
prevent any switching noise generated within the UPS radiating back into the mains supply and the UPS output.
Battery Charger
As its name suggests, the Battery Charger is responsible for providing the Battery with a permanent, regulated float
charge voltage. The charger circuit is live whenever the UPS mains power is available – irrespective of whether or
not the UPS is switched on. The battery float voltage is adjustable by means of a control potentiometer and
normally set to provide a float voltage of approximately 2.3V/cell. In addition to charging the battery, the Battery
Charger output also provides an input power source to the LV Power Supplies block and the DC-DC Converter.
Battery
The number of batteries contained in the UPS varies according to the UPS rating: ranging from 2 x12V blocks in
the GXT700MT-230 to 8 x 12V blocks in the GXT300RT-230. However, in each case the batteries are contained
in a sub-assembly which can be fully withdrawn from the unit after disconnection. This simplifies battery
replacement, and is intended that such an operation is undertaken by an operator. Note that the Battery Fuse is
located on the Power Board and is not accessible without removing the UPS cover.
Only lead acid batteries of valve-regulated, non-spillable design should be used with the GXT equipment.
LV Power Supplies
A switched-mode DC-DC converter provides the +24V, +12V and +5V low voltage supply rails required by the
UPS control system. As this circuit is powered from the battery busbar, the LV supplies are available whenever the
UPS input supply is present or the batteries are connected. An additional set of isolated +15V and -5V power
supplies, not shown in the block diagram, are also powered from the battery bus. These are required by the inverter
power transistor drive circuits – as explained later in this chapter.
Note: the cooling fans are powered directly from the +12V supply rail and the sound of their rotation is a good
indication that the LV Power Supply Block is basically functioning.
2 Issue -1- 01/10/98

DC-DC Converter
The DC-DC Converter is responsible for converting the battery bus voltage to two regulated busbars at +410Vdc
and -410Vdc (with respect to 0V ground) for use by the inverter in the absence of the UPS input supply. As
illustrated in the block diagram, the DC-DC Converter output is effectively connected in parallel with that of the
PFC Rectifier at the input to the PWM Inverter section – this permits the PWM Inverter to operate from either
power source.
PFC Rectifier
The Power Factor Correction (PFC) Rectifier converts the UPS input mains supply into two regulated ±380Vdc
busbars which, under normal circumstances, provide the operating power source for the PWM Inverter. The
manner in which the converter is controlled automatically brings the input current in phase with the input voltage,
which leads to a higher input power factor than is the case with more traditional rectifier circuits.
The PFC Rectifier is selected ON by the UPS control system only if the input relays (RL2 / RL3) are closed and
the input fuse is healthy.
PWM inverter
The PWM Inverter converts the DC Busbar into a regulated 230Vac output supply. As described above, the DC
Busbar can itself be derived from the PFC Rectifier (when the input supply is present) or the Battery Busbar via
the DC-DC Converter (when the input supply is absent), it is therefore a design requirement that the inverter section
is able to produce a regulated output over a widely varying range of input (DC Busbar) voltages – which is achieved
through the implementation of pulse-width modulation (PWM) control.
In brief, in order to maintain a regulated a.c. output voltage the inverter PWM mark-space ratio is made to increase
as the DC Busbar voltage reduces: this is also true with respect to load current – i.e. as the load increases then the
PMW mark-space ratio also increases to allow the extra current through to the load without causing a reduction of
the output voltage. The point at which the inverter is unable to sustain its regulated output voltage, and is therefore
shut down, is thus determined by both the DC Busbar voltage and the prevailing load demand – i.e. on light loads
the inverter can maintain its correct output voltage at a lower DC Busbar level than is possible on higher loads.
Issue -1- 01/10/98 3

1.3 Basic operation
UPS Power-up
1. When mains power is initially connected to the UPS input supply socket the Battery Charger and LV Power
Supply sections become active and produce the low voltage power rails required by the UPS control system
together with the cooling fan(s). The sound made by the rotating fan(s) is thus a good indication that the power
supplies are operating correctly.
2. The control system monitors the input supply and closes the Input Relay if the supply voltage and frequency
are found to be valid. This routes the input supply, via the bypass line and Output Relay, to the UPS output
sockets and thereby connects the load equipment directly to the Input Supply.
Note: The ‘Bypass’ led illuminates on the UPS Control Panel to indicate that the load is ‘on bypass’ and the
audible alarm sounds at approximately 2 minute intervals to remind the user that the load is being supplied with
unprocessed power.
3. The PFC Rectifier operates as soon as the mains is applied. Its output initially ramps up to approximately
750Vdc and then settles at around 660Vdc (i.e. ±330Vdc balanced with respect to 0V ground).
Pressing the ON push-button

1. When the ON push-button is pressed, the UPS control system runs through a series of validity checks on the
DC busbar and inverter and, if satisfactory, energises the Output Relay after approximately 10 seconds. This
transfers the load to the inverter output which now provides it with processed and backed-up power.
Note: The ‘Bypass’ led extinguishes and the ‘UPS ON’ led illuminates on the front panel to indicate the revised
load supply status.
2. After a further 4 seconds (approximately) the UPS control system performs an automatic battery test whereby
the PFC Rectifier is turned off for approximately 15 seconds and the DC busbar voltage is monitored while the
inverter is being powered from the batteries. If the batteries sustain the DC busbar satisfactorily during this time
the batteries are considered to be healthy and the PFC Rectifier is turned on again to restore the UPS to normal
operation. If the batteries fail the test the load is transferred to the bypass supply (by releasing the Output Relay)
and the ‘Fault’ led illuminates.
Operation during mains failure and return

1. If the input supply fails while the UPS is operating normally, the PFC Rectifier and Battery Charger are shut
down and the batteries provide the inverter power source via the DC-DC Converter. This situation continues
until the batteries have discharged to the point at which they are unable to sustain the DC busbar voltage at an
acceptable level – when this point is reached the control system attempts to transfer the load to the bypass sup-
ply; but if the input supply is still missing the bypass supply is also unavailable and the UPS therefore totally
shuts down and drops the load.
Note: When operating ‘On-Battery’ the remaining battery time is indicated by the front panel leds.
2. When the UPS shuts down due to battery undervoltage the low voltage DC Power Supply block is also turned
off and will not be reactivated until the input mains supply is restored.
3. If the Input Supply returns to normal before the battery reaches its undervoltage level, the PFC Rectifier block
is turned on and once again takes over the responsibility of providing the inverter input power. The Battery
Charger is also turned back on to recharge the batteries.
Operation under fault conditions

1. If the UPS develops a fault which prevents it from producing its specified output supply the load is transferred
to the bypass supply (via the Output Relay).
2. The decision over whether or not to shut down the individual UPS power blocks is taken by the control system
according to the particular fault symptoms.
Note: Some fault conditions are positively identified by the front panel leds.
4 Issue -1- 01/10/98

1.4 Major component connection details

Figure 1.2 - Internal connection details
Model Power Board Battery Input Filter Output Input Ext. Batt
Filter Fuse Fuse
700MT 710-01126-XX2 2 off 80946-001 094-00045-00 094-00050-00 5A -
3 off 80949-00
1000MT 710-01179-XX2 094-00046-01 094-00050-00 6.3A -
or 80950-001
1000RT 710-01440-XX2 3 off 33956-00 094-00046-01 094-00050-00 6.3A 6.3 A
1500RT 710-01460-XX 4 off 33965-00 094-00061-00 094-00050-00 10A4 10.0 A
2000RT 710-01042-XX 8 off 80901-01 094-00080-03 710-01108-XX 15A4 15.0 A

or 80927-00 or
3000RT 710-01421-XX 4 off 33956-003 094-00120-00 710-01108-XX 20A4 / 5 20.0 A
Note 1: External battery connector not fitted

Note 2: Only one fan is fitted to these models (connected to either Fan1 or Fan2 connectors)
Note 3: Nominal battery voltage is 96Vdc therefore an additional disconnect socket is fitted mid-way along the
battery string to allow the battery to be split into two 48V groups for safe fitting/removal.
Note 4: On the larger models the input fuse is replaced by a resettable circuit breaker.
Note 5: The 300RT model is also fitted with a resettable output circuit breaker.
Issue -1- 01/10/98 5

Figure 1.3 - Ferrite core usage
Model Ferrite Core A Ferrite Core B Ferrite Core C Ferrite Core D
700MT Not fitted Not fitted Not fitted -

1000MT 80957-00 Not fitted 80959-00 -
1000RT Not fitted Not fitted Not fitted 80915-00
1500RT Not fitted Not fitted 80914-00 80915-00
2000RT 80904-00 80223-XX 80902-00 80910-00
3000RT 80904-00 80223-XX 80903-00 80910-00
6 Issue -1- 01/10/98

1.5 Control Panel description

Figure 1.4 - Control Panel
Load /
Battery Level /
ON / Fault Ident
Alarm Silence / Indicators
Batt. Test
OFF /
Bypass System
Status
Indicators
1.5.1 Control Panel push-buttons

There are two tactile push-buttons located on the Control Panel, as described below. To prevent inadvertent
operation, these push-buttons must be held pressed for 0.5 seconds before their closure is recognised by the UPS
control system.
ON / Alarm Silence / Batt. Test button

As its title suggests, this push-button has three functions depending on the current UPS operational status.
1. When the UPS is either fully powered down or running ‘On Bypass’ (21#%<3$66 status indicator illuminated),
pressing this button initiates the UPS start-up operation to bring the UPS on-line.
2. If the UPS is running (836#21#status indicator illuminated), pressing the button will silence the audible alarm –
providing the cause of the alarm condition is no longer present.
3. If the UPS is running and there is no alarm condition, pressing the button initiates a battery test sequence
which transfers the load to the battery for approximately 15 seconds to test its serviceability.
OFF / Bypass button

This button is operative only when the UPS is running, whereupon pressing it once transfers the load to the bypass
supply (21#%<3$66 status indicator illuminated) and pressing it for the second time within four seconds shuts down
the UPS (21#%<3$66 and 21#836 indicators both extinguished) – if more than four seconds elapse between the first
and second button presses the second press has no effect. To shut down the UPS when it is operating ‘On Bypass’,
the button must be pressed twice within four seconds.
1.5.2 System Status indicators

The four leds on the right-hand side of the Control Panel indicate the general UPS operating status.
BYPASS
This amber led illuminates when the load is being powered from the bypass supply and will illuminate briefly when
the UPS is initially turned on as the control system goes through its start-up routine. If this led illuminates during
normal UPS operation it could be due to an internal UPS fault, an inverter overload, or due to a ‘transfer-to-bypass’
request from the operator – see the ‘OFF / Bypass’ button description above.
Note: When this led is illuminated the load is not being provided with backed-up or processed power.
Issue -1- 01/10/98 7

UPS ON
This green led is normally illuminated, and indicates that the UPS is ‘On Load’ – i.e. the load is being provided
with backed-up and processed power.
BATTERY
This amber led illuminates whenever the battery is discharging; usually due to an input supply failure, and is
accompanied by an audible warning. The led also illuminates when the battery test sequence is performed (whether
initiated manually or automatically).
AC INPUT
This green led is normally illuminated and indicates that the input supply is present and within the operating voltage
and frequency tolerances required by the UPS control system.
1.5.3 Bargraph Led
Figure 1.5 - Operator Panel Bargraph led functions
The function of the bargraph led in the centre of the Operator Panel depends on the UPS operational status. In all
instances the top (red) led is used to indicate a detected fault condition.
Load indicator
When the UPS is operating normally (836#21 led illuminated), the bargraph indicates the applied load as a
percentage of the UPS’s rating in steps of 25% – i.e. the lower led illuminates for loads up to 25%, the lower two
leds illuminate for loads between 26% and 50%... and so on. The fifth, amber, led illuminates in the event of an
overload prior to the UPS transferring the load to bypass.
Charge indicator
If the UPS changes to battery operation (%$77(5< led illuminated) the leds indicate the state of battery charge as a
percentage of the remaining back-up time. For example, when the UPS first reverts to battery operation all the leds
will be illuminated (except the ‘fault’ led) and as the battery discharges they will extinguish from the bottom led
upwards as the remaining time falls below the levels indicated. When the amber (0-20%) led only is illuminated it
indicates that the battery is almost fully discharged and that it would be wise to shut down the load equipment in
an orderly fashion – as the UPS is about to fully shut down and drop the load supply.
Note that when operating ‘On Battery’ the audible warning will sound every 10 seconds to alert the operator. This
will increase to two beeps every five seconds when there is approximately 2 minutes of battery time remaining.
Fault indicator
If the UPS detects a fault it will indicate the nature of the fault condition by illuminating a combination of the
bargraph leds in addition to the ‘Fault’ led – see Chapter 4 (troubleshooting) of this manual for more details.
8 Issue -1- 01/10/98

CHAPTER 2 - Power Board
Figure 2.1 - 1500VA Power Board
J I
A
C D E F G H
A Battery positive connector B Battery Fuses

C Bypass Relay (RL1) D UPS output power connections
E Input Fuse F Input Relays
G UPS Input power connections H Charger voltage adjustment pot
I Control Board connector J Battery negative connector
The Power Board contains all the power components associated with the Battery Charger, DC Power Supply, PFC
Rectifier, DC-DC Converter, and PWM Inverter. A description of each of these power blocks is described in this
chapter.
WARNING
This Board contains potentially dangerous voltages whenever the mains supply OR batteries are connected. The
large electrolytic capacitors may retain a high charge when the UPS is turned OFF and should be discharged
using a suitable bleed resistor (e.g. 100R / 10W) before working on the board.
Issue -1- 01/10/98 9

GXT-230 Repair Manual Power Board
2.1 Battery Charger
2.1.1 Introduction
As its name suggests, the primary purpose of the Battery Charger circuit is to produce a regulated voltage to float
charge the batteries while the input mains supply is available. The charger output voltage is normally set to a value
of 2.3V per cell – e.g. 55.2Vdc for the 24 cells contained in the 1500RT model.
The Battery Charger obtains its power directly from the incoming 230Vac mains supply and is active whenever the
input supply is live – i.e. the Battery Charger function is not affected by the front panel ON/OFF push-buttons.
Note: the Charger is fed from the ‘live’ side of the input relays and is therefore not affected by the relay(s) or input
fuse status.
The DC Power Supply block, which provides the low voltage operating supplies for the control circuits, is also
connected to the battery bus, and is therefore also powered from the Battery Charger output under normal
circumstances.
2.1.2 Circuit description

Note: The signal annotation flags shown on the circuit diagrams contained at the rear of this manual are shown
within a ‘square’ and ‘angled’ bracket in the manual text – for example, the signal annotated “BAT.V” on the
diagram will be shown as >%$719!.
Figure 2.2 - Battery Charger – Power Circuit Diagram

DC Power Supply
CN2-17
SWPOWER
P1 To Input Relay
LIVE Power Supply CN2-11
BAT.V
D5 D6
Uncontrolled DC Bus TX2 F1/F2 P5
Input Mains
REC2 To Battery Pos
Supply
20A
R43 + C12 +
C33
C2
P2 +
P6
C30
NEUTRAL To Battery Neg.
To PFC Circuit
Power Supply
R46
D27
C32
+
Power Supply
C36
+
R27/28
Q8
PWM Control Sig

Battery Charger
Electronic Control
System Current Sense
R45
0R75 VR01
Volts Adjust
Power Supply
R37
Volts Feedback
Power circuit operation

The incoming 230Vac mains supply is full-wave rectified by REC2 and smoothed by C30 (470uF) to provide an
uncontrolled dc busbar of approximately 575V which is connected to a switched-mode DC-DC converter designed
around Q8 and TX2.
When its gate terminal is taken high, Q8 turns ON and draws current from the uncontrolled dc busbar through TX1
primary which, through transformer action, induces a current in TX2 secondaries which in turn gives rise to the
secondary voltages. The resistance in the primary circuit is very low, and the rise in input current when Q8 turns
on is determined almost entirely by the reactance of TX2 primary – the peak current is therefore controlled by the
length of time that Q8 is allowed to conduct. If Q8 is turned On for an excessive time (or goes short circuit drain-
source) the transformer primary could saturate and the excessive current could cause (further) damage to the
Charger circuit, or trip the external mains supply.
10 Issue -1- 01/10/98

The main battery charger output is rectified and smoothed by D5, D6, C12 and C2, and connected to the battery
terminals via fuses (F1/F2). The voltage at the junction of D5/D6 is connected to the battery charger control circuit
in the form of a voltage feedback signal to a closed-loop control system which determines the battery charger
output voltage. Note that this signal doesn’t ‘see’ the battery voltage when the input mains supply is absent, due to
the blocking effect of D6.
In addition to charging the battery, the battery charger output at the cathode of D6 (which is also known as the
‘battery bus’) is also connected to:
1. The DC Power Supply block, where it provides the input power source (see figure 2.4).
2. To the Control Panel ‘ON’ switch >6:32:(5!#+&1504:,, via the Control Board (see figure 3.6).
3. To the Control Board electronics >%$719!#+&15044,#in the form of a battery voltage sense signal.
Notice that these three outputs are also valid when the Battery Charger is shut down (e.g. due to mains failure)
where-upon the voltages are furnished by the battery. This implies that:
1. The DC Power Supply block operation is sustained when the UPS is operating ‘on-battery.’
2. The Control Panel ‘ON’ switch is functional while the input mains is unavailable, provided the battery is
connected.
3. The Control Board electronics monitor the battery voltage directly when the charger is shut down and is thereby
able to sense the battery voltage as it discharges.
TX2 secondary functions

TX2 has three secondary windings in addition to the one used to provide the main battery charger output, as
illustrated in Figure 2.2:
1. The top winding is half-wave rectified and used as a dedicated 15V supply for the input relay coil(s) (see figure
2.15).
2. The third output drives a dedicated power supply used by the PFC Rectifier control circuit, and is necessary to
provide an isolated power source for the PFC driver circuit.
3. The lower secondary winding provides a secondary power source for the Battery Charger control circuit.
Issue -1- 01/10/98 11

Figure 2.3 - Battery Charger – control circuit
P1 (L)
REC2
C 3 3 10n
R43A
100k
R46
C33A
P2 (N) 100k
R43
100k
+ 10n
C30 +
47u C32 TX2
100u C36 D25 D26 D27
10n
R42
Q8
47R
7
Vcc
6
8 O/P
Vref
R48
3k3 4
R/C 3
IS
CN2-5
Comp
GND
VF
U6
CHGOFF+ R49
U4
1
UC3845 1k0
1
C37
R45
0R75
2
CN2-6
C35 V-fbk
CHGOFF- C39
Control circuit operation

The Battery Charger control circuit is based on a UC3845 ‘current-mode PWM controller’ device (U6) which is
also located on the Power Board. This device produces a 20µs pulse-train (approximately) which is connected as
a drive signal to the base of Q8. The Battery Charger output voltage is controlled by varying the drive signal’s duty
cycle (mark-to-space ratio) – i.e. as the duty cycle (m:s) increases more current is drawn through TX2 primary
which leads to an increased battery charger output voltage, and vice versa.
The drive signal’s duty cycle is determined by a control loop which takes into account the battery charger output
voltage (fed back via R27/R28/VR01 etc.) and the charger current (obtained by monitoring the volts drop across
R45 in Q8 drain). The action of the control loop thus maintains a stable float charge voltage.
Note that VR01 affects the voltage feedback signal sensitivity and thereby provides a means of adjusting the float
charge voltage.
The UC3845 (U6) obtains it operating power from the uncontrolled dc busbar via a series dropper resistor (R46
100K) and can operate over a supply voltage in the range 11V - 34V (typical).
Although all the components associated with the battery charger control circuit are located on the Power Board,
the circuit receives an ON/OFF control signal from the micro-control system on the Control Board which is applied
via an opto-isolator (U4) and connected via CN2 pins 5 & 6. The Control Board turns ON U4 when it requires the
Battery Charger to be shut down – see page 34.
12 Issue -1- 01/10/98

2.2 DC Power Supply

Figure 2.4 - DC Power Supply Circuit Diagram
D33
Battery Charger
+IGBT +15V
Output
+ C49 R55
P5 F1/F2 TX3
Battery Pos. BAT.V +IGBT 0V
20A + C48
P6 ZD3
Battery Neg. 5V1
+IGBT -5V
Q2
D32
PWM Control Sig
-IGBT +15V
DC Power Supply
Electronic Control + C41 R47
System (U2) Current Sense
Volts Feedback
R23
-IGBT 0V
0R5
+ C41
ZD2
5V1
-IGBT -5V
D3
CN2-18 D20
SD
CN2-1
D19
+24V
CN2-2
Fan Supply +12V
+12V
CN2-49 CN2-3
HF.POWER+ U3
+5V
79L05
+ C19 + C28 2 1
To Control Board VI VO +5V
CN2-4
CN2-50
3
HF.POWER- 0V GND
GND
2.2.1 Introduction
The DC Power Supply block provides various low voltage power supplies required to operated the UPS control
electronics. The circuit’s input is connected to the Battery Bus which under normal circumstances is held at a
regulated 55.2Vdc (2.3V/cell) by the action of the Battery Charger circuit; however when the UPS is operating ‘on-
battery’ this voltage will immediately fall to 48Vdc (nominal) and further reduce to 40Vdc as the battery discharges
to its end-of-discharge voltage (1.67V/cell). The DC Power Supply must therefore be able to sustain its regulated
outputs over this broad range of input voltages.

The DC Power Supply circuit is based on a switched-mode DC-DC converter designed around Q2 and TX3.
When its gate terminal is taken high, Q2 turns ON and draws current from the battery busbar through TX3 primary
which, through transformer action, induces a current in TX3 secondaries which in turn gives rise to the secondary
voltages. The resistance in the primary circuit is very low, and the rise in input current when Q2 turns on is
determined almost entirely by the reactance of TX3 primary – the peak current through TX3 is therefore controlled
by the length of time that Q2 is allowed to conduct. If Q2 is turned ON for an excessive time (or goes short circuit
d-s) the transformer primary could saturate and the excessive current might:
a. further damage other DC Power Supply components.
b. rupture the battery fuse.
c. shut-down the battery charger due to over-current.
In any event, failure of the DC Power Supply will cause a general UPS failure and transfer the load to bypass.
TX3 has three secondary windings, as illustrated in Figure 2.4:
1. The two windings shown on the right-hand side of the transformer in the diagram above provide isolated +15V
and -5V for the inverter IGBT transistor drive circuits – see Figure 2.14.
2. The left-hand winding provides the regulated dc power rails, as described below.
Issue -1- 01/10/98 13

The left-hand winding is centre-tapped. The lower part is rectified by D20/C28 and produces a +24V rail which is
used by the Control Board. The upper part of the winding is rectified by D19/C19 to provide a +12V rail, which in
turn drives a three terminal +5V regulator (U3) to provide a stable +5V rail. The +12V and +5V rails are used
extensively by the Power Board’s electronics and are also connected to the Control Board and Operator Panel. The
+12V rail also powers the cooling fan(s).
As illustrated in Figure 2.4, the ac voltage from the top half of the left-hand winding is also connected to the Control
Board (>+)32:(5.! and >+)32:(50!) where it drives a further transformer which produces various power supplies
for the use of the communications interface system etc. – see Figure 3.3. The voltage between >+)32:(5.! and
>+)32:(50! is approximately 16Vrms.

The DC Power Supply control circuit is similar to the Battery Charger control circuit in that it is based on a UC3845
‘current-mode PWM controller’ device (U2).
The drive signal’s duty cycle is determined by a control loop which takes into account the value of the 12V power
rail (fed back via a network comprising R20, R19 and R10) and the source current (obtained by monitoring the
volts drop across R23). The action of the control loop thus maintains a stable +12V supply rail voltage.
Note that the voltage feedback resistor network is fixed and the +12V rail is therefore not adjustable.
All the components associated with the DC power Supply control circuit are located on the Power Board; however
the power supply to U2 is obtained through a switching transistor which can be turned OFF by a logic low
shutdown signal (>6'!) generated on the Control Board and applied to the circuit via CN2-18 and D3 – see Figure
3.6.
14 Issue -1- 01/10/98

2.3 PFC Rectifier

Figure 2.5 - PFC Rectifier Circuit Diagram
L2
P1 F3
LIVE D18
Input Mains 10A
Supply DC BUS POS
P2
NEUTRAL
+ C51/68
Input Relay
Regulated DC Bus
CT2 To DC-DC Converter
And Inverter Sections
+ C52/73
D42-D46 D13
DC BUS NEG
I/P Current Sense
I/P Volts Sense
a d
REC2
PF.VCC+
PF.VCC- Q14 c b
PWM Control Sig

PFC Rectifier
Electronic Control
System (U11)
PF.VCC0 +BUS.V CN2-24
DC Voltage DC Bus Volts

DC Bus Volts FBK
Feedback Signal Sense Signals to
CN2-26 ON/OFF Control Processing Control Board
PFC.OFF
CN2-33 -BUS.V CN2-25

Input Voltage Line.V
Sense Signal Input Voltage
Processing Sense Signals to LINE+ CN2-27
Control Board
Line.L CN2-32
LINE- CN2-26
2.3.1 Introduction
The Input Power Factor Correction (PFC) circuit, which is shown in full in Figure 2.5, serves two important
functions:
1. It converts (rectifies) the input mains supply into two regulated DC busbars of about ±380Vdc with respect to
ground – which then provide the input power source for the inverter section.
2. In performing the above conversion it controls the input current waveform such as to keep it in-phase with the
input voltage and thereby maintain a higher input power factor than would otherwise be the case with more
traditional rectifier circuits.
The mains supply is connected to the circuit via the input fuse (F3) and the Input Relays which, when closed, also
grounds (earths) the input neutral. The Input Relays are powered by a dedicated supply obtained from the Battery
Charger block (see figure 2.15) and controlled by an energising signal from the Control Board (>,235/<!) which
closes the relay only if it confirms that the input voltage and other system parameters are valid – see Figure 3.7.
2.3.2 PFC Principles of operation

The PFC circuit employs two ‘boost converters’ operating back-to-back to control both positive and negative half
cycles of the incoming mains waveform and thereby produce individually-controllable 380Vdc positive and
negative busbars. Figure 2.5 shows that the junction of the DC busbar reservoir capacitors is grounded and thus
provides the 0V reference level for both busbars.
PFC Circuit as a basic rectifier

Before describing the boost converters’ operation, first consider the operation of the circuit as a basic full-wave
rectifier – i.e. ignoring the effects of Q14 and diode bridge REC2 (see figure 2.6). Under these circumstances,
during positive half cycles the input current flows from left to right through the input choke (L2), diode D18 and
back to the earthed input neutral via reservoir capacitors C51/C68 and the earth point – the capacitors consequently
charge to a value approaching 1.4 times the input rms voltage (e.g. 325Vdc). During negative half cycles the
reverse action takes place; and current is drawn out of the circuit via C52/C73 and D13 – charging up C52/C73 in
a negative direction and producing the negative 325Vdc busbar.
Issue -1- 01/10/98 15

Figure 2.6 - PFC Circuit as a basic rectifier
+ve half-cycle
-ve half cycle
L2
P1 D18
F3
LIVE DC BUS POS
10A
Input Mains
Supply P2 + C51/68
NEUTRAL
Regulated DC Bus
Input Relay To DC-DC Converter
+ C52/73
D13
DC BUS NEG
A ‘boost converter’ is required for two reasons: first, the dc busbar voltage produced by the basic rectifier circuit
is unregulated, and will vary with changes in load current and/or input mains voltage; second, the inverter section,
which converts the dc busbars back into an ac waveform, requires a higher dc voltage to enable it to produce a
sinusoidal output waveform over its complete operating range.
Boost converter – basic principles

The PFC circuit is a form of peak-current switching regulator normally associated with DC-DC converters rather
than the AC-DC conversion utilised in this application. To understand how the PFC power circuit works it is best
to consider the operation of a standard DC-DC converter and then discuss the additional control features required
by the PFC circuit. Figure 2.7 shows a simplified diagram of the boost converter operating with a dc input supply.
Figure 2.7 - Boost converter – basic principles
L2
P1 D18
+ F3
DC BUS POS
10A
E
P2 + C51/68
–
Input Relay REC2a
+ C52/73
Q14
DC BUS NEG
PFC Rectifier PWM Control Sig
Electronic Control
System
REC2b
If the input voltage (E) in the circuit above is held constant (i.e. a d.c. value) and transistor Q14 is never turned on
then clearly all that will happen in the circuit is that positive dc bus reservoir capacitors C51/68 will charge to the
input voltage (+E volts) via D18.
If a logic high pulse is applied to Q14 gate it will turn hard on and effectively ground the right-hand side of L2 (via
two diodes of REC2). This will not affect the charge on C51/68 as D18 blocks any discharge current; however, it
will increase the current drawn through L12 and REC2(a/b). The amount of increased current depends on the values
of the input voltage (+E) and the drive pulse duration - and can be described using the well known formula
E = -L∂i/∂t .
As the input voltage (E) and inductance (L) are both constant, the current through L2 increases linearly while Q14
is turned on and therefore reaches its peak value at the end of Q14’s drive pulse.
Q14 will turn off when the drive pulse is removed from its gate; however, the current through L2 cannot reduce to
zero instantaneously (one of the properties of a choke) and since Q14 now represents an open circuit the only path
available for the decaying current is through D18 and C51/68, which therefore charge up to a voltage greater than
the input voltage.
16 Issue -1- 01/10/98

Another way to view this action is to consider that the energy stored in the magnetic field around L2 when it draws
current (½LI2) is transferred to capacitors when Q14 turns off.
In the practical PFC circuit the current passing through D18 not only charges C51/68 but also supplies the UPS
load (via the inverter). C51/68 therefore act as a reservoir capacitor, taking on charge when D18 is passing current
(Q14 off) and providing the DC Busbar load current when Q14 is turned on.
In a standard DC-DC converter the output voltage is usually regulated by comparing it with a reference level and
using any error signal resulting from the comparison to control the width or frequency of the drive pulse. For
example, if the circuit's output voltage falls below the reference level then the control circuit would increase the
pulse width (or increase its repetition rate), allowing more current to build up in the choke and thereby restore the
output voltage to nominal. A similar regulation regime is used in the GXT PFC control circuit.
Figure 2.8 - Boost Converter operation on negative half cycles
L2
P1 F3
– DC BUS POS
10A
E + C51/68
P2
+
Input Relay
+ C52/73
D13
DC BUS NEG
REC2d
PFC Rectifier PWM Control Sig

Electronic Control
System
Q14
REC2c
During negative half-cycles of the mains supply the ‘line’ input at P1 is negative with respect to the ‘neutral’ input
at P2 (which is grounded via the input relay), and from a ‘dc’ point of view the input voltage can be considered to
be ‘negative’. Under these circumstances the boost converter works in an identical manner to that described above
for a positive dc input, however the current polarity is now reversed and the circuit controls the negative dc busbar.
That is, when Q14 turns on, current flows from Earth, REC2c, Q14, REC2d, L2, and F3; back to terminal P1.
Current is set up in L2 in the same manner as for the positive half cycle; however, in this case when Q14 turns off
the inductive current is dissipated via C52/73 and D13 – charging up the capacitors and increasing the negative DC
busbar amplitude with respect to ground (earth).
The above examples show that both half-cycles of the input waveform are controlled by a single transistor (Q14)
in conjunction with bridge rectifier REC2.
Issue -1- 01/10/98 17

2.3.3 The practical PFC power circuit

The PFC circuit employed in this equipment works essentially in the same way as the DC-DC boost converter just
described. The main difference between the two circuits is that the PFC circuit input voltage is 220/240Vac and
not a fixed dc level.
To overcome the fact that the circuit is fed with an ac voltage, the transistor drive pulse used in the PFC circuit is
very narrow compared with the period of the input supply – in fact the drive circuit operates at up to 50kHz and
therefore has a maximum pulse-width of 20µs. As the mains frequency is 50Hz this means that Q14 is turned off
and on up to 100 times during every cycle of the input supply; and, despite the fact that the PFC’s input voltage is
sinusoidal, by using such a narrow drive pulse the input voltage can be considered to be constant during each
transistor turn-on period – even though this ‘constant level' will vary slightly from one drive pulse to the next.
The circuit maximises the input power factor by controlling the input current in such a way as to not only make it
sinusoidal but also keep it in phase with the input voltage. This is achieved by pulse-width modulating the drive
signal applied to Q14 - i.e. by turning Q14 on for shorter periods when the input mains voltage is at the low points
of its waveform and for longer periods when it is at the higher points. This means that although Q14’s drive signal
is held at a constant frequency, the mark-to-space ratio (or duty cycle) is made to vary in sympathy with the input
voltage waveform amplitude.
The waveform diagram below shows the principles of this circuit by illustrating the rising and falling current pulses
against the input voltage; however, this diagram shows only a few current pulse (due to the restriction of the
drawing definition) and in practice the current waveform outline at 50kHz is very smooth in comparison to that
shown.
Figure 2.9 - Input Voltage/Current waveforms

20mS period (50Hz)
50Hz Mains supply

has a 20ms period
Individual current
One 10ms Positive pulses are wider
half cycle of the as the input mains
mains supply voltage is around
its peak value
Input mains current

follows the peak
current pulses’
amplitude
10mS Positive half-cycle
18 Issue -1- 01/10/98

2.3.4 PFC Control circuit operation
Figure 2.10 - PFC Control circuit block diagram

L2
P1 F3
LIVE D18
Input Mains 10A
Supply DC BUS POS
P2
NEUTRAL
+ C51/68
Input Relay
Regulated DC Bus
CT2 To DC-DC Converter
+ C52/73
D42-D46 D13
DC BUS NEG
I/P Current Sense
I/P Volts Sense
a d
REC2
PF.VCC+
PF.VCC- Q14 c b
PWM Control Sig

PFC Rectifier
Electronic Control
System (U11)
PF.VCC0 +BUS.V CN2-24
DC Voltage DC Bus Volts

DC Bus Volts FBK
CN2-26 ON/OFF Control Processing Control Board
PFC.OFF
Input Voltage CN2-33 -BUS.V CN2-25

Line.V
Sense Signal Input Voltage
Processing Sense Signals to LINE+ CN2-27
Control Board
Line.L CN2-32
LINE- CN2-26
Figure 2.11 - PFC Drive signal details
L2
P1 F3
LIVE D18
Input Mains 10A DC BUS POS
Supply P2
NEUTRAL
+ C51/68
Input Relay
CT2
+ C52/73
D13
PWM Control Sig
DC BUS NEG
U11-16
PF.VCC-
a d
REC2
C29A R132 D36
+ Q14
TX2 U10 c b
2
R52
6
3
R133
R67/68
C29 ZD4
15V
+
Battery Charger TX
D14
PF.VCC+
PF.VCC0
The PFC control circuit is based on a UC3854 ‘average current-mode controller’ (U11) which is located on the
Power Board. This device is powered from the +24Vdc power rail (see figure 2.4) and its output PWM drive signal
is connected to Q14 via an opto-isolator (U10) whose output is powered from the isolated PFC power supply rails
(PF.VCC) obtained from the Battery Charger transformer (see figure 2.11).
Issue -1- 01/10/98 19

The controller (U11) monitors the following signals:

1. Input voltage sense –
The input voltage is sensed at the cold side of the input fuse (F3). The control system rectifies the input voltage
and converts it to a proportional rms value. The PWM controller uses this signal as a reference input for the
current control (i.e. the greater the instantaneous input voltage then the greater the current limit level) and also
as a ‘feed-forward’ signal, as a means of detecting changes in the input mains supply voltage.
The Control Board also monitors two aspects of the input voltage: first an attenuated ac signal#>/LQH1/! provides
the Control Board with an input frequency/phase sensing signal which it uses for synchronisation purposes etc.
(see figure 3.5). Second, the#>/LQH19! signal is a half-wave rectified signal proportional to the input supply, and
provides the means to allow the Control Board to detect the input voltage characteristics (see figure 3.4).
2. Input current sense –
The input current is sensed by CT2, rectified by D42-D46 and fed to the PWM controller’s current sense/limit
inputs.
3. DC Busbar voltage sense –
As each DC Busbar is independently controlled, their voltages are sensed and processed by two individual
signal processing circuits which therefore produce two independent DC Voltage Feedback signals; one
proportional to the positive bus and the other proportional to the negative bus.
As shown in Figure 2.10, the DC Voltage Feedback Signal Processing circuit provides only one feedback signal
to the PFC Controller (U11). This function is controlled by the >/,1(.! and#>/,1(0! signals from the Control
Board which allows either the positive bus voltage feedback signal or negative bus voltage feedback signal
through to U11 depending on the polarity of the input half-cycle being processed – i.e. during positive half
cycles#>/,1(.! switches the positive busbar feedback signal through to U11 (and vice versa).
Effects of the inputs from the Control Board

The effect of >/,1(.! and#>/,1(0! on the PFC control circuit described above was somewhat simplified as, in practice,
the feedback signal is not permanently applied during the respective whole half cycle but is in fact ‘modulated’.
This permits the micro-controller to moderate the effect of the feedback signal and so effect fine adjustment of the
DC busbar(s) voltage. The purpose of applying this control technique is to enable the micro-controller to control
the DC Busbar voltage balance with respect to 0V. That is, the micro monitors the two busbar feedback voltages
(>.%8619! &#>0%8619!) together with the 0V rail, and detects any bus voltage offset. If an error is found it is corrected
by the modifying the effective DC bus voltage feedback signals by means of the >/,1(.! and#>/,1(0! signals.
The microcontroller on the Control Board also provides the PFC with an ON/OFF control signal >3)&2))! which
is applied to U11-10 via CN2-26 (low = OFF) – (see figure 3.7).
20 Issue -1- 01/10/98

2.4 DC-DC Converter

Figure 2.12 - DC-DC Converter circuit
Positive BUS
Regulated POS DC Bus

L4
+ C51/68
D24 D23
TX1
BAT.V
Q3/4/6 D11 D12
DC-DC Converter
Electronic Control
System (U1) + C52/73
L5
Regulated NEG DC Bus

Q7/10/11
Negative BUS
CN2-24
+BUS.V
DC Bus volts feedback DC Voltage DC Bus Volts

Processing Control Board
-BUS.V CN2-25
CN2-23
3525.OFF LINE+ CN2-27
ON/OFF Control
LINE- CN2-26
2.4.1 Introduction
When the mains supply fails, the PFC Rectifier circuit is unable to produce the DC Busbar required by the inverter
for its power operation. Under these circumstances, the DC-DC Converter takes over control of the DC Busbar by
converting the battery voltage >%$7B9! to a controlled DC busbar of approximately 410Vdc. This allows the inverter
to continue its operation from battery-sourced power until the mains supply returns (or the battery becomes fully
discharged).

The power circuit is a form of push-pull DC-DC Converter. Transformer TX1 centre-tapped primary is connected
to the battery busbar [%$7B9> and its winding extremities are connected to ground (0V) via two transistors operating
in push-pull. In practice, in the 1500RT circuit shown in Figure 2.12, each of the transistors comprises three
transistors connected in parallel – to provide sufficient drive current. Q3/Q4/Q6 turn on to draw current through
one primary winding and Q7/Q1/Q11 turn on to draw current through the other.
By alternately switching on these two groups of transistors (i.e. push-pull operation) an a.c. current is set up in the
transformer which is rectified by D11/D12/D23/D24 and fed to the DC Busbars via L4/L5.
Notice that the centre-tap of TX1 secondary is grounded, which ties together the 0V reference points of the DC-
DC Converter and the PFC Rectifier.

The DC-DC Converter control circuit is based on a UC3525 ‘SMPS controller’ device (U1) which produces two
complementary outputs on pins 11 and 14 which form the transistor drive signals.
The drive signal duty cycle is determined by a control loop which monitors the DC Busbar voltage via the same
feedback control circuit as that used by the PFC Rectifier control circuit described previously.
The Control Board’s processor system also furnishes a DC-DC Converter 2122)) control signal >658582))! which
is applied via CN2-23 (high = off) – see Figure 3.5.
Issue -1- 01/10/98 21

2.5 PWM Inverter

Figure 2.13 - Inverter Circuit Diagram
Bypass Line
Mains(L)
DC BUS +
Q13
+ C51/ D38
C68
CN2-36
L1/L3
PWM signals PWM+12V P3
Inverter
From Control
CN2-37 PWM+ Electronic UPS Output Live
Board
Control
PWM- CT1
System
P4
CN2-38
UPS Output Neutra
C16
+ C52/
C73 D34
Q12
DC BUS -
Isolated Power Supplies
From DC Power Supply Cct
For IGBT Drive Circuits
Inverter Voltage
CN2-12 INV.L O/P Volts Sense
Sense Signal to D7-D10
INV.L
Control Board
CN2-8
Filter/Output Current LC.+
LC.+
Sense Signals to
O/P Current Sense
Control Board CN2-9
LC.-
LC.-
2.5.1 Introduction
The inverter is responsible for converting the DC Busbar into a 230Vac/50Hz supply which is then connected to
the load equipment as the UPS output.
2.5.2 Power circuit description

The inverter function is carried out by two IGBTs, Q12/Q13, connected in series across the positive and negative
DC Busbars, as shown in Figure 2.13. These are driven by complementary 20kHz PWM signals to produce the
required 230V/50Hz output. The 20kHz component is removed from the output waveform by the action of the
output filter formed by L1/L3 and C16, and the ultimate UPS output supply is taken from the junction of these
components and connected to the output sockets via the output relay.
CT1 is a current sensing transformer which monitors both the filter current and output current. The resulting current
sense signal is rectified and fed back to the control logic on the Control Board via CN2 pins 8 & 9 >/1&10! & >/1&1.!.
The output voltage waveform is also monitored by the Control Board via the >,191/! signal at CN2-12.
2.5.3 Control circuit description

The inverter transistor drive signals’ PWM pattern is generated on the Control Board and connected to the Power
Board via CN2 pins 36-38 as#>3:0.!#and#>3:00! and >3:0.459!. The PWM frequency is determined by the micro-
controller on the Control Board which synchronises the inverter output to the bypass frequency under normal
circumstances, and determines the inverter frequency when the mains supply is unavailable. However, the mark-
space of the PWM signal is determined by an analogue circuit on the Control Board which compares the micro-
controller’s reference waveform with the inverter voltage and current feedback signals – and produces a waveform
with the mark-space ratio necessary to produce the correct inverter output voltage (see figure 3.8). The voltage is
not adjustable; however, VR1 (on the Control Board) provides a means of adjusting the output voltage balance to
allow the mid-point of the output ac waveform to be centred about the earth reference.
The >3:0.!#and#>3:00! drive signals, which are always complementary, are connected to the power transistors via
opto-coupled devices (U6/U7) to provide the necessary isolation. The isolator devices (see figure 2.14) use the
>3:0.459! supply from the Control Board to power its input section and the isolated IGBT power supplies
illustrated in Figure 2.4 to power its outputs.
22 Issue -1- 01/10/98

Figure 2.14 - Inverter drive signal coupling
DC BUS +
+IGBT15V
+IGBT-5V
+IGBT.0V
PWM +12V
D37
Q13
8
U6
6 R56
Pos IGBT
Drive Signal From
Control Board
3
5
PWM+
R54
-IGBT+15V
-IGBT-5V
-IGBT.0V
PWM +12V
D35
Q12
2
U7
6 R50
Neg IGBT
Drive Signal From
Control Board
3
PWM-
R51
DC BUS -
2.6 Input relay control

Figure 2.15 - Input relay control circuit
RY3 RY2
I/P fuse
P1 (L)
Input Mains
P2 (N)
D15
+15V
+ C26
TX2 RY3 RY2
100u
Battery Charger
Transformer
From Control I/RLY

Board (0=close) CN2-10
The input relay coils are provided with a permanent +15V supply by rectifying the output of one of the Battery
Charger transformer outputs. The relays are then controlled by a single open/close signal derived on the Control
Board and applied via CN2-10.
Issue -1- 01/10/98 23

24 Issue -1- 01/10/98

CHAPTER 3 - Control Board
Figure 3.1 - Control Board
Control
Board
Location
The Control Board is mounted perpendicular to the Power Board and connected directly to it by means of a 50-pin
connector (CN2), as shown above. Once fitted, the board is held in place by a screw which secures the two boards
together and is also secured to the rear of the UPS chassis by means of two threaded studs which screw into the 9-
pin D-type socket.
3.1 Control system operation
3.1.1 Introduction
The various power blocks located on the Power Board are affected by a micro-controller-based ‘system level’
control circuit centred on the Control Board. Although the internal functions of the micro-controller are complex,
and beyond the scope of this manual, the purpose of its various input and output signals, and their relevant values,
are described in this section to a level which should aid general fault-finding – i.e. to assist the troubleshooting
engineer to establish whether or not the Control Board appears to be working normally.
IMPORTANT NOTE
The following description contains several ‘simplified’ circuit diagrams to help understand the Control Board
functions; however, when the board is in-situ most of its components are inaccessible, and the easiest method
of checking that the board is working correctly is to monitor the input/output signals between the Control Board
and the Power Board at the soldered points of connector CN2 – i.e. on the back of the Control Board PCB.
CAUTION: This requires a steady hand and should be undertaken with EXTREME care.
The pin numbers for CN2 are shown in the diagram below.
Issue -1- 01/10/98 25

GXT-230 Repair Manual Control Board
Figure 3.2 - Control Board Connector pin-outs
1 CN2 pin-out to 49
2 Power Board 50
CN1 pin-out to
Display Panel
2 16
1 15
CN3 pin-out to
comms option
25 1
26 2
26 Issue -1- 01/10/98

The Control Board circuits, which are totally isolated from the high voltage environment found on the Power
Board, can be categorised into the following areas:
• Micro-controller sub-system.
• UPS output voltage and frequency regulation control through the generation of the PWM Inverter drive
signals.
• Start-Stop control of the various Power Board power blocks as part of the general UPS control
management and protection system.
• Load transfer decision making and implementation through controlling the Inverter (output) Relay.
• Interfacing the UPS control system with the Operator Panel and Remote Communication ports.
Issue -1- 01/10/98 27

3.1.2 Control Board power supplies
Figure 3.3 - Control Board power supplies
+5V
CN2-3
5V
+ C14
+12V
U8
7812
CN2-1 1 3
24V
VI VO
GND
+ C15
2
CN2-4
GND
CN3-10
+10.8Vdc
-8V
D22
+Vcc
+ C47
R86 C18 C45
TX1 R95
+ + CN3-7
D19
+ C46
-6.8Vdc
D21
-Vcc
CN2-49 HFPOWER+
D20
CN3-2
CN2-50 HFPOWER-
13.4Vdc
R93 + C48
General control power supplies

The Control Board obtains its main operating power from the +5V and +24V power rails generated on the Power
Board via CN2 pins 3 and 1 respectively (CN2-4 = 0V). On the Control Board the +24V supply also drives a three-
terminal +12V regulator (U8) which provides a general +12V power rail. The +12V rail is also fed back to the
Power Board as >3:01459! via CN2-36.
In order to preserve isolation of the signals presented to the communications port (CN3 / CN4) the Control Board
generates dedicated power supplies which are connected to the associated signal opto-isolator devices (±Vcc).
This circuit is based on TX1, whose primary is driven by the 16Vac (approximately) >+132:(5.! and >+132:(50!
outputs from the DC Power Supply circuit on the Power Board (see figure 2.4). TX1 has three secondary windings
which drive standard half wave rectifier circuits, as shown, to produce the following isolated outputs:
1. -8V supply rail which is used by the output voltage balance potentiometer (see figure 3.8).
Note: this potentiometer may not be fitted to some models.
2. +10.8Vdc and -6.8Vdc rails which are annotated ±Vcc. These provide the operating power for the serial
communications driver chip (U19) together with opto-couplers U12 and U17.
+Vcc (10.8Vdc) can be monitored at CN3-10 and -Vcc (-6.8Vdc) can be monitored at CN3-7.
3. +13.4Vdc supply which is connected to CN3-2 and provides signalling power to the remote communications
device.
28 Issue -1- 01/10/98

3.1.3 Micro-controller analogue inputs

The microcontroller (U6) contains an 8-bit analogue-digital converter which monitors the following signals:
Figure 3.4 - Micro-controller analogue inputs
+5V
D17
CN2-24
+BUS.V +BUS.V 35
C35
+5V
D16
CN2-25 -BUS.V
-BUS.V 38
C36
+5V
D12
CN2-11
BAT.V BAT.V 37
R32 +
C9
+5V
D15
CN2-33 LINE.V R119
LINE.V 42
C37
Block Micro-controller
Output
Current Limit
C-LIMIT
(U6)
Detector +5V
D18
CN2-8 R83
CURR.V 40
C33
CN2-9 L.C-
5V
CN2-34 CN2-34
TH
CN2-35 CN2-35
R14 TEMP.V
36
NTC1
C34
+5V
Block
D9
CN2-12 INV.L R43 Active Half- INV.V
41
Wave Rectifier
C32
Block
Zero Cross
Over Circuit
Block
Inv. Volts
PWM Pattern
F/Back Filter
Generator
DC Bus voltage sensing

Under normal operating conditions the positive and negative DC Busbar voltages are independently controlled
(with respect to 0V ground) by the PFC Rectifier circuit on the Power Board. When the input mains supply fails
this responsibility is taken over by the DC-DC Converter. The micro-controller monitors the voltage of both DC
busbars in order to detect abnormal (fault) conditions and provide associated alarms and indications.
The micro-controller also uses the DC busbar sense signals to detect an unbalanced condition between the two DC
busbars and applies a correction to the PFC/DC-DC Converter feedback circuit (see figure 2.10). In addition, the
micro-controller provides the PFC Rectifier and DC-DC Converter with independent 58126723 command signals
– see Figure 3.7.
Issue -1- 01/10/98 29

A resistor network on the Power Board attenuates the DC Busbar voltages and, depending on the loading, the
resulting voltage sense signals >.%8619! and >0%8619! applied to the Control Board are typically in the range 2.5Vdc
to 3.5Vdc at nominal DC Busbar voltage (note that due to the effects of the busbar balance control circuit these
signals are not necessarily identical at a given time).
Battery Bus voltage sensing

The battery voltage sense signal >%$719!/ connected to CN2-11, is obtained from the Battery Bus on the Power
Board. Under normal circumstances the Battery Bus is controlled by the Battery Charger output at the appropriate
battery float charge voltage and reverts to the actual battery voltage when the input mains supply is absent. The
microcontroller monitors the battery voltage in order to detect abnormal (fault) conditions and provide associated
alarms and indications.
Note: the micro-controller does not play a direct part in controlling the Battery charger voltage with the exception
of providing it with 58126723 command signals.
The >%$719! signal is connected to the Battery Bus via a series resistor chain on the Power Board. This chain is
terminated by R32 on the Control Board, which drops the nominal sense voltage by approximately 92% – e.g.
approximately 4.2V at a nominal float charge voltage of 55.2V.
Input line (bypass)voltage monitor

The input line voltage is sensed on the Power Board at the cold side of the input fuse. The signal is then attenuated
and passed through an active rectifier circuit before being connected to the Control Board via CN2-33 as >/,1(19!.
At nominal input mains voltage >/,1(19! is approximately 2.3V.
The micro-controller monitors the input mains voltage in order to detect abnormal (fault) conditions, determine
when it is appropriate to switch the UPS to its ‘battery mode’ of operation, and provide associated alarms and
indications.
Inverter current monitor

The inverter current monitor input to CN2-8 and CN2-9 takes the form of a d.c signal proportional to the inverter
current, as detected by CT1 on the Power Board. This signal combines both the output (load) current and the output
filter current.
On the Control Board this signal is used by the microcontroller to detect abnormal (fault) conditions and also drives
a hardware-based overload circuit which applies a current-limit input to the PWM pattern generator circuit.
Temperature
The micro-controller monitors the ambient temperature via an NTC and normally-closed thermostat located on the
semiconductors’ heatsink on the Power Board which opens at 90°C
Inverter output voltage monitor

The inverter output voltage is sensed on the Power Board at the inverter side of the output relay. The signal is
passed through a series resistor chain and then connected to the Control Board via CN2-12 as >,191/!. At nominal
230V output voltage >,191/! is approximately 17.2V.
On the Control Board, >,191/! is processed by three circuits:
1. >,191/! is attenuated and half-wave rectified by an active circuit and applied to the microcontroller as a
proportional voltage sense signal. The microcontroller monitors the inverter voltage in order to detect abnormal
(fault) conditions, determine when it is appropriate to transfer the load between the inverter and bypass
supplies, and provide associated alarms and indications.
2. >,191/! is processed by a zero-crossing circuit which converts the sinusoidal inverter output sense signal into a
square-wave coinciding with the zero-crossing points (see figure 3.5).
3. >,191/! is also connected to the PWM pattern generator circuit in the form of an inverter voltage feedback signal
which directly affects the inverter voltage regulation loop (see figure 3.8).
30 Issue -1- 01/10/98

3.1.4 Micro-controller digital inputs
Figure 3.5 - Micro-controller digital inputs
+5V
R58
U5-1
Block
CN2-32 Zero Cross
LINE-ZER 84
Over Circuit
D13
Block
CN2-12 INV.L Active
Half-wave
R43 Rectifier
+5V
R65
U5-2
Block
Zero Cross R66
INV-ZER 83
Over Circuit
D14
Block
Inv. Volts
PWM Pattern
Feedback
Generator
Filter
5V
Micro-controller
(U6)
R76
R75
R74
R73
CN2-20
MODEL0 53
CN2-21
MODEL1 52
CN2-46
MODEL2 51
CN2-47
MODEL3 50
CN1-14
OFFSW 47
R6
C52
+5V
D3
SWSTUTS 46
SW-ON
R15
R16 C53
+5V
+VCC R87
48
1
U10 +5V
V? R88
2
49
1
R98
U11
SW1
2
R99
DIP(2))
Input line (bypass) frequency monitor

The input line frequency monitor circuit is driven by an input mains voltage sense signal which is derived on the
Power Board from the cold side of the input fuse. This signal (>/,1(1/!) is passed through a series resistor chain on
the Power Board before being connected to the Control Board via CN2-32 from where is drives a zero-crossing
detector circuit which converts the sinusoidal input voltage waveform into a 50Hz, 5V square-wave.
Issue -1- 01/10/98 31

The zero-crossing signal is used by the microcontroller as a frequency reference input with which to synchronise
the inverter frequency. It thereby affect the timing of the clock signal produced by the micro and applied to the
PWM pattern generator circuit (see figure 3.8). It is also used as part of the load transfer control mechanism to
inhibit a non-synchronous load transfer between the inverter and bypass supplies.
Inverter output frequency monitor

The inverter frequency is monitored through the inverter output voltage sense signal described earlier in
conjunction with Figure 3.4.
>,191/! is processed by a zero-crossing circuit which converts the sinusoidal inverter output sense signal into a
square-wave coinciding with the zero-crossing points. This produces a frequency/phase signal relative to the
inverter output which is used by the microcontroller to synchronise the inverter frequency to the bypass supply
(using the input line frequency sense signal described above). It is also used as part of the load transfer control
mechanism to inhibit a non-synchronous load transfer between the inverter and bypass supplies.
Model identification
The four inputs to U6 pins 50-53 are used to inform the Control Board which model of Power Board is currently
connected. This allows the Control Board to understand the UPS model rating, working battery voltage etc. The
inputs to U6 are pulled down by jumpers fitted on the Power Board and connected via the CN2 as shown in the
table below:
Table 3.1 - Model ident jumpers
UPS Model Model0 (CN2-20) Model1 (CN2-21) Model2 (CN2-46) Model3 (CN2-47)
GXT700MT-230 – – JP01 Fitted JP02 Open

GXT1000MT-230 – – JP01 Open JP02 Open
GXT1000RT-230 – – JP01 Open JP02 Open
GXT1500RT-230 GND – GND JP02 Open
GXT2000RT-230 +5V GND JP01 Fitted –
GXT3000RT-230 +5V GND JP01 Open –
OFF Switch
The >2))6:! input to U6 pin 47 is taken high (+5V) when the OFF switch is pressed on the Operator Panel. The
Operator Panel is connected to the Control Board via CN1, and the +5V supply for the switch, and also the supply
to the leds is connected to CN1 pin 13.
ON Switch
The >6:67876! input to U6 pin 46 is taken high (+5V) when the ON switch is pressed on the Operator Panel.
The path for this signal includes the Power Board, as shown in Figure 3.6. The power source >6:32:(5! is obtained
from the battery bus on the Power Board via R16. When the ON switch is pressed on the Operator Panel this supply
is further dropped across R15 and R16 on the Control Board, raising U6 input pin 46 to logic high (+5V), which
informs the micro-controller that the ON button is operated.
The >6:67876! signal is inhibited if the micro-controller is calling for the UPS to be shut down due to a detected
fault condition. This is effected by a logic high >6+87'2:1! output from U6-61 which is inverted to a low at U1
pin 10 which clamps the >6:021! signal by hold D2 cathode low.
The [S-D> signal is also passed to the Power Board where is shuts down the Battery Charger and Control Power
Supply circuits.
DIP-Switch
The input to U6 pins 48 & 49 are opto-coupled to the two sections of a DIP Switch which protrude through he UPS
back panel and are used to select the working output voltage.
Note: turn the UPS off before selecting a new working voltage.
32 Issue -1- 01/10/98

Figure 3.6 - ON-Switch signal path
CN2-17 CN1-16 Operator

R16 SWPOWER Panel
15k ON
CN2-40 CN1-15
SW1
SWPOWER
Control
SW-ON
Board
+5V
CN2-41 D3
SWSTUTS 46
SW-ON
R15
Power R16 C53
Board
Micro-controller
D2
(U6)
U1
CN2-18 D23
10 7 SHUTDOWN 61
S-D S-D
+
C50
Control Pwr 100u
Supply &
Batt. Charger
When the UPS is switched ON by means of the Operator Panel ON button, a logic high >6:67876! signal is applied
to U6 pin 46 via the path shown in Figure 3.6. This signal is sourced from the battery bus >6:32:(5! and is
therefore available when the battery is connected or the input mains is live.
If the micro-controller detects a fault that requires the system to be shut down, the >6+87'2:1! output from U6-61
is driven high, which clamps the >6:67876! signal and prevents it from requesting an ‘ON’ condition at U6-46.
This also provides a logic low >60'! input to the Power Board, via CN2-18, which turns off the Control Power
Supply and Battery Charger operation.
Issue -1- 01/10/98 33

3.1.5 Micro-controller digital outputs

The micro-controller contains several data ports through which it communicates with the Operator Panel, external
(remote) communication facilities and the remainder of the control system. The functions described in this sub-
section are concerned with the digital command signals produced by the micro-controller which affect the rest of
the UPS Control system – as illustrated in Figure 3.7 below:
Figure 3.7 - Micro-controller digital outputs

CN5
2
1
R70 CN2-6
55 CHGOFF-
CN2-23
56 3525OFF
CN2-26
57 PFCOFF
CN2-13
INVRLY-
Q2
+24V
R7 CN2-14
58 R101
INVRLY+
R8 + U4
10u
Micro-controller
(U6)
61
SHUTDOWN (see figure 3.6)
62 R5
+12V
D1
R3
R4
Q1
BL
BZ1
BR
BK
CN2-30
26 A0
CN2-31
27 A1
CN2-27
30 LINE+
CN2-28
31 LINE-
CN2-10
I/PRLY
Q3
33 R10
R9
Battery charger ON/OFF control

The micro-controller controls the battery charger ON/OFF function through the >&+*2))0! output from U6 pin 55
which is taken low to turn OFF the battery charger – this signal can also be invoked by fitting a jumper to CN5.
34 Issue -1- 01/10/98

This output is coupled to the Power Board via CN2-6 where it turns on an opto-isolator (U4) which inhibits the
Battery Charger’s Control circuit. The positive supply to the opto device is also derived on the Control Board and
connected to the Power Board via CN2-5 (>&+*2)).!).
DC-DC Converter ON/OFF control

The micro-controller controls the DC-DC Converter ON/OFF function through the >68582))! output from U6 pin
56 which is taken low to turn OFF the converter. This signal is not easily monitored on the Control Board; however,
on the Power Board it can be measured at the ‘cold’ end of R14 (other end is held at +5V) or directly on pin 10 of
the DC-DC Converter controller i.c. U1.
Power Factor Correction Rectifier ON/OFF control

The micro-controller controls the PFC Rectifier ON/OFF function through the >3)&2))! output from U6 pin 57
which is taken low to turn OFF the PFC. Once again this signal is not easily monitored on the Control Board;
however, on the Power Board it can be measured at one end of R86 (other end is held at 0V) or directly on pin 10
of the PFC Rectifier controller i.c. U11.
Inverter (output) relay control
The inverter relay status determines whether the load is connected to the inverter output or the bypass supply, and
the controlling output from U6 pin 58 is the result of a complex decision-making process carried out by the micro-
controller in response to several of its analogue and digital inputs.
When U6-58 is taken high, it turns on Q2 and pulls CN2-13 to 0V which then energises the inverter (output) relay
on the Power Board – thereby placing the load ‘on-inverter.’ The supply to the relay coil positive connection is
made via CN2-14, as illustrated in Figure 3.7.
UPS Shutdown
The output from U6 pin 61 is driven high when the micro-controller wishes to shutdown the UPS – this is inverted
by U1-10 and applied to the Power Board as a logic low >61'1! signal. The passage of this signal to the control Power
Supply and Battery Charger blocks of the Power Board is illustrated in Figure 3.6, which also shows that the
Operator Panel ON switch is effectively inhibited while the shutdown signal is active.
Audible alarm
The audible alarm is controlled from U6-62 whose output activates the sounder via driver transistor Q1.
PFC Rectifier voltage selector

The >$3! & >$4! outputs from U6 pins 26/27 are connected to the DC Busbar voltage feedback circuit on the Power
Board where they determine the gain of the positive and negative busbar voltage feedback amplifiers.
These are used to select the appropriate working voltage selection according to model rating.
PFC Rectifier voltage control

The PFC Rectifier control circuit on the Power Board uses a single controller i.c. to individually control the positive
and negative DC Busbar voltages. The >/,1(.! & >/,1(0! outputs from U6 pins 30/31 are used to control solid-state
switches on the Power Board which are in series with the busbar voltage feedback signals. These signals allow the
micro-controller to control the gain of the feedback loop and are used to effect voltage balance control on the two
busbars with respect to 0V – (see figure 2.10).
These signals are not easily monitored on the Control Board; however, on the Power Board they can be viewed at
one end of R115 and R125 respectively.
Input relay control

The Input Relay is energised when U6-33 is driven high. This turns on Q3 which pulls CN2-10 down to the 0V
rail. The Input Relay’s positive voltage is provided by a dedicated output from the Battery Charger circuit (see
figure 2.2).
Issue -1- 01/10/98 35

3.1.6 PWM Pattern Generator
Figure 3.8 - PWM Pattern Generator circuit
U1-15
INV.L CN2-37
Block PWM+
U5-13
Block
13 Summing R41 Block
Amp Buffer
Complementary
Comparator
R23 Signal
Micro-controller +5V Generator
VR1
R481
(U6)
U4-12
-8V
Block Block U1-16
12 CLOCK Divide Integrator CN2-38

By Two
PWM-
U1-13
U1-14
Block
16 PWMOFF
PWM
+12V
Shutdown
U4-1
Logic
U7-1
CN2-36
Block Block
Current Current
L.C+ Limit Limit PWM12V
Detector Shutdown
The inverter PWM control regime is largely based on an analogue closed-loop regulation circuit which constantly
monitors the output voltage and amends the PWM drive signal pattern as necessary to regulate the UPS output.
The micro-controller provides the circuit with three signals.
1. >3:5! is a digitally-generated, fixed amplitude reference a.c. waveform which is synchronised to the input
(bypass) supply frequency and ac-coupled to the ‘summing amp’ where it is compared with the output voltage
feedback signal >,191/!. The ‘summing amp’ output thus takes the form of an ac waveform superimposed with
a ‘voltage error’ signal, which serves as a ‘control’ input to the ‘buffer-comparator’ block.
Note that the output voltage balance potentiometer (RV1) provides an offset input to the ‘summing amp’ and
is used to centralise the output voltage about the neutral point – i.e. to balance the rms values of the positive
and negative half cycle voltages.
2. The#>&/2&.! output from U6-12 determines the basic PWM frequency.
The ‘buffer-comparator’ compares the ‘summing amp’ output and the divided clock signal and produces a
PWM output depending on the relative signals – the output pattern can be monitored at U5 pin 13.
3. The >3:02))! output from U6-16 provides the means for the micro-controller to turn-off the inverter when
required – due to a fault condition for example. This output can be monitored at U1 pin 13 as a logic low when
the inverter is being commanded OFF – (note that this is inverted with respect to the output at U6-16 shown).
The ‘complementary signal generator’ block converts the PWM pattern presented to U5 pin 13 into two
complementary waveforms which are then connected to the inverter transistor drive circuits via CN2 pins 37 & 38,
as shown. This block also contains certain timing elements which impart a controlled degree on under-lap between
the two waveforms to allow the off-going inverter IGBT time to turn off before the on-coming IGBT is triggered.
The PWM drive signals can be inhibited by the ‘current limit shutdown’ block if the ‘current limit detector’ senses
an inverter current overload. This takes place on a sub-cycle basis. In an overcurrent event U7 pin 1 switches to a
logic high (+12V) which resets U4 and sends U4 pin 1 low – note that the overcurrent operating threshold is not
adjustable.
36 Issue -1- 01/10/98

3.1.7 9-Pin Communications Interface Port
Figure 3.9 - 9-Pin Communications Interface Port circuit details

R122
S.LINFAIL
330R
4
D24
U14
3
S.BATLOW R121
1
4
330R
D25
U16
2
Tx DATA
Rx DATA
CN4
1
9
+5V 2
R90 8
3
7
1k R129 4
BAT.SHUT 6
330R
4
D27
U18
0V
3
+5V
+Vcc
R91
1k
ANYSHUT
U17
4
D26
R120
330R
3
The Control Board contains a 9-pin (female) connector which protrudes through the UPS back panel and provides
passage for several signals which can be monitored by the connected computer running the Liebert SiteNet (or
other) UPS monitoring and control software.
The signals passing through this port, which are all connected via opto-isolator to provide the required signal
isolation, are shown in Figure 3.9, and described below.
Mains Failure
The >61/,1()$,/! signal switches high in the event of a mains failure and produces a low impedance between CN4
pins 8 & 9.
Low Battery
When the UPS is operating ‘on-battery’ the [S.BATLOW> signal switches high when the battery voltage
approaches its ‘end-of-discharge’ value (i.e. the UPS is near to shutting down). When active, this produces a low
impedance between CN4 pins 1 & 7.
Serial data transmit

The micro-controller contains a serial communications facility which transmits data pertaining to the UPS
operating status and parameter values (such as mains and UPS power values) in pre-arranged packets via CN4 pin
2. This data can be processed by suitable software (such as SiteNet) and displayed at a remote terminal.
Issue -1- 01/10/98 37

Serial data receive

This is similar to the Serial Data Transmit feature described above, and allows the UPS to receive commands etc.
from a remote station via CN4 pin 3 (using suitable software).
Remote battery shutdown

When pulled high (5-12Vdc), the input to CN4 pin 4 causes the UPS to shut down if it is operating ‘on-battery’.
This facility can be used when the mains power fails to shut down the UPS (and thereby conserve battery charge)
once the attached computer has been shut down in a controlled manner.
UPS Shutdown
The input to CN4 pin 6 will shut down the UPS if taken low (i.e. if connected to CN4 pin 5 externally).
38 Issue -1- 01/10/98

3.1.8 UPS INTELLISLOT™ Communications

The UPS contains an INTELLISLOT™ communications port for use with an optional internal Ethernet SNMP
card which can be fitted in a receptacle at the back of the UPS after removing a cover-plate.
When this option is fitted, the card is connected to the Control Board CN3 via a ribbon cable – note that when the
INTELLISLOT™ is fitted the Tx Data#and Rx Data serial communication facilities of the 9-pin D-type connector
are disabled, but the opto-coupled signals shown in Figure 3.9 are still active.
Details of the signal functions at CN3 are shown in the following table – when working on the Control Board in-
situ these are best monitored at the soldered side of the board (see figure 3.2).
Table 3.2 - CN3 signal details
Pin # In/Out Signal Function
1 – SELV isolated 0V supply rail (common for pins 1-10)

2 – SELV isolated supply (+7Vdc to +10Vdc @ 500mA)
3 In Rx Data from SNMP card to Control Board
4 Out Tx Data from Control Board to SNMP card
5 – Rx Data from SNMP card to PC
6 – Tx Data from PC to SNMP card
7 Out SELV isolated supply (-Vcc RS232 level -8Vdc to -12Vdc)
8 In Goes high when SNMP card fitted (inhibits D-type connector data comms facility)
9 – SELV isolated 0V supply rail (common for pins 1-10)
10 Out SELV isolated supply (+Vcc RS232 level +8Vdc to +12Vdc @ 100mA)
11 – Reserved
12 – Reserved
13 – Reserved
14 – Reserved
15 – Reserved
16 – Reserved
17 In Logic low shuts down UPS when operating in ‘On-Battery’ mode
18 In Logic Low shuts down UPS when operating in any mode
19 Out Goes high when any UPS alarm is active (summary alarm)
20 Out Goes high when the UPS is operating in ‘On-Bypass’ mode
21 Out Goes high when UPS detects a mains failure (i.e. goes to ‘On-Battery’ mode)
22 Out Goes high when a new UPS fault alarm is activated
23 – 0V Ground (common for pins 17-26)
24 Out Goes high when the UPS battery voltage is near ‘end-of-discharge’ value
25 Out +24V supply (+22Vdc to +28Vdc)
26 Out +12V supply (+11Vdc to +12Vdc)
Issue -1- 01/10/98 39

40 Issue -1- 01/10/98

CHAPTER 4 - Operating Procedures
Figure 4.1 - UPS Control Panel

Load /
Battery Level /
ON / Fault Ident
Alarm Silence / Indicators
Batt. Test
OFF /
Bypass System
Status
Indicators
4.1 Start-up procedure

1. Connect and energise the UPS input mains supply:
• The UPS fans should operate.
• The ‘BYPASS’ status led should illuminate and the audible alarm should sound at approximately 2
minute intervals to remind the user that the load is being supplied with unprocessed power.
• The ‘Load’ bargraf leds should illuminate according to the percentage load being supplied.
2. Hold the UPS ON push-button pressed for 2-4 seconds:
• The UPS control system should run through a series of validity checks and, if successful, transfer the load
to the UPS inverter after approximately 10 seconds.
• The ‘BYPASS’ status led should extinguish and the ‘UPS ON’ status led should illuminate to indicate the
revised supply status.
• After a further 4 seconds the UPS control system should perform an automatic battery test (for
approximately 10-15 seconds) and, if successful, return to normal operation.
4.2 Manual battery test

To perform a manual battery test while the UPS is on-line:
1. Hold the UPS ON push-button pressed for 2-4 seconds:
• The ‘Battery’ status led should illuminate.
• The ‘Battery Autonomy’ bargraf leds should illuminate to show the available autonomy time (all
segments should illuminate if the battery is healthy and fully charged).
• After approximately 10-15 seconds the UPS should revert to normal operation; unless the batteries are
faulty, in which case the ‘Fault’ led should illuminate accompanied by an audible alarm.
4.3 Shutdown procedure

1. Press the OFF push-button:
• The load should transfer to bypass. The ‘Bypass’ status led should illuminate on the UPS Control Panel
and the ‘Inverter’ status led should extinguish.
2. Press the OFF push-button again within 4 seconds:
• The UPS should immediately turn OFF the load supply and fully shut down after approximately 10
seconds.
Note: to shutdown the UPS when operating on bypass press the OFF push-button twice within 4 seconds.
Issue -1- 01/10/98 41

GXT-230 Repair Manual Operating Procedures
42 Issue -1- 01/10/98

CHAPTER 5 - Maintenance & Repair Procedures
5.1 Maintenance
The GXT UPS is virtually maintenance-free.
Batteries
The lead acid batteries are valve regulated, non-spillable should be maintained in a charged state in order to obtain
their designed life. Under normal circumstances the batteries are continuously float charged while the UPS is
turned ON; however, if the UPS is to be removed from service for any length of time, it should be powered-up for
at least 24 hours every four to six months to ensure the batteries remain adequately charged.
Cleaning
The UPS case can be cleaned with a dampened lint-free cloth if required. Do not use solvent cleaner.
Remove any excessive dirt build-up on the fan ventilation grill(s) if necessary.
Issue -1- 01/10/98 43

GXT-230 Repair Manual Maintenance & Repair
5.2 Repair Procedures

This section contains procedures pertaining to the removal and refitting of the UPS major components. Photgraphs
of the 1500VA model are used to illustrate the procedures, but the general methods described apply to the other
models in the GXT range.
IMPORTANT: If a major component is replaced, carry out a general UPS functional check as detailed in
Paragraph 5.6.
5.2.1 Important Safety Considerations

• The following procedures should be undertaken by qualified service personnel only.
• DO NOT perform 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 the UPS is live.
• Turn off the UPS and disconnect input power cord before removing the outer cover – AC mains voltage is always
present if the input AC power is still available.
• High voltages may be present at the DC capacitors. Wait for at least five minutes after turning off the UPS before
removing the outer cover.
• Take care to avoid shorting the internal batteries.
• If the battery is disconnected, be sure to plug in the input power cord and apply input mains power before re-
connecting the battery connector.
44 Issue -1- 01/10/98

5.3 Gaining internal access to the UPS components (all *230RT models)
Figure 5.1 - Removing the top cover and front bezel
5.3.1 Removing the Top and Front bezel:

1. Remove the two screws (A) securing the top cover to the UPS back panel.
2. Push the top panel towards the back of the UPS to disengage its locating lugs from the inner panel, then lift
away.
3. Remove the two screws (B) securing the front bezel mounting brackets to the UPS bottom chassis (these screws
pass through the front feet). Then remove two similar screws securing the bezel mounting brackets to the UPS
inner top cover.
4. Pull away the front bezel over the lifting handles.
5.3.2 Removing the left and right side covers

5. The left-hand cover is L-shaped and also forms the inner top cover. To remove this cover first remove the
screws securing it to the right-hand cover, back-panel top and left side, and the UPS chassis base.
6. Once the left-hand panel is removed the right-hand panel can also be removed in the same manner.
7. This provides full access to the internal components as shown in Figure 5.2.
Figure 5.2 - Internal components accessibility with covers removed

Power Control Cables to
Board Board Comms assembly
Rear
Fan
Operator
Panel
Input
Filter
Front
Fan
Output
Filter
Cables to
External
Battery Fuse
& Connector
Issue -1- 01/10/98 45

5.4 Disconnecting, replacing / servicing the Batteries (all *230RT Models)

Figure 5.3 - Removing the batteries
C E
D
F
1. Remove the top cover and front bezel as described in Paragraph 5.3.1.
2. Remove the screws securing the battery connector cover (C).
3. Withdraw the battery connector (E) and disconnect it.
4. Remove the screws securing the battery assembly cover-plate (D).
5. Withdraw the battery assembly (F). CAUTION: the battery assemblies fitted to the larger models are heavy.
Figure 5.4 - Dismantling the battery assembly
G G
6. If the batteries require changing or visual examination they can be accessed by removing the four screws (G)
which secure the battery assembly top cover to the main assembly.
CAUTION: Lift away the top cover carefully to prevent shorting the battery terminals.
7. To reassemble the battery follow the dismantling instructions in reverse order.
IMPORTANT: A self adhesive insulating strip is applied across the front of the batteries and folds down over
the terminals to prevent the battery assembly top cover shorting out the terminals.
ENSURE THIS STRIP IS FITTED BEFORE REASSEMBLING THE BATTERY PACK.
WARNING: When refitting the battery pack, apply mains power to the UPS and allow it to run before you
reconnect the battery connector (E). This pre-charges the Battery Charger electrolytics and avoids rupturing the
battery fuses due to the initial inrush current when the battery is connected – Note: if the electrolytics have not
been discharged there is no need to observe this precaution (refer to Paragraph 5.5. for details concerning
discharging the electrolytics).
46 Issue -1- 01/10/98

5.5 Replacing the Power Board & Control Board

1. Gain internal access as described in Paragraph 5.3.
2. Ensure that the battery is disconnected (see paragraph 5.4).
3. On the Control Board:
a. Disconnect the ribbon cables from CN1 and CN3.
b. Remove the D-type connector securing screws at the UPS back panel.
4. To remove the Control Board independent of the Power Board, remove the screw securing the two boards
together (located to the rear of the Control Board) and separate the main connector CN2 – to remove both
boards together continue with this procedure.
Figure 5.5 - Board replacement – detailed points

F F E F H G F
J
F F D C F F
5. On the Power Board:

a. Disconnect the battery positive (A) and negative (B) cables.
b. Disconnect the input supply cables (C).
c. Disconnect the UPS output cables (D).
d. Disconnect the Fan supply cable(s) (E)
6. Remove the (8) screws (F) securing the board to the UPS chassis, and withdraw the Power Board (& Control
Board) from the UPS housing.
WARNING: The Battery Charger and DC Busbar electrolytic capacitors on the Power Board may still be
charged. Do not rest the Power Board on a conductive (i.e. metal) surface or damage might occur.
a. To discharge the Battery Charger electrolytics, temporarily connect a discharge resistor (100R / 10W)
across the Control Board’s battery positive (A) and negative (B) terminals.
b. To discharge the positive DC Busbar electrolytics, temporarily connect a discharge resistor (100R / 10W)
between the right-hand side of R58 (G) and the flange of U3 (J) (ground).
c. To discharge the negative DC Busbar electrolytics, temporarily connect a discharge resistor (100R / 10W)
between TP1 (H) and the flange of U3 (J) (ground).
7. To refit the board follow the above procedure in reverse.
WARNING: If the Battery Charger electrolytics have been discharged do not reconnect the battery connector
(see figure 5.3) before the UPS has been restarted (see paragraph 5.4).
Issue -1- 01/10/98 47

5.6 Functional check procedures

This procedure should be used following the replacement of a major component, or at any other time where the
UPS’s general serviceability is suspect.
CAUTION: Do not operate the unit for long periods with the covers removed as it may cause the Battery Charger
transformer (TX3) to overheat.
5.6.1 Preliminary information

1. The procedure assumes:
a. The UPS is isolated from the input mains supply.
b. Full access to the internal components – the top and side panels are removed.
c. The UPS is complete (all assemblies fitted).
d. The battery is disconnected (see figure 5.3) and no external batteries are connected.
e. The UPS is isolated from the input mains supply.
f. The DIP switches on the back of the UPS have been set correctly for the required output voltage.
5.6.2 Battery Charger calibration
Figure 5.6 - Battery charger calibration points

A
1. On the Power Board, connect a DVM to the battery terminals (A) and (B).
2. Connect and energise the input mains supply.
a. The cooling fans should run.
b. The DVM should indicate the Battery Charger output voltage.
3. If necessary adjust VR01 (C) to obtain the nominal charge voltage of 2.3V/cell (i.e. 55.2V in 1500RT model).
4. Turn OFF the input mains supply, wait 2 minutes then connect the battery.
Note: a small arc may be experienced when the battery connector is initially ‘made’.
5. With the DVM still connected verify that the battery off-load voltage is satisfactory (nominal 48Vdc) if found
to be substantially less than this then remove the battery pack and check for faulty cell(s) or incorrectly wired
battery (see paragraph 5.4).
6. Turn ON the input mains supply and check the battery float charge voltage. If this is substantially less than the
value set in step 3 it may be due to the battery being fully discharged and causing the Battery Charger to operate
in current limit mode. Leave the battery on charge for a few hours to see if the voltage increases as the battery
takes on charge – if this fails to occurs then again it could be due to a faulty cell(s).
7. Once you are satisfied that the battery charger is operating correctly:
a. Turn OFF the input mains supply.
b. Disconnect the DVM.
c. Ensure the battery assembly and connector are correctly housed then fit and secure their front cover-plates.
48 Issue -1- 01/10/98

5.6.3 Bypass check

1. Turn ON the input mains supply
a. All of the load/battery leds should illuminate momentarily.
b. The unit should be in the ‘BYPASS’ mode, with the ‘Bypass’ and ‘AC input’ leds illuminated, and will emit
a 1 second warning beep (every two minutes.
2. Connect a true rms-reading DMV to the UPS output socket and verify that the bypass voltage is present (and
identical to the input mains supply voltage).
5.6.4 UPS switch ON check

1. Press the UPS ON button.
a. The UPS control system should run through a series of validity checks on the DC busbar and inverter and,
if satisfactory, energises the Output Relay after approximately 10 seconds. This transfers the load to the
inverter and the ‘Bypass’ led should extinguish and the ‘UPS ON’ led illuminate.
b. After a further 4 seconds (approximately) the UPS control system should perform an automatic battery test
whereby the PFC Rectifier is turned off for approximately 15 seconds and the DC busbar voltage is
monitored while the inverter is being powered from the batteries. The ‘Battery’ led should illuminate during
this period and the ‘load/battery’ bargraph leds should fully illuminate if the battery is well charged.
2. At the end of the battery test sequence:
a. The ‘Battery’ led should extinguish.
b. The load/battery bargraph leds should extinguish.
c. The ‘UPS ON’ led should illuminate to show that the output is now ‘on-inverter’.
Note: If the batteries fail the test the load is transferred to the bypass supply and the ‘Fault’ led illuminates.
Issue -1- 01/10/98 49

5.6.5 DC Busbar voltage checks

The following checks verify the correct operation of the PFC Rectifier, DC-DC Converter and Inverter:
CAUTION: High voltages are present. Care must be taken when connecting and disconnecting the DVM from the
circuit under test. If in doubt, turn OFF the UPS and input mains supply between taking the following
measurements.
Note: the voltage measurements given below will vary slightly according to the value of the input mans voltage,
and also assume that the UPS is totally unloaded.
DC Bus voltage (from PFC Rectifier)
Figure 5.7 - DC Bus voltage calibration

B C A
1. Turn OFF the UPS and the input mains supply.

2. Connect a DVM across the DC Busbar – the right-hand side of R58 (A) is the positive bus and TP1 (B) is the
negative bus.
3. Turn ON the input mains supply:
a. The PFC Rectifier should turn ON.
b. The DC Bus voltage indicated on the DVM will initially rise to approximately 750Vdc and then fall back
to approximately 630-660Vdc as the regulation circuit settles down.
4. Measure the individual positive and negative DC busbar voltages with respect to 0V (ground) to ensure that
they are balanced – i.e. using U3 flange (C) as the 0V reference point, the voltages between A-C and B-C should
be equal.
DC Bus voltage (from DC-DC Converter)

5. Repeat steps (1) and (2) above.
6. Turn ON the UPS and allow it to run through its start-up test sequence and give it time to settle into normal
operation – i.e. ‘ON UPS’ led illuminated.
7. Turn OFF the input mains supply:
a. The ‘AC INPUT’ led should extinguish and the ‘BATTERY’ led illuminated to indicate that the UPS is
operating on battery power.
b. The DC Bus voltage indicated on the DVM should rise to approximately 790-800Vdc.
8. Measure the individual positive and negative DC busbar voltages with respect to 0V (ground) to ensure that
they are balanced – i.e. using U3 flange (C) as the 0V reference point, the voltages between A-C and B-C should
be equal.
9. Restore the input supply and observe the DC Busbar voltages return to their normal levels.
50 Issue -1- 01/10/98

5.6.6 Output voltage offset check
Figure 5.8 - Low pass filter adapter
Low Pass filter adapter
100K /2W
From UPS output (Line) To DVM Positive
10uf/250V
10uf/250V
From UPS output (Neutral) To DVM Negative
1. Connect a DVM, set to DC Volts, to the UPS output socket via the low pas filter adapter shown above (locally
constructed).
2. With the UPS running both normally (mains supply connected) and ‘on-battery’ (mains supply disconnected)
check that the DVM indicates no more than 400mV.
Issue -1- 01/10/98 51

52 Issue -1- 01/10/98

CHAPTER 6 - Troubleshooting Procedures
6.1 Introduction
When the UPS detects an internal fault it will usually transfer the load to the bypass supply and indicate the nature
of the problem by illuminating a combination of the left-hand bargraph LEDs on the Operator Panel – note that the
top-most (red) LED signifies ‘Fault’ – (see paragraph 1.5.3).
Troubleshooting table
If the UPS malfunctions the likely cause usually can be found by interpreting the LED indications in Table 2 and
carrying out the suggested checks.
Dismantling the equipment

In most instances the Control Board and/or Power Board must be removed to enable the detailed checks to be
carried out – full dismantling details are provided in the Repair chapter (see paragraph 5.2). Remember always to
discharge the Charger and DC Bus capacitors when removing the Power Board (see paragraph 5.5).
Live functional checks

When a faulty unit is repaired it should be fully functionally checked as described in Paragraph 5.6. This ensures
that the unit is correctly set-up and ready to be put back into service.
Using the ‘Quick Start (for 2000/3000VA models see Paragraph 6.11)’ Procedure
By their very nature, the ‘power components’ are those most likely to be affected by an internal UPS fault, or
extreme overload problem.
The ‘Quick Start (for 2000/3000VA models see Paragraph 6.11)’ troubleshooting procedure describes a series of
checks that can be carried out on the primary components located in the various UPS power blocks, and can be
used as a general troubleshooting procedure which can be undertaken ahead of the more detailed procedures: i.e.
a problematic area can usually be quickly identified, or narrowed down, by following the ‘Quick Start (for 2000/
3000VA models see Paragraph 6.11)’ procedure.
This procedure should also be used if there is a problem in starting the UPS.
Procedures
The procedures contained in this chapter are listed below:
Procedure 6.3 Quick Start (for 2000/3000VA models see Paragraph 6.11)
Procedure 6.4 PFC Rectifier check procedure (for 2000/3000VA models see Paragraph 6.12)
Procedure 6.5 DC-DC Converter check procedure (for 2000/3000VA models see Paragraph 6.13)
Procedure 6.6 DC Power Supply check procedure (for 2000/3000VA models see Paragraph 6.14)
Procedure 6.7 Battery Charger check procedure (for 2000/3000VA models see Paragraph 6.15)
Procedure 6.8 Inverter check procedure (for 2000/3000VA models see Paragraph 6.16)
Procedure 6.9 Overtemperature checks
Procedure 6.10 DC Voltage Feedback loop checks (for 2000/3000VA models see Paragraph 6.18)
Issue -1- 01/10/98 53

GXT-230 Repair Manual Troubleshooting
6.2 Operating problems

Table 6-1 describes the actions to take in respect of Operating Problems – i.e. those situations that occur which do
not illuminate the )$8/7 led (which are described in the Troubleshooting Table 6-2).
Table 6.1 - Operating Problems
SYMPTOM POSSIBLE CAUSE ACTIONS
Turn OFF the UPS. Disconnect all

loads and ensure that nothing is
UPS Output is short circuited or
lodged in the output sockets.
overloaded
UPS Fails to start when the ON Ensure loads are not internally
button is pressed shorted
Carry out the Quick Start (for 2000/
Faulty internal fuse or power
3000VA models see Paragraph
component
6.11) check procedure
Ensure input supply cable is
UPS not connect to input mains
connected and mains supply is
supply
turned ON
BATTERY indicator is illuminated Rectify the cause of mains failure.

The UPS is responding normally to
UPS input supply failure a mains supply problem
– SAVE DATA AND CLOSE
APPLICATIONS
Allow the batteries to charge for 24
Poorly charged battery
hours then repeat the test.
UPS Fails Battery Test
Inspect the batteries and replace if
Faulty battery cell(s)
necessary
Allow the batteries to charge for 24
Battery not fully charged
hours then repeat the test.
UPS Has reduced battery time Check the displayed load level and
UPS is overloaded
reduce if applicable
Ageing batteries Replace batteries
54 Issue -1- 01/10/98

Table 6.2 - Fault indication
INDICATION INTERPRETATION CAUSE & INITIAL ACTIONS
Possible Cause=#
O/P load is larger than the UPS VA or Wattage rating.
On Bypass due to
Actions:
output overload
Reduce the load connected to the UPS output socket to an
acceptable level (within the UPS rating).
Possible Cause 1:
Ambient Temperature is above the specified permissible
operating temperature.
Actions:
1. Reduce the ambient temperature if possible
2. Ensure ventilation grills are unobstructed
On Bypass due to
3. Temporarily reduce the O/P load to allow the UPS to cool
Over-temperature
down
Possible Cause 2:
Thermal detection circuit failed.
Actions:
Refer to the functional check procedure in Paragraph 6.9.
Possible Cause 1:
Some non-fatal misbehaviour of UPS.
Actions:
Turn 2)) the UPS then turn it back 21 to see if the problem
clears.
Possible Cause 2:
PFC Rectifier circuit failure.
Actions:
Refer to the functional check procedure in Paragraph 6.4
On Bypass due to
DC Bus Overvoltage
Possible Cause 3:
DC/DC circuit failure.
(In this situation, AC INPUT LED will not light).
Actions:
Possible Cause 4:
Bus voltage feedback circuit problem.
Actions:
Issue -1- 01/10/98 55

Possible Cause 1:
Too much step load added on O/P under Backup mode.
Actions:
Remove excess load.
Possible Cause 2:
Battery capacity is too low.
On Bypass due to Actions:
DC Bus Undervoltage 1. Reduce the load (or leave ‘On-bypass’) and allow the
batteries to re-charge.
2. Replace faulty or aging battery.
Possible Cause 3:
DC/DC circuit problem.
Actions:
Possible Cause:
On Bypass due to PFC circuit Failed.
PFC Rectifier failure Actions:
Possible Cause 1:
O/P short circuit.
(In this situation, no power will transfer to the O/P socket.)
Actions:
Remove short circuit condition, turn 2)) the UPS then turn it
On Bypass due to
back 21 again.
Inverter failure
Possible Cause 2:
Inverter circuit failed.
Actions:
Possible Cause:
Battery too weak.
On Bypass due to
Actions:
failed battery test
Charging battery for a while then re-test. If the problem still
exists then replace the batteries.
Possible Cause:
UPS has received a signal from the attached computer.
UPS Shut down by Actions:
command from the Problem with the attached computer (software incorrectly
communications port installed).
Problem with communications cable (or incorrect
communications cable is in use).
56 Issue -1- 01/10/98

GXT-230 Repair Manual 700VA / 1000VA / 1500VA Model Troubleshooting
6.3 Quick Start (for 2000/3000VA models see Paragraph 6.11)

Figure 6.1 - ‘Quick Start’ procedure component location*
U I J C D K L O M P N
T S G B H R F E
-#3KRWRJUDSK#VKRZV#48339$#3RZHU#%RDUG1#&RPSRQHQWV#DUH#LQ#VDPH#UHODWLYH#SRVLWLRQV#RQ#:339$#)#4333#9$#PRGHOV
1. Remove the Power Board following the dismantling procedure in Paragraph 5.5 and discharge the Charger and
DC Bus capacitors.
2. Check the Battery Fuses F1/F2 (A) (F1 only on 700VA model)
If the battery fuse(s) are ruptured it could be due to:
– faulty battery; faulty Battery Charger; faulty L.V Power Supply (or problem elsewhere on the board placing
a short on the power supply rails)
3. Check the Input Fuse F3 (B)
If the input fuse is blown it could be due to:
– faulty PFC Rectifier; faulty Control Board; faulty Inverter or severe instantaneous output overload.
4. PFC Rectifier section:
– Check D13 (C) and D18 (D) for open/short circuit.
– Check diode bridge REC1 (E) for open/short circuit between any two legs.
– Check FET Q14 (F) Drain-to-Source for open/short circuit.
5. DC-DC Converter:
– Check FETs Q3/Q4/Q6 (G) Drain-to-Source for open/short circuit (no Q3/Q7 fitted on 700VA model).
(Note these devices are connected in parallel and all three should be replaced if any one fails).
– Check FETs Q7/Q10/Q11 (H) Drain-to-Source for open/short circuit.
– Check power diodesD11 (I), D12 (J) D23 (K), D24 (L) for open/short circuit.
(Note: these are connected in a bridge format across the DC Busbar and the busbar capacitors can be seen
charging/discharging depending on the polarity of the meter leads).
6. Inverter:
– Check FETs Q12 (M) and Q13 (N) Drain-to-Source for open/short circuit
– Check power diodesD34 (O), D38 (P) for open/short circuit (Note: these are in parallel with Q12 and Q13)
7. Battery Charger:
– Check FET Q8 (R) Drain-to-Source for open/short circuit
– Check power diodes D5 (S), D6 (T) for open/short circuit
8. DC Power Supply:
– Check FET Q2 (U) Drain-to-Source for open/short circuit
Issue -1- 01/10/98 57

6.4 PFC Rectifier check procedure (for 2000/3000VA models see Paragraph 6.12)
Figure 6.2 - ‘PFC Rectifier’ procedure component location*
C D
A
G
F
E
I
B J
6.4.1 Fault characteristics

A PFC Rectifier fault usually can be attributed to:
a. A faulty PFC power component, which renders the circuit inoperable and likely to rupture the input fuse.
b. An overload on the circuit’s output DC Busbar(s), due to shorted busbar or inverter problem. Once again,
this could rupture the input fuse in extreme cases, or else force the PFC to operate in a current limited mode.
c. A PFC Control fault which either fails to turn on the controlling transistor (resulting in low DC Bus volts
and perhaps a ‘battery on-load’ condition) or, conversely, turns on the transistor inappropriately – causing
an unbalanced output, or once again rupturing the input fuse.
This procedure seeks to identify a problem falling into the (a) and (b) categories above; however, due to the
inaccessibility of the components on the Control Board when it is in-situ there is little that can be done to
troubleshoot the control circuit at component level, and this situation is best remedied by replacing the Control
Board and returning the suspect Board for bench testing.
6.4.2 Static checks

DC Bus capacitors.
2. Check ALL the following PFC Rectifier components and replace where necessary:
REF Component Normal Value Fault Value?
A input Fuse F3 Short circuit Open circuit

B PFC Power Controller Transistor Q14 (Drain-Source) 0.46 (diode range) Short/Open circuit
C/D Flywheel diode D13 / D18 0.46 (diode range) Short/Open circuit
E Resistor R52 47 Ohms Short/Open circuit
F Diode bridge REC1 (between adjacent terminals) 0.46 (diode range) Short/Open circuit
58 Issue -1- 01/10/98

3. Check out the DC Busbar by measuring the resistance across the positive bus capacitors (G) and negative bus
capacitors (H) (observe polarity) (only one capacitor fitted to each position on 700VA model). The result
should show typical capacitor charging characteristics to high impedance. If a short-circuit or low resistance is
indicated then:
a. check for a faulty electrolytic capacitor and replace where necessary.
b. if the capacitors are serviceable then there is likely to be a faulty Inverter power component, or short-
circuited diode in the DC-DC Converter circuit’s output – carry out the Inverter / DC-DC Converter static
checks.
6.4.3 Power checks

4. If ALL the components listed in step (2) are serviceable (or have been replaced) then refit the Power Board and
Control Board, and attempt to start the UPS to see if the fault is rectified.
WARNING: Do not reconnect the batteries before applying the input mains power or the inrush current from
the battery to the Charger circuit might rupture the battery fuse and damage the charger’s electrolytic(s).
5. If the UPS appears to operate correctly:
a. carry out the Functional Check Procedure (see paragraph 5.6).
b. completely reassemble the UPS and return it to service.
6. If the PFC Rectifier still fails to work correctly.
a. remove the Power Board once again (remember to discharge the Charger and DC Busbar capacitors).
b. replace U11 (3854) (I) and U10 (TLP250) (J).
c. refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then check
out the DC Feedback loop components (see paragraph 6.10) or replace the Power Board and Control Board
in turn.
Issue -1- 01/10/98 59

6.5 DC-DC Converter check procedure (for 2000/3000VA models see Paragraph 6.13)
Figure 6.3 - DC-DC Converter procedure component identification*
I H E E E E
A F
B (D) C (D)

A DC-DC Converter fault usually can be attributed to:
a. A faulty power component, which renders the circuit inoperable. Depending on the failure mode, this is
likely to rupture the battery fuses (F1/F2) or render the circuit incapable of sustaining the UPS output when
working ‘on battery’. A short-circuited DC-DC Converter output diode could also effectively present a
short-circuit to the DC Busbar which in turn could affect the PFC Rectifier’s operation (with possible input
fuse failure).
this could rupture the battery fuses in extreme cases, or else force the DC-DC Converter to operate in a
current limited mode, which prevents correct operation when ‘on battery’.
Note: if there is a short-circuit fault on the DC Bus / Inverter, it will also affect the PFC Rectifier operation
(see paragraph 6.4) under normal circumstances and will affect the DC-DC converter only in the event of
an input supply failure.
c. A DC-DC Converter control fault which either fails to turn on the controlling transistors (resulting in total
inability to run the UPS ‘on battery’ or, conversely, turns on the transistor inappropriately – causing an
unbalanced or excessive DC Busbar voltage, or once again rupturing the battery fuses.
60 Issue -1- 01/10/98

6.5.2 Static checks

DC Bus capacitors.
2. Check ALL the following DC-DC Converter components and replace where necessary:
A Battery fuses F1/F2 Short circuit Open circuit

B Transistors Q3*/Q4/Q6 (paralleled) (Drain-Source) 0.43 (diode range) Short/Open circuit
C Transistors Q7*/Q10/Q11 (paralleled) (Drain-Source) 0.43 (diode range) Short/Open circuit
D Gate resistors R26*/R32/R33/R35*/R39/R40 (10R) 10 Ohms Short/Open circuit
E Diodes D11/D12/D23/D24 0.40 (diode range) Short/Open circuit
*Not fitted on 700VA model
3. Check out the DC Busbar by measuring the resistance across the positive bus capacitors (F) and negative bus
capacitors (G) (observe polarity) (only one capacitor fitted to each position on 700VA model). The result
should show typical capacitor charging characteristics to high impedance. If a short-circuit or low resistance is
indicated then:
circuited diode in the DC-DC Converter circuit’s output – carry out the Inverter / PFC Rectifier static
checks.
6.5.3 Power checks

4. If ALL the components listed in steps (2/3) are serviceable (or have been replaced) then refit the Power Board
and Control Board, and attempt to start the UPS to see if the fault is rectified.
the battery to the Charger circuit might rupture the battery fuses and damage the charger’s electrolytic(s).
6. If the DC-DC converter still fails to work correctly (i.e. the UPS will not operate ‘on battery’):
b. replace U1 (3525) (H) and transformer TX1 (I).
in turn.
Issue -1- 01/10/98 61

6.6 DC Power Supply check procedure (for 2000/3000VA models see Paragraph 6.14)
Figure 6.4 - DC Power Supply procedure component identification*
C F B A D I E/H G J
B (D) C (D)

A DC Power Supply fault will render the UPS totally inoperable to the extent that the UPS totally shuts down and
the Operator Panel may appear to be totally ‘dead’ (no indications) or display ‘nonsensical conditions’. This type
of fault will also prevent the UPS from being started, and if it occurs when on line it could also cause fault
repercussions in other areas of the UPS.
A DC Power Supply fault usually can be attributed to:
a. A faulty Power Supply power component, which renders the circuit inoperable. Depending on the failure
mode, this is could rupture the battery fuses (F1/F2).
b. An overload on one of the circuit’s output supply rails due to a faulty UPS control circuit component (on
either the Power Board or Control Board).
Note: such a problem may affect the operation of any of the UPS power blocks and initiate a related error
indication.
c. A problem with the Battery Charger block.
The DC Power Supply is normally powered from the Battery Charger output and if this power source is
unavailable it will take its operating power from the battery, thereby causing the battery to discharge.
This procedure seeks to identify a problem falling into the (a) and (b) categories above; the Battery Charger circuit
check procedure is provided in Paragraph 6.7.
62 Issue -1- 01/10/98

6.6.2 Static checks

DC Bus capacitors.
2. Check ALL the following DC Power Supply components and replace where necessary:
A Switching transistor Q2 (Drain-Source) 0.43 (diode range) Short/Open circuit

B Resistor R18 47 Ohms Short/Open circuit
C Resistor R21 1 kOhm Short/Open circuit
Resistor R23/R23A 0.5 Ohms
D Short/Open circuit
(No R23A on 700VA / 100VA) 0.22 Ohm (700VA)
E Regulator U3 (between Input and Output) >1 MOhm Short/Open circuit
Controller i.c. (3845) U2:
Pin 5-6 >1 MOhm
F Pin 5-7 >1 MOhm Lower resistance
Pin 5-8 >1.5 kOhm
Pin 6-8 >1 MOhm
3. Carry out a resistance check of the power supply rails as detailed below. If the measured resistance is much
lower than the suggested figures it indicates that the original problem was due to an overload on one of the
Power Supply outputs. Unless the components causing the overload problem can be identified by observation
(i.e. shows signs of overheating / distortion) then return the faulty board(s) for repair:
Note: Use the flange of U3 (E) as the 0V reference.
REF Test Point Control Board Typical Resistance

Fitted?
G +24V Rail at D20 cathode Yes / No 2.4k /2.4k Ohms

H +12V Rail at U3 input Yes / No >1M / >1M Ohms
I +5V Rail at U3 output (or C21+) Yes / No 8.4k / 2.6k Ohms
6.6.3 Power checks

6. If the UPS still fails to work correctly and indicates a Power Supply problem then:
b. replace U2 (3845) (F) and transformer TX3 (J).
c. refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace
the Power Board and Control Board in turn.
Issue -1- 01/10/98 63

6.7 Battery Charger check procedure (for 2000/3000VA models see Paragraph 6.15)
Figure 6.5 - Battery Charger procedure component identification*
D (D5) D (D6) E A C F B D (D25/26)

A Battery Charger malfunction could affect the UPS in several ways:
• If the charger just stop working (e.g. turned OFF by the Control Board) not only would the battery lose
its float charge supply but it would also begin to slowly discharge as it is now required to furnish the DC
Power Supply operating power.
The same effects would result from a charger overload which causes its output voltage to fold-back under
current limit control.
• If the charger operates at too great a voltage it could cause a rise in battery temperature (and battery
damage in extreme cases) and the DC Power Supply switching transistor circuitry.
• If the charger develops a short-circuit output it will rupture the Battery fuses F1/F2, the DC Power Supply
will also lose its operating power and the UPS would therefore totally shutdown (perhaps in a disorderly
manner which triggers failure in other UPS power areas).
A Battery Charger fault usually can be attributed to:
a. A faulty Battery Charger power component, which renders the circuit inoperable.
b. An overload on its output supply rail due to a faulty DC Power Supply, or serious battery problem.
Note: a DC Power Supply problem may affect the operation of any of the UPS power blocks and initiate a
related error indication.
c. A problem with the Battery Charger control fault which either fails to turn on the controlling transistor
(resulting in low output volts and perhaps a ‘battery on-load’ condition) or, conversely, turns on the
transistor inappropriately – causing an excessive charger output voltage.
This procedure seeks to identify a problem falling into the (a) and (b) categories above; a control problem can be
identified by carrying out the functional check procedure in Paragraph 5.6
64 Issue -1- 01/10/98

6.7.2 Static checks

DC Bus capacitors.
2. Check ALL the following Battery Charger components and replace where necessary:
A Switching transistor Q8* (Drain-Source) 0.5 (diode range) Short/Open circuit

0.75 Ohm
C Resistor R45 Short/Open circuit
(1 Ohm on 700/1000VA)
D Diodes D25 / D26 / D5 / D6 0.5 - 0.5 (diode range) Short/Open circuit

Diode bridge REC2 (measure across C30)
E 0.5 (diode range) Short/Open circuit
(Bridge is formed by D28-D31 on 700VA / 1000VA models)

Pin 5-6 45 - 50 kOhm
Pin 5-8 3 - 4 kOhm
Pin 6-8 50 - 60 kOhm
* If Q8 is faulty then also replace ALL other components listed in the above table.
6.7.3 Power checks

5. If the UPS still fails to work correctly:
b. replace U6 (3845) U4 Opto and transformer TX2.
6. Refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace
Issue -1- 01/10/98 65

6.8 Inverter check procedure (for 2000/3000VA models see Paragraph 6.16)
Figure 6.6 - Inverter procedure component identification*
G D C
B E C F H D

An Inverter fault usually can be attributed to:
a. A faulty Inverter power component, which renders the circuit inoperable. In extreme circumstances this
could overload the PFC Rectifier to the extent that it could rupture the input fuse.
b. An overload on the circuit’s output, due to a problem with the load or output filter components. An output
overload problem should trip the inverter off line in a controlled manner (transferring the load to the bypass
supply).
c. An Inverter control fault which turns on the Inverter transistors in such a manner as to produce an incorrect
output voltage or inappropriate waveform – this is normally due to a Control Board micro-controller
problem (which controls the PWM waveform).
66 Issue -1- 01/10/98

6.8.2 Static checks

DC Bus capacitors.
2. Check ALL the following Inverter components and replace where necessary:
A Input Fuse F3 Short Open circuit

B Battery Fuses F1 / F2 Short Open circuit
C Inverter transistors Q12 / Q13* 0.42 (diode range) Short/Open circuit
D Gate drive resistors R50 / R56** 47 Ohms Short/Open circuit
* Q12 is in parallel with D38 (E) and Q13 with D34 (F). If a short circuit is found across the transistors it
could be due to a faulty diode - replace both transistors and both diodes if a fault is found.
** If a gate drive resistor is found faulty then replace opto-isolators U7/U8 (G/H) as a precaution, as they
too are likely to be damaged.
6.8.3 Power checks

3. If ALL the components listed in steps (2) are serviceable (or have been replaced) then refit the Power Board
a. replace the Control Board to determine if it is the cause of the problem. If the Inverter operates correctly
with the replacement Control Board then replace U1 / U2 / U3 / U5 on the removed Control Board and then
refit it to determine if it is now serviceable (if not then return the Control Board for repair).
b. If the problem is not rectified by substituting the Control Board then replace the Power Board and return the
old board for repair.
Refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace the
Power Board and Control Board in turn.
Issue -1- 01/10/98 67

6.9 Overtemperature checks

The inverter transistors’ heatsink temperature is monitored by a normally-closed thermostat which opens at 90°C
to provide the Overtemperature Warning. The UPS is rated at full load over a temperature range of 0-40°C.

The heatsink temperature is affected by the of power being demanded by the output load and the amount (and
temperature) of cooling air being drawn across the heatsink by the cooling fans.
An overtemperature fault can therefore usually can be attributed to:
a. Too high a load demand for an extended period with consideration to the prevailing ambient air temperature.
b. Excessive ambient air temperature.
c. Low cooling air flow due to failed fan(s), blocked / obstructed ventilation grill(s).
d. Faulty thermostat or Control Board electronics.
6.9.2 Check procedure

1. Check the indicated UPS Load and reduce if applicable.
2. Check ambient air temperature, and ensure that the UPS ventilation grills (front / rear) are unobstructed – rectify
problem(s) as applicable.
3. Verify that the cooling fans are running (both audibly and by feeling for available airflow). If the fans are not
working then turn OFF the UPS, gain internal access (see paragraph 5.3) and replace the fan(s) as necessary.
4. If all the above appear to be satisfactory then:
a. turn OFF the UPS, gain internal access (see paragraph 5.3)
b. check the thermostat / wiring for open-circuit fault.
c. Replace the thermostat if found faulty, otherwise suspect a problem with the Control Board. Replace the
Control Board.
68 Issue -1- 01/10/98

6.10 DC Voltage Feedback loop checks (for 2000/3000VA models see Paragraph 6.18)
Figure 6.7 - DC Feedback component identification*
D

The DC Busbar voltage feedback circuit provides a signal which controls the regulated outputs of both the PFC
Rectifier and DC-DC Converter – i.e. the supply voltage to the Inverter when it is operating in ‘on-mains’ and ‘on-
battery’ modes respectively. In extreme circumstances it can prevent the inverter from operating.
A faulty DC Voltage feedback component can lead to:
a. DC Overvoltage fault condition
b. DC Undervoltage fault condition
c. Unbalanced inverter output (with respect to ground).
Carry out the following repair procedure if you have worked through the PFC Rectifier or DC-DC Converter check
procedures without successfully clearing the associated UPS fault.
6.10.2 Repair procedure

This procedure assumes that there is a problem with the PFC Rectifier or DC-DC Converter output (DC Busbar
voltage) and that the appropriate check procedure has been carried out without curing the problem.
1. Gain internal UPS access and replace the Control Board.
2. If this rectifies the problem then suspect a faulty micro-controller (U6) on the removed Control Board.
3. If replacing the Control Board does not rectify the problem then
a. remove the Power Board following the dismantling procedure in Paragraph 5.5 and discharge the Charger
and DC Bus capacitors.
b. on the Power Board, replace U9 (A), U12 (B), Q15 (C), Q16 (D).
4. Refit the Power Board and Control Board, and measure the DC Busbar voltage.
5. If the DC Busbar voltage is still incorrect then replace the Power Board and return the faulty board for repair.
Issue -1- 01/10/98 69

GXT-230 Repair Manual 2000VA / 3000VA Model Troubleshooting
6.11 Quick Start (for 700/100/1500VA models see Paragraph 6.3)

Figure 6.8 - ‘Quick Start’ procedure component location*
U P N M O
L
KJI
A
R B G H C D F E
-#3KRWRJUDSK#VKRZV#63339$#3RZHU#%RDUG1#&RPSRQHQWV#DUH#LQ#VDPH#UHODWLYH#SRVLWLRQV#RQ#5333#9$#PRGHOV
DC Bus capacitors.
2. Check the Battery Fuses F2/3 (A)
If the battery fuse(s) are ruptured it could be due to:
– faulty battery; faulty Battery Charger; faulty L.V Power Supply (or problem elsewhere on the board placing
a short on the power supply rails)
3. Check the Input Fuse F1 (B)
If the input fuse is blown it could be due to:
– faulty PFC Rectifier; faulty Control Board; faulty Inverter or severe instantaneous output overload.
4. PFC Rectifier section:
– Check D509 (C) and D510 (D) for open/short circuit.
– Check diode bridge BR02 (E) for open/short circuit between any two legs.
– Check FET Q1A (F) Drain-to-Source for open/short circuit.
5. DC-DC Converter:
– Check FETs Q501/502/503 (G) Drain-to-Source for open/short circuit (Q501 not fitted to 2000VA model).
– Check FETs Q504/505/506 (H) Drain-to-Source for open/short circuit (Q504 not fitted to 2000VA model).
– Check power diodesD501 (I), D502 (J) D503 (K), D504 (L) for open/short circuit.
(Note: these are connected in a bridge format across the DC Busbar and the busbar capacitors can be seen
charging/discharging depending on the polarity of the meter leads).
70 Issue -1- 01/10/98

6. Inverter:
– Check FETs Q5/7 (M) and Q12/13 (N) Drain-to-Source for open/short circuit
– Check power diodesD12 (O), D13 (P) for open/short circuit (Note: these are in parallel with Q5/7 & Q12/13)
7. Battery Charger:
– Check FET Q208 (R) Drain-to-Source for open/short circuit
– Check power diodes D511 (S), D202A (T) for open/short circuit
8. DC Power Supply:
– Check FET Q3 (U) Drain-to-Source for open/short circuit
Issue -1- 01/10/98 71

6.12 PFC Rectifier check procedure (for 700/100/1500VA models see Paragraph 6.4)
Figure 6.9 - ‘PFC Rectifier’ procedure component location*
C D B F J
-#3KRWRJUDSK#VKRZV#63339$#3RZHU#%RDUG1#&RPSRQHQWV#DUH#LQ#VDPH#UHODWLYH#SRVLWLRQV#RQ#5333#9$#PRGHOV I

A PFC Rectifier fault usually can be attributed to:
a. A faulty PFC power component, which renders the circuit inoperable and likely to rupture the input fuse.
this could rupture the input fuse in extreme cases, or else force the PFC to operate in a current limited mode.
c. A PFC Control fault which either fails to turn on the controlling transistor (resulting in low DC Bus volts
and perhaps a ‘battery on-load’ condition) or, conversely, turns on the transistor inappropriately – causing
an unbalanced output, or once again rupturing the input fuse.
72 Issue -1- 01/10/98

6.12.2 Static checks

DC Bus capacitors.
2. Check ALL the following PFC Rectifier components and replace where necessary:
A input Fuse F1 Short circuit Open circuit

B PFC Power Controller Transistor Q1A (Drain-Source) 0.46 (diode range) Short/Open circuit
C/D Flywheel diode D509 / D510 0.46 (diode range) Short/Open circuit
E Resistor R2A 10 Ohms Short/Open circuit
F Diode bridge BR02 (between adjacent terminals) 0.46 (diode range) Short/Open circuit
3. Check out the DC Busbar by measuring the resistance across the positive bus capacitors (G) and negative bus
capacitors (H) (observe polarity). The result should show typical capacitor charging characteristics to high
impedance. If a short-circuit or low resistance is indicated then:
circuited diode in the DC-DC Converter circuit’s output – carry out the Inverter / DC-DC Converter static
checks.
6.12.3 Power checks

4. If ALL the components listed in step (2) are serviceable (or have been replaced) then refit the Power Board and
Control Board, and attempt to start the UPS to see if the fault is rectified.
the battery to the Charger circuit might rupture the battery fuse and damage the charger’s electrolytic(s).
6. If the PFC Rectifier still fails to work correctly.
b. replace U305 (3854) (I) and U10 (TLP250) (J).
in turn.
Issue -1- 01/10/98 73

6.13 DC-DC Converter check procedure (for 700/100/1500VA models see Paragraph 6.5)
Figure 6.10 - DC-DC Converter procedure component identification*
F
E
I B/D H C/D

A DC-DC Converter fault usually can be attributed to:
a. A faulty power component, which renders the circuit inoperable. Depending on the failure mode, this is
likely to rupture the battery fuses (F2/F3) or render the circuit incapable of sustaining the UPS output when
working ‘on battery’. A short-circuited DC-DC Converter output diode could also effectively present a
short-circuit to the DC Busbar which in turn could affect the PFC Rectifier’s operation (with possible input
fuse failure).
this could rupture the battery fuses in extreme cases, or else force the DC-DC Converter to operate in a
current limited mode, which prevents correct operation when ‘on battery’.
Note: if there is a short-circuit fault on the DC Bus / Inverter, it will also affect the PFC Rectifier operation
(see paragraph 6.12) under normal circumstances and will affect the DC-DC converter only in the event of
an input supply failure.
c. A DC-DC Converter control fault which either fails to turn on the controlling transistors (resulting in total
inability to run the UPS ‘on battery’ or, conversely, turns on the transistor inappropriately – causing an
unbalanced or excessive DC Busbar voltage, or once again rupturing the battery fuses.
74 Issue -1- 01/10/98


DC Bus capacitors.
2. Check ALL the following DC-DC Converter components and replace where necessary:
A Battery fuses F2/F3 Short circuit Open circuit

B Transistors Q501*/502/503 (paralleled) (Drain-Source) 0.43 (diode range) Short/Open circuit
C Transistors Q504*/505/506 (paralleled) (Drain-Source) 0.43 (diode range) Short/Open circuit
D Gate resistors R510-R516 (10R) 10 Ohms Short/Open circuit
E Diodes D510-D508 0.40 (diode range) Short/Open circuit
*Q501/Q504 are not fitted to 2000VA model even though they are shown on the circuit diagram
3. Check out the DC Busbar by measuring the resistance across the positive bus capacitors (F) and negative bus
capacitors (G) (observe polarity). The result should show typical capacitor charging characteristics to high
impedance. If a short-circuit or low resistance is indicated then:
circuited diode in the DC-DC Converter circuit’s output – carry out the Inverter / PFC Rectifier static
checks.
6.13.3 Power checks

6. If the DC-DC converter still fails to work correctly (i.e. the UPS will not operate ‘on battery’):
b. replace U501 (3525) (H) and transformer TX501/502 (I).
in turn.
Issue -1- 01/10/98 75

6.14 DC Power Supply check procedure (for 700/100/1500VA models see Paragraph 6.6)
Figure 6.11 - DC Power Supply procedure component identification*
B/ C A F/ I/ J E/ H J D G

A DC Power Supply fault will render the UPS totally inoperable to the extent that the UPS totally shuts down and
the Operator Panel may appear to be totally ‘dead’ (no indications) or display ‘nonsensical conditions’. This type
of fault also prevents the UPS from being started, and if it occurs when on line it could also cause fault
repercussions in other areas of the UPS.
A DC Power Supply fault usually can be attributed to:
a. A faulty Power Supply power component, which renders the circuit inoperable. Depending on the failure
mode, this is could rupture the battery fuses (F2/F3).
b. An overload on one of the circuit’s output supply rails due to a faulty UPS control circuit component (on
either the Power Board or Control Board).
Note: such a problem may affect the operation of any of the UPS power blocks and initiate a related error
indication.
c. A problem with the Battery Charger block.
The DC Power Supply is normally powered from the Battery Charger output and if this power source is
unavailable it will take its operating power from the battery, thereby causing the battery to discharge.
This procedure seeks to identify a problem falling into the (a) and (b) categories above; the Battery Charger circuit
check procedure is provided in Paragraph 6.15.
76 Issue -1- 01/10/98


DC Bus capacitors.
2. Check ALL the following DC Power Supply components and replace where necessary:
A Switching transistor Q3 (Drain-Source) 0.43 (diode range) Short/Open circuit

C Resistor R404 1 kOhm Short/Open circuit
D Resistor R32 0.5 Ohms Short/Open circuit
E Regulator U311 (between Input and Output) >1 MOhm Short/Open circuit
Pin 5-6 >1 MOhm
Pin 5-8 >1.5 kOhm
Pin 6-8 >1 MOhm
3. Carry out a resistance check of the power supply rails as detailed below. If the measured resistance is much
lower than the suggested figures it indicates that the original problem was due to an overload on one of the
Power Supply outputs. Unless the components causing the overload problem can be identified by observation
(i.e. shows signs of overheating / distortion) then return the faulty board(s) for repair:
Note: Use the flange of U311 (E) as the 0V reference.
REF Test Point Control Board Typical Resistance

Fitted?
G +24V Rail at D330 cathode Yes / No 2.4k /2.4k Ohms

H +12V Rail at U311 input Yes / No >1M / >1M Ohms
I +5V Rail at U311 output (or C21+) Yes / No 8.4k / 2.6k Ohms
6.14.3 Power checks

6. If the UPS still fails to work correctly and indicates a Power Supply problem then:
b. replace U302 (3845) (F) and transformer TX305 (J).
c. refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace
Issue -1- 01/10/98 77

6.15 Battery Charger check procedure (for 700/100/1500VA models see Paragraph 6.7)
Figure 6.12 - Battery Charger procedure component identification*
D (D202A)
D (D511)
G
A
D(D32)
B(R226) H E D (D205)
C(R230)
F(U206) -#3KRWRJUDSK#VKRZV#63339$#3RZHU#%RDUG1#&RPSRQHQWV#DUH#LQ#VDPH#UHODWLYH#SRVLWLRQV#RQ#5333#9$#PRGHOV

A Battery Charger malfunction could affect the UPS in several ways:
• If the charger just stop working (e.g. turned OFF by the Control Board) not only would the battery lose
its float charge supply but it would also begin to slowly discharge as it is now required to furnish the DC
Power Supply operating power.
The same effects would result from a charger overload which causes its output voltage to fold-back under
current limit control.
• If the charger operates at too great a voltage it could cause a rise in battery temperature (and battery
damage in extreme cases) and the DC Power Supply switching transistor circuitry.
• If the charger develops a short-circuit output it will rupture the Battery fuses F2/F3, the DC Power Supply
will also lose its operating power and the UPS would therefore totally shutdown (perhaps in a disorderly
manner which triggers failure in other UPS power areas).
A Battery Charger fault usually can be attributed to:
a. A faulty Battery Charger power component, which renders the circuit inoperable.
b. An overload on its output supply rail due to a faulty DC Power Supply, or serious battery problem.
Note: a DC Power Supply problem may affect the operation of any of the UPS power blocks and initiate a
related error indication.
c. A problem with the Battery Charger control fault which either fails to turn on the controlling transistor
(resulting in low output volts and perhaps a ‘battery on-load’ condition) or, conversely, turns on the
transistor inappropriately – causing an excessive charger output voltage.
This procedure seeks to identify a problem falling into the (a) and (b) categories above; a control problem can be
identified by carrying out the functional check procedure in Paragraph 5.6
78 Issue -1- 01/10/98


DC Bus capacitors.
2. Check ALL the following Battery Charger components and replace where necessary:
A Switching transistor Q208* (Drain-Source) 0.5 (diode range) Short/Open circuit

C Resistor R230 0.75 Ohm Short/Open circuit
D Diodes D511/202A/205/32 0.5 - 0.5 (diode range) Short/Open circuit
E Diode bridge BR01 (measure across C16) 0.5 (diode range) Short/Open circuit
Pin 5-6 45 - 50 kOhm
Pin 5-8 3 - 4 kOhm
Pin 6-8 50 - 60 kOhm
* If Q208 is faulty then also replace ALL other components listed in the above table.
6.15.3 Power checks

b. replace U206 (3845)(F), U6 Opto (G) and transformer TX1 (H).
6. Refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace
Issue -1- 01/10/98 79

6.16 Inverter check procedure (for 700/100/1500VA models see Paragraph 6.8)
Figure 6.13 - Inverter procedure component identification*
E D C(Q12/13) C(Q5/7) F
Adjacent trans
H

An Inverter fault usually can be attributed to:
a. A faulty Inverter power component, which renders the circuit inoperable. In extreme circumstances this
could overload the PFC Rectifier to the extent that it could rupture the input fuse.
b. An overload on the circuit’s output, due to a problem with the load or output filter components. An output
overload problem should trip the inverter off line in a controlled manner (transferring the load to the bypass
supply).
c. An Inverter control fault which turns on the Inverter transistors in such a manner as to produce an incorrect
output voltage or inappropriate waveform – this is normally due to a Control Board micro-controller
problem (which controls the PWM waveform).
80 Issue -1- 01/10/98


DC Bus capacitors.
2. Check ALL the following Inverter components and replace where necessary:
A Input Fuse F1 Short Open circuit

B Battery Fuses F2 / F3 Short Open circuit
C Inverter transistors Q5 / Q7 / Q12 / Q13 0.42 (diode range) Short/Open circuit
D Gate drive resistors R10 / R11 / R30 / R33 ** 47 Ohms Short/Open circuit
* Q12/13 are in parallel with D12 (E) and Q5/7 with D13 (F). If a short circuit is found across the transistors
it could be due to a faulty diode - replace both transistors and both diodes if a fault is found.
** If a gate drive resistor is found faulty then replace opto-isolators U2/U3 (G/H) as a precaution, as they
too are likely to be damaged.
6.16.3 Power checks

3. If ALL the components listed in steps (2) are serviceable (or have been replaced) then refit the Power Board
a. replace the Control Board to determine if it is the cause of the problem. If the Inverter operates correctly
with the replacement Control Board then replace U1 / U2 / U3 / U5 on the removed Control Board and then
refit it to determine if it is now serviceable (if not then return the Control Board for repair).
b. If the problem is not rectified by substituting the Control Board then replace the Power Board and return the
old board for repair.
Refit the Power Board and Control Board and attempt to start the UPS. If the fault is still present then replace the
Power Board and Control Board in turn.
Issue -1- 01/10/98 81

6.17 Overtemperature checks

The inverter transistors’ heatsink temperature is monitored by a normally-closed thermostat which opens at 90°C
to provide the Overtemperature Warning. The UPS is rated at full load over a temperature range of 0-40°C.

The heatsink temperature is affected by the of power being demanded by the output load and the amount (and
temperature) of cooling air being drawn across the heatsink by the cooling fans.
An overtemperature fault can therefore usually can be attributed to:
a. Too high a load demand for an extended period with consideration to the prevailing ambient air temperature.
b. Excessive ambient air temperature.
c. Low cooling air flow due to failed fan(s), blocked / obstructed ventilation grill(s).
d. Faulty thermostat or Control Board electronics.
6.17.2 Check procedure

1. Check the indicated UPS Load and reduce if applicable.
2. Check ambient air temperature, and ensure that the UPS ventilation grills (front / rear) are unobstructed – rectify
problem(s) as applicable.
3. Verify that the cooling fans are running (both audibly and by feeling for available airflow). If the fans are not
working then turn OFF the UPS, gain internal access (see paragraph 5.3) and replace the fan(s) as necessary.
4. If all the above appear to be satisfactory then:
a. turn OFF the UPS, gain internal access (see paragraph 5.3)
b. check the thermostat / wiring for open-circuit fault.
c. Replace the thermostat if found faulty, otherwise suspect a problem with the Control Board. Replace the
Control Board.
82 Issue -1- 01/10/98

6.18 DC Voltage Feedback loop checks (for 700/100/1500VA models see Paragraph 6.10)
Figure 6.14 - DC Feedback component identification*
A B
D(Q10) C(Q9)

The DC Busbar voltage feedback circuit provides a signal which controls the regulated outputs of both the PFC
Rectifier and DC-DC Converter – i.e. the supply voltage to the Inverter when it is operating in ‘on-mains’ and ‘on-
battery’ modes respectively. In extreme circumstances it can prevent the inverter from operating.
A faulty DC Voltage feedback component can lead to:
a. DC Overvoltage fault condition
b. DC Undervoltage fault condition
c. Unbalanced inverter output (with respect to ground).
Carry out the following repair procedure if you have worked through the PFC Rectifier or DC-DC Converter check
procedures without successfully clearing the associated UPS fault.
6.18.2 Repair procedure

This procedure assumes that there is a problem with the PFC Rectifier or DC-DC Converter output (DC Busbar
voltage) and that the appropriate check procedure has been carried out without curing the problem.
1. Gain internal UPS access and replace the Control Board.
2. If this rectifies the problem then suspect a faulty micro-controller (U6) on the removed Control Board.
3. If replacing the Control Board does not rectify the problem then
a. remove the Power Board following the dismantling procedure in Paragraph 5.5 and discharge the Charger
and DC Bus capacitors.
b. on the Power Board, replace U304 (A), U1 (B), Q9 (C), Q10 (D).
4. Refit the Power Board and Control Board, and measure the DC Busbar voltage.
5. If the DC Busbar voltage is still incorrect then replace the Power Board and return the faulty board for repair.
Issue -1- 01/10/98 83

84 Issue -1- 01/10/98

CHAPTER 7 - Spare Parts
7.1 Spare Parts Kits
GXT700MT-230
Part Number Qty Description
102-00937-00 1 FUSE BUSS/S505 5A 250V CERAMIC (TIME DELAY)
118-20016-00 1 FAN NMB/3110KL-04W-B50- P00 80*80*25
373-00056-00 1 Enclosure, Top
520-00249-00 1 Bezel
710-01110-00 1 PCB SUB-ASSY 1XXX PANEL (LIEBERT) Display Board
710-01116-02 1 PCB SUB-ASSY 10X3 CNTL (LIEBERT) 230V Control Board
710-01126-00 1 PCB SUB-ASSY PSDR-1033 (LIEBERT) Main Power Board
GXT1000MT-230
094-00046-01 1 FILTER DELTA/06DBDW3S
094-00050-00 1 FILTER DELTA/10DBAG5
100-20045-00 1 FUSE HOLDER EDK/FH-B12 10A 250V 5*20
100-70041-00 1 RECEPTACLE IEC320 C13 WS-045 4/4 10A250V OUTLET
102-00520-00 1 FUSE BUSS/S505 6.3A 250Vac TIME DELAY
108-00310-00 1 POWER CORD AWG12*(180,220) BLK,RED BANANA HEAD 2PAM
108-00311-00 1 POWER CORD AWG12*370 BLK,RED+CORD BANANA HEAD 2 PAF
118-20016-00 1 FAN NMB/3110KL-04W-B50- P00 80*80*25
520-00249-00 1 Bezel
710-01179-01 1 PCB SUB-ASSY 1053 PSDR( LIEBERT)MT Main Power Board
GXT2000RT-230
092-25050-00 1 NFB JOINTECH/ W28-XQ1A-12 12A 250Vac
102-21150-01 1 FUSE 30A 660V 10*38
118-20026-00 2 FAN NMB/3610KL-04W-B50- L00 12Vdc 92*82.5*25.8
373-02032-00 1 Enclosure, Top/Side
373-02033-00 1 Enclosure, Side
520-00239-00 1 Bezel
710-01108-01 1 PCB SUB-ASSY 1073,1083 EMI (LIEBERT) EMI/MOV Board
710-01402-01 1 PCB SUB-ASSY 1073 PSDR (LIEBERT) Main Power Board
Issue -1- 01/10/98 85

GXT-230 Repair Manual Spare Parts
GXT3000RT-230+A28
092-22500-00 1 NFB PROTECTORS/UB2-X-1- 620E-16 1P 16A
092-25010-00 1 NFB JOINTECH/ W28-XQ1A-10 10A 250Vac
102-21150-01 1 FUSE 30A 660V 10*38
118-20026-00 2 FAN NMB/3610KL-04W-B50- L00 12Vdc 92*82.5*25.8
520-00239-00 1 Bezel
710-01108-01 1 PCB SUB-ASSY 1073,1083 EMI (LIEBERT) EMI/MOV Board
710-01421-01 1 PCB SUB-ASSY 1083 PSDR (LIEBERT) Main Power Board
GXT1500RT-230
520-00239-00 1 Bezel
710-01110-00 1 Display Board
710-01116-02 1 Control Board
710-01460-00 1 Main Power Board
373-02031-00 Enclosure, Top
118-20016-00 1 Fan
GXT1000RT-230
520-00239-00 1 Bezel
710-01110-00 1 Display Board
710-01116-02 1 Control Board
710-01440-01 1 Main Power Board
118-20016-00 1 Fan
86 Issue -1- 01/10/98

7.2 GXT700MT-230 BILL OF MATERIALS
Note: The following basic bill of materials for each model, have been included in this manual as sup-
plementary information. They are to be used as a guide only when locally sourcing components.
Qty Cct Ident Description Manufacturer

1 FUSE BUSS/S505 5A 250V CERAMIC (TIME DELAY) BUSSMANN
1 FILTER DELTA/06GEEG3E DELTA
1 FILTER DELTA/10DBAG5 DELTA
1 FUSE BUSS/S505 5A 250V CERAMIC (TIME DELAY) BUSSMANN
2 BATTERY PANASONIC/ LC-R127R2PG1 12V 7.2AH MATSUSHITA SEMICONDUCTOR
1 FAN NMB/3110KL-04W-B50- P00 80*80*25 HWAN CHONG
1 LD502 LED LTL-3251A YELLOW 5*2 EVERLIGHT
1 LD503 LED LTL-3231A GREEN 5*2 EVERLIGHT
1 LD501 LED LTL-3211A RED 5*2 EVERLIGHT
1 SW501 SWITCH TACK TAP 5.0mm 12Vdc 50mA FORWARD
1 R10 RES CF 1/4W 510 J TY-OHM
1 R106 RES CF 1/4W 2.2K J KOA
1 R39 RES CF 1/4W 36K J KOA
Issue -1- 01/10/98 87


1 R101 RES NFMOF 1W 300 J TY-OHM
1 R121 RES PMF 1/4W 330 F KOA
1 R41 RES PMF 1/4W 1K F KOA
1 R1 RES PMF 1/4W 4.99K F TY-OHM
88 Issue -1- 01/10/98


1 R30 RES PMF 1/4W 16.9K F KOA
1 R119 RES PMF 1/4W 20K F TY-OHM
Issue -1- 01/10/98 89


1 R24 RES PMF 1/4W 1M F KOA
1 R96 METAL GLAZE 1/4W 3.9M J KOA
1 R72 METAL-GLAZE 1/4W 4.7M J KOA
1 NTC1 THERMISTOR,NTC 15K UPPERMOST
1 C9 CAP EL-AL 1uF 50V M 5*11 RL2 RAD TAP 5mm 105¢J NIPPON CHEMI-CON
1 C27 CAP EL-AL 10uF 50V M 5*11RL2 RAD TAP 5mm NIPPON CHEMI-CON
1 C50 CAP EL-AL 100uF 50V M 8* 12RL2 RAD TAP 5mm 105¢J NIPPON CHEMI-CON
1 C14 CAP EL-AL 220uF 35V M 10 *13RL2 RAD TAP 5mm 105¢J NIPPON CHEMI-CON
1 C17 CAP EL-AL 1uF 100V M 5*11RL2 RAD TAP 5mm 85¢J NIPPON CHEMI-CON
1 C7 CAP PE 0.0010uF 50V J RAD(IND) TAP 5mm TAIWAN TAI YANG
1 C60 CAP MPE 1.000uF 63V J RAD TAP 5mm TEAPO
1 C40 CAP CER MONO 22P 200V J NPO AXI TAP 26mm "220" AVX CO.,
1 C25 CAP CER MONO 100P 200V J J NPO AXI TAP26mm "101" AVX CO.,
1 C6 CAP CER MONO 470P 100V J NPO AXI TAP26mm "471" AVX CO.,
1 C1 CAP CER MONO 220PF 50V J COG AXI TAP26mm "221" AVX CO.,
1 C19 CAP CER MONO 0.1uF 50V M Z5U AXI TAP26mm "104" AVX CO.,
90 Issue -1- 01/10/98


1 C22 CAP CER MONO 103 50V K X7R AXI TAP 26mm "103" AVX CO.,
1 C12 CAP CER MONO 102 50V J N NPO AXI TAP 26mm "102" AVX CO.,
1 C61 CAP CER DISC 0.001uF 250Vac K Y-,X- GRANSTAR
1 TX1 TX 1P 105X 55:49:52:29:44 EE-16 LION
1 U5 IC LINEAR LM339N MOTOROLA SEMICONDUCTOR C
1 U3 IC LINEAR TL074BCN T.I. SEMICONDUCTOR CO.,
1 U13 IC LINEAR TL431AC SAMSUNG SEMICONDUCTOR CO
1 U8 IC LINEAR UA7812UC MOTOROLA SEMICONDUCTOR C
1 U4 IC LOGIC MC14013BCP MOTOROLA SEMICONDUCTOR C
1 U1 IC LINEAR ULN2003AN MOTOROLA SEMICONDUCTOR C
1 U19 IC LOGIC HI3-5051-5 HARRIS SEMICONDUCTOR CO.
1 U10 IC PHOTO NEC/PS2561-1-V (W) NEC SEMICONDUCTOR CO.,
1 D19 D. GI/1N4937 1A 600V TAP pitch 0.8mm G.I.
1 D1 D. ROHM/1N4148 0.15A 75V ULTRAFAST ROHM SEMICONDUCTOR CO.,
Issue -1- 01/10/98 91


1 Q1 TR BIP TOSHIBA/2SC1815 150mA 60V NPN TAP TOSHIBA
1 Q2 TR MOSFET TOSHIBA/ 2SK941 600mA 100V TAP TOSHIBA
1 SW1 SWITCH DIP 2P
1 XL1 CRYSTAL,CERAMIC 12MHZ TXC
1 BZ1 BUZZER 20335 3.0-20Vdc OBO SEAHORN
1 IC CPU MC68HC711K4CFN3/ SC416389CFN3 MOTOROLA SEMICONDUCTOR C
1 R11 RES CF 1/4W 10 J KOA
1 R31 RES SSNF 3W 100 J TY-OHM
1 R43 RES SSNF 3W 100K J RSS TY-OHM
92 Issue -1- 01/10/98


Issue -1- 01/10/98 93


1 R23 RES NRWW 2W 0.22 J (NON-IND) TY-OHM
94 Issue -1- 01/10/98


1 R45 RESISTOR NRWW 2W 1 J (NON-IND) TY-OHM
1 R57 RES NRWW 5W 10 J TY-OHM
1 R18 RES FMF 1/2W 47 J TY-OHM
1 R21 RES FMF 1/2W 1.0K J TY-OHM
1 VR01 VR 1K 1T 3323PEW-4-102 BOURNS
1 NTC1 THERMISTOR,NTC 10 5A UPPERMOST
1 C30 CAP EL-AL 47uF 450V M 16 *35.5RL2 RAD 7.5mm 105¢J NIPPON CHEMI-CON
1 C51 CAP EL-AL 330uF 450V M 30*50SN2 RAD 10mm NIPPON CHEMI-CON
1 C19 CAP EL-AL 2200uF 16V M 12.5*25RL2 RAD 7.5mm85¢J NIPPON CHEMI-CON
1 C2 CAP EL-AL 4700uF 35V M 18*40RL2 RAD 7.5mm 85¢J NIPPON CHEMI-CON
1 C16 CAP MPE 3.3uF 250VAC M RAD X- OKAYA
1 C22 CAP MPP 0.022uF 1000V J RAD WIMA
Issue -1- 01/10/98 95


1 C68 CAP MPE 0.47uF 275VAC M RAD X2- OKAYA
1 C59 CAP CER MONO 3.9nF 50V J NPO RAD TAP 5mm "392" AVX CO.,
1 C24 CAP CER MONO 47PF 50V J COG AXI TAP 26mm "470" AVX CO.,
1 C42 CAP CER DISC 470PF 1000V M Z5U TAP 5mm "471" EVER GRACE
1 C17 CAP CER DISC 1nF 1000V M Y5P TAP 5mm "102" EVER GRACE
1 C46 CAP CER DISC 2.2nF 1000V K Y5P TAP 5mm "222" EVER GRACE
1 C33 CAP CER DISC 0.01uF 1000V M Z5U EVER GRACE
1 CT1 CT 1:1:1000 EI-28 LION
1 CT2 CT 1:1:1000 EI-28 LION
1 TX3 TX 1030 1P 100:100:48:62 :62 37KHZ FER EEL-16 LION
1 TX2 TX 103X 1P 84:6:6:11:6 37KHZ FER EI-30 LION
1 TX1 TX 103X 1P 2:2:36:36 50KHZ FER EE-42/20 LION
96 Issue -1- 01/10/98


1 L4 CHOKE 105X 600uH 5A 0.7D FER ROD MYLEE COMPANY LIMITED CO
1 L5 CHOKE 105X 600uH 5A 0.7D FER ROD MYLEE COMPANY LIMITED CO
1 L3 CHOKE 103X 5.0mH 5A 0.9D FER T22 CM THE DIANN
1 L1 CHOKE 1033 4mH 3.5A 0.9D 77440-A7 O/P THE DIANN
1 L2 CHOKE 1033 8mH 3.5A 0.8D 77439-A7 I/P THE DIANN
1 U9 IC LINEAR LM324N T.I. SEMICONDUCTOR CO.,
1 U3 IC V. REGULATOR 1A 5V 2% MC78T05ACT MOTOROLA SEMICONDUCTOR C
1 Q5 IC LINEAR TL431CP TAP T.I. SEMICONDUCTOR CO.,
1 U1 IC LINEAR SG3525AN MOTOR0LA 084-02300-00 MOTOROLA SEMICONDUCTOR C
1 U2 IC LINEAR UC3845N MOTOROLA SEMICONDUCTOR C
1 U11 IC LINEAR UC3854N UNITRODE SEMICONDUCTOR C
1 U4 IC PHOTO TLP521-1BL TOSHIBA
1 U10 IC PHOTO TLP250 TOSHIBA
1 D11 D. HARRIS/RHRP8120 8A1200V HARRIS SEMICONDUCTOR CO.
1 REC1 D. GI/GBU6M 6A 1000V BRIDGE G.I.
1 D17 D. GI/1N4007 1A 1000V TAP pitch 0.8mm GENERALINSTRUMENT SEMICO
Issue -1- 01/10/98 97


1 D5 D. GI/UF5402 3A 200V G.I.
1 D6 D. GI/UF5402 3A 200V G.I.
1 D28 D. GI/IN5399GP 1.5A 1000V TAP pitch 25.4mm GENERALINSTRUMENT SEMICO
1 ZD4 ZD NEC/RD3.3 1/2W 3.3V NEC SEMICONDUCTOR CO.,
1 ZD2 ZD NEC/RD5.1E 1/2W 5.1V NEC SEMICONDUCTOR CO.,
1 ZD1 ZD NEC/RD12E 1/2W 12V NEC SEMICONDUCTOR CO.,
1 Q10 TR MOSFET HARRIS/RFP 50N06 50A 60V HARRIS SEMICONDUCTOR CO.
1 Q2 TR MOSFET HARRIS/IRF620 5A 200V
1 Q8 TR MOSFET TOSHIBA/ 2SK793 5A 850V TOSHIBA
1 Q12 TR IGBT TOSHIBA/GT15Q101 15A 1200V TOSHIBA
1 RY2 RELAY OMRON/G4W-2212P- VD-TV5 10A 250V C:12Vdc OMRON
1 RY1 RELAY OMRON/G2R-1-E 16A 250V Coil:12Vdc OMRON
1 TSA SWITCH THERMAL WAKO/CS- 7SA NFZ-250-90C WAKO
1 MOV1 VARISTOR HARRIS/ V320LA20A HARRIS SEMICONDUCTOR CO.
1 F1A FUSE CLIP 100057 littelfuse
1 F1B FUSE CLIP 100057 littelfuse
1 F1 FUSE (AUTO) 40A 32V LITTEL F
1 F3 FUSE BEL/5FSP5 5A 250Vac (FAST ACTING) BEL FUSE INC.
98 Issue -1- 01/10/98

7.3 GXT1000MT-230 BILL OF MATERIAL

2 FUSE BUSS/S505 6.3A 250Vac TIME DELAY BUSS
1 FILTER DELTA/06DBDW3S DELTA
1 FUSE BUSS/S505 6.3A 250Vac TIME DELAY BUSS
Issue -1- 01/10/98 99


100 Issue -1- 01/10/98


Issue -1- 01/10/98 101


102 Issue -1- 01/10/98


1 TX1 TX 1P 105X 55:49:52:29:44 EE-16 LION
Issue -1- 01/10/98 103


1 SW1 SWITCH DIP 2P
104 Issue -1- 01/10/98


Issue -1- 01/10/98 105


1 R45 RESISTOR NRWW 2W 1 J (NON-IND) TY-OHM
1 R17 RES CWW 5W 1K J TYPE/SQM TY-OHM
106 Issue -1- 01/10/98


1 NTC1 THERMISTOR,NTC 10 6A KETEMA
1 C30 CAP EL-AL 47uF 450V M 16 *35.5RL2 RAD 7.5mm 105¢J NIPPON CHEMI-CON
1 C51 CAP EL-AL 220uF 450V M 25*50SN2 RAD 10mm 105¢J MARCON
1 C2 CAP EL-AL 3300uF 50V M 18*35.5RL2 RAD 7.5mm85¢J NIPPON CHEMI-CON
1 C16 CAP MPE 4.7uF 250VAC M RAD X- OKAYA
Issue -1- 01/10/98 107


1 CT1 CT 1:1:1000 EI-28 LION
1 CT2 CT 1:1:1000 EI-28 LION
1 TX3 TX 1P 105X 100:100:72:62:62 EEL-16 LION
1 TX1 TX 1P 105X 3:3:33:33 EE-55 LION
108 Issue -1- 01/10/98


1 TX2 TX 1053 1P 96:19:7:7:7 40KHZ EE-35 LIEBERT LION
1 Q5 IC LINEAR TL431AC SAMSUNG SEMICONDUCTOR CO
1 U1 IC LINEAR SG3525AN MOTOROLA MOTOROLA SEMICONDUCTOR C
1 REC1 D. GI/GBU8M 8A 1000V BRIDGE G.I.
Issue -1- 01/10/98 109


1 D5 D. GI/UF5402 3A 200V G.I.
1 D6 D. GI/UF5402 3A 200V G.I.
1 Q10 TR MOSFET HARRIS/RFP 40N10 40A 100V TO-220 HARRIS SEMICONDUCTOR CO.
1 Q8 TR. MOSFET 2SK1358 9A 90 0V TOSHIBA
1 TSA SWITCH THERMAL WAKO/CS- 7SA NFZ-250-90C WAKO
1 F1 FUSE LITTEL/322020 20A 65Vdc INALWAYS
1 F2 FUSE LITTEL/322020 20A 65Vdc INALWAYS
1 F3 FUSE BEL/5FSP6.3 6.3A 250Vac (FAST ACTING) BEL FUSE INC.
110 Issue -1- 01/10/98

7.4 GXT1500RT-120 BILL OF MATERIAL

1 FUSE BUSS/ABC-20 20A 250Vac BUSS
1 FILTER DELTA/15DKDG3 DELTA
1 FUSE BUSS/ABC-20 20A 250Vac BUSS
1 Output Filter FIXED-PLATE,105X,106X "RT" Liebert "91" Chiah Jyh co.,
1 BAT. COVER-PLATE(¤G),1XXX "RT" LIEBERT "05" Chiah Jyh co.,
Issue -1- 01/10/98 111


112 Issue -1- 01/10/98


1 R46 RES PMF 1/4W 2.2M F KOA
1 VR1 VR METALIZE 100K 0.7T (SIDE TRIME) KINGTEK
Issue -1- 01/10/98 113


114 Issue -1- 01/10/98


1 TX1 TX 1P 105X 55:49:52:29:44 EE-16 LION
Issue -1- 01/10/98 115


1 SW1 SWITCH DIP 2P
1 R117 RES CF 1/4W 100 J KOA
1 R119 RES CF 1/4W 100 J KOA
1 R2 RES NFMOF 1W 2.2K J TY-OHM
1 R46 RES NFMOF 2W 50K J TY-OHM
116 Issue -1- 01/10/98


1 R43A RES SSNF 3W 100K J RSS TY-OHM
Issue -1- 01/10/98 117


1 R22A RES PMF 1/4W 150K F KOA
118 Issue -1- 01/10/98


1 R23A RES NRWW 2W 0.5 J (NON-IND) TY-OHM
1 R45 RESISTOR NRWW 2W 0.75 J (NON-IND) TY-OHM
1 R45A RESISTOR NRWW 2W 0.75 J (NON-IND) TY-OHM
1 R17 RES CWW 5W 1K J TYPE/SQM TY-OHM
1 NTC1 THERMISTOR,NTC 1.0 20A KETEMA
1 C30 CAP EL-AL 220uF 200V M 18*35.5RL2 RAD 7.5mm105C NIPPON CHEMI-CON
Issue -1- 01/10/98 119


1 C12 CAP EL-AL 470uF 63V M 13*25RL2 RAD 5mm 105¢J JAMICON
1 C51 CAP EL-AL 1500uF 250V M 35*50SN2 RAD 10mm 85¢J NIPPON CHEMI-CON
1 C2 CAP EL-AL 1200uF 63V M 18*40RL2 RAD TAP7.5mm105 NIPPON CHEMI-CON
1 C2A CAP EL-AL 1200uF 63V M 18*40RL2 RAD TAP7.5mm105 NIPPON CHEMI-CON
1 C2B CAP EL-AL 1200uF 63V M 18*40RL2 RAD TAP7.5mm105 NIPPON CHEMI-CON
1 C16 CAP MPE 18uF 180VAC U RAD FALN 70¢J MARCON
1 C22 CAP MPP 0.33uF 400Vdc 25 0Vac J RAD 100¢J WIMA
1 C23 CAP MPP 0.33uF 400Vdc 25 0Vac J RAD 100¢J WIMA
120 Issue -1- 01/10/98


1 C33A CAP CER DISC 0.01uF 1000V M Z5U EVER GRACE
1 C58 CAP CER DISC 0.01uF 250VAC M Y-,X- GRANSTAR
1 CT1 CT 1:1:1000 EI-28 LION
1 CT2 CT 1:1:1000 EI-28 LION
1 TX2 TX 1060 1P 6:24:42:7:10 37KHZ EI35/12 LION
1 TX1 TX 1060 1P 4:4:18:18 44KHZ EE55 LION
1 TX3 TX 1P 1060 68:28:22:40: 40 100KHZ EEL16 LION
1 L4 CHOKE 1060 150uH 6A 1.0D FER ROD LIEBERT LION
1 L5 CHOKE 1060 150uH 6A 1.0D FER ROD LIEBERT LION
1 L2 CHOKE 1060 700uH 15A 1.5D IRON T184 LIEBERT TEH DIANN
1 Q5 IC LINEAR TL431AC SAMSUNG SEMICONDUCTOR CO
1 D5 D. HARRIS/RHRP860 8A 600V HARRIS SEMICONDUCTOR CO.
Issue -1- 01/10/98 121


1 D6 D. MOTOROLA/MUR460 4A 600V ULTRAFAST MOTOROLA SEMICONDUCTOR C
1 REC1 D. 25A 600V BRIDGE SHINDENGEN
1 REC2 D. GI/2W10G 2A 1000V BRIDGE G.I.
1 D19 D. SHINDENGEN/D2S6M 2A 60V FAST SHINDENGEN
1 Q1 TR BIP MOTOROLA/2N5551 0.6A 160V NPN TAP MOTOROLA SEMICONDUCTOR C
1 Q10 TR MOSFET IR/IRFP260 46A 200V INTERNATIONAL RECTIFIER
122 Issue -1- 01/10/98


1 Q8 TR MOSFET HARRIS/IRF840 8A 500V HARRIS SEMICONDUCTOR CO.
1 Q12 TR IGBT TOSHIBA/GT50J102 50A 600V TOSHIBA
1 Q13 TR IGBT TOSHIBA/GT50J102 50A 600V TOSHIBA
1 RY2 RELAY 12Vdc,30A 240Vac 1b P&B/T9AS1D12-12 P&B
1 TS SWITCH THERMAL WAKO/CS- 7SA NFZ-250-90C WAKO
1 MOV1 VARISTOR SAS/ SAV-271KD14 AINO AMERICAN SILICON
1 F1 FUSE BUSS/GBB-20 20A 125Vdc/250Vac BUSSMANN
1 F2 FUSE BUSS/GBB-20 20A 125Vdc/250Vac BUSSMANN
1 F3 FUSE LITTEL/324020 20A 250Vac (FAST ACTING) INALWAYS
1 MOV1 VARISTOR SAS 471KD20 AINO AMERICAN SILICON
1 MOV2 VARISTOR SAS 471KD20 AINO AMERICAN SILICON
Issue -1- 01/10/98 123

7.5 GXT3000RT-230 BILL OF MATERIAL

1 FILTER DELTA/16DBDG3 DELTA
1 FUSE BLOCK 13/32" SINGLE POLE 10*38 BUSS
1 FUSE 30A 660V 10*38 FERRAZ
2 FAN NMB/3610KL-04W-B50- L00 12Vdc 92*82.5*25.8 HWAN CHONG
1 R801 METAL-GLAZE 1/4W 1M F KOA
1 C806 CAP CER DISC 0.0022uF 250VAC M Y-,X- MURATA
1 C807 CAP CER DISC 0.0022uF 250VAC M Y-,X- MURATA
124 Issue -1- 01/10/98


Issue -1- 01/10/98 125


126 Issue -1- 01/10/98


Issue -1- 01/10/98 127


1 TX1 TX 1P 105X 55:49:52:29:44 EE-16 LION
128 Issue -1- 01/10/98


1 SW1 SWITCH DIP 2P
1 R389A RES NFMOF 2W 12K J TY-OHM
1 R18 RES SSNF 3W 17K J TY-OHM
1 R18A RES SSNF 3W 17K J TY-OHM
Issue -1- 01/10/98 129


1 R40A RES PMF 1/4W 4.7K F KOA
1 R31A RES PMF 1/4W 4.99K F TY-OHM
1 R352B RES PMF 1/4W 4.99K F TY-OHM
1 R358B RES PMF 1/4W 4.99K F TY-OHM
1 R31B RES PMF 1/4W 15K F KOA
1 R31C RES PMF 1/4W 15K F KOA
1 R31D RES PMF 1/4W 15K F KOA
1 R31E RES PMF 1/4W 15K F KOA
130 Issue -1- 01/10/98


1 R389B RES PMF 1/4W 47.5K F KOA
1 R325B RES PMF 1/4W 100K F KOA
Issue -1- 01/10/98 131


1 R389C RES PMF 1/4W 270K F KOA
1 R38A RES PMF 1/4W 1M F KOA
1 R2A RES FMF 1/2W 10 J TY-OHM
1 NTC1 THERMISTOR,NTC 1.0 20A KETEMA
1 NTC2 THERMISTOR,NTC 5 5A DOSHINE
1 C318C CAP EL-AL 100uF 50V M 8* 12RL2 RAD TAP 5mm 105¢J NIPPON CHEMI-CON
132 Issue -1- 01/10/98


1 CA CAP EL-AL 100uF 50V M 8* 12RL2 RAD TAP 5mm 105¢J NIPPON CHEMI-CON
1 C219A CAP EL-AL 100uF 200V M 16*32RL2 RAD 7.5mm 105¢J NIPPON CHEMI-CON
1 C16 CAP EL-AL 100uF 450V M 22*35*SN2 RAD 10mm 85C NIPPON CHEMI-CON
1 C219C CAP EL-AL 1200uF 200V M 30*50SN2 RAD 10mm 105¢J NIPPON CHEMI-CON
1 C318B CAP PE 0.0022uF 50V J RAD(IND) TAP 5mm TAIWAN TAI YANG
1 C221A CAP PE 0.0047uF 50V J RAD(IND) TAP 5mm TAIWAN TAI YANG
1 C11 CAP MPE 10uF 250VAC M RAD X- OKAYA
1 C12 CAP MPE 10uF 250VAC M RAD X- OKAYA
1 C13 CAP MPP 0.022uF 400V JRA D TAIWAN TAI YANG
1 C511 CAP MPP 0.22uF 630V K RA D 105¢J MARCON
1 C512 CAP MPP 0.22uF 630V K RA D 105¢J MARCON
1 C318A CAP CER MONO 220PF 50V J COG AXI TAP26mm "221" AVX CO.,
1 C12A CAP CER MONO 0.1uF 50V M Z5U AXI TAP26mm "104" AVX CO.,
Issue -1- 01/10/98 133


1 C31B CAP CER MONO 0.1uF 50V M Z5U AXI TAP26mm "104" AVX CO.,
1 C4B CAP CER MONO 0.1uF 50V M Z5U AXI TAP26mm "104" AVX CO.,
1 CB CAP CER MONO 0.1uF 50V M Z5U AXI TAP26mm "104" AVX CO.,
1 CT1 CT 1:1:1000 EI-28 LION
1 CT2 CT 1:1:1000 EI-28 LION
1 TX501 TX 108X 1P 7:7:30:30 50KHZ FER EE-55 LION
1 TX502 TX 108X 1P 7:7:30:30 50KHZ FER EE-55 LION
1 TX1A TX 1083 1P 67:5:40:5:7 37KHZ EE42-15 LION
1 TX305 TX 108X 1P 80:17:13:27: 27 100KHZ FER ZE6 LION
1 U203 IC LINEAR TL431CP TAP T.I. SEMICONDUCTOR CO.,
134 Issue -1- 01/10/98


1 D33 D. MOTOROLA/1N4937 1A 600V FAST MOTOROLA SEMICONDUCTOR C
1 D6B D. GI/1N4937 1A 600V TAP pitch 0.8mm G.I.
1 D511 D. MOTOROLA/MUR860 8A 600V ULTRAFAST MOTOROLA SEMICONDUCTOR C
1 BR02 D. 25A 600V BRIDGE SHINDENGEN
1 D12 D. HARRIS/RHRG30120 30A 1200V HARRIS SEMICONDUCTOR CO.
1 D202B D. ROHM/1N4148 0.15A 75V ULTRAFAST ROHM SEMICONDUCTOR CO.,
1 D2A D. ROHM/1N4148 0.15A 75V ULTRAFAST ROHM SEMICONDUCTOR CO.,
Issue -1- 01/10/98 135


1 D6A D. ROHM/1N4148 0.15A 75V ULTRAFAST ROHM SEMICONDUCTOR CO.,
1 D202A D. GI/UF5402 3A 200V G.I.
1 D7 D. GI/UF5402 3A 200V G.I.
1 BR01 D. GI/2W10G 2A 1000V BRIDGE G.I.
1 Q8 TR BIP MOTOROLA/2N5551 0.6A 160V NPN TAP MOTOROLA SEMICONDUCTOR C
1 Q3 TR MOSFET IR/IRF730 5.5A 400V INTERNATIONAL RECTIFIER
1 Q1A TR IGBT TOSHIBA/GT60M301 60A 900V TOSHIBA
1 RLY01 RELAY OMRON/G7L-2A-P 20A 277V 12Vdc OMRON
1 RLY04 RELAY OMRON/G2R-1-E 16A 250V Coil:12Vdc OMRON
1 TS1 SWITCH THERMAL WAKO/CS- 12A NFZ-250-95C WAKO
1 FC2AF FUSE BUSS/GBB-20 20A 125Vdc/250Vac BUSSMANN
1 FC3AF FUSE BUSS/GBB-20 20A 125Vdc/250Vac BUSSMANN
1 F1 FUSE LITTEL/324020 20A 250Vac (FAST ACTING) INALWAYS
136 Issue -1- 01/10/98

CHAPTER 8 - Specification
PARAMETER GXT700MT-230 GXT1000MT-230 GXT1000RT-230
Rating VA/KW 700 / 490 1000 / 700 1000 / 700

Physical characteristics
162 x 397 x 225 177 x 490 x 430
Unit Dimensions:mm (in)
(6.4 x 15.6 x 8.9) (7.0 x 19.3 x 16.9)
298 x 526 x 367 340 x 660 x 565
Shipping Dimensions:mm (in)
(11.73 x 20.72 X 14.44) (13.38 x 26.0 x 22.25)
Unit Weight: kg (lbs) 13.2 (29.0) 16.0 (35.2) 25.5 (56.1)
Shipping Weight: kg (lbs) 15.4 (33.9) 18.2 (40.1) 29.2 (64.4)
Input AC Parameters
Voltage range (typical) 230Vac; variable based on output load
100% - 90% Loading
164 - 275Vac
90% - 70% Loading
70% - 30% Loading 144 - 275Vac
30% - 0% Loading 124 - 275Vac
Input frequency (capture range) 47.0 - 52.0Hz or 57.5 - 62.5Hz (Auto sensing)
Input connector CEE 22 Socket CEE 22 Socket CEE 22 Socket
Output AC Parameters
Output sockets (4) CEE 22 Socket (4) CEE 22 Socket (4) CEE 22 Socket
Voltage 208/220/230/240 (switch selectable) ±3%
Frequency 50Hz or 60Hz (auto-selected from input frequency)
Waveform Sinusoidal
Mains mode overload 200% for 8 cycles; 130% for 10 secs with transfer to bypass
Battery Parameters
Battery type Valve-regulated, non-spillable, lead acid
Qty x Voltager x Rating 2 x 12V x 7.0/7.2AH 3 x 12V x 7.0/7.2AH 3 x 12V x 7.0/7.2AH
Environmental
Operating temperature 0°C to +40°C (+32F to +104F)
Storage temperature -15°C to +50°C (+5F to +122F)
Relative humidity 0% to 95%, non-condensing
Operating eleavtion Up to 3000m (10,000ft) at 40°C without derating
Storage Elevation 15,000m (50,000ft) maximum
Audible noise <45dBA, at 1 metre
Agency compliances
Safety EN50091-1, TUV/GS Listed, CE Low Voltage Directive
RFI / EMI EN55022, Clas B: CE EMC Directive
IEC 801-2, Level 4 / IEC 801-3, Level 3 /
Immunity
IEC801-4, Level 4 / IEC 801-5, Level 3
Issue -1- 01/10/98 137

GXT-230 Repair Manual Specification
PARAMETER GXT1500RT-230 GXT2000RT-230 GXT3000RT-230
Rating VA/KW 1500 / 1050 2000 / 1400 3000 / 2100

Physical characteristics
177 x 490 x 430
Unit Dimensions:mm (in)
(7.0 x 19.3 x 16.9)
340 x 660 x 565
Shipping Dimensions:mm (in)
(13.38 x 26.0 x 22.25)
Unit Weight: kg (lbs) 28.6 (62.9) 38.8 (85.4) 40.8 (89.8)
Shipping Weight: kg (lbs) 32.3 (71.2) 42.5 (93.7) 44.8 (98.8)
Input AC Parameters
Voltage range (typical) 230Vac nominal; variable based on output load
100% - 90% Loading 191 - 275Vac
90% - 70% Loading 164 - 275Vac
70% - 30% Loading 144 - 275Vac
30% - 0% Loading 124 - 275Vac
Input frequency (capture range) 47.0 - 52.0Hz or 57.5 - 62.5Hz (Auto sensing)
Input connector CEE 22 Socket CEE 22 Socket CEE 19 Socket
Output AC Parameters
(4) CEE 22 Socket
Output sockets (4) CEE 22 Socket (4) CEE 22 Socket
(1) CEE 19 Socket
Voltage 208/220/230/240 (switch selectable) ±3%
Frequency 50Hz or 60Hz (auto-selected from input frequency)
Waveform Sinusoidal
Mains mode overload 200% for 8 cycles; 130% for 10 secs with transfer to bypass
Battery Parameters
Battery type Valve-regulated, non-spillable, lead acid
Qty x Voltager x Rating 4 x 12V x 7.0/7.2AH 8 x 12V x 6.5/7.0AH 8 x 12V x 7.0/7.2AH
Environmental
Operating temperature 0°C to +40°C (+32F to +104F)
Storage temperature -15°C to +50°C (+5F to +122F)
Relative humidity 0% to 95%, non-condensing
Operating eleavtion Up to 3000m (10,000ft) at 40°C without derating
Storage Elevation 15,000m (50,000ft) maximum
Audible noise <50dBA, at 1 metre
Agency compliances
Safety EN50091-1, TUV/GS Listed, CE Low Voltage Directive
RFI / EMI EN55022, Clas B: CE EMC Directive
IEC 801-2, Level 4 / IEC 801-3, Level 3 /
Immunity
IEC801-4, Level 4 / IEC 801-5, Level 3
138 Issue -1- 01/10/98

CHAPTER 9 - Drawings
TITLE Drawing Number

GXT700MT/RT-230 Circuit Diagram SK8103-3205-00
GXT1000RT-230 Circuit Diagram SK8103-5209-01
Operator Control Panel Circuit Diagram (Generic all models) SK8103-3503-00
Control Board Circuit Diagram (Generic all models) SK8103-3106-01
Issue -1- 01/10/98 139

GXT-230 Repair Manual Drawings
140 Issue -1- 01/10/98

A B C D E F G H I J K L M N O
INV DRIVE
1 330K* R4 R5 1
+IGBT-5V
+IGBT15V
+IGBT.0V
PF.VCC-
330K*
PWM12V
PF.VCC+
PWM+
PWM-
LINE.L INV.L
SC1 R69 R70 LINE.V 330K* 330K*
CNP01
I/PRLY C53
600UH C48
TX1
104P
L4 104P
RY3 RY2 EE42
P850 1 6 1 6 RHRP8120 10 9
P1 L2 REC1 R32
NTC1 F3 D18 47/F
1 2
GBU6M 11 8 Q6 Q13 RY1 P3
2 3 2 3 D
C23
G2R-1-E
2 4 3 D23 D24 R31 50N06 U8 R58
2
100ohm/3W(016)
5 4 5 4 C20 D D37 GT15Q101 D NC
FU5A/250Vac/F 5 6 RHRP8120 12 7 100ohm/3W(016) 47/F ICTLP250
C38
4
RHRP8120
10ohm/5A R33 8 3
1u/275VAC
G4W-2212 G4W-2212 8.0mH/3.5A(1033) D13 1 P4
-
13 6 G 2
C22 223/1KV
102MP/1KV 1N4148
5
6
2
3
S G Q4 2 7
RHRP8120 C51 330u/450V G 8 1 NC
14 5 S R56
+
50N06 3 6 S D38
RHRP8120
MOV1
R57 15 4 4 TLP250 5 47/F INVRLY+
4
CT2 R54 C50
10ohm/5W(020) Q14 D36 ICTLP250 16 3 471KP/1KV
0.47U/250VAC
CT1:1:1000 1N4148 49.9K*

C68
2SK1723 U10 U7 INVRLY-

D 8 17 2 C25
223/1KV
L3 1 C52 330u/450V D12 R36 D ICTLP250 6 L1 5
320L20
D11 D 1 8 D35 3 4
C46 R52 7 2 18 1 Q10 Q12 D
P850 T22/5MH/5A RHRP8120 100ohm/3W(016) 50N06 2 7 2 1
P2 222KP/1KV G 6 3 4.0mH/3.5A(1033) 24V 12V 5V GND
47/F 102MP/1KV G 1N4148
RHRP8120 G 3 6
100ohm/3W(016)
S 5 TLP250 4 R53
D42 S S R50 G
4 TLP250 5
Q11 R40 R39 47/F S UC3854 X X
GT15Q101
D46 1N4148 L5 50N06 47/F 47/F R51 D34
3 C60
1N4148
600UH 49.9K* UC3525 X X
3
C16
C58
3.3u/250V
103P
RHRP8120
D45
5
6
2
3
3.3V ZD4 C45
U9 CT1 324 X X
NC IC324 1N4148 104P C42
2 - R84 CT1:1:1000
R71 R83 R82 R93 324 1 D41 1N4148
CNTL X X X X
4
10.7K* 3 + 471KP/1KV
11K*
BATTERY
R91 330K* 330K* 330K* R74 100ohm TP1
NC NC +24V
D40 1N4148 TP 1N4148 I/P COIL X X
D44 9 - U9 D39 R75 L.C+
SITE+ U13 R124 D9
324 8 O/P COIL X X
-IGBT-5V
-IGBT15V
-IGBT.0V
4 1 R88 1.8K* 30K*
4.99K*
NC 10 + 3.74K*
D47 R8 IC324 1N4148 R73 R76
R2
NC 10K* 2K* 15K* D10
R87 1N4148 TLP250(IGBT) 15V 0V -5V
3 TLP 2 R1 R94 150K*
SITE- 521 300ohm* 11K* R72
15K* C56 C55 TLP250(PFC) 12V 0V
470ohm*
C65 104P
4 471P
4
R30
220P D8
D2 U11 C59 392P 1N4148
+24V
1N4148 C UC3854
Q1 1 GND GTDRV 16 D7
S.D. B L.C-
C1815 2 PKLMT VCC 15 C64 10u/50V R67 3K* 1N4148
3 CAOUT CT 14
E C54 4 IS
R127 SS 13
5 M.T REST 12 R118 15K* R68 3K*
D1 104P 6 IAC C70
C1 VS 11 104P R104
SWPOWER 7 VAOUT ENA 10 C63 10u/50V
10K* 1N4148 8 9 10K*
VRMS VREF R86 100K*
47u/50V IC3854 R123
ZD1 470K R105 100K*
R16 12V R122 200K* R120 10K* U12
R89 C66 472J R117 1u/50V R92 R78 R79 R64 178K*
P850 3.3k* 1 2 C71
C67 820K* 4066
P5 F1 10u/50V 300ohm* 13 IC4066 100K* 178K* 178K*
P5-1 R77 R110 +5V
C74 U9
5 NC
P850
FU40A/32V(AUTO)
R90
1M*
C57
221P
10K* +12V 103P 14 324
IC324
- 13
+ 12
R102
10.7K*
9.1K* 5
P6 D43 +12V
R121 U12 R106
P6-1 1N4937GI R119 4 3 A1
NC 1N4148 4066 75K*
D15 NC 300ohm*
1N4148
5 IC4066 R107
D3
R43 C33 A0
R46 100K*
D29 100K/3W C26 R59 R60 R61 R62 R63
DB25P50
100u/50V
1N5399 D28 1N5399 C30 100K/3W 103MP/1KV
6.8K* 150K* 178K* 178K* 178K* CN2
R9
2
1
D27
D25 1N4937GI 10k*
47u/450V 1N4937GI
C32
D33 49.9K* 12V 24V
1N5399 D30 D31 100u/50V C12 +5V C3 POWER
1
Q8 TX2 +IGBT15V +12V
6 1N5399 U6 IC3845 D26 2SK793 D EI30 1N4937GI C49 GND 5V

6
3
7UC3845 220u/50V R6 103P
C36 104P 1N4148 D5 D6 TX3 4066PIN14 R109 R114 R101 R81 R66 R103 CHGOFF- CHGOFF+
VCC 6 9 R116
8 6 R55
5
5 10 UF5402 UF5402 C2 TX1033/EEL16 47u/50V +12V 10K* 100K*
Vref O/P G 4.99K* L.C+ FANSP/F
R48 4.7K* R42 6 +IGBT.0V 324PIN4 4.99K* 178K* 178K* 178K* 178K* U1
7
2 12
4700u/35V
4 IS 3 47/F S UC3525
R/C R49 1 11 Q15 16 VREF INV 1 I/PRLY L.C-
5 C47
48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
9
COMP GND VF C1815 15 VIN NI 2
1 5 2 8 ZD3 C75 C C61 14 3 INV.L BAT.V
C35 C39 1K/F 7 C69 R108 10K* 10u/50V OUTB SYNC
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
103P 102P 7 PF.VCC+ 4 220u/50V 5.1V B 13 VC OSC 4
D14 +IGBT-5V 10ohm INVRLY+ INVRLY-
1ohm/2W(020)
4 1N4937GI 3 8 104P 104P +5V 12 GND CT 5

3 R22 E R111 R95 C72 11 OUTA RT 6
C29 2 9 -IGBT15V R98 100K* 10 7
C37 R44 270K* C40 R115 SHUT DISC
ICTLP521 49.9K* R45 100u/50V D32 324PIN11 4.99K* 9 8 R11
CHGOFF+ 472J 10 6.8K* R7 COMP SOFT S.D. SWPOWER
1 1N4937GI +12V 1u/50V 6.8K* 104P
PF.VCC- R47 4066PIN7 C62 IC3525 START
1 U4 4 47u/50V 49.9K* C11 MODEL0 GND
6.8K* R85 4.99K*
ICTLP521 -IGBT.0V DC/DC MODEL1
C7 4.99K* R126 104P C9 GND
U5 R29 C4
TLP R37 100ohm C41 10K* R113 R12 392P R15
7 CHGOFF-
2
521
3 4 1
NC
R28
47K* C10
104P
U2 IC3845
7 UC3845
1N4148
D4 IRF620
D Q2
R24 100ohm
R25 220u/50V ZD2
5.1V
Q16
C1815 C
7
U9
324
- 6
+ 5
100K*
R100
178K* 178K*
R80 R65
178K*
3.9K*
150K*
103P
+BUS.V
PFCOFF
3525OFF
-BUS.V 7
3 TLP 2 47u/50V VCC R18 -IGBT-5V IC324 LINE- LINE+
521 8 6 B PFC
Vref O/P G
47/F R20 +12V A0 GND
C31 C24 R13 4 D20 C28
104P R34 470P R/C IS 3 S C17 C18 49.9K* E
LINE.L A1
470K R27 4.7K* COMP GND VF R21
D19 1N4937GI
100u/50V 24V 12V
102MP/1KV
3.9K* 1 5 2 1K/F THERMAL+ LINE.V

102MP/1KV
C15 1N4937GI R125 3525OFF

R41 +5V
K
R35
R26
R17
4.99K*
R3
510ohm C6 PWM12V THERMAL-
12V
R
Q5 472J +12V
10K*
10K*
C8 C5
BAT.V
1K-VR1T U3 IC7805 TS PWM- PWM+

C13 R14
A
NC
NC
TL431 471P R23 I 7805 O 104P
VR01 104P R112 R96 10u/50V
R10 C14 0.22ohm/2W(020) R19 5V R99 R97 49.9K* TH SW1
1M* 13K* A 75K* 47K* 20K* 7.5K* NC
2200U/16V
104P C21 TSA SYNC+ SW-ON
+5V
C27
C19
PFCOFF
8 TH SITE+ SYNC-
8
+BUS.V
-BUS.V
LINE-
LINE+
THSW90
104P 100u/50V +5V MODEL2 SITE-
HFPOWER- GND JP01
MODEL3
A0
A1
JP1000
HFPOWER- HFPOWER+
50 50
HFPOWER+
JP02
49
FAN
1 NC
1N4007GI JST-2P
2
D21
Q9 D D17
K941
R38 1N4007GI
FANSP/F G
510ohm
9 S
D22
9
1N4007GI
098-01126-01
REVISE: 00
Liebert
Part No. Title: Drawn: Designer: Checked: Approved:
SHEET 1 OF 1
GXT700MT-230 STEPHEN 4/29/97
SK8103-3205-00
Date:4/17/97 Sub-Assembly Part No : 710-01126-00 File Name:0112600E.sch
1 1
INV DRIVE
330K*
+IGBT-5V
+IGBT15V
+IGBT.0V
R4 R5
PF.VCC-
330K*
PWM12V
PF.VCC+
PWM+
PWM-
2 1 2 1
LINE.L 1 2 1 2 INV.L
SC1 R69 R70 LINE.V 330K* 330K*
CNP01
C53
1
I/PRLY
2 TX1
C48
2
104P
104P
1
L4 EE55
P850 RY3 RY2 600UH 11 10
11 6 11 6 L2
2
P1 NTC1 REC1 D18 RHRP8120 R26
F3 1 2 12 9 Q6 R32 RY1 P3
2
GBU8M Q13
2
22 3 22 3 2 1
102MP/1KV D 2 10/F 10/F G2R-1-E
2 1 40N10
100ohm/3W(016)
4 3 2 1
55 4 55 4 C23 D24 13 8 C20 D 2 D 2 U8 D37 GT15Q1012 D NC
FU6.3A/250VAC/F RHRP8120
1
5 6 4
R31
4
SG314 D23 10/F ICTLP250 4 5 3
1R33
1
1 2 6
R58
C38 1 2 8 3
1
4.0MH/5A(1029) D13 C51 C68 1 2
1
G4W-2212 G4W-2212 14 7 1 2
P4
-
2 7
G 1 1 1N4148 1
3
2
1 2 223/1KV 100ohm/3W(016)
5
6
2
3
220U/450V S 3 G Q4 G Q3 2 7 8 1
NC
2
220U/450V G
2
RHRP8120 RHRP8120 15 6 8 1
1
2.2u/250VAC S 3 S 3 R56
+
40N10 40N10 3 6 1 2 3 S D38
RHRP8120
16 5
1
47/F INVRLY+
1
R57 4 TLP250 5
1
MOV1 C52 C73 C50
2
1
1
CT2 D36 ICTLP250 C22 17 4 R54
320L20 10ohm/5W(020) Q14 220U/450V 471KP/1KV
CT1:1:1000 1N4148 49.9K*
2
U10 102MP/1KV U7
D 2 2SK1723 220U/450V 18 3 C25 Q7 INVRLY-
2
8
2
1 223/1KV R36 ICTLP250 6 5 6 5
2
D12 D 2 L1 L3
D 2 40N10
2
D11 19 D 2 1 2
1 8 D35 3 4 3 4
C46 R52 7 2 2 Q10 Q12 2 D
P850
3 222KP/1KV
1 2 1 RHRP8120 100ohm/3W(016)
1
40N10 2 7 1 2
4.0MH/5A(1030)
2 1 2 1
24V 12V 5V GND
3
1
P2 G 6 3 20 1 1 1 1N4148 1.2MH/5A(1031)
47/F RHRP8120 G G G 3 6 1
S 3 1 2
1
5 TLP250 4
100ohm/3W(016)
D42 S 3 S 3 S 3 R50 G
R53
R35 4 TLP250 5
2 1 R40 R39 47/F 3 S UC3854 X X
1
Q11
GT15Q101
1N4148 10/F 10/F 10/F R51
2
40N10
1
C16
1
L5 D34
C58 C60
103P
D46 600UH 49.9K* UC3525 X X
RHRP8120
2
2
1
475K/250V
D45 1N4148
5
6
2
3
2
1N4148 C45 SC
1 2
D41 C42 CT1 324 X X
U9 1N4148 104P
2
NC 2 - R84
2 1 CT1:1:1000
R71 R83 R82 R93 324 1 2 1 ZD4 3.3V CNTL X X X X
4
110.7K* 471KP/1KV
1
2 1 2 3 + 11K*
1 2 1 2 IC324 BATTERY
R91 330K* 330K* 330K* TP1
NC NC D40 1N4148 R742 100ohm
1 TP 1N4148 I/P COIL X X
+24V U9
2
U13 D44 9 - D39 1 2 R124 R75 L.C+

SITE+ 8 2 1 2 1 2 1 D9 O/P COIL X X
324
-IGBT-5V
-IGBT15V
-IGBT.0V
2 1
1
4 1 R882 1.8K*1 15K*
4 NC 10 + 3.6k
4
1
D47 IC324 R73
2
R8 1N4148
10K* 2K* 2 R76 1
NC D10
1
R30 TLP250(IGBT) 15V 0V -5V
2
R87 30K*
2
2 1
1
R94 1N4148
1
2
3 TLP 2 R3 R1 150K* 300ohm*
SITE- 521 R2 1.8K* 11K* R72
1.8K* 15K* C56 C55 TLP250(PFC) 12V 0V
1
C65 104P D8
2
2
1
102P
470P
D2 1.8K* U11 C59 392P
+24V 1N4148
1N4148 C UC3854 D7
1
2
B 2 Q1 1 GND GTDRV 16 L.C-
S.D. 1 3C1815 2 PKLMT VCC 15 C64 10u/50V R67 3K*
3 CAOUT
2 1 1N4148
E C54 CT 14
4 IS SS 13
R127 5 M.T R118 15K* R68 3K*
104P REST 12 2 1 2 1
C1 D1 6 IAC VS 11 R104 C70
104P
1
SWPOWER 1 2
7 VAOUT ENA 10 C63 2 1 10u/50V
10k* 1N4148 8 9 10K*
1 2
VRMS VREF R86 100K*
1
2 1
2
47u/50V IC3854 R123
5 470K R105 100K*

5
2
ZD1 2 1 2 1 2 1 2 1
1
2
R16 12V R122 200K* R120 10K* U12

R89 C66 472J R117 1u/50V R92 R78 R79 R64 178K*
FC335/AIB 10K* 2 1 1 2 C71 2 1 2 1 2 1 2 1
P5 C67
2
4066
1
665k*
2
1 2
2
P850 FC1A F1 FC1B 10u/50V 2 1 300ohm* 13 IC4066 100K* 178K* 178K*
P5-1 R77 R110 +5V
10K* C74 U9
1
NC FC335/AIU +12V 103P - 13 1 2
14
1
F2 324 R102 9.1K*
R90 C57 12 2 1
P6 1M* 221P IC324 +
+12V
10.7K*
P850 FC2A FC2B D43
2
1
FC335/AIU FC335/AIB 2 1 R121 U12 R106
P6-1 1N4937GI D3 R119 4 3 2 1 A1
1 2 2 1 75K*
NC 1N4148 4066
D15 1N4148 NC 300ohm* R107 1
5 IC4066
2
C33 2
1
R43 A0
2
R46 100K*
D29 100K/3W C26 R59 R60 R61 R62 R63
DB25P50
100u/50V 2 1 2 1 2 1 2 1 2 1
1
1N5399 D28 1N5399 C30 100K/3W 103MP/1KV

6 6
1
6.8K* 150K* 178K* 178K* 178K* CN2
R9
2
1
1N4937GI D27
2
D25 R172 1K/5W 20K*

2
47u/450V 1
1N4937GI
2
C32
D33 49.9K* 12V 24V
1
100u/50V 2 1 C3
C12 +5V
1
1N5399 D30 D31 POWER
1
Q8 TX2 1 2 +12V
2 1 +IGBT15V GND 5V
1N5399 IC3845 D26 2SK13582 D C49
1
U6 1053-EE35 1N4937GI 1 2
3
7 UC3845 220u/50V R6
1
C36 104P D5 D6 103P R103 CHGOFF- CHGOFF+
2
VCC 1N4148 6 5 1
11 TX3 1 2 4066PIN14 R116 R109 R114 R101 R81 R66
1
8 6 R55
5
2 1 2 1 1 TX1053/EEL16 47u/50V 2 1 2 1 2 1 2 1 2 1 100K*
Vref O/P 5 12 UF5402 UF5402 C2 +12V 10K*
2
R48 4.7K* G
6 10
6 4.99K* 4.99K* 178K* 178K* 178K* 178K* U1 L.C+ FANSP/F

R42 +IGBT.0V 324PIN4
7
2 1 4 2 2
14 3300u/50V
IS 3 47/F 3 S UC3525
1
1
R/C 13 1 I/PRLY L.C-
2
R49 1 9
5 C47 Q15 16 VREF INV
48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
9
COMP GND VF 2 1 C1815 15 2
3
10 C VIN NI
C75 C61 INV.L BAT.V
2
C35 1 5 2 C39 1K/F 7 1 2 ZD3 C69 R108 10K* 10u/50V 14 OUTB SYNC 3
2
9
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
4 2
1
1 2
1
103P 471P 8
PF.VCC+ 220u/50V 5.1V B 13 4
1
2 1 VC OSC
D14 +IGBT-5V 10ohm INVRLY+ INVRLY-
2
4
4 3 8 104P 104P 1 3 1 2
+5V 12 GND CT 5
1
1
1N4937GI C72 11 6
OUTA RT
2
3 E R111 R95
2
7 1 2 -IGBT15V R982 100K*

2
C29 R22 2 9 10 7
2
C37 R44 C40 R115 1 2 1 2 1 SHUT DISC

1
1
100u/50V D32 324PIN11 9 8 R11
2
ICTLP521 49.9K*
7 R45 1ohm/2W(020) 442K* 4.99K* COMP SOFT
7
1
472J 6.8K* R7 S.D. SWPOWER
2
CHGOFF+ 1 10 1N4937GI +12V 1u/50V 6.8K* 104P
1
1 2 4066PIN7 C62 IC3525 START
2
U4 PF.VCC- R47 49.9K*
1
1 4 47u/50V C11 MODEL0 GND
2
4.99K* 1 2
1
6.8K*
2
ICTLP521 2 1 -IGBT.0V DC/DC
2
C72 1 R126 104P C9 GND MODEL1
1
2
2
U5 R29 C4
100ohm 10K* R12 392P
2
2
R37 C41
1
TLP R113 R15
2
2 3 4 1
6.8K* 104P U9 R100 R80 R65 +BUS.V 3525OFF
521 1N4148 R24 100ohm - 6 2 1 2 1 2 1 2 1 3.9K* 103P
1
1
R28 1 2
U2 IC3845 150K*
7
1
D4 IRF6202 D R25 324 100k* 178K* 178K* 178K* PFCOFF -BUS.V
1
CHGOFF- C10 220u/50V Q16
2
75K* Q2 ZD2 + 5
1
7 UC3845 1 2 IC324
1
5.1V C1815 C
1
VCC LINE- LINE+

1
3 TLP 2 47u/50V 8 6 2 R18 1 -IGBT-5V 2

2
521 1 B PFC
Vref O/P
1
G 1 3 +12V A0 GND
47/F
2
C24 R13 R20

2
C31 4 D20
IS 3
1
1 3 S C17 C18 49.9K* E

1
R34 2 1 2
2
470P R/C
1
2
1
104P 1 2 LINE.L A1
470K R27 4.7K* 24V
2
COMP GND VF R21 12V

D19 1N4937GI
102MP/1KV
3.9K* 1K/F
2
1 5 2 THERMAL+ LINE.V
2
1
1
102MP/1KV
1N4937GI R125
2
C15
1
R41 +5V 3525OFF

K
3
1
2
2
510ohm 4.99K*
2
1
R1
C6 PWM12V THERMAL-
1
1
12V
1
2
Q5 472J C28
1
C8 +12V C5
BAT.V
8 8
2
TS
2
1K-vr1t 100u/50V U3 IC7805 PWM- PWM+
2
C13 R14
A
1
TL431AC R23 104P
1
2
471P
2
I 7805 O
2
104P R112 10u/50V
2
VR01 C14 5V R99 R97 R96

2
R10 0.5ohm/2W(020) R19 TH

2
1 3
2
1M* 13K* 2 75K* 7.5K* 49.9K* SW1

A 47K* 20K* NC
2
104P
1
C21 TSA SYNC+ SW-ON
1
1
+5V
C27
C19
PFCOFF
TH SITE+ SYNC-
+BUS.V
-BUS.V
LINE-
LINE+
THSW90
104P +5V
2
2200u/16V 100u/50V MODEL2 SITE-

HFPOWER- GND JP01
MODEL3
A0
A1
NC
FAN HFPOWER- HFPOWER+
50 50
HFPOWER+
1
JST-2P JP02
49
1N4007GI 2
D21 NC
1
9 Q9
K941
2 D D17
9
2
R38 1N4007GI
2
2 1 3
FANSP/F
1
510ohm G
1 S
D22
2
1N4007GI
REVISE: 00
Liebert
SHEET 1 OF 1 Stephen
SK8103-5209-01 GXT1000MT(RT)-230 4/29 ‘97
Date 4/29/97 Filename:0144001A.sch
Sub-Assembly Part No.: 710-01440-01 710-01179-01
INV DRIVE
1 JP1000 330K* R4A R5
1
+IGBT-5V
+IGBT15V
+IGBT.0V
PF.VCC0
PF.VCC-
330K*
PWM12V
PF.VCC+
PWM+
PWM-
2 1 2 1
LINE.L INV.L
R R R R R R
R R R R
SC1 R69 R69A R70 LINE.V 330K* 330K*
JP1000
R
CNP01
R
R4
C53
1
I/PRLY
150UH C48
TX1
104P
104P
1
L4 1063-EE55
P850 RY3 RY2 11 10
11 6 11 6 L2 P3
2
P1 NTC1 REC1 D18 RHRP15120 R26
F3 1 12 9 Q6 RY1 P850
2 R32
2
100ohm/3W(016)
2
2
NTC2 GBU8M Q13
2
22 3 22 3 2 1 D 2 10/F 10/F R58 G2R-1-E
2 1 2 1 4 3 2 1
R31 C20 IRFP260 D 2 D 2 U8
55 4 55 4 FU10A/250VAC RHRP15120 C23 D24 13 8 D37 GT25Q1012 D
1
5 6 4
4
SG306 D23 100ohm/3W(016)1 10/F ICTLP250 4 5 3
SG306 C38
2
1R331 2 8 6 3
1
2.0mH/10A D13 0.1u/1KV 1 2
1
1 2
C51
C68
G4W-2212 G4W-2212 14 7
-
2 7
G 1 1 1N4148
3
2
1 2 102MP/1KV 1
5
6
2
3
RHRP15120 S 3 G Q4 G Q3 2 7
2.0MH/6A(1032)
8 1
330U/450V
C
330U/450V G
2
15 6
C
RHRP15120 8 1
1
2.2U/250VAC S 3 S 3 R56
+
IRFP260 IRFP260 3 6 1 2 3 S D38
471KP/1KV
CT1:1:1000
RHRP15120
16 5 P4
1
47/F INVRLY+
1
4 5
C73
L1
R57 TLP250 P850
1
MOV1 C50
2
CT2 D36 ICTLP250 C22 17 4 R54
C52
320L20 10ohm/5W(020) Q14 330U/450V
1N4148 49.9K*
2
U10 U7
D 2 G30N60C3 330U/450V 18 3 C25 Q7 INVRLY-
C
8
2
1 R36 ICTLP250
C
6 5
2
D12 D 2 L3
D 2IRFP260
2
0.1u/1KV D11 D 2 1 2
1 8 D35 3 4
C46 R52 7 2 19 2 Q10 Q12 2 D
P850 1 2 1 RHRP15120 100ohm/3W(016) IRFP260 2 7 2 1
222KP/1KV
R R
1 1 2
24V 12V 5V GND
1
P2 G 6 3 20 1 1 102MP/1KV 1 1N4148 2.0MH/6A(1032)
47/F
100ohm/3W(016)
3 RHRP15120 G G G 3 6 1 2 1
S
1
R133 5 4 R53
2
R R
TLP250 D42 3 S 3 3 R50 G

S S R35 4 5
49.9K* 2 1
R40 R39 TLP250 3 S UC3854 X X
47/F
1
Q11
1
3 3
GT25Q101
1N4148 10/F 10/F 10/F R51
2
IRFP260
1
C16
1
L5 D34
C60 D46 150UH 49.9K* UC3525 X X
RHRP15120
103P
2
1
D45 1N4148
10U/250V
5
6
2
3
2
C45
1 2
D41 C42 CT1 324 X X
U9 IC324 1N4148 104P
2
2 - R84
2 1 CT1:1:1000
R71 R83 R82 R93 324 1 2 R R
1 1N4148 CNTL X X X X
4
2 R R
1 2 R R
110.7K* 3 + 11K* ZDA 471KP/1KV

1 R R
2 1 R R
2 BATTERY
330K* 330K* 330K* 3.3V TP1
+24V
D40 1N4148 2 1 1N4148 I/P COIL X X
9 - U9 D39
R R
TP L.C+
1 2 R124 R74 2100ohm1
324 8 2 1 2 1 D9 O/P COIL X X
-IGBT-5V
-IGBT15V
-IGBT.0V
R R R R
1
10 + R882 1.8K*1 3.6k R75 15K*
1
R73
R R
R8 IC324 1N4148
4.99k* 2K* 2 R76 1 R R
D10 R30 R30A TLP250(IGBT) 15V 0V -5V
20K* R38
2
20K* R3
R87 30K*
2
+12V 2 1
1
R
R
R R
1N4148
R
R94
R
2
R1
R
R2 150K* R72
20K* 11K*
R
C56
R
20K* C55 TLP250(PFC) 12V 0V
4 15K* 220ohm* 2K*
4
R
D48
R
2
1
C65 104P D8
2
2
1
102P
1 2 470P
D2 1N4148 U11 C59 392P 1N4148
+24V
1N4148 Q1 UC3854 D7
2
2 1 GND GTDRV 16
1 L.C-
S.D. 2 PKLMT VCC 15 C64 10u/50V R67 3K*
N5551 3 CAOUT
2
R R
1 1N4148
3
C54 CT 14
4 IS SS 13
R127 5 M.T R118 20K* R68 3K*
104P REST 12 2 R R
1 2
R R
1
D1 6 IAC VS 11 R104 C70
104P
1
SWPOWER 1 2
7 VAOUT ENA 10 C63 2 R R
1 10u/50V
C1 8 9
R
1 2
10k* 1N4148 10K*
R
VRMS VREF R86 100K*

1
2 R R
1
IC3854 R123
2
100u/50V 470K R105 100K*

2
ZD1 2 R
1 R
2 R R
1 2 R R
1 2 R R
1
2
R16 12V R122 200K* R120 10K* U12
R89 C66 222J R117 1u/50V R92 R78 R79 R64 178K*
P850 FC335/AIU FC335/AIB 15K* 2 1 1 2 C71 2 1 2 1 2 1 2 1
C67 1M*
R R R R R R R R R R
2
4066
1
2
F1A F1 F1B
R
1 2
2
P5 FU20A/125VDC/F 10u/50V 2 R R
1 220ohm* 13 IC4066 100K* 178K* 178K*

+5V
5 P5-1
1 R77
10K* C74 U9 R110
5
1
P850 +12V 103P - 13 1 R R
2
14
1
FC335/AIU F2A F2B FC335/AIB P7 324 R102 9.1K*
P850 R90 C57 + 12 2 R R
1
P850 1M* 221P 10.7K*
F2 +12V IC324
R
P6 D43
2
1
FU20A/125VDC/F 2 1 R121 U12 R106
P6-1 103MP/1KV 103MP/1KV 1N4937GI D3 R119 4 3 2 R R
1 A1
1 2
R R
2 R R
1 75K*
P850 1N4148 4066
D15 1N4148 NC 220ohm* R107 1
5 IC4066
2
R43A R43 C33A 2
2
C33
1
A0
R R
1
R46 100K*
REC2 100K/3W C26 R59 R60 R61 R62 R63
DB25P50
100u/50V 2 1 2 1 2 1 2 1 2 1
1
R R R R R R R R R R
2
2
C30
+
100K/3W
1
6.8K* 150K* 178K* 178K* 178K* CN2
100K/3W R9
2
1
D27
2
R172 1K/5W1
-
1N4937GI 20K*
47U/450V
R
1N4937GI
R
D25
2
2W10G C32 470u/63V
C12 D33 49.9K* 12V 24V
1
100u/50V 2 1 C3
+5V
1
Q8 TX2 1 2 +12V
+IGBT15V
6 D5 D6
6
2 1
IC3845 D26 2SK13582 D 1063-EE35/12 C49 GND 5V
1
U6 1N4937GI 1 2
3
UC3845
7 RHRP860 MUR460 R6
1
C36 104P C2 103P R103 CHGOFF- CHGOFF+
2
VCC 1N4148 6 5 1
9 TX3 1 2 4066PIN14 R109 R114 R101 R81 R66
R
R116
1
R
8 6 R55
5
1 2 2 1 2 1 2 1 2 1 2 1
3300u/63V
2 1 1 PF.VCC+ 1063-EL16 47u/50V 100K*
R
R R R R R R R R R R
2 1 5 10 +12V 10K*
R
Vref O/P
2
R48 3.3k* G
6 10
D14 4.99K* 4.99K* 178K* 178K* 178K* 178K* U1 L.C+
R42
R
1N4937GI +IGBT.0V 324PIN4
7
2 1 4 2 2
12
IS 3 47/F 3 S UC3525
1
R49
R
1
R/C 1 I/PRLY L.C-
2
2 1 1 9 11 C29 C47 Q15 16 VREF INV
48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
9
COMP GND VF 1K/F ZD4 C1815 15 VIN NI 2
8 C
2
3
47u/50V C75 C61 INV.L BAT.V
2
C35 1 5 2 C39 R45A 15V 1 2 ZD3 C69 R108 10K* 10u/50V 14 OUTB SYNC 3
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
7 2
1
1
103P 471P 8
220u/50V 5.1V B 13 4
1
2 1 VC OSC
0.75ohm/2W(020)
R R
+IGBT-5V 10ohm INVRLY+ INVRLY-

2
4
4 PF.VCC0 104P 104P 1 3 1 2
+5V 12 GND CT 5
R22
1
1
C72 11 6
R45
OUTA RT
2
NC 3 E R111 R95
2
7 1 2 -IGBT15V
R
499K* R982 100K*
2
10 7
R
2
2
C37 R44 C29A R132 C40 R115 1 R R
2 R R
1 2 R R
1 SHUT DISC
1
1
D32 324PIN11 9 8 R11
2
ICTLP521 49.9K* 4.99K* COMP SOFT
1
472J
R
CHGOFF+ 6.8K* R7 S.D. SWPOWER
R
1N4937GI +12V 1u/50V 6.8K* 104P
1
R45B 220u/35V 4.7K* 1 2 4066PIN7 C62 IC3525
2
U4 R47 49.9K*
1
1 4 47u/50V C11 GND
R
R22A
2
NC 4.99K*
R
1 2
1
R
2
ICTLP521 100K* -IGBT.0V
2
10K* PF.VCC- R126 104P C9 GND MODEL1
1
2
2
R
R
2 1
R
C4
7 U5 C72 1
7
R
10K* R12 392P
2
2
R37 C41
1
TLP R29 R113 R113A R15
2
2 3 4 1
10K* 100ohm/1W U9 R100 R80 R65 +BUS.V 3525OFF
521 1N4148 - 6
R R R R
2 R R
1 2 R R
1 2 R R
1 3.9K* 104J
1
R28 104P 100ohm/1W 1 2
U2 IC3845 IRF620 150K*

7
1
D4 324 178K* 178K* 178K* PFCOFF -BUS.V
1
CHGOFF- C10 2 D Q2 JP1000 100k*
1
220u/50V Q16
2
ZD2 + 5
1
100K* 7 UC3845
R24
R25
1 2
1
5.1V C1815 C
1
VCC LINE- LINE+

1
3 TLP 2 47u/50V 8 6 2 R18 1 -IGBT-5V 2 IC324

521 1 B
2
Vref O/P
1
G 1 3 +12V A0 GND
47/F
2
C24 R13 R20

2
C31 R34 2 1 4 3 2 1 3 S D20 E

IS
2
470P R/C 47K*

1
1
2
1
104P C17 C18

1
1 2 LINE.L A1
470K R27 4.7K* 24V
2
COMP GND VF R21 12V

D19 1N4937 C28
0.5ohm/2W(020)
0.5ohm/2W(020)
3.9K* 1K/F
2
1 5 2 THERMAL+ LINE.V
1
1
2
102MP/1KV
1N4937GI R125
R
C15
1
+5V 3525OFF
R
R41
K
2
3
102MP/1KV
2
2
R128
R129
R130
R131
1
2
510ohm 4.99K*
1
2
1
R1
R23A
C6 PWM12V THERMAL-
1
12V
1
2
C5
Q5 472J
1
+12V
1
1
BAT.V
C8
2
1K-VR1T U3 IC7805 PWM- PWM+
2
C13 R14
A
1
TL431AC R23 104P
1
2
R
471P I 7805 O
2
R
R
104P R112 220u/50V
2
VR01 5V R96
R
C14 R99 R97
2
R10 R19
R
2
1 3
2
49.9K* SW1
10K*
10K*
100u/50V
10K*
10K*
1M* 11K* 2 A 75K* 47K* 20K* 7.5K*
R
1
2
104P
1
C21 TSA SYNC+ SW-ON
1
8 8
1
+5V
C19
PFCOFF
C27
TH SITE+ SYNC-
+BUS.V
-BUS.V
LINE-
LINE+
104P +5V THSW90
2
2200U/16V 100u/50V SITE-
HFPOWER- GND JP02
A0
A1
NC
FAN1 HFPOWER- HFPOWER+
50 50
HFPOWER+
1
JST-2P
49
2
FAN2
1
JST-2P
2
9 9
710-01170-02(A)
Revise:
Liebert
Part no: Sheet 1 of 1 Title: Drawn Designer Checked Approved
SK8103-6204-00 GXT1500RT-230 Stephen 4/17’97
A B C D E F G H I J K L M N O #A1
Date:4/17/97 Sub-Assembly Part No.:710-01460-00 File Name:0146000d.SCH
I/P(L)
R65A 220K* R65 220K* R66 220K*
LINE.L
1 I/P(N) 1
LINE(L)
REF.AC
I/P.RLY
PWM12V
+IGBT-5
I/PRLY +IGBT0
PWM+ +IGBT+12
2 BAT(+)
+BUS.FB 2
D509 RHRG30120
GT25Q101
2.2U/250VAC
150UH
L501
CN16L
SG301 G7L-2A-P
COMMON/2MH/20A
2.2U/250VAC
D Q501 D501 D Q13
8 6 FU15A/250VAC/F 1MH/10A(0945)
NC
GT25Q101
NTC1 C1 C2 4 2 F1 10 11 RHRP8120 D10 1N4148
100ohm/3W(016) 222KP/1KV
C507
P850 L2 L1 G ICTLP250 G
1 0 9 12 D502 U2
3
2
6
5
100ohm/3W(016)
MOV1 RLY01 1MH/10A(0945) S R30 47/F S
L0 D Q502
C320 C332 C334 C338
R14
R510
RHRP8120
3 320L20 CT1:1:1000 8 13
3
NC
1N4148 IRFP264
D12
CN16N Q12 D
330u/450V
330u/450V
330u/450V
D311 7 14
G D14 1N4148
1
D312
10/F
C12A
D Q503
NC
R507
C2A S 6 15 RHRP8120 TLP250
G
1N4148 CT2 IRFP264
R511
CT(+) 1N4148 104P
P850 5 16 R11 47/F S
471KP/1KV
D503
C511
224/630V
51ohm
G
RHRG30120
NC D313
R381
10/F
C9
D314 S 4 17
R512
1N4148
R4
NC
RHRP8120
R12
CT(-) 3 18
NC 47.5K*
D3B D504
SITE+ 2 19
4 4
25XB60
4 U5 1 NC R509 1 20
D
NC
47.5K* TX501
D3A
GT25Q101
+ - TX108X/EE55
3 TLP 2
621 G
SITE- S Q1A BR02
10ohm/5W
10 11
R3
GT60M301 D Q5
C512
224/630V
RHRP8120
D2A
9 12
GT25Q101
1N4148
D Q504 ICTLP250 D15
RHRG30120
D505
R2A
8 13 U3 G
NC
1N4148
C313 C321
10/F
C333 C335
5 S
5
471KP/1KV
7 14 RHRP8120 47/F
100ohm/3W(016) 222KP/1KV
D Q505
222KP/1KV
G
C10
8
C508
330u/450V
1
330u/450V
330u/450V
C8 IRFP264 6 15 R10 D Q7
2 7 S D506
PF.VCC+
R514
C126
NC
NC
5 16 1N4148
3 6 G TLP250 D19
D13
10/F
D Q506 104P
C4B
PF.VCC0 S G
R1 3K*
R2
4 5 4 17
R515
TLP250 IRFP264 RHRP8120 47/F
47.5K*
100ohm/3W(016)
104P
R508
PF.VCC- ICTLP250 G 3 18
R15
U10 D507
10/F
R33
S 2 19 RHRP8120
R516
PFC.O/P
R13
1 20 47.5K*
6 D508
6
150UH
L502
TX502
TX108X/EE55
R513
C501
47.5K* 850UH/10A(1026)
RHRG30120 850UH/10A(1026)
104P D510 PWM- 850UH/10A(1026)
100K*
R505 L5 L6 L7
U501 -IGBT-5
UC3525 G2R-1-E
16 VREF INV 1 4
15 VIN NI 2 3
7 BUS.M
+5V
14
13
OUTB SYNC
VC OSC
3
4
-IGBT+12
2
8 1
INVRLY-
7
BAT(+)
12 GND CT 5 100ohm
3
2
6
5
+12V
11 6 -BUS.FB RLY04
OUTA RT
10 SHUT DISC 7 -IGBT0 INVRLY+
R503
9 8
1.5K*
COMP SOFT
R54
15K* 12V IC3525 CT1
1
C506
C509
R502 R500 104P CT1:1:1000

R501
6.8U/250V
6.8U/250V
150K* CN17L
1 U7 4 3.9K* C504
C11
C12
P850
220u/35V
C503 392P
C502 D61 D62
ICTLP521 104P 1N4937GI 1N4937GI CN17N
8 2 TLP 3
104P
D63 D64 P850
8
521 1N4937GI 1N4937GI
3525OFF 150ohm
R71
R67 R68 R68A
INV.L
220K* 220K* 220K*
1073LD-1.SCH
9 098-01190-05 L.C+ 9
L.C-
REVISE: 00
Liebert
SHEET OF GXT2000RT-230
SK8103-7205-01 1 3
DATE:04/29/97 Sub-Assembly Part NO:710-01402-01
PFCOFF
PFC.O/P
1 CT(+) 1
CT(-)
C318C +24V
100u/50V
2 ZD2
C318 2
2 - U304 3.3V R364 30K* C328 102P C330
LINE.V 1 104P
R340 R329 R316 C307 102P 324 C327 102P
3 + U305
REF.AC IC324 221P
330K* 499K* 150K* UC3854
1 GND GTDRV 16
R313 10.7K* R368 15k* 2 PKLMT VCC 15
R336 3 CAOUT CT 14
R337 4
1.5K* 10.5K* R363 15K* IS SS 13
3 9 - U304 D301
5
6
M.T
IAC
REST 12
VS 11
3
324 8 7 VAOUT ENA 10
+12V
SMALL SIGNAL COMPONENTS

10 + 8 9
IC324 1N4148 VRMS VREF C317
R312 IC3854 472J
11K* R363A 2K* R355 10K*
FOR ALL
R325A R325B
FOR IC4066 FOR IC324
R367 1M* R61 1M* DB25P50L
2
1
100u/50V
178K* 100K*
4 C319A C314 4
10u/50V
C307A R324 C315 C318A CN1
CB CA R318 3.3K*
104P 12V 24V
C322
104P 104P 104P 10K*
1
10u/50V C325
104P 221P D16 1N4148 GND +5V
+12V
3
R323 100K*
+5V CHGROFF CHGROFF+
R346
5
C318B 472J FANSP/F
R353
9.1K* C323 L.C+
15K*
C319 1u/50V
103P
7
U1 I/P.RLY L.C-
R361A
100K*
104P
R362 470K
5 5
C324
R358
48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
9
R343 13 - IC4066 R359
R342 R344 R345 U304 8 9 220ohm* INV.L BAT.V
178K* 178K* 200K* 324 14
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
100K* 4066
+BUS.FB 12 + IC324 10K* R361 INVRLY+ INVRLY-
6
+12V 200K*
R53 R51 R358A INVSTS- INVSTS+
A0
R52 100K* 10.7K* Q10 10K* S.D. SWPOWER
A1 C1815
75K* +5V GND
6 LINE+
R358B
GND
6
R41 R42 R43 R44 4.99K*
178K* 178K* 178K* 150K* +BUS.V 3525OFF
+BUS.V
R45 +5V PFCOFF -BUS.V
6.8K*
R50 LINE- LINE+
4.99K* BUS.M
A0 GND
7 -BUS.FB
R46
178K*
R47
178K*
R48 R49
178K* LINE.L A1
7
178K*
-IGBT0 -BUS.V
+5V THERMAL1 LINE.V
R24 R23 20K* R23A 7.5K*
47.5K* PWM12V THERMAL2
A1 U1
PWM- PWM+
R25 75K* U304 IC4066 +12V
A0 5 + IC324 11 10 R352 JP
R331 R332 R333 R334 324 7 4066 BATSCR
C310 220ohm* NC
8 47.5K* 220K* 200K* 178K*
6 -
R315 10K*
10u/50V 12 SYNC+ 8
R352A
C310A
+5V 10K* SITE+ SYNC-
R335 R335A R307 100K* JP1
SITE-
6.8K* 6.8K* JP500
104P C311 1u/50V
Q9
R352B C1815 HFPOWER- HFPOWER+
50 50
LINE-
9 4.99K* 9
49
1073LD-2.sch
Liebert REVISE: 00 2

SHEET OF GXT2000RT-230
SK8103-7205-01 2 3
R31C R31E D6B +12V
15K* 15K* 1N4937GI I/PRLY

+24V R31A C31A
1 R31D 1
20K*
R31B
R28
104P
4.99K*
1N4148
D6A
SWPOWER 15K* 15K* BAT(+)
270K* 1M*
C BAT.V
Q8
S.D. B R389C R389
N5551
TX1A
12V
CN15++ CN15+ FC335/AIU FC335/AIB E
FC2A FC2B 1N4937GI
2 C31B
R310A
D6 1N4148 2
ZD1
+IGBT+12
TX1083/EEL16/LIE D335
C25
FC3A FC3B 10K* D202B 1N4148 6
47u/50V
P850 P850 104P R389B 47.5K*
C375
4.7K*
102MP/1KV
R40
CN15-- CN15- D511 5 7
FC335/AIU FC335/AIB TX108X/EE42-15 TX1
1 12 MUR860 4 8
D202A UF5402 +IGBT0
C13 100ohm/3W(016)
1200U/200V
P850 P850 R18 11 3 9
17K/3W R389A
C219C
C219B
1N4937GI
R37
3 223/400V C219 3
C219A
1N4937GI 12K/2W 2 10
220u/35V
R238 3 10
5.1VZD3
100K/3W 1200u/200V
D20
C371
NC
100u/200V 1
17K/3W
D4
R18A
C17
8
TX305
5 +IGBT-5
C374 100u/50V 100u/50V
D205 6 7 D333 1N4937GI
BR01 -IGBT+12
Q208 D1N4937GI NC
1N4937GI
NTC2 C16 C224 104P R40A
4 U206 IC3845
4
+
7.5V
D33
7.5V
I/P(L) C376
7 UC3845
47u/50V
1N4148 PF.VCC+
ZD11
ZD10
G 47u/50V
C222
100u/450V
VCC 4.7K*
-
3.74K* 8 6 D32
5ohm/5A Vref O/P 2SK793 S PF.VCC0
2W10G R36 -IGBT0
4 3 R226 47/F
R/C IS PF.VCC- C368
COMP GND VF R235 1K/F IRF730 D Q3 220u/35V
220u/35V
C221A ZD4
4.7K*
C223
R390
C221 1 5 2
R233 R230 U302 5.1V
5 I/P(N) 472J 104P C220 47.5K* 7 UC3845 G -IGBT-5 5
102P VCC R402 47/F S D330
8 6 24V
0.5ohm/2W(020) Vref O/P
1N4937GI 10K* 10K*
104P 4 R404 1K/F
CHGROFF 30K* IS 3 C373
R373A
C365
R373
R/C
R403 COMP GND VF 104P
R218A 1 5 2
C205 1.5K* 100u/50V
521 3 4 U202 1 R27 IC3845
2
6 TLP
6
ICTLP521
R212A
200K*
ICTLP521 30K*
U6
C26 HFPOWER+
C210 R38A
C21
3 TLP 2 R32
D7
1 4 521 104P 221P C24 R21
UF5402
510ohm C22 1M* 12V
CHGROFF+ R234 104P C23 +12V +5V
104P
C18 472J 102P
0.5ohm/2W(020)
R207
47u/50V
3.74K* 47.5K* IC7805 U311
472J I 7805 O
C20
+5V
A
7 R229 470K 7
47.5K*
R39
VR301 C364
C377 C363
C361
1K-VR1T R38 104P
11K* 2200u/16V 100u/50V
U203 R 104P
K A
GND
TL431
CN22B
8 1
2
8
JST-2P
Q20 D
510ohm
FANSP/F G CN22C
R70 1
9 2SK1112S
D30 D31 2
9
GND 1N4007GI 1N4007GI
1073LD-3.SCH JST-2P
REVISE: 00
Liebert
SHEET OF
SK8103-7205-01 3 3 GXT2000RT-RT
DATE:04/29/97 Sub-Assembly Part N0:710-01402-01
I/P(L)
R65A 220K* R65 220K* R66 220K*
LINE.L
1 I/P(N) 1
LINE(L)
REF.AC
I/P.RLY
PWM12V
+IGBT-5
I/PRLY +IGBT0
PWM+ +IGBT+12
2 +BUS.FB 2
BAT(+) D509 RHRG30120
GT25Q101
150UH
L501
CN16L
SG301 G7L-2A-P
COMMON/2MH/20A
2.2U/250VAC
2.2U/250VAC
1.5MH/15A(1028) D Q501 D501 D Q13
8 6 FU20A/250VAC/F
IRFP264
GT25Q101
NTC1 C1 C2 4 2 F1 10 11 RHRP8120 D10 1N4148
100ohm/3W(016) 222KP/1KV
C507
P850 L2 L1 G ICTLP250 G
1 0 9 12 D502 U2
3
2
6
5
C9 100ohm/3W(016)
MOV1 RLY01 1.5MH/15A(1028) S R30 47/F S
L0 D Q502
C320 C332 C334 C338
R14
3 3
R510
10/F
320L20 1N4148 CT1:1:1000 IRFP264 8 13 RHRP8120
D12
CN16N Q12 D
330u/450V
330u/450V
330u/450V
330u/450V
D311 7 14
G D14 1N4148
1
D312
10/F
C12A
D Q503
R507
C
C2A S 6 15 RHRP8120 TLP250
C
1N4148 CT2 IRFP264 G
R511
CT(+) 1N4148 104P
P850 5 16 R11 47/F S
471KP/1KV
D503
C511
224/630V
51ohm
G
RHRG30120
NC D313
R381
10/F
D314 S 4 17
R512
1N4148
R4
NC
RHRP8120
R12
CT(-) 3 18
NC 47.5K*
D3B D504
SITE+ 2 19
4 4
25XB60
U5 1 R509
R
4 NC 1 20
R
D
NC
47.5K* TX501
D3A
GT25Q101
+ - TX108X/EE55
3 TLP 2
621 G
SITE- S Q1A BR02
10ohm/5W
10 11
R3
GT60M301 D Q5
C512
224/630V
RHRP8120
D2A
9 12
GT25Q101
1N4148
D Q504 D505 ICTLP250 D15
RHRG30120
R2A
8 13 U3 G
IRFP264
1N4148
C313 C321
10/F
5 C333 C335 S
5
471KP/1KV
7 14 RHRP8120 47/F
100ohm/3W(016) 222KP/1KV
D Q505
222KP/1KV
G
C10
8
C508
330u/450V
1
330u/450V
330u/450V
330u/450V
C8
S IRFP264 6 15 R10 D Q7
PF.VCC+ 2 7 D506
R514
10/F
C126
5 16 1N4148
C
3 6 G D19
C
TLP250
D13
10/F
D Q506 104P
C4B
PF.VCC0 S G
R1 3K*
R2
4 5 4 17
R515
TLP250 IRFP264 RHRP8120 47/F
47.5K*
100ohm/3W(016)
104P
R508
PF.VCC- ICTLP250 G 3 18
R15
U10 D507
10/F
R33
S 2 19 RHRP8120
R516
PFC.O/P
R13
47.5K*
6 1 20 D508
6
150UH
L502
TX502
TX108X/EE55
R513
C501 R R
47.5K* 950UH/16A(1027) 950UH/16A(1027)

RHRG30120
104P D510 PWM-
100K*
R505 L7 L8
U501 -IGBT-5
R
R
UC3525 G2R-1-E
16 VREF INV 1 4
15 2 3
7 BUS.M
+5V
14
13
VIN
OUTB SYNC
VC
NI
OSC
3
4
-IGBT+12
2
8 1
INVRLY-
7
BAT(+)
12 GND CT 5 100ohm*
3
2
6
5
+12V
11 6 RLY04
OUTA RT -BUS.FB
10 SHUT DISC 7 -IGBT0 INVRLY+
R503
9 8
1.5K*
COMP SOFT
R
R54
15K* 12V CT1

R
IC3525
1
R
C506
R
R R
C509
R502
R
R500 104P CT1:1:1000

R501 CN17L
10U/250V
10U/250V
3.9K* C504
R R
150K*
1 U7 4
C11
C12
P850
220u/35V
C503 392P
C502 D61 D62
104P 1N4937GI 1N4937GI
8 2 TLP 3
104P
D63 D64
CN17N
P850
8
ICTLP521 521 1N4937GI 1N4937GI
3525OFF 100ohm*
R71
R67 R68 R68A
R R R R R R
INV.L
220K* 220K* 220K*
1083LF-1.SCH
9 098-01421-00(D) L.C+ 9
L.C-
REVISE: 00
Liebert
SHEET OF
SK8103-8204-01 1 3 GXT3000RT-230
PFCOFF
PFC.O/P
1 CT(+) 1
CT(-)
C318C +24V
100u/50V
2 ZD2
C318 2
2 - U304 3.3V R364 30K* C328 102P C330
LINE.V 1 104P
R340 R329 R316 C307 102P 324 C327 102P
3 + U305
REF.AC IC324 221P
330K* 330K* 330K* UC3854
1 GND GTDRV 16
R313 10.7K* R368 15k* 2 PKLMT VCC 15
R336 R337 3 CAOUT CT 14
1.5K* 10.5K* 4 IS SS 13
R363 15K*
3 9 - U304 D301
5
6
M.T
IAC
REST
VS
12
11
3
324 8 7 VAOUT ENA 10
+12V
SMALL SIGNAL COMPONENTS

10 + 8 9
IC324 1N4148 VRMS VREF C317
R312 IC3854 10K* 472J
11K* R363A 2K* R355
FOR ALL
R325A R325B R367 R61 1M*
FOR IC4066 FOR IC324 1M*
2
1
100u/50V
178K* 100K* DB25P50
4 C319A C314 4
10u/50V
C307A R324 C315 C318A CN1
CB CA R318 3.3K*
104P 12V 24V
C322
104P 104P 104P 10K*
1
10u/50V C325
104P 221P D16 1N4148 GND +5V
+12V
3
R323 100K*
+5V CHGROFF CHGROFF+
R346
5
C318B 222J FANSP/F
R353
9.1K* C323 L.C+
15K*
C319 1u/50V
103P
7
U1 I/P.RLY L.C-
R361A
100K*
104P
R362 470K
5 5
C324
R358
48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
9
R343 13 - IC4066 R359
R342 R344 R345 U304 8 9 220ohm* INV.L BAT.V
178K* 178K* 200K* 324 14
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
100K* 4066
+BUS.FB 12 + IC324 10K* R361 INVRLY+ INVRLY-
6
+12V 200K*
R53 R51 R358A INVSTS- INVSTS+
A0
R52 100K* 10.7K* Q10 10K* S.D. SWPOWER
A1 C1815
75K* +5V GND
6 LINE+
R358B
GND
6
R41 R42 R43 R44 4.99K*
178K* 178K* 178K* 150K* +BUS.V 3525OFF
+BUS.V
R45 +5V PFCOFF -BUS.V
6.8K*
R50 LINE- LINE+
4.99K* BUS.M
A0 GND
7 -BUS.FB
R46
178K*
R47
178K*
R48 R49
178K* LINE.L A1
7
178K*
-IGBT0 -BUS.V
+5V THERMAL1 LINE.V
R24 R23 20K* R23A 7.5K*
47.5K* PWM12V THERMAL2
A1 U1
PWM- PWM+
R25 75K* U304 IC4066 +12V
A0 5 + IC324 11 10 R352 JP
R331 R332 R333 R334 324 7 4066 BATSCR
C310 220ohm* NC
8 47.5K* 220K* 200K* 178K*
6 -
R315 10K*
10u/50V 12 SYNC+ 8
R352A
C310A
+5V 10K* SITE+ SYNC-
R335 R335A R307 100K* JP1
SITE-
6.8K* 6.8K* NC
104P C311 1u/50V
Q9
R352B C1815 HFPOWER- HFPOWER+
50 50
LINE-
9 4.99K* 9
49
1083LF-2.sch
REVISE:
Liebert 00 2

SHEET OF
SK8103-8204-01 2 3 GXT3000RT-230
R31C R31E D6B +12V
15K* 15K* 1N4937GI I/PRLY

+24V R31A
R31D C31A
1 1
20K*
R31B
R28
104P
4.99K*
1N4148
D6A
SWPOWER 15K* 15K* BAT(+)
270K* 1M*
C BAT.V
Q8
S.D. B R389C R389
N5551
20A/125VDC/F TX1A
12V
CN15++ CN15+ FC335/AIU FC335/AIB E
FC2A FC2B C31B 1N4937GI
2 R310A
D6 1N4148 2
ZD1
+IGBT+12
TX1083/EEL16/LIE D335
C25
20A/125VDC/F 10K* D202B 1N4148 6
47u/50V
P850 P850 104P R389B 47.5K*
C375
4.7K*
102MP/1KV
R40
CN15-- CN15- FC3B 5 7
FC3AFC335/AIU FC335/AIB TX108X/EE42-15 TX1 D511
1 12 MUR860 4 8
D202A UF5402 +IGBT0
C13 100ohm/3W(016)
1200U/200V
P850 P850 R18 11 3 9
17K/3W R389A
C219C
C219B
1N4937GI
R37
3 223/400V C219
3
C219A
12K/2W 2 10
220u/35V
R238 3 10
5.1VZD3
100K/3W 1200u/200V
D20
C371
NC
100u/200V 1
17K/3W
D4
R18A
1N4937GI
C17
8
TX305
5 +IGBT-5
C374 100u/50V 100u/50V
D205 6 7 D333 1N4937GI
BR01 -IGBT+12
1N4937GI Q208 D NC 1N4937
NTC2 C16 C224 104P R40A
U206 IC3845
+
4 4
7.5V
7.5V
1N4148 D33 C376
I/P(L) 7 UC3845
47u/50V
PF.VCC+
ZD11
C222
G 47u/50V
ZD10
100u/450V
VCC 4.7K*
-
3.74K* 8 6 D32 2SK793

5ohm/5A Vref O/P S PF.VCC0
2W10G R36 -IGBT0
4 R226 47/F
R/C IS 3 PF.VCC- C368
COMP GND VF R235 1K/F IRF730 D Q3 220u/35V
220u/35V
C221A ZD4
4.7K*
C223
R390
C221 1 5 2
R233 R230 U302 5.1V
5 I/P(N) 472J 104P C220 102P 47.5K* 7 UC3845
VCC
G
D330
-IGBT-5 5
8 6 R402 47/F S
Vref O/P 24V
0.5ohm/2W(020) 1N4937GI 10K* 10K*
104P 4 R404 1K/F
CHGROFF 30K* IS 3 C373
R373A
C365
R373
R/C
R403 COMP GND VF 104P
R218A 1 5 2
C205 1.5K* 100u/50V
521 3 4 U202 1 R27 IC3845
2 TLP
ICTLP521
6 ICTLP521
R212A
200K* 6
30K*
U6
C26 HFPOWER+
C210 R38A
C21
3 TLP 2 R32
D7
1 4 521 104P 221P C24 R21
UF5402
510ohm C22 1M* 12V
CHGROFF+ R234 104P C23 +12V +5V
104P
C18 472J 102P
0.5ohm/2W(020)
R207
47u/50V
3.74K* 47.5K* IC7805 U311
472J I 7805 O
C20
+5V
A
7 R229 470K 7
47.5K*
R39
VR301 C364
C377 C363
C361
1K-VR1T R38 104P
11K* 2200u/16V 100u/50V
U203 R 104P
K A
GND
TL431
CN22B
1
8 2
8
JST-2P
Q20 D
510ohm
FANSP/F G CN22C
R70 1
9 2SK1112S
D30 D31 2 9
GND 1N4007GI 1N4007GI
1083LF-3.SCH JST-2P
REVISE: 00
Liebert
SHEET OF
SK8103-8204-01 3 3 GXT3000RT-230
DATE:04/29/97 Sub-Assembly Part-NO:710-01421-01
1 LD506 25% 1
LEDS(G)
LD505 50%
LEDS(G)
2 2
+5V
LD504 75%
LEDS(G)
PIN16
1
2
3 LD503 100% 3
LEDS(G)
LD502 OVERLOAD
LEDS(Y)
4 CN501 4
LD501 FAULT
LEDS(R)
LD508 BYPASSLED
LEDS(Y)
5 5
LD510 INVERTERLED
15
16
LEDS(G)
6 LD509 BATLED 6
LEDS(Y)
LD507 LINELED
LEDS(G)
7 7
SW501
TACK
8 OFFSW 8
SW502
9 TACK 9
ONSW
DEVISE:
Liebert
Part No. SHEET 1 OF 1 Title: GXTXXXXMT Drawn: Designer: Checked: Approved:
SK8103-3503-00 GXTXXXXMT
PANEL SCHEMATIC
DATE 05/09/97 Sub-Assembly Part No: 710-01110-00
A B C D E F G H I J KCN1
L M N U8
O
1
12V
2
O 7812 I
DB25P16
U6SKT 25% LINELED IC7812
A
220u/35V
SOCKET-84P 50%
510ohm
220u/35V
+BUS.V 75% BATLED 1 24V
+12V
C15
C14
510ohm
+5V +12V 100% 2
R3
1 THERMAL+
+5V +5V R115 510ohm
OVERLOAD
FAULT
OFFSW 3 5V
1
R6
BZ1 4 GND(POWER) CN2
C52
BYPASS 510ohm
R111
THERMAL- R116 510ohm INVERTER Q1 BZ20335 5 CHGOFF+
1
2
D17 BL BR
R112
R78 C1815 6 CHGOFF-
10K*
104P
BAT.V R77 R117 510ohm R4
7 FANSP/F
510ohm
10K* 4.99K* SKT-84P BK
-BUS.V R118 510ohm +5V 4.99K* 8 L.C+
2
R119 20K* 1N4148
LINE.V U7 9 L.C-
6
4
510ohm
220K* R61 +5V C43 - 7 SWPOWER SHUTDOWN 10 I/PRLY
LINE.L 1N4148 5 393
+5V
10K*
11 BAT.V
6
R80
R58 10K* C26 C31 C38
R110
D15 + IC393 C27 C39 SW1 FANSP/F
U5 12 INV.L
15
16
12V -8V GND IC339 6 R113
8
- R56 R5 INVSTS-
2 1 C35 100K* 13 INVRLY-
2
102P
MC4081 14 7 7 339 103P NC C42 10u/50V 104P 104P
50 48 46 44 42 40 38 36 34 32 30 28 26 24 22 20 18 16 14 12 10
R108
104P INVRLY- 14 INVRLY+
9
+ 49.9K* LINE-ZER 104P D1
10u/50V
C37 1N4148
MC4013 14 7 R59 R79 INVRLY+ 15 INVSTS+
49 47 45 43 41 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11
R14 C41 2 23 64
510ohm
+5V 104P 16 INVSTS-
220P PFCOFF
20K* R57
C55
LM393 8 4 100K* XL1 VDD VDD VDD U1 17 SWPOWER
4.99K*
510ohm
4.99K* 71 MODA/ LIR PB0/ADDR8 11 6 2003 11 3525OFF 18 S.D.
R60
C22
D13
LM339 3 12 4.99K* 1N4148 XL12MHZ 70 10 Q2 K941
MODB/ Vstby PB1/ADDR9
103P
IC2003 D CHGOFF- 19 GND(DC/START)
103P
NTC1 C34 69 RESET PB2/ADDR10 9
TL074 4 11 68 8
300OHM/1W
20 MODEL0
1N4148
+5V
R107
XTAL PB3/ADDR11
NTC05/15K
C40 220P R72 67 7 R7 +24V
D18
CD4066 EXTAL PB4/ADDR12 21 MODEL1
+5V 4.7M/03 +5V 66 6 G
R109
R83 XOUT PB5/ADDR13 510ohm 22 GND(DC/DC)
R101
104P D12 65 E PB6/ADDR14 5 S
10k*
L.C+
R87
34 4 23 3525OFF
3 +12V 10K*
C33
1N4148 +BUS.V
TEMP.V
35
36
AVdd
PE7/AN7
PE6/AN6
PB7/ADDR15
PC7/DATA7 62
61 1
CN5
R8
+VCC 24 +BUS.V
25 -BUS.V
3
L.C- BAT.V BAT.V 37 PC6/DATA6 10K*
49.9K*
-BUS.V PE5/AN5 PC5/DATA5 60 2 26 PFCOFF
223P +5V 38 PE4/AN4 59 C4 10u/50V U10 1
R82
PC4/DATA4
+5V R84 D16
R32
39 PE3/AN3 PC3/DATA3 58 R19 4.99K* JST-2P +5V 4 27 LINE+
+12V -8V 40
1u/50V
4.99K* PE2/AN2 PC2/DATA2 57 28 LINE-
1N4148 41 PE1/AN1 56 NEC2561
C3 104P 2 U7 42 PC1/DATA1 29 GND(PFC)
C9
- R85 49.9K* C30 10u/50V PE0/AN0 U6 PC0/DATA0 55 TLP
43 3 2
10k*
1 30 A0
R88
Vrl R70 510ohm 621
C21 104P 3 393 C-LIMIT 44 Vrh
MC68HC(7)11K4
46 31 A1
+ 49.9K* 45 MC68L11K4 PF7/ADDR7 SWSTUTS
IC393 C36 AVss PF6/ADDR6 47 OFFSW R98 32 LINE.L
C44 104P C12 +5V 103P
C29 104P
1 PF5/ADDR5 48 4.99k*
4 C20 C59
102P LINE-ZER 84
83
PA0/IC3
PA1/IC2
PA2/IC1
PF4/ADDR4
PF3/ADDR3
49
50
51
+5V
+VCC
SW1
33 LINE.V
34 THERMAL+ 4
INV-ZERO 82 PF2/ADDR2 35 THERMAL-
1N4148
R42 150K* LINE.V PA3/IC4/OC5/OC1 52 4 U11 1
81 PA4/OC4/OC1 PF1/ADDR1 MODEL3 36 PWM12V
104P 104P CURR.V 80 53
10K*
PF0/ADDR0
D9
1N4148
10K*
10K*
10K*
PA5/OC3/OC1 MODEL2
4.99k*
R43 U3 INV.V 79 S.BATLOW SW-DIP2 37 PWM+
R99
6 PA6/OC2/OC1 77 MODEL1
INV.L - 7 D10 78 PA7/PA1/OC1 PD5/ SS ANYSHUT TLP 38 PWM-
1M* 76 3 2
5 TL074 12 PD4/SCK
+5V MODEL0 621 39 BATSCR
R74
R73
R75
R76
+5V + PH0/PW1 PD3/MOSI 75 30k* NEC2561
CLOCK
100K*
220K*
I/PRLY
R63
ICTL074 13 74 R62 40 SW1

R50
PH1/PW2 PD2/MISO
U5 +5V PW2 14 PH2/PW3 PD1/TxD 73 Q3 D 41 SW-ON
-8V +12V R34 BAT.SHUT
R25
4 IC339 15 72
C32
PH3/PW4 PD0/RxD
1N4148
D28
- 200K* 16 SITE+ 42 SYNC+
NC
10K*
C23 104P 2 PH4/CSIO R10

R65
S.LNFAIL 26
102P
5 339 17 PG7/R/ W A0 43 SYNC-
5 + R46 NC U3 PWM-OFF 18
PH5/CSGP1
PH6/CSGP2 PG6 27 A1 510ohm
G
44 SITE+ 5
49.9K*
VR1
+ 19 PG5/XA18 28 LINELED S K941
101P
R68 R66 INV-ZERO S.UPSFAL PH7/CSPROG
49
50
12 TL074 PG4/XA17 29 BATLED 45 SITE-
100K* 49.9K* - 14 +12V S.SUMALM 20 TEST16
1 PG3/XA16 30 LINE+ R9 46 MODEL2
13 ICTL074 31
3.9M/03
S.BYPASS 21 XIR/Vppe 2 PG2/XA15 LINE- 10K* 47 MODEL3 DB25P50L

1U/100VBP
32
C17
C25
C11 221P PG1/XA14 BATSCR

R64
R67
4.99K* C28 R11 +VCC

27K*
10K* 22 TEST15 1 33 48 PWM-OFF1

R96
R94
PG0/XA13
JP1000
1U/100VBP -8V
R47
D14
103P 1N4148 54 +5V 1N4937GI 49 H.FPOWER+

25 TEST14 1 IRQ
R40 C24 R41 10 U5 D22 50 H.FPOWER-
470K
C16
VSS VSS VSS
-8V
2.2k
- 13
4.99K*
102Y/250VAC
NC
100K* R81 301K* 1K* 11 339 3 24 63
4.99K*
10u/50V
R71
R134
104P
R106
C10 + IC339
R95
10K*
ICMC68HC(LIE) TX1
C47
R39 +VCC +VCC 47u/50V
6 R86
6
C18
D11 NC EEL16 C45
47u/50V
C54
36K U5 R12 +5V 10
+12V
10K*
C6 R27 10K* 473J
471P 1N4937GI
R24
10K*
C8 102J R69 ICHI3-5051-5 9 1
339 9
8
1M*
12 11 U19 1 U9 4 C46 D19

R51
NEC2561
+
-
U2 10u/50V
C61
R29 U3 R26 4.99K* R37 220K* R31 1 4.99K* 16 S1
V L V+
D1 1 8 2
10K* 3 D7 1N4148 +VCC -VCC
+ ICTL074 10K* 2 4081 4 S3 D3 3 H.FPOWER- NEC2561
10 TL074 1N4937GI 7 3
14
200K* IC339 R20 20K* 15 A1 2 2 TLP 3 D21
- 8 R38 22.6K* IC4081 621 F.FPOWER+ 3
621
2
D24
R28 9 1u/63V C60 10 A2 7 6 4 TLP
R114
510ohm
R130
R49
2k*
200K* U3 1N4148 9 D2 8
90.9k*
4.99K*
R30 S2
1N4148
C7 + R48 1K* D20 5
3 TL074 ICTL074
47U/50v
D5
JP1000 R22 5 S4 D4 6 1N4937GI
16.9K* 1 C2 221P 4 U14 1
10K* R93
R103
- 10K* VR V-
C48
PW2 R122 330ohm*
7 102J 2
U2 13 14
7
NEC2561
R33 R45 U12 1
R100
C5 C13 221P 5 U2 4 R97
20K* 4 D6 12 R129
104P 6 4081 11
4081 9
8
R23 100K* 13 4081 510ohm
1N4148 U2 510ohm
C19 R44 470K IC4081 R21 -VCC S.LNFAIL
470K IC4081 IC4081 3 TLP 2 +5V
C-LIMIT 621 NEC2561 1K*
CLOCK +12V 20K* NEC2561 R91 1K*
1N4148
U1 -VCC 1 U18
10
104P IC4013 U4 U4 D8 4
+5V +12V 1 U17 R90
14
C1 ANYSHUT 4
1N4148
10 4013 4 4013 1N4148 1 2003 16
D2 R52
IC2003 U1 BAT.SHUT +5V
9 RST 12 5RST 2 221P U1 IC2003 CN3
D27
Q Q
3 2003
SW-ON D D BAT.SHUT
10K* TLP
49.9K*
1N4148
11 13 3 1 2 2003 15 DB25P26 +VCC 2 3

R15
D26
1N4148 R55 CLK Q CLK Q 2 TLP 3 621
S.D. Q6 +12V IC2003 1
621
8 SET SET
8
D3
4.99K* R17 4.99K* R18 4.99K* 25

D23 IC2003 U1 C1815 8 IC4013 6 D4 1N4148 U1 NEC2561
SHUTDOWN 13 2003 4 2 26
7 2003 10 R89 R120 621
+12V 3 2
D25
TLP ANYSHUT
C53
1N4148 +12V R54 20K* VRH IC2003

R53
C50
C49
1K* 510ohm
1N4148
49.9K*
S.SUMALM
20K* R13
K
+12V
R16
10u/50V
R2 1K* U13 C51
4 U16 1
104P
100u/50V R121
R
104P
SWSTUTS 10K* U1
R1 TL431AC PWM-OFF1 S.BYPASS PWM12V
A
12 2003 5 330ohm*
5
9
4
8
3
7
2
6
1
S.LNFAIL R92 510ohm
SYNC+ IC2003 4.99K* S-BATLOW
S.UPSFAL GND S.BATLOW 24V 12V
DB27P09 CN4
9 R35 510ohm
PWM-
PWM+
9
R36 510ohm
PWM-OFF
098-01116-01
REVISE: 00
Liebert
SHEET 1 OF 1
GXTXXXXRT(MT)-230
SK8103-3106-01 Control Circuit Diagram Stephen 5/16 ’97
Date : 5/16/97 Sub-Assembly Part No.:710-01116-02 File Name:0111602A.SCH

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UPStation GXT Series

Manual Part Nº04577451-1

• ALTERNATIVELY FAX A COPY OF THIS FORM TO THE ABOVE ADDRESS ON

GXT-230 Manual Registration

Name of Registered Holder

Address of Holder Company

Issue -1- 12/08/98

Issue -1- 12/08/98

CHAPTER 2 - Power Board 9

CHAPTER 3 - Control Board 25

CHAPTER 4 - Operating Procedures 41

Issue -1- 01/10/98 i

CHAPTER 6 - Troubleshooting Procedures 53

CHAPTER 7 - Spare Parts 85

Issue -1- 01/10/98 ii

CHAPTER 8 - Specification 137

CHAPTER 9 - Drawings 139

Issue -1- 01/10/98 iii

iv Issue -1- 01/10/98

Read this manual carefully before working on this UPS equipment

Important Safety Instructions

GXT-230 Repair Manual Preliminary Information

vi Issue -1- 01/10/98

Description Rating (kVA/kW) Case Style

GXT700MT-230 700 /490 Mini Tower

GXT-230 Repair Manual Functional Description

1.2 Principles of operation

1.2.1 Block diagram

2 Issue -1- 01/10/98

Issue -1- 01/10/98 3

1.3 Basic operation

Pressing the ON push-button

Operation during mains failure and return

Operation under fault conditions

4 Issue -1- 01/10/98

1.4 Major component connection details

700MT 710-01126-XX2 2 off 80946-001 094-00045-00 094-00050-00 5A -

1000RT 710-01440-XX2 3 off 33956-00 094-00046-01 094-00050-00 6.3A 6.3 A

1500RT 710-01460-XX 4 off 33965-00 094-00061-00 094-00050-00 10A4 10.0 A

2000RT 710-01042-XX 8 off 80901-01 094-00080-03 710-01108-XX 15A4 15.0 A

Note 1: External battery connector not fitted

Issue -1- 01/10/98 5

Figure 1.3 - Ferrite core usage

Model Ferrite Core A Ferrite Core B Ferrite Core C Ferrite Core D

700MT Not fitted Not fitted Not fitted -

6 Issue -1- 01/10/98

1.5 Control Panel description

1.5.1 Control Panel push-buttons

ON / Alarm Silence / Batt. Test button

OFF / Bypass button

1.5.2 System Status indicators

Issue -1- 01/10/98 7

1.5.3 Bargraph Led

Figure 1.5 - Operator Panel Bargraph led functions

8 Issue -1- 01/10/98

Figure 2.1 - 1500VA Power Board

A Battery positive connector B Battery Fuses