GTEC Europe

ZS110-6-10K Repairing Manual

Version 1.0
Research and Development Center

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Index
Index .............................................................................................................................. 2
1 Abbreviation used in this manual ................................................................................ 3
2 Basic topology of online ZS110-6-10K UPS .............................................................. 3
3 Troubleshooting of LED Version ................................................................................ 4
3.1 Definition of LED panel ................................................................................... 4
3.2 Audible alarm and LED indication of UPS operating ZS110-atus and faults .. 4
3.3 Troubleshooting ................................................................................................ 5
3.3.1 Overheating fault ........................................................................................... 5
3.3.2 Inverter fault................................................................................................... 6
3.3.3 Bus voltage fault ............................................................................................ 6
3.3.4 over charge fault ............................................................................................ 7
3.3.5 over load fault ................................................................................................ 7
3.3.6 Fan fault ......................................................................................................... 7
3.3.7 Short-circuited fault ....................................................................................... 8
3.3.8 Charger fail fault ............................................................................................ 8
3.3.9 Site fault ......................................................................................................... 8
4 Troubleshooting of LCD Version ................................................................................ 9

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1 Abbreviation used in this manual

PSDR: Main power board.

CNTL: The control board, the “brain” of the UPS
CHGR: the charger board, it’s powered by mains input or bus voltage in the PSDR and charges
the battery.
SPS: SyZS110-em power supply board, the “heart” of the UPS. It provides 5V, 12V voltages for
the CNTL and other boards.
IGBTDRV: The IGBT drive board.
Linemode: In this mode the UPS is powered by mains input and the inverter is working, typically
the output is 220V and the output frequency is following the input frequency.
Batterymode: When the mains input fails the UPS transfers to this mode. UPS is power by battery
and the inverter is working, typically the output is 220V/50Hz
PFC: Power factor corrector. It converts mains AC to DC bus voltage.

2 Basic topology of online ZS110-6-10K UPS

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3 Troubleshooting of LED Version

3.1 Definition of LED panel

No. Color Indicator Description

When the indicator on, it shows that
1# Red Fault indicator
the UPS in abnormal condition.
2# Orange Load/battery capacity indicator Show the capacity of load/battery:
3# Green Load/battery capacity indicator 1.Indicate the percentage of the load
4# Green Load/battery capacity indicator capacity in Line mode and bypass
5# Green Load/battery capacity indicator mode
2. Indicate the battery capacity level in
6# Green Load/battery capacity indicator battery mode.
When the indicator on, it shows that
7# Orange Bypass indicator the loading current is supplied from the
utility power directly
When the indicator on, it shows that
8# Green Utility power indicator
the utility power is normal.
When the indicator on, it shows that
9# Green Inverter indicator the load current is supplied from utility
power or battery via the inverter.
When the indicator on, it shows that
10# Orange Battery indicator the load current is supplied from
battery via the inverter.

3.2 Audible alarm and LED indication of UPS operating ZS110-atus and

faults

LED indicators
Operating ZS110-atus 1 2 3 4 5 6 7 8 9 Audible alarm
No 10#
# # # # # # # # #
1 0%--25%Load ● ● ● none

2 26%--50% Load ● ● ● ● none

Normal
mode
3 51%--75% Load ● ● ● ● ● none

4 76%--100% Load ● ● ● ● ● ● none

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Beep once every
5 101%--105% Load ● ● ● ● ● ● ●
sec
0~25% Beep once every
6 ● ● ●
battery capacity sec
26~50% Beep once every
7 ● ● ● ●
battery capacity 4 sec.
Battery 51~75% Beep once every
8 ● ● ● ● ●
mode battery capacity 4 sec.
76~100% Beep once every
9 ● ● ● ● ● ●
battery capacity 4 sec.
100% Beep once every
10 ● ● ● ● ● ● ●
battery capacity 4 sec.
Beep once every
11 Bypass mode ↑ ↑ ↑ ↑ ● ● ↑
2min.
Overloaded in bypass mode, Beep twice
12 ● ● ● ● ● ● ↑
pre-alarm every sec
13 Utility power abnormal ↑ ↑ ↑ ↑ ● ↑ ★ ↑ ↑ ↑
Overload in Battery mode, Beep once every
14 ● ● ● ●
pre-alarm sec
Overloaded in Normal mode, Beep once every
15 ● ● ● ●
pre-alarm sec
SuZS110-ained
16 Overheating fault ● ● ↑ ↑
beep
SuZS110-ained
17 Inverter fault ● ● ↑ ↑
beep
SuZS110-ained
18 Bus voltage fault ● ● ↑ ↑
beep
↑ ↑ SuZS110-ained
19 Over voltage of charger output ● ●
beep
SuZS110-ained
20 Output short circuited ● ● ● ↑
beep
SuZS110-ained
21 Overload fault ● ● ● ↑
beep
22 Battery voltage abnormal ↑ ↑ ↑ ↑ ↑ ● ↑ ★ ↑

Reversed polarity (L, N) of

Beep once every
23 input wiring or disconnected ↑ ↑ ↑ ↑ ● ↑ ★ ↑ ↑
2 min.
with ground.

Beep once every

24 Charger or battery fault ● ★
sec
25 Fan failure ● ● ● ↑ ↑ ↑ ↑ Beep every sec

LED indictor description: ●：O n ★：Flash ↑：Depending on other conditions

3.3 Troubleshooting

3.3.1 Overheating fault

ZS110-atus: #1, #6 LED lighted, the buzzer beeps continuously

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Cause Judge Action

The temperature of the heat
sinks in the PSDR is high
NTC is not correctly
connected to CN2 in the
PSDR
CNTL detecting circuit is
out of work
the environment temperature is Replace the fan if it’s fault.
higher than 40 ℃ and the load is Reduce some load to cool
more than 80% or the fan is out of down the heat sinks.
work
It gives this fault information after Check the NTC is well
the UPS works for a few minutes connected to the CN06 in
even it has no load. PSDR and the cracks in the
bottom is good.
t gives this fault information after the Check the values of
UPS works for a few minutes even it R131(2.49K) and R220(1K)
has no load. and D35

3.3.2 Inverter fault

ZS110-atus: #1, #5 LED lighted, the buzzer beeps continuously.

Cause: It means the inverter is out of work. Usually the INV IBGT failed or the IBGT driver
board is out of work. Situation caused by CNTL failure is very rare.
Cause Judge Action
INV IGBT fails Check the CE resiZS110-ances of Replace the IGBT
Q201(Q202)/Q203(Q204) are close or
larger than 60K, GE resiZS110-ance is
47K(ZS110-6K)OR23K(ZS110-10K) ;
usually the resiZS110-ances are bigger
than 1M ohm.
INV IGBT drive ZS110-10K(S):R119R112R113R120(10o Replace these
resiZS110-ances fails hm),R117R118R110 R111(3.3ohm) resiZS110-ances
ZS110-6K(S):R119 R112(10ohm)
If the resiZS110-ance fails, the value is
bigger than 1K

The IGBT drive module (IGBTDRV) fails. (PCB1,PCB2,PCB3,PCB4):

Cause Judge Action
No drive power Power on the UPS. TeZS110- the voltage Check the diodes of
of C01, C02 of IGBTDRV. D01/D02
V C01: 15V～18V
V C02: -5V～ -12V
Output transiZS110-ors Q01(PNP) Veb, Vcb 0.7V, less than 0.1V Replace these
fails transiZS110-or short circuited. transiZS110-ors
Q02(NPN) Vbe, Vbc 0.7V less than 0.1V
transiZS110-or short circuited.

If all these are checked and the UPS ZS110-ill gives inverter fault, replace the control board. This
situation is very rare. The DSP send the Inverter control signals through U02 (UL2003). If the
control board fails, replace this IC.

3.3.3 Bus voltage fault

ZS110-atus: #1, #4 LED lighted, the buzzer beeps continuously.

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Cause: Normally the Bus voltage is positive/negative 360V. If the bus voltage is higher than 420V
or lower than 280V for a certain time, the UPS will give bus voltage fault.

Cause Judge Action

Inductive Load Make sure the load is RCD/R load.
Inductive load shall charge the bus
through inverter and this is not
controllable.
PFC part fails(check check line input SCR Q301,Q302;BAT
this if it gives bus fault MODE SCR Q305; PFC IGBT
when the mains input Q316-Q318,Q311-Q315
presents) (ResiZS110-ances GE is 23.5K OR
15.6K;
ResiZS110-ances GC/CE > 60K), PFC
diode D31/D30.
Drive resiZS110-ances
R169/R175/R178/R172/R180/R185
(10ohm)
IGBT drive module(PCB3,PCB4)
If it’s inductive load, reduce
the load to make sure that
load power less than half
UPS rated power
Check these components and
replace them if they are out
of work. The way of
checking the IGBTDRV is
the same as mentioned in the
inverter fault.

If all these are checked and the UPS ZS110-ill gives inverter fault, replace the control board. This
situation is very rare.

3.3.4 over charge fault

ZS110-atus: #1, #3 LED lighted, the buzzer beeps continuously.

Cause: The output voltage of the charger is higher than rated value. The UPS shall give over
charge fault to protect the battery.

Model Rated charge voltage Action

ZS110-6 219±2.5V Check photo-coupler U3, TL431 Q08, feed back
-10K(S) resiZS110-ances R29(9.53K),R30-R32 (220K)

3.3.5 over load fault

ZS110-atus: #1, #2 LED lighted, the buzzer beeps continuously.

Cause: When the load capacity exceeds the rated one, the UPS shall give this fault and shutdown
the inverter to protect internal overheating.
Action: To reduce some non-critical load.

3.3.6 Fan fault

ZS110-atus: #1, #2, #6 LED lighted, the buzzer beeps continuously.

Cause: When the fan is out of work or the fan detecting circuit fails, the UPS shall give this fault
to protect internal overheating.
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Action: To reduce some non-critical load.
Cause Judge Action
Fan ZS110-opped - Change the fan with the
rotating same model and brand.
Fan detecting circuit ZS110-6-10K:Check the SPS Q3(2222A) 1、 Replace these
fails ZS110-6K:Check the SPS,there is a short transiZS110-ors
pin put on the CN1(pin2,pin3) 2、 Short the CN1(pin2
pin3).

3.3.7 Short-circuited fault

ZS110-atus: #1, #2, #5LED lighted, the buzzer beeps continuously.

Cause: Output short-circuited.
Action: Check the load.

3.3.8 Charger fail fault

ZS110-atus: #1 LED lighted, #10 LED flashes, the buzzer beeps continuously.
Cause: When the charger is out of work, the UPS will give this fault to protect the battery.

ZS110-andard UPS with battery inside:

Model check Action
ZS110-6-1 Driver ResiZS110-ances R04(10ohm),The Diode Change these components
0K D06,D01,RY1, MOS Q04

3.3.9 Site fault

ZS110-atus: #8 LED flashes.

Cause: L/N is reversely connected or the protective earth is not well connected or the NE voltage
is too high.
Action: Connected the protective earth, check the L/N.

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4 Troubleshooting of LCD Version

In fact, the repairing of LCD version UPS is the same as LED version. The LCD displays the fault
and alarm information code. You can check the code by pressing the function key to check them.
The meaning of the code is liZS110-ed below.
F: It means fault, usually in this situation the inverter is out of work.
A: It means alarm. Usually in this situation the UPS ZS110-ill works, it juZS110- remind user the
UPS is not in normal ZS110-atus.

Faults
Fault/Warning Fault/Alarm type
code Fault icon Alarm
on
Bus soft ZS110-art fails(the repairing
conZS110-ant Beep
way is the same as bus fault)
F01 ly continuously
on
Bus over voltage fault(the repairing
conZS110-ant Beep
way is the same as bus fault)
F02 ly continuously
on
Bus low voltage fault(the repairing
conZS110-ant Beep
way is the same as bus fault)
F03 ly continuously
on
conZS110-ant Beep
F05 ly continuously Bus short-circuited
on
conZS110-ant Beep Inv soft ZS110-art fails(the repairing
F06 ly continuously way is the same as inverter fault)
on
Inv voltage low fault(the repairing way
conZS110-ant Beep is the same as inverter fault)
F07 ly continuously
on
Inv voltage high fault(the repairing
conZS110-ant Beep way is the same as inverter fault)
F08 ly continuously
on
conZS110-ant Beep Inv short
F10 ly continuously
on
conZS110-ant Beep
F17 ly continuously Inv negative power fault
on
conZS110-ant Beep
F21 ly continuously React power fault.
on
conZS110-ant Beep
F22 ly continuously over load fault
on
conZS110-ant Beep
F23 ly continuously over Temperature
on
conZS110-ant Beep
F24 ly continuously Inv Relay open Fault
on
conZS110-ant Beep
F25 ly continuously Inv Relay ZS110-ick Fault
on
conZS110-ant Beep
F26 ly continuously Line SCR fault
on
conZS110-ant Beep
F29 ly continuously Rectifier fault

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on
conZS110-ant Beep
F32 ly continuously Communicate wire disconnect
on
conZS110-ant Beep
F34 ly continuously CAN connect fault
on
conZS110-ant Beep
F35 ly continuously Synchronous communicate fault
on
conZS110-ant Beep
F36 ly continuously Power fault
on
conZS110-ant Beep
F42 ly continuously Line fuse open fault
on
conZS110-ant Beep
F57 ly continuously Battery fault

Blink once
A04 every second No beep Line fail
Blink once
A05 every second No beep ground line unconnected
Blink once Beep once every
A07 every second two minutes reversed polarity (L,N) of site wiring
Blink once
A08 every second No beep By pass fail
Blink once Beep once every
A10 every second second Batteries unconnected
Blink once Beep once every
A11 every second second Battery voltage low
Blink once Beep
A12 every second continuously Battery overcharging
Blink once Beep twice every
A14 Overload pre-warning
every second second
Blink once Beep
A15 Overload fault
every second continuously
Blink once Beep once every
A16 Fan failure
every second second
Blink once Beep
A18 every second continuously Charger fail
Blink once
A20 every second No beep ZS110-art UPS fail
Blink once
A33 every second No beep Parallel mode fault
Blink once
A34 every second No beep Eeprom fault
Blink once Beep
A35 every second continuously ID repetition
Blink once Beep
A53 every second continuously Unrecognized UPS model
Blink once Beep
A61 every second continuously Slave PSDR fault

Repair the UPS according to the Fault/Alarm type in the ways mentioned in the LED version.

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