Xtreme Power Conversion M90, Service Manual

Page 1: ...M90 M90L Modular Online Three Phase UPS 20kVA 40kVA 60kVA Models Service Manual www xpcc com 2017 Xtreme Power Conversion Corporation All rights reserved ...

Page 2: ...ipal of the Major Functional Block 8 Switch Power Supply 9 PFC Booster 9 Inverter 9 Charger 10 EMI Board 10 Function Explanations for Each PCBA 11 PFC Board Power Factor Correct Board 11 INV Board Inverter Board 11 CNTL Board Control Board 11 COMMBoard CommunicationBoard 11 IPOP Board 11 Pre charger board 11 Parallel board 11 Panel Main LED key board 11 EMI board 12 SPS board 12 STS main board 12 ...

Page 3: ...Converter Mode 16 ECO Mode 17 Shutdown Mode 17 Trouble Shooting 17 LCD Panel Display Pattern Definition 1 Trouble shooting for warning icon in LCD display 17T rouble shooting for fault codes in LCD display 18 Repair 21 Basic Instruments and tools 21 Quick Start 21 Power Module 21 STSModule 22 Major parameters of IPOP Board section 22 Major parameters of PFC Board section 23 ...

Page 4: ... this section explains you all the PCBs of the UPS system Interface this section shows you the LCD interface including display and setting Trouble Shooting this section gives you the way to find the problems Test Step this section tells you how to test the UPS after you repair the unit Appendix this section shows you the basic waveforms for reference and the basic communication commands Important ...

Page 5: ...0 load THD i 100 load 3 Mains Input Bypass Input Topology Three Phase Neutral Ground Nominal Voltage 208V 220V Voltage Range Upper limit 10 15 default 15 Lower limit 10 20 default 20 Nominal Frequency 50Hz 60Hz Frequency Range 1Hz 2Hz 4Hz default 4Hz Transfer Time between Bypass and Inverter Synchronous transfer 1ms Asynchronous transfer 1 cycle Model M90 Output Output Topology Three Phase Neutral...

Page 6: ... Maximum charging current 8A At low input voltage the UPS recharge capability increases with load decrease Environmental Parameters Model M90 Operating Temperature Range 0 C 40 C Output Capacity will be de rated when temperature is over 30 C 35 C de rated to 90 40 C de rated to 80 Storage Temperature 15 C 60 C UPS 0 35 C Battery Relative Humidity 0 95 No condensing Altitude 1000m for Nominal power...

Page 7: ... indicating the status of the UPS The CONTROL block in the STS controls the action of Bypass SCR It works with COMM board and LCD panel to be user interface as well The COMM block provides the communication interface for receiving and executing command from users The IPOP and PFC blocks are the input stage of the UPS The blocks convert AC input power into two stable DC power stored in the BUS capa...

Page 8: ... interruption on output power The charger charges the battery when the utility is normal The charger converts AC input power to DC power for recharging the battery The Input and Output EMI section provides EMI filter function The input and output EMI filters can prevent the UPS from being interference by external electronic magnetic noise which is generated by other electronic system and prevent o...

Page 9: ...such as HCT The 12V Fan is supplied to fans and relays The HFPW supplies a high frequency power for the switch SCR IGBT driver and some other drive boards PFC Booster PFC Booster As shown in the Figure4 2 when Q3 Q4is on and D1 D2 is off the current will increase to store energy in choke L1 L2 When the Q3 Q4 is off and D1 D2 is on the choke will release energy Therefore we can control the current ...

Page 10: ...oint Then the charge current will decrease accordingly now it s in second stage After constant voltage charging the charge voltage will change to floating charge voltage in general the charger will control the output voltage at a constant level to optimize battery recharge time and prolong the life time of batteries without overcharging Topology of the charger EMIBoard Input EMI board is connected...

Page 11: ...he higher DC power INV board Inverter Board The INV Board includes STS and Inverter It supplies the power for the system and it converts the DC power to a pure sine waveform in the purpose of less or no transfer time there is one STS CNTL board Control Board The CNTL board is the core of the UPS system It controls the actions of the semiconductors and other mechani cal switches COMM board Communic...

Page 12: ...y It used to provide power to all function board STS main board The STS main board is control the bypass SCR and FAN control and communication Interface board The interface board is Dry Contact board Dry contact refers to a contact of a relay which does not make or break a current Usually some other relay or device has the job of starting or stopping the current Function Flow Chart This chapter de...

Page 13: ...n M90 M90L Service Manual Page 13 Uninterruptible Power Supply Standby Mode UPS Mode Description Power On Mode A Off B Off C Off D Off E Off F Off G Off Bypass Mode UPS Mode Description Bypass Mode A On B On C On D On E Off F Off G Off ...

Page 14: ...ration M90 M90L Service Manual Page 14 Uninterruptible Power Supply Line Mode UPS Mode Description Line Mode A Off B Off C On D On E On F Off G On Battery Mode UPS Mode Description Line Mode A Off B Off C Off D Off E Off F On G On ...

Page 15: ...l Page 15 Uninterruptible Power Supply Battery Test Mode UPS Mode Description Battery Test Mode A Off B Off C Off D Off E Off F On G On Fault Mode UPS Mode Description Fault Mode A On B On C Off D Off E Off F Off G Off A Off B Off C Off D Off E Off F Off G Off ...

Page 16: ...ation M90 M90L Service Manual Page 16 Uninterruptible Power Supply Converter Mode UPS Mode Description Converter Mode A Off B Off C On D On E On F Off G On ECO Mode UPS Mode Description ECO Mode A On B On C On D On E On F Off G Off ...

Page 17: ... warning or fault code via theRS232 if possible otherwise listen to the description of end users 2 Inspect failure board for static checking 3 Replace failure components 4 Static checking 5 Power on checking 6 Test after repair Following section will help service person to solve the most problems LCD Panel Display Pattern Definition Trouble shooting for warning icon in LCD display Any warning disp...

Page 18: ... specified duration Shutdown and remove this power module Check pre charge of PFC PCBA Fault Inverter Soft Start Time Out Inverter bus voltage cannot reach desired voltage within specified duration Shutdown and remove this power module Check IPOP and Inverter PCBA Fault Inverter Voltage High Inverter Voltage is too high Shutdown and remove this power module Check IPOP and Inverter PCBA Fault Inver...

Page 19: ... the fan is working Shutdown and remove this power module Check IPOP and Inverter and PFC PCBA Fault Can Fault CAN communication fault Shutdown and remove this power module Check IPOP and Control PCBA Fault TRIG0 Fault Trigger signal fault Shutdown and remove this power module Check IPOP and Control PCBA Fault Relay Fault Inverter relay fault Shutdown and remove this power module Check IPOP and Co...

Page 20: ...BA Warning Eeprom Fail Eeprom operation error Shutdown and remove this power module Change Control PCBA Warning Fan Lock As stated Check FANs of power module or STS module Warning Line Phase Error As stated Check input Phase and sequence Warning Bypass Phase Error As stated Check input Phase and sequence of STS Warning N Loss Neutral loss Check N phase Warning Internal Initial Fail As stated Shutd...

Page 21: ... tubes and clamp termi nals with different specifications QuickStart Before any detail check for UPS please check the components listed in the following table This action could help you find problem quickly and make debug procedures go smoothly Note Make sure that the capacitor voltage is lower than the safety voltage before disassembling any parts to do checking procedure Power module IPOP Board ...

Page 22: ...Board Component Type Checked components Failure condition MOSFET Q1 Q2 Q3 Q5 Q6 Q7 Q8 D S shortor open FUSE F10 F11 F12 F13 F16 F17 F14 F15 OPEN Diode D35 D34 D17 D28 D29 D31 D47 D4 8 D46 D39 D40 D38 D62 Short or open Communication Board Component Type Checked components Failure condition MOSFET Q2 D S short or open Diode D12 D4 D2 D11 Short or open Major parameters of IPOP Board section The most ...

Page 23: ...D22 D21 Diode Voltage Droop 0 24V Short or open F10 F11 F12 F13 F15 F14 F22 F23 F24 F19 F20 F21 F16 F17 F18 Diode Voltage Droop 0V open Note If MOSFET SCR is OK but the parameter is not close to the reference value it is very possible that the cor responding driver is damaged so please try to change the IGBT driver component Major parameters of PFC Board section The most likely problems occur on P...

Page 24: ... R12 R11 R16 R22 R26 R32 R36 R 45 R44 R49 R58 R57 R62 R68 R72 R7 8 R82 R91 R90 R97 R107 R106 R114 R120 R124 R130 R134 R143 R142 Resistance 15Ω 1 Value change R4 R13 R8 R17 R23 R27 R33 R37 R46 R42 R50 R59 R54 R63 R69 R73 R79 R83 R92 R88 R98 R108 R103 R115 R121 R125 R131 R135 R144 R140 Resistance 3Ω 1 Value change R10 R9 R7 R18 R21 R31 R28 R43 R38 R41 R56 R55 R53 R67 R64 R77 R74 R89 R84 R87 R104 R10...

Page 25: ...ange R77 R76 R73 R72 R75 R70 R69 R92 R93 R91 R97 Resistance 1MΩ 1 Value Change R79 R78 R71 Resistance 49 9kΩ 1 Value change R84 R96 R83 R82 R85 Resistance 20kΩ 1 Value change R86 Resistance 15kΩ 1 Value change R88 R89 Resistance 1 5MΩ 1 Value change Q5 Q6 D S Diode Voltage Droop 0 25V Short or open G S Resistance 50kΩ Short or open D2 D3 D7 D4 D9 D11 D5 D6 Diode Voltage Droop 0 3 0 7V Short or ope...