Xtreme Power Conversion P91, Service Manual

Page 1: ...P91 TX91 TX91L TXVR Service Manual www xpcc com 2019 Xtreme Power Conversion Corporation All rights reserved Rev 4 26 19 ...

Page 2: ...alBlock 8 4 1 Switch Power Supply 8 4 2 PFC Booster 9 4 3Inverter 9 4 4Charger 10 4 5EMIBoard 10 5 Function explanations for each PCB 11 5 1 SPS Charger Board 11 5 2ControlBoard 12 5 3 Communication Board 12 5 4 EMI Board 12 5 5 Main Power Board 13 5 6 Para Board 14 5 7 O P Relay Board 15 6Interface 15 6 1LEDDisplay 15 6 2LCDDisplay 16 6 3 LCD Display Icon 16 7 Troubleshooting 18 7 1 LCD Panel Dis...

Page 3: ... for each PCB 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 comman...

Page 4: ...OX Software CD horizontal brackets tower pedestals USB cable AVAILABLE OPTIONS 5 year extended warranty 4 post rail kit 2 post shelf kit transformer Depending on load level MODEL NUMBER TXVR 3 8K TXVR 5K TXVR 6K TXVR 10K CAPACITY Power rating 3 8kVA 3 8kW 5kVA 5kW 6kVA 6kW 10kVA 10kW INPUT Voltage nominal 208 220 230 240VAC Voltage range 110 300VAC Frequency 46 54Hz or 56 64Hz OUTPUT Voltage 240 1...

Page 5: ...put output Terminal blocks or optional PDU Dimensions W x D x H 9 9 x 23 3 x 32 4 in Weight 272 lbs 275 lbs 278 lbs 307 lbs OPTIONAL Battery quantity and size BP20 20 12V 9AH BP40 40 12V 9AH BP60 60 12V 9AH BATTERY PACKS Dimensions W x D x H 9 9 x 23 3 x 32 4 in Weight BP20 190lbs BP40 320 lbs BP60 450 lbs OPTIONAL PDU Input connection Terminal blocks or 6 ft L6 30P Terminal blocks 120V receptacle...

Page 6: ... 273VDC PHYSICAL Input output Terminal blocks or optional PDU Dimensions W x D x H 9 9 x 23 3 x 32 4 in Weight 152 lbs 155 lbs 158 lbs 187 lbs OPTIONAL PDU Input connection Terminal blocks or 6 ft L6 30P Terminal blocks 120V receptacle options 5 15 20R 240V receptacle options L6 30R L6 20R 6 15 20R C19 ENVIRONMENT Temperature 32 104 F 0 40 C Audible noise 50dBA Altitude 11 500 ft above sea level A...

Page 7: ...gy comprising functional blocks as shown in Figure 3 1 Figure 3 1 Function block Diagram The CNTL block controls the action of the UPS system It also provides the communication interface for receiving and executing command from users via the panel or other communication protocol When the UPS becomes abnormal in most case the CNTL can provide basic information indicating the status of the UPS ...

Page 8: ...lity the controller can detect the interruption in very short time During the short interval of detecting the interruption the output power will be provided by the power stored in the BUS capacitor In this way there is no any interruption on output power The charger charges the battery when the UPS system is working Yo u can set the current to be 1A 2A 3A 4A by LCD or command And you can choose a ...

Page 9: ...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 4 2 PFC Booster N Q1 Q2 UBUS UBUS Utility Battery L1 D2 D1 C1 C2 N L2 Q3 Q4 Q5 Figure 4 2 PFC Booster As shown in the Figure 4 2 when Q1 Q2 is on and D1 D2 is off the current will increase to store energy in choke L1 L2 When the Q1 Q2 is off and D1 D2 is on...

Page 10: ...voltage point Then the charge current will decrease accordingly now it s in second stage After one hour of 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 13 65V 1 per battery to optimize bat tery recharge time and prolong the lifetime of batteries without overcharging Figure 4 4 Topology...

Page 11: ...302114 XXG 1 For 6kVA model 10k 71 301756 XXG 1 For 10kVA model 6 Para A 71 302096 XXG 1 They are optional for parallel function Para B 71 302097 XXG 1 Para 71 303273 XXG Just for tower 7 O P Relay 71 300026 XXG 1 Note XX in the serial number is the version of the PCB It may be modified according to releasing version in the future 5 1 SPS Charger board The SPS Charger board consists of switch powe...

Page 12: ...e communication with the computer and other important tasks 5 3 Communication board The Communication board provides RS232 USB interface to the users and it also provide one EPO port to cut off the output immediately 5 4 EMI board The EMI board can prevent the UPS from external electronic magnetic noise generated by other electronic systems and also prevent other systems from the noise generated i...

Page 13: ...ble Power Supply 6k 10k 5 5 Main Power board The Main converts the AC DC power to a pure sine waveform And then it converts the DC AC power There are many semiconductors and easy failure components on the board so it s required to pay more attention when UPS is abnormal component side 10k 6k ...

Page 14: ...on P91 TX91 TX91L TXVR Service Manual Page 14 Uninterruptible Power Supply 10k 5 6 Para board The Para A board and Para B board is used for parallel communication when the UPS system is running in paral lel mode Board 1 Board 2 Board 3 ...

Page 15: ...stalled for parallel system For single system it can be removed The board can disconnect the UPS from the output parallel system 6 Interface 6 1 LED Display Table 6 1 LED Display Mode LED Bypass Line Battery Fault UPS Startup No Output mode Bypass mode AC mode Battery mode CVCF mode Battery Test ECO mode Fault Note means LED is lighting and means LED is faded ...

Page 16: ...UPS is in Bypass mode these two numbers indicating the power capacity 06 for 6K model and 10 for 10K model Fault information Indicates that the warning and fault occurs Indicates the fault codes and the codes are listed in details in section 7 1 Mute operation Indicates that the UPS alarm is disabled Output Battery voltage information Indicates the output voltage frequency or battery voltage Vac o...

Page 17: ...king Indicates the bypass circuit is working Indicates the ECO mode is enabled Indicates the Inverter circuit is working Indicates the output is working Battery information Indicates the Battery capacity by 0 25 26 50 51 75 and 76 100 Indicates the battery is fault Indicates low battery level and low battery voltage Input Battery voltage information Indicates the input voltage or frequency or batt...

Page 18: ...icating that some situation that may endanger the reliability of the UPS has occurred but these situations don t immediately lead to interruption of power supply LCD icon Flashing Alarm Possible cause Action 1 Beeping second Low battery Check the battery voltage 2 Beeping second Over load Check the loads 1 Beeping second Battery disconnected Check the battery wiring 1 Beeping second Battery Charge...

Page 19: ...BUS voltage re mains higher than 230V for more than 200ms the fault signal will be displayed Maybe the main board is dam aged Check if power components such as IGBT and SCR for the PFC and the utility power SCR are well Meanwhile check if components on the drive circuit are well 04 None BUS voltage unbal ance When the difference between the Bus voltage absolute value remains more than 40V for 2 mi...

Page 20: ...heck if the heavy load or unique load is connected to the UPS 6D None Inverter current detection error The sample average value of Inverter current output current share current is too high Check if the INV and output cur rent detecting circuit is OK 77 None Transformer over temperature Transformer is over temperature limit for 1 minute Just for cTUVus model Check if the Transformer Fan is damaged ...

Page 21: ... board Or replace the CNTL board and COMMU board or update the firmware 43 Overload The load over 100 Check the loads and remove some non critical loads Check whether some loads are failed 6A None Battery Turn on failure During on UPS by battery the bus voltage is high or having high current PFC or INV components are prob ably damaged Replace the main board 6B None PFC current failure in battery m...

Page 22: ...fferent in parallel system 33 Locked in bypass after overload 3 times in 30min 3A Cover of maintain switch is open 3D Bypass unstable 3E Boot loader is missing 42 Over temperature on transformer 45 Overload on parallel redundancy Warning Icon flashing Alarm Battery low Beeping every second Overload Beeping twice every second Battery unconnected Beeping every second Over charge Beeping every second...

Page 23: ...e taking the following steps we strongly suggest reading previous section for trouble shooting first Then check the components listed in section 7 2 4 to find out which block fails 7 2 1 Basic Instruments and tools 1 One computer with RS232 port and one standard RS232 cable 2 Wire cutters and clamps 3 One electric soldering iron 4 One multimeter 5 One oscilloscope voltage and current probe needed ...

Page 24: ...ing param eter 2 See the Figure 7 1 If you want to adjust charger current please adjust parameter 3 See Figure 7 1 Figure 7 1 Set charge current on LCD Set charge current by command You need set charger current command as follow 7 2 4 Configuration of charging voltage on the Charger Board or through command Set 5 jumpers JP01 JP02 JP03 JP04 and JP05 on the charger mode according to the following t...

Page 25: ...SP XX command XX is two digits from 00 to 99 Then press the ENTER key and BUS voltage will rise drop about X XV 4 BUS voltage regulation Type BUSN XX command XX is two digits from 00 to 99 Then press the ENTER key and BUS voltage will rise drop about X XV 5 INV output voltage regulation Type V XX command XX is two digits from 00 to 99 Then press the ENTER key and output voltage will rise drop abou...

Page 26: ...nt can be regulated about 0 1A every point by using output voltage regulation command Notes 1 Make sure the ground of the UPS connects to earth safely during parameter regulation 2 New assembly UPS must be regulated 3 UPS which have been replaced CNTL and or SPS Charger board must be regulated again 4 All the commands use capital letters 5 All the above parameter regulation cannot be accumulated 6...

Page 27: ...rger Section Circuit Block Checked components Component Type Failure condition D2 D3 D7 D8 D11 Diode Short or open Q1 Q2 MOSFET D S short or open IC1 Power IC I O short or open Others Q28 MOSFET D S short or open F1 Fuse Open REC1 Rectifier Bridge Short or open Q6 Q15 Q28 MOSFET D S short or open D8 D16 D13 D7 D17 D18 D33 Power Diode Short or open U1 U4 Power IC I O short or open U9 U10 Power Cont...

Page 28: ... rise to V Press ON button more than 0 5s INV voltage rise to V INV CNTL failure and repair it LCD light and fan rotates Shutdown and turn on the IP breaker without DC source and battery BUS voltage rise to V Rectifier CNTL failure and repair it Press ON button more than 0 5s Yes Yes Check the wiring and correct it No Yes Yes Yes Yes Yes Yes Yes No No No No No CNTL failure and repair it No No End ...

Page 29: ... Power Supply 9 Appendix 9 1 Reference Waveforms Below are some waveform charts to show normal UPS operation It s a very useful reference to verify the test result in section 8 CH1 IP SCR driver CH2 IP voltage CH3 BUS voltage CH4 BUS voltage Figure 9 1 Switch on the input breaker without turn on ...

Page 30: ...ltage CH3 BUS voltage CH4 BUS voltage CH1 INV voltage CH2 Battery voltage CH3 BUS voltage CH4 BUS voltage AC mode transfer from Bypass mode Battery mode Figure 9 2 Turn on the UPS CH1 IP voltage CH3 VGE PFC PWM CH4 VGE PFC PWM CH1 INV voltage CH2 Battery voltage CH3 VGE PFC PWM CH4 VGE PFC PWM AC mode Battery mode Figure 9 3 PFC PWM ...

Page 31: ...Figure 9 4 INV PWM 9 2 Basic communication command In this section we will show you some basic communication commands that will help you debug or regulate the UPS system 9 2 1 QGS QGS means to request general status parameters of the system The command format is Computer QGS cr UPS MMM M HH H LLL L NN N QQQ Q DDD KKK K VVV V SSS S XXX X TTT T b9b8b7b6b5b4b3b2b1b0a0a1 cr ...

Page 32: ...is an Integer ranging from 0 to 9 The units is V l SSS S P Battery voltage S is an Integer ranging from 0 to 9 The units is V m XXX X N Battery voltage X is an Integer ranging from 0 to 9 The units is V n TTT T Max Temperature of the de tecting pointers T is an integer ranging from 0 to 9 The units is C o b 9 b 8 b 7 b 6 b 5 b 4 b 3 b 2 b1b0 a0a1 Ups status B9 b8 00 standy 01 line interactive 10 o...

Page 33: ...CK inverter output voltage will then rise drop about X XV Otherwise responds NAK Voltage For example Computer V 01 Enter UPS ACK Meanings Inverter voltage will increase about 0 1Volt 9 2 4 BUSP n This command is to adjust the positive BUS voltage the format is Computer BUSP n Enter XX is two digits 00 01 99 UPS ACK or NAK If UPS accepts this command responds ACK BUS voltage will then rise drop abo...

Page 34: ...QVFW QVFM means to request the version of the firmware The command format is Computer QVFM Enter UPS VERFW NNNNN NN N is a HEX number from 0 9 or A F Example Computer QVFW Enter UPS VERFW 00123 01 Meanings 00123 is the firmware series number and 01 is the version 9 2 8 OC n This command is to regulate the UPS sampled output current value which you can ready by QGS command to match your measured va...