Xtreme Power Conversion M90S 12kVA, Service Manual

Page 1: ...M90S Online Single Phase UPS 6kVA 12kVA 18kVA 24kVA Models Service Manual www xpcc com 2019 Xtreme Power Conversion Corporation All rights reserved ...

Page 2: ...al 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 In...

Page 3: ...nverter 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: ...he UPS Interface this section show you the LCD interface include display and setting Trouble shooting this section will give you the way to find the trouble Test step this section tell you how to test the UPS after you repair the unit Electric Specifications this section show you the basic electric specification of the UPS Important Safety Instructions For qualified service person only Do NOT perf...

Page 5: ...L N Voltage Regulation 1 balance load 2 unbalance load Output Frequency Follows Bypass Frequency if the bypass is ok except the convert mode 50 60 0 1 Hz if bypass is not ok or in convert mode Voltage Distortion 4 for nonlinear load 2 Full Linear Load Current Crest Ratio 3 1max Transfer Time 0ms Line Battery 0ms Inverter Bypass 10ms Inverter ECO Short Circuit Protection Yes Battery Nominal Battery...

Page 6: ...ut after 200ms Battery mode Auto Retransfer Yes Interface USB 1 1 Yes Intelligent Slot SNMP card Optional RS485 card To be considered AS400 card Optional Dry Contact 5 channel Dry Contact Card Optional EPO Yes Environment Operating Temperature 0 to 40 C Humidity 95 No condensing Acoustic Noise 58dB Standard ESD IEC 61000 4 2 Level 4 RS IEC 61000 4 3 Level 3 EFT IEC 61000 4 4 Level 4 Surge IEC 6100...

Page 7: ...he BUS capacitor also The Inverter block is the output stage of the UPS used to convert the DC power from the BUS capacitor into sine waveform output power When the utility is within the tolerance range the UPS uses the utility input at this time the Rectifier and PFC work In case the utility is outside the tolerance range due to either the voltage or the frequency the UPS will stop the Rectifier ...

Page 8: ... of the dots on the transformer primary and secondary these dots show starts of the windings When Q6 is ON the dot ends of all windings are positive with respect to their no dot ends Output rectifier diodes D6 D7 D8 and D21 are reverse biased and all the output load currents are supplied from storage filter capacitors C12 C13 The primary coil of the transformer acts as an inductor and stored energ...

Page 9: ... Q2 are off the choke releases energy and the D1 D2 are on the current of the choke will decrease as time passes Therefore we can control the current waveform of chocks intput current by regulating the duration of Q1 Q2 on and off 4 3 Inverter circuit Figure 4 3 T three level topology The topology works as the following Q1 Q4 and Q2 Q3 are switched on at alternate half cycles The junction voltage ...

Page 10: ...reasing the charge current decreases accordingly until the charge voltage reached the constant voltage level and then the charger turns to the floating charge mode The charger employed a double forward topology Figure 4 4 charger circuit topology 4 5 EMI Board Input EMI board is connected between utility and the input of rectifier Output EMI board is connected between the output of inverter and ou...

Page 11: ...XXG 1 6 BUS 71 302936 XXG 1 7 IPOP 71 302901 XXG 1 8 EPO COMM 71 302264 XXG 1 9 SYS LCD PANEL 12 400134 XXG 71 303040 XXG 1 LCD 12 400134 XXG com bine with PCBA 71 3 03040 XXG 10 PFC SCR DRIVE 71 302256 XXG 2 11 INV SCR DRIVE 71 300785 XXG 6 12 INV DRIVER 71 302905 XXG 2 13 Switch 71 302258 XXG 1 Note XXG in the serial number is the version of the PCB It may be modified according to releasing vers...

Page 12: ...e the Rectifier and PFC will work It changes the AC power to DC power stored in the BUS capacitor When UPS works in Battery mode the PFC will boost the battery voltage to higher DC BUS voltage Figure 5 1 2 M90S PCF board 5 2 INV board Inverter Board The INV Board includes STS and Inverter It converts the DC power to a pure sine waveform in the purpose of less or no transfer time Figure 5 2 3 M90S ...

Page 13: ...ing battery test and the charge current can be set from 1A 4A via LCD or communication port Figure 5 3 1 M90S 1 1 3 1 3 3 10K Charge Board Figure 5 3 2 M90S Charge Board 5 4 CNTL board Control board CNTL board controls the action of the semiconductors and other mechanical switches the display of the LED LCD the sound of the buzzer the communication with the computer and other important items Figur...

Page 14: ...S board The BUS board work as stable DC power storing energy from PFC and passing it to inverter and charger Figure 5 5 Bus board 5 6 SPS board Switch power supply The SPS board supplies DC power for the UPS system The input voltage of t he SPS is the battery or AC input voltage Figure 5 6 SPS board ...

Page 15: ... generated by other electronic systems and also protect other systems from the noise generated inside the UPS system Figure 5 7 1 M90S IPOP EMI Board 5 8 EPO and Communication board Communication board includes EPO and COMM board The Communication board provides USB interface to the user and it also provides one EPO port to cut off the output immediately Figure 5 8 Communication board ...

Page 16: ...sion Corporation M90S Service Manual Page 16 Uninterruptible Power Supply 5 9 SYS LCD Panel board LCD combine with PCBA the Panel board provide the LED and LCD display to the user Figure 5 9 1 Panel PCBA Figure 5 9 2 LCD ...

Page 17: ...Xtreme Power Conversion Corporation M90S Service Manual Page 17 Uninterruptible Power Supply 5 10 SWITCH board The AC input disconnect used for DC start Figure 5 10 Switch board 6 Interface ...

Page 18: ...ous page in the screen Or press this button to increase the number in the setting DOWN Press this button to select the next item in the menu Press this button to enter menu selection Or press this button to jump to next page in the screen Or press this button to decrease the number in the setting UP DOWN To allow LCD display to rotate 90 automatically press these two buttons at the same time This ...

Page 19: ...terruptible Power Supply 6 3 LCD Display 6 3 1 LCD Structure Figure 6 1 below illustrates LCD menu structure Figure 6 1 LCD Menu Structure 6 3 2 Main interface Home Page After initialization the main screen will display as Figure 2 Main screen is divided into four parts ...

Page 20: ...s the number 3 UPS Measurement Data 4 When alarms happen the warning or fault information will display When UPS in Battery mode or Battery Test mode the backup time will display 5 When the front panel is not operated for 2 minutes the display page will return back to home page 6 Press the UP or DOWN button to enter menu 7 When it displays home page in LCD if UPS is in bypass or standby you could p...

Page 21: ...obably happened 7 2 Fault mode 1 When Fault LED illuminates and the buzzer beeps continuously it means that there is a fatal error about UPS Users can get the fault code from LCD panel Please refer to the trouble shooting table to check what problems probably happen 2 Don t try to turn on the UPS again before the problem is clear If the problems can t be fixed please contact the distributor or ser...

Page 22: ...it are well Fault 05 Bus Volt Vary DC bus voltage changes too fast Mainly check that the IGBT and SCR etc power components for the PFC and the utility power SCR are well Meanwhile check that the components on the drive circuit are well Fault 06 PFC Over Curr PFC current is higher than the maximum current Mainly check that the IGBT and SCR etc power components for the PFC and the utility power SCR ...

Page 23: ...e components on the drive circuit are well Fault 1A Nega Power R R phase inverter output negative power is beyond the range Check the AC output Voltage If the actual output voltage and the default voltage difference is bigger Fault 1B Nega Power S S phase inverter Output Negative Power is beyond the range Check the AC output Voltage If the actual output voltage and the default voltage difference i...

Page 24: ... well con nected 3 Check the setting of Nominal Battery voltage 4 Contact service personnel if necessary Warning 03 Bat PhaseLoss The voltage between positive and negative battery is different Check the battery connection Warning 04 Lin eIpNLoss Neutral loss Check if the Neutral connection is well and contact service personnel Warning 05 LinePhas eError As stated Check if the Mains phase sequence ...

Page 25: ...supply UPS will transfer to bypass mode from line mode Reduce some load and check output Load Capacity in specification Warning 17 EpoActive Check the EPO connector Check if the connector is loose when EPO acts abnormally Warning 18 Main tainOpen The UPS is in maintenance mode Check if the 2 pin plate is not connected to EMBS connector on the back panel of communi cation module when it acts abnorm...

Page 26: ...hooting In this section some debug skills are listed to help you finding the failure components and problems as soon as possible Before taking the following steps we suggest that you should read problem shooting chart in previous section then check the boards listed in section 5 to find out which board is failure Basic Instruments and tools 1 One computer with RS232 port and one standard RS232 cab...

Page 27: ...e step 6 INV output voltage setting Type VXXX command XXX is 208 220 230 240 then press the ENTER key INV output voltage will be set to 208V 220V 230V 240V 7 charger current setting CHGC XX command XX is from 0 to 4 then press the ENTER key Charger current will be set to 1A 4A Regulation Process for Single UPS 1 BUS voltage regulation When the UPS runs into AC mode measure BUS voltage with the mul...

Page 28: ...power source with current limitation function to the battery terminal 4 Press the Battery start button activating the SPS the LCD will be lit and the Fan will rotate If not please check the input voltage of the SPS if the voltage is the DC source output voltage please repair the SPS again 5 According to the sequence press the ON ENTER UP or DOWN ON ENTER button then UPS should be DC started If UPS...

Page 29: ...rmation of the N o LCD display OK CNTL failure and repair it Yes Press ON more than 0 5s Yes BUS voltage rise to No 360V Booster CNTL failure and repair it Yes INV voltage rise to No 220V INV CNTL failure and repair it Yes Shutdown and turn on the IP breaker without DC source and ery LCD light and fan No rotates Charger failure and repair it Yes BUS voltage rise to No 311V Rectifier CNTL failure a...