Xtreme Power Conversion P80, Service Manual

Page 1: ...P80 Online UPS 1000VA 5000VA Models Service Manual www xpcc com 2017 Xtreme Power Conversion Corporation All rights reserved Rev 11 7 17 ...

Page 2: ...ty Instructions 6 Operation and setting 7 Switch panel 7 LCD Panel 7 UPS Setting 9 Operating Mode Description 13 Faults Reference Code 14 Warning indicator 14 Audible Alarm 15 Circuit principle 15 Functional diagram 15 Subsystem instruction 15 Charger Sub System 16 Auxiliary Power Supply Sub System 16 InverterSub System 17 OutputandfilterSub System 17 DC DC Converter Sub System 18 Control board 18...

Page 3: ...n G90 Service Manual Page 3 Uninterruptible Power Supply Protection sub system 18 Signaling Sub System 18 Trouble Shooting 20 Trouble Shooting Chart 20 FailureDiagnosis 21 Step to open the case 21 Critical component list 22 Overview 24 ...

Page 4: ...ceptacles connect to mission critical loads 3 AC input 4 Input circuit breaker 5 Network Fax Modem surge protection 6 Emergency power off function connector EPO 7 USB communication port 8 RS 232 communication port 9 SNMP intelligent slot 10 External battery connector only available for L model 800 1 1K 1 5K IEC Type 2K IEC Type 3K IEC Type 800 1 1 1 5K NEMA Type 2K NEMA Type 2 5K 3K NEMA Type 5K ...

Page 5: ...t on battery Battery deep discharge protection minimum battery level linked with customer load level Battery test at each start up and then once every week Additional features Nominalvoltage outputvoltagecanbesetthroughtheUPSLCDpanel 208 220 230 240V 110 115 120 127V Emergency Power Off EPO EPO connector at rear panel allow to turn off the output voltage Green function when autonomy the UPS will s...

Page 6: ...ting This part describes the possible failure conditions and procedures to repair it Before starting to serve this UPS be sure to read this manual carefully for a correct and safe operation Important Safety Instructions 1 For qualified service personnel only 2 DO NOT perform any internal service or adjustment of this product unless another person is capable of render ing first aid and resuscitatio...

Page 7: ... this button at least 2 seconds to turn off the UPS Confirm selection key Press this button to confirm selection in UPS setting mode SELECT Button Switch LCD message Press this button to change the LCD message for input voltage input frequency battery voltage output voltage and output frequency Setting mode Press and hold this button for 3 seconds to enter UPS setting mode when UPS is off Down key...

Page 8: ...input voltage output input frequency or battery voltage V volt age Hz frequency Load information Indicates the load level by 0 24 25 49 50 74 and 75 100 Indicates overload Indicates the load or the UPS output is short circuited UPS status Indicates that programmable management outlets are working Indicates that the UPS alarm is disabled Indicates the UPS powers the output directly from the mains I...

Page 9: ...scape ON ON OK OK EP EPO AO Active open AC Active close TP Temperature CH Charger RAC Rack display TOE Tower display SF Site Fault EE EEPROM error BR Battery Replacement UPS Setting Parameters 1 Parameters 2 There are two parameters to set up the UPS Parameter 1 It s for program alternatives Refer to below table for details Parameter 2 It s setting options or values for each program ...

Page 10: ...age is 240Vac For 110 115 120 127 VAC models you may choose the following output voltage 110 presents output voltage is 110Vac 115 presents output voltage is 115Vac 120 presents output voltage is 120Vac Default 127 presents output voltage is 127Vac Programmable outlets enable disable Interface Setting ENA Programmable outlets enable Default DIS Pro grammable outlets disable Programmable outlets se...

Page 11: ...for super charger LCD display direction setting Interface Setting RAC the LCD display is horizontal TOE the LCD display is vertical Autonomy limitation setting Interface Setting Parameter 2 Set up backup time on battery mode for general outlets 0 999 setting the backup time in minutes from 0 999 for general outlets on battery mode DIS Disable the autonomy limitation and the backup time will depend...

Page 12: ...apacity from 7 999 in AH Please set the correct battery total capacity if ex ternal battery bank is connected EPO logic setting Interface Setting Set up the EPO function control logic AO Active Open Default When AO is selected as EPO logic it will activate EPO function with Pin 1 and Pin 2 in open status AC Active Close When AC is selected as EPO logic it will activate EPO function with Pin 1 and ...

Page 13: ...op working for energy saving Buck mode when AC is normal When the input voltage is higher than the voltage regulation range but lower than high loss point the buck AVR will be activated Boost mode when AC is normal When the input voltage is lower than the voltage regulation range but higher than low loss point the boost AVR will be activated Battery mode When the input voltage is beyond the accept...

Page 14: ...erter voltage Low 13 x Charger failure 45 x Warning indicator Warning Icon flashing Alarm Low Battery Sounding every 2 seconds Overload Sounding every second Battery is not connected Sounding every 2 seconds Over Charge Sounding every 2 seconds Site wiring fault Sounding every 2 seconds EPO enable Sounding every 2 seconds Over temperature Sounding every 2 seconds Charger failure Sounding every 2 s...

Page 15: ...MI EFI Output Filter OP CT INV CT L N G L N G L Subsystem instruction This Otima series UPS system contains two major PCB assemblies They are including 1 Power board Contains major parts of 1 Charger 2 Auxiliary power supply 3 DC DC converter 4 Inverter 5 Output filter 2 Control board Contains major parts of protection signaling circuits regulation and control circuits of inverter The functional d...

Page 16: ...so limits the current flowing into batteries and therefore protects and prolongs the life time of charged batteries Note For detail circuit diagram and key waveforms and values see Annexures circuit diagram Auxiliary Power Supply Sub System The input of the auxiliary power supply is connected to the battery bus i e the output of the charger The output of auxiliary power supplies provides 12 Vdc fo...

Page 17: ...from PWM generation circuit through a pair of photo couplers to trigger the upper IGBT and the lower IGBT alternately The output of IGBT s is filtered by an LC circuit to reduce the o p voltage harmonics distortion Note For detail circuit diagram and key waveforms and values see Annexures circuit diagram Output and filter Sub System The bypass relay receives signal from control circuit to switch t...

Page 18: ...f three major circuits as following REGULATION CONTROL SUB SYSTEM This portion can be seen as brain of the UPS It provides the control pulses to the switching elements which deliver power to the output The sub system also regulates the output to ensure that the UPS is delivering constant AC voltage to the loads The inverter signal is sensed directly by resistor division It is compared with a refer...

Page 19: ...elves from thermal runaway The output relay stays at inverter output position unless a continuous over load is detected or an abnormal inverter operation occurs Battery over or under shut down Upon the battery voltage declines to battery under over level the UPS will warning and the LCD will display the fault code then shut down In case of the battery voltage is high voltage the UPS will warning a...

Page 20: ...ower Supply Trouble Shooting Due to careful design and strict tests of our products fail of UPS seldom occurs However once they do fail in some situations please check them according to Trouble Shooting Chart that will help you solve the most prob lems on UPS Trouble Shooting Chart ...

Page 21: ...Xtreme Power Conversion Corporation G90 Service Manual Page 21 Uninterruptible Power Supply Failure Diagnosis Steps to open the case ...

Page 22: ...eme Power Conversion Corporation G90 Service Manual Page 22 Uninterruptible Power Supply Critical component list We must use multi meter to check the value the following is PCB block diagram 1K PCB 2K PCB ...

Page 23: ...Xtreme Power Conversion Corporation G90 Service Manual Page 23 Uninterruptible Power Supply 3K PCB 5K PCB Standard CHG DC DC Converter DC AC Inverter SPS Standard CHG DC DC Converter DC AC Inverter SPS ...

Page 24: ... G D S short or open DC DC CONVERTER Step Checked components Instrument function Reference Value Failed condition 1 MOSFET Q2 Q3 Q4 Q6 Q15 Q18 S D D S G S G D Diode Diode 0 46 0 6 Short Short or 0 6 2 Fuse F9 F15 Resistance 0 ohm Open 3 Diode D27 D31 D44 D45 Diode 0 42 Short or open 4 Resistor R56 R32 R64 R66 R31 R54 Resistance 22 ohm 25 ohm or Open DC AC INVERTER Step Checked components Instrumen...

Page 25: ...14 1252 PIN 5 6 5 7 5 8 6 8 Ω 38k 4K 412k 415K too low After you have replaced all defect components on power stage PSDR connect with control board Supply appro priate DC voltage 3Amp limited current with DC power via BAT and BAT then turn on the switch on panel you will see current limit on the DC power supply for about 2 seconds If not there are some defective components you have not found When ...

Page 26: ...232 transmitter to computer output 5 GND Note that the computer will control information exchange by a query followed by cr Character Return UPS will respond with information followed by a cr or action All the information is provided in ASCII format 2 USB PORT The USB is compatible to USB2 0 specification and implemented for customized HID and self powered device The customized HID bi directionall...