Xtreme Power Conversion M90 Manual de usuario
M90 & M90L Modular Online
Three-Phase UPS
20kVA, 40kVA, 60kVA Models
Service Manual
www.xpcc.com | © 2017 Xtreme Power Conversion Corporaon. All rights reserved.
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 2
Uninterrupble Power Supply
Table of Contents
General Informaon.................................................................................... 4
Geng Started................................................................................................................................4
Important Safey Instrucons.........................................................................................................4
Electronic Specicaons..............................................................................5
Environmental Parameters..............................................................................................................6
Funconal Block...........................................................................................7
Working Pricipal of the Major Funconal Block..............................................................................8
Switch Power Supply......................................................................................................................9
PFC/Booster....................................................................................................................................9
Inverter............................................................................................................................................9
Charger..........................................................................................................................................10
EMI Board......................................................................................................................................10
Funcon Explanaons for Each PCBA..........................................................11
PFC Board (Power Factor Correct Board).......................................................................................11
INV Board (Inverter Board)............................................................................................................11
CNTL Board (Control Board)..........................................................................................................11
COMM Board (Communicaon Board)...........................................................................................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
Interface board..............................................................................................................................12
Funcon Flow Chart...................................................................................12
Power on Mode.............................................................................................................................12
Standby Mode...............................................................................................................................13
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 3
Uninterrupble Power Supply
Bypass Mode.................................................................................................................................13
Line Mode.....................................................................................................................................14
Baery Mode................................................................................................................................15
Baery test Mode.........................................................................................................................15
Fault Mode....................................................................................................................................15
Converter Mode............................................................................................................................16
ECO Mode.....................................................................................................................................17
Shutdown Mode...........................................................................................................................17
Trouble Shoong........................................................................................17
LCD Panel Display Paern Denion..............................................................................................1
Trouble shoong for warning icon in LCD display.......................................................................17T
rouble shoong 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 secon......................................................................................22
Major parameters of PFC Board secon........................................................................................23
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 4
Uninterrupble Power Supply
General Informaon
Geng started
This manual is for the M90 and M90L UPS. It can help service person perform the basic maintenance and repair
service. This manual only focuses on the service secon, so you should get the basic operaon of the UPS from
the user manual, and make sure you had read and understood the user manual before reading the manual. The
manual includes 9 secons:
●General Informaon, this secon shows you the general informaon of the service manual.
●Electric Specicaons, this secon shows you the basic electric specicaon of the UPS.
●Funconal block, this secon shows you the major funconal block of the UPS.
●Working Principle of the Major Funconal Block, this secon shows you the working principle of the major func-
onal block.
●Funcon explanaons for each PCB, this secon explains you all the PCBs of the UPS system.
●Interface, this secon shows you the LCD interface, including display and seng.
●Trouble Shoong, this secon gives you the way to nd the problems.
●Test Step, this secon tells you how to test the UPS aer you repair the unit.
●Appendix, this secon shows you the basic waveforms for reference and the basic communicaon commands.
Important Safety Instrucons
For qualied service person only.
Do NOT perform any internal service or adjustment of this product unless the technical person is well
trained and experienced.
Dangerous voltage exists at several points in this product. To avoid personal injury, don’t touch any
exposed connecons or components while UPS is on.
Turn o the UPS and switch o the input breaker before removing protecve case. AC voltage is always
present if the input AC power is sll available.
High voltage may exist at DC capacitors. Before removing the protecve case, wait for at least ve minutes
aer turning o the UPS.
Verify input source (voltage and frequency) is within the maximum range before service.
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 5
Uninterrupble Power Supply
Electronic Specicaons
Model M90
Power kVA 20 40 60
Power kW 18 36 54
Mains Input (Recer input Line)
Input Topology Three Phase, Neutral + Ground
Nominal Voltage 208/220
Voltage Range (Full
Load) 156 ~ 253 100% load;
Voltage Range (Derang) 121V~ 253V with <70% Load
Voltage Comeback Low Loss Voltage +10V, High Loss Voltage -10V
Nominal Frequency 50Hz/60Hz(Auto-selectable)
Frequency Range 40Hz ~ 70Hz
Synchronized Range +/- 1Hz, +/- 2Hz, +/- 4Hz (default: 4Hz)
Power Factor > 0.99 at 100% load, >0.98 at 50% 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 + Ground
Nominal Voltage 208V/220V L-L
Voltage Regulaon < 1% Typical (balanced load)
(Steady state) < 2% Typical (unbalanced load)
Voltage DC Oset < +/-50mV
Synchronized Range
(Synchronize to Bypass)
+/- 1Hz, +/- 2Hz, +/- 4Hz
(default: 4Hz)
Overload Capability 1 hour for 105 ~110%,
10 mins for 111~125%,
1 min for 126~150%,
200ms for >150%
Crest Factor 3:1
V THD 100% linear load: <2%
100% nonlinear load: <4% (PF = 0.8 ~ 1)
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
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Uninterrupble Power Supply
Eciency > 92.5 % at over 50% load
(Power Module Measurement)
Model M90
Baery
Nominal Voltage +/- 120V
Baery Charger
Floang Voltage 2.3V/cell
Boost Charging 2.35V/cell
Temperature compensaon
(Opon)
-3mV/°C/cell
Charger Voltage
Regulaon
< 1%
Ripple Voltage < 1%
Ripple Current < 5%
Charger Power* 20% of nominal power
Maximum charging current* 8A
*At low input voltage the UPS recharge capability increases with load decrease.
Environmental Parameters
Model M90
Operang 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(Baery)
Relave Humidity 0-95%( No condensing)
Altude <1000m for Nominal power
(Over 1000m the power derang is 1 % every 100m)
Mechanical Requirements
Model M90
Dimensions (WxHxD) 515mm x 760mm x 1000mm
Noise (1m) full load Max. 70 dB
IP protecon IP20
Module Specicaon
Power Module
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 7
Uninterrupble Power Supply
Dimensions (WxHxD) 490 x 130 (3U) x 736.5 mm
Net Weight 34.5 kg
Funconal Block
As a true online UPS, the product applies a double conversion topology, comprising funconal blocks as shown in
the gure below.
I/P EMI
& surgr
CHARGE
Board
Funcon Block Diagram
The CONTROL block in the module controls the acon of the UPS system. The control board detects the voltage
and current to control PFC and inverter, also they supply the protecon for the UPS, when the UPS becomes
abnormal. In most case, the CNTL can provide basic informaon indicang the status of the UPS.
The CONTROL block in the STS controls the acon of Bypass SCR. It works with COMM
board and LCD panel to be user interface as well.
The COMM block provides the communicaon interface for receiving and execung 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 capacitor. In the mean me, PFC (Power Factor Correcon) will be executed and allows
input current tracking the input voltage waveform. Therefore, the input power factor will be corrected to 1 to
achieve maximum eciency and produce lowest power polluon to the ulity.
The PFC block in baery mode, also called Booster, is used to convert the low voltage DC
power to higher voltage with stable DC power, stored in the BUS capacitor.
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 8
Uninterrupble Power Supply
The Inverter block is the output stage of the UPS and used to convert DC power from the
BUS capacitor to sine waveform output power.
When the ulity is within the acceptable range, the UPS will provide power directly from the ulity input and
the Recer and PFC will be executed at the same me. When the ulity is outside of the acceptable range, no
maer it’s because of input voltage or input frequency, the UPS will shutdown the Recer and PFC funcons
and turn on the Baery Booster. In case of sudden interrupon from input ulity, the controller can detect the
interrupon in very short me. During the short interval of detecng the interrupon, the output power will be
provided by the power stored in the BUS capacitor. In this way, there is no any interrupon on output power.
The charger charges the baery when the ulity is normal. The charger converts AC input power to DC power for
recharging the baery.
The Input and Output EMI secon provides EMI lter funcon. The input and output EMI lters can prevent the
UPS from being interference by external electronic/magnec noise which is generated by other electronic system
and prevent other systems from the noise generated inside the UPS system.
The SPS generates DC power supply needed by operaon of the circuit of the UPS itself. The Bypass provides a
path that ulity can power the output directly when the Inverter is not executed.
The Maintenance Bypass provides another path that ulity can power the output directly when UPS is in
maintenance status.
Working Principle of the Major Funconal Block
Switch Power Supply
The Switch Power Supply (SPS) supplies DC power for UPS operaon. The input source of the SPS is the baery,
or the AC input.
Basic circuit of power supply
DC
TX
7812
7912
7805
HF-
HF+
+12V.FAN
+12V.P
+12V
-12V
+5V
D2
D3 D7
D4 D9
Q5
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 9
Uninterrupble Power Supply
The gure above is a yback converter. When Q5 is on, all recer diodes (D2/D3/D4/D9) are on open status
and all output capacitors supply currents to the load. The primary coil of the transformer will become a pure
inductor and the primary current will linearly increase to store energy in the coil. When Q5 is o, primary current
will stop and all recer diodes (D2/D3/D4/D9) will turn to “close” status. It will release the stored energy from
the primary coil of the transformer to the secondary coil to supply loads. At the same me, it will charge output
capacitors including +12V, -12V, +5V, +12V.P, +12V.Fan, and HF-power.
The power of +12V, -12V, +5V, +12V.P, +12V.Fan supplies stable voltage to all kinds of ICs and other devices
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 o, the current will increase to store energy in choke
(L1/L2). When the Q3/Q4 is o and D1/D2 is on, the choke will release energy. Therefore, we can control the
current in chokes (input current) by regulang the me of Q3/Q4 on and o. There are three independent PFC/
Booster for each phase.
Inverter
The input of the Neutral Point Clamped(NPC) Inverter topology is two DC voltages, and the output is an AC
voltage, as shown in the Figure4.3.When Q2is on and Q4 is o, the Q3 and Q1 are connued on and o for on
upper of sine wave. When Q3 is on and Q1 is o, the Q4 and Q2 are connued on and o for on lower of sine
wave. The L1 and C1 are AC
power lter.
L2
Q3
Q4
Q5
Q6
Q1
Q2
D1
D2
C1
C2
N
NR/S/T
Battery
+Vbus
-Vbus
Q2
D4
Q3
D5
Q4
D6
D1
D2
L1
C1
N
N
Relay 1
Vo
+Vbus
-Vbus
INV.STS
Xtreme Power Conversion Corporaon
M90 & M90L Service Manual
Page 10
Uninterrupble Power Supply
Neutral Point Clamped Inverter
Charger
The funcon of charger is to charge and maintain the baeries at fully charged condion. The charger charges
the baeries with a constant current at inial stage. At the same me, the baery voltage keeps increasing unl
reaching the constant charge voltage point. Then, the charge current will decrease accordingly, now it’s in second
stage. Aer constant voltage charging, the charge voltage will change to oang charge voltage, in general, the
charger will control the output voltage at a constant level to opmize baery recharge me and prolong the life
me of baeries without overcharging.
Topology of the charger
EMIBoard
Input EMI board is connected between ulity and the input of recer. Output EMI board is
connected between the output of inverter and output terminal block.
Topology of the input/output EMI
Q1
Q2
L1
D1
Q3
D3
D2
Q4
D4
N
+Vbus
-Vbus
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