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Xtreme Power Conversion E90 Series Service Manual
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Xtreme Power Conversion E90 Series Service Manual

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E90 Online UPS
10kVA, 15kVA, 20kVA Models
Service Manual
www.xpcc.com
| © 2019 Xtreme Power Conversion Corporation. All rights reserved. (Rev 8/13/18)

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Summary of Contents for Xtreme Power Conversion E90 Series

  • Page 1 E90 Online UPS 10kVA, 15kVA, 20kVA Models Service Manual www.xpcc.com | © 2019 Xtreme Power Conversion Corporation. All rights reserved. (Rev 8/13/18)
  • Page 2 Parallel system commissioning......................42 Display Messages/Troubleshooting....................43 Options ............................45 Specifications....................47 Problems and Solution................48 USB communication port definition.............49 RS232 communication port definition............50 RS485 communication port definition............51 BAT_T communication port definition............52 REPO instruction..................53 Obtaining Service..................54 Xtreme Power Conversion Limited Warranty..........55 Xtreme Power Conversion Corporation Page 2...
  • Page 3 - application: Work station, network server, and computer rooms and data center Features Three-phase UPS This E90 series is three-phase in to three-phase out UPS with a large capacity, the three phase input current is balanced which can balance the load of each phase. Digital control Digital control is used for all parts of the UPS, which makes the performance indicators very excellent and the system more stable.
  • Page 4 Shut down inverter in Line mode and transfer to bypass(if bypass normal) ; Shut down inverter under the battery mode, UPS down; Battery cold start when off status Xtreme Power Conversion Corporation Page 4...
  • Page 5 Now close the maintenance air-switch for supplying power from bypass. When finish maintenance, the air- switch cannot be open until the UPS is in bypass, or it will cause the power down of load. Xtreme Power Conversion Corporation Page 5...
  • Page 6 As shown above, A (yellow box) shows the rectifier circuit, B (blue box) shows the battery input circuit, C (other part) shows the boost circuit. A and C form the PFC rectifier circuit while B and C form the battery boost circuit Xtreme Power Conversion Corporation Page 6...
  • Page 7 As shown above, A (yellow box) represents bypass circuit of UPS, B (blue box) shows the inverter circuit, which converts the Bus voltage into the AC output. Charging principle Battery Charging Fuse Charging fuse As shown above, charger reduces the Bus voltage to a suitable voltage to charge the battery. Xtreme Power Conversion Corporation Page 7...
  • Page 8 User manual, RS-232 communication cable, USB cable, Muser monitoring software AVAILABLE OPTIONS External maintenance bypass, output distribution, external battery packs, parallel cables *Depending on load level. **Battery life is reduced above 30°C, UPS capacity derates above 40°C and 5,200 ft above sea level Xtreme Power Conversion Corporation Page 8...
  • Page 9 E90 Service Manual Uninterruptible Power Supply E90 Cabinet View Outlook Front View Side View Rear view Xtreme Power Conversion Corporation Page 9...
  • Page 10 (10) Maintenance switch & its cover (11) Bypass Switch (12) Terminal block for Input, output & GND (13) EPO switch (14) REPO port (15) Parallel port 2 (16) Parallel port 1 (17) I/P Switch (18) Terminal block for battery Xtreme Power Conversion Corporation Page 10...
  • Page 11 (10) Maintenance switch & its cover (11) Bypass Switch (12) Terminal block for Input, output & GND (13) EPO switch (14) REPO port (15) Parallel port 2 (16) Parallel port 1 (17) I/P Switch (18) Terminal block for battery Xtreme Power Conversion Corporation Page 11...
  • Page 12 Uninterruptible Power Supply Internal view of UPS PFC power board EPO interface board INV power board Input board UPS left view Output breaker Maintenance switch Input breaker Input filter ring Battery fuse Batteries UPS right view Xtreme Power Conversion Corporation Page 12...
  • Page 13 E90 Service Manual Uninterruptible Power Supply INV inductor board Output EMI board PFC drive board PFC inductor board UPS module inside view (20KVA) PFC inductor board(10-15KVA) Xtreme Power Conversion Corporation Page 13...
  • Page 14 E90 Service Manual Uninterruptible Power Supply 6pcs PFC inductors 2pcs charging inductors PFC inductor board(20KVA) PFC drive board IGBT drive board Charging fuse PFC power board Xtreme Power Conversion Corporation Page 14...
  • Page 15 Uninterruptible Power Supply 6pcs inv. inductors 3pcs inv. capacitors 3pcs inverter fuse 3pcs inverter SCR drive board BUS capacitor Inverter inductor board Radiator Auxiliary power INV. Power board Control detection board Output EMI board Xtreme Power Conversion Corporation Page 15...
  • Page 16 E90 Service Manual Uninterruptible Power Supply Input EMI board(15-20KVA) Input board Input filter inductor board Input fuse board Xtreme Power Conversion Corporation Page 16...
  • Page 17 E90 Service Manual Uninterruptible Power Supply Adapter RJ45 interface board EPO interface board USB interface board Xtreme Power Conversion Corporation Page 17...
  • Page 18 BAT+ input Description: UHTWSZ Wiring copper bar II welded assemblies plated bright nickel BPS_A_IN Name:blade terminal BPS_A_IN Bps A phase input Bps A phase Description:4PIN 10A M4screw hole straight leg input 8*8.4*11.1mm T0.8mm tinned copper Xtreme Power Conversion Corporation Page 18...
  • Page 19 Description: 2001S-2P P=2.54mm 180° single SCR- SCR drive row square PIN white Negative battery Name: neilsbed BAT1- Negative battery SCR drive 1 Description: 2001S-2P P=2.54mm 180° single SCR1 SCR drive 1 row square PIN white Xtreme Power Conversion Corporation Page 19...
  • Page 20 SCR drive 3 Description: 1121S-2P P=3.96mm 180° single drive 3 row square PIN white PFC drive board Function overview: -Bypass SCR drive circuit -Battery SCR drive circuit -Charging SCR drive circuit Figure 33.PFC drive board interface Xtreme Power Conversion Corporation Page 20...
  • Page 21 SCR2 drive Description: 1121S-2P P=3.96mm 180° SCR2 drive single row square PIN white C phase bypass Name: neilsbed BPS_C_SCR1 C phase bypass SCR1 SCR drive1 Description: 1121S-2P P=3.96mm 180° drive single row square PIN white Xtreme Power Conversion Corporation Page 21...
  • Page 22 BAT+/BAT- battery cold start battery cold Description: 1121S-3P P=3.96mm 180° single power start power row square PIN white BUS+/BUS- Name: neilsbed BUS+/ BUS+/BUS- BUS+/BUS- Description: 1121S-3P P=3.96mm 180° single BUS- Voltage detec- row square PIN white tion Xtreme Power Conversion Corporation Page 22...
  • Page 23 Description: 4PIN 10A M4screw hole straight leg 8*8.4*11.1mm T0.8mm tinned copper BPS_C Name: blade terminal BPS_C Bypass C phase Bypass C phase Description: 4PIN 10A M4screw hole straight Output Output 8*8.4*11.1mm T0.8mm tinned copper Xtreme Power Conversion Corporation Page 23...
  • Page 24 Output voltage sam- voltage sampling pling INV SCR drive/output Name: neilsbed INV SCR drive/ current detection signal Description: 301S-26P P=2.54mm 180° output cur- two rows square PIN black horn rent detection signal Xtreme Power Conversion Corporation Page 24...
  • Page 25 SWITCH ture detection REC temperature de- single row square PIN white tection upper half bridge INV Name:neilsbed upper half drive signal Description:301S-12P P=2.54mm 180° bridge INV two rows square PIN black horn drive signal Xtreme Power Conversion Corporation Page 25...
  • Page 26 PIN white sampling signal B phase INV voltage/ Name:neilsbed Vinv_B/ B phase INV volt- output voltage sam- Description:1121S-5P P=3.96mm 180° Vout_B age/output voltage pling signal single row square PIN white sampling signal Xtreme Power Conversion Corporation Page 26...
  • Page 27 PIN black horn INV. inductor board Name:neilsbed INV. inductor INV. SCR drive/out- Description:301S-26P P=2.54mm 180° board INV. SCR put current detection two rows square PIN black horn drive/output signal current detec- tion signal Xtreme Power Conversion Corporation Page 27...
  • Page 28 T=0.8mm Name:blade terminal output A phase Description:copper tinning 1PIN 10A W=6.3mm T=0.8mm Name:blade terminal output B phase Description:copper tinning 1PIN 10A W=6.3mm T=0.8mm Name:blade terminal output C phase Description:copper tinning 1PIN 10A W=6.3mm T=0.8mm Xtreme Power Conversion Corporation Page 28...
  • Page 29 Description:UHTWSZ Wiring copper bar II welded assemblies plated bright nickel Vin-C Name:blade terminal Vin-C Input C phase Description:UHTWSZ Wiring copper bar II welded assemblies plated bright nickel Adapter board Function overview: -Signal adapter function adapter interface Xtreme Power Conversion Corporation Page 29...
  • Page 30 Description:2001S-5P P=2.54mm 180° single row square PIN white SNMP2 signal Name:blade terminal SNMP2 IN SNMP2 signal Description:2001S-5P P=2.54mm 180° single row square PIN white RJ45 interface board Function overview: -signal interface function Figure 20.RJ45 interface board interface Xtreme Power Conversion Corporation Page 30...
  • Page 31 Table 14 EPO interface board interface Definition Specification Name Description EPO signal Name:neilsbed EPO signal Description:2001S-2P P=2.54mm 180° single row square PIN white EPO signal Name:neilsbed EPO signal Description:PLTBH1.5-2-S-3.8 12PIN P=3.81mm 90° square PIN green (male) Xtreme Power Conversion Corporation Page 31...
  • Page 32 USB signal Description:USB interface female 6PIN black square 90° Parallel interface board Function overview: -External parallel signal interface function Figure 23.parallel interface board interface Input and output interface definition Table 16 parallel interface board interface Xtreme Power Conversion Corporation Page 32...
  • Page 33 3. Check if the external signal of the battery box and LBS (when needed) connections are good or correct? 4. Check if the internal signal cable is connected well, if the cable is loosed by shaking it gently 5. Check if the internal boards or components are disconnected or damaged? Xtreme Power Conversion Corporation Page 33...
  • Page 34 8) If the battery has liquid leakage or housing damaged, place it in the ant-acid container and deal it according to the local regulations. 9) If the electrolyte touches your skin, immediately wash it with a plenty of water. 10) The battery must be handled with reference to local environmental regulations. Xtreme Power Conversion Corporation Page 34...
  • Page 35 Part of circuits are still at work. In maintenance mode, the load is directly connected to the power via the bypass, so the UPS will not provide any protection. Xtreme Power Conversion Corporation Page 35...
  • Page 36 B6 Switch off the maintenance switch, install baffles and screws, the unit goes to the bypass mode; B7 If both the mains and battery are normal, the unit goes into the line mode and charging after a period of time; Xtreme Power Conversion Corporation Page 36...
  • Page 37 3. If fan doesn’t work with mains input, confirm that if the auxiliary power of the INV-POWER board is damaged and needs to be replaced 4. Charger shows abnormal, check if the charging circuit in the PFC power board is damaged and need to be replaced. Xtreme Power Conversion Corporation Page 37...
  • Page 38 3 for operation Check if the ±15V in INV- Replace DSP POWER board is normal Check If the fuse of INV- Replace the fuse POWER board is good Replace INV-power board If repaired Xtreme Power Conversion Corporation Page 38...
  • Page 39 Soft start fail long beep Fault ON PFC power PFC inductor control detec- board board tion board Rectifier over- twice/s Fault ON PFC power temperature board Inv. Over-tem- twice/s Fault ON INV power perature board Xtreme Power Conversion Corporation Page 39...
  • Page 40 Inv. DC exces- once/2s INV flash INV inductor control detec- sive board tion board Overload in once/2s INV flash output over- Redundancy control detec- parallel load number set- tion board ting is im- proper Xtreme Power Conversion Corporation Page 40...
  • Page 41 ±150mV. The battery pack capacity will be affected if there is one or more battery voltages differ too much. In the worst case, it will damage the other battery. The voltage difference should be reduced after a long period of charging. Xtreme Power Conversion Corporation Page 41...
  • Page 42 6. Replace the PCB, package the old PCB; 7. Install the screws and cables; 8. install the right panel and screws ; 9. Continue with the steps 4-9 in process A or 4-8 in process B in chapter 3; Xtreme Power Conversion Corporation Page 42...
  • Page 43 6. Replace the PCB, package the old PCB; 7. Install the nuts, screws and cables; 8. install the left panel and screws; 9. Continue with the steps 4-9 in process A or 4-8 in process B in chapter 3; Xtreme Power Conversion Corporation Page 43...
  • Page 44 6. Replace with a new fan; 7. Install the screws and cables; 8. Install right and left panels, and the screws; 9. Continue with the steps 4-9 in process A or 4-8 in process B in chapter 3; Xtreme Power Conversion Corporation Page 44...
  • Page 45 BOOST IGBT Q1-12 Ω ≈10KΩ open or short Charge FUSE F3-4 Ω 0Ω open Charge MOS- Q13-14 S->D diode ≈0.46V open or short Charge MOS- Q13-14 Ω ≈20KΩ open or short Xtreme Power Conversion Corporation Page 45...
  • Page 46 4) After AC start, check the LCD menu, working mode, matching ID number, the VA of UPS, output voltage level and the frequency is the same with the actual values.( refer to the following pictures). If not the same, immediately disconnect the mains to check or cal the customer service hotline. Xtreme Power Conversion Corporation Page 46...
  • Page 47 While in the Data page, additional data pages to view will be shown on the right side of the screen. Input: Press ENTER key for approximately 1 sec. The display will show all three phases of the Main voltage, current, and frequency and the Bypass voltage and frequency as shown below. Xtreme Power Conversion Corporation Page 47...
  • Page 48 E90 Service Manual Uninterruptible Power Supply Output: Press the scroll key for approximately 1 sec. The display will show all three phases of the Output voltage, current, and frequency as shown below. Xtreme Power Conversion Corporation Page 48...
  • Page 49 Load : Press the scroll key for approximately 1 sec. The display will show all three phases of the Load %, kW, and kVA as shown below INSIDE: press key for approximately 1 sec. to move to the fifth page, the fifth page of data is Inside data. Xtreme Power Conversion Corporation Page 49...
  • Page 50 Setting: Press the scroll key for approximately 1 sec. to move to the setting page, then press ENTER key to enter setting-user page. Press the scroll key to change item, press ENTER key to enter item and press the scroll key to change value, press ENTER key confirm the setting. Available settings are: Xtreme Power Conversion Corporation Page 50...
  • Page 51 ENTER to confirm. The Battery manual test command can test battery discharge for 10s, 10min and to EOD. Maintenance : Press + ENTER key to enter maintenance and display a password window, press change the number and press ENTER to select the value, the password is “1121”. Xtreme Power Conversion Corporation Page 51...
  • Page 52 Record-Event : Press the scroll key to select Up or Down or Delete. Press ENTER key to confirm. Record-Fault : Press the scroll key to select Up or Down or Delete. Press ENTER key to confirm. Note: If Delete is selected, all event or fault records will be deleted. Xtreme Power Conversion Corporation Page 52...
  • Page 53 The display will show a password window, press the Scroll key to change the number and press Enter to select the value, the password is “1121”. Once the Maintenance password is entered, press the Enter key. The UPS goes into the Setting-System window as shown below. Xtreme Power Conversion Corporation Page 53...
  • Page 54 Note: Under single UPS mode, until this device address setting save and exit, single UPS setting is done. 5) OFF turns off the sensor switch, ON turns on the sensor switch and send query command to sensor with address 11 and 12 every second. Xtreme Power Conversion Corporation Page 54...
  • Page 55 Setting-Bypass: press the Enter key to enter item and confirm value, press the Scroll key to change the value. The following parameters can be adjusted: Setting-Bypass Range Default Upper Limit 10%, 15%, 20%, 25% 25% VAC Lower Limit -10%, -20%, -30%, -40% -40% VAC F_Range 1%, 2%, 4%, 5%, 10% 10% HZ Xtreme Power Conversion Corporation Page 55...
  • Page 56 3. Group is the number of strings of batteries 4. I-Maxcharge is the maximum charger current. Setting this above 15A on the E90-10kVA increases the input current rating and requires an input circuit for 45A Xtreme Power Conversion Corporation Page 56...
  • Page 57 2. Number - Program the total number of UPS systems in parallel. Maximum of 4 in parallel. 3. Redu. Num. – Program to the total number of UPS systems in parallel to be used for redundancy Xtreme Power Conversion Corporation Page 57...
  • Page 58 Emergency shutdown Connect all the EPO ports to a key switch according to the following figure. When emergency occurs, switch on the key can turn off all the outputs of UPS in this parallel system. Xtreme Power Conversion Corporation Page 58...
  • Page 59 If the REC and INV burning are both fail, the INV burning (Re-Update) has to be operated firstly. Cut off the mains and then power on the UPS, then the REC burning (Update) can be executed. Xtreme Power Conversion Corporation Page 59...
  • Page 60 After the setting done, pls click “Open device” as shown in Fig (1) e time, you can only use one of them at one time. Figure(1) After the above steps, it shows below Fig (2), pls click the “OK” button Xtreme Power Conversion Corporation Page 60...
  • Page 61 Connect the UPS RS232 to the computer’s serial port, make sure the communication between them is good Figure(3) After set up the communication between UPS and computer, click “Update” as shown in Figure (4) Figure(4) Xtreme Power Conversion Corporation Page 61...
  • Page 62 If need go on the programming, pls return to step 3. If finish and stop the programming, pls turn OFF the maintenance breaker, put on the panel, work the UPS to inverter power supply. Xtreme Power Conversion Corporation Page 62...
  • Page 63 E90 Service Manual Uninterruptible Power Supply Figure(7) Figure(8) Figure(9) Xtreme Power Conversion Corporation Page 63...
  • Page 64 -bus voltage long Fault voltage>470V >470V beep Last time: Last time: 20ms 20ms Bus under- Bus volt- Bus voltage is 10V lower long Fault voltage age <280V than setting value beep time:120ms Time: 2min Xtreme Power Conversion Corporation Page 64...
  • Page 65 Bypass over- X phase Bypass Output current greater than the rated 125% once/s current flash Over load X phase load rate( Inv. or Bypass) greater than rated 105% once/s INV or flash Xtreme Power Conversion Corporation Page 65...
  • Page 66 Bypass close) i) Auxiliary power power down and shutdown 2) manually start invalid Reserve Inverter not on Output switch Once per not ON 3 seconds Xtreme Power Conversion Corporation Page 66...

This manual is also suitable for:

E90-10kE90-15kE90-20k