Xtreme Power Conversion P91 User manual
P91, TX91, TX91L, TXVR
Service Manual
www.xpcc.com | © 2019 Xtreme Power Conversion Corporaon. All rights reserved. (Rev 4/26/19)
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 2
Uninterrupble Power Supply
Table of Contents
1 General Informaon..................................................................................3
1.1 Geng Started...........................................................................................................................3
1.2 Important Safey Instrucons....................................................................................................3
2 Specicaons............................................................................................4
3 Funconal Block........................................................................................7
4 Working Principle of the Major Funconal Block...........................................8
4.1 Switch Power Supply..................................................................................................................8
4.2 PFC/Booster...............................................................................................................................9
4.3 Inverter.......................................................................................................................................9
4.4 Charger......................................................................................................................................10
4.5 EMI Board.................................................................................................................................10
5 Funcon explanaons for each PCB.........................................................11
5.1 SPS-Charger Board...................................................................................................................11
5.2 Control Board...........................................................................................................................12
5.3 Communicaon 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
6 Interface..................................................................................................15
6.1 LED Display...............................................................................................................................15
6.2 LCD Display...............................................................................................................................16
6.3 LCD Display Icon......................................................................................................................16
7 Troubleshoong......................................................................................18
7.1 LCD Panel Display Paern Denion.......................................................................................18
7.2 Repair.......................................................................................................................................23
7.2 Repair.......................................................................................................................................23
8 Test Step.................................................................................................28
9 Appendix.................................................................................................29
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 3
Uninterrupble Power Supply
1 General Informaon
1.1 Geng start
This manual is for P91, TX91, TX91L, TXVR tower and R/T UPS. It can help service person perform the basic main-
tenance 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 include 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 funconal 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.
1.2 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 ex-
posed 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
P91, TX91, TX91L, TXVR Service Manual
Page 4
Uninterrupble Power Supply
2. Specicaons
MODEL NUMBER P91-5K P91-6K P91-10K
CAPACITY Power rang 5kVA (5kW) 6kVA (6kW) 10kVA (10kW)
INPUT Voltage 110–300VAC*
Frequency 50/60Hz
OUTPUT Voltage 200/208/220/230/240VAC (208/120V or 240/120V with oponal transformer)
Frequency 50/60Hz ± 4Hz
THD (full load) < 4%
Overload capacity 110% 10 min; 130% 1 min; > 130% 1 sec
Eciency Up to 95% online mode or 99% ECO mode
BATTERY Charger amps 1–4A
Nominal/oat voltage 240/273VDC
DIMENSIONS & Dimensions (W x D x H) 17.2 x 23.6 x 3.5 in
WEIGHT Weight 33.1 lbs 39.7 lbs
BYPASS Model XBDM-P91A XBDM-P91B
DISTRIBUTION Input connecon L6–30P (5, 6kVA) Terminal Block (5,6,10kVA)
MODULE Output connecon (2) L6-30R+(2) C19 Terminal block + (1) L6-30R+(2) C19
Oponal: L6–30R, L6–20R, 6–20R Oponal: L6–30R, L6–20R, 6–20R
ENVIRONMENT Operang temperature 32–104°F (0–40°C)
Audible noise < 55dBA < 58dBA
Altude 11,500 above sea level
APPROVALS UL, FCC, RoHS (pending)
WARRANTY 3 years electronics, 3 years baery warranty (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, USB, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX Soware 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 rang 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 240/120VAC or 230/115VAC
Voltage Regulaon ± 1%
Frequency 50Hz ± 0.1Hz or 60 Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency up to 97% ECO mode, 91% online mode
Harmonic Distoron <2% @ 100% linear load (regardless of input distoron)
PHYSICAL Input/output Terminal blocks or oponal PDU
Dimensions (W x D x H) 9.8 x 23.2 x 32.4 in
Weight 142 lbs 145 lbs 148 lbs 187 lbs
OPTIONAL PDU Input connecon Terminal Block with 6 L6-30P* Terminal Block
120V receptacle opons 5-15/20R
240V receptacle opons L6-30R, L6-20R, 6-15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 11,500 above sea level
APPROVALS UL, cUL, RoHS
WARRANTY 3 years electronics (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware CD
AVAILABLE OPTIONS 5 year extended warranty, output PDU, input L6-30P cord (for 3.8kVA, 5kVA, 6kVA)
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 5
Uninterrupble Power Supply
*Depending on load level.
MODEL NUMBER TX91-3.8K TX91-5K TX91-6K TX91-10K
CAPACITY Power rang 3.8kVA (3.8kW) 5kVA (5kW) 6kVA (6kW) 10kVA (10kW)
INPUT Voltage (nominal) 208VAC (200VAC, 220VAC, 230VAC, 240VAC oponal)
Voltage range 110-300VAC
Frequency 46–64Hz auto-sensing
OUTPUT Voltage 240/120VAC or 230/115VAC
Voltage regulaon ± 1%
Frequency 50/60Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency Up to 97% ECO mode, 91% online mode
BATTERY/CHARGER Baery type Sealed, maintenance-free lead acid
Baery quanty and size
(standard / XR models) (20) 12V 9AH / (20) 12V 580W
Charger voltage/current 273VDC / 1A-4A (selectable)
PHYSICAL Input/output Terminal blocks or oponal 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 Baery quanty 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 connecon Terminal blocks or 6 , L6–30P* Terminal blocks
120V receptacle opons 5–15/20R
240V receptacle opons L6–30R, L6–20R, 6–15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 11,500 above sea level
APPROVALS UL1778, cUL, FCC Class A, RoHS
WARRANTY 3 years electronics, 3 years baery warranty (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware CD
AVAILABLE OPTIONS 5 year extended warranty, output PDU, input L6–30P cord (for 3.8kVA, 5kVA & 6kVA)
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 6
Uninterrupble Power Supply
MODEL NUMBER TX91L-3.8K TX91L-5K TX91L-6K TX91L-10K
CAPACITY Power rang 3.8kVA (3.8kW) 5kVA (5kW) 6kVA (6kW) 10kVA (10kW)
INPUT Voltage (nominal) 208VAC (200VAC, 220VAC, 230VAC, 240VAC oponal)
Voltage range 110-300VAC
Frequency 46–64Hz auto-sensing
OUTPUT Voltage 240/120VAC or 230/115VAC
Voltage regulaon ± 1%
Frequency 50/60Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency Up to 97% ECO mode, 91% online mode
BATTERY/CHARGER Charger amps 1A-4A (max) programmable from LCD
Charger voltage 273VDC
PHYSICAL Input/output Terminal blocks or oponal 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 connecon Terminal blocks or 6 , L6–30P* Terminal blocks
120V receptacle opons 5–15/20R
240V receptacle opons L6–30R, L6–20R, 6–15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 11,500 above sea level
APPROVALS UL1778, cUL, FCC Class A, RoHS
WARRANTY 3 year electronics (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware CD
AVAILABLE OPTIONS 5 year extended warranty, output PDU, input L6–30P cord (for 3.8kVA, 5kVA & 6kVA)
*6kVA system capacity will be reduced by 30A input circut
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 7
Uninterrupble Power Supply
3. Funconal Block
As a true online UPS, the product applies a double conversion topology, comprising funconal blocks as shown in
Figure 3.1
Figure 3.1 Funcon block Diagram
The CNTL block controls the acon of the UPS system. It also provides the communicaon interface for receiving
and execung command from users via the panel or other communicaon protocol. When the UPS becomes
abnormal, in most case, the CNTL can provide basic informaon indicang the status of the UPS.
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 8
Uninterrupble Power Supply
The Recer 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 meanme, 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.
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 shut down 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 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 dierent voltage corresponding to dierent baery
pieces by changing the jumper on the CNTL board, either LCD or command.
The Input EMI secon provides EMI lter funcon. The input 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.
4. Working Principle of the Major Funconal Block
4.1 Switch Power Supply
The Switch Power Supply (SPS) supplies DC power for UPS operaon. The input source of the SPS is the
grid when the grid voltage is higher than 110V . Or the input source of the SPS is the baery.
Figure 4.1 Basic circuit of power supply
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
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Uninterrupble Power Supply
Figure 4.1 is a yback converter. When Q1 is on, all recer diodes (D1/D2/D3) are on open status and all out-
put capacitors (C1/C2/C3) 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 Q1 is o, primary cur-
rent will stop and all recer diodes (D1/D2/D3) 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 15V, +12V, +5V, +12V(Fan), and HFPW.
The power of 12V, +5V 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.
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 o, the current will increase to store energy in
choke(L1/L2). When the Q1/Q2 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 Q1/Q2 on and o.
4.3 Inverter
The input of the three level inverter topology is two DC voltages, and the output is an AC voltage, as shown in
the Figure 4.3. When Q1/Q2 is on and Q/Q3 is o, the voltage of the bridge midpoint is +BUS. When Q1/Q2 is o
and Q3/Q4 is on, the voltage of the midpoint bridge is –BUS. We can get any voltage waveform between ±BUS
voltage from LC lter output by regulang the duty cycle of Q1/Q2/Q3/Q4, including sine wave form.
Figure 4.3 Three level inverter bridge
Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 10
Uninterrupble Power Supply
4.4 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 one hour of 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 (13.65V±1% per baery) to opmize bat-
tery recharge me and prolong the lifeme of baeries
without overcharging.
Figure 4.4 Topology of the charger
4.5 EMI Board
Input EMI board is connected between ulity and the input of recer.
CX
CY
CY
CY
CY
CX
Input Output
Common
Choke
Figure 4.5 Topology of the EMI
This manual suits for next models
18
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