Xtreme Power Conversion 20kVA Model Operating manual

R91 Online UPS
20kVA Model
User & Installaon Manual
www.xpcc.com | © 2016 Xtreme Power Conversion Corporaon. All rights reserved. (Rev 7/21/16)

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R91 User’s Manual
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Uninterrupble Power Supply
Table of Contents
Introducon.................................................................................................7
Product Descripon......................................................................................7
Main Features..................................................................................................................................7
System Conguraon...................................................................................8
Unpacking the UPS..........................................................................................................................8
Installaon Notes.............................................................................................................................9
External Protecve Devices.............................................................................................................9
Power Cables.................................................................................................................................10
Power Cables Connecon..............................................................................................................10
UPS Mul-Module Installaon......................................................................................................12
CYCLON Baery Pack Connecon...............................................................15
BP-XR4U480A Baery Pack Connecon......................................................16
Assembly........................................................................................................................................17
4 Post Rail Mounng.....................................................................................................................20
Mulple Baery Pack Connecons................................................................................................20
Installaon and Setup....................................................................................................................21
BP-XR2U480A Baery Pack Connecon......................................................22
Assembly........................................................................................................................................23
4 Post Rail Mounng......................................................................................................................26
Mulple Baery Pack Connecons...............................................................................................26
Installaon and Setup....................................................................................................................27
Operaon...................................................................................................28
Operaon Modes...........................................................................................................................28
Turn On / O the UPS....................................................................................................................29
Communicaon Port Denions (RS232, RS485)..........................................................................35
LCD Display....................................................................................................................................36
Opons..........................................................................................................................................44
Troubleshoong.........................................................................................45

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Specicaons.............................................................................................46
Shipping List.............................................................................................. 46
Obtaining Service.......................................................................................47
Xtreme Power Conversion Limited Warranty...............................................48

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Thank you for selecng this uninterrupble power supply (UPS). It provides you with protecon for connected
equipment. Please read this manual before installing the R91-20KVA model as it provides important informaon
that should be followed during installaon and maintenance of the UPS and baeries, allowing you to correctly
set up your system for the maximum safety and performance. Included is informaon on customer support and
service, if it is required. If you experience a problem with the UPS, please refer to the Troubleshoong secon in
this manual to correct the problem. If the problem is not corrected, please collect informaon so that the Technical
Support personnel can more eecvely assist you.

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Important Safety Instrucons: (Save These Instrucons)
CAUTION! (UPS having Internal Baeries): Risk of electrical shock – Hazardous live parts inside this unit are ener-
gized from the baery supply even when the input AC power is disconnected.
CAUTION! (No User serviceable Parts): Risk of electrical shock, do not remove cover. No user serviceable parts
inside. Refer servicing to qualied service personnel.
CAUTION! (Non-isolated Baery supply): Risk of electric shock, baery circuit is not isolated from AC input, haz-
ardous voltage may exist between baery terminals and ground. Test before touching.
WARNING! (Fuses): To reduce the risk of re, replace only with the same type and size of fuse.
WARNING! Unit intended for installaon in a controlled environment.
CAUTION! Do not dispose of baeries in a re, the baery may explode.
CAUTION! Do not open or mulate the baery, released electrolyte is harmful to the skin and eyes.
CAUTION! A baery can present a risk of electric shock and high short circuit current. The following precauon
should be observed when working on baeries:
• Remove watches, rings or other metal objects.
• Use tools with insulated handles.
To reduce the risk of electric shock, disconnect the UPS from the main supply before installing a computer inter-
face signal cable. Reconnect the power cord only aer signaling interconnecons have been made.
Servicing of baeries should be performed or supervised by personnel with knowledge of baeries and the re-
quired precauons. Keep unauthorized personnel away from baeries.
These UPS units are extremely heavy. Cauon should be taken in moving and posioning equipment. The instruc-
ons contained within this safety manual are deemed important and should be closely followed at all mes during
installaon and follow-up maintenance of the UPS and baeries.

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CAUTION
The unit has a dangerous amount of voltage. If the UPS indicator is on, the unit’s outlets may have a
dangerous amount of voltage even when not plugged into the wall outlet because the baery may con-
nue to supply power.
Care should be taken to undertake installaon indoors, free from electrically-conducve parcles which
are under temperature and humidity control, in order to reduce the risk of electric shock.
It is best to disconnect the device using the power supply cord. Ensure that the equipment is placed in
a posion near the outlet where easily accessible.
Except for replacing the baeries, all servicing on this equipment must be carried out by qualied ser-
vice personnel.
Before conducng any maintenance, repair, or shipment, rst ensure that everything is turned o com-
pletely and disconnected.
For addional safety instrucons, please use the Safety Manual as a reference.
Special Symbols
The following symbols used on the UPS warn you of precauons:
RISK OF ELECTRIC SHOCK - Please observe the warning that a risk of electric shock is present
CAUTION: REFER TO OPERATOR’S MANUAL - Refer to the operator’s manual for addional informaon,
such as important operang and maintenance instrucons.
SAFE GROUNDING TERMINAL - Indicates primary safe ground
Please do not discard of the UPS or the UPS baeries as the UPS may have valve-regulated lead-acid bat-
teries. Please recycle baeries appropriately.

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Introducon
The informaon provided in this manual covers three-phase 20kVA uninterrupble power systems, its basic func-
ons, operang procedures, opons available and emergency situaons. It also includes informaon on how to
ship, store, handle, and install the equipment. Only detailed requirements of the UPS units are described herein,
and installaon must be carried out in accordance with this manual. Electrical installaon must also carefully
follow local legislaon and regulaons. Only qualied personnel should conduct these installaons as failure to
acknowledge electrical hazards could prove to be fatal.
Product Descripon
Many dierent kinds of sensive electrical equipment can be protected by an Uninterrupble Power Supply (UPS)
including computers, workstaons, process control systems, telecommunicaons systems, sales terminals, other
crical instrumentaon, etc. The purpose of the UPS is to protect these systems from poor quality ulity power,
complete loss of power, or other associated problems.
Electrical interference exists in many forms, causing problems in AC power, from lightning, power company ac-
cidents and radio transmission motors, air condioners, and vending machines. Protecon of sensive electrical
equipment is vital to protect against power outages, low or high voltage condions, slow voltage uctuaons,
frequency variaons, dierenal and common-mode noise, transients, etc.
To prevent power line problems from reaching crical systems causing damage to soware, hardware, and equip-
ment malfuncons, the UPS maintains constant voltage, isolang crical load output and cleaning the ulity AC
power.
Main Features
This is a three phase input / three phase output high-frequency online UPS. The UPS protects against power fail-
ures, power sag, power surge, under-voltage, over-voltage, line noise, frequency variaons, switching transients,
and harmonic distoron which can all cause crical problems to supported sensive electronic equipment in the
market today.
Funcons and Features
• 3 phase input/output high-density UPS
• Digital Control
o The UPS is controlled by Digital Signal Processor (DSP) which increases reliability, performance,
self-protecon, self-diagnoscs, etc.
• Modular Design
• Baery Conguraon
o The baery voltage can be congured based on needs
• Charging Conguraon
o The charging current can be customized to meet site requirements
• Intelligent Charging Method
o 1st stage = high current constant current charging to restore baeries to 90% capacity
o 2nd stage = constant current charging to assure baeries remain fully charged
o 3rd stage = oat charge
The 3-stage charging method extends the life of the baeries and guarantees rapid recharging
• LCD Display
o Both LED and LCD displays allow for ease of use and availability of crical UPS status and opera-
onal parameters, including: input/output voltage, frequency and load %, baery %, ambient tem-

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perature, etc.
• EPO Funcon
System Conguraon
The UPS device and the external baeries make up the system. Depending on the site and load requirements of
the installaon, certain addional opons are available for the soluon.
Planning a UPS system, the following should be taken into consideraon:
• The total demand of the protected system shall dictate the output power rang (VA). Allow a margin for
future expansion or calculaon inaccuracies from measured power requirements.
• Backup me required will indicate the baery size needed. If the load is less than the UPS nominal power
rang, then actual backup me is longer.
• The following opons are available:
o Connecvity Opons –SNMP/WEB card
o Extended Baery Packs - minimum 1 required
See the Specicaon secon of this manual for addional model informaon.
Unpacking the UPS
1. Do not lean the UPS against anything when moving it out of the packaging.
2. Check the physical appearance of the UPS to see if it was damaged during transportaon. Do not switch on the
UPS if damage is found. Please contact your dealer or distributor immediately for assistance.
3. Check the accessories according to the packing list to assure that you have all required pieces.
R91-20K front view
Baery
Connecon
Input
Breaker
Input Terminals Output Terminals
RS485 /
RS232
Parallel
Port 1
Parallel
Port 2
SNMP
Port
EPO
Maintain-AUXSWS
R91-20KVA rear view diagram

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Front panel
Installaon Notes
• Place the UPS in a clean, stable environment, avoiding vibraon, dust, humidity, ammable gas and liquid,
corrosive objects, etc. Check the operang temperature of the room where the UPS is being installed to
assure it is within range of UPS specicaon.
• Baeries should be installed in an environment where the temperature is within the required specica-
ons of the product. Temperature is a major factor in determining baery life and capacity. Normal baery
installaon requires the temperature be maintained from 15°C to 25°C. Keep baeries away from heat
sources and main air venlaon areas.
WARNING!
Typical baery performance data is quoted for an operang temperature between 20°C and 25°C. Operang
above this range will reduce the baery life while operaon below this range will reduce the baery capacity. If
the equipment is not to be installed immediately, it must be stored in a room so as to protect it against excessive
heat and humidity sources.
CAUTION!
An unused baery must be recharged every 6 months. Temporarily connecng the UPS to a suitable AC source and
acvang the UPS for the me required to recharge the baeries is required.
• To monitor the UPS with the soware, simply connect the RS232 cable to the UPS and to a computer.
External Protecve Devices
For safety reasons, it is necessary to install an external circuit breaker at the input AC ulity and to the baery.
External Baery
The UPS and its associated baeries are protected against the eect of over-current through a DC compable
thermo-magnec circuit breaker located close to the baery.

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UPS Output
Any external distribuon board used for load distribuon shall be ed with protecve devices so as to avoid the
risk of UPS overload.
Over-Current Protecon
A protecon device shall be installed at the distribuon panel of the incoming ulity power, and should idenfy
the power cables current capacity as well as the overload capacity of the system.
CAUTION!
Select a thermo-magnec circuit-breaker with an IEC 60947-2 trip curve D (normal) for 125% of the current as
listed below. 40A Input Circuit Breaker required.
Power Cables
The cable design shall comply with the voltages and currents provided in this secon, and in accordance with local
electrical codes.
WARNING!
UPON STARTING, PLEASE ENSURE THAT YOU ARE AWARE OF THE LOCATION AND OPERATION OF THE EXTERNAL
ISOLATORS WHICH ARE CONNECTED TO THE UPS INPUT/BYPASS SUPPLY OF THE UTILITY DISTRIBUTION PANEL.
CHECK TO SEE IF THESE SUPPLIES ARE ELECTRICALLY ISOLATED, AND POST ANY NECESSARY WARNING SIGNS TO
PREVENT ANY INADVERTENT OPERATION
Cable Sizes
UPS MODEL CABLE SIZES (THHW wiring at 75°C)
AC INPUT AC OUTPUT DC INPUT GROUNDING
R91-20K 8 awg 8 awg 6 awg 8 awg
CAUTION!
Protecve earth ground cable: connect each cabinet to an earth ground, following the shortest route possible.
WARNING!
FAILURE TO FOLLOW ADEQUATE GROUNDING PROCEDURES MAY RESULT IN ELECTROMAGNETIC INTERFERENCE
OR IN HAZARDS INVOLVING ELECTRICAL SHOCK AND FIRE.
Power Cables Connecon
Aer the equipment has been properly posioned and secured, connect the power cables as described below.
Verify the UPS is totally isolated from its external power source and all circuit breakers to the UPS are open. Check
to see that everything is electrically isolated, and post any necessary warning signs to prevent inadvertent opera-
on of the breakers.

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Power cable connecon diagram
Select the appropriate power cable size, paying aenon to the diameter of the connecon terminal of the cable,
which should be greater than or equal to the connecon posts.
Wiring diagram

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WARNING!
IF THE LOAD EQUIPMENT IS NOT READY TO ACCEPT POWER WHEN THE UPS INSTALLATION IS OCCURRING, ENSURE
THAT THE UPS OUTPUT CABLES ARE SAFELY ISOLATED AT THE CABLE ENDS.
CAUTION!
The earth ground and neutral bonding arrangement must be in accordance with local and/or naonal electrical
code pracces.
UPS Mul-Module Installaon
The basic installaon procedure for a parallel system consisng of two or more R91-20KVA modules is that same
as that of a single module. The following provides installaon procedures related to a parallel system.
Cabinet Installaon
Connect all R91-20KVA UPS required in the parallel system as shown in the diagram below.
WARNING!
MAKE SURE THE N, A(L1), B(L2), AND C(L3) WIRING IS CORRECT, AND THAT GROUND IS CONNECTED.
Parallel Cable Installaon
The shielded and double insulated control cables must be interconnected in a ring-conguraon between UPS
modules as shown in the diagram below. The parallel control board is mounted in each UPS module. The ring-
conguraon ensures high-reliability of the control funcon.

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Parallel connecon of UPS

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Remote Emergency Power O (EPO) for Parallel Systems
EPO for parallel systems must be connected in parallel and installed as shown below. Once the EPO funcon of one
of the UPS in the parallel system is acvated, the UPS will send out a remote command and shut down the other
UPS’s in the parallel system.
CAUTION!
The remote emergency kill switch must be voltage-free and “normally open”.
EPO connecons for parallel systems
Requirements for a Parallel System
A group of parallel UPS modules behave as one large UPS system with the advantage of presenng higher reli-
ability. In order to assure that all modules are equally ulized and comply with relevant wiring regulaons, please
follow the requirements below.
1. All UPS modules must be of the same rang and be connected to the same bypass source.
2. The Bypass and Ulity input sources must be referenced to the same neutral potenal.
3. The outputs of all the UPS modules must be connected to a common output bus.

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4. The length and specicaon of power cables including the bypass input cables and the UPS output cabi-
nets should be the same size. This facilitates load sharing when operang in bypass mode.
5. Up to 4 UPS modules may be paralleled with common baery if desired.
CYCLON Baery Pack Connecon
The CYCLON baery pack contains four idencal baery trays. Each tray contains 60 5AH CYCLON cells connected
in series. The four trays are then connected in series. The following three diagrams respecvely display baery
pack internal connecons, internal cell connecons in each individual tray and baery pack external connecons
to UPS and another baery pack.
R91-BPSYS baery pack wiring diagram
R91-BPSYS baery module connecon
CAUTION!
Ensure correct polarity of the baery string series connecon. DO NOT mix baeries with dierent capacity or dif-
ferent brands, or new or old baeries.
WARNING!
ENSURE CORRECT POLARITY OF STRING END CONNECTIONS TO THE BATTERY CIRCUIT BREAKER, AND FROM THE
BATTERY CIRCUIT BREAKER TO THE UPS TERMINALS (I.E. (+) TO (+) / (-) TO (-) / (N) TO (N)). DISCONNECT ONE OR
MORE BATTERY CELL LINKS IN EACH TIER. DO NOT RECONNECT THESE LINKS AND DO NOT CLOSE THE BATTERY
CIRCUIT BREAKER UNLESS ALL CONNECTIONS ARE PROPERLY CHECKED AND APPROVED.

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R91-20K to R91-BPSYS baery connecon
BP-XR4U480A Baery Pack Connecon
The BP-XR4U480A baery pack dimension is 443W x 861.5D x 175H mm (17.4 x 33.9 x 7.0 in) and unit weight is
127 kgs (280 lbs). It includes baery connecon cables, breaker, fuse, terminal, etc, with a maximum capacity of
40 pcs CSB UPS12580 baeries inside. The baery connecon could be congured to output ±240V, two groups
baeries connect in series as BAT+, N, BAT–.

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Complete BP-XR4U480A cabinet
Assembly
Dismount the Cabinet Shell
Put the baery pack on a level, pull of bolts at the right side baery tray, than pull out the baery tray, remove the
baery tray top covers for easier baery installaon and connecon, as shown below

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Baery Installaon and Connecon
Users need 40 pcs baeries, divide into 2 groups. Each group has 20 pcs baeries in series, as (BAT+ N BAT-) shown
below.
40 pcs baeries installaon and connecon:
Each baery tray t 10pcs baeries, then connect the baeries as shown in below pictures.
40pcs baeries installaon

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40 pcs baeries connecon
Aer the baery installaon and connecon done, check if BAT+ to N & N to BAT- voltages are correct with mul-
meter or other equipment. Install the cover if the voltages are correct.
Note: Baery “+” “-” poles cannot be reversed, also cannot short the baery “+” “-” poles, otherwise baeries
would be damaged or other accidents would happen. Don’t touch the baery “+” “-” poles at the same me. It’s
beer only single man make the operaon.
Fuse in Baery Pack
The baery pack has 2 x fuses inside as shown in below picture.

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4 Post Rail Mounng
Mulple Baery Pack Connecons
CAUTION!
Ensure correct polarity of the baery string series connecon. DO NOT mix baeries with dierent capacity or dif-
ferent brands, or new or old baeries.
WARNING!
ENSURE CORRECT POLARITY OF STRING END CONNECTIONS TO THE BATTERY CIRCUIT BREAKER, AND FROM THE
BATTERY CIRCUIT BREAKER TO THE UPS TERMINALS (I.E. (+) TO (+) / (-) TO (-) / (N) TO (N)). DISCONNECT ONE OR
MORE BATTERY CELL LINKS IN EACH TIER. DO NOT RECONNECT THESE LINKS AND DO NOT CLOSE THE BATTERY
CIRCUIT BREAKER UNLESS ALL CONNECTIONS ARE PROPERLY CHECKED AND APPROVED.