Xtreme Power Conversion M90S Series User manual

M90S Online Single-Phase UPS
6kVA, 12kVA, 18kVA, 24kVA Models
Service Manual
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Xtreme Power Conversion Corporaon
M90S Service Manual
Page 2
Uninterrupble Power Supply
Table of Contents
General Informaon.................................................................................... 4
Geng Started................................................................................................................................4
Important Safey Instrucons.........................................................................................................4
Electronic Specicaons..............................................................................5
Environmental Parameters..............................................................................................................6
Funconal Block...........................................................................................7
Working Pricipal of the Major Funconal Block..............................................................................8
Switch Power Supply......................................................................................................................9
PFC/Booster....................................................................................................................................9
Inverter............................................................................................................................................9
Charger..........................................................................................................................................10
EMI Board......................................................................................................................................10
Funcon Explanaons for Each PCBA..........................................................11
PFC Board (Power Factor Correct Board).......................................................................................11
INV Board (Inverter Board)............................................................................................................11
CNTL Board (Control Board)..........................................................................................................11
COMM Board (Communicaon 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
Funcon Flow Chart...................................................................................12
Power on Mode.............................................................................................................................12
Standby Mode...............................................................................................................................13

Xtreme Power Conversion Corporaon
M90S Service Manual
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Uninterrupble Power Supply
Bypass Mode.................................................................................................................................13
Line Mode.....................................................................................................................................14
Baery Mode................................................................................................................................15
Baery test Mode.........................................................................................................................15
Fault Mode....................................................................................................................................15
Converter Mode............................................................................................................................16
ECO Mode.....................................................................................................................................17
Shutdown Mode...........................................................................................................................17
Trouble Shoong........................................................................................17
LCD Panel Display Paern Denion..............................................................................................1
Trouble shoong for warning icon in LCD display.......................................................................17T
rouble shoong for fault codes in LCD display.............................................................................18
Repair.........................................................................................................21
Basic Instruments and tools..........................................................................................................21
Quick Start.....................................................................................................................................21
Power Module...............................................................................................................................21
STS Module....................................................................................................................................22
Major parameters of IPOP Board secon......................................................................................22
Major parameters of PFC Board secon........................................................................................23

Xtreme Power Conversion Corporaon
M90S Service Manual
Page 4
Uninterrupble Power Supply
1. General Informaon
1.1 Geng started
This manual is for the M90S series UPS. It can help service personel perform the basic maintenance and repair
service.
This manual only focuses on the service secon, so you should get the basic operaon of the UPS from the user
manual, and make sure you have read and understood the user manual before reading the manual.
The manual include 8 secons, as follows
• General Informaon, this secon show you the general informaon of the service manual
• Funconal Block, this secon show you the major funconal block of the UP S
• Working Principle of the major Funconal Block , this secon show you the m ajor funconal block
• Funcon explanaons for each PCB, this secon show you all the PCBs of the UPS
• Interface, this secon show you the LCD interface, include display and seng
• Trouble shoong, this secon will give you the way to nd the trouble
• Test step, this secon tell you how to test the UPS aer you repair the unit
• Electric Specicaons, this secon show you the basic electric specicaon of the UPS
Important Safety Instrucons
For qualied 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 connecons or components while UPS is on.
Turn o the UPS and switch o the input breaker before removing protecve case. AC voltage is always
present if the input AC power is sll available.
High voltage may exist at DC capacitors. Before removing the protecve case, wait for at least ve minutes
aer turning o the UPS.
Verify input source (voltage and frequency) is within the maximum range before service.

Xtreme Power Conversion Corporaon
M90S Service Manual
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Uninterrupble Power Supply
2. Electric Specicaons
Input
Input Voltage 88~155
VAC(L-N)
Input Frequency 46~54 Hz for 50Hz system
56~64 Hz for 60Hz system
Input Power Factor ≥ 0.99 @100% R/RCD Load
≥ 0.97 @ 50% R/RCD Load
Input THD(Full Load) <4%@ Linear load
Generator Support
Output
Output Power (VA/Wa) 6000VA/6000W
Nominal Output Voltage 100/110/115/120/
127VAC(L-N)
Voltage Regulaon <1%(balance load)
<2% (unbalance load)
Output Frequency Follows Bypass Frequency if the bypass is ok(except the convert mode)
(50/60+0.1) Hz if bypass is not ok or in convert mode
Voltage Distoron
≤4%
for nonlinear load
≤2% @ Full Linear Load
Current Crest Rao 3:1max
Transfer Time
0ms @ Line <> Baery
0ms @ Inverter <> Bypass
<10ms @ Inverter <> ECO
Short Circuit Protecon Yes
Baery
Nominal Baery Voltage +/- 96~120V
Acceptable Baery
Quanty (PCS) (8~10)×12V/pc*2
Type/Capacity 12V/9Ah or equivalent
Backup Time (minutes)
>5 mins @ +/- 8 pcs
Baeries
>7 mins @ +/- 10 pcs Baeries
Eciency
Line Mode 91
Baery Mode 90
ECO Mode >97%

Xtreme Power Conversion Corporaon
M90S Service Manual
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Uninterrupble Power Supply
Overload Protecon
100%~110% Alarm and Transfer To Bypass aer 30min @ Line mode
Alarm and Cut O Output aer 3min @ Baery mode
110%~130% Alarm and Transfer To Bypass aer 5min @ Line mode
Alarm and Cut O Output aer 30s @ Baery mode
130%~150% Alarm and Transfer To Bypass aer 10s @ Line mode
Alarm and Cut O Output aer 10s @ Baery mode
Over 150% Alarm and Transfer To Bypass aer 200ms @ Line mode
Alarm and Cut O Output aer 200ms @ Baery mode
Auto Retransfer Yes
Interface
USB 1.1 Yes
Intelligent Slot
SNMP card (Oponal)
RS485 card (To be considered)
AS400 card (Oponal)
Dry Contact 5 channel Dry Contact Card (Oponal)
EPO Yes
Environment
Operang Temperature 0° to 40°C
Humidity <95% (No condensing)
Acousc Noise ≤58dB
Standard
ESD IEC 61000‐4‐2 Level 4
RS IEC 61000-4-3 Level 3
EFT IEC 61000‐4‐4 Level 4
Surge IEC 61000-4-5 Level 4
Conducon FCC 47 CFR15, Subpart B
Radiaon
Safety IEC62040‐1‐1
Drop ASTM D5276-94
Vibraon ASTM D4728-87
Mechanical
Inlet Terminal Block
Outlet Terminal Block and Receptacle
Outline Dimension
W x H x D (mm3) 635 *418 *132
- Net Weight (kg) 22
- Packaging Dimension
W x H x D (mm3) 580*250*870
- Gross Weight (kg) 25

Xtreme Power Conversion Corporaon
M90S Service Manual
Page 7
Uninterrupble Power Supply
3. Funconal block
As a true online UPS, the product employs a double conversion topology, comprise following funconal
blocks, as shown in Figure 3.1.
Figure 3.1 funcon block diagram
The CNTL block controls the acon of the UPS system, the CNTL also provi des the communicaon
interface for receiving and execung command from user via the panel or other communicaon
protocol. When the UPS becomes abnormal, in most case, the CNTL can provide basic informaon
indicang the status of the UPS.
The Recer and PFC blocks are the input stage of the UPS, The blocks converts the AC input power
into two stable DC power storing on the BUS capacitor. In the mean me, PFC(Power Factor Correcon)
is performed, the input current tracking the input voltage waveform, and the input power factor can be
corrected to 1, achieving maximum eciency and producing the lowest power polluon to the ulity.
The PFC block in baery mode, called also Booster, is used to convert the low voltage DC power into
higher voltage and more stable DC power, storing on the BUS capacitor also.
The Inverter block is the output stage of the UPS, used to convert the DC power from the BUS
capacitor into sine waveform output power.
When the ulity is within the tolerance range, the UPS uses the ulity input, at this me, the Recer
and PFC work; In case the ulity is outside the tolerance range, due to either the voltage or the
frequency, the UPS will stop the Recer and PFC working, start the Baery Booster. In case the input
ulity interrupts suddenly, the controller can detect the interrupon in very short me, and in the
interval before detecng the interrupon, the output power will be maintained by energy stored in the
BUS capacitor, there will never be interrupon on output. The charger charges the baery when the
ulity is normal. The charger converts the AC input power intoDC power for recharging the baery.
The Input or Output EMI secon provides EMI lter funcon. This secon can prevent the UPS from
being interfered by external electronic/magnec noise generated by the other electronic systems, and
it can prevent the noise generated inside the UPS system from interfering other systems too.
The SPS generates DC power supply needed by operaon of the circuit of the UPS itself.
The Bypass provides a path that ulity can power the output directly when the Inverter doesn’t work.

Xtreme Power Conversion Corporaon
M90S Service Manual
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Uninterrupble Power Supply
4. Working principle of the major funconal block
4.1 Switch Power Supply
The switch power supply (SPS) supplies DC power for UPS operaon. The input voltage of the SPS is the baery
or AC input voltage.
Figure 4.1 basic circuit of power supply
This is the y-back DC-DC converter, y-back operaon can be easily recognized from the posion of
the dots on the transformer primary and secondary (these dots show starts of the windings). When
Q6 is ON, the dot ends of all windings are posive with respect to their no-dot ends. Output recer
diodes D6, D7, D8 and D21 are reverse-biased and all the output load currents are supplied from
storage lter capacitors C12, C13.The primary coil of the transformer acts as an inductor and stored
energy.
When Q6 is OFF, the stored energy in the primary coil is delivered to secondary llter capacitors C18,
C20,
C22, C25 and C31.
As shown in gure 4.1, this circuit may generate several output voltage, such as +5V, +12V, -12V,
+12V(FAN), HFPW+,3843VCC.

Xtreme Power Conversion Corporaon
M90S Service Manual
Page 9
Uninterrupble Power Supply
4.2 PFC/Boost circuit
Figure 4.2 Boost circuit topology
As shown in the Figure 4.2, when Q1/Q2 are on, and D1/D2 are o, the choke (L1/L2) will store energy
and the current following through the choke will increase as me passes. When the Q1/Q2 are o, the
choke releases energy and the D1/D2 are on, the current of the choke will decrease as me passes.
Therefore, we can control the current waveform of chocks (intput current) by regulang the duraon of
Q1/Q2 on and o.
4.3 Inverter circuit
Figure 4.3 “T”three level topology
The topology works as the following. Q1&Q4 and Q2&Q3 are switched on at alternate half cycles. The juncon
voltage of Q1 and Q2 is a high frequency rectangular waveform. This rectangular wave through the LC lter will
become a standard sine wave.

Xtreme Power Conversion Corporaon
M90S Service Manual
Page 10
Uninterrupble Power Supply
4.4 Charger
The Charger is to recharge and maintain the baeries at fully charged condion .The charger charges the
baeries with a constant current at inial stage, and as baery voltage keeps increasing, the charge current
decreases accordingly unl the charge voltage reached the constant voltage level, and then the charger turns to
the oang charge mode.
The charger employed a double forward topology.
Figure 4.4 charger circuit topology
4.5 EMI Board
Input EMI board is connected between ulity and the input of recer.
Output EMI board is connected between the output of inverter and output terminal block.
C
Y
C
X
Input
C
Y
Comm on
Choke
C
Y
C
X
Output
C
Y
Figure 4.5 Topology of the EMI