Xtreme Power Conversion P80 User manual

P80 Online UPS
1000VA - 5000VA Models
Service Manual
www.xpcc.com | © 2017 Xtreme Power Conversion Corporaon. All rights reserved. (Rev 11/7/17)

Xtreme Power Conversion Corporaon
G90 Service Manual
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Uninterrupble Power Supply
Table of Contents
Overview and introducon...........................................................................4
UPS range........................................................................................................................................5
Topology..........................................................................................................................................5
Charger features..............................................................................................................................5
Baery features...............................................................................................................................5
Addional features..........................................................................................................................5
Important Safety Instrucons......................................................................6
Operaon and seng..................................................................................7
Switch panel....................................................................................................................................7
LCD Panel........................................................................................................................................7
UPS Seng....................................................................................................................................9
Operang Mode Descripon.........................................................................................................13
Faults Reference Code...................................................................................................................14
Warning indicator..........................................................................................................................14
Audible Alarm...............................................................................................................................15
Circuit principle.........................................................................................15
Funconal diagram.......................................................................................................................15
Subsystem instrucon...................................................................................................................15
Charger Sub-System......................................................................................................................16
Auxiliary Power Supply Sub-System...............................................................................................16
Inverter Sub-System.......................................................................................................................17
Output and lter Sub-System.........................................................................................................17
DC-DC Converter Sub-System.......................................................................................................18
Control board................................................................................................................................18
Regulaon & control sub-system..................................................................................................18

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G90 Service Manual
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Uninterrupble Power Supply
Protecon sub-system..................................................................................................................18
Signaling Sub-System....................................................................................................................18
Trouble Shoong.......................................................................................20
Trouble Shoong Chart.................................................................................................................20
Failure Diagnosis............................................................................................................................21
Step to open the case...................................................................................................................21
Crical component list..................................................................................................................22
Overview.......................................................................................................................................24

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G90 Service Manual
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Uninterrupble Power Supply
Overview and introducon
Rear Panel View
1. Programmable outlets: connect to non-crical loads.
2. Output receptacles: connect to mission-crical loads.
3. AC input
4. Input circuit breaker
5. Network/Fax/Modem surge protecon
6. Emergency power o funcon connector (EPO)
7. USB communicaon port
8. RS-232 communicaon port
9. SNMP intelligent slot
10. External baery connector (only available for L model)
800/1.1K/1.5K IEC Type 2K IEC Type
3K IEC Type 800/1.1/1.5K NEMA Type
2K NEMA Type 2.5K/3K NEMA Type
5K

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G90 Service Manual
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Uninterrupble Power Supply
UPS range
Standard models: 800/1000/1500/2000/3000/5000VA, 120/230V
Topology
• Line interacve type.
• Sine waveform output voltage
• High frequency transformer for DC/DC conversion and DC/AC conversion
• Low frequency transformer for buck-boost (AVR)
Charger features
• Charger works even if the UPS is in standby mode.
• 3 stage charging management.
• OVP and short-circuit protecon
• Charger smart controlled by CPU.
Baery features
• Cold start: the unit can start on baery.
• Baery deep discharge protecon: minimum baery level linked with customer load level.
• Baery test: at each start-up and then, once every week.
Addional features
• Nominal voltage: output voltage can be set through the UPS LCD panel (208/220/230/240V) (110/115/120/127V).
• Emergency Power O (EPO): EPO connector at rear panel allow to turn o the output voltage.
• Green funcon: when autonomy, the UPS will shut down automacally when equipment power consumpon
less than 5%.
• Programmable Outlet: when autonomy, the programmable outlet power supply me can be set through the
monitor soware or the UPS LCD panel.
• High Surge level immunity
• Smart fan speed control
• RS232/USB and Slot operaon simultaneous.
• Dry contact signal in DB9 port(oponal)

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G90 Service Manual
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Uninterrupble Power Supply
Aenons
For all series of UPS, they are strictly tested and carefully designed. We always do our best to make our products
more reliable and safer; this is also the goal of our company. However, due to the lifeme of electrical components
and some unpredictable reasons, there will be unavoidable failures of this UPS. If this situaon occurs, service of
qualied person is needed. This service manual will guide the technicians to repair and adjust a problemac UPS.
If the UPS sll does not work properly, please contact with us and we will be glad to solve any problems you met.
Because of the following unique features of this series UPS (Uninterrupble Power System), it is very easy to main-
tain and service.
* All major power components are put on POWER PCB.
* POWER PCB and CONTROL PCB are interconnected with connectors.
* Major parts are simply connected with exible insulated wires and plugs.
This service manual consists of 4 major parts:
• Introducon.
• Principle of operaon: It describes the funcons and principles of each part.
• Alignments: It describes the locaons and methods needed to adjust this UPS.
• Trouble shoong: This part describes the possible failure condions and procedures to repair it.
Before starng to serve this UPS, be sure to read this manual carefully for a correct and safe operaon.
Important Safety Instrucons
1. For qualied service personnel only.
2. DO NOT perform any internal service or adjustment of this product unless another person is capable of render-
ing rst aid and resuscitaon is present.
3. 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 acve.
4. Turn o the UPS and disconnect input power cord before removing outside protecve cover.
5. AC voltage is always present if the input AC power is sll available.
6. High voltage may present at DC capacitors. Before opening the outside cover, wait for at least ve minutes
aer turning o the UPS.
7. Verify input source (voltage and frequency) before service.
1. DO NOT make internal baeries short-circuited.
2. If the baery connectors are disconnected, be sure to plug in the input power cord and the input power is
available before re-connect the baery connectors.
3. Aer service, verify the polarity of baeries, the ghtness of all screws and connectors before restarng the
UPS.
Aer opening the cover, please always check the ghtness of all wires, connectors and screws rst. Then check if
there are any de-colored components inside.

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G90 Service Manual
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Uninterrupble Power Supply
Operaon and seng
Switch panel
Buon Funcon
ON/MUTE Buon • Turn on the UPS: Press and hold ON/Mute buon for at least 2 seconds to turn
on the UPS.
• Mute the alarm: Aer the UPS is turned on in baery mode, press and hold this
buon for at least 3 seconds to disable or enable the alarm system. But it’s not
applied to the situaons when warnings or errors occur.
• Up key: Press this buon to display previous selecon in UPS seng mode.
• Switch to UPS self-test mode: Press and hold ON/Mute buon for 3 seconds to
enter UPS self-tesng while in AC mode
OFF/ENTER Buon • Turn o the UPS: Press and hold this buon at least 2 seconds to turn o the
UPS
• Conrm selecon key: Press this buon to conrm selecon in UPS seng
mode.
SELECT Buon • Switch LCD message: Press this buon to change the LCD message for input
voltage, input frequency, baery voltage, output voltage and output frequency.
• Seng mode: Press and hold this buon for 3 seconds to enter UPS seng
mode when UPS is o.
• Down key: Press this buon to display next selecon in UPS seng mode.
Select + OFF/Enter Buon • Rack or Tower display switch: Press Select and OFF/Enter buons simultane-
ously for 3 seconds. The display change from/to Rack to/from Tower.
LCD Panel
Battery info
Load info
Input/output
and Battery
info
UPS status
Warning
& Fault info/
Setting
operation
Backup
time
info
Load info
UPS status
Backup time
info
Input/output
and Battery
info
Warning & Fault info/
Setting operation
Battery info
Rack Display Tower Display

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G90 Service Manual
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Backup me informaon
Indicates the backup me in pie chart.
Indicates the backup me in numbers.
H: hours, M: minute
Warning & Fault informaon
Indicates that the warning and fault occurs.
Indicates the warning and fault codes, and the codes are listed in details in 3-5 secon.
Seng Operaon
Indicates the seng operaon.
Input/Output & Baery informaon
Indicates the output/input voltage, output/input frequency or baery voltage. V: volt-
age, Hz: frequency
Load informaon
Indicates the load level by 0-24%, 25-49%, 50-74%, and 75-100%.
Indicates overload.
Indicates the load or the UPS output is short circuited.
UPS status
Indicates that programmable management outlets are working.
Indicates that the UPS alarm is disabled.
Indicates the UPS powers the output directly from the mains
Indicates the baery charger is working.
Indicates the UPS is working in boost mode
Indicates the UPS is working in buck mode
Baery informaon
Indicates the Baery level by 0-24%, 25-49%, 50-74%, and 75-100%.
Indicates low baery.
Indicates there is something wrong with baery.

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G90 Service Manual
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Uninterrupble Power Supply
LCD display wordings index
Abbreviaon Display content Meaning
ENA Enable
DIS Disable
ESC Escape
ON ON
OK OK
EP EPO
AO Acve open
AC Acve close
TP Temperature
CH Charger
RAC Rack display
TOE Tower display
SF Site Fault
EE EEPROM error
BR Baery Replacement
UPS Seng
Parameters 1
Parameters 2
There are two parameters to set up the UPS.
Parameter 1: It’s for program alternaves. Refer to below
table for details.
Parameter 2: It’s seng opons or values for each program.

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G90 Service Manual
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Output voltage seng
Interface Seng
For 208/220/230/240 VAC models, you may choose the
following output voltage:
208: presents output voltage is 208Vac 220: presents
output voltage is 220Vac
230: presents output voltage is 230Vac (Default) 240:
presents output voltage is 240Vac
For 110/115/120/127 VAC models, you may choose the
following output voltage:
110: presents output voltage is 110Vac 115: presents
output voltage is 115Vac
120: presents output voltage is 120Vac (Default) 127:
presents output voltage is 127Vac
Programmable outlets enable/disable
Interface Seng
ENA: Programmable outlets enable (Default) DIS: Pro-
grammable outlets disable
Programmable outlets seng
Interface Seng
Seng the backup me limits in minutes from 0-999
for programmable outlets which connect to non-cri-
cal devices on baery mode.

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G90 Service Manual
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Maximum charger current seng
Interface Seng
Set up the maximum charger current.
1/2/4/6/8: seng the maximum charger current at
1/2/4/6/8 Ampere. (Default: 8A)
Note: This seng is only eecve for super charger.
LCD display direcon seng
Interface Seng
RAC: the LCD display is horizontal. TOE: the LCD display
is vercal.
Autonomy limitaon seng
Interface Seng
Parameter 2: Set up backup me on baery mode for
general outlets.
0-999: seng the backup me in minutes from 0-999
for general outlets on baery mode.
DIS: Disable the autonomy limitaon and the backup
me will depend on baery capacity. (Default)
Note: When seng as “0”, the backup me will be only
10 seconds.

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G90 Service Manual
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Baery total AH seng
Interface Seng
Parameter 2: Set up the baery total AH of the UPS.
7-999: seng the baery total capacity from 7-999 in
AH. Please set the correct baery total capacity if ex-
ternal baery bank is connected.
EPO logic seng
Interface Seng
Set up the EPO funcon control logic.
AO: Acve Open (Default). When AO is selected as EPO
logic, it will acvate EPO funcon with Pin 1 and Pin 2
in open status.
AC: Acve Close. When AC is selected as EPO logic, it
will acvate EPO funcon with Pin 1 and Pin 2 in close
status.

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G90 Service Manual
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Uninterrupble Power Supply
Operang Mode Descripon
Operang mode Descripon LCD display
ECO mode When the input voltage is within
voltage regulated range, UPS will
power the output directly from the
mains. ECO is an abbreviaon of Ef-
ciency Correcve Opmizer. In this
mode, when baery is fully charged,
the fan will stop working for energy
saving.
Buck mode when AC is normal. When the input voltage is higher
than the voltage regulaon range
but lower than high loss point, the
buck AVR will be acvated.
Boost mode when AC is normal. When the input voltage is lower
than the voltage regulaon range
but higher than low loss point, the
boost AVR will be acvated.
Baery mode When the input voltage is beyond
the acceptable range or power fail-
ure and alarm is sounding every 10
seconds, UPS will backup power
from baery.
Standby mode UPS is powered o and no output
supply power, but sll can charge
baeries.

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G90 Service Manual
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Uninterrupble Power Supply
Faults Reference Code
Fault event Fault code Icon Fault event Fault code Icon
Bus start fail 01 x Inverter output short 14 x
Bus over 02 x Baery voltage too
high
27 x
Bus under 03 xBaery voltage too
low
28 x
Inverter so
start fail
11 x Over temperature 41 x
Inverter voltage
high
12 x Overload 43
Inverter voltage
Low
13 xCharger failure 45 x
Warning indicator
Warning Icon (ashing) Alarm
Low Baery Sounding every 2 seconds
Overload Sounding every second
Baery is not connected Sounding every 2 seconds
Over Charge Sounding every 2 seconds
Site wiring fault Sounding every 2 seconds
EPO enable Sounding every 2 seconds
Over temperature Sounding every 2 seconds
Charger failure Sounding every 2 seconds
Baery fault Sounding every 2 seconds
EEPROM error Sounding every 2 seconds
(At this me, UPS is o to remind
users of something wrong with bat-
tery)
Baery replacement Sounding every 2 seconds

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G90 Service Manual
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Uninterrupble Power Supply
Audible Alarm
Baery Mode Sounding every 5 seconds
Low Baery Sounding every 2 seconds
Overload Sounding every second
Fault Connuously sounding
Circuit principle
Funconal diagram
Input
Input Relay(Safety Backfeed Relay)
Boost Relay Buck Relay
AVR TX
TVSS
EMI/RFI
Input Filter
O/P RLY
com Relay
UPS
output
P1 Relay
Series resonant DC/DC
converter
HF
Battery charger Battery
Power supply
D2D
controller
Full Bridge
Inverter
CNTL
F r o n t p a n e l
EPO
DB9
RS232 (Dry contact optional)
USB
Mini-Slot
USB
MCU
Main Control
MCU
+
-
External battery connector
+
-
HF
Cr
Line interactive UPS
EMI/EFI
Output
Filter
OP CT
INV CT
L
N
G
L
N
G
L
Subsystem instrucon
This Oma series UPS system contains two major PCB assemblies. They are including:
1. Power board Contains major parts of (1) Charger, (2) Auxiliary power supply, (3) DC-DC converter, (4)
Inverter, (5) Output lter.
2. Control board Contains major parts of protecon, signaling circuits, regulaon and control circuits of
inverter
The funconal diagram shows how the major circuits are connected and illustrates the overall system funcons.
The block diagram shows the UPS at normal operaon from le to right. this Line-interacve UPS system ulizes
AVR TX to achieve high ecient performance. This UPS can deliver a clean, regulated sine-wave output in case
the input voltage is loss and UPS transfer to baery mode at any load under full load. The sub-systems are
described as below:
800 / 1000 / 1500 / 2000 / 3000/ 5000 VA

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As shown in funconal diagram, the power stage consists of charger, DC power supply, DC-DC converter, inverter
and output lter.
Charger Sub-System:
The purpose of charger is to charge and to maintain the baeries at full charged condion. Refer to circuit
diagram, the voltage y back switching power supply provides a constant DC voltage (13.65Vdc/PCS baery) for
baeries. Besides providing constant voltage, the power supply also limits the current owing into baeries and
therefore protects and prolongs the life me of charged baeries.
Note: For detail circuit diagram and key waveforms and values, see Annexures-circuit diagram.
Auxiliary Power Supply Sub-System:
The input of the auxiliary power supply is connected to the baery bus, i.e., the output of the charger. The
output of auxiliary power supplies provides +12 Vdc for the bias supply of IC’s working voltage and the fan(s)
voltage. The DC power supply works only when the 12 Vdc regulator supplies Vcc to its control IC. To have proper
operaon of 12 Vdc regulators, its input power is controlled by the switch as indicated in circuit diagram.
Block Diagram for UPS
Charger Circuit Diagram

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G90 Service Manual
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Uninterrupble Power Supply
Note: For detail circuit diagram and key waveforms and values, see Annexures-circuit diagram.
Inverter Sub-System:
The UPS transfers DC bus voltages to the AC output voltage through an inverter of full bridge conguraon at
normal operaon. The schemac diagram of inverter is shown below. To construct a high frequency (19.2 kHz)
PWM inverter, the drivers receive switching signals from PWM generaon circuit through a pair of photo-
couplers to trigger the upper IGBT and the lower IGBT alternately. The output of IGBT’s is ltered by an LC circuit
to reduce the o/p voltage harmonics distoron.
Note: For detail circuit diagram and key waveforms and values, see Annexures-circuit diagram.
Output and lter Sub-System:
The bypass relay receives signal from control circuit to switch the output of the UPS from ECO to inverter, and
vice versa. The output noise lter circuit blocks EMI noise to the loads. Note: For detail circuit diagram and key
waveforms and values, see Annexures-circuit diagram.
Auxiliary power supply circuit diagram
Schemacs for Inverter

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G90 Service Manual
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DC-DC Converter Sub-System:
The major funcon of the UPS is to deliver accurate AC power to the loads connected to it whenever the AC line
is correct or fails. In this system, the baeries release the stored energy to supply inverter immediately upon AC
line fails.
Refer to circuit diagram, the baery voltage is transformed through a push-pull DC-DC converter to 360Vdc(180V
for LV model) as DC buses for inverter. When the line fails, the 360Vdc (180V for LV model) DC sources are caught
up to supply the power needed by the inverter immediately.
Note: For detail circuit diagram and key waveforms and values, see Annexures-circuit diagram.
Control Board
These assemblies are the control center of UPS. It is composed of three major circuits as following.
REGULATION & CONTROL SUB-SYSTEM:
This poron can be seen as brain of the UPS. It provides the control pulses to the switching elements which
deliver power to the output. The sub-system also regulates the output to ensure that the UPS is delivering
constant AC voltage to the loads.
The inverter signal is sensed directly by resistor division. It is compared with a reference signal from sine wave
generator. The dierence of these two signals (error signal) alter the pulse widths of PWM signals which control
the duty cycles of switching elements to regulate the output voltage within specicaon
PROTECTION SUB-SYSTEM:
The UPS provides the following protecon circuits:
Overload protecon
The load detector senses the load current. I.e. the inverter current, and sends the signal by two paths. In baery
mode, the UPS will go to failure mode if overload condion happened. The panel will indicate the fault condion.
There are two kinds of protecon in our UPS:
DC -DC circuit

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A. Overload Protecon: The UPS collects the connuous overload signals through CPU switch the output
relay.
In line mode, if the output load is higher than 103% and lower than 110% of rated load (VA ,or Waage) the UPS
will warning, aer 5minutes go to fault mode. If the output load is between 110% and 130% of rated load (VA ,or
Waage) the UPS will warning, aer 10seconds go to fault mode.. If the output load is higher than 130% of rated
load, the UPS will go to fault mode aer 1second.
In baery mode, if the output load is higher than 110% and lower than 120% of rated load (VA ,or Waage) the
UPS will warning, aer 0.5minutes go to fault mode. If the output load is between 120% and 130% of rated load
(VA ,or Waage) the UPS will warning, aer 10seconds go to fault mode.. If the output load is higher than 130%
of rated load, the UPS will go to fault mode aer 1 second.
B. Cycle by Cycle Current Limit: When output loads sink a high surge current for a short me, a high
inverter current is detected and the inverter switches, i.e. the IGBTs, are turned o pulse by pulse to protect
themselves from thermal runaway. The output relay stays at inverter output posion unless a connuous over-
load is detected or an abnormal inverter operaon occurs.]
Baery over or under shut down
Upon the baery voltage declines to baery-under/over level, the UPS will warning and the LCD will display the
fault code, then shut down.
In case of the baery voltage is high voltage, the UPS will warning and the LCD will display the fault code.
Inverter output abnormal protecon
The inverter failure signal shuts down the inverter immediately, makes the buzzer a connuous alarm, and the
LCD displays the fault code.
“The failure signal latches itself unless SW o or baery is empty”.
Over temperature protecon
The thermal switch detects the temperature of PSDR heat sink. The thermal switch is electrically connected to
the CPU. An opened thermal switch is thought as temperature failure by the UPS. The LCD will display the fault
code.
Bus over/under/unbalance-voltage protecon
To protect any BUS over/under voltage condion. The LCD will display the fault code.
Signaling Sub-System
When the AC line is unable to supply, the baeries release energy inside to supply the inverter immediately. At
the same me, the buzzer beeps every 5 seconds.
Upon the baeries are discharged to baery-low level, the baery-low signal is acvated and the buzzer beeps
every 2 second.

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G90 Service Manual
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Trouble Shoong
Due to careful design and strict tests of our products, fail of UPS seldom occurs. However, once they do fail in
some situaons, please check them according to Trouble Shoong Chart that will help you solve the most prob-
lems on UPS.
Trouble Shoong Chart