Xtreme Power Conversion P91 User manual

P91, TX91, TX91L, TXVR
Service Manual
www.xpcc.com | © 2019 Xtreme Power Conversion Corporaon. All rights reserved. (Rev 4/26/19)

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 2
Uninterrupble Power Supply
Table of Contents
1 General Informaon..................................................................................3
1.1 Geng Started...........................................................................................................................3
1.2 Important Safey Instrucons....................................................................................................3
2 Specicaons............................................................................................4
3 Funconal Block........................................................................................7
4 Working Principle of the Major Funconal 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 Funcon explanaons for each PCB.........................................................11
5.1 SPS-Charger Board...................................................................................................................11
5.2 Control Board...........................................................................................................................12
5.3 Communicaon 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 Troubleshoong......................................................................................18
7.1 LCD Panel Display Paern Denion.......................................................................................18
7.2 Repair.......................................................................................................................................23
7.2 Repair.......................................................................................................................................23
8 Test Step.................................................................................................28
9 Appendix.................................................................................................29

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 3
Uninterrupble Power Supply
1 General Informaon
1.1 Geng 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 secon, so you should get the basic operaon 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 secons:
● General Informaon, this secon shows you the general informaon of the service manual.
● Electric Specicaons, this secon shows you the basic electric specicaon of the UPS.
● Funconal block, this secon shows you the major funconal block of the UPS.
● Working Principle of the Major Funconal Block, this secon shows you the working principle of the
major funconal block.
● Funcon explanaons for each PCB, this secon explains you all the PCBs of the UPS system.
● Interface, this secon shows you the LCD interface, including display and seng.
● Trouble Shoong, this secon gives you the way to nd the problems.
● Test Step, this secon tells you how to test the UPS aer you repair the unit.
● Appendix, this secon shows you the basic waveforms for reference and the basic communicaon
commands.
1.2 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 ex-
posed 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
P91, TX91, TX91L, TXVR Service Manual
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2. Specicaons
MODEL NUMBER P91-5K P91-6K P91-10K
CAPACITY Power rang 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 oponal transformer)
Frequency 50/60Hz ± 4Hz
THD (full load) < 4%
Overload capacity 110% 10 min; 130% 1 min; > 130% 1 sec
Eciency 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 connecon L6–30P (5, 6kVA) Terminal Block (5,6,10kVA)
MODULE Output connecon (2) L6-30R+(2) C19 Terminal block + (1) L6-30R+(2) C19
Oponal: L6–30R, L6–20R, 6–20R Oponal: L6–30R, L6–20R, 6–20R
ENVIRONMENT Operang temperature 32–104°F (0–40°C)
Audible noise < 55dBA < 58dBA
Altude 11,500  above sea level
APPROVALS UL, FCC, RoHS (pending)
WARRANTY 3 years electronics, 3 years baery warranty (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, USB, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX Soware 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 rang 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 Regulaon ± 1%
Frequency 50Hz ± 0.1Hz or 60 Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency up to 97% ECO mode, 91% online mode
Harmonic Distoron <2% @ 100% linear load (regardless of input distoron)
PHYSICAL Input/output Terminal blocks or oponal 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 connecon Terminal Block with 6 L6-30P* Terminal Block
120V receptacle opons 5-15/20R
240V receptacle opons L6-30R, L6-20R, 6-15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 11,500  above sea level
APPROVALS UL, cUL, RoHS
WARRANTY 3 years electronics (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware CD
AVAILABLE OPTIONS 5 year extended warranty, output PDU, input L6-30P cord (for 3.8kVA, 5kVA, 6kVA)

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
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Uninterrupble Power Supply
*Depending on load level.
MODEL NUMBER TX91-3.8K TX91-5K TX91-6K TX91-10K
CAPACITY Power rang 3.8kVA (3.8kW) 5kVA (5kW) 6kVA (6kW) 10kVA (10kW)
INPUT Voltage (nominal) 208VAC (200VAC, 220VAC, 230VAC, 240VAC oponal)
Voltage range 110-300VAC
Frequency 46–64Hz auto-sensing
OUTPUT Voltage 240/120VAC or 230/115VAC
Voltage regulaon ± 1%
Frequency 50/60Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency Up to 97% ECO mode, 91% online mode
BATTERY/CHARGER Baery type Sealed, maintenance-free lead acid
Baery quanty and size
(standard / XR models) (20) 12V 9AH / (20) 12V 580W
Charger voltage/current 273VDC / 1A-4A (selectable)
PHYSICAL Input/output Terminal blocks or oponal 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 Baery quanty 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 connecon Terminal blocks or 6 , L6–30P* Terminal blocks
120V receptacle opons 5–15/20R
240V receptacle opons L6–30R, L6–20R, 6–15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 11,500  above sea level
APPROVALS UL1778, cUL, FCC Class A, RoHS
WARRANTY 3 years electronics, 3 years baery warranty (USA and Canada)
COMMUNICATIONS INTERFACE RS-232, EPO, intelligent slot for oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware CD
AVAILABLE OPTIONS 5 year extended warranty, output PDU, input L6–30P cord (for 3.8kVA, 5kVA & 6kVA)

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
Page 6
Uninterrupble Power Supply
MODEL NUMBER TX91L-3.8K TX91L-5K TX91L-6K TX91L-10K
CAPACITY Power rang 3.8kVA (3.8kW) 5kVA (5kW) 6kVA (6kW) 10kVA (10kW)
INPUT Voltage (nominal) 208VAC (200VAC, 220VAC, 230VAC, 240VAC oponal)
Voltage range 110-300VAC
Frequency 46–64Hz auto-sensing
OUTPUT Voltage 240/120VAC or 230/115VAC
Voltage regulaon ± 1%
Frequency 50/60Hz ± 0.1Hz
Overload capacity 200% for 1 min 150% for 1 min 130% for 1 min
Eciency 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 oponal 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 connecon Terminal blocks or 6 , L6–30P* Terminal blocks
120V receptacle opons 5–15/20R
240V receptacle opons L6–30R, L6–20R, 6–15/20R, C19
ENVIRONMENT Temperature 32–104°F (0–40°C)
Audible noise < 50dBA
Altude 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 oponal cards (Web/SNMP, Relay/dry contact, Modbus)
INCLUDED IN BOX User manual, RS-232 communicaon cable, ViewPower Soware 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 Corporaon
P91, TX91, TX91L, TXVR Service Manual
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Uninterrupble Power Supply
3. Funconal Block
As a true online UPS, the product applies a double conversion topology, comprising 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. It also provides the communicaon interface for receiving
and execung command from users 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.

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
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Uninterrupble Power Supply
The Recer 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 meanme, PFC (Power Factor Correcon) 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 eciency and produce lowest power polluon to the ulity.
The PFC block in baery 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 ulity is within the acceptable range, the UPS will provide power directly from the ulity input and
the Recer and PFC will be executed at the same me. When the ulity is outside of the acceptable range, no
maer it’s because of input voltage or input frequency, the UPS will shut down the Recer and PFC funcons
and turn on the Baery Booster. In case of sudden interrupon from input ulity, the controller can detect the
interrupon in very short me. During the short interval of detecng the interrupon, the output power will be
provided by the power stored in the BUS capacitor. In this way,
there is no any interrupon on output power.
The charger charges the baery 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 dierent voltage corresponding to dierent baery
pieces by changing the jumper on the CNTL board, either LCD or command.
The Input EMI secon provides EMI lter funcon. The input EMI lters can prevent the UPS from being
interference by external electronic/magnec 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 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 is not executed. The Maintenance Bypass
provides another path that ulity can power the output directly when UPS is in maintenance status.
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 source of the SPS is the
grid when the grid voltage is higher than 110V . Or the input source of the SPS is the baery.
Figure 4.1 Basic circuit of power supply

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P91, TX91, TX91L, TXVR Service Manual
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Uninterrupble Power Supply
Figure 4.1 is a yback converter. When Q1 is on, all recer 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 recer 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 regulang 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 regulang the duty cycle of Q1/Q2/Q3/Q4, including sine wave form.
Figure 4.3 Three level inverter bridge

Xtreme Power Conversion Corporaon
P91, TX91, TX91L, TXVR Service Manual
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4.4 Charger
The funcon of charger is to charge and maintain the baeries at fully charged condion. The charger charges
the baeries with a constant current at inial stage. At the same me, the baery voltage keeps increasing unl
reaching the constant charge voltage point. Then, the charge current will decrease accordingly, now it’s in second
stage. Aer one hour of constant voltage charging, the charge voltage will change to oang charge voltage, in
general, the charger will control the output voltage at a constant level (13.65V±1% per baery) to opmize bat-
tery recharge me and prolong the lifeme of baeries
without overcharging.
Figure 4.4 Topology of the charger
4.5 EMI Board
Input EMI board is connected between ulity and the input of recer.
CX
CY
CY
CY
CY
CX
Input Output
Common
Choke
Figure 4.5 Topology of the EMI