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M90 & M90L Modular Online Three-Phase UPS 15kVA, 20kVA, 30kVA, 40kVA, 45kVA, 60kVA Models Service Manual www.xpcc.com | © 2017 Xtreme Power Conversion Corporation. All rights reserved. M90 & M90L Service Manual Uninterruptible Power Supply Table of Contents General Information.................................................................................... 4 Getting Started................................................................................................................................4 Important Safefty Instructions.........................................................................................................4 Electronic Specifications..............................................................................5 Environmental Parameters..............................................................................................................6 Functional Block...........................................................................................7 Working Pricipal of the Major Functional Block..............................................................................8 Switch Power Supply......................................................................................................................9 PFC/Booster....................................................................................................................................9 Inverter............................................................................................................................................9 Charger..........................................................................................................................................10 EMI Board......................................................................................................................................10 Function Explanations for Each PCBA..........................................................11 PFC Board (Power Factor Correct Board).......................................................................................11 INV Board (Inverter Board)............................................................................................................11 CNTL Board (Control Board)..........................................................................................................11 COMM Board (Communication 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 Function Flow Chart...................................................................................12 Power on Mode.............................................................................................................................12 Standby Mode...............................................................................................................................13 Xtreme Power Conversion Corporation Page 2 M90 & M90L Service Manual Uninterruptible Power Supply Bypass Mode.................................................................................................................................13 Line Mode.....................................................................................................................................14 Battery Mode................................................................................................................................15 Battery test Mode.........................................................................................................................15 Fault Mode....................................................................................................................................15 Converter Mode............................................................................................................................16 ECO Mode.....................................................................................................................................17 Shutdown Mode...........................................................................................................................17 Trouble Shooting........................................................................................17 LCD Panel Display Pattern Definition..............................................................................................1 Trouble shooting for warning icon in LCD display.......................................................................17T rouble shooting 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 section......................................................................................22 Major parameters of PFC Board section........................................................................................23 Xtreme Power Conversion Corporation Page 3 M90 & M90L Service Manual Uninterruptible Power Supply General Information Getting started This manual is for the M90 and M90L UPS. It can help service person perform the basic maintenance and repair service. This manual only focuses on the service section, so you should get the basic operation of the UPS from the user manual, and make sure you had read and understood the user manual before reading the manual. The manual includes 9 sections: General Information, this section shows you the general information of the service manual. Electric Specifications, this section shows you the basic electric specification of the UPS. Functional block, this section shows you the major functional block of the UPS. Working Principle of the Major Functional Block, this section shows you the working principle of the major functional block. Function explanations for each PCB, this section explains you all the PCBs of the UPS system. Interface, this section shows you the LCD interface, including display and setting. Trouble Shooting, this section gives you the way to find the problems. Test Step, this section tells you how to test the UPS after you repair the unit. Appendix, this section shows you the basic waveforms for reference and the basic communication commands. Important Safety Instructions For qualified 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 connections or components while UPS is on. Turn off the UPS and switch off the input breaker before removing protective case. AC voltage is always present if the input AC power is still available. High voltage may exist at DC capacitors. Before removing the protective case, wait for at least five minutes after turning off the UPS. Verify input source (voltage and frequency) is within the maximum range before service. Xtreme Power Conversion Corporation Page 4 M90 & M90L Service Manual Electronic Specifications Uninterruptible Power Supply Model Power kVA Power kW Mains Input (Rectifier input Line) Input Topology Nominal Voltage Voltage Range (Full Load) Voltage Range (Derating) Voltage Comeback Nominal Frequency Frequency Range Synchronized Range Power Factor THD i (100% load) Mains Input (Bypass) Input Topology Nominal Voltage Voltage Range Nominal Frequency Frequency Range Transfer Time (between Bypass and Inverter) M90 20 40 60 18 36 54 Three Phase, Neutral + Ground 208/220 156 ~ 253 100% load; 121V~ 253V with <70% Load Low Loss Voltage +10V, High Loss Voltage -10V 50Hz/60Hz(Auto-selectable) 40Hz ~ 70Hz +/- 1Hz, +/- 2Hz, +/- 4Hz (default: 4Hz) > 0.99 at 100% load, >0.98 at 50% load < 3% Three Phase, Neutral + Ground 208V/220V Upper limit: +10, +15, default: +15% Lower limit: -10, -20, default:-20% 50Hz/60Hz +/- 1Hz, +/- 2Hz, +/- 4Hz (default: 4Hz) Synchronous transfer: <= 1ms Asynchronous transfer: < 1 cycle Model Output Output Topology Nominal Voltage Voltage Regulation (Steady state) Voltage DC Offset Synchronized Range (Synchronize to Bypass) Overload Capability Crest Factor V THD M90 Three Phase, Neutral + Ground 208V/220V L-L < 1% Typical (balanced load) < 2% Typical (unbalanced load) < +/-50mV +/- 1Hz, +/- 2Hz, +/- 4Hz (default: 4Hz) 1 hour for 105 ~110%, 10 mins for 111~125%, 1 min for 126~150%, 200ms for >150% 3:1 100% linear load: <2% 100% nonlinear load: <4% (PF = 0.8 ~ 1) Xtreme Power Conversion Corporation Page 5 M90 & M90L Service Manual Efficiency Model Battery Nominal Voltage Battery Charger Floating Voltage Boost Charging Temperature compensation (Option) Charger Voltage Regulation Ripple Voltage Ripple Current Charger Power* Maximum charging current* > 92.5 % at over 50% load (Power Module Measurement) M90 +/- 120V 2.3V/cell 2.35V/cell -3mV/°C/cell < 1% < 1% < 5% 20% of nominal power 8A Uninterruptible Power Supply *At low input voltage the UPS recharge capability increases with load decrease. Environmental Parameters Model Operating Temperature Range Storage Temperature Relative Humidity Altitude M90 0°C ~ 40 °C (Output Capacity will be de-rated when temperature is over 30°C, @ 35°C de-rated to 90%; @ 40°C, de-rated to 80%) -15°C~60°C(UPS) 0~35°C(Battery) 0-95%( No condensing) <1000m for Nominal power (Over 1000m the power derating is 1 % every 100m) Mechanical Requirements Model Dimensions (WxHxD) Noise (1m) full load IP protection M90 515mm x 760mm x 1000mm Max. 70 dB IP20 Module Power Module Specification Xtreme Power Conversion Corporation Page 6 M90 & M90L Service Manual Dimensions (WxHxD) Net Weight Uninterruptible Power Supply 490 x 130 (3U) x 736.5 mm 34.5 kg Functional Block As a true online UPS, the product applies a double conversion topology, comprising functional blocks as shown in the figure below. Function Block Diagram The CONTROL block in the module controls the action of the UPS system. The control board detects the voltage and current to control PFC and inverter, also they supply the protection for the UPS, when the UPS becomes abnormal. In most case, the CNTL can provide basic information indicating the status of the UPS. The CONTROL block in the STS controls the action of Bypass SCR. It works with COMM board and LCD panel to be user interface as well. The COMM block provides the communication interface for receiving and executing command from users. The IPOP 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 time, PFC (Power Factor Correction) 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 efficiency and produce lowest power pollution to the utility. The PFC block in battery 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. Xtreme Power Conversion Corporation Page 7 M90 & M90L Service Manual Uninterruptible Power Supply 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 utility is within the acceptable range, the UPS will provide power directly from the utility input and the Rectifier and PFC will be executed at the same time. When the utility is outside of the acceptable range, no matter it's because of input voltage or input frequency, the UPS will shutdown the Rectifier and PFC functions and turn on the Battery Booster. In case of sudden interruption from input utility, the controller can detect the interruption in very short time. During the short interval of detecting the interruption, the output power will be provided by the power stored in the BUS capacitor. In this way, there is no any interruption on output power. The charger charges the battery when the utility is normal. The charger converts AC input power to DC power for recharging the battery. The Input and Output EMI section provides EMI filter function. The input and output EMI filters can prevent the UPS from being interference by external electronic/magnetic 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 operation of the circuit of the UPS itself. The Bypass provides a path that utility can power the output directly when the Inverter is not executed. The Maintenance Bypass provides another path that utility can power the output directly when UPS is in maintenance status. Working Principle of the Major Functional Block Switch Power Supply The Switch Power Supply (SPS) supplies DC power for UPS operation. The input source of the SPS is the battery, or the AC input. TX D2 HFHF+ +12V.F AN +12V.P D3 Q5 D7 7812 +12V DC D4 D9 7912 7805 -12V +5V Basic circuit of power supply Xtreme Power Conversion Corporation Page 8 M90 & M90L Service Manual Uninterruptible Power Supply The figure above is a flyback converter. When Q5 is on, all rectifier diodes (D2/D3/D4/D9) are on open status and all output capacitors 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 Q5 is off, primary current will stop and all rectifier diodes (D2/D3/D4/D9) 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 time, it will charge output capacitors including +12V, -12V, +5V, +12V.P, +12V.Fan, and HF-power. The power of +12V, -12V, +5V, +12V.P, +12V.Fan 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. PFC/Booster Q3 Q5 +V bus D1 Q1 C1 N R/S/T Q4 Battery Q6 Q2 L2 N C2 D2 -V bus PFC/Booster As shown in the Figure4.2, when Q3/Q4is on and D1/D2 is off, the current will increase to store energy in choke (L1/L2). When the Q3/Q4 is off and D1/D2 is on, the choke will release energy. Therefore, we can control the current in chokes (input current) by regulating the time of Q3/Q4 on and off. There are three independent PFC/ Booster for each phase. Inverter The input of the Neutral Point Clamped(NPC) Inverter topology is two DC voltages, and the output is an AC voltage, as shown in the Figure4.3.When Q2is on and Q4 is off, the Q3 and Q1 are continued on and off for on upper of sine wave. When Q3 is on and Q1 is off, the Q4 and Q2 are continued on and off for on lower of sine wave. The L1 and C1 are AC +V bus power filter. D1 N D2 -V bus Q2 D4 L1 Q3 D5 Q4 D6 INV. ST S Relay 1 C1 Vo N Xtreme Power Conversion Corporation Page 9 M90 & M90L Service Manual Uninterruptible Power Supply Neutral Point Clamped Inverter Charger The function of charger is to charge and maintain the batteries at fully charged condition. The charger charges the batteries with a constant current at initial stage. At the same time, the battery voltage keeps increasing until reaching the constant charge voltage point. Then, the charge current will decrease accordingly, now it's in second stage. After constant voltage charging, the charge voltage will change to floating charge voltage, in general, the charger will control the output voltage at a constant level to optimize battery recharge time and prolong the life time of batteries without overcharging. L1 +Vbus Q3 Q1 D3 D1 N D2 -V bus Q2 D4 Q4 Topology of the charger EMIBoard Input EMI board is connected between utility and the input of rectifier. Output EMI board is connected between the output of inverter and output terminal block. Topology of the input/output EMI Xtreme Power Conversion Corporation Page 10 M90 & M90L Service Manual Function explanations for each PCBA PCB information of Power module M90 Item PCBA Name PCBA serial number 1 STS Main Board 71-301695-xxG 2 Communication Board 71-300826-xxG 3 SPS Board 71-301616-xxG 4 Interface Board 71-300869-xxG 5 EMI Board 71-301675-xxG 6 Panel Main Board 71-301704-xxG 7 Panel Key Board 71-300846-xxG 8 Panel LED Board 71-300528-xxG 9 Parallel Board 71-300821-xxG Uninterruptible Power Supply Quantity 1 1 2 1 1 1 1 1 1 Remark PFC board (Power Factor Correct Board) The PFC board consists of Rectifier and PFC/Booster. When UPS works in line mode, the Rectifier and PFC will work, It changes the AC power to DC power stored in the BUS capacitor. When works in Battery mode, the PFC will only work as boost to get the higher DC power. INV board (Inverter Board) The INV Board includes STS and Inverter. It supplies the power for the system, and it converts the DC power to a pure sine waveform, in the purpose of less or no transfer time, there is one STS. CNTL board (Control Board) The CNTL board is the core of the UPS system. It controls the actions of the semiconductors and other mechanical switches. COMM board (Communication Board) The COMM board is charged of display of the LED/LCD, the communication with the computer, and other important tasks IPOP board There are charger, input and output EMI on IPOP board. The charger is fully charged the battery capacity. Input EMI and output EMI are interference prevention at conducted and radiated. Pre-charger board The Pre-charger board function is Pre-charging BUS capacity. Parallel board The Parallel board is used for parallel communication when the UPS system is running in parallel mode. Panel Main/LED/key board The Panel board provides LED and LCD display to the users. Xtreme Power Conversion Corporation Page 11 M90 & M90L Service Manual Uninterruptible Power Supply EMI board The EMI board can prevent the UPS from external electronic/magnetic noise generated by other electronic sys- tems, and also prevent other systems from the noise generated inside of the UPS system. SPS board The SPS board is DC power supply. It used to provide power to all function board. STS main board The STS main board is control the bypass SCR and FAN control and communication. Interface board The interface board is Dry Contact board. Dry contact refers to a contact of a relay which does not make or break a current. Usually some other relay or device has the job of starting or stopping the current. Function Flow Chart This chapter describes the various functional states on front panel. Power on Mode UPS Mode Power On Mode Description A:Off, B:Off, C:Off, D:Off, E:Off, F:Off, G:Off Xtreme Power Conversion Corporation Page 12 M90 & M90L Service Manual Standby Mode Uninterruptible Power Supply UPS Mode Power On Mode Bypass Mode Description A:Off, B:Off, C:Off, D:Off, E:Off, F:Off, G:Off UPS Mode Bypass Mode Description A:On, B:On, C:On, D:On, E:Off, F:Off, G:Off Xtreme Power Conversion Corporation Page 13 M90 & M90L Service Manual Line Mode Uninterruptible Power Supply UPS Mode Line Mode Battery Mode Description A:Off, B:Off, C:On, D:On, E:On, F:Off, G:On UPS Mode Line Mode Description A:Off, B:Off, C:Off, D:Off, E:Off, F:On, G:On Xtreme Power Conversion Corporation Page 14 M90 & M90L Service Manual Battery Test Mode Uninterruptible Power Supply UPS Mode Battery Test Mode Fault Mode Description A:Off, B:Off, C:Off, D:Off, E:Off, F:On, G:On UPS Mode Fault Mode Description A:On, B:On, C:Off, D:Off, E:Off, F:Off, G:Off A:Off, B:Off, C:Off, D:Off, E:Off, F:Off, G:Off Xtreme Power Conversion Corporation Page 15 M90 & M90L Service Manual Converter Mode Uninterruptible Power Supply UPS Mode Converter Mode ECO Mode Description A:Off, B:Off, C:On, D:On, E:On, F:Off, G:On UPS Mode ECO Mode Description A:On, B:On, C:On, D:On, E:On, F:Off, G:Off Xtreme Power Conversion Corporation Page 16 M90 & M90L Service Manual Shutdown Mode Uninterruptible Power Supply UPS Mode Shutdown Mode Description A:Off, B:Off, C:Off, D:Off, E:Off, F:Off, G:Off Trouble Shooting This section describes how to find the troubles when UPS is abnormal. We suggest you to follow the service procedure below: 1. Check the UPS status via LED and LCD display, the sound of the buzzer and get the warning or fault code via theRS232 if possible, otherwise listen to the description of end users. 2. Inspect failure board for static checking. 3. Replace failure components. 4. Static checking. 5. Power-on checking. 6. Test after repair Following section will help service person to solve the most problems. LCD Panel Display Pattern Definition Trouble shooting for warning icon in LCD display Any warning display implies some abnormity happened to the UPS, indicating that some situation that may endanger the reliability of the UPS has occurred, but these situations don't immediately lead to interruption of power supply. Xtreme Power Conversion Corporation Page 17 M90 & M90L Service Manual Trouble shooting for fault codes in LCD display When the UPS is fault, it will transfer to Fault mode. Uninterruptible Power Supply Representation in display LCD Fault! Bus Over Voltage Fault! Bus Under Voltage Fault! Bus Voltage Unbalance Fault! Bus Short Fault! Bus Soft Start Time Out Fault! Inverter Soft Start Time Out Fault! Inverter Voltage High Fault! Inverter Voltage Low Fault! R Inverter Voltage Short Fault! S Inverter Voltage Short Fault! T Inverter Voltage Short Fault! ST Inverter Voltage Short Explanation Conduct item DC bus voltage is too high DC bus voltage is too low DC bus voltage is not balanced Shutdown and remove this power module Check have any problem this module Shutdown and remove this power module Check have any problem this module Shutdown and remove this power module Check have any problem this module DC bus is short Shutdown and remove this power module Check have any problem this module The rectifiers could not start due to Shutdown and remove this power low DC bus voltage within module specified duration Check pre-charge of PFC PCBA Inverter bus voltage cannot reach desired voltage within specified duration Shutdown and remove this power module Check IPOP and Inverter PCBA Inverter Voltage is too high Shutdown and remove this power module Check IPOP and Inverter PCBA Inverter Voltage is too Low Shutdown and remove this power module Check IPOP and Inverter PCBA R phase inverter Output is shorted Shutdown and remove this power module Check IPOP and Inverter PCBA S phase inverter Output is shorted Shutdown and remove this power module Check IPOP and Inverter PCBA R-S inverter Output is shorted Shutdown and remove this power module Check IPOP and Inverter PCBA S-T inverter Output is shorted Shutdown and remove this power module Check IPOP and Inverter PCBA Xtreme Power Conversion Corporation Page 18 M90 & M90L Service Manual Fault! TR Inverter Voltage Short Fault! Inverter R Negative Power Fault! Inverter S Negative Power Fault! Inverter T Negative Power Fault! Over Load Fault Fault! Battery Fault Fault! Over Temperature Fault! Can Fault Fault! TRIG0 Fault Fault! Relay Fault Fault! Line SCR Fail Fault! Eeprom Fault Fault! Parallel Cable Loosen Fault Fault! DSP MCU Stop Communicate Fault! Bypass SCR Fault Warning! EPO Active Warning! Over Load Fail Uninterruptible Power Supply T-R inverter Output is shorted Shutdown and remove this power module Check IPOP and Inverter PCBA R phase inverter Output Negative Power over range Shutdown and remove this power module Check IPOP and Inverter PCBA S phase inverter Output Negative Power over range Shutdown and remove this power module Check IPOP and Inverter PCBA T phase inverter Output Negative Power over range Shutdown and remove this power module Check IPOP and Inverter PCBA The load devices are demanding Check output load more power than the UPS can supply. Battery reverse Check battery input wire( + N - ) Make sure adequate space is Shutdown and remove this power allowed for air vents and the fan is module working Check IPOP and Inverter and PFC PCBA CAN communication fault Shutdown and remove this power module Check IPOP and Control PCBA Trigger signal fault Shutdown and remove this power module Check IPOP and Control PCBA Inverter relay fault Shutdown and remove this power module Check IPOP and Control PCBA Line scr short circuit fault Shutdown and remove this power module Check IPOP and PFC PCBA Eeprom operation error Test again or Shutdown and remove this power module Check Control PCBA As stated. Shutdown Rack UPS Check Parallel PCBA and the wire As stated. Shutdown and remove this power module Check Control PCBA As stated. Check main PCBA of STS module Check SCR of STS module Check the EPO connector Check EPO connector and wire The load devices are demanding Check output Load-Capacity and more power than the UPS can specification supply. Xtreme Power Conversion Corporation Page 19 M90 & M90L Service Manual Uninterruptible Power Supply Warning! Communicate Can Fail Warning! Over Load Warning! Battery Open Warning! Battery voltage High Warning! Module Un-Lock Warning! Turn On Abnormal Warning! Charge Fail Warning! Eeprom Fail Warning! Fan Lock Warning! Line Phase Error Warning! Bypass Phase Error Warning! N Loss Warning! Internal Initial Fail Warning! CommSyn Signal Fail Warning! Comm TRIG0 Fail Warning! Redundancy Set Fail Warning! Parallel Sys Config Wrong CAN communication error Shutdown and remove this power module Check Control and Parallel PCBA The load devices are demanding Check over load have >100% more power than the UPS can supply. Battery not connected Check battery breaker or battery units Battery voltage is too High Check battery number Check charger voltage As stated. Check Module Un-Lock As stated. Check input voltage or frequency As stated. Shutdown and remove this power module Check IPOP PCBA Eeprom operation error Shutdown and remove this power module Change Control PCBA As stated. Check FANs of power module or STS module As stated. Check input Phase and sequence As stated. Check input Phase and sequence of STS Neutral loss Check N phase As stated. Shutdown and remove this power module Change Control PCBA Communicate Synchronization Signal Fail Shutdown and remove this power module Change Control PCBA or wire of RACK Communicate Trigger signal fault Shutdown and remove this power module Change Control PCBA or wire of RACK As stated. Set-up again Parallel System Configure error Shutdown and remove this power module Change Control PCBA or wire of RACK Xtreme Power Conversion Corporation Page 20 M90 & M90L Service Manual Uninterruptible Power Supply Repair In this section, some debug skills are listed to help you finding the failed components and problems as soon as possible. Before proceeding the following steps, we strongly suggest to read previous section for trouble shooting first. Basic Instruments and Tools 1. One computer with RS232 port and one standard RS232 cable; 2. Wire cutters and clamps; 3. One electric soldering iron; 4. One multimeter; 5. One oscilloscope(voltage and current probe needed); 6. Diagonal pliers, snipe nose pliers, cross screw drivers(150mm/75mmlength), flat screw drivers (75mm length) and PVC insulating tapes etc; 7. Make-self tools including Balance voltage test equipments, current limiting resistors, tubes and clamp termi- nals with different specifications; QuickStart Before any detail check for UPS, please check the components listed in the following table. This action could help you find problem quickly and make debug procedures go smoothly. Note: Make sure that the capacitor voltage is lower than the safety voltage before disassembling any parts to do checking procedure. Power module IPOP Board Component Type SCR Diode MOSFET FUSE Checked components Failure condition Q7,Q8,Q12,Q16,Q4,Q6,Q13,Q15,Q A-K Short or open 3,Q5,Q9,Q14,Q1,Q2,Q10, Q11,Q19 ,Q20,Q21,Q24,Q17,Q18,Q22,Q23,Q 46,Q47,Q48,Q49 ,Q50,Q51,Q28,Q29,Q32,Q36 D36,D7,D9,D35,D11,D32,D13,D25, Short or open D2,D1,D3,D4,D5,D7,D8,D1 0,D12,D14,D16,D21,D22 Q27,Q30,Q35,Q31,Q52,Q53 D-S short or open F15,F14,F10,F11,F12,F13,F22,F23,F open 24,F19,F20,F21,F16,F17,F18 PFC Board Component Type IGBT Checked components Failure condition Q4,Q10,Q17,Q1,Q7,Q14,Q5,Q16,Q C-E short or open 12,Q2,Q8,Q15,Q6,Q11,Q18,Q3,Q1 3,Q9 Xtreme Power Conversion Corporation Page 21 M90 & M90L Service Manual Inverter Board Component Type IGBT MOSFET Uninterruptible Power Supply Checked components Failure condition IGBT1,IGBT2,Q1,IGBT3,IGBT4,IGBT5 C-E shortor open ,IGBT6,IGBT7,IGBT8,Q2 ,IGBT9,OGBT10,Q3,IGBT11,IGBT12, IGBT13,IGBT14,IGBT15,I GBT16,Q4I GBT17,IGBT18,Q5,IGBT19,IGBT20,I GBT21,IGBT22,IGBT23,IGBT24,Q6 Q19 D-S shortor open SPS Board Component Type MOSFET Diode Checked components Q6,Q5 D2,D11,D3,D7,D4,D9,D6 Failure condition D-S shortor open Short or open Fuse Board Component Type FUSE Checked components Failure condition F1,F2,F3,F4,F5,F6,F7,F8,F9,F10,F11 open STS Main Board Component Type MOSFET FUSE Diode Checked components Failure condition Q1,Q2,Q3,Q5,Q6,Q7,Q8 D-S shortor open F10,F11,F12,F13,F16,F17,F14,F15 OPEN D35,D34,D17,D28,D29,D31,D47,D4 Short or open 8,D46,D39,D40,D38,D62 Communication Board Component Type MOSFET Diode Checked components Q2 D12,D4,D2,D11 Failure condition D-S short or open Short or open Major parameters of IPOP Board section The most likely problems occur on IPOP board section including: open fuse, broken MOSFET, broken Diode, broken SCR, and broken SCR driver resistor. IPOP Board Checked components Q7,Q8,Q12,Q16,Q4,Q6,Q13, (A,K) Q15,Q5,Q3,Q9,Q14,Q1,Q2,Q1 0,Q11,Q19,Q20,Q21,Q24,Q17 (G,K) ,Q18,Q22,Q23 Q28,Q29,Q32,Q36,Q46,Q47,Q (A,K) 48,Q49,Q50,Q51 (G,K) Instrument func- Reference Value tion Resistance >2M Resistance ·20 Resistance Resistance >2M ·30 Failed Condition Short Short Short Short Xtreme Power Conversion Corporation Page 22 M90 & M90L Service Manual Uninterruptible Power Supply R400,R399,R398,R404,R401,R403,R40 Resistance 8,R405,R407 49.9k±0.1% R323,R319,R321,R318,R344,R315 Resistance 402k±0.1% R389,R402,R406 Resistance 200K±0.1% R331,R332,R333,R355,R334,R293,R33 Resistance 5,R296,R328,R329,R330,R354,R346,R3 06,R347,R308,R325,R326,R327,R353,R 342,R343,R356,R357 750K±0.1% R24,R23,R33,R45,R18,R16, R40,R39,R1 Resistance 7,R15,R28,R42,R8,R9,R32,R31,R54,R5 3,R57,R65,R48,R49,R60,R61 47±1% R19,R20,R27,R41,R11,R13, R36,R34,R1 Resistance 2,R10,R26,R35,R6,R7,R29,R30,R50,R5 1,R56,R62,R46,R47,R58,R59 510±1% Q35,Q31 (D,S) Diode ·0.24V Voltage Droop (G,S) Resistance >50k D36,D7,D9,D35,D11,D32,D13,D25,D2, Diode D1,D3,D4,D5,D6,D8,D10,D12 Voltage Droop ·0.38V D14,D16,D22,D21 Diode Voltage Droop ·0.24V F10,F11,F12,F13,F15,F14,F22,F23,F24, Diode Voltage ·0V F19,F20, F21,F16,F17,F18 Droop Value change Value change Value change Value change Value change Value change Short or open Short or open Short or open Short or open open Note: If MOSFET/SCR is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. Major parameters of PFC Board section The most likely problems occur on PFC board section including: broken IGBT, broken Diode, and broken IGBT driver resistor. PFC Board Checked components R66,R84,R127,R62,R123,R82, R64,R80,R125 Instrument function Resistance Reference 30±1% R 7 3 , R 8 9 , R 1 4 8 , R 5 8 , R 7 6 , R 1 0 6 , Resistance R70,R146,R88,R57,R74,R105, R72,R87,R147,R56,R104,R75 10±1% R54,R71,R92,R55,R69,R91, R53, R90, R68 Resistance 2.2±1% R 6 7 , R 8 5 , R 1 2 8 , R 6 0 , R 7 9 , R 1 1 5 , Resistance R63,R124,R83,R59,R77,R114, R65,R81,R126,R61,R113,R78 49.9k±1% Q 4 , Q 1 0 , Q 1 7 , Q 1 , Q 7 , Q 1 4 , Q 5 , (C,E) Q16,Q12,Q2,Q8,Q15,Q6,Q11, Q18,Q3Q13,Q9 (G,E) Diode Voltage ·2.0V Droop Resistance >25k Failed Value change Value change Value change Value change Short or open Short or open Xtreme Power Conversion Corporation Page 23 M90 & M90L Service Manual Uninterruptible Power Supply R17,R49,R13,R45,R9,R29,R5,R25,R1 Resistance ,R21, R20, 52,R16,R48,R12,R32,R8,R2 8,R4,R24, R18,R19,R50,R51,R14,R46,R 15,R47,R10,R30,R11,R31,R6,R26,R7,R 27,R2,R22,R3,R23 162k±0.1% Value change Note: If IGBT is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. Major parameters of INVERTER Board section The most likely problems occur on Inverter board section including: broken IGBT, broken Diode and broken IGBT driver resistor. Inverter Board Checked components Instrument function R3,R12,R11,R16,R22,R26,R32,R36,R Resistance 45,R44,R49,R58,R57,R62,R68,R72,R7 8,R82,R91,R90,R97,R107,R106,R114 ,R120, R124,R130,R134,R143,R142 R4, R13, R8, R17, R23, R27, R33, R37, Resistance R46, R42, R50, R59, R54, R63, R69, R73, R79, R83, R92, R88, R98, R108, R103, R115, R121, R125, R131, R135, R144,R140 R10,R9,R7,R18,R21,R31,R28,R43, R38, Resistance R41, R56, R55, R53, R67, R64, R77, R74, R89, R84, R87, R104 ,R105, R102,R119,R116,R129, R126, R141, R136 , R139 IGBT1,IGBT2,Q1,IGBT3,OGBT4 (C,E) ,IGBT5, IGBT6, IGBT7, IGBT8, Q2 , IGBT9, IGBT10, Q3, IGBT12, IGBT11, IGBT14, IGBT13, IGBT10, IGBT15, Q4, Q5, IGBT18, IGBT17, IGBT19, IGBT20, (G,E) IGBT22, IGBT21, IGBT24, IGBT23 Diode Voltage Droop Resistance Reference 15±1% 3±1% 49.9k±1% ·2.0V >25k Failed Value change Value change Value change Short or open Short or open Note: If IGBT is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. Xtreme Power Conversion Corporation Page 24 M90 & M90L Service Manual Uninterruptible Power Supply Major parameters of SPS Board section The most likely problems occur on Inverter board section including: broken MOSFET, broken Diode , and broken MOSFET driver resistor. SPS Board Checked components Instrument function Q95,Q90,Q94,Q87 Resistance R77,R76,R73,R72,R75,R70,R69,R92, Resistance R93,R91,R97 R79,R78,R71 Resistance R84,R96,R83,R82,R85 Resistance R86 Resistance R88,R89 Resistance Q5,Q6 (D,S) Diode Voltage Droop (G,S) Resistance D2,D3,D7,D4,D9,D11,D5,D6 Diode Voltage Droop Reference Value 30k±1% 1M±1% Failed Condition Value Change Value Change 49.9k±1% Value change 20k±1% Value change 15k±1% Value change 1.5M±1% Value change ·0.25V Short or open >50k Short or open 0.3~0.7V Short or open Note: If MOSFET is OK, but the parameter is not close to the reference value, it is very possible that the corresponding driver is damaged, so please try to change the IGBT driver component. 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