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Technical presentation
EVOLUTION line UPS
Contents
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
General data
 The ASTRID UPS of the EVOLUTION series are ON-LINE
DOUBLE CONVERSION, with DC/AC isolating transformer
(inverter section)
 The whole line is designed to maximise the reliability index MTBF
by means of:
 Use of common electronic cards
 Reduced number of cabling and interconnections among the various
elements of the system
 Such solutions allow the reduction of the repairing time in case of
failure (MTTR)
General data
 The EVOLUTION series is basically composed by THREE main
models:
 PLANET/E
 HALLEY/E
 SATURN/E
(20-30kVA – 3Ph/1Ph)
(20-160kVA – 3Ph/3Ph)
(200-650kVA – 3Ph/3Ph)
 The two widest categories are divided into sub-categories,
according to the functional and technical solution chosen:




HALLEY/E
HALLEY/E
SATURN/E
SATURN/E
20÷32kVA e 40÷80kVA
100÷160kVA
200÷300kVA
400÷650kVA
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
Common technical features
 Total-controlled three-phase (6 pulses) thyristor-based rectifier
 1ph and 3Ph IGBT inverter (H bridge)
 Inverter output isolating transformer
 Thyristor-based static switch with redundant supply
 Parallelability up to 4 UPS with microprocessor load sharing
control, and communication protocol with high noise immunity
 Use of common parts and solutions on all the range
 Microprocessor control card
 LCD panel, that’s to say same data access mode
 Test software
PLANET/E 20-30kVA (3Ph / 1Ph)
 Input:





3 x 380÷415Vac
Output:
1 x 220÷240Vac
Power:
20kVA – 30kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) – Internal up to 24Ah
Crest factor: 3:1
Overload capability: 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 1
type 1
type 1
HALLEY/E 20-30kVA (3Ph / 3Ph)
 Input:





3 x 380÷415Vac
Output:
3 x 380÷415Vac
Power:
20kVA – 30kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) – Internal up to 24Ah
Crest factor: 3:1
Overload capability: 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 1
type 2
type 2
HALLEY/E 40÷80kVA (3Ph / 3Ph)
 Input:





3 x 380÷415Vac
Output:
3 x 380÷415Vac
Power:
40kVA – 60kVA – 80kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) - External
Crest factor: 3:1
Overload capability: 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 2
type 3
type 2
HALLEY/E 100÷160kVA (3Ph / 3Ph)
 Input:





3 x 380÷415Vac
Output:
3 x 380÷415Vac
Power:
100kVA – 125kVA – 160kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) - External
Crest factor: 3:1
Overload capability : 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 2
type 3
type 2
SATURN/E 200÷300kVA (3Ph / 3Ph)
 Input:





3 x 380÷415Vac
Output:
3 x 380÷415Vac
Power:
200kVA – 250kVA – 300kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) - External
Crest factor: 3:1
Overload capability: 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 2
type 3
type 2
SATURN/E 400÷650kVA (3Ph / 3Ph)
 Input:





3 x 380÷415Vac
Output:
3 x 380÷415Vac
Power:
400kVA – 500kVA – 650kVA, p.f. = 0,8
Battery:
192 cells Pb (384Vdc) - External
Crest factor: 3:1
Overload capability: 125%Pn x 10min
150%Pn x 1min
200%In x 100ms
 Rectifier:
 Inverter:
 Static switch:
type 2
type 3
type 3 (except 400kVA)
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
Rectifier
Rectifier’s features
 All the rectifiers of the EVOLUTION series UPS, from 20kVA to
650kVA, use compact-type thyristors (SemiPack) and are
manufactured according to the schematic diagram shown
previously, with small variations:
 The saturation-type choke L3 is used on the UPS up to 80kVA
 The fuse-holder BCB is installed only on the units with internal
batteries (20 and 30kVA). The battery switch is not installed on units
having higher power
 The forced cooling of the heatsink is provided starting from the 40kVA
 The rectifiers of the 500kVA and 650kVA uses two three-phase rectifier
bridges with input/output parallel connection
Rectifier typologies
 Two different types of rectifiers can be defined according to the
manufacturing solution, and particularly basing on the control cards
used
 TYPE 1
It’s the “compact” typology, as shown subsequently. The control
cards are physically separated from the thyristors and
interconnected to the firing card by means of flat cables. The 12pulse configuration is not possible.
Cards used:
 PRCH
 FIR-91
 LOOP
(PB114)
(PB113)
(PB115)
Rectifier typologies
 TYPE 2
The control card is only one and includes also the the thyristors
firing section. The card is fixed directly on the power
components.The 12-pulse configuration uses a control card for
each three-phase bridge (one in MASTER configuration, the other
SLAVE). The same solution is used in the 500kVA and 650kVA that
uses two three-phase bridge in parallel also in the 6-pulse
configuration
Cards used:
 SYNC-12
 RCLS-1
(PB116)
(PB117)
PRCH card (PB114)
 The PRCH card is composed by the following main sections:





Generation of the DC power supply (12V/24V)
Generation of the synchronism signals for the thyristors firing
Control of the rectifier AC supply voltage
Control of the internal DC supply
Generation of the thyristors turn-on signals (initial stage)
PRCH card (PB114)
Generation of the DC power supply and synchronism signals
 +24Vdc for the supply of the firing pulses
 +/-12Vdc for the supply of the control electronic circuits
 The synchronism signals are taken from a secondary winding of the
transformer and used for both the control of the AC supply voltage and
the generation of the control ramps of the thyristors’ delay angle
Synch.
+12V
+24V
R S T
U4
D13
D14
D15
1N4004
1N4004
1N4004
+
T1
IN
C8
1000u 50V
6,3x32 1A
6,3x32 1A
C10
100n
16
15
3
4
F3
C9
47u 25V
12
11
1
2
F2
+
LM7812
6,3 x32 1A
10
9
5
6
D16
D17
D18
1N4004
1N4004
1N4004
+
C11
1000u 50V
1
F1
3
14
13
2
18
17
+
GND
1
2
3
4
5
2
8
7
M2
OUT
GND
1
IN
U5
OUT
C12
47u 25V
C13
100n
3
LM7912
-12 V
A CM10 08
PRCH card (PB114)
Control of the AC supply voltage
 Input phase sequence control (signal 0_SCOK) and lighting of LED
DL1 if the phase sequence is correct
 Low mains voltage control, with FIXED threshold 400Vac -15%, and
lighting of LED DL2.
 Generation of the signal 1_ROK (mains OK) if both the previous
signals are OK
R1
DL1
+12V
2K21
R2
8K25
R
S
T
C1
470n
D2
R3
2K21
D3
5V 6
R47
100K
U1A
1
+12V
Q1
BC337
2
R4
2
1
0_SCOK
2
3 Q10
BC337
1
40106
3
2K21
R6
33K2
R5
8K25
+
C2
10u- 50V
R7
8K25
+12V
R8
R10
10K
+12V
10K
R12
R11
D8
R9
1K
+12V
R15
22K1
R17
R18
10
100K
100K
C5
470n
9
+
-
U2C
LM324
4
33K2
5
8
6
R19
10K
+
-
11
R14
10K
4
10K
C4
470n
C3
V RM
R16
10K
4
D7
3
7
2
U2B
LM324
D10
6V 2
R13
2K21
100n
+
-
11
D6
11
D5
1
U2A
LM324
DL2
1_ROK
D9
R20
2K21
PRCH card (PB114)
Control of the DC supply and rectifier start-up
 The +12V supply is controlled by a comparator. If the supply is within
the tolerance range the LED DL4 is lit and the signal 1_PSOK is
activated
 Such signal is then put in AND logic with 1_ROK (mains OK) and, if
both of them are OK, the LED DL3 is lit and the rectifier is enabled to
start-up through the signal 0_ON
DL3
R21
+12V
2K21
R23
U3A
1_ROK
U1C
1
D11
100R
3
1_PSOK
5
2
R22
806K
R25
10K
4081
+
V RM
13
+12V
R26
10K
Stop
U1B
12
+
U2D
14
3
4
1_PSOK
-
11
D12
3V 9
4
R24
10K
LM324
R27
40106
2K21
R28
909R
C7
1n
DL4
C6
40106
10u- 50V
6
0_ON
PRCH card (PB114)
Generation of the thyristors turn-on signals
 The IC TCA785 generates a ramp signal in phase with the
corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8)
 Each ramp is compared with a control level (TP5). The result of the
comparison (square wave) defines the thyristors’ delay angle
 The square wave is “mixed” with a high frequency signal (TP9). The
resulting series of pulses represents the initial stage of the thyristors
control circuit
Control
Level
+12V
+12V
High
Freq.
Mixer & Driver
C23 100n
TP9
10
TP5
U3C
9
0_ON
R41
249K
8
2
3
4
C24
470n
R42
5
S
51K2
C25
220n
6
7
D27
D28
8
GND
VS
Q2N
Q2
QU
Q1
Q1N
L
V sync C12
I
V 11
QZ
C10
V ref
R9
U9
TCA 785
16
HF
U11C
8
10
15
3
16
9
14
4081
13
U12B
ULN2804
10
9
R39
10K
TP7
U11D
5
12
4
HF
4
15
6
11
4081
10
C26
47n
9
P2
1
R43
60K4
ULN2804
9
1
U1D
40106
2
D26
3
100K
PRCH card (PB114) – Settings and controls
POTENTIOMETERS
P1
Amplitude regulation of the ramp phase R
P2
Amplitude regulation of the ramp phase S
P3
Amplitude regulation of the ramp phase T
CONTROL LED
COLOUR
DL1
Correct phase sequence
YELLOW
DL2
AC voltage in tolerance (>340Vac)
YELLOW
DL3
Rectifier ON
GREEN
DL4
Internal DC supply correct
YELLOW
 The LEDs are normally lit steady, they are OFF in case of alarm
PRCH card (PB114) – Interfaces with I/S-CL (mP)
 PRCH  I/S-CL
 MAINS FAILURE signal
• Pin 1-2 connector M1
 RECTIFIER ON signal
• Pin 1-2 connector M3
 I/S-CL  PRCH
 No controls or commands are sent by the microprocessor card to the
PRCH card
FIR-91 card (PB113)
Final stage of the thyristors control circuit
 For simplicity we will represent only two sections (they are 6 in total) of
the final stage for the thyristors control circuit
 The R-C circuit at the transformer input generates the real pulse, that
is subsequently transferred to the gate of the thyristor
 The card contains also the snubbers (R-C circuits) that limits the
commutation spikes, connected between the phases and the rectifier
output poles
C3
100n
DL1
TF1
SQUARE WA V E
1
R1
68R-5 W
R2
3
6
4
G1
D1
1N4936
R4
47R
4R7-2 W
SCR1/R
TI112046
K1
C12
100n
DL4
TF4
SQUARE WA V E
1
R17
68R-5 W
+24V
R18
3
6
4
TI112046
G2
D4
1N4936
R19
47R
4R7-2 W
SCR2/R
K2
LOOP card (PB115)
 The LOOP card is composed by the following main sections:




Voltage control loop
Battery current control loop
General control stage
Battery charging voltage thermal compensation control (OPTIONAL)
LOOP card (PB115)
Generation of the internal reference
 Whenever the signal 1_ON is active (originating from the PRCH card),
and therefore the rectifier start-up is enabled, the card generates a
stabilised internal voltage reference (VREF), that is used in the voltage
control loop
+12V C26
100n
D9
R48 100R
R49 51K
2
-
4
R51 33K
+
+
C30
100uF 25V
R53
51K
U10
R50
6
OP07
C27
VREF
100R
R52
6K81
R54
10K
3
3
1
100n
-12 V
R56 15K4
C33
1u
R55
3K92
2
1_ON
7
R57
3K32 Not mo unt.
U11
TL431A B
LOOP card (PB115)
Voltage control loop
 Generation of the SET-POINT (using the signal VREF) and
comparison with the feedback signal
 Regulation of the FLOATING and BOOST voltage (if enabled)
R7
15K4
C4
R-S2
R-S1
47n
+12V
TR-2
TR-1
R12 4K75
3
1
2
3
4
5
6
7
8
9
10
R19
1K82
R20
4K75
1
B2
3
2
2
+
-
6
TP12
U4
6
OP07
2
OP07
C14
1
R30
3K32
D1
C11
100n
1
-12 V
11
12
+V
-V
C10
100n
-12 V
-
R26 121K
2
R59
4K75
3
U6
+
7
1
1
2
3
4
5
R28
10K
3
3
M1
R25
8K25
RL2
P2
2 5K
54K9
+12V C12
100n
RL1
V REF
P5
5K
10K
R10
54K9
7
2
11
12
+12V
C6 100n
U5
3160
R21
4K75
B1
7
-
R16
4
R18
2K21
4
CN1
R15
6
4
1
5
2
100n
+
7
R11 10K
7
C8
TR-2
TR-1
R32 10K
1u
LOOP card (PB115)
Battery current control loop
 The output signal of the battery current control loop is inserted in the
control loop for the total stability
 The SET-POINT that defines the battery limitation current is adjusted
through the potentiometer P3
+12V
P3
100K
3
1
R29
820R
3
511R
D5
R36 511R
C19
100n
-
+12V
C18 100n
+12V C17
100n
TP2
R38 10K
6
3
U7 OP07
2
+
-
7
100n
V RM
R37 12K
3
U9
R39
6
OP07
2
10K
+
-
U8
6
OP07
R40 100K
C21
4
4
M1
2
+
R34 4K99
4
7
R33 100K
R35
C16
7
+12V
2
C15 100n
1
2
3
4
5
-12 V
C20
100n
R42
4K64
D3
-12 V
C22
100n
6V 4
C34
100n
100n
-12 V
R27
R45 511R
R46 511R
R43 100K
10K
D8
C25
100n
C24
100n
C23 1u
R47
10K
D7
LOOP card (PB115)
General control stage
 The output voltage and battery current control loops are joined
together
 The battery current loop has the priority only when the current is
limited during the battery re-charge phase
 The error signal Ve is used for the generation of the correct thyristors
turn-on delay angle
+12V C5
100n
3
R14
V OLTAGE LOOP
2
1
TP13
JP1
U3
+
6
-
OP07
4
C9
1
2
100K
3
P1
10K
1-2 AUT.
2-3 MAN.
+12V C3
100n
3
R31
3K92
2
100n
R23
-12 V
464K
R8
10K
7
CURRENT LOOP
3
2
D2
R41
P4
100K
3
C13
R22
10K
+
-
4
R13
1K
+12V
7
R9
10K
U2
6
OP07
C7
1
100n
220n
2
1K
-12 V
R17
10K
Ve
LOOP card (PB115)
Thermal compensation of the charging voltage
 A temperature probe, installed inside the battery room, is connected to
the terminal board M2
 The feedback signal is opportunely amplified and inserted in the
voltage control loop
V REF
R1
6K81
7
+12V
R2 10K
3
2
1
3
2
R4
178R
+
-
R5
54K9
U1
6
OP07
R3 1K
4
M2
+12V C1
100n
-12 V
C2 100n
R6 1K
All'anello di
controllo
tensione
LOOP card – Settings
POTENTIOMETER
P1
Output voltage regulation in MANUAL control mode
P2
Output voltage regulation (FLOATING voltage) in
AUTOMATIC control mode
P3
Regulation of the battery current limitation
P4
Regulation of the stability of the regulation loops (output
voltage and battery current)
P5
Output voltage regulation (BOOST voltage) in AUTOMATIC
control mode
LOOP card – Interfaces with I/S-CL (mP)
 LOOP  I/S-CL
 Signal of the battery SHUNT for the mP battery current reading (only
when the BOOST charge is enabled)
• Connector M3
 I/S-CL  LOOP
 Command of the relay RL1 for the BATTERY TEST
• Pin 3-6 connector CN1
 Command of the relay RL2 for FLOATING/BOOST commutation
• Pin 2-4 connector CN1
 Command of the relay RL3 for RECTIFIER STOP
• Pin 1-5 connector CN1
SYNC-12 card (PB116)
 The SYNC-12 card is composed by the following main sections:
 Generation of the DC power supply (12V/24V)
 Generation of the synchronism signals for the thyristors firing
SYNC-12 card (PB116)
Generation of the DC power supply
 +24Vdc for the supply of the firing pulses
 +/-12Vdc for the supply of the control electronic circuits
+24V
Q1
R7
3
2
1R 2W
BDX34C
2
1
1
3
Q2
2N2907A
+12V
U1
R8
1
IN
D2
D3
1N4004
1N4004
1N4004
+
T2
C1
1000u 50V
F4
1A 6,3x32
F5
1A 6,3x32
C4
100n
16
15
3
4
F6
C2
47u 25V
12
11
1
2
1A 6,3x32
10
9
5
6
D4
D5
D6
1N4004
1N4004
1N4004
+
C5
1000u 50V
U2
14
13
2
18
17
1
1
2
3
4
5
+
LM7812
+
GND
M2
C3
100n
2
8
7
OUT
GND
1R 5W
D1
3
IN
OUT
C6
47u 25V
C7
100n
3
LM7912
A CM10 08
-12 V
SYNC-12 card (PB116)
Generation of the synchronism signals
 The card uses a transformer with two secondary windings, displaced
by 30°, so that it can be used as the only “generator” of synchronism
signals also in the 12-pulse configuration
 The synchronism signals are used for both the control of the AC
supply voltage and the generation of the control ramps of the
thyristors’ delay angle
CN1
1
2
3
4
5
6
7
8
9
10
T1
R1
8
7
470R 3W
M1
1
2
3
4
5
F1
1A 6,3x32
F2
R3
1A 6,3x32
470R 3W
16
15
3
4
F3
R2
12
11
1
2
470R 3W
1A 6,3x32
10
9
5
6
CN2
14
13
18
17
A CM1 008
R4
470R 3W
R5
470R 3W
R6
470R 3W
1
2
3
4
5
6
7
8
9
10
RCLS-1 card (PB117)
 The RCLS-1 card is composed by the following main sections:









Control of the rectifier AC supply voltage
Control of the internal DC supply
Generation of the thyristors turn-on signals (initial stage)
Thyristors firing circuit (final stage)
Voltage control loop
Battery current control loop
Total current control loop
General control stage
Battery charging voltage thermal compensation control (OPTIONAL)
RCLS-1 card (PB117)
Control of the AC supply voltage
 Input phase sequence control (signal 0_SCOK if the phase sequence
is OK)
 Low mains voltage control, Threshold adjustable with the
potentiometer P13
 Generation of the signal 1_AR (Mains failure) in case of anomaly of
the previous signals
R165
8K25
R
S
T
U22B
3
+12V
C100
470n
D32
R176
2K21
D23 3V 9
R167
Q8
BC337
2
4
1
0_SCOK
40106
U32D
12
3
11
2K21
P13
50K
R148
3
100K
100K
C86
2
+
-
33K2
U31A
LM324
5
1
6
R156
10K
R155
2K21
4
10K
+12V
V RM
D18
+12V
R150
2
R160
+
-
11
R154
10K
DL12
MR
4
C87
470n
4093
R159
10K
R158
C83
470n
1_A R
13
R166
8K25
R152
100R
11
D30
3
D29
1
D28
C96
10u- 63V
R164
10K
4
R178
8K25
+
10
7
U31B
LM324
9
+
-
11
R175
12K
R153
10K
100n
8
U31C
LM324
D21
RCLS-1 card (PB117)
Control of the DC supply and rectifier start-up
+12V
JP5
1-2 = M
2-3 = S 1
3
SLA VE
2
R138
205K
U22C
R137
+12V
5
6
R182
40106
2
R173
10K
+
SW1
U32A
U22D
C73
22u- 50V
1
1K
2
9
8
1
3
0=FB
0=START
1=STOP
39K
+
1_A R
4093
40106
1_STOP
U30A
0=FB1
M9
0_FB
1
U26A
3
0_A T
1
2
3
4
5
6
7
8
9
10
2
+12V
1
2
8
9 1=A V ARIA
0=RA DDR. OK
1_A V
3
4
5
6
4075
4093
4075
U30B
R174
10K
R181
4
6
U32B
TP11
5
1K
0=A T
4093
6
+
4093
C97
10u- 63V
R147
806K
V RM
4
R151
10K
U22E
12
13
+12V
R149
10K
+
U31D
14 11
10
11
D16
3V 9
0=RA DDR. OK
5
4
LM324
R140
909R
C82
1n
40106
TP10
U26B
C95
10u- 63V
1_PSOK
0_ON
0=STA RT
1=STOP
RCLS-1 card (PB117)
Control of the DC supply and rectifier start-up
 The +12V supply is controlled by a comparator (signal 1_PSOK)
 Such signal is then put in OR logic with the fault signals due to the
fuses failure (0_FB) or high temperature (0_AT)
 A OR logic is used again to establish the rectifier start-up conditions,
comparing the previous signal (1_AV), the mains failure signal (1_AR)
and the stop command (1_STOP) depending on either the switch SW1
of the card or possible commands by microprocessor
 The start-up command (0_ON) is generated if none of the previous
signals is active
 In case of 12-pulse configuration it’s important to note that the logic
described previously is managed by the SLAVE rectifier too, except for
the Start/Stop signal that is generated by the MASTER card only
RCLS-1 card (PB117)
Generation of the internal reference
 The presence of the signal ON enable the soft-start of the rectifier
(1_SOFT); the signal 1-SOFT activates the circuits that generates the
stabilised internal voltage reference (VREF), that is used in the voltage
control loop
+12V C113
100n
2
+
-
1-SOFT
4
R196
54K9
+
C116
100u- 25V
R193
51K1
R192
10K
R28
100R
U34
6
V REF
OP07
C114
3
3
R11
6K81
1
100n
-12 V
R185 15K
C115 1u
R10
3K9
2
R194
51K1
7
R195
100R
D48
U1
TL431A B
All'anello di
controllo
tensione
RCLS-1 card (PB117)
Generation of the thyristors turn-on signals
+12V
High
Freq.
TP5
TP9
Mixer & Driver
C71 100n
10
+12V
Control
Level
U24C 4081
HF
U19C
8
10
4
R183
300K
3
C81
10n
R145
C105
470n
2
4
5
S
10K
6
7
D17
D15
8
GND
16
VS
Q2N
Q2
QU
Q1
Q1N
15
14
U24D 4081
13
V 11
C10
V ref
R9
U19D
12
TP7
HF
10
C80
47n
9
P12
1
R146
60K4
3
100K
+24V
DL13
TF4
1
R126
3
G3
AA
6
4
D9 R125
47R
4R7 2W
SCR1
TI112046
K3
C32
100n
DL3
TF3
1
R90
3
G4
BB
R60
68R 5W
15
13
11
C67
100n
R132
68R 5W
4
ULN2804
U25 TCA 785
To the
final
stage
12
11
V sync C12
QZ
AA
ULN2804
L
I
16
9
10 9
3
ON
R127
10K
9
1
U17B
40106
2
D33
3
6
4
TI112046
D8 R96
47R
4R7 2W
SCR2
K4
BB
RCLS-1 card (PB117)
Generation of the thyristors turn-on signals
 The IC TCA785 generates a ramp signal in phase with the
corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8)
 Each ramp is compared with a control level (TP5). The result of the
comparison (square wave) defines the thyristors’ delay angle
 The square wave is “mixed” with a high frequency signal (TP9). The
resulting series of pulses represents the initial stage of the thyristors
control circuit
 The final stage, similar to the circuit of the FIR-91 card, is integrated
inside the RCLS-1 card, as well as the snubber circuits for the
limitation of the commutation spikes
RCLS-1 card (PB117)
Voltage control loop
R37 15K4
C12
FBK
47n
+12V
C5
R5
10K
R33 4K75
3
2
R4
1K82
R30
4K75
R20
6
+12V
C14 100n
-
U3
3160
10K
R43
54K9
1
R41
54K9
R21
4K75
7
3
2
P4
5K
2
3
2
2
7
-12 V
U6
+
D3
6
P3
3
-
2
C21
1
1
4
100K
100n
R63
4K75
R38
10K
7
2
1
2
3
4
5
M1
R39 10K
1
D42
RL6
11
12
D41
D43
C15
1
OP07
-12 V
+12V
C24
100n
R40
8K25
1
R62
3K32
OP07
4
TR-1
TR-2
RL2
12
11
P5
2 5K
6
-
+12V C11
100n
7
3
3
V REF
R6
715R
RL1
U7
+
2
11
12
TST-1
TST-2
TP12
4
1
5
R2
2K21
100n
+
7
R1
7
47K 12W
1u
RCLS-1 card (PB117)
Voltage control loop
 Generation of the SET-POINT (using the signal VREF) and
comparison with the feedback signal
 Regulation of the FLOATING and BOOST voltage (if enabled)
 Further possible voltage regulation in MANUAL charge mode
(OPTIONAL) with external potentiometer and contact command of the
relay RL6 on the connector M1
 The relays RL1 and RL2 are controlled by the microprocessor card
and used respectively for the BATTERY TEST and for the BOOST
charge command
 The feedback signal is normally taken directly on the card (DC bus jumper JP3 in position 1-2). When the DC choke is installed, the signal
is taken externally and connected to the pin 6 of CN4
RCLS-1 card (PB117)
Battery current control loop
 The output signal of the battery current control loop is inserted in the
control loop for the total stability
 The SET-POINT that defines the battery limitation current is adjusted
through the potentiometer P15
P15 100K
3
1
R71 68K1
2
+12V C34
100n
+12V
C110
100n
R188
3K32
-
U33
OP07
2
10K
C112
R190
287K
TP15
7
R189
6
+
-
U11
6
OP07
C42
220n
4
2
+
3
4
3
C26 100n
R191
12K
7
R187
10K
V RM
100n
R53 100K
+12V
C27
-12 V
R58
R59
3
511R
511R
C31
100n
2
100n
U10
6
-
4
1
5
D46
+
R57
100R
P6
3
1
R56 100K
511R
C28
100n
R64 10K
C35 1u
3160
R67
511R
-12 V
C33 1u
100K
R54
C111
100n
R69 10K
2
1
2
3
4
5
6
7
8
7
CN4
C25
100n
D6
RCLS-1 card (PB117)
Total current control loop
 The output signal of the battery current control loop is inserted in the
control loop for the total stability
 The SET-POINT that defines the total limitation current is adjusted
through the potentiometer P2
R48
R46
+12V
+12V
+12V 806K
6K81
R66 10K
5
D5
+12V
4
R18 100K
C4
6V 2
R70 15K4
V RM
7
R23 511R
3
511R
+12V
C9
2
D37
+
-
2
OL
U9B
LM339
R51 68K1
-
3160
3
100n
+
R68
68K1
100n
U2
6
2
+12V C20
100n
P1
1
R49 12K
D40 N.M.
3
R16 511R
100K
2
P2
50K
3
C3
100n
TP14
U8
+
6
-
OP07
R47 100K
C30
4
1
100n
+12V
-12 V
2
100n
R17 100K
D39
C8
100n
C19 1u
7
R32
511R C10
R19 10K
3
2
+
-
U5
R52 10K
R36
6
OP07
C17
10K
1u
C37
R25 10K
R22
10K
220n
4
1
2
3
4
5
6
7
8
D38 N.M.
R26
4
1
5
CN4
100n
7
+12V
12
C7 100n
3
C23
R65
825R
-12 V
C18
100n
D4
RCLS-1 card (PB117)
General control stage
 The output voltage, battery current and total current control loops are
joined together
 The current loops have the priority only when the current is limited
(battery re-charge phase or output current exceeding the maximum
value allowed)
 The error signal Ve is used for the generation of the correct thyristors
turn-on delay angle
JP7
+12V C43
100n
TP15
R55 1K
R77
BA TTERY CURR. LOOP
2
6
-
3
OP07
4
C47
1-2 = Man
2-3 = Aut
TOTA L CURR. LOOP
12
R91
10K
13
+
U16D
14
-
LM324
11
100n
P9
10K
-12 V
R81 464K
R88
10K
D7
P8
3
C50
1
100K 220n
2
TP14
1 2
JP1
100K
R61 1K
1
TP13
U15
+
R93
10K
3
3
2
1-2 = M
2-3 = S
V E'
Rect.
Slave
4
D49
3
V OLTAGE LOOP
2
TP12
R79
10K
7
R42 1K
+12V
1
12P CURRENT BA LANCE
R97
10K
VE
RCLS-1 card (PB117)
12-pulse current balance
 A Hall effect CT, connected to the connector CN2 of the RCLS-1
MASTER, control the current difference of the two bridges
 The error signal, opportunely amplified and filtered, is used to vary the
control level in the circuit that generates the thyristors delay angle
P10 50K
3
R115
1
-12 V
33K2
4
33K2
2
R108
+12V
5
C51 100n
3
10K
511R
2
+
U16A
1
R110
-
LM324
10K
C57 100n
R98 511K
-12 V
R101
22K1
C53
100n
+
+
C52
10u- 63V
U16B
7
-
LM324
R106
604K
C54
100n
C55
10u- 63V
11
R94
6
+
4
R92
11
+12V
10K
-12 V
CN2
10
9
8
7
6
5
4
3
2
1
R114
+12V
R113
10K
12 PULSES
CURRENT
BA LANCE
RCLS-1 card (PB117)
Thermal compensation of the charging voltage
 A temperature probe, installed inside the battery room, is connected to
the connector CN1 (through a interface card)
 The feedback signal is opportunely amplified and inserted in the
voltage control loop
V REF
+12V C6
100n
10
9
8
7
6
5
4
3
2
1
100n
7
CN1
R8
6K81
R35 10K
3
2
R7
178R
-12 V
+
-
U4
R27
6
OP07
R31 1K
4
C109
C13 100n
-12 V
+12V
R24 1K
54K9
All'anello di
controllo
tensione
RCLS-1 card - Settings
POTENTIOMETERS
P1
Regulation of the off-set OP-AMP TOTAL CURRENT
P2
Regulation of the TOTAL CURRENT limitation
P3
Regulation of the VOLTAGE loop stability
P4
Output voltage regulation (FLOATING) in AUTOMATIC control mode
P5
Output voltage regulation (BOOST) in AUTOMATIC control mode
P6
Regulation of the off-set OP-AMP BATTERY CURRENT
P8
Regulation of the TOTAL control stability
P9
Output voltage regulation in MANUAL control mode
P10
Regulation of the current sharing in 12-pulse configuration
P11
Regulation of the amplitude ramp phase R
P12
Regulation of the amplitude ramp phase S
P13
Regulation of the AC voltage tolerance (alarm AR)
P14
Regulation of the amplitude ramp phase T
P15
Regulation of the BATTERY CURRENT limitation
RCLS-1 card - Controls
CONTROL LED
COLOUR
DL4
Rectifier overload (Iout>100%)
YELLOW
DL5
Internal DC supply not correct
RED
DL6
Rectifier OFF
GREEN
DL7
High temperature of the rectifier bridge
RED
DL8
Protection fuses failure
RED
DL9
Fans failure (not used)
RED
DL10 Mains failure
RED
DL11 Input phase sequence not correct
YELLOW
DL12 AC supply low voltage
RED
 The LEDs are normally lit steady, blinking in case of alarm (except
DL12 that is normally OFF and lit in case of alarm)
RCLS-1 card – Interfaces with I/S-CL (mP)
 RCLS-1  I/S-CL
 MAINS FAILURE signal
• Pin 1-2 connector CN7
 RECTIFIER ON signal
• Pin 5-6 connector CN5
 FUSES FAILURE signal
• Pin 1-2 connector CN5
 WRONG PHASE SEQUENCE signal
• Pin 3-4 connector CN5
 Signal of the battery SHUNT for the mP battery current reading (only
when the BOOST charge is enabled)
• Pin 7÷10 connector CN5
RCLS-1 card – Interfaces with I/S-CL (mP)
 I/S-CL  RCLS-1
 Command of the relay RL1 for the BATTERY TEST
• Pin 3-6 connector CN6
 Command of the relay RL2 for FLOATING/BOOST commutation
• Pin 2-4 connector CN6
 Command of the relay RL3 for RECTIFIER STOP
• Pin 1-5 connector CN6
 The RCLS-1 card can be also connected to a relay card to repeat
to a remote location the 6 main alarms
Summary of the rectifier cards’ functions
PRCH
PB115
LOOP
PB114
FIR-91
PB113
SYNC-12
PB116
RCLS-1
PB117
Generation of the 12V/24V supply
X
X
Generation of the synchronism
signals
X
X
AC supply voltage control
X
X
Internal DC supply control
X
X
Generation of the thyristors firing
signals
X
X
Thyristor firing
Voltage control loop
X
X
X
X
NOT PROVIDED
X
Battery current control loop
X
X
General control
X
X
Thermal compensation of the
charging voltage (OPTIONAL)
X
X
NOT PROVIDED
X
Total current control loop
Interface with a relay card
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
Inverter
 Single-phase inverter
 The rectifier output voltage (battery) is applied to the IGBT bridge,
composed by four power components controlled through PWM
technology
 The inverter bridge output voltage is adapted by the isolation
transformer and subsequently filtered by the low-pass filter formed by
the inductance integrated in the transformer and the AC capacitors
Inverter
 Three-phase inverter
 The rectifier output voltage (battery) is applied to the IGBT bridge,
composed by six power components controlled through PWM
technology
 The inverter bridge output voltage is adapted by the isolation
transformer and subsequently filtered by the low-pass filter formed by
the inductance integrated in the transformer and the AC capacitors
Inverter typologies
 As already seen for the rectifiers, also the inverters can be
separated in different typologies, according to the constructive
solution chosen
 TYPE 1
It’s the single-phase inverter, with the following manufacturing
features




Use of two power components, each containing two IGBTs
Installation on a single heatsink
Forced cooling with single fan
Power connections carried out through interface card IBPC-7 (PB120),
which includes the DC capacitors and the Hall effect CT
Inverter typologies
 TYPE 2
It’s the three-phase inverter, with the following manufacturing
features




Use of two power components, each containing two IGBTs
Installation on a single heatsink
Forced cooling with single fan
Power connections carried out through interface card IBPC-7 (PB120),
which includes the DC capacitors and the Hall effect CT
 TYPE 3
It’s the three-phase inverter used starting form the 40kVA. The
power components are connected with cables and/or copper bars,
without interface card. Double IGBT packs (that is a single
component containing two IGBTs) are generally used up to 160kVA
range
Static switch
 Single-phase static switch
 It’s composed by two pairs of thyristors, connected in anti-parallel, that
interrupt the phase conductors (inverter/bypass)
 The bypass component is protected by a fast-acting fuse
 In order not to modify the grounding system the neutral conductor is
not interrupted
Static switch
 Three-phase static switch
 It’s composed by six pairs of thyristors, connected in anti-parallel, that
interrupt the phase conductors (inverter/bypass)
Static switch typologies
 TYPE 1
It’s the single-phase static switch
 TYPE 2
It’s the three-phase static switch that uses compact type thyristors
(SemiPack)
 TYPE 3
It’s the three-phase static switch that uses disc-type thyristors
(used only on the 500kVA and 650kVA)
 The three types of static switch use different firing cards, that vary
on the basis of the components layout
Inverter & static switch control
 Unlike the rectifier, where the control of the operating parameters is
purely analogue, the control of the inverter is completely entrusted
to the microprocessor (HC16 Motorola), that develops the following
main functions
 Generation of the reference sine-wave used for the creation of the
PWM
 Complete management of the operating logics of the inverter and
static switch
 Management and control of the measure shown on the display
 Control of the synchronism, in stand-alone and parallel operation
 The microprocessor card uses some additional cards, each of
them with its own specific function
Inverter & static switch control
 The following electronic cards are used for the inverter and static
switch control
 INVERTER
• I/S-CL
◆ RCB
◆ VCB
◆ SCB
•
•
•
•
PS-HV
ID
INV-AV
FCI
(PB003), inclusive of:
(PB011)
(PB012)
(PB014)
(PB001)
(PB013)
(PB004/PB018)
(PB047)
 STATIC SWITCH
• VOLT-REF
• SCR-FIR
(PB005/PB019)
(PB009/PB010/PB016)
PS-HV card (PB001)
 The PS-HV card is the system power supply, the one that “creates”
the different power supplies for the whole control electronic
(except, obviously, the rectifier)
 It’s a switch-mode power supply, with IN/OUT galvanic isolation
provided by a high frequency transformer
 According to the UPS nominal DC voltage (in our case 384Vdc) the
power supply can be divided in:
 PS-HV
 PS-MV
 PS-LV
(PB001) Supply range: 300÷600Vdc
(PB002) Supply range: 180÷300Vdc
(PB184) Supply range: 180÷300Vdc
 For application where the power required is higher because of, for
example, the use of parallel IGBTs (SATURN series,
Pnom>200kVA) it’s used a power supply called PS-SAT (PB107),
similar to the PS-HV except for the higher power
PS-HV card (PB001)
 The power supply card is composed by the following main
sections:






Microprocessor supply section
Analogue part supply section
IGBT drivers supply section
Relays and BUS supply section
Serial ports supply section
DC voltage measure section
PS-HV card (PB001)
Microprocessor supply
 This section supplies all the digital part (microprocessor) and the LCD
panel
 The voltage is further stabilised by a 5V stabiliser mounted on board
the microprocessor card
 The supply AC3-AC4, that will be described later on, is taken from the
same secondary winding of the transformer
FU6
PF 2A
R59
1K
D22
MUR120
D23
MUR120
R61
1K
R63
10K
17
C40
100u 50V
+
CN1
C41
100n
R57
10K
TP8
FU1
A C3
18
PF 2A
A C4
T2- E
R60
1K
D24
MUR120
D25
MUR120
R62
1K
TP9
10
9
8
7
6
5
4
3
2
1
FLA T 1 0P
PS-HV card (PB001)
Analogue part supply
 This section supplies all the analogue part of the microprocessor card
 The supply AC1-AC2, that will be described later on, is taken from the
same secondary winding of the transformer
R51
TP5
T2- C
10
D14
FU2
10K
PF 5A
R50
LD3
4K7
G 3mm
+24V
+
C29
100u 50V
MUR120
1
+
D16
MUR120
D17
MUR120
V OUT
C30
100u 50V
2
12
A C2
TP2
+12V
10K
D20
1N4004
A C2
TP4
R46
LD1
2K21
G 3mm
C15
1u
D19
MUR120
D18
MUR120
TP3
MUR120
10K
OUT
3
R47
GND
C31
100u 50V
IN
1
2
U5
LM7912
D21
1N4004
C28
1u
LD2
2K21
G 3mm
10
9
8
7
6
5
4
3
2
1
FLA T 1 0P
R48
D15
14
A C1
R49
U4
LM7812
A C1
13
CN2
3
GND
11
V IN
C13
1u
-12 V
+
PS-HV card (PB001)
Relays and BUS supply
 This section provides a 12V stabilised voltage for:
•
•
•
•
Relays of the alarm card ARC (PB031) – pin 9-10
Rectifier card relays (battery test, floating/boost, stop) – pin 9-10
Parallel BUS – pin 9-10
Digital signal interface card FCI (PB047) – pin 1-2
D26
CN3
FU7
7
MUR120
PF 3,5A
+
C46
100u 50V
C47
1u
R64
10K
R66
2K21
8
LD4
G 3mm
D27
9
T2- F
MUR120
D28
19
PF 2A
MUR120
+
T2- G
12V /RELA Y E BUS
12V /RELA Y
FLA T 1 0P
FU8
20
10
9
8
7
6
5
4
3
2
1
C48
10u 63V
C34
1u
R68
2K21
LD5
G 3mm
PS-HV card (PB001)
IGBT drivers and serial port supply
 The IGBT drivers are supplied by the 40khz square wave AC1-AC2
 A rectifying circuit, that provides also to isolate galvanically the supply
of the driver, is provided on board the driver itself
 The serial ports are supplied by the 40khz square wave AC3-AC4
 A rectifying circuit, that provides also to isolate galvanically the supply
of the serial ports, is provided on board the card RCB
PS-HV card (PB001)
DC voltage measure
 This section provides a stabilised voltage, proportional to the
amplitude of the DC supply voltage
 Such signal is sent to the microprocessor as feedback for the correct
display of the inverter input voltage
TP1
D6
R23
+12V
9
+12V C33
100n
BY V26 C
P1
C18
1u
3
5K
2
+
-
U1
R26
6
OP07
4
R24
R25
1K
7
T1- D
10
CN4
1K
1K
-12 V
C32
100n
V dc MEA SURE
261R
10
9
8
7
6
5
4
3
2
1
FLA T 1 0P
PS-HV card – Settings and controls
POTENTIOMETERS
P1
Regulation of the DC voltage measure
P2
Regulation of the IGBT drivers supply voltage
CONTROL LED
COLOUR
DL1
+12V analogue part supply
GREEN
DL2
-12V analogue part supply
GREEN
DL3
+24V analogue part supply
GREEN
DL4
+12V relays and BUS (pin 9-10 CN3)
GREEN
DL5
+12V FCI card relays (pin 1-2 CN3)
GREEN
ID card (PB013)
 The ID card is the IGBT driver and it’s designed for the control of a




complete inverter leg (IGBT+ / IGBT-)
It’s composed by two identical sections, each one with its own
power supply
With proper addition of components each section of the card can
control up to two IGBTs in parallel, but such option is not provided
for the actual production line
For the control of parallel IGBTs in the high power range UPS
(>200kVA) another card is used, the DR-SAT (PB108), a card for
each switch (therefore two cards for each bridge leg)
Besides the functions of the ID card, the DR-SAT is provide with an
additional protection with a desaturation sensor
ID card (PB013)
Power supply section
 The square wave AC1-AC2, originating from the power supply card
PS-HV, is used to generate the isolated supplies for both sections of
the card
+15V
1
TR1
D5 1N4148
R33 1K
V IN
+
V OUT
2
GND
C9 1u
C10
10u- 63V
LD3
C12
1u
3
A C1
+5V
U2
78L05
D4 1N4148
D6 1N4148
+
CN1
C11
10u- 63V
1
2
3
4
5
6
7
8
9
10
TI117239/ACM2008
D7 1N4148
-15 V
Power supply IGBT+
+15V F
TR2
C21 1u
D12 1N4148
+
V OUT
2
LD4
C24
1u
3
C22
10u- 63V
R34 1K
V IN
GND
1
A C2
+5V F
U6
78L05
D11 1N4148
D13 1N4148
+
C23
10u- 63V
TI117239/ACM2008
D14 1N4148
-15 VF
Power supply IGBT-
ID card (PB013)
Initial stage
 A opto-coupler provides for the de-coupling of the PWM signal coming
from the I/S-CL card
 A low-pass filter introduces a little delay in the pulse transfer (dead
time)
 The LED LD1 indicates the presence of the PWM signal
6
0=ON 1
3
5
2
U1A
4 0=ON
3
6
10
HP2601
4093
4093
4093
14
7
U3
+
R3 ***
1K
1=ON
9
R4 1K8
7
PWM
D1
1N4148
U1C
8
7
1K8
U1B
5
C5
1n
C2
10u- 63V
R6
3K3
U1D
12
11
13
LD1
4093
7
2
R5
680K
14
R2
3K3
14
R1
100n
8
7
C1
14
D3
1N4148
D2
1N4148
1=ON
+5V
ID card (PB013)
Final stage
 The signal is amplified by a MOSFET amplifier that provides also for
the translation of the signal between +/-15V
 Such voltage can be adjusted by the potentiometer P2 of the PS-HV
card
+15V
R11 **
R9
390R 2W
R10
390R 2W
D
C4
+
C7
DZ2
18V
G
S
Q2
IRFD014
1u
Q4
IRFD9014
R7
1=ON
10u- 63V
R15
1K
D
G
S
DZ1
24V
R13 **
C3
100n
22R
D
G
S
C6
R8
9K09
Q3
IRFD014
10u- 63V
-15 V
+
C8
1u
1
2
DZ3
18V
M1
G1H
S1H
INV-AV card (PB004/PB018)
 The INV-AV card is divided in INV-AV-1F (PB018), for single-phase
inverter and INV-AV-3F (PB004), for three-phase inverter
 The card is basically composed by two sections:
Inverter voltage feedback
 The inverter output voltage, taken directly on the AC capacitors, is
connected to the connector CN1. Three transformers (one on the INVAV-1F) adapt the voltage that can be used as feedback signal for the
output voltage regulation loop
Output current measure
 The three output CTs (one on the single-phase inverter) are connected
to the connector CN3. The voltage drop on the resistors R4 (phase R),
R5 (phase S), R6 (phase T), due to the CT’s secondary current, is
used as reference signal for the measure of the output current
VOLT-REF card (PB005/PB019)
Electrical drawing
+24V ST
+5V ST
V IN
V OUT
C2
10u 50V
C6
0,1u
2
+
3
CN3
R2
511R
GND
1
10
9
8
7
6
5
4
3
2
1
DL1
+
U1
7805
C7
10u 50V
R1
22R 2W
D1
T1
D2
D3
10
D7
D8
D9
10
+
C1
100u 50V
2
2
9
C3
2,2 u 250V
T4
9
D4
D5
13
D6
D10
D11
C8
2,2 u 250V
D12
13
7
7
BYPASS
CN1
T
N
1
2
3
4
5
6
7
T2
10
10
OUTPUT
CN5
1
2
3
4
5
6
7
T5
2
2
9
C4
2,2 u 250V
9
13
C9
2,2 u 250V
13
7
7
CON7
T3
12
12
10
10
9
9
2
C5
2,2 u 250V
T6
2
13
C10
2,2 u 250V
13
7
7
12
12
FU1
CN4
FU2
1
2
3
4
5
6
7
S
12
1
2
3
4
5
6
7
8
9
10
R
12
FANS
SUPPLY
CN2
FU3
R
S
T
N
VOLT-REF card (PB005/PB019)
 The VOLT-REF card is divided in VOLT-REF-1F (PB019), for
single-phase inverter and VOLT-REF-3F (PB005), for three-phase
inverter
 The card is basically composed by four sections:
Bypass voltage feedback
 The BYPASS voltage, taken on the static switch input, downstream the
thyristors protection fuses, is adapted by the three transformers (one
on the VOLT-REF-1F). The signals obtained are used by the
microprocessor as reference for the measure and control of the
tolerance limits
Bypass voltage feedback
 The OUTPUT voltage, taken on the static switch output is adapted by
the three transformers (one on the VOLT-REF-1F). The signals
obtained are used by the microprocessor as reference for the measure
and control of the tolerance limits
VOLT-REF card (PB005/PB019)
Static switch logics supply
 The secondary voltage of the transformers (one of the two secondary
windings) is rectified and stabilized in order to obtain two supplies:
24Vdc not stabilised and 5Vdc stabilised
 The 24Vdc is used for the supply of the final stage (card SCR FIRING)
of the bypass thyristors control circuit
 The 5Vdc is used for the supply of the SCB card, that manages the
static switch operating logic
Fans supply section
 The three couples of phase-neutral supplies on the connector CN3 are
used on the units up to 30kVA for the supply of the cooling fans
SCR-FIR card (PB009/PB010/PB016)
 The SCR FIRING cards contain the final stage for the inverter and
bypass static switch control circuit (see card FIR-91 for the
rectifier), and are fixed directly on the thyristors
SCRSF-3F
(PB009)
 Designed for the control of 6 couples of thyristors (a complete threephase static switch)
SCRSF-1F
(PB010)
 Designed for the control of 2 couples of thyristors, inverter and bypass
(a complete single-phase static switch or a section of a three-phase
static switch)
2SCR-FIR
(PB016)
 Designed for the control of 1 couple of thyristors
FCI card (PB047)
 The FCI card is basically a relay card, and is used to de-couple the
microprocessor card from the digital signal originated externally
(auxiliary contacts of breakers, etc.)
 Such contacts are normally connected to the connector M3 of the
I/S-CL (PB003) card
 In the standard production the FCI card is used on the units
starting from 40kVA
 It’s important to remember that the supply of the relays of the card
comes directly from the power supply card (PS-HV), pin 1-2 of the
connector CN3
FCI card (PB047)
Configurations of the signals
SIGNALS
SIDE
FCI – M1
Origin
1-2
Signal
mP SIDE
FCI – M2
Not used - Spare
1-2
3-4
Rectifier card
Mains failure
3-4
5-6
EPO push-button
Emergency Power Off
5-6
7-8
BCB aux contact
BCB open/closed
7-8
9-10
OCB aux contact
OCB open/closed
9-10
11-12
Switch SW1
Bypass switch
11-12
13-14
MBCB aux contact
MBCB open/closed
13-14
15-16
Thermal switch
High temperature
15-16
17-18
Parallel card
Parallel configuration
17-18
I/S-CL card (PB003)
 The I/S-CL card contains the microprocessor and all the electronic
logics for the inverter and static switch operation. It’s composed by
the following main sections:











Digital supply
Memories
Watchdog and reset circuit
Measures – Internal A/D converter
Measures – External A/D converter
Current protection
Voltage control loop card VCB
PWM generation
Static switch control card SCB
Serial port supply card RCB
Digital inputs
I/S-CL card (PB003)
Digital supply
 The voltage originated from the power supply card, connector CN1
(about 9V), is further stabilised by means of a precision stabiliser,
filtered by means of L-C filters and made suitable for the supply of the
microprocessor
V NR
+5V
1
C131
C137
100NF
C122
+
470uF
E
U
3
M
L4
CN14-9
100NF
+5V
U75
TEA 7605
D69
GREEN
FILTERS
2
CN14-10
CN14-1
CN14-2
GND
COMMON MODE
D50
R146
1N4148
+V RAM
D49
1N4148
D48
SD103
BT
1
ON
2
J2
3
OFF
I/S-CL card (PB003)
RAM (U58)
 The RAM contains the events log (up to 900 events), the information
related to the year for the clock setting and the tables for the voltage
fast sensors (described later on)
 A back-up battery provides to keep the data stored
EEPROM (U71)
 The EEPROM contains the UPS’ functional parameters and all the
settings
EPROMs (U55-U65)
 The EPROMs contain the operating program, split into odd (U65) and
even (U55) addresses
Watchdog e reset
 The microprocessor is controlled by a smart “watchdog” that provides
for the reset of the program in case of processing error or problems in
the supply voltage (undervoltage lock-out)
 The microprocessor can be manually reset through the push-button
SW3
I/S-CL card (PB003)
Measures – Internal A/D converter
 The measures related to the bypass and output voltage are directly
acquired by the microprocessor and converted by the internal
analogue/digital converter
 The signal are translated of 2,5V in comparison to the zero, therefore
the microprocessor recognise automatically the level “zero”
MICRO BUS
R
FI1
BY PASS FREQUENCY
OP AMP
+5V
D62
D60
D61
D55
D54
R152
10K
D53
R150
10K
2K2 1% X6
R
R
A DA1
S
A DA2
T
A DA3
R
A DA4
S
T
D52
C113
V R/2
C110
C109
C100
C98
C97
R209
D57
D58
R208
D59
R207
D64
R205
D65
R204
A DA5
R206
A DA0
R172
CN13-4
S
R171
T
R173
R
R166
S
R165
T
R164
CN13-3
BYPASS
CN13-2
CN13-5
CN13-6
CN13-7
OUTPUT
I/S-CL card (PB003)
Measures – External A/D converter
 Some measures are acquired by the microprocessor in serial mode,
after they have been converted by a analogue/digital converter (SPI –
Serial Peripheral Interface) placed in the analogue part of the card
+5A
D31
D16
D17
D32
D14
D15
D34
D35
INVERTER V OLTAGE R
D36
INVERTER V OLTAGE S
U22
20
19
18
17
16
15
14
13
12
11
DA TA_ OUT
V CC
EOC
CLK
A DRIN
DOUT
CS
REF+
REFIN10
IN9
IN0
IN1
IN2
IN3
IN4
IN5
IN6
IN7
IN8
GND
1
2
3
4
5
6
7
8
9
10
Inv. V olt. R
Inv. V olt. S
Inv. V olt. T
Out. Cur r. R
Out. Cur r. S
Out. Cur r. T
V DC
IBS
CFPA R
INVERTER V OLTAGE T
OUTPUT CURRENT R
OUTPUT CURRENT S
OUTPUT CURRENT T
DC V OLTA GE
IBOOST
INVERTER INPUT CURR
TLC1542
A
PA RAL LEL CORRECTION
BA TTERY BOOST CURR
D42
A
C72
D22
C51
D23
C52
D43
C73
D20
C49
D6
D21
C50
C64
D5
D33
C65
C66
I/S-CL card (PB003)
Measures – External A/D converter
 In order to read correctly the values, a software adjustment during the
microprocessor setting phase provides to define the level “zero”,
where the actual value of the parameter is void
 The measures for which the “zero” must be set are:
•
•
•
•
•
•
•
Inverter voltage phase R
Inverter voltage phase S
Inverter voltage phase T
Output current phase R
Output current phase S
Output current phase T
Inverter input DC current
 The parameter CFPAR is used only in the PARALLEL configuration
 The parameter IBOOST is used only when the boost charge in
enabled
I/S-CL card (PB003)
Measures – Summary
 For further clarity the origin of the signals used by the microprocessor
for the measures are summarised hereunder
Signal
Provenienza
BYPASS voltage (phases R/S/T)
VOLT-REF-3F (1F) card
OUTPUT voltage (phases R/S/T)
VOLT-REF-3F (1F) card
INVERTER voltage (phases R/S/T)
VCB cards
OUTPUT current (phases R/S/T)
INV-AV-3F (1F) card
DC voltage
PS-HV card
DC current
Inverter input Hall effect CT
I/S-CL card (PB003)
Current protection
 The current protection is carried out acquiring the signal related to the
inverter bridge input current, function of the UPS output current
 A Hall effect CT, connected on the positive cable (or copper bar)
between the DC capacitors and the inverter bridge, is used for this
purpose
 Such configuration guarantees the control and protection against
possible short-circuits of the inverter bridge, caused by the failure of
one IGBT
 In the UPS that uses the interface card IBPC-7 (PB120) for the power
connections the CT is mounted on the card itself
 The supply of the CT (+12V/-12V) comes from the power supply card
PS-HV (analogue supply section) via the connector M1 of the I/S-CL
card
I/S-CL card (PB003)
Short circuit protection
+12A
C19
M1-2
FEEDBA CK
J10
R39
47R
100NF
R27
A
D73
3
C28
1NF
J9
J100
R40
100R
1K
2
SD103
D72
SD103
+
U16A
1
MC34074
R38
2K
A
C27
R18
22R
R25
1K
A
1n
R26
P2
10K
1K
TP2
Current
Signal
I/S-CL card (PB003)
Short circuit protection
 The feedback signal originated by the Hall effect CT is acquired by the
microprocessor card
 The feedback current generates a voltage drop flowing through the
resistors R18-R39-R40, so that it can be used for the control circuit
 By means of a amplifier, which gain can be varied with the
potentiometer P2, the value of the signal is adapted to the dynamic of
the protection circuit
 The signal on the test point TP2 must be equal to 4Vpeak when the
inverter supplies the nominal load (100%)
 In case of short circuit the output current is limited at 200% for 100ms,
and then to 125% for 5 seconds, after which the inverter is switched
off (according to EN62040-3)
I/S-CL card (PB003)
“Current stop” protection
U15B
+5A
+12A
3
4
U5C
C20
100NF
R15
10K
FEEDBA CK
10K
R13
10
CA 3130
9
+12A
3K3
7
5
A
3
R39
2
J10
+
U11
6
R50
U5D
12
-
R49
11
200K
A
13
R16
R40
C28
1NF
C13
10K
J9
1NF
1K
A
N1
100pF
A
R18
J100
A
D3
LMCS
4093
4
8
1
M1-2
R17
8
40106
SW4
PPMCS
4093
CURRENT STOP
+
C148
10u 25V
I/S-CL card (PB003)
“Current stop” protection
 The resistors R18-R39-R40 are properly combined according to the
IGBT’s nominal current
 In case of “bridge leg” short circuit the PWM is stopped before the
input current exceed the 200% of the IGBT’s nominal current
 The detection time and the subsequent inverter stop is not higher than
a PWM pulse (max. 250ms)
 The inverter stop due to “Current stop” is signalled by the LED D3,
placed on the front of the I/S-CL card
 The program provides for the automatic reset of the stop condition for
three times, re-starting the inverter
 If the block repeats, therefore a real failure exists in the inverter bridge,
the inverter is definitely stopped and must be re-started only after
having verified the reason of the malfunction
I/S-CL card (PB003)
VCB card (PB012) – Voltage control loop
 The VCB card contains all the electronic logics for the voltage control
loop
 Each inverter output phase is controlled by a different card, therefore
the I/S-CL card for a three-phase inverter will mount three VCB cards
 Three main sections can be identified:
• Generation of the reference sine-wave
• Voltage correction
• Inverter voltage measure
 The output signal from the VCB card is used by final stage of the PWM
generation, in the I/S-CL card
I/S-CL card (PB003)
VCB card (PB012) – Sine-wave generation
 The digital signal coming from the microprocessor (that represents the
digital sine-wave) is converted by a D/A converter in order to obtain a
real sine-wave
 The amplitude of the sine-wave is varied by the AUTOMATIC
regulation loop (jumper J1 in position 1-2) in function of a set-point
managed by the microprocessor adjustable through the potentiometer
P1
 Each phase of the inverter is disengaged and can be varied
independently
 In order to carry put functional tests, the regulation loop can be set in
MANUAL mode (jumper J1 in position 2-3), in such case the amplitude
is varied operating on the potentiometer P1 of the I/S-CL card
 In this case the inverter output voltages are varied contemporary
I/S-CL card (PB003)
VCB card(PB012) – Voltage correction
 The voltage correction circuit is used to modify the PWM reference
signal in order to “correct” possible distortions on the output sine-wave
and can be disabled removing the jumper J2
 The feedback signal, coming from the INV-AV-3F (1F) card is
compared with the reference sine-wave e properly filtered
 The resulting signal is added again to the reference sine-wave
+5A
+12A
C22
R36
10K
R30 10K
U6C
V REF
10
9
+
8
-
5
6
LM324
R31 10K
NOTCH
FILTER
100NF
U6B
+
A
7
-
R39 10K
LM324
V REF
R32 10K
A
V FBK
R40 10K
R37
C14
1NF
C15
1NF
43K2
C20
U6D
12
C19
100NF
J2
13
+
LM324
A
A
R41 10K
1NF
+5A
R42 11K8
14
V PWM
I/S-CL card (PB003)
VCB card(PB012) – Inverter voltage measure
 A section of the card is dedicated to the creation of of a signal that can
be used as reference for the measure of the inverter output voltage
 The feedback signal, originating from the card INV-AV-3F (1F), is
rectified, filtered and sent to the SPI, and then to the microprocessor
I/S-CL card (PB003)
Generation of the PWM reference frequency
 The generation of the IGBT’s turn-on pulses is carried out comparing
two signals: the reference signal (sinusoidal at 50 or 60kz) originated
from the VCB card and a triangular waveform with a frequency equal
to the desired commutation frequency
 The triangular waveform is a function of a reference signal generated
by the microprocessor
+5A
+12A
R33
300K
C34
C41
100NF
A
7
1
100NF
A
3
R66 *
C54
2
6K81
100NF
-
C42
100NF
4
8
FREF
U17
+
A
-12 A
6
OP07
R66 = 6K81 for 8KHz
13K6 for 4KHz
R67
24K9 for 2KHz
C55
10NF
220K
FPWM
I/S-CL card (PB003)
PWM generation – Final stage
 The final stage is the real comparison of the sine-wave with the
triangle and the following transmission of the resulting PWM signal to
the IGBT driver cards
+12A
C24
100NF
+12A
C18
100NF
A
U9A
5
1STOP
6
+12A
1
CN7-8
3
U14C
40106
CN7-7
2
A
A C1
4093
+TA
CN7-1
CN7-3
U14D
A
+12A
9
FPWM (TRIA NGLE)
A
3
+
2
CN7-4
-TA
A
U12
6
U9B
+12A
5
4
-
6
C15
4
8
1
C14
22NF
22NF
A
A
4093
A
A
CN7-2
40106
CA 3130
V PWM (SINEWA VE)
R9
1K
A C2
7
5
R10
1K
C22
100NF
8
N5
47pF
CN7-10
CN7-9
I/S- CL card (PB003)
SCB card (PB014) – Static switch control
 The SCB card contains the decisional logics of the static switch
(inverter & bypass)
 It’s directly supplied by the bypass or the output through the VOLTREF-3F (1F) card
 The LED L1 signals the presence of the 5V supply
 The bypass static switch thyristors are controlled directly by the SCB
card
 The inverter static switch thyristors are controlled by the I/S-CL card
according to the consents originated from the SCB card
RCB card (PB011) – Serial ports supply
 The RCB card contains the drivers for the serial interface ports RS232
and RS485 and for the microprocessor’s digital outputs (alarm relay
card)
 The supply is isolated, created internally using the square wave AC3AC4 coming from the PS-HV card
I/S-CL card (PB003)
Digital inputs
 The digital inputs are connected directly, or through the de-coupling
card FCI, to the connector M3
 Such signals are internally de-coupled and connected to the
microprocessor
I/S-CL
M3
Signal
1-2
Not used - Spare
3-4
Mains failure
5-6
Emergency Power Off
7-8
BCB open/closed
9-10
OCB open/closed
11-12
Bypass switch
13-14
MBCB open/closed
15-16
High temperature
17-18
Parallel configuration
I/S-CL card configuration
 The I/S-CL card can be easily configured with simple operations
and can be adapted to all the production range (Standard and
custom UPS)
 Four different configurations can be identified:




Configuration of the nominal parameters
Configuration of the switching frequency
Configuration of the current protection
Configuration of the jumpers
I/S-CL card configuration
Configuration of the nominal parameters
 The nominal parameters can be configured by means of dip switches
 At the start-up the program recognises the position of each dip switch
and configures the operating parameters accordingly
 For the correct configuration of the dip switches refer to the relevant
technical documentation
Configuration of the switching frequency
 The switching frequency depends on the frequency of the triangular
waveform that is compared with the reference sine-wave to generate
the PWM signal
 The frequency of the triangle can be varied modifying the value of the
resistor R66:
• R66 = 6K81
• R66 = 13K6
• R66 = 24K9



fswitching = 8khz
fswitching = 4khz
fswitching = 2khz
I/S-CL card configuration
Configuration of the current protection
 The current protection, and particularly the “Current stop” protection,
can be configured combining properly the resistors R18-R39-R40
according to the IGBT’s nominal current
 For the standard UPS a configuration table does exist, the calculation
form is shown hereunder
10 x KLEM
REQ = -------------------2 x IIGBT
Where:
REQ = Series combination of R18-R39-R40
KLEM = Conversion ratio of the LEM
IIGBT = IGBT’s nominal current
I/S-CL card configuration
Configuration of the jumpers
 The I/S-CL card is provided with some jumpers, necessary to
configure some operating parameters
 The most interesting jumpers for the configuration “on field” are shown
in the following table
Jumper
J1
Pos
Function
1-2
SINGLE-PHASE inverter
2-3
THREE-PHASE inverter
J2
Closed
Back-up battery connected
J7
Closed
Watchdog enabled
J9
Closed
Resistor R40 (100R) inserted
J10
Closed
Resistor R39 (47R) inserted
J100
Closed
Resistor R18 (22R) inserted
I/S-CL card – Settings and controls
POTENTIOMETERS
P1
Regulation of the inverter voltage in MANUAL mode
P2
Regulation of the current signal (TP2)
CONTROL LED
COLOUR
D3
“Current stop” protection
RED
D8
Short circuit protection
RED
D11
Presence of the analogue part’s supply (+12V)
GREEN
D69
Presence of the digital part’s supply (+5V)
GREEN
Protections and controls of the SW program
 The software program provides for the control of the UPS
functionality basing on the instructions assigned
 The setting of the I/S-CL card’s dip switches gives the program the
main indications to define the control and protection thresholds
 The two most important controls, for the purpose of the inverter
bridge and load protection, will be defined in detail
 Control of the output and bypass waveforms
 Overload protection (Thermal image)
Waveform control
 The control is based on the sampling of the sine-wave and the





subsequent comparison of the samples with a reference value
The sine-wave is sampled 36 times in a period
The RMS value of the sine-wave is calculated using the samples
obtained, and compared with the minimum and maximum
thresholds defined in the software
Each of the 36 samples (Vsn) is also compared with values
contained inside reference tables (VtL/VtH) so that the following
disequations are satisfied
VtL1< Vs1< VtH1 ; VtL2< Vs2< VtH2 ; …. ; VtL36< Vs36< VtH36
The tables are part of the program and are downloaded in the RAM
at each start-up of the program itself
If 4 consecutive samples of one of the phases don’t satisfy the
comparison the voltage is declared out of tolerance
Overload protection
 The overload protection is also called “Thermal image” because





it’s indeed based on the calculation of the energy stored during the
overload operation
The overload is defined when at least one of the output currents
exceed the 100% of the nominal value
As soon as a overload is detected the program starts to take
samples of the output current, calculating the integral I2t
The value of the integral (energy accumulation) is compared with a
limit value, equal to the overload capability of the equipment (125%
In x 10 minutes)
When the limit is reached the program stops the inverter and the
load is transferred to bypass (if available)
The inverter is switched on again after 30 minutes
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
User interfaces
 The UPS is provided with two serial ports and a optional relay card




for the interface with the external world
The serial port RS485 is used only for the connection with the
remote panel
The serial port RS232 is used for the interface with software
applications and transmits all the UPS data through a proprietary
protocol
The relay card ARC provides the indication of a operating status
and 3 alarms, that can be modified only by changing the software
on board the microprocessor card
The most important user interface is however the LCD panel, that
makes the UPS operating parameters (measures, status and
alarms) immediately available to the user
LCD panel
 The LCD panel is the graphic interface of the microprocessor, and
provides at each instant the indication of the UPS operating
parameters
 The mimic on the left aids the comprehension of the energy flux
and provides the immediate display of possible anomalies
 The display is basically a passive component, except for some
basic functionalities that allow the active interface with the
microprocessor
LCD panel – Measures
 The measures available on the LCD panel are the same described
before for the microprocessor card I/S-CL
OUTPUT measures




Voltage of the three phases (measure Ph-N)
Frequency
Current of the three phases (phase current)
Percentage of load on each phase
BYPASS measures
 Voltage of the three phases (measure Ph-N)
 Frequency
INVERTER measures
 Voltage of the three phases (measure Ph-N)
 Frequency
LCD panel – Measures
DC measures
 Inverter input voltage
BATTERY measures





Battery voltage
Battery type (autonomy in Ah)
Battery current *
Battery residual autonomy (in minutes) *
Battery residual autonomy (in percent) *
* The data indicated with asterisk are active only with the battery in
discharge mode
 The menu relevant to the battery measures is automatically activated
in case of mains failure and battery discharging
LCD panel – Status and alarms
 The software program is able to process the information relevant to




6 different operating status and 25 alarms, defined by means of
alphanumeric codes
Each alarm is associated with an internal protection, controlled by
the microprocessor, that disabled certain UPS functions in order to
avoid possible loss of supply to the load
The alarm codes are stored in the event log (history log)
The history logs the event, that is both the alarm and its automatic
reset (if any), indicating the reset with a star next to the code
Besides the alphanumeric code of the alarm, the history log
indicates date, hour and minute of the event
LCD panel – Status
Cod.
Name
Description
S1
AC/DC OK
Rectifier output voltage within tolerance
S2
BATTERY OK
Battery connected to the DC bus
S3
INVERTER OK
Inverter voltage within tolerance
S4
INVERTER SYNC
Synchronism reference within tolerance
S5
INVERTER  LOAD
Inverter static switch closed, load on
inverter
S6
BYPASS OK
Bypass voltage and frequency within
tolerance
LCD panel – Alarms
Cod.
Name
Description
A1
MAINS FAULT
Rectifier input mains failure
A2
CHARGER FAULT
Battery charger failure
A3
RECT FUSE
One or more rectifier fuses are blown
A4
THERMAL IMAGE
Load transferred to mains due to overload.
A5
AC/DC FAULT
Rectifier output voltage out of tolerance
A6
INPUT WR SEQ
Input phase rotation not correct
A7
BCB OPEN
Battery circuit breaker open
A8
BATT DISCH
The battery is discharging
A9
BATT AUT END
Battery autonomy (calculated) has expired
A10
BATT FAULT
Battery test failed or intervention of the safety
timer during boost charge
A11
BATT IN TEST
Battery test in progress
A12
PLL FAULT
Problems
system
A13
INV OUT TOL
Inverter output voltage out of tolerance
with
the
digital
synchronisation
LCD panel – Alarms
Cod.
Name
Description
A14
OVERLOAD
Inverter overload (load exceeding 100%)
A15
BYP FAULT
Emergency mains not available
A16
BYP FEED LOAD
Load fed by bypass
A17
RETR BLOCK
Transfer between bypass and inverter blocked
A18
MBYP CLOSE
Manual bypass breaker closed
A19
OCB OPEN
UPS output breaker open
A20
FANS FAILURE
Optional
A21
HIGH TEMP
High temperature on the inverter and/or rectifier
bridge
A22
BYP SWITCH
Closure of the commutation switch which forces
the load to bypass (maintenance)
A23
EPO BUS
Intervention of the emergency power off switch
according to the EN62040-1
A24
CURR STOP
Inverter bridge stop for max current
A25
SHORT CIRCUIT
Intervention of the short circuit protection
LCD panel – Commands
 The LCD panel is provided with a section through which it’s
possible to carry out some simple functional test
 The section can be accessed through the menu SPECIAL
SETTINGS
 Section for the setting of the local date and time
UPS TEST
 Static switch commutation test
 The inverter is stopped and the load transferred to bypass
BATTERY TEST
 The battery test is carried out reducing the rectifier voltage for 30
seconds
 If the voltage reaches the pre-alarm level, the alarm “A10 – Battery
fault” is activated
RESET HISTORY
 Section for deleting the events log
General data
Inverter & Static switch
Technical features
User interfaces
Rectifier
Test software
“UPSTest” software
 The UPSTest software is used to verify the UPS’ operating
parameters
 Besides it offers the possibility to control the software program’s
flux so that to identify possible anomalies
 Refer to the technical documentation for further information about
the software settings and the relevant commands
 It’s divided in the following main sections:







Measures
UPS data
Variables
Outputs
Inputs
Alarms
Status
“UPSTest” software
“UPSTest” software
Section MEASURES
 The section MEASURES shows all the voltages and currents acquired
by the microprocessor
Section ALARMS
 The section ALARMS shows all the alarms managed by the
microprocessor, that are the same displayed by the LCD panel
Section STATUS
 The section STATUS shows all the operating status managed by the
microprocessor, that are the same displayed by the LCD panel
“UPSTest” software
Section UPS DATA
 The section UPS DATA shows all the UPS’ nominal data, that are
generally set by changing the position of the dip switches of the I/S-CL
UPS’ nominal data, depending on the position of the dip
switches of the I/S-CL card
Battery data, adjustable through software commands
Voltage thresholds settings, fixed and not adjustable if not
changing the UPS’ control software
Tolerance limits of the bypass frequency, adjustable through
software commands
Display of the residual battery autonomy
“UPSTest” software
Section VARIABLES
 The section VARIABLES shows all the software variables, used to
guarantee the correct operation of the system
 Each variable operates on a certain section of the UPS, so they can
be divided in 4 different groups:
•
•
•
•
Variables relevant to the DC section
Variables relevant to the INVERTER section
Variables relevant to the BYPASS section
Variables relevant to the USCITA section
 The activation of a variable is indicated by a blue background
“UPSTest” software
Section VARIABLES
DC Variables
VDC_OK
INVERTER Variables
INV_ON
SSW_ON
IOK
IFL
CONAC
O_LOAD
HITE
VUOK
SYNCOK
IMTERM
BYPASS Variables
ROK_X
FROK
RMSOK
USCITA Variables
COK
I_OVER
“UPSTest” software
Section VARIABLES
 VDC_OK
• It indicates that the INVERTER INPUT voltage is in tolerance, that is within
the limits specified in the section UPS Data  VDC
 INV_ON
• It’s the command for the inverter start-up, that is managed by the
microprocessor during the AUTOMATIC operating mode, or by software
command in MANUAL mode
 SSW_ON
• It’s the command for the inverter static switch
 IOK
• It indicates that the inverter is ready to supply the load
 IFL
• It indicates that the inverter static switch is closed
 CONAC
• It’s the variable managing the modulation command for the inverter bridge
IGBTs
“UPSTest” software
Section VARIABLES
 O_LOAD
• It indicates the inverter stop following an extended overload (intervention of
the thermal image protection)
 HITE
• It indicates the intervention of the inverter bridge thermal protection
• The thermal protection can also be constituted by the series of different
protections (inverter bridge, rectifier bridge, transformer, etc.)
 VUOK
• It indicates that the INVERTER voltage is in tolerance, that is within the
limits specified in the section UPS Data  INV
 SYNCOK
• It indicates the correct generation of the inverter-bypass synchronism
signal
 IMTERM
• It indicates the activation and the operation of the thermal image counter
“UPSTest” software
Section VARIABLES
 ROK_X
• It’s the “AND” combination of the variables FROK and RMSOK
 FROK
• It indicates that the BYPASS frequency is in tolerance, that is within the
limits specified in the section UPS Data
 RMSOK
• It indicates that the BYPASS voltage is in tolerance, that is within the limits
specified in the section UPS Data  BYP
 COK
• It indicates that the OUTPUT voltage is in tolerance, that is within the limits
specified in the section UPS Data  OUT
• The variables RMSOK and COK indicates that the waveforms are correct
and without particular distortions (see the “waveform control” carried out by
the microprocessor)
 I_OVER
• It indicates that the output current exceeds the nominal value (overload)
“UPSTest” software
Section OUTPUTS
 The section OUTPUTS shows all the commands generated by the
microprocessor for the management of the various UPS sections
“UPSTest” software
Section OUTPUTS
 COK
• It’s the command relevant to the variable COK, and is managed by the
static switch control logic (SCB card)
 BY_BL
• It’s the command that blocks the load on bypass, disabling the re-transfer
of the static switch on inverter
 IFL
• It’s the closing command of the inverter static switch
 CONAC
• It’s the command relevant to the variable CONAC and represents the real
consent for the inverter bridge modulation
 OVERLOAD
• It’s the command relevant to the variable O_LOAD and represents the
inverter stop command following an extended overload
“UPSTest” software
Section OUTPUTS
 RES_RITR_BL
• It’s the command that unlocks the static switch after a re-transfer block
 R3_INV_FEED
• It’s the command of the relay RL3
• E’ il comando del relè RL3 (load supplied by inverter) of the alarm card
ARC
 R4_BYP_FEED
• It’s the command of the relay RL4 (load supplied by bypass) of the alarm
card ARC
 R5_LOW_BATT
• It’s the command of the relay RL5 (battery low – pre-alarm) of the alarm
card ARC
 R6_MAINS_FAU
• It’s the command of the relay RL6 (rectifier mains failure) of the alarm card
ARC
“UPSTest” software
Section INPUTS
 The section INPUTS shows the status of all the microprocessor’s
digital inputs
“UPSTest” software
Section INPUTS
 MBY_CLOSE
• When active, the switch MBCB (manual bypass) is closed
 EPO_BUS
• When active, the UPS stop by EPO is not enabled
 BO_BUS
• When active, the switch BCB (battery) is open
 BYP_SW (FUSE)
• When active, the bypass switch (commutation test) is active
 TERMO_SW
• When active, the thermal protection on the bridges has operated
 OCB
• When active, the switch OCB (UPS output) is closed
 MCS
• When active indicates the Current stop protection has operated
“UPSTest” software
Section INPUTS
 MRR
• When active, the mains failure signal, originated by the rectifier card, is
not active
 RECT_FAIL
• When active, the rectifier failure signal, originated by the rectifier card, is
not active
 ERR_SC
• When active, the wrong phase sequence signal, originated by the rectifier
card, is not active
 BF_RECT
• When active, the fuses failure signal, originated by the rectifier card, is not
active
 PUL_XX
• These variables indicates the push button on the LCD panel have pressed
“UPSTest” software
Additional sections
UPS serial number (set by software command) and software
version installed on board the I/S-LC card
TXCheck: transmission check (cyclic increment)
PACKT: number of the data packets received
Section to digit software command strings
Flag MASTER/SLAVE for the parallel operation
Inverter/bypass synchronisation data
Battery charge percentage
Increment of the thermal image counter
“UPSTest” software
Sezioni aggiuntive
KF BY: position of the bypass voltage’s control table
KF OU: position of the output voltage’s control table
Panel for the fast setting of the display’s language
Dip Sw: it opens a panel that shows the setting of the dip
switches in the I/S-CL card
Par Data: it opens a panel that shows the control parameters
during the parallel operation
BOOST: it opens a panel that shows the current thresholds
for the BOOST charge operation
Set Date: it sets the date and time on the display (see menu
special, SETTINGS) in function of the date and time set in the
PC’s operating system
End of the presentation