UPS Technical Presentation

Technical presentation EVOLUTION line UPS

Contents

General dataGeneral data

Technical featuresTechnical features User interfacesUser interfaces

Test softwareTest softwareRectifierRectifier

Inverter & Static switchInverter & Static switch


Technical featuresTechnical features

RectifierRectifier


User interfacesUser interfaces

Test softwareTest 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 (20-30kVA – 3Ph/1Ph) HALLEY/E (20-160kVA – 3Ph/3Ph) SATURN/E (200-650kVA – 3Ph/3Ph)

The two widest categories are divided into sub-categories, according to the functional and technical solution chosen:

HALLEY/E 20÷32kVA e 40÷80kVA HALLEY/E 100÷160kVA SATURN/E 200÷300kVA SATURN/E 400÷650kVA



RectifierRectifier





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: type 1 Inverter: type 1 Static switch: 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


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


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


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


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: type 2 Inverter: type 3 Static switch: type 3 (except 400kVA)



RectifierRectifier



Test softwareTest softwareRectifierRectifier

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 12-pulse configuration is not possible.

Cards used:

PRCH (PB114) FIR-91 (PB113) LOOP (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 (PB116) RCLS-1 (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

+24V+12V

-12V

R TS

F2 6,3x32 1A

F3 6,3 x32 1A

F1 6,3x32 1AM2

12345

D16

1N4004

D14

1N4004

D18

1N4004

D17

1N4004+ C12

47u 25V

+ C111000u 50V

+ C947u 25V

U5 LM7912

2 3

1

IN OUT

GN

D

U4

LM7812

1 3

2

IN OUT

GN

D

+ C81000u 50V

C13100n

C10100n

D15

1N4004T1

ACM1008

1

3

8

12

7

2

56

4

11

1615

109

1413

1817

D13

1N4004

Synch.

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

+12V

+12VVRM

+12V

+12V

+12V

R S T

0_SCOK

1_ROKR1410K

R1522K1

+

-

U2CLM324

10

98

411

R1010K

R47100K

R202K21

DL2

R8

10K

D10

6V2

R1

2K21

R91K

U1A

40106

1 2

R17

100K

R18

100K

D3 5V6

+

- U2ALM324

3

21

411

R1610K

D5 D6

R58K25

D7C3

100n

C5470n

R4

2K21

R78K25

R1910K

DL1

C1470n

R12

33K2

+

- U2BLM324

5

67

411

D2Q1BC337 1

23

D8

R28K25

D9

R32K21

+ C210u-50V

R132K21

R633K2

C4470n

R11

10K

Q10BC337

12

3

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

+12V

VRM

+12V

Stop

0_ON

1_PSOK

1_ROK

1_PSOK

R23

100RD11

R2410K

D123V9

R22806K

+

-

U2D

LM324

12

1314

411

+ C610u-50V

U3A

4081

1

23

R27

2K21

R2510K

R2610K

C71n

DL4

U1C

40106

5 6

R28909R

U1B

40106

3 4

R21

2K21

DL3

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

HF

HF

TP7

+12V+12V

TP5 TP9

0_ON

S

R3910K

R41249K

R4360K4

D28 P2

100K

1 3

2

D27

C25220n

U9 TCA785

2

3

4

5

6

7

8

11

10

9

12

13

14

1

15

16

Q2N

QU

Q1N

Vsync

I

QZ

Vref

V11

C10

R9

C12

L

Q1

GND

Q2

VS

R42

51K2

C23 100n

C2647n

C24470n

U3C

4081

8

910

U12B

4081

5

64

U11C

ULN2804

3 16

109

U11D

ULN2804

4 15

109

U1D40106

9 8

D26

Mixer & Driver

ControlLevel

HighFreq.

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 (P) 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

SQUARE WAVE

SQUARE WAVE

+24V

G1

K1

G2

K2

TF4

TI112046

1

6

3

4

DL4

D41N4936

R18

4R7-2WR1947R

C12100n

R1768R-5W

TF1

TI112046

1

6

3

4R447R

R2

4R7-2WD11N4936

DL1

R168R-5W

C3100n

SCR1/R

SCR2/R

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

-12V

VREF1_ON

U11TL431AB2

3

1

R50

100R

R553K92

R526K81

+ C30100uF 25V

R48 100R

R51 33KR5351K

R49 51K

R573K32 Not mount.

C27

100n

+

-

U10

OP07

3

26

74

C26100n

C331u

R56 15K4

R54

10K

D9

LOOP card (PB115)

+12V

+12V

-12V

TP12

+12V

-12V

VREF

TR-1TR-2

R-S2R-S1

TR-2TR-1

B1

B2

M1

12345

R26 121K

R214K75

R12 4K75

R204K75

R191K82 R25

8K25

RL2

71

21112

P55K

13

2

R303K32

C6 100n

C10

100n

+

-

U4

OP07

3

26

74

R594K75

P25K

13

2

RL1

71

21112

CN1

123456789

10

R16

54K9R1054K9

D1C11

1u

R15

10K

R2810K C14

100n

C12100n

+

-

U6

OP07

3

26

74

R182K21

+

- U53160

3

26

74 1 5

R32 10K

C8

100nR11 10K

R7 15K4

C4

47n

+V-V

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)

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+12V

-12V

+12V

-12V

TP2

-12V

+12V

VRM

R34 4K99

+

-

U8

OP07

3

26

74 C21

100n

C17100n

R43 100K

C16

100n

P3 100K13

2

+

- U7 OP07

3

26

74

R27

10K

R36 511R

C23 1uC24100n

D7

C15 100n

R33 100K

R46 511R

C20100n C34

100n

C18 100n

C22100n

+

-

U9

OP07

3

26

74

R4710K

R38 10K

R424K64

C19100n

R35

511R

D8

R45 511R

D5

C25100n

M1

12345

R37 12K

R40 100K

R39

10K

R29820R

D3

6V4

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

-12V

+12V

+12V

-12V

TP13

Ve

CURRENT LOOP

VOLTAGE LOOPR14

100K

R910K

C9

100n

+

-

U3

OP07

3

26

74

C5100n

C13

220n

D2

R23 464K

C7

100n

C3100n

+

-

U2

OP07

3

26

74

P110K

13

2

R810K

R41

1K

R131K

P4100K

13

2

JP1

1

2

3

R17

10K

R2210K

R313K92

1-2 AUT.2-3 MAN.

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

+12V

-12V

+12VVREF

C1100n

+

-

U1

OP07

3

26

74 C2 100n

R2 10K

R3 1K

R6 1K

R16K81

R4178R

M2

123

R554K9 All'anello di

controllotensione

LOOP card – Settings

POTENTIOMETER

P1 Output voltage regulation in MANUAL control mode

P2Output voltage regulation (FLOATING voltage) in AUTOMATIC control mode

P3 Regulation of the battery current limitation

P4Regulation of the stability of the regulation loops (output voltage and battery current)

P5Output voltage regulation (BOOST voltage) in AUTOMATIC control mode

LOOP card – Interfaces with I/S-CL (P) LOOP I/S-CL

Signal of the battery SHUNT for the P 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

+12V

-12V

U2

LM7912

2 3

1

IN OUT

GND

+ C51000u 50V + C6

47u 25V

C4100n

+ C247u 25V

+ C11000u 50V

C7100n

U1

LM7812

1 3

2

IN OUT

GND

D6

1N4004

D4

1N4004

Q1

BDX34C

2

1

3

C3100n

Q22N2907A

32

1

R8

1R 5W

R7

1R 2W

F6 1A 6,3x32

T2

ACM1008

1

3

8

12

7

2

56

4

11

1615

109

1413

1817

D1

1N4004

D2

1N4004

F4 1A 6,3x32M2

12345

D3

1N4004

D5

1N4004

F5 1A 6,3x32

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

M1

12345 CN2

12345678910

CN1

12345678910

T1

ACM1008

1

3

8

12

7

2

56

4

11

1615

109

1413

1817

R1

470R 3W

R4470R 3W

R5470R 3W

R6470R 3W

F1 1A 6,3x32

F3 1A 6,3x32

F2 1A 6,3x32R3

470R 3W

R2

470R 3W

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

0_SCOK

1_AR

+12V

+12V

VRM +12V

R15410K

+

-

U31ALM324

3

21

411

P1350K

13

2

R152100R

R15910K

R1552K21

DL12

R148

100K

R150

100K

D23 3V9

+

- U31CLM324

10

98

411

R1788K25

D29

R16410K

D30

C83470n

C86

100n

R1668K25

R167

2K21

R15610K

C100470n

Q8BC337 1

23

D32

+

- U31BLM324

5

67

411

R160

33K2

R1658K25

D18

D21

R1762K21

C87470n

+ C9610u-63V

R17512K

U22B

40106

3 4

R158

10K

D28

R15310K

U32D

4093

12

1311

SR T

MR

RCLS-1 card (PB117)

Control of the DC supply and rectifier start-up

1_AR

1_STOP

1_AV

0_ON

0_AT

0_FB

1_PSOK

TP11

TP10

+12V

+12V

+12V

VRM

+12V

U26A

4075

128

9

U26B

4075

345

6

JP51 3

2

U22C

40106

5 6R137

39K

+

C9510u-63V

+

C9710u-63V

U30B

4093

5

64

R181

1K

R147806K

U32B

4093

5

64

C821n

SW1

12

R140909R

R138205K

M9

123456789

10

U30A

4093

1

23

R14910K

U32A

4093

1

23

R17410K

+

-

U31D

LM324

12

1314

411

+ C7322u-50V

R17310K

D163V9

R182

1K

U22D

40106

9 8

R15110K U22E

40106

11 10

0=RADDR. OK

SLAVE

1=AVARIA0=RADDR. OK

0=START1=STOP

0=S

TAR

T 1=

STO

P

1-2 = M2-3 = S

0=AT

0=FB1

0=FB

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

VREF

-12V

+12V

R185 15K

C115 1u

R19351K1

U1TL431AB2

3

1

R116K81

R103K9

D48

R19654K9 +

C116100u-25V

R195100R

R19210K

C113100n

C114

100n

+

-

U34

OP07

3

26

74

R19451K1 R28

100R

1-SOFT

All'anello dicontrollotensione

RCLS-1 card (PB117)

Generation of the thyristors turn-on signals

HF

HF

TP5

TP7

+12V+12V

TP9

U17B40106

3 4

R12710K

R14660K4

P12

100K

1 3

2

U25 TCA785

2

3

4

5

6

7

8

11

10

9

12

13

14

1

15

16

Q2N

QU

Q1N

Vsync

I

QZ

Vref

V11

C10

R9

C12

L

Q1

GND

Q2

VS

C71 100n

C8047n

D33

R183300K

C105470n

D17

R145

10K

D15

C8110n

U19C

ULN2804

3 16

109

U24D 408112

1311

U19D

ULN2804

4 15

109

U24C 40818

910

ON

SBB

AA

ControlLevel

HighFreq.

To thefinalstage

Mixer & Driver

+24V

G3

G4

K3

K4

C67100n

R13268R 5W

C32100n

R6068R 5W

TF3

TI112046

1

6

3

4

TF4

TI112046

1

6

3

4

R126

4R7 2W

DL13

D9 R12547R

R90

4R7 2W

DL3

D8 R9647R

AA

BB

SCR1

SCR2

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

+12V

+12V

-12V

TP12

+12V

-12V

+12VD42

R33 4K75

R214K75

R304K75

RL6

71

21112

M1

12345

R41K82

D41

+

-

U7

OP07

3

26

74

C14 100n

C24

100n

RL1

71

21112

R6715R

P3

100K

13

2

R4354K9

D3C15

1u

R20

10K

R3810K

C11100n

C21

100n

+

-

U6

OP07

3

26

74

R22K21

R147K 12W

+

- U33160

3

26

74 1 5

R39 10K

R5 10K

C5

100n

RL2

71

21112

P45K

13

2

R37 15K4

C12 47n

P55K

13

2

D43

R634K75

R623K32

R4154K9

R408K25

TST-2

TR-1

TR-2

VREF

TST-1

FBK

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 SET-POINT that defines the battery limitation current is adjusted through the potentiometer P15

+12V

VRM

-12V

+12V

-12V

TP15

+12V

R67

511R

R69 10K

R53 100K

R57100R

+

-

U10

3160

3

26

74 1 5

R54

511R

D46

C28100n

P6

100K

13

2

R56 100K

R59

511R

CN4

12345678

C25100n

C27

100n

C31100n

R58

511R

C26 100n

P15 100K13

2

+

-

U33

OP07

3

26

74

R71 68K1

R1883K32

C34100n

C112

220n

+

-

U11

OP07

3

26

74

C35 1u

R64 10K

C42

100n

R189

10K

R19112K

C110100n

D6

C111100n

R190287K

C33 1u

R18710K

RCLS-1 card (PB117)Total current control loop


The SET-POINT that defines the total limitation current is adjusted through the potentiometer P2

+12V

-12V

+12V

+12V

+12V+12V

-12V

TP14

+12V

VRM

+12V+12V

D39R17 100K

+

-

U2

3160

3

26

74 1 5

C4

100n

P1

100K

13

2

CN4

12345678

R23 511R

C3100n

R18 100K

C7 100n

R16 511R

D37C9

100n

C10

100n

R32511R

R26

511R

D38 N.M.

D40 N.M.

C37

220n

C18100n

+

-

U5

OP07

3

26

74

R25 10K

P2 50K13

2

R19 10KR36

10K

C8 100n

R2210K

R65825R

R51 68K1

C23

100n

+

- U9BLM339

5

42

312

R47 100K

R66 10K

D5

6V2

C19 1u

C30

100n

R49 12K

R70 15K4

R52 10K

R6868K1

C20100n

R48

806K

+

-

U8

OP07

3

26

74

R46

6K81

D4

C17 1u

OL

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

VOLTAGE LOOP

BATTERY CURR. LOOP

TOTAL CURR. LOOP

12P CURRENT BALANCE

TP12

+12V

-12V

TP13

+12V

TP15

TP14

R77

100K

R7910K

C47

100n

C43100n

+

-

U15

OP07

3

26

74

P8

100K

13

2

D7C50

220n

R81 464K

R61 1K

P910K

13

2

JP1

3 1

2

R9110K

R8810K

R9710K

+

-

U16D

LM324

12

1314

411

R42 1K

D49

R9310K

R55 1K

JP7

13

2

VE

VE'

1-2 = Man2-3 = Aut

Rect.Slave

1-2 = M2-3 = S

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

-12V

+12V

-12V

+12V

+12V -12V

R115

33K2

R114

33K2

+

-

U16B

LM324

5

67

411

R108

10K

CN2 12345678910

R110

10K

R106604K

R11310K

+

-

U16A

LM324

3

21

411

C51 100n

C57 100n

R92

10K

R94

511R

C53100n

R10122K1

+ C5510u-63V

+

C5210u-63V

C54100n

R98 511K

P10 50K13

2

12 PULSESCURRENTBALANCE

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

+12V

+12V

-12V -12V

CN1

123456789

10

C6100n

+

-

U4

OP07

3

26

74 C13 100n

R35 10K

R31 1K

R24 1K

R86K81

R7178R

R27

54K9

C109

100n

VREF

All'anello dicontrollotensione

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

The LEDs are normally lit steady, blinking in case of alarm (except DL12 that is normally OFF and lit in case of alarm)

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

RCLS-1 card – Interfaces with I/S-CL (P) 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 P battery current reading (only when the BOOST charge is enabled)

• Pin 7÷10 connector CN5

RCLS-1 card – Interfaces with I/S-CL (P) 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 X X

Voltage control loop X X

Total current control loop NOT PROVIDED X

Battery current control loop X X

General control X X

Thermal compensation of the charging voltage (OPTIONAL)

X X

Interface with a relay card NOT PROVIDED X



RectifierRectifier





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 (PB003), inclusive of:◆ RCB (PB011)◆ VCB (PB012)◆ SCB (PB014)

• PS-HV (PB001)• ID (PB013)• INV-AV (PB004/PB018)• FCI (PB047)

STATIC SWITCH• VOLT-REF (PB005/PB019)• SCR-FIR (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 (PB001) Supply range: 300÷600Vdc PS-MV (PB002) Supply range: 180÷300Vdc PS-LV (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

AC3

AC4

TP8

TP9R601K

R621K

+

C40100u 50V

R5710K

FU6

PF 2A

FU1

PF 2A

R6310K

CN1

FLAT 10P

12345678910

T2-E

17

18

D22MUR120

R591K

D24MUR120

D23MUR120

C41100n

R611K

D25MUR120

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

TP5

TP2 +12V

TP3 -12V

TP4

+24VFU2

PF 5A

U5LM7912

2 3

1

IN OUT

GN

D

R51

10K

R50

4K7

LD3

G 3mm

T2-C10

11

12

13

14

C151uD20

1N4004

R49

10K

LD1

G 3mm

R46

2K21

D15

MUR120

D14

MUR120

D16MUR120

D19MUR120

D17MUR120

D18MUR120

D211N4004

R47

2K21

LD2

G 3mm

R48

10K

C281u

+

C31100u 50V

+C30

100u 50V

CN2

FLAT 10P

12345678910

U4LM7812

1

2

3VIN

GN

D

VOUT

+C29100u 50V

C131u

AC2

AC2

AC1

AC1

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

T2-F

7

8

9D27

MUR120

D26

MUR120+ C46

100u 50VC471u

R6410K

R682K21

T2-G

19

20

D28

MUR120+ C48

10u 63VLD5G 3mm

C341u

R662K21

FU8

PF 2A

LD4G 3mm

CN3

FLAT 10P

12345678910

FU7

PF 3,5A12V/RELAY E BUS

12V/RELAY

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

+12V

-12V

TP1+12V

CN4

FLAT 10P

12345678910

D6

BYV26CT1-D

9

10 C181u

P1

5K

R23

1K

R24

1K

+

-

U1

OP07

3

26

74

C32100n

C33100n

R251K

R26

261R

Vdc MEASURE

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

AC1

AC2

+15VF

-15V

+5VF

-15VF

+5V+15V

CN1

123456789

10

U278L05

1

3

2VIN

GND

VOUT

D13 1N4148

D14 1N4148

D6 1N4148

D5 1N4148

TR2

TI117239/ACM2008

R33 1K

D12 1N4148 +C2210u-63V

C9 1u +C1010u-63V

D7 1N4148

C121u

D4 1N4148

TR1

TI117239/ACM2008

LD4

+C2310u-63V

D11 1N4148

+C1110u-63V

U678L05

1

3

2VIN

GND

VOUT

R34 1K

LD3

C21 1u

C241u

Power supply IGBT+

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

+5V

U1B

4093

5

64

147

+C210u-63V

D31N4148

R5680K

U1C

4093

8

910

147

U1D

4093

12

1311

147

R63K3

LD1

U3 HP2601

2

3

6

5

7 8

D11N4148

R1

1K8

C1 100n R23K3

U1A

4093

1

23

147

R3 ***1K

D21N4148

R4 1K8

C51n

1=ON

0=ON 0=ON1=ON

PWM

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

+15V

DZ218V

DZ318V M1

12

R7

22R

Q2IRFD014

D

GS

R9390R 2W

R10390R 2W

DZ124V

C3100n

Q4IRFD9014

D

GS

Q3IRFD014

D

GS

R89K09

+C4

10u-63V

C7

1u

C8

1u

+C6

10u-63V

R11 **

R151K

R13 **1=ON

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 INV-AV-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+24VST

+5VST

CN1

CON7

1234

65

7

C32,2 u 250V

C82,2 u 250V

C42,2 u 250V

C52,2 u 250V

C92,2 u 250V

C102,2 u 250V

CN4

1 2 3 4 5 6 7 8 9 10

CN5

1234

65

7

D1 D2 D3

D4 D6D5

FU1 FU2

D7 D9D8

D10 D11 D12

CN3

12345678910DL1

+C2

10u 50V

T1

R2511R

R122R 2W

T2

+C7

10u 50V

T3

C60,1u

T4

FU3

T5

T6

U17805

1

2

3VIN

GND

VOUT

+C1

100u 50V

CN21 2 3 4 65 7

7

2

10

9

13

12

2

7

10

9

13

12

7

2

10

9

13

12

7

2

10

9

13

12

7

2

12

10

13

9

7

2

12

10

13

9

R

S

T

N

OUTPUTBYPASS

N

T

S

R

FANSSUPPLY

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 three-

phase 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 – M1Origin Signal

P SIDE

FCI – M2

1-2 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

VNR +5V

+VRAM

+5V

ON

OFF3

1

U75TEA7605

2

31

M

UE

L4

C137

100NF

C131

100NF

+C122

470uF

D49

1N4148

D48

SD103

BT

D69GREEN

R146D50

1N4148

CN14-9

CN14-10

CN14-1

CN14-2GND COMMON MODE

2

J2

FILTERS

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”

+5V

VR/2

ADA2

ADA3

ADA5

ADA0

ADA4

ADA1

FI1 BYPASS FREQUENCY

C109

D60

D64

D61D62R15210K

D52D57D58D59

C97C98C100C110

C113

R20

9

R20

5

R172

R164

R165

R166

R173

R171

D54D55

R20

8

R20

7

R20

4

R20

6D65

R15010KD53

MICRO BUS

CN13-4

CN13-3

CN13-2

CN13-5

CN13-6

CN13-7

BYPASS

OUTPUT

2K2 1% X6

R

S

T

R

S

T

R

R

S

S

T

T

OP AMPR

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

OUTPUT CURRENT R

OUTPUT CURRENT T

DATA_OUT

INVERTER VOLTAGE R

PARALLEL CORRECTION

INVERTER VOLTAGE S

INVERTER VOLTAGE T

OUTPUT CURRENT S

DC VOLTAGE

INVERTER INPUT CURR

BATTERY BOOST CURR

D31 D16 D32 D14 D15 D34 D35 D36

D22 D23 D43 D20 D21 D6 D33 D5

D17

U22

TLC1542

1234567891011

121314151617181920

IN0IN1IN2IN3IN4IN5IN6IN7IN8

GNDIN9IN10REF-REF+CSDOUTADRINCLKEOCVCC

D42

C51 C49C52 C64 C66C73 C65C72 C50

A

VDC

Inv. Volt. R

CFPARIBS

IBOOST

Inv. Volt. SInv. Volt. TOut. Curr. ROut. Curr. SOut. Curr. T

A

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

TP2

FEEDBACK

P2

10K

D73

SD103

C19

100NF

R26

1K

R27

1K

R1822R

R40100R

C27 1n

D72

SD103

C281NF

R382K

+

-

U16A

MC34074

3

21

R3947R

R25

1K

M1-2

A

J9

J100

A

J10

A

CurrentSignal

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

+12A

+12A

+5A

FEEDBACK

CURRENT STOP

+

-

U11

CA3130

3

26

7 54 8 1

U15B

40106

3 4

R1510K

C13

1NF

U5D

4093

12

1311

N1

100pF

U5C

4093

8

910

D3LMCS

R40

R17 10K

C281NF

R16

10K

C20100NF

R13

3K3

R39

+ C14810u 25V

R50

200KR49

1K

SW4

PPMCSR18

M1-2

J9

A

J10

A

A

A

A

J100

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. 250s) 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

+12A+5A

+5A

VFBK

VPWM

VREF

VREF

+

-

U6B

LM324

5

67

+

-

U6D

LM324

12

1314

+

-

U6C

LM324

10

98

R39 10K

R40 10K

R3610K

C19100NF

R41 10K

C20

1NF R42 11K8

R37

43K2

R32 10K

R30 10K

R31 10K

C22

100NF

C151NF

C141NF

A

A

J2

A

A

NOTCHFILTER

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

+12A+5A

-12A

FREFFPWM

R67

220K

+

-

U17

OP07

3

26

7 14 8

C42100NF

C41100NFR33

300K

R66 *

6K81

C34

100NF

C55

10NF

C54

100NF

A

A

A

R66 = 6K81 for 8KHz

13K6 for 4KHz

24K9 for 2KHz

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

AC1

AC2

+12A

+12A

+12A

1STOP

+12A

FPWM (TRIANGLE)

VPWM (SINEWAVE)

U14D

40106

9 8

U9A

4093

1

23

U9B

4093

5

64

C18100NF

C22

100NFR101K

R9

1K

+

-

U12

CA3130

3

26

7 54 8 1

N547pF

C14

22NF

C15

22NF

C24100NF

U14C40106

5 6

CN7-9

CN7-10

CN7-7

CN7-8

CN7-2

CN7-4

CN7-1

CN7-3

A A

A

A

A

A

A

+TA

-TA

A

A

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 VOLT-

REF-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 AC3-AC4 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

M3Signal

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 fswitching = 8khz




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

--------------------2 x IIGBT

REQ =

Where: REQ = Series combination of R18-R39-R40

KLEM = Conversion ratio of the LEM

IIGBT = IGBT’s nominal current


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 Pos Function

J11-2 SINGLE-PHASE inverter

2-3 THREE-PHASE inverter

J2 Closed Back-up battery connected

J7 Closed Watchdog enabled

J9 Closed Resistor R40 (100R) inserted



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



RectifierRectifier





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 LOADInverter static switch closed, load on inverter

S6 BYPASS OKBypass voltage and frequency within tolerance

LCD panel – Alarms


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 FAULTBattery test failed or intervention of the safety timer during boost charge

A11 BATT IN TEST Battery test in progress

A12 PLL FAULTProblems with the digital synchronisation system

A13 INV OUT TOL Inverter output voltage out of tolerance

LCD panel – Alarms


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 TEMPHigh temperature on the inverter and/or rectifier bridge

A22 BYP SWITCHClosure of the commutation switch which forces the load to bypass (maintenance)

A23 EPO BUSIntervention 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



RectifierRectifier



Test softwareTest softwareTest softwareTest 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


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


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


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


Section VARIABLES

DC VariablesVDC_OK

INVERTER VariablesINV_ONSSW_ONIOKIFLCONACO_LOADHITEVUOKSYNCOKIMTERM

BYPASS VariablesROK_XFROKRMSOK

USCITA VariablesCOKI_OVER


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


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


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)


Section OUTPUTS The section OUTPUTS shows all the commands generated by the

microprocessor for the management of the various UPS sections


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


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


Section INPUTS The section INPUTS shows the status of all the microprocessor’s

digital inputs


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


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


Additional sections

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

UPS serial number (set by software command) and software version installed on board the I/S-LC card

Increment of the thermal image counter

Battery charge percentage


Sezioni aggiuntive

KF BY: position of the bypass voltage’s control tableKF 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 cardPar Data: it opens a panel that shows the control parameters during the parallel operationBOOST: it opens a panel that shows the current thresholds for the BOOST charge operationSet 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

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UPS Technical Presentation

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