Medi Microcontroller based Higher Capacity Domestic Sinewave UPS-cum-Inverter with Charger

2007 model

How to do the Setup

Document Revision 1.00 / 12th February 2007

Wiring Diagram

How to do Setup
To do the setup no special type connection is required. The setup switched are to be connected to connector CN3 to which normally the ON/OFF switch and UPS/INV selection will be connected. During setup there will be 3 switched: UP, DOWN and ENTER. The connection of these switches are as shown below.

There will be a default value already set for parameters such as battery low, battery full charge etc. So, there is no need of changing the values. Only the calibration of the meter is required by taking the calibrate mode. Also after the wiring and finishing of the inverter in the cabinet, the no-load set should be done. If you change any setup values and want to store those values (Selecting Done menu) you should put the small jumper near the 8 pin IC 24C04. Then only the changed values will be written to 24C04. If you forget to put the jumper the changed values will be present in the temporary memory of the chip and will not be written to 24C04. This time the system will work as per the changed setup values but when you disconnect the battery and connect again all changed values will be lost.

To enter setup simply press Enter switch and then power on the system. The display will show ‘Enter Setup [N]’. Note that the default choice is ‘No’ which prevents accidental entry to setup mode. To change the choice to Yes, press the Up switch. Pressing Up swith again and again will toggle the choice between Yes and No. While the choice is Yes (display is showing: ‘Enter Setup [Y]’) press Enter switch. Now the system is in setup mode. If no switches are pressed for around 15 second the system will not enter setup, but will start normal working.

Menu driven setup
We have provided a very user friendly menu driven setup procedure. The menu style is as below: Main Menu 1. Parameters 2. Calibrate 3. No Load Set 4. Done 5. Discard

Sub Menu 2 2.1 Zero Set 2.2 Bat V 2.3 AC In 2.4 AC Out 2.5 Exit

Do NoLoad test

Sub Menu 1 1.1 Bat Low 1.2 Bat Too Lo 1.3 Bat Full 1.4 Bat Reconn 1.5 Inv Volt 1.6 Inv Load 1.7 Char Amp 1.8 Bat Nos 1.9 Exit

Save changes & Exit Discard changes & Exit When you enter setup you are starting at Menu1: Parameters. If you press up switch you will see menu 2: Calibrate. Up switch is for going to the next item while Down switch is for going to the previous item. Menu is having auto-wrap facility, means: While displaying the last item in a menu if up switch is pressed then the first item is displayed. Similarly while displaying the first item in a menu if down switch is pressed then the last item is displayed. To enter a menu just press the enter switch while the menu is displayed. For example if you want to enter the calibration menu: While you are in the main menu, press up or down switches until the display show 2. Calibrate and then press enter. From the sub menu if you want to go back to the main menu: press up or down switches until the display show ‘Exit’ and press Enter. 1. Parameters menu This menu is for setting various parameters like battery full charge voltage, battery low voltage etc. Normally these voltages will be automatically set by the microcontroller at power on time. Normally there is no need to change any parameters. 2. Calibrate Menu The second menu if for calibrating various parameters that the microcontroller reads. For example the battery voltage is given to the microcontroller through a resistance divider network which scale down the voltage to 0.2034. Due to the variation of resistance value this scale down may not be correct. So the system may show some different reading. To make the reading correct we have to do the calibration. Calibration is required for Battery voltage, AC input and AC output.

3. No Load Set menu This is for a kind of self test of the system. After assembling the PCB you need to run the No-Load test at least once. This is required for correct functioning of the system. 4. Done Menu Execute this menu if you have done the necessary changes in the setup and want to write this to the nonvolatile memory. Before doing this you should make sure that the two pin jumper JP1 near pin 4 of IC U3 (24C04) is placed, that is jumper shorted. Otherwise the setup values will not be saved to the memory. But the changed setup values will be in memory as long as the system is powered. On next power on these values will be lost. This jumper may be removed after the setup values are written to the memory. If the jumper is not present it is guaranteed that the setup values will not be changed. So it is better to send the system to the field without jumper. 5. Discard Menu Execute this menu if you have somehow done some unwanted changes in the setup values so do not want to write this to the non-volatile memory. The changes you have made will be discarded and the old values will be restored. Sub-Menus of Parameter Menu Paremeter menu has seven sub menus (plus one exit menu to go back to main menu). They are: 1.1 Bat Low, 1.2 Bat Too Lo, 1.3 Bat Full, 1.4 Bat Reconn, 1.5 Inv Volt, 1.6 Inv Load and 1.7 Char Amp. The two numbers separated by dot in the display indicate the menu number and sub menu number. For example 1.4 Bat Reconn means Sub menu 4 of main menu 1. 1.1 Bat Low This menu is for setting the battery low voltage (that is, the battery voltage level at which the battery low warning should start). To change this simply press enter while this menu is displayed. The display will show the present setting. Press Up or Down switches to change to the desired value and press enter. The default value for this parameter is 10.5V. Normally you need not change this. 1.2 Bat Too Low This menu is for setting the battery low too voltage (that is, the battery voltage level at which the system go to immediate cut). To change this simply press enter while this menu is displayed. The display will show the present setting. Press Up or Down switches to change to the desired value and press enter. The default value for this parameter is 9.0V. Normally you need not change this. 1.3 Bat Full This menu is for setting the battery full charge voltage (that is, the battery voltage level at which charger turns off). To change this simply press enter while this menu is displayed. The display will show the present setting. Press Up or Down switches to change to the desired value and press enter. The default value for this parameter is 14.0V. Normally you need not change this.

1.4 Bat Reconn This menu is for setting the battery reconnect voltage (that is, the battery voltage level at which the charger restart). To change this simply press enter while this menu is displayed. The display will show the present setting. Press Up or Down switches to change to the desired value and press enter. The default value for this parameter is 13.2V. Normally you need not change this. 1.5 Inv Volt This menu is for setting the output voltage of inverter. To change this simply press enter while this menu is displayed. The display will show the present setting. Press Up or Down switches to change to the desired value and press enter. The default value for this parameter is 220V. Normally you need not change this. 1.6 Inv Load This menu is for setting the inverter load. To change this simply press enter while this menu is displayed. The display will show the present setting. The setting is a K value which is inversely proportional to the inverter max load. If you increase this K value the load capacity will decrease and vice versa. Press Up or Down switches to change the K to the desired value and press enter. If you are changing the inverter load few trial and error adjustments may be required. The default value for this parameter is 127K. Normally you need not change this. 1.7 Char Amp This menu is for setting the charging current. To change this simply press enter while this menu is displayed. The display will show the present setting. Similar to inverter load setting the setting is a K value which is inversely proportional to the charging current. If you increase this K value the charging current will decrease and vice versa. Press Up or Down switches to change the K to the desired value and press enter. If you are changing the charging current, few trial and error adjustments may be required. The default value for this parameter is 127K. Normally you need not change this. Very Important: If you change the K value for charging current setting you should test in real condition and confirm that charging current do not rise beyond a limit at critical conditions. The most critical condition happens when battery is in discharged condition. So after setting the charging current, connect a discharged battery, apply mains through a dimmerstat and confirm that the charging current do not rise much at various mains voltages. Do repeated tests at mains voltage is low (near 100-120V) and mains voltage high (near 250-260V) 1.8 Bat Nos This menu is for setting the number of batteries used for the system. This parameter is to be set properly for getting correct battery readings in battery related menus. 1.9 Exit This menu is for exiting from the sub menu and go back to the main menu Parameters. Sub-Menus of Calibration Menu Calibration menu has four sub menus (plus one exit menu to go back to main menu). They are: 2.1 Zero Set, 2.2 Bat V, 2.3 AC In, 2.4 AC Out. The two numbers separated by dot in the display indicate the menu number and sub menu number. For example 2.3 AC In means Sub menu 3 of main menu 2. The calibration menu is given for correcting the reading shown by the system. That is, if the battery voltage is 12.3V but the system shows 12.8V then we can use the calibration menu to correct the display. You have to use a good multimeter while doing the calibration. After assembling the PCB the it is recommended to do

the calibration because there is a good chance for slight variations in the display of various parameters due to the tolerance of resistors. 2.1 Zero Set Actually this menu do not has much relation with the calibration of parameters. It is given as the sub menu of calibration because technically it belong to the calibration submenu. After assembling the PCB you have to run this sub menu at least once. When this sub menu is run the system will take some internal readings and will check the correctness of some parameters. These tests will be completed within a short time. While running this test the AC input should not be given because if AC is present the system can not successfully complete the test and as an indication the buzzer will beep continuously. After assembling the PCB you have to run Zero Set sub menu at least once. If it is not run there is a chance that at over loaded condition instead of showing ‘Over Load’ the system will show ‘Heavy Load’. Of course, this is not a serious problem. 2.2 Bat V This menu if for calibrating the battery voltage reading. To enter this menu press Enter while the display shows this menu. Inside this menu the display will show the present battery voltage. Suppose the display show 13.0V but with a good multimeter you measure the actual battery voltage as 12.5V. Now press Down switch to correct the reading. When the reading is OK press Enter switch. 2.3 AC In This menu if for calibrating the AC input reading. To enter this menu press Enter while the display shows this menu. Inside this menu the display will show the present mains voltage. Suppose the display show 230V but with a good multimeter you measure the actual AC input voltage as 238V. Now press Up/Down switch to correct the reading. When the reading is OK press Enter switch. 2.4 AC Out This menu if for calibrating the AC output reading. To enter this menu press Enter while the display shows this menu. The inverter will start with an output around 140-150V. Inside this menu the display will show the present inverter output voltage. Suppose the display show 180V but with a good multimeter you measure the actual inverter output voltage as 147V. Now press Up/Down switch to correct the reading. When the reading is OK press Enter switch. 2.5 Exit This menu if to exit the submenu and go back to the main menu Calibration. Menu 3: No Load Set Inside this menu the system takes some readings that are important for the correct working of the inverter. It is very important to run this menu at least once. Very Important: If you replace the transformer or change the primary or secondary connection of the transformer you should run the No Load Set at least once. This is important because inside this menu the system sense the polarity of the transformer. It is needed for correct line interactive changeover. Incorrect polarity can cause the re-boot of the computer and sometimes damage the MOSFETs.

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