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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

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 ASTRID UPS of the EVOLUTION series are ON-LINE DOUBLE CONVERSION.

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. that’s to say same data access mode  Test software . and communication protocol with high noise immunity  Use of common parts and solutions on all the range  Microprocessor control card  LCD panel.

= 0.f.PLANET/E 20-30kVA (3Ph / 1Ph)  Input:      3 x 380÷415Vac Output: 1 x 220÷240Vac Power: 20kVA – 30kVA.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 type 1 type 1 type 1  Rectifier:  Inverter:  Static switch: . p.

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 type 1 type 2 type 2  Rectifier:  Inverter:  Static switch: .

8 Battery: 192 cells Pb (384Vdc) . = 0. p.f.HALLEY/E 40÷80kVA (3Ph / 3Ph)  Input:      3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 40kVA – 60kVA – 80kVA.External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms type 2 type 3 type 2  Rectifier:  Inverter:  Static switch: .

= 0.External Crest factor: 3:1 Overload capability : 125%Pn x 10min 150%Pn x 1min 200%In x 100ms type 2 type 3 type 2  Rectifier:  Inverter:  Static switch: .f. p.8 Battery: 192 cells Pb (384Vdc) .HALLEY/E 100÷160kVA (3Ph / 3Ph)  Input:      3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 100kVA – 125kVA – 160kVA.

p.External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms type 2 type 3 type 2  Rectifier:  Inverter:  Static switch: .SATURN/E 200÷300kVA (3Ph / 3Ph)  Input:      3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 200kVA – 250kVA – 300kVA.f. = 0.8 Battery: 192 cells Pb (384Vdc) .

SATURN/E 400÷650kVA (3Ph / 3Ph)  Input:      3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 400kVA – 500kVA – 650kVA. p.f.External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms type 2 type 3 type 3 (except 400kVA)  Rectifier:  Inverter:  Static switch: .8 Battery: 192 cells Pb (384Vdc) . = 0.

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) .

3 x32 1A 5 6 12 11 16 15 10 9 14 13 + LM7812 C9 47u 25V C10 100n 1 D16 1N4004 D17 1N4004 D18 1N4004 + C11 1000u 50V 2 + 2 18 17 ACM1008 GND C12 47u 25V C13 100n IN U5 OUT LM7912 3 -12V .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 R S T +24V 1 D13 D14 1N4004 D15 + 1N4004 1N4004 C8 1000u 50V U4 IN OUT 3 GND T1 8 7 M2 1 2 3 4 5 F1 6.3x32 1A 1 2 F2 6.3x32 1A 3 4 F3 6.

and lighting of LED DL2.  Generation of the signal 1_ROK (mains OK) if both the previous signals are OK R1 +12V 2K21 R2 8K25 +12V R S T C1 470n D2 R3 2K21 D3 5V6 R4 2K21 R5 8K25 R6 33K2 + C2 10u-50V R7 8K25 R8 D5 D6 D7 R10 10K +12V U2C LM324 8 R19 10K 10K R12 33K2 5 6 +12V D8 R9 1K C3 R13 2K21 100n 1 U2A LM324 DL2 D9 R20 2K21 1_ROK +12V Q1 BC337 2 1 3 1 R47 100K 2 0_SCOK 2 3 Q10 BC337 40106 DL1 U1A 1 R11 10K 4 C4 470n R14 10K R15 22K1 R17 R18 10 100K 9 4 3 7 U2B LM324 D10 6V2 2 + - + - C5 470n 11 11 100K 11 4 + - VRM R16 10K .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%.

the LED DL3 is lit and the rectifier is enabled to start-up through the signal 0_ON R21 +12V 2K21 R23 U3A 1_ROK 1_PSOK R22 806K VRM R24 10K D12 3V9 +12V R26 10K R28 909R C7 1n 12 13 1 3 2 4081 R25 10K + C6 40106 10u-50V D11 100R 5 6 0_ON U1C DL3 Stop U1B U2D 14 LM324 3 4 1_PSOK R27 2K21 DL4 4 + - 11 40106 .PRCH card (PB114) Control of the DC supply and rectifier start-up  The +12V supply is controlled by a comparator. if both of them are OK. 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.

The resulting series of pulses represents the initial stage of the thyristors control circuit Control Level TP5 D26 U1D 40106 0_ON R41 249K C24 470n 9 8 R42 S 51K2 D27 C25 220n D28 8 5 6 7 R39 10K 1 2 3 4 16 15 14 13 TP7 12 HF 11 4081 ULN2804 10 9 R43 60K4 C26 47n 1 100K 6 5 4 4 15 +12V +12V C23 100n High Freq. T-TP8)  Each ramp is compared with a control level (TP5). S-TP7. TP9 U3C Mixer & Driver 10 U11C 10 9 4081 U12B ULN2804 3 16 GND Q2N QU Q1N VS Q2 Q1 L HF 8 10 9 U11D Vsy nc C12 I QZ Vref U9 V11 C10 R9 TCA785 2 P2 3 9 . The result of the comparison (square wave) defines the thyristors’ delay angle  The square wave is “mixed” with a high frequency signal (TP9).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.

they are OFF in case of alarm .PRCH card (PB114) – Settings and controls POTENTIOMETERS P1 Amplitude regulation of the ramp phase R P2 P3 Amplitude regulation of the ramp phase S Amplitude regulation of the ramp phase T CONTROL LED DL1 DL2 DL3 DL4 Correct phase sequence AC voltage in tolerance (>340Vac) Rectifier ON Internal DC supply correct COLOUR YELLOW YELLOW GREEN YELLOW  The LEDs are normally lit steady.

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 TF1 SQUARE WAVE R1 68R-5W 1 6 TI112046 3 4 D1 1N4936 R4 47R 4R7-2W DL1 R2 G1

SCR1/R
K1

C12 100n TF4 SQUARE WAVE R17 68R-5W +24V 1 6 TI112046 3 4

DL4 R18 G2 D4 1N4936 R19 47R 4R7-2W

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)

the card generates a stabilised internal voltage reference (VREF). and therefore the rectifier start-up is enabled.LOOP card (PB115) Generation of the internal reference  Whenever the signal 1_ON is active (originating from the PRCH card). that is used in the voltage control loop +12V C26 100n 1_ON D9 R51 33K + C30 100uF 25V R53 51K R54 10K R48 100R R49 51K 3 2 7 U10 6 OP07 C27 100n -12V R55 3K92 R56 15K4 U11 TL431AB R57 3K32 Not mount. + - R50 VREF R52 6K81 1 4 C33 1u 2 3 100R .

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 R-S2 R-S1 TR-2 TR-1 R11 10K R12 4K75 3 CN1 1 2 3 4 5 6 7 8 9 10 VREF 2 R18 2K21 R19 1K82 R20 4K75 +12V C8 C4 47n 15K4 7 100n R15 6 U5 3160 +12V R25 8K25 C12 100n 10K R16 54K9 R10 54K9 3 2 +12V C6 100n + - 7 TP12 U4 6 OP07 C10 100n 4 1 5 + - 1 7 2 11 12 RL1 B1 B2 R21 4K75 7 3 2 R28 10K + - U6 6 -12V OP07 C14 100n D1 C11 3 3 M1 1 2 3 4 5 P5 5K P2 2 5K RL2 2 1 7 2 11 12 R30 3K32 TR-2 TR-1 -12V 4 R26 121K R32 10K 4 1u 1 +V -V R59 4K75 1 .

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 C15 100n +12V R33 100K R35 3 511R D5 M1 1 2 3 4 5 C19 100n R36 511R 2 C16 +12V C18 100n R38 10K 6 U7 OP07 3 2 1 R29 820R R34 4K99 +12V C17 100n R37 12K 3 U9 6 OP07 10K D3 -12V R45 511R C25 100n R46 511R R43 100K 10K D8 C24 100n R47 10K D7 C23 1u C22 100n 6V4 C34 100n -12V R27 R40 100K C21 100n R39 2

2

VRM

7

7

100n

TP2

7
+ U8 6 OP07

+ -

+ -

4

-12V

C20 100n

R42 4K64

4

4

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

+12V TP13

7

R13 1K VOLTAGE LOOP

3 R14 2 100K

+ -

U3 6 OP07 C9 100n 1

JP1 3 2 P1 10K +12V C3 100n R8 10K 3 2

R31 3K92 CURRENT LOOP R23

4

1-2 AUT. 2-3 MAN.
3

-12V 464K

2

1

R9 10K

7
+ U2 6 OP07 C7 100n

Ve

D2 R41 3 1K

P4 100K 1

C13 220n

R22 10K

-12V R17 10K

2

4

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

VREF +12V R1 6K81 R2 10K 3 2 R4 178R R3 1K

+12V C1 100n

M2 3 2 1

7

+ -

U1 6 OP07 C2 100n R6 1K

R5 54K9

All'anello di controllo tensione

-12V

4

LOOP card – Settings POTENTIOMETER P1 P2 P3 P4 P5 Output voltage regulation in MANUAL control mode Output voltage regulation (FLOATING voltage) in AUTOMATIC control mode Regulation of the battery current limitation Regulation of the stability of the regulation loops (output voltage and battery current) 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 .

3x32 3 4 1A 6.3x32 1 2 1A 6.3x32 5 6 12 11 16 15 10 9 14 13 D2 1N4004 D3 + 1N4004 C1 1000u 50V C3 100n GND 1R 5W + LM7812 C2 47u 25V C4 100n 1 D4 1N4004 D5 1N4004 D6 1N4004 + C5 1000u 50V U2 2 + 2 18 17 ACM1008 GND C6 47u 25V C7 100n IN OUT LM7912 3 -12V .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 R7 3 1R 2W 1 2 3 Q2 2N2907A R8 Q1 2 BDX34C 1 +12V U1 1 IN OUT 3 D1 T2 1N4004 8 7 M2 1 2 3 4 5 F4 F5 F6 1A 6.

3x32 3 4 1A 6.SYNC-12 card (PB116) Generation of the synchronism signals  The card uses a transformer with two secondary windings.3x32 5 6 12 11 R3 16 15 470R 3W 10 9 14 13 18 17 ACM1008 R4 470R 3W R5 470R 3W R6 470R 3W CN2 1 2 3 4 5 6 7 8 9 10 . 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 R2 470R 3W T1 R1 8 7 470R 3W M1 1 2 3 4 5 F1 F2 F3 1A 6.3x32 1 2 1A 6. displaced by 30°.

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) .

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 C100 470n D32 R176 2K21 D23 3V9 +12V R167 2K21 R178 8K25 R175 12K + C96 10u-63V R166 8K25 R159 10K Q8 BC337 1 2 3 3 U22B 4 0_SCOK 40106 12 13 U32D 11 1_AR 4093 DL12 MR R158 R160 33K2 5 6 R156 10K D18 R155 2K21 7 U31B LM324 R164 10K 10 9 VRM +12V C86 R153 10K 100n 8 U31C LM324 D21 D28 D29 D30 R152 100R C83 470n R148 2 100K 100K R150 3 2 +12V U31A LM324 1 3 4 10K C87 470n R154 10K P13 50K 4 + - + - 11 11 1 11 4 + - .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.

OK 1_AV 1_STOP 3 4 5 4075 U26B 6 TP10 0_ON 0=START 1=STOP 5 4 U32B 0=AT 6 4093 TP11 0=RADDR. OK 6 U22E + 11 U31D 14 11 LM324 10 1_PSOK 40106 .RCLS-1 card (PB117) Control of the DC supply and rectifier start-up +12V JP5 1-2 = M 2-3 = S 1 2 3 SLAVE R138 205K U22C R137 +12V 39K R173 10K R182 1 1K + 4093 C95 10u-63V M9 1 2 3 4 5 6 7 8 9 10 +12V 4093 4075 U30B R174 10K R181 5 4 1K + 4093 C97 10u-63V R147 806K VRM R151 10K D16 3V9 +12V R149 10K R140 909R C82 1n 12 13 4 5 6 SW1 U32A U22D 3 0=FB 9 8 1 + C73 22u-50V 2 0=START 1=STOP 2 40106 1_AR 40106 U30A 0=FB1 0_FB 0_AT 1 3 2 1 2 8 U26A 9 1=AVARIA 0=RADDR.

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) 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).

RCLS-1 card (PB117) Generation of the internal reference  The presence of the signal ON enable the soft-start of the rectifier (1_SOFT). that is used in the voltage control loop +12V C113 100n D48 R195 100R R194 51K1 3 2 7 + - U34 6 OP07 C114 100n R28 100R VREF R11 6K81 1 R10 3K9 1-SOFT R196 54K9 C116 100u-25V + R193 51K1 R192 10K -12V R185 15K 4 3 All'anello di controllo tensione U1 TL431AB C115 1u 2 . the signal 1-SOFT activates the circuits that generates the stabilised internal voltage reference (VREF).

TP9 Mixer & Driver 10 U19C U19D To the final stage Vsy nc C12 I QZ Vref V11 C10 R9 2 P12 3 U25 TCA785 +24V C67 100n TF4 1 AA R132 68R 5W C32 100n TF3 1 BB R60 68R 5W 6 TI112046 4 D8 R96 47R 4R7 2W 3 6 TI112046 DL3 R90 G4 4 D9 R125 47R 4R7 2W 3 DL13 R126 G3 SCR1 K3 SCR2 K4 9 10 9 .RCLS-1 card (PB117) Generation of the thyristors turn-on signals Control Level +12V +12V C71 100n U24C 4081 HF D33 U17B 40106 ON R183 300K C105 470n S 10K D17 D15 8 3 R145 4 C81 10n R127 10K 1 2 3 4 5 6 7 GND Q2N QU Q1N VS Q2 Q1 L 16 15 14 U24D 4081 13 12 11 TP7 HF 12 11 13 ULN2804 10 9 R146 60K4 C80 47n 1 100K 4 15 BB 8 10 9 ULN2804 3 16 AA TP5 High Freq.

The resulting series of pulses represents the initial stage of the thyristors control circuit  The final stage. The result of the comparison (square wave) defines the thyristors’ delay angle  The square wave is “mixed” with a high frequency signal (TP9). as well as the snubber circuits for the limitation of the commutation spikes . T-TP8)  Each ramp is compared with a control level (TP5). S-TP7.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. similar to the circuit of the FIR-91 card. is integrated inside the RCLS-1 card.

RCLS-1 card (PB117) Voltage control loop R37 15K4 C12 FBK 47K 12W R1 R5 10K R33 4K75 3 2 R2 2K21 R4 1K82 1 7 2 TST-1 TST-2 11 12 RL1 R6 715R R30 4K75 +12V C5 47n 7 100n R20 6 U3 3160 10K R41 54K9 R43 54K9 3 2 +12V C14 100n + - 7 TP12 U7 6 OP07 C24 100n 4 1 5 R21 4K75 + - TR-1 TR-2 +12V C11 100n 3 3 RL2 12 11 2 2 7 1 3 2 7 VREF P4 5K R40 8K25 U6 6 3 OP07 C21 100n -12V D3 P3 1 100K 1u P5 2 5K + - 4 C15 4 1 1 -12V R62 3K32 R63 4K75 R38 10K +12V D42 1 2 3 4 5 M1 D43 2 RL6 11 12 D41 1 7 R39 10K 2 .

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 +12V C110 100n R187 10K 3 2 C26 100n R188 3K32 R53 100K CN4 1 2 3 4 5 6 7 8 R57 100R R58 511R D46 C31 100n R59 3 511R 2 +12V C27 VRM R191 12K 3 U33 6 OP07 10K C112 220n 100n -12V C111 100n -12V R190 287K R189 2 +12V C34 100n 2 7 7 TP15 U11 6 OP07 C42 + - + - 7 + - 100n U10 6 4 C33 1u R69 10K 4 R64 10K C35 1u 2 3160 3 P6 1 D6 4 1 5 100K R56 100K R54 511R C28 100n R67 511R C25 100n .

M.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 +12V +12V 806K C23 R65 825R C7 100n +12V +12V R18 100K CN4 1 2 3 4 5 6 7 8 R26 511R +12V C9 D37 100n 3 100K 2 R32 511R C10 100n R17 100K D39 C3 100n 3 +12V P2 50K 1 R47 100K C30 100n -12V C19 1u U5 6 OP07 10K C37 220n C18 100n D4 R36 C17 1u R52 10K C8 100n R19 10K 3 2 R25 10K R22 10K D40 N. C4 6V2 VRM R70 15K4 D5 4 R66 10K 5 6K81 R46 +12V 3 + - 100n 2 OL U9B LM339 R68 68K1 R51 68K1 +12V C20 100n 7 + - 100n U2 6 2 3160 12 1 R49 12K 3 4 1 5 7 P1 TP14 U8 6 OP07 + - -12V 4 7 + - 2 4 .M. R16 511R R23 511R 3 2 D38 N.

LOOP 100K R61 1K TP14 TOTAL CURR. 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 12P CURRENT BALANCE JP7 +12V C43 100n R42 1K TP12 VOLTAGE LOOP D49 TP15 BATTERY CURR. Slave 7 + - 2 P9 10K R91 10K 12 13 4 + U16D 14 LM324 1 2 1 1-2 = Man 2-3 = Aut 4 VE 3 2 11 .RCLS-1 card (PB117) General control stage  The output voltage. LOOP 100n -12V R81 464K R88 10K D7 P8 3 1 100K 220n C50 R97 10K C47 R55 1K R77 2 +12V TP13 U15 6 OP07 3 JP1 R93 10K R79 10K 3 1 2 1-2 = M 2-3 = S 3 VE' Rect.

is used to vary the control level in the circuit that generates the thyristors delay angle R114 CN2 P10 50K 3 33K2 1 33K2 R108 +12V C51 100n 10K 6 R92 R94 10K 511R R98 511K -12V R101 22K1 C53 100n 3 2 5 R115 -12V 10 9 8 7 6 5 4 3 2 1 +12V 2 4 + U16B 7 LM324 12 PULSES CURRENT BALANCE +12V -12V 4 + - U16A 1 LM324 C57 100n R110 10K 11 R113 10K C52 10u-63V R106 604K 11 + C55 10u-63V C54 100n + . opportunely amplified and filtered. connected to the connector CN2 of the RCLS-1 MASTER. control the current difference of the two bridges  The error signal.RCLS-1 card (PB117) 12-pulse current balance  A Hall effect CT.

is connected to the connector CN1 (through a interface card)  The feedback signal is opportunely amplified and inserted in the voltage control loop VREF C109 CN1 10 9 8 7 6 5 4 3 2 1 100n R8 6K81 R35 10K 3 2 R7 178R -12V +12V R31 1K +12V C6 100n 7 U4 6 OP07 C13 100n 54K9 + - R27 All'anello di controllo tensione -12V R24 1K 4 . installed inside the battery room.RCLS-1 card (PB117) Thermal compensation of the charging voltage  A temperature probe.

Settings POTENTIOMETERS P1 Regulation of the off-set OP-AMP TOTAL CURRENT P2 P3 P4 P5 P6 P8 P9 P10 P11 Regulation of the TOTAL CURRENT limitation Regulation of the VOLTAGE loop stability Output voltage regulation (FLOATING) in AUTOMATIC control mode Output voltage regulation (BOOST) in AUTOMATIC control mode Regulation of the off-set OP-AMP BATTERY CURRENT Regulation of the TOTAL control stability Output voltage regulation in MANUAL control mode Regulation of the current sharing in 12-pulse configuration Regulation of the amplitude ramp phase R P12 P13 P14 P15 Regulation of the amplitude ramp phase S Regulation of the AC voltage tolerance (alarm AR) Regulation of the amplitude ramp phase T Regulation of the BATTERY CURRENT limitation .RCLS-1 card .

Controls CONTROL LED DL4 Rectifier overload (Iout>100%) COLOUR YELLOW DL5 DL6 DL7 DL8 Internal DC supply not correct Rectifier OFF High temperature of the rectifier bridge Protection fuses failure RED GREEN RED RED DL9 Fans failure (not used) RED RED YELLOW RED DL10 Mains failure DL11 Input phase sequence not correct DL12 AC supply low voltage  The LEDs are normally lit steady.RCLS-1 card . 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 Generation of the 12V/24V supply Generation of the synchronism signals AC supply voltage control Internal DC supply control Generation of the thyristors firing signals Thyristor firing Voltage control loop Total current control loop Battery current control loop General control Thermal compensation of the charging voltage (OPTIONAL) X NOT PROVIDED X X X X X X X X X LOOP PB114 FIR-91 PB113 SYNC-12 PB116 X X X X X X X X X X X RCLS-1 PB117 Interface with a relay card NOT PROVIDED X .

General data Inverter & Static switch Technical features User interfaces Rectifier Test software .

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  Single-phase inverter  The rectifier output voltage (battery) is applied to the IGBT bridge.

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 .

which includes the DC capacitors and the Hall effect CT . with the following manufacturing features     Use of two power components. according to the constructive solution chosen  TYPE 1 It’s the single-phase inverter. each containing two IGBTs Installation on a single heatsink Forced cooling with single fan Power connections carried out through interface card IBPC-7 (PB120).Inverter typologies  As already seen for the rectifiers. also the inverters can be separated in different typologies.

with the following manufacturing features     Use of two power components. The power components are connected with cables and/or copper bars.Inverter typologies  TYPE 2 It’s the three-phase inverter. which includes the DC capacitors and the Hall effect CT  TYPE 3 It’s the three-phase inverter used starting form the 40kVA. Double IGBT packs (that is a single component containing two IGBTs) are generally used up to 160kVA range . without interface card. each containing two IGBTs Installation on a single heatsink Forced cooling with single fan Power connections carried out through interface card IBPC-7 (PB120).

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 . connected in anti-parallel.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) .Static switch  Three-phase static switch  It’s composed by six pairs of thyristors.

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 .

each of them with its own specific function .Inverter & static switch control  Unlike the rectifier. 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. the control of the inverter is completely entrusted to the microprocessor (HC16 Motorola). where the control of the operating parameters is purely analogue.

Inverter & static switch control  The following electronic cards are used for the inverter and static switch control  INVERTER • I/S-CL ◆ RCB ◆ VCB ◆ SCB (PB003). inclusive of: (PB011) (PB012) (PB014) • • • • PS-HV ID INV-AV FCI (PB001) (PB013) (PB004/PB018) (PB047)  STATIC SWITCH • VOLT-REF • SCR-FIR (PB005/PB019) (PB009/PB010/PB016) .

the one that “creates” the different power supplies for the whole control electronic (except. Pnom>200kVA) it’s used a power supply called PS-SAT (PB107). the rectifier)  It’s a switch-mode power supply. obviously. for example. 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. the use of parallel IGBTs (SATURN series. similar to the PS-HV except for the higher power .PS-HV card (PB001)  The PS-HV card is the system power supply.

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 .

that will be described later on.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. is taken from the same secondary winding of the transformer FU6 PF 2A R59 1K 17 + 18 T2-E R60 1K D24 MUR120 D25 MUR120 R62 1K TP9 D22 MUR120 D23 MUR120 R61 1K C40 100u 50V C41 100n R57 10K TP8 FU1 AC3 PF 2A AC4 R63 10K CN1 10 9 8 7 6 5 4 3 2 1 FLAT 10P .

PS-HV card (PB001) Analogue part supply  This section supplies all the analogue part of the microprocessor card  The supply AC1-AC2. is taken from the same secondary winding of the transformer R51 TP5 FU2 T2-C 10 D14 + MUR120 1 11 + D16 MUR120 12 D17 MUR120 C30 100u 50V VIN VOUT 3 R49 U4 LM7812 TP2 10K R46 D20 1N4004 C15 1u 2K21 R48 D19 MUR120 MUR120 2 IN OUT 3 R47 U5 LM7912 D21 1N4004 C28 1u 2K21 G 3mm LD2 D18 MUR120 10K TP3 -12V G 3mm +12V TP4 LD1 C29 100u 50V C13 1u 4K7 G 3mm AC2 AC1 CN2 10 9 8 7 6 5 4 3 2 1 FLAT 10P PF 5A 10K R50 +24V LD3 AC1 13 AC2 D15 14 C31 100u 50V 1 GND 2 + GND . that will be described later on.

stop) – pin 9-10 Parallel BUS – pin 9-10 Digital signal interface card FCI (PB047) – pin 1-2 D26 7 MUR120 + 8 C46 100u 50V C47 1u R64 10K FU7 PF 3.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.5A R66 2K21 LD4 G 3mm CN3 10 9 8 7 6 5 4 3 2 1 12V/RELAY E BUS D27 9 T2-F MUR120 FU8 D28 19 MUR120 + 20 T2-G C48 10u 63V C34 1u PF 2A R68 2K21 LD5 G 3mm 12V/RELAY FLAT 10P . floating/boost.

that provides also to isolate galvanically the supply of the serial ports. is provided on board the driver itself  The serial ports are supplied by the 40khz square wave AC3-AC4  A rectifying circuit.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. is provided on board the card RCB . that provides also to isolate galvanically the supply of the driver.

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 9 BY V26C T1-D P1 10 C18 1u 5K R24 1K C32 100n 3 2 1K R25 1K U1 6 OP07 261R R26 Vdc MEASURE R23 +12V C33 100n +12V CN4 10 9 8 7 6 5 4 3 2 1 FLAT 10P -12V 4 7 + - .PS-HV card (PB001) DC voltage measure  This section provides a stabilised voltage.

PS-HV card – Settings and controls POTENTIOMETERS P1 Regulation of the DC voltage measure P2 Regulation of the IGBT drivers supply voltage CONTROL LED DL1 DL2 DL3 DL4 DL5 +12V analogue part supply -12V analogue part supply +24V analogue part supply +12V relays and BUS (pin 9-10 CN3) +12V FCI card relays (pin 1-2 CN3) COLOUR GREEN GREEN GREEN GREEN GREEN .

the DR-SAT is provide with an additional protection with a desaturation sensor . a card for each switch (therefore two cards for each bridge leg) Besides the functions of the ID card. 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.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. the DR-SAT (PB108). 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.

originating from the power supply card PS-HV.ID card (PB013) Power supply section  The square wave AC1-AC2. is used to generate the isolated supplies for both sections of the card +15V D4 1N4148 TR1 C9 1u AC1 D5 1N4148 + C10 10u-63V D6 1N4148 CN1 1 2 3 4 5 6 7 8 9 10 + C11 10u-63V TI117239/ACM2008 D7 1N4148 -15V 1 U2 78L05 VIN GND +5V R33 1K VOUT 2 LD3 C12 1u 3 Pow er supply IGBT+ +15VF D11 1N4148 TR2 C21 1u AC2 D12 1N4148 + C22 10u-63V D13 1N4148 + C23 10u-63V TI117239/ACM2008 D14 1N4148 -15VF 1 U6 78L05 VIN GND +5VF R34 1K VOUT 2 LD4 C24 1u 3 Pow er 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 C1 100n R2 3K3 14 R1 2 1K8 3 U3 D1 1N4148 U1A 3 5 4 0=ON 6 9 R4 1K8 4093 8 14 7 8 D3 1N4148 D2 1N4148 1=ON R5 680K 14 U1B U1C 10 4093 U1D 11 R6 3K3 1=ON 6 5 HP2601 0=ON 1 2 4093 + R3 *** 1K C5 1n C2 10u-63V 12 13 14 7 PWM 7 7 LD1 4093 7 .

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 G S Q2 IRFD014 R7 1=ON 22R G S C6 R8 9K09 Q3 IRFD014 10u-63V + C8 1u G S DZ1 24V C3 100n D D Q4 IRFD9014 R13 ** 10u-63V 1u R15 1K DZ3 18V D C4 + C7 DZ2 18V 1 2 M1 G1H S1H -15V .

is used as reference signal for the measure of the output current . taken directly on the AC capacitors. for three-phase inverter  The card is basically composed by two sections: Inverter voltage feedback  The inverter output voltage. due to the CT’s secondary current. is connected to the connector CN1.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). 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. R5 (phase S). R6 (phase T). The voltage drop on the resistors R4 (phase R).

2 u 250V 7 9 9 D4 13 D5 D6 D10 D11 D12 13 7 C8 2.2 u 250V 7 9 13 13 9 C10 2.1u R1 22R 2W D1 D2 D3 D7 2 D8 GND D9 T1 2 10 + C1 100u 50V 10 T4 2 C3 2.2 u 250V BYPASS CN1 12 12 OUTPUT CN5 T5 2 R S T N 1 2 3 4 5 6 7 CON7 T2 2 10 10 C4 2.2 u 250V 7 1 2 3 4 5 6 7 R S T N 12 12 T3 2 10 10 T6 2 C5 2.2 u 250V 7 9 13 13 9 C9 2.VOLT-REF card (PB005/PB019) Electrical drawing +24VST +5VST 1 VIN VOUT 3 CN3 R2 511R + U1 7805 C7 10u 50V DL1 10 9 8 7 6 5 4 3 2 1 + C2 10u 50V C6 0.2 u 250V 7 12 12 FU1 FU2 FU3 1 2 3 4 5 6 7 8 9 10 CN4 CN2 1 2 3 4 5 6 7 FANS SUPPLY .

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). 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). 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 . downstream the thyristors protection fuses. taken on the static switch input. for three-phase inverter  The card is basically composed by four sections: Bypass voltage feedback  The BYPASS voltage.

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 .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.

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 . 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.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).

pin 1-2 of the connector CN3 . 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). and is used to de-couple the microprocessor card from the digital signal originated externally (auxiliary contacts of breakers.FCI card (PB047)  The FCI card is basically a relay card.

Spare Mains failure mP SIDE FCI – M2 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16 17-18 EPO push-button BCB aux contact OCB aux contact Switch SW1 MBCB aux contact Thermal switch Parallel card Emergency Power Off BCB open/closed OCB open/closed Bypass switch MBCB open/closed High temperature Parallel configuration 5-6 7-8 9-10 11-12 13-14 15-16 17-18 .FCI card (PB047) Configurations of the signals SIGNALS SIDE FCI – M1 1-2 3-4 Rectifier card Origin Signal Not used .

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 .

connector CN1 (about 9V). filtered by means of L-C filters and made suitable for the supply of the microprocessor VNR CN14-10 CN14-9 C137 100NF CN14-1 CN14-2 GND COMMON MODE +5V U75 TEA7605 1 E U 3 C122 + 470uF +5V L4 C131 100NF M 2 FILTERS D69 GREEN D50 R146 1N4148 +VRAM D49 D48 SD103 BT 1 2 1N4148 ON J2 3 OFF .I/S-CL card (PB003) Digital supply  The voltage originated from the power supply card. is further stabilised by means of a precision stabiliser.

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 .

therefore the microprocessor recognise automatically the level “zero” MICRO BUS FI1 BY PASS FREQUENCY +5V R OP AMP D62 D61 D60 D55 D54 D53 R152 10K R150 10K 2K2 1% X6 ADA0 ADA1 ADA2 ADA3 ADA4 ADA5 R S T R S T D65 D64 D59 D58 D57 D52 R S T R S T R172 CN13-4 R171 R173 R166 R165 R164 CN13-7 CN13-3 CN13-2 CN13-5 CN13-6 BYPASS OUTPUT R205 R206 R204 R207 R208 C113 VR/2 C110 C109 C100 C98 C97 R209 .5V in comparison to the zero.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.

Volt. Curr. T Out. R Out. S Inv . Volt. R Inv . Curr. S Out. Volt. Curr. T VDC IBS CFPAR IBOOST INVERTER VOLTAGE T OUTPUT CURRENT R OUTPUT CURRENT S OUTPUT CURRENT T DC VOLTAGE INVERTER INPUT CURR PARALLEL CORRECTION BATTERY BOOST CURR D42 D22 D23 D43 D20 D21 D6 D33 D5 A C72 C51 C52 C73 C49 C50 C64 C65 C66 . after they have been converted by a analogue/digital converter (SPI – Serial Peripheral Interface) placed in the analogue part of the card +5A D31 U22 20 19 18 17 16 15 14 13 12 11 VCC EOC CLK ADRIN DOUT CS REF+ REFIN10 IN9 TLC1542 A D16 D17 D32 D14 D15 D34 D35 D36 INVERTER VOLTAGE R INVERTER VOLTAGE S DATA_OUT IN0 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 GND 1 2 3 4 5 6 7 8 9 10 Inv .I/S-CL card (PB003) Measures – External A/D converter  Some measures are acquired by the microprocessor in serial mode.

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 – 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”.

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 BYPASS voltage (phases R/S/T) OUTPUT voltage (phases R/S/T) INVERTER voltage (phases R/S/T) OUTPUT current (phases R/S/T) DC voltage Provenienza VOLT-REF-3F (1F) card VOLT-REF-3F (1F) card VCB cards INV-AV-3F (1F) card PS-HV card DC current Inverter input Hall effect CT .

connected on the positive cable (or copper bar) between the DC capacitors and the inverter bridge.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. 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 . is used for this purpose  Such configuration guarantees the control and protection against possible short-circuits of the inverter bridge.

I/S-CL card (PB003) Short circuit protection +12A C19 M1-2 FEEDBACK J10 R39 47R R27 C28 1NF R40 100R 1K D72 SD103 D73 3 J9 SD103 R38 2K C27 R25 1K A 100NF A + - U16A 1 MC34074 A 2 TP2 Current Signal J100 R18 22R P2 10K 1n R26 1K .

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. and then to 125% for 5 seconds. after which the inverter is switched off (according to EN62040-3) . so that it can be used for the control circuit  By means of a amplifier. 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. which gain can be varied with the potentiometer P2.

I/S-CL card (PB003) “Current stop” protection U15B +5A C20 100NF R15 10K R17 R39 J10 R16 R40 C28 1NF J9 A +12A 3 4 U5C 40106 8 10 9 +12A 3K3 4093 D3 LMCS R13 CA3130 M1-2 FEEDBACK 10K A 7 5 U11 6 R49 1K A 3 2 + - R50 U5D 12 200K 13 4093 CURRENT STOP + C148 10u 25V 11 A 10K C13 1NF N1 100pF SW4 PPMCS R18 J100 A 4 8 1 .

250ms)  The inverter stop due to “Current stop” is signalled by the LED D3. 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 . placed on the front of the I/S-CL card  The program provides for the automatic reset of the stop condition for three times.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.

in the I/S-CL 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.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.

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 . the regulation loop can be set in MANUAL mode (jumper J1 in position 2-3).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.

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 VREF 10 9 U6C + LM324 R31 10K VFBK R37 C14 1NF A 8 NOTCH FILTER 5 6 100NF U6B + LM324 A A 7 R39 10K VREF R40 10K 12 C19 100NF J2 13 R32 10K U6D + LM324 A C15 1NF 43K2 C20 1NF 14 VPWM R41 10K +5A R42 11K8 .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.

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. is rectified. filtered and sent to the SPI. and then to the microprocessor . originating from the card INV-AV-3F (1F).

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 C34 R33 300K +12A C41 100NF 100NF A A 7 1 3 U17 + 6 OP07 FPWM C54 2 C42 100NF A R66 * FREF 6K81 100NF R66 = 6K81 for 8KHz 13K6 for 4KHz 24K9 for 2KHz C55 10NF 220K -12A R67 4 8 .

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 A C18 100NF U9A 1 2 +12A 1STOP 5 U14C 40106 A 6 +12A 3 AC1 CN7-8 CN7-7 CN7-1 CN7-3 +TA 4093 U14D +12A 9 8 A AC2 CN7-2 CN7-4 -TA A FPWM (TRIANGLE) VPWM (SINEWAVE) R10 1K C22 100NF A CA3130 40106 U9B 5 6 4093 A 7 5 3 2 U12 6 + - +12A 4 CN7-10 CN7-9 R9 1K C14 22NF A C15 22NF A A 4 8 1 N5 47pF .

I/S. created internally using the square wave AC3AC4 coming from the PS-HV card .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.

to the connector M3  Such signals are internally de-coupled and connected to the microprocessor I/S-CL M3 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16 17-18 Signal Not used .Spare Mains failure Emergency Power Off BCB open/closed OCB open/closed Bypass switch MBCB open/closed High temperature Parallel configuration . or through the de-coupling card FCI.I/S-CL card (PB003) Digital inputs  The digital inputs are connected directly.

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 .

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.I/S-CL card configuration Configuration of the current protection  The current protection. 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 .

necessary to configure some operating parameters  The most interesting jumpers for the configuration “on field” are shown in the following table Jumper J1 J2 J7 J9 J10 J100 Pos 1-2 2-3 Closed Closed Closed Closed Closed Function SINGLE-PHASE inverter THREE-PHASE inverter Back-up battery connected Watchdog enabled Resistor R40 (100R) inserted Resistor R39 (47R) inserted Resistor R18 (22R) inserted .I/S-CL card configuration Configuration of the jumpers  The I/S-CL card is provided with some jumpers.

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 D3 D8 D11 D69 “Current stop” protection Short circuit protection Presence of the analogue part’s supply (+12V) Presence of the digital part’s supply (+5V) COLOUR RED RED GREEN GREEN .

for the purpose of the inverter bridge and load protection.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. will be defined in detail  Control of the output and bypass waveforms  Overload protection (Thermal image) .

VtL2< Vs2< VtH2 .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. . …. 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 . 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 .

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 .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.

General data Inverter & Static switch Technical features User interfaces Rectifier Test software .

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 .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.

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  The LCD panel is the graphic interface of 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 .

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. controlled by the microprocessor. hour and minute of the event . 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.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. the history log indicates date.

load on inverter Bypass voltage and frequency within tolerance .LCD panel – Status Cod. Name AC/DC OK Description Rectifier output voltage within tolerance S1 S2 S3 S4 S5 S6 BATTERY OK INVERTER OK INVERTER SYNC INVERTER  LOAD BYPASS OK Battery connected to the DC bus Inverter voltage within tolerance Synchronism reference within tolerance Inverter static switch closed.

A1 Name MAINS FAULT Description Rectifier input mains failure A2 A3 A4 A5 A6 CHARGER FAULT RECT FUSE THERMAL IMAGE AC/DC FAULT INPUT WR SEQ Battery charger failure One or more rectifier fuses are blown Load transferred to mains due to overload. Rectifier output voltage out of tolerance Input phase rotation not correct A7 A8 A9 A10 A11 A12 A13 BCB OPEN BATT DISCH BATT AUT END BATT FAULT BATT IN TEST PLL FAULT INV OUT TOL Battery circuit breaker open The battery is discharging Battery autonomy (calculated) has expired Battery test failed or intervention of the safety timer during boost charge Battery test in progress Problems system with the digital synchronisation Inverter output voltage out of tolerance .LCD panel – Alarms Cod.

LCD panel – Alarms Cod. A14 Name OVERLOAD Description Inverter overload (load exceeding 100%) A15 A16 A17 A18 A19 BYP FAULT BYP FEED LOAD RETR BLOCK MBYP CLOSE OCB OPEN Emergency mains not available Load fed by bypass Transfer between bypass and inverter blocked Manual bypass breaker closed UPS output breaker open A20 A21 A22 A23 A24 A25 FANS FAILURE HIGH TEMP BYP SWITCH EPO BUS CURR STOP SHORT CIRCUIT Optional High temperature on the inverter and/or rectifier bridge Closure of the commutation switch which forces the load to bypass (maintenance) Intervention of the emergency power off switch according to the EN62040-1 Inverter bridge stop for max current Intervention of the short circuit protection .

the alarm “A10 – Battery fault” is activated RESET HISTORY  Section for deleting the events log .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.

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 .

that are the same displayed by the LCD panel .“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.

adjustable through software commands Display of the residual battery autonomy . 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.“UPSTest” software Section UPS DATA  The section UPS DATA shows all the UPS’ nominal 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.

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  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.

“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 .

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 . that is within the limits specified in the section UPS Data  VDC  INV_ON • It’s the command for the inverter start-up.“UPSTest” software Section VARIABLES  VDC_OK • It indicates that the INVERTER INPUT voltage is in tolerance. that is managed by the microprocessor during the AUTOMATIC operating mode.

“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. transformer. etc. 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 . rectifier bridge.)  VUOK • It indicates that the INVERTER 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 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.

“UPSTest” software Section OUTPUTS  The section OUTPUTS shows all the commands generated by the microprocessor for the management of the various UPS sections .

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  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.

“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 .

the bypass switch (commutation test) is active  TERMO_SW • When active. the switch OCB (UPS output) is closed  MCS • When active indicates the Current stop protection has operated . the switch MBCB (manual bypass) is closed  EPO_BUS • When active. the switch BCB (battery) is open  BYP_SW (FUSE) • When active. the UPS stop by EPO is not enabled  BO_BUS • When active. the thermal protection on the bridges has operated  OCB • When active.“UPSTest” software Section INPUTS  MBY_CLOSE • When active.

“UPSTest” software Section INPUTS  MRR • When active. originated by the rectifier card. the mains failure signal. the rectifier failure signal. is not active  BF_RECT • When active. originated by the rectifier card. is not active  RECT_FAIL • When active. the wrong phase sequence signal. is not active  ERR_SC • When active. is not active  PUL_XX • These variables indicates the push button on the LCD panel have pressed . originated by the rectifier card. originated by the rectifier card. the fuses failure signal.

“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 .