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UM0527 User manual

UPS evaluation board


Introduction
The UPS evaluation board provides a complete solution addressing the low/medium range UPS segment with 700 VA output power capability. The evaluation board, from a hardware and firmware point of view, is ready to support the development of a complete solution. Thanks to the PC software it's possible to monitor all the relevant system parameters using the RS232 interface or the USB. The evaluation board is available for the 120 Vac market and 230 Vac market. The UPS evaluation board is built in offline topology with AVR regulation of the mains boost and buck. The inverter module contains the push-pull DC/DC converter and the DC/AC output full-bridge generating quasi-sine waveform.

July 2008

Rev 1

1/66
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Contents

UM0527

Contents
1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Hardware architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16 1.1.17 1.1.18 General realization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Detailed description of electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DC/DC converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DC/AC inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Charger AC/DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Mains protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 UPS modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Microcontroller IN/OUT signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Signals functions table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Detailed description of mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2

Software architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10 1.2.11 Data models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Main loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ADC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

2
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Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

UM0527

Contents

2.1 2.2 2.3

Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45


2.3.1 2.3.2 2.3.3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

2.4

Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 PCB: mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PCB: outlet output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PCB: AVR transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PCB: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.5

Signalization description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.1 2.5.2 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Sound alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.6

Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.6.1 2.6.2 Bill of material for 120 Vac version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Bill of material for 230 Vac version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

3 4

Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

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List of figures

UM0527

List of figures
Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DC/DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DC/AC inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 AC/DC battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Main flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 DC/AC inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 DC/DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Power switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 AC/DC battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 PC interface stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Measurement stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Bottom view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Mechanical view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 UPS with assembled rear outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 UPS with front button and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 UPS with batteries and battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 UPS with battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 UPS with AVR transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 UPS with automatic fuse and power wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 UPS with motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 UPS fully assembled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

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UM0527

General description

1
1.1
1.1.1

General description
Hardware architecture
General realization
The UPS evaluation board is built in offline topology with AVR regulation of the mains boost and buck. The inverter module contains the push-pull DC/DC converter and the DC/AC output full-bridge generating quasi-sine waveform. The battery charger module is connected at the output of the UPS and it also has the function of taking over the reactive power which is present on the inverter during battery operation with reactive - resistive load. The microcontroller controls all UPS functions. It monitors the mains parameters in order to ensure the proper level of the output voltage. The microcontroller measurement parameters are input/output mains voltage and phase, output inverter voltage, battery voltage, output current and output power. The UPS has a built-in RS232, joint signals and USB interfaces (USB for RS232 converter).

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General description

UM0527

1.1.2

Block diagram
Figure 1. Block diagram
RFIEMI12st05v031.sch EMI/RFI FILTER

FUSE
AC_IN2 AC_IN1

Microcontroller unit

INPUT

Interface12st05v031.sch

Inerface unit

VCC GND GND BAT_LOW ACF! ACF1! UPS_OFF!

VCC GND ACF! ACF1! UPS_OFF!

VCC GND BAT_LOW ACF! ACF1! UPS_OFF!

BAT_LOW

FUSE

AC_IN2

AC_IN1

LED INDICATIONS BUTTON Microcontroller12st05v031.sch

Relays12st05v031.sch

Power Relays

AC_IN2

AC_IN1

GND

USB_IN! TXD RXD

USB_IN! TXD RXD

USB_IN! TXD

AC_IN2 GND AC_IN1 Input Voltage & Phase Measurement

AC_IN1 AC_IN2

AC_IN1 AC_IN2

RXD

INP_LEV VCC

INP_LEV VCC VDD

INP_LEV VCC VDD PHASE InputVoltage12st05v031.sch

PHASE

PHASE

ACI! ACF ACL! ACH! OUT_REL!

ACI! ACF ACL! ACH! OUT_REL! GND InverterVoltage12st05v031.sch GND Output Voltage Inverter

ACI! ACF ACL! ACH! OUT_REL!

AVR TRAFO

OUT_LEV

OUT_LEV

OUT_LEV AC_1 AC_2

AC_1 AC_2

INV_A INV_B

INV_A INV_B

AC_1 AC_2

DC/DC converter

DCDC12st05v031.sch VDCDC

DCAC12st05v031.sch VDD INV_A INV_B

VDCDC

VDCDC

INV_OUT2 INV_OUT1

INV_OUT2 INV_OUT1 DC/AC Invverter

SHD

SHD

SHD VAKK

HVDC

HVDC

HVDC VDD GND

GND CHOFF

GND

VDD

VDD

VDD

VAKK

VDD

GND

CHOFF

GND VAKK GND

ACDC12st05v031.sch

GND Battery Overcurrent

AC/DC Charger

GND

CHOFF

VDD

VCC AKK_LEV

VCC

AKK_LEV

VCCPU VCC ON/OFF SW_ONP

VCCPU VCC ON/OFF SW_ONP

PWR_LEV

PWR_LEV

BATTERY GND

VBAT

VBAT +VOUT VDD

AC_1 AC_2

AC_1 AC_2

AC_1 AC_2

Protection VBAT Battery Voltage GND Power Supply VBAT

BatOver12st05v031.sch

+VOUT

VDD

BatteryVoltage12st05v031.sch VBAT GND VCC AKK_LEV

VCCPU GND VCC ON/OFF SW_ONP PowerSupply12st05v031.sch GND VPP

VCC IOUT_1 PWR_LEV IOUT_2 GND

Output Current Measurement OutputCurrent12st05v031.sch

+VOUT

VDD

AC_IN1 AC_IN2

AC_IN1 AC_IN2

AC_IN1 AC_IN2

VPP

IOUT_1

IOUT_1

IOUT_2

IOUT_2

GND

GND

OUTPUT

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1.1.4
Figure 2.

1.1.3

UM0527

DC/DC CONVERTER
RAD5 10uF/50V C62 GND GND 13 Heatsink GND 10R Heatsink GND 11 VAKK OutB C14 R35 1k 3W A TI1 R66 B VAKK C GND D30 D STTH302S Q7 OUT_B Q8 R62 10R R36 Vref 3.3k R55 22k RAD6 GND R56 22k Heatsink U4 PDTC114ET Heatsink SHD C43 1nF GND GND GND GND SHD Heatsink GND R61 10R 1.5uH / 10A 11 L2 GND GND GND GND 3300uF/35V 3300uF/35V R67 0R 330R 2W 2 12 STTH302S C64 470uF/63V C66 1.5uH / 10A 10 4 C65 8 C67 10nF 100nF 100nF 330R 2W C15 D29 L1 1 14 R341k 3W D25 OUT_A R60 10R Q6 C86 D27 Q5 Heatsink HVDC R59 100nF R53 22k R69 200k 100k R54 22k C72 GND GND RAD7 RAD9

VDD R33 R68 200k 100k

47R

100uF/25V

GND

100nF

C32

C12

DC/DC converter

DC/DC converter module

U3 VC

15

GND

VDD VAKK

VDD VAKK HVDC

SG3525A

VCC

GND OutA 1nF 1kV 1.5nF 1kV

Vref C13 100nF

16

Vref

R17

Disch

33R

STP75NF75

GND

Rt

STTH8R06D STTH803D

STTH8R06D STTH803D

7.5k

STP75NF75

C33 GND 4.7nF

Ct

R18

R70 200k 100k C87 330nF 1uF R71 200k 100k VDCDC VDCDC R30 5.6k R32 390k 100k C68 10nF

Detailed description of electronics

C34

R19 100k GND

1nF

ShutDown ErrAmpOut Clock ErrAmp+ SoftStart ErrAmp-

Sync

STTH8R06D STTH803D

R28 0R GND 12 STP75NF75

C50 100pF

GND GND

D26 TI700/24/1v01 TI700/24/2v01 RAD8

D28 GND GND GND RAD10

STTH8R06D STTH803D

GND

GND

GND

STP75NF75

R29 6.8k

R31 36k 30k

GND

GND

General description

230Vac Model 120Vac Model

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General description

UM0527

The converter is based on push-pull topology. The PWM controller works in voltage mode. The power components used for the low voltage side are switches 5 - 8 and a transformer. The energy recovery circuit includes L1, D1, L2, D2, C1 and R1. It works as both a clamp and a snubber. Power components on the secondary side are limited to rectifier diodes D3 D6 and a small voltage smoothing capacitor. The output voltage is limited with direct control loop without insulation. An internal soft-start circuit is used to limit the voltage rise rate on the output of the DC/AC converter. The soft-start circuit is controlled from the microcontroller by an additional transistor. The PWM controller is powered from the main UPS power supply section. The output converter voltage range is battery voltage dependent and has been set to achieve maximum efficiency. Table 1. DC/DC specification
DC/DC converter Output voltage Output power Efficiency Frequency PWM controller U1 Power switches 5 8 Push-pull transformer T11 Rectifiers diodes D1 D4 120 Vac version 130 190 V 450 W > 80% 40 kHz 10% SG3525 STP75NF75 EE42 STTH803 230 Vac version 250 - 360 V 450 W > 80% 40 kHz 10% SG3525 STP75NF75 EE42 STTH8R06

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1.1.5
Figure 3.

UM0527

HVDC

HVDC

VDD

VDD

GND RAD1 HVDC

GND

DC/AC INVERTER
RAD3

R3 0R Q1 STP12NM50 STP12NM50 STP22NS25Z R13 10k C2 10uF/25V INV_OUT1 R9 100R STP22NS25Z R7 100R R11 10k

DC/AC inverter module

DC/AC inverter

D3 Heatsink BAS16 R5 0R Heatsink Q3

BAS16 D6

VDD C1

VDD D2 R172 SMBYT01 10R R2 100R C4 10uF/35V GND C10 100nF R174 47R 8 7 6 5 U2 L6387D VCC
GND

R1 100R

R16410R

D1

GND

C3

SMBYT01 10uF/25V

GND

10uF/35V C8 100nF R173 47R

GND

C9 100nF

U1

L6387D

C11 100nF 3 VB HVG VO LVG D48 STTH1L06A HIN LIN


4

VCC

INV_A INV_B RAD2 RAD4


INV_OUT2

HIN LIN

GND

INV_A INV_B

2 1

VB HVG VO LVG

8 7 6 5

INV_OUT1

2 1

INV_B INV_A C39 100pF GND

INV_B INV_A C40 100pF GND

C36 100pF

D47

C35 100pF GND GND INV_OUT2 R4 51R Q2 STP12NM50 STP22NS25Z STP12NM50 STP22NS25Z D4 Heatsink BAS16 Heatsink Q4

STTH1L06A

BAS16

D7

R6 51R

R8 ZD1 SM6T18A R12 10k

100R R14 10k ZD2 SM6T18A D8 BAS16

R10 100R

D5 BAS16

GND

General description

230Vac Model 120Vac Model

9/66

General description

UM0527

The DC/AC inverter was built in full-bridge topology. The output waveform is a quasi-sine waveform. The inverter is controlled by the microcontroller across two PWM drivers which switch four power transistors. The high-side driver parts are supplied with the bootstrap circuitry D1, C1 and D2, C2. The diodes D1 and D2 are high-voltage fast-recovery diodes. Switching off all transistors is achieved with driver internal logic if both INV_A and INV_B signals are set high or low. There is no any additional overcurrent protection for bridge transistors. Drivers are powered from the main UPS supply unit. Table 2. DC/AC specification
DC/AC inverter Output voltage RMS Frequency (microcontroller outputs) Drivers U1, U2 Power switches Q1 Q4 Bootstrap diode D1, D2 120 Vac version 120 Vac +5%/ -10% 60 Hz 0.1 Hz L6387 STP22NS25Z SMBYT01-400 230 Vac version 230 Vac +5%/ -10% 50 Hz 0.1Hz L6387 STP12NM50 SMBYT01-400

10/66

1.1.6
Figure 4.

UM0527

INV_OUT2 INV_OUT1 AC_1 AC_2 AC_1 AC_2 INV_OUT2 INV_OUT1

Power switches

Power switches

IOUT_1 IOUT_2 IOUT_1 IOUT_2 3 4 L8 1:1000

VPP

VPP

AVR

GND 1 BLACK 6.3x0.8 J4 RT2 JNR15S70L JNR15S2R5M RT1 JNR15S70L JNR15S2R5M

GND

t 1 VPP J5 6.3x0.8 RM85-2011-25-1024 SCL-1-H-DPNO BAS16 D31 BZV55C10 BZV55C10 1 RED J6 6.3x0.8 D36 BZV55C75 D32 D34 BZV55C20 D12 BAS16 VPP RL4 D10 RL1 VPP WHITE VPP RL3

t 1 2

J7 1 6.3x0.8 J8 RL5 VPP 1 6.3x0.8 RM84-2022-25-1024 BROWN

AC_IN2

AC_IN2

RL2

OUTPUT
BLUE

RM85-2011-25-1024

D11 BAS16

D33 BZV55C20

AC_IN1

AC_IN1

RM84-2012-25-1024 D49 BZV55C75 D13 BAS16

D14 BAS16

D35 BZV55C20

OUT_REL! ACF ACI! ACH! ACL!

OUT_REL! ACF ACI! ACH! ACL!

General description

230Vac Model 120Vac Model

11/66

General description The power line contains:


UM0527

two pole separation relays DPNO (RL1) (with 2 mm gap) two relays DPDT (RL2, RL3) two pole switching battery/mains relays DPDT (RL4) two pole output on/off relays DPNO (RL5)

All relay coils are powered from the battery and charger voltage. The current transformer is used for monitoring UPS output current and power. The additional AVR boost/buck autotransformer has two sections: winding and output power 60VA. Relay coils are controlled by the microcontroller signals through an additional driver.

1.1.7

RFI/EMI filter
Figure 5. RFI/EMI filter

RFI/EMI FILTER
J9 BROWN 1 6.3x0.8 J10 1 6.3x0.8 J11 1 6.3x0.8 N JVR-20N471K JVR-20N271K PE YELLOW/GREEN L C119 4,7nF C120 4,7nF RV1 R90 200k R88 200k R89 200k AC_IN2 AC_IN2 AC_IN1 AC_IN1

MAINS

C108 470nF

BLUE

An additional EMI/RFI filter contains one X-type capacitor and a pair of Y-type capacitors.

12/66

1.1.8
Figure 6.

UM0527

RAD11

Charger AC/DC

Heatsink

GND Charger Output Pout(max)=50W Q9 STP80PF55 R138 VBAT Q10 STP80PF55

GND

AC/DC BATTERY CHARGER


100nF C100 C19 1 T1 1 BR1 KBU605 10uH/3A R16 10k 33k +VOUT D37 STTH1R06 4 6 D15 C20 ` 100nF 100nF GND GND GND TI50/30v02 CHOFF R15 10k C18 D16 BAS16 VDD RAD12 Q11 R57 22k 8 D17 L6565 BAS16 GD CS Heatsink R137 4 R133 33R 1 R136 39k 8 R115 3.3k 2 3 6 7 Q12 BC857B U12 7 ZCD R63 10R 100nF R132 750k 5 GND U11 3 VFF COMP VFB R134 16k GND VDD CHOFF GND GND GND U6 PDTC114ET C21 C101 C102 GND R95 10k BAS16 1000uF/50V 1000uF/50V 7 8 9 10 ZD3 BZX84C12 C96 R128 2 3 C97 R123 100k R127 120k 3W 120k 3W 2 GND 4 R129 10R R124 100k 3 100uF/50V C99 R65 10R L11 13 D38 12 11 STPS8H100D

1nF 500V

R64 10R

VBAT +VOUT VDD +VOUT VDD

1,25A 2A 100nF X2 680pF 1600V

L9

AC/DC battery charger

AC_1

AC_1

F1

10uH/3A

C95 47nF X2 GND 47uF/50V R130 R131 750k GND 750k R126 100k R125 100k C98

C44 47nF X2

GND

GND

AC_2

AC_2

10uH/3A

L10

STP5NK90Z

Control voltage output VBAT MAX +28.2V Current Mode Charging VBAT MIN +26.8V Voltage Mode Charging

GND +VOUT R139 5.6k

C79 10nF 2 1 6 GND C49 1nF R20 R94 10k 100k R122 100k R135 43k GND 0.68R 2W

TH1 TYN608 TL431CD

GND

R140 180R

R52 4.7R 3W

GND

GND

GND

GND

Overvoltage Protection 32V

General description

230Vac Model 120Vac Model

13/66

General description

UM0527

The battery charger is used as a battery charger for the mains mode or as a reactive power recirculation circuit for the inverter mode. For both modes the charger output power is accepted by the battery. The charger power converter is built in quasi-resonant flyback mode based on the controller L6565 with external power switch Q1 and output diode D1. The PWM controller is powered from the main UPS supply module and from the auxiliary winding on the flyback transformer. The transformer is designed with the ETD29 core. The CHOFF signal is used to switch (Q2 and Q3 STP80PF55) charging modes by the microcontroller. An additional output voltage loop limits open output charger voltage. The charger module also contains a battery overvoltage protection circuit with SCR TYN608 and voltage reference TL431. Table 3. Battery charger specifications
120 Vac version 29 Vdc 5% 50 W >80% 100kHz 10% L6565 STP5NK90Z ETD29 STPS8H100 STTA106 230 Vac version

AC/DC converter Max output voltage Max output power Efficiency Minimal switching frequency Controller U1 Power switch Q11 Transformer core Rectifier diode D1 Clamp diode D3

14/66

1.1.9

UM0527

R104 330R R106 VCC VCC R109 330R VCC R108 330R GA RA YA

J2 R107 330R

TX VCCPU OSC1 OSC2 GND RST! ICC_SEL INV_B! INV_A! LEDY LEDG

Figure 7.

GND 44 43 42 41 40 39 38 37 36 35 34 ST72F324BJ6T6 U29 BUTTON 100R VCCPU VDD C17 GND VCC VCC VCC R118 R114 3.3k U9 E R113 3.3k GND 2.2k 2.2k B1 1 2 BPT-14 OUT_REL! ACI! ACF R86 VCCPU C48 100nF GND GND M95020WMN6P GND 4.7k R87 10k 8 7 6 5 Q15 MMBTA42 1 INV_A INV_B ACL! ACH! 2 R120 2.2k R119 VCC 1 GND 100nF 3 BAS16 U8 RESET! RES VSS C88 22pF Y1 16MHz OSC2 C89 22pF GND GND 2 RST!R110 4.7k OSC1 STM809L SW_ONP 10k R111 SW_ONP IDC10 D9 VCC

L3 R105 330R 330R R92

LEDG LEDR LEDY 2 4 6 8 GND 10 1 3 5 7 9

4.7uH

Control unit

VCCPU

L4

VSSA C16 100nF VAREF

4.7uH PE0/TDO Vdd_2 OSC1 OSC2 Vss_2 RESET Vpp/ICCSEL PA7 (HS) PA6 (HS) PA5 (HS) PA4 (HS)

ICP programming C-FLASH

J1 IDC10

GND

VCC

1 3 5 7 9 PD5/AIN5 VAREF VSSA MCO/AIN8/PF0 BEEP/PF1 (HS) PF2 (HS) OCMP1_A/AIN10/PF4 ICAP1_A/PF6 (HS) EXTCLK_A/PF7 (HS) Vdd_0 Vss_0

2 4 6 8 10

ICC_DATA ICC_CLK RST! ICC_SEL

Control unit

GND

10k GND R91

RX ACF! ACL ACH OUT_REL BAT_LOW NC1 PWR_LEV AKK_LEV OUT_LEV INP_LEV PE1/RDI PB0 PB1 PB2 PB3 PB4 (HS) PD0/AIN0 PD1/AIN1 PD2/AIN2 PD3/AIN3 PD4/AIN4 Vss_1 Vdd_1 PA3 (HS) AIN15/SS/PC7 ICCCLK/SCK/PC6 AIN14/MOSI/PC5 ICCDATA/MISO/PC4 ICAP1_B/PC3 ICAP2_B/PC2 AIN13/OCMP1_B/PC1 AIN12/OCMP2_B/PC0

1 2 3 4 5 6 7 8 9 10 11

33 32 31 30 29 28 27 26 25 24 23

GND VCCPU LEDR CS! ICC_CLK MOSI ICC_DATA BUTTON UPS_OFF! PHASE USB_IN!

TXD RXD OUT_REL! ACI!

TXD RXD VDCDC 12 VAREF 13 VSSA 14 CHOFF 15 BUZZER 16 ACI 17 ON/OFF 18 19 SHD ACF1! 20 VCCPU 21 22 GND

L5

4.7uH TX RX

INV_A INV_B ACL! ACH!

L6 GND ACF! U10 CS! ICC_DATA MISO R37 1k GND MOSI ICC_CLK 1k VCCPU GND R39 4.7k RESET! VCCPU GND R38 SCK HOLD! VCCPU S VCC Q HOLD W C VSS D 1 2 3 4 BAT_LOW UPS_OFF! PHASE PWR_LEV AKK_LEV OUT_LEV INP_LEV VDCDC CHOFF USB_IN! SHD ON/OFF ACF! ACF1! ULN2003D R93 COM 9 10k NC1

4.7uH

INV_A! INV_B! ACL ACH BUZZER OUT_REL ACI 7B 6B 5B 4B 3B 2B 1B

8 7 6 5 4 3 2 1 7C 6C 5C 4C 3C 2C 1C

10 11 12 13 14 15 16

BAT_LOW UPS_OFF! PHASE PWR_LEV AKK_LEV OUT_LEV INP_LEV VDCDC CHOFF USB_IN! SHD ON/OFF ACF! ACF1!

VCCPU

VCCPU

VCC C70 10nF 10nF C76 10nF GND C77 10nF GND GND 10nF GND GND C74 C71 UPS_OFF! AKK_LEV RST! USB_IN! BUTTON

VCC

GND

GND

C51

100pF 100pF

C52

100pF 100pF

100pF

General description

MOSI ICC_SEL ICC_DATA ICC_CLK C53 TX C54 GND RX C55 GND C56 GND GND GND GND 100pF

PHASE C73 INV_B! INV_A! C37 1nF C38 1nF 1nF GND GND GND

230Vac Model 120Vac Model

15/66

General description

UM0527

The control unit contains the main microcontroller ST72F324J6T6 - in the TQFP 44 10x10 package with an ICP connector for programming, a reset STM809, a buffer ULN2003A for driving signals and an external EEPROM with SPI interface. Analog signals are measured with an internal 10-bit A/D converter. Digital inputs / outputs are used to control internal and external UPS signals. A thermistor is used to monitor internal UPS temperature.

16/66

1.1.10
Figure 8.

UM0527

Q16 BDX53C D51 STTH102A C41 C46 100nF 47uF/25V GND D50 BZV55C22 GND R96 33k

Power supply

1,25A

BR2 B600C1500

J3 C45 10uF/100V

6.3x0.8 BLACK

F3

Power supply

J17 GND GND

GND

6.3x0.8 BLACK VPP 1uF / 50V C110 VPP

GND Voltage From AC/DC Charger +VOUT Voltage From Battery VBAT L12 1 330uH / 0.9A R153 36k FB 5 R152 22R 1W C28 +15Vdc VDD 3

+VOUT

+VOUT VDD D42 STTH102A 8 D43 STTH102A OUT STTH102A D44 VCC +5Vdc VCC U27 LD1086V50 LD1086 GND IN OUT 2

VBAT C27 100nF

VBAT

GND U26 L5970D 6 2 SYNC COMP GND INH 4 7 3 VCC VREF

GND

GND

POWER SUPPLY

L7 4.7uH C29 1 C113 47uF/25V 100nF GND GND GND RAD13 100nF GND GND

VCCPU VCCPU C30

AC_IN2

AC_IN2

100k R72 200k

100k R73 200k

U25

C104 22uF/35V

AC_IN1 SFH620A-2 GND C112 C61 U7 PDTC114ET 100pF R58 22k 22nF D45 STPS1L60A D21 BAS16

AC_IN1

R74

R75

C114 100nF 47uF/25V GND GND

By button

200k 100k

200k 100k

C105 R116 100uF/35V 3.3k

SW_ONP

SW_ONP

ON/OFF GND GND

ON/OFF Heatsink

VDD power supply control

DL1 R175 VCC 2.2k GND LED

General description

17/66

General description

UM0527

The power supply unit provides two outputs used in UPS blocks: +15 V for most of the analog circuits and +5 V for the microcontroller. The switching voltage converter was built in step-down topology with an integrated regulator L5970. The microcontroller is supplied by linear regulator +5 V U3 LD1086V50. The switching regulator is controlled by the microcontroller ON / OFF signal and the BUTTON signal from the front panel ON/OFF switch. Additional supply is switched on by optocoupler SFH620 powered from the mains.

18/66

1.1.11 Interface
Figure 9.

UM0527

V+ R145 J14 COM 820R COM R146 V+ ACFL VCC 2.4k COM COM ACF1! 4.7k R148 U20 PC817C GND C109 2.2uF/50V COM VPC COM TS555CDT 4 VCC R D19 OFF DIS BAS16 6 D20 1 C25 100nF VCC BAS16 COM 3.3k 6.8k GND GND V+ PC817C 2.2k TXD1 J15 100R BC857B R99 20k 6 GND VCC 16 C26 100nF U24 VCC INH GND +5V_USB VCC VR46 ICP GND1 IDC10 +5V_USB 4.7k GND1 VPP_USB R43 OSCOUT TxD_USB C59 100pF R44 +5V_USB 4.7k RxD_USB R169 10k GND1 GND1 GND1 GND1 GND1 GND1 GND1 GND1 GND1 R170 10k R171 10k C60 100pF U18 PC817C R143 VCC 4.3k GND1 GND 7 8 M74HC4053RM13TR GND 4.7k Y2 24MHz OSCIN +5V_USB 4.7k U17 PC817C R47 VCC GND R42 U16 PC817C 4.7k Q14 Q13 BC846B R112 USB_IN! U23 R144 VCC RXD1 R142 PC817C R149 VCC U22 R41 4.7k GND THR 7 4.7k COM 4.7k GND VCC UPS_OFF! R45 U21 R48 PC817C TRIG CVolt Q 2 5 C23 R121 2.2k 8 U14 3 BTL BTL BAT_LOW 4.7k R147 PC817C V+ U19

D39

VPC

D40 BAT54S

BAT_LOW

OFF RXD1 OFF TXD1 ACFL

C103

BAT54C

22uF/35V

Interface

COM

R97

COM

1 6 2 7 3 8 4 9 5

ACF1!

10k

C22

100nF

C5

D18

D41

10uF/35V

BAS16

UPS_OFF!

100nF

VCC GND

VPC

OFF

BAT54A

V-

GND1

USB

100nF

USB_IN!

C106

R141

USBVCC

U13 USB6B1

1.5k

J13

1 2 3 4

1 2 3 4

Vcc1 Vcc2 In1 Out1 In2 Out2 Gnd1Gnd2

8 7 6 5

+5V_USB USBDM USBDP

GND1 10 VPP_USB 8 RST_USB 6 ICCCLK 4 ICCDATA 2 9 7 5 3 1

USB Socket

Data Protection GND1

RST_USB +5V_USB C24 100nF GND1 GND1 GND1 C92 22pF

USB-B

C80

1 +5V_USB 2 OSCOUT 3 OSCIN GND1 4 TxD_USB 5 RxD_USB 6 RST_USB 7 NC13 8 VPP_USB 9 10 NC12 11 NC11 12 NC10 USBVCC USBDM USBDP GND1 NC4 ICCDATA ICCCLK NC5 NC6 NC7 NC8 NC9

A B C VEE VSS

14 15 4

RXD TXD

RXD TXD

10nF

C57

100pF

100pF

GND1

ICCDATA ICCCLK C58

GND1 GND1

U15 ST72F63BE2M1 SO24 24 VDD USBVCC 23 OSCOUT USBDM 22 OSCIN USBDP 21 VSS VSSA 20 PC1 PA0 19 PC0 PA1 18 RESET PA2 17 PB6 PA3 16 VPP PA4 15 PB3 PA5 14 PB2 PA7 13 PB1 PB0 R98 GND1 10k 10uF/35V C6 C91 GND1 22pF

11 10 9 12 13 2 1 5 3

ADDR A ADDR B ADDR C A1 A2 B1 B2 C1 C2

R40 10k R165 10k R166 10k

NC13 NC12 NC11 R167 10k R168 10k

NC10 NC9 NC8 NC7 NC6 NC5 NC4

R84 10k

R85 10k

GND1

GND1

GND1

General description

230Vac Model 120Vac Model

19/66

General description

UM0527

The interface unit provides the connection from the UPS unit to the PC via RS, USB or joint signals. The interface contains a USB to RS232 converter based on the microcontroller ST72F623F2M1, in the SO20 package powered from the PC, with optoisolation barrier (PC817B) and RS232 with optoisolation barrier (PC817B). The required voltage for the RS232 circuits is realized by the voltage pump converter built with NE555. The interface unit also contains an analog multi/demultiplexer M74HC4053 used to switch signals from the USB and RS232 to the microcontroller.

20/66

UM0527

General description

1.1.12

Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage
Figure 10. Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage
OUTPUT CURRENT
VCC VCC VCC D23 BAS16 U28C PWR_LEV PWR_LEV C84 10nF GND C118 1.5nF R155 1k 8 9 LM324 R156 47.5k R151 6.8k R50 4.7k C117 1.5nF 10 R51 GND 4.7k R157 47.5k R150 6.8k R158 20R 10R IOUT_2 IOUT_2 IOUT_1 IOUT_1 GND GND VCC

BATTERY VOLTAGE
VCC VBAT D24 BAS16 R25 100k VBAT VCC GND AKK_LEV AKK_LEV C63 R159 20k 10uF/50V VBAT VCC GND

GND

GND

230Vac Model 120Vac Model

INVERTER OUTPUT VOLTAGE


R80 200k 100k R81 R160 82k R161 2.4k 2k 200k 100k R82 200k 100k R83 200k 100k AC_2 AC_1 AC_2 AC_1

OUT_LEV

OUT_LEV C85 10nF

GND

GND

GND

GND

GND

2 1

INPUT VOLTAGE
VCC D22 BAS16 U28D INP_LEV INP_LEV C83 10nF GND R154 1k 12 14 13 LM324 R21 100k C116 R24 22k R78 R49 750k 360k 2k R79 750k 360k AC_IN2 AC_IN2 R100 10k C115 1.5nF R101 GND 10k R22 100k R23 22k GND R176 2k R76 750k 360k R77 750k 360k AC_IN1

VCC

230Vac M 120Vac M

AC_IN1

1.5nF

INPUT VOLTAGE PHASE


R162 1M VCC R102 10k PHASE PHASE D46 BAT54 1 2 R103 10k 11 LM324 R117 10k R27 10k VCC VDD 4

GND

U28A 3

R26 1k

GND

GND GND VDD VCC VDD VCC GND

VDD U28B C31 100nF GND C7 10uF/35V GND 6 7 5 LM324 GND

GND

230Vac Model 120Vac Model

21/66

General description Referring to Figure 10, the measurements are defined as follows: a)

UM0527

Output current. Input voltage measurement unit is built as a differential amplifier with a 2.5 V offset (LM324). The output signal from the amplifier is connected to the A/D converter in the microcontroller. Battery voltage. The input voltage phase unit works as a comparator (LM324) and contains information about the sign of the input voltage waveform. Inverter output voltage. Output current unit is built as a differential amplifier with 2.5 V offset (LM324). The output signal from the amplifier is connected to the A/D converter in the microcontroller. Input voltage. The inverter output voltage is monitored through the voltage divider and connected to the microcontroller A/D converter input. Input voltage phase. The battery voltage measurement uses a resistive voltage divider and the next A/D converter input of the microcontroller.

b) c)

d) e)

1.1.13

Battery overcurrent protection


Figure 11. Battery overcurrent protection

J12 1 F2 3,15A 250V J16 1 GND

VAKK VAKK VBAT VBAT

GND

The battery overcurrent protection is given by a fuse.

1.1.14

Mains protection
The mains is protected by an automatic fuse mounted in an enclosure. If tripping occurs, the fuse can be reset by the UPS user.

1.1.15
Table 4.

UPS modes
UPS modes
Mains mode UPS input UPS output On On/off On Off Boost mode On On/off On Off Buck mode On On/off On Off Inverter mode Off On Off
(1)

Standby mode Off Off Off Off

Standby charge mode On Off On Off

OFF mode Off Off Off Off

Battery charger Inverter

On

22/66

UM0527 Table 4. UPS modes (continued)


Mains mode Power supply VDD and VCC Communication
1. Programming microcontroller only

General description

Boost mode On On

Buck mode On On

Inverter mode On On

Standby mode On On

Standby charge mode On On

OFF mode Off Off

On On

1.1.16
Table 5.
Signal name LEDR LEDG LEDY INV_A! INV_B! ACF! ACL ACH OUT_REL BAT_LOW USB_IN! PHASE UPS_OFF! BUTTON ICC_DATA MOSI ICC_CLK Unused TERM PWR_LEV AKK_LEV OUT_LEV INP_LEV

Microcontroller IN/OUT signals


Microcontroller IN/OUT signals
Port ST7 PA3 PA4 PA5 PA6 PA7 PB0 PB1 PB2 PB3 PB4 PC0 PC1 PC2 PC3 PC4 PC5 PC6 PC7 PD0 PD1 PD2 PD3 PD4 Pin no ST7 31 34 35 36 37 2 3 4 5 6 23 24 25 26 27 28 29 30 7 8 9 10 11 ADC analog input ADC analog input ADC analog input ADC analog input ADC analog input Temperature sense Output current measurement signal Battery voltage measurement signal Inverter output voltage measurement signal Input voltage measurement signal Type/active state digital output/active low digital output/active low digital output/active low digital output/active high digital output/active high digital output/active low digital output/active high digital output/active high digital output/active high digital output/active high digital input/active low digital input/active high digital input/active low digital input/active high SPI/ICC SPI SPI/ICC Description Red LED control Green LED control Yellow LED control Inverter control Inverter control Input voltage (mains) fail AVR boost control AVR buck control UPS output on/off Battery low voltage USB connected to source (PC) signal Input voltage (mains) phase signal The UPS output off joint signal Button signal Data input from external EEPROM / ICC data input (flash programming) Data output for external EEPROM SPI clock / ICC clock output (flash programming)

23/66

General description Table 5.


Signal name VDCDC TX RX CHOFF BUZZER ACI ON/OFF SHD Unused ICC_SEL RST! OSC1 OSC2

UM0527

Microcontroller IN/OUT signals (continued)


Port ST7 PD5 PE0 PE1 PF0 PF1 PF2 PF4 PF6 PF7 TST/V PP RESET OSC1 OSC2 Pin no ST7 12 44 1 15 16 17 18 19 20 38 39 42 41 Input input ICC mode flash programming Reset Resonator oscillator inverter output External clock input or resonator oscillator inverter input Type/active state ADC analog input SCI transmit data out SCI receive data in digital output/active high digital output/active high digital output/active high digital output/active high output Description Converter DC/DC output voltage measurement signal RS-232C TxD signal RS-232C RxD signal Battery charging mode control signal Buzzer signal Mains relay control signal Power supply VDD on/off Shutdown DC/DC converter signal

1.1.17
Table 6.

Signals functions table


Signals functions table
Mains mode Boost mode H H H L L/H L L L Active Active Active H Active Active Buck mode H H L H L/H L L L Active Active Active H Active Active Inverter mode L L L L H Active Active Active Active H Active H Active Active Standby mode L L L L L L L L Active L Active H Active Active Standby charge mode H H L L L L L L Active Active Active H Active Active Off mode L L L L L L L L Inactive Inactive Inactive L Active Inactive

ACI ACF! ACL ACH OUT_REL INV_A! INV_B! SHD TERM CHOFF BUZZER ON/OFF BUTTON LEDR

H H L L L/H L L L Active Active Active H Active Active

24/66

UM0527 Table 6. Signals functions table (continued)


Mains mode LEDG LEDY TX RX USB_IN! BAT_LOW UPS_OFF! MOSI ICC_SEL ICC_DATA/ MISO ICC_CLK/ SCK PHASE INP_LEV OUT_LEV PWR_LEV Active Active Active Active H or L L H or L Active L L/ Active L/ Active Active Active Inactive Active Boost mode Active Active Active Active H or L L H or L Active L L/ Active L/ Active Active Active Inactive Active Buck mode Active Active Active Active H or L L H or L Active L L/ Active L/ Active Active Active Inactive Active Inverter mode Active Active Active Active H or L H or L H or L Active L L/ Active L/ Active Active Active Active Active Standby mode Active Active Active Active H or L H or L H Active L L/ Active L/ Active Active Active Inactive Inactive Standby charge mode Active Active Active Active H or L L H Active L L/ Active L/ Active Active Active Inactive Inactive

General description

Off mode Inactive Inactive Inactive Inactive L L L Inactive Active(1) Active(1)/ Inactive Active(1)/ Inactive Inactive Inactive Inactive Inactive

1. Programming microcontroller only H - high level +5 Vdc L - low level 0 Vdc Active - active signal Inactive - inactive signal

1.1.18

Detailed description of mechanics


The standard enclosure dimensions are as follows:

Main PCB: Dimensions: 230 x 160 mm Type: double-sided GE (glass - epoxy), FR4 with SMOBC Dimensions: 80 x 25 mm Type: single-sided GE (glass - epoxy), FR4 with SMOBC

LEDs and button PCB:

25/66

General description

UM0527

1.2
1.2.1

Software architecture
Data models
The setting of the UPS is stored in EEPROM memory. The data format is shown in Table 7: Table 7. Memory mapping
Name OFF_ADDR ATR_ADDR SHUT_ADDR BATT_ADDR ASHD_ADDR Length (bytes) 1 1 1 1 1 Description Flag indicating state of UPS (on/off) Auto restart flag Shutdown type Battery condition Auto shutdown flag

Address 0 1 2 3 4

1.2.2

Protocols
The SEC protocol is described briefly below. All messages sent between the PC and the UPS look like: ^<type><len><data> where:

^ : the header character <type>: the type of message being sent P: PC polls UPS (a query) S: PC sets UPS variable D: UPS returns data to PC (result of query) 0: UPS rejected command sent from PC 1: UPS accepted command sent from PC

The PC sends the following message types to the UPS:

The UPS returns the following message types to the PC:

<len>: 3 characters length of following data (zero padded decimal ASCII) <data> - "len" characters of data

Commands are contained in the <data> field and are always 3 characters long. The orders supported are listed in Table 8. Table 8. Poll commands
Response (values separated by commas) Auto restart: 0 - disabled or 1 - enabled ST UPS reference design 230,500,230,500,700,450,1,1 for EU version and 120,600,120,600,700,450,1,1 for US version

Query (3 characters) ATR MAN MOD NOM

26/66

UM0527 Table 8. Poll commands

General description

Query (3 characters) SDA ST1 ST2 ST3 STR AP1 AP2 VER

Response (values separated by commas) Shutdown type: 0 output, 1 - system Battery condition (0 good, 1 weak, 2 - replace), battery status (0 normal, 1 low, 2 - depleted), battery voltage (V/10), battery current (A/10) Input num lines (1), mains frequency (Hz/10), mains voltage (V/10) Output source (0 normal, 1 on battery, 3 reducing, 4 boosting, 5 out off), output voltage (V/10), output current (A/10), output power (W) Test result summary (1 passed, 2 in progress, 4 battery test fail) 10,16,17,18,19,20,22,24,43 51,58,59,60,61,62,63,64,65,68,73,76,77,80,82,83,84,85,87 V 1-0-0-0 w

Table 9.

Set commands
Response (values separated by commas) Auto restart: 0 - disabled or 1 - enabled Shutdown type: 0 output, 1 - system Shutdown after delay (if parameter > 0: second to shutdown, if parameter = -1: cancel shutdown) Reboot with duration (parameter seconds to startup after shutdown) Startup after delay (parameter seconds to startup) Battery test: 1 test or -1 cancel test

Query (3 characters) ATR SDA PSD RWD STD TST

Table 10.

Additionally UPS support order not defined in SEC protocol


Response (values separated by commas) Auto shutdown: 0 disabled, 1 enabled or poll. UPS is shut down when output current is less than or equal to 100 mA.

Query (3 chars) ASH

1.2.3 1.2.4

System architecture Main loop

The UPS works in 7 modes: Inverter mode - if the mains voltage is lower than 167 VAC RMS(87 for US version) or higher than 286 VAC RMS(153 for US version) the inverter is switched on. At outputs INV_B and INV_A, a PWM signal 50 Hz (60 for US version) with 40% or less duty cycles (depends on DC/DC output voltage) is generated. In inverter mode the ACF signal is switched on. If the mains voltage returns to the correct value (167 - 286 VAC or 87 - 153 VAC for US version), the PWM signal is

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General description

UM0527 synchronized with the mains, the ACF! signal is set to low and the inverter is switched off.

Mains mode - in this mode the battery charger is switched on and the UPS is supplied from the mains. The inverter is switched off (INV_A and INV_B are in low state), and ACF! is high. Buck mode - in this mode the battery charger is switched on and the UPS is supplied from the mains. The ACH signal is switched on, the inverter is switched off, ACF! is high and the ACL signal is in low state. Boost mode - in this mode the battery charger is switched on and the UPS is supplied from the mains. The ACL signal is switched on, the inverter is switched off, ACF! is high and the ACH signal is in low state. Standby mode - in this mode the battery charger is switched off and the UPS is supplied from the battery. ACH and ACL are in low state, ACF! is low, CHOFF is high, and the inverter is switched off. Standby charge mode - the UPS is in this state when the mains is lower than the low level boost mode. ACH and ACL are in low state, ACF! is high, CHOFF is low, and the inverter is switched off. OFF mode - the UPS in this mode is totally switched off. This state is availably only in battery mode after pressing the on/off key longer than 4 seconds.

Additionally the UPS tests the battery. The battery test is done by switching to the inverter mode. During the test the MCU measures UPS output load and battery voltage. If the battery voltage during the test falls below the limit, the battery is failing. The value of the limit depends on time and load current. The test can be forced by the user with a PC. The battery condition can by checked after switching to the inverter mode without forcing the test. A load is necessary to test the battery. Table 11. Signal state in different modes
INV_A INV_B ACH ACL ACF! CHOFF SHD Signal is switched to L after rising edge INV_A or INV_B and switched to H before falling edge INV_A or INV_B. H H H H Depends on battery voltage L H H L

Work mode

Inverter mode

50 Hz (60 for US 50 Hz (60 for US version) PWM version) PWM signal (less than signal (less than 40% duty cycle) 40% duty cycle)

Mains mode Buck mode Boost mode Standby mode Standby charge mode Off mode

L L L L L L

L L L L L L

L L H L L L

L H L L L L

H H H L H H

Depends on battery voltage

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UM0527 Figure 12. Main flowchart

General description

1.2.5

ADC
The ADC thread measures values as described below:

Mains voltage - the voltage measured at INP_LEV is needed for calculating the following values: RMS - true RMS main voltage which determines the working mode of the UPS: mains mode, buck mode, boost mode or inverter mode. This value is calculated for one period of input voltage. SAMPLE - actual sample voltage which is the value needed for calculating RMS. Additionally this value is needed to compare with the predicted value of the mains

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General description

UM0527 value. The result of the comparison is used to make the decision to change the working mode from the mains to the inverter.

Battery voltage - the value measured at AKK_LEV input determines the process of charging and discharging the battery. The value is averaged. During battery operation a signal is needed to indicate a low level of the battery or to protect the battery. In mains mode this value determines the charger's working mode. Battery state
Battery voltage >=21.75 V (+/- 1%) < 21.75 V (+/- 1%) BAT_LOW L H

Table 12.

In DC/DC converter voltage the value is not averaged and is used to check if out is in short-circuit state. During load current the value is measured at PWR_LEV input. The value is needed for calculating the power of the load (RMS for one period), battery current, overloading.

1.2.6

Communication
The thread of communication is in charge of communication to the PC. This thread completes the packet from the PC and sends answers. Received packets are interpreted in the main loop.

1.2.7

SPI
SPI interface is using for communication to EEPROM memory. SPI needs four signals: MISO, MOSI, SCK and CS. In inactive state all signals are high.

1.2.8

Keyboard
The keyboard contains only one key button connected to BUTTON input active low. The reaction for this signal depends on the working mode: Table 13.
No 1 2 3 4 5 6 7

Working modes
State Working mode OUT_REL Mains/boost/buck mode Mains/boost/buck mode Mains/boost/buck mode Mains/boost/buck mode Inverter mode Inverter mode Inverter mode H H L L H H H BUTTON L time Short Long Short Long Short Long Double long OUT_REL No change Fall to L Rise to H Rise to H No change Fall to L ON/OFF H H H H H H Fall to L Action Reaction

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UM0527 Table 13.


No 8 9

General description Working modes (continued)


State Working mode OUT_REL Off Off L L BUTTON L time Short Long OUT_REL L Rise to H ON/OFF H H Action Reaction

Note:

Long = 2 s, Short = 20 ms Additionally the state of OUT_REL is stored in EEPROM memory and restored after a cold start independent of the AUTOSTART setting.

1.2.9

LEDs
LEDs indicates the state of the UPS. The active state is H. Table 14. LED states
State Mains mode Battery mode Low battery in battery mode Buck/boost mode Battery charging Overload (mains) Overload ( battery) Self test Fault ( mains) Fault (battery) Standby mode LED green L H H 2 Hz 50% duty cycle L L H L L H H LED yellow H L 2 Hz 50% duty cycle H 2 Hz 50% duty cycle H L L H L H LED red H H H H H 2 Hz 50% duty cycle 2 Hz 50% duty cycle H L L 0,5 Hz 50% duty cycle

1.2.10

Charger
The battery charger works in two steps: constant current charging and hysteresis constant voltage. In the constant current step, the battery is charging in current mode until the voltage of the battery is lower than 28.2 VDC. In the second step, the charger is switched on when the battery voltage is lower than 26.8 VDC and switched off if the value is higher than 27.8 VDC. The microcontroller controls the process by switching the CHOFF signal. Table 15. Battery charge modes
Battery voltage < 28,2 V Current mode charging >= 28,2 V H CHOFF L Description Charging mode active only after battery working mode. Switch to buffered working mode.

Step of charge process

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General description Table 15. Battery charge modes (continued)


Battery voltage < 26,8 Buffered working mode >= 27,8 H CHOFF L Description

UM0527

Step of charge process

1.2.11

Inverter
The inverter is controlled by signals generated by the PWM module. In battery working mode the microcontroller generates two signals: INV_A and INV_B. The frequency depends on the firmware version: EU - 50 Hz, US - 60 Hz. The duty cycle is less than 50% and depends on the voltage of the DC/DC converter. The phase of the INV_B signal has to be shifted by a half time period to INV_A. The inverter is controlled by a timer interrupt. The frequency of the interrupt is 32 times higher than the mains frequency: every half-period is divided into 16 steps, and the number of steps is stored in a global variable. Before any steps the SHD signals are checked and if they are inactive (H), the inverter signals are switched off (rise to H). Table 16.
Step no 1 2 - 13 14 - 15 16

SHD signals
SHD Description Proper inverter signal falls to L. In any steps the squared value of the output voltage accumulates. The accumulated value is compared with the nominal RMS output constant, and if it is greater, the SHD signal rises to H.

Fall to L L H H

The accumulated value of the output voltage is cleared, the variable storing a step is not cleared. The inverter phase is changed to the opposite state.

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UM0527

Technical description

2
2.1

Technical description
Circuit diagram
Figure 13. Circuit diagram
RFIEMI12st05v031.sch EMI/RFI FILTER

FUSE
AC_IN2 AC_IN1

Microcontroller unit

INPUT

Interface12st05v031.sch

Inerface unit

VCC GND GND BAT_LOW ACF! ACF1! UPS_OFF!

VCC GND ACF! ACF1! UPS_OFF!

VCC GND BAT_LOW ACF! ACF1! UPS_OFF!

BAT_LOW

FUSE

AC_IN2

AC_IN1

LED INDICATIONS BUTTON Microcontroller12st05v031.sch

Relays12st05v031.sch

Power Relays

AC_IN2

AC_IN1

GND

USB_IN! TXD RXD

USB_IN! TXD RXD

USB_IN! TXD

AC_IN2 GND AC_IN1 Input Voltage & Phase Measurement

AC_IN1 AC_IN2

AC_IN1 AC_IN2

RXD

INP_LEV VCC

INP_LEV VCC VDD

INP_LEV VCC VDD PHASE InputVoltage12st05v031.sch

PHASE

PHASE

ACI! ACF ACL! ACH! OUT_REL!

ACI! ACF ACL! ACH! OUT_REL! GND InverterVoltage12st05v031.sch GND Output Voltage Inverter

ACI! ACF ACL! ACH! OUT_REL!

AVR TRAFO

OUT_LEV

OUT_LEV

OUT_LEV AC_1 AC_2

AC_1 AC_2

INV_A INV_B

INV_A INV_B

AC_1 AC_2

DC/DC converter

DCDC12st05v031.sch VDCDC

DCAC12st05v031.sch VDD INV_A INV_B

VDCDC

VDCDC

INV_OUT2 INV_OUT1

INV_OUT2 INV_OUT1 DC/AC Invverter

SHD

SHD

SHD VAKK

HVDC

HVDC

HVDC VDD GND

GND CHOFF

GND

VDD

VDD

VDD

VAKK

VDD

GND

CHOFF

GND VAKK GND

ACDC12st05v031.sch

GND Battery Overcurrent

AC/DC Charger

GND

CHOFF

VDD

VCC AKK_LEV

VCC

AKK_LEV

VCCPU VCC ON/OFF SW_ONP

VCCPU VCC ON/OFF SW_ONP

PWR_LEV

PWR_LEV

BATTERY GND

VBAT

VBAT +VOUT VDD

AC_1 AC_2

AC_1 AC_2

AC_1 AC_2

Protection VBAT Battery Voltage GND Power Supply VBAT

BatOver12st05v031.sch

+VOUT

VDD

BatteryVoltage12st05v031.sch VBAT GND VCC AKK_LEV

VCCPU GND VCC ON/OFF SW_ONP PowerSupply12st05v031.sch GND VPP

VCC IOUT_1 PWR_LEV IOUT_2 GND

Output Current Measurement OutputCurrent12st05v031.sch

+VOUT

VDD

AC_IN1 AC_IN2

AC_IN1 AC_IN2

AC_IN1 AC_IN2

VPP

IOUT_1

IOUT_1

IOUT_2

IOUT_2

GND

GND

OUTPUT

33/66

VCC R173 47R

INV_OUT1

GND

INV_A INV_B RAD2 RAD4 INV_OUT2

HIN LIN

VB HVG VO LVG

VB HVG VO LVG R174 47R D48 STTH1L06A

GND

D47

34/66
RAD1 HVDC

Technical description

HVDC

HVDC

VDD

VDD

GND

GND

DC/AC INVERTER
RAD3

R3 0R Q1 STP12NM50 STP12NM50 STP22NS25Z R13 10k R9 100R STP22NS25Z R7 100R R11 10k

Figure 14. DC/AC inverter

D3 Heatsink BAS16 R5 0R Heatsink Q3

BAS16 D6

VDD C1

VDD C2 10uF/25V INV_OUT1 D2 R172 SMBYT01 10R R2 100R C4 10uF/35V GND C10 100nF 8 7 6 5 U2 L6387D VCC HIN LIN 3 2 1 INV_B INV_A C39 100pF GND INV_OUT2 R4 51R Q2 STP12NM50 STP22NS25Z D4 Heatsink BAS16 Heatsink Q4 STP12NM50 STP22NS25Z R10 100R R12 10k R14 10k ZD2 SM6T18A D8 BAS16 BAS16 D7 R6 51R GND INV_B INV_A C40 100pF C11 100nF GND

R1 100R

R16410R

D1

GND

C3

SMBYT01 10uF/25V

10uF/35V C8 100nF

GND

C9 100nF

U1

L6387D

INV_A INV_B

2 1

8 7 6 5

C36 100pF

C35 100pF GND GND

STTH1L06A

R8 ZD1 SM6T18A

100R

D5 BAS16

GND

230Vac Model 120Vac Model

UM0527

UM0527

DC/DC CONVERTER
VDD R33 RAD5 10uF/50V C62 GND GND 15 13 Heatsink GND 10R Heatsink GND 11 OUT_A VAKK OutB C14 R35 1k 3W A TI1 B VAKK C GND D30 D STTH302S Q7 OUT_B R62 10R R36 Vref 3.3k RAD6 GND R55 22k R56 22k Heatsink U4 PDTC114ET SHD C43 1nF GND GND Heatsink GND GND SHD Heatsink R61 10R 1.5uH / 10A 11 L2 GND GND GND GND 3300uF/35V 3300uF/35V 2 12 STTH302S C64 470uF/63V C66 1.5uH / 10A 10 4 C65 8 C67 10nF 100nF 100nF 330R 2W C15 D29 L1 1 14 R341k 3W R60 10R Q6 C86 D25 D27 Q5 Heatsink HVDC R59 100nF SG3525A VCC VC R53 22k R54 22k C72 GND GND RAD7 RAD9 47R R68 200k 100k

100uF/25V

GND

100nF

C32

C12

GND

R69 200k 100k

VDD VAKK

VDD VAKK HVDC

Figure 15. DC/DC converter

U3

GND OutA 1nF 1kV 1.5nF 1kV

Vref C13 100nF

16

Vref

R17

Disch

33R

STP75NF75

GND

GND

Rt

STTH8R06D STTH803D

STTH8R06D STTH803D

7.5k

STP75NF75

C33 4.7nF R66

Ct

R18

R70 200k 100k C87 330nF 1uF R71 200k 100k VDCDC

C34

R19 100k Sync GND

1nF

ShutDown ErrAmpOut Clock ErrAmp+ SoftStart ErrAmp-

R67 0R

VDCDC 330R 2W R30 5.6k D26 D28 GND GND R32 390k 100k C68 10nF GND

STTH8R06D STTH803D

R28 0R GND 3 12 STP75NF75

C50 100pF

GND GND

Q8 GND

TI700/24/1v01 TI700/24/2v01 RAD8 RAD10 STP75NF75

STTH8R06D STTH803D

GND GND GND

R29 6.8k

R31 36k 30k

GND

GND

Technical description

230Vac Model 120Vac Model

35/66

TX VCCPU OSC1 OSC2 GND RST! ICC_SEL INV_B! INV_A! LEDY LEDG

44 43 42 41 40 39 38 37 36 35 34

GND OSC1 Y1 16MHz GND VCC VCC VCC R118 R114 3.3k U9 E R113 3.3k GND 2.2k 2.2k R119 GND OSC2 C89 22pF GND 1 22pF GND C17 100nF

VCC

1 3 5 7 9

2 4 6 8 10

ICC_DATA ICC_CLK RST! ICC_SEL

C88

Figure 16. Control unit

GND

10k GND R91

RX ACF! ACL ACH OUT_REL BAT_LOW NC1 PWR_LEV AKK_LEV OUT_LEV INP_LEV 1 2 3 4 5 6 7 8 9 10 11 PE1/RDI PB0 PB1 PB2 PB3 PB4 (HS) PD0/AIN0 PD1/AIN1 PD2/AIN2 PD3/AIN3 PD4/AIN4 Vss_1 Vdd_1 PA3 (HS) AIN15/SS/PC7 ICCCLK/SCK/PC6 AIN14/MOSI/PC5 ICCDATA/MISO/PC4 ICAP1_B/PC3 ICAP2_B/PC2 AIN13/OCMP1_B/PC1 AIN12/OCMP2_B/PC0 GND VCCPU LEDR CS! ICC_CLK MOSI ICC_DATA BUTTON UPS_OFF! PHASE USB_IN! 4.7k 33 32 31 30 29 28 27 26 25 24 23

VSS

J1 IDC10

PE0/TDO Vdd_2 OSC1 OSC2 Vss_2 RESET Vpp/ICCSEL PA7 (HS) PA6 (HS) PA5 (HS) PA4 (HS)

PD5/AIN5 VAREF VSSA MCO/AIN8/PF0 BEEP/PF1 (HS) PF2 (HS) OCMP1_A/AIN10/PF4 ICAP1_A/PF6 (HS) EXTCLK_A/PF7 (HS) Vdd_0 Vss_0

VDCDC 12 VAREF 13 VSSA 14 CHOFF 15 BUZZER 16 ACI 17 ON/OFF 18 SHD 19 ACF1! 20 VCCPU 21 GND 22

100pF

100pF

GND

UM0527

GND

100pF

GND

100pF

GND

100pF

GND

100pF

36/66
R104 330R R106 VCC VCC R109 330R VCC R108 330R GA RA YA J2 R107 330R LEDG LEDR LEDY R105 U29 BUTTON 100R VCCPU VDD 3 BAS16 RST!R110 RESET! 2 RES U8 STM809L SW_ONP 10k R111 SW_ONP VCC IDC10 D9 330R 330R R92 2 4 6 8 GND 10 1 3 5 7 9 ST72F324BJ6T6 VCC B1 1 2 BPT-14 OUT_REL! ACI! 9 ACF R86 VCCPU C48 100nF GND M95020WMN6P GND MOSI ICC_CLK 1k VCCPU GND R38 SCK R39 4.7k HOLD! GND GND 4.7k R87 10k 8 7 6 5 S VCC Q HOLD W C VSS D Q15 MMBTA42 1 INV_A INV_B ACL! ACH! 2 R120 2.2k INV_A INV_B ACL! ACH! OUT_REL! ACI! GND ACF! U10 CS! ICC_DATA MISO R37 1k VCCPU 1 2 3 4 BAT_LOW UPS_OFF! PHASE PWR_LEV AKK_LEV OUT_LEV INP_LEV VDCDC CHOFF USB_IN! SHD ON/OFF ACF! ACF1! RESET! VCCPU GND ULN2003D R93 COM 10k NC1 INV_A! INV_B! ACL ACH BUZZER OUT_REL ACI 7B 6B 5B 4B 3B 2B 1B 8 7 6 5 4 3 2 1 7C 6C 5C 4C 3C 2C 1C 10 11 12 13 14 15 16 C70 10nF C74 10nF C76 10nF GND C77 10nF GND GND 10nF GND GND C71 UPS_OFF! AKK_LEV RST! USB_IN! BUTTON C51 C52 C53 GND MOSI ICC_SEL ICC_DATA ICC_CLK TX C54 RX C55 C56 PHASE INV_B! C73 INV_A! C37 1nF C38 1nF 1nF GND GND GND

Technical description

GND

L3

4.7uH

VCCPU

L4

VSSA C16 100nF VAREF

4.7uH

ICP programming C-FLASH

TXD RXD

TXD RXD

L5

4.7uH TX RX

L6

4.7uH

BAT_LOW UPS_OFF! PHASE PWR_LEV AKK_LEV OUT_LEV INP_LEV VDCDC CHOFF USB_IN! SHD ON/OFF ACF! ACF1!

VCCPU

VCCPU

VCC

VCC

GND

GND

230Vac Model 120Vac Model

UM0527

INV_OUT2 INV_OUT1 AC_1 AC_2 AC_1 AC_2 INV_OUT2 INV_OUT1

Figure 17. Power switches

IOUT_1 IOUT_2 IOUT_1 IOUT_2 3 4 L8 1:1000

VPP

VPP

AVR

GND 1 BLACK 6.3x0.8 J4 RT2 JNR15S70L JNR15S2R5M

GND

RT1 JNR15S70L JNR15S2R5M

t 1 VPP WHITE J5 6.3x0.8 RM85-2011-25-1024 SCL-1-H-DPNO BAS16 D31 D32 BZV55C10 BZV55C10 1 RED J6 6.3x0.8 D36 BZV55C75 D34 BZV55C20 D12 BAS16 VPP D10 RL1 VPP VPP RL3

t 1 2

J7 1 6.3x0.8 J8 RL5 RL4 RM84-2022-25-1024 RM84-2012-25-1024 D49 BZV55C75 D13 BAS16 D14 BAS16 D35 BZV55C20 OUT_REL! ACF ACI! ACH! ACL! VPP 1 6.3x0.8 BROWN

AC_IN2

AC_IN2

RL2

OUTPUT
BLUE

RM85-2011-25-1024

D11 BAS16

D33 BZV55C20

AC_IN1

AC_IN1

OUT_REL! ACF ACI! ACH! ACL!

Technical description

230Vac Model 120Vac Model

37/66

100uF/50V

1,25A 2A C96 R128 +VOUT D37 STTH1R06 4 6 D15 C20 ` 100nF 100nF GND GND GND TI50/30v02 CHOFF R15 10k C18 D16 BAS16 VDD RAD12 Q11 R57 22k 8 D17 L6565 BAS16 GD CS R137 4 R133 33R Heatsink 1 R136 39k 8 R115 3.3k GND R20 R94 10k 100k R122 100k GND 2 3 6 7 7 ZCD R63 10R 100nF R132 750k 5 GND U11 3 VFF COMP VFB R134 16k GND VDD CHOFF GND GND GND C21 C101 C102 GND BAS16 1000uF/50V 1000uF/50V 7 8 9 10 2 3 C97 R127 120k 3W 2 GND 4 R129 10R R124 100k 3 100nF X2

L9

R123 100k 33k 120k 3W

R16 10k

R138

680pF 1600V

R131 750k GND

750k

47uF/50V

STP5NK90Z

TL431CD

GND C49 1nF R135 43k

GND

0.68R 2W

38/66
RAD11 Heatsink GND Charger Output Pout(max)=50W Q9 STP80PF55 VBAT Q10 STP80PF55 VBAT +VOUT ZD3 BZX84C12 R95 10k GND GND VDD +VOUT VDD GND

Technical description

AC/DC BATTERY CHARGER


100nF C100 C19 C99 R65 10R 10uH/3A L11 1 T1 BR1 KBU605 13 D38 12 11 STPS8H100D

1nF 500V

R64 10R

Figure 18. AC/DC battery charger

AC_1

AC_1

F1

10uH/3A

C95 47nF X2 GND R130 R126 100k R125 100k C98

C44 47nF X2

AC_2

AC_2

10uH/3A

L10

U6 PDTC114ET

Control voltage output VBAT MAX +28.2V Current Mode Charging VBAT MIN +26.8V Voltage Mode Charging

GND +VOUT R139 5.6k

C79 10nF

U12

Q12 BC857B

TH1 TYN608

R140 180R

R52 4.7R 3W

GND

GND

GND

Overvoltage Protection 32V

230Vac Model 120Vac Model

UM0527

UM0527

V+ R145 J14 COM 820R COM R146 V+ ACFL VCC 2.4k COM COM ACF1! 4.7k R148 U20 PC817C GND C109 2.2uF/50V COM VPC COM TS555CDT 4 VCC R D19 OFF DIS BAS16 6 D20 100nF 1 C25 100nF BAS16 COM 3.3k 6.8k GND RXD1 R142 PC817C R149 VCC U22 R41 4.7k GND THR 7 4.7k COM 4.7k GND VCC UPS_OFF! R45 U21 R48 PC817C TRIG CVolt Q 2 5 C23 R121 2.2k 8 U14 3 BTL BTL BAT_LOW 4.7k R147 PC817C V+ U19

D39

VPC

D40 BAT54S

BAT_LOW

OFF RXD1 OFF TXD1 ACFL

C103

BAT54C

22uF/35V

COM

R97

COM

1 6 2 7 3 8 4 9 5

ACF1!

10k

C22

100nF

C5

D18

Figure 19. PC interface stage

D41

10uF/35V

BAS16

UPS_OFF!

VCC GND

VCC GND

VPC

OFF V+ U23 PC817C R144 VCC 2.2k TXD1 J15 100R BC857B R99 20k 6 GND VCC 16 +5V_USB VCC VR46 IDC10 ICP GND1 +5V_USB 4.7k GND1 VPP_USB R43 OSCOUT TxD_USB C59 100pF R44 +5V_USB 4.7k RxD_USB R169 10k GND1 GND1 GND1 GND1 GND1 GND1 GND1 GND1 GND1 R170 10k R171 10k C60 100pF U18 PC817C R143 VCC 4.3k GND1 GND 7 8 4.7k +5V_USB 4.7k U17 PC817C R47 VCC GND R42 U16 PC817C 4.7k VCC INH Q14 Q13 BC846B R112

BAT54A

V-

GND1

USB_IN!

USB

100nF

USB_IN!

C106

R141

USBVCC

U13 USB6B1

1.5k

GND1 10 VPP_USB 8 RST_USB 6 ICCCLK 4 ICCDATA 2 9 7 5 3 1

C26 100nF U24 GND

J13

1 2 3 4

1 2 3 4

Vcc1 Vcc2 In1 Out1 In2 Out2 Gnd1Gnd2

8 7 6 5

+5V_USB USBDM USBDP

USB Socket

Data Protection GND1

RST_USB +5V_USB C24 100nF GND1 GND1 GND1 C92 22pF

USB-B

C80

1 +5V_USB 2 OSCOUT 3 OSCIN GND1 4 TxD_USB 5 RxD_USB 6 RST_USB 7 8 NC13 VPP_USB 9 NC12 10 NC11 11 NC10 12 USBVCC USBDM USBDP GND1 NC4 ICCDATA ICCCLK NC5 NC6 NC7 NC8 NC9

A B C VEE VSS

14 15 4

RXD TXD

RXD TXD

10nF

C57

100pF

100pF

GND1

ICCDATA ICCCLK C58

GND1 GND1 Y2 24MHz OSCIN

U15 ST72F63BE2M1 SO24 24 VDD USBVCC 23 OSCOUT USBDM 22 OSCIN USBDP 21 VSS VSSA 20 PC1 PA0 19 PC0 PA1 18 RESET PA2 17 PB6 PA3 16 VPP PA4 15 PB3 PA5 14 PB2 PA7 13 PB1 PB0 R98 GND1 10k 10uF/35V C6 C91 GND1 22pF

11 10 9 12 13 2 1 5 3

ADDR A ADDR B ADDR C A1 A2 B1 B2 C1 C2

M74HC4053RM13TR GND

R40 10k R165 10k R166 10k

NC13 NC12 NC11 R167 10k R168 10k

NC10 NC9 NC8 NC7 NC6 NC5 NC4

R84 10k

R85 10k

GND1

GND1

GND1

Technical description

230Vac Model 120Vac Model

39/66

2 SYNC COMP GND INH 4 7 FB 5 3

VCC

AC_IN2

AC_IN2

100k R72 200k

100k R73 200k

U25

R153 36k

C104 22uF/35V GND

C28 100nF GND GND RAD13

GND

40/66
Q16 BDX53C D51 STTH102A C41 C46 100nF 47uF/25V GND D50 BZV55C22 GND R96 33k

Technical description

1,25A

BR2 B600C1500

J3 C45 10uF/100V

Figure 20. Power supply

6.3x0.8 BLACK

F3

J17

GND

GND

GND

6.3x0.8 BLACK VPP 1uF / 50V C110 VPP

GND Voltage From AC/DC Charger +VOUT Voltage From Battery VBAT L12 1 330uH / 0.9A +15Vdc VDD R152 22R 1W

+VOUT

+VOUT VDD D42 STTH102A D43 STTH102A OUT STTH102A D44 VCC +5Vdc VCC U27 LD1086V50 LD1086 3 IN OUT 2

VBAT C27 100nF

VBAT

GND U26 L5970D 6 VREF

GND

GND

POWER SUPPLY

L7 4.7uH C29 100nF GND C113 47uF/25V GND

VCCPU VCCPU C30 C114 100nF 47uF/25V GND GND

AC_IN1 SFH620A-2 GND C112 C61 U7 PDTC114ET 100pF R58 22k 22nF D45 STPS1L60A D21 BAS16

AC_IN1

R74

R75

By button

200k 100k

200k 100k

C105 R116 100uF/35V 3.3k

SW_ONP

SW_ONP

ON/OFF

ON/OFF Heatsink GND GND DL1 R175 VCC 2.2k GND LED

VDD power supply control

UM0527

UM0527 Figure 21. Measurement stages


OUTPUT CURRENT

Technical description

VCC VCC VCC D23 BAS16 U28C PWR_LEV PWR_LEV C84 10nF GND C118 1.5nF R155 1k 8 9 LM324 R156 47.5k R151 6.8k R50 4.7k C117 1.5nF 10 R51 GND 4.7k R157 47.5k R150 6.8k R158 20R 10R IOUT_2 IOUT_1 GND

VCC GND

IOUT_1

IOUT_2

BATTERY VOLTAGE
VCC VBAT D24 BAS16 R25 100k VBAT VCC GND AKK_LEV AKK_LEV C63 R159 20k 10uF/50V VBAT VCC GND

GND

GND

230Vac Model 120Vac Model

INVERTER OUTPUT VOLTAGE


R80 200k 100k R81 R160 82k R161 2.4k 2k 200k 100k R82 200k 100k R83 200k 100k AC_2 AC_1 AC_2 AC_1

OUT_LEV

OUT_LEV C85 10nF

GND

GND

GND

GND

GND

2 1

INPUT VOLTAGE
VCC D22 BAS16 U28D INP_LEV INP_LEV C83 10nF GND R154 1k 12 14 13 LM324 R21 100k C116 R24 22k R78 R49 750k 360k 2k R79 750k 360k AC_IN2 AC_IN2 R100 10k C115 1.5nF R101 GND 10k R22 100k R23 22k GND R176 2k R76 750k 360k R77 750k 360k AC_IN1

VCC

230Vac M 120Vac M

AC_IN1

1.5nF

INPUT VOLTAGE PHASE


R162 1M VCC R102 10k PHASE PHASE D46 BAT54 1 2 R103 10k 11 LM324 R117 10k R27 10k VCC VDD 4

GND

U28A 3

R26 1k

GND

GND GND VDD VCC VDD VCC GND

VDD U28B C31 100nF GND C7 10uF/35V GND 6 7 5 LM324 GND

GND

230Vac Model 120Vac Model

41/66

Technical description Figure 22. RFI/EMI filter


RFI/EMI FILTER
J9 BROWN 1 6.3x0.8 J10 1 6.3x0.8 J11 1 6.3x0.8 N JVR-20N471K JVR-20N271K PE YELLOW/GREEN L C119 4,7nF C120 4,7nF RV1 R90 200k R88 200k R89 200k AC_IN2 AC_IN1

UM0527

AC_IN1

MAINS

C108 470nF

BLUE

AC_IN2

Figure 23. Battery overcurrent protection


J12 1 F2 3,15A 250V J16 1 GND GND VBAT VBAT VAKK VAKK

42/66

UM0527

Technical description

2.2

Layout
Figure 24. Top view

43/66

Technical description Figure 25. Bottom view

UM0527

44/66

UM0527

Technical description

2.3
2.3.1

Assembly description
General
Table 17. UPS components
Model Type Case Power cord Control panel Battery AVR transformer Switch/fuse Output wires Ground wire Ferrite toroidal core Battery fuse Motherboard 120 Vac version UPS Ares 700/1000 3 x 1.0 mm2 UPS 500 rack VRLA type 2 x 7,2 Ah/12 V AVR 700/ST/120/1 ETA 3120-F35G-P7M1-D04X -12 A AVR 700/ST/230/1 ETA 3120-F35G-P7M1-D04X -6 A
2,

230 Vac version

Twisted 2x1.0 mm 30 cm long 1x1.0 mm2, 30 cm long Richco RT250-150-120 40 A ver. 020

45/66

Technical description

UM0527

2.3.2

Electrical
The schematic of the electrical connections is shown in Figure 26. Figure 26. Electrical connections

2.3.3

Mechanical
The UPS case with assembled front and power cord. Figure 27. Mechanical view

46/66

UM0527 Figure 28. UPS with assembled rear outlets

Technical description

Figure 29. UPS with front button and indicators

Figure 30. UPS with batteries and battery fuse

47/66

Technical description Figure 31. UPS with battery fuse

UM0527

Figure 32. UPS with AVR transformer

Figure 33. UPS with automatic fuse and power wires

48/66

UM0527 Figure 34. UPS with motherboard

Technical description

Figure 35. UPS fully assembled

49/66

Technical description Figure 36. UPS

UM0527

2.4
2.4.1

Connectors
PCB: mains input
Table 18. PCB: mains input
Type Tabs Tabs Tabs Description Line in L Line in N PE

Connector identification J9 J10 J11

2.4.2

PCB: outlet output


Table 19. PCB: outlet output
Type Tabs Tabs Description Line out L Line out P

Connector identification J7 J8

2.4.3

PCB: AVR transformer


Table 20. PCB: AVR transformer
Type Tabs Tabs Tabs Description Black White Red

Connector identification J4 J5 J6

50/66

UM0527 Table 20. PCB: AVR transformer (continued)


Type Tabs Tabs

Technical description

Connector identification J3 J17

Description Brown Brown

2.4.4

PCB: battery
Table 21. PCB: battery
Type Solder pad Solder pad Description Battery Battery +

Connector identification -BAT +BAT

2.4.5

PCB
Table 22. PCB
Type IDC10 Description Control panel

Connector identification J2

2.4.6

PCB
Table 23. PCB
Type IDC10 Description ISP for ST72F324J6T6

Connector identification J1

2.4.7

PCB
Table 24. PCB
Type IDC10 Description ISP for ST72F623F2M1

Connector identification J15

51/66

Technical description

UM0527

2.5
2.5.1

Signalization description
Indicators
Table 25. Indicators
Green LED (mains) Mains mode Battery mode Buck/boost mode Battery charging Overload (mains) Overload ( battery) Self test Fault ( mains) Fault (battery) Standby mode Solid on Off Flash on Solid on Solid on Off Solid on Solid on Off Off Yellow LED (battery) Off Solid on Flash On (BATLOW) Off Flash on Off Solid On Solid on Off Solid on Off Red LED (failure/overload) Off Off Off Off Flash on Flash on Off Solid on Solid on Flash on (one per 2 sec.)

2.5.2

Sound alarms
Table 26. Sound alarms
Beeper alarm sequence 1 beep with 1 s. interval by 15 s. and after this 1 beep with 15 s. interval 1 beep with 0.3 s. interval continuous signal Beeper alarm sequence 1 beep with 1 s. interval by 15 s. and after this 1 beep with 15 s. interval

State Inverter mode Overload BATLOW State Inverter mode

2.6
2.6.1
Table 27.

Bill of material
Bill of material for 120 Vac version
Bill of material for 120 Vac version
Designator R137 R28 Manufacturer Royal Yageo Qty 1 1 Ordering code MOR I 2W J 68K T 1 0 RC 0805 J R-07 0R L

Part type 0.68 R 2 W 0R

52/66

UM0527 Table 27. Bill of material for 120 Vac version (continued)
Designator R5,R3 F1, F3 R141 C115,C118,C116,C117 L2,L1 L8 R162 R35,R34 R154,R38,R37,R26,R155 C86 C99 C38,C34,C49,C73,C43,C37 C87 C110 R119,R175,R118,R121,R120 C109 R148 R176,R49,R161 F2 R115,R114,R116,R36,R113 R142 C120,C119 R144,R143 R52 R48,R110,R39,R43,R41,R42, R46,R86,R45,R40,R47,R44,R50, R51 R145,R146 C33 L4,L7,L3,L5,L6 R30 R139 J8,J10,J7,J5,J4,J9,J11,J6,J3,J17 R150,R149,R29,R151 Manufacturer Yageo ESKA Yageo Yageo Richco DTW Yageo Royal Yageo Vishay Vishay Yageo EVOX Rifa Kemet Yageo Yageo Yageo Yageo ESKA Yageo Yageo Vishay Yageo Royal Yageo Yageo Yageo Vishay Yageo Yageo Zierick Yageo Qty 2 1 1 4 2 1 1 2 5 1 1 6 1 1 5 1 1 3 1 5 1 2 2 1 14 2 1 5 1 1 10 4

Technical description

Part type 0R 1,25 A 1.5 k 1.5 nF 1.5 H / 10 A 1:1000 1M 1 k 3 W 1 k 1 nF 1 kV 1 nF 500 V 1 nF 1 F 400 V 1 F / 50 V 2.2 k 2.2 F/50 V 2.4 k 2 k 3,15 A 250 V 3.3 k 3.3 k 4,7 nF 4.3 k 4.7 R 3 W 4.7 k 4.7 k 4.7 nF 4.7 H 5.6 k 5.6 k 6.3x0.8 6.8 k

Ordering code RC 1206 J R-07 0R L RFTQ 1.25A RC 0805 J R-07 1K5 L CC0805KRX7R9BB152 RI-RRH50-15-110 1000CT1307C RC 0805 J R-07 1M L MOR I 3W J 102 T 1 0 RC 0805 J R-07 1K L 1DF0D10 1DF0D10 CC 0805 M R X7R 9 B B 102 PHE426KF7100J C06(4)(1)105K5X5C(2) RC 0805 J R-07 2K2 L SH050M2R20A5F-0511 RC 0805J R-07 2K4 L RC 0805 F R-07 2K L RFTQ 3.15A RC 0805 J R-07 3K3 L RC 1206 J R-07 3K3 L VY2472M49Y5US6*V7 RC 0805 J R-07 4K3 L MOR I 3W J 47J T 1 0 RC 0805 J R-07 4K7 L RC 1206 J R-07 4K7 L CC 0805 M R X7R 9 B B 473 IMC1210-4.7 RC 0805 F R-07 5K6 L RC 1206 J R-07 5K6 L 836/836-Tape RC 0805 F R-07 6K8 L

53/66

Technical description Table 27. Bill of material for 120 Vac version (continued)
Designator R18 R129,R158 R64,R61,R60,R62,R59,R63,R65, R164,R172 R91,R97,R87,R117,R95,R170,R 171,R94,R27,R102,R101,R100,R 103,R166,R92,R96,R165,R98, R169,R93,R168,R167 R11,R12,R16,R15,R14,R13 C80,C79,C76,C85,C68,C81,C67, C77,C84,C83,C70,C71,C74 C2,C1 C3,C4,C7,C6,C5 C63,C62 C45 Y2 ZD3 Y1 R134 R159 R152 R23,R57,R24,R58,R55,R56,R54, R53 C112 C91,C90,C88,C89,C92 C103,C104 L10,L11,L9 R31 R17 R133 R99,R138, R96 R153 R136 R135 R157,R156 R33 Manufacturer Yageo Yageo Yageo Qty 1 2 9

UM0527

Part type 7.5 k 10 R 10 R

Ordering code RC 0805 J R-07 7K5 L RC 0805 J R-07 10R L RC 1206 J R-07 10R L

10 k 10 k 10 nF 10 F/25 V 10 F/35 V 10 F/50 V 10 F/100 V 12 MHz 12 V 16 MHz 16 k 20 k 22 R 1 W 22 k 22 nF 22 pF 22 F/35 V 10 H/3 A 30 k 33 R 33 R 33 k 36 k 39 k 43 k 47.5 k 47 R

Yageo

22

RC 0805 J R-07 10K L

Yageo Yageo Yageo Yageo Yageo Yageo CQ Fairchild CQ Yageo Yageo Royal Yageo Yageo Yageo Yageo Feryster Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo

6 13 2 5 2 1 1 1 1 1 1 1 8 1 5 2 3 1 1 1 3 1 1 1 2 1

RC 1206 J R-07 10K L CC 0805 M K X7R 9 B N 103 SB025M0010A5F-0611 SH035M0010A5F-0511 SH050M0010A5F-0511 SH035M0010A5F-0511 12.00M HC49-S BZX84C12 16.00M HC49-S RC 0805 J R-07 16K L RC 0805 F R-07 20K L MOR I 1W J 220 T 1 0 RC 0805 F R-07 22K L CC 0805 M K Y5V 9 B N 223 CC0805MKX7R9BN220 SH035M0022A5F-0511 DSz-8/10/3-V RC 0805 F R-07 30k L RC 0805 J R-07 33R L RC 1206 J R-07 33R L RC 0805 J R-07 33K L RC 1206 J R - 07 36K L RC 0805 J R-07 39K L RC 0805 J R-07 43K L RC 0805 F R-07 47K5 L RC 0805 J R-07 47R L

54/66

UM0527 Table 27. Bill of material for 120 Vac version (continued)
Designator R173,R174 C95 C113,C114, C46 C98 R6,R4 R160 R111,R112 R2,R8,R1,R9,R10,R7 R122,R21,R20,R25,R22,R32, R19 R123,R68,R126,R71,R69,R70,R 124,R125,R80,R72,R73,R83,R81 ,R82,R75,R74 C20,C19,C12,C14,C15,C13,C11, C18,C21,C30,C29,C28,C8,C72,C 23,C25,C16,C17,C24,C22,C9, C10,C26,C48,C27,C31,C41 C96 C50,C57,C58,C54,C55,C53,C51, C52,C56,C35,C36,C39,C61,C40, C59,C60 C32 C105 C100 R128,R127 R140 R88,R89,R90 R67,R66 R107,R106,R108,R105,R109, R104 L12 R78,R76,R77,R79 C106 C108 C66 C97 R131,R130,R132 Manufacturer Yageo Arcotronics Yageo Yageo Yageo Yageo Yageo Yageo Yageo Qty 2 1 2 1 2 1 2 6 7

Technical description

Part type 47 R 47 nF X2 47 F/25 V 47 F/50 V 51 R 82 k 100 R 100 R 100 k 100 k

Ordering code RC 1206 J R-07 47R L MKPX2-47NR15 SH025M0047A5F-0511 SC050M0047A5F-0611 RC 1206 J R-07 51R L RC 0805 F R-07 82K L RC 0805 J R-07 100R L RC1206JR-07100RL RC 0805 J R-07 100K L

Yageo

16

RC 1206 J R-07 100K L

100 nF

Yageo

27

CC 0805 K R X7R 9 B B 104 MKPY2-100NR15 CC 0805 M R X7R 9 B B 101 SH050M0010A5F-0611 SC035M0100A5F-0811 SC050M0100A5F-0815 MOR I 3W J 124 T 1 0 RC 0805 J R-07 180R L RC 1206 F R-07 200K L MOR I 2W J 331 T 1 0 RC 0805 J R-07 330R L DSz-9/330/0,9-V RC 1206 F R-07 360K L CC 0805 M K X7R 9 B N 474 MKPX2-470NR22 63 YXG 470 M CA 16X20 FKP1 680/1600 RC 1206 J R-07 750K L

100 nF X2 100 pF 100 F/25 V 100 F/35 V 100 F/50 V 120 k 3 W 180 R 200 k 330 R 2 W 330 R 330 H / 0.5 A 360 k 470 nF 470 nF 470 F/63 V 680 pF 1600 V 750 k

Arcotronics Yageo Yageo Yageo Yageo Royal Yageo Yageo Royal Yageo Feryster Yageo Yageo Arcotronics Rubycon WIMA Yageo

1 16 1 1 1 2 1 3 2 6 1 4 1 1 1 1 3

55/66

Technical description Table 27. Bill of material for 120 Vac version (continued)
Designator R147 C101,C102 C65,C64 D15,D5,D6,D22,D7,D24,D21,D19 ,D14,D11,D23,D18,D13,D3,D20, D9,D4,D17,D16,D12,D10,D8 D46 D41 D39 D40 Q13 Q12,Q14 Q16 B1 BR2 D32,D31 Manufacturer Yageo Rubycon Yageo Fairchild Vishay Vishay Vishay Vishay Infineon technologies Fairchild STMicroelectronics Bestar electronics industry DC Components Central semiconductor, Microsemi Central semiconductor, Microsemi Central semiconductor, Microsemi Central semiconductor, Microsemi Central semiconductor, Microsemi Fideltronik Fideltronik Fischer elektronik Molex Molex Joyin Qty 1 2 2 22 1 1 1 1 1 2 1 1 1 2

UM0527

Part type 820 R 1000 F/50 V 3300 F/35 V BAS16 BAT54 BAT54A BAT54C BAT54S BC846B BC857B BDX53C BPT-14 B600C1500 BZV55C10

Ordering code RC 0805 J R-07 820R L 50 YXG 1000 M CA 16X25 SC035M3300A5F-1836 BAS16 BAT54-GS18 BAT54A-GS18 BAT54C-GS18 BAT54S-GS18 BC846B BC857B BDX53C BPT-14 B600C1500 BZV55C10

BZV55C20

D34,D33

BZV55C20

BZV55C20

D35

BZV55C20

BZV55C22

D50

BZV55C22

BZV55C75 Heatsink Heatsink Heatsink IDC10 IDC10 JNR15S2R5M

D49,D36 RAD5,RAD6 RAD13,RAD10,RAD9,RAD7, RAD8 RAD12,RAD4,RAD1,RAD3, RAD11,RAD2 J15,J1 J2 RT1,RT2

2 2 5 6 2 1 2

BZV55C75 40X53X20 (MUP831) LM-317 (MUPS190) SK145 37,5 STS TO220 MX-5332-10GS1 MX-5332-10GS1 JNR15S2R5M

56/66

UM0527 Table 27. Bill of material for 120 Vac version (continued)
Designator RV1 BR1 U26 U1,U2 U11 U27 DL1 U28 U24 U10 Q15 U17,U23,U16,U18,U19,U21,U22, U20 U7,U6,U4 RL4 RL5 RL2,RL3 RL1 U25 U3 ZD2,ZD1 D2,D1 U29 U15 U8 Q11 Q3,Q4,Q1,Q2 Q8,Q6,Q5,Q7 Q10,Q9 D45 D38 D37 D48,D47 D43,D42,D44, D51 Manufacturer Joyin Taiwan semiconductor ST STMicroelectronics STMicroelectronics STMicroelectronics Kingbrigth STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Sharp Philips Relpol Relpol Relpol Song Chuan Vishay STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Qty 1 1 1 2 1 1 1 1 1 1 1 8 3 1 1 2 1 1 1 2 2 1 1 1 1 4 4 2 1 1 1 2 4

Technical description

Part type JVR-20N271K KBU605 L5970D L6387D L6565 LD1086V50 LED LM324 M74HC4053RM13TR M95020MN6P MMBTA42 PC817C PDTC114ET RM84-2012-25-1024 RM84-2022-25-1024 RM85-2011-25-1024 SCL-1-H-DPNO SFH620A-2 SG3525A SM6T18A SMBYT01 ST72F324J6T6 ST72F623F2M1 STM809L STP5NK90Z STP22NS25Z STP75NF75 STP80PF55 STPS1L60A STPS8H100D STTA106 STTH1L06A STTH102A

Ordering code JVR-20N271K 70-070-65 Elfa L5970D013TR L6387D L6565D LD1086V50 L-934LSRD LM324D M74HC4053RM13TR M95020MN6P MMBTA42 PC817C PDTC114ET RM84-2012-25-1024 RM84-2022-25-1024 RM85-2011-25-1024 SCL-1-H-DPNO (24V coil voltage) SFH620A-2 SG3525AP SM6T18A SMBYT01 ST72F324J6T6 ST72F623F2M1 STM809LWX6F STP5NK90Z STP22NS25Z STP75NF75 STP80PF55 STPS1L60A STPS8H100D STTA106U STTH1L06A STTH102A

57/66

Technical description Table 27. Bill of material for 120 Vac version (continued)
Designator D30,D29 D28,D25,D26,D27 T1 TI1 U12 U14 TH1 U9 U13 J13 Manufacturer STMicroelectronics STMicroelectronics Sigma Sigma Fairchild STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics JST Qty 2 4 1 1 1 1 1 1 1 1

UM0527

Part type STTH302S STTH803D TI50/30v01 TI700/24/2v01 TL431CD TS555CDT TYN608 ULN2003D USB6B1 USB-B

Ordering code STTH302S STTH803D TI50/30v01 TI700/24/2v01 TL431CD TS555CDT TYN608RG ULN2003D USB6B1RL UBB-4R-D10T-1

2.6.2
Table 28.

Bill of material for 230 Vac version


Bill of material for 230 Vac version
Designator R137 R28 R3,R5 F1, F3 R141 C117,C116,C115,C118 L2,L1 L8 R162 R34,R35 R26,R155,R38,R37,R154 C86 C99 C43,C37,C49,C38,C34,C73 C110 R119,R118,R120,R175,R121 C109 R148,R161 R49,R176 Manufacturer Royal Yageo Yageo ESKA Yageo Yageo Richco DTW Yageo Royal Yageo Vishay Vishay Yageo Kemet Yageo Yageo Yageo Yageo Qty 1 1 2 1 1 4 2 1 1 2 5 1 1 6 1 5 1 2 2 Ordering code MOR I 2W J 68K T 1 0 RC 0805 J R-07 0R L RC 1206 J R-07 0R L RFTQ 1.25A RC 0805 J R-07 1K5 L CC0805KRX7R9BB152 RI-RRH50-15-110 1000CT1307C RC 0805 J R-07 1M L MOR I 3W J 102 T 1 0 RC 0805 J R-07 1K L 1DF0D10 1DF0D10 CC 0805 M R X7R 9 B B 102 C06(4)(1)105K5X5C(2) RC 0805 J R-07 2K2 L SH050M2R20A5F-0511 RC 0805J R-07 2K4 L RC 0805 F R-07 2K L

Part type 0.68 R 2 W 0R 0R 1,25 A 1.5 k 1.5 nF 1.5 H / 10 A 1:1000 1M 1 k 3 W 1 k 1 nF 1 kV 1 nF 500 V 1 nF 1 F / 50 V 2.2 k 2.2 F/50 V 2.4 k 2 k

58/66

UM0527 Table 28. Bill of material for 230 Vac version (continued)
Designator F2 R115,R116,R114,R36,R113 R142 C119,C120 R143,R144 R52 R48,R40,R41,R86,R110,R45, R43,R47,R44,R39,R46,R42,R51, R50 R145,R146 C33 L7,L4,L3,L6,L5 R30 R139 J8,J10,J7,J5,J4,J9,J11,J6, J3, J17 R149,R151,R29,R150 R18 R129 R172,R60,R63,R164,R59,R62, R64,R61,R65 R166,R171,R91,R117,R102, R103,R169,R167,R93,R168, R170,R165,R98,R95,R87,R96, R100,R92,R97,R27,R94,R101 R16,R12,R13,R15,R11,R14 C79,C76,C77,C74,C70,C71,C67, C85,C81,C84,C83,C68,C80 C2,C1 C4,C6,C3,C7,C5 C62,C63 C45 L10,L11,L9 Y2 Y1 R134 R158 Manufacturer ESKA Yageo Yageo Vishay Yageo Royal Yageo Yageo Yageo Vishay Yageo Yageo Zierick Yageo Yageo Yageo Yageo Qty 1 5 1 2 2 1 14 2 1 5 1 1 10 4 1 1 9

Technical description

Part type 3,15 A 250 V 3.3 k 3.3 k 4,7 nF 4.3 k 4.7 R 3 W 4.7 k 4.7 k 4.7 nF 4.7 H 5.6 k 5.6 k 6.3x0.8 6.8 k 7.5 k 10 R 10 R

Ordering code RFTQ 3.15A RC 0805 J R-07 3K3 L RC 1206 J R-07 3K3 L VY2472M49Y5US6*V7 RC 0805 J R-07 4K3 L MOR I 3W J 47J T 1 0 RC 0805 J R-07 4K7 L RC 1206 J R-07 4K7 L CC 0805 M R X7R 9 B B 473 IMC1210-4.7 RC 0805 F R-07 5K6 L RC 1206 J R-07 5K6 L 836/836-Tape RC 0805 J R-07 6K8 L RC 0805 J R-07 7K5 L RC 0805 J R-07 10R L RC 1206 J R-07 10R L

10 k 10 k 10 nF 10 F/25 V 10 F/35 V 10 F/50 V 10 F/100 V 10 H/3 A 12 MHz 16 MHz 16 k 20 R

Yageo

22

RC 0805 J R-07 10K L

Yageo Yageo Yageo Yageo Yageo Yageo Feryster CQ CQ Yageo Yageo

6 13 2 5 2 1 3 1 1 1 1

RC 1206 J R-07 10K L CC 0805 M R X7R 9 B B 103 SB025M0010A5F-0611 SH035M0010A5F-0511 SC050M0010A5F-0511 SH035M0010A5F-0511 DSz-8/10/3-V 12.00M HC49-S 16.00M HC49-S RC 0805 J R-07 16K L RC 0805 F R-07 20R L

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Technical description Table 28. Bill of material for 230 Vac version (continued)
Designator R159 R152 R24,R55,R53,R57,R56,R58,R54, R23 C112 C90,C92,C91,C89,C88 C104,C103 R17 R133 R138,R99, R96 R153,R31 R136 R135 R156,R157 R33 R173,R174 C95 C114,C113, C46 C98 R4,R6 R160 R112,R111 R7,R1,R2,R8,R9,R10 R20,R25,R21,R122,R22,R19 R123,R125,R126,R124 C26,C18,C30,C29,C48,C21,C25, C28,C27,C24,C22,C23,C20,C11, C12,C15,C16,C13,C19,C17,C72, C14,C31,C9,C10,C8, C41 C96 C40,C52,C61,C35,C51,C59,C39, C60,C55,C57,C50,C56,C54,C36, C58,C53 C32 C105 C100 Manufacturer Yageo Royal Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Arcotronics Yageo Yageo Yageo Yageo Yageo Yageo Yageo Yageo Qty 1 1 8 1 5 2 1 1 3 2 1 1 2 1 2 1 3 1 2 1 2 6 6 4

UM0527

Part type 20 k 22 R 1 W 22 k 22 nF 22 pF 22 F/35 V 33 R 33 R 33 k 36 k 39 k 43 k 47.5 k 47 R 47 R 47 nF X2 47 F/25 V 47 F/50 V 51 R 82 k 100 R 100 R 100 k 100 k

Ordering code RC 0805 F R-07 20K L MOR I 1W J 220 T 1 0 RC 0805 F R-07 22K L CC 0805 M K Y5V 9 B N 223 CC0805MKX7R9BN220 SH035M0022A5F-0511 RC 0805 J R-07 33R L RC 1206 J R-07 33R L RC 0805 J R-07 33K L RC 1206 J R - 07 36K L RC 0805 J R-07 39K L RC 0805 J R-07 43K L RC 0805 F R-07 47K5 L RC 0805 J R-07 47R L RC 1206 J R-07 47R L MKPX2-47NR15 SH025M0047A5F-0511 SC050M0047A5F-0611 RC 1206 J R-07 51R L RC 0805 F R-07 82K L RC 0805 J R-07 100R L RC 1206 J R-07 100R L RC 0805 J R-07 100K L RC 1206 J R-07 100K L CC 0805 M K X7R 9 B N 104 MKPY2-100NR15 CC 0805 M K X7R 9 B N 101 SH050M0010A5F-0611 SC035M0100A5F-0811 SC050M0100A5F-0815

100 nF

Yageo

27

100 nF X2 100 pF 100 F/25 V 100 F/35 V 100 F/50 V

Arcotronics Yageo Yageo Yageo Yageo

1 16 1 1 1

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UM0527 Table 28. Bill of material for 230 Vac version (continued)
Designator R128,R127 R140 R82,R83,R89,R80,R90,R81,R88, R70,R72,R68,R69,R73,R71,R75, R74 R66,R67 R108,R104,R106,R105,R109,R1 07 C87 L12 R32 C106 C108 C66 C97 R78,R76,R79,R77,R130,R131, R132 R147 C101,C102 C64,C65 D15,D7,D16,D6,D4,D17,D11,D18 ,D23,D24,D20,D14,D13,D10,D19 ,D5,D22,D9,D12,D3,D8,D21 D46 D41 D39 D40 Q13 Q12,Q14 Q16 B1 BR2 D32,D31 Manufacturer Royal Yageo Yageo Royal Yageo EVOX Rifa Feryster Yageo Yageo Arcotronics Rubycon WIMA Yageo Yageo Rubycon Yageo Fairchild Vishay Vishay Vishay Vishay Infineon technologies Fairchild STMicroelectronics Bestar electronics industry DC Components Central semiconductor , microsemi Qty 2 1 15 2 6 1 1 1 1 1 1 1 7 1 2 2 22 1 1 1 1 1 2 1 1 1 2

Technical description

Part type 120 k 3 W 180 R 200 k 330 R 2 W 330 R 330 nF 330 H / 0.9 A 390 k 470 nF 470 nF 470 F/63 V 680 pF 1600 V 750 k 820 R 1000 F/50 V 3300 F/35 V BAS16 BAT54 BAT54A BAT54C BAT54S BC846B BC857B BDX53C BPT-14 B600C1500 BZV55C10

Ordering code MOR I 3W J 124 T 1 0 RC 0805 J R-07 180R L RC 1206 F R-07 200K L MOR I 2W J 331 T 1 0 RC 0805 J R-07 330R L PHE426MD6330J DSz-9/330/0,9-V RC 0805 F R-07 390K L CC 0805 M K X7R 9 B N 474 MKPX2-470NR22 63 YXG 470 M CA 16X20 FKP1 680/1600 RC 1206 F R-07 750K L RC 0805 J R-07 820R L 50 YXG 1000 M CA 16X25 SC035M3300A5F-1836 BAS16 BAT54-GS18 BAT54A-GS18 BAT54C-GS18 BAT54S-GS18 BC846B BC857B BDX53C BPT-14 B600C1500 BZV55C10

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Technical description Table 28. Bill of material for 230 Vac version (continued)
Designator D35 Manufacturer Central semiconductor, microsemi Central semiconductor, microsemi Central semiconductor, microsemi Central semiconductor, microsemi Fairchild Fideltronik Fideltronik Fischer Elektronik Molex Molex Joyin Joyin Taiwan Semiconductor STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Kingbrigth STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Sharp Philips Relpol Relpol Relpol Qty 1

UM0527

Part type BZV55C20

Ordering code BZV55C20

BZV55C20

D34,D33

BZV55C20

BZV55C22

D50

BZV55C22

BZV55C75 BZX84C12 Heatsink Heatsink Heatsink IDC10 IDC10 JNR15S70L JVR-20N471K KBU605 L5970D L6387D L6565 LD1086V50 LED LM324 M74HC4053RM13TR M95020MN6P MMBTA42 PC817C PDTC114ET RM84-2012-25-1024 RM84-2022-25-1024 RM85-2011-25-1024

D36,D49 ZD3 RAD5,RAD6 RAD10,RAD9,RAD13,RAD8,RA D7 RAD11,RAD3,RAD1,RAD4,RAD 2,RAD12 J1,J15 J2 RT1,RT2 RV1 BR1 U26 U1,U2 U11 U27 DL1 U28 U24 U10 Q15 U21,U18,U16,U19,U22,U17,U20, U23 U6,U4,U7 RL4 RL5 RL2,RL3

2 1 2 5 6 2 1 2 1 1 1 2 1 1 1 1 1 1 1 8 3 1 1 2

BZV55C75 BZX84C12 40X53X20 (MUP831) LM-317 (MUPS190) SK145 37,5 STS TO220 MX-5332-10GS1 MX-5332-10GS1 JNR15S70L JVR-20N471K KBU605 L5970D013TR L6387D L6565D LD1086V50 L-934LSRD LM324D M74HC4053RM13TR M95020MN6P MMBTA42 PC817C PDTC114ET RM84-2012-25-1024 RM84-2022-25-1024 RM85-2011-25-1024

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UM0527 Table 28. Bill of material for 230 Vac version (continued)
Designator RL1 U25 U3 ZD1,ZD2 D2,D1 U29 U15 U8 Q11 Q1,Q2,Q4,Q3 Q6,Q5,Q8,Q7 Q10,Q9 D45 D38 D37 D48,D47 D27,D26,D25,D28 D43,D42,D44, D51 D29,D30 T1 TI1 U12 U14 TH1 U9 U13 J13 Manufacturer Song Chuan Vishay STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics Sigma Sigma Fairchild STMicroelectronics STMicroelectronics STMicroelectronics STMicroelectronics JST Qty 1 1 1 2 2 1 1 1 1 4 4 2 1 1 1 2 4 4 2 1 1 1 1 1 1 1 1

Technical description

Part type SCL-1-H-DPNO SFH620A-2 SG3525A SM6T18A SMBYT01 ST72F324J6T6 ST72F623F2M1 STM809L STP5NK90Z STP12NM50 STP75NF75 STP80PF55 STPS1L60A STPS8H100D STTA106 STTH1L06A STTH8R06D STTH102A STTH302S TI50/30v01 TI700/24/1v01 TL431CD TS555CDT TYN608 ULN2003D USB6B1 USB-B

Ordering code SCL-1-H-DPNO 24V SFH620A-2 SG3525AP SM6T18A SMBYT01 ST72F324J6T6 ST72F623F2M1 STM809LWX6F STP5NK90Z STP12NM50 STP75NF75 STP80PF55 STPS1L60A STPS8H100D STTA106U STTH1L06A STTH8R06D STTH102A STTH302S TI50/30v01 TI700/24/1/v01 TL431CD TS555CDT TYN608RG ULN2003D USB6B1RL UBB-4R-D10T-1

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Technical specifications

UM0527

Technical specifications
Table 29. Technical specifications
Parameters Output rating power Input voltage Input frequency Power factor Operating modes input voltage Mains mode Boost mode Buck mode Inverter mode Output voltage Mains mode Boost mode Buck mode Inverter mode Battery voltage 28 20 Vdc0.4 Vdc Output frequency Transfer time Typical Maximum Inverter output waveform Inverter output waveform THD Backup time (full load) Battery 2 pcs. Type Nominal voltage Capacity Recharge time (after full discharge) BATLOW level Battery protection level (UPS output shutdown) Maintenance free Lead Acid 12 V 7.2 Ah max 8 h for 90% recharge max 4 h for 80% recharge 22 21.5 Vdc 18 19 Vdc for load >100 W 20 21 Vdc for load <100 W Maintenance free Lead Acid 12 V 7.2 Ah max 8h for 90% recharge max 4h for 80% recharge 22 21.5Vdc 18 19 Vdc for load >100 W 20 21 Vdc for load <100 W 96 138Vac3Vac 96 115Vac3Vac 117 - 133Vac3Vac 120Vac +5/-10% 60Hz0.1Hz class 3 [EN62040-3] 4 ms 10 ms Quasi-sine (square wave) 70% 2.5 3 min 184 - 265 Vac 3 Vac 184 - 220 Vac 3 Vac 224 - 256 Vac 3 Vac 230 Vac +5/-10% 50 Hz 0.1Hz class 3 [EN62040-3] 4 ms 10 ms Quasi-sine (square wave) 70% 2.5 - 3 min 96 138 Vac3 Vac 83 100 Vac 3 Vac 134 - 153 Vac3 Vac 0 - 87 Vac3 Vac 153 - 175 Vac3 Vac 184 - 265 Vac3 Vac 160 - 191 Vac 3 Vac 257 - 294 Vac3 Vac 0 -167 Vac3 Vac 286-300 Vac3 Vac 120 V/60 Hz model 700 VA/450 W 83 Vac3% - 153 Vac3% 60 Hz 0.6 lagging at 700 VA 230 V/50 Hz model 700 VA/450 W 160 Vac3% - 294 Vac3% 50 Hz 0.6 lagging at 700 VA

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UM0527 Table 29. Technical specifications (continued)


Parameters Battery recharge First step Second step 120 V/60 Hz model Two recharge steps Constant current (Imax=2.16 A, Vmax=28.2 Vdc) Hysteresis constant voltage V=27.3 Vdc 0.5 Vdc

Revision history

230 V/50 Hz model Two recharge steps Constant current (Imax=2.16 A, Vmax=28.2 Vdc) Hysteresis constant voltage V=27.3 Vdc 0.5 Vdc

Revision history
Table 30.
Date 18-Jul-2008

Document revision history


Revision 1 Initial release Changes

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UM0527

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