Borri Ups b9000 Ups Service Manual

UPS SERVICE MANUAL
B9000 200-250-300kVA
JUD409399
WARNING: This is a Class A-UPS Product. In a domestic environment,
this product may cause radio interference,
in which case, the user may be required to take additional measures.
UPS SERVICE MANUAL
Index of sections Code
1 – TECHNICAL SPECIFICATION JUD408572

2 – OPERATING MANUAL JUD408826
3 – ELECTRICAL DRAWING JUD307466
4 – UPS OPERATING DESCRIPTION JUD409400
5 – TROUBLESHOOTING AND MAINTENANCE JUD409401
6 – “UPSTEST” SOFTWARE JUD409402
7 – “WRC MONITOR” SOFTWARE JUD409403
8 – PARALLEL – OPERATING MANUAL JUD409404
9 – PARALLEL – MAINTENANCE AND TROUBLESHOOTING JUD409405
Issued 13/04/07 JUD409399 3 of 3

TECHNICAL DATA SHEET
B9000 200-250-300 kVA
GENERAL INFORMATION
POWER - kVA 200 250 300
UPS typology ON LINE - Double Conversion
Nominal output power (Cos Ø 0,8) - kVA 200 250 300
Nominal output power (Cos Ø 1,0) - kW 160 200 240
Efficiency (AC ÷ AC) - % > 93 > 93 > 93
Heat dissipation at nominal load and voltage
- kW 11,2 14,0 16,8
- kcal/hour (x1000) 9,6 12,0 14,4
UPS ambient temperature -°C 0 ÷ 40
BATTERY ambient temperature -°C 0 ÷ +25
UPS storage temperature -°C -10 ÷ +70
BATTERY storage temperature -°C -10 ÷ +60
Relative humidity (non condensing) < 95%
Altitude < 1000 mt (Above See Level)
Power derating for altitude > 1000mt According to “IEC62040-3”
Ventilation FORCED
Requested cooling air volume – mt3/h 3500 4100 4500
Audible noise level (according EN 50091) < 62 db < 62 db < 62 db
Standard battery type lead acid (n° of cells) 300 300 300
Protection degree IP 20
Immunity According to “EN 50091-2”
(CE label)
Paint RAL 7035
Accessibility Front and top access for service
Installation
Dimensions (mm) W = 1200 D = 860 H = 1900
Weights (kg) (without battery) 870 1020 1200
Static load (kg/m2) (without battery) 925 1085 1277
Input/output cable connection Bottom Side (Top Side on Request)
Transport Base provided for forklift handling
Transport mechanical stress According to “IEC62040-3”
Design standard According to
“EN50091” - “IEC EN 62040”
“ISO9000:2000”
Free contact interface On request
Serial communication interface RS232-RS485 (SNMP-Option)
Parallel configuration Up to 4 redundant
Rev.A JSD409388 JUD408572 1 of 7

BLOCK DIAGRAM
1
5
2 4 6
1. Input mains (separate for by-pass and rectifier)

2. Rectifier and battery charger
3. Standard external battery
4. Inverter
5. Emergency line (by-pass)
6. Inverter (SSI) and by-pass (SSB) static switch
DESCRIPTION:
The UPS is designed following the criteria of low environmental impact.
The quantity of the raw material used on the magnetic components and the
number of semiconductors is minimized by the means of very advanced design
criteria.
The high overall efficiency minimizes the power consumption.
The expected battery lifetime is maximized by the very advanced digital battery
charger.
The UPS is equipped by a built in very advanced self diagnostic program
indicating the problems and suggesting to the service people how to repair the
faults.
The inverter transformer prevents the direct feed-through of the battery potential
into the critical load and allows a very high rejection ratio of the power supply
disturbances (spikes, surges etc.).
The high input power factor and the low harmonic level of the input current allows
to reduce the dimensioning of the installation in terms of size of the cables and the
circuit breakers.
The high efficiency and input power factor reduces the costs during the normal
operation of the UPS.
Rev.A JSD409388 JUD408572 2 of 7

UPS INPUT: RECTIFIER and BATTERY CHARGER
POWER - kVA 200 250 300

Nominal Input Voltage - Vac 400 V +10% -20%
Input Frequency – Hz 50 - 60 Hz +/- 5 Hz
Input Power Factor (@ 400 V) > 0,96 > 0,96 > 0,96
Input Current THD <5% <5% <5%
DC Output Voltage Accuracy +/- 1%
DC Output Voltage Ripple 1% rms
Battery Recharging Characteristic IU (DIN 41773)
Temperature Voltage Compensation On Request
Maximum Recharging Current (at nom. load) - A 30 40 40
AC-DC converter type IGBT
Input protection Fuses
Nominal Current Absorbed from Mains
(At nominal load and Battery charged) - A 250 310 375
Maximum Current Absorbed from Mains
(At nom. load and max. recharging current) - A 280 350 410
DESCRIPTION:
The Input rectifier is designed to minimize the harmonics rejected into the input
mains.
The technology is based on a full bridge 6-IGBT matrix, fully digitally controlled.
Large input mains variations are allowed.
The battery charger function is included on the same converter.
The converter is designed to recharge the battery for long time autonomies.
Rev.A JSD409388 JUD408572 3 of 7

BATTERY
POWER - kVA 200 250 300

Type Free maintenance
Number of Cells 300 300 300
Floating Voltage at 25°C - V 681 681 681
Minimum Discharge Voltage - V 495 495 495
Power Requested by Inverter (At nominal Load) -kW 168 210 252
Curr. Req. by Inverter (nominal load - minimum Vdc) - A 340 425 510
Battery Protection (external to the UPS) Wall Mounted Fuse Box on
Request
Battery Test Included as standard
DESCRIPTION:
The standard battery is composed 300 sealed lead cells.
The boost charge is available as an option for other battery types.
The battery temperature compensation is available as an option.
Long autonomy batteries can used.
Different automatic and manual battery tests are available (see the operating manual).
UPS OUTPUT: INVERTER
DESCRIPTION:
The Inverter design is based on a full bridge 6-IGBT matrix, fully digitally
controlled.
The output voltage stability and the dynamic response are optimised
The output voltage total harmonic distortion is kept very low with both linear and
not linear (switching).
The selectivity in case of short-circuit is very high and the recovery of the voltage
is digitally controlled (Soft Short Recovery Loop “SSRL”).
The Inverter is designed to minimize the battery stress during the discharge.
ECO mode available: load on by-pass and inverter on, the load transfer time is
less than 5 msec.
Rev.A JSD409388 JUD408572 4 of 7

INVERTER
POWER - kVA 200 250 300
Inverter Bridge IGBT (High Frequency Comm.)
Nominal output power (Cos Ø 0,8) - kVA 200 250 300
Nominal output power (Cos Ø 1,0) - kW 160 200 240
Permissible range of load power factor See Above
Nominal Output Voltage - Vca (selectable) 380 ÷ 415
Output Voltage Stability
-Static (Balanced Load) +/- 1%
-Static (Unbalanced Load) +/- 2%
-Dynamic (Step Load 0÷100%÷0) +/- 5%
-Output Volt. Recovery Time (after step load) Within 40ms
Phase Angle
-Balanced Load +/- 1 Degree
-100% Unbalanced Load +/- 2 Degrees
Output Frequency -Hz 50 - 60
Output Frequency Stability
-Free Running Quartz Oscillator +/- 0,001Hz
-Inverter Sync. with Mains +/- 2Hz (Adjustable)
Nominal Output Current - A
- Cos φ 0,8 290 360 430
- Cos φ 1 230 290 360
Overload Capability 125% for 10 min, 200% for 100ms
Short Circuit Current 460 580 720
Short Circuit Characteristic Elect. short circuit protection, current
limited at 2 times nominal current.
Automatic stop after 5 seconds
Selectivity Within ½ cicle (Fuse gl 20% In)
Output Waveform Sinusoidal
Output Harmonic Distortion
- Linear Load <2%
- Non Linear Load (Crest factor 3:1) <5%
- IEC 62040-3 Fully complayed
Crest Factor (Non linear load) 3:1
Rev.A JSD409388 JUD408572 5 of 7

UPS OUTPUT: BY PASS
Automatic Static By-Pass Electronic Thyristor Switch

Protection Fuses
Nominal Voltage - Vac 220-230-240 +/-10%
Nominal Frequency - Hz 50 - 60 +/-5Hz
Transfer mode Without interruption
Transfer Inverter ÷ Static By-Pass In case of :
-Static Switch test
-Inverter failure
-Input inv. Volt. out of limit
-Output Volt. out of limit
Retransfer Static By-Pass ÷ Inverter - Automatic
- Block on bypass after 6
commutations within 2 min.
- Reset by front panel or by
remote command
Overload Capability -125% Continously
-1000% For 1 Cicle
Manual By-Pass Standard:
- Electronically controlled
- No break
DESCRIPTION:
The manual by-pass is included as a standard. The electronic control avoids the
risks of power interruption in case of transfer from inverter to manual by-pass and
vice-versa.
PARALLEL
Automatic Parallel Redundant Configuration Up to four by an additional card
Parallel Configuration Redundant N-1 on N
Connection Type CAN Bus Loop
Share Accuracy 10% max unbalancement
Maximum Distance Between two Units 10 mt
Overload Capability N x 200% Continuously
Automatic By-Pass On each unit
Manual By-Pass On each unit (common as
option)
DESCRIPTION:
The parallel control is full digital and acts on both active and reactive power on
each output phase.
The Loop connection permits to disconnect one of the units from the parallel string
allowing the normal operation of the remaining units.
Rev.A JSD409388 JUD408572 6 of 7

ALARMS,CONTROLS AND SIGNALS
LOCAL ON THE “SYSTEM CONTROL PANEL” :
- Synoptic diagram showing : power flow, circuit breaker status and alarms
- Battery test indicator
- LCD display
- Keyboard
REMOTE ON PC (by the means of a special test software):

- All the local indications alarms and measures
- Battery test functions
- Basic troubleshooting
FREE CONTACTS (by the means of an additional card):

- Four signals are available on free contacts.
REMOTE PANEL (by the means of an RS485 connection):

- Synoptic diagram showing : power flow, circuit breaker status and alarms
- Battery test indicator
- LCD display
- Keyboard
REMOTE ON LAN (by additional box):

- All the local indications alarms and measures are available on the following
standards:
1. SNMP
2. Modem
OPTIONS
1. BATTERY TEMPERATURE VOLTAGE COMPENSATION
2. INSULATION TRANSFORMER ON BY-PASS
3. INPUT VOLTAGE ADAPTATION AUTO-TRANSFORMER
4. FREE CONTACTS CARD
5. SERIAL INTERFACE RS-485 for REMOTE PANEL
6. SNMP
7. MODEM
8. PARALLEL CARD
9. EXTERNAL BATTERY CABINET
10. WALL MOUNTED FUSES BOX
11. IN/OUT TOP CABLE ENTRY
12. SPECIAL PAINT
Rev.A JSD409388 JUD408572 7 of 7

UPS OPERATING MANUAL
B9000 200-250-300kVA
UPS OPERATING MANUAL
Index of sections Code
1 – UPS GENERAL DESCRIPTION AND INSTALLATION JUD408827

2 – FRONT PANEL JUD408828
3 – START-UP, SHUT-DOWN AND MANUAL BYPASS JUD408829
JUD408826 18/07/06 Issued

3-3
Ups general description & installation
UPS GENERAL DESCRIPTION AND INSTALLATION
Index
1. INTRODUCTION.................................................................................. 3
2. GENERAL UPS DESCRIPTION.......................................................... 3
2.1 TYPOLOGY ......................................................................................................3
2.2 DESCRIPTION OF THE SYSTEM ....................................................................4
2.2.1 Rectifier.....................................................................................................4
2.2.2 Inverter ......................................................................................................4
2.2.3 Battery and charger .................................................................................4
2.2.4 Static bypass ............................................................................................4
2.2.5 Manual bypass .........................................................................................4
2.2.6 Front Panel ...............................................................................................5
2.3 OPERATING STATUS......................................................................................6
2.3.1 Normal Operation.....................................................................................6
2.3.2 Load supplied by bypass due to inverter fault ......................................6
2.3.3 Rectifier failure or mains failure .............................................................7
2.3.4 Manual bypass .........................................................................................7
3. INSTALLATION................................................................................... 8
3.1 RECEIPT OF UPS ............................................................................................8
3.2 HANDLING OF THE UPS.................................................................................8
3.3 POSITIONING AND INSTALLATION...............................................................9
3.3.1 Base plan, static load and weights.........................................................9
3.3.2 Dimensions and distances ....................................................................10
3.4 ELECTRICAL CONNECTION ........................................................................11
3.4.1 Terminal Board.......................................................................................11
3.5 BATTERY POSITIONING AND CONNECTION .............................................12
3.5.1 Connections ...........................................................................................12
JUD408827 02/10/06 Rev. A

(JSD408936 Rev. A 02/10/06)
1 - 12
Index of pictures
Picture 1 – Block diagram............................................................................................................................. 3
Picture 2 – Normal operation........................................................................................................................ 6
Picture 3 – Load supplied by bypass............................................................................................................ 6
Picture 4 – Rectifier failure or mains failure.................................................................................................. 7
Picture 5 – Manual bypass ........................................................................................................................... 7
Picture 6 – Handling B9000 200-300kVA..................................................................................................... 8
Picture 7 – Base plan ................................................................................................................................... 9
Picture 8 – Distance from the walls ............................................................................................................ 10
Picture 9 – Layout B9000 200-300kVA ...................................................................................................... 10
Picture 10 – Terminal Board....................................................................................................................... 11
Picture 11 – Battery cabinet link................................................................................................................. 12
2 JUD408827 02/10/06 Rev. A

1. INTRODUCTION
Thank you for having chosen an BORRI product for the safety of your equipment. In
order to fully take advantage of the performance of your UPS B9000 (uninterruptible
power supply), we suggest that you dedicate some time to reading the following
manual.
The purpose of this manual is to briefly describe the parts that constitute the UPS
and to guide the installer or user to a correct installation of the equipment.
The installer or user should read and correctly carry-out the instructions provided,
with particular attention to the information regarding security, according to the CEI 64-8
and DPR 46-90 standards.
The manufacturer declines all responsibility of damages towards persons or
things due to the non-compliance of the above.
2. GENERAL UPS DESCRIPTION

2.1 TYPOLOGY
The B9000 UPS are double conversion on-line ; the inverter constantly supplies
energy to the load, whether mains is available or not (according to the battery
autonomy time).
WARNING
The UPS output is energized even during mains failure, therefore in compliance with
the prescriptions of EN50091-1 / EN62040-1, the installer will have to identify the line or
the plugs supplied by the UPS making the User aware of this fact.
This configuration guarantees the best service to the User, as it supplies clean
continuously regulated power and guarantees the voltage and frequency will be
stabilised at nominal value independently from mains status. Thanks to the double
conversion, it makes the load completely immune from micro-interruptions due to
excessive mains variation, and prevents damage to the critical load (Computer -
Instrumentation - Scientific equipment etc.).
Picture 1 – Block diagram
JUD408827 02/10/06 Rev. A 3

2.2 DESCRIPTION OF THE SYSTEM
2.2.1 Rectifier
It converts the three phase voltage of the mains into continuous DC voltage.
The UPS has got a total-controlled IGBT three-phase bridge to reach a low harmonic
distortion.
This configuration is used in order to reduce the distortion of the mains’ absorbed
power (THD) to a value inferior to 5%. This guarantees, with respect to other loads, that
the rectifier does not distort the mains voltage and avoids the overheating of the cable
due to the circulation of the harmonic currents.
The rectifier is designed to supply the inverter at full load and the battery at the
maximum recharge current.
2.2.2 Inverter
Required to convert the continuous voltage coming from the rectifier or from the
battery, into alternating voltage, stabilized in amplitude and frequency.
The inverter uses IGBT technology with a frequency commutation of approximately
10 KHz.
The control electronics is completely digital and uses a 16 Bit µP, that, thanks to its
processing capability, generates an excellent output sine-wave, which has a very low
distortion even in presence of loads having high crest factor currents.
2.2.3 Battery and charger

The battery is located in an external cabinet.
The battery charger control logic is completely integrated inside the total-controlled
rectifier control board; the battery is charged, according to the DIN 41773 Standard,
every time it has been partially or completely discharged and it is kept floating, even
when it’s charged, to compensate for any autodischarge.
2.2.4 Static bypass

It’s designed to transfer the load between INVERTER and MAINS, and vice-versa,
without break, and uses SCR’s as power commutation elements.
2.2.5 Manual bypass

It‘s used to by-pass the UPS, supplying the load directly to the mains in case of
maintenance or serious failure.
WARNING
The sequence of bypass switching must be carried out with respect to the procedure
in the UPS Operating Manual in the chapter “Start-up, shut-down and manual bypass”.
The manufacturer cannot accept responsibility for damages arising from incorrect
operation.
4 JUD408827 02/10/06 Rev. A

2.2.6 Front Panel

The front panel of the UPS, consisting of a double row alphanumeric displays plus 5
function keys, allows the complete monitoring of the UPS status.
The mimic diagram helps to understand the operating status of the UPS.
For more information see the chapter “FRONT PANEL”.
JUD408827 02/10/06 Rev. A 5

2.3 OPERATING STATUS

The following paragraphs show all the possible operating status of the UPS.
2.3.1 Normal Operation

The inverter is supplied by the rectifier; the load, through the static switch, is supplied
directly by the inverter output.
Picture 2 – Normal operation
2.3.2 Load supplied by bypass due to inverter fault

The load is transferred to bypass through the static switch; the transfer is carried out
without interruption.
Picture 3 – Load supplied by bypass
6 JUD408827 02/10/06 Rev. A

2.3.3 Rectifier failure or mains failure

The inverter is supplied by the battery for the required autonomy time; the load,
through the static switch, is supplied directly by the inverter output.
Picture 4 – Rectifier failure or mains failure
2.3.4 Manual bypass

The load is supplied by the mains through the manual bypass; the operator can work
in safety on the UPS to carry out maintenance or repairing operations.
Picture 5 – Manual bypass
JUD408827 02/10/06 Rev. A 7

3. INSTALLATION
3.1 RECEIPT OF UPS
When the UPS is received, please attend immediately to its unpacking and carry-out
an accurate visual check to be sure that the equipment has not been damaged during
transport.
IMPORTANT
In case of objections relating to damage incurred during transport these must be
immediately notified to the transportation company after receipt of the equipment.
When the UPS is not installed immediately it must be stored carefully in vertical
position, as indicated on the packing and conserved in a dry and sheltered room in its
box so that it is protected from dust.
3.2 HANDLING OF THE UPS
Before positioning the UPS, in order to avoid risks of turnover, it’s recommended to
move the system on the wood pallet on which the UPS is fixed.
Before the positioning in the final location, remove the UPS from the pallet.
The UPS can be lifted and handled using a pallet truck or a forklift; It can be handled
only after having taken-off (manually) the lower front panel, so that a pallet truck or a
forklift can be inserted (see picture 6). The UPS technical data are shown on a label
fixed on the internal side of the front door.
Picture 6 – Handling B9000 200-300kVA
8 JUD408827 02/10/06 Rev. A

3.3 POSITIONING AND INSTALLATION

The UPS must be installed in a clean and dry room, preferably not dusty. The User
must ensure that there is enough air exchange in the room so that the equipment can
be adequately cooled; if this is not guaranteed, the room must be adequately aired.
3.3.1 Base plan, static load and weights
Picture 7 – Base plan
UPS 200 250 300

(kVA) 3F
L1 – mm 1175
P1 – mm 800
L2 – mm 115
UPS 3Ph (kVA) 200 250 300

Weight without battery – kg 870 1020 1200
Weight with battery – kg - - -
Static load – kg/m2 925 1085 1277
JUD408827 02/10/06 Rev. A 9

3.3.2 Dimensions and distances
Picture 8 – Distance from the walls
Picture 9 – Layout B9000 200-300kVA

UPS 3F (kVA) 200 250 300
L – mm 1200
P – mm 860
H – mm 1900
10 JUD408827 02/10/06 Rev. A

3.4 ELECTRICAL CONNECTION

The electrical connection is part of the work which is normally provided by the
supplier that carries out the electrical installation and not by the UPS manufacturer. For
this reason, the following recommendations are only an indication, as the UPS
manufacturer is not responsible for the electrical installation.
In any case we recommend to carry-out the installation and the electrical connections
of the input and output in compliance with the local standards.
During the electrical installation take particular care to check the phase rotation with
a suitable instrument.
The terminal boards are positioned at the front of the UPS, under the breakers. To
access the terminals remove the protection, extracting the fixing bolts.
WARNING
The connection to the mains must be carried out with protection fuses between the
mains and the UPS.
The use of residual current devices in the line supplying the UPS is
unadvisable. The leakage current due to the RFI filters is rather high and it can
cause spurious tripping of the protection device.
According to the EN50091-1 / EN62040-1 standard, in order to take into account the
UPS’ leakage current, residual current devices having adjustable threshold can be
used.
The connection cables section is shown in the following tables:
UPS 3Ph (kVA) 200 250 300

Rectifier 3x400 3x500 3x630
Input fuses (A)
Bypass 3x500 3x500 3x630
Input cables Rectifier 3x185 3x240 3x300
(mm2) Bypass 4x300 2x4x185 2x4x185
Ground cables (mm2) 300 300 2x185
Output cables (mm2) 4x300 2x4x185 2x4x185
Battery cables (mm2) 2x240 2x300 2x2x185
3.4.1 Terminal Board
Picture 10 – Terminal Board
JUD408827 02/10/06 Rev. A 11

3.5 BATTERY POSITIONING AND CONNECTION

IMPORTANT
For battery installation please respect the prescriptions of the EN50091-1 / EN62040-
1 standard, paragraph 4.5.
To obtain the battery life indicated by the battery manufacturer, the operating
temperature must remain between 0 and 25 °C. However, although the battery can
operate up to 40 °C , there will be a significant reduction of the battery life.
To avoid the formation of any kind of potentially explosive hydrogen and oxygen
mixture, suitable ventilation must be provided where the battery are installed (see
EN50091-1 / EN62040-1 annex N).
The batteries are external for all the series, however, it is recommended to install
them when the UPS is capable of charging them. Please remember that, if the battery is
not charged for periods over 2-3 months they can be subject to irreparable damage.
3.5.1 Connections
The following picture shows the electrical connection between the UPS and the
external battery cabinet.
Picture 11 – Battery cabinet link

The connection cables are two power cables, with section that varies according to
the UPS size (see table at page 11) and with length ranging from 2 to 50 meters.
Longer cables are subject to excessive voltage drop, so their section must be
increased accordingly.
12 JUD408827 02/10/06 Rev. A

Front panel
FRONT PANEL
Index
1. INTRODUCTION.................................................................................. 3
2. DESCRIPTION..................................................................................... 4
2.1 MIMIC DESCRIPTION ......................................................................................4
2.2 ALARMS AND OPERATING STATUS.............................................................5
3. LCD DISPLAY MANAGEMENT .......................................................... 8
3.1 DEFAULT .........................................................................................................8
3.2 MAIN MENU .....................................................................................................8
3.3 MEASURES ......................................................................................................9
3.3.1 Output .....................................................................................................10
3.3.2 Bypass ....................................................................................................10
3.3.3 Inverter ....................................................................................................11
3.3.4 AC/DC......................................................................................................11
3.3.5 Battery.....................................................................................................11
3.4 ALARMS.........................................................................................................13
3.4.1 UPS Status..............................................................................................13
3.4.2 History.....................................................................................................14
3.4.3 List of alarms and status .......................................................................15
3.5 SPECIAL.........................................................................................................16
3.5.1 Reset .......................................................................................................17
3.5.2 Settings ...................................................................................................17
3.5.3 Test Ups ..................................................................................................17
3.5.4 Battery test .............................................................................................17
3.5.5 Reset history ..........................................................................................17
3.6 MENU STRUCTURE.......................................................................................18
JUD408828 18/07/06 Issued

1 - 18
Front panel
Index of pictures
Picture 1 – B9000 front panel ....................................................................................................................... 3
Picture 2 – Menu structure ......................................................................................................................... 18
2 JUD408828 18/07/06 Issued

Front panel
1. INTRODUCTION
front panel of the UPS, consisting of a double row alphanumeric display plus 5
function keys, allows the complete monitoring of the UPS status.
The mimic flow helps to understand the operating status of the UPS.
Picture 1 – B9000 front panel
JUD408828 18/07/06 Issued 3

Front panel
2. DESCRIPTION
2.1 MIMIC DESCRIPTION
Picture1 shows the mimic present on the display, with the names of the circuit
breakers/isolator switches of the UPS. Also the led's and blocks that comprise the UPS
are clearly identified.
LED 1 ⇒ Lit-up green = Mains present at the rectifier input.

Otherwise off.
LED 2 ⇒ Lit-up green = Emergency line present and phase

sequence correct. Otherwise off.
LED 3 ⇒ Lit-up green = Rectifier feeding correctly.

Red light = Rectifier output voltage out of tolerance.
LED 4 ⇒ Lit-up green = Battery OK.

Green flashing = Battery discharging or battery in test.
Orange flashing = BCB open.
Lit-up red = Battery test aborted.
LED 5 ⇒ Lit-up green = Inverter static switch closed.

Otherwise off.
LED 6 ⇒ Lit-up orange = Emergency line static switch closed.

Otherwise off.
LED 7 ⇒ Lit-up green = Voltage present on the load.

Lit-up orange = OCB circuit breaker open.
LED 8 ⇒ Orange light = Manual by-pass closed. Otherwise off.
LED 9 ⇒ Red light = EPO button pressed.
4 JUD408828 18/07/06 Issued

Front panel
2.2 ALARMS AND OPERATING STATUS

The alpha-numeric display offers a complete diagnostic of the system, through the
visualization of 25 alarms and six operating status conditions.
Each alarm is associated with a code which allows it to be stored in the events’
history.
A1 MAINS FAULT = Rectifier input mains failure
Possible causes: 1) Central system black-out (mains failure)

2) Distribution problems upstream of the UPS
3) RCB open
A2 CHARGER FAULT = Battery charger failure
A3 RECT FUSE = One or more rectifier fuses are blown
A4 THER IMAGE = Load transferred to mains due to overload. After 30’

the load is transferred back to inverter
A5 AC/DC FAULT = Rectifier output voltage out of tolerance
Possible causes: 1) Mains input voltage too high/low

3) RCB open
4) Rectifier bridge failure
A6 INPUT WR SEQ = Input phase rotation not correct
A7 BCB OPEN = Battery circuit breaker open
A8 BATT DISCH = The battery is discharging
Possible causes: 1) Rectifier input mains failure (alarm A1 present)

2) Rectifier failure
A9 BATT AUT END = Battery autonomy (calculated) has expired
A10 BATT FAULT = Battery test failed
Possible causes: 1) The test has been carried out with the battery not
perfectly charged
2) One or more battery cells are damaged
A11 BATT IN TEST = Battery test in progress
A12 PLL FAULT = Problems with the digital synchronisation system
JUD408828 18/07/06 Issued 5

Front panel
Possible causes: 1) Emergency mains excessively disturbed or

intermittent
2) Mains variation speed not acceptable for the UPS
A13 INV OUT TOL = Inverter output voltage out of tolerance
Possible causes: 1) Intervention of the inverter current limitation for

excessive load (more than 200%)
2) Inverter failure
A14 OVERLOAD = Inverter overload (load exceeding 100%). The

thermal image protection is started
A15 BYP FAULT = Emergency mains not available
Possible causes: 1) Emergency mains failure

3) SBCB open
4) Wrong input phase rotation
A16 BYP FEED LOAD = Load fed by bypass
Possible causes: 1) Inverter overload

2) Thermal image intervention
3) Forced commutation due to the bypass switch
operation
4) Inverter failure
A17 RETR BLOCK = Re-transfer between bypass and inverter blocked,

load on bypass
Possible causes: 1) Excessive repeated overloads on inverter
It is possible, after having verified that the load is correct, to reset the UPS, and
switch back the load to the inverter (see menu SPECIAL).
A18 MBYP CLOSE = Manual bypass breaker closed (the inverter is

shutdown)
A19 OCB OPEN = UPS output breaker open
A20 FANS FAILURE = Optional
A21 HIGH TEMP = High temperature on the inverter and/or rectifier

bridge
Possible causes: 1) Excessive load

2) Failure or malfunctioning of the cooling system
3) Wrong positioning of the UPS (distance from walls,
altitude)
6 JUD408828 18/07/06 Issued

Front panel
A22 BYP SWITCH = Closure of the commutation switch which forces the
load to bypass (maintenance)
A23 EPO BUS = Intervention of the emergency shut down switch in
accordance to EN50091-1
A24 CURR STOP = Inverter bridge stop for max current
Possible causes: 1) Repeated short circuits at the UPS output

2) Inverter bridge malfunctioning
It is possible to reset this state using a button on the µP card.
A25 SHORT CIRCUIT = Short-circuit protection intervention (current

exceeding 200%)
Possible causes: 1) Problems on load

2) Distribution problems downstream of the UPS
JUD408828 18/07/06 Issued 7

Front panel
3. LCD DISPLAY MANAGEMENT

3.1 DEFAULT
<NAME> xxx KVA
XXX YYY ZZZ Volt
3Ph UPS
The default screen appears on the LCD panel when the UPS is operating normally
(with no alarm present); it shows the name of the UPS (for example, B9000), the
nominal power and the value of the output voltage.
Pressing a key the main menu, with all the functions and parameters, is accessed
After 5’ during which no key is pushed, if there isn’t any alarm and the battery is not
in discharge mode the Default screen is shown again.
.
3.2 MAIN MENU
The screens of the main menu appears as follows: Pressing a key the main menu,
with all the functions and parameters, is accessed
<NAME> xxx KVA SPECIAL MENU. To access

SPECIAL press the key (see 3.5); to
scroll the other menus, press the
or key.
<NAME> xxx KVA MEASURES MENU. To access

MEASURES press the key (see 3.3); to
scroll the other menus, press the
or key.
<NAME> xxx KVA ALARM MENU. To access press

ALLARMS the key (see 3.4); to scroll the
other menus, press the or
key.
8 JUD408828 18/07/06 Issued

Front panel
3.3 MEASURES
The following pictures show the structure of the MEASURES menu.
<NAME> xxx KVA OUTPUT measures. To access

OUTPUT press the key (see 3.3.1); to
scroll the other sub-menus press
the or key.
<NAME> xxx KVA BYPASS measures. To access

BYPASS press the key (see 3.3.2); to
the or key.
<NAME> xxx KVA INVERTER measures. To access

INVERTER press the key (see 3.3.3); to
the or key.
<NAME> xxx KVA DC meaures. To access press

AC/DC the key (see 3.3.4); to scroll
the other sub-menus press the
or key.
<NAME> xxx KVA BATTERY measures. To access

BATTERY press the key (see 3.3.5); to
the or key.
<NAME> xxx KVA By pressing the key the main

EXIT menu screen returns; to scroll the
other sub-menus press the or
key.
PLEASE NOTE
The voltage measures are always referred to the phase-to-neutral value.
JUD408828 18/07/06 Issued 9

Front panel
3.3.1 Output
OUTPUT VOLTAGE Pressing the key the following
XXX YYY ZZZ Volt parameter is shown, while the key
leads to the previous screen.
OUTPUT FREQUENCY Pressing the key the following

XX Hertz parameter is shown, while the key
OUTPUT CURRENT Pressing the key the following

XXX YYY ZZZ Ampere parameter is shown, while the key
LOAD % Pressing the key the following

XXX YYY ZZZ parameter is shown, while the key
<NAME> xxx KVA Pressing the key leads to the

EXIT MEASURES menu screen (see
3.3), pressing the keys or
the measures are shown again.
3.3.2 Bypass
BYPASS VOLTAGE Pressing the key the following
BYPASS FREQUENCY Pressing the key the following


10 JUD408828 18/07/06 Issued

Front panel
3.3.3 Inverter
INVERTER VOLTAGE Pressing the key the following
INVERTER FREQUENCY Pressing the key the following


3.3.4 AC/DC
This menu is active only when the battery is not discharging. If the battery is in
discharge mode, the BATTERY menu is automatically shown.
AC/DC VOLTAGE Pressing the key the following

XXX Vdc parameter is shown, while the key

3.3.5 Battery
BATTERY VOLTAGE Pressing the key the following
XXX Vdc parameter is shown, while the key
BATTERY TYPE Pressing the key the following

XXX Ah parameter is shown, while the key
JUD408828 18/07/06 Issued 11

Front panel
BATTERY CURRENT This measure is active only when

XXX Ampere the battery is discharging.
Pressing the key the following
parameter is shown, while the key
leads to the previous screen
AUTONOMY Pressing the key the following

XXX min parameter is shown, while the key
AUTONOMY % Pressing the key the following

XXX % parameter is shown, while the key

3.3), pressing the key or the
measures are shown again.
12 JUD408828 18/07/06 Issued

Front panel
3.4 ALARMS
This menu, when selected, shows the status of the equipment and the current alarms
are shown (see list below).
Each time an alarm occurs, the display goes to this menu to indicate the alarms
present; the audible alarm can be silenced pressing the key . The exit is disabled if
the alarm is not silenced.
The following pictures shows the structure of the ALARMS menu.
<NAME> xxx KVA Alarms and UPS status. Press the

UPS STATUS key to access (see 3.4.1),
pressing the or keys scrolls
the other sub-menus.
<NAME> xxx KVA Alarm’s history. To access press

HISTORY the key (see 3.4.2); to scroll
the sub-menus press the or
keys.
<NAME> xxx KVA Pressing the key the main

EXIT menu is shown; to scroll the sub-
menus press the or key.
3.4.1 UPS Status

UPS STATUS Pressing the key scrolls all the
1° alarm/status other UPS status’ and/or
successive alarms; with the
key the previous screen is
accessed.
UPS STATUS Pressing the key accesses the

Last alarm/status previous alarm; pressing the
key the EXIT screen is accessed.
UPS STATUS Pressing the key the ALARM

EXIT menu screen is accessed (see
3.4), with the or key the
alarms and status are shown
again.
JUD408828 18/07/06 Issued 13

Front panel
3.4.2 History
RET TO EXIT HISTORY Pressing the key the following
1° alarm/status alarm is shown; pressing the key
exit the history, leading to the
ALARMS menu screen (see 3.4).


RET TO EXIT HISTORY Pressing the key the first alarm

Last alarm/status is shown again; pressing the key
The first alarm shown is the most recent in order of time; a new alarm makes all the
alarms shift one position, clearing the oldest event.
For each event is shown the alarm code, the date and time; an asterisk next to the
code indicates that the alarm has cleared at the date and time indicated. The following
example shows two possible screens.
RET TO EXIT HISTORY Alarm A1 (MAINS FAULT) at

A1 251201 1848 18:48 on 25/12/01.
RET TO EXIT HISTORY A1 alarm reset at 20:12 on

A1 * 251201 2012 25/12/01.
14 JUD408828 18/07/06 Issued

Front panel
3.4.3 List of alarms and status
List of alarms List of status
A1 MAINS FAULT S1 AC/DC OK

A2 CHARGER FAULT
A3 RECT FUSE
A5 AC/DC FAULT
A6 INP WR SEQ
A7 BCB OPEN S2 BATT OK
A8 BATT DISCH
A9 BATT AUT END
A10 BATT FAULT
A11 BATT IN TEST
A12 PLL FAULT S5 INV SYNC

A13 INV OUT TOL S3 INV OK
A14 OVERLOAD S4 INV FEED OK
A4 THERM IMAGE
A15 BYP FAULT S6 BYP OK

A16 BYP FEED LO
A17 RETR BLOCK
A18 MBYP CLOSE

A19 OCB OPEN
A20 FANS FAILURE (OPTION)
A21 HIGH TEMP
A22 BYP SWITCH
A23 EPO BUS
A24 CURR STOP
A25 SHORT CIRC
The status shown in this list are always displayed in ascending order when the
STATUS menu is entered, the alarms are shown when they are present and must be
silenced with the buzzer. The alarms remain displayed whilst they are present and they
are automatically stored in the event history memory with date and time.
.
JUD408828 18/07/06 Issued 15

Front panel
3.5 SPECIAL
IMPORTANT
When entering the SPECIAL menu a password is required, as the operations which
are allowed needs to be carried out by competent personnel. For each operation a
confirmation is required.
.
PASSWORD Password entering; if wrong the

000 main menu screen is shown.
SPECIAL MENU RESET UPS. To access press the

RESET key (see 3.5.1); to scroll the
sub-menus press the or key.
SPECIAL MENU SETTINGS. Pressing the key

SETTINGS (see 3.5.2) accesses the settings;
to scroll the sub-menus press the
or keys.
SPECIAL MENU UPS TEST. To access press the

UPS TEST key (see 3.5.3); to scroll the
sub-menus press the or key.
SPECIAL MENU BATTERY TEST. To access

BATTERY TEST press the key (see 3.5.4); to
scroll the sub-menus press the
or key.
SPECIAL MENU RESET HISTORY. To access

RESET HISTORY press the key (see 3.5.5); to
scroll the sub-menus press the
or key.
SPEICAL MENUS Pressing the key the main

EXIT menu screen appears; to scroll
the sub-menus press the or
key.
16 JUD408828 18/07/06 Issued

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3.5.1 Reset
PRESS RESET This menus provides a general
TO RESET UPS reset of the UPS status pressing
the key . Pressing another
key exit the menu
3.5.2 Settings
This menu allows to update the date and time settings for the history of alarms.
CLOCK SETTING: The numbers can be modified

25-12-01 18:48 with the key or and they are
confirmed by pressing .
Pressing the key leads to
the special menu (see 3.5).
3.5.3 Test Ups

PRESS RESET Pressing the key causes
FOR COMMUTATION the commutation to bypass.
Pressing the key leads to the
special menu (see 3.5).
3.5.4 Battery test

The BATTERY TEST cannot be started if the dip-switch on the µP is in the OFF
position.
PRESS RESET Pressing the key the

TO START TEST battery test is started. Pressing
the key leads to the special
menu (see 3.5).
WARNING
This test may affect the continuity of power supply to the loads if the battery is not
fully charged.
3.5.5 Reset history

PRESS RESET Pressing the key the
TO CLEAR HISTORY alarms history is cleared.
Pressing the key leads to the
special menu (see 3.5).
WARNING
The above operation causes the cancellation of the events’ history memory.
JUD408828 18/07/06 Issued 17

Front panel
3.6 MENU STRUCTURE
Picture 2 – Menu structure
18 JUD408828 18/07/06 Issued

Start-up, shut-down & manual bypass
START-UP, SHUTDOWN & MANUAL BYPASS
Index
1. INTRODUCTION................................................................................ 2
2. START UP PROCEDURE ................................................................. 2
2.1 START-UP TROUBLESHOOTING...................................................................4
3. SHUT DOWN PROCEDURE ............................................................. 5
4. MANUAL BYPASS PROCEDURE.................................................... 5
5. START-UP FROM MANUAL BYPASS ............................................. 6
JUD408829 18/07/06 Issued

1-6
1. INTRODUCTION
Before performing any of the procedures described in this chapter, read carefully the
instructions, to avoid possible damages to persons or things deriving from incorrect
manoeuvres.
2. START UP PROCEDURE
WARNING
Before switching on the UPS, make sure:
1) the emergency power off “EPO” push-button, placed near the front panel, is in the
release position; if not, press it and proceed with the start-up procedure;
2) the input and output phase rotation is correct.
NOTE
The BCB battery switch is found on the outside of the UPS system.
WARNING
Do not close the battery breaker BCB before it’s required by the front panel. Serious
damages to UPS internal parts and battery may occur if the breaker is closed before the
rectifier is started-up.
Nr. LCD DISPLAY ACTION UPS OPERATION

1 BLAND Close RCB
2 UPS START UP The rectifier is supplied and the DC voltage
PLEASE WAIT increases up to the nominal value. All LED’s
in the front panel are lit green.
The microprocessor checks all the start-up
conditions are ok. LED’s #1 and #3 are lit
green.
3 BOOSTER START UP The IGBT rectifier bridge starts to modulate
PLEASE WAIT and the inverter input voltage reaches the
nominal value. LED #3 green light on.
4 INVERTER START UP The inverter bridge starts to modulate and
PLEASE WAIT the AC voltage reaches the nominal value.
After a few seconds the static inverter switch
closes. LED #5 green light on.
5 BYPASS START UP
Close SBCB
CLOSE SBCB
6 BYPASS START UP The microprocessor checks that all the
PLEASE WAIT bypass parameters (voltage, phase
sequence, frequency) are within the
tolerance limits. LED #2 green light on.
2 JUD408829 18/07/06 Issued

7 BATTERY START UP
Close BCB
CLOSE BCB
8 BATTERY START UP The microprocessor checks that all the
PLEASE WAIT conditions for the following steps are ok.
LED #4 green light on.
9 START UP END
Close OCB
CLOSE OCB
10 START UP END The microprocessor checks that all the
PLEASE WAIT output parameters (voltage, current,
frequency) are within the tolerance limits.
End UPS MODEL After a short time the default screen is
VOLTAGE OUTPUT displayed.
JUD408829 18/07/06 Issued 3

2.1 START-UP TROUBLESHOOTING

This paragraph provides the basic information if any alarms occur during the start-up
procedure. In case the problem cannot be solved contact the service department.
1) After having closed the RCB the LCD display is still blank
• Check the input phase rotation.
• Check the rectifier protection fuses; these are installed inside the UPS.
2) After Step #2 the UPS does not go on to Step #3 and displays the alarm A1 –
Network failure
• Make sure alarm A2 is functioning. Check the input phase rotation.
• Check the rectifier protection fuses F1-F2-F3.
3) After Step #3 the UPS displays alarm messages
• Open RCB and check the connections.
• Close RCB and try to restart the UPS.
4) After Step #4 the UPS displays alarm messages
• Check that the EPO button, if provided on the outside of the UPS, is in the
release position
• Open RCB and control the connections.
• Close RCB and try restarting the UPS.
5) After Step #5 the display does not go to Step #6 and displays the alarm A15 –
BYP NOT AVLB
• Check the protection fuses of the Bypass static switch; they are installed
inside the UPS.
• Control the phase rotation voltage.
• Check that the voltage and frequency are within the tolerance limits.
6) After Step #7 the display does not go on to Step #8 and the alarm A7 – BCB
OPEN is displayed.
7) Check the battery fuses.
• Control the inter-connection between the auxiliary contact of the battery
switch (in the external cabinet) and the clamps Bac1-Bac2 of the UPS.
4 JUD408829 18/07/06 Issued

3. SHUT DOWN PROCEDURE
Nr. ACTION LCD DISPLAY UPS OPERATION

1 Open OCB A19 OCB OPEN The supply to the load is interrupted. LED #7
lit orange
2 Open BCB A7 BCB OPEN The battery is disconnected from the
rectifier. LED #4 flashing red light.
3 Open SBCB A7 BCB OPEN The bypass line is disconnected. LED #2 off.
4 Open RCB A1 NETWORK Booster and Inverter are switched off.
FAILURE
5 OFF End of shut down procedure.
4. MANUAL BYPASS PROCEDURE

WARNING
During manual bypass operation the load is supplied directly by the mains, therefore
continuous supply is not guaranteed.
Nr. ACTION LCD DISPLAY UPS OPERATION

1 Move the “NORMAL- A16 BYPÆLOAD The load is transferred to the by-pass
BY-PASS” selector line. LED #5 off, LED #6 orange light.
to “BY-PASS”
2 Close MBCB A16 BYPÆLOAD The load is supplied from the mains
through the manual by-pass switch. The
by-pass static switch is still off.
3 Open BCB A1 MAINS FAULT Rectifier is switched off; the inverter is
still on and supplied by the batteries.
LED #1 off, LED #4 flashing green.
4 Open RCB A1 MAINS FAULT The batteries are disconnected and the
inverter is switched of. The load is still
supplied by the by-pass static switch.
LED #4 flashing orange.
5 Open SBCB OFF The by-pass line is disconnected.
6 Open OCB OFF The load is supplied directly by the
mains through the manual by-pass
switch. The UPS is isolated.
JUD408829 18/07/06 Issued 5

5. START-UP FROM MANUAL BYPASS

Before the start-up from manual by-pass (after a maintenance or repairing) check
that the “NORMAL-BYPASS” switch is in BYPASS position.
Nr. LCD DISPLAY ACTION UPS OPERATION

1 BLAND Close RCB
2 UPS START UP The rectifier is supplied and DC voltage
PLEASE WAIT increases to the nominal value. All the
LEDs on the front panel are lit.
The microprocessor checks that all the
start up conditions are o.k. LED #1 and
#3 green lights on. LED #8 orange light
on.
3 BYPASS START UP
Close SBCB
CLOSE SBCB
4 BYPASS START UP The microprocessor checks that all the
PLEASE WAIT bypass parameters (voltage, phase
sequence, frequency) are within the
tolerance limits. LED #2 green light on.
The by-pass static switch is turned off,
LED #6 orange light on.
5 CLOSE BCB The microprocessor checks that all the
PLEASE WAIT Close BCB conditions for the following steps are ok.
6 CLOSE OCB The load is supplied by the bypass static
PLEASE WAIT Close OCB switch. The MBCB switch is still off.
7 OPEN MBCB The load is supplied by the bypass static
PLEASE WAIT Open MBCB switch only and the inverter can be
started up. LED #8 off.
8 INVERTER START UP The inverter bridge starts to modulate
PLEASE WAIT and the AC voltage reaches the nominal
value. The microprocessor checks the
synchronisation with the by-pass line.
9 MOVE BYP SWITCH Move the “NORMAL- The load is transferred to the inverter
PLEASE WAIT BYPASS” switch to static switch. LED #5 green light on.
NORMAL
10 START UP END The microprocessor checks that all the
PLEASE WAIT output parameters (voltage, current,
frequency) are within the tolerance limits.
11 UPS MODEL
OUTPUT VOLTAGE
6 JUD408829 18/07/06 Issued

UPS Functioning Description
UPS FUNCTIONING DESCRIPTION
Index
1 INTRODUCTION.................................................................................. 5
1.1 OPERATING STATUS......................................................................................5
2 RECTIFIER .......................................................................................... 7
3 INVERTER ........................................................................................... 8
4 STATIC SWITCH ................................................................................. 9
5 RECTIFIER PCB’S ............................................................................ 10
5.1 INT-R...............................................................................................................10
5.1.1 Description of operation........................................................................10
5.2 RTF .................................................................................................................15
5.3 ID-HY (RECTIFIER IGBT DRIVER) ................................................................15
5.3.2 Programming instructions ....................................................................16
5.4 D-CPU-RC (RECTIFIER MICROPROCESSOR CONTROL) ..........................17
5.4.1.1 Introduction .......................................................................................17
5.4.1.2 Digital power supply ..........................................................................17
5.4.1.3 RAM, FLASH and EEPROM .............................................................17
5.4.1.4 Rectifier bridge protection .................................................................17
5.4.1.5 Analog inputs ....................................................................................18
5.4.1.6 Control LEDs.....................................................................................18
6 INVERTER PCB’S ............................................................................. 19
6.1 DR-HY (INVERTER IGBT DRIVER) ...............................................................19
6.1.2 Programming instructions ....................................................................21
6.2 INV-AV-3F.......................................................................................................21
6.3 PS-MIS............................................................................................................21
6.4 PWM-SAT .......................................................................................................22
Issued 13/04/07 JUD409400 1 of 35

7 STATIC SWITCH PCB’S....................................................................23

7.1 VOLT-REF-3F ................................................................................................ 23
7.1.1 Description of operation ....................................................................... 23
7.2 2SCR-FIR ....................................................................................................... 23
8 COMMON PCB’S ...............................................................................24
8.1 PS-SAT .......................................................................................................... 24
8.1.2 Programming instructions.................................................................... 25
8.2 I/S-CL (MICROPROCESSOR CONTROL LOGIC) ........................................ 26
8.2.1.1 Introduction ...................................................................................... 26
8.2.1.2 Digital Inputs .................................................................................... 26
8.2.1.3 Dip Switches .................................................................................... 26
8.2.1.4 Fast Analog Inputs ........................................................................... 27
8.2.1.5 External A/D Converter .................................................................... 28
8.2.1.6 Watchdog and Reset........................................................................ 28
8.2.1.7 RAM, EPROMs and EEPROM......................................................... 29
8.2.1.8 Digital Power Supply ........................................................................ 29
8.2.1.9 RCB board ....................................................................................... 29
8.2.1.10 SCB board and Thyristor drivers ...................................................... 29
8.2.1.11 Current Limitation and Max Current Stop ......................................... 29
8.2.1.12 VCB board........................................................................................ 30
8.2.1.13 PWM generator ................................................................................ 31
8.2.2 Programming instructions.................................................................... 33
8.2.3 SCB board.............................................................................................. 34
8.2.4 VCB board.............................................................................................. 34
8.3 FCI.................................................................................................................. 35
Issued 13/04/07 JUD409400 2 of 35

Index of pictures
Picture 1 – UPS block diagram .................................................................................................................... 5
Picture 2 – Normal operation........................................................................................................................ 5
Picture 3 – Load supplied by by-pass .......................................................................................................... 6
Picture 4 – Rectifier failure or mains failure.................................................................................................. 6
Picture 5 – Manual by-pass .......................................................................................................................... 6
Picture 6 – Rectifier diagram ........................................................................................................................ 7
Picture 7 – Inverter diagram ......................................................................................................................... 8
Picture 8 – Static switch diagram ................................................................................................................. 9
Picture 9 – INT-R – 24Vdc supply (thyristors) ............................................................................................ 10
Picture 10 – INT-R – 5Vdc supply (serial interfaces) ................................................................................. 10
Picture 11 – INT-R – Rectifier microprocessor supply ............................................................................... 11
Picture 12 – INT-R – Mains monitoring ...................................................................................................... 11
Picture 13 – INT-R – DC voltage feedback ................................................................................................ 11
Picture 14 – INT-R – Battery current feedback (to I/S-CL for boost charge control).................................. 12
Picture 15 – INT-R – Digital signals to D-CPU-RC .................................................................................... 13
Picture 16 – INT-R – Digital signals to I/S-CL ............................................................................................ 14
Picture 17 – INT-R – Relay output ............................................................................................................. 14
Picture 18 – ID-HY – Power supply............................................................................................................ 15
Picture 19 – ID-HY – Input stage................................................................................................................ 15
Picture 20 – ID-HY – Output stage............................................................................................................. 16
Picture 21 – ID-HY board (Rectifier IGBT driver) ....................................................................................... 16
Picture 22 – D-CPU-RC – Digital power supplies ...................................................................................... 17
Picture 23 – D-CPU-RC – IGBT bridge protection ..................................................................................... 18
Picture 24 – DR-HY – Power supply .......................................................................................................... 19
Picture 25 – DR-HY – Input stage .............................................................................................................. 19
Picture 26 – DR-HY – Output stage ........................................................................................................... 20
Picture 27 – DR-HY – “Under-voltage lock-out” ......................................................................................... 20
Picture 28 – DR-HY – De-saturation .......................................................................................................... 20
Picture 29 – DR-HY board (Inverter IGBT driver)....................................................................................... 21
Picture 30 – PS-MIS – Power supply ......................................................................................................... 22
Picture 31 – PS-MIS – DC voltage feedback ............................................................................................. 22
Picture 32 – 2SCR-FIR electrical drawing.................................................................................................. 23
Picture 33 – PS-SAT – Microprocessor supply .......................................................................................... 24
Picture 34 – PS-SAT – Analog part supply ................................................................................................ 24
Picture 35 – PS-SAT – Relay and bus supply............................................................................................ 25
Picture 36 – PS-SAT board ........................................................................................................................ 25
Picture 37 – I/S-CL – Fast analog inputs.................................................................................................... 28
Issued 13/04/07 JUD409400 3 of 35

Picture 38 – I/S-CL – External A/D converter............................................................................................. 28

Picture 39 – I/S-CL – Digital supply............................................................................................................ 29
Picture 40 – I/S-CL – Short circuit protection ............................................................................................. 30
Picture 41 – I/S-CL – “Current stop” protection .......................................................................................... 30
Picture 42 – VCB – Instantaneous value loop............................................................................................ 31
Picture 43 – I/S-CL – PWM generator ........................................................................................................ 31
Picture 44 – I/S-CL block diagram.............................................................................................................. 32
Picture 45 – I/S-CL board ........................................................................................................................... 33
Picture 46 – SCB board .............................................................................................................................. 34
Picture 47 – VCB board .............................................................................................................................. 34
Picture 48 – FCI electrical drawing............................................................................................................. 35
Issued 13/04/07 JUD409400 4 of 35

1 INTRODUCTION
The UPS of the B9000 product line are on-line, double conversion; the inverter supplies
always energy to the load, whether the mains is available or not (according to the battery
autonomy time).
WARNING
The UPS output is energized even during mains failure, therefore in compliance with the
prescriptions of EN 50091-1, the installer will have to identify the line or the plugs supplied by
the UPS making the User aware of this fact.
This configuration guarantees the best service to the User, as it supplies clean continuously
regulated power and guarantees the voltage and frequency will be stabilised at nominal value
independently from mains status. Thanks to the double conversion, it makes the load
completely immune from micro-interruptions due to excessive mains variation, and prevents
damage to the critical load (Computer - Instrumentation - Scientific equipment etc.).
Picture 1 – UPS block diagram

The UPS is composed by three main sections: rectifier (R), inverter (I), static switch (SS).
These sections will be described in the following chapters.
The final chapter includes the description of the various electronic boards installed inside the
UPS as well as their block diagrams and programming instructions.
1.1 OPERATING STATUS

Final task of a UPS system is to protect the load from micro-interruptions, black-outs and
various disturbances on the network, and guarantee a reliable supply also when internal faults
occur. During normal operation the rectifier keeps the batteries in floating charge and provide
energy for the inverter to supply the load through the static switch.
Picture 2 – Normal operation
Issued 13/04/07 JUD409400 5 of 35

In case of an inverter failure or an overload the load is automatically transferred, without

interruption, to the by-pass static switch.
Picture 3 – Load supplied by by-pass

The inverter is the primary supply source, so when its voltage and frequency are in tolerance
it synchronises with the by-pass line and the load is transferred again through the static switch.
In case of mains failure (or rectifier failure) the inverter draws energy from the battery for the
specified autonomy time, after which the inverter is turned off.
Picture 4 – Rectifier failure or mains failure

For maintenance operations it’s possible to supply the load through the manual by-pass
circuit breaker MBCB, connecting directly the by-pass line to the UPS output. During the manual
by-pass procedure the load remains supplied, without any interruptions.
Picture 5 – Manual by-pass
Issued 13/04/07 JUD409400 6 of 35

2 RECTIFIER
The three-phase mains is connected to the input terminals 1-L1, 1-L2, 1-L3, directly under
the input switch RCB. The filter RF1 provides to reduce the radio frequency disturbances
according to the limits given by the EN50091-2 standard.
The input AC capacitors Cac1÷Cac3 limits the high-frequency harmonics generated during
the commutation of the rectifier bridge smoothing the waveform of the input voltage.
The thyristors PS7÷PS9 are used to pre-charge the DC capacitors and rectify the AC mains;
they also work as de-coupling elements and avoid that high reverse voltages are applied to the
IGBTs. The booster bridge is made by the IGBT modules PS1÷PS6. Each module contains two
components, one of which is used as a diode by short-circuiting the Gate with the Emitter. The
input high-frequency chokes are the elements that store and release energy during the bridge
commutation thus providing the DC voltage to increase (step-up or booster operation).
When powering up the unit, the electronic board INT-R is supplied; it provides the DC
supplies to the microprocessor control board (D-CPU-RC) as well as the synchronisation signals
for the generation of the control pulses of the thyristors. These control signals are then
managed by the board INT-R2 (mounted directly on the INT-R) and sent to the thyristors
through the board RTF (final stage).
The voltage feedback (positive and negative, with reference to the central point of the
capacitors) is taken directly on the rectifier output, across the DC capacitors. By comparing the
voltage feedback value with a programmed set-point the microprocessor provides to regulate
the turn-on time of the IGBTs by modifying the PWM, thus maintaining the DC output voltage
within the specified range (+/-1%).
The measures of the input current across the three phases is provided by the current
transducers TA1÷TA3.
The rectifier provides the energy necessary to the inverter to work at full load and keeps the
battery in floating charge to compensate the self discharging. In case of mains failure the
inverter draws energy from the battery for the specified autonomy time. When the batteries
needs to be recharged the microprocessor board provides to limit the recharging current by
comparing an programmable threshold with the feedback signal generated by the current
transducer TA4.
Picture 6 – Rectifier diagram
Issued 13/04/07 JUD409400 7 of 35

3 INVERTER
The inverter is composed by six power blocks, controlled by the IGBT driver boards
DR1÷DR6. The inverter bridge is connected to the transformer T1, which provides the galvanic
insulation between the DC bus and the AC output. The transformer is provided with a leakage
inductance that forms a low-pass filter with the output capacitors Cr-Cs-Ct; the filter provides to
eliminate the high frequency harmonics from the output waveforms in order to reduce the
distortion of the sine-waves.
The inverter supplies the load through the inverter static switch thyristors, which are
connected to the output switch OCB. The current transformers TAR-TAS-TAT provide the
signals for the output current measures.
When the inverter is started up the microprocessor control logic I/S-CL generates the IGBT’s
control signals (PWM – Pulse Width Modulation) and send them to the driver boards DR1÷DR6;
the bridge starts to modulate and the output voltage increases. The voltage feedback provided
by the INV-AV-3F board is used to control the output voltages value, according to the value set
on the three VCB boards (mounted on the I/S-CL).
The inverter current protection (Max Current Stop) and the short circuit current limitation are
also managed by the I/S-CL, using the feedback signal provided by the hall-effect current
transducer TA1, which is mounted on the inverter bridge input.
Picture 7 – Inverter diagram
Issued 13/04/07 JUD409400 8 of 35

4 STATIC SWITCH
The three-phase emergency line is connected to the terminals 2-L1, 2-L2, 2-L3, 2-N.
The by-pass line is energized by closing the input switch SBCB; the fuses F4-F5-F6 protects
the static switch thyristors in case of short-circuit at the UPS output.
The static by-pass switch is controlled by the SCB board, mounted on the microprocessor
control logic I/S-CL; the control signals for the thyristors are generated by the I/S-CL and sent to
the firing board 2-SCRFIR, connected directly to the gate of the thyristors.
The VOLT-REF-3F board provides the feedback signals for the by-pass and output voltage
measures.
The UPS automatically transfers the load to the by-pass line in case of an inverter failure or
overload. The manual by-pass switch MBCB connects directly the emergency line input to the
load in case of UPS maintenance.
Picture 8 – Static switch diagram
Issued 13/04/07 JUD409400 9 of 35

5 RECTIFIER PCB’S
5.1 INT-R
5.1.1 Description of operation
The board INT-R is the interface between the power conversion section of the rectifier and
the microprocessor (board D-CPU-RC). It’s mainly composed by the following parts:
1) Power supply: the three-phase AC mains is connected to the connector M8 and then,
through the fuses FUSE1÷FUSE3 to the Graetz-bridge formed by the diodes D13÷D18.
The DC voltage Vbulk+/Vbulk- is the input voltage to the switching power supply, which
uses a output transformer (T5) to isolate the various power supplies.
The following table summarize all the different outputs.
Test GND
SECTION LED Pot.
point TP
Local auxiliary voltage 1 DL1 TP1 TP2
Local auxiliary voltage 2 TP3 TP4
+24V thyristor drivers and transformers DL2 TP6 TP5
+12V analog circuits DL3 TP12 TP5
+5V serial interface DL4 TP7 TP8
+15V rectifier CPU DL5 TP9 TP11
-15V rectifier CPU DL6 TP10 TP11
IGBT drivers power supply (PS_AC1 / PS_AC2) RV1
TP6 +24V_SSW
D41 1N4007
T5 D40 U15 LM317T

7 1 2 U16 LM7815 TP12 POS_SSW
IND OUT 1 2
BY V32-200 N D42 R106 IND OUT
G N
R105 4k75 G R107 X8 X13
255R 1N4007 C53 3k32 C55
8 C51 3 D43 10u C56
220u 10u DL2 C54 3
R104 C52 DL3 1N4007 100n
4k75 4u7 100n
9 X7
GND_SSW
TP5
Picture 9 – INT-R – 24Vdc supply (thyristors)
T5 BY V27-200 U17 TP7 +5V_SER

16 1 2
IND OUT
D44 N R108
G
LM7805 1k
17 D46 C59
C57 3 C58
100u DL4 1N4007 10u 100n
D45
18
BY V27-200 TP8 GND_SER
Picture 10 – INT-R – 5Vdc supply (serial interfaces)
Issued 13/04/07 JUD409400 10 of 35

POS_CPU1
BY V27-200 U18 TP9
T5 D47 LM7815 X9 X12
10 1 2
IN OUT
D
D48 N R109
G
BY V27-200 3k32
D49 C62
7
11 X6 C60 3 0
0 C61
220u 4 10u 100n
X11 DL5 N
1
PS_AC2
TP11
12
R110 GND_CPU1
PS_AC1
3k32
X10 C63 D52 C65
7
13 0 C64
0
X5 220u 4 10u 100n
DL6 N
1
BY V27-200 3 U19
D50
14 1 D 2
INN OUT
G
D51 LM7915 TP10 NEG_CPU1
BY V27-200
Picture 11 – INT-R – Rectifier microprocessor supply
2) Mains monitoring: the three-phase AC mains is connected through the connector M8 to

the transformers T1-T2-T3. The secondary voltage of the transformers is transferred to
the microprocessor through the connection CN7 INT-R Æ CN5 D-CPU-RC.
The microprocessor provides to control the phase sequence and the RMS values of the
three phases.
T1
1 3 VMA_U
CN7_4
R24
2 4
511R
T2
V_MA_U 1 3 VMA_V
M8_1 CN7_5
V_MA_V
M8_3
R25
V_MA_W 2 4
M8_5
511R
T3
1 3 VMA_W
CN7_6
R26
2 4
511R
GND_CPU1
Picture 12 – INT-R – Mains monitoring
3) DC voltage feedback: the DC voltage is measured across the DC capacitors, connected in

series. It’s then converted by the voltage transducers VM2-VM3 and finally sent to the
CPU through the connection CN7 INT-R Æ CN5 D-CPU-RC.
POS_CPU1 POS_CPU1
NEG_CPU1
NEG_CPU1
R16 R34
+V_BOOST +HT + -V_BOOST +HT +
M7_1 M6_3
22k 3W 22k 3W
VM2 - VM3 -
R17 R33
GND_BOOST -HT M +VBOOST GND_BOOST -HT M -VBOOST
M7_3 CN7_9 M6_1 CN7_10
22k 3W 22k 3W
LV 25-P LV 25-P
R23 R35
287R 287R
GND_CPU1 GND_CPU1
Picture 13 – INT-R – DC voltage feedback
Issued 13/04/07 JUD409400 11 of 35

4) AC current feedback: the AC input current, controlled in order to reduce the harmonics
and the input power factor, is measured by the current transducers TA1-TA2-TA3. The
feedback signal is sent to the connectors M1 (C_MA_U), M2 (C_MA_V) and M3
(C_MA_W) of the board INT-R and finally transferred to the CPU through the following
connections:
Signal INT-R D-CPU-RC

C_MAINS_U CN4 Æ CN1
C_MAINS_V CN5 Æ CN2
C_MAINS_W CN6 Æ CN3
5) Battery current feedback: the battery current is measured by the current transducer TA4.
The feedback signal is sent to the connector M4 (C_BAT_POS) of the board INT-R and
finally transferred to the CPU through the connection CN4 INT-R Æ CN1 D-CPU-RC.
The current signal is also sent to the board I/S-CL through an isolation amplifier
(connector M11) for the boost charge management.
POS_CPU1
C80 100n
R19 8 U23A GND_CPU1

C_BAT_POS 3 + R22
M4_2
1
1k
2 -
1k
LM358
NEG_CPU1
4
POS_CPU1 +12A
C79 R20 M11_7

100n
1 U8 9
69k8
GND_CPU1
R21 R2
15 7 C_BAT M11_9
10k
511R
GND_CPU1 ISO122
C68
100n
NEG_CPU1 6 0 -12A
2 1 8 1 GND_A
M11_8
C67
C66 C4 C3 100n
100n 100n 220n
M11_10
GND_CPU1 GND_A
Picture 14 – INT-R – Battery current feedback (to I/S-CL for boost charge control)
6) Digital signals to D-CPU-RC: the digital signals coming from the rectifier bridge are
acquired by the INT-R and transferred to the rectifier CPU to control the rectifier status.
I_FB Æ rectifier protection fuses status
I_TH_SW Æ thermal switch status
SW_RECT_ON Æ switches on and off the rectifier by external switch
The route of such signals is shown in the following table.
Signal INT-R INT-R D-CPU-RC

I_FB Æ M9-1/2 CN5-19/20 Æ CN2-19/20
I_TH_SW Æ M15-1/2 CN11-1/4 Æ CN11-1/4
SW_RECT_ON Æ M10-1/2 CN4-19/20 Æ CN1-19/20
Issued 13/04/07 JUD409400 12 of 35

7) Interface I/S-CL Æ D-CPU-RC: the INT-R works as interface for the digital signals
exchanged between the rectifier CPU (D-CPU-RC) and the inverter CPU (I/S-CL). The
I/S-CL is interfaced with the INT-R through the connection CN5 RCB Æ CN15 INT-R (wire
W34) and controls the rectifier by means of the following signals:
CMD_BOOST Æ enable the boost charge level
CMD_ON_HC16 Æ switches on and off the rectifier (command from I/S-CL)
CMD_TEST_BATT Æ enable the battery test
Such digital signals are interfaced with relays inside the INT-R and transferred to the
board D-CPU-RC as voltage-free contacts.
+12V_RCB
I_CON_HC16_ON
CN6_19
RL1
RET_I_CON_HC16_ON 1
CN6_20
7 D1
1N4148
12
11 CMD_HC16_ON
CN15_5
MZ12HS-K
+12V_RCB
I_TEST_BATT
M15_3
RL2
1
M15_4
7 D2
1N4148
12
11 CMD_TEST_BATT
CN15_6
MZ12HS-K
+12V_RCB
I_BOOST
M15_5
RL3
1
M15_6
7 D3
1N4148
12
11 CMD_BOOST
CN15_4
MZ12HS-K
Picture 15 – INT-R – Digital signals to D-CPU-RC
8) Interface D-CPU-RC Æ I/S-CL: the status of the rectifier is acquired by the inverter CPU
(I/S-CL) through the INT-R, by means of the connection M11 INT-R Æ M2 I/S-CL (wire
W33) which transfers the following signals:
0_BF_RECT Æ rectifier protection fuses blown
0_ERR_SC_RECT Æ input wrong phase sequence
0_RECT_FAIL Æ rectifier general fault
0_MAINS_FAULT Æ mains failure (battery discharging)
The route of such signals is shown in the following table.
Signal from D-CPU-RC INT-R INT-R I/S-CL

0_BF_RECT Æ CN14-4 M11-1/2 Æ M2-1/2
0_ERR_SC_RECT Æ CN14-5 M11-3/4 Æ M2-3/4
0_RECT_FAIL Æ CN14-6 M11-5/6 Æ M2-5/6
0_MAINS_FAULT Æ CN14-7 M12-1/2 Æ M3-3/4*
* The “mains fault” contact is connected to the interface board FCI (PB047), terminal
board M1/3-4.
Issued 13/04/07 JUD409400 13 of 35

+12V_RELE
M11
1 O_BF_RECT R11 1k RELE2
CN14_4
2
3 O_ERR_SC_RECT R12 1k RELE3
CN14_5
4 M12
5 O_RECT_FAIL R13 1k RELE4 1 RET_O_MAINS_FAULT
CN14_6 M12_1
6 2 O_MAINS_FAULT
7 +12A M12_2
M11_7
8 -12A
M11_8
9 C_BAT
M11_9
10
M11_10
GND_A
Picture 16 – INT-R – Digital signals to I/S-CL
9) Relay output: the D-CPU-RC generates some status and alarms signals that can be
transferred, through the connector CN17 of the INT-R, to a optional relay card SRC
(PB218).
U6
1 18 B_RL1
IN1 OUT1 CN17_3
2 17 B_RL2
IN2 OUT2 CN17_4
3 16 B_RL3
IN3 OUT3 CN17_5
4 15 B_RL4
IN4 OUT4 CN17_6
5 14 B_RL5
IN5 OUT5 CN17_7
6 13 B_RL6
IN6 OUT6 CN17_8
7 12 B_RL7
IN7 OUT7 CN17_9
8 11 B_RL8
IN8 OUT8 CN17_10
GND
10
+12V_RELE COM
ULN2804
9
GND_SSW
Picture 17 – INT-R – Relay output

The meaning of the various outputs is shown in the following table:
Signal Description S/A

B-RL1 Rectifier modulating Status
B-RL2 Input mains OK Status
B-RL3 Protection fuses blown Alarm
B-RL4 High temperature Alarm
B-RL5 Rectifier overload Alarm
B-RL6 Rectifier fault Alarm
B-RL7 Input wrong sequence Alarm
B-RL8 Battery test Alarm
10) Board INT-R2: the board INT-R2 is connected to the INT-R by strip-lines. The generation
of the thyristor firing pulses is enabled by the command SCR_PRECHARGE_ON sent by
the CPU. The INT-R2 is provided with a soft-start circuit that allows a soft pre-charge of
the DC capacitors using four of the six thyristors of the bridge. As soon as the DC voltage
has reached a programmed value, the D-CPU-RC sends the command
SCR_BRIDGE_ON, which turn-on the remaining two thyristors. After the start-up the
thyristors work as a non-controlled three-phase Graetz bridge.
Issued 13/04/07 JUD409400 14 of 35

5.2 RTF
The board RTF contains the final stage for the thyristors firing control; it’s composed by six
identical stages, one for each thyristor. The control signals on pin 3÷8 of the connector CN1,
generated by the board INT-R2, pass through a R-C filter and a high frequency transformer and
are finally connected between gate and cathode of the thyristors. The board is provided with six
LED’s installed at the high frequency transformer output to check the operation of each stage.
5.3 ID-HY (RECTIFIER IGBT DRIVER)

The rectifier IGBT drivers ID-HY are connected to the connectors CN1-CN2-CN3 of board
INT-R. Each driver is made of two identical sections, one for each IGBT.
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
INT-R, is used to generate the isolated supplies for both sections of the card.
+15V U2 +5V
D4 1N4148 78L05 R33 1K
1 2
TR1 VIN VOUT
C9 1u D5 1N4148 +
GND
AC1 C10 LD3
10u-63V C12
1u
3
D6 1N4148
+
CN1 C11
10u-63V
1
2 TI117239/ACM2008
3 D7 1N4148
4 -15V
5 Power supply IGBT+
6
7
8 +15VF +5VF
9 U6
D11 1N4148 78L05 R34 1K
10 1 2
TR2 VIN VOUT
C21 1u D12 1N4148 +
GND
AC2 C22 LD4

10u-63V C24
1u
3
D13 1N4148
+
C23
10u-63V
TI117239/ACM2008
D14 1N4148
-15VF Power supply IGBT-
Picture 18 – ID-HY – Power supply
2) Input stage: the PWM is isolated by an opto-coupler. The R4-C5 low pass filter creates the
dead time for the PWM modulation, through the NAND gate U1. The red LED LD1
indicates the presence on the PWM.
D3 R5
+5V 1N4148 680K
C1 100n R2 D2
3K3 1N4148
14
1=ON U1B
14
14
7
R1 U1A 5 U1C
2 6 0=ON 1 4 0=ON 8
3 6 10 1=ON
1K8 3 5 2 9
D1 R4 1K8 4093
PWM 1N4148 U3 HP2601 4093 4093
7
R6
14
7
+ U1D 3K3
R3 *** C5 C2 12
1K 1n 10u-63V 11
13
LD1
4093
7
Picture 19 – ID-HY – Input stage
Issued 13/04/07 JUD409400 15 of 35

3) Output stage: the final stage DZ1, Q2, Q3 and Q4 translates the modulation signal
between +15V (ON Level) and -15V (OFF Level) and works as a buffer. The modulation
signal can be adjusted with the potentiometer RV1 of the board INT-R.
+15V
R11 **
R9 R10
390R 2W 390R 2W D
C4 + C7 DZ2
G 18V
S 10u-63V 1u R15 G1H
Q2 D 1K 1
IRFD014 Q4 2 S1H
R7 IRFD9014 R13 ** DZ3
1=ON G DZ1 C3 18V M1
S 24V 100n
22R D
G
S
C6 + C8
Q3
R8 IRFD014 10u-63V 1u
9K09
-15V
Picture 20 – ID-HY – Output stage

5.3.2 Programming instructions
CN1
LD3
Power supply ON
LD4
Power supply ON
LD1 LD2
Modulation ON Modulation ON
R30
IGBT’S
R11 gate
IGBT’S GND IGBT1 GND IGBT2
gate
M1 M4
Picture 21 – ID-HY board (Rectifier IGBT driver)
Issued 13/04/07 JUD409400 16 of 35

5.4 D-CPU-RC (RECTIFIER MICROPROCESSOR CONTROL)

5.4.1.1 Introduction
The rectifier microprocessor control board D-CPU-RC uses a 40MHz 32-bit Tricore™-based
microcontroller, provided with two 16-channel 12-bit A/D converters and a TwinCAN™ interface
for highly demanding industrial application.
It controls the rectifier operation and allows the inverter microprocessor board I/S-CL to
monitor the status and alarms by interfacing its I/O signals through the board INT-R.
5.4.1.2 Digital power supply
The digital part of the D-CPU-RC has its own power supplies, generated by the switching
converter U37.
VCCIN-AUX1 R242
POS-CPU1
D35 L1 22R
POS-CPU1 A K VDDSB-CPU1
22uH/2.6A C129
MBRS360T3 100N
C130 D36 U37
100N C131 A K 33 7 U38
47uF/25V BOOST Q_STB TLE4274GSV33 3V3-CPU1
GND-CPU1 MBRS360T3 29 L2 D110
SW 31 A K
C132 SW 22uH/2.6A I Q
100N K D
R837 0R D37 BAS40-SOT N
1 G
30 C133 MBRS360T3 C134 C135
32 IN 470N 22uF/10V 1uF C491
R246 0R IN 1uF
35 28 A
R247 SLEW BOOTSTRAP
2
34
WAKE 25
R838 10K 21 FB/L_IN 26 2V5-CPU1 3V3-CPU1 +5V-CPU1
C+ FB/L_IN
0R (N.M.)
C136 27
100N Q_LD01 24
3 Q_LD02 14 R243 R244 R245
20 Q_LD03
22 C- 8 120R 120R 220R
CCP Q_T1 9 R250 R251
23 Q_T2 10
SEL Q_T3 11 2V5-CPU1 0R 0R +5V-CPU1
Q_T4 12 LED3 LED4 LED5
Q_T5 1- A 1- A 1- A
3 13 2 2 2
2 CS Q_T6 M M M
4 CLK 17 1 e 1 e 1 e
L d L d L d
DI R1 16 C144 C145 0 r 0 r 0 r
7 e 7 e 7 e
R2 10uF/10V 10uF/10V 6 V 6 V 6 V
1 15 T T T
C146 18 GND R3 G d G d G d
L e L e L e
220N 19 GND 6 K L K L K L
36 GND ERR 5
GND DO
TLE6361G
Picture 22 – D-CPU-RC – Digital power supplies

5.4.1.3 RAM, FLASH and EEPROM
The EEPROM U35 contains the functional parameters of the rectifier and the adjustments.
The two RAM U23-U23 contain the variables of the program
The two FLASH U25-U26 contain the software program.
5.4.1.4 Rectifier bridge protection
The IGBT bridge is protected if the AC input current or the DC output voltage exceed a
threshold value.
The input current is measured through the current transducers TA1-TA2-TA3, which signals
are connected to the INT-R and then to the D-CPU-RC. The comparison of the feedback signal
with a fixed threshold generates the signal Low_IMax.
The DC voltage is measured through the voltage transducers VM2-VM3 inside the INT-R.
The comparison of the feedback signal with a fixed threshold generates the signal
High_Max_Booster. A third signal, Low_Bad_Supply, depends on the voltage supply of the
microprocessor.
A logic OR is made with these three signals, so that an anomaly of one of them stops the
PWM protecting the IGBT bridge (signal Low_PWM_Trip).
Issued 13/04/07 JUD409400 17 of 35

High_Max_Booster
U30A U18C
U18A 1 8
Low_Bad_Supply 1 1 3 10 PWM_BP_U
3 2 PWM TA+ 9
Low_IMax_U 2
4071 4093
4093 U18B
5
4 Low_Pwm_Trip_U To the
6 IGBT
4093 drivers
U18D
12
11 PWM_BN_U
PWM TA- 13
4093
Picture 23 – D-CPU-RC – IGBT bridge protection

5.4.1.5 Analog inputs
All the analog inputs (voltage and current measures) are directly connected to the
microprocessor A/D converter. The signals come from the board INT-R and are connected to
the following points:
Signal Connector
AC input VOLTAGE U Æ CN5-4
AC input VOLTAGE V Æ CN5-5
AC input VOLTAGE W Æ CN5-6
AC input CURRENT U Æ CN1-12
AC input CURRENT V Æ CN2-12
AC input CURRENT W Æ CN3-12
DC VOLTAGE (Positive) Æ CN5-9
DC VOLTAGE (Negative) Æ CN5-10
Battery CURRENT Æ CN1-13
5.4.1.6 Control LEDs
The following table shows the meaning of the various LEDs on the board D-CPU-RC.
SECTION LED
Microprocessor positive supply (POS_CPU) DLP1
Microprocessor negative supply (NEG_CPU) DLN1
SPI supply (+5V_SSW) DLSS
Microprocessor supply (2V5_CPU) LED3
Microprocessor supply (3V3_CPU) LED4
Microprocessor supply (+5V_CPU) LED5
Microprocessor reset LED6
Program running LED1
Issued 13/04/07 JUD409400 18 of 35

6 INVERTER PCB’S
6.1 DR-HY (INVERTER IGBT DRIVER)
The inverter IGBT drivers DR-HY are connected to the board PWM-SAT. Each driver is
made of two identical sections, one for each IGBT (connected in parallel).
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
PS-SAT, is used to generate the isolated supplies for both sections of the card.
CN1-10 VDD U1 +5V
CN1-9 LM78L05 R1
D2
CN1-8 1 2
CN1 VIN VOUT
1N4148 2K21
GND
10 D5
D1
9 T1 3 + C3
8 Verde fi=3mm
C1 1uF
7 C25 1uF 47uF/25V
1N4148
3
6 6
5 2
4 4
3
2 1 D6
1 + Verde fi=3mm
5 D3 C2
FLAT 10P 47uF/25V
ACM2008 R9
1N4148
D4 6K81
VNN
1N4148
Picture 24 – DR-HY – Power supply
2) Input stage: the PWM is isolated by an opto-coupler. The transistor Q1 and the NAND
gate U1 provide to a level translation of the modulation signal. The red LED LD14
indicates the presence on the PWM.
R34 VDD
3K3
Chiudere sul pin 5 VDD
CN1
+5V C5 +5V D14
10 100NF Giallo fi=3mm
9 R11 C7 1uF
8 3K3
7 ISO1
8
7
R35 1K81 HCPL2601 R10

6 2 3K3 U4A
5 1 = ON 1
4 3
3 3 2
2 3 6 0 = ON 2
1 1
Q1 CD4093B
FLAT 10P 2N2222A
5
UNDERVOLTAGE LOCK-OUT
Picture 25 – DR-HY – Input stage
3) Output stage: the signal is amplified by a MOSFET amplifier that provides also for the
translation of the signal between +15 and -15V. The modulation signal can be adjusted
with the potentiometer P2 of the board PS-SAT.
Issued 13/04/07 JUD409400 19 of 35

J1
D9
RON1 18V/1W 1
VDD 2
3
10R/2W 4
R25 5
RON2 1K CON 5P
R21 R22 SFP9Z24 C17 D10

390R/2W 390R/2W Q4 1uF 10R/2W 18V/1W
+ + + +
C15 C33 C29 C34 1 TPG1
47uF/25V 47uF/25V 47uF/25V 47uF/25V
1 TPS
Q3 C14
BSS89 D8 1 TPG2
100NF 24V/1W
Q5
C18 ROFF1 D12
IRFZ24N 1uF 18V/1W
R23 + + + + R26
9K09 C16 C35 C30 C36 10R/2W 1K
47uF/25V 47uF/25V 47uF/25V 47uF/25V J2
ROFF2
1
2
10R/2W D11 3
VNN 18V/1W 4
5
CON 5P
D18 R19 D7
DE-SATURATION 1 2
1K MUR1100E
8.2V/1W
Picture 26 – DR-HY – Output stage
4) “Under-voltage lock-out” protection

+5V VDD
C4 D19
+
R6 10uF/25V 1N4148
3K3
U2 R3 R2
8 110K 10K
R8 1M 1 VDD
2 OUT1 7
3 HIST1 OUT2 6
SET1 SET2 5
4 HIST2
GND C32
R7 ICL7665S R5
10K R4 10K 1NF
1M
VNN
1 = ALIM. OK
Picture 27 – DR-HY – “Under-voltage lock-out”
5) De-saturation protection
VDD
U3 C6 J2
9 3 10uF/25V
INPUT VPOS C11 1
10 14 100NF R18 2
T_MOR VSS 1K 3
5 R20 4
OUT_ST 1 5
2 OUT1 16
VDD OUT2 CON 5P
4 100R D18 R19 D7
11 CL_PROG 13
SELECT IN_DES 1 2
15 12
COM LIV_DES 7
MON_DEL 1K MUR1100E
8.2V/1W
8 6
VREF ALARM
C8 L6353
100NF R16
12K1 R15 C12

1NF 0 = ALARM
10K R17
C13 C10 12K1
1NF 1NF
Picture 28 – DR-HY – De-saturation
Issued 13/04/07 JUD409400 20 of 35

D6 TPG1
Supply ON Test Point IGBT1
TP5
GROUND
J1
CN1 TPG2
Test Point IGBT2
J2
D14
Modulation ON
D5 D17
Supply ON Led fixed: inverter OK
Led blinking: under voltage lock-out
Picture 29 – DR-HY board (Inverter IGBT driver)
6.2 INV-AV-3F
The INV-AV-3F provides the inverter voltage feedback for the real-time control loop. The
inverter output phases (L1-L2-L3), taken on the filter capacitor Cr-Cs-Ct, are connected on CN1
pin 1-3-5 respectively; the voltage values are reduced by the transformer T1-T2-T3 and sent to
the microprocessor control logic I/S-CL through the connector W18.
The UPS output current transformers TA2-TA3-TA4 are connected to CN3 pin 1-2, 3-4 and
5-6 respectively; the current generated by TA2-3-4 flows through the resistors R4-R5-R6,
generating voltage drops proportional to the UPS output current; this waveforms are sent to the
I/S-CL measuring section for the output current reading.
6.3 PS-MIS
The board PS-MIS is mounted directly on two DC capacitors connected in series; it’s
composed by two sections:
1) Supply of the board PS-SAT: the voltage across the DC capacitors bank is connected to
the connector M1-5/6 and de-coupled by a diode. The voltage across the capacitors C1-
C2 (on which the board is fixed) is lower than the input voltage owing to the voltage drop
Issued 13/04/07 JUD409400 21 of 35

on the resistors bank connected to the connector M3. The board PS-SAT is connected to
the connector M2.
D1
+VDC +VDC_PS
M1_1 M3_1 M3_3 M2_1
C1+
PIAZZOLA
S
C
2
1-
E
T
5 A-
R k C1-
2 PIAZZOLA
2
C2+
PIAZZOLA
S
C
2
1-
6 E
T
R A
-
k
2
2
PIAZZOLA
C2-
-VDC -VDC_PS
M1_5 M2_3
Picture 30 – PS-MIS – Power supply
2) DC voltage feedback: the PS-MIS provides the DC voltage feedback to the inverter
microprocessor control I/S-CL for the DC voltage measure. The feedback signal is
provided by the transducer VM1.
+12A C1
10u-50V
R1
27k-ATE-12CS +
+VDC +HT + C2
M1_1
100n
-
R4
CN1_5
-VDC -HT M MIS_VDC
M1_5 CN1_6
1k
R2
27k-ATE-12CS VM1 R3
LV 25-P
82R-1/2W
GND_A
Picture 31 – PS-MIS – DC voltage feedback
6.4 PWM-SAT
The board PWM-SAT is the interface between the inverter bridge and the microprocessor
control I/S-CL. The modulation signals is available from the I/S-CL on the connectors CN1 (leg
A), CN2 (leg B), and CN3 (leg C). The PWM-SAT split the signal in two parts to make it
available for each single switch of the inverter bridge (positive and negative).
It also collects the current feedbacks coming from the current transducers TA5-TA6-TA7 and
send the resulting signal to the microprocessor control through the connection M1 PWM-SAT Æ
M1 I/S-CL.
Finally, it collects the de-saturation and under-voltage lock-out protections coming from each
driver, generating a single output signal that is sent to the microprocessor.
Issued 13/04/07 JUD409400 22 of 35

7 STATIC SWITCH PCB’S

7.1 VOLT-REF-3F
The VOLT-REF-3F provides the signals for the by-pass line and output voltage
measurement. The by-pass is connected on CN1 pin 1-3-5 (L1-L2-L3) and 7 (neutral) and
supplies the double-secondary transformers T1-T2-T3; the secondary windings of the
transformers through to the Graetz bridge formed by the diodes D1÷D6 and the stabilizer U1,
creates a +5V supply that is sent to the I/S-CL board through the connector CN3. This is a
redundant supply for the static switch control logic (SCB board) and its presence can be verified
by checking the status of the LED DL1. The other secondary windings are used to send the
microprocessor, for measuring purposes, a waveform proportional to the by-pass voltage value,
through the connector CN4, pin 1 (neutral), 2, 3 and 4.
The UPS output is connected on CN5 pin 1-3-5 (L1-L2-L3) and 7 (neutral) and supplies the
double-secondary transformers T4-T5-T6; the secondary windings are connected to the Graetz
bridge formed by the diodes D7÷D12, which output is connected in parallel to the stabilizer U1.
The other secondary windings are used to send the microprocessor, for measuring purposes, a
waveform proportional to the output voltage value, through the connector CN4, pin 5, 6, 7 and 8
(neutral).
7.2 2SCR-FIR
The 2SCR-FIR is the thyristors firing board and is installed directly on the static switch
thyristors. The control signals generated by the I/S-CL are connected on CN1; they are then
isolated by the high frequency transformer TR1 and sent directly to the thyristors. The LED’s
DL1-DL2 show that the thyristor is turned on.
DL1 R5 D Ri
G1
D1 4,7R 1W
R1
TR1 C1 *
47R
3 0,1u
K1
1
4
R7 R6 DL2 R4 + l
8 6
G2 a
nr
27R 5W C4 27R 5W 4,7R 1W
et
5 D2 R2 x
47R C2 * E
0,1u
0,1u K2
A
2- 4- 8- 0
1 3 7 1- A
CN1 9
-
R3
27R
Ru
C3
D
0,1u
Picture 32 – 2SCR-FIR electrical drawing
Issued 13/04/07 JUD409400 23 of 35

8 COMMON PCB’S
8.1 PS-SAT
This board provides the different power supplies to all the sections of the I/S-CL
(microprocessor board) and to the front panel. It’s supplied by the DC bus through the board
PS-MIS. The insulation voltage between the output section and the DC input is 2,5kV.
The PS-SAT is composed by the following sections:
1) Microprocessor supply: the microprocessor supply is strongly filtered and stabilised at +5V
on the microprocessor side (I/S-CL) by means of a precision voltage stabiliser.
FU6
PF 2A
C42 R59 D22 D23 R61 C44 R63

100p NM 1K MUR120 MUR120 1K 100p NM 10K
17 CN1
+ C40 C41 R57 TP8 10

100u 50V 100n 10K 9
8
18 7
AC4 6
T2-E C43 R60 D24 D25 R62 C45 TP9 AC3 5
100p NM 1K MUR120 MUR120 1K 100p NM 4
AC4 3
2
AC3 1
FLAT 10P
Picture 33 – PS-SAT – Microprocessor supply
2) Analog part supply: supply the analog side of the microprocessor card (I/S-CL).
R51
TP5
FU2 10K
+24V
T2-C D14 PF 5A R50 LD3

10 +
C29 C13
MUR120 100u 50V 1u 4K7 G 3mm
R18 0R5 5W CN2
3 2
AC2 10
11
Q8 9
+ 1 Q4 BDX34 R49 AC1 8
D16 D17 C30 R16 2 7
1
MUR120 MUR120 100u 50V 3R3 1W 3 TP2 +12V 6

12 2N2907 10K 5
TP4 4
1 3
VIN VOUT 3
R46 2
LD1
GND
AC1 1
C15
13 C35 D20 1u
AC2
470n U4 1N4004 2K21 G 3mm FLAT 10P
LM7812
2
D15 R48
14 D19 D18
MUR120 MUR120 TP3 -12V
MUR120 10K
2 3
IN OUT
R47 LD2
GND
+
C31 D21 C28
100u 50V U5 1N4004 1u 2K21
LM7912 G 3mm
1
Picture 34 – PS-SAT – Analog part supply
3) Relay and bus supply: this section provides a +12V stabilised voltage for the supply of:
Relays of the alarm card ARC (PB031) Æ pin 9-10
Relays of the rectifier interface INT-R Æ pin 9-10
Parallel bus Æ pin 9-10
Inverter interface card FCI (PB047) Æ pin 1-2
Issued 13/04/07 JUD409400 24 of 35

D26 FU7 CN3

7
10
MUR120 PF 3,5A 9
+ C46 C47 R64 8
100u 50V 1u 10K R66 7
8 2K21 6
5
4
12V/RELAY E BUS 3
2
D27
9 LD4 1
G 3mm
T2-F MUR120 FLAT 10P
D28 FU8 R68

19
MUR120 PF 2A 2K21
+ C48 LD5
20 10u 63V C34 G 3mm 12V/SCR
1u
T2-G
Picture 35 – PS-SAT – Relay and bus supply
4) IGBT drivers supply: the supply of the IGBT driver boards DR-HY is taken from the 40kHz
square wave AC1-AC2
5) Serial ports supply: the supply of the serial communication ports is taken from the 40kHz
square wave AC3-AC4
P2 TP9
IGBT’s gate voltage
CN1
TP8
P1
Not used
FB2
VB- CN4
LD5
LD4
TP3
VB+ -12V
CN3
FB1 TP4
GND
TP2
+12V
CN2
LD2 LD1 TP5
LD3
+24V
Picture 36 – PS-SAT board
Issued 13/04/07 JUD409400 25 of 35

The following table summarizes all the different outputs:
Test GND
SECTION LED Pot. Value
point TP
LD1 +12V Analog TP2 TP4
Analog part supply LD2 -12V Analog TP3 TP4
LD3 +24V Analog TP5 TP4
Free contacts and parallel bus LD4 +12V / Relay & Bus
Free contacts LD5 +12V
Microprocessor and display +9V TP8 TP9
IGBT’s drivers Power Supply P2 Sq. Wave AC1-AC2
RS-232 and RS-485 Sq. Wave AC3-AC4
8.2 I/S-CL (MICROPROCESSOR CONTROL LOGIC)

8.2.1.1 Introduction
The I/S Control Logic (I/S CL) controls all the UPS functions and signals. It takes the digital
inputs (like auxiliary contacts, switches and so on), performs all the analog measures (like
voltages, currents and so on) and provides the total control of the UPS.
8.2.1.2 Digital Inputs
The digital inputs are connected to the I/S CL to the connector M3, directly or through the
interface card FCI. The connector M2 contains all the alarms and signals coming from the
rectifier (see 5.1.1, point 8). The following table shows the various digital inputs connected to
the I/S-CL.
I/S-CL
Signal
M3
1-2 Not used - Spare
3-4 Mains failure (from INT-R)
5-6 Emergency Power Off push button
7-8 BCB auxiliary contact
9-10 OCB auxiliary contact
11-12 SW1 auxiliary contact
13-14 MBCB auxiliary contact
15-16 High temperature
17-18 Parallel configuration (from RPI-BUSCAN)
8.2.1.3 Dip Switches

The dip switches SW1 and SW2 are connected to the microprocessor bus through the
latches U67 and U68. The functions of the UPS can be programmed by setting these switches
as follows.
A) Dip Switch SW1
Issued 13/04/07 JUD409400 26 of 35

Dip no. Position Description

Off Single UPS
1
On Parallel
Off Frequency 50Hz
2
On Frequency 60Hz
Off Single / Parallel
3
On Hot stand-by
4 On Nominal Vout
5 On 220V
4 Off Nominal Vout
5 On 120V
4 On Nominal Vout
5 Off 230V
4 Off Nominal Vout
5 Off 240V)
Off TEST mode
6
On NORMAL mode
Off Buzzer DISABLED
7
On Buzzer ENABLED
Off THREE-PHASE output
8
On
B) Dip Switch SW2
Dip no. Position Description

Off protocol
1
On
Off BOOST CHARGE enabled
2
On BOOST CHARGE disabled
Off Automatic battery test
ENABLED (every 30 days)
3
On Automatic battery test
DISABLED
Off Battery test ENABLED
4
On Battery test DISABLED
5-6-7-8 Configure the power as follows
UPS
Dip 5 Dip 6 Dip 7 Dip 8
[kVA]
200 Off On Off Off

250 Off Off On On
300 Off Off On Off
8.2.1.4 Fast Analog Inputs

The measures of the bypass L1, L2 and L3 phases and output L1, L2 and L3, are directly
connected to the microprocessor A/D converter. The signals comes from the board VOLT-REF-
3F and can be checked, with reference to the MICROPROCESSOR ground, in the following
points:
D52 (K) Æ Output L3 D57 (K) Æ Output L2 D58 (K) Æ Output L1
D59 (K) Æ Bypass L3 D64 (K) Æ Bypass L2 D65 (K) Æ Bypass L1
Issued 13/04/07 JUD409400 27 of 35

MICRO BUS R
FI1 BYPASS FREQUENCY OP AMP
+5V
R152 R150
D62 D61 D60 D55 D54 D53 10K 10K
2K2 1% X6
R172
ADA0 R R
CN13-4
ADA1 S S R171
CN13-3 BYPASS
ADA2 T T R173
CN13-2
ADA3 R R R166
CN13-5
ADA4 S S R165
CN13-6 OUTPUT
ADA5 T T R164
CN13-7
D65 D64 D59 D58 D57 D52
R205
R206
R204
R207
R208
R209
C113
VR/2
C110 C109 C100 C98 C97
Picture 37 – I/S-CL – Fast analog inputs

8.2.1.5 External A/D Converter
Several analog measures are sent to the microprocessor through the external A/D converter
U22. These measures can be checked, with reference to the ANALOG ground in the following
points:
A/D Test
Measure
Channel Point
Inverter Output Voltage R #0 D43 (K)
Inverter Output Voltage S #1 D20 (K)
Inverter Output Voltage T #2 D21 (K)
Output Current R #3 D6 (K)
Output Current S #4 D33 (K)
Output Current T #5 D5 (K)
Inverter Input Voltage (DC) #6 D23 (K)
Inverter Input Current (DC) #7 D22 (K)
Phase Correction for Parallel Redundant #8 D42 (K)
Battery Current for Boost Charger #9 D74 (K)
+5A
INVERTER VOLTAGE R
D31 D16 D17 D32 D14 D15 D34 D35 D36
U22 INVERTER VOLTAGE S
20 1 Inv. Volt. R INVERTER VOLTAGE T

19 VCC IN0 2 Inv. Volt. S
18 EOC IN1 3 Inv. Volt. T
17 CLK IN2 4 Out. Curr. R OUTPUT CURRENT R
DATA_OUT 16 ADRIN IN3 5 Out. Curr. S
15 DOUT IN4 6 Out. Curr. T OUTPUT CURRENT S
14 CS IN5 7 VDC
13 REF+ IN6 8 IBS OUTPUT CURRENT T
12 REF- IN7 9 CFPAR
11 IN10 IN8 10 DC VOLTAGE
IN9 GND
IBOOST INVERTER INPUT CURR
TLC1542
A PARALLEL CORRECTION
BATTERY BOOST CURR
D42 D22 D23 D43 D20 D21 D6 D33 D5
C72 C51 C52 C73 C49 C50 C64 C65 C66

A
Picture 38 – I/S-CL – External A/D converter

8.2.1.6 Watchdog and Reset
The microprocessor is controlled by a smart watchdog system that provides an automatic
reset in case of an error of the microprocessor during the normal operation or a problem in the
Issued 13/04/07 JUD409400 28 of 35

microprocessor power supply (under-voltage lock-out). It is also possible to reset manually the
microprocessor by pressing the reset push-button SW3.
8.2.1.7 RAM, EPROMs and EEPROM
The EEPROM U71 contains the functional parameters of the UPS and the adjustments.
The RAM U58 contains the history of the alarms of the UPS. Up to 900 events can be stored
in this device and the backup battery allows to preserve the information for three days after the
power has been removed.
The two EPROMs contain:
U55 Program odd addresses
U65 Program even addresses.
8.2.1.8 Digital Power Supply
The digital part of the I/S CL has its own power supply (5 volt). This voltage can be checked
on the LED D69 (green) and measured between U75 pin 2 (ground) and pin 3.
VNR +5V +5V
CN14-10 U75
L4 TEA7605
CN14-9 1 3
E U
C122
M
C137 C131 + D69
FILTERS GREEN
100NF 100NF 470uF
2
CN14-1
CN14-2
GND COMMON MODE
D50
R146
1N4148
+VRAM
D49 D48
1N4148 SD103
BT
1 ON
2
J2
3 OFF
Picture 39 – I/S-CL – Digital supply

8.2.1.9 RCB board
The RCB is an additional card which is fixed on the I/S-CL. It contains the drivers for the
digital outputs of the microprocessor. Each output is de-coupled and buffered on this card. The
RCB contains also the RS232 and RS485 drivers for the serial communication ports.
8.2.1.10 SCB board and Thyristor drivers
The SCB is an additional card which is fixed on the I/S-CL. It contains the decisional logic for
both bypass and inverter static switches. It can turn-on directly the bypass static switch or send
the command to the I/S-CL to close the inverter static switch.
This card can be programmed through the jumpers J1÷J8 (see figura 51) and it is powered
directly by the emergency line at +5V (see 7.1.1). This supply can be checked on the LED L1
(green) and measured between U11 pin 10 (ground) and pin 20.
8.2.1.11 Current Limitation and Max Current Stop
The current flowing in the inverter bridge is measured through a hall-effect current transducer
on the connector M1 pin 2.
1) Short circuit protection: the feedback signal originated by the Hall effect CT is acquired by
the microprocessor card where it generates a voltage drop flowing through the resistors
R18-R39-R40, so that it can be used for the control circuit. By means of a amplifier, which
gain can be varied with the potentiometer P2, the value of the signal is adapted to the
dynamic of the protection circuit.
Issued 13/04/07 JUD409400 29 of 35

The signal on the test point TP2 must be equal to 4Vpk when the inverter supplies the
nominal load (100%).
In case of short circuit the output current is limited at 200% for 100ms, and then to 125%
for 5 seconds, after which the inverter is switched off (according to EN62040-3).
+12A
C19
M1-2 FEEDBACK
R39 100NF
J10 47R
R27 D73 A
3 U16A
+
1 TP2
C28 R40 1K SD103 2
-
1NF J9 100R D72 Current
R38 MC34074
SD103
2K A
Signal
C27 1n
R18
J100 22R
R25 R26
P2
1K 10K 1K
A
Picture 40 – I/S-CL – Short circuit protection
2) “Current stop” protection: the resistors R18-R39-R40 are properly combined according to
the IGBT’s nominal current so that, 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.
250μs)
The inverter stop due to “Current stop” is signalled by the LED D3, placed on the front of
the I/S-CL card. The program provides for the automatic reset of the stop condition for
three times, re-starting the inverter. If the block repeats, therefore a real failure exists in
the inverter bridge, the inverter is definitely stopped and must be re-started only after
having verified the reason of the malfunction.
U15B
+5A +12A 3 4
U5C
C20 40106 8 R13
100NF 10
R15 CA3130 9
10K +12A 3K3
4093 D3
7
5
A LMCS
R17 10K
FEEDBACK 3 U11 R50
M1-2 +
6 U5D
R39 2 12
-
J10 R49 200K 11
13 A
R16
4
8
1
C13 1K 4093
10K
R40
C28 J9 1NF N1 CURRENT STOP
1NF A 100pF
+ C148
A 10u 25V
SW4
R18 PPMCS
J100
Picture 41 – I/S-CL – “Current stop” protection

8.2.1.12 VCB board
The VCB is an additional card which is fixed on the I/S-CL. It’s made by the following
sections.
1) Sine-wave generator: the digital samples coming from the microprocessor (that represents
the digital sine-wave) are converted by a D/A converter in order to obtain a real sine-wave
which is transferred to the PWM generator (see 8.2.1.13). The amplitude of the sine-wave
Issued 13/04/07 JUD409400 30 of 35
is varied by the AUTOMATIC regulation loop (jumper J1 in position 1-2) in function of a

set-point managed by the microprocessor adjustable through the potentiometer P1. Each
phase of the inverter is disengaged and can be varied independently.
In order to carry put functional tests, the regulation loop can be set in MANUAL mode
(jumper J1 in position 2-3), in such case the amplitude is varied turning the potentiometer
P1 of the I/S-CL card. In this case the inverter output voltages are varied contemporary.
2) Voltage correction (instantaneous value loop): the voltage correction circuit is used to
modify the PWM reference signal in order to “correct” possible distortions on the output
sine-wave and can be disabled removing the jumper J2. The feedback signal, coming
from the INV-AV-3F card is compared with the reference sine-wave e properly filtered.
The resulting signal is added again to the reference sine-wave.
+5A +12A
C22
R36
10K
R30 10K U6C 100NF
VREF 10 NOTCH A
+ U6B
8 FILTER 5
+
9 7
-
6
-
LM324 R39 10K
LM324 VREF
R31 10K R32 10K
VFBK A
R40 10K U6D
R37 12
C14 +
C15 14 VPWM
1NF 1NF 43K2 C19 J2 13
-
C20 100NF
LM324
A A
1NF R41 10K R42 11K8
+5A
Picture 42 – VCB – Instantaneous value loop
3) Inverter voltage measure: a section of the card is dedicated to the creation of a signal that
is used as reference for the measure of the inverter output voltage. The feedback signal,
coming from the board INV-AV-3F, is rectified, filtered and sent to the external A/D
converter (see 8.2.1.5), and then to the microprocessor
8.2.1.13 PWM generator
The I/S-CL can be used to generate both single-phase and three-phase output voltages. This
function can be programmed by setting the jumper J1 on the I/S-CL. The PWM generator
compares the sine-waves coming from the VCB card with a triangular waveform at the switching
frequency (U17 pin 6) to generate the PWM modulation to control the inverter power bridge.
+12A +12A
C18
C24 100NF
100NF
A U9A +12A CN7-8
5 6 1
1STOP
3
CN7-7 +TA
U14C 2
40106 AC1
A
CN7-1
4093
CN7-3
U14D
+12A A
9 8 AC2 CN7-2
C22 CN7-4
CA3130 40106
100NF -TA
R10
7
5
A A
1K
FPWM (TRIANGLE) 3 U12 U9B
+ +12A CN7-10
6 5
VPWM (SINEWAVE) 2 4
- CN7-9
6
R9 C14 C15
1K
4
8
1
4093
22NF 22NF
A
A A
A N5
47pF
Picture 43 – I/S-CL – PWM generator
Issued 13/04/07 JUD409400 31 of 35

32 of 35
Addresses and Data Bus
18
SW1
17 SPARE
16
15 THERMAL SWITCH 9 8 Ad0 EEPROM
14
10 7 Ad1
13 MBCB AUX. CONTACT Ad2 Parameters
Output Buffers
11 6
12
12 5 Ad3 Microprocessor RAM EPROM EPROM
11 BYPASS SWITCH 13 4 Ad4
U74
Ad5 U71 History Odd Even
Fast Analog to Digital Conversion
10
14 3
9 OCB AUX. CONTACT 15 2 Reset
Input Latches
U48-U52-U53
Input Latches
8
Optocouplers
16 1
EPO CONTACT Rx
U67-U68
7 1
SW2
BT
6 U61 U58 U55 U65 Tx 2
5 BCB AUX. CONTACT Gnd 3
4 Backup battery Pos 4
9 8
3 MAINS FAULT 5
RS232
Buffer
2 10 7 6
U15
11 6
RESET
1 SPARE 7
M3
12 5
SW3
Watch-dog and
Optocouplers
8
13 4 9
14 3 Undervoltage
Channels
10
6 15 2 Lockout Out- 11
16 1
5 CHARGER FAULT Out+ 12
+12V
4 Optocouplers In- 13
3 SPARE In+ 14
CN13-4
2 By-Pass R 15
CN13-3
SPARE By-Pass S U11 pin 10
+5V
1 16
RS485
CN13-2
M2
Buffer
By-Pass T 17
U14
Relays
CN14-10
18
CN13-5
Output R U75 pin 3 Output Buffer

19
CN13-6
CN14-9
Output S
CN4
20
CN13-7
Output T Digital U11
L2
L1
Power
+12V-SCR
K1
RELAY #2
RELAY #3
RELAY #1
RELAY #4
RELAY #5
RELAY #6
RELAY #7
POS-REL
POS-REL
POS-REL
U11 pin 9
Supply
CN14-1
U75
D69
CN14-2
10
9 20
8 Display
10
9
8
7
6
5
4
3
2
1
Driver
Optocoupler
CN6
CN5
RCB
JUD409400
7
Thyristors
2
1
CN10
M1
6 Inverter Feed Load Signal 1 U75 pin 2
U39
Driver
5
4
3
2
Addresses and Data Bus
CN5
1
+5ST
Optocouplers Optocouplers Optocouplers Optocouplers Optocouplers Optocouplers Optocouplers

10 +24V
9
J1 J2 J3 J4
8 U11 pin 20
7
6 +5ST
5 Static Switch
4
Control Programmable J5 J6 J7 J8 Single Phase Single Phase Single Phase
CN8-10
3
Feed-back Feed-back Feed-back Inv. Voltage R In0 In3 Output Curr. R
Array Logics
CN8-9
L1
2 Inv. Voltage S In1 In4 Output Curr. S
Short Circuit
Current Stop
P1 P1 P1
External A/D
CN8-8
GND U11 pin 10 Inv. Voltage T In2 In5 Output Curr. T
CN9
1
DC Current In7
Converter
M2-9CN3-2 CN4-6
Thyristors SCB In6 Inverter Inp. Volt.
Signal
Signal
Driver
Picture 44 – I/S-CL block diagram

Sinus Wave Sinus Wave Sinus Wave
U22
Generator Generator Generator In8 Phase Correct.
J2 U4 J2 U4 J2 U4
10 In9 Battery Curr.
D3
9
8
VCB VCB VCB
RESET
7
6 J1 J1 J1
SW4
5 Short Circuit
Detector
4
3
2
CN11
+12V
Max Current
Stop
CN4-10
P1 U7 pin 1
CN4-9
M1-2
Inverter Bridge Current
CN4-3 CN4-8
J9 J10 J100 Switching Frequency PWM Generator Analog
Generator U17 U9-U14 J1 Power
IGBT's Current
TP2
Supply
Issued 13/04/07
Selection
CN4-2
Current U7
D11
CN4-1
Limitation
U7 pin 2
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
CN7
CN1
CN2
P2
R40-100R Current J11-MBCB

Analog Test point Aux. contact
ground R39-47R J10
CN6 NC=1-2 Reset max.
J9 D8-short circuit
NA=2-3 curr.
CN5 CN4 CN3 CN2 CN1
M1
Led
max corr.
J100 CN7
M2 J1
1Ph = 1-2
R18 3Ph = 2-3
M3 22R
Man. Inv.
volt. adj.
P2 U17
ACW=incr.
Curr. limit. adjust. Pin 6=Triangle
Modul.
ACW=increase curr.
D11 CN8
Correct D23
R66 Vdc measur.
+12V analog 6K8 = 8KHz
13K3 = 4KHz
CN11
CN10
CNB Front
panel
CN9
J2
Battery connected
1-2 Closed = backup CN12
Debug
CN14
RST–RST CN8 CN7
Emer. line - Output
CN13 (D65..D52) ODD Normal
Reset Debug
selection
CN15 EVN
J7 SW1 SW2
Microprocessor D69-Correct Open=Watchdog
ground +8V digital excluded
Closed=Watchdog
included
Picture 45 – I/S-CL board
Issued 13/04/07 JUD409400 33 of 35

8.2.3 SCB board

U12 U11 JP2
TP1-2 SAFE_22 OUTGEN Open = aut. Retransfer
Closed = man. retransfer
JP7 JP1
JP3
Open = hot stand by – parallel red.
Closed = single unit
JP4
JP5 JP8 JP6
Picture 46 – SCB board

Note: for parallel redundant UPS, U11 must be changed to OUTGEN41 and U12 to
SAFE1_23.
8.2.4 VCB board
J1 P1
Inv. Voltage reg. Close loop inverter voltage adj.
1-2 = closed loop
2-3 = manual
J2
Closed = istant. loop included
Open = istant. loop not included
J3
Always open
Picture 47 – VCB board
Issued 13/04/07 JUD409400 34 of 35

8.3 FCI
The FCI board provides a de-coupling function for all the digital inputs (see point 8.2.1.2) and
it’s connected to the microprocessor through the terminal M2. In detail, the function of each
relay is the following:
K1 (terminals 17-18) Æ used for UPS in parallel configuration
K2 (terminals 15-16) Æ Inverter bridge thermal sensors
K3 (terminals 13-14) Æ MBCB (manual by-pass breaker) position
K4 (terminals 11-12) Æ SW1 (by-pass test switch) position
K5 (terminals 9-10) Æ OCB (UPS output breaker) position
K6 (terminals 7-8) Æ BCB (battery circuit breaker) position
K7 (terminals 5-6) Æ EPO (Emergency Power Off)
K8 (terminals 3-4) Æ Mains failure (from rectifier control logic)
K9 (terminals 1-2) Æ Not used - Spare
CN1
+12V
10 J1 J2
9
1
8
7 2 2
6
5
4
3
3
2
1
K1
1N4148
D1
OUAZ-SH-112D
K2
1N4148
D2
OUAZ-SH-112D
M2
M1 K3
1N4148 18
18 17
17 16
16 D3 15
15 OUAZ-SH-112D 14
14 13
13 12
12 K4 11
11 1N4148 10
10 9
9 8
8 D4 7
7 OUAZ-SH-112D 6
6 5
5 4
4 K5 3
3 1N4148 2
2 1
1
D5
OUAZ-SH-112D
K6
1N4148
D6
OUAZ-SH-112D
K7
1N4148
D7
OUAZ-SH-112D
K8
1N4148
D8
OUAZ-SH-112D
K9
1N4148
D9
OUAZ-SH-112D
Picture 48 – FCI electrical drawing
Issued 13/04/07 JUD409400 35 of 35

Troubleshooting and Maintenance
TROUBLESHOOTING AND MAINTENANCE
Index
1 INTRODUCTION.................................................................................. 4
1.1 TOOLS FOR SERVICE.....................................................................................4
2 TROUBLESHOOTING PROCEDURES .............................................. 5
2.1 A1 – MAINS FAULT .........................................................................................5
2.1.1 Troubleshooting procedure ....................................................................5
2.2 A2 – CHARGER FAULT...................................................................................6
2.3 A3 – RECTIFIER FUSE ....................................................................................6
2.4 A4 – THERMAL IMAGE ...................................................................................7
2.5 A5 – AC/DC FAULT..........................................................................................8
2.6 A6 – INPUT WRONG SEQUENCE...................................................................8
2.7 A7 – BCB OPEN...............................................................................................9
2.8 A8 – BATTERY DISCHARGE ..........................................................................9
2.9 A9 – BATTERY AUTONOMY END ..................................................................9
2.10 A10 – BATTERY FAULT ..............................................................................9
2.11 A11 – BATTERY TEST .................................................................................9
2.12 A12 – PLL FAULT.......................................................................................10
2.13 A13 – INVERTER OUT OF TOLERANCE ..................................................10
2.13.1 Troubleshooting procedure...............................................................10
2.14 A14 – OVERLOAD......................................................................................11
2.15 A15 – BYPASS FAULT...............................................................................11
Issued 13/04/07 JUD409401 1 of 26

2.16 A16 – BYPASS FEED LOAD ..................................................................... 12

2.16.1 Troubleshooting procedure .............................................................. 13
2.17 A17 – RETRANSFER BLOCKED .............................................................. 13
2.18 A18 – MANUAL BYPASS CLOSED .......................................................... 13
2.19 A19 – OCB OPEN ...................................................................................... 14
2.20 A20 – FANS FAILURE ............................................................................... 14
2.21 A21 – HIGH TEMPERATURE .................................................................... 14
2.22 A22 – BYPASS SWITCH ........................................................................... 14
2.23 A23 – EPO BUS ......................................................................................... 15
2.24 A24 – CURRENT STOP ............................................................................. 15
2.25 A25 – SHORT CIRCUIT ............................................................................. 16
3 PCB’S AND COMPONENTS SUBSTITUTION..................................17
3.1 PCB’S SUBSTITUTION ................................................................................. 17
3.1.1 PB003 – I/S-CL ....................................................................................... 17
3.1.2 PB004 – INV-AV-3F ................................................................................ 19
3.1.3 PB005 – VOLT-REF-3F .......................................................................... 20
3.1.4 PB107 – PS-SAT .................................................................................... 20
3.1.5 PB223 – INT-R........................................................................................ 21
3.1.6 PB228 – PS-MIS ..................................................................................... 21
3.1.7 PB249 – D-CPU-RC................................................................................ 21
3.2 COMPONENTS SUBSTITUTION .................................................................. 22
3.2.1 RECTIFIER IGBT’S ................................................................................ 22
3.2.2 RECTIFIER BRIDGE THYRISTORS (PRE-CHARGE) ........................... 22
3.2.3 INVERTER BRIDGE IGBT’S .................................................................. 22
3.2.4 STATIC SWITCH THYRISTORS ............................................................ 23
4 ON-FIELD TEST PROCEDURES ......................................................23
4.1 RECTIFIER..................................................................................................... 23
Issued 13/04/07 JUD409401 2 of 26
4.1.1 General notes on the TEST mode.........................................................23

4.1.2 Setting the rectifier in TEST mode........................................................23
4.2 INVERTER ......................................................................................................24
4.2.1 General notes on the TEST mode.........................................................24
4.2.2 Blank test of the I/S-CL board ...............................................................24
4.2.3 Inverter manual start-up ........................................................................25
4.2.4 Inverter automatic start-up....................................................................25
4.3 STATIC SWITCH ............................................................................................26
4.3.1 Check of the redundant supply.............................................................26
4.3.2 Commutation tests.................................................................................26
Index of pictures
Picture 1 – Signal on cathode of D65 (D64-D59)....................................................................................... 12
Picture 2 – Current signal on TP2 at 100% of load .................................................................................... 18
Picture 3 – IGBT turn-on signal .................................................................................................................. 20
Picture 4 – Triangle (switching frequency) ................................................................................................. 24
Issued 13/04/07 JUD409401 3 of 26

1 INTRODUCTION
This troubleshooting includes a first-level fault description based on the UPS alarms and
suggests how to check the unit to solve the problems. This description assumes that all the
connections inside the unit are correct: check them (connectors, power cables, signals and so
on) before to start with the procedures. The first-level troubleshooting eventually leads to the
substitution of the components of the UPS without attempting to repair them.
The procedures listed below takes into account the operator is provided with all the testing
tools and perfectly confident with the test software.
1.1 TOOLS FOR SERVICE

The tools necessary for service are described below:
1. External power supply

The external power supply is necessary for the supply of the inverter logics to test their
functionality.
2. Interface card PB213 (SLOT-SER)
This card must be connected by means of a 10-wire flat cable to the connector CN8 of
the board PB249 (D-CPU-RC). It contains the RS232 and USB ports for the interface
with the rectifier control software.
3. External ON/OFF switch
The external ON/OFF switch must be connected to the connector M10 of the board
PB223 (INT-R). It enables the rectifier start-up.
4. External 3Ph AC supply cable
This cable must be connected to the connector M8 of the board PB223 (INT-R). It’s
necessary for the supply of the rectifier logics to test their functionality.
5. Software “UPSTest”
The “UPSTest” software is used to control the UPS operation by interfacing the
computer with the microprocessor of the board PB003 (I/S-CL)
6. Software “WRC Monitor”
The “WRC Monitor” software is used to control the rectifier operation by interfacing the
computer with the microprocessor of the board PB249 (D-CPU-RC).
7. Software “WRC EEPROM Manager”
The “WRC EEPROM Manager” software is used to change the programming of the
rectifier’s nominal data and to adjust the voltage and current measures (which are not
shown on the front panel, but are used by the rectifier control to regulate the operating
parameters).
Issued 13/04/07 JUD409401 4 of 26

2 TROUBLESHOOTING PROCEDURES
2.1 A1 – MAINS FAULT
This alarm normally indicates that there is no power at the input of the UPS. The normally
closed contact of the relay RL5 on the board INT-R is connected to the pins 1-2 of M12. This
contact is sent to the I/S-CL on M3 pins 3-4 through the wire W35. When this contact is closed
(relay not energised) the alarm is active; when the mains is considered good, the relay is
energised and the alarm disappears.
2.1.1 Troubleshooting procedure
1. Is the input voltage present and within the tolerance?
YES: go to step #2
NO: check the UPS supply line
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence. Is it
active?
YES: follow the procedure at 2.6.1
NO: go to step #3
3. Check the AC voltage measures on the software “WRC Monitor”. Are they in
tolerance?
YES: go to step #4
NO: go to step #6
4. Check the status RMSOK. Is it active?

YES: go to step #5
NO: replace the board PB249 (D-CPU-RC)
5. Check the status FROK. Is it active?

YES: go to step #8
6. Check the connection between the AC mains and the connector M8 of the board INT-R
(wire W51). Is it good?
YES: replace the board INT-R. Go to step #7
NO: re-connect or replace the wire W51
7. After having substituted the board INT-R is the problem solved?

YES: END
8. Check the connection between the connector CN11 of the board D-CPU-RC and CN14
of the board INT-R. Is it good?
YES: go to step #9
9. Check the connection between the connector M12 of the board INT-R and M3 of the
board I/S-CL. Is it good?
YES: replace the I/S-CL
Issued 13/04/07 JUD409401 5 of 26

2.2 A2 – CHARGER FAULT

This alarm normally indicates that there is a fault on the rectifier / battery charger. The signal,
generated by the board D-CPU-RC (PB249) is sent to the board PB223 through the flat-cable
W38 (CN11 PB249 Æ CN14 PB223) and acquired by the inverter microprocessor card PB003
(I/S-CL) through the wire W33 (M11 PB223 Æ M2 PB003).
1. Open the battery breaker BCB and check the rectifier output voltage. Is it within the
tolerance values?
YES: go to step #2
NO: go to step #3
2. Check the connection between M11 of the board INT-R and M2 of the board I/S-CL. Is
it good?
3. Connect the software “WRC Monitor” and check the alarm Booster Fault. Is it active?
YES: go to step #4
4. Check the alarm High Temperature on the software “WRC Monitor”. Is it active?
YES: go to step #5
NO: go to step #7
5. Check the status of the pins 1-2 of M15 in the board INT-R. Is the contact closed?
YES: go to step #6
NO: Check and/or replace the thermal switch
6. Check the connection between the connector CN11 of the board INT-R and CN4 of the
board D-CPU-RC. Is it good?
YES: replace the board PB249 (D-CPU-RC)
7. Set the rectifier in TEST mode (see 4.1.2) and check the IGBT’s turn-on signal
according to the picture 3. Is it good?
YES: replace the board PB223 (INT-R). Go to step #8
NO: replace the faulty IGBT and the driver board
8. After having substituted the component is the problem solved?

YES: END
2.3 A3 – RECTIFIER FUSE

This alarm normally indicates that there is a rectifier input fuse blown.
The normally closed contact of the fuses is connected to the connector M9 of the board
PB223 (INT-R). Then, it’s acquired by the rectifier microprocessor through the flat-cable W43
(CN5 PB223 Æ CN2 PB249). The signal is sent back to the board PB223 through the flat-cable
W38 (CN11 PB249 Æ CN14 PB223) and finally acquired by the inverter microprocessor card
PB003 (I/S-CL) through the wire W33 (M11 PB223 Æ M2 PB003).
Issued 13/04/07 JUD409401 6 of 26


1. Check the rectifier input fuses. Are they OK?
YES: go to step #2
NO: replace the broken fuse(s)
2. Check the connection between the auxiliary contact of the fuses and the connector M9
of the board PB223 (INT-R). Is it OK?
YES: go to step #3
NO: re-connect or replace the interconnection cable
3. Check the status of the pins 1-2 of M9 in the board INT-R. Is the contact closed?
YES: go to step #4
NO: replace the faulty fuse indicator(s) on the protection fuse(s)
4. Connect the software “WRC Monitor” and check the alarm Fuse Blown. Is it active?
YES: go to step #5
NO: go to step #6
5. Check the connection between the connector CN5 of the board INT-R and CN2 of the
board D-CPU-RC. Is it good?
YES: go to step #7
2.4 A4 – THERMAL IMAGE

This alarm normally indicates that the UPS thermal protection has stopped the inverter.
The output current transformers measure an output current exceeding the nominal output
current (see the alarm A14 – Overload). The microprocessor starts to calculate the energy pulse
I2t. As this pulse reaches the 100% the inverter is stopped for 30' and the load is transferred to
the bypass.
1. Measure the UPS output current and compare the measure with the reading on the
UPSTest screen (or front panel). Are the values shown equal to those measured?
YES: go to step #2
NO: replace the board PB004 (INV-AV-3F) and re-adjust the output current reading
with the UPSTest (see 3.1.2). Go to step #3
2. Is the alarm A14 - Overload present? (The output current exceeds the UPS nominal
current)
YES: the overload is still present. Reduce the load.
NO: the overload has finished and the load is still supplied by by-pass.
3. Repeat the step #1. Are the values shown equal to those measured?
Issued 13/04/07 JUD409401 7 of 26
YES: END. Check that the load doesn’t exceed the nominal load.
NO: replace the I/S-CL
2.5 A5 – AC/DC FAULT

This alarm normally indicates that the inverter input DC voltage is beyond the limits
programmed for the correct operation of the inverter. These limits can be checked on the
UPSTest software.
The measure of the DC voltage comes from the board PS-MIS (PB228), connector CN1, to
the connector CN4 of the board I/S-CL. The measure can be checked with a multimeter or a
oscilloscope between the analog ground the diode D23 (K).
1. Open the battery breaker BCB and measure the inverter input voltage. Is it within the
limits shown by the following table?
Battery cells Minimum Histeresys Maximum Histeresys

300 496 Vdc 660 Vdc 750 Vdc 730 Vdc
YES: go to step #2
NO: check for the alarm A2 – charger fault; follow the procedures described at 2.2
2. Check the measure of the DC voltage on the test software and adjust it by the TVBA
command. Does the measure change?
YES: go to step #3
3. Put the unit in manual by-pass (or switch it off if allowed) and switch it on again. Is the
measure correct?
YES: END
NO: replace the board PS-MIS (see procedure at 3.1.6). Go to step #4
4. After replacing the board PS-MIS, is the measure correct?

YES: END
2.6 A6 – INPUT WRONG SEQUENCE

This alarm normally indicates that the rectifier input phase sequence is wrong. The signal,
generated by the board D-CPU-RC (PB249) is sent to the board PB223 through the flat-cable
W38 (CN11 PB249 Æ CN14 PB223) and acquired by the inverter microprocessor card PB003
(I/S-CL) through the wire W33 (M11 PB223 Æ M2 PB003).
1. Check the input phase sequence (L1ÆL2ÆL3). Is it OK?
YES: go to step #2
NO: re-connect correctly the cables
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence. Is it
active?
NO: go to step #3
Issued 13/04/07 JUD409401 8 of 26

YES: go to step #4
2.7 A7 – BCB OPEN

This alarm indicates that the battery circuit breaker is open. This signal comes from the
battery circuit breaker auxiliary contact to the I/S-CL M3 pins 7-8.
1. Is the battery breaker BCB open?
YES: END
NO: go to step #2
2. Check the connection between the auxiliary contact of the external battery switch and
the terminals Bac1-Bac2 in the UPS. Is it OK?
YES: go to step #3
NO: re-connect or replace the interconnection cable
3. Check the status of the pins 7-8 of M3 in the I/S-CL board. Is the contact closed?
NO: replace the BCB auxiliary contact
2.8 A8 – BATTERY DISCHARGE

This alarm is generated by the software and indicates that the battery is discharging; it
always occurs together with the alarm A1 – mains fault.
YES: follow the procedures described at 2.1
NO: END. There’s a mains failure and the inverter draws energy from the battery
2.9 A9 – BATTERY AUTONOMY END

This alarm indicates that the UPS is discharging the battery and the battery voltage has gone
below the voltage programmed as battery low level by the command LOBA.
When this alarm occur it means that the battery, during the discharge cycle, has reached the
low voltage level; no troubleshooting procedure is provided for this alarm as it depends on a
software setting that can be changed only by skilled personnel.
2.10 A10 – BATTERY FAULT

This alarm indicates that the UPS has tested the battery and the test has failed (see alarm
A11 – Battery test). In case this alarm occurs after a battery test check the battery (connection,
status of the cells, voltage and so on).
This alarm must be cleared by entering the special menu in the UPS front panel.
2.11 A11 – BATTERY TEST

This alarm indicates that the UPS is testing the battery. The test is performed by reducing the
rectifier DC voltage so that the battery is discharged. The microprocessor checks the status of
Issued 13/04/07 JUD409401 9 of 26

the battery by measuring the battery voltage during the discharge. If the test fails the alarm A10
- Battery fault is activated.
The battery test can be activated manually by the operator or automatically by the UPS if the
automatic battery test is enabled (see 3.1.1 - microprocessor settings).
2.12 A12 – PLL FAULT

This alarm indicates that the inverter can’t synchronise with the emergency line whenever the
bypass it is available (see alarm A15 – Bypass fault). Replace the I/S-CL.
2.13 A13 – INVERTER OUT OF TOLERANCE

This alarm indicates that the inverter output voltage is outside the tolerance values (see
UPSTest screen for details). This alarm generally occurs together with other alarms.
1. Is the inverter ON? (red LED’s on the driver board ID ON)
YES: go to step #2
NO: go to step #4
2. Measure the inverter output voltage (upstream the inverter static switch) and compare
the measure with the reading on the UPSTest screen (or front panel). Are the values
shown equal to those measured?
YES: go to step #3
NO: re-adjust the inverter voltage reading with the UPSTest software (see 3.2.1). Go
to step #4
3. Is the inverter output voltage over the higher limit?

YES: replace the board PB004 (INV-AV-3F)
NO: check the UPS settings on the I/S-CL (nominal power, nominal voltage)
4. Switch off the inverter, switch it on again and check the measures on the UPSTest
screen. Are the values shown equal to those measured?
YES: END
5. Is the alarm A4 – Thermal image present?

YES: follow the procedure described at 2.4.1
NO: go to step #6
6. Is the alarm A5 – AC/DC fault present?

NO: go to step #7
7. Is the alarm A18 – Manual bypass closed present?

NO: go to step #8
8. Is the alarm A21 – High temperature present?

NO: go to step #9
9. Is the alarm A23 – EPO bus present?

NO: go to step #10
Issued 13/04/07 JUD409401 10 of 26

10. Is the alarm A24 – Current stop present?

NO: go to step #11
11. In case the inverter turn-on and off cyclically check for the alarm A25 in the alarms
history and follow the procedure described at 2.25.1.
2.14 A14 – OVERLOAD

This alarm normally indicates that load at the output of the UPS exceeds the nominal power.
The output current transformers measure an output current exceeding the nominal output
current. The alarms is activated and the thermal image protection (see the alarm A4 – Thermal
image) starts to calculate the thermal pulse.
1. Measure the output current with a current clamp. Does it exceed the UPS nominal
current?
YES: END. A overload is present. Check and/or reduce the load.
NO: go to step #2
2. Compare the measure with the reading on the UPSTest screen (or front panel). Are the
values shown equal to those measured?
YES: check the UPS settings on the I/S-CL (nominal power, nominal voltage)
NO: replace the board PB004 (INV-AV-3F) and re-adjust the output current reading
with the UPSTest software (see 3.1.2). Go to step #3
3. Repeat the step #2. Are the values shown equal to those measured?
YES: END. Check that the load doesn’t exceed the nominal load.
2.15 A15 – BYPASS FAULT

This alarm indicates that emergency line is not available. The measure of the by-pass
voltage is taken as follows :
UPS 3 Phase: the emergency line is connected to the UPS through the SBCB circuit breaker
to the VOLT-REF-3F CN1 which adapts the signals to the microprocessor and send them
through the connector CN4 to the I/S-CL CN13. These signals can be checked on the I/S CL in
the following points (picture 1 shows the waveform):
Microprocessor ground Æ Cathode of D65 Bypass R

Microprocessor ground Æ Cathode of D64 Bypass S
Microprocessor ground Æ Cathode of D59 Bypass T
The emergency line is checked as frequency (the frequency limits can be programmed
through the command TFFR; if the frequency is OK the variable FROK is active), as RMS value
(if the RMS value is OK the variable RMSOK is active) and instantaneous value.
Issued 13/04/07 JUD409401 11 of 26

Picture 1 – Signal on cathode of D65 (D64-D59)

YES: go to step #2
NO: check the UPS supply line
2. Check the bypass fuses. Are they OK?

YES: go to step #3
NO: replace the broken fuse(s)
3. Measure the by-pass input voltage and compare the measure with the reading on the
UPSTest screen (or front panel). Are the values shown equal to those measured?
YES: go to step #5
NO: replace the board PB005 (VOLT-REF-3F). Go to step #4
4. After replacing the VOLT-REF board, are the values shown equal to those measured?
YES: END
5. Is the variable RMSOK active on the UPSTest software?

YES: go to step #6
NO: check the phase sequence
6. Is the variable FROK active on the UPSTest program?

NO: go to step #7
7. Measure the by-pass input frequency. Is it within the tolerance limits?

NO: check and/or adjust the input frequency window
2.16 A16 – BYPASS FEED LOAD

This alarm indicates that the emergency line (by-pass) is feeding the load. Normally this
alarm occurs if the inverter is switched off (check for the alarm A13 – Inverter out of tolerance).
In this case the reason for the inverter failure must be investigated (refer to the procedure
described at 2.13.1).
Issued 13/04/07 JUD409401 12 of 26


1. Is the alarm A13 present?
NO: go to step #2
2. Is the alarm A22 present?

NO: go to step #3
3. Measure the UPS output voltage. Is it within the tolerance limits?

YES: go to step #4
NO: check the static switch thyristors
4. Compare the measure with the reading on the UPSTest screen (or front panel). Are the
values shown equal to those measured?
NO: replace the board PB005 (VOLT-REF-3F). Go to step #5
5. After replacing the VOLT-REF board, are the values shown equal to those measured?
YES: END
2.17 A17 – RETRANSFER BLOCKED

This alarm indicates that the load is blocked on the emergency line (by-pass) after 6
transfers to by-pass in 2 minutes. Normally it occurs when there are several heavy load steps
(like motors starting, printers and so on) in a very short time. In this case, as the current
exceeds two times the nominal value, the short circuit monitor (see alarm A25 – Short circuit)
transfers automatically the load to by-pass, and after a few seconds the inverter takes back the
load. If this situation happens six times in two minutes, the UPS protects itself by blocking the
load to by-pass and the alarm is activated. This condition can be reset by sending the command
RESE000 or by resetting the UPS from the special menu in the front panel.
1. Are there heavy load steps exceeding two times the nominal output current?
YES: check and/or reduce the load
NO: go to step #2
2. Open SBCB (by-pass line breaker), turn on the inverter only and check the output
voltage waveform (downstream the inverter static switch) on the three phases. Is it
sinusoidal?
YES: go to step #3
NO: replace the thyristor relevant to the phase where the waveform is wrong
3. With the inverter ON and SBCB open, measure the voltage upstream the by-pass
thyristors. Is it equal to zero?
NO: replace the thyristor relevant to the phase where the waveform is not zero (the
thyristor is in short circuit).
2.18 A18 – MANUAL BYPASS CLOSED

This alarm indicates that the manual bypass circuit breaker is closed. This signal comes from
the MBCB circuit breaker auxiliary contact to the I/S-CL M3 pins 13-14.
Issued 13/04/07 JUD409401 13 of 26

When MBCB is closed together with OCB the electronic protection turn off the inverter
generating the alarm A13.
1. Is the manual by-pass breaker MBCB closed?
YES: END
NO: go to step #2
2. Check the status of the pins 13-14 of M3 in the I/S-CL board. Is the contact open?
NO: replace the MBCB auxiliary contact
2.19 A19 – OCB OPEN

This alarm indicates that the UPS output circuit breaker is open. This signal comes from the
OCB circuit breaker auxiliary contact to the I/S-CL M3 pins 9-10.
1. Is the output breaker OCB open?
YES: END
NO: go to step #2
NO: replace the OCB auxiliary contact
2.20 A20 – FANS FAILURE

This alarm is not available in the HYPERION UPS line.
2.21 A21 – HIGH TEMPERATURE

This alarm indicates that the thermal switch on the bridge heatsink has stopped the inverter.
The thermal switch TH1 mounted on the inverter bridge heatsink is normally closed, as the
temperature exceeds 80°C the thermal switch opens. The signal comes directly from TH1 to the
I/S-CL M3 pins 15-16.
1. Is the temperature of the heatsink lower than 80°C?
YES: go to step #2
NO: go to step #3
NO: replace the faulty thermal switch
3. Are the cooling fans correctly working?

YES: check the load. Repeated overloads (alarms A14, A4) have caused the UPS
overheating
NO: replace the faulty fan(s)
2.22 A22 – BYPASS SWITCH

The UPS is equipped with a bypass switch that forces the load to bypass. If this switch is in
the Bypass position the alarm A22 is activated and the load is transferred to bypass (see alarm
Issued 13/04/07 JUD409401 14 of 26

A16 – Bypass feeds load). This signal comes directly from the switch SW1 to the I/S-CL M3 pins
11-12.
1. Is the switch in NORMAL position?
YES: go to step #2
NO: END; move it to NORMAL
NO: replace the switch SW1
2.23 A23 – EPO BUS

The UPS is equipped with two terminals (Eac1-Eac2) for connection of the remote
emergency shutdown push-button. If the remote push-button is pressed the supply to the loads
is interrupted by opening the output static switch, the alarm A23 is activated and there is no
voltage at the output of the UPS. This signal comes directly from the terminals Eac1-Eac2 to the
I/S-CL M3 pins 5-6.
1. Is the EPO push-button pressed?
YES: END. Check the reason why the button has been pressed; before pressing it
again check that no danger to persons or things will be caused by the UPS re-
start.
NO: go to step #2
NO: replace EPO push-button
2.24 A24 – CURRENT STOP

This alarm indicates that the maximum current monitor has detected a fault on the inverter
bridge. This protection works as follows: the hall effect transducer TA1 transmits the inverter
bridge current to the I/S-CL on the connector M1. If the current on the bridge exceeds the 250%
of the nominal current the current stop protection is activated and the inverter is switched off.
1. Check the IGBT’s by following the procedure described at 3.2.3, point 1 to 9. Is there
any IGBT or driver (boards DR-SAT) broken?
YES: replace the broken components, repeat the checks and re-start the unit.
NO: go to step #2
2. Check the status of the battery. If the battery life has almost expired and its voltage
drops quickly it might cause the current on the bridge to exceed the current stop
protection during short mains failures. Are the batteries OK?
YES: go to step #3
NO: replace the batteries
3. Check the IGBT’s turn-on signal (see picture 3). Is it OK?

NO: adjust it by turning the potentiometer P2 on the POWER SUPPLY board. Go to
step #4
Issued 13/04/07 JUD409401 15 of 26

4. Re-start the inverter. Does the alarm occur again?

YES: replace the POWER SUPPLY. Go to step #5
NO: END
5. Re-start the inverter. Does the alarm occur again?

NO: END
2.25 A25 – SHORT CIRCUIT

This alarm indicates that the short circuit monitor has detected a short at the output of the
inverter. This protection works as follows: the hall effect transducer TA1 transmits the inverter
bridge current to the I/S-CL on the connector M1. This signal is amplified on the test point TP2
and can be set at 4Vpeak at 100% load by turning the potentiometer P2. As this signal exceeds
two times the nominal output current, the current limitation starts to work and the alarm A25 is
activated. This happens if the emergency line is not available, otherwise the load is
automatically transferred to bypass. Normally the alarm A25 can be found in the alarm history,
as it is automatically reset as the short circuit is removed.
1. Are there heavy load steps exceeding two times the nominal output current?
YES: check and/or reduce the load
NO: go to step #2
2. Check the inverter input current waveform on test point TP2 (see picture 2). Is there
any spike or distortion?
YES: replace the inverter IGBT driver boards. Go to step #3
3. After replacing the IGBT driver boards, is the waveform on TP2 correct?
YES: END
NO: replace the POWER SUPPLY. Go to step #4
4. After replacing the POWER SUPPLY, is the waveform on TP2 correct?

YES: END
NO: replace the IGBT’s of the inverter bridge
Issued 13/04/07 JUD409401 16 of 26

3 PCB’S AND COMPONENTS SUBSTITUTION

This chapter describes in detail all the checks that have to be done after the substitution of
electronic boards or power components installed in the HYPERION UPS systems, giving all the
instructions to check the operation parameters or to change the UPS settings.
3.1 PCB’S SUBSTITUTION

3.1.1 PB003 – I/S-CL
1. Check the setting of DSW1 and DSW2 according to the following tables. Check that they
are in the same position of the old board.
• Setting of DSW1
Dip no. Stato Descrizione

Off Single UPS
1
On Parallel
Off Frequency 50Hz
2
On Frequency 60Hz
Off Single / Parallel
3
On Hot stand-by
4 On Nominal Vout
5 On 220V
4 Off Nominal Vout
5 On 120V
4 On Nominal Vout
5 Off 230V
4 Off Nominal Vout
5 Off 240V)
Off TEST mode
6
On NORMAL mode
Off Buzzer DISABLED
7
On Buzzer ENABLED
Off THREE-PHASE output
8
On
• Setting of DSW2
Dip no. Stato Descrizione

Off ASTRID protocol
1
On
Off BOOST CHARGE enabled
2
On BOOST CHARGE disabled
Off Automatic battery test
ENABLED (every 30 days)
3
On Automatic battery test
DISABLED
Off Battery test ENABLED
4
On Battery test DISABLED
5-6-7-8 Configure the power as follows
Issued 13/04/07 JUD409401 17 of 26

UPS
Dip 5 Dip 6 Dip 7 Dip 8
[kVA]
200 Off On Off Off

250 Off Off On On
300 Off Off On Off
2. Install the same software version (EPROM) that was installed in the old board.
3. Check the setting of the jumpers J1-J2-J3-J4-J5-J6-J7.
4. Check the setting of the resistors R39-R40-R18 (current control circuit), R66 (PWM
frequency) according to the following table.
UPS JUMPERS
R66 Freq PWM R Hall
(KVA) J9 J10 J100
200 6K81 + 6K81 4 KHz 47R Closed Open Closed
250 6K81 + 6K81 4 KHz 47R Closed Open Closed
300 6K81 + 6K81 4 KHz 33R* Open Closed Closed
* On the 300kVA the resistor R40 (100R) must be changed with 33R
5. Change the resistor R37 on the VCB boards (PB012); R37 = 27K4.
6. Measure the resistance between ground and TP2 (current protection) and set the same
value on the new board by means of the potentiometer P2. Take into account that the
peak value of the signal between ground and TP2, adjustable by means of the
potentiometer P2, must be equal to 4V with UPS supplying 100% of load. Check the
waveform of the signal (see picture 2), and adjust the peak value according to the
available load (load 100% Vp=4V, load 50% Vp=2V).
Picture 2 – Current signal on TP2 at 100% of load

7. Check that the jumper J1 is in position 2-3 (UPS 3 Phase).
8. Check that the jumper J2 on the PB012 (VCB) boards is closed (voltage correction
inserted) and that the jumper J1 is in position 1-2 (voltage loop closed).
9. Check the setting of the jumpers of the board PB014 (SCB) according to those of the old
board.
10. Close RCB and start-up completely the UPS.
Issued 13/04/07 JUD409401 18 of 26

11. Measure the output voltage and, if necessary, adjust it by means of the potentiometer P1
on the board PB012 (VCB).
12. Check that all the measure on the UPSTest screen, or on the front panel, correspond to
the values measured; on the contrary modify the value read on the screen with the
following commands:
TIFRxxx (inverter voltage setting phase R; xxx is the value measured)
TIFSxxx (inverter voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TIFTxxx (inverter voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TUFRxxx (output voltage setting phase R; xxx is the value measured).
TUFSxxx (output voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TUFTxxx (output voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TBFRxxx (by-pass voltage setting phase R; xxx is the value measured).
TBFSxxx (by-pass voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TBFTxxx (by-pass voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TCFRxxx (output current setting phase R; xxx is the value measured).
TCFSxxx (output current setting phase S; xxx is the value measured); only 3Ph UPS.
TCFTxxx (output current setting phase T; xxx is the value measured); only 3Ph UPS.
TVBAxxx (battery voltage setting; xxx is the value measured)
Store all the settings by sending the command MEEE000, or pressing F4.
13. Carry out some mains failure tests and commutations to by-pass.
14. Personalize the UPS with the following commands:
TYBAxxx (nominal capacity of the battery; xxx is the value of the nominal capacity)
TAUTxxx (battery autonomy; xxx is the time in minutes)
PHASxxx (set the phase shifting between inverter and the bypass, refer to the
following table)
UPS type COMMAND Parameter

Single 50 Hz PHAS270 PHASE=2700
Single 60 Hz PHAS300 PHASE=3000
Parallel 50 Hz PHAS400 PHASE=4000
Parallel 60 Hz PHAS450 PHASE=4500
BATCxxx (First three digits of the serial number)

NUMBxxx (Last three digits of the serial number)
Store all the settings by sending the command MEEE000, or pressing F4.
15. Check the setting of the date and time on the front panel
16. Reset the history log.
3.1.2 PB004 – INV-AV-3F
1. Measure the inverter output voltage on the three phases, connecting the multimeter
between the neutral and the inverter static switch (upstream).
If the values shown don’t correspond to those measured, modify the reading with the
following commands (UPSTest software):
TIFRxxx (inverter voltage setting phase R; xxx is the value measured)
TIFSxxx (inverter voltage setting phase S; xxx is the value measured)
TIFTxxx (inverter voltage setting phase T; xxx is the value measured)
Store the settings by pressing F4.
2. Measure the output current on the three phases; If the values shown don’t correspond to
those measured, modify the reading with the following commands (UPSTest software):
TCFRxxx (output current setting phase R; xxx is the value measured)
TCFSxxx (output current setting phase S; xxx is the value measured)
TCFTxxx (output current setting phase T; xxx is the value measured)
Issued 13/04/07 JUD409401 19 of 26

3.1.3 PB005 – VOLT-REF-3F

1. Measure the by-pass voltage on the three phases, connecting the multimeter between
the neutral and the by-pass static switch (upstream).
If the values shown don’t correspond to those measured, modify the reading with the
TBFRxxx (by-pass voltage setting phase R; xxx is the value measured)
TBFSxxx (by-pass voltage setting phase S; xxx is the value measured)
TBFTxxx (by-pass voltage setting phase T; xxx is the value measured)
2. Measure the output voltage on the three phases; If the values shown don’t correspond to
those measured, modify the reading with the following commands (UPSTest software):
TUFRxxx (output voltage setting phase R; xxx is the value measured)
TUFSxxx (output voltage setting phase S; xxx is the value measured)
TUFTxxx (output voltage setting phase T; xxx is the value measured)
3.1.4 PB107 – PS-SAT
1. On the μProcessor board PB003 (I/S-CL) move the DIP6 SW1 in position OFF.
2. Select the “manual” regulation mode on the μProcessor board, moving the jumper J1 on
the boards PB012 (VCB) in position 2-3.
3. Disconnect the flat cable W9 from the connector CN4 of the board PB003 (I/S-CL).
4. Connect an external 10-wire flat cable between the connector CN4 of the board PB107
(PS-SAT) and the connector CN4 of the board PB003 (I/S-CL).
5. Disconnect the connector CNB and connect the external power supply.
6. Connect a PC to the serial port RS232, run the UPSTest software and press F6 to start
the IGBT bridge modulation (the inverter will start only if the variable VDC_OK is active).
7. Check the signal between Gate and Source of the IGBT’s according to the following
picture:
Picture 3 – IGBT turn-on signal

If necessary modify the amplitude of the positive part of the waveform until it reaches 16V,
turning the potentiometer P2.
8. Turn-off the inverter pressing F7 and disconnect the external power supply.
9. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of the
board PB003 (I/S-CL).
Issued 13/04/07 JUD409401 20 of 26

10. Select the “Automatic” operating mode on the μProcessor board, moving the jumper J1 on
the board PB012 (VCB) in position 1-2. Move the DIP6 SW1 in position ON on the
μProcessor board.
11. Re-connect the connector CNB on the power supply board.
3.1.5 PB223 – INT-R
1. Check the setting of the jumpers JP1-JP2-JP3.
2. Set the rectifier in TEST mode (see 4.1.2).
3. Move the external ON/OFF switch in position ON.
4. Verify the correct sequence of the pre-charge phase; thyristors PS7-PS8 first (LED’s DL1-
2-3-4 of the card PB023-RTF lit steady), and then complete turn-on of the thyristor bridge
(thyristors PS7-PS8-PS9, LED’s DL1-2-3-4-5-6 of the card PB023-RTF lit steady).
5. Verify that the red LED’s of the boards PB246 (ID-HY, IGBT drivers) are lit steady. In this
condition the duty cycle of the PWM is fixed at 50%.
6. Verify the voltage waveform between emitter (E) and gate (G) of the IGBT’s (see picture
3). If necessary modify the amplitude of the positive part of the waveform until it reaches
16V, turning the potentiometer RV1 on the board PB223 (INT-R).
7. Move the external ON/OFF switch in position OFF.
8. Disconnect the external AC supply cable from the connector M8 of the board PB223 (INT-
R).
9. Re-connect the AC supply cable W51 to the connector M8.
10. Remove the jumper from the pins 11-12 of the connector M15 (TEST mode disabled).
11. Remove the external ON/OFF switch.
12. Close RCB and wait for the complete start-up of the UPS.
13. Connect the software “WRC monitor” and verify that the measures shown are equal to the
actual value, measured with a multimeter and a current clamp.
14. If the values shown don’t correspond to those measured, modify the reading starting the
software “EEPROM Manager” and pressing the button Fine scaling.
3.1.6 PB228 – PS-MIS
1. On the μProcessor board PB003 (I/S-CL) move the DIP6 SW1 in position OFF (TEST
mode).
2. Close RCB and switch on the rectifier.
3. Measure the DC voltage and compare the measure with the value shown on the UPSTest
software (or on the display).
4. If the value shown don’t correspond to that measured, modify the reading with the
TVBAxxx (DC voltage setting; xxx is the value measured)
3.1.7 PB249 – D-CPU-RC
2. Connect the software “EEPROM Manager”, set the rectifier’s nominal parameters and
program the setting by pressing the button Program.
3. Disconnect the external AC supply cable from the connector M8 of the board PB223 (INT-
R).
6. Remove the external ON/OFF switch.
7. Close RCB and wait for the complete start-up of the UPS.
8. Connect the software “WRC monitor” and verify that the measures shown are equal to the
actual value, measured with a multimeter and a current clamp.
9. If the values shown don’t correspond to those measured, modify the reading starting the
software “EEPROM Manager” and pressing the button Fine scaling.
Issued 13/04/07 JUD409401 21 of 26

3.2 COMPONENTS SUBSTITUTION

3.2.1 RECTIFIER IGBT’S
1. Change the IGBT driver board(s) and check the connection with the IGBT(s).
3. Move the external ON/OFF switch in position ON.
4. Verify the correct sequence of the pre-charge phase; thyristors PS7-PS8 first (LED’s
DL1-2-3-4 of the card PB023-RTF lit steady), and then complete turn-on of the thyristor
bridge (thyristors PS7-PS8-PS9, LED’s DL1-2-3-4-5-6 of the card PB023-RTF lit steady).
5. Verify that the red LED’s of the boards PB246 (ID-HY, IGBT drivers) are lit steady. In this
condition the duty cycle of the PWM is fixed at 50%.
6. Verify the voltage waveform between emitter (E) and gate (G) of the IGBT’s (see picture
3). If necessary modify the amplitude of the positive part of the waveform until it reaches
16V, turning the potentiometer RV1 on the board PB223 (INT-R).
8. Disconnect the external AC supply cable from the connector M8 of the board PB223
(INT-R).
11. Disconnect the connector CNB from the inverter power supply board PB107 (PS-SAT).
12. Close RCB and move the external ON/OFF switch in position ON.
13. Verify the correct sequence of the pre-charge phase (see point 4 above).
14. Measure the DC voltage across the bulk capacitors and verify the value is equal to:
Vdc = Vac x 1,35 (with 400Vac the DC voltage is about 550V).
15. Verify that the IGBT’s are turned on and that the DC voltage increases up to the nominal
value.
17. Open RCB and remove the external ON/OFF switch.
18. Re-connect the connector CNB to the inverter power supply board PB107 (PS-SAT).
19. Close RCB, start-up the UPS and check the rectifier operation under load.
3.2.2 RECTIFIER BRIDGE THYRISTORS (PRE-CHARGE)
1. Re-connect carefully the component to the firing board.
2. Connect the external ON/OFF switch to the connector M10 of the board PB223 (INT-R)
and make sure the contact of the switch is open.
3. Close RCB and move the external ON/OFF switch in position ON.
4. Verify the correct sequence of the pre-charge phase (see 3.2.1, point 4).
5. Measure the DC voltage across the bulk capacitors and verify the value is equal to:
Vdc = Vac x 1,35 (with 400Vac the DC voltage is about 550V).
7. Open RCB and remove the external ON/OFF switch.
3.2.3 INVERTER BRIDGE IGBT’S
1. Change the IGBT driver board(s) and check the connection with the IGBT(s).
2. On the μProcessor board (PB003 – I/S-CL) move the DIP6 SW1 in OFF position (TEST
mode).
3. On the VCB boards move the jumper J1 in position 2-3 (manual).
4. Disconnect the flat cable W9 from the connector CN4 of the board PB003 (I/S-CL) and
connect an external 10-wire flat cable between it and the connector CN4 of the POWER
SUPPLY board.
5. Connect the external power supply to the Power Supply board, connect a PC to the UPS
and run the UPSTest software.
6. With the external power supply the DC voltage is outside the nominal range, so the
variable VDC_OK is not active (blue). The variable can be activated changing the DC
Issued 13/04/07 JUD409401 22 of 26

voltage measure to floating voltage (within the range) sending the command TVBAxxx
where xxx is the floating voltage (TVBA680).
7. Turn on the inverter sending the command INON000, or pressing F6.
8. Check that all the red LED’s on the driver boards are on and verify the voltage waveform
between emitter (E) and gate (G) of the IGBT’s (see picture 3). If necessary modify the
amplitude of the positive part of the waveform until it reaches 16V, turning the
potentiometer P2 on the board PB107 (PS-SAT).
9. Turn off the inverter sending the command INOF000, or pressing F7.
10. Close RCB, start-up the inverter by sending the command INON000, or pressing F6, and
increase the modulation by means of the potentiometer P1 on the microprocessor board.
Check that the output waveform increases regularly up to the nominal value.
11. Reduce the modulation to zero by turning back the potentiometer, send the command
INOF000, or press F7, to turn off the inverter and open RCB.
12. Disconnect the external power supply and re-connect the connector CNB to the POWER
SUPPLY board.
13. On the μProcessor board (PB003 – I/S-CL) move the DIP6 SW1 in ON position
(automatic mode).
14. On the VCB boards move the jumper J1 in position 1-2 (automatic).
15. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
16. Close RCB, start-up the UPS and check the inverter operation under load.
3.2.4 STATIC SWITCH THYRISTORS
1. Re-connect carefully the component to the firing board.
2. Check that the output waveform, relevant to the phase controlled by the thyristors that
has been substituted, is correct. Repeat this check with the load connected.
4 ON-FIELD TEST PROCEDURES

This chapter describes the most common operating procedures used to test the various
sections of the UPS during repairing or maintenance operations.
These procedures assumes that all the power components (fuses, thyristors, cables, etc.)
are OK, no modifications have been made in the power and auxiliary circuitry and that the unit is
switched off or in manual by-pass (all the control circuits are off).
4.1 RECTIFIER
4.1.1 General notes on the TEST mode
Owing to the use of two different microprocessors inside the UPS, there exist two different
TEST modalities: one for the rectifier and one for the inverter, which is described at 4.2.1.
The TEST mode on the rectifier is enabled by closing the pins 11-12 of the connector M15 of
the board PB223 (INT-R). The condition of the contact is acquired by the microprocessor at the
start-up and only if the DC voltage is lower than 50Vdc (no AC voltage present).
The TEST mode set the duty cycle of the IGBT’s PWM at 50% and is used to check the
IGBT’s turn-on signals before the rectifier start-up.
4.1.2 Setting the rectifier in TEST mode
The operation described below are carried out on the board PB223 (INT-R).
1. Disconnect the cable W51 from the connector M8.
2. Connect a jumper between pins 11-12 of the connector M15.
3. Disconnect the jumper from the connector M10.
4. Connect the external ON/OFF switch to the connector M10 and make sure the contact of
the switch is open.
5. Connect the external 3Ph AC supply to the connector M8.
Issued 13/04/07 JUD409401 23 of 26

Now the board INT-R is supplied and the microprocessor will acquire the TEST mode
condition.
4.2 INVERTER
4.2.1 General notes on the TEST mode
The TEST mode is a operating condition where the inverter doesn’t start-up automatically but
waits for the commands sent by the operator through the UPSTest software. In this condition
some alarms are hidden and the UPS can be tested completely. When the UPS is in manual by-
pass for example, only the TEST mode allows the operator to check the UPS operation. The
TEST mode can be set by moving the DIP6 SW1 in position OFF in the I/S-CL board. The
microprocessor acquires the position of the dip-switch only after it has been reset (switching off
the UPS or by pressing the push-button SW3 in the I/S-CL).
4.2.2 Blank test of the I/S-CL board
The procedure that follows is part of the factory test procedure, related to the preliminary
checks carried out on the microprocessor board I/S-CL before proceeding with the inverter start-
up. It’s useful when, after an inverter failure, the operator wants to be sure that no damage have
occurred in the control section.
1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the I/S-CL
board.
2. Select the “manual” voltage regulation, moving the jumper J1 on the VCB boards in
position 2-3. This setting disable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the I/S-CL board.
3. Disconnect the flat cable W9 from the connector CN4 of the board PB003 (I/S-CL) and
connect an external 10-wire flat cable between it and the connector CN4 of the POWER
SUPPLY board. This external connection is necessary for the microprocessor to acquire
the DC voltage reading.
4. On the POWER SUPPLY board disconnect the connector CNB and connect the external
power supply. The microprocessor is now supplied and after some seconds the front
panel will show all the alarms present at that moment.
5. Connect the oscilloscope probe between analog ground and pin 6 of U17 and check the
presence of a signal as in picture 4:
Picture 4 – Triangle (switching frequency)
Issued 13/04/07 JUD409401 24 of 26

This waveform is compared with the reference sine-wave generated by the microprocessor
to create the IGBT’s PWM signals.
In the following steps the sine-wave generated by the microprocessor and the IGBT’s turn-on
signals will be checked. The inverter can be turned-on only if all the software conditions are
fulfilled, so it’s necessary to change the DC voltage reading (now coming from the external
power supply) to enable the variable VDC_OK.
6. Change the DC voltage reading sending the command TVBAxxx, where xxx is the
floating voltage, and check that the command is acquired by the microprocessor and that
the variable VDC_OK is activated.
7. Turn-on the IGBT modulation by sending the command INON000 or pressing F6.
8. Place the oscilloscope probe between the analog ground and pin 7 of U2 (VCB boards),
rotate P1 of the I/S-CL board («) and check that the amplitude of the generated sine-
wave increases, and then turn back P1 until the sine-wave is at zero again (¬).
9. Check that the red LED’s on the IGBT driver boards are correctly lit.
10. Verify the turn-on signal between emitter (E) and gate (G) of the IGBT’s (see picture 3).
11. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7.
12. Disconnect the external power supply.
13. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
After the disconnection of the external power supply the microprocessor is reset and the DC
voltage setting, which has been modified before, is cleared, therefore the unit will show the
exact DC voltage value at the following start-up.
4.2.3 Inverter manual start-up
This procedures assumes that all the power components in the inverter bridge have been
previously checked (see paragraph 4.2.2). The inverter output voltage is increased starting from
zero to check the behaviour of the components (AC capacitors, fans, etc.) at reduced AC
voltage after having identified a failure in the inverter section.
board.
2. Select the “manual” voltage regulation, moving the jumper J1 on the VCB boards in
position 2-3. This setting disable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the I/S-CL board.
3. Close RCB and supply the unit. After some seconds the front panel will show all the
alarms present at that moment.
5. Verify that, after some seconds, the inverter static switch closes by checking the green
LED’s in the firing boards 2SCR FIR.
6. Rotate P1 of the I/S-CL board («) and increase the inverter output voltage. Check that
the sine waves are present downstream the inverter static switch and that the shape is
correct.
7. Place the oscilloscope probe between the analog ground and the test point TP2 and
check that the shape of the inverter bridge current is correct (see picture 2).
8. Rotate P1 of the I/S-CL board (¬) to set the modulation signal to zero.
10. Open RCB and switch off the unit.
4.2.4 Inverter automatic start-up
This procedures follows the previous one and it’s used to check the correct operation of the
inverter with the voltage loop closed.
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board.
2. Select the “automatic” voltage regulation, moving the jumper J1 on the VCB boards in
position 1-2. This setting enable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the VCB board.
3. Close RCB and supply the unit. After some seconds the front panel will show all the
alarms present at that moment.
5. Verify that the inverter output voltage increases up to the nominal value. If necessary
adjust it by rotating (¬) the potentiometer P1 of the VCB board.
6. Verify that, after some seconds, the inverter static switch closes by checking the green
7. Place the oscilloscope probe between the analog ground and the test point TP2 and
check that the shape of the inverter bridge current is correct (see picture 2).
9. Open RCB and switch off the unit.
4.3 STATIC SWITCH

4.3.1 Check of the redundant supply
The VOLT-REF board provides a redundant supply for the static switch control logic, so that
the by-pass static switch is supplied even when the microprocessor is off (POWER SUPPLY
board not supplied).
1. Close the by-pass circuit breaker SBCB and check that the LED L1 in the SCB board is
correctly lit (green).
2. Verify that, after some seconds, the by-pass static switch closes by checking the red
4.3.2 Commutation tests
The commutation tests are useful to check the correct operation of the static switch.
1. Start-up the inverter in automatic mode (see procedure at 4.2.4) and verify that the
inverter static switch closes.
2. Close SBCB, wait for the status S6 – BYPASS OK is activated.
3. Measure with a multimeter the voltage difference between the by-pass input and the
inverter output and verify that it doesn’t exceed 20Vac. The inverter is now synchronised
with the by-pass.
4. Move the NORMAL-BYPASS switch SW1 in by-pass position and verify that the load is
transferred to the by-pass static switch. Then move it back and verify that the load is
supplied again by the inverter.
5. Repeat the previous steps and verify that at the sixth time the load remains supplied by
the by-pass and the alarm A17 – Retransfer blocked is activated.
6. Reset the blocking condition by sending the command RESE000 or entering the special
menu in the front panel.
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UPS Test Software
UPS TEST SOFTWARE
Index
1. INTRODUCTION.................................................................................. 3
2. TEST AND MONITORING SOFTWARE ............................................. 3

2.1 SOFTWARE INSTALLATION...........................................................................4
2.2 SERIAL PORT CONFIGURATION ...................................................................4
2.3 UPS TEST PANEL............................................................................................5
2.3.1 MEASURES...............................................................................................6
2.3.2 UPS DATA.................................................................................................6
2.3.3 VARIABLES ..............................................................................................7
2.3.4 OUTPUTS ..................................................................................................7
2.3.5 INPUTS ......................................................................................................7
2.3.6 ALARMS AND STATUS............................................................................8
2.3.7 ACTIVE KEYS ...........................................................................................8
2.3.8 GAUGES ...................................................................................................8
2.3.9 CONTROLS ...............................................................................................8
2.3.10 PARALLEL ............................................................................................8
BOOST OPERATION .............................................................................................8
2.4 SERIAL MESSAGES FOR PERSONALISATION AND SETTING...................9
2.4.1 BYPASS ..................................................................................................10
2.4.2 OUTPUT ..................................................................................................10
2.4.3 INVERTER ...............................................................................................10
2.4.4 BATTERY ................................................................................................10
2.4.5 BATTERY TEST ......................................................................................10

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UPS Test Software
2.4.6 BOOST CHARGE ................................................................................... 10
2.4.7 GENERAL COMMANDS ........................................................................ 11
2.4.8 IDENTIFICATION.................................................................................... 11
2.4.9 TIMER SETTING..................................................................................... 12
2.5 HYSTORY OF ALARMS................................................................................ 12
2.6 SHORTCUT KEYS......................................................................................... 12
Index of pictures
Picture 1 – RS232 connection cable ............................................................................................................ 3
Picture 2 – Communication configure panel................................................................................................. 4
Picture 3 – Modem setup.............................................................................................................................. 5
Picture 4 – UPS Test screen ........................................................................................................................ 5
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UPS Test Software
1. INTRODUCTION
The monitoring and test software of the UPS, UPS-Test allows, by means of RS232
connection, to control all the measures and status of the equipment and to carry out settings
and modifications of the UPS configuration.
2. TEST AND MONITORING SOFTWARE

The UPS-Test software is connected through the RS232 serial port of the PC to the RS232
serial of the UPS. The RS232 connection cable is built according to the picture 1.
Picture 1 – RS232 connection cable
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UPS Test Software
2.1 SOFTWARE INSTALLATION

The installation of the software is carried out like a standard WINDOWS application. The
software can be supplied on several floppy disks, in this case proceed to install the program
starting from DISK 1, or by means of a CD-ROM. From the menu, start the Set-up program and
carry out the instructions required by the installation software.
2.2 SERIAL PORT CONFIGURATION

From the menu configure it is possible to configure the serial port RS232 for the connection
to the UPS.
Picture 2 – Communication configure panel

Port adress: Set the serial COM where the UPS is connected.
Baud rate: Set the speed of the serial communication. Set to 2400 baud.
Stop bits: Select “1”.
Data bits: Select “8”.
Parity: Select “None”.
Flow Control: Select “None”.
Connection: Select “Local” to connect the PC to the UPS. Select “Remote” to connect the
PC to the UPS trought a mode connection.
Syncro_Key: Select “No”.
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UPS Test Software
From the “Modem” button it is possible to set the parameter for remote connection.
Picture 3 – Modem setup

Init. string: Set the initialization string for the modem.
Dial string: Set the command string for the modem to dial the UPS.
Hang upp string: Set the command string for the modem to close the connection.
2.3 UPS TEST PANEL

All the following paragraphs, describing the software functions, refer to the picture 4, where
the UPS Test screen is shown.
Picture 4 – UPS Test screen
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UPS Test Software
2.3.1 MEASURES
On the area “Measures” all the analog measurements inherent to the UPS are shown, in the
following order:
BYP_V_R Æ Emergency bypass voltage Ph. R (V)

BYP_V_S Æ Emergency bypass voltage Ph. S (V)
BYP_V_T Æ Emergency bypass voltage Ph. T (V)
OUT_V_R Æ UPS output voltage Ph. R (V)

OUT_V_S Æ UPS output voltage Ph. S (V)
OUT_V_T Æ UPS output voltage Ph. T (V)
INV_V_R Æ Inverter voltage Ph. R (V)

INV_V_S Æ Inverter voltage Ph. S (V)
INV_V_T Æ Inverter voltage Ph. T (V)
ACDC_V Æ Battery voltage (V)
DC_CUR Æ Inverter Input current (A)
IB_BOO Æ Battery Recharging Current ( A )
F_BYP Æ Emergency bypass frequency (Hz)
F_INV Æ Inverter frequency (Hz).
In the area below, the field “NUMBER” represents the serial n° of the equipment and the
field “VER. SW.” represents the revision of the UPS control software installed.
On the area “TX Check” the transmission control indicator is represented. If the connection
is correct the figures increases cyclically up to 250 automatically.
2.3.2 UPS DATA
The area titled “UPS data” represents the relevant characteristics and settings. The first 7
lines contain the nominal values for:
POT_NOM Æ UPS nominal power (kVA).

VOLT_NOM Æ UPS nominal output voltage (V).
CURR_NOM Æ UPS nominal output current (A).
VDC_NOM Æ Battery nominal voltage (V).
IDC_NOM Æ Inverter nominal input current at full load (A).
BAT_TYP Æ Battery capacity (Ah).
AUT_NOM Æ Nominal autonomy (min).
The following 4 groups represent the limit values (for the voltage to be declared available)
and the histeresys for:
BYP Æ Emergency bypass (V) #1

INV Æ Inverter Output (V) #2
OUT Æ UPS Output (V) #3
VDC Æ Inverter input (V) #4
The following 3 groups represent the limit values (for the frequency to be declared in
tolerance) and the histeresys for emergency bypass as follows:
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UPS Test Software
FREQ Æ Emergency bypass nominal frequency (Hz)

FREQ MIN Æ Emergency bypass lower frequency (Hz)
FREQ MAX Æ Emergency bypass higher frequency (Hz) #5
The last 2 lines contain the following information:
AUT. MIN Æ Residual Battery autonomy (min)

AUT. % Æ Residual Battery autonomy (as % of the nominal).
2.3.3 VARIABLES
The area titled “Variables” represents the relevant internal status variables of the UPS. The
meaning of each variable is described below:
INV_ON Æ When active the command inverter on is active too

SSW_ON Æ When active the command inverter SSW on is active too
IOK Æ If active the inverter is ready to supply the load
ROK_X Æ If active the bypass is in tolerance (ROK = RMSOK+FROK)
O_LOAD Æ If active an overload has stopped the inverter
HITE Æ If active an over temperature (thermal protection) is active too
FROK Æ If active the emerg. byp. frequency is in tolerance (see limit group #5)
RMS_OK Æ If active the emerg. byp. voltage is in tolerance (see limit group #1)
COK Æ If active the UPS output voltage is in tolerance (see limit group #3)
VUOK Æ If active the Inverter output voltage is in tolerance (see limit group #2)
SYNCOK Æ If active the inverter is synchronized with the emergency bypass
I_OVER Æ If active an overload (output current > nominal) is active too
IMTERM Æ If active the thermal image counter (time vs current) is active too
VDC_OK Æ If active the Inverter input voltage is in tolerance (see limit group #4)
2.3.4 OUTPUTS
The area titled “Outpus” represents the relevant digital outpus of the UPS. The meaning of
each variable is described below:
COK Æ If active the UPS output voltage is in tolerance (see limit group #3)
BY_BL Æ When active the load is blocked on the emergency bypass
IFL Æ When active the inverter SSW is closed
CONAC Æ When active the PWM of the inverter IGBT bridge is on
RESET_RITR_BL Æ When active the BY_BL condition is reset
R3_INV_FEED Æ When active relay Inv. Feeds Load is active too (ARC card)
R4_BYP_FEED Æ When active relay Bypass Feed Load is active too (ARC card)
R5_LOW_BATT Æ When active relay Low Battery is active too (ARC card)
R6_MAINS_FAU Æ When active relay Mains Fault is active too (ARC card)
2.3.5 INPUTS
The area titled “Inputs” represents the relevant digital inputs of the UPS. The meaning of
each variable is below described:
MBY_CLOSE Æ When active the MBCB (manual bypass) is closed

EPO_BUS Æ When active the EPO (emergency power off) is not active
BO_BUS Æ When active the BCB (battery breaker) is open
BYP_SW (FUSE) Æ When active the Bypass Switch (commutation test) is active
TERMO_SW Æ When active the Thermal switch (bridge protection) is active
OCB Æ When active the OCB (output breaker) is closed
MCS Æ When active the IGBT’s desaturation protection is active
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UPS Test Software
MRR Æ When active Mains fault signal (from the rectifier) is not active
RECT_FAIL Æ When active Rectifier fault sign. (from the rectifier) is not active
ERR_SC Æ When active Input wrong seq. sign. (from the rectifier) is not active
BF_RECT Æ When active Blown fuse sign. (from the rectifier) is active
PUL_UP Æ When active the up arrow key on the front panel is pressed
PUL_DOWN Æ When active the down arrow key on the front panel is pressed
PUL_ENTER Æ When active the enter key on the front panel is pressed
PUL_ BUZZ Æ When active the buzzer key on the front panel is pressed
PUL_RESET Æ When active the reset key on the front panel is pressed
2.3.6 ALARMS AND STATUS
On the areas named “Alarms” and “Status”, the 25 alarms and 6 operating status are
represented. For a detailed explanation of them, see the Operating Manual.
2.3.7 ACTIVE KEYS
The push button “Dip Sw” visualizes the mapping of the dip switches for configuration on
the μP board (see foregoing paragraphs).
By clicking on the relevant country on the flags area the language on the display of the UPS
can be changed.
2.3.8 GAUGES
The two gauges located under the third column represents the following values:
EN. CAR Æ Stored energy in the battery as % of the total

ACCUMU Æ Thermal image progress as % of the total (100 % Æ inverter stopped)
2.3.9 CONTROLS
The area above the flags contains the following control parameters:
FEFO Æ Must be 180

KF_BY Æ Must be between 800 and 900
KF_OU Æ Must be between 800 and 900
2.3.10 PARALLEL
If the UPS is working in parallel mode the relevant area “MASTER” under the second
column and the active key “Par. Data” are active. For the description of the relevant functions
refers to the Parallel Redundant Operating Manual.
BOOST OPERATION
If the Boost function is active, the push button “BOOST“ visualizes the parameter of the
Boost Operation
IB_TR Æ Battery current limit for Floating to Boost Charge ( A )

IB_RT Æ Battery current limit for Boost to Float Charge ( A )
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UPS Test Software
2.4 SERIAL MESSAGES FOR PERSONALISATION AND SETTING

WARNING
Before sending any message insure that the computer writes with capital letters (CAPS). All
commands consist in 4 letters and 3 numbers LLLLXXX.
After having sent a message, wait for an acoustic confirmation signal (BEEP) before sending
new strings. If the signal does not arrive it means that the operation has had a negative result,
so the last message must be repeated.
VERY IMPORTANT
The usage of these messages is recommended to specialized personnel only.
Don’t forget to send the command MEEE000 to store the variations on the UPS memory.
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UPS Test Software
2.4.1 BYPASS
TBFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TBFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TBFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.2 OUTPUT
TUFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TUFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TUFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
ZCFR000 phase R zero current (for UPS 1Ph and 3Ph)

ZCFS000 phase S zero current (only for UPS 3Ph)
ZCFT000 phase T zero current (only for UPS 3Ph)
TCFRXXX (XXX=005/999) phase R current (for UPS 1Ph and 3Ph)

TCFSXXX (XXX=005/999) phase S current (only for UPS 3Ph)
TCFTXXX (XXX=005/999) phase T current (only for UPS 3Ph)
2.4.3 INVERTER
ZIFR000 phase R zero voltage (for UPS 1Ph and 3Ph)
ZIFS000 phase S zero voltage (only for UPS 3Ph)
ZIFT000 phase T zero voltage (only for UPS 3Ph)
TIFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)

TIFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TIFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.4 BATTERY
TVBAXXX (XXX=100/600) Voltage
TCBAXXX (XXX=010/999) Current
TYBAXXX Battery type (i.e.: batt. 24Ah = TYBA024)
TAUTXXX (XXX=002/999) Nominal auton. (i.e.: aut. 20’ = TAUT020)
LOBA XXX (XXX=100/600) Low battery level
BATT000 Forces to the 100% battery autonomy

ZCBA000 zero current
2.4.5 BATTERY TEST
TEBAXXX (XXX=000/002) battery test choice
STDBXXX (XXX=000/999) battery test length setting
TBOF000 battery test stop
TBONXXX (XXX=000/999) battery test for XXX minutes
2.4.6 BOOST CHARGE

TCRBXXX (XXX=010/999) battery current for boost adjustment
TBTRXXX (XXX=000/999) current limit for floating to boost
TBRTYYY (XXX=000/999) current limit for boost to floating
BOST000 boost charge ON
ZCRB000 zero battery current for boost charge
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UPS Test Software
2.4.7 GENERAL COMMANDS

TFFRXXX (XXX=010/060) frequency window: for values see (1)
TVLX000 fast voltage monitor
MEEE000 Store the value in E2PROM
REHI000 reset HISTORY
BUZZ000 BUZZER quieting
RESE000 reset UPS
INON000 on inverter
INOF000 off inverter
PHASXXX (XXX=000/999) set the phase shifting between inverter and
the bypass normal setting.
Single unit
PHAS270 set phase = 2700
Parallel unit
PHAS400 set phase = 4000
2.4.8 IDENTIFICATION
CNAMXXX (XXX=000/005) Set the name of the unit
CLANXXX (XXX=000/005) UPS language
XXX = 000 (Italian)

XXX = 001 (German)
XXX = 002 (French)
XXX = 003 (English)
XXX = 004 (Portuguese)
XXX = 005 (Spanish)
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UPS Test Software
2.4.9 TIMER SETTING

TMINXXX (XXX = 000/059) minutes setting
THOUXXX (XXX = 000/023) hour setting
TDAYXXX (XXX = 000/031) day setting
TMONXXX (XXX = 000/012) month setting
TYEAXXX (XXX = 000/099) year setting
(*) Values not to be modified.
(1) TFFR +
060 +/- 6%
055 +/- 5,5%
050 +/- 5%
045 +/- 4,5%
040 +/- 4% standard setting
035 +/- 3,5%
030 +/- 3%
025 +/- 2,5%
020 +/- 2%
015 +/- 1,5%
010 +/- 1%
2.5 HYSTORY OF ALARMS

It is possible to download the alarm history on the computer by typing the following
command:
READ XXX XXX = 000 last 100 events

XXX = 001 previous 100 events
XXX = 002 previous 100 events
..........
XXX = 008 first 100 events
During the download the TX CHECK counter on the computer starts to count from 0 to 1800.
To read the history on the computer the F1 key can be pressed.
2.6 SHORTCUT KEYS

Key Description
F1 After the READ000 command allows to read the history on the computer.
F2 Sends RESE000 command.
F3 Sends all the zeroes to the UPS.
F4 Sends E2PROM data storing command : MEEE000.
F5 Sends the buzzer quieting command : BUZZ000.
F6 Sends the inverter ON command : INON000.
F7 Sends the inverter OFF command : INOF000.
F8 Adjusts the limits for the bypass and the output voltage : TVLX000.
F9 Adjusts the limits for the frequency at +/- 4% : TFFR040.
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“WRC Monitor” Software Manual
“WRC MONITOR” SOFTWARE MANUAL
Index
1 INTRODUCTION................................................................................. 3
2 SYSTEM REQUIREMENTS ............................................................... 3
3 INSTALLATION OF THE SOFTWARE .............................................. 4
4 COLLEGAMENTO DEL PC ALL’UPS ............................................... 6
4.1 INSTALLATION OF THE USB DRIVERS ........................................................6
5 WRC MONITOR.................................................................................. 7
5.1 TOOLBAR ........................................................................................................7
5.1.1 COM settings ............................................................................................8
5.1.2 Language setting .....................................................................................8
5.2 FRAME “ALARMS”..........................................................................................9
5.3 FRAME “STATUS”...........................................................................................9
5.4 FRAME “AC MEASURES” ............................................................................10
5.5 FRAME “DC MEASURES” ............................................................................10
5.6 FRAME “TEMPERATURE”............................................................................10
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Index of the pictures

Picture 1 – Start of the installation................................................................................................................ 4
Picture 2 – End of the installation ................................................................................................................. 5
Picture 3 – PB213-SLOT-SER ..................................................................................................................... 6
Picture 4 – PB185 CN7................................................................................................................................. 6
Picture 5 – Main window............................................................................................................................... 7
Picture 6 – Toolbar ....................................................................................................................................... 7
Picture 7 – COM setting................................................................................................................................ 8
Picture 8 – Language setting........................................................................................................................ 8
Picture 9 – Frame “Alarms” .......................................................................................................................... 9
Picture 10 – Frame “Status” ......................................................................................................................... 9
Picture 11 – Frame “AC Measures”............................................................................................................ 10
Picture 12 – Frame “DC Measures”............................................................................................................ 10
Picture 13 – Frame “Temperature” ............................................................................................................. 10
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1 INTRODUCTION
“WRC Monitor” is the PC software for the monitoring of the UPS of the “B9000” and
“Tethys” series.
It allows the display of the status and the alarms of the unit, the AC measures
(voltage, current and mains frequency) and the DC measures (battery voltage and
current).
2 SYSTEM REQUIREMENTS
Minimum system requirements:
- Pc Pentium 1000Mhz or compatible.

- Monitor 15”
- Graphic resolution 1024x768
- CD-Rom 2x
- Windows 98 / Me / NT / Xp
- Serial port RS232 or USB
Recommended hardware:
- Pc Pentium 1500Mhz or compatible (or better).

- Monitor 17” (or better)
- Graphic resolution 1280x1024
- CD-Rom 24x or faster
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3 INSTALLATION OF THE SOFTWARE

Before installing the software, make sure that no older version is already installed on
the computer. Otherwise remove the older version by using the control-panel of
windows for installing and removing software.
Insert the CD into the CD-drive and launch “setup.exe”. The following screen should
appear:
Picture 1 – Start of the installation

Click on the “Next”-button to proceed.
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If the software has been installed successful the following message appears:
Picture 2 – End of the installation

Click the “Finish” button to end the procedure.
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4 COLLEGAMENTO DEL PC ALL’UPS

The connection of the PC to the UPS can be carried out only with the additional
board PB213 (“SLOT-SER”).
Picture 3 – PB213-SLOT-SER
Connect the connector CN1 of the PB213 to the connector CN7 of the board PB249
(D-CPU-RC) through a 10-pole flat-cable:
Picture 4 – PB185 CN7

Now the computer can be connected to the UPS through the RS232 port ( DB9
female connector CN2 on the board PB213) or the USB interface (connector USB-Type
B, CN3 of the board PB213).
4.1 INSTALLATION OF THE USB DRIVERS
On the CD a directory named “USB Drivers” consist of the necessary driver for UPS-
communication.
For installing the driver please use the procedure “Installing new hardware” in the
WINDOWS-control panel.
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5 WRC MONITOR
Upon the software start-up, the following window is shown:
Picture 5 – Main window

All the elements of the main window are described in the following paragraphs.
5.1 TOOLBAR
The buttons for the software configuration are shown on the toolbar:
Picture 6 – Toolbar
Connect/Disconnect: it allows to start and stop the communication with the UPS.
The data exchange is signalled by the status LED that can
be seen at the right side of the toolbar.
COM Settings: it opens the window related to the configuration of the serial
port (see par. 5.1.1).
Language: it opens the window related to the setting of the language

(see par. 5.1.2).
Exit: Quit the program
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5.1.1 COM settings

Clicking on the button “COM settings” opens the window related to the settings of the
serial communication port.
Picture 7 – COM setting

The communication port can be changed selecting the desired port and pressing the
button OK.
5.1.2 Language setting

Clicking on the button “language” opens the window related to the settings of the
language of the software.
Picture 8 – Language setting

The language can be changed selecting the desired language and pressing the
button OK.
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5.2 FRAME “ALARMS”

The frame “Alarms” signals with red LED’s the presence of alarms in the UPS:
Picture 9 – Frame “Alarms”

5.3 FRAME “STATUS”
The frame “Status” signals with green LED’s the status of the UPS. SCOK indicates
that the input phase sequence is correct; RMSOK indicates that the RMS value of the
mains voltage on the three phases is correct; FROK indicates that the mains frequency
is correct and ROK is the logic OR of the above signals.
Picture 10 – Frame “Status”
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5.4 FRAME “AC MEASURES”

The frame “AC Measures” shows the measure of the mains, that’s to say the RMS
value of the voltage and current on the three phases and the mains frequency.
Picture 11 – Frame “AC Measures”

5.5 FRAME “DC MEASURES”
The frame “DC Measures” shows the measures of the battery, that’s to say the value
of the voltage of the positive and negative battery banks and the battery current.
Picture 12 – Frame “DC Measures”

5.6 FRAME “TEMPERATURE”
The frame “temperature” shows the temperature of the battery and the UPS.
Picture 13 – Frame “Temperature”
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Parallel Redundant System - Operating Manual
PARALLEL REDUNDANT SYSTEM - OPERATING

MANUAL
Index
INTRODUCTION......................................................................................... 3
1. PARALLEL REDUNDANT SYSTEM TYPOLOGY ............................ 3
2. PARTS CONSTITUTING THE SYSTEM ............................................ 4
3. OPERATING CONDITION.................................................................. 5
3.1 “N” UPS NORMAL CONDITION ......................................................................5
3.2 “N-1” UPS NORMAL CONDITION...................................................................6
3.3 “MAINS FAILURE”...........................................................................................7
3.4 “N” BYPASS AVAILABLE ...............................................................................8
3.5 “N-1 BYPASS AVAILABLE”............................................................................9
3.6 MANUAL BYPASS .........................................................................................10
4. INSTALLATION................................................................................ 11
4.1 ADDITIONAL HARDWARE ............................................................................11
4.2 POSITIONING.................................................................................................11
4.3 CONNECTIONS..............................................................................................12
4.4 INTERCONNECTIONS DIAGRAM .................................................................13
4.5 BUS CABLE ...................................................................................................15
5. SYSTEM PERFORMANCES............................................................ 15
5.1 OVERLOAD ....................................................................................................15
5.2 SHORT CIRCUIT ............................................................................................15
6. START-UP ........................................................................................ 16
6.1 TWO UPS – DIRECT START-UP ...................................................................16
6.2 TWO UPS – START-UP FROM MANUAL BY-PASS.....................................16
6.3 MORE THAN TWO UPS – START-UP FROM MANUAL BY-PASS ..............16
7. MANUAL BY-PASS TRANSFER PROCEDURE .............................. 17
7.1 MANUAL BY-PASS TRANSFER PROCEDURE............................................17
7.2 RE-START FROM MANUAL BY-PASS .........................................................17
7.2.1 Two UPS – Re-start from MANUAL BYPASS .......................................17
7.2.2 More than two UPS – Re-start from MANUAL BYPASS ......................17
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Index of pictures
Picture 1 - Block diagram ............................................................................................................................. 4
Picture 2 - “N” ups normal condition ............................................................................................................. 5
Picture 3 - “N-1” ups normal condition.......................................................................................................... 6
Picture 4 - “Mains Failure” ............................................................................................................................ 7
Picture 5 - “N” bypass available.................................................................................................................... 8
Picture 6 - “N-1”bypass available ................................................................................................................. 9
Picture 7 - Manual bypass .......................................................................................................................... 10
Picture 8 - Positioning................................................................................................................................. 11
Picture 9 - Connections .............................................................................................................................. 12
Picture 10 - Interconnections diagram........................................................................................................ 13
Picture 11 - Interconnection........................................................................................................................ 14
Picture 12 - Interconnection with BCCON – PB123 ................................................................................... 14
Picture 13 - Bus cable connections ............................................................................................................ 15
Issued 13/04/07 JUD409404 2 of 18

INTRODUCTION
The scope of this manual is to guide the installer and the user to the correct
installation of the parallel redundant system in the chosen room.
Before reading this manual, the installer and the user will have to read with
care and attention the “UPS OPERATING MANUAL” to carry-out correctly the
given instructions for the single units, especially those relevant to security
according to CEI 64-8 and to 46-90 standards.
The manufacturer declines all responsibility of damages to people or things

deriving from non-fulfilment of the above.
1. PARALLEL REDUNDANT SYSTEM TYPOLOGY

The parallel system consists of “n” (up to 6) units, which are equipped like standard
units. Only the manual bypass can be external and unique for all the units.
On each unit one extra pcb (RPI-BUSCAN), that provides the parallel redundant
functions, is installed.
In addition to the standard functions as uninterruptible power supply, total power
control and protection of the load from mains distortion, the parallel redundant system
guarantees an uninterrupted power supply even in case of an internal failure in one of
the UPS units.
It is possible because all units are constantly in operation and feed the load in
parallel at “total load / n”, where “n” is the number of the UPS.
The AC automatic current sharing control equalizes the currents of the “n” units and
reduces the total unbalance at less than 10%, under all load conditions.
The load is supplied by the inverters in parallel for an instantaneous overload up to “n
x 200%” of the nominal load of the single unit.
In case of a failure in one unit, the other units supply the load. The load is supplied by
the static bypass, only if there is an additional failure in the other units.
Issued 13/04/07 JUD409404 3 of 18

2. PARTS CONSTITUTING THE SYSTEM

All the units consist of six functional components:
- Rectifier (R)
- Inverter (I)
- Battery (B)
- Static Switch: Static Switch Inverter (SSI) Static bypass (SB)
- Manual bypass (MB) (on all the units or unique ad external)
- Front panel
For the description of the single parts, see: “UPS OPERATING MANUAL”
OM226002.
Picture 1 - Block diagram
Issued 13/04/07 JUD409404 4 of 18

3. OPERATING CONDITION
During “n UPS normal condition” any failure transfers the parallel redundant system
to “n-1 UPS normal condition”, or to “n rectifier failure or mains failure” condition.
During “n-1 UPS normal condition” or “n rectifier failure or mains failure” condition,
any failure transfers the parallel redundant system to “n-1 rectifier failure or mains
failure” condition or to “bypass feeds load” condition. In these operating conditions the
parallel redundant system signals a failure with audible and visual alarms.
During “n-1 rectifier failure or mains failure” condition or to “bypass feeds load”
condition, an additional failure may interrupt the power supply to the load, depending on
the kind of failure.
During “manual bypass” condition the mains feeds the load directly for maintenance
or serious failure.
3.1 “N” UPS NORMAL CONDITION

Load on inverter and possibility of continuous failure
Picture 2 - “N” ups normal condition
Issued 13/04/07 JUD409404 5 of 18

3.2 “N-1” UPS NORMAL CONDITION

Load on inverter and, in case of failure, transfer on bypass (if available)
Picture 3 - “N-1” ups normal condition
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3.3 “MAINS FAILURE”

Load on inverter supplied from the battery
Picture 4 - “Mains Failure”
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3.4 “N” BYPASS AVAILABLE

Load on bypass in case of at least two inverter failures or overload.
Picture 5 - “N” bypass available
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3.5 “N-1 BYPASS AVAILABLE”

Load on bypass in case of at least two inverter failures or overload
Picture 6 - “N-1”bypass available
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3.6 MANUAL BYPASS
Picture 7 - Manual bypass
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4. INSTALLATION
Before installing the parallel redundant system, see “INSTALLATION” in the
“OPERATING MANUAL” for the single units, in order to be informed about the following:
- receipt of the UPS

- dimensions and weights
- distance from the walls
- connections cables, fuses and terminal boards
4.1 ADDITIONAL HARDWARE

To transform “n” standard units into a parallel redundant system the following
additional hardware is required:
- N. “1 x n” RPI-BUSCAN pcb (parallel redundant card)

- N. “n-1” interconnections bus cable (DB9)
The output of the “n” units must be connected in parallel to the load bus bar.
4.2 POSITIONING
We suggest positioning the UPS’s with a distance between one and the other of 10
cm (minimum) for cables passage.
10 cm
Picture 8 - Positioning
Issued 13/04/07 JUD409404 11 of 18

4.3 CONNECTIONS
The following picture shows a simple connections diagram between two UPS’s in
parallel redundant configuration.
For more information about the UPS’s interconnections see the interconnections
diagram (picture 10).
Picture 9 - Connections
WARNING
We suggest to connect the two outputs of the UPS’s to the load with cables that have
the same section and same length.
Issued 13/04/07 JUD409404 12 of 18

4.4 INTERCONNECTIONS DIAGRAM

In the following diagram the modifications are illustrated to transform two single units
into a parallel redundant system.
Picture 10 - Interconnections diagram

For more than 2 units, “N-2“ BCCON PB123 board is added.
Issued 13/04/07 JUD409404 13 of 18

Picture 11 - Interconnection
Picture 12 - Interconnection with BCCON – PB123
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4.5 BUS CABLE

In the following picture the connections diagram of the bus cable are illustrated, with
the signals description.
Picture 13 - Bus cable connections
5. SYSTEM PERFORMANCES
The parallel redundant system has better static and dynamic performances in
comparison with a single unit as, due to the redundancy, the total amount of power
available is higher than the nominal load of the system.
5.1 OVERLOAD
The overload limit of a parallel redundant system depends on the number of the
units, which are connected to the load:
Imax = n * In
where “n” = number of the units, “In” = nominal current of each unit
The load exceeds this limit the thermal image starts and after a certain time the load
is transferred to bypass (if available).
5.2 SHORT CIRCUIT

If there is a short circuit at the output the system transfers the load to bypass (if it is
available), otherwise all the units supply 200% In for 5 cycles and after 125% for 5
seconds.
Issued 13/04/07 JUD409404 15 of 18

6. START-UP
6.1 TWO UPS – DIRECT START-UP
When the parallel UPS’s are only two, it’s possible to start the system by switching
on the unit having the lower position (Number 1), closing RCB and following the
procedure shown on the display.
At the end of the start-up of the first unit, the second one can be switched on
normally, closing RCB and following the procedure shown on the display.
6.2 TWO UPS – START-UP FROM MANUAL BY-PASS

The parallel system can also be switched on starting from manual by-pass. The unit
having the lower position (Number 1) must be started-up first:
o Close the manual by-pass breaker MBCB on the unit Number 1

o On the same unit (Number 1) move the By-pass switch in BY-PASS position
o Close RCB
o Follow all the instructions shown on the display until the unit is completely
started-up and supplies correctly the load
o Start-up the unit Number 2 closing RCB and following the instructions shown
on the display
6.3 MORE THAN TWO UPS – START-UP FROM MANUAL BY-PASS

When the parallel UPS’s are more than two, the system can only be switched on
starting from manual by-pass, in order to have all the units connected contemporary to
the load bus. The procedure is the following:
o Close the manual by-pass breaker MBCB in ALL the UPS

o Move the by-pass switches in BY-PASS position in ALL the UPS
o Close RCB in ALL the UPS
o Follow the instructions on the display on the UPS having the lower position
(Number 1) until it shows the message “OPEN ALL MBCB”. Do not open the
MBCB breakers at this point.
o Proceed as indicated above for all the units up to the one having the higher
position (Number “N”)
o Verify that all the by-pass static switches are closed
o Open the manual by-pass breaker MBCB in ALL the UPS
o Upon the display request, move the by-pass switches of all the units in
position NORMAL, starting from the UPS Number 1.
Issued 13/04/07 JUD409404 16 of 18

7. MANUAL BY-PASS TRANSFER PROCEDURE

During the normal operation of a parallel redundant system, the by-pass switch has
the function to disconnect the UPS from the supply of the load, opening the inverter
static switch. The load is transferred to the by-pass (emergency line) according to the
settings of the parallel logic RPI.
If the parallel system (2 UPS) is programmed with the logic “1 on 2” (parallel
redundant) the load is transferred to the emergency line only when both by-pass
switches are in BY-PASS position.
If the parallel system (2 UPS) is programmed with the logic “2 on 2” (power parallel)
the load is transferred to the emergency line when at least one by-pass switch is in BY-
PASS position.
7.1 MANUAL BY-PASS TRANSFER PROCEDURE

Move ALL by-pass switches in position BY-PASS, so that the load is transferred to
the emergency line on all the UPS systems (LED 6 on the front panel lit orange).
Close one or more MBCB (all the inverter will stop with the alarm A13).
Starting from the UPS having the higher position (Number “N”), open the breakers
OCB, SBCB, BCB, RCB.
7.2 RE-START FROM MANUAL BY-PASS

The system is in Manual By-pass condition, with one or more MBCB breakers closed
and ALL the by-pass switches in BY-PASS position, according to the procedure
described at point 7.1.
The system can be re-started according to the following procedures, depending on
the number of UPS composing the parallel system.
7.2.1 Two UPS – Re-start from MANUAL BYPASS

o Close RCB on UPS Number 1
o Follow all the instructions shown on the display until the unit is completely
started-up and supplies correctly the load
o On UPS Number 2 move the by-pass switch in NORMAL position
o Close RCB on UPS Number 2 and follow the instructions shown on the display
until the unit is completely started-up and supplies correctly the load
7.2.2 More than two UPS – Re-start from MANUAL BYPASS

o Close RCB in ALL the UPS
o Follow the instructions on the display on the UPS having the lower position
(Number 1) until it shows the message “OPEN ALL MBCB”. Do not open the
MBCB breakers at this point.
o Proceed as indicated above for all the units up to the one having the higher
position (Number “N”)
o Verify that all the by-pass static switches are closed
o Open the manual by-pass breaker MBCB in ALL the UPS
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o Upon the display request, move the by-pass switches of all the units in
position NORMAL, starting from the UPS Number 1.
ATTENTION
When all the displays will show “OPEN ALL MBCB”, the operator must open ALL
MBCB breakers and/or MBCB installed in external cabinets.
NOTE
In a parallel systems with more than 2 UPS, the load will be transferred to the
inverter(s) in accordance with the redundancy logic set on the RPI board (N-1/N).
If the system is composed by 3 UPS with a redundancy logic of “2 of 3”, the load will
be transferred to the inverter only when the second unit is completely started.
Issued 13/04/07 JUD409404 18 of 18

Parallel redundant system - Maintenance and Troubleshooting
PARALLEL REDUNDANT SYSTEM

MAINTENANCE AND TROUBLESHOOTING
Index
INTRODUCTION......................................................................................... 3
1. MAINTENANCE PROCEDURES ....................................................... 3
1.1 MAINTENANCE WITH THE LOAD UNDER CONTINUITY..............................3
1.2 MAINTENANCE WITH THE LOAD IN MANUAL BY-PASS ............................4
2. TROUBLESHOOTING PROCEDURES ............................................. 6
2.1 CHECK OF LED STATUS ................................................................................6
2.1.1 Check of the Power Supply LED’s on the RPI Board ...........................8
2.1.2 Check of the front LED’s on the RPI Board ..........................................8
2.2 CHECK OF AUXILIARY CONTACTS ............................................................10
2.2.1 Check of MBCB signal ..........................................................................10
2.2.2 Check of EPO signal .............................................................................11
2.2.3 Check of BYPASS SWITCH signal.......................................................12
2.3 CHECK OF CURRENT MEASURES..............................................................13
2.3 CHECK OF SYNCHRONIZATION SIGNALS .................................................15
3. RPI BOARD REPLACEMENT PROCEDURE.................................. 17
3.1 RPI GENERAL SETTINGS.............................................................................17
3.2 SYNCHRONIZATION ADJUSTMENTS..........................................................17
3.3 COMMUTATION TESTS ................................................................................18
3.4 SYSTEM RE-START ......................................................................................18
4. PARALLEL SYSTEM SOFTWARE (RPITEST) ................................ 19
4.1 INTRODUCTION.............................................................................................19
4.2 DESCRIPTION OF THE SOFTWARE ............................................................20
4.3 SUMMARY OF THE COMMANDS .................................................................27
4.4 UPGRADE OF THE PARALLEL SYSTEM ....................................................28
4.4.1 INTRODUCTION......................................................................................28
4.4.2 HARDWARE MODIFICATIONS ..............................................................28
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4.4.3 PARAMETERS SETTING....................................................................... 28

5. CONFIGURATION FROM SINGLE UPS TO PARALLEL ................30
5.1 PCB SETTINGS ............................................................................................. 30
5.2 MODIFICATIONS FOR UPS 15÷32 KVA ..................................................... 30
5.3 MODIFICATIONS FOR UPS 40÷650 KVA.................................................... 31
6. CONFIGURATION FROM PARALLEL TO SINGLE UPS ................33
6.1 MODIFICATIONS FOR UPS 40÷650 KVA.................................................... 33
6.2 MODIFICATIONS FOR UPS 15÷32 KVA ..................................................... 34
Index of pictures
Picture 1 – Bus cable connections ............................................................................................................... 9
Picture 2 – Digital inputs on RPITest control panel .................................................................................... 10
Picture 3 – Digital outputs on RPITest control panel.................................................................................. 10
Picture 4 – Signals on TR and TP14 .......................................................................................................... 14
Picture 5 – Signal on TS and TP14 ............................................................................................................ 14
Picture 6 – Signal on TT and TP14 ............................................................................................................ 14
Picture 7 – RPITest control panel............................................................................................................... 20
Picture 8 – RPITest control panel (PID controller) ..................................................................................... 20
Picture 9 – Parallel interconnections diagram ............................................................................................ 32
Issued 13/04/07 JUD409405 2 of 35

INTRODUCTION
The scope of this manual is to guide the technician to the correct maintenance and
troubleshooting of the parallel redundant system.
NOTE
Before reading this manual, the technician will have to read with care and attention
the “PARALLEL REDUNDANT SYSTEM OPERATING MANUAL” to carry-out correctly the
given instructions. The manufacturer declines all responsibility for damages to people or
things deriving from non-fulfilment of the above.
1. MAINTENANCE PROCEDURES
The parallel system allows the operator to carry out the maintenance of one or more units in
two different operating conditions, that’s to say, under continuity, where the load is still supplied
by the other inverter(s) or in manual by-pass condition.
NOTE
The modality of intervention must take into consideration the operating condition of
the plant, and must be agreed with the final user. For the operating procedures refer to
the technical documentation related to the UPS installed.
1.1 MAINTENANCE WITH THE LOAD UNDER CONTINUITY

Using this procedure the operator can work on one UPS at a time, leaving the load bus
supplied by the remaining UPS(s) so that the continuity of the supply is guaranteed. This
procedure is valid only for parallel redundant systems, not for power parallel.
NOTE
The operator carrying out the maintenance must consider under his own responsibility the
operating risks for himself and for the final user.
The procedure to disconnect the UPS under maintenance is the following:

o Move the by-pass switch on BY-PASS to disconnect the UPS from the load bus
o Open OCB
o Open SBCB
o Open BCB
o Open RCB
Wait until the UPS is completely switched off and carry out the maintenance.
Upon completion of the works, if necessary, the inverter can be tested in the following
manner (for further details refer to the specific procedures):
o Put the UPS in TEST mode (Dip 6 SW1 in OFF on PB003)

o Move the by-pass switch in NORMAL position
o Supply the logic with the external power supply
o Close RCB and start the inverter modulation by PC command
o At the end of the soft-start the inverter static switch will close and it will be possible to
check the output voltage waveform.
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o Moving the by-pass switch in BY-PASS position will cause the inverter static switch to
open but the load is not transferred to by-pass. The SBCB breaker must be kept
open.
Upon completion of the test the UPS can be put again “on line” with the following procedure:
o Put the UPS in NORMAL mode (Dip 6 SW1 in ON on PB003)

o Restore the normal supply of the logic.
o Re-start the unit normally, closing RCB and following the instructions shown on the
display
1.2 MAINTENANCE WITH THE LOAD IN MANUAL BY-PASS

Using this procedure the operator can work on all the UPS systems, leaving the load bus
supplied by the manual by-pass so that the continuity of the supply is not guaranteed
NOTE
The operator carrying out the maintenance must consider under his own responsibility the
operating risks for himself and for the final user.
The procedure to transfer the load in manual by-pass and disconnect the UPS before the
maintenance is described in the PARALLEL SYSTEM OPERATING MANUAL.
Wait until the UPS is completely switched off and carry out the maintenance.
Upon completion of the works, if necessary, the inverter and the by-pass static switch can be
tested in the following manner (for further details refer to the specific procedures):
o Put the UPS in TEST mode (Dip 6 SW1 in OFF on PB003)

o Supply the logic with the external power supply
o By the RPITest software set the UPS redundancy logic at 1 on the RPI board with the
command SNUL001 (logic 1 on “N”)
o By the UPSTest software connected to the RS232 of the UPS, send the command
MAST001 (MASTER condition forced)
o Close RCB and start the inverter modulation by PC command
o At the end of the soft-start the inverter static switch will close and it will be possible to
check the output voltage waveform.
o In case it’s necessary to perform commutation tests or checks on the static switch
operation, close SBCB and wait until the status S6 – BYPASS OK is active on the
UPSTest screen.
o Moving the by-pass switch in BYPASS position will cause the load transfer to the by-
pass so that the commutation between inverter and by-pass line can be tested.
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At the end of the tests restore the initial status:
o By the UPSTest software connected to the RS232 of the UPS, send the command
MAST000 (MASTER condition reset)
o Set the UPS redundancy logic at “n” on the RPI board, by the command SNULxxx,
with xxx=”n”.
o Put the UPS in NORMAL mode (Dip 6 SW1 in ON on PB003)
o Restore the normal supply of the logic.
o Move the by-pass switch in BYPASS position
o Start with the maintenance of the next unit, if necessary.
The whole system can be re-started following the procedures described at paragraph 7.2 of
the PARALLEL SYSTEM OPERATING MANUAL.
Issued 13/04/07 JUD409405 5 of 35

2. TROUBLESHOOTING PROCEDURES
This troubleshooting includes a first level fault description for Parallel System and suggests
how to check the unit to solve the problems.
All the tests described in this document must be carried out with the parallel system in
Manual Bypass unless otherwise specified.
Please refer to the PARALLEL SYSTEM OPERATING MANUAL for the correct procedure to
transfer the load from normal operation (inverter mode) to manual bypass.
This description assumes that all the connections inside the unit are correct; check them
(connectors, power cables, signals and so on) before starting with the procedures. The first
level troubleshooting consists of substituting the RPI-BUSCAN Board without attempting to
repair it. To replace the RPI Board refer to the instructions given at chapter 3 of this manual.
2.1 CHECK OF LED STATUS
The RPI-BUSCAN (PB110) board is provided with LED’s, indicating the various operating
condition of the board itself and the presence of the DC supply. The colour and function of the
LED’s is shown in the tables below; the first table shows the LED’s indicating the DC supply to
the RPI board, the second one the LED’s in the front of the RPI board indicating the operating
status of the parallel system.
a) DC SUPPLY LED’s
LED NAME COLOUR DESCRIPTION / FUNCTION / STATUS

DL1 GREEN It indicates the presence of the +5PS DC supply, generated
using the one coming from the power supply board (PS-HV -
PB001), section 12V/RELAY AND BUS, through the 60-pole
connector CNB. It must always be steady ON.
NOTE: the +12V supply is also transmitted through the
BUSCAN cable to the other units of the parallel system.
DL2 GREEN It indicates the presence of the +5F DC supply for the
microprocessor of the RPI board. This supply is generated
using the square waves AC3/AC4 coming directly from the
power supply board (PS-HV - PB001), connector CN1, to the
connector CN7 of RPI board.
DL3 GREEN It indicates the presence of the -5F DC supply for the
microprocessor of the RPI board. This supply is generated
using the square waves AC3/AC4 coming directly from the
power supply board (PS-HV - PB001), connector CN1, to the
connector CN7 of RPI board.
DL14 GREEN It indicates the presence of the +5PSRG DC supply, generated
using the one coming from the power supply board (PS-HV -
PB001), section 12V/RELAY AND BUS, through the 60-pole
connector CNB. It must always be steady ON.
NOTE: the +12V supply is also transmitted through the
BUSCAN cable to the other units of the parallel system.
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b) FRONT LED’s
LED NAME COLOUR DESCRIPTION / FUNCTION / STATUS

DL11 BUS_OK GREEN It indicates that the transmission between the units on the
BUSCAN is correct on both transmission lines (BUSCAN_H
and BUSCAN_L). It must always be steady ON.
DL12 MASTER RED It indicates the MASTER unit, that is, among the UPS that are
supplying the load, that with the lowest position. during normal
operation it’s ON in the MASTER and OFF in the SLAVE.
DL13 CON_OFF RED It indicates if the connector of the BUSCAN cable is connected
correctly to the RPI board. It must always be OFF.
DL9 UPS1 YELLOW It’s solid ON in the UPS1 (TX – Transmitting), indicating this
UPS is transmitting through the BUSCAN.
It’s BLINKING on the other UPS systems (RX – Receiving),
indicating they are receiving message from the UPS1 through
the BUSCAN.
the BUSCAN.
the BUSCAN. It’s OFF in case the parallel system is composed
by less than three units.
by less than four units.
by less than five units.
by less than six units.
DL10 OUT_ON YELLOW When ON It indicates that the load is supplied by at least one
inverter, otherwise OFF.
Before to start the tests described below, transfer the load on Manual Bypass, switch off all the
units and set them in Test Mode, moving the DIP6 SW1 on I/S Control Logic in OFF position.
Then close RCB on all the units (Logics start-up).
Issued 13/04/07 JUD409405 7 of 35

2.1.1 Check of the Power Supply LED’s on the RPI Board

1. Are the DL2 and DL3 ON?
YES: go to step #4
NO: check the continuity of the flat cable from CN7 of RPI Board to CN1 of the PS-HV
board. Go to step #2.
2. Is the continuity of flat cable correct?

YES: replace the PS-HV board. Go to step #3
NO: replace the flat cable. Go to step #3.
3. Are the DL2 and DL3 ON now?

YES: END
NO: replace the RPI board.
4. Remove the DB9 BUSCAN Connector, are DL1 and DL14 both ON?
YES: END
NO: check the continuity of the 60-pole flat cable CNB and the flat cable from CN1 of
PS-HV board to CN15 of I/S-CL board. Go to step #5.
5. Is the continuity of flat cables correct?

YES: go to step #6
NO: replace the flat cable(s).
6. Are both of them OFF?

YES: replace the PS-HV board. Go to step #7
7. Are DL1 and DL14 ON now?

YES: END
NO: replace the RPI board
Before re-connecting the BUSCAN cable, switch off the unit opening RCB and wait the
complete shut-down of the logics.
2.1.2 Check of the front LED’s on the RPI Board

1.1. Is DL11 “BUS_OK” ON?
YES: go to step #2.1
NO: check the continuity of the BUSCAN cable between the units according to the
picture 1 (see next page).
1.2. Is the continuity of the cable correct?

YES: disconnect in sequence each RPI from the bus, until DL11 is ON again. Replace
the faulty RPI.
NO: replace the BUSCAN cable.
2.1. Is DL13 “CON_OFF” OFF?

NO: check the DB9 connector of the BUS cable and the short circuit between pin6
and pin1. Go to step #2.2.
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2.2. Is the connector ok?

YES: replace the RPI board. Go to step #3.1.
NO: replace or repair the DB9 connector and go back to step #2.1.
3.1. Is DL9 on UPS1 (TX - Transmitting Message) ON?

NO: check if the Dip1 of SW1 on the RPI board of UPS1 is ON and all the other Dip
OFF (set the position of the UPS as UPS1) if is ok replace RPI Board.
3.2. Is the position of the dip switch on UPS1 correct?

YES: replace the RPI board.
NO: correct the position of the dip switch and go back to step #3.1.
3.3. Is DL4 on UPS2 (TX - Transmitting Message) ON?

YES: END
NO: check if the Dip2 of SW1 on the RPI board of UPS2 is ON and all the other Dip
OFF (set the position of the UPS as UPS2) if is ok replace RPI Board.
3.4. Is the position of the dip switch on UPS2 correct?

NO: correct the position of the dip switch and go back to step #3.3.
Check if all the others TX (Transmitting Message) and RX Leds (Receiving Message) are ON
or blinking according to the table shown at paragraph 2.1.
Picture 1 – Bus cable connections
Issued 13/04/07 JUD409405 9 of 35

2.2 CHECK OF AUXILIARY CONTACTS

The UPS systems are in manual by-pass condition, with all MBCB breakers closed.
Start-up the units in test mode moving the DIP6 SW1 on I/S Control Logic in OFF position.
Then close RCB on all the units (Logics start-up). The digital signals related to the position of
MBCB breaker, EPO contact and By-pass Switch are shown on the control panel of the RPITest
software (see picture 2). The digital outputs, that’s to say the commands that the RPI send to
the I/S-CL board are shown in the same control panel (see picture 3).
Picture 2 – Digital inputs on RPITest control panel
l
Picture 3 – Digital outputs on RPITest control panel
2.2.1 Check of MBCB signal

Open MBCB on UPS2 (MBCB of UPS1 is closed) and connect a PC with the RPITest
software to the RPI Board of UPS1.
The auxiliary contact of MBCB is connected to the RPI board on the connector M5, pin 5/6;
according to the position of the contact the RPI board generates the MBCB_CLOSE_BUS
signal.
1. Verify that all the units show A18 - MBCB CLOSE alarm on the display.
YES: END. Close MBCB on UPS2 and open MBCB on UPS1 and repeat the same
check.
NO: go to step #2
2. Is the alarm present on the unit where MBCB is closed?

YES: go to step #9
NO: check the digital input “MBCB close” on the RPITest software. Go to step #3.
3. Is the digital input “MBCB close” active?

YES: check the digital output MBCB_CLOSE_BUS. Go to step #5.
NO: check the operation of the auxiliary contact of MBCB breaker. Go to step #4
4. Is the auxiliary contact working properly?
Issued 13/04/07 JUD409405 10 of 35


NO: replace the auxiliary contact. Go back to step #3
5. Is the digital output “MBCB_CLOSE_BUS” active?

YES: check the continuity of the 60-pole flat cable CNB. Go to step #6.

YES: replace the RPI board. Go to step #7.
NO: replace the flat cable. Go back to step #5.
7. Do all the units show A18 - MBCB CLOSE alarm on the display?
YES: END
NO: replace the I/S-CL board.
8. Connect the PC with the RPITest to the RPI board of the UPS that has MBCB open. Is
the digital output “MBCB_CLOSE_BUS” active?
YES: Go to step #9.
NO: check the communication between the units (TX and RX LED’s, see paragraph
2.1.2, points 3.3 and 3.4) and replace the RPI board.
9. Check the continuity of the 60-pole flat cable CNB. Is the continuity of flat cable
correct?
10. Does this unit show A18 - MBCB CLOSE alarm on the display?
YES: END
2.2.2 Check of EPO signal

The auxiliary contact of EPO button is connected to the RPI board on the connector M5, pin
1/2; according to the position of the contact the RPI board generates the EPO_BUS signal.
1. Press the EPO button on the UPS1 and verify that all the units show A23 - EPO
PRESSED alarm on the display.
YES: Go to step #2
NO: go to step #3
2. Release the EPO on UPS1 and press the EPO button on the UPS2 and verify that all
the units show A23 - EPO PRESSED alarm on the display.
YES: END.
NO: go to step #3
3. Is the alarm present on the unit where EPO is pressed?

YES: go to step #9
NO: check the digital input “EPO_bus” on the RPITest software. Go to step #4.
4. Is the digital input “EPO_bus” active?

YES: check the digital output O_EPO_BUS. Go to step #6.
NO: check the operation of the contact of EPO button. Go to step #5
5. Is the contact working properly?
Issued 13/04/07 JUD409405 11 of 35

NO: replace the auxiliary contact. Go back to step #4
6. Is the digital output “O_EPO_BUS” active?


8. Do all the units show A23 - EPO PRESSED alarm on the display?
YES: END
9. Connect the PC with the RPITest to the RPI board of the UPS where the EPO is not
pressed. Is the digital output “O_EPO_BUS” active?
YES: Go to step #10.
NO: check the communication between the units (TX and RX LED’s, see paragraph
2.1.2, points 3.3 and 3.4) and replace the RPI board.
10. Check the continuity of the 60-pole flat cable CNB. Is the continuity of flat cable
correct?
11. Does this unit show A23 - EPO PRESSED alarm on the display?
YES: END
2.2.3 Check of BYPASS SWITCH signal

The contact of the Bypass Switch is connected to the RPI board on the connector M7, pin
1/2; according to the position of the contact the RPI board generates the Byp_SW signal.
1. Move the Bypass switch of the UPS1 in position BYPASS and verify that the unit
shows A22 – BYP SWITCH alarm on the display.
YES: END
NO: go to step #2
2. Check the digital input “Byp_SW” on the RPITest software. Is the digital input
“Byp_SW” active?
YES: check the digital output O_BYP_SW. Go to step #4.
NO: check the operation of the Bypass switch contact. Go to step #3.
3. Is the contact working properly?

NO: replace the Bypass Switch. Go back to step #2
Issued 13/04/07 JUD409405 12 of 35

4. Is the digital output “O_BYP_SW” active?

YES: Check the connection between M8 of the RPI board and M3 of the I/S-CL board
(pins 11-12). If the FCI board is installed M8 is connected to M1, pins 11-12. Go
to step #5.
5. Is the connection good?

NO: replace the connection. Go back to step #4.
6. Does the unit shows A22 – BYP SWITCH alarm on the display?
YES: END
Repeat the procedure described above for all the other UPS of the parallel system.
2.3 CHECK OF CURRENT MEASURES
NOTE
This check can be carried out only with the parallel system connected to the load.
1. Is the current sharing between the units good (difference +/- 10 %)?
YES: END
NO: Move the bypass switch of UPS2 in BYPASS position, so that only the UPS1
supplies the load. Connect the PC with the RPITest to the RPI board of UPS1.
Go to step #2.
2. On the PID control panel, check the value of “Output freq.”, that must be 20000 (+/-
1000) for 50Hz units and 18000 (+/-1000) for 60Hz units. Is this value correct?
YES: go to step #5
NO: go to step #3
3. On the RPI board check with an oscilloscope connected between TP14-GNDF the
presence of a 50Hz (60Hz) square wave (see picture 4). Is the waveform present?
NO: check the output voltage of the phase R on the connector M4 pins 1-3 and the
fuse F1. Go to step #4.
4. Is the fuse ok?

NO: replace the fuse. Go back to step #3.
5. Connect an oscilloscope between TR-GNDBUS, TS-GNDBUS, TT-GNDBUS and

check the output current of the three phases according to the percent of load. The sine-
wave must have a peak-to-peak value of 2V at 50% of load and must be shifted of
2,5Vdc above the zero (see pictures 4-5-6). Are the waveforms correct?
YES: go to step #7
NO: depending on which signal is missing, check the connection between M1 (phase
R), M2 (Phase S), M3 (Phase T) and the current transformers TP1-TP2-TP3. Go
to step #6.
Issued 13/04/07 JUD409405 13 of 35

Picture 4 – Signals on TR and TP14
Picture 5 – Signal on TS and TP14
Picture 6 – Signal on TT and TP14
6. Is the connection ok?

YES: replace the current transformer(s).
Issued 13/04/07 JUD409405 14 of 35
NO: replace the connection(s).
7. On the PID control panel of the RPITest check the values of CURR_LOC on the three
phases. These values must be 1200 (+/-10%) at 50% of load, except CURR_LOC
Quad R that must be zero with resistive load, and varies proportionally according to the
actual load. Are the values correct?
YES: go to step #8
8. Move the bypass switch of UPS2 in NORMAL position and the Bypass Switch of UPS1
in BYPASS, so that only the UPS2 supplies the load. Connect the PC with the RPITest
to the RPI board of UPS2 and repeat the checks from point 2 to 7. Go to step #9.
9. Take note of the values of CURR_LOC shown on the PID control panel (Phase R,
Quad R, Phase S, Phase T). Transfer the load to the UPS1 again by means of the
bypass switches, connect the RPITest to the RPI board of UPS1 and check the values
of CURR_LOC in the UPS1. Are these values the same of those shown by UPS2?
YES: END
NO: According to the actual load, adjust the measures to be the same for both UPS,
with the potentiometers POT4 (Phase R), POT5 (Phase S), POT6 (Phase T).
Remember the measures must be 1200 at 50% of load, except CURR_LOC
Quad R that must be zero (+/-70) with resistive load.
2.3 CHECK OF SYNCHRONIZATION SIGNALS
The UPS systems are in manual by-pass condition, with all MBCB breakers closed.
ATTENTION
If the UPS is a single-phase output, short-circuit the neutral pole of the output breaker OCB
(putting a jumper between IN and OUT) in both units (see point 3.2 for further explanations).
Only the neutral pole of OCB must be short-circuited.
Start-up the units in test mode moving the DIP6 SW1 on I/S Control Logic in OFF position. Then
close RCB on all the units (Logics start-up).
a) By the UPS-Test software connected to RS232 of the UPS, send the command
MAST001 (Master condition Forced) to the UPS1.
b) Verify the presence of the MASTER label (red) on the UPS-Test screen. This UPS now
is the MASTER in the system.
c) Switch on all the inverters. (by the UPS-Test software, sending the command
INON000). Wait that all the inverter static switches are closed.
1. Check the synchronization of the SLAVE unit measuring the voltage difference between
the phases R of the two units. Is the SLAVE synchronized?
YES: go to step #8
NO: go to step #2
2. On the RPI board of the MASTER unit check with an oscilloscope connected between
TP1-GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform
present?
YES: go to step #5
NO: replace the RPI board. Go to step #3.
3. After replacing the RPI board is the waveform present on TP1?
Issued 13/04/07 JUD409405 15 of 35

YES: go to step #5
NO: check the continuity of the 60-pole flat cable CNB. Go to step #4.

YES: replace the I/S-CL board.
5. On the RPI board of the SLAVE unit check with an oscilloscope connected between TP1-
GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform present?
YES: Replace the RPI board
NO: replace the BUS cable. Go to step #6.
6. After replacing the BUS cable is the waveform present on TP1?

YES: END
NO: check the continuity of the 60-pole flat cable CNB. Go to step #7.

8. Close SBCB on both units and wait for the BYPASS_OK signal (status S6 on the
UPSTest screen) Check the synchronization between the MASTER and the bypass,
measuring the voltage difference between the phase R of the bypass and the phase R of
the inverter. Is the MASTER synchronized?
YES: END
NO: go to step #9
9. On the RPI board of the MASTER unit check with an oscilloscope connected between
TP2-GNDBUS the presence of a square wave (MAINS_SYNC_BUS). Is the waveform
present?
NO: replace the RPI board. Go to step #11.

11. After replacing the RPI board is the waveform present on TP2?
YES: END
d) Open SBCB on both units.

e) Send the command MAST000 (Master condition Reset) to the UPS1, connect the
UPSTest software to the RS232 of the UPS2 and send the command MAST001. Now
the UPS2 is the MASTER in the system.
f) Repeat the checks from point 1 to 10.
Issued 13/04/07 JUD409405 16 of 35

3. RPI BOARD REPLACEMENT PROCEDURE

This procedure describes how to replace the RPI board. The parallel system must be put in
manual bypass condition.
3.1 RPI GENERAL SETTINGS
1. Remove the BUSCAN bus wire from the defective RPI.
2. Remove the RPI Board (PB110) from the UPS.
3. Measure the values of the potentiometers POT1, POT4, POT5 and POT6 on the faulty
RPI.
4. On the new RPI board set the same values of the potentiometers POT1, POT4, POT5
and POT6.
5. Copy the setting of the Dip Switch from the defective RPI board to the new RPI Board
(set the position of the UPS in the parallel system).
6. Insert the new RPI board on the UPS. Re-connect all the flat cables, wires and the
BUSCAN cable.
7. Put ALL the UPS of the system in Test Mode, setting the Dip6 SW1 of the I/S Control
Logic (PB003 Board) in OFF position.
8. For each UPS, move the Bypass Switch in NORMAL Position.
9. Close all the RCB (Mains Input breakers) and wait the alarms in each UPS.
10. Check the LED’s operation on the RPI Board (PB110) according to the paragraph 2.1.
11. Connect the PC with the RPITest to the new RPI board and set the parallel parameters
sending the commands SNULxxx and SNUPxxx. (refer to the section 4 of this manual).
12. Check if the values of the parameters of the PID controller, on the PID Control Panel of
the RPITest software are correct. (refer to the section 4 of this manual).
KC_COS[FR] KC_COS[QR] KC_COS[FS] KC_COS[FT]
KBI_EE[FR] KBI_EE[QR] KBI_EE[FS] KBI_EE[FT]
13. Check if the value of the parameter Curr_TH_Integ of the PID controller on the PID
Control Panel of the RPITest software is correct. (Refer to the section 5 of this manual).
14. After having set all the parallel control parameters, send the command MEEE000 to save
the new settings and check the acquisition of the settings by waiting for the message
“MESSAGE RECEIVED” on the RPITest screen..
3.2 SYNCHRONIZATION ADJUSTMENTS
1. By the UPS-Test software connected to RS232 of the UPS, send the command
MAST001 (Master condition Forced) to one of the UPS of the parallel system (not the
UPS with the new RPI board). Verify the presence of the MASTER label (RED) on the
UPSTest screen. This UPS now is the MASTER in the system.
2. Switch on all the inverters by the UPSTest software, sending the command INON000.
3. Wait that all the inverter static switch are closed. In the UPS with the new RPI board,
check the inverter output voltage. If there is a difference with the nominal value, it can be
adjusted by the potentiometer P1 on the VCB boards (PB012).
4. With a multimeter, check the voltage difference between the output phases R, measuring
between the input of the OCB of the UPS MASTER and the input of the OCB of the UPS
SLAVE (that is the unit with the new RPI Board). If a phase shift is found, it can be
compensated by turning the potentiometer POT2 on the new RPI Board.
ATTENTION
Issued 13/04/07 JUD409405 17 of 35

If the UPS is a single-phase output the neutral conductor is not common as it is interrupted
by the output breaker OCB, that must be kept open (the units are operating in manual by-
pass). Therefore, in order to read with the multimeter the voltage difference between the
inverter output voltages, it’s necessary to link the two output neutral conductors, by short-
circuiting the neutral pole of the output breaker OCB (putting a jumper between IN and OUT).
CAUTION
On single-phase UPS, only the neutral pole of OCB must be short-circuited.
5. Switch off ALL the inverters (by the UPSTest software, sending the command INOF000).
6. Send the command MAST000 (Master condition Reset) to the UPS MASTER.
7. Send the command MAST001 to the UPS with the new RPI Board (PB110)
8. Switch on all the inverter by the UPSTest software, sending the command INON000) and
wait that all the inverter static switch are closed.
9. Close the SBCB breakers (Emergency line breaker) in all the units and wait for Bypass
OK signal (Status S6 – BYPASS OK on all the units and status S5 – INV SYNC on the
MASTER unit).
10. With a multimeter, check the synchronization of the MASTER unit with the mains,
measuring between the input of the OCB of the UPS with the new RPI Board and the
input of the SBCB. If a phase shift is found, it can be compensated by turning the
potentiometer POT3 on the new RPI Board.
3.3 COMMUTATION TESTS
All the inverters are now working synchronized with the bypass line. The static switch
operation can be tested according to the following procedure. Take into consideration that the
following are blank tests, carried out with the output breaker open
1. On the UPS with the new RPI board, move the Bypass Switch in BYPASS position.
The inverter static switch will open and the load will be supplied by the other units,
according to the redundancy logic set on the RPI boards.
2. Move the Bypass Switch in BYPASS position in all the other units of the parallel
system. All the bypass static switches will close and the load will be supplied by the
mains.
3. Switch off all the inverters by the UPS-Test software, sending the command
INOF000).
4. Open all the SBCB breakers (Emergency Line breakers)
5. Open all the RCB breakers (Input Mains breakers).
3.4 SYSTEM RE-START
1. Set all the systems in Automatic mode, moving the Dip6 SW1 of the I/S Control Logic
(PB003 Board) in ON position.
2. In case the UPS is a single-phase output, remove the jumpers on the neutral pole of
the OCB breakers (put during the synchronization procedure at point 3.2).
3. Move ALL Bypas Switches in BYPASS position.
4. Now the units are completely switched off with the MBCB breakers closed and the
Bypass Switches in BYPASS position.
5. Re-start the units from MANUAL BYPASS condition following the instructions of the
PARALLEL SYSTEM OPERATING MANUAL.
Issued 13/04/07 JUD409405 18 of 35

4. PARALLEL SYSTEM SOFTWARE (RPITEST)

4.1 INTRODUCTION
This document is a guide for the correct configuration of the parameters of the card RPI-
BUSCAN PB110 for a parallel redundant system.
The parallel optional card allows the connection of up to 6 units in parallel.
For a correct installation and interconnection of the parallel cards refer to the parallel test
procedure. Particular attention must be paid to the configuration of the dip switches, through
which the position of each UPS system is defined in univocal way, allowing the correct
exchange of the signals among the systems.
WARNING
Two UPSs can not have the same configuration of the dip-switches, that’s to say the
same position in the parallel system, otherwise there are conflicts of identification of the
messages running through the CAN BUS
The Parallel system has the MASTER condition distributed on the System.
The MASTER is, among the UPS’s supplying the load, the one which has the Lowest
Position Number.
Each UPS uses a CAN connection to “converse” with the other units, and send messages
through the CAN according to its position in the system.
The message contains the information related to the local currents “Phase component of
the phase R”, “Quadrature component of the phase R”, “Phase component of the phase
S”, “Phase component of the phase T”, as well as the status of the digital inputs.
Issued 13/04/07 JUD409405 19 of 35

4.2 DESCRIPTION OF THE SOFTWARE

In order to display the data exchanged among the UPS’s in the parallel system, the PC with
the RPI-Test software installed must be connected through the card SER-CAN PB130 to the
connector CNS of the RPI card.
As soon as the connection is established the following screen is displayed:
Picture 7 – RPITest control panel

Clicking on the button “Show” will display the PID control panel.
Picture 8 – RPITest control panel (PID controller)
Issued 13/04/07 JUD409405 20 of 35

The different sections of the program are described as follows.
Tx Check (transmission control) shows the bytes

received by the serial buffer.
The number of bytes for each packet is 250.
Packt is the number of the packet transmitted at the
moment.
Ver SW indicates the version of the software mounted
on the RPI Board.
N_UPS is the number of the UPS in the System this
parameter can be set with the command SNUPxxx
where xxx is the number of the UPS. See above for
more details.
WARNING
The setting of the RPI card must be carried out only by authorised and trained personnel.
Incorrect settings may be dangerous for the safety of the persons, cause damage to the
system and void the manufacturer’s warranty.
NOTE
The appropriate value for the Ver SW is shown for the version above PCAN40 and with RPI-
Test software above v2.0. For versions preceding PCAN51 it’s advisable to update the parallel
system to the latest release. Refer to the last chapter of this manual for information on the
update procedure and parameters’ setting.
The button “Show” displays the Panel for the

currents measures and control PID parameters.
The parameters C_F_Rm, C_Q_Rm, etc......are the

components of the currents for the Load sharing
control. See also the current measures on the PID
control panel.
RX1,RX2,........RXN are the number of messages

received from the CAN for the UPS where the Serial
cable is connected.
TX1,TX2,........TXN are not implemented.
ERR_RX indicates how many CAN messages have

been lost in Reception mode.
ERR_TX indicates how many CAN messages have
been lost in Transmission mode.
ID1,ID2,........IDN is the identifier of the CAN Msg.

Msg1==>ID1=264
Msg2==>ID2= 520
These parameters are fixed by the manufacturer and
cannot be changed.
Issued 13/04/07 JUD409405 21 of 35

These are the Digital Inputs of the RPI. The red

border indicates the UPS where the software is
connected (in this case UPS2).
The green border indicates the data reception from
this UPS through the CAN (UPS1).
During the normal operation of the parallel system
only GREEN labels will be shown.
Particularly, the following signals will be present:
Cok_bus
Inv_x_on
Rok_1
Inv_1_ok
Sync_1_ok
If one or more of this signals is not present, the
parallel system can’t operate correctly, therefore it’s
necessary to check the system and repair the
possible failure.
Green label means Normal Status for the System.
Orange label means Status changed by the
operator.
Red label means Not Normal Status for the System.
The labels highlighted with a colour indicates that
the relative signal is active.
(By_bus, BCB_open, MBCB_Close....).
These are the variables that are elaborated to

generate the Digital outputs. The local digital inputs
are shown together with the digital signals coming
from the CAN.
Some signals are elaborated with logic 1 of 6 (for
example EPO_BUS) other with the logic N-1/N as
for example INV_OK etc...
See the command SNULxxx.
This section shows the Digital Outputs, which are

the signals exchanged between the PRI and the I/S
Control Logic.
A coloured label means that the signal is active.
During normal operating conditions only the GREEN
label, except 0_BLOC_WR, are active:
0_COK_BUS
INV_OK_N-1/N
SYNC_OK_N-1/N
ROK_N-1/N
For the SLAVE : 0_BLOC_WR active
For the MASTER: 0_BLOC_WR not active
Clicking on the SHOW button the PID parameter setting panel is shown.
Issued 13/04/07 JUD409405 22 of 35

This is the control panel for the Current Phase R

(Phase component of phase R).
There are 4 panels, one for each component.
Phase R it is used to control the CFPAR parameter
(Parallel Phase Contribution). This parameter works
on the phase shift between the Inverter SLAVE and
the Inverter MASTER.
The range of variation is 0÷255, that corresponds to
a phase variation from –400 to 400 (See UPS-Test
software clicking the button Par_Data).
The Quad R (Quadrature component of phase R)
works on the amplitude of phase R (VCB card of the
phase R).
The Phase S works on the amplitude of the Phase S
(VCB card of the phase S).
The Phase T works on the amplitude of the Phase T
(VCB card of the phase T).
Curr_Ing and Curr_Fil are the intermediate values

used for the calculation of CURR_LOC.
CURR_LOC is the value of the current that the UPS
is supplying in a certain moment.
CURR_MED is the “Mean” current, the current that
the UPS should supply in order to share equally the
load with the other systems.
Curr_med=(Curr_loc1+Curr_loc2+.........Curr_loc
N)/n-IFL where Curr-Loc are the current supplied by
each UPS and n-IFL is the number of units that are
supplying the load in that moment (Number of
Inverters Feeding the Load).
The value of the local current shall always aim,
except for little variations, to the value of the mean
current.
This section shows the different parts of the PID

control (Proportional, Integrative, Derivative).
This is the control variable of the PID (OUT of PID).

The range of variation is 0÷255 (1 byte).
The value 128 means that there is no correction.
This variable can change from 0 to 255.
DAC_FR works on CFPAR. DAC_FR=0 CFPAR= –
400 DAC_FR=255 CFPAR= +400
DAC_QR works on VCB-R DAC_FR=0 VoutR=
Nominal +4V DAC_FR=255 Vout R= Nominal-4V
DAC_FS works on VCB-S DAC_FS=0 Vout S=
Nominal +4V DAC_FS=255 Vout S= Nominal-4V
DAC_FT works on VCB-T DAC_FT=0 Vout T=
Nominal +4V DAC_FT=255 Vout T= Nominal-4V
Issued 13/04/07 JUD409405 23 of 35

Control parameter of the PID.

KC_COS[FR] is the Proportional constant KC of the
P.
KBI_COS[FR] is the Integrative constant KI of the I.
KBI_EE[FR] is set in the EEPROM and became
KBI_COS[FR] when the Curr_med is above
Curr_TH_Integer.
KBT_COS[FR] is the anti wind_up of the PID. This
parameter is not used and must be set at 0.
Commands for the setting of the parameters:

KCFRxxx is used to set the KC_COS[FR]
KCQRxxx is used to set KC_COS[QR]
KCFSxxx is used to set the KC_COS[FS] and
KC_COS[FT]
KIFRxxx is used to set the KI_COS[FR]
KIQRxxx is used to set KI_COS[QR]
KIFSxxx is used to set the KI_COS[FS] and
KI_COS[FT]
KTFRxxx is used to set the KT_COS[FR]
KTQRxxx is used to set KT_COS[QR]
KTFSxxx is used to set the KT_COS[FS] and
KT_COS[FT]
Commands section.
After having sent a command, and if the command is
accepted, the box shows a “Message Received”
text.
The command, like the UPS-Test software, are
composed by 4 capital letters and 3 numbers.
Counter of RESET of HC16 of the RPI board and of

the Reset of the CAN Controller.
Clicking on the button “Reset Counter” and then
sending the command MEEE000 all the counters
are reset.
Issued 13/04/07 JUD409405 24 of 35

Output Freq is the period of the output voltage

(phase R).
Seconds is the seconds counter.
N_Filter Cycles was used in the previous parallel

software releases, up to PCAN40 and it was set with
the command NFILxxx. Note that this parameter is
not used and it’s fixed at 1 with the command
NFIL001.
Curr_TH_Integer is the threshold of the curr_med

above which the Integrative part of the PI is
activated (SCIIxxx).
From the revision PCAN51 this parameter isn’t used
and must be set at 0 (SCII000). For previous
versions this parameter remains set at 300
(SCII300).
N_UPS is the number of units that compose the

parallel system.
This value can be set sending the command
SNUPxxx, where xxx is the number of units that
compose the parallel system. All the parallel cards
must have the same setting. This parameter is
critical and must be set correctly.
N_INV_LOAD is the number of the UPS that are

supplying the load at the moment.
N_UPS(N-1/N) is the number of UPS for the

redundancy logic of the parallel system.
Generally this logic is set by the manufacturer as “N-
1”; if the parallel system is composed by 3 units, the
logic is set at 2, so that at least two inverters are
necessary to supply the load (logic 2 out of 3).
This parameter is set by the command SNULxxx
and fix the redundancy logic of the bypass and
inverter for the parallel system.
The range of variation of this parameter is from 1
and 6 (maximum number of units in the parallel
system).
Example for 4 UPS parallel system:
LOAD ON BYPASS
COMMANDS
INVERTER AVAILABLE
SNUL001 1 inverter out of 4 1 bypass out of 4
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This value must be set correctly to obtain the

desired behaviour of the system.
The command SNULxxx is implemented starting
from the parallel software release PCAN40.
WARNING
The description of the command given above
refers to the parallel systems with the software
version PCAN55 and with the PAL U12
SAFE1_23 and U11 OUTGEN41 installed on
board the card SCB PB014.
For versions preceding the PCAN55 and with
PAL SAFE1_22 and OUTGEN4 the command
SNUL must be equal to the logic described
above plus 1.
Example:
New release
Logic 1 out of 2 Æ SNUL001
Old release
Logic 1 out of 2 Æ SNUL002
It’s strongly suggested to update the firmware of
the parallel system to the latest release, as
shown in the following chapters.
Issued 13/04/07 JUD409405 26 of 35

4.3 SUMMARY OF THE COMMANDS
COMMAND Values of “xxx” Description

Number of units that compose the parallel system
SNUPxxx 002÷006
CRITICAL
Command to set the redundancy logic. xxx indicates
the minimum number of inverters for the load to be
SNULxxx 001÷006 supplied by inverter.
CRITICAL Implemented form Ver PCAN40
Current Threshold on Curr_med for activate from P
to PI controller .
SCIIxxx 000÷999 From Rev. PCAN51 the integrative part is always
active, the parameter must be fixed to 0 with the
command SCI000
NFILxxx 002÷006 Always fixed at 1
Reset the RESET Counters HC16 and CAN
CLRR000 000
Debug
Set the constant proportional KC of the PI phase R
KCFRxxx 016,032,064 (suggest value 16,32,64)
Set the constant proportional KC of the PI quad R
KCQRxxx 016,032 (suggest value 16,32)
Set the constant proportional KC of the PI phase S
KCFSxxx 016,032,064 and T (suggest value 16,32,64)
Set the constant integrative KI of the PI phase R
KIFRxxx 002,004,008 (suggest value 2,4,8)
Set the constant integrative KI of the PI quad R
KIQRxxx 002,004,008 (suggest value 2,4,8)
Set the constant integrative KI of the PI Phase S and
KIFSxxx 002,004,008 T (suggest value 2,4,8)
Set the constant KT anti wind-up phase R
KTFRxxx 000
NOT USED FIXED TO 0
Set the constant KT anti wind-up quad R
KTQRxxx 000
NOT USED FIXED TO 0
Set the constant KT anti wind-up phase S and T
KTFSxxx 000
NOT USED FIXED TO 0
Memorize the parameters on EEPROM it is
MEEE000 000 necessary to fix the values set.
Force the HC16 to initialise the CAN controller
INCA000 000
Debug
Issued 13/04/07 JUD409405 27 of 35

4.4 UPGRADE OF THE PARALLEL SYSTEM
4.4.1 INTRODUCTION
The parallel system can be upgraded using the following components:
• A couple of EPROM for the firmware of the UPS (I/S Control Logic PB003), compatible
with the version installed in the system. Example V145E or higher.(*)
• Two PAL of the static switch control card (SCB PB014) U12 SAFE1_23 e U11
OUTGEN41
• A couple of Flash memory PCAN55 or higher for the card RPI PB110.
(*) for non-standard software contact the UPS manufacturer’s Customer Support Service.
ATTENTION
Take particular care to the parameter PHASE, that can be examined in the panel PAR-Data
in the UPS-Test software.
This parameter is set in the following way:
PHASE=2700 for single UPS 50 Hz
PHASE=4000 for parallel UPS 50 Hz
Using the software of the Evolution UPS series (V145E) the value is automatically modified
by changing the configuration of the dip-switches of the I/S Control Logic card to set the
Single/Parallel operation.
Some software releases exist, where the value of this parameter is not controlled by the
position of the dip-switches and must be set with the command PHASxxx:
PHAS270 for single UPS PHASE=2700
PHAS400 for parallel UPS PHASE 4000.
(Software version V145SOL, V145S….)
When substituting the software on the I/S Control Logic, verify always the correctness of the
setting of the parameter PHASE according to what described above.
4.4.2 HARDWARE MODIFICATIONS

For the upgrade of the parallel system, each UPS shall be modified according to the
following instructions:
1. Substitute the EPROM of the I/S Control Logic card, upgrading the firmware release to
the version V145E or higher.
2. Substitute the IC U10 of the SCB PB014 card with the chip marked SAFE1_23 and U11
with the chip marked OUTGEN41.
3. Verify the redundancy logic, that’s to say the parameter N_UPS(N-1/N) on the RPI-Test
software, modifying the value with the command SNULxxx if necessary (it depends on the
required redundancy logic).
4. Substitute the flash memories of the RPI card with the version PCAN55 or higher.
4.4.3 PARAMETERS SETTING

Connect the test software RPI-Test, release2.5 or higher, and send all the RPI cards the
command shown in the following paragraphs
Issued 13/04/07 JUD409405 28 of 35

4.4.3.1 System with 2 UPS – Parallel redundant 1 out of 2

SNUP002
SNUL001
KCFR016
KCQR016
KCFS016
KIFR004
KIQR002
KIFS004
KTFR000
KTQR000
KTFS000
SCII000
MEEE000

SNUP003
SNUL002
KCFR016
KCQR016
KCFS016
KIFR004
KIQR002
KIFS004
KTFR000
KTQR000
KTFS000
SCII000
MEEE000

SNUP004
SNUL003
KCFR016
KCQR016
KCFS016
KIFR004
KIQR002
KIFS004
KTFR000
KTQR000
KTFS000
SCII000
MEEE000
Issued 13/04/07 JUD409405 29 of 35

5. CONFIGURATION FROM SINGLE UPS TO PARALLEL

This procedure describes the modifications to carry out to change a single unit into a UPS
configured as a parallel UPS. The procedure take into account that the microprocessor board
I/S-CL (PB003) is already modified for the parallel operation and the UPS is provided with all
interface cables.
5.1 PCB SETTINGS
Install the RPI board (PB110) on the UPS. Check the Dip Switch position on the RPI board
according to the following table.
POS
DIP1 DIP2 DIP3
UPS
1 ON OFF OFF
2 OFF ON OFF
3 ON ON OFF
4 OFF OFF ON
5 ON OFF ON
6 OFF ON ON
POS UPS is the physical position of UPS in the parallel system.

5.2 MODIFICATIONS FOR UPS 15÷32 KVA
1. Move the cable W27 from the I/S-CL board, connector M3 5-6, to the RPI board,
connector M5 1-2.
2. Insert a jumper on the I/S-CL board, connector M3 5-6.
3. Move the W14-1-MBCB from the I/S-CL board, connector M3 13-14, to the RPI board,
connector M5 5-6.
4. Move the W14-1-SW1 from the I/S-CL board, connector M3 11-12, to the connector M7
of RPI board.
5. Connect the cable W14 3-4 between the connector M8 of the RPI board and the I/S-CL,
connector M3 11-12.
6. Connect the cable W101 from the RPI board, connector M6, and the I/S-CL connector
M3 17-18.
7. Insert the cable W100 on the RPI board, connector M4.
8. Connect the 60-pole flat cables WB, from the RPI board, connector CNB, to the I/S-CL
board, connector CNB.
9. Connect the flat cable W102 from the RPI board, connector CN6, to the I/S-CL board,
connector CN3.
10. Insert the flat cable W6A on the RPI board, connector CN7.
11. Insert the cable W103 (W104 and W105 if present) on the RPI board, connector M1
(W104 Æ M2, W105 Æ M3 ).
12. Insert a jumper on the connector M5 3-4 of the RPI board
13. Install the bus cable CANBUS on the DB9 connector.
14. Refer to the Parallel Redundant System – Test Procedure to test the unit.
Issued 13/04/07 JUD409405 30 of 35


1. Move the cable W27 from the FCI (PB047) board, connector M1 5-6, to the RPI board,
connector M5 1-2.
2. Insert a jumper on the FCI board, connector M1 5-6.
3. Remove the connection between the I/S-CL board, connector M3 11-12, and the FCI
board, connector M2 11-12.
4. Remove the connection between the I/S-CL board, connector M3 13-14, and the FCI
5. Connect the W14-1-MBCB from the FCI board, connector M2 13-14, to the RPI board,
connector M5 5-6.
6. Connect the W14-1-SW1 from the FCI board, connector M2 11-12, to the connector M7
of RPI board.
7. Connect the cable W14 3-4 between the connector M8 of the RPI board, to the I/S-CL
8. Connect the cable W101 from the RPI board connector M6, to the I/S-CL board,
connector M3 17-18.
9. Insert the cable W100 on the RPI board, connector M4.
10. Connect the 60-pole flat cables WB from the RPI board, connector CNB, to the I/S-CL
11. Connect the flat cable W102 from the RPI board, connector CN6, to the I/S-CL board,
connector CN3.
12. Insert the flat cable W6A on the RPI board, connector CN7.
13. Insert the cable W103 (W104 and W105 if present) on the RPI board, connector M1
(W104 Æ M2, W105 Æ M3 ).
14. Insert a jumper on the connector M5 3-4 of the RPI board
15. Install the bus cable CANBUS on DB9 connector.
16. Refer to the Parallel Redundant System – Test Procedure to test the unit.
Issued 13/04/07 JUD409405 31 of 35

Picture 9 – Parallel interconnections diagram
Issued 13/04/07 JUD409405 32 of 35

6. CONFIGURATION FROM PARALLEL TO SINGLE UPS

1. Remove the BUSCAN cable.
2. Remove the jumper on the FCI board (PB047), connector M1 5-6.
3. Move the cable W27 from the RPI board connector M5 1-2, to the FCI board, connector
M1 5-6.
4. Disconnect the cable W14 3-4 from the RPI board, connector M8, and from the I/S-CL
5. Disconnect the cable W14-1-MBCB from the FCI board, connector M2 13-14, and from
the RPI board, connector M5 5-6.
6. Disconnect the cable W14-1-SW1 from the FCI board, connector M2 11-12, and from the
RPI board, connector M7.
7. Insert the connection between the I/S-CL board, connector M3 11-12, and the FCI board,
connector M2 11-12.
8. Insert the connection between the I/S-CL board, connector M3 13-14, and the FCI board,
connector M2 13-14.
9. Disconnect the 60-pole flat cable WB from the RPI board, connector CNB, and the I/S-CL
10. Disconnect the cable W101 from the connector M6 of the RPI board, and from the I/S-CL
11. Disconnect the flat cable W102 from the connector CN6 of the RPI board, and from the
I/S-CL, connector CN3.
12. Remove the flat cable W6 from the connector CN7 of the RPI board.
13. Remove the cable W100 from the connector M4 of the RPI board.
14. Remove the cable W103 (W104 and W105 if present) from the RPI board.
15. Put a jumper between 1-2 of W103 (W104 and W105 if present).
16. Isolate with insulating ribbon the connectors W100, W103 (W104 and W105 if present).
17. Remove the RPI board from the UPS.
18. On the I/S-CL board, move the Dip1 DSW1 in OFF
19. On the I/S-CL board, move the Dip6, DSW1 in OFF
20. On the SCB board (PB014), replace IC U11 (OUTGEN4_1) with the OUTGEN3.
21. On the SCB board, replace IC U12 (SAFE 1_23) with SAFE1_22.
22. On the SCB board (PB014), close JP1.
23. Remove the resistor on the IC U56 on the I/S-CL board.
24. Close the RCB breaker and start-up the logics.
25. By the UPSTest software, connected to RS232, switch-on the inverter sending the
command INON000.
26. With a multimeter, measure the inverter output voltage. If there is some difference with
the nominal value, it’s possible to adjust it with the potentiometer P1 of the VCB card
(PB012).
27. Check the measures (inverter and output voltage) on the UPSTest screen; if they are
different from the actual values (measured), adjust them by sending the appropriate
commands.
28. Store the previous settings by sending the command MEEE000.
29. Switch-off the inverter sending the command INOF000.
Issued 13/04/07 JUD409405 33 of 35
30. Open RCB.

31. On the I/S-Cl board, move the Dip6, DSW1 in ON (Automatic mode).
32. Restart the UPS following the standard procedures.
1. Remove the BUSCAN cable.
2. Remove the jumper on the I/S-CL board (PB003), connector M3 5-6.
3. Move the cable W27 from the RPI board, connector M5 1-2, to the I/S-CL board,
connector M3 5-6.
4. Disconnect the cable W14 3-4 from the RPI board, connector M8 and from the I/S-CL
5. Move the cable W14-1-MBCB from the RPI board, connector M5 5-6, to the I/S-CL board,
connector M3 13-14.
6. Move the cable W14-1-SW1 from the RPI board, connector M7, to the I/S-CL board,
connector M3 11-12.
7. Disconnect the 60-pole flat cable WB from the RPI board, connector CNB and from the
I/S-CL board, connector CNB.
8. Disconnect the cable W101 from the connector M6 of the RPI board and from the I/S-CL
9. Disconnect the flat cable W102 from the connector CN6 of the RPI board and from the
I/S-CL board, connector CN3.
10. Remove the flat cable W6 from the connector CN7 of the RPI board.
11. Remove the cable W100 from the connector M4 of the RPI board.
12. Remove the cable W103 (W104 and W105 if present) from the RPI board.
13. Put a jumper between 1-2 of W103 (W104 and W105 if present).
14. Isolate with insulating ribbon the connectors W100, W103 (W104 and W105 if present).
15. Remove the RPI board from the UPS.
16. On the I/S-CL board, move the Dip1 DSW1 in OFF
17. On the I/S-CL board, move the Dip6, DSW1 in OFF
18. On the SCB board (PB014), replace IC U11 (OUTGEN4_1) with the OUTGEN3.
19. On the SCB board, replace IC U12 (SAFE 1_23) with SAFE1_22.
20. On the SCB board (PB014), close JP1.
21. Remove the resistor on the IC U56 on the I/S-CL.
22. Close the RCB breaker and start-up the logics.
23. By the UPSTest software, connected to RS232, switch-on the inverter sending the
command INON000.
24. With a multimeter, measure the inverter output voltage. If there is some difference with
the nominal value, it’s possible to adjust it with the potentiometer P1 of the VCB card
(PB012).
25. Check the measures (inverter and output voltage) on the UPSTest screen; if they are
different from the actual values (measured), adjust them by sending the appropriate
commands.
26. Store the previous settings by sending the command MEEE000.
27. Switch-off the inverter sending the command INOF000.
28. Open RCB.
29. On the I/S-Cl board, move the Dip6, DSW1 in ON (Automatic mode).
Issued 13/04/07 JUD409405 34 of 35

30. Restart the UPS following the standard procedures.
Issued 13/04/07 JUD409405 35 of 35

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UPS SERVICE MANUAL

Index of sections Code

1 – TECHNICAL SPECIFICATION JUD408572

Issued 13/04/07 JUD409399 3 of 3

Rev.A JSD409388 JUD408572 1 of 7

1. Input mains (separate for by-pass and rectifier)

Rev.A JSD409388 JUD408572 2 of 7

POWER - kVA 200 250 300

Rev.A JSD409388 JUD408572 3 of 7

POWER - kVA 200 250 300

UPS OUTPUT: INVERTER

Rev.A JSD409388 JUD408572 4 of 7

Rev.A JSD409388 JUD408572 5 of 7

Automatic Static By-Pass Electronic Thyristor Switch

Rev.A JSD409388 JUD408572 6 of 7

REMOTE ON PC (by the means of a special test software):

FREE CONTACTS (by the means of an additional card):

REMOTE PANEL (by the means of an RS485 connection):

REMOTE ON LAN (by additional box):

Rev.A JSD409388 JUD408572 7 of 7

Index of sections Code

1 – UPS GENERAL DESCRIPTION AND INSTALLATION JUD408827

JUD408826 18/07/06 Issued

UPS GENERAL DESCRIPTION AND INSTALLATION

JUD408827 02/10/06 Rev. A

2 JUD408827 02/10/06 Rev. A

2. GENERAL UPS DESCRIPTION

Picture 1 – Block diagram

JUD408827 02/10/06 Rev. A 3

2.2 DESCRIPTION OF THE SYSTEM

2.2.3 Battery and charger

2.2.4 Static bypass

2.2.5 Manual bypass

4 JUD408827 02/10/06 Rev. A

2.2.6 Front Panel

JUD408827 02/10/06 Rev. A 5

2.3 OPERATING STATUS

2.3.1 Normal Operation

Picture 2 – Normal operation

2.3.2 Load supplied by bypass due to inverter fault

Picture 3 – Load supplied by bypass

6 JUD408827 02/10/06 Rev. A

2.3.3 Rectifier failure or mains failure

Picture 4 – Rectifier failure or mains failure

2.3.4 Manual bypass

Picture 5 – Manual bypass

JUD408827 02/10/06 Rev. A 7

Picture 6 – Handling B9000 200-300kVA

8 JUD408827 02/10/06 Rev. A

3.3 POSITIONING AND INSTALLATION

3.3.1 Base plan, static load and weights

Picture 7 – Base plan

UPS 200 250 300

UPS 3Ph (kVA) 200 250 300

JUD408827 02/10/06 Rev. A 9

3.3.2 Dimensions and distances

Picture 8 – Distance from the walls

Picture 9 – Layout B9000 200-300kVA

10 JUD408827 02/10/06 Rev. A

3.4 ELECTRICAL CONNECTION

The connection cables section is shown in the following tables:

UPS 3Ph (kVA) 200 250 300

3.4.1 Terminal Board

Picture 10 – Terminal Board