Opm 40 Kva

2 x 40 KVA UPS
OPERATING MANUAL
KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

CONTENTS
1. OVERVIEW
2. PRELIMINARY DESIGN DOCUMENT
3. GENERAL DESCRIPTION
4. SCHEMATIC DIAGRAM & BILL OF MATERIAL
5. GUARANTEED TECHNICAL PARTICULARS
6. SYSTEM ON – OFF PROCEDURE
7. MAINTENANCE AND TROUBLE SHOOTING
8. PCB DESCRIPTION & DIAGRAMS
9. ERECTION AND COMMISSIONING PROCEDURE
10. CATALOGUES

2 x 40 KVA UPS
1. OVERVIEW

The UPS system is designed to provide emergency power to the load when the input power source
fails, typically mains power, failure. This UPS offers 100% parallel redundancy, with bypass. The
system consists of two UPS and SVS also each UPS rated to full load with separate battery banks
and output of both UPS is connected together. The UPS have the Facility to transfer load manually
from UPS to bypass and vice versa.
The UPS system consists of the rectifier section, which receives the power from mains
supply lines. It rectifies the input supply and feeds to the inverter input and charges the battery bank
at required voltage. The DC voltage is maintained at +1% for AC input variation of +10%.
The inverter section converts the DC to alternating current in the form of sine wave. In case of the
failure of the rectifier section, the inverter will be fed from battery.
The system consists of two identical 40 KVA UPS connected in parallel for
100% redundancy, with bypass supply derived through a static voltage stabilizer. In normal
operation UPS1 and UPS2 receives power from mains supply through input circuit breaker Q100 and
operates in parallel redundant mode and share the load equally among them. While both UPS
systems are in parallel mode of operation, one UPS acts as MASTER mode and other shall operate in
SLAVE mode. The MASTER mode UPS will follow the Bypass supply output and the SLAVE
follows the MASTER.
In case any failure occurs in any one of the UPS the entire load will be fed by
the other UPS. If the shutdown is on SLAVE UPS entire load will be fed by MASTER UPS and in
case shutdown is on MASTER UPS, SLAVE UPS will be switched over automatically to MASTER
mode and feed the entire load. And when the two UPS is shout down, the entire load will be fed by
the bypass supply. During failure of inverter section of any one of the UPS, fault UPS shall get
isolated automatically from the system, generate alarm and other UPS shall take care of entire load
without any interruption.
The Digital Signal Processor based control circuit is used for the closed loop
control of the rectifier. The controller will read voltage reference, input voltage feedback, input
current details, battery voltage feedback, battery current feedback, inverter current, inverter output
voltage, inverter output current and bypass voltage feedback.

Both MANUAL and AUTO modes with selector switch shall be provided for
boost charging. In the AUTO mode the Current Sensor provided will sense the demand for more
charging current persisting beyond a pre- set value and the charging operation will go automatically
to boost mode. Boost charging will automatically return to float after normalization of demand.
Float/ boost selector switch is provided for selecting boost
charging/ float charging of the battery. Boost charging will automatically return to float after
normalization of demand.
During failure of the input supply (AC mains failure) or any failure in rectifier
section, the load will be fed from the battery bank by the inverter section at the specified output
voltage frequency without any interruption.
STATIC VOLTAGE STABILIZER
The input AC supply is connected to the transformer T105 through the MCCB Q100.
The transformer is connected in 3ph to 1ph configuration and the secondary voltage is connected to
the output terminal through a booster transformer T450. The auxiliary secondary terminals are
connected to a diode bridge and the rectified dc voltage is connected to an inverter bridge. The
inverter output voltage is varied in accordance with the variations in the input and is added to the
transformer secondary voltage. The inverter voltage control is accomplished with the help of a DSP
based controller. The DSP controller ensures fast response and high degree of regulation of the
output voltage. Q750 is provided for the isolation of the SVS output voltage

2 x 40 KVA UPS
2. PRELIMINARY DESIGN DOCUMENT

2.1 Technology Trends and Basic Scheme
2.1.1 INTRODUCTION
In the present scenario, commercial power supply is not capable of providing

clean and consistent electric power demanded by sensitive equipments. Sensitive equipments
require consistent power of correct specification for their proper operation, hardware protection,
and continuity of process, storage and transfer of information. It is essential that the equipments
are protected against power problems like surges, spikes, blackouts etc. Such a situation demands
an Uninterruptible Power Supply (UPS) that can take care of critical loads. The installation of an
uninterruptible power supply system is nowadays accepted as being a vital element in the
protection of sensitive equipments.
2.1.2 TYPES OF UPS

A. ON LINE UPS SYSTEMS
The ON line UPS system consists of a Rectifier / Battery charger, Battery

bank and an Inverter. The mains supply drives the Rectifier / Battery charger which supplies DC
to the Inverter and charges the Battery bank. When the mains is present, the inverter draws power
from the mains and when the main supply fails or varies from the specified limits, the inverter
draws power from the battery providing a smooth AC signal of fixed amplitude and frequency.
The load is always driven from the inverter.
B. OFF LINE UPS SYSTEMS
The OFF line UPS system consists of a Battery bank and a Rectifier / Inverter.
Under normal power condition the load is driven directly by the mains and the rectifier charges
the battery Bank. When the main supply fails, the inverter provides AC power to the critical load
from the back up battery.
2.1.3 TECHNOLOGICAL TRENDS
A. DOUBLE CONVERSION ON LINE UPS SYSTEMS
The block diagram of double conversion UPS system is shown in fig.1. The 3-
phase AC input from the mains is connected to the Rectifier / Charger block, which consists of a
controlled rectifier bridge. The output of the Rectifier is connected to the Battery and the Inverter.
When the mains supply is within the specified limits, the charger rectifies the AC supply and the
battery will be charged to its rated voltage. The DC voltage available at the input side of the

inverter is converted into AC power and feeds to the critical load. When the main supply is not
present or varies from the specified limits, the rectifier output is isolated and the input to the
inverter is taken from the battery. Thereby the UPS is continuously giving AC power to the load.
The mains voltage and current waveforms are shown in fig.2.
STATIC SWITCH
MAINS LOAD
~ =
~ = ~
INVERTER
C
Fig.1 BLOCK DIAGRAM OF DOUBLE CONVERSION UPS SYSTEM
Fig.2 Mains Voltage and Current Waveforms of a Double conversion System
DRAWBACKS
• This double conversion UPS system will introduce harmonic currents to the mains supply
since most of them have a thyristor-controlled converter at the input side. Such harmonic
currents disturb the voltage quality, which in turn may cause sensitive equipments to
malfunction.
• Low input power factor. This leads to requirements for over dimensioned power installation
on both the distribution and transmission levels.
• The double conversion scheme has two conversion stages. So the energy losses will be high.

B. SINGLE CONVERSION OFF LINE UPS SYSTEMS
The block diagram of single conversion UPS system is shown in fig.3. This
scheme has only one conversion stage whereas the double conversion scheme has two conversion
stages. During the normal operating condition, the static switch is closed and the power to the
load is taken from the mains via the choke. Thus the power is not converted twice as in the case of
double conversion scheme. So the energy loss is very low when compared to the double
conversion scheme. The input voltage to the load is sinusoidal, it follows that the current taken
from the mains via the choke is also sinusoidal. Thus there are no mains harmonic currents from
this technique.
STATIC SWITCH
MAINS
LOAD
=
~
DUAL
CONVERTER
Fig, 3 BLOCK DIAGRAM OF SINGLE CONVERSION UPS SYSTEM
Fig. 4 Mains Voltage and Current Waveforms of a Single conversion System

In the case of mains supply failure; the energy to the load is taken from the
battery. Now the dual converter will act as an inverter and feeds AC power to the load. In order
not to feed back into the mains during battery operation, the static switch is opened. If the main
supply is present, the static switch is closed again and the power to the load is taken from the
mains. Now the dual converter will act as a rectifier and the battery will be charged to its rated
voltage. The mains voltage and current waveforms are shown in fig.4.
DRAWBACKS
Low power factor. Furthermore the power factor varies with the mains and with the load.
Load is not protected from the transient disturbances on the mains.
3. BASIC SCHEME OF DYNAMIC POWER MANAGER (DPM) UPS SYSTEM
The Dynamic Power Manager UPS system overcomes the drawbacks of

conventional double conversion and single conversion UPS systems. The block diagram of DPM
UPS system is shown in fig.5. The scheme has two inverters connected to a common battery / DC
bus. DVR Inverter is rated at 30% of rated output power of the UPS and it is connected via a
transformer in series with the mains supplying the load. The main Inverter is a fully rated inverter
and has basically the same function as the inverter in the single conversion UPS system.
The DPM UPS system controls the input power to the UPS and also the input
power factor to almost unity. When the mains is present, the DVR inverter regulates the output
voltage and the main inverter controls the power factor and charges the battery. When the mains
fails, main inverter supplies the load from the battery. The static switch is used to prevent back
feed into the mains when the mains supply is not present. The mains voltage and current
waveforms are shown in fig.6.

Fig. 5 BLOCK DIAGRAM OF DPM UPS SYSTEM
Fig.6 Mains Voltage and Current Waveforms of a Grid Interactive UPS System
ADVANTAGES OF DYNAMIC POWER MANAGER UPS SYSTEM
• Near unity power factor at input

• Higher efficiency starting from 20% load
• High reduction in energy waste
• Back feed of harmonic current reduction
• Optimum utilization of installed capacity
Disadvantages of Dynamic Power Manager UPS System
It is not the perfect choice to Frequency critical loads

2.2 BASIC SCHEME OF DSP BASED ONLINE UPS SYSTEM WITH IGBT BASED RECTIFIER
The DSP based online ups system with IGBT based Front End Converter
overcomes the drawbacks of double conversion and single conversion UPS systems. The block
diagram of this system is shown in fig.6. In this scheme inverter connected to a common battery /
DC bus.
This UPS system controls the input power to the UPS and also the input power
factor to almost unity. When the mains is present, the Rear End Inverter regulates the output
voltage and the frequency; also the Front End Converter controls the power factor and charges the
battery. When the mains fail, Rear End Inverter supplies the load from the battery. The mains
voltage and current waveforms are shown in fig.7.
INPUT LOAD
FEC Inverter Inverter SS
Battery
Bypass SS
Fig. 6 Block diagram of DSP based online UPS system with IGBT Based Rectifier
Fig.7 Mains Voltage and Current Waveforms of a DSP based online UPS system with IGBT
BASED Front End Converter

ADVANTAGES OF DSP BASED ONLINE UPS SYSTEM WITH IGBT BASED FRONT
END CONVERTER
• Near unity power factor at input

• Higher efficiency starting from 25% load
• High reduction in energy waste
• Back feed of harmonic current reduction
• Optimum utilization of installed capacity
2.3 DESCRIPTION OF POWER SECTION - INVERTER
The Inverter of the UPS is working on the principle of PWM technique. The
Control circuit is built on TMS 320LF2407A DSP controller. The DSP generates 10 KHz PWM
pulses to switch the power devices. IGBT is used as switching elements. The higher switching
frequency ensures better performance for dynamic as well as static conditions. Supervising
alarms, indication, and display are some of the features of the system. Modbus connectivity can
be added for monitoring the status and for diagnosing the fault.
2.3.1 DESIGNS AND MODE OF OPERATION OF THE INVERTER
1. Inverter power Control Device (IGBT Bridge).

2. Output Isolation Transformer.
3. Output Smoothening LC filter.
4. Inverter static switch.
5. Output MCCB. (Q750)
FIG 3.1

1. INVERTER POWER CONTROL DEVICE (IGBT BRIDGE).
Inverter Power Control Section can be divided into two subsections
1. POWER CIRCUIT
2. CONTROL CIRCUIT
POWER CIRCUIT
The Inverter of the UPS consists of IGBTs. The gate pulse from the Control
Card is fed to the device through IGBT GATE DRIVE CARDS. The DC voltage from Charger
and Battery is fed to the Inverter Bridge Circuit
CONTROL CIRCUIT
The Controller of the Inverter is working on the principle of PWM technique
.The Control circuit is built on TMS320Lf 2407A DSP platform. The DSP generates 10 KHz
PWM pulses to switch the power devices. Block Schematic of the control circuit is shown below.
FIG 3.2
The controller of the Inverter comprise of Voltage controller and Current

controller. Voltage controller is PI Controller and Current controller is P Controller. These
controllers generates PWM pulses from the feedbacks Iload (load current measured by Hall Effect
sensor), Vload (output voltage measured by PT), Iinv (inverter output current measured by Hall
Effect sensor), VDC (dc voltage feedback). These pulses are fed to Gate Drive cards which drives

the power control devices. This controller offers faster response. The advantage of DSP based
inverter is that the lower Output Voltage THD and fast transient response
2. OUTPUT ISOLATION TRANSFORMER
Output transformer provides isolation from the load to the ups power circuit. It
step up or step down the voltage so that it meets output voltage.
3. OUTPUT SMOOTHENING LC FILTER

.
The inverter output will be switched waveform as shown FIG 3.3. The LC
filter makes the waveform sinusoidal as shown in FIG 3.4. As the switching frequency is very
high rating of the components needed is low. This avoids the use of bulk inductor and capacitors.
FIG 3.3 FIG 3.4
4. INVERTER STATIC SWITCH.
Static switches are two anti parallel Thyristors with a common gate. It can be
switched on in the order of micro seconds. This avoids any break in the waveform while
transferring load from UPS to Bypass and vice versa
5. OUTPUT MCCB
Output MCCB allows us to disconnect the load from UPS.

2 x 40 KVA UPS
3. GENERAL DESCRIPTION

40 KVA UPS
Keltron UPS system delivers continuous power supply to the load with
regulated voltage & frequency. The UPS system consists of sub modules viz, the
RECTIFIER / CHARGER, the ‘INVERTER’ and STATIC SWITCHES housed in a single
cubicle by the principle of integrated design.
Description
1.0 40 KVA UPS modules
Ref : SD 105 008 671
Page1/4 of SD 105 008 671

The block schematic of the UPS is shown. The 415V, 3ph, 4 wire AC
supply is connected to the input terminals.Q100 is the input MCCB used to isolate the UPS
from the supply.Q101 is the input contactor and the working of the contactor is illustrated
in page 2/4. T105 is the input transformer which translates the input voltage to the desired
value. A bridge circuit is used to rectify the AC voltage into DC voltage and the DC voltage
is fed to the battery through Q300. The DC voltage is also connected to the inverter bridge
and the DC voltage is converted into AC voltage. The AC voltage is connected to the load
through the static switch. Q750 is used to isolate the output from load.
Page2/4 of SD 105 008 671
The healthiness of the input supply is shown by the LEDs LD100, LD100A,
and LD100B. Potential Transformers PT1-PT3 are used to sense the input voltage and its
secondary voltages are connected to the controller PCB. The power supply is derived from
the input voltage as well as from the battery. MCB103 connects the input voltage to the
transformer T103 and its secondary is rectified by V340 and the DC voltage is connected to
the SMPS.

The SMPS generates the required voltage levels +15V, +5V, +12V,-12V.The
rectified DC voltage from V341 is connected to the dc bus through MCB303. The DC filter
capacitor C301 (A, B, C) is charged through resistor R301. This circuit is known as pre
charging circuit. The output filter capacitor can also be charged from the battery supply
through MCB301 .When the capacitor voltage reaches about 150V, the controller PCB will
give command to switch on the input contactor Q101, if input MCCB Q100 is in ON
condition. Now the AC supply is connected to the bridge circuit constituted by V111-116
through the transformer T105.
The reverse diode across the IGBT rectifies the AC voltage into DC voltage.
Now the unit is ready for switching ON. The unit ON command from the mimic shall be
given to switch on the system. The PWM pulses generated by the controller are connected
to the IGBT module through the driver circuit. Hall Effect sensors LEM1 and LEM2 are
used to sense the input current and LEM9 is used to sense the battery current and is used to
limit the charging current of the battery. The battery voltage is connected to the earth fault
PCB and when either of the battery terminals shows earth leakage the earth fault PCB gives
the earth fault alarm. L111 and L112 are the panel illumination lamps and are controlled by
the door limit switch DLS111 and DLS112.
Page 3/4 of SD 105 008 671

The DC voltage is connected to Inverter Bridge constituted by V411-414 and
the output is connected to the inverter transformer T450. The PWM pulses from the
controller PCB is connected to the inverter bridge through the gate drive circuit. The PWM
output of the inverter bridge circuit is filtered by the filter circuit L601 - C601 and the
sinusoidal waveform is connected to the output through the static switch formed by V611-
612. Q750 is the isolator MCCB. LEM3 is used to sense the inverter current. PT4 is used to
sense the inverter voltage and Potential Transformers PT7-PT8 are used to sense the bypass
voltage. E640, E640A, E640B, E641, E641A and E641B are the cooling fans.

2 x 40 KVA UPS
4. SCHEMATIC DIAGRAM AND BOM

3900
1500 1500 900 900

UPS 1 UPS 2 SVS + SS
DSS40 DSS40 SVS40+SS
INSTRUMENT PLATE 1 INSTRUMENT PLATE 2 INSTRUMENT PLATE 1

INSTRUMENT PLATE 2
INSTRUMENT PLATE 3
V (M102) A (M101) V (M602) A (M601) V (M102) A (M101) V (M602) A (M601) A (M101) V (M102)
INPUT VOLTAGE INPUT CURRENT OUTPUT VOLTAGE OUTPUT CURRENT INPUT VOLTAGE INPUT CURRENT OUTPUT VOLTAGE OUTPUT CURRENT INPUT CURRENT INPUT VOLTAGE
Hz (M103) Hz (M603) Hz (M103) Hz (M603)

(M103)
R R OFF
OFF OFF (SW101)
(SW101) (SW101)
VRY IR
VBR IB
FREQUENCY METER FREQUENCY METER FREQUENCY METER FREQUENCY METER
VRY I R
VRY I R
VBR IB
VBR IB
Ø100 Ø750 Ø100 Ø750
Ø960 Ø960
INPUT INPUT
A (M301)
VYB IY
TO LOAD A (M301)
VYB IY
TO LOAD
Hz VYB I Y
Ø940 Ø940
VM/AM SELECTOR SWITCH
VM/AM SELECTOR SWITCH VM/AM SELECTOR SWITCH
BYPASS BYPASS
INPUT FREQUENCY
INVERTER CURRENT ON INVERTER CURRENT ON

OFF OFF
SYSTEM ON-OFF SYSTEM ON-OFF A (M701) V (M702)
V (M303) A (M302) V (M303) A (M302)
( FRONT )
BYPASS OUTPUT CURRENT BYPASS OUTPUT VOLTAGE
BATTERY VOLTAGE BATTERY CURRENT BATTERY VOLTAGE BATTERY CURRENT
A (M901) V (M902)
DISPLAY MODULE1 DISPLAY MODULE1
UPS 2000
OUTPUT CURRENT OUTPUT VOLTAGE
Hz (M903)
LD100 LD100A LD100B LD305 LD306 LD100 LD100A LD100B LD305 LD306
INPUT-R INPUT-Y INPUT - B DC EARTH FAULT OUTPUT EARTH FAULT INPUT-R INPUT-Y INPUT - B DC EARTH FAULT OUTPUT EARTH FAULT OUTPUT FREQUENCY
LD303 LD304 LD301 LD302 LD303 LD304 LD301 LD302
AUTO MANUAL FLOAT BOOST AUTO MANUAL FLOAT BOOST
SW301 SW302 SW301 SW302

(PB1) (PB1)
LD640 LD901 LD902 LD701

2000
SVS ON FAN ON STATIC SWITCH OUTPUT LOAD ON SERVICE SVS FAIL

FUSE FAIL EARTH FAULT BYPASS
ACCEPT AUTO/MANUAL SELECTOR FLOAT/BOOST SELECTOR ACCEPT AUTO/MANUAL SELECTOR FLOAT/BOOST SELECTOR
SW102
1900
BYPASS TRANSFER SWITCH
F.F.L
INPUT MCCB
(Q100)
M12 FOUNDATION BOLT,

12 Nos*
F.F.L F.F.L ISMC 100x50 BASE F.F.L
CABLE ENTRY CABLE ENTRY CABLE ENTRY CABLE TRENCH
(450Wx600D min)
FRONT VIEW
125 (450)
NOTE:-
1. PANEL IS DESIGNED FOR OVER HEAD CRANE TRANSIT.

2. PANEL IS INDOOR ,FLOOR MOUNTED & FORCED AIR COOLED TYPE;
CUBICLE FRAME IS FABRICATED FROM 2,5mm THK.CRCA SHEET STEEL &
DOORS ARE OF 2mm THK.
3. CABLE ENTRY IS FROM BOTTOM OF CUBICLE.
4. FINISH : ALL FRAME,DOORS&COVERS ETC. ARE PRETREATED BY 7 TANK-
PROCEES-(AS PER IS 6005); PRIMER COATED & PAINTED
49
FINAL PAINT FINISH OF EQUIPMENT IS EPOXY LIGHT GREY;SHADE AS PER 631 OF IS 5

49
0
5. APPROX.WT.OF PANELS :
( FRONT ) UPS 1 = 1100 Kg.
UPS 2 = 1100 Kg.
SVS = 650 Kg.
CABLE ENTRY CABLE ENTRY
6. PANEL PROTECTION : IP42
CABLE ENTRY
GLAND PLATE GLAND PLATE GLAND PLATE 7. REFERENCE DOCUMENTS/ DRAWINGS:-
>1860
(a). SCHEMATIC DIAGRAM FOR UPS :- SD 105 008 671

900
850
(b). ELECTRICAL BOM FOR UPS :- DPL 105 008 671

=
(c). SCHEMATIC DIAGRAM FOR SVS + SS :- SD 105 008 672

(d). ELECTRICAL BOM FOR SVS + SS :- DPL 105 008 672
8. FRONT & BACK DOORS ARE PROVIDED WITH CONCEALED
150 1200 300 1200 300 600 (150) HINGES & LATCH TYPE LOCKING ARRANGEMENT (WITH KEYS) .
9. BRACKETED DIMENSIONS INDICATES MINIMUM CLEARANCE
01 03 15/11/19 AS BUILT
BOTTOM VIEW (Foundation) 01 02 27/06/19 REVISED
01 01 27/05/19 REVISED
01 00 27/03/19 ORIGINAL
ISSUE REV. No. DATE DESCRIPTION ENGINEER APPROVED NUMBER QTY. ITEM
PROJ. EM1\E:\2019\DS40 DPS HWP\DMA671

CUSTOMER : M/s DEPARTMENT OF ATOMIC ENERGY
TOL. GEN. ± PJT.
PROJECT : DPS HEAVY WATER PROJECT INTER AXIS ±
PO.No. : PO. No. : DPS/CPU/10/B1/1656-TPT/PO/42270 Dtd 11-02-2019 TITLE
DRAWN ENGINEER APPROVED DIMNS SCALE
MAIN ARRANGEMENT OF 2 x 40kVA UPS & SVS40+SS
SJK MM NTS
DATE 27/03/19 DATE DOC. NUMBER SIZE REV.No.
READ THIS DRG.ALONG WITH PAGES 2 & 3 CODE A3 03
DMA 105 008 671 NO. OF 1
SHEETS 3
DETAIL OF DISPLAY MODULE-UPS DETAIL OF INSTRUMENT PLATE-1
R
Ø100 Ø750
Ø960
INPUT
TO LOAD
Ø940
V (M102) A (M101)
BYPASS
ON
OFF
SYSTEM ON-OFF
INPUT VOLTAGE INPUT CURRENT
Hz
(M103)
OFF
(SW101)
FREQUENCY METER
VRY IR
VBR IB
LD100 LD100A LD100B LD305 LD306
A (M301)
VYB I Y
INPUT-R INPUT-Y INPUT - B DC EARTH FAULT OUTPUT EARTH FAULT
VM/AM SELECTOR SWITCH
LD303 LD304 LD301 LD302

INVERTER CURRENT
AUTO MANUAL FLOAT BOOST V (M303) A (M302)
SW301 SW302
PB1 BATTERY VOLTAGE BATTERY CURRENT
ACCEPT AUTO/MANUAL SELECTOR FLOAT/BOOST SELECTOR
01 03 15/11/19 AS BUILT
01 02 27/06/19 REVISED
01 01 27/05/19 REVISED
01 00 27/03/19 ORIGINAL

TOL. GEN. ± PJT.
READ THIS DRG.ALONG WITH PAGES 1& 3 DRAWN ENGINEER APPROVED DIMNS SCALE
SJK MM NTS
CODE A3 03
DMA 105 008 671 NO. OF 2
SHEETS 3
DETAIL OF INSTRUMENT PLATE-SVS+SS
DETAIL OF INSTRUMENT PLATE-2

A (M101) V (M102)
INPUT CURRENT INPUT VOLTAGE
V (M602) A (M601) (M103)

OFF
(SW101)
VRY IR
VBR IB
OUTPUT VOLTAGE OUTPUT CURRENT
VYB I Y
Hz
VM/AM SELECTOR
Hz (M603)
INPUT FREQUENCY
A (M701) V (M702)
FREQUENCY METER
BYPASS OUTPUT CURRENT BYPASS OUTPUT VOLTAGE
A (M901) V (M902)
LEGENDS:- OUTPUT CURRENT OUTPUT VOLTAGE
1)DSS40 2)SVS+SS
M101 -INPUT CURRENT M101 -INPUT CURRENT Hz (M903)
M102 -INPUT VOLTAGE M102 -INPUT VOLTAGE

M103 -FREQUENCY METER M103 -INPUT FREQUENCY
M301 -INVERTER CURRENT M701 -BYPASS OUTPUT CURRENT
M302 -BATTERY CURRENT M702 -BYPASS OUTPUT VOLTAGE OUTPUT FREQUENCY
M303 -BATTERY VOLTAGE M901 -OUTPUT CURRENT
M601 -OUTPUT CURRENT M902 -OUTPUT VOLTAGE
M602 -OUTPUT VOLTAGE M903 -OUTPUT FREQUENCY
M603 -FREQUENCY METER SW101 -VM/AM SELECTOR
SW101 -VM/AM SELECTOR SWITCH SW102 -BYPASS TRANSFER SWITCH LD640 LD901 LD902 LD701
SW301 -AUTO/MANUAL SELECTOR LD640 -FAN ON
SW302 -FLOAT/BOOST SELECTOR LD901 -STATIC SWITCH FAIL
PB1 -ACCEPT LD902 -OUTPUT EARTH FAULT
LD100 -INPUT-R SVS ON FAN ON STATIC SWITCH OUTPUT LOAD ON SERVICE SVS FAIL
LD701 -LOAD ON SERVICE BYPASS
LD100A -INPUT-Y
LD100B -INPUT-B
LD301 -FLOAT SW102
LD302 -BOOST
LD303 -AUTO
LD304 -MANUAL
LD305 -DC EARTH FAULT
LD306 -OUTPUT EARTH FAULT BYPASS TRANSFER SWITCH
01 03 21/11/19 AS BUILT
01 02 27/06/19 REVISED
01 01 27/05/19 REVISED
01 00 27/03/19 ORIGINAL

TOL. GEN. ± PJT.
READ THIS DRG.ALONG WITH PAGE 1& 2 DRAWN ENGINEER APPROVED DIMNS SCALE
SJK MM NTS
CODE A3 02
DMA 105 008 671 NO. OF 3
SHEETS 3
1 2 3 4 5 6
UPS1 UPS2 SVS

INPUT 415V AC, 3 Ph, 50 Hz, 3 Wire
INPUT 415V AC, 3 Ph, 50 Hz, 4 Wire INPUT 415V AC, 3 Ph, 50 Hz, 4 Wire
A A
100 A Q100 100 A Q100
.V .V .V
0 - 500V 0 - 500V 0 - 500V
95 A Q101 .A 95 A Q101 .A 150 A Q100 .A
0 - 100A 0 - 100A 0 - 150A
59.3 KVA .F 59.3 KVA .F .F

B T105 T105 48 KVA T105 B
415V/248.4V 415V/248.4V
0-55 Hz 0-55 Hz 415V/99V 0-55 Hz
.
.
RECTIFIER RECTIFIER
.
.
Q300 Q300
.
0 - 150A 125A 0 - 150A
125A
A
.
C
A C
V V 9.6 KVA T450

.
.
INVERTER 0 - 600 0 - 600 125V/22V
BTY BTY
.
.
A A .V
0 - 150A 0 - 150A
0 - 200V
48 KVA T450 48 KVA T450
227.7 V/110V 227.7 V/110V .A
Q940
400 A 0 - 600A
.
.
D STATIC SWITCH STATIC SWITCH D
.
STATIC SWITCH
.
.
500A Q750 500A Q750
0 - 150V 0 - 150V
.V .V
630 A Q960
0 - 600A 0 - 600A
.A .A 0 - 200V
.V
0-55 Hz 0-55 Hz
E .F .F 0 - 600A
E
.A
0-55 Hz
.F
To LOAD
04 PROJECT: M/s Department Of Atomic Energy Size
F 03
DPS PO NO. - DPS/CPU/10/B1/1656 - TPT/PO/42270 <title>
F
Dtd 11-02-2019 Page
02 20-05-19 For Approval Heavy Water Project
TITLE
26-03-19 For Approval
DSS 40 1
01
00 13-02-19 For Approval

40KVA, 1Ph, 110V UPS (DSP Based) 4
KERALA STATE ELECTRONICS NUMBER 00
REV. DATE DESCRIPTION CHECKED REVIEWED APPROVED DEVELOPMENT CORPORATION LTD. SD 105 008 671 Issue
1 2 3 4 5 6
1 2 3 4 5 6
T650.1
T650.4
M103 M102 T650.1
M101
T650.4
F V A
M301
A A A
.
.
.
.
CC-DB3-18
SW101
SMPS1-V2-8
SMPS1-V2-5
V1
V2
A1
A2
CCDB3.17
CC-DB3-6
DC +VE
SELECTOR SWITCH
R Y B R1 Y1 B1
PA111 PA113 PA115 SH 301
10
11
2
6
7
9
-
-
Pulse C Pulse C Pulse C
V111
V113
V115
+12V
TRIP TRIP TRIP
GND
.
F105.
F106.
.
.
.
.
.
.
-12V
F104
M
G G G
Q100 Q101 L101R
R T105 LEM1 * * *
.
.
.
.
. . 1 2 1 2 0V 0V 0V
. .
15V E 15V E 15V E
C304
C302
C303
CT101
F101
INPUT415V, 3 Ph
+12V
GND
-12V
Y L101Y
M
B . . . 3 4 3 4 To DC BUS B
. .
EMI FILTER
LEM2 F102
.
.
.
.
CT102 Page -2
+ + +
L101B C301A C301B C301C
B F103
. . . . . 5 6 5 6
CT103
Pulse C Pulse C Pulse C
V114
5 6
V112
V116
Z101 3 4 TRIP TRIP TRIP
N 1 2 G G G
. . . . . 7 8 0V * 0V * 0V *
CCDB2.3 (GND) 13 14
.
D100 15V E 15V E 15V E

LD100 R100 MOV1 MCB101
CCDB2.1
.
PA112 PA114 PA116 DC -VE

LD100A D100A R100A MOV2
C TRIP1 C
M302
GND
SH 302
LD100B D100B C101 *
R100B MOV3
+15V A
MIMIC
M303
F302
PT3 PT2 PT1
1 2 1 2 5 17 6 4 7 20 8 15 6 19 8
V
D101
6 4 6 2 6 2
1
F303
SMPS2.V2
CONTROL
CONTROL
CONTROL
CARD(V2)
CONTROL
CONTROL
CARD(V2)
CARD(V2)
K101
CARD(V2)
CARD(V2)
9 11
CONTROL
CONTROL
9 11 9 11
CARD(V2)
CARD(V2)
2
T650.1
T650.4
VgYB(CC-DB3-14)
GND(CC-DB3-15)
VgBN(CC-DB3-2)
VgRY(CC-DB3-1)
R301
1
B411 1 2 1 2 1 2
SMPS1-V2-8
SMPS1-V2-6
D B111 B112 B113 D

CCDB3.13 Q300
D304
MCB302
4 2
MCB103 V340 4 3 Q300
-
VDC -ve
T103 +12V V2.8 D302
R 1 2 1 4 300V SMPS 1 VDC +ve 2 1
Q300
6
V2.2 (360V)
3
0V
MCB301
415V 3 V Batt.
D301
+
Y 3 4 2 5 270V
3
2 1
4
S101 TC101 SPH101
D303
+
F111 4 3
1 2
MCB303
VDC -ve
TB2 V341 SMPS 2 VDC +ve
F112 L111 +15V V2.1
-
Q100.1 1 2 1 1 230V,20W, (360V)

GND T2
2 CFL V2.2 V Batt. SMPS1 +12V T6
E Q100.2 2 DLS111 E
R311
1
PS111 LAMP T8 F300

3 R310
3 GND T4
L112 PCB 301 T1
2 1 1 230V,20W, FFPCB1 . +12V SMPS1-V2-8
2 CFL Voltage Sensing PCB FF Sensing PCB -12V SMPS1-V2-5
LEM9
DLS112
2
LAMP .
M CC- DB3-22
+12V CN1.1 .
GND CCDB3.17
(SMPS1)
Low Battery .
-12V CN1.2
DC EARTH FAULT CN2.5 RLPCB1.T76
GND CN1.3
-VE +VE
LD305 R318 BATTERY
GND R314 SMPS1 V1.30 CN1.6
T5 Battery +VE
PCB1 T3
MIMIC T6 Earth Fault SD 105 010 344
R315
SMPS1 +12V T8 SD 105 010 310 T2 Battery -VE AW 205 840 255
F AW 205 840 268 F
GND T4 T1
03
Dtd 11-02-2019 Page

02 20-05-19 For Approval Heavy Water Project TITLE
* . 2 in parallel
DSS 40 2
01

1 2 3 4 5 6
1 2 3 4 5 6
SMPS1 +12V
T8 T6
FF Sensing PCB
T650.1
GND T4 FFPCB2
A T1 T2 T650.4 A
R316
M603
M602
M601
R410 R411
V load (DB3-3)
GND (DB3-17)
D601
D603
F410
F V A
DC +VE PA411 PA413
SMPS V2.8
SMPS V2.5
CCDB3.17
CC.DB3.7
Pulse C Pulse C
V411
V413
MCB601
TRIP TRIP 9 11
D602
D604
CC DB2.3 (GND)
G G PT4
CC DB2.9 13 14 4
. +12V
6
. GND
R317
. -12V
0V 0V
F602
F603
1 2
. M
15V E 15V E L601 Q750
B I Inv T450 F601 V611 B
1 2 T5
360V DC LEM3 V612
CT601
From DC BUS Page-2
Z645
* To SVS T5 & T6
C305
C306
C601
OUTPUT 110V, 1 Ph. 50 Hz
+ +
C305A C305B
3 4 T6
PA412 PA414
Pulse
C Pulse
C
V412
V414
TRIP TRIP 13 14 CCV5.7 (GND)
V 611G
V 611K
V 612G
V 612K
G G 1 2
F604
F605
F606
C 0V * 0V * MCB640 C
K1
1
K2
G1
G2
15V E 15V E
DC -VE
SS DRIVER CARD
T650
3 E640 E640A E640B
DSD PE 057 0005
230V,64W
AW 205 840 324
Z640
Z640A
Z640B
TRIP2 +5V (SMPS1) DB1 2 3
1
4
+15V
R304
R305
+15V (SMPS1 V2.1)
GND CCDB3.8 (V Ref)
GND (SMPS1 V2.2)
13 14 MCB642.11
+12V (SMPS1) CCDB3.21 (I Ref) SMPS1 V2.7
2 17 5 6 1 2 1 4 20 7 8 1 2
R302
R303
RV1
RV2
RV3
RV4
F607
F608
F609
D CONTROL CONTROL MCB641 D
CARD(V3) SMPS-2 CARD(V3)
(V2)
O/P EARTH FAULT
LD301
LD302
LD306 R319 E641 E641A E641B

B411 B412 GND R316
T5 D603.K
230V,64W
B111.1 1 2 1 2 PCB2 T3
Z641
Z641A
Z641B
CC - DB3-11 MIMIC MIMIC Earth Fault R317
RLPCB2.T5 D604.A
Boost
Boost
Boost
Float
Float
Float
T6 T2
SD 105 010 310
SMPS1 +12V T8 AW 205 840 268
C1
C2
CCV5.16
A1
A2
B1
B2
GND T4 T1 MCB641.12 13 14
1 2
AUTO / MANUAL SELECTOR SWITCH FLOAT / BOOST SWITCH SW302
MCB642 E642
E E
230V,64W
Z642
SW301
. 13 C
. 11 A
. 23 B
Auto +5V
. 12
. 24
. 14
A1
AW 205 840 229/1
CCDB3.20 A A2 Manual GND

RELAY PCB
+12V (SMPS1) 22 .
CC DB3.12 (ATM) 8 . RLPCB 3

LD303
R306
B1 Auto +12 V
.
.
10
27
R307 04 PROJECT: M/s Department Of Atomic Energy Size

9
GND B B2 Manual GND

F 03
F
LD304 Dtd 11-02-2019 Page
TITLE
MIMIC
DSS 40 3
01

2 in parallel NUMBER 00
* REV. DATE DESCRIPTION CHECKED REVIEWED APPROVED
KERALA STATE ELECTRONICS
DEVELOPMENT CORPORATION LTD. SD 105 008 671 Issue
1 2 3 4 5 6
1 2 3 4 5 6
CONTROLLER CARD CONNECTOR DETAILS SMPS.1 CARD CONNECTOR DETAILS CONTROL CARD (V2) CONTROL CARD PARAMETER ON TFT DISPLAY
25 PIN D-CONNECTOR- DB3 V2 9 PIN D-CONNECTOR- V2 FEC_GATE DRIVER CARDS (V5 Connection Details)
1. Input Voltage
1 +15V --- StaticSwitch Cards 1 TRIP1 1 NC
DB3 2. Input current
2 GND 2 PULSE (R Ph TOP) 2 NC
1 V grid RY --- PT1/9 3. Input frequency
3 NC 3 NC 3 NC
2 V grid BN --- PT3/9 4. Output Voltage
A 4 NC 4 PULSE (Y Ph TOP) 4 NC A
3 V load --- PT4/9 5. Output current
5 5 5 Manual Transfer
4
-12V --- LEMs GND DB5A / 5B.10 MIMIC PCB
6. Output frequency
NC 6 6 6 System-ON/OFF
5
I/P Cont. Control --- Q101/K101 GND V4.22 7. DC Voltage
By SS Control (DB5A.7) 7 7
For Pulses 7 GND
6
INV.SS.Control --- INV.SS.PCB/DB1/3 GND V4.23 8. Battery current
I grid Yph --- (LEM2/M) 8 8 8 LED - FEC
7
+12V --- LEMs & K101 GND V4.30 9. Bypass Voltage
I Inv --- (LEM3/M) 9 9 9 LED - INV
8 RLPCB3.8(ATM) NC V4.28 10. Bypass current
V Ref (RV1.1) 10 RLPCB1.T4
9
NC
I load --- (DB5A.3) INVERTER SS PCB 11 10 LED - Bypass
10
NC V4.26 ALARMS ON TFT DISPLAY
RV5.3 (V load Ref.) 9 PIN D-CONNECTOR- DB1 12 11 LED - INV.SS
11
NC V4.24
B412.2 (Temp Fault) DB1 1. Mains Under Voltage
13 NC RLPCB1.T5
12 DAC PCB CON1.3 1 +15V --- SMPS/V2/1 2. Mains Over voltage
14 12 LED BATT.
13 2
NC CON2.3 3. Over temp. / Gate Driver Fault
GND GND --- SMPS/V2/2 15 13 Display Reset
B 14 3
PULSE (B Ph TOP) DAC CON1.6 4. DC Under voltage B
V grid YB --- PT2/9 SMPS/V2/7 16 14 NC
15
NC 5. DC Over voltage
GND (PT GND) INTERCONNECTION DETAILS 17 15 NC
16 V bypass (DB5A.5) 9 PIN D CONNECTOR
PULSE (R Ph BOTTOM) 6. Output Under voltage
UPS1 UPS2 18 16 Cooling fan OFF
17 DB4
NC MCB 641.12
7. Output Over voltage
GND (LEM GND) 19
18 CCDB2.8 CCDB2.4 PULSE (B Ph BOTTOM) 8. Inverter Overload trip
I grid Rph --- LEM1/M 5
20
19 CCDB2.3 (GND) CCDB2.3 (GND) PULSE (Y Ph BOTTOM) 9. Freq. Out of Sync
GND (PT GND) 6 MIMIC PCB
20 CCDB2.4 CCDB2.8 (CON2 Connection Details) 10. Cooling Fan OFF
SW 301.A 7
21 CCDB2. 5(GND) CCDB2.5 (GND) CONTROL CARD (V3) 1 5V From SMPS 11. Inverter Over current
I Ref (RV3.1) 8
INV_GATE DRIVER CARDS
22 NC NC 2 NC 12. Rectifier Fuse Fail
I Batt. (LEM5/M) 9
1 TRIP2
23 DAC OUT1 --- DAC PCB/CON.1.5 3 LED - BATT CC V5.12 13. Inverter Fuse Fail
25 PIN D CONNECTOR 2 PULSE (R Ph TOP)
24 DAC OUT2 --- DAC PCB/CON.1.4 UPS1 / UPS2 4 NC 14. Rectifier Over current / Trip
DB5A / DB5B * * 3 NC
25 System Reset ---DAC PCB/CON.1.7 5 NC 15. AC Earth Fault
C SMPS V2.8 (+12V) 4 C
1 PULSE (N TOP) 6 NC
SMPS V2.5 (-12V) 2 5 GND STATUS ON TFT DISPLAY
7 NC
CCDB3.9 6
3 GND 1. Load on Inverter
V7 V1 SMPS GND ( SMPS) 7
For Pulses
CONTROL CARD
4 GND 2. Load on Bypass

CCDB3.3 8 DAC PCB
5 GND (CON1 Connection Details) 3. Grid status (UPS input supply ok)
GND ( SMPS) 9 NC
V4 MIMIC
6 15V From SMPS
V5 1 4. Bypass status (Bypass supply ok)
PCB CCDB3.5 10
7 NC 2 GND 5. Load on Battery
GND ( SMPS) CC DB3.19
8 11 NC
To SVS 3 Hooter Signal CC DB3.12
SMPS V2.1(15V) 12
9 NC 4 DAC OUT 2 CC DB3.24
V4 NC CC V5.5 13 POTENTIAL FREE CONTTACTS
10 NC 5 DAC OUT 1
GND(Manual By.) CC DB3.23
11 14 NC TB1
6 Display Reset CC V5.13
D GD 15 NC RLPCB1.T11 1 D
7 System Reset Load on Bypass
V2 FEC 16 CC DB3.25 RLPCB1.T12
25 NC 2
17 PULSE (R Ph BOTTOM) RLPCB1.T15
TB2
DAC PCB 3 Load on Battery
GD 18 NC (CON2 Connection Details) RLPCB1.T16 4
Q300.3 (Bty +Ve) 4
V3 INV 19 1 NC RLPCB1.T19
Q300.6 (Bty -Ve) 5
NC 5
Low Battery
20 PULSE (N BOTTOM) 2 NC RLPCB1.T20 6
Only in UPS-2
3 NC RLPCB1.T23
7
TJ4 UPS O/P Voltage low
DB1 RLPCB2.T18 12V(SMPS) GND 4 NC H101 RLPCB1.T24
TJ10 1 8
RLPCB2.T17 12V(SMPS) GND 5 Hooter +ve RLPCB1.T27
2 1 TFT INTERFACE T1 T3 9
UPS ON
3 2 TJ15 RLPCB1 T1 T3 6 Hooter -ve RLPCB1.T28 10
+5V
5 3
BOARD 1 SD 105 010 350 RLPCB2 7 NC HOOTER RLPCB1.T31 11
GND Load on Bypass Inverter Trip
2 RL1 T11 TB1.1 SD 105 010 350 RLPCB1.T32
CC V5.10 T4 12
E Load on UPS RL1 E
T12 TB1.2 T11 TB1.13 RLPCB2.T11
CC DB1.1 T4 13
PB1 Output Earth Fault
RLPCB2.T4 Load on Battery T12 TB1.14 RLPCB2.T12
1 RL2 T15 TB1.3 CCDB2.6 2 1 GND 14
4 RLPCB1.T8 CC V5.12 T5 RLPCB2.T15 15
T16 TB1.4 RL2 T15 TB1.15 ACCEPT Load on UPS
6 RLPCB1.T9 Output Earth Fault RLPCB2.T16 16
Low Battery T16 TB1.16
RLPCB1.T7 RL3 T19 TB1.5 PCB2.T5 T5 RLPCB1.T29
9 PCB 301.CN2.5 T6 T17 TFT.TJ15.1 17
UPS OFF
T20 TB1.6 CCDB3.10 RLPCB1.T30 18
DB2 T18 TFT.TJ4.1
UPS O/P Voltage low RV5 19
3
1 MCB101.14 RL4 T23 TB1.7
CC DB1.9 T7 GND 2 1 +5V 20
9 MCB601.14 T24 TB1.8
PB1.2 (ACCEPT) V load Ref.
6 RL5 T27 TB1.9
2 UPS ON / OFF
T28 TB1.10
GND CC DB1.4 T8 PROJECT: Size
F 3 T29 TB1.17 04 M/s Department Of Atomic Energy F
5 T30 03
TB1.18
Dtd 11-02-2019 Page
** 02 20-05-19 For Approval Heavy Water Project
TITLE
UPS 1 Inverter Trip 26-03-19 For Approval DSS 40 4
UPS 2 RL6 T31 TB1.11 01
DB5A DB5B
CC DB1.6 T9
T32 TB1.12 NUMBER 00
KERALA STATE ELECTRONICS
1 2 3 4 5 6
ITEM
. No.
REV. DESCRIPTION MAKE QTY CIRCUIT
REFERENCE
I MCCBs, MCBs, Contactors & Relays
Input MCCB 100A, 4 pole 415V AC
1 Type No : CSC3S4 – 100A C&S 1 Q100
Battery MCCB 125A, 500V DC , 3 pole

2 Type No : CSC3S3-125 A C&S 1 Q300
Output MCCB 500A, 3 pole, 415V,

3 Type No : CSC6N3-500A C&S 1 Q750
MCB 0.5A, 3 pole with Aux

4 Type No : CSMBS3C0.5 + CSMBAXSF1 C&S 1 MCB101
MCB 6A, 2 pole, 415V

MCB103, MCB301,
5 Type No : CSMBS2C6 C&S 4
MCB302, MCB303
MCB 2A, 1 pole with Auxiliary MCB640, MCB641,
6 Type No : 5SL41027RC + 5ST3010 SIEMENS 3
MCB642
MCB 0.5 A, 1 pole with Auxiliary
7 Type No : CSMBS1C0.5+ CSMBAXSF1 C&S 1 MCB601
Input Contactor 95 A, 3 pole, 415V,

8 with 1NO+1NC Aux. 230V AC Coil C&S 1 Q101
Type No : TC1-D9511M5
9 Control Relay Type No: 4R3 12V DC OEN 1 K101
Selector Switch 6Amps, 2Pole 2Way Kaycee
10 1 SW301
Type No: 2TD 26B
Selector Switch 6Amps, 3Pole 2Way Kaycee
11 1 SW302
Type No: 3TD36B
VM/AM selector switch Kaycee
12 1 SW101
Type : SRP1310MB28
Push button With 1NO contact
13 C&S 1 PB1
Yellow- RCB2–BA5 + RB2-BE101
II THYRISTORS, IGBT & DIODES,
1 IGBT 200A / 1200V, Dual Pack (2 in parallel) SEMIKRON/ 6 V111–V116
Type No: SKM300GB126D
Manufacturer:- Page
02 20- 05-19 For Approval KERALA STATE ELECTRONICS 1 of 5

DEVELOPMENT CORPORATION LTD
01 26- 03-19 For Approval
00 00 13- 02-19 For Approval PO.No. DPS/CPU/10/B1/1656 - TPT/PO /
Issue Rev. Date Description Checked Reviewed Approved 42270 Dtd 11-02-2019
Customer : Title : BILL OF MATERIAL Doc. No.
M/s Department of Atomic Energy System : DSS 40 DPL 105 008 671
(DPS Heavy Water Project) 40KVA, 110V, 1Ph, UPS (DSP Based)
ITEM.
No.
REFERENCE
2 IGBT 300A 1200V (Dual pack)
Type No : SKM300GB12T4 SEMIKRON 4 V411–V414
on heat sink SP3979 2 in parallel HMI
3 Discrete Thyristor 445A/600V On heat sink
Hirect/
Type No: H445CH06 2 V611-V612
Semikron
Type No: MDT551 /16E
4 Thermostat L20A/80X MIKRON 5 B111-B113, B411-B412
III CAPACITORS
1 DC Spike protection Capacitors
CDET 10 C302 - C306
0.47mfd, 1200V Type No: 940C12P47K-F
2 AC Filter Capacitor 8.7 KVAR, 480V,3ph
Type :B25667L5127A375 EPCOS 1 C101
Size : (116 × 164 mm)
3 AC Filter Capacitor 12.5KVAR, 400V,1ph
Type : MKK-400-1-12.5-01 EPCOS 2 C601
B25667 –C3247-A175
4 Filter capacitors 6800 mfd / 350V, 2 in series ALCON
C301A, 301B, 301C
Type No : PG6DI - AEST 76x146 ELECTRONICS/ 10
C401A, C401B
Type No : KI02350682_M0J143 76x143 KENDEIL
IV RESISTOR & DIODE
1 Wire wound Resistor 560E, 50W. STEAD 1 R301
2 Resistor 470K/ 2W ‘’ 2 R314, R315
3 Resistor 220K/ 2W 4 R316, R317, R310, R410
4 Resistor 4K7/ ½ W ‘’ 8 R302, R303, R304, R305,
R306, R307,R318,R319
5 Resistor 47K/2W 3 R100, R100A, R100B
6 W.W Resistor 5K6 , ½ watt 2 R311, R411
Z640, Z640A, Z640B,
RC Combination Resistor 47E/1W and RMC
7 7 Z641, Z641A, Z641B,
Capacitor 0.1 mfd / 630V Polyster
Z642
RC Combination Resistor 10E/6W and
RMC
8 Capacitor 0.47 mfd / 1200V,Type No: 2 Z101, Z645
940C12P47K-F
V340(4Nos.) V341(4Nos)
D100, D100A, D100B,
9 Rectifier diode IN 5408 cdil 22
D101, D111, D301-D306,
D601-D604
Pot. Meters 10 K, 1W (Multi turn) Pavan/Pankaj/
10 5 RV1 - RV5
Model No.2010 or 3010 Eqvt
11 MOV 20D511K HEL 3 MOV1, MOV2, MOV3
12 LED (Green with holder) Kwality 2 LD301, LD303
Manufacturer:- Page

ITEM.
No.
REFERENCE
LD100,LD302,
13 LED (Red with holder) Kwality 5
LD304-LD306
14 LED (Yellow with holder) Kwality 1 LD100A
15 LED (Blue with holder) Kwality 1 LD100B
16 Hooter IPB27 ION 1 H101
V WOUND COMPONENTS
1 3Ph Input Transformer KAB 2868
59.3 KVA, Class H KELTRON 1 T105
Py : 415 V,82.5A Sy : 248.4 V,137.8A
1Ph Input Series choke KAB 2869
2 KELTRON 3 L101R, L101Y, L101B
0.198 mH, 114.8A Class H
Inverter Transformer KAB 2870
3 48 KVA, Class H KELTRON 1 T450
Py. 227.7 V, 210.8A, Sy. 110 V ,436.3A
1Ph Inverter Series choke KAB2871
4 KELTRON 1 L601
0.055 mH, 400 A Class H
Control Transformer KAB 1284
5 KELTRON 4 PT1, PT2, PT3, PT4
(Feedback Transformer), 240V/ 10V
Control Transformer KAB 1426
6 KELTRON 1 T103
Py. Voltage: 415V, Sy. Voltage: 200V
7 Auto transformer KAB 2042 KELTRON 1 T650
110 / 230 V AC
8 Measurement CT 100 /5A, 5VA Acc:1% AE/MECO 3 CT101-CT103
9 Measurement CT 600 /5A, 10VA Acc:1% AE/MECO 1 CT601
10 Shunt 150A/ 75 mV 2 SH301,SH302
VI METERS
1 AC Voltmeter, 0 – 500V AC, 3 ½ digit , aux AE/RISHABH
1 M102
supply 240V,Size(48x96x88) /MECO
2 AC Ammeter, 0-100A, 3 ½ digit , aux
,, 1 M101
supply 240V,Size(48x96x88)
3 Frequency meter, 3 ½ digit , aux supply
240V,Size(48x96x88) to read (45-60Hz), i/p ,, 2 M103, M603
415AC, aux supply 240V
4 DC ammeter, 0-150A, 3 ½ digit , aux supply
,, 2 M301, M302
240V,Size(48x96x88)
5 DC Voltmeter, 0 – 600VDC,
,,
3.5 Digit, aux supply 240V,Size(48x96x88) 1 M303
6 AC Voltmeter, 0 – 150V AC, 3 ½ digit , aux
,, 1 M602
7 AC Ammeter, 0-600A, 3 ½ digit , aux
,, 1 M601
Manufacturer:- Page

ITEM.
No.
REFERENCE
VII FUSES & BASES

Semiconductor Fuse 200 A EATON
1 3 F101, F102, F103
Type : 200 MMT
Bridge fuse 160A EATON
2 1 F410
Type No : 160EET
Output fuse 560A EATON
3 1 F601
Type No : 560MMT
4 Battery Fuse, 160 A HRC Fuse with base EATON 1 F300
Fuse Type No: 160NHG00B
Base Type No: SB00PB
5 HRC fuse NSD2 with FA20base EATON 13 F104-F106,F302,F303,
F602-F609
VIII PCBs, FAN & SENSORS
1 IGBT Gate drive PCB AW 205 840 265/2 PA 111- PA116
KELTRON 10
(15V) PA 411- PA414
2 SS Gate Drive Card AW 205 840 324 KELTRON 1
3 Controller CARD AW BGF PE 061 00151 KELTRON 1
4 Power Supply Card (SMPS) 360VDC
KELTRON 1 SMPS 1
AW No: BGF PE 040 0098
5 Power Supply Card (SMPS) 15V
AW No: BGF PE 040 0098 KELTRON 1 SMPS2
(I/P: 360V, O/P : +15V)
6 Mimic PCB AW 205 840 319 KELTRON 1
7 DAC PCB AW 205 840 320 KELTRON 1
8 Earth fault PCB AW 205 840 268 (+12V) KELTRON 2 PCB1, PCB2,
9 Relay PCB AW 205 840 310
KELTRON 2 RLPCB1, RLPCB2
SD 105 010 350 (12V)
10 Fuse fail sensing PCB, (12V)
KELTRON 2 FFPCB1, FFPCB2
AW 205 840 268
11 Relay PCB AW 205 840 229/1
KELTRON 1 RLPCB3
SD 105 010 255A (12V)
12 Voltage Sensing PCB AW 205 840 303 KELTRON
1 PCB 301
SD 105 010 344
13 Axial Fan Single ph. 230 V AC 64W, 2550 Ebm Papst E640, E640A, E640B,
7
RPM Model No.W2E.200-HK38-01 E641, E641A, E641B, E642
14 Hall Effect current sensor LEM LEM
3 LEM1,LEM2,LEM9
200A, Type No: HAS 200S
15 Hall Effect current sensor LEM LEM
1 LEM3
Manufacturer:- Page

ITEM.
No.
REFERENCE
IX TFT DISPLAY
TFT Interface Board
1 KELTRON 1 TFT Interface Board
SD 105 010 412 , AW 205 840 375
4.3 Inch TFT Display
2 Micro electronics 1
Type: ConnectEVE
X PANEL ILLUMINATION
1 Fuse 6A Fuse NSD6 with FA20 base EATON 2 F111, F112
2 Toggle switch , 1 Pole ,ON/OFF -KT 1021BY Kaycee 2 S101,S102
3 Door light switch Type:MPU-1, 4A, 250VDC ELCOM 2 DLS111, DLS112
4 Space heater 250W ,240VAC PYROS/Girish-EGO 1 SPH101
5 Thermal cut out (Thermostat) Girish – E.G.O 1 TC101
Set. Range 25ºC - 85ºC, with 250V, 15A, NC
contact. Model No : EGO- 205 - C
6 230V, 20W CFL lamp with holder Philips 2 L111, L112
7 5A, 3Pin plug socket Ancher 1 PS111
8 80A EMI Filter 1 EMI Filter
Type No : FN 3256H-80-35 (80A) EMIS
Type No : MF423-4-3DD-100 (100A)
9 Connectors CST 2.5 / CTS2.5 Connect well
1 TB1
with end plate & end clamp 20 way
10 Connectors CST 2.5 / CTS2.5 Connectwell
1 TB2
Manufacturer:- Page

1 2 3 4 5 6
M103
F
T106.4
T106.5
.
.
.
.
A A
V A
M102 M101
.
.
.
.
SW101
V1
V2
A1
A2
SELECTOR SWITCH
10
11
2
6
7
9
-
-
T106.4
.
.
.
.
.
.
.
.
.
T106.5
6
4
2
.
.
MCB101
A
Q100 T105 M701
5
3
1
T1
1 2
OUTPUT 110V, 1 Ph. 50 Hz

B B
R CT101
INPUT 415V +10%, -15%
F702
CT104
T2
Q101.1
C602
3 4 T450 M702 . To Page 2
Y CT102 V . Q101.3
T3 Q600
5 6 R640 D640
1 2
B CT103 SMPS-V2-8 1 2 4 6
MCB640 E640 K600 PT3
Z640
T4 F101
4
D600 9 11
LD640
N SMPS V2 / 6
V bypass (DB3.16)
2
5
5
3
1
Z600
V load (DB3-3)
GND (DB3-17)
C MCB102 C
T103
6
4
2
1 4 FFPCB1.T2
R410.2
F410 . +12V
3 5 . -12V
LEM1
. M
CC DB3.7
PA411 PA413
D111 D113 Pulse
C Pulse
C . 0V
V411
V413
TRIP TRIP
F410.1
6 2 6 2 +12V T6 T2
Q101 G G
R411
C601
PT2 PT1 1 2 0V 0V T8
11 9 11 R410
D 9 D
15V 15V GND F410.2
E E T4
R301
L601 T1
VgYB (CC DB3.14)
GND (CC DB3. 15)

VgRY (CC DB3.1)
FFPCB1
C302
C303
FF Sensing PCB
+ +
3 4 C301 C301A C301B
+
Z101 PA412 PA414

Pulse
C Pulse
C
V412
V414
5 4 TRIP TRIP
D112 D114
SMPS V2 / 4 2 1 G G
0V 0V
K101 S111 TC101 SPH101
15V E 15V E F111
1 2
D101
E SMPS-V2-8 E
TB1
F112 L111
MCB303 TRIP2 R 1 2 1 1 230V,20W,
V103 2
+
1 2 +15V N 2 DLS111 CFL
1
PS111 LAMP
GND 3
-
3
3 4 L112
2 1 1 230V,20W,
+ (1)
2
0 (2)
2 17 5 6 1 4 20 7 8 DLS112 CFL
2
V Batt. LAMP
D301 +15V
CONTROL CONTROL
SMPS-1
VDC +ve SMPS

MCB103 GND CARD(V3) CARD(V3)
T104
(V2)
V104
+
VDC -ve
R 1 2 1 4
-
B111 04 PROJECT: M/s Department Of Atomic Energy Size

F Y 3 4 3 5 CC - DB3-11 1 2 F
03
GND
Dtd 11-02-2019 Page
TB1 MCB302 D302 02 20-05-19 For Approval Heavy Water Project
TITLE 1
From UPS-2 Bty +Ve 4 1 2 01 26-03-19 For Approval
SVS 40 + SS Bypass Panel
Battery Bty -Ve 5 3 4 00 13-02-19 For Approval
40KVA, 1Ph, 110V SVS (DSP Based) 3
1 2 3 4 5 6
1 2 3 4 5 6
A A
T5
T106.4
110V AC, 1Ph, 50 Hz T106.5
M903
M902
M901
From UPS1 & UPS2
T6
D901.K / D902.K
B
D903.A / D903.A F V A B
T106
MCB900 DB5A.3 / DB5B.3 1 4
R901 LD901
+12V 11 12 GND DB5A.4 / DB5B.4 110V 230V
2 1 STATIC SWITCH FUSE FAIL 3 5
. +12V
. -12V
F902
. 0V
. M
Q940 Q960
F901 V911 LEM2
1 2 A1 T7
V912 A
A2
110V AC, 1Ph, 50 Hz CT902 P
From Page 1 Z644 OUTPUT 110V, 1 Ph, 50Hz.
C C
3 4 B1 T8
B
B2
R902 N
V 911G
V 911K
V 912K
V 912G
Load on Service Bypass
4 6 NC C1
D911
D913
C GND
PT5 +12V DC C2
9 11 R701 LD701
K2
K1
G1
G2
DB5A.6 / DB5B.6
DB5A.5 / DB5B.5 SS DRIVER CARD
DSD PE 057 0005
AW 205 840 324
D912
D914
DB1 1 2 3
D
R903 D
SS Ctrl (D905.K / D906.K)
GND (DB3.1.8 / DB3.2.8)
+ 15V (D907.K / D908.K)
O/P EARTH FAULT

E E
LD902 R904
GND R902
T5 PCB1 D913.K
+12V T3
T7 Earth Fault
R903
+12V T8 SD 105 010 310 T2 D914.K
0V T4 AW 205 840 268 T1
F 03
DPS PO NO. - DPS/CPU/10/B1/1656 - TPT/PO/42270 <title> F
Dtd 11-02-2019 Page

TITLE
SVS 40 + SS Bypass Panel 2

1 2 3 4 5 6
1 2 3 4 5
CONTROLLER CARD CONNECTOR DETAILS SMPS.1 CARD CONNECTOR DETAILS CONTROL CARD (V3)
INV_GATE DRIVER CARDS DAC PCB
25 PIN D-CONNECTOR- DB3 9 PIN D-CONNECTOR- V2 (CON1 Connection Details)
V2
DB3 1 TRIP1 1 NC
1 +15V ---
A 1 V grid RY --- PT1/9 2 PULSE (R Ph TOP) 2 GND CC DB3.17 A
2 GND
2 NC 3 NC 3 NC
3 NC
3 V load - (PT3 - 9) 4 PULSE (N TOP) 4 DAC OUT 2 CC DB3.24
4 I/P Cont. Control --- K101
4 NC 5 GND 5 DAC OUT 1 CC DB3.23
5 -12V --- LEM (LEM1)
5 NC 6 GND 6 NC
6 Cont. Control --- K600 For Pulses
6 NC 7 GND 7 System Reset CC DB3.25
7 NC
7 I Inv ---(LEM1/M) 8 GND
8 +12V --- LEM (LEM 1) & K101
8 NC 9 NC
9 NC
9 NC 10 NC
10 NC 11 NC
11
BYPASS SS PCB 12
NC NC
12
9 PIN D-CONNECTOR- DB1 13
B
NC DB1
NC B
13 GND 14 NC
1 +15V --- SMPS/V2/1
14 V grid YB --- PT2/9 15 NC
2 GND --- SMPS/V2/2
15 GND, PT3 - 11 16 NC
3 SS Ctrl (D905.K / D906.K)
16 V Bypass --- PT3/9 17 PULSE (R Ph BOTTOM)
17 GND 18 NC
18
+12V --- SMPS/V2/8 19
NC NC
19
-12V --- SMPS/V2/5 20
GND PULSE (N BOTTOM)
20
DB3 --- CC/DB3
NC
21 NC
22 NC For UPS 1 For UPS 2
23 DAC OUT1 --- DAC PCB/CON.1.5 DB5A DB5B
D901 LEM 2 / +12V D902
C 24 DAC OUT2 --- DAC PCB/CON.1.4 1 1 C
25 System Reset --- DAC PCB/CON.1.7 LEM 2 / -12V

2 2
D903 LEM 2 / M D904
3 3
4 LEM 2 / GND 4
V7 V1 SMPS 5 PT5.9 5
6
PT5.11 6
Bypass SS Signal
SS DC-1.T3
7 7
R906 D906
D905
V5 NC 8 SS DC-1.T2 GND 8
CONTROL CARD
D907 SS DC-1.T1 + 15 V D908

9 9
Bypass Transfer Switch

D SW102 D
V4 NC 10 10
11
GND 11
12 12
13 13
GD
V3 INV 14 14
25 25
SVS ON
DB1
E 04 PROJECT: M/s Department Of Atomic Energy Size E
4
GND LD702 03
5 Page
Heavy Water Project Dtd 11-02-2019
6 TITLE
LD703 01 26-03-19 For Approval
SVS 40 + SS Bypass Panel 3
SVS FAIL
MIMIC
1 2 3 4 5
ITEM.
No.
REFERENCE
I MCBS, CONTACTORS & SWITCH
Input MCCB 150A, 3 pole 415V
1 Q100
1 Type No : CSC4S3-150A C&S
2 Contactor 110 A,3 pole,415V with 220V AC
Coil C&S 1 Q101
Type No : LC1FDP115AM5
3 Contactor, 185 A, 3 pole, 415V, with 220V
AC Coil C&S 1 Q600
Type No : LC1FDP185AM5
4 Output Switch 400 A, 2 pole, 415V,
Type No : CSSD400DM2 C&S 1 Q940
5 Output MBB 630 A,250VAC Make Before

Break(MBB) 2 pole 2 way NO- OFF
KAYCEE 1 Q960
Type No: SC 6029A/ MB + with Aux 1 No
Type No:. SRPM313A (40A)
6 MCB 2A, 1 pole
1 MCB640
Type No : 5SL41027RC SIEMENS
7 MCB 0.5 A, 1 pole with Auxiliary
1 MCB900
Type No : 5SL41057RC + 5ST3010 SIEMENS
8 MCB 6A, 2 pole, 415VAC
MCB303,MCB103,
Type No : CSMBS2C6 C&S 3
MCB302
9 MCB 2A, 3 Pole.415V,

Type No : CSMBS3C2 C&S 1 MCB101
11 MCB 6A, 3 Pole, 415VAC

Type No : CSMBS3C6 C&S 1 MCB102
12 VM/AM selector switch

KAYCEE 1 SW101
Type No : SRP1310MB28
13 Switch 6A 1 Pole ON/OFF
Kaycee 1 SW102
Type No : 1TD 16O.
II DIODES, IGBTs & HEATSINK
1 IGBT 300A / 1200V, Dual Pack
INFINEON
Type No : FF300R12KT3 2 V411 – V414
Type No : SKM300GB12T4 on heat sink
Manufacturer:- Page

M/s Department of Atomic Energy System : SVS40
DPL 105 008 672
(DPS Heavy Water Project) 40KVA, 110V, 1Ph, SVS (DSP Based)
ITEM.
No.
REFERENCE
II DIODES, IGBTs & HEATSINK
1 IGBT 300A / 1200V, Dual Pack
INFINEON
Type No : FF300R12KT3 2 V411 – V414
Type No : SKM300GB12T4 on heat sink
2 Diode 100A /1200V
Hirect/
Type No : HDD100N12
Semikron 2 D111 – D114
Type No : SKKD 100/16E (SEMI PACK)
3 Discrete Thyristor 445A/600V On heat sink
Type No: H445CH06 Hirect/ 2
V911 – V912
Type No: MDT551 /16E Semikron
4 Diode IN 5408 V103 (4 Nos), D301,
V104(4 Nos), D302,
CDIL 25 D640, D901 – D908,
D911-D914, D101,
D600
5 Thermostat L20A/80X MIKRON 1 B111
III CAPACITORS
1 DC capacitors 4700 mfd / 400V
ALCON 2 C301A, C301B
Type No : PG6DI - AEST
2 DC Spike protection Capacitors 2 C302 - C303
CDET
0.47mfd, 1200V Type No: 940C12P47K
3 DC capacitors 4700 mfd / 400V
ALCON
Type No : PG6DI - AEST 2 C301
4 AC filter capacitors 36MFD 440V Advance 3 C601,C602
IV WOUND COMPONENTS
1 3 Phase to single phase transformer 48 KVA,
KAB 2872 Class H KELTRON
1 T105
Py: 415 V ,66A,
Sy1: 99 V,404A, Sy2: 230 V,34.7A
2 Boost Transformer 1 Phase 9.6 KVA KELTRON
KAB 2873 1 T450
Py: 125 V,76.8A, Sy: 22 V,436A
3 Filter choke KAB 2874 Class H
1 L601
0.3 mH, 76.8 A KELTRON
4 Feedback Transformer , 415V/ 10V
4 PT1 – PT3, PT5
Type No: KAB 1284 KELTRON
Manufacturer:- Page

DPL 105 008 672
ITEM.
No.
REFERENCE
5 Control Transformer KAB 1426 KELTRON
Primary Voltage : 415V 2 T103, T104
Secondary Voltage: 200VAC/270V/300V
6 Control Transformer KAB 2833 KELTRON
Primary Voltage : 110 V 1 T106
Secondary Voltage: 230 V
V FAN
1 Fan Single phase 230V AC, 64 Watts. Model
1 E640
No. W2E-200-HK38-01 Ebm Papst
VI RESISTOR
1 RC Combination Resistor 47E/1W and VEPL
1 Z640
Capacitor 0.1 mfd / 630V Polyster
2 RC Combination Resistor 10E/6W and RMC 3 Z101, Z600, Z644
Capacitor 0.47 mfd / 1200V.
Type No: 940C12P47K
3 Wire wound Resistor 100E,50W. STEAD 1 R301
4 Resistor 27K/ 12W Watts/ Keltron 1 R640
5 Resistor 10K/ ½W Watts/ Keltron 1 R906
6 Resistor 220K, ½W Watts/ Keltron 1 R410
7 Resistor 5.6K/ ½W Watts/ Keltron 3 R411,R701,R901
8 Resistor 470K/ 2W Watts/ Keltron 2 R902,R903
9 Resistor 4K7/ ½ W Watts/ Keltron 1 R904
10 LED (Red with holder) Kwality LD640,LD701,
4
LD901,LD902
VII CONTROL RELAY OEN
2 K101,K600
Type No: 4R3 12V DC
V111 PCBs
1 IGBT Gate Driver Card KELTRON
4 PA411 – PA414
AW 205 840 265/2, PL 105 010 335/1
2 CONTROLLER CARD KELTRON
1
AW BGF PE 061 00151
3 Power Supply Card (SMPS) 360V KELTRON
1
AW No: BGF PE 040 0098 01
4 DAC PCB AW 205 840 320 KELTRON 1
5 SS Driver Card AW 205 840 324 KELTRON 1 SSD 1
6 Earth fault PCB AW 205 840 268 (+12V) KELTRON 1 PCB1
6 Earth fault PCB AW 205 840 268 (+12V) KELTRON 1 PCB1
7 Fuse fail sensing PCB AW 205 840 268 KELTRON 1 FF PCB1
Manufacturer:- Page

DPL 105 008 672
ITEM.
No.
REFERENCE
1X FUSE
1 Semiconductor fuse 160 A Cooper Buss
1 F410
Type No : 160 EET Mann
2 Output fuse 450A Cooper Buss
1 F901
Type No : 450 MMT mann
3 Control Fuse 6A with base Cooper Buss
2 F702, F902
Type No: NSD2 with FA20 base Mann
4 Neutral Link 63A KELTRON 1
X METERS,CT & TRANSDUCERS
1 Digital Panel Meter:AC Voltmeter (0-500V)
Model No. A1 LED - 7 segment digital type ,
Size - 48 x 96 x115 4½ digit Operating AE M102
1
Voltage 650V AC Aux. Supply 230 V AC ±
10% 50Hz, Maximum indication 19999.
2 Digital Panel Meter: AC Ammeter(0-150 A)
Model No:A1 LED 7segment digital type
Size - 48 x 96 x115
AE 1 M101
4½ digit Operating Current AC with Ext.CT
5A,Aux Supply 230 V AC ±10% 50Hz,
Maximum Indication 19999
3 AC Ammeter ,0-600A, 3 ½ digit , aux supply
AE 2 M701, M901
240V,Size(48x96x88)
4 Digital Panel Meter:AC Voltmeter (0-200V)
Model No. A1 LED - 7 segment digital type ,
Size - 48 x 96 x115 4½ digit Operating AE 2 M702, M902
Voltage 650V AC Aux. Supply 230 V AC ±
10% 50Hz, Maximum indication 19999.
5 Frequency meter, 3 ½ digit , aux supply
240V,Size(48x96x88) to read (45-60Hz), i/p ,, 1 M703
415AC, aux supply 240V
6 Current Sensor 200 Amps
LEM 1 LEM1
Type No : HAS 200 S
7 Hall Effect current sensor LEM LEM 1 LEM2
8 Digital frequency meter, 230V, 96Sq.mm to
PRESTIGE 1 M103
read 45 to 65Hz
9 Measurement CT 150/5A, 10VA, Class 1.0 MECO 3 CT101 - CT 103
10 Measurement CT 600/5A, 10VA, Class 1.0 ,, 2 CT902, CT104
XI1 PANEL ILLUMINATION
Cooper Buss F111, F112
1 Fuse 6A Fuse NSD6 with FA20 base 2
Mann
Manufacturer:- Page

DPL 105 008 672
ITEM. No.
REFERENCE
2 Toggle switch , 1 Pole ,ON/OFF KT 1021BY Kaycee 1 S111

Door light switch DLS111, DLS112
3 ELCOM
Type: MPU-1 , 4A , 250VDC 2
4 Space heater 250W ,240VAC Girish – E.G.O 1 SPH101
Thermal cut out (Thermostat) Set. TC101
5 Range 25ºC - 85ºC, with 250V, 15A, NC Girish – E.G.O 1
contact. Model No : EGO- 205 - C
6 230V 11W CFL lamp with holder Philips 2 L111, L112
7 5A, 3Pin plug socket Ancher 1 PS111
XI1I Connectors
1 25 Pin D Connector Connectwell 2 DB5A, DB5B
2 Connectors CST 2.5 / CTS2.5 Connectwell
1 TB1
Manufacturer:- Page
KERALA STATE ELECTRONICS 5 of 5

42270 Dtd 11-02-2019
Issue Rev. Date Description Checked Reviewed Approved
DPL 105 008 672
2 x 40 KVA UPS
5. GUARANTEED TECHNICAL PARTICULARS

Sl. No Description Particulars
Kerala State Electronics Development
Name of vendor
Corporation Limited
1.0 Make KELTRON
1.1 Applicable Standards IEC 146/IEC 62040
1.2 Model DSS 40
True On Line, Double conversion type
1.3 Topology UPS for continuous duty , Parallel
Redundant
2.0 Environmental parameters
2.1 Operating temperature 0-50OC
2.2 Relative humidity 95% non-condensing
2.3 Altitude 0-1000 Meters above sea level
2.4 Storage temperature 0 to 50OC
2.5 Noise level < 75dBa at 1 meter distance
3.0 Panel
3.1 Material used for frames 2.5 mm thick CRCA
3.2 Material used for doors & covers 2.00 mm thick CRCA
3.3 Protection class IP 42
Free standing floor mounted on base
3.4 Type of construction
frame
3.5 Cable Entry From Bottom
3.6 Painting & Paint shade Shade 631 of IS 5
3.7 Type of cooling Forced Air Cooling
Dimension (W x D x H ) in mm
3.8 UPS DSS 40 2 x (1500 x 900 x 1900)

SVS 40 900 x 900 x 1900
4.0 Electrical Parameters – Charger

4.1 Type of charger DSP Controlled IGBT Based rectifier
4.2 Input voltage for Charger & Bypass 415V, 3Phase, 4Wire
4.3 Permissible Voltage Variation -10% to +10%

4.4 Input Frequency 50Hz ± 5%
4.5 Efficiency 95 %
4.6 Voltage Regulation ± 1%
4.7 Ripple content < 1%
4.8 Current limit Provided
4.9 Power factor Near unity
4.10 Input Current THD < 5%
4.11 Soft Start Feature Provided
Normal vanish impregnated
4.12 Input Isolation Transformer
Transformer Provided
5.0 Electrical Parameters – Inverter
DSP Controlled IGBT based PWM
5.1 Type of Inverter
Inverter
125% for 10 Minutes,
5.2 Over Load capacity
150% for 1 minute
5.3 Output Voltage & frequency 110V, 1Phase
50Hz ± 0.1% (in synchronous with
5.4 Frequency Range
bypass supply)
5.5 Total Harmonic distortion <3%
5.6 Output rating 40 KVA
5.7 Power factor 0.8 (Rated)
Transfer time from inverter to bypass and
5.8 No break
bypass to inverter in synchronous mode
Transfer time from inverter to bypass and
5.9 < 18msec
bypass to inverter in asynchronous mode
5.10 Crest factor 3:1

5.11 Output wave form Pure sine wave
5.12 Efficiency of inverter at full load 92%
6.0 Protections in UPS
6.1 Rectifier over current Provided

6.2 DC overvoltage Provided
6.3 DC under voltage Provided
6.4 Output over voltage Provided
6.5 Output under voltage Provided
6.6 Short circuit Provided
6.7 Inverter over current Provided
6.8 Battery Current Limit Provided
6.9 Over Temperature Provided
6.10 Output Overload Provided
7.0 LED Indications
7.1 Mains ON Provided
7.2 DC ON Provided
7.3 Inverter ON Provided
7.4 Battery on Float Provided
7.5 Battery on Boost Provided
7.6 Manual bypass switch ON Provided
7.7 UPS ON Battery Provided
7.8 UPS on Bypass Provided
7.9 Auto mode ON Provided
7.10 Manual Mode ON Provided
8.0 ALARMS ON TFT DISPLAY
8.1 Mains Failure Provided
8.2 Over Temperature / Gate drive Fault Provided
8.3 DC under voltage Provided
8.4 DC over voltage Provided
8.5 Output under voltage Provided

8.6 Output over voltage Provided
8.7 Inverter overload Trip Provided
8.8 System on overload Provided
8.9 Frequency out of sync Provided
8.10 Cooling fan OFF Provided
8.11 Inverter over current Provided
8.12 Rectifier fuse fail Provided
8.13 Inverter fuse fail Provided
9.0 PARAMETERS ON TFT DISPLAY
9.1 Input Voltage Provided
9.2 Input Current Provided
9.3 Input frequency Provided
9.4 Output Voltage Provided
9.5 Output Current Provided
9.6 Output Frequency Provided
9.7 DC Voltage Provided
9.8 Battery Current Provided
9.9 Bypass Voltage Provided
9.10 Bypass Current Provided
10.0 Battery
10.1 Type Ni Cd
10.2 Battery backup 60 min
10.3 Battery Bank Voltage 360V
10.4 No. of Cells 300
10.5 Capacity 170 AH

2 x 40 KVA UPS
6. SYSTEM ON/OFF PROCEDURE

SYSTEM ON/OFF PROCEDURE
WARNING!
• ENSURE ALL THE ISOLATION SWITCHES, MCCBs AND MCB’s ARE

IN OFF CONDITION BEFORE PROVIDING INPUT SUPPLY TO THE
UNIT.
• ENSURE THAT THE SERVICE BYPASS ISOLATOR MBB SWITCH

Q960 IS IN UPS MODE BEFORE TURNING ON THE SYSTEM.
• DO NOT OPERATE THE SERVICE BYPASS ISOLATOR MBB SWITCH

Q960 WHEN THE UPS IS IN OPERATION.
• DO NOT TURN ON BATTERY MCCB Q300 WITHOUT PRECHARGING

THE SYSTEM.TO PRECHARGE THE SYSTEM FOLLOW THE STEPS
, IN SYSTEM ON PROCEDURE.
• DO NOT PRESS THE DSP RESET SWITCH (PBD) IN THE DAC PCB
WHEN THE SYSTEM ON/OFF SWITCH IS ON.
1.1 STEPS TO TURN ON UPS1 and UPS2
1. Ensure that Input MCCB (Q100), Battery MCCB (Q300), Output MCCB (Q750) of UPS1
and UPS2 and Load isolator MBB switch (Q960) in position 1 (UPS Mode), Bypass isolator
switch (Q940) of SVS are OFF. Ensure that the system ON/OFF switch in the front panel of
UPS is in OFF position and the UPS/Bypass transfer switch in the front panel of the UPS is
in bypass mode.
2. Switch ON the SVS by turning ON MCB104, MCB302, MCB103, MCB102, MCB101, and
Q100 in the order.
3. Turn ON control supply MCB's (MCB103 and MCB 302) and ensure that System ON-OFF
switch is OFF and UPS/Bypass transfer switch in SVS is in UPS mode.
4. Press the display reset button (PBM) and system reset button (PBD) provided in the DAC
PCB.
5. Turn ON the Precharge from input MCB (MCB 303) or Precharge from battery MCB
(MCB301) and wait till DC voltage reaches 320V (Voltage shown in Display). Then turn off
the precharge MCB.
6. Turn ON the fan MCBs (MCB640, MCB641 and MCB642).
7. Turn ON the Battery MCCB (Q300), Input MCCB (Q100) and Isolator MCCB (Q750).
8. Follow the instructions from 2 to 6 for UPS2.
9. Turn ON Bypass Isolator switch (Q940) and Load Isolator MBB switch (Q960) in SVS in
UPS Mode.
10. Switch ON UPS by pressing the ON/OFF switch provided in the front panel of each system.

1.2 SYSTEM OFF PROCEDURE (To bring the System to dead condition)
1. Switch OFF the System ON/OFF switch in the front panel of the UPS.
2. Switch OFF the Input Supply MCB Q100, Isolator Q750 and Battery MCCB Q300.
3. Discharge the DC bus to 0V or wait for 10 minutes.
4. Switch OFF the control supply MCB 302 and MCB103.
5. Now the System is OFF.
6. Follow the same procedure from 1 to 5 for UPS2 also.
WARNING!
Do not turn ON the system immediately if Step 3 in system OFF procedure is not
done. Wait for before Turning ON the system until the DC bus is zero.
1.3 STEPS TO FOLLOW IF THE SYSTEM (either 1 or 2) FAILS WHEN IN

OPERATION
1. Switch OFF the System ON/OFF switch in the front panel of the System.
2. Press the DSP reset switch (PBD) and Display reset switch (PBM) in the DAC PCB.
3. The Display should indicate- 1. Gate Drive OK. 2. Grid Present. 3. Battery Connected. 4.
Ready to Switch ON. After few seconds.
4. If all conditions are OK Switch On the system ON/OFF switch.
WARNING!
Do not Press DSP reset switch (PBD) in the DAC PCB when the System ON/OFF
switch is in ON.
1.4 STEPS TO BE FOLLOWED TO BRING THE SYSTEM TO SERVICE

BYPASS (Without Load Break).
1. Ensure that the SVS is ON.

2. Transfer the System Load to bypass supply by using UPS/Bypass Transfer Switch provided in
the front panel of UPS, to bring the UPS to bypass mode. The Bypass Static Switch LED
(Green LED) will glow in the mimic panel of UPS, indicating that the Load is transferred to
bypass supply.
3. Turn on MBB switch Q960 to service bypass position.
4. Switch off UPS1 and UPS2 using the system ON/OFF provided in the front panel of UPS1
and UPS2.

5. Turn OFF Battery MCCB (Q300), Input MCCB (Q100) and Isolator MCCB (Q750) of UPS1
and UPS2 and Bypass isolator switch (Q940).
6. Turn OFF the fan MCBs (MCB640, MCB641 and MCB642) of both UPS.
7. Turn OFF control supply MCB's (MCB103 and MCB 302) of UPS1 and UPS2.
8. Now both UPS is isolated from load and ready for servicing.
1.5 TO RETRANSFER THE SYSTEM LOAD TO UPS UNDER THIS CONDITION

FOLLOW THE STEPS GIVEN BELOW (Without Load Break).
1. Ensure that Input MCCB (Q100), Battery MCCB (Q300), and Isolator MCCB (Q750) of
UPS1 and UPS2 are OFF and bypass Isolator switch (Q940) is off.
2. Switch ON the control supply MCB's (MCB103 and MCB 302) and ensure that System ON-
OFF switch is OFF and UPS/Bypass Transfer switch in UPS is in UPS mode.
3. Press the display reset button (PBM) and system reset button (PBD) provided in the DAC
PCB.
4. Turn ON the Precharge from input MCB (MCB 303) or Precharge from battery MCB
(MCB301) and wait till DC voltage reaches 320V (Voltage shown in Display). Then turn off
the precharge MCB.
5. Turn ON the fan MCBS (MCB640, MCB641, MCB642).
6. Turn ON the Battery MCCB (Q300), Input MCCB (Q100) of UPS1 and Bypass Isolator
switch (Q940) of SVS.
7. IMPORTANT: Ensure that load isolator switch (Q750) of UPS1 and UPS2 are OFF and
UPS/Bypass transfer switch (in front panel of UPS) is in UPS mode.
8. Switch ON UPS1 and by pressing the ON/OFF switch provided in the front panel of the UPS
to sync with the bypass supply. Turn ON Load isolator MCCB (Q750) of UPS1 and UPS2.
9. Now switch on the UPS2 and make both the UPS running in parallel.
10. Change the UPS/Bypass transfer switch in front panel of UPS to BYPASS mode.
11. IMPORTANT: Change the Service Bypass isolator MBB switch (Q960) of SVS to UPS
position.
12. Press the UPS/Bypass Transfer switch provided in the front panel of both UPS, to UPS mode.
Now the Load is shared by UPS1 and UPS2.

THE LOAD STATUS
i. LOAD ON UPS
ii. LOAD ON BATTERY
iii. POWER FAILURE
iv. BATTERY ON FLOAT CHARGE
v. BATTERY ON BOOST CHARGE
vi. RECTIFIER ON
vii. INVERTER ON
viii. INPUT R, Y, B
FAULT OCCURANCE
a) MAINS FAILURE
b) DC OVER VOLTAGE
c) DC UNDER VOLTAGE
d) BATTERY LOW
e) OUTPUT UNDER VOLTAGE
f) OUTPUT OVER VOLTAGE
g) OUTPUT OVERLOAD
h) OVER TEMPERATURE
STATUS ON TFT DISPLAY
i. LOAD ON INVERTER
ii. LOAD ON BYPASS
iii. GRID STATUS (UPS INPUT SUPPLY OK)
iv. BYPASS STATUS (BYPASS SUPPLY OK)
v. LOAD ON BATTERY

2 x 40 KVA UPS
7. MAINTENANCE PROCEDURE & AND TROUBLE SHOOTING

7. MAINTENANCE PROCEDURE & AND TROUBLE SHOOTING
Item Inspection period Procedure

Weekly 3 Months 6 Months 12 Months
1. Operating controls & indicators Check all controls for operability check the
operations of all meters. Replace any damaged
or malfunctioning components connections.
Check cables for the input and output power and
internal wiring. Check for damaged or loose
Check all indications lights and replace any

defective lamp
Inspect the diodes and thyristors and their heat

dissipation for loose mounting screws or
defective electrical connection. Tighten screws
and nut. Repair any electrical connector.
Inspect the general condition of PCBs. Check

the components for evidence, over heating or
cracks. Repair or replace board if necessary.
2. Internal Components Inspect PCB sockets for loose electrical

connection. Tighten mounting screws and
electrical connection. Replace defective socket.
Inspect terminal board for breaks or loose
mounting screws. Replace any defective terminal
board. Tighten mounting Screws

Remove all dust and foreign particles
from the chassis using compressed air.
Check mounting bolts and terminals for
3. Chassis assembly
looseness. Tighten bolts and loose
terminations.
Clean the cabinet and panel assemblies with

cleaning solvent. Dry with a clean cloth or
4. Cabinet
compressed air.
Inspect transformers for evidence of

overheating damaged insulation or loose
mounting screws. Correct any
5. Wound components
Malfunctioning before operating the units.
Tighten mounting screws if necessary.
Inspect input and output switches/ contactors

carefully for loose screws units. Clean the
electrical contact with a clean cloth with
6. Switches & Contactors
carbon tetra chloride. Do not use cleaning
solvent on electrical connection replace
item found defective

PROBABLE FAULTS AND TROUBLE SHOOTING
Some of the more likely faults and nature of their cure are given below. A visual inspection should
be made for any burnout or damaged components in the equipment. Similarly, broken loose or burnt
wire should be thoroughly checked any malfunctioning of the unit should be traced step by step after
understanding the working principles. However an effort is made here to give some of the normal
fault conditions and the remedy for the same.
POSSIBLE FAULTS
a. No output
b. Low output voltage.
c. High output voltage
d. Poor regulation.
e. Increased ripple.
a. No output: This type of fault may occur for the following reasons.
1. Blowing of input / output fuses.
2. Rectifying element fuse blowing or open circuit in the rectifying element.
Normally the supervisory alarms will indicate if a particular fault condition exists. When the
faults is due to open circuit of SCRs or loss of pulses to SCRs, check should be done with proper
measuring meter or by oscilloscope to detect the fault.
b. Low output voltage: This type of fault is normally observed if any fuse is failed or static switch
not working.
c. High output: The possible reason is fault in the feedback loop or fault in the controller card and
hence these should be checked accordingly.
d. Poor regulation: Fault can be in the controller circuit .Leaky filter condenser and lower setting of
the current limit can also be reasons for this fault.
e. Increased ripple: This is caused when filter circuit is not working or IGBT not switching
correctly.

2 x 40 KVA UPS
8. PCB DESCRIPTION AND DIAGRAMS

DESCRIPTION OF PCBs
THE CONTROL CIRCUIT CONSIST OF THE FOLLOWING PCBs
1. CONTROLLER CARD
AW BGF PE 061 00151
DSD PE 067 0003
2. IGBT GATE DRIVER CARD

AW BGF PE 041 0049
DSD PE 057 0001
3. SS GATE DRIVE CARD

AW 205 840 324
DSD PE 057 0005
4. POWER SUPPLY (SMPS)

AW BGFPE040 0098 (360V DC)
DSD PE 067 0004
5. MIMIC PCB
AW 205 840 319
SD 105 010 356
6. DAC PCB
AW 205 840 320
SD 105 010 357
7. EARTH FAULT PCB (+12V)

AW 205 840 268
SD 105 010 310
8. RELAY PCB (+12V)

AW 205 840 310
SD 105 010 350
9. RELAY PCB (+12V)

AW 205 840 229/1
SD 105 010 255A
10. VOLTAGE SENSING PCB (+12V)

AW 205 840 303
SD 105 010 344

1. CONTROLLER CARD
AW BGF PE 061 00151
DSD PE 0670003
The controller PCB is built on TMS320LF2407A DSP platform .The

feedback signals like input voltage, input current, output voltage, battery current are read by 12 bit
ADC provided in the controller PCB. The different status signals like on, off, etc are read by input
ports. The DSP will resolve the 3 phase input signals into direct axis component and quadrature
axis component and PWM signals are generated accordingly. This scheme ensures near unity
input power factor and improved input harmonic elimination. The controller PCB also takes care
the protections like over current, over voltage, under
voltage etc
2. IGBT GATE DRIVE PCB (+15V)
SD 105 010 355,
AW 205 840 265/2
+15V dc supply is connected at pin1.The circuit comprised of IC1, IC2 generates high
frequency waveform and is connected to Mosfet Q1 through transformer T1. The secondary of the
transformer is rectified and regulated to +20V and is connected to the hybrid IC, IC3.The gate
pulse signal from the controller PCB is connected at pin5.This signal drives the internal opto
coupler of the IC3.The output pulse is connected to the IGBT gate and cathode through pin7, 8 &
9, 10. The C terminal is connected to the collector of the IGBT. If the collector current increases
beyond the limit, the voltage at C increases and the trip circuit of IC3 pulls down pin3 to low state
and the controller circuit will block the pulses to the IGBT.
3. SS GATE DRIVE CARD
AW 205 840 324
DSD PE 057 0005
The SS gate drive card is used to generate the gate trigger pulse for the
inverter/bypass static switch thyristors
4. POWER SUPPLY (SMPS)
AW BGFPE040 0098 (360V DC)
DSD PE 067 0004
The SMPS PCB generates +5V,+/-12V voltages for the controller PCB. It takes input
from the mains supply and from the battery. The dc voltage feedback circuit is included in this
PCB. The circuit converts the 360 V DC into +15V and from this 15 V multiple outputs is
generated

5. MIMIC PCB
AW 205 840 319
SD 105 010 356
This PCB reads the set, accept, up down push button status and sends the required signal to
controller pcb
6. DAC PCB
AW 205 840 320
SD 105 010 357
This PCB is used for debugging the program .The voltage level, current level
etc read by the DSP can be converted into analog signal and can be verified. It also houses the
system reset push button and display reset push buttons.
7. EARTH FAULT PCB (+12V)

AW 205 840 268
SD 105 010 310
The function of the PCB is to detect the earth leakage in the DC bus. It
consists of an input leakage sensing circuit using opto isolator and a relay driver part. The
sensing circuitt triggers the opto isolator upon getting an earth leakage, which can be adjusted by
resistors R4, R5 inside the PCB. This opto isolator triggers a relay through a transistor driver
stage. The potential free contact of this relay is used of earth fault annunciation.
8. RELAY PCB
SD 105 010 350,

AW 205 840 310
This PCB houses six numbers of relay which are used to extend potential free contacts for fault.
The following faults are extended by this PCB.

9. RELAY PCB
SD 105 010 229/1

AW 205 840 255A
This PCBs consist of two relays, connection details of which are available in schematic
diagram. These relays are used for different trip initiation of the charger. During these trip
conditions the potential free contact of the corresponding relays are wired to the appropriate
parts of the circuit as detailed in SD. .
10. VOLTAGE SENSING PCB
SD 105 010 344

AW 205 840 303
This PCB has 3 comparator channels and can be used for different protections . Channel 1 has
an additional amplifier circuit which can be used for amplifying low signals like shunt signal etc
and this amplified signal is compared with a set reference from RV1 and when the signal
exceeds the set value IC1B output goes high and Q1 becomes on. The transistor Q1 can be used
to drive a relay. Channel 2 and channel 3 senses voltage. When voltage goes outside the limits
IC output goes high giving the indications. Potentiometer RV1 is used to set the channel1
parameter,RV2 is used to set the channel2 parameter ,RV3 is used to set channel3 parameter.

5 4 3 2 1
RP1
H1
U1 PWM1 2
1D[0..15]
1A[0..14] PWM2 3
1A[0..14] U2 PWM3 4
1A0 80 127 1D0 1D0 7 5 1A0 PWM4 5
1A1 A0 D0 1D1 1D1 I/O1 A0 1A1
78 A1 D1 130 8 I/O2 A1 4 PWM5 6
1A2 74 TMS320LF24O7A 132 1D2 1D2 9 3 1A2 PWM6 7
1A3 A2 D2 1D3 1D3 I/O3 A2 1A3
71 A3 D3 134 10 I/O4 A3 2 PWM7 8
D 1A4 68 136 1D4 1D4 13 18 1A4 PWM8 9 D
1A4 A4 D4 I/O5 A4
1A5 64 138 1D5 1D5 14 44 1A5
U3 1A6 A5 D5 1D6 1D6 I/O6 A5 1A6
61 A6 D6 143 15 I/O7 A6 43
1A7 57 5 1D7 1D7 16 42 1A7 H1
OSC 3 CLKIN A7 D7 I/O8 A7
1A8 53 9 1D8 1D8 29 27 1A8 STATUS_UPS1 2 RP2
30MHz 1A9 A8 D8 1D9 1D9 I/O9 A8 1A9
51 A9 D9 13 30 I/O10 A9 26 1O/P_PORT1 3
1 NC 1A10 48 15 1D10 1D10 31 25 1A10 1O/P_PORT2 4
1A11 A10 D10 1D11 1D11 I/011 A10 1A11
45 A11 D11 17 32 I/O12 A11 24 1O/P_PORT3 5
XTL OSC 1A12 43 20 1D12 1D12 35 21 1A12 1O/P_PORT4 6
1A13 A12 D12 1D13 1D13 I/O13 A12 1A13
39 A13 D13 22 36 I/O14 A13 20 1I/P_PORT1 7
1A14 34 24 1D14 1D14 37 19 1A14 8
A14 D14 I/O15 A14 1I/P_PORT2
31 27 1D15 1D15 38 9
A15 D15 I/O16 1I/P_PORT3
Vdc_1 112 ADCIN00 T1PWM/T1CMP/IOPB4 16 SYS_BYPASS
110 18 28 6 1PS
Temp1_OUT ADCIN01 T2PWM/T2CMP/IOPB5 M_BYPASS NC0 CE
107 83 STATUS_UPS1 22 17 1WE H1
5V VCC Temp3_OUT ADCIN02 CAP1/QEP1/IOPA3 NC1 WE
105 79 STATUS_UPS2 23 40 PWM9 2
Vdc_2 ADCIN03 CAP2/QEP2/IOPA4 NC2 BHE
103 75 STATUS_UPS3 1 39 PWM10 3 RP3
H ADCIN04 CAP3/IOPA5 NC3 BLE 1RD
102 ADCIN05 PWM1/IOPA6 56 PWM1 OE 41 PWM11 4
100 54 L PWM12 5
ADCIN06 PWM2/IOPA7 PWM2
R2 99 ADC1N07 PWM3/IOPB0 52 PWM3 SRAM DOWN 6
C R1 113 47 7 C
IBAT ADCIN08 PWM4/IOPB1 PWM4 UP
Temp2_OUT 111 ADCIN09 PWM5/IOPB2 44 PWM5 ACCEPT 8
LED1
109 ADCIN10 PWM6/IOPB3 40 PWM6 SET 9
108 ADCIN11 PDPINTA 7 PDPINTA
S1 106 8
ADCIN12 T3PWM/T3CMP/IOPF2 1O/P_PORT4 VDD
L 1 2 104 6 R9
1RS ADCIN13 T4PWM/T4CMP/IOPF3 1O/P_PORT3
101 65 H R11
PBD_1 ADCIN14 PWM7/IOPE1 PWM7 U6A
+ U5A 98 62
C1 ADCIN15 PWM8/IOPE2 PWM8
H 115 59 STATUS_UPS2 2 1
VREFHI PWM9/IOPE3 PWM9 STATUS_UPSIN2
L 114 55
VREFLO PWM10/IOPE4 PWM10
L 126 46 C4L
1O/P_PORT1 TCLKINB/IOPF5 PWM11/IOPE5 PWM11 R10
2 38 H
1O/P_PORT2 TDIRB/IOPF4 PWM12/IOPE6 PWM12 U6B R12
JP1 1I/P_PORT1 37 137
TCLKINA/IOPB7 PDPINTB PDPINTB
TD2_I 23 88 STATUS_UPS3 4 3 STATUS_UPSIN3
2 Freq_CTRL XINT1/IOPA2 CAP4/QEP3/IOPE7 FREQ_BR
TDO_1 21 81
1 R3 LATCH_RST XINT2/ADCSOC/IOPD0 CAP5/QEP4/IOPF0 FREQ_RY
H 121 69 C5L
XF BOOT_EN /XF CAP6/IOPF1 FREQ_YB
L 118 30 SPISIMO
R4 BIO MP/MC SPISIMO/IOPC2 U6C R13
119 BIO/IOPC1 SPICLK/IOPC4 35 SPICLK
H R5
DSP2_EMU0 120 READY SPISTE/IOPC5 33 SPISTE 5 6
1I/P_PORT2131 32 STATUSOUT_UPS1
DSP2_EMU1 IOPF6 SPISOMI/IOPC3 SPISOMI
B 1I/P_PORT3 14 11 B
DSP2_TRST CLKIN 123 TDIRA/IOPB6 PLLF 1PS U7A
DSP2_TMS XTAL1/CLKIN PS 84
124 XTAL2 IS 82 1IS 2 STATUS_UPS1
U4 R7
19 W/R/IOPC0 RD 93 1RD 3
13 90 89 1 U7B
EMU0 EMUO WE 1WE
14 91 73 C3 5 PDPINTA
EMU1 EMU1/OFF CLKOUT/IOPE0 TP1
TRST 2 1 TRST R/W 92 6
TMS 1 144 TMS CANTX/IOPC6 72 4 PDPINTB
3 TDI_IN TD1_I 139 70 C2
TDI TDO_IN TDO_1142 TD1 CANRX/IOPC7
TDO 7 TDO PLLF2 10
TCK 11 135 TCK DS 87
TCK_RET 9 TCK_CLK 36 TMS2 VIS_OE 97 R8
60 122 H
EMUPOD TP1 ENA_144
R6 63 TP2 STRB 96
JP2 JP3 H 1RS 133 25
RS SCITXD/IOPA0 SCI1_TXD
TD1_I TDO_1 26
3 TDI_IN 3 TDO_IN SCIRXD/IOPA1 SCI1_RXD
2 2
1 TD2_I 1 TD2_O
Prepared Checked Approved
A A
Title
EPUPS-DSP CONTROLLER
Size Document Number Rev
A4
DSD PE 067 0003
Date: Friday, December 09, 2011 Sheet 1 of 7
KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION Ltd.
5 4 3 2 1
5 4 3 2 1
1D[0..15] 1D[0..15]
VCC
U8 C6 U9 C13
1D11 29 H L 1D11 29 H L R22 L
1D10 30 DB11 DB11 R23
DB10 VDRIVE 36 1D10 30
DB10 VDRIVE 36 Igr
1D9 31 25 5V L 1D9 31 25 5V L
1D8 32 DB9 AVDD C7 R14 DB9 AVDD R24 C15
DB8 DVDD 35 Vgry
1D8 32
DB8 DVDD 35
1D7 33 7 1D7 33 7 C14 R26
1D6 34 DB7 SL1 DB7 SL1 R25 L L
DB6 SL2 8 R16
1D6 34
DB6 SL2 8
1D5 38 9 1D5 38 9 R27
D DB5 SL3 C8 Vgyb DB5 SL3 Igy D
1D4 39 10 R15 1D4 39 10
DB4 SL4 DB4 SL4 R28
1D3 40 11 5V 1D3 40 11 5V C16
1D2 41 DB3 H/S SEL L R18 DB3 H/S SEL CSADC2
DB2 CS 4 Vlry
1D2 41
DB2 CS 4
1D1 42 13 R17 C9 1D1 42 13 R29 L
1D0 43 DB1 VIN4B DB1 VIN4B
DB0 VIN4A 14 1D0 43
DB0 VIN4A 14 R30
15 CSADC1 L 15 L
VIN3B R19 C10 VIN3B R31
1RD 5 RD VIN3A 16 1RD 5 RD VIN3A 16 Ilr
AD7864-1
AD7864-1
1WE 6 WR VIN2B 18 1WE 6 WR VIN2B 18 R32
19 L 19 C17
VIN2A L VIN2A
44 EOC VIN1B 20 Vlyb 44 EOC VIN1B 20
3 21 R20 3 21 R33 L
XF CONVST VIN1A XF CONVST VIN1A
1 22 5V 1 22 5V
BIO BUSY STBY C11 BUSY STBY R34 L
26 AGND 26 AGND
17 2 R21 17 2
AGND FRSTDATA AGND FRSTDATA L R36
37 DGND VREF 24 37 DGND VREF 24 R35 Ily
12 AGND INT/EXCLK 27 12 AGND INT/EXCLK 27
23 28 L C12 L L 23 28 C18 C19
L VR GND CLKIN VR GND CLKIN L
AD7864-1 AD7864-1 R37 L
1A[0..14] U10
C C
R38 R39 1D[0..15]
H 5V 1A0 1 15 CSADC1
U6D 1A1 A Y0 CSADC2 U11 C24
2 B Y1 14 R71
8 9 1A2 3 13 CSADC3 1D11 29 H L L
SYS_BYPASS SYS_BYPASS_I C Y2 DB11
12 1D10 30 36 R72
C20 L Y3 CS_DAC DB10 VDRIVE Ilb
11 1D9 31 25 5V L
Y4 CSPORT DB9 AVDD R73
5V 6 10 1D8 32 35 C28
1A3 4 G1 Y5 DB8 DVDD C25
G2A Y6 9 1D7 33
DB7 SL1 7 R75
H R40 R41 5V R74 L L
1IS 5 G2B Y7 7 1D6 34
DB6 SL2 8
U6E 1D5 38 R76
DB5 SL3 9 Iinvr
10 11 74HCT138 1D4 39 10
M_BYPASS M_BYPASS_I DB4 SL4 R77
1D3 40 11 5V C29
L 1D2 41 DB3 H/S SEL CSADC3
DB2 CS 4
H 1D1 42 13 R78 L
DB1 VIN4B
C21 VDD IBAT_IN R50 1D0 43 14
R51 DB0 VIN4A R79 L
15
3
D1 Iinvr VIN3B R80
R42 U12A R45 R52 5 16
Iinvy 1RD RD VIN3A Iinvy
AD7864-1
Vgyb 7 R53 6 18
+ Iinvb R54 1WE WR VIN2B R81
1 Igr 19 C26
FREQ_YB VIN2A
6 Igy R55 44 20
-
Ilr R56 EOC VIN1B R82 L
B XF 3 21 B
C22 R43 LM339 Ily R57 CONVST VIN1A 5V
1 BUSY STBY 22 R83
12
R44 L Ilb R58 26 L
L AGND
17 AGND FRSTDATA 2
37 24 L R84
DGND VREF Iinvb
12 27 R85
H L AGND INT/EXCLK C30 C27
Vgry 23 VR GND CLKIN 28
VDD R59 R60 L
Vgry_I
AD7864-1 R86 L
3
D2 U12B R49 R61 Vgyb R62
R46 Vgyb_I
Vgry 5 + R63 Vgbr R64
2 FREQ_RY Vgbr_I
4 - Vlry
R65 R66
Vlry_I
C23 R47 LM339
R67 Vlyb
12
R48 L R68
Vlyb_I
R69 Vlbr R70
L Vlbr_I
L
A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
5 4 3 2 1
1D[0..15] U14
RV1 VDD
1D0 R106 R107
14 DB0 VREFA 4
U13 1D1 13
1D2 DB1 R105 R108 - U15B
12 DB2 RFBA 3 6
1D3 11 7
DB3 DACOUT1
R87
R88
R89
R90
R91
R92
1 16 1D4 10 2 L3 U15A 5 +
PWM1 1UT DB4 OUTA C31 +
1D5 9 1
1D6 DB5
PWM2 2 15 1UB 8 DB6 2 -
1D7 7 R109
D DB7 AD824 D
PWM3 3 14 1VT 1WE RFBB 19
16 WR
4 13 15 20 R110
PWM4 1VB CS OUTB
1 AGND U15C R112
R111
PWM5 5 12 1WT 5 DGND VREFB 18 L10
+
6 C32 8
1A4 DACA/DACB U15D
PWM6 6 11 1WB 9 -
AD7628 DAC 13 -
AD824 R113
PDPINTA 7 10 PDPINTA# 14 DACOUT2
12 +
L8 U16A
9
2 RV2 AD824
1WE R114
3 L
MC1413B 1 CS_DAC
5V 74HCT32
R93 R95 2 - U19A

R115
R94 3 R120 1 Vdc_2
PDPINTA# 1 Q1 3 +
R116 R117 Vdc_Opt
C 2 2 - U18A TLV2465 C
Temp1
1 R121 H JP4
R118 Temp1_OUT
8
9
C33 4V 3 + L
SCI1_TXD
TLV2465 TXIN 1
R119 H 2
C37 SCI2_TXD 3
8
9
L
U17 R122
6 - U19B
R123 R124 R127 7 Vdc_1
R96
R97
R98
R99
1 16 6 - U18B 5 +
R100
R101
PWM7 2UT Temp2 Vdc_I
7 TLV2465
C34 R125 Temp2_OUT SCI1_RXD
2 15 4V 5 + R128 H
PWM8 2UB 1
8
9
TLV2465 VCC L RXOUT

L R126 H 2
PWM9 3 14 2VT SCI2_RXD 3
8
9
H C38
4 13 JP5
PWM10 2VB U20 DB1
5 12 R139 TXIN 2 5 1
PWM11 2WT R129 U5B T1IN T1OUT
1 T2IN T2OUT 18 6
B PWM12 6 11 2WB R130 R131 RXOUT 4 3 3 4 2 B
U18C R1OUT R1IN
Temp3 11 - 20 R2OUT R2IN 19 7
PDPINTB 7 10 PDPINTB# R132 10 Temp3_OUT 3
C35 12 + 8 11 8
4V C1+ C2+
L8 9 TLV2465 13 15 4
L R133 H C1- C2+
17 V- C2- 16 9
8
9
12 V- C2- 10 5
MC1413B 14 6
5V V+ GND L
MAX233
R102 R134
R104
R103 3 R135 R136
PDPINTB# 1 Q2 15 - U18D
IBAT_IN
2 16 IBAT
C36 R137 14 +
10V
TLV2465
R138
L H
8
9

A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
5 4 3 2 1
H H
VCC 5V R144 5V R145
U21A U21B 5V 5V
4
10
U22A U22B
4
10
H 2 5 H 12 9
D Q PDPINTB D Q PDPINTA
PR
PR
5V 2 5 5V 12 9
D Q D Q
PR
PR
RST 3 RST 11
CLK CLK RST 3 CLK LED2 RST 11
CLK LED3
6 8
CL
CL
Q Q
6 8
CL
CL
D 74HCT74 Q Q D
1
13
1
13
U23A R140 U23C
COM_FAULT H COM_FAULT R142 H InverterFault ChargerFault
1 2 5 6
5V 5V 5V R147
R141 R143 R146 U24B
5V 5V 5V
10
U23B U23D U24A
4
3 4 InverterFault 9 8ChargerFault 5V 12 9
2GFLT 1GFLT D Q
PR
5V 2 5
D Q
PR
C39 C40 RST 11 LED5
RST CLK
3 CLK LED4
L L 8
CL
Q
6
CL
Q
13
U25B
1
U25A 4 3 DC_OV
2 1 TEMP_Fault
5V
U23E
U6F R150
11 10 H
1RS 5V
C 12 13 VDD C
1I/P_PORT1 1I/P_PORT_1
U26A C42
3
DC_OV 1 2 D3 U12C R154
U27A R151 R153
R148 9
Vgbr +
U23F 2 1 14
1I/P_PORT2 1I/P_PORT_2 FREQ_BR
WD_DSP 13 12 COM_FAULT C43 8
C46 -
U27B R152
LM339
R149
12
5V 4 3 L R155 R156 L
1I/P_PORT3 1I/P_PORT_3
U26B C44
TEMP_Fault 3 4
L L
C41 5V
5V
R170
L 5V
R159 VDD
C45 U26C LED7
VDD
R157 L 5 6 L
3
R167 1O/P_PORT1
U29A U12D
BYPASS_CTRL R164 R171
LED6 1 2 11
1D[0..15] Vdc_1 +
U28 WD_DSP 5V 13 DC_OV U26D LED8
1D0 U29B R158 VDD R165 L
B 3 2 10 1O/P_PORT2 9 8 B
1D1 D0 Q0 -
4 D1 Q1 5 3 4 IN_SS_CTRL R166
1D2 L LM339 R172
7 D2 Q2 6
R160
12
1D3 8 9 U29C U26E LED9
1D4 D3 Q3 L L
13 D4 Q4 12 5 6 PCR_CTRL 1O/P_PORT3 11 10
1D5 14 15 R168
1D6 D5 Q5 U29D R161 H R169 H R173
17 D6 Q6 16
1D7 18 19 9 8 U5C U5D
D7 Q7 DC_MC_CTRL
5 6 RST 9 8 LED10 L
R162 LATCH_RST 1O/P_PORT4
1 U29E
5V OC
11 G 11 10 IP_MC_CTRL
74HCT373 U29F R163 VDD
U16B
13 12 Temp_CTRL
5 JP6
1WE
6 ChargerFault
2 InverterFault
4 CSPORT 1
74HCT32

A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
5 4 3 2 1
U30 2D[0..15]
2A[0..15] 2A[0..15]
U31
2A0 80 127 2D0 2D0 7 5 2A0
A0 D0 I/O1 A0 RP4
2A1 78 130 2D1 2D1 8 4 2A1
2A2 A1 TMS320F24O7A D1 2D2 2D2 I/O2 A1 2A2 H
74 A2 D2 132 9 I/O3 A2 3 1
2A3 71 134 2D3 2D3 10 2 2A3 2PORT1 2
2A4 A3 D3 2D4 2D4 I/O4 A3 2A4 2PORT2
68 A4 D4 136 13 I/O5 A4 18 3
2A5 64 138 2D5 2D5 14 44 2A5 BUZZER_IN 4
2A6 A5 D5 2D6 2D6 I/O6 A5 2A6 LCDRS_IN
61 A6 D6 143 15 I/O7 A6 43 5
D 2A7 57 5 2D7 2D7 16 42 2A7 LCDWR_IN 6 D
2A8 A7 D7 2D8 2D8 I/O8 A7 2A8 LCD_EN_IN
53 A8 D8 9 29 I/O9 A8 27 7
2A9 51 13 2D9 2D9 30 26 2A9 DUMMY_IN 8
2A10 A9 D9 2D10 2D10 I/O10 A9 2A10 CAN2_RS
48 A10 D10 15 31 I/011 A10 25 9
2A11 45 17 2D11 2D11 32 24 2A11
2A12 A11 D11 2D12 2D12 I/O12 A11 2A12
43 A12 D12 20 35 I/O13 A12 21
2A13 39 22 2D13 2D13 36 20 2A13
2A14 A13 D13 2D14 2D14 I/O14 A13 2A14
34 A14 D14 24 37 I/O15 A14 19
2A15 31 27 2D15 2D15 38
A15 D15 I/O16
Vdc_1 112 ADCIN00 T1PWM/T1CMP/IOPB4 16 ChargerON/OFF
VCC 110 18 28 6 2PS
L_Vgry ADCIN01 T2PWM/T2CMP/IOPB5 InverterON/OFF NC0 CE
107 83 22 17 2WE
5V L_Vgbr ADCIN02 CAP1/QEP1/IOPA3 NC1 WE
H 105 79 23 40
L_Igy ADCIN03 CAP2/QEP2/IOPA4 NC2 BHE
103 75 2PORT1 1 39
L_Vlyb ADCIN04 CAP3/IOPA5 NC3 BLE
102 56 41 2RD L
L_Ilr ADCIN05 PWM1/IOPA6 TP3 OE
R175 100 54 SRAM
L_Ilb ADCIN06 PWM2/IOPA7
HS2_Temp_OUT 99 ADC1N07 PWM3/IOPB0 52 LCDRS_IN
R174 113 47 2A[0..15]
LED11 IBAT ADCIN08 PWM4/IOPB1 LCDWR_IN U32 2D[0..15]
L_Vgyb 111 ADCIN09 PWM5/IOPB2 44 LCD_EN_IN
109 40 2A0 2 46 2D0
S2 L_Igr ADCIN10 PWM6/IOPB3 DUMMY_IN A0 I/O0
C 108 7 2A1 3 45 2D1 C
L_Vlry ADCIN11 PDPINTA SET A1 I/O1
L 11 10 2RS 106 8 2A2 4 44 2D2
L_Vlbr ADCIN12 T3PWM/T3CMP/IOPF2 ACCEPT A2 I/O2
104 6 2A3 5 43 2D3
L_Ily ADCIN13 T4PWM/T4CMP/IOPF3 A3 I/O3
U5E 101 65 BUZZER_IN 2A4 6 42 2D4
PBD_2 HS1_Temp_OUT ADCIN14 PWM7/IOPE1 A4 I/O4
62 2A5 7 40 2D5
GD_VOLTAGE H 98 ADCIN15 PWM8/IOPE2 Battery_ON A5 I/O5
+ 115 59 2A6 9 39 2D6
C47 VREFHI PWM9/IOPE3 Freq_CTRL A6 I/O6
L 114 55 2A7 10 38 2D7
VREFLO PWM10/IOPE4 A7 I/O7 2D8
DOWN 126 TCLKINB/IOPF5 PWM11/IOPE5 46 2A8 11
A8 I/O8 36
L 2 38 2A9 13 35 2D9
UP TDIRB/IOPF4 PWM12/IOPE6 A9 I/O9
37 137 2A1014 34 2D10
Inv_SSON/OFF TCLKINA/IOPB7 PDPINTB A10 I/O10
23 88 2A1115 AT29LV1024
32 2D11
2PORT2 XINT1/IOPA2 CAP4/QEP3/IOPE7 FREQ_RY A11 I/O11 2D12
TP4 21 XINT2/ADCSOC/IOPD0 CAP5/QEP4/IOPF0 81 2A1217
A12 I/O12 31
121 69 CAN2_RS 2A1318 30 2D13
L 118 BOOT_EN /XF CAP6/IOPF1 A13 I/O13 2D14
MP/MC SPISIMO/IOPC2 30 SPISIMO
2A1419
A14 I/O14 29
119 35 2A1520 28 2D15
R176 BIO/IOPC1 SPICLK/IOPC4 SPICLK A15 I/O15
H 120 33
READY SPISTE/IOPC5 SPISTE 2RD
131 IOPF6 SPISOMI/IOPC3 32 SPISOMI 47 OE NC 48
14 11 2WE 22
BypassON/OFF TDIRA/IOPB6 PLLF 2PS 2DS WE
CLKIN 123 XTAL1/CLKIN PS 84 27 CE
124 XTAL2 IS 82 2IS
B 19 93 2RD R180 B
W/R/IOPC0 RD U33
DSP2_EMU0 90 EMUO WE 89 2WE
91 73 C49 CAN2_TX1 8 CAN2_RS
DSP2_EMU1 EMU1/OFF CLKOUT/IOPE0 TP2 D RS V1
DSP2_TRST 1 TRST R/W 92
144 72 CAN2_TX L2 7
DSP2_TMS TMS CANTX/IOPC6 GND CANH 1
139 70 CAN2_RX C48
TD2_I TD1 CANRX/IOPC7 R181 2
TD2_O 142 TDO PLLF2 10 H3
VCC CANL 6 3
135 87 2DS L
TCK_CLK TCK DS 4
36 TMS2 VIS_OE 97 R179
CAN2_RX4
R VREF 5
60 122 H
TP1 ENA_144 SN65HVD230
R177 63 TP2 STRB 96
H 2RS 133 25 SCI2_TXD
R178 RS SCITXD/IOPA0
SCIRXD/IOPA1 26 SCI2_RXD
VDD
U27C
BUZZER_IN5 6 BUZZER

A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
5 4 3 2 1
R221 5V R255
R186 2D[0..15]
U37
R217 R218 LCDRS
15 - U35D 2D0 3 2 L0 U39A
R182 Ilr D0 Q0
R183 2 - U34A 16 2D1 4 5 L1 1 2
Vgry R219 L_Ilr D1 Q1 LCDRS_IN
1 L_Vgry C57 4V 14 + 2D2 7 6 L2
C50 10V R184 + TLV2465 2D3 D2 Q2 L3 R256
3 8 D3 Q3 9 LCDWR
TLV2465 L R220 H 2D4 L4
R185 13 D4 Q4 12 U39B
8
9
L H 2D5 14 15 L5 3 4
D5 Q5 LCDWR_IN
8
9
2D6 17 16 L6
2D7 D6 Q6 L7 R257
R226 18 D7 Q7 19 LCD_EN
D D
R191 U39C
R222 CS2PORT 1 5 6
R223 OC LCD_EN_IN
2 - U36A 5V 11
R187 R188 Ilb G R258
6 - U34B 1
Vgyb R224 L_Ilb DUMMY
7 C58 4V 3 + 74HCT373 U39D
R189 L_Vgyb DUMMY_IN
C51 10V 5 + TLV2465 9 8
TLV2465 L R225 H 5V R245 H
R190 VCC R259
8
9
L H U27D R249
DP0
8
9
DOWN_IN 9 8 DOWN U39E
L0 11 10
R231 R246 R250
R196 5V C62 H
U27E R260
R227 R228 DP1
R192 6 - U36B 11 10 U39F
R193 Ily UP_IN UP
11 - U34C 7 C63 L1 13 12
Vgbr R229 L_Ily R251
10 C59 4V 5 + H
R194 L_Vgbr R247 R261
C52 10V 12 + TLV2465 5V U27F
R230 DP2
TLV2465 H 13 12 U40A
R195 ACCEPT_IN ACCEPT
8
9
L H L L2 1 2
R252
8
9
5V R248 H
C64 U38A R262
R236 DP3
C 1 2 U40B C
R201 SET_IN SET
L3 3 4
R232 R233 C65
R197 11 - U36C
R198 Igr R263
15 - U34D 10 L
Vlbr R234 L_Igr DP4
16 C60 4V 12 + U40C
R199 L_Vlbr
C53 10V 14 + TLV2465 +15V U41 L4 5 6
R235 10V
TLV2465 L H 4 5
R200 IN OUT R264
8
9
L H C67
DP5
8
9
C66 3 R253 C68 U40D
NC L5 9 8
R206 2 GND FB/NC 1
R265
R254 DP6
+15V 15 - U36D U40E
R202 R203
2 - U35A 16 L6 11 10
Vlyb GD_VOLTAGE
1 R237 14 +
R204 L_Vlyb R266
C54 10V 3 + TLV2465
DP7
R205 TLV2465 R238 H U40F
8
9
L H L +15V U42 L7 13 12
4V
8
9
C61 4 5
IN OUT C70
B C69 3 C71 B
R211 NC R267
U16C
L R239 R241
R207 R208 2 GND FB/NC 1 2WE 9
6 - U35B 8CS2PORT
Vlry
7 11 - U19C R268 10
R209 L_Vlry 2IS
C55 10V 5 + 10
R240 HS1_Temp_OUT
TLV2465 12 +
R210 HS1_TOUT
L H TLV2465
8
9
H
8
9
R216 R242 R244
L
R212 R213
11 - U35C 15 - U19D
Igy
R214 10 L_Igy R243 16 HS2_Temp_OUT
C56 4V 12 + 14 +
HS2_TOUT
TLV2465 TLV2465
L R215 H H
8
9
8
9
A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
5 4 3 2 1
V2 V3 DB3 5V
V7
1GFLT 1 2GFLT 1 1 Vgry_I
1UT 2 2UT 2 14 Vgyb_I 1
DB2 2 Vgbr_I
3 3 5V V4 V5 L 2
1VT 4 2VT 4 1I/P_PORT_1 1 15 3
C72 L 6 3
5 5 1 SET_IN 1 1I/P_PORT_2 Vlry_I 4
5V L 2 16 +
6 6 2 ACCEPT_IN 2 Vlyb_I 5
+
L L 7 4
C73
7 7 3 UP_IN 3 Vlbr_I 6
L 3 17 L
8 8 LCDRS 4 DOWN_IN 4 7
8 5
R269
D 9 9 LCDWR 5 M_BYPASS_I 5 STATUSOUT_UPS1 BYPASS_CTRL 8 D
+15V 5V +15V 5V 4 18 L
10 10 LCD_EN 6 SYS_BYPASS_I 6 STATUS_UPSIN2 Igr 9
L 9 6 +15V
11 11 DP0 7 7 STATUS_UPSIN3 Igy 10
5V 5V L 5 19 L
12 12 DP1 8 Charger_ON/OFF 8 11
13 13 DP2 9 Inverter_ON/OFF 9 7 Iinvr 12
5V 5V 20
14 14 DP3 10 Bypass_ON/OFF 10 Iinvy 13
8 C74 +
R270
1WT 2WT DP4 11 Inv_SS_ON/OFF 11 Iinvb 14
1GFLT 15 2GFLT 15 V6 V9 21
16 16 DP5 12 Batt_ON 12 IBAT_IN 15
1UB 17 2UB 17 DP6 13 PBD_2 13 Vdc_Opt 1 Temp1 1 9 Ilr 16
DP7
L HS1_TOUT Temp2 22 Ily
18 18 5V R271 14 14 2 2 17
1WB 19 2WB 19 15 BUZZER 15 HS2_TOUT 3 Temp3 3 10 Ilb 18
L L 23 VDD L
1VB 20 2VB 20 16 1I/P_PORT_3 16 4 4 DACOUT1 19
DUMMY 11 TEMP_Fault 20
24 DACOUT2 21
12 Temp_CTRL 22
V8 U44 TCP_5V 25 +
R272 PBD_1 C75 23
TCP_L +15V U43 H 5V 1 3 13
TCP_5V 1 27 +VIN +VOUT + L 24
2 28 1 +VIN +VOUT 7 C78 C79 25
+C77 + LED12 C80 C81 L
3 29 26
+
2 6 L 2 4 C76 VSS
4 30 CNT TRM -VIN -VOUT TCP_L 27
5 31 -VOUT 5 VSS 28
C L 3 4 DCCONVERTER C
6 32 -VIN NC IP_MC_CTRL 29
L
7 33 R277 30
DC-DC(PC3 (6W TYPE)) TCP_5V Vdc_I L
8 34 TCP_RS/ H R275 S3 31
9 35 PD4 L TCP_RS/ PCR_CTRL 32
10 36 DC_MC_CTRL 33
PD4 TCP_5V R273 5V
6
8
1
3
11 37 SCI2_RXD IN_SS_CTRL 34
PD5 L VCC
12 38 PD5 5V
3
1
8
6
13 39
U46
14 40 H R278 U38B R283
15 41
16 42 U45 ChargerON/OFF 3 4 Charger_ON/OFF
5V
17 43 R276 R279
5
7
4
2
L TCP_5V H U38C R284
18 44 TCP_L
19 45 InverterON/OFF 5 6 Inverter_ON/OFF
2
4
7
5
R274
20 46 U26F H R280 U38D R285
21 47
22 48 12 13 SCI2_TXD BypassON/OFF 9 8 Bypass_ON/OFF
23 49 +15V H R281 U38E R286
24 50 TCP_5V
25 51 Inv_SSON/OFF 11 10 Inv_SS_ON/OFF
CD43
B TCP_L L B
26 52 H R282 U38F R287
Battery_ON 13 12 Batt_ON
5V
CD4
CD5
CD6
CD7
CD25
CD26
CD27
CD28
CD29
CD37
CD38
CD39
CD40
CD44
CD46
CD22
CD20
CD23
CD24
CD1E
CD10
CD16
CD30E
L
5V
VDD VSS TCP_5V H
+ + + + +
CD1
CD8
CD9
CD11
CD30
CD45
CD36
CD35
CD33
CD34
CD12
CD14
CD32
CD15A
CD15B
CD31B
L L L TCP_L L
CD3
CD1A
CD1D
CD1F
CD1G
CD18
CD21
CD1C
CD2A
CD2B
CD19
CD1B
CD30A
CD30B
CD30D
CD30F
CD30G
CD31A
CD30C
A A
Title
A4
DSD PE 067 0003
5 4 3 2 1
1 2 3 4 5
T1 1 24V 1 T13
D1 1 T11
T2 1 +15V VDD C1 RL1
4 2
GND 3 1 1 T12
C2 5 3 J1
IC1A 8 2
1
R1 Q1 6 1 1 T14
A T4 1 3 2 7 3 J2 A
1
4050 2
R13 C3 R2
8
T3 1 VSS GND
1 T17
24V 1 T15
RL2
D2 4 2
3 1 1 T16
5 3 J3
IC1B R3 8 2
Q2 6 1 1 T18
T5 1 5 4 7 3 J4
1
2
R14 C4 R4
GND
1 T21
24V 1 T19
RL3
D3 4 2
3 1 1 T20
5 3 J5
IC1C R5 8 2
B 6 1 1 B
Q3 T22
T6 1 7 6 7 3 J6
1
2
R15 C5 R6
GND
1 T25
24V 1 T23
RL4
D4 4 2
3 1 1 T24
5 3 J7
IC1D R7 8 2
Q4 6 1 1 T26
T7 1 9 10 7 3 J8
1
2
R16 C6 R8
GND
1 T29
24V 1 T27
RL5
D5 4 2
3 1 1 T28
C 5 3 J9 C
IC1E R9 8 2
Q5 6 1 1 T30
T8 1 11 12 7 3 J10
1
2
R17 C7 R10
GND
1 T33
24V 1 T31
RL6
D6 4 2
3 1 1 T32
5 3 J11
IC1F R11 8 2
Q6 6 1 1 T34
T9 1 14 15 7 3 J12
1
2
R18 C8 R12
GND
D D
Title
RELAY PCB with BUFFER
Custom SD 105 010 350 00
Date: Tuesday, August 04, 2009 1 of Sheet
1
AW 205 840 310
KERALA STATE ELECTRONIC DEVELOPMENT CORPORATION LTD.
1 2 3 4 5
5 4 3 2 1
Vsosc
T3
DH1 4
F1 RH
Vdc+ T3.B
Z1 Z2
Q1 R3 3 2 AGND1
Vbat
D D1 6 T3.A D
DH2
T3.C 1
1
Z3 Z4
R4 5
+ C8
R1 C1 T1A
2
R7 RV1 R8
U1
R9 1 18
2
2 17 Vctrl
CT1 3 16
C4
3 R10 4 15
1
5 14
+ 1 6 13
SG3526
C2 R5 R6 C5
R2 2 7 12
8 11 C44
2
C 4 9 10 R47 C
C6
Q2
+
C7
Vctrl
D2 C3
R11
Vdc-
+15V
R14 R15
R12 R13 C9
B B
AGND2
+12V
D3
RV2
R26
7
5
R27 CA3140
Vbat 3 +
6 Vdc_I
Vdc- 2 -
U2
R28
4
8
1
TP1 TP2 TP3
Vdc- Vdc+ Vbat
AGND2
R29

A A
Title
EPUPS POWER SUPPLY CARD
A4 DSD PE 067 0004
5 4 3 2 1
5 4 3 2 1
GDPS
U5
+15V 1 16 CO_PC2
T1C D8 L1B PCR_CTRL
Z6 2 15 CO_MC2
3 4 R23 MC_CTRL
5
R46
3 14
C17
R24 TH SS_CTRL
+
R22
D SSI D
C16 SSI 4 13
CO_SS2
6
LED2 DVR_CTRL 5 12
C20
R25
DVR_SS
6 11
AGND1
7 10
AGND1 8 9
+15V +12V
MC1413B
T4A
D9 1 RV3 R33
R32
U3
C T4B 2 1 18 C
4 R34 2 17 R48
C23 3 16
4 15 C43
R35
5 14
3 6 13 U4
SG3526
+ 7 12 C45 AGND2
5
6
8
C21 Q4 C24
R30 R31 8 11 R42 R45
9 10 2 +
7 +12V DELYD
C25 C42
3 -
+
AGND2
+
4
1
C26
R43
C22 R36
AGND2
AGND1 AGND2
B R44 B
+5V
Z7 R37
AGND1
V2
+15V 1
DVR_SS 6
AGND1 2
CO_SS2 7
+12V DELYD 3
+12V 8
CO_MC2 4
CO_PC2 9
-12V 5

A A
Title
A4 DSD PE 067 0004
5 4 3 2 1
5 4 3 2 1
L2A
D10
1 2 +5V
V1
T4C
C31 R39 1
5 2
+ +5V 3
C27 C28 R38 4
D 5 D
6 6
C32 LED3
7
8
9
L2B AGND1 10
D11 11
AGND1
12
3 4 13
+12V GDPS
T4D 14
R40 +15V 15
7 16
C33 C35 C36
+ AGND1 17
18
19
8 20
LED4 +12V
C37 21
22
23
AGND2 24
C L2C AGND2 -12V 25 C
D12 26
-12V 27
5 6 28
T4E DVR_CTRL 29
Vdc_I 30
9 C40 LED5 AGND1
31
+ PCR_CTRL 32
C38 C39 EARTH MC_CTRL 33
SS_CTRL 34
10
FRC CON.
C41 R41 -12V
-12V
-12V
R16A
D6 Vctrl
Vsosc D7
L1A
T1B
T2A
3 1 2
B R16B 1 8 B
+ R21 C14
R17 C12 C13 R20 +
D5 LED1
C15
2 7
C11
4
T2D
R16C AGND1
D4 R18
Q3
5 TP4
4
+
C10 Z5 T2C
T2B
6
R19
3
Vdc-
EARTH
A A
Title
A4 DSD PE 067 0004
5 4 3 2 1
5 4 3 2 1
VDD
VDD
T1 D3 R13
3 Rg1
U1 D2
T1.B
1 8 R1 1
GND VCC R12
T1.A
4
TRIGER 2 7 Rk1
D TRG DCGE Z1 D
2 5
T1.C Rg2
FREQ_O 3 6TRIGER R2 D1 D4 R15
O/P THRLD R14
VDD R9 Q1 6
4 5 Rk2
REST CTRL
C1 C2
555 TIMER
VDD
T2 D6
VDD VDD R17
3 Yg1
R3 R6 D5 T2.B
U2A U3A U3D 1
FREQ_O 1 R16
T2.A
3 3 2 9 10 4
C INHIBIT 2 Yk1 C
R4 Z2 2 5
R7
U2B U3E T2.C Yg2
U3B R19
5 D7
R18
4 5 4 11 12
6 R10 Q2 6
R5 R8 Yk2
U2C U3C U3F
8
10 7 6 14 15
9
VDD
T3 R21
3 Bg1
D8
VDD VDD T3.B
1 D9
R20
T3.A
4
DB1 C3 Bk1
B B
+
1 Z3 2 5
6 R24 Bg2
GND T3.C D10 R23
2
7 R22
3 INHIBIT R11 6
Q3 Bk2
8
4
9 VDD
5 D11
C4
CD1 CD2 CD3

A A
Title
UPS GATE DRIVE PCB FOR STATIC SWITCH
A4 DSD PE 057 0005
Date: Monday, December 07, 2009 Sheet 1 of 1
5 4 3 2 1
1
1 T1 D1 R1
1 1 3
VDD + Z2 C6
C1 C7
R12 C2 2 4 R2 Z6
Z1
GND +
C10 Z3
D2 C8 C9
+ GND
6
16
IC2A LD1
C3 C4 C5
J
GND
K 5
Q 1 Z4
2 Z5
VDD
1 GND VSS 3 CLK Q 2
S
VSS
R
4027
1
7
8
4
4049
3 2 5 4 7 6 9 10 VSS
IC1A IC1B IC1C IC1D
8
Q1
VSS
10
R3 C11 R4 IC2B
R5
J
11 12 1
K 11
Q 15
13 CLK Q 14 IC1E
3
4049
4027 GND
S
R
14 15
9
12
3 R18 IC1F
A 1 VDD 4049 A
PB1 GND
C14 R6
C16 + LD3
R13
GND
D3 C
16
5
1
D4 IC5
1
2
5 EN Q0 2 IC4 IC3
R17
VDD
R15 4 S0
3 R0 Q1 9 Y2 2
Y6 6
Q3 GND 5 Y5 R7 R8
4
2
6 S1 1 7
Y3 3
R14 Q2 10 GND 15 G
12 S2 1 8
11 R2 R11 Y1 1 C12
Q2 Q3 1 14 E +
14 S3 Y9 9 R9
R1 7 C13 1 9
VSS
15 R3 LD2
R10
C15 4043 R16 GND
8
1 10
GND
4
1
5 Title
1 IGBT GATE DRIVE - REV 070807
6 A4
1 GND SD 105 010 335-R
Date:
Monday, August 06, 2007 Sheet 1 of 1
1
5 4 3 2 1
1 2
SW2
CON2 CON7 CON6 CON5
7
6
5
4
3
2
1
1
2
1
2
1
2
D D
D7 R5 R4 D11 D9
D6 D10 D8
R3 D5
CON1 V4
C 1 1 34 C
1 1 34
2 2 2 2 33 33
3 3 3 3 32 32
4 4 31 JP1 R1 D4 JP2
4 4 31
5 5 5 5 30 30 1 2 1 2
6 6 6 6 29 29 D3
7 7 7 7 28 28
8 8 8 8 27 27 D2
9 9 9 9 26 26
10 10 10 10 25 25 D1
11 11 11 11 24 24
12 12 12 12 23 23
13 13 13 13 22 22
14 14 14 14 21 21
15 15 15 15 20 20
16 16 16 16 19 19
17 17 18 18
3
1
3
1
3
1
3
1
B B
PB2 PB3 PB4
PB1
4
2
4
2
4
2
4
2
1
2
CON4
1 2
SW1

A A
Title
MIMIC PCB - DSP UPS
SD 105 010 356
AW 205 840 319
Date: Wednesday, January 18, 2012 Sheet 1 of 1
5 4 3 2 1
5 4 3 2 1
R8 560E/1W
CON1 R1
1 1
D 2 D
2 3
3 1K/1W
4 4
5 5 R2 8 4
6 TP1 D3 Q1 IC1
6 7 1 2 1
7 BC 107 100K VCC 4
7
1
7 3
TP2 O/P
1 1N756 D1 R3
680K 555C
1N4007 2 2
6 6 5 GND
2
TP3
1
C1 5 1
TP4 10mf,25V
1 0.01mf C2
C C
SW1-PBM
1 2
DISPLAY RESET
SW2-PBD
1 2
SYSTEM RESET
D2
CON2 C3 R5 R6 Q2
1 1 1 2 D4 LED
2 2
3 3 100nf,63V R4 1N4007 18K 12K BC 107
4 4
B 5 33K B
5 6
6 R7 15K
7 7
10mf,63V
C4

A A
Title
DAC PCB - DSP UPS
SD 105 010 357
AW 205 840 320
Date:
Wednesday, April 19, 2006 Sheet 1 of 1
5 4 3 2 1
5 4 3 2 1
D
T1 T2 T3 T8 T5 T6 T7 T4 D
1
1
1
1
1
1
1
1
K1
4
3
5
D1 8
6
7
1
2
R1
R3 R2
C C
Q1
R4 R5 D2 D3 U1 R6
1 6
R7
5 R8
D4
2 4 Q2
4N33 D5
D6 D7
R9 R10 D8 LED
B B

A A
Title
EARTH FAULT PCB
A4
SD 105 010 310
Date: Tuesday, May 14, 2002 Sheet 1 of 1
KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LTD
5 4 3 2 1
1 2 3 4 5
+12V VDD VCC
CON1 -12V R3
R8 D1
1 VSS R5
11
A IC1A A
2 GND R1
3
11
2 -
V-
4 R6
5 LM324OUT 1 6 - IC1B
V-
6 R2 R9
1
7
V+
3 + 7
R7 LM324OUT
V+
2 5 +
DC/OL
4
R4 RV1 LD1 R19 CON2
4
R27 1
R18 R20
3
GND GND Q1 2
3
GND 4
5
6
7
B B
DC/OV LD2 R22

+12V
R10 D2 R21 R23

Q2
C1 GND
VDD GND
4
R11
10 +
V+
R13
1
LM324OUT 8 DC/UV LD3 R25

R12
2 9 - IC1C
V-
RV2 R24 R26

Q3
11
D3
C GND C
C2
3
VSS
GND
C3
GND
1
RV3
R14 R16 D4
2
4
IC1D
12 +
V+
R17
3

GND LM324OUT 14
D D
13 -
V-
Title
2
R15 D5 VOLTAGE SENSING PCB

11

A4 0
Z1 SD 105 010 344
GND AW 205 840 303/2 Date: Monday, October 13, 2014 Sheet 1 of 1
1
KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LTD.

1 2 3 4 5
1 2 3 4 5
A A
RELAY PCB
22 21
14 RL2 14 D1
D2
13 RL1 13
8 7
12 08 08 17
9 12 12 20
RL2 RL1
B B
11 04 04 18
14 07 07 15
27 11 RL2 RL1 11 2
13 03 03 16
25 06 06 5
28 10 10 19
RL2 RL1
26 02 02 6
24 05 05 3
C C
10 09 RL2 RL1 09 1
23 01 01 4
AW : 205 840 229/1
D D
Title
RELAY PCB
Custom SD 105 010 255/2
Date: Wednesday, February 23, 2011 Sheet 1 of 1
KERALA STATE ELECTRONIC DEVELOPMENT CORPORATION LTD.
1 2 3 4 5
2 x 40 KVA UPS
9. ERECTION AND COMMISSIONING PROCEDURE

PROCEDURE FOR ERECTION, INSTALLATION, AND COMMISSIONING OF
40 KVA UPS
1. REFERENCES
a. Approved GA and schematic drawings and bill of material.
DMA 105 008 671
SD 105 008 671
PL 105 008 671
b. Technical Specification for UPS
GTP 105 008 671
2. INSTALLATION PROCEDURE OF UPS SYSTEM
Refer drawing number DMA 105 008 671
2.1 UPS panels of DS10 shall be transported keeping it upright in original packing to the
unloading bay of the building. Unpack and shift the panels to the UPS room.
2.2 UPS panel is positioned as per the DMA drawing referred above at the Specified
locations
2.3 Check the insulation resistance of the UPS panel using Meggar
2.4 Establish power connections for INPUTS, OUTPUT & BATTERY at UPS end and as
per schematic drawings
2.5 Keep all MCCBs, MCBs and Switches inside panels in OFF position
3. INSTALLATION CHECKS
Sl. no Description Requirement Observed Remarks

1 Physical damages ,if any No damage
2 Cable entry as per design OK
Cable terminations at UPS
3 OK
inputs and output.
Tightness of cable
4 OK
terminations inside UPS panel
5 Battery terminal polarity OK
6 Earthing of panels OK
7 Room ventilation OK
8 Illumination in room OK

4. COMMISSIONING CHECKS
4.1 CHARGER AND INVERTER
SL. Observed
Parameter Test Point Required Value Remarks
No. value
Input 3phase Terminals R Y B
1 415V+ 10%, -15%
supply Between RY,YB & BR
Input phase Terminals R Y B Clockwise rotation of
2
sequence Between RY,YB & BR phase sequence meter
Inverter ON/OFF ON/OFF push button
Status of ON/OFF push
and Load released and transfer
3 button and Transfer
Transfer push push button in UPS
push button
button mode.
4 Device Cooling MCBs 640, 641 & 642 ON
fan ON/OFF
Close Control
supply MCB’s
180 to 300 VDC
(MCB103 from SMPS1 Terminals
5
charger input / (+) ve and (-)ve.
MCB 302 from
battery)
LEDs 2,3,4,&5
SMPS output corresponding to SMPS LEDs 2 to 5 glow in
6
voltages output voltages +15, SMPS 1
+5,+12 & -12 V DC
Across pin nos. 1&2 in
Gate Drive Card
7 gate drive PCB’s of 15 +/- 1V DC
Power Supply
charger inverter
Pre-charging of
capacitor bank by
8 C301,C305 300-350V DC
closing MCB301
/ MCB 303
Battery Bank
9 MCB Q300 ON
Isolator
Open MCB301/
10 MCB303 at the C301,C305 300-350V DC
end of precharge
Display shows-Grid
11 Close Q100 Display is present and Ready
for ups operation
System reset and Push buttons PB1 &

12 Press PB1 and PB2
Display Reset PB2 in DAC PCB

1.System ON/OFF
push button 1.Press to switch ON Charger and Inverter
13
2.Load transfer 2.Press for ups are ON
push button operation
DC Voltage
across DC filter
14 Charger output voltage 426 V DC/510VDC
bank C301 to
C305
Inverter output
15 Q750 input terminals 110VAC,50Hz
voltage
Input terminals of
Inverter
16 Q750 50 Hz ±1%
frequency
Load voltage
Output terminals 110V AC ±1%
17 (close Q750)
All Block indications
18 Display on Mimic Block indications glow except Bypass SS
block.
4.2 BATTERY OPERATION
1. System is in normal operation with inverter on load bus

2. Mains failure is simulated by switching OFF Q100
Charger become OFF.
Battery Supplies the UPS system.
3. Close Q100
Charger Become ON.
4.3 BATTERY CURRENT LIMIT
Battery is discharged and being charged with Charger.
set value Current Limit

Sl.No Condition
voltage Required Observed
1 Float mode 426V
2 Boost mode 510V

4.4 MAINS FAIL / RESTORATION TEST
Sl.No Observati
Description Expected Remarks
. on
Input Mains Switched Charger OFF. Inverter operates
1
OFF on Battery backup
Input Mains switched Charger becomes ON
2
ON automatically and feeds inverter
4.5 Bypass mode operation
Sl.No
Description Expected Observation Remarks
.
Switch on bypass Bypass supply will be
switch Q740 connected to the load terminal.
1 Press UPS/bypass
Transfer switch of
mimic PCB
Release UPS/bypass
UPS supply will be connected
2 Transfer switch of
to the load terminal
mimic PCB
4.6 Manual Bypass Switch operation
Sl.No
Description Expected Observation Remarks
.
Switch on bypass Bypass supply will be
switch Q740 connected to the load terminal.
1 Press UPS/bypass
Transfer switch of
mimic PCB
Put the Manual
Bypass supply will be
bypass switch 960 in
connected directly to the load
2 Service position.
terminal and the UPS can be
Switch off Q740.
taken for servicing
Switch off Q750

2 x 40 KVA UPS
10. CATALOGUES

www.cselectric.co.in
New WiNbreak MCCB
State of the art Manufacturing Facilities

New WiNbreak
Haridwar, Noida Ph-I

& Noida Ph-II Plant
C&S Electric Ltd.

Corporate Office : 222, Okhla Industrial Estate, New Delhi - 110 020
Tel. : +91-11-3088 7520 - 29, Fax: +91-11-2684 7154, 2682 9063
International Business Division: Tel. : +91-11-4161 3503, 3088 7520-29, Fax: +91-11-2683 8291, 2684 7342
email : exports@cselectric.co.in
Central Marketing Office: Tel. : +91-11- 3088 7520-29 , Fax: +91-11-2684 8241, 2684 7342
email : cmo@cselectric.co.in, info@cselectric.co.in Moulded Case Circuit Breaker
We touch your electricity everyday!
Overview
upgrade of WiNbreak series New WiNbreak
Upgrade breaking capacity

440V
85kA
CSC5L CSC6L
85kA 85kA
65kA
CSC5H CSC6S
Compatible and differentiated design Upgrade breaking capacity 50 65kA 50 65kA
50kA CSC5S
CSC3H CSC4N
- Compatible with WiNbreak MCCB 100AF: 10 18kA 35 50kA 35 50kA
37kA
125AF: 25 37kA CSC3S CSC4S CSC5N CSC6N
25 37kA 35 37kA
Upgrade the coordination 250AF: 25 37kA
26kA
CSC4N
- Upgrade the coordination with WiNbreak2 MCCB 250AF: 35 50kA 18 26kA
18kA
400AF: 25 37kA CSC1S CSC2N
400AF: 35 50kA 14kA

800AF: 50 65kA CSC1N
Ics = 100% Icu

50AF 100AF 125AF 250AF 400AF 800AF
2 C&S Electric Ltd. C&S Electric Ltd. 3

External Configuration
Handle
n Fixed Thermal Magnetic MCCB n Function of indications - “ON” “OFF” “TRIP”
n Resetting - When the handle indicate “tripped” position it
n 100% compatible with WiNbreak MCCB Handle
n Standardized dimension (depth, cutout) offering

flexibility for panel designers.
New WiNbreak n
must first be reset by moving the handle to the “OFF”
position and then closing is possible
Trip-Free even if the handle is held at “ON”, the breaker will
Terminal
trip if an over current flows

n Suitable for verification of the main contact position under
abnormal conditions because the handle doesn’t indicate
position
Moulded Case Circuit Breaker

Arc-Extinguishing
Arc-Extinguishing unit unit
n Patent technique PASQ Arch-Extinguishing
PASQ (Puffer Assisted Self-Quenching)
n Reduce of arc voltage for a short time
Trip button (push to trip)

Enables tripping mechanically for outside, for confirming to
operation of the MCCB and the manual resetting function.
Contact
Mechanism
Trip Trip Button
Short Circuit Breaking Capacity
New WiNbreak Application of PASQ Arc Extinguishing Application of Current limiting structure
CSC-L
WiNbreak CSC-H
CS-C CSC-S • Current limiting repulsion
structure (U fixed structure)
The reduction of breaking time
CS-B
CSC-N by applying PASQ arc • Toggle structure: When the
CS-A extinguishing for inhibition of arc operating unit repulses by
voltage for a short time. short circuit current, repulsion
structure at bigger angle.
Upgraded Breaking Capacity
100AF 125AF 250AF 250AF

10 18kA 25 37kA 25 37kA 35 50kA
400AF 400AF 630AF 800AF
25 37kA 35 50kA 50 65kA 50 65kA

Selection Table
AF 50AF 100AF 125AF 250AF
Frame type CSC1 CSC2 CSC3 CSC4
N-Type S-Type
CSC1N2 CSC1S2 CSC2N2 - - CSC4N2 - -
CSC1N3 CSC1S3 CSC2N3 CSC3S3 CSC3H3 CSC4N3 CSC4S3 CSC4H3
CSC1N4 CSC1S4 CSC2N4 CSC3S4 CSC3H4 CSC4N4 CSC4S4 CSC4H4
15,20,30,40,50
690 690
500 500
750 750
8 8
2.5 5
7.5 10
14 18
18 22
30 35
5 10
5 10
100 100
AF 50AF 100AF 125AF 250AF

Type
CSC1N1 CSC2N CSC4N

CSC-N
14kA 18kA 26kA
CSC1S CSC3S CSC4S

CSC-S
18kA 37kA 37kA
CSC3H CSC4H
CSC-H
50kA 50kA
(Fig. 1) (Fig. 2) (Fig. 3)

Selection Table
AF 400AF 800AF 1000AF 1200AF
Frame type CSC5 CSC6 CSC7 CSC8
CSC5N3 CSC5S3 CSC5H3 CSC5L3 CSC6N3 CSC6S3 CSC6L3 CSC7S3 CSC7L3 CSC8S3 CSC8L3
CSC5N4 CSC5S4 CSC5H4 CSC5L4 CSC6N4 CSC6S4 CSC6L4 CSC7S4 CSC7L4 CSC8S4 CSC8L4
1200
AF 400AF 800AF 1000AF 1200AF

Type
CSC5N CSC6N
CSC-N
37kA 37kA
CSC5S CSC6S CSC7S CSC8S

CSC-S
50kA 65kA 65kA 65kA
CSC5H
CSC-H
65kA
CSC5L CSC6L CSC7L CSC8L

CSC-L
85kA 85kA 85kA 85kA
(Fig.4) (Fig. 5) (Fig. 6)

Accessories
Electrical accessories
Auxiliary Switch
Alarm Switch Alarm Switch
Shunt Trip
Shunt Trip Shunt Trip
Undervoltage Trip Undervoltage Trip Undervoltage Trip

Alarm Switch
Auxiliary Switch
Auxiliary Switch Auxiliary Switch
Alarm Switch
AL AL SHT SHT AL AL
or or
AX AX UVT UVT AX AX
Combination switch
Combination Switch
Option for connection Option for connection
Option of connecting AX or AL or AX+AL Option of connecting SHT or UVT or AX or AL or AX+AL AX or AL or AX+AL SHT or UVT or AX or AL or AX+AL
This seat is not available for 2 Pole breakers This seat is not available for 2 pole breakers This seat is not available for ELCB.
Maximum possibilities Maximum possibilities

CSC2 CSC3 CSC4
2P 3/4P 2P 3/4P 3/4P

External Accessories & Operating Curve Operating Curve
Front and rear connection CSC3S & CSC3H

Several kinds of terminals can be equipped with ELCBs as well as MCCBs.
- Terminals for front connection
- Rear connection terminals
Rated current: 15~30A, 40~140A Rated current: 125A Compensation Curves
Plug-in base
It makes to extract and/or rapidly replace the circuit breaker without having to touch
connections.(Easy replacement and maintenance)
Direct & Extended Rotary Handle

There are two types of rotary handles.
- Direct rotary handle(with or w/o key lock device)
- Extended rotary handle
Locking device
- Fixed padlock
- Removable padlock
- Key lock device on direct handle
Insulation barrier
These allow the insulation characteristics between the phases at the connections to be increased.
Insulation terminal cover

The terminal covers are applied to the circuit-breaker to prevent accidental contact
with live parts and thereby guarantee protection against direct contacts.
CSC1N, CSC1S & CSC2N CSC4N, CSC4S & CSC4H
Rated current: 15~30A Rated current: 40~100A Compensation Curves Rated current: 100~225A Rated current: 125A Compensation Curves
Rated current: 15~30A

Operating Curve Overall Dimensions
CSC5N, CSC5S, CSC5H, CSC5L, CSC6N, CSC6S & CSC6L CSC1N, CSC1S & CSC2N
Rated current: 250~400A Rated current: 500~800A Compensation Curves Terminal Details
Panel drilling Front panel cutting
CSC7S, CSC7L & CSC8S CSC3S & CSC3H
Rated current: 1000~1200A Compensation Curves

Mounting Details

Overall Dimensions
CSC4N, CSC4S & CSC4H CSC6N, CSC6S & CSC6L
Mounting Details
Terminal Details Connecting
CSC5N, CSC5H, CSC5S & CSC5L CSC7S, CSC7L, CSC8S & CSC8L
Terminal Details
Panel drilling Front panel cutting Conneting Panel drilling Front panel cutting

Overall Dimensions
Rotary handle - Direct mounting type (D-handle 50~250AF) Rotary handle - Direct mounting type (E-handle 50~250AF)
DHC100 EHC100
DHC125 EHC125
DHC250 EHC250
Direct mounting type (N-handle 400~800AF) Extended mounting type (N-handle, 400~800AF)
E-70U (400AF)
N-70S, N-70M
E-80U (800AF)

SKM300GB126D
Absolute Maximum Ratings
Symbol Conditions Values Unit
IGBT
VCES Tj = 25 °C 1200 V
IC Tc = 25 °C 310 A
Tj = 150 °C
Tc = 80 °C 218 A
ICnom 200 A
ICRM ICRM = 2xICnom 400 A
VGES -20 ... 20 V
SEMITRANS® 3 VCC = 600 V
tpsc VGE ≤ 15 V Tj = 125 °C 10 µs
VCES ≤ 1200 V
Trench IGBT Modules Tj -40 ... 150 °C
Inverse diode
IF Tc = 25 °C 250 A
Tj = 150 °C
SKM300GB126D Tc = 80 °C 169 A
IFnom 200 A
IFRM IFRM = 2xIFnom 400 A
Features tp = 10 ms, sin 180°, Tj = 25 °C
IFSM 1656 A
• Trench = Trenchgate technology
Tj -40 ... 150 °C
• VCE(sat) with positive temperature
coefficient Module
• High short circuit capability, self limiting It(RMS) 500 A
to 6 x IC Tstg -40 ... 125 °C
• UL recognized, file no. E63532
Visol AC sinus 50 Hz, t = 1 min 4000 V
Typical Applications* Characteristics

• Electronic welders
Symbol Conditions min. typ. max. Unit
• AC inverter drives
• UPS IGBT
VCE(sat) IC = 200 A Tj = 25 °C 1.70 2.10 V
VGE = 15 V
chiplevel Tj = 125 °C 2.00 2.46 V
VCE0 Tj = 25 °C 1 1.2 V
chiplevel
Tj = 125 °C 0.9 1.1 V
rCE VGE = 15 V Tj = 25 °C 3.5 4.5 mΩ
chiplevel Tj = 125 °C 5.5 6.8 mΩ
VGE(th) VGE=VCE, IC = 8 mA 5 5.8 6.5 V
ICES VGE = 0 V Tj = 25 °C 2.7 mA
VCE = 1200 V Tj = 125 °C mA
Cies f = 1 MHz 14.4 nF
VCE = 25 V
Coes f = 1 MHz 0.75 nF
VGE = 0 V
Cres f = 1 MHz 0.65 nF
QG VGE = - 8 V...+ 20 V 1800 nC
RGint Tj = 25 °C 3.8 Ω
td(on) VCC = 600 V Tj = 125 °C 280 ns
tr IC = 200 A Tj = 125 °C 37 ns
VGE = +15/-15 V
Eon Tj = 125 °C 21 mJ
RG on = 1.5 Ω
td(off) RG off = 1.5 Ω Tj = 125 °C 560 ns
tf Tj = 125 °C 100 ns
Eoff Tj = 125 °C 33 mJ
Rth(j-c) per IGBT 0.12 K/W
GB
© by SEMIKRON Rev. 1.0 – 20.07.2015 1

SKM300GB126D
Characteristics
Inverse diode
VF = VEC IF = 200 A Tj = 25 °C 1.60 1.80 V
VGE = 0 V
chiplevel Tj = 125 °C 1.60 1.80 V
VF0 Tj = 25 °C 1 1.1 V
chiplevel
Tj = 125 °C 0.8 0.9 V
rF Tj = 25 °C 3 3.5 mΩ
chiplevel
Tj = 125 °C 4 4.5 mΩ
SEMITRANS® 3 IRRM IF = 200 A Tj = 125 °C 290 A
Qrr di/dtoff = 6200 A/µs T = 125 °C 44 µC
j
VGE = -15 V
Trench IGBT Modules Err VCC = 600 V T j = 125 °C 18 mJ
Rth(j-c) per diode 0.25 K/W
Module
SKM300GB126D
LCE 15 nH
RCC'+EE' TC = 25 °C 0.35 mΩ
terminal-chip
TC = 125 °C 0.5 mΩ
Features
Rth(c-s) per module 0.02 0.038 K/W
• Trench = Trenchgate technology
• VCE(sat) with positive temperature Ms to heat sink M6 3 5 Nm
coefficient Mt to terminals M6 2.5 5 Nm
• High short circuit capability, self limiting Nm
to 6 x IC
w 325 g
Typical Applications*
• Electronic welders
• UPS
GB
2 Rev. 1.0 – 20.07.2015 © by SEMIKRON

SKM300GB126D
Fig. 1: Typ. output characteristic, inclusive RCC'+ EE' Fig. 2: Rated current vs. temperature IC = f (TC)
Fig. 3: Typ. turn-on /-off energy = f (IC) Fig. 4: Typ. turn-on /-off energy = f (RG)
Fig. 5: Typ. transfer characteristic Fig. 6: Typ. gate charge characteristic
© by SEMIKRON Rev. 1.0 – 20.07.2015 3

SKM300GB126D
Fig. 7: Typ. switching times vs. IC Fig. 8: Typ. switching times vs. gate resistor RG
Fig. 9: Transient thermal impedance Fig. 10: Typ. CAL diode forward charact., incl. RCC'+ EE'
Fig. 11: Typ. CAL diode peak reverse recovery current Fig. 12: Typ. CAL diode peak reverse recovery charge
4 Rev. 1.0 – 20.07.2015 © by SEMIKRON

SKM300GB126D
SEMITRANS 3
GB
This is an electrostatic discharge sensitive device (ESDS), international standard IEC 60747-1, Chapter IX
* The specifications of our components may not be considered as an assurance of component characteristics. Components have to be tested
for the respective application. Adjustments may be necessary. The use of SEMIKRON products in life support appliances and systems is
subject to prior specification and written approval by SEMIKRON. We therefore strongly recommend prior consultation of our staff.
© by SEMIKRON Rev. 1.0 – 20.07.2015 5

SKM300GB12T4
Absolute Maximum Ratings
Symbol Conditions Values Unit
IGBT
VCES Tj = 25 °C 1200 V
IC Tc = 25 °C 422 A
Tj = 175 °C
Tc = 80 °C 324 A
ICnom 300 A
ICRM ICRM = 3xICnom 900 A
VGES -20 ... 20 V
SEMITRANS® 3 VCC = 800 V
tpsc VGE ≤ 15 V Tj = 150 °C 10 µs
VCES ≤ 1200 V
Fast IGBT4 Modules Tj -40 ... 175 °C
Inverse diode
IF Tc = 25 °C 353 A
Tj = 175 °C
SKM300GB12T4 Tc = 80 °C 264 A
IFnom 300 A
IFRM IFRM = 3xIFnom 900 A
Features tp = 10 ms, sin 180°, Tj = 25 °C
IFSM 1548 A
• IGBT4 = 4. generation fast trench IGBT
Tj -40 ... 175 °C
(Infineon)
• CAL4 = Soft switching 4. generation Module
CAL-diode It(RMS) Tterminal = 80 °C 500 A
• Isolated copper baseplate using DBC Tstg -40 ... 125 °C
technology (Direct Bonded Copper)
Visol AC sinus 50 Hz, t = 1 min 4000 V
• Increased power cycling capability
• With integrated gate resistor
• For higher switching frequenzies up to Characteristics
20kHz
IGBT
Typical Applications* VCE(sat) IC = 300 A Tj = 25 °C 1.85 2.10 V
• AC inverter drives VGE = 15 V
• UPS chiplevel Tj = 150 °C 2.25 2.45 V
• Electronic welders at fsw up to 20 kHz VCE0 Tj = 25 °C 0.8 0.9 V
chiplevel
Remarks Tj = 150 °C 0.7 0.8 V
• Case temperature limited rCE VGE = 15 V Tj = 25 °C 3.50 4.00 m
to Tc = 125°C max. chiplevel Tj = 150 °C 5.17 5.50 m
• Recommended Top = -40 ... +150°C VGE(th) VGE=VCE, IC = 12 mA 5 5.8 6.5 V
• Product reliability results valid
ICES VGE = 0 V Tj = 25 °C 4.0 mA
for Tj = 150°C
VCE = 1200 V Tj = 150 °C mA
Cies f = 1 MHz 17.6 nF
VCE = 25 V
Coes f = 1 MHz 1.16 nF
VGE = 0 V
Cres f = 1 MHz 0.94 nF
QG VGE = - 8 V...+ 15 V 1700 nC
RGint Tj = 25 °C 2.5 
td(on) VCC = 600 V Tj = 150 °C 200 ns
tr IC = 300 A Tj = 150 °C 44 ns
VGE = ±15 V
Eon Tj = 150 °C 27 mJ
RG on = 1.5 
td(off) RG off = 1.5  Tj = 150 °C 450 ns
tf di/dton = 7500 A/µs Tj = 150 °C 90 ns
di/dtoff = 3350 A/µs
Eoff Tj = 150 °C 29 mJ
Rth(j-c) per IGBT 0.11 K/W
GB
© by SEMIKRON Rev. 1 – 03.09.2013 1

SKM300GB12T4
Characteristics
Inverse diode
VF = VEC IF = 300 A Tj = 25 °C 2.17 2.49 V
VGE = 0 V
chiplevel Tj = 150 °C 2.11 2.42 V
VF0 Tj = 25 °C 1.3 1.5 V
chiplevel
Tj = 150 °C 0.9 1.1 V
rF Tj = 25 °C 2.9 3.3 m
chiplevel
Tj = 150 °C 4.0 4.4 m
SEMITRANS® 3 IRRM IF = 300 A Tj = 150 °C 345 A
Qrr di/dtoff = 7300 A/µs T = 150 °C 54 µC
j
VGE = ±15 V
Fast IGBT4 Modules Err VCC = 600 V T j = 150 °C 23 mJ
Rth(j-c) per diode 0.17 K/W
Module
SKM300GB12T4
LCE 15 20 nH
RCC'+EE' TC = 25 °C 0.25 m
terminal-chip
TC = 125 °C 0.5 m
Features
Rth(c-s) per module 0.02 0.038 K/W
• IGBT4 = 4. generation fast trench IGBT
(Infineon) Ms to heat sink M6 3 5 Nm
• CAL4 = Soft switching 4. generation Mt to terminals M6 2.5 5 Nm
CAL-diode Nm
• Isolated copper baseplate using DBC
w 325 g
technology (Direct Bonded Copper)
• Increased power cycling capability
• With integrated gate resistor
• For higher switching frequenzies up to
20kHz
Typical Applications*
• UPS
• Electronic welders at fsw up to 20 kHz
Remarks
• Case temperature limited
to Tc = 125°C max.
• Recommended Top = -40 ... +150°C
• Product reliability results valid
for Tj = 150°C
GB
2 Rev. 1 – 03.09.2013 © by SEMIKRON

SKM300GB12T4
Fig. 1: Typ. output characteristic, inclusive RCC'+ EE' Fig. 2: Rated current vs. temperature IC = f (TC)
Fig. 3: Typ. turn-on /-off energy = f (IC) Fig. 4: Typ. turn-on /-off energy = f (RG)
Fig. 5: Typ. transfer characteristic Fig. 6: Typ. gate charge characteristic
© by SEMIKRON Rev. 1 – 03.09.2013 3

SKM300GB12T4
Fig. 7: Typ. switching times vs. IC Fig. 8: Typ. switching times vs. gate resistor RG
Fig. 9: Transient thermal impedance Fig. 10: Typ. CAL diode forward charact., incl. RCC'+ EE'
Fig. 11: CAL diode peak reverse recovery current Fig. 12: Typ. CAL diode peak reverse recovery charge
4 Rev. 1 – 03.09.2013 © by SEMIKRON

SKM300GB12T4
SEMITRANS 3
GB
This is an electrostatic discharge sensitive device (ESDS), international standard IEC 60747-1, Chapter IX
* The specifications of our components may not be considered as an assurance of component characteristics. Components have to be tested
for the respective application. Adjustments may be necessary. The use of SEMIKRON products in life support appliances and systems is
subject to prior specification and written approval by SEMIKRON. We therefore strongly recommend prior consultation of our staff.
© by SEMIKRON Rev. 1 – 03.09.2013 5

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2 x 40 KVA UPS

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

2. PRELIMINARY DESIGN DOCUMENT

4. SCHEMATIC DIAGRAM & BILL OF MATERIAL

5. GUARANTEED TECHNICAL PARTICULARS

6. SYSTEM ON – OFF PROCEDURE

7. MAINTENANCE AND TROUBLE SHOOTING

8. PCB DESCRIPTION & DIAGRAMS

9. ERECTION AND COMMISSIONING PROCEDURE

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

STATIC VOLTAGE STABILIZER

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

2. PRELIMINARY DESIGN DOCUMENT

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

In the present scenario, commercial power supply is not capable of providing

2.1.2 TYPES OF UPS

The ON line UPS system consists of a Rectifier / Battery charger, Battery

B. OFF LINE UPS SYSTEMS

2.1.3 TECHNOLOGICAL TRENDS

A. DOUBLE CONVERSION ON LINE UPS SYSTEMS

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

Fig.1 BLOCK DIAGRAM OF DOUBLE CONVERSION UPS SYSTEM

Fig.2 Mains Voltage and Current Waveforms of a Double conversion System

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

Fig, 3 BLOCK DIAGRAM OF SINGLE CONVERSION UPS SYSTEM

Fig. 4 Mains Voltage and Current Waveforms of a Single conversion System

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

3. BASIC SCHEME OF DYNAMIC POWER MANAGER (DPM) UPS SYSTEM

The Dynamic Power Manager UPS system overcomes the drawbacks of

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

ADVANTAGES OF DYNAMIC POWER MANAGER UPS SYSTEM

• Near unity power factor at input

Disadvantages of Dynamic Power Manager UPS System

It is not the perfect choice to Frequency critical loads

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

FEC Inverter Inverter SS

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

• Near unity power factor at input

2.3 DESCRIPTION OF POWER SECTION - INVERTER

2.3.1 DESIGNS AND MODE OF OPERATION OF THE INVERTER

1. Inverter power Control Device (IGBT Bridge).

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

The controller of the Inverter comprise of Voltage controller and Current

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

2. OUTPUT ISOLATION TRANSFORMER

3. OUTPUT SMOOTHENING LC FILTER

FIG 3.3 FIG 3.4

4. INVERTER STATIC SWITCH.

Output MCCB allows us to disconnect the load from UPS.

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KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

Page1/4 of SD 105 008 671

Page2/4 of SD 105 008 671

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

Page 3/4 of SD 105 008 671

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

4. SCHEMATIC DIAGRAM AND BOM

KERALA STATE ELECTRONICS DEVELOPMENT CORPORATION LIMITED

1500 1500 900 900

DSS40 DSS40 SVS40+SS

INSTRUMENT PLATE 1 INSTRUMENT PLATE 2 INSTRUMENT PLATE 1