1.

SYSTEM OVERVIEW
1.1. Construction of the UPS

General Topology：

The UPS syst em is composedof i nput breakers, i nput fi lter & protect ion networ k,
r ect i f i er,bat t er y bank,
i nver t er, s ta t ic swi t ch, bypas s br eaker, i s ol at i on t rans f orm
and output filter. The basic topology is shown in the diagram above. Under normal
AC mode, energy from the AC source is converted to DC power and supplied to the
inverter to charge the batteries to its full capacity all the time, ready to support th
output load in case of AC source failure.

Although the principle and operation of a UPS seems simple and straightforward, the
requirement for a reliable and intelligent UPS makes the design and manufacturing
o f a h i g h p o w e r U P S o n e r e q u i r i n g a d v a n c e d t e c h n o l o g y, i n t e l l i g e n c e , e x p
and most important, consideration of the user interface. Many years have been spent
in designing the most rugged, intelligent and reliable UPS for the market, and a safe
and convenient UPS for the user.

Choosing the best and most suitable UPS for a given application can
difficult, depending on the client’s knowledge of key parameters. The most obvious
specification, output power, depends on the size of the load. Often, an allowance of
50% more power is added to the present load requirement, both for tolerance and for
future expansion.

1
A n o t h e r i m p o r t a n t i s s u e i s r e l i a b i l i t y. T h e p r i m e a i m o f a U P S i s t o p r o
load. Therefore, the UPS should be much more reliable than the AC
unreliable UPS may suffer the problem of frequent break down, even more frequent
t han AC fail ure, and t he cost of repai r m ay become m ore t han the cost of t he u
itself.

Generally, there are four different modes of operation, the NORMAL OPERATION
M O D E , t h e B A C K - U P ( B AT T E RY ) M O D E , t h e R E S E
MAINTENANCE BYPASS MODE. These are explained below.

Normal Operation Mode:

The rectifier converts the AC input to DC power to supply the inverter and charge the
batteries simultaneously. All the fluctuations, surges and spikes of the AC input are
removed during AC to DC conversion. Therefore, the AC supplied by the inverter is
clean and stable.

2
Back-up Mode:

Since the batteries are connected directly to the DC bus, when the A
batteries change immediately from receiver to donor, s
inverter instead of receiving energy from the rectifier
interrupted. Therefore, the load connected to the output is protected.

Reserve Mode:

W h e n t h e i n v ei rstienr a n a b n o r m ca ol n d i t i, o snu c h a s o vt e m
r perature, short
circuit, abnormaloutput voltage or overloaded for a period exceeding the inverter’s
l i m ,i tt h e i n v e r t e ra uwt iol m
l a t i csahl ul ytd o w ni n o r d e r t o p r o t e c t i t s e l f f
damage. If the utility power is normal, the static switch shall transfer the load to the
reserve source without interruption of AC output.

3
Maintenance Bypass Mode:

In case of UPSmaintenanceor battery repl acement , and where the load cannot be
interrupted, the user can turn off the inverter, close the bypass breaker and then open
t h e r e c t i f i e r a n d r eb sr e ra vk ee. r T
s he AC output will not be interrupted d
manual bypass transfer procedure. Therefore,maintenance the bypass switch keeps
continuously supplying power to the load. Electricity will not exist in UPS except the
output transformer, thus ensuring the safety of service personnel.

Generally, the UPS is expected to run 24 Hours a day in normal operation mode once
it is installed, except when the utility power fails, under overload
during maintenance.

Normal operation with batteries connected provides clean, sta

uninterrupted power to the load, free from any spikes and surges. Therefore, the UPS
can be regarded as a perfect AC power source, limited in back-up time, under mains
failure, only by the capacity of the batteries.

4
1.2. Features and Advantages

(a) Reliable input protection: Circuit breakers are placed in each individual input
loop to ensure power can continue through another loop in case of breaker trip
caused by an abnormal condition in either rectifier or load.

(b)I n p u t s u r g e p r o t eAcnt M
i oOn V
: (surge protector) is added at th
providing protection to both UPS and the load from any lightnin
surges caused by neighboring large loads.

(c) E M I s u p p r e s s A
i onnE: M I f i l t e r i s a d d e d t o m e e t t h e i n t e r n a t i o n a
limits. Therefore, very low noise is emitted, and no interference is supplied to
other equipment connected to the same AC source.

(d)Ruggedness: The rectifier employs phase control technology to regulate the DC

bus voltage. This is the most efficient method to charge the batteries. The SCR
used are inherently rugged. Additionally, a large inductor is added at the input to
avoid deforming the AC source waveform.

(e) H i g h f r e q u e n c y dTehs ei ginn :v e r t e r u s e s h i g h f r e q u e n c y , h i g h

IGBT, PWM methodology to convert the DC power to AC power. Therefore, the
number of components is fewer, reliability is improved, and the size and weight
of UPS is reduced, performance is improved, and acoustic noise is minimized.

(f) True Galvanic isolation: An isolation transformer is placed at the output. This
can solve the problem of poor input grounding, can allow a differ
between input and output, can avoid the annoying problem of ground
current, and can be tied to any potential provided on site. The A
isolated under every mode of operation. Additionally, the user gets the bonus of
attenuation of common mode noise from the output isolation transformer.

5
(g) P l u g & P l a y M o d u l a r dTehsei gpno:w e r c i r c u i t i s s e p a r a t e d i n t o s
modules plugged into slots in the UPS, which are easy to pull out, perm
quick maintenance and easier trouble shooting.

(h)Cold start function:the UPS can be started without an AC source, that is, can
be st a rte d wi th b at te ry po we r on ly. This is po ssib le b e
circuitry is added, preventing the problem of large inrush current blo
battery fuse and damaging the DC capacitors when batteries are connected to an
empty DC bus (before the DC bus is energized).

(i) M u l t i - C P U d e sSi eg vne: r a l C P U s a r e e m p l o y e d i n t h e c o n t r o l c i r

critical functions are designed with parallel redundancy to improve r
Therefore, in case of one CPU failure, the other CPUs keep the UPS operational,
and the output AC is not affected.

(j) P r o t e c t i o n a g a i n s t m i sTuhsee :U P S i s d e s i g n e d w i t h b r e a k e r o n / o f f s e n s o
power suppl y s ensor, et c. The ref or e, any oper at i onal m i st ake m ade by the
causes no harm to the UPS.

(k)Accepts wide input range:

The UPS is designed to accept a wide input range,
so that it can work effectively under an unstable AC source. All of
components used are specifically selected to handle extreme high vol
high current.

(l) O p e r a t i n g e n vEi ar co hn mc eo nm tp: o n e n t o f t h e U P S i

large safety margin to accommodate extreme environments, such as temperature,
humidity, altitude, shock or contamination.

(m) Intelligent charger: The UPS will automatically recharge (boost charge) the
batteries every time the batteries are depleted to a voltage level equal to 2V/Cell.
Thus, the batteries can be restored to full capacity as soon as possible, and made
ready for the next back-up requirement. In order to keep the batteries in the best
condition, the UPS will boost charge the batteries for several hours (selectable
a u t o m a t i c a l l y e v e r y m o n t h . To a v o i d o v e r c h a r g i n g t h e b a t t e r i e s , b o o s
will stop when the ambient temperature is over 35 oC (95oF).

6
(n)Intelligent battery test: The batteries are tested after every boost (initiated by
battery discharge or by the monthly boost charge cycle). This is done
interrupting the operation of the rectifier, preventing the risk of output AC failure
i n c a s e o f a b a d b a t t e r y. T h e u s e r i s i n f o r m e d o f t h e b a t t e r y c o n d i t i o n , s
action can be taken before the full capacity of the batteries is needed.

(o) Huge charging power: The charging power is selectable (Lo/Me/Hi) according
to Ah rating of the batteries, and can charge up battery banks providing more than
8Hrs back-up time without adding an extra charger.

(p)MTBF of fans are extended:Fans used to cool the UPS, are designed to slow
down under light load, so that the life expectancy of the fans is extended beyond
the normal.

(q)Re d u n d a n t p o we r s u p pA
l y:s up pl em en t a l po we r s up pl y i s ad de d t o p r ov i d e
redundancy for supplying power to the static switch, so that there wil
output no matter what happens to the UPS.

(r) V a r i e t y o f a c c e s s o W r yi t h( o bp ut ii lo t n- si )n : i n t e l l i g e n t c
interface as well as output ports of RS-232, RS-485, and dry contacts, there are
several options are hence available such as remote contr
software for PC monitoring, auto dialing module, battery monitoring module, 3
phases SNMP card, and emergent power off (EPO) switch. Please refer
chapter 7 of options for details.

7
1.3. Rectifier

The main function of a rectifier is to convert the AC input to DC power, and supply it
t o t he i nvert e r. The i nvert er t hen conver t s t he D C power t o AC pow er f or t he l
The UPS use the DC power to charge the batteries as well, which is the most efficient
method of charging.

RECTIFIER
AC DC
BREAKER INDUCTOR
INPUT OUTPUT

SCR
CAPACITOR

6-PULSE FULL CONTROL RECTIFIER

U P S s i n t h e s i z e s 1 01 K 00 VKAV At o u s e 6 - p u l s e f u l l y c o n t r o l l e d r
( o p t i o n a l 1 2 - p u l. sA
e )n i n d u c t o r i s a d d e d b e f o r e t h e r e c t i f i e r t o i m p r o v e t h e p o
factor, smooth the current waveform and eliminate the harmonic current. The control
circuit regulates the DC bus within 1%. Soft walk-in circuitry (approximately 20sec.)
and current limit circuitry is used to prevent over current or ins
current.

Extra under-voltage and over-voltage protections are added to improve reliability and
to shutdown the rectifier in case of abnormal conditions. The DC bus is adjustable to
fit different types of batteries. The power component used in the rectifier is specially
selected to handle extreme high voltage and high current. The rectifier is designed to
operate under a wide range of AC input, from 177 to 300VAC, to operate under th
poor power conditions found in some areas.

8
 PHASE SHIFT
TRANSFORMER

DC
RECTIFIER SCR OUTPUT
AC
BREAKER INDUCTOR
INPUT

CAPACITOR

SCR

12-PULSE FULL CONTROL RECTIFIER

In order to further improve the power factor and reduce harmonic current drawn
the rectifier, UPS at 120KVA and above, use the 12-pulse full controlled rectifier. The
t o t a l c u r r e n t h a r m o n i c c u r r e n t c a n b e r e d 5% u c e, da nt do pa roowuenrd f 1a c t o r
improved to over 0.8. A phase shift transformer is added to achieve this performance.
The input inductor is retained also to obtain the best result. Although this result
higher cost, the unit is much more reliable and rugged. Users do not need to increase
t h e i n p u t b r e a k e r a n d c a b l e s i z e s , s i n c e i n p u t K VA a n d h a r m o n i c c u r r e n t
minimized, fulfilling the worldwide energy saving requirements.

The harmonic current can be further lowered by adding harmonic

installation available). The total harmonic current can be reduced to appro
9%.

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1.4. Inverter

DC+

AC

AC

DC-

IGBT INVERTER

The inverter is composed of IGBT, inductor, capacitor, snubber, control circuitry and
p r o t e c t i o n c i r c u i t r y. T h e i n v e r t e r c o n v e r t s t h e D C p o w e r f r o m t h e D
power to supply the output load. The UPS uses IGBT technology which switches a
frequencies beyond the audible range, therefore producing no audible noise.

The UPS uses voltage regulation circuitry to limit the voltage variation with
Special compensation circuitry is added to eliminate the output
component is oversized to accept the wide DC input range (from 285 to 420VDC), so
t h a t t h e o u t p u t w a v e f o r m r e m a i n s s i n u s o i d a l t h r o u g h o u t t h e r a n g e . Wi t h t h
dynamic feedback loop the inverter will keep a sine waveform even under non-linear
load.

An independent inverter is used for each phase. Although it is more expensive, each
inverter has its independent feedback, so that the voltage is unaffected when load
added to the adjacent phase, producing excellent voltage regu
unbalanced load.

The IGBT is operated in its optimal condition to obtain best effic

minimize the power cost of the user.

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U s u a l l y, t h e m o s t f r e q u e n t f a i l u r e s o f t h e U P S o c c u r a t t h e i n v e r t e r. T h e r e f
have added redundant protection circuitry to protect the inverter. A strong snubber is
added to suppress the spikes and noise, oversized, high quality components are used
throughout, semi-conductor fuses are provided, and ventilation is ma
result of this design is a more rugged, reliable and high efficient inverter. At the same
time, the inverter can sustain overload and high peak current draw
Additionally, a longer MTBF is achieved.

1.5. Static Switch

RESERVE RESERVE
TO LOAD

TO LOAD
FILTER

FILTER
INVERTER INVERTER

RESERVE MODE INVERTER MODE

The static switch is composed of two pairs of SCRs, connected back-to-b

switch can transfer the load from reserve to inverter or from in
without losing power at the output. Therefore, it is a very important portion of a UPS.

Detection circuitry is added to the control circuit to achieve zero dead time transfer
Extra detection logic is employed to control when the static switch should tra
For example, when output is short circuited, under normal mode operation, the UPS
d e t e c t s t h e s h o r t c i r c u i t a n d s t o p s t h e i n v e r t e r. T h e s t a t i c s w i t c h w i
power to the reserve circuit, which might damage the reserve breaker. In case of
overload, the UPS will stop the inverter after a period the inverter can endur
then transfer the load to the reserve circuit, since the overload capability of the static
switch is higher than the inverter.

The transfer action is determined according to the reserve-input voltage and frequency
to protect supplying incorrect power to the load. Finally, there is a double check
the CPU as to whether the transfer is successful or not.

11
1.6. Maintenance Bypass Switch

Unlike other UPS, the maintenance bypass switch is already installed inside the UPS
for convenience. It should be open under normal operation, and only closed d
maintenance. For the sake of safety of maintenance personnel, all po
inside the UPS should be disconnected before touching any parts insi
Thus, the maintenance bypass switch is a necessity to maintain AC
output and yet keep maintenance personnel safe at the same tim
breaker is closed under normal operation, the inverter will stop and the load will b
automatically transferred to reserve to prevent the inverter connecting directly to the
AC source. Of course, you cannot switch on the inverter as long as the maintenance
bypass breaker is closed.

To p r o p e r l y u s e t h e m a i n t e n a n c e b y p a s s b r e a k e r , s w i t c h o f f t h e i n v e r t e
static switch will automatically transfer the load to reserve without dead time. Th
one can close the maintenance bypass breaker, then open the reserve breaker, so that
the load gets power from the output without interruption.

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1.7. Dimension & Drawings

10KVA - 60KVA
OUTLINE DRAWING

13
 10KVA - 60KVA
INTERIOR DRAWING

14
 80KVA - 160KVA
OUTLINE DRAWING

15
 80KVA - 160KVA
INTERIOR DRAWING

16
 200KVA - 320KVA
OUTLINE DRAWING

17
INTER-PCB DIAGRAM

18
19
1.8. Front Panel

20
T h e f r o n t p a n e l i s l o c a t e d a t t h e f r o n t o f t h e P C B h o l d e r. I t g a t h e r s t h
information of the UPS and shows them clearly to the user. It also provides switches
for cont r ol li ng a nd set t i ng t he UPS. T hrough t hi s panel , t he UPS can be not on
stand alone machine supplying the load, but also closely monitored by the user. Each
part of the panel is explained below.

A : L C D d i s p l aRye:a l t i m e s t a t u s , d a t a o r h i s t o r i c a l e v e n t s a r e d i s p l a y
L C D. T he U P S p ar a m et er s , r e a l t i m e c l o ck , i n ve r t e r, an d bu zz e r a l s o c a n be
through this LCD. The LCD is back-lighted by LEDs to provide a sharp display. In
o r d e r t o l e n g t h e n t h e L E D ’s l i f e t i m e , t h e L E D a r e a u t o m a t
minutes after no key is activated, but will light up aga
up/down/enter key is pushed.

B: Status LEDs: 24 LEDs, representing all of the important information of the UPS,
p r o v i d e t h e m o s t u p t o d a t e i n f o r m a t i o n t o t h e u s e r. T h e r e f o r e t h e s e
espe ci al l y i m port ant when a bnorm al condi t i ons occur. T he 24 i nfor m at i on i
are as shown below:

INVERTER ON – inverter is running.

INVERTER SS – inverter static switch conducts while the reserve static switch
is opened.
SHORT CIRCUIT – UPS output is in short circuit state.
FUSE/OVER TEMP SD – inverter shutdown due to either fuse broken or over
temperature condition.
INVERTER FAIL SHUTDOWNinverter – shutdown due to inverter output
voltage too low.
BYPASS ON SHUTDOWN –inverter shutdown due to bypass breaker being
closed while the inverter is running.
H I G H D C S H U T D O Wi N n v –e r t e r s h u t d o w n d u e t o o v e r l y h i g h D C
voltage condition while the inverter is running.
O V E R L O A D S H U T D Oi nWv N e r –t e r s h u t d o w n d u e t o o v e r l o a
inverter for a period over that which the inverter can endure; will restart 7
seconds after overload removed.
7 0 % L O A D l–o a d c o n n e c t e d t o t h e o u t p u t i s a t o r o v e r 7 0 % o f t h
rating.

21
 110% LOAD – load connected to the output is over 110% of the UPS rating.
125% LOAD – load connected to the output is over 125% of the UPS rating.
150% LOAD – load connected to the output is over 150% of the UPS rating.
RESERVE AC FAIL – reserve AC magnitude is out of range.
RESERVE FREQ FAIL – reserve frequency is out of range.
B AT T E RY L O W D – C bus (or battery) is lower than 320VDC, low batter
shutdown is approaching.
B AT T E RY L O W S H U T D O i nW
v eNr t –e r s h u t d o w n d u e t o D C b
battery) lower than 295VDC (lower than the acceptable DC voltage of the
inverter).
RECT AC FAIL – rectifier AC magnitude is out of range.
ROTATION ERROR – rectifier AC phase rotation is incorrect.
RECTIFIER SHUTDOWN – rectifier shutdown due to DC bus too high (over
445VDC), will automatically restart 30 seconds after abnormal s
has been cleared.
HIGH DC –DC voltage over 430VDC and the bus voltage will be limited at
this voltage.
BOOST CHARGE – the batteries are being boost charged by the rectifier.
BATTERY TEST – batteries are being tested.
E M E R G E N C Y S T Oi nPv –e r t e r s h u t d o w n d u e t o e m e r g e n c y s t o
pushed.
D A T A L I N Eb l –i n k s w h e n d a t a i s t r a n s m i t t e d t o o r r e c e
communication port.

C: Warning LEDs: When abnormal condition happens, these LEDs will light to warn
the user according to the cause of the faulty condition. Therefore all these LED
should be extinguished under normal condition. These LEDs are as shown below:
RECT AC FAIL –rectifier AC input is abnormal either due to AC magnitude
out of the range or phase rotation error, rectifier shutdown.
RESERVE FAIL –reserve AC input is abnormal either due to AC magnitude
out of range or frequency out of range.
FUSE/TEMP –Inverter fuse is blown or over temperature condition exists.
OVERLOAD – output is overloaded by over 110%, 125% or 150%.

22
 HIGH DC – the LED will light as long as the DC voltage is over 430VDC.
B A T L O W t–h e L E D w i l l l i g h t a s l o n g a s t h e D C v o l t a g e i s l o
320VDC.
BAT LOW STOP – the LED will light as long as the DC voltage is lower than
295VDC, inverter cannot start.
F A U L T t –h e i n v e r t e r i s s h u t d o w n d u e t o a b n o r m a l c
overload, short circuit, high DC, fuse over temperature, bypass breaker on
or emergency stop.
Since these LEDs are located behind the transparent window, the user can see
them clearly without opening the door.

D: Audible (buzzer) alarm: The user should not be expected to watch the UPS all the
t i m e . T h e r e f o r e , w h e n a b n o r m a l c o n d i t i o n s o c c u r, a n a u d i b l e s o u n d
emitted to warn the user to check the status of the UPS. The alarm buzzer will beep
under any one of the following conditions:

INVERTER IS OVERLOADED-
>110%, beep once / 3 seconds
>125%, beep once / second
>150%, beep twice / second
BACK- UP
>320VDC, beep once / 3 seconds
<320VDC, beep twice / second
<295VDC, no beeping
INVERTER IS SHORT CIRCUITED - beep continuously
FUSE BROKEN - beep continuously
HEAT SINK OVER TEMPERATURE - beep continuously
HIGH DC SHUTDOWN - beep continuously
BYPASS ON STOP - beep continuously
EMERGENCY STOP – (emergency power off) beep continuously
The buzzer will also beep once every time the inverter is switched on or off to
acknowledge to the user that his key is valid and accepted.

23
E. Bypass LED: This LED will light when the maintenance bypass breaker is closed.
When the maintenance bypass breaker is closed, the inverter cannot be switched on
and will stop immediately even when inverter is already running.

F. Reserve LED: This LED will light when the reserve breaker is closed, and there is
AC power supply present at the reserve terminal.

G . R e c t i f i e r LT
E hDi :s L E D w i l l l i g h t w h e n t h e r e c t i f i e r i s o p e r a t i n g
meaning the rectifier Mains are within the range specified, the rotation sequence
of three phases is correct, the rectifier breaker is closed, and no high DC voltage is
on the bus.

H. Back-up LED: This LED will light when the UPS is in back-up mode. This is also
as the indicator for battery test result. If the battery test does not pass, this LE
will flash even if the UPS is not in back-up mode, to prompt the user to change the
batteries.

I. Inverter LED T :h i s L E D w i l l l i g h t w h e n t h e i n v e r t e r i s s w i t c h e d o n , i n d i c a
whether the inverter is running or not.

J . I n v e r t e r STS h iLs E L D E: D w i l l l i g h t w h e n t h e i n v e
is turned on and the reserve static switch is turned off, i.e., the load is supplied from
the inverter. Usual ly t his LED will l ight 7 seconds aft er the invert er is swi tc
on.

K. Reserve SS LED: This LED will light when the reserve static switch is turned on
and the inverter static switch is turned off, i.e., the load is sup
reserve. Since the reserve static switch and inverter static switch will never bo
t u r n o n s i m u l t a n e o u s l y, t h e I n v e r t e r S S L E D a n d t h e R e s e r v e S S L
never both be lit simultaneously.

L. Output LED:This LED will light when there is AC power present at the output
terminal. This is an important indication to the user at to whether AC is available
at the output or not.

24
M. Up key:This is a LCD control key. It is for moving the cursor one item upward
when items are being selected or for changing the number/character forward when
data or parameter of the UPS is being set.

N . D o w n k eTy h: i s i s a L C D c o n t r o l k e y . I t i s f o r m o v i n g t h e c u r s o
downward when items are being selected or for changing the number/ char
backward when data or parameter of the UPS is being set.

O. Enter key: This is a LCD control key. It is for changing backward to the previous
page, and also for confirming the number/character /item is selected.

P. I n v e r t e r o n s w i t cThh:i s i s a n i n v e r t e r c o n t r o l s w i t c h . W h e n t h i s k e y i s p u s h e
with the control key simultaneously, the inverter will be switched on.

Q. Inverter control sw T hi tics hi:s a n i n v e r t e r c o n t r o l s w i t c h . W h e n t h i s

pushed with the inverter on key simultaneously, the inverter will be switched on.
S i m i l a r l y, w h e n t h i s k e y i s p u s h e d w i t h t h e i n v e r t e r o ff k e y s i m u l t a n e o u s
inverter will be switched off. Thus, this key is a guard for mistaken key strokes.

R. Inverter off switch: This is an inverter control switch. When this key is pushed
with the control key simultaneously, the inverter will be switched off.

25