Borri Ups b9000 Ups Service Manual - Compress

UPS SERVICE MANUAL
B9000 200-250-300kVA
200-250-300kVA
JUD409399

WARNING: This is a Class A-UPS Product. In a domestic environment,

thi s produ ct may cause radio int erference,
in w hich case, the user may be required to t ake addition al mea
measures.
sures.

UPS SERVIC
SERVICE
E MANUA
MANUALL
Index of section s Code
1 – TECHNICAL SPECIFICATION JUD408572

2 – OPERATIN
OPERATING
G MANUAL JUD408826
JUD408826
3 – ELECTRICAL DRAWING JUD307466
JUD307466
4 – UPS OPERATING DESCRIPTION JUD409400
5 – TROUBL
TROUBLESHOOTING
ESHOOTING AND MAINTENA
MAINTENANCE
NCE JUD409401
6 – “ UPST
UPSTEST”
EST” SOFTW
SOFTWARE
ARE JUD409402
JUD409402
7 – “ WRC MONIT
MONITOR”
OR” SOFT
SOFTWARE
WARE JUD409403
JUD409403
8 – PARAL LEL – OPER

OPERATING
ATING MANUAL JUD40940
JUD409404
4
9 – PARAL LEL – MAINTENANCE AND TROUBLESHOOT
TROUBLESHOOTING
ING JUD40940
JUD409405
5
Issued 13/04/07 JUD409399 3 of 3

TECHNICAL DATA SHEET

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

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

2. Rectifier and battery charger
3. Standard external battery
4. Inverter
5. Emergency line (by-pass)
6. Inverter (SSI) and by-pass (SSB) static switch
DESCRIPTION:
The UPS is designed following the criteria of low environmental impact.

The quantity of the raw material used on the magnetic components and the

number of semiconductors is minimized by the means of very advanced design

criteria.
The high overall efficiency minimizes the power consumption.

The expected battery lifetime is maximized by the very advanced digital battery

charger.

The UPS is
indicating equipped
the problems byand
a built in very
v ery advanced
suggesting self diagnostic
to the service people how program
to repair the
faults.
 The inverter transformer prevents the direct feed-through of the battery potential
into the critical load and allows a very high rejection ratio of the power supply
disturbances (spikes, surges etc.).
 The high input power factor and the low harmonic level of the input current allows
to reduce the dimensioning of the installation in terms of size of the cables and the
circuit breakers.
 The high efficiency and input power factor reduces the costs during the normal
operation of the UPS.
Rev.A JSD409388 JUD408572 2 of 7

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

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

BATTERY
POWER - kVA 200 250 300

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

INVERTER
POWER - kVA 200 250 300

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

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

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

ALARMS,CONTROLS
ALARMS,CONTROLS AND SIG
SIGNALS
NALS
LOCAL ON THE “ SYS
SYSTEM
TEM CON
CONTRO
TROLL PANEL” :
- Synoptic diagram showing : power flow, circuit breaker status and alarms
- Battery test indicator
- LCD display
- Keyboard
REMO
RE MOTE
TE OONN PC ((by
by t he means of a special t est so ftw are)
are)::
- All the local indications alarms and measures
- Battery test functions
- Basic troubleshooting
FREE CONTACTS (by the means of an additional card):

- Four signals are available on free contacts.
REMOTE
REM OTE PANEL (by the means o f an RS48
RS485 5 conn ecti
ection):
on):
- Synoptic diagram showing : power flow, circuit breaker status and alarms
- Battery test indicator
- LCD display
- Keyboard
REMOTE ON LAN (by additional box):

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

UPS OPERATING MANUAL
B9000 200-250-300kVA

UPS OPERATING MANUAL
Index of sections Code
1 – UPS GENERAL DESCRIPTION AND INSTALLATION JUD408827

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

3-3

Ups general description & installation
UPS GENERAL DESCRIPTION AND INSTALLATION
Index
1. INTRODUCTION......
INTRODUCTION....................
............................
...........................
...........................
................................... 3
.....................
2. GENERAL UPS DESCRIPTION...........
DESCRIPTION.........................
...........................
................................. 3
....................
2.1 TYPOL
TYPOLOGY
OGY ...........
.......................
.......................
.......................
.......................
.......................
.......................
.................................3
......................3
2.2 DESCRIPTION OF THE SYSTEM ............
.........................
.........................
.........................
.........................
.................. 4
......4
2.2.1 Rectifier.....................................................................................................4
2.2.2 Inverter......................................................................................................4
2.2.3 Batter
Battery
y and char
charger
ger ...........
......................
......................
.......................
.......................
......................
.........................4
..............4
2.2.4 Static bypa
bypass
ss ..........
......................
.......................
.......................
.......................
.......................
.......................
........................4
.............4
2.2.5 Manuall bypa
Manua bypass
ss ..........
.....................
.......................
.......................
......................
......................
..................................4
.......................4
2.2.6 Front Panel ...........
......................
.......................
.......................
......................
......................
.......................
............................5
................5
2.3 OPERATING STATUS......................................................................................6
2.3.1 Normal Operation.....................................................................................6
2.3.2 Load supplied
supplied by bypass du
due
e to inve
inverter
rter fault
fault............
.......................... ............ 6
..........................
2.3.3 Rectifier
Rectifier failur
failure
e or mains failure ...........
......................
......................
.......................
............................7
................7
2.3.4 Manuall bypa
Manua bypass
ss ..........
.....................
.......................
.......................
......................
......................
..................................7
.......................7
3. INSTALLATION ............................
INSTALLATION.............. ............................
............................
......................................... 8
...........................
3.1 RECEIPT
RECEIPT OF UPS ...........
.......................
.......................
.......................
.......................
.......................
.......................
.......................8
............8
3.2 HANDLING OF THE UPS.................................................................................8
3.3 POSITIONING AND INSTALLATION.
INSTALLATION..............
..........................
..........................
.........................
....................... 9
...........9
3.3.1 Base plan, static load and weights
weights.............
..........................
.........................
.........................
................... 9
......9
3.3.2 Dimensions and distances....................................................................10
3.4 ELEC
ELECTRICA
TRICAL
L CONNE
CONNECTION
CTION ...........
......................
.......................
.......................
.......................
...........................11
...............11
3.4.1 Terminal Board.
Board..............
.........................
.........................
.........................
.........................
.......................... .......... 11
.......................
3.5 BATTERY POSITIONING AND CONNECTION ...........
........................
.........................
..................... 12
.........12
3.5.1 Connection
Connections
s ...........
.......................
.......................
.......................
.......................
.......................
..................................12
......................12
JUD408827 02/10/06 Rev. A

(JSD408936 Rev. A 02/10/06)
1 - 12

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

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

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

2.2 DESCRIPTION OF THE SYSTEM
2.2.1 Rectifier
It converts the three phase voltage of the mains into continuous DC voltage.
The UPS has got a total-controlled IGBT three-phase bridge to reach a low harmonic
distortion.
This configuration is used in order to reduce the distortion of the mains’ absorbed
power (THD) to a value inferior to 5%. This guarantees, wwith
ith respect to other loa
loads,
ds, that
the rectifier does not distort the mains voltage and avoids the overheating of the cable
due to the circulation of the harmonic currents.
The rectifier is designed to supply the inverter at full load and the battery at the
maximum recharge current.
2.2.2 Inverter
Required to convert the continuous voltag voltage
e coming from the rectifier or from the
battery, into alternating voltage, stabilized in amplitude and frequency.
The inverter uses IGBT technology with a frequency commutation of approximately
10 KHz.
The control electronics is completely digital output

and uses µP, that, thanks to its
a 16 Bit which
processing capability, generates an excellent sine-wave, has a very low
distortion even in presence of loads having high crest factor currents.
2.2.3 Battery and charger

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

It’s designed to transfer the load between INVERTER and MAINS, and vice-versa,
without break, and uses SCR’s as power commutation elements.
2.2.5 Manual bypass
It‘s used to by-pass the UPS, supplying the load directly to the mains in case of
maintenance or serious failure.
WARNING
The sequence of bypass switching must be carried out with respect to the procedure
in the UPS Operating Manual in the chapter “Start-up, shu
shut-down
t-down and manua
manuall bypass”.
The manufacturer cannot accept responsibility for damages arising from incorrect
operation.
4 JUD408827 02/10/06 Rev. A

2.2.6 Front Panel

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

2.3 OPERATING STATUS

The following paragraphs show all the possible operating status of the UPS.
2.3.1 Normal Operation
The inverter
directly is supplied
by the inverter by the rectifier; the load, through the static switch, is supplied
output.
Picture 2 – Normal operation
2.3.2 Load su
supplied
pplied by bypass d
due
ue to inverter fault
The load is transferred to bypass through the static switch; the transfer is carried out
without interruption.
Picture 3 – Load supplied by bypass
6 JUD408827 02/10/06 Rev. A

2.3.3 Rectifier failure or mains failure

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

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

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

3.3 POSITIONING AND INSTALLATION

The UPS must be installed in a clean and dry room, preferably not dusty. The User
must ensure that there is enough air exchange in the room so that the equipment can
be adequately cooled;
cooled; if this is not guaranteed, the room must be adequately
adequately aired.
3.3.1 Base plan, s

static
tatic load and weights
Picture 7 – Base plan
UPS 200 250 300

(kVA) 3F
L1 – mm 1175
P1 – mm 800
L2 – mm 115
UPS 3Ph (kVA) 200 250 300
Weig
Weight
ht with
withou
outt batt
batter
ery
y – kg 870
870 1020
1020 1200
1200
Weight with battery – kg - - -
Static load – kg/m2 925 1085 1277
JUD408827 02/10/06 Rev. A 9

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

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

3.4 ELECTRICAL CONNECTION

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

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

3.5 BATTERY POSITIONING AND CONNECTION

IMPORTANT
For battery installation please respect the prescriptions
pr escriptions of the EN50091-1 / EN62040-
1 standard, paragraph 4.5.
To obtain the battery life indicated by the battery manufacturer, the operating
temperature must remain between 0 and 2 25
5 °C. However, although the battery can
operate up to 40 °C , there will be a significant reduction of the battery life.
To avoid the formation of any kind of potentially explosive hydrogen and oxygen
mixture, suitable ventilation must be provided where the battery are installed (see
EN50091-1 / EN62040-1 annex N).
The batteries are external for all the series, however, it is recommended to install
them when the UPS is capable of charging them. Please remember that, if the battery is
not charged for periods over 2-3 months they can be subject to irreparable damage.
3.5.1 Connections
The following picture shows the electrical connection between the UPS and the
external battery cabinet.
Picture 11 – Battery cabinet link
The connection cables are two power cables, with section that varies according to
the UPS size (see table at page 11) and with length ranging from 2 to 50 meters.
Longer cables are subject to excessive voltage drop, so their section must be
increased accordingly.
12 JUD408827 02/10/06 Rev. A

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

1 - 18

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

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

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

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

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

Red light = Rectifier output voltage out of tolerance.
LED 4
4 ⇒ Lit-up green = Battery OK.
Green flashing = Battery discharging
discharging or battery in test.
Orange flashing = BCB open.
Lit-up red = Battery test aborted.
LED 5 ⇒ Lit-up green = Inverter static switch closed.

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

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

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

Front panel
2.2 ALARMS AND OPERATING STATUS

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

2) Distribution prob
problems
lems ups
upstream
tream of the UPS
3) RCB open
A2 CHARGER FAULT = Battery charger failure
A3 RECT FUSE = One o

orr more rectifier fuses are blo
blown
wn
A4 THER IMAGE = Load transferred to mains due to overload. After 30’

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

problems
lems ups
upstream
tream of the UPS
3) RCB open
4) Rectifier bridge failure
A6 INPUT WR SEQ = Input phase rotation not correct
A7 BCB OPEN = Battery circuit breaker open
A8 BATT DISCH = The battery is discharging
Possible causes: 1) Rectifier in

input
put ma
mains
ins failure (alarm A1 present)
2) Rectifier failure
A9 BATT AUT END = Battery autonomy (calculated) has expired
A10 BATT FAULT = Battery test failed
Possible causes: 1) The test has been carried out with the battery not
perfectly charged
2) One or more battery cells are damaged
A11 BATT IN TEST = Battery test in progress
A12 PLL FAULT = Problems with the digital synchronisation system
JUD408828 18/07/06 Issued 5

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

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

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

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

problems
lems ups
upstream
tream of the UPS
3) SBCB open
4) Wrong input phase rotation
A16 BYP FEED LOAD = Load fed by bypass
Possible causes: 1) Inverter overload

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

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

A18 MBYP CLOSE = Manual bypass breaker closed (the inverter is
shutdown)
A19 OCB OPEN = UPS output breaker open
A20 FANS FAILURE = Optional
A21 HIGH TEMP = High temperature on the inverter and/or rectifier

bridge
Possible causes: 1) Excessive load

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

Front panel
A22 BYP SWITCH = Closure of the commutation swswitch

itch which force
forces
s the
load to bypass (maintenance)
A23 EPO BUS = Intervention of the emerge
emergency
ncy shut down switch in
accordance to EN50091-1
A24 CURR STOP = Inverter bridge stop for ma

max
x current
Possible causes: 1) Repeated short circuits at the UPS o
output
utput
2) Inverter bridge malfunctioning
It is possible to reset this state using a button on the µP card.
A25 SHORT CIRCUIT = Short-circuit protection intervention (current

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

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

Front panel
3. LCD DISPLAY MANAGEMENT

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

The screens of the main menu appears as follows: Pressing a key the main menu,
with all the functions and parameters, is accessed
<NAME> xxx KVA SPECIAL MENU. To access

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

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

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

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

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

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

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

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

BATTERY pr
pres
ess
s tth
he ke
keyy ((se
see
e 3
3.3
.3.5
.5);
); to
the or key.
<NAME> xxx KVA By pressing

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

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

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

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

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

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


10 JUD408828 18/07/06 Issued

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


3.3.4 AC/DC
This menu is active only when the battery is no
nott discharging. If the battery is in
discharge mode, the BATTERY menu is automatically shown.
AC/DC VOLTAGE Pressing the key the following

XXX Vdc parameter is shown, while the key
<NAME> xxx KVA Pressing the key

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

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

Front panel
BATTERY CURRENT This measure is active only when

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

XXX parameter is shown, while the key

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

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

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

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

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

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

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

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

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


RET TO EXIT HISTORY

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

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

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

Front panel
3.4.3 List of alarms and status
List of alarms List of status

status
A1 MAINS FAULT S1 AC/DC OK

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

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

A16 BYP FEED LO
A17 RETR BLOCK
A18 MBYP CLOSE

A19 OCB OPEN
A20 FANS FAILURE (OPTION)
A21 HIGH TEMP
A22 BYP SWITCH
A23 EPO BUS
A24 CURR STOP
A25 SHORT CIRC
The status shown in this list are always displaye

displayed
d in asc
ascending
ending order when the
STATUS menu is entered, the alarms are shown when they are present and must be
STATUS
silenced with the buzzer. The alarms remain displayed whilst they are present and they
are automatically stored in the event history memory with date and time.
.
JUD408828 18/07/06 Issued 15

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

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

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

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

UPS TEST key (see 3.5.3); to scroll the
sub-menus press the or key.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.1 START-UP TROUBLESHOOTING

This paragraph provides the basic information if any alarms occur during the start-up
procedure. In case the problem cannot be solved contact the service department.
1) After having closed the RCB the LC
LCD
D display is still blank
•
Check the input phase rotation.
• Check the rectifier protection fuses; these are installed inside the UPS.
2) After Step #2 the UPS does not go on to Step #3 and display
displays
s the alarm A1 –
Network failure
• Make sure alarm A2A2 is functioning. Check the input p
phase
hase rotation.
• Check the rectifier protection fuses
f uses F1-F2-F3.
3) After Step #3 the UPS d
displays
isplays alarm messages
• Open RCB and check the connections.
connections.
• Close RCB and try to restart the UPS.
UPS.
4) After Step #4 the UPS d
displays
isplays alarm messages
• Check that the EPO button,
button, if provided on the outside of
of the UPS, is in the
release position
• Open RCB and control the connec
connections.
tions.
• Close RCB and try restarting the UPS.
5) After Step #5 the display does not go to Step #6 and displays
displays the alarm A15 –
BYP NOT AVLB
• Check the protection fuses of the Bypass static switch; they are installed
inside the UPS.
UPS.
• Control the phase rotation voltage.
• Check that the voltage and frequency are within the tolerance limits.
6) After Step #7 the display does not go on to Step #8 and the alarm A7 – BCB
OPEN is displayed.
displayed.
7) Check the battery fuses.
• Control the inter-connection between the auxiliary contact of the battery
switch (in the external cabinet) and the clamps Bac1-Bac2 of the UPS.
4 JUD408829 18/07/06 Issued

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

1 Open OCB A19 OCB OPEN The supply to the lo
load
ad is interrupted.
interrupted. LED #7
lit orange
2 Open BCB A7 BCB OPEN The battery is disconnected
disconnected from the
rectifier. LED #4 flashing red light.
3 Open SBCB A7 BCB OPEN The bypass line iis
s disconnected.
disconnected. LED #2 off.
4 Open RCB A1 NETWORK Booster and Inverter are switched off.
FAILURE
5 OFF End of shut down procedure.
4. MANUAL BYPASS PROCEDURE
WARNING
WARNING
During manual bypass operation the load is supplied directly by the mains, therefore
continuous supply is not guaranteed.
Nr. ACTION LCD DISPLAY UPS OPERATION

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

5. START-UP FROM MANUAL BYPASS

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

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

UPS
UPS Functioning De
Descripti
scripti on
UPS FUNCTIONING DESCRIPTION
Index
1 INTRODUCTI
INTRODUCTION.........
ON.......................
...........................
..........................
...........................
................................. 5
...................
1.1 OPERATING
OPERATING STATUS..........
STATUS......................
.......................
......................
......................
.......................
...............................5
...................5
2 RECTIFIER
RECTIFIER .............
..........................
..........................
...........................
...........................
..................................... 7
........................
3 INVERTER
INVERTER.............
...........................
............................
...........................
...........................
............................
.......................
......... 8
4 STATIC SWITCH..............
SWITCH ...........................
...........................
...........................
........................................ 9
...........................
5 RECTIFIER
RECTIFIER PCB’
PCB’SS .............
..........................
...........................
...........................
...........................
.......................
......... 10
5.1 INT-R...............................................................................................................10
5.1.1 Description of operation........................................................................10
5.2 RTF ...........
......................
......................
......................
.......................
.......................
......................
.......................
.......................
.......................15
............15
5.3 ID-HY (RECT
(RECTIFIER
IFIER IGBT DRIVE
DRIVER)
R) ...........
......................
......................
......................
...............................15
....................15
5.3.2 Programm
Prog ramm ing
in g inst
in stru
ructi
cti ons ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........16
....16
5.4 D-CPU-RC (RECTIFIER MICROPROCESSOR CONTROL)..........................17
5.4.1.1 Introduction
Introduction ............
.......................
......................
......................
.......................
.......................
..............................17
...................17
5.4.1.2 Digital power supply..........................................................................17
5.4.1.3 RAM, FLASH and EEPROM ............ .........................
..........................
.......................... .......... 17
.......................
5.4.1.4 Rectifier
Rectifier bridg
bridge e prote
protection
ction ..........
.....................
......................
......................
.................................17
......................17
5.4.1.5 Analog inputs .............
..........................
..........................
.........................
.........................
..........................
.................... 18
.......18
5.4.1.6 Control LEDs.....................................................................................18
6 INVERTER
INVERTER PCB’
PCB’SS .............
..........................
...........................
...........................
...........................
........................
.......... 19
6.1 DR-HY (INVERTER
(INVERTER IGBT DRIVE
DRIVER)
R) ..........
.....................
......................
......................
...............................19
....................19
6.1.2 Programm
Prog ramm ing
in g inst
in stru
ructi
cti ons ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............21
........21
6.2 INV-AV-3F..................
INV-AV-3F.............................
.......................
.......................
......................
......................
.......................
.............................21
.................21
6.3 PS-MIS.........................
PS-MIS....................................
......................
......................
.......................
.......................
......................
...........................21
................21
6.4 PWM-SAT
PWM-SAT ..........
......................
.......................
......................
.......................
.......................
......................
......................
.........................22
..............22
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7 STATIC SWITCH PCB

PCB’S
’S.............
..........................
..........................
..........................
..........................
................
... 23
7.1 VOLT-REF-3F
VOLT-REF-3F ...........
......................
......................
.......................
.......................
......................
.......................
............................. 23
.................
7.1.1 Descri pt
ption
ion of oper
operatio
atio n ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........... 23
.......
7.2 2SCR-FIR
2SCR-FIR..........
.....................
......................
.......................
.......................
......................
.......................
.......................
......................... 23
..............
7.2.1 Descri pt
ption
ion of oper
operatio
atio n ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........... 23
.......
8 COMMON
COMMON PCB’
PCB’SS ..............
...........................
...........................
............................
............................
........................
..........24
24
8.1 PS-SAT ...........
......................
.......................
.......................
......................
......................
.......................
.......................
........................... 24
................
8.1.1 Descri pt
ption
ion of oper
operatio
atio n ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........... 24
.......
8.1.2 Programm
Prog rammin
ingg inst
in stru
ructi
cti ons ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............ 25
........
8.2 I/S-CL (MICROPROCES
(MICROPROCESSOR
SOR CONTR
CONTROL
OL LOGIC) ..........
.....................
.............................. 26
...................
8.2.1 Descri pt
ption
ion of oper
operatio
atio n ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........... 26
.......
Introduction ..........
.....................
......................
......................
......................
......................
................................ 26
.....................
8.2.1.2 Digital
Digital Input
Inputs
s ..........
.....................
.......................
.......................
......................
.......................
............................. 26
.................
8.2.1.3 Dip Switc
Switches
hes ..........
.....................
......................
......................
......................
......................
.............................. 26
...................
8.2.1.4 Fast Analog Inputs ...........
......................
......................
......................
......................
............................... 27
....................
8.2.1.5 External A/D Conv
External Convertererter ..........
.....................
.......................
.......................
......................
........................ 28
.............
8.2.1.6 Watchdog
Watc hdog and Rese
Reset....................
t...............................
......................
.......................
.............................. 28
..................
8.2.1.7 RAM, EPROMs and EEPR EEPROM OM..........
.....................
.......................
.......................
........................ 29
.............
8.2.1.8 Digital
Digital Powe
Powerr Supp
Supply ly ..........
......................
.......................
......................
......................
............................ 29
.................
8.2.1.9 RCB boar
boardd ...........
......................
......................
......................
.......................
.......................
............................... 29
....................
8.2.1.10 SCB board and Thyri Thyristor
stor drivers ...........
......................
......................
................................ 29
.....................
8.2.1.11 Current
Curre nt Limitatio
Limitation n and Max Current Stop .......... ....................
.....................
.....................
.......... 29
8.2.1.12 VCB board....
board...............
.......................
.......................
......................
......................
.......................
............................ 30
................
8.2.1.13 PWM gene
generator
rator ...........
......................
......................
.......................
.......................
......................
........................ 31
.............
8.2.2 Programm
Prog rammin
ingg inst
in stru
ructi
cti ons ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............ 33
........
8.2.3 SCB bo
board
ard ............
.......................
.......................
.......................
.......................
.......................
......................
......................... 34
..............
8.2.4 VCB bo
board
ard ............
.......................
.......................
.......................
.......................
.......................
......................
......................... 34
..............
8.3 FCI.....................
FCI................................
......................
......................
.......................
.......................
......................
......................
.......................... 35
...............
8.3.1 Descri pt
ption
ion of oper
operatio
atio n ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........... 35
.......
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Index
Index of pictur es
Picture 1 – UPS block
block diagram .................................................................................................................... 5
diagram ....................................................................................................................
Picture 2 – Normal operation........................................................................................................................ 5
Normal operation........................................................................................................................
Picture 3 – Load supplied by by-
by-pass .......................................................................................................... 6
pass ..........................................................................................................
Picture 4 – Rectifier failure
failure or mains failure.................................................................................................. 6
failure..................................................................................................
Picture 5 – Manual
Manual by-pass .......................................................................................................................... 6
by-pass ..........................................................................................................................
Picture 6 – Rectifier
Rectifier diagram
diagram ........................................................................................................................ 7
........................................................................................................................
Picture 7 – Inverter
Inverter diagram
diagram ......................................................................................................................... 8
.........................................................................................................................
Picture 8 – Static switch diagram
diagram ................................................................................................................. 9
.................................................................................................................
Picture 9 – INT-R
INT-R – 24Vdc supply
supply (thyristors) ............................................................................................ 10
(thyristors) ............................................................................................
Picture 10 – INT-R – 5Vdc supply
supply (serial interfaces) ................................................................................. 10
.................................................................................
Picture 11 – INT-R – Rectifier microproce
microprocessor
ssor supply ............................................................................... 11
...............................................................................
Picture 12 – INT-R – Mains monitoring
monitoring ...................................................................................................... 11
......................................................................................................
Picture 13 – INT-R – DC voltage feedback ................................................................................................ 11
................................................................................................
Picture 14 – INT-R – Battery current feedback
feedback (to I/S-CL for boost charge control).................................. 12
control)..................................
Picture 15 – INT-R – Digital signals
signals to D-CP
D-CPU-RC
U-RC .................................................................................... 13
....................................................................................
Picture 16 – INT-R
INT-R – Digital signals ............................................................................................ 14
signals to I/S-CL ............................................................................................
Picture 17
17 – INT-R – Relay output
output ............................................................................................................. 14
.............................................................................................................
Picture 18 – ID-HY – Power supply............................................................................................................ 15
Picture 19 – ID-HY – Input stage.............................................................................................

stage................................................................................................................
................... 15
Output stage............................................................................................................. 16
Picture 20 – ID-HY – Output
....................................................................................... 16
Picture 21 – ID-HY board (Rectifier IGBT driver) .......................................................................................
Picture 22 – D-CPU-RC – Digital p
power
ower sup
supplies ...................................................................................... 17
plies ......................................................................................
Picture 23 – D-CPU-RC – IGBT bridge protection ..................................................................................... 18
protection .....................................................................................
Picture 24 – DR-HY – Power supply
supply .......................................................................................................... 19
..........................................................................................................
Picture 25 – DR-HY – Input stage
stage .............................................................................................................. 19
..............................................................................................................
Picture 26 – DR-HY – Output stage ........................................................................................................... 20
stage ...........................................................................................................
Picture 27 – DR-HY – “Under-voltage
“Under-voltage lock-out” ......................................................................................... 20
lock-out” .........................................................................................
Picture 28 – DR-HY – De-saturation
De-saturation .......................................................................................................... 20
..........................................................................................................
Picture 29 – DR-HY board (Inverter driver)....................................................................................... 21
(Inverter IGBT driver).......................................................................................
Picture 30 – PS-MIS – Power supply .......................................................................
.........................................................................................................
.................................. 22
............................................................................................. 22
Picture 31 – PS-MIS – DC voltage feedback .............................................................................................
Picture 32 – 2SCR-FIR
2SCR-FIR electrical drawing.................................................................................................. 23
drawing..................................................................................................
Picture 33 – PS-SAT – Microprocessor .......................................................................................... 24
Microprocessor supply ..........................................................................................
Picture 34 – PS-SAT – Analog part supply
supply ................................................................................................ 24
................................................................................................
Picture 35 – PS-SAT – Relay supply............................................................................................ 25
Relay and bus supply............................................................................................
Picture 36 ........................................................................................................................ 25
36 – PS-SAT board ........................................................................................................................
Picture 37 – I/S-CL – Fast analog inputs..................................................................................................... 28
analog inputs...................................................................................................
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External A/D converter............................................................................................. 28

Picture 38 – I/S-CL – External
Digital supply............................................................................................................ 29
Picture 39 – I/S-CL – Digital
Picture 40 – I/S-CL
I/S-CL – Short circuit
circuit protection
protection ............................................................................................. 30
.............................................................................................
Picture 41 – I/S-CL – “Current
“Current stop” pro
protection .......................................................................................... 30
tection ..........................................................................................
Picture 42 – VCB – Instantaneous
Instantaneous value lo
loop
op.................................................................................... ........ 31
............................................................................................
generator........................................................................................................ 31
Picture 43 – I/S-CL – PWM generator........................................................................................................
Picture 44 – I/S-CL block diagram.............................................................................................................. 32
block diagram..............................................................................................................
Picture 45 – I/S-CL board ........................................................................................................................... 33
board ...........................................................................................................................
Picture 46 – SCB board.............................................................................................................................. 34
SCB board..............................................................................................................................
Picture 47 – VCB board.............................................................................................................................. 34
VCB board..............................................................................................................................
Picture 48 – FCI electrical
electrical drawing............................................................................................
drawing.............................................................................................................
................. 35
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UPS Functioning De
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scripti on
1 INTRODUCTION
The UPS of the B9000 product line are on-line, double conversion; the inverter supplies
always energy to the load, whether the mains is available or not (according to the battery
autonomy time).
WARNING
WARNING
The UPS output is energized even during mains failure, therefore in compliance with the
prescriptions of EN 50091-1, the installer will have to identify the line or the plugs supplied by
the UPS making the User aware of this fact.
This configuration guarantees the best service to the User, as it supplies clean continuously
regulated power and guarantees the voltage and frequency will be stabilised at nominal value
independently from mains status. Thanks to the double conversion, it makes the load
completely immune from micro-interruptions due to excessive mains variation, and prevents
damage to the critical load (Computer - Instrumentation - Scientific equipment etc.).
Picture 1 – UPS block diagram
The UPS is composed by three main sections: rectifier (R), inverter (I), static switch (SS).
These sections will be described in the following chapters.
The final chapter includes the description of the various electronic boards installed inside the
UPS as well as their block diagrams and programming instruction
instructions.
s.
1.1 OPERATING STATUS

Final task of a UPS system is to protect the load from micro-interruptions, black-outs and
various disturbances on the network, and guarantee a reliable supply also when internal faults
occur. During normal operation the rectifier keeps the batteries in floating charge and provide
energy for the inverter to supply the load through the static switch.
Picture 2 – Normal operation
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In case of an inverter failure or an overload the load is automatically transferred, without

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

The inverter is the primary supply source, so when its voltage and frequency are in tolerance
it synchronises with the by-pass line and the load is transferred again through the static switch.
In case of mains failure (or rectifier failure) the inverter draws energy from the battery for the
specified autonomy time, after which the inverter is turned off.
Picture 4 – Rectifier failure or mains failure
For maintenance operations it’s possible to supply the load through the manual by-pass
circuit breaker MBCB, connecting directly the by-pass line to the UPS output. During the manual
by-pass procedure the load remains supplied, without any interruptions.
Picture 5 – Manual by-pass
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2 RECTIFIER
The three-phase mains is connected to the input terminals 1-L1, 1-L2, 1-L3, directly under
the input switch RCB. The filter RF1 provides to reduce the radio frequency disturbances
according to the limits given by the EN50091-2 standard.
The input AC capacitors Cac1÷Cac3 limits the high-frequency harmonics generated during
the commutation of the rectifier bridge smoothing the waveform of the input voltage.
The thyristors PS7÷PS9 are used to pre-charge the DC capacitors and rectify the AC mains;
they also work as de-coupling elements and avoid that high reverse voltages are applied to the
IGBTs. The booster bridge is made by the IGBT modules PS1÷PS6. Each module contains two
components, one of which is used as a diode by short-circuiting the Gate with the Emitter. The
input high-frequency chokes are the elements that store and release energy during the bridge
commutation thus providing the DC voltage to increase (step-up or booster operation).
Whentopowering
supplies up the unit,
the microprocessor
microprocesso the electronic
r control board INT-R
board (D-CPU-RC) is as
as well supplied; it provides the
the synchronisation DC
signals
for the generation of the control pulses of the thyristors. These control signals are then
managed by the board INT-R2 (mounted directly on the INT-R) and sent to the thyristors
through the board RTF (final stage).
The voltage feedback (positive and negative, with reference to the central point of the
capacitors) is taken directly on the rectifier output, across the DC capacitors. By comparing the
voltage feedback value with a programmed set-point the microprocessor provides to regulate
the turn-on time of the IGBTs by modifying the PWM, thus maintaining the DC output voltage
within the specified range (+/-1%).
The measures of the input current across the three phases is provided by the current
transducers TA1÷TA3.
The rectifier provides the energy necessary to the inverter to work at full load and keeps the
battery in floating charge to compensate the self discharging. In case of mains failure the
inverter draws energy from the battery for the specified autonomy time. When the batteries
needs to be recharged the microprocessor board provides to limit the recharging current by
comparing an programmable threshold with the feedback signal generated by the current
transducer TA4.
Picture 6 – Rectifier diagram
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3 INVERTER
The inverter is composed by six power blocks, controlled by the IGBT driver boards
DR1÷DR6. The inverter bridge is connected to the transformer T1, which provides the galvanic
insulation between the DC bus and the AC output. The transformer is provided with a leakage
inductance that forms a low-pass filter with the output capacitors Cr-Cs-Ct; the filter provides to
eliminate the high frequency harmonics from the output waveforms in order to reduce the
distortion of the sine-waves.
The inverter supplies the load through the inverter static switch thyristors, which are
connected to the output switch OCB. The current transformers TAR-TAS-TAT provide the
signals for the output current measures.
When the inverter is started up the microprocessor control logic I/S-CL generates the IGBT’s
control signals (PWM – Pulse Width Modulation) and send them to the driver boards DR1÷DR6;
the bridge starts to modulate and the output voltage increases. The voltage feedback provided
by the INV-AV-3F board is used to control the output voltages value, according to the value set
on the three VCB boards (mounted on the I/S-CL).
The inverter current protection (Max Current Stop) and the short circuit current limitation are
also managed by the I/S-CL, using the feedback signal provided by the hall-effect current
transducer TA1, which is mounted on the inverter bridge input.
Picture 7 – Inverter diagram
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4 STATIC SWITCH
The three-phase emergency line is connected to the terminals 2-L1, 2-L2, 2-L3, 2-N.
The by-pass line is energized by closing the input switch SBCB; the fuses F4-F5-F6 protects
the static switch thyristors in case of short-circuit at the UPS output.
The static by-pass switch is controlled by the SCB board, mounted on the microprocessor
control logic I/S-CL; the control signals for the thyristors are generated by the I/S-CL and sent to
the firing board 2-SCRFIR, connected directly to the gate of the thyristors.
t hyristors.
The VOLT-REF-3F board provides the feedback signals for the by-pass and output voltage
measures.
The UPS automatically transfers the load to the by-pass line in case of an inverter failure or
overload. The manual by-pass switch MBCB connects directly the emergency line input to the
load in case of UPS maintenance.
Picture 8 – Static switch diagram
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UPS
UPS Functioning De
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5 RECT
RECTIFIER
IFIER PCB’
PCB’SS
5.1 INT-R
5.
5.1.
1.1
1 De
Descri
scri pti on of operation
The board INT-R is the interface between the power conversion section of the rectifier and
the microprocessor (board D-CPU-RC).
D-CPU-RC). It’s mainly composed by the following parts:
1) Power supply: the three-phase

three-phase AC mains
mains is connected
connected to the connector M8 and
and then,
then,
through the fuses FUSE1÷FUSE3 to the Graetz-bridge formed by the diodes D13÷D18.
The DC voltage Vbulk+/Vbulk- is the input voltage to the switching power supply, which
uses a output transformer (T5) to isolate the various power supplies.
The following table summarize all the different outputs.
Test GND
SECTION
SECTION LED Pot.
Pot .
point TP
Local auxiliary voltage 1 DL1 TP1 TP2
Local auxiliary voltage 2 TP3 TP4
+24V thyristor drivers and transformers DL2 TP6 TP5
+12V analog circuits DL3 TP12 TP5
+5V serial interface DL4 TP7 TP8
+15V rectifier CPU DL5 TP9 TP11
-15V rectifier CPU DL6 TP10 TP11
IGBT drivers power supply (PS_AC1 / PS_AC2) RV1
TP6 +24V_SSW
D4
D41
1 1N40
1N4007
07
T5 D40 U15 LM LM31

317T
7T
7 1 2 U16 LM LM78
7815
15 TP12 POS_SSW
I N OU T 1 2
D
BYV32-200 N D42 R106 I N OU T
G D
R105 4k75 N R107 X8 X13
G
255R 1N4007 C53 3k32 C55
8 C51 3 D43 10u C56
220u 10u DL2 C54 3
R104 C52 DL3 1N4007 100n
4k75 4u7 100n
9 X7
GND_SSW
TP5

Picture 9 – INT-R – 24Vdc supply (thyristors)
T5 BYV27-200 U17 TP7 +5V_SER

16 1 2
I N OU T
D
D44 N R108
G
LM7805 1k
17 D46 C59
C57 3 C58
100u DL4 1N4007 10u 100n
D45
18
BYV27-200 TP8 GND_SER

Picture 10 – INT-R – 5Vdc supply (serial interfaces)
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POS_CPU1
BYV27-200 U18 TP9
T5 D47 LM7815 X9 X12
10 1 2
I N OU T
D
D48 N R109
G
BYV27-200 3k32
D49 C62
7
11 X6 C60 3 0 C61
0
220u 4 10u 100n
X11 DL5 N
1
PS_AC2
TP11
12
R110 GND_CPU1
PS_AC1
3k32
X10 C63 D52 C65
7
13 0 C64
0
X5 220u 4 10u 100n
DL6 N
1
BYV27-200 3 U19
D50
14 1 D 2
I NN OU T
G
D51 LM7915 TP10 NEG_CPU1
BYV27-200

Picture 11 – INT-R – Rectifier microprocessor supply
2) Mains monitoring: the three-phase AC mains is connected through the connector M8 to

the transformers T1-T2-T3. The secondary voltage of the transformers is transferred to
the microprocessor through the connection CN7 INT-R  CN5 D-CPU-RC.
The microprocessor provides to control the phase sequence and the RMS values of the
three phases.
three phases.
T1
1 3 VMA_U
CN7_4
R24
2 4
511R
T2
V_MA_U 1 3 VMA_V
M8_1 CN7_5
V_MA_V
M8_3 R25
V_MA_W 2 4
M8_5
511R
T3
1 3 VMA_W
CN7_6
R26
2 4
511R
GND_CPU1

Picture 12 – INT-R – Mains monitoring
3) DC voltage feedback: the DC voltage is measured across the DC capacitors, connected in

series. It’s then converted by the voltage transducers VM2-VM3 and finally sent to the
CPU through the connection CN7 INT-R  CN5 D-CPU-RC.
POS_CPU1 POS_CPU1
NEG_CPU1
NEG_CPU1
R16 R34
+V_BOOST +HT + -V_BOOST +HT +
M7_1 M6_3
22k 3W 22k 3W
VM2 - VM3 -
R17 R33
GND_BOOST -HT M +VBOOST GN D_BOOST -HT M -VBOOST
M7_3 CN 7_9 M6_1 CN7_10
22k 3W 22k 3W
LV 25-P LV 25-P
R23 R35
287R 287R
GND_CPU1 GND_CPU1

Picture 13 – INT-R – DC voltage feedback
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4) AC current feedback: the AC input current, controlled in order to reduce the harmonics
and the input power factor, is measured by the current transducers TA1-TA2-TA3. The
feedback signal is sent to the connectors M1 (C_MA_U), M2 (C_MA_V) and M3
(C_MA_W) of the board INT-R and finally transferred to the CPU through the following
connections:
Si gn
gn a
all INT-R D-CPU-RC
C_MAINS_U CN4  CN1
C_MAINS_V CN5  CN2
C_MAINS_W CN6  CN3
5) Battery current feedback: the battery current is measured by the current transducer TA4.
The feedback signal is sent to the connector M4 (C_BAT_POS) of the board INT-R and
finally transferred to the CPU through the connection CN4 INT-R  CN1 D-CPU-RC.
The current signal is also sent to the board I/S-CL through an isolation amplifier
(connector M11) for the boost charge management.
management.
POS_CPU1
C80 100n
R19 8 U23A GND_CPU1

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

100n
1 U8 9
69k8
GND_CPU1
R21 R2
15 7 C_BAT M11_9
10k
GND_CPU1 ISO122 511R

C68
100n
NEG_CPU1 6 0 -12A
2 1 8 1 GND_A
M11_8
C67
C66 C4 C3 100n
100n 100n 220n
M11_10
GND_CPU1 GND_A

Picture 14 – INT-R – Battery current feedback (to I/S-CL for boost charge control)
6) Digital signals to D-CPU-RC:

D-CPU-RC: the digital
digital signals coming from the rectifier bridge are
acquired by the INT-R and transferred to the rectifier CPU to control the rectifier status.
I_FB  rectifier protection fuses status
I_TH_SW  thermal switch status
SW_RECT_ON  switches on and off the rectifier by external switch
The route of such signals is shown in the following table.
Signa
ignal INT-R INT-R D-CPU-RC
I_FB  M9-1/2 CN5-19/20  CN2-19/20
I_TH_SW  M15-1/2 CN11-1/4  CN11-1/4
SW_RECT_ON  M10-1/2 CN4-19/20  CN1-19/20
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7) Interface I/S-CL  D-CPU-RC: the INT-R works as interface for the digital signals
exchanged between the rectifier CPU (D-CPU-RC) and the inverter CPU (I/S-CL). The
I/S-CL is interfaced with the INT-R through the connection CN5 RCB  CN15 INT-R (wire
W34) and controls the rectifier by means of the following signals:
CMD_BOOST  enable the boost charge level
CMD_ON_HC16  switches on and off the rectifier (command from I/S-CL)
CMD_TEST_BATT  enable the battery test
Such digital signals are interfaced with relays inside the INT-R and transferred to the
board D-CPU-RC as voltage-free contacts.
+12V_RCB
I_CON_HC16_ON
CN6_19
RL1
CN6_20 RET_I_CON_HC16_ON 1
7 D1
1N4148
12
11 CMD_HC16_ON
CN15_5
MZ12HS-K
+12V_RCB
I_TEST_BATT
M15_3
RL2
1
M15_4
7 D2
1N4148
12
11 CMD_TEST_BATT
CN15_6
MZ12HS-K
+12V_RCB
I_BOOST
M15_5
RL3
1
M15_6
7 D3
1N4148
12
11 CMD_BOOST
CN15_4
MZ12HS-K

Picture 15 – INT-R – Digital signals to D-CPU-RC
8) Interface D-CPU-RC  I/S-CL: the status of the rectifier is acquired by the inverter CPU
(I/S-CL) through the INT-R, by means of the connection M11 INT-R  M2 I/S-CL (wire
W33) which transfers the following signals:
0_BF_RECT  rectifier protection fuses blown
0_ERR_SC_RECT  input wrong phase sequence
0_RECT_FAIL  rectifier general fault
0_MAINS_FAULT  mains failure (battery discharging)
discharging)
The route of such signals is shown in the following table.
Signal
ignal from D-CPU
-CPU-R
-RC
C IN
INT
T-R INT-
INT-R
R I/
I/S-
S-CL
CL
0_BF_RECT  CN14-4 M11-1/2  M2-1/2
0_ERR_SC_RECT  CN14-5 M11-3/4  M2-3/4
0_RECT_FAIL  CN14-6 M11-5/6  M2-5/6
0_MAINS_FAULT  CN14-7 M12-1/2  M3-3/4*
* The “mains
“mains fault” contact is connected to the interface
interface board
board FCI (PB047), terminal
terminal
board M1/3-4.
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+12V_RELE
M11
1 O_BF_RECT R11 1k RELE2
CN14_4
2
3 O_ERR_SC_RECT R12 1k RELE3
CN14_5
4 M12
5 O_RECT_FAIL R13 1k RELE4 1 RET_O_MAINS_FAULT
CN14_6 M12_1
6 2 O_MAINS_FAULT
7 +12A M12_2
M11_7
8 -12A
M11_8
9 C_BAT
M11_9
10
M11_10
GND_A
Picture 16 – INT-R – Digital signals to I/S-CL
9) Relay output: the D-CPU-RC generates some status and alarms signals that can be
transferred, through the connector CN17 of the INT-R, to a optional relay card SRC
(PB218).
U6
1 18 B_RL1
IN1 OUT1 CN17_3
2 17 B_RL2
IN2 OUT2 CN17_4
3 16 B_RL3
IN3 OUT3 CN17_5
4 15 B_RL4
IN4 OUT4 CN17_6
5 14 B_RL5
IN5 OUT5 CN17_7
6 13 B_RL6
IN6 OUT6 CN17_8
7 12 B_RL7
IN7 OUT7 CN17_9
8 11 B_RL8
IN8 OUT8 CN17_10
D
10 N
COM G
+12V_RELE
ULN2804
9
GND_SSW
Picture 17 – INT-R – Relay output
The meaning of the various outputs is shown in the following table:
Signal Descrip
Descrip tion S/A
B-RL1 Rectifier modulating Status
B-RL2 Input mains OK Status
B-RL3 Protection
Protecti on fuses blown Alarm
B-RL4 High temperature Alarm
B-RL5 Rectifier overload Alarm
B-RL6 Rectifier fault Alarm
B-RL7 Input wrong sequence Alarm
B-RL8 Battery test Alarm
10) Board INT-R2:

INT-R2: the board INT-R2
INT-R2 is connected to the INT-R by strip-lines. The generation
generation
of the thyristor firing pulses is enabled by the command SCR_PRECHARGE_ON sent by
the CPU. The INT-R2 is provided with a soft-start circuit that allows a soft pre-charge of
the DC capacitors using four of the six thyristors of the bridge. As soon as the DC voltage
has reached a programmed value, the D-CPU-RC sends the command
SCR_BRIDGE_ON, which turn-on the remaining two thyristors. After the start-up the
thyristors work as a non-controlled three-phase Graetz bridge.
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5.2 RTF
5.
5.2.
2.1
1 De
Descri
The board RTF contains the final stage for the thyristors firing control; it’s composed by six
identical stages, one for each thyristor. The control signals on pin 3÷8 of the connector CN1,
generated by the board INT-R2, pass through a R-C filter and a high frequency transformer and
are finally connected between gate and cathode of the thyristors. The board is provided with six
LED’s installed at the high frequency transformer output to check the operation of each stage.
5.3 ID-HY (RECTIFIER IGBT DRIVER)

5.
5.3.
3.1
1 De
Descri
The rectifier IGBT drivers ID-HY are connected to the connectors CN1-CN2-CN3 of board
INT-R. Each driver is made of two identical sections, one for each IGBT.
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
INT-R, is used to generate the isolated supplies for both sections of the card.
+15V U2 +5V
D4 1N414
1N4148
8 78L05 R33 1K
1 2
TR1 VIN VOUT
C9 1 u D5 1N414
1N4148
8 + D
AC1 C10 N LD3
10u-63V G C12
1u
3
D6 1N414
1N4148
8
+
CN1 C11
10u-63V
1
2 TI117239/ACM2008
3 D7 1N414
1N4148
8
4 -15V
5 Power supply IGBT+
6
7
8 +15VF +5VF
U6
9 D11 1N4148 R34 1K
78L05
10 1 2
TR2 VIN VOUT
C21 1u D12 1N4148 + D
AC2 C22 N LD4
10u-63V G C24
1u
3
D13 1N4148
+
C23
10u-63V
TI117239/ACM2008
D14 1N4148
-15VF Power supply IGBT-
Picture 18 – ID-HY – Power supply
2) Input stage: the PWM is isolated by an opto-coupler. The R4-C5 low pass filter creates the
dead time for the PWM modulation, through the NAND gate U1. The red LED LD1
indicates the presence on the PWM.
D3 R5
+5V 1N4148 680K
C1 100n R2 D2
3K3 1N4148 4
1
7 8 1
4 1=ON U1B 1
4
R1 U1A 5 U1C
2 6 0=ON 1 4 0=ON 8
3 6 10 1=ON
1K8 3 5 2 9
D1 R4 1K
1K8
8 4093
PWM 1N4148 U3 HP2601 4093 7 4093
7 4
7 R6
1
+ U1D 3K3
R3 *** C5 C2 12
1K 1n 10u-63V 11
13
LD1
4093
7
Picture 19 – ID-HY – Input stage
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3) Output stage:
stage: the
the final
final stage DZ1, Q2,
Q2, Q3 and Q4 translates
translates the modulation
modulation signal
between +15V (ON Level) and -15V (OFF Level) and works as a buffer. The modulation
signal can be adjusted with the potentiometer RV1 of the board INT-R.
+15V
R11 **
R9 R10
390R 2W 390R 2W D
C4 + C7 DZ2
G 18V
S 10u-63V 1u R15 G1H
Q2 D 1K 1
IRFD014 Q4 2 S1H
R7 IRFD9014 R13 ** DZ3
1=ON G DZ1 C3 18V M1
S 24V 100n
22R D
G
S
Q3 C6 + C8
R8 IRFD014 10u-63V 1u
9K09
-15V
Picture 20 – ID-HY – Output stage

5.
5.3.
3.2
2 Programming instru ctions
5.
5.3.
3.2
2 Programming instru ctions
CN1
LD3
Power supply ON
LD4
Power supply ON
LD1 LD2
Modulation ON Modulation ON
R30
IGBT’S
R11 gate
IGBT’S GND IGBT1 GND IGBT2
gate
M1 M4
Picture 21 – ID-HY board (Rectifier IGBT driver)
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5.4 D-CPU-RC (RECTIFIER MICROPROCESSOR CONTROL)

5.
5.4.
4.1
1 De
Descri
The rectifier microprocessor control board D-CPU-RC uses a 40MHz 32-bit Tricore™-based
microcontroller,
microcontroll er, provided with two 16-channel 12-bit A/D converters and a TwinCAN™ interface
for highly demanding industrial application.
It controls the rectifier operation and allows the inverter microprocessor board I/S-CL to
monitor the status and alarms by interfacing its I/O signals through the board INT-R.
5.4.1.2 Digital p
power
ower s
supply
upply
The digital part of the D-CPU-RC has its own power supplies, generated by the switching
converter U37.
VCCIN-AUX1 R242
POS-CPU1
D35 L1 22R
POS-CPU1 A K VDDSB-CPU1
22uH/2.6A C129
MBRS360T3 100N
C130 D36 U37
100N C131 A K 33 7 U38
47uF/25V BOOST Q_STB TLE4274GSV33 3V3-CPU1
GND-CPU1 MBRS360T3 29 L2 D110
SW 31 A K
C132 SW 22uH/2.6A I Q
100N K D
R837 0R D37 BAS40-SOT N
1 G
30 C133 MBRS360T3 C134 C135
32 IN 22uF/10V 1uF
470N C491
R246 0R IN 1uF
35 28 A
R247 SLEW BOOTSTRAP
2
34
WAKE 25
FB/L IN
R838 10K 21 26 2V5-C PU 1 3V3-CPU1 +5V-C PU 1
C+ FB/L_IN
0R (N.M.)
C136 27
100N Q_LD01 24
3 Q_LD02 14 R243 R244 R245
Q_LD03
20
22 C- 8 120R 120R 220R
CCP Q_T1 9 R250 R251
23 Q_T2 10
SEL Q_T3 11 2V5-CPU1 0R 0R +5V-CPU1
Q_T4
12 1 A LED3
1- A
LED4
1- A
LED5
3 Q_T5 13 -
CS Q_T6 2 2 2
2 M M M
CLK 1 e 1 e 1 e
4 17 L d L d L d
DI R1 0 r 0 r 0 r
16 C144 C145 7 e 7 e 7 e
R2 10uF/10V 10uF/10V 6 V 6 V 6 V
1 15 T T T
C146 18 GND R3 G d G d G d
L e L e L e
220N 19 GND 6 K L K L K L
36 GND ERR 5
GND DO
TLE6361G

Picture 22 – D-CPU-RC – Digital power supplies
5.4.1.3 RAM, FLASH and EEPR
EEPROM
OM
The EEPROM U35 contains the functional parameters of the rectifier and the adjustments.
The two RAM U23-U23 contain the variables of the program
The two FLASH U25-U26 contain the software program.
5.4.1.4 Rectifier bridge protection
The IGBT bridge is protected if the AC input current or the DC output voltage exceed a
threshold value.
The input current is measured through the current transducers TA1-TA2-TA3, which signals
are connected to the INT-R and then to the D-CPU-RC. The comparison of the feedback signal
Low_ IMax..
with a fixed threshold generates the signal Low_IMax
The DC voltage is measured through the voltage transducers VM2-VM3 inside the INT-R.
The comparison of the feedback signal with a fixed threshold generates the signal
High_Max_Booster .. A third signal, Low_Bad_Supply
High_Max_Booster Low_Bad_Supply,, depends on the voltage supply of the
microprocessor.
A logic OR
OR is
is made with these three signals, so that an anomaly of one of them stops the
PWM protecting the IGBT bridge (signal Low_PWM_Trip
Low_PWM_Trip). ).
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High_Max_Booster
U30A U18C
U18A 1 8
Low_Bad_Supply1
Low_Bad_Supply1 1 3 10 PWM_BP_U
3 2 PWM TA+ 9
Low_IMax_U 2
4071 4093
4093 U18B
5
4 Low_Pwm_Trip_U To t he
6 I GBT
dr i v er
er s
4093
U18D
12
11 PWM_BN_U
PWM TA- 13
4093

Picture 23 – D-CPU-RC – IGBT bridge protection
5.4.1.5 Analog inputs

All the analog inputs (voltage and current measures) are directly connected to the
microprocessor A/D converter. The signals come from the board INT-R and are connected to
the following points:
Signal Connector
AC input VOLTAGE U  CN5-4
AC input VOLTAGE V  CN5-5
AC input VOLTAGE V CN5 5
AC input VOLTAGE W  CN5-6
AC input CURRENT
CURRENT U  CN1-12
AC input CURRENT
CURRENT V  CN2-12
AC input CURRENT
CURRENT W  CN3-12
DC VOLTAGE (Positive)  CN5-9

DC VOLTAGE (Negative)  CN5-10
Battery CURRENT  CN1-13
5.4.1.6 Control LEDs

The following table shows the meaning of the various LEDs on the board D-CPU-RC.
SECTION LED
Microprocessorr positive supply (POS_CPU)
Microprocesso DLP1
Microprocessorr negative supply (NEG_CPU)
Microprocesso DLN1
SPI supply (+5V_SSW) DLSS
Microprocessor supply (2V5_CPU) LED3
Microprocessor supply (3V3_CPU) LED4
Microprocessor supply (+5V_CPU) LED5
Microprocessorr reset
Microprocesso LED6
Program running LED1
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6 INVER
INVERTER
TER PCB’
PCB’SS
6.1 DR-HY (INVERTER IGBT DRIVER)
6.
6.1.
1.1
1 De
Descri
The inverter IGBT drivers DR-HY are connected to the board PWM-SAT. Each driver is
made of two identical sections, one for each IGBT (connected in parallel).
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
PS-SAT, is used to generate the isolated supplies for both sections of the card.
CN1-10 VDD U1 +5V
CN1-9 LM78L05 R1
D2
CN1-8 1 2
CN1 VIN VOUT
10 1N4148 D
N
2K21 D5
D1
9 T1 3 + G C3
8 Verde fi=3mm
C1 1uF
7 C 25
25 1 uF
uF 47uF/25V
1N4148 3
6 6
5 2
4 4
3
2 1 D6
1 + Verde fi=3mm
5 D3 C2
FLAT 10P 47uF/25V
ACM2008 R9
1N4148
D4 6K81
VNN
1N4148
Picture 24 – DR-HY – Power supply
2) Input stage: the PWM is isolated

isolated by an opto-coupler.
opto-coupler. The transistor Q1 and
and the NAND
gate U1 provide to a level translation of the modulation signal. The red LED LD14
indicates the presence on the PWM.
R34 VDD
3K3
Chiude
hiudere
re sul pin 5 VDD
CN1
+5V C5 +5V D14
10 100NF Giallo fi=3mm
9 R11 C7 1u
1uF
F
8 3K3
7 ISO1 8 7
R35 1K81 HCPL2601 R10
6 2 3K3 U4A
5 1 = ON 1
4 3
3 3 2
2 3 6 0 = ON 2
1 1
Q1 CD4093B
FLAT 10P 2N2222A
5
UNDERVOLTAGE LOCK-OUT
Picture 25 – DR-HY – Input stage
3) Output stage: the signal is amplified

amplified by a MOSFET
MOSFET amplifier
amplifier that provides
provides also for the
translation of the signal between +15 and -15V. The modulation signal can be adjusted
with the potentiometer P2 of the board PS-SAT.
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J1
D9
RON1 18V/1W 1
VDD 2
3
10R/2W 4
R25 5
RON2 1K CON 5P
R21 R22 SFP9Z24 C17 D10

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

+5V VDD
C4 D19
+
R6 10uF/25V 1N4148
3K3
U2 R3 R2
8 110K 10K
R8 1M 1 VDD
2 OUT1 7
3 HIST1 OUT2 6
SET1 SET2 5
4 HIST2
GND C32
R7 ICL7665S R5
10K R4 10K 1NF
1M
VNN
1 = ALIM. OK
Picture 27 – DR-HY – “Under-voltage lock-out”

lock-out”
5) De-saturation protection
VDD
U3 C6 J2
9 3 10uF/25V
INPUT VPOS C11 1
10 14 100NF R18 2
T_MOR VSS 1K 3
5 R20 4
OUT_ST 1 5
2 OUT1 16
VDD OUT2 CON 5P
4 100R D18 R19 D7
11 CL_PROG 13
SELECT IN_DES 1 2
15 12
COM LIV_DES 7
MON_DEL 1K MUR1100E
8 6 8.2V/1W
VREF ALARM
C8 L6353
100NF R16
12K1 R15 C12

1NF 0 = ALARM
10K R17
C13 C10 12K1
1NF 1NF
Picture 28 – DR-HY – De-saturation
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6.
6.1.
1.2
2 Programming instruc tions
D6 TPG1
Supply ON Test Point IGBT1
TP5
GROUND
J1
CN1 TPG2
Test Point IGBT2
J2
D14
Modulation ON
D5 D17
Supply ON Led fixed: inverter OK
Led blinking: under voltage lock-out
Picture 29 – DR-HY board (Inverter IGBT driver)
6.2 INV-AV-3F
6.
6.2.
2.1
1 De
Descri
The INV-AV-3F provides the inverter voltage feedback for the real-time control loop. The
inverter output phases (L1-L2-L3), taken on the filter capacitor Cr-Cs-Ct, are connected on CN1
pin 1-3-5 respectively; the voltage values are reduced by the transformer T1-T2-T3 and sent to
the microprocessor control logic I/S-CL through the connector W18.
The UPS output current transformers TA2-TA3-TA4 are connected to CN3 pin 1-2, 3-4 and
5-6 respectively; the current generated by TA2-3-4 flows through the resistors R4-R5-R6,
generating voltage drops proportional to the UPS output current; this waveforms are sent to the
I/S-CL measuring section for the output current reading.
6.3 PS-MIS
6.
6.3.
3.1
1 De
Descri
The board PS-MIS is mounted directly on two DC capacitors connected in series; it’s
composed by two sections:
1) Supply of the board PS-SAT: the voltage across the DC capacitors bank is connected to
the connector M1-5/6 and de-coupled by a diode. The voltage across the capacitors C1-
C2 (on which the board is fixed) is lower than the input voltage owing to the voltage drop
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on the resistors bank connected to the connector M3. The board PS-SAT is connected to
the connector M2.
D1
+VD C +VD C _PS
M1_1 M3_1 M3_3 M2_1
C1+
PIAZZOLA
S
C
2
1-
E
T
5 A-
R k C1-
2 PIAZZOLA
2
C2+
PIAZZOLA
S
C
2
1-
6 ET
R A
-
k
2
2
PIAZZOLA
C2-
-VDC -VDC_PS
M1_5 M2_3

Picture 30 – PS-MIS – Power supply
2) DC voltage feedback: the PS-MIS provides the DC voltage feedback to the inverter
microprocessor control I/S-CL for the DC voltage measure. The feedback signal is
provided by the transducer VM1.
+12A C1
10u-50V
R1
27k-ATE-12CS +
+VDC +HT C2
M1_1 +
100n
-
R4
CN1_5
-VDC MI S_VD C
M1_5 - HT M CN1_6
1k
R2
27k -ATE-12CS VM1 R3
LV 25-P
82R-1/2W
GND_A

Picture 31 – PS-MIS – DC voltage feedback
6.4 PWM-SAT
The board PWM-SAT is the interface between the inverter bridge and the microprocessor
control I/S-CL. The modulation signals is available from the I/S-CL on the connectors CN1 (leg
A), CN2 (leg B), and CN3 (leg C). The PWM-SAT split the signal in two parts to make it
available for each single switch of the inverter bridge (positive and negative).
It also collects the current feedbacks coming from the current transducers TA5-TA6-TA7 and
send the resulting signal to the microprocessor control through the connection M1 PWM-SAT 
M1 I/S-CL.
Finally, it collects the de-saturation and under-voltage lock-out protections coming from each
driver, generating a single output signal that is sent to the microprocessor.
microprocessor.
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7 STATIC SWITC
SWITCH
H PCB’S
PCB’ S
7.1 VOLT-REF-3F
7.
7.1.
1.1
1 De
Descri
The VOLT-REF-3F provides the signals for the by-pass line and output voltage
measurement. The by-pass is connected on CN1 pin 1-3-5 (L1-L2-L3) and 7 (neutral) and
supplies the double-secondary transformers T1-T2-T3; the secondary windings of the
transformers through to the Graetz bridge formed by the diodes D1÷D6 and the stabilizer U1,
creates a +5V supply that is sent to the I/S-CL board through the connector CN3. This is a
redundant supply for the static switch control logic (SCB board) and its presence can be verified
by checking the status of the LED DL1. The other secondary windings are used to send the
microprocessor, for measuring purposes, a waveform proportional to the by-pass voltage value,
microprocessor,
through the connector CN4, pin 1 (neutral), 2, 3 and 4.
The UPS output is connected on CN5 pin 1-3-5 (L1-L2-L3) and 7 (neutral) and supplies the
double-secondary transformers T4-T5-T6; the secondary windings are connected to the Graetz
bridge formed by the diodes D7÷D12, which output is connected in parallel to the stabilizer U1.
The other secondary windings are used to send the microprocessor, for measuring purposes, a
waveform proportional
proportional to the output voltage value, through the connector CN4, pin 5, 6, 7 and 8
(neutral).
7.2 2SCR-FIR
7.
7.2.
2.1
1 De
Descri
The 2SCR-FIR is the thyristors firing board and is installed directly on the static switch
thyristors. The control signals generated by the I/S-CL are connected on CN1; they are then
isolated by the high frequency transformer TR1 and sent directly to the thyristors. The LED’s
DL1-DL2 show that the thyristor is turned on.
DL1 R5 D Ri
G1
D1 4,7R 1W
R1
TR1 C1 *
47R
3 0,1u
K1
1
4
R7 R6 DL2 R4 + l
8 6
G2 a
nr
27R 5W C4 27R 5W 4,7R 1W
et
5 D2 R2 x
47R C2 * E
0,1u
0,1u K2
A
2- 4- 8- 0
1 3 7 1- A
CN1 9
-
R3
27R Ru
C3
D
0,1u

Picture 32 – 2SCR-FIR electrical drawing
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8 COMM
COMMON
ON PCB’
PCB’SS
8.1 PS-SAT
8.
8.1.
1.1
1 De
Descri
This board provides the different power supplies to all the sections of the I/S-CL
(microprocessor board) and to the front panel. It’s supplied by the DC bus through the board
PS-MIS. The insulation voltage between the output section and the DC input is 2,5kV.
The PS-SAT is composed by the following sections:
1) Microprocessor
Microprocessor supply: the microprocessor
microprocessor supply is strongly filtered and stabilised at +5V
on the microprocessor side (I/S-CL) by means of a precision voltage stabiliser.
FU6
PF 2A
C42 R59 D22 D23 R61 C44 R63

100p NM 1K MUR120 MUR120 1K 100p NM 10K
17 CN1
10
+ C40 C41 R57 TP8
100u 50V 100n 10K 9
8
18 7
AC4 6
T2-E C43 R60 D24 D25 R62 C45 TP9 AC3 5
100p NM 1K MUR120 MUR120 1K 100p NM 4
AC4 3
2
AC3 1
FLAT 10P
Picture 33 – PS-SAT – Microprocessor supply
2) Analog part supply: supply the analog side of the microprocessor

microprocessor card (I/S-CL).
R51
TP5
FU2 10K
+24V
T2-C D14 PF 5A R50 LD3

10 +
C29 C13
MUR120 100u 50V 1u 4K7 G 3mm
R18 0R5 5W CN2
3 2
AC2 10
11
Q8 9
+ 1 Q4 BDX34 R49 AC1 8
D16 D17 C30 R16 2 7
1
MUR120 MUR120 100u 50V 3R3 1W 3 TP2 +12V 6
12 2N2907 10K 5
TP4 4
1 3
VIN VOUT 3
R46 2
AC1 D
LD1
C15 1
N
13 C35 G D20 1u
AC2
470n U4 1N4004 2K21 G 3mm FLAT 10P
2 LM7812
D15 R48
14 D19 D18
MUR120 MUR120 TP3 -12V
MUR120 10K
2 3
IN OUT
R47 LD2
D
N
+ G
C31 D21 C28
100u 50V U5 1N4004 1u 2K21
1 LM7912 G 3mm
Picture 34 – PS-SAT – Analog part supply
3) Relay and bus supply: this section provides a +12V stabilised voltage for the
the supply
supply of:
Relays of the alarm card ARC (PB031)  pin 9-10
Relays of the rectifier interface INT-R  pin 9-10
Parallel bus  pin 9-10
Inverter interface card FCI (PB047)  pin 1-2
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UPS
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D26 FU7 CN3

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

19
MUR120 PF 2A 2K21
+ C48 LD5
20 10u 63V C34 G 3mm 12V/SCR
1u
T2-G
Picture 35 – PS-SAT – Relay and bus supply
4) IGBT drivers supply: the supply of the IGBT driver boards DR-HY is taken from the 40kHz
square wave AC1-AC2
5) Serial ports supply: the supply of the serial

serial communication
communication ports
ports is taken
taken from the 40kHz
square wave AC3-AC4
8.
8.1.
1.2
P2 TP9
IGBT’s gate voltage
CN1
TP8
P1
Not used
FB2
VB- CN4
LD5
LD4
TP3
VB+ -12V
CN3
FB1 TP4
GND
TP2
+12V
CN2
L D2 LD1 TP5
LD3
+24V
Picture 36 – PS-SAT board
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The following table summarizes all the different outputs:
Test GND
SECTION L ED
ED Po t . Val ue
ue
point TP
LD1 +12V Analog TP2 TP4
Analog part supply
supply LD2 -12V Analog TP3 TP4
LD3 +24V Analog TP5 TP4
Free contacts and parallel bus LD4 +12V / Relay & Bus
Free contacts LD5 +12V
Microprocessorr and display
Microprocesso +9V TP8 TP9
IGBT’s drivers Power Supply P2 Sq. Wave AC1-AC2
RS-232 and RS-485 Sq. Wave AC3-AC4
8.2 I/S-CL (MICROPROCESSOR CONTROL LOGIC)

8.
8.2.
2.1
1 De
Descri
The I/S Control Logic (I/S CL) controls all the UPS functions and signals. It takes the digital
inputs (like auxiliary contacts, switches and so on), performs all the analog measures (like
voltages, currents and so on) and provides the total control of the UPS.
8.2.1.2 Digital Inputs
The digital inputs are connected to the I/S CL to the connector M3, directly or through the
interface card FCI. The connector M2 contains all the alarms and signals coming from the
rectifier (see 5.1.1, point 8). The following table shows the various digital inputs connected to
the I/S-CL.
I/S-CL
Signal
M3
1-2 Not used - Spare
3-4 Mains failure (from INT-R)
5-6 Emergency Power Off push button
7-8 BCB auxiliary contact
9-10 OCB auxiliary contact
11-12 SW1 auxiliary contact
13-14 MBCB auxiliary contact
15-16 High temperature
17-18 Parallel configuration (from RPI-BUSCAN)
8.2.1.3 Dip Switches

The dip switches SW1 and SW2 are connected to the microprocessor bus through the
latches U67 and U68. The functions of the UPS can be programmed by setting these switches
as follows.
A) Dip Switch SW1
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Di p n o . Po s i t i o n Des c r i p t i o n
Off Single UPS
1
On Parallel
Off Frequency 50Hz
2
On Frequency 60Hz
Off Single / Parallel
3
On Hot stand-by
4 On
On Nominal Vout
5 On 220V
4 Off Nominal Vout
5 On 120V
120V
4 On
On Nominal Vout
5 Off
Off 230V
4 Off Nominal Vout
5 Off
Off 240V)
Off TEST mode
6
On NORMAL mode
Off Buzzer DISABLED
7
On Buzzer ENABLED
Off THREE-PHASE output
8
On
B) Dip Switch SW2
Di p n o . Po s i t i o n Des c r i p t i o n
Off protocol
1
On
Off BOOST CHARGE enabled
2 On BOOST CHARGE disabled
Off Automatic battery test
ENABLED (every 30 days)
3
On Automatic battery test
DISABLED
Off Battery test ENABLED
4
On Battery test DISABLED
5-6-7-8 Configure the power as follows
UPS
Dip 5 Dip 6 Dip 7 Dip 8
[kVA]
200 Off On

On Off Off
250 Off Off On

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

The measures of the bypass L1, L2 and L3 phases and output L1, L2 and L3, are directly
connected to the microprocessor A/D converter. The signals comes from the board VOLT-REF-
3F and can be checked, with reference to the MICROPROCESSOR ground, in the following
points:
D52 (K)  Output L3 D57 (K)  Output L2 D58 (K)  Output L1
D59 (K)  Bypass L3 D64 (K)  Bypass L2 D65 (K)  Bypass L1
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MICRO BUS R
FI1 BYPASS FREQUENCY OP AMP
+5V
R152 R150
D62 D61 D60 D55 D54 D53 10K 10K
2K2 1% X6
R172
ADA0 R R
CN13-4
ADA1 S S R171
CN13-3 BYPASS
ADA2 T T R173
CN13-2
ADA3 R R R166
CN13-5
ADA4 S S R165
CN13-6 OUTPUT
ADA5 T T R164
CN13-7
D65 D64 D59 D58 D57 D52

5 6 4 7 8 9
0 0 0 0 0 0
2 2 2 2 2 2
R R R R R R
C113
VR/2
C110 C109 C100 C98 C97
Picture 37 – I/S-CL – Fast analog inputs

8.2.1.5 External A/D Converter
Several analog measures are sent to the microprocessor through the external A/D converter
U22. These measures can be checked, with reference to the ANALOG ground in the following
points:
A/D Test
Measure
Channel Point
Inverter Output Voltage R #0 D43 (K)
Inverter Output Voltage S #1 D20 (K)
Inverter Output Voltage T #2 D21 (K)
Output Current R #3 D6 (K)
Output Current S #4 D33 (K)
Output Current T #5 D5 (K)
Inverter Input Voltage (DC) #6 D23 (K)
Inverter Input Current (DC) #7 D22 (K)
Phase Correction for Parallel Redundant #8 D42 (K)
Battery Current for Boost Charger #9 D74 (K)
+5A
INVERTER VOLTAGE R
D31 D16 D17 D32 D14
D1 D 15 D34 D35
D3 D36
U22 INVERTER VOLTAGE S
20 1 Inv. Volt. R INVERTER VOLTAGE T

19 VCC IN0 2 Inv. Volt. S
18 EOC IN1 3 Inv. Volt. T
17 CLK IN2 4 Out. Curr. R OUTPUT CURRENT R
DATA_OUT 16 ADRIN IN3 5 Out. Curr. S
15 DOUT IN4 6 Out. Curr. T OUTPUT CURRENT S
14 CS IN5 7 VDC
13 REF+ IN6 8 IBS OUTPUT CURRENT T
12 REF- IN7 9 CFPAR
11 IN10 IN8 10 DC VOLTAGE
IN9 GND
IBOOST INVERTER INPUT CURR
TLC1542
A PARALLEL CORRECTION
BATTERY BOOST CURR
D42 D22 D23 D43 D20 D21 D6 D33 D5
C72 C51 C52 C73 C4

9 C50
C64 C65 C66
A
Picture 38 – I/S-CL – External A/D converter

8.2.1.6 Watchdog and Reset
The microprocessor is controlled by a smart watchdog system that provides an automatic
reset in case of an error of the microprocessor during the normal operation or a problem in the
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microprocessor power supply (under-voltage lock-out). It is also possible to reset manually the
microprocessor
microprocessor by pressing the reset push-button SW3.
8.2.1.7 RAM, EPROMs and EEPROM
The EEPROM U71 contains the functional parameters of the UPS and the adjustments.
The RAM U58 contains the history of the alarms of the UPS. Up to 900 events can be stored
in this device and the backup battery allows to preserve the information for three days after the
power has been removed.
The two EPROMs contain:
U55 Program odd addresses
U65 Program even addresses.
8.2.1.8 Digital Power Supply
The digital part of the I/S CL has its own power supply (5 volt). This voltage can be checked
on the LED D69 (green) and measured between U75 pin 2 (ground) and pin 3.
VNR +5V +5V
CN14-10 U75
L4 TEA7605
CN14-9 1 3
E U
C122
C131 + M D69
C137
FILTERS GREEN
100NF 100NF 470uF 2

CN14-1
CN14-2
GN D COMMON MODE
D50
R146
1N4148
+VRAM
D49 D48
1N4148 SD103
BT
1 ON
2

J2
3 OFF

Picture 39 – I/S-CL – Digital supply

8.2.1.9 RCB board
The RCB is an additional card which is fixed on the I/S-CL. It contains the drivers for the
digital outputs of the microprocessor. Each output is de-coupled and buffered on this card. The
RCB contains also the RS232 and RS485 drivers for the serial communication ports.
8.2.1.10 SCB board and Thyristor drivers
The SCB is an additional card which is fixed on the I/S-CL. It contains the decisional logic for
both bypass and inverter static switches. It can turn-on directly the bypass static switch or send
the command to the I/S-CL to close the inverter static switch.
This card can be programmed through the jumpers J1÷J8 (see figura 51) and it is powered
directly by the emergency line at +5V (see 7.1.1). This supply can be checked on the LED L1
(green) and measured between U11 pin 10 (ground) and pin 20.
8.2.1.11 Current Limitation and Max Current Stop
The current flowing in the inverter bridge is measured through a hall-effect current transducer
on the connector M1 pin 2.
1) Short circuit protection: the feedback signal originated by the Hall

Hall effect CT is
is acquired
acquired by
the microprocessor card where it generates a voltage drop flowing through the resistors
R18-R39-R40,
R18-R39-R 40, so that it can be used for the control circuit. By means of a amplifier, which
gain can be varied with the potentiometer P2, the value of the signal is adapted to the
dynamic of the protection circuit.
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The signal on the test point TP2 must be equal to 4Vpk when the inverter supplies the
nominal load (100%).
In case of short circuit the output current is limited at 200% for 100ms, and then to 125%
for 5 seconds, after which the inverter is switched off (according to EN62040-3).
+12A
C19
M1-2 FEEDBACK
R39 100NF
J10 47R
R27 D73 A
3 U16A
+
1 TP2
C28 R40 1K SD103 2
-
1NF J9 100R D72 Current
R38 MC34074
SD103 Signal
2K A
C27 1n
R18
J100 22R
R25 R26
P2
1K 10K 1K
A
Picture 40 – I/S-CL – Short circuit protection

2) Current stop protection: the resistors R18-R39-R40
R18-R39-R40 are properly combined according to
the IGBT’s nominal current so that, in case of “bridge leg” short circuit the PWM is
stopped before the input current exceed the 200% of the IGBT’s nominal current. The
detection time and the subsequent inverter stop is not higher than a PWM pulse (max.
250μs)
The inverter stop due to “Current stop” is signalled by the LED D3
D3,, placed on the front of
the I/S-CL card. The program provides for the automatic reset of the stop condition for
three times, re-starting the inverter. If the block repeats, therefore a real failure exists in
the inverter bridge, the inverter is definitely stopped and must be re-started only after
having verified the reason of the malfunction.
U15B
+5A +12A 3 4
U5C
C20 40106 8 R13
100NF 10
R15 CA3130 9
10K +12A 3K3
4093 D3
7 5
A LMCS
R17 10K
FEEDBACK 3 U11 R50
M1-2 +
6 U5D
R39 2 12
-
J10 R49 200K 11
13 A
R16 4 8 1
C13 1K 4093
10K
R40
C28 J9 1NF N1 CURRENT STOP
1NF A 100pF
+ C148
A 10u 25V
SW4
R18 PPMCS
J100
A
Picture 41 – I/S-CL – “Current stop” protection

8.2.1.12 VCB board
The VCB is an additional card which is fixed on the I/S-CL. It’s made by the following
sections.
1) Sine-wave generator: the digital samples coming from the microprocessor

microprocessor (that represents
the digital sine-wave) are converted by a D/A converter in order to obtain a real sine-wave
which is transferred to the PWM generator (see 8.2.1.13). The amplitude of the sine-wave
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is varied by the AUTOMATIC regulation loop (jumper J1 in position 1-2) in function of a

set-point managed by the microprocessor adjustable through the potentiometer P1. Each
phase of the inverter is disengaged and can be varied independently.
In order to carry put functional tests, the regulation loop can be set in MANUAL mode
(jumper J1 in position 2-3), in such case the amplitude is varied turning the potentiometer
P1 of the I/S-CL card. In this case the inverter output voltages are varied contemporary.
contemporary.
2) Voltage correction (instantaneous

(instantaneous value loop): the voltage correction circuit is used to
modify the PWM reference signal in order to “correct” possible distortions on the output
sine-wave and can be disabled removing the jumper J2. The feedback signal, coming
from the INV-AV-3F card is compared with the reference sine-wave e properly filtered.
The resulting signal is added again to the reference sine-wave.
+5A +12A
C22
R36
10K
R30 10K U6C 100NF
VREF 10 NOTCH A
+ U6B
8 FILTER 5
+
9 7
-
6
-
LM324 R39 10K
LM324 VREF
R31 10K R32 10K
VFBK A
R40 10K U6D
R37 12
C14 +
C15 14 VPWM
1NF 1NF 43K2 C19 J2 13
-
C20 100NF
LM324
A A
1NF R41 10K R42 11K8
1NF
+5A
Picture 42 – VCB – Instantaneous value loop
3) Inverter voltage measure: a section

section of the card is dedicated to the
the creation
creation of a signal that
is used as reference for the measure of the inverter output voltage. The feedback signal,
coming from the board INV-AV-3F, is rectified, filtered and sent to the external A/D
converter (see 8.2.1.5), and then to the microprocessor
8.2.1.13 PWM generator
The I/S-CL can be used to generate both single-phase and three-phase output voltages. This
function can be programmed by setting the jumper J1 on the I/S-CL. The PWM generator
compares the sine-waves coming from the VCB card with a triangular waveform at the switching
frequency (U17 pin 6) to generate the PWM modulation to control the inverter power bridge.
+12A +12A
C18
C24 100NF
100NF
A U9A +12A CN7-8
5 6 1
1STOP
3
CN7-7 +TA
U14C 2
40106 AC1
A
CN7-1
4093
CN7-3
U14D
+12A A
9 8 AC2 CN7-2
C22 CN7-4
CA3130 40106
100NF -TA
R10 7 5
A A
1K
FPWM (TRIANGLE) 3 U12 U9B
+ +12A CN7-10
6 5
VPWM (SINEWAVE) 2 4
- CN7-9
6
R9 C14 C15
1K 4 8 1 4093
22NF 22NF
A
A A
A N5
47pF
Picture 43 – I/S-CL – PWM generator
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CN11 CN9 CN5

M3
M2
0 0 0
1 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 7 8 9 1
0 1 2 3 4 5 6 7 8
1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1
G + +
N 5 2
D S 4
T V
M1-2 U U
1 1
1 1
p p S S C S M B E O B M T S
i
n i
n Thyristors P P H P A C P C Y B H P
A A A A I
N B O B P C E A
I
n 1 2 Driver R R R R C A B R R
v 0 L1 0 E E S A A S M
e G E U O U A E
r E F X N X S U A
t
e +5ST
R A . S L
r U . T X
F L C A C W . S
B T O C O C W
r A I
T O
i
d C U N T N C I
g o Optocoupler L T T N T
e n S T A A H T C
A t O U39 C C A H
C r or t
u D T p T T C
r r h a l a
r
t
i
t
o I
n T
r y P c
e
n v y
i r
i L r S
c
o v
e
t e s o o u r
r o
t g g r w
i
p
l
t
e
J r
s i a t
c e r
G I 9 s m c r F Optocouplers
S B J m h s e
a e
e T 1 b d
l s
e ' L
c C 0
l
e o
t
i a
o
n u
J J J d
r 1
r 5 1 S
e 0 J J i
n 0 6 2
g
n
t a Input Latches
S J J l
C 7 3 U48-U52-U53
B J J
SW4 D3
8 4
RESET
P L M
2 i C
m a
i u S x
t
a r
r t C
o
i e
t
o n p u
r 6 5 4 3 2 1 0
1 1 1 1 1 1 1 9
6 5 4 3 2 1 0
1 1 1 1 1 1 1 9
n t r
e
n CN10 CN13-7
CN13-6
CN13-5
CN13-2
CN13-3
CN13-4 SW2 SW1
t
0
1 2
TP2
O O O B B B
u u u y y y
t
p t t -P -P -P 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
O u p p
u u a a a
t t s
s
T S t
Current Stop p s
t Display R s s s
Signal o T S R
c Driver
o
S u Input Latches
D h Short Circuit p
l
e U67-U68
e o Signal r
t r
e t s
c C
t
o i
r
r c
u Fast Analog to Digital Conversion
S i
t Channels
G w O A A A A A A
i
e t p d d d d d d
n c t 5 4 3 2 1 0
e h i
n
o
c U W U M
r g
a o
t u L n a 6 i
c
o F p o d t
c 1 R r
r r l c e h o
e
U q
e k r v d
- e p
r
s o o s r
1 u CN14-2
CN14-1 CN14-9
CN14-10 u l o e o
7 e t g
t a t c
n g a e
c e n s
y s
d o
r
P P P
1 J 1 SW3
U a E
2 7 r E
a
J 1 m P
1
CN7 S
F O S P D e R
G
S e i
n p U t O
e
i e g t 7 u ow g
i RESET BT
r M
10
U e
n l
d e o
c 5 p
p e a i
t s
n u - o l r l
9 4 e s b P
a h u y
8 r
a W p B
7 V t a
c a
k s l
e a
o
6
C
B
B r ev e s
r c
k
u H A
5 A D69 p U i
s R d
4 d b 5 t A d
d a 8 o M r
e
3
r U U +5V r
y s
e 7 7 t
t s
2
s 5 5 e e
1 s r
y s
e p p a
s i
n i
n n
a 2 3 d
n
P d D
CN1 J 1 D a
t
2 a U E a
P J t
a B
10
W 1 S O
5
5
O P u
9
U M F B d R s
8 9 S
G e i
n p
t
u
s
d O
- G i
n e g o M
U e l
d e
7 U c U U
1 e n u - o 1 1
6
n
4 e 4 e s b P
a h u 1 1
5
V r
a W c a p
r t k s l
e p p
4 a
t C o av r i
n i
n
3 o B r e e s
r 9 L2 1
2 0
1
+12V E
C U E P
N 6 v R
6 5 e O
n M
CN5
CN2
J P
RELAY #2
1 10 RELAY #3 O
10 J 1 9 RELAY #1 u O
9 2 8
U t
p R p
J RELAY #4
u e t
o
8
1 S O
7 RELAY #5 1 t
1 B a l c
7 F 6 RELAY #6 o Output Buffers
6 S
G e i
n p 5 u y u
i
n e g t
o RELAY #7 f s
f
p
l U74
U e d e
l e e
5 c 4
n u - o
POS-REL
r r
4 4 e s b P
a h u
3 POS-REL s
3
V r W
a c p 2 POS-REL
t
o a a
k s l
e
2
C v
r e e r
1 K1
1
B s
M1
2
I 1
n I
n I
n
D v v v
C .V V . .
V Optocouplers
C o o o
l
u t l t
t l
r a
+12V-SCR
r g a
g
a
g
CN
N4
CN4-2
4 -1
-CN4-3
1 CN
N4
CN4-9
4CN4-10
-8
-8
e e
t e e
n T S R
I
n I n I
n I n O
7 2 1 0 p L1 RS485 RS232
t
o Buffer Buffer
c
o
External A/D u
p I O O
I n P G T R
Converter l
e U14 n U15
o n x x
I I I r + - u u
n U22 n n I n I
n I n s R t
+ t
- s d
9 8 6 5 4 3
C
S P A
U B P I
n O O O B
7 u o n
p w a a a h
t s
v u u u
e t
p e o l t r p t t
l r g
y
e e
r t
e u p p
u u 0 9 8 7 6 5 4 3 2 1 0 9 8 7 6 5 4 3 2 1
2 1 1 1 1 1 1 1 1 1 1
y C r t
C C t t
C
C o I
n u
u r r p r u u
r e . r r r
r
. c V T . r . r .
CN4
D11 t
. o S R
l
t
+12V .
U U
7 7
p p
i
n i
n M2-9CN3-2 CN4-6
CN8-8
CN8-9
CN8-10
2 1

Picture 44 – I/S-CL block diagram
Issued 13/04/07 JUD409400

JUD409400 32 of 35
UPS
UPS Functioning De
Descripti
scripti on
8.
8.2.
2.2
R40-100R Current J11-MBCB

Analog Test point Aux. contact
ground R39-47R J10
CN6 NC=1-2 Reset max.
J9 D8-short circuit
NA=2-3 curr.
CN5 CN4 CN3 CN2 CN1
M1
Led
max corr.
J100 CN7
M2 J1
R18 1Ph = 1-2

3Ph = 2-3
M3 22R
Man. Inv.
volt. adj.
P2 U17
ACW=incr.
Curr. limit. adjust. Pin 6=Triangle
Modul.
ACW=increase curr.
D11 CN8
Correct D23
R66 Vdc measur.
+12V analog 6K8 = 8KHz
13K3 = 4KHz
CN11
CN10
CNB Front
panel
CN9
J2
Battery connected
1-2 Closed = backup CN12
Debug
CN14
RST–RST CN8 CN7
Emer. line - Output
CN13 (D65..D52) ODD Normal
Reset Debug
selection
CN15 EVN
J7 SW1 SW2
Microprocessor D69-Correct Open=Watchdog
ground +8V digital excluded
Closed=Watchdog
included
Picture 45 – I/S-CL board
Issued 13/04/07 JUD409400

JUD409400 33 of 35
UPS
UPS Functioning De
Descripti
scripti on
8.2.3
8.2.3 SCB boar
boardd
U12 U11 JP2
TP1-2 SAFE_22 OUTGEN Open = aut. Retransfer
Closed = man. retransfer
JP3 JP7 JP1

Open = hot stand by – parallel red.
Closed = single unit
JP4
JP5 JP8 JP6

Picture 46 – SCB board
Note: for parallel redundant UPS, U11 must be changed to OUTGEN41 and U12 to
SAFE1_23.
8.2.4
8.2.4 VCB boar
boardd
J1 P1
Inv. Voltage reg. Close loop inverter voltage adj.
1-2 = closed loop
2-3 = manual
J2
Closed = istant. loop included
Open = istant. loop not included
J3
Always open
Picture 47 – VCB board
Issued 13/04/07 JUD409400

JUD409400 34 of 35
UPS
UPS Functioning De
Descripti
scripti on
8.3 FCI
8.
8.3.
3.1
1 De
Descri
The FCI board provides a de-coupling function for all the
t he digital inputs (see point 8.2.1.2) and
it’s connected to the microprocessor through the terminal M2. In detail, the function of each
relay is the following:
K1 (terminals 17-18)  used for UPS in parallel configuration
configuration
K2 (terminals 15-16)  Inverter bridge thermal sensors
K3 (terminals 13-14)  MBCB (manual by-pass breaker) position
K4 (terminals 11-12)  SW1 (by-pass test switch) position
K5 (terminals 9-10)  OCB (UPS output breaker) position

K6 (terminals 7-8)  BCB (battery circuit breaker) position
K7 (terminals 5-6)  EPO (Emergency Power Off)
K8 (terminals 3-4)  Mains failure (from rectifier control logic)
K9 (terminals 1-2)  Not used - Spare
CN1
+12V
10 J1 J2
9 1 1
8
7
2 2
6
5
4
3
3 3
2
1
K1
1N4148
D1
OUAZ-SH-112D
K2
1N4148
D2
OUAZ-SH-112D
M2
M1 K3
1N4148 18
18 17
17 16
16 D3 15
15 OUAZ-SH-112D 14
14 13
13 12
12 K4 11
11 1N4148 10
10 9
9 8
8 D4 7
7 OUAZ-SH-112D 6
6 5
5 4
4 K5 3
3 1N4148 2
2 1
1
D5
OUAZ-SH-112D
K6
1N4148
D6
OUAZ-SH-112D
K7
1N4148
D7
OUAZ-SH-112D
K8
1N4148
D8
OUAZ-SH-112D
K9
1N4148
D9
OUAZ-SH-112D

Picture 48 – FCI electrical drawing
Issued 13/04/07 JUD409400

JUD409400 35 of 35

Troubleshooting and Maintenance
TROUB
TROUB L ESHO
ESHOOTIN
OTING
GAAND
ND MA
MAINTE
INTENANCE
NANCE
Index
1 INTRODUCTI
ON.......................
...........................
..........................
...........................
................................. 4
...................
1.1 TOOLS FOR SERVICE.....................................................................................4
2 TROUBL
TROUBL ESHO
ESHOOTING
OTING PROC
PROCEDURE
EDURES
S .............
..........................
................................. 5
....................
2.1 A1 – MAINS
MA INS FAUL T ............
.........................
..........................
..........................
..........................
.......................... ............ 5
.........................
2.1.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............5
........5
2.2 A2 – CHARGER
CHA RGER FAUL
FAULTT .............
.........................
.........................
..........................
..........................
..........................
...................
......66
2.2.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............6
........6
2.3 A3 – RECTIFIER FUSE .............
..........................
..........................
..........................
..........................
..........................
...................
......66
2.3.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............7
........7
2.4 A4 – THERMAL
THERMA L IMA GE ............
..........................
...........................
..........................
..........................
..........................
..................
.....77
2.4.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............7
........7
2.5 A5 – A C/DC FAUL
FAULT........
T.....................
..........................
..........................
..........................
...........................
...........................
................
...88
2.5.1 Trou
Troubl
bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........
........8
....8
2.6 A6 – INPUT WRONG SEQUENCE.............
SEQUENCE ...........................
...........................
..........................
.......................... .8
..............8
2.6.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............8
........8
2.7 A7 – BCB
B CB OPEN ............
.........................
..........................
.........................
.........................
..........................
..........................
................... 9
......9
2.7.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............9
........9
2.8 A8 – B ATTERY DISCHA
DISCHARGE
RGE ............
.........................
..........................
..........................
.......................... .......... 9
.......................
2.8.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
............9
........9
2.9 A9 – B ATTERY A
AUTONOMY
UTONOMY END ............
........................
.........................
..........................
..........................
................ 9
...9
2.10 A10 – B ATTERY FA
FAULT
ULT .............
..........................
..........................
.........................
.........................
.......................... .9
..............9
2.11 A11 – B ATTERY TEST .........................
............ .........................
.........................
.........................
.........................
...................
......99
2.12 A12 – PLL
PL L FAUL T.........
T......................
..........................
...........................
...........................
.......................... ............ 10
.........................
2.13 A13 – INVERTER OUT OF TOLERA NCE ............
.........................
.......................... ............ 10
.........................
2.13.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
edure.......
e...........
........
........
........
........
........
........
........
........
........
........
........
............10
........10
2.14 A14 – OVERLOAD
OVERL OAD ............
.........................
..........................
..........................
..........................
.......................... ......... 11
......................
2.14.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
edure.......
e...........
........
........
........
........
........
........
........
........
........
........
........
............11
........11
2.15 A15 – B YPASS FA
FAULT
ULT............
.........................
.........................
.........................
..........................
..........................
................ 11
...11
2.15.1 Troubl
Trou bleshoo
eshoo ti ng proc
pr ocedur
edure.......
e...........
........
........
........
........
........
........
........
........
........
........
........
............12
........12
Issued 13/04/07 JUD409401 1 of 26

2.16 A16 – BYPASS

B YPASS FEED L
LOAD
OAD ...........
.........................
...........................
..........................
.......................... ..... 12
..................
2.16.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 13
......
2.17 A17 – RETRANSFER
RETRA NSFER BL
BLOCKED
OCKED ..............
...........................
..........................
........................... ........ 13
......................
2.17.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 13
......
2.18 A18 – MANUAL
MA NUAL BYPA
BYPASS
SS CLOSED ..............
...........................
..........................
.......................... ..... 13
..................
2.18.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 14
......
2.19 A19 – OCB OPEN ............
.........................
...........................
...........................
..........................
.......................... ........ 14
.....................
2.19.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 14
......
2.20 A20 – FANS
FA NS FAIL URE .............
..........................
..........................
..........................
.......................... ............... 14
..........................
2.21 A21 – HIGH TEMPERATURE
TEMPERA TURE .............
..........................
..........................
..........................
......................... .... 14
................
2.21.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 14
......
2.22 A22 – BYPASS
B YPASS SWITCH .............
..........................
..........................
..........................
.......................... .......... 14
.......................
2.22.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 15
......
2.23 A23 – EPO BUS
B US .............
..........................
..........................
..........................
..........................
........................... .......... 15
........................
2.23.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 15
......
2.24 A24 – CURRENT STOP .............
..........................
..........................
..........................
.......................... ............ 15
.........................
2.24.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
.......... 15
......
2.25 A25 – SHORT CIRCUIT ...........
........................
..........................
..........................
..........................
......................... .. 16
..............
2.25.1 Troubles
Trou bleshoo
hoo ti ng proc
pr ocedur
eduree ....
........
........
........
........
........
........
........
........
........
........
........
........
........
........
......
.. 16
3 PCB’S
PCB’ SA
AND
ND COMPON
COMPONENTS
ENTS SUBSTITUTION..................................17
SUBSTITUTION..................................17
3.1 PCB’S SUBSTITUT
SUBSTITUTION
ION ...........
......................
.......................
.......................
......................
......................
......................... 17
..............
3.1.1 PB003 – I/S-CL ...........
.......................
.......................
......................
......................
.......................
............................... 17
...................
3.1.2 PB004 – INV-AV-3F....................
INV-AV-3F...............................
......................
......................
......................
........................... 19
................
3.1.3 PB005 – VOLT-REF
VOLT-REF-3F
-3F ...........
......................
......................
......................
.......................
.............................. 20
..................
3.1.4 PB107 – PS-SAT ...........
......................
......................
......................
......................
......................
............................. 20
..................
3.1.5 PB223 – INT-R..............
INT-R.........................
.......................
.......................
......................
......................
............................. 21
..................
3.1.6 PB228 – PS-MIS
PS-MIS..........
......................
.......................
......................
.......................
.......................
............................. 21
..................
3.1.7 PB249 – D-CPU

D-CPU-RC............
-RC.......................
......................
......................
......................
.......................
.......................
............. 21
3.2 COMPO
COMPONENTS
NENTS SUBSTITUT
SUBSTITUTION ION ..........
.....................
......................
......................
................................... 22
......................
3.2.1 RECTIFIER
RECTIFIER IGBT’S ..........
.....................
......................
......................
......................
.......................
.......................... 22
..............
3.2.2 RECTIFIER
RECTIFIER BRIDGE THYRIS
THYRISTORS
TORS (PRE
(PRE-CHARGE)
-CHARGE) ...........
........................... 22
................
3.2.3 INVERTER
INVERTER BRIDGE IIGBT’S
GBT’S ..........
.....................
......................
.......................
.................................. 22
......................
3.2.4 STATIC SWITCH THYRISTORS
THYRISTORS ..........
.....................
......................
......................
............................ 23
.................
4 ON-FIELD
ON-FIELD TEST PROCEDURES
PROCEDURES .............
..........................
..........................
..........................
...............
.. 23
4.1 RECTIFIER.
RECTIFIER............
.......................
.......................
......................
......................
.......................
.......................
................................ 23
.....................
Issued 13/04/07 JUD409401 2 of 26

4.1.1 General notes on the TEST mode.........................................................23

4.1.2 Setting the rectifier in TEST mode........................................................23
4.2 INVERTER
INVERTER ...........
.......................
.......................
......................
......................
.......................
.......................
..................................24
.......................24
4.2.1 General notes on the TEST mode.........................................................24
4.2.2 Bl ank tes
testt of th e I/S-C
I/S-CL
L bo
board
ard ...........
......................
.....................
.....................
...............................24
....................24
4.2.3 Invert
Inv erter
er manu al st art
art-up
-up ...........
......................
......................
.......................
.......................
...........................25
................25
4.2.4 Inverter automatic start-up....................................................................25
4.3 STATIC SWITC
SWITCH
H ............
.......................
......................
......................
......................
......................
......................
.........................26
..............26
4.3.1 Check of the redundant supply.............................................................26
4.3.2 Commutation tests.................................................................................26
Index
Index of pictur es
Picture 1 – Signal on cathode (D64-D59)....................................................................................... 12
cathode of D65 (D64-D59).......................................................................................
Picture 2 – Current
Current signal
signal on TP2 at 1
100%
00% of loa
load .................................................................................... 18
d ....................................................................................
Picture 3 – IGBT turn-on
turn-on signal
signal .................................................................................................................. 20
..................................................................................................................
Picture 4 – Triangle
Triangle (switching
(switching frequency) ................................................................................................. 24
frequency) .................................................................................................
Issued 13/04/07 JUD409401 3 of 26

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

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

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

2 TROUBL
TROUBLESHOOTING
ESHOOTING PROCEDURES
2.1 A1 – MAINS FAULT
This alarm normally indicates that there is no power at the input of the UPS. The normally
closed contact of the relay RL5 on the board INT-R is connected to the pins 1-2 of M12. This
contact is sent to the I/S-CL on M3 pins 3-4 through the wire W35. When this contact is closed
(relay not energised) the alarm is active; when the mains is considered good, the relay is
energised and the alarm disappears.
2.
2.1.
1.1
1 Troubl eshooti ng proc edure
1. Is the input voltage present and within the tolerance?
YES
YES:
NO:: : check
NO go to step #2
the UPS
UPS supply
supply line
line
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence.
sequence. Is it
active?
YES:: follow
YES follow the procedure at 2.6.1
NO:: go to step #3
NO
3. Check the AC voltage
voltage measures
measures on the
the software
software “WRC
“WRC Monitor”.
Monitor”. Are
Are they
they in
tolerance?
YES:: go to step #4
YES
NO:: go to step #6
NO
4. Check the status RMSOK

RMSOK.. Is it active?
YES:: go to step #5
YES
NO:: replace the board
NO board PB249
PB249 (D-CPU-RC)
(D-CPU-RC)
5. Check the status FROK
FROK.. Is it active?
YES:: go to step #8
YES
NO board PB249
PB249 (D-CPU-RC)
(D-CPU-RC)
6. Check the connection between the AC mains and the connector M8 of the board INT-R
(wire W51). Is it good?
YES:: replace
YES replace the board INT-R. Go to step #7
NO:: re-connect or replace
NO replace the wire W51
W51
7. After having substituted the board INT-R is the problem solved?

YES:: END
YES
NO board PB249
PB249 (D-CPU-RC)
(D-CPU-RC)
8. Check the connection between the connector CN11 of the board D-CPU-RC and CN14
of the board INT-R. Is it good?
YES:: go to step #9
YES
W38
9. Check the connection between the connector M12 of the board INT-R and M3 of the
board I/S-CL. Is it good?
YES:: replace
YES replace the I/S-CL
W35
Issued 13/04/07 JUD409401 5 of 26

2.2 A2 – CHARGER FAULT

This alarm normally indicates that there is a fault on the rectifier / battery charger. The signal,
generated by the board D-CPU-RC (PB249) is sent to the board PB223 through the flat-cable
W38 (CN11 PB249  CN14 PB223) and acquired by the inverter microprocessor card PB003
(I/S-CL) through the wire W33 (M11 PB223  M2 PB003).
2.
2.2.
2.1
1 Troublesho oti ng pro cedure
1. Open the battery breaker BCB and check the rectifier output voltage. Is it within the
tolerance values?
YES:: go to step #2
YES
NO:: go to step #3
NO
2. Check the connection between M11 of the the board

board INT-R and M2 of the board I/S-CL. Is
it good?
YES:: replace the I/S-CL
YES
W33
3. Connect the software “WRC Monitor” and check the alarm Booster Fault.
Fault. Is it active?
YES:: go to step #4
YES
NO:: replace the board PB249 (D-CPU-RC)
NO
4. Check the alarm High Temperature on
Temperature on the software “WRC Monitor”. Is it active?
YES:: go to step #5
YES
NO:: go to step #7
NO #7
5. Check the status of the pins 1-2 of M15 in the board INT-R. Is the
the contact
contact closed?
YES:: go to step #6
YES
NO:: Check and/or replace the thermal
NO thermal switch
switch
6. Check the connection between the connector CN11 of the board INT-R and CN4 of the
board D-CPU-RC. Is it good?
YES:: replace the board PB249 (D-CPU-RC)
YES
W41
7. Set the rectifier in TEST

TEST mode
mode (see
(see 4.1.2)
4.1.2) and
and check
check the IGBT’s
IGBT’s turn-on
turn-on signal
signal
according to the picture 3. Is it good?
YES:: replace
YES replace the board PB223 (INT-R). Go to step #8
NO:: replace the faulty IGBT and the
NO the driver board
8. After having substituted the component is the problem solved?

YES:: END
YES
NO:: replace the board PB249 (D-CPU-RC)
NO
2.3 A3 – RECTIFIER FUSE

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

2.
2.3.
3.1
1. Check the rectifier input fuses. Are they OK?
YES:: go to step #2
YES
NO:: replace the broken fuse(s)
NO
2. Check the connection between the auxiliary contact of the fuses and the connector M9
of the board PB223 (INT-R). Is it OK?
YES:: go to step #3
YES
NO:: re-connect or
NO or replace the interconnection
interconnection cable
cable
3. Check the status of the

the pins
pins 1-2 of M9 in the board INT-R. Is the contact closed?
YES:: go to step #4
YES
NO:: replace the faulty fuse indicator(s)
NO indicator(s) on the protection fuse(s)
4. Connect the software “WRC Monitor” and check the alarm Fuse Blown.
Blown. Is it active?
YES:: go to step #5
YES
NO:: go to step #6
NO
5. Check the connection between the connector CN5 of the

the board INT-R and CN2 of the
board D CPU RC. Is it good?
YES:: replace
YES replace the board PB249 (D-CPU-RC)
W43
YES:: go to step #7
YES
W38
YES:: replace
W33
2.4 A4 – THER
THERMAL
MAL IMAGE
This alarm normally indicates that the UPS thermal protection has stopped the inverter.
The output current transformers measure an output current exceeding the nominal output
current (see the alarm A14 – Overload). The microprocessor
microprocessor starts to
t o calculate the energy pulse
2
I t. As this pulse reaches the 100% the inverter is stopped for 30' and the load is transferred to
the bypass.
2.
2.4.
4.1
1. Measure the UPS output current and compare the measure with the reading on the
UPSTest screen (or front panel). Are the values shown equal to those measured?
YES:: go to step #2
YES
NO:: replace the board PB004
NO PB004 (INV-AV-3F) and re-adjust
re-adjust the output current rea
reading
ding
with the UPSTest (see 3.1.2). Go to step #3
2. Is the alarm A14 - Overload

Overload present? (The output current exceeds the UPS nominal
current)
YES:: the overload
YES overload is still present. Reduce the load.
NO:: the overload has
NO has finished and the load is still supplied
supplied by by-pass.
by-pass.
3. Repeat the step #1. Are the values shown equal to those measured?
Issued 13/04/07 JUD409401 7 of 26

YES: END.
YES: END. Check that the load doesn’t exceed the nominal load.
NO:: replace the I/S-CL
NO
2.5 A5 – AC/DC FAULT

This alarm normally indicates that the inverter input DC voltage is beyond the limits
programmed for the correct operation of the inverter. These limits can be checked on the
UPSTest software.
The measure of the DC voltage comes from the board PS-MIS (PB228), connector CN1, to
the connector CN4 of the board I/S-CL. The measure can be checked with a multimeter or a
oscilloscope between the analog ground the diode D23 (K).
2.
2.5.
5.1
1. Open the battery breaker BCB and measure the inverter input voltage. Is it within the
limits shown by the following table?
Batte
Battery
ry ce
cells
lls Minimu
inimumm His
iste
tere
resys
sys Maximum
ximum Histe
isteresys
resys
300 496 Vdc 660 Vdc 750 Vdc 730 Vdc
YES: go to step #2
YES:
NO:: check for the alarm
NO alarm A2 – charger fault;
fault; follow the procedures
procedures described
described at 2.2
2. Check the measure
measure of the DC voltage on the test
test software
software and adjust it by the TVBA
command. Does the measure change?
YES:: go to step #3
YES
NO
3. Put the unit in

in manual
manual by-pass (or switch
switch itit off if allowed)
allowed) and switch it on again. Is the
measure correct?
YES:: END
YES
NO:: replace the board PS-MIS (see procedure
NO procedure at 3.1.6).
3.1.6). Go to step #4
4. After replacing the board PS-MIS, is the measure correct?

YES:: END
YES
NO
2.6 A6 – INPUT WRONG SEQUENCE

This alarm normally indicates that the rectifier input phase sequence is wrong. The signal,
generated by the board D-CPU-RC (PB249) is sent to the board PB223 through the flat-cable
W38 (CN11 PB249  CN14 PB223) and acquired by the inverter microprocessor card PB003
(I/S-CL) through the wire W33 (M11 PB223  M2 PB003).
2.
2.6.
6.1
1. Check the input phase sequence (L1L2L3). Is it OK?
YES:: go to step #2
YES
NO:: re-connect correctly the cables
NO
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence.
sequence. Is it
active?
YES:: replace the board PB249 (D-CPU-RC)
YES
NO:: go to step #3
NO
Issued 13/04/07 JUD409401 8 of 26

YES: go to step #4
YES:
W38
YES:: replace
W33
2.7 A7 – BCB OPEN

This alarm indicates that the battery circuit breaker is open. This signal comes from the
battery circuit breaker auxiliary contact to the I/S-CL M3 pins 7-8.
2.
2.7.
7.1
1. Is the battery breaker BCB open?
YES:: END
YES
NO:: go to step #2
NO
2. Check the connection between the auxiliary contact of the external battery switch and
the terminals Bac1-Bac2 in the UPS. Is it OK?
YES:: go to step #3
YES
NO:: re-connect or
NO or replace the interconnection
interconnection cable
cable
3. Check the status of the pins 7-8 of M3 in the I/S-CL

I/S-CL board. Is the contact closed?
YES:: replace
NO:: replace the BCB auxiliary
NO auxiliary contact
2.8 A8 – BA
BATTER
TTERY
Y DISCH
DISCHARGE
ARGE
This alarm is generated by the software and indicates that the battery is discharging; it
always occurs together with the alarm A1 – mains fault.
2.
2.8.
8.1
YES:: follow the procedures described at 2.1
YES
NO:: END. There’s a mains
NO mains failure and the inverter draws
draws energy from the battery
2.9 A9 – BA TTERY AUTONOMY END

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

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

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

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

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

This alarm indicates that the inverter output voltage is outside the tolerance values (see
UPSTest screen for details). This alarm generally occurs together with other alarms.
2.
2.13
13.1
.1 Troubl eshooti ng p rocedur e
1. Is the inverter ON? (red LED’s on the driver board ID ON)
YES:: go to step #2
YES
NO:: go to step #4
NO
2. Measure the inverter output voltage (upstream the inverter static switch) and compare
the measure with the reading on the UPSTest screen (or front panel). Are the values
shown equal to those measured?
YES:: go to step #3
YES
NO:: re-adjust the inverter
NO inverter voltage reading
reading with the UPSTest
UPSTest software (see 3.2.1).
3.2.1). Go
to step #4
3. Is the inverter output voltage over the higher limit?

YES:: replace the board PB004 (INV-AV-3F)
YES
NO:: check the UPS settings
NO settings on the I/S-CL (nominal pow
power,
er, nominal voltage)
voltage)
4. Switch off the inverter, switch it on

on again
again and check the measures on the UPSTest
screen. Are the values shown equal to those measured?
YES:: END
YES
NO
5. Is the alarm A4 – Thermal image present?

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

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

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

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

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

10. Is the alarm A24 – Current stop present?

YES:: follow
YES follow the procedure described at 2.24.1
NO:: go to step #11
NO
11. In case the inverter turn-on

turn-on and off
off cyclically check for the
the alarm A25 in the alarms
history and follow the procedure described at 2.25.1.
2.14 A14 – OVERLOAD

This alarm normally indicates that load at the output of the UPS exceeds the nominal power.
The output current transformers measure an output current exceeding the nominal output
current. The alarms is activated and the thermal image protection (see the alarm A4 – Thermal
image) starts to calculate the thermal pulse.
2.
2.14
14.1
.1 Troublesho oti ng p rocedur e
1. Measure the output current with a current clamp. Does it exceed
exceed the UPS nominal
current?
YES:: END.
YES END. A overload is present. Check and/or reduce the load.
NO:: go to step #2
NO
2. Compare the measure with the reading on the UPSTest screen (or front panel). Are the
values shown equal to those measured?
YES:: check
YES check the UPS settings on the I/S-CL (nominal power, nominal voltage)
NO board PB004 (INV-AV-3F) and re-adjust
re-adjust the output current
current reading
with the UPSTest software (see 3.1.2). Go to step #3
3. Repeat the step #2. Are the values shown equal to those measured?
YES:
YES
NO: : replace
NO: END. Check
END. that the load doesn’t exceed the nominal load.
the I/S-CL
2.15 A15 – BYPASS FAULT

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

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

Picture 1 – Signal on cathode of D65 (D64-D59)
2.
2.15
15.1
YES: go to step #2
YES:
NO:: check the UPS supply line
NO
2. Check the bypass fuses. Are they OK?

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

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

YES
NO: go to step #7
NO:
7. Measure the by-pass input frequency. Is it within the tolerance limits?
YES
NO:: check and/or adjust the input frequency window
NO
2.16 A16 – BYPASS FEED LOAD

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

2.
2.16
16.1
1. Is the alarm A13 present?
YES:: follow
NO:: go to step #2
NO
2. Is the alarm A22 present?

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

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

This alarm indicates that the load is blocked on the emergency line (by-pass) after 6
transfers to by-pass in 2 minutes. Normally it occurs when there are several heavy load steps
(like motors starting, printers and so on) in a very short time. In this case, as the current
exceeds two times the nominal value, the short circuit monitor (see alarm A25 – Short circuit)
transfers automatically the load to by-pass, and after a few seconds the inverter takes back the
load. If this situation happens six times in two minutes, the UPS protects itself by blocking the
load to by-pass and the alarm is activated. This condition can be reset by sending the command
RESE000 or by resetting the UPS from the special menu in the front panel.
2.
2.17
17.1
1. Are there heavy load steps exceeding two times the nominal output current?
YES:: check and/or reduce the load
YES
NO:: go to step #2
NO
2. Open SBCB (by-pass line breaker), turn on the inverter only and check the output
voltage waveform (downstream the inverter static switch) on the three phases. Is it
sinusoidal?
YES:: go to step #3
YES
NO: replace the thyristor

NO: thyristor relevant to the phase
phase where the waveform is wrong
wrong
3. With the inverter ON and SBCB open, measure the voltage upstream the by-pass
thyristors. Is it equal to zero?
YES:: replace
NO:: replace the thyristor relevant
NO relevant to the phase where the wave
waveform
form is not zero (the
thyristor is in short circuit).
2.18 A18 – MANUAL B YPASS CLOSED

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

When MBCB is closed together with OCB the electronic protection turn off the inverter
generating the alarm A13.
2.
2.18
18.1
1. Is the manual by-pass breaker MBCB closed?
YES:: END
YES
NO:: go to step #2
NO
2. Check the status of the pins 13-14 of M3

M3 inin the
the I/S-CL
I/S-CL board. Is the contact open?
YES
NO:: replace the MBCB
NO MBCB auxiliary
auxiliary contact
2.19 A19 – OCB OPEN

This alarm indicates that the UPS output circuit breaker is open. This signal comes from the
OCB circuit breaker auxiliary contact to the I/S-CL M3 pins 9-10.
2.
2.19
19.1
1. Is the output breaker OCB open?
YES:: END
YES
NO:: go to step #2
NO
M3 in the
the I/S-CL
YES
NO:: replace the OCB
NO OCB auxiliary
auxiliary contact
2.20 A20 – FANS FAILURE

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

This alarm indicates that the thermal switch on the bridge heatsink has stopped the inverter.
The thermal switch TH1 mounted on the inverter bridge heatsink is normally closed, as the
temperature exceeds 80°C the thermal switch opens. The signal comes directly from TH1 to the
I/S-CL M3 pins 15-16.
2.
2.21
21.1
1. Is the temperature of the heatsink lower than 80°C?
YES:: go to step #2
YES
NO:: go to step #3
NO
2. Check the status of the pins 15-16 of M3 in the I/S-CL board. Is the contact closed?
YES
NO:: replace the faulty
NO faulty thermal
thermal switch
switch
3. Are the cooling fans correctly working?

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

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

A16 – Bypass feeds

feeds load). This signal
signal comes directly
directly from the switch SW1 to the I/S-CL M3 pins
pins
11-12.
2.
2.22
22.1
1. Is the switch in NORMAL position?
YES:: go to step #2
YES
NO:: END; move it to NORMAL
NO

M3 in
in the
the I/S-CL
YES:: replace
NO:: replace the switch SW1
NO
2.23 A23 – EPO BUS

The UPS is equipped with two terminals (Eac1-Eac2) for connection of the remote
emergency shutdown push-button. If the remote push-button is pressed the supply to the loads
is interrupted by opening the output static switch, the alarm A23 is activated and there is no
voltage at the output of the UPS. This signal comes directly from the terminals Eac1-Eac2 to the
I/S-CL M3 pins 5-6.
2.
2.23
23.1
1. Is the EPO push-button pressed?
YES:: END. Check the reason why the button has been pressed; before pressing it
YES
again check that no danger to persons or things will be caused by the UPS re-
start.
NO:: go to step #2
NO
2. Check the status of the pins 5-6 of M3 in the I/S-CL

YES: replace
YES: replace the I/S-CL
NO:: replace EPO push-button
NO
2.24 A24 – CURRENT STOP

This alarm indicates that the maximum current monitor has detected a fault on the inverter
bridge. This protection works as follows: the hall effect transducer TA1 transmits the inverter
bridge current to the I/S-CL on the connector M1. If the current on the bridge exceeds the 250%
of the nominal current the current stop protection is activated and the inverter is switched off.
2.
2.24
24.1
1. Check the IGBT’s by following the procedure described at 3.2.3, point 1 to 9.
9. Is there
any IGBT or driver (boards DR-SAT) broken?
YES:: replace
YES replace the broken components, repeat the checks and re-start the unit.
NO:: go to step #2
NO
2. Check the status of the battery. If the battery life has almost expired and its voltage
voltage
drops quickly it might cause the current on the bridge to exceed the current stop
protection during short mains failures. Are the batteries OK?
YES:: go to step #3
YES
NO:: replace the batteries
NO
3. Check the IGBT’s turn-on signal (see picture 3). Is it OK?

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

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

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

YES
NO:: END
NO
2.25 A25 – SHORT CIRCUIT

This alarm indicates that the short circuit monitor has detected a short at the output of the
inverter. This protection works as follows: the hall effect transducer TA1 transmits the inverter
bridge current to the I/S-CL on the connector M1. This signal is amp
amplified
lified on the test point TP2
and can be set at 4Vpeak at 100% load by turning the potentiometer P2. As this signal exceeds
two times the nominal output current, the current limitation starts to work and the alarm A25 is
activated. This happens if the emergency line is not available, otherwise the load is
automatically transferred to bypass. Normally the alarm A25 can be found in the alarm history,
as it is automatically reset as the short circuit is removed.
2.
2.25
25.1
YES:: check and/or reduce the load
YES
NO:: go to step #2
NO
2. Check the inverter input current waveform on test point

point TP2 (see picture 2). Is there
any spike or distortion?
YES:: replace
YES replace the inverter IGBT driver boards. Go to step #3
NO
3. After replacing the IGBT driver boards, is the waveform on TP2 correct?
YES:: END
YES
NO:: replace the POWER SUPPLY. Go to step #4
NO
4. After replacing the POWER SUPPLY, is the waveform on TP2 correct?

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

3 PCB’ S AND COMPONENTS SUBSTITUTION

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

SUBSTITUTION
TION
3.1.1 PB003 – I/S-CL
1. Check the setting of DSW1
DSW1 and DSW2DSW2 according
according to the following tables. Check
Check that they
are in the same position of the old board.
• Setting of DSW1
Dip no. Stato Descrizion e
Off Single UPS
1
On Parallel
Off Frequency 50Hz
2
On Frequency 60Hz
Off Single / Parallel
3
On Hot stand-by
4 On
On Nominal Vout
5 On 220V
4 Off Nominal Vout
5 On 120V
120V
4 On
On Nominal Vout
5 Off
Off 230V
4 Off Nominal
240V)Vout
5 Off
Off
Off TEST mode
6
On NORMAL mode
Off Buzzer DISABLED
7
On Buzzer ENABLED
Off THREE-PHASE output
8
On
• Setting of DSW2
Dip no. Stato Descrizion e

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

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

On Off Off
250 Off Off On
On On
On
300 Off Off On
On Off
2. Install the same software

software version
version (EPROM) that was installed in the old board.
board.
3. Check the setting
setting of the jumpers J1-J2-J3-J4-J5-J6-J7.
J1-J2-J3-J4-J5-J6-J7.
4. Check the setting
setting of the resistors
resistors R39-R40-R18
R39-R40-R18 (current control circuit), R66 (P
(PWM
WM
frequency) according to the following table.
UPS JUMPERS
R66 Freq PWM R Hall
(KVA) J9 J10 J100
200 6K81 + 6K81 4 KHz 47R Closed Open Closed
250 6K81 + 6K81 4 KHz 47R Closed Open Closed
300 6K81 + 6K81 4 KHz 33R* Open Closed Closed
* On the 300kVA the resistor R40 (100R) must be changed with 33R
5. Change the resistor R37 on the VCB boards (PB012);

(PB012); R37
R37 = 27K4.
27K4.
6. Measure the resistance between ground and TP2 (current protection)
protection ) and set the same
value on the new board by means of the potentiometer P2. Take into account that the
peak value of the signal between ground and TP2, adjustable by means of the
potentiometer P2, must be equal to 4V with UPS supplying 100% of load. Check the
waveform of the signal (see picture 2), and
and adjust the peak value
value according to to the
available load (load 100% Vp=4V, load 50% Vp=2V).
Picture 2 – Current signal on TP2 at 100% of load

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

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

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

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

3.1.3 PB005 – VOLT-REF-3F

1. Measure the by-pass
by-pass voltage on the three phases,
phases, connecting
connecting the multimeter
multimeter between
the neutral and the by-pass static switch (upstream).
If the values shown don’t correspond to those measured, modify the reading with the
following commands (UPSTest software):
TBFRxxx (by-pass voltage setting phase R; xxx is the value measured)
TBFSxxx (by-pass voltage setting phase S; xxx is the value measured)
TBFTxxx (by-pass voltage setting phase T; xxx is the value measured)
2. Measure the output voltage
voltage on the
the three phases; If the
the values shown don’t
don’t correspond
correspond to
those measured, modify the reading with the following command
commands s (UPSTest software):
TUFRxxx (output voltage setting phase R; xxx is the value measured)
TUFSxxx (output voltage

TUFTxxx (output voltage setting
setting phase
phase T;
S; xxx
xxx is
is the
the value
value measured)
measured)
3.1.4 PB107 – PS-SAT
1. On the μProcessor board PB003 (I/S-CL) move the DIP6 SW1 in position OFF.
2. Select the “manual” regulation mode on the μProcessor board, moving the jumper J1 on
the boards PB012 (VCB) in position 2-3.
3. Disconnect the flat cable W9 from the connector CN4 of the board PB003 (I/S-CL).
4. Connect an external 10-wire flat cable between the connector CN4 of the board PB107
(PS-SAT) and the connector CN4 of the board PB003 (I/S-CL).
5. Disconnect the connector CNB and connect the external power supply.
6. Connect a PC
PC to the serial
serial port RS232,
RS232, run the UPSTest
UPSTest software
software and press F6 to start
start
the IGBT bridge modulation (the inverter will start only if the variable VDC_OK is active).
7. Check the signal between Gate and Source of the IGBT’s according to the following
picture:
Picture 3 – IGBT turn-on signal

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

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

3.2 COMPONENTS SUBSTITUTION

3.2.1 RECTIFIER IGBT’ S
1. Change the IGBT driver
driver board(s)
board(s) and check the connection with the IGBT(s).
3. Move the external ON/OFF switch in position ON.
4. Verify the correct
correct sequence of of the pre-charge
pre-charge phase; thyristors
thyristors PS7-PS8 first (LED’s
DL1-2-3-4 of the card PB023-RTF lit steady), and then complete turn-on of the thyristor
bridge (thyristors PS7-PS8-PS9, LED’s DL1-2-3-4-5-6
DL1-2-3-4-5-6 of the card PB023-RTF lit steady).
5. Verify that the red LED’s of the boards
boards PB246 (ID-HY, IGBT drivers)
drivers) are lit steady. In this
this
condition the duty cycle of the PWM is fixed at 50%.
6. Verify the voltage waveform
waveform between
between emitter (E) and gate (G) of the IGBT’s (see picture
picture
3). If necessary modify the amplitude of the positive part of the waveform until it reaches
16V, turning the potentiometer RV1 on the board PB223 (INT-R).
8. Disconnect thethe external AC supply cable from the connector
connector M8 of the boardboard PB223
(INT-R).
9. Re-connect the AC supply cable W51 to the connector
connector M8.
M8.
10. Remove the jumper from the pins 11-12 of the connector M15 (TEST mode disabled).
11. Disconnect the connector
connector CNB from the inverter power supply board PB107 (PS-SAT).
12. Close RCB and move the external ON/OFF switch in position ON.
13. Verify the correct sequence of the pre-charge phase (see point 4 above).
14. Measure the DC voltage across the bulk capacitors and verify the value is equal to:
Vdc = Vac x 1,35 (with 400Vac the DC voltage is about 550V).
15. Verify that the IGBT’s are turned on and that
t hat the DC voltage increases up to the nominal
value.
16. Move the external ON/OFF switch in position
position OFF.
17. Open RCB and remove the external
external ON/OFF switch.
18. Re-connect the connector
connector CNB to the inverter power supply board PB107 (PS-SAT).
19. Close RCB, start-up the UPS and check the rectifier operation under load.
3.2.2 RECTIFIER BRIDGE THYRISTORS (PRE-CHARGE)
1. Re-connect carefully the component
component to the firing board.
2. Connect the external ON/OFF switch to the the connector
connector M10 of the board PB223
PB223 (INT-R)
and make sure the contact of the switch is open.
3. Close RCB
RCB and move the external ON/OFF switch
switch in position ON.
4. Verify the correct sequence
sequence of the pre-charge
pre-charge phase
phase (see 3.2.1, point
point 4).
5. Measure the DC voltage across the bulk
bulk capacitors
capacitors and verify
verify the value is equal to:
Vdc = Vac x 1,35 (with 400Vac the DC voltage is about 550V).
7. Open RCB and remove the external ON/OFF switch.
3.2.3 INVERTER BRIDGE IGBT’ S
1. Change the IGBT driver
driver board(s)
board(s) and check the connection with the IGBT(s).
2. On the μProcessor board (PB003 – I/S-CL) move the DIP6 SW1 in OFF position (TEST
mode).
3. On the VCB
VCB boards
boards move the jumper
jumper J1 in position 2-3 (manual).
(manual).
4. Disconnect the
the flat cable W9
W9 from the connector
connector CN4 of the board PB003
PB003 (I/S-CL) and
and
connect an external 10-wire flat cable between it and the connector CN4 of the POWER
SUPPLY board.
5. Connect the external power
power supply
supply to the Power
Power Supply
Supply board, connect a PC to the UPS
and run the UPSTest software.
6. With the external
external power supply
supply the DC voltage
voltage is outside the nominal range, so the
variable VDC_OK is not active (blue). The variable can be activated changing the DC
Issued 13/04/07 JUD409401 22 of 26

voltage measure to floating voltage (within the range) sending the command TVBAxxx
where xx x is the floating voltage (TVBA680).
7. Turn on the inverter sending the command INON000
INON000,, or pressing F6.
8. Check that all the red
red LED’s on
on the driver
driver boards are
are on and
and verify the voltage waveform
waveform
between emitter (E) and gate (G) of the IGBT’s (see picture 3). If necessary modify the
amplitude of the positive part of the waveform until it reaches 16V, turning the
potentiometer P2 on the board PB107 (PS-SAT).
9. Turn off the inverter sending the command INOF000
INOF000,, or pressing F7.
10. Close RCB, start-up the inverter by sending the command INON000
INON000,, or pressing F6, and
increase the modulation by means of the potentiometer P1 on the microprocessor board.
Check that the output waveform increases regularly up to the nominal value.
11. Reduce the modulation to zero by turning back the potentiometer, send the command
INOF000,, or press F7, to turn off the inverter and open RCB.
INOF000
12. Disconnect the external power
power supply and re-connect the connector CNB to the POWER
SUPPLY board.
13. On the μProcessor board (PB003 – I/S-CL) move the DIP6 SW1 in ON position
(automatic mode).
14. On the VCB boards move the jumper J1 in position 1-2 (automatic).
15. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
16. Close RCB, start-up the UPS and check the inverter operation under load.
3.2.4 STATIC SWITCH THYRISTORS
1. Re-connect carefully the component to the firing board.
2. Check that the output waveform, relevant
relevant to the phase controlled
controlled by the thyristors that
has been substituted, is correct. Repeat this check with the load connected.
4 ON-FIEL
ON-FIELDD TEST PROCEDURES
This chapter describes the most common operating procedures used to test the various
sections of the UPS during repairing
repairing or maintenance operations.
operations.
These procedures assumes that all the power components (fuses, thyristors, cables, etc.)
are OK, no modifications have been made in the power and auxiliary circuitry and that the unit is
switched off or in manual by-pass (all the control circuits are off).
4.1 RECTIFIER
4.1.1
4.1.1 General not es on the TES
TEST
T mod e
Owing to the use of two different microprocessors inside the UPS, there exist two different
TEST modalities: one for the rectifier and one for the inverter, which is described at 4.2.1.
The TEST mode on the rectifier is enabled by closing the pins 11-12 of the connector M15 of
the board PB223 (INT-R). The condition of the contact is acquired by the microprocessor at the
start-up and only if the DC voltage is lower than 50Vdc (no AC voltage present).
The TEST mode set the duty cycle of the IGBT’s PWM at 50% and is used to check the
IGBT’s turn-on signals before the rectifier start-up.
4.
4.1.
1.2
2 Se
Setti
tti ng the re
recti
cti fier in T
TES
EST
T mode
The operation described below are carried out on the board PB223 (INT-R).
1. Disconnect the cable
cable W51 from the connector M8.
2. Connect a jumper between pins 11-12 of the connector M15.
3. Disconnect the jumper from the connector M10.
4. Connect the
the external ON/OFF switch to the connector
connector M10 and make sure the contact of
the switch is open.
5. Connect the external
external 3Ph AC supply
supply to the connector
connector M8.
M8.
Issued 13/04/07 JUD409401 23 of 26

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

frequency)
Issued 13/04/07 JUD409401 24 of 26

This waveform is compared with the reference sine-wave generated by the microprocessor
to create the IGBT’s PWM signals.
In the following steps the sine-wave generated
generated by the microprocessor
microprocessor and the IGBT’s turn-on
signals will be checked. The inverter can be turned-on only if all the software conditions are
fulfilled, so it’s necessary to change the DC voltage reading (now coming from the external
power supply) to enable the variable VDC_OK.
6. Change the DC voltage reading sending the command TVBAxxx, where xxx is the
floating voltage, and check that the command is acquired by the microprocessor
microprocessor and that
the variable VDC_OK is activated.
7. Turn-on the
the IGBT modulation
modulation by
by sending the command
command INON000
INON000 or pressing
pressing F6.
8. Place the oscilloscope probe between the analog ground and pin 7 of U2 (VCB boards),
rotate P1 of the I/S-CL board () and check that the amplitude of the generated sine-
wave increases, and then turn back P1 until the sine-wave is at zero again ().
9. Check that
that the red
red LED’s on the IGBT driver boards are
are correctly
correctly lit.
10. Verify the turn-on signal between emitter (E) and gate (G) of the IGBT’s (see picture 3).
11. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7.
12. Disconnect the external
external power supply.
13. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
After the disconnection
disconnection of the external power supply the microprocessor is reset and the DC
voltage setting, which has been modified before, is cleared, therefore the unit will show the
exact DC voltage value at the following start-up.
4.
4.2.
2.3
3 Inverter manual start-up
This procedures assumes that all the power components in the inverter bridge have been
previously checked (see paragraph 4.2.2). The inverter output voltage is increased starting from
zero to check the behaviour of the components (AC capacitors, fans, etc.) at reduced AC
voltage after having identified a failure in the inverter section.
1. Choose thethe inverter TEST mode, moving

moving the DIP6
DIP6 SW1 in position OFF in the I/S-CL
board.
2. Select the “manual” voltage regulation, moving the jumper J1 on the VCB boards in
position 2-3. This setting disable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the I/S-CL board.
3. Close RCB and supply the unit. After some seconds the front panel will show all the
alarms present at that moment.
4. Turn-on the
the IGBT modulation
modulation by
by sending the command
command INON000
INON000 or pressing
pressing F6.
5. Verify that, after
after some seconds,
seconds, the inverter
inverter static switch
switch closes by checking the green
LED’s in the firing boards 2SCR FIR.
6. Rotate P1 of the I/S-CL board () and increase the inverter output voltage. Check that
the sine waves are present downstream the inverter static switch and that the shape is
correct.
7. Place the oscilloscope
oscilloscope probe
probe between the analog ground
ground and the test point TP2 and
and
check that the shape of the inverter bridge current is correct (see picture 2).
8. Rotate P1 of the I/S-CL board () to set the modulation signal
signal to zero.
9. Turn-off the IGBT modulation
modulation by sending the command
command INOF000 or pressing
pressing F7.
10. Open RCB and switch off the unit.
4.
4.2.
2.4
4 Inverter automatic start-up
This procedures follows the previous one and it’s used to check the correct operation of the
inverter with the voltage loop closed.
Issued 13/04/07 JUD409401 25 of 26

1. Choose the inverter TEST mode, moving moving the DIP6 SW1 in position
position OFF in in the I/S-CL
board.
2. Select the “automatic”
“automatic” voltage
voltage regulation,
regulation, moving the jumper
jumper J1 on the VCB boardsboards in
position 1-2. This setting enable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the VCB board.
3. Close RCB and and supply the unit.
unit. After some seconds
seconds the front panel w will
ill show all the
alarms present at that moment.
4. Turn-on the IGBT modulation
modulation by sending thethe command
command INON000 or pressing
pressing F6.
5. Verify that the inverter
inverter output voltage
voltage increases
increases up to the nominal
nominal value.
value. If necessary
adjust it by rotating () the potentiometer P1 of the VCB board.
6. Verify that, after some seconds,
seconds, the inverter
switch closes by
by checking the green
7. Place the oscilloscope
oscilloscope probe
probe between the analog ground
ground and the test point TP2 and and
check that the shape of the inverter bridge current is correct (see picture 2).
8. Turn-off the IGBT modulation
modulation by sending
sending the
the command
command INOF000 or pressing
pressing F7.
9. Open RCB and switch off the unit.
4.3 STATIC SWITCH

4.
4.3.
3.1
1 Che
Check
ck of the redundant suppl y
The VOLT-REF board provides a redundant supply for the static switch control logic, so that
the by-pass static switch is supplied even when the microprocessor is off (POWER SUPPLY
board not supplied).
1. Close the by-pass circuit

circuit breaker
breaker SBCB and
and check that
that the LED L1 in the SCB board is
correctly lit (green).
2. Verify that, after some seconds,
seconds, the by-pass
by-pass static switch
switch closes by
by checking the
the red
4.
4.3.
3.2
2 Commut ation tests
The commutation tests are useful to check the correct operation of the static switch.
1. Start-up the inverter

inverter in automatic mode
mode (see procedure
procedure at 4.2.4) and verify that the
inverter static switch closes.
2. Close SBCB, waitwait for the status
status S6 – BYPASS
BYPASS OK is activated.
activated.
3. Measure with a multimeter the voltagevoltage difference between the by-pass
by-pass input and the
inverter output and verify that it doesn’t exceed 20Vac. The inverter is now synchronised
with the by-pass.
4. Move the NORMAL-BYPASS
NORMAL-BYPASS switch SW1 in by-pass position position and verify
verify that the load
load is
transferred to the by-pass static switch. Then move it back and verify that the load is
supplied again by the inverter.
5. Repeat the previous steps
steps and verify that at the sixth time the load remains supplied
supplied by
6. the by-pass
Reset and thecondition
the blocking alarm A17by–sending
Retransfer
theblocked
commandis activated.
RESE000 or entering the special
menu in the front panel.
Issued 13/04/07 JUD409401 26 of 26

UPS Test Soft ware
UPS TEST SOFTWARE
Index
1. INTRODUCTI
ON.......................
...........................
..........................
...........................
................................. 3
...................

2. TEST AND MON
MONITORIN
ITORING
GSSOFTWARE
OFTWARE .............
..........................
..........................
...................
...... 3
2.1 SOFTWARE
SOFTWARE INSTALL
INSTALLATION...........
ATION......................
......................
......................
......................
...............................4
....................4
2.2 SERIAL PORT CONF

CONFIGURATION
IGURATION............
.......................
......................
.......................
.................................4
.....................4
2.3 UPS TEST PANEL....................

PANEL...............................
.......................
.......................
......................
......................
...........................5
................5
2.3.1 MEASURES.........................
MEASURES.....................................
.......................
......................
......................
.......................
.........................6
.............6
2.3.2 UPS DATA ..........

......................
.......................
......................
......................
.......................
.......................
..............................6
...................6
2.3.3 VARIAB LES ...........

.......................
.......................
......................
......................
......................
......................
...........................7
................7
2.3.4 OUTPUTS
OUTPUTS ...........
.......................
.......................
......................
......................
.......................
.......................
..............................7
...................7
2.3.5 INPUTS
INPUTS ...........
.......................
.......................
.......................
.......................
.......................
.......................
.................................7
......................7
2.3.6 AL ARMS A ND STATUS

STATUS.............
..........................
..........................
.........................
......................... ............ 8
.........................
2.3.7 ACTIVE K EYS ............

.........................
..........................
..........................
..........................
.........................
......................... ..8
...............8
2.3.8 GAUGES ..........

.....................
......................
......................
......................
......................
.......................
..................................8
......................8
2.3.9 CONTROLS
CONTROLS ..........
.....................
.......................
.......................
......................
.......................
.......................
............................8
.................8
2.3.10 PARALL
PARA LLEL
EL ...........
......................
......................
......................
......................
.......................
.......................
.........................8
..............8
BOOST OPERATION ...........

......................
......................
.......................
.......................
......................
......................
..........................8
...............8
2.4 SERIAL
SERIAL MESSAGES FOR PERS
PERSONALISA
ONALISATION
TION AND SETTING...................9
SETTING...................9
2.4.1 BYPASS ...........

......................
.......................
.......................
......................
......................
.......................
...............................10
...................10
2.4.2 OUTPUT
OUTPUT ...........
......................
.......................
.......................
......................
......................
.......................
...............................10
...................10
2.4.3 INVERTER
INVERTER ...........
......................
......................
......................
......................
......................
......................
.............................10
..................10
2.4.4 BA TTER
TTERY
Y ...........
......................
......................
.......................
.......................
......................
.......................
.............................10
.................10
2.4.5 BA TTER
TTERY
Y TEST ..........
.....................
......................
......................
......................
......................
................................10
.....................10
Issued 13/04/07 JUD409402 1 of 12

UPS Test Soft ware
2.4.6 BOOST CHARGE ..........

......................
.......................
......................
......................
.......................
............................ 10
................
2.4.7 GENERAL
GENERAL COMM
COMMANDS
ANDS ..........
......................
.......................
......................
......................
............................ 11
.................
2.4.8 IDENTIFICATION......
IDENTIFICATION.................
.......................
.......................
......................
.......................
................................. 11
.....................
2.4.9 TIMER SETT

SETTING............
ING.......................
......................
......................
......................
......................
............................. 12
..................
2.5 HYSTORY
HYSTORY OF AL ARMS ...........
......................
......................
......................
......................
......................
......................... 12
..............
2.6 SHORTCUT
SHORTCUT KEYS
KEYS...........
......................
......................
.......................
.......................
......................
................................. 12
......................
Index
Index of pictures
Picture 1 – RS232 connection

connection cable
cable ............................................................................................................ 3
............................................................................................................
Picture 2 – Communication configure

configure panel................................................................................................. 4
panel.................................................................................................
Picture 3 – Modem setup.............................................................................................................................. 5
setup..............................................................................................................................
Picture 4 – UPS Test screen ........................................................................................................................ 5

screen ........................................................................................................................
Issued 13/04/07 JUD409402 2 of 12

UPS Test Soft ware
1. INTRODUCTION
The monitoring and test software of the UPS, UPS-Test allows, by means of RS232
connection, to control all the measures and status of the equipment and to carry out settings
and modifications of the UPS configuration.
2. TEST A ND MONITORING SOFTWARE

The UPS-Test software is connected through the RS232 serial port of the PC to the RS232
serial of the UPS. The RS232 connectio
connection
n cable is built according
according to the picture 1.
Picture 1 – RS232 connection cable
Issued 13/04/07 JUD409402 3 of 12

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

From the menu configure it is possible to configure the serial port RS232 for the connection
to the UPS.
Picture 2 – Communication configure panel
Port adress: Set the serial COM where the UPS is connected.
connected.
Baud rate: Set the speed of the serial communication. Set to 2400 baud.
Stop bits: Select “1”.
Data
Da ta bits : Select “8”.
Parity: Select “None”.
Flow Control: Select “None”.
Connection: Select “Local” to connect the PC to the UPS. Select “Remote” to connect the
PC to the UPS trought a mode connection.
Syncro_Key: Select “No”.
Issued 13/04/07 JUD409402 4 of 12

UPS Test Soft ware
From the “Modem” button it is possible to set the parameter for remote connection.
Picture 3 – Modem setup

Init. string: Set the initialization string for the modem.
Dial string: Set the command string for the modem to dial the UPS.
Hang upp string: Set the command string for the modem to close the connection.
2.3 UPS TEST PANEL
All the following paragraphs, describing the
t he software functions, refer to the picture 4, where
the UPS Test screen is shown.
Picture 4 – UPS Test screen
Issued 13/04/07 JUD409402 5 of 12

UPS Test Soft ware
2.3.1 MEASURES
On the area “Measures” all
all the analog measurements
measurements inherent to the UPS are shown, in the
following order:
BYP_V_R  Emergency bypass voltage Ph. R (V)

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

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

INV_V_S  Inverter voltage Ph. S (V)
INV_V_T  Inverter voltage Ph. T (V)
ACDC_V  Battery voltage (V)

DC_CUR  Inverter Input current (A)
IB_BOO  Battery Recharging

Recharging Current
Current ( A )
F_BYP  Emergency bypass frequency (Hz)
F_INV  Inverter frequency (Hz).
In the area below, the field “ NUMBER

NUMBER”” represents the serial n° of the equipment and the
field “ VER. SW.” represents the revision of the UPS control software installed.
On the area “ TX Check”
Check” the transmission control indicator is represented. If the connection
is correct the figures increases cyclically up to 250 automatically.
2.3.2 UPS DATA
The area titled “ UPS data” represents the relevant characteristics and
and settings. The first 7
lines contain the nominal values for:
POT_NOM  UPS nominal power (kVA).

VOLT_NOM  UPS nominal output voltage (V).
CURR_NOM  UPS nominal output current (A).
VDC_NOM  Battery nominal voltage (V).
IDC_NOM  Inverter nominal input current at full load (A).
BAT_TYP  Battery capacity (Ah).
AUT_NOM  Nominal autonomy (min).

The following 4 groups represent the limit values (for the voltage to be declared available)
and the histeresys
histeresys for:
BYP  Emergency bypass (V) #1

INV  Inverter Output (V) #2
OUT  UPS Output (V) #3
VDC  Inverter input (V) #4
The following 3 groups represent the limit values (for the frequency to be declared in
tolerance) and
and the histeresys for emergency bypass
bypass as follows:
follows:
Issued 13/04/07 JUD409402 6 of 12

UPS Test Soft ware
FREQ  Emergency bypass nominal frequency (Hz)

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

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

on is active too
SSW_ON  When active the command i nverter SSW on is on is active too
IOK  If active the inverter is ready to supply the load
ROK_X  If active the bypass is in tolerance (ROK = RMSOK+FROK)
O_LOAD  If active an overload
overload has
has stopped the inverter
HITE  If active an over temperature (thermal
temperature (thermal protection) is active too
FROK  If active the eme
emerg.
rg. byp . frequency is in tolerance (see limit group #5)
RMS_OK  If active the eme
emerg.
rg. by p. vol tage is in tolerance (see limit group #1)
COK  If active the UP
UPSS outpu t v oltage is in tolerance (see limit group #3)
VUOK  If active the Inverter output volt age is in tolerance (see limit group #2)
SYNCOK  If active the inverter is synchronized with the emergency bypass
I_OVER  If active an overload
overload (output
(output current > nominal) is active too
IMTERM  If active the thermal image counter (time
(time vs current) is active too
VDC_OK  If active the Inverter input vol tage is in tolerance (see limit group #4)
2.3.4 OUTPUTS
The area titled “Outpus” represents the relevant digital outpus
outpus of the UPS. The meaning
meaning of
each variable is described below:
COK active the UP

 If UPS
S output volt age is in tolerance (see limit group #3)
BY_BL  When active the load is bloc ked on the emergency
emergency byp ass
IFL  When active the inverter SSW is closed
CONAC  When active the PWM of t he
he inverter IGBT bridg e is on
RESET_RITR_BL  When active the BY_
BY_BL
BL condi tion is reset
R3_INV_FEED  When active relay Inv. Feeds Load is
Load is active too (ARC card)
card)
R4_BYP_FEED  When active relay Bypass Feed Load is
Load is active too (ARC card)
R5_LOW_BATT  When active relay Low Battery is
Battery is active too (ARC card)
card)
R6_MAINS_FAU  When active relay Mains Fault is
Fault is active too (ARC card)
2.3.5 INPUTS
The area titled “Inputs” represents the relevant
relevant digital inputs
inputs of the UPS. The
The meaning of
each variable is below described:
MBY_CLOSE  When active the MBCB (manual bypass) is closed

closed
EPO_BUS  When active the EPO (emergency power off) is not active
BO_BUS  When active the BCB (battery breaker) is open
BYP_SW (FUSE)  When active the Bypass Switch (commutation test) is active
TERMO_SW  When active the Thermal
Thermal switc h (bridge protection) is active
OCB  When active the OCB (output breaker) is closed
MCS  When active the IGBT’s desaturation protection is active
IGBT’s
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UPS Test Soft ware
MRR  When active Ma

Mains
ins f ault signal (from
signal (from the rectifier) is not active
RECT_FAIL  When active Re
Rectif
ctif ier fault
fault sign
sign.. (from the rectifier) is not active
ERR_SC  When active Input wrong seq. sign. (from
sign. (from the rectifier) is not active
BF_RECT  When active Blown fuse sign. (from
sign. (from the rectifier) is active
PUL_UP  When active the up arrow
arrow key
key on
on the front panel is pressed
PUL_DOWN  When active the down arrow
arrow key
key on
PUL_ENTER  When active the enter key
key on
PUL_ BUZZ  When active the buzzer key
key on
PUL_RESET  When active the reset
reset key on the front panel is pressed
2.3.6 AL
ALARMS
ARMS AND STATUS
On the areas named “Alarms” and “Status”, the 25 alarms and 6 operating status are
represented.. For a detailed explanation of them, see the Operating Manual.
represented
2.3.7 ACTIVE KEYS
The push button “Dip Sw” visualizes the mapping of the dip switches for configuration on
the μP board (see foregoing paragraphs).
By clicking on the relevant country on the flags
flags area
area the language on the display of the UPS
can be changed.
2.3.8 GAUGES
The two gauges located under the third
t hird column represents the following values:
EN. CAR  Storedenergy in the battery as % of the total

ACCUMU  Thermal image progress as % of the total (100 %  inverter stopped)
2.3.9 CONTROLS
The area above the flags contains the following control parameters:
FEFO  Must be 180
KF_BY  Must be between 800 and 900
KF_OU  Must be between 800 and 900
2.3.10 PARALLEL
If the UPS is working in parallel mode the relevant area “ MAST MASTER”
ER” under the second
“ Par. Data” are active. For the description of the relevant functions
column and the active key “Par.
refers to the Parallel Redundant Operating Manual.
BOOST OPERATION
If the Boost function is active, the push button “BOOST“ visualizes the parameter of the
Boost Operation
IB_TR  Battery current limit for Floating to Boost Charge ( A )

IB_RT  Battery current limit for Boost to Float Charge ( A )
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UPS Test Soft ware
2.4 SERIAL MES

MESSAGES
SAGES FOR PERSONAL
PERSONALISATION
ISATION AND SETTING
WARNING
Before sending any message insure that the computer writes with capital letters (CAPS). All
commands consist in 4 letters and 3 numbers LLLLXXX.
After having sent a message, wait for an acoustic confirmation signal (BEEP) before sending
new strings. If the signal does not arrive it means that the operation has had a negative result,
so the last message must be repeated.
VERY IMPORTANT
The usage of these messages is recommended to specialized personnel only.
Don’t fo rget to send the com mand MEEE
MEEE00
000
0 to st ore the variations on t he UPS
UPS memory.
Issued 13/04/07 JUD409402 9 of 12

UPS Test Soft ware
2.4.1 BYPASS
TBFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TBFSXXX
TBFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TBFTXXX
TBFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.2 OUTPUT
TUFRXXX
TUFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TUFSXXX
TUFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TUFTXXX
TUFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
ZCFR000
ZCFR000 phase R zero current (for UPS 1Ph and 3Ph)
ZCFS000
ZCFS000 phase S zero current (only for UPS 3Ph)
ZCFT000
ZCFT000 phase T zero current (only for UPS 3Ph)
TCFRXXX
TCFRXXX (XXX=005/999) phase R current (for UPS 1Ph and 3Ph)
TCFSXXX
TCFSXXX (XXX=005/999) phase S current (only for UPS 3Ph)
TCFTXXX
TCFTXXX (XXX=005/999) phase T current (only for UPS 3Ph)
2.4.3 INVERTER
ZIFR000
ZIFR000 phase R zero voltage (for UPS 1Ph and 3Ph)
ZIFS000
ZIFS000 phase S zero voltage (only for UPS 3Ph)
ZIFT000
ZIFT000 phase T zero voltage (only for UPS 3Ph)
TIFRXXX
TIFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TIFSXXX
TIFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TIFTXXX
TIFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.4 BATTERY
TVBAXXX
TVBAXXX (XXX=100/600)
(XXX=100/600) Voltage
TCBAXXX
TCBAXXX (XXX=010/999)
(XXX=010/999) Current
TYBAXXX
TYBAXXX Battery type (i.e.: batt. 24Ah = TYBA024)
TAUTXXX
TAUTXXX (XXX=002/999)
(XXX=002/999) Nominal auton. (i.e.: aut. 20’ = TAUT020)
LOBA XXX
XXX (XXX=100/600)
(XXX=100/600) Low battery level
BATT000 Forces to the 100% battery autonomy

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

TCRBXXX
TCRBXXX (XXX=010/999)
(XXX=010/999) battery current for boost adjustment
TBTRXXX
TBTRXXX (XXX=000/999) current limit for floating to boost
TBRTYYY
TBRTYYY (XXX=000/999) current limit for boost to floating
BOST000
BOST000 boost charge ON
ZCRB000
ZCRB000 zero battery current for boost charge
Issued 13/04/07 JUD409402 10 of 12

UPS Test Soft ware
2.4.7 GENERAL COMMANDS

TFFRXXX
TFFRXXX (XXX=010/060)
(XXX=010/0 60) frequency window: for values see (1)
(1)
TVLX000
TVLX000 fast voltage monitor
MEEE000 Store the value in E2PROM
REHI000 reset HISTORY
BUZZ000 BUZZER quieting
RESE000 reset UPS
INON000 on inverter
INOF000 off inverter
PHASXXX (XXX=000/999) set the phase shifting between inverter and
the bypass normal setting.
Single unit
PHAS270 set phase = 2700
Parallel unit
PHAS400 set phase = 4000
2.4.8 IDENTIFICATION
CNAMXXX
CNAMXXX (XXX=000/005)
(XXX=000/005) Set the name of the unit
CLANXXX
CLANXXX (XXX=000/005)
(XXX=000/005) UPS language
XXX = 000 (Italian)

XXX = 001 (German)
XXX = 002 (French)
XXX = 003 (English)
XXX = 004 (Portuguese)
XXX = 005 (Spanish)
Issued 13/04/07 JUD409402 11 of 12

UPS Test Soft ware
2.4.9 TIMER SETTING

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

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

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

Key Description
Description
F1
F1 After the READ000 command allows to read the history on the computer.
F2
F2 Sends RESE000 command.
F3
F3 Sends all the zeroes to the UPS.
F4
F4 Sends E2PROM data storing command : MEEE000.
F5
F5 Sends the buzzer quieting command : BUZZ000.
F6
F6 Sends the inverter ON command : INON000.
F7
F7 Sends the inverter OFF command : INOF000.
F8
F8 Adjusts the limits for the bypass and the output voltage : TVLX000.
F9
F9 Adjusts the limits for the frequency at +/- 4% : TFFR040.
Issued 13/04/07 JUD409402 12 of 12

“ WR
WRC
CMMonitor
onitor ” Software Ma
Manual
nual
“ WRC MON
MONITO
ITOR”
R” SO
SOFTW
FTWARE
ARE MANUAL
Index
1 INTRODUCTIO
INTRODUCTION.............
N..........................
..........................
...........................
...........................
...........................
................ 3
2 SYSTEM REQUI
SYSTEM REQUIREMEN
REMENTS
TS ..........................
........................................
............................
.......................
......... 3
3 INSTALL ATION OF THE SOFTWARE
SOFTWARE .........................
......................................
.....................
........ 4

4 COLLEGAMENTO
COLLEGAMENTO DEL PC AL
ALL’
L’UPS
UPS ....
........
.........
.........
........
.........
.........
.........
.........
........
........
.... 6

4.1 INSTALL
INSTALLATION
ATION OF THE USB DRIVE
DRIVERS
RS ...........
......................
......................
.......................
.......................6
...........6
5 WRC MONITOR.........
MONITOR.......................
...........................
..........................
...........................
...........................
...................
...... 7
5.1 TOOLBA
TOOLBARR ............
.......................
......................
.......................
.......................
.......................
.......................
.......................
.......................
............7
.7
5.1.1 COM set
setti
ti ng
ngss ...........
......................
......................
......................
......................
.......................
.......................
......................
..............8
...8
5.1.2 Langu
Lan guage
age set
setti
ti ng ...........
.......................
.......................
......................
.......................
.......................
......................
.................8
......8
5.2 FRAME “ AL ARMS” ..........
.....................
......................
.......................
.......................
......................
......................
......................
.............9
..9
5.3 FRAME “ STATUS” ..........

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

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

- Monitor 17” (or better)
- Graphic resolution 1280x1024
-
CD-Rom 24x or faster
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“ WR
WRC
CMMonitor
Manual
nual
3 INSTALL ATION OF THE SOFTWARE

SOFTWARE
Before installing the software, make sure that no older version is already installed on
the computer. Otherwise remove the older version by using the control-panel of
windows for installing and removing software.
Insert the CD into the CD-drive and launch “setup.exe”. The following screen should
appear:
Picture 1 – Start of the installation
Click on the “Next”-button to proceed.
Issued 13/04/07 JUD409403 4 of 10

“ WR
WRC
CMMonitor
Manual
nual
If the software has been installed successful the following message appears:
Picture 2 – End of the installation
Click the “Finish” button to end the procedure.
Issued 13/04/07 JUD409403 5 of 10

“ WR
WRC
CMMonitor
Manual
nual
4 COLLEGAMENTO
COLLEGAMENTO DEL PC AL
ALL’
L’UPS
UPS
The connection of the PC to the UPS can be carried out only with the additional
board PB213 (“SLOT-SER”).
Picture 3 – PB213-SLOT-SER
Connect the connector CN1 of the PB213 to the connector CN7 of the board PB249
(D-CPU-RC) through a 10-pole flat-cable:
Picture 4 – PB185 CN7
Now the computer can be connected to the UPS through the RS232 port ( DB9
female connector CN2 on the board PB213) or the USB interface (connector USB-Type
B, CN3 of the board PB213).
4.1 INSTALL
INSTALLATION
ATION OF THE USB DRIVE
DRIVERS
RS
On the CD a directory named “USB
“USB Drivers”
Drivers” consist of the necessary driver for UPS-
communication.
For installing the driver please use the procedure “Installing new hardware” in the
WINDOWS-control panel.
Issued 13/04/07 JUD409403 6 of 10

“ WR
WRC
CMMonitor
Manual
nual
5 WRC MONITOR
Upon the software start-up, the following window is shown:
Picture 5 – Main window
All the elements of the main window are described

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

(see par. 5.1.2).
Exit: Quit the program
Issued 13/04/07 JUD409403 7 of 10

“ WR
WRC
CMMonitor
Manual
nual
5.1.1
5.1.1 COM sett
settin
ings
gs
Clicking on the button “COM settings” opens the window related to the settings of the
serial communication port.
Picture 7 – COM setting

The communication port can be changed selecting the desired port and pressing the
button OK.
5.1.2
5.1.2 Langu age sett
setting
ing
Clicking on the button “language” opens the window related to the settings of the
language of the software.
Picture 8 – Language setting
The language can be changed selecting the desired language and pressing the
button OK.
Issued 13/04/07 JUD409403 8 of 10

“ WR
WRC
CMMonitor
Manual
nual
5.
5.2
2 FR
FRAME
AME “ ALARMS
ALARMS””
The frame “Alarms” signals with red LED’s the presence of alarms in the UPS:
Picture 9 – Frame “Alarms”
5.3 FRAME “ STATU

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

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

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

TEMPER
PERATURE
ATURE””
The frame “temperature” shows the temperature of the battery and the UPS.
Picture 13 – Frame “Temperature”
Issued 13/04/07 JUD409403 10 of 10

Parallel
Parallel Redundant System - Operating Ma
Manual
nual
PARAL
PARA L L EL REDU
REDUNDANT
NDANT SYST
SYSTEM
EM - OPE
OPERATING
RATING
MANUAL
Index
INTRODUCTI
INTRODUCTION
ON..............
...........................
...........................
...........................
...........................
...........................
.....................
........ 3
1. PARALLEL
PARAL LEL RED
REDUND
UNDANT
ANT SYSTE
SYSTEM
M TYPO
TYPOLOGY
LOGY .........
.............
........
.........
.........
......
.. 3
2. PARTS CONSTITUTIN
CONSTITUTING
G THE SYSTEM
SYSTEM .........................
......................................
...................
...... 4
3. OPERATING
OPERATING COND
CONDITION.......
ITION....................
..........................
..........................
..........................
....................
....... 5
3.1 “ N” UPS NOR
NORMAL
MAL CONDIT
CONDITION
ION...........
......................
......................
......................
......................
.......................
...............5
...5
3.2 “ N-1” UPS NORMAL CONDIT
CONDITION.................
ION............................
.......................
.......................
......................
................6
.....6
3.3 MAINS FAILURE ..........
.....................
......................
......................
......................
......................
......................
.......................
...............7
...7
3.4 “ N” B
BYPASS
YPASS AVA
AVAILA
ILABL
BLEE ...........
......................
.......................
.......................
......................
......................
......................
............8
.8
3.5 “ N-1 BYPASS AVAILA BL
BLE”
E” ...........
......................
......................
......................
......................
......................
.....................9
..........9
3.6 MANUAL BYPASS ..........
......................
.......................
......................
......................
......................
......................
......................
............10
.10
4. INSTALLA
INSTAL LA TION................................
TION.............................................
...........................
...........................
.....................
........ 11

4.1 ADDITIONA
ADDITIONALL HA RDWARE ............
.........................
.........................
.........................
..........................
..........................
............. 11
4.2 POSITIONING.................................................................................................11
4.3 CONNECTIONS..............................................................................................12
4.4 INTERCONNE
INTERCONNECTION
CTIONS
S DIAGRAM ...........
......................
......................
......................
.....................
.....................13
...........13
4.5 BUS CAB
CABLE
LE ...........
......................
......................
......................
......................
......................
.......................
.......................
.....................15
..........15
5. SYSTEM
SYSTEM PERFO
PERFORMANCES......................
RMANCES....................................
...........................
........................
........... 15

5.1 OVERLOAD ...........
.......................
.......................
......................
......................
......................
......................
......................
......................15
...........15
5.2 SHORT
SHORT CIRCUI
CIRCUIT
T ...........
......................
......................
......................
......................
......................
......................
......................
...............15
....15
6. START-UP............
START-UP ..........................
...........................
...........................
...........................
..........................
......................
......... 16

6.1 TWO UPS – DIRECT START-UP ...........
.......................
.......................
......................
.......................
......................16
..........16
6.2 TWO UPS – START-UP FROM

FROM MANUAL B Y-PASS...........
......................
......................
...............16
....16
6.3 MORE THAN TWO UPS – START-UP FROM
FROM MANUAL B Y-PASS ..............16
7. MANUAL BY-PASS TRANSFER PROCE

PROCEDURE
DURE ...........................
..............................
... 17
7.1 MANUAL BY-PASS TRANSFER PROCEDUR
PROCEDURE..........
E....................
.....................
......................
.............17
..17
7.2 RE-START
RE-START FROM MANUAL BY-PASS ...........
......................
......................
......................
......................
.............17
..17
7.2.1 Two UPS – Re-start from MANUAL BYPASS.......................................17
7.2.2 More th an tw o UPS – Re-
Re-star
startt f ro
romm MANUAL B YPASS......
YPASS..........
........
........
........17
....17
Issued 13/04/07 JUD409404 1 of 18

Parallel
Manual
nual
Index
Index of pictures
Picture 1 - Block di
diagram
agram ................................................................................
.............................................................................................................................
............................................. 4
Picture 2 - “N” ups norma
normall condition............................................................................................................. 5
Picture 3 - “N-1” ups normal
normal condition..........................................................................................................
condition.......................................................................................................... 6
Picture 4 - “Mains
“Mains Failure”
Failure” ............................................................................................................................
............................................................................................................................ 7
Picture 5 - “N” bypass available.........................................................
available....................................................................................................................
........................................................... 8
Picture 6 - “N-1”bypass
“N-1”bypass available
available .................................................................................................................
................................................................................................................. 9
Picture 7 - Manual
Manual bypass.............................................................................
bypass ..........................................................................................................................
............................................. 10
Picture 8 - Positioning.........................................................................................................
Positioning.................................................................................................................................
........................ 11
Picture 9 - Connections
Connections ..............................................................................................................................
.............................................................................................................................. 12
Picture 10 - Interconnections
Interconnections diagram........................................................................................................
diagram........................................................................................................ 13
Picture 11 - Interconnection..............................................................................................
Interconnection........................................................................................................................
.......................... 14
Picture 12 - Interconnectio
Interconnection
n with BCCON – PB123 ................................................................................
...................................................................................
... 14
Picture 12 Interconnectio
Interconnection
n with BCCON PB123 ................................................................................
...................................................................................
... 14
Picture 13 - Bus cable
cable connections
connections ............................................................................................................
............................................................................................................ 15
Issued 13/04/07 JUD409404 2 of 18

Parallel
Manual
nual
INTRODUCTION
The scope of this manual is to guide the installer and the user to the correct
installation of the parallel redundant system in the chosen room.
Before rea
reading
ding this manual, the installe
installerr and the user will have to rea
read
d with
care and
and attenti on th e “ UP
UPS
S O
OPE
PERATI
RATING
NG MANU
MANUAL”
AL” to carr y-out cor rectly t he
given instructions for the single units, especially those relevant to security
according to CEI 64-8 and to 46-90 standards.
standards.
The manufacturer declines all responsibility of damages to people or things

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

Parallel
Manual
nual
2. PARTS CONSTITUTING THE SYSTEM

All the units consist of six functional components:
components:
- Rectifier (R)
- Inverter (I)
- Battery (B)
- Static Switch: Static Switch Inverter (SSI) Static bypass (SB)
- Manual bypass (MB) (on all the units or unique ad external)
- Front panel
For the description of the single parts, see: “UPS OPERATING MANUAL”
OM226002.
Picture 1 - Block diagram
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Parallel
Manual
nual
3. OPERATING CONDITION
During “n UPS normal condition” any failure transfers the parallel redundant system
to “n-1 UPS normal condition”, or to “n rectifier failure or mains failure” condition.
During “n-1 UPS normal condition” or “n rectifier failure or mains failure” condition,
any failure transfers the parallel redundant system to “n-1 rectifier failure or mains
failure” condition or to “bypass feeds load” condition. In these operating conditions the
parallel redundant system signals a failure with audible and visual alarms.
During “n-1 rectifier failure or mains failure” condition or to “bypass feeds load”
condition, an additional failure may interrupt the power supply to the load, depending on
the kind of failure.
During “manual bypass” condition the mains feeds the load directly for maintenance
or serious failure.
3.1 “ N” U
UPS
PS NORMAL CONDI
CONDITION
TION
Load on inverter and possibility of continuous failure
Picture 2 - “N” ups normal condition
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Parallel
Manual
nual
3.2 “ N-1” UPS NORMAL COND

CONDITION
ITION
Load on inverter and, in case of failure, transfer on bypass (if available)
Picture 3 - “N-1” ups normal condition
Issued 13/04/07 JUD409404 6 of 18

Parallel
Manual
nual
3.3 “ MAINS FAILURE

FAILURE””
Load on inverter supplied from the battery
Picture 4 - “Mains Failure”
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Parallel
Manual
nual
3.
3.4
4 “ N” BYPAS
BYPASS
S AVAILABLE
Load on bypass in case of at least two inverter failures or overload.
Picture 5 - “N” bypass available
Issued 13/04/07 JUD409404 8 of 18

Parallel
Manual
nual
3.
3.5
5 “ N-
N-1
1 BYPAS
BYPASS
S AVAILABLE”
Load on bypass in case of at least two inverter failures or overload
Picture 6 - “N-1”bypa
“N-1”bypass
ss available
Issued 13/04/07 JUD409404 9 of 18

Parallel
Manual
nual
3.6 MANUAL BYPASS

Picture 7 - Manual bypass
Issued 13/04/07 JUD409404 10 of 18

Parallel
Manual
nual
4. INSTALLATION
Before installing the parallel redundant system, see “INSTALLATION” in the
“OPERATING MANUAL” for the single units, in order to be informed about the following:
- receipt of the UPS

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

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

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

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

Parallel
Manual
nual
4.4 INTERCONNECTIONS DIAGRA

DIAGRAMM
In the following diagram the modifications are illustrated to transform two single units
into a parallel redundant system.
Picture 10 - Interconnections diagram
For more than 2 units, “N-2“ BCCON PB123 board is added.
Issued 13/04/07 JUD409404 13 of 18

Parallel
Manual
nual
Picture 11 - Interconnection
Picture 12 - Interconnection with BCCON – PB123
Issued 13/04/07 JUD409404 14 of 18

Parallel
Manual
nual
4.5 BUS CAB

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

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

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

The parallel system can also be switched on starting from manual by-pass. The unit
having the lower position (Number
(Number 1)
1) must be started-up first:
o Close the manual by pass breaker MBCB on thet he unit Number 1
1
o On the same unit (Number
(Number 1) move the By-pass switch in BY-PASS position
o Close RCB
o Follow all the instructions shown on the display until the unit is completely
started-up and supplies correctly the load
o Start-up the unit Number 2
2 closing RCB and following the instruction
instructions
s shown
on the display
6.3 MORE THAN TWO UPS – START-UP FROM

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

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

Parallel
Manual
nual
7. MANUAL BY-PA
BY-PASS
SS TRANSFER PROC
PROCEDURE
EDURE
During the normal operation of a parallel redundant system, the by-pass switch has
the function to disconnect the UPS from the supply of the load, opening the inverter
static switch. The load is transferred to the by-pass (emergency line) according to the
settings of the parallel logic RPI.
If the parallel system (2 UPS) is programmed with the logic “1 on 2” (parallel
redundant) the load is transferred to the emergency line only when both by-pass
switches are in BY-PASS position.
If the parallel system (2 UPS) is programmed with the logic “2 on 2” (power parallel)
the load is transferred to the emergency line when at least one by-pass switch is in BY-
PASS position.
7.1 MANUA
MANUALL BY-PA
BY-PASS
SS TRANSFER PROCEDURE
Move ALL by-pass switches in position BY-PASS, so that the load is transferred to
the emergency line on all the UPS systems (LED 6 on the front panel lit orange).
Close one or more MBCB (all the inverter will stop with the alarm A13).
Starting from the UPS having the higher position (Number
(Number “N”),
“N”), open the breakers
OCB, SBCB, BCB, RCB.
7.2 RE-ST
RE-START
ART FROM MANUAL BY-PASS
The system is in Manual By-pass condition, with one or more MBCB breakers closed
and ALL the by-pass switches in BY-PASS position, according to the procedure
described at point 7.1.
The system can be re-started according to the following procedures, depending on
the number of UPS composing the parallel system.
7.2.1
7.2.1 Two UPS – Re
Re-start
-start fr
from
om MANUAL B
BYPASS
YPASS
o Close RCB on UPS Number 1 1
o Follow all the instructions shown on the display until the unit is completely
started-up and supplies correctly the load
o On UPS Number 2 move2 move the by-pass switch in NORMAL position
o Close RCB on UPS Number 2 and 2 and follow the instructions shown on the display
until the unit is completely started-up and supplies correctly the load
7.2.2
7.2.2 More th an tw o UPS – R
Re-start
e-start fr
from
om MANUAL BYPASS
oClose RCB in ALL the UPS
o Follow the instructions on the display on the UPS having the lower position
(Number 1) until it shows the message “OPEN ALL MBCB”. Do not open the
MBCB breakers at this point.
o Proceed as indicated above for all the units up to the one having the higher
position (Number
(Number “N”)
“N”)
o Verify that all the by-pass static switches are closed
o Open the manual by-pass breaker MBCB in ALL the UPS
Issued 13/04/07 JUD409404 17 of 18

Parallel
Manual
nual
o Upon the display request, move the by-pass switches of all the units in
position NORMAL, starting from the UPS Number 1.
1.
ATTENTION
When all the displays will show “OPEN ALL MBCB”, the operator must open ALL
MBCB breakers and/or MBCB installed in external cabinets.
NOTE
In a parallel systems with more than 2 UPS, the load will be transferred to the
inverter(s) in accordance with the redundancy logic set on the RPI board (N-1/N).
If the system is composed by 3 UPS with a redundancy logic of “2 of 3”, the load will
be transferred to the inverter only when the second unit is completely started.
Issued 13/04/07 JUD409404 18 of 18

Parallel
Parallel redund ant system - M
Maintenance
aintenance a
and
nd Troub leshoot ing
PARALLEL REDUNDANT SYSTEM

MAINTENANCE AND
A ND TROUBL
TROUBLESH
ESHOOTI
OOTING
NG
Index
INTRODUCTION
INTRODUCTION..............
...........................
...........................
...........................
...........................
...........................
.....................
........ 3
1. MAINTENANCE PROCEDURE
PROCEDURES S .............
..........................
..........................
..........................
................
... 3
1.1 MAINTENANCE WITH THE L OAD UNDE
UNDER
R CONTINUITY...............
CONTINUITY..............................3
...............3
1.2 MAINTENANCE WITH THE LOA
LOADD IN MANUAL B Y-PASS ..........
............................4
..................4
2. TROUBL
TROUBLESHOO
ESHOOTING
TING PROC
PROCEDUR
EDURES
ES ............
.........................
................................. 6
....................
2.1 CHECK
CHECK OF LED STATUS ............
.......................
......................
......................
......................
......................
........................6
.............6
2.1.1 Check of th
theeP
Pow
ower
er Suppl y LED’s o
onn th e R
RPI
PI Board ....
........
........
........
........
...........8
.......8
2.1.2 Check of
o f t he fr
front
ont LED’s on the
th e RP
RPII Board ....
........
........
........
........
........
........
........
........
..........8
......8
2.2 CHECK
CHECK OF AUXILIA RY CONTACTS ..........
.....................
.......................
.......................
...........................10
................10
2.2.1 Check o f MBCB si gn

gnal
al ...........
......................
.......................
.......................
......................
......................
..................10
.......10
2.2.2 Check of EPO si gn
gnal
al ..........
......................
.......................
......................
......................
.................................11
......................11
2.2.3 Check of BYPASS SWITC
SWITCH
H sig nal .....................
................................
......................
.......................12
............12
2.3 CHECK OF CURRENT MEASURES..............................................................13
2.3 CHECK
CHECK OF SYNC
SYNCHRONI
HRONIZATION
ZATION SIGNALS ...........
......................
......................
...........................15
................15
3. RPI BOARD REPLACEMENT PROCEDU
PROCEDURE..................
RE.................................. 17
................
3.1 RPI GENE
GENERAL
RAL SETTIN
SETTINGS
GS............
.......................
......................
......................
......................
................................17
.....................17
3.2 SYNCHRONIZATION ADJUSTMENTS..........................................................17
3.3 COMMUTATION
COMMUTATION TESTS ..........
.....................
......................
......................
......................
......................
..........................18
...............18
3.4 SYSTEM
SYSTEM RE-ST
RE-START
ART ...........
.......................
.......................
......................
......................
.......................
..............................18
..................18
4. PARALL
PARA LL EL SYSTE
SYSTEM
M SOFTW
SOFTWARE
ARE (RPITE
(RPITEST)
ST) .............
................................ 19
...................
4.1 INTRODUCTION.............................................................................................19
4.2 DESC
DESCRIPTIO
RIPTION
N OF THE SOFT
SOFTWARE
WARE ...........
......................
......................
......................
...........................20
................20
4.3 SUMM
SUMMARY
ARY OF THE COMMANDS ...........
......................
......................
......................
................................27
.....................27
4.4 UPGR
UPGRADE
ADE OF THE PARAL LEL SYSTE
SYSTEM
M ...........
.......................
.......................
.............................28
..................28
4.4.1 INTRODUCTION......................................................................................28
4.4.2 HARDWARE MODIF
MODIFICATIONS
ICATIONS ..........
.....................
.......................
.......................
.............................28
..................28
Issued 13/04/07 JUD409405 1 of 35

Parallel
Parallel redundant sy stem - M
Maintenance
aintenance a
and
nd Troubl eshooti ng
4.4.3 PARAMETERS SETTIN

SETTING..................
G.............................
......................
......................
............................... 28
....................
5. CONFIGURATION
CONFIGURATION FROM SINGLE UPS TO PARALLEL
PARAL LEL ................ 30
................30
5.1 PCB SETT
SETTINGS
INGS ..........
.....................
......................
.......................
.......................
......................
.......................
........................... 30
...............
5.2 MODIFICATIONS
MODIFICATIONS FOR UPS 15÷3
15÷32
2 KVA ...........
......................
......................
............................... 30
....................
5.3 MODIFICATIONS
MODIFICATIONS F
FOR
OR UPS 4
40÷650
0÷650 KVA
KVA..........
.....................
.....................
............................... 31
.....................
6. CONFIGURATION
CONFIGURATION FROM PARA
PARALL
LLEL
EL TO SINGLE ................ 33
SINGLE UPS ................
6.1 MODIFICATIONS
MODIFICATIONS F
FOR
OR UPS 4
40÷650
0÷650 KVA
KVA..........
.....................
.....................
............................... 33
.....................
6.2 MODIFICATIONS
MODIFICATIONS FOR UPS 15÷3
15÷32
2 KVA ...........
......................
......................
............................... 34
....................
Index
Index of pictures
Picture 1 – Bus cable connections ............................................................................................................... 9
...............................................................................................................
Picture 2 – Digital inputs on RPITest
RPITest control panel .................................................................................... 10
panel ....................................................................................
Picture 3 – Digital outputs panel.................................................................................. 10
outputs on RPITest control panel..................................................................................
Picture 4 – Signals
Signals on TR and .......................................................................................................... 14
and TP14 ..........................................................................................................
Picture 5 – Signal
Signal on TS and ............................................................................................................ 14
and TP14 ............................................................................................................
Picture 6 – Signal on
on TT and ............................................................................................................ 14
and TP14 ............................................................................................................
Picture 7 – RPITest control
control panel............................................................................................................... 20
panel...............................................................................................................
Picture 8 – RPITest
RPITest control panel
panel (PID contr
controller) ..................................................................................... 20
oller) .....................................................................................
Picture 9 – Parallel
Parallel interconnections diagram............................................................................................ 32
interconnections
Issued 13/04/07 JUD409405 2 of 35

Parallel
Maintenance
aintenance a
and
INTRODUCTION
The scope of this manual is to guide the technician to the correct maintenance and
troubleshooting
troubleshooting of the parallel redundant system.
NOTE
Before reading
reading this manual, the technician will have to read
read with care and
and attention
the “ PARALLEL REDUN
REDUNDANT
DANT SYSTEM
SYSTEM OPERATIN
OPERATING G MANUAL”
MANUAL” to c arry-ou t co rrect ly the
t he
given instructions. The manufacturer declines all responsibility for damages to people or
things deriving from non-fulfilment of the above.
1. MAINTENANCE
MAINTENA NCE PROCEDURES
The parallel system allows the operator to carry out the maintenance of one or more units in
two different operating conditions, that’s to say, under continuity, where the load is still supplied
by the other inverter(s) or in manual by-pass condition.
NOTE
The modality of intervention must take into consideration the operating condition of
the plant, and must be agreed with the final user. For the operating procedures refer to
the technical d ocumentation related
related to the UP
UPS
S installed.
1.1 MAINTENA
MAINTENANCE
NCE WITH THE LOA
LOADD UNDER CONTINUITY
Using this procedure the operator can work on one UPS at a time, leaving the load bus
supplied
procedureby the remaining
is valid UPS(s)
only for parallel so that systems,
redundant the continuity
not forofpower
the supply
parallel.is guaranteed. This
NOTE
The operator carrying out the maintenance must consider under his own responsibility the
operating risks for himself and for the final user.
The procedure to disconnect the UPS under maintenance is the following:

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

o Move the by-pass switch in NORMAL position
o Supply the logic with the external power supply
o Close RCB and start the
t he inverter modulation by PC command
o At the end of the soft-start the inverter static switch will close and it will be possible to
check the output voltage waveform.
Issued 13/04/07 JUD409405 3 of 35

Parallel
Maintenance
aintenance a
and
o Moving the by-pass switch in BY-PASS position will cause the inverter static switch to
open but the load is not transferred to by-pass. The SBCB breaker must be kept
open.
open.
Upon completion of the test the UPS can be put again “on line” with the following procedure:
procedure:
o Put the UPS in NORMAL mode (Dip 6 SW1 in ON on PB003)

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

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

o Supply the logic with the external power supply
o By the RPITest software set the UPS redundancy logic at 1 on the RPI board with the
command SNUL001 (logic 1 on “N”)
o By the UPSTest software connected to the RS232 of the UPS, send the command
MAST001 (MASTER condition forced)
o Close RCB and start the inverter modulation by PC command
o At the end of the soft-start the
t he inverter static switch will close and it will be possible to
check the output voltage waveform.
o In case it’s necessary to perform commutation tests or checks on the static switch
operation, close SBCB and wait until the status S6 – BYPASS OK is active on the
UPSTest screen.
o Moving the by-pass switch in BYPASS position will cause the load transfer to the by-
pass so that the commutation between inverter and by-pass line can be tested.
Issued 13/04/07 JUD409405 4 of 35

Parallel
Maintenance
aintenance a
and
At the end of the tests restore

restore the initial status:
status:
o By the UPSTest software connected to the RS232 of the UPS, send the command
MAST000 (MASTER condition reset)
o Set the UPS redundancy logic at “n” on the RPI board, by the command SNUL xx x ,
with xx x =”n”.
o Put the UPS in NORMAL mode (Dip 6 SW1 in ON on PB003)
o Restore the normal supply of the logic.
o Move the by-pass switch in BYPASS position
o Start with the maintenance of the next unit, if necessary.
The whole system can be re-started following the procedures described at paragraph 7.2 of
the PARALLEL SYSTEM OPERATING MANUAL.
Issued 13/04/07 JUD409405 5 of 35

Parallel
Maintenance
aintenance a
and
2. TROUBL
TROUBLESHOOTING
ESHOOTING PROCEDURES
This troubleshooting includes a first level fault description for Parallel System and suggests
how to check the unit to solve the problems.
All the tests described in this document must be carried out with the parallel system in
Manual Bypass unless otherwise specified.
Please refer to the PARALLEL SYSTEM OPERATING MANUAL for the correct procedure to
transfer the load from normal operation (inverter mode) to manual bypass.
This description assumes that all the connections inside the unit are correct; check them
(connectors, power cables, signals and so on) before starting with the procedures. The first
level troubleshooting consists of substituting the RPI-BUSCAN Board without attempting to
repair it. To replace the RPI Board refer to the
t he instructions given at chapter 3 of this manual.
2.1 CHECK OF LED STATUS
The RPI-BUSCAN (PB110) board is provided with LED’s, indicating the various operating
condition of the board itself and the presence of the DC supply. The colour and function of the
LED’s is shown in the tables below; the first table shows the LED’s indicating the DC supply to
the RPI board, the second one the LED’s in the front of the RPI board indicating the operating
status of the parallel system.
a) DC SUPPLY
SUPPLY LED’s
LED NAME COLOUR DESCRIPTION / FUNCTION / STATUS

DL1 GREEN It indicates the presence of the +5PS DC supply, generated
using the one coming from the power supply board (PS-HV -
PB001),
connectorsection
CNB. It12V/RELAY
must alwaysAND BUS,ON
be steady through
ON. . the 60-pole
NOTE: the +12V supply is also transmitted through the
BUSCAN cable to the other units of the parallel system.
DL2 GREEN It indicates the presence of the +5F DC supply for the
microprocessor of the RPI board. This supply is generated
using the square waves AC3/AC4 coming directly from the
power supply board (PS-HV - PB001), connector CN1, to the
connector CN7 of RPI board.
DL3 GREEN It indicates the presence of the -5F DC supply for the
microprocessor of the RPI board. This supply is generated
using the square waves AC3/AC4 coming directly from the
power supply board (PS-HV - PB001), connector CN1, to the
connector CN7 of RPI board.
DL14 GREEN It
I t indicates the presence of the +5PSRG DC supply, generated
using the one coming from the power supply board (PS-HV -
PB001), section 12V/RELAY AND BUS, through the 60-pole
connector CNB. It must always be steady ON
ON..
NOTE: the +12V supply is also transmitted through the
BUSCAN cable to the other units of the parallel system.
Issued 13/04/07 JUD409405 6 of 35

Parallel
Maintenance
aintenance a
and
b) FRONT LED’s
LED NAME COLOUR DESCRIPTION / FUNCTION / STATUS

DL11 BUS_OK GREEN It indicates that the transmission between the units on the
BUSCAN is correct on both transmission lines (BUSCAN_H
and BUSCAN_L). It must always be steady ON ON..
DL12 MASTER RED It indicates the MASTER unit, that is, among the UPS that are
supplying the load, that with the lowest position. during normal
operation it’s ON
ON in
in the MASTER and OFF
OFF in
in the SLAVE.
DL13 CON_OFF RED It indicates if the connector of the BUSCAN cable is connected
correctly to the RPI board. It must always be OFF
OFF..
DL9 UPS1 YELLOW It’s solid ON in the UPS1 (TX – Transmitting), indicating this
UPS is transmitting through the BUSCAN.
It’s BLINKING
BLINKING on the other UPS systems (RX – Receiving),
indicating they are receiving message from the UPS1 through
the BUSCAN.
DL4 UPS2 YELLOW It s solid ON in the UPS2 (TX Transmitting), indicating this
It’s BLINKING
the BUSCAN.
It’s BLINKING
the BUSCAN. It’s OFFOFF in
in case the parallel system is composed
by less than three units.
It’s BLINKING
by less than four units.
It’s BLINKING
by less than five units.
UPS is transmitting
It’s BLINKING
BLINKING through
on the otherthe BUSCAN.
UPS systems (RX – Receiving),
the BUSCAN. It’s OFF OFF in
by less than six units.
DL10 OUT_ON YELLOW When ON ON It
It indicates that the load is supplied by at least one
inverter, otherwise OFFOFF..
Before to start the tests described below, transfer the load on Manual Bypass, switch off all the
units and set them in Test Mode, moving the DIP6 SW1 on I/S Control Logic in OFF position.
Then close RCB on all the units (Logics start-up).
Issued 13/04/07 JUD409405 7 of 35

Parallel
Maintenance
aintenance a
and
2.
2.1.
1.1
1 Che
Check
ck of the Power Supply LED
LED’s
’s on the RP
RPII Board
1. Are the DL2 and DL3 ON?
YES:: go to step #4
YES
NO:: check the continuity of the flat cable from CN7 of RPI Board to CN1 of the PS-HV
NO
board. Go to step #2.
2. Is the continuity of flat cable correct?

YES:: replace the PS-HV board. Go to step #3
YES
NO:: replace the flat cable.
NO cable. Go to step #3.
#3.
3. Are the DL2 and DL3 ON now?
YES
YES:
NO::: END
NO replace the RPI board.
4. Remove the DB9 BUSCAN Connector, are DL1 and DL14 both ON?
YES:: END
YES
NO:: check the continuity
NO continuity of the 60-pol
60-pole
e flat cable CNB an
and
d the flat cable from CN1
CN1 of
PS-HV board to CN15 of I/S-CL board. Go to step #5.
5. Is the continuity of flat cables correct?

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

YES:: replace
YES replace the PS-HV board. Go to step #7
NO:: replace the RPI board.
NO
7. Are DL1 and DL14 ON now?

YES:: END
YES
NO:: replace the RPI board
NO
Before re-connecting the BUSCAN cable, switch off the unit opening RCB and wait the
complete shut-down of the logics.
2.
2.1.
1.2
2 Che
Check
ck of the fro nt LED’s on the RP
RPII Board
1.1. Is DL11 “BUS_OK” ON?
YES:: go to step #2.1
YES
NO:: check the continuity
NO continuity of the BUSCAN cable
cable between the units according
according to the
picture 1 (see next page).
1.2. Is the
YES:
YES continuity ofinthe
: disconnect cable correct?
sequence each RPI from the bus, until DL11 is ON again. Replace
the faulty RPI.
NO:: replace the BUSCAN cable.
NO
2.1. Is DL13 “CON_OFF” OFF?

YES
NO:: check the DB9 connector
NO connector of the BUS cable and
and the short circuit between
between pin6
and pin1. Go to step #2.2.
Issued 13/04/07 JUD409405 8 of 35

Parallel
Maintenance
aintenance a
and
2.2. Is the connector ok?

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

YES
NO:: check if the Dip1 of SW1 on the RPI
NO RPI board of UPS1 is ON and a allll the other Dip
OFF (set the position of the UPS as UPS1
UPS1)) if is ok replace RPI Board.
3.2. Is the position

position of the
the dip
dip switch on UPS1 correct?
YES:: replace
YES replace the RPI board.
NO:: correct the position
NO position of the dip switch and go back
back to step #3.1.
#3.1.
3.3. Is DL4 on UPS2 (TX - Transmitting Message) ON?

YES:: END
YES
NO:: check if the Dip2 of SW1 on the RPI
NO RPI board of UPS2 is ON and a allll the other Dip
OFF (set the position of the UPS as UPS2
UPS2)) if is ok replace RPI Board.
3.4. Is the position
position of the
the dip
dip switch on UPS2 correct?
YES:: replace
YES replace the RPI board.
NO:: correct the position
NO position of the dip switch and go back
back to step #3.3.
#3.3.
Check if all the others TX (Transmitting Message) and RX Leds (Receiving Message) are ON
or blinking according to the table shown at paragraph 2.1.
Picture 1 – Bus cable connections
Issued 13/04/07 JUD409405 9 of 35

Parallel
Maintenance
aintenance a
and
2.2 CHECK OF AUXILIA

AUXILIARY
RY CONTACTS
The UPS systems are in manual by-pass condition, with all MBCB breakers closed.
Start-up the units in test mode moving the DIP6 SW1 on I/S Control Logic in OFF position.
Then close RCB on all the units (Logics start-up). The digital signals related to the position of
MBCB breaker, EPO contact and By-pass Switch are shown on the control panel of the RPITest
software (see picture 2). The digital outputs, that’s to say the commands that the RPI send to
the I/S-CL board are shown in the same control panel (see picture 3).
Picture 2 – Digital inputs on RPITest control panel
l
Picture 3 – Digital outputs on RPITest control panel
2.2.1
2.2.1 Check of MBCB signal
si gnal
Open MBCB on UPS2 (MBCB of UPS1 is closed) and connect a PC with the RPITest
software to the RPI Board of UPS1.
The auxiliary contact of MBCB is connected to the RPI board on the connector M5, pin 5/6;
according to the position of the contact the RPI board generates the MBCB_CLOSE_BUS
signal.
1. Verify that all the units show A18 - MBCB CLOSE alarm on the display.
YES:: END. Close MBCB on UPS2 and open MBCB on UPS1 and repeat the same
YES
check.
NO:: go to step #2
NO
2. Is the alarm present on the unit where MBCB is closed?

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

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

Parallel
Maintenance
aintenance a
and
YES: replace the RPI board.

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

“MBCB_CLOSE_BUS” active?
YES:: check the continuity of the
YES t he 60-pole flat cable CNB. Go to step #6.
NO

YES:: replace the RPI board. Go to step #7.
YES
NO:: replace the flat cable. Go back to step #5.
NO
7. Do all the units show A18 - MBCB CLOSE alarm on the display?
YES: END
YES:
NO:: replace the I/S-CL board.
NO
8. Connect the PC with the RPITest

RPITest to the RPI board
board of the UPS that has
has MBCB open. Is
the digital output “MBCB_CLOSE_BUS” active?
YES: Go to step #9.
YES:
NO:: check the communication
NO communication between the units
units (TX and RX LED’s, see paragraph
paragraph
2.1.2, points 3.3 and 3.4) and replace the RPI board.
9. Check the continuity

continuity of the 60-pole flat cable
cable CNB. Is the continuity of flat cable
correct?
YES
NO:: replace the flat cable. Go back to step #8.
NO
10. Does this unit show A18 - MBCB CLOSE alarm on the display?
YES:: END
YES
NO
2.2.2
2.2.2 Check of EPO sig nal
The auxiliary contact of EPO button is connected to the RPI board on the connector M5, pin
1/2; according to the position of the contact the RPI board generates the EPO_BUS signal.
1. Press the
the EPO button on the
the UPS1
UPS1 and
and verify
verify that all the
the units
units show
show A23
A23 - EPO
PRESSED alarm on the display.
YES:: Go to step #2
YES
NO:: go to step #3
NO
2. Release the EPO onon UPS1

UPS1 and
and press the EPO button
button on the UPS2 and verify that all
all
the units show A23 - EPO PRESSED alarm on the display.
YES: END.
YES:
NO:: go to step #3
NO
3. Is the alarm present on the unit where EPO is pressed?

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

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

Parallel
Maintenance
aintenance a
and
NO:: replace the auxiliary contact. Go back to step #4

NO
6. Is the digital output “O_EPO_BUS” active?

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

YES
NO cable. Go back to step #6.
8. Do all the units show A23 - EPO PRESSED alarm on the display?
YES:: END
YES
NO
9. Connect the PC with

with the RPITest to the RPI board
board of the UPS where the EPO
EPO is not
pressed. Is the digital output “O_EPO_BUS” active?
YES:: Go to step #10.
YES
NO:: check the communication between the units (TX and RX LED’s, see paragraph
NO
2.1.2, points 3.3 and 3.4) and replace the RPI board.
10. Check the continuity

continuity of the
the 60-pole flat cable CNB. Is the continuity
continuity of flat cable
correct?
YES
11. Does this unit

unit show
show A23
A23 - EPO PRESSED
PRESSED alarm on the display?
YES:: END
YES
NO
2.2.3
2.2.3 Check of BYPASS SWI
SWITCH
TCH signal
si gnal
The contact of the Bypass Switch is connected to the RPI board on the connector M7, pin
1/2; according to the position of the contact the RPI board generates the Byp_SW signal.
1. Move the Bypass switch of the

the UPS1
UPS1 in position BYPASS and verify that the unit
unit
shows A22 – BYP SWITCH alarm on the display.
YES:: END
YES
NO:: go to step #2
NO
2. Check the digital input “Byp_SW” on the RPITest

RPITest software.
software. Is the
the digital
digital input
“Byp_SW” active?
YES:: check the digital output O_BYP_SW. Go to step #4.
YES
NO operation of the Bypass switch contact. Go
Go to step #3.
#3.
3. Is the contact working properly?

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

Parallel
Maintenance
aintenance a
and
4. Is the digital output “O_BYP_SW” active?

YES:: Check the connection between M8 of the RPI board and M3 of the I/S-CL board
YES
(pins 11-12). If the FCI board is installed M8 is connected to M1, pins 11-12. Go
to step #5.
NO
5. Is the connection good?

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

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

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

Parallel
Maintenance
aintenance a
and
Picture 4 – Signals on TR and TP14

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

YES:: replace the current transformer(s).
YES
Issued 13/04/07 JUD409405 14 of 35

Parallel
Maintenance
aintenance a
and
NO:: replace the connection(s).

NO connection(s).
7. On the PID control panel of the

the RPITest check the values of CURR_LOC on the three
phases. These values must be 1200 (+/-10%) at 50% of load, except CURR_LOC
Quad R that
R that must be zero with resistive load, and varies proportiona
proportionally
lly according to the
actual load. Are the values correct?
YES:: go to step #8
YES
NO
8. Move the bypass switch of UPS2 in NORMAL position and the Bypass Switch of UPS1 UPS1
in BYPASS, so that only the UPS2 supplies the load. Connect the PC with the RPITest
to the RPI board of UPS2 and repeat the checks from point 2 to 7. Go to step #9.
9. the values of CURR_LOC shown on the PID control panel (Phase R,

Take note of the
Quad R, Phase S, Phase T).T ). Transfer the load to the UPS1 again by means of the
bypass switches, connect the RPITest to the RPI board of UPS1 and check the values
of CURR LOC in the UPS1. Are these values the same of those shown by UPS2?
YES: END
YES:
NO:: According to the actual
NO actual load, adjust the measures
measures to be the same
same for both UPS,
with the potentiometers POT4 (Phase R), POT5 (Phase S), POT6 (Phase T).
Remember the measures must be 1200 at 50% of load, except CURR_LOC
Quad R that
R that must be zero (+/-70) with resistive load.
2.3 CHECK OF SYNCHRONIZATION SIGNAL
SIGNALSS
The UPS systems are in manual by-pass condition, with all MBCB breakers closed.
ATTENTION
If the UPS is a single-phase output, short-circuit the neutral pole of the output breaker OCB
(putting a jumper between IN and OUT) in both units (see point 3.2 for further explanations)
explanations)..
Only the neutral pole of OCB
OCB must be short-circu ited.
ited.
Start-up the units in test mode moving the DIP6 SW1 on I/S Control Logic in OFF position. Then
close RCB on all the units (Logics start-up).
a) By the
the UPS-Test
UPS-Test software connected to RS232 RS232 of the UPS, send the command
MAST001 (Master condition Forced) to the UPS1.
b) Verify the presence of the MASTER label (red) on the UPS-Test screen. This UPS now
is the MASTER in the system.
c) Switch on allall the inverters. (by the
the UPS-Test
UPS-Test software,
software, sending the command
INON000). Wait that all the inverter static switches are closed.
1. Check the synchronization

synchronization of the SLAVE u unit
nit measuring the voltage
voltage difference between
between
the phases R of the two units. Is the SLAVE synchronized?
YES:: go to step #8
YES
NO:: go to step #2
NO
2. On the RPI board of of the MASTER unit check

check with an oscilloscope
oscilloscope connected
connected between
between
TP1-GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform
present?
YES:: go to step #5
YES
NO board. Go to step #3.
3. After replacing
replacing the RPI board is the waveform present on TP1?
Issued 13/04/07 JUD409405 15 of 35

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

YES:: replace the I/S-CL board.
YES
5. On the RPI board of

of the SLAVE unit check
check with an oscilloscope
oscilloscope connected
connected between TP1-
GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform present?
YES:: Replace the RPI board
YES
NO:: replace the BUS cable. Go to step #6.
NO #6.
6. After replacing
replacing the BUS cable
cable is the waveform present on TP1?
YES:: END
YES
NO:: check the continuity of the 60-pole flat cable CNB.
NO CNB. Go to step
step #7.
YES
8. Close SBCB on both units and wait wait for the BYPASS_OK signal (status S6 on the
UPSTest screen) Check the synchronization between the MASTER and the bypass,
measuring the voltage difference between the phase R of the bypass and the phase R of
the inverter. Is the MASTER synchronized?
YES:: END
YES
NO:: go to step #9
NO
9. On the RPI board of the MASTER unit unit check with an oscilloscope connected between
between
TP2-GNDBUS the presence of a square wave (MAINS_SYNC_BUS). Is the waveform
present?
YES:: check the continuity of the 60-pole flat cable CNB. Go to step #10.
YES
NO:: replace the RPI board. Go to step #11.
NO

YES
11. After replacing the RPI board is the waveform present on TP2?
YES:: END
YES
NO
d)
e) Open SBCB
Send on both units.
the command MAST000 (Master condition Reset) to the UPS1, connect the
UPSTest software to the RS232 of the UPS2 and send the command MAST001. Now
the UPS2 is the MASTER in the system.
f) Repeat the checks from point 1 to 10.
Issued 13/04/07 JUD409405 16 of 35

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

Parallel
Maintenance
aintenance a
and
If the UPS is a single-phase output the neutral conductor is not common as it is interrupted
by the output breaker OCB, that must be kept open (the units are operating in manual by-
pass). Therefore, in order to read with the multimeter the voltage difference between the
inverter output voltages, it’s necessary to link the two output neutral conductors, by short-
circuiting the neutral pole of the output breaker OCB (putting a jumper between IN and OUT).
CAUTION
On single-phase U
UPS
PS,, only t he neutral pole of OCB must b e short-circ uited.
uited.
5. Switch off ALL

ALL the inverters
inverters (by the UPSTest software,
software, sending the command INOF000).
6. Send the command MAST000 (Master condition Reset) to the UPS MASTER.
7. Send the command MAST001
MAST001 to the UPS with the new RPI Board Board (PB110)
8. Switch on all
all the inverter by the UPSTest
UPSTest software, sending
sending the command
command INON000) and
wait that all the inverter static switch are closed.
9. Close the SBCB
SBCB breakers (Emergency
(Emergency line
line breaker) in all the units and
and wait for Bypass
Bypass
OK signal (Status S6 – BYPASS OK on all the units and status S5 – INV SYNC on the
MASTER unit).
10. With a multimeter, check the synchronization of the MASTER unit with the mains,
measuring between the input of the OCB of the UPS with the new RPI Board and the
input of the SBCB. If a phase shift is found, it can be compensated by turning the
potentiometer POT3 on the new RPI Board.
3.3 COMMUTATION TESTS
All the inverters are now working synchronized with the bypass line. The static switch
operation can be tested according to the following procedure. Take into consideration that the
following are blank tests, carried out with the output breaker open
1. On the UPS with the new new RPI board, move the By Bypass
pass Switch in BYPASS
BYPASS position.
The inverter static switch will open and the load will be supplied by the other units,
according to the redundancy logic set on the RPI boards.
2. Move the Bypass Switch
Switch in BYPASS position in a allll the other units of the parallel
parallel
system. All the bypass static switches will close and the load will be supplied by the
mains.
3. Switch off all the inverters by the UPS-Test software, sending the command
INOF000).
4. Open all
all the SBCB breakers
breakers (Emergency
(Emergency Line breakers)
breakers)
5. Open all
all the RCB breakers
breakers (Input
(Input Mains breakers).
3.4 SYSTEM RE-START
1. (PB003
Set all the systems
system
Board) s in position.
in ON Automatic m
mode,
ode, moving the Dip6 SW1 of the
the I/S Control Logic
Logic
2. In case the UPS
UPS is a single-phase
single-phase output,
output, remove the jumpers
jumpers on the neutral pole of
the OCB breakers (put during the synchronization procedure
procedure at point 3.2).
3. Move ALL Bypas Switches in BYPASS position.
4. Now the units are completely
completely swi
switched
tched off with the MBCB
MBCB breakers closed
closed and the
Bypass Switches in BYPASS position.
5. Re-start the units from
from MANUAL BYPASS
BYPASS condition following
following the instructions
instructions of the
PARALLEL SYSTEM OPERATING MANUAL.
Issued 13/04/07 JUD409405 18 of 35

Parallel
Maintenance
aintenance a
and
4. PARALL
PARA LLEL
EL SYST
SYSTEM
EM SOFTW
SOFTWARE
ARE (RPITE
(RPITEST)
ST)
4.1 INTRODUCTION
This document is a guide for the correct configuration of the parameters of the card RPI-
BUSCAN PB110 for a parallel redundant system.
The parallel optional card allows the connection of up to 6 units in parallel.
For a correct installation and interconnection of the parallel cards refer to the parallel test
procedure. Particular attention must be paid to the configuration of the dip switches, through
which the position of each UPS system is defined in univocal way, allowing the correct
exchange of the signals among the systems.
WARNING
Two UPSs can not have the same configuration of the dip-switches, that’s to say the
same position in the parallel system, otherwise there are conflicts of identification of the
messages
messages runn ing th rough t he CAN
CAN BUS
BUS

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UPS SERVICE MANUAL

WARNING: This is a Class A-UPS Product. In a domestic environment,

Index of section s Code

1 – TECHNICAL SPECIFICATION JUD408572

8 – PARAL LEL – OPER

Issued 13/04/07 JUD409399 3 of 3

TECHNICAL DATA SHEET

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

number of semiconductors is minimized by the means of very advanced design

POWER - kVA 200 250 300

POWER - kVA 200 250 300

UPS OUTPUT: INVERTER

POWER - kVA 200 250 300

Automatic Static By-Pass Electronic Thyristor Switch

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

REMOTE ON LAN (by additional box):

UPS OPERATING MANUAL

UPS OPERATING MANUAL

Index of sections Code

1 – UPS GENERAL DESCRIPTION AND INSTALLATION JUD408827

JUD408826 18/07/06 Issued

Ups general description & installation

UPS GENERAL DESCRIPTION AND INSTALLATION

JUD408827 02/10/06 Rev. A

Ups general description & installation

2 JUD408827 02/10/06 Rev. A

Ups general description & installation

2. GENERAL UPS DESCRIPTION

Picture 1 – Block diagram

JUD408827 02/10/06 Rev. A 3

Ups general description & installation

2.2 DESCRIPTION OF THE SYSTEM

The control electronics is completely digital output

2.2.3 Battery and charger

2.2.4 Static bypass

4 JUD408827 02/10/06 Rev. A

Ups general description & installation

2.2.6 Front Panel

JUD408827 02/10/06 Rev. A 5

Ups general description & installation

2.3 OPERATING STATUS

2.3.1 Normal Operation

Picture 2 – Normal operation

Picture 3 – Load supplied by bypass

6 JUD408827 02/10/06 Rev. A

Ups general description & installation

2.3.3 Rectifier failure or mains failure

Picture 4 – Rectifier failure or mains failure

2.3.4 Manual bypass

Picture 5 – Manual bypass

JUD408827 02/10/06 Rev. A 7

Ups general description & installation

Picture 6 – Handling B9000 200-300kVA

8 JUD408827 02/10/06 Rev. A

Ups general description & installation

3.3 POSITIONING AND INSTALLATION

3.3.1 Base plan, s

Picture 7 – Base plan

UPS 200 250 300

UPS 3Ph (kVA) 200 250 300

Weight with battery – kg - - -

Static load – kg/m2 925 1085 1277

JUD408827 02/10/06 Rev. A 9