Technical presentation EVOLUTION line UPS

Contents

General dataThe ASTRID UPS of the EVOLUTION series are ON-LINE DOUBLE CONVERSION, with DC/AC isolating transformer (inverter section)

The whole line is designed to maximise the reliability index MTBF by means of:Use of common electronic cardsReduced number of cabling and interconnections among the various elements of the system

Such solutions allow the reduction of the repairing time in case of failure (MTTR)

General dataThe EVOLUTION series is basically composed by THREE main models:

PLANET/E(20-30kVA 3Ph/1Ph)HALLEY/E(20-160kVA 3Ph/3Ph)SATURN/E(200-650kVA 3Ph/3Ph)

The two widest categories are divided into sub-categories, according to the functional and technical solution chosen:

HALLEY/E2032kVA e 4080kVAHALLEY/E100160kVASATURN/E200300kVASATURN/E400650kVA

Common technical featuresTotal-controlled three-phase (6 pulses) thyristor-based rectifier1ph and 3Ph IGBT inverter (H bridge)Inverter output isolating transformerThyristor-based static switch with redundant supplyParallelability up to 4 UPS with microprocessor load sharing control, and communication protocol with high noise immunityUse of common parts and solutions on all the rangeMicroprocessor control cardLCD panel, thats to say same data access mode Test software

PLANET/E 20-30kVA (3Ph / 1Ph)Input:3 x 380415VacOutput:1 x 220240VacPower:20kVA 30kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) Internal up to 24AhCrest factor:3:1Overload capability:125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 1Inverter:type 1Static switch:type 1

HALLEY/E 20-30kVA (3Ph / 3Ph)Input:3 x 380415VacOutput:3 x 380415VacPower:20kVA 30kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) Internal up to 24AhCrest factor:3:1Overload capability:125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 1Inverter:type 2Static switch:type 2

HALLEY/E 4080kVA (3Ph / 3Ph)Input:3 x 380415VacOutput:3 x 380415VacPower:40kVA 60kVA 80kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) - ExternalCrest factor:3:1Overload capability:125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 2Inverter:type 3Static switch:type 2

HALLEY/E 100160kVA (3Ph / 3Ph)Input:3 x 380415VacOutput:3 x 380415VacPower:100kVA 125kVA 160kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) - ExternalCrest factor:3:1Overload capability :125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 2Inverter:type 3Static switch:type 2

SATURN/E 200300kVA (3Ph / 3Ph)Input:3 x 380415VacOutput:3 x 380415VacPower:200kVA 250kVA 300kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) - ExternalCrest factor:3:1Overload capability:125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 2Inverter:type 3Static switch:type 2

SATURN/E 400650kVA (3Ph / 3Ph)Input:3 x 380415VacOutput:3 x 380415VacPower:400kVA 500kVA 650kVA, p.f. = 0,8Battery:192 cells Pb (384Vdc) - ExternalCrest factor:3:1Overload capability:125%Pn x 10min150%Pn x 1min200%In x 100ms

Rectifier:type 2Inverter:type 3 Static switch:type 3 (except 400kVA)

Rectifier

Rectifiers featuresAll the rectifiers of the EVOLUTION series UPS, from 20kVA to 650kVA, use compact-type thyristors (SemiPack) and are manufactured according to the schematic diagram shown previously, with small variations:

The saturation-type choke L3 is used on the UPS up to 80kVAThe fuse-holder BCB is installed only on the units with internal batteries (20 and 30kVA). The battery switch is not installed on units having higher powerThe forced cooling of the heatsink is provided starting from the 40kVA The rectifiers of the 500kVA and 650kVA uses two three-phase rectifier bridges with input/output parallel connection

Rectifier typologiesTwo different types of rectifiers can be defined according to the manufacturing solution, and particularly basing on the control cards used

TYPE 1Its the compact typology, as shown subsequently. The control cards are physically separated from the thyristors and interconnected to the firing card by means of flat cables. The 12-pulse configuration is not possible.Cards used:

PRCH(PB114)FIR-91(PB113)LOOP(PB115)

Rectifier typologiesTYPE 2The control card is only one and includes also the the thyristors firing section. The card is fixed directly on the power components.The 12-pulse configuration uses a control card for each three-phase bridge (one in MASTER configuration, the other SLAVE). The same solution is used in the 500kVA and 650kVA that uses two three-phase bridge in parallel also in the 6-pulse configurationCards used:

SYNC-12(PB116)RCLS-1(PB117)

PRCH card (PB114)The PRCH card is composed by the following main sections:

Generation of the DC power supply (12V/24V)Generation of the synchronism signals for the thyristors firingControl of the rectifier AC supply voltageControl of the internal DC supplyGeneration of the thyristors turn-on signals (initial stage)

PRCH card (PB114)Generation of the DC power supply and synchronism signals+24Vdc for the supply of the firing pulses+/-12Vdc for the supply of the control electronic circuitsThe synchronism signals are taken from a secondary winding of the transformer and used for both the control of the AC supply voltage and the generation of the control ramps of the thyristors delay angle

PRCH card (PB114)Control of the AC supply voltageInput phase sequence control (signal 0_SCOK) and lighting of LED DL1 if the phase sequence is correctLow mains voltage control, with FIXED threshold 400Vac -15%, and lighting of LED DL2.Generation of the signal 1_ROK (mains OK) if both the previous signals are OK

PRCH card (PB114)Control of the DC supply and rectifier start-upThe +12V supply is controlled by a comparator. If the supply is within the tolerance range the LED DL4 is lit and the signal 1_PSOK is activatedSuch signal is then put in AND logic with 1_ROK (mains OK) and, if both of them are OK, the LED DL3 is lit and the rectifier is enabled to start-up through the signal 0_ON

PRCH card (PB114)Generation of the thyristors turn-on signalsThe IC TCA785 generates a ramp signal in phase with the corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8)Each ramp is compared with a control level (TP5). The result of the comparison (square wave) defines the thyristors delay angleThe square wave is mixed with a high frequency signal (TP9). The resulting series of pulses represents the initial stage of the thyristors control circuit

PRCH card (PB114) Settings and controlsThe LEDs are normally lit steady, they are OFF in case of alarm

POTENTIOMETERSP1Amplitude regulation of the ramp phase RP2Amplitude regulation of the ramp phase SP3Amplitude regulation of the ramp phase T

CONTROL LEDCOLOURDL1Correct phase sequenceYELLOWDL2AC voltage in tolerance (>340Vac)YELLOWDL3Rectifier ONGREENDL4Internal DC supply correctYELLOW

PRCH card (PB114) Interfaces with I/S-CL (mP)PRCH I/S-CLMAINS FAILURE signalPin 1-2 connector M1RECTIFIER ON signalPin 1-2 connector M3

I/S-CL PRCHNo controls or commands are sent by the microprocessor card to the PRCH card

FIR-91 card (PB113)Final stage of the thyristors control circuitFor simplicity we will represent only two sections (they are 6 in total) of the final stage for the thyristors control circuitThe R-C circuit at the transformer input generates the real pulse, that is subsequently transferred to the gate of the thyristorThe card contains also the snubbers (R-C circuits) that limits the commutation spikes, connected between the phases and the rectifier output poles

LOOP card (PB115)The LOOP card is composed by the following main sections:

Voltage control loopBattery current control loopGeneral control stageBattery charging voltage thermal compensation control (OPTIONAL)

LOOP card (PB115)Generation of the internal referenceWhenever the signal 1_ON is active (originating from the PRCH card), and therefore the rectifier start-up is enabled, the card generates a stabilised internal voltage reference (VREF), that is used in the voltage control loop

LOOP card (PB115)Voltage control loopGeneration of the SET-POINT (using the signal VREF) and comparison with the feedback signalRegulation of the FLOATING and BOOST voltage (if enabled)

LOOP card (PB115)Battery current control loopThe output signal of the battery current control loop is inserted in the control loop for the total stabilityThe SET-POINT that defines the battery limitation current is adjusted through the potentiometer P3

LOOP card (PB115)General control stageThe output voltage and battery current control loops are joined togetherThe battery current loop has the priority only when the current is limited during the battery re-charge phaseThe error signal Ve is used for the generation of the correct thyristors turn-on delay angle

LOOP card (PB115)Thermal compensation of the charging voltageA temperature probe, installed inside the battery room, is connected to the terminal board M2The feedback signal is opportunely amplified and inserted in the voltage control loop

LOOP card Settings

POTENTIOMETERP1Output voltage regulation in MANUAL control modeP2Output voltage regulation (FLOATING voltage) in AUTOMATIC control modeP3Regulation of the battery current limitationP4Regulation of the stability of the regulation loops (output voltage and battery current)P5Output voltage regulation (BOOST voltage) in AUTOMATIC control mode

LOOP card Interfaces with I/S-CL (mP)LOOP I/S-CLSignal of the battery SHUNT for the mP battery current reading (only when the BOOST charge is enabled)Connector M3

I/S-CL LOOPCommand of the relay RL1 for the BATTERY TESTPin 3-6 connector CN1Command of the relay RL2 for FLOATING/BOOST commutationPin 2-4 connector CN1Command of the relay RL3 for RECTIFIER STOPPin 1-5 connector CN1

SYNC-12 card (PB116)The SYNC-12 card is composed by the following main sections:

Generation of the DC power supply (12V/24V)Generation of the synchronism signals for the thyristors firing

SYNC-12 card (PB116)Generation of the DC power supply+24Vdc for the supply of the firing pulses+/-12Vdc for the supply of the control electronic circuits

SYNC-12 card (PB116)Generation of the synchronism signalsThe card uses a transformer with two secondary windings, displaced by 30, so that it can be used as the only generator of synchronism signals also in the 12-pulse configurationThe synchronism signals are used for both the control of the AC supply voltage and the generation of the control ramps of the thyristors delay angle

RCLS-1 card (PB117)The RCLS-1 card is composed by the following main sections:

Control of the rectifier AC supply voltageControl of the internal DC supplyGeneration of the thyristors turn-on signals (initial stage)Thyristors firing circuit (final stage)Voltage control loopBattery current control loopTotal current control loopGeneral control stageBattery charging voltage thermal compensation control (OPTIONAL)

RCLS-1 card (PB117)Control of the AC supply voltageInput phase sequence control (signal 0_SCOK if the phase sequence is OK)Low mains voltage control, Threshold adjustable with the potentiometer P13Generation of the signal 1_AR (Mains failure) in case of anomaly of the previous signals

RCLS-1 card (PB117)Control of the DC supply and rectifier start-up

RCLS-1 card (PB117)Control of the DC supply and rectifier start-upThe +12V supply is controlled by a comparator (signal 1_PSOK)Such signal is then put in OR logic with the fault signals due to the fuses failure (0_FB) or high temperature (0_AT)A OR logic is used again to establish the rectifier start-up conditions, comparing the previous signal (1_AV), the mains failure signal (1_AR) and the stop command (1_STOP) depending on either the switch SW1 of the card or possible commands by microprocessorThe start-up command (0_ON) is generated if none of the previous signals is activeIn case of 12-pulse configuration its important to note that the logic described previously is managed by the SLAVE rectifier too, except for the Start/Stop signal that is generated by the MASTER card only

RCLS-1 card (PB117)Generation of the internal referenceThe presence of the signal ON enable the soft-start of the rectifier (1_SOFT); the signal 1-SOFT activates the circuits that generates the stabilised internal voltage reference (VREF), that is used in the voltage control loop

RCLS-1 card (PB117)Generation of the thyristors turn-on signals

RCLS-1 card (PB117)Generation of the thyristors turn-on signalsThe IC TCA785 generates a ramp signal in phase with the corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8)Each ramp is compared with a control level (TP5). The result of the comparison (square wave) defines the thyristors delay angleThe square wave is mixed with a high frequency signal (TP9). The resulting series of pulses represents the initial stage of the thyristors control circuitThe final stage, similar to the circuit of the FIR-91 card, is integrated inside the RCLS-1 card, as well as the snubber circuits for the limitation of the commutation spikes

RCLS-1 card (PB117)Voltage control loop

RCLS-1 card (PB117)Voltage control loopGeneration of the SET-POINT (using the signal VREF) and comparison with the feedback signalRegulation of the FLOATING and BOOST voltage (if enabled) Further possible voltage regulation in MANUAL charge mode (OPTIONAL) with external potentiometer and contact command of the relay RL6 on the connector M1The relays RL1 and RL2 are controlled by the microprocessor card and used respectively for the BATTERY TEST and for the BOOST charge command The feedback signal is normally taken directly on the card (DC bus - jumper JP3 in position 1-2). When the DC choke is installed, the signal is taken externally and connected to the pin 6 of CN4

RCLS-1 card (PB117)Battery current control loopThe output signal of the battery current control loop is inserted in the control loop for the total stabilityThe SET-POINT that defines the battery limitation current is adjusted through the potentiometer P15

RCLS-1 card (PB117)Total current control loopThe output signal of the battery current control loop is inserted in the control loop for the total stabilityThe SET-POINT that defines the total limitation current is adjusted through the potentiometer P2

RCLS-1 card (PB117)General control stageThe output voltage, battery current and total current control loops are joined togetherThe current loops have the priority only when the current is limited (battery re-charge phase or output current exceeding the maximum value allowed)The error signal Ve is used for the generation of the correct thyristors turn-on delay angle

RCLS-1 card (PB117)12-pulse current balanceA Hall effect CT, connected to the connector CN2 of the RCLS-1 MASTER, control the current difference of the two bridgesThe error signal, opportunely amplified and filtered, is used to vary the control level in the circuit that generates the thyristors delay angle

RCLS-1 card (PB117)Thermal compensation of the charging voltageA temperature probe, installed inside the battery room, is connected to the connector CN1 (through a interface card)The feedback signal is opportunely amplified and inserted in the voltage control loop

RCLS-1 card - Settings

POTENTIOMETERSP1Regulation of the off-set OP-AMP TOTAL CURRENTP2Regulation of the TOTAL CURRENT limitationP3Regulation of the VOLTAGE loop stabilityP4Output voltage regulation (FLOATING) in AUTOMATIC control modeP5Output voltage regulation (BOOST) in AUTOMATIC control modeP6Regulation of the off-set OP-AMP BATTERY CURRENTP8Regulation of the TOTAL control stabilityP9Output voltage regulation in MANUAL control modeP10Regulation of the current sharing in 12-pulse configurationP11Regulation of the amplitude ramp phase RP12Regulation of the amplitude ramp phase SP13Regulation of the AC voltage tolerance (alarm AR)P14Regulation of the amplitude ramp phase TP15Regulation of the BATTERY CURRENT limitation

RCLS-1 card - ControlsThe LEDs are normally lit steady, blinking in case of alarm (except DL12 that is normally OFF and lit in case of alarm)

CONTROL LEDCOLOURDL4Rectifier overload (Iout>100%)YELLOWDL5Internal DC supply not correctREDDL6Rectifier OFFGREENDL7High temperature of the rectifier bridgeREDDL8Protection fuses failureREDDL9Fans failure (not used)REDDL10Mains failureREDDL11Input phase sequence not correctYELLOWDL12AC supply low voltage RED

RCLS-1 card Interfaces with I/S-CL (mP)RCLS-1 I/S-CLMAINS FAILURE signalPin 1-2 connector CN7RECTIFIER ON signalPin 5-6 connector CN5FUSES FAILURE signal Pin 1-2 connector CN5WRONG PHASE SEQUENCE signalPin 3-4 connector CN5Signal of the battery SHUNT for the mP battery current reading (only when the BOOST charge is enabled)Pin 710 connector CN5

RCLS-1 card Interfaces with I/S-CL (mP)I/S-CL RCLS-1Command of the relay RL1 for the BATTERY TESTPin 3-6 connector CN6Command of the relay RL2 for FLOATING/BOOST commutationPin 2-4 connector CN6Command of the relay RL3 for RECTIFIER STOPPin 1-5 connector CN6

The RCLS-1 card can be also connected to a relay card to repeat to a remote location the 6 main alarms

Summary of the rectifier cards functions

PRCHPB115LOOPPB114FIR-91PB113SYNC-12PB116RCLS-1PB117Generation of the 12V/24V supplyXXGeneration of the synchronism signalsXXAC supply voltage controlXXInternal DC supply controlXXGeneration of the thyristors firing signalsXXThyristor firingXXVoltage control loopXXTotal current control loopNOT PROVIDEDXBattery current control loopXXGeneral controlXXThermal compensation of the charging voltage (OPTIONAL)XXInterface with a relay cardNOT PROVIDEDX

InverterSingle-phase inverterThe rectifier output voltage (battery) is applied to the IGBT bridge, composed by four power components controlled through PWM technologyThe inverter bridge output voltage is adapted by the isolation transformer and subsequently filtered by the low-pass filter formed by the inductance integrated in the transformer and the AC capacitors

InverterThree-phase inverterThe rectifier output voltage (battery) is applied to the IGBT bridge, composed by six power components controlled through PWM technologyThe inverter bridge output voltage is adapted by the isolation transformer and subsequently filtered by the low-pass filter formed by the inductance integrated in the transformer and the AC capacitors

Inverter typologiesAs already seen for the rectifiers, also the inverters can be separated in different typologies, according to the constructive solution chosen

TYPE 1Its the single-phase inverter, with the following manufacturing featuresUse of two power components, each containing two IGBTsInstallation on a single heatsinkForced cooling with single fanPower connections carried out through interface card IBPC-7 (PB120), which includes the DC capacitors and the Hall effect CT

Inverter typologiesTYPE 2Its the three-phase inverter, with the following manufacturing featuresUse of two power components, each containing two IGBTsInstallation on a single heatsinkForced cooling with single fanPower connections carried out through interface card IBPC-7 (PB120), which includes the DC capacitors and the Hall effect CTTYPE 3Its the three-phase inverter used starting form the 40kVA. The power components are connected with cables and/or copper bars, without interface card. Double IGBT packs (that is a single component containing two IGBTs) are generally used up to 160kVA range

Static switchSingle-phase static switchIts composed by two pairs of thyristors, connected in anti-parallel, that interrupt the phase conductors (inverter/bypass)The bypass component is protected by a fast-acting fuseIn order not to modify the grounding system the neutral conductor is not interrupted

Static switchThree-phase static switchIts composed by six pairs of thyristors, connected in anti-parallel, that interrupt the phase conductors (inverter/bypass)

Static switch typologiesTYPE 1Its the single-phase static switchTYPE 2Its the three-phase static switch that uses compact type thyristors (SemiPack)TYPE 3Its the three-phase static switch that uses disc-type thyristors (used only on the 500kVA and 650kVA)

The three types of static switch use different firing cards, that vary on the basis of the components layout

Inverter & static switch controlUnlike the rectifier, where the control of the operating parameters is purely analogue, the control of the inverter is completely entrusted to the microprocessor (HC16 Motorola), that develops the following main functionsGeneration of the reference sine-wave used for the creation of the PWMComplete management of the operating logics of the inverter and static switchManagement and control of the measure shown on the displayControl of the synchronism, in stand-alone and parallel operationThe microprocessor card uses some additional cards, each of them with its own specific function

Inverter & static switch controlThe following electronic cards are used for the inverter and static switch controlINVERTERI/S-CL(PB003), inclusive of:RCB(PB011)VCB(PB012)SCB(PB014)PS-HV(PB001)ID(PB013)INV-AV(PB004/PB018)FCI(PB047)

STATIC SWITCHVOLT-REF(PB005/PB019)SCR-FIR(PB009/PB010/PB016)

PS-HV card (PB001)The PS-HV card is the system power supply, the one that creates the different power supplies for the whole control electronic (except, obviously, the rectifier)Its a switch-mode power supply, with IN/OUT galvanic isolation provided by a high frequency transformerAccording to the UPS nominal DC voltage (in our case 384Vdc) the power supply can be divided in:PS-HV(PB001)Supply range: 300600VdcPS-MV(PB002)Supply range: 180300VdcPS-LV(PB184)Supply range: 180300VdcFor application where the power required is higher because of, for example, the use of parallel IGBTs (SATURN series, Pnom>200kVA) its used a power supply called PS-SAT (PB107), similar to the PS-HV except for the higher power

PS-HV card (PB001)The power supply card is composed by the following main sections:

Microprocessor supply sectionAnalogue part supply sectionIGBT drivers supply sectionRelays and BUS supply sectionSerial ports supply sectionDC voltage measure section

PS-HV card (PB001)Microprocessor supplyThis section supplies all the digital part (microprocessor) and the LCD panelThe voltage is further stabilised by a 5V stabiliser mounted on board the microprocessor cardThe supply AC3-AC4, that will be described later on, is taken from the same secondary winding of the transformer

PS-HV card (PB001)Analogue part supplyThis section supplies all the analogue part of the microprocessor cardThe supply AC1-AC2, that will be described later on, is taken from the same secondary winding of the transformer

PS-HV card (PB001)Relays and BUS supplyThis section provides a 12V stabilised voltage for:Relays of the alarm card ARC (PB031) pin 9-10Rectifier card relays (battery test, floating/boost, stop) pin 9-10Parallel BUS pin 9-10Digital signal interface card FCI (PB047) pin 1-2

PS-HV card (PB001)IGBT drivers and serial port supplyThe IGBT drivers are supplied by the 40khz square wave AC1-AC2A rectifying circuit, that provides also to isolate galvanically the supply of the driver, is provided on board the driver itself

The serial ports are supplied by the 40khz square wave AC3-AC4A rectifying circuit, that provides also to isolate galvanically the supply of the serial ports, is provided on board the card RCB

PS-HV card (PB001)DC voltage measureThis section provides a stabilised voltage, proportional to the amplitude of the DC supply voltageSuch signal is sent to the microprocessor as feedback for the correct display of the inverter input voltage

PS-HV card Settings and controls

POTENTIOMETERSP1Regulation of the DC voltage measureP2Regulation of the IGBT drivers supply voltage

CONTROL LEDCOLOURDL1+12V analogue part supplyGREENDL2-12V analogue part supplyGREENDL3+24V analogue part supplyGREENDL4+12V relays and BUS (pin 9-10 CN3)GREENDL5+12V FCI card relays (pin 1-2 CN3)GREEN

ID card (PB013)The ID card is the IGBT driver and its designed for the control of a complete inverter leg (IGBT+ / IGBT-)Its composed by two identical sections, each one with its own power supplyWith proper addition of components each section of the card can control up to two IGBTs in parallel, but such option is not provided for the actual production lineFor the control of parallel IGBTs in the high power range UPS (>200kVA) another card is used, the DR-SAT (PB108), a card for each switch (therefore two cards for each bridge leg)Besides the functions of the ID card, the DR-SAT is provide with an additional protection with a desaturation sensor

ID card (PB013)Power supply sectionThe square wave AC1-AC2, originating from the power supply card PS-HV, is used to generate the isolated supplies for both sections of the card

ID card (PB013)Initial stageA opto-coupler provides for the de-coupling of the PWM signal coming from the I/S-CL cardA low-pass filter introduces a little delay in the pulse transfer (dead time)The LED LD1 indicates the presence of the PWM signal

ID card (PB013)Final stageThe signal is amplified by a MOSFET amplifier that provides also for the translation of the signal between +/-15VSuch voltage can be adjusted by the potentiometer P2 of the PS-HV card

INV-AV card (PB004/PB018)The INV-AV card is divided in INV-AV-1F (PB018), for single-phase inverter and INV-AV-3F (PB004), for three-phase inverterThe card is basically composed by two sections:

Inverter voltage feedbackThe inverter output voltage, taken directly on the AC capacitors, is connected to the connector CN1. Three transformers (one on the INV-AV-1F) adapt the voltage that can be used as feedback signal for the output voltage regulation loopOutput current measureThe three output CTs (one on the single-phase inverter) are connected to the connector CN3. The voltage drop on the resistors R4 (phase R), R5 (phase S), R6 (phase T), due to the CTs secondary current, is used as reference signal for the measure of the output current

VOLT-REF card (PB005/PB019)Electrical drawing

VOLT-REF card (PB005/PB019)The VOLT-REF card is divided in VOLT-REF-1F (PB019), for single-phase inverter and VOLT-REF-3F (PB005), for three-phase inverterThe card is basically composed by four sections:Bypass voltage feedbackThe BYPASS voltage, taken on the static switch input, downstream the thyristors protection fuses, is adapted by the three transformers (one on the VOLT-REF-1F). The signals obtained are used by the microprocessor as reference for the measure and control of the tolerance limitsBypass voltage feedbackThe OUTPUT voltage, taken on the static switch output is adapted by the three transformers (one on the VOLT-REF-1F). The signals obtained are used by the microprocessor as reference for the measure and control of the tolerance limits

VOLT-REF card (PB005/PB019)Static switch logics supplyThe secondary voltage of the transformers (one of the two secondary windings) is rectified and stabilized in order to obtain two supplies: 24Vdc not stabilised and 5Vdc stabilisedThe 24Vdc is used for the supply of the final stage (card SCR FIRING) of the bypass thyristors control circuitThe 5Vdc is used for the supply of the SCB card, that manages the static switch operating logicFans supply sectionThe three couples of phase-neutral supplies on the connector CN3 are used on the units up to 30kVA for the supply of the cooling fans

SCR-FIR card (PB009/PB010/PB016)The SCR FIRING cards contain the final stage for the inverter and bypass static switch control circuit (see card FIR-91 for the rectifier), and are fixed directly on the thyristorsSCRSF-3F(PB009)Designed for the control of 6 couples of thyristors (a complete three-phase static switch)SCRSF-1F(PB010)Designed for the control of 2 couples of thyristors, inverter and bypass (a complete single-phase static switch or a section of a three-phase static switch)2SCR-FIR(PB016)Designed for the control of 1 couple of thyristors

FCI card (PB047)The FCI card is basically a relay card, and is used to de-couple the microprocessor card from the digital signal originated externally (auxiliary contacts of breakers, etc.)Such contacts are normally connected to the connector M3 of the I/S-CL (PB003) cardIn the standard production the FCI card is used on the units starting from 40kVAIts important to remember that the supply of the relays of the card comes directly from the power supply card (PS-HV), pin 1-2 of the connector CN3

FCI card (PB047)Configurations of the signals

SIGNALS SIDEFCI M1OriginSignalmP SIDEFCI M21-2Not used - Spare1-23-4Rectifier cardMains failure3-45-6EPO push-buttonEmergency Power Off5-67-8BCB aux contactBCB open/closed7-89-10OCB aux contactOCB open/closed9-1011-12Switch SW1Bypass switch11-1213-14MBCB aux contactMBCB open/closed13-1415-16Thermal switchHigh temperature15-1617-18Parallel cardParallel configuration17-18

I/S-CL card (PB003)The I/S-CL card contains the microprocessor and all the electronic logics for the inverter and static switch operation. Its composed by the following main sections:

Digital supplyMemoriesWatchdog and reset circuitMeasures Internal A/D converterMeasures External A/D converterCurrent protectionVoltage control loop card VCBPWM generationStatic switch control card SCBSerial port supply card RCBDigital inputs

I/S-CL card (PB003)Digital supplyThe voltage originated from the power supply card, connector CN1 (about 9V), is further stabilised by means of a precision stabiliser, filtered by means of L-C filters and made suitable for the supply of the microprocessor

I/S-CL card (PB003)RAM (U58)The RAM contains the events log (up to 900 events), the information related to the year for the clock setting and the tables for the voltage fast sensors (described later on)A back-up battery provides to keep the data storedEEPROM (U71)The EEPROM contains the UPS functional parameters and all the settingsEPROMs (U55-U65)The EPROMs contain the operating program, split into odd (U65) and even (U55) addressesWatchdog e resetThe microprocessor is controlled by a smart watchdog that provides for the reset of the program in case of processing error or problems in the supply voltage (undervoltage lock-out)The microprocessor can be manually reset through the push-button SW3

I/S-CL card (PB003)Measures Internal A/D converterThe measures related to the bypass and output voltage are directly acquired by the microprocessor and converted by the internal analogue/digital converterThe signal are translated of 2,5V in comparison to the zero, therefore the microprocessor recognise automatically the level zero

I/S-CL card (PB003)Measures External A/D converterSome measures are acquired by the microprocessor in serial mode, after they have been converted by a analogue/digital converter (SPI Serial Peripheral Interface) placed in the analogue part of the card

I/S-CL card (PB003)Measures External A/D converterIn order to read correctly the values, a software adjustment during the microprocessor setting phase provides to define the level zero, where the actual value of the parameter is voidThe measures for which the zero must be set are: Inverter voltage phase RInverter voltage phase SInverter voltage phase TOutput current phase ROutput current phase SOutput current phase TInverter input DC currentThe parameter CFPAR is used only in the PARALLEL configurationThe parameter IBOOST is used only when the boost charge in enabled

I/S-CL card (PB003)Measures SummaryFor further clarity the origin of the signals used by the microprocessor for the measures are summarised hereunder

SignalProvenienzaBYPASS voltage (phases R/S/T)VOLT-REF-3F (1F) cardOUTPUT voltage (phases R/S/T)VOLT-REF-3F (1F) cardINVERTER voltage (phases R/S/T)VCB cardsOUTPUT current (phases R/S/T)INV-AV-3F (1F) cardDC voltagePS-HV cardDC currentInverter input Hall effect CT

I/S-CL card (PB003)Current protectionThe current protection is carried out acquiring the signal related to the inverter bridge input current, function of the UPS output currentA Hall effect CT, connected on the positive cable (or copper bar) between the DC capacitors and the inverter bridge, is used for this purposeSuch configuration guarantees the control and protection against possible short-circuits of the inverter bridge, caused by the failure of one IGBTIn the UPS that uses the interface card IBPC-7 (PB120) for the power connections the CT is mounted on the card itselfThe supply of the CT (+12V/-12V) comes from the power supply card PS-HV (analogue supply section) via the connector M1 of the I/S-CL card

I/S-CL card (PB003)Short circuit protection

I/S-CL card (PB003)Short circuit protectionThe feedback signal originated by the Hall effect CT is acquired by the microprocessor cardThe feedback current generates a voltage drop flowing through the resistors R18-R39-R40, so that it can be used for the control circuitBy 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 circuitThe signal on the test point TP2 must be equal to 4Vpeak 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)

I/S-CL card (PB003)Current stop protection

I/S-CL card (PB003)Current stop protectionThe resistors R18-R39-R40 are properly combined according to the IGBTs nominal currentIn case of bridge leg short circuit the PWM is stopped before the input current exceed the 200% of the IGBTs nominal currentThe detection time and the subsequent inverter stop is not higher than a PWM pulse (max. 250ms)The inverter stop due to Current stop is signalled by the LED D3, placed on the front of the I/S-CL cardThe program provides for the automatic reset of the stop condition for three times, re-starting the inverterIf 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

I/S-CL card (PB003)VCB card (PB012) Voltage control loopThe VCB card contains all the electronic logics for the voltage control loopEach inverter output phase is controlled by a different card, therefore the I/S-CL card for a three-phase inverter will mount three VCB cardsThree main sections can be identified:Generation of the reference sine-waveVoltage correctionInverter voltage measureThe output signal from the VCB card is used by final stage of the PWM generation, in the I/S-CL card

I/S-CL card (PB003)VCB card (PB012) Sine-wave generationThe digital signal coming from the microprocessor (that represents the digital sine-wave) is converted by a D/A converter in order to obtain a real sine-waveThe amplitude of the sine-wave 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 P1Each phase of the inverter is disengaged and can be varied independentlyIn 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 operating on the potentiometer P1 of the I/S-CL cardIn this case the inverter output voltages are varied contemporary

I/S-CL card (PB003)VCB card(PB012) Voltage correctionThe 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 J2The feedback signal, coming from the INV-AV-3F (1F) card is compared with the reference sine-wave e properly filteredThe resulting signal is added again to the reference sine-wave

I/S-CL card (PB003)VCB card(PB012) Inverter voltage measureA section of the card is dedicated to the creation of of a signal that can be used as reference for the measure of the inverter output voltageThe feedback signal, originating from the card INV-AV-3F (1F), is rectified, filtered and sent to the SPI, and then to the microprocessor

I/S-CL card (PB003)Generation of the PWM reference frequencyThe generation of the IGBTs turn-on pulses is carried out comparing two signals: the reference signal (sinusoidal at 50 or 60kz) originated from the VCB card and a triangular waveform with a frequency equal to the desired commutation frequencyThe triangular waveform is a function of a reference signal generated by the microprocessor

I/S-CL card (PB003)PWM generation Final stageThe final stage is the real comparison of the sine-wave with the triangle and the following transmission of the resulting PWM signal to the IGBT driver cards

I/S- CL card (PB003)SCB card (PB014) Static switch controlThe SCB card contains the decisional logics of the static switch (inverter & bypass)Its directly supplied by the bypass or the output through the VOLT-REF-3F (1F) cardThe LED L1 signals the presence of the 5V supplyThe bypass static switch thyristors are controlled directly by the SCB cardThe inverter static switch thyristors are controlled by the I/S-CL card according to the consents originated from the SCB cardRCB card (PB011) Serial ports supplyThe RCB card contains the drivers for the serial interface ports RS232 and RS485 and for the microprocessors digital outputs (alarm relay card)The supply is isolated, created internally using the square wave AC3-AC4 coming from the PS-HV card

I/S-CL card (PB003)Digital inputsThe digital inputs are connected directly, or through the de-coupling card FCI, to the connector M3Such signals are internally de-coupled and connected to the microprocessor

I/S-CLM3Signal1-2Not used - Spare3-4Mains failure5-6Emergency Power Off7-8BCB open/closed9-10OCB open/closed11-12Bypass switch13-14MBCB open/closed15-16High temperature17-18Parallel configuration

I/S-CL card configurationThe I/S-CL card can be easily configured with simple operations and can be adapted to all the production range (Standard and custom UPS)Four different configurations can be identified:

Configuration of the nominal parametersConfiguration of the switching frequencyConfiguration of the current protectionConfiguration of the jumpers

I/S-CL card configurationConfiguration of the nominal parametersThe nominal parameters can be configured by means of dip switchesAt the start-up the program recognises the position of each dip switch and configures the operating parameters accordinglyFor the correct configuration of the dip switches refer to the relevant technical documentationConfiguration of the switching frequencyThe switching frequency depends on the frequency of the triangular waveform that is compared with the reference sine-wave to generate the PWM signalThe frequency of the triangle can be varied modifying the value of the resistor R66:R66 = 6K81fswitching = 8khzR66 = 13K6fswitching = 4khzR66 = 24K9fswitching = 2khz

I/S-CL card configurationConfiguration of the current protectionThe current protection, and particularly the Current stop protection, can be configured combining properly the resistors R18-R39-R40 according to the IGBTs nominal currentFor the standard UPS a configuration table does exist, the calculation form is shown hereunder10 x KLEM--------------------2 x IIGBTREQ =Where:REQ = Series combination of R18-R39-R40KLEM = Conversion ratio of the LEMIIGBT = IGBTs nominal current

I/S-CL card configurationConfiguration of the jumpersThe I/S-CL card is provided with some jumpers, necessary to configure some operating parametersThe most interesting jumpers for the configuration on field are shown in the following table

JumperPosFunctionJ11-2SINGLE-PHASE inverter2-3THREE-PHASE inverterJ2ClosedBack-up battery connectedJ7ClosedWatchdog enabledJ9ClosedResistor R40 (100R) insertedJ10ClosedResistor R39 (47R) insertedJ100ClosedResistor R18 (22R) inserted

I/S-CL card Settings and controls

POTENTIOMETERSP1Regulation of the inverter voltage in MANUAL modeP2Regulation of the current signal (TP2)

CONTROL LEDCOLOURD3Current stop protectionREDD8Short circuit protectionREDD11Presence of the analogue parts supply (+12V)GREEND69Presence of the digital parts supply (+5V)GREEN

Protections and controls of the SW programThe software program provides for the control of the UPS functionality basing on the instructions assignedThe setting of the I/S-CL cards dip switches gives the program the main indications to define the control and protection thresholdsThe two most important controls, for the purpose of the inverter bridge and load protection, will be defined in detail

Control of the output and bypass waveformsOverload protection (Thermal image)

Waveform controlThe control is based on the sampling of the sine-wave and the subsequent comparison of the samples with a reference valueThe sine-wave is sampled 36 times in a periodThe RMS value of the sine-wave is calculated using the samples obtained, and compared with the minimum and maximum thresholds defined in the softwareEach of the 36 samples (Vsn) is also compared with values contained inside reference tables (VtL/VtH) so that the following disequations are satisfiedVtL1< Vs1< VtH1 ; VtL2< Vs2< VtH2 ; . ; VtL36< Vs36< VtH36The tables are part of the program and are downloaded in the RAM at each start-up of the program itselfIf 4 consecutive samples of one of the phases dont satisfy the comparison the voltage is declared out of tolerance

Overload protectionThe overload protection is also called Thermal image because its indeed based on the calculation of the energy stored during the overload operationThe overload is defined when at least one of the output currents exceed the 100% of the nominal valueAs soon as a overload is detected the program starts to take samples of the output current, calculating the integral I2tThe value of the integral (energy accumulation) is compared with a limit value, equal to the overload capability of the equipment (125% In x 10 minutes)When the limit is reached the program stops the inverter and the load is transferred to bypass (if available)The inverter is switched on again after 30 minutes

User interfacesThe UPS is provided with two serial ports and a optional relay card for the interface with the external worldThe serial port RS485 is used only for the connection with the remote panelThe serial port RS232 is used for the interface with software applications and transmits all the UPS data through a proprietary protocolThe relay card ARC provides the indication of a operating status and 3 alarms, that can be modified only by changing the software on board the microprocessor cardThe most important user interface is however the LCD panel, that makes the UPS operating parameters (measures, status and alarms) immediately available to the user

LCD panelThe LCD panel is the graphic interface of the microprocessor, and provides at each instant the indication of the UPS operating parametersThe mimic on the left aids the comprehension of the energy flux and provides the immediate display of possible anomaliesThe display is basically a passive component, except for some basic functionalities that allow the active interface with the microprocessor

LCD panel MeasuresThe measures available on the LCD panel are the same described before for the microprocessor card I/S-CLOUTPUT measuresVoltage of the three phases (measure Ph-N)FrequencyCurrent of the three phases (phase current)Percentage of load on each phaseBYPASS measuresVoltage of the three phases (measure Ph-N)FrequencyINVERTER measuresVoltage of the three phases (measure Ph-N)Frequency

LCD panel MeasuresDC measuresInverter input voltageBATTERY measuresBattery voltageBattery type (autonomy in Ah)Battery current *Battery residual autonomy (in minutes) *Battery residual autonomy (in percent) *

*The data indicated with asterisk are active only with the battery in discharge mode

The menu relevant to the battery measures is automatically activated in case of mains failure and battery discharging

LCD panel Status and alarmsThe software program is able to process the information relevant to 6 different operating status and 25 alarms, defined by means of alphanumeric codesEach alarm is associated with an internal protection, controlled by the microprocessor, that disabled certain UPS functions in order to avoid possible loss of supply to the loadThe alarm codes are stored in the event log (history log)The history logs the event, that is both the alarm and its automatic reset (if any), indicating the reset with a star next to the codeBesides the alphanumeric code of the alarm, the history log indicates date, hour and minute of the event

LCD panel Status

Cod.NameDescriptionS1AC/DC OKRectifier output voltage within toleranceS2BATTERY OKBattery connected to the DC busS3INVERTER OKInverter voltage within toleranceS4INVERTER SYNCSynchronism reference within toleranceS5INVERTER LOADInverter static switch closed, load on inverterS6BYPASS OKBypass voltage and frequency within tolerance

LCD panel Alarms

Cod.NameDescriptionA1MAINS FAULTRectifier input mains failureA2CHARGER FAULTBattery charger failureA3RECT FUSEOne or more rectifier fuses are blownA4THERMAL IMAGELoad transferred to mains due to overload. A5AC/DC FAULTRectifier output voltage out of toleranceA6INPUT WR SEQInput phase rotation not correctA7BCB OPENBattery circuit breaker openA8BATT DISCHThe battery is dischargingA9BATT AUT ENDBattery autonomy (calculated) has expiredA10BATT FAULTBattery test failed or intervention of the safety timer during boost chargeA11BATT IN TESTBattery test in progressA12PLL FAULTProblems with the digital synchronisation systemA13INV OUT TOLInverter output voltage out of tolerance

LCD panel Alarms

Cod.NameDescriptionA14OVERLOADInverter overload (load exceeding 100%)A15BYP FAULTEmergency mains not availableA16BYP FEED LOADLoad fed by bypassA17RETR BLOCKTransfer between bypass and inverter blockedA18MBYP CLOSEManual bypass breaker closedA19OCB OPENUPS output breaker openA20FANS FAILUREOptionalA21HIGH TEMPHigh temperature on the inverter and/or rectifier bridgeA22BYP SWITCHClosure of the commutation switch which forces the load to bypass (maintenance)A23EPO BUSIntervention of the emergency power off switch according to the EN62040-1A24CURR STOPInverter bridge stop for max currentA25SHORT CIRCUITIntervention of the short circuit protection

LCD panel CommandsThe LCD panel is provided with a section through which its possible to carry out some simple functional testThe section can be accessed through the menu SPECIALSETTINGSSection for the setting of the local date and timeUPS TESTStatic switch commutation testThe inverter is stopped and the load transferred to bypassBATTERY TESTThe battery test is carried out reducing the rectifier voltage for 30 secondsIf the voltage reaches the pre-alarm level, the alarm A10 Battery fault is activatedRESET HISTORYSection for deleting the events log

UPSTest softwareThe UPSTest software is used to verify the UPS operating parametersBesides it offers the possibility to control the software programs flux so that to identify possible anomaliesRefer to the technical documentation for further information about the software settings and the relevant commandsIts divided in the following main sections:MeasuresUPS dataVariablesOutputsInputsAlarmsStatus

UPSTest software

UPSTest softwareSection MEASURESThe section MEASURES shows all the voltages and currents acquired by the microprocessor

Section ALARMSThe section ALARMS shows all the alarms managed by the microprocessor, that are the same displayed by the LCD panel

Section STATUSThe section STATUS shows all the operating status managed by the microprocessor, that are the same displayed by the LCD panel

UPSTest softwareSection UPS DATAThe section UPS DATA shows all the UPS nominal data, that are generally set by changing the position of the dip switches of the I/S-CLUPS nominal data, depending on the position of the dip switches of the I/S-CL cardBattery data, adjustable through software commandsVoltage thresholds settings, fixed and not adjustable if not changing the UPS control softwareTolerance limits of the bypass frequency, adjustable through software commandsDisplay of the residual battery autonomy

UPSTest softwareSection VARIABLESThe section VARIABLES shows all the software variables, used to guarantee the correct operation of the system

Each variable operates on a certain section of the UPS, so they can be divided in 4 different groups:

Variables relevant to the DC sectionVariables relevant to the INVERTER sectionVariables relevant to the BYPASS sectionVariables relevant to the USCITA section

The activation of a variable is indicated by a blue background

UPSTest softwareSection VARIABLESDC VariablesVDC_OK

INVERTER VariablesINV_ONSSW_ONIOKIFLCONACO_LOADHITEVUOKSYNCOKIMTERMBYPASS VariablesROK_XFROKRMSOK

USCITA VariablesCOKI_OVER

UPSTest softwareSection VARIABLESVDC_OKIt indicates that the INVERTER INPUT voltage is in tolerance, that is within the limits specified in the section UPS Data VDCINV_ONIts the command for the inverter start-up, that is managed by the microprocessor during the AUTOMATIC operating mode, or by software command in MANUAL modeSSW_ONIts the command for the inverter static switchIOKIt indicates that the inverter is ready to supply the loadIFLIt indicates that the inverter static switch is closedCONACIts the variable managing the modulation command for the inverter bridge IGBTs

UPSTest softwareSection VARIABLESO_LOADIt indicates the inverter stop following an extended overload (intervention of the thermal image protection)HITEIt indicates the intervention of the inverter bridge thermal protectionThe thermal protection can also be constituted by the series of different protections (inverter bridge, rectifier bridge, transformer, etc.)VUOKIt indicates that the INVERTER voltage is in tolerance, that is within the limits specified in the section UPS Data INVSYNCOKIt indicates the correct generation of the inverter-bypass synchronism signalIMTERMIt indicates the activation and the operation of the thermal image counter

UPSTest softwareSection VARIABLESROK_XIts the AND combination of the variables FROK and RMSOKFROKIt indicates that the BYPASS frequency is in tolerance, that is within the limits specified in the section UPS DataRMSOKIt indicates that the BYPASS voltage is in tolerance, that is within the limits specified in the section UPS Data BYPCOKIt indicates that the OUTPUT voltage is in tolerance, that is within the limits specified in the section UPS Data OUTThe variables RMSOK and COK indicates that the waveforms are correct and without particular distortions (see the waveform control carried out by the microprocessor)I_OVERIt indicates that the output current exceeds the nominal value (overload)

UPSTest softwareSection OUTPUTSThe section OUTPUTS shows all the commands generated by the microprocessor for the management of the various UPS sections

UPSTest softwareSection OUTPUTSCOKIts the command relevant to the variable COK, and is managed by the static switch control logic (SCB card)BY_BLIts the command that blocks the load on bypass, disabling the re-transfer of the static switch on inverterIFLIts the closing command of the inverter static switchCONACIts the command relevant to the variable CONAC and represents the real consent for the inverter bridge modulationOVERLOADIts the command relevant to the variable O_LOAD and represents the inverter stop command following an extended overload

UPSTest softwareSection OUTPUTSRES_RITR_BLIts the command that unlocks the static switch after a re-transfer blockR3_INV_FEEDIts the command of the relay RL3E il comando del rel RL3 (load supplied by inverter) of the alarm card ARCR4_BYP_FEEDIts the command of the relay RL4 (load supplied by bypass) of the alarm card ARCR5_LOW_BATTIts the command of the relay RL5 (battery low pre-alarm) of the alarm card ARCR6_MAINS_FAUIts the command of the relay RL6 (rectifier mains failure) of the alarm card ARC

UPSTest softwareSection INPUTSThe section INPUTS shows the status of all the microprocessors digital inputs

UPSTest softwareSection INPUTSMBY_CLOSEWhen active, the switch MBCB (manual bypass) is closedEPO_BUSWhen active, the UPS stop by EPO is not enabledBO_BUSWhen active, the switch BCB (battery) is openBYP_SW (FUSE)When active, the bypass switch (commutation test) is activeTERMO_SWWhen active, the thermal protection on the bridges has operatedOCBWhen active, the switch OCB (UPS output) is closedMCSWhen active indicates the Current stop protection has operated

UPSTest softwareSection INPUTSMRRWhen active, the mains failure signal, originated by the rectifier card, is not activeRECT_FAILWhen active, the rectifier failure signal, originated by the rectifier card, is not activeERR_SCWhen active, the wrong phase sequence signal, originated by the rectifier card, is not activeBF_RECTWhen active, the fuses failure signal, originated by the rectifier card, is not activePUL_XXThese variables indicates the push button on the LCD panel have pressed

UPSTest softwareAdditional sectionsTXCheck: transmission check (cyclic increment)PACKT: number of the data packets receivedSection to digit software command stringsFlag MASTER/SLAVE for the parallel operationInverter/bypass synchronisation dataUPS serial number (set by software command) and software version installed on board the I/S-LC cardIncrement of the thermal image counterBattery charge percentage

UPSTest softwareSezioni aggiuntiveKF BY: position of the bypass voltages control tableKF OU: position of the output voltages control tablePanel for the fast setting of the displays languageDip Sw: it opens a panel that shows the setting of the dip switches in the I/S-CL cardPar Data: it opens a panel that shows the control parameters during the parallel operationBOOST: it opens a panel that shows the current thresholds for the BOOST charge operationSet Date: it sets the date and time on the display (see menu special, SETTINGS) in function of the date and time set in the PCs operating system

End of the presentation