Technical presentation EVOLUTION line UPS

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Technical presentation EVOLUTION line UPS
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Contents
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General data

• The 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 cards
• Reduced 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)

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General data

• The 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/E 2032kVA e 4080kVA
• HALLEY/E 100160kVA
• SATURN/E 200300kVA
• SATURN/E 400650kVA

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Common technical features

• Total-controlled three-phase (6 pulses)
  thyristor-based rectifier
• 1ph and 3Ph IGBT inverter (H bridge)
• Inverter output isolating transformer
• Thyristor-based static switch with redundant
  supply
• Parallelability up to 4 UPS with microprocessor
  load sharing control, and communication protocol
  with high noise immunity
• Use of common parts and solutions on all the
  range
• Microprocessor control card
• LCD panel, thats to say same data access mode
• Test software

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PLANET/E 20-30kVA (3Ph / 1Ph)

• Input 3 x 380415Vac
• Output 1 x 220240Vac
• Power 20kVA 30kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) Internal up to
  24Ah
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 1
• Inverter type 1
• Static switch type 1

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HALLEY/E 20-30kVA (3Ph / 3Ph)

• Input 3 x 380415Vac
• Output 3 x 380415Vac
• Power 20kVA 30kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) Internal up to
  24Ah
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 1
• Inverter type 2
• Static switch type 2

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HALLEY/E 4080kVA (3Ph / 3Ph)

• Input 3 x 380415Vac
• Output 3 x 380415Vac
• Power 40kVA 60kVA 80kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) - External
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 2
• Inverter type 3
• Static switch type 2

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HALLEY/E 100160kVA (3Ph / 3Ph)

• Input 3 x 380415Vac
• Output 3 x 380415Vac
• Power 100kVA 125kVA 160kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) - External
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 2
• Inverter type 3
• Static switch type 2

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SATURN/E 200300kVA (3Ph / 3Ph)

• Input 3 x 380415Vac
• Output 3 x 380415Vac
• Power 200kVA 250kVA 300kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) - External
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 2
• Inverter type 3
• Static switch type 2

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SATURN/E 400650kVA (3Ph / 3Ph)

• Input 3 x 380415Vac
• Output 3 x 380415Vac
• Power 400kVA 500kVA 650kVA, p.f. 0,8
• Battery 192 cells Pb (384Vdc) - External
• Crest factor 31
• Overload capability 125Pn x 10min
• 150Pn x 1min
• 200In x 100ms
• Rectifier type 2
• Inverter type 3
• Static switch type 3 (except 400kVA)

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Rectifier
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Rectifiers features

• All 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 80kVA
• The 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 power
• The 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

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Rectifier typologies

• Two different types of rectifiers can be defined
  according to the manufacturing solution, and
  particularly basing on the control cards used
• TYPE 1
• Its 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)

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Rectifier typologies

• TYPE 2
• The 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 configuration
• Cards used
• SYNC-12 (PB116)
• RCLS-1 (PB117)

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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 firing
• Control of the rectifier AC supply voltage
• Control of the internal DC supply
• Generation of the thyristors turn-on signals
  (initial stage)

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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
  circuits
• The 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

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PRCH card (PB114)

• Control of the AC supply voltage
• Input phase sequence control (signal 0_SCOK) and
  lighting of LED DL1 if the phase sequence is
  correct
• Low 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

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PRCH card (PB114)

• Control of the DC supply and rectifier start-up
• The 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 activated
• Such 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

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PRCH card (PB114)

• Generation of the thyristors turn-on signals
• The 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 angle
• The square wave is mixed with a high frequency
  signal (TP9). The resulting series of pulses
  represents the initial stage of the thyristors
  control circuit

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PRCH card (PB114) Settings and controls
POTENTIOMETERS POTENTIOMETERS
P1 Amplitude regulation of the ramp phase R
P2 Amplitude regulation of the ramp phase S
P3 Amplitude regulation of the ramp phase T
CONTROL LED CONTROL LED COLOUR
DL1 Correct phase sequence YELLOW
DL2 AC voltage in tolerance (gt340Vac) YELLOW
DL3 Rectifier ON GREEN
DL4 Internal DC supply correct YELLOW

• The LEDs are normally lit steady, they are OFF in
  case of alarm

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PRCH card (PB114) Interfaces with I/S-CL (mP)

• PRCH ? I/S-CL
• MAINS FAILURE signal
• Pin 1-2 connector M1
• RECTIFIER ON signal
• Pin 1-2 connector M3
• I/S-CL ? PRCH
• No controls or commands are sent by the
  microprocessor card to the PRCH card

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FIR-91 card (PB113)

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

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LOOP card (PB115)

• The LOOP card is composed by the following main
  sections
• Voltage control loop
• Battery current control loop
• General control stage
• Battery charging voltage thermal compensation
  control (OPTIONAL)

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LOOP card (PB115)

• Generation of the internal reference
• Whenever 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

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LOOP card (PB115)

• Voltage control loop
• Generation of the SET-POINT (using the signal
  VREF) and comparison with the feedback signal
• Regulation of the FLOATING and BOOST voltage (if
  enabled)

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LOOP card (PB115)

• Battery current control loop
• The output signal of the battery current control
  loop is inserted in the control loop for the
  total stability
• The SET-POINT that defines the battery limitation
  current is adjusted through the potentiometer P3

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LOOP card (PB115)

• General control stage
• The output voltage and battery current control
  loops are joined together
• The battery current loop has the priority only
  when the current is limited during the battery
  re-charge phase
• The error signal Ve is used for the generation of
  the correct thyristors turn-on delay angle

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LOOP card (PB115)

• Thermal compensation of the charging voltage
• A temperature probe, installed inside the battery
  room, is connected to the terminal board M2
• The feedback signal is opportunely amplified and
  inserted in the voltage control loop

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LOOP card Settings
POTENTIOMETER POTENTIOMETER
P1 Output voltage regulation in MANUAL control mode
P2 Output voltage regulation (FLOATING voltage) in AUTOMATIC control mode
P3 Regulation of the battery current limitation
P4 Regulation of the stability of the regulation loops (output voltage and battery current)
P5 Output voltage regulation (BOOST voltage) in AUTOMATIC control mode
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LOOP card Interfaces with I/S-CL (mP)

• LOOP ? I/S-CL
• Signal of the battery SHUNT for the mP battery
  current reading (only when the BOOST charge is
  enabled)
• Connector M3
• I/S-CL ? LOOP
• Command of the relay RL1 for the BATTERY TEST
• Pin 3-6 connector CN1
• Command of the relay RL2 for FLOATING/BOOST
  commutation
• Pin 2-4 connector CN1
• Command of the relay RL3 for RECTIFIER STOP
• Pin 1-5 connector CN1

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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

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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

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SYNC-12 card (PB116)

• Generation of the synchronism signals
• The 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 configuration
• The 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

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RCLS-1 card (PB117)

• The RCLS-1 card is composed by the following main
  sections
• Control of the rectifier AC supply voltage
• Control of the internal DC supply
• Generation of the thyristors turn-on signals
  (initial stage)
• Thyristors firing circuit (final stage)
• Voltage control loop
• Battery current control loop
• Total current control loop
• General control stage
• Battery charging voltage thermal compensation
  control (OPTIONAL)

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RCLS-1 card (PB117)

• Control of the AC supply voltage
• Input phase sequence control (signal 0_SCOK if
  the phase sequence is OK)
• Low mains voltage control, Threshold adjustable
  with the potentiometer P13
• Generation of the signal 1_AR (Mains failure) in
  case of anomaly of the previous signals

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RCLS-1 card (PB117)

• Control of the DC supply and rectifier start-up

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RCLS-1 card (PB117)

• Control of the DC supply and rectifier start-up
• The 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 microprocessor
• The start-up command (0_ON) is generated if none
  of the previous signals is active
• In 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

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RCLS-1 card (PB117)

• Generation of the internal reference
• The 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

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RCLS-1 card (PB117)

• Generation of the thyristors turn-on signals

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RCLS-1 card (PB117)

• Generation of the thyristors turn-on signals
• The 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 angle
• The square wave is mixed with a high frequency
  signal (TP9). The resulting series of pulses
  represents the initial stage of the thyristors
  control circuit
• The 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

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RCLS-1 card (PB117)

• Voltage control loop

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RCLS-1 card (PB117)

• Voltage control loop
• Generation of the SET-POINT (using the signal
  VREF) and comparison with the feedback signal
• Regulation 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 M1
• The 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

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RCLS-1 card (PB117)

• Battery current control loop
• The output signal of the battery current control
  loop is inserted in the control loop for the
  total stability
• The SET-POINT that defines the battery limitation
  current is adjusted through the potentiometer P15

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RCLS-1 card (PB117)

• Total current control loop
• The output signal of the battery current control
  loop is inserted in the control loop for the
  total stability
• The SET-POINT that defines the total limitation
  current is adjusted through the potentiometer P2

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RCLS-1 card (PB117)

• General control stage
• The output voltage, battery current and total
  current control loops are joined together
• The 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

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RCLS-1 card (PB117)

• 12-pulse current balance
• A Hall effect CT, connected to the connector CN2
  of the RCLS-1 MASTER, control the current
  difference of the two bridges
• The error signal, opportunely amplified and
  filtered, is used to vary the control level in
  the circuit that generates the thyristors delay
  angle

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RCLS-1 card (PB117)

• Thermal compensation of the charging voltage
• A 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

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RCLS-1 card - Settings
POTENTIOMETERS POTENTIOMETERS
P1 Regulation of the off-set OP-AMP TOTAL CURRENT
P2 Regulation of the TOTAL CURRENT limitation
P3 Regulation of the VOLTAGE loop stability
P4 Output voltage regulation (FLOATING) in AUTOMATIC control mode
P5 Output voltage regulation (BOOST) in AUTOMATIC control mode
P6 Regulation of the off-set OP-AMP BATTERY CURRENT
P8 Regulation of the TOTAL control stability
P9 Output voltage regulation in MANUAL control mode
P10 Regulation of the current sharing in 12-pulse configuration
P11 Regulation of the amplitude ramp phase R
P12 Regulation of the amplitude ramp phase S
P13 Regulation of the AC voltage tolerance (alarm AR)
P14 Regulation of the amplitude ramp phase T
P15 Regulation of the BATTERY CURRENT limitation
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RCLS-1 card - Controls
CONTROL LED CONTROL LED COLOUR
DL4 Rectifier overload (Ioutgt100) YELLOW
DL5 Internal DC supply not correct RED
DL6 Rectifier OFF GREEN
DL7 High temperature of the rectifier bridge RED
DL8 Protection fuses failure RED
DL9 Fans failure (not used) RED
DL10 Mains failure RED
DL11 Input phase sequence not correct YELLOW
DL12 AC supply low voltage RED

• The LEDs are normally lit steady, blinking in
  case of alarm (except DL12 that is normally OFF
  and lit in case of alarm)

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RCLS-1 card Interfaces with I/S-CL (mP)

• RCLS-1 ? I/S-CL
• MAINS FAILURE signal
• Pin 1-2 connector CN7
• RECTIFIER ON signal
• Pin 5-6 connector CN5
• FUSES FAILURE signal
• Pin 1-2 connector CN5
• WRONG PHASE SEQUENCE signal
• Pin 3-4 connector CN5
• Signal of the battery SHUNT for the mP battery
  current reading (only when the BOOST charge is
  enabled)
• Pin 710 connector CN5

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RCLS-1 card Interfaces with I/S-CL (mP)

• I/S-CL ? RCLS-1
• Command of the relay RL1 for the BATTERY TEST
• Pin 3-6 connector CN6
• Command of the relay RL2 for FLOATING/BOOST
  commutation
• Pin 2-4 connector CN6
• Command of the relay RL3 for RECTIFIER STOP
• Pin 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

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Summary of the rectifier cards functions
PRCH PB115 LOOP PB114 FIR-91 PB113 SYNC-12 PB116 RCLS-1 PB117
Generation of the 12V/24V supply X X
Generation of the synchronism signals X X
AC supply voltage control X X
Internal DC supply control X X
Generation of the thyristors firing signals X X
Thyristor firing X X
Voltage control loop X X
Total current control loop NOT PROVIDED NOT PROVIDED NOT PROVIDED X
Battery current control loop X X
General control X X
Thermal compensation of the charging voltage (OPTIONAL) X X
Interface with a relay card NOT PROVIDED NOT PROVIDED NOT PROVIDED X
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Inverter

• Single-phase inverter
• The rectifier output voltage (battery) is applied
  to the IGBT bridge, composed by four power
  components controlled through PWM technology
• The 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

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Inverter

• Three-phase inverter
• The rectifier output voltage (battery) is applied
  to the IGBT bridge, composed by six power
  components controlled through PWM technology
• The 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

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Inverter typologies

• As already seen for the rectifiers, also the
  inverters can be separated in different
  typologies, according to the constructive
  solution chosen
• TYPE 1
• Its the single-phase inverter, with the
  following manufacturing features
• Use of two power components, each containing two
  IGBTs
• Installation on a single heatsink
• Forced cooling with single fan
• Power connections carried out through interface
  card IBPC-7 (PB120), which includes the DC
  capacitors and the Hall effect CT

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Inverter typologies

• TYPE 2
• Its the three-phase inverter, with the
  following manufacturing features
• Use of two power components, each containing two
  IGBTs
• Installation on a single heatsink
• Forced cooling with single fan
• Power connections carried out through interface
  card IBPC-7 (PB120), which includes the DC
  capacitors and the Hall effect CT
• TYPE 3
• Its 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

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Static switch

• Single-phase static switch
• Its 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 fuse
• In order not to modify the grounding system the
  neutral conductor is not interrupted

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Static switch

• Three-phase static switch
• Its composed by six pairs of thyristors,
  connected in anti-parallel, that interrupt the
  phase conductors (inverter/bypass)

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Static switch typologies

• TYPE 1
• Its the single-phase static switch
• TYPE 2
• Its the three-phase static switch that uses
  compact type thyristors (SemiPack)
• TYPE 3
• Its 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

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Inverter static switch control

• Unlike 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 functions
• Generation of the reference sine-wave used for
  the creation of the PWM
• Complete management of the operating logics of
  the inverter and static switch
• Management and control of the measure shown on
  the display
• Control of the synchronism, in stand-alone and
  parallel operation
• The microprocessor card uses some additional
  cards, each of them with its own specific function

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Inverter static switch control

• The following electronic cards are used for the
  inverter and static switch control
• INVERTER
• I/S-CL (PB003), inclusive of
• RCB (PB011)
• VCB (PB012)
• SCB (PB014)
• PS-HV (PB001)
• ID (PB013)
• INV-AV (PB004/PB018)
• FCI (PB047)
• STATIC SWITCH
• VOLT-REF (PB005/PB019)
• SCR-FIR (PB009/PB010/PB016)

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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
  transformer
• According to the UPS nominal DC voltage (in our
  case 384Vdc) the power supply can be divided in
• PS-HV (PB001) Supply range 300600Vdc
• PS-MV (PB002) Supply range 180300Vdc
• PS-LV (PB184) Supply range 180300Vdc
• For application where the power required is
  higher because of, for example, the use of
  parallel IGBTs (SATURN series, Pnomgt200kVA) its
  used a power supply called PS-SAT (PB107),
  similar to the PS-HV except for the higher power

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PS-HV card (PB001)

• The power supply card is composed by the
  following main sections
• Microprocessor supply section
• Analogue part supply section
• IGBT drivers supply section
• Relays and BUS supply section
• Serial ports supply section
• DC voltage measure section

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PS-HV card (PB001)

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

70
PS-HV card (PB001)

• Analogue part supply
• This section supplies all the analogue part of
  the microprocessor card
• The supply AC1-AC2, that will be described later
  on, is taken from the same secondary winding of
  the transformer

71
PS-HV card (PB001)

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

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PS-HV card (PB001)

• IGBT drivers and serial port supply
• The IGBT drivers are supplied by the 40khz square
  wave AC1-AC2
• A 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-AC4
• A rectifying circuit, that provides also to
  isolate galvanically the supply of the serial
  ports, is provided on board the card RCB

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PS-HV card (PB001)

• DC voltage measure
• This section provides a stabilised voltage,
  proportional to the amplitude of the DC supply
  voltage
• Such signal is sent to the microprocessor as
  feedback for the correct display of the inverter
  input voltage

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PS-HV card Settings and controls
POTENTIOMETERS POTENTIOMETERS
P1 Regulation of the DC voltage measure
P2 Regulation of the IGBT drivers supply voltage
CONTROL LED CONTROL LED COLOUR
DL1 12V analogue part supply GREEN
DL2 -12V analogue part supply GREEN
DL3 24V analogue part supply GREEN
DL4 12V relays and BUS (pin 9-10 CN3) GREEN
DL5 12V FCI card relays (pin 1-2 CN3) GREEN
75
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 supply
• With 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 line
• For the control of parallel IGBTs in the high
  power range UPS (gt200kVA) 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

76
ID card (PB013)

• Power supply section
• The 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

77
ID card (PB013)

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

78
ID card (PB013)

• Final stage
• The signal is amplified by a MOSFET amplifier
  that provides also for the translation of the
  signal between /-15V
• Such voltage can be adjusted by the potentiometer
  P2 of the PS-HV card

79
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 inverter
• The card is basically composed by two sections
• Inverter voltage feedback
• The 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 loop
• Output current measure
• The 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

80
VOLT-REF card (PB005/PB019)

• Electrical drawing

81
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 inverter
• The card is basically composed by four sections
• Bypass voltage feedback
• The 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 limits
• Bypass voltage feedback
• The 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

82
VOLT-REF card (PB005/PB019)

• Static switch logics supply
• The 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 stabilised
• The 24Vdc is used for the supply of the final
  stage (card SCR FIRING) of the bypass thyristors
  control circuit
• The 5Vdc is used for the supply of the SCB card,
  that manages the static switch operating logic
• Fans supply section
• The 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

83
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 thyristors
• SCRSF-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

84
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) card
• In the standard production the FCI card is used
  on the units starting from 40kVA
• Its 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

85
FCI card (PB047)

• Configurations of the signals

SIGNALS SIDE FCI M1 Origin Signal mP SIDE FCI M2
1-2 Not used - Spare 1-2
3-4 Rectifier card Mains failure 3-4
5-6 EPO push-button Emergency Power Off 5-6
7-8 BCB aux contact BCB open/closed 7-8
9-10 OCB aux contact OCB open/closed 9-10
11-12 Switch SW1 Bypass switch 11-12
13-14 MBCB aux contact MBCB open/closed 13-14
15-16 Thermal switch High temperature 15-16
17-18 Parallel card Parallel configuration 17-18
86
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 supply
• Memories
• Watchdog and reset circuit
• Measures Internal A/D converter
• Measures External A/D converter
• Current protection
• Voltage control loop card VCB
• PWM generation
• Static switch control card SCB
• Serial port supply card RCB
• Digital inputs

87
I/S-CL card (PB003)

• Digital supply
• The 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

88
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
  stored
• EEPROM (U71)
• The EEPROM contains the UPS functional
  parameters and all the settings
• EPROMs (U55-U65)
• The EPROMs contain the operating program, split
  into odd (U65) and even (U55) addresses
• Watchdog e reset
• The 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

89
I/S-CL card (PB003)

• Measures Internal A/D converter
• The measures related to the bypass and output
  voltage are directly acquired by the
  microprocessor and converted by the internal
  analogue/digital converter
• The signal are translated of 2,5V in comparison
  to the zero, therefore the microprocessor
  recognise automatically the level zero

90
I/S-CL card (PB003)

• Measures External A/D converter
• Some 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

91
I/S-CL card (PB003)

• Measures External A/D converter
• In 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 void
• The measures for which the zero must be set
  are
• Inverter voltage phase R
• Inverter voltage phase S
• Inverter voltage phase T
• Output current phase R
• Output current phase S
• Output current phase T
• Inverter input DC current
• The parameter CFPAR is used only in the PARALLEL
  configuration
• The parameter IBOOST is used only when the boost
  charge in enabled

92
I/S-CL card (PB003)

• Measures Summary
• For further clarity the origin of the signals
  used by the microprocessor for the measures are
  summarised hereunder

Signal Provenienza
BYPASS voltage (phases R/S/T) VOLT-REF-3F (1F) card
OUTPUT voltage (phases R/S/T) VOLT-REF-3F (1F) card
INVERTER voltage (phases R/S/T) VCB cards
OUTPUT current (phases R/S/T) INV-AV-3F (1F) card
DC voltage PS-HV card
DC current Inverter input Hall effect CT
93
I/S-CL card (PB003)

• Current protection
• The current protection is carried out acquiring
  the signal related to the inverter bridge input
  current, function of the UPS output current
• A Hall effect CT, connected on the positive cable
  (or copper bar) between the DC capacitors and the
  inverter bridge, is used for this purpose
• Such configuration guarantees the control and
  protection against possible short-circuits of the
  inverter bridge, caused by the failure of one
  IGBT
• In the UPS that uses the interface card IBPC-7
  (PB120) for the power connections the CT is
  mounted on the card itself
• The 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

94
I/S-CL card (PB003)

• Short circuit protection

95
I/S-CL card (PB003)

• Short circuit protection
• The feedback signal originated by the Hall effect
  CT is acquired by the microprocessor card
• The feedback current generates a voltage drop
  flowing through the resistors R18-R39-R40, so
  that it can be used for the control circuit
• By means of a amplifier, which gain can be varied
  with the potentiometer P2, the value of the
  signal is adapted to the dynamic of the
  protection circuit
• The 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)

96
I/S-CL card (PB003)

• Current stop protection

97
I/S-CL card (PB003)

• Current stop protection
• The resistors R18-R39-R40 are properly combined
  according to the IGBTs nominal current
• In case of bridge leg short circuit the PWM is
  stopped before the input current exceed the 200
  of the IGBTs nominal current
• The 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 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

98
I/S-CL card (PB003)

• VCB card (PB012) Voltage control loop
• The VCB card contains all the electronic logics
  for the voltage control loop
• Each inverter output phase is controlled by a
  different card, therefore the I/S-CL card for a
  three-phase inverter will mount three VCB cards
• Three main sections can be identified
• Generation of the reference sine-wave
• Voltage correction
• Inverter voltage measure
• The output signal from the VCB card is used by
  final stage of the PWM generation, in the I/S-CL
  card

99
I/S-CL card (PB003)

• VCB card (PB012) Sine-wave generation
• The 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-wave
• The 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 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 operating on the potentiometer P1 of
  the I/S-CL card
• In this case the inverter output voltages are
  varied contemporary

100
I/S-CL card (PB003)

• VCB card(PB012) Voltage correction
• 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
  (1F) card is compared with the reference
  sine-wave e properly filtered
• The resulting signal is added again to the
  reference sine-wave

101
I/S-CL card (PB003)

• VCB card(PB012) Inverter voltage measure
• A 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
  voltage
• The feedback signal, originating from the card
  INV-AV-3F (1F), is rectified, filtered and sent
  to the SPI, and then to the microprocessor

102
I/S-CL card (PB003)

• Generation of the PWM reference frequency
• The 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
  frequency
• The triangular waveform is a function of a
  reference signal generated by the microprocessor

103
I/S-CL card (PB003)

• PWM generation Final stage
• The 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

104
I/S- CL card (PB003)

• SCB card (PB014) Static switch control
• The 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) card
• The LED L1 signals the presence of the 5V supply
• The bypass static switch thyristors are
  controlled directly by the SCB card
• The inverter static switch thyristors are
  controlled by the I/S-CL card according to the
  consents originated from the SCB card
• RCB card (PB011) Serial ports supply
• The 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

105
I/S-CL card (PB003)

• Digital inputs
• The digital inputs are connected directly, or
  through the de-coupling card FCI, to the
  connector M3
• Such signals are internally de-coupled and
  connected to the microprocessor

I/S-CL M3 Signal
1-2 Not used - Spare
3-4 Mains failure
5-6 Emergency Power Off
7-8 BCB open/closed
9-10 OCB open/closed
11-12 Bypass switch
13-14 MBCB open/closed
15-16 High temperature
17-18 Parallel configuration
106
I/S-CL card configuration

• The 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 parameters
• Configuration of the switching frequency
• Configuration of the current protection
• Configuration of the jumpers

107
I/S-CL card configuration

• Configuration of the nominal parameters
• The nominal parameters can be configured by means
  of dip switches
• At the start-up the program recognises the
  position of each dip switch and configures the
  operating parameters accordingly
• For the correct configuration of the dip switches
  refer to the relevant technical documentation
• Configuration of the switching frequency
• The switching frequency depends on the frequency
  of the triangular waveform that is compared with
  the reference sine-wave to generate the PWM
  signal
• The frequency of the triangle can be varied
  modifying the value of the resistor R66
• R66 6K81 ? fswitching 8khz
• R66 13K6 ? fswitching 4khz
• R66 24K9 ? fswitching 2khz

108
I/S-CL card configuration

• Configuration of the current protection
• The current protection, and particularly the
  Current stop protection, can be configured
  combining properly the resistors R18-R39-R40
  according to the IGBTs nominal current
• For the standard UPS a configuration table does
  exist, the calculation form is shown hereunder

10 x KLEM -------------------- 2 x IIGBT
REQ
Where REQ Series combination of
R18-R39-R40 KLEM Conversion ratio of the
LEM IIGBT IGBTs nominal current
109
I/S-CL card configuration

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

Jumper Pos Function
J1 1-2 SINGLE-PHASE inverter
J1 2-3 THREE-PHASE inverter
J2 Closed Back-up battery connected
J7 Closed Watchdog enabled
J9 Closed Resistor R40 (100R) inserted
J10 Closed Resistor R39 (47R) inserted
J100 Closed Resistor R18 (22R) inserted
110
I/S-CL card Settings and controls
POTENTIOMETERS POTENTIOMETERS
P1 Regulation of the inverter voltage in MANUAL mode
P2 Regulation of the current signal (TP2)
CONTROL LED CONTROL LED COLOUR
D3 Current stop protection RED
D8 Short circuit protection RED
D11 Presence of the analogue parts supply (12V) GREEN
D69 Presence of the digital parts supply (5V) GREEN
111
Protections and controls of the SW program

• The software program provides for the control of
  the UPS functionality basing on the instructions
  assigned
• The setting of the I/S-CL cards dip switches
  gives the program the main indications to define
  the control and protection thresholds
• The 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 waveforms
• Overload protection (Thermal image)

112
Waveform control

• The control is based on the sampling of the
  sine-wave and the subsequent comparison of the
  samples with a reference value
• The sine-wave is sampled 36 times in a period
• The RMS value of the sine-wave is calculated
  using the samples obtained, and compared with the
  minimum and maximum thresholds defined in the
  software
• Each of the 36 samples (Vsn) is also compared
  with values contained inside reference tables
  (VtL/VtH) so that the following disequations are
  satisfied
• VtL1lt Vs1lt VtH1 VtL2lt Vs2lt VtH2 . VtL36lt
  Vs36lt VtH36
• The tables are part of the program and are
  downloaded in the RAM at each start-up of the
  program itself
• If 4 consecutive samples of one of the phases
  dont satisfy the comparison the voltage is
  declared out of tolerance

113
Overload protection

• The overload protection is also called Thermal
  image because its indeed based on the
  calculation of the energy stored during the
  overload operation
• The overload is defined when at least one of the
  output currents exceed the 100 of the nominal
  value
• As soon as a overload is detected the program
  starts to take samples of the output current,
  calculating the integral I2t
• The 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

114
(No Transcript)
115
User interfaces

• The UPS is provided with two serial ports and a
  optional relay card for the interface with the
  external world
• The serial port RS485 is used only for the
  connection with the remote panel
• The serial port RS232 is used for the interface
  with software applications and transmits all the
  UPS data through a proprietary protocol
• The 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 card
• The most important user interface is however the
  LCD panel, that makes the UPS operating
  parameters (measures, status and alarms)
  immediately available to the user

116
LCD panel

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

117
LCD panel Measures

• The measures available on the LCD panel are the
  same described before for the microprocessor card
  I/S-CL
• OUTPUT measures
• Voltage of the three phases (measure Ph-N)
• Frequency
• Current of the three phases (phase current)
• Percentage of load on each phase
• BYPASS measures
• Voltage of the three phases (measure Ph-N)
• Frequency
• INVERTER measures
• Voltage of the three phases (measure Ph-N)
• Frequency

118
LCD panel Measures

• DC measures
• Inverter input voltage
• BATTERY measures
• Battery voltage
• Battery 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

119
LCD panel Status and alarms

• The software program is able to process the
  information relevant to 6 different operating
  status and 25 alarms, defined by means of
  alphanumeric codes
• Each 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 load
• The 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 code
• Besides the alphanumeric code of the alarm, the
  history log indicates date, hour and minute of
  the event

120
LCD panel Status
Cod. Name Description
S1 AC/DC OK Rectifier output voltage within tolerance
S2 BATTERY OK Battery connected to the DC bus
S3 INVERTER OK Inverter voltage within tolerance
S4 INVERTER SYNC Synchronism reference within tolerance
S5 INVERTER ? LOAD Inverter static switch closed, load on inverter
S6 BYPASS OK Bypass voltage and frequency within tolerance
121
LCD panel Alarms
Cod. Name Description
A1 MAINS FAULT Rectifier input mains failure
A2 CHARGER FAULT Battery charger failure
A3 RECT FUSE One or more rectifier fuses are blown
A4 THERMAL IMAGE Load transferred to mains due to overload.
A5 AC/DC FAULT Rectifier output voltage out of tolerance
A6 INPUT WR SEQ Input phase rotation not correct
A7 BCB OPEN Battery circuit breaker open
A8 BATT DISCH The battery is discharging
A9 BATT AUT END Battery autonomy (calculated) has expired
A10 BATT FAULT Battery test failed or intervention of the safety timer during boost charge
A11 BATT IN TEST Battery test in progress
A12 PLL FAULT Problems with the digital synchronisation system
A13 INV OUT TOL Inverter output voltage out of tolerance
122
LCD panel Alarms
Cod. Name Description
A14 OVERLOAD Inverter overload (load exceeding 100)
A15 BYP FAULT Emergency mains not available
A16 BY