Borri Ups b9000 Ups Service Manual
Borri Ups b9000 Ups Service Manual
B9000 200-250-300kVA
JUD409399
WARNING: This is a Class A-UPS Product. In a domestic environment,
this product may cause radio interference,
in which case, the user may be required to take additional measures.
UPS SERVICE MANUAL
GENERAL INFORMATION
POWER - kVA 200 250 300
UPS typology ON LINE - Double Conversion
Nominal output power (Cos Ø 0,8) - kVA 200 250 300
Nominal output power (Cos Ø 1,0) - kW 160 200 240
Efficiency (AC ÷ AC) - % > 93 > 93 > 93
Heat dissipation at nominal load and voltage
- kW 11,2 14,0 16,8
- kcal/hour (x1000) 9,6 12,0 14,4
UPS ambient temperature -°C 0 ÷ 40
BATTERY ambient temperature -°C 0 ÷ +25
UPS storage temperature -°C -10 ÷ +70
BATTERY storage temperature -°C -10 ÷ +60
Relative humidity (non condensing) < 95%
Altitude < 1000 mt (Above See Level)
Power derating for altitude > 1000mt According to “IEC62040-3”
Ventilation FORCED
Requested cooling air volume – mt3/h 3500 4100 4500
Audible noise level (according EN 50091) < 62 db < 62 db < 62 db
Standard battery type lead acid (n° of cells) 300 300 300
Protection degree IP 20
Immunity According to “EN 50091-2”
(CE label)
Paint RAL 7035
Accessibility Front and top access for service
Installation
Dimensions (mm) W = 1200 D = 860 H = 1900
Weights (kg) (without battery) 870 1020 1200
Static load (kg/m2) (without battery) 925 1085 1277
Input/output cable connection Bottom Side (Top Side on Request)
Transport Base provided for forklift handling
Transport mechanical stress According to “IEC62040-3”
Design standard According to
“EN50091” - “IEC EN 62040”
“ISO9000:2000”
Free contact interface On request
Serial communication interface RS232-RS485 (SNMP-Option)
Parallel configuration Up to 4 redundant
1
5
2 4 6
DESCRIPTION:
The UPS is designed following the criteria of low environmental impact.
The quantity of the raw material used on the magnetic components and the
number of semiconductors is minimized by the means of very advanced design
criteria.
The high overall efficiency minimizes the power consumption.
The expected battery lifetime is maximized by the very advanced digital battery
charger.
The UPS is equipped by a built in very advanced self diagnostic program
indicating the problems and suggesting to the service people how to repair the
faults.
The inverter transformer prevents the direct feed-through of the battery potential
into the critical load and allows a very high rejection ratio of the power supply
disturbances (spikes, surges etc.).
The high input power factor and the low harmonic level of the input current allows
to reduce the dimensioning of the installation in terms of size of the cables and the
circuit breakers.
The high efficiency and input power factor reduces the costs during the normal
operation of the UPS.
DESCRIPTION:
The Input rectifier is designed to minimize the harmonics rejected into the input
mains.
The technology is based on a full bridge 6-IGBT matrix, fully digitally controlled.
Large input mains variations are allowed.
The battery charger function is included on the same converter.
The converter is designed to recharge the battery for long time autonomies.
DESCRIPTION:
The standard battery is composed 300 sealed lead cells.
The boost charge is available as an option for other battery types.
The battery temperature compensation is available as an option.
Long autonomy batteries can used.
Different automatic and manual battery tests are available (see the operating manual).
DESCRIPTION:
The Inverter design is based on a full bridge 6-IGBT matrix, fully digitally
controlled.
The output voltage stability and the dynamic response are optimised
The output voltage total harmonic distortion is kept very low with both linear and
not linear (switching).
The selectivity in case of short-circuit is very high and the recovery of the voltage
is digitally controlled (Soft Short Recovery Loop “SSRL”).
The Inverter is designed to minimize the battery stress during the discharge.
ECO mode available: load on by-pass and inverter on, the load transfer time is
less than 5 msec.
DESCRIPTION:
The manual by-pass is included as a standard. The electronic control avoids the
risks of power interruption in case of transfer from inverter to manual by-pass and
vice-versa.
PARALLEL
Automatic Parallel Redundant Configuration Up to four by an additional card
Parallel Configuration Redundant N-1 on N
Connection Type CAN Bus Loop
Share Accuracy 10% max unbalancement
Maximum Distance Between two Units 10 mt
Overload Capability N x 200% Continuously
Automatic By-Pass On each unit
Manual By-Pass On each unit (common as
option)
DESCRIPTION:
The parallel control is full digital and acts on both active and reactive power on
each output phase.
The Loop connection permits to disconnect one of the units from the parallel string
allowing the normal operation of the remaining units.
1. SNMP
2. Modem
OPTIONS
1. BATTERY TEMPERATURE VOLTAGE COMPENSATION
2. INSULATION TRANSFORMER ON BY-PASS
3. INPUT VOLTAGE ADAPTATION AUTO-TRANSFORMER
4. FREE CONTACTS CARD
5. SERIAL INTERFACE RS-485 for REMOTE PANEL
6. SNMP
7. MODEM
8. PARALLEL CARD
9. EXTERNAL BATTERY CABINET
10. WALL MOUNTED FUSES BOX
11. IN/OUT TOP CABLE ENTRY
12. SPECIAL PAINT
B9000 200-250-300kVA
UPS OPERATING MANUAL
Index
1. INTRODUCTION.................................................................................. 3
2. GENERAL UPS DESCRIPTION.......................................................... 3
2.1 TYPOLOGY ......................................................................................................3
2.2 DESCRIPTION OF THE SYSTEM ....................................................................4
2.2.1 Rectifier.....................................................................................................4
2.2.2 Inverter ......................................................................................................4
2.2.3 Battery and charger .................................................................................4
2.2.4 Static bypass ............................................................................................4
2.2.5 Manual bypass .........................................................................................4
2.2.6 Front Panel ...............................................................................................5
2.3 OPERATING STATUS......................................................................................6
2.3.1 Normal Operation.....................................................................................6
2.3.2 Load supplied by bypass due to inverter fault ......................................6
2.3.3 Rectifier failure or mains failure .............................................................7
2.3.4 Manual bypass .........................................................................................7
3. INSTALLATION................................................................................... 8
3.1 RECEIPT OF UPS ............................................................................................8
3.2 HANDLING OF THE UPS.................................................................................8
3.3 POSITIONING AND INSTALLATION...............................................................9
3.3.1 Base plan, static load and weights.........................................................9
3.3.2 Dimensions and distances ....................................................................10
3.4 ELECTRICAL CONNECTION ........................................................................11
3.4.1 Terminal Board.......................................................................................11
3.5 BATTERY POSITIONING AND CONNECTION .............................................12
3.5.1 Connections ...........................................................................................12
Index of pictures
Picture 1 – Block diagram............................................................................................................................. 3
Picture 2 – Normal operation........................................................................................................................ 6
Picture 3 – Load supplied by bypass............................................................................................................ 6
Picture 4 – Rectifier failure or mains failure.................................................................................................. 7
Picture 5 – Manual bypass ........................................................................................................................... 7
Picture 6 – Handling B9000 200-300kVA..................................................................................................... 8
Picture 7 – Base plan ................................................................................................................................... 9
Picture 8 – Distance from the walls ............................................................................................................ 10
Picture 9 – Layout B9000 200-300kVA ...................................................................................................... 10
Picture 10 – Terminal Board....................................................................................................................... 11
Picture 11 – Battery cabinet link................................................................................................................. 12
1. INTRODUCTION
Thank you for having chosen an BORRI product for the safety of your equipment. In
order to fully take advantage of the performance of your UPS B9000 (uninterruptible
power supply), we suggest that you dedicate some time to reading the following
manual.
The purpose of this manual is to briefly describe the parts that constitute the UPS
and to guide the installer or user to a correct installation of the equipment.
The installer or user should read and correctly carry-out the instructions provided,
with particular attention to the information regarding security, according to the CEI 64-8
and DPR 46-90 standards.
The manufacturer declines all responsibility of damages towards persons or
things due to the non-compliance of the above.
WARNING
The UPS output is energized even during mains failure, therefore in compliance with
the prescriptions of EN50091-1 / EN62040-1, the installer will have to identify the line or
the plugs supplied by the UPS making the User aware of this fact.
This configuration guarantees the best service to the User, as it supplies clean
continuously regulated power and guarantees the voltage and frequency will be
stabilised at nominal value independently from mains status. Thanks to the double
conversion, it makes the load completely immune from micro-interruptions due to
excessive mains variation, and prevents damage to the critical load (Computer -
Instrumentation - Scientific equipment etc.).
2.2.1 Rectifier
It converts the three phase voltage of the mains into continuous DC voltage.
The UPS has got a total-controlled IGBT three-phase bridge to reach a low harmonic
distortion.
This configuration is used in order to reduce the distortion of the mains’ absorbed
power (THD) to a value inferior to 5%. This guarantees, with respect to other loads, that
the rectifier does not distort the mains voltage and avoids the overheating of the cable
due to the circulation of the harmonic currents.
The rectifier is designed to supply the inverter at full load and the battery at the
maximum recharge current.
2.2.2 Inverter
Required to convert the continuous voltage coming from the rectifier or from the
battery, into alternating voltage, stabilized in amplitude and frequency.
The inverter uses IGBT technology with a frequency commutation of approximately
10 KHz.
The control electronics is completely digital and uses a 16 Bit µP, that, thanks to its
processing capability, generates an excellent output sine-wave, which has a very low
distortion even in presence of loads having high crest factor currents.
WARNING
The sequence of bypass switching must be carried out with respect to the procedure
in the UPS Operating Manual in the chapter “Start-up, shut-down and manual bypass”.
The manufacturer cannot accept responsibility for damages arising from incorrect
operation.
3. INSTALLATION
3.1 RECEIPT OF UPS
When the UPS is received, please attend immediately to its unpacking and carry-out
an accurate visual check to be sure that the equipment has not been damaged during
transport.
IMPORTANT
In case of objections relating to damage incurred during transport these must be
immediately notified to the transportation company after receipt of the equipment.
When the UPS is not installed immediately it must be stored carefully in vertical
position, as indicated on the packing and conserved in a dry and sheltered room in its
box so that it is protected from dust.
3.2 HANDLING OF THE UPS
Before positioning the UPS, in order to avoid risks of turnover, it’s recommended to
move the system on the wood pallet on which the UPS is fixed.
Before the positioning in the final location, remove the UPS from the pallet.
The UPS can be lifted and handled using a pallet truck or a forklift; It can be handled
only after having taken-off (manually) the lower front panel, so that a pallet truck or a
forklift can be inserted (see picture 6). The UPS technical data are shown on a label
fixed on the internal side of the front door.
WARNING
The connection to the mains must be carried out with protection fuses between the
mains and the UPS.
The use of residual current devices in the line supplying the UPS is
unadvisable. The leakage current due to the RFI filters is rather high and it can
cause spurious tripping of the protection device.
According to the EN50091-1 / EN62040-1 standard, in order to take into account the
UPS’ leakage current, residual current devices having adjustable threshold can be
used.
3.5.1 Connections
The following picture shows the electrical connection between the UPS and the
external battery cabinet.
FRONT PANEL
Index
1. INTRODUCTION.................................................................................. 3
2. DESCRIPTION..................................................................................... 4
2.1 MIMIC DESCRIPTION ......................................................................................4
2.2 ALARMS AND OPERATING STATUS.............................................................5
3. LCD DISPLAY MANAGEMENT .......................................................... 8
3.1 DEFAULT .........................................................................................................8
3.2 MAIN MENU .....................................................................................................8
3.3 MEASURES ......................................................................................................9
3.3.1 Output .....................................................................................................10
3.3.2 Bypass ....................................................................................................10
3.3.3 Inverter ....................................................................................................11
3.3.4 AC/DC......................................................................................................11
3.3.5 Battery.....................................................................................................11
3.4 ALARMS.........................................................................................................13
3.4.1 UPS Status..............................................................................................13
3.4.2 History.....................................................................................................14
3.4.3 List of alarms and status .......................................................................15
3.5 SPECIAL.........................................................................................................16
3.5.1 Reset .......................................................................................................17
3.5.2 Settings ...................................................................................................17
3.5.3 Test Ups ..................................................................................................17
3.5.4 Battery test .............................................................................................17
3.5.5 Reset history ..........................................................................................17
3.6 MENU STRUCTURE.......................................................................................18
Index of pictures
Picture 1 – B9000 front panel ....................................................................................................................... 3
Picture 2 – Menu structure ......................................................................................................................... 18
1. INTRODUCTION
front panel of the UPS, consisting of a double row alphanumeric display plus 5
function keys, allows the complete monitoring of the UPS status.
The mimic flow helps to understand the operating status of the UPS.
2. DESCRIPTION
2.1 MIMIC DESCRIPTION
Picture1 shows the mimic present on the display, with the names of the circuit
breakers/isolator switches of the UPS. Also the led's and blocks that comprise the UPS
are clearly identified.
Possible causes: 1) The test has been carried out with the battery not
perfectly charged
2) One or more battery cells are damaged
A22 BYP SWITCH = Closure of the commutation switch which forces the
load to bypass (maintenance)
A23 EPO BUS = Intervention of the emergency shut down switch in
accordance to EN50091-1
3Ph UPS
The default screen appears on the LCD panel when the UPS is operating normally
(with no alarm present); it shows the name of the UPS (for example, B9000), the
nominal power and the value of the output voltage.
Pressing a key the main menu, with all the functions and parameters, is accessed
After 5’ during which no key is pushed, if there isn’t any alarm and the battery is not
in discharge mode the Default screen is shown again.
.
3.2 MAIN MENU
The screens of the main menu appears as follows: Pressing a key the main menu,
with all the functions and parameters, is accessed
3.3 MEASURES
The following pictures show the structure of the MEASURES menu.
PLEASE NOTE
The voltage measures are always referred to the phase-to-neutral value.
3.3.1 Output
OUTPUT VOLTAGE Pressing the key the following
XXX YYY ZZZ Volt parameter is shown, while the key
leads to the previous screen.
3.3.2 Bypass
BYPASS VOLTAGE Pressing the key the following
XXX YYY ZZZ Volt parameter is shown, while the key
leads to the previous screen.
3.3.3 Inverter
INVERTER VOLTAGE Pressing the key the following
XXX YYY ZZZ Volt parameter is shown, while the key
leads to the previous screen.
3.3.4 AC/DC
This menu is active only when the battery is not discharging. If the battery is in
discharge mode, the BATTERY menu is automatically shown.
3.3.5 Battery
BATTERY VOLTAGE Pressing the key the following
XXX Vdc parameter is shown, while the key
leads to the previous screen.
3.4 ALARMS
This menu, when selected, shows the status of the equipment and the current alarms
are shown (see list below).
Each time an alarm occurs, the display goes to this menu to indicate the alarms
present; the audible alarm can be silenced pressing the key . The exit is disabled if
the alarm is not silenced.
The following pictures shows the structure of the ALARMS menu.
3.4.2 History
RET TO EXIT HISTORY Pressing the key the following
1° alarm/status alarm is shown; pressing the key
exit the history, leading to the
ALARMS menu screen (see 3.4).
The first alarm shown is the most recent in order of time; a new alarm makes all the
alarms shift one position, clearing the oldest event.
For each event is shown the alarm code, the date and time; an asterisk next to the
code indicates that the alarm has cleared at the date and time indicated. The following
example shows two possible screens.
The status shown in this list are always displayed in ascending order when the
STATUS menu is entered, the alarms are shown when they are present and must be
silenced with the buzzer. The alarms remain displayed whilst they are present and they
are automatically stored in the event history memory with date and time.
.
3.5 SPECIAL
IMPORTANT
When entering the SPECIAL menu a password is required, as the operations which
are allowed needs to be carried out by competent personnel. For each operation a
confirmation is required.
.
3.5.1 Reset
PRESS RESET This menus provides a general
TO RESET UPS reset of the UPS status pressing
the key . Pressing another
key exit the menu
3.5.2 Settings
This menu allows to update the date and time settings for the history of alarms.
WARNING
This test may affect the continuity of power supply to the loads if the battery is not
fully charged.
WARNING
The above operation causes the cancellation of the events’ history memory.
Index
1. INTRODUCTION................................................................................ 2
2. START UP PROCEDURE ................................................................. 2
2.1 START-UP TROUBLESHOOTING...................................................................4
3. SHUT DOWN PROCEDURE ............................................................. 5
4. MANUAL BYPASS PROCEDURE.................................................... 5
5. START-UP FROM MANUAL BYPASS ............................................. 6
1. INTRODUCTION
Before performing any of the procedures described in this chapter, read carefully the
instructions, to avoid possible damages to persons or things deriving from incorrect
manoeuvres.
2. START UP PROCEDURE
WARNING
Before switching on the UPS, make sure:
1) the emergency power off “EPO” push-button, placed near the front panel, is in the
release position; if not, press it and proceed with the start-up procedure;
2) the input and output phase rotation is correct.
NOTE
The BCB battery switch is found on the outside of the UPS system.
WARNING
Do not close the battery breaker BCB before it’s required by the front panel. Serious
damages to UPS internal parts and battery may occur if the breaker is closed before the
rectifier is started-up.
7 BATTERY START UP
Close BCB
CLOSE BCB
8 BATTERY START UP The microprocessor checks that all the
PLEASE WAIT conditions for the following steps are ok.
LED #4 green light on.
9 START UP END
Close OCB
CLOSE OCB
10 START UP END The microprocessor checks that all the
PLEASE WAIT output parameters (voltage, current,
frequency) are within the tolerance limits.
LED #7 green light on.
End UPS MODEL After a short time the default screen is
VOLTAGE OUTPUT displayed.
Index
1 INTRODUCTION.................................................................................. 5
1.1 OPERATING STATUS......................................................................................5
2 RECTIFIER .......................................................................................... 7
3 INVERTER ........................................................................................... 8
4 STATIC SWITCH ................................................................................. 9
5 RECTIFIER PCB’S ............................................................................ 10
5.1 INT-R...............................................................................................................10
5.1.1 Description of operation........................................................................10
5.2 RTF .................................................................................................................15
5.2.1 Description of operation........................................................................15
5.3 ID-HY (RECTIFIER IGBT DRIVER) ................................................................15
5.3.1 Description of operation........................................................................15
5.3.2 Programming instructions ....................................................................16
5.4 D-CPU-RC (RECTIFIER MICROPROCESSOR CONTROL) ..........................17
5.4.1 Description of operation........................................................................17
5.4.1.1 Introduction .......................................................................................17
5.4.1.2 Digital power supply ..........................................................................17
5.4.1.3 RAM, FLASH and EEPROM .............................................................17
5.4.1.4 Rectifier bridge protection .................................................................17
5.4.1.5 Analog inputs ....................................................................................18
5.4.1.6 Control LEDs.....................................................................................18
6 INVERTER PCB’S ............................................................................. 19
6.1 DR-HY (INVERTER IGBT DRIVER) ...............................................................19
6.1.1 Description of operation........................................................................19
6.1.2 Programming instructions ....................................................................21
6.2 INV-AV-3F.......................................................................................................21
6.2.1 Description of operation........................................................................21
6.3 PS-MIS............................................................................................................21
6.3.1 Description of operation........................................................................21
6.4 PWM-SAT .......................................................................................................22
Index of pictures
Picture 1 – UPS block diagram .................................................................................................................... 5
Picture 2 – Normal operation........................................................................................................................ 5
Picture 3 – Load supplied by by-pass .......................................................................................................... 6
Picture 4 – Rectifier failure or mains failure.................................................................................................. 6
Picture 5 – Manual by-pass .......................................................................................................................... 6
Picture 6 – Rectifier diagram ........................................................................................................................ 7
Picture 7 – Inverter diagram ......................................................................................................................... 8
Picture 8 – Static switch diagram ................................................................................................................. 9
Picture 9 – INT-R – 24Vdc supply (thyristors) ............................................................................................ 10
Picture 10 – INT-R – 5Vdc supply (serial interfaces) ................................................................................. 10
Picture 11 – INT-R – Rectifier microprocessor supply ............................................................................... 11
Picture 12 – INT-R – Mains monitoring ...................................................................................................... 11
Picture 13 – INT-R – DC voltage feedback ................................................................................................ 11
Picture 14 – INT-R – Battery current feedback (to I/S-CL for boost charge control).................................. 12
Picture 15 – INT-R – Digital signals to D-CPU-RC .................................................................................... 13
Picture 16 – INT-R – Digital signals to I/S-CL ............................................................................................ 14
Picture 17 – INT-R – Relay output ............................................................................................................. 14
Picture 18 – ID-HY – Power supply............................................................................................................ 15
Picture 19 – ID-HY – Input stage................................................................................................................ 15
Picture 20 – ID-HY – Output stage............................................................................................................. 16
Picture 21 – ID-HY board (Rectifier IGBT driver) ....................................................................................... 16
Picture 22 – D-CPU-RC – Digital power supplies ...................................................................................... 17
Picture 23 – D-CPU-RC – IGBT bridge protection ..................................................................................... 18
Picture 24 – DR-HY – Power supply .......................................................................................................... 19
Picture 25 – DR-HY – Input stage .............................................................................................................. 19
Picture 26 – DR-HY – Output stage ........................................................................................................... 20
Picture 27 – DR-HY – “Under-voltage lock-out” ......................................................................................... 20
Picture 28 – DR-HY – De-saturation .......................................................................................................... 20
Picture 29 – DR-HY board (Inverter IGBT driver)....................................................................................... 21
Picture 30 – PS-MIS – Power supply ......................................................................................................... 22
Picture 31 – PS-MIS – DC voltage feedback ............................................................................................. 22
Picture 32 – 2SCR-FIR electrical drawing.................................................................................................. 23
Picture 33 – PS-SAT – Microprocessor supply .......................................................................................... 24
Picture 34 – PS-SAT – Analog part supply ................................................................................................ 24
Picture 35 – PS-SAT – Relay and bus supply............................................................................................ 25
Picture 36 – PS-SAT board ........................................................................................................................ 25
Picture 37 – I/S-CL – Fast analog inputs.................................................................................................... 28
1 INTRODUCTION
The UPS of the B9000 product line are on-line, double conversion; the inverter supplies
always energy to the load, whether the mains is available or not (according to the battery
autonomy time).
WARNING
The UPS output is energized even during mains failure, therefore in compliance with the
prescriptions of EN 50091-1, the installer will have to identify the line or the plugs supplied by
the UPS making the User aware of this fact.
This configuration guarantees the best service to the User, as it supplies clean continuously
regulated power and guarantees the voltage and frequency will be stabilised at nominal value
independently from mains status. Thanks to the double conversion, it makes the load
completely immune from micro-interruptions due to excessive mains variation, and prevents
damage to the critical load (Computer - Instrumentation - Scientific equipment etc.).
2 RECTIFIER
The three-phase mains is connected to the input terminals 1-L1, 1-L2, 1-L3, directly under
the input switch RCB. The filter RF1 provides to reduce the radio frequency disturbances
according to the limits given by the EN50091-2 standard.
The input AC capacitors Cac1÷Cac3 limits the high-frequency harmonics generated during
the commutation of the rectifier bridge smoothing the waveform of the input voltage.
The thyristors PS7÷PS9 are used to pre-charge the DC capacitors and rectify the AC mains;
they also work as de-coupling elements and avoid that high reverse voltages are applied to the
IGBTs. The booster bridge is made by the IGBT modules PS1÷PS6. Each module contains two
components, one of which is used as a diode by short-circuiting the Gate with the Emitter. The
input high-frequency chokes are the elements that store and release energy during the bridge
commutation thus providing the DC voltage to increase (step-up or booster operation).
When powering up the unit, the electronic board INT-R is supplied; it provides the DC
supplies to the microprocessor control board (D-CPU-RC) as well as the synchronisation signals
for the generation of the control pulses of the thyristors. These control signals are then
managed by the board INT-R2 (mounted directly on the INT-R) and sent to the thyristors
through the board RTF (final stage).
The voltage feedback (positive and negative, with reference to the central point of the
capacitors) is taken directly on the rectifier output, across the DC capacitors. By comparing the
voltage feedback value with a programmed set-point the microprocessor provides to regulate
the turn-on time of the IGBTs by modifying the PWM, thus maintaining the DC output voltage
within the specified range (+/-1%).
The measures of the input current across the three phases is provided by the current
transducers TA1÷TA3.
The rectifier provides the energy necessary to the inverter to work at full load and keeps the
battery in floating charge to compensate the self discharging. In case of mains failure the
inverter draws energy from the battery for the specified autonomy time. When the batteries
needs to be recharged the microprocessor board provides to limit the recharging current by
comparing an programmable threshold with the feedback signal generated by the current
transducer TA4.
3 INVERTER
The inverter is composed by six power blocks, controlled by the IGBT driver boards
DR1÷DR6. The inverter bridge is connected to the transformer T1, which provides the galvanic
insulation between the DC bus and the AC output. The transformer is provided with a leakage
inductance that forms a low-pass filter with the output capacitors Cr-Cs-Ct; the filter provides to
eliminate the high frequency harmonics from the output waveforms in order to reduce the
distortion of the sine-waves.
The inverter supplies the load through the inverter static switch thyristors, which are
connected to the output switch OCB. The current transformers TAR-TAS-TAT provide the
signals for the output current measures.
When the inverter is started up the microprocessor control logic I/S-CL generates the IGBT’s
control signals (PWM – Pulse Width Modulation) and send them to the driver boards DR1÷DR6;
the bridge starts to modulate and the output voltage increases. The voltage feedback provided
by the INV-AV-3F board is used to control the output voltages value, according to the value set
on the three VCB boards (mounted on the I/S-CL).
The inverter current protection (Max Current Stop) and the short circuit current limitation are
also managed by the I/S-CL, using the feedback signal provided by the hall-effect current
transducer TA1, which is mounted on the inverter bridge input.
4 STATIC SWITCH
The three-phase emergency line is connected to the terminals 2-L1, 2-L2, 2-L3, 2-N.
The by-pass line is energized by closing the input switch SBCB; the fuses F4-F5-F6 protects
the static switch thyristors in case of short-circuit at the UPS output.
The static by-pass switch is controlled by the SCB board, mounted on the microprocessor
control logic I/S-CL; the control signals for the thyristors are generated by the I/S-CL and sent to
the firing board 2-SCRFIR, connected directly to the gate of the thyristors.
The VOLT-REF-3F board provides the feedback signals for the by-pass and output voltage
measures.
The UPS automatically transfers the load to the by-pass line in case of an inverter failure or
overload. The manual by-pass switch MBCB connects directly the emergency line input to the
load in case of UPS maintenance.
5 RECTIFIER PCB’S
5.1 INT-R
5.1.1 Description of operation
The board INT-R is the interface between the power conversion section of the rectifier and
the microprocessor (board D-CPU-RC). It’s mainly composed by the following parts:
1) Power supply: the three-phase AC mains is connected to the connector M8 and then,
through the fuses FUSE1÷FUSE3 to the Graetz-bridge formed by the diodes D13÷D18.
The DC voltage Vbulk+/Vbulk- is the input voltage to the switching power supply, which
uses a output transformer (T5) to isolate the various power supplies.
The following table summarize all the different outputs.
Test GND
SECTION LED Pot.
point TP
Local auxiliary voltage 1 DL1 TP1 TP2
Local auxiliary voltage 2 TP3 TP4
+24V thyristor drivers and transformers DL2 TP6 TP5
+12V analog circuits DL3 TP12 TP5
+5V serial interface DL4 TP7 TP8
+15V rectifier CPU DL5 TP9 TP11
-15V rectifier CPU DL6 TP10 TP11
IGBT drivers power supply (PS_AC1 / PS_AC2) RV1
TP6 +24V_SSW
D41 1N4007
GND_SSW
TP5
D45
18
POS_CPU1
BY V27-200 U18 TP9
T5 D47 LM7815 X9 X12
10 1 2
IN OUT
D
D48 N R109
G
BY V27-200 3k32
D49 C62
7
11 X6 C60 3 0
0 C61
220u 4 10u 100n
X11 DL5 N
1
PS_AC2
TP11
12
R110 GND_CPU1
PS_AC1
3k32
X10 C63 D52 C65
7
13 0 C64
0
X5 220u 4 10u 100n
DL6 N
1
BY V27-200 3 U19
D50
14 1 D 2
INN OUT
G
D51 LM7915 TP10 NEG_CPU1
BY V27-200
R24
2 4
511R
T2
V_MA_U 1 3 VMA_V
M8_1 CN7_5
V_MA_V
M8_3
R25
V_MA_W 2 4
M8_5
511R
T3
1 3 VMA_W
CN7_6
R26
2 4
511R
GND_CPU1
287R 287R
GND_CPU1 GND_CPU1
4) AC current feedback: the AC input current, controlled in order to reduce the harmonics
and the input power factor, is measured by the current transducers TA1-TA2-TA3. The
feedback signal is sent to the connectors M1 (C_MA_U), M2 (C_MA_V) and M3
(C_MA_W) of the board INT-R and finally transferred to the CPU through the following
connections:
5) Battery current feedback: the battery current is measured by the current transducer TA4.
The feedback signal is sent to the connector M4 (C_BAT_POS) of the board INT-R and
finally transferred to the CPU through the connection CN4 INT-R Æ CN1 D-CPU-RC.
The current signal is also sent to the board I/S-CL through an isolation amplifier
(connector M11) for the boost charge management.
POS_CPU1
C80 100n
Picture 14 – INT-R – Battery current feedback (to I/S-CL for boost charge control)
6) Digital signals to D-CPU-RC: the digital signals coming from the rectifier bridge are
acquired by the INT-R and transferred to the rectifier CPU to control the rectifier status.
I_FB Æ rectifier protection fuses status
I_TH_SW Æ thermal switch status
SW_RECT_ON Æ switches on and off the rectifier by external switch
The route of such signals is shown in the following table.
7) Interface I/S-CL Æ D-CPU-RC: the INT-R works as interface for the digital signals
exchanged between the rectifier CPU (D-CPU-RC) and the inverter CPU (I/S-CL). The
I/S-CL is interfaced with the INT-R through the connection CN5 RCB Æ CN15 INT-R (wire
W34) and controls the rectifier by means of the following signals:
CMD_BOOST Æ enable the boost charge level
CMD_ON_HC16 Æ switches on and off the rectifier (command from I/S-CL)
CMD_TEST_BATT Æ enable the battery test
Such digital signals are interfaced with relays inside the INT-R and transferred to the
board D-CPU-RC as voltage-free contacts.
+12V_RCB
I_CON_HC16_ON
CN6_19
RL1
RET_I_CON_HC16_ON 1
CN6_20
7 D1
1N4148
12
11 CMD_HC16_ON
CN15_5
MZ12HS-K
+12V_RCB
I_TEST_BATT
M15_3
RL2
1
M15_4
7 D2
1N4148
12
11 CMD_TEST_BATT
CN15_6
MZ12HS-K
+12V_RCB
I_BOOST
M15_5
RL3
1
M15_6
7 D3
1N4148
12
11 CMD_BOOST
CN15_4
MZ12HS-K
8) Interface D-CPU-RC Æ I/S-CL: the status of the rectifier is acquired by the inverter CPU
(I/S-CL) through the INT-R, by means of the connection M11 INT-R Æ M2 I/S-CL (wire
W33) which transfers the following signals:
0_BF_RECT Æ rectifier protection fuses blown
0_ERR_SC_RECT Æ input wrong phase sequence
0_RECT_FAIL Æ rectifier general fault
0_MAINS_FAULT Æ mains failure (battery discharging)
The route of such signals is shown in the following table.
* The “mains fault” contact is connected to the interface board FCI (PB047), terminal
board M1/3-4.
+12V_RELE
M11
1 O_BF_RECT R11 1k RELE2
CN14_4
2
3 O_ERR_SC_RECT R12 1k RELE3
CN14_5
4 M12
5 O_RECT_FAIL R13 1k RELE4 1 RET_O_MAINS_FAULT
CN14_6 M12_1
6 2 O_MAINS_FAULT
7 +12A M12_2
M11_7
8 -12A
M11_8
9 C_BAT
M11_9
10
M11_10
GND_A
9) Relay output: the D-CPU-RC generates some status and alarms signals that can be
transferred, through the connector CN17 of the INT-R, to a optional relay card SRC
(PB218).
U6
1 18 B_RL1
IN1 OUT1 CN17_3
2 17 B_RL2
IN2 OUT2 CN17_4
3 16 B_RL3
IN3 OUT3 CN17_5
4 15 B_RL4
IN4 OUT4 CN17_6
5 14 B_RL5
IN5 OUT5 CN17_7
6 13 B_RL6
IN6 OUT6 CN17_8
7 12 B_RL7
IN7 OUT7 CN17_9
8 11 B_RL8
IN8 OUT8 CN17_10
GND
10
+12V_RELE COM
ULN2804
9
GND_SSW
10) Board INT-R2: the board INT-R2 is connected to the INT-R by strip-lines. The generation
of the thyristor firing pulses is enabled by the command SCR_PRECHARGE_ON sent by
the CPU. The INT-R2 is provided with a soft-start circuit that allows a soft pre-charge of
the DC capacitors using four of the six thyristors of the bridge. As soon as the DC voltage
has reached a programmed value, the D-CPU-RC sends the command
SCR_BRIDGE_ON, which turn-on the remaining two thyristors. After the start-up the
thyristors work as a non-controlled three-phase Graetz bridge.
5.2 RTF
5.2.1 Description of operation
The board RTF contains the final stage for the thyristors firing control; it’s composed by six
identical stages, one for each thyristor. The control signals on pin 3÷8 of the connector CN1,
generated by the board INT-R2, pass through a R-C filter and a high frequency transformer and
are finally connected between gate and cathode of the thyristors. The board is provided with six
LED’s installed at the high frequency transformer output to check the operation of each stage.
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
INT-R, is used to generate the isolated supplies for both sections of the card.
+15V U2 +5V
D4 1N4148 78L05 R33 1K
1 2
TR1 VIN VOUT
C9 1u D5 1N4148 +
GND
AC1 C10 LD3
10u-63V C12
1u
3
D6 1N4148
+
CN1 C11
10u-63V
1
2 TI117239/ACM2008
3 D7 1N4148
4 -15V
5 Power supply IGBT+
6
7
8 +15VF +5VF
9 U6
D11 1N4148 78L05 R34 1K
10 1 2
TR2 VIN VOUT
C21 1u D12 1N4148 +
GND
D13 1N4148
+
C23
10u-63V
TI117239/ACM2008
D14 1N4148
-15VF Power supply IGBT-
2) Input stage: the PWM is isolated by an opto-coupler. The R4-C5 low pass filter creates the
dead time for the PWM modulation, through the NAND gate U1. The red LED LD1
indicates the presence on the PWM.
D3 R5
+5V 1N4148 680K
C1 100n R2 D2
3K3 1N4148
14
1=ON U1B
14
14
7
R1 U1A 5 U1C
2 6 0=ON 1 4 0=ON 8
3 6 10 1=ON
1K8 3 5 2 9
D1 R4 1K8 4093
PWM 1N4148 U3 HP2601 4093 4093
7
R6
14
7
+ U1D 3K3
R3 *** C5 C2 12
1K 1n 10u-63V 11
13
LD1
4093
7
3) Output stage: the final stage DZ1, Q2, Q3 and Q4 translates the modulation signal
between +15V (ON Level) and -15V (OFF Level) and works as a buffer. The modulation
signal can be adjusted with the potentiometer RV1 of the board INT-R.
+15V
R11 **
R9 R10
390R 2W 390R 2W D
C4 + C7 DZ2
G 18V
S 10u-63V 1u R15 G1H
Q2 D 1K 1
IRFD014 Q4 2 S1H
R7 IRFD9014 R13 ** DZ3
1=ON G DZ1 C3 18V M1
S 24V 100n
22R D
G
S
C6 + C8
Q3
R8 IRFD014 10u-63V 1u
9K09
-15V
CN1
LD3
Power supply ON
LD4
Power supply ON
LD1 LD2
Modulation ON Modulation ON
R30
IGBT’S
R11 gate
IGBT’S GND IGBT1 GND IGBT2
gate
M1 M4
POS-CPU1
D35 L1 22R
POS-CPU1 A K VDDSB-CPU1
22uH/2.6A C129
MBRS360T3 100N
C130 D36 U37
100N C131 A K 33 7 U38
47uF/25V BOOST Q_STB TLE4274GSV33 3V3-CPU1
GND-CPU1 MBRS360T3 29 L2 D110
SW 31 A K
C132 SW 22uH/2.6A I Q
100N K D
R837 0R D37 BAS40-SOT N
1 G
30 C133 MBRS360T3 C134 C135
32 IN 470N 22uF/10V 1uF C491
R246 0R IN 1uF
35 28 A
R247 SLEW BOOTSTRAP
2
34
WAKE 25
R838 10K 21 FB/L_IN 26 2V5-CPU1 3V3-CPU1 +5V-CPU1
C+ FB/L_IN
0R (N.M.)
C136 27
100N Q_LD01 24
3 Q_LD02 14 R243 R244 R245
20 Q_LD03
22 C- 8 120R 120R 220R
CCP Q_T1 9 R250 R251
23 Q_T2 10
SEL Q_T3 11 2V5-CPU1 0R 0R +5V-CPU1
Q_T4 12 LED3 LED4 LED5
Q_T5 1- A 1- A 1- A
3 13 2 2 2
2 CS Q_T6 M M M
4 CLK 17 1 e 1 e 1 e
L d L d L d
DI R1 16 C144 C145 0 r 0 r 0 r
7 e 7 e 7 e
R2 10uF/10V 10uF/10V 6 V 6 V 6 V
1 15 T T T
C146 18 GND R3 G d G d G d
L e L e L e
220N 19 GND 6 K L K L K L
36 GND ERR 5
GND DO
TLE6361G
High_Max_Booster
U30A U18C
U18A 1 8
Low_Bad_Supply 1 1 3 10 PWM_BP_U
3 2 PWM TA+ 9
Low_IMax_U 2
4071 4093
4093 U18B
5
4 Low_Pwm_Trip_U To the
6 IGBT
4093 drivers
U18D
12
11 PWM_BN_U
PWM TA- 13
4093
Signal Connector
AC input VOLTAGE U Æ CN5-4
AC input VOLTAGE V Æ CN5-5
AC input VOLTAGE W Æ CN5-6
AC input CURRENT U Æ CN1-12
AC input CURRENT V Æ CN2-12
AC input CURRENT W Æ CN3-12
DC VOLTAGE (Positive) Æ CN5-9
DC VOLTAGE (Negative) Æ CN5-10
Battery CURRENT Æ CN1-13
5.4.1.6 Control LEDs
The following table shows the meaning of the various LEDs on the board D-CPU-RC.
SECTION LED
Microprocessor positive supply (POS_CPU) DLP1
Microprocessor negative supply (NEG_CPU) DLN1
SPI supply (+5V_SSW) DLSS
Microprocessor supply (2V5_CPU) LED3
Microprocessor supply (3V3_CPU) LED4
Microprocessor supply (+5V_CPU) LED5
Microprocessor reset LED6
Program running LED1
6 INVERTER PCB’S
6.1 DR-HY (INVERTER IGBT DRIVER)
6.1.1 Description of operation
The inverter IGBT drivers DR-HY are connected to the board PWM-SAT. Each driver is
made of two identical sections, one for each IGBT (connected in parallel).
1) Power supply section: the square wave AC1-AC2, originating from the power supply card
PS-SAT, is used to generate the isolated supplies for both sections of the card.
CN1-10 VDD U1 +5V
CN1-9 LM78L05 R1
D2
CN1-8 1 2
CN1 VIN VOUT
1N4148 2K21
GND
10 D5
D1
9 T1 3 + C3
8 Verde fi=3mm
C1 1uF
7 C25 1uF 47uF/25V
1N4148
3
6 6
5 2
4 4
3
2 1 D6
1 + Verde fi=3mm
5 D3 C2
FLAT 10P 47uF/25V
ACM2008 R9
1N4148
D4 6K81
VNN
1N4148
2) Input stage: the PWM is isolated by an opto-coupler. The transistor Q1 and the NAND
gate U1 provide to a level translation of the modulation signal. The red LED LD14
indicates the presence on the PWM.
R34 VDD
3K3
Chiudere sul pin 5 VDD
CN1
+5V C5 +5V D14
10 100NF Giallo fi=3mm
9 R11 C7 1uF
8 3K3
7 ISO1
8
7
UNDERVOLTAGE LOCK-OUT
3) Output stage: the signal is amplified by a MOSFET amplifier that provides also for the
translation of the signal between +15 and -15V. The modulation signal can be adjusted
with the potentiometer P2 of the board PS-SAT.
J1
D9
RON1 18V/1W 1
VDD 2
3
10R/2W 4
R25 5
RON2 1K CON 5P
+ + + +
C15 C33 C29 C34 1 TPG1
47uF/25V 47uF/25V 47uF/25V 47uF/25V
1 TPS
Q3 C14
BSS89 D8 1 TPG2
100NF 24V/1W
Q5
C18 ROFF1 D12
IRFZ24N 1uF 18V/1W
R23 + + + + R26
9K09 C16 C35 C30 C36 10R/2W 1K
47uF/25V 47uF/25V 47uF/25V 47uF/25V J2
ROFF2
1
2
10R/2W D11 3
VNN 18V/1W 4
5
CON 5P
D18 R19 D7
DE-SATURATION 1 2
1K MUR1100E
8.2V/1W
R6 10uF/25V 1N4148
3K3
U2 R3 R2
8 110K 10K
R8 1M 1 VDD
2 OUT1 7
3 HIST1 OUT2 6
SET1 SET2 5
4 HIST2
GND C32
R7 ICL7665S R5
10K R4 10K 1NF
1M
VNN
1 = ALIM. OK
5) De-saturation protection
VDD
U3 C6 J2
9 3 10uF/25V
INPUT VPOS C11 1
10 14 100NF R18 2
T_MOR VSS 1K 3
5 R20 4
OUT_ST 1 5
2 OUT1 16
VDD OUT2 CON 5P
4 100R D18 R19 D7
11 CL_PROG 13
SELECT IN_DES 1 2
15 12
COM LIV_DES 7
MON_DEL 1K MUR1100E
8.2V/1W
8 6
VREF ALARM
C8 L6353
100NF R16
10K R17
C13 C10 12K1
1NF 1NF
D6 TPG1
Supply ON Test Point IGBT1
TP5
GROUND
J1
CN1 TPG2
Test Point IGBT2
J2
D14
Modulation ON
D5 D17
Supply ON Led fixed: inverter OK
Led blinking: under voltage lock-out
6.2 INV-AV-3F
6.2.1 Description of operation
The INV-AV-3F provides the inverter voltage feedback for the real-time control loop. The
inverter output phases (L1-L2-L3), taken on the filter capacitor Cr-Cs-Ct, are connected on CN1
pin 1-3-5 respectively; the voltage values are reduced by the transformer T1-T2-T3 and sent to
the microprocessor control logic I/S-CL through the connector W18.
The UPS output current transformers TA2-TA3-TA4 are connected to CN3 pin 1-2, 3-4 and
5-6 respectively; the current generated by TA2-3-4 flows through the resistors R4-R5-R6,
generating voltage drops proportional to the UPS output current; this waveforms are sent to the
I/S-CL measuring section for the output current reading.
6.3 PS-MIS
6.3.1 Description of operation
The board PS-MIS is mounted directly on two DC capacitors connected in series; it’s
composed by two sections:
1) Supply of the board PS-SAT: the voltage across the DC capacitors bank is connected to
the connector M1-5/6 and de-coupled by a diode. The voltage across the capacitors C1-
C2 (on which the board is fixed) is lower than the input voltage owing to the voltage drop
on the resistors bank connected to the connector M3. The board PS-SAT is connected to
the connector M2.
D1
+VDC +VDC_PS
M1_1 M3_1 M3_3 M2_1
C1+
PIAZZOLA
S
C
2
1-
E
T
5 A-
R k C1-
2 PIAZZOLA
2
C2+
PIAZZOLA
S
C
2
1-
6 E
T
R A
-
k
2
2
PIAZZOLA
C2-
-VDC -VDC_PS
M1_5 M2_3
2) DC voltage feedback: the PS-MIS provides the DC voltage feedback to the inverter
microprocessor control I/S-CL for the DC voltage measure. The feedback signal is
provided by the transducer VM1.
+12A C1
10u-50V
R1
27k-ATE-12CS +
+VDC +HT + C2
M1_1
100n
-
R4
CN1_5
-VDC -HT M MIS_VDC
M1_5 CN1_6
1k
R2
27k-ATE-12CS VM1 R3
LV 25-P
82R-1/2W
GND_A
6.4 PWM-SAT
The board PWM-SAT is the interface between the inverter bridge and the microprocessor
control I/S-CL. The modulation signals is available from the I/S-CL on the connectors CN1 (leg
A), CN2 (leg B), and CN3 (leg C). The PWM-SAT split the signal in two parts to make it
available for each single switch of the inverter bridge (positive and negative).
It also collects the current feedbacks coming from the current transducers TA5-TA6-TA7 and
send the resulting signal to the microprocessor control through the connection M1 PWM-SAT Æ
M1 I/S-CL.
Finally, it collects the de-saturation and under-voltage lock-out protections coming from each
driver, generating a single output signal that is sent to the microprocessor.
7.2 2SCR-FIR
7.2.1 Description of operation
The 2SCR-FIR is the thyristors firing board and is installed directly on the static switch
thyristors. The control signals generated by the I/S-CL are connected on CN1; they are then
isolated by the high frequency transformer TR1 and sent directly to the thyristors. The LED’s
DL1-DL2 show that the thyristor is turned on.
DL1 R5 D Ri
G1
D1 4,7R 1W
R1
TR1 C1 *
47R
3 0,1u
K1
1
4
R7 R6 DL2 R4 + l
8 6
G2 a
nr
27R 5W C4 27R 5W 4,7R 1W
et
5 D2 R2 x
47R C2 * E
0,1u
0,1u K2
A
2- 4- 8- 0
1 3 7 1- A
CN1 9
-
R3
27R
Ru
C3
D
0,1u
8 COMMON PCB’S
8.1 PS-SAT
8.1.1 Description of operation
This board provides the different power supplies to all the sections of the I/S-CL
(microprocessor board) and to the front panel. It’s supplied by the DC bus through the board
PS-MIS. The insulation voltage between the output section and the DC input is 2,5kV.
The PS-SAT is composed by the following sections:
1) Microprocessor supply: the microprocessor supply is strongly filtered and stabilised at +5V
on the microprocessor side (I/S-CL) by means of a precision voltage stabiliser.
FU6
PF 2A
17 CN1
FLAT 10P
2) Analog part supply: supply the analog side of the microprocessor card (I/S-CL).
R51
TP5
FU2 10K
+24V
AC1 1
C15
13 C35 D20 1u
AC2
470n U4 1N4004 2K21 G 3mm FLAT 10P
LM7812
2
D15 R48
14 D19 D18
MUR120 MUR120 TP3 -12V
MUR120 10K
2 3
IN OUT
R47 LD2
GND
+
C31 D21 C28
100u 50V U5 1N4004 1u 2K21
LM7912 G 3mm
1
3) Relay and bus supply: this section provides a +12V stabilised voltage for the supply of:
Relays of the alarm card ARC (PB031) Æ pin 9-10
Relays of the rectifier interface INT-R Æ pin 9-10
Parallel bus Æ pin 9-10
Inverter interface card FCI (PB047) Æ pin 1-2
MUR120 PF 2A 2K21
+ C48 LD5
20 10u 63V C34 G 3mm 12V/SCR
1u
T2-G
4) IGBT drivers supply: the supply of the IGBT driver boards DR-HY is taken from the 40kHz
square wave AC1-AC2
5) Serial ports supply: the supply of the serial communication ports is taken from the 40kHz
square wave AC3-AC4
8.1.2 Programming instructions
P2 TP9
IGBT’s gate voltage
CN1
TP8
P1
Not used
FB2
VB- CN4
LD5
LD4
TP3
VB+ -12V
CN3
FB1 TP4
GND
TP2
+12V
CN2
LD2 LD1 TP5
LD3
+24V
Test GND
SECTION LED Pot. Value
point TP
LD1 +12V Analog TP2 TP4
Analog part supply LD2 -12V Analog TP3 TP4
LD3 +24V Analog TP5 TP4
Free contacts and parallel bus LD4 +12V / Relay & Bus
Free contacts LD5 +12V
Microprocessor and display +9V TP8 TP9
IGBT’s drivers Power Supply P2 Sq. Wave AC1-AC2
RS-232 and RS-485 Sq. Wave AC3-AC4
I/S-CL
Signal
M3
1-2 Not used - Spare
3-4 Mains failure (from INT-R)
5-6 Emergency Power Off push button
7-8 BCB auxiliary contact
9-10 OCB auxiliary contact
11-12 SW1 auxiliary contact
13-14 MBCB auxiliary contact
15-16 High temperature
17-18 Parallel configuration (from RPI-BUSCAN)
UPS
Dip 5 Dip 6 Dip 7 Dip 8
[kVA]
MICRO BUS R
FI1 BYPASS FREQUENCY OP AMP
+5V
R152 R150
D62 D61 D60 D55 D54 D53 10K 10K
2K2 1% X6
R172
ADA0 R R
CN13-4
ADA1 S S R171
CN13-3 BYPASS
ADA2 T T R173
CN13-2
ADA3 R R R166
CN13-5
ADA4 S S R165
CN13-6 OUTPUT
ADA5 T T R164
CN13-7
R205
R206
R204
R207
R208
R209
C113
VR/2
A/D Test
Measure
Channel Point
Inverter Output Voltage R #0 D43 (K)
Inverter Output Voltage S #1 D20 (K)
Inverter Output Voltage T #2 D21 (K)
Output Current R #3 D6 (K)
Output Current S #4 D33 (K)
Output Current T #5 D5 (K)
Inverter Input Voltage (DC) #6 D23 (K)
Inverter Input Current (DC) #7 D22 (K)
Phase Correction for Parallel Redundant #8 D42 (K)
Battery Current for Boost Charger #9 D74 (K)
+5A
INVERTER VOLTAGE R
D31 D16 D17 D32 D14 D15 D34 D35 D36
U22 INVERTER VOLTAGE S
microprocessor power supply (under-voltage lock-out). It is also possible to reset manually the
microprocessor by pressing the reset push-button SW3.
8.2.1.7 RAM, EPROMs and EEPROM
The EEPROM U71 contains the functional parameters of the UPS and the adjustments.
The RAM U58 contains the history of the alarms of the UPS. Up to 900 events can be stored
in this device and the backup battery allows to preserve the information for three days after the
power has been removed.
The two EPROMs contain:
U55 Program odd addresses
U65 Program even addresses.
8.2.1.8 Digital Power Supply
The digital part of the I/S CL has its own power supply (5 volt). This voltage can be checked
on the LED D69 (green) and measured between U75 pin 2 (ground) and pin 3.
VNR +5V +5V
CN14-10 U75
L4 TEA7605
CN14-9 1 3
E U
C122
M
C137 C131 + D69
FILTERS GREEN
100NF 100NF 470uF
2
CN14-1
CN14-2
GND COMMON MODE
D50
R146
1N4148
+VRAM
D49 D48
1N4148 SD103
BT
1 ON
2
J2
3 OFF
1) Short circuit protection: the feedback signal originated by the Hall effect CT is acquired by
the microprocessor card where it 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 4Vpk when the inverter supplies the
nominal load (100%).
In case of short circuit the output current is limited at 200% for 100ms, and then to 125%
for 5 seconds, after which the inverter is switched off (according to EN62040-3).
+12A
C19
M1-2 FEEDBACK
R39 100NF
J10 47R
R27 D73 A
3 U16A
+
1 TP2
C28 R40 1K SD103 2
-
1NF J9 100R D72 Current
R38 MC34074
SD103
2K A
Signal
C27 1n
R18
J100 22R
R25 R26
P2
1K 10K 1K
A
2) “Current stop” protection: the resistors R18-R39-R40 are properly combined according to
the IGBT’s nominal current so that, in case of “bridge leg” short circuit the PWM is
stopped before the input current exceed the 200% of the IGBT’s nominal current. The
detection time and the subsequent inverter stop is not higher than a PWM pulse (max.
250μs)
The inverter stop due to “Current stop” is signalled by the LED D3, placed on the front of
the I/S-CL card. The program provides for the automatic reset of the stop condition for
three times, re-starting the inverter. If the block repeats, therefore a real failure exists in
the inverter bridge, the inverter is definitely stopped and must be re-started only after
having verified the reason of the malfunction.
U15B
+5A +12A 3 4
U5C
C20 40106 8 R13
100NF 10
R15 CA3130 9
10K +12A 3K3
4093 D3
7
5
A LMCS
R17 10K
FEEDBACK 3 U11 R50
M1-2 +
6 U5D
R39 2 12
-
J10 R49 200K 11
13 A
R16
4
8
1
C13 1K 4093
10K
R40
C28 J9 1NF N1 CURRENT STOP
1NF A 100pF
+ C148
A 10u 25V
SW4
R18 PPMCS
J100
1) Sine-wave generator: the digital samples coming from the microprocessor (that represents
the digital sine-wave) are converted by a D/A converter in order to obtain a real sine-wave
which is transferred to the PWM generator (see 8.2.1.13). The amplitude of the sine-wave
Issued 13/04/07 JUD409400 30 of 35
UPS Functioning Description
2) Voltage correction (instantaneous value loop): the voltage correction circuit is used to
modify the PWM reference signal in order to “correct” possible distortions on the output
sine-wave and can be disabled removing the jumper J2. The feedback signal, coming
from the INV-AV-3F card is compared with the reference sine-wave e properly filtered.
The resulting signal is added again to the reference sine-wave.
+5A +12A
C22
R36
10K
R30 10K U6C 100NF
VREF 10 NOTCH A
+ U6B
8 FILTER 5
+
9 7
-
6
-
LM324 R39 10K
LM324 VREF
R31 10K R32 10K
VFBK A
R40 10K U6D
R37 12
C14 +
C15 14 VPWM
1NF 1NF 43K2 C19 J2 13
-
C20 100NF
LM324
A A
1NF R41 10K R42 11K8
+5A
3) Inverter voltage measure: a section of the card is dedicated to the creation of a signal that
is used as reference for the measure of the inverter output voltage. The feedback signal,
coming from the board INV-AV-3F, is rectified, filtered and sent to the external A/D
converter (see 8.2.1.5), and then to the microprocessor
8.2.1.13 PWM generator
The I/S-CL can be used to generate both single-phase and three-phase output voltages. This
function can be programmed by setting the jumper J1 on the I/S-CL. The PWM generator
compares the sine-waves coming from the VCB card with a triangular waveform at the switching
frequency (U17 pin 6) to generate the PWM modulation to control the inverter power bridge.
+12A +12A
C18
C24 100NF
100NF
A U9A +12A CN7-8
5 6 1
1STOP
3
CN7-7 +TA
U14C 2
40106 AC1
A
CN7-1
4093
CN7-3
U14D
+12A A
9 8 AC2 CN7-2
C22 CN7-4
CA3130 40106
100NF -TA
R10
7
5
A A
1K
FPWM (TRIANGLE) 3 U12 U9B
+ +12A CN7-10
6 5
VPWM (SINEWAVE) 2 4
- CN7-9
6
R9 C14 C15
1K
4
8
1
4093
22NF 22NF
A
A A
A N5
47pF
17 SPARE
16
15 THERMAL SWITCH 9 8 Ad0 EEPROM
14
10 7 Ad1
13 MBCB AUX. CONTACT Ad2 Parameters
Output Buffers
11 6
12
12 5 Ad3 Microprocessor RAM EPROM EPROM
11 BYPASS SWITCH 13 4 Ad4
U74
Ad5 U71 History Odd Even
Fast Analog to Digital Conversion
10
14 3
9 OCB AUX. CONTACT 15 2 Reset
Input Latches
U48-U52-U53
Input Latches
8
Optocouplers
16 1
EPO CONTACT Rx
U67-U68
7 1
SW2
BT
6 U61 U58 U55 U65 Tx 2
5 BCB AUX. CONTACT Gnd 3
4 Backup battery Pos 4
UPS Functioning Description
9 8
3 MAINS FAULT 5
RS232
Buffer
2 10 7 6
U15
11 6
RESET
1 SPARE 7
M3
12 5
SW3
Watch-dog and
Optocouplers
8
13 4 9
14 3 Undervoltage
Channels
10
6 15 2 Lockout Out- 11
16 1
5 CHARGER FAULT Out+ 12
+12V
4 Optocouplers In- 13
3 SPARE In+ 14
CN13-4
2 By-Pass R 15
CN13-3
+5V
1 16
RS485
CN13-2
M2
Buffer
By-Pass T 17
U14
Relays
CN14-10
18
CN13-5
CN14-9
Output S
CN4
20
CN13-7
L2
L1
Power
+12V-SCR
K1
RELAY #2
RELAY #3
RELAY #1
RELAY #4
RELAY #5
RELAY #6
RELAY #7
POS-REL
POS-REL
POS-REL
U11 pin 9
Supply
CN14-1
U75
D69
CN14-2
10
9 20
8 Display
10
9
8
7
6
5
4
3
2
1
Driver
Optocoupler
CN6
CN5
RCB
JUD409400
7
Thyristors
2
1
CN10
M1
6 Inverter Feed Load Signal 1 U75 pin 2
U39
Driver
5
4
3
2
Addresses and Data Bus
CN5
1
+5ST
CN8-10
3
Feed-back Feed-back Feed-back Inv. Voltage R In0 In3 Output Curr. R
Array Logics
CN8-9
L1
Short Circuit
Current Stop
P1 P1 P1
External A/D
CN8-8
GND U11 pin 10 Inv. Voltage T In2 In5 Output Curr. T
CN9
1
DC Current In7
Converter
M2-9CN3-2 CN4-6
Thyristors SCB In6 Inverter Inp. Volt.
Signal
Signal
Driver
U22
Generator Generator Generator In8 Phase Correct.
J2 U4 J2 U4 J2 U4
10 In9 Battery Curr.
D3
9
8
VCB VCB VCB
RESET
7
6 J1 J1 J1
SW4
5 Short Circuit
Detector
4
3
2
CN11
+12V
Max Current
Stop
CN4-10
P1 U7 pin 1
CN4-9
M1-2
Inverter Bridge Current
CN4-3 CN4-8
J9 J10 J100 Switching Frequency PWM Generator Analog
Generator U17 U9-U14 J1 Power
IGBT's Current
TP2
Supply
Issued 13/04/07
Selection
CN4-2
Current U7
D11
CN4-1
Limitation
U7 pin 2
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
CN7
CN1
CN2
P2
UPS Functioning Description
M1
Led
max corr.
J100 CN7
M2 J1
1Ph = 1-2
R18 3Ph = 2-3
M3 22R
Man. Inv.
volt. adj.
P2 U17
ACW=incr.
Curr. limit. adjust. Pin 6=Triangle
Modul.
ACW=increase curr.
D11 CN8
Correct D23
R66 Vdc measur.
+12V analog 6K8 = 8KHz
13K3 = 4KHz
CN11
CN10
CNB Front
panel
CN9
J2
Battery connected
1-2 Closed = backup CN12
Debug
CN14
RST–RST CN8 CN7
Emer. line - Output
CN13 (D65..D52) ODD Normal
Reset Debug
selection
CN15 EVN
J7 SW1 SW2
Microprocessor D69-Correct Open=Watchdog
ground +8V digital excluded
Closed=Watchdog
included
JP7 JP1
JP3
Open = hot stand by – parallel red.
Closed = single unit
JP4
J1 P1
Inv. Voltage reg. Close loop inverter voltage adj.
1-2 = closed loop
2-3 = manual
J2
Closed = istant. loop included
Open = istant. loop not included
J3
Always open
8.3 FCI
8.3.1 Description of operation
The FCI board provides a de-coupling function for all the digital inputs (see point 8.2.1.2) and
it’s connected to the microprocessor through the terminal M2. In detail, the function of each
relay is the following:
K1 (terminals 17-18) Æ used for UPS in parallel configuration
K2 (terminals 15-16) Æ Inverter bridge thermal sensors
K3 (terminals 13-14) Æ MBCB (manual by-pass breaker) position
K4 (terminals 11-12) Æ SW1 (by-pass test switch) position
K5 (terminals 9-10) Æ OCB (UPS output breaker) position
K6 (terminals 7-8) Æ BCB (battery circuit breaker) position
K7 (terminals 5-6) Æ EPO (Emergency Power Off)
K8 (terminals 3-4) Æ Mains failure (from rectifier control logic)
K9 (terminals 1-2) Æ Not used - Spare
CN1
+12V
10 J1 J2
9
1
8
7 2 2
6
5
4
3
3
2
1
K1
1N4148
D1
OUAZ-SH-112D
K2
1N4148
D2
OUAZ-SH-112D
M2
M1 K3
1N4148 18
18 17
17 16
16 D3 15
15 OUAZ-SH-112D 14
14 13
13 12
12 K4 11
11 1N4148 10
10 9
9 8
8 D4 7
7 OUAZ-SH-112D 6
6 5
5 4
4 K5 3
3 1N4148 2
2 1
1
D5
OUAZ-SH-112D
K6
1N4148
D6
OUAZ-SH-112D
K7
1N4148
D7
OUAZ-SH-112D
K8
1N4148
D8
OUAZ-SH-112D
K9
1N4148
D9
OUAZ-SH-112D
Index
1 INTRODUCTION.................................................................................. 4
1.1 TOOLS FOR SERVICE.....................................................................................4
2 TROUBLESHOOTING PROCEDURES .............................................. 5
2.1 A1 – MAINS FAULT .........................................................................................5
2.1.1 Troubleshooting procedure ....................................................................5
2.2 A2 – CHARGER FAULT...................................................................................6
2.2.1 Troubleshooting procedure ....................................................................6
2.3 A3 – RECTIFIER FUSE ....................................................................................6
2.3.1 Troubleshooting procedure ....................................................................7
2.4 A4 – THERMAL IMAGE ...................................................................................7
2.4.1 Troubleshooting procedure ....................................................................7
2.5 A5 – AC/DC FAULT..........................................................................................8
2.5.1 Troubleshooting procedure ....................................................................8
2.6 A6 – INPUT WRONG SEQUENCE...................................................................8
2.6.1 Troubleshooting procedure ....................................................................8
2.7 A7 – BCB OPEN...............................................................................................9
2.7.1 Troubleshooting procedure ....................................................................9
2.8 A8 – BATTERY DISCHARGE ..........................................................................9
2.8.1 Troubleshooting procedure ....................................................................9
2.9 A9 – BATTERY AUTONOMY END ..................................................................9
2.10 A10 – BATTERY FAULT ..............................................................................9
2.11 A11 – BATTERY TEST .................................................................................9
2.12 A12 – PLL FAULT.......................................................................................10
2.13 A13 – INVERTER OUT OF TOLERANCE ..................................................10
2.13.1 Troubleshooting procedure...............................................................10
2.14 A14 – OVERLOAD......................................................................................11
2.14.1 Troubleshooting procedure...............................................................11
2.15 A15 – BYPASS FAULT...............................................................................11
2.15.1 Troubleshooting procedure...............................................................12
Index of pictures
Picture 1 – Signal on cathode of D65 (D64-D59)....................................................................................... 12
Picture 2 – Current signal on TP2 at 100% of load .................................................................................... 18
Picture 3 – IGBT turn-on signal .................................................................................................................. 20
Picture 4 – Triangle (switching frequency) ................................................................................................. 24
1 INTRODUCTION
This troubleshooting includes a first-level fault description based on the UPS alarms and
suggests how to check the unit to solve the problems. This description assumes that all the
connections inside the unit are correct: check them (connectors, power cables, signals and so
on) before to start with the procedures. The first-level troubleshooting eventually leads to the
substitution of the components of the UPS without attempting to repair them.
The procedures listed below takes into account the operator is provided with all the testing
tools and perfectly confident with the test software.
2 TROUBLESHOOTING PROCEDURES
2.1 A1 – MAINS FAULT
This alarm normally indicates that there is no power at the input of the UPS. The normally
closed contact of the relay RL5 on the board INT-R is connected to the pins 1-2 of M12. This
contact is sent to the I/S-CL on M3 pins 3-4 through the wire W35. When this contact is closed
(relay not energised) the alarm is active; when the mains is considered good, the relay is
energised and the alarm disappears.
2.1.1 Troubleshooting procedure
1. Is the input voltage present and within the tolerance?
YES: go to step #2
NO: check the UPS supply line
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence. Is it
active?
YES: follow the procedure at 2.6.1
NO: go to step #3
3. Check the AC voltage measures on the software “WRC Monitor”. Are they in
tolerance?
YES: go to step #4
NO: go to step #6
6. Check the connection between the AC mains and the connector M8 of the board INT-R
(wire W51). Is it good?
YES: replace the board INT-R. Go to step #7
NO: re-connect or replace the wire W51
8. Check the connection between the connector CN11 of the board D-CPU-RC and CN14
of the board INT-R. Is it good?
YES: go to step #9
NO: re-connect or replace the wire W38
9. Check the connection between the connector M12 of the board INT-R and M3 of the
board I/S-CL. Is it good?
YES: replace the I/S-CL
NO: re-connect or replace the wire W35
2. Check the connection between M11 of the board INT-R and M2 of the board I/S-CL. Is
it good?
YES: replace the I/S-CL
NO: re-connect or replace the wire W33
3. Connect the software “WRC Monitor” and check the alarm Booster Fault. Is it active?
YES: go to step #4
NO: replace the board PB249 (D-CPU-RC)
4. Check the alarm High Temperature on the software “WRC Monitor”. Is it active?
YES: go to step #5
NO: go to step #7
5. Check the status of the pins 1-2 of M15 in the board INT-R. Is the contact closed?
YES: go to step #6
NO: Check and/or replace the thermal switch
6. Check the connection between the connector CN11 of the board INT-R and CN4 of the
board D-CPU-RC. Is it good?
YES: replace the board PB249 (D-CPU-RC)
NO: re-connect or replace the wire W41
7. Set the rectifier in TEST mode (see 4.1.2) and check the IGBT’s turn-on signal
according to the picture 3. Is it good?
YES: replace the board PB223 (INT-R). Go to step #8
NO: replace the faulty IGBT and the driver board
2. Check the connection between the auxiliary contact of the fuses and the connector M9
of the board PB223 (INT-R). Is it OK?
YES: go to step #3
NO: re-connect or replace the interconnection cable
3. Check the status of the pins 1-2 of M9 in the board INT-R. Is the contact closed?
YES: go to step #4
NO: replace the faulty fuse indicator(s) on the protection fuse(s)
4. Connect the software “WRC Monitor” and check the alarm Fuse Blown. Is it active?
YES: go to step #5
NO: go to step #6
5. Check the connection between the connector CN5 of the board INT-R and CN2 of the
board D-CPU-RC. Is it good?
YES: replace the board PB249 (D-CPU-RC)
NO: re-connect or replace the wire W43
6. Check the connection between the connector CN11 of the board D-CPU-RC and CN14
of the board INT-R. Is it good?
YES: go to step #7
NO: re-connect or replace the wire W38
7. Check the connection between the connector M11 of the board INT-R and M2 of the
board I/S-CL. Is it good?
YES: replace the I/S-CL
NO: re-connect or replace the wire W33
2. Is the alarm A14 - Overload present? (The output current exceeds the UPS nominal
current)
YES: the overload is still present. Reduce the load.
NO: the overload has finished and the load is still supplied by by-pass.
3. Repeat the step #1. Are the values shown equal to those measured?
Issued 13/04/07 JUD409401 7 of 26
Troubleshooting and Maintenance
YES: END. Check that the load doesn’t exceed the nominal load.
NO: replace the I/S-CL
YES: go to step #2
NO: check for the alarm A2 – charger fault; follow the procedures described at 2.2
2. Check the measure of the DC voltage on the test software and adjust it by the TVBA
command. Does the measure change?
YES: go to step #3
NO: replace the I/S-CL
3. Put the unit in manual by-pass (or switch it off if allowed) and switch it on again. Is the
measure correct?
YES: END
NO: replace the board PS-MIS (see procedure at 3.1.6). Go to step #4
2. Connect the software “WRC Monitor” and check the alarm Wrong sequence. Is it
active?
YES: replace the board PB249 (D-CPU-RC)
NO: go to step #3
3. Check the connection between the connector CN11 of the board D-CPU-RC and CN14
of the board INT-R. Is it good?
YES: go to step #4
NO: re-connect or replace the wire W38
4. Check the connection between the connector M11 of the board INT-R and M2 of the
board I/S-CL. Is it good?
YES: replace the I/S-CL
NO: re-connect or replace the wire W33
2. Check the connection between the auxiliary contact of the external battery switch and
the terminals Bac1-Bac2 in the UPS. Is it OK?
YES: go to step #3
NO: re-connect or replace the interconnection cable
3. Check the status of the pins 7-8 of M3 in the I/S-CL board. Is the contact closed?
YES: replace the I/S-CL
NO: replace the BCB auxiliary contact
the battery by measuring the battery voltage during the discharge. If the test fails the alarm A10
- Battery fault is activated.
The battery test can be activated manually by the operator or automatically by the UPS if the
automatic battery test is enabled (see 3.1.1 - microprocessor settings).
2. Measure the inverter output voltage (upstream the inverter static switch) and compare
the measure with the reading on the UPSTest screen (or front panel). Are the values
shown equal to those measured?
YES: go to step #3
NO: re-adjust the inverter voltage reading with the UPSTest software (see 3.2.1). Go
to step #4
4. Switch off the inverter, switch it on again and check the measures on the UPSTest
screen. Are the values shown equal to those measured?
YES: END
NO: replace the I/S-CL
11. In case the inverter turn-on and off cyclically check for the alarm A25 in the alarms
history and follow the procedure described at 2.25.1.
2. Compare the measure with the reading on the UPSTest screen (or front panel). Are the
values shown equal to those measured?
YES: check the UPS settings on the I/S-CL (nominal power, nominal voltage)
NO: replace the board PB004 (INV-AV-3F) and re-adjust the output current reading
with the UPSTest software (see 3.1.2). Go to step #3
3. Repeat the step #2. Are the values shown equal to those measured?
YES: END. Check that the load doesn’t exceed the nominal load.
NO: replace the I/S-CL
UPS 3 Phase: the emergency line is connected to the UPS through the SBCB circuit breaker
to the VOLT-REF-3F CN1 which adapts the signals to the microprocessor and send them
through the connector CN4 to the I/S-CL CN13. These signals can be checked on the I/S CL in
the following points (picture 1 shows the waveform):
The emergency line is checked as frequency (the frequency limits can be programmed
through the command TFFR; if the frequency is OK the variable FROK is active), as RMS value
(if the RMS value is OK the variable RMSOK is active) and instantaneous value.
3. Measure the by-pass input voltage and compare the measure with the reading on the
UPSTest screen (or front panel). Are the values shown equal to those measured?
YES: go to step #5
NO: replace the board PB005 (VOLT-REF-3F). Go to step #4
4. After replacing the VOLT-REF board, are the values shown equal to those measured?
YES: END
NO: replace the I/S-CL
4. Compare the measure with the reading on the UPSTest screen (or front panel). Are the
values shown equal to those measured?
YES: replace the I/S-CL
NO: replace the board PB005 (VOLT-REF-3F). Go to step #5
5. After replacing the VOLT-REF board, are the values shown equal to those measured?
YES: END
NO: replace the I/S-CL
2. Open SBCB (by-pass line breaker), turn on the inverter only and check the output
voltage waveform (downstream the inverter static switch) on the three phases. Is it
sinusoidal?
YES: go to step #3
NO: replace the thyristor relevant to the phase where the waveform is wrong
3. With the inverter ON and SBCB open, measure the voltage upstream the by-pass
thyristors. Is it equal to zero?
YES: replace the I/S-CL
NO: replace the thyristor relevant to the phase where the waveform is not zero (the
thyristor is in short circuit).
When MBCB is closed together with OCB the electronic protection turn off the inverter
generating the alarm A13.
2.18.1 Troubleshooting procedure
1. Is the manual by-pass breaker MBCB closed?
YES: END
NO: go to step #2
2. Check the status of the pins 13-14 of M3 in the I/S-CL board. Is the contact open?
YES: replace the I/S-CL
NO: replace the MBCB auxiliary contact
2. Check the status of the pins 9-10 of M3 in the I/S-CL board. Is the contact closed?
YES: replace the I/S-CL
NO: replace the OCB auxiliary contact
2. Check the status of the pins 15-16 of M3 in the I/S-CL board. Is the contact closed?
YES: replace the I/S-CL
NO: replace the faulty thermal switch
A16 – Bypass feeds load). This signal comes directly from the switch SW1 to the I/S-CL M3 pins
11-12.
2.22.1 Troubleshooting procedure
1. Is the switch in NORMAL position?
YES: go to step #2
NO: END; move it to NORMAL
2. Check the status of the pins 11-12 of M3 in the I/S-CL board. Is the contact closed?
YES: replace the I/S-CL
NO: replace the switch SW1
2. Check the status of the pins 5-6 of M3 in the I/S-CL board. Is the contact closed?
YES: replace the I/S-CL
NO: replace EPO push-button
2. Check the status of the battery. If the battery life has almost expired and its voltage
drops quickly it might cause the current on the bridge to exceed the current stop
protection during short mains failures. Are the batteries OK?
YES: go to step #3
NO: replace the batteries
2. Check the inverter input current waveform on test point TP2 (see picture 2). Is there
any spike or distortion?
YES: replace the inverter IGBT driver boards. Go to step #3
NO: replace the I/S-CL
3. After replacing the IGBT driver boards, is the waveform on TP2 correct?
YES: END
NO: replace the POWER SUPPLY. Go to step #4
• Setting of DSW1
• Setting of DSW2
UPS
Dip 5 Dip 6 Dip 7 Dip 8
[kVA]
2. Install the same software version (EPROM) that was installed in the old board.
3. Check the setting of the jumpers J1-J2-J3-J4-J5-J6-J7.
4. Check the setting of the resistors R39-R40-R18 (current control circuit), R66 (PWM
frequency) according to the following table.
UPS JUMPERS
R66 Freq PWM R Hall
(KVA) J9 J10 J100
200 6K81 + 6K81 4 KHz 47R Closed Open Closed
250 6K81 + 6K81 4 KHz 47R Closed Open Closed
300 6K81 + 6K81 4 KHz 33R* Open Closed Closed
* On the 300kVA the resistor R40 (100R) must be changed with 33R
5. Change the resistor R37 on the VCB boards (PB012); R37 = 27K4.
6. Measure the resistance between ground and TP2 (current protection) and set the same
value on the new board by means of the potentiometer P2. Take into account that the
peak value of the signal between ground and TP2, adjustable by means of the
potentiometer P2, must be equal to 4V with UPS supplying 100% of load. Check the
waveform of the signal (see picture 2), and adjust the peak value according to the
available load (load 100% Vp=4V, load 50% Vp=2V).
11. Measure the output voltage and, if necessary, adjust it by means of the potentiometer P1
on the board PB012 (VCB).
12. Check that all the measure on the UPSTest screen, or on the front panel, correspond to
the values measured; on the contrary modify the value read on the screen with the
following commands:
TIFRxxx (inverter voltage setting phase R; xxx is the value measured)
TIFSxxx (inverter voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TIFTxxx (inverter voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TUFRxxx (output voltage setting phase R; xxx is the value measured).
TUFSxxx (output voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TUFTxxx (output voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TBFRxxx (by-pass voltage setting phase R; xxx is the value measured).
TBFSxxx (by-pass voltage setting phase S; xxx is the value measured); only 3Ph UPS.
TBFTxxx (by-pass voltage setting phase T; xxx is the value measured); only 3Ph UPS.
TCFRxxx (output current setting phase R; xxx is the value measured).
TCFSxxx (output current setting phase S; xxx is the value measured); only 3Ph UPS.
TCFTxxx (output current setting phase T; xxx is the value measured); only 3Ph UPS.
TVBAxxx (battery voltage setting; xxx is the value measured)
Store all the settings by sending the command MEEE000, or pressing F4.
13. Carry out some mains failure tests and commutations to by-pass.
14. Personalize the UPS with the following commands:
TYBAxxx (nominal capacity of the battery; xxx is the value of the nominal capacity)
TAUTxxx (battery autonomy; xxx is the time in minutes)
PHASxxx (set the phase shifting between inverter and the bypass, refer to the
following table)
10. Select the “Automatic” operating mode on the μProcessor board, moving the jumper J1 on
the board PB012 (VCB) in position 1-2. Move the DIP6 SW1 in position ON on the
μProcessor board.
11. Re-connect the connector CNB on the power supply board.
3.1.5 PB223 – INT-R
1. Check the setting of the jumpers JP1-JP2-JP3.
2. Set the rectifier in TEST mode (see 4.1.2).
3. Move the external ON/OFF switch in position ON.
4. Verify the correct sequence of the pre-charge phase; thyristors PS7-PS8 first (LED’s DL1-
2-3-4 of the card PB023-RTF lit steady), and then complete turn-on of the thyristor bridge
(thyristors PS7-PS8-PS9, LED’s DL1-2-3-4-5-6 of the card PB023-RTF lit steady).
5. Verify that the red LED’s of the boards PB246 (ID-HY, IGBT drivers) are lit steady. In this
condition the duty cycle of the PWM is fixed at 50%.
6. Verify the voltage waveform between emitter (E) and gate (G) of the IGBT’s (see picture
3). If necessary modify the amplitude of the positive part of the waveform until it reaches
16V, turning the potentiometer RV1 on the board PB223 (INT-R).
7. Move the external ON/OFF switch in position OFF.
8. Disconnect the external AC supply cable from the connector M8 of the board PB223 (INT-
R).
9. Re-connect the AC supply cable W51 to the connector M8.
10. Remove the jumper from the pins 11-12 of the connector M15 (TEST mode disabled).
11. Remove the external ON/OFF switch.
12. Close RCB and wait for the complete start-up of the UPS.
13. Connect the software “WRC monitor” and verify that the measures shown are equal to the
actual value, measured with a multimeter and a current clamp.
14. If the values shown don’t correspond to those measured, modify the reading starting the
software “EEPROM Manager” and pressing the button Fine scaling.
3.1.6 PB228 – PS-MIS
1. On the μProcessor board PB003 (I/S-CL) move the DIP6 SW1 in position OFF (TEST
mode).
2. Close RCB and switch on the rectifier.
3. Measure the DC voltage and compare the measure with the value shown on the UPSTest
software (or on the display).
4. If the value shown don’t correspond to that measured, modify the reading with the
following commands (UPSTest software):
TVBAxxx (DC voltage setting; xxx is the value measured)
3.1.7 PB249 – D-CPU-RC
1. Set the rectifier in TEST mode (see 4.1.2).
2. Connect the software “EEPROM Manager”, set the rectifier’s nominal parameters and
program the setting by pressing the button Program.
3. Disconnect the external AC supply cable from the connector M8 of the board PB223 (INT-
R).
4. Re-connect the AC supply cable W51 to the connector M8.
5. Remove the jumper from the pins 11-12 of the connector M15 (TEST mode disabled).
6. Remove the external ON/OFF switch.
7. Close RCB and wait for the complete start-up of the UPS.
8. Connect the software “WRC monitor” and verify that the measures shown are equal to the
actual value, measured with a multimeter and a current clamp.
9. If the values shown don’t correspond to those measured, modify the reading starting the
software “EEPROM Manager” and pressing the button Fine scaling.
voltage measure to floating voltage (within the range) sending the command TVBAxxx
where xxx is the floating voltage (TVBA680).
7. Turn on the inverter sending the command INON000, or pressing F6.
8. Check that all the red LED’s on the driver boards are on and verify the voltage waveform
between emitter (E) and gate (G) of the IGBT’s (see picture 3). If necessary modify the
amplitude of the positive part of the waveform until it reaches 16V, turning the
potentiometer P2 on the board PB107 (PS-SAT).
9. Turn off the inverter sending the command INOF000, or pressing F7.
10. Close RCB, start-up the inverter by sending the command INON000, or pressing F6, and
increase the modulation by means of the potentiometer P1 on the microprocessor board.
Check that the output waveform increases regularly up to the nominal value.
11. Reduce the modulation to zero by turning back the potentiometer, send the command
INOF000, or press F7, to turn off the inverter and open RCB.
12. Disconnect the external power supply and re-connect the connector CNB to the POWER
SUPPLY board.
13. On the μProcessor board (PB003 – I/S-CL) move the DIP6 SW1 in ON position
(automatic mode).
14. On the VCB boards move the jumper J1 in position 1-2 (automatic).
15. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
16. Close RCB, start-up the UPS and check the inverter operation under load.
3.2.4 STATIC SWITCH THYRISTORS
1. Re-connect carefully the component to the firing board.
2. Check that the output waveform, relevant to the phase controlled by the thyristors that
has been substituted, is correct. Repeat this check with the load connected.
4.1 RECTIFIER
4.1.1 General notes on the TEST mode
Owing to the use of two different microprocessors inside the UPS, there exist two different
TEST modalities: one for the rectifier and one for the inverter, which is described at 4.2.1.
The TEST mode on the rectifier is enabled by closing the pins 11-12 of the connector M15 of
the board PB223 (INT-R). The condition of the contact is acquired by the microprocessor at the
start-up and only if the DC voltage is lower than 50Vdc (no AC voltage present).
The TEST mode set the duty cycle of the IGBT’s PWM at 50% and is used to check the
IGBT’s turn-on signals before the rectifier start-up.
4.1.2 Setting the rectifier in TEST mode
The operation described below are carried out on the board PB223 (INT-R).
1. Disconnect the cable W51 from the connector M8.
2. Connect a jumper between pins 11-12 of the connector M15.
3. Disconnect the jumper from the connector M10.
4. Connect the external ON/OFF switch to the connector M10 and make sure the contact of
the switch is open.
5. Connect the external 3Ph AC supply to the connector M8.
Now the board INT-R is supplied and the microprocessor will acquire the TEST mode
condition.
4.2 INVERTER
4.2.1 General notes on the TEST mode
The TEST mode is a operating condition where the inverter doesn’t start-up automatically but
waits for the commands sent by the operator through the UPSTest software. In this condition
some alarms are hidden and the UPS can be tested completely. When the UPS is in manual by-
pass for example, only the TEST mode allows the operator to check the UPS operation. The
TEST mode can be set by moving the DIP6 SW1 in position OFF in the I/S-CL board. The
microprocessor acquires the position of the dip-switch only after it has been reset (switching off
the UPS or by pressing the push-button SW3 in the I/S-CL).
4.2.2 Blank test of the I/S-CL board
The procedure that follows is part of the factory test procedure, related to the preliminary
checks carried out on the microprocessor board I/S-CL before proceeding with the inverter start-
up. It’s useful when, after an inverter failure, the operator wants to be sure that no damage have
occurred in the control section.
1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the I/S-CL
board.
2. Select the “manual” voltage regulation, moving the jumper J1 on the VCB boards in
position 2-3. This setting disable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the I/S-CL board.
3. Disconnect the flat cable W9 from the connector CN4 of the board PB003 (I/S-CL) and
connect an external 10-wire flat cable between it and the connector CN4 of the POWER
SUPPLY board. This external connection is necessary for the microprocessor to acquire
the DC voltage reading.
4. On the POWER SUPPLY board disconnect the connector CNB and connect the external
power supply. The microprocessor is now supplied and after some seconds the front
panel will show all the alarms present at that moment.
5. Connect the oscilloscope probe between analog ground and pin 6 of U17 and check the
presence of a signal as in picture 4:
This waveform is compared with the reference sine-wave generated by the microprocessor
to create the IGBT’s PWM signals.
In the following steps the sine-wave generated by the microprocessor and the IGBT’s turn-on
signals will be checked. The inverter can be turned-on only if all the software conditions are
fulfilled, so it’s necessary to change the DC voltage reading (now coming from the external
power supply) to enable the variable VDC_OK.
6. Change the DC voltage reading sending the command TVBAxxx, where xxx is the
floating voltage, and check that the command is acquired by the microprocessor and that
the variable VDC_OK is activated.
7. Turn-on the IGBT modulation by sending the command INON000 or pressing F6.
8. Place the oscilloscope probe between the analog ground and pin 7 of U2 (VCB boards),
rotate P1 of the I/S-CL board («) and check that the amplitude of the generated sine-
wave increases, and then turn back P1 until the sine-wave is at zero again (¬).
9. Check that the red LED’s on the IGBT driver boards are correctly lit.
10. Verify the turn-on signal between emitter (E) and gate (G) of the IGBT’s (see picture 3).
11. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7.
12. Disconnect the external power supply.
13. Disconnect the external 10-wire flat cable and re-connect W9 to the connector CN4 of
the board PB003 (I/S-CL).
After the disconnection of the external power supply the microprocessor is reset and the DC
voltage setting, which has been modified before, is cleared, therefore the unit will show the
exact DC voltage value at the following start-up.
4.2.3 Inverter manual start-up
This procedures assumes that all the power components in the inverter bridge have been
previously checked (see paragraph 4.2.2). The inverter output voltage is increased starting from
zero to check the behaviour of the components (AC capacitors, fans, etc.) at reduced AC
voltage after having identified a failure in the inverter section.
1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the I/S-CL
board.
2. Select the “manual” voltage regulation, moving the jumper J1 on the VCB boards in
position 2-3. This setting disable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the I/S-CL board.
3. Close RCB and supply the unit. After some seconds the front panel will show all the
alarms present at that moment.
4. Turn-on the IGBT modulation by sending the command INON000 or pressing F6.
5. Verify that, after some seconds, the inverter static switch closes by checking the green
LED’s in the firing boards 2SCR FIR.
6. Rotate P1 of the I/S-CL board («) and increase the inverter output voltage. Check that
the sine waves are present downstream the inverter static switch and that the shape is
correct.
7. Place the oscilloscope probe between the analog ground and the test point TP2 and
check that the shape of the inverter bridge current is correct (see picture 2).
8. Rotate P1 of the I/S-CL board (¬) to set the modulation signal to zero.
9. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7.
10. Open RCB and switch off the unit.
4.2.4 Inverter automatic start-up
This procedures follows the previous one and it’s used to check the correct operation of the
inverter with the voltage loop closed.
1. Choose the inverter TEST mode, moving the DIP6 SW1 in position OFF in the I/S-CL
board.
2. Select the “automatic” voltage regulation, moving the jumper J1 on the VCB boards in
position 1-2. This setting enable the voltage loop, and the inverter voltage regulation
signal is adjusted with the potentiometer P1 of the VCB board.
3. Close RCB and supply the unit. After some seconds the front panel will show all the
alarms present at that moment.
4. Turn-on the IGBT modulation by sending the command INON000 or pressing F6.
5. Verify that the inverter output voltage increases up to the nominal value. If necessary
adjust it by rotating (¬) the potentiometer P1 of the VCB board.
6. Verify that, after some seconds, the inverter static switch closes by checking the green
LED’s in the firing boards 2SCR FIR.
7. Place the oscilloscope probe between the analog ground and the test point TP2 and
check that the shape of the inverter bridge current is correct (see picture 2).
8. Turn-off the IGBT modulation by sending the command INOF000 or pressing F7.
9. Open RCB and switch off the unit.
1. Close the by-pass circuit breaker SBCB and check that the LED L1 in the SCB board is
correctly lit (green).
2. Verify that, after some seconds, the by-pass static switch closes by checking the red
LED’s in the firing boards 2SCR FIR.
4.3.2 Commutation tests
The commutation tests are useful to check the correct operation of the static switch.
1. Start-up the inverter in automatic mode (see procedure at 4.2.4) and verify that the
inverter static switch closes.
2. Close SBCB, wait for the status S6 – BYPASS OK is activated.
3. Measure with a multimeter the voltage difference between the by-pass input and the
inverter output and verify that it doesn’t exceed 20Vac. The inverter is now synchronised
with the by-pass.
4. Move the NORMAL-BYPASS switch SW1 in by-pass position and verify that the load is
transferred to the by-pass static switch. Then move it back and verify that the load is
supplied again by the inverter.
5. Repeat the previous steps and verify that at the sixth time the load remains supplied by
the by-pass and the alarm A17 – Retransfer blocked is activated.
6. Reset the blocking condition by sending the command RESE000 or entering the special
menu in the front panel.
Index
1. INTRODUCTION.................................................................................. 3
2.3.1 MEASURES...............................................................................................6
2.4.8 IDENTIFICATION.................................................................................... 11
Index of pictures
1. INTRODUCTION
The monitoring and test software of the UPS, UPS-Test allows, by means of RS232
connection, to control all the measures and status of the equipment and to carry out settings
and modifications of the UPS configuration.
From the “Modem” button it is possible to set the parameter for remote connection.
2.3.1 MEASURES
On the area “Measures” all the analog measurements inherent to the UPS are shown, in the
following order:
In the area below, the field “NUMBER” represents the serial n° of the equipment and the
field “VER. SW.” represents the revision of the UPS control software installed.
On the area “TX Check” the transmission control indicator is represented. If the connection
is correct the figures increases cyclically up to 250 automatically.
2.3.2 UPS DATA
The area titled “UPS data” represents the relevant characteristics and settings. The first 7
lines contain the nominal values for:
The following 4 groups represent the limit values (for the voltage to be declared available)
and the histeresys for:
The following 3 groups represent the limit values (for the frequency to be declared in
tolerance) and the histeresys for emergency bypass as follows:
COK Æ If active the UPS output voltage is in tolerance (see limit group #3)
BY_BL Æ When active the load is blocked on the emergency bypass
IFL Æ When active the inverter SSW is closed
CONAC Æ When active the PWM of the inverter IGBT bridge is on
RESET_RITR_BL Æ When active the BY_BL condition is reset
R3_INV_FEED Æ When active relay Inv. Feeds Load is active too (ARC card)
R4_BYP_FEED Æ When active relay Bypass Feed Load is active too (ARC card)
R5_LOW_BATT Æ When active relay Low Battery is active too (ARC card)
R6_MAINS_FAU Æ When active relay Mains Fault is active too (ARC card)
2.3.5 INPUTS
The area titled “Inputs” represents the relevant digital inputs of the UPS. The meaning of
each variable is below described:
MRR Æ When active Mains fault signal (from the rectifier) is not active
RECT_FAIL Æ When active Rectifier fault sign. (from the rectifier) is not active
ERR_SC Æ When active Input wrong seq. sign. (from the rectifier) is not active
BF_RECT Æ When active Blown fuse sign. (from the rectifier) is active
PUL_UP Æ When active the up arrow key on the front panel is pressed
PUL_DOWN Æ When active the down arrow key on the front panel is pressed
PUL_ENTER Æ When active the enter key on the front panel is pressed
PUL_ BUZZ Æ When active the buzzer key on the front panel is pressed
PUL_RESET Æ When active the reset key on the front panel is pressed
2.3.6 ALARMS AND STATUS
On the areas named “Alarms” and “Status”, the 25 alarms and 6 operating status are
represented. For a detailed explanation of them, see the Operating Manual.
2.3.7 ACTIVE KEYS
The push button “Dip Sw” visualizes the mapping of the dip switches for configuration on
the μP board (see foregoing paragraphs).
By clicking on the relevant country on the flags area the language on the display of the UPS
can be changed.
2.3.8 GAUGES
The two gauges located under the third column represents the following values:
BOOST OPERATION
If the Boost function is active, the push button “BOOST“ visualizes the parameter of the
Boost Operation
VERY IMPORTANT
The usage of these messages is recommended to specialized personnel only.
Don’t forget to send the command MEEE000 to store the variations on the UPS memory.
2.4.1 BYPASS
TBFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TBFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TBFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.2 OUTPUT
TUFRXXX (XXX=100/250) phase R voltage (for UPS 1Ph and 3Ph)
TUFSXXX (XXX=100/250) phase S voltage (only for UPS 3Ph)
TUFTXXX (XXX=100/250) phase T voltage (only for UPS 3Ph)
2.4.8 IDENTIFICATION
(1) TFFR +
060 +/- 6%
055 +/- 5,5%
050 +/- 5%
045 +/- 4,5%
040 +/- 4% standard setting
035 +/- 3,5%
030 +/- 3%
025 +/- 2,5%
020 +/- 2%
015 +/- 1,5%
010 +/- 1%
During the download the TX CHECK counter on the computer starts to count from 0 to 1800.
To read the history on the computer the F1 key can be pressed.
Index
1 INTRODUCTION................................................................................. 3
2 SYSTEM REQUIREMENTS ............................................................... 3
3 INSTALLATION OF THE SOFTWARE .............................................. 4
4 COLLEGAMENTO DEL PC ALL’UPS ............................................... 6
4.1 INSTALLATION OF THE USB DRIVERS ........................................................6
5 WRC MONITOR.................................................................................. 7
5.1 TOOLBAR ........................................................................................................7
5.1.1 COM settings ............................................................................................8
5.1.2 Language setting .....................................................................................8
5.2 FRAME “ALARMS”..........................................................................................9
5.3 FRAME “STATUS”...........................................................................................9
5.4 FRAME “AC MEASURES” ............................................................................10
5.5 FRAME “DC MEASURES” ............................................................................10
5.6 FRAME “TEMPERATURE”............................................................................10
1 INTRODUCTION
“WRC Monitor” is the PC software for the monitoring of the UPS of the “B9000” and
“Tethys” series.
It allows the display of the status and the alarms of the unit, the AC measures
(voltage, current and mains frequency) and the DC measures (battery voltage and
current).
2 SYSTEM REQUIREMENTS
Minimum system requirements:
Recommended hardware:
Insert the CD into the CD-drive and launch “setup.exe”. The following screen should
appear:
If the software has been installed successful the following message appears:
Picture 3 – PB213-SLOT-SER
Connect the connector CN1 of the PB213 to the connector CN7 of the board PB249
(D-CPU-RC) through a 10-pole flat-cable:
5 WRC MONITOR
Upon the software start-up, the following window is shown:
Picture 6 – Toolbar
Connect/Disconnect: it allows to start and stop the communication with the UPS.
The data exchange is signalled by the status LED that can
be seen at the right side of the toolbar.
COM Settings: it opens the window related to the configuration of the serial
port (see par. 5.1.1).
INTRODUCTION......................................................................................... 3
1. PARALLEL REDUNDANT SYSTEM TYPOLOGY ............................ 3
2. PARTS CONSTITUTING THE SYSTEM ............................................ 4
3. OPERATING CONDITION.................................................................. 5
3.1 “N” UPS NORMAL CONDITION ......................................................................5
3.2 “N-1” UPS NORMAL CONDITION...................................................................6
3.3 “MAINS FAILURE”...........................................................................................7
3.4 “N” BYPASS AVAILABLE ...............................................................................8
3.5 “N-1 BYPASS AVAILABLE”............................................................................9
3.6 MANUAL BYPASS .........................................................................................10
4. INSTALLATION................................................................................ 11
4.1 ADDITIONAL HARDWARE ............................................................................11
4.2 POSITIONING.................................................................................................11
4.3 CONNECTIONS..............................................................................................12
4.4 INTERCONNECTIONS DIAGRAM .................................................................13
4.5 BUS CABLE ...................................................................................................15
5. SYSTEM PERFORMANCES............................................................ 15
5.1 OVERLOAD ....................................................................................................15
5.2 SHORT CIRCUIT ............................................................................................15
6. START-UP ........................................................................................ 16
6.1 TWO UPS – DIRECT START-UP ...................................................................16
6.2 TWO UPS – START-UP FROM MANUAL BY-PASS.....................................16
6.3 MORE THAN TWO UPS – START-UP FROM MANUAL BY-PASS ..............16
7. MANUAL BY-PASS TRANSFER PROCEDURE .............................. 17
7.1 MANUAL BY-PASS TRANSFER PROCEDURE............................................17
7.2 RE-START FROM MANUAL BY-PASS .........................................................17
7.2.1 Two UPS – Re-start from MANUAL BYPASS .......................................17
7.2.2 More than two UPS – Re-start from MANUAL BYPASS ......................17
Index of pictures
Picture 1 - Block diagram ............................................................................................................................. 4
Picture 2 - “N” ups normal condition ............................................................................................................. 5
Picture 3 - “N-1” ups normal condition.......................................................................................................... 6
Picture 4 - “Mains Failure” ............................................................................................................................ 7
Picture 5 - “N” bypass available.................................................................................................................... 8
Picture 6 - “N-1”bypass available ................................................................................................................. 9
Picture 7 - Manual bypass .......................................................................................................................... 10
Picture 8 - Positioning................................................................................................................................. 11
Picture 9 - Connections .............................................................................................................................. 12
Picture 10 - Interconnections diagram........................................................................................................ 13
Picture 11 - Interconnection........................................................................................................................ 14
Picture 12 - Interconnection with BCCON – PB123 ................................................................................... 14
Picture 13 - Bus cable connections ............................................................................................................ 15
INTRODUCTION
The scope of this manual is to guide the installer and the user to the correct
installation of the parallel redundant system in the chosen room.
Before reading this manual, the installer and the user will have to read with
care and attention the “UPS OPERATING MANUAL” to carry-out correctly the
given instructions for the single units, especially those relevant to security
according to CEI 64-8 and to 46-90 standards.
It is possible because all units are constantly in operation and feed the load in
parallel at “total load / n”, where “n” is the number of the UPS.
The AC automatic current sharing control equalizes the currents of the “n” units and
reduces the total unbalance at less than 10%, under all load conditions.
The load is supplied by the inverters in parallel for an instantaneous overload up to “n
x 200%” of the nominal load of the single unit.
In case of a failure in one unit, the other units supply the load. The load is supplied by
the static bypass, only if there is an additional failure in the other units.
- Rectifier (R)
- Inverter (I)
- Battery (B)
- Static Switch: Static Switch Inverter (SSI) Static bypass (SB)
- Manual bypass (MB) (on all the units or unique ad external)
- Front panel
For the description of the single parts, see: “UPS OPERATING MANUAL”
OM226002.
3. OPERATING CONDITION
During “n UPS normal condition” any failure transfers the parallel redundant system
to “n-1 UPS normal condition”, or to “n rectifier failure or mains failure” condition.
During “n-1 UPS normal condition” or “n rectifier failure or mains failure” condition,
any failure transfers the parallel redundant system to “n-1 rectifier failure or mains
failure” condition or to “bypass feeds load” condition. In these operating conditions the
parallel redundant system signals a failure with audible and visual alarms.
During “n-1 rectifier failure or mains failure” condition or to “bypass feeds load”
condition, an additional failure may interrupt the power supply to the load, depending on
the kind of failure.
During “manual bypass” condition the mains feeds the load directly for maintenance
or serious failure.
4. INSTALLATION
Before installing the parallel redundant system, see “INSTALLATION” in the
“OPERATING MANUAL” for the single units, in order to be informed about the following:
The output of the “n” units must be connected in parallel to the load bus bar.
4.2 POSITIONING
We suggest positioning the UPS’s with a distance between one and the other of 10
cm (minimum) for cables passage.
10 cm
Picture 8 - Positioning
4.3 CONNECTIONS
The following picture shows a simple connections diagram between two UPS’s in
parallel redundant configuration.
For more information about the UPS’s interconnections see the interconnections
diagram (picture 10).
Picture 9 - Connections
WARNING
We suggest to connect the two outputs of the UPS’s to the load with cables that have
the same section and same length.
Picture 11 - Interconnection
5. SYSTEM PERFORMANCES
The parallel redundant system has better static and dynamic performances in
comparison with a single unit as, due to the redundancy, the total amount of power
available is higher than the nominal load of the system.
5.1 OVERLOAD
The overload limit of a parallel redundant system depends on the number of the
units, which are connected to the load:
Imax = n * In
where “n” = number of the units, “In” = nominal current of each unit
The load exceeds this limit the thermal image starts and after a certain time the load
is transferred to bypass (if available).
6. START-UP
6.1 TWO UPS – DIRECT START-UP
When the parallel UPS’s are only two, it’s possible to start the system by switching
on the unit having the lower position (Number 1), closing RCB and following the
procedure shown on the display.
At the end of the start-up of the first unit, the second one can be switched on
normally, closing RCB and following the procedure shown on the display.
o Upon the display request, move the by-pass switches of all the units in
position NORMAL, starting from the UPS Number 1.
ATTENTION
When all the displays will show “OPEN ALL MBCB”, the operator must open ALL
MBCB breakers and/or MBCB installed in external cabinets.
NOTE
In a parallel systems with more than 2 UPS, the load will be transferred to the
inverter(s) in accordance with the redundancy logic set on the RPI board (N-1/N).
If the system is composed by 3 UPS with a redundancy logic of “2 of 3”, the load will
be transferred to the inverter only when the second unit is completely started.
Index
INTRODUCTION......................................................................................... 3
1. MAINTENANCE PROCEDURES ....................................................... 3
1.1 MAINTENANCE WITH THE LOAD UNDER CONTINUITY..............................3
1.2 MAINTENANCE WITH THE LOAD IN MANUAL BY-PASS ............................4
2. TROUBLESHOOTING PROCEDURES ............................................. 6
2.1 CHECK OF LED STATUS ................................................................................6
2.1.1 Check of the Power Supply LED’s on the RPI Board ...........................8
2.1.2 Check of the front LED’s on the RPI Board ..........................................8
2.2 CHECK OF AUXILIARY CONTACTS ............................................................10
2.2.1 Check of MBCB signal ..........................................................................10
2.2.2 Check of EPO signal .............................................................................11
2.2.3 Check of BYPASS SWITCH signal.......................................................12
2.3 CHECK OF CURRENT MEASURES..............................................................13
2.3 CHECK OF SYNCHRONIZATION SIGNALS .................................................15
3. RPI BOARD REPLACEMENT PROCEDURE.................................. 17
3.1 RPI GENERAL SETTINGS.............................................................................17
3.2 SYNCHRONIZATION ADJUSTMENTS..........................................................17
3.3 COMMUTATION TESTS ................................................................................18
3.4 SYSTEM RE-START ......................................................................................18
4. PARALLEL SYSTEM SOFTWARE (RPITEST) ................................ 19
4.1 INTRODUCTION.............................................................................................19
4.2 DESCRIPTION OF THE SOFTWARE ............................................................20
4.3 SUMMARY OF THE COMMANDS .................................................................27
4.4 UPGRADE OF THE PARALLEL SYSTEM ....................................................28
4.4.1 INTRODUCTION......................................................................................28
4.4.2 HARDWARE MODIFICATIONS ..............................................................28
Index of pictures
Picture 1 – Bus cable connections ............................................................................................................... 9
Picture 2 – Digital inputs on RPITest control panel .................................................................................... 10
Picture 3 – Digital outputs on RPITest control panel.................................................................................. 10
Picture 4 – Signals on TR and TP14 .......................................................................................................... 14
Picture 5 – Signal on TS and TP14 ............................................................................................................ 14
Picture 6 – Signal on TT and TP14 ............................................................................................................ 14
Picture 7 – RPITest control panel............................................................................................................... 20
Picture 8 – RPITest control panel (PID controller) ..................................................................................... 20
Picture 9 – Parallel interconnections diagram ............................................................................................ 32
INTRODUCTION
The scope of this manual is to guide the technician to the correct maintenance and
troubleshooting of the parallel redundant system.
NOTE
Before reading this manual, the technician will have to read with care and attention
the “PARALLEL REDUNDANT SYSTEM OPERATING MANUAL” to carry-out correctly the
given instructions. The manufacturer declines all responsibility for damages to people or
things deriving from non-fulfilment of the above.
1. MAINTENANCE PROCEDURES
The parallel system allows the operator to carry out the maintenance of one or more units in
two different operating conditions, that’s to say, under continuity, where the load is still supplied
by the other inverter(s) or in manual by-pass condition.
NOTE
The modality of intervention must take into consideration the operating condition of
the plant, and must be agreed with the final user. For the operating procedures refer to
the technical documentation related to the UPS installed.
NOTE
The operator carrying out the maintenance must consider under his own responsibility the
operating risks for himself and for the final user.
Wait until the UPS is completely switched off and carry out the maintenance.
Upon completion of the works, if necessary, the inverter can be tested in the following
manner (for further details refer to the specific procedures):
o Moving the by-pass switch in BY-PASS position will cause the inverter static switch to
open but the load is not transferred to by-pass. The SBCB breaker must be kept
open.
Upon completion of the test the UPS can be put again “on line” with the following procedure:
NOTE
The operator carrying out the maintenance must consider under his own responsibility the
operating risks for himself and for the final user.
The procedure to transfer the load in manual by-pass and disconnect the UPS before the
maintenance is described in the PARALLEL SYSTEM OPERATING MANUAL.
Wait until the UPS is completely switched off and carry out the maintenance.
Upon completion of the works, if necessary, the inverter and the by-pass static switch can be
tested in the following manner (for further details refer to the specific procedures):
o By the UPSTest software connected to the RS232 of the UPS, send the command
MAST000 (MASTER condition reset)
o Set the UPS redundancy logic at “n” on the RPI board, by the command SNULxxx,
with xxx=”n”.
o Put the UPS in NORMAL mode (Dip 6 SW1 in ON on PB003)
o Restore the normal supply of the logic.
o Move the by-pass switch in BYPASS position
o Start with the maintenance of the next unit, if necessary.
The whole system can be re-started following the procedures described at paragraph 7.2 of
the PARALLEL SYSTEM OPERATING MANUAL.
2. TROUBLESHOOTING PROCEDURES
This troubleshooting includes a first level fault description for Parallel System and suggests
how to check the unit to solve the problems.
All the tests described in this document must be carried out with the parallel system in
Manual Bypass unless otherwise specified.
Please refer to the PARALLEL SYSTEM OPERATING MANUAL for the correct procedure to
transfer the load from normal operation (inverter mode) to manual bypass.
This description assumes that all the connections inside the unit are correct; check them
(connectors, power cables, signals and so on) before starting with the procedures. The first
level troubleshooting consists of substituting the RPI-BUSCAN Board without attempting to
repair it. To replace the RPI Board refer to the instructions given at chapter 3 of this manual.
2.1 CHECK OF LED STATUS
The RPI-BUSCAN (PB110) board is provided with LED’s, indicating the various operating
condition of the board itself and the presence of the DC supply. The colour and function of the
LED’s is shown in the tables below; the first table shows the LED’s indicating the DC supply to
the RPI board, the second one the LED’s in the front of the RPI board indicating the operating
status of the parallel system.
a) DC SUPPLY LED’s
b) FRONT LED’s
Before to start the tests described below, transfer the load on Manual Bypass, switch off all the
units and set them in Test Mode, moving the DIP6 SW1 on I/S Control Logic in OFF position.
Then close RCB on all the units (Logics start-up).
4. Remove the DB9 BUSCAN Connector, are DL1 and DL14 both ON?
YES: END
NO: check the continuity of the 60-pole flat cable CNB and the flat cable from CN1 of
PS-HV board to CN15 of I/S-CL board. Go to step #5.
Before re-connecting the BUSCAN cable, switch off the unit opening RCB and wait the
complete shut-down of the logics.
Check if all the others TX (Transmitting Message) and RX Leds (Receiving Message) are ON
or blinking according to the table shown at paragraph 2.1.
l
Picture 3 – Digital outputs on RPITest control panel
1. Verify that all the units show A18 - MBCB CLOSE alarm on the display.
YES: END. Close MBCB on UPS2 and open MBCB on UPS1 and repeat the same
check.
NO: go to step #2
7. Do all the units show A18 - MBCB CLOSE alarm on the display?
YES: END
NO: replace the I/S-CL board.
8. Connect the PC with the RPITest to the RPI board of the UPS that has MBCB open. Is
the digital output “MBCB_CLOSE_BUS” active?
YES: Go to step #9.
NO: check the communication between the units (TX and RX LED’s, see paragraph
2.1.2, points 3.3 and 3.4) and replace the RPI board.
9. Check the continuity of the 60-pole flat cable CNB. Is the continuity of flat cable
correct?
YES: replace the RPI board. Go to step #10.
NO: replace the flat cable. Go back to step #8.
10. Does this unit show A18 - MBCB CLOSE alarm on the display?
YES: END
NO: replace the I/S-CL board.
1. Press the EPO button on the UPS1 and verify that all the units show A23 - EPO
PRESSED alarm on the display.
YES: Go to step #2
NO: go to step #3
2. Release the EPO on UPS1 and press the EPO button on the UPS2 and verify that all
the units show A23 - EPO PRESSED alarm on the display.
YES: END.
NO: go to step #3
8. Do all the units show A23 - EPO PRESSED alarm on the display?
YES: END
NO: replace the I/S-CL board.
9. Connect the PC with the RPITest to the RPI board of the UPS where the EPO is not
pressed. Is the digital output “O_EPO_BUS” active?
YES: Go to step #10.
NO: check the communication between the units (TX and RX LED’s, see paragraph
2.1.2, points 3.3 and 3.4) and replace the RPI board.
10. Check the continuity of the 60-pole flat cable CNB. Is the continuity of flat cable
correct?
YES: replace the RPI board. Go to step #11.
NO: replace the flat cable. Go back to step #9.
11. Does this unit show A23 - EPO PRESSED alarm on the display?
YES: END
NO: replace the I/S-CL board.
1. Move the Bypass switch of the UPS1 in position BYPASS and verify that the unit
shows A22 – BYP SWITCH alarm on the display.
YES: END
NO: go to step #2
2. Check the digital input “Byp_SW” on the RPITest software. Is the digital input
“Byp_SW” active?
YES: check the digital output O_BYP_SW. Go to step #4.
NO: check the operation of the Bypass switch contact. Go to step #3.
6. Does the unit shows A22 – BYP SWITCH alarm on the display?
YES: END
NO: replace the I/S-CL board.
Repeat the procedure described above for all the other UPS of the parallel system.
2.3 CHECK OF CURRENT MEASURES
NOTE
This check can be carried out only with the parallel system connected to the load.
1. Is the current sharing between the units good (difference +/- 10 %)?
YES: END
NO: Move the bypass switch of UPS2 in BYPASS position, so that only the UPS1
supplies the load. Connect the PC with the RPITest to the RPI board of UPS1.
Go to step #2.
2. On the PID control panel, check the value of “Output freq.”, that must be 20000 (+/-
1000) for 50Hz units and 18000 (+/-1000) for 60Hz units. Is this value correct?
YES: go to step #5
NO: go to step #3
3. On the RPI board check with an oscilloscope connected between TP14-GNDF the
presence of a 50Hz (60Hz) square wave (see picture 4). Is the waveform present?
YES: replace the RPI board.
NO: check the output voltage of the phase R on the connector M4 pins 1-3 and the
fuse F1. Go to step #4.
7. On the PID control panel of the RPITest check the values of CURR_LOC on the three
phases. These values must be 1200 (+/-10%) at 50% of load, except CURR_LOC
Quad R that must be zero with resistive load, and varies proportionally according to the
actual load. Are the values correct?
YES: go to step #8
NO: replace the RPI board.
8. Move the bypass switch of UPS2 in NORMAL position and the Bypass Switch of UPS1
in BYPASS, so that only the UPS2 supplies the load. Connect the PC with the RPITest
to the RPI board of UPS2 and repeat the checks from point 2 to 7. Go to step #9.
9. Take note of the values of CURR_LOC shown on the PID control panel (Phase R,
Quad R, Phase S, Phase T). Transfer the load to the UPS1 again by means of the
bypass switches, connect the RPITest to the RPI board of UPS1 and check the values
of CURR_LOC in the UPS1. Are these values the same of those shown by UPS2?
YES: END
NO: According to the actual load, adjust the measures to be the same for both UPS,
with the potentiometers POT4 (Phase R), POT5 (Phase S), POT6 (Phase T).
Remember the measures must be 1200 at 50% of load, except CURR_LOC
Quad R that must be zero (+/-70) with resistive load.
2.3 CHECK OF SYNCHRONIZATION SIGNALS
The UPS systems are in manual by-pass condition, with all MBCB breakers closed.
ATTENTION
If the UPS is a single-phase output, short-circuit the neutral pole of the output breaker OCB
(putting a jumper between IN and OUT) in both units (see point 3.2 for further explanations).
Only the neutral pole of OCB must be short-circuited.
Start-up the units in test mode moving the DIP6 SW1 on I/S Control Logic in OFF position. Then
close RCB on all the units (Logics start-up).
a) By the UPS-Test software connected to RS232 of the UPS, send the command
MAST001 (Master condition Forced) to the UPS1.
b) Verify the presence of the MASTER label (red) on the UPS-Test screen. This UPS now
is the MASTER in the system.
c) Switch on all the inverters. (by the UPS-Test software, sending the command
INON000). Wait that all the inverter static switches are closed.
1. Check the synchronization of the SLAVE unit measuring the voltage difference between
the phases R of the two units. Is the SLAVE synchronized?
YES: go to step #8
NO: go to step #2
2. On the RPI board of the MASTER unit check with an oscilloscope connected between
TP1-GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform
present?
YES: go to step #5
NO: replace the RPI board. Go to step #3.
YES: go to step #5
NO: check the continuity of the 60-pole flat cable CNB. Go to step #4.
5. On the RPI board of the SLAVE unit check with an oscilloscope connected between TP1-
GNDBUS the presence of a square wave (INT_SYNC_BUS). Is the waveform present?
YES: Replace the RPI board
NO: replace the BUS cable. Go to step #6.
8. Close SBCB on both units and wait for the BYPASS_OK signal (status S6 on the
UPSTest screen) Check the synchronization between the MASTER and the bypass,
measuring the voltage difference between the phase R of the bypass and the phase R of
the inverter. Is the MASTER synchronized?
YES: END
NO: go to step #9
9. On the RPI board of the MASTER unit check with an oscilloscope connected between
TP2-GNDBUS the presence of a square wave (MAINS_SYNC_BUS). Is the waveform
present?
YES: check the continuity of the 60-pole flat cable CNB. Go to step #10.
NO: replace the RPI board. Go to step #11.
11. After replacing the RPI board is the waveform present on TP2?
YES: END
NO: replace the I/S-CL board.
If the UPS is a single-phase output the neutral conductor is not common as it is interrupted
by the output breaker OCB, that must be kept open (the units are operating in manual by-
pass). Therefore, in order to read with the multimeter the voltage difference between the
inverter output voltages, it’s necessary to link the two output neutral conductors, by short-
circuiting the neutral pole of the output breaker OCB (putting a jumper between IN and OUT).
CAUTION
On single-phase UPS, only the neutral pole of OCB must be short-circuited.
5. Switch off ALL the inverters (by the UPSTest software, sending the command INOF000).
6. Send the command MAST000 (Master condition Reset) to the UPS MASTER.
7. Send the command MAST001 to the UPS with the new RPI Board (PB110)
8. Switch on all the inverter by the UPSTest software, sending the command INON000) and
wait that all the inverter static switch are closed.
9. Close the SBCB breakers (Emergency line breaker) in all the units and wait for Bypass
OK signal (Status S6 – BYPASS OK on all the units and status S5 – INV SYNC on the
MASTER unit).
10. With a multimeter, check the synchronization of the MASTER unit with the mains,
measuring between the input of the OCB of the UPS with the new RPI Board and the
input of the SBCB. If a phase shift is found, it can be compensated by turning the
potentiometer POT3 on the new RPI Board.
3.3 COMMUTATION TESTS
All the inverters are now working synchronized with the bypass line. The static switch
operation can be tested according to the following procedure. Take into consideration that the
following are blank tests, carried out with the output breaker open
1. On the UPS with the new RPI board, move the Bypass Switch in BYPASS position.
The inverter static switch will open and the load will be supplied by the other units,
according to the redundancy logic set on the RPI boards.
2. Move the Bypass Switch in BYPASS position in all the other units of the parallel
system. All the bypass static switches will close and the load will be supplied by the
mains.
3. Switch off all the inverters by the UPS-Test software, sending the command
INOF000).
4. Open all the SBCB breakers (Emergency Line breakers)
5. Open all the RCB breakers (Input Mains breakers).
3.4 SYSTEM RE-START
1. Set all the systems in Automatic mode, moving the Dip6 SW1 of the I/S Control Logic
(PB003 Board) in ON position.
2. In case the UPS is a single-phase output, remove the jumpers on the neutral pole of
the OCB breakers (put during the synchronization procedure at point 3.2).
3. Move ALL Bypas Switches in BYPASS position.
4. Now the units are completely switched off with the MBCB breakers closed and the
Bypass Switches in BYPASS position.
5. Re-start the units from MANUAL BYPASS condition following the instructions of the
PARALLEL SYSTEM OPERATING MANUAL.
WARNING
Two UPSs can not have the same configuration of the dip-switches, that’s to say the
same position in the parallel system, otherwise there are conflicts of identification of the
messages running through the CAN BUS
The Parallel system has the MASTER condition distributed on the System.
The MASTER is, among the UPS’s supplying the load, the one which has the Lowest
Position Number.
Each UPS uses a CAN connection to “converse” with the other units, and send messages
through the CAN according to its position in the system.
The message contains the information related to the local currents “Phase component of
the phase R”, “Quadrature component of the phase R”, “Phase component of the phase
S”, “Phase component of the phase T”, as well as the status of the digital inputs.
WARNING
The setting of the RPI card must be carried out only by authorised and trained personnel.
Incorrect settings may be dangerous for the safety of the persons, cause damage to the
system and void the manufacturer’s warranty.
NOTE
The appropriate value for the Ver SW is shown for the version above PCAN40 and with RPI-
Test software above v2.0. For versions preceding PCAN51 it’s advisable to update the parallel
system to the latest release. Refer to the last chapter of this manual for information on the
update procedure and parameters’ setting.
Clicking on the SHOW button the PID parameter setting panel is shown.
Commands section.
After having sent a command, and if the command is
accepted, the box shows a “Message Received”
text.
The command, like the UPS-Test software, are
composed by 4 capital letters and 3 numbers.
LOAD ON BYPASS
COMMANDS
INVERTER AVAILABLE
SNUL001 1 inverter out of 4 1 bypass out of 4
SNUL002 2 inverter out of 4 2 bypass out of 4
SNUL003 3 inverter out of 4 3 bypass out of 4
SNUL004 4 inverter out of 4 4 bypass out of 4
4.4.1 INTRODUCTION
The parallel system can be upgraded using the following components:
• A couple of EPROM for the firmware of the UPS (I/S Control Logic PB003), compatible
with the version installed in the system. Example V145E or higher.(*)
• Two PAL of the static switch control card (SCB PB014) U12 SAFE1_23 e U11
OUTGEN41
• A couple of Flash memory PCAN55 or higher for the card RPI PB110.
(*) for non-standard software contact the UPS manufacturer’s Customer Support Service.
ATTENTION
Take particular care to the parameter PHASE, that can be examined in the panel PAR-Data
in the UPS-Test software.
This parameter is set in the following way:
PHASE=2700 for single UPS 50 Hz
PHASE=4000 for parallel UPS 50 Hz
Using the software of the Evolution UPS series (V145E) the value is automatically modified
by changing the configuration of the dip-switches of the I/S Control Logic card to set the
Single/Parallel operation.
Some software releases exist, where the value of this parameter is not controlled by the
position of the dip-switches and must be set with the command PHASxxx:
PHAS270 for single UPS PHASE=2700
PHAS400 for parallel UPS PHASE 4000.
(Software version V145SOL, V145S….)
When substituting the software on the I/S Control Logic, verify always the correctness of the
setting of the parameter PHASE according to what described above.
1. Substitute the EPROM of the I/S Control Logic card, upgrading the firmware release to
the version V145E or higher.
2. Substitute the IC U10 of the SCB PB014 card with the chip marked SAFE1_23 and U11
with the chip marked OUTGEN41.
3. Verify the redundancy logic, that’s to say the parameter N_UPS(N-1/N) on the RPI-Test
software, modifying the value with the command SNULxxx if necessary (it depends on the
required redundancy logic).
4. Substitute the flash memories of the RPI card with the version PCAN55 or higher.
POS
DIP1 DIP2 DIP3
UPS
1 ON OFF OFF
2 OFF ON OFF
3 ON ON OFF
4 OFF OFF ON
5 ON OFF ON
6 OFF ON ON