Technical presentation EVOLUTION line UPS Contents General data Inverter & Static switch Technical features User interfaces Rectifier Test software General data Inverter & Static switch Technical features User interfaces Rectifier Test software General data The ASTRID UPS of the EVOLUTION series are ON-LINE DOUBLE CONVERSION, with DC/AC isolating transformer (inverter section) The whole line is designed to maximise the reliability index MTBF by means of: Use of common electronic cards Reduced number of cabling and interconnections among the various elements of the system Such solutions allow the reduction of the repairing time in case of failure (MTTR) General data The EVOLUTION series is basically composed by THREE main models: PLANET/E HALLEY/E SATURN/E (20-30kVA – 3Ph/1Ph) (20-160kVA – 3Ph/3Ph) (200-650kVA – 3Ph/3Ph) The two widest categories are divided into sub-categories, according to the functional and technical solution chosen: HALLEY/E HALLEY/E SATURN/E SATURN/E 20÷32kVA e 40÷80kVA 100÷160kVA 200÷300kVA 400÷650kVA General data Inverter & Static switch Technical features User interfaces Rectifier Test software Common technical features Total-controlled three-phase (6 pulses) thyristor-based rectifier 1ph and 3Ph IGBT inverter (H bridge) Inverter output isolating transformer Thyristor-based static switch with redundant supply Parallelability up to 4 UPS with microprocessor load sharing control, and communication protocol with high noise immunity Use of common parts and solutions on all the range Microprocessor control card LCD panel, that’s to say same data access mode Test software PLANET/E 20-30kVA (3Ph / 1Ph) Input: 3 x 380÷415Vac Output: 1 x 220÷240Vac Power: 20kVA – 30kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) – Internal up to 24Ah Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 1 type 1 type 1 HALLEY/E 20-30kVA (3Ph / 3Ph) Input: 3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 20kVA – 30kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) – Internal up to 24Ah Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 1 type 2 type 2 HALLEY/E 40÷80kVA (3Ph / 3Ph) Input: 3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 40kVA – 60kVA – 80kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) - External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 2 type 3 type 2 HALLEY/E 100÷160kVA (3Ph / 3Ph) Input: 3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 100kVA – 125kVA – 160kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) - External Crest factor: 3:1 Overload capability : 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 2 type 3 type 2 SATURN/E 200÷300kVA (3Ph / 3Ph) Input: 3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 200kVA – 250kVA – 300kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) - External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 2 type 3 type 2 SATURN/E 400÷650kVA (3Ph / 3Ph) Input: 3 x 380÷415Vac Output: 3 x 380÷415Vac Power: 400kVA – 500kVA – 650kVA, p.f. = 0,8 Battery: 192 cells Pb (384Vdc) - External Crest factor: 3:1 Overload capability: 125%Pn x 10min 150%Pn x 1min 200%In x 100ms Rectifier: Inverter: Static switch: type 2 type 3 type 3 (except 400kVA) General data Inverter & Static switch Technical features User interfaces Rectifier Test software Rectifier Rectifier’s features All the rectifiers of the EVOLUTION series UPS, from 20kVA to 650kVA, use compact-type thyristors (SemiPack) and are manufactured according to the schematic diagram shown previously, with small variations: The saturation-type choke L3 is used on the UPS up to 80kVA The fuse-holder BCB is installed only on the units with internal batteries (20 and 30kVA). The battery switch is not installed on units having higher power The forced cooling of the heatsink is provided starting from the 40kVA The rectifiers of the 500kVA and 650kVA uses two three-phase rectifier bridges with input/output parallel connection Rectifier typologies Two different types of rectifiers can be defined according to the manufacturing solution, and particularly basing on the control cards used TYPE 1 It’s the “compact” typology, as shown subsequently. The control cards are physically separated from the thyristors and interconnected to the firing card by means of flat cables. The 12pulse configuration is not possible. Cards used: PRCH FIR-91 LOOP (PB114) (PB113) (PB115) Rectifier typologies TYPE 2 The control card is only one and includes also the the thyristors firing section. The card is fixed directly on the power components.The 12-pulse configuration uses a control card for each three-phase bridge (one in MASTER configuration, the other SLAVE). The same solution is used in the 500kVA and 650kVA that uses two three-phase bridge in parallel also in the 6-pulse configuration Cards used: SYNC-12 RCLS-1 (PB116) (PB117) PRCH card (PB114) The PRCH card is composed by the following main sections: Generation of the DC power supply (12V/24V) Generation of the synchronism signals for the thyristors firing Control of the rectifier AC supply voltage Control of the internal DC supply Generation of the thyristors turn-on signals (initial stage) PRCH card (PB114) Generation of the DC power supply and synchronism signals +24Vdc for the supply of the firing pulses +/-12Vdc for the supply of the control electronic circuits The synchronism signals are taken from a secondary winding of the transformer and used for both the control of the AC supply voltage and the generation of the control ramps of the thyristors’ delay angle Synch. +12V +24V R S T U4 D13 D14 D15 1N4 004 1N4 004 1N4 004 + T1 IN C8 1000u 50V 6,3x32 1A 6,3x32 1A C10 100n 16 15 3 4 F3 C9 47u 25V 12 11 1 2 F2 + LM7 812 6,3 x32 1A 10 9 5 6 D16 D17 D18 1N4 004 1N4 004 1N4 004 + C11 1000u 50V 1 F1 3 14 13 2 18 17 + G ND 1 2 3 4 5 2 8 7 M2 OUT G ND 1 IN U5 OUT C12 47u 25V C13 100n 3 LM7 912 -12V ACM1008 PRCH card (PB114) Control of the AC supply voltage Input phase sequence control (signal 0_SCOK) and lighting of LED DL1 if the phase sequence is correct Low mains voltage control, with FIXED threshold 400Vac -15%, and lighting of LED DL2. Generation of the signal 1_ROK (mains OK) if both the previous signals are OK R1 DL1 +12V 2K2 1 R2 8K2 5 R S T C1 470n D2 R3 2K2 1 D3 5V6 R47 100K U1A 1 +12V 1 0_S COK 2 3 Q10 BC337 Q1 BC337 1 2 3 R4 2 40106 2K2 1 R6 33K 2 R5 8K2 5 + C2 10u-50V R7 8K2 5 +12V R8 R10 10K +12V 10K R12 R11 D8 R9 1K +12V R15 22K 1 R17 R18 10 100K 100K C5 470n 9 + - U2C LM3 24 4 33K 2 5 8 6 R19 10K + - 11 R14 10K 4 10K C4 470n C3 VRM R16 10K 4 D7 3 7 2 U2B LM3 24 D10 6V2 R13 2K2 1 100n + - 11 D6 11 D5 1 U2A LM3 24 DL2 1_ROK D9 R20 2K2 1 PRCH card (PB114) Control of the DC supply and rectifier start-up The +12V supply is controlled by a comparator. If the supply is within the tolerance range the LED DL4 is lit and the signal 1_PSOK is activated Such signal is then put in AND logic with 1_ROK (mains OK) and, if both of them are OK, the LED DL3 is lit and the rectifier is enabled to start-up through the signal 0_ON DL3 R21 +12V 2K2 1 R23 U3A 1_ROK U1C 1 D11 100R 3 1_P SOK 5 2 R22 806K R25 10K 4081 + VRM 13 +12V R26 10K Stop U1B 12 + U2D 14 3 4 1_P SOK - 11 D12 3V9 4 R24 10K LM3 24 R27 40106 2K2 1 R28 909R C7 1n DL4 C6 40106 10u-50V 6 0_ON PRCH card (PB114) Generation of the thyristors turn-on signals The IC TCA785 generates a ramp signal in phase with the corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8) Each ramp is compared with a control level (TP5). The result of the comparison (square wave) defines the thyristors’ delay angle The square wave is “mixed” with a high frequency signal (TP9). The resulting series of pulses represents the initial stage of the thyristors control circuit Control Level +12V +12V High Freq. Mixer & Driver C23 100n TP 9 10 TP 5 U3C 9 0_ON R41 249K 8 2 3 4 C24 470n R42 5 S 51K 2 C25 220n 6 7 D27 D28 8 GND VS Q2N Q2 QU Q1 Q1N L Vsync C12 I V11 QZ C10 Vref R9 U9 TCA785 16 HF U11 C 8 10 15 3 16 9 14 4081 13 U12 B ULN2804 10 9 R39 10K TP 7 U11 D 5 12 4 HF 4 15 6 11 4081 10 C26 47n 9 P2 1 R43 60K 4 ULN2804 9 1 U1D 40106 2 D26 3 100K PRCH card (PB114) – Settings and controls POTENTIOMETERS P1 Amplitude regulation of the ramp phase R P2 Amplitude regulation of the ramp phase S P3 Amplitude regulation of the ramp phase T CONTROL LED COLOUR DL1 Correct phase sequence YELLOW DL2 AC voltage in tolerance (>340Vac) YELLOW DL3 Rectifier ON GREEN DL4 Internal DC supply correct YELLOW The LEDs are normally lit steady, they are OFF in case of alarm PRCH card (PB114) – Interfaces with I/S-CL (mP) PRCH I/S-CL MAINS FAILURE signal • Pin 1-2 connector M1 RECTIFIER ON signal • Pin 1-2 connector M3 I/S-CL PRCH No controls or commands are sent by the microprocessor card to the PRCH card FIR-91 card (PB113) Final stage of the thyristors control circuit For simplicity we will represent only two sections (they are 6 in total) of the final stage for the thyristors control circuit The R-C circuit at the transformer input generates the real pulse, that is subsequently transferred to the gate of the thyristor The card contains also the snubbers (R-C circuits) that limits the commutation spikes, connected between the phases and the rectifier output poles C3 100n DL1 TF1 SQUA RE WAV E 1 R1 68R-5W R2 3 6 4 G1 D1 1N4 936 R4 47R 4R7 -2W SCR1/R TI112046 K1 C12 100n DL4 TF4 SQUA RE WAV E 1 R17 68R-5W +24V R18 3 6 4 TI112046 G2 D4 1N4 936 R19 47R 4R7 -2W SCR2/R K2 LOOP card (PB115) The LOOP card is composed by the following main sections: Voltage control loop Battery current control loop General control stage Battery charging voltage thermal compensation control (OPTIONAL) LOOP card (PB115) Generation of the internal reference Whenever the signal 1_ON is active (originating from the PRCH card), and therefore the rectifier start-up is enabled, the card generates a stabilised internal voltage reference (VREF), that is used in the voltage control loop 3 D9 R48 100R R49 51K 2 - 4 R51 33K + + C30 100uF 25V R53 51K U10 R50 6 OP 07 C27 VREF 100R R52 6K8 1 R54 10K 3 1_ON 1 100n -12V R55 3K9 2 R56 15K 4 C33 1u 2 R57 3K3 2 Not mo unt. 7 +12V C26 100n U11 TL4 31AB LOOP card (PB115) Voltage control loop Generation of the SET-POINT (using the signal VREF) and comparison with the feedback signal Regulation of the FLOATING and BOOST voltage (if enabled) R7 15K 4 C4 R-S2 R-S1 47n +12V TR-2 TR-1 R12 4K7 5 3 CN1 R18 2K2 1 1 2 3 4 5 6 7 8 9 10 R19 1K8 2 R20 4K7 5 10K R28 10K 3 3 M1 - 6 TP 12 U4 6 OP 07 2 OP 07 C14 1 R30 3K3 2 D1 C11 100n 1 -12V 11 12 +V -V C10 100n -12V - R26 121K 2 1 2 + U6 + 7 R59 4K7 5 3 4 3 RL2 P2 2 5K +12V R10 54K 9 7 B2 RL1 2 P5 5K C12 100n 4 2 11 12 54K 9 R25 8K2 5 R21 4K7 5 B1 7 R16 C6 100n U5 3160 +12V 1 VREF 1 2 3 4 5 - R15 6 4 1 5 2 100n + 7 R11 10K 7 C8 TR-2 TR-1 R32 10K 1u LOOP card (PB115) Battery current control loop The output signal of the battery current control loop is inserted in the control loop for the total stability The SET-POINT that defines the battery limitation current is adjusted through the potentiometer P3 +12V P3 100K 3 1 R29 820R 3 511R D5 R36 511R C19 100n - +12V C18 100n +12V C17 100n TP 2 R38 10K 6 3 U7 OP 07 2 + - 7 100n VRM R37 12K 3 U9 R39 6 OP 07 2 10K + - U8 6 OP 07 R40 100K C21 4 4 M1 2 + R34 4K9 9 4 7 R33 100K R35 C16 7 +12V 2 C15 100n 1 2 3 4 5 -12V C20 100n R42 4K6 4 D3 -12V C22 100n 6V4 100n C34 100n -12V R27 R45 511R R46 511R R43 100K 10K D8 C25 100n C24 100n C23 1u R47 10K D7 LOOP card (PB115) General control stage The output voltage and battery current control loops are joined together The battery current loop has the priority only when the current is limited during the battery re-charge phase The error signal Ve is used for the generation of the correct thyristors turn-on delay angle 3 R14 VOLTA GE LOOP 2 TP 13 JP1 U3 + 6 - OP 07 4 C9 1 2 100K 3 P1 10K 1-2 AUT. 2-3 MAN. +12V 3 R31 3K9 2 2 C3 100n 100n R23 -12V 464K R8 10K 7 CURRENT LOOP 3 2 D2 R41 P4 100K 3 C13 R22 10K + - 4 R13 1K +12V 7 R9 10K C5 100n 1 +12V U2 6 OP 07 C7 1 100n 220n 2 1K -12V R17 10K Ve LOOP card (PB115) Thermal compensation of the charging voltage A temperature probe, installed inside the battery room, is connected to the terminal board M2 The feedback signal is opportunely amplified and inserted in the voltage control loop VREF R1 6K8 1 7 +12V R2 10K 3 2 1 3 2 R4 178R + - R5 54K 9 U1 6 OP 07 R3 1K 4 M2 +12V C1 100n -12V C2 100n R6 1K All'anello di controllo tensione LOOP card – Settings POTENTIOMETER P1 Output voltage regulation in MANUAL control mode P2 Output voltage regulation (FLOATING voltage) in AUTOMATIC control mode P3 Regulation of the battery current limitation P4 Regulation of the stability of the regulation loops (output voltage and battery current) P5 Output voltage regulation (BOOST voltage) in AUTOMATIC control mode LOOP card – Interfaces with I/S-CL (mP) LOOP I/S-CL Signal of the battery SHUNT for the mP battery current reading (only when the BOOST charge is enabled) • Connector M3 I/S-CL LOOP Command of the relay RL1 for the BATTERY TEST • Pin 3-6 connector CN1 Command of the relay RL2 for FLOATING/BOOST commutation • Pin 2-4 connector CN1 Command of the relay RL3 for RECTIFIER STOP • Pin 1-5 connector CN1 SYNC-12 card (PB116) The SYNC-12 card is composed by the following main sections: Generation of the DC power supply (12V/24V) Generation of the synchronism signals for the thyristors firing SYNC-12 card (PB116) Generation of the DC power supply +24Vdc for the supply of the firing pulses +/-12Vdc for the supply of the control electronic circuits +24V Q1 R7 3 2 1R 2W BDX34C 2 1 1 3 Q2 2N2 907A +12V U1 R8 1 IN D2 D3 1N4 004 1N4 004 1N4 004 + T2 C1 1000u 50V F4 1A 6,3x32 F5 1A 6,3x32 C4 100n 16 15 3 4 F6 C2 47u 25V 12 11 1 2 1A 6,3x32 10 9 5 6 D4 D5 D6 1N4 004 1N4 004 1N4 004 + C5 1000u 50V U2 14 13 2 18 17 1 1 2 3 4 5 + LM7 812 + G ND M2 C3 100n 2 8 7 OUT G ND 1R 5W D1 3 IN OUT C6 47u 25V C7 100n 3 LM7 912 ACM1008 -12V SYNC-12 card (PB116) Generation of the synchronism signals The card uses a transformer with two secondary windings, displaced by 30°, so that it can be used as the only “generator” of synchronism signals also in the 12-pulse configuration The synchronism signals are used for both the control of the AC supply voltage and the generation of the control ramps of the thyristors’ delay angle CN1 1 2 3 4 5 6 7 8 9 10 T1 R1 8 7 470R 3W M1 1 2 3 4 5 F1 1A 6,3x32 F2 R3 1A 6,3x32 470R 3W 16 15 3 4 F3 R2 12 11 1 2 470R 3W 1A 6,3x32 10 9 5 6 CN2 14 13 18 17 ACM1008 R4 470R 3W R5 470R 3W R6 470R 3W 1 2 3 4 5 6 7 8 9 10 RCLS-1 card (PB117) The RCLS-1 card is composed by the following main sections: Control of the rectifier AC supply voltage Control of the internal DC supply Generation of the thyristors turn-on signals (initial stage) Thyristors firing circuit (final stage) Voltage control loop Battery current control loop Total current control loop General control stage Battery charging voltage thermal compensation control (OPTIONAL) RCLS-1 card (PB117) Control of the AC supply voltage Input phase sequence control (signal 0_SCOK if the phase sequence is OK) Low mains voltage control, Threshold adjustable with the potentiometer P13 Generation of the signal 1_AR (Mains failure) in case of anomaly of the previous signals R16 5 8K2 5 R S T U22 B 3 +12V C10 0 470n D32 R17 6 2K2 1 D23 3V9 R16 7 Q8 BC337 2 4 1 0_S COK 40106 U32 D 12 3 11 2K2 1 P13 50K R14 8 3 100K 100K C86 2 + - 33K 2 U31 A LM3 24 5 1 6 R15 6 10K R15 5 2K2 1 4 10K +12V VRM D18 +12V R15 0 2 R16 0 - R16 4 10K 10 + 11 R15 4 10K DL1 2 MR 4 C87 470n 4093 R15 9 10K R15 8 C83 470n 1_A R 13 R16 6 8K2 5 R15 2 100R 11 D30 3 D29 1 D28 C96 10u-63V 4 R17 8 8K2 5 + 7 U31 B LM3 24 9 + - 11 R17 5 12K R15 3 10K 100n 8 U31 C LM3 24 D21 RCLS-1 card (PB117) Control of the DC supply and rectifier start-up +12V JP5 1-2 = M 2-3 = S 1 3 SLA VE 2 R13 8 205K U22 C R13 7 +12V 5 6 R18 2 40106 2 R17 3 10K + SW1 U32 A U22 D C73 22u-50V 1 1K 2 9 8 1 3 0=FB 0=S TART 1=S TOP 39K + 1_A R 4093 40106 1_S TOP U30 A 0=FB 1 M9 0_FB 1 U26 A 3 0_A T 1 2 3 4 5 6 7 8 9 10 2 +12V 1 2 8 9 1=A VARIA 0=RADDR. OK 1_A V 3 4 5 6 4075 4093 4075 U30 B R17 4 10K R18 1 4 6 U32 B TP 11 5 1K 0=A T 4093 6 + 4093 C97 10u-63V R14 7 806K VRM 4 R15 1 10K U22 E 12 13 +12V R14 9 10K + U31 D 14 11 10 11 D16 3V9 0=RADDR. OK 5 4 LM3 24 R14 0 909R C82 1n 40106 TP 10 U26 B C95 10u-63V 1_P SOK 0_ON 0=S TART 1=S TOP RCLS-1 card (PB117) Control of the DC supply and rectifier start-up The +12V supply is controlled by a comparator (signal 1_PSOK) Such signal is then put in OR logic with the fault signals due to the fuses failure (0_FB) or high temperature (0_AT) A OR logic is used again to establish the rectifier start-up conditions, comparing the previous signal (1_AV), the mains failure signal (1_AR) and the stop command (1_STOP) depending on either the switch SW1 of the card or possible commands by microprocessor The start-up command (0_ON) is generated if none of the previous signals is active In case of 12-pulse configuration it’s important to note that the logic described previously is managed by the SLAVE rectifier too, except for the Start/Stop signal that is generated by the MASTER card only RCLS-1 card (PB117) Generation of the internal reference The presence of the signal ON enable the soft-start of the rectifier (1_SOFT); the signal 1-SOFT activates the circuits that generates the stabilised internal voltage reference (VREF), that is used in the voltage control loop +12V C11 3 100n 2 + - 1-SOFT 4 R19 6 54K 9 + C11 6 100u-25V R19 3 51K 1 R19 2 10K R28 100R U34 6 VREF OP 07 C11 4 3 3 R11 6K8 1 1 100n -12V R18 5 15K C11 5 1u R10 3K9 2 R19 4 51K 1 7 R19 5 100R D48 U1 TL4 31AB All'anello di controllo tensione RCLS-1 card (PB117) Generation of the thyristors turn-on signals +12V High F req. TP 5 TP 9 Mix er & Driv er C71 100n 10 +12V Control Lev el U24 C 4081 HF U19 C 8 10 4 R18 3 300K 3 C81 10n R14 5 C10 5 470n 2 4 5 S 10K 6 7 D17 D15 8 GND 16 VS Q2N Q2 QU Q1 Q1N 15 14 U24 D 4081 13 V11 C10 Vref R9 U19 D 12 TP 7 HF 10 C80 47n 9 P12 1 R14 6 60K 4 3 100K +24V DL1 3 TF4 1 R12 6 3 G3 AA D9 6 4 R12 5 47R 4R7 2W SCR1 TI112046 K3 C32 100n DL3 TF3 1 R90 3 G4 BB R60 68R 5W 15 13 11 C67 100n R13 2 68R 5W 4 ULN2804 U25 TCA785 To the f inal stage 12 11 Vsync C12 QZ AA ULN2804 L I 16 9 10 9 3 ON R12 7 10K 9 1 U17 B 40106 2 D33 3 D8 6 4 TI112046 R96 47R 4R7 2W SCR2 K4 BB RCLS-1 card (PB117) Generation of the thyristors turn-on signals The IC TCA785 generates a ramp signal in phase with the corresponding phase of the input voltage (R-TP6, S-TP7, T-TP8) Each ramp is compared with a control level (TP5). The result of the comparison (square wave) defines the thyristors’ delay angle The square wave is “mixed” with a high frequency signal (TP9). The resulting series of pulses represents the initial stage of the thyristors control circuit The final stage, similar to the circuit of the FIR-91 card, is integrated inside the RCLS-1 card, as well as the snubber circuits for the limitation of the commutation spikes RCLS-1 card (PB117) Voltage control loop R37 15K 4 C12 FBK 47n +12V C5 R5 10K R33 4K7 5 3 2 R4 1K8 2 R30 4K7 5 R20 6 +12V C14 100n - U3 3160 10K R43 54K 9 1 R41 54K 9 R21 4K7 5 7 3 2 P4 5K 2 3 2 2 7 -12V U6 + D3 6 P3 3 - 100K 2 1 1 4 C21 100n R63 4K7 5 R38 10K 7 2 1 2 3 4 5 M1 R39 10K 1 D42 RL6 11 12 D41 D43 C15 1 OP 07 -12V +12V C24 100n R40 8K2 5 1 R62 3K3 2 OP 07 4 TR-1 TR-2 RL2 12 11 P5 2 5K 6 - +12V C11 100n 7 3 3 VREF R6 715R RL1 U7 + 2 11 12 TS T-1 TS T-2 TP 12 4 1 5 R2 2K2 1 100n + 7 R1 7 47K 12W 1u RCLS-1 card (PB117) Voltage control loop Generation of the SET-POINT (using the signal VREF) and comparison with the feedback signal Regulation of the FLOATING and BOOST voltage (if enabled) Further possible voltage regulation in MANUAL charge mode (OPTIONAL) with external potentiometer and contact command of the relay RL6 on the connector M1 The relays RL1 and RL2 are controlled by the microprocessor card and used respectively for the BATTERY TEST and for the BOOST charge command The feedback signal is normally taken directly on the card (DC bus jumper JP3 in position 1-2). When the DC choke is installed, the signal is taken externally and connected to the pin 6 of CN4 RCLS-1 card (PB117) Battery current control loop The output signal of the battery current control loop is inserted in the control loop for the total stability The SET-POINT that defines the battery limitation current is adjusted through the potentiometer P15 P15 100K 3 1 R71 68K 1 2 +12V +12V C11 0 100n R18 8 3K3 2 - U33 OP 07 2 10K C11 2 R19 0 287K TP 15 7 R18 9 6 U11 + 6 - OP 07 C42 220n 4 2 + 3 4 3 C26 100n R19 1 12K 7 R18 7 10K C34 100n VRM 100n R53 100K +12V C27 -12V R58 R59 3 511R 511R C31 100n 2 100n U10 6 - 4 1 5 D46 + R57 100R P6 3 1 R56 100K 511R C28 100n R64 10K C35 1u 3160 R67 511R -12V C33 1u 100K R54 C11 1 100n R69 10K 2 1 2 3 4 5 6 7 8 7 CN4 C25 100n D6 RCLS-1 card (PB117) Total current control loop The output signal of the battery current control loop is inserted in the control loop for the total stability The SET-POINT that defines the total limitation current is adjusted through the potentiometer P2 R48 R46 +12V +12V +12V 806K 6K8 1 R66 10K 5 D5 +12V 4 R18 100K C4 6V2 R70 15K 4 VRM 7 R23 511R 3 511R +12V C9 2 D37 + - 2 OL U9B LM3 39 R51 68K 1 - 3160 3 100n + R68 68K 1 100n U2 6 2 +12V C20 100n P1 1 R49 12K D40 N.M. 3 R16 511R 100K 2 P2 50K 3 C3 100n TP 14 U8 + 6 - OP 07 R47 100K C30 4 1 100n +12V -12V 2 100n R17 100K D39 C8 100n C19 1u 7 R32 511R C10 R19 10K 3 2 + - U5 R52 10K R36 6 OP 07 C17 10K 1u C37 R25 10K R22 10K 220n 4 1 2 3 4 5 6 7 8 D38 N.M. R26 4 1 5 CN4 100n 7 +12V 12 C7 100n 3 C23 R65 825R -12V C18 100n D4 RCLS-1 card (PB117) General control stage The output voltage, battery current and total current control loops are joined together The current loops have the priority only when the current is limited (battery re-charge phase or output current exceeding the maximum value allowed) The error signal Ve is used for the generation of the correct thyristors turn-on delay angle JP7 TP 15 R55 1K R77 BA TT ERY CURR. LOOP 2 TP 13 U15 + 6 - 3 OP 07 4 C47 1-2 = Man 2-3 = Aut TOTA L CURR. LOOP 12 R91 10K 13 + U16 D 14 - LM3 24 11 100n P9 10K -12V R81 464K R88 10K D7 P8 3 C50 1 100K 2 TP 14 1 2 JP1 100K R61 1K R93 10K 3 3 2 1-2 = M 2-3 = S 220n VE ' Rec t. Slav e 4 D49 1 VOLTA GE LOOP 3 TP 12 R79 10K +12V 7 R42 1K C43 100n 2 +12V 1 12P CURRENT B ALA NCE R97 10K VE RCLS-1 card (PB117) 12-pulse current balance A Hall effect CT, connected to the connector CN2 of the RCLS-1 MASTER, control the current difference of the two bridges The error signal, opportunely amplified and filtered, is used to vary the control level in the circuit that generates the thyristors delay angle P10 50K 3 R11 5 1 -12V 33K 2 4 33K 2 2 R10 8 +12V 5 C51 100n 3 10K 511R 2 + U16 A 1 R11 0 - LM3 24 10K C57 100n R98 511K -12V R10 1 22K 1 C53 100n + + C52 10u-63V U16 B 7 - LM3 24 R10 6 604K C54 100n C55 10u-63V 11 R94 6 + 4 R92 11 +12V 10K -12V CN2 10 9 8 7 6 5 4 3 2 1 R11 4 +12V R11 3 10K 12 PULSES CURRENT BA LANCE RCLS-1 card (PB117) Thermal compensation of the charging voltage A temperature probe, installed inside the battery room, is connected to the connector CN1 (through a interface card) The feedback signal is opportunely amplified and inserted in the voltage control loop VREF +12V C6 100n 10 9 8 7 6 5 4 3 2 1 100n 7 CN1 R8 6K8 1 R35 10K 3 2 R7 178R -12V + - U4 R27 6 OP 07 R31 1K 4 C10 9 C13 100n -12V +12V R24 1K 54K 9 All'anello di controllo tensione RCLS-1 card - Settings POTENTIOMETERS P1 Regulation of the off-set OP-AMP TOTAL CURRENT P2 Regulation of the TOTAL CURRENT limitation P3 Regulation of the VOLTAGE loop stability P4 Output voltage regulation (FLOATING) in AUTOMATIC control mode P5 Output voltage regulation (BOOST) in AUTOMATIC control mode P6 Regulation of the off-set OP-AMP BATTERY CURRENT P8 Regulation of the TOTAL control stability P9 Output voltage regulation in MANUAL control mode P10 Regulation of the current sharing in 12-pulse configuration P11 Regulation of the amplitude ramp phase R P12 Regulation of the amplitude ramp phase S P13 Regulation of the AC voltage tolerance (alarm AR) P14 Regulation of the amplitude ramp phase T P15 Regulation of the BATTERY CURRENT limitation RCLS-1 card - Controls CONTROL LED COLOUR DL4 Rectifier overload (Iout>100%) YELLOW DL5 Internal DC supply not correct RED DL6 Rectifier OFF GREEN DL7 High temperature of the rectifier bridge RED DL8 Protection fuses failure RED DL9 Fans failure (not used) RED DL10 Mains failure RED DL11 Input phase sequence not correct YELLOW DL12 AC supply low voltage RED The LEDs are normally lit steady, blinking in case of alarm (except DL12 that is normally OFF and lit in case of alarm) RCLS-1 card – Interfaces with I/S-CL (mP) RCLS-1 I/S-CL MAINS FAILURE signal • Pin 1-2 connector CN7 RECTIFIER ON signal • Pin 5-6 connector CN5 FUSES FAILURE signal • Pin 1-2 connector CN5 WRONG PHASE SEQUENCE signal • Pin 3-4 connector CN5 Signal of the battery SHUNT for the mP battery current reading (only when the BOOST charge is enabled) • Pin 7÷10 connector CN5 RCLS-1 card – Interfaces with I/S-CL (mP) I/S-CL RCLS-1 Command of the relay RL1 for the BATTERY TEST • Pin 3-6 connector CN6 Command of the relay RL2 for FLOATING/BOOST commutation • Pin 2-4 connector CN6 Command of the relay RL3 for RECTIFIER STOP • Pin 1-5 connector CN6 The RCLS-1 card can be also connected to a relay card to repeat to a remote location the 6 main alarms Summary of the rectifier cards’ functions PRCH PB115 LOOP PB114 FIR-91 PB113 SYNC-12 PB116 RCLS-1 PB117 Generation of the 12V/24V supply X X Generation of the synchronism signals X X AC supply voltage control X X Internal DC supply control X X Generation of the thyristors firing signals X X Thyristor firing Voltage control loop X X X X NOT PROVIDED X Battery current control loop X X General control X X Thermal compensation of the charging voltage (OPTIONAL) X X NOT PROVIDED X Total current control loop Interface with a relay card General data Inverter & Static switch Technical features User interfaces Rectifier Test software Inverter Single-phase inverter The rectifier output voltage (battery) is applied to the IGBT bridge, composed by four power components controlled through PWM technology The inverter bridge output voltage is adapted by the isolation transformer and subsequently filtered by the low-pass filter formed by the inductance integrated in the transformer and the AC capacitors Inverter Three-phase inverter The rectifier output voltage (battery) is applied to the IGBT bridge, composed by six power components controlled through PWM technology The inverter bridge output voltage is adapted by the isolation transformer and subsequently filtered by the low-pass filter formed by the inductance integrated in the transformer and the AC capacitors Inverter typologies As already seen for the rectifiers, also the inverters can be separated in different typologies, according to the constructive solution chosen TYPE 1 It’s the single-phase inverter, with the following manufacturing features Use of two power components, each containing two IGBTs Installation on a single heatsink Forced cooling with single fan Power connections carried out through interface card IBPC-7 (PB120), which includes the DC capacitors and the Hall effect CT Inverter typologies TYPE 2 It’s the three-phase inverter, with the following manufacturing features Use of two power components, each containing two IGBTs Installation on a single heatsink Forced cooling with single fan Power connections carried out through interface card IBPC-7 (PB120), which includes the DC capacitors and the Hall effect CT TYPE 3 It’s the three-phase inverter used starting form the 40kVA. The power components are connected with cables and/or copper bars, without interface card. Double IGBT packs (that is a single component containing two IGBTs) are generally used up to 160kVA range Static switch Single-phase static switch It’s composed by two pairs of thyristors, connected in anti-parallel, that interrupt the phase conductors (inverter/bypass) The bypass component is protected by a fast-acting fuse In order not to modify the grounding system the neutral conductor is not interrupted Static switch Three-phase static switch It’s composed by six pairs of thyristors, connected in anti-parallel, that interrupt the phase conductors (inverter/bypass) Static switch typologies TYPE 1 It’s the single-phase static switch TYPE 2 It’s the three-phase static switch that uses compact type thyristors (SemiPack) TYPE 3 It’s the three-phase static switch that uses disc-type thyristors (used only on the 500kVA and 650kVA) The three types of static switch use different firing cards, that vary on the basis of the components layout Inverter & static switch control Unlike the rectifier, where the control of the operating parameters is purely analogue, the control of the inverter is completely entrusted to the microprocessor (HC16 Motorola), that develops the following main functions Generation of the reference sine-wave used for the creation of the PWM Complete management of the operating logics of the inverter and static switch Management and control of the measure shown on the display Control of the synchronism, in stand-alone and parallel operation The microprocessor card uses some additional cards, each of them with its own specific function Inverter & static switch control The following electronic cards are used for the inverter and static switch control INVERTER • I/S-CL ◆ RCB ◆ VCB ◆ SCB • • • • PS-HV ID INV-AV FCI (PB003), inclusive of: (PB011) (PB012) (PB014) (PB001) (PB013) (PB004/PB018) (PB047) STATIC SWITCH • VOLT-REF • SCR-FIR (PB005/PB019) (PB009/PB010/PB016) PS-HV card (PB001) The PS-HV card is the system power supply, the one that “creates” the different power supplies for the whole control electronic (except, obviously, the rectifier) It’s a switch-mode power supply, with IN/OUT galvanic isolation provided by a high frequency transformer According to the UPS nominal DC voltage (in our case 384Vdc) the power supply can be divided in: PS-HV PS-MV PS-LV (PB001) Supply range: 300÷600Vdc (PB002) Supply range: 180÷300Vdc (PB184) Supply range: 180÷300Vdc For application where the power required is higher because of, for example, the use of parallel IGBTs (SATURN series, Pnom>200kVA) it’s used a power supply called PS-SAT (PB107), similar to the PS-HV except for the higher power PS-HV card (PB001) The power supply card is composed by the following main sections: Microprocessor supply section Analogue part supply section IGBT drivers supply section Relays and BUS supply section Serial ports supply section DC voltage measure section PS-HV card (PB001) Microprocessor supply This section supplies all the digital part (microprocessor) and the LCD panel The voltage is further stabilised by a 5V stabiliser mounted on board the microprocessor card The supply AC3-AC4, that will be described later on, is taken from the same secondary winding of the transformer FU6 PF 2A R59 1K D22 MUR120 D23 MUR120 R61 1K R63 10K 17 C40 100u 50V + CN1 C41 100n R57 10K TP 8 FU1 AC3 18 PF 2A AC4 T2-E R60 1K D24 MUR120 D25 MUR120 R62 1K TP 9 10 9 8 7 6 5 4 3 2 1 FLA T 10P PS-HV card (PB001) Analogue part supply This section supplies all the analogue part of the microprocessor card The supply AC1-AC2, that will be described later on, is taken from the same secondary winding of the transformer R51 TP 5 T2-C 10 D14 FU2 10K PF 5A R50 LD3 4K7 G 3mm +24V + C29 100u 50V MUR120 1 + D16 MUR120 D17 MUR120 VOUT C30 100u 50V 2 12 AC2 TP 2 U4 LM7 812 +12V 10K D20 1N4 004 AC2 TP 4 R46 LD1 2K2 1 G 3mm C15 1u D19 MUR120 D18 MUR120 TP 3 MUR120 10K OUT 3 R47 G ND C31 100u 50V IN 1 2 U5 LM7 912 D21 1N4 004 C28 1u LD2 2K2 1 G 3mm 10 9 8 7 6 5 4 3 2 1 FLA T 10P R48 D15 14 AC1 R49 AC1 13 CN2 3 G ND 11 VIN C13 1u -12V + PS-HV card (PB001) Relays and BUS supply This section provides a 12V stabilised voltage for: • • • • Relays of the alarm card ARC (PB031) – pin 9-10 Rectifier card relays (battery test, floating/boost, stop) – pin 9-10 Parallel BUS – pin 9-10 Digital signal interface card FCI (PB047) – pin 1-2 D26 CN3 FU7 7 MUR120 PF 3,5A + C46 100u 50V C47 1u R64 10K R66 2K2 1 8 LD4 G 3mm D27 9 T2-F MUR120 D28 19 PF 2A MUR120 + T2-G 12V /RELAY E B US 12V /RELAY FLA T 10P FU8 20 10 9 8 7 6 5 4 3 2 1 C48 10u 63V C34 1u R68 2K2 1 LD5 G 3mm PS-HV card (PB001) IGBT drivers and serial port supply The IGBT drivers are supplied by the 40khz square wave AC1-AC2 A rectifying circuit, that provides also to isolate galvanically the supply of the driver, is provided on board the driver itself The serial ports are supplied by the 40khz square wave AC3-AC4 A rectifying circuit, that provides also to isolate galvanically the supply of the serial ports, is provided on board the card RCB PS-HV card (PB001) DC voltage measure This section provides a stabilised voltage, proportional to the amplitude of the DC supply voltage Such signal is sent to the microprocessor as feedback for the correct display of the inverter input voltage TP 1 D6 R23 +12V 9 +12V C33 100n BY V26C P1 C18 1u 3 5K 2 + - U1 R26 6 OP 07 4 R24 R25 1K 7 T1-D 10 CN4 1K 1K -12V C32 100n Vdc MEAS URE 261R 10 9 8 7 6 5 4 3 2 1 FLA T 10P PS-HV card – Settings and controls POTENTIOMETERS P1 Regulation of the DC voltage measure P2 Regulation of the IGBT drivers supply voltage CONTROL LED COLOUR DL1 +12V analogue part supply GREEN DL2 -12V analogue part supply GREEN DL3 +24V analogue part supply GREEN DL4 +12V relays and BUS (pin 9-10 CN3) GREEN DL5 +12V FCI card relays (pin 1-2 CN3) GREEN ID card (PB013) The ID card is the IGBT driver and it’s designed for the control of a complete inverter leg (IGBT+ / IGBT-) It’s composed by two identical sections, each one with its own power supply With proper addition of components each section of the card can control up to two IGBTs in parallel, but such option is not provided for the actual production line For the control of parallel IGBTs in the high power range UPS (>200kVA) another card is used, the DR-SAT (PB108), a card for each switch (therefore two cards for each bridge leg) Besides the functions of the ID card, the DR-SAT is provide with an additional protection with a desaturation sensor ID card (PB013) Power supply section The square wave AC1-AC2, originating from the power supply card PS-HV, is used to generate the isolated supplies for both sections of the card +15V 1 TR1 D5 1N4 148 R33 1K VIN + VOUT 2 G ND C9 1u C10 10u-63V LD3 C12 1u 3 AC1 +5V U2 78L05 D4 1N4 148 D6 1N4 148 + CN1 C11 10u-63V 1 2 3 4 5 6 7 8 9 10 TI117239 /ACM200 8 D7 1N4 148 -15V Power supply IGBT+ +15V F TR2 C21 1u D12 1N4 148 + VOUT 2 LD4 C24 1u 3 C22 10u-63V R34 1K VIN G ND 1 AC2 +5V F U6 78L05 D11 1N4 148 D13 1N4 148 + C23 10u-63V TI117239 /ACM200 8 D14 1N4 148 -15VF Power supply IGBT- ID card (PB013) Initial stage A opto-coupler provides for the de-coupling of the PWM signal coming from the I/S-CL card A low-pass filter introduces a little delay in the pulse transfer (dead time) The LED LD1 indicates the presence of the PWM signal 6 0=ON 1 3 5 2 U1A 4 0=ON 3 6 10 HP 2601 4093 4093 4093 14 7 U3 + R3 *** 1K 1=ON 9 R4 1K8 7 PWM D1 1N4 148 U1C 8 7 1K8 U1B 5 C5 1n C2 10u-63V R6 3K3 U1D 12 11 13 LD1 4093 7 2 R5 680K 14 14 R1 R2 3K3 8 7 C1 100n 14 D3 1N4 148 D2 1N4 148 1=ON +5V ID card (PB013) Final stage The signal is amplified by a MOSFET amplifier that provides also for the translation of the signal between +/-15V Such voltage can be adjusted by the potentiometer P2 of the PS-HV card +15V R11 ** R9 390R 2W R10 390R 2W D C4 + C7 DZ2 18V G S Q2 IRFD0 14 1u Q4 IRFD9 014 R7 1=ON 10u-63V R15 1K D G S DZ1 24V R13 ** C3 100n 22R D G S C6 R8 9K0 9 Q3 IRFD0 14 10u-63V -15V + C8 1u 1 2 DZ3 18V M1 G1H S1H INV-AV card (PB004/PB018) The INV-AV card is divided in INV-AV-1F (PB018), for single-phase inverter and INV-AV-3F (PB004), for three-phase inverter The card is basically composed by two sections: Inverter voltage feedback The inverter output voltage, taken directly on the AC capacitors, is connected to the connector CN1. Three transformers (one on the INVAV-1F) adapt the voltage that can be used as feedback signal for the output voltage regulation loop Output current measure The three output CTs (one on the single-phase inverter) are connected to the connector CN3. The voltage drop on the resistors R4 (phase R), R5 (phase S), R6 (phase T), due to the CT’s secondary current, is used as reference signal for the measure of the output current VOLT-REF card (PB005/PB019) Electrical drawing +24V ST +5V ST VIN VOUT C2 10u 50V C6 0,1u 2 + 3 CN3 R2 511R G ND 1 10 9 8 7 6 5 4 3 2 1 DL1 + U1 7805 C7 10u 50V R1 22R 2W D1 T1 D2 D3 10 D7 D8 D9 10 + C1 100u 50V 2 2 9 C3 2,2 u 250V T4 9 D4 D5 13 D6 D10 D11 C8 2,2 u 250V D12 13 7 7 BY PASS CN1 T N 1 2 3 4 5 6 7 T2 10 10 OUTPUT CN5 1 2 3 4 5 6 7 T5 2 2 9 C4 2,2 u 250V 9 13 C9 2,2 u 250V 13 7 7 CON7 T3 12 12 10 10 9 9 2 C5 2,2 u 250V T6 2 13 C10 2,2 u 250V 13 7 7 12 12 FU1 CN4 FU2 1 2 3 4 5 6 7 S 12 1 2 3 4 5 6 7 8 9 10 R 12 F ANS SUPPLY CN2 FU3 R S T N VOLT-REF card (PB005/PB019) The VOLT-REF card is divided in VOLT-REF-1F (PB019), for single-phase inverter and VOLT-REF-3F (PB005), for three-phase inverter The card is basically composed by four sections: Bypass voltage feedback The BYPASS voltage, taken on the static switch input, downstream the thyristors protection fuses, is adapted by the three transformers (one on the VOLT-REF-1F). The signals obtained are used by the microprocessor as reference for the measure and control of the tolerance limits Bypass voltage feedback The OUTPUT voltage, taken on the static switch output is adapted by the three transformers (one on the VOLT-REF-1F). The signals obtained are used by the microprocessor as reference for the measure and control of the tolerance limits VOLT-REF card (PB005/PB019) Static switch logics supply The secondary voltage of the transformers (one of the two secondary windings) is rectified and stabilized in order to obtain two supplies: 24Vdc not stabilised and 5Vdc stabilised The 24Vdc is used for the supply of the final stage (card SCR FIRING) of the bypass thyristors control circuit The 5Vdc is used for the supply of the SCB card, that manages the static switch operating logic Fans supply section The three couples of phase-neutral supplies on the connector CN3 are used on the units up to 30kVA for the supply of the cooling fans SCR-FIR card (PB009/PB010/PB016) The SCR FIRING cards contain the final stage for the inverter and bypass static switch control circuit (see card FIR-91 for the rectifier), and are fixed directly on the thyristors SCRSF-3F (PB009) Designed for the control of 6 couples of thyristors (a complete threephase static switch) SCRSF-1F (PB010) Designed for the control of 2 couples of thyristors, inverter and bypass (a complete single-phase static switch or a section of a three-phase static switch) 2SCR-FIR (PB016) Designed for the control of 1 couple of thyristors FCI card (PB047) The FCI card is basically a relay card, and is used to de-couple the microprocessor card from the digital signal originated externally (auxiliary contacts of breakers, etc.) Such contacts are normally connected to the connector M3 of the I/S-CL (PB003) card In the standard production the FCI card is used on the units starting from 40kVA It’s important to remember that the supply of the relays of the card comes directly from the power supply card (PS-HV), pin 1-2 of the connector CN3 FCI card (PB047) Configurations of the signals SIGNALS SIDE FCI – M1 Origin 1-2 Signal mP SIDE FCI – M2 Not used - Spare 1-2 3-4 Rectifier card Mains failure 3-4 5-6 EPO push-button Emergency Power Off 5-6 7-8 BCB aux contact BCB open/closed 7-8 9-10 OCB aux contact OCB open/closed 9-10 11-12 Switch SW1 Bypass switch 11-12 13-14 MBCB aux contact MBCB open/closed 13-14 15-16 Thermal switch High temperature 15-16 17-18 Parallel card Parallel configuration 17-18 I/S-CL card (PB003) The I/S-CL card contains the microprocessor and all the electronic logics for the inverter and static switch operation. It’s composed by the following main sections: Digital supply Memories Watchdog and reset circuit Measures – Internal A/D converter Measures – External A/D converter Current protection Voltage control loop card VCB PWM generation Static switch control card SCB Serial port supply card RCB Digital inputs I/S-CL card (PB003) Digital supply The voltage originated from the power supply card, connector CN1 (about 9V), is further stabilised by means of a precision stabiliser, filtered by means of L-C filters and made suitable for the supply of the microprocessor VNR +5V 1 C13 1 C13 7 100NF C12 2 + 470uF E U 3 M L4 CN14-9 100NF +5V U75 TE A7605 D69 GREE N FILTERS 2 CN14-10 CN14-1 CN14-2 GND COMMON MODE D50 R14 6 1N4 148 +VRAM D49 1N4 148 D48 SD103 BT 1 ON 2 J2 3 OFF I/S-CL card (PB003) RAM (U58) The RAM contains the events log (up to 900 events), the information related to the year for the clock setting and the tables for the voltage fast sensors (described later on) A back-up battery provides to keep the data stored EEPROM (U71) The EEPROM contains the UPS’ functional parameters and all the settings EPROMs (U55-U65) The EPROMs contain the operating program, split into odd (U65) and even (U55) addresses Watchdog e reset The microprocessor is controlled by a smart “watchdog” that provides for the reset of the program in case of processing error or problems in the supply voltage (undervoltage lock-out) The microprocessor can be manually reset through the push-button SW3 I/S-CL card (PB003) Measures – Internal A/D converter The measures related to the bypass and output voltage are directly acquired by the microprocessor and converted by the internal analogue/digital converter The signal are translated of 2,5V in comparison to the zero, therefore the microprocessor recognise automatically the level “zero” MICRO BUS R FI1 BY PA SS FRE QUE NCY OP AMP +5V D62 D60 D61 D55 D54 R15 2 10K D53 R15 0 10K 2K2 1% X6 R R ADA1 S ADA2 T ADA3 R ADA4 S T D52 C11 3 VR/2 C11 0 C10 9 C10 0 C98 C97 R20 9 D57 D58 R20 8 D59 R20 7 D64 R20 5 D65 R20 4 ADA5 R20 6 ADA0 R17 2 CN13-4 S R17 1 T R17 3 R R16 6 S R16 5 T R16 4 CN13-3 BY PASS CN13-2 CN13-5 CN13-6 CN13-7 OUTPUT I/S-CL card (PB003) Measures – External A/D converter Some measures are acquired by the microprocessor in serial mode, after they have been converted by a analogue/digital converter (SPI – Serial Peripheral Interface) placed in the analogue part of the card +5A D31 D16 D17 D32 D14 D15 D34 D35 INVE RTE R VOL TAGE R D36 INVE RTE R VOL TAGE S U22 20 19 18 17 16 15 14 13 12 11 DA TA _OUT VCC EOC CLK ADRIN DOUT CS RE F+ RE FIN10 IN9 IN0 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 GND 1 2 3 4 5 6 7 8 9 10 Inv. Vol t. R Inv. Vol t. S Inv. Vol t. T Out. Curr. R Out. Curr. S Out. Curr. T VDC IBS CFP AR INVE RTE R VOL TAGE T OUTP UT CURRE NT R OUTP UT CURRE NT S OUTP UT CURRE NT T DC V OLT AGE IBOOST INVE RTE R INPUT CURR TLC1542 A PA RA LLEL CORRE CTION BA TT ERY B OOS T CURR D42 A C72 D22 C51 D23 C52 D43 C73 D20 C49 D6 D21 C50 C64 D5 D33 C65 C66 I/S-CL card (PB003) Measures – External A/D converter In order to read correctly the values, a software adjustment during the microprocessor setting phase provides to define the level “zero”, where the actual value of the parameter is void The measures for which the “zero” must be set are: • • • • • • • Inverter voltage phase R Inverter voltage phase S Inverter voltage phase T Output current phase R Output current phase S Output current phase T Inverter input DC current The parameter CFPAR is used only in the PARALLEL configuration The parameter IBOOST is used only when the boost charge in enabled I/S-CL card (PB003) Measures – Summary For further clarity the origin of the signals used by the microprocessor for the measures are summarised hereunder Signal Provenienza BYPASS voltage (phases R/S/T) VOLT-REF-3F (1F) card OUTPUT voltage (phases R/S/T) VOLT-REF-3F (1F) card INVERTER voltage (phases R/S/T) VCB cards OUTPUT current (phases R/S/T) INV-AV-3F (1F) card DC voltage PS-HV card DC current Inverter input Hall effect CT I/S-CL card (PB003) Current protection The current protection is carried out acquiring the signal related to the inverter bridge input current, function of the UPS output current A Hall effect CT, connected on the positive cable (or copper bar) between the DC capacitors and the inverter bridge, is used for this purpose Such configuration guarantees the control and protection against possible short-circuits of the inverter bridge, caused by the failure of one IGBT In the UPS that uses the interface card IBPC-7 (PB120) for the power connections the CT is mounted on the card itself The supply of the CT (+12V/-12V) comes from the power supply card PS-HV (analogue supply section) via the connector M1 of the I/S-CL card I/S-CL card (PB003) Short circuit protection +12A C19 M1-2 FEE DB ACK J10 R39 47R 100NF R27 A D73 3 C28 1NF J9 J100 R40 100R 1K 2 SD103 D72 SD103 + U16 A 1 MC34074 R38 2K A C27 R18 22R R25 1K A 1n R26 P2 10K 1K TP 2 Current Signal I/S-CL card (PB003) Short circuit protection The feedback signal originated by the Hall effect CT is acquired by the microprocessor card The feedback current generates a voltage drop flowing through the resistors R18-R39-R40, so that it can be used for the control circuit By means of a amplifier, which gain can be varied with the potentiometer P2, the value of the signal is adapted to the dynamic of the protection circuit The signal on the test point TP2 must be equal to 4Vpeak when the inverter supplies the nominal load (100%) In case of short circuit the output current is limited at 200% for 100ms, and then to 125% for 5 seconds, after which the inverter is switched off (according to EN62040-3) I/S-CL card (PB003) “Current stop” protection U15 B +5A +12A 3 4 U5C C20 100NF R15 10K FEE DB ACK 10K R13 10 CA 3130 9 +12A 3K3 7 5 A 3 R39 2 J10 + U11 6 R50 U5D 12 - R49 11 200K A 13 R16 R40 C28 1NF C13 10K J9 1NF 1K A N1 100pF A R18 J100 A D3 LMCS 4093 4 8 1 M1-2 R17 8 40106 SW4 PPMCS 4093 CURRE NT S TOP + C14 8 10u 25V I/S-CL card (PB003) “Current stop” protection The resistors R18-R39-R40 are properly combined according to the IGBT’s nominal current 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. 250ms) The inverter stop due to “Current stop” is signalled by the LED D3, placed on the front of the I/S-CL card The program provides for the automatic reset of the stop condition for three times, re-starting the inverter If the block repeats, therefore a real failure exists in the inverter bridge, the inverter is definitely stopped and must be re-started only after having verified the reason of the malfunction I/S-CL card (PB003) VCB card (PB012) – Voltage control loop The VCB card contains all the electronic logics for the voltage control loop Each inverter output phase is controlled by a different card, therefore the I/S-CL card for a three-phase inverter will mount three VCB cards Three main sections can be identified: • Generation of the reference sine-wave • Voltage correction • Inverter voltage measure The output signal from the VCB card is used by final stage of the PWM generation, in the I/S-CL card I/S-CL card (PB003) VCB card (PB012) – Sine-wave generation The digital signal coming from the microprocessor (that represents the digital sine-wave) is converted by a D/A converter in order to obtain a real sine-wave The amplitude of the sine-wave is varied by the AUTOMATIC regulation loop (jumper J1 in position 1-2) in function of a set-point managed by the microprocessor adjustable through the potentiometer P1 Each phase of the inverter is disengaged and can be varied independently In order to carry put functional tests, the regulation loop can be set in MANUAL mode (jumper J1 in position 2-3), in such case the amplitude is varied operating on the potentiometer P1 of the I/S-CL card In this case the inverter output voltages are varied contemporary I/S-CL card (PB003) VCB card(PB012) – Voltage correction The voltage correction circuit is used to modify the PWM reference signal in order to “correct” possible distortions on the output sine-wave and can be disabled removing the jumper J2 The feedback signal, coming from the INV-AV-3F (1F) card is compared with the reference sine-wave e properly filtered The resulting signal is added again to the reference sine-wave +5A +12A C22 R36 10K R30 10K U6C VREF 10 9 + 8 - 5 6 LM3 24 R31 10K NOTCH F ILTER 100NF U6B + A 7 - R39 10K LM3 24 VREF R32 10K A VFB K R40 10K R37 C14 1NF C15 1NF 43K 2 C20 U6D 12 C19 100NF J2 13 + LM3 24 A A R41 10K 1NF +5A R42 11K 8 14 VP WM I/S-CL card (PB003) VCB card(PB012) – Inverter voltage measure A section of the card is dedicated to the creation of of a signal that can be used as reference for the measure of the inverter output voltage The feedback signal, originating from the card INV-AV-3F (1F), is rectified, filtered and sent to the SPI, and then to the microprocessor I/S-CL card (PB003) Generation of the PWM reference frequency The generation of the IGBT’s turn-on pulses is carried out comparing two signals: the reference signal (sinusoidal at 50 or 60kz) originated from the VCB card and a triangular waveform with a frequency equal to the desired commutation frequency The triangular waveform is a function of a reference signal generated by the microprocessor +5A +12A R33 300K C34 C41 100NF A 7 1 100NF A 3 R66 * C54 2 6K8 1 100NF - C42 100NF 4 8 FRE F U17 + A -12A 6 OP 07 R66 = 6K81 f or 8KHz 13K6 f or 4KHz R67 24K9 f or 2KHz C55 10NF 220K FPWM I/S-CL card (PB003) PWM generation – Final stage The final stage is the real comparison of the sine-wave with the triangle and the following transmission of the resulting PWM signal to the IGBT driver cards +12A C24 100NF +12A C18 100NF A U9A 5 1ST OP 6 +12A 1 CN7-8 3 U14 C 40106 CN7-7 2 A AC1 4093 +TA CN7-1 CN7-3 U14 D A +12A 9 FPWM (TRIA NGLE ) A 3 + 2 CN7-4 -TA A U12 6 U9B +12A 5 4 - 6 C15 4 8 1 C14 22NF 22NF A A 4093 A A CN7-2 40106 CA 3130 VP WM (S INE WAV E) R9 1K AC2 7 5 R10 1K C22 100NF 8 N5 47pF CN7-1 0 CN7-9 I/S- CL card (PB003) SCB card (PB014) – Static switch control The SCB card contains the decisional logics of the static switch (inverter & bypass) It’s directly supplied by the bypass or the output through the VOLTREF-3F (1F) card The LED L1 signals the presence of the 5V supply The bypass static switch thyristors are controlled directly by the SCB card The inverter static switch thyristors are controlled by the I/S-CL card according to the consents originated from the SCB card RCB card (PB011) – Serial ports supply The RCB card contains the drivers for the serial interface ports RS232 and RS485 and for the microprocessor’s digital outputs (alarm relay card) The supply is isolated, created internally using the square wave AC3AC4 coming from the PS-HV card I/S-CL card (PB003) Digital inputs The digital inputs are connected directly, or through the de-coupling card FCI, to the connector M3 Such signals are internally de-coupled and connected to the microprocessor I/S-CL M3 Signal 1-2 Not used - Spare 3-4 Mains failure 5-6 Emergency Power Off 7-8 BCB open/closed 9-10 OCB open/closed 11-12 Bypass switch 13-14 MBCB open/closed 15-16 High temperature 17-18 Parallel configuration I/S-CL card configuration The I/S-CL card can be easily configured with simple operations and can be adapted to all the production range (Standard and custom UPS) Four different configurations can be identified: Configuration of the nominal parameters Configuration of the switching frequency Configuration of the current protection Configuration of the jumpers I/S-CL card configuration Configuration of the nominal parameters The nominal parameters can be configured by means of dip switches At the start-up the program recognises the position of each dip switch and configures the operating parameters accordingly For the correct configuration of the dip switches refer to the relevant technical documentation Configuration of the switching frequency The switching frequency depends on the frequency of the triangular waveform that is compared with the reference sine-wave to generate the PWM signal The frequency of the triangle can be varied modifying the value of the resistor R66: • R66 = 6K81 • R66 = 13K6 • R66 = 24K9 fswitching = 8khz fswitching = 4khz fswitching = 2khz I/S-CL card configuration Configuration of the current protection The current protection, and particularly the “Current stop” protection, can be configured combining properly the resistors R18-R39-R40 according to the IGBT’s nominal current For the standard UPS a configuration table does exist, the calculation form is shown hereunder 10 x KLEM REQ = -------------------2 x IIGBT Where: REQ = Series combination of R18-R39-R40 KLEM = Conversion ratio of the LEM IIGBT = IGBT’s nominal current I/S-CL card configuration Configuration of the jumpers The I/S-CL card is provided with some jumpers, necessary to configure some operating parameters The most interesting jumpers for the configuration “on field” are shown in the following table Jumper J1 Pos Function 1-2 SINGLE-PHASE inverter 2-3 THREE-PHASE inverter J2 Closed Back-up battery connected J7 Closed Watchdog enabled J9 Closed Resistor R40 (100R) inserted J10 Closed Resistor R39 (47R) inserted J100 Closed Resistor R18 (22R) inserted I/S-CL card – Settings and controls POTENTIOMETERS P1 Regulation of the inverter voltage in MANUAL mode P2 Regulation of the current signal (TP2) CONTROL LED COLOUR D3 “Current stop” protection RED D8 Short circuit protection RED D11 Presence of the analogue part’s supply (+12V) GREEN D69 Presence of the digital part’s supply (+5V) GREEN Protections and controls of the SW program The software program provides for the control of the UPS functionality basing on the instructions assigned The setting of the I/S-CL card’s dip switches gives the program the main indications to define the control and protection thresholds The two most important controls, for the purpose of the inverter bridge and load protection, will be defined in detail Control of the output and bypass waveforms Overload protection (Thermal image) Waveform control The control is based on the sampling of the sine-wave and the subsequent comparison of the samples with a reference value The sine-wave is sampled 36 times in a period The RMS value of the sine-wave is calculated using the samples obtained, and compared with the minimum and maximum thresholds defined in the software Each of the 36 samples (Vsn) is also compared with values contained inside reference tables (VtL/VtH) so that the following disequations are satisfied VtL1< Vs1< VtH1 ; VtL2< Vs2< VtH2 ; …. ; VtL36< Vs36< VtH36 The tables are part of the program and are downloaded in the RAM at each start-up of the program itself If 4 consecutive samples of one of the phases don’t satisfy the comparison the voltage is declared out of tolerance Overload protection The overload protection is also called “Thermal image” because it’s indeed based on the calculation of the energy stored during the overload operation The overload is defined when at least one of the output currents exceed the 100% of the nominal value As soon as a overload is detected the program starts to take samples of the output current, calculating the integral I2t The value of the integral (energy accumulation) is compared with a limit value, equal to the overload capability of the equipment (125% In x 10 minutes) When the limit is reached the program stops the inverter and the load is transferred to bypass (if available) The inverter is switched on again after 30 minutes General data Inverter & Static switch Technical features User interfaces Rectifier Test software User interfaces The UPS is provided with two serial ports and a optional relay card for the interface with the external world The serial port RS485 is used only for the connection with the remote panel The serial port RS232 is used for the interface with software applications and transmits all the UPS data through a proprietary protocol The relay card ARC provides the indication of a operating status and 3 alarms, that can be modified only by changing the software on board the microprocessor card The most important user interface is however the LCD panel, that makes the UPS operating parameters (measures, status and alarms) immediately available to the user LCD panel The LCD panel is the graphic interface of the microprocessor, and provides at each instant the indication of the UPS operating parameters The mimic on the left aids the comprehension of the energy flux and provides the immediate display of possible anomalies The display is basically a passive component, except for some basic functionalities that allow the active interface with the microprocessor LCD panel – Measures The measures available on the LCD panel are the same described before for the microprocessor card I/S-CL OUTPUT measures Voltage of the three phases (measure Ph-N) Frequency Current of the three phases (phase current) Percentage of load on each phase BYPASS measures Voltage of the three phases (measure Ph-N) Frequency INVERTER measures Voltage of the three phases (measure Ph-N) Frequency LCD panel – Measures DC measures Inverter input voltage BATTERY measures Battery voltage Battery type (autonomy in Ah) Battery current * Battery residual autonomy (in minutes) * Battery residual autonomy (in percent) * * The data indicated with asterisk are active only with the battery in discharge mode The menu relevant to the battery measures is automatically activated in case of mains failure and battery discharging LCD panel – Status and alarms The software program is able to process the information relevant to 6 different operating status and 25 alarms, defined by means of alphanumeric codes Each alarm is associated with an internal protection, controlled by the microprocessor, that disabled certain UPS functions in order to avoid possible loss of supply to the load The alarm codes are stored in the event log (history log) The history logs the event, that is both the alarm and its automatic reset (if any), indicating the reset with a star next to the code Besides the alphanumeric code of the alarm, the history log indicates date, hour and minute of the event LCD panel – Status Cod. Name Description S1 AC/DC OK Rectifier output voltage within tolerance S2 BATTERY OK Battery connected to the DC bus S3 INVERTER OK Inverter voltage within tolerance S4 INVERTER SYNC Synchronism reference within tolerance S5 INVERTER LOAD Inverter static switch closed, load on inverter S6 BYPASS OK Bypass voltage and frequency within tolerance LCD panel – Alarms Cod. Name Description A1 MAINS FAULT Rectifier input mains failure A2 CHARGER FAULT Battery charger failure A3 RECT FUSE One or more rectifier fuses are blown A4 THERMAL IMAGE Load transferred to mains due to overload. A5 AC/DC FAULT Rectifier output voltage out of tolerance A6 INPUT WR SEQ Input phase rotation not correct A7 BCB OPEN Battery circuit breaker open A8 BATT DISCH The battery is discharging A9 BATT AUT END Battery autonomy (calculated) has expired A10 BATT FAULT Battery test failed or intervention of the safety timer during boost charge A11 BATT IN TEST Battery test in progress A12 PLL FAULT Problems system A13 INV OUT TOL Inverter output voltage out of tolerance with the digital synchronisation LCD panel – Alarms Cod. Name Description A14 OVERLOAD Inverter overload (load exceeding 100%) A15 BYP FAULT Emergency mains not available A16 BYP FEED LOAD Load fed by bypass A17 RETR BLOCK Transfer between bypass and inverter blocked A18 MBYP CLOSE Manual bypass breaker closed A19 OCB OPEN UPS output breaker open A20 FANS FAILURE Optional A21 HIGH TEMP High temperature on the inverter and/or rectifier bridge A22 BYP SWITCH Closure of the commutation switch which forces the load to bypass (maintenance) A23 EPO BUS Intervention of the emergency power off switch according to the EN62040-1 A24 CURR STOP Inverter bridge stop for max current A25 SHORT CIRCUIT Intervention of the short circuit protection LCD panel – Commands The LCD panel is provided with a section through which it’s possible to carry out some simple functional test The section can be accessed through the menu SPECIAL SETTINGS Section for the setting of the local date and time UPS TEST Static switch commutation test The inverter is stopped and the load transferred to bypass BATTERY TEST The battery test is carried out reducing the rectifier voltage for 30 seconds If the voltage reaches the pre-alarm level, the alarm “A10 – Battery fault” is activated RESET HISTORY Section for deleting the events log General data Inverter & Static switch Technical features User interfaces Rectifier Test software “UPSTest” software The UPSTest software is used to verify the UPS’ operating parameters Besides it offers the possibility to control the software program’s flux so that to identify possible anomalies Refer to the technical documentation for further information about the software settings and the relevant commands It’s divided in the following main sections: Measures UPS data Variables Outputs Inputs Alarms Status “UPSTest” software “UPSTest” software Section MEASURES The section MEASURES shows all the voltages and currents acquired by the microprocessor Section ALARMS The section ALARMS shows all the alarms managed by the microprocessor, that are the same displayed by the LCD panel Section STATUS The section STATUS shows all the operating status managed by the microprocessor, that are the same displayed by the LCD panel “UPSTest” software Section UPS DATA The section UPS DATA shows all the UPS’ nominal data, that are generally set by changing the position of the dip switches of the I/S-CL UPS’ nominal data, depending on the position of the dip switches of the I/S-CL card Battery data, adjustable through software commands Voltage thresholds settings, fixed and not adjustable if not changing the UPS’ control software Tolerance limits of the bypass frequency, adjustable through software commands Display of the residual battery autonomy “UPSTest” software Section VARIABLES The section VARIABLES shows all the software variables, used to guarantee the correct operation of the system Each variable operates on a certain section of the UPS, so they can be divided in 4 different groups: • • • • Variables relevant to the DC section Variables relevant to the INVERTER section Variables relevant to the BYPASS section Variables relevant to the USCITA section The activation of a variable is indicated by a blue background “UPSTest” software Section VARIABLES DC Variables VDC_OK INVERTER Variables INV_ON SSW_ON IOK IFL CONAC O_LOAD HITE VUOK SYNCOK IMTERM BYPASS Variables ROK_X FROK RMSOK USCITA Variables COK I_OVER “UPSTest” software Section VARIABLES VDC_OK • It indicates that the INVERTER INPUT voltage is in tolerance, that is within the limits specified in the section UPS Data VDC INV_ON • It’s the command for the inverter start-up, that is managed by the microprocessor during the AUTOMATIC operating mode, or by software command in MANUAL mode SSW_ON • It’s the command for the inverter static switch IOK • It indicates that the inverter is ready to supply the load IFL • It indicates that the inverter static switch is closed CONAC • It’s the variable managing the modulation command for the inverter bridge IGBTs “UPSTest” software Section VARIABLES O_LOAD • It indicates the inverter stop following an extended overload (intervention of the thermal image protection) HITE • It indicates the intervention of the inverter bridge thermal protection • The thermal protection can also be constituted by the series of different protections (inverter bridge, rectifier bridge, transformer, etc.) VUOK • It indicates that the INVERTER voltage is in tolerance, that is within the limits specified in the section UPS Data INV SYNCOK • It indicates the correct generation of the inverter-bypass synchronism signal IMTERM • It indicates the activation and the operation of the thermal image counter “UPSTest” software Section VARIABLES ROK_X • It’s the “AND” combination of the variables FROK and RMSOK FROK • It indicates that the BYPASS frequency is in tolerance, that is within the limits specified in the section UPS Data RMSOK • It indicates that the BYPASS voltage is in tolerance, that is within the limits specified in the section UPS Data BYP COK • It indicates that the OUTPUT voltage is in tolerance, that is within the limits specified in the section UPS Data OUT • The variables RMSOK and COK indicates that the waveforms are correct and without particular distortions (see the “waveform control” carried out by the microprocessor) I_OVER • It indicates that the output current exceeds the nominal value (overload) “UPSTest” software Section OUTPUTS The section OUTPUTS shows all the commands generated by the microprocessor for the management of the various UPS sections “UPSTest” software Section OUTPUTS COK • It’s the command relevant to the variable COK, and is managed by the static switch control logic (SCB card) BY_BL • It’s the command that blocks the load on bypass, disabling the re-transfer of the static switch on inverter IFL • It’s the closing command of the inverter static switch CONAC • It’s the command relevant to the variable CONAC and represents the real consent for the inverter bridge modulation OVERLOAD • It’s the command relevant to the variable O_LOAD and represents the inverter stop command following an extended overload “UPSTest” software Section OUTPUTS RES_RITR_BL • It’s the command that unlocks the static switch after a re-transfer block R3_INV_FEED • It’s the command of the relay RL3 • E’ il comando del relè RL3 (load supplied by inverter) of the alarm card ARC R4_BYP_FEED • It’s the command of the relay RL4 (load supplied by bypass) of the alarm card ARC R5_LOW_BATT • It’s the command of the relay RL5 (battery low – pre-alarm) of the alarm card ARC R6_MAINS_FAU • It’s the command of the relay RL6 (rectifier mains failure) of the alarm card ARC “UPSTest” software Section INPUTS The section INPUTS shows the status of all the microprocessor’s digital inputs “UPSTest” software Section INPUTS MBY_CLOSE • When active, the switch MBCB (manual bypass) is closed EPO_BUS • When active, the UPS stop by EPO is not enabled BO_BUS • When active, the switch BCB (battery) is open BYP_SW (FUSE) • When active, the bypass switch (commutation test) is active TERMO_SW • When active, the thermal protection on the bridges has operated OCB • When active, the switch OCB (UPS output) is closed MCS • When active indicates the Current stop protection has operated “UPSTest” software Section INPUTS MRR • When active, the mains failure signal, originated by the rectifier card, is not active RECT_FAIL • When active, the rectifier failure signal, originated by the rectifier card, is not active ERR_SC • When active, the wrong phase sequence signal, originated by the rectifier card, is not active BF_RECT • When active, the fuses failure signal, originated by the rectifier card, is not active PUL_XX • These variables indicates the push button on the LCD panel have pressed “UPSTest” software Additional sections UPS serial number (set by software command) and software version installed on board the I/S-LC card TXCheck: transmission check (cyclic increment) PACKT: number of the data packets received Section to digit software command strings Flag MASTER/SLAVE for the parallel operation Inverter/bypass synchronisation data Battery charge percentage Increment of the thermal image counter “UPSTest” software Sezioni aggiuntive KF BY: position of the bypass voltage’s control table KF OU: position of the output voltage’s control table Panel for the fast setting of the display’s language Dip Sw: it opens a panel that shows the setting of the dip switches in the I/S-CL card Par Data: it opens a panel that shows the control parameters during the parallel operation BOOST: it opens a panel that shows the current thresholds for the BOOST charge operation Set Date: it sets the date and time on the display (see menu special, SETTINGS) in function of the date and time set in the PC’s operating system End of the presentation