401985

Contents of JUE 401985
UPS E-2001 Service Manual

This Service Manual consists of the following documents:
1. 2. 3. 4. 5. 6. 7. 8. 9.
SAFETY INSTRUCTIONS GENERAL SYSTEM DESCRIPTION INSTALLATION AND INITIAL START-UP OPERATION FRONT PANEL CONTROL LOGIC TROUBLESHOOTING TECHNICAL DATA PCBs SCHEMATICS
Pag.
2 3 8 14 20 27 64 80 82
Issued See rev. doc. JSE401923
22.12.98 05.11.98
F. Fabbri F. Fabbri G. Pisellini
22.12.98
A4
82
22.12.98
JUE401985
UPS E-2001 - Service Manual
1. Safety Instructions
1.1 SAFETY INSTRUCTIONS
The unit must be used as intended. Follow the instructions given in the Operating Manual.
Dangerous voltages are present inside the unit.
Installation and use of this equipment must comply to all national and local regulations and procedures.
To prevent overheating do not obstruct the flow of air for ventilation openings to the unit.
The components inside the unit are not repairable by the user. The user must not open the equipment cabinets or remove any protective covers from inside the cabinets.
This equipment must be installed and serviced by qualified personnel.
To completely isolate the equipment, the input, putput and battery (if preset) switches must be switched off.
Connect protective earth before power supply cables.
Earth leakage protection: this device may have a high leakage current towards protective earthing. When setting the threshold of the earth leakage circuit breaker installed upstream from this equipment consider this amount of current and that due to the loads.
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2. General System Description
Chapters
1 UPS ASSEMBLY
1.1 1.2 1.3 1.4 1.5 1.6 1.7 Features UPS System Structure Rectifier/Battery Charger Battery (Accumulator) Inverter Static Switch Unit Maintenance Bypass 4 5 5 5 6 6 7
Pictures
PIC. 1.1 UPS Block-Diagram PIC. 1.2 Rectifier Block-Diagram PIC. 1.3 Inverter Block-Diagram PIC. 1.4 Static Switch Block-Diagram
5 5 6 6
PIC. 1.5 Maintenance Bypass Block-Diagram 7
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1 UPS ASSEMBLY 1.1 Features
UPS Function The uninterruptible power supply (UPS) is connected between the consumers equipment or installations (the load) and supply mains. Its function is to guarantee a continuous and conditioned power supply to the load. Even in the case of a total black-out it will supply the load for a predetermined time (autonomy time). In addition, the UPS provides the following advantages in comparison with conventional supply systems (mains, motor generator sets, etc.): The UPS output voltage frequency and amplitude control guarantee consistent and stabilized output power. Mains voltage fluctuations and frequency changes that are usually present in electricity supply systems do not affect the UPS output voltage. By using double energy conversion from ac to dc and back to ac, all mains distortions are filtered out. Therefore, each unit connected to the UPS system is protected against mains distortions that are usually present in industrial electricity supply systems. This is especially important for sensitive electronic devices, e.g. computer systems. During long term or short term ac mains supply interruption, the UPS system guarantees continuous load supply by means of a battery. The battery is connected to the rectifier and the inverter of the UPS system. In normal operation the inverter (which feeds the load) is fed by the rectifier. In case of a mains failure, the battery feeds the inverter. Thus the load is supplied without interruption. However, the load can only be supplied by the battery for a certain time. If longer autonomy times are required, we recommend the use of a Diesel Generator Set. In this case the battery autonomy time only has to be sufficient for the time span between mains failure and full operating capacity of the Diesel-Generator-Set.
Better Output Power Characteristics
Uncoupling from Mains Distortion
Complete Protection against Mains Failures
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1.2 UPS System Structure
The basic E-2001 power supply unit is an ac/dc/ac converter; the block diagram Figure 1.1 illustrates six essential functional components: Rectifier/battery charger (6 pulse) (GR) Battery (B) Inverter (WR) Static inverter switch (SW) Static bypass (SB) Maintenance bypass (QIBY) All components are located in a single housing. They are explained in detail on the following pages.
QIRA
1.3 Rectifier/Battery Charger

The charger is a three phase/6 pulse rectifier that converts ac voltage to dc voltage. An isolation transformer and a commutation choke is used at the input of the rectifier bridge. The dc output of the rectifier feeds the inverter and the battery. The battery is connected to the rectifier through a saturation choke which reduces ac ripple current to the battery, thus increasing on the battery life. The rectifier is designed to feed both the inverter at maximum load conditions and simultaneously the battery with maximum charging current. The rectifiers recharge characteristic is of the I/ U type. This means that the recharging current limitation is accomplished by reduction of the dc voltage according to a specified curve, thus assuring that the batteries will not be damaged by excessive charging current values.
QIRP
1.4 Battery (Accumulator)

The battery supplies power in case of a short interruption or a total breakdown of the ac mains source. In case of a rectifier failure (no dc voltage output), the load will be fed by the battery. The battery is only capable of feeding the load for a certain time (autonomy time), depending on battery capacity and actual load. The number of cells within the battery depends on the battery type and may also vary due to specific customer requirements.
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1.5 Inverter
The inverter converts dc voltage supplied by the rectifier or battery to ac voltage of precisely stabilized amplitude and frequency that is suitable for power supply to most sophisticated electrical equipment. The inverter output voltage is generated by pulse width modulation (PWM). The use of a high clock rate for the PWM and a dedicated ac filter circuit consisting of the transformer and capacitor, assure a very low distortion of the output voltage (THD<3%). The inverter control logic restricts the maximum output current to 150% of the nominal current in case of a short circuit. In case of overload (up to 125% of the nominal current), the output voltage is kept constant. For higher currents the output voltage is reduced. However, this will only occur if the static bypass is not available; otherwise the UPS will switch to bypass operation for currents higher than 125% of the nominal current. The inverter transistors are fully protected from severe short circuits by means of a saturation monitor or electronic fuse.
1.6 Static Switch Unit

The block diagram illustrates the two static switch units that use thyristors as switching elements. During normal UPS operation, SW is closed and SB is open, thus connecting the load to the inverter output. During overload or inverter failure conditions, SW is switched off and SB is switched on, providing power supply from a backup source (mains, output of another UPS system, diesel generator set....). By always actuating both switches together for a short period, an uninterrupted power supply during the switching is ensured. This is an essential condition to reliably meet all power supply requirements for connected sensitive equipment.
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Switching Conditions, Inverter - Bypass a) Voltage and frequency of the bypass line have to be within tolerance limits, and the inverter has to be synchronized with the bypass line. b) Under overload or inverter failure conditions, the UPS switches to bypass operation. c) If the conditions under a) are not met,
- the inverter continues to operate with reduced output voltage under overload conditions, or - the inverter stops under inverter failure conditions.
Switching Conditions, Bypass - Inverter a) The UPS switches automatically back to inverter operation when inverter voltage and frequency are within tolerance limits and the inverter is synchronized with the bypass line. b) In the case of a remaining overload condition the inverter might not be able to take the load and the UPS will switch back to bypass operation. c) After three unsuccessful attempts within 3 minutes to switch to inverter operation, the UPS remains in bypass operation and signals an alarm. d) After pressing RESET, the UPS automatically tries again to switch back to inverter operation.
1.7 Maintenance Bypass

The maintenance bypass function is to supply power directly to the connected load during UPS system failure or maintenance. The bypass consists essentially of one make before break c.o. switch QIBY. With E-2001 series UPS systems, commutation from different operating modes to maintenance bypass will take place without interruption. With the maintenance bypass on, the power supply system may be completely switched off, thus permitting maintenance work to be carried out safely ( there is only voltage at the input and output terminals and their connections to the by - pass c.o. switch).
QIRA
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3. Installation and Initial Start-Up
Chapters
1 INSTALLATION
1.1 1.2 Mechanical Installation Electrical Installation 9 11
Pictures
PIC. 1.1 - Moving the UPS PIC. 1.2 - UPS Floor space PIC. 1.2 - UPS Room size
9 10 10 11
INITIAL START - UP
2.1 Start Up Procedure 12
PIC. 1.2 - UPS connection diagram
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1 INSTALLATION 1.1 Mechanical Installation
Equipment Delivery and Storage After delivery, check equipment for damages that may have occurred during shipment. If you do not wish to install the equipment immediately, please observe the following storage recommendations: Store equipment in a vertical position in a well conditioned room, protected against humidity. Do not store the equipment in close proximity to frequently used passageways and keep it away from movable parts. If the UPS system is already unpacked, please ensure storage in a clean environment protected from dust, away from heat sources. The UPS can be lifted and moved by means of a lifting truck or a fork lifter. Remove front side and rear side base sheets. The UPS can now be moved with a lifting fork. Caution : Secure equipment against being knocked over
Handling the UPS System
PIC. 1.1 - Moving the UPS
Setting Up
The UPS system should be installed in a dry, clean and lockable room. Provisions have to be made to remove heat created by the system. Under all installation conditions, the unrestricted flow of cooling air must be assured.
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PIC. 1.2 - UPS floor space (base only - without side panels)
PIC. 1.3 - UPS room size
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1.2 Electrical Installation
This equipment must be installed by service personnel. Switch off QIRP, QIRA, QIB and put QIBY c.o. switch in normal position. All primary power switches installed remote from the UPS area will be fit with the following label: "Isolate uninterruptible power supply (UPS) before working on this circuit". General All electrical connections must be made in accordance with local standards and all input terminals must be protected by external fuse switch or circuit breaker. If possible, install battery cables separately from other power cables in order to avoid possible RF interference. Before wiring, open all system switches.
QIRA
PIC. 1.4 - UPS connection diagram
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2 INITIAL START-UP 2.1 Start Up Procedure
General With the Start Up procedure the correct installation of the UPS according to chapter 1 is checked. It must be carried out by specialized personnel. Safety precautions according to the national safety standards must be applied. For direct control of current, voltage, UPS output power and UPS operating status by the DATA MONITOR PANEL, refer to section 5. Should problems arise during the Start Up Procedure, call for service assistance. For carrying out the Start Up Procedure you need a 3 digit voltmeter with 1% accuracy, a DC clip-on ammeter, a large screwdriver for the terminals and a small screwdriver for potentiometers. The installation of the UPS must have been carried out according to chapter 1. Check that the ventilation system of the UPS room is ready to operate. Check that all switches QIRP - QIRA - QIB are open Check that QIBY c.o. switch is in normal position Switch on the external mains supply to the UPS. Check that the supply voltage at terminals X1.1, X1.2, X1.3 is within 10% of the UPS rated voltage. Close QIRP. ? Is LED LSC on the RPD board continually illuminated? no Open QIRP, switch off the external mains supply and reconnect the three phases of the external mains supply to input terminals X1.1, X1.2, X1.3, observing the phase rotation. Return to A. The rectifier supply voltage is o.k. and the rectifier and inverter automatically start to operate. Wait until the Data Monitor Panel is illuminated (the panel automatically executes a self-test). Make sure that the batteries have been installed according to the instructions in chapter 1.
Preparation
A: Rectifier Power Supply Check
yes
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Measure the battery voltage in the battery terminals XB+.1 / XB-.1:
? Does this voltage have a correct polarity? no Open QIRP, wait for 2 minutes, and then reconnect the battery cables at the terminals which lead to the switch(es) where the wrong polarity was detected. Return to B. Close QIB circuit breaker. Check that QIBY c.o. switch is in normal position.
yes
C: Bypass Power Supply Check
Switch on the external supply for the bypass. Close QIRA. ? Is the green status LED "Emergency Line" on the operating panel on?
no
Check the voltage of the static bypass supply. Return to C. The start-up procedure has been successfully completed now.
yes
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4. Operating Modes
Chapters
1 OPERATING MODES
1.1 1.2 1.3 1.4 1.5 General Normal Operation Battery Operation Bypass Operation Maintenance Bypass Operation 15 16 16 16 16 PIC. 1.1 PIC. 1.2 PIC. 1.3 PIC. 1.4
Pictures
Normal Operation Battery Operation Bypass Operation Maintenance Bypass Operation
16 16 16 16
OPERATING INSTRUCTIONS
2.1 2.2 2.3 Switching On Switching Off Manual by-pass 17 18 18
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4. Operating Modes
1 OPERATING MODES 1.1 General
The standard on-line UPS-system composes of four different operating modes to ensure the uninterrupted power supply of the load under various conditions. Transitions between these operating modes are performed without interruption of the power supply to the load. Safety concept in "Normal Operation" any failure, internal or external, will transfer the UPS system either to "battery operation" or to "bypass operation". in "Battery Operation" or "Bypass Operation" an additional failure may interrupt the power supply to the load, depending on the kind of failure. In both operating modes the UPS signals a failure condition (audible and visual alarm) to indicate that any additional failure bears the risk of interrupting the power supply to the load. "Maintenance Bypass Operation" is used to supply the load directly from mains during maintenance or repair work.
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4. Operating Modes
1.2 Normal Operation
"Normal Operation" is the standard operating mode of the UPS Mains power is present. The rectifier converts ac power to dc power which charges the batteries and feeds the inverter. The inverter converts this dc power to ac power used to feed the connected load.
QIRA
1.3 Battery Operation

The "Battery Operation" mode is activated by a mains failure or rectifier failure The rectifier supplies no power. The battery supplies the required dc power to the inverter. The inverter supplies ac power to the load as described above. Power will only be supplied to the load for a certain period of time depending on the battery capacity.
QIRA
1.4 Bypass Operation

The "Bypass Operation" mode is activated by an inverter failure or overload The rectifier supplies dc power only to the battery. The static inverter switch SW opens automatically after the static bypass switch SB is closed. The load is supplied directly from mains through the static bypass.
QIRA
1.5 Maintenance Bypass Operation

The "Maintenance Bypass Operation" mode is used to supply the load directly from mains during maintenance or repair work. In this mode, the individual functional components are completely separated from the load (e.g. for maintenance work). Power for the load is supplied directly from mains through c.o.switch QIBY.
QIRA
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4. Operating Modes
2 OPERATING INSTRUCTIONS 2.1 Switching On
Initial UPS Operating Mode:
QIRA
The UPS is switched off, the load is not supplied, and all power switches are open.
Operating Steps: Switch on the external mains supply for the UPS. Open the UPS front door. Close QIRP switch. The UPS performs a self-test and the rectifier and inverter start automatically. Wait until the front panel is illuminated. Close QIB switch. Close QIRA switch.
Final UPS Operating Mode: The UPS is now in normal operation mode, as described in chapter 1.2. The green LEDs "LINE", "UPS ON" and "EMERGENCY LINE" on the front panel must be illuminated.
QIRA
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4. Operating Modes
2.2 Switching Off
Initial UPS Operating Mode: The UPS is in any operating mode described in chapter 1. All power switches are closed, and the load is fed either through the inverter or the static bypass.
QIRA
Operating Steps: Make sure that the green LED "EMERGENCY LINE" is illuminated (i.e. the bypass supply voltage is ok). Open QIRA switch. Open QIB switch.
QIRA
Open QIRP switch. After opening the QIRP switch the display is only powered by the DC capacitors and will fade out within a few seconds.
2.3 Manual by-pass operation

2.3.1 From normal operation to manual by-pass
Initial UPS Operating Mode: The UPS is in any operating mode described in chapter 1. All power switches are closed, and the load is fed either through the inverter or the static bypass. Operating Steps: Make sure that the green LED "EMERGENCY LINE" is illuminated (i.e. the bypass supply voltage is ok). Open QIB switch. Open QIRP switch. After opening the QIRP switch the display is only powered by the DC capacitors and will fade out within a few seconds. The inverter stops and the UPS automatically transfers to bypass operation without interruption. Move QIBY switch to I + II position The load is now supplied by the static bypass and the maintenance bypass in parallel. Move QIBY switch to II position.
QIRA
QIRA
Now the load is only supplied by the maintenance bypass. Final UPS Operating Mode: The UPS is now shut down. The load is supplied directly from the mains supply via the maintenance bypass.
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4. Operating Modes
Attention! Although the load is no longer supplied by the UPS, there is still voltage at QIRA, the inputs of QIRP, QIB and at the respective terminals.
2.3.2 From manual by-pass to normal operation

Initial UPS Operating Mode: The UPS is supplied via maintenance by pass.
QIRA
Operating Steps: Close QIRP switch. The UPS performs a self test and the rectifier and inverter start automatically. Wait until the front panel is illuminated Close QIB switch. . Move QIBY switch from II to I + II position Attention! Wait until the inverter is synchronized with the emergency line (Led LSOK on IWM-3 card must be lit on) Move QIBY switch to I position.
QIRA
Final UPS Operating Mode: The UPS is in normal operation as described in chapter 1.2.
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5. Front Panel DME/S
Chapters
1 FUNCTIONS
1.1 1.2 1.3 1.4 1.5 1.6 1.7 General Measurements Protective Functions UPS Operating Mode Indication Alarm signalling AS 400 Interface Remote Monitoring 22 22 22 23 23 23 23
Pictures
PIC. 1.1 - E 2001 front panel DME/S PIC. 1.2 - METERS Display PIC. 1.3 - UPS block diagram PIC. 1.4 - Alarm LEDs PIC. 2.1 - Setting of SW1 PIC. 2.2 - Setting of SW2 PIC. 2.3 - Setting of SW3
21 - 22 22 23 23 24 25 25
PANEL SETTINGS
2.1 2.2 DIP Switch Settings Measurement Adjustment 24 26
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1 FUNCTIONS
PIC. 1.1 - E 2001 Front Panel DME/S
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1.1 General
The front panel DME/S is the user-interface of the UPS. It is a microprocessor controlled panel and it provides the following functions: Alarms are indicated by red LEDs in the upper line of the display. Measured values are shown in the METERS display. The UPS status (operating mode) is indicated by LEDs in the block diagram of the UPS. Remote monitoring options via RS232 and RS485 interface
1.2 Measurements
The measurements are shown in the "METERS" display. The actual measurement is indicated by a green LED. The various measurements can be selected by pressing the "PUSH" button in the "METERS" display. The following values can be shown in the "METERS" display: Battery voltage Output voltage Output current UPS output load % Output frequency
1.3 Protective Functions

BACK UP The "BACK UP" alarm indicates that only a certain time of the battery autonomy is left. The red LED "BACK UP" lights up and the alarm buzzer beeps. The static switch is blocked after three unsuccessful attempts to switch back to inverter operation. In this case there is either an inverter failure or an overload condition, the red LED above the right RESET push-button is lit. After resolving the problem, the static switch can be reset by pressing the RESET push-button at the right side.
Static Switch Blocking
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1.4 UPS Operating Mode Indication
On the front panel a block diagram of the UPS is shown. The operating mode of the UPS is indicated with LEDs integrated into the block diagram: LINE: Voltage and frequency of the mains supply are within tolerance limits. EMERGENCY LINE: Voltage and frequency of the static bypass supply are within tolerance limits. UPS ON: The load is supplied by the inverter. BYPASS: The load is supplied by the static bypass. MANUAL BYPASS: The maintenance bypass switch QIBY in by-pass position
1.5 Alarm signalling

Alarms are signalled by the front panel optically and acoustically: One or more of the red alarm LEDs light up. The integrated buzzer signals an alarm by beeping. The buzzer can be muted by pressing the left RESET button at the front panel. The available alarms are: Mains failure: voltage and/or frequency of the mains supply are out of the tolerance limits. Battery discharge: the battery is feeding the load (led flashing); when the battery autonomy time has almost expired the relevant led light-on Inverter failure: the inverter output voltage is out of the tolerance limits.
1.6 AS 400 Interface

The front panel features an integrated UNIX - NOVELL - LAN AS 400 interface for remote signalling with voltage-free contacts. The provided messages are: Load fed by inverter. Load fed by static bypass. Battery OK. Mains supply OK. UPS output voltage OK.
1.7 Remote Monitoring

The front panel offers the possibility to communicate with a computer through RS232 and RS485 interfaces. With the RS232 and RS485 interfaces it is possible to transmit all the necessary data up to a distance of 400m (RS485).
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2 PANEL SETTINGS 2.1 DIP Switch Settings
With the DIP switches SW1 and SW2 and SW3 at the back of the front panel, the operation parameters can be set according to actual conditions and desired functions. The setting of the DIP switches is explained in the tables FIG. 2.1 to FIG. 2.3. The meaning of the various settings is explained below (shown for version 4.0.2 software).
DIP Switch SW1
Dip 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1
Dip 2 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1
Dip 3 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1
Dip 4 0 0 0 0 0 0 0 0 1 0 1 1 1 1 1 1
NOMINAL POWER
Nominal Power: The nominal

output power of the UPS in kVA.
5 kVA 10 kVA 15 kVA 20 kVA 25 kVA 30 kVA 40 kVA 50 kVA 60 kVA 80 kVA 100 kVA 120 kVA 150 kVA 200 kVA 250 kVA 300 kVA
CURRENT TRANSFORMER
Current Transformer: The

trasformation ratio of the UPS output current transformer
Dip 5 0 1 0 1 DIP 7 0 1 DIP 8 0 1
Dip 6 0 0 1 1
100 200 400 600
Output: For E-2001 UPS systems

OUTPUT A.L.
ONE PHASE THREE PHASE
output has to be set to single phase.
Power Factor: Selectable for

UPS output load % calculation in reference to the loads power factor.
COS
0,8 1
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DIP Switch SW2
DIP 1 0 1
THERMAL FIGURE
ON OFF
NON INFLUENCE THERMAL FIGURE Minutes Seconds SEC PROTOCOL START UP/ SHUTDOWN OFF
Thermal figure inverter protection against overloads. Attenction: the

intervenction of thermal image cause the inverter cut - off
DIP 2
DIP 3 0 1
Thermal figure: select seconds

only for test
DIP 4
1 DIP 5, 6, 7 0 1 0 1 0 1 0 1 0 0 1 1 0 0 1 1 DIP 8 0 1 0 0 0 0 1 1 1 1
ON NOMINAL INPUT VOLTAGE 415 200 525 480 440 400 380 208 NOMINAL INPUT FREQUENCY 50Hz 60Hz
DIP Switch SW3
DIP 1 0 1 DIP2 0 1
PANEL TYPE
Panel type: for E2001 UPS system select Engineering
Engineering Standard
MANUFACTURER
BORRI
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2.2 Measurement Adjustment
At the front panel, the read-outs of the following measurements can be controlled and adjusted: Battery voltage UPS output voltage UPS output current UPS output current offset Preparation
Connect an AC voltmeter with 1% accuracy to the inverter output between phases R and N. Connect an AC clip-on ampmeter to phase R (true RMS measurement). Set switch 7 of SW2 to ON (manual measurement mode). Switch on the UPS. Press the "PUSH"-button below the METERS display until the green LED corresponding to OUTPUT CURRENT lights up. If the displayed current is not zero, adjust it to zero by turning the potentiometer RV5 at the back of the front panel. Move QIBY to normal position Apply nominal load to the UPS output If the current measured with the AC clip-on ampmeter does not correspond to the displayed current, adjust it by turning the potentiometer RV4 at the back of the front panel. Press the "PUSH"-button below the METERS display until the green LED corresponding to OUTPUT VOLTAGE lights up. If the voltage measured with the AC voltmeter does not correspond to the voltage shown in the METERS display, adjust the displayed voltage by turning the potentiometer RV3 at the back of the front panel. Connect a DC voltmeter to the battery terminals between B+ and B-. Press the "PUSH"-button below the METERS display until the green LED corresponding to BATTERY VOLTAGE lights up. If the voltage measured with the DC voltmeter does not correspond to the voltage shown in the METERS display, adjust the displayed voltage by turning the potentiometer RV2 at the back of the front panel. Set switch 7 of SW2 to OFF (automatic measurement mode).
Current Offset Adjustment
Output Current Read-out Adjustment
Output Voltage Read-out Adjustment
Battery Voltage Read-out Adjustment
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6. Control Logic
Chapters
1 RECTIFIER CONTROL LOGIC
1.1 1.2 1.3 Functional description RPD Card RVR41773 Card 28 32 35
Pictures
PICT. 1.1 - Rectifier subsystem - Block diagram (1 of 2) PICT. 1.2 - Rectifier subsystem - Block diagram (2 of 2) PICT. 1.3 - RPD Block diagram
30 31 33 34 37 38 41 42 45 46 48 49 51 52 53 56 57 59 60 62 63
INVERTER CONTROL LOGIC

2.1 2.2 2.3 2.4 2.5 Functional description IST Card IWM-3 Card IPS Card IGD Card 39 43 47 50 53
PICT. 1.4 - RPD Front view PICT. 1.5 - RVR41773 Block diagram PICT. 1.6 - RVR41773 Front vew PICT. 2.1 -Inverter subsystem - block diagram (1 of 2) PICT. 2.2 -Inverter subsystem - block diagram (2 of 2) PICT. 2.3 -IST - Block diagram
STATIC SWITCH CONTROL LOGIC

3.1 3.2 3.3 Functional Description SCLT Card SPT Card 54 58 61
PICT. 2.4 -IST - Block diagram PICT. 2.5 -IWM-3 - Block diagram PICT. 2.6 -IWM-3 - Front view PICT. 2.7 -IPS - Block diagram PICT. 2.8 -IPS Front view PICT. 2.9 -IGD - Block diagram PICT. 3.1 -Static switch subsystem - Block diagram (1 of 2) PICT. 3.2 -Static switch subsystem - Block diagram (2 of 2) PICT. 3.3 -SCLT Block diagram PICT. 3.4 -SCLT Front view PICT. 3.5 -SPT Block diagram PICT. 3.6 -SPT Front view
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6. Control Logic
1 RECTIFIER CONTROL LOGIC 1.1 Functional description of Rectifier
With reference to the block diagram shown in pict. 1.1 - 1.2, the description of the rectifier system is specified as follows : - The three-phase voltage of the supply mains (R,S,T) reaches SCR's TH1TH6 of the rectifying bridge by closing switch QIRP through F1F3. Such SCR's are put into conduction by the control signals supplied by the SCR drive placed on card RPD, processed by pulse transformers TR1TR6 of Rect. tyr. firing card. Mains voltage (R,S,T) reaches also card YY Sync & supply through cable W13 and it is reduced fro 380V to 22V by transformers TR1TR6 and sent through W5 to card RPD (GR, GS, GT) where it is rectified by diodes D1D6. The outputs of diodes are finally used to carry out a number of controls on mains voltage, in order to supply the startup consent to the rectifier and to generate +12V and +24Vservice voltage. In addition, following controls are carried out on RPD card: the cyclic sense of phases, the possible absence of one phase, the voltage which should not be lower than 75% of rated value and the status of rectifying bridge fuse. In case the first three checks specified are carried out successfully, the "Startup Consent" logic generate signal 0CA which enables the operation of RVR 41773 and generates signal 1ROK which enables the formation of +24V to feed the loads. The functions controlled on RPD are monitored through the leds placed on the card front and through the alarms shown on the front panel DME/S. Signals GR - GS - GT are also sent to the logic generating the conduction angles, which generates the synchronism signals to calculate the SCR's conduction angle keeping signal VE into account, which represents the final result of all the processing carried out on card RVR41773 about voltage and current on rectifier output. Therefore it is just VE which determines the conduction angle of the bridge SCR's under the control of relevant logic. The next "SCR drive" block with the signal generated by the high frequency oscillator, supplies the firing signals of the SCR's. Signal 1GPS blocks the SCR drive and therefore the rectifier in case of malfunction, so that the bridge SCR's are put into conduction in the manner and time determined by the logic of RPD card. Signals +IR,m -IR and VU are taken from the output circuit, through shunts SHR - SHB and the resistive divider installed on RBP41773. Such signals are used on card RVR41773 to verify the rectifier output and, after all, to generate the signal VE which affects the conduction angle of the SCR's on the rectifying bridge. The generation of error voltage VE, carried out on card RVR41773, is controlled by startup consent signal 0CA suppled by RPD which, after being processed, supplies signal 1 GPS.
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6. Control Logic
Such signal is sent to card RPD (on which, when it is at level 1, it block the H.F. oscillator and enables the mains failure sensor) and it starts the operation of card RVR41773 and basically of the whole rectifier by generating soft-start signal 1SSR. Such signal, at the initial operation stage, gradually allows the rectifier output to reach the voltage and current rated value so as to avoid excessive stress on the various components of the system. At the end of this initial phase, value VE is determined by controlling output voltage and current on RVR41773. In particular, it is verified that output current is not exceeding the maximum value the rectifier is able to supply, that output voltage is present and it is not exceeding the maximum value allowed. Possible overload and failing rectifier conditions are displayed on the front panel DME/S; whereas voltage VE is sent to card RPD to choke te SCR's conduction angle. The management of recharge levels is completely automatic. In case the 2 levels charge is set, it is controlled by the "management of 2 levels" charge block where battery current relay handles the changeover from floating to boost charge and vice-versa, should conditions arise In order to prevent malfunctions on this sensor, a safety timer with setting range from 424h, forces the system to floating charge whenever the maximum recharge time tolerated by the battery is exceeded. The blocks concerning "4th LEVEL" and "RECHARGE BLOCK" force the rectifier to relevant output voltages in case relevant command arrives from the unit (OPTIONAL). The block concerning "RECHARGE MANAGEMENT with EXTERNAL TIMERS" interface the control logic with the external recharge timers in case they are preset to control recharge time and modes (OPTIONAL). Following hereunder are the detailed descriptions of the cards making up the Rectifier Control Logic. The description is divideed as follows: - RPD Card - RVR41773 Card
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Pict. 1.1 Rectifier subsystem - Block diagram ( 1 of 2 )
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Pict. 1.2 Rectifier subsystem - Block diagram ( 2 of 2 )
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1.2 RPD Card
The RPD card, whose detailed block diagram is shown in Pict. 1.3, includes: A Rectifier section (3) for three phases of mains voltages coming from the rectifier supply line, through YY Sync & supply, obtaining +24Vdc direct voltage, present between TP1 and earth (TP3) and, after closing switch IA, direct voltage PSP corresponding to +12Vdc, present between TP2 and earth. The presence of such voltages lights leds LPSP1 and LPSP respectively. B Section for cyclic sense monitoring (correct connection of mains phases R, S, T on rectifier output) with flashing led LSC in case of error. C Section monitoring the failure of one or more phases, with potentiometer P2, setting the alarm threshold, and flashing led LMFin case of error. D Section monitoring the supply voltage of logics PSP. The simultaneous absence of error in sections B, C, D generates signal ROK with led LROK flashing in case of error coming from sections B, C, D. Signal ROK is also taken to pin 7C by means of a relay which closes at earth when ROK shows the absence of alarm (led LROK steady). E Section controlling the ventilation failure of the heatsink, which enables relay MV taking pin 5C to earth and making led LMV flash in case of alarm. F Section controlling the status of mains fuses F1, F2 and F3, which signals the interruption of one of the input fuses on the rectifier, such signal is given by the flashing of led LFB and by taking pin 4C to earth through the operation of relay FB. G Section generating the control signal of the rectifier SRC's, synchronized with mains through signals R,R; S,S; T,T and which receives the choking command of the conduction angle "" from VCO or, alternatively (with J4 open), from pin 10C. VCO is controlled through trimmer P1 when the rectifier operates in TEST mode; P1 allows to modify Vdc on rectifier output with open loop (J2 closed). By closing J1 the system operates with closed loop and VCO is controlled by error signal VE coming from RVR41773. Signal 1GPS on pin 15C, when it is high (led LGPS flashing), disables VCO output and blocks the high frequency oscillator; at the same time it operates relay BB which closes pin 13C 12C together.
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Pict. 1.3 RPD - Block diagram
Attention!
- With logic level 1, leds are on with fixed light and relays are not energized. - With logic level 0, leds flash and relays are energized (alarm).
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RPD Front view The picture shows potentiometers, circuit breakers, test points and leds of card RPD accessible on the front side.
Red flashing led: placing sequence of phases R, S, T of incorrect mains
+12V Supply voltage switch
Red led on with fixed light: +24V supply voltage present +24V Test point Red led on with fixed light: input supply OK
Red led on with fixed light: generation of control pulses on rectifier SCR's OK +12V Test point Red led on with fixed light: +12V supply voltage present 0 V: earth terminal connected to the negative pole of the battery Red flashing led: phase failure on input voltage Red flashing led: failure of heatsink ventilation (heatsinks faults)
Potentiometer for variation of rectifier output voltage, with open loop (NOTE) Red flashing led: interrupted fuse on the rectifier
Pict. 1.4 RPD - Front view
NOTE : Such operation is only possible when the UPS operates in TEST mode, with J1 open and J2 closed.
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1.3 RVR41773 Card
A The RVR41773 card, whose detailed block diagram is shown in picture 1.5, includes: Control section for rectifier startup (soft start) which, after receiving the consents, 0CA, with relevant led LCA lighting steadily (flashing in case of alarm), coming from card RPD and of the signal on pin 5A, concerning an alarm contact due to the heating of the SCR heatsink, with relevant flashing led LTS (in case of alarm) and relay TS operated due to the signal to the Front Panel (along with relay MV of RPD), commences the soft start. At the end of the procedure led LSS lights steadily . Control section of output voltage which, starting from VU voltage signal (30C), allows to limit the max. voltage on rectifier output, fixing its value through potentiometer P6. Through potentiometer P1 it is also possible to affect the rectifier stability by subsequently varying the dynamic characteristics of the control loop. Through an accurate setting on potentiometer P4 the voltage drop on rectifier output cables may be compensated in order for the rated voltage to be taken to the external battery terminals. Finally we have the actual control of rectifier output voltage which, through trimmers P2 - P3 - P5, transfers the control level to the bar of the analogue OR which, after being buffered, is turned into error signal VE set to card RPD through pin 21C. Control section of the current delivered by the rectifier which, starting from the signal coming from the current shunt of the rectifier, after turnng it from differential signal (IR) into common mode signal (IR) by means of a differential amplifier with adjustable offset through potentiometer P7, allows to fix the max. current to be delivered by the rectifier at its rated operating voltage. This is achieved by operating on potentiometer P8, which sets the limitation threhold f current above which, by operating n the analogue OR bar, the current control prevails over the voltage control, reducing output voltage to keep output current constant on load variation. Control section of the current delivered by the rectifier to the battery which, starting from the signal coming from the battery (IB) into common mode signal (+IB), by means of the differential amplifier with adjustable offset through potentiometer P14, allows to affect the rectifier voltage, prevailing over the other controls coming to the analogue OR bar. Therefore the recharging current of the battery cannot exceed the treshold set through potentiometer P9. Once the consents coming from pins 10A and 5A have arrived, the rectifier starts with the soft start sequence of output voltage, controlled by the action on the analogue OR bar by means of D16; then the control the output voltage is taken by one of sections B, C, D depending on the operating conditions of the system. Monitoring section of rectifier overload which, starting from current signal +IR delivered by the rectifier and comparing it with the treshold set by means of potentiometer P11 (usually 1.25 In) signals, after a delay t, the overload condition making led LOL flash and operating relay OL for signaling to SIR's.
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F Monitoring section of voltage and current range on rectifier output which, in case of parameters out of the limits, generates an alarm condition which makes NO DELIVERY led LME flash and causes the operation of relay ME, which takes the earth to pin 23C. G Management of 2 levels charge according to DIN41773, which is controlled by a current relay on which (through P10) the setting of the changeover level from floating charge to boost charge and vice-versa is carried out. In case the changeover from boost to floating charge does not occur within the maximum time allowed, a safety timer will bring the system back to floating charge, signalling the failure to the recharge system. H 4th level, operated by the unit through the earthing of pin 24A. It blocks the system (under any charging condition) at the 4th level set through P2. I Recharge block, operated by the unit through the earthing of pin 17A. It blocks the system (under any charging condition) at the floating value (to be set through P3). L Max. output voltage relay. It disconnects the rectifier in case output voltage exceeds the max.acceptable value set through P15. In this case the system will remain blocked until the RESET push button is operated manually. M Minimum voltage or insufficient floating relay. It supplies a signal in case the recharging voltage is lower than the desired value adjustable through P13 and P12 (reset hysteresis) for a time longer than one set through SW2. N Logic of external timers voltage. It interfaces RVR41773 with the external timers (OPTIONAL) in case the management of the battery recharge is performed by a programming and timing system.
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Pict. 1.5 RVR41773 - Blocks diagram
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RVR41773 Front view
The picture shows potentiometers, circuit breakers, test points and leds of card RVR41773 accessible on the front.
Potentiometer to set floating charge Potentiometer for automatic floating charge Potentiometer for voltage drop comensation on rectifier output cables Potentiomer for automatic boost charge Potentiometer for battery current limitation Red led on with fixed light: shows manual charge Green led on with fixed light: shows floating charge Yellow led on with fixed light: shows boost charge Red led on with fixed light: shows max. protection voltage Red led on with fixed light: shows startup consent Red led flashing: overload condition Red led on with fixed light: commencement of soft start Red led on with fixed light: thermal protection Red led flashing: shows no delivery Reset push button for max. voltage protection
Push button for boost charge reset
Automatic charge / manual charge switch
Pict. 1.6 RVR41773 - Front view
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2 INVERTER CONTROL LOGIC 2.1 Functional Description
The inverter system, whose block diagram is specified in figures 2.1a and 2.1b, converts the DC voltage delivered by the rectifier, or by the battery, into an AC voltage with low harmonic content. This is carried out by the inverter power section which has been represented, for simplicity, with a capacitive filter on the input, two IGBT bridge assemblies (maybe either half-bridge or full-bridge assemblies) and four IGD cards. The on/off control signals for the IGD cards are supplied by the IWM-3 card in order to perform the DC-AC conversion. The IWM-3 card controls the inverter output voltage and limits the output current in case of an overload, measured via the cards I/F-SG (voltage, the signal +VUF) and LOV (current, the signal +CUF). These measurements are analog-ORed and compared with a reference voltage set with P2. The resultant error voltage is sent to the "PWM generation" block, which sets the necessary pulse modulation width in order to rmaintain the inverter output voltage at the desired level. The signal +CUF, which is a DC voltage proportional to the total current flowing in the inverter bridge(s), can be trimmed using P3 and is compared with the threshold set by P4 in order to signal an overload if the nominal output current is exceeded. If this occurs, led LOL will flash and the relay OL will signal the overload condition to the front panel. The pulse width modulation may also be varied by the synchronisation control circuitry which will vary the phase and / or frequency of the inverter output voltage in order to maintain it phaselocked (or in synchronism) with the bypass line voltage coming from the bypass static switch section. In the case that the bypass supply is not present, the mains tolerance frequency selector transfers the synchronisation control to the frequency generated by the 50 or 60Hz oscillator. The selector output, through the PLL and the dividers, generates the "F" signal used to generate a triangular wave signal, which is compared with the sinusoidal modulating voltage. The result of the comparison within the PWM generation circuitry determines the modulation width and therefore the conduction time of the transistors of the inverter bridge. Returning to the control performed on the presence of the bypass supply, we point out that the signal 0MR, together with the startup consent 0CA, is used to: Energise the relay SOK which signals to the front operating panel when the inverter is synchronised, light led LSOK (On, fixed implies synchronised; Blinking implies not synchronised), Inform the bypass static switch control logic and the IST card (signal 0SOK) that the inverter is synchronised with the bypass supply (for interruption-free transfers between the two supplies), The signal 0CA, which is the start-up consent of the inverter itself, is generated by the IST card after it has verified: the inverter electronic power supply voltage PSP, generated by the IPS card is in order,
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the presence of signal 0VIOK, also generated on the IPS card and determines whether the inverter input voltage is in tolerance, there is no inverter overtemperature or no fuse blown (see the section on the IST card) and the correct operation of the power transistors and their relevant control (desaturation detection). The inverter output voltage is monitored on the IST card in order to ascertain whether it is within the required tolerance window. Also, the signals ROK and 0BY, which are supplied by the bypass static switch, are included in the inverter control logic. Such signals inform the inverter that the bypass line is in order in determining which source (inverter or bypass line) is to feed the load. The control signals for the reed relays IOK and IFL, which signal to the front operating panel that the inverter is in order and the inverter output static switch is closed, respectively, and the signal "INV.OK" which informs the bypass static switch control logic that the inverter is in order and therefore the inverter may feed the load are generated on the IST card. Another output of this control logic block enables the pulse generating highfrequency oscillator, which enables the firing of the inverter output static switch SCR's. The IPS card is the inverter electronic power supply and it generates the +12V, +24V and +26V supply voltages as well as two AC voltages in order to supply the ITD-2 cards. Still on the IPS card, the sensor "battery running down" generates a signal to the front operating panel, informing the operator that the battery is about to end its rated autonomy. In the following sections, detailed descriptions of the cards making up the inverter control logic are given. The descriptions are subdivided as follows:
IST Card IWM-3 Card IPS Card IGD Card
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Pict. 2.1 Inverter subsystem - Block diagram ( 1 of 2 )
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Pict. 2.2 Inverter subsystem - Block diagram ( 2 of 2 )
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2.2 IST Card
The IST card, whose detailed block diagram is shown in figure 2.3, includes: The input signal 14AC is used to monitor the inverter heat sink and transformer temperature using thermal switches. The inputs 19AC and 18A are for the optional connection of fan monitoring circuits and are normally not connected. The opening of one of the thermal switches will cause the input at 14AC to go to a high level at +12V and the LED LST will flash. The relay MV is used to signal the overtemperature condition to the front panel. The LED LMV will flash only if an optional fan monitoring circuit is installed and one of the monitored fans fails. The start-up consent will not be given to the inverter (the signal 1CA) as this point will be pulled to a low level via D12 if an overtemperature occurs. If the inverter was already running, it will shutdown. The fuse monitoring circuit is connected at the input 13AC (a high level here indicates a blown fuse) and again in this case the startup consent for the inverter will not be given unless the fuses are in order. The input at 4C arrives from the IPS pcb and a low level at this input indicates that the inverter input voltage (or battery voltage) is in tolerance (i.e. Vin(min) < Vin < Vin(max)). Again, if this input goes to a high level, the inverter start-up consent will not be given due to D12 pulling the signal 1CA to a low level. The inverter electronic power supply, PSP, generated on the IPS pcb is monitored for set tolerances and if it is determined not to be in order, the inverter start-up consent will be removed by pulling 1CA to a low level via D9. The inverter transistors are monitored by a desaturation monitor coming from the IGD pcbs at 16AC. A high level at this input will activate the desaturation control circuitry, switching off the inverter by setting the inverter start-up consent, 1CA, to a low level. The desaturation circuitry may retry to connect the inverter to the load, releasing the start-up consent to a high level. This circuit may also be set into a "locked state" via the flip-flop set by the signal "1STOP" and must then be reset by switching the microswitch MSW first to the OFF position and then again to the ON position. If all the above listed conditions are in order, the inverter start-up consent will be given when an ON command is present (the input 15AC is at a low level) and the relay ICA is energised. The signal 1CA will then be high and this signal is sent to the IWM-3 card via the signal 0CA and output 30C in order to start the inverter. On starting the inverter, the following conditions are monitored:
- The inverter output voltage is monitored via the input 4A which is a DC signal proportional to the output voltage. The over and under voltage tolerances of the inverter output voltage are adjusted with P1 and P2 respectively. The inverter output voltage must be within this window for the signal 1OK to go high. - The signal 0CC, coming from the input 12AC, which is at a low level if a short circuit occurs on the inverter output or the inverter peak current limitation detector is active and - The command for a manual commutation to the bypass supply (or another inverter in a hot-standby or parallel/redundant system), which is enabled only if the inverter is synchronised (1SOK).
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If these 3 conditions are in order then the LED LVU will be lit, fixed. Additionally, for the inverter to signal to the front operating panel that it is in order, the following conditions must be true:
- The inverter start-up consent must be present and - the signal 1CM must be true indication that on command to release the inverter firing (relay ICA) and the inverter output (relay 0CA) is present.
When the inverter is in order (0IOK and the output at 20A are at a low level), the inverter static switch control logic will close the inverter output static switch if, in addition, the following conditions are met:
- the signal 0BY must not be at a low level indicating that the a command for the transfer to bypass supply is present and - the inverter output static switch of the second unit in a hot-standby or a parallel / redundant system must not be on.
If in the case of a short-circuit on the output, the inverter voltage will go outside the tolerance window in order to limit the output current. In this case, the signals 0ROK (low if the bypass supply is in order) and 0I2OK (low if the second inverter in a hot-standby or parallel / redundant system is in order), will allow the inverter output static switch to remain on if both are at a high level.
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Pict. 2.3 IST Control Pcb - Blocks diagram
Note:
With logic level 1, led's are lit, fixed and relays are not energised. With logic level 0, led's flash and relays are energised.
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IST Front View The figure shows potentiometers, switches, test points and leds on the IST card which are accessible from the front.
- Red led flashing: Blown fuse - Changeover push button for test mode: manual changeover from inverter to the bypass line (enabled only when the bypass supply is in order). - Microswitch to enable the inverter start-up. Also used to reset the inverter after desaturation of a transistor.
- Red led flashing: Fan failure.
- Red led flashing: Overtemperature.
- Red led flashing: Inverter static switch open.
- Red led flashing: Inverter output not in order. - Pot. for the setting of the minimum threshold of the inverter output voltage (normal setting -10%, max -15%) - Pot. for the setting of the maximum threshold of the inverter output voltage (normal setting +10%, max 15%)
Pict. 2.4 IST - Front view
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2.3 IWM-3 Card
The IWM-3 card, whose detailed block diagram is shown in figure 2.4, includes: The synchronisation selection switch, depending on whether the square wave of the bypass supply line is present on the pins 6C-5A, synchronises the reference signal generated by the PWM circuitry with the bypass supply, if it is available, or with the local crystal oscillator if the bypass supply is not available or out of the frequency tolerance limits, or with an external synchronisation signal available on pin 7C. This external signal arrives from the IPL card (for hot-standby and parallel / redundant systems only) and the jumpers J3 must be closed and J4 open in this case. The potentiometer P5 sets the central point of the phase lock window with the nominal frequency desired (50 or 60Hz). This is normally adjusted in order to have 5.1V dc at TP1. When the phase lock loop (PLL) is locked, the output LS of the phase detector goes high and, if the bypass supply is in order, the led LSOK will be on, fixed and the relay SOK will be energised signalling to the front panel that the inverter is in synchronism with the bypass supply. The soft start section which, starting from signal 0CA on 29A, coming from the IST card, which is the inverter start-up consent, slowly enables the control on output voltage in order to gradually rise the inverter output voltage; when the signal 0CA is at a low level, the led LBCC becomes lit, fixed. The control section of the inverter output voltage which, starting from the feedback signal proportional to the inverter output voltage (VU), on pin 30C, the signalled is filtered and regulated by the output voltage regulator to the value set with the potentiometer P2 as long as the current remains below the current limitation value. An analog OR using the diodes D12 and D10 determines whether the output shall be voltage or current controlled. This closed loop operation may be replaced, by closing J1 and opening J2, with the test (or manual) mode operation which allows to set the inverter output voltage manually in an open loop mode using the potentiometer P1. By means of the output at pin 28A the same filtered signal (VU) is sent to the IST card, in order to monitor the tolerance limits of inverter output voltage. The control section of the current delivered by the inverter which, starting from the signal coming from the current transformers at pin 2A (+CU), allows to set the max. current limitation threshold using the potentiometer P3. The current regulator, when the signal CUF exceeds the set limit, reduces the output voltage through the diode analog OR as mentioned above. The control section for a load short circuit, which based on the signal CUF, controls the inverter voltage during the short-circuit period in two ways:
- the Led LCC will flash and the signal 0CC on pin 14C will go low, signalling the short-circuit to IST in order to commutate to the bypass supply if it is present. - It temporarily stops the PWM by disabling the high frequency oscillator for the transistor output driver.
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The overload monitoring section which, when the current exceeds the threshold set with the potentiometer P4, causes the led LOL to flash, operates the relay OL and sends a low level to pin 26A which signals the overload condition to the front operating panel. The PWM generation section which, synchronised through the PLL using the signal "F", varies the modulation amplitude of the modulating sinewave, generated on-board using the EPROM and digital-to-analog conversion, according to the amplitude of the signal from the diode analog OR. The PWM is generated by comparing the generated sinusoid with a triangular carrier wave with fixed amplitude and frequency. The PWM signal is sent to the output drivers, which modulates this signal with a high frequency carrier (AF), coming from the oscillator AF (when it is enabled by the signals 1CA and 0CC) and controls the turn on and off pulses of the inverter power stage via the ITD-2 cards.
Pict. 2.5 IWM-3 - Block diagram
Note:
- With logic level 1, Leds are on, fixed and relays are not energised. - With logic level 0, Leds flash and relays are energised.
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IWM-3 Front View
The figure shows potentiometers, test points and leds on the IWM3 card accessible from the front: - Test point: to set the inverter PLL centre frequency. Adjust P5 for 5.1 Vdc, common at TP16, IPS card. - Potentiometer to set the inverter PLL centre frequency (at TP1). - Potentiometer to adjust the inverter output voltage.
- Potentiometer to adjust the inverter output voltage in test (or manual) mode.
- Red led flashing: inverter is overloaded.
- Red led flashing: inverter short-circuit or peak current limitation.
- Red led on, fixed : Inverter start-up consent active.
- Red led on, fixed : inverter synchronised with the bypass supply.
Pict. 2.6 IWM-3 - Front view
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2.4 IPS Card
The IPS card, whose detailed block diagram is shown in figure 2.6, includes: The supply section which, uses the battery voltage available between pins 27AC, 19AC and 31AC to generate the required inverter electronic supply voltages of +26V on pin 7AC (with LVU on, fixed if the voltage is in order), +24V on pin 5AC and +12V on pin 1AC; all of them referred to the electronic common point, 32AC. The DC to high-frequency AC converter part of the power supply generates an alternate voltage at a fixed frequency between pins 13AC and pin 3AC to supply the transistor driver cards IGD. The output voltage may be regulated through the trimmer P2 and led LFI, on with a fixed light, shows the correct operation of the regulation feed back. The section starting from +B (inverter input voltage) monitors the voltage at the inverter input that it is within the upper and lower limits set through the trimmers P3 and P4 respectively. If the voltage is outside this window, the LED LVI flashes and the signal 0VIOK on pin 11AC goes high, signalling the failure to the IST card. Battery running down sensor which, when the inverter input voltage (or battery voltage) drops below the set voltage level, enables relay PFS, which signals the corresponding condition to the front operating panel. The feed-forward section which from the inverter input voltage at +B and -B, generates a DC signal on pins 16AC-26AC, which is proportional to the inverter input voltage in order to prewarn the inverter of a voltage drop due to a load transient or dip in the mains supply of the connected rectifier. The signal is sent to the the voltage control loop on the IWM-3 card.
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Pict. 2.7 IPS - Block diagram
Note:
LVU lit, OK; off, alarm. LAS lit, OK; off, alarm. LFI lit, OK; off, alarm. LVI lit, OK; flashing, alarm.
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IPS Front View The figure shows potentiometers, switches, test points and leds on the IPS card accessible from the front: - ON / OFF Switch, Inverter Eletronic Power Supply
- Red led lit with fixed light: DC input supply voltage available
Test Test Test Test
point point point point
+12 V (PSP) electronic ground (0V) +26 V (PSP-1) +24 V (PSP - A)
- Jumper for test mode - Red led lit with fixed light: rectifier output voltage OK. - Red led lit with fixed light: inverter electonic power supply OK. - Red led lit with fixed light: inverter DC input voltage within tolerance limits - Pot. to set the upper limit of the inverter DC input voltage - Pot. to set the lower limit of the inverter DC input voltage
Pict. 2.8 IPS - Front view
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2.5 IGD Card
Power Supply Each pcb generates its own internal power supply to provide isolation from other modules. The V+ and V- levels are generated from the high frequency alternating waveform coming from the IPS pcb. The switching waveform for each IGBT is generated on the ICT-2 pcb. This waveform is opto-coupled to the pulse control circuitry on the IGD pcb. The capacitor C12 controls the dead time. The output of the pulse control circuit is fed directly to the driver stage, the resistors R29 and R30 controlling the on and off times respectively. The emitter-collector voltage VCE of each IGBT is continuously monitored during the on-state. If this voltage exceeds a set value, the desaturation detector will be activated, blocking the on-pulse and signalling the ICP pcb of a desaturation of an IGBT via an opto-coupled output.
IGBT Driver Circuit
Desaturation Monitor
FIG 2.9 IGD Block Diagram.
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3 STATIC SWITCH CONTROL LOGIC 3.1 Functional Description
The bypass static switch control logic, whose block diagram is shown in figures 3.1a. and 3.1b., is the logic which continuously monitors the UPS output for set tolerances and includes the control and drivers of the bypass static switch thyristors. The bypass line voltage is sent to the SPT card via an auxiliary transformer on the SSV1F card and it is rectified and then used to generate the bypass electronic supply voltages PSP, PSP1 and PSPA on the SPT card. In addition, after being filtered and rectified, the resultant voltage is sent to the high/low mains voltage comparators, which verifies if the bypass line voltage is within the desired tolerance limits. The control logic block following thereafter, generates signal 0ROK which is at a low level if the bypass supply voltage is in order and the bypass supply frequency is within the set toerance window thereby generating the signal 1FROK. The 0ROK signal (IROKA) is then sent to the inverter control logic which enables the PLL to synchronise to the bypass supply line. The signal IROKB is only used in case of Hot-standby and Parallel / redundant configurations. The signal SR is proportional to the bypass supply line voltage waveform and phase and is then converted into a square wave (FR) by the zero detector and used to monitor the bypass supply frequency. In addition, the same signal (FR) is phase regulated and sent to the inverter as a reference signal for synchronisation. The UPS output voltage is sent to the SPT card via an auxiliary transformer on the SSV1F pcb, is rectified and filtered on the SPT pcb and is also used to redundantly generate the electronic supply voltages for the case where the bypass supply fails and the inverter is connected to the UPS output. The signal is also compared in the high/low voltage comparators for the UPS output voltage. The result of this comparison and of the logic processing following thereafter is the signal 0COK, which is at a low level if the UPS output voltage is within the tolerance limits. Based on the signals 0COK and 0ROK, the SCLT card determines whether the load is to be supplied by the bypass or the inverter supplies via the bypass commutation decision logic block. In normal operating conditions (when the unit is not programmed in an off-line mode), the inverter supply will feed the load and the signals 0COK and 0ROK will be at a low level. The signal 0BY indicates that the load is supplied by the bypass supply when at a low level.
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The SCLT card receives the signals INV.1 OK and S1OK from the inverter when the inverter is in order and synchronised, respectively. Through the control logic block following thereafter, these galvanically decoupled signals (along with INV.2OK and S2OK if the unit is part of a hot-standby or parallel / redundant system) are used to illuminate the LEDs shown and to signal the UPS condition to the front operating panel. The manual bypass is open under normal operating conditions: it is closed only in case of maintenance or repair work on the UPS itself. In the following sections detailed functional descriptions of the electronic control cards (or Pcbs) composing the bypass static switch control logic are given. The descriptions are subdivided as follows:
- SPT Card - SCLT Card
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Pict. 3.1 - Static switch subsystem - Block diagram (1 of 2 )
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Pict. 3.2 - Static switch subsystem - Block diagram (2 of 2 )
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3.2 SCLT Card
The SCLT card whose detailed block diagram is shown in figure 3.2, consists of: The input / interface sections between inverters 1 and 2 (only for hot-standby and parallel / redundant configurations) and the bypass control logic transfer the information "inverter OK" and "synchronism of inverter with the bypass supply" from the control logic of the respective inverter, taking it from pins 3C2C, 9C-5C, 8C-2C and 6C-5C, by means of optocouplers and generating the signals 1I1OK (i.e. a high level if inverter 1 is OK) and 1SOK (i.e. a high level if the inverter-bypass supplies are synchronised for either inverter and the respective inverter is in order). Leds LI1OK, LI2OK, S1OK, S2OK will flash if the respective condition is not true (with one inverter present only, LI2OK and S2OK flash continuously). The presence of a high level on 1IOK and 1SOK energises the respective relays IOK and SOK which signal the UPS status to the front operating panel. The control section of the inverter output and bypass supply line status which, receiving the signals 1IOK and 1SOK mentioned above, as well as the signals 0COK, based on the status for UPS output voltage in order and coming in at the pin 14C, and 0ROK, based on the status of the bypass supply input voltage in order and coming in at the pin 13C (both coming from the SPT card), determines whether the load is to be fed by the inverter, or needs to be commutated to the bypass supply line. If it is determined that the load must be supplied by the bypass supply line, the led LSS lights, fixed and the relay RC is energised signalling to the front operating panel that the load is being fed by the bypass supply. The high frequency oscillator is also enabled to in order to transfer the firing pulses to the SCR's of the bypass static switch, via the SCR drivers. At the same time, the signal 0BY becomes low, preventing the closing of the inverter output static switch(es) of inverters 1 and 2 (for hot-standby and parallel / redundant configurations). The section managing the load commutations between the inverter and the bypass supply operates in two modes depending on the status of microswitch MSWA. With MSWA in position M (manual), the reset for retransfer of the load to the inverter supply is only possible through the reset push button PR or through an external reset coming from pin 16C. With MSWA in position A (automatic), the reset for retransfer of the load to the inverter supply, once the conditions have been verified, occurs automatically. To prevent continuous retransfers under failure conditions, the control logic allows only 3 retransfer attempts within 1 minute and if more retranfers are attempted, the automatic retransfer control becomes blocked, signalling the condition the the front operating panel via the relay RPM and the Led LBR flashes. In this case, the blocked condition must be reset as in the case when the microswitch MSWA is in the manual position.
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6. Control Logic
Pict. 3.3 SCLT - Block diagram
Note: With logic level 1, leds are lit, fixed and relays are not energised. With logic level 0, leds flash and relays are energised. Led LSS flashes when the load is fed by the inverter (normal operation) and becomes lit, fixed when the load is fed by the bypass supply line.
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6. Control Logic
SCLT Front View
The figure shows potentiometers, switches and leds on the SCLT card accessible from the front.
- Red led flashing: Bypass static switch open.
- Red led flashing: automatic retransfer of the load from the mains to inverter supply is blocked (Reset using pushbutton PR below). - Microswitch for manual/automatic control when commutating between the inverter and bypass supplies (In manual mode the UPS does not attempt to retransfer; in automatic mode it attempts 3 retransfers within 1 minute). - Red led lit, fixed: Inverter 1 synchronised - Red led lit, fixed: Inverter 1 OK
- Red led flashing: Inverter 2 not synchronised* - Red led flashing: Inverter 2 not OK* - Pushbutton to reset after the retransfer of the load to the inverter is blocked.
Pict. 3.4 SCLT - Front view
These leds are always flashing when inverter 2 is not present i.e. when there is no hot-standby or parallel / redundant configuraton.
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6. Control Logic
3.3 SPT Card
The SPT card, whose detailed block diagram is shown in figure 3.4, consists of following sections: Section for rectification and filtration of incoming bypass supply voltage which, after being rectified, feeds the non-regulated DCpower supply PSPA. Section for rectification and filtration of the incoming UPS output voltage which, after being rectified, redundantly to that above, feeds the DC power supply PSPA. The SPT card may be used with three phase or single phase systems. For single-phase systems, the DIP switch DSW1 is set as follows:
- Poles 1-4 open; pole 5 closed.
Pole 5 inserts more filtration on the signal CR. The supply section which, starting from the non-regulated DC voltage PSPA, generates the supply voltage for the bypass electronic power supply, PSP, available at TP3 (referred to the common for the bypass electronics at TP4) via the voltage regulator PVR when the microswitch MSWA is closed. The bypass electronic supply monitor verifies that the bypass electronic supply voltage, PSP, is within set tolerance limits and, by generating the signal 1PSOK, enables the DC supply PSP1, available on TP1 and on pin 15AC, which is used for firing the bypass static switch thyristors. The relay BYS is also energised to signal the condition that the bypass electronic power supply is in order. The control section of the bypass supply line voltage amplitude limits which allows to set the minimum and maximum value of the line voltage by means of potentiometers P1 and P2 respectively (nominal setting of 10%). The control section of bypass supply line frequency where the frequency range to be set through the jumpers J3, J4, J5, J6 (50 / 60 Hz) and potentiometers P6 and P7 for the setting of the min. and max. frequency tolerance limits. The following leds light when the bypass supply frequency is not within the limits set:
- LFB if the frequency is lower than the minimum limit, - LFA if the frequency is higher than the maximum limit. Otherwise the Leds are off.
When the bypass supply voltage amplitude is above the minimum level, the bypass electronic supply, PSP, is in order (1PSOK) and the bypass frequency is on order (1FROK), the signal 1RM becomes high. After a fixed delay, if the mains voltage amplitude is below the maximum threshold and the bypass line is not blocked externally via the relay 0BC coming from pins 7AC, the led LROK will light, fixed to show that the bypass supply line is in order. The signal 0ROK will be at a low level and is sent to the SCLT card via the pins 8AC and the high level signals 1ROKA (to inverter 1) and 1ROKB (to inverter 2 for hot-standby and parallel / redundant systems) to pins 5AC and 3AC respectively. The signal 1FROK, which enables the inverter-bypass supply synchronisation, will be at a
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6. Control Logic
high level if the bypass supply line frequency is within the set tolerance limits (LFA and LFB both off) and the level 1RM is high. Under these conditions the led 1FROK lights, fixed and a high level will be present on TP21. The control section for the amplitude limits of the UPS output voltage which feeds the load (taken downstream of both static switches but before the output switch QIUG). This section, starting from the signal CR, allows to set the minimum and maximum thresholds, through potentiometers P3 and P4 respectively. If the UPS output voltage is out of the set tolerance limits, the led LCOK will flash and the signal 0COK at 31A will go to a high level.
Pict. 3.5 SPT - Block diagram
Note:
- With logic level 1, leds are lit, fixed and relays are not energised. - With logic level 0, leds flash and relays are energised. - LFA and LFB are off and they light in case of alarm.
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6. Control Logic
The section for the generation of a square wave for the bypass inverter synchronisation which, after taking the voltage SR coming from the bypass supply input volatge from pins 28AC, converts it into a square wave and, if enabled by the signal 1RM, transfers the square wave signal for the first and the second inverters (in case of hot-satndby and parallel / redundant configurations) to pins 10AC and 6AC respectively. The potentiometer P5 (phase regulator) allows to adjust the phase difference between the bypass supply and the inverter output supply for correct synchronisation.
SPT Front View
The figure shows potentiometers, switches, test points and leds on the SPT card accessible from the front.
- ON / OFF Switch, Bypass Electronic Power Supply - Adjustment of the upper limit of the UPS output voltage monitor. - Adjustment of the lower limit of the UPS output voltage monitor. - Red led flashing: lower threshold of the bypass supply line freq. out of the tolerance limit. - Pot. to adjust the lower threshold of the bypass line frequency. - Red led flashing: upper threshold of the bypass supply line freq. out of the tolerance limit. - Pot. to adjust the upper threshold of the bypass line frequency. - Red led lit, fixed: freq. and voltage of the bypass line in order. - Pot. to adjust the upper threshold of the bypass line voltage. - Red led lit, fixed: UPS output voltage OK (adjustable with P3 and P4). - Adjustment of the lower limit for the bypass input line voltage. - Pot. for adjustment of the phase difference between the inverter and bypass supplies. - Red led lit, fixed: bypass supply line in order. - Test point +24V (PSP1) for firing the bypass static switch SCRs. - Test point common (0V) for the bypass control electronic. - Test point +12 V (PSP) for the bypass electronic control. - Test point +28 V (PSPA).
Pict. 3.6 SPT - Front view
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7. Troubleshooting
Chapters
1 GENERAL DESCRIPTION
1.1 1.2 Introduction Troubleshooting procedures 65 65
INVERTER ON
8.1 Troubleshooting procedure 73
MAINS OK LED OFF

2.1 Troubleshooting procedures 66
INVERTER FAULT
BLOWN FUSES
10 OVERLOAD
RECTIFIER TROUBLE
11 STATIC SWITCH BLOCK RESET

MAX.RECTIFIER VOLT./ MAX.VOLTAGE RESET

12 MAINS FAULT
RECTIFIER MINIMUM VOLTAGE

13 LOAD FED BY MAINS

SYSTEM TEST
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7. Troubleshooting
1 GENERAL DESCRIPTION 1.1 Introduction
This chapter contains the troubleshooting procedures for "E-2001" system. Such procedures help the technician to locate the faulty part causing the malfunction.
1.2 Troubleshooting
The troubleshooting procedures mentioned hereunder result almost exclusively from fault symptoms shown by the lighting of relevant leds. Starting from a particular alarm, the technician is guided inside the system with the help of signals (leds) placed on the logics cards.The procedures do not take into account possible interruptions of tracks and wirings on various back panels and on the printed circuits of cards.
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7. Troubleshooting
2 MAINS OK LED OFF 2.1 Trobleshooting procedure
Mains OK led OFF! Open the front panel of "E-2001" system and check the status of the leds installed on the internal p.c. boards. 2A: Is led "MAINS OK" on card RPD flashing? No: Yes: 2B: Is led "Phase sequence OK" on card RPD flashing? Yes: The cyclic sense of mains is not correct for some reason, restore the cyclic sense R-S-T. Continue with 2C. replace RPD card. contine with 2B.
No: 2C: Is led "Phase failure" on card RPD flashing? No: Yes: 2D: Are the leds on card YY-SYNC.& SUPPLY lit? Yes: No:
replace RPD card . continue with 2D.
replace YY-SYNC.& SUPPLY card. check fuses F1-F2-F3 and replace them if needed. OK ? No: replace YY-SYNC.& SUPPLY card. OK ? Yes: Troubleshooting finished. No: Supply mains is not correct.
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7. Troubleshooting
3 BLOWN FUSES 3.1 Troubleshooting procedure
Blown fuses led on! Open the front door of "E-2001" system and check the status of the leds installed on the internal p.c. boards. 3A: Is led "Blown fuses" on card RPD lit? No: Yes: replace RPD card. check fuses F1-F2-F3 of rectifier bridge and replace the faulty one.
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7. Troubleshooting
4 RECTIFIER FAULT 4.1 Troubeshooting procedure
Rectifier trouble led on Open the front door of "E-2001" system and check the status of the leds installed on the internal p.c. boards. 4A: Is led "No Rectifier Output" on card RVR41773 flashing? No: Yes: 4B: Is led "Blown fuses" on card RPD flashing? No: Yes: Continue with 4C. Read troubleshooting procedure 3 (Blown fuses) OK ? Yes: Troubleshooting finished No: Continue with 4C replace RVR41773 card. Continue with 4B.
4C: Is led "Mains OK" on card RPD flashing? No: Yes: Continue with 4D. Read troubleshooting procedure 2 (MAINS OK led off). OK ? Yes: Troubleshooting finished. No: Continue with 4D.
4D: Is led "Thermal Protection" on card RVR41773 flashing? Yes: check the temperature on the rectifer bridge or the thermal sensor. Continue with 4E.
No: 4E: Is led "MAX volt.protection" flashing ? No: Yes:
replace RVR41773 card. read troubleshooting procedure
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7. Troubleshooting
4F: Is led "STARTUP CONSENT" on card RVR41773 flashing? No: Yes: replace RVR41773 card. continue with points 4B - 4C - 4D - 4E. OK? Yes: Troubleshooting procedure finished. No: replace RPD card.
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7. Troubleshooting
5 MAX. RECT VOLTAGE - MAX. VOLTAGE RESET 5.1 Troubleshooting prcedure
Max. rect. voltage - max.voltage reset button led ON! Open the front door of "E-2001" system and check the status of the leds installed on the internal p.c. boards. 5A: Is led "MAX. VOLT.PROTECTION" on card RVR41773 flashing? No: Yes: replace RVR41773 card. the rectifier has set to MAX. VOLTAGE protection due to a serious failure on the control electronics. Call for service in order to carry out a general checkup and restore the system.
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7. Troubleshooting
6 RECTIFIER MINIMUM VOLTAGE 6.1 Troubleshooting procedure
RECTIFIER MINIMUM VOLTAGE led on! Open the front door of "E-2001" system, remove the front panel of control cards and check the status of the leds installed on the internal cards. 6A: Is the yellow led "L MIN" on? No: Yes: 6B: Is Vdc voltage on rectifier output at the nominal vaue of the charge in progress ( 5% )? No: Yes: 6C: Is battery recharging current still > 0.1 C10? No: Yes: 6D: Is the red led "LCG" on card RVR41773? No: Yes: replace RVR41773 card. there's a failure on the recharging system or on the battery. Call for service in order to carry out a general checkup on E 2001 system. replace RVR41773 card. continue with 6D. replace RVR41773 card. continue with 6C. replace RVR41773 card. continue with 6B.
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7. Troubleshooting
7 SYSTEM TEST 7.1 Test procedure to assess operational efficiency
Open the front door of "E-2001" system (only in case of systems with no optional "RECHARGE TEST" push button) and press button PRC. 7A: Led FLOATING CHARGE on RVR41773 shall go off and led BOOST CHARGE on RVR41773 shall light. Ok? No: replace RVR41773 card. Yes: continue with 7B. 7B: Make sure output voltage sets to the boost charge value. OK? No: replace RVR41773 card. Yes: Wait 30" for charge and make sure the system is switched back to floating (Floating Charge on and Boost Charge off). OK? Yes: Successful testing. No: Continue with 7C. 7C: Is the current absorbed by the battery exceeding the changeover level "BOOST CHARGE - FLOATING"? No: Yes: 7D: Wait for the recharging cycle to end and check what specified in point 7C. OK? Yes: Test and recharge ended successfuly. No: continue with 7E. 7E: Has the red led LGC on RVR41773 lit? No: Yes: replace RVR41773 card. continue with 7B and following points. replace RVR41773 card. the battery was flat. Continue with 7D.
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7. Troubleshooting
8 INVERTER ON LED OFF 8.1 Troubleshooting Procedure
Inverter ON led OFF! Open the front door of the "E-2001" system and check the status of leds placed on the internal cards. 8A: Is led LOSS flashing on card IST? No: Yes: 8B: Is led INVERTER OK on the panel OFF, too? Yes: No: See troubleshooting procedure for INVERTER FAULT. Replace IST card. OK? Yes: End ! No: Replace SCLT card. Replace IST card. continue with 8B.
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7. Troubleshooting
9 INVERTER FAULT 9.1 Troubleshooting Procedure
Inverter fault led ON! Open the front door of the "E-2001" system and check the status of the leds placed on the internal cards. 9A: Is led LVU on card IST flashing? No: Replace IST card.
Yes: Is switch MSW on card IST on ON? No: Set MSW to ON. Yes: Continue with following procedure. Is the switch on the front panel ON? No: Set the switch on ON. Yes: Continue with following procedure. Is led LAS on card IPS ON? Yes: Proceed with 9B. No: Proceed with 9C. 9B: Are also leds LVU, LFI and LVI on card IPS lit with steady light? No: Yes: 9C: Is switch MSW on card IPS positioned on ON? No: Yes: 9D: Is led LST on card IST flashing? No: Yes: Proceed with 9E. Check fans efficiency. Ok? Yes: After ascertaining environmetal conditions meet the installation specifications, switch the inverter OFF, let the system cool and switch the inverter ON again (with rated load). Proceed with 9F . No: Check the fuse integrity. Ok? Yes: Replace the faulty fan. No: Replace the fuse. Set MSW on ON. Replace the fuse. Replace IPS card. Proceed with 9D.
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7. Troubleshooting
9E: Are leds LFT on cards ITD-2 all lit with fixed light ? Yes: Replace card IST. Ok? Yes: End! No: Replace the card. Ok? Yes: End! No: Check the integrity of the output filter components and of the capacitive filter on inverter input. All Ok? Yes: Check the integrity of transformer TR1. No: Replace the failing component.
No: 1. THEY ARE ALL OFF Replace fuse F1 on the logic back panel. 2. THEY ARE ALL FLASHING Replace IWM-3 card. 3. ONE LED IS FLASHING
Switch the inverter OFF and then ON. Is the led still flashing? No: A protection has tripped due to unidentified causes. The inverter has started operating again. Yes: Replace relevant IGD card. Ok? Yes: End! No: Replace relevant PTM module. 9F: Is the alarm occurring again? No: Yes: End! Check the efficiency of the thermostat installed on transformer TR1 and of the transformer itself.
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7. Troubleshooting
10 OVERLOAD 10.1 Troubleshooting Procedure
Overload led ON! Is led LOL on card IWM-3 flashing? No: Yes: Replace IWM-3 card. Make sure the load be within the nominal values specified in the technical data of the system.
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7. Troubleshooting
11 STATIC SWITCH BLOCK RESET 11.1 Troubleshooting Procedure
Led Static switch block RESET ON! Press the RESET push button for static switch block when the red luminous signal inside the push button flashes, or press push button PR on card SCLT. Is the alarm occurring again? No: End! Repeated overcurrents on the load had occurred within a short time. Replace SCLT card. Ok? Yes: End! No: The fault is located on the inverter power part. See paragraph 2.
Yes:
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7. Troubleshooting
12 LED MAINS FAULT ON 12.1 Troubleshooting
Led MAINS FAULT ON! Open the front door of the "E-2001" system and check the status of the leds placed on the internal cards. Is Led MAINS OK on the front panel OFF? 1. Is mains voltage present on the system input? No: Restore mains voltage on system input. Yes: Check the status of lamp MAINS OK on the front panel. 2. Is led LROK on card SPT flashing? Yes: Make sure mains voltage be within the nominal values specified in the technical data of the system. No: Replace SPT card.
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7. Troubleshooting
13 LOAD FED BY MAINS 13.1 Troubleshooting
Led LOAD FED BY MAINS ON! Open the door of the front panel of the "E-2001" system and check the status of the leds placed on the internal cards. Is led LSS on card SCLT flashing? No: Check the other alarms in progress and follow relevant troubleshooting procedures.
Yes:
Replace SCLT card.
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8. Technical Data
1.1 Technical data
SIZE (kVA) Input Voltage Vdc Voltage
Rectifier output current (A) Rectifier input current (A)
48 11.3 7.85 92 96 22.7 15.7 93 140 33.2 23 93
10
15
20
30
40
50
380 Vac ( 10%) 3ph 50 Hz 110 Vdc 192 45.6 31.4 93 280 66.3 45.9 94 383 90.6 62.7 94 479 113.4 78.5 95
Rectifier
Input Power (kVA) Efficiency (%) Battery capacity (Ah) (30 min autonomy) Battery charging current (A) Input voltage (Vdc) Output voltage (Vac)
37 / 50
75 / 100
125
150 / 200
250
400
400 / 500
Battery
7.5
15
22.5
30 95 - 165
45
60
75
115 (110-120) or 230 (220-240)
Inverter
Nominal output current (A) 230V/115V Input Power (kW) Efficiency (%) Overall efficiency Protection degree
17 / 34
35 / 70
52 / 104
69 / 138
104 / 208
139 / 278
174 / 348
4.6 86 79
9.2 87 81
13.6 88 82
18.2 88 83 IP20 0C 40 0C 85 95% 2000 msl RAL 7032
27.2 88 83
36 89 84
45 89 84
Operation Temperature Storage Temperature Relative Humidity Altitude Painting colour Dimensions (mm) Weight (Kg)
W H D 1200 1800 800 450 1200 1800 800 500 1200 1800 800 600
1200 1800 800 650
1800 1800 800 820
1800 1800 800 900
1800 1800 800 1000
Table 1.1 Technical Data
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8. Technical Data
SIZE (kVA) Input Voltage Vdc Voltage

Rectifier output current (A) Rectifier input current (A)
10
15
20
30
40
50
60
80
100
380 Vac ( 10%) 3ph 50 Hz 220 Vdc 24 11.3 7.8 92 48 22.5 15.6 93 72 33.7 27.3 93 96 45.1 31.2 93 140 65.6 45.4 94 192 75.6 62.3 94 232 108.8 75.3 95 280 131.5 91 95 383 179.6 124.3 95 479 224.8 155.6 95
Rectifier
Input Power (kVA) Efficiency (%) Battery capacity (Ah) (30 min autonomy) Battery charging current (A) Input voltage (Vdc) Output voltage (Vac)
25
37 / 50
75
75 / 100
125
150 / 200
200
250
400
400 / 500
Battery
3.75
7.5
11.25
15
22.5 176 - 325
30
37.5
45
60
75
115 (110-120) or 230 (220-240)
Inverter
Nominal output current (A) 230V/115V Input Power (kW) Efficiency (%) Overall efficiency Protection degree
17 / 34
35 / 70
52 / 104
69 / 138
104 / 208
130 / 260
174 / 348
208 / 416
278 / 556
348 / 696
4.5 88 81
9 89 83
13.2 91 85
17.3 92 85
26.1 92 86 IP20
34.8 92 86
43.5 92 87
51.2 93 88
68.8 93 88
86 93 88
Operation Temperature Storage Temperature Relative Humidity Altitude Painting colour Dimensions (mm) Weight (Kg)
W H D 1200 1800 800 450 1200 1800 800 500 1200 1800 800 600 1200 1800 800 650
0C 40 0C 85 95% 2000 msl RAL 7032 1200 1800 800 750 1200* 1800 800 830 1400 1800 800 920 1800 1800 800 1050 1800 1800 800 1140 1800 1800 800 1300
Table 1.2 Technical Data
NOTE : * 1400 if 110Vac output
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9. PCBs Schematics
WIRING DIAGRAM
YY SYNC. & SUPPLY : I/F - SG : SSV1F : ST - 1F: RECT. TYR. FIRING CPSII-CP RECT. TYR. FIRING 6P SGV02C: RBP41773: IBMU / IGBT: SBTR: RVR41773: RPD: IWM - 3: IPS 120: IPS 208: IST: IPL: SCLT : SPT: IGD/N50/I DATA MONITOR PANEL DME/S: ORA-8 / ORA-14: SA/IF IBM38 AS400 JUE 300636 JUE 300242 JUE 300011 JUE 300689 SE 053B116 SE 053B112 JUE 300257 JRE 300550 JUE 302158 SE 032B003D JRE 300528 SE 013B004 JUE 300195 SE1663 SE 023A027A SE 023A002 SE 23B006 SE 033AA003 SE 033A001 JUE 300349 JUE 302039 JUE 302200 / JUE 302209 (Optional) SE053B108B (Optional) JUE401985 82 JUE 300351 JUE 300197 JRE 300530 A
PRINTED CIRCUIT
JUE 300638 JUE 300244 JUE 300013 JUE 300691

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Contents of JUE 401985

UPS E-2001 Service Manual

Issued See rev. doc. JSE401923

F. Fabbri F. Fabbri G. Pisellini

UPS E-2001 - Service Manual

Dangerous voltages are present inside the unit.

This equipment must be installed and serviced by qualified personnel.

Connect protective earth before power supply cables.

UPS E-2001 - Service Manual

2. General System Description

PIC. 1.5 Maintenance Bypass Block-Diagram 7

UPS E-2001 - Service Manual

2. General System Description

Better Output Power Characteristics

Uncoupling from Mains Distortion

Complete Protection against Mains Failures

UPS E-2001 - Service Manual

2. General System Description

1.3 Rectifier/Battery Charger

1.4 Battery (Accumulator)

UPS E-2001 - Service Manual

2. General System Description

1.6 Static Switch Unit

UPS E-2001 - Service Manual

2. General System Description

1.7 Maintenance Bypass

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

PIC. 1.2 - UPS connection diagram

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

Handling the UPS System

PIC. 1.1 - Moving the UPS

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

PIC. 1.3 - UPS room size

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

PIC. 1.4 - UPS connection diagram

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

A: Rectifier Power Supply Check

UPS E-2001 - Service Manual

3. Installation and Initial Start-Up

Measure the battery voltage in the battery terminals XB+.1 / XB-.1:

C: Bypass Power Supply Check

UPS E-2001 - Service Manual

Normal Operation Battery Operation Bypass Operation Maintenance Bypass Operation

UPS E-2001 - Service Manual

UPS E-2001 - Service Manual

1.3 Battery Operation

1.4 Bypass Operation

1.5 Maintenance Bypass Operation

UPS E-2001 - Service Manual

UPS E-2001 - Service Manual

2.3 Manual by-pass operation

UPS E-2001 - Service Manual

2.3.2 From manual by-pass to normal operation

UPS E-2001 - Service Manual

5. Front Panel DME/S

UPS E-2001 - Service Manual

5. Front Panel DME/S

PIC. 1.1 - E 2001 Front Panel DME/S