JST OM226025 - UPS Functioning Description
JST OM226025 - UPS Functioning Description
JST OM226025 - UPS Functioning Description
Index
1. UPS ...................................................................................................... 3
1.1 SINGLE PHASE OUTPUT - 180 BATTERY CELLS JST mono 10/15kVA..... 3
1.2 SINGLE PHASE OUTPUT - 192 BATTERY CELLS-JST mono 20-32kVA.... 4
1.3 THREE PHASE OUTPUT - 180 BATTERY CELLS-JST delta 10/15kVA....... 5
1.4 THREE PHASE OUTPUT - 192 BATTERY CELLS-JST delta 20-32kVA....... 6
1.5 THREE PHASE OUTPUT - 192 BATTERY CELLS - JST delta ab 40kVA
JST mega 6 puls............................................................................................. 7
2. PCB’S................................................................................................... 8
2.1 I/S CONTROL LOGIC ...................................................................................... 8
2.1.1 Introduction ............................................................................................. 8
2.1.2 Digital inputs............................................................................................ 8
2.1.3 Dip switches ............................................................................................ 8
2.1.4 Fast analog inputs................................................................................... 8
2.1.5 Watchdog and reset ................................................................................ 8
2.1.6 Ram EPROM’s and EEPROM.................................................................. 9
2.1.7 Digital power supply ............................................................................... 9
2.1.8 Rcb............................................................................................................ 9
2.1.9 Scb and thyristor drivers ........................................................................ 9
2.1.10 Current limitation and max. current stop ................................................ 9
2.1.11 Vcb............................................................................................................ 10
2.1.12 PWM generator ........................................................................................ 10
2.1.13 External A/D Converter ........................................................................... 10
2.2 INTERFACES (SINGLE PHASE UPS) .......................................................... 11
2.2.1 Inv-Av-1F (PB018).................................................................................. 11
2.2.2 Volt-Ref-1F (PB019) ............................................................................... 11
Rev.
Description Date Issued Checked Approved Language Page of Pag.
A First Issue 15.01.02 O.Böke M.Rieks
E 1 13
Code
OM226025
UPS functioning description
2 OM2226025 Rev. A
UPS functioning description
1. UPS
1.1 SINGLE PHASE OUTPUT - 180 BATTERY
In this type of UPS the three phase input mains is connected to the 1-L1, 1-L2 and 1-
L3 terminal boards. The RF1 EMI filter provides to reduce the high frequency
disturbances according to the EN50091 -2 limits.
You can power on the unit by closing the input automatic circuit breaker RCB. The
input choke L1 filters the switching to the mains, before the full controlled SCR rectifier
bridge PS1,PS2 and PS3.
The PRCH (PB114) board and LOOP (PB115) are the monitoring and powering
system of the SCR rectifier bridge.
The battery BB is normally mounted inside the UPS; the SCR rectifier in addition to
supplying the inverter, provides the recharging current and keeps the battery in floating
to compensate the self discharging. The battery recharging current reading is carried
out by the SH1 shunt.
In case of mains fault, the inverter supplies the load taking energy from the
battery.
The inverter bridge is composed by the two IGBT’s (bridge leg configuration) PS1
and PS2 controlled by the drivers ID1 and ID2.
The hall effect ammeter TA1 provides the current signal for the inverter bridge
protection (Max Current Stop) and the current limitation in case of short circuit at the
inverter output.
The inverter bridge is connected to the output transformer T1, which provides the
galvanic insulation between the bridge and the output and, by its leakage inductance,
forms a low pass filter with the C7…C11 output capacitors, assembled on the IBPC4
(PB087) for the high frequency. The inverter normally supplies the load through the
inverter static switch (PS.. ON IBPC4-PB087) and the output circuit breaker OCB.
The emergency line is connected to the 2-L1 and 2-N terminal boards. The fuse F1
protects the SCR’s (PS.. ON IBPC4-PB087) of the static automatic bypass switch, in
case of a short circuit at the output of the unit.
The UPS automatically transfers the load to the bypass in case of an inverter failure
or an overload higher than 2 times the nominal output current.
The manual bypass circuit breaker MBCB connects directly the input emergency line
to the load in case of maintenance of the unit.
The PS-HV takes the DC voltage across the inverter bridge capacitors and provides
the power supply to all the control PCB’s.
The I/S Control Logic (I/S CL) controls all the UPS’s functions and signals. It takes
the digital inputs (like auxiliary contacts, switches and so on), makes all the analog
measures (like voltages, currents and so on) and provides the total control of the UPS.
All the analog measures are transferred to the I/S CL through the interface board
IBPC4-PB087
The SCP front panel represents all the information, alarms and measures coming
from the UPS through a LCD display and leds.
OM226025 Rev. A 3
UPS functioning description
4 OM2226025 Rev. A
UPS functioning description
OM226025 Rev. A 5
UPS functioning description
6 OM2226025 Rev. A
UPS functioning description
In this type of UPS the three phase input mains is connected to the 1-L1, 1-L2 and 1-
L3 terminal boards. The RF1 EMI filter provides to reduce the high frequency
disturbances according to the EN50091 -2 limits.
You can power on the unit by closing the input circuit breaker RCB. The input
inductor L1 reduces the commutation disturbances before the full controlled SCR
rectifier bridge PS1, PS2 and PS3. The SCR’s of the bridge are protected by the F1, F2
and F3 fuses. The SYNC-12 card provides the synchronization and the power supply to
the RCLS-1 card which controls the rectifier. The shunt SH1 provides the total rectifier
current limitation signal, the shunt SH2 is for the battery current limitation.
The battery is mounted outside the UPS and can be connected to the unit through
the +B -B terminal boards; the rectifier provides the recharging current and keeps the
battery in floating to compensate the self discharging.
In case of mains fault, the inverter supplies the load taking energy from the battery.
The inverter bridge is composed by the three IGBT’s (single switch configuration)
PS1, PS2, PS3, (PS4, PS5 and PS6) controlled by the drivers ID1, ID2 and ID3.
The hall effect ammeter TA1 provides the current signal for the inverter bridge
protection (max. Current Stop) and the current limitation in case of short circuit at the
inverter output.
The inverter bridge is connected to the output transformer T1, which provides the
galvanic insulation between the bridge and the output and, by its leakage inductance,
forms a low pass filter with the Cr,Cs,and Ct output capacitors for the hihg frequency.
The inverter normally supplies the load through the inverter static switch (SCRSF) and
the output circuit breaker OCB.
The emergency line is connected to the same terminal boards than the input mains
(plus the 1-N terminal for the neutral). The SBCB circuit breaker connects the
emergency line to the automatic bypass static switch SCR’s; the F1, F2 and F3 fuses
protect the automatic bypass thyristors PS7, PS8 and PS9.
The UPS automatically transfers the load to the bypass in case of an inverter failure
or an overload higher than 2 times the nominal output current. The manual bypass
circuit breaker MBCB connects directly the input emergency line to the load in case of
maintenance of the unit.
The PS-HV takes the DC voltage across the inverter bridge capacitors and provides
the power supply to all the control PCB’s.
The I/S Control Logic (I/S CL) controls all the UPS’s functions and signals. It takes
the digital inputs (like auxiliary contacts, switches and so on), makes all the analog
measures (like voltages, currents and so on) and provides the total control of the UPS.
All the analog measures are transferred to the I/S CL through the interfaces INV. AV-
3F and VOLT REF 3F.
The SCP front panel represents all the information, alarms and measures coming
from the UPS through a LCD display and leds.
N.B. In the 12 pulses configuration (12P), a phase shift transformer is added at the
input of the rectifier which is divided in two half bridges in parallel with electronic
balancing. The control of the second bridge is carried out by adding a second RCLS-1
programmed as a Slave.
OM226025 Rev. A 7
UPS functioning description
The phase shift transformer is can be with two secondary windings (galvanic
insulation of the mains rectifier), or connected only to the Slave input bridge. In this case
there is no galvanic insulation from the mains.
12 pulse configuration is available from 40 KVA upwards.
2. PCB’S
2.1 I/S CONTROL LOGIC
2.1.1 Introduction
The I/S Control Logic (I/S CL) controls all the UPS’s functions and signals. It takes
the digital inputs (like auxiliary contacts, switches and so on) ,makes all the analog
measures (like voltages, currents and so on) and provides the total control of the UPS.
8 OM2226025 Rev. A
UPS functioning description
2.1.8 Rcb
The RCB is an additional card which is fixed on the I/S CL. It contains the drivers for
the digital outputs of the microprocessor. Each output is decoupled and buffered on this
card (see the RCB electrical drawing). The RCB contains also the RS232 and Rs485
drivers for the communication.
The K1 relay (though the M1 connector) drives the precharging thyristor (units up to
40 KVA).
OM226025 Rev. A 9
UPS functioning description
the UPS Test Procedure). As the unit goes in limitation the short circuit detector sends
the short circuit signal to the microprocessor (alarm A25 Short Circuit).
2.1.11 Vcb
The VCB is an additional card which is fixed on the I/S CL. It contains the sinus wave
generator which converts the digital samples of the sinus wave coming from the
microprocessor into an analog signal which is transferred to the PWM generator (see
below). This card can be programmed by the J1 for work in manual control, (in this case
the inverter output voltage can be controlled manually by turning the potentiometer P1
on the I/S CL) or in closed loop control (in this case the inverter output voltage can be
setted by turning the potentiometer P1 on the VCB and it is kept the same in all the
conditions by the control loop). It is also possible to include or exclude the
instantaneous value loop by adding or removing the jumper J2 (see the Programming of
PCB’s). This card also sends the measure of the inverter output voltage the
microprocessor through the external A/D Converter (see below).
A/D Test
Measure
Channel Point
Inverter Output Voltage R #0 D43 (K)
Inverter Output Voltage S #1 D20 (K)
Inverter Output Voltage T #2 D21 (K)
Output Current R #3 D6 (K)
Output Current S #4 D33 (K)
Output Current T #5 D5 (K)
Inverter Input Voltage (DC) #6 D23 (K)
Inverter Input Current (DC) #7 D22 (K)
Phase Correction for Parallel
#8 D42 (K)
Redundant
Battery Current for Boost
#9 D74 (K)
Charger
10 OM2226025 Rev. A
UPS functioning description
OM226025 Rev. A 11
UPS functioning description
the SCB on the I/S CL through the connector CN3 (pins 1-2-3-4 —> ground; pins 5-6 —
> +5V and pins 9-10 —> +24V). The connector CN2 (through the fuses FU1, FU2 and
FU3) supplies the fans of the inverter transformer (FU1), the inverter bridge (FU2) and
the static switch (FU3).
12 OM2226025 Rev. A
UPS functioning description
3. ID (IGBT’S DRIVER)
The IGBT’s Driver ID allows to drive a full bridge leg composed by two IGBT’s in
parallel for each of the two switches.
It is composed by two identical sections (see the ID Electrical Drawing), one to drive
the high switch of the bridge leg (U1, U2, U3 and so on), the other for the low switch
(U4, U5, U6 and so on).
We will describe the high switch section only: you can extend this description to the
other section of the driver.
This section of the driver takes the power from the 40 Khz square wave on CN1 pin 1
and 3, which comes from the PS (Power Supply): the pulse transformer TR1, the diodes
D4, D5, D6 and D7 create a power supply +/- 15V galvanically insulated from the PS
itself.
The voltage regulator U2 provides a +5V which can be checked on the led LD3
(green).
The on command for the IGBT’s, coming from the I/S CL, is transferred to the Driver
through the connector CN1 pin 7 (ground) and pin 8 (+12V = ON) and the optocoupler
U3. The R4-C5 low pass filter creates the dead time for the pwm modulation, trough the
nand gates U1.
The final stage DZ1, Q2, Q3 and Q4 translates the modulation signal between +15V
(ON Level) and -15V (OFF Level) and works as a buffer.
You can programme the ON and OFF resistors R11, R12, R13 and R14 as follows:
OM226025 Rev. A 13