Digital Pure Sine Wave Uninterruptible

Power Supply (UPS) Reference Design Power Supply (UPS) Reference Design
Demo Instructions
Whats Included?
Offline UPS
CD-ROM with
documentation
and code
Offline UPS
Reference Design
3x 12V SLA Batteries
Battery Input Cable
2x Battery Jumper Cables
Output Power Cord
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2x Battery Jumper Cables
Setup and Connections
Visually Inspect the System to ensure
no damage has been caused during
shipping.
Ensure the ON/OFF switch is in the OFF
position as shown below. p
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Setup and Connections
Ensure that the Mains Input switch is in
the OFF position as shown below
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Setup and Connections
Ensure that the battery input cable is
disconnected from the system
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Setup and Connections
Use supplied batteries only!
Connect the batteries in series using
the supplied battery jumper cables pp y j p
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Setup and Connections
Connect the supplied battery input
cable to the positive and negative
terminals of the series-connected
batteries as shown.
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Setup and Connections
Caution: Ensure correct polarity for the
battery cable!!
Connect Red
cable to positive
Connect Black
cable to negative
terminal terminal
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Setup and Connections
Now connect the battery cable to the
battery input terminal on the Offline
UPS. A loud click will be heard when
the connection is made.
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Setup and Connections
Connect the supplied
t t bl t output power cable to
the UPS Output
terminal The other terminal. The other
end of this cable
should be connected
to the load. (See
Application note for
load specifications)
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Setup and Connections
To perform load steps, connect a 5A,
250Vac switch in series with the output 250Vac switch in series with the output
cable (not supplied).
Differential probes must be used to observe Differential probes must be used to observe
the output voltage. The differential probe
can be connected to the open end of the
output cable.
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Setup and Connections
With the Mains
switch in the OFF
position, connect a
standard power
cord (not supplied)
to the Mains input.
Plug the other end g
to a 220V, 50Hz AC
outlet
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Apply Mains
First apply AC Mains input by flipping
the Mains input switch to the ON
position
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Turn ON UPS
Turn the Offline UPS Reference Design
ON by flipping the On/Off switch to the
ON position
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System Power Up
After turning the system ON, the LCD
screen will briefly display the Microchip
Logo and the software version. The
fans will also start running.
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System Power Up
Note: AC Mains must be present when
starting up the Offline UPS. If Mains is
not available during startup, the UPS
will enter the System Error mode.
This feature is implemented as a p
protection scheme to minimize stress
on the system components during y p g
startup.
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System Operation
After the system startup sequence is
completed, the LCD will display the
mode of operation and other status
information.
With Mains connected, the UPS will ,
operate in the Battery Charger mode
and AC Mains will supply power to the pp y p
load.
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Switch-Over Test
To simulate a Mains
failure flip the Mains failure flip the Mains
input switch to the
OFF position.
In this position, the
UPS will switch to the
Inverter Mode The Inverter Mode. The
LCD screen will
display the mode,
b tt t t t t battery status, output
voltage and output
current.
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Switch-Over Test
Capture the waveform on the
oscilloscope during a switch-over
event and observe the transfer time.
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Switch-Over Test
Flip the Mains input
switch to the ON switch to the ON
position to connect
AC Mains to the UPS
again.
In this position, the
UPS ill it h b k UPS will switch back
to the Battery
Charger mode and g
AC Mains will
provide power to the
load
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load.
Switch-Over Test
Capture the oscilloscope waveform
during the switch-over event and
observe the transfer time.
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Load Step
Next, we will test the dynamic load response
f th UPS of the UPS
With the load in the OFF state, flip the Mains
i t it h t th OFF iti t it h t input switch to the OFF position to switch to
the Inverter mode.
Now turn the Load ON and observe the Now turn the Load ON and observe the
response of the UPS output on the
oscilloscope. oscilloscope.
Turn the Load OFF and observe the response
of the UPS output on the oscilloscope.
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p p
Known Issues / Updates
Depending on the load conditions, AC mains to Inverter switchover time may
exceed 10ms
Th Hi h C t f t i i di l d th LCD ft l The High Crest factor warning may remain displayed on the LCD after normal
load conditions are reinstated
Inductive load has been tested to 1000VA .8pf
In order to increase reliability of the UPS the maximum operating power was
d t d t 800W ti l d 1000Wf l th 1 i t derated to 800W operational and 1000W for less than 1 minute.
PCB Issues
The 15V mask should be labeled as 12V
The inverter output inductor is mislabeled, should be L2 not TR1
R i t R83 d R86 h dt 1k DNP ti l Resistor R83 and R86 were changed to 1k, DNP respectively.
Cooling fan for the Push-Pull section was replaced with fan P/N: PF92251B1-000U-A99
(MFG: SunonFans), to decrease DC loading of the Auxiliary power supply.
UPS MAINS-INPUT Earth Ground connections is now connected to the UPS
Chassis and to the UPS OUTPUT Chassis and to the UPS OUTPUT.
Depending on the silicon revision of the LCD Display Microcontroller
(PIC18F2420) the CKE bit ( SSPSTAT register bit #6) should be set as follows:
PIC18F2420 Silicon Rev 1, Rev 2, Rev 3 set CKE=1
PIC18F2420 Silicon Rev 4 set CKE=0
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Note: LCD setup code is located in \LCD Code pic18f2420\main.asm, line #399