Sect 1

Section 1: System Description
Chapter 1 - Functional Description

1.1 System overview ...................................................................................... 1-1
1.2 7200 Series UPS single-module configuration ...................................... 1-2
1.2.1 Power rectifier & battery charging .............................................. 1-2
1.2.2 Battery charging modes ............................................................... 1-3
1.2.3 Power inverter .............................................................................. 1-4
1.2.4 Static switch assembly ................................................................. 1-5
1.3 UPS Power Switch Configuration ............................................................ 1-6
1.3.1 Maintenance bypass supply ......................................................... 1-6
1.3.2 Static bypass configuration .......................................................... 1-6
1.4 1+1 Parallel-module system ................................................................. 1-7
1.4.1 Redundant vs Non-Redundant configuration ............................... 1-7
1.4.2 Inter-module power rectifier control ............................................ 1-8
1.4.3 Inter-module inverter control ....................................................... 1-8
1.4.4 Inter-module static switch control ............................................... 1-9
Chapter 2 - Main Power Circuit Diagram Descriptions
2.1 Chapter overview ................................................................................... 1-11
2.2 30kVA Model description SE-5410303-P .......................................... 1-12
2.3 40kVA Model description SE-5410304-Q .......................................... 1-17
2.4 60kVA Model description SE-5410308-U .......................................... 1-22
S-1.fm5 - Issue 2 Dated 21/08/97
SECTION 1 - System Description
ii
7200 Series UPS Service Manual
S-1.fm5 - Issue 2 Dated 21/08/97
Section 1:
Chapter 1 - Functional Description
1.1
System overview
A 7200 Series Uninterruptible Power Supply (UPS) system is designed to furnish
a well regulated 3 phase power supply to a critical load, such as a computer, under
all rated load and input supply conditions. Being of a category known as an online UPS system, it is permanently connected between the utility 3-phase supply
and the load equipment and operational at all times, as shown in Figure 1-1.
Figure 1-1: UPS System connections
Q1
Input
Mains
Q4
Output
to
Load
7200 UPS
Input Sw
Output Sw
SW-BAT
BATTERY
The UPS system offers the user the following advantages:
Increased power quality: The UPS has its own internal voltage and frequency
regulator circuits which ensure that its output is maintained within close tolerances independent of voltage and frequency variations on the mains power lines.
Increased noise rejection: By rectifying the input AC power to DC power, and
then converting it back to AC, any electrical noise present on the input mains
supply line is effectively isolated from the UPS output, therefore the critical load
sees only clean power.
Power blackout protection: If the mains power fails, the UPS continues to
power the critical load from its back-up battery source, leaving the load immune
from power disturbances even complete power blackouts.
This manual describes two types of system configuration; a single-module system, and a two-module parallel-operating system which is known as a 1+1 system. Note that the modules used in both system configurations are broadly
identical, and it is possible to convert a single-module system to a 1+1 parallel-operating system with the addition of a second module and a degree of intermodule control and power wiring.
This chapter continues by functionally describing a single-module UPS system
followed by details of the changes and additions applicable to the 1+1 configuration. To understand the functional operation of a 1+1 system you should
therefore first read the single-module description.
s1-c1.fm5 - Issue 2 Dated 21/08/97
1-1

CHAPTER 1 - Functional Description
1.2
7200 Series UPS single-module configuration

The 7200 UPS comprises two major controlled power modules, the rectifier and
inverter, which together operate as an AC-DC-AC converter (See Figure 1-2).
1.2.1
Power rectifier & battery charging

The first conversion stage (from AC to DC) uses a 3 phase, fully-controlled SCR
bridge rectifier to convert the incoming mains supply into a regulated d.c. busbar
which, when the input supply is present, powers the inverter section and also provides the battery with its continuous float charging voltage. The nominal d.c.
busbar voltage (i.e. battery float voltage) depends on the number of cells forming
the battery, which in turn varies according to the systems nominal working voltage (See Table 1-1). Also, a temperature-compensated battery charging regime is
used to prolong battery life, and this will slightly affect the dc busbar (float) voltage produced by the rectifier by reducing the charge voltage as the battery temperature rises.
Table 1-1: DC Bus voltage parameters
Parameter
380V
400V
415V
192
198
204
Nominal battery float charge
432Vdc
446Vdc
459Vdc
Nominal battery boost charge
460Vdc
475Vdc
490Vdc
End of battery discharge
320Vdc
330Vdc
340Vdc
Absolute maximum (manual)
480Vdc
495Vdc
510Vdc
Number of battery cells
In the event of a mains power failure, the rectifier becomes inoperative and the
inverter is powered solely from the battery, which obviously begins to discharge.
Critical load power is thus maintained under these conditions until either the input
mains is restored or the battery is fully discharged (See Table 1-1) whereupon
the UPS shuts down.
The period for which the load can be maintained following a mains power failure
is known as the system's Autonomy Time and is dependent upon both the battery
A/Hr capacity and the applied percentage load.
Figure 1-2: Block diagram of main power flow
DC Busbar
Q1
Input
Mains
Q4
Rectifier
Output
to
Load
Inverter
Input Sw
Output Sw
SW-BAT
BATTERY
1-2
1.2.2

Battery charging modes

The batteries are connected to the DC busbar via an external circuit breaker and
the rectifier voltage can be controlled at three selected battery charge levels.
These level are described as:
Float charge
Boost charge
Manual charge
Caution
1.2.2.1
Boost charge should not be used with valve-regulated (sealed-cell) batteries

Float charge
This is the normal mode of operation when using non-sealed cells and the ONLY
permissible mode when using sealed-cells. In the float charge mode the rectifier
is set to operate at 2.27V/cell (2.23V/cell for Yuasa batteries) calibrated by a
potentiometer on the Rectifier Logic Board (See section 4 paragraph 2.3.2).
Battery current limit
A hall-effect DCCT fitted in the battery feeder monitors the charging current and
drives a current-limit circuit on the Rectifier Logic Board (See section 4 paragraph 2.3.4.1) which, when appropriate, restricts the charge current to a preset
maximum level by reducing the DC busbar voltage. This is adjustable within the
range 025% of the rectifier input current rating and is factory set at 15%.
In practice, this circuit is only likely to come into operation when the mains
supply is restored following a prolonged outage and the batteries are heavily discharged. Under these circumstances you may observe a reduced DC busbar voltage when the mains initially return. As the batteries take on charge, and the charge
current therefore reduces, the effects of the current limit control is gradually lifted
and the busbar voltage increases to nominal.
1.2.2.2
Boost charge
If the boost charge facility is enabled and the batteries undergo a heavy discharge during a mains outage, the Rectifier can automatically switch to its boost
charge mode of operation when the mains supply returns. This increases the DC
busbar voltage to the preset boost charge level (See Table 1-1). The resulting increase in battery charge current reduces the time taken by the batteries to regain
their lost charge in readiness for the next mains failure. The boost charge level
is set on the Rectifier Logic Board (See section 4 paragraph 2.3.2).
Note: the battery current limit function is still active when boost charge is invoked.
Float/Boost changeover
If the boost charge facility is enabled the rectifier does not necessarily adopt the
boost charge mode every time the mains supply returns from an outage; but is
invoked only if the charge current exceeds a certain threshold (known as the
float/boost changeover threshold) after a brief time has elapsed i.e. if the
charge current does not exceed the float/boost changeover threshold the rectifier will adopt, and remain in, its float charge mode upon mains return.
If the current does exceed the float/boost changeover threshold the rectifier will
adopt the boost mode until the batteries are sufficiently charged that their charge
current falls below the changeover threshold, whereupon it will switch back to
1-3

its float charge level. The time for which the batteries are subjected to the boost
charge is therefore mainly dependant on the discharge level.
Boost duration timer
If there is a fault on the battery string, such as several shorted cells, the resulting
increased charge current could be sufficient to trigger off the boost mode irrespective of whether or not the batteries had been heavily discharged. Also, under such
circumstances the charge current is unlikely to fall back below the float/boost
threshold and the rectifier will continue to operate at its boost charge level indefinitely; which in turn could lead to yet further battery damage. To overcome such
events, a timer in included in the float/boost changeover control logic which
limits the duration for which the rectifier is allowed to operate in the boost charge
mode.
Although the rectifier float and boost charge voltages are set by variable resistors located on the Rectifier Logic Board, the changeover threshold and duration timer are processor controlled and can be set from the UPS Control Panel.
Note: it is also possible to invoke an immediate boost charge manually from the
UPS Control Panel (normally undertaken only during commissioning).
1.2.2.3
Manual charge
When manual charge is selected (from the UPS Control Panel) the rectifier
(D.C. busbar) voltage is manually controlled by a potentiometer on the Rectifier
Logic Board and can be adjusted from zero up to the rated maximum (See
Table 1-1). In practice this facility is used as a means of controlling the rectifier
during troubleshooting and can also be useful when applying the initial battery
charge during commissioning (open vented cells only).
When the rectifier is operating in the manual mode the inverter is automatically
shut-down to prevent damage.
1.2.3
Power inverter
Embracing the latest IGBT switching technology, the inverter power section employs PWM control techniques to convert the dc busbar into an a.c. voltage which
is then transformed up to the nominal system working voltage and fed to the load
terminals via the output static switch.
The purpose of the inverter is therefore to convert the wide-ranging D.C. busbar
voltage (See Table 1-1) into a tightly controlled 3-phase 50Hz sinusoidal output.
The inverter control philosophy includes independent voltage regulation control
of each of the output three phases, together with current limit and overload protection. The output frequency is digitally controlled and normally synchronised to
the bypass supply see description of the Static Switch operation below.
1-4
1.2.4

Static switch assembly

Figure 1-3: Block diagram showing Static Bypass
BYPASS
Q2
BYP-SS
Bypass Sw
Static
Switch
MAINS
Q1
Rectifier
Input Sw
Inverter
Q4
INV-SS
Output Sw
Figure 1-3 shows a block diagram of the static switch and its relationship with the
other UPS power blocks. As the diagram shows, the static switch comprises two
areas: one (INV-SS) is connected between the inverter and output terminals and
the other (BYP-SS) is connected between the output terminals and a switched 3phase bypass supply line.
The purpose of the static switch is to provide a means of transferring the load between the inverter and raw bypass supply in a controlled manner such that it experiences no power-break when transferring from one to the other.
Under normal circumstances the inverter-side static switch (INV-SS) is closed
and the load is powered from the inverter output; however in the event of an inverter fault, or overload which exceeds the inverter capability, the inverter-side
static switch opens and the bypass-side closes, in a make-before break fashion,
and transfers the load to the 3-phase bypass supply. Conversely, when the inverter
becomes available (or the overload condition clears) the load is transferred back
to the inverter-side and the system continues its normal operation.
In order for a no-break transfer to take place the inverter frequency is normally
synchronised to the bypass supply at all times provided the bypass frequency
remains within a specified frequency window. An out of sync alarm annunciates
if the inverter is unable to synchronise to the bypass supply due to an out-ofwindow condition or unstable bypass supply. This does not affect the normal UPS
operation, in as much as the inverter frequency will remain within its prescribed
limits, however if this condition is present when a transfer-to-bypass is requested
then there will be a slight break (max 1 cycle) in the load supply while the transfer
takes place to protect the critical load from possible high voltage transients
when switching between out-of-phase supplies.
In practice, the inverter-side static switch function is served by a contactor while
the bypass-side static switch comprises a pair of inverse-parallel connected
SCRs in each bypass line (6 SCRs in total). The contactor coil and SCR gates are
controlled by an interlocking circuit on a common control circuit board which
prevents both sides of the static switch from being energised at the same time.
1-5

1.3
UPS Power Switch Configuration

Figure 1-4: Power Switch configuration
Q3
Maint Bypass SW
BYPASS
Q2
BYP-SS
Bypass Sw
MAINS
Q1
Q4
Rectifier
Input Sw
1.3.1
Inverter
INV-SS
Output Sw
Maintenance bypass supply

An alternative hard-wired bypass supply is made when Q3 is closed. This connects the UPS output terminals directly to the bypass supply and is designed to
allow the load to be powered from the bypass while the remainder of the UPS is
shut-down for maintenance or troubleshooting.
If the UPS control logic detects that Q3 and Q4 are closed simultaneously, it will
shut-down the inverter and open the inverter-side static switch to prevent the
UPS being damaged by reverse power flowing into the inverter output terminals
from the maintenance bypass line.
Caution
1.3.2
The load is not protected against supply aberrations when connected to the bypass supply either on Maintenance Bypass or when running on Static Bypass
Static bypass configuration

Figure 1-4 illustrates that links are connected between the bypass supply terminals and UPS input mains terminals. This allows the UPS to be configured for
either a split or common bypass system as explained below.
Common-bypass configuration
In a common-bypass installation the bypass supply lines are connected to the

input mains terminals via the bypass links and there are no external power connections to the bypass terminals.
Split-bypass configuration
In a split-bypass installation the links between the input mains and bypass terminals are removed and a dedicated 3-phase bypass supply is connected to the
bypass terminals. The advantage of this type of installation is that a separate
power source may be used for the bypass lines which can be totally segregated
from the UPS input mains, thus leaving the bypass supply available on occasions
when the input mains supply has failed.
1-6
1.4

1+1 Parallel-module system

Figure 1-5: 1+1 System configuration block diagram
RECTIFIER
INVERTER
Rectifier
Control Logic
Inverter
Control Logic
INV (SS)
Static
Bypass
BYP (SS)
Static Switch
Control Logic
Inter-Module Parallel Control Logic
Maint. Bypass
Output
(LOAD)
PowerSupply
Maint. Bypass
Static Switch
Control Logic
Inter-Module Parallel Control Logic
Rectifier
Control Logic
Inverter
Control Logic
RECTIFIER
INVERTER
Static
Bypass
BYP (SS)
INV (SS)
As illustrated in Figure 1-5 above, the 7200 Series 1+1 system comprises two
standard UPS modules, as used in a single-module system, which are modified
to allow their outputs to be connected in parallel. These can then be used in a redundant or non-redundant configuration as explained below.
The diagram shows that from a power viewpoint each module is internally identical to the single-module configuration, with each module containing a rectifier, inverter, static switch (inverter and bypass sides), together with static bypass
and maintenance bypass supplies.
However, due to the parallel connection of the two modules outputs a 1+1
system requires additional inter-module control signals to manage current sharing, synchronising and bypass switching between the modules.
As shown, the inter-module control features are implemented via a control bus
connected between the two modules which affects the rectifier, inverter and static
switch module control blocks. A brief description of the affects on each of these
blocks is given below.
1.4.1
Redundant vs Non-Redundant configuration

Redundant system
If a 1+1 system is configured as a redundant system the modules are sized

such that the potential maximum load can be powered by just one of the two modules. Under normal circumstances both modules are operational and share the
load current equally; but if one module develops a fault, or is shut down, the second, healthy module is able to take over the full load demand and continue to provide it with processed, backed-up power.
1-7

Non-redundant system
In a non-redundant configuration, the system is sized such that both UPS modules are required to feed the potential maximum load, and if either of the two modules develops a fault, or is for some reason shut down, the other module is
automatically shut down also note that in such an event the load is transferred
to the static bypass supply, as described later.
In terms of overall system reliability, the advantages of a redundant system over
that of a non-redundant system are self evident.
Changing a 1+1 system between a redundant and non-redundant configuration is quite straightforward, and is carried out by selecting configuration links on
the control circuit boards fitted to both modules.
1.4.2
Inter-module power rectifier control

The power rectifier is only affected by the parallel control bus in a 1+1 system
if a common battery is used i.e. if both UPS modules are connected to a single
battery bank (via separate battery isolators of course). In this type of installation
the power rectifiers in each module are effectively connected in parallel and must
be controlled such that the battery charge current is shared equally between them.
A common battery option kit is available. This contains DCCTs (DC Current
Transformers) which are fitted to the battery power lines and connected via the
parallel control bus to a sharing circuit in the rectifier control block.
See the Options section in the relevant system IOM user manual for full details.
1.4.3
Inter-module inverter control

Synchronisation:
As the outputs from both UPS modules are connected together to provide a single
critical load supply, it is imperative that the inverters are fully synchronised both
in frequency and phase. This is achieved by digitally locking the two inverter control oscillators. Similarly, as has previously been mentioned, it is necessary for the
inverters to be synchronised to the bypass supply to enable a no-break transfer
to take place when the static switch transfers the load to the bypass supply. The
inverter control oscillators are therefore not only locked together but also made to
track the bypass frequency.
Current sharing:
The parallel control circuit compares each module's output current with that of its
partner and is thereby able to effect current sharing by making fine adjustments
to an individual module's output voltage.
Reverse current:
A reverse current monitor circuit detects current flowing into, rather than out of,
a module's output terminals. Such a condition can arise if one module develops an
internal power fault which sinks power from the second modules output, or if for
some reason the two modules become unbalanced. A reverse current is liable to
further damage a module and also degrade the load supply.
If a reverse current is detected the inverter on the affected module is immediately
shut down and the load transferred to the bypass supply if the system is configured
to be non-redundant.
1-8
1.4.4

Inter-module static switch control

Note: in the following text the term inverter-side static switch refers to the inverter output contactor.
There are three important conditions imposed on the static switch operation in a
1+1 system:
1. Under no circumstances must the inverter-side of one module be closed at the
same time as the bypass-side is closed in the other module, as this would
effectively parallel the output of one module with the bypass mains supply
and likely to damage the system.
2. For similar reasons, the inverter-side of both modules must be opened if the
maintenance bypass isolator is closed in either module.
3. Finally, when the system is started up the inverter-side must not be closed
until its associated inverter is fully synchronised with the inverter in the second module. This is especially important in the case of a redundant installation where one module may be on-line and supplying the load before the
second module is started.
In a non-redundant configuration the start-up control sequence operates
such that both inverters must be operating and fully synchronised before the
static switch is allowed to transfer the load from the static bypass to the
inverters.
In a non-redundant system the parallel control bus effectively ties together the
static switches in both modules i.e. both modules are either on inverter-side or
bypass-side.
1-9

1-10
Section 1:
Chapter 2 - Main Power Circuit Diagram Descriptions
2.1
Chapter overview
This chapter contains individual descriptions of the Power Drawings for each of
the 7200 Series models and should be read in conjunction with the appropriate circuit diagram and assembly drawings indicated in Table 1-2.
Table 1-2:
Model
Circuit Diagram
Assembly Diagram
30kVA
SE-5410303-P (3 pages)
AM-5410303-P (12 pages)
40kVA
SE-5410304-Q (3 pages)
AM-5410304-Q (12 pages)
60kVA
SE-5410308-U (3 pages)
AM-5410308-Q (12 pages)
Each drawing comprises several pages and a system of cross-referencing is used

where connections are made across different pages. The cross-reference takes the
form of a page number followed by a grid reference and will be shown in the following text encased in square brackets for example [2/C3] refers to page 2 area
C3. The grid reference system is shown on the left-side (A-R) and top (1-19)
edges of the drawings.
30kVA Description (see paragraph 2.2 on page 1-12)

1-11

CHAPTER 2 - Main Power Circuit Diagram Descriptions
2.2
30kVA Model description SE-5410303-P

SE-5410303-P Page 1. This page shows the UPS input, rectifier, dc bus, inverter and output transformer power circuits.
Bypass supply feed
The UPS input mains supply is connected to terminals U(1)-V(1)-W(1) which are
in turn connected directly to the input switch Q1.
If a common bypass system is used the input supply terminals U(1)-V(1)-W(1)
are connected by links to the bypass terminals U(3)-V(3)-W(3)-N(3) [2/G2]. If a
split-bypass system is used then these links must be removed and a dedicated
bypass supply connected to U(3)-V(3)-W(3)-N(3) [page 2].
Input switch Q1 to rectifier
The input mains is connected to the rectifier via the input switch (Q1), input fuses
F10-F12, RFI filter (Z1), optional input filter (4641015P) and input choke (L1).
The input voltage is monitored by the control system via wires 15-17 and the High
Voltage Interface Board [3/N8]. This is used to detect input voltage failure
(-20%), input phase rotation error and also provides basic phase-timing information for the rectifier SCR control logic. The V and W phases also power the control power supply transformer (T2) via F8 and F9. T2 primary has three taps
which are selected according to the working voltage to produce a nominal 30Vac
secondary voltage tap selection details are shown on the diagram [R6]. T2s secondary feeds one input to the AC-DC Power Supply (4503030-M) [3/D19]
Power rectifier block
The rectifier assembly, shown as a dashed block, is shown in detail in diagram

SE-4612043-H (circuit diagram) and AM-4612043-H (assembly drawing). This
assembly also contains the static switch power components in addition to those
belonging to the rectifier.
Considering the rectifier, this assembly contains the six SCRs associated with the
rectifier together with their Gate Drive Control Board (SE-4542040-W) and snubber board (SE-4540043-B). There are also two thermostats fitted to the U and V
phase heatsinks (not normally used).
The rectifier gate drive signals are applied to connector X7 on the Gate Driver
Control Board (SE-4542040-W) via ribbon cable W4, and the rectifiers output
DC power rails are connected to the dc busbar via cables 27 (+) and 28 (-).
DC Busbar
The DC busbar is controlled by the rectifier to be at the required battery charging

voltage at all times and is smoothed by a capacitor bank (C1-C4) less than 1%
voltage ripple. The smoothed busbar is then connected to the batteries via an external circuit breaker, and to the inverter (4612143-D). In the battery line is a
DCCT (T11) which provides the UPS control system with a battery current sense
signal via the High Voltage Interface Board [3/G6] used for battery current limit
control and metering. A battery fuse (F13) is fitted and monitored by means of a
micro-switch to detect its failure [3/G2].
Wires 27 and 28 provide the rectifier control system with a dc busbar (battery)
feedback voltage via the High Voltage Interface Board [3/N9] used for closedloop voltage control and dc bus (battery) voltage metering. The dc busbar is also
connected to a DC-DC control power supply board [3/E7] via fuses F4-F5 the
1-12

same fused supply is connected to the inverter output contactor control circuit on
the static switch assembly [2/G8], described below.
Power inverter
The inverter assembly, shown as a dashed block, is shown in detail in diagram

SE-4612143-D (circuit diagram) and AM-4612143-D (assembly drawing). This
assembly contains the six inverter IGBT transistors (3 x twin pack devices), three
Base Drive Boards (4519015-H), and suppression capacitors.
The transistor drive signals from the inverter control electronics are connected via
ribbon cables W1-W2-W3 to CN1 on each Base Drive Board.
Power inverter to output switch
The inverter output is connected to the output transformer where it is stepped-up

to the required output voltage. The output transformer step-up ratio is 1:2 and it
is delta-star (zig-zag) wound with the output star point connected to the systems
neutral.
Capacitors C5-C10, connected across the output line-to-line, act as a filter to
remove any remnants of the PWM switching frequency from the output waveform, thus producing a clean sinusoidal output at the nominal output frequency.
Current transformers T9 and T10 provide the inverter voltage regulation control
system with output current sense signals, via the High Voltage Interface Board
[3/G7-G8]. These are used by the inverter regulation control electronics to enhance the inverter regulation during load changes, and also by the output current
limit protection control system.
Wires 9-11 provide the inverter voltage control system with an output voltage
feedback signal, via the High Voltage Interface Board [3/H4]. This is used by the
inverter voltage regulation control system and static switch fault and transfer
control logic.
SE-5410303-P Page 2. This page shows the bypass input and UPS output
power connections together with the bypass circuits.
Bypass supply feed
If the UPS is connected with a split-bypass supply the dedicated bypass supply
is connected to U(3)-V(3)-W(3)-N(3) from where it is connected to the static
bypass switch Q2 and maintenance bypass switch Q3. If a common bypass
system is used there are no external connections to U(3)-V(3)-W(3)-N(3) and the
power to Q2 and Q3 is obtained from the UPS input mains supply terminals
U(1)-V(1)-W(1) [page 1] via links which are connected between the mains and
bypass input terminals [1/C2].
Maintenance bypass switch
The maintenance bypass switch (Q3) makes a direct connection between the
bypass supply and UPS output terminals, therefore completely bypassing the UPS
for maintenance and troubleshooting purposes. This switch is always open during
normal UPS operation, and can be padlocked in that position. If the switch is
closed while the inverter is operating (i.e. while Q4 is closed) its auxiliary contacts [3/L1] trigger a safety circuit in the UPS control system which will open the
inverter output contactor to isolate the power inverter from the output terminals
and prevent any damage which might otherwise occur due to reverse power flow.
1-13

Static bypass switch (Q2) to static switch assembly
Q2 connects the three-phase bypass supply to the static switch assembly and must
be closed during normal UPS operation to ensure the availability of the static
bypass supply when required.
The bypass voltage at the switched side of Q2 is monitored by the High Voltage
Interface Board via wires 1,2,3 and 4. This is used for bypass voltage error detection and inverter synchronisation control; the U and V phases also power the control power supply transformer (T3) via F6 and F7. T3 primary has three taps
secondary voltage tap selection details are shown on the diagram [G6]. T3s secondary feeds one input to the AC-DC Power Supply (4503030-M) [3/D19].
The static switch assembly, shown as a dashed block, is shown in detail in diagram SE-4612043-H (circuit diagram) and AM-4612043-H (assembly drawing).
This assembly also contains the rectifier power components in addition to those
belonging to the static switch, as described earlier.
From the static switch point of view, this assembly contains the six SCRs associated with the bypass static switch together with their Gate Drive Control Board
(SE-4542041-X) and snubber board (SE-4540043-B).
All the connectors shown in the static bypass block on page 2 refer to the Gate
Driver Control Board (SE-4542041-X):
Connector X13 is connected to the UPS Logic Board X5 [3/G16] and
interfaces the Gate Driver Control Board with the remainder of the UPS
control system via ribbon cable W7.
Connector X10 monitors the inverter output contactors auxiliary contacts,
which are used for interlocking and status indication purposes.
Connector X9 carries the switched supply for energising the coil of the
inverter output contactor.
Connector X8 is connected to the DC busbar [1/H8] via F4-F5 and is the
source of the inverter output contactor energising supply.
Terminals A-C and A'-C' are the mains input/output power connections.
Static switch assembly to output switch Q4
The static switch power outputs are connected to the output switch (Q4) via an
output RFI filter (Z2) and output current sensing CTs (T4-T6), which are used for
metering purposes and overload monitoring. Note that the inverter output contactor is connected in parallel with the bypass static switch outputs and is fed from
the output transformer [1/D18]
Wires 5-8 are used for output voltage monitoring and metering purposes, and are
connected to various sections of the UPS control system via the High Voltage Interface Board [3/N8]. They also provide power for the cooling fans which are all
single-phase operating and distributed across the phases as shown. There is no fan
redundancy, and the fan annotated option input filter is fitted to the optional
input filter cabinet.
The output switch Q4 is a 4-pole switch with a set of auxiliary contacts which are
monitored by the control system in the same manner as those described above for
the maintenance bypass (Q3) [3/L1].
1-14

Remote connections
The lower left-hand area of page 1 shows details of various remote connections
to terminal block X3 (X3 connections are made by spade connectors). These
connections are used for:
Emergency stop normally closed (volt-free) circuit connected between
X3 terminals 10 and 11. If an external emergency stop option is not in use
then these two terminals must be shorted together at the terminal block.
Battery temperature sensing the battery temperature is sensed by the
float charge control system such as to decrease the float voltage by
1.5Vdc/C as the temperature increases above 25C. The temperature sensor is connected between X3 terminals 2 and 3, and is polarity sensitive.
Note: Only one temperature sensing device is used even if additional battery cabinets are utilised by the system.
Battery CB-AUX the external battery circuit breaker auxiliary contacts
are connected between X 3 terminals 4 (ground) and 3 such as to short
these terminals together when the breaker is closed.
Battery trip the battery circuit breaker is manually operated but can be
tripped by the UPS control system if required e.g. Low Battery trip when
the battery discharges to 320Vdc. The trip circuit is connected via X3 terminals 4 (ground) and 6 (logic high to trip) and is normally applied to the
breaker via an opto-coupled trip circuit for supply isolation.
SE-5410303-P Page 3. This page shows the UPS control system circuit
boards and their interconnections. A basic description of the individual boards
functions are provided below.
High Voltage Interface Board 4590054-O
This board interfaces the high-voltage sense and control signals of the UPS power
circuits with the low-voltage environment on the control circuit boards.
X1 connects the low voltage signals produced on this board to the UPS
Logic Board from where they are transmitted to the remaining boards
X2 DC bus (battery) voltage sense inputs [1/G8]
X3 Input mains voltage sensing inputs [1/F7]
X4 UPS output voltage sensing inputs [2/H14]
X5 Inverter output voltage sensing inputs [1/C16]
X6 Bypass voltage sensing inputs [2/G5]
X7 Power switch auxiliary contacts
X8 Interface to external connection block X3 [2/M2-M5]
X9 Battery cabinet temperature sensor inputs [2/M3]
X10 Input air temperature sensor inputs for display metering
X11 Inverter output air temperature sensor inputs for display metering
X12 Transformer cabinet temperature sensor inputs for display metering
X13 Inverter assembly thermostats (n/c open above 90C)
X14 Not in use
X15 Battery fuse monitor [1/N4]
X16 Not in use (linked out)
X18 Rectifier assembly thermostats (n/o not normally used)
X19 Output current monitoring W-ph [2/F16]
X20 Output current monitoring V-ph [2/F16]
X21 Output current monitoring U-ph [2/F16]
X22 Battery current monitoring [1/M8]
X23 Not in use
1-15

X24 Inverter current monitoring V-ph [1/E13]

X25 Inverter current monitoring W-ph [1/F14]
X26 Not in use
X27 Not in use
UPS Logic Board 4550004-E
This board serves two major functions: first it contains the logic which controls
the static switch/inverter output contactor and load transfer between inverter and
static bypass supplies. Second, it contains the fault-detection-based general
system control logic which determines the operation of the rectifier (via the Rectifier Logic Board) and inverter (via the Inverter Logic Board).
Note: When compared with the circuit boards fitted in the 7400 Series UPS, this
board combines the UPS Logic Board and Static Switch Logic Board functions.
In addition to the above functions this board also provides an interface between
the general control system and the Operator Panel and external alarms option.
Rectifier Logic Board 4520074-A
The Rectifier Logic Board provides the rectifier SCRs with their gate drive signals at a suitable conduction angle to produce the required battery charge voltage.
It receives battery voltage and battery current feedback signals, and input voltage
sense signals via the High Voltage Interface Board and UPS Logic Board. The
drive pulses are processed on the Rectifier Gate Drive Board (4542040-W) before
application to the SCR gates.
The Rectifier Logic Board receives its operating power from the AC-DC Power
Supply assembly (4503030-M) which is energised whenever the input mains
supply or bypass supply is live (via T2 [1/K5]) or (via T3 [2/H7]) i.e. both these
transformers feed the same power supply circuit in parallel.
Inverter Logic Board 4530024-S
The Inverter Logic Board provides the inverter IGBTs with their base drive signals with a suitable PWM pattern to produce the required output voltage. It receives output voltage and current feedback signals, and bypass voltage sense
signals via the High Voltage Interface Board and UPS Logic Board. The drive
pulses are processed on the Inverter Drive Interface Boards (4519015-H) before
application to the IGBTs.
The Inverter Logic Board receives its operating power from the DC-DC Power
Supply assembly (4503028-K) which is energised via fuses F4-F5 [1/H8] whenever the DC busbar is live i.e. either due to the rectifier being operative (when
the input mains is present) or when the batteries are connected to the dc busbar
(external circuit breaker closed).
Control power supplies
The power supplies from the Inverter Logic Board and Rectifier Logic Board are
paralleled on the UPS Logic Board and fed to the other boards as necessary.
Therefore when the UPS is started-up the control system is powered-up as soon
as the AC-DC Power Supply is energised by the closure of the input mains switch
(Q1). Once the rectifier is fully operational the DC-DC Power Supply provides an
alternative (parallel) supply source which supports the control system operation
if the input mains supply subsequently fails.
Note: the Inverter Logic Board and Inverter Driver Board are energised from the
DC-DC supply only.
1-16
2.3

40kVA Model description SE-5410304-Q

SE-5410304-Q Page 1. This page shows the bypass input and UPS output
Bypass supply feed
system is used, there are no external connections to U(3)-V(3)-W(3)-N(3) and the
power for Q2 and Q3 is obtained from the UPS input mains supply terminals
normal UPS operation, and can be padlocked in the open position. If the switch is
closed while the inverter is operating (i.e. while Q4 is closed) its auxiliary contacts [3/L1] will trigger a safety circuit in the UPS control system which will open
the inverter output contactor to isolate the power inverter from the output terminals and prevent any damage which might otherwise occur due to a reverse power
flow.
secondary voltage tap selection details are shown on the diagram. T3s secondary feeds one input to the AC-DC Power Supply (4503030-M) [3/D19].
The static switch assembly, shown as a dashed block, is shown in detail in diagram SE-4612044-I (circuit diagram) and AM-4612044-I (assembly drawing).
belonging to the static switch.
1-17


source of the inverter output contactor energising supply mentioned
above.
metering and overload monitoring purposes. Note that the inverter output contactor is connected in parallel with the bypass static switch outputs and is fed from
the output transformer [2/B17-B18]
single-phase operating and distributed across the phases as shown. There is no fan
redundancy, and the fan annotated option input filter is fitted to the optional
input filter cabinet.
the maintenance bypass switch (Q3).
Remote connections
The lower left-hand ares of page 1 shows details of various remote connections to
terminal block X3 (X3 connections are made by spade connectors). These connections are used for:
1.5Vdc/C as the temperature increases between 25C and 35C. The temperature sensor is connected between X3 terminals 2 and 3, and is polarity
sensitive.
SE-5410304-Q Page 2. This page shows the UPS input, rectifier, dc bus, inverter and output transformer power circuits.
Bypass supply feed
1-18


are connected by links to the bypass terminals U(3)-V(3)-W(3)-N(3) [1/C1]. If a
bypass supply is connected to U(3)-V(3)-W(3)-N(3) [page 1].
The input mains passes from the input switch Q1 to the rectifier via the input fuses
F10-F12, input RFI filter (Z1), optional input filter (4641016-Q) and input filter
choke.
(-20%), input phase rotation error and also provides basic phase-timing information for the rectifier SCR control logic. The V and W phases also power the control power supply transformer (T2) via F8 and F9. This transformer is identical to
T3 which is fed from the bypass supply and described on the previous page, and
once again its primary is tapped to suit the working mains supply voltage tap
details shown on [2/P7].

SE-4612044-I (circuit diagram) and AM-4612044-I (assembly drawing). This assembly also contains the static switch power components in addition to those belonging to the rectifier.
phase heatsinks but these are not normally used.
DC Busbar

voltage ripple. The smoothed busbar is then connected to the batteries via an external circuit breaker, and to the inverter (4612145-F). In the battery line is a
signal via the High Voltage Interface Board [3/G6], and a battery fuse (F13)
which is monitored by means of a micro-switch to detect its failure.
feedback voltage via the High Voltage Interface Board [3/N9] used for closedloop voltage control and dc bus (battery) voltage metering. This signal also provides a battery voltage metering function. The dc busbar is also connected to a
DC-DC control power supply board [3/E7] via fuses F4-F5 (1A) the same fused
supply is connected to the inverter output contactor control circuit on the static
switch assembly [1/G8], as described earlier.
Power inverter

SE-4612145-F (circuit diagram) and AM-4612145-F (assembly drawing). This
assembly contains the six inverter IGBT transistors (single pack devices), three
1-19

Base Drive Boards (4519015-H), suppression capacitors and two normally-closed

series-connected thermostats.
The transistor drive signals from the inverter control electronics are connected via
ribbon cables W1-W2-W3 to CN1 on each Base Drive Board.

neutral.
Capacitors C5-C10 connected across the output line-to-line act as a filter to
inverter voltage regulation control circuits and static switch fault and transfer
control logic.
SE-5410304-Q Page 3. This page shows the UPS control system circuit
Logic Board from where they are transmitted to the remaining boards
X2 DC bus (battery) voltage sense inputs [2/G8].
X8 Interface to external connection block X3 [1/M3]
X14 Not in use
1-20


X23 Not in use
X26 Not in use
X27 Not in use
This board serves two major functions:

first it contains the logic which controls the static switch/inverter output
contactor and load transfer between inverter and static bypass supplies.
second, it contains the fault-detection-based general system control logic
which determines the operation of the rectifier (via the Rectifier Logic
Board) and inverter (via the inverter Logic Board).
paralleled on the UPS Logic Board and fed to the other boards in the control
system as necessary. Therefore when the UPS is started-up the control system
is powered-up as soon as the AC-DC Power Supply is energised by the closure of
the input mains switch (Q1). Once the rectifier is fully operational the DC-DC
1-21

Power Supply provides an alternative (parallel) supply source which supports the
control system operation if the input mains supply subsequently fails.
paralleled on the UPS Logic Board and fed to the other boards as necessary.
Therefore when the UPS is started-up the control system is powered-up as soon
as the AC-DC Power Supply is energised by the closure of the input mains switch
(Q1). Once the rectifier is fully operational the DC-DC Power Supply provides an
alternative (parallel) supply source which supports the control system operation
if the input mains supply subsequently fails.
DC-DC supply only.
2.4
60kVA Model description SE-5410308-U

SE-5410308-U Page 1. This page shows the bypass input and UPS output
Bypass supply feed
system is used, there are no external connections to U(3)-V(3)-W(3)-N(3) and the
power for Q2 and Q3 is obtained from the UPS input mains supply terminals
normal UPS operation, and can be padlocked in the open position. If the switch is
closed while the inverter is operating (i.e. while Q4 is closed) its auxiliary contacts [3/L1] will trigger a safety circuit in the UPS control system which will open
the inverter output contactor to isolate the power inverter from the output terminals and prevent any damage which might otherwise occur due to a reverse power
flow.
secondary voltage tap selection details are shown on the diagram. T3s secondary feeds one input to the AC-DC Power Supply (4503030-M) [3/D19].
1-22

The static switch assembly, shown as a dashed block, is shown in detail in diagram SE-4612045-J (circuit diagram) and AM-4612045-J (assembly drawing).
belonging to the static switch.
source of the inverter output contactor energising supply mentioned
above.
metering and overload monitoring purposes [3/G6]. Note that the inverter output
contactor is connected in parallel with the bypass static switch outputs and is fed
from the output transformer [2/B17-B18]
single-phase operating and distributed across the phases as shown.
the maintenance bypass switch (Q3).
Remote connections
The lower left-hand ares of page 1 shows details of various remote connections to
terminal block X3 (X3 connections are made by spade connectors). These connections are used for:
1.5Vdc/C as the temperature increases between 25C and 35C. The temperature sensor is connected between X3 terminals 2 and 3, and is polarity
sensitive.
1-23


SE-5410308-U Page 2. This page shows the UPS input, rectifier, dc bus, inverter and output transformer power circuits.
Bypass supply feed
are connected by links to the bypass terminals U(3)-V(3)-W(3)-N(3) [1/C1]. If a
bypass supply is connected to U(3)-V(3)-W(3)-N(3) [page 1].
The input mains passes from the input switch Q1 to the rectifier via the input fuses
F10-F12, input RFI filter (Z1), optional input filter (4641017-R) and input filter
choke.
(-20%), input phase rotation error and also provides basic phase-timing information for the rectifier SCR control logic. The V and W phases also power the control power supply transformer (T2) via F8 and F9 (1A). This transformer is
identical to T3 which is fed from the bypass supply and described on the previous
page, and once again its primary is tapped to suit the working mains supply voltage tap details shown on [2/P7].

SE-4612047-R (circuit diagram) and AM-4612047-R (assembly drawing). This
assembly also contains the static switch power components in addition to those
belonging to the rectifier.
phase heatsinks (not normally used).
DC Busbar

voltage ripple. The smoothed busbar is then connected to the batteries via an external circuit breaker, and to the inverter (4612145-F). In the battery line is a
signal via the High Voltage Interface Board [3/G6], and a battery fuse (F13)
which is monitored by means of a micro-switch to detect its failure.
1-24

feedback voltage via the High Voltage Interface Board [3/N9] used for closedloop voltage control and dc bus (battery) voltage metering. This signal also provides a battery voltage metering function. The dc busbar is also connected to a
DC-DC control power supply board [3/E7] via fuses F4-F5 (1A) the same fused
supply is connected to the inverter output contactor control circuit on the static
switch assembly [1/G8], as described earlier.
Power inverter

SE-4612145-F (circuit diagram) and AM-4612145-F (assembly drawing). This
assembly contains the six inverter IGBT transistors (single pack devices), three
Base Drive Boards (4519015-H), suppression capacitors and two normally-closed
series-connected thermostats.
The transistor drive signals are connected via ribbon cables W1-W2-W3 to CN1
on each Base Drive Board.

neutral.
Capacitors C5-C10 connected across the output line-to-line act as a filter to
inverter voltage regulation control circuits and static switch fault and transfer
control logic
SE-5410308-U Page 3. This page shows the UPS control system circuit
Logic Board from where they are transmitted to the remaining boards as
required.
X2 DC bus (battery) voltage sense inputs [2/G8].
1-25

X8 Interface to external connection block X3 [1/M3]

X14 Not in use
X23 Not in use
X26 Not in use
X27 Not in use
This board serves two major functions:

first it contains the logic which controls the static switch/inverter output
contactor and load transfer between inverter and static bypass supplies.
second, it contains the fault-detection-based general system control logic
which determines the operation of the rectifier (via the Rectifier Logic
Board) and inverter (via the inverter Logic Board).
1-26

paralleled on the UPS Logic Board and fed to the other boards in the control
system as necessary. Therefore when the UPS is started-up the control system
is powered-up as soon as the AC-DC Power Supply is energised by the closure of
the input mains switch (Q1). Once the rectifier is fully operational the DC-DC
Power Supply provides an alternative (parallel) supply source which supports the
control system operation if the input mains supply subsequently fails.
DC-DC supply only.
1-27

1-28

Sect 1

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Section 1: System Description

Chapter 1 - Functional Description

S-1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

S-1.fm5 - Issue 2 Dated 21/08/97

Chapter 1 - Functional Description

The UPS system offers the user the following advantages:

s1-c1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

7200 Series UPS single-module configuration

Power rectifier & battery charging

Nominal battery float charge

Nominal battery boost charge

End of battery discharge

Absolute maximum (manual)

Number of battery cells

s1-c1.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 1 - System Description

Battery charging modes

Boost charge should not be used with valve-regulated (sealed-cell) batteries

s1-c1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

s1-c1.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 1 - System Description

Static switch assembly

s1-c1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

UPS Power Switch Configuration

Maintenance bypass supply

Static bypass configuration

In a common-bypass installation the bypass supply lines are connected to the

s1-c1.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 1 - System Description

1+1 Parallel-module system

Inter-Module Parallel Control Logic

Inter-Module Parallel Control Logic

Redundant vs Non-Redundant configuration

If a 1+1 system is configured as a redundant system the modules are sized

s1-c1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

Inter-module power rectifier control

Inter-module inverter control

s1-c1.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual

SECTION 1 - System Description

Inter-module static switch control

s1-c1.fm5 - Issue 2 Dated 21/08/97

SECTION 1 - System Description

7200 Series UPS Service Manual

s1-c1.fm5 - Issue 2 Dated 21/08/97

Chapter 2 - Main Power Circuit Diagram Descriptions

AM-5410303-P (12 pages)

AM-5410304-Q (12 pages)

AM-5410308-Q (12 pages)

Each drawing comprises several pages and a system of cross-referencing is used