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This manual contains the structure, settings and calibrations, detection and correction of failure and operating
principle of the BB and BC Series Uninterruptible Power Supply (UPS).
BB and BC Series Uninterruptible Power Supply (UPS) has the technology of Online-Double Conversion UPS and
Three Level Inverter which provides high efficiency. These Technologies and UPS operating states will be mentioned
elaborative in this manual. Besides, the function of electronic card and components, the test and measurement
points will be identified, circuit charts will be given.
To demand technical support or documents about ENEL UPS productions, please contact with ENEL executive
engineers.
If you require assistance for a failure or any related issues, call our Technical Support Center.
Company ………………………………
IMPORTANT SAFETY INFORMATION (BE SURE TO READ)
Life Safety
! Be careful while carrying loads. Do not carry heavy loads without help.
! Slide roller devices on smooth and even surfaces.
! Do not use slopes with angles over 10°.
! Adhere to following recommendations about load weights.
! An adult can carry loads up to 18 kg weight.
! Two adults can carry loads up to 32 kg weight.
! Three adults can carry loads up to 55 kg weight.
! Use pallet jack, forklift or similar devices for carrying loads over 55 kg weight.
! Keep packaging material for use in case the UPS has to be transported to an authorized
service or to another location.
UPS Safety
! The UPS must be safeguarded against voltage overload or short circuit voltages by means
of a readily accessible circuit breaker.
! Do not operate the UPS at environment temperatures or relative humidity that exceeds
the limits given in the manual.
! Never operate the UPS in liquid environments or in overly humid environments.
! Never allow water or foreign substances to penetrate in the UPS.
! Strictly do not clog ventilation grids of the UPS.
! Never expose the UPS to direct sunlight or a direct heat source.
! The UPS’ useful life is 10 years.
Special Safety Information
Measurements
8/10
12/15
255 x 870 x 710
16/20
Figure 1.1 View of BB-BC Series UPS Table 1.1 Measurement and weight chart
Net weight
Size (mm)
without battery
Width x Height x Depth
(kg)
255 x 710 x 640 26
Table 1.2 Size and weight table
Front Panel
Boost
Board
Inverter
Power Board
Battery Shaft
Safety Fuse
Input
Filter
SMPS
Board
Rectifier
Power
Board
Safety Fuse
Output
Filter
3 Screen Liquid Cyristal Display (LCD) which shows the operating informations
No. BUTTON >3 s. (Push longer than 3 s.) <3 s. (Push shorter than 3 s.)
RS232 RS232
User exits Telecomunication
Telecomunication
M.Bypass M.Bypass
Battery Safety fuse Safety fuse
Safety Fuse
Exit Safety Exit Safety
Fuse Fuse
Connectors
Enterance Enterance
Safety Fuse Safety Fuse
a. 30 items 7-9Ah
b. 20 items 7-9Ah
BB-BC Series are suitable to work with Online-Double Conversion UPS technologies and has the operating principle
below.
Online-Double Conversion UPS provides double energy conversion at the same time. While the rectifier rectifies
the grid voltage, inverter inverts the output voltage of rectifier and creates stable and high-quality output voltage
independent from the grid voltage and frequency. Created voltage is transfered to the exit by bypass/inverter unit.
During, the grid voltage is in the range of input voltage, double energy conversion continues and batteries are
charged at the same time.
When the grid voltage is no longer in the range of input voltage, rectifier stops working and battery charging
procedure will be ended. Inverter unit starts feeding non-gradual from the batteries. In the process of start working
from the batteries, the output voltage and frequency of inverter do not change. Rectifier starts when the grid
voltage is in the input voltage range, in the same time working from battery is ended, inverter starts feeding from
rectifier and batteries starts to be charged. In addition, in the process of transferring from battery to grid, output
voltage and frequency quality of inverter do not change.
Bypass line is used for overload, overheat, failure of inverter or rectifier to stabilizied output voltage’s invariability.
Bypass/inverter transferring unit, transfers the grid voltage to the exit interruptible by separates the inverter and
the output voltage. By the way, it provides, the load is not to be effected. Thus, output and grid voltage are
synchronized.
Manuel bypass line are used for to seperate UPS from the input voltage and feed the load from grid during
correction of failure or servicing. The transfer to this working status is done by manually and provides safe operate
on the UPS.
a. Input/Output Filter
It filters the high-frequency electrical noise from the grid input and inverter output voltage. While protecting UPS
from the electromagnetic (EMI) and radio frequency (RFI) effects of the grid, also protects the loads from
electromagnetic and radio frequency effects of the UPS.
b. Rectifier
The sinus-wave grid voltage is rectified with switching on thyristors. Softstart method is applied to avoid DC busbar
capacitors gets simultenous high current. The grid voltage with effective value of 220/230/240Vac is rectified to
create rectifier output voltage with the value of ±310/±325/±340Vdc. The total amount of harmonic distortion
(THD) of rectifier input voltage is high, however, input power factor (cosφ) is low.
Rectifier output current which, has a high harmonic distortion and low power factor is corrected, by switching on
IGBTs. It provides to draw current, which is sinusoidal and has no differention from grid voltage(at 1 power factor),
from the grid. Also, rectifier output voltage is rised (boost) to create DC busbar voltage in ±375Vdc. In state of
working from battery, battery load at 240Vdc (20 batteries) or 360Vdc (30 batteries) is rised to create DC busbar
voltage.
d. Inverter
±375V dc busbar voltage is transformed into sinusoidal voltage, which is 220/230/240Vac and 50/60 Hz, with
swithching IGBTs at 19,2kHz frequency in the tree-level inverter.
e. Battery Transfer
Battery voltage is transfered to PFC enterance via thyristors. When the grid voltage or frequency is not anymore at
the limit values or starting from battery, 240Vdc(20 battery) or 360Vdc(30 Battery) battery voltage is transfered
into the PFC enterance by switching the thyristors.
f. Charger
By switching the ±375Vdc busbar voltage at another circuit, 135Vdc voltage for 20 batteries, ±202,5Vdc voltage for
30 batteries are created and batteries are charged by the method of qualification current.
g. Inverter/Bypass Transfer
h. Manuel Bypass
Three Level Inverter technology increases the UPS efficiency and provides developed control. Output LC filter sizes
are shrinked and it provides high efficiency by this inverter. Besides, by switching the half DC busbar voltage, high
quality output voltage and frequency are created. DC offset components which is a serious problem for inverters,
are contorolled more sensitive and high reliability output is provided.
Switching at Two Level Inverter is done between +Vdc/2 and –Vdc/2 voltages and output LC filter size is larger since
the ripple at inverter current. Switching at Three Level Inverter is done between +Vdc/2, 0 and –Vdc/2 voltages and
output LC filter size is smaller since the ripple at inverter current is lower. Thus, energy efficiency is higher at UPSs
which have Three Level Inverter.
P P
Cdc
Vdc Vdc
2 2
Cdc
Vçıkış Vçıkış
0 0
Cdc
Vdc Vdc
2 2
Cdc
N N
(a) (b)
Form 2.2 (a) Two Level Inverter (b) Three Level Inverter
2.2 BB-BC Series UPS Operation Modes
a. Normal Mode
Grid voltage reaches the rectifier via input filter. Rectifier current is rectified at PFC unit to rise voltage and DC
busbar voltage is created. By the time, charger charges the batteries with feeding from DC busbar. By creating
output voltage at inverter bypass/inverter transfer and output transfered into output via filter.
b. Battery Mode
By terminated battery charging procedure, battery voltage is transfered into PFC input via battery transfer unit. DC
busbar voltages are created by rising battery voltage at PFC unit. Bypass/inverter and output are transfered to
output via filter by creating output voltage at Inverter.
Grid voltage is transfered into output passing by input filter at static bypass line, via bypass/inverter unit and
output filter. By the time, charger does not charge batteries.
Voltage driver entegration feeding voltage and switching voltage is +20Vdc, entegration driver voltage is +12Vdc.
Signals from Microprocessor Card switches the thyristors properly.
P16 Q7, Q8 Thyristors P22 Q15, Q16, Q23, Q24 triggers Thyristors.
There are two different circuits at the card. By switching the transformer on driver card from Isolated Feeding Card
of Switching Voltage, entegrated feeding and IGBT switching voltage are created. Signals from microprocessor card
switch the positive and negative DC busbar IGBTs properly.
Entegrated feeding voltage and switching voltage are VCC1. IGBT driver cards isolated feeding voltage is created by
switching the VCC1 voltage on transformers which are in the PFC Driver Card.
Entegrated feeding and IGBT switching voltage are created by switching the transformer on driver from Isolated
Feeding Card of Switching Voltage. Signals from microprocessor card switch positive and negative DC busbar IGBTs
properly.
Entegrated feeding and IGBT switching voltage are created by switching transformers on driver from Isolated
Feeding Card of Switching Voltage. Entegrated driver and secondary feeding voltage is +5Vdc. IGBTs are properly
switched by signals from Microprocessor Card. Driver entegrated failure signal are sent to Microprocessor Card.
Entegrated feeding voltage and switching voltage are VCC1. IGBT driver cards’ isolated feeding voltage is created by
switching VCC1 on transformers which are in the PFC Driver Card and Inverter Driver Card.
Driver entegrated feeding voltage and switching voltage is +20Vdc, entegrated driver voltage is +12Vdc. Signals
from Microprocessor Card switch the thyristors properly.
Inverter Power Card involves; shock bobbins, capacitors, thyristors, Inverter IGBTs ve socket cards.
P17 Q9 and Q10 IGBTs P18 trigger Q11 and Q12 IGBTs
Driver entegrated feeding voltage and switched voltage is +20Vdc, entegrated driver voltage is +12Vdc. Signals
from Microprocessor switch the thyristors properly.
Entegrated feeding voltage and switching voltage is VCC1. IGBT driver card’s isolated feeding voltage is created by
switching VCC1 voltage on transformers which are on the PFC Driver Card and Inverter Driver Card.
VCC2 voltage (18Vdc) , which is created by limiting BAT+ voltage, is used for entegration feeding. SMPS switches
SMPS mosfet at 80Khz with getting the information of feedback, and set the SMPS voltage as +20Vdc. Besides,
+5Vdc voltage which composed at the transformer’s output, is moved to Microprocessor Card to be used at
telecomunication circuit. The switching processor is stopped by signals; from panel in case of terminating from grid
or battery or from Microprocessor Card for low battery capacity.
Voltage of feeding board is +5Vdc, ±12Vdc and isolated +5Vdc. At Microprocessor Board:
• Output current illustration signals with input, inverter and output voltage,
• Negative and positive DC busbar and battery voltage illustration signals,
• NTC signals that provides heat informations of inverter and rectifier cooler,
• Panel button signals,
• Over current rectifier and inverter failure warning signals,
• Emergency close, service/failure bypass and user output signals
Evaluate;
Generates.
Charger board feeds from DC busbar. Switching entegrated feeding voltage is created by bordering positive DC
busbar voltage. By getting battery middle point voltage feedback information, switches charger mosfets at 40kHz
frequency and sets charger voltage as ±135Vdc (20 batteries) or ±203Vdc (30 batteries). Current-controlled charger
entegration limits charge current in range of 1-7A. When cooler heat increases, switching is stopped by the signal
which created at NTC. Its work is controlled by on/off signal from Microprocessor Board.
Board feeding voltages are +5Vdc and +12Vdc. Button signals are sent to Microprocessor Board; LCD
character, buzzer and panel led signals are recieved.
It provides protection for RFI (Radio Frequency Interference) and EMI (Electromagnetic Interference)
destructive effects and lightning pulse voltage of the grid. It filters high frequency electrical noises and
magnetic effects.
There is a settings menu which provides the test and calibrations of BB-BC Series.
When UPS is completely close and just ENTERANCE safety fuse is open, push button until hear warning voice.
1. Open ‘SETTINGS’ menu. For moving forward to another menu push , to change option push
button.
2. To reverse menu progression, push button until warning voice stops.
BB-BC Series has a test mode to make detection of failure easier. In this mode, by doing tests of power circuits,
failure can be detected completely.
1. When UPS is completely close and just the ENTERANCE safety fuse open, push button until hear a
warning voice.
2. Open ‘SETTINGS’ menu. For moving forward to another menü push , to change option push
button.
3. Go to ’08-TEST MODE’ menu and set as ‘open’.
4. Push button until warning voice stops, close UPS completely.
5. Push button until hear a warning voice to open UPS.
6. Open ‘TEST MODE’ menu. To move another test push button, to perform the test push button.
7. To reverse menu progression, push button until warning voice stops.
In the part of INV IGBT TEST, under the TEST MODE, inverter IGBTs are tested. With pushing ‘ON/OFF’ button until
1s, INV IGBT TEST is become On. When 6-10V voltage and 19,2 kHz switching frequency measured between G and S
edges at inverter IGBTs which are in the part of inverter, it is tested that El-38 ( BC ) or El-13 ( BB ) inverter driver
board and IGBTs are working. To perform this test DC bar voltage should be les than ±20Vdc.
In the part of REC IGBT TEST, under the TEST MODE, rectifier IGBTs are tested. With pushing ‘ON/OFF’ button until
1s, REC IGBT TEST is become On. When 6-10V voltage and 19,2 kHz switching frequency measured between G and S
edges at rectifier IGBTs which are in the part of rectifier, it is tested that El-38 ( BC ) or El-13 rectifier driver board
and IGBTs are working.
In the part of BYP SCR TEST, under the TEST MODE, bypass thyristors and El-14 board are tested. With pushing
‘ON/OFF’ button until 1s, BYP SCR TEST is become ‘on’. When BYP SCR TEST is ‘off’ bypass voltage is not seen at the
screen or out. A low voltage is read. When BYP SCR TEST is ‘on’, bypass voltage can be seen at screen and UPS’s out
terminals directly. In case of vice versa, there must be a problem at bypass thyristors or El-14 thyristor driver board.
To fix the problem both bypass thyristors and El-14 driver board are changed.
In the part of INV SCR TEST under the TEST MODE, inverter thyristors and El-14 thyristor driver board are tested. To
perform this test respectively 14-RECTIFIER TEST and 07-INVERTER TEST should be ‘ON’. Because, DC bar has to be
full and inverter part can be worked to work inverter thyristors. Otherwise, wrong values are measured. If inverter
thyristors and thyristor driver board are working correctly, the voltage between 80-100V for R,S and T is shown at
the screen and out terminals.
Note: For BB Series Product (1 phase output), just R phase value can be read at the screen. S and T phases will be
Zero (0).
In part of BAT SCR TEST under the TEST MODE, battery thyristors are tested. Pushing ‘ON/OFF’ button about 1 s
BAT SCR TEST is become ‘on’. If the battery thyristors are working correctly, nearly (depends on number of
batteries) ±135 V or ±202V voltage is seen at the screen and DC bar terminals.”To perform this test correctly, DC
bar voltage should be less than 100V.”
In part of REC SCR TEST under TEST MODE, rectifier thyristors are tested. Pushing ‘ON/OFF’ button about 1s, REC
SCR TEST is become ‘on’. If rectifier thyristors are working correctly, about ±290 - 310 V voltage is seen at the
screen and DC bar terminals. If this voltage is not created, there is a failure. Rectifier thyristors and El-14 thyristor
driver board has to be changed.
07-INVERTER TEST
In part of INVERTER TEST under TEST MODE, inverter blocks are tested. To INVERTER TEST correctly, the part of 14-
RECTIFIER TEST should be ‘on’. Pushing ‘ON/OFF’ button 1s INVERTER TEST is become ‘on’. If INVERTER TEST is
become ‘on’, nearly 80-100V voltage is measured for R, S and T phases at inverter voltage screen and output
terminals.
In part of BOOST TEST under TEST MODE, DC bar voltage of device is tested correctly or not. Pushing ‘ON/OFF’
button 1s BOOST TEST is become ‘on’. Each phases is tested positive and negative individually. Positive and
Negative DC bar voltages should be read as about ±375V at the screen and DC bar terminals.
14-RECTIFIER TEST
In part of RECTIFIER TEST under TEST MODE, rectifier block is tested to operate correctly. Pushing ‘ON/OFF’ button
1s RECTIFIER TEST is become ‘on’. Nearly ±375 V is seen at the screen and DC bar terminals.
Parameters should be read correctly and calibred well to operate UPS smoothly. This is done by
Calibration Menu. To activate the CALIBRATION menu: First of all, output loads should be closed
and output safety fuse should be become ‘OFF’. If device is on, it should be closed.
1. When UPS is completely close and just ENTERANCE safety fuse is open push button until
hear warning voice.
2. Open ‘SETTINGS’ menu. To pass another menu push button, to change option push
button.
3. Go ’09-CALIBRATION’ menu and set it as ‘on’
4. Push button until warning voice stops and UPS is completely close.
5. Push button until hear warning voice and UPS is open.
6. UPS is opened. After Bypass light is on, push button and see ‘Start from Grid’ warning. Wait
for UPS passes normal mode.
7. After UPS passed normal mode, open EXIT safety fuse. During calibration, UPS should be on
normal mode and shouldn’t be loaded as current calibration.
8. Push button to go ‘CALIBRATION’ menu and push button to go to the menu.
9. To go to next calibration push button. To reverse menu progressing push button until
warning voice stops.
10. To change calibration parameter push button. To reverse parameter increase push button
until warning voice stops.
11. To exit the menu push button.
CALIBRATION DESCRIPTION
01-DAY Enter actual day info.
02-MONTH Enter actual month info.
01-DATE/TIME 03-YEAR Enter actual year info.
04-TIME Enter actual time info.
05-MINUTE Enter actual minute info.
Measure voltage between input notr (N1) terminals with input R-phase.
01-IN-R VOL CAL
Calibrate voltage by changing parameter.
Measure voltage between input nötr (N1) terminals with input S-phase.
02-IN-S VOL CAL
Calibrate voltage by changing parameter.
Measure voltage between input nötr (N1) terminals with input T-phase.
03-IN-T VOL CAL
Calibrate voltage by changing parameter.
Load input R-phase with constant load at least %50 rate.
04-IN-R CUR CAL Measure current.
Calibrate voltage by changing parameter.
02-INPUT Load input S-phase with constant load at least %50 rate.
05-IN-S CUR CAL Measure current.
Calibrate voltage by changing parameter.
Load input T-phase with constant load at least %50 rate.
06-IN-T CUR CAL Measure current.
Calibrate voltage by changing parameter.
07-IN-R CUR DNG After calibration; R current is balanced with S and T currents by
changing parameters.
08-IN-S CUR DNG After calibration; S current is balanced with R and T currents by
changing parameters.
09-IN-T CUR DNG After calibration; T current is balanced with R and S currents by
changing parameters.
Measure voltage between BAT+ and BATN terminals on charger board
(EL-20).
01-POS BATTERY CAL
Calibrate voltage by changing parameter.
4.1.3.2 02-Output
Values from grid is written on screen at start menu and current calibration is done. It has 9 sub-menus.
Voltage between input R phase and notr terminals is measured and written on the screen.
Figure 4.15
Voltage between input S phase and notr terminals is measured and written on the screen.
Figure 4.16
Voltage between input T phase and notr terminals is measured and written on the screen.
Figure 4.17
04-INPUT R CUR CAL
Current which is drawn from input R phase, is measured and written on the screen.
Current which is drawn from input S phase, is measured and written on the screen.
Current which is drawn from input T phase, is measured and written on the screen.
At the BATTERY/DC BAR menu Battery and DC bar calibrations is made. It has 4 sub-menus.
Voltage between BAT+ and BATN terminals which are on the Charger Board (EL-50 or EL-20) is measured
and written on the screen.
Figure 4.24
Voltage between BAT+ and BATN terminals which are on the Charger Board (EL-50 or EL-20) is measured
and written on the screen.
Figure 4.25
+Bat and –Bat are balanced with the pot on the solder board which is on the charger board.
If the voltage differantion between Bat + and Bat – is more than 1,5 Volt, the charger is malfunctioned.
Voltage between DC+ and BATN terminals which are on the Charger Board (EL-50 or EL-20) is measured
and the value of measuring device is made 375V by changing the parameter on the screen.
Figure 4.25
04-NEG BAR CAL
Voltage between DC- and BATN terminals which are on the Charger Board (EL-50 or EL-20) is measured
and the value of measuring device is made 375V by changing the parameters on the screen.
Figure 4.26
The voltage between out R phase and notr (N2) terminals is measured and the value of measuring device is set to
220V, 230V or 240V by changing the parameters on the screen.
Value of voltage on the LCD screen does not change (220, 230 veya 240)!
The voltage between out S phase and notr (N2) terminals is measured and the value of measuring device is set to
220V, 230V or 240V by changing the parameters on the screen.
Value of voltage on the LCD screen does not change (220, 230 veya 240)!
The voltage between out T phase and notr (N2) terminals is measured and the value of measuring device is set to
220V, 230V or 240V by changing the parameters on the screen.
Value of voltage on the LCD screen does not change (220, 230 veya 240)!
Positive edge of multimeter is bounded to out R phase, negative edge is bounded to out notr. Value of multimeter
screen is set 100 mV by changing parameters
parameters.
Positive edge of multimeter is bounded to out S phase, negative edge is bounded to out notr. Value of multimeter
screen is set 100 mV by changing parameters
parameters.
Positive edge of multimeter is bounded to out T phase, negative edge is bounded to out notr. Value of multimeter
screen is set 100 mV by changing parameters
parameters.
4.1.3.1 05-OUTPUT
Calibration of out R phase is done. Device is become the desired-out-voltage by changing the parameter.
Figure 4.27
Calibration of out S phase is done. Device is become the desired-out-voltage by changing the parameter.
Figure 4.28
Calibration of out T phase is done. Device is become the desired-out-voltage by changing the parameter.
Figure 4.29
Figure 4.30
Figure 4.31
Figure 4.32
4. FAILURE DETECTION
Y
14-RECTIFIER is done. Rectifier or PFC unit should rise the N
±DC bar voltage to ±375Vdc. PFC board is faulty.
Y
N
Inverter IGBTs or inverter
07-INVERTER TEST is done. There should be 80-100Vac
driver board is faulty.
open convert voltage on the screen, when DC bars are full.
Note: REC SCR TEST should be done first. Before doing BINVERTER SCR TEST, RECTIFIER TEST and INVERTER TEST
should be done respectively.
In case of a fault of EVR SCR ARIZA, device cannot operate in normal mode and pass the bypass mode.
Faulty material should be detected and removed. If the faulty material cannot be detected by visually or with a
measuring device, material’s board should be renewed.
FAILURE ON INVERTER:
Note: REC SCR TEST should be done first. Before doing INVERTER TEST, RECTIFIER TEST should be done.
Faulty material should be detected and removed. If the faulty material cannot be detected by visually or with a
measuring device, material’s board should be renewed.
DC LOW- DC HIGH:
It appears after a failure on rectifier board. Since PFC cannot control current-voltage, device passes the bypass
mode.
Faulty material should be detected and removed. If the faulty material cannot be detected by visually or with a
measuring device, material’s board should be renewed.
Not: When the UPS warns “BYP SCR ARIZA”, device cannot pass to bypass mode when necessary and it close its
out.
Faulty material should be detected and removed. If the faulty material cannot be detected by visually or with a
measuring device, material’s board should be renewed.
HIGH BATTERY:
Y
N
Device is turned on normal mode. Charger board should be fault.
Charger board should be measured. BAT+,BAT- and Charger trimmer should be unadjusted.
BATN. For 20 batteries ±135V, for 30 batteries ±205 V
If the device senses over current IGBT warning for three times, it
gives this warning.
IGBTs should be fault.
Inverter board should be fault.
If UPS which is on bypass mode, gives the over current bypass warning, the
device will cut its out. Loads should be decrease carefully.
Thermic can be faulty. Device can be overheated. Fans might be broken. Rectifier or inverter may be faulty.
Faulty material should be detected and removed. If the faulty material cannot be detected by visually or with a
measuring device, material’s board should be renewed.
CHARGER FAILURE:
MAINTENANCE