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ST UM0527 User Manual

ST UM0527 User Manual

Ups evaluation board
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UM0527
User manual
UPS evaluation board
Introduction
The UPS evaluation board provides a complete solution addressing the low/medium range
UPS segment with 700 VA output power capability. The evaluation board, from a hardware
and firmware point of view, is ready to support the development of a complete solution.
Thanks to the PC software it's possible to monitor all the relevant system parameters using
the RS232 interface or the USB. The evaluation board is available for the 120 Vac market
and 230 Vac market.
The UPS evaluation board is built in offline topology with AVR regulation of the mains boost
and buck. The inverter module contains the push-pull DC/DC converter and the DC/AC
output full-bridge generating quasi-sine waveform.
July 2008
Rev 1
1/66
www.st.com

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Summary of Contents for ST UM0527

  • Page 1 UM0527 User manual UPS evaluation board Introduction The UPS evaluation board provides a complete solution addressing the low/medium range UPS segment with 700 VA output power capability. The evaluation board, from a hardware and firmware point of view, is ready to support the development of a complete solution.

  • Page 2: Table Of Contents

    Contents UM0527 Contents General description ......... . 5 Hardware architecture .
  • Page 3 UM0527 Contents Circuit diagram ..........33 Layout .
  • Page 4 List of figures UM0527 List of figures Figure 1. Block diagram ............6 Figure 2.

  • Page 5: General Description

    UM0527 General description General description Hardware architecture 1.1.1 General realization The UPS evaluation board is built in offline topology with AVR regulation of the mains boost and buck. The inverter module contains the push-pull DC/DC converter and the DC/AC output full-bridge generating quasi-sine waveform. The battery charger module is connected at the output of the UPS and it also has the function of taking over the reactive power which is present on the inverter during battery operation with reactive - resistive load.

  • Page 6: Block Diagram

    General description UM0527 1.1.2 Block diagram Figure 1. Block diagram RFIEMI12st05v031.sch FUSE FUSE BAT_LOW BAT_LOW BAT_LOW ACF! ACF! ACF! ACF1! ACF1! ACF1! UPS_OFF! UPS_OFF! UPS_OFF! USB_IN! USB_IN! USB_IN! AC_IN1 AC_IN2 AC_IN1 AC_IN2 AC_IN1 AC_IN2 INP_LEV INP_LEV INP_LEV PHASE PHASE PHASE InputVoltage12st05v031.sch...

  • Page 7: Detailed Description Of Electronics

    UM0527 General description 1.1.3 Detailed description of electronics 1.1.4 DC/DC converter module Figure 2. DC/DC converter 7/66...
  • Page 8 General description UM0527 The converter is based on push-pull topology. The PWM controller works in voltage mode. The power components used for the low voltage side are switches 5 - 8 and a transformer. The energy recovery circuit includes L1, D1, L2, D2, C1 and R1. It works as both a clamp and a snubber.

  • Page 9: Dc/Ac Inverter Module

    UM0527 General description 1.1.5 DC/AC inverter module Figure 3. DC/AC inverter 9/66...
  • Page 10 General description UM0527 The DC/AC inverter was built in full-bridge topology. The output waveform is a quasi-sine waveform. The inverter is controlled by the microcontroller across two PWM drivers which switch four power transistors. The high-side driver parts are supplied with the bootstrap circuitry D1, C1 and D2, C2.

  • Page 11: Power Switches

    UM0527 General description 1.1.6 Power switches Figure 4. Power switches 11/66...

  • Page 12: Rfi/Emi Filter

    General description UM0527 The power line contains: ● two pole separation relays DPNO (RL1) (with 2 mm gap) ● two relays DPDT (RL2, RL3) ● two pole switching battery/mains relays DPDT (RL4) ● two pole output on/off relays DPNO (RL5) All relay coils are powered from the battery and charger voltage.

  • Page 13: Charger Ac/Dc

    UM0527 General description 1.1.8 Charger AC/DC Figure 6. AC/DC battery charger 13/66...
  • Page 14 General description UM0527 The battery charger is used as a battery charger for the mains mode or as a reactive power recirculation circuit for the inverter mode. For both modes the charger output power is accepted by the battery. The charger power converter is built in quasi-resonant flyback mode based on the controller L6565 with external power switch Q1 and output diode D1.

  • Page 15: Control Unit

    UM0527 General description 1.1.9 Control unit Figure 7. Control unit 15/66...
  • Page 16 General description UM0527 The control unit contains the main microcontroller ST72F324J6T6 - in the TQFP 44 10x10 package with an ICP connector for programming, a reset STM809, a buffer ULN2003A for driving signals and an external EEPROM with SPI interface. Analog signals are measured with an internal 10-bit A/D converter.

  • Page 17: Power Supply

    UM0527 General description 1.1.10 Power supply Figure 8. Power supply 17/66...
  • Page 18 General description UM0527 The power supply unit provides two outputs used in UPS blocks: +15 V for most of the analog circuits and +5 V for the microcontroller. The switching voltage converter was built in step-down topology with an integrated regulator L5970. The microcontroller is supplied by linear regulator +5 V U3 LD1086V50.

  • Page 19: Interface

    UM0527 General description 1.1.11 Interface Figure 9. Interface 19/66...
  • Page 20 General description UM0527 The interface unit provides the connection from the UPS unit to the PC via RS, USB or joint signals. The interface contains a USB to RS232 converter based on the microcontroller ST72F623F2M1, in the SO20 package powered from the PC, with optoisolation barrier (PC817B) and RS232 with optoisolation barrier (PC817B).

  • Page 21: Measurements: Input Voltage, Input Voltage Phase, Output Current, Inverter Output Voltage, Battery Voltage

    UM0527 General description 1.1.12 Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage Figure 10. Measurements: input voltage, input voltage phase, output current, inverter output voltage, battery voltage OUTPUT CURRENT 4.7k 4.7k R157 BAS16 C117 47.5k 1.5nF...

  • Page 22: Battery Overcurrent Protection

    General description UM0527 Referring to Figure 10, the measurements are defined as follows: Output current. Input voltage measurement unit is built as a differential amplifier with a 2.5 V offset (LM324). The output signal from the amplifier is connected to the A/D converter in the microcontroller.

  • Page 23: Microcontroller In/Out Signals

    UM0527 General description Table 4. UPS modes (continued) Standby Mains Boost Buck Inverter Standby charge mode mode mode mode mode mode mode Power supply VDD and VCC Communication 1. Programming microcontroller only 1.1.16 Microcontroller IN/OUT signals Table 5. Microcontroller IN/OUT signals...

  • Page 24: Signals Functions Table

    General description UM0527 Table 5. Microcontroller IN/OUT signals (continued) Signal Port Pin no Type/active state Description name Converter DC/DC output voltage VDCDC ADC analog input measurement signal SCI transmit data out RS-232C TxD signal SCI receive data in RS-232C RxD signal...

  • Page 25: Detailed Description Of Mechanics

    UM0527 General description Table 6. Signals functions table (continued) Mains Boost Inverter Standby Standby Buck mode Off mode mode mode mode mode charge mode LEDG Active Active Active Active Active Active Inactive LEDY Active Active Active Active Active Active Inactive...

  • Page 26: Software Architecture

    General description UM0527 Software architecture 1.2.1 Data models The setting of the UPS is stored in EEPROM memory. The data format is shown in Table Table 7. Memory mapping Address Name Length (bytes) Description OFF_ADDR Flag indicating state of UPS (on/off)

  • Page 27: System Architecture

    UM0527 General description Table 8. Poll commands Query (3 characters) Response (values separated by commas) Shutdown type: 0 – output, 1 - system Battery condition (0 – good, 1 – weak, 2 - replace), battery status (0 – normal, 1 – low, 2 - depleted), battery voltage (V/10), battery current (A/10) Input num lines (1), mains frequency (Hz/10), mains voltage (V/10) Output source (0 –...
  • Page 28 General description UM0527 synchronized with the mains, the ACF! signal is set to low and the inverter is switched off. – Mains mode - in this mode the battery charger is switched on and the UPS is supplied from the mains. The inverter is switched off (INV_A and INV_B are in low state), and ACF! is high.

  • Page 29: Adc

    UM0527 General description Figure 12. Main flowchart 1.2.5 The ADC thread measures values as described below: ● Mains voltage - the voltage measured at INP_LEV is needed for calculating the following values: – RMS - true RMS main voltage which determines the working mode of the UPS: mains mode, buck mode, boost mode or inverter mode.

  • Page 30: Communication

    General description UM0527 value. The result of the comparison is used to make the decision to change the working mode from the mains to the inverter. – Battery voltage - the value measured at AKK_LEV input determines the process of charging and discharging the battery.

  • Page 31: Leds

    UM0527 General description Table 13. Working modes (continued) State Action Reaction Working mode OUT_REL BUTTON L time OUT_REL ON/OFF Short Long Rise to H Note: Long = 2 s, Short = 20 ms Additionally the state of OUT_REL is stored in EEPROM memory and restored after a cold start independent of the AUTOSTART setting.

  • Page 32: Inverter

    General description UM0527 Table 15. Battery charge modes (continued) Step of charge Battery CHOFF Description process voltage < 26,8 Buffered working mode >= 27,8 1.2.11 Inverter The inverter is controlled by signals generated by the PWM module. In battery working mode the microcontroller generates two signals: INV_A and INV_B.

  • Page 33: Technical Description

    UM0527 Technical description Technical description Circuit diagram Figure 13. Circuit diagram RFIEMI12st05v031.sch FUSE FUSE BAT_LOW BAT_LOW BAT_LOW ACF! ACF! ACF! ACF1! ACF1! ACF1! UPS_OFF! UPS_OFF! UPS_OFF! USB_IN! USB_IN! USB_IN! AC_IN1 AC_IN2 AC_IN1 AC_IN2 AC_IN1 AC_IN2 INP_LEV INP_LEV INP_LEV PHASE PHASE PHASE InputVoltage12st05v031.sch...

  • Page 34: Figure 14. Dc/Ac Inverter

    Technical description UM0527 Figure 14. DC/AC inverter 34/66...

  • Page 35: Figure 15. Dc/Dc Converter

    UM0527 Technical description Figure 15. DC/DC converter 35/66...

  • Page 36: Figure 16. Control Unit

    Technical description UM0527 Figure 16. Control unit 36/66...

  • Page 37: Figure 17. Power Switches

    UM0527 Technical description Figure 17. Power switches 37/66...

  • Page 38: Figure 18. Ac/Dc Battery Charger

    Technical description UM0527 Figure 18. AC/DC battery charger 38/66...

  • Page 39: Figure 19. Pc Interface Stage

    UM0527 Technical description Figure 19. PC interface stage 39/66...

  • Page 40: Figure 20. Power Supply

    Technical description UM0527 Figure 20. Power supply 40/66...

  • Page 41: Figure 21. Measurement Stages

    UM0527 Technical description Figure 21. Measurement stages OUTPUT CURRENT 4.7k 4.7k R157 BAS16 C117 47.5k 1.5nF U28C R150 IOUT_1 R155 IOUT_1 PWR_LEV R158 6.8k PWR_LEV LM324 R156 R151 IOUT_2 IOUT_2 10nF 6.8k 47.5k C118 1.5nF BATTERY VOLTAGE VBAT VBAT VBAT...

  • Page 42: Figure 22. Rfi/Emi Filter

    Technical description UM0527 Figure 22. RFI/EMI filter RFI/EMI FILTER BROWN AC_IN1 AC_IN1 C119 6.3x0.8 4,7nF 200k C108 YELLOW/GREEN 470nF C120 200k 4,7nF 6.3x0.8 200k BLUE AC_IN2 AC_IN2 JVR-20N471K 6.3x0.8 JVR-20N271K Figure 23. Battery overcurrent protection VAKK VAKK VBAT VBAT 3,15A 250V...

  • Page 43: Layout

    UM0527 Technical description Layout Figure 24. Top view 43/66...

  • Page 44: Figure 25. Bottom View

    Technical description UM0527 Figure 25. Bottom view 44/66...

  • Page 45: Assembly Description

    UM0527 Technical description Assembly description 2.3.1 General Table 17. UPS components Model Type 120 Vac version 230 Vac version Case UPS Ares 700/1000 Power cord 3 x 1.0 mm Control panel UPS 500 rack Battery VRLA type 2 x 7,2 Ah/12 V...

  • Page 46: Electrical

    Technical description UM0527 2.3.2 Electrical The schematic of the electrical connections is shown in Figure Figure 26. Electrical connections 2.3.3 Mechanical The UPS case with assembled front and power cord. Figure 27. Mechanical view 46/66...

  • Page 47: Figure 28. Ups With Assembled Rear Outlets

    UM0527 Technical description Figure 28. UPS with assembled rear outlets Figure 29. UPS with front button and indicators Figure 30. UPS with batteries and battery fuse 47/66...

  • Page 48: Figure 31. Ups With Battery Fuse

    Technical description UM0527 Figure 31. UPS with battery fuse Figure 32. UPS with AVR transformer Figure 33. UPS with automatic fuse and power wires 48/66...

  • Page 49: Figure 34. Ups With Motherboard

    UM0527 Technical description Figure 34. UPS with motherboard Figure 35. UPS fully assembled 49/66...

  • Page 50: Connectors

    Technical description UM0527 Figure 36. UPS Connectors 2.4.1 PCB: mains input Table 18. PCB: mains input Connector identification Type Description Tabs Line in L Tabs Line in N Tabs 2.4.2 PCB: outlet output Table 19. PCB: outlet output Connector identification...

  • Page 51: Pcb: Battery

    UM0527 Technical description Table 20. PCB: AVR transformer (continued) Connector identification Type Description Tabs Brown Tabs Brown 2.4.4 PCB: battery Table 21. PCB: battery Connector identification Type Description -BAT Solder pad Battery - +BAT Solder pad Battery + 2.4.5 Table 22.

  • Page 52: Signalization Description

    Technical description UM0527 Signalization description 2.5.1 Indicators Table 25. Indicators Green LED Yellow LED Red LED (mains) (battery) (failure/overload) Mains mode Solid on Solid on Battery mode Flash On (BATLOW) Buck/boost mode Flash on Battery charging Solid on Flash on...
  • Page 53 UM0527 Technical description Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code R5,R3 Yageo RC 1206 J R-07 0R L 1,25 A F1, F3 ESKA RFTQ 1.25A 1.5 kΩ R141 Yageo RC 0805 J R-07 1K5 L 1.5 nF...
  • Page 54 Technical description UM0527 Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code 7.5 kΩ Yageo RC 0805 J R-07 7K5 L 10 R R129,R158 Yageo RC 0805 J R-07 10R L R64,R61,R60,R62,R59,R63,R65, 10 R...
  • Page 55 UM0527 Technical description Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code 47 R R173,R174 Yageo RC 1206 J R-07 47R L 47 nF X2 Arcotronics MKPX2-47NR15 47 µF/25 V C113,C114, C46 Yageo SH025M0047A5F-0511 47 µF/50 V...
  • Page 56 Technical description UM0527 Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code 820 R R147 Yageo RC 0805 J R-07 820R L 1000 µF/50 V C101,C102 Rubycon 50 YXG 1000 M CA 16X25 3300 µF/35 V...
  • Page 57 UM0527 Technical description Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code JVR-20N271K Joyin JVR-20N271K Taiwan KBU605 70-070-65 Elfa semiconductor L5970D L5970D013TR L6387D U1,U2 STMicroelectronics L6387D L6565 STMicroelectronics L6565D LD1086V50 STMicroelectronics LD1086V50 Kingbrigth...

  • Page 58: Bill Of Material For 230 Vac Version

    Technical description UM0527 Table 27. Bill of material for 120 Vac version (continued) Part type Designator Manufacturer Ordering code STTH302S D30,D29 STMicroelectronics STTH302S STTH803D D28,D25,D26,D27 STMicroelectronics STTH803D TI50/30v01 Sigma TI50/30v01 TI700/24/2v01 Sigma TI700/24/2v01 TL431CD Fairchild TL431CD TS555CDT STMicroelectronics TS555CDT TYN608...
  • Page 59 UM0527 Technical description Table 28. Bill of material for 230 Vac version (continued) Part type Designator Manufacturer Ordering code 3,15 A 250 V ESKA RFTQ 3.15A 3.3 kΩ R115,R116,R114,R36,R113 Yageo RC 0805 J R-07 3K3 L 3.3 kΩ R142 Yageo...
  • Page 60 Technical description UM0527 Table 28. Bill of material for 230 Vac version (continued) Part type Designator Manufacturer Ordering code 20 kΩ R159 Yageo RC 0805 F R-07 20K L Royal Ω 22 R 1 W R152 MOR I 1W J 220 T 1 0 R24,R55,R53,R57,R56,R58,R54, 22 kΩ...
  • Page 61 UM0527 Technical description Table 28. Bill of material for 230 Vac version (continued) Part type Designator Manufacturer Ordering code Royal Ω 120 kΩ 3 W R128,R127 MOR I 3W J 124 T 1 0 180 R R140 Yageo RC 0805 J R-07 180R L R82,R83,R89,R80,R90,R81,R88, 200 kΩ...
  • Page 62 Technical description UM0527 Table 28. Bill of material for 230 Vac version (continued) Part type Designator Manufacturer Ordering code Central BZV55C20 semiconductor, BZV55C20 microsemi Central BZV55C20 D34,D33 semiconductor, BZV55C20 microsemi Central BZV55C22 semiconductor, BZV55C22 microsemi Central BZV55C75 D36,D49 semiconductor, BZV55C75...
  • Page 63 UM0527 Technical description Table 28. Bill of material for 230 Vac version (continued) Part type Designator Manufacturer Ordering code SCL-1-H-DPNO Song Chuan SCL-1-H-DPNO 24V SFH620A-2 Vishay SFH620A-2 SG3525A STMicroelectronics SG3525AP SM6T18A ZD1,ZD2 STMicroelectronics SM6T18A SMBYT01 D2,D1 STMicroelectronics SMBYT01 ST72F324J6T6 STMicroelectronics...

  • Page 64: Technical Specifications

    Technical specifications UM0527 Technical specifications Table 29. Technical specifications Parameters 120 V/60 Hz model 230 V/50 Hz model Output rating power 700 VA/450 W 700 VA/450 W Input voltage 83 Vac±3% - 153 Vac±3% 160 Vac±3% - 294 Vac±3% Input frequency...

  • Page 65: Revision History

    UM0527 Revision history Table 29. Technical specifications (continued) Parameters 120 V/60 Hz model 230 V/50 Hz model Battery recharge Two recharge steps Two recharge steps Constant current Constant current First step (Imax=2.16 A, Vmax=28.2 Vdc) (Imax=2.16 A, Vmax=28.2 Vdc) Hysteresis constant voltage...
  • Page 66 No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein.

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