ST UM0527 User manual

July 2008 Rev 1 1/66
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.
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Contents UM0527
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Contents
1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 Hardware architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1 General realization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Detailed description of electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.4 DC/DC converter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1.5 DC/AC inverter module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1.6 Power switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1.7 RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.1.8 Charger AC/DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1.9 Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1.10 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.1.11 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.1.12 Measurements: input voltage, input voltage phase, output current, inverter
output voltage, battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.1.13 Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.1.14 Mains protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.1.15 UPS modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.1.16 Microcontroller IN/OUT signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.1.17 Signals functions table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1.18 Detailed description of mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2 Software architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.1 Data models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.2 Protocols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3 System architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4 Main loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.5 ADC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.7 SPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.8 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.9 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.10 Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.11 Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2 Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

UM0527 Contents
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2.1 Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.3 Assembly description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.2 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3.3 Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.1 PCB: mains input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.2 PCB: outlet output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.3 PCB: AVR transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.4.4 PCB: battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4.5 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4.6 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4.7 PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.5 Signalization description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.1 Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.5.2 Sound alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.6 Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.6.1 Bill of material for 120 Vac version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.6.2 Bill of material for 230 Vac version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Revision history . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

List of figures UM0527
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List of figures
Figure 1. Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2. DC/DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3. DC/AC inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4. Power switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5. RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 6. AC/DC battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 7. Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 8. Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 9. Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 10. Measurements: input voltage, input voltage phase, output current, inverter output
voltage, battery voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 11. Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 12. Main flowchart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 13. Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 14. DC/AC inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 15. DC/DC converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 16. Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Figure 17. Power switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 18. AC/DC battery charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 19. PC interface stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 20. Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Figure 21. Measurement stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 22. RFI/EMI filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 23. Battery overcurrent protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 24. Top view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 25. Bottom view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 26. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 27. Mechanical view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 28. UPS with assembled rear outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 29. UPS with front button and indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 30. UPS with batteries and battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 31. UPS with battery fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 32. UPS with AVR transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 33. UPS with automatic fuse and power wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 34. UPS with motherboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 35. UPS fully assembled. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 36. UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

UM0527 General description
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1 General description
1.1 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.
The microcontroller controls all UPS functions. It monitors the mains parameters in order to
ensure the proper level of the output voltage. The microcontroller measurement parameters
are input/output mains voltage and phase, output inverter voltage, battery voltage, output
current and output power. The UPS has a built-in RS232, joint signals and USB interfaces
(USB for RS232 converter).

General description UM0527
6/66
1.1.2 Block diagram
Figure 1. Block diagram
HVDC
INV_A INV_B
INV_OUT1
INV_OUT2
VDD
VDD GND
VDD
DC/AC Invverter
DCAC12st05v031.sch
HVDC
VAKK
VDD
SHD
VDCDC
GND
DC/DC converter
DCDC12st05v031.sch
VCC
BAT_LOW
ACF!
UPS_OFF!
USB_IN!
TXD
RXD
INP_LEV
PHASE
ACL!
ACH!
ACF
OUT_REL!
OUT_LEV
INV_A
INV_B
SHD
CHOFF
AKK_LEV
VCC
ON/OFF
SW_ONP
PWR_LEV
VDCDC
ACI!
GND
VCCPU
VCC
VCC
ACF1!
Microcontroller unit
Microcontroller12st05v031.sch
AC_IN1 AC_IN2
ACL!
ACH!
ACF
OUT_REL!
IOUT_2
IOUT_1
AC_1
AC_2
INV_OUT1
INV_OUT2
AC_IN2
AC_IN1
ACI!
GND
VPP
AC_IN1
AC_IN2
AC_1
AC_2
Power Relays Relays12st05v031.sch
AC_2
AC_1
VDD CHOFF
VBAT
VDD
+VOUT
GND
AC/DC Charger
ACDC12st05v031.sch
VCC
BAT_LOW
ACF!
UPS_OFF!
USB_IN!
TXD
RXD
GND
ACF1!
Inerface unit Interface12st05v031.sch
VDD VBAT +VOUT
AC_IN2
ON/OFF
SW_ONP
VCC
AC_IN1
GND
VPP
VCCPU
Power Supply
PowerSupply12st05v031.sch
IOUT_1
IOUT_2
PWR_LEV
GND
VCC
Output Current Measurement
OutputCurrent12st05v031.sch
VBAT
AKK_LEV
GND
VCC
Battery Voltage
BatteryVoltage12st05v031.sch
AC_2
AC_1
OUT_LEV
GND
Output Voltage Inverter
InverterVoltage12st05v031.sch
AC_IN1
AC_IN2
PHASE
VCC
GND
VDD
INP_LEV
Input Voltage & Phase Measurement
InputVoltage12st05v031.sch
AC_IN1 AC_IN2
EMI/RFI FILTER
RFIEMI12st05v031.sch
VBAT
VAKK GND
Battery Overcurrent Protection
BatOver12st05v031.sch
AVR TRAFO
INPUT
OUTPUT
LED INDICATIONS
BUTTON
FUSE
FUSE
VCC
BAT_LOW
ACF!
UPS_OFF!
USB_IN!
TXD
RXD
INP_LEV
PHASE
ACI!
ACF
ACL!
ACH!
OUT_REL!
OUT_LEV
INV_A
INV_B
VDCDC
SHD
CHOFF
VAKK
VBAT
AKK_LEV
VCC
ON/OFF
SW_ONP
PWR_LEV
+VOUT
VDDVDD
AC_IN2
AC_IN1
AC_1
AC_2
AC_1
AC_2
AC_IN1
AC_IN2
IOUT_1
IOUT_2
AC_IN1 AC_IN2
BATTERY
VDD
HVDC
GND
GND
GND
GND
GND
GND
GND
GND
GND GND
GND
GND
VCCPU
VCC
VDD
VCC
ACF1!

UM0527 General description
7/66
1.1.3 Detailed description of electronics
1.1.4 DC/DC converter module
Figure 2. DC/DC converter
R60 10R Q6
STP75NF75
GND
D26
STTH8R06D
D28
STTH8R06D
D25
STTH8R06D
D27
STTH8R06D
R53 22k
GND
VAKK
VAKK
R61 10R
Q7
STP75NF75
GND
R55 22k
GND
DC/DC CONVERTER
C64
3300uF/35V
GND
R59 10R R62 10R
Q8
STP75NF75
Q5
STP75NF75
R56 22k
GND
R54 22k
GND
GND GND
A
1
D
2
C B
12 11
TI1
TI700/24/1v01
C66
470uF/63V
GND
R35 1k 3W D29
STTH302S D30 STTH302S
C86
1nF 1kV
R66
330R 2W
C87 330nF
GND
R18
7.5k
GND
C34 1nF
C33
4.7nF
GND
R28 0R
OUT_B OUT_A
R19
100k
VDD
R31 36k
GND
Vref
16
Clock 4
Ct
5
Rt
6
Disch
7
Sync
3
ErrAmp+
2
ErrAmp-
1SoftStart 8
VCC 15
VC 13
ShutDown 10
GND
12
OutB 14
OutA 11
ErrAmpOut
9
U3 SG3525A
R17
33R
R36 3.3k
Vref
GND
Vref
R30 5.6k
GND
R70
200k
C67
10nF
GND
HVDC
SHD
VDCDC
L1 1.5uH / 10A L2 1.5uH / 10A
R71 200k
R32 390k C68
10nF
GND
GNDGND
R69 200k R68 200k
R29 6.8k
GND
R67
330R 2W
RAD10 Heatsink
RAD8 Heatsink RAD7 Heatsink
RAD9 Heatsink
RAD5 Heatsink RAD6 Heatsink
R341k 3W
U4 PDTC114ET
R33 47R C62
10uF/50V
C32
100uF/25V
C12
100nF
GND
GND
GND
C50 100pF
GND
C65
3300uF/35V
GND
C13
100nF
GND
C15
100nF
GND
C14
100nF
GND
TI700/24/2v01
0R
1.5nF 1kV
STTH803D
STTH803D
STTH803D
STTH803D
100k
100k
100k
100k
100k
30k
120Vac Model 230Vac Model
VDCDC
SHD
HVDC
VDDVDD
VAKKVAKK
GNDGND
C72 100nF
GND
C43
1nF
GND
1uF

General description UM0527
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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. Power components on the secondary side are limited to rectifier diodes D3 -
D6 and a small voltage smoothing capacitor. The output voltage is limited with direct control
loop without insulation. An internal soft-start circuit is used to limit the voltage rise rate on
the output of the DC/AC converter. The soft-start circuit is controlled from the microcontroller
by an additional transistor. The PWM controller is powered from the main UPS power supply
section. The output converter voltage range is battery voltage dependent and has been set
to achieve maximum efficiency.
Table 1. DC/DC specification
DC/DC converter 120 Vac version 230 Vac version
Output voltage 130 – 190 V 250 - 360 V
Output power 450 W 450 W
Efficiency > 80% > 80%
Frequency 40 kHz ± 10% 40 kHz ± 10%
PWM controller U1 SG3525 SG3525
Power switches 5 – 8 STP75NF75 STP75NF75
Push-pull transformer T11 EE42 EE42
Rectifiers diodes D1 – D4 STTH803 STTH8R06

UM0527 General description
9/66
1.1.5 DC/AC inverter module
Figure 3. DC/AC inverter
DC/AC INVERTER
HVDC
GND
D1 SMBYT01
VDD
R12 10k R11 10k
R7 100R
C1
10uF/25V
R14
10k
R13 10k
LIN
1HIN 2
VCC
3
GND
4
LVG 5
VO 6
HVG 7
VB 8
U1 L6387D
Q1 STP12NM50 Q2 STP12NM50 Q4
STP12NM50
Q3
STP12NM50
D2
SMBYT01
VDD
C2
10uF/25V
LIN 1
HIN 2
VCC 3
GND
4
LVG
5VO 6HVG 7VB 8
U2 L6387D
INV_B INV_A
INV_A INV_B
INV_OUT2
INV_OUT1
R1 100R R2 100R
C8
100nF
C10
100nF
C9
100nF
C11
100nF
GND GND
GND GND
R3 0R D3
BAS16
R8 100R
R4 51R D4
BAS16
R10 100R
R6 51R
D7
BAS16
R9 100R
R5 0R
D6
BAS16
ZD1
SM6T18A
D5
BAS16
ZD2
SM6T18A
D8 BAS16
STP22NS25Z STP22NS25Z STP22NS25Z STP22NS25Z
RAD1 Heatsink
RAD3 Heatsink
RAD2 Heatsink
RAD4 Heatsink
C4
10uF/35V
C3
10uF/35V
INV_A INV_B INV_A
INV_B
INV_OUT1
INV_OUT2
120Vac Model 230Vac Model
HVDC
GND
GND
HVDC
VDD VDD
R173 47R
R16410R
D47
STTH1L06A
D48 STTH1L06A
R174 47R
R172 10R
C36 100pF
GND
C35 100pF
GND
C39 100pF C40
100pF
GND
GND

General description UM0527
10/66
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. The diodes D1 and D2 are high-voltage fast-recovery diodes.
Switching off all transistors is achieved with driver internal logic if both INV_A and INV_B
signals are set high or low. There is no any additional overcurrent protection for bridge
transistors. Drivers are powered from the main UPS supply unit.
Table 2. DC/AC specification
DC/AC inverter 120 Vac version 230 Vac version
Output voltage RMS 120 Vac +5%/ -10% 230 Vac +5%/ -10%
Frequency (microcontroller
outputs) 60 Hz ± 0.1 Hz 50 Hz ± 0.1Hz
Drivers U1, U2 L6387 L6387
Power switches Q1 – Q4 STP22NS25Z STP12NM50
Bootstrap diode D1, D2 SMBYT01-400 SMBYT01-400

UM0527 General description
11/66
1.1.6 Power switches
Figure 4. Power switches
1
J8 6.3x0.8
1
J7 6.3x0.8
1
2
3
4
L8 1:1000
IOUT_2
IOUT_1
RL5
RM84-2022-25-1024
RL2
RM85-2011-25-1024
RL3
RM85-2011-25-1024
1
J5
6.3x0.8
1
J4
6.3x0.8
D12
BAS16
D34
BZV55C20
D33
BZV55C20
D11
BAS16
VPP
VPP
VPP
ACL! ACH!
D35
BZV55C20
D14
BAS16 OUT_REL!
RL4
RM84-2012-25-1024
INV_OUT1
INV_OUT2
1
J6
6.3x0.8
D13
BAS16
D36
BZV55C75
VPP
D10
BAS16
D31
BZV55C10
VPP
ACF
OUTPUT
IOUT_2 IOUT_1
OUT_REL!
ACH! ACL!
ACF
AVR
AC_1 AC_2
AC_IN1 AC_IN2 RL1
SCL-1-H-DPNO
ACI!
ACI!
D32
BZV55C10
120Vac Model 230Vac Model
INV_OUT2 INV_OUT1
AC_IN2 AC_IN1
VPP
GND GND
VPP
AC_1 AC_2
t
RT1
JNR15S70L
t
RT2
JNR15S70L
JNR15S2R5M JNR15S2R5M
D49
BZV55C75
BLACK WHITE
RED
BROWN BLUE

General description UM0527
12/66
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. The current transformer is
used for monitoring UPS output current and power. The additional AVR boost/buck
autotransformer has two sections: winding and output power 60VA. Relay coils are
controlled by the microcontroller signals through an additional driver.
1.1.7 RFI/EMI filter
Figure 5. RFI/EMI filter
An additional EMI/RFI filter contains one X-type capacitor and a pair of Y-type capacitors.
L
N
C120
4,7nF
AC_IN1
AC_IN2
PE R90
200k
MAINS
RFI/EMI FILTER
RV1
JVR-20N471K
R88
200k
R89
200k
JVR-20N271K
AC_IN1
AC_IN2
1
J9
6.3x0.8
1
J10
6.3x0.8
1
J11
6.3x0.8
C119
4,7nF C108
470nF
BROWN
BLUE
YELLOW/GREEN

UM0527 General description
13/66
1.1.8 Charger AC/DC
Figure 6. AC/DC battery charger
AC/DC BATTERY CHARGER
GND
R94 10k
C101
1000uF/50V
GND
D38
STPS8H100D
D16 BAS16
GND
C99
1nF 500V R64 10R
R16 10k
GND
C20
100nF
GND
L11 10uH/3A
C19
100nF
GND
+VOUT
GND
1 4
12 10
6 7 3 2
9
`8
11 13
T1
TI50/30v02
R20 100k
VDD
F1 1,25A C96
100nF X2
VFF
3
VDD 8
ZCD 5
VFB
1
COMP
2
GD 7
CS 4
GND
6
U11 L6565
GND
GND
R134 16k R132 750k
R135 43k
R95 10k
GND
R138
33k
VBAT MAX +28.2V
6 1
8
7
2
3
U12
TL431CD
R136
39k
R115
3.3k
R57 22k
GND
R139 5.6k R140 180R
Q12 BC857B
Overvoltage Protection 32V
TH1
TYN608
GND
2
1
3
4
BR1
KBU605
Control voltage output Current Mode Charging Voltage Mode Charging
Pout(max)=50W Charger Output
VBAT
R129
10R
GND
GND
Q11
STP5NK90Z
R133 33R
R15 10k
GND
CHOFF
VBAT MIN +26.8V
R123 100k
D37 STTH1R06
R127 120k 3W
C97
680pF 1600V
AC_2 AC_1
Q10 STP80PF55
U6
PDTC114ET
+VOUT
ZD3
BZX84C12
C100
100uF/50V
GND
RAD11 Heatsink
2A
R131 750k
R130 750k
GND
R63 10R
R124 100k
R125 100k
R126 100k
GND
C98
47uF/50V
C21
100nF
GNDGND
C102
1000uF/50V
R122 100k
GND
R65 10R
R128
120k 3W
RAD12 Heatsink
R137
0.68R 2W
L9 10uH/3A L10 10uH/3A
C18
100nF
C49 1nF
C79 10nF
C95
47nF X2
120Vac Model 230Vac Model
CHOFF
AC_1 AC_2
D15 BAS16
D17
BAS16
Q9 STP80PF55
VBAT
GND
+VOUT
GND
+VOUT
VDDVDD
R52 4.7R 3W
C44
47nF X2

General description UM0527
14/66
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.
The PWM controller is powered from the main UPS supply module and from the auxiliary
winding on the flyback transformer. The transformer is designed with the ETD29 core. The
CHOFF signal is used to switch (Q2 and Q3 STP80PF55) charging modes by the
microcontroller. An additional output voltage loop limits open output charger voltage. The
charger module also contains a battery overvoltage protection circuit with SCR TYN608 and
voltage reference TL431.
Table 3. Battery charger specifications
AC/DC converter 120 Vac version 230 Vac version
Max output voltage 29 Vdc ± 5%
Max output power 50 W
Efficiency >80%
Minimal switching frequency 100kHz ± 10%
Controller U1 L6565
Power switch Q11 STP5NK90Z
Transformer core ETD29
Rectifier diode D1 STPS8H100
Clamp diode D3 STTA106

UM0527 General description
15/66
1.1.9 Control unit
Figure 7. Control unit
GND GND
C88
22pF
C89
22pF
Y1 16MHz
NC1
ON/OFF
BUZZER
GND
VCCPU
RX
TX
RST!
PHASE
INV_A!
INV_B!
BUTTON
ACL ACF! PWR_LEV INP_LEV AKK_LEV
TX RX
L64.7uH L54.7uH
ACI
VCCPU
R110 4.7k
GND
C17 100nF
GND
VDD 3
RES
2
VSS
1
U8 STM809L
L4 4.7uH L3 4.7uH
GND
VCCPU
RST! RESET!
ICC_CLK
ACH
VAREF VSSA
OUT_REL
R91 10k
RST! ICC_SEL
GND
ICC_DATA
ICP programming C-FLASH
11 22
B1 BPT-14
R120 2.2k
VCC
ACI
R113 3.3k
R114
3.3k
COM 9
1B
11C 16
2B
22C 15
3B
33C 14
4B
44C 13
5B
55C 12
6B
66C 11
7B
77C 10
8
E
U9
ULN2003D
ACF! INV_A! INV_B!
OUT_REL!
INV_A INV_B
GND
OUT_REL
ACL!
ACL ACH
VCC
ACH!
OUT_LEV
R118
2.2k
R119
2.2k
VCC VCC
ICC_DATA ICC_CLK
UPS_OFF! LEDR
LEDG
BAT_LOW
CHOFF
VCC
1 3 5 7
2 4 6 8
910
J2 IDC10
GND
VCC
VCC
D9
BAS16
BUTTON
YA RA GA
R109 330R
R107 330R
SW_ONP
R92
10k
VCC
R111
100R
R104 330R R106
330R
R108 330R
LEDR LEDG
R105 330R
LEDY
OSC1
OSC2
OSC1 OSC2
ICC_SEL
VAREF
13
VSSA
14
MCO/AIN8/PF0
15
BEEP/PF1 (HS)
16
OCMP1_A/AIN10/PF4
18
ICAP1_A/PF6 (HS)
19
EXTCLK_A/PF7 (HS)
20
AIN12/OCMP2_B/PC0 23 AIN13/OCMP1_B/PC1 24
ICAP2_B/PC2 25 ICAP1_B/PC3 26
ICCDATA/MISO/PC4 27
AIN14/MOSI/PC5 28
ICCCLK/SCK/PC6 29
AIN15/SS/PC7 30
PA3 (HS) 31
PA4 (HS) 34
PA6 (HS) 36
PA7 (HS) 37
Vpp/ICCSEL 38
RESET 39
Vss_2 40
OSC2 41
OSC1 42
Vdd_2 43
PE0/TDO 44
PE1/RDI
1
PB0
2
PB3
5
PB4 (HS)
6
PD0/AIN0
7
PD1/AIN1
8
PB1
3
PB2
4
PD2/AIN2
9
PD3/AIN3
10
PD4/AIN4
11
PD5/AIN5
12
PF2 (HS)
17
Vdd_0
21
Vss_0
22
Vdd_1 32
Vss_1 33
PA5 (HS) 35
U29
ST72F324BJ6T6
LEDY
VDCDC
VCCPU GND
GND
VCCPU
VCCPU
GND
VAREF
VSSA
USB_IN!
SHD
TXD RXD
INV_A INV_B
ACL! ACH!
ACF
OUT_REL!
SW_ONP
BAT_LOW
UPS_OFF!
PHASE
PWR_LEV AKK_LEV OUT_LEV
INP_LEV
VDCDC
CHOFF
USB_IN!
BAT_LOW UPS_OFF! PHASE PWR_LEV AKK_LEV OUT_LEV INP_LEV VDCDC CHOFF USB_IN!
SHD SHD
1 3 5 7
2 4 6 8
910
J1 IDC10
GND
VCC
R38 1k
R37 1k
S
1
Q
2
W
3
VSS
4
VCC 8
HOLD 7
C6 D5
U10 M95020WMN6P
MOSI
MOSI ICC_CLK SCK
ICC_DATA
GND
MISO
VCCPU
VCCPU
R39
4.7k
RESET! HOLD!
CS!
ACF1!
R93 10k NC1
GND
ACI!
ACI!
BUZZER
GND
GND
CS!
PHASE INV_B! INV_A!
UPS_OFF! AKK_LEV
GND
C48
100nF
C37
1nF
C38
1nF
GND
ON/OFF
RST! USB_IN!
ICC_CLK ICC_SEL ICC_DATA
BUTTON
RX TX MOSI
GND
GND
GND
GND
GND
GND
C70
10nF C71
10nF
C73
1nF
C74
10nF C76
10nF C77
10nF
GND
GND
GND
GND
C51
100pF
C52
100pF
C53
100pF
C54
100pF
C55
100pF
C56
100pF
GND
GND
GND VCCPU
C16
100nF
ON/OFF
120Vac Model 230Vac Model
GND
TXD RXD
VCCPU
VCC
GND GND
VCC VCCPU
Q15 MMBTA42
R86 4.7k R87
10k
GND
ACF! ACF!
ACF1! ACF1!

General description UM0527
16/66
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. Digital inputs / outputs are used to control internal and
external UPS signals. A thermistor is used to monitor internal UPS temperature.

UM0527 General description
17/66
1.1.10 Power supply
Figure 8. Power supply
D43
STTH102A
GND
ON/OFF SW_ONP D21 BAS16
U25
SFH620A-2 C112
22nF
VBATGND +VOUT
C27
100nF
VDD
INH
3
GND
7
OUT 1
FB 5
VREF
6
SYNC
2
COMP
4
VCC 8
U26 L5970D
D45
STPS1L60A
GND
C61
100pF R58
22k
L12 330uH / 0.9A
SW_ONP
AC_IN1
R153 36k
ON/OFF
R116 3.3k
AC_IN2
GND
R152 22R 1W
+5Vdc
VDD power supply control
C30
100nF
By button
C29
100nF
Voltage From Battery
C28 100nF
Voltage From AC/DC Charger
+15Vdc
POWER SUPPLY
VCCPU
VCC
IN
3OUT 2
GND
1
LD1086
U27 LD1086V50
GNDGND GNDGND
R72 200k
GND GND GND
U7
PDTC114ET
100k 100k
100k 100k RAD13
Heatsink
R73 200k
R74
200k
R75 200k
C110
1uF / 50V
GND
C104
22uF/35V
C113
47uF/25V
C114
47uF/25V
C105
100uF/35V
D42
STTH102A D44
STTH102A
L7 4.7uH
VPP
AC_IN1 AC_IN2
+VOUT
VBAT
VDD VCC
VCCPU
VPP
GND GND
+VOUT VBAT
DL1 LED
R175 2.2k GNDVCC
1
J17 6.3x0.8
1
J3 6.3x0.8
BLACK BLACK
2
1
3
4
BR2
B600C1500
F3 1,25A
GND
C41 100nF
GND
GND
GND
C45
10uF/100V
C46
47uF/25V
D51 STTH102A
GND
R96 33k
D50 BZV55C22
Q16 BDX53C

General description UM0527
18/66
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. The switching regulator is controlled by the
microcontroller ON / OFF signal and the BUTTON signal from the front panel ON/OFF
switch. Additional supply is switched on by optocoupler SFH620 powered from the mains.

UM0527 General description
19/66
1.1.11 Interface
Figure 9. Interface
COM
C103
22uF/35V
V+
COM
R121
2.2k
C109
2.2uF/50V
TRIG
2
Q3
R
4
CVolt
5THR 6
DIS 7
VCC 8 GND
1
U14TS555CDT
COM
C25
100nF
C23
100nF
C5
10uF/35V
C22
100nF
R97
10k
R41 4.7k
V-
D18
BAS16
COM
COM
VPC VPC
OFF OFF
1 6 2 7 3 8 4 9 5
J14
U21 PC817C
U19 PC817C U20 PC817C
D19
BAS16
R45
4.7k
R148 2.4k R147 820R
BTL ACFL OFF R146
4.7k R145 4.7k
R48 4.7k
U22 PC817C
U23 PC817C
R112
100R
R99 20k
R144
2.2k
R149
6.8k
D20
BAS16
R142
3.3k
V-
V+
TXD1 RXD1
COM
VCC VCC
GND
VCC
COM COM
COM
V+ V+
VCC
COM VPC
BAT_LOW
ACF1!
UPS_OFF! RXD TXD
Q13 BC846B
Q14
BC857B
GND
ACF1!
BAT_LOW UPS_OFF!
RXD TXD
GND
TxD_USB
GND1 GND1 C92
22pF
C91
22pF Y2
24MHz
USBDM
GND1
1 2 3 4
J13
USB-B
GND1
C24
100nF
R43
4.7k
GND1 TxD_USB
USB
RxD_USB
OSCOUT OSCIN RST_USB
USBDP USBVCC
+5V_USB
OSCOUT
OSCIN
+5V_USB USBDM USBDP
ICCCLK
ICCDATA
VPP_USB
C6
10uF/35V
ICCDATA ICCCLK RST_USB VPP_USB
GND1
+5V_USB
ICCDATA ICCCLK
R98
10k
VPP_USB
GND1
USBVCC
R141 1.5k
USB Socket
C57
100pF
C58
100pF
C80
10nF
GND1
RST_USB
RxD_USB
ICP
RXD1 TXD1 ACFL BTL
OFF
U17 PC817C U18 PC817C
R44
4.7k
R143
4.3k
+5V_USB
GND1
GND
R47
4.7k
VCC
U16 PC817C
R42 4.7k
GND1
+5V_USB
R46
4.7k
GND VCC
GND
GND
+5V_USB
INH
6
ADDR A
11
ADDR C
9
A1
12
A2
13
B1
2
B2
1
C1
5
C2
3C4
A14 B15
VCC 16
VSS
8
ADDR B
10
VEE
7
U24 M74HC4053RM13TR
VCC
USB_IN!
GND1
GND1
D40 BAT54S
D39 BAT54C D41 BAT54A
Vcc1
1Vcc2 8
Out1 7
In1
2
In2
3
Gnd1
4Out2 6
Gnd2 5
U13 USB6B1
Data Protection
C26 100nF
GND
C59
100pF
C60
100pF
GND1
GND1
C106
100nF
GND1
+5V_USB
GND1
GND1
VCC
1 3 5 7
2 4 6 8
910
J15 IDC10
120Vac Model 230Vac Model
USB_IN!
VCC
GNDGND
VCC
NC10 NC9
NC8 NC4 NC5 NC6 NC7
R165 10k
GND1
R166 10k
GND1
R167 10k
GND1
R168 10k
GND1
R169 10k
GND1
R170 10k
GND1
R171 10k
GND1
NC10 NC9 NC8 NC4 NC5 NC6 NC7
VSS
4
USBDM 23
USBDP 22
RESET
7
OSCIN
3OSCOUT 2
PA7 14
PB6
8
PA5 15 PA4 16
PB3
10
PB2
11
PB1
12 PB0 13
VDD
1
PA1 19 PA0 20
USBVCC 24
VPP
9
PC0
6
VSSA 21
PC1
5
PA3 17 PA2 18
U15 ST72F63BE2M1 SO24
GND1
NC11 NC12 NC13
R85 10k
GND1
R84 10k
GND1
R40 10k
GND1
NC11 NC12 NC13

General description UM0527
20/66
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). The required voltage for the
RS232 circuits is realized by the voltage pump converter built with NE555. The interface unit
also contains an analog multi/demultiplexer M74HC4053 used to switch signals from the
USB and RS232 to the microcontroller.