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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

Contents
1 INTRODUCTION ........................................................................................................................... 2
2 RECTIFIER LOGIC CALIBRATION ........................................................................................... 3
12-phase CS166 ............................................................................................................................... 3
6-phase CS112 ................................................................................................................................. 5
3 STATIC SWITCH LOGIC CALIBRATION CS168 (SF643) ........................................................ 8
4 INVERTER LOGIC CALIBRATION ............................................................................................ 9
3-phase CS221 ................................................................................................................................ 9
Single-phase CS273 ...................................................................................................................... 14
5 SIGNALLING INTERFACE CALIBRATION CS245 (SF292) ................................................. 17
On-screen room temperature and peak factor calibration .............................................................. 18
6 CONVERTER CS007 and CS228 CALIBRATION ...................................................................... 19

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

1 INTRODUCTION
This document provides information required to calibrate the 3-phase and single-phase
SAFEPOWER-EVO UG machines.
Thus the different electronic boards on the machine must be worked on. These boards are listed
below:

1) 12-phase rectifier logic CS166 D0357392 (SF392);

6-phase rectifier logic D0248296 (SF296)
2) Static switch logic CS168 D0513643 (SF643);
3) 3-phase inverter logic CS221 D0502597S (SF597);
Single-phase inverter logic CS273 D0627732S (SF732)
4) Signalling interface CS245 D0250292C (SF656);
5) DC/AC Converter CS007 D0048063 (SF063); CS228 D0476608 (SF608)

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

2 CALIBRATING THE RECTIFIER LOGIC

12-PHASE CS166 SF392

Trimmer P1: regulates continuous over voltage.

Trimmer P2: regulates the heat probe reference.
Trimmer P4: regulates battery charge current.
Trimmer P5: regulates maximum rectifier output current (I out Max).
Trimmer P7: regulates the fast charge voltage level.
Trimmer P8: regulates the buffer charge voltage level.
Trimmer P9: regulates R/S phase input voltage read by the display.
Trimmer P10: regulates S/T phase input voltage read by the display.
Trimmer P11: regulates T/R phase input voltage read by the display.
TP37: board reference

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

Input voltages read by the display

Regulate P9 so that the mains input of 400 V on TP42 (phase R) corresponds to 1.510 VAC.
Regulate P10 so that the mains input of 400 V on TP43 (phase S) corresponds to 1.510 VAC.
Regulate P11 so that the mains input of 400 V on TP44 (phase T) correspond to 1.510 VAC.

Heat probe reference value

W5 enable - disable temperature offset (W5 open = enable; W5 Closed = disable)
Calibrate TP30 to –2.98 Vdc using P2 with W5 closed.

Over voltage
(W1 open = standard operation; W1 closed = memory function)
Position probe on TP47 and regulate using P1.
Bring rectifier output voltage to 475 V DC (575 V DC for high dynamic UPS). Then with P1
switch the signal on TP47 from "0" logic status to "1" logic status
The rectifier stops and the rectifier Vout falls to approximately 385 Vdc. Thus the signal on TP47
returns to "0" and the rectifier restarts*. Bring rectifier output voltage to 446 V DC.

* With W1 closed, the rectifier does not restart because restart is inhibited by the memory effect

Total output current calibration (I out total)

On TP33 1 Vdc corresponds to ~50 A of the rectifier output.
The probe on IC19 Pin N.3 (or U19 in the old boards) calibrates, through trimmer P5, the value
in volt equal to the corresponding value on TP33.

Battery charge current calibration

The probe on TP40 calibrates, through trimmer P4, the battery charge current. Discharge the
batteries for about 5-10 min (open the rectifier input switch), reset the rectifier and check the
current limitation on TP40, meaning the signal switch from "I" logic status to "0" logic status. At
this point, with the switch from buffer charge to fast charge, the required battery current can be
calibrated.

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

6-PHASE CS112 SF298

Trimmer P1: regulates T/R phase input voltage read by the display.
Trimmer P2: regulates continuous over voltage.
Trimmer P3: regulates R/S phase input voltage read by the display.
Trimmer P4: regulates the heat probe reference.
Trimmer P5: regulates S/T phase input voltage read by the display.
Trimmer P6: regulates continuous voltage (reference for display reading).
Trimmer P7: regulates battery charge current.
Trimmer P9: regulates maximum rectifier output current (I out Max).
Trimmer P10: regulates the fast charge voltage level.
Trimmer P11: regulates the buffer charge voltage level.
TP30: board reference

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Input voltages read by the display

Regulate P3 so that the mains input of 400 V on TP58 (phase R) corresponds to 1.510 VAC.
Regulate P5 so that the mains input of 400 V on TP57 (phase S) corresponds to 1.510 VAC.
Regulate P1 so that the mains input of 400 V on TP56 (phase T) correspond to 1.510 VAC.

Heat probe reference value

W2 enables - disables the temperature offset (W2 Open = enabled. ; W2 Closed = disabled.)
Calibrate TP59 to –2.98 Vdc using P4 with W2 closed.

Over voltage
(W9 Open = standard operation; W9 closed = memory function)
Position probe on TP4 and regulate using P2.
Bring rectifier output voltage to 475 V DC (575 V DC for high dynamic UPS). Then with P2
switch the signal on TP44 from "0" logic status to "1" logic status
The rectifier stops and the rectifier Vout falls to approximately 385 Vdc. Thus the signal on TP4
returns to "0" and the rectifier restarts*. Bring rectifier output voltage to 446 V DC.

* With W9 closed, the rectifier does not restart because restart is inhibited by the memory effect

Continuous voltage calibration (reference for display reading).

Tester on TP23, use P6 to regulate the signal on TP23 to a value of about 2% of
the battery voltage (2 V every 100V), i.e. to approximately 8.9V (445 Vdc).

Total output current calibration (I out total)

On TP20 1 Vdc corresponds to ~50 A of the rectifier output. The value of TP20 is equal to IC2
input 9.
With the tester on IC2 pin 10, calibrate, using trimmer P9, the value in volt slightly higher to the
corresponding IC2 value on pin 9.
Example: 40kVA rectifier I max = 110A
TP20 = 9 of IC2 = 1/50 x 110 = 2.2V
calibrate IC2 10 to about 2,3V – 2,4V.

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

Battery charge current calibration

The probe on TP1 calibrates, through trimmer P7, the battery charge current. Discharge the
batteries for about 5-10 min (open the rectifier input switch), reset the rectifier and check the
current limitation on TP1, meaning the signal switch from "I" logic status to "0" logic status. At
this point, with the switch from buffer charge to fast charge, the required battery current can be
calibrated.

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Calibration UPS Safepower‐evo UG.. 3‐phase and 1‐phase

3 STATIC SWITCH LOGIC CALIBRATION CS168 (SF643)

With a tester in continuous, position the ground on TP37 and calibrate minimum and maximum
voltages on the mains and inverter output (1V every 100V).
Trimmer P1: regulates minimum mains voltage. With P1 bring TP45 to 2,10V = 207V.
Trimmer P2: regulates maximum mains voltage. With P2 bring TP44 to 2.52V = 253V.
Trimmer P3: regulates minimum inverter output voltage.
With P3 bring TP47 to 1.96V = 196V.
Trimmer P4: regulates maximum inverter output voltage.
With P4 bring TP46 to 2.65V = 265V.
Notes: The following values are general (and must therefore be verified each time) for one UPS
(400V-230V).
The calibrations apply to both three-phase and single-phase UPS.

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4 INVERTER LOGIC CALIBRATION

THREE-PHASE CS221 (SF597)

TP34

P9 P12
TP33
TP26 P13
TP2
SW8 TP25 TP27
P1 P10
P6
P11
TP1

P14
P8 P7

TP30 P2 P5 P4

Trimmer P1: regulates 125% inverter overload

Trimmer P2: regulates 100% inverter overload
Trimmer P4: regulates IGBT current limitation
Trimmer P5: regulates the 3 inverter output voltages.
Trimmer P6: regulates offset to zero
Trimmer P7: regulates S phase voltage
Trimmer P8: regulates T phase voltage
Trimmer P9: regulates mains-inverter synchronism

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Trimmer P10: regulates 1.41 peak factor display reading

Trimmer P11: regulates maximum output current (phase R)
Trimmer P12: regulates maximum output current (phase S)
Trimmer P13: regulates maximum output current (phase T)
Trimmer P14: fine offset regulation
TP34: board reference

Inizial setting of weldable jumpers and dip-switches

SW1 Number of parallel UPS and range of coupling frequency range

SW2 System

SW3 System

SW4 Programming/Normal

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SW5 50/60Hz

SW7 N° of parallel UPS and switching frequency

SW8 Slow voltage loop

Weldable jumpers:
W7 Closed for units with three Hall sensors fitted
W8 Closed for units with two Hall sensors fitted (standard case)
W9 Closed for 3 KHz units
W10 Closed for 2 KHz units

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Inverter output voltage calibration

Note: board in stock (already factory calibrated)
Connect one or two testers to the UPS output filter to read V AC values (phase R, S, T).
open the regulation ring: turn SW8-1 to ON
Turn on the inverter. The LED related to the operation of the inverter on synoptical panel of the
UPS will switch on and the static disconnecting switch will close the inverter output. Gradually
bring all three output voltages to the required value by rotating the P5 potentiometer (increase
clockwise).
Now rotate P7 (phase S) and P8 (phase T) so that phase S is 2V higher than the other two
phases. Phase R is automatically set.
Calibrate Offset to zero. With P6, bring voltage on TP2 near 0V DC and with P14 precisely to
zero. Turn SW8-1 to OFF. This way the output voltage slow offset ring is regulated and on.

Maximum output current calibration (overload)

Note: board in stock (already factory calibrated)
The purpose of this procedure is to calibrate board overload based on rated UPS power. Calibrate
the UPS where the board will be mounted.

With the inverter on, make sure TP30 is between 3.6 V DC and 4 V DC. If this is not the case,
regulate with P4.
With the load powered by the mains or inverter, apply a load with a current equivalent to the
rated power of the unit (the cos of the load is irrelevant).
In this condition, calibrate:
P11 so that TP25 is 2 V AC (phase R)
P12 so that TP26 is 2 V AC (phase S)
P13 so that TP27 is 2 V AC (phase T)
If the rated load cannot be applied, read the real load with an ampere meter clamp; calibrate the
corresponding proportional value on the relevant TP, equal to:
I
2 
In

Where:
- I is the actual read current
- In is the rated current of the unit
100% and 125% overloads are automatically set to the UPS rated power.

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Synchronism calibrations
Switch the inverter off, move the forced switch to position ON and close the reserve switch. As
soon as the static disconnecting switch closes the reserve, switch the inverter on and use an
oscilloscope to set to zero the residual phase between the inverter and the reserve by adjusting
trimmer P9.
Once these calibrations are completed, turn the forced switch to OFF to return the load on the
inverter.

Equipartition calibration for UPS system in parallel

With the above-described adjustments, the equipartition between units running in parallel is
generally guaranteed.
However, it is still important to calibrate the voltages of the single phases so that the units that
are designed to be connected in parallel have the same value (see paragraph “Inverter output
voltage calibration).
If there are significant unbalances due to the fact that the output cables are of different lengths
or if it is necessary to fine tune equipartition, it is possible to use potentiometer P6 as described
below. Rotate the potentiometer clockwise to allow the unit to increase the load, while it is
reduced by rotating counter-clockwise. Thus, move this trimmer sparingly since it is highly
sensitive. The same can be done with potentiometer P14 which, since less sensitive (runs with
wide rotations), allows for calibration for slight load current offsets.

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SINGLE PHASE CS273 (SF732)

Trimmer P1: regulates 125% inverter overload.

Trimmer P2: regulates 100% inverter overload. .
Trimmer P4: regulates inverter output voltage regulates IGBT current limitation.
Trimmer P5: fine offset regulation to zero
Trimmer P6: regulates offset to zero.
Trimmer P7: regulates mains-inverter synchronism
Trimmer P8: regulates maximum output current
TP34: board reference

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Inizial setting of weldable jumpers and dip-switches

SW1 Number of parallel UPS and range of coupling frequency range

SW2 N° of parallel UPS and switching frequency

SW3 Programming/Normal

SW4 50/60Hz

SW5 (external control Vout ON=Normal/Disabled OFF=Enabled)

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SW6 Slow voltage loop

Weldable jumper:
W4 Closed

Inverter output voltage calibration

Note: board in stock (already factory calibrated)

Connect a tester on the UPS output filter to read the phase VAC value.
open the regulation ring: turn SW6-1 to ON
Turn on the inverter. The LED related to the operation of the inverter on synoptical panel of the
UPS will switch on and the static disconnecting switch will close the inverter output. Gradually
bring the output voltages to the required value by rotating the P4 potentiometer (increase
clockwise).
Calibrate Offset to zero. With P6, bring voltage on TP3 near 0V DC and with P5 precisely to
zero. Turn SW6-1 to OFF. This way the output voltage slow offset ring is regulated and on.

Maximum output current calibration (overload)

Note: board in stock (already factory calibrated)
The purpose of this procedure is to calibrate board overload based on rated UPS power. Calibrate
the UPS where the board will be mounted.

With the inverter on, make sure TP2 is between 3.6 V DC and 4 V DC. If this is not the case,
regulate with P3.
With the load powered by the mains or inverter, apply a load with a current equivalent to the
rated power of the unit (the cos of the load is irrelevant).
In this condition, calibrate:
P8 so that TP15 is 2 V AC (phase)
If the rated load cannot be applied, read the real load with an ampere meter clamp; calibrate the
corresponding proportional value on the relevant TP15, equal to:
I
2 
In

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Where:
- I Is the actual read current
- In is the rated current of the unit
100% and 125% overloads are automatically set to the UPS rated power.

Synchronism calibrations
Switch the inverter off, move the forced switch to position ON and close the reserve switch. As
soon as the static disconnecting switch closes the spare, switch the inverter on and use an
oscilloscope to set to zero the residual phase between the inverter and the reserve by adjusting
trimmer P7.
Once these calibrations are completed, turn the forced switch to OFF to return the load on the
inverter.

Equipartition calibration for UPS system in parallel

With the above-described adjustments, the equipartition between units running in parallel is
generally guaranteed.
However, it is still important to calibrate the voltages of the single phases so that the units that
are designed to be connected in parallel have the same value (see paragraph “Inverter output
voltage calibration).
If there are significant unbalances due to the fact that the output cables are of different lengths
or if it is necessary to fine tune equipartition, it is possible to use potentiometer P6 as described
below. Rotate the potentiometer clockwise to allow the unit to increase the load, while it is
reduced by rotating counter-clockwise. Thus, move this trimmer sparingly since it is highly
sensitive. The same can be done with potentiometer P5 which, since less sensitive (runs with
wide rotations), allows for calibration for slight load current offsets.

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5 SIGNALLING INTERFACE CALIBRATION CS245 (SF292)

Calibrations only change the reading of the displayed values; they do not compromise UPS
operations.
Calibrate and check the value on the display.

Reserve input voltage calibration between phase and neutral read on

the display
Trimmer P7 phase R
Trimmer P8 phase S
Trimmer P9 phase T

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Output voltage calibration between phase and neutral read on the

display
Trimmer P10 phase R
Trimmer P11 phase S
Trimmer P12 Phase T

Battery voltage calibration read on the display

Trimmer P6

Output current calibration read on the display

Trimmer P13 Phase R
Trimmer P14 Phase S
Trimmer P15 Phase T

Battery current calibration read on the display

Trimmer P4.

Following are additional calibrations on the display using the other electronic boards

Room temperature calibration on the display

Calibrate inverter interface board P1 (CS223 or CS270)

Calibrate the peak factor C.F. 1.41:

Apply a linear load equivalent to more than half the rated current (it is possible to apply both a
resistive and inductive load).
Calibrate CS221 inverter logic board P10 so that the signalling display interface displays a value
above 1.41, then reduce the read value until it slowly reaches 1.41. Perform these adjustments
slowly because the display does not show values below 1.41, so the display only shows this
value.

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6 CONVERTER CALIBRATION

DC/AC CONVERTER 100W CS007 (SF063)

TP8
TP6

TP7

TP5 board reference

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DC/AC CONVERTER 400W CS228 (SF608)

TP4 board reference

Maximum battery voltage calibration (Vmax)

Bring Rectifier output/Inverter input voltage to 480V (580V for 40 monoblocks).
Using board potentiometer P1, use a oscilloscope to check that the signal on TP6 (TP2 CS228),
normally High "1", switches to Low "0". Thus the "Suitable Battery" message disappears from
the display and the inverter turns off.

Calibrate the battery pre-alarm value.

Bring Rectifier output/Inverter input voltage to 360V (440V for 40 monoblocks).
Using board potentiometer P3, use a oscilloscope to check that the signal on TP8(CS007) or pin
8 on IC7(CS228), normally High "1", switches to Low "0". Thus the "Battery pre-alarm" message
appears on the display.

Minimum battery voltage calibration (Vmin)

Bring rectifier output/inverter input voltage to 330V (400V for 40 monoblocks).
Using board potentiometer P2, use a oscilloscope to check that the signal on TP7(CS007) or
TP3(CS228), normally High "1", switches to Low "0“. (the "Battery suitable" message
disappears and the inverter switches off).
Set the rectifier output/inverter input voltage to the previously calibrated value.
Verify that the signal on TP7 returns to High "1" (message "Suitable battery" disappears and
the inverter restarts).

REV. Date Prepared by Checked by Issued by ID:NUMBER

Issue/000 2014-06-20 A. Mazza E. Rusconi P. Baggi PO-DT-F002E
Page 21 of 21 + FR
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000 2014-06-20 - Prima Emissione A. Mazza E. Rusconi P. Baggi

ID:NUMBER
STATO DELLE REVISIONI PO-DT-F002E
Taratura UPS Safepower‐evo Trifase e Monofase       MD111 Rev00 Page. FR1 of FR1