OFF LINE产品架构介绍.doc

age 372020/1/25 Arista 400/600/800 service manualSERVICE MANUAL使用细则Arista 400/600/800 SeriesArista 400/600/800系列UNINTERRUPTIBLE POWER SYSTEM不间断电源系统（UPS）1.0 Revision Summary1.0 版本摘要REVISIONSECTIONDESCRIPTIONRev. 01Formal Release版次部分（节）描述01版正式发行Table of Contents(目录表)1. Introduction（绪论） .42. Block Diagram(方块图) .53. Control Power Circuit （电源控制电路）.74. Battery Charger（蓄电池充电器）105. Line and Zero-Crossing Detection (输入线与过零侦测).116. Green Power Function (绿色电源功能)137 Inverter Operation(逆变器操作)148. Active Clamp(主动钳位).179. Microcontroller (CPU) Control Circuit(微处理器控制电路).1710. Relay Circuit(继电器电路).1911. Displays, Audio Alarm and Control Button(显示,声音报警与控制按扭).2112. Load Detecting Circuit(负载侦测电路) 2313. Interface Circuit(接口电路) .2414. Trouble Shooting(故障处理).25Index of Figure(数字索引)Electrical circuit Schematic diagram(电子线路示意图)Figure S-1 Block Diagram (图S-1:方块图) Figure S-2Control Power Circuit(图S-2:电源控制电路)Figure S-3Charger Circuit(图S-3充电器电路)Figure S-4Line and Zero Crossing Detecting Circuit(图S-4:输入线与过零侦测电路)Figure S-5Inverter Circuit(图S-5:逆变器电路)Figure S-6Green function circuit(图S-6:绿色功效电路)Figure S-7CPU Circuit(图S-7:CPU电路)Figure S-8Relay Circuit(图S-8:继电器电路)Figure S-9Interface Circuit(图S-9:接口电路)Figure S-10Load Detecting Circuit(图S-10:负载侦测电路)Figure S-11 USB Circuit(图S-11:USB电路) Waveform & flowchart(波形&流程图)Figure W-1Cold Start(图W-1:冷机启动)Figure W-2Zero Crossing(图W-2:过零)Figure W-3 Inverter Circuit(图W-3:逆变(换相)电路) (1)Figure W-4 Relay Speed up Capacitor(图W-4:继电器加速电容)Figure W-5 Battery Mode Examination Flowchart(图W-5:电池模式检查流程图)Figure W-6 Line Mode Examination Flowchart(图W-6:输入线模式检查流程图)1. Introduction(引言)Arista series is an off-line power system that has a step wave output and prevents impulse, surge, sag and power outage situations. It provides the UPS output load with a reliable source. It has the following functions: Arista系列是一款拥有阶梯式波动输出并预防冲力,浪涌,下陷和功率中断状况的离线式电源，给UPS输出负载提供了一个可靠源，其具有以下功能:1-1 Boost:(升压)If the commercial line is under voltage, the Boost will raise the UPS output voltage to 1.18 times its input voltage.(如果供应线欠压,boost会将UPS输出电压升到其输入电压的1.18倍)1-2 Buck: (降压)If the commercial line is over voltage, the Buck will reduce the UPS output voltage to 0.85 times its input voltage.(如果供应线过压,buck会将UPS输出电压降低到其输入电压的0.85倍)1-3 50/60Hz automatic frequency selection:(50/60Hz自动频率选择)The output frequency will automatically match the input frequency (50 or 60Hz). (输出频率将自动与输入频率匹配,50或60Hz)1-4 Communication port (USB): (通讯口USB)Computer interface with USB communication port will provide remote shutdown capacities.(计算机端可利用USB通讯口提供远程关断能力)1-5 Telephone line protection: (电话输入线保护:)The unit provides RJ11 ports to provide transient voltage surge suppression (TVSS) for telephone line.(这个单元提供RJ11接口去给电话线做瞬变浪涌电压抑制(TVSS)1-6 Cold start (DC start): (冷机启动(直流启动)It comes with a DC start feature while without input power source.(在没有输入(交流)电源时,其拥有直流启动特色)1-7Green Power Function: (绿色电源功能)When the unit is in battery mode and the load can hardly be detected, the system will cease releasing power for energy saving.(当此电源系统处于电池模式，并且负载很难被侦测到,为了节约能源,它将会终止功率输出)This service manual contains block diagram, principle of operation, system outline and troubleshooting. (此使用细则包含方块图,工作原理,系统概要及故障处理)2 Block Diagram(方块图)The Block diagram of Arista series (refer to Figure S-1) is divided into following parts:(Arista系列方块图(参考S-1)划分为以下几个部分:)2-1 Main Relay (SAFETY-RY): (主继电器(安全继电器)To switch the UPS between line and battery mode, its mechanical action also affects the UPS power loss time.(让UPS在电源输入线模式及电池模式之间做切换,它的机械作用也影响UPS功率损耗的时间)2-2 Boost Relay (BOOST-RY): (升压继电器)In line mode, this is a switch used to increase UPS output voltage 18% when the commercial line source is under voltage.(在电源输入线模式下,当供应线欠压,这个开关用来增加UPS 18%的输出电压)Relay OFF: line voltage is normal(继电器OFF:电源输入电压正常)Relay ON: line voltage is under voltage.(继电器ON:电源输入欠压)2-3 Buck Relay: (降压继电器)In line mode, this is a switch used to decrease UPS output voltage 15% when the commercial line source is over voltage.(在电源输入线模式下,当供应线过压时,这个开关用来降低UPS 15%的输出电压)Relay OFF: line voltage is normal(继电器OFF:电源输入电压正常)Relay ON: line voltage is over voltage.(继电器ON:电源输入欠压)2-4 O/P Relay: ( 输出继电器)This is a switch used to turn on/off the output of UPS。(这是用来开启或关断UPS输出的开关)Relay OFF: UPS doesnt have output voltage. (继电器OFF:UPS无电压输出)Relay ON: UPS has output voltage. (继电器ON:UPS有电压输出)2-5 Main Transformer (MAIN TX): (主变压器)The main transformer has three functions: (主变压器含三个功能:)2-5.1 Inverter Transformer (逆变变压器)Providing inverter voltage to UPS output. It performs a full bridge transformer when UPS is in battery mode.(将逆变电压输至UPS输出端,在UPS处于电池模式下,其表现为全桥变压器)2-5.2 Boost/Buck (升/降压)The output coils have an output ratio. Thus the output voltage at boost mode is given by Boost Relay ON: (输出绕组有一个电压比,在升压模式下,当升压继电器打开,输出电压是这样获取的:)VOUT = VIN * 1.18The Buck relay is ON when the line voltage is over voltage.(当电源输入线过压时,降压继电器打开) It can reduce output voltage by: (其降低输出电压为:)VOUT = VIN * 0.852-5.3 Charger: (充电器:)The battery is charged by the input mains through transformer and boost charger.(蓄电池是由输入回路通过变压器与升压充电器充电的)2-6 Line Sense(输入线感测)The MCU detects the input mains by input voltage and frequency signals converted from the amplifier.(MCU侦测输入回路中通过放大器转换的输入电压和频率信号)2-7 CPU (Freescale/MC68HC908JL8C)The Central Process Unit(中央处理单元)2-8 Electricity Switch(电子开关)It controls the +5Vdc and +12Vdc supplies.(控制+5V及+12V输出)+5Vdc and +12Vdc Control Power Generator: (+5V与+12V控制功率发生器)Provide +5Vdc (generated from 7805 regulator) and +12Vdc power supply.(提供+5V(从7805调整器中产生)与+12V电源供应)2-9 Charger: (充电器)The source for the Charger comes from input mains through the transformer and boost charger. The charger is controlled by high frequency technology, and the charging voltage is 13.514V. (充电器电源通过变压器及升压充电器从输入回路而来,充电器是通过高频技术控制,其充电电压是13.5V14V)2-10 Inverter Circuit: (逆变电路)The inverter circuit is based on a push-pull circuitry.(逆变电路是基于推挽线路的)2-11 Interface Circuit:(接口电路)The UPS display device contains one/three LED (Optional) and one switch. (UPS显示设备包含一个或三个LED(可选)及一个开关按扭)2-12 Batteries: (蓄电池)Acts as a power supply source while the UPS is in battery mode. Different types of batteries are used in different models of UPS: (作为UPS在电池模式的电源供应,不同型号的蓄电池会用在不用型号的UPS上:)400VA: 12V4.5Ah *1pc or equal capability(400VA:12V4.5Ah*1pc或等效容量)600VA: 12V7Ah *1pc or equal capability (同)800VA: 12V9Ah *1pc or equal capability (同)Figure S-1 Block Diagram3 Control Power Circuit(电源控制电路)The control power (+12Vdc and +5Vdc) comes from the following cases (Figure S-2).(控制电源(+12Vdc与+5Vdc)从以下部分获取(S-2)3-1 Start without input AC power (Cold start):(无AC输入的启动)A “Cold start “is described as follows: (冷机启动如下描述:)3-1.1 When “ON/OFF” switch (SW1) is pressed, a positive battery current flows through SW1 to charge C32.(当”ON/OFF”开关(SW1)按下的时候,会通过SW1提供正向充电电流给C32)3-1.2 Q11 base receives a HI pulse and turn on (signal bypass C32 at t=0, and charge C32 at t0).(Q11基极受到高电平脉冲并开启(在t=0时刻,信号旁路掉C32,而t0时,则给C32充电)3-1.3 When Q11 turns on, the Q11 collector will drop to LOW and turn on Q10 (MBS2907A).(当Q11开通,集电极会被拉低并开启Q10(MBS2907A).3-1.4 When Q10 turns on, the positive battery voltage via Q11 collector and establishes a +12Vdc power supply. The +12Vdc power supply passes through U4 (78L05) generating a +5Vdc logic power supply. And CPU send HI signal (shutdown) to sustain Q11 on.(当Q10开通,正向充电电流通过Q11集电极并建立+12Vdc电源.这个+12Vdc通过U4(78L05)产生一个+5Vdc逻辑电源，并且CPU送出高电平信号(关断)去维持Q11导通)3-1.5 Figure W-1 shows the pulse on the C32, i.e. the base signal of Q11 during the cold start.(图W-1表明了C32上的脉冲,也就是Q11冷机启动状态下的基极信号)3-2 Start with input AC power (AC start):3-2.1 When we connected UPS with AC source, half-wave rectifier(D100) and ZD1、Q33 turns on Q11;as a result Q10 turns on and establishes +12Vdc and +5Vdc power supply similar to “Cold start”.(当我们将UPS连接至AC电源,半波整流器(D100)与ZD1,Q33开通Q11,结果Q10导通并建立+12Vdc与+5Vdc电源,类似于冷机启动)The SHUTDOWN network, triggered by pin15 of the CPU, is used to shutdown the UPS from Battery mode and AC mode. When a battery under-voltage occurs, the CPU sends a Low signal to turn off Q11. This causes Q10 to be turned off and isolates the control power from batteries.(由CPU 15脚来触发的“关断”网络被用来将UPS从电池模式与AC输入线模式关掉.当蓄电池发生欠压的时候,CPU会送出低电平信号去关断Q11,这将导致Q10被关断并从蓄电池电源控制中隔离.)Figure S-2 Control Power CircuitCH1: +12V CH2: C32 GNDFigure W-1 Cold Start 4 Battery Charger(蓄电池充电器)The action of charger is described as follows: (Figure S-3)(充电器的作用描述为以下:)4-1 When UPS connected to AC source, the CPU was activated because the control power (+5Vdc) is established. (当UPS接至AC电源,CPU因+5V控制电源建立而被激活)4-2 The CPU turned on SAFETY Relay (RY1, RY5), AC power flow into Main Transformer.(CPU打开安全继电器(RY1,RY5),AC电源能量流入主变压器)4-3 Source for the charging circuit comes from the charger coil of the Main Transformer. (充电电路的能量来自于变压器的充电器绕组)4-4 A new charging circuit is used for the UPS. A Timer IC 555 is used to adjust the charging current and the battery charging voltage. The charging voltage can be set by changing the value of R132, and R134.(新的充电电路被用于UPS,555计时器用于调整充电电流和蓄电池充电电压,可通过设置R132&R134的阻值来调整充电电压)Figure S-3 Charger Control Circuit5 Line and Zero-Crossing Detection(电源输入线与过零侦测)Please refer Figure S-4(请参考S-4)5-1 Line Detection(电源输入线侦测)The input voltage is full-rectified. The signal passes through amplifier U1 (LM358), feed into pin 11 of CPU. By monitoring this rectified sinusoidal voltage, the CPU can find the unnaturalness of commercial line. The CPU has two ways to judge line voltage loss.(输入电压为全波整流,信号从放大器U1(LM358)馈送至CPU的11脚.通过对此整流后的正弦电压的监控,CPU会找出供应线的不一致,CPU有两种方式去判定电源输入线的电压损耗.)5-1.1 Waveform detection: (波形侦测)If there is a rapid voltage drop occurs, the CPU is able to immediately detect it and transfer to battery mode. The waveform detection has a short response time.(如果有快速电压跌落发生,CPU能立即侦测并转换到电池模式,波形侦测具有较短的响应时间)5-1.2 RMS value detection: (RMS值侦测)CPU calculates input RMS value every cycle. If RMS value is not in range of UPS specification for 3 cycles, UPS will transfer to battery mode. The RMS value detection has more accurate voltage detection but it can not sense a rapid voltage transition immediately.(CPU每个周期都会计算有效值,如果有效值连续三个周期都不在规格范围内,UPS将转换到电池模式,RMS值侦测具有更准确的电压侦测,但它不能对快速电压转换作出立即感测)5-2 Zero Crossing Detection(过零侦测)Zero Crossing Detection is used to minimize the phase difference between the Inverter voltage and the input line voltage while UPS is switching from battery mode to line mode. If the phase difference is too large, it can create a large amount of energy which may damage the internal passive components such as relays.(过零侦测是为了将UPS在从电池模式切换到电源输入线模式过程中,逆变器与电源输入电压所产生的相位差异最小化,如果相位差异太大,可能会产生非常大的能量而损坏内部被动元件比如继电器)The Zero Crossing signal is gets by the following ways: (过零信号是通过如下方式获取的:)5-2.1 Use the voltage reduced from input line voltage (by amplifier U1 (LM358) to drive Q6 (PMBT2222ASM).(使用对输入线的压差(通过放大器U1(LM358)去驱动Q6(PMBT2222ASM)5-2.2 The Zero Crossing signal comes from the collector of Q6, goes to the CPU pin 27. Refer to Figure W-2, Waveform measured from Q6 collector and line input detection circuit.(过零信号从Q6的集电极取得,进入CPU的27脚,参看图W-2:从Q6集电极和电源输入侦测电路的量测波形)When the line signal (reduced from input line) is applied to the base of Q6, the first half cycle (positive half-wave) makes VBE 0.5Volts and turns on Q6.(当此输入线电压(从电源输入线减小过来)印加到Q6的基极,第一个半周(正半周波形)使得VBE 0.5V并开启了Q6)When Q6 is off, the +5 Volts is sent to CPU, setting HI. When Q6 is off (on?), the +5 Volts is sent to CPU, setting LOW. Thus, the line frequency can be detected by measuring the time interval between the first falling and second falling edge of VCE of Q6. Also it is used by the CPU to determine when to switch from battery mode to line mode.(当Q6关断,+5V电压被送至CPU,设定HI高电平,当Q6关断(开通?),+5V被送至CPU,设定LOW低电平.这样,输入频率就可以通过测量Q6的VCE第一次与第二次下降沿的时间间隔来侦测,也用于让CPU决定什么时候从电池模式切换到电源输入线模式)Leos remark: some deflection/misunderstanding/confusion were found in this paragraph, so I marked them with blue fonts, please check them carefully.Figure S-4 Line and Zero Crossing Detecting CircuitCH1: Q14 collectorCH2: Line-I/PFigure W-2 Zero Crossing6 Green Function Detection(绿色功效侦测) Please refer Figure S-5.(请参看图5)6-1 Without Green function(无绿色功效)If R190 is NC, UPS will have no Green function.(如果R190没有接的话(not connected),UPS即不具备绿色功效)6-2 With Green function(拥有绿色功效)If R190 is connected, UPS will have Green Function. The value of R190 will suit for 1KSM*(0603).(如果R190已连接,UPS将具备绿色功效,R190的值适合1KSM*(0603)Figure S-5 Green Function7 Inverter Operation(逆变器操作)The Inverter circuit (Figure S-6) and PWM control are only active under battery mode.The Inverter circuit of Arista is based on a Push-Pull circuitry and its output is driven by a transistor which is controlled by CPU.(逆变器电路(图S-6)与PWM控制仅在电池模式下是生效的,Arista逆变器电路是基于推挽电路的,而且其输出是由受CPU控制的电晶体驱动的)Refer to the Inverter circuit diagram, the DS-N and DS-P signals are generated by CPU. Figure W-3 illustrates the waveforms of DS-N and DS-P while the system is at no load condition. The duty cycles of DS-N and DS-P signals are controlled by feedback signal of output voltage detection circuit to get a stable output.(参看逆变器电路框图,DS-N与DS-P信号是由CPU产生,图W-3阐明了系统处于空载条件下DS-N和DS-P的波形, DS-N和DS-P信号的占空比受输出电压侦测电路的反馈信号控制以获得稳定的输出)The gates of MOSFETs are driven by transistors Q14, Q20, which are controlled by the DS-N and DS-P. Those signals are from CPU pin18 & 19 directly. Figure W-3 shows the collector waveforms for CPU pin18 & 19 while the system is at no load condition at battery mode.(MOSFET的栅极是由受DS-N和DS-P控制的晶体管来驱动的,这些信号是直接从CPU的18&19脚取得的,图W-3显示了系统处于电池模式空载条件下,集电极的波形)These inverter transistors are turned on and off interlaced to make DC voltage of battery to come into being an AC step output voltage, and then magnified through the transformer, producing a stable 230VAC output.(这些逆变晶体管交错导通与关断使得蓄电池的直流输出电压形成AC阶梯式输出电压,并通过变压器来放大,产生稳定的230Vac输出)According to the diagram showing on “Figure W-3 Control logic”, while the driving signal CLMP_OFF gets LOW and drives the signal CHG_PWM to HI and the Q16 turn on in battery mode, the step output waveform gets approximately zero, which is named CLAMP(根据”图W-3控制逻辑”显示,)在电池模式下,当驱动信号CLMP_OFF变成低电平并驱动CHG_PWM信号成高电平,而且Q16开通,此阶梯式驱动电压波形大约变成0,命名为CLAMP.Figure S-6 Inverter circuitFigure W-3 Control logic8 Active Clamp(主动钳位)The purpose of Clamp is to pull down the output voltage while one sets of charger MOSFET are OFF. The Clamp effect is active during the period of 0Vac at battery mode. CLAMP principle is shown in the last paragraph of “7. Inverter Operation”.(钳位的目的是为了当充电器MOSFET关断时降低输出电压,此钳位作用在电池模式0Vac期间激活,原理在”7.逆变器操作”最后一段有说明)9 Microcontroller(CPU) Control Circuit (微处理器(CPU)控制电路)The CPU is supplied by +5Vdc power supply to pin7 with ground pin at pin3. An extra oscillation circuitry, (consisting of C8, C9, and crystal XL1) is connected to pin4 &5. The Arista series use a CPU type Freescale/MC68HC908JL8C. The pin definition of Arista CPU is listed below (Figure S-7): (CPU是通过跨接于7脚和3脚(地)的+5Vdc来供电的,附加振荡电路接于pin4 &5(由C8,C9以及晶体XL1组成),Arista使用Freescale/MC68HC908JL8C的CPU,引脚定义如下列表(图S-7):PINFUNCTIONPin1+5VoltsPin2Main-SWPin3groundPin4oscillation circuitPin5oscillation circuitPin6main relay controlPin7+5VoltsPin8series detect (GREEN FUNTION)Pin9Series detect (AVR FUNTION)Pin10O/P-V detectionPin11input line detectionPin12load detectionPin13RXDPin14TXDPin15shutdownPin16Buzzer controlPin17battery voltage detectionPin18inverter PWM signal (DS-P)Pin19inverter PWM signal (DS-N)Pin20CLMP_OFFPin21CHG-OFFPin22VA detectPin23series detectPin24LED1 controlPin25LED2 controlPin26LED3 controlPin27ZERO-CRO controlPin28buck relay controlPin29boost relay controlPin30reset controlPin31O/P RelayPin32Voltage detectFigure S-7 CPU Control Circuit10 Relay Circuit(继电器电路)Please refer to Figure S-8. (请参看图S-8)The RY1 and RY5 (main relay) is used for switching between line and battery modes. When the UPS is changing from battery to line mode, CPU pin6 is set to HI to turn on Q2 (PMBT2222ASM) and this activates RY1 and RY5. Alternatively, if the UPS is changing from line mode to battery mode, CPU pin6 is set to LOW and turn off Q2. This causes RY1 and RY5 to be OFF and return to its normal state. (RY1和RY5(主继电器)用于在电源输入线模式与电池模式之间做切换,当UPS从电池模式切换到电源输入线模式,CPU设置高电平HI去开通Q2(PMBT2222ASM)并且激活RY1与RY5,相反地,如果UPS pin6是从电源输入线模式切换到电池模式,CPU pin6设置低电平LOW,关断Q2,这将使得RY1与RY5变成OFF,并回到正常状态)R2, R12, D1, C5 and Q5 are used to speed up the relay action, so the power loss time can be reduced to minimum. When UPS transfers to battery mode, C5 is charged by +12 Volts. After the main relay makes contact, C5 provides instantaneous power to the relay coils. This increases the magnetic force and speeds up the relay to reduce the transfer time from battery mode to line mode. See Figure W-4 for voltage changes on C5 while transferring from line to battery mode.(R2,R12,D1,C5与Q5用于加速继电器动作,这样的话功率损耗时间可降到最小,当UPS转换到电池模式,C5由+12V充电.在主继电器接通后,C5提供瞬时功率给继电器线圈,增加了磁力并加速了继电器,减小了从电池模式到电源输入线模式的转换时间,请看图W-4:电源输入线模式至电池模式转换过程中C5的电压变化)CPU pin29 is used to driv