PICREF-1

PICREF-1 SCHEMATICS UPS System Overview

The UPS may be split into 4 main circuits: Input Power
Factor Correction, Battery Boost, Free-Running Chop-
per, and Inverter. The UPS is an on-line device which
normally will have the Power Factor Correction circuit
feeding the Chopper, which then feeds the Inverter. If
the input power should be lost, the Power Factor Cor-
rection circuit falls out of the power flow and the Battery
Boost circuit automatically provides power to the Chop-
per.
The Inverter is driven by the Inverter Drive circuitry,
which in turn is controlled by the Inverter Control cir-
cuitry containing the microcontroller.
UPS circuit board (PCB) power flow is shown in
Figure 1.
In the Battery Boost circuit, the transistor pairs are con-
nected in parallel for the purpose of handling high cur-
rents. The current transformer T2 is connected as
shown to sense each pair’s current with just one trans-
former, i.e., to prevent it from saturating.
The control for the 120V/240V relay (power switch) was
not implemented. Wherever input power monitoring
would take place, monitoring for 120 or 240V would
also occur and switch the relay. These functions would
be placed before the PFC circuit.
Power Factor Correction
The Power Factor Correction circuit is provisional, so
the parts listed are generic parts.

FIGURE 1: PCB POWER FLOW

Inverter Control Card

From Battery Boost PCB
Battery
PIC17C43,
Hardware
Protection Inverter Drive Card

IGBT Drivers

From Power Factor H-Bridge To

Input Free-Running
Correction PCB Chopper PCB (Inverter) Output
Filter Filter

Power Flow PCB

Other
Control Circuitry

 1997 Microchip Technology Inc. page 1

 Battery Boost Circuit

page 2
D1 L1 D3
DESI 30-12A 500uH DESI 30-12A
FIGURE 2:

T1
ZZ3449

BATTERY(+)BUS
C1
PICREF-1

1uF
600V
Q1 D2
Q2
IRFP264 DESI 30-12A
IRFP264

Q1_DRIVE Transistor Pair A

Push-Pull Battery 380Vdc Bus
Boost Circuit +DC_BUSS
Q2_DRIVE I_GND

R4
C5 100k
6100uF 2W
Q3 350V
Q4
IRFP264 C4
IRFP264
1uF
600V
Q3_DRIVE Transistor Pair B
Push-Pull Battery
Q4_DRIVE Boost Circuit
C6 R5
6100uF 100k
UPS SYSTEM OVERVIEW - PAGE 1 OF 3

350V 2W

BB_I_FDBK1

T2
ZZ3450
BB_I_FDBK2 I_GND

B_GND

B_GND

LEGEND

External to Board
AC_IN_HI PWR_AC_IN_HI DC_BUS_OUT(+)
Input Filter / Power Factor
Protection Correction Internal to Board
AC_IN_LO PWR_AC_IN_LO DC_BUS_OUT(-)

I_GND

 1997 Microchip Technology Inc.

 FIGURE 2:

240Vac or 120Vac
Power Switch
Free-Running Chopper Circuit
+DC_BUSS
T6

 1997 Microchip Technology Inc.

CH_I_FDBK1 CH_I_FDBK2 ZZ3455
X1 Rectifier Circuit
T4 T5
ZZ9454 ZZ9454

CH_GND CH_GND RYL1

X2
D9 L4
DESI 60-12A 725uH
Q5 Q6
2N6770 2N6770 RECT_WAV

Q5_DRIVE Q6_DRIVE

C10
Q5_DRIVE_RET Q6_DRIVE_RET R6
250uF 100k
350V 2W
UPS SYSTEM OVERVIEW - PAGE 2 OF 3

C9
1uF
600V
O_GND
C11
RYL2 250uF R7
Q7 Q8 100k
350V
2N6770 2N6770 2W
Q7_DRIVE Q8_DRIVE

D10
Q7_DRIVE_RET Q8_DRIVE_RET DESI 60-12A

120_OR_240
O_GND
I_GND

I_GND
PICREF-1

page 3
 page 4
FIGURE 2:

IGBT H-Bridge
RECT_WAV
PICREF-1

Q9_C Q10_C

Output Filtering
Q9 Q10 L5 L7 T7
Q9_G Q10_G 300uH 50uH ZZ3459
AC_OUT_HI

C12 C13
Q9_E 0.58uF Q10_E 0.58uF
R8
5.6 OUT_IFDBK1
C14 C15 C17
10uF 10uF 10uF
600V 600V 600V
OUT_IFDBK2
C16
Q11_C Q12_C
10uF
UPS SYSTEM OVERVIEW - PAGE 3 OF 3

L6 600V
300uH

AC_OUT_LO
Q11 Q12
Q11_G Q12_G

Q11_E Q12_E

O_GND

 1997 Microchip Technology Inc.

 D5
DESI60-06A
FIGURE 3:

DC BUS OUT(+) (To page 2)

D6
DESI60-06A
L1
500µH

L1 OUT (To page 2)

 1997 Microchip Technology Inc.

I SENSE (To page 2)
R1
375k
Vcc

D1 D2
MDA4008 MDA4008 C2 C3
PWR_AC_IN_HI
1µF 0.47µF
PWR_AC_IN_LO
R2 C5 C6
375k 0.47µF 1µF
D3 D4
MDA4008 MDA4008 P_GND
13 R9
C4 4.7k
Vcc 1µF
P_GND 1 3
I(SENSE) EA 0
2 4 INV VREF
MULT INV
(To page 2) (To page 2)
8 5 R8
R(T) U1 OVP OVP 12k
6 UC3854 12 (To page 2) Q5
I(SIN) Unitrode OUT 2N2222A
7 14
RAMPC VREF
16 10
C(T) SHUT R10
POWER FACTOR CORRECTION (PFC) – PAGE 1 OF 2

R3 R4 R5 15 9 10k
C1 SIG_G CLK
25.98k 5.1k 29.3k
0.01µF PWR_G
R6 R7
11 10k 1k
P_GND
P_GND
LEGEND

External to Board

Internal to Board
PICREF-1

page 5
 L1 OUT

page 6
(From page 1)
FIGURE 3:

Vcc
DC BUS OUT(+)
(From page 1)
C7 C8 DC_BUS_OUT(+)
1µF 0.47µF
PICREF-1

Q1 Q2 Q3 Q4

P_GND R19 R20 C9 R23

180k 180k 6100µF 100k
R13 R14 R15 R16
VDD VDD
24 24 24 24
OUT
C11
IN
VREF 1µF
(From page 1) OUT
PFC – PAGE 2 OF 2

U2
TSC429CPA R18 R21 C10 R24
180k 180k 6100µF 100k
GND GND

P_GND

INV
D7 (From page 1)
R11 1N4150-1
20k
OVP
I SENSE (From page 1)
(From page 1) T1
R12
100 R17 R22
4.87k 4.56k
500:1

P_GND DC_BUS_OUT(-)

P_GND

LEGEND

External to Board

Internal to Board

 1997 Microchip Technology Inc.

 Vcc
R3 R2
37.5k 37.5k
C5
FIGURE 4:

FEEDBACK C6
1µF 0.47µF
B_GND
VREF
R1 R8 C7
523 10k R25 R26
470pF 2.49k 2.49k

C18 15 13 16 2
B_GND B_GND
1µF
Vcc Vc VREF NL

 1997 Microchip Technology Inc.

R9 1 U4a
B_GND INV 4049
2.67k
3 11 3 2
E/A OUT OUT A Out A (To page 2)
C8 5
2700pF Rt U5
6 UC3825AN 14 5 4
BB_SYN1 Ct OUT B Out B (To page 2)
7 U4b
RAMP
4 12 4049
CLK/LEB PGND
R10 R11
24 6.8k SS I Lim GND
8 9 10
C19 C10
C9 100pF 100pF R12
B_GND 510
0.01µF

B_GND
R24
C11 C12 1.5k
470pF 680pF

R13
B_GND 1k

Vcc
C15 R21 R20
0.1µF 10k 100
BATTERY BOOST (BB) CONTROL CARD – PAGE 1 OF 3

D15 D16
R23 1N4150-1 1N4150-1
LOW_BAT
69.8k B_GND 2 4 R14 BB_I_FDBK1
BATTERY(+)BUS -
1 Q1 6.2 BB_I_FDBK2
3 2N2222A 1/4W
VREF + U6a
11 LM139 D17 D18
LEGEND
1N4150-1 1N4150-1
C17 R22 C16
10nF 10k 10nF
External to Board
B_GND
B_GND
Internal to Board B_GND
PICREF-1

page 7
 page 8
Vcc
FIGURE 4:

C3 C4
Portion of Battery Boost Circuit
1µF 0.47µF
PICREF-1

B_GND
1 8
VDD VDD R6
R4 5.6
2k OUT 7 Q1_DRIVE
2 IN Transistor Pair A
OUT A
OUT 6 Q2_DRIVE Push-Pull Battery
(From page 1)
Q1_DRIVE Boost Circuit
BB – PAGE 2 OF 3

R7
U2
R5 5.6
1k TSC429CPA Q2_DRIVE

GND GND
4 5
B_GND

B_GND

Vcc Transistor Pair B

Push-Pull Battery
Q3_DRIVE Boost Circuit

C13 C14 Q4_DRIVE

1µF 0.47µF

B_GND
1 8
VDD VDD R17
R15 5.6
2k OUT 7 Q3_DRIVE
2 IN
OUT B
OUT 6 Q4_DRIVE
(From page 1)
LEGEND
R18
R16 U3
5.6
1k TSC429CPA
B_GND
External to Board
GND GND
4 5
B_GND
Internal to Board

B_GND

 1997 Microchip Technology Inc.

 FIGURE 4:

R19 Q1_DRIVE
47 Vcc 1
1/2w U1 Q2_DRIVE
1 2
I 7815 O 3
T1

 1997 Microchip Technology Inc.

X1 R 3 B_GND
ZZ3448 2
D1 D2 4
1N5615 1N5615
C1 C2 5 Q3_DRIVE
33µF 100µF
BB – PAGE 3 OF 3

35V 25V 6 Q4_DRIVE

D3 D4 7 B_GND
1N5615 1N5615
8
X2
9 BB_I_FDBK1

B_GND 10

11 BB_I_FDBK2

12

13
LEGEND 14
1 X1 15 FEEDBACK

External to Board 2 X2 16

3 BB_SYN1 CN2
4 B_GND
Internal to Board

CN1 BATTERY(+)BUS
1
2 B_GND

3 LOW_BAT

4 B_GND

CN3
PICREF-1

page 9
 C3
Vcc 1µF

page 10
C4
0.47µF
FIGURE 5:

CH_GND
15 13 16 2
Vcc Vc VREF NL
R3 1 U5a
CH_GND INV
1.5k 4049
PICREF-1

3 11 3 2
E/A OUT OUT A 100kHz Out A
C7 5 (To page 2)
4700pF Rt U2
6 UC3825AN 14 5 4
FRC_SYN1 Ct OUT B 100kHz Out B
7 U5b (To page 2)
RAMP
4 12 4049
CLK/LEB PGND
R1
24 C10 SS I Lim GND
100pF
8 9 10

CH_GND CH_GND

CH_GND
C10 C11
Vcc
470pF 680pF

R6 R7
1k 510
D7 R19 R18 R4 CH_GND
1N985B 100k 4.7k 100 D8
1N4150-1
D6
1N985B Q2 CH_I_FDBK1
2N2222A
D5
1N985B Q2 CH_I_FDBK2
2N2222A
D9
R5 R7 1N4150-1
10k 20.0

+DC_BUSS
CH_GND

CH_GND CH_GND

CH_GND
FREE-RUNNING CHOPPER (FRC) CONTROL CARD – PAGE 1 OF 3

LEGEND

External to Board

Internal to Board

 1997 Microchip Technology Inc.

 Vcc

Portion of Free-Running Chopper Circuit

FIGURE 5:

C5 C6
1µF 0.47µF

+DC_BUSS

CH_GND
1 8
VDD VDD
R8 CH_I_FDBK1 CH_I_FDBK2

 1997 Microchip Technology Inc.

2.2k OUT 7
100kHz 2 IN
Out A
(From page 1) OUT 6

U3
R9
TSC429CPA T2 CH_GND CH_GND
1k
FRC – PAGE 2 OF 3

Q5_DRIVE
GND GND
R12
4 5 12
Q5_DRIVE_RET

CH_GND Q8_DRIVE Q5_DRIVE Q6_DRIVE

R13
12
Q8_DRIVE_RET Q5_DRIVE_RET Q6_DRIVE_RET

Vcc Q7_DRIVE
R14
12
Q7_DRIVE_RET
C12 C13
1µF 0.47µF Q6_DRIVE
Q7_DRIVE Q8_DRIVE
R15
12

CH_GND Q6_DRIVE_RET Q8_DRIVE_RET

Q7_DRIVE_RET
1 8
VDD VDD
R10
100kHz 2.2k OUT 7
2 IN
Out B
(From page 1) OUT 6

U4
R11
1k TSC429CPA
LEGEND
GND GND
4 5
External to Board

CH_GND
Internal to Board
PICREF-1

page 11
 page 12
FIGURE 5:

R17
PICREF-1

47 Vcc
1/2 W U1
1 Q5_DRIVE
I 7815 O 3 1
X1 T1 R
2 Q5_DRIVE_RET
ZZ3448 2
D1 D2
1N5615 1N5615 3
C1 C2 4 Q6_DRIVE
33µF 100µF
FRC – PAGE 3 OF 3

35V 25V Q6_DRIVE_RET

5
D3 D4 6
1N5615 1N5615
7 Q7_DRIVE
X2
8 Q7_DRIVE_RET

CH_GND 9
10 Q8_DRIVE

11 Q8_DRIVE_RET

12

LEGEND 13
X1 14 CH_I_FDBK1
1
External to Board 2 X2 15 CH_GND

FRC_SYN1 16 CH_I_FDBK2
3
Internal to Board 4 CH_GND 17 CH_GND

J1 18

19
20 +DC_BUSS

J2

 1997 Microchip Technology Inc.

 +5V

R28
U21 U19 1k
FIGURE 6:

FLT+ 4N35 ENABLE+ 4N35

l l

U5
FLT- ENABLE- ADC10154CIN

R27 D7 13 4 CH0 (From page 2)

DB7 CH0
1k U1 D6 14 5
+5V PIC17C43 DB6 CH1 CH1 (From page 2)
D5 15 6

 1997 Microchip Technology Inc.

DB5 CH2
D4 16 7 -5V +5V
21 RA5/TX/CK RD7/AD16 33 D7 DB4 CH3
R29 D3 17 1
U20 1k 22 RA4/RX/DT RD6/AD14 34 D6 DB3 AV+
ZC+ 4N35 D2 18 9
23 RA3 RD5/AD13 35 D5 DB2 Vr+
l D1 19 10
24 RA2 RD4/AD12 36 D4 DB1 Vr-
D0 20 11
25 RA1/T0CKI RD3/AD11 37 D3 DB0 V-
RD’ 3 8
26 RA0/INT RD2/AD10 38 D2 RD Vrout
WR’ 23 C13 C14
ZC- 18 RB7 RD1/AD9 39 D1 WR C23 0.1µF 0.1µF
INT’ 21 330µF
17 RB6 RD0/AD8 40 D0 INT
+5V CS’ 2 10v
U4 16 RB5/TCLK3 RC7/AD7 9 RD’ +5V CS
CTX171 22 CLK
14 15 RB4/TCLK12 RC6/AD6 8 WR’
25MHz 24 -5V
VDD 14 7 CS’ C6 DV+ C31 C32
RB3/PWM2 RC5/AD5
C5 0.1µF 12 DGND 0.1µF 0.1µF
PWM 13 RB2/PWM1 RC4/AD4 6 INT’
0.1µF
Gnd Out (To page 3) 12 RB1/CAP2 RC3/AD3 5 ALARM
7 8 11 RB0/CAP1 RC2/AD2 4 POS_NEG
27 TEST RC1/AD1 3 FAULT R36
R26
19 2 +5V 100
OSC1/CLKIN RC0/AD0 ENABLE 4.75k
+5V 20 28 (To/from R37
OSC2/CLKOUT RE2/WR 100
1 29 page 3) R25
VDD RE1/OE 4.75k R23
31 VSS RE0/ALE 30 D10 6 4.75k
C4 R30 -
10 32 47k 1N4150-1 7
0.1µF VSS MCLR/VPP -5V 5
+ U16b
R31 LM158
11 C26 4.75k
Clr
10 4.7µF
INVERTER CONTROL (INV CRTL) CARD – PAGE 1 OF 4

Clk R32
10V 4.75k
9 R24
U9 Q1
7 4.75k
74HC4040 Q2
6 3.125MHz
Q3 3.125MHz
5 (To page 2) +12V
LEGEND Q4
+5V 3 2 8
Q5 -
2 1
Q6 3
External to Board C7 4 195kHz + U16a
0.1µF Q7 195kHz 4
13 (To page 2) LM158
Q8
12 -12V
Q9
Internal to Board 14
Q10
15
Q11
1
Q12
PICREF-1

page 13
 page 14
FIGURE 6:

R2
931
R8
+5V +5V 82k
D6 +12V R5 R7 D8 R9
PICREF-1

R11 100k 100k R12 1k

8 2 6
2.2k - OSENSE_1 2.2k - CSENSE_1
1 7
CH0 CH1
(To page 1) 3 (To page 1) 5
U6a + OSENSE_2 U6b +
LT1013CN8 4 LT1013CN8
D5 R4 R6 D7 R10
-12V 100k 100k 49.9
-5V -5V
R3 C10 C11
931 47pF 47pF
INV CRTL - PAGE 2 OF 4

+5V T2

R21 BB_SYNC1
220
10
U18c 8
9 7400 BB_SYNC2
3.125MHz
(From page 1) C21 FRC_SYNC1
0.1µF
10 1
U15c 8 U15a 3
9 74AC00 2 74AC00 FRC_SYNC2

R20 PFC_SYNC1
R22 1k
1k 13 U15d 4 U15b Q1
195kHz 74AC00 11 74AC00 6 2N2222A
12 5 PFC_SYNC2
(From page 1)
C22 +5V
22pF
C24 LEGEND
0.1µF

External to Board

Internal to Board

 1997 Microchip Technology Inc.

 U2 U7
FIGURE 6:

+12V
1 2
T1 I 7812 O 3 I 7905 O 3
HF_BIAS1 C3 C9
C1 R R
2.2µF 2.2µF
D3 D4 47µF 2 25V 1
25V 25V -5V
1N5615 1N5615 L1

U3 +5V U8
1 2
I 7805 O 3 I 7912 O 3
D1 D2 C8 C2 C12
R R

 1997 Microchip Technology Inc.

1N5615 1N5615 47µF 2.2µF 2.2µF
25V 2 25V 1
25V -12V
HF_BIAS2

+5V

D9
INV CRTL – PAGE 3 OF 4

1N4150-1
R1
4.75k +5V
Out of 1
Saturation U13a 3
2 74AC00 FAULT 1
(From page 4) C29 U18a 3 4
0.1µF 2 7400 U14b 6
5 74AC00 Q10_DRIVE

1
4 U13b 10 13 U14a 3
U13c 8 U13d 11 1 13 2 74AC00 Q12_DRIVE
ENABLE 74AC00 6
5 9 74AC00 12 74AC00 U11a 3 U18d 11 10 1
2 74AC00 12 7400 U11c 8 U17a 3 4
9 74AC00 2 7486 U17b 6
5 7486
PWM
R19 +5V R33 +5V
4.75k 1k C27
1nF
4
C25 U11b 6 R35
0.1µF POS_NEG 5 74AC00 1k
L_HI

4
U18b 6 13
5 7400 U14d 11
12 74AC00 Q9_DRIVE
LEGEND
10
U14c 8
9 74AC00 Q11_DRIVE
External to Board 13 10
U11d 11 U17c 8 13
12 74AC00 9 7486 U17d 11
12 7486 +5V
Internal to Board R34
1k C28
1nF C30
0.1µF
L_HI
PICREF-1

page 15
 page 16
FIGURE 6:

R13
1k
1 Q9_OC_ALARM
PICREF-1

1 HF_BIAS1 1 OSENSE_1
2 C15
1nF 2 2 OSENSE_2
3 Q9_DRIVE
3 3 CSENSE_1
4 R14
1k 4 HF_BIAS2 4
5 Q10_OC_ALARM
CN2 CN5
6 C16
5
1nF 4 Out of
U10a 1
7 Q10_DRIVE Saturation ZC+ BB_SYNC1
3 4082 1 1
(To page 3)
8 R15 2 BB_SYNC2
ZC-
INV CRTL – PAGE 4 OF 4

1k 2 2
9 Q11_OC_ALARM CHP_SYNC1
3 FLT+ 3
10 C17 4 FLT- 4 CHP_SYNC2
1nF
11 Q11_DRIVE
CN3 CN6
12 R16
1k
13 Q12_OC_ALARM 1 ENABLE+ 1 PFC_SYNC1

14 C18 12 2 ENABLE- 2 PFC_SYNC2

1nF 11 U10b 13
15 Q12_DRIVE 3 3
10 4082
9
16 4 4
+5V
17 C20 CN4 CN7
18 0.1µF
+12V
19 C19 LEGEND
20 0.1µF

CN1 External to Board

Internal to Board

 1997 Microchip Technology Inc.

 +12Vdc
FIGURE 7:

R1, R5,
R9, R13 U9, U10
1.5k R3, R7, U11, U12
R11, R15 7818
1.5k
3 1
O I
R
T1, T2, T3, T4
C3, C7, 2 D5, D9, D7, D11, ZZ3448
C4, C8, D13, D17 D15, D19
U5, U6, U7, U8 C11, C15 X1

 1997 Microchip Technology Inc.

C12, C16
Q#_OC_ALARM H11L1 100µF 33µF 1N5615 1N5615
25V 35V
To Inverter
Control Board

D6, D10, D8, D12,

O_GND Q#_GND X2
D14, D18 D16, D20
1N5615 1N5615
C17, C18, D1, D2,
C19, C20 D3, D4
330pF ERA34-10

+5Vdc Q#_GND
5 4 6

R2, R6, Q#_C

R10, R14 OVP 2
1.5k
C1, C5, R4, R8,
15 C9, C13
33µF R12, R16
35V 33
3
AMP Q#_G
14 1 C2, C6,
Q#_DRIVE
C10, C14
From Inverter 33µF
Control Board U1, U2, U3, U4 35V
EXB840
9 Q#_E
INVERTER DRIVE (INV DRV) CARD – PAGE 1 OF 2

Q#_GND
Q# of
Inverter
H-Bridge

LEGEND

External to Board

Internal to Board
Note: The Inverter Drive Card has four (4) circuits as shown
to drive each of the four Inverter H-Bridge transistors
(# = 9, 10, 11, 12).
PICREF-1

page 17
 page 18
FIGURE 7:

1 Q9_OC_ALARM 1 X1 1 Q9_C

2 2 X2 2

3 Q9_DRIVE 3 3 Q9_G

4 4 4 Q9_E
PICREF-1

5 Q10_OC_ALARM CN2 CN3

6

Q10_DRIVE 1 Q10_C
7
8 2

Q11_OC_ALARM 3 Q10_G
9
4 Q10_E
10

11 Q11_DRIVE CN4
INV DRV – PAGE 2 OF 2

12
1 Q11_C
13 Q12_OC_ALARM
2
14
3 Q11_G
15 Q12_DRIVE
4 Q11_E
16 +5Vdc
CN5
17
18
+12Vdc Q12_C
1
19
2
20
3 Q12_G
CN1 Q12_E
O_GND 4

CN6

LEGEND

External to Board

Internal to Board

 1997 Microchip Technology Inc.