GUTOR OP2446/640-1017 Main Processor Board

General Description

The OP2446/640-1017 processor board is designed for GUTOR’s range of industrial UPS systems, which provide clean, uninterrupted power to critical loads such as process control systems, telecommunications, and data centers. The board integrates a high-performance microcontroller with dedicated power management algorithms. It controls the rectifier, inverter, static bypass, and battery converter functions, ensuring seamless transfer between operating modes.

Key Features

• Processor: 32-bit RISC microcontroller with floating-point unit, 100 MHz clock.

• Control Functions: PWM generation for IGBT switching, voltage and current regulation loops, synchronization with mains.

• Monitoring: Real-time measurement of input/output voltages, currents, frequency, battery status, and temperature.

• Protection: Overload, short-circuit, overtemperature, battery deep discharge, and inverter fault protection.

• Communication Ports: RS232, RS485 (Modbus RTU), and optional Ethernet for remote monitoring.

• Memory: 2 MB Flash, 512 KB SRAM for event logging and parameter storage.

• Redundancy: Supports parallel UPS configurations for N+1 redundancy.

• Diagnostics: LED indicators for power, status, fault, and communication activity.

Technical Specifications

• Power Supply: 5 V DC and ±15 V DC from UPS power supply board.

• Analog Inputs: 16 channels, 12-bit resolution for voltage/current sensing.

• Digital Inputs: 8 optically isolated, 24 V DC.

• Relay Outputs: 6 changeover relays, 250 V AC / 30 V DC, 2 A.

• Operating Temperature: -10°C to +55°C.

• Storage Temperature: -40°C to +85°C.

• Dimensions: 200 x 150 x 30 mm (Eurocard format).

Functional Description

The processor board executes the UPS control algorithm with a typical cycle time of 50 µs. It samples voltage and current waveforms, computes power factor, and generates switching signals for the power semiconductors. It also manages battery charging with temperature-compensated voltage control. The board maintains a history of events (up to 1000) and fault records, accessible via serial communication. The integrated real-time clock time-stamps all events.

Applications

• Industrial UPS systems for process control and instrumentation.

• Power protection for critical loads in power plants, refineries, and chemical plants.

• Data centers and telecommunications infrastructure.

• Medical facilities and hospital equipment.

Installation and Maintenance

The board plugs into a dedicated slot within the UPS chassis. It is keyed to prevent incorrect insertion. Firmware updates can be performed via the serial port using GUTOR’s service tool. Routine maintenance includes checking LED status and ensuring ventilation is unobstructed. The board can be replaced while the UPS is in maintenance bypass mode.

Certifications

• CE marked, RoHS compliant.

• Designed to IEC 62040-2 (EMC) and IEC 62040-1 (safety).

• Marine certifications (DNV, ABS) available.

Note: This document is for technical reference; refer to the GUTOR UPS service manual for detailed information.