Introduction:

An uninterruptible power supply, also uninterruptible power source, UPS or battery backup, is an
electrical apparatus that provides emergency power to a load when the input power source,
typically the utility mains, fails. A UPS differs from an auxiliary or emergency power system or
standby generator in that it will provide instantaneous or near-instantaneous protection from
input power interruptions by means of one or more attached batteries and associated electronic
circuitry for low power users, and or by means of diesel generators and flywheels for high power
users. The on-battery runtime of most uninterruptible power sources is relatively short—5–15
minutes being typical for smaller units—but sufficient to allow time to bring an auxiliary power
source on line, or to properly shut down the protected equipment.

While not limited to protecting any particular type of equipment, a UPS is typically used to
protect computers, data centers, telecommunication equipment or other electrical equipment
where an unexpected power disruption could cause injuries, fatalities, serious business disruption
and/or data loss. UPS units range in size from units designed to protect a single computer
without a video monitor (around 200 VA rating) to large units powering entire data centers,
buildings, or even cities

UPS are classified in three types i.e. ONLINE , OFFLINE & LINE INTERACTIVE. In online
UPS the power is supplied to load through the inverter irrespective of the presence or absence of
mains. Whereas in on offline UPS the load is powered by mains directly if mains don’t fail
otherwise the batteries through inverter are used.

Block Diagram:

Rectifier & Inverter Critical

Charger 48V Load

~ 230, 50hz Batteries

Fig.1
UPS is divided in 4 major blocks: 1) Rectifier & charger

2) Batteries

3) Inverter

1) Rectifier & Charger: It can be defined as an electronic device which converts an Ac into
a pulsating DC. Rectifiers are classified mainly two types i.e. Half wave & Full wave, depending
upon the number of output +ve peaks in one cycle. It basically consists of diodes connected
appropriately to convert the –ve half cycle into +ve peak. It’s the most important block of DC
power supply. Full wave rectifiers are more efficient than half wave.

The output of pulsating DC is given to a filter which reduces ripple factor (ripples are unwanted
AC component in DC). Further a voltage regulator (discrete or integrated) is used to get a steady
DC. This voltage is used to charge the batteries & also given simultaneously to inverter, the load.

2) Batteries :
These are the heart of the UPS. Whenever the power fails the required power is delivered to load
by the batteries. The batteries have to be chosen very carefully depending upon the required AH
rating. The batteries must be able to deliver the necessary power for specified time. The
efficiency of battery is decided by two efficiencies i.e. Ampere-Hour efficiency & Watt-hour
efficiency. Normally a lead acid battery is used. The charging of batteries has two stages 1.
Constant current charging 2. Constant voltage charging. Batteries having voltage of 24, 48, and
72 are chosen depending upon the application.

3) Inverter:
An inverter is an electrical device that converts direct current (DC) to alternating current (AC);
the converted AC can be at any required voltage and frequency with the use of appropriate
transformers, switching, and control circuits.

Static inverters have no moving parts and are used in a wide range of applications, from small
switching power supplies in computers, to large electric utility high-voltage direct current
applications that transport bulk power. Inverters are commonly used to supply AC power from
DC sources such as solar panels or batteries.

The electrical inverter is a high-power electronic oscillator. It is so named because early

mechanical AC to DC converters were made to work in reverse, and thus were "inverted", to
convert DC to AC.
The inverter performs the opposite function of a rectifier.

 Advantages of PWM inverter:

1) It is possible to output volt without adding to the total number of power ckt. Components
of the inverter.
2) Output can be change by changing width of pulse.
3) It is possible to reduce lower order harmonic freq.
4) Input power factor is high.

DESIGN STATEMENT:
Design an ‘ONLINE’ UPS to drive a critical load of 400W (Power factor =1).

Assume that the load can be driven by 200V (RMS)

DESIGN:
 Output transformer design:

T1

1:4
Fig.2

The load needs 400W power with power factor 1.It needs 400VA .If we provide load 200V it
needs 2A current. So it’s required to design a step up transformer to step up 48V to 200V as the
output of inverter is 48V.

n 1 48
=
n 2 200

n1 6
=
n 2 25

n1 1
∴ =
n2 4

Power required at output of transformer = 400W

The efficiency of transformer ɳ = 97%

The input of transformer = 400 /¿ɳ

=412.37W

400
The current through the secondary =
200

=2A

412.37
The current in primary =
48

=8.59A ≅ 9 A

The area of equation = √ ¿ ¿/0.97)

w p= VA rating

= 400 VA

The area of core of transformer= √ ¿/0.97)

Area = 20.23cm 2

 INVERTER:

Fig.3

I=9A

V= 48V
 ∴ I Q ≥9A
V CE max ≥48V
Hence use BJT having above ratings.
So BJT MJE3055T (TO-220AB) is used.

PIV= 48V for diodes

Hence Diode GP600

Peak amplitude of modulating signal

m a=
Peak amplitude of carrier signal

Let assume both peak value are same, hence m a= 1

Gain of full bridge PWM inverter= 0.707¿ m a

Gain =0.707

Distortion factor= 0.707*m a

= 0.707
1
2
Harmonic factor= ⌊ −1 ⌋ 2
ma

=1

 CONTROL CIRCUIT :
i) Sine wave generator:

Vo
( R3 + R 4 ¿ = =5/1mA
I
= 5kΩ
R3=2 R4

∴ 3 R4 =5kΩ

R4 =1.6kΩ
R3=3.3kΩ

Amplifier gain A:
 A=1+ R3/ R4
=3.06
Let R1= R2 =4.7kΩ
f= 1/2∏RC
C=1/2∏Rf
∴ C=0.677uf
ii) Triangular wave generator:

V op = 2 R1 V sat / R2
let R1=10 kΩ
k∗9
10=2∗10
R2
R2=18kΩ
f= R2 /¿4 R1RC
500=18k / (4*10k*R*0.01uf)
R=0.9MΩ

Now output of both sine & triangular generator applied to input of op-amp

So that at output of op-amp PWM control signal got.

 Fig.4

 BATTERY DESIGN :

Let efficiency of inverter= 0.85

412.37
p¿ =
0.85
=485.14watt
p¿= V dc * I dc
485.14=48∗I dc
I dc= 485.14/48 =10.10A

AH rating of Battery= I dc*(time in Hr)

= 10.10* .5
=5.05
≅5 AHr
 REGULATOR:

MJE2955T Rlim

1.0

Reb LM 317HV
LINE VREG
VOLTAGE
1.0
COMMON
R1

240

50% R2

8.97k

Fig.5

Regulator output= 48V

Hence use ‘LM314HV’ to regulate voltage

It has max capacity up to 57V & having current capacity of 1.5A
Formula:
R
V out = 1.25 ⌊ 1+ ⌋
240

R
48=1.25 ⌊ 1+ ⌋
240

R=8.976kΩ

Pd = I 2*R
= 89.76uW (here I is leakage current =0.1 mA)
Pd =89.7uW
Hence use 10k pot & adjusted to 8.97k Ω.

Heat sink:
Ѳ sa=[ (T j- T a)/ P D] – {Ѳ jc+ Ѳcs }
125−25
¿ [ 3∗1.5 ] −2.3̊c/w

¿19.92̊c/w
 Ѳ sacal =19.92̊c/w

Ѳ ja=Ѳ jc+Ѳ cs +Ѳ sa
Ѳ sa=Ѳ ja - Ѳ jc-Ѳc s
Ѳ sa=35−2.3
Ѳ saact =32.7 ̊c/w

∴ Ѳ sacal <Ѳ saact

Hence heat sink does not require.

 CURRNET BOOSTING:

V c =V EB+V drop +V o

= 0.7+3+48

= 51.7V

I c =9 A

∴ Select transistor such that V ce >= 3.7V & I cmax>=9A

Hence select transistor MJE2955T (TO220AB)

It has V ce = 3.7V & I cmax=10A

According to datasheet,

V EB=1.8V

∴ V c =V CE(sat)+48

= 7+48

= 55V

Again V EB=1.8V

R EB=1.5A/1.8V . . . . . . .( as I R =1.5A )

R EB=0.83Ω
I* Rlim ¿ ¿=V CE(sat)

Rlim ¿ ¿=V CE(sat)/I

= 7/9

Rlim ¿=0.78 ¿Ω

P Dmax= V CEmax * I Cmax

= 7*9

P Dmax = 63watt

From datasheet, from graph of ‘power derating’ &’SOA’

It is found that no need of heat sink for this operating condition.

Fig.6

 Filter Design:

V DC 2
= = 0.6366
Vm ∏
V m=V DC/0.6366 = 86.40V

w c∗R L=10 ……. (4<= w c∗R L <=10)

Rs
=20%
RL
 But R L=V o /I o = 48/10 = 4.8Ω
R s=4.8*0.2 =0.96Ω
R s=0.96Ω

Ripple Factor:-
RF=V ripple /(2√ 2V DC)

Let RF=55dB
∴ RF=562.34
V¿
=562.34
V¿
V ¿(ripple)=8.43V
RF=8.43/(2√ 2∗55 ¿*100
RF=5.41%
V DC
C=w c∗R L/[2∏f ]
Io
∴C’=10/(2*3.14*50*55/10)
C’=5790uf
C=C’+300uf
C=6100uf
Volt across capacitor =1.4*V DC
=1.4*55
V c =77 V

 RECTIFIRE DESIGN:

From Shade’s plot

I frms
i) I favg
=1.8
I fpeak
ii) I favg
=8

I favg= I 0/2 =10/2

I favg=5A

I frms=1.8* I favg = 9A

I fpeak = 8* I favg =40A

PIV=V m=86.4V

I surg=V m/ R s = 86.4/0.96 =90A

∴Diode use should have rating as follows

PIV>=86.4V, I surg>=90A

Hence use GP601

 INPUT TRANSFORMER:
T

4:1
Fig.7

i) RMS volt at secondary coil:-

V s = [V m+0.1n]/√ 2
= (86.4+0.1)/√ 2

V s =61.16V

ii) VA rating:-

VA rating=V s * I s
= 61.16* I rms*√ 2
= 61.16*9*√ 2

VA rating=778.43VA

iii) Area of core:-

wp
√
Ai =
0.97
w p=VA rating
 ∴ A i = 778.43
√
097

Ai =28.32cm 2

iv) Turn ratio:-

V¿
ɳ= Vs
ɳ= 230/61.16 ≅ 4

ɳ = 4:1

 protection circuit :

1)current limiting fuse:

As output current of inverter = 9A
∴ I fuse =1.5∗I max
I fuse = 1.5*9A
∴ I fuse=13.5A
Hence use fuse having maximum current capacity of 13.5A

2)MOV (metal oxide variastor):

It is basically a surge suppressor .MOV should be connected on primary side of input

transformer .

primary volt=230V

factor of safety=1.2

∴MOV ≅1.2*230

MOV=280

Device NFELV300 has capacity to handle 280V .

 Efficiency:
output power
Efficiency= * 100
input power
 ∴effi= (400watt/485.14watt)*100 …….( input power=battery
power)
Efficiency= 82.45%

 TESTING & PARAMETERS:

Sr Parameter Value
no.
1 Output voltage 230V¿ 5%
2 Output volt waveform PWM
3 Output frequency 50Hz
4 Battery capacity 48V ( > 5AH capacity)
5 Power ratting 400watt
6 Protection circuit Over current protection,MOV,
7 Efficiency ≅ 82%

Output wave form

Fig.8