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Proposal of a 5KVA single-phase on-line UPS with high frequency isolation

and power factor correction

Conference Paper · September 2009

DOI: 10.1109/COBEP.2009.5347694

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 PROPOSAL OF A 5KVA SINGLE-PHASE ON-LINE UPS WITH HIGH
FREQUENCY ISOLATION AND POWER FACTOR CORRECTION
René P. T. Bascopé1, Carlos G. C. Branco2, Cícero M. T. Cruz3, Eduardo F. de Oliveira4
and Gean J. M. Sousa5
Federal University of Ceará, Department of Electrical Engineering, Energy Processing and Control Group
Fortaleza-CE - Brazil
1
rene@dee.ufc.br , 2gustavo@dee.ufc.br , 3cicero@dee.ufc.br , 4edufacanha@yahoo.com.br , 5geanjacques@hotmail.com
Abstract – A high performance isolated double
conversion uninterruptible power supply (UPS) with
power factor correction using a high frequency
transformer, and input voltages equal to 110V/220V is
proposed. The arrangement is suitable to rack type
structures because it has small size and reduced weight.
For both input voltages, the proposed converter has
almost the same efficiency processing the same output
power. Other relevant features are soft commutation of
the controlled switches in the chopper and the boost
stage, simple control strategy that can be implemented
with well-known integrated circuits, and the use of few
batteries in series due to the step-up stage. Qualitative
analysis and experimental results obtained for a 5kVA
prototype show a normal efficiency of over 87% for the
worst case of input voltage and an input power factor of
over 99%.
Keywords - double conversion UPS system, high
frequency transformer, power factor correction (PFC),
soft commutation.
I. INTRODUCTION
With the increased dependence on the critical loads such
as medical support systems and communications systems,
more priority certainly will be placed on supplying
continuous and disturbance-free power in the future. For this
purpose extensive work have been done to provide
equipments more reliable, with reduced size and weight.
This type of equipment is called uninterruptible power
systems (UPS) and they are extensively used to protect
sensitive loads against a wide variety of utility voltage
disturbances and power outages. Most of such systems
consist in the true on-line UPS configuration. In general, this
is the most reliable UPS configuration due to its simplicity,
and the continuous charge of the batteries, which means that
they are always ready for the next power outage. This kind of
UPS provides total independence between input and output
voltage amplitude and frequency, and, thus, high output
voltage quality can be obtained [1].
Most of true on-line UPS operates with a low frequency
transformer using a silicon-steel core. In this configuration, it
is normally required an isolating transformer for proper
operation of the bypass circuit and also to improve reliability
of the system, since the transformer offers a galvanic
isolation to the load from undesirable disturbances of the
main supply [2]. Such transformer is placed at the input or
output depending on the topology arrangement. The addition
978-1-4244-3370-4/09/$25.00 © 2009 IEEE
of such magnetic component increases both weight and
volume, and also adds cost and difficulties in the
transportation to the installation site.
Transformerless UPS incorporating common neutral bus
line could be a solution to improve power conversion
efficiency, volume and weight reduction [3], [4]. Although
this UPS topology offered a way to obtain these advantages,
this type is more susceptible to interference from spikes and
transients caused by assorted devices connected to the utility
grid [5].
Several UPS topologies with high frequency isolation
characteristic have been proposed in [6]-[10]. These
configurations belongs to topologies derived from isolated
boost full-bridge converter [6-8], flyback [9], and chopper-
boost [10].
A common drawback found in most of approaches are the
hard commutation of the controlled switches that
compromises efficiency, several batteries in series
connection to achieve high DC-link voltage and pulsed
current drawn by the battery bank that affects the reliability
of the battery set.
The topology proposed in [10] with modifications and
adjustments were adopted in this work to increase the output
power level. The advantages of such topology compared to
the previous ones are: it allows the UPS operation with two
values of input voltage (110V/220V), simple control strategy
and presents soft commutation of main switches from the
isolated AC-DC Stage.
II. THE PROPOSED UPS
A. Topology Description
The proposed UPS is shown in Fig. 1. It is composed by
the following parts: an isolated chopper comprising of the
rectifier diodes D1-D4, a high frequency input filter
comprising of the inductor Lf and capacitors Cf1 and Cf2, a
controlled full-bridge comprising of the switches S1-S4, a
high frequency transformer Tr, coupled inductors Lr1-Lr2, and
rectifier diodes Dr1-Dr4; a traditional boost converter
comprising of the inductor Lb, switch Sb, diode Db and
capacitor Cb; a full-bridge voltage source inverter (VSI)
comprising of the switches S5-S8; and the output filter formed
by inductor Lfi and capacitor Cfi. In addition, the waveforms
corresponding to the operation of each stage are indicated in
this figure.
886
B. Modes of operation
The operation of the proposed UPS can be divided in two
modes: the grid mode, which is also sometimes referred as
normal mode and the battery powered mode.
1) Grid mode: During the normal mode, i.e., under the
condition which there isn’t power failure or the utility is at
least 85% of its rated operating condition, the isolated
chopper stage, boost stage, inverter stage and battery charger
circuit are operating. In accordance with the utility voltage
level, an automatic detector sets the UPS for the proper input
voltage. For utility voltage of 220Vac, the selector switch
(SS) should be set to position 220V. On the other hand, if the
utility voltage is 110Vac, the SS should be switched to
position 110V. The SS is implemented by an electromagnetic
relay controlled by the supervisory circuit.
The detailed principle of operation for each stage is shown
in the following sections.
2) Battery powered mode: When the supervisory circuit
detects ac line failure, the isolated chopper stage is turned off
and switch St turns on, transferring the input of the boost
stage from the isolated chopper to the battery bank for boost
dc/dc operation. In this operating mode, the battery charger
circuit is disabled. During this transition, the Vbus capacitors
were designed to provide sufficient energy to the inverter,
whereas the battery bank is not connected.
When the supervisory circuit detects ac line voltage
reestablishment in normal operating ranges, the isolated
chopper stage is turned on, whereas the boost converter
control and the inverter control are synchronized with the
input voltage.
III. ANALYSIS OF THE CHOPPER OPERATION WITH
INPUT VOLTAGE EQUAL TO 110V
A. Principle of operation
The chopper operates with fixed duty cycle (D≅0.5) using
dedicated integrated circuit (IC) UC3525A. The control
strategy allows the application of high frequency voltage
Vab
Vi
pulses to the primary windings of transformer Tr, enabling
the use of a high frequency transformer.
When the input voltage is 110V, the SS (manual or
automatic) must be turned on and adjusted to the 110V
position point. Under this condition, diodes D2 and D4 are
always reverse biased.
Considering the positive semicycle of the input voltage,
during half of the switching period, the converter operation
can be resumed to four stages, as shown in Fig. 2, as the
relevant waveforms are shown in Fig. 3. The operation of the
topology in the negative semicycle is analogous.
Interval (t0-t1): At t=t0, switches S1 and S2 are turned on.
The input voltage charges inductor Lr1, and the current
increases linearly from zero to nILb. The output current ILb is
freewheeling.
Interval (t1-t2): During this interval, energy is transferred
from the input source Vi to the load, through the rectifier
diodes Dr1 and Dr4, to the chopper output represented by
current source ILb.
Interval (t2-t3): At t=t2, switches S1 and S2 are turned off
under zero voltage condition due to the intrinsic
capacitances. Half of the energy stored in inductor Lr1 is
transferred to inductor Lr2. The intrinsic capacitances are then
charged and discharged.
Interval (t3-t4): When the voltages across switches S1 and
S2 is equal Vi, the antiparallel diodes of switches S3 and S4 are
directly biased. During this interval, switches S3 and S4 must
be turned on.
In the chopper stage, duty cycle reduction ΔD occurs due
to the input voltage across commutation inductors Lr1 and
Lr2, and also to the transformer leakage inductances, which
cause the linear variation of the current through them. During
this interval, output current ILb is freewheeling through
rectifier diodes Dr1-Dr4. Therefore, there is no power transfer
from the input to the load.
Vcd V bus
Vo

0 t 0 t 0 t 0 t 0 t

CHOPPER BOOST INVERTER

a c
D1 D2 S3 D r1 D r2 Lb S7 S5 L fi
Lf S1 L r1 Tr Db
R1
C f1 St
220V Np1 R3
SS M +
Vi Cb C fi Vo
110V Ns Sb
Np2 +
R4
C f2 R2
Batteries
L r2 D r3 D r4
S2 S4 S6
D3 D4 S8
b d
Sb S5 S6 S7 S8
S1 S2 S3 S4 Sample of the
input voltage
Boost Inverter
Chopper
control control
control
Vi + +
- V - V refi
refb

Fig. 1. Proposed single-phase high frequency isolated UPS.

978-1-4244-3370-4/09/$25.00 © 2009 IEEE 887

 iS1 iS1
+ +
S3 S1 vS1 S3 S1 vS1
D1 D2 c D1 D2 c
Lf C f1 - C f1 -
L r1 D r1 D r2 Lf L r1 D r1 D r2
220V 220V
SS iLr1+ vLr1 - SS iLr1+ vLr1-
Np Np
M M
Vi Ns I Lb Vi I Lb
110V 110V Ns
Np Np
iLr2 L r2 iLr2 L r2
- vLr2 + - vLr2 +
C f2 C f2
D3 D4 D r3 D r4 D3 D r3 D r4
S2 S4 D4 S2 S4
d d

Interval ( t0 -t1 ) Interval ( t1 -t2 )

iS1 iS1
+ +
S3 S1 vS1 S3 S1 vS1
D1 D2 c D1 D2 c
C f1 - C f1 -
Lf L r1 Lf L r1 D r1 D r2
D r1 D r2
220V 220V
iLr1+ vLr1 - SS iLr1+ vLr1 -
SS Np Np
M M
Vi I Lb Vi Ns I Lb
110V Ns 110V
Np Np
iLr2 L r2 iLr2 L r2
- vLr2 + - vLr2 +
C f2 C f2
D r3 D r4 D3 D4 D r3 D r4
D3 D4 S2 S2 S4
S4
d d

Interval ( t2 -t3 ) Interval ( t3 -t4 )

Fig. 2. Operating intervals of the chopper circuit when the input voltage is 110V.

Ts/2 Ts 2 Lr1 f S nILb ( pk ) sin (θ )

S1, S2 ΔD = (6)
S3, S 4 DTs t
Vi ( pk )110V sin (θ )
ΔDTs t
where fs is the switching frequency.
vLr1 Vi The root-mean-square (rms) output voltage of the
iLr1 nILb
chopper, which supplies the boost converter, is given by
t π
1
2 ( D − ΔD ) ( nV )
2
sin (θ ) dθ (7)
π∫
vLr2 Vcd ( rms ) = i ( pk )110V
Vi -Vi
iLr2 0
Simplifying (7) yields

-nILb
t
vcd (rms ) = nVi ( pk )110V (D − ΔD ) (8)
vS1
-Vi where Vcd(rms) is the chopper rms output voltage, and D is the
2Vi
iS1 vS1 nILb duty cycle. The inductor peak current is calculated with
iS1
2 P0
t I Lb ( pk ) ≅ (9)
Vcd (rms )
to t1 t2 t3 t4 t5 t6 t7 t8
where Po is the UPS active output power.
Fig. 3. Main theoretical waveforms when the input voltage is 110V.
IV. ANALYSIS OF THE CHOPPER OPERATION WITH
The duty cycle reduction can be obtained from the
INPUT VOLTAGE EQUAL TO 220V
inductor voltage given by
ΔiL
vL = L , (1) A. Principle of operation
Δt
In this mode, the selector switch SS must be set to the
as the involved parameters are
220V position. The control strategy is the same one used
vL = vi ( pk )110V sin(θ ) (2) when the input voltage is 110V.
Considering the positive semicycle of the input voltage,
ΔiL = 2nILb ( pk ) sin(θ ) (3) during half of the switching period, the converter operation
can be represented by four stages, as shown in Fig. 4, where
Δt = ΔDTS (4)
the theoretical waveforms are shown in Fig. 5. The
L = Lr1 = Lr 2 (5) description of the operation is similar to the case where the
where n is the transformer turns ratio, ILb(pk) is the peak input voltage is 110V.
current through the boost inductor, Vi(pk) is the peak input Although the current flows simultaneously through both
voltage, θ=ωt is the phase angle of the input voltage, and Ts inductors when the chopper operates with 220V, the
is the switching period. equivalent inductance, considering the mutual inductance
Substituting (2)-(5) in (1) results in the following and coupling coefficient nearly unity, is equal to four times
expression: Lr1 or Lr2, i.e., Lreq = 4 Lr1 = 4 Lr 2 .

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 iS1 iS1
+ +
S3 S1 vS1 c S3 S1 vS1
D1 D2 D1 D2 c
C f1 - L C f1 -
Lf r1 D r1 D r2 Lf L r1 D r1 D r2
220V 220V
SS iLr1+ vLr1 -
SS iLr1+ vLr1 -
Np Np
M M
Vi I Lb Vi Ns I Lb
110V Ns 110V
Np Np
iLr2 L r2 iLr2 L r2
- vLr2 + - vLr2 +
C f2 C f2
D3 D r3 D r4 D3 D4 D r3 D r4
D4 S2 S4 S2 S4
d d

Interval ( t0 -t1) Interval ( t1 -t2)

iS1 iS1
+ +
S3 S1 vS1 S3 S1 vS1
D1 D2 c D1 D2 c
C f1 - C f1 - L
Lf L r1 D r1 D r2 Lf r1 D r1 D r2
220V 220V
iLr1+vLr1 - SS iLr1+ vLr1 -
SS Np Np
M M
Vi I Lb Vi Ns I Lb
110V Ns 110V
Np Np
iLr2 L r2 iLr2 L r2
- vLr2 + - vLr2 +
C f2 C f2
D r3 D r4 D3 D4 D r3 D r4
D3 D4 S2 S4 S2 S4
d d

Interval ( t2 -t3) Interval ( t3 -t4 )

Fig. 4. Operating intervals of the chopper circuit when the input voltage is 220V.

Ts/2 Ts Db
ILb Lb
c Ls
S1, S 2
DTs t +
S3, S 4 Cs1
t Da1
ΔDTs +
+
vLr1 Vi/2 Vcd Da2 Da3 Cb V bus
iLr1 Sb Cs2
nILb/2
Snubber
t
-
-nILb/2
vLr2 -Vi/2
d
Vi/2
iLr2
nILb/2 Fig. 6. DC/DC converter stage schematic.
t
-nILb/2
VI. BATTERY CHARGER
-Vi/2
vS1 Vi The battery charger is based on a non-isolated buck
iS1 vS1
nILb/2 converter, as shown in Fig. 7. The converter operates in
iS1
continuous conduction mode (CCM) of the current through
t
the filter inductor, and is supplied by the dc link bus voltage.
t0 t1 t2 t3 t4 t5 t6 t7 t8 The implemented charge control strategy is based in one
Fig. 5. Main theoretical waveforms when the input voltage is 220V. voltage and one current control compensator, where, both
operates using the OR logic. In this application the battery is
charged under constant current controlled by the current
V. DC/DC CONVERTER STAGE regulator, then when the battery reaches the fluctuation
voltage, the voltage controller acts to maintain the rated
The boost converter configuration used is shown in Fig. 6. voltage.
The converter choice was made based to its reliable and For this operation only the total battery bank voltage is
easier control implementation based on known control monitored and there isn’t another control to improve battery
techniques. Current mode control were used and health or battery cells voltage equalization.
implemented with the well-known pulse-width modulation
Lb Db
(PWM) IC UC3854B. c BOOST

The boost converter functions in this system are: output +

voltage regulation, power factor correction, and stepping the +
St Sb
battery voltage up to the output voltage Vbus. Additionally, Vcd V bus
Lch Sch
this stage provides an active filtering to block the pulsating + Dch2 + +
Vbat Cb
current of the nonlinear load (i.e. the inverter stage) from the Cch Dch1
BATTERIES
battery bank. Switch Sb operates with zero voltage switching -

in a wide range of output power using a passive non- d BATTERY CHARGER

dissipative snubber circuit [11]. Fig. 7. Battery charger stage schematic.

978-1-4244-3370-4/09/$25.00 © 2009 IEEE 889

 As the voltage across terminals c and d is chopped at Heatsink
60kHz and the ripple frequency is 120Hz, as shown in Fig. 1,
a controlled switch St is necessary. For this application, a
silicon controlled thyristor (SCR) associated with a passive
snubber was used.
Switch St is turned on when the ac mains voltage is null or Converters
out of the input voltage range, and it is turned off when ac
mains voltage is within the desired limits. The gating signal
is turned off during normal operation, so it is reverse biased Magnetics
naturally when Vcd voltage is higher than battery bank
voltage.

VII. DC-AC CONVERTER STAGE

The dc/ac configuration used is based on the full-bridge

inverter, shown in Fig. 8. This converter choice was made Fig. 9. Photograph of the prototype.
based to its reliable and robustness for its desired application.
The control implementation was realized using sinusoidal TABLE II
PWM control with unipolar voltage switching, synchronized Mechanical construction data
with the utility. In order to protect the switches against Prototype dimensions Height: 50cm
Width: 31,5cm
overvoltages, a RCD clamping snubber circuit was placed in Length: 62,5cm
each inverter leg as shows the Fig. 8. Weight of mounted printed circuit 10kg
board with heatsink
S5
+ S7 L fi Total weight of magnetics components 10kg
snubber (Inductors and transformers)
Magnetics components quantity 13 parts
Battery bank 16 Batteries (7Ah / 12V)
V bus C fi Vo
B. Waveforms and curves for the grid and battery modes
operation.
S6 S8 The grid mode operation experimental results were
-
realized for two different input voltages levels. The results
Fig. 8. DC-AC converter stage schematic. shown in Figs. 10-13 were obtained for an input voltage
equal to 110Vac and the results shown in Figs 14-20 were
VIII. EXPERIMENTAL RESULTS obtained for an input voltage equal to 220Vac.
Figs. 10 and 14 show the input voltage and input current
waveforms. It can be observed that the input current is close
A. Developed system specifications to sinusoidal and has a unity input power factor. The high
The design specifications of the proposed UPS system are frequency noise seen in the voltage waveform is due to high
shown in Table I. The switching frequency for the chopper switching frequency and absence of an EMI input filter. The
and boost stage is assumed fs=30kHz. The switching harmonic analysis graph for the harmonics above
frequency for the inverter stage is assumed fs=20kHz fundamental for the input current waveform shown in Fig. 14
TABLE I is show in Fig. 15, where can be seen that the input current
Developed UPS specifications presents a low THD value.
Input Voltage Vi = 110 Vca / 220 Vca ±15%
Output Voltage Vo = 110 Vca Figs 11 and 16 show the voltage behavior across one
DC-link voltage Vbus = 400 Vdc controlled switches of the chopper and boost stages,
Grid Frequency fr = 60 Hz respectively. It can be seen that the spikes is under the
Output Power Capacity S0 = 5 kVA
Output Frequency f0 = 60 Hz controlled switch voltage specification (600V). In Fig. 12 is
Input Power Factor 0.99 shown the dc-link voltage that is regulated in 400V.
Output Power Factor 0.7 The output voltages and currents of the inverter are shown
Number of Batteries (in series) 16 (12 V / 7 Ah)
in Figs. 13, 17 and 18, where a high quality sinusoidal
A photograph of the prototype is shown in Fig. 9. It is voltage waveform is obtained, independently of the load
divided into two parts: a main board circuit level and a characteristic. (Harmonic analysis shown in Fig. 19).
magnetics level. The lower level is reserved for batteries.
Fig. 20 shows the transition between the grid mode and
In Table II is shown the information regarding the
battery mode for full load condition. As can be seen, the
mechanical construction of the prototype. It can be seen that
the developed equipment have a total weight without output voltage is not disrupted at any moment during the
batteries, rack and EMI filter of approximately 20kg. transition of modes. Fig. 21 shows the voltage and current in
Compared to the typical isolated UPS systems for the same the batteries during the operation in battery mode. It is
purpose that is approximately 65kg (without batteries), it has observed a current without pulsating characteristic.
a considerable smaller size and weight.

978-1-4244-3370-4/09/$25.00 © 2009 IEEE 890

 Fig. 10. Input voltage and current. Operation in 110 Vac. Fig. 13. Output voltage and current. Operation in 110 Vac.
(Ch1:50V/div., Ch3:50A/div.; 4ms/div.) (Ch4:50V/div., Ch3:25A/div.; 4ms/div.)

Fig. 11. Voltage across the chopper stage switch S1. Operation in Fig. 14. Input voltage and current. Operation in 220 Vac.
110 Vac. (Ch1:200V/div.; 10us/div.) (Ch1:100V/div., Ch3:25A/div.; 4ms/div.)

TDHv = 4.41%
TDHi = 7.17%

Fig. 15. Harmonic spectrum of the input current. Operation in

Fig. 12. DC-link output voltage. Operation in 110 Vac. 220 Vac
(Ch4:200V/div.; 4ms/div.)

978-1-4244-3370-4/09/$25.00 © 2009 IEEE 891

 TDHv = 1.85%
TDHi = 120.30%

Fig. 19. Harmonic spectrum of output voltage for non-linear load.

Operation in 220 Vac.

Fig. 16. Voltage across the boost stage switch Sb. Operation in
220 Vac. (Ch1:100V/div.; 10us/div.)

Fig. 20. Transition from grid mode to battery mode (Operation in

Fig. 17. Output voltage and current. Operation in
220 Vac. (Ch4:50V/div., Ch3:50A/div.; 4ms/div.)
220 Vac). From top to bottom are shown: the dc-link voltage, the
input voltage, the current through the boost inductor and output
voltage.
(Ch1:200V/div., Ch2:100V/div., Ch3:25A/div., Ch4:500V/div.;
20ms/div.)

Fig. 21. Voltage and current in the batteries bank during the
Fig. 18. Output voltage and current of the inverter for non-linear operation in battery mode.
load. Operation in 220 Vac. (Ch1:50V/div., Ch3:50A/div.; 4ms/div.) (Ch4:100V/div., Ch3:25A/div.; 4ms/div.)

978-1-4244-3370-4/09/$25.00 © 2009 IEEE 892

 Figs. 22 and 23 show the efficiency and the input power
factor behavior of the UPS for the operation in 110Vac and
220Vac, respectively. As can be seen, a good performance for
both operating conditions is obtained.
Fig. 22. Efficiency and input power factor of the UPS system in
grid mode operation as a function of the output power for 110Vac.
Fig. 23. Efficiency and input power factor of the UPS system in
grid mode operation as a function of the output power for 220Vac.
IX. CONCLUSIONS
In this paper was proposed a high performance double
conversion UPS that uses high frequency transformer for
isolation. This type of technology reduces significantly the
total weight and size of the overall system as shown in the
experimental results section. The proposed system is also
suitable to operate with rms input voltages values equal to
110V/220V, 115V/230V, or 120V/240V. The qualitative
analysis of the chopper stage for the input voltage values
equal to 110V/220V, and experimental results obtained from
5kVA prototype have been presented.
Accordingly to Figs. 10 and 14, the system presents power
factor correction. This characteristic is due to the boost stage,
which is controlled using a simple and well know dedicated
analog IC, which simplifies the design. The maximum input
power factor obtained at full-load is near unity, as shown in
Figs. 22 and 23, either the UPS is fed with 110Vac or 220Vac.
The chopper stage converts the 120Hz pulsated
continuous input voltage to high frequency AC voltage, so
978-1-4244-3370-4/09/$25.00 © 2009 IEEE
that the use of a high frequency transformer is possible. Due
to the secondary voltage of the isolation transformer which is
also compatible with the battery bank voltage (i.e. around
216V for fluctuation voltage), it is used a bridge rectifier
connected in the secondary of the isolation transformer. As
shown in the experimental results section, the overall
efficiency continues high compared to the previous circuits.
The inverter stage presents sinusoidal output voltage when
supplying linear or nonlinear loads, according to Figs. 13, 17,
and 18. At low output power condition, hard commutation of
the switches is verified, so in order to limit the voltage
overshoot across them, a simple RCD snubber were used.
Finally, the experimental results demonstrated the
performance of the proposed UPS system. The global
efficiency obtained at full load for grid mode operation was
87% for an input voltage equal to 110Vac, and 86.5% for an
input voltage equal to 220Vac, as showed in Figs. 22 and 23,
respectively.
ACKNOWLEDGMENT
The authors would like to thank “CM Comandos Lineares
Ltda” due to research financial support with agreement of
MCT (Ministério de Ciência e Tecnologia do Brasil).
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