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A High Frequency Transformer Isolation 110V/220V Input Voltage UPS System
A High Frequency Transformer Isolation 110V/220V Input Voltage UPS System
A High Frequency Transformer Isolation 110V/220V Input Voltage UPS System
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Abstract – This paper proposes a double conversion UPS system The UPS shown in Fig. 2 was studied in [3]. The circuit is
with power factor correction, high frequency transformer composes by, a modified PFC current-fed full-bridge pre-
isolation and 110V/220V input voltage characteristics. It’s suitable regulator and a voltage source full-bridge inverter, similar to
for rack type structure because it has small size and reduced the previous one. This topology has the advantages of reduced
weight. For both input voltages, the proposed converter has
almost the same efficiency processing the same output power.
amount of semiconductors in series during power transfer,
Other relevant features of this structure are: soft commutation of contributing for reduction of conduction losses and improving
the controlled switches of the chopper and of the boost stage, efficiency. The disadvantages are hard commutation of the
simple control strategy that can be implemented with well-known controlled switches, and many batteries in series to achieve
integrated circuits and the use of few batteries in series due to high DC bus voltage that feed the inverter.
step-up stage. Qualitative analysis and experimental results Fig. 3 shows the series-parallel resonant system with
obtained from 2kVA laboratory prototype are presented. galvanic isolation between the input, the output and the battery
proposed in [4]. This system has the advantages of power
I. INTRODUCTION
factor correction, single pre-regulator stage, soft commutation
Nowadays uninterruptible power supply systems are being of the controlled switches and few batteries in series. On the
used to protect sensitive loads against a wide range of utility other hand, the disadvantages are: the complex control strategy
voltage disturbances and power outages. A large amount of and resonant parameters adjustment.
these systems consists in the double conversion UPS In [5], as shows Fig. 4, a two power conversion stages UPS
configuration that operates normally with a low frequency was studied. The first stage consists of a PFC-DCM flyback
isolation using a silicon-steel core transformer. Such converter with integrated battery charger, and the second stage
transformer is placed at the input or at output depending on the consists of a boost inverter. Due to the discontinuous
topology arrangement. The addition of this magnetic conduction mode operation of the flyback converter, the
component increases both weight and volume, and also add system is suitable for low power applications (<500W).
costs and difficulties in the transportation to the installation
place. L1
Lin Lb
T1 T3 T5 Q3
Ls1 Ls2 Cs2
Cs1 Vbat L2
Vi Vbat C5
C2
Q4
HF T4 T6
Cs1 T2 Transformer
Fig.5. UPS system proposed in [6].
0 t 0 t 0 t 0 t 0
363
L = Lr1 = Lr 2 . (5)
II. DESCRIPTION OF THE PROPOSED TOPOLOGY
Substituting (2), (3), (4), and (5) in (1), ∆D is obtained, as in
The proposed UPS is shown in Fig. 6, it is composed by the 2 Lr1 f s nI Lb ( pk ) sin(θ )
following parts: a full-bridge rectifier given by diodes D1-D4; a ∆D = , (6)
full-bridge chopper given by controlled switches S1-S4, high Vi ( pk )110V sin(θ )
frequency transformer Tr, commutation coupled inductors Lr1- where Lr1 is the commutation inductance, fs is the commutation
Lr2, and rectifier diodes Dr1-Dr2; a classical boost circuit given frequency, n is the transformer turns ratio, ILb(pk) is the peak
by inductor Lb, switch Sb, diode Db and capacitor Cb; a full- current through boost inductor, and Vi(pk) is the input peak
bridge inverter given by controlled switches S5-S8, inductor Lfi, voltage. The rms chopper output voltage that also feed the
and capacitor Cfi; and, a high frequency input filter given by boost converter is given by:
inductor Lf and capacitors Cf1 and Cf2. 1π
( )
2
Vcd ( rms ) = ∫ 2 ( D − ∆D ) nVi ( pk )110V sin (θ ) dθ . (7)
III. ANALYSIS OF THE CHOPPER OPERATION WITH INPUT π 0
VOLTAGE EQUAL TO 110V Simplifying (7) yields
A. Principle of Operation Vcd ( rms ) = nVi ( pk )110V ( D − ∆D ) , (8)
The chopper operates with fixed duty cycle (D≅0.5) using where Vcd(rms) is the rms chopper output voltage, and D is the
PWM modulation obtained from integrated circuit UC3525A. duty cycle. The inductor peak current is calculated using
The control strategy allows the application of high frequency 2 Po
voltage pulses to the primary windings of the transformer Tr, I Lb ( pk ) ≅ , (9)
Vcd ( rms )
enabling the use of a high frequency transformer.
When the input voltage is 110V, the selector switch SS where Po is the active output power of the UPS.
iS1
(manual or automatic) must be turned on and adjusted to the S3 S1
+
vS1
110V position point. Under this condition, diodes D2 and D4 Lf
D1 D2
Cf1 -
Dr1 c
are always reverse biased. 220V Lr1
iLr1+ vLr1 -
SS Ns
During the positive semi-cycle of the input voltage, in one Vi
M
Np
iLr1+vLr1
output intrinsic capacitances of the controlled switches of the SS
Np Ns
110V M
chopper, and so to guarantee ZVS commutation of them. Such Vi
ILb
During this condition, there is no power transfer from the input. VLr1
iLr1
Vi
nILb
where -nILb
vL = Vi ( pk )110V sin (θ ) ,
-Vi
(2) vS1
iS1 vS1
2Vi
nILb
iS1
∆iL = 2nI Lb ( pk ) sin(θ ) , (3)
t
∆t = ∆DTs , (4)
to t1 t2 t3 t4 t5 t6 t7 t8
364
IV. ANALYSIS OF THE CHOPPER OPERATION WITH INPUT S1, S2 Ts/2 Ts
iLr1 nILb/2
-nILb/2
intervals as shown in Fig. 9, according to the waveforms in Fig. -Vi/2
10. The commutation process is similar to that presented for vS1
iS1 vS1
Vi
Fig. 10. Main theoretical waveforms when the input voltage is 220V.
the equivalent commutation inductance, considering the mutual
inductance and coupling coefficient next to unity, is equal to c Lb Ls Db
four times Lr1 or Lr2 i.e. Lreq = 4 Lr1 = 4 Lr 2 . +
ILb Cs1
According to Fig. 9, there are always two controlled +
+
semiconductors involved in power transference. Although the Vcd Sb Cs2 Snubber
Co Vbus
input voltage is twice that in Section III, the current through the
semiconductors is reduced to a half. Therefore, losses are -
d BATTERY CHARGER
Interval (t5-t6)
Fig. 9. Operating stages of the chopper circuit when the input voltage is 220V. Fig. 12. Battery charger scheme.
365
VIII. SIMPLIFIED DESIGN EXAMPLE 2 ⋅110 ⋅ 0.048
Lr1 = Lr 2 = = 3.85µ H .
2 ⋅ 50000 ⋅1 ⋅19.36
A. Preliminary Specifications
The input filter capacitances must be small, so are arbitrarily
The design specifications of the proposed UPS system are chosen as C f 1 = C f 2 = 6.6µ F . Thus, the filter inductance is
shown in Table I. The switching frequency of the converters
1
was assumed fs=50kHz. Lf = ≅ 137.18µ H . (11)
C f ( eq ) ( 0.94 f s )
2
TABLE I. UPS SPECIFICATION
Mains input voltage Vi = 110Vac / 220Vac C. Design Procedure of the Boost Converter Circuit
AC mains frequency fr = 60Hz
The boost inductor and filter capacitor are obtained
Output voltage Vo = 110Vac according to [7]. Thus,
Maximum active output power Po = 1400W 2Vcd ( rms ) Dboost
Maximum apparent output power So = 2kVA Lb = = 338.60 µ H , (12)
f s ∆ILb max
AC output frequency fo = 60Hz
2 Po ∆t
The design parameters of the UPS system stages are listed in Co = = 2167.9µ F , (13)
Vbus 2 − V12
Table II.
TABLE II. DESIGN PARAMETERS OF THE UPS STAGES
where,
• Chopper Circuit: 2Vcd ( rms )
Dboost = 1 − = 0.34 . (14)
Transformer turns ratio n = Ns / N p = 1 Vbus
Maximum duty cycle Dmax = 0.48 D. Design Procedure of the Battery Charger Circuit
Maximum duty cycle reduction ∆Dmax = 0.048 The inductance of the filter inductor is substituting the
Input filter resonant frequency f f = 0.15 f s design parameters values in
• Boost Circuit: V (1 − Dch )
Lch = bat = 11.01mH . (15)
Boost inductor current ripple ∆ILb max = 0.15ILb ( pk ) f s ∆I ch
DC link output voltage Vbus = 220V The capacitance of the filter capacitor and equivalent series
Hold-up time ∆t = 8.333 × 10 −3 s resistance are calculated using
Minimum DC link output voltage V1 = 190V ∆I ch
Cch = = 1.25µ F , (16)
• Battery Charger Circuit: 8 f s ∆Vbat
Maximum battery voltage Vbat = 108V
∆Vbat
Maximum battery charge current I ch = 1A Rse ≤ ≤ 2Ω . (17)
Current ripple through the filter inductor ∆I ch = 0.1A ∆I ch
Duty cycle of the buck converter Dch = 0.49 The prototype was implemented with an electrolytic
Voltage ripple across battery bus ∆Vbat = 0.2V capacitor of 100µF/250V.
• Inverter Circuit: E. Design Procedure of the Voltage Source Inverter Circuit
Modulation index ma = 0.71
The inductance of the filter inductor is obtained substituting
Filter inductor ripple current ∆IL fi = 2.7 A
the design parameters values in
B. Design Procedure of the Chopper Circuit
L fi ≅
(Vbus − 2Vo ma ) = 170µ H . (18)
The rms output voltage of the chopper is calculated using 2 f s ∆IL fi
(8). Thus,
The resonance frequency of the inverter output LC filter
Vcd ( rms ) = 1⋅ 2 ⋅110 ⋅ ( 0.48 − 0.048) = 102.25V . applying unipolar voltage switching technique is given by
The peak output current of the chopper is determined using 2f
(9). Substituting, f fi ≤ s . (19)
10
2 ⋅1600 From (19), the inverter output filter capacitor must be higher
I Lb ( pk ) ≅ ≅ 19.36 A .
102.25 than Cfi ≥ 14.7µF. The prototype was implemented with a
The coupled inductors inductance is obtained from (6) metalized polypropylene film capacitor of 30µF/250Vac.
considering θ = π 2 . Therefore, the corresponding equation is
given by IX. EXPERIMENTAL RESULTS
Vi ( pk )110V ∆Dmax In order to verify the feasibility and performance of the
Lr1 = Lr 2 = . (10) proposed UPS system, a laboratory prototype was implemented
2 f s nI Lb ( pk )
and evaluated. The experimental results consist of relevant
Substituting values in (10), the inductances of the coupled voltage and current waveforms, and also efficiency and power
inductors are given by factor curves.
366
A. Waveforms and Curves for 110V Input Voltage 17 shows efficiency curve, as a function of output power.
Fig. 13 shows the input voltage and input current waveforms Finally, Fig. 18 illustrates the power factor behavior as a
where high power factor is observed. Fig. 14 shows the voltage function of the output power.
and the current waveforms though switch S1, where soft B. Waveforms and Curves for 220V Input Voltage
commutation details are observed. The output voltages and The corresponding waveforms for 220V input voltage are
currents of the inverter are shown in Figs. 15 and 16, where it shown from Figs. 19 to 24. The analysis of the waveforms and
can be seen a high quality sinusoidal voltage waveform, curves is similar to the case when the input voltage is 110V.
independently of the characteristic of the connected load. Fig.
Fig. 13. Mains input voltage and current Fig. 14. Voltage and current of the chopper switch Fig. 15. Output voltage and current of the inverter
(50V/div.; 10 A/div.; 2ms/div.) S1 (100V/div.; 10 A/div.; 5us/div.) for linear load (50V/div., 10A/div.; 2ms/div.)
η 92 PF 1
0.98
91
0.97
90
89 0.95
88 0.94
87 0.93
86 0.91
85 0.9
84 0.88
83 0.86
82
0.85
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
Po[W] Po[W]
Fig. 16. Output voltage and current of the inverter Fig. 17. Efficiency of the UPS system as a Fig. 18. Power factor as a function of the output
for non-linear load (50V/div., 20A/div.; 2ms/div.) function of the output power. power.
Fig. 19. Mains input voltage and current Fig. 20. Voltage and current of the chopper switch Fig. 21. Output voltage and current of the invert
(100V/div.; 5 A/div.; 2ms/div.) S1 (100V/div.; 5 A/div.; 4us/div.) for linear load (50V/div.; 10 A/div.; 2ms/div.)
η 92 PF 1
91 0.98
90 0.97
89 0.95
88 0.94
87 0.93
86 0.91
85 0.9
84 0.88
83 0.86
82 0.85
0 200 400 600 800 1000 1200 1400 1600 0 200 400 600 800 1000 1200 1400 1600
Po[W] Po[W]
Fig. 22. Output voltage and current of the inverter Fig. 23. Efficiency of the pre-regulator circuit as a Fig. 24. Power factor as a function of the output
for non-linear load (50V/div., 20A/div.; 2ms/div.) function of the output power. power.
367
The main parameters of the implemented prototype are experimental results obtained from 2kVA output power
summarized in Tables III, IV and V. prototype have also been presented.
TABLE III. PARAMETERS OF UPS RECTIFIER AND CHOPPER STAGE For both input voltages, chopper switches S1–S4 present zero
Rectifier Diodes GBPC3508A voltage switching, avoiding the use of snubber circuits. The
Input Filter Inductor Lf = 137.18µH proposed system efficiency is the same for both input voltages,
Input Filter Capacitors Cf1 = Cf2 = 3 x 2.2µF / 400Vdc
because semiconductors losses at the primary side of the
transformer are also almost the same. The chopper operates
Switches S1 - S4 IXFX44N60
with fixed pulses of D≅0.5 obtained from conventional PWM
Coupled Inductors Lr1 = Lr2 = 3.9µH integrated circuit.
NEE-65/39 (Thornton Ipec) The boost converter performs power factor correction,
High Frequency Transformer
Np=12 turns; Ns=12turns
regulates the output voltage and steps the battery bank voltage
Diodes Dr1 and Dr2 HFA30PA60C
up to the DC bus output voltage that feed the inverter. It is
TABLE IV. PARAMETERS OF UPS BOOST STAGE controlled in closed loop using average current-mode control,
Boost Inductor Lb = 338.60µH and implemented with conventional PWM integrated circuit.
Output Capacitor Co = 3 x 680µF / 450V The voltage source full-bridge inverter converts DC bus
Diode Db HFA25PB60 voltage in AC voltage. It’s controlled using unipolar voltage
technique. In this circuit, the controlled switches of the inverter
Switch Sb IXFX44N60
stage present hard commutation degrading efficiency.
Resonant Inductors LS = 0.9µH
CS1 = 120nF ACKNOWLEDGMENT
Polypropylene Film Capacitors
CS2 = 6.8nF
The authors would like to thank Texas Instruments,
Diodes Da1, Da2 and Da3 MUR460
International Rectifier, On Semiconductor, Cree and Epcos for
TABLE V. PARAMETERS OF UPS FULL BRIDGE INVERTER STAGE supplying the samples.
Output Filter Inductor Lfi = 170µH
REFERENCES
Output Filter Capacitor Cfi = 30µH
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A photograph of the implemented prototype is shown in Fig. [2] K. Hirachi, et al. “A Feasible High-Performance Single-Phase UPS
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[10] F. K. A. Lima, C. M. T. Cruz, F. L. M. Antunes, “A Family of Turn-On
and Turn-Off Non-Dissipative Passive Snubbers for Soft-Switching
X. CONCLUSION Single-Phase Rectifier with Reduced Conduction Losses”, in PESC 2004
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capable of operating in a wide input voltage range is presented. [11] R. P. Torrico-Bascopé, D. S. Oliveira Jr., C. G. C. Branco, F. L. M.
Other important features of the proposed system are: unity Antunes, “A PFC Pre-Regulator with 110V/220V input voltage and high
power factor, simple control scheme using conventional control frequency isolation for UPS applications”, in IECON’05 – IEEE
Industrial Electronics Society Annual Conference Proceedings, vol. 01,
technique and soft commutation. High frequency isolation 2005.
reduces the volume and weight of the system. The qualitative
analysis of the UPS for 110V and 220V input voltages and
368