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Application Seminar
October 2008
Matthias Dreier
Technology Manager
1
Agenda
Date Date
09:00 10:30 10:50 12:30
2
UPS in the Mid-Point Between
Utility & Critical Load
Alternating Voltage or
Power Station Utility Network UPS Direct Voltage (Current)
Critical Load
- Computers
High Mains - Control Systems
Alternating Voltage Quality - Safety Systems
- Motors
Poor Mains Quality
- Heaters
- General Lighting
3
Industrial versus Commercial UPS
Industrial Engineering Documentation Service
(Process & Power) Customized solutions Customized layout Comprehensive
Flexible specifications Approval procedure 20 years life
FAT / Type Testing Project related Spare parts
Many options Upgrade packages
Upgradeable
Harsh environment
4
Industrial versus Commercial UPS
Industrial
Electrical Design
(Process & Power)
Full Inverter output performance over wide load power factor range
Galvanic isolation between Input, DC branch and output
Different DC levels (battery voltage) available
Individually scalable modules (rectifier, inverter, bypass)
Mechanical Design
Segregated disconnect- and incomer panel
Front access for major components
Commercial Electrical Design
(IT) Full Inverter output performance limited to certain load power factor
No- or only limited galvanic isolation
DC level typically 400 VDC center tap or 2 x 400 VDC
Given module sizes
Mechanical Design
Integrated disconnect- and incomer section
Limited front access to major components
5
Typical Mains Disturbances
3% of failures are related to direct power failures.
The rest is mainly due to fluctuations.
TRANSIENT MOMENTARY
VOLTAGE SAG INTERRUPTION
SURGE
VOLTAGE OVER-
DISTORTION VOLTAGE
6
DC UPS Systems
Mains DC Voltage
Consumers / Load
3 Phase AC Input
RECTIFIER
AC / DC Converter
Online System
7
System Ratings
DC UPS Systems
Battery Voltage
(VDC) 24 48 110 125 220
RECTIFIER INVERTER
AC / DC Converter DC / AC Converter
3 Phase Input
BATTERY
Energy Storage
Voltage: 3x200... 3x690 VAC
Frequency: 50 or 60 Hz
6-pulse thyristor-controlled Rectifier 4 Standard
DC Voltages: 1- or 3-Phase Output
Option: 12 pulse thyr.-contr. Rectifier 110, 125, 220 or 400 IGBT-PWM controlled Inverter
Option: oversized for higher charging VDC Short-circuit proof
current or DC-load Lead Acid Type Option: oversized Inverter Module to
Float- and Boost charge Nickel Cadmium Type interrupt bigger fuses
DC Voltage AC Voltage
DC Bus
Consumers / Load
INVERTER
DC / AC Converter
BATTERY
Energy Storage
Online System
10
System Ratings
Traditional AC UPS Systems (XXW)
Inverters (WXW)
Battery 110 125 220 400
Voltage (VDC)
UPS Rating 5 5 5 120
(kVA)
- - - -
Single Phase
PEW 40 40 100 200
12 pulse rectifier
configuration is optional
RECTIFIER INVERTER
AC / DC Converter DC / AC Converter
3 Phase Input
BATTERY
Energy Storage
Voltage: 3x190... 3x690 VAC
Frequency: 41 - 70 Hz
PFC Rectifier (Power Factor Correction)
DC Voltage: 1- or 3-Phase Output
MOSFET Technology 400 VDC IGBT-PWM controlled Inverter
Input PF > 0.96 / THDi < 5% Range: 335 540 VDC Short-circuit proof
Float- / Boost- / Initial charge Lead Acid Type Transformerless-Design possible
Low battery ripple current Nickel Cadmium Type
UPS Rating 5
(kVA) -
Three Phase
PXP 3000 160
13
DC Single Unit Configuration
14
DC Redundant System Configuration
Rectifier Module B
50 %
Rectifier Input
Module B
15
DC UPS Systems Redundant
Common Battery
Distribution
RECTIFIER 1 Load
AC / DC Converter
Active communication between RECT 1
and RECT 2 with active load sharing
16
DC UPS Systems Redundant
Individual Battery
Q001 T001
Q003
RECTIFIER 1 Distribution
AC / DC Converter
Active communication between RECT 1 Load
and RECT 2 with active load sharing Battery 1
Q001 T001
Q003
17
DC UPS Systems Redundant
Battery Charging
Q003 open
RECTIFIER 1 Distribution
AC / DC Converter
Active communication between RECT 1 Load
and RECT 2 Battery 1
Q001 T001
Q003
Q003 closed
RECTIFIER 2
AC / DC Converter
Battery 2
Float charge battery 2
18
DC UPS Systems Voltage Window
Distribution
5V 17V
Voltage Window:
RECTIFIER Load
AC / DC Converter 195-230V
Distribution
5V 17V
Voltage Window:
RECTIFIER Load
AC / DC Converter 195-230V
Distribution
5V 17V
Voltage Window:
RECTIFIER Load
AC / DC Converter 195-230V
Distribution
5V 17V
Voltage Window:
RECTIFIER Load
AC / DC Converter 195-230V
RECTIFIER 1 Distribution
AC / DC Converter
Load
Battery 1
Q001 T001
Q003
23
DC UPS Systems Redundant
Load Voltage control
Q001 T001 Q003
Distribution
Load
RECTIFIER 1
AC / DC Converter
Battery 1
RECTIFIER 2
AC / DC Converter
Battery 2
24
AC Single Unit Configuration
Bypass Input
Manual Bypass Switch
25
AC Redundant System Configuration
Bypass Input
UPS Module B
50 %
Rectifier Input Secured Load Bus
Module B
UPS Module A
50 %
Rectifier Input
Module A
26
Features & Benefits
Parallel / Redundant System
Features Benefits
No master/slave system All systems can work as masters. Possible to
switch individual units OFF for service.
Bus system for communication Two control links between each unit
Priority control The system will stay in the highest possible
operational mode. The system will save battery
capacity as long as enough energy can be taken
from the mains.
Active load sharing Each unit takes the same percentage of the
actual load
Up to four units can be switched in parallel For redundancy or power increase
Masterlogic for parallel coordination Disabling of parallel communication if one unit is
disconnected / coupling switch open
Independent batteries for each unit Avoids the danger of a single battery acting as a
common failure point
27
AC Full Dual System Configuration
Bypass Input
Module B
UPS Module B
Bypass Input
Module A
UPS Module A
28
DC System with Stand-alone Inverter
DC Secured
Inverter Module
Load Bus
Inverter
Static Switch
Battery
DC Loads
29
DC Detailed Single Line Wiring
Diagram
Q004
Rectifier X002
B+, B-
A030
T001 L001 Q003
X001 Q001 F026 V015 X004
Mains Load
L1, L2, L3 L+, L-
PE
Isolation
Fuse Fuse Fuse
Fuse
Transformer
E001...
Fan
Control
A050... Speed monitored heavy duty fans
PSU AC
A071 INTERFACE / PSU PSU DC
30
Traditional UPS Detailed Single Line
Bypass
Wiring Diagram
Isolation Battery Choke
Inverter
Transformer
Static
Switch
Rectifier
Isolation Rectifier Inverter
Transformer Isolation
Transformer
31
Traditional UPS detailed Single Line
Wiring Diagram
Segregated Bypass Panel
32
Constructional Details
33
PFC UPS Detailed Single Line Wiring
Diagram
Option:
Bypass
Isolation
Transformer
Option:
Input Static
Isolation Switch
Transformer
Option:
Inverter
Isolation
Transformer
PFC
Rectifier &
PWM
Inverter
Modules
34
PFC UPS Constructional Details
Modular, pluggable 20kVA power modules
Small footprint
35
Rectifier 6-Pulse Configuration
+
o
0 30o
DC-Load/Inverter
+
Mains
Mains current
distortion ~28% -
Characteristics:
Input isolation transformer with 30 phase shift
Full wave 6-pulse thyristor bridge
LC smoothing filter
uP driven control loop
36
Rectifier 6-Pulse Harmonics
Order of Harm. Current
Harmonics % of total load 6-pulse Thyristor Controlled
1 100
3 0
5 20 30
7 13.5
9 0 25
11 7.7 % of full load
13 6.2 20
17 4.5
19 3.9 15
23 3
25 2.7 10
29 2.2
31 2 5
35 1.6
37 1.4 0
41 1.2
THD
3
5
7
9
11
13
17
19
23
25
29
31
35
37
41
43
47
49
43 1.1
47 1
49 0.9 Harmonics
THD 27.4
37
Rectifier 6-Pulse Harmonics
Voltage L1 to L2
Current L1
Current L2
Current L3
38
Rectifier 6-Pulse
Diesel Generator Sizing
Load factor vs distortion for 6-pulse loads
18
40%
16
%
n 35%
14 tio
V o lta g e d isto rtio n %
tor
is
12 n td 30%
r re
10 Cu 25%
8 20%
6
5%
4
2
0
0 +/- 30% 50 100
Generator load % 39
Rectifier 12-Pulse Configuration
+
+ DC-Load
o Inverter
0
o
0
-
Mains
o
30
Mains current
distortion ~12% +
Characteristics:
Input isolation transformer with 0 and 30 phase shift
2 x full wave 6-pulse thyristor bridges coupled with 30 phase shift
LC smoothing filter
uP driven control loop with active load sharing 40
Rectifier 12-Pulse Harmonics
Order of Harm. Current
Harmonics % of total load 12-pulse Thyristor Controlled
1 100
3 0
5 3 14
7 2
9 0 12
11 7,7 % of total current
13 6,2
10
17 0,3 8
19 0,2
23 3 6
25 2,7
29 0,1 4
31 0,1
2
35 1,6
37 1,4 0
41 0
3
5
7
9
11
13
17
19
23
25
29
31
35
37
41
43
47
49
THD
43 0
47 1
49 0,9 Harmonics
THD 11,6
41
Rectifier 12-Pulse Harmonics
Voltage L1 to L2
Current L1
Current L2
Current L3
14
%
20%
n
12
tio
Voltage distortion %
or
ist
td
10 15%
n
rre
8 Cu
10%
6
5%
4
0
0 50 +/- 70% 100
Generator load %
43
How can the Harmonic Current
be reduced ?
DC Input from
Rectifier
and/or Battery
+ Output
-
Characteristics:
Pulse Width Modulation (PWM) with >2kHz carrier frequency
IGBT Insulated Gate Bipolar Transistor switching-bridges
Linear inverter isolation transformer with connected sine wave filter
Fast control loop and digital monitoring
45
Inverter Performance
Inverter Loadprofile
120
100
80
kVA [%]
60 kVA [%]
40 Full rating
20
0
0
0.2
0.4
0.6
0.8
0.8
0.6
0.4
0.2
0
lagging leading
Powerfactor (cos )
46
Inverter Performance
120
Outputvoltage [%]
100
80
Inverter
60 Constant
U [%]
40 Current
20
0
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
Inverter Output Current [%]
47
Inverter Performance
120
Outputvoltage [%]
100
80
Inverter
60 U [%]
40
20
0
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
Inverter Outputcurrent [%]
48
PFC UPS Topology
Characteristics:
20kVA Power Modules for Rectifier- and Inverter Part
Battery Charger with very low voltage ripple
49
PFC UPS Topology
Normal Operation
Battery Operation
1 x 400VDC
Characteristics:
Power Factor Correction (PFC) rectifier with THDi < 5% and PF > 0.96
High efficiency with transformerless topology
Full Digital Signal Processing (DSP)
50
Upstream Supply Set-up
Source 1 Source 2
Tie-up
Bus 1 Bus 2
UPS
51
Downstream Distribution Set-up
UPS 1 UPS 2
Tie-up
52
UPS Load Types
Linear Loads
- Sinusoidal input current / no harmonics feed-back
- Traditional loads and power factor corrected (PFC) SMPS loads
- Single- or dual inputs
PFC
AC Input 1
PFC Linear Load with dual inputs
AC Input 2
53
UPS Load Types
Non-linear Loads
- Distorted input current with high crest factor
- Non power factor corrected SMPS loads
- Single- or dual inputs
54
UPS Load Types - Sizing
Power Factor:
The power factor PF is the ratio
between the active power P and the PF = P (W) / S (VA)
apparent power S
cosine :
The cosine is the displacement factor
between the line voltage and the current.
The PF and the cosine are only equal with a pure Sine wave
55
UPS Load Types - Calculation
Specification:
Input voltage = 230 VAC
Input current = 3,8 A
Output power = 400 W PWM
Efficiency = 0,77
Crest factor = 3.5
Inrush current = 24 A
Calculation:
Apparent input power: S = 230V x 3,8A = 874 VA
Real input power: P = 400W / 0,77 = 520 W
Power Factor: PF = P / S = 520W / 874VA = 0,6
Peak input current = 3,8A x 3,5 = 13,3 A
56
UPS Load Types - Calculation
90 270
Displacement 0,6
90 270
Displacement = 0
cosphi = 1
60
Batteries
61
Batteries
62
Batteries
Battery Installation
1 2 108
+ - + - + -
String 1
+ - + - + -
String 2
63
DC-Voltage Range
& applicable number of cells
UPS Voltage Range Battery Type
for standard Ni-CD Lead-Acid Sealed
Battery applications
Nominal with AC output
Voltage (VDC) voltage in max.V/c max. V/c max. V/c
tolerance +/-1% 1.6 2.4 2.33
(minimum values)
65
Batteries
Temperature Compensation
Temperature compensated
charging helps to minimise the
negative impact of elevated
temperatures
66
Capacity of Lead-Acid / NiCd-Batteries
in relationship to the temperature
67
Batteries Key factors
The nominal capacity is defined as follows:
For lead acid batteries = At 10 hours discharge time, a discharge end voltage of 1.80V/cell and at 20C
For NiCd batteries = At 5 hours discharge time, a discharge end voltage of 1.00V/cell and at 20C
The battery capacity cannot be recalculated linear over the respective discharging time.
If the discharging time is lower, then the capacity to be drawn from a battery is also lower.
If the discharge end voltage is lower, then the capacity to be drawn from a battery is higher.
Higher temperatures on lead acid batteries will result in higher capacities to be available from the
battery, but will significantly reduce their lifetime.
The available capacity and the aging of a lead acid battery are mainly influenced by the battery temperature.
Generally, the lifetime reduces by 50% if the battery temperature of sealed lead acid batteries increases by 10C
(taken from the reference temperature of 20C).
For lead acid batteries, the tested capacity must be at least 95% of the nominal capacity for the 1st cycle test and
must be 100% after a maximum number of 5 cycle tests.
For NiCd batteries, the tested capacity must be 95% of the nominal capacity after the 5th cycle test.
The factory test procedures are given in the applicable standards IEC60896 for lead acid batteries, and IEC60623
for NiCd batteries.
68
Batteries Standards
Safety requirements for battery rooms acc. to VDE 0510 part 2 or EN 50272-2
69
Battery Configurations
Common Batteries
Mains +
Load
Mains Load
+
Short-circuit
70
Battery Configurations
Individual Batteries
Mains +
Load
Mains Load
+
Short-circuit
71
Built in Battery Capacity Test
Features:
UBAT Full discharge cycle
Rectifier is kept on stand-by for safety
Boost Charge Voltage Level
Automatic recharge (float- or boost charge)
Time
Recharge Time on Boost
Battery Backup Time
Recharge Time on Float Charge
72
Built in Battery Monitoring and
Testing Advanced Battery Monitor
UBAT
= Expected discharge curves
Features:
Monitored discharge with reference data
VBAT at 25% of Displaying actual backup time
expected Battery back-
Ex. 2 Ex. 1 up time
Automated periodical partial battery test
VBAT at 50% of expected
Battery back-up time
At 10% load
At 10% load
Expected battery
Load = 100% 90% 75% 50% 10% back-up time
Example 1.: Battery weak: VBAT falls below VBAT 25% time before 25% of the time is reached
Example 2.: Battery defective: VBAT falls below VBAT 50% time before 25% of the time is reached
73
Single Cell Battery Management
System GBMS
Features:
Single Cell Voltage / Resistance Monitoring and Recording
WEB Based Front End for remote monitoring
Single Cell Equalize Charging
Monitored Discharge Testing
74
Features & Benefits Rectifier
FEATURES BENEFITS
75
Traditional Man Machine Interface
OPERATING STATUS
INDICATION OPERATION DISPLAY UNIT
normal operation
ON ON
OFF OFF GUTOR load power 50%
7 8 9
ON
OFF
SYSTEM MAINS
VOLTAGE
BATTERY
VOLTAGE
OUTPUT
VOLTAGE
ON
4 5 6
MAINS BATTERY OUTPUT
CURRENT CURRENT CURRENT
OFF
1 2 3
INVERTER OUTPUT
EA EN CURRENT FREQ.
LAMP
ON
TEST 0
OFF
RECT. MAINS FAULT BATTERY OPERATION INVERTER FAULT BYPASS MAINS FAULT OVERTEMPERATURE OPTION
RECT. FAILURE BATTERY DISCHARGED OVERLOAD INV/BYPASS MANUAL BYPASS ON FAN FAILURE OPTION
DC OUT OF TOLERANCE BATTERY DISCONNECTED INVERTER FUSE BLOWN EN INHIBITED POWER SUPPLY FAULT OPTION
ALARM INDICATION
76
Operator Access
"OPERATIONAL" SECTION
1 2 0 0
INVERTER
CURRENT
PASS-WORD
protected "ALARM" "LOG-ALARM
"OPERATIONAL SECTION SECTION
PARAMETER"
SECTION List of present Event Logger
"CALIBRATION "GENES
SECTION SECTION alarms with
User menu
Time Stamps
Factory settings Settings
77
PFC UPS Man Machine Interface
Normal operation
No r ma l O p er at i on ESC
Battery operation F lo a t c ha rg e
L o ad 8 0 % C hr g 90 % ?
Bypass operation
4 1 0V i n 4 01 V ou t 5 0H z
Common Alarm
ON OFF
Rectifier Inverter
Mains
Output
Input
Q001 T001 T101 T301 T401 K402 Q611
SBS
Q601
Q401
Float charge
Q691
Bypass
Input
Q501 T501 Q502
78
PFC UPS Operator Access
"OPERATIONAL" SECTION SERVICE-PORT" SECTION
79
Networking / Remote Monitoring
UPS System
Browser
Network Client
with WEB Browser
80
UPS - Communication Facilities
81
Features & Benefits
Traditional UPS System
FEATURES BENEFITS
High Inverter overload capability 1.5 x Inom for 60 s
1.25 x Inom for 10 min
Optionally up to 30 min
Short-circuit: 200% for 100 ms
100% asymmetric load capability for 3-phase Unbalanced loading acceptable
systems
Sustained short-circuit proof No internal damage in case of a fault in the
downstream distribution
Galvanic isolation between Input / DC branch / Throughout galvanic isolation for a high
Output degree of safety and immunity
Static switch without bridging contactors Fast transfer / No tear and wear
Flexible sizing of power modules Rectifier: for higher charge current / DC loads
Inverter: for interruption of bigger fuses
N+1 two speed cooling fans with RPM Each fan has its own built-in monitoring
monitoring circuit.
Manual Bypass Switch with 3 positions Possibility to isolate & test the UPS system for
(make-before-break) service without disturbing the Load
82
Features & Benefits
Traditional UPS System
FEATURES BENEFITS
Digital processing and setting of all parameters Transparent system operation, better control
via keypad on the front panel. over system functions.
Password protected access Long-term stability
Monitoring of all parameters on the front Precise fault diagnosis
panel display and / or via interface with Remote monitoring
MODBUS- or WEB Protocol WEB Solution: No additional SW required
Alarm- and event logger, with a date and time- Precise fault diagnosis
stamped event log memory 250 events capacity for AC Units
Redundant internal power supply units for the Secures UPS availability in the case of an
control electronics internal power supply failure.
One power supply is supplied from mains and
one is supplied from DC (battery).
Advanced Battery Monitoring & test Battery test with the actual load but with
reference to original discharge data
Battery capacity test Controlled discharge of battery.
83
Features & Benefits
PFC UPS System
FEATURES BENEFITS
PFC Rectifier topology Sinusoidal input current & power factor > 0.96
High Inverter overload capability 1.5 x Inom for 60 s
1.25 x Inom for 10 min
Short-circuit: 230% for 60 ms
100% asymmetric load capability for 3-phase Unbalanced loading acceptable
systems
Sustained short-circuit proof No internal damage in case of a fault in the
downstream distribution
Galvanic isolation between Input / DC branch / Throughout galvanic isolation for a high
Output with optional integrated transformers degree of safety and immunity
Standardised 20kVA pluggable Power Reduced spare parts stock
Modules for rectifier & inverter function Excellent interchange-ability
N+1 two-speed cooling fans with RPM Each fan has its own built-in monitoring
monitoring circuit.
Manual Bypass Switch with 3 positions Possibility to isolate & test the UPS system for
(make-before-break) service without disturbing the Load
84
Features & Benefits
PFC UPS System
FEATURES BENEFITS
Full Digital Signal Processing (DSP) Long-term stability
Controlled system monitoring & configuration Transparent system operation, better control
through Service Port over system functions & configuration
Monitoring of all parameters on the front Precise fault diagnosis
panel display and / or via interface with Remote monitoring
MODBUS- or WEB Protocol WEB Solution: No additional SW required
Alarm- and event logger, with a date and time- Precise fault diagnosis
stamped event log memory
Distributed internal power supply units for the Secures UPS availability in the case of an
control electronics internal power supply failure
Advanced Battery Monitoring & test Battery test with the actual load but with
reference to original discharge data
Battery capacity test Controlled discharge of battery
85
Features & Benefits
Enclosures
FEATURES BENEFITS
Steel cabinet, standard IP20 outside Triple-hinged doors
IP20 with open doors Safe operation with the front doors open
Option of up to IP52 Protection against dropping water from top
and against dust.
Safety connection panel for total electrical The UPS-part can be totally isolated for safe
isolation of the UPS section maintenance
86
Standards
ISO 9001 Quality System
87
Standards for Industrial UPS UL / FCC
UL 1778 Uninterruptible Power Supply Equipment
- UPS
- Inverter
- Battery Protection
- (Rectifier)
UL 67 Panelboards
- AC & DC Distribution
88
Standards for Industrial UPS
IEEE / NEMA
IEEE 519 Recommended Practices and Requirements for Harmonic
Control in Electrical Power Systems
89
Conformity
90
THE FOCUS OF OUR ATTENTION
Our Customers
-
The Focus of our Attention