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A Study On Transformerless On-Line UPS
A Study On Transformerless On-Line UPS
( )
2009
A Study on Transformerless On-line UPS
with High Performance
ABSTRACT
power factor collection and regulates a constant dc-link voltage. The battery
charger/discharger eliminates the need for the transformer and the increase of the
number of battery and supplies the power demanded by the load to the dc-link
capacitor in the event of the input power failure or abrupt decrease of the input
voltage. The inverter provides a regulated sinusoidal output voltage to the load
and limits the output current under an impulsive load. By utilizing the battery
system is improved and the size, weight, and cost of the system are significantly
reduced. New control algorithms of the rectifier, the charger/discharger, and the
inverter are proposed. The proposed adaptive gain control algorithms of the
the UPS.
For each UPS, experimental results show the performances of the proposed
UPSs. Also, the experimental results show the systems have good transient and
1 Introduction 1
5 Conclusions 92
References
.. 96
List of Figure Captions
1.1 The operation of the typical off-line UPS
1.2 The operation of the typical on-line UPS
1.3 Conventional single- to single-phase on-line UPS
Introduction
1.1 Background
Sources that produce these disturbances are very diverse. Overvoltage may be
caused by sudden decreases in the system load. Undervoltage may be caused by
overload conditions, by start of induction motors, or for may other reasons.
Occasional large voltage spike may be a result of switching in or out of power
factor correction capacitors, power lines, or even such things as
pump/compressor motors in the vicinity. Chopping of the voltage waveform may
be caused by ac-to-dc line-frequency thyristor converters. The voltage
harmonics may be caused by a variety of sources. These include magnetic
saturation of power system transformers as well as the harmonic currents
injected by power electronic loads. These harmonic currents flowing through the
ac system impedances result in harmonic voltages. Electromagnetic interference
is produced by most power electronics equipment due to rapid switching of
voltages and currents.
For supplying very critical loads such as computers used for controlling
important processes, some medical equipment, and the like, it may be necessary
to use uninterrupted power supplies (UPSs). These are used to supply clean and
uninterrupted high quality power to critical loads. Generally, an UPS system
requires the regulated sinusoidal output voltage with low total-harmonic-
distortion (THD) that is independent from the changes in the input voltage or in
the load, low transient response time from on-line mode to back-up mode and
vice versa, low THD sinusoidal input current and unity power factor, high
reliability, high efficiency, low cost, low weight, and small size, etc.
In accordance with the topology or configuration, UPS can be classified as
off-line, line-interactive, and on-line UPS [1]-[29]. In an off-line UPS, the load
is powered directly by the input power and the backup power circuitry is only
invoked when the utility power fail. A line-interactive UPS maintains the
inverter in line and redirects the batterys dc current path from the normal
charging mode to supplying current when power is lost. An on-line UPS uses a
double conversion method of accepting ac input, rectifying to DC for passing
through the battery, then inverting back to ac for powering the protected
equipment.
Fig 1.1 shows the operation of the typical off-line UPS. Off-line UPS is now
the most commonly used technology for protecting PCs. In the normal mode, the
load is supplied by the power line as shown in Fig. 1.3. In the event of a power
problem (outage, voltage sags or spikes), the UPS transfers the load to the
batteries to supply stabilized power. Off-line UPS is very economical on account
of the small number of components used. However, off-line UPS is only used for
small power due to some disadvantage. One of them is transfer time. The typical
transfer time for an off-line UPS is 2-10 milliseconds. Therefore, the power
supply of the connected equipments can support longer hold time than 4
milliseconds. Another problem is in situations where there are frequent
disturbances. The principle of sequential operation (on main/on battery) behind
the off-line UPS makes it unsuitable for use in situations where there are
frequent disturbances. It is extremely likely that the UPS will keep switching to
the batteries without being able to recharge them. At the end of the battery
backup time, the UPS will shutdown and it will not be possible to start it again,
unless the disturbances cease.
The operational block diagram of the typical on-line UPS is shown in Fig. 1.2.
The on-line UPS is generally preferred due to the wide tolerance of the input
voltage variation, the precise regulation of output voltage, and high reliability of
the system [1]. As shown in Fig. 1.1, on-line UPS consist of a rectifier/charger,
an inverter, a battery bank, and so on. Fig. 1.2 shows the operation of the typical
on-line UPS. The rectifier/charger is connected to the main ac line and the
inverter is connected to the load. When the UPS operates on normal AC power,
the rectifier/charger provides the power to the inverter and acts a charger for the
battery. Under over/under voltage or power loss, the required power of the
inverter is provides from the battery. Due to the specifications limiting the
maximum harmonics that are allowed to be generated in the ac line, the recent
trend of the rectifier/charger is to incorporate a high power factor corrector to
minimize the generated line harmonics. For additional reliability, the power line
itself or the additional power source is used as a backup to the UPS, and a static
transfer switch transfers the load from the UPS to the power line as shown in
third figure of Fig. 1.2. By carrying continuous double conversion, the on-line
UPS significantly attenuates electrical disturbances, which might otherwise
damage connected equipments. This possibility is not available on off-line UPS,
which explains why on-line UPS always deliver better filtering capacity than
off-line UPS.
A conventional single-phase on-line UPS consists of a full-bridge rectifier, a
battery set, a full-bridge inverter, two transformers, and a bypass circuit, as
shown in Fig. 1.3. The rectifier converts the input voltage into the dc-link
voltage with pulse-width modulation (PWM) strategy and acts as a charger for
the battery. On the other hand, the inverter converts the dc-link voltage into the
output voltage with PWM strategy. Therefore, the regulated sinusoidal output
voltage can be achieved. The battery which is connected in parallel with the dc-
link capacitor is charged when the input voltage is in the normal condition and is
discharged when loss of the input power or abrupt decrease of the input voltage
occurs. For proper operation of the bypass circuit or ensuring the human safety,
an isolated transformer at the output side is necessary. Also, an isolated
transformer at the input side is employed to reduce the number of the battery
which is placed in parallel with the dc-link capacitor. However, since the
transformers are operated at line frequency, several drawbacks such as large size
and heavy weight exist. Recently, a three-leg-type converter has been proposed
to improve the performance of the UPS in the literature [7]-[13]. The most
outstanding feature is that the power losses can be reduced by using a common
leg for both the PWM rectifier and the PWM inverter. However, the drawbacks
caused by the transformer are still remained. An approach which is to add one
more phase leg in parallel with the dc-link capacitor is introduced in the
literature [14]-[16]. By using bidirectional dc-dc converter, the UPS can be
implemented without transformer. Hence, the UPS has the advantages such as
the improvement of the conversion efficiency, the reduction of volumetric size
and weight. However, the unbalance problem between the upper and lower dc-
link voltage can be occurred.
Line Running on normal AC power
Load
Rectifier/charger Inverter
Battery
Rectifier/charger Inverter
Battery
Rectifier/charger Inverter
Battery
Line
Over/Under voltage, or power loss Load
Rectifier/charger Inverter
Battery
Rectifier/charger Inverter
Battery
This thesis is divided into three parts. One is a single- to single-phase on-line
UPS (chapter 2). Another is a three- to single-phase on-line UPS (chapter 3). The
third is a three- to three-phase on-line UPS (chapter 4).
In chapter 2, a high performance single-phase transformerless on-line UPS is
proposed. The proposed UPS is composed of a four-leg-type converter witch
operates as a rectifier, a battery charger/discharger, and an inverter. The rectifier
has the capability of power factor correction and regulates a constant dc-link
voltage. The battery charger/discharger eliminates the need for the transformer
and the increase of the number of battery and supplies the power demanded by
the load to the dc-link capacitor in the event of the input power failure or abrupt
decrease of the input voltage. The inverter provides a regulated sinusoidal output
voltage to the load and limits the output current under an impulsive load. The
control of the dc-link voltage enhances the transient response of the output
voltage and the utilization of the input power. By utilizing the battery
charger/discharger, the overall efficiency of the system is improved and the size,
weight, and cost of the system are significantly reduced. Experimental results
obtained with a 3kVA prototype show a normal efficiency of over 95.6% and an
input power factor of over 99.7%.
In chapter 3, a high performance three-phase to single-phase on-line UPS is
proposed. The proposed UPS is composed of five legs: three legs are a three-
phase rectifier, one leg is a battery charger/discharger, and the other is a single-
phase inverter. New control algorithms of the rectifier, the charger/discharger,
and the inverter are proposed. The proposed algorithms of the rectifier and the
charger/discharger improve dynamic performance at step load change.
Additionally, experimental results obtained with a 10kVA prototype verify the
performance.
In chapter 4, a transformerless three-phase on-line UPS is proposed. The
proposed UPS is composed of a three-phase rectifier, a three-phase inverter, and
a battery charger/discharger. Since both neutral lines of the input and output
voltages are connected at the center of the dc-link, the need for an isolation
transformer is eliminated and the size, weight, and cost of the system are
significantly reduced. Additionally, new control algorithms of the inverter are
proposed. Experimental results obtained with a 10kVA prototype verify the
performance.
In chapter 5, the conclusions are given.
Chapter 2
Transformerless Single- to
Single-Phase On-Line UPS
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 1a
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 2a
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 3a
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 4a
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 1b
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 2b
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 3b
S1 S3 S5 S7
is ib io
Cd Vd
Ls Lb Lo
Vb
vs vo Co load
S2 S4 S6 S8
Mode 4b
dis
vs Ls 0 (2.1)
dt
where vs and is are the input voltage and current, respectively, and Ls is the
inductance of the input inductor. In the positive cycle of the input voltage, when
the switches S1 and S6 are turned on (Mode 2), the stored energy in the inductor
is transferred to the dc-link capacitor Cd. As in the same manner, in the negative
cycle, the switches S2 and S5 are turned on (Mode 4) to release the stored energy
to the dc-link capacitor Cd. Thus, the voltage equation is achieved as
dis
vs Ls Vd sgn(is ) 0 (2.2)
dt
where Vd is the dc-link voltage of the capacitor and sgn(·) denotes the sign of (·).
It is noted that sgn(vs) = sgn(is) under the unity power factor control. Depending
on the duty ratio D1 of the switch S1 and D2 of the switch S2, the average
inductor voltage over a switching period Ts gives the input current variation is
as follows:
is
vs D1 vs Vd 1 D1 Ls vs 0 (2.3)
Ts
is
vs D2 vs Vd 1 D2 Ls vs 0. (2.4)
Ts
D Dn Dc (2.5)
which is composed of a nominal duty ratio Dn and a controlled duty ratio Dc.
Then, the nominal duty ratio Dn and the controlled duty ratio Dc can be
represented as
Vs
Dn 1 sin t (2.6)
Vd
Ls is
Dc (2.7)
Vd Ts
where Vs and are the maximum input voltage and angular frequency,
respectively. To force the current is of the rectifier to track its current command
is*, a proportional and integral (PI) current controller is utilized as follows:
Dc k p ie ki ie dt (2.8)
where kp and ki are the proportional and integral gains, respectively, and the
current error ier is given by
ie is * is . (2.9)
Fig. 2.3 shows the proposed unity power factor controller of the rectifier circuit.
To regulate the dc-link voltage, a PI-type voltage controller is used. The output
Dc of the current controller only generates the inductor voltage drop required to
maintain the sinusoidal input current. With the addition of the nominal Dn to the
rectifier, which is originally a nonlinear dynamic system, the relation between
the input Dc and output |is| of the rectifier becomes a first-order linear dynamic
system (2.7) with easy controllability. Thus, the addition of the nominal duty Dn
relaxes the burden of the current controller and improves the input current
waveform.
With loss of the input power, the magnetic contactor (MC) is opened and the
rectifier is disabled. The power demanded by the load is supplied from the
battery. The common leg is switched at the line frequency synchronized to the
input voltage. Upon the return of the input power, the rectifier performs back to
the unity power factor control. The output voltage is slowly adjusted to be in
phase with the line voltage using a phase-locked loop. Once synchronism is
achieved and the magnitude of the input voltage is in the working range, the
UPS starts to operate in the on-line mode while the MC connects the line to the
rectifier.
Fig. 2.4 shows the control block diagram of the inverter. The output voltage is
regulated through the PI-type voltage controller. According to the absolute value
of the output current |io|, the proposed current limiter consists of two modes: a
normal mode and a current limit mode. The reference value of the overcurrent
(OC) is greater than the reference value of the current limit (CL). When the
absolute value of the output current |io| is lower than the reference value of
current limit, the inverter operates in the normal mode. In this mode, the duty of
the inverter is determined as
where m is the output of the voltage controller and sin_ref is the sine reference
value obtained from the sine lookup table. Due to the sinusoidal reference
sin_ref, the inverter generates sinusoidal output voltage in the normal mode.
When the impulsive load such as a capacitive rectifier load is attached, the
inverter supplies excessive current to charge the load capacitor. This excessive
current may damage the switching devices in the inverter. If the inverter output
voltage is forced to have smaller amplitude, it is possible to limit the power
delivered to a load. Thus, the duty of the inverter leg in the current limit mode is
determined by modifying sin_ref to limit the amplitude of the output current in
the proposed UPS. When the detected output current |io| is higher than or equal
to the reference value of overcurrent, the inverter operates in a current limit
mode and sin_limit becomes zero. Hence, the output voltage is gradually
increased by the proportional gain after becoming almost zero. Until the polarity
of the output voltage is changed, the output current is controlled under the
reference value of the current limit and the capacitor of the load is charged to
some degree. When the output current |io| is detected between CL and OC, the
present value of sin_ref is stored to sin_limit. After one control period, sin_ref is
compared to the sin_limit according to the polarity of the output voltage. If
sin_ref is greater than sin_limit in the positive output voltage, sin_ref is adjusted
with proportional gain depending on the difference between |io| and CL. Then,
the capacitor of the load is charged to some degree without increasing the
current. The above process is repeated several times until sin_limit is greater
than sin_ref.
Similarly, when sin_ref is less than sin_limit in the negative output voltage,
sin_ref is adjusted with proportional gain until sin_limit is less than sin_ref.
When the capacitor is fully charged in some cycles, no further impulsive current
flows through the inverter, and the inverter operates in the normal mode. The
output voltage is recovered to its rated value. The detailed algorithm of the
current limiter is shown in Fig. 2.5. As the p-type controller is used, various
impulsive loads can be attached to the system. The system will recover its rated
output value immediately.
vs Vs sin t
io
sin t
D
Vo*
m m sin t
Vo
sin_ref = sin t
Yes sin_limit = 0
|io| OC
mode = current limit
No
No
No Yes Yes
D = m × sin_ref
dib
Vd Lb Vb 0 (2.11)
dt
where Vb and ib are the battery voltage and current, respectively, and Lb is the
inductance of the battery inductor. On the other hand, when the switch S3 is
turned off, the inductor current ib is freewheeling through the body diode of the
switch S4. Thus, the voltage equation is achieved as
dib
Lb Vb 0. (2.12)
dt
Depending on the duty ratio D3 of the switch S3, the average inductor voltage
over a switching period Ts gives the battery current variation ib as follows:
ib
Vd Vb D3 Vb 1 D3 Lb . (2.13)
Ts
Vb Lb ib
D3 Dn Dc (2.14)
Vd Vd Ts
which is composed of a nominal duty ratio Dn and a controlled duty ratio Dc. To
force the current ib of the battery to track its current command ib*, a PI-type
current controller is utilized as follows:
Dc k p ie ki ie dt (2.15)
where kp and ki are the proportional and integral gains, respectively, and the
current error ie is given by
ie ib* ib . (2.16)
dib
Vb Lb 0. (2.17)
dt
On the other hand, when switch S4 is turned off, the stored energy in the inductor
Lb is supplied to the dc-link capacitor Cd through the body diode of the switch S3.
Thus, the voltage equation is achieved as
dib
Vb Lb Vd 0. (2.18)
dt
Depending on the duty ratio D4 of the switch S4, the average inductor voltage
over a switching period Ts gives the following battery current variation ib:
ib
Vb D4 Vb Vd 1 D4 Lb . (2.19)
Ts
Vb Lb ib
D4 Dn Dc 1 (2.20)
Vd Vd Ts
which is composed of a nominal duty ratio Dn and a controlled duty ratio Dc. To
force the current ib of the battery to track its current command ib*, a PI-type
current controller is utilized as in (2.15). Fig. 2.6(b) shows the control block
diagram of the battery charger/discharger in the discharging mode.
In the event of abrupt decrease of the input voltage, the excessive current
flows through the rectifier. This excessive current may damage the switching
devices in the rectifier. Hence, the MC is opened and the power demanded by
the load is supplied from the battery in the conventional UPS. It results in the
low utilization of the input power and frequent use of the battery. In addition,
since the UPS must instantly compensate for the required dc-link voltage to
minimize the transient effect on the output voltage, the fast detection technique
of the input voltage is required. To overcome these problems, the control
technique of the dc-link voltage is employed in the proposed UPS. Fig. 2.7
shows the variation of the dc-link voltage according to the input power condition.
When the loss of the input power or abrupt decrease of the input voltage occurs,
the dc-link voltage is instantly decreased. If the dc-link voltage arrives at the
starting voltage of the discharging Vd_start, the battery charger/discharger operates
as the discharging mode which steps up the battery voltage to the dc-link voltage.
The dc-link voltage is regulated to be the output voltage of the discharging
Vd_dchg. The rectifier is disabled at the loss of the input power and supplies a
limited current, which is less than the rated current, at the abrupt decrease of the
input voltage. Upon the return of the input power, the rectifier performs back to
the normal unity power factor control and the battery charger/discharger operates
as the charging mode, which steps down the dc-link voltage to the battery
voltage, and the dc-link voltage is regulated to be the output voltage of the
rectifier Vd_pfc.
Since the operation mode of the battery charger/discharger is changed by the
dc-link voltage, the power demanded by the load is supplied by both the input
power and battery power in case of the abrupt decrease of the input voltage. In
addition, if the power demanded by the load is sustained as lower than the power
supplied from the rectifier with the limited current, the power demanded by the
load is supplied from the input power without using the battery power. Hence, by
utilizing the limited current of the rectifier which is lower than the rated current
in the abrupt decrease of the input voltage, the utilization of the input power is
enhanced and the use of the battery power is reduced. Moreover, since the dc-
link voltage is immediately compensated by changing the operation mode of the
battery charger/discharger, the transient effect of the output voltage is minimized
and uninterrupted power is supplied to the load irrespective of the line condition.
Vd
Vd _ pfc
Vd _ dchg
Vd _ start
2Vs
power
(b)
battery charging/
rectifier leg common leg inverter leg
discharging leg
S1 S3 S5 S7
is ichrg io
Cd Vd
MC Ls Lb Lo
vb
vs battery Co vo
S2 S4 S6 S8
load
S1 S2 S3 S4 S5 S6 S7 S8
Gate driver
dsPIC30F3011
rectifier
Vd
control algorithm
vs
is PWM
battery charger/discharger
vb A/D converter pulse generator
control algorithm
ichrg
vo
inverter
io
control algorithm
No Store
Store
negative edge time tn positive edge time tp
No
90° < tn - tp < 220° ?
Yes
Obtain phase
Peak time = +
t90°[k] = tp + (tn - tp)/2
Degree step
= 360° × Tctrl/T
Fig. 2.12. Input voltage and current waveforms of the proposed UPS.
Fig. 2.13. Compensated output voltage and current under impulsive load.
Fig. 2.14. Voltage and current waveforms according the load change.
(a) Load step response from 0% to 100%.
(b) Load step response from 100% to 0%.
TABLE 2.1
PARAMETERS OF DSPIC30F3011 PROCESSOR
Parameters Value
Architecture 16-bit
CPU speed 30MIPS
Program Memory 24 kB
RAM 1024 bytes
I/O pins 30
Pin counts 40
A/D converters 10bits, 9 channels
Motor control PWM channels 6 channels
TABLE 2.2
SYSTEM PARAMETERS OF THE PROTOTYPE
Transformerless Three- to
Single-Phase On-Line UPS
Fig. 3.1 shows the configuration of the proposed on-line UPS. The proposed
UPS is composed of a rectifier, a charger/discharger, an inverter, and transfer
switches as shown in Fig. 3.1. Three-phase normal ac sources ea, eb, and ec are
connected to the rectifier through a magnetic contactor and a neutral line N is
connected at a center of dc-link capacitors. A single-phase bypass ac source vbps
is connected to an output voltage vo through a bypass switch S11. The bypass ac
source is an independently reserved source of electric energy. In the event of an
internal malfunction of UPS or an overload of the inverter, the power demanded
by the load is directly supplied from the bypass ac source. Since a magnitude of
the output voltage is the same with a rated phase voltage of the normal ac source,
the inverter is designed as a half-bridge type and one side of the output voltage is
connected to the neutral line of the three-phase ac source. Therefore, if the
bypass ac source is unavailable, then the bypass ac source can be replaced with a
phase voltage of the normal ac source without an additional transformer and the
cost is reduced.
When the normal ac input voltage is within the preset tolerance, the UPS
operates in the normal mode. In the normal mode, the thyristor S11 is off-state
and S12 is on-state, respectively. The rectifier boosts the input voltage into the dc-
link voltage Vd with PFC function and the inverter converts Vd into the
sinusoidal output voltage. Since the inverter is the half-bridge type, Vd has to be
higher than a doubled peak value of vo. If the rectifier can provide enough power
to supply the output power, then the charger/discharger operates as a battery
charger. When voltage sag of the normal input source occurs, if the rectifier
cannot supply the output power alone, the charger/discharger operates as a
discharger. The output power is provided by both the rectifier and the discharger.
When the normal ac input source goes outside the preset tolerance, the back-up
mode starts. The rectifier is disabled and the MC is opened. The
charger/discharger operates as the discharger and the output power is totally
supplied from the battery set. In the event of the internal malfunction of UPS or
the overload of the inverter, the bypass mode starts. In the bypass mode, the
thyristor S11 is on-state and S12 is off-state, respectively. The power demanded by
the load is directly supplied from the bypass ac source.
To save the energy stored in the battery set and to increase back-up time, the
rectifier has to operate not only in a very wide input voltage range but also in an
unbalanced input voltage condition. Therefore, each phase current is
independently controlled as shown in Fig. 3.2 and the rectifier with the three-
phase input can be considered as three single-phase half-bridge rectifiers
operating in parallel. The analysis for the a-phase voltage is described, since the
analyses for the others are analogous.
Two switches of each leg are complementarily driven with pulse width
modulation. While the switch S1 is on-state, the voltage equation of the boost
inductor L is obtained as
d Vd
L ia ea (3.1)
dt 2
d Vd
L ia ea . (3.2)
dt 2
Depending on a duty ratio DS1 of the switch S1, the average inductor voltage over
a switching period Ts gives input current variation ia as follows:
Vd Vd ia
ea DS1 ea 1 DS1 L . (3.3)
2 2 Ts
ea L
DS 1 0.5 ia
Vd Vd Ts (3.4)
Dn Dc
where the nominal duty Dn and the controlled duty Dc are represented as
Ea
Dn 0.5 sin t
Vd
(3.5)
L
Dc ia
Vd Ts
The output Dc of the current controller only generates the inductor voltage drop
required to maintain the sinusoidal input current. With the addition of the
nominal duty Dn to the rectifier, which is originally a nonlinear dynamic system,
the relation between Dc and ia of the rectifier becomes a first-order linear
dynamic system (3.5) with easy controllability. Thus, the addition of Dn relaxes
the burden of the current controller and improves the input current waveform. As
shown in Fig. 3.2, the control strategy uses multiple control loops for each leg.
One is an outer voltage loop and the other is an inner current loop. The dc-link
voltage is regulated by the slow outer loop, whereas the inner loop that shapes
the input current is much faster producing a good input power factor.
3.1.2 Adaptive gain control of the rectifier and the discharger
The block diagram for the control of the rectifier is shown in Fig. 3.2. The dc-
link voltage is regulated by slow voltage controller whereas the current
controller that shapes the input current is much faster resulting in a good input
power factor. Under the real load conditions, the output currents are usually
neither sinusoidal nor balanced, and the dc-link capacitors may have voltage
ripples due to the input and output power difference of the UPS. Therefore, the
voltage controller of the rectifier has to be designed to ensure that the input
current command is not affected by this low frequency harmonic ripple. In a
conventional PI voltage controller, the voltage controller is designed slowly with
small proportional gain kp in order to minimize adverse effects on the input
current command. However, small kp usually results in unacceptable variation of
dc-link voltage at step load change from no load to full load or vice versa.
If three-phase input currents of the rectifier are sinusoidal and balanced, then
the input power of the rectifier is nearly dc as 3EaIa/2. However, the output
power of the UPS has a low frequency ripple component. In case of a resistive
load, the instantaneous output power po of the UPS is
po (t ) Vo sin tI o sin t
(3.7)
0.5Vo I o (1 cos 2 t )
where Vo and Io are the peak values of vo and io, respectively. Therefore, the
instantaneous current ic flowing through the dc-link capacitors is
Vo I o
ic (t ) cos 2 t. (3.8)
2Vd
The difference of input and output power of the UPS results in a dc-link voltage
ripple vd expressed as
2 Vo I o
vd (t ) ic (t ) cos 2 t. (3.9)
C d1 Vd Cd1
Therefore, the voltage controller has to be designed to ensure that the input
current command is not affected by vd. In the conventional PI voltage controller,
the controller is utilized as follows:
ki (Vd ) Vd _ pfc Vd dt
where kp(Vd) and ki(Vd) are functions of Vd, and k1, k2, and a are constant values.
As shown in Fig. 3.3(a), when the voltage error (Vd_pfc - Vd) is small, the gain
kp(Vd) is small to improve steady-state performance, whereas when the voltage
error (Vd_pfc - Vd) is large, kp(Vd) is larger than the conventional one to improve
dynamic performance and to reduce voltage variation range. In a similar manner,
the adaptive gain controller can be applied to the integral gain to track dc-link
voltage command quickly. Experimental results show that the proposed adaptive
controller reduces the dc-link voltage variation by more than 50% without
adverse effects on input current command.
Although achieving steady-state and dynamic analyses of this controller are
difficult due to the nonlinearity of gains, its implementation is very simple and
does not require deep knowledge of the circuit and control theory. The practical
guide lines of the control parameters are described as follows. From (3.5), the
proportional gain of the PI current controller (3.6) is obtained as L/VdTs. To
obtain the control parameters of the adaptive gain controller, it may be required
to go through the following procedure. Firstly, the proportional gain in the
conventional PI voltage controller should be determined. Secondly, the
parameter k1 is determined less than the proportional gain in the conventional PI
controller. Thirdly, due to the performance limitation of the processor such as the
microcontroller, the parameter a can not be a floating point number. Therefore,
the parameter a is always selected as 1 due to simplification of calculation.
Finally, the maximum ripple voltage of dc-link Vd,ripple at the step load change is
roughly expected from (3.11) as follows:
where I*a,peak is the peak value of the input current at rated condition. Therefore,
from (3.12), the parameter k2 can be obtained. Since the integral gains are not
tightly related with performance of the UPS and too large integral gains
adversely affect the stability of the rectifier, the integral gains of the current and
voltage controller are set as very small numbers.
When the normal ac source goes outside the tolerance, MC is opened and the
rectifier is disabled. The power demanded by the load is supplied from the
battery set. Once magnitudes of the input voltages enter into the working range
and synchronism is achieved, MC is closed and the rectifier starts to perform
unity power factor control.
p gain
proposed adaptive
gain controller
kp(Vd)
at k1>0, k2>0, a=1
conventional
PI controller kp
k1
voltage error
(a)
Current
reference
proposed adaptive
gain controller
Ia,limit
conventional
PI controller
voltage error
-Ia,limit
(b)
Fig. 3.3. Comparison of proportional gain and current reference with respect to voltage error.
3.1.3 Inverter and charger/discharger control
Fig. 3.4 shows the control block diagram of the inverter with the current
limiter. The operation of the inverter is divided into two modes according to the
absolute value of an output current |io|. When |io| is lower than a current limit
value, the inverter operates in the normal mode. In the normal mode, the duty
ratio of inverter switch S9 is determined as
Vd _ pfc
DS 9 0.5 m sin_ ref (3.13)
Vd
where m is the output of the PI voltage controller and sin_ref is sin t obtained
from a sine look up table. S10 is driven complementarily with S9. If the bypass ac
source is within tolerance, then sin t is synchronized with the bypass ac input
voltage to transfer the power demanded by the load without a break when the
UPS enters the bypass mode. To compensate dc-link voltage variation quickly,
(3.13) includes the feed-forward term Vd. Since the feed-forward control of Vd is
faster than PI control of m, it improves the transient response of the output
voltage at the step load change. Since the current limiter of Fig. 3.5 has similar
operation with that of single- to single-phase on-line UPS, the description about
current-limiter is omitted in this chapter.
When the rectifier becomes unavailable or when the current required by the
load exceeds the output rating of the rectifier, the battery supplies the load power.
In the discharging mode, the switch S7 of the charger/discharger is consistently
turned off and the charger/discharger operates as a conventional boost converter.
To obtain the desired battery voltage and capacity, the battery set is made up
of some cells which are electrically connected in series or a combination of
series and parallel. To charge the battery set at a specific charging rate until the
battery voltage reaches a given end-of-charge voltage or a floating voltage, the
battery charger must be able to limit the charging current to a given rated battery
current Ichrg_limit. When the battery voltage is lower than the floating voltage, the
output of voltage controller is limited to the given rated battery current. Once the
battery voltage reaches the floating voltage, the battery current decreases slowly
and the battery voltage is controlled at the floating voltage.
The control block diagrams of battery charger/discharger are shown in Fig. 3.5.
More detail descriptions of battery charger/discharger are omitted in this chapter
since its operation is similar with that of single- to single-phase on-line UPS.
vbps Vbps sin t
PLL for
inverter
sin t
io Current
0.5
limiter
sin_ref
Voltage m DS 9
Vo *
controller
Vo Vd _ pfc
Vd
Fig. 3.4. Control block diagram of the inverter.
*
Voltage Current ichrg ie Current Dc DS 7
Vbat* controller limiter controller
( DS 8 0)
I chrg _ limit Dn
Vbat ichrg
Vbat
Vd
(a)
*
Voltage ibat ie Current Dc DS 8
Vd *_ dchg controller controller
( DS 7 0)
Dn
Vd ibat
Vbat
1
Vd
(b)
ia
[20A/div.]
ibat
[20A/div.]
vo
[500V/div.]
time[20ms/div.]
(a)
(b)
(c)
Vd
[100V/div.]
ibat
[50A/div.]
io
[50A/div.]
time[20ms/div.]
(d)
Parameters Value
Architecture 16-bit
CPU speed 30MIPS
Program Memory 144 kB
RAM 8192 bytes
Pin counts 64
A/D converters 10bits, 16 channels
Standard PWM channels 8 channels
Motor control PWM channels 6 channels
TABLE 3.2
SYSTEM PARAMETERS OF THE PROTOTYPE
Chapter 4
Transformerless Three- to
Three-Phase On-Line UPS
Fig. 4.2 shows the configuration of the proposed on-line UPS. The proposed
UPS is composed of a rectifier, a charger/discharger, an inverter, and transfer
switches. The UPS has three modes: normal mode, back-up mode, and bypass
mode. In the normal and back-up modes, the thyristor S15, S16, S17 are off-state
and S18, S19, S20 are on-state, respectively. Thus, the power can be transferred
through the inverter. In the event of an internal malfunction of the UPS or an
overload of the inverter, the bypass mode is started. In the bypass mode, the
thyristor S15, S16, S17 are on-state and S18, S19, S20 are off-state, respectively. The
power demanded by the load is directly supplied from the ac input source. Three
parts, which are the rectifier, the charger/discharger, and the inverter, are
independently controlled with PWM strategy. Three-phase ac input voltages vrn,
vsn, and vtn are connected to the rectifier through a magnetic contactor (MC). The
MC is closed while the rectifier is operating. The rectifier regulates the voltage
across the dc-link capacitors Cd1, Cd2 and performs PFC in the normal mode. In
the normal or back-up mode, the inverter provides three sinusoidal output
voltages vun, vvn, and vwn. In order to achieve no transition time at the moment of
mode change from normal to bypass, each inverter output voltage vun, vvn, and
vwn is synchronized with vrn, vsn, and vtn, respectively. With normal dc-link
voltage, the battery charger/discharger is operated as a buck converter which
supplies the energy into the battery set. When the dc-link voltage is
instantaneously decreased, the battery charger/discharger is operated as a boost
converter which steps up the battery voltage to the dc-link voltage.
4.1.1 Inverter control
Vd _ pfc
DS 9 0.5 m sin_ ref (4.1)
Vd
where m is the output of the PI voltage controller and sin_ref is sin t obtained
from PLL. If the input ac source is within a preset tolerance, then sin t is
synchronized with its corresponding input voltage vrn in order to transfer power
to the load without a break when the UPS enters the bypass mode. To reduce
adverse effects from the dc-link voltage ripple, (4.1) includes the feed-forward
term Vd which can be immediately obtained by A/D conversion. Since the feed-
forward control of Vd is faster than PI control of m, it improves a transient
response of the output voltage for dc-link voltage variation occurred at step load
change or at outage of the input source.
Various loads such as linear, nonlinear, single-phase or three-phase loads, and
so on can be attached at the output of the inverter. The nonlinear load such as a
capacitive rectifier in Fig. 4.4 may be the worst case of the loads. When the
capacitive rectifier is attached to the inverter, the inverter of the UPS will deliver
excessive current because the large charging current will flow until the capacitor
of the load is fully charged. This high current is adverse to the switching devices
in the inverter. If the inverter output voltage is forced to have smaller amplitude,
then it is possible to limit the power delivered to the load. International
electrotechnical commission (IEC) has established a standard IEC 62040-3
concerning the method of specifying the performance and test requirements [23],
[39]. According to IEC 62040-3, the nonlinear load as shown in Fig. 4.4 is tested
for impulsive loading. The values of the filter capacitor Cf, the series line resistor
Rs, and the load resistor RL can be calculated according to the IEC 62040-3
guideline.
To comply with IEC 62040-3, a new inverter control technique for impulsive
loading is proposed. Similar to the normal mode of the inverter, the u-phase
analysis is described. Before the capacitive rectifier in Fig. 4.4 is attached to the
inverter, the voltage across Cf is zero. When the capacitive rectifier is attached to
the inverter, the initial short-circuit current can exceed the current-limit value,
since Rs is a very small value. A large transient current spike may occur due to
the stored energy in the output filter capacitor Co of the inverter. However, it is
not necessary to protect this peak short-circuit current, since the duration of the
initial transient is very short. Once the stored energy in Co is dissipated, the large
charging current will flow from the inverter until Cf is fully charged. This high
current adversely affects to the switching devices in the inverter. If the amplitude
of the output voltage is forced to be near the voltage of Cf, then it is possible to
limit the current flowing into the load. To limit this excessive current, the
inverter enters into a current limit mode when |iu| is greater than the current limit
level (CL). The duty of inverter switches in the current limit mode is determined
in a different way from the normal mode. The value of sin_ref is sin t in normal
mode. However, in the current limit mode, it is modified to limit the amplitude
of the output current under CL and the output waveform is deformed. The
detailed algorithm for the proposed current limiter is explained in the flowchart
shown in Fig. 4.5 When the capacitive load is attached, a large current spike
over the over current level (OC) is detected since the stored energy in Co is
dissipated. At the moment, the mode of the inverter goes into the current limit
mode and sin_limit becomes zero. Until the polarity of the output voltage is
changed, the output current is controlled near the current limit level. At some
degree of the next half period, the output current |io| is detected between CL and
OC and the present value of sin_ref is stored to sin_limit. Until sin_limit is
greater than sin_ref, the output current is controlled near CL and the capacitor of
the load is charged to some degree. The above process is repeated several half
periods. When the capacitor of load is fully charged in some cycles, no further
impulsive current flows through the inverter, and the inverter is operated in the
normal mode. The output voltage is recovered to its rated value. The advantage
of this scheme is that it can be implemented with a software program without an
additional hardware. In addition, it has an adjusting ability for different
nonlinear loads such as strong or weak, long or short impulsive loads.
vrn
sin t
iu 0.5
m DS 9
Vun*
Vun Vd _ pfc
Vd
DS11
DS13
vun Cf RL
Rs
vvn Cf RL
Rs
vwn Cf RL
Rs
sin_ref = sin t
Yes sin_limit = 0
|iu| OC
mode = current limit
No
No
No Yes Yes
sin_ref
The rectifier with the three-phase input in Fig. 4.1 can be considered as
three single-phase half-bridge rectifiers operating in parallel. When the input
source goes into the preset working range and the synchronism of phase locked
loop (PLL) is achieved, MC is closed and the rectifier starts to perform the unity
power factor control. When the input power is lost, MC is opened and the
rectifier is disabled. The power demanded by the load is supplied from the
battery set.
If the rectifier can provide power enough to supply the output power, then
the charger/discharger in Fig. 4.1 is operated in a charging mode, otherwise the
charger/discharger is operated in a discharging mode. In the charging mode, the
charger/discharger is operated as a conventional buck converter and the switch
S8 of the battery charger/discharger is consistently turned off. When the rectifier
becomes unavailable or the current required by the load exceeds the output
rating of the rectifier, the battery supplies the load power. In the discharging
mode, the switch S7 of the charger/discharger is consistently turned off and the
charger/discharger is operated as a conventional boost converter. Fig. 4.6 and 4.7
is the control block diagrams of the rectifier and the charger/discharger,
respectively. The detail descriptions of them are omitted in this chapter.
*
ichrg ie Dc DS 7
Vbat*
( DS 8 0)
*
ibat ie Dc DS 8
Vd *_ dchg
( DS 7 0)
Dn
Vd ibat
Vbat
1
Vd
4.2 Experimental Results
(b)
(b)
Fig. 4.9 Major waveforms at the outage and sag of the input source.
(b)
Conclusions
transformerless on-line UPSs. The UPSs are used to improve power source
quality as well as to protect critical loads such as computers, industrial control
systems, communication system, medical equipment, etc, since interruptions of
those systems may result in a substantial financial loss. A conventional on-line
UPS consists of a full-bridge rectifier, a battery set, a full-bridge inverter, two
transformers, and a bypass circuit. For proper operation of the bypass circuit or
ensuring the human safety, an isolated transformer at the output side is necessary.
Also, an isolated transformer at the input side is employed to reduce the number
of the battery which is placed in parallel with the dc-link capacitor. However,
since the transformers are operated at line frequency, several drawbacks such as
large size and heavy weight exist.
This thesis presents three types of on-line UPSs. Three proposed UPSs are
single- to single-phase UPS, three- to three-phase UPS, and three- to three-phase
UPS. Each UPS is composed of a rectifier, a battery charger/discharger, and an
inverter. The rectifier has the capability of power factor collection and regulates
a constant dc-link voltage. The battery charger/discharger eliminates the need for
the transformer and the increase of the number of battery and supplies the power
demanded by the load to the dc-link capacitor in the event of the input power
failure or abrupt decrease of the input voltage. The inverter provides a regulated
sinusoidal output voltage to the load and limits the output current under an
impulsive load. By utilizing the battery charger/discharger and a transformerless
type, the overall efficiency of the system is improved and the size, weight, and
cost of the system are significantly reduced.
Also, this thesis presents new control algorithms for improving the
performance and reliability. New control algorithms of the rectifier, the
charger/discharger, and the inverter are proposed. The proposed adaptive gain
control algorithms of the rectifier and the charger/discharger improve dynamic
performance at step load change. To improve the transient response of the output
voltage at outage of an input source, mode change method of the
charger/discharger is also proposed. Additionally, a proposed current limit
algorithm of the inverter can be implemented without an additional hardware
and it increases the reliability of the UPS.
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