5.

5 Battery/inverter systems

5.5.1 Introduction

Dc systems, particularly when they are large, may supply static inverters as loads; these inverters were, in
the past, often referred to as uninterruptible power supplies. However, it is becoming more common to
utilize a dedicated battery, charger, inverter, and accessories (e.g., a static transfer switch), when there is a
need for an uninterruptible power source. This combination of battery, rectifier/charger, static inverter
and accessories, represent today’s static UPS system. The primary purpose of the UPS is to provide
continuity and quality of power to the critical load(s) supplied by it. The batteries used with UPS systems
are the stationary type discussed in 5.3.2.

These UPS systems are available in a number of designs and sizes, ranging from less than 100 W to
several megawatts. UPS systems may provide single-phase or three-phase power at power frequencies
(i.e., 50 or 60 Hz) or at higher frequencies (e.g., 400 Hz). In addition, static UPS systems, because of their
wide range of design and application, may provide power of which the output purity may vary from a
near-perfect sine wave (less than 1% total harmonic distortion [THD]) to essentially a square wave
(greater than 25% THD).

5.5.2 Static UPS system description

The static UPS system is an electronically controlled solid-state system designed to provide man alternate
source of conditioned, reliable, and break-free electrical power to a user’s equipment. This equipment is
often referred to as the “critical” or “protected” load. A UPS system maintains power to the critical load
in the event of a partial or total failure of the normal source of power, typically, the power supplied by the
electric utility.

There are a variety of UPS configurations available that provide for voltage regulation, line conditioning,
lightning protection, redundancy, EMI management, extended run time, load transfer to other units, and
other such features required to protect the critical load(s) against failure of the normal ac source, or
against other power system disturbances.

Today, UPS technology continues to change making it more appropriate to describe a UPS system by its
performance characteristics, rather than its electronic components, which may vary from system to system
or change with time and technology. Therefore, a UPS system should have the following primary
attributes as a minimum:

— The UPS must provide uninterruptible power. As the normal source falls outside of voltage
limits, becomes excessively noisy, threatens to be disrupted in any manner, disappears, or
becomes incapable of performing acceptably, the UPS should continue to provide continuous,
break-free power to the critical load(s) it supplies for at least a minimum period of time (i.e.,
backup time).

The minimum backup time is generally specified by the user, but the actual operating time will
be determined by the size of the energy storage device (i.e., the battery)m associated with the
UPS or by the load on the UPS at the time of failure of the normal power source.

— The UPS must provide its power at a stable frequency. The base frequency may be power
frequencies such as 50 or 60 Hz, or other frequencies such as 400 or 1000 Hz. A typical
requirement for 50 or 60 Hz UPS systems is to maintain the base frequency within ±0.5%.

— For most applications, the output waveform of a UPS system should be sinusoidal, with the THD
of voltage 10% or less when tested on a linear load, with a single frequency component of 5% or
less. It is recognized, however, that there are loads that can operate reliably with input
waveforms having a higher harmonic content or as an extreme, with essentially square wave
inputs (e.g., step function quasi-sine waves). Although some loads can function well with square
wave input, the electrical interference that the square wave produces may affect other electrical
equipment in the vicinity of the UPS.
 — A system may include equipment that will provide transfers from line to battery or battery to line
that are not continuous (i.e., containing breaks or discontinuities), depending upon the load or
user requirements. These products that produce breaks during the transfer from line to battery or
from battery to line are referred to as “standby power systems” (SPSs). They are sometimes
incorrectly referred to as “standby UPS systems”. Many SPSs are still applied today particularly
for small UPS systems; e.g., for small computer systems in which a break in power flow is
supported by the ride-through characteristics of the computer power supply, although the ride-
through capability may be lost when the normal power source is lower than normal.

5.5.3 Types of UPS systems

There are two basic types of UPS systems used today. These are used in a variety of configurations. The
types of UPS systems are discussed in this subclause, while the various configurations are discussed in
5.5.4. (The discussion that follows on UPS types and configurations, at times, refers to a single battery;
however, this may be either a single or multiple strings of cells connected in parallel to obtain the
required battery capacity.) In general, these two types of UPS systems have proven to be reliable when
properly applied. The reliability of any UPS system can vary based upon a number of factors. Similarly,
the availability of a UPS system can be increased by the addition of transfer switches, redundant
equipment, and so forth. The topic of reliability is addressed in IEEE Std 493-1990 [B13]; reliability of
emergency and standby power systems is addressed in Chapter 6 of that standard.

5.5.3.1 Double-conversion systems

Double-conversions systems are characterized by their topology. In these systems, the incoming line is
first converted to dc. The dc then provides input power to a dc-to-ac converter (i.e., an inverter). The
inverter output is ac, which is used to power the critical load. Many different types of inverters are used,
each employing a variant of available technology. (Note that the recently revised NEMA PE 1-1993
[B23], identifies the double-conversion system as a “rectifier- inverter.”)

Historically, the double-conversion UPS has found the most prominence in the industry. The double-
conversion UPS system has been available for many years and has proven to be reliable when operated
within its design limits. This type of system is the static electrical equivalent to the motor-generator set.
The battery is connected in parallel with the dc input to the inverter, and provides continuous power to it
any time the incoming line is outside of its specification or fails. Switching to the battery is automatic,
with no break in either the input to the inverter or the output from it.

The double-conversion system has several advantages:

— It provides excellent frequency stability.

— There is a high degree of isolation from variations in incoming line voltage and frequency.

— A zero transfer time is possible.

— Operation is relatively quiet.

— Some systems can provide a sinusoidal output waveform with low distortion.

In the lower power UPS applications (0.1–20 kW), the double-conversion UPS has the following
disadvantages. (Many of these disadvantages can be minimized if the system is carefully specified to use
the latest topologies.)

— There is lower overall efficiency.

— A large dc power supply is required (typically, 1.5 times the full rated load rating of the UPS).

— Noise isolation line to load can be poor.

— There is greater heat dissipation, which may affect the service life of the UPS.
In addition, if the inverter is the pulse width modulated type, the high-frequency circuitry may produce
electromagnetic interference (EMI). This may require special filtering and shielding to protect sensitive
equipment from radiated and conducted interference. The double- conversion UPS may also produce
excessive battery ripple current, possibly resulting in reduced battery life (see IEEE Std 1184-1994).

5.5.3.2 Single-conversion systems

Single-conversion UPS systems are those in which, during normal operation, the incoming line is used to
provide power to the critical load either through a transformer or in conjunction with some series
impedance. Some forms of single-conversion UPS products are classified as “line interactive” (see
5.5.3.2.1). The single-conversion UPS usually provides a higher operating efficiency at lower cost than
the double-conversion UPS at a comparable system reliability. (Note that the recently revised NEMA PE
1-1993 [B23], identifies the single-conversion system as a “single-conversion converter.”)

Unlike the double-conversion system, the incoming line to the single-conversion UPS is not rectified to
produce dc power to provide input to the inverter. The normal ac power is supplied directly to the critical
load through a series inductor or a linear or ferroresonant transformer. The normal ac also supplies a
small charger used to maintain the UPS batteries in a fully charged condition. Thus the battery is only
used when inverter requires the battery’s output to supplement or replace the normal power source.
Single-conversion UPSs include the ferroresonant type, some variants of the tri-port type, line interactive
types, and some SPS designs. A discussion of some of these systems follows.

5.5.3.2.1 Line interactive systems

The line interactive UPS is rapidly achieving prominence in the industry. Lower cost, simplicity of
design, and smaller “package” are some of the advantages of this design.

In the line interactive UPS, line power is not converted into dc but is fed directly to the critical load
through a series inductor or transformer. Regulation and continuous power to the load is achieved through
use of inverter switching elements in combination with inverter magnetic components such as inductors,
linear transformers, or ferroresonant transformers.

The term “line interactive UPS” derives from the fact that the inverter interacts with the line to buck,
boost, or replace incoming power as needed to maintain constant voltage to the critical load. In the
absence of line power, the line interactive UPS provides the total power to the critical load. Some line
interactive products exhibit a break in power to the critical load during line-to-battery or battery-to-line
transfers (this type of system would be an SPS). Other designs are capable of producing true unbroken
power to the critical load. Line interactive UPSs are available as single-phase or three-phase units.

5.5.3.2.2 Tri-port systems

The tri-port UPS provides line conditioning and good isolation from input to output by means of a multi-
winding linear transformer combined with suitable filtering. In this arrangement, the inverter runs
continuously, and shares the same transformer core as the ac input winding. Phasing is adjusted so that
the inverter, although operating continuously, normally provides little or no power to the critical load. In
some cases, the inverter may be configured to act as a battery charger when not called into service to
deliver power to the load. When the ac input is outside of specification, or fails, the inverter responds and
power to the inverter winding is magnetically coupled to the load through the transformer core, supplying
the critical load. Since the inverter runs continuously, there is a true no-break power transfer to the critical
load. In this arrangement power may be added or subtracted from the incoming line to maintain regulation
and power flow to the critical load. This power correction is often referred to as “line interaction,” and the
tri-port UPS may be considered a form of line interactive UPS.

The advantages of the tri-port system are that a higher overall efficiency can be achieved compared to the
double-conversion-type of UPS, and a separate battery charger may often be eliminated. A disadvantage
of this type of system includes production of EMI due to the high-frequency inverter running
continuously. This can require the addition of filtering and shielding to protect the critical load(s).
Another disadvantage is that, because the transformer is linear, changes in input voltages may be
transferred to the critical load and common-mode noise rejection may be low.

5.5.3.2.3 Ferroresonant systems

The ferroresonant transformer type of UPS is similar to the tri-port. It is also a form of lineinteractive
UPS. In this arrangement, a ferroresonant transformer magnetically couples the ac input to the critical
load much like the linear tri-port transformer. The basic difference is that in the ferroresonant-based UPS,
the inverter is not running continuously.

When the system line monitor detects that the line voltage either is outside of specification, has excessive
noise imposed upon it, or has failed, the incoming line is automatically disconnected from the transformer
primary and the inverter is simultaneously turned on. During the transfer to inverter power, the energy
that is stored in the tank circuit of the ferroresonant transformer continues to provide power to the critical
load, and since the inverter provides power to the core before this tank voltage can decay significantly,
the load receives true, continuous, no-break power. This energy storage feature makes the ferroresonant
type of UPS a true on-line UPS, even though the inverter is not running continuously.

While the ac input is present, the ferroresonant transformer provides line conditioning, lightning
protection, noise isolation, ground isolation, and voltage regulation with the ferroresonant load winding
operating in saturation. Magnetic compensation in the ferroresonant design provides a good sine-wave to
the critical load without the need for complicated and expensive filtering elements. In the ferroresonant
transformer, the windings are wound on different sections of the core. This construction provides physical
and noise isolation between the primary and secondary winding. A Faraday shield provides additional
noise isolation and enhanced lightning protection.

The ferroresonant transformer offers several advantages over the linear transformer in singleconversion
UPS applications. For example, the ferroresonant transformer provides line regulation, typically ±3% for
a 15% variation in the ac input. The ferroresonant transformer also provides approximately 120 dB (i.e.,
one million to one) attenuation of common-mode incoming noise, and about 70 dB rejection of
transverse-mode noise. With the unit on-line, typical operating efficiencies are 91% or greater, and when
“on-inverter,” typical operating efficiencies are 89% at full load. Efficiencies are slightly less as the
amount of load on a system is decreased from full-load. Additionally, good common-mode noise rejection
and isolation are provided. The ferroresonant transformer tends to smooth out the input power factor,
presenting a near-unity power factor to the line when the transformer is loaded with poor power factor
loads. Typically, 0.7 pf (lagging) load is reflected back to the ferroresonant transformer primary as a 0.97
pf load.

The ferroresonant transformer can provide power to high crest factor loads. Excess energy stored in the
magnetic tank circuit can provide high peak currents. Output frequency on-line can be as good as the
power line grid (typically ±0.5%). Frequency stability on-inverter is computer-derived and is typically
better than ±0.03 Hz (for a 60 Hz system). The ferroresonant transformer inverter operates at line
frequency (50 or 60 Hz). Low-frequency inverter operation results in higher inverter efficiency, lower
heat losses, reduced EMI, and lower cost.

There are also some disadvantages of the ferroresonant transformer including its weight when compared
to an equivalent high frequency PWM inverter. In most installations, however, this has not proven to be a
problem because a UPS is considered to be stationary equipment and is not moved once installed.
Additionally, output harmonics tend to increase as the load level goes below 50%. In most cases,
however, the THD is about 5%. Although the ferroresonant transformer is as efficient as a linear
transformer when operated at or near rating, the efficiency of the ferroresonant transformer becomes
lower when lightly loaded, typically 77% when the transformer is operated at 25% of rating. A
comparison of the ferroresonant and linear transformers is presented in table 5-2.
5.5.3.3 Other types

Other UPS types include dc-to-dc systems, which are often used for special applications. These are
usually found on small computer systems, control systems, and alarm systems (e.g., annunciators).