final report 2okva inverter system - ryerson universitybwu/buffer/report_lumacell_ups.pdf · final...

Final Report

2OkVA Inverter System

For

Lumacell Inc.

Prepared By

Bin Wu & Jim Koch

Dept. of Electrical & Computer Engineering

Ryerson Polytechnic University

January31,1999

FinalReport 20kVA Inverter Svstem

Table of Contents

1. Main Specifications

2. Test Results2.1 Energy Efficiency and Total Harmonic Distortion2.2 Voltage Regulation2.3 Rectifier Testing

3. System Diagnostics and User's Instruction3.1 Setting Clock and Auto Monthlyl/early Test Time3.2 Control Function Keys3.3 Front Panel LEDs3.4 LCD Screens Constants (lncluding Alarm Messages)

4. AppendixesAppendix A Waveforms Recorded During Open-loop System Efficiency Test (Table 2)Appendix B Waveforms Recorded During Voltage Regulation Test (Table 4)Appendix C Waveforms Recorded During Charger Test (Table 5)Appendix D Waveforms Recorded During Load Transfer Test

\v_ Appendix E Measured Waveforms with HID Lamp LoadAppendix F FlowchartsAppendix G Connection DiagramsAppendix H Schematic - Logic Power Supply / Relay BoardAppendix I Schematic - SGR Gating BoardAppendix J Schematic - Standard Transfer InverterAppendix K Schematic - 68HC11 ControllerAppendix L Schematic - PI/LCD BoardAppendix M Schematic - Connection Between 68HC11 Controller and PllLCD BoardAppendix N Schematic - Inverter Control BoardAppendix O Schematic - Interface BoardAppendix P Schematic - Front Panel InterconnectionAppendixQ Schematic-KeypadAppendix R Schematic - Laminated Bus BarAppendix S Schematic - Laminated Insulator

Final Report 1 20kVA Inverter Svstem

Final Report

20kVA lnverter System

ByBin Wu and Jim Koch

Dept. of Electrical & Computer EngineeringRyerson Polytechnic University

According to the Agreement (effective on May 11, 1998) between Ryerson Polytechnic University andLumacell Inc., a 20kVA off-line UPS prototype has been developed. As shown in Figure 1, the UPS ismainly composed of an SCR battery charger, an IGBT inverter and a microprocessor-based diagnosticsystem. The prototype unit has been fully tested by both Ryerson research team and Lumacell engineers.As summarized in Table 1, all technical specifications proposed in the Agreement have been met. lnaddition, a reliable electronic short circuit protection, which was not included in the original proposal, hasbeen successfully implemented and tested.

From Utility Line

?I

ChargerControl

Diagnosticsilicroprocessor

Figure 1 Block diagram of 20kVA off-line UPS system.


1. Main Specifications

The proposed and measured technical specifications are summarized in Table 1.

Table I Proposed and Measured Specifications

Item Proposed Achieved (measured)

Rated Output Power 20KVA 20KVA

Rated Output Voltage 347V 347V

Total Harmonic Distortion < 5o/" < 4"/"under any operating conditions

Output Voltage Regulation < 1o/" < O.4o/"from no load to full load

lnverter Efficiencyat rated output

> 90% excluding the output(step-up) transformer.

90% including the output(step-up) transformer, closedloop operation.91.8o/" including the output(step-up) transformer, openloop operation.

Short Circuit Protection Fuse Electronic shut-down

Overcurrent Protection Not specified lmplemented

Final Report 20kVA Inverter Svstem

2. Test Result

2.1 System Etficiency and Total Harmonic Distortion [fHDt

Table 2 Open Loop Etficiency and THD

Load

(/")

lac

(A)

Vac

(v)

ldc

(A)

Vdc

(v)

THD

(%\

Efficiency (%)

lnverter + '

Transformer

Max.IGBT

Base-plate

Temperature

("c)

Testing conditions

25 14.7 388.9 23.4 261 2.4 93.6 30 Rg = 3.3 ohms

fsw = 20(nHz

Resistive load

Filter capacitor: 20uF

IGBT gating board: VPT v.1

IGBT:Semikron SKM 400

GB123D

Open loop control

Room temp:23'C

50 29 372.4 44.75 256 2.8 94.3 34

75 M.2 359.5 68 253 2.7 92.4 43

100 58.6 346.5 88.5 250 2.9 91.8 52

1 1 0 64.7 342.2 98 249 2.8 90,7 59

Final Report 4 20kVA lnverter Svstem

Table 3 Closed-Loop Etficiency, THD and Temperature

Time

(Minutes)

Load

(%)

Vdc

(v)ldc

(A)

Vac

(v)lac

(A)

THD

f/")

Cabinet

Temp 'C

IGBT

Base

Temp "C

Efficiency

('/.)

0 1 0 254 9.45 345 6.0 3.0 31 0.86

I 20 250 18.9 345 12.3 3.2 32 0.90

10 30 249 28.0 345 18.4 3.8 29 0.91

13 40 248 36.0 345 23.8 3.9 28 0.92

14 50 247 45.0 345 30.0 3.9 29 0.93

17 60 246 54.5 344 35.4 3.9 30 0.91

1 8 70 2M 65.0 344 42.2 3.7 30 0.92

1 9 80 243 75.0 3M 48.2 3.7 30 0.91

20 90 243 83.0 3M 53.0 3,5 30 0.90

25 100 242 90.0 344 56.8 3.3 31 0.90

40 100 240 90.0 344 56.7 3.2 32 55 0.90

60 100 237 91.5 3M 56.7 3.1 32 0.90

75 100 235 92.5 3M 56.6 3.1 33 0.90

90 100 231 94.0 344 56,6 3.0 u 0.90

105 100 228 95.5 344 56.6 2.8 u 0.89

120 100 222 98.5 344 56.6 3.3 35 0.89

125 100 218 100 344 56.6 3.0 0.89


\-/ 2.2 Yoltage Regulation

Table 4 Voltage Regulation and THD

Load Inverter Output Current 1^(A)

Inverter Output Voltage V,(v)

Total HarmonicDistortion

(%)

o% 0 347.0 1 . 8

25o/" 14.8 346.0 3.9

SOY' 29.4 346.0 4.0

75Y" 43.1 346.0 3.8

100% 58.4 345.5 3.4

110% 64.2 345.5 3.2

Testing Conditions

DC Voltage: 250V Output Transformer Turns Ratio: 150/382

Gate Resistance: Rg = 3.3 Ohms Switching Frequency: 2000H2

Load: Resistive Filter Capacitor: 20uF

IGBT Gating Board: VPT (New Design) IGBT: Semikron SKM 400 GB123D

Closed Loop Control Pl Parameters: Cfd = 3.4uF, Rfd = 2.7K, Rin =10K

Measured Voltage Regulation: (347.0 - 345.5) I 347 = O.4o/o


v 2.3 Rectifier Testing

Table 5 Rectifier Power Factor and Efficiency

ldc

(ref)

(A)

Vac

(v)lac

(A)

pf Pac

(w)Vdc

(v)ldc

(A)

Efficiency (%)

Rectlfier +

Transformer

Testing conditions

2.0 338 4.02 0.46 630.5 252 2.05 81.9 SCR Snubber parameters:

0.22uF. 25 Ohms

Transformer turns ratio:

347t260V

DC choke:

1mH

Load: 300AH battery bank

4.0 337 6.73 0.45 101 1 2U 3.88 89.7

8.0 338 12.35 0.50 2063 239 7.95 92.1

16.0 336 22.08 0.60 M20 259 16.1 94.3

20.0 3€ 27.17 0.63 5778 270 20.18 94.3

24.0 3€ 30.71 0.68 71M 279 24.25 94.7


3 System Diagnostics and User's Instruction

3.1 Setting Clock and Auto Monthlyffearly Test Time

Please no te tha t a 24 hour c lock is used.

Time Set Screen has 5 modes.Set t ime hours (hours f lash ing) .Set t ime minutes (minu tes f lash ing) .Set tes t t ime hours ( tes t hours f lash i r tg ) .S e t t e s t t i m e m i n u t e s ( t e s E m i n u t e s f l a s h i n g ) .L0 second screen display before returning to systemdisp lays (no f lash ing numbers) .

Press and hold CLOCK/SET key unt i l the t ime set screen appears. I f the t imehours are not f lashing press and release the CLOCK/SET key. The t ime 'HOURS"

d ig i ts shou ld s ta r t to f lash .

To advance through the sett ing modes press the CLOCK/SET key.

Use the UP or Down keys to change the value of the flashing number. The valueof the nurnber will be incremented or decremented with each push of the UP orDown key respectively. The new setting musE Ehen be saved by pressing the SAVEkey. The next, number to be set wi l l then starE to f lash, except when mode 5has been reached. Once in mode 5 the Eime set screen wi l l be displayed for 10seconds and then the screen wi l-L return to system displays.

I f a number does not need to be set, press the CLOCK/SET key to advance to thenex t se t t ing mode.

During the 10 second period in mode 5, the CLOCK/SET key can be pressed. againand correct ions can be made using the above sett ing method.

I f a digi t is lef t f lashing for more than one minute the display wi l l revertback to the sys tem d isp lays .

T1i:_:::_::::::_ _ __ _ _+

The' t .

z i

q .

l 2 4 H R T i m e : l - 0 : 1 0 : 0 0

IlUex t Auto Tes t @:

| 9 : 1 5 I n 3 0 D a y ( s )

>Time of day

>Test t ime and days le f t un t i l nex t au to tes t .- - - - - - - +

Clock Funct ion Kevs

Clock /Set : Br ings up c lock Screen, Advances th rough se t t ing modes.Up: Increments f lash ing va lue .


Down: Decrements f lashing val-ue.Save: Saves val-ue being modif ied, advances to next sett ing mode.

3.2 Control Function Keys

Restart /Reset: Press to clear alarm screens, restart the charger or invertera f t e r a f a u l t .

Manual Test: press to shut dorarn charger and start inverter. Can be cancel_edb y R e s t a r t / R e s e t .

Si lence B:uzzer: Press to turn off bwzzer wh€?I in faul t condit ion.

Pause: Press once to pause a screen, p ress once to re lease. Pause w i l lho ld a screen fo r one minute .

Reca l l - Data : Press to see the resu l ts o f the las t tes t , tes t h is to ry , andf a u l t h i s t o r v .

Equa l ize On: Press to fo rce the charger in to equa l ize mode. Wi l l on lywork i f charger i s in f loa t mode.

3.3 Front Panel LEDS

AC ON: fndicates Power is coming from AC mains.

AC FAIL: Indicates power from AC mains has been lost.

ALARM: Ind ica tes an a fa rm cond i t ion ex is ts .

FLOAT: Indicates thaE the charger is in f loat mode.

TEST: Ind ica tes tha t a manua l - o r au to tes t i s in p rogress .

EQUALTZE/HIGH CHARGE: rndicates that the charger is in equal izeor high charge mode.

DATA RECALL: rndicates that the screens being displayed are testd a t a .

3.4 LCD SCREENS CONSTANTSPOWER ON RESET

CPU RESET!

PTess RESET/RESTARTTo S ta r t Cha rge r .


\!- | HrcH cHARGE MoDE

I D C V o l t : x x x . x V

l o c c u r r : x x . x A

lea t te ry : - xxx*

MESSAGE 2

I reualrzE MoDEI D C V o l t : x x x . x Vl o c c u r r : x x . x A;lBa t te ry : _ xxx t

I FLOAT MODEI D C V o l t : x x x . x Vl o c c u r r : x x . x A

lBat te ry : _ xxx t

I DISCHARGE MODE

l o c v o t t : x x x . x vloc cu r r : xxx .x Aleat tery : _ xxxt

l load - AC Mains ON

lload: xxxVac xx.xAacI xx.x KVA

l F r e q : x x . x H z

I Load - Inverter ON| toad: xxxVac xx .xAac

I xx.x KVA

l r r e q : 6 0 H z

CURRENT CHARGE MODE FRAME 1 MESSAGE ]-f - - - - - - - -

OR lf ,oad - Inverter OFF I

FinalReport 1 0 20kVA Inverter Svstem

TEMPERATURE FRAME 3 MESSAGE ]-+ - - - - - - -

I Lumacell Vl- . 0 xx: xx II rnput AC: V Il C a b i n e t T e m p : x x . x ' C l

l:i: :::1-l:T- -:i-I- !1ATOD READING

+ - - - - - - - - - - - - +

lVac xxxx If1 xxxx

I IfZ xxxx Vdc xxxx

I Iac xxxx Vac xxxx

ltf xxxx T2 xxxx

loeo xxx VOLTAGE Ref

loAl xxx CURRENT Ref

lOa2 xxx Inverter VoI+ - - - - - - - - - - - - +

ALARM ]. - HIGH DC BATTERY VOLTAGE

CHARGER SHUTDOWN!H igh DC Vo l tage !DC Vo l - t : xxx . x Vxxxxxxxxxxxxxxxxxxxx * S t a t u s M e s s a g e 0 , t , 2

STAT 0: lHigh Charge ModeSTAT l - : Inqua l ize ModeSTAT 2 : I r loa t Mode

Fau l t cond i t ion :Ac t i -on :

Auto Reset :Ac t ion :

Vdc >= Vmax for > 3 seconds.Record fau l t and t r ip po in t .D isab le Charger .Turn on charger faul t output.Vdc <= Vf loa t fo r > 3 seconds.

Restar t Charger i f a l -a rms 11 .1 , LL .2 , and 18 are norTurn off charger faul t output i f Alarm 6 and 18 notC1ear a la rm.

a c t i v e .

a c t i v e .


ALARM 2 _ SYSTEM OVERLOAD+ - - - - - - - - - - - - +

SYSTEM OVERLOAD!xxxxxxxxxxxxxxxxxxxxLoad: xxxVac xx.xAac

xx.x KVA

* Sta tus Messagfe 7 , 8

T - - - - - - -

STAT 7: I Inverter ON ISTAT 8: I Inverter OFF

Fau l t , cond i t ion : Iac > 1 -008 ra ted fo r > 3 seconds.Ac t ion : Record fau l t and t r ip po iq tg .

ALl-ow inverter Eo run for 9 minuEes before shutt ing down.Manual Reset: Press RESET/RESTART when alarm message is being displayed.A c t i o n : R e s t a r t i n v e r t e r i f A C i s s t i l l o f f .

CLear a1arm.

ALARM 3 - LOW VOLTAGE DROPOUT+ - - - - - - - -

* * * WARNING * * *

LVDD C V o l t A t : x x x . x VInver ter Disconnect

+ - - - - - - - -

Fau l t cond i t ion : Vdc < 91 t nomina l fo r > 3 seconds.Ac t ion : Record fau l t and t r ip po in t .

D isab l -e inver te r .Auto Reset: Vdc >= 958 nominal- for > 3 seconds in high charge mode.Ac t ion : C l -ear aLarm.

ALARM 4 - LOW FLOAT VOLTAGE+ - - - - - - - - - - - - +

I >>>> ALARM

I Low F loa t Vo l t age !

l oc vo l tage : xxx .x vlBa t . t e ry Temp: xx . x 'C

- - - - - - - +

Fau] t cond i t ion : Vdc < 988 Vf loa t and rdc < lA /s t r ing fo r > 3 seconds.Ac t ion : Record fau l t and t , r ip po in ts .Manual Reset: Press RESET/RESTART when afarm message is being displayed.Ac t ion : C lear a l -a rm.

Final Reoort 1 2 20kVA Inverter Svstem

A L A R M 5 - C H A R G E R F A I L+ - - - - - - - - - - - - T

!/ I >>>> ALARM

lCharger Fa i lu re ! DCI n n t i n a r , eas ] ' ng .

I D C V o l t : x x x . x V

Faul- t condi t ion: Vdc < nominal af ter 6 hours of charging and Vac > 938.Ac t i on : Reco rd f au l t and t , r i p po in t s .Manual- Reset : Press RESET/RESTART when a larm message is being d isplayed.A c t i o n : C l e a r a l a r m .

ALARM 6 - HTGH CHARGE CURRENT

I tttt ALARM

lH igh Charge Cur ren t !

l o c c u r r : x x . x AI xxxxxxxxxxxxxxxxxxxx * S t , a t u s M e s s a g e 0 , L , 2+ - - - - - - - - - - - - T

STAT 0: lHigh Charge ModeSTAT l - : Inqua l ize ModeSTAT 2: I Float Mode

Fau l t cond i t ion : Idc > 105t ra ted fo r > 3 seconds.Ac t ion : Record fau l t and t r ip po inEs.

Turn on charger faul t output.Manual Reset: Press RESET/RESTART when afarm message is being displayed.Act ion: Turn off charger faul t output i f Alarms 1 and 18 not act ive.

C lear a la rm.

ALARM 7 - HIGH INPUT AC VOLTS

| * * * WARNING ***

lHigrh rnput vol t ,age!

IAC Vo l tage: VI xxxxxxxxxxxxxxxxxxxx * S t a t u s M e s s a g e 0 , I , 2 , 3 , 4 , 5

STAT O:STAT ]- :STAT 2 :STAT 3 :STAT 4 :STAT 5 :

High Charge ModeEgual ize ModeFloat ModeDischarge ModeTest ModeRestar t ing Charger

Fau l t cond i t ion : Vac > 108* nomina l fo r > 3 seconds.Ac t ion : Record fau l t and t r ip po in ts .Auto Reset : Vac < 1058 nomina l fo r > 3 seconds.Ac t ion : C l -ear a l -a rm.


ALARM 8 - LOW ]NPUT AC VOLTSr - - - - - - - - - - - - +

| * * * WARNING ***

I t ,ow lnput Voltage I

lac vo l tage: xxx vI

I xxxxxxxxxxxxxxxxxxxx * S t a t u s M e s s a g e 0 , L , 2 , 3 , 4 , 5

STAT OSTAT ]-STAT 2STAT 3STAT 4STAT 5

Fau l t cond i t ion :A c t i o n :

AuEo Reset :A c t i o n :

High Charge ModeEqual ize ModeFl-oat ModeDischarge ModeTest Mode

Restar t ing Charger

Fau l t cond i t ion : Vac < 908 nomina l - fo r > 3 seconds.Ac t ion : Record fau l t and t r ip po in ts .Auto Reset : Vac > 93 t nomina l fo r > 3 seconds.A c t i o n : C l e a r a l a r m .

ALARM 9 - AC FAILURE / BROWN+ - - - - - - - - - - - - +

I tttt ALARM

laC ra i tu re /Brownout !

laC rnput Vo l t .s < 908

lxxx Minutes elapsed.

Vac < 84 t nomina] fo rRecord faul t and tr ipShutdown charger andVac > 93t nominal- forC lear a1arm.

> I . 6 7 s e c o n d s ( 1 0 0 c y c l e s )p o i n t s .

t rans fer to inver te r .> 3 s e c o n d s .

ALARM 1-O - AC FA]LURET - - - - - - - - - - - - +

I >>>> ALARMI A C F a i l u r e !

laC rnput Vo1ts < 67?:

lxxx Minu tes e lapsed

Fau l t cond i t ion :A c t i o n :

Auto Reset . :A c t i o n :

Vac < 678 nominalRecord faul t andShutdown chargerVac > 938 nomina lCfear a ]a rm.

fo r 2 cyc les .t r i p p o i n t s .and t rans fer to inver te r .

f o r > 3 s e c o n d s .

l!qlfleport 1 4 20kVA Inverter Svstem

ALARM 1] . .1. - HIGH CABIN TEMP+ - - - - - - - - - - - - +

\v- lxxxxxxxxxxxxxxxxxxxx

lHigh Cabinet Temp!

l T e m p : x x . x ' C x x x F

I xxxxxxxxxxxxxxxxxxxx

* S t a t u s M e s s a g e 9 , 1 0

* S t a t u s M e s s a g e 0 , 1 - , 2 , 3 , 4 , 5

Fault condit ion: Temperat,ure between 50 & 50 degrees C.Ac t ion : Record fau l t and t r ip po in ts .Auto Reset : Tempera ture fa l l s be l_ow 45C.Act . ion : C lear a l -a rm.

FauLt cond i t ion : Tempera ture > 50CAction: Shutdown charger or inverter.

Record fau l t and t r ip po in ts .v Manual Reset: Press RESET/RESTART when alarm message is being displayed.

Vac > 93t nominal- for > 3 seconds.Ac t ion : I f in inver te r o r tes t mode res tar t inver te r . C ]ear a la rm.

I f in high charge mode rest,art charger only i fA l -a rms 1- , 1 ,1 , .2 , l -8are no t ac t i ve , and tempera ture is < 45C. C lear a la rm.

ALARM ].1..2 - HIGH BATTERY TEMP+ - - - - - - - - - - - - ?

lxxxxxxxxxxxxxxxxxxxxl * Status Message 9, 1_0lHigrh Battery Temp ! |I t e m p : x x . x ' C x x x F Ifxxxxxxxxxxxxxxxxxxxxl * Status Message 0, L, 2, 3, 4, 5+ - - - - - - - - - - - - !

STAT O:STAT ].:STAT 2 :

STAT 3 :STAT 4 :

STAT 5 :

STAT 9STAT 10

STAT O:STAT 1 :STAT 2 :STAT 3 :STAT 4 :STAT 5 :

STAT 9STAT 10

High Charge ModeEqual ize ModeFloat ModeDischarge ModeTest Mode

Restar t ing Charger

* * * WARNING * * *

UNIT SHUTDOWN!

High Charge ModeEqual ize ModeF loa t ModeDischargre ModeTesE ModeRestar t ing Charger

* *:k WARNING * * *

UNIT SHUTDOWN!

fl4alReport 1 5 20kVA Inverter Svstem

Fault condit ion: Temperature between 50 & 60 degrees C.Ac t ion : Record fau l t and t r ip po in ts .

\ - . Au to Reset : Tempera ture fa l l s be low 45C.Act ion : CLear a la rm.

Fault condit ion: Temperature > 60CAction: Shutdown charger or inverter.

Record fau l t and t r ip po in ts .Manual Reset: Press RESET/RESTART when alarm message is being displayed.

Vac > 93 t nomina l fo r > 3 seconds.Ac t ion : I f in inver te r o r tes t mode res tar t inver te r . C l -ear a la rm.

r F i n h i a h a l t 3 l g e m o d e r e s t a r t c h a r g e r o n l y i f A l a r m s 1 ,I I . L , 1 8 a r e n o t a c t i v e , a n d t e m p e r a t u r e i s < 4 5 C . C l e a ra1arm.

ALARM 12 - GROUND LEAKAGE

I >>>> ALARM

I Battery Ground

lr ,eakage !

I xxxxxxxxxxxxxxxxxxxx * S t a t u s M e s s a g e 0 , L , 2 , 3 , 4 , 5+ - - - - - - - - - - - - +

STAT 0: lHigh Charge ModeSTAT 1: I nqual ize Mode

v STAT 2: l Float ModeSTAT 3 : lo ischarge ModeSTAT 4 : l tes t ModeSTAT 5 : lRes tar t ing Charger

Fault condit ion: External input takes port pin pE7 low.A c t i o n : Record fau l t and t r ip po in ts .Manual Reset: Press RESET/RESTART when a]arm messagfe is being displayed.A c t i o n : CLear a la rm.

ALARM 13 - LOAD CIRCUIT BREAKER OR FUSE OPENT - - - -

| >tt t ALARM

lLoad Fuse Open!lon r ,oad Ci rcu ic -

lereaker Tr ipped!+ - - - - - - - - - - - - +

Fau l t cond i t ion : Ex terna l inpu t takes Por t p in PE6 Iow.Act ion : Record fau l - t and t r ip po in ts .Manual Reset: Press RESET/RESTART when alarm message is being displayed.Ac t ion : C lear a1arm.

Final Report 1 6 20kVA Inverter Svstem

ALARM 14 - Higrh AC output+ - - - - - - - - - - - - +

I ttrt ALARM

lHigrh Inverter OutputI Inverter Shutdown!

IAC Vo l tage: xxx V

Fau] t cond i t ion : Vac > l -08 t nomina l fo r > 3 seconds.Act ion: Shutdown inverter.

Record fau l t and t r ip po in ts .Manual Reset: Press RESET/RESTART when alarm message

Vac > 93 t nomina l fo r > 3 seconds.Ac t ion : Res tar t inver te r i f s t i l l i n tes t mode

Clear aLarm.

ALARM l-5 - Low AC output

| * * * WARNING ***

lLow Inverter Output

I Inverter Operat ing!

lec vo t tage: v

is be ing d isp layed.

or AC f a i ]u re .

and unit is notFau l t cond i t ion :

Ac t , ion :Auto Reset :A c t i o n :

Vac < 90t nominal forove r l oaded .Record faul t and t , r ipVac > 93t nominal forC lea r a1a rm.

> 3 seconds,

p o i n t s .> 3 s e c o n d s .

ALARM 1-6 - Inverter Tripped+ - - - - - - - -

I tttt ALARM

lOutput Shor ted !

I Inverter Shut,down I

I

Faul-t condit ion:A c t i o n :

Manual Reset:A c t i o n :

External input takes Port pin PA1 1ow.Shutdown inverter.Record fau l t and t r ip po in ts .Press RESET/RESTART when alarm message is being displayed.Restar t inver te r i f s t i l l i n tes t mode or AC fa i lu re .C lear a la rm.


"i:iY_11___l1T_l:_::** ro AC MArNS

* * * WARNTNG ***

AC Power Restored!Load Transfers ToAC Mains in xx.x min

+ - - - - - - -

Fau l t cond i t i on : Vac > 93 t nomina l f o r > 3 seconds .Ac t i on : Sw i t ch back to AC ma ins i n a t ime pe r i od spec i f i ed by D IP

s w i t c h s e t t i n g .Reco rd f au l - t and t r i p po in tg .

Au to Rese t : Sw i t ch back to cha rg ing .A c t i o n : C l e a r a l a r m .

ALARM 1-8 - CHARGER CIRCUTT LOST POWER CB off or tripped OR FUSE

+ - - - - - - - -

I tttt ALARM

I InpuE AC to Charger

lOff-charger ShutdownlRestore AC & RESET

Fault condit ion: External input Eakes pin PA2 low.Act ion : Record fau l t and t r ip po in t .

D isab le Charger .Turn on charger faul t output.

Manual Reset: Press RESET/RESTART when al-arm message is being displayed.Ac t ion : Res tar t Charger i f a l -a rms 1 , L1- .L , and 1 l - .2 a re no t ac t i ve .

Turn off charger faul t output i f Alarms 1 and 6 not act ive.Cl-ear al-arm.

Test Message FRAME 1+ - - - - - - - - - - - - +

lxxxxxxxxxxxxxxxxxxxxl * Status message 11, L2, 1_3

I xx Minutes elapsed IlVdc xxx .xV Idc xx .xA llBaEterv : xxx t I+ - - - - - - - - - - - - +

S T A T 1 1 :STAT 12:S T A T 1 3 :

MANUAL TESTMONTHLY TESTYEARLY TEST

FinalReport 1 8 20kVA lnverter Svstem

.::::_T::i::__:Y: ?Ixxxxxxxxxxxxxxxxxxxxl * Status message 11, 12, 13

I toad: xxxvac xx .xKVA|

IAC Cur ren t : xx .xA II F r e q : 6 0 H z I

STAT 1-] . :STAT 12:STAT ]-3:

MANUAL TESTMONTHLY TESTYEARLY TEST

Test data recal l Messaqe FRAME 1T - - - - - - - - - - - - +

I tes t DaEa Reca l l Ilxxxxxxxxxxxxxxxxxxxxl * Status message

lTes t Dura t ion xxx m. I

1l:::_::i:::::::Ti::l * S'�a'�us messase

L t , L 2 , L 3 , L 6

! 4 , 1 5 , 1 6 , L 7

STAT 1-1STAT 12STAT ]-3

STAT 14STAT ]-5STAT 15STAT 1-7

}4ANUAL TESTMONTHLY TESTYEARLY TEST

PassedFa i l ed

NO da ta !Cancel l -ed

TesE dat .a recal l MessageT - - - - - - - - - - - - +

l TesE Da ta @ Min :I oc vot-c : xxx. x vloc cu r r : xxx .x Alnat tery : _ xxxt+ - - - - - - - - - - - - T

Test data recal l Message FRAMEf - - - - - - - - - - - - +

l Tes t Da ta @ Min : xxlac vo l tage: xxx VIAC Cur ren t : xx . x Al r r e q : 6 0 H z

FRAME 2

al l Message FRAME 1

l a la rm His to ry Reca l l

| 1 : xxxxxxxxxxxxxxxxxx

| 2 : xxxxxxxxxxxxxxxxxx| 3 : xxxxxxxxxxxxxxxxxx

* A]arm Recal- ] Messaqes


ALARM DATA RECALL MESSAGESNO FAULTS NO FAULT

\v. ALARM 1- High battery voltALARM 2 System overLoadedALARM 3 LVDALARM 4 Low float voltageALARM 5 Charger failureALARM 5 High charge curr.ALARM 7 High input AC VALARM I Low input AC VALARM 9 AC Brourn-outALARM l-0 Input AC FailureALARM L1 High temperatureALARM 12 Ground leakageALARM 1-3 Fuse/CB openALARM l-4 High AC output VALARM l-5 Low AC output VALARM 1-6 Inverter TripALARM 1-7 AC RestoredALARM 1-8 Charger AC Lost

PRINT Test data h is tory recal l Message FRAME 2+ - - - - - - - - - - - - +

l T e s t H i s t o r y R e c a l 1 |

l 1 : xxxxxxxx xxxxxxxxx l * S ta tus message 1 -5 ,18 , t g S ta tus message 14 , l . � 5 , L7.- l2 :xxxxxxxx xxxxxxxxxl

I i _ :::::i:-::::il:::lS T A T 1 - 4 : l P a s s e dS T A T 1 5 : I r a i l e dSTAT 1-6 : luo dara !S T A T 1 7 : l C a n c e l l e dSTAT 18 lMonthlySTAT 19 lvearly

TIME SCREEN+ - - - - - - - -

l 2 4 H R T i m e : x x : x x : x xII

lNex t Auto TEST O:

l x x : x x I n x x D a y ( s )i - - - - - - - - - - - - +

MODE START MESSAGES HI CHARGE MODE

INIT. Charge Mode

1 9

FinalReport 20 20kVA Inverter System

MODE START MESSAGES EQUALIZE MODE

IN IT . Equa l i ze Mode

+ - - - - - - - - - - - - +

MODE START MESSAGES FLOAT MODE

IN IT . F loa t Mode

STATUS MESSAGES

STAT 0 High Charge ModeSTAT l- Equalize ModeSTAT 2 Float ModeSTAT 3 Discharge ModeSTAT 4 Test ModeSTAT 5 Star t ing ChargerSTAT 5 Star t ing Inver terSTAT 7 Inverter ONSTAT 8 Inverter OFFSTAT 9 *** WARNING ***

STAT 1-O UNIT SHUTDOWN!STAT 11 MANUAL TESTSTAT 12 MONTHLY TESTSTAT 13 YEARLY TESTSTAT l -4 PassedSTAT 15 Fa i l edSTAT l -5 NO data!STAT l -7 Cancel- IedSTAT l-8 MonthlySTAT 19 Year lysrAr 20 | |

Final Report 2OkVA Inverter Svstem

Appendix A

Waveforms Recorded During Open-loop System Etficiency Test (Table 2)

Appendix A Open LoopSystem Efficiency & THD (Tabte 2)

Tek Run: 10.0kS/s Sample

gE r .oo v

Tek Run : 10 .0ks /s

:----------**{--T-- }**--*-----."-i

I a , l eo t / t1 |u

( ̂ " 5 e o v / d , v

f t , Zg ,z A /c t ,v

25 7" LoaD

T e k 0 0 0 0 5 ( 6 4 0 x 4 8 0 x 2 t i f f )

Sample

2 1 N o v 1 9 9 8I 7 : 5 9 : 2 7

2 l N o v 1 9 9 8I 8 : 0 2 : 1 I

L u ' I x / / 7 , y

V a. Soov' / d,v

I l z g t t A / / ' v

5o 7 LoAD

d s - , : 2 K H z

g|E 1.oo v

Appendlx A Open Loop System Eflicienc & THD Oable 2)

i----*------- [- r"- l.*-*--^-*----iTek Run: l0.0ks/s Sample

Tek Run : l 0 .0ks /s

I a< | ooe /a;v

V u . 9 . , . " v f a , n

1 r , 2 s e e / d , v

-75 7c L9AD

T e k O 0 0 0 8 ( 6 4 0 x 4 8 0 x 2 t i f f )

Sample

2 l N o v 1 9 9 8t 8 : 0 5 : 1 2

2 ' l N o v 1 9 9 8I 8 : 0 8 : 5 5

I a. l ,co a /t t ,v

Vn. *ov/dt

1T, zfo A/t\tv

\ rzo 2o LoeD

I t " , : 7 Vnz

i................................................r.........r-.......I..-.........-.-............-.................ii L I J i

qE r .oo v

Appendlx A Open Loop Syctem Efflclency & THD (table 2)

1.00MS/s Sample reTek Run: DPO Br ightness: 40 %

qE 1 . 0 0 v

T e k 0 0 0 1 0 ( 6 4 0 x 4 8 0 x 2 t i f f )

Tek Run: 5 .00Ms/s Sample re DPO Br igh t l

T o . t r z e a / 4 , ,

Vr^ , 5 . .o v / tJ ,v

z5 e A /c l r vril

2 ' l N o v 1 9 9 8I 8 : I l : 2 9

2 l N o v 1 9 9 81 8 : 1 2 : 2 0

T. a, leeA /d,v

V o. qeol / / tv

fr, >9o A/t),v

l o o

{r-

/" Lor+D

2 k n e

DPO Br ightness: 40

qE r .oo v

Appendk A Open Loop Syotem Efflcienc & THD (Iable 2)

i-*-*-------^-t--r-- "1-----*------iTek Run: 10 .0kS/s Sample

T e k 0 0 0 1 2 ( 6 4 0 x 4 8 0 x 2 t i f f )

Tek Run: 5.00MS/s Sample re DPO Brightness: 40 %

2 l N o v 1 9 9 8I 8 : 1 7 : 5 6

2 1 N o v 1 9 9 8' l 8 : 1 8 : 4 1

T a " I o o 4 / / , ,

V n. <eo v f t)rt

Irr zto A/cti l

t r , > / o

( ^ )1 5 u l a

LOAD

Y V Z

I a, rotz14/4,u

Vn, 9ee v /tlrv

r i - , z5o A/d tv

1 . 0 0 v

Appendlx A

Tek EI$E 2s.oks/s

Open Loop Systern & THD (fable 2)

- f c r .

+ r i .v roeA/d,v

- V;'., gwrt /drv

- r *P loA/d,v

2 l N o v 1 9 9 8I 8 : 3 3 : 2 I

gE s.00 v

T e k 0 0 0 1 3 ( 6 4 0 x 4 8 0 x 2 t i f f )

83 Acqs

5 . 0 0 v

t ( e 7 , L o t + D

+ V i . 5oo v / al,v

alcAf v a /cl,v

2 1 N o v 1 g g 8l 8 : 3 2 : 4 0

--t

..?

I a t

r i -v toa A /d tv

T€l( Run: 10.0kS/s Samplei"*--*--- *--- {--r*--l-- -*------^ !

i"---------^ --[--r-- l---------- *-i

1 . 0 0 v

Final Report 20kVA Inverter Svstem

Appendix B

waveforms Recorded During voltage Regulation Test (Table 4)

Appendix B Voltage Regulatlon Test flable 4)

Tel( EIUE l0.0ks/s 268 Acqs

ch3 r . 0 0 v

Vo Seov/4,y

I o 9o a/d,v

l o = o / )

Ir )SoA/du

frm 5.0$ v

o f t LoaD

i . i 14 . i . t ) t : t \1

2 5 7 ' L o a D

5 Dec 1 998l 7 : 5 0 : 5 2

5 Dec I 99817:28:41

gooV / du

E o A /d,ty'

= t4. t A (rs\ . )

2s o A/dt v

Vo

f o

T-o

-rJ T

I

3

l,t't,".;.,,., r,",,. .,..,..,r,, - *.,. .....*,.,.1rti,1r,r.;, ;ar",rr,J .8.).i

ms

g E 1 . o o v

Appendix B

Tel( EIUE 10.0ks/sl

Test Cfabb4)

vo

ao = t4 -v ts ( t"Z-)

5o7. LeaD

64 Acqs. - T : -

T-

5 Dec '1998

I 7 : 2 9 : 3 1

5 Dec I 9981 7 : 4 8 : 3 7

v o

T- l

T , = 4 1 . t A ( z y ? )

5 . lltS \,1

1E 7' Lo,qD

ms

Tek Run: 10.0kS/s Samplet - - " , - " -"" r " - - - - - -^-^-- l

1 . 0 0 v

c h 3 r . 0 0 v :@.w3

Tek Run: l0 .0ks /s Samplet

c h 3 1 . 0 0 v

Jo = t 8 ,+A ( t o ' 2 ,

f r

vo

Tek Run: 5.00MS/s Sample DIreI r :

l .

Lo,aD

[ . t ]0 11

I o o / " L o a D

DPO Erightness: 40 %" - - - l

5 D e c 1 9 9 8I 7 : 3 5 : 1 8

5 D e c l g g Sl 7 : 3 4 : 3 6

vo

f o = 5 & ' U A (,o,?.

1 7

wffi 5.i)fi v

\oo / "

1 . 0 0 v

Appendix B Voltage Regulation Test (Iable 4)

Tek Run: l0 .oks/s samplef . .

vo

f o = b v . z a ( r o l o ' .

J-,-

3 . 4 * V

t t t z / ,

409 Acqs

5 D e c 1 9 9 817:37:26

Tel( EIUE s.00MS/sI

Lea>

DPO Brightness: 40 %" " - " ' - t

vo

J o = b * - z A { t r o 7 , )

f1

Wffi i.(',) v*

t t t > /o LoaD

5 D e c l g 9 8I 7 : 3 9 : 3 3

c h 3 1 . 0 0 v

Finalf;eport 20kVA Inverter Svstem

Appendix CWaveforms Recorded During Charger Test (Table 5)

Appendlx C Ch€rger Test

Tek Run: 25.0ks/s Sample

TOk Run: 25 .0ks /s Sanrp le

200mV

T oo- (AVer) : b- O f)

V"ur (Pecr )

l o t > V / d t v

Vt, . t ((ecr)

l o e V / d t v

Iout (Pecr)

S r n / / , u

l 7 N o v 1 9 9 81 6 : 2 8 : I 3

Vou, ( Pect )

l e o V / d t V

V,n, ( 8ec-t^)

wet t / Av

f oo, ( KzLT )

Eea/dt

l 7 N o v 1 9 9 81 6 : 3 7 : 5 8

Ch4 200mV

f o r t ( A V A ) =

Appendlr C

qlE 10.omv

i-----*-*-- { T--} --------**-i

Ch4 200rf iV

f ou t ( / \ v h ) = 1 ,8 . , 2 / )

Charger Test

Tek Run: 25.0ks/s Sample

Tek Run: 25 .0ks /s SarnPlei -*--""t--r---l--^-----"----i

Ch4 200mV

T o l t ( A V G ) = 2 4 ' o 4

Vour ( PELT)

1oo V / / 1y

V,,.t ( Rect 1t 0 o V / d t v

I or..,r ( Qea )

5v A/d tv

1 7 N o v 1 9 9 8l 6 : 3 4 : 3 4

Vo,.tt ( flecr)

l 0 o V / d r V

Vr,./ ( Pect)

1 , > o v / d t v

Iout ( Qeq )

tro */ dtv

t 7 N o v 1 9 9 8l 6 : 1 7 : 1 7

glp 10.0mv


Appendix DLoad Transfer Test

Appendix D Load Transfef Test

Tel( EISE s00 s/s

Vo Soev/dtv

To 9oa/du

. I ' r , ( T 6 8 T )

2 2 D e c 1 9 9 8I 4 : 5 0 : 1 8

Loao SwtTct '16.3 €p,o,q tNvhRTEQ To3ol tpLY ( tv l t tdrJeL T. . -sr )

Tek EIUE s00 s/s 4 Acqs

(o Seov /cltrl

To E,ta/dt

lr, G e'gT )

2 2 D e c 1 9 9 814i48:28

r . l-".*^^-'.r

LOAD <V)tTcHeS (B. ,zrur SOpnL' { To \Jve(r6R (P4rsNUat- fesr)

Appendlr D Load Transter Test

Tek EIUE Single Seq 2.50ks/sr l

ch3 1 .00 v wK) 5.0* \ /

Vo 9oe0lc(tv

I o Q Nvepren)

5 o a / d t v

(Rer )v o

1 0 D e c 1 9 9 81 5 : 0 9 : 0 1

gE 1 .oo v { } \ 4 7 , , t } * V

I o Sectt /dru

f o ( t { v e Q r e P )

5o A / c l t v

v,fr ((e€ )

l 0 D e c 1 9 9 81 5 : I 2 : 0 9

l r tJVeRte( pow€BeD u P w rTH Dt€F€€€AlT LoaDt i l& LoNDt r i c {6

Appendlx D Load Transler Test

Tek EEil Single Seq 2.s0ks/s

Vo eoov /4t,/

I , z ( t N v e e r e P )

e o A / d t v

\/: (ReF )

l 0 D e c 1 9 9 8l 5 : 2 4 : 1 5

gE 1 .oo v { :114 5.0$ V

Tek EIqE single seq 2.50ks/s; T

EIIE 1 .00 v i ' . i t4 : i . / ' .1 ! \ \ ;

l o o / o L o r + D

Vo lee ! /d rv

1o ( r.rsvercrer<)

6 e A r r d r V

Y; (Kec )

l 0 D e c 1 9 9 81 5 : 3 2 : I I

txJvar t reR PouoefZeD 0? Wtr H Dr€(e BeNr Laao uJ6 LoN DrTror .Js

FinalRepoft 20kVA Inverter Svstem

Appendix E

Measured Waveforms with HID Lamp Load

Appondlx E HID Lamp Load

T e k E E i l l 0 . 0 k S / s ' ' t ' 2 1 c q s ^ - - | - - � � � � � � �

Clr3 s .00 V Wtr i '2 .0$t rv

Z t - o o @ x b H P s L a v p S

SreeoY STare opePAQo!

V" 2JoV/a,v

fo 1ory 'a, ,

22 Dec I gg81 6 : 0 5 : 2 2

qiru\ "{ltu,\: ' it't�

rff.r .f-.r.

\ l i l\.ir,\ i i r

. \ o'!',,'

f r | I{ . : ' t 1I i ! , lr.-i-r*r- r..t-i".t1

3

m v M 5 . 0 0 m s

Appcndlx E HID Lamp Load

Tek EluE ro.oks/s

Wffi lt).(Jt11\i

Tek EEil l o.oks/s l 3 Acqs

Clr3 5.00 V l&f f i ] t t ' j . r . j1111' /

6 Acqsl - - 1 : - - - - l

Vo zsoV/hv

!o l , ze /do

TerDv = 4^4%

T u D i = I Z Z

2 2 D e c 1 9 9 816:22i24

(" zsoV / / tv

Io l ,zA /d tv

THD v - 4 . t * lo

T H D d = I U V \ "

22 Dec I 9981 6 : 2 3 : 4 5

4o,! x 6 F/Ps L/,lr4p s

Ho T lQesrBt re

5 . 0 0 v

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3

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I

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fff

m

Final Report 20kVA lnverter Svstem

Appendix F

Flowcharts

AppondhF Fbwcharts

.ff'ffiH,T:3.T:,,F-MAIN

F-ALARM]-F-ALARM2F_ALARM3F_ALARM4F*ALARM5F_ALARM6F_ALARMTF_ALARMSF_ALARM9F-ALRMI0F_ALRM11F-ALRMIBF_ALRM12F_ALRM]"3F_ALRM14F-ALRM15F-ALRM1 6F_AIRMI?F-ALRMI8F-ALRMI9F_ALRM2OF_ALRM2].F-ALRM22F-ALRM2 3F_ALRM24F_ALRM25F_ALRM25F_ALRM27F-ALRM28F-ALRM3 OF-ALRM29F_ALRM3 ]-F_ALRM3 2F_ALRM3 3F-ALRM34F ' C H p C 1

r L E K U Z

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F*FLT1.7F T T . T l Q

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P SP SPSPSP SP SPS

P SP SPSP SP SPSr J

PSP S

P S

P Sr JPSPSP SP SP SP SPSPSP SP SP S

PSPSPSP SP S

Appendix F Flowcharts

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Appendlx F E Flowcharts

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Appendlx F 1 0 Flowcharts

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final report 2okva inverter system - ryerson universitybwu/buffer/report_lumacell_ups.pdf · final...

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