DESIGN AND CONSTRUCTION OF 500VA

UNINTERUPTED POWER SUPPLY (UPS)SYSTEM

ABSTRACT
500VA power UPS system is a DC to AC conversion system of 500VA
power rating and expected to carry around 400 watts load. It provides
power to electronic and electrical appliances such as radio sets, TV
DVD/VCD, computers, fans and lighting. The design was conceived and
put down as block diagram. Corresponding circuit diagrams for each
black box were sourced and drawn. The component values according to
desired specifications were designed from the first principle and needed
values derived. The transformer was also designed and with
measurements and component values we went to the market. Most of
the transistors were not in the market and order was made with the
trader and they were later collected. These components were first wired
on project board, tested before being removed and transferred to
veroboard where they were soldered permanently and tested. The tests
carried out were successfully including the capacity of the transformer
and the transformer stability and hum-free operation. The circuit
veroboard and transformer along with meters, switches, indicators and
output sucket were all carefully packaged inside the system box and test
carried out again. This financial test was also successful.

CHAPTER ONE
INTRODUCTION:

The Background of the Problem

Power inverter system is a unit developed for the conversion of direct
current (DC) into alternating current (AC) to serve electronic and
electrical appliances, such as radio sets, television sets, DVD/VCD,
computer, photocopying machine etcetera and also provide lighting and
power to fans. Inverter systems could be used in conjunction with the
solar energy conversion system for the harnessing of solar power energy
and also as vital part of uninterrupted power surprise system.
The concept and development of power inverter system because
necessary of the poor national power supply system that resulted in
incessant power supply and power outages. Power inverter is also found
in use where there is no supply of electricity in the first place.

The Purpose/Objective/Aim of the Project

The purpose of the project is to design and construct a 500VA power
inverter system for the supply of A.C power to serve load of about
400watts power (the active or real power, 500VA x 0.8 = 400 watts).
The objective of the project is to ensure that the research produce an
inverter and step-up transformer that would be able to transform few
D.C voltage of about 12 voltage to up to 220 volt A.C 50Hz obtainable
from the national power supply. Electronic appliances designed and
constructed for use in Nigeria are meant to work at the designed
specification of 220/230 Volt AC, 50Hz in contrast to similar equipment
meant to work in a country like Japan whose national electric power
supply is 110 volt A.C., 60Hz.
The designed and constructed power inverter system in accordance with
the specification of national power supply will not discriminate against
any equipment nor serve only a particular electronic appliance. The
inverter system will be universally accepted by any system operating in
Nigeria or in countries that adopted same specification. BY this, the aim
of the project design and construction must have been achieved.

Scope of the Project

This project is on the design and construction of 500VA power inverter
system with an in-built battery supply. In the first place, the 12 VDC
battery is not part of the system to be designed implemented. The scope
of the project includes designing and deriving the component values of
all the circuits involved for the implementation of this project. These
components are sourced and fixed in the vero board according to the
determined circuitry, wired and tested through. The circuitry is
completed by the design of transformer laminations and coils or
windings, packaging and clamping of these laminations to air tight
condition and testing through to ensure the specified rating of 400W
which will supply a real power of 500VA x 0.8.
The scope of the project also coverted testing of the entire system after
packaging in a metal construction with vent that will ensure in-let of air
as coolant to the transformer that is expected to generate heat while in
operation including power transistors.
The power inverter system produced cannot work along wired
installation of power supply from the national grid unless other units are
incorporated. It works on stand alone bases where no power was
extended from the national into operation intermittently
CHAPTER TWO
2.0 LITERATURE REVIEW

2.1 BACKGROUND
DC and AC Current
In the world today there are currently two forms of electrical
transmission, Direct Current (DC) and Alternating Current (AC), each
with its own advantages and disadvantages. DC power is simply the
application of a steady constant voltage across a circuit resulting in a
constant current. A battery is the most common source of DC
transmission as current flows from one end of a circuit to the other.
Most digital circuitry today is run off of DC power as it carries the ability
to provide either a constant high or constant low voltage, enabling
digital logic to process code executions. Historically, electricity was first
commercially transmitted by Thomas Edison, and was a DC power line.
However, this electricity was low voltage, due to the inability to step up
DC voltage at the time, and thus it was not capable of transmitting
power over long distances.
V=IR
P=Iv
As can be seen in the equations above, power loss can be derived from
the electrical current squared and the resistance of a transmission line.
When the voltage is increased, the current decreases and concurrently
the power loss decreases exponentially; therefore high voltage
transmission reduces power loss. For this reasoning electricity was
generated at power stations and delivered to homes and businesses
through AC power. Alternating current, unlike DC, oscillates between
two voltage values at a specified frequency, and it‘s ever changing
current and voltage makes it easy to step up or down the voltage. For
high voltage and long distance transmission situations all that is
needed to step ‗up or down the voltage is a transformer. Developed in
1886 by William Stanley Jr, the transformer made long distance
electrical transmission using AC power.
Electrical transmission has therefore been mainly based upon AC
power, supplying most homes with a 240 volt AC source. It should be
noted that since 1954 there have been many high voltage DC
transmission systems implemented around the globe with the advent
of DC/AC enviers, allowing the easy stepping up and down of DC
voltage. Like DC power, there exist many devices such as power tools,
radios and TV‘s that run off of AC power. It is therefore crucial that
both forms of electricity transmission exist; the world cannot be
powered with one simple form. It then becomes a vital matter for
there to exist easy ways to transform DC to AC power and vice versa
in an efficient manner. Without this ability people will be restricted to
what electronic devices they use depending on the electricity source
available.
Inversion is the conversion of de power to ac power at a desired
output voltage or current and frequency. A static semiconductor
inverter circuit performs this electrical energy inverting transformation.
The terms voltage-fed and current-fed are used in connection with the
output from inverter circuits.

A voltage-source inverter (VSI) is one in which the dc input voltage is

essentially constant and independent of the load current drawn. The
inverter specifies the load voltage while the drawn current shape is
dictated by the load.
A current-source inverter (CSI) is one in which the source, hence the
load current is predetermined and load impedance determines the
output voltage. The supply current cannot change quickly. This current
is controlled by series de supply inductance which prevents sudden
changes in current. The load current magnitude is controlled by
varying the input dc voltage to the large inductance; hence inverter
response to load changes is slow. Being a current source, the inverter
can survive an output short circuit thereby offering fault ride-through
properties.
Voltage control may be required to maintain a fixed output voltage
when the dc input voltage regulation is poor, or to control power to a
load. The inverter and its output can be single-phase, three-phase or
multi-phase. Variable output frequency may be required for ac motor
speed control where, in conjunction with voltage or current control,
constant motor flux can be maintained.
Inverter output waveforms (either voltage or current) are usually
rectilinear in nature and as such contain harmonics which may lead to
reduced load efficiency and performance. Load harmonic reduction can
be achieved by either filtering, selected harmonic-reduction chopping
or pulse-width modulation.

2.2 INVERTERS AND APPLICATIONS

Power inverters are devices which can convert electrical energy of DC
form into that of AC. They come in all shapes and sizes, from low
power functions such as powering a car radio to that of backing up a
building in case of power outage. Inverters can come in may different
varieties, differing in price, power efficiency and purpose. The of a
DC/AC power inverter is typically to take DC power supplied by a
battery, such as a 24 volt car battery, and transform it into a 240 volt
AC power source operating at 50Hz, e the power available at an
ordinary household electrical outlet.
Most inverters do theft job by performing two main functions: first
they convert the incoming DC into AC, and then they step up the
resulting AC to mains voltage level using a transformer. And the goal
of the designer is to have the inverter perform these function as
efficiently as possible so that as much as possible of the energy drawn
from the battery or solar panel is converted into mains voltage AC, and
as little as possible is wasted as heat. Electric grid may not be as
accessible to hook into. Inverters allow the user to provide AC power
in areas where only batteries can be made available, allowing
portability and freeing the user of long power cords.
On the market today are two different types of power inverters,
modified sine wave and pure sine wave generators. These inverters
differ in their outputs, providing varying levels of efficiency and
distortion that can affect electronic devices in different ways.

A modified sine wave is similar to a square wave but instead has a

―stepping‖ look to it that relates more in shape to a sine wave. This
can be seen in Figure 1, which displays how a modified sine wave tries
to emulate the sine wave itself. The waveform is easy to produce
because it is just the product of switching between 3 values at set
frequencies, thereby leaving out the more complicated circuitry needed
for a pure sine wave. The modified sine wave inverter provides a
cheap and easy solution to powering devices that need AC power. It
does have some drawbacks as not all devices work properly on a
modified sine wave, products such as computers and medical
equipment are not resistant to the distortion of the signal and must be
run off of a pure sine wave power source.
The modified sine wave units can be very efficient, as there is not
much processing being performed on the output waveform, but this
results in a waveform with a high number of harmonics, which can
affect sensitive equipment such as medical monitors. Many of the very
cheap devices output a square wave, perhaps a slightly modified
square wave, with the proper RMS voltage, and close to the right
frequency.

Pure sine wave inverters are able to simulate precisely the AC power
that is delivered by a wall outlet. Usually sine wave inverters are more
expensive than modified sine wave generators due to the added
circuitry. This cost, however, is made up for in its ability to provide
power to all AC electronic devices, allow inductive loads to run faster
and quieter, and reduce the audible and electric noise in audio
equipment, TV and fluorescent lights.

2.3 PULSE WIDTH MODULATION

In electronic power converters and motors, PWM is used extensively as
a means of powering alternating current (AC) devices with an available
direct current (DC) source or for advanced DC/AC conversion.
Variation of duty cycle in the PWM signal to provide a DC voltage
across the load in a specific pattern will appear to the load as an AC
signal, or can control the speed of motors that would otherwise run
only at full speed or off. This is further explained in this section. The
pattern at which the duty cycle of a PWM signal varies can be created
through simple analog components. a digital micro controller, or
specific PWM integrated circuits.
Analog PWM control requires the generation of both reference and
carrier signals that feed into a comparator which creates output signals
based on the difference between the signals 10. The reference signal is
sinusoidal and at the frequency of the desired output signal, while the
carrier signal is often either a saw tooth or triangular wave at a
frequency significantly greater than the reference. When the carrier
signal exceeds the reference, the comparator output signal is at one
state, and when the reference is at a higher voltage, the output is at
its second state. This process is shown with the triangular
carrier wave in red, sinusoidal reference wave in blue and modulated
and modulated sine pulses.

In order to source an output with a PWM signal, transistor or other

switching technologies are used to connect the source to the load
when the signal is high or low. Full or half bridge configurations are
common switching schemes used in power electronics. Full bridge
configurations require the use of four switching devices and are often
referred to as H Bridges due to their orientation with respect to a load.

2.4 INVERTER AND DESIGN

Many topologies, or circuit designs, have evolved in the quest for
creating higher power AC from low Voltage DC sources.
Square wave and modified square wave low frequency transformer
based inverter. The following topologies are based on low frequency
switching of the low voltage DC side, applying the resulting DC pulses
to a step transformer two common topologies are the push-pull, and
the H-Bridge. The push-pull topology is suitable for production of
square and modified square output waveforms, while the H-Bridge is
useful for producing modified square wave and sine wave outputs.

2.5 THE SQUARE WAVE INVERTER

The Square Wave Inverter derives its name from the shape of the
output waveform. Square wave inverters were the
original ―electronic‖
inverter. The first versions, such as TrippliteỘ, use a mechanical
vibrator type switch to break up the low voltage DC into pulses. These
pulses are then applied to a transformer where they are stepped up.
With the advent of semiconductor switches the mechanical vibrator
was replaced with ―solid state‖ transistor switches.
A common circuit topology referred to as ―push-pull‖ is used to
produce a square wave output the basic theory of operation behind a
push-pull design is as follows:

The top transistor switch closes and causes current to flow from the
battery negative through the transformer primary to the battery
positive; This induces a voltage in the secondary side of the
transformer that is equal to the battery voltage times the turn‘s ratio
of the transformer. Note: Only one switch at a time is closed.
After a period of approximately 8ms (one-half of a 60 Hz AC cycle),
the switches flip- flop. The top switch opens and then the bottom
switch closes allowing current to flow in the opposite direction. This
cycle continues and higher voltage AC power is the result.
The major problem with the push-pull approach is that the current in
the transformer has to suddenly reverse directions. This would be like
shifting your car into reverse at fifty miles per hour. This causes a
large reduction in efficiency as well as potential for large transients,
thus degrading the waveform. Another drawback is the transformer
required for a push-pull design must have two primaries. This is a
complex task to design a transformer meeting this requirement and
increases cost and bulkiness.
Square wave inverters are still produced but have several m
drawbacks. The output wave form has high total harmonic distortion
(Ti-ID). It does work okay for powering motors although the motor will
generate excess heat. Most electronic equipment will not operate well
(if at all) from a square wave. This is due to waveform characteristics,
and lack of voltage regulation. The peak voltage of the output pulse is
directly related to buffer voltage. Since the transformer ratio is fixed,
any change in battery voltage will affect the peak output voltage. For a
square wave, RMS voltage is equal to peak voltage and as a result
power output is dependent on battery voltage.
Finally, most square wave inverters have mediocre efficiency (typically
about 80%), and the idle power draw is relatively high.

2.6 MODIFIED SQUARE WAVE INVERTER

The addition of an extra winding in the transformer along with a few
other parts allows output of a Modified Square Wave (often referred to
as a modified sine wave by marketing types) while still utilizing a
push-pull topology.
The switching cycle is identical to that described in the section on
square wave inverters, except for one additional step. in the switching
cycle, another step is added which ―clears‖ out the transformer
reducing the problems associated with the sudden change in current
direction. This is accomplished by the off time shorting winding shown
in figure below. As one switch opens and before the second switch
closes, the switch across the shorting winding closes, effectively
removing the current from the transformer. This would be like slowing
a car to a stop and then shifting to reverse, much better than the
situation mentioned previously. Off-time shorting provides a better
zero crossing of the waveform, which equates to better ability to
operate electronic devices. Improved efficiency and lower total
harmonic distortion of the waveform are other benefits. Several
manufacturers accomplish off-time shorting by placing a solid-state
switch directly across the AC output lines. This approach works,
however the switch is not isolated from the AC output line, and as a
result it is subject to abuse from transients, which can be caused by
reactive loads (i.e.- electric motors). Utilizing a shorting winding in the
transformer is preferable due to the isolation provided from the AC
output.
The major advantage to a modified square wave is the ability to
regulate RMS voltage by means of varying the pulse width, and off
time periods. The pulse width variation method of regulation is
referred to as pulse width modulation or PWM.
The idea behind RMS regulation is to keep the area inside the
waveform equal at all times. since the peak voltage, or pulse height, is
a product of battery voltage and transformer ratio (as we learned
previously), when the peak voltage increases the area inside the pulse
will increase if the pulse width remains the same. With a square wave
inverter nothing can be done about this RMS voltage increase, but
PWM control allows the width of the pulse to be narrowed, thus
maintaining a constant area inside the Conversely, if the battery
voltage decreases the RIV1S voltage will also decrease if the pulse
width remains the same. In this situation, RMS voltage regulation may
be achieved by increasing the pulse width Increase and decrease of
pulse width is accomplished by controlling the on and off time of the
16
transistor switches. Realistically, there is a point where the zero time
is no longer present as the pulse width is increased, and essentially a
square wave is present. Beyond this point the RMS voltage becomes
unregulated.
Modified square wave inverters are a great improvement over square
wave types. They offer good voltage regulation, lower total harmonic
distortion and better overall efficiency. Electric motors operate much
better from a modified square wave and most electronic equipment
will operate without problems.
Summary of push-pull topology
The push-pull topology was the first step in ―electronic‖ inverter
technology Some major disadvantages are complexity of the
transformer design and higher transformer losses in a square wave
design.
The Advantage is the simplicity of the overall circuit design, and
opportunity for cost effective manufacturing.

2.7 H-BRIDGE INVERTERS

The H-Bridge topology accomplishes its task in much the same manner
as a push-pull topology. The main advantage of this design is the
simplicity of needing only one primary winding on tile transformer. H-
Bridge inverters have evolved with improvement in transistor
characteristics. Since current flows through two transistor switches in
series, instead of one as in the push-pull design, older more inefficient
transistors meant twice the losses in the inverter. This kept push-pull

topologies as the primary means of producing square and modified

square waveforms. The advent of FET‘s (Field Effect
Transistors) allows the H-Bridge design to be easily utilized. The
transistors are divided into four groups or ―corners‖ with the
transformer primary connected across the middle of the ―bridge‖ thus
forming an ―H‖ pattern. In practice each transistor switch is made up
of multiple transistors in parallel allowing higher current handling and
lower resistance when the switches turn on (called ―on resistance‖ of
the transistor). Notice also that there is no off time shorting winding in
the H-Bridge transformer. The current flow still reverses direction but
now the shorting is accomplished by closing the bottom two switch
groups at the, same type. This effectively shorts the transformer
primary removing residual current flow after the upper set of switches
turn off Just as in a push-pull circuit, the transistors are switched on
and off in a specific pattern to produce each part of the waveform. The
pattern is as follows:
Two opposite corners of the bridge are closed, allowing current to flow
from the battery negative through the transformer primary to the
positive terminal of the battery. This current induces a
current flow in the secondary of the transformer, which has‘ a peak
voltage equal to the battery voltage times the turn‘s ratio of the
transformer. After a period of time (variable according to pulse width
modulation for voltage regulation) the switches that were closed open,
and the bottom two transistor switches close providing off-time
Shorting. The length of the on and off-time is determined according to
the PWM controller. Next the two corners opposite step A, close and
allow current flow through the transformer in a direction opposite to
the current flow. After this cycle is completed, the bottom switches
close for off-time shorting and then the cycle repeat in this way AC is
produced.
An inverter system consists of:
AUTO - CHANGE OVER CIRCUIT: Which has a relay and converter,
which are sequential switches? The relay controls the inverter neutral
state and power Holding company supply, the comparator switches
between the battery to the oscillator circuit and the charging circuit.
The relay cut off the charging circuit to the terminal of the battery.
OVER - CHARGING CUT - OFF: This is by the operation of the
comparator which compares the battery voltage with a fixed reference
and detect when is fully charged. THE INVERTER STAGE: This convert
DC to AC input, thereby providing reliably stable output voltage and
frequency to the load when the main supply fails.
LOW DC VOLTAGE INDICATOR: This sense the operational state of
the battery when drained, hence shuts down after the time lapse of
five minutes.
CHAPTER THREE: MATERIALS AND METHODOLOGY

In this design, the building block or the working principle of the

system is evidently presented using a simple block diagram, as
you can see below,

DC SUPPLY OSCILLATOR AMPLIFIER

STEP UP
The above block diagram is further elaborated using simple
simulated circuit schematic diagram below.

INVERTER CIRCUIT
LIST OF MATERIALS:
12 volt DC battery

D1- 1n4007

D2- LED

C1- 0.1uf

C2-2200uf/16v electrolytic capacitors

U1- CD4047 IC

R1-6,7,8,9,10- 100 ohm resistor

R4,R5- 220 ohm resistor

Q1,2,3,4,5,6- IRF3205 n-channel mosfet

TR1- Step up transformer

DC SUPPLY :

In the inverter circuit, the DC power supply consist of a 12volt

battery,C2-2200uf/35v electrolytic capacitors.

The DC supply, provides an adequate DC voltage for the system, which

will be utilized for an electrical inverting process
OSCILLATOR :

U1- SG3525 integrated circuit (IC) is a muti vibrator IC, which is used in
the circuit to producing an oscillation which is frequency is dependent
on the configurations used, where in our circuit, we used C1-0.1uf, R3-
18K ohm, in setting the oscillator circuit in producing a 50Hz frequency
of operation.

The output signal of the oscillator is a simple clock wave or square wave
signal,alternating currents.

Generally, the oscillator, converts the DC supply into an alternating

currents AC.

AMPLIFIER :

The amplifier stage of the circuit, consist of an N-channel

mosfet transistors, Q1,2,3,4,5,6- IRF3205,and R1,6,7,8,9,10-
100 ohm resistor.

The amplifier, is divided into two parts of equal

components.the mosfet transistors are paired into three unit
components,which are connected in parallel,in order to be able
drive the the transformer of high wattage ratings,since we are
aiming at 500VA inverter system.
The amplifier takes up the signal from the oscillator circuit,
which is feed through the gate of the mosfet transistor,and
utilizes the signal in driving the high wattage transformer.

VOLTAGE STEP UP:

The voltage step up part of the circuit,consist of a step up

transformer,which has a high turn ratio at the secondary turn of the
transformer.

The primary turn of the transformer, takes the oscillation signal of the
oscillator circuit, via the driving of the amplifier circuit in creating an
induced currents at the secondary side of the transformer.the magnetic
flux created by the primary side of the transformer, moves through the
core elements of the transformer down to the secondary side of the
transformer. Theses alternating magnetic flux, creates a voltage at the
secondary turn of the transformer,which is dependent on the number of
turn we have in the secondary side.

Using the 1000 watt transformer, we where able to convert 12v DC

battery to 220V AC using the circuit,and this process is termed inverting.
 RESULT AND CONCLUSION

RESULT:

As we tested the 1KVA inverter system, the result was full of success.the
device was able to able to produce the essential AC voltage required of it,
where in our own case the value is 220V/240V, when the circuit is
triggered via the 12 volt battery,the oscillation reflected by the
oscillatory circuit, is observed as it gets the power transistor driven with
a very high frequency,which in our own case we use 50Hz.

The amplifier in a very high push-pull system,is found efficient in aiding

the transformer stepping up the voltage in its high state.

Below is the device,when its set active for proper functionality.

Below is the oscillator part of the circuit, as it was measured from the
oscilloscope.

More
CONCLUSION:
In this project, which turned out to be full of success, I constructed a
device that can send and power the house hold or industrial electrical
appliances as an alternative power supply,once the grid line or the
generator sets are not ACTIVE.

The project was implemented according to the following plan,

- I studied the configurations of oscillator circuits.

- I studied the signal amplification processes.

- I studied also, the working principle of a simple transformer

- Components and materials were listed accordingly

- The schematic and block diagram was elaborately shown.

-the complete assembly and testing of the inverter system was made,
and the result was a positive one.
REFERENCES: