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Method for Calculating the Discharge Time of a UPS Uninterruptible Power Supply

a. Basic Formula: Active power of the load × Support time = Battery discharge capacity × Battery voltage × UPS inverter efficiency. Where: Active power of the load = Total load power × Load power factor; UPS inverter efficiency ≈ 0.9; Battery discharge capacity = Nominal battery capacity × Battery discharge efficiency. Battery discharge efficiency depends on the discharge current or discharge duration and can be determined by referring to the table below: b. Calculation Formula: Active power of the load × Support time = Battery discharge capacity × Battery voltage × UPS inverter efficiency. c. Example Calculation: Example: Total load power is 3000 VA, load power factor is 0.7, UPS battery voltage is 96 V, and the required support time is 1 hour. Determine the appropriate battery capacity to be selected. Calculation: 3000 (VA) × 0.7 × 1 (h) = Battery discharge capacity × 96 × 0.9 Battery discharge capacity = UPS (VA) × 0.7 × 1 (h) / Battery voltage × 0.9 Nominal battery capacity = Battery discharge capacity / Discharge efficiency. Result: Battery discharge capacity = 24.3 (Ah); Nominal battery capacity = 24.3 / 0.6 = 40.5 (Ah). Conclusion: A 38 Ah battery (8 units of 12 V/38 Ah batteries) can be selected. The battery discharge within the UPS should be a constant-power discharge, meaning the load power remains unchanged regardless of whether the mains power is normal or not. Battery discharge current = (Load apparent power × Load power factor) / (Inverter efficiency × Total battery pack voltage). Any change in the load characteristics will result in a change in the discharge current. It is important to note that the UPS does not have a concept of constant-current discharge. However, when determining the battery configuration, some battery manufacturers provide battery parameters only for constant-current discharge (because the definition of battery capacity is based on constant-current discharge). In such cases, the constant-current discharge parameters may need to be used. Total load power × Load power factor × Support time = Nominal battery capacity × Discharge efficiency × Battery voltage × UPS inverter efficiency. Support time = (Nominal battery capacity × Discharge efficiency × Battery voltage × UPS inverter efficiency) / (Total load power × Load power factor). Nominal battery capacity = (Total load power × Load power factor × Support time) / (Discharge efficiency × Battery voltage × UPS inverter efficiency). Support time = (Ah × Discharge efficiency × Battery voltage × 0.9) / (KVA × 0.7). Nominal battery capacity = (KVA × 0.7 × Support time) / (Discharge efficiency × Battery voltage × 0.9).

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2019/02

Solutions for Electromagnetic Compatibility Compliance Issues in UPS Uninterruptible Power Supplies

According to years of research and practical experience in electromagnetic compatibility (EMC), if we assume that addressing EMC issues during the product development phase costs 1 unit, then resolving them during the prototype development phase could cost as much as 10 units. By the time of mass production, the cost could soar to 100 units, and by the time of on-site installation, the cost could be thousands of times higher—or even become impossible to resolve altogether. Therefore, EMC issues for UPS uninterruptible power supplies must be addressed during the product’s development phase. Given the specific characteristics of UPS products, their EMC primarily involves the following aspects: conducted emissions from the power input and output; radiated emissions from the power supply; and the UPS’s immunity to interference. Below, we will discuss in detail the design methods for meeting the relevant standard requirements. 1. Suppression of Conducted Emissions from Input and Output For conducted emissions, we can consider three key aspects: the emission source, the conduction path, and direct suppression of interference. A. Elimination and Reduction of Emission Sources: In a UPS, there are AC/DC rectifiers, DC/AC inverters employing SPWM technology, high-frequency PFC circuits, and DC/DC conversion stages—all of which are significant sources of interference within the UPS. Particularly critical are transformers, inductors, and high-frequency current loops. Therefore, carefully designing the parameters and manufacturing processes of these components and optimizing their placement within the overall system can significantly reduce their interference levels. Additionally, properly designing the PCB layout and wiring for high-frequency currents can further improve the UPS’s emission performance. For the drive circuits in power converters, increasing the drive resistance without compromising efficiency or internal impedance can lengthen the rise and fall times of switching signals, thereby reducing the high-frequency harmonic content of voltage and current. B. Suppression of Conduction Paths: Since all conducted emissions can only affect the UPS’s input and output terminals via appropriate spatial paths and conductive pathways, minimizing these transmission paths is an effective way to reduce the UPS’s interference. For example, placing all emission sources as far away as possible from the input and output terminals, routing power cables away from the vicinity of emission sources, reinforcing suppression measures at the entry and exit points of emission sources, using shielding to spatially isolate emission sources from other components, and positioning the input and output terminals at relatively distant locations within the entire system—these strategies can all help reduce conducted emissions effectively. C. Direct Suppression of Interference: If, after adopting the above methods, the UPS still fails to meet the standard requirements, directly installing appropriate EMI filtering components—such as inductors, high-frequency capacitors, or dedicated filters—in the input and output circuits can once again effectively suppress the UPS’s conducted emissions. Practice has shown that simply increasing the relevant parameters and attenuation dB values of the filters typically allows the UPS’s conducted emissions to be reduced below the standard limits. Of course, it’s crucial to install the filters as close as possible to the input and output terminals, since even a few extra centimeters of wiring can increase interference. Plug-in filters are the most ideal choice in this regard. Moreover, the capacitors used in the filters or externally added EMI filtering capacitors should ideally be non-inductive to enhance their filtering effectiveness. 2. Suppression of Radiated Emissions from the Entire System For radiated emissions from the UPS, there are two primary approaches: suppressing the intensity of the radiation sources and managing the radiation paths. A. Suppression of Radiation Sources: In a UPS, the method for suppressing the radiation intensity of emission sources is essentially the same as that used for conducted emissions, since the emission sources themselves generate both conducted and radiated interference. Additionally, for radiated interference, applying appropriate shielding measures to the radiation sources can effectively reduce the level and energy of the radiated emissions. B. Managing Radiation Paths: Equal-potential design of the entire system’s enclosure: According to electromagnetic field theory, in a well-grounded, ideally sealed metallic enclosure with six closed surfaces, there is no mutual interference between the internal and external electromagnetic fields. Therefore, the UPS enclosure should generally be made of metal, with all surfaces properly connected to ensure they form a single equipotential body. This approach can significantly weaken the UPS’s external radiated emissions. In general, for applications with strict EMC requirements, it’s best not to use plastic for the UPS enclosure. Handling connections entering and exiting the UPS enclosure: Since the UPS must have connections such as input and output power terminals and battery expansion terminals passing through its enclosure, proper handling of these connections to prevent interference is extremely important and directly affects whether the test results meet the standard requirements. Generally, adding suitable high-frequency magnetic rings and high-frequency capacitors to these lines can achieve excellent results. 3. Immunity Design for UPS Systems The immunity of a UPS mainly refers to the anti-interference capability of its control circuitry. From a circuit perspective, this can be divided into two aspects: immunity of analog circuits and immunity of digital circuits. Good anti-interference performance is a prerequisite for ensuring the normal operation of the UPS. Therefore, during the initial design stage of the UPS’s control circuitry, its anti-interference capability must be taken into account. Otherwise, when exposed to external interference, the entire control scheme could be completely compromised. A. Immunity of Analog Circuits: For open-loop analog control systems, it’s common practice to add appropriate RC circuits to parts where interference might occur, thus eliminating the disturbance. For closed-loop analog control systems, in addition to using RC circuits, it’s also essential to appropriately adjust the frequency characteristics of the closed-loop amplifier’s gain to ensure that any interfering signals won’t have adverse effects on the loop. For the power-stage circuits, shortening all wiring lengths, adding dummy loads, and reducing the complexity of the power-drive circuits can all effectively enhance the power circuit’s anti-interference capability. B. Immunity of Digital Circuits: For digital control circuits, their anti-interference capability is crucial to the reliability of the UPS, since nearly all modern UPS control systems now employ microcontrollers with digital control. A system with poor anti-interference performance could lead to UPS shutdowns or damage. Effective filtering of the digital circuit’s power supply is the fundamental guarantee against interference; all I/O ports should undergo appropriate RC treatment; the control circuitry should be kept as far away as possible from the power stage; appropriate electromagnetic shielding measures should be implemented; and a well-designed PCB layout can all effectively prevent digital systems from being affected by external interference. It’s important to emphasize that for closed-loop voltage regulation and synchronization control in UPS systems, the anti-interference capability of the control model and software filtering techniques must be thoroughly and reasonably considered during system modeling and fully tested during system commissioning.

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2019/02

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