Design And Construction Of A 500W Uninterruptible Power Supply Using SG3524N
The design and construction of a 500W uninterruptible power supply (UPS) utilizing the SG3524N integrated circuit (IC) involve several key steps. Initially, the system requirements and specifications, including input voltage range, output voltage, efficiency targets, and battery backup duration, must be defined. Following this, the design process involves selecting appropriate components such as transformers, MOSFETs, diodes, capacitors, and resistors, considering their compatibility with the SG3524N IC and the desired power output. The SG3524N IC, functioning as a pulse width modulator (PWM) controller, plays a central role in generating regulated square wave signals for controlling the power switching devices. These signals are then fed into a power stage comprising MOSFETs configured in a push-pull or bridge topology, along with associated driver circuitry. Additionally, a feedback loop incorporating error amplifiers and voltage/current sensing circuits ensures stable and regulated output voltage under varying load conditions. The UPS also incorporates battery charging and management circuitry to maintain the battery’s health and provide seamless transition between mains and battery power. Proper layout design and thermal management are critical for reliability and efficiency. Testing and validation procedures, including load testing, efficiency measurements, and reliability assessments, are carried out to ensure the UPS meets performance specifications and safety standards. Finally, documentation of the design process, including schematics, bill of materials (BOM), and assembly instructions, facilitates replication and troubleshooting. Through meticulous design and construction processes, a robust and efficient 500W UPS can be realized, catering to diverse power backup requirements in various applications.
ABSTRACT
The purpose of this project is to design and construct an uninterruptible power supply. Uninterruptible power supply is a voltage regulatory and uninterruptible power device planned to electromechanically sustain a constant voltage level and supply an uninterruptible power to devices.
This device receive minimum voltage of 120vac and maximum of 260vac and filter the current and voltage thereby brings out suitable voltage output to be used by the devices in it, then when there an unexpected power outage from the utility mains or generator the system will automatically switch over to the inverter source thereby providing additional power to the appliances in use without interruption.
This device stabilizes an AC input voltage of 120-260V to give an AC output voltage of 240V, provide a rechargeable backup power supply the system and also provide low battery indication automatically. The automatic feature can be achieved by the electronics devices used such SG3524N IC, electro-magnetic device (relay), auto- transformer and other electronics devices.
CHAPTER ONE
1.0 INTRODUCTION
In this modern society, electricity has great control over the most daily activities for instance in domestic and industrial utilization of electric power for operations. Electricity can be generated from public supply to consumers in different ways including the use of water, wind or steam energy to drive the turbine as well as more recently the use of gas. Generators, solar energy and nuclear energy are also source of electricity.
In Nigeria and some other parts of the world today, the electricity power supply to consumers (at homes and industries) is not maintained at a stipulated voltage say 240 volts. But the electronic gadgets and some other power operated machines, that we use in our homes, offices and industries requires power with constant and interruptible for their efficiency, and to avoid damage by the voltage. In Nigeria, there is inconsistence supply of electricity by the power supplying company to the consumers. The use of additional electric power source such as electric power generators and most recently the use of semiconductor power devices such as the Bipolar Transistor, Thyristors and particularly MOSFET to generate electric power in conjunction with a DC battery in few kilowatts. An Inverter offers a better additional power source to Generators as well as UPS considering its long duration, cost effectiveness and maintainability.
Uninterruptible Voltage supply is an electronic control circuit or device that is capable of providing a constant output voltage even when there is variation in load or input voltage as low as 160 volt can be boost up to 240 volt by stabilizer at output stage without any voltage fluctuation with a backup battery which provide additional power to the device during mains power outage.
It is designed to meet up with the AC voltage safety, stability and accuracy demand in industries and in homes. Uninterruptible power supply is useful in devices such as computer Power supplies, alternators and central power station generator plants, voltage regulators control the output of the plant. In an electric power distribution system, voltage regulators may be installed at a substation or along distribution lines so that all customers receive steady voltage independent of how much power is drawn from the line.
An uninterruptible power supply is designed to automatically maintain a constant AC voltage level. An AC Voltage supply may be a simple “feed-forward” design or may include negative feedback control loops. It makes use an electromechanical mechanism, and other electronic components. Depending on the design, it may be used to regulate one or more AC voltages.
This project is designed to stabilize an AC input voltage of 160-250V to give an AC output voltage of 240V at 50Hz automatically. The automatic feature can be achieved by the electronics devices used such voltage comparator IC, electro-magnetic device (relay), auto- transformer and other electronics devices
1.1 PURPOSE OF THIS PROJECT
The purpose of this project is to design and construct an uninterruptible power supply. This device stabilizes an AC input voltage of 160-260V to give an AC output voltage of 240V with a backup power source which provide additional power to the device during mains power outage automatically at 50Hz using a 12v battery. The automatic feature can be achieved by the electronics devices used such voltage comparator IC, electro-magnetic device (relay), auto- transformer and other electronics devices.
1.2 OBJECTIVE OF THE PROJECT
The objective of this work is to construct a device whose function is to maintain constant and uninterruptible power to electrical appliances, and power line conditioning to the equipment load of 500w under a wide variety of conditions, even when the utility input voltage, frequency or system load vary widely and also indicate when the battery of the system gets low. An uninterruptible power stabilizer consists of an all copper, multiple tapped, contain independently controlled inverse parallel electronic switches for each of the 7 taps per phase to provide tight voltage regulation, rechargeable battery and an inverter. The phase current shall be monitored for zero current recognition to initiate any required tap change. Linear devices shall be used for line synchronization to prevent phase shift errors normally associated with zero current crossing acquisition.
1.3 SIGNIFICANCE OF THE PROJECT
The uninterruptible power supply is a voltage regulator planned to mechanically sustain a constant voltage level and supply an uninterruptible power to devices. It can also use electromechanical components. It can be used majorly to regulate one or more DC or AC depending on the design. Therefore, the functions of this equipment are very wide and can be used majorly for various purposes. Electronic voltage regulators can be used majorly for various purposes. It has various functions like it can be used mainly for stabilizing the DC voltages that can be used by the processor and its main parts. In central power station generator plants and automobile alternators, voltage regulators control the output of the plant. In this distribution system, it may be installed at along distribution lines so that all clients recognize steady voltage self-regulating of how much power is drawn from the line. There are many functions of operating the AC depending upon the design. It is very good option to maintain the constant voltage level. Automatic voltage regulator is a superb invention of science, which is an electric device designed to authorize a constant voltage in a settable level. It is very helpful to maintain the preferred voltage for the generators within particular limits. The main working of it depends upon the laws of electromechanical physics. It consists of numerous vigorous and unreceptive electrical parts like thermostats, adopters and diodes. Apart from this, there are many reliable Automotive Suppliers in India that produce many kinds of equipments like generator, regulator and other major parts. They are well known for various kinds of functions and various specifications. They not only produce higher quality products, but also they will provide some additional benefits with the parts of these equipments. Auto Voltage Regulator Generator is the most important part for great amplifier to work. Its types are many, but they are highly in functionality and better performance. They are well equipped with self functioning controls and starts up functions which make them very easy and useful to handle easily and completely. They have different sizes, shapes and colors. There are also automatic regulators which are so small that they can be easily places on a small printed circuit board. They are very easy and portable to handle. They may cover a higher volume of small house sometimes. Therefore, there is a wide variety in the uninterruptible power supply sand each has its own specifications.
1.4 THE SCOPE OF THE PROJECT
The design and construction of an uninterruptible power supply is the project we are construction. I am working on this machine because we have some idea on how this machine can be constructed and also on how it works. We are also doing this because we want to learn more about it.
As we have mentioned earlier, this device is a protective device that protects our electrical and electronic appliances out of current and voltage fluctuation and unexpected power interruption. This is how it works. When this system is plugged into the socket or supply, it will receive a minimum voltage of 120vac and filter the current and voltage thereby brings out suitable voltage output to be used by the devices in it, then when there an unexpected power outage from the utility mains the system will automatically switch over to the inverter source thereby providing additional power to the appliances in use.
So, I am building or constructing this device to reduce risk and damages the fluctuation of current / voltage caused by power fluctuations and unexpected power interruption and the device is rated 500W.
1.6 LIMITATION OF THE PROJECT
The system design shall be capable of operating at an input frequency range of -15% to +10% of nominal, without clearing protective devices or causing component failure within the uninterruptible power supply. During mains power outage the system shall be working with inverter source section, but when generator or utility power is restored, the uninterruptible power supply shall automatically restart. Upon turn on or restart, the output of the uninterruptible power supply shall not exceed the specified output regulation limits.
Response Time: The uninterruptible power supply shall respond to any line voltage variation in 1/2 cycle while operating linear or non-linear loads, with a load power factor of 0.60 of unity. Peak detection of the voltage sine wave shall not be permitted to avoid inaccurate tap switching due to input voltage distortion.
Operating Frequency: The uninterruptible power stabilizer shall be capable of operating at +10% to -15% of the nominal frequency, 50Hz.
Rating: this device is rated at 500VA.
Access Requirements: The uninterruptible power supply shall have removable panels on the front, rear and sides as required for ease of maintenance and/or repair.
Metering: An input meter is provided to reading line voltages
Ventilation: The uninterruptible power supply isolation transformer shall be designed for convection cooling. A fan cooling is required for the solid state electronic switching devices.
1.7 DEFINITION
(i) Inverter Unit: This unit converts a DC voltage into an AC voltage with the help of a oscillator, the oscillator ic used is SG3524N IC.
(ii) Automatic Control Unit: This provides all the required control needed to meet up the objectives of the whole system.
(iii) Battery Unit: This is a secondary cell unit capable of storing enough DC voltage of which is later converted to AC voltage.
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Design And Construction Of A 500W Uninterruptible Power Supply Using SG3524N:
Designing a 500W uninterruptible power supply (UPS) using the SG3524N PWM controller requires careful consideration of various components and their specifications. The SG3524N is a versatile PWM controller IC that can be used in various power supply applications.
Here’s a basic schematic and explanation of how you can design such a UPS:
### Components Needed:
1. **SG3524N PWM Controller IC**
2. **MOSFETs for Inverter Stage**
3. **Transformer**
4. **Battery**
5. **Rectifier**
6. **Filter Capacitors**
7. **Voltage Regulator IC (if necessary)**
8. **Other passive components (resistors, diodes, etc.)**
### Schematic Overview:
1. **AC Input Stage:**
– The AC mains input is connected to the rectifier stage.
– The rectifier converts AC to DC.
– A filter capacitor smoothens the rectified DC.
2. **Battery Charger Stage:**
– The rectified DC from the AC input stage is used to charge the battery.
– Proper charging circuitry should be implemented to ensure safe and efficient charging of the battery.
3. **Inverter Stage:**
– The SG3524N PWM controller generates PWM signals.
– MOSFETs are used as switches in the inverter stage.
– The PWM signals control the switching of MOSFETs, which in turn control the output voltage and frequency of the inverter.
– The transformer steps up the voltage to the required level.
– The inverted AC is then used to power the load.
4. **Control and Monitoring Stage:**
– This stage may include feedback mechanisms to monitor the battery level, output voltage, and other parameters.
– It may also include circuitry for controlling the charging process and managing the transition between AC mains and battery power.
### Considerations:
– **Transformer Design:** The transformer should be designed to handle the power requirements and provide isolation between input and output.
– **Battery Selection:** Choose a suitable battery with appropriate capacity and voltage rating for the application.
– **Heat Dissipation:** MOSFETs and other components may generate heat, so proper heat sinking should be provided.
– **Protection Circuits:** Overload protection, short-circuit protection, and overcharge protection circuits should be included to ensure safe operation of the UPS.
### Design Steps:
1. **Determine Requirements:** Understand the load requirements, input voltage range, battery capacity, and other specifications.
2. **Select Components:** Choose suitable components based on the requirements.
3. **Schematic Design:** Design the schematic diagram incorporating all the stages mentioned above.
4. **Simulation:** Simulate the circuit to ensure proper functionality and performance.
5. **Prototyping:** Build a prototype of the UPS circuit.
6. **Testing:** Test the prototype under various conditions to validate its performance.
7. **Fine-tuning:** Make necessary adjustments to improve efficiency, reliability, and performance.
This is a high-level overview, and designing a UPS involves detailed analysis, calculations, and testing to ensure proper functionality and reliability. It’s recommended to consult datasheets, application notes, and possibly seek assistance from experienced engineers during the design process.