GE Digital Energy Power Quality

UPS Application Guide

Digital Energy Uninterruptible Power Supply

15 TRANSFORMERS

GE Consumer & Industrial General Electric Company CH 6595 Riazzino (Locarno) Switzerland T +41 (0)91 / 850 51 51 F +41 (0)91 / 850 51 44 www.gedigitalenergy.com

Title: Date of issue: File name: Version:

Transformers November 2008 APG_015_TRANSFOR_XGB_V010 1.0

Up-dating Revision Concerns Date

Table of contents
15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8

Page

15 Transformers..................................................................................................................................................................................... 1
INPUT ISOLATION TRANSFORMER.................................................................................................................................................3 TRANSFORMERS TYPE.........................................................................................................................................................................3 INPUT RECTIFIER ISOLATION TRANSFORMER...........................................................................................................................4 INPUT BYPASS ISOLATION TRANSFORMER................................................................................................................................5 INPUT BYPASS TRANSFORMER WITH EXTERNAL MAINTENANCE BYPASS ..................................................................6 AUTOTRANSFORMER ...........................................................................................................................................................................7 BI-MONO TRANSFORMER..................................................................................................................................................................7 K-FACTOR .................................................................................................................................................................................................8

COPYRIGHT 2008 by GE Consumer & Industrial Data subject to change without prior notice. All brands and product names are Trademarks or Registered Trademarks of their respective owners. Reproduction only upon written consent by GE.

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15.1 INPUT ISOLATION TRANSFORMER

Typically a UPS system is directly connected to the Input Mains. In some applications a galvanic separation between the UPS and the Input Mains or a dedicated grounding system for the UPS and its loads is required. In these cases an input isolation transformer on the UPS rectifier or bypass Input Mains shall be installed. This document shows the different transformers topology used, the possible configurations and the relative features.

15.2 TRANSFORMER TYPES

Three different transformer types, characterized by wiring connections, can realize the UPS galvanic separation. The tables here below show the different characteristics of the used type and relative applications: Type Symbol Wiring connections Voltage displacement
L1
30 l1

Characteristics
30 electrical degrees phase shift between primary and secondary wiring neutral on secondary wiring 0 electrical degrees phase shift between primary and secondary wiring 0 electrical degrees phase shift between primary and secondary wiring neutral on secondary wiring

L1

l1 l2 l3 n
L3
L1

Dyn11

30
L1,L2,L3 l1,l2,l3

L2 L3

l3 l2 L2

Dd0

0
L1,L2,L3 l1,l2,l3

L1 L2 L3

l1 l2 l3
L3

l1 l2 l3 L1 l1 l2 L3 l3 L2 L2

L1

0
Dzn0
L1,L2,L3 l1,l2,l3

l1 l2 l3 n

L2 L3

Table 2-1 Transformers typology

Type

Bypass input isolation transformer

Rectifier input isolation transformer

Dyn11

X X

X
with neutral not connected

Dd0

X X
with neutral not connected (solution not practically used)

Dzn0

Table 2-2 Transformers typology applications

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15.3 INPUT RECTIFIER ISOLATION TRANSFORMER

UPS SSM INPUT MAINS Lk RECTIFIER ISOLATION TRANSFORMER RECTIFIER INVERTER L1/L2/L3

NEUTRAL

NEUTRAL

POWER DISTRIBUTION UNIT BATTERY

Fig. 3-1 Electrical configuration

Configuration The isolation transformer is installed upstream the UPS rectifier between the rectifier and the Input Mains; the transformer neutral shall be not ground (earth) connected. This configuration is also used with UPS in RPA (Redundant Parallel Configuration), to realize a phase shift displacement between/among the different UPS, to reduce the rectifier harmonic effects. Applications For safety reasons. To realize a galvanic separation between the Input Mains and the UPS rectifier. This configuration is typically used with PB battery (not VRLA) that require periodical check by service engineers who operate directly on the battery (e.g. filling in electrolyte in battery blocks or checking the electrolyte density). For more details please refer to fig. 3-2 and 3-3. Efficiency effect The total UPS efficiency is affected by the transformer of about 12% .
RECTIFIER BRIDGE INPUT MAINS TRANSFORMER INPUT MAINS INVERTER BRIDGE
INPUT MAINS TRANSFORMER INPUT MAINS INPUT ISOLATION TRANSFORMER RECTIFIER BRIDGE INVERTER BRIDGE

GALVANIC SEPARTION BETWEEN INPUT MAINS AND UPS RECTIFIER

BATTERY

BATTERY

CURRENT FLOWING THROUGH HUMAN BODY

GALVANICALLY SEPARATED FROM INPUT M

Fig. 3-2 UPS without input rectifier isolation transformer

Fig. 3-3 UPS with input rectifier isolation transformer

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15.4 INPUT BYPASS ISOLATION TRANSFORMER

BYPASS ISOLATION TRANSFORMER +30 UPS SSM RECTIFIER Lk INVERTER L1/L2/L3 NEUTRAL

INPUT MAINS

Dyn11

NEUTRAL

POWER PE (GROUND) current flowing in normal mode operation current flowing in bypass mode operation DISTRIBUTION UNIT BATTERY

Configuration Configuration realized by a transformer installed on the UPS bypass input. Two different transformers can be used: Dyn11 (30 el. degr. phase shift) for the applications where the transformer phase-shift has no influence on the UPS output. Standard configuration. Dzn0 (0 el. degr. phase shift) where an UPS input/output electrical phase shift is not allowed. Solution more expensive than the previous one, due to the zig-zag transformer winding. This configuration is used when an external maintenance bypass is installed, to avoid phase shift with the UPS bypass Applications For a local grounding arrangement, in order to realize the neutral wiring for the UPS and its loads, different from the one available on the Input Mains. This is the case where the UPS Input Mains is distributed without neutral (3 wire + ground) or where the replacement of the existing neutral conductor with a larger one could be problematic or costly. to avoid the propagation of the UPS loads current upstream the UPS on the Input Mains, even when the UPS is running in bypass mode. In fact with the UPS in normal mode, with the loads supplied by the UPS inverter, the current is limited to the inverter transformer without any propagation on the Input Mains distribution (refer also to the fig. 4-1). When the UPS is running in bypass mode the load current is spread on the UPS input electrical distribution; this can cause problems on other load there installed specially when the UPS supply non-linear loads with high harmonics contents or with high unbalanced loads (with high 3rd and multiple harmonic contents specially on the neutral conductor). Efficiency effect The introduction of a transformer on the bypass line has no influence on the UPS efficiency because not part of the UPS normal mode power conversion operation.

Fig. 4-1 Electrical configuration

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15.5 INPUT BYPASS TRANSFORMER WITH EXTERNAL MAINTENANCE BYPASS

EXTERNAL MAINTENANCE BYPASS

BYPASS ISOLATION TRANSFORMER 0

UPS

INPUT

Dzn0 RECTIFIER INVERTER L1/L2/L3

MAINS Lk

SSM

NEUTRAL

NEUTRAL

POWER PE (GROUND) BATTERY DISTRIBUTION UNIT

Fig. 4.1-1 Example of input bypass transformer with external maintenance bypass

In some UPS applications an external maintenance bypass for UPS and bypass transformer is required for maintenance reason or to allow the possibility to remove the UPS maintaining the loads active. With this configuration it must be taken into account to have no phase shift between the UPS and the external maintenance bypass circuits. If a bypass isolation transformer is required, it shall be realized by a Dzn0 (Delta zig-zag with 0 el. degr. phase shift). Special attention has to be given if a differential protection relay is installed upstream the UPS; this can have false trip if the grounding connection between the Input Mains transformer and the Input isolation transformer is not realized properly.

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15.6 AUTOTRANSFORMER
Adding an autotransformer it is possible to adapt the input and (or) the output UPS voltage. The use of this one at the ups input is allow only if the neutral is available. Contrarily a Dyn transformer is mandatory. An Autotransformer is an electrical transformer with only one winding, thus there will be no galvanic separation. Because it requires both fewer windings and a smaller core, an autotransformer for power applications is typically lighter and cheaper than a two winding transformer.

15.7 BI-MONO TRANSFORMER

By using a bi/mono transformer is possible to supply a mono-phase load. The size of UPS will be 1,78 times the load applied. In fact: VAload mono /0,97 (trasf.) /400V= Iphase-UPS Iphase-UPS x 3 x 230V = Pmin-UPS Anyway bypass is always available and only two phases will be loaded. Example: Load (mono-phase) = 120kVA Iphase-UPS = 120kVA / 0,97 / 400V = 309A Pmin-UPS = 309A x 3 x 230 = 213kVA (213kVA / 120kVA = 1,78) Size UPS 213kVA Sgseries 250kVA

Note: Its not allowed to use Bi/mono transformer with LP33 models. mono phase load (kVA) 5 (max 5,5) 8 (max 8,2) 10 (max 11,2) 15 (max 16,8) 20 (max 22,5) 30 (max 33,7) 40 (max 44,9) 50 (max 56,2) 60 (max 67,4) 80 (max 89,9) 100 (max 112,3) 120 (max 140,4) 160 (max 168,5) 200 (max 224,7) 250 (max 280,9) 3 phase UPS (kVA) 10 15 20 30 40 60 80 100 120 160 200 250 300 400 500 additional cabinet (mm) ---* ---* ---* ---* ---* 500 500 500 500 500 500 500 (SP 680) 850 (SP 680) 1100 1100

* additional cabinet for SP10/40kVA is not required ONLY if batteries are mounted in separate cabinet. In this case the transformer will be mounted in UPS battery cavity, otherwise a 500mm cabinet will be used. Its possible to have in SP10/40kVA battery cavity both the transformer and the 5th harmonic filter, but an additional cooling kit is required (art. n 12038).
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15.8 K-FACTOR
K-Factor is a weighting of the harmonic load currents according to their effects on transformer heating, as derived from ANSI/IEEE C57.110 and K-Factor ratings are described in UL1561(5). A K-Factor of 1.0 indicates a linear load (no harmonics). The higher the K-Factor, the greater the harmonic heating effects:

K Factor= ( Ih)

where Ih is the load current at harmonic h, expressed in A per-unit basis such that the total RMS current equals one Amp, i.e.,

( Ih)

= 1.0

One problem associated with K-Factor calculation is the selection of the harmonic frequencies range. Someone use up to the 15th harmonic, someone else up to the 25th harmonic, others up to the 50th harmonic. For the same load, each of these calculations can yield significantly different K-Factors because even very small current levels associated with the higher harmonics, when multiplied by the harmonic number squared (e.g., 502 = 2500), may change significantly the result. Based on the underlying assumptions of C57.110, it seems reasonable to limit the K-Factor calculation to harmonic currents up to the 25th harmonic. Factor transformers differ from standard transformers. They have additional thermal capacity to tolerate the heating effects of the harmonic currents. Beyond that, well-designed K-Factor transformers will also minimize the winding eddy current losses through the use of parallel conductors and other winding techniques. The K-Factor indicates the multiple of the 60 Hz winding eddy current losses that the transformer can safely dissipate: Transformer load losses consist of winding I2R losses plus stray losses. Using UL1561 test methods, stray losses are assumed to be primarily winding eddy current losses for transformers 300 kVA and smaller. For example, a transformer having winding I2R losses of 2000 watts and 60 Hz stray losses of 100 watts would, with a K-20 rating, be required to dissipate the 2000 watts of I2R losses plus 20 times the 60 Hz stray losses of 100 watts for a total load loss of 4000 watts without exceeding the maximum winding temperature rise. The result is a larger, more expensive transformer. Standardized K factors K-1 : resistive load (no harmonics) K-4 : THDi up to 26% K-9 : THDi up to 45% K-13 : THDi up to 58% K-20 : THDi up to 81% K-30 : THDi up to 124% K-40 : THDi up to 208%

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Example: Input isolation transformer for SitePro Taking into consideration that the input isolation transformer is used to feed the rectifier and that the harmonics spectrum is: 5th 25.8% 7th 7.4% 11th 5.9% 13th 4.1% 17th 1.8% 19th 2.1% 23th 1.0% 25th 0.9%

we have that the K-factor is: K = 1*1 + 52x0.2582 + 72x0.0742 + 112x0.0592 + 132x0.0412 + 172x0.0182 + 192x0.0212 + 232x0.012 + 252*0.0092 = 4.09

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