The UPS Team 5

Team 5: Staff Michael Myers BSEE Fernando Muñoz Jesus Lopez Adam Bitter Jake Koturbo BSEE

Team 5: Expertise & Experience Michael Myers Fernando Muñoz Jesus Lopez Adam Bitter Jake Kotrba Expertise: Power and Electromagnetics Experience: Kimberly-Clark, General Motors Expertise: Power, Motors Experience: Airforce electrician Expertise: Controls, Power Experience: We energies, Gossen Corporation Expertise: Controls Experience: N/A Expertise: Power, Motors Experience: Chicago-Kenosha Building Developement

The UPS Power backup for small power consumption appliances: features and functions!!!!!! PCs Space heaters Elaborate more

+ + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load Display CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Performance Requirements Input AC Voltage: 105-132 V Input AC Current: max 15 A Input AC Frequency: 60Hz +/- 3Hz Output AC Voltage: 105-132 V Output AC Current: max 15 A Output AC Frequency: 60Hz +/- 3Hz Battery Size: 12V battery Battery Life: 1 hour Digital Functions: User display refreshed every 1/10 sec, monitoring and display input AC User Interface: LEDs indicator, push pad Power Mode: On/Off manual switch Sensory: Current, Voltage and Frequency Mounting: Feet Plug: Type B

Standard Requirements Operating Range: -15 -- 50ºC Max Operating Relative Humidity: 95% Operating Pressure Range: 1 atm +/- 15% Max Storage Duration: 10 years Energy Sources: AC, automotive battery Source connections: AC utility and DC battery Power Consumption: 5200 Watt hours per year Max Volume: 40000 cm3 Max Weight: 14 kg

Project Plan

+ + + + + Vac Sensor Jake AC Switch Jesus Main Switch Jesus Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Name: Michael Myers Major: Electrical engineering Team 5: UPS Assignment: block 1 Block 1: Inverter

+ + + AC Vac Sensor Jake Charging Switch Jesus Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Inverter Once the power fluctuates outside the boundaries a control switch will allow the inverter power to transfer to the circuit.

Power Inverter The job of this inverter is to transfer 12Vdc to 120Vac. This device will always be on Control switch will allow inverter power to flow

Analog and digital interfacing – N/A Signal Table Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current   Nominal Min Max Power1 VCC +12 DC- Power Input 12.0V 10.2 13.2V DC N/A 5.00% 0.1V 18A Power2 VCC -15V AC- Power Output 120.0V 102V 132.0V AC 57 63 0.25V 15.00A Analog and digital interfacing – N/A

Prototyping Plan Inverter 700 Fiber Glass Solder Yes Flat Pins Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Inverter 700 Fiber Glass Solder Yes Flat Pins

DFM Sub Circuit Type Applicable Worst Case Analysis Plan (See DFM Analysis Guide)  Task Task 1 Task 2 Task 3 Task 4 Task 5 Task 6 Task 7 Task 8 Task 9 Task 10 Timer IC R, L & C Tol RLC Specs Gain vs Freq Phase vs Slewrate BW Step Resp Input Impedance Output DC Offset V Total Noise Wave formation Max Offset Voltage DC Gain vs Component Variations DC Gain vs Freq vs Comp Var Phase vs Freq vs Comp Var Power Bandwidth Pulse Response & Delay   Smoother Step Responce Transformer Nominal Value or Max Value Adjustment Range, %/Turn Tolerance Around Derated Capacity Maximum Working Constant Current Surge Current Composition Dielectric or Form Q Factor or Frequency Variation Package

Inverter Block Diagram Timing Unit 57-63 HZ Transistor switching Transformer Out to Load DC input 12-15 VDC

Schematic Diagram

Functionality Simulation Supposed to be -12<=V<=12 before Transformed to -120<V<120 This is the desired output not Yet achieved Due to Pspice limitations, a worst Case scenario was not able to be Obtained.

Bill of Materials Part Part # Quantity Description Price Source R1 311-10.0KFCT-ND 1 10k Resistor, ±.1%, .25W 0.88 Digikey R2 311-100KFCT-ND 100k Resistor, ±.1%, .25W R3 311-100FCT-ND 100 ohm Resistor, ±.1%, .25W R4 4LG54BK-ND 50k potentiometer, ±25%, .3W 0.59 C1, C2 493-1329-ND 0.1 uF Capacitor, ±10% 0.26 C3 0.01 uF Capacitor, ±10% 0.54 C4 P11706-ND 2700 uF Capacitor,±10% 6.37 Q1 497-2622-5-ND TIP41A, NPN Resistor, 100V 0.95 Q2 497-2552-5-ND TIP42A, PNP Resistor, -100V 1.04 L1 5300-01-ND 1uH, ±15% 0.67 T1 273-1511 Transformer 1/10 10.49 Radio Shack

Name: Fernando Muñoz Major: Electrical engineering Team 5: UPS Assignment: Power Block Block 2a: Charger (Rectifier) Block 2b: Battery Jjkjk

+ + + Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Main Purpose Keep a constant charge in the battery so when commercial power is lost, the device to which the UPS is connected to stays on for about a half hour or until the battery drains completely. Provide 5 VDC logic to the CPU which power s all essential controls and sensors.

Power Inputs and Outputs Transformer Input : 120 VAC / 20Amp Transformer Output / Rectifier Input : 15.7 VAC (Step Down) Rectifier Output #1 : 14.3 VDC Rectifier Output #2 : 5 VDC

Power Electrical Interface Signals Power Signals Type Direction Voltage Voltage Range Freq Freq Range % V-Reg V-Ripple Current   Nominal Min Max Power-1 AC Input AC Power Input 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 15A Power-2 VCC +14.3V DC Power Output 14.3V 12.15V 15.73V DC 1.00% 0.01V 35A Power-3 VCC +14.3V 2A

Block diagram of Power Supply System 120 VAC Main Input Transformer Rectification Smoothing Regulation 14.3 / 5 VDC Regulated output 14.3 VDC With Ripple 15.7 VAC 14.3 VDC

5 VDC Power Regulated System

Prototyping Plan Block Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Power 700 Copper Solder No B type plug Flat Pins

Functionality Simulations

Transient Response

Maximum WV for Capacitors Referencing to the manufacturer (Digikey) specification the following value was chosen as WV. 470uF Capacitor: WV : 10VDC Leakage Current: 235uA Ripple Current: 570mA Dimensions: 32(L)*10.3(D)*0.8(d) mm

Power Ratings Diodes: P = V*I P = (16V)*(2A) = 32W Resistors: They were only placed in Pspice simulation in order to have the transformer work properly and give accurate results.

Capacitor Tolerance This Solid Axial 470uF Capacitor has a range of small long life (20000H). Tolerance±20% and ±10% on request Usable Temperature range:-80oC to +125oC

Off Board Connectors Battery Post: To achieve a mechanically secure and tight connection we’ll be using adjustable clamps. Transformer: It will be sitting on a hard surface at the bottom of the UPS, we’ll use flat pin connectors to connect wires going to the rectifier. DC to DC Connector: Flat pin connectors.

Charge Type Trickle Charge : Constantly supplies the battery with 14.3 VDC at 2 Amps. Logic Charge : Constant +5 VDC converted from the 12 VDC coming out of the battery, this will power CPU, sensors and interface.

Bill of Materials Part Part # Quantity Description Price Source C1   C1 4278PHCT-ND 1 470 uF Capacitor 4.49 Digikey C2,C3 4931829-ND 0.1 uF Capacitor 0.54 Conv. 179-1011-ND DC to DC Converter 71.5 Diode 1N4001 Bridge Rectifier 1.6 Maplin VDC P174-ND Lead Acid Battery 34.56 T1 DCT-10-120 Transformer 120/16 56 Grainger

Name: Jesus Lopez Major: Electrical engineering Team 5: UPS Assignment: blocks 3 and 4 Block 3: Switching Gear Block 4: Display

Switching Gear The switching for this project will be effectuated by a solid state relay. Main switch. Charging switch. Note: other switches may be needed for different. Blocks.

+ + + AC Vac Sensor Jake Charging Switch Jesus Main Switch Jesus Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Switching Gear Sub-Blocks Main Switch Charging Switch Note: switch elimination

From the Utility Main Switch To the load From the inverter Charging Switch To the rectifier From the utility

Main Switch Selects utility or battery. CPU control.

Main Switch Nominal Ratings Control Input : 6 Vdc Input: 120 Vac Output: 25 A

Charging Switch Battery Charging CPU control

Switch Nominal Ratings Control Input : 5 Vdc Input: 120 Vac Output: 30 A

Main Switch Signal Table Power Signals   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 DC +5 DC Power Input 5.0V 4.75V 5.25V 5.00% 0.1V 1.2A Power1 AC AC Power 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 1.0A Power2 AC Output Power3 AC

Charging Switch Signal Table Power Signals   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 VCC +5 DC Power Input 5.0V 4.75V 5.25V 5.00% 0.1V 1.2A Power2 AC AC Power 120V 102V 132V 60Hz 57Hz 63Hz 15.00% N/A 1.0A Power3 AC

Switching Key Components SPDT switch SPST switch Note: zero cross switch application & phase lock loop

Switches Bill of Materials Item Package Units Power Consumption Price $ Vendor Switch Relay 1 27mW 34.00 Digikey N/A

Switching Gear DFM Plan Main Switch Sub-Block Type Input Type Max input Voltage Min Input Voltage Power Consumption Relay AC: Output DC: Control Input Output: 132 V Control Input: 6.5 V 102 V Control Input: 3.5 V 17 mW

Display Features: On/Off manual power switch. On/Off LEDs. AC/DC LEDs. Fast/Slow charging mode LEDs. Remaining power LED array indicator.

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load Display Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Display Sub-Blocks Remaining power LED bar indicator UPS status LEDs On/Off Switch

To the battery terminal Manual Input Power On/Off Switch From the CPU LED Bar From the CPU Status LEDs

Display Signal Table Power Signals Type Direction Voltage Nominal   Type Direction Voltage Nominal Voltage Range Freq Freq Range % V-Reg Max V-Ripple Current Min Power1 VCC +5 (switch) DC Power Input 5.0V 4.75V 5.25V DC N/A 5.00% 0.1V 1.2A 8-bit channel Digital

Display Key Components LED Bar Graph Arrays Manual Switch LEDs

Display Bill of Materials Item Package Units Power Consumption Price $ Vendor LED bar graph array Chip 1 750 mW 2.10 DigiKey LEDs N/A 4 300mW 2.00 On/Off switch Minimal Resistance 1.50

Display DFM Plan Display Sub-Block Type Input Type Max input Voltage Min Input Voltage Power Consumption Remaining Power LED Chip DC 6.0 V 3.5 V 750 mW Status LEDs Indicators 300 mW On/Off Switch Manual N/A

End of UPS blocks 3 and 4 !!!

Name: Adam Bitter Major: Electrical engineering Team 5: UPS Assignment: CPU

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

CPU The CPU will do the following things: Read in a utility (AC) voltage signal Read in a battery voltage signal Control the switching of the power source switch Control the switching of the charging switch Output a battery life signal to the display

CPU The CPU will switch to the battery when the voltage read in is below 105 V When the battery is run dead the CPU will switch on the fast charger for a certain period of time

CPU The CPU will send a signal to the display indicating the life of the battery based on the battery voltage level If necessary it will also be able to send more outputs to the display

Sensor Signals 8 bits = 28 = 256 values Vac range = 0 – 132V 132/256 approx = .5V per bit Vdc range = 0 – 14.3V 14.3/256 approx = 50mV per bit

Vac Sensor Input Digital Input 8 bits of input at 5V Approx .5V per bit UPS switched on when input is less than 105V = 11010010

Vdc Sensor Input Digital Input 8 bits of input at 5V Approx 50mV per bit

Display Output Digital Output 8 bits of output at 5V Display is LED’s 8 levels of battery life 11111111 is fully charged battery 00000000 is dead battery

Lattice M4 64/32 15JC

DC Drive Device Parameters CPU Dig Device Output Type Input Type Tech Type DC Drive Device Parameters Vil max Vih min Iil (-) Max Iih Vol Voh Iol Ioh (-) Min Vhyst Checked CPU Std CMOS 0.8V 2.0V 0.2uA -0.2uA 0.6V 4.3V 4.6mA -2mA N/A

CPU Timing Min Clock Setup Time: 5ns Min Clock Hold Time: 3.5ns Min Input Register Setup Time: 2ns Min Input Register Hold Time: 3ns Min Input Latch Setup Time: 2ns Min Input Latch Hold Time: 3ns Max Output Enable Time: 9.5ns Max Output Disable Time 9.5ns

CPU Prototype Plan Block Name Block Area (cm2) Total PCB Area (cm2) Substrate Type Comp Attachment Socketed Components Types of Connectors CPU 100 12 Copper solder Yes Ribbon Cable

CPU Signals

CPU Power

Pseudo Code Start: Read in Vac if Vac < 11010010 switch on power switch if power switch on if Vac > 11010010 switch off power switch Read in Vdc output Vdc to display if Vdc < Dead Battery switch on fast charger for 1 hour Loop Start

CPU Signals Input: AC voltage: 8 bits, 5V DC DC voltage: 8 bits, 5V DC Output: Display: 8 bits, 5V DC Charging Switch: 1 bit, 5V DC Power Switch: 1 bit, 5V DC

Name: Jake Koturbo Assignment: block 6 Block 6: Sensors

Purpose: It’s how the CPU interfaces with the input and output power.

Advantages of Using Sensors Upper and lower limit can be adjusted with a small change in the CPU’s programming. Provide accurate user interface read-outs

Sensor Performance Requirements Input: Analog (nominal) 120Vac 5Vdc Output: Digital (nominal) 8-bits (5V logic)

Output continued… Directly interface with only the CPU All sensor outputs will supply the eight bit signal to the CPU. All sensors will use A/D converters and therefore use 5volt.

The reason for 8-bits 28 = 256 partitions 132V divided by 256 gives us a measuring accuracy of about 0.5V

Sensor Standard Requirements Operating Voltage: Max 5.25Vdc Min 4.75Vdc Operating Temperature: Max 50 C Min -15 C Humidity: Max 95% r.h.

+ + + AC Vac Sensor Jake Charging Switch Power Source Switch Load User Interface Jesus + CPU Adam Quick Charger Fernando Trickle Charger Fernando Inverter Mike + + Battery Fernando Vdc Sensor Jake Idc Sensor Jake

Sensor Power Interface Type Direction Voltage Nominal Voltage Range Frequency Nominal Frequency Range % V-Reg. V-Ripple Current Min Max DC Power Input 5.0V 4.75V 5.25V 5% 0.2V 0.5A

Sensor Analog Interface Analog Signal Type Direction Coupling Voltage Amplitude Maximium Impedence Frequency Range Leakage Max Min Max Vac Analog Input Xfmr 132V 5k 20k 63Hz 500uA Vdc 14.3V 1Hz Idc 5.25V

Sensor Digital Interface Digital Signals Type Direction Input Structure Technology Logic Voltage Output Characteristics Voh Min Ioh Max Vol Max Iol Min Vac 8-bits Digital Output Standard TTL 5V 3.25V 0.5mA 1.8V 0.1mA Vdc 8-bits Idc 8-bits

Convert to a proportional 0-5Vdc analog signal Simplified Sensor Analog Signal CPU Convert to a proportional 0-5Vdc analog signal ADC Vcc~5V

Vac Sensor Measure the input voltage from the commercial supply. Produce an eight bit output. Signal is monitored by the CPU to initilize the use of the inverter.

Placement of the Vac Sensor AC power AC power CPU

Basic Schematic Layout

Because of the large voltage capabilities of the bridge rectifier, no step-down transformer is needed

Basic Schematic Layout Without the transformer

Calculations for the Vac Sensor If Rtotal = R1 + R2 and resistors are .25W I=P/Vmax, I = 0.25W/132V = 2.08mA Rtotal = 132V/2.08mA = 122k R2 = 5*122k/132 = 4.6k R1 = Rtotal – R2 = 117.4k

Transient Analysis

DC Sweep

Major Components Bridge Rectifier Resistors Capacitor Analog to Digital Converter

Vdc Sensor Measure the battery voltage. Produce an eight bit output directed to the CPU. Used to determine emergency CPU shutdown (when battery runs too low). Used in conjunction with the Idc sensor to estimate battery expectancy.

Placement of the Vdc Sensor Quick Charger Trickle Charger Inverter Vdc and Idc Sensors Battery

Calculations for the Vdc Sensor If Rtotal = R1 + R2 and resistors are .25W I=P/Vmax, I = 0.25W/15.7V = 15.9mA That’s too much current, Use I = 500uA Rtotal = 15.7V/500uA = 31.4k R2 = 5*31.4k/15.7 = 10k R1 = Rtotal – R2 = 21.4k

Major Components Resistors Analog to Digital Converter

The ADC is in both sensors It’s the major major component

Comparison between CPU and ADC ADC output CPU input Vlow(max) 0.4V 0.8V Vhigh(min) 2.4V 2.0V Ilow(max) 1.6mA N/A Ihigh(min) -360uA Limits fall within acceptable range

Further Comparison between CPU and ADC ADC Conversion time 103us – 114us CPU Setup time = 6ns Hold time = 0ns Total time required for latch => 6ns ?

Bill of Materials Resistors Rated: 0.25W 200V working max 4.64k Ω ±1%

B.O.M. continued… Capacitor 470uF±20% WV = 10V Voltage range 6V-200V

B.O.M. continued… Bridge Rectifier Imax = 1A 50V < Vrated < 1000V 50Hz < operating frequency < 1kHz 1Vmax, drop per diode

B.O.M. continued… Analog to Digital Converters (ADC) Vcc supply = 5V ± 0.25V Clock frequency: 100kHz – 1460kHZ Output High: 2.4Vmin -360uA Low: 0.4Vmax 1.6mA Input 0-5V range 1uA max

B.O.M. continued… 8- Conductor Ribbon (6’’ long) 300Vmax 26AWG stranded

Block Prototyping Plan Template Name Block Area (cm2) Total PCB Area (cm2) PCB Substrate Type Comp Attachment Socketed Components Types of Connectors Sensors 120 700 Fiber Glass Wire Wrap N/A Spade connector, Cupper bus, easy disconnect

Compiled B.O.M. Part Part # Quantity Description Price (1) Source R1 MFR-25FBF-4K64 1 4.64k Resistor 0.11 Digikey R2 MFR-25FRF-118K 118k Resistor R3 MFR-25FBF-10K0 10k Resistor R4 MFR-25FBF-21K5 21.5k Resistor C1 4173PHBK-ND 470uF Capacitor 3.01

Compiled B.O.M. cont… Part Part # Quantity Description Price (1) Source ADC ADC0804 2 Analog-to-Digital Conv. 3.00 Iguana Labs D 497-2622-5-ND 1 Bridge Rectifier ? Ribbon WM08-06-ND 1.08 Digikey PCB   Chester's Con1 4 spade connectors (m&f pairs) 2.50 Con2 Ribbon Connectors(m&f pairs) 5.10

Compiled B.O.M. cont… Approximately $25 without the bridge rectifier Original Material Estimate: $126 Well under bid Original Estimated Hours 50 hrs. Quickly approching

Analog-to-Digital Conv. Bill of Materials Part Part # Quantity Description Price (1) Source R1 311-4.6KFCT-ND 1 4.6k Resistor 0.88 Digikey R2 311-120KFCT-ND 120k Resistor R3 311-10kFCT-ND 10k ohm Resistor R4 4LG22K-ND 22k potentiometer 0.59 C1 4173PHBK-ND 470uF Capacitor 3.01 ADC ADC0804 2 Analog-to-Digital Conv. 3.00 IguanaLabs D 497-2622-5-ND Bridge Rectifier   ?

Chronological Disparities Can’t begin to construct prototype until all parts have been obtained. Can’t obtain all parts until part list has been compiled. Can’t test the whole project as a hole until everyone gets their blocks put together and debugged. Can’t test the whole project until all safety standards and regulations have been met.

Prototype UPS Shelf