Inverter and battery testing for uninterruptible power systems

• US 5,182,518 A
• Filed: 04/11/1991
• Issued: 01/26/1993
• Est. Priority Date: 04/11/1991
• Status: Expired due to Term

• Current Assignee: Best Power Technology, Inc. (SPX Corporation)
• Original Assignee: Best Power Technology, Inc. (SPX Corporation)
• Inventors: Baxter, Richard V. Jr., Podewils, Herbert A., Stich, Frederick A., Layden, David L.
• Primary Examiner(s): Strecker, Gerard R.
• Assistant Examiner(s): DO, DIEP N
• Application Number:
  US07/685,068
• Time in Patent Office: 656 Days
• Field of Search: 324/426, 324/427, 324/511, 324/510, 324/537, 307/66
• US Class Current: 324/511
• CPC Class Codes: G01R 31/40 Testing power supplies testing photovoltaic devices H02S50/10
• CPC Class Codes: H02J 9/062 for AC powered loads

Abstract

The inverter of an uninterruptible power system is tested by turning on switches in the inverter at a selected test phase in each half-cycle of the AC input waveform so that the inverter provides a voltage which opposes the AC input voltage waveform during part of each half-cycle of the waveform. The resulting current drawn from the inverter battery, if any, is measured and its peak may be found. The peak battery current during each half-cycle is compared to maximum allowable peak currents to determine if an inverter failure has occurred. If the peak currents are lower than a maximum acceptable value, the test is repeated on a subsequent AC input waveform at a decreased test phase (a shorter time delay from the zero crossing of each half-cycle of the waveform) until the peak current in the first half-cycle is at a selected value, at which time the peak in the second half-cycle is checked to determine if it is within an acceptable range. If not, an inverter test failure is indicated. Inverter test failure is also indicated if repeated cycles during which the test phase is reduced fail to cause the first peak to reach the proper value and the test phase is finally reduced to a minimum allowable test phase. If the inverter has been tested and is found to be operating properly, a battery test can be conducted by selectively disconnecting the AC power system from the load, turning on the inverter for a selected period of time, and detrmining remaining available run time based on the battery voltage while the inverter was running.

Claims

1. A method for testing an inverter which receives power from a DC source such as a battery and which is adapted to provide an AC output voltage from the inverter by switching the polarity of the voltage from the DC source, comprising the steps of:

(a) coupling the output of the inverter to a power system which provides an AC voltage to a load so that the voltage provided from the inverter can be applied against the AC voltage waveform from the power system;

(b) turning on the inverter at a test phase corresponding to a chosen point in time after the start of a half-cycle of the AC power system voltage to apply a voltage coupled to the power system which is of the same polarity as the AC voltage waveform at that time and turning off the inverter at a selected point thereafter in the half-cycle of the waveform; and

(c) measuring the current flowing from the inverter during the time it is on such that the measured current can be compared with acceptable values of current to determine whether the inverter is properly functioning.

2. The method of claim 1 wherein the peak current is measured and including the step of comparing the measured peak current to a selected maximum allowable peak value and, if the measured peak is greater than the maximum allowable peak value, providing an indication that a failure has occurred.

3. The method of claim 1 wherein the peak current is measured and including the step of comparing the measured peak to a selected maximum allowable peak value, providing a failure indication if the measured peak is above the maximum allowable peak value and if the measured peak is below the maximum allowable peak value, repeating steps (b)-(c) of claim 1 on subsequent waveform cycles of the input waveform with the test phase being decreased by a selected amount for each subsequent repetition of these steps until the measured peak meets or exceeds the selected peak value, and thereafter halting the test, or until the test phase is below a selected minimum test phase and then providing an indication of an inverter failure.

4. The method of claim 1 wherein steps (b) and (c) of claim 1 are carried out at the same test phase in both the positive half-cycle and the negative half-cycle of a cycle of the AC power system waveform and the peak inverter current is measured for each half-cycle, and further including the steps of comparing the peak values from the two half-cycles to determine if they are within a selected range of each other, and if not, providing an indication that the inverter test has failed.

5. The method of claim 4 wherein the step of comparing the measured peaks to each other in the two half-cycles is carried out by repeating the steps of (b)-(c) of claim 1 and reducing the test phase for each repetition until the peak in the first half-cycle (Peak 1) is at or near a selected value and then determining if the peak in the second half-cycle (Peak 2) is inside or outside a chosen range about that selected value, and if outside, providing an indication that the inverter test has failed.

6. The method of claim 5 wherein the selected value for Peak 1 is about 50% of the maximum rated current for the inverter and the range for Peak 2 is between about 25% and 75% of the maximum rated inverter current.

7. The method of claim 1 further including the step of testing the AC voltage from the power system to determine if the voltage is at at least a minimum allowable voltage level which will allow the inverter test to operate properly before the step of turning on the inverter.

8. The method of claim 3 wherein after steps (b) and (c) are carried out during a particular waveform cycle of the AC power system voltage waveform, if the test is to be repeated, delaying the repetition of steps (b)-(c) of claim 1 for a selected period of time spanning many cycles of the AC input waveform.

9. The method of claim 1 wherein, if the inverter has been operated to provide power from the DC source to a load, the carrying out of steps (b)-(c) is prevented for a period of time selected such that a DC source such as a battery can be recharged.

10. A method for testing an inverter which receives power from a DC source such as a battery and which is adapted to provide an AC output voltage from the inverter by switching the polarity of the voltage from the DC source, comprising the steps of:

(a) coupling the output of the inverter to a power system which provides an AC voltage to a load so that the voltage provided from the inverter can be applied against the AC voltage waveform from the power system;

(b) turning on the inverter at a test phase corresponding to a chosen point in time after the start of a half-cycle of the AC power system voltage to apply a voltage coupled to the power system which is of the same polarity as the AC voltage waveform at that time and turning it off at a selected point thereafter in the half-cycle of the waveform, and turning on the inverter during the second half-cycle of the waveform at the same test phase after the start of the second half-cycle of the AC power system waverform to apply a voltage coupled to the power system which is of the same polarity as the AC voltage waveform at that time and turning it off at a selected point thereafter in the second half-cycle of the waveform;

(c) measuring the peak current flowing from the inverter during the time that it is on in each half-cycle to determine a first peak current and a second peak current;

(d) then, determining whether a limit condition has occurred, the limit condition selected from the group consisting of (i) the first peak exceeding a selected maximum allowable peak value, (ii) the second peak exceeding a maximum allowable peak value, (iii) the first and second peaks deviating in value from each other by greater than a selected maximum deviation, (iv) the test phase being smaller than a selected minimum test phase, (v) combinations of limit conditions (i) through (iv), and (vi) the first peak being substantially at a selected value and the second peak being within a selected range about that value of the first peak, and if any of the limit conditions (i) through (v) are found, providing an indication of inverter test failure;

(e) if any limit condition is found, then terminating the inverter test;

(f) if a limit condition is not found, delaying for a selected period of time which spans several cycles of the AC voltage input waveform, then reducing the value of the test phase by a selected amount; and

(g) then, repeating steps (b) through (f) until a limit condition is reached.

11. The method of claim 10 wherein the selected maximum allowable peak value for limit condition (i) is about 50% of the maximum rated current for the inverter.

12. The method of claim 10 wherein in the limit condition (vi) at which the first peak is at a selected value and the second peak is within a selected range of the first peak, the selected value for the first peak is about 50% of the maximum rated current for the inverter and the range for the second peak is between about 25% and 75% of the maximum rated inverter current.

13. The method of claim 10 wherein, before the step (b) of turning on the inverter, the additional step of testing the AC line voltage from the power system to determine if it is at at least a minimum allowable voltage level which will allow the inverter test to operate properly, and, if so, proceeding with the remaining steps, and, if not, delaying the further steps until the AC voltage is at the minimum allowable voltage level.

14. The method of claim 10 wherein the period of time between repetitions of the inverter test steps (b) through (f) of claim 10 is selected to be a sufficient to allow a DC source such as a battery to be recharged.

15. The method of claim 10 wherein the steps of measuring the peak current flowing from the inverter includes the steps of sampling the inverter current at periodic points in time during each cycle of inverter test and providing digital data corresponding to the sampled current, and searching the data samples to find the peak value of the data in each half-cycle.

16. The method of claim 10 wherein the initial test phase is set at a point in time which is less than a quarter-cycle from the zero crossing starting the first half-cycle and less than a quarter-cycle from the zero crossing starting the second half-cycle of the waveform, and wherein the inverter is turned off at the quarter-cycle point of the first half-cycle and at the three-quarter cycle point in the second half-cycle.

17. The method of claim 10 wherein the output of the inverter is coupled to the power system through a transformer, the power system connected to the primary of the transformer, the inverter connected to an auxiliary primary of the transformer which is coupled to the power system primary, and wherein the transformer further includes a secondary connected to the load such that power from either the power system or the inverter will be coupled through the transformer to the load.

18. The method of claim 17 wherein the transformer has a split primary connected to the inverter and the inverter has two switches, one connected to each side of the inverter primary, the switches being operable to turn-on to provide alternating polarity of DC voltage to the transformer as reflected to the primary connected to the power system and to the secondary connected to the load.

19. The method of claim 10 wherein the DC power source is a battery and further including the step of recharging the battery between repetitions of steps (b) through (f) of claim 10.

20. A method of testing a battery supplying power to an inverter for an uninterruptible power system which can be selectively coupled to a load, the load also receiving power coupled thereto from an AC power system, comprising the steps of:

(a) disconnecting power from the power system to the load and turning on the inverter to provide power from the battery through the inverter to the load;

(b) while the inverter is running, measuring the battery voltage;

(c) then, turning off the inverter and reconnecting power from the power system to the load;

(d) calculating the remaining run time of the battery based on the measured battery voltage, the rated ampere hour capacity of the battery, the full charge voltage of the battery, and the minimum allowable battery voltage at which power can be provided from the battery to the load; and

(e) providing a low battery indication if the calculated remaining run time is less than a selected value.

21. The method of claim 20 wherein the power being drawn through the inverter from the battery during the time the inverter is turned on is measured and compared to a selected full load power level, and providing a run time value for the battery that is corrected to indicate the length of the battery run time if the battery is required to operate at full load, and comparing the full load battery run time value with a full load battery run time threshold to determine if the remaining battery run time exceeds the threshold, and, if not, providing an indication of low battery run time.

22. The method of claim 20 wherein the remaining inverter run time which can be provided from the battery under load conditions is calculated in accordance with the following expression:

##EQU2## where;

T_IR is the calculated remaining run time of the inverter,

K is an experimentally determined constant,

B_C is the rated ampere hour capacity of the battery,

V_DC is the measured DC output voltage from the battery,

V_BL is the predetermined low battery voltage set point at which the battery should no longer provide power,

V_FC is the full charge battery voltage,

P_LD is a calculated power drawn by the load in watts, and

P_LS is the loss in watts in the inverter.

23. The method of claim 20 wherein steps (a) through (e) of claim 20 are carried out repetitively at periodic points in time which are sufficiently far apart to allow substantial recharge of the battery between tests, and including the step of recharging the battery between tests, and wherein before each repetition, the additional step of testing the inverter is carried out to determine whether or not there is an inverter failure, and, if so, the battery test sequence is delayed until the inverter is subsequently tested and found to be operating properly.

24. The method of claim 23 wherein the step of testing the inverter is carried out by:

(a) coupling the output of the inverter to the power system while it is providing an AC voltage to the load so that the voltage provided from the inverter can be applied against the AC voltage waveform from the power system;

(b) turning on the inverter at a test phase corresponding to a chosen point in time after the start of a half-cycle of the AC power system voltage to apply a voltage coupled to the power system which is of the same polarity as the AC voltage waveform at that time and turning it off at a selected point thereafter in the half-cycle of the waveform, and turning on the inverter during the second half-cycle of the waveform at the same test phase after the start of the second half-cycle of the AC power system waveform to apply a voltage coupled to the power system which is of the same polarity as the AC voltage waveform at that time and turning it off at a selected point thereafter in the second half-cycle of the waveform;

(c) measuring the peak current flowing from the inverter during the time that it is on in each half-cycle to determine a first peak current and a second peak current;

(d) then, determining whether a limit condition has occurred, the limit condition selected from the group consisting of (i) the first peak exceeding a selected maximum allowable peak value, (ii) the second peak exceeding a maximum allowable peak value, (iii) the first and second peaks deviating in value from each other by greater than a selected maximum deviation, (iv) the test phase being smaller than a selected minimum test phase, (v) combinations of limit conditions (i) through (iv), and (vi) the first peak being substantially at a selected value and the second peak being within a selected range about that value of the first peak, and, if any of the limit conditions (i) through (v) are found, providing an indication of inverter test failure;

(e) if any limit condition is found, then terminating the inverter test;

(f) if a limit condition is not found, delaying for a selected period of time which spans several cycles of the AC voltage input waveform, then reducing the value of the test phase by a selected amount; and

(g) then, repeating steps (b) through (f) until a limit condition is reached.

25. The method of claim 24 wherein the selected maximum allowable peak value for limit condition (i) is about 50% of the maximum rated current for the inverter.

26. The method of claim 24 wherein in the limit condition (vi) at which the first peak is at a selected value and the second peak is within a selected range of the first peak, the selected value for the first peak is about 50% of the maximum rated current for the inverter and the range for the second peak is between about 25% and 75% of the maximum rated inverter current.

27. The method of claim 24 wherein, before the step (b) of turning on the inverter, the additional step of testing the AC line voltage from the power system to determine if it is at at least a minimum allowable voltage level which will allow the inverter test to operate properly, and, if so, proceeding with the remaining steps, and, if not, delaying the further steps until the AC voltage is at the minimum allowable voltage level.

28. The method of claim 24 wherein the period of time between repetitions of the inverter test steps (b) through (f) of claim 24 is selected to be a sufficient to allow a DC source such as a battery to be recharged.

29. The method of claim 24 wherein the initial test phase is set at a point in time which is less than a quarter-cycle from the zero crossing starting the first half-cycle and less than a quarter-cycle from the zero crossing starting the second half-cycle of the waveform, and wherein the inverter is turned off at the quarter-cycle point of the first half-cycle and at the three-quarter cycle point in the second half-cycle.

30. An improved uninterruptible power system of the type having a transformer with a primary connectable to an AC power system, a secondary connectable to a load, and an auxiliary primary, an inverter connected to the auxiliary primary and a battery supplying DC power to the inverter, the inverter adapted to switch to provide alternating polarity of the battery voltage across the auxiliary primary to provide AC output power at the secondary to supply the load when power from the AC power system is not available, the improvement comprising:

(a) control means for turning on the inverter to test the inverter while AC power is available from the AC power source at a test phase corresponding to a chosen point in time after the start of a half-cycle of the AC power system voltage to apply a voltage across the transformer which is of the same polarity as the AC voltage waveform at that time and turning off the inverter at a selected point thereafter in the half-cycle of the waveform; and

(b) means for measuring the current flowing from the inverter during the time that it is on, the control means comparing the measured current with acceptable values of current to determine whether the inverter is properly functioning.

31. The uninterruptible power system of claim 30 wherein the transformer is a ferroresonant transformer having a secondary connected in a ferroresonant circuit.

32. The uninterruptible power system of claim 30 wherein the inverter includes two switches connected to opposite sides of the auxiliary primary and the battery is connected to a center tap of the auxiliary primary, the switches being connected so that when turned on each will provide current from the battery flowing through the auxiliary primary in opposite directions to provide an AC voltage across the secondary as the switches are alternately turned on and off.

33. The uninterruptible power system of claim 32 including a shunt resistance in series with the battery through which the battery current flows and wherein the means for measuring the current measures the voltage across the shunt resistance and determines the peak value of the voltage to thereby determine the peak value of the current.

34. The uninterruptible power system of claim 30 further including means responsive to the control means for selectively disconnecting the AC power system voltage from the primary of the transformer, and wherein the control means periodically disconnects the power from the AC power system to the transformer and turns on the inverter to provide power from the battery to the load for a selected period of time, and thereafter reconnects the AC power system power to the primary to supply the load, and including means for measuring the voltage across the battery while the inverter is operating, and the control means determining from this voltage the remaining run-time of the battery at a selected load condition.

35. The uninterruptible power system of claim 34 wherein the control means tests the inverter to determine if it is properly functioning before a battery test is carried out and allows the battery test to be carried out only if the inverter has passed the inverter test.

36. The uninterruptible power system of claim 30 wherein the control means compares the peak of the measured current to a selected maximum allowable peak value and, if the measured peak is greater than the maximum allowable peak value, provides an indication that a failure has occurred.

37. The uninterruptible power system of claim 30 wherein the control means compares the peak of measured current to a selected maximum allowable peak value, provides a failure indication if the measured peak is above the maximum allowable peak value, and if the measured peak is below the maximum allowable peak value, repeats the turn on of the inverter and measuring of peak current on subsequent waveform cycles of the input waveform with the test phase being decreased by a selected amount for each subsequent repetition of these steps until the measured peak meets or exceeds the selected maximum allowable peak value, and thereafter halts the test, or until the test phase is below a selected minimum test phase and then provides an indication of an inverter failure.

38. The uninterruptible power system of claim 30 wherein the control means turns on the inverter at the same test phase in both the positive half-cycle and the negative half-cycle of a cycle of the AC power system waveform and the peak inverter current is measured for each half-cycle, and further compares the peak values from the two half-cycles to determine if they are within a selected range, and if not, provides an indication that the inverter test has failed.

39. The uninterruptible power system of claim 38 wherein the control means repeats the turn on and off of the inverter for additional AC input waveform cycles and reduces the test phase for each repetition until the peak in the first half-cycle (Peak 1) is at or near a selected value and then determines if the peak in the second half-cycle (Peak 2) is inside or outside a chosen range, and if outside, provides an indication that the inverter test has failed.

40. The uninterruptible power system of claim 39 wherein the selected value for Peak 1 is about 50% of the maximum rated current for the inverter and the range for Peak 2 is between about 25% and 75% of the maximum rated inverter current.

41. The uninterruptible power system of claim 30 further including means for testing the AC voltage from the power system to determine if the voltage is at at least a minimum allowable voltage level which will allow the inverter test to operate properly before the step of turning on the inverter.

42. The uninterruptible power system of claim 37 wherein during a particular waveform cycle of the AC power system voltage waveform, if the test is to be repeated, the control means delays the repetition of the test for a selected period of time spanning many cycles of the AC input waveform.

43. The uninterruptible power system of claim 30 wherein, if the inverter has been operated to provide power from the DC source to a load, the control means delays a repetition of the turn-on of the inverter, to test the inverter, for a period of time selected such that a DC source such as a battery can be recharged.