Battery Charger for a Military/Ruggedized UPS System
Uninterruptible power supplies (UPS) supply power from a separate source, typically a battery, when utility power is not available. A UPS provides uninterrupted power to equipment, typically for 5–15 minutes until an auxiliary power supply can be turned on, utility power restored, or equipment safely shut down. While not limited to safeguarding any particular type of equipment, a UPS is typically used to protect computers, data centers, telecommunication equipment or other electrical equipment where an unexpected power disruption could cause injuries, fatalities, serious business disruption or data loss. UPS units come in sizes ranging from units which will back up a single computer without monitor (around 200VA) to units which will power entire data centers or buildings (several megawatts).
Our customer specializes in ruggedized UPS systems designed for demanding remote or mobile applications for use in harsh physical and electrical environments worldwide. The subject 2500 VA UPS system, which has wide universal inputs and frequency tolerances, can operate in international power environments and be used in tracked and wheeled vehicles. Typical run time is 8.5 minutes. About the size of a smaller-than-average suitcase, the system weighs about 135 pounds.
The Vicor battery charger solution was designed using four 375 V Maxi DC-DC converters, each with a DC output of 54 V at 600 W. A 48 Vin Micro DC-DC converter provided 12 V at 100 W for auxiliary power. These converter modules are fully encapsulated using a proprietary spin fill process making them suitable for the most harsh environments. They can withstand temperatures from –10 to +100°C (operating) and –20 to +125°C (storage). The modules were subjected to the environmental testing requirements of MIL-STD-810, MIL-S-901, MIL-STD-202 and undergo 100% environmental stress screening.