Owner`s manual

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3.5 to 21 kVA N+1

Inverter

Owner's Manual

Summary of content (56 pages)

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I M P O R TA N T S A F E T Y I N S T R U C T I O N S SAVE THESE INSTRUCTIONS This manual contains important instructions for all static inverters, that must be followed during installation, operation, and maintenance of the equipment. WARNING Opening enclosures expose hazardous voltages. personnel only. Always refer service to qualified ATTENTION L'ouverture des cabinets expose des tensions dangereuses. Assurez-vous toujours que le service ne soit fait que par des personnes qualifiees.
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WARNING To reduce the risk of fire or electric shock, install in a temperature and humidity controlled indoor area free of conductive contaminants. This equipment is intended only for installations in a RESTRICTED ACCESS LOCATION. ATTENTION Pour réduire le riske d'inccendie ou d'électrocution, installer dans une enciente intérieure contrôlée en température et humidité et sans contaminants conducteurs. Ce matériel est destiné seulement pour des installations dans un EMPLACEMENT RESTREINT d'cAccès.
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Owner’s Manual This manual covers these models: Product: List number: 64034 64074 64104 64144 64174 64214 Comcode reference: Rating: 407-607-853 3.5 kVA 7.0 kVA 10.5 kVA 14.0 kVA 17.5 kVA 21.0 kVA 3.5 kVA to 21.5 kVA Inverter Owner's Manual For service call 1-800-523-0142 86-153460-01 X1 03/02 Copyright © 2002 MGE UPS Systems, Inc. All rights reserved. Printed in U.S.A. MGE UPS Systems, Inc.
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3.5 to 21 kVA N+1 Inverter 3.5 to 21 kVA N+1 Inverter Owner ’s Manual Warranty The liability of MGE UPS Systems, Inc. hereunder is limited to replacing or repairing at MGE UPS Systems, Inc.’s factory or on the job site at MGE UPS Systems, Inc.’s option, any part or parts which are defective, including labor, for a period of 12 months from the date of purchase. The MGE UPS Systems, Inc.
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Owner’s Manual Contents section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Important Safety Instructions . . . . . . . . . . . . . .Inside Front Cover Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Service & Factory Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iv Property Rights Statement . . . . . . .
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3.5 to 21 kVA N+1 Inverter section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Chapter II - Installation & Operation 2.0 2.1 2.1.1 2.1.2 2.2 2.2.0 2.2.1 2.3 2.3.0 2.3.1 2.3.1.1 2.3.1.2 2.3.1.3 2.3.2 2.3.3 2.3.3.1 2.3.3.2 2.3.3.3 2.3.4 2.3.5 2.3.5.1 2.3.5.2 2.3.6 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 Handling .
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Owner’s Manual section description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .page Chapter IV - Theory of Operation 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.7.1 4.7.1.1 4.7.1.2 4.8 4.8.1 4.8.1.1 4.8.1.2 4.8.1.3 4.8.1.4 4.8.1.5 4.8.1.6 4.8.1.7 4.8.1.8 4.8.1.9 4.8.1.10 4.8.1.11 4.8.2 4.8.2.1 4.8.3 4.8.3.1 4.8.3.2 Glossary Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1 “Receiver” Cabinet “Controller” . . . . . . . . . . . . . . . . . . .
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3.5 to 21 kVA N+1 Inverter page viii Figure Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page 3-2 4-1 Dual Inverter and Waveform Diagram . . . . . . . . . . . . . . . . . . .3-5 Block Diagram of the 21 kVA Inverter System . . . . . . . . . . . . .4-2 4-2 4-3 4-4 Block Diagram of the S4 Inverter Power System . . . . . . . . . . .4-3 Block Diagram of Power Module . . . . . . . . . . . . . . . . . . . . . . .
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Owner’s Manual How To Use This Manual: This manual is designed for ease of use and easy location of information. To quickly find the meaning of terms used within the text, look in the Glossary. To quickly find a specific topic, look in the Index. This manual uses Noteboxes to convey important information.
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Owner’s Manual Introduction WARNING An AC output will be present at the output terminals immediately when AC input is energized. ATTENTION La tension alternative de sortie appara ît dès la mise sous tension de l'entrée. WARNUNG Eine Ausgangsspannung liegt an den Ausgangsklemmen, sobald der Netzeingang angeschlossen wird. 1.0 Scope This manual provides technical information for installation, operation, and maintenance of MGE UPS Systems’ modular inverter systems series ranging from 3.5 kVA to 21 kVA.
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3.5 to 21 kVA N+1 Inverter locations where commercial AC power is not available. With a built-in static transfer switch, the inverter also forms a reliable and economical part of uninterruptible power supply systems in either on-line or off-line mode. See chapter 8, Theory of Operation, for detailed information on inverter characteristics. This series employed modular design to provide N+1 redundancy, and twin controller cards to double reliability.
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Owner’s Manual Table 1-2: Inverter Module Dimensions Inverter Module HEIGHT (in/cm) DEPTH (in/cm) WIDTH (in/cm) WEIGHT (lb/kg) 5.18 / 13.3 15.12 / 38.85 15.76 / 40.5 46 / 20.44 64004-9MSK1 Note: Weight: 1 six-mod receiver = 135 lbs. 1 UPS Module = 46 lbs. Total System Weight, 21 kVA system = 411 lbs. 1.3 Electrical Specifications Electrical Specifications are subject to revision without notice. 1.3.1 DC Input Nominal: -48Vdc; Operating Range: -39.
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3.5 to 21 kVA N+1 Inverter 1.3.4 Power Factor Rated kVA is available over a power factor range of 0.6 lagging to 0.6 leading at nominal voltage. Watt rating should not be exceeded. 1.3.5 Total Harmonic Distortion Less than 1% for linear load conditions, 3% maximum for crest factor loads up to 3:1. 1.3.6 Line Regulation System output voltage variation, less than 1% over the DC voltage range. 1.3.7 Load Regulation System output voltage variation, less than 1% from zero to full load at nominal DC input.
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Owner’s Manual The system measurement information is displayed on the LCD “Display” panel. Switch SW3 is pushed down (or up) to scroll the LCD’s screens for more information. Individual inverter module has only one control, an ON/OFF circuit breaker, located at the upper left corner of the front panel. This breaker is used to energize (or de-energize) the inverter module. Note: The module circuit breakers must be turned on prior to turning the system output voltage on.
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3.5 to 21 kVA N+1 Inverter Table 1-4: Alarm Connections J21 terminal block screw position MAJOR ALARM MAJOR ALARM No Major Alarm No Major Alarm Minor Alarm No Minor Alarm Utility Alarm No Utility Alarm ------------------- 1 2 X X X 3 X 4 X 5 6 X X 7 8 9 X X X X 10 11 12 X X X X X “X” indicates a short circuit between J21 terminal block points. 1.6 Mechanical Specification Table 1-5: S4 Receiver Cabinet Mechanical Dimensions and Weights MODEL 3.5 kVA 7 kVA 10.5 kVA 14 kVA 17.
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Owner’s Manual 1.7.6 Audible Noise Less than 65 dBA per Type 2, IEC and ANSI SI.4, when measured in a 40 dBA environment at a distance of 4 feet from any surface. At nominal ambient (+23C) and 75% load, typical audible noise is 50 dBA in the ON-LINE mode, 56 dBA in the OFF-LINE mode. 1.7.7 Cooling Forced air. Air intake is through the front of the unit, exhaust out the sides. 1.7.8 Thermal Dissipation Heat rejection: 602.28 BTU/Hr for each rated KW of the inverter system.
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Owner’s Manual Installation & Operation 2.0 Scope This chapter describes installation of the inverters, including receiving, handling, and storage procedures; prerequisites to the installation; installation procedures; and start-up procedures. 2.1 Receiving Before accepting the shipment from the freight carrier, inspect the exterior surfaces of all shipping containers or packaging used, and the equipment, for damage that may have occurred during transit.
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3.5 to 21 kVA N+1 Inverter 2.2.0 Mechanical Mounting The equipment can be either mounted on a floor, or rack-mounted in a 19”, 23”, or 25” rack. Optional mounting bracket kits can be ordered for rack mounting in a 19” or 23” rack. Ordering information is as follows: All receivers and inverter power modules are shipped separately from the factory. Receivers will be shipped on a pallet.
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Owner’s Manual Figure 2-1: Installation Drawing, 7 kVA Inverter System FOR 1", 1-1/2" CONDUITS (4 PLACES) 8.870 6.270 2.825 16.060 FOR 1", 2", 3" CONDUITS (2 PLACES) TOP VIEW 12.210 1.650 3.250 FOR 1/2", 3/4" CONDUITS (2 PLACES) xxxxx xxxxx 8.925 11.675 15.
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3.5 to 21 kVA N+1 Inverter Figure 2-2: Front View, 7 kVA, System Component Description Microcontroller Power Switch WARNING: Communications Port WARNING: Disconnect AC (Mains) and DC supply before removing this cover. Disconnect AC (Mains) and DC supply before removing this cover.
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Owner’s Manual 2.2.1 Location The equipment is designed for installation in a protected environment. Factors to be considered in selecting a location include ventilation, temperature, humidity, and accessibility. Install the unit in a clean, dry location with an unrestricted air flow. The equipment is cooled by forced air. Allow at least 6 inches of air space around the equipment for proper cooling. 2.3 Common Installation Procedure Note: The installation procedure is common with all units. 2.3.
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3.5 to 21 kVA N+1 Inverter Figure 2-3: Static Switch Jumper Positions Suggested DC circuit breaker ratings: Inverter rating 3.5 kVA 7 kVA 10.5 kVA 14 kVA 17.5 kVA 21 kVA DC breaker rating 125A 250A 375A 500A 650A 750A 2.3.1.3 Connections All DC input connections are made through the “knock-outs”, located in the top or left side panel. Refer to Figure 2-1.
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Owner’s Manual to the lower terminal connection landing. Note that there is room for three lugs with two holes spaced one inch apart. Cables and terminal lugs are not furnished with the inverter and must be ordered separately for the 3.5 kVA to 145 kVA units. The 17.5 kVA and 21 kVA inverter require the super flexible (fine strand) wire, which is supplied as an option with the Maintenance Bypass unit. The utility input and output cables are connected to a screw type terminal block.
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3.5 to 21 kVA N+1 Inverter connector. Swing the “Display” panel back to its vertical position and install the two screws to hold the panel in position. Do not tighten the screws very much, since they will be removed again. 2.3.3.2 System Personalization Before installing the power modules into the receiver rack, apply the 48 DC input voltage (44 to 56VDC). The controller (microprocessors) within the unit should become activated.
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Owner’s Manual 2.3.5.1 Power-Up Procedure Turn the main source DC input circuit breaker ON to apply 48VC to the system. The “controller” boards and LCD “Display” panels are now energized. The following message will be displayed (paragraph 4 of chapter 1 gives full details of LCD readout): Line 1: Line 2: INV: BYP: off static normal AC LOW If the system is equipped with two controllers, one controller will take control of the system, the other will be a backup.
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Owner’s Manual Maintenance 3.0 Scope This chapter describes maintenance and service of MGE UPS Systems Modular Inverter System, including safety instructions, preventive maintenance, descriptions of replacement kits, and service. 3.1 Safety Instructions IMPORTANT SAFETY INSTRUCTIONS FOR INVERTER SERVICING SHOULD BE PERFORMED OR SUPERVISED BY QUALIFIED PERSONNEL ONLY. WARNING IMPORTANT SAFETY INSTRUCTIONS FOR INVERTER SERVICING SHOULD BE PERFORMED OR SUPERVISED BY QUALIFIED PERSONNEL ONLY.
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3.5 to 21 kVA N+1 Inverter 3.2.3 Air Intake Cleaning Inspect the air intake and exhaust openings for blockage. Verify that air flows freely through the equipment. Clean the air intake and exhaust openings with a vacuum and a soft brush. 3.2.4 AC Fan Replacement Procedure Every five years, replace the two AC fans on the “Static Switch” front panel, (MGE UPS SYSTEMS part number 0422130).
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Owner’s Manual 3.3 Replacement Parts Replacement parts are available from MGE UPS Systems. Contact MGE UPS Systems Customer Support Services for ordering replacement parts. Having replacement parts on hand will prevent unnecessary delays in critical service times. 3.4 Troubleshooting and Servicing Should you encounter a problem in the operation of the inverter and need MGE UPS Systems to service your equipment, it is recommended to leave the unit in its current state.
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3.5 to 21 kVA N+1 Inverter Inverter rating 3.5 kVA 7 kVA 10.5 kVA 14 kVA 17.5 kVA 21 kVA 125A 250A 375A 500A 650A 750A DC breaker rating 3.4.2.2 AC Output Circuit Breaker It is not required, but highly recommended. A power “Distribution” panel is available from MGE UPS Systems at a nominal cost. Order part number XXXXXXXXX, which will accommodate up to 24 single-pole circuit breakers, “Square-D” QO type. 3.4.2.
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Owner’s Manual 3.4.2.9 Dual Half-Bridge Inverters In or to provide more choices of output voltage, two identical half-bridge inverters are used to produce either 120VAC or 240VAC depending on parallel or series connection of the outputs. A network that consists of a coupled inductors and high frequency capacitors form a second-order low pass filter and is connected across at each inverter’s output for removing PWM signal. See figure 4-4. 3.4.2.
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Owner’s Manual Theory of Operation This chapter describes the theory of operation of the S4 inverter system. 4.0 SCOPE The following is a brief description of the mechanical configuration and how the S4 inverter system functions. It is not intended to provide complete details of all of the circuits within the unit, but gives some details as to the function of each block. The system is a modular 48VDC to 120/240VAC inverter, which consists of 3.5 kVA/3KW modules housed in a “Receiver” cabinet.
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Owner’s Manual Figure 4-2: Block Diagram of the S4 Inverter Power System 4.3 Alarm Relays Located just to the left side of the “Controller” printed circuit board card cage is the “Alarm” relay board. This is a plug in circuit board with a terminal block located on the front of the card. Wire routing to the card will be through a knock out located near the DC input, AC input/output knock out landings.
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3.5 to 21 kVA N+1 Inverter 4.5 DC Input Power Connections The “Receiver” cabinet also contains the DC distribution bus bar system, which is called a “DC Raceway”. It consists of a sheet metal enclosure with two copper bus bars, 1.5” wide, 0.125” thick. These bus bars have ELCON connectors attached to them. The “power modules” have short bus bars projecting out the back of the chassis, which supply the power to the module. These bus bars plug into the ELCON connectors.
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Owner’s Manual Figure 4-3: Block Diagram of Power Module Theory of Operation page 4 — 5
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Owner’s Manual 4.7.1 Power Module Configuration The power module output current is approximately 10A/volt when it is configured for 120VAC, 5A/volt when configured for 240VAC. Figure 4-2 to 4-4 are block diagrams of the power module. DC power enters the module via bus bars and is applied to a small EMI filter (called a “PI filter”). The filter is designed to reduce the high frequency switching ripple and noise on the battery bus.
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3.5 to 21 kVA N+1 Inverter 4.7.1.2 Inverter The boost transformer has two secondary windings, 22 turns, center tapped at 11 turns. The two secondary windings, which are rectified, make two separate outputs of +212.5V and –212.5V each. These DC voltages are applied to a filter “Capacitor” PCB, which connects to the inverter IGBTs. The primary has eight turns, center tapped at 4 turns.
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Owner’s Manual 4.7.1.2.4 Average Current Mode If the inverter “current command” control signal can be made to control a current source (or sink), then the pole/zero associated with the output L-C filter becomes a first order system, that is, a current source discharging or charging a capacitor. It is much easier to stabilize this type of control loop. It also provides the needed current limiting function.
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3.5 to 21 kVA N+1 Inverter the two signals is not zero, then the inverter has failed. The inverter must be disconnected and shut down. Shut down is accomplished by opening the inverters output relay as quickly as possible, turning of the drive to the IGBTs, inhibiting the battery booster, and issue a signal to the “Controller” that the module is not OK via the MODSOK signal line. A “minor” alarm signal will be issued by the “Controller” so the user will now that a fault has occurred.
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Owner’s Manual zero to +5V. The +2.495V is used as the reference for the LMC660 amplifiers, signal transformers, which are used to measure the AC input and load voltages, and AC current transformers. 4.8.1.1 “Controller” Input Signals The DC current sensor used to measure the battery current is “LEM” HTA types and require +15VDC, return, and –15VDC. We do not have a negative 15VDC supply, thus the LEM was offset by 15V.
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3.5 to 21 kVA N+1 Inverter Function Micro port Input at 0.250V Input at 0.500V Input at 4.500V Input at 4.750V Notes: I backfeed P0.0 Ibat, battery current. P0.1 No. modules installed. P0.2 See below No. modules OK. P0.3 See below Vbat, battery voltage. P0.4 66.613 65.030 39.696 38.113 Vacin, RMS input volts. P0.5 143.51 127.52 127.52 143.51 Iacout., rms load current. P0.6 30.23 34.02 90.68pk 102.05pk Vacout, RMS load volts. P0.7 143.51 127.52 127.52 143.
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Owner’s Manual 4.8.1.7 High Voltage Drivers The processor PCB also has a high voltage transistor array (ULN7002), which is used to control the tri-colored “STATUS” LEDs and “alarm relays”. The LEDs are powered directly from the 48V input bus through dropping resistors. The transistor array shorts out the appropriate Red and/or Green LED to produce the Green, Amber, or Red color. The “Alarm” relays operate directly from the +48VDC supply, thus the high voltage driver is needed. 4.8.1.
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3.5 to 21 kVA N+1 Inverter 4.8.2.1 Static Switch Driver On the right-hand side panel of the “receiver” cabinet is the “Static Switch” gate driver printed circuit board. This board serves two functions. One, it has a 120/240VAC, 50/50Hz bias transformer mounted to it which provides the auxiliary 48VDC for operating the “Controller” and “LCD” “Display”.
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Owner’s Manual The output of this current transformer is clamped to a maximum of +/-1.1V by means of back-to-back diodes, which is in parallel with a high value burden resistor. This signal is supplied to the “Controller”. If back-feed current should be detected when the inverter is operating, the system will be shut down, that is, latched OFF. Reset us accomplished by cycling the system OFF ON/ switch on the LCD display panel.
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Owner’s Manual Glossary Appendix A Symbols Definition/Meaning @ At. / And/or. +/- Plus or Minus. # Number. °C Degree Celsius. °F Degree Fahrenheit. Ø Phase angle. W Ohm; unit of resistance. ® Trade Mark. 2nd Second. AC or ac Alternating current, also implies root-mean-square (rms). Ambient Temp. Temperature of surrounding air. Ambient noise Acoustical noise of surrounding environment. ANSI American National Standard Institute. AWG American Wire Gauge.
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3.5 to 21 kVA N+1 Inverter DC or dc Direct current. Digital Meter The LCD display on the front panel of inverter system. Earth ground A ground circuit that has contact with the earth. Electrician Refers to an installation electrician qualified to install heavy-duty electrical components in accordance with local codes and regulations. Not necessarily qualified to maintain or repair electrical or electronic equipment. Freq. Frequency. Frequency slew rate The change in frequency per unit of time.
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Owner’s Manual NFPA National Fire Protection Association. NO. or No. Part number. On-line mode Inverter output power is the primary energy source to load. Off-line mode Inverter output is off, and the load connected at the inverter output receives power from utility line via a static transfer switch or maintenance bypass relay. OSHA Occupational Safety and Health Agency. PWM Pulse Width Modulation. SCR Silicon controlled rectifier.
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