System Details
System Details
System Details
Figure H-1
Figure H-2
1.2
1.2.1
AC input EMI
DC/DC Converter
Figure H-3
The single-phase AC power is first input through EMI filtering circuit, which enables two functions: 1) To prevent the line peak voltage caused by other related equipment (such as thysristor) or due to the lightning strike from damaging the rectifier module. 2) To prevent the rectifier module from feeding high-frequency disturbance caused in switching modulation to the power network. In addition, a surge current suppressing circuit is provided in the AC input circuit to reduce the surge from the power supply to the power network and to protect against lightning strike, thus the reliability of power supply is greatly improved. 1. DC-DC Circuit DC-DC main circuit adopts the topology of single-end flyback structure. The control circuit adopts pulse width modulation (PWM) control mode, in which the pulse width of power transistor is automatically regulated according to the load, high-voltage DC current is inverted to the pulse voltage whose width is regulated. After the pulse is rectified and filtered, stable DC voltage is output. The circuit
adopts advanced switching technologies such as lossless ZVS and ZCS, thus the switching loss is greatly lowered and the efficiency reaches up to 87%. 2. Load-sharing technology HD4810-5 (51) module adopts advanced low-difference active load sharing technology. When multiple HD4810 rectifier modules are operating in parallel, they enable a good load sharing performance. The operating theory is illustrated in Figure H-4. Each module load-sharing unit samples its own output current via a uniform amplying factor in order to form a sampling voltage. After comparing all sampling voltage, the highest one is selected as the reference voltage VBUS on the current sharing bus. The module corresponding to the reference voltage is called master module, and it has the highest output current. Other modules are called slave modules. The reference voltage passes into respective current sharing unit of each module via current sharing bus, and controls the switch pulse width of DC/DC converter of the module after the difference comparison and amplification with its sampling voltage, then enables the output currents tending to be uniform by regulating the output voltage of all the modules. When EC is balanced, the output current of the slave modules is very close to that of the master module and current difference is tending to zero. Advantages of this current sharing method are in two aspects: 1) Load is well shared with imbalance less than 3%, which is better than ministry standard 5%. 2) The master rectifier module is arbitrarily generated through comparison. When the master module stops working for some reason, the system will compare automatically to generate another module with the largest output current as the master module and re-adjust the output current to reach new balance. Thus, the system breakdown caused by module failure can be avoided.
V11
V12
V13
HD4810
load sharing adjust
HD4810
load sharing adjust
HD4810
load sharing adjust
Vbus
Figure H-4
3. Monitor processing interface The rectifier module has interfaces for monitor signal and sends the signal to monitor module through motherboard. The PSM-8 monitor module is provided for HD4810-5 rectifier module, and the PSM-81 monitor module is provided for HD4810-51 rectifier module to form a complete set. The output status information of rectifier module is: Mains input, AC input over/under-voltage and module failure signal. The input control signals of the rectifier module are: switching signal of Equalized/Floating charge, current-limiting control signal and On/Off signal. Above signals are all the digital value.
1.2.2
Specifications
1. AC input AC input rated voltage: 220V, 50Hz Voltage fluctuation range: 150V 300V
Line frequency range: 50Hz 10% 2. Rated values of DC Output Equalized charge voltage: 56.5V(can be regulated internally) Floating charge voltage: 53.5V (can be regulated internally)
Rated output current: 10A (When the input voltage is between 150V output current should be higher than 7A.) 3. Alarm and safety protection 1) Input over-voltage protection
The module alarms and shuts down to protect itself when the AC input over-voltage reaches 305 3VAC, and automatically restores to normal operation when the voltage drops to 295 3VAC. 2) Input under-voltage protection The module alarms and shuts down to protect itself when the AC input under-voltage drops to 145 3VAC, and automatically restores to normal 3VAC.
The modules will give alarm and will be turned off and locked for protection when the DC output over-voltage reaches 59.5 0.5V, and after troubleshooting, the rectifier module will be restarted. 4) Current-limiting protection The module has two-level current-limiting protection; the current-limiting protection values of the first level and the second level are 10.5 11.0A and 6.5 7.0A respectively.
5) Short-circuit protection The rectifier module has current limiting retraction and short-circuit protection. When short-circuit occurs at the output terminals of the rectifier module, the retraction current eliminated. 4.0A, and the rectifier can restore to work after the fault is
6) Overheating protection Detecting the temperature of the heatsink, when the temperature is higher than 90 65 , the module will alarm and protect. When the temperature drops to below , operation can be automatically resumed.
4. Intelligent information processing HD4810-5 (51) rectifier module provides remote control terminal and remote communication terminal, where: Remote control functions include: Power on/off, equalized/floating charge switching, and current-limiting control. Remote communication signals include: AC Mains available/unavailable, AC over/under-voltage, and module failure. 5. Mechanical features HD4810-5 rectifier module: Dimensions (Length Width Weight: 2.3kg HD4810-51 rectifier module: Dimensions (Length Width Weight: 2.3kg 6. Efficiency Overall efficiency is higher than 87%. Height): 318.5mm 144mm 70mm Height): 318.5mm 60mm 167mm
1.3
1.3.1
Figure PU-1
3.2
25
3.2.1
Operating Theory
Operating theory of PDU4840CF AC&DC power distribution unit is illustrated in Figure PU-2.
Figure PU-2
In AC&DC power distribution unit, AC power input is introduced into the AC over/under voltage protection board via circuit breaker QF1, then to the backboard, and finally supplies power to the rectifier module via the connectors on the backboard. DC output is connected to two groups of batteries and three branch circuits of loads via the backboard. Shunts R1, R2, R3, and R4 respective detect the current of two groups of batteries and three branch circuits of loads. Contactors KM1 and KM2 are controlled by the monitor module to enable automatically load connection function. Connection/disconnection signals of QF2, QF3, QF4, QF5 and QF6 and current signals of R1, R2, R3 and R4 are sent to the monitor module via the backboard.
3.2.2
Performance Description
1. Secondary LVD functions When the AC power failure occurs and the battery voltage lower than the secondary LVD voltage, DC output of QF4 and QF5 will be automatically disconnected.
26
2. Battery over-discharge protection When the AC power failure occurs, the battery connected to the AC&DC power distribution unit will supply power to the system. When the battery voltage is lower than the battery over-discharge protection voltage, the battery and all DC loads will be automatically disconnected to avoid over discharge of the battery.
3.2.3
Specifications
1. AC input Input voltage: 150VAC 300VAC
2. Battery branch circuit Two branches, 50A for each 3. DC load branch circuit -48V/32A, three circuits, and the total operating current is not higher than 40 A. 4. Secondary LVD voltage -44.0 0.2V
When the battery voltage is lower than -44.0 0.2V, DC output of QF4 and QF5 will be automatically disconnected to enable secondary LVD protection. 5. Battery over-discharge protection voltage -41.0 0.2V 0.2V, all
connection between the battery and loads will be automatically disconnected to enable automatically battery over-discharge protection.
27
Dimension of PSM-81 is shown in Figure PM-2: 1. Dimension: 330mm 2. Weight: 1.45 Kg 144mm 55mm(the height of the panel is 70mm)
31
4.2
4.2.1
Figure PM-3
32
4.2.2
33
reserved values, overlimit of ambient temperature, and overlimit of ambient humidity. The setup parameters sent by the host to the monitor module are: voltage for disconnection of transfer module, voltage for disconnection of user module, current-limiting state of 28A, temperature alarm upper limit, temperature alarm lower limit, temperature sensor measurement lower limit, temperature sensor measurement upper limit, humidity alarm upper limit, humidity alarm lower limit, humidity sensor measurement lower limit, humidity sensor measurement upper limit, reserved capacity alarm upper limit, reserved capacity alarm lower limit, reserved values measurement lower limit, and reserved values measurement upper limit. The control commands sent by the host to the monitor module:
disconnection/connection of master load, disconnection/connection of slave load, disconnection/connection of rectifier module 4, disconnection/connection of rectifier module 3, disconnection/connection of rectifier module 2,
disconnection/connection of rectifier module 1, and current-limiting control. 2. Control Functions PSM-8 can send control signal according to detected values or the control commands sent by the host. (1) The host sends On/Off command of the rectifier module to the monitor module according to the rectifier module alarm signal sent by the monitor module and users requirements. Upon receiving the On/Off command, the monitor module enables On/Off of the corresponding rectifier module. (2) The host sends 28A current-limiting signal. The monitor module controls the state of current-limiting of 28A via the instructions. (3) The host sends user module power on/off and transfer module on/off commands to the monitor module according to users requirements. The monitor module sends corresponding control signals to control the power on/off of the user module and of the transfer module. When all rectifier modules are not powered, the monitor module disconnects the user module and transfer module at differently time according to the voltage of the busbar. When the voltage of the busbar is lower than the power off voltage of the user module, the user module will be disconnected.; when it is lower than the power off voltage of the transfer
34
module, the transfer module will be disconnected. When the rectifier module is powered, the transfer module and user module will be connected. (4) Conduct equalized charge once if the two groups of batteries have operated for 60 days in mode of continuous floating charge, and conduct equalized charging if the charging power recovers after the power have been off for longer than15 minutes. 3. Detecting Functions PSM-8 monitor module can detect AC power distribution cabinet, modules, and DC power distribution cabinet and environment values. (1) AC power distribution cabinet PSM-8 can monitor AC mains available/unavailable state, AC mains over/under-voltage state. (2) Rectifier module Detect the fault state and on/off states of 4 rectifier modules. (3) DC power distribution--Bus-bar voltage, current of user load, current of transfer load, fuse state of user load, fuse state of transfer load, current of battery group 1, current of battery group 2, fuse state of battery group 1 and fuse state of battery group 2. (4) Environment values-- Environment temperature and humidity, smoke and fog alarm, infrared/magnetic door alarm and water-immersing sensor alarm according to the installation of sensors. Of the above detected values, bus-bar voltage, ambient temperature, humidity, current of modules, battery current, current of user load, current of transferring load are all analog values, others are digital values. 4. Power Failure Protection Functions When the power failure occurs in the monitor module, the configuration parameters and control state that have already been set remain unchanged. If the user wants to use the default parameters, he can short circuit the No.1 and 2 pins of J4 on the M1441U1 printed board of the monitoring module and the default configured values can recover after the system is powered on again.
35
1.1.2
Common Configuration
Rectifier module, environment values and AC power distribution of PS4840/10 power supply system can be configured as following: 1. Using 2, 3 or 4 rectifier modules can form 20A, 30A or 40A power supply system can be formed. 2. Environment values: temperature, humidity, smoke sensor, water-immersing, infrared and magnetic door. 3. PD220/60A power distribution cabinet enables good AC input protection function and lightning protection function, so it should be preferred in the configuration of the system. But HD4810-5 has AC input alarm function, so PD220/60AD power distribution cabinet may not be provided in the system. In addition, one single-phase lightning protection box SPD23SZ can be selected to satisfy the requirements for lightning protection.
41
1.2
1.2.1
42
Each
environment
value
including
smoking,
infrared/magnetic
door,
water-immersing, temperature and humidity can be acquired and reported by the system through monitor module.
AC Input
AC mains I AC mains II
power module
power module
power module
power module
DC backboard
Sensor Smoking Temperature Humidity Water infrared/ gate-magnetic Battery group 1 Battery group 2 User 1 User 2 Monitoring module
Host computer
Figure P1-1
43
1.2.2
Specifications
1. AC Input (PD220/60AD is configured) Two branch circuits of single-phase AC mains input (one for master input, the other for reserved input) Rated input voltage: 220VAC Maximum input current: 63A Frequency: 50Hz 10% 2. Battery Input Working in equalized or floating charge mode, the positive and negative poles of two groups of batteries are connected in parallel with the DC output of the rectifier module. Rated input voltage of each group of battery is 48V and the rated capacity is 100Ah or more. 3. AC Power Distribution output Three circuits of output, 220VAC and 20A for each. 4. DC Output Standard voltage: -48VDC Voltage regulation range: -43V ~ -58V (adjustable inside the rectifier module ) Total DC output current: 40A DC power distribution branch-circuit: Users load 1 Users load 2 Battery 1 Battery 2 5. DC Output Noise Psophometrically weighted noise: Broad band noise voltage: 2mV 150KHz) 30A 30A 45A 45A
50mV (3.4KHz
44
7. Operating Efficiency 87% 8. Dynamic Load Response When the load is changed from 20% to 80% rated load, recovery time is shorter than or equal to 200mS and the over-shoot is lower than or equal to 0.5%. 9. Anti-lightning Strike Index Maximum operating line-to-neutral voltage: 385V, 50Hz Maximum discharge: The maximum through capacity is 40kA, once, 8/20 surge current Rated through capacity: 20kA, 20 times, 8/20 Maximum response time: 25ns 10. Insulation Resistance The insulation resistance between DC part, AC part and cases should be higher than 2M (experimental voltage is 500VDC). s surge current s
11. Insulation Strength Apply 50Hz, 3000V AC power between AC input and DC output for 1 minute, there should be no breakdown nor arc; Apply 50Hz, 1500V AC power between AC mains and case for 1min, there should be no breakdown nor arc; Apply 50Hz, 500V AC power between cases and DC output for 1min, there should be no breakdown nor arc. 12. Mechanical Features Cooling method: Air cooling Dimension: 177mm 483mm 386.2mm (Height Width Depth)
45
1.3
Installation of PS4840/10
Upon the transportation of PS4840/10, monitor module and all rectifier modules have already been installed in the main case of the system, as shown in Figure P1-2. (System capacity is 30A, combined by three HD4810-5 rectifier modules and one monitor module). Popular 19-inch/4U structure is adopted in main case of PS4840/10 power supply system, with system backboard installed in the rea part used for electrical connection with external devices.
PSM8
OFF VocEN
HD48105
ON OFF
HD48105
ON OFF
HD48105
ON OFF
ON RESET
VocDIS VinON VinALM FAIL RECHARG TXD Vin ALM RUN Vin ALM RUN Vin ALM RUN
RUN
RXD
The parts need to be installed at the site of users of PS4840/10 include AC power distribution cabinet PD220/60AD, main case of the system, lightning protection box and sensors. Please refer to the Section 2.3 Installation of PD220/60AD in Chapter two of Part One System (page 12) and Installation of Sensors of PS4840/10 and PS4840-2/10 Power Supply Systems in Chapter Six of Part Two System for installation of AC power distribution cabinet PD220/60AD and sensors. The lightning protection box has its own users manual. The installation of the main case of the system is mainly described in the following. When connecting the main case with external equipment, users only need to finish the electrical connection between the main case and external equipment.
46