SMPS
SMPS
Sources of power:
Telecommunication systems need uninterrupted power supply round the
clock and throughout the year. For any uninterrupted power supply system,
two sources are required.
1. Normal or Main source-Main Source is D.C derived from
commercial source.
2. Secondary or standby source- Secondary cells
By name we can define Normal source is one which supplies power to the
load round the clock and secondary source is one which supplies power to
the load only during the absence of power from normal source.
Hence it is a must to convert AC from commercial mains to D.C.
A.C to D.C conversions:
Previously M.G (Motor-Generator) sets were used for A.C to D.C conversion.
In this A.C motor rotates on commercial A.C. supply. To the shaft of this AC
motor, D.C. Generator will be coupled which generates D.C. Now a days
static rectifiers using static electronic components like metal or diode
rectifiers are used.
In this scheme two sets of Batteries (24 cells each set) are connected in
parallel to the output of the rectifier. The output of the rectifier is 51.5 V.
Hence floating voltage of each cell is 51.5 divided by 24 = 2.15V/ cell. Hence
always 90% of battery capacity will be available for emergency usage
For the operation of the scheme POWER PLANT is designed by TRC
(Telecom Research Centre)
Operating voltage:
Now a days almost all of our telecom equipment works on -48 volts D.C.
supply i.e. positive lead is earthed.
Earthing of one pole of D.C:
FLOAT RECTIFIER
The function of the Float Rectifier is to receive three phase 440 V AC and to
give a constant 51.5 Volts D.C without AC ripples.
The steps involved to achieve the function are
a. Step-down
b. Rectification
c. Filtering
d. Regulation.
Step down
Transformer steps down the 3 phase A.C voltage from 440 volts to around 80
volts.
Rectification
Any unidirectional device rectifies the AC to DC.
Here Diodes & SCRs are used for rectification.
Filtering:
Here multi-stage L.C. Filters are used for filtering the A.C. Ripples.
Regulation:
What is Regulation?
As far as Float Rectifier is concerned, Regulation is the mechanism by which
the output of a float rectifier is kept constant at 51.5 0.5V irrespective of
input voltage variations of 12%. Output load variations of 5% to 105% and
input frequency variations of 4% or 48-52 Hz.
In this a transductor is placed in series with the rectifier and uses the
principle that the impedance of an iron cored coil can be varied by varying
the degree of saturation of the core.
By varying the series impedance to rectifier, we can vary the portion of
input cycle that is fed to Rectifier.
SCR Method.
In this the SCR is used as rectifying element.
Let us recapitulate the working of SCR.
In the normal 'off' state the device restricts current flow to the leakage current.
When the gate to source current exceeds a certain point, the device turns
'on' and conducts current. The device will remain in the 'on' state even after
gate current is removed so long as current through the device remains above
the holding current. Once current falls below the holding current the device will
switch off. If the applied voltage increases rapidly, it may induce enough
leakage current to trigger the device into the on state, but this is harmful to
the device. The reverse blocking voltage is limited in any device.
SCR can be switched on by applying the positive pulse to the gate. Once if
the
SCR is switched on, it will be in ON condition as long as the current flowing
through SCR is above a threshold value called Holding current.
In a Float rectifier, across each half cycle one SCR is connected. Hence for 3
phases i.e. R, Y, B totally 6 SCRs connected.
Let an SCR is connected across the positive half cycle of a phase. The total
time period of an half cycle is 10 ms. Within this half cycle triggering pulses
can be given at any time. Assume that triggering pulse is given to SCR at
Point A after 4 ms of starting of the half cycle, the SCR will be on. Even
though the triggering pulse is removed, the SCR will remains on. But the
current flowing through SCR depends on the amplitude applied across its
terminals. At 9 ms i.e. @ point B, let the current flowing through the SCR is
just below the holding current. The SCR will be switched off. That means
switching on of SCR is in our hands, but switching off of SCR is not in our
hands, it is automatic. In this case the portion of half cycle between the
points A and B is rectified.
The output voltage of the FR depends on both the input AC voltage and
output
DC load and position of triggering pulse advanced or delayed
-Look at the above table. Whenever the input voltage increases or output
load decreases the output DC voltage increases and vice versa. Hence if we
monitor
output voltage, it is sufficient to regulate it.
-If the output voltage is increased, then the triggering pulse to the SCR will
be delayed or retarded, point A moves towards B, hence the portion of AC
cycle rectified will be reduced, hence output voltage will be automatically
reduced and
brought to the specified value.
-If the output voltage is decreased, then the triggering pulse to the SCR will
be advanced, hence output voltage will be automatically increased and
brought to the
specified value. -This is how regulation is achieved by using SCR.
2. Output Voltage :
Float mode :
Nominal voltage : -54.0 + 0.5V,
Adjustment range : -48.0 to 56.0 V
Charge mode Voltage : -55.2 + 0.5 V
3. Rated current : 100 Amps.
4. Psophometric noise :
Less than 4 mV without battery floated.
Less than 2 mV with battery floated.
5. Input power factor :
Greater than 0.95 lag with 25% to 100% load at nominal input.
6. Efficiency :
Greater than 90% at full Load and nominal input.
7. Protection :
a.
b.
c.
d.
: Green LED
: Red LED
: Red LED
: Amber/Yellow LED
: Green LED
For System
1. Input Voltage:
a. 3 Phase, 4 Wire, 50 Hz (Range 320V to 480V RMS)
b. Frequency : 45 Hz . 65 Hz.
2. Output Voltage :
a. Float mode Voltage : -54.0 + 0.5V
b. Charge mode Voltage : -55.2 + 0.5V
3. Rated Current :
a. Equipment
: 1100 Amps.
b. Batteries
4. Protection
a. Short circuit/Over load protection.
b. Input over/under voltage protection.
c. Battery/Equipment over voltage protection.
- Red LED
- Red LED
- Red LED
- Red LED
- Green LED
- Red LED
- Red LED
- Red LED
- Green LED
- Red LED
This Power System is of multi rack type and consists of the following:
a. Eight racks One main, one auxiliary and six extension racks.
b. AC Distribution module in each rack.
c. Rectifier modules (A maximum of three modules in extension rack and
two each in main rack and auxiliary rack).
d. DC distribution module in each rack.
e. Metering in each rack.
f. Power system controller in main rack.
a. Rack:
The rack is made of mild steel profiles with hinged front door. The door
accommodates display and alarm enunciator. The rack is convection cooled
and has ventilatory slots in the front and sides. The rear panel is screw type
and can be dismantled. The cabinet accommodates 19 subsystems. Air
baffles are provided for better heat transfer. Depending upon the load
: Red
: Red
: Red
: Red
: Red
: Green
: Red
: Red
: Green
: Red
the coded signal M1 and M2 from the controller. Depending on the state of
batteries, the ATM circuit either gives a signal for float or charge. These
signals are encoded by an encoder to obtain suitable coded signals M1 and
M2. Depending upon the mode of operation of Rectifier modules, they
acknowledge coded signals S1 and S2. These signals are decoded to display
whether the modules are in auto float/charge or fail condition. The total
battery current can be suitably programmed to limit the current supplied
from the modules through current programming pin in modules.
SMPS 48V 5600W Introduction
The SMPS 48V-5600W is a three-phase, unity power factor power supply with
a
wide input voltage range of 3 X 185 Vac to 275 Vac (with neutral wire) and
with a useful output power of 5600W delivered to the load. This unit has
been developed for cost effective but highly intelligent modular
telecommunication power systems. It fulfills the specification of Primary
application of the rectifiers SMPS 48V-5600W are in the supply of Telecom
equipment. The convection cooled unit may be operated up to 60C ambient
air temperature.
The rectifier operates from a nominal 3 X 230 V ac rms (with neutral wire)
source.
The mains frequency may vary from 45 Hz to 65 Hz. Total harmonic distortion
(THD) of the input current wave form is below 5%. The output of the rectifier
conforms to the generic requirements of telecommunication power supplies
in terms of noise, voltage programmability, as well as over voltage, overload
and short-circuit protection. The rectifier SMPS 48V-5600W can be set in the
3 modes auto float, auto charge and manual boost by the power system
controller.
primarily during the turn-off process of the boost diode. The output of boost
converter is a stabilised 400 Vdc voltage. Further conversion of the stabilised
high voltage output of the power factor corrector circuit is necessary to
generate the isolated low voltage output and to provide the required
protection functions for telecommunication application. These tasks are
achieved in the dc/dc converter circuit, which is based on a full-bridge
topology. The full bridge circuit is operated by phase-shift pulse-width
modulation with current-mode control. This control method provides zero
voltage switching conditions for all primary side power semiconductors
effectively reducing switching losses and electromagnetic interference. An
advanced solution reduces the stresses on the output rectifier diodes. Proper
operation of the power converters is managed by individual control circuits
and supervised by the housekeeping electronics. Remote commanding and
monitoring of the modules are possible through a power system controller.
Block diagram of a single sub-module R, S or T
This chapter gives more detailed information about the technical merit of
single
sub-module based on the functional blocks shown in the diagram below (R, S
and T).
Input Section
Block 1 of the drawing presented above is the input EMI filter of the
rectifier. The fixed frequency, synchronized operation of the different circuits
allowed to optimise the filters performance. It has only one differential and
one common mode filter stage.
Block 2 represents the Inrush Current Limiter circuit, which consists of
series
combination of surge rated power resistors and fuse. The circuit limits the
input current of the rectifier during the initial charging of the energy storage
1.
Scope
This Engineering instructions describes the testing procedure of High Frequency Switch
mode Power Supply (SMPS) power plants, which is mainly to evaluate technical parameters &
functional aspect of SMPS techniques used in Telecom Network.
2.
General
With the advent of digitalisation in the arena of power supply system, conventional power
plants are being replaced by High Frequency Switch Mode Power Supply System called SMPS
power plants. These plants are of different capacities i.e. 12.5A stand alone module to 7000A Rack
Power System, arrived by using compact (SMR-Switch Mode Rectifier) package; rack power system
is used to supply uninterrupted (using suitable VRLA battery back up) and disturbance free DC power
for Telecom equipments.
Since these SMPS power plants used MOSFETs, FETs in SMRs (Switch Mode Rectifier),
microprocessor controls etc. it has a typical testing procedure as described below:
3.
Testing instruments
The instruments required are 500 Volts Insulation tester, Standard A.C. Ammeters, Voltmeter,
DC mV volt calibrator, Voltmeter, Tong tester Digital Multimeter, Psophometer, Thermometers, Earth
tester & DC load.
4.
Tests
4.1
LAR: Location alignment & rigidity of the unit is checked as per approved plan and ensured
that physical mountings of all SMRs plugged-in securely in magazines.
4.2
Earth testing: Check (as given below), that a good earth, of value 0.5 is connected with
power plant. Suitability and gauge of earthing lead should also be checked as per specification.
Method of measuring Earth Resistance (4 terminal)
Drive two ground rods (auxiliary electrode) 2 feet deep, in a
straight line. The 1st electrode (p1)20 meter away from earth, and 2nd
electrode (c1) 40 meter away from earth under test. connect the wires
taken from p1 & c1 to p1 and c1 terminals of the tester. Also connect the
earthing under test at p2, c2 shorted together terminals. Turn the handle
at rated speed or above. The value indicated as per selected scale is the
earthing resistance. It is advisable to moisten the ground around the
electrodes. It is also important to place all 3 electrodes (i.e. eth, p1, c1)
approximately in a line.
4.3
1.
(i)
(ii)
2.
(a)
(b)
(a)
(b)
(a)
(b)
Connect insulation tester between shorted input and shorted output terminals.
Operate the megger and record the reading.
Limit: Insulation resistance shall be better then 2 M-, 1 M , & 5 M for test 1,2, & 3
respectively .
4.4 Power Factor
Record the reading of power factor using power factor meter at nominal I/P, max. output,
load 25% to 100% .
Limit : PF shall be better then 0.95 lagging in above condition .
4.5
(i)
(ii)
(iii)
(iv)
Psophometric Noise
Connect the psophometer probes to out put terminals ve and ve.
Check the calibration of psophometer .
Select the psophometer in weighted mode
Record the psophometric value at 100% load at nominal I/P 400 v/230.
Limit : Psophometric noise without battery be less then 4 mv. and 2 mv with rated capacity
battery floated across the output.
4.6
Meter Calibration
4.6.1
DC Voltmeter
4
5
6
7
8
9
4.6.2
DC Ammeter
(i)
Instrument required:
Secondary standard DC mV calibrator.
Set panel meter voltage corresponding to millivolt drop at 15, 30, 45, 60, & 75 (units in
millivolt)
(ii)
4.6.3
AC Volt meter:
(i)
Record the input power, out put voltage and current at nominal input and full rated load.
----------------------------------------------- X 100
I/P power
4.8 Load sharing
Balanced condition :
Imbalance in load
% Unbalance -------------------------- X 100
rated capacity
4.9 Load Limiting (Voltage Droop)
In Auto Float/Charge mode
(A) Disable ATM (Auto trickle mode)
(B) Switch ON the unit in Auto Float Mode.
At output vol tage54 V
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Gradually increase the load till voltage droop takes place Note down the reading of load
current Amp. (shall be nearly 110%).
Similarly voltage droop test is repeated for output voltage 56V by repeating the steps (a) to
(g).
4.10Voltage Settability
Disable ATM
(ii)
Switch ON the system at nominal I/P voltage adjust the output voltage by adjusting potentiometer/ preset to 52.8 V for
conventional battery and 54 V for VRLA battery.
(iii)
With the help of voltage adjustment potentiometer adjust the output voltage to -48 V to -56 V.
(iv) Observation: output voltage settability gets adjusted/does not gets adjusted.
(B)
(i)
(ii)
(iii)
Switch ON the system at nominal input of 230V for single phase/400V for 3 phase. Adjust
the output voltage adjustment potentiometer/preset to 55.2V for both conventional lead acid and
VRLA battery.
(iv) Repeat the steps (A) (iii) & (iv) as above .
(C)
(i)
Switch over the unit to Manual Boost Mode and adjust output voltage adjustment
potentiometer/preset to 65V. With the help of voltage adjustment potentiometer
adjust the Output voltage between -56 V to -65V.
Load Regulation
(A)
(i)
Switch ON the equipment in Auto Float mode at 25% load, nominal I/P.
(ii)
(iii)
Load the equipment to 50% of its rated capacity & repeat record of parameter as at
(ii).
(iv)
Load the equipment to 100% of its rated capacity and repeat the record of parameters as at
(ii).
(B)
Repeat all the test (I) to (iv) for Manual Boost Mode at 25%, 50%, & 100%
Load.
Check power factor, output voltage should not vary.
4.12
(A)
(i)
(b)
(c)
Switch on the unit at nominal input voltage & observe for Mode in which it starts .
Repeat (b) for the battery path Voltage 52.8V, 54V & 55.2V.
Observation :In all these cases the unit shall start in Float mode and remain in Float mode
only.
Increase the battery path current more than trickle charge value.
Switch ON the unit & observe for Mode in which it starts.
Repeat
4.13
(i)
Place the thermometers in close contact with surface of all the possible heat
generating equipment.
Limit: Maximum temperature limit of transformer and chockes is 70C and for
transistors/diode/FET etc 60C.
If it is not possible to place the thermometer in close contact with heat generating
equipment hang thermometer inside the module at a suitable place and observe
module inside temperature.
Limit: Module inside ambient temperature is equal to not more than 10C above room
ambient temperature.
(ii)
(iii)
Put the unit (under test) on 100% load at float voltage i.e. - 54V.
Record the temperatures for first five hours hourly last three hours with a duration of 30
minutes.
Limit: No abnormality shall be observed. Temperature rise in all the case shall be within
limits.
Alarms
(A)
FR/BC fail
(i)
(ii)
(B)
(i)
(b)
(c)
(d)
(e)
(ii)
(iii)
On FR/BC Module
Same as above for (I) & (ii)
(C)
DC Under voltage
(i)
(a)
(b)
(c)
isolated (shall be 43.2 0.25 V for VRLA and 44.4 0.25V conventional lead acid
battery, creating audio/visual alarm.
Increase the output voltage slowly till the battery reconnects (voltage shall be 44.4 0.25 V
(d)
for VRLA & 45.6 0.25 V for conventional lead acid battery.
(e)
(ii)
(D)
Mains fail
(i)
(ii)
(E)
(i)
(ii)
(iii)
(iv)
(v)
(vii)
(F)
(i)
(ii)
(G)
(ii)
Replace the rectifier unit.
(iii) Switch ON the unit & observe.
(iv) Audio/visual alarm generated.
4.16
Switch 'OOF' the AC mains supply. Shift the change over switch to E/A supply so
that when E/A starts its output is connected to SMPS Power plant. Start the E/A set put
'ON' the MCB's of all three phases. Connect the full load gradually for some time. Observe
all parameters of SMPS power plant. After satisfactory operation, disconnect the E/A
supply and normal all the switches.
END