Eltek Middle East (System Training)

By Mahmood Sheikh
July 2006

Training Outline

Why DC Power & not AC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Why DC Power and not AC Power?

Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Why DC Power?
Provide a reliable power supply for the telecom industry.
All telecom equipment (PABX, P.O.P sites, Base Stations, Main Switching Centers etc) must operate when the AC supply (mains power) is absent. The telecom equipment must be supplied by stored energy (e.g. batteries) while the AC supply is absent.

A filter for noise (EMC, surges etc) present on the AC power lines.
Telecom equipment can be damaged by EMC, surges and spikes etc which can be present on AC Power. A DC power system filters this noise and provides a clean, safe power source for the telecom equipment.

Charge the system batteries

Batteries are today the cheapest and most efficient way to store electrical energy. Batteries can only be charged by DC. When AC mains is present the DC power system converts the AC power to DC power which charges the batteries and supplies the telecom equipment.

Why DC Power?
To monitor and control the system and provide alarms in case of failure.
A wide range of alarms can be monitored by the DC system in order to ensure an efficient and reliable power source.

To regulate the system in order to achieve long lifetime and MTBF (Mean Time Before Failure) of the complete supply and back-up system.
DC systems can use temperature compensated charging. This ensures the optimum battery charging voltage according to the ambient temperature and prolongs the life of the batteries.

Basic Electrical Theory

Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Water Analogy
A DC power system can be easily explained using a simple water Analogy as follows..
A dam in a river is a good representation of a battery. The pressure across the dam represents the voltage of the battery A pump that pumps the water into the dam is a good representation of a rectifier that pumps current into a battery. The water represents the current in an electrical circuit.

The pipe (cable) that the water (current) flows through is a good representation of resistance.

Water Analogy

Water = CURRENT

Pump =
RECTIFIER Dam =

Pipe = RESISTANCE

BATTERY

Definition of Electrical Terms

Current A flow of electrical charge caused by a potential difference. Current is measured in Amps (A)
Voltage The difference in potential between two points that causes electrical charge to flow. Voltage is measured in volts (V) Resistance The opposition to the flow of current. Resistance is measured in Ohms () Power The time rate at which energy is transmitted to the time rate of doing work. Power is measured in Watts (W)

Definition of Electrical Terms

Energy The ability to do work. Energy is measured in Joules (J) Efficiency The ratio of the output power to the input power. Efficiency is usually measured as a percentage (%) Power Factor The derivation between the AC current and the AC voltage. Power factor is a number between 0 and 1. The power factor of any equipment should be close to 1 (i.e. >0.98)

Basic Electrical Equations

Ohms Law
Voltage (V) = Current (I) x Resistance (R) Power
P
I V R

Power (P) = Voltage (V) x Current (I) Energy Energy (J) = Power (P) x Time (t)

J P t

The Elements of a Power System

Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Elements of a Power System

UPS AC/DC BATTERY DC/AC AC INPUT PROTECTION ALARM MODULE RECT #1 RECT #2 OUTPUT DISTRIBUTION INVERTER DC/AC AC LOAD

AC SWITCH BOARD

TELECOM EQUIPMENT

G
DIESEL GENERATOR

LVBD

RECT #n

BATTERIES Output: Amperes

SMALL SURGE PROTECTION

REDUNDANT RECTIFIER SYSTEM MEDIUM AC/DC

1000 >

LARGE

10000 >

BATTERY DISTRIBUTION

The Elements of Power System

AC Switch Board The AC input to the power system is taken from the AC switch board
Diesel Generator The diesel generator is a small power plant that is capable of generating its own AC power. The generator is connected when the normal mains AC power fails. The generator can be started manually or automatically. AC Input Protection Each rectifier is protected by its own individual miniature circuit breaker (MCB). Surge Protection This is additional protection against surges and voltage spikes which can occur on the AC mains supply

The Elements of Power System

DC Rectifier System
The DC rectifier system converts the current from AC to DC. The system will usually consist of a number of rectifier modules, a monitoring and control unit and various output distribution.

Rectifiers
The rectifier is the unit which converts the AC into DC.
AC Mains Input

~AC
Rectifier

=DC

DC Output

Monitoring and Control Unit

This unit monitors all the essential parameters in the DC system (voltage, current and alarms). Parameters can also be controlled and changed from this unit.

The Elements of Power System

Output Distribution
Fuses, switches or circuit breakers which distribute the DC power to remote distribution panels or directly to the telecom equipment.

Batteries The batteries are where the energy is stored for use when the AC mains fail.
Battery Distribution Fuses or circuit breakers for protection of individual battery banks against short circuit.

The Elements of Power System

LVLD LVLD (Low Voltage Load Disconnect) is the device used for disconnecting the Secondary or Non- priority loads. Therefore when a mains failure occurs the non-priority loads are disconnected so that the Priority loads get the maximum amount of battery power. LVBD LVBD (Low Voltage Battery Disconnect) is the device used for disconnecting the batteries before they are damaged due to deep discharge.

The Elements of Power System

UPS
The UPS (Uninterruptible Power Supply) converts AC to DC and back to AC again. There is normally a small battery bank (15 or 30 minutes) which is used during the period when the AC mains fails to when the generator is started.

AC Mains Input

~AC

=DC

=DC

~AC

AC Output

Rectifier

Inverter

Battery

UPS

The Elements of Power System

Inverter The inverter converts a DC output into AC. Inverters are normally used to power essential AC loads which require long battery backup.
DC Input

=DC
Inverter

~AC

AC Output

Telecom Equipment The essential equipment for various telecom applications which is normally fed by DC power.
AC Loads Equipment requiring an AC input.

Current Flow in a DC System

Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Current Flow in a DC System - Normal

AC Mains Input is OK. Telecom Equipment is fed power by the Rectifier System. Batteries are being float charged. AC INPUT RECTIFIER SYSTEM

TELECOM EQUIPMENT

BATTERY BANK

Current Flow in a DC System Mains Fail

AC Mains input failed. Telecom Equipment is fed power by the Batteries. Batteries are discharging.

AC INPUT

RECTIFIER SYSTEM

TELECOM EQUIPMENT

BATTERY BANK

Current Flow in a DC System Mains Back

AC Mains Input is OK. Telecom Equipment is fed power by the Rectifier System. Batteries are Recharging. AC INPUT RECTIFIER SYSTEM

TELECOM EQUIPMENT

BATTERY BANK

Voltage Sequence in a DC System

V
54.5 Mains Failure

43.2 Disconnect Voltage

Mains Resume

Float charge

Battery Discharge

Battery Recharge

Current Limitation

Batteries
Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Battery Definitions
Cell A cell is 2V consisting of a positive plate a separator and a negative plate. This is where the chemical reaction takes place. Smaller battery blocks can consist of more than one cell (e.g. 12V or 6V blocks)
2V

Battery Block / Monoblock This is the physical block, the container where the cells are housed. Battery blocks can have multiple cells (e.g. 12V, 6V or 2V monoblocks etc).
12V OR 6V OR 2V

Battery Definitions
Battery Bank A group of battery cells connected in series to obtain the required voltage (normally -48V in telecoms). A bank is able to be isolated as an individual bank.
MCB

String A group of battery cells connected in series to obtain the required voltage. These groups of cells are then connected in parallel increase the capacity, however maintain the required voltage. There maybe multiple strings in a single bank
String 1
MCB String 2

Battery Management Definitions

Float Voltage The recommended charge voltage to be applied to a battery under normal conditions.
Capacity This is the electrical energy stored in a battery and is measured in ampere hours (Ah).

Capacity (C) = Amps (A) x Hours (h)

A

C h

C10 Capacity is normally specified at a 10 hour discharge rate. Therefore C10 means the normal capacity referred to after a 10 hour discharge. Capacity can however refer to a longer rate (C8 or C20 for example).

Battery Management Definitions

Equalizing Batteries A high voltage is applied to the batteries in order to equalize the cell voltage on a string of batteries.
Boost Voltage Is a voltage higher than the float voltage for fast charging or equalizing of batteries. Temperature Compensation A technique that uses a temperature probe to monitor the ambient temperature of the batteries. The DC system control unit regulates the float voltage in accordance with the temperature. This technique will increase the lifetime of the batteries.

Battery Management Why?

Ensure Long Battery Lifetime
This is done by applying the correct float voltage using temperature compensated charging and maintaining a temperature controlled environment.

Prevent Deep Discharge Damage

If a battery is over discharged it will become damaged beyond repair and unable to fully charge to its maximum capacity. To prevent this from happening an LVBD (Low Voltage Battery Disconnect) is used to disconnect the battery at a pre-set disconnect voltage and stop it from discharging any further. The disconnect voltage is usually approx. 43Vdc since most telecom equipments operating voltage is somewhere between 45Vdc ~ 72Vdc. Below approx. 45Vdc the telecom equipment would not operate so the batteries can be disconnected.

Float Voltage Vs Temperature

2.38 2.36
2.34

DC Voltage per cell

2.32 2.30 2.28 2.26

2.24 2.22
-10 0 10 20 30 40

Ambient Temperature (C)

Lifetime Vs Temperature
25

Design Life (Years)

20

15

10

0 20

25

30

35

40

45

50

Ambient Temperature (C)

Temperature Compensation Comparison

Self Discharge Vs Time

40 30 20 10

Capacity (%)
0

10

12

14

16

18

20

22

24

Time (Months)

DC System Redundancy
Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

Redundancy
Why have Redundancy? To cater for inevitable failure within the DC system. To allow for planned and unplanned system maintenance . Pros and Cons of Redundancy There are various levels of redundancy, as the redundancy is increased the system reliability is increased, however so is the system cost! Types of Redundancy Entire DC System Rectifier Module Battery

Dual System ~ Full (Rectifiers & Batteries)

DC System A

~AC

=DC

TELECOM EQUIPMENT
Load = 100A

Rectifier System A to support 100A load plus battery recharge power

Very High Reliability

Parallel Battery Strings for to support 100A DC System B

Very High Cost Large Area Required for DC Systems

~AC

=DC

Rectifier System B to support 100A load plus battery recharge power

Parallel Battery Strings for to support 100A

Dual System ~ Partial (Rectifiers Only)

DC System A

~AC

=DC

TELECOM EQUIPMENT
Load = 100A

Rectifier System A to support 100A load plus battery recharge power

High Reliability
Parallel Battery Strings for to support 50A DC System B

High Cost Smaller Area Required for DC Systems

~AC

=DC

Rectifier System B to support 100A load plus battery recharge power

Parallel Battery Strings for to support 50A

Dual System ~ No Redundancy

DC System A

~AC

=DC

TELECOM EQUIPMENT
Load = 100A

Rectifier System A to support 50A load plus battery recharge power

High Reliability
Parallel Battery Strings for to support 50A DC System B

Lower Cost Smaller Area Required for DC Systems

~AC
Rectifier System B to support 50A load plus battery recharge power

=DC

Parallel Battery Strings for to support 50A

Rectifier Redundancy
N+1 in Normal Operation Assuming the AC power has just returned after a mains failure, the rectifiers will be feeding the load and charging the batteries. In addition to this there will be 1 completely redundant rectifier.
30A 30A 30A 30A

TELECOM EQUIPMENT
Load = 100A

30A

Redundant Module

BATTERY BANK
Recharge = 15A

Rectifier Redundancy
N+1 with one Rectifier Failure There is now no spare rectifier power. Only just enough to feed the load and recharge the batteries.

30A 30A 30A 30A

TELECOM EQUIPMENT
Load = 100A

BATTERY BANK
Recharge = 15A

Rectifier Redundancy
N+1 with two Rectifier Failures No capacity available for battery recharge. The rectifiers are now not able to supply the load by themselves. The battery is slowly discharging and the standby time is reducing.

30A 30A

TELECOM EQUIPMENT
Load = 100A

30A

BATTERY BANK
Battery Slowly Discharging

DC System Sizing
Why DC Power and not DC Power? Basic Electrical Theory The Elements of a Power System Current Flow in a DC System Battery Management DC System Redundancy DC System Sizing

DC System Sizing Calculations

What Do We Need To Know? Required Maximum DC Load (Amps or Watts) Required System Voltage (Volts, normally -48) Battery Standby Period (Hours) Battery Recharge Period (Hours) Recharge Calculation Where IR = Recharge Current

IR =

IL * 1.15 * TS TR

IL
1.15 TS TR

= Load Current
= Battery Coefficient = Standby Time = Recharge Time

DC System Sizing Calculations

System Size Calculation Total system size needs to be able to feed the load and recharge the batteries after a mains failure. Where

Total System = Size

IL + IR

IL IR

= Load Current = Recharge Current

How Many Rectifier Modules? Divide the total system size by the output of the chosen rectifier module. Then add the desired number of redundant rectifiers.

Questions & Answers

Eltek
Excellence in Telecom Power