ZLD22020TB And ZLD1140TB Rectifier

ZLD22020TB series of rectifier is the important rectifier for EP system. It is widely

applied in the DC power system in
power plant, hydraulic power plant and high-level substations.

ZLD22020TB series of rectifier uses intelligent cooling mode and uses natural cooling at
light load, which adapts to the actual operating conditions of electric power system.
Meanwhile, the rectifier efficiency is improved, and the
dimensions and weight are reduced.

Model Description

Product series
See the following table for product series.

Product series and ordering information

Name Model Unit Ordering Remark
direction
Rectifier ZLD22020TB PCS The number of Intelligent
rectifiers air cooling,
needed excluding
depends on the accessories
system
requirement

Rectifier ZLD11040TB PCS The number of Intelligent

rectifiers air cooling,
needed excluding
depends on the accessories
system
requirement

Operating Principle
The operating principle of the rectifier is illustrated in the following figure.2-1-1
 Figure 2-1-1 ZLD22020TB rectifier diagram

ZLD22020TB consists of two power parts: 3-phase passive PFC and DC/DC converter. In
addition, it also has auxiliary power supply and input/output detection and protection
circuits.

The 3-phase passive PFC in first stage consists of input EMI and 3-phase passive PFC.
These two parts function as
AC input rectifying and filtering, and power factor correction of input current to achieve a
power factor higher than 0.94,
so as to enable the product to meet the 3-phase harmonic standard in DL/T781-2001 and
the EMI / EMC standards in
GB/T 17794.2.2-2003.

The DC/DC converter uses a PWM generator that makes the DC voltage output from PFC
in first stage to be a pulse
voltage. The high frequency transformer transfers the pulse voltage to another voltage.
The rectifying and filtering
circuit rectifies and filters this voltage and finally outputs a stable DC voltage.

The auxiliary power supply is behind the 3-phase passive PFC and before the DC/DC
converter. It is fed by the DC
output of 3-phase passive PFC and provides the DC power for control circuit.

The input detection circuit fulfills the input over/under voltage and phase failure detection.
The detection and protection circuit of DC/DC includes the output voltage and current
detection and heatsink temperature detection. All these detected signals are used for
DC/DC control and protection.

Structure And Interfaces

1. Appearance

The appearance of ZLD22020TB is shown below. figure 2-1-2

 Figure 2-1-2 ZLD22020TB appearance

2. Front panel

The front panel is shown in the following figure.2-1-3

Figure 2 -1-3 Rectifier front panel

1) LED display
The LED can display the output voltage and current or alarms of the rectifier.

You can switch the display between output voltage and current by pressing the A/V button.
It can display three digits.
The display precision of voltage is ±0.3V and that of the current is ±0.4A.

Upon rectifier faults, the fault code will flash on the LED.

2) Indicator

There are three indicators on the front panel. Their functions are shown in the following
table.2-1-1

Table 2-1-1 Indicator function

Indicator Normal status Exception status Exception Meaning

Power On Off No input power and
indicator(Green) rectifier internal auxiliary
power supply does not
work
Protection Off On AC over/under voltage
indicator(yellow) DC output over voltage,
and output under voltage
alarm
Rectifier is
over-temperature
Rectifier is not plugged
into the system correctly

Fault indicator (red) Off Blink Fan does not work

3) A/V

The A/V button is used to switch the display content of the LED. When the present display
is output voltage, press this button once to make LED display output current, and press it
again to make LED display back to voltage.

4) Manual voltage adjustment buttons

There are two voltage adjustment buttons on the front panel, which are used to adjust the
output voltage of the rectifiers in manual state. Press the left button one time, the output
voltage drops by 1V, while press the right button one time, the output voltage rises by
0.5V. Note that they are valid only when the rectifier is in the manual state.

5) DIP switch

The DIP switch is used to set the control mode and rectifier communication address, as
shown in the following figure.2-1-4
 Figure 2-1-4 6-bit DIP switch for rectifier address setting and

Control mode selection

A、 Control mode setting

The leftmost bit of the DIP switch is the control mode set switch. It is used to set the
rectifier to auto mode or manual mode. Upper position is used to set to auto mode and
lower position to manual mode, as shown in the above figure.

Auto mode: In auto mode, the controller will control the output voltage and current limiting
point, and switch on/off the rectifier, and manual mode cannot be used. If the rectifier is
connected to power bus to charge battery, it should beet to auto mode.

Manual mode: In manual mode, the output voltage of the rectifier can be adjusted by the
potentiometer on the panel. The controller cannot control the output voltage and current
limiting point, and cannot switch on or off the rectifier. But the operating data of the
rectifier can be reported to the controller. If the rectifier is connected to the control bus, it
needs to output single stable voltage, it should be set to manual mode, and the output
voltage should be adjusted to the desired value through the potentiometer. In this case,
the current limiting point of the rectifier should be 100% of rated value.

Note

By adjusting the voltage adjustment button, the output voltage of the rectifier can be
adjusted up to 286V. When the system is operating normally, do not adjust this button
unless it is absolutely necessary. The output of the rectifier has been set to 234V float
voltage before delivery for safety consideration as different users select different numbers
of battery cells.

B、Broadcast address setting

The left second bit of the DIP switch is broadcast address switch. This switch is used for
rectifier to recognize broadcast data package. When it is put to the upper position, rectifier
recognized the data package with address 255 as broadcast data package. When it is put
to the lower position, rectifier recognized the data package with address 254 as broadcast
data package.

C、Address setting

The right four bits are address switches. The address switches are used to set the
communication address of the rectifier. The communication address is a binary number.
Binary “0” is set by sliding the DIP switch to the upper position, while binary “1” is set by
sliding the switch to the lower position. The leftmost switch of the 4-bit address
switch is the highest bit, while the rightmost switch is the lowest bit.

The 4-bit address switch determines address setting range within 0 ~ 15, therefore, the
number of the rectifiers connecting to the same communication port of the controller
cannot exceed 16. If the number of rectifiers is larger than 16, they should be divided into
two groups and each group of rectifiers should be connected to a serial port of controller
separately.

Rectifier address is the unique identification for controller to identify each rectifier. Under
no circumstance shall addresses of two or more rectifiers in the same EP system be
identical. For a same rectifier, the address set in the rectifier and the controller must be
the same. Otherwise, the communication between the rectifier and controller will be
abnormal.

The rectifier address in the controller is a decimal number. The relationship between
binary code and decimal number is given in the following table.

Table 2-1-2 The relationship between binary and decimal systems

Address switch Binary Decimal

1 2 3 4
0 0 0 0 0000 1
0 0 0 1 0001 2
0 0 1 0 0010 3
0 0 1 1 0011 4
0 1 0 0 0100 5
0 1 0 1 0101 6
0 1 1 0 0110 7
0 1 1 1 0111 8
1 0 0 0 1000 9
1 0 1 0 1001 10
1 0 1 1 1010 11
1 1 0 0 1011 12
1 1 0 1 1100 13
1 1 1 0 1101 14
1 1 1 1 1111 15

For example, if the DIP switch is set as shown in Figure 2-11 (black for switch position), it
reads binary 1010. From the table, you can find its decimal equivalent is 10.

3. Rear panel

There is an integrated connector on the rear panel of ZLD22020TB and the rear panel is
shown in the following figure.2-1-5
 Figure 2-1-5 ZLD22020TB rectifier rear panel

The rectifier uses the input and output integrated connector. They are hot-pluggable,
convenient for installation and maintenance. See the following figure for the dimensions
and pin assignment of the connector.

Figure 2-1-6 Pin Assignment of the connector

The following table describes the pin assignment of the connector.

Table 2-1-3 Pin assignment of connector

Signal category Pin Signal Description
No.
AC input 1 Phase V Rectifier AC input in 3-phase 3-wire mode
input
2 Phase U
input
3 Phase W
 input
4 PE Rectifier PE terminal, that has been connected
to rectifier enclosure inside the rectifier
Communication 12 DATA+ Low voltage signal terminal. Being
interface 15 DATA- asynchronous serial transmission interface for
communication between the rectifier and PCU.
Communication mode: RS485
Load sharing 21 SHARE+ Low voltage signal terminal. This terminal
24 SHARE- should be connected in parallel as two or more
rectifiers are connected in parallel to share load
DC output 26, 28 Positive Rectifier DC output, isolated from rectifier
27, 29 Negative enclosure

Main Functions

1. Protection function

The rectifier has the following protection functions: input over voltage protection, input
under voltage protection, output over voltage protection, output under voltage alarm, short
circuit protection, phase failure protection, over current protection at primary side, over
temperature protection and fan fault alarms.

The protection characteristics are shown in the following table.

Table 2-1-4 ZLD22020TB Rectifier Protection characteristics

Item ZLD22020TB ZLD11040TB

Input over voltage 485 ±10Vac No output after protection.

protection Auto-recoverable. Recovery
threshold point: 460 ±15Vac

nput under voltage 313 ±10Vac No output after protection.

protection Auto-recoverable, Recovery
threshold point: 335 ±10Vac

Output over voltage 325 ±5Vdc 165 ±5Vdc No output after protection. Not
auto-recoverable. You need to
power it off and on to restart it

Output under 198 ±1Vdc 99 ±1Vdc Output available after protection,

voltage alarm auto-recoverable.

Short circuit Foldback current ≤ 40%

foldback of output rated current,
Auto-recoverable
Phase failure 10A/260V 20A/130V Limited output power: 2600W
protection

Over temperature Over temperature threshold:

80°C. Recovery
point: 60°C
Over current Rectifier is under protection
protection at due to over current in
primary side rectifying side in abnormal
conditions
Fan speed control Controlled base on
temperature or the
temperature and current
together, 3 kinds of speed:
stop, half speed and full
speed.

Upon rectifier faults, the alarm information will flash on LED in the form of fault code. You
can switch the display content to voltage by pressing the A/V button. The code meaning is
shown in the following table.

Table 2-1-4 Fault codes vs. alarms

Fault codes E31 E32 E33 E34 E36

Alarm Output Rectifier AC Phase Output over

under over over/under failure voltage
voltage temperature voltage

2. Communication function

The rectifier can communicate with the controller through RS485 port. It can report to the
controller its output voltage, current, protection and alarm information, as well as receive
and execute control commands from the controller. See the following table for details.

Table 2-1-5 ZLD22020TB rectifier communication function

No Item Specifications Remark

1 Remotely acquired Report to the controller the fault and

alarm/digital signal protection signals (such as AC
over/under-voltage, phase failure,
output over/under-voltage, and
over-temperature)

2 Remotely acquired Measure the output voltage and

analog signal current of the rectifier and report
them
to the controller

3 Remotely controlled Control the rectifier power on/off and Manual

system state float charging / boost charging control is
switchover according to the available and
commands from the controller can
disable the
4 Remotely adjusting Adjust the output voltage of rectifier control
voltage analog signal according to the commands from functions of
the controller the
controller.
Adjust the output current limit of
rectifier within the range of 10% ~
100% according to the commands
from the controller

Technical Data
1. Environmental requirements

The environmental specifications are shown in the following table.

Table 2-1-6 ZLD22020TB rectifier environmental

requirements
Item Specifications

Operating temperature -10°C ~ 40°C

Storage temperature -25°C ~ 55°C

Relative humidity ≤ 95%

Air pressure 70 kPa ~ 106kPa (corresponding elevation

is about 0~3000m)

Cooling method Intelligent air cooling

2. Input

The input specifications are shown in the following table.

Table 2-1-7 ZLD22020TB Rectifier Input

Item Specifications

Input voltage 323V ~ 475V (3-phase, 3-line)

Input current ≤ 15A

Input AC frequency 45Hz ~ 65Hz

Efficiency ≥ 93%

Power factor ≥ 0.94

3. Output

The output specifications are shown in the following table.

Table 2-1-8 ZLD22020TB rectifier output

Item ZLD22020TB ZLD11040TB

utput voltage range 176V ~ 320V 87V ~ 160V

Rated output current 20A 40A

Max. output current 20.5A (output voltage 260V) 42A (output voltage 130V)

Voltage ramp-up time 3 ~ 8s (Soft start time)

Output constant current 10% ~ 100%

range
Current stabilization ≤ ±0.5% (20% current limiting test)

Ripple ≤ 0.1%

Voltage stabilization ≤ ±0.5%

Temperature coefficient ≤ 0.2‰

(1/°C)

Load sharing imbalance ≤ ±5% (50% ~ 100% rated load)

4. Acoustic noise: <55dB

5. Insulation resistance and dielectric strength

1) Insulation resistance

I/O to chassis and input to output > 10M (Test voltage: 500Vdc)

2) Dielectric strength

Impose 50Hz 2000Vac (RMS value) for one minute between input / output and the
chassis after shorting the input and output. No breakdown or flashover.

6. Safety and EMC

Meet CE standard. EMC meets the following standards and levels.

Table 2-8-1 Safety and EMC

No Item Standard Level

1 Immunity to electrostatic discharge GB/T 17626.2-1998 Level 3 criterion B

Table 2

2 Immunity to oscillatory waves GB/T Level 3 criterion B

17626.12-1998
Table 2

3 Immunity to conducted EN 55022 Class A

interference

4 mmunity to electrical fast GB/T17626.4-1998 Level 3criterion B

transient/bursts
5 mmunity to surges GB/T17626.5-1998 Level 3criterion B

6 Immunity to conducted GB/T17626.5-1998 Level 3criterion B

disturbances,
induced by radio-frequency field
7 mmunity to power frequency GB/T17626.8-1998 Level 4criterion B
magnetic fields
8 Immunity to damped oscillatory GB/T17626.10-1998 Level 4criterion B
magnetic field
9 Immunity to radiated, RF GB/T17626.3-1998 Level 3criterion B
electromagnetic field
10 Immunity to voltage dips, short EC61000-4-11 95% 0.5 Period
Interruptions and voltage criterion B
variations > 30% 25 Period
criterion B
> 90% 250 Period
criterion B

1. MTBF > 300,000 hours

Installation Design

Rectifier Mechanical Parameters

1. Appearance and dimensions (L × W × H) of rectifier: 430mm × 110mm × 268mm

2. Rectifier weight: < 15kg

Installation Design

The installation dimensions of the ZLD22020TB rectifier module are illustrated in the
following figure.

Figure 2-1-7 Rectifier installation dimensions (unit: mm)

Packaging And Maintenance

Shipment And Packaging

As the rectifier is prevented from slipping out of the system by a M4 screw on the panel, it
is not connected with the cabinet fixedly. The rectifier must be removed from the cabinet
and packed separately before delivery. It is forbidden to ship the cabinet in which the
rectifier is installed, or else it may cause damage to the cabinet and the rectifier.

Maintenance

1. Clean dust mesh

After longtime operating in a dusty environment, the dust mesh may accumulate dust and
dirt that affect heat dissipation of the rectifier. You need to regularly clean the dust mesh.

To clean the dust mesh, do as follows:

1. Remove the fan cover on the front panel of the rectifier.

2. Pull out the dust mesh from the fan cover (pay attention to the direction), wash it with
clean water, and then re-install it after it completely dries.

3. Restore the fan cover to the rectifier front panel.

Important Points In Use

Load sharing

Load sharing refers to the rectifiers connecting to the same bus sharing the load with the
same output current. The rectifiers have undergone strict load sharing test before delivery.
If they work in auto mode and their output voltages are set to same value, any load
sharing adjustment is not needed. So no external adjustment device is provided with
the rectifier.

If there are rectifiers connected to the control bus in one system, only communication
cable should be connected between the rectifiers connected to the control bus and that
connected to the power bus. The load sharing cable cannot be connected. In no event
shall cables other than communication cable be connected between the two kinds of
rectifiers.

Note

To ensure the rectifier load sharing capability, the maximum number of rectifiers
connected to one bus in parallel is 20+1.

In case of big load sharing imbalance, replace the rectifier causing the imbalance. Method
of identifying the rectifier with load sharing failure is as follows:

At first, check the rectifiers one by one if the load sharing bus and load sharing cable are
properly connected, or the rectifiers work in auto mode. If normal, use the following steps
to identify the faulty rectifier.

1. Disconnect the load sharing cable and communication cable of the rectifiers, and only
turn on one rectifier (other rectifiers will be turned off).

2. After the rectifier is turned on, apply load with 1/3 ~ 2/3 rated current.

3. Measure the voltage of load sharing bus with multimeter. The normal voltage is 0.6 ~
1.2V

4. Measure the voltage of the load sharing bus of each rectifier when load is applied. The
rectifier is normal if the voltage is in normal range. If no voltage is detected when load is
applied, it indicates that the load sharing circuit of the rectifier has been damaged.

Note

When the rectifiers are connected to different buses, do not connect the load sharing
cable between the rectifiers connected to the control bus and that connected to the power
bus. Do not connect the load sharing cable to the controller.

Although the voltage of load sharing bus is low, it belongs to dangerous circuit and does
not belong to SELV circuit. Do not touch the bus and protect the bus when measuring the
load sharing bus voltage.

Voltage Regulation

While the rectifier is in manual mode, its output voltage is regulated through the A/V button
on the panel. Press the left button one time, the output voltage drops by 1V, while press
the right button one time, the output voltage rises by 0.5V. In auto mode, the voltage is
controlled by the controller.

Alarm Phenomenon And Troubleshooting

The rectifier has following common faulty phenomena, accompanied by flashing fault
codes (display of current)displayed by the LED:

RUN indicator (green) off

Protection indicator (yellow) on

Fault indicator (red) on

The table below lists common phenomena and troubleshooting suggestions.

Table 2-9-1 Common phenomena and troubleshooting suggestions

Phenomenon Cause Actions

Power indicator (green) off No AC input Check if the AC input is

normal

Rectifier internal fault Return the rectifier to

Emerson for repair

Protection indicator (yellow) Output under voltage E31 Check if the output voltage
on is normal

Rectifier over temperature mbient over temperature.

E32 EP system
thermal design is improper
AC over/under voltage E33 Check if the AC input
voltage is normal

Phase failure E34 Check if there is any AC

phase failure

Fault indicator (red) on Output over voltage E36 Reset the AC power supply