SMPS FUNDAMENTALS

&
48V POWER PLANT

Presented By

Kishor Kumar
Deputy Manager-SMPS& CRC

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CONTENTS
 General introduction
 Why Power & Battery
 Switched Mode Designs
 Power Plants Building Block
 Elements of Power Plant
 Advantage of SMPS
 Application of SMPS
 Technical Specification
 Protections
 Types of Power Plant
 Features of Power Plant

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Why Power & Batteries

WHY DO WE NEED POWER SUPPLY?

- AND WHY DO WE NEED BATTERIES?

Why Power & Batteries

1. PROVIDE A RELIABLE DC-POWER SUPPLY TO
TELECOM EQUIPMENT.

2. CHARGE THE BATTERIES.

3. MONITOR AND CONTROL THE SYSTEM TO ACHIEVE
A LONG LIFETIME AND MTBF (MEANTIME BEFORE
FAILURE) OF THE COMPLETE SUPPLY- AND BACK-
UP SYSTEM.

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WHY DC AND NOT AC POWER SUPPLY ?

 A filter for all the noise (EMC, surges etc) present
on the AC power lines.
 All telecom equipment (PABX, Base Stations,
Main Switches) have to operate when the AC
supply (mains) is absent.
The telecom equipment have to be supplied by
stored energy while the AC supply (mains) is
absent.
Batteries are today the cheapest and most
efficient way to store electrical energy, and can
only be charged by DC.

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 When the AC supply (mains) fails. 6 . to charge the batteries and to supply the Telecom equipment (load) when mains is present. The rectifier system will then recharge the batteries. WHY DC AND NOT AC POWER SUPPLY ?  A DC Power Supply System converts the AC power to DC Voltage. the batteries will supply the Telecom equipment (load) until the mains supply returns.  The DC power supply will monitor and control the system and provide alarms in case of failure.

SWITCHED MODE DESIGNS 7 .

the conversion of AC to DC is accomplished in two stages as shown in previous Fig ( Switch Mode design ). 8 .  i) First Stage conversion: The input AC voltage is directly rectified and converter in high voltage DC.BASIC THEORY AND CONCEPT OF SMPS TECHNOLOGY SMPS Design The design of the SMPS based power plants is based on the following technique: a) Two Stage Conversion SMPS: In these systems.

 High voltage DC is then converted in to a very high frequency AC (20 KHz and higher).  High frequency AC is stepped down to the required level by means of a small high frequency transformer.  Conversion of high voltage DC to high frequency AC is achieved by means of very powerful and fast semi- conductor switching devices.  Stepped down AC is rectified to DC of desired voltage and filtered by means of high frequency filters.BASIC THEORY AND CONCEPT OF SMPS TECHNOLOGY ii) Second Stage Conversion:  Rectified high voltage DC is stored in a capacitors. 9 .

Vin -is the high frequency stepped down AC voltage K -is a constant corresponding to the shape of the waveform and "D" is the duty cycle. 10 .For system Output Voltage Regulation in SMPS Power Plants Vo = K*Vin*D Vo -is the required Output DC voltage.

ADVANTAGE OF SMPS  Modular concept  Small size  Less weight  Higher efficiency  Wide Input Voltage range  Auto battery charging/discharging  Easy repair and maintenance 11 .

g.  Telecom Power Plants  Medical equipments  Defense equipments  Domestic appliances  Highly sophisticated machines 12 . APPLICATION OF SMPS Due to better performance and advance features. SMPS are now used in almost every product e.

Power system building blocks UPS AC/DC BATTERY DC/AC INVERTER AC DC/AC LOAD AC INPUT POWER PROTECTION DISTRIBUTION Control AC switch Module TELECOM board EQUIPMENT RECTIFIER #1 RECTIFIER #2 LVBD G SURGE PROTECTION RECTIFIER #n DIESEL BATTERIES GENERATOR REDUNDANT RECTIFIER SYSTEM BATTERY AC/DC DISTRIBUTION .

The generator can be connected manually or automatically. The elements in a Power system AC Switch The AC input to the power system is taken from the board: switch board Diesel The diesel generator is a small power plant that generate generator: AC current. that will be connected when mains fail. The generator is used as a standby power. AC input Circuit breakers for protection of individual rectifiers. . protection: Surge Protection against surge and voltage spikes on the AC protection: supply.

The system consist of rectifiers and a control and monitoring unit Rectifiers: The rectifiers converts AC to DC. . current and alarms). Parameters can also be changed from the unit. Power Fuses of circuit breakers for distribution of DC power to distribution the telecom equipment. DC AC Control and The control unit monitors all the essential parameters in monitoring unit: the system (voltage. The elements in a Power system DC rectifier The rectifier system converts the current from AC to system: DC.

UPS Converts power from AC to DC and back to AC again. Battery Fuses for protection of individual battery banks against distribution: short circuit. Used for AC load that require long battery backup. . The UPS usually have a small battery bank on the DC side Inverter Converts from DC to AC. The elements in a Power system Batteries The batteries stores the energy for use when the AC mains fail LVBD Low voltage battery disconnect (LVBD) is used for disconnecting the batteries before they are damaged due to deep discharge.

RECTIFIER TELECOM AC SYSTEM EQUIPMENT INPUT BATTERY BANK 17 . CURRENT FLOW IN A SYSTEM •MAINS INPUT OK •LOAD SUPPLIED BY THE RECTIFIER SYSTEM •BATTERIES ON FLOAT CHARGE.

CURRENT FLOW IN A SYSTEM •MAINS INPUT FAILED (ABSENT) •LOAD SUPPLIED BY THE BATTERIES •BATTERIES ARE DISCHARGING RECTIFIER TELECOM AC SYSTEM EQUIPMENT INPUT BATTERY BANK 18 .

CURRENT FLOW IN A SYSTEM •MAINS INPUT OK •LOAD SUPPLIED BY THE RECTIFIER SYSTEM •BATTERIES ARE RECHARGING RECTIFIER TELECOM AC SYSTEM EQUIPMENT INPUT BATTERY BANK 19 .

2 / 24=1.8v) t Float charge Battery discharge Battery recharge -w/current limitation 20 .2 Disconnect Voltage (43. VOLTAGE SEQUENCE IN A DC POWER SYSTEM Mains U failure 53.5 Mains resume Charge Current Limitation Normal charge current 43.

small telecom systems of rural /semi urban. Ultimate Capacity 150/200A Indoor  25A . Ultimate Capacity 450A Indoor  50A . BTS )  25A . Ultimate Capacity 450A Outdoor 21 . CLASSIFICATION OF SMPS POWER PLANTS a)Low capacity power plant Systems ( Single/three Phase. Ultimate Capacity 150/200A Outdoor  50A .

medium and large Transmission Centre)  100A . CLASSIFICATION OF SMPS POWER PLANTS b)High capacity power plant Systems ( Three Phase. Ultimate Capacity 1000A Indoor  100A . Ultimate Capacity 600A Indoor  100A . Ultimate Capacity 3000A Indoor 22 . Ultimate Capacity 1500A Indoor  100A /200A.

Alarm. Switching. POWER PLANT CONFIGURATION Distribution. Control and Monitoring(DSCA) unit 23 .

CONTROL AND MONITORING(DSCA) UNIT Distribution and Switching unit  Termination of battery and load  The switching and interconnecting devices for battery.  Shunts for meters  Modules 24 . ALARM. load and input AC  Contactor for battery low disconnect and AC input out of range. SWITCHING. DISTRIBUTION.

POWER PLANT CONFIGURATION Control. Alarm and Monitoring unit  Microprocessor controlled  Remote supervision  Battery Monitoring  Battery Path current limiting 25 .

Range.  Humidity : 95% Max. Two Stage (Optional)  Disconnect Voltage : 44.  Environment Spec.90-300V Single Phase  Frequency 48-52Hz. Charge Mode-51 –56V DC  Power factor : Near Unity.  Storage Temperature : -100C to + 600C.4V.  LVD : Single. Range-320-480V. TECHNICAL SPECIFICATIONS  AC Input : Nominal 400V AC.  DC Distribution : Custom configurable as per requirement.  220V AC. 26 . : Operating Temperature 0 –50 degree centigrade.5V (settable)  Temp. Compensation : 3mV / degree Centigrade / cell. reconnect 51. 3 Phase.  DC Output : Float Mode-48 –56V.

 System Current  Load Current  Individual Battery Current  System Voltage  Load Voltage  Individual Battery Voltage  Individual Module Current 27 . TECHNICAL SPECIFICATIONS Metering  AC Input Voltage.

TECHNICAL SPECIFICATIONS Alarms (Audio/Visual)  AC Input Abnormal  Load Over Voltage. 28 . Compensation Fail  Battery Fail/ No battery  Battery isolation.  Load Under Voltage  Rectifier Fail  Mains on Battery Discharge  System Overload  Temp.

at stage I protection box  Class C.at building level  Class B.at stage II rack level  Class D. SURGE PROTECTION Classified into four categories :  Class A.at stage III module level 29 .

 Class B conducts if Voltage reaches > 4KV. 30 .  Class C conducts if Voltage reaches > 1500V. FUNCTIONS OF SURGE PROTECTORS When surge strikes :  Class D first conducts and maximum 500V is build up across it.  Minimum inductance required for correct co- ordination for inductor between Class B & C is 15micro H & for inductor between class C & class D is 5 micro H.

BATTERY SMPS PP feature for specific battery requirement (VRLA-Valve Regulated Lead Acid & Conventional Lead Acid)  Auto float charge operation  Deep discharge prevention  Battery under voltage protection  Battery Health check(optional) 31 .

TWO BATTERY BANK-1500AH 32 .

SWITCHED MODE RECTIFIER MODULE 25A 25A Module 25A Module 33 .

SWITCHED MODE RECTIFIER MODULE 100A & 200A 100A Module 200A Module 34 .

LOW CAPACITY POWER SUPPLY SYSTEM. INDOOR 35 . • Switched Mode Rectifier Modules of Capacity 25A/50A as Basic Power module. 25A & 50A SYSTEM CONFIGURATIONS The Rack Power System consists of: - • Small size rack. • AC Distribution Module. • Load & Battery Termination arrangement. • Monitoring & Control Module.

25A & 50A SYSTEM CONFIGURATIONS The Rack Power System consists of: - • Small Size rack for OUTDOOR • AC Distribution Module. • Switched Mode Rectifier Modules of Capacity 25A/50A as Basic Power module. • Monitoring & Control Module. • Load & Battery Termination arrangement. OUTDOOR 36 .LOW CAPACITY POWER SUPPLY SYSTEM.

37 . • SPD . • AC HIGH & LOW VOLTAGE CUTOFF Monitoring & Control Module. • AC Distribution -MCB for module. ACDB PANNEL SYSTEM ACDB The Rack Power System consists of:- • AC INPUT TERMINAL AC CONTACTOR.

1500A SYSTEM CONFIGURATIONS The Rack Power System consists of: - • 750mm wide rack. LARGE CAPACITY RACK SYSTEM –48V. • Monitoring & Control Module. • AC Distribution Module. • Switched Mode Rectifier Modules of Capacity 100A as Basic Power module. 38 . • Load & Battery Termination arrangement.

• Switched Mode Rectifier Modules of Capacity 200A as Basic Power module. • Load & Battery Termination arrangement. • DCDB. LARGE CAPACITY RACK SYSTEM The Rack Power System consists of: - • 19” Standard Rack. • Monitoring & Control Module. • AC Distribution Module. (Optional) 39 .

• Large Back lit Alpha numeric display Showing Load and Battery Voltage and Currents and other system parameters. • Near sinusoidal Input Current. • Micro Controller based efficient Monitoring and Control Module to monitor system parameters providing extensive information on System Status and Alarm Conditions. • Provides efficiency better than 90% @ Nominal input voltage Full Load. • AC Input Termination (Three Phase) • Near Unity Power Factor. 40 . LARGE CAPACITY RACK SYSTEM SALIENT FEATURES • Modular Muti-rack Power systems using 100A/200A module.

• Battery Under Voltage Isolation • Temperature Compensation of battery Voltage • Battery Under Voltage Isolation • Temperature Compensation of battery Voltage • Battery charge discharge test. • High / Low AC voltage Disconnect. LARGE CAPACITY RACK SYSTEM SALIENT FEATURES. • Detection and Indication of Alarm Conditions. 41 . • Automatic Switchover from Auto Charge Mode to Float Mode and vice versa.

conductance and temperature at a set periodicity (Optional). LARGE CAPACITY RACK SYSTEM SALIENT FEATURES High / Low AC voltage Disconnect. • Two stage Low Voltage Disconnect (Optional). trickle current. current. • Central remote monitoring & control for NMS (Optional). 42 . • Battery Health Check . • Protected against Lightning Electromagnetic Impulse & other High Surges• Protected against low voltage surges • RS-485 compatible.Provision of monitoring cell voltage.

43 .ITI LIMITED & SMPS BASED POWER PLANTS The Company is one of the leading manufacturers of Switch Mode Power Supply (SMPS) based power sources and has been catering to the telecom sector powering connectivity across India for over two decades.

GURGAON-2006-07 FOR GR-2005  TOT FROM M/s. ELTEK ENERGY SYSTEM. EXICOM TELESYSTEM. HISTORY  TOT FROM ASCOM ENERGY SYSTEM. GURGAON-2008-017 FOR GR-2005 .2010. SWITZERLAND 1995-1996 FOR GR-97& GR- 2001  TOT FROM M/s. 2014 & 2015  SUPPLY TO BSNL/MTNL/DEFFENCE-OVER 500 CRORES  SUPPLY IN PROCESS 44 .

TELECOMMUNICATION ENGINEERING CENTRE(TEC) TEC function under Department of Telecommunication (DOT). Government of India  Issue of Generic Requirements(GR).  Field evaluation of products and systems  National Fundamental Plans  Support to DOT on technology issues  Testing & Certification of telecom product 45 .Service Requirements(SR) and Standards for Telecom Products and services.Interface Requirements(IR).

SMPS MANUFATURING ELECTRONIC COMPONENTS ASSEMBLY MACHANICAL ASSEMBLY RACK WIRING & ASSEMBLY CARDS & MODULE TESTING INTEGRATION & SYSTEM TESTING BURN-IN TESTING QA & BSNLQA -TESTING 46 .

ELECTRONIC COMPONENTS ASSEMBLY & TESTING MATERIALS INPUT PCB PREPARARTION & COMPONENTS FORMING KITTING MANUAL COMPONENTS INSERTION WAVESOLDERING CARD TESTING MODULE ASSEMBLY MODULE TESTING 47 .

ELECRICAL INTEGRATION & SYSTEM TESTING BURN-IN QA TESTING 48 . RACK ASSEMBLY & TESTING MATERIALS INPUT RACK ASSEMBLY-MECHANICAL WIRING PANNEL ASSEMBLY RACK ASSEMBLY.

THANK YOU 49 .

POWER PLANT-100A(14+1).1500A U/C 50 .

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