220AC电力开关电源模块(智能型)技术说明书(英).doc

220VAC Electric power supply moduleTechnical Instruction Shijiazhuang Tonhe Electronics Technologies Co.Ltd.IndexChapter 1 Overview.21.1 Preface21.2 Main features of the system21.3 Main features of the module.21.4 Main functions41.5 Technical parameters51.6 Model definition.6Chapter 2 Module configuration.62.1 Operating principle.62.2 Overall dimension.72.3 Installation of module.92.4 Operate instruction.10Chapter 3 Operating Condition.12Appendix.13Chapter 1 overview 1.1 Preface “TH” series intelligent high-frequency switch power supply modules are developed based on the patent technology “resonant voltage dual loop control soft switching power transformation”. They feature high efficiency and stability, small size and light weight. Equipped with RS-485 communication interface, easy to work with automation system.1.2 Main features of the systeml Modular design, N+1 backup，smooth expansionl Perfect monitoring function, high intelligentl Main monitor items: turn on/off, output voltage regulation, output current limit set, automatic battery managementl Automatic Battery management and maintaining: real-time monitoring of battery pack terminal voltage, charge/discharge current, automatic even and float charging & regular even charging l Automatic temperature compensationl Hot plug, easy to replace and safe 1.3. Main features of the module l High efficiency, over 93%。l Low weight, small in sizel Separated automatic current sharing, the imbalance in parallel connection3%, can ensure twenty modules work well by parallel connection. l With RS-485 communication interface，digit displayl have the functions of communication, data display and failure alarming1.4. Main functions1.4.1 protection functionl Output overvoltage protectionTo prevent the disastrous accident caused by output overvoltage to electric consumers, there is overvoltage protection circuit in the module. When output overvoltage occurs, the module locks up automatically, the relative module fault indication light is on, the faulty module quits work automatically and doesnt affect the normal operation of the entire system. l Output current limiting protect The output current cannot increase infinitely. The maximum value of the output current of each module is limited to the rated output current 105%, in this range, the output current value of the module is continuously adjustable. If the load output of the module, the module will play down the output voltagel Output short-circuit protectionWhen output short circuit, the module draws the output voltage to 0 immediately, limit the short circuit current below 15%limit current point to protect the module. The module will not be damaged under short circuit state for a long time, and can go back to work automatically after debugging.ILoad increaseVOutput short circuitFig.1-1 output feature l Module parallel protectionThere is parallel protection circuit in each module to ensure that when the fault module quits the system, the normal work of other modules and the system wont be effect. As the picture 1-2 shows belowPig.1-2 parallel output diagramModule 1Module 2Module NParallel protection circuitParallel protection circuitParallel protection circuitOver-temperature protectionOver-temperature protection is mainly for protecting large power converters, under normal operating circumstance, the module design leaves enough margin, under special circumstance, when the module detects that the temperature of the radiator is over 90, it will shut down automatically to protect itself. When the temperature of radiator get down, the module will restart work automatically.l Output over-current protectionBecause of the limit of the module output power, the output current cannot increase infinitely. In the range, the output current value of the module is continuously adjustable. If overloaded, the module can reduce output voltage automatically to make it not surplus the rated output limit point in order to protect the power components. The over current protection can be resumed automatically.1.4.2 Measuring function：Measure the output voltage/current and working position.And the user can know the working condition of the module and system through thedigit display.1.4.3 Fault alarm function：When failure it alarms and the indicating lamp lights and the same time the failure information shows on the display screen. The user can easily identify the failure and remove timely. 1.4.4 set function Output voltage set：Set the output voltage through upper controller and manual setup, determine the output voltage according to charging status, float charging voltage, even charging voltage and etc. located in controller. Stepless current limit：random set current limit points within 20% - 100% rated current，set the current limit points in upper controller and determine output current limit according to voltage setup, output current limit and etc.State control：Control the module ON/OFF, even/float charging voltage change.1.4.5 communication function Communicate with host controller through RS-485，to achieve parameter setup, working parameter inquiry and working condition control through communication. 1.5. Technical parameterTH230D05ZZ-220AC/TH230D10ZZ-220AC/TH110D20ZZ-220AC/ TH110D10ZZ-220AC ModelItems TH230D05ZZ-220ACTH230D10ZZ-220ACTH110D20ZZ-220ACTH110D10ZZ-220ACOutput current（A）5102010Power（KW）1.53.03.01.5Input voltagerange（VAC）Min187Typical220Max253OutputAdjustableVoltagerang（VDC）Min19095Typical220110Max300150voltage stabilization0.5%Charger efficiency（efficiency）93%Audible Noise max（dB）50Storage temperature（）Min-40Typical25Max60WorkingConditionstemperature（）Min-10Typical25Max40uneven current in parallel operation3%Start delay (s)3S-8SRipple factor 0.5%Load grade Continuous working with Grade I(100%) rating output currentAutomatic current limiting technologyThe output current cannot increase infinitely. When output current exceed limited current value, a constant current output. The maximum output current value of each module is limited to the rated output.Output overvoltage protection functionAfter output overvoltage occurs(3205VDC), the module locks up automaticallyoutput short circuit protection When the output current get short circuit, the module will protect itself from broken. After the faults get removed, it will restart working automatically.Note：The constant Voltage Stabilization Tolerance does not contain the built-in isolating diodes influence。 1.6. Model definition TH 220AC：Designed nominal input voltage 220VACZZ：intelligent self cooling Nominal output current：05,07,10,20 Module category：D electric power moduleDC output voltage lever 230 nominal output 220V 110 nominal output 110V Company Code: Tonghe series Chapter 2 Module configuration2.1 Operating principleAC inputInput protectionBridge rectifierPassive PFCSmooth filterDC/DC convertSmooth filterOutput protectionCurrent sharing controlResonance voltage type double loop control circuitFeedback samplingOver voltage/current short circuit protectionMicroprocessor Digit display button&code switchRS485OverheatprotectionDC output Electric power supply module working principle 2.2 Overall dimensionTH230D05ZZ-220AC/TH110D10ZZ-220AC intelligent natural cooling module. overall dimension is as followsFront panel back panel Overall sketch TH230D10ZZ-220AC/TH110D20ZZ-220AC intelligent natural cooling module l. overall dimension is as followsOverall sketch 2.3 Installation of moduleCombination connector （JMD-29T）definition is as follows Terminal no.Jack specificationDefinition Function 1Press hole12#DC+DC output +2Press hole12#DC-DC output -22Plate hole20#485BCommunication 20Plate hole 20#485A16Plate hole20#JL+Current sharing 14Plate hole20#JL-26Press hole12#GNDGrounding 28Press hole12#LAC input L29Press hole12#NAC input NRemarks： terminal unmarked is empty, no connection keep a favorable ventilation around the moduleaccomplish even current sharing by connecting together according to “current equalizing +”, “current equalizing -” the host monitor accomplish automatic control to the module through by connecting RS485 terminal A and B between each module and RS485 terminal A and B of data acquisition module. Notes：the voltage and current limit value should be set same when parallel working (two modules and more) 2.4 operating instruction（take TH230D05ZZ-220AC for example ） TH230D05ZZ-220AC natural cooling, the front panel is as Fig.1 shows Fig 1-1 front panel 2.4.1 Digit display screen Show the information including voltage, current, warning, OFF. Change over voltage/current display by the option button. 3 digits displayed and the voltage precision is 0.5V, current precision is 0.2A. In case warning, check the fault code by option button. When power off, the OFF code displayed by pushing the option button. 2.4.2 Indicating light There are 3 indicating lights and the functions are shown as table 1-1Table 1-1 indication light functionIndicator Normal Abnormal Reasons Power indicator （green）ONOFFNO input voltage, the axuilary power inside the module does not workoverheat（red）OFFONOverheat inside the modulefault（red）OFFONFault inside the module2.4.3 DIP OPERATION INSTRUCTION Two options: Information Inquiry and Parameter Set, choose via the “Auto”&”Manual” DIP Switch. It is “Information Inquiry” when the DIP on top side and is “Parameter Set” when at the bottom side. 1. Information Inquiry：The DIP switch (the most left DIP) is on the top side. The following functions available: , Indicate the voltage, current and fault information, Define the charger address via the grouping DIP and address DIPl LCD screenIndicate the voltage, current, alarms of the charger. Switch over by the button V/A Table 1 Fault code and identificationCodeE01E02E04E05E06E20IdentificationUnder voltageOver voltage Over voltage/current protectionOver temperature Input fault Setting over rangel Grouping DIP switchThe second code button from left is grouping DIP switch (broadcast address identification code ) and used for identifying packets groups (Broadcasting Data packet.)If TonHe protocol: if switch to the top side, the charger is in packet group 1, the data packets addressed 253 and 255 are broadcast data packet. If switch to the bottom, the charger is in packet group 2, and the data packets addressed 254 and 255 are broadcast data packet. If MODBUS protocol: switch to the top side, the charger is in packet group 1, the data packet addressed 255 is broadcast data packet. If switch to the bottom, the charger is in packet group 2 and the data packet addressed 254 is broadcast data packet. l Address set DIPThe right 4 communication addresses set DIP and the broadcast address identification code are composed of communication address set DIP switch, which is used for setting the communication address of the module. The address is binary number, and means 0 if the DIP is on the top and means 1 if at the bottom. The rightmost code among is the lowest digit and the leftmost code is the highest digit. The address DIP of power supply module are 5 digits, so the set range of communication address is 031. That is to say, maximally 32 modules could be connected to one serial port of the host controller. The address is the only sign the controller could identify each module and the address of each module must be different in one system. For one module, the communication address setting must be same as the address setting of the host controller module. Otherwise abnormal communication occurs. The address in controller is decimal digit and the relation table is as follows.Table 2 relation between binary and decimal digit二进制00000000010001000011001000010100110001110100001001010100101001100011010111001111十进制0123456789101112131415二进制10000100011001010011101001010110110101111100011001110101101111100111011111011111十进制16171819202122232425262728293031For example：the DIP set above highlighted in black is binary digit 10101, corresponding decimal address is 21. This charger is in Group 2.2. Parameter set Come to parameter setting when switch the left most DIP to the bottom (read 1). Use the Grouping DIP and right 4 address bits to make different set. The DIP switch and identifications are as follows.Table 3 DIP identification (220V/110V)Grouping DIP1234FunctionSetting range Default 00000Working mode0-IND., 1-MANU, 2-AUTO200001Communication protocol0-Modbus，1-TonHe100010Over voltage alarm set220V Under voltage threshold -300V260V110V Under voltage threshold-150V130V00011Under voltage alarm set220V 190V-over voltage threshold190V 110V 95V-over voltage threshold95V00100Charging state set0-float charge, 1-boost charge 000101Float charge voltage220V型190V-300V242V110V型95V-150V121V00110Boost charge voltage set220V型176V-300V253V110V型88V-150V126V00111Charging current limit set10%-105% rated current105%01000Current threshold from float to boost chargeCurrent threshold from boost to float charge-105%80%01001Current threshold from boost to float charge0.5-current threshold from float to boost20%01010Tail current charging time0-10 hours 301011Max boost charge time0-99 hours 1001100Boost charge cycle0-999 days18001101Fault output node set0-normally open 1-normally close0NOTE: you need to power on the charger again if you change the communication protocol on lineWhen the DIP setting is over the range in the table above, will indicate E20. If -3G and -5 series products, the low end of voltage range is 176V/88V, the under voltage alarm default is 176V/88V. The current set range is 10-110% and the highest current from float to boost charge is 110% rated output current. The setting operation instruction:1) Switch the DIP to “MANU” i.e. “1” position, otherwise cannot enter the setting interface;2) Follow the tables above to enter setting interface required;3) Push the button “V/A” once, then the leftmost letter flashes. Now you can adjust the data;4) Use the “V ADJ” button “,” to adjust the value. Push “” once, the value decrease a unit. Push “”, increase a unit.5) Then push “V/A button again to make sure the leftmost letter stop flash. Then the set finishes and setting is saved successfully. The working mode of the charger is optional. Three modes optional, Independent, Automatic,工Manual and two communication protocol optional, TH and MODBUS. The RS485 interface available between charger and controller/ charger and charger: l Independent “IND.”: the charger will work independently when set working mode “0”. The DIP switch position “00000”. Then the communication protocol ”00001“-“1” (“TH” protocol) will be advised. Under this working mode, the charger cannot communicate with the upper controller, but the automatic float and boost charge is available. The charger can manage the charging process automatically. The same time, it is capable to send charging voltage and current command to control other chargers if several chargers work in parallel.This mode is suitable for the conditions without upper controller and several chargers work in parallel. One charger will be “IND.” mode as master module to send command to other chargers. The other chargers will be set “AUTO” mode and ”TH” protocol.l Manual ”MANU”: set working mode “00000” -“1”, the charger will be Manual mode. Communication protocol is “TonHe” when the DIP setting “00001”-“1”, is “MODBUS” when set “00001”-“0”. The user can set accordingly to the upper controller. Under this working mode, the charger can communicate with the controller and send data back to the controller. Automatic float and boost charge function is available but the charger can not send command to other chargers. This mode is suitable for that the additional controller does not have automatic float and boost charge function but the controller need to know the working status of chargers. Normally for system one charger and one battery bank. l Automatic “AUTO”: corresponding DIP set is “00000”-“2”. Communication protocol is “TonHe” when the DIP setting “00001”-“1”, is “MODBUS” when set “00001”-“0”. If choose “AUTO” mode, the setting indication in the tables above is null. The charger will work following the setting of the controller. In this mode, the controll