TITEL PROJECT

DESIGN OF 48V RECTIFIER FOR SUBSTATIOS

Submitted to
DEPARTMENT OF ELECTRICAL ENGINEERING KOMBOLCHA
INSTITUTE OF TECHNOLOGY WOLLO UNIVERSITY
KOMBOLCHA

power stream Section A

SUBMTTED BY: ID NUMBERS

1. BELAY MELESE KITR/0219/05
2. BELAY MILASHU KITR/0220/05
3. BEKALU ATANAW KITR/0216/05
4. BEREKET ABATNEH KITR/0229/05
5. BELETE GEZAHEGN KITR/0224/05
6. BRIHANIE BAZEZEW KITR/0262/05

Adivaser's Name Engineer Marilon

pg. i
 ACKNOWLEDGMENT

We would like to thank first our project advisor to Marlon for his patience, motivation,
enthusiasm, immense knowledge and constant support. His guidance has helped us
throughout our mini project work. We would like to thank all our friends and especially
our classmates for all the discussions. We have enjoyed their companionship during our
work in this semester.

We are especially indebted to our parents for their love, sacrifice, and support. Our full
dedication to the work would have not been possible without their blessings and moral
support. This mini project is a dedication to them.

pg. ii
 ABSTRACT
Valve-regulated Lead-acid batteries most economical for larger power applications here
weight are of little concern. One of the main differences between the other battery types
is the initial purchase cost of the battery. However, when selecting a battery, the initial
cost can give a very misleading impression of the total cost to the user during the
system’s lifetime.

The selection of a battery based on cost alone can have a major impact on the life cycle
cost of the system being supported due to such factors as installation, replacement,
maintenance, testing and downtime cost.

Designed to be permanently connected in parallel with a critical load and rectifier/charger

system, where the rectifier/charger forms the primary source of power for the load and
the battery provides the secondary source in the event of a primary source failure.

This project observes the current, voltage waveform and also the harmonics component
before and after the compensation to the nonlinear load. In this work mat lap simulation
is used to simulate the proposed system. Simulation results are presented and the
improvement in the output voltage will show in this work.

LIST OF TABLE:

pg. iii
Table 5.1: Firing angle values
Table 5.2: Elements values
List of figures:
Figure 2.1: Single Phase Fully Controlled rectifier
Figure 3.1: Block diagram of battery charger using SCR
Figure 4.1: single phase Fully Controlled RE load rectifier
Figure 4.2: Waveform of single phase fully controlled RE load rectifier

SYMBOL
a= Firing angle
Ω=Ohm

ABRIVATION:

SCR: - Silicon Controlled Rectifier

DC: - Direct Current
AC: - Alternative Current
T: - Thyristors
PS:-Power Supply
V:-Voltage
C:-Capacitor
NiCad: - Nickel-Cadmium
VRLA:- Valve-Regulated Lead Acid
E:-DC Source
F:-Farad

TABLE OF CONTENTS PAGES

pg. iv
ACKNOWLEDGEMENT---------------ii
ABSTARACT---------iii
LIST OF TABLE-----iv
LIST OF FIGURE--------------iv
CHAPTER1:
INTRODUCTION --------------------------1
1.1Background--------------------------------------------------------------------------------2
1.2. Statement of the Problem---------------------------------------------------------------3
1.3. Significance of the Study---------------------------------------------------------------3
1.4 Scope of the Study -----------------------------------------------------------------------3
1.5 Scope Objective of the Study------------------------------------------------------------4

CHAPTER 2:
LITERATRE REVIEW
2.1 battery charger------------------------------------------------------------------------------
5
2.2 Type of battery charger-------------------------------------------------------------------6
2.2.1 Valve-Regulated Lead Acid (VRLA) battery charger------------------------------6
2.2.2 Nickel-Cadmium (NiCad) battery charger-------------------------------------------6
2.3 Specifications of VRLA Type (48V) Battery: ---------------------------------------6

CHAPTER THREE:-
DATA COLLECTION AND ANALYSIS METHODS-----------------------------------------7
3.1 Single phase full controlled rectifier---------------------------------------------------- 7
3.2 Silicon controlled rectifier-----------------------------------------------------------------8
3.2.1 Silicon controlled rectifier operating modes------------------------------------------9
3.2.2 Application of Silicon controlled rectifier---------------------------------------------9
3.3 Battery charger using SCR---------------------------------------------------------------10
3.4 Research Methodology -------------------------------------------------------------------10

CHAPTER FOUR:
SIMULATION RESULTS AND ANALYSIS
4.1 System modeling mat lab Simulink-------------------------------------------------11
4.2 FFT Analysis ---------------------------------------------------------------------------15
4.3 Result------------------------------------------------------------------------------------19

CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS……………………………………...20
5.1 CONCLUSIONS…………………………………………………………….20
5.2 RECOMMENDATIONS AND FUTURE WORK---------------------------------20

pg. v
CHAPTER 6: Reference------------------------------------------------------------------------21

pg. vi
CHAPTER ONE
1. INTRODUCTION
48v-rectifiers Substation Batteries are well suited for mobile power system applications
and for communications. Acting as the heart of the entire system, batteries play a critical
role as a back-up power source for lost or interrupted station power. This battery charger
system must be designed for the purpose intended and to meet the requirements of all
applicable standards.

The primary role of the substation battery system is to provide a source of energy that is
independent of the primary ac supply, so that in the event of the loss of the primary
supply the substation control systems that require energy to operate can still do so safely.

The battery is required to supply the DC electrical requirements of the substation,

including SCADA, control, protection indication, communications and circuit breaker
switching operations when there is no output from the battery charger.

Mobile DC Power Systems offer user flexibility as either a back-up or redundant power
source. They also serve as invaluable tools to facilitate proper DC power station
maintenance.

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1.1Background
VRLA batteries were sold as being able to meet the required 15-20 year life while
requiring no maintenance, unlike conventional vented lead acid batteries, in reality the
batteries really lasted more than 5 year. In extreme condition the life could be as short as
2 years. Furthermore, Vented-Lead acid batteries could be monitored though electrolyte
level and specific gravity measurement, the state of health of VRLA batteries could be
monitored reliably only by conforming full capacity test.

Utilities are caution about replacing the existing without many successes full trials. This
reflect the poor experience with other replacement technology in past, particularly VRLA
batteries in 1980’s and 1990’s.

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1.2. Statement of the Problem

AC-DC power converters (rectifiers) are used in industry to convert an AC input voltage
into a DC voltage that is either fed into a load or into another power converter. The AC
source for almost all rectifiers is provided by the utility. There are stringent regulatory
agency requirements on the harmonic content of the current that is drawn by power
electronic converters to avoid the harmonic pollution of the utility voltage. Since the
number of electronic appliances is growing, an increasing amount of non-sinusoidal
current is drawn from the distribution network. Consequently, due to the increasing
amount of harmonic currents drawn, the distribution network becomes more and more
polluted. As a direct consequence, available power from the grid becomes less. This is
because unnecessary current components, which contribute to the root mean square
(RMS) value of the line current is drawn from the grid which produces unnecessary.

1.3. Significance of the Study

The significance of design single phase FW controlled rectifier to improve the 48v DC
battery charger in substation for communication purpose.

1.4. Scope of the Study

Gives minimum requirements for 48 VDC Chargers, Batteries and DC control and
distribution Boards, to be supplied at various telecommunications and communications
sites spread across the country.
In our project we selects single phase full controlled rectifier, since to do simple material
Simulink mat lab requires and usesVRLA batteries because this batteries are well suited
for mobile power system applications.

They are typically more space efficient, easier to install, require less maintenance and are
relatively lower in cost compared to most other battery types.

pg. 3
1.5 Objective of the Study

The general objective is to design 48v-rectifiers Substation Batteries are well suited for
mobile power system applications and for communications.

This shall the general objective of this paper showing the Design of 48v 3-phase rectifier
for substations (48v battery charger) how we can convert AC-DC Voltage and to constant
magnitude. These specifications include Design, installation works, testing, and
commissioning work.

The goals of this research are:

 To simulate and analyze the typical DC output voltage.

 To investigate the effects of specific output voltage to the power system.

pg. 4
CHAPTER TWO
LITERATRE REVIEW

2.1 Battery Charger

Battery charger systems must be designed for the purpose intended And to meet the
requirements of all applicable standards the primary role of the substation battery system
is to provide a source of energy that is independent of the primary ac supply, so that in
the event of the loss of the primary supply the substation control systems that require
energy to operate can still do so safely.

The battery is required to supply the DC electrical requirements of the substation,

Including SCADA, control, protection indication, communications and circuit breaker
switching operations when there is no output from the battery charge.
The battery charger is to be solid state, SCR technology or switch mode technology
Microprocessor controlled. It must be designed to float or equalize batteries using a
constant voltage, current limiting logic. Timer and controls must be static.
The battery charger may be supplied by single phase A.C input up to 50A DC Output
100ADC and 200ADC output, shall have three phase AC input.

The battery charger functions as the primary DC power source for maintaining battery
float voltage and providing current to continuous dc station loads.
For trailer applications where VRLA batteries are used, it is highly recommended that
chargers are equipped with an option allowing a temperature compensated charging
algorithm. This feature allows the charger to automatically adjust its output voltage based
on actual battery temperature. Temperature compensation helps ensure proper charge
voltage and promotes intended battery life.

The battery is charged with small amount of AC voltage or DC voltage. So if you want to
charge your battery with AC source then should follow these steps, we need first limit the
large AC voltage, need to filter the AC Voltage to remove the noise, regulate and get the
Constant voltage and then give the resulting voltage to the battery for charging. Once
charging is completed the circuit should automatically turned off.

pg. 5
2.2Type of battery charger

There are two specific battery type

 Valve-Regulated Lead Acid (VRLA)

 Nickel-Cadmium (NiCad)

2.2.1Valve-Regulated Lead Acid (VRLA) battery charger

Valve-Regulated Lead Acid Batteries are well suited for mobile power system
applications.
They are typically more space efficient, easier to install, require less maintenance and are
relatively lower in cost compared to most other battery types.
Their internal construction consisting of a micro-porous fiber plate wrap offers a higher
level of shock and vibration protection (versus standard VLA type batteries) while the
trailer is in transit.

2.2.2 Nickel-Cadmium (NiCad) battery charger

Nickel-Cadmium Batteries offer a rugged mechanical design where periods of shock and
vibration are common during trailer transportation to and from the intended site.
NiCad Batteries experience minimal performance degradation in environments with
potentially large differentials in ambient and/or operational temperatures often associated
with these applications.

This is particularly true where climatically controlled devices are inoperative or not
available.
NiCad Batteries are able to electrically recover back to their nameplate capacity and
operational cell voltages after deep discharge or from depleted capacity due to extended
periods on open circuit.

2.3 SPECIFICATIONS OF VRLA Type Battery:

The batteries shall be made of closed type lead acid cells with VRLA Type
(48V) plates manufactured to conform to IS: 1652-1991.

pg. 6
The capacity of the batteries shall be as follows:
i) Voltage. - 48V
ii) Output at 270 C - 100AH at 10 hrs. Discharge rate.
The batteries shall normally remain under ‘floating’ condition with the ‘trickle’
Charger supplying the continuous load.

The batteries shall be Capable of supplying the following loads under emergency
conditions without any assistance from the chargers and without their terminal voltage
falling below 43V [90% of rated voltage] Stage emergency - 15A for 3 hours for lighting.
The number of cells for 48V batteries shall be so chosen that for the nominal floating
voltage of the cells, the battery voltage shall be 51.85V and for the minimum [discharged
condition] voltage of the cells, the voltage of the battery Shall not be less than 43.2V,
while the assigned rating of the battery bank can Not lowered below its rated voltage of
48V volts.
CHAPTER THREE
DATA COLLECTION AND ANALYSIS

3.1 Single Phase Fully Controlled Rectifier

The output voltage of thyristor rectifiers is varied by controlling the delay or firing angle
of thyristors.
A phase‐control thyristor is turned on by applying a short Pulse to its gate and turned off
due to natural or line Commutation. Since these rectifiers convert from AC to DC, these
Controlled rectifiers are also called ac‐dc converters and are used extensively in industrial
applications, especially in Variable‐speed drives, ranging from fractional horsepower to
megawatt power level.

pg. 7
Circuit Diagram:

:-Fig3.1Single Phase Fully Controlled RE load rectifier

To design Single phase RE Load Rectifier fully controlled converter use the following
Elements

 Thyristor (Silicon Controlled Rectifier)

 DC Source (E)
 Resister
 Power source
 Capacitors

3.2 Silicon Controlled Rectifier (SCR)

It is made up of three PN junction diodes also; it is solid state equivalent of gas filled
triode and has around four semi-conductor layers. SCR can conduct the current in a
single direction or we can say SCR’s are unidirectional. The SCR can be triggered only at
the gate through the current. SCR will combine the features of rectifier and transistor.

They are mainly used in switching applications. They can also be triggered with the break
over voltage (if the forward voltage is more than the break down voltage of the

pg. 8
Component. They are mainly used in the high voltage and high power for controlling
purpose. They are also used in the light dimming, voltage regulators, motor control etc.

3.2.1 SCR Operating Modes:

To turn on the SCR the small amount of voltage or voltage equal to break over voltage is
required to the gate which will trigger the SCR and when the SCR is turned on, it will
have very low resistance and allow the power to conduct and also increase the anode
current. Even if we remove the gate voltage also it will be in conduction. The only way to
make the SCR to turn off is to make the voltage to zero or make the current less than the
handling current between the anode and cathode.

There are two ways to turn on the SCR is the first way is to turn on by opening the gate
and compensate the power supply to the break over voltage And second way is to
supplying the voltage to operate the SCR with less than break over voltage and applying
the small amount of about 1.5V applied to the gate which will trigger the SCR.When the
SCR is turned off it will have high resistance and restrict the current to the leakage
current. To turn off the SCR from on state also have only one ways normally people think
that if we stop the gate current the SCR will become turn off, but it will not this state is
called “loss of control”, the only way is turnoff the SCR is reducing the supply voltage to
zero.

3.2.2 Applications of SCR:

SCR can be used as switch, because SCR has two states ON and OFF state. We know
that to turn on the SCR we need to increase the supply voltage equal to break over
voltage or by giving the small voltage to the gate for triggering, by this we can turn on
the SCR; we can turn off the SCR by decreasing the current to less than holding current,
or we have another method called force communication in this we discharge a capacitor
in parallel with SCR to make it turn off; by this we can use SCR as typical SWITCH.
There is lot of advantages using SCR as switch like switching speed of SCR is very high
like switching operation per second.

pg. 9
It allows huge current up to 100 mA through the load just by triggering the gate with very
low voltage to turn it on.

Small in size and has low noise which give high efficiency and reliable.
SCR can be used in half wave rectifier, full wave rectifier, inverter circuits, power control
circuits, static contactor, over light detector, speed control circuit, crowbar circuit,
automobile ignition circuits, etc.
SCR is a current trigger device.
Gate is the control element of SCR.
Angle of conduction can be changed by changing the gate voltage.

3.3 Battery Charger Using SCR

The battery charged with small amount of AC Voltage or DC voltage. So if you want to
charge your battery with AC source then should follow these steps, we need first limit the
large AC voltage, need to filter the Ac voltage to remove the noise, regulate and get
constant voltage and then give the resulting voltage to the battery for charging. Once
charging is completed the circuit should automatically turned off.

Fig 3.1Block diagram of battery charger using SCR

3.4 Research Methodology

The research was carried out in two stages via analysis and mat lab Simulink. A
completed studies and investigations were carried out on the characteristic of output
voltage, voltage and current distortion and total harmonic distortion. In the literature

pg. 10
survey, various topologies have been evaluated which might be able to fulfill the design
specifications. Based on the literature survey, several topologies were selected for further
evaluation.
In measuring DC output voltage, harmonics in term of Total Harmonic Distortion (THD)
fundamental and harmonic components of the supply current, MATLAB software was
used.
After collecting the data and identifying the problems associated with, single phase
controlled an RE load circuit has been designed in order to achieve 48 DC voltages.

Finally the results were recorded and some evaluations were made.
The design and analysis of the circuit is based on full controlled RE load rectifiers circuit
required for Substation battery charger application.

CHAPTER FOUR

SIMULATION RESULT AND DISCUUSSION

4.1 System Modeling Mat lab/Simulink

Software Used: Mat lab – Simulink

Aim:
To simulate single phase fully controlled RE load rectifier.

Procedure: Mat lab – Simulink

 Open Mat Lab → ‘Simulink’ → open ‘New Model’, Use ‘Simulink’ and
‘SimPowerSystems’ blocks to pick circuit elements,
 Drag and drop circuit elements on the ‘New Model/untitled’ window,
 Connect the circuit elements and measuring devices,
 Fill the parameters of each element, Name the signals to be displayed on the
measuring device connection line.
 Run the circuit

pg. 11
Circuit Diagram-

Fig 4.1: Single Phase Fully Controlled RE load rectifier

Simulink Models:

pg. 12
Entering Firing Angle Values ()
In order to trigger thyristors we have to give proper triggering pulses to it using a pulse
generator. We can enter values in the box which is obtained by double clicking pulse
generator.
Complete Triggering Values
Thyristors No Firing Angle in degree() Firing Angle in seconds

T1 150 0.0088888

T2 150 0.008888

T3 330 0.018888

T4 330 0.018888

Table 5.1 Firing Angle Values

Elements of the Simulink model Values

E 45v
R1 10 Ω
C 400F

Table 5.2 Elements Values

Theory:

pg. 13
Single phase RE load fully controlled Rectifier
A single phase fully controlled converter is obtained by four thyristors as shown in Fig1.
For any current to flow in the load at least one device from the top group (T1, T3) and
one from the bottom group (T2, T4) must conduct.
During =0 to 150
There is power supply, but not conduct until 150 since there is not conducting device.

During = 150to180
T1T2 are forward biased and got fired, thus they conducts supply current to the output.
Supply voltage appears at the output though T1T2

During = 180to 330

T1T2 are Reversing biased and T3T4 are forward biased, but T3T4 do not conduct
supply current since they do not be trigger.
During = 330
T3T4 are forward biased got fired signal and they conduct.

Graph

pg. 14
Fig 4.2 Waveform of single phase fully controlled RE load rectifier

4.2 FFT Analysis

The FFT analysis to display dc, fundamental and harmonic components of the supply
current.
Supply voltage (vs.) of FFT graph

pg. 15
The fundamental and THD For Supply Voltage (vs)

Output current (io) of FFT graph

pg. 16
The fundamental and THD for Output current (io) of FFT

Output Voltage (vo) of FFT graph

pg. 17
The fundamental and THD for Output voltage (vo) of FFT graph

Supply current(is) of FFT graph

pg. 18
The fundamental and THD for Supply current (io) of FFT graph

4.3 RESULT:
Design single phase RE load fully controlled rectifier is simulated and graphs are
obtained 48VDC.
This DC voltage is used in substation for communication purpose.

pg. 19
 CHAPTER FIVE
CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION

The project includes the single phase full controlled rectifier, Mat lab Simulink, and
capacitor banking with RE load to Display 48v dc battery charger.
This 48v dc battery charger is uses in substation for communication system availability
and Mobile DC Power Systems offer user flexibility as either a back-up or redundant
power source. They also serve as invaluable tools to facilitate proper DC power station
maintenance.
The battery charger functions as the primary DC power source for maintaining battery
float voltage and providing current to continuous dc station loads.

5.2 RECOMMENDATIONS AND FUTURE WORK

We would like to recommend our department to implement this single phase full
controlled RE load system design project for substations by extending the project to 3-
phase full controlled RE load rectifier in order to charging full in short period of time.

Finally we would like to recommend our department to give the supportive introductory
courses of Lab Software like Simulink Mat Lab, multiuse and Lab Views that helps
student to be familiar with the use of software for simulation purpose in their projects.

pg. 20
CHAPTER 6: REFERENCES

[1] Internet, Google books

.[2]Power electronics reference books
[3] K. Thorborg, “Power Electronics”, Prentice-Hall International (UK) Ltd., 1988.
[4] M. H. Rashid, “Power Electronics, Circuits Devices and Applications”, Prentice-Hall
International Editions, 1992.
[5] N. Mohan, T. M. Undeland, and W. P. Robbins, “Power Electronics: Converters,
Applications, and Design”, John Wiley and Sons, 1989.
[6] J. Arrillaga, D. A. Bradley, and P. S. Bodger, “Power System Harmonics”, John
Wiley and
Sons,
Press, 1988.
[8] M. E. Villablanca and J. Arrillaga, “Pulse Multiplication in Parallel Convertors by
Multilap

21

pg. 21