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Emerson HD22020-3(HD11040-3) Rectifier Module

editor:admin    date:2014-07-22

Operation Principle of HD22020-3 (HD11040-3)

The Emerson rectifiers comprise two parts: 3phase passive PFC and DC/DC converter circuit. Besides, there are the auxiliary power supply and the I/O detection protection circuit. The operation principle of rectifiers is shown in Figure HD22020-3

1) The 3-phase passive PFC circuit at the front-end comprises input EMI and passive PFC, which are used to rectify and filter the AC input, and to calibrate the input current, so as to ensure that the power factor of the input circuit is bigger than 0.94, meeting the related EMI and EMC standards in GB/T 17794.2.2-2003, as well as the 3-phase harmonic standard in DL/T781-2001.
2) The DC/DC converter circuit at the back end uses PWM generator to control the PFC-output DC voltage, and output DC voltage through high frequency transforming, rectification and filtering. It is used to convert the rectified voltage from the front end into the steady DC voltage output as required by the power system.
3) The auxiliary power supply is located between the input passive PFC and the DC/DC converter. It uses the DC output from the 3-phase passive PFC and powers the control circuits. 
4) The input detection circuit can detect input over/under-voltage and phase failure, while DC/DC detection circuit can detect output voltage/current and heat sink temperature. All these signals are used for the control and protection of DC/DC conversion.
Major Functions of HD22020-3(HD11040-3 ,Emerson)
1. Protection
1) Input over/under-voltage protection
The rectifiers are capable of over/under-voltage protection. When the input voltage is smaller than the set under-voltage or bigger than the over-voltage, the rectifier will be shut down for protection. There will be no DC output, and the protection indicator (yellow) will turn on. The rectifier will return to normal operation when the voltage returns normal.
2) Output over-voltage protection & under-voltage alarm
The rectifiers are capable of output over-voltage protection and under-voltage alarm. When the output voltage is higher than the preset over-voltage, the rectifier will shut down, with no output, and the alarm indicator (red) will turn on. The rectifier cannot be auto-reset. You need to power it off and on to reset it.
When the output voltage is lower than the preset under-voltage, the alarm will be raised, but the rectifier will keep its output, and the protection indicator (yellow) will turn on. This alarm will be cleared once the voltage restores to normal.
3) Short circuit foldback of output
The rectifiers are capable of limiting output upon short circuit, during which the output current will be limited to 40% of rated output current. The output will restore to normal after the short is removed.
4) Phase failure protection
The rectifiers are capable of phase failure protection. Upon input phase failures, the rectifiers will derate and output half power. The output current is 5A at the output voltage of 260V.
5) Over-temperature protection
The over-temperature protection will be triggered when the temperature is higher than the set point, either due to too high ambient temperature, or because rectifier air inlet is blocked. The Protection Indicator (yellow) on the rectifier front panel will turn on, and there will be no output. This protection can be reset automatically when abnormality is cleared and rectifier internal temperature restores to normal. 
6) Front-end over-current protection  
This protection will be triggered upon over-current at the rectifier’s rectification part. It cannot be reset automatically. To reset it, you need to power it off and on.
2. Other functions
1) Fan speed control
There are 3 classes of fan speed: stop, half-speed and full speed, determined by taking both temperature and output current into consideration.
2) Fault display
Upon rectifier faults, the alarm information will real-time flash on LED in the form of fault code. You can switch the display content to voltage by pressing the A/V button (current/voltage display switching button).
3) Communication function
The rectifier can communicate with the host through RS485 port. It can report to the host its output voltage, current, protection and alarm information, as well as receive and execute control orders from the host.
Front panel of HD22020-3 (HD11040-3) Rectifier Module
1. LED
It displays the rectifier voltage, current or alarm information. You can switch the display between output voltage and current by pressing the display switchover button (or A/V, as shown in the figure). It can display 3 digits, and the voltage display precision is ± 0.3V. As for the display precision of current, HD22010-3 is ± 0.2A, HD22020-3 and HD11020-3 is ± 0.4A, and HD11040-3 is ± 0.8A.
Upon rectifier faults, the fault code will flash on the LED.
2. Indicator
There are three indicators on the front panel, namely RUN (green), ALM (yellow) and Fault (red). Their being on indicates normal operation, protection, and fault respectively.
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 switch it to output current, and press it again to switch it back to voltage.
4. V ADJ (voltage adjustment)
These two buttons are used to adjust the output voltage of the rectifiers in manual state. They are valid only when the rectifier is in the manual state (configurable through the first bit of the DIP switch on rectifier front panel). 
5. DIP switch
The DIP switch is used to set the control mode and rectifier’s communication address.
6. Cover plate of the handle
The rectifier handle is under the cover plate. You need to pull the cover down to show the handle. 
7. Fan cover and dust mesh
The fan cover can avoid sucking alien material into the rectifier and protect the rectifier. The dust mesh is used to filter the dust to prolong rectifier’s life span.
More information refer to
Specifications of Emerson HD22020-3, and HD11040-3 Rectifier Module
Input voltage
323V ~ 475V (3ph 3 wire system)
Input current
≤ 15A
≤ 15A
AC input frequency
45Hz ~ 65Hz
Power factor
Output voltage range
176V ~ 320V
88 ~ 160V
Rated output current
Max. output current
Soft start time
3 ~ 8s
Output constant current range
10% ~ 100%
10% ~ 100%
Current stabalization (for 20% rated current or above)
≤ ± 0.5%
≤ 0.1%
Voltage stabalization
≤ ± 0.5%
Load sharing imbalance
≤ ± 5%, (typical 3%, 50% ~ 100% rated load)
Accoustic noise
Short circuit foldback of output
Foldback current ≤ 40% rated current. Auto-reset enabled
Output over-voltage protection
325 ± 5Vdc
165 ± 5Vdc
Output under-voltage protection
198 ± 1Vdc
99 ± 1Vdc
Input over-voltage
Protection point
485 ± 10Vac
Recovery point
460 ± 15Vac
Input under-voltage
Protection point
313 ± 10Vac
Recovery point
335 ± 10Vac
Over-temperature protection
Protection point
Recovery point
Fan speed control
Under the combined control of temperature and current
Insulation resistance
I/O to chassis and input to output >10MΩ (Test voltage: 1000Vdc)
Dielectric strength
Impose AC between I/O and the chassis aftering shorting the input and output. Frequency: 50Hz. RMS: 2000V. No breakdown or flashover
Operation temperature
-10°C ~ 40°C
Storage temperature
-25°C ~ 55°C
Relative humidity
≤ 95%
Air pressure
70 ~ 106kPa
Size (L × W × H) (Unit: mm)
Cooling method
Natural cooling together with forced cooling, with dust proof design