HTL-06 – ELECTRICAL & POWER INTEGRATION SPECIFICATION

• HTL-06 – ELECTRICAL & POWER INTEGRATION SPECIFICATION
• 1. Purpose
  • 1.1 Document Objective
  • 1.2 Authority
  • 1.3 Change Governance
• 2. Scope
  • 2.1 In-Scope
  • 2.2 Out-of-Scope
• 3. Definitions
  • 3.1 Control Voltage
  • 3.2 Actuator Power Line
  • 3.3 Hardware Interlock
  • 3.4 Brownout
  • 3.5 Inrush Current
  • 3.6 Opto-Isolation
  • 3.7 EMI (Electromagnetic Interference)
  • 3.8 Fail-Safe State
• 4. Assumptions
  • 4.1 Operational Assumptions
  • 4.2 Technical Assumptions
  • 4.3 Capacity Assumptions
• 5. System Description
  • 5.1 Power Topology Overview
  • 5.2 Actuator Integration Model
  • 5.3 Grounding & Noise Isolation Model
  • 5.4 Hardware Interlock Model
  • 5.5 Brownout & Power Fault Model
  • 5.6 Panel Segmentation Model
• 6. Technical Specification
  • 6.1 Power Budget Calculation
  • 6.2 Relay & Contactor Rating
  • 6.3 Fuse & Protection Baseline
  • 6.4 Cable Sizing Baseline
  • 6.5 Power Quality Requirement
  • 6.6 Environmental Constraints
  • 6.7 Safety Interlock Requirement
  • 6.8 Startup & Recovery Rule
  • 6.9 EMI & Transient Suppression
  • 6.10 Electrical Failure Scenarios
• 7. Constraints
  • 7.1 Power Capacity Constraint
  • 7.2 Relay Electrical Rating Constraint
  • 7.3 Thermal Constraint
  • 7.4 Grounding Constraint
  • 7.5 EMI Constraint
  • 7.6 Power Reliability Constraint
• 8. Failure Handling
  • 8.1 Power Loss
  • 8.2 Brownout Oscillation
  • 8.3 Relay Weld Contact
  • 8.4 Short Circuit Actuator
  • 8.5 Thermal Overload
  • 8.6 EMI-Induced Reset
  • 8.7 Surge Event
• 9. Interfaces
  • 9.1 Node Electrical Interface
  • 9.2 Gateway Power Interface
  • 9.3 Server Power Interface
  • 9.4 Hardware Interlock Interface
  • 9.5 Panel Wiring Interface
• 10. Open Issues
• 11. Revision History

1. Purpose

1.1 Document Objective

Menjadi referensi teknis integrasi elektrikal untuk:

• Node power supply
• Actuator drive
• Panel wiring
• Electrical protection
• Hardware safety interlock
• EMI mitigation
• Grounding strategy

Dokumen ini menjamin bahwa implementasi HortiLink aman secara fisik.

1.2 Authority

HTL-06 mengikat:

• Tim Electrical
• Tim Panel Builder
• Tim Firmware (terkait safe-state behavior)
• QA safety validation

Perubahan rating atau proteksi wajib review lintas tim.

1.3 Change Governance

Perubahan berikut wajib review arsitektur:

• Relay/contact rating
• Power topology
• Interlock logic
• Grounding model
• Supply voltage baseline

Jika mempengaruhi:

• HTL-02 (fail-safe)
• HTL-03 (gateway supply)
• HTL-00 (failure containment)

Maka revisi lintas dokumen wajib.

2. Scope

2.1 In-Scope

• DC supply design (12–24V → 5V/3.3V)
• Node power protection
• Relay & contactor integration
• Inrush handling
• Overcurrent protection
• Fuse/MCB selection baseline
• EMI suppression
• Grounding scheme
• Panel layout baseline
• Brownout behavior
• Surge protection

2.2 Out-of-Scope

• Utility-level grid design
• High-voltage distribution > 400VAC
• Certified safety compliance documentation (dibuat terpisah)
• Mechanical enclosure design detail

3. Definitions

3.1 Control Voltage

Tegangan rendah untuk Node (3.3V / 5V / 12–24V DC).

3.2 Actuator Power Line

Line daya utama untuk pompa, motor, valve (AC/DC).

3.3 Hardware Interlock

Proteksi fisik yang mencegah kondisi unsafe tanpa bergantung software.

3.4 Brownout

Kondisi tegangan supply turun di bawah threshold operasional MCU.

3.5 Inrush Current

Arus awal tinggi saat motor/pompa start.

3.6 Opto-Isolation

Isolasi galvanik antara MCU dan beban daya.

3.7 EMI (Electromagnetic Interference)

Gangguan elektromagnetik akibat switching beban induktif.

3.8 Fail-Safe State

Kondisi default aktuator saat:

• Node reset
• Supply hilang
• Firmware crash

4. Assumptions

4.1 Operational Assumptions

• Sistem pertanian outdoor/semi-outdoor
• Beban dominan: pompa air, valve solenoid
• Power source: 220VAC atau 110VAC
• Lingkungan lembab & berdebu mungkin terjadi

4.2 Technical Assumptions

• Node menggunakan ESP32
• Aktuator dikendalikan via relay/contact
• Tidak ada direct MCU-to-motor control
• Semua aktuator default OFF saat reset

4.3 Capacity Assumptions

Per Node:

• Maks 2–4 relay output
• Beban pompa ≤ 1HP (baseline)
• Total panel load sesuai kapasitas site

Rating final dikunci sebelum produksi massal.

5. System Description

Section ini mendefinisikan arsitektur elektrikal per Node dan integrasinya dengan panel daya site.

Tujuan utama:

• Mencegah kegagalan software menyebabkan kondisi unsafe
• Mencegah gangguan daya merusak MCU
• Memastikan isolasi kontrol & beban
• Memastikan degradasi aman saat power fault

5.1 Power Topology Overview

✔ Layer Daya

1. AC Input (110/220VAC)

   • MCB utama
   • Surge protection (SPD)
   • EMI filter

2. DC Control Supply (12–24VDC)

   • SMPS industrial grade
   • Fuse terpisah untuk control line

3. Local Regulation

   • 24V → 5V regulator
   • 5V → 3.3V regulator
   • Brownout detection aktif

4. Separation

   • Jalur daya aktuator terpisah dari jalur MCU

✔ Prinsip Utama

• Control supply terpisah dari actuator supply
• Ground star topology
• Fuse per-segment
• Tidak ada beban induktif langsung ke MCU

5.2 Actuator Integration Model

✔ Struktur Kontrol Aktuator

MCU GPIO → Opto-isolated driver → Relay coil / Contactor coil → Actuator power line

✔ Aturan Wajib

• Opto-isolation mandatory
• Flyback diode untuk DC coil
• RC snubber untuk AC load
• Contactor untuk beban > rating relay kecil
• Relay hanya sebagai signal switching, bukan load switching besar

✔ Inrush Handling

Untuk pompa/motor:

• Gunakan contactor rating sesuai inrush
• Pertimbangkan soft-start jika daya besar
• Hindari start simultan beberapa motor

Firmware tidak boleh menjadi satu-satunya proteksi inrush.

5.3 Grounding & Noise Isolation Model

✔ Grounding Principle

• Star grounding
• Power ground dan signal ground dikontrol
• Shield cable untuk sensor analog
• Avoid ground loop

✔ EMI Mitigation

• Snubber pada relay contact
• Twisted pair untuk signal
• Decoupling capacitor dekat MCU
• Ferrite bead pada supply jika perlu

5.4 Hardware Interlock Model

Interlock fisik tidak boleh bergantung software.

Contoh:

• Level switch seri dengan coil contactor
• Thermal overload relay inline
• Pressure switch mechanical

Jika MCU crash:

→ Interlock fisik tetap bekerja.

5.5 Brownout & Power Fault Model

Saat supply drop:

1. Brownout detect MCU
2. Node reset
3. Relay default OFF
4. Actuator OFF

Tidak boleh ada kondisi latch ON setelah reset.

Power recovery:

• Delay sebelum enable control
• Hindari start bersamaan

5.6 Panel Segmentation Model

Panel dibagi menjadi:

1. Power Section (AC input, MCB, contactor)
2. Control Section (SMPS, Node, Gateway)
3. Signal Section (sensor wiring)

Wiring duct terpisah untuk:

• High voltage
• Low voltage
• Signal analog

6. Technical Specification

6.1 Power Budget Calculation

✔ 6.1.1 Control Power Budget (Per Node)

Baseline konsumsi:

• ESP32: ~150–300 mA peak (WiFi active)
• Relay coil (per channel): 50–90 mA @5V
• Sensor analog/digital: 10–100 mA
• Margin safety: +30%

Disarankan:

• Supply 5V minimum 2A per Node assembly
• 24V supply margin ≥ 2× total estimated current

✔ 6.1.2 Gateway & Pi Budget

Gateway ESP32:

• Peak WiFi + ESP-NOW burst

Raspberry Pi:

• 5V supply minimum 3A (disarankan 5A)

Total panel control supply harus dihitung agregat.

6.2 Relay & Contactor Rating

✔ 6.2.1 Relay Control (Low Load)

Untuk beban kecil (< 5A):

• Relay minimal 250VAC rating
• Current rating ≥ 2× nominal load
• Mechanical endurance ≥ 100k cycle

✔ 6.2.2 Contactor (Motor Load)

Untuk pompa/motor:

• Rating sesuai motor HP
• Inrush rating diperhitungkan
• Coil voltage sesuai control supply (24V disarankan)

Thermal overload relay disarankan inline.

✔ 6.2.3 Switching Rule

Tidak diperbolehkan:

• Relay PCB langsung menggerakkan motor > 0.5HP
• MCU GPIO langsung ke coil tanpa driver

6.3 Fuse & Protection Baseline

✔ 6.3.1 AC Input Protection

• MCB utama sesuai total load
• Surge Protection Device (SPD) class sesuai site
• EMI filter sebelum SMPS

✔ 6.3.2 DC Control Protection

• Fuse terpisah untuk:

  • Node
  • Gateway
  • Pi

• Short circuit protection wajib

✔ 6.3.3 Per-Actuator Protection

• MCB atau fuse per motor
• Thermal overload relay untuk motor
• Flyback/snubber wajib

6.4 Cable Sizing Baseline

✔ 6.4.1 Control Wiring

• Minimal 0.5–0.75 mm² untuk control line
• Shielded cable untuk sensor analog

✔ 6.4.2 Power Wiring

• Disesuaikan dengan current rating
• Voltage drop < 5%
• Outdoor rating jika diperlukan

6.5 Power Quality Requirement

✔ 6.5.1 Voltage Stability

Control supply tidak boleh:

• Drop >10% nominal
• Ripple berlebihan

SMPS industrial grade disarankan.

✔ 6.5.2 Brownout Threshold

MCU brownout threshold harus diaktifkan.

Setelah brownout:

• Relay default OFF
• No auto resume tanpa valid state

6.6 Environmental Constraints

✔ 6.6.1 Temperature

Panel harus mampu:

• 0–50°C baseline
• Ventilasi cukup
• Hindari direct sunlight

✔ 6.6.2 Humidity

• IP-rated enclosure jika outdoor
• Anti-condensation jika perlu

✔ 6.6.3 Dust & Insects

• Filter ventilation
• Sealed gland untuk kabel

6.7 Safety Interlock Requirement

✔ 6.7.1 Mandatory Hardware Interlock

Untuk pompa:

• Level switch seri dengan coil
• Thermal overload mechanical

Untuk greenhouse:

• Limit switch fisik jika ada mekanik

✔ 6.7.2 Software Tidak Boleh Jadi Satu-Satunya Proteksi

Interlock fisik tetap harus bekerja jika:

• MCU hang
• Node reset
• Firmware crash
• Gateway offline

6.8 Startup & Recovery Rule

✔ 6.8.1 Power-Up Sequence

1. Stabilize supply
2. MCU boot
3. Relay default OFF
4. Self-check
5. Enable control

Tidak boleh auto-start motor tanpa explicit command atau schedule.

✔ 6.8.2 Simultaneous Start Protection

Jika banyak motor:

• Firmware stagger start
• Delay antar start

Panel harus mampu menangani peak current.

6.9 EMI & Transient Suppression

✔ 6.9.1 Snubber

• AC contact: RC snubber
• DC coil: Flyback diode

✔ 6.9.2 Decoupling

• 100nF + bulk capacitor dekat MCU
• Ferrite bead jika noise tinggi

6.10 Electrical Failure Scenarios

Minimal harus diuji:

1. Power loss saat motor ON
2. Brownout oscillation
3. Short circuit actuator
4. Relay weld contact
5. Surge spike
6. EMI dari motor start
7. Sensor cable short

Panel harus fail-safe.

7. Constraints

7.1 Power Capacity Constraint

• Total panel load tidak boleh melebihi rating MCB utama
• Control supply harus memiliki margin ≥ 30%
• Simultaneous motor start harus diperhitungkan

Panel tidak boleh bergantung pada firmware untuk membatasi arus total.

7.2 Relay Electrical Rating Constraint

• Relay rating ≥ 2× nominal current
• Tidak boleh digunakan mendekati rating maksimum terus-menerus
• Mechanical cycle limit harus diperhitungkan

Relay PCB bukan pengganti contactor industri.

7.3 Thermal Constraint

• Temperatur internal panel harus terkontrol
• Ventilasi atau fan jika load tinggi
• SMPS tidak boleh overheat

7.4 Grounding Constraint

• Star grounding wajib
• Hindari ground loop
• Shield sensor harus di-ground satu sisi

Improper grounding dapat menyebabkan noise dan reset MCU.

7.5 EMI Constraint

• Beban induktif wajib snubber
• Motor start tidak boleh menyebabkan reset Node
• Cable high voltage dan signal harus dipisah

7.6 Power Reliability Constraint

• Brownout harus ditangani
• No uncontrolled actuator start saat power recovery
• No latch ON setelah reset

8. Failure Handling

Format: Detection → Impact → Recovery → Owner

8.1 Power Loss

Detection:

• Supply drop
• Brownout reset

Impact:

• Node reset
• Actuator OFF

Recovery:

• Controlled restart
• No auto resume

Owner:

• Electrical + Firmware

8.2 Brownout Oscillation

Detection:

• Repeated reset log
• Unstable voltage

Impact:

• Relay chatter
• Possible contact wear

Recovery:

• Investigate supply
• Add stabilization
• Increase hold-up capacity

Owner:

• Electrical

8.3 Relay Weld Contact

Detection:

• Actuator ON meski output OFF
• Current sensor anomaly (jika ada)

Impact:

• Unsafe actuator state

Recovery:

• Manual inspection
• Replace relay
• Add contact feedback in future revision

Owner:

• Maintenance

8.4 Short Circuit Actuator

Detection:

• Fuse blow
• MCB trip

Impact:

• Load offline

Recovery:

• Replace fuse
• Inspect wiring
• Verify load

Owner:

• Electrical technician

8.5 Thermal Overload

Detection:

• Overload relay trip

Impact:

• Motor OFF

Recovery:

• Cooling period
• Manual reset overload relay
• Root cause analysis

Owner:

• Operator / Electrical

8.6 EMI-Induced Reset

Detection:

• Unexpected reset
• Log restart reason

Impact:

• Telemetry interruption
• Actuator OFF

Recovery:

• Improve shielding
• Add snubber
• Improve grounding

Owner:

• Electrical + Firmware

8.7 Surge Event

Detection:

• SPD indicator
• Multiple device failure

Impact:

• Hardware damage

Recovery:

• Replace SPD
• Inspect panel
• Validate isolation

Owner:

• Electrical

9. Interfaces

9.1 Node Electrical Interface

• GPIO via opto-isolated driver
• Brownout detect
• Relay control line
• Sensor analog input

Referensi HTL-02.

9.2 Gateway Power Interface

• Dedicated 5V stable supply
• Brownout handling
• No shared heavy load line

Referensi HTL-03.

9.3 Server Power Interface

• Dedicated supply
• UPS recommended
• Surge protection

Referensi HTL-04.

9.4 Hardware Interlock Interface

Interlock harus:

• Seri dengan coil
• Tidak dapat dibypass software
• Tidak tergantung MCU state

9.5 Panel Wiring Interface

Segregasi wajib:

• High voltage
• Low voltage
• Signal analog

Cable duct terpisah.

10. Open Issues

Harus dikunci sebelum produksi massal:

1. Rating maksimal motor yang didukung per Node?
2. Apakah soft-starter diwajibkan untuk motor > 1HP?
3. Apakah feedback current sensor diwajibkan?
4. Apakah UPS wajib untuk semua site?
5. IP rating enclosure baseline?
6. Surge protection class final?
7. Standar kabel minimum?

Tanpa keputusan ini, panel tidak boleh distandarisasi.

11. Revision History