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SMPS BASED BATTERY CHARGER (POWER PLANT) FOR RAILWAY’S TELECOM APPLICATION
The 48V SMPS based power plant, designed as per customer’s load requirement and capacity of battery, is suitable for High Frequency Switched-Mode Technique for the use by Indian Railways for Telecom Equipments i.e. Exchanges, Multiplexing Equipments, Microwave Radio Equipments, GSM-R Equipments, TETRA Equipments, OFC Equipments etc.
The design, manufacturing process, quality assurance process is approved by the RDSO. The type testing of the complete Power Plant and its sub modules are also witnessed and approved by RDSO.

  • Designed as per RDSO specification RDSO/SPN/TL/23/99 VER. 4.0
  • Wide input ac supply range 150-275 volt.
  • High input power factor >0.99
  • High power switches mode rectifiers for battery charging.
  • Low input current distortion <10%.
  • N+1, N+2 redundancy of modules for better reliability.
  • Remote display and alarm for module fail, and battery condition.
  • Type tested by NABL accredited laboratory for environmental condition as per IS-9000 and for EMI/EMC as per CISPR “22A”.
  • Performance tested and approved by RDSO Lucknow.
  • Remote monitoring of parameters through RS232.
  • Compact space saving design.
  • Separate panels for SMPS, AC and DC circuits.
  • Surge protection for input and output circuits.
  • All modules rated for 70°C.
  • Entire system rated for 55°C.

SWITCH MODE RECTIFIER (SE-SMR-1400)

SE-SMR-1400 48V/25A (S48-25)
ELECTRICAL
Input supply Single Phase
Input Voltage 165-260VAC (RE),  90-300VAC (NRE)
Input Frequency 50Hz±2Hz
Input Amp Consumption (approx.) 8.5A AC NOMINAL
Output Voltage 57.6V±1% DC
Voltage setting range 48-64.8V DC
Output Current 25A at 57.6V, 12.5A at 64.8V
Current Setting range 12.5-25A DC
Voltage ripple (without battery connected) 300mV Pk-Pk,
4mV psophometeric
Efficiency (at nominal input and rated load) ≥85%
PF (at nominal input and load 75%-100%) 0.95 lag to 0.98 lead.
Voltage undershoot/Overshoot (For step load change of 25% to 100% and vice-versa)  ±5% of set value and returns to steady state in 20ms
Protections DC Over Voltage
DC Over Load/Short Ckt.
Input Surge Protection
Fan Fail (Over Temp.)
Metering on LCD Display DC Voltage
DC Current
Indications on LCD Display Mains
Float
Boost
Over Load/Short-Circuit
Under Voltage
Output Fail
Over Voltage
Over Temp.
Fan Fail
Alarms on LCD display Over Load/Short-Circuit
Under Voltage
Output Fail
Over Voltage
Over Temp.
Fan Fail
Dielectric level at 50Hz. For 1min 1.5kV rms
Insulation level
AC I/P to E
DC O/P to E
AC I/P to DC O/P
>2ME
>1ME
>5ME
MECHANICAL
Installation Indoor, Rack mounted
Enclosure Modular, CRCA Fabricated
Degree of protection IP-20
Color  RAL-7032
Dimension W-495, H-100, D-355mm
Main I/P, O/P connections Through Plug-in Power Connectors
CLIMATIC  
Ambient Temperature -5°C-55°C
Storage temperature -10°C-70°C
Relative humidity 95% non-condensing
Cooling Forced air
Altitude 1000m Max. above MSL

SWITCH MODE RECTIFIER (SE-SMR-700)

SE-SMR-1400 48V/12.5A (S48-12.5)
ELECTRICAL
Input supply range Single Phase
Input Voltage range 165-260VAC (RE),   90-300VAC (NRE)
Input Frequency range 50Hz±2Hz
Input Amp Consumption (approx.) 4.0A AC NOMINAL
Output Voltage range 57.6V±1% DC
Voltage setting range 48-64.8V DC
Output Current range 12.5A at 57.6V, 6.3A at 64.8V
Current Setting range 6.3-12.5A DC
Voltage ripple (without battery connected) 300mV Pk-Pk,
4mV psophometeric
Efficiency (at nominal input and rated load) ≥85%
PF (at nominal input and load 75%-100%) 0.95 lag to 0.98 lead.
Voltage undershoot/Overshoot (For step load change of 25% to 100% and vice-versa)  ±5% of set value and returns to steady state in 20ms
Protections DC Over Voltage
DC Over Load/Short Ckt.
Input Surge Protection
Over Temp.
Metering on LCD Display DC Voltage
DC Current
Indications on LCD Display – Mains
– Float
– Boost
– Over Load/Short-Circuit
– Under Voltage
– Output Fail
– Over Voltage
– Over Temp.
Alarms on LCD display – Over Load/Short-Circuit
– Under Voltage
– Output Fail
– Over Voltage
– Over Temp.
Dielectric level at 50Hz. For 1min 1.5kV rms
– Insulation level
– AC I/P to E
– DC O/P to E
– AC I/P to DC O/P
>2ME
>1ME
>5ME
MECHANICAL
Installation Indoor, Rack mounted
Enclosure Modular, CRCA Fabricated
Degree of protection IP-20
Color RAL-7032
Dimension W-108, H-306, D-365mm
Main I/P, O/P connections Through Plug-in Power Connectors
CLIMATIC
Ambient Temperature -5°C-55°C
Storage temperature -10°C-70°C
Relative humidity 95% non-condensing
Cooling Forced air
Altitude 1000m Max. above MSL

SMPS BASED BATTERY CHARGERS

ITEM VALUES
ELECTRICAL
Rated input voltage range 230V (165-260 VAC) for RE Area or (90-300VAC) for NRE
Rated frequency range 50Hz ± 2Hz
Nominal output voltage 48VDC
Type of batteries Lead Acid-Tubular, SMF/VRLA
Voltage setting Float Boost
Lead Acid Tubular 2.2V/Cell 2.4-2.7V/Cell
SMF/VRLA 2.25V/Cell 2.3V/Cell
Rated Current Adjustment 80%-100%
Battery current adjustment 50%-100% of the Max. Battery Charging Current (10% of the Ah)
Type of SMR used a.     48V/25A (S48-25)
b. 48V/12.5A (S48-12.5)
Ultimate Rack capacity As per the Customer’s order. Standard SMR modules of required rating are connected in parallel load sharing arrangement
Type of voltage regulator High Frequency Switched Mode using MOSFETs
Inherent voltage regulation ±1% for specified input voltage variation output load from 0 to rated (100%) Load
Power Factor

·         0.95 lag to 0.98 leading at nominal input & output voltages and load 75% to 100%.

·          0.90 lag to 0.90 lead in any other working conditions and load between 25% to 100%.

Efficiency – Better than 85% at nominal input, output at 100% load.
– Better than 80% for other specified input, output conditions and load “between” 25% to 100%.
THD – TVHD ≤ 10%
– TCHD ≤ 10% contributed.
Ripple content at nominal input supply and rated load output 300mV Pk-Pk, 4mV Psophometric
Metering on LCD Display – AC Voltage
– Load Voltage
– Battery Voltage
– System Current
– Battery Current
Status on LCD display – Float
– Boost
Protection Alarms and Indications on LCD – Lightening and Line Surge Suppressor
– Load Voltage High
– DC Over Voltage
– DC Under Voltage
– Over Load/Short circuit
– FRBC Fail
– Temp. Comp. Fail
– Mains Fail
– Mains Output of range
– Battery Isolation
– Battery Reverse
Remote Alarms Two sets of Potential Free contacts for Mains fail, DC Under Voltage, DC Over voltage and FRFC Fail
Remote Communication Through RS-232/RS-485 MODBUS protocol
Noise level at ambient noise of 45dBA 60 dBA Max at a Distance of 1 meter
Insulation level a) AC I/P TO E    >2ME
b) DC O/P TO E   >1ME
c) AC I/P TO DC O/P >5ME
EMI/EMC COMPLIANCE As per IEC 61000-4, IEC CISPR22
MECHANICAL
Installation Indoor in a well ventilated area
Enclosure Rack, CRCA, 1.5mm
Degree of protection Rack-IP-31
Color Siemens Gray-RAL7032
Dimension W-600, D-600, H-2000mm Max.
Main I/P, O/P connections rack Through rail mounted terminals.
CLIMATIC
Ambient Temperature -5°C-55°C
Storage temperature -10°C-70°C
Relative humidity 95% non-condensing
Cooling Forced air
Altitude 1000M max. above SML

INFORMATION TO BE SUPPLIED BY THE PURCHASER

  • Type of battery to be used, VRLA or conventional lead acid.
  • For single phase either 90-300V or 165-260V
  • Battery capacity and number of banks.
  • Ultimate expandable capacity of power plant.
  • Type, number and configuration of SMR modules.
  • Power plant to work as Float Rectifier-cum-charger (FR-FC, N+1) or Float rectifier cum-boost charger (FRBC, N+2) depending on type of Lead Acid battery used SMF-VRLA, LM-Conventional respectively.

Power System Configuration: The configuration of 48 V DC Power Plant with FR-FC & FR-BC Modules shall be as under:

S. No. Basic SMR Module Configuration Permissible Ultimate Capacity
1 12.5A FR-FC (n+1) 50A
2 25A FR-FC (n+1) 150A
3 50A FR-FC (n+1) 800A
4 12.5A FR-BC (n+2) 50A
5 25A FR-BC (n+2) 150A
6 50A FR-BC (n+2) 800A

The FR-FC or FR-BC modules shall be housed in (n+1) or (n+2) parallel configuration in a single rack where ‘n’ is the actual required number of FR-FC, FR-BC modules for meeting the particular load requirement.
Railway shall indicate the Type, number and configuration of SMR modules, depending upon the load requirement. Railway shall also indicate Ultimate Expandable Capacity considering future expansion requirement.

Rack Configuration:

  • Float-Rectifier Cum Float Charger (FR-FC) Modules or Float Rectifier cum Boost Charger (FR-BC) Modules.
  • Distribution-switching-control-alarm Arrangement (DSCA)
  • The number and rating of FR-FC, FR-BC modules shall be provided as per purchaser’s requirement. The distribution-switching-control-alarm Arrangement (DSCA) shall be provided for the Ultimate Expandable Capacity. All factory wiring for the rack shall be for the Ultimate Expandable Capacity so that only plugging-in of FR-FC or FR-BC module shall enhance the DC Power output.