SMPS BASED BATTERY CHARGER (POWER PLANT) FOR RAILWAY’S TELECOM APPLICATION
The 48V SMPS based battery charger 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 Telecom SMPS 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 Telecom 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%. |
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| 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%. |
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| THD | – TVHD ≤ 10% – TCHD ≤ 10% contributed. |
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| 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 |
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| Status on LCD display | – Float – Boost |
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| 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 |
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| 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 |
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| 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.
