4.5 kW Underslung Constant Voltage, Regulated CUM Emergency Battery Charger For LHB AC Coaches
Specification No. RDSO/PE/SPEC/AC/0183-2018 (Rev-1) & RDSO/PE/SPEC/AC/0183-2018 (Rev-1)
Features:
- Natural-cooled IGBT/SiC based, DSP-controlled charger with keypad-settable voltage and current limiting
- Dual-mode operation with 4.5 kW RBC in normal mode and 2.5 kW EBC backup in emergency mode
- Built-in protections including over/under voltage, short-circuit, reverse polarity, earth leakage, and galvanic isolation
- LED indications, RTC-based fault logging with 300+ events, and USB port for easy data download
- Rugged IP65 stainless steel enclosure, vibration-tested, and designed for reliable underslung mounting on LHB coaches
Technical Specifications:
| Ratings & I/O | |
|---|---|
| RBC Input | 415 V AC, 3-phase, 4-wire, 50 Hz; THD ≤ 10% |
| RBC Output | 110–135 V DC (keypad-settable), 35 A max; Battery charge current 10–15 A (keypad-settable) |
| Battery Type | 70/120 Ah lead-acid (flooded or VRLA) |
| EBC Input | 240 V AC single-phase, 50 Hz |
| EBC Output | 110 V ± 5% DC, 22 A, up to 2.5 kW |
| Operating Modes | |
| Normal | RBC feeds full 4.5 kW; EBC on standby |
| Emergency | EBC auto-activates on RBC failure; feeds 2.5 kW at 110 V DC; “Emergency Mode ON” LED provided |
| Regulation, Efficiency & Ripple | |
| Output Regulation | 122 ± 2% V during normal charging across input/load range |
| Efficiency | RBC ≥ 85% (½-load), ≥ 92% (full-load); EBC ≥ 90% (full-load) |
| Ripple (r.m.s.) | RBC: Voltage ≤ 2%, Current ≤ 3%; EBC: Voltage ≤ 2% at full load |
| Environmental & Mechanical | |
| Ambient Conditions | −5 °C to +55 °C; RH up to 98%; vibration per IEC 61373 (≈ 3 g); altitude ≤ 1200 m |
| Enclosure | IP-65 SS-304, 2.0 mm; natural cooling; under-slung mounting |
| Dimensions | L: 900 mm (max), W: 600 mm (max), H: 650 mm (max); Mounting hole CTC L: 850 ±0.8, W: 300 ±0.5 |
| Weight | ≤ 120 kg |
| Protections | |
| RBC Input | O/V–U/V trip: 480 ±5 V / 300 ±5 V; withstand 510 V AC for 2 min; auto-reset |
| RBC Output | O/V trip: 136 ±2 V; Current limit: 35 A total, 10–15 A battery (keypad-settable); 42 A overload |
| EBC Protection | Input O/V & U/V at 240 V ±15%; Output current limit = 24 A |
| General Protection | Reverse polarity, short-circuit protection; earth-leakage indication >≈30 mA; IP65 protection; galvanic isolation |
| Indications & Diagnostics | |
| LED Indications | R/Y/B, battery charging ON, single-phasing, +/− earth-leakage, battery not healthy, emergency mode ON |
| Diagnostics | Fault log stores last ≥ 300 events with RTC; USB port for data download (FIFO, no deletion) |
| Construction Highlights | |
| Industrial-grade electronics; FR-4 PCBs; SS hardware; H-class HF transformer with galvanic isolation; SS-304/S2 or SS-304/L enclosure; two M10 earthing pads | |