CP Power and Automation Ltd

110Vdc Dual Charger System with 110Vac Input

Dual 110Vdc Charger Application

The customer required a dual 110Vdc Battery Charger powered from a 110Vac input, to run in a warm Middle East environment. The charger needed to fit into a very slim space and have the following charging characteristics:

Solution

Our engineers built two ZAT3000/110/25 power supplies / battery chargers into a slim-line IP54 cabinet just 210mm deep, with cooling fans, gland plate and output breakers. The ZAT units are rated at 110Vdc 25A but when running on 110Vac are de-rated to provide a 110Vdc 10A output each

50kW 250V DC Power Supply with Polarity Reversal

Application

The customer required a 0-250Vdc 0-200A (50kW) power supply for an electrolysis application. In order to reduce deposits building up on the electrodes, the application needed the polarity of the DC supply to be reversed at a variable time interval set by the customer. Because the end destination was Canada, it was required to operate from a 575Vac 3 Phase Supply and to be compliant with the requirements of CSA.  

Solution

A 50kW 0-250Vdc, 0-200A Controllable DC Power Supply from our range was modified to work from a 575Vac 3 phase input.

Our engineering team built a PLC based control panel which allowed the customer access via an HMI on the door to control the process and change variables such as changeover time, output voltage, current limit etc. The polarity changeover was achieved using a complex contactor arrangement whilst at the same time controlling the output of the power supply to a zero value at the point of switch over for extra protection / prolonged life.

The end destination for this product was Canada and consequently CSA approval was requested. Our solution was built to meet the requirements of CSA and was then tested and approved once it arrived in Canada as it was not possible to have the testing done in the UK.

The great benefit of the PLC control system to manage the process was the display and adjustment of values via a touchscreen display, the controlling of pumps, and the ability to have an alarm log easily accessible via the HMI.

Electric Vehicle Motor and Controller Testing

Introduction

This application note provides an example of testing an E-Motor and Controller for electric vehicles. Traditional test setups require a dedicated DC source and load in parallel to deal with bi-directional energy flow. This can require a complex test setup to coordinate energy flow and to avoid damaging expensive equipment.

The PSB 9000 is a bi-directional DC source and electronic load which simplifies the test setup, avoids catastrophic damage and decreases test times. This electronic load has the unique option of back-feeding converted energy into the grid.

Rack Mountded 24Vdc DC UPS for Rail Applications

Application

The customer required a battery backed 24Vdc 20A supply for an on board application to power track monitoring equipment. There was limited space available within the 19” cabinet (5U max), so the requirement was fit the largest battery possible within the confines of the rack.

Solution

Our engineers designed a 19" Rack Mount DC UPS Solution. The system operated from a 230Vac mains input and provided a 22A 24Vdc output with an integral 24Vdc 15Ah Battery, all fitted into a 3U 19" Chassis. The rack was ruggedised to comply with the requirements of EN50155 for shock and vibration.

All the connections are made at the rear of the rack and both the battery and main power output are protected with easy to change fuses. The system also provides a 30A low voltage disconnect relay to protect the battery in the event of prolonged discharge.

A full range of signals are available via a set of phoenix terminals, including mains fail alarm, DC OK signal and battery low alarm

72Vdc Portable Battery Charger for Rail Application

Application

The customer had a situation where the Pantograph on their trains needed to be lifted to make connection with overhead cables. This was done via a battery system which was normally charged during the running of the train. In depot / servicing situations these batteries were sometimes run flat which meant the train could not be started / moved without first recharging this battery pack.

Solution

Our engineers designed a visible yellow cabinet on castors and were issued with a diecast metal battery plug by the train company. Inside the cabinet were 4 x 72Vdc 600W modules set up to produce an 83.7Vdc charging voltage, but because these modules are identical they can be easily interchanged in the event of a single module failure. The system operated from a 230Vac mains input, again with a specific mains plug to suit the customers site.

All the connections are made via input and output cables wound onto a handy cable storage device at the rear. There is a handle for easy maneuvering and version 2 of the product was fitted with a flashing beacon to show charging operation.

Note: Once commissioning on site there was an issue with a very low earth leakage trip level on the customers distribution board. Our engineers managed to solve this by changing capacitors in the input stage of the power modules to ensure compatibility.

Rack Mounted 24Vdc DC UPS for Rail Applications

Application

The customer required a battery backed 24Vdc 20A supply for an on board application to power track monitoring equipment. There was limited space available within the 19” cabinet (5U max), so the requirement was fit the largest battery possible within the confines of the rack.

Solution

Our engineers designed a 19" Rack Mount DC UPS Solution. The system operated from a 230Vac mains input and provided a 22A 24Vdc output with an integral 24Vdc 15Ah Battery, all fitted into a 3U 19" Chassis. The rack was ruggedised to comply with the requirements of EN50155 for shock and vibration.

All the connections are made at the rear of the rack and both the battery and main power output are protected with easy to change fuses. The system also provides a 30A low voltage disconnect relay to protect the battery in the event of prolonged discharge.

A full range of signals are available via a set of phoenix terminals, including mains fail alarm, DC OK signal and battery low alarm