TIANJIN ESTEL ELECTRONIC SCIENCE AND TECHNOLOGY CO., LTD

 

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STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module

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STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module

China STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module supplier

Large Image :  STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module

Product Details:

Place of Origin: China
Brand Name: ESTEL
Certification: ISO9001:2008
Model Number: STC-CPL48150ER

Payment & Shipping Terms:

Minimum Order Quantity: 1 Set
Packaging Details: Wooden Case
Delivery Time: 15~20 Days
Payment Terms: T/T,L/C
Supply Ability: 10000 Sets
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Detailed Product Description

STC-CPL48150ER Embedded Power System
  Input:90~290Vac; Output: -42~-58Vdc
Application
 

■   Small scale program controlled exchanges

■   Access network

■   Transmission equipment

■   Mobile communication

■   Satellite communication ground station

■   Microwave communication

 
Main features
Adoption of active power factor compensation technology with factor >0.98
Wide operating range of AC input voltage: 90~290Vac
Operating temperature range: -25℃~+55℃
Zero current/voltage switching tech with high efficiency ≥91%
Lifecycle of battery prolonged by perfect battery management,  including electrical charge/discharge management, battery temperature compensation, battery capacity test, reversal connection proof protection
Hot-swappable
Input over/under voltage protection
Output over voltage protection
Output over current protection
Output short circuit protection
Auto current sharing
Embedded mounting
   
The STC-CPL48150ER embedded power system consists of the distribution frame, monitoring module and rectifier module, with functions of AC lightning proof and DC current sharing. The monitor module supports outside signal input, communication transformation, AC/DC detection and contactor control. The whole system is of high reliability and performance, and can be operated through PC software.
 
 
Statement
1.The performance of STC-CPL48150ER embedded power system is detailed in the specification. Please learn the specification before any operation is conducted in compliance with safety rules. Our warrant will not apply to any damage of product caused by improper operation or utilization out of range specified in this specification.
2.The information in this specification is subject to change without any notice.
 
1. General Introduction
1.1 System configuration
 
The system consists of distribution unit, rectifier module (from 1 set, up to 3 sets) and monitoring module. The configuration is optional, as following table: 
 

Configuration

Rectifier Module

Monitoring Module

Distribution

Remark

Standard

STC-CPL4850RM 

STC-CPL-MA (With Ethernet Port)

AC distribution: 3-phase, 4-wire input,  4-pole AC breaker @ general line (32A);

DC distribution: Battery fuse 100A×2;

LVLD: 32A×4  16A×2 10A×2

LVBD: 63A×2

For details, please refer to the specifications of modules.

 
1.2 Operating principle
 
AC power is first input AC-INPUT MCB and then fed into the rectifier module after the EMI filtering. AC-INPUT acts as protection to over load and short circuit to AC power. The user’s battery is connected to the DC output side through MCB BAT and KM2, and the circuit breaker provides disconnection control, over-load and short-circuit protection to the battery.
Under normal conditions, every parameter of rectifier modules and distribution unit are all under control of the monitoring module, operating according to the pre-set parameter or user’s commands. If AC mains faults, the battery will power to the system. With the battery discharge, the terminal voltage of the battery starts to descend. When the voltage is under -47V±0.5V, the monitor send DC under voltage alarm signal and when the voltage is under -46.0V±0.5V (adjustable), the KM1cuts off non-priority loads and retaining power to priority loads. If the voltage drops to -43.0V±0.5V (adjustable), the KM2 will cut off output of priority loads and then the power system will stop working. If the external AC mains recovers, the system will normally work again. (All above monitoring data are system default values and can be reset by user).
Except for battery over-discharge protection, battery or load over-temperature protection is prohibitive under default, users can send command to activate or inactivate according to the demanding. 
 
2. System Properties
 

Environment

Item

Min.

Typical

Max.

Unit

Remark

Operating temperature

-25

 

55

°C

When ≥55°C, decreased power output 

Storage temperature

-40

 

80

°C

 

Humidity

10

 

90

%

Relative humidity without condensing

Atmospheric pressure

70

 

106

KPa

 

Altitude

0

 

3000

m

 

Cooling

Forced cooling with fan

 
 
 

Input

Item

Min.

Typical

Max.

Unit

Remark

Input voltage range

90

220

290

Vac

 

Input frequency

45

50

65

Hz

 

Input current

 

 

20

A

 

Power factor

0.98

 

 

 

Rated load

Input over voltage protection 

300

 

 

Vac

Automatically recoverable

Input over voltage recovery 

290

 

 

Vac

Return difference ≥5V

Input under voltage protection 

 

 

85

Vac

Automatically recoverable

Input under voltage recovery 

 

 

90

Vac

Return difference ≥5V

Input over current protection

 

 

 

 

MCB in AC Input supplied protection 

 

Output

Item

Min.

Typical 

Max.

Unit

Remark

Output voltage range

42

53.5

58

Vdc

Adjustable by monitor, tested in no load

Output power

 

8000

 

W

Make sure rated 4800W output when input voltage is 176~290VAC (rated power includes battery power plus load power)

 

4000

 

W

150~175VAC input

 

2000

 

W

90~150VAC input

Output over voltage protection 

58.5

 

60.5

Vdc

Lock up

Output current limiting protection 

 

 

 

 

Current limiting protection

Output short circuit protection

 

 

 

 

Long-term short circuit protection, automatically recoverable

Over temperature protection

 

 

 

 

Automatically recoverable in normal temperature 65℃

Battery power-down protection

 

 

 

 

Battery power-down protection

Battery polarities reversal connection protection

 

 

 

 

No damage on battery and power system

Voltage withstand efficiency

 

 

±1

%

 

 

Normal Parameters

Item

Min.

Typical

Max.

Unit

Remark

Temperature coefficient

 

 

±0.2

‰/℃

 

Current sharing unbalance 

 

 

±5

%

Within 50~100%load range

Start-up/shunt-down overshoot range

 

 

±5

%

Any module is removed when operating, (the load current should be less than total output current), the system output voltage fluctuates 

Dynamic response recovery time

 

 

200

uS

25%~50%~25% load variation

50%~75%~50% load variation

Dynamic response overshoot

 

 

±5

%

Rated output voltage, rated load current

Efficiency 

90

92

 

%

220Vac input, rated input voltage, rated load current 

83

 

 

%

110Vac input, rated output voltage, rated load current 

Start-up time

3

 

8

S

pre-current limiting is fitted with start-up output between rated start up input voltage and rated output voltage established period

Pressure drop

 

 

500

mV

 

Peak-peak noise voltage 

 

 

200

mV

 

Psophometrically weighted noise voltage

 

 

2

mV

 

 

Other Parameters

Item

Requirement

Acoustic noise

≤55dB(A)

Smelling

any abnormal and poisonous smelling is not allowed

Components

rated temperature of  the electrolytic capacitor ≥105℃

Hot swappable

the rectifier module meets the hot-swappable requirement

Mixed insertion

rectifier modules can mixed insertion

Ineffective separation

rectifier module can separate with system when it is ineffective 

Cooling

Forced cooling by fan mounted on rectifier, face in, back out. The fan is mounted on rectifier front panel; can be disassembled. Fan speed and temperature can be controlled by user

 

Insulation Rating

Parameters

Min.

Typical

Max.

Unit

Remark

Input-chassis

 

750

 

Vdc

 

Input-output

 

1414

 

Vdc

 

Output-chassis

 

750

 

Vdc

 

Insulating Resistance

relative humidity is 90%, 
In normal atmospheric pressure, when relative humidity is 90%, testing voltage is 500VDC, the insulating  voltage of input-output, input-grounding, output-grounding is ≥10MΩ

 

3. Mechanical Properties

 

Mechanical specifications

Dimensions (Overall)

482.6*350*219.3mm 

Weight(kg)(Overall)

≤(Inclusive of module)

         ≤( Frame + Distribution, exclusive of module)

STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module

4. Installation Instruction
 
4.1 Module Front View
 
STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module
4.2 Installation
 
First insert the embedded power system to the specified location till the system is well fixed. Keep the 8 fixing holes on the bracket in line with those on the cabinet and then screw up 8pcs M4 cross rounded head screws. Finally complete the installation after tightening the screw.
Note: The cabinet shall be provided by the user.
 
5. Electric connection
 
5.1 Electrical connection
Chassis connects with external electric through system interface board. As shown in figure below:
 
STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module
MCB descriptions:
(1)  4-phase AC input MCB; AC SPD;
(2)  LOAD (+)--power load+ (10 MCBs), 
LOAD (-)--power load- (copper bar at back of system);
(3)  BATT (-)-battery- (fuse or MCB), 
BATT (+) ---battery+ (copper bar at the back of system)
 
5.2 Process of electric connections
 
Electric connection between main cabinet and external component includes: connection of AC input line, connection of DC output and battery, connection of communication cables, connection of GND cables. The main requirements of electrical connection are safety and reliability. The following are detailed description.
(1) AC input cable connections
The connectors for AC input cable are screwed double (4-pin) on the front panel of system. The AC cable can be directly crimped to the connector.
(2) Connection of DC load cables
The load connection connectors of power system are (10 MCBs), locating on the front panel of the system. The cable can be directly inserted to the MCB.
a. The specifications and model of the cables shall be according to the engineering design requirements.
b. Connect one end of positive connection cable to the positive copper bar at the back of system;
c. Connect one end of negative connection cable to the MCB or fuse at the front of system;
(3) Connection of DC battery cables
Connection terminal of system and battery is fuse or MCB, indicated as BAT-. The cable can be directly inserted to the MCB or screwed upon the fuse holder. The detailed process of battery connection is as following: 
a. Prepare positive connection cables and negative connection cables(including terminals and polarity identifications ready).
b. Fasten up the battery connection cable
c. Connect one end of positive connection cable to the positive copper bar on back of system;
d. Connect one end of negative connection cable to the MCB or fuse at the front of system;
(4) Recommended cable specifications
 

Item

Sign

AWG/ Min. section(#/mm2)

AWG / Max. section(#/mm2)

Temp rating(℃)

Withstand voltage

(V)

Output load wire

Load1, Load1-,

Load2, Load2-

12#/4

10#/5.5

105

600

Output load wire

Load3, Load3-

Load4, Load4-

6#/10

4#/16

105

600

Input GND wire

PEin

9#/6

6#/10

105

600

Mains neutral wire

Nin

6#/10

4#/16

105

600

Mains live wire

Lin

6#/10

4#/16

105

600

Battery +

(BATT +)

2#/35

1#/50

105

600

Battery -

(BATT -)

2#/35

1#/50

105

600

Output load wire

Load1, Load1-,

Load2, Load2-

12#/4

10#/5.5

105

600

 
(5) Connection of GND cables
PE connection: The GND section is near the left bracket of system. Connect the chassis GND point of system main cabinet and external earth with cable of 10mm2 above.
(6) Connection of communication cables
LAN and RS-485, communication interface of STC-CPL48150ER, locates at the monitoring module, function for communication with the host.
LAN Ethernet communication code: Directly connect to the PC with cross wires or with common wire through a router.
RS-485 communication mode:
a. Connect one end of communication cable to RS-485 on front board of STC-CPL48150ER
b. Pin2 of communication cable linked to RS-485+ (at RS-485 converter-RS485 to RS) , Pin 3 linked to RS485-, connect COM interface of PC through RS232.
 
5.3 Instruction of Interfaces on the Back Panel
 
The rectifier modules and monitor module are connected on back panel of system STC-CPL48150ER, through which AC output goes to current collection bar; control signals of the monitor modules drives the contactor; AC SPD within distribution frame transfers signals to monitor;  monitors and rectifiers communicate with each other; signals of current sharing goes into monitor. 
 
STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module
 Draft of Back Panel Design
 
Interfaces list is as following:
 

Contactor NO.

Terminal type

I/O

Signal function

Other panel, contact and signal connected

Remark

J2

AC voltage(A phase)detection 

I

AC voltage(A phase)signal input

AC A phase voltage

None

J3

AC SPD alarm signal 

I

AC PSD alarm signal input

AC PSD connection alarm signal

None

J4

Battery conactor control signal 

0

Battery contactor control signal output

Connection between cable and contactor coil

Installation requirement marked on coil terminal of sample signal

J5

Battery current sharing interface 

I

Battery current sharing sample signal input

Cable connection current sharing sample signal

Cable of sample signal includes positive and negtive ones

J6

Load contactor control signal interface 

O

Load contactor control signal output

Cable connection contactor control coil

Installation requirement marked on coil terminal of sample signal

J7

Load current sharing signal interface 

I

Load current sharing sample signal input

Sample signal of cable connection current sharer 

Cable of sample signal includes positive and negative ones

CON8

Load and battery output signal detection terminal

I

Load and battery signal detection input

None

Attention:

D1-D2 battery

D3-D14 load

CON1

CON2

 CON3

Rectifier module interface

I/O

Rectifier signal input and output, rectifier power output

None

None

CON7

PMU 96PIN connector 

I/O

Monitor signal input and output

Terminal connects with PMU 

None

 

6. STC-CPL48150ER Distribution Frame

STC-CPL48150ER,Rectifier,150A,3 Phase,Five 30A Rectifier Modules and one Monitoring Module

7.1 Monitor Module Function

Function

Remark

Remote monitoring of the host

The host can conduct enquiries, settings and control upon the monitoring and realize the remote message, remote sense and remote control.

Rectifier management by monitoring module

To send controlling orders to or get data from the rectifier module via RS485 communication.

Battery management

To manage the low voltage, power down, equalizing/float charge, temperature compensation and capacity testing of the battery.

Output management by monitoring module

To inspect and control the system

LED indicator

Signal indication

6 dry contacts output

Stem nodes setting

COM port signal

RS232

LCD display 

to conduct setting and modification on the menu

For details, please refer to specifications of “GPE 48150D”.

 

7.2 PC Software

Please refer to “Instruction of PC Software” documents for the detailed information.
 
8. GPR4850D Rectifier Module
 
8.1 Instruction of Rectifier Parameters
 

Item

Unit

Min.

Typical

Max.

Testing conditions

AC Input Voltage

Vac

90

220

290

 

AC input voltage frequency

Hz

45

50

65

Rated load

Input power factor

 

0.99

 

 

Rated voltage/rated load

Output voltage range

Vdc

44

53.5

58

 

Output current

A

0

50

 

176~290V AC input

A

0

22

 

90~175V AC input

Output voltage withstand regulation

 

 

 

±1%

 

Peak-peak value Vp-p

mV

 

 

200

Tested with each of 0.1uF ceramic capacitor and 10uF electrolytic capacitor with 20MHzband width.

Output power

W

0

2900

 

When 176Vac~290Vac input, 2900W output is met with 

W

0

1200

 

90Vac~175Vac input

Output efficiency

%

92

93

 

220V AC input  (1. when input voltage is 220Vac, rated output voltage, 25% above rated output voltage. 2. up to 94%)

%

86

 

 

110V AC input

Input over voltage protection

Vdc

300

 

 

Automatically recoverable

Input over voltage protection recovery point

Vdc

290

 

 

 

Input under voltage protection

Vdc

 

 

85

Automatically recoverable

Input under voltage protection recovery point

Vdc

 

 

90

 

Output over voltage protection point

V

58.5

59

60.5

1. module internal failure will result in over voltage and module itself locked up

2. when external voltage above over voltage protection point is added, module works normally. 

Output current limiting protection

A

54

 

 

Automatically recoverable

Short circuit protection 

A

long-term short circuit is available, automatically recoverable

Over temperature protection

 

Automatically recoverable under 65℃ ambient temperature

The detailed information is listed in GPR4850D rectifier specification

 

8.2 Installation of Rectifier Module
 
Handles on panel of rectifier module and monitoring module are equipped. When inserting component into the main cabinet, the operator shall clutch the handle with one hand while holding it with the other hand. Slowly push the component into its slot until the connection terminal on back of the component inserted into corresponding socket of system bar in the main cabinet. Finally, finish the installation by firmly fixing the screw on the panel to the main cabinet. When removing component from the main cabinet, first screw off the bolt on panel then slowly remove the component from its slot while clutching the handle.
 
9. System Maintenance
 
(1) Failure: yellow LED on rectifier module flickers continuously, communication fails;
Maintenance solution: check the communication network to see whether the internet connection is loose or internet interface is damaged or not. 
(2) Failure: yellow LED on rectifier lights on;
Maintenance solution: check whether the fan is blocked, load current exceeds the max. value; AC voltage is too lower, then the auto rate decrease starts; over temperature pre-alarm starts; remote shut-down is started on PC software.
(3) Failure: Red LED on rectifier lights on;
Maintenance solution: check whether the voltage is too high/too low or under voltage protection is on; fan is blocked; ambient temperature is too high; load is short circuit or not.
If above mentioned parts are ok but the red LED is still on, then there is problem on the module, please return it to factory for repairing.
(4) Failure: Yellow, red, green LEDs on rectifier are all off;
Maintenance solution: Firstly check whether AC input is available or not, if not, then check the electrical circuit; if yes, the module is in malfunction, please return the module to factory for repairing.
       

Contact Details
TIANJIN ESTEL ELECTRONIC SCIENCE AND TECHNOLOGY CO., LTD

Contact Person: Ms. Fiona Liang

Tel: 86--13752765943

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