4.5kW Battery Charger

4.5 kW 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-2)

Description :

  • Naturally cooled, IGBT/SiC-based, DSP-controlled Constant Voltage Regulated cum Emergency Battery Charger.
  • Equipped with output current and voltage limiting features.
  • Suitable for underslung mounting on LHB coaches of Indian Railways.
  • Integrates a separate Emergency Battery Charger (EBC) to feed the coach if the main RBC path fails.
  • Operates on a nominal input 3-phase, 4-wire supply of 415 Volts ±15%, 50 Hz ±3%.

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); Total 35 A max; Battery charge current 10–15 A (settable)
Battery Type 70/120 Ah lead-acid (flooded or VRLA) banks
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 4.5 kW; EBC on standby
Emergency If RBC fails, EBC auto-activates to feed 2.5 kW at 110 V DC; “Emergency Mode ON” LED
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%; dusty/coastal; vibration IEC 61373 (≈3 g); altitude ≤1200 m
Enclosure IP-65 SS-304, 2.0 mm cubicle; natural cooling; under-slung mounting
Dimensions L: 900 mm (max); W: 600 mm (max); H: 650 mm (max); 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: 10–15 A battery (settable), 35 A total; overload 42 A
EBC Protection Input O/V & U/V: 240 V ±15%; Output current limit: 24 A
General Protection Reverse-polarity, short-circuit, earth-leakage >≈30 mA; galvanic isolation; IP65 protection
Indications & Diagnostics
LED Indications R/Y/B, battery charging ON, single-phasing, ±earth-leakage, battery not healthy, emergency mode ON
Diagnostics Logs ≥300 events with RTC; USB port download (FIFO, no deletion)
Construction Highlights
Industrial-grade electronics; FR-4 PCBs; SS hardware; H-class HF transformer; SS-304/S2 or SS-304/L enclosure; 2× M10 earthing pads