A Brief Overview
Helios Power Solutions developed a bespoke dual-output, modular battery charger system for a transmission substation in Northern New Zealand. The project was commissioned by an undisclosed electricity distribution and generation company. The solution comprised two 21U, 5.5kW 110VDC and 1.2kW 24VDC battery charger systems, including battery banks.
These chargers were designed to be wall-mounted, addressing spatial constraints while ensuring redundant power for both critical and non-critical loads. Notable features included high-temperature operation, expandability via additional rectifier modules, and remote monitoring capabilities through a web interface, SNMP via Ethernet, and email reporting.
The system’s batteries, chosen for their longevity and high-temperature tolerance, provide stable backup power, enhancing the substation’s reliability and operational efficiency.
Key Facts
- End customer: Electricity distribution and generation company in NZ (name cannot be disclosed)
- Location: North Island, New Zealand
- Solution:Â 2X21U 5.5kW 110VDC & 1.2kW 24VDC Battery Charger Systems + Battery Banks
Features
- 2 XÂ CAB 907Â 5.5kW 110VDC and 1.2kW 24VDC modular, redundant, compact, fully controllable battery chargers were fit in 21U wall mounted cabinet
- 4 x CSB 409 24V Diode Rack with 1XP95 diodes, ensures the load output is configured for redundant application, there are 2 in each CAB 907
- 2 X BR154 Battery Rack 3 tier for 18 X NSB210FT HT RED 210Ah – High Temperature Battery. (110VDC Chargers)
- 2 X BR155 Battery Rack 3 tier for 2 X NSB210FT HT RED 210Ah – High Temperature Battery. (24VDC Chargers)
Customer's Requirement
Our customer required two redundant wall-mounted battery chargers 110V 5kW and 24V 1kW respectively, for powering the critical and non critical loads in a new transmission substation in the far north of New Zealand. Each one with full N+N redundancy on the battery banks for each voltage. Space restrictions were advised. The end user was currently using switch mode and modular battery charger technology.
High-temperature operation was also required, so power conversion equipment as well as batteries must meet this specific spec.
Helios' Solution
2X21U 5.5kW 110VDC & 1.2kW 24VDC Battery Charger Systems + Battery Banks
Key design features were advised and wall mounting required, our design engineers faced some challenges due to weight of equipment and heat dissipation but at the end came up with the following proposal.
CAB 907 Main Technical Features
- 400VAC Input for each charger
- Expandable – the power rating of each charger can be increased by adding rectifier modules
- Each out voltage is adjusted by the temperature compensation feature of the unit
- Extractor –fan power independably from external 230VAC
- Chargers configured for redundancy with output diodes
- Mains, battery and load MCBs are front access and monitored by the controller
- Various alarms per charger
- Remote monitoring and programming with a webpage interface
- SNMP v2.5 via Ethernet & Modbus
- Email Reporting
Battery Racks & Batteries
Four external battery racks with 212Ah high temperature batteries NSB210FT HT RED were supplied to back up the complete 24V and 110V protection and communications system. Each battery rack has its battery test & battery terminals and fuses.
Environment is key when selecting batteries which will supply the backup power in case loss of AC of mains supply. Temperature operation, vibration and design life are some of the factors that might affect the operative life of the complete DC System.
The NSB210 HT RED 12V 210Ah High-temperature, front terminal, was the battery chosen to provide 400Ah and 200Ah to each battery bank. A key factor for choosing this battery, was the long design life at the expected peak temperature, 14 years at 30°C .
Primary Products Installed
- Power limiting and wide range AC input.
- Available in 24, 48, , 125, 125 & 220 VDC standard output variants.
- Hot Swappable.
- Local and remote setup, adjustment.
- Universal Controller for all 24 - 220 VDC The Sol Series Cordex Systems
- Integrated USB host for local firmware upgrades, configuration updates & system backup/restoration
- Seamless integration of multiple energy systems
- External ADIO peripherals for customizing unique I/O configurations
- Pure lead electrochemistry greatly increases temp and corrosion resistance, while reducing component ageing
- Thin plates deliver large surface area, high power density and low resistance
- Design life 15 years at 20°C (68°F)
- Extra-long life at high temp operation 40°C (104°F)
- We usually have stock of NSB Series of High Temperature Batteries in our warehouse in Auckland ( 40Ah, 60Ah, 100Ah, 125Ah, 155Ah , 190Ah and 210Ah models), contact us at sales@heliosps.co.nz for further information.
