Project Details
Description:
Delivering 1200 A continuously at 28 Vdc requires more than scaling up a conventional rectifier. At this current level, input harmonics, thermal distribution, output stability and system monitoring become central design considerations. To meet these requirements, EPC engineered a 33.6 kW industrial rectifier based on a dual thyristor bridge and 12-pulse conversion architecture.
Input: 3 × 380 Vac + N + PE, 50/60 Hz — Output: 28 Vdc, 1200 A — Rated DC Power: 33.6 kW — Technology: Thyristor-controlled rectifier — Configuration: Dual AC/DC converter stages, 12-pulse — Input current THDi: 10–12% — Cooling: Forced-air ventilation — Communication: Modbus TCP/IP, RS485 and RS232 — Manufacturing lead time: 8–10 weeks.
High-current rectifiers can generate significant harmonic distortion on the upstream AC network. In this project, the input transformer incorporates star and delta secondary windings. The resulting 30-degree phase displacement allows the two thyristor bridges to operate as a 12-pulse conversion system, limiting input current THDi to approximately 10–12% under rated conditions — without requiring an active harmonic filter. An RFI filter is also installed at the system input to reduce conducted high-frequency interference.
The power stage is divided between two thyristor-controlled AC/DC converters connected to a common DC output bus. Each converter incorporates its own snubber network and dedicated thyristor driver board. This architecture provides balanced power conversion, improved thermal distribution, reduced electrical stress on individual power components, and easier maintenance and fault diagnosis.
The rectifier is controlled through a DSP-based platform managing thyristor firing, synchronisation, output regulation, alarms and system supervision. A front-mounted touchscreen HMI gives operators direct access to input and output measurements, operating status, load information, active alarms, charging and operating modes, and system diagnostics. NTC-based temperature compensation supports controlled battery-charging operation according to ambient or battery temperature conditions.
DC output current and voltage are continuously measured through dedicated transducers with 4–20 mA signals. The system also includes DC earth-leakage detection, input and output protection, emergency-stop input, dry-contact alarm relays, and monitored forced-air cooling. Modbus TCP/IP, RS485 and RS232 communication interfaces enable direct integration into industrial SCADA and BMS environments without requiring a separate monitoring platform.
The rectifier is suitable for continuous industrial DC supply and battery-charging applications where high output current, controlled harmonic performance and remote supervision are required. Typical applications include industrial production facilities, oil and gas installations, power generation and distribution, telecommunications infrastructure, transportation systems and critical DC auxiliary supplies.
CE işaretli olup IEC 60146-1, IEC 61204 ve EN 60335-1 standartlarına göre tasarlanmıştır. Sipariş onayından itibaren standart üretim süresi 8–10 haftadır.
