Recently, a U.S.-based customer successfully installed and commissioned a batch of high-power high-frequency switch-mode rectifiers supplied by Chengdu Xingtongli Power Supply Equipment Co., Ltd. These rectifiers, rated at 50V 5000A, are being used in an advanced hydrogen electrolysis system, marking another milestone in our commitment to supporting clean energy solutions worldwide.
Innovative Design and Reliable Performance
The rectifier system consists of six modular 45kW power units operating in parallel to deliver a total output power of 250kW. This modular approach ensures higher efficiency, ease of maintenance, and enhanced reliability. The system is controlled via an advanced PLC and touchscreen interface, offering precise monitoring and seamless operation.
Electrolytic Hydrogen Rectifier Specifications
|
Parameter |
Specification |
| Input Voltage | Three-phase AC 480V ±10% / 400V ±10% / Customizable |
| Input Frequency | 50Hz / 60Hz |
| Output Voltage | 50V DC (Adjustable) |
| Output Current | 5000A DC (Adjustable) |
| Rated Power | 250kW (6 × 45kW modules in parallel) |
| Rectification Mode | High-frequency switch-mode rectification |
| Control Method | PLC + HMI (Touchscreen Control) |
| Cooling Method | Air-cooled / Water-cooled |
| Efficiency | ≥ 90% |
| Power Factor | ≥ 0.9 |
| EMI Filtering | EMI filter reactor for reduced interference |
| Protection Functions | Overvoltage, Overcurrent, Overtemperature, Phase Loss, Short Circuit, Soft Start |
| Transformer Core | Nano-materials with low iron loss & high permeability |
| Busbar Material | Oxygen-free pure copper, tin-plated for corrosion resistance |
| Enclosure Coating | Acid-proof, anti-corrosion, electrostatic spraying |
| Environmental Conditions | Temperature: -10°C to 50°C, Humidity: ≤ 90% RH (non-condensing) |
| Installation Mode | Floor-mounted Cabinet / Customizable |
| Communication Interface | RS485 / MODBUS / CAN / Ethernet (Optional) |
Design Principle
Humanized operation and convenient maintenance: The system is designed with an openable door panel, ensuring that vulnerable parts are positioned for easy access, avoiding obstructions that complicate disassembly.
Safety and reliability: High-voltage and low-voltage lines are separated, with high-voltage danger signs placed in eye-catching locations and strong grounding measures in place.
Electromagnetic interference (EMI) reduction: An EMI filter reactor in the AC incoming line minimizes interference between the power supply and the grid.
High-efficiency components: The high-frequency main transformer core utilizes nano-materials with low iron loss and high magnetic permeability, while oxygen-free pure copper wire enhances conductivity.
Minimized interference and environmental protection: Strong and weak current lines are strictly separated with safe distances, and signal lines are shielded to prevent interference. Control circuits are isolated from strong magnetic fields and environmental pollutants such as dust and acid mist.
Durability and protection: Circuit boards undergo secondary paint dipping for moisture, dust, and corrosion resistance. Power cords and signal line contacts are sealed with silica gel to prevent leakage and corrosion.
Cabinet durability: The cabinet surface is treated with acid-proof, anti-corrosion coating and electrostatic spraying, making it suitable for corrosive environments containing acids, alkalis, and humidity.
User-friendly interface: The front panel of each power module features an AC input switch, a DC output current display, and a working status indicator. The entire system is controlled via PLC and HMI for intuitive operation.
Busbar and connection design: All electrical connections use oxygen-free pure copper, with an economic current density of ≤3A/mm². The copper bars are tinned to prevent oxidation and ensure long-term conductivity.
AC power design: The system operates on a three-phase AC480V±10% input, using a three-phase five-wire system.
Comprehensive protection system:
AC power protection: Equipped with AC phase loss, overvoltage, and undervoltage protection, with fault signals transmitted to the PLC for automatic protection.
Overcurrent protection: Limits the current when the load is short-circuited or exceeds the rated value.
Soft start protection: Gradually increases output current when the rectifier is powered on, preventing sudden surges.
Principle Sketch
The customer has shared on-site images of the rectifiers in operation, highlighting their seamless integration into the hydrogen production process. This successful deployment further demonstrates Chengdu Xingtongli’s expertise in delivering high-performance power solutions for industrial applications.
As the global demand for green hydrogen grows, Chengdu Xingtongli Power Supply Equipment Co., Ltd. remains committed to providing cutting-edge power solutions to support sustainable energy initiatives. For more information about our high-frequency rectifiers, feel free to contact us.
Post time: Mar-14-2025
