IP-RCD NONLINEAR RECTIFIER LOAD

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RCD load is a non-linear analog load used to test UPS power supplies, inverters, etc., to understand their true working capacity when carrying computer, network equipment and other non-linear loads.

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Details

An RCD load is a non-linear simulated load used to test UPS power supplies, inverters, etc., to understand their actual operating capabilities when driving non-linear loads such as computers and network equipment. Through precise detection of power supply output power and quality, it can prevent the power supply from being unable to drive the load or polluting the power grid during actual use, thus ensuring power supply safety. With the development of digitalization and networking in today's society, rectifying loads such as computers and network equipment are widely used. These loads, composed of rectifying filter circuits, have non-linear characteristics, and their resistance is not constant, requiring higher requirements for the output range and stability of the power supply equipment. Therefore, for network UPS power supplies, inverters, and other power supply equipment, it is necessary to use a simulated load with non-linear characteristics to debug and test parameters such as the peak factor.

Traditional RLC simulated loads are based on linear loads and cannot simulate the changing characteristics of non-linear loads, making it difficult to test the actual performance of UPS power supplies and inverters in data centers and network power environments. Only by using an RCD non-linear load can the most accurate judgment of the power supply equipment's output power and power quality be made.

Based on GB/T 7260.3-2003 {Uninterruptible power supply equipment (UPS) Part 3: Methods and test requirements for determining performance} and other relevant national standards, through in-depth research and development and testing, the design specifications and parameter standards of the RCD load have been determined, and a new RCD simulated load has been developed.

The IP-RCD load box uses new power consumption components for the resistive load. The resistors are heat-shrunk and sealed in stainless steel tubes. The outer surface of the steel tubes has insulated heat sinks, which are moisture-proof, corrosion-resistant, have good heat dissipation, high insulation, and are safe and reliable. The power density of the resistor elements is high, with no red-hot phenomenon. An independent cooling fan ensures the heat dissipation and service life of the entire system. The capacitive load uses original imported Hitachi capacitors with a working time of over 6000 hours. The fan uses a small axial flow fan with large air volume, good heat dissipation, and low noise. These features make the unit superior to imported products in terms of safety, reliability, and noise reduction.

Technical Requirements

◆ Customizable according to customer requirements

Product Material

1. Alloy Resistor

The core part of the load—the dry-type load module—converts electrical energy into thermal energy to perform continuous discharge tests on the generator sets, power supplies, and other equipment under test. Our company uses self-made alloy resistors to form the load module. Considering that the safety of dry-type loads is easily affected by temperature, strict quality control is implemented in terms of temperature coefficient and heat dissipation performance. The produced alloy resistors have small temperature drift, slow temperature rise, and fast heat dissipation, and have stronger heat resistance during full-load operation, allowing for stable operation over a long period.

Specific technical solutions and objectives are as follows:

(1) The alloy resistance wire material uses high-temperature resistant (can operate at up to 1300℃), electrically stable, and low temperature drift coefficient (5*10-5/℃) nickel-chromium alloy (NiCr6023). This alloy resistor represents the most advanced level of alloy resistor manufacturing technology currently available.

(2) The materials of each component of the power resistor are strictly specified. The tube body uses 321 stainless steel (1Cr18Ni9Ti) with high ductility and oxidation resistance. The filling material is export-grade electrical crystalline magnesium oxide powder (Sg-9), which conforms to the standard JBY-TE4088-199. During the manufacturing process, the magnesium sand density is 3.0g/cm3±0.2. The connecting screws and fixed screw columns use 304 stainless steel (0Cr18Ni9) that is corrosion-resistant and high-temperature resistant. Through strict and clear material control, it is possible to ensure that mass-produced alloy resistors have highly consistent performance.

(3) The heat sink uses 321 stainless steel material with a height of 7mm±2 and a thickness of 0.4mm±0.2. The winding interval of the heat sink is less than or equal to 3mm±0.2.

(4) The withstand voltage of a single power resistor is DC3000V or AC1500V, 50Hz for 1 minute without breakdown. By connecting multiple alloy resistors in series, the withstand voltage can reach 20kV.

(5) Under normal operating conditions, the average temperature of the heat sink of the alloy resistor is 300℃, and the maximum is 320℃, which is nearly 5 times the margin from the maximum temperature of the resistor (1300℃). This ensures that the alloy resistor can operate continuously for a long time.

(6) When the power resistor reaches 300-400, the temperature drift is still ?%, ensuring that the load resistance will not fluctuate greatly at high temperatures, and a stable power value can be loaded at any temperature.

(7) The load error is ?% regardless of whether it is cold or hot.

(8) The temperature at the outlet of the unit is 80℃ (1M range).

2. Capacitor

(1) Imported aluminum electrolytic capacitors are used. The imported capacitors used have a small volume, large capacity, and long service life. Aluminum electrolytic capacitors are usually made of metal foil (aluminum/tantalum) as the positive electrode and the insulating oxide layer (aluminum oxide/tantalum pentoxide) of the metal foil as the dielectric. The negative electrode of the aluminum electrolytic capacitor is made of thin paper/film or electrolyte polymer soaked in electrolyte (liquid electrolyte).

(2) The imported capacitors used have a withstand voltage of 450V and a withstand temperature of 105℃. When the load is operating normally, the voltage is around 290V~310V, and the temperature is in the range of 40℃~50℃.

Product Specifications

IP-RCD Rectifier Load
Model	IP-RCD5K	IP-RCD10K	IP-RCD50K	IP-RCD100K	IP-RCD300K
Main Technical Indicators of Load Box
Rated Voltage	AC220V	AC230V	AC380V	AC380V	AC380V
Frequency	50HZ/60HZ	50HZ/60HZ	50HZ/60HZ	50HZ/60HZ	50HZ/60HZ
Test Power	5KVar	10KVar	50KVar	100KVar	300KVar
Power Segmentation	0.05K-5K	0.1K-10K	1K-50K	1K-100K	1K-300K
Power Factor	±0.3-1.0	±0.3-1.0	±0.3-1.0	±0.3-1.0	±0.3-1.0
Quality Factor	Qf=1.0	Qf=1.0	Qf=1.0	Qf=1.0	Qf=1.0
Control Method	Manual/Automatic	Manual/Automatic	Manual/Automatic	Manual/Automatic	Manual/Automatic
Optional	AC Circuit Breaker	AC Circuit Breaker	AC Circuit Breaker/Button	Button/Touch Screen/PC	Button/Touch Screen/PC
Adjusting Precision	±3%	±3%	±3%	±3%	±3%
Meter Display	LED Digital Display	LED Digital Display	LED Digital Display	LED Digital Display	LED Digital Display
Optional	Voltage/Current	Voltage/Current	Voltage/Current	Voltage/Current	Voltage/Current
Current Precision	±0.5%	±0.5%	±0.5%	±0.5%	±0.5%
Voltage Precision	±5%	±5%	±5%	±5%	±5%
Load Protection (Optional)	Overtemperature Alarm	Overtemperature Alarm	Overtemperature Alarm	Overtemperature Alarm	Overtemperature Alarm
	Air Pressure Monitoring	Air Pressure Monitoring	Air Pressure Monitoring	Air Pressure Monitoring	Air Pressure Monitoring
	Overcurrent Protection	Overcurrent Protection	Overcurrent Protection	Overcurrent Protection	Overcurrent Protection
	Short Circuit Protection	Short Circuit Protection	Short Circuit Protection	Short Circuit Protection	Short Circuit Protection
Heat Dissipation Method	Forced Air Cooling	Forced Air Cooling	Forced Air Cooling	Forced Air Cooling	Forced Air Cooling
Operating Power Supply	AC220V	AC220V	AC380V	AC380V	AC380V
Volume	480700750	480700750	6501300900	9401600950	12001600950
Operating Environment	-10℃~+40℃	-10℃~+40℃	-10℃~+40℃	-10℃~+40℃	-10℃~+40℃
Optional Functions
Remote Control	PC Host/Remote Control Box
Communication Interface	232C/485/CAN
Protection Functions	Overcurrent protection, overvoltage protection, fan failure alarm

◆ Special specifications can be customized according to customer requirements (power, stepping, size, display, customized model circumference is slightly longer)

◆ Ordering and Selection Notes: To facilitate customers' better purchase of our products, please provide the following parameters before ordering:

1. Rated voltage, 2. Rated power, 3. Power stepping requirements, 4. Operating environment conditions, 5. Operating mode (default long-term operating mode)

Note: If the specification requirements cannot meet your needs, customization is available!

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