Battery Charger Training Manual

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r t+'.;l.dSlt a;s3nlJf aSJ.AJfSaudi Electricity Gompany

ARA$IAN BEMCO CONTRACTING CO- LTD.INDUSTRTAL & FOW€R pftOJECTS - DEVELOPmS A CONTRACTOR9

QURAYYAII COMBINED CYCLE POWER PLANT

INTEGRATED TRAINING MANUAL

DC SYSTEM

Battery charger Training Manual

Rev. Description Date Checked Released Date Type of doc.

Pag. N°

Pag. Tot.

- First Issue 24.06.2009 V.Lomonico 24.06.2009 A4 1 149 Approved Date P.Conti 24.06.2009 Cod. JGE411929

COMMESSA - JOB :

0 8 0 A 1 6 9 6

ORDINE N° - ORDER N°

B I O - Q U R - O 4 2 R E V . B D T D 2 1 . 0 4 . 2 0 0 8

CLIENTE - CUSTOMER :

DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :

C O N S T R U C T I O N O F Q U R A Y Y A H O P E N C Y C L E G A S T U R B I N E P O W E R P L A N T

B A T T E R I E S , B A T T E R Y C H A R G E R S & U P S S Y S T E M S IMPIANTO - SITE :

QURAYYAH SAUDI ARABIA

TITOLO - TITLE :

BATTERY CHARGER TRAINING MANUAL

MATRICOLA - PART NUMBER :

113-116-117-118-119-120-126 / 08

CODICE DOC. - DOCUMENT NUMBER :

JGE411929

Il presente documento è di esclusiva della BORRI S.r.l. che tutelerà i propri diritti a termine di legge This document remains the exlusive property of BORRI S.r.l. and we reserve all rights according to copyright laws

Battery charger Training Manual


Pag. N°

Pag. Tot.


BATTERY CHARGER TRAINING MANUAL

Index of sections Code

1 – BATTERY CHARGER TECH DATA JUD407772

2 – BATTERY CHARGER INSTALLATION,

OPERATING AND MAINTENANCE MANUAL JGE410502

3 – TEST PROCEDURE JUD411352

4 – BATTERY CHARGER CONFIGURATION JUD411353

5 – BATTERY CHARGER BLOCK DIAGRAM JUD411354

6 – BATTERY CHARGER MAINTENANCE JUD411546

7 – BATTERY CHARGER TROUBLESHOOTING PROCEDURES JUD411295

8 – BATTERY CHARGER APPENDIX SERVICE MANUAL JUD411479

Operating instr. for termal probe mounting on RTB.e JUD409515

Operating instr. for N_FS3011 board mounting JUD409517

Operating instr. for battery recharge LEM use JUD409518

BATTERY CHARGER

SERIES “ RTB_E ” GENERAL

TECHNICAL DATA

BATTERY CHARGER General data

Rev. Descrizione Description

Data Date

Emesso Issued

Controllato Checked

Approvato Approved

Lingua Language

Pagina Page

di Pag. of Pag.

First Issue 24/10/05 A.Ferri E. Simoni E. Simoni A Revision 07/06/07 P.Conti E. Simoni E. Simoni E 1 14 B Revision JSE410375 17/03/08 P.Conti E. Simoni E. Simoni Codice / Code

JUD407772

BATTERY CHARGER – GENERAL TECHNICAL DATA

Index

1 INTRODUCTION..............................2

2 GENERAL DESCRIPTION ..............2

3 TECHNICAL CHARACTERISTICS..2

4 PROGRAMMING AND PARAMETER SETTING..........................................2

5 ALARMS, STATUS AND SIGNALS 2

6 FRONT PANEL................................3

7 BATTERY CHARGER FUNCTIONS3 7.1 AUTOMATIC RECHARGE OF THE

BATTERY .................................................3 7.1.1 Recharge IU according to the DIN

41773 standard ........................................4 7.1.2 I1 I2 U recharge........................................4

7.1.3 U1 U2 I recharge ..................................... 4 7.2 TIMED BOOST CHARGE........................ 4 7.3 MANUAL RECHARGE ............................ 5

8 PARALLEL REDUNDANT OPERATION ....................................5

9 DESIGN STANDARDS ....................6

10 MECHANICAL LAYOUT..................6

11 SINGLE-LINE DIAGRAM.................6

12 DATASHEETS .................................7 12.1 RTB_E 24VDC OUTPUT ......................... 7 12.2 RTB_E 48VDC OUTPUT ......................... 9 12.3 RTB_E 110VDC OUTPUT ..................... 11 12.4 RTB_E 220VDC OUTPUT ..................... 13

Index of pictures

Picture 1 – Front panel ................................................3 Picture 2 – IU recharge................................................4 Picture 3 – I1 I2 U recharge.........................................4 Picture 4 – U1 U2 I recharge .......................................4 Picture 5 – Timed recharge .........................................5

Picture 6 – RTB_e in parallel with single battery ......... 5 Picture 7 – RTB_e in parallel with two separated batteries ...................................................................... 5 Picture 8 – Single-line diagram ................................... 6


2 of 14 JUD407772 Rev.B JSE410375 17/03/08

1 INTRODUCTION The Rectifier-Battery Charger (RTB_e) is a

static thyristor AC/DC converter, controlled by a 16-bit microprocessor. The control is full digital and the structure of the software is open. This allows us to configure the system and to modify its operation according to the customer’s Technical Specification (ST).

2 GENERAL DESCRIPTION The RTB_e rectifier converts the alternate

voltage in the input, with frequency and amplitude variable according to the ST, into a continuous output voltage that is stabilized in voltage and controlled in current, by means of a three-phase SCR rectifier bridge (6 pulses version) or a couple of bridges connected in parallel (12 pulses version).

The galvanic isolation of the input mains (when required by the ST) is carried out by means of a transformer. Additional protection against power surges, under and over voltage are included as a standard. Optionally we can provide a grounded screen between the and secondary windings and semiconductor fast transient protection devices (varistors).

A programmable soft-start, reducing the inrush current of the rectifier during the start up, is included as a standard.

The system is provided with an alphanumeric display interface and keyboard (front panel) for the programming of the parameters and the visualisation of the measurements. Also RS232 for PC remote and RS485 (MODBUS protocol) interfaces are available.

In “Manual Regulation” mode it is possible to set the output rectifier voltage by means of external potentiometers. In this modality a maximum current limitation (to be set) is also active.

The transfer command “AUTOMATIC/MANUAL” and vice-versa is activated by means of key on the front panel; it is also possible to carry out the same command through the remote PC.

The front panel shows the operating status of the equipment, all the measures, the alarms and settings. The memory history can store up to 500 events in a non volatile memory with calendar.

The system can be interfaced with similar equipment through a digital link for parallel operation with the equal sharing of the load (+/-5% tolerance) and automatic exclusion of the faulty unit.

The different parts composing a standard Rectifier-Battery Charger are: 1. Input MCCB and output Load switch (battery

breaker in option) 2. Insulation transformer

3. 6 or 12 pulses thyristor bridge 4. Output filter (to reduce the voltage the ripple

at < 1%) 5. Front panel with LCD, Keyboard, Leds and

Power Flow Diagram 6. Voltage control loop, total current and

battery current individual control loops

3 TECHNICAL CHARACTERISTICS For technical characteristics see the attached

data sheet.

4 PROGRAMMING AND PARAMETER SETTING

The parameter menu on the front panel allows to adjust the various intervention thresholds for the alarms and the status changes of the equipment.

In alternative the programming can be carried out by PC connected to the serial port RS232, using the dedicated software.

At the end of the setting the modified parameters must be memorized in the non-volatile memory (EEPROM).

5 ALARMS, STATUS AND SIGNALS

The RTB_e control system offers the following list of alarms and statuses to help the user to better understand the status of the Rectifier and Battery. For the complete description of the alarms and statuses below mentioned see the chapter FRONT PANEL of the Operating Manual.

ALARM DESCRIPTION Fix Progr.

A1 Mains Fault x A2 Blown Fuses x A3 High Temperature x A4 Overload x A4 Thermal Image x A5 Max Out Voltage x A6 Min Out Voltage x A7 Charging Fault x A8 Fans Failure x A9 Open C. Breaker x

A91 RICB Open A92 BCB Open A93 ROCB Open

A10 Earth Fault x A11 Free Description x A12 Free Description x A13 Free Description x A14 Free Description x A15 EEProm Error x A16 Emergency Level x

RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 3 of 14

The first column indicates the alarm code. The alarm A4 stands for both overload and thermal image (see the chapter FRONT PANEL). The alarm A9 is splitted into three sub-alarms to show which breaker is actually open. The alarms from A11 to A14 are programmable by the system engineering.

STATUS DESCRIPTION Fix Progr.

S1 Rectifier OK x S2 Battery Discharge x

S21 Level 1 x S22 Level 2 x S23 Level 3 x

S3 Battery Charge x S31 Floating Charge x S32 Boost Charge x S33 Manual Charge x

S4 Battery OK x The first column indicates the status code.

The status S2 is split into three sub-status to show which level of discharge has been reached. The status S3 is divided into three sub-status to show which recharge type is actually active.

Each alarms and status can be remotely transferred by the means of a free voltage, two positions, relay contact. The Signaling card ARC#1 is included as a standard.

ARC #1

RELAY MEANING RL1 Mains Fault RL2 Rectifier OK RL3 Open Circuit Breaker RL4 Overload or Thermal Image RL5 Rectifier Max Voltage RL6 Rectifier Min Voltage

ARC #2

RELAY MEANING RL1 Charging Fault RL2 Earth Fault RL3 Free Description RL4 Free Description RL5 Free Description RL6 Free Description

ARC #3

RELAY MEANING RL1 Level 1 RL2 Level 2 RL3 Level 3 RL4 Battery Discharge

6 FRONT PANEL The RTB_e front panel consists in an 4 rows

alphanumeric display and 16 operating keys. It allows the complete monitoring of the RTB_e status and the setting of all operating parameters.

The power flow diagram facilitates the comprehension of the operating status.

Picture 1 – Front panel

The front panel main functions are: - Show all the relevant input and output

current, voltage and frequency measures - Show all the alarms and status of the

RTB_e - Set all the relevant functional parameters

and set-points - Show the events history The following remote connections are also

available: 1. Through an RS232 protocol 2. Through a ModBus RS485 protocol A periodical programmable automatic test of

the status of the batteries is also possible. In case of mains fault the RTB_e can provide a signalling (optical or through free contacts) of up to four pre-programmed discharging levels of the battery (voltage relay function).

7 BATTERY CHARGER FUNCTIONS

When the RTB_e is used as rectifier and battery charger it can carry out the following functions (selectable according to the requirements of the ST): 7.1 AUTOMATIC RECHARGE OF THE

BATTERY When selected the rectifier recharges the

battery automatically, according to the predefined modalities. The recharging cycle begins consequently according to one of the following events (which are programmable):

- Mains failure for a period longer than the programmed value

- Intervention of the current threshold. - Intervention of the voltage threshold.


4 of 14 JUD407772 Rev.B JSE410375 17/03/08

- Timed boost charge The predefined cycles can be programmed in

the Menu Parameters. 7.1.1 Recharge IU according to the DIN

41773 standard The recharge is divided in two different

phases: - Phase 1: the current is constant and the

voltage increases. - Phase 2: the current decreases and the

voltage is constant. When the recharging current goes below a

certain value the battery is assumed fully recharged and the cycle ends. Consequently the output voltage is set at the floating level. During the floating the battery voltage is controlled as minimum value in order to avoid undesirable discharges, and as maximum value in order to avoid excessive heating of the electrolyte. The “thermal compensation” of the floating voltage in function of the battery temperature can be added as an option.

Picture 2 – IU recharge

7.1.2 I1 I2 U recharge This recharge is used mainly for Ni-Cd

batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows:

If the mains fails for a time longer than the programmable threshold, when the mains returns the output voltage of the rectifier switches to a level higher than the floating, called boost charge and a safety timer is activated. If the recharging current exceeds the programmed threshold, normally a certain percent of C10, the voltage is maintained and a first phase of boost charge starts, where the current is constant and the voltage is increasing.

After a certain time the current starts to decrease and the voltage remains constant at the boost charge level. This is the second phase of the boost charge. Finally, when the current go down below the programmed level for the return in floating, the output voltage of the rectifier is

taken back to floating. If this does not happen within the max. programmed time, the safety timer blocks the charge and the voltage is forced to floating. This event generates an alarm.

Picture 3 – I1 I2 U recharge

7.1.3 U1 U2 I recharge This recharge is used mainly for Ni-Cd

batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows:

If the mains fails for a time which is longer than the programmable threshold, when the mains returns the output voltage of the RTB_e switches to a level higher than the floating, called boost charge and a safety timer is activated.

If the recharging voltage doesn’t exceed the programmed crossing threshold, normally a certain percent of the floating, the voltage is maintained and a first phase of boost charge starts, where the current is constant and the voltage is increasing.

After a certain time the recharging voltage reaches the programmed level for the second phase of boost charge; a timer is started and the battery is kept under boost charge conditions for the time programmed. After this time has elapsed the output voltage of the rectifier is switched back to the floating value. If this does not happen within the maximum programmed time, the safety timer block the charge and the voltage is forced to floating. This event generates an alarm.

Picture 4 – U1 U2 I recharge

7.2 TIMED BOOST CHARGE This recharge is used mainly for Ni-Cd

batteries. During the recharge a boost charge of approx. 125% is provided, to compensate the

RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 5 of 14

losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows:

If the mains fails for a time longer than the programmable threshold, when the mains returns the output voltage of the rectifier switches to a level higher than the floating, called boost charge for a pre-programmed time. The boost charge command can also be associated to an external command.

Picture 5 – Timed recharge

7.3 MANUAL RECHARGE The manual recharge of the battery, called

also of forming or of equalizing is a function offered by the RTB_e that allows the operator to carry out a recharge under his own manual control. This modality of recharge can be used to form the battery after that it has been stocked for a long period, or after that the electrolyte has been filled up, in the case of batteries having been shipped dry, or in order to equalize the voltage of the battery cells after having been used for a certain period.

The manual recharge procedure is described in detail in the relevant menu of the FRONT PANEL chapter of the Operating Manual. Generally, when manual recharge is selected it is possible to change manually the output voltage by means of a potentiometer to vary the recharging battery current. Such current is however always limited to a pre-selectable maximum value.

8 PARALLEL REDUNDANT OPERATION

Two rectifiers can operate in parallel redundant configuration, connected through blocking diodes to a single DC bus-bar, where the DC loads and one or two battery banks are connected.

Picture 6 – RTB_e in parallel with single battery

Picture 7 – RTB_e in parallel with two separated batteries

The rectifiers are connected by means of a communication cable, through which all the information necessary for the current sharing and the alarms management are exchanged.

During the floating charge each RTB_e supply the 50% of the total load (Active Current Sharing), therefore in case of failure of one unit the load is supplied by the remaining rectifier without affecting the DC bus-bar.

During a mains failure the batteries supply the necessary energy.

The battery charging cycle is automatically started upon the mains return; during the current limitation phase (operation as current generator) the current is completely supplied by the RTB_e #1, whereas the RTB_e #2 follows the DC bus-bar voltage without supplying any current. In case of failure of the RTB_e #1 the load is supplied by the RTB_e #2, still operative, without affecting the DC bus-bar. At the end of the current limitation phase the Active Current Sharing control is restored.

In case two batteries are connected to the DC bus-bar the recharge is carried out limiting the battery that absorbs the highest current.

The Active Current Sharing and the current limitation on the double battery are automatically enabled or disabled according to the position of


6 of 14 JUD407772 Rev.B JSE410375 17/03/08

the bus-tie, if provided between the two rectifiers, and the rectifier output switches ROCB.

9 DESIGN STANDARDS Quality / Environment : ISO 9001:2000

EN 14001 Rectifier basic standard : EN 60146 EMC standard : EN 61000-6-2

EN 61000-6-4 Performances : EN 62040-3 Power transformers : IEC 60076 Low voltage switchgear : IEC 60439

CEI 60947-2 Cables : CEI 20-38

CEI 20-22 CEI 20-14

Safety : EN 50178 EN 62040-1-2

Protection degree : IEC 60529 Mechanical : EN 60439-1

EN 62040-1 Semiconductors : EN 60146 Protection devices : EN 60127 Contactors : EN 60947-4 Lamps : EN 60945-5

10 MECHANICAL LAYOUT The following drawings are given as examples

of mechanical layout for the rectifier series RTB_e. Width and depth varies according to the

voltage and current ratings; further details are given in the datasheet.

Version 1 : IP20

Version 2 : IP31

11 SINGLE-LINE DIAGRAM

Picture 8 – Single-line diagram

RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 7 of 14

12 DATASHEETS 12.1 RTB_E 24VDC OUTPUT

RTB_e 24Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ELECTRICAL DATA

Input Voltage (Vac) 400 ± 10% 3Wires (Other voltages are available on request)

Input frequency 50÷60 Hz ± 5Hz Input short circuit current (at 400Vac, IEC Standard) ≤16KA rms (other on request)

Max. Input Power kVA at 100% load , nominal input 1,95 3,90 5,85 7,62 11,4 15,2 18,6 22,3 29,8 37,2

Input Current distortion at nominal load (THD%)

≤27 % with 6 pulses bridge (standard) ≤12 % with 12 pulses bridge (on request)

≤6 % % with 12 pulses plus input THD filter (on request) Input Power Factor (At nominal input voltage, 100% load)

≥ 0,75 (No manual charge provided)

Output Voltage (Vdc) -Nominal : -Floating :

-Boost : -Equalizing : (Manual Charge)

48 Vdc

2,2÷2,3 V/cell for Lead acid battery (Adjustable)

1,4÷1,5 V/cell for NiCd battery (Adjustable)

2,4÷2,45 V/cell for Lead acid battery (Adjustable) 1,5÷1,65 V/cell for NiCd battery (Adjustable)

up to 2,7 V/cell for Lead acid battery

up to 1,7 V/cell for NiCd battery

Forced boost push button (on request) Thermal compensation for sealed lead acid battery (on request)

Output Ripple ≤1%rms (other on request) Overload capability < 120% for 20 min. / < 150% for 2 min. / > 150% for 20 sec. Battery recharging system See the above description

25% ≥63 ≥63 ≥63 ≥64 ≥64 ≥65 ≥66 ≥66 ≥67 ≥67 50% ≥70 ≥70 ≥70 ≥71 ≥72 ≥72 ≥73 ≥73 ≥74 ≥74 75% ≥74 ≥74 ≥74 ≥75 ≥75 ≥76 ≥76 ≥77 ≥77 ≥77

Efficiency at nominal load (%)

100% ≥82 ≥82 ≥82 ≥84 ≥84 ≥84 ≥86 ≥86 ≥86 ≥86 Parallelability (on request) Active Load Sharing - CAN bus Connection

Heat dissipation at nominal load - kW 0,263 0,527 0,790 0,914 1,37 1,83 1,95 2,34 3,13 3,91 Cable wiring See above mentioned standards


8 of 14 JUD407772 Rev.B JSE410375 17/03/08

RTB_e 24Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ENVIRONMENTAL DATA

Acoustic noise level (according EN 50091) - dB < 65 < 68 < 70 EMI EN 61000-6-2 /EN 61000-6-4 Operating Temperature (°C) -10 .. +40 Storage Temperature (°C) -20 .. +70 Relative Humidity (non condens.) < 95% (with tropicalization on request)

Ventilation Natural up to 500 A Altitude (mt. above see level) < 2000 ( de-rating According EN62040-3)

MECHANICAL DATA

Protection degree (IEC60529) IP 20 (other on request) Painting colour and type RAL 7035, ≥ 60μm (others on request) Dimensions (mm) (<IP 41) - W 600 800 1000 - D 800 800 800 - H 2100 2100 2100Weights (Kg) 220 230 240 260 300 360 430 590 770 860 Input/output cable connection Bottom Side (Top Side on Request) Transport Base provided: for forklift handling

(for lifting belts and load balancing hooks -on request) Transport mechanical stress According to EN 62040-1 Restricted Installation 30 cm from ceiling

Air inlet from the front. Air outlet from the top and rear Accessibility Front

GENERAL

Measures Commands Adjustable Values Input Voltage Rectifier On / Off Floating Voltage Batt. Discharge Level 1 Input Current Boost On / Off Battery Current (Lim.) Batt. Discharge Level 2

Input Frequency Voltage Boost Boost Voltage Batt. Discharge Level 3 Input Power Current Boost Time after Mains Fault Output Max.Voltage

Input Power Factor Normal / Manual Safety Timer (in Hours) Output Min. Voltage Output Voltage Battery Test Float to Boost Current Floating Voltage Low Battery Voltage Rectifier Reset Boost to Float Current Floating Voltage High Output Current Float to Boost Voltage Min Input Voltage Battery Current Boost to Float Voltage Max Input Voltage

Internal Temp. (opt.) Eq. Starting Voltage Minimum Input Freq. Battery Temp. (opt.) Total Current (Output) Maximum Input Freq. Battery Temp. (opt.) Emergency Voltage

RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 9 of 14

12.2 RTB_E 48VDC OUTPUT

RTB_e 48Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ELECTRICAL DATA



Max. Input Power kVA at 100% load , nominal input 3,77 7,53 11,3 14,7 22,1 29,4 36,0 42,7 56,9 71,1







48 Vdc








25% ≥65 ≥65 ≥66 ≥68 ≥68 ≥68 ≥69 ≥69 ≥69 ≥69 50% ≥73 ≥73 ≥73 ≥75 ≥75 ≥75 ≥77 ≥77 ≥79 ≥80 75% ≥76 ≥76 ≥77 ≥80 ≥80 ≥80 ≥82 ≥83 ≥83 ≥84



Heat dissipation at nominal load – kW 0,424 0,847 1,27 1,43 2,15 2,87 2,97 3,20 4,27 5,33 Cable wiring See above mentioned standards


10 of 14 JUD407772 Rev.B JSE410375 17/03/08

RTB_e 48Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ENVIRONMENTAL DATA



MECHANICAL DATA

Protection degree (IEC60529) IP 20 (other on request) Painting colour and type RAL 7035, ≥ 60μm (others on request) Dimensions (mm) (<IP 41) - W 600 800 1000 - D 800 800 800 - H 2100 2100 2100 Weights (Kg) 250 270 290 320 380 450 530 700 900 1010Input/output cable connection Bottom Side (Top Side on Request) Transport Base provided: for forklift handling



GENERAL





RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 11 of 14


RTB_e 110Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ELECTRICAL DATA



Max. Input Power kVA at 100% load , nominal input 8,43 16,9 25,3 33,3 48,9 65,2 80,6 96 128 160







110 Vdc








25% ≥68 ≥68 ≥68 ≥69 ≥69 ≥69 ≥70 ≥70 ≥70 ≥70 50% ≥75 ≥75 ≥75 ≥84 ≥84 ≥84 ≥85 ≥85 ≥85 ≥85 75% ≥80 ≥80 ≥80 ≥85 ≥85 ≥85 ≥88 ≥88 ≥88 ≥88



Heat dissipation at nominal load – kW 0,822 1,64 2,45 3,00 3,67 4,89 5,44 5,74 7,65 9,57 Cable wiring See above mentioned standards


12 of 14 JUD407772 Rev.B JSE410375 17/03/08

RTB_e 110Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ENVIRONMENTAL DATA



MECHANICAL DATA

Protection degree (IEC60529) IP 20 (other on request) Painting colour and type RAL 7035, ≥ 60μm (others on request) Dimensions (mm) (<IP 41) - W 600 800 1000 1000 - D 800 800 800 1000 - H 2100 2100 2100 2100 Weights (Kg) 280 320 380 450 520 600 700 800 980 1200Input/output cable connection Bottom Side (Top Side on Request) Transport Base provided: for forklift handling



GENERAL





RTB_e General data

Rev.B JSE410375 17/03/08 JUD407772 13 of 14


RTB_e 220Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ELECTRICAL DATA



Max. Input Power kVA at 100% load , nominal input 16,7 33,3 50 66 98 129 160 191 252 315







220 Vdc








25% ≥68 ≥68 ≥68 ≥69 ≥69 ≥69 ≥70 ≥70 ≥70 ≥70 50% ≥75 ≥75 ≥75 ≥84 ≥84 ≥84 ≥85 ≥85 ≥85 ≥85 75% ≥80 ≥80 ≥80 ≥85 ≥85 ≥85 ≥88 ≥88 ≥88 ≥88



Heat dissipation at nominal load – kW 1,50 3,00 4,50 5,44 7,33 8,70 9,57 11,48 13,25 16,56Cable wiring See above mentioned standards


14 of 14 JUD407772 Rev.B JSE410375 17/03/08

RTB_e 220Vdc - SIZE (A) 50 100 150 200 300 400 500 600 800 1000

ENVIRONMENTAL DATA



MECHANICAL DATA

Protection degree (IEC60529) IP 20 (other on request) Painting colour and type RAL 7035, ≥ 60μm (others on request) Dimensions (mm) (<IP 22) - W 600 800 1000 1200 1000 1000 - D 800 800 800 800 800 1000 - H 2100 2100 2100 2100 2100 2100 Weights (Kg) 330 460 550 630 750 870 970 1050 1350 1500Input/output cable connection Bottom Side (Top Side on Request) Transport Base provided: for forklift handling



GENERAL





Battery Charger Installation, Operating and Maintenance Manual


Pag. N°

Pag. Tot.


COMMESSA - JOB :

0 8 0 A 1 6 9 6

CLIENTE - CUSTOMER :

ORDINE N° - ORDER N°

B I O - Q U R - O 4 2 R E V . B D T D 2 1 . 0 4 . 2 0 0 8

DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :

C O N S T R U C T I O N O F Q U R A Y Y A H O P E N C Y C L E G A S T U R B I N E P O W E R P L A N T

B A T T E R I E S , B A T T E R Y C H A R G E R S & U P S S Y S T E M S IMPIANTO - SITE :

QURAYYAH SAUDI ARABIA

TITOLO - TITLE :

BATTERY CHARGER INSTALLATION, OPERATING AND MAINTENANCE MANUAL

MATRICOLA - PART NUMBER :

113-116-117-118-119-120-126 / 08

CODICE DOC. - DOCUMENT NUMBER :

JGE410502

Il presente documento è di esclusiva della BORRI S.r.l. che tutelerà i propri diritti a termine di legge This document remains the exlusive property of BORRI S.r.l. and we reserve all rights according to copyright laws

Battery Charger Installation, Operating and Maintenance Manual


Pag. N°

Pag. Tot.


INDEX

1. RTB.e GENERAL DESCRIPTION AND INSTALLATION ……………………. 3 2. RTB.e FRONT PANEL ………….………………………………………………. 15 3. START-UP AND SHUT DOWN……………………………………………………. 70

RTB.e general description and installation

Issued 10.12.2008 JGE410502 1 of 11

RTB.e GENERAL DESCRIPTION AND INSTALLATION

Index

1. INTRODUCTION .................................................................................. 3 2. RTB.E GENERAL DESCRIPTION ...................................................... 4

2.1 TYPOLOGY ...................................................................................................... 4 2.1.1 Basic structure ......................................................................................... 4 2.1.2 Protection ................................................................................................. 5 2.1.3 User interface ........................................................................................... 6

2.2 SYSTEM CONFIGURATION ............................................................................ 6 2.2.1 6 Pulses Rectifier ..................................................................................... 6 2.2.3 Front panel ................................................................................................ 6

3. BATTERY CHARGER FUNCTIONS ................................................... 7

3.1 AUTOMATIC RECHARGE OF THE BATTERY ............................................... 7 3.1.1 Automatic recharge of the battery .......................................................... 7 3.1.2 Recharge IU according to the DIN 41773 standard .............................. 7 3.1.3 I1 I2 U recharge ........................................................................................ 8 3.1.4 U1 U2 I recharge ....................................................................................... 8 3.1.5 Manual recharge ....................................................................................... 9

4. INSTALLATION ................................................................................. 10 4.1 RECEIPT OF THE RTB.E ............................................................................... 10 4.2 RTB.E HANDLING .......................................................................................... 10 4.3 POSITIONING ON SITE ................................................................................. 10

4.3.1 Basic plant, static load and weights ..................................................... 10 4.3.2 Distances to be observed ...................................................................... 10

4.4 ELECTRICAL CONNECTIONS ...................................................................... 11 4.4.1 Terminal boards ..................................................................................... 11

4.5 EXTERNAL BATTERY AND BATTERY FUSE BOX ..................................... 11


2 of 11 JGE410502 Issued 10.12.2008

Index of picture

Picture 1 – Drawing of principles .................................................................................................................. 5 Picture 2 – 12 pulse rectifier ......................................................................................................................... 6 Picture 3 – IU recharge ................................................................................................................................. 7 Picture 4 – I1 I2 U recharge .......................................................................................................................... 8 Picture 5 – U1 U2 I recharge ........................................................................................................................ 9


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1. INTRODUCTION

The purpose of this manual is to briefly describe the parts of the RTB.e, and to guide the electrician or user for the correct installation of the equipment on site.

The electrician or the user will have to read and carry out correctly the instructions given in this manual, with particolar attention to the safety requirements in compliance with the CEI 64-8 standards and the DPR 46-90.

The manufacturer declines any responsability of damage to people or things,

deriving from the non-fulfilment of the instructions. The RTB.e system consists in one 6 pulse rectifier with SCR (thyristor) technology

developed as per Technical Specification 46-TMSS-02 rev. 0, as supply system for continuous loads and battery-charger.

For this purpose the manual must be integrated with the Technical Drawings (TD), the Technical Specification 46-TMSS-02 rev. 0 (TS) and the Data Sheet (DS) to be applied with the RTB.e system.

As all the functions of control and regulation are carried out completely digitally, by means of the use of a 16 bit microprocessor, the user interface, which is the front panel, allows to vary all the operating parameters such as the output voltage, the max. battery current and so on.

We recommend expert personnel to carry out such functions. In order to protect the system from wrong programming the menu’s are protected by password. The password is different for each system and will be communicated to the user during the installation.


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2. RTB.e GENERAL DESCRIPTION

2.1 TYPOLOGY The RTB.e rectifier converts the alternate voltage in the input, 480Vac 3Ph 60Hz, into

a continuous output voltage 125Vdc that is stabilized in voltage and controlled in current, by means of a three-phase SCR rectifier bridge (6 pulses version).

The galvanic isolation of the input mains is carried out by means of a power transformer DY11 480/131Vac 3Ph 60Hz.

ATTENTION

The RTB.e can be connected to a battery system and therefore supplied during the absence of mains . Ensure that no voltages are present, both alternate than continuous, before operating inside the RTB.e equipment.

2.1.1 Basic structure The RTB.e basic structure, which is documented in the TD drawings, is the following:

• The input mains is filtered by the high frequency emission filter (EMI), protected

by the input surge suppressor (MOV) and enters the primary of the input transformer T1, trough the Q1-RICB breaker.

• Both the syncronization signals for the control of the SCR firing angle and the

measurement of the input currents are taken from the auxiliary transformer T9 and T10 connected to the primary side of input transformer T1.

• The supply voltage for the control logics (redounded from the battery) is taken

from the secondary side. The SCR bridge is connected to the secondary by means of the proctection fuses.

• The control logic mounted in the rack named DR16 is composed by the

following boards: BP-DR16 Cod. N_TR3004 Interconnection panel

PS-DR16 Cod. N_TR3005 Power supply DR16-COMP Cod. N_TR3006 Control board (CPU)

• The firing of the SCR’s is controlled by the DR16 board and is carried out by

means of the board: RTF Cod. N_TR3002 SCR firing board

• The rectified and controlled voltage is filtered by the group L1 (series chokes),

C1 (parallel capacitor), calculated in function of the maximum ripple allowed in the TS.


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• At the output of that group, the feedback voltage for the voltage control is taken upstream the blocking diode DB; the measurement of the total output current (for the total limitation) is always carried out by the lem U1 and the discharge and recharge current by the lem U2 and voltage of the battery are also measured.

• The RTB.e output is connected to the DC distribution input Q5-QGD switch by

means of the Q2-ROCB switch. The DC distribution is connected to the Battery Fuse Box by means of Q7-BCB switch.

Picture 1 – Drawing of principles

2.1.2 Protection The main protections of the RTB.e are listed below: The thermal protection of the brigde is carried out both by thermoswitches, which are

placed on each heat sink, and by calculation of the thermal image. The thermal image is calculated measuring the output current. If it exceeds by 100%

the nominal current but remains lower than 120%, the overload is accepted for 20 minutes before the RTB.e is stopped.

Over 120% normally the output current limitation intervenes and the RTB.e works as a current generator.

If the output current is between 120 % and 150 % the overcurrent is accepted for 2 minutes before the RTB.e is stopped. Above 150% the overcurrent is accepted for 20 seconds only.

The electrical protection of the bridges is carried out by means of a fuses placed on each input phase and in series to the SCR. In addition, the ouput current limitation limits the peak current supplied by the each SCR.

The correct value of the supplied voltages is checked by means of the double measurement of the output and battery voltage. Moreover the correct operation of the control loop is also verified.

Each step of the battery recharge is controlled and supervised by a safety timer.


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2.1.3 User interface The user can interface with the RTB.e system by means of the following devices: - Front panel SFP with alphanumeric LCD display. - Serial port RS232 and control software. - Free voltage contact board (ARC card N_TR3009).

2.2 SYSTEM CONFIGURATION

2.2.1 6 Pulses Rectifier The configuration of the RTB.e is a 6 pulses three phase SCR bridge. It is

dimentioned to supply a continuous load and to recharge the battery at the maximum recharging current provided in the TS and DS. The standard value of the harmonic distortion (THD) re-injected into the mains by a 6 pulse rectifier is < 27%.

Picture 2 – 6 pulse rectifier

2.2.3 Front panel The front panel RTB.e is composed by a 4-row alphanumeric display at plus an

alphanumeric multi-function keyboard. It allows the complete monitoring of the RTB.e status, the programming of the paramenters and the execution of the main functions.

The power flow diagram helps to comprehend the RTB.e operating status and the system conditions. For further information see chapter “FRONT PANEL”.


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3. BATTERY CHARGER FUNCTIONS

The RTB.e used as rectifier and battery charger can carry out the following functions according to the requirements of the ST and DS: 3.1 AUTOMATIC RECHARGE OF THE BATTERY

3.1.1 Automatic recharge of the battery The automatic recharging cycle begins consequently according to one of the

following events (which are programmable): - Mains failure for a longer period than the programmed value - Intervention of the current threshold. - Intervention of the voltage threshold.

The predefined cycles can be programmed in the Menu Parameters. The automatic recharging cycle is programmed for intervention of current threshold.

3.1.2 Recharge IU according to the DIN 41773 standard The recharge undergoes to phases: - Phase 1: the current is constant and the voltage increases. - Phase 2: the current decreases and the voltage is constant. When the recharging current goes below a certain value the battery is assumed fully

recharged and the cycle ends. Consequently the output voltage is set at the floating level. During the floating the battery voltage is controlled as minimum value in order to avoid undesirable discharges, and towards as maximum value in order to avoid excessive heating of the electrolyte. The “thermal compensation” of the floating voltage in function of the battery temperature can be added as an option.

Picture 3 – IU recharge


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3.1.3 I1 I2 U recharge This recharge is used mainly for Ni-Cd batteries. During the recharge a boost charge

of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows:

If the mains fails for a time which is longer than the programmable threshold, when

the mains returns the output voltage of the RTB.e is taken to a higher level than the floating, called boost charge and a safety timer is activated. If the recharging current exceeds the programmed crossing threshold, normally a certain percent of C10, the voltage is maintained and a first phase of boost charge starts, in which the current is constant and the voltage is increasing.

After a certain time the current starts to decrease and the voltage remains constant at the level of boost charge. This is the second phase of the boost charge. Finally, when the current goes below the programmed level for the return in floating, the output voltage of the RTB.e is taken back to floating. If this does not happen within the max. programmed time, the safety timer intervenes and the voltage is forced to floating. This event generates an alarm.

Picture 4 – I1 I2 U recharge

3.1.4 U1 U2 I recharge This recharge is used mainly for Ni-Cd batteries. During the recharge a boost charge

of approx. 125% is provided, to compensate the losses in discharge and recharge of the battery (estimated in approx. 25%). The recharge works as follows:

If the mains fails for a time which is longer than the programmable threshold, when

the mains returns the output voltage of the RTB.e is taken to a higher level than the floating, called boost charge and a safety timer is activated.

If the recharging voltage doesn’t exceed the programmed crossing threshold, normally a certain percent of the floating, the voltage is maintained and a first phase of boost charge starts, in which the current is constant and the voltage is increasing.

After a certain time the recharging voltage reaches the programmed level for the second phase of boost charge; a timer is started and the battery is kept under boost


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charge conditions for the time programmed. After this time has elapsed the output voltage of the RTB.e is brought back to the floating value. If this does not happen within the maximum programmed time, the safety timer intervenes and the voltage is forced to floating. This event generates an alarm.

Picture 5 – U1 U2 I recharge

3.1.5 Manual recharge The manual recharge of the battery, called also of forming or of equalizing is a

function offered by the RTB.e that allows the operator to carry out a recharge under his own manual control. This modality of recharge can be used to form the battery after that it has been stocked for a long period, or after that the electrolyte has been filled up, in the case of batteries having been shipped dry, or in order to equalize the voltage of the battery cells after having been used for a certain period.

The manual recharge procedure is described in detail in the relevant menu of the FRONT PANEL chapter. Generally, when manual recharge is selected it is possibile to intervene manually on the output voltage by means of a potentiometer to vary the recharging battery current. Such current is however always limited to a preselectable maximum value.


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4. INSTALLATION

Th installation of the RTB.e must be carried out by qualified personnel. The information contained in this manual will have to be integrated with the technical monograph, the technical specification and all technical back-up documentation. In order to verify the updated status of such documentation please contact our Technical Office.

4.1 RECEIPT OF THE RTB.e Upon receipt of the RTB.e remove the packaging and carried out an accurate visual

control, in order to make sure that the equipment has not been damaged during transport.

IMPORTANT In case of damage during transport, please submit your claim directly to the

shipping agency immediately after reception of the equipment. If the RTB.e is not installed immediately, keep it stocked in vertical position as

indicated on the packaging, and stock it in a dry and sheltered place and cover it with a packaging to protect it from dust.

4.2 RTB.e HANDLING For the handling of the RTB.e before its final positioning we suggest to leave it on its

wooden pallet to avoid risks of overturning. Before final positioning, remove the RTB.e from its palled removing the fixing bolts. The RTB.e can be lifted and moved by means of a forklift or by eyebolts. Please

verify the back-up documentation before handling. 4.3 POSITIONING ON SITE

The RTB.e must be installed in a clean ,dry and possibly not dusty place. The installer must ensure that the environment has enough air exchange so that the equipment can cool itself adeguately. Should this not be guaranteed then the environment will have to be cooled adeguately.

If the technical specification provides of a IPxx protection degree higher than IP20, the installer will have to ensure that the environment is compatible with the requested protection degree.

4.3.1 Basic plant, static load and weights The relevant data of the RTB.e are contained in the Technical Drawings in annex.

4.3.2 Distances to be observed Unless other given indications contained in the Technical Drawings, below we are

suggesting the distances to be observed: Minimum distance from the rear wall: x = 50 mm. Minimum distance from the top : y = 500 mm. Minimum distance from the front wall: d = 1000 mm.


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4.4 ELECTRICAL CONNECTIONS The electrical connections are part of the installation and must be carried out by

specialized personnel, following the indication of the Technical Drawings. The RTB.e manufacturer is not responsible of the electrical connection. It is recommended to carry out the installation and input and output electrical connections according to the local standards.

During the electrical installations take special care to respect the sequence of the input phases.

ATTENTION

The connection to the mains has to be carried out by interposing protections fuses between the mains and the RTB.e.

The use of residual protection devices in the mains supply line of the RTB.e is not recommended; the current dispersion to the ground, due to the RFI filters is quite high and can cause undesired protection interventions.

In compliance with the EN50091-1 standards , differential devices with settable intervention threshold can be used, in order to keep into consideration the current dispersion of the RTB.e.

4.4.1 Terminal boards The position of the input, output and signalling terminal boards is shown in the

Technical Drawings. It is recommended to consider the recommended cable sections. 4.5 EXTERNAL BATTERY AND BATTERY FUSE BOX

The external battery is used to keep the output loads energized even in the case of mains failure. During the battery discharge, the control logic of the RTB.e remains supplied allowing the signalling of the discharge levels.

IMPORTANT

The battery voltage is present inside the RTB.e even in case of mains failure. Disconnect the external battery before maintenance.

The battery switch is assembled inside the DC distribution panel and between RTB.e

and Battery banks there is a Battery Fuse Box with power protection fuses, battery voltage and current instruments and Battery High Impedance monitor.

Connect the auxiliary contact to the RTB.e according to the indications on the Technical Drawings.

Front Panel

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FRONT PANEL

Index

1. INTRODUCTION ............................................................................. 3 2. DESCRIPTION................................................................................ 4

2.1 DESCRIPTION OF THE PANEL ................................................................ 4 2.1.1 Flow diagram ..................................................................................... 4 2.1.2 Alarm and signalling panel ............................................................... 4

LED 6 ⇒ MAINS OK ................................................................... 4

LED 7 ⇒ RECTIFIER OK ............................................................ 4

LED 8 ⇒ FLOATING CHARGE .................................................. 4

LED 9 ⇒ BOOST CHARGE ........................................................ 4

LED 10 ⇒ MANUAL CHARGE ..................................................... 4 LED 11 ⇒ LOW DC VOLTAGE .................................................... 4

LED 12 ⇒ HIGH DC VOLTAGE.................................................... 4

LED 13 ⇒ BLOWN FUSES/RICB TRIP ........................................ 4

LED 14 ⇒ OVERLOAD ................................................................. 4 LED 15 ⇒ DIODE FAILURE 3. LCD DISPLAY MANAGEMENT 4

3. LCD DISPLAY MANAGEMENT ..................................................... 5

3.1 DEFAULT .................................................................................................. 5 3.2 KEY MENU’S ............................................................................................. 5

3.2.1 On-off ................................................................................................. 7 3.2.2 Clock settings .................................................................................... 8 3.2.3 Measures ........................................................................................... 8 3.2.4 Alarms-Statuses .............................................................................. 10 3.2.5 Boost ................................................................................................ 16 3.2.6 Normal-Manual ................................................................................ 16 3.2.7 Reset ................................................................................................ 18

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3.2.8 Parameter ........................................................................................ 19 3.2.8.1 Parameters Boost Charge .......................................................... 19

a) CURRENT BOOST, or rather recharge I1 I2 U ................................. 22 b) VOLTAGE BOOST, or rather recharge U1 U2 I ............................... 24

3.2.8.2 Parameters Manual Charge ........................................................ 27 3.2.8.3 Parameters Battery Data ............................................................. 29

c) Recharge IU according to the DIN 41773 standard ......................... 30 d) Discharge level settings .................................................................... 32

3.2.8.4 Parameters Input Data ................................................................ 34 3.2.8.5 Parameters Output Data ............................................................. 34 3.2.8.6 Parameters Battery Info .............................................................. 37 3.2.8.7 Parameters Default Parameters ................................................. 38

3.2.9 Status ............................................................................................... 39 3.2.10 History .......................................................................................... 41

4. SFP SYSTEM DATA ..................................................................... 43

4.1 75A 125VDC BLOCK DC SYSTEMS ...................................................... 43 4.2 160A 125VDC STATION DC SYSTEMS ................................................. 44 4.3 300A 125VDC GAS COMPRESSOR DC SYSTEMS .............................. 45

Drawings index

Figure 1 – RTB.e front panel ................................................................................................................. 3 Figure 2 – Charge I1 I2 U ................................................................................................................... 24 Figure 3 – Recharge U1 U2 I .............................................................................................................. 27 Figure 4 – Recharge IU ....................................................................................................................... 30

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1. INTRODUCTION

The RTB.e front panel consists in an 4 rows alphanumeric display and 16 operating keys. It allows the complete monitoring of the RTB.e status and the setting of all operating parameters.

The power flow diagram facilitates the comprehension of the operating status.

Figure 1 – RTB.e front panel

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2. DESCRIPTION

2.1 DESCRIPTION OF THE PANEL The figure 1 shows the front panel that is divided in three parts. The higher left

hand part represents the power flow diagram; underneath the alarm and signalling panel with leds and finally on the right side the 4 rows display and the alphanumeric keyboard.

2.1.1 Flow diagram

LED 1 ⇒ Green light on = Rectifier Mains presence Red light on = Otherwise

LED 2 ⇒ Green light on = RTB.e operating. Red light on = RTB.e failure or blocked Switched off for mains failure. LED 3 ⇒ Green light on = Rectifier in floating charge. Orange light on = Rectifier in rapid charge.

LED 4 ⇒ Green light on = Battery in recharge and ok.

Orange light on = Battery in discharge or battery test. Red light on = Battery KO.

LED 5 ⇒ Green light on = Output OK and ROCB closed.

Red light on = Otherwise.

2.1.2 Alarm and signalling panel

LED 6 ⇒ MAINS OK

LED 7 ⇒ RECTIFIER OK LED 8 ⇒ FLOATING CHARGE LED 9 ⇒ BOOST CHARGE LED 10 ⇒ MANUAL CHARGE LED 11 ⇒ LOW DC VOLTAGE LED 12 ⇒ HIGH DC VOLTAGE LED 13 ⇒ BLOWN FUSES/RICB TRIP LED 14 ⇒ OVERLOAD LED 15 ⇒ DIODE FAILURE

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3. LCD DISPLAY MANAGEMENT

3.1 DEFAULT RECTIFIER CHARGER FLOATING CHARGE VDC = xxx V IDC = yyy A

The default screen is shown on the LCD panel when the RTB.e is operating

normally (no submenu selected); it shows the equipment name, the charge status, the measures of the output voltage (125Vdc) and current (???). If there is any alarm active a * is shown on the second row. By pressing any operating key the relevant menu is entered, from which it is possible to access all the following listed operations.

NOTE

In this section all the value “xxx”, “yyy”, “fff”, “zzz” are depending of the size of the battery charger as per technical specification TS and data sheet DS.

See chapter 4 for detailed system value.

3.2 KEY MENU’S By pressing an operating key the relevant menu is accessed and it is possible to

see the status, alarms and measurement, to send commands and to carry out settings. The menu’s can be classified as follows:

S

ON/OFF

Menu: ON-OFF MENU Type: SETTING Password: NO It is accessed by pressing the key

S

CLOCK

Menu: CLOCK SETTINGS Type: SETTING Password: NO It is accessed by pressing the key

S

MEASURES

Menu: MEASURES Type: VISUALISATION Password: NO It is accessed by pressing the key

S

ALARMS

Menu: ALARMS-STATUSES Type: VISUALISATION Password: NO It is accessed by pressing the key

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ESC

EXIT

Function: ESCAPE AND SILENCE Type: COMMAND Password: NO It is carried out by pressing the key

1

BOOST

Menu: CALL BOOST CHARGE Type: COMMAND Password: NO It is accessed by pressing the key

2

NOR/MAN

Menu: NORMAL-MANUAL Type: COMMAND Password: NO It is accessed by pressing the key

4

RESET

Menu: RECTIFIER RESET Type: COMMAND Password: NO It is accessed by pressing the key

8

PARAMETER

Menu: PARAMETERS Type: SETTINGS Password: YES It is accessed by pressing the key

9

STATUS

Menu: BATTERY STATUS Tipe: VISUALISATION and COMMAND Password: NO It is accessed by pressing the key

0

HISTORY

Menu: HYSTORY Type: SETTINGS Password: YES It is accessed by pressing the key

ENT

Function: ENTER KEY Type: COMMAND Password: NO It is accessed by pressing the key

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3.2.1 On-off This menu is entered by pressing the key:

S

ON/OFF

Menu: ON-OFF MENU Type: SETTING Password: NO It is accessed by pressing the key

In the menu the following screen is entered:

ON-OFF MENU NOW SET AT: ON PRESS 0 TO MODIFY

After having pressed the key:

0

HISTORY

Following Submenu is entered:

ON-OFF MENU

NOW SET AT: ON + OR – FOR CHANGE

AND CONFIRM

If you press following keys in this submenu:

5

+

Or

6

-

If the RTB.e is on it will shutdown or viceversa.

NOTE This key works as a two position ON-OFF switch which remains positioned on

the last selected position. This means that if you have selected ON, the RTB.e starts-up automatically until OFF is selected. It is possible to support this command with a manual switch which in its turn blocks the start-up of the RTB.e. For this purpose consult the Technical Monograph.

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3.2.2 Clock settings The menu is entered by pressing the key command:

S

CLOCK

Menu: CLOCK SETTINGS Type: SETTINGS Password: NO It is accessed by pressing the key


CLOCK SETTINGS da mo ye ho mi 00 00 00 00 00 12 12 03 15 52 30

The last line shows, in this order, the present date, in the format “day month year”

and the present time in the format “ hours minutes second”. The alphanumeric keyboard enables the update. The numbers enter from right to left in the third line.

At the end of data entering press the key:

ENT

To confirm.

NOTE

The correct entering of the date and hour is essential for the correct operation of the alarms history.

3.2.3 Measures The menu is entered by pressing the key:

S

MEASURES

Menu: MEASURES Type: VISUALISATION Password: NO It is accessed by pressing the key


MEASURES Ph: U V W Vin: xxx xxx xxx V Iin: yyy yyy yyy A

The second line shows which input phase the measure refers to. The third and

fourth line show, respectively, the three input voltages (phase-neutral) and the three input currents of the RTB.e.

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If in this menu the down key is pressed:

7

The following measures are accessed:

MEASURES

FREQUENCY:fff HZ IN.POWER:zzz KVA P. FACTOR: 80 %

The second line shows the frequency of the input mains in Hertz. The third line

represents the total input power in kVA. The fourth line shows the RTB.e input power factor in % meaning that 80% indicate 0.8.


7


MEASURES

RECT BATT VOLT: xxx xxx V CURR: yyy yyy A

The second line shows which point the measure refers to, respectively the

rectifier output and the battery terminals. The third line shows the relevant voltages. The fourth line shows the relevant currents in ampere.


7


MEASURES TEMPERATURE

BATTERY: 38 °C INTERNAL: 40 °C

The third line shows the internal temperature of the RTB.e, the fourth line the

battery temperature. These indications are options. For this purpose please consult the Technical Monograph.

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NOTE The arrows up (key 3) is for backward browsing. By using the ESCAPE key you

can exit from any point.

3.2.4 Alarms-Statuses The menu is entered by pressing the key:

S

ALARMS

Menu: ALARMS-STATUSES Type: VISUALISATION Password: NO It is accessed by pressing the key


ALARMS-STATUSES Use Arrows Up & Down To Browse The Pages Press ESC To Exit

If you press the up and down keys in this menu:

7

3

The alarms and present statuses are scrolled:

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List of alarms List of statuses A1 MAINS FAULT S1 RECTIFIER OK A2 BLOWN FUSES A3 HIGH TEMPERATURE A4 OVERLOAD A5 MAX OUTPUT VOLTAGE S2 BATTERY DISCHARGE A6 MIN OUTPUT VOLTAGE S2-1 DISCHARGE LEVEL 1° A7 CHARGING FAULT S2-2 DISCHARGE LEVEL 2° A8 FANS FAILURE S2-3 DISCHARGE LEVEL 3° A9 OPEN CIRCUIT BREAKER A10 EARTH FAULT A11 PROGRAMMABLE - 1 S3 BATTERY ON CHARGE A12 PROGRAMMABLE - 2 S3-1 FLOATING CHARGE A13 PROGRAMMABLE - 3 S3-2 BOOST CHARGE A14 PROGRAMMABLE - 4 S3-3 MANUAL CHARGE A15 EEPROM FAULT S4 BATTERY OK A16 EMERGENCY VOLTAGE S4 BATTERY NOT OK

When the menu is entered the statuses and alarms, are visualised in increasing

order. Each new alarm activates a buzzer for 30 seconds. The alarms remain visualised until they are present and are registered automatically, together with the statuses, in the events history, with date and hour at each change.

The alphanumeric display offers, moreover, the complete diagnosis of the system, by means of the visualisation of 15 alarm causes and 4 operating statuses.

Each alarm is associated with a code, which is stored in the events history, and a description in order to facilitate the troubleshooting.

A1: Mains Fault A1:Mains Fault RTB.e mains input failure due to: Wrong sequence 1. wrong sequence Out of Tolerance 2. out of tolerance

Depending on which cause is shown, check the input phase sequences, or the

input voltage and frequency, comparing them with the operating limits allowed in the technical specification.

A2: Blown Fuses A2:Blown Fuses RTB.e input fuses blown on the: Blown Fuses On

Bridge 1 SCR bridge number 1 Bridge 2 SCR bridge number 2

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The SCR bridge number 1 is always present (6 pulse configuration). The SCR

bridge number 2 is present only in the double bridge configuration (12 pulses configuration). When one of the fuses blown, the relevant bridge is shutdown.

A3: High Temperature A3:High Temperature High temperature of the heatsink relevant to: High Temperature On

Bridge 1 SCR bridge number 1 Bridge 2 SCR bridge number 2

The SCR bridge number 1 is always present (6 pulse configuration). The SCR

bridge number 2 is present only in the configuration with double bridge configuration (12 pulses configuration). When one of the thermal probes intervenes, the relevant bridge is shutdown.

A4: Overload A4:Overload Iout total current supplied by RTB.e exceeds Rectifier Current In nominal shown in the technical specification.

> Than The overload is managed Nominal Current as follows:

if In < Iout < In*1.2 the overload is kept for 20 minutes;

if In*1.2 < Iout < In*1.5 the overload is kept for 2 minutes

if Iout > In*1.5 the overload is kept for 20 seconds.

At the end of the time RTB.e shuts down for 20 minutes. In this case the following screen is shown:

A4:Thermal Image Rectifier Stopped

For 20 Minutes After The Overload

After 20 minutes the RTB.e starts up again automatically. If overload continues

the countdown starts again.

A5: Max Out Voltage A5:Max Out Voltage Vout output voltage of the RTB.e exceeds Stop for Out Volt the max. programmed threshold.

> Than Such thresh. depends on the variable MAX_VRECT Output Max Voltage as follows:

If Vout > MAX_VRECT the alarm is delayed for a programmable time. All the parameters can be checked and varied in the menu PARAMETERS (see)

or from the serial port, by means of the suitable software interface.

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At the end of the time the RTB.e shuts down automatically and does not restart until it is RESET (see).

A6: Min Out Voltage A6:Min Out Voltage Vout, the output voltage of the RTB.e, goes belows Stop for Out Volt the minimum programmed threshold.

< Than Such threshold depends on the variable MIN_VRECT Output Min Voltage as follows:

The condition Vout < MIN_VRECT causes a delayed alarm. All the parameters can be checked and varied in the menu PARAMETERS (see) or

from the serial port, by means of the suitable software interface. At the end of the time the alarm becomes active. The alarm resets automatically

if the condition Vout > MIN_VRECT returns.

A7: Charging Fault A7:Charging Fault RTB.e charging system failure due to: Wrong Floating High 1. high floating voltage Wrong Floating Low 2. low floating voltage Safety Timer Active 3. safety timer activation

Wrong Floating High: If, in floating voltage, the V_batteria > MAX_VBAT

the alarm is delayed for a programmable time. At the end of the time the RTB.e shuts down automatically and does not restart until it is RESET (see). Wrong Floating Low: If, in floating voltage, the V_batteria < MIN_VBAT the

alarms is activated after the programmable delay. Safety Timer Active: If, in boost charge, the safety timer is active, the

RTB.e returns to floating and the alarm is activated and remains memorized until a RESET (see) is carried out.

Al the parameters can be checked and varied in the menu PARAMETERS (see) or

from the serial port, by means of the suitable software interface.

A8: Fans Failure A8: Fans Failure The fans cooling monitoring board of the

Alarm From RTB.e has intervened. Fans Monitor

Card

The presence of fans depends on the type of cooling (forced cooling or natural

ventilation ). For further information consult the Technical Monograph.

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A9: Open C. Breaker A9: Open C. Breaker One of the breakers of the RTB.e in open:

RICB Open 1. mains input breaker BCB Open 2. battery breaker

ROCB Open 3. output breaker The presence and the type of the breakers depends on the RTB.e configuration. For more information consult the technical monograph

A10: Earth Fault A10: Earth Fault The earth fault relay signal has intervened

Alarm From due to an isolation loss towards earth Earth Fault of one of the controlled poles. Monitor Card

The presence and type of earth fault relay depends on the RTB.e configuration.

For more information consult the Technical Monograph.. The alarms A12, A13 and A14 are programmable. For more information please

consult the Technical Monograph.

A15: EEProm Error A15: EEProm Error An internal error has occurred. Internal Error It is necessary to contact the Service. Contact the Service

A16: Emergency Volt A16:Emergency Level The output voltage Vout of the RTB.e is forced

Output Voltage to a programmed fixed level. Forced at Such level depends on the variable LIVELLO4 and

The Emergency is forced by means, of an external contact. The LEVEL4 can be checked and varied in the menu PARAMETERS (see) or from

the serial port, by means of the suitable software interface.

S1: Rectifier OK S1: Rectifier OK No alarms are active.

No Active Alarms Present

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S2: Battery Discharge S2:Battery Discharge The battery is in discharge (due to mains failure)

Level 1 1. the discharge has reached the 1° Level Level 2 2. the discharge has reached the 2° Level Level 3 3. the discharge has reached the 3° Level

During the battery discharge the RTB.e can monitor the voltage and signal the

reaching of one or more programmable discharge levels. Each of the three levels, LEVEL1, LEVEL2 and LEVEL3, can be checked and

varied in the menu PARAMETERS (see) or from the serial port, by means of the suitable software interface.

For more information please consult the Technical Monograph.

S3: Battery Charge S2:Battery Charge The battery is charged in the following mode: Float Charge Mode 1. Floating Charge Boost Charge Mode 2. Boost Charge Manual Charge Mode 3. Manual Charge

The battery recharge mode of the RTB.e can be enabled and varied in the menu

PARAMETERS (see) or from the serial port, by means of the suitable software interface.

The choices to carry out depend on the type of battery installed. For more information consult the Technical Monograph and Technical Specification.

The recharging procedures are described in the chapter RTB.e General Description And Installation.

S4: Battery OK S4: Battery OK The battery is completely efficient as:

Battery Connected 1. it is connected to the load Battery Test OK 2. the last battery test was OK.

In case one of the conditions is not ok , the status changes as follows:

S4: Battery not OK S4: Battery not OK The battery is not completely efficient as: Batt. Not Connect. 1. it is not connected to the load Battery Test not OK 2. the last battery test was not ok.

The alarm Battery Test not OK does not reset automatically. It is necessary to

RESET (see), after having checked and repaired the battery.

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The battery test modes on the RTB.e can be enabled and varied in the menu PARAMETERS (see) or from the serial port, by means of the suitable software interface.

The choices to carry out depends on the type of battery installed. For more information consult the Technical Monograph and Technical Specification.

3.2.5 Boost The menu is entered by pressing the key command:

1

BOOST

Menu: CALL BOOST CHARGE Type: COMMAND Password: NO It is accessed by pressing the key


CALL RECH.BOOST MENU Press ENTER

TO CALL BOOST Press ESC To Exit

By pressing the ENTER key the RTB.e brings the output voltage to the

programmed level for the boost charge SETP_VDC_BOOST. The level is maintained for 30 seconds and then returns to floating. All the battery recharge modes and the relevant levels can be enabled and varied in the menu PARAMETERS (see) or from the serial port, by means of the suitable software interface. For more information consult the Technical Monograph and Technical Specification.

3.2.6 Normal-Manual The menu is entered by pressing the key command:

2

NOR/MAN

Menu: NORMAL-MANUAL Type: COMMAND Password: NO It is accessed by pressing the key


NORMAL-MANUAL MENU NOW SET AT: NORMAL PRESS 0 TO MODIFY

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0

HISTORY

The submenu is entered:

NORMAL-MANUAL MENU NOW SET AT: NORMAL + OR – FOR CHANGE

AND CONFIRM

If in this submenu the following keys are pressed:

5

+

and

6

-

If the RTB.e is set on Manual it switches to Normal and viceversa.

NOTE This key works as a two positions switch M-A that remains positioned on the last

selected position. This means that if NORMAL has been selected the RTB.e remains in Normal mode until the operating mode is changed into in MANUAL.

Normally the RTB.e is used to recharge the battery automatically and therefore

the NORMAL mode is selected. The battery manual recharge, called also equalizing, is a function offered by the

RTB.e to allow the operator to carry out a recharge under his own manual control. This recharge modality can be used to form the battery after it has been stocked

for a long period, or after having filled it up with electrolyte, in case of dry delivered batteries, or to equalize the voltage of the battery cells after these have been used for a certain time.

The manual recharge procedure is the following:

Step 1: With RTB.e shutdown the battery voltage that has to be equalized is measured.

Step 2: Enter menu PARAMETERS, menu MANUAL CHARGE (See 3.2.8.2 Parameters Manual Charge), and set, in the following order :

a. The setup voltage (SETP_VDC_EQUAL) in Volt. b. The max charge current (CORR_LIM_EQUAL) in Amp. c. The max time of permanence (MAXTIME EQUAL) in minutes.

Step 3: The regulation potentiometer is positioned at approx. 10%. Step 4: Enter the menu NORMAL-MANUAL and select the MANUAL mode; in

this way the position of the potentiometer is read as starting setup voltage for the equalizing charge.

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Step 5: Start-up the RTB.e. The voltage goes to the starting set-up value. By means of the potentiometer the voltage of the batteries to be equalized can be varied, controlling the recharge current in conformity with the battery specifications. The current however cannot go over the set limit. If it remains in this condition for a longer time than the set limit the voltage returns automatically to the starting setup value.

Step 6: At the end of the procedure shutdown the RTB.e and select again the NORMAL mode; in this way the automatic recharge system is enabled again.

Step 7: Re-start the RTB.e. This procedure can be repeated several time to fraction the forming charge in

several steps with the current limits in different times.

IMPORTANT The manual recharge function or equalizing cannot be used for all types of

batteries. The responsibility of the correct use of the batteries is of the operator. We recommend the use of the manual charge only by specialized personnel.

The choices to carry out and the recharging mode depend on the type of battery installed. For more information consult the Technical Monograph and the Technical Specification.

3.2.7 Reset The menu is entered by pressing the key command:

4

RESET

Menu: RECTIFIER RESET Type: COMMAND Password: NO It is accessed by pressing the key


RECTIFIER RESET MENU Press ENTER TO RESET

Press ESC To Exit

If the key ENTER is pressed the RTB.e carries out a general reset of all the stored

error conditions, or rather of those that do not reset automatically when the anomaly has terminated. Such conditions are forced in the following way:

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TIMEOUT_B = 0 Cancels the intervention of the boost charge safety timer TIMER_BOOST = 0 Zeroing of the boost charge safety timer BOOST = 0 Cancels the intervention of the boost charge recall relay TIMER_EQUAL = 0 Zeroing of the manual charge safety timer MAX_RAD = 0 Cancels the intervention of the max output voltage relay TEMPO_MAX_RAD = 0 Zeroing of the max output voltage intervention relay WRONG_HIGH = 0 Cancels the intervention of the max floating voltage relay TEMPO_MAX_BAT = 0 Zeroing of the max floating voltage intervention relay TEST_OK =1 Resets the battery test not OK alarm.

3.2.8 Parameter The menu is entered by pressing the key command:

8

PARAMETER

Menu: PARAMETERS Type: SETTINGS Password: Yes It is accessed by pressing the key

In the menu the following screen, in which the password has to be entered, is

accessed :

MENU PASS.PROTECTED INSERT THE PASSWORD

**** AND PRESS ENTER

Only if the correct password of 4 numbers is entered the next submenus can be

used. Once entered, the correct password remains active for about 5 minutes.

NOTE The qualifying password is different for each RTB.e. For more information please

consult the Technical Monograph. The menu of the parameters enables to vary the operating modalities of the

various procedures which are programmed on the RTB.e, that are the thresholds and the delays of the protection interventions. For this purpose we recommend the use only by specialised personnel.

7

3

All the available submenus are browsed:

Depending on the entered submenus various screens and options are shown.

3.2.8.1 Parameters Boost Charge In this submenu all parameters relevant to the boost charge can be varied.

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The next screen allows to select the mode with which the RTB.e performs the boost charge of the battery; or rather for:

Intervention of the voltage threshold VOLTAGE BOOST Intervention of the current threshold CURRENT BOOST

BOOST CHARGE MODE

VOLTAGE BOOST PRESS 0 TO MODIFY ARROWS TO SELECT


0

HISTORY


BOOST CHARGE MODE

VOLTAGE BOOST + OR – TO CHANGE ENTER TO CONFIRM

If you press the following key in this submenu:

5

+

And

6

-

If the RTB.e is set in VOLTAGE BOOST, it switches to CURRENT BOOST and

viceversa.

BOOST CHARGE MODE VOLTAGE BOOST

+ OR – TO CHANGE ENTER TO CONFIRM

IMPORTANT

Normally the boost charge mode depends on the battery type. For this reason the mode, once chosen, should never be varied. For more information consult the Technical Monograph.

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The next screen allows to select the delay, after mains failure, with which the RTB.e forces the output voltage to start the boost charge. Such delay is useful to avoid that, at each short mains interruption, RTB.e restarts in boost charge.

MAINS F.DELAY(SEC) NOW SET AT: 0120 PRESS 0 TO MODIFY ARROWS TO SELECT


0

HISTORY


MAINS F.DELAY(SEC) NOW SET AT: 0120

0000 ENTER TO CONFIRM

By means of the alphanumeric keyboard a new delay in seconds can be set

which is memorized in the variable MAX_TIME_MAINS_FAULT. The next screen allows to select the time of intervention of the boost charge

safety timer, after which the RTB.e, forces the output voltage again to floating. If the RTB.e for any reason does not exit the boost charge, the battery voltage is taken anyhow back to floating and an alarm is given.

SAFETY TIMER (MIN) NOW SET AT: 0480 PRESS 0 TO MODIFY ARROWS TO NAVIGATE


0

HISTORY


SAFETY TIMER (MIN) NOW SET AT: 0480


By means of an alphanumeric keyboard the new time in minutes can be set

which is memorized in the variable SAFETY_TIME_B.

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Now the two modes of boost charge are described, and the relevant parameters

that can be changed in this submenu:

a) CURRENT BOOST, or rather recharge I1 I2 U This recharge is mainly used for Ni-Cd batteries. During the recharge the over-

charge of about 125% is provided (called also boost-charge), to compensate the losses in discharge and charge of the battery (estimated in about 25% ). The recharge takes place as follows:

If the mains fails for a time exceeding the programmed time in

MAX_TIME_MAINS_FAULT, at the restart the output voltage of the RTB.e is taken to a higher level than floating, called boost charge and a safety timer is activated.

The next screen sets the voltage of the boost charge:

BOOST CHARGE VOLTAGE NOW SET AT: xxx

PRESS 0 TO MODIFY ARROWS TO SELECT


0

HISTORY

The submenu is entered

BOOST CHARGE VOLTAGE

NOW SET AT: xxx 000.0

ENTER TO CONFIRM

By means of the alphanumeric display a new voltage in Volt can be set. That

voltage will be memorized in SETP_VDC_BOOST. If the boost charge current exceeds the programmed threshold, normally a

certain percent of C10, the set point of the voltage is maintained at the boost level and a first phase of boost charge starts in which the current is constant and the voltage is increasing.

The next screen show how to set the crossing threshold:

FLOAT-BOOST CURRENT NOW SET AT: yyy

PRESS 0 TO MODIFY ARROWS TO NAVIGATE

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0

HISTORY


FLOAT-BOOST CURRENT

NOW SET AT: yyy 000.0

ENTER TO CONFIRM

By means of the alphanumeric keyboard a new current in Ampere can be set.

That current is memorized in the variable CORR_FLOAT_BOOST.

After a certain time the current starts to decrease and the voltage remains constant at the level of boost charge. This is the second phase of the boost charge. Finally, when the current goes below the programmed level for the return in floating the output voltage of the RTB.e it is taken back to floating.

The following screen shows how to set the return threshold:

BOOST-FLOAT CURRENT NOW SET AT: yyy



0

HISTORY


BOOST-FLOAT CURRENT NOW SET AT: yyy

000.0 ENTER TO CONFIRM

By means of an alphanumeric display a new current in Ampere can be set. That

current is memorized in the variable CORR_BOOST_FLOAT.

If this does not happen within the maximum time programmed in SAFETY_TIME_B, the safety timer intervenes and the voltage is forced to floating. This event generates an alarm.

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Figure 2 – Charge I1 I2 U

b) VOLTAGE BOOST, or rather recharge U1 U2 I This recharge is mainly used for Ni-Cd batteries. During the recharge the over-

charge of about 125% is provided (called also boost-charge), to compensate the losses in discharge and charge of the battery (estimated in about 25% ). The recharge takes place as follows:

If the mains fails for a time exceeding the programmed time in MAX_TIME_MAINS_FAULT, at the restart, the output voltage of the RTB.e is taken to a higher level than floating, called boost charge and a safety timer is activated.

The following screen enables to set the boost charge:

BOOST CHARGE VOLTAGE NOW SET AT: xxx



0

HISTORY


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BOOST CHARGE VOLTAGE


ENTER TO CONFIRM

By means of the alphanumeric keyboard a new voltage in Volt can be set. That

voltage is memorized in the variable SETP_VDC_BOOST.

If in the boost charge condition the battery voltage does not exceed the programmed voltage threshold, normally a certain percentage of floating, the boost charge voltage set point is maintained and a first phase of boost charge starts in which the current is constant and the voltage increasing.

The following screen shows how to set the voltage threshold:

FLOAT-BOOST VOLTAGE NOW SET AT: xxx



0

HISTORY


FLOAT-BOOST VOLTAGE


ENTER TO CONFIRM


voltage is memorized in the variable VOLT_FLOAT_BOOST.

After a certain time that the voltage increases it exceeds the programmed level for the return in floating and, after a programmed delay, the output voltage of the RTB.e it is taken back to floating.

The following screen show how to set the return threshold:

BOOST-FLOAT VOLTAGE NOW SET AT: xxx


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0

HISTORY


BOOST-FLOAT VOLTAGE


ENTER TO CONFIRM


voltage is memorized in the variable VOLT_BOOST_FLOAT.

The next screen allows to select the delay of the return from boost to float after that the recharging voltage has reached the VOLT_BOOST_FLOAT level.

D. BOOST-FLOAT (MIN)

NOW SET AT: xxx PRESS 0 TO MODIFY ARROWS TO NAVIGATE


0

HISTORY


D. BOOST-FLOAT (MIN)

NOW SET AT: xxx 0000

ENTER TO CONFIRM

By means of an alphanumeric keyboard the new time in minutes can be set

which is memorized in the variable MAXTEMPO_BOOST_FLOAT. If the voltage doesn’t return automatically to the floating before the maximum

time programmed in SAFETY_TIME_B, the safety timer intervenes and the voltage is forced to floating. This event generates an alarm.

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Figure 3 – Recharge U1 U2 I

3.2.8.2 Parameters Manual Charge In this submenu all parameters relevant to the manual or equalizing charge can

be set. The next screen enables to set the starting voltage for the manual charge:

EQUAL.START. VOLTAGE NOW SET AT: xxx



0

HISTORY


EQUAL.START. VOLTAGE


ENTER TO CONFIRM


voltage is memorized in the variable SETP_VDC_EQUAL.

The next screen enables to set up the max recharging current of the battery during the manual charge (limitation).

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EQUAL. MAX CURRENT NOW SET AT: yyy



0

HISTORY


EQUAL. MAX CURRENT NOW SET AT: yyy


By means of the alphanumeric keyboard a new current in Ampere can be set.

That current is memorized in the variable CORR_LIM_EQUAL.

The next screen enables to select the intervention time of the manual charge safety timer, after which the RTB.e forces the output voltage back again to the starting value.

EQUAL. TIMER (MIN) NOW SET AT: 0540 PRESS 0 TO MODIFY ARROWS TO NAVIGATE


0

HISTORY


EQUAL. TIMER (MIN) NOW SET AT: 0540


By means of an alphanumeric keyboard a new time in minutes can be set which

is memorized in the variable MAXTIME_EQUAL.

NOTE The procedure of manual charge is described in the relevant paragraph in menu

3.2.6 Normal-Manual.

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3.2.8.3 Parameters Battery Data In this submenu all the relevant parameters for the maximum recharging current

of the battery and the battery floating voltage can be set. The next screen enables to set the battery floating voltage:

FLOATING VOLTAGE NOW SET AT: xxx



0

HISTORY


FLOATING VOLTAGE NOW SET AT: xxx


By means of an alphanumeric keyboard a new voltage in Volt can be set.

That voltage is memorized in the variable SETP_VDC_FLOAT.

The next screen enables to set the maximum recharging current of the battery during the automatic charge.

RECHARGE MAX CURRENT

NOW SET AT: yyy PRESS 0 TO MODIFY ARROWS TO NAVIGATE


0

HISTORY


RECHARGE MAX CURRENT NOW SET AT: yyy


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By means of an alphanumeric keyboard a new current in Ampere can be set.That current is memorized in the variable CORR_LIM_AUTO.

Adjusting these two parameters it is possible to set the following recharge function:

c) Recharge IU according to the DIN 41773 standard The recharge takes place in two phases : Phase 1: the current is constant and the voltage increases Phase 2: the current decreases and the voltage is constant When the current of recharge goes below a certain value the battery is

considered recharged and the cycles ends. Consequently the output voltage is set back to the floating voltage.

Figure 4 – Recharge IU

During floating the battery voltage is controlled towards the minimum level in order to avoid undesired discharges and towards the maximum level in order avoid an excessive heating of the electrolyte. (For the same reason an option for thermal compensation of the floating voltage – battery voltage versus battery temperature - can be added).

The next screen enables to set the minimum floating voltage:

LOW FLOATING LEVEL NOW SET AT: xxx


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0

HISTORY


LOW FLOATING LEVEL NOW SET AT: xxx



That voltage is memorized in the variable MIN_VBAT. If the battery voltage goes below this threshold and alarm is given.

The next screen enables to set the maximum floating voltage:

HIGH FLOATING LEVEL NOW SET AT: xxx



0

HISTORY


HIGH FLOATING LEVEL


ENTER TO CONFIRM

By means of an alphanumeric keyboard a new voltage in Volt can be set. That voltage is memorized in the variable MAX_VBAT. If the battery voltage

exceeds this threshold an alarm is given and the RTB.e is shut down in permanent mode (it has to be RESET).

The next screen enables to the delay time for the intervention of the maximum floating voltage, after which the RTB.e shuts down and generates an alarm:

HIGH FLOAT DELAY (S) NOW SET AT: 0005 PRESS 0 TO MODIFY ARROWS TO NAVIGATE

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HISTORY


HIGH FLOAT DELAY (S)

NOW SET AT: 0005 0000

ENTER TO CONFIRM

By means of an alphanumeric keyboard a new time in seconds can be set which

is memorized in the variable MAX_TEMPO_MAX_BAT.

d) Discharge level settings During the discharge of the battery (mains fault) the control logic of the RTB.e

remains active and voltage threshold levels can be set to signal the discharge levels reached by the battery.

The next screen enables to set the first discharge level:

DISCHARGE LEVEL 1 NOW SET AT: xxx



0

HISTORY





That voltage is memorized in the variable LIVELLO1. If the battery voltage goes below this threshold an alarm is given.

The next screen enables to set the second discharge level:




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0

HISTORY






The next screen enables to set the third discharge level:




0

HISTORY






NOTE The management of the discharge levels and the above described recharge

modalities depend on the type of battery and application. For more information consult the Technical Monograph and the Technical Specification.

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3.2.8.4 Parameters Input Data In this submenu all the control parameters relevant to the RTB.e input can be

visualized. The next screen shows the frequency limits:

FREQUENCY MAX fff HZ NOM fff HZ MIN fff HZ

Using the keys:

7

3

All the available screens can be browsed.

The following screen shows the input voltage limits in Volt:

VOLTAGE MAX xxx Vac NOM xxx Vac MIN xxx Vac

3.2.8.5 Parameters Output Data In this submenu all the control parameters relevant to the RTB.e voltage and

current output can be visualized. Some are fix and others can be varied. The next screen shows the nominal value of the output voltage in Volt::

OUTPUT DATA NOMINAL VOLTAGE

VALUE: xxx ARROWS TO NAVIGATE

Using the keys:

7

3

All the available screens can be browsed.

The next screen shows the nominal output current in Ampere: OUTPUT DATA

NOMINAL CURRENT VALUE: yyy ARROWS TO NAVIGATE

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The next screen shows the maximum output current in Ampere (total output current limitation):

OUTPUT DATA MAX TOTAL CURRENT

VALUE: yyy ARROWS TO NAVIGATE

The next screen enables to set the threshold of maximum output voltage of the RTB.e:

MAX OUTPUT VOLTAGE NOW SET AT: xxx



0

HISTORY


MAX OUTPUT VOLTAGE NOW SET AT: xxx


By means of an alphanumeric keyboard a new voltage in Volt can be set. That voltage is memorized in the variable MAX_VRECT. If the output voltage

exceeds this threshold an alarm is given and the RTB.e is shut down in permanent mode (it has to be RESET).

The next screen enables to adjust the delay time for the intervention of the maximum output voltage, after which the RTB.e shuts down and generates an alarm.

MAX-VOUT DELAY (S) NOW SET AT: 0005 PRESS 0 TO MODIFY ARROWS TO NAVIGATE


0

HISTORY


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MAX-VOUT DELAY (S) NOW SET AT: 0005


By means of an alphanumeric keyboard a new time in seconds can be set which

is memorized in the variable MAX_TEMPO_MAX_RAD. The next screen enables to set the minimum output voltage:

MIN OUTPUT VOLTAGE NOW SET AT: xxx



0

HISTORY


MIN OUTPUT VOLTAGE NOW SET AT: xxx



That voltage is memorized in the variable MIN_VRECT If the output voltage goes below this threshold an alarm is given.

The next screen enables to set the emergency voltage level to which the output voltage of the RTB.e can be forced by means of an external contact:

EMERGENCY LEVEL NOW SET AT: xxx



0

HISTORY


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EMERGENCY LEVEL NOW SET AT: xxx



That voltage is memorized in the variable LIVELLO4. If the contact is active, the output voltage is forced to the set value and an alarm is given.

NOTE

The presence of the emergency output level depends on the type of application. For more information please consult the Technical Monograph and the Technical

Specification.

3.2.8.6 Parameters Battery Info In this submenu the parameters relevant to the type of battery installed can be

visualized and varied with the RTB.e. This screen enables to set the battery capacity in Ampere-hour.

BATTERY SIZE (Ah) NOW SET AT: yyy



0

HISTORY


BATTERY SIZE (Ah) NOW SET AT: yyy


By means of the alphanumeric keyboard a new capacity in Ampere-hour can be

set. The next screen shows to set the battery installation date in format mm/yy

(month/year):

BATTERY INST. DATE NOW SET AT: 21/03 PRESS 0 TO MODIFY ARROWS TO NAVIGATE

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0

HISTORY


BATTERY INST. DATE NOW SET AT: 21/03


By means of the alphanumeric keyboard a new date of installation can be set.

The figures enter from right to left and therefore to set May/2002 you need to digit 05 and then 02 and press ENTER.

IMPORTANT

The setting of the correct capacity is mandatory for a correct calculation of the residual battery autonomy.

For more information please consult the Technical Monograph and the Technical Specification.

3.2.8.7 Parameters Default Parameters This submenu enables to recall all the default operating parameters of the RTB.e,

or rather those that were memorized in the factory. The next screen enables to recall the default settings.

PRESS 0 TO RELOAD THE DEFAULT

PAMETERS; THEN RESTART THE RECTIFIER


0

HISTORY

The RTB.e must be shutdown and completely restarted in order to reload the

default parameters. NOTE

The reloading of the default parameters cancels all the previous settings. The use of this function is recommended only by specialized personnel.

For more information please consult the Technical Monograph and the Technical Specification.

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3.2.9 Status This menu is entered by pressing the command:

9

STATUS

Menu: BATTERY STATUS Type: VISUALISATION and COMMAND Password: YES It is accessed by pressing the key

In the menu the next screen is entered:






consult the Technical Monograph. If the automatic recharge mode is active, the following screen is shown:

BATTERY STATUS Battery Charged

At 095 % PRESS 0 TO TEST

The third row indicates the % of the recharged autonomy. The fourth row indicates if the battery test is enabled. The enabling of the test depends on setting (see the Technical Monograph and the Technical Specification), on the last test status (if ok) and on the recharged autonomy > 90%. If the test is enabled and you press the key:

0

HISTORY

The battery test starts and the following screen is shown:

BATTERY IN TEST Vbat: xxx Ibat: yyy Time: 150 End: 180 PRESS 0 TO STOP

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On the second row the battery voltage and current are shown. The third row represents the remaining autonomy in minutes.

The test works as follows:

Step 1: The output voltage of the RTB.e is set at the first dicharge level LIVELLO1.

Step 2: The battery discharges at the current Idisc which depends on the connected load.

Step 3: The discharging current Idisc is compared to the output nominal current of the RTB.e Inom.

Step 4: The battery is discharged for Tdisc = Inom / Idisc (minutes), up to the max time of: Tdisc ≤ 3 (minutes). Step 5: If LIVELLO1 is reached, the test is stopped, the floating voltage is

restored and the test fails TEST_OK = 0. If during Tdisc, the battery voltage doesn’t reach LIVELLO1 the RTB.e is set back to the floating and the test is successful (TEST_OK = 1).

Step 6: If, during the test, the 0 Key is pressed the test is stopped, the RTB.e is set back to the floating and the variable TEST_OK is not changed.

IMPORTANT

The responsibility of the correct use of the batteries is of the operator. We recommend the use of the manual charge only by specialized personnel.

If the test fails, la variable TEST_OK = 0 is memorized until the RESET (see). The status S4 (Battery OK or Battery Not OK) depends on the value of the

variable TEST_OK. If the battery is discharging the following screen is shown:

BATTERY STATUS Battery Dicharge

Vbat: xxx Ibat: yyy Aut: 0020 (MIN)

On the third row the battery voltage and current are shown. The fourth row

represents the remaining autonomy in minutes. If the manual charge is selected the following screen is shown:

BATTERY STATUS MANUAL CHARGE STATUS Vbat: xxx Ibat: yyy Timer: 0050 (MIN)

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On the third row the battery voltage and current are shown. The fourth row represents the recharging time in minutes.

NOTE

This menu can be used to verify the correct operation of the RTB.e. Its use is not strictly necessary during the current use of the RTB.e.

3.2.10 History The RTB.e memorizes up to 500 alarm events with relevant indication of the

date and time. When the alarm 501 is memorized the first is cancelled and so on. The relevant menu is entered by pressing the key:

0

HISTORY

Menu: HYSTORY Type: SETTINGS Password: Yes It is accessed by pressing the key

In the menu the next screen is entered:






consult the Technical Monograph. If the password is correct, the following screen is shown:

1. ALARMS HISTORY 2. RESET HISTORY

PRESS ESC TO EXIT


1

BOOST

The events history which is structured as follows is accessed:

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A11* 05 01 03 09:20 A12* 05 01 03 09:19

A11 05 01 03 09:15 A12 05 01 03 09:15

Using the keys:

7

3

You can browse up and down the alarms event memory

The star after the code indicates when the alarm has ended:

If, instead, inside the following screen:

1. Alarms History 2. Reset History

Press ESC To Exit

The following key is pressed:

2

NOR/MAN

The cancelling of the events history is accessed

If inside the following screen:

RESET HISTORY PRESS ENTER TO CONTINUE ESC To Exit

The following key is pressed:

ENT

The alarms history is cancelled.

IMPORTANT

The cancelling of the alarms history can cause the irreversible loss of important information necessary for the service and maintenance of the RTB.e. This operation is therefore recommended to be carried out by competent personnel during service.

Code Date

Time

Front Panel

Issued 10.12.2008 JGE410502 43 of 45

4. SFP SYSTEM DATA

4.1 75A 125VDC BLOCK DC SYSTEMS INPUT VOLTAGE Ph-N 277 Vac INPUT FREQUENCY 60 Hz INPUT CURRENT 16 A INPUT POWER 13,1 kVA FLOATING 129,3 Vdc BOOST 136,3 Vdc RECTIFIER CURRENT 75 A BATTERY CURRENT 31 A FLOAT-BOOST CURRENT 28 A BOOST-FLOAT CURRENT 11 A FLOAT-BOOST VOLTAGE 104 Vdc BOOST-FLOAT VOLTAGE 136 Vdc EQUAL. START VOLTAGE 90 Vdc EQUAL. MAX. CURRENT 31 A RECHARGE MAX. CURRENT 31 A LOW FLOATING LEVEL 126 Vdc HIGH FLOATING LEVEL 132 Vdc DISCHARGE LEVEL 1 110 Vdc DISCHARGE LEVEL 2 108 Vdc DISCHARGE LEVEL 3 106 Vdc FREQUENCY MAX 62 Hz FREQUENCY NOMINAL 60 Hz FREQUENCY MIN 58 Hz NOMINAL OUTPUT CURRENT 75 A MAX. OUTPUT CURRENT 80 A MAX. OUTPUT VOLTAGE 145 Vdc EMERGENCY LEVEL N.U. BATTERY SIZE 308 Ah

Front Panel

44 of 45 JGE410502 Issued 10.12.2008

4.2 160A 125VDC STATION DC SYSTEMS

INPUT VOLTAGE Ph-N 277 Vac INPUT FREQUENCY 60 Hz INPUT CURRENT 16 A INPUT POWER 13,1 kVA FLOATING 129,3 Vdc BOOST 136,3 Vdc RECTIFIER CURRENT 160 A BATTERY CURRENT 61 A FLOAT-BOOST CURRENT 54 A BOOST-FLOAT CURRENT 18 A FLOAT-BOOST VOLTAGE 104 Vdc BOOST-FLOAT VOLTAGE 136 Vdc EQUAL. START VOLTAGE 90 Vdc EQUAL. MAX. CURRENT 61 A RECHARGE MAX. CURRENT 61 A LOW FLOATING LEVEL 126 Vdc HIGH FLOATING LEVEL 132 Vdc DISCHARGE LEVEL 1 110 Vdc DISCHARGE LEVEL 2 108 Vdc DISCHARGE LEVEL 3 106 Vdc FREQUENCY MAX 62 Hz FREQUENCY NOMINAL 60 Hz FREQUENCY MIN 58 Hz NOMINAL OUTPUT CURRENT 160 A MAX. OUTPUT CURRENT 170 A MAX. OUTPUT VOLTAGE 145 Vdc EMERGENCY LEVEL N.U. BATTERY SIZE 609 Ah

Front Panel

Issued 10.12.2008 JGE410502 45 of 45

4.3 300A 125VDC GAS COMPRESSOR DC SYSTEMS

INPUT VOLTAGE Ph-N 277 Vac INPUT FREQUENCY 60 Hz INPUT CURRENT 16 A INPUT POWER 13,1 kVA FLOATING 129,3 Vdc BOOST 136,3 Vdc RECTIFIER CURRENT 300 A BATTERY CURRENT 122 A FLOAT-BOOST CURRENT 109 A BOOST-FLOAT CURRENT 42 A FLOAT-BOOST VOLTAGE 104 Vdc BOOST-FLOAT VOLTAGE 136 Vdc EQUAL. START VOLTAGE 90 Vdc EQUAL. MAX. CURRENT 122 A RECHARGE MAX. CURRENT 122 A LOW FLOATING LEVEL 126 Vdc HIGH FLOATING LEVEL 132 Vdc DISCHARGE LEVEL 1 110 Vdc DISCHARGE LEVEL 2 108 Vdc DISCHARGE LEVEL 3 106 Vdc FREQUENCY MAX 62 Hz FREQUENCY NOMINAL 60 Hz FREQUENCY MIN 58 Hz NOMINAL OUTPUT CURRENT 300 A MAX. OUTPUT CURRENT 310 A MAX. OUTPUT VOLTAGE 145 Vdc EMERGENCY LEVEL N.U. BATTERY SIZE 1218 Ah

Start-up and Shutdown

Issued 10.12.2008 JGE410502 1 of 6

START-UP AND SHUTDOWN

Index

1. INTRODUCTION ................................................................................. 2

2. START-UP PROCEDURE .................................................................. 2

3. PROCEDURE OF SHUTDOWN AND DISCONNECTION ................. 4

4. SIMPLE SHUTDOWN PROCEDURE ................................................. 6

Start-up and Shut-down

2 of 6 JGE410502 Issued 10.12.2008

1. INTRODUCTION

The following procedures show the Start-up and Shutdown procedure for the RTB.e. Further information could be contained in the Technical Specification and in the Technical Monograph. It is recommended to consult all the available documentation before carrying out the procedures which follow.

NOTE

Here is indicated the function and position of each circuit breaker that will be mentioned in this manual.

Q1-RICB RTB.e mains input circuit breaker. Q2-ROCB RTB.e output circuit breaker. Q7-BCB Battery breaker

IMPORTANT Any operation carried out both for the connection or disconnection of RTB.e from the

mains, the battery and the loads must be carried out by skilled personnel. The manufacturer declines any responsibility of damage caused by the equipment

due to wrong operations.

2. START-UP PROCEDURE

To start-up the RTB.e proceed as follows: 1) Close Q1-RICB and wait that the display goes on. 2) If the RTB.e is off (status OFF) following screen is shown:

RECTIFIER CHARGER

SWITCHED OFF PRESS ON TO START

3) Pressing the key:

S

ON/OFF


Issued 10.12.2008 JGE410502 3 of 6

In the menu following screens are entered:

ON-OFF MENU

NOW SET AT: OFF PRESS 0 TO MODIFY


0

HISTORY


If in this submenu following keys are pressed:

5

+

Or

6

-

The RTB.e starts up and the following screen is shown .

RECTIFIER CHARGER

SWITCHED ON Wait Please

Startup in Progress

IMPORTANT This key works as two position ON-OFF switch which remains on the last

chosen position. This means that if ON was selected, the RTB.e start-up automatically until OFF is chosen.

ON-OFF MENU NOW SET TO: OFF + OR – FOR CHANGE

AND CONFIRM


4 of 6 JGE410502 Issued 10.12.2008

4) If the start-up is positive the following screen will show on the display and the buzzer starts:

RECTIFIER CHARGER

CLOSE BCB VDC = 240 V IDC = 000 A

NOTE

The output voltage measure depends on the characteristics of the RTB.e. Please check the Technical Monograph in annex:

5) Close Q7-BCB.

6) Close Q2-ROCB.

7) When the start up is finished the following screen will be shown.

RECTIFIER CHARGER FLOATING VOLTAGE

VDC = 240 V IDC = 000 A

3. PROCEDURE OF SHUTDOWN AND DISCONNECTION

To stop the RTB.e follow this procedure: 1) Press the key:

S

ON/OFF

The following screen is shown:

ON-OFF MENU

NOW SET AT: ON PRESS 0 TO MODIFY


0

HISTORY

The submenu is entered::


Issued 10.12.2008 JGE410502 5 of 6

If in this submenu following keys are pressed:

5

+

Or

6

-

The RTB.e shuts down and and on the display following is shown:

RECTIFIER CHARGER SWITCHED OFF PRESS ON TO START

IMPORTANT

This keys works as two position ON-OFF switch which remains on the last chosen position. This means that if ON was selected, the RTB.e start-up automatically until OFF is chosen.

2) Open Q1-RICB.

3) Open Q7-BCB. 4) Open Q2-ROCB.

IMPORTANT

Before carrying out the opening of the RTB.e breakers check if this operation could cause any damage to the supplied loads.

For this purpose consult the Technical Monograph in annex.

ON-OFF MENU NOW SET AT: ON + OR – FOR CHANGE

AND CONFIRM


6 of 6 JGE410502 Issued 10.12.2008

4. SIMPLE SHUTDOWN PROCEDURE

The RTB.e can be disconnected from the mains from the battery and from the loads (without shutdown from an external key or from the front panel) proceeding as follows:

1) Open Q1-RICB.

2) Open Q7-BCB. 3) Open Q2-ROCB.

IMPORTANT

Before carrying out the opening of the RTB.e breakers check if this operation could cause any damage to the supplied loads.

For this purpose consult the Technical Monograph in annex.

BATTERY CHARGER Test Procedure


Data Date

Emesso Issued

Controllato Checked

Approvato Approved

Lingua Language

Pagina Page

di Pag. of Pag.

/ First Issue 28/01/09 P. Conti E. Simoni E. Simoni I 1 16 Codice / Code

JUD411352

BATTERY CHARGER TEST PROCEDURE

Index

1. INTRODUCTION.................................................................................. 3

2. VISUAL CHECK .................................................................................. 3

3. SWITCH AND JUMPERS SETTING ................................................... 3

4. SETTING OF THE STARTING PARAMETERS.................................. 4

5. START-UP IN MANUAL MODE .......................................................... 6

6. START-UP IN AUTOMATIC MODE .................................................... 9

7. LOAD TESTS .................................................................................... 10

8. SETTING OF THE MANUAL CHARGE ............................................ 12

9. SETTING OF THE BOOST CHARGE ............................................... 12

10. SETTING OF THE THERMAL PROBE (RECHARGING VOLTAGE COMPENSATION).................................................................................... 13

11. FINAL TEST .................................................................................... 13

12. TEST OF THE RTB.E SYSTEM IN PARALLEL REDUNDANT CONFIGURATION .................................................................................... 14


2 of 16 JUD411352 First Issue 28/01/09

Drawing index

Figure 1 – DWG 1......................................................................................................................................... 3 Table 1 – jumper settings JP1, JP2, JP3, JP8 and JP9 pcboard DR16-COMP........................................... 3 Table 2 – jumper settings JP10, JP11, JP12 and JP13 board DR16-COMP............................................... 4 Dwg. 2 – 6 pulse rectifier output without DC filter (ADEG080)................................................................... 7 Dwg. 3 – 6 pulse rectifier output without DC filter (ADEG080).................................................................. 8


First Issue 28/01/09 JUD411352 3 of 16

1. INTRODUCTION

The scope of this procedure is to guide the technician through the correct final testing of the equipment.

2. VISUAL CHECK

1) Check the wiring harness 1) Ensure that all the cables and connectors are correctly identified by the code

and relevant number in compliance with the electric diagram. 2) Check that the cables or the power bars section are those indicated on the

relevant wiring list.

3. SWITCH AND JUMPERS SETTING

1) Set SW1 of board DR16-COMP (N_FS3006) as required from the technical specification.

Dip n. Status Description

Off Battery test disabled 1 On Battery test enabled Off Rapid Charge disabled 2 On Rapid charge enabled Off Manual Charge disabled 3 On Manual Charge enabled Off Parallel configuration disabled 4 On Parallel configuration enabled

Figure 1 – DWG 1

The Dips 4, 5, 6, 7, 8 are not used presently and must be left on Off position.

2) Set jumpers JP1, JP2, JP3, JP8 and JP9 according to the following table comparing the nominal and recharging current of the system with the type of Hall effect ammeter on the equipment.

I out nominal

Hall effect ammeter ratio

I batteryrecharge

I total of the output

I share

JP1 JP2 I Max Sat. JP8 JP9 I Max Sat. JP3 I Max Sat. 50 A 2000/1 yes no 108A Yes no 202A yes 30A 100 A yes no 108A Yes no 202A yes 30A 150 A No yes 300A no Yes 300A yes 30A 200 A No yes 300A no Yes 300A yes 30A 250 A yes yes 408A Yes Yes 502A yes 30A 300 A 4000/1 No yes 600A no Yes 600A yes 60A 500 A 5000/1 No yes 750A no Yes 750A yes 76A 750 A yes yes 816A Yes Yes 1004A yes 76A

>950 A Please refer to Operating Instructions PB132008

Table 1 – jumper settings JP1, JP2, JP3, JP8 and JP9 pcboard DR16-COMP



3) Set jumpers JP10, JP11, JP12 and JP13 according to the following table and in function of the output voltage type of the rectifier.

4) Voltage: Rectifier Battery

JP10 JP11 JP12 JP13 24-48-110 Vdc No No No No

220-380 Vdc yes yes yes yes

Table 2 – jumper settings JP10, JP11, JP12 and JP13 board DR16-COMP

4. SETTING OF THE STARTING PARAMETERS

1) Disconnect the positive pole of the dc capacitors that compose the DC filter taking care not to disconnect the bars + and – of rectifier from the voltage feedback (cable connected to M15 of the Back-Panel board). Disconnect the filter capacitor terminals from the filters assembled before the RICB and BCB switches.

2) Without inserting boards DR16-COMP and PS-DR16, close the input switch

RICB powering up the system. Check on the back-side of the Back-Panel the following connectors:

M20: verifying the presence of the primary voltage of the input transformer. M1: verifying the presence of the secondary voltage of the auxiliary transformer.

Give particular attention to the phase sequence of the three phase trio on the two above mentioned connections.

3) Open RICB and insert the boards DR16-COMP and PS-DR16 with the relevant

aluminium front covers. Ensure that both boards are correctly connected to the Back-panel terminals. The board PS-DR16 must be inserted in the left slide.

4) Open contact 19-20 of M18 on the Back-panel board in order to put the

modulation of the rectifier bridge in OFF mode for the next start-up. 5) Start-up the system by closing RICB. Check that following Leds are on of the

board PS-DR16.

Led +15 V Green fix on Led -15 V Green fix on Led +5 SER Green fix on Led +5 FIR Green fix on

Led +5 SPI Green fix on Led -12 SPI Green fix on

6) Check that following Leds are on of the microprocessor board DR16-COMP.



Led MicroOk Green flashing Led +5 V Green fix on Phase Sequence Green fix on

Verify that front panel transmits the start-up errors.

7) Silence the buzzer by means of the relevant push button and send the

command MEEE000. Press the push button Parameters, enter the password and scroll the surfing keys until you reach the menu Default Parameters ; follow the instructions of the this submenu.

8) Once you have carried out the instructions open RICB and wait until the boards

are unenergized.

9) Connect, by means of the communication board SER-DR16 on the rectifier, the PC with the test software. Close RICB again. For approximately 5 seconds the microprocessor will download the given default parameters. After this lapse of time, check that the PC communicates correctly with the system and that on the Parameters Panel of the PC the data correspond to the required ones.

10) On the test software click the key PID Panel to check the parameters of the

proportional and supplementary control that have to be set as follows::

KC_BATT = 100 Can be changed with KCBAxxx KBI_BATT = 10 Can be changed with KIBAxxx KC_CTOT = 100 Can be changed with KCTOxxx KBI_CTOT = 10 Can be changed with KITOxxx

KC_V = 100 (*) Can be changed with KCFRxxx KBI_V = 20 Can be changed with KIFRxxx

Only for 12 pulse configuration, send the following commands, to force to zero the unbalancement of the two bridges.

BPOR000 BNER000

Check on the DR16 Test that the value Balance Compensation is zero.

Send command MEEE000 to memorize the performed settings.

11) Measure the input voltage of the system, phase – neutral, and set the relevant

readings by means of the following commands:

TIFRxxx xxx = value of the voltage measure referred to the neutral for phase R TIFSxxx xxx = value of the voltage measure referred to the neutral for phase S TIFTxxx xxx = value of the voltage measure referred to the neutral for



phase T

Send the command MEEE000 to memorize the performed settings. Verify the readings on the PC.

12) Press the button ON/OFF of the front panel and check that the rectifier is on OFF mode. If not carry out the instructions to put in OFF mode.

ATTENTION (*): the parameter KC_V must be fixed to 200 if the revision index of the rectifier’s

control logic card (N_FS3006) is A.

5. START-UP IN MANUAL MODE

1) Open RICB and re close the contact 19-20 of M18 on the Back-Panel. Connect the burden resistor between + and the bar – of the rectifier and the eventual blocking diode of the rectifier and battery branch. Connect in parallel with the burden resistor a multimeter and an isolated oscilloscope.

2) Close RICB. Verify that the front panel transmits the start-up errors. Digit the

command ADEG120 and switch-on the modulation of the rectifier by means of the ON/OFF press button on the front panel.

3) Digit the command ADEG080, measure the output voltage and send the

following command:

VRECxxx xxx = value halve the measure of the rectifier output voltage on the load.

Don’t send the command MEEE000



4) With the isolated oscilloscope, check that in a period of the primary supplying voltage 6 pulses or 12 pulses can be distinguished. In dwg 2, the example of a 6 pulse rectifier where 6 impulses can be distinguished in a period of 20ms of the supply voltage.

Dwg. 2 – 6 pulse rectifier output without DC filter (ADEG080)

5) Digit the command ADEG001 and verify the value of the output value that will have to be equal to 1.35 times the secondary line voltage of the input transformer.



6) With the isolated oscilloscope, check that in a period of the primary supplying voltage 6 pulses or 12 pulses can be distinguished. In dwg 3, the example of a 6 pulse rectifier where 6 impulses can be distinguished in a period of 20ms of the supply voltage.

Dwg. 3 – 6 pulse rectifier output without DC filter (ADEG080)

7) Digit the command ADEG080, measure the output voltage and send the following command:

VRECxxx xxx = real value of the rectifier output dc voltage on

the load Send the command MEEE000

8) By means of the press button ON/OFF on the front panel , switch-off the rectifier

modulation. 9) Send the command ADEG080 and the command MEEE000. Wait that the

continous voltage goes to 0 V. Open RICB, remount the DC filter, the voltage feed-back and the filter capacitors terminal assembled before the circuit breakers RICB and BCB. Remove the burden capacitor.



6. START-UP IN AUTOMATIC MODE

1) Close RICB and wait for the alarms visualisation on the front panel. By means of the press button ON/OFF of the front panel switch on the rectifier bridge. At the end of the softstart, verify that the final voltage coincides with the set one. Verify the reading of the real output voltage with the one shown on the front panel. Reset in case it does not coincide with the command VRECxxx (xxx = value the rectifier dc output voltage).

2) Set the reading of the battery voltage by means of the command

VBATxxx xxx = value of the measure of the rectifier dc output

voltage on the battery.

Send the command MEEE000 to memorize the performed setting. Verify the reading on the PC.

3) Open RICB and wait that the dc voltage goes below 0 V.



7. LOAD TESTS

ATTENTION Care must be given to connect and disconnect the various load steps due to the

reduction of the cutting power of the dc switches. Particularly , in order to remove the load, it is necessary to switch-off the rectifier modulation, operate the switches and

restart with softstart.. 1) Connect on both on the battery side than on the load side a resistive load. 2) Close RICB and start-up the rectifier. 3) Close the output breaker ROCB and connect a first load step : set the reading

of the total current by means of the command:

CTOTxxx xxx = value of the measure of the rectifier total output current on the load side.

Send the command MEEE000 to memorize the performed setting. Verify the

reading on the PC.

Only for 12 pulse configuration, check the current sharing of the two bridges: they have to supply the 50% +/- 10% of the total load. In case the difference is higher than the specified limits, it's possible to adjust the current sharing with the following commands:

BPORXXX (value 0 to 400) to increase the current supplied from bridge 1 BNERXXX (value 0 to 400) to increase the current supplied from bridge 2 Verify the reading on the PC, on the label Balance Compensation of Dr16-

Test software. Verify, applying various step of load at the output, that the current sharing is

in tolerance with the value specified above. Send the command MEEE000 to memorize the performed setting. Verify the

reading on the PC.

Vary the load and verify the linearity of the reading of the front panel at full load.

4) Verify the total current limitation connecting a higher load than the one set at maximum output current. Verify that the output voltage remains stable during the limitation. (V out nominal +/- 2%). 5) Connect a load equal to 50 % of the nominal and set the reading of the input

current by means of the following commands.



TCIRxxx xxx = value of the measure of the absorbed current on the phase R.

TCISxxx xxx = value of the measure of absorbed current on

the phase S. TCITxxx xxx = value of the measure of the absorbed current

on the phase T.

Send the command MEEE000 to memorize the performed setting. Verify the reading on the PC. Vary the output load and verify the linearity of the reading of the front panel.

6) Remove the load.

7) Close the battery breaker BCB and connect a first load step: set the battery

current reading by means of following command:

CBATxxx xxx = value of the measure of the rectifier output current on the battery side.

Send the command MEEE000 to memorize the performed setting. Verify the reading on the PC. Vary the load and verify the linearity of the reading of the front panel.

8) Verify the battery current limitation connection a higher load than the one set at maximum recharge current.

9) Shut-down the system and wait that the voltage goes to zero. Remove the

resistite load on the battery side and connect the batteries.

10) Start-up the system following the start-up procedure. Connect a load on the output and induce a battery discharge switching off the rectifier modulation by means of the press button ON/OFF on the panel.

11) Switch on again the rectifier modulation by means of the ON/OFF button on the

panel and watch the behaviour of the system during the battery current limitation. Verify that the recharging current is equal to the set one ± 2%.

12) Remove the load and open the battery breaker.

13) In compliance with the technical book and the project characteristics, verify the

auxiliary signalling, the operating of the eventual shunt trips for the battery minimum voltage and whatever else may be present.



8. SETTING OF THE MANUAL CHARGE

1) To enable the manual charge function, operate on the Dip n.3 of the board DR16-COMP referring to fig. 1

2) Close RICB and put the rectifier on OFF status. Rotate the potentiometer on

the front of the equipment to the maximum and send the command:

POTA150 for systems with output nominal voltage 220 Vdc POTA075 for systems with output nominal voltage 110 Vdc

Send command MEEE000 to memorize performed setting.

3) Rotate the potentiometer to the minimum and select on the front panel the MANUAL CHARGE mode by means of the key NOR/MAN.

4) Verify that the rectifier goes to the set starting voltage. Rotate the potetiomenter

and verify that the output voltage varies. Verify on the PC that the system is in EQUAL status.

9. SETTING OF THE BOOST CHARGE

1) To enable the boost charge function, operate on the Dip n.2 of the board DR16-COMP referring to fig. 1

2) Switch on the rectifier and check on the Parameters Panel of the test software

on the PC the presence of the data relevant to the Boost Charge mode and their accuracy.

3) Connect the output load and close BCB; switch-off the rectifier modulation

inducing a long battery discharge.

4) Restart the rectifier modulation and watch the phase of battery recharging. Verify that if the absorbed battery current is higher that the set one from Float to Boost (current boost mode) or if the battery voltage is lower that the 1rs Level threshold (voltage boost mode) , the rectifier enters the boost phase showing it on the front panel. Verify on PC that the Set-Point Vdc corresponds to the boost voltage.



10. SETTING OF THE THERMAL PROBE (RECHARGING VOLTAGE COMPENSATION)

1) Shut-down the system. 1a) Connect the thermal probe on the back panel (N_FS3004) as per operating

instruction JRE409515. 1b) Start-up the system. 2) Measure the ambient temperature and send the command:

TEMPxxx where xxx is the temperature

(es.: TEMP020 for 20°C)

Memorize the command MEEE000.

3) Check the temperature reading on the display on the menu MEASURES. 4) Wait at least 5 minutes from the moment of the temperature setting and verify,

heating the probe with a hairdryer, that the floating output voltage varies with following progress :

T ↑ ⇒ VOUT ↓

11. FINAL TEST

1) With switched on rectifier, check on the front panel the correctness of the set data.

2) Verify the correct regulation of the eventual analog measuring instruments on

the front of the equipment

3) Reset hour and date by means of the appropriate key on the front keyboard.

4) Reset the alarms event

5) Shutdown the equipment, fix the bolts on the boards on the racks.

6) Fill the measurement report



12. TEST OF THE RTB.e SYSTEM IN PARALLEL REDUNDANT CONFIGURATION

This procedure is based on a configuration of two RTB.e connected in parallel on one DC BUS BAR and to one or two batteries these also connected in parallel to the DC BUS BAR.

ATTENTION

Both rectifiers have to be tested and the measures of the battery voltage, battery current, output current and voltage have to coincide. Verify both RTB.e that with the same load and battery current have the same readings on the PC.

Verify that both RTB.e generalt settings (Floating-Boost voltage, recharging parameters, thermal compensation coefficients) are the same.

1. In both the RTB.e, connect the board N_FS3011 on the board N_FS3006 (See operating instruction JRE409517).

2. On board N_FS3006, set the DIPSW 4 in position ON.

3. Verify that on the board N_FS3006 the setting have been carried out as per

operating instruction JRE409518.

4. Connect the connecting cable between the two RTB.e. The cable has to be connected to the female DB9 connectors, that are on the front of the rack of the control boards.

5. If no joining breaker is present between RTB.e 1 and RTB.e 2, connect a

jumper on the pins 17-18, of M18 of the Back-Panel N_FS3004 board.

6. For both the RTB.e, close RICB and put the rectifier on OFF mode.

7. Send to RTB.e 1 the command POSI001 and memorize with command MEEE000.

8. Send to RTB.e 2 the command POSI002 and memorize with command

MEEE000. 9. On RTB.e 1, verify the following led on the front of the rack on the control

boards:

TRX1 fix on TRX2 blinking

10. On RTB.e 2, verify the following led on the front of the rack on the control

boards:

TRX1 blinking TRX2 fix on



11. On both RTB.e send following commands KCSH100

KISH020

Send MEEE000 to memorize . On the test software, click on the PID Panel and verify the proportional and integrative parameters that have to be set as follows:

KC_SH = 100 Can be changed with KCSHxxx KI_SH = 20 Can be changed with KISHxxx 12. With two batteries in parallel procede as follows:

12a) Open RICB on both RTB.e and close the eventual interconnection device between the two RTB.e .

12b) Connect the restive load on the battery side (battery 2) of RTB.e 2. 12c) Close RICB on RTB.e 1 and start-up the rectifier. 12d) Close battery breaker BCB on RTB.e 2 and connect a first load step.

Connect the PC to RTB.e 1 and set the battery current by means of the command

SBATxxx xxx = value of the rectifier output current measured on the battery side.

Send command MEEE000 to memorize the performed setting. Verify the reading on the PC/on the front panel. Vary the resistive charge and verify the linearity of the reading.

12e) Open RICB, ROCB of RTB.e 1 and BCB of RTB.e 2. 12f) Disconnect the resistive load of the battery on RTB.e 2 and connect it to

the battery of RTB.e 1. 12g) Close RICB on RTB.e 2 and start-up rectifier. 12h) Close the battery breaker BCB on RTB.e 1 and connect a first load step.

Connect the PC to RTB.e 2 and set the reading of the battery current by means of the command:

SBATxxx xxx = value of the rectifier output current on the battery.

Send command MEEE000 to memorize the performed setting. Verify the reading on the PC/on the front panel. Vary the resistive load and verify the linearity of the readings.

12i) Open RICB, ROCB of RTB.e 2 and BCB of RTB.e 1 Disconnect the

resistive load.

13. Close RICB on RTB.e 1 and start-up the rectifier. When start-up is completed close ROCB.

14. Close RICB of RTB.e 2 and start-up the rectifier. When start-up is completed

close ROCB.

15. Apply a load on the Dc Bus Bar. If the interconnection device is closed, the Active Current Sharing system will be active and the two RTB.e will share the



load at 50%. If the interconnection is open the RTB.e will operate in Single Configuration.

16. Verify the stability of output current and the various steps of the load.

17. With the load connected open RICB of RTB.e 1 and verify the intake of the load

by RTB.e 2.

18. Close RICB of RTB.e 1 and verify connection of RTB.e 1 on the Dc Bus Bar and the activation of the current sharing.

19. Repeat points 17 and 18 for RTB.e 2.

20. Close battery breaker BCB (if there are two batteries, close the breaker

conntected to battery of RTB.e 1).

21. Verify the battery limitation current. In this case, if the interconnection device is closed RTB.e1 will supply the load and battery current while RTB.e2 will not supply current following the bus bar voltage)

22. In case of two batteries close also the battery breaker connected to RTB.e2 .

23. Making a mains fault test discharging the batteries. Verify when the mains

returns that RTB.e1 intakes all the load limiting the current in the two batteries.

BATTERY CHARGER Configuration


Data Date

Emesso Issued

Controllato Checked

Approvato Approved

Lingua Language

Pagina Page

di Pag. of Pag.

/ First Issue 24.01.09 P. Conti E. Simoni E. Simoni E 1 9 Codice / Code

JUD411353

BATTERY CHARGER CONFIGURATION

Index

1. INTRODUCTION.................................................................................. 2

2. CONFIGURATION VIA DIP SWITCHES............................................. 2

3. TEST AND MONITORING SOFTWARE ............................................. 3

3.1 CONNECTION CABLE.....................................................................................3

3.2 SOFTWARE INSTALLATION...........................................................................3

3.3 SOFTWARE DESCRIPTION ............................................................................4

3.4 SERIAL MESSAGES FOR RTB.e SETTING ...................................................5

3.5 SERIAL MESSAGES FOR RTB.e SETTING ...................................................6

3.6 SERIAL MESSAGES TO SEND COMMANDS TO RTB.e ...............................8

3.7 SERIAL MESSAGES FOR LOOP CONTROL .................................................9

Index of pictures

Fig. 1 – Dip Switches on card DR16-COMP ................................................................................................ 2 Fig. 2 – Connection cable............................................................................................................................. 3 Fig. 3 – Typical screen ................................................................................................................................. 4



1. INTRODUCTION

A test and monitoring software RCN-Monitor is available for the RCN unit that allows to check all the measurements and the operating statuses of the unit via an RS232 connection, as well as to carry out settings and configuration changes on the RCN unit.

2. CONFIGURATION VIA DIP SWITCHES

Some operating parameters are configured via Dip Switches on card DR16-COMP. The setting of the Dip Switches depends on the RTB.e size.

Dip no. Status Description

Off Battery test disabled 1 On Battery test enabled Off Boost charge disabled 2 On Boost charge enabled Off Manual charge disabled 3 On Manual charge enabled Off Parallel disabled 4 On Parallel enabled Off 5 On Off 6 On Off 7 On Off 8 On

Fig. 1 – Dip Switches on card DR16-COMP



3. TEST AND MONITORING SOFTWARE

RCN-Monitor software is connected from the serial port RS-232 of the PC, properly configured, to the serial port RS-232 of the RTB.e unit. For the connection a dedicated cable must be used, with the connections as indicated in the figure below. 3.1 CONNECTION CABLE

Fig. 2 – Connection cable

3.2 SOFTWARE INSTALLATION The software installation is performed like any other WINDOWS application. The software can be supplied on several floppy disks. In this case the software will

be installed starting from DISK1, or via a CD-ROM. Start the Setup program from the START menu, then follow the instructions as they

are requested by the installation software.



3.3 SOFTWARE DESCRIPTION The software allows to check values variables and system parameters, as well as to

perform settings. Therefore it is a necessary testing tool, whereas parameters can also be changed using the front panel.

As a rule, the software allows to display the status of the system updated in real time. Communication is therefore unidirectional from RTB.e to the PC.

When the communication is properly performed, the window named N. Bytes contains a number ranging from 1 to 250.

Fig. 3 – Typical screen

The user can send one of the messages listed below entering the text in the appropriate window.



NOTE Before sending any message, make sure the computer is writing in capital letters

(CAPS). All the controls consist of 4 letters and 3 numbers LLLLXXX. After sending a message, wait for the acoustic confirmation signal (double BEEP)

before sending a new string. If the signal is not received, it means the operation has failed and the last message must be sent once again.

IMPORTANT

Ratings and settings are not stored by RTB.e until the MEEE000 command is entered.

3.4 SERIAL MESSAGES FOR RTB.e SETTING The following messages allow to set the measurements made by RTB.e.

MAINS INPUT TIFRXXX (XXX=161/279) phase R voltage (Phase - Neutral) TIFSXXX (XXX=161/279) phase S voltage (Phase - Neutral) TIFTXXX (XXX=161/279) phase T voltage (Phase - Neutral) TCIRXXX (XXX=001/998) phase R current TCISXXX (XXX=001/998) phase S current TCITXXX (XXX=001/998) phase T current

DC VOLTAGE

VRECXXX (XXX=000/999) RTB.e output voltage (Feedback) VBATXXX (XXX=000/999) battery voltage (Measurement) ZCTO000 Zero total output current CTOTXXX (XXX=005/999) Setting of total output current ZCBT000 Zero battery current CBATXXX (XXX=005/999) battery current setting ZCBL000 Zero 12p balancing current CBALXXX (XXX=005/999) Setting of 12p balancing current

SPECIAL POTAXXX (XXX=010/300) Adjustment range of manual charge pot. (Vdc)

TEMPXXX (XXX=000/100) Temperature in degrees (from thermal probe) SBATXXX (XXX=000/999) charging current setting of second battery

(parallel config.)



3.5 SERIAL MESSAGES FOR RTB.e SETTING The following messages allow to set the operating parameters of RTB.e by working

on the internal variables that are also altered via the PARAMETERS menu on the front panel.

BOOST CHARGE PARAMETERS

Setting Range Variable Description MTMFXXX (XXX=000/999) TIMER_AFTER_MAINS_FAULT Mains failure delay (sec) SFTYXXX (XXX=000/999) SAFETY_TIME_B Safety timer (min) BOOSXXX (XXX=000/999) SETP_VDC_BOOST Boost charge voltage (V) FLBOXXX (XXX=000/999) CORR_FLOAT_BOOST Float → Boost switching current (A) BOFLXXX (XXX=000/999) CORR_ BOOST_FLOAT Boost → Float switching current (A) VFLBXXX (XXX=000/999) VOLT_FLOAT_BOOST Float → Boost switching voltage (V) VBFLXXX (XXX=000/999) VOLT_BOOST_FLOAT Boost → Float switching voltage (V) TIBOXXX (XXX=000/999) MAXTEMPO_BOOST_FLOAT Return-to-float timer (min) STTB001 / / Timed Boost cycle start SETBXXX (XXX=000/999) MaxTimeForced Timed Boost cycle timer (min) MANUAL CHARGE PARAMETERS

Setting Range Variable Description EQUAXXX (XXX=000/999) SETP_VDC_EQUAL Starting voltage (V) CLEQXXX (XXX=000/999) CORR_LIM_EQUAL Maximum battery current (A) MTEQXXX (XXX=000/999) MAXTIME_EQUAL Safety timer (min) BATTERY CHARGING AND DISCHARGING PARAMETERS

Setting Range Variable Description SPDCXXX (XXX=000/999) SETP_VDC_FLOAT Floating voltage (V) CLBAXXX (XXX=000/999) CORR_LIM_AUTO Maximum battery current (A) WRLOXXX (XXX=000/999) MIN_VBAT Minimum floating voltage (V) WRHIXXX (XXX=000/999) MAX_VBAT Maximum floating voltage (V) MTWHXXX (XXX=000/198) TEMPO_MAX_BAT Delay due to max. float. volt. (sec) COSTXXX (XXX=000/060) CONST_CMP_TEMP Battery thermal comp. (mV/°C)*Cell LEVAXXX (XXX=000/999) LIVELLO1 1st discharge level (V) LEVBXXX (XXX=000/999) LIVELLO2 2nd discharge level (V) LEVCXXX (XXX=000/999) LIVELLO3 3rd discharge level (V) INPUT PARAMETERS

Setting Range Variable Description FSUPXXX (XXX=000/005) FREQ_RETE_SUP Upper frequency limit (%) FRNOXXX (XXX=050/060) FREQ_RETE_NOMI Nominal frequency (Hz) FINFXXX (XXX=000/005) FREQ_RETE_INF Lower frequency limit (%) VIMAXXX (XXX=000/015) MAX_VIN Upper voltage limit (%) VINNXXX (XXX=000/999) VIN_NOM Nominal input voltage (V) VIMIXXX (XXX=000/015) MIN_VIN Lower voltage limit (%)



OUTPUT PARAMETERS

Setting Range Variable Description VOUNXXX (XXX=000/999) NOM_OUT_V Nominal output voltage (V) IOUNXXX * (XXX=000/999) NOM_OUT_I Nominal output current (A)

CLTOXXX ** (XXX=001/998) TOT_LIM_CURR Maximum output current (A) DRPOXXX (XXX=001/050) CONST_CMP_DROOP Positive compensation of cable drop (%) DRNEXXX (XXX=001/050) CONST_CMP_DROOP Negative compensation of cable drop (%) MAXRXXX (XXX=000/999) MAX_RECT_V Maximum output voltage (V) MTMRXXX (XXX=000/198) RECT_MAX_TIME Delay due to max. output volt. (sec) MINRXXX (XXX=000/999) MIN_RECT_V Minimum output voltage (V) LEVDXXX (XXX=000/999) LEVEL4 Emergency output level (V)

* : Example: IOUN020 ⇒ Nominal output current = 200A **: Example: CLTO020 ⇒ Maximum output current = 200A

BATTERY PARAMETERS (Battery Info)

Setting Range Variable Description

TYBAXXX (XXX=000/999) BATTERY_SIZE Battery capacity (Ah) / / BATTERY_DATE Battery installation date

FULL000 / Batt_Energy Forces the capacity stored in the battery to 0%

FULL100 / Batt_Energy Forces the capacity stored in the battery to 100%



3.6 SERIAL MESSAGES TO SEND COMMANDS TO RTB.e The following messages allow to send commands to RTB.e. Such commands cause

actions. LIST OF COMMANDS EQUIVALENT TO BUTTONS

Command Action on RTB.e RBOO000 Retrieves the boost charge level for 30 seconds MANU000 If the unit is in automatic charge, it forces the manual charge and vice versa EEDF000 Retrieves default parameters RESE000 Resets the unit HIZE000 Sets the alarm log to zero

ONOF000 Shuts the RTB.e down when started, and vice versa TEBA001 Starts the Deep Battery Test TEBA002 Starts the Quick Battery Test TEBA000 Interrupts the Battery Test

ALARM LOG READING The alarm log can be transferred to the computer by entering the following command:

READXXX XXX = 000 the latest 100 events XXX = 001 the 100 previous events ………….. …………………… XXX = 004 The first 100 events FORCING OF CONDUCTION ANGLE AND 12P BRIDGE BALANCING The conduction angle of the SCR’s can be forced (eliminating the regulation loops)

via the following command (to be only used during test):

ADEGXXX XXX = 001/179 forces the angle ADEG000 restores the loops BPORXXX XXX = 000/400 Setting of the pos. phase difference of 12p bridges BNERXXX XXX = 000/400 Setting of the neg. phase difference of 12p bridges



3.7 SERIAL MESSAGES FOR LOOP CONTROL The following messages allow to set the control parameters of RTB.e regulation

loops by working on the internal variables that cannot be altered via the PARAMETERS menu on the front panel.

PID VOLTAGE REGULATOR

Setting Range Variable Description KCFRXXX (XXX=000/999) KC_COS Proportional constant KIFRXXX (XXX=000/999) KBI_COS Integrating constant KDFRXXX (XXX=000/999) KBD_COS Derivative constant PID TOTAL CURRENT REGULATOR

Setting Range Variable Description KCTOXXX (XXX=000/999) TOT_KC_COS Proportional constant KITOXXX (XXX=000/999) TOT_KBI_COS Integrating constant KDTOXXX (XXX=000/999) TOT_KBD_COS Derivative constant PID BATTERY CURRENT REGULATOR

Setting Range Variable Description KCBAXXX (XXX=000/999) BATT_KC_COS Proportional constant KIBAXXX (XXX=000/999) BATT_KBI_COS Integrating constant KDBAXXX (XXX=000/999) BATT_KBD_COS Derivative constant PID PARALLEL REGULATOR

Setting Range Variable Description KCSHXXX (XXX=000/999) SH_KC_COS Proportional constant KISHXXX (XXX=000/999) SH_KBI_COS Integrating constant KDSHXXX (XXX=000/999) SH_KBD_COS Derivative constant RCN POSITION IN A PARALLEL SYSTEM In a parallel redundant system, each RTB.e unit is given a position by entering the following

command: POSIXXX XXX = 001 Position 1

XXX = 002 Position 2 STORAGE MEEE000 Stores the ratings and the settings made. (They become permanent).

BATTERY CHARGER Block Diagrams


Data Date

Emesso Issued

Controllato Checked

Approvato Approved

Lingua Language

Pagina Page

di Pag. of Pag.

/ First Issue 28.01.09 P. Conti E. Simoni E. Simoni E 1 12 Codice / Code

JUD411354

BATTERY CHARGER BLOCK DIAGRAMS

Index

1. GENERAL DESCRIPTION OF THE UNIT .......................................... 3

1.1 TYPOLOGY ......................................................................................................3

1.1.1 Basic structure .........................................................................................3

1.1.2 6-pulse Rectifier (Standard) ....................................................................4

1.1.3 12-pulse Rectifier (Optional) ...................................................................4

2. PCB BLOCK DIAGRAMS .................................................................. 5

2.1 BACK PANEL: BP-DR16 – N_FS3004 ............................................................5

2.2 POWER SUPPLY: PS-DR16 – N_FS3005 .......................................................7

2.3 CONTROL: DR16-COMP – N_FS3006 ............................................................8

2.3.1 Direct analog readings on AD.................................................................8

2.3.2 Direct analog readings on AD.................................................................9

2.3.3 Digital inputs ..........................................................................................10

2.3.4 Communication via RS232 ....................................................................11

2.3.5 SCR firing................................................................................................12



Index of pictures

Figure 1 – RCN block diagram ..................................................................................................................... 4 Figure 2 – BP-DR16 – N_FS3004 ................................................................................................................ 5 Figure 3 – PS-DR16 – N_FS3005 ................................................................................................................ 7 Figure 4 – DR16-COMP – N_FS3006: Input circuit of Type 1 ..................................................................... 8 Figure 5 – DR16-COMP – N_FS3006: Input circuit of Type 2 ..................................................................... 9 Figure 6 – DR1-COMP6 – N_FS3006: Input circuit of Type 3 ..................................................................... 9 Figure 7 – DR16-COMP – N_FS3006: Input circuit of Type 4 ................................................................... 10 Figure 8 – DR16-COMP – N_FS3006: Input circuit of Type 5 ................................................................... 10 Figure 9 – DR16-COMP – N_FS3006: Digital input circuit......................................................................... 11 Figure 10 – DR16-COMP – N_FS3006: Interface RS232.......................................................................... 11 Figure 11 – DR16-COMP – N_FS3006: SCR firing ................................................................................... 12



1. GENERAL DESCRIPTION OF THE UNIT

1.1 TYPOLOGY Rectifier RTB.e converts the alternate input voltage having a variable amplitude and

frequency into a constant-voltage and current-controlled direct output power source. Its function is to control the output values via a three-phase fully controlled SCR rectifier bridge (6-pulse version) or via two of these paralleled bridges (12-pulse version).

Galvanic insulation from the input mains (when provided for by the technical specification is achieved via a transformer.

1.1.1 Basic structure The basic structure of RTB.e is the following: • The input mains crosses the EMI filter for high frequency emissions and gets

into the primary winding of input transformer T1, via isolator RICB. The synchronism signals are taken from the primary winding for the control of the

SCR firing angle, the input currents for the measurement and the supply voltage for the control logic (battery redounded)

• The secondary winding is connected to the SCR bridge via protection fuses.

• In the 12-pulse version, the input transformer has got 2 secondary windings and 2 SCR bridges.

• The control logic, housed in the rack named DR16, consists of the following

cards: BP-DR16 Id. no. N_FS3004 Interconnection panel PS-DR16 Id. no. N_FS3005 System power supply DR16-COMP Id. no. N_FS3006 Control card (CPU) CAN-LINK Id. no. N_FS3011 Connection card CAN_BUS (optional

for parallel redundant configuration)

• The firing of the SCR’s is controlled by card DR16-COMP, and is performed via card: RTF Id. no. N_FS3002 SCR firing card

• The rectified and controlled voltage is filtered by an L (series inductance) and C

(paralleled capacitors) unit, calculated in accordance with the maximum ripple voltage provided for by the Technical Specification.

• On the output of said unit, a feedback voltage is taken for the voltage control

and measurements are made regarding the total output current (for the total limitation), as well as the charging and discharging current and voltage of the battery, if this function is provided.



• The RCN output is connected to the loads via isolator ROCB.

Figure 1 – RCN block diagram

1.1.2 6-pulse Rectifier (Standard) The type of standard bridge configuration used by RTB.e is three-phase, fully

controlled, with SCR’s and 6 pulses. It is so sized as to supply direct current loads and to recharge the battery to the maximum charging current provided for by the Technical Specification. The nominal standard value of the current harmonic distortion (THD) reintroduced into the mains by a 6-pulse rectifier is < 27%.

1.1.3 12-pulse Rectifier (Optional) The 12-pulse configuration is used to reduce the current harmonic distortion (THD)

reintroduced into the mains, to a value < 12%. This prevents affecting the supply line while respecting the other loads, and avoids

the overheating of cables due to the circulation of harmonics. It consists of two rectifier bridges which, thanks to a phase-shift transformer, operate

with 30° difference, eliminating the harmonics typical of 6-pulse bridges, namely the 5th and the 7th harmonic. As a consequence, the harmonics left are the highest ones, namely the 11th, the 13th and multiple ones.



2. PCB BLOCK DIAGRAMS

2.1 BACK PANEL: BP-DR16 – N_FS3004 This card includes all the connections coming from the power side and from the

signals to the control electronics and the power supply.

Figure 2 – BP-DR16 – N_FS3004



Terminal board Pin Name Description

M1 1-3-5 R-S-T Supplies on transf. secondary side M2 1-2 +24V - Massa 24Vdc auxiliary supply M5 1-2-3 Pos-Misura-Neg Hall effect of total current M6 1-2-3 Pos-Misura-Neg Hall Effect of 12p balancing current M7 1-2-3 Pos-Misura-Neg Hall Effect of battery current

1-2 C_INR-Massa Input current phase R M8 3-4 C_INS-Massa Input current phase S M9 1-2-3 Pos-Misura-Massa Manual charge potentiometer POT1

M10 1-2 Ingresso digitale: Ing0 Imposition of LEVEL4 (Emergency) M11 1-2 Ingresso digitale: Ing1 Spare personalization input M12 1-2 Ingresso digitale: Ing2 Spare personalization input M13 1-2-3 Pos-Misura-Massa Spare for 0-20 mA measurement M14 1-2-3 Pos-Misura-Massa Temperature meas. from BTP probe M15 1-4 Neg-Pos RCN output feedback M16 1-4 Neg-Pos Battery voltage measurement

1-2 Caux_RICB-Massa Auxiliary contact RICB 3-4 Caux_BCB-Massa Auxiliary contact BCB 5-6 Caux_ROCB-Massa Auxiliary contact ROCB 7-8 THSW_BR2-Massa Thermal sensor of Bridge 2 heat sink

9-10 FUSE_BR2-Massa Auxiliary contact of Bridge 2 fuses 11-12 THSW_BR1-Massa Thermal sensor of Bridge 1 heat sink 13-14 FUSE_BR1-Massa Auxiliary contact of Bridge 1 fuses 15-16 Sign_FANS-Massa Fan fault signal from FMC 17-18 Caux_CONG.-Massa Auxiliary contact of parallel bus tie 19-20 COMM-ON/OFF-Massa ON/ OFF changeover switch 21-22 Sign_EARTH_F-Massa Pole-to-earth signal from ground relay

M18

23-24 PULS-ON/OFF-Massa RTB.e RESET button M19 To be used for compatibility with standard UPS control logic

M20 1-3-5 U_IN-V_IN-W_IN Synchronism and measurement on transf. primary side

Connector Pin No. Connected to Description

CN3 20 CN1-SCP Mimic panel control CN4 10 CN1-RTF Ponte 2 Bridge 2 control CN5 10 CN1-RTF Ponte 1 Bridge 1 control CN6 10 CN1-LED-DR16 Front Led Panel Control CN7 10 CN1-ARC #1 ARC #1 Card Control CN8 10 CN1-ARC #2 ARC #2 Card Control CN9 10 CN1-ARC #3 ARC #3 Card Control CN10 10 To be used for compatibility with standard UPS control logic CN11 10 CN1-SER_CAN Communication via RS232 and RS485

CAN DB 9 Another RTB.e Communication on CAN for parallel connection



2.2 POWER SUPPLY: PS-DR16 – N_FS3005 This card creates all the power supplies required by RTB.e by taking energy from the

secondary voltage of the transformer and from the battery respectively. It also contains the three transformers for the synchronism and the measurement of the input voltage of RTB.e.

V_MA_W

S

V_MA_V

POS-BATT

NEG-BATT

U_IN

T

V_IN

U_IN

W_IN

V_IN

W_IN

R

T

R

POS-BATT

NEG-BATT

POS-BATT

NEG-BATTNEG-BATT

POS-BATT

GND_SPI

GND_MICRO

GND_SPI

+12SER

+24FIR+5FIR

GND_MICRO

GND_SER

+5FIR+24FIR

+5SER

+15V-15V

GND_FIR

GND_SER

AC1

+15V

-12SPI+5SPI

+5SER

AC2

+12SPI

+5SPI

+8V

+12SER

GND_SER

-15V

GND_FIRGND_FIR

GND_MICRO

+8V

-12SPI

GND_FIR

+12SPI

S

V_MA_U

J2-C

123456789

1011121314151617181920212223242526272829303132

J2-A

1234567891011121314151617181920212223242526272829303132

J1-A1234567891011121314151617181920212223242526272829303132

J1-C

123456789

1011121314151617181920212223242526272829303132

GraetzBridge

InsulatedForwardConverter

MultipleOutputs

3 Syncr. andMeasureTransformers

Figure 3 – PS-DR16 – N_FS3005

The multiple output voltages are generated by a switching power supply of forward type, with 2500 Vac insulation, which takes its supply from the transformer’s secondary voltage (R,S,T) and by the redundant battery (POS_BATT, NEG_BATT).

The three synchronism and measurement voltages (V_MA_U, V_MA_V, V_MA_W) are generated starting from the three input voltages of RTB.e (U_IN, V_IN, W_IN).



2.3 CONTROL: DR16-COMP – N_FS3006 This card controls the whole operation of RTB.e. It is based on a 16-bit

microprocessor (Motorola HC16) where all the digital control algorithms are implemented.

Its main functions can be subdivided as follows:

2.3.1 Direct analog readings on AD The following readings are performed directly on the channels of the AD converter

located within HC16:

Value Input circuit AD channel no. Variable Zero Input Voltage Phase U Type 1 AD0 VOLT_ING_R No Input Voltage Phase V Type 1 AD1 VOLT_ING_S No Input Voltage Phase W Type 1 AD2 VOLT_ING_S No

Battery Current Type 2 AD3 VOLT_VAL_CBAT Yes Input Current Phase U Type 2 AD4 CORR_ING_R No (Total) Output Current Type 2 AD5 VOLT_VAL_CTOT Yes Input Current Phase V Type 2 AD6 CORR_ING_S No 12p Balancing Current Type 2 AD7 VOLT_VAL_CBAL Yes Input Current Phase W Type 2 -(AD4+AD6) CORR_ING_T No

V_MA_V

VMains_V

-15V

+15V

-15V

+15V

J1-C-4

R13

3K92

C29

100N

C26100N

R15

3K32 +

-

U6OP-07/SO

3

26

7 14 8

CB 470N

BAT41D6

D5BAT41

Figure 4 – DR16-COMP – N_FS3006: Input circuit of Type 1



C_BATT

CBAT

+15V

-15V

J1-C-7

C424N7

JP1JUMPER-2

12

C444N7

R32332R

R28

154K

JP2JUMPER-2

12

C434N7

C414N7

R31332R

C38100N

R29

154K

+

- U10

OP-07/SO3

26

7 14 8

R33332R

C40

100N

C34 1uF

R34332R


2.3.2 Direct analog readings on AD The following readings are performed on the channels of the external (serial) AD

converter U24-TLC1542:

Value Input circuit AD input no. Variable Zero Battery Temperature Type 3 IN0 TEMPERATURA No Manual Charge Pot. Type 4 IN1 POT1 No

Used as (digital) Input 0 Type 4 IN2 ING0 No Used as (digital) Input 1 Type 4 IN3 ING1 No Used as (digital) Input 2 Type 4 IN4 ING2 No 0-20 mA analog input Type 3 IN5 SPI_SPARE No

RCN Feedback Voltage Type 5 IN6 VRECT No Battery Voltage Type 5 IN7 VBATT No

GND_SPI

TEMPERATURESPI_TEMP

+12SPI

+12SPI

-12SPI

J2-A-2

R123

10K

D68

BAT41

C1151uF

R128

10K

R124

47K5

+

- U36

OP-07/SO3

26

7 14 8 C111

100N

D70

BAT41

R130

33R

R271

562R

R127

100KC114

100N

Figure 6 – DR1-COMP6 – N_FS3006: Input circuit of Type 3



POT-1SPI_POT1

-12SPI+12SPI

+12SPI

J2-A-3

R137

100K

R133

10K

R140

24K9

D72

BAT41R138

10KC120

100N

+

- U37

OP-07/SO3

26

7 14 8 C117

100N

C1211uF

R134

10K

D74

BAT41

R272

562R


V-RECT-RET

V-RECT

SPI_VRECT

-12SPI

+12SPI

-12SPI

+12SPI

J2-C-6

J2-C-7

R277

562R

R147

10K

R141

10K

C128

100N

C130

100N

C123

1uF

C125100N

C122

470N

C124100N

+

- U43

OP-07/SO3

26

7 14 8

C1294N7

R152

100KC1331uF

R1482K74

R154100K

R143

100K

D76

BAT41

R144

100K

+

- U42

OP-07/SO3

26

7 14 8

D75

BAT41

R142

10K

R1482K74

C1294N7


2.3.3 Digital inputs The following digital inputs are sensed by an opto-coupler and selected via the chip

select CS2 that goes to latches U15 and U16 - 74HC244; the Dip Switches of SW1 are sensed in the same way:

Connector Pin OPTO Origin

A-14 ISO1 Auxiliary contact RICB A-9 ISO1 Auxiliary contact BCB

C-14 ISO2 Auxiliary contact ROCB A-12 ISO2 ON/ OFF changeover switch C-9 ISO3 Fan fault signal from FMC

C-10 ISO3 Auxiliary contact of parallel bus tie C-11 ISO4 Auxiliary contact of Bridge 2 fuses C-12 ISO4 Auxiliary contact of Bridge 1 fuses A-10 ISO5 Thermal probe of Bridge 2 heat sink A-11 ISO5 Thermal probe of Bridge 1 heat sink A-13 ISO6 Pole-to-earth signal from ground relay

J2

C-13 ISO6 RTB.e RESET button



DIP4

D4

I_ROCB

I_FANS

I_BCB

I_THSW_BR1

I_FUSE_BR2

I_FUSE_BR2I_RICHIAMO_CARICA_RAPIDA

I_RESET_MAX_VOUTD10

D2

CS2

D8

I_THSW_BR2FUSE_BR1_aux D7

D9

D12

I_FUSE_BR1

D0

I_NORMALE/MANUALE

D6

D15

I_RICB

CS2

I_RADD_ON/OFF

D14FUSE_BR2_aux

D11

D3

D1

DIP1

D13DIP2DIP3

I_FUSE_BR1D5

+5V

+12SPI

+5V

+5V

+12SPI

J2-C-12

J2-C-11

ISO47

68

5

1

2

3

4

R881K54

U16

74HC244

246811131517

119

18161412

9753

20

10

1A11A21A31A42A12A22A32A4

1G2G

1Y11Y21Y31Y42Y12Y22Y32Y4

VCC

GND

C83100N

D29

1N4148

R904K7

D27

1N4148

C80100N

C79

100NU15

74HC244

246811131517

119

18161412

9753

20

10

1A11A21A31A42A12A22A32A4

1G2G

1Y11Y21Y31Y42Y12Y22Y32Y4

VCC

GND

D33

1N4148

R941K54

D31

1N4148

C82

100N

R914K7

Figure 9 – DR16-COMP – N_FS3006: Digital input circuit

2.3.4 Communication via RS232 The following section is used to interface the microprocessor with card SER_DR16

for the serial connection, in compliance with standard RS232. +5SER

0

0

0

+5V

TXD_SER

RXD_SER

RXD

TXD

C195

100N

R226365R

R225 365R

C196

100N

OP9

HP26018

6

7

5

3

2

OP8

HP26018

6

7

5

3

2

U53B

74HC14A

34

R211

365R

U53A

74HC14A

1 2

R227365R

J2-A-31

CN1-16

J2-C-31

CN1-17

Figure 10 – DR16-COMP – N_FS3006: Interface RS232



2.3.5 SCR firing The following section allows to transfer the firings digitally generated by the

microprocessor, to the SCR’s of Bridge 1 and Bridge 2 (12p configuration).

+5V

+5V

+5FIR

+5FIR

D7

D4

D2

D6

D3

D1D0

D5

CS5

BR2_ENABLE (Selects BR2)

BR1_ENABLE (Selects BR1)

FIR_BR2_SCR1FIR_BR2_SCR2FIR_BR2_SCR3FIR_BR2_SCR4FIR_BR2_SCR5FIR_BR2_SCR6

FIR_BR1_SCR1FIR_BR1_SCR2FIR_BR1_SCR3FIR_BR1_SCR4FIR_BR1_SCR5FIR_BR1_SCR6

C225

100N

U6274HC273

1

10

11

20

256912151619

3478

13141718

CLR

GN

D

CLK

VCC 1Q

2Q3Q4Q5Q6Q7Q8Q

1D2D3D4D5D6D7D8D

R270

10K

C156

100N

U3274HC273

1

10

11

20

256912151619

3478

13141718

CLR

GN

D

CLK

VCC 1Q

2Q3Q4Q5Q6Q7Q8Q

1D2D3D4D5D6D7D8D

C156

100N

U3374HC273

1

10

11

20

256912151619

3478

13141718

CLR

GN

D

CLK

VCC 1Q

2Q3Q4Q5Q6Q7Q8Q

1D2D3D4D5D6D7D8D

J1-A-24J1-C-24J1-A-23J1-C-23J1-A-22J1-C-22

J1-A-21J1-C-21J1-A-20J1-C-20J1-A-19J1-C-19

Opt

ocou

pler

s

Driv

erD

river

Figure 11 – DR16-COMP – N_FS3006: SCR firing

Integrated circuits U62, U32, U33 are the firing latches that allow to switch the firing pulses to the two bridges.

BATTERY CHARGER MAINTENANCE MANUAL

BATTERY CHARGER maintenance


Data Date

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JUD411546

BATTERY CHARGER MAINTENANCE MANUAL

Index

1 MAINTENANCE OPERATIONS............................................................ 2

1.1 VISUAL INSPECTION OF ELECTRICAL CONNECTIONS .....................................2

1.2 CHECK OF ALARMS ON FRONT PANEL DISLPAY..............................................2

1.3 AIR FILTER CHECK AND CLEANING ....................................................................3

1.4 FANS CONTROL AND CLEANING .........................................................................3

1.5 CHECK OF INPUT VOLTAGE .................................................................................3

1.6 CONTROLS ON DC VOLTAGE & BATTERY CHARGE FACILITIES.....................3

1.7 CURRENT ABSORBED BY DC FILTER .................................................................4

1.8 BATTERY TEST.......................................................................................................4

1.9 MEASURE OF OUTPUT VOLTAGE RIPPLE ..........................................................4

1.10 CLEANING OF MAGNETIC PARTS ........................................................................4

1.11 CLEANING OF ELECTRONIC BOARDS.................................................................4

2 MAINTENANCE PROGRAM ................................................................ 5

Index of pictures

Picture 1 – Front panel …………………………………………………………………………………………….2



1 MAINTENANCE OPERATIONS

1.1 VISUAL INSPECTION OF ELECTRICAL CONNECTIONS Make sure all cables and / or bars are firmly tightened the clamps connection and that no connection has loosened. A link not perfectly executed can increase the resistance of contact with all its consequences such as heating connection and increased voltage drop of the line.

1.2 CHECK OF ALARMS ON FRONT PANEL DISLPAY In order to verify the proper functioning of the system is advisable to check the history of alarms. This can be done through the front panel (see Operatingl Manual). If necessary, it is possible even simulate a condition of alarm (or an indication) to test the effective functioning of signalization.

Picture 1 – Front panel



LED 1 ⇒ Green light on = Rectifier Mains presence

Red light on = Otherwise

LED 2 ⇒ Green light on = RTB.e operating. Red light on = RTB.e failure or blocked Switched off for mains failure. LED 3 ⇒ Green light on = Rectifier in floating charge. Orange light on = Rectifier in rapid charge.

LED 4 ⇒ Green light on = Battery in recharge and ok.

Orange light on = Battery in discharge or battery test. Red light on = Battery KO.

LED 5 ⇒ Green light on = Output OK and ROCB closed.

Red light on = Otherwise

The meanings of Leds from 6 to 15 are depending from applications and are written beside the leds on the front panel.

1.3 AIR FILTER CHECK AND CLEANING Check whether the air input / output is blocked by dirt. If so clean them with compressed air blowing from the inside of the cabinet

1.4 FANS CONTROL AND CLEANING Monitoring the correct operation of fans (if presents) can be done with the rectifier on, making sure that does not appear on the display the alarm "A8 FAN Failure." In any case it is advisable to remove dust possibly deposited on the fans through a brush and blow with compressed air.

This operation should be done with the rectifier turned off.

1.5 CHECK OF INPUT VOLTAGE

Check with a multimeter C.A. that the input voltage is within the parameters defined in the data sheet.

1.6 CONTROLS ON DC VOLTAGE & BATTERY CHARGE FACILITIES

• Check of Floating Voltage



Measure with a D.C. multimeter the voltage at the rectifier output terminals and verify that the value is correct.

• Check of boost charge Start quick charge by pressing the button "BOOST" on the front panel and check that the LED 3 takes the color orange.

1.7 CURRENT ABSORBED BY DC FILTER Measure with D.C.current clamp the current absorbed by the DC capacitors; the value to ensure a longer life to capacitors must not exceed 25 amperes / capacitor.

1.8 BATTERY TEST In order to test the battery the battery test should be activated [see Operating Manual, chapter JUD407770 (“Front Panel”) par. 3.2.9 ]. If the rectifier is equipped with discharge facility the battery shall be discharged following a customized discharge profile (setted manually by service engineer)

1.9 MEASURE OF OUTPUT VOLTAGE RIPPLE Place the oscilloscope probe on the rectifier output terminals; measure the value peak to peak alternating component (AC) superimposed on the DC voltage and make sure that does not exceed 5 Volt (with battery connected).

1.10 CLEANING OF MAGNETIC PARTS

This operation should be done with rectifiers off Open the doors of rectifier cabinets. Remove protection by removing the screws. Remove dust deposited on the magnetic parts through a brush and blow with compressed air inside the gorges of the windings to remove any deposits.

1.11 CLEANING OF ELECTRONIC BOARDS

This operation should be done with rectifiers off. Open the front doors of rectifier cabinets. Remove the protections by removing the screws. Using a brush and / or blowing compressed air, eliminate dust deposited on the cards



2 MAINTENANCE PROGRAM

Equipment Operation Frequency Visual inspection of electrical connections 1 Year Check of alarms 6 Months Air filter check and cleaning 1 Year (*) Fans control and cleaning 1 Year (*) Check of input voltage 1 Year Control on DC voltage & Battery charger facilities

1 Year

Check of current absorbed by DC Filter 1 Year Battery Test 1 Year Measure of output voltage ripple 1 Year Cleaning of magnetic parts 2 Year (*) Cleaning of electronic boards 2 Year (*)

RTB_e

(*) In case of equipment operating in places particularly dusty increase the frequency of operation

WARNING If the values found or the result of tests made following the procedures described on Chapter 2( Maintenance ) are different from those expected please contact the customer service. The manufacturer declines any responsibility for damage to people or things, deriving from the non-fulfilment of the instructions or from wrong manoeuvres made by not qualified personnel.

BATTERY CHARGER Troubleshooting procedures


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JUD411295

BATTERY CHARGER TROUBLESHOOTING PROCEDURES

Index

1 INTRODUCTION.................................................................................. 3

2 TROUBLESHOOTING PROCEDURES .............................................. 3

2.1 A1 – MAINS FAULT .........................................................................................3

2.1.1 Troubleshooting procedure ....................................................................3

2.2 A2 – BLOWN FUSES .......................................................................................4


2.3 A3 – HIGH TEMPERATURE ............................................................................4


2.4 A4 – OVERLOAD / THERMAL IMAGE ............................................................4


2.5 A5 – MAX OUTPUT VOLTAGE........................................................................5


2.6 A6 – MIN OUTPUT VOLTAGE .........................................................................5


2.7 A7 – CHARGING FAULT .................................................................................6

2.7.1 Troubleshooting procedure (Wrong Floating Low)...............................6

2.7.2 Troubleshooting procedure (Wrong Floating High)..............................6

2.7.3 Troubleshooting procedure (Safety timer).............................................6

2.8 A8 – FANS FAILURE .......................................................................................7


2.9 A9 – OPEN CIRCUIT BREAKERS...................................................................7


2.10 A10 – EARTH FAULT ...................................................................................7

2.10.1 Troubleshooting procedure.................................................................7

2.11 A15 – EEPROM ERROR...............................................................................8

2.11.1 Troubleshooting procedure.................................................................8

BATTERY CHARGER troubleshooting procedures


2.12 A16 – EMERGENCY LEVEL........................................................................ 8

2.13 PROGRAMMABLE ALARMS ...................................................................... 8

3 PCB’S AND COMPONENTS SUBSTITUTION....................................9

3.1 PCB’S SUBSTITUTION ................................................................................... 9

3.1.1 PS-DR16 (N_FS3005)............................................................................... 9

3.1.2 DR16-COMP (N_FS3006)......................................................................... 9

3.2 COMPONENTS SUBSTITUTION .................................................................. 10

3.2.1 RECTIFIER BRIDGE THYRISTORS ...................................................... 10

Index of pictures

Picture 1 – Rectifier input current waveform............................................................................................... 10



1 INTRODUCTION This troubleshooting includes a first-level fault description based on the rectifier alarms and

suggests how to check the unit to solve the problems. This description assumes that all the connections inside the unit are correct: check them (connectors, power cables, signals and so on) before to start with the procedures. The first-level troubleshooting eventually leads to the substitution of the components of the Rectifier without attempting to repair them.

The procedures listed below takes into account the operator is provided with all the testing tools and perfectly confident with the test software.

2 TROUBLESHOOTING PROCEDURES

2.1 A1 – MAINS FAULT This alarm normally indicates that there is no power at the input of the Rectifier. The mains

voltage is acquired on the connector M1 of the back panel card BP-DR16 (N_FS3004) through the auxiliary transformer T10.

2.1.1 Troubleshooting procedure 1. Is the input voltage present and within the tolerance?

YES: go to step #2 NO: check the rectifier supply line

2. Measure the rectifier input voltage and compare the measure with the reading on the

DR16-Test screen (or front panel). Are the values shown equal to those measured? YES: go to step #6 NO: go to step #3

3. Check the fuses F11. Is there any fuse blown? YES: replace the broken fuse(s) NO: go to step #4

4. Check the auxiliary transformer T10 by measuring the secondary voltages directly on the transformer terminals. Do the voltage values match the transformer rating plate? YES: replace the card PS-DR16. Go to step #5 NO: replace the transformer T10

5. Is the problem solver after replacing the card PS-DR16? YES: END NO: replace the card DR-16

6. Is the variable RMSOK active on the DR16-Test software? YES: go to step #7 NO: check the phase sequence

7. Is the variable FROK active on the DR16-Test software? YES: replace the card DR-16 NO: go to step #8

8. Measure the rectifier input frequency. Is it within the tolerance limits? YES: replace the card DR-16 NO: check and/or adjust the input frequency window



2.2 A2 – BLOWN FUSES This alarm normally indicates that there is a rectifier input fuse blown. The normally closed contact of the fuses is connected to the connector M18 (13-14) of the

back panel card BP-DR16 (N_FS3004). For the 12-pulse configuration the contact of the protection fuses of the slave bridge is connected to the connector M18 (9-10).

2.2.1 Troubleshooting procedure 1. Check the rectifier input fuses. Are they OK?

YES: go to step #2 NO: replace the broken fuse(s)

2. Check the connection between the auxiliary contact of the fuses and the connector

M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable

2.3 A3 – HIGH TEMPERATURE This alarm indicates that the thermal switch on the bridge heatsink has stopped the rectifier.

The thermal switch(es) B1 (B1÷B3) mounted on the rectifier bridge heatsink(s) is normally closed, as the temperature exceeds 90°C the thermal switch opens. The signal comes directly from the switch to the connector M18 (11-12) of the back panel card BP-DR16. For the 12-pulse configuration the contact of the thermal switch of the slave bridge is connected to the connector M18 (7-8).

2.3.1 Troubleshooting procedure 1. Is the temperature of the heatsink lower than 80°C?

YES: go to step #2 NO: go to step #4

2. Check the thermal switch contact. Is it OK? YES: go to step #3 NO: replace the faulty thermal switch

3. Check the connection between the thermal switch(es) and the connector M18 of the card BP-DR16. Is it OK? YES: replace the DR-16 NO: re-connect or replace the interconnection cable

4. Are the cooling fans correctly working? YES: check the load. Repeated overloads (alarm A4) have caused the rectifier

overheating NO: replace the faulty fan(s)

2.4 A4 – OVERLOAD / THERMAL IMAGE This alarm gets two different meanings, according to the operating conditions; normally it

indicates that the rectifier is overloaded, and after a certain time (basing on the overload rate) the rectifier is stopped by the thermal image protection and the alarms become “Thermal Image”. The output current transformer measures a current exceeding the nominal output current. The alarm is activated and the microprocessor starts to calculate the energy pulse I2t.



2.4.1 Troubleshooting procedure 1. Measure the output current with a current clamp. Does it exceed the rectifier nominal

current? YES: END. A overload is present. Check and/or reduce the load. NO: go to step #2

2. Compare the measure with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the card DR-16 NO: replace the output current transformer TA1 and re-adjust the output current

reading with the DR16-Test software. Go to step #3 3. Repeat the step #2. Is the value shown equal to the measured one?

YES: END. Check that the load doesn’t exceed the nominal load. NO: replace the card DR-16

2.5 A5 – MAX OUTPUT VOLTAGE This alarm normally indicates that the rectifier output voltage is higher than the set limit. The

value can be checked through the front panel under PARAMETERS. The alarm provides to switch the rectifier off and remains stored. It can be reset manually from the front panel.

2.5.1 Troubleshooting procedure 1. Reset the alarm and measure the rectifier output voltage after the start-up. Is it higher

than the limit? YES: replace the CARD DR-16 NO: go to step #2

2. Compare the measure with the reading on the DR16-Test screen (or front panel). Is the

value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VRECxxx. Go to step #3

3. Re-start the rectifier. Does the alarm occur again?

YES: replace the CARD DR-16 NO: END

2.6 A6 – MIN OUTPUT VOLTAGE This alarm normally indicates that the rectifier output voltage is lower than the set limit. The

value can be checked through the front panel under PARAMETERS.

2.6.1 Troubleshooting procedure 1. Open the battery breaker and measure the rectifier output voltage. Does the alarm

disappear? YES: the rectifier was in current limitation mode. Check the battery NO: go to step #2

2. Check the measure on the DR16-Test screen (or front panel). Is the value shown equal

to zero? YES: go to step #3 NO: go to step #4



3. Check the fuses F13. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16

4. Compare the measure with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VRECxxx. Go to step #5



2.7 A7 – CHARGING FAULT This alarm normally indicates that there’s something wrong with the batteries and the rectifier

is not capable of providing a suitable charge. It depends on three different alarm conditions, all of them shown in the front panel under the alarm row.

2.7.1 Troubleshooting procedure (Wrong Floating Low) 1. Check the battery voltage measure on the DR16-Test screen (or front panel). Is the

value shown equal to zero? YES: go to step #3 NO: go to step #4

2. Check the fuses F14. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16

3. Measure the battery voltage and compare the value with the reading on the DR16-Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VBATxxx. Go to step #5



2.7.2 Troubleshooting procedure (Wrong Floating High) 1. Measure the battery voltage and compare the measure with the reading on the DR16-

Test screen (or front panel). Is the value shown equal to the measured one? YES: replace the CARD DR-16 NO: re-adjust the measure with the command VBATxxx. Go to step #5

2. Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END

2.7.3 Troubleshooting procedure (Safety timer) When the alarm A7 depends on the operation of the safety timer the batteries are probably

old or worn out and need to be checked carefully. If the batteries are in order the problem is probably in the rectifier control loop, so we suggest to replace the card DR-16.



2.8 A8 – FANS FAILURE This alarm normally indicates that there is at least one defective cooling fan. The normally closed contact coming from the fans monitoring card FMC is connected to the

connector M18 (15-16) of the back panel card BP-DR16 (N_FS3004).

2.8.1 Troubleshooting procedure 1. Check the fans monitoring card FMC. Is there any red LED lit?

YES: replace the fan connected to the channel indicated by the RED led. Go to step #2 NO: go to step #3

2. Re-start the rectifier. Does the alarm occur again? YES: replace the card FMC NO: END

3. Is the green LED DL5 lit? YES: go to step #4 NO: replace the card FMC

4. Check the connection between the card FMC and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable

2.9 A9 – OPEN CIRCUIT BREAKERS This alarm indicates that one of the rectifier circuit breakers is open. The alarm is split into

three different sub-alarms; A91 (input breaker), A92 (battery breaker), A93 (output breaker). The auxiliary contacts of the circuit breaker are connected to the connector M18 of the back

panel card BP-DR16, to the pins 1-2 (input), 3-4 (battery) and 5-6 (output). The troubleshooting procedure that follows is not referred to a specific sub-alarms, as it is the

same for all of them.

2.9.1 Troubleshooting procedure 1. Is the breaker open?

YES: END NO: go to step #2

2. Check the connection between the auxiliary contact of the breaker and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable

2.10 A10 – EARTH FAULT This optional alarm depends on the status of the external earth fault detector that may be

installed on request. The normally closed contact of the external detector is connected to the connector M18 (21-22) of the back panel card BP-DR16 (N_FS3004).

2.10.1 Troubleshooting procedure 1. Check the external earth fault detector; is the internal alarm activated?

YES: END. There’s a earth fault, check the loads and their connections to the rectifier. NO: go to step #2



2. Check the connection between the detector and the connector M18 of the card BP-DR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable

2.11 A15 – EEPROM ERROR This alarm depends on a wrong alignment of the data inside the EEPROM when the memory

is checked by the microprocessor. It is normally a fake alarm, but leads to a blocking condition of the rectifier.

2.11.1 Troubleshooting procedure 1. Connect the DR16-Test software and send the command MEE000, wait for 10 seconds

and re-start the rectifier after having turned it off. Does the alarm occur again? YES: replace the card DR-16 NO: END

2.12 A16 – EMERGENCY LEVEL This alarm indicates that the rectifier has been forced to lower the output voltage to the

programmed level as “emergency”. This operating mode is used when the rectifier is connected to critical loads which supply voltage range is lower than the floating voltage. The emergency level is commanded by an external contact connected to the connector M10 (1-2) of the back panel card BP-DR16. When the contact is closed the microprocessor forces the modification of the voltage set-point to the programmed “emergency level” (the value can be checked through the front panel under PARAMETERS).

2.13 PROGRAMMABLE ALARMS The alarms from A11 to A14 can be programmed during the engineering phase, in case the

technical specification requires additional signalisations. They can either be generated by mixing the standard rectifier alarms or depend on the free digital inputs available (connector M11 and M12 of the back panel card BP-DR16).

Considering the wide number of possible combinations a troubleshooting procedure cannot be given.



3 PCB’S AND COMPONENTS SUBSTITUTION This chapter describes in detail all the checks that have to be done after the substitution of

electronic boards or power components installed in the digital rectifier, giving all the instructions to check the operating parameters or to change the rectifier settings.

3.1 PCB’S SUBSTITUTION 3.1.1 PS-DR16 (N_FS3005)

1. Re-connect carefully the card to the back panel. 2. Re-start the rectifier and check that all the green LED on the front of the card are steady

lit.

3.1.2 DR16-COMP (N_FS3006) 1. Check the setting of SW1 according to the following table. Check that the dip-switches

are in the same position as the old board.

Dip n. Status Description Off Battery test disabled 1 On Battery test enabled Off Rapid Charge disabled 2 On Rapid charge enabled Off Manual Charge disabled 3 On Manual Charge enabled Off Parallel configuration disabled 4 On Parallel configuration enabled

The dip switches 5-6-7-8 are not used and must be set to OFF.

2. Check the software version installed and, if necessary, replace the FLASH memory in the microprocessor card MC16 (installed on the solder side of the card DR-16).

3. Check the setting of the jumpers JP1-JP2-JP3-JP8-JP9 according to the following table. Check that they are in the same position as the old board.

Iout nominal JP1 JP2 JP8 JP9 JP3

50 A Yes No Yes No Yes 100 A Yes No Yes No Yes 150 A No Yes No Yes Yes 200 A No Yes No Yes Yes 250 A Yes Yes Yes Yes Yes 300 A No Yes No Yes Yes 500 A No Yes No Yes Yes 750 A Yes Yes Yes Yes Yes

>950 A Please refer to Operating Instructions PB132008

4. Set the jumpers JP10-JP11-JP12-JP13 according to the following table.

Nominal Voltage JP10 JP11 JP12 JP13

24-48-110 Vdc No No No No 220-380 Vdc Yes Yes Yes Yes

5. Close the input breaker and start-up completely the rectifier.



6. Check that all the measure on the DR16-Test screen, or on the front panel, are equal to the values measured; on the contrary modify the value read on the screen with the following commands:

TIFRxxx (input voltage setting phase R; xxx is the value measured) TIFSxxx (input voltage setting phase S; xxx is the value measured TIFTxxx (input voltage setting phase T; xxx is the value measured) TCIRxxx (input current setting phase R; xxx is the value measured) TCISxxx (input current setting phase S; xxx is the value measured TCITxxx (input current setting phase T; xxx is the value measured) VRECxxx (output voltage setting; xxx is the value measured). VBATxxx (output current setting; xxx is the value measured). CRECxxx (battery voltage setting; xxx is the value measured). CBATxxx (battery current setting; xxx is the value measured). Store all the settings by sending the command MEEE000.

7. Check in the front panel that all the operating parameters (charging voltages and current, voltage and current thresholds, and so on) match the requirements of the technical specification.

8. Check the setting of the date and time on the front panel 9. Reset the history log.

3.2 COMPONENTS SUBSTITUTION 3.2.1 RECTIFIER BRIDGE THYRISTORS

1. Re-connect carefully the component to the firing board. 2. Check that the input current waveform, relevant to the phase controlled by the thyristors

that has been substituted, is symmetric (see picture, given for a 6-pulse system).

Picture 1 – Rectifier input current waveform


BATTERY CHARGER APPENDIX SERVICE MANUAL

Index of sections Code

1 – Operating instr. for termal probe mounting on RTB.e JUD409515 2 – Operating instr. for N_FS3011 board mounting JUD409517 3 – Operating instr. for battery recharge LEM use JUD409518


Data Date

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Lingua Language

Pagina Page

di Pag. of Pag.

/ First Issue 27.06.07 P. Conti E. Simoni E. Simoni I/E 1 1 Codice / Code

JRE409515

ISTRUZIONE OPERATIVA DI MONTAGGIO

Sonda termica su RTB_e con compensazione termica

MOUNTING OPERATING INSTRUCTION

Thermal probe on RTB_e with thermal compensation

Nei sistemi RTB_e con compensazione termica della tensione di tampone, collegare la FS1523, come riportato in figura 1, a M14 della scheda N_FS3004 con molex a 3 poli.

On RTB_e systems with thermal compensation of floating voltage, connect FS1523 (Picture 1) to M14 of N_FS3004 board with 3 poles molex.

Figura 1 – Picture 1


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JRE409517

ISTRUZIONE OPERATIVA

Montaggio scheda N_FS3011 CAN-LINK

OPERATING INSTRUCTION

Mounting board N_FS3011 CAN-LINK

1) Montare la scheda N_FS3011 sulla

scheda FS1420 come mostrato nella foto seguente.

1) Mount the N_FS3011 board on the

FS1420 as showed on the following picture.

2) Collegare il Pin 1 di M1 della

N_FS3011 al Pin2 del connettore DB9 femmina posto sul frontale del rack delle schede di controllo.

3) Collegare il Pin 2 di M1 della

N_FS3011 al Pin7 del connettore DB9 femmina posto sul frontale del rack delle schede di controllo.

2) Connect Pin 1 of M1 of N_FS3011 to Pin 2 of DB9 female connector placed on the front side of the control boards rack.

3) Connect Pin 2 of M1 of N_FS3011 to

Pin 7 of DB9 female connector placed on the front side of the control boards rack.

JRE409517 ISSUE 2

Cavo di collegamento CAN_BUS RTB_e in parallelo ridondante

Connection cable CAN_BUS parallel redundant RTB_e

Materiale: 2 connettori DB9 maschio, cavo bipolare

Material: 2 DB9 male connectors, bipolar cable

1) Collegare il Pin 2 di un connettore al

Pin 2 dell’altro connettore. 2) Collegare il Pin 7 di un connettore al

Pin 7 dell’altro connettore.

1) Connect Pin 2 of DB9 connector to Pin 2 of other DB9 connector.

2) Connect Pin 7 of DB9 connector to

Pin 7 of other DB9 connector.


Data Date

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JRE409518

ISTRUZIONE OPERATIVA DI MODIFICA

Per utilizzo LEM ricarica batteria su raddrizzatori digitali in configurazione parallelo ridondante

Questa istruzione si riferisce ad una configurazione generica composta da due RTB_e e

una o due batterie. Si possono distinguere le seguenti configurazioni: 1. Due RTB_e con diodo di blocco, connessi in parallelo su un’unica barra e una

batteria collegata anch’essa in parallelo alla barra.

I due sensori di corrente di batteria devono essere collegati al connettore M7 della

N_FS3004 di ciascun RTB_e. Sul connettore M18 della N_FS3004 di ciascun RTB_e, si devono cortocircuitare con un

jumper i pin 17-18.

JRE409518 ISSUE 2

2. Due RTB_e con diodo di blocco, connessi in parallelo su un’unica barra e due batterie collegate anch’esse in parallelo alla barra e congiuntore fra i due sistemi.

Ogni batteria deve avere un sensore di corrente (Hall effect ammeter) per ciascun RTB_e. La tabella sotto riportata evidenzia la logica di collegamento dei sensori di corrente sulla N_FS3004.

BATTERIA 1 BATTERIA 2RTB_e1 M7 M13 RTB_e2 M13 M7

Sulla scheda FS1420 dovranno essere implementate le seguenti modifiche in base alla

corrente di ricarica di batteria degli RTB_e.

R122 = 10 k ¼ w R129 = in accordo alla seguente tabella

Rapporto di

trasformazione del sensore ad effetto

Hall di batteria

Massima corrente di ricarica della

batteria

R 129 [kOhm]

1W

151A 33 230A 22 2000/1 305A 33 // 33

4000/1 300A 33 5000/1 760A 33 // 33

Il contatto ausiliario del congiuntore dovrà essere portato ad entrambi gli RTB_e. Nel caso in cui il congiuntore non fosse previsto, si dovrà provvedere a cortocircuitare

con un jumper, in ogni RTB_e, i pin 17-18 del connettore M18 della N_FS3004.

JRE409518 ISSUE 3

MODIFICATION OPERATING INSTRUCTION

To use battery recharge LEM on parallel redundant digital rectifiers

This instruction is related to a generic configuration of two RTB_e and one or two batteries.

We can have the following configurations: 1. Two RTB_e with blocking diode, connected in parallel in one sinlge bar and one

battery aswell connected in parallel to the bar.

The two battery current sensors have to be connected to M7 connector of N_FS3004 of

each RTB_e. On M18 connector of N_FS3004 of each RTB_e, the pin 17-18 have to be short circuit

with a jumper.

JRE409518 ISSUE 4

2. Two RTB_e with blocking diode, connected in parallel on one single bar and two batteries aswell connect in parallel to the bar and coupling switch between the two system.

Each battery must have a current sensor (Hall effect ammeter) for each RTB_e The following table show the connection logic of current sensories on N_FS3004.

BATTERY 1 BATTERY 2 RTB_e1 M7 M13 RTB_e2 M13 M7

On the FS1420 board will have to be implemented following modifications according to

the battery recharge current of RTB_e.

R122 = 10 k ¼ w R129 = as according of following table

Battery Hall effect ammeter ratio

Maximum Battery recharge current

R 129 [kOhm]

1W 151A 33 230A 22 2000/1 305A 33 // 33

4000/1 300A 33 5000/1 760A 33 // 33

The auxiliary contact of coupling switch will have to be carried on each RTB_e. If there is not coupling switch, we will have to short circuit pin 17-18 of M18 connector of

N_FS3004 with a jumper, on each RTB_e.

Battery Charger Training Manual

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Transcript of Battery Charger Training Manual