Battery Charger Training Manual

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dSlt SaudiElectricity Gompany
ARA$IAN BEMCO CONTRACTING COLTD.

pftOJECTS - DEVELOPmS INDUSTRTAL & FOWR A CONTRACTOR9
QURAYYAII COMBINED CYCLE POWER PLANT
l)
INTEGRATED TRAINING MANUAL
DC SYSTEM
Battery charger Training Manual
COMMESSA - JOB :
CLIENTE - CUSTOMER :
080A1696
ORDINE N - ORDER N
BIO-QUR-O42 REV.B D T D 2 1 . 0 4 . 2 0 0 8
DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :
CONSTRUCTION OF QURAYYAH OPEN CYCLE GAS TURBINE POWER PLANT BATTERIES, BATTERY CHARGERS & UPS SYSTEMS
IMPIANTO - SITE :
QURAYYAH SAUDI ARABIA
TITOLO - TITLE :
BATTERY CHARGER TRAINING MANUAL

MATRICOLA - PART NUMBER : CODICE DOC. - DOCUMENT NUMBER :
113-116-117-118-119-120-126 / 08
JGE411929
Il presente documento di esclusiva della BORRI S.r.l. che tuteler 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 Rev. Description Date 24.06.2009 Checked Released Date Type of doc. Pag. N Pag. Tot.
First Issue
V.Lomonico
Approved
24.06.2009 A4
Date
149
P.Conti
24.06.2009 Cod. JGE411929
Battery charger Training Manual
BATTERY CHARGER TRAINING MANUAL
Index of sections 1 BATTERY CHARGER TECH DATA 2 BATTERY CHARGER INSTALLATION, OPERATING AND MAINTENANCE MANUAL 3 TEST PROCEDURE 4 BATTERY CHARGER CONFIGURATION 5 BATTERY CHARGER BLOCK DIAGRAM 6 BATTERY CHARGER MAINTENANCE 7 BATTERY CHARGER TROUBLESHOOTING PROCEDURES 8 BATTERY CHARGER APPENDIX SERVICE MANUAL Operating instr. for termal probe mounting on RTB.e Operating instr. for N_FS3011 board mounting Operating instr. for battery recharge LEM use
Code JUD407772
JGE410502 JUD411352 JUD411353 JUD411354 JUD411546 JUD411295 JUD411479 JUD409515 JUD409517 JUD409518
Rev.
Description
Date 24.06.2009
Checked
Released
Date
Type of doc.
Pag. N
Pag. Tot.
First Issue
V.Lomonico
Approved
24.06.2009 A4
Date
149
P.Conti
24.06.2009 Cod. JGE411929
BATTERY CHARGER SERIES RTB_E GENERAL TECHNICAL DATA
BATTERY CHARGER General data
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 FUNCTIONS 3
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 7.3 TIMED BOOST CHARGE........................ 4 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
Rev.
Descrizione Description
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
A B
First Issue Revision Revision JSE410375
24/10/05 07/06/07 17/03/08
A.Ferri P.Conti P.Conti
E. Simoni E. Simoni E. Simoni
E. Simoni E. Simoni E. Simoni
E
Codice / Code
14
JUD407772
INTRODUCTION
3. 4. 5. 6.
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 customers Technical Specification (ST).
6 or 12 pulses thyristor bridge Output filter (to reduce the voltage the ripple at < 1%) Front panel with LCD, Keyboard, Leds and Power Flow Diagram Voltage control loop, total current and battery current individual control loops
TECHNICAL CHARACTERISTICS
GENERAL DESCRIPTION
For technical characteristics see the attached data sheet.
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 2 of 14
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 nonvolatile memory (EEPROM).
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 A1 A2 A3 A4 A4 A5 A6 A7 A8 A9 A91 A92 A93 A10 A11 A12 A13 A14 A15 A16 DESCRIPTION Mains Fault Blown Fuses High Temperature Overload Thermal Image Max Out Voltage Min Out Voltage Charging Fault Fans Failure Open C. Breaker RICB Open BCB Open ROCB Open Earth Fault Free Description Free Description Free Description Free Description EEProm Error Emergency Level Fix Progr. x x x x x x x x x x
x x x x x x x
JUD407772
Rev.B JSE410375 17/03/08
RTB_e General data 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. x x x x x x x x x x
Picture 1 Front panel
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.
Rectifier OK S1 Battery Discharge S2 Level 1 S21 Level 2 S22 Level 3 S23 Battery Charge S3 S31 Floating Charge Boost Charge S32 Manual Charge S33 Battery OK S4
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 RL1 RL2 RL3 RL4 RL5 RL6 MEANING Mains Fault Rectifier OK Open Circuit Breaker Overload or Thermal Image Rectifier Max Voltage Rectifier Min Voltage ARC #2 RELAY RL1 RL2 RL3 RL4 RL5 RL6 MEANING Charging Fault Earth Fault Free Description Free Description Free Description Free Description ARC #3 RELAY RL1 RL2 RL3 RL4 MEANING Level 1 Level 2 Level 3 Battery Discharge
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).
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.
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BATTERY CHARGER General data 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. 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
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 4 of 14
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 doesnt 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 Rev.B JSE410375 17/03/08
JUD407772
RTB_e General data 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 6 RTB_e in parallel with single battery
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.
Picture 7 RTB_e in parallel with two separated batteries
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.
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 busbar 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 5 of 14
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BATTERY CHARGER General data the bus-tie, if provided between the two rectifiers, and the rectifier output switches ROCB. voltage and current ratings; further details are given in the datasheet. Version 1 : IP20
DESIGN STANDARDS
: : : : : : : ISO 9001:2000 EN 14001 EN 60146 EN 61000-6-2 EN 61000-6-4 EN 62040-3 IEC 60076 IEC 60439 CEI 60947-2 CEI 20-38 CEI 20-22 CEI 20-14 EN 50178 EN 62040-1-2 IEC 60529 EN 60439-1 EN 62040-1 EN 60146 EN 60127 EN 60947-4 EN 60945-5
Quality / Environment Rectifier basic standard EMC standard Performances Power transformers Low voltage switchgear Cables
Version 2 : IP31
Safety Protection degree Mechanical Semiconductors Protection devices Contactors Lamps
: : : : : : :
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
11
SINGLE-LINE DIAGRAM
Picture 8 Single-line diagram
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RTB_e General data
12
DATASHEETS
RTB_e 24Vdc - SIZE (A)
50 100 150 200 300 400 500 600 800 1000
12.1 RTB_E 24VDC OUTPUT
ELECTRICAL DATA Input Voltage (Vac) Input frequency Input short circuit current (at 400Vac, IEC Standard) Max. Input Power kVA at 100% load , nominal input Input Current distortion at nominal load (THD%) Input Power Factor (At nominal input voltage, 100% load) Output Voltage (Vdc) -Nominal : -Floating : -Boost : -Equalizing : (Manual Charge) 400 10% 3Wires (Other voltages are available on request) 5060 Hz 5Hz 16KA rms (other on request) 1,95 3,90 5,85 7,62 11,4 15,2 18,6 22,3 29,8 37,2
27 % with 6 pulses bridge (standard) 12 % with 12 pulses bridge (on request) 6 % % with 12 pulses plus input THD filter (on request)
0,75 (No manual charge provided)
48 Vdc 2,22,3 V/cell for Lead acid battery (Adjustable) 1,41,5 V/cell for NiCd battery (Adjustable) 2,42,45 V/cell for Lead acid battery (Adjustable) 1,51,65 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 Overload capability Battery recharging system 25% Efficiency at nominal 50% load (%)
1%rms (other on request) < 120% for 20 min. / < 150% for 2 min. / > 150% for 20 sec. See the above description
63 70 74 82 63 70 74 82 63 70 74 82 64 71 75 84 64 72 75 84 65 72 76 84 66 73 76 86 66 73 77 86 67 74 77 86 67 74 77 86
Parallelability (on request) Heat dissipation at nominal load - kW Cable wiring
75% 100%
Active Load Sharing - CAN bus Connection

0,263 0,527 0,790 0,914 1,37 1,83 1,95 2,34 3,13 3,91
See above mentioned standards
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50
100
150
200
300
400
500
600
800
1000
ENVIRONMENTAL DATA Acoustic noise level (according EN 50091) - dB EMI Operating Temperature (C) Storage Temperature (C) Relative Humidity (non condens.) Ventilation Altitude (mt. above see level) Protection degree (IEC60529) Painting colour and type Dimensions (mm) (<IP 41) W D H Weights (Kg) Input/output cable connection Transport Transport mechanical stress Installation Accessibility < 65 < 68 EN 61000-6-2 /EN 61000-6-4 -10 .. +40 -20 .. +70 < 95% (with tropicalization on request) Natural up to 500 A
< 2000 ( de-rating According EN62040-3)
< 70
MECHANICAL DATA
IP 20 (other on request)
RAL 7035, 60m (others on request) 600 800 800 800 2100 2100 230 240 260 300 360 430 590 770 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front GENERAL 1000 800 2100 860
220
Measures Input Voltage Input Current Input Frequency Input Power Input Power Factor Output Voltage Battery Voltage Output Current Battery Current Internal Temp. (opt.) Battery Temp. (opt.) Battery Temp. (opt.)
Commands Rectifier On / Off Boost On / Off Voltage Boost Current Boost Normal / Manual Battery Test Rectifier Reset
Adjustable Values Floating Voltage Battery Current (Lim.) Boost Voltage Time after Mains Fault Safety Timer (in Hours) Float to Boost Current Boost to Float Current Float to Boost Voltage Boost to Float Voltage Eq. Starting Voltage Total Current (Output) Emergency Voltage Batt. Discharge Level 1 Batt. Discharge Level 2 Batt. Discharge Level 3 Output Max.Voltage Output Min. Voltage Floating Voltage Low Floating Voltage High Min Input Voltage Max Input Voltage Minimum Input Freq. Maximum Input Freq.
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RTB_e General data 12.2 RTB_E 48VDC OUTPUT
50
100
150
200
300
400
500
600
800
1000
ELECTRICAL DATA Input Voltage (Vac) Input frequency Input short circuit current (at 400Vac, IEC Standard) Max. Input Power kVA at 100% load , nominal input Input Current distortion at nominal load (THD%) Input Power Factor (At nominal input voltage, 100% load) Output Voltage (Vdc) -Nominal : -Floating : -Boost : -Equalizing : (Manual Charge) 400 10% 3Wires (Other voltages are available on request) 5060 Hz 5Hz 16KA rms (other on request) 3,77 7,53 11,3 14,7 22,1 29,4 36,0 42,7 56,9 71,1
65 73 76 85 65 73 76 85 66 73 77 85 68 75 80 87 68 75 80 87 68 75 80 87 69 77 82 89 69 77 83 90 69 79 83 90 69 80 84 90
Parallelability (on request) Heat dissipation at nominal load kW Cable wiring
75% 100%

0,424 0,847 1,27 1,43 2,15 2,87 2,97 3,20 4,27 5,33
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50
100
150
200
300
400
500
600
800
1000
< 70
MECHANICAL DATA
RAL 7035, 60m (others on request) 600 800 2100 270 800 1000 800 800 2100 2100 290 320 380 450 530 700 900 1010 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front GENERAL
250
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50
100
150
200
300
400
500
600
800
1000
ELECTRICAL DATA Input Voltage (Vac) Input frequency Input short circuit current (at 400Vac, IEC Standard) Max. Input Power kVA at 100% load , nominal input Input Current distortion at nominal load (THD%) Input Power Factor (At nominal input voltage, 100% load) Output Voltage (Vdc) -Nominal : -Floating : -Boost : -Equalizing : (Manual Charge) 400 10% 3Wires (Other voltages are available on request) 5060 Hz 5Hz 16KA rms (other on request) 8,43 16,9 25,3 33,3 48,9 65,2 80,6 96 128 160
68 75 80 87 68 75 80 87 68 75 80 87 69 84 85 88 69 84 85 90 69 84 85 90 70 85 88 91 70 85 88 92 70 85 88 92 70 85 88 92
75% 100%

0,822 1,64 2,45 3,00 3,67 4,89 5,44 5,74 7,65 9,57
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50
100
150
200
300
400
500
600
800
1000
< 70
MECHANICAL DATA
RAL 7035, 60m (others on request) 600 800 1000 1000 800 800 800 1000 2100 2100 2100 2100 320 380 450 520 600 700 800 980 1200 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front GENERAL
280
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50
100
150
200
300
400
500
600
800
1000
ELECTRICAL DATA Input Voltage (Vac) Input frequency Input short circuit current (at 400Vac, IEC Standard) Max. Input Power kVA at 100% load , nominal input Input Current distortion at nominal load (THD%) Input Power Factor (At nominal input voltage, 100% load) Output Voltage (Vdc) -Nominal : -Floating : -Boost : -Equalizing : (Manual Charge) 400 10% 3Wires (Other voltages are available on request) 5060 Hz 5Hz 16KA rms (other on request) 16,7 33,3 50 66 98 129 160 191 252 315
68 75 80 88 68 75 80 88 68 75 80 88 69 84 85 89 69 84 85 90 69 84 85 91 70 85 88 92 70 85 88 92 70 85 88 93 70 85 88 93
75% 100%

1,50 3,00 4,50 5,44 7,33 8,70 9,57 11,48 13,25 16,56
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50
100
150
200
300
400
500
600
800
1000
< 70
MECHANICAL DATA
RAL 7035, 60m (others on request) 600 800 2100 330 460 800 1000 1200 1000 1000 800 800 800 800 1000 2100 2100 2100 2100 2100 550 630 750 870 970 1050 1350 1500 Bottom Side (Top Side on Request) Base provided: for forklift handling (for lifting belts and load balancing hooks -on request) According to EN 62040-1 Restricted 30 cm from ceiling Air inlet from the front. Air outlet from the top and rear Front GENERAL
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Battery Charger Installation, Operating and Maintenance Manual
COMMESSA - JOB :
CLIENTE - CUSTOMER :
080A1696
ORDINE N - ORDER N
BIO-QUR-O42 REV.B D T D 2 1 . 0 4 . 2 0 0 8
DESCRIZIONE PROGETTO - PROJECT DESCRIPTION :
CONSTRUCTION OF QURAYYAH OPEN CYCLE GAS TURBINE POWER PLANT BATTERIES, BATTERY CHARGERS & UPS SYSTEMS
IMPIANTO - SITE :
QURAYYAH SAUDI ARABIA
TITOLO - TITLE :
BATTERY CHARGER INSTALLATION, OPERATING AND MAINTENANCE MANUAL

MATRICOLA - PART NUMBER : CODICE DOC. - DOCUMENT NUMBER :
113-116-117-118-119-120-126 / 08
JGE410502
Il presente documento di esclusiva della BORRI S.r.l. che tuteler 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 Rev. Description Date 10.12.2008 Checked Released Date Type of doc. Pag. N Pag. Tot.
First Issue
V.Lomonico
Approved
10.12.2008 A4
Date
70
P.Conti
10.12.2008 Cod. JGE410502
Battery Charger Installation, Operating and Maintenance Manual
INDEX
1. RTB.e GENERAL DESCRIPTION AND INSTALLATION . 2. RTB.e FRONT PANEL .. 3 15 70
3. START-UP AND SHUT DOWN.
Rev.
Description
Date 10.12.2008
Checked
Released
Date
Type of doc.
Pag. N
Pag. Tot.
First Issue
V.Lomonico
Approved
10.12.2008 A4
Date
70
P.Conti
10.12.2008 Cod. JGE410502
RTB.e general description and installation
RTB.e GENERAL DESCRIPTION AND INSTALLATION

Index 1. INTRODUCTION.................................................................................. 3 2. RTB.E GENERAL DESCRIPTION ...................................................... 4
2.1 TYPOLOGY ...................................................................................................... 4 2.1.1 2.1.2 2.1.3 2.2.1 2.2.3 3.1 Basic structure ......................................................................................... 4 Protection ................................................................................................. 5 User interface ........................................................................................... 6 6 Pulses Rectifier ..................................................................................... 6 Front panel................................................................................................ 6
2.2 SYSTEM CONFIGURATION ............................................................................ 6
3. BATTERY CHARGER FUNCTIONS ................................................... 7

AUTOMATIC RECHARGE OF THE BATTERY ............................................... 7 Automatic recharge of the battery .......................................................... 7 Recharge IU according to the DIN 41773 standard .............................. 7 I1 I2 U recharge ........................................................................................ 8 U1 U2 I recharge ....................................................................................... 8 Manual recharge....................................................................................... 9 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5
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 4.3.2 4.4.1 Basic plant, static load and weights ..................................................... 10 Distances to be observed ...................................................................... 10 Terminal boards ..................................................................................... 11
4.4 ELECTRICAL CONNECTIONS ...................................................................... 11 4.5 EXTERNAL BATTERY AND BATTERY FUSE BOX ..................................... 11
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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 menus 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 PS-DR16 DR16-COMP Cod. N_TR3004 Cod. N_TR3005 Cod. N_TR3006 Interconnection panel Power supply Control board (CPU)
The firing of the SCRs 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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RTB.e general description and installation 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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RTB.e general description and installation 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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RTB.e general description and installation 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 doesnt 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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RTB.e general description and installation 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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RTB.e general description and installation 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.
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Front Panel
FRONT PANEL
Index 1. INTRODUCTION............................................................................. 3 2. DESCRIPTION................................................................................ 4

2.1 DESCRIPTION OF THE PANEL................................................................ 4 Flow diagram ..................................................................................... 4 Alarm and signalling panel............................................................... 4 2.1.1 2.1.2
LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 LED 12 LED 13 LED 14 LED 15
3.1 3.2
MAINS OK ................................................................... 4 RECTIFIER OK ............................................................ 4 FLOATING CHARGE .................................................. 4 BOOST CHARGE ........................................................ 4 MANUAL CHARGE ..................................................... 4 LOW DC VOLTAGE .................................................... 4 HIGH DC VOLTAGE.................................................... 4 BLOWN FUSES/RICB TRIP........................................ 4 OVERLOAD ................................................................. 4 DIODE FAILURE 3. LCD DISPLAY MANAGEMENT 4
3. LCD DISPLAY MANAGEMENT ..................................................... 5

DEFAULT .................................................................................................. 5 KEY MENUS ............................................................................................. 5 On-off ................................................................................................. 7 Clock settings.................................................................................... 8 Measures ........................................................................................... 8 Alarms-Statuses .............................................................................. 10 Boost ................................................................................................ 16 Normal-Manual ................................................................................ 16 Reset ................................................................................................ 18
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3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7
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Front Panel 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 3.2.10 4.1 4.2 4.3 Status ............................................................................................... 39 History .......................................................................................... 41
4. SFP SYSTEM DATA..................................................................... 43

75A 125VDC BLOCK DC SYSTEMS ...................................................... 43 160A 125VDC STATION DC SYSTEMS ................................................. 44 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 Green light on = RTB.e operating. Red light on = RTB.e failure or blocked Switched off for mains failure. Green light on = Rectifier in floating charge. Orange light on = Rectifier in rapid charge. Green light on = Battery in recharge and ok. Orange light on = Battery in discharge or battery test. Red light on = Battery KO. Green light on = Output OK and ROCB closed. Red light on = Otherwise.
LED 2
LED 3
LED 4
LED 5
2.1.2 Alarm and signalling panel
LED 6 LED 7 LED 8 LED 9 LED 10 LED 11 LED 12 LED 13 LED 14 LED 15
MAINS OK RECTIFIER OK FLOATING CHARGE BOOST CHARGE MANUAL CHARGE LOW DC VOLTAGE HIGH DC VOLTAGE BLOWN FUSES/RICB TRIP OVERLOAD DIODE FAILURE
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3.
LCD DISPLAY MANAGEMENT

RECTIFIER CHARGER FLOATING CHARGE VDC = xxx V IDC = yyy A
3.1 DEFAULT
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 MENUS 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 menus can be classified as follows:
S
ON/OFF
Menu: ON-OFF MENU Type: SETTING Password: NO It is accessed by pressing the key Menu: CLOCK SETTINGS Type: SETTING Password: NO It is accessed by pressing the key Menu: MEASURES Type: VISUALISATION Password: NO It is accessed by pressing the key Menu: ALARMS-STATUSES Type: VISUALISATION Password: NO It is accessed by pressing the key
S
CLOCK
S
MEASURES
S
ALARMS
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Function: ESCAPE AND SILENCE Type: COMMAND Password: NO It is carried out by pressing the key
ESC
EXIT
1
BOOST
Menu: CALL BOOST CHARGE Type: COMMAND Password: NO It is accessed by pressing the key Menu: NORMAL-MANUAL Type: COMMAND Password: NO It is accessed by pressing the key Menu: RECTIFIER RESET Type: COMMAND Password: NO It is accessed by pressing the key Menu: PARAMETERS Type: SETTINGS Password: YES It is accessed by pressing the key Menu: BATTERY STATUS Tipe: VISUALISATION and COMMAND Password: NO It is accessed by pressing the key Menu: HYSTORY Type: SETTINGS Password: YES It is accessed by pressing the key Function: ENTER KEY Type: COMMAND Password: NO It is accessed by pressing the key
2
NOR/MAN
4
RESET
8
PARAMETER
9
STATUS
0
HISTORY
ENT
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Front Panel 3.2.1 On-off This menu is entered by pressing the key:
Menu: ON-OFF MENU Type: SETTING Password: NO It is accessed by pressing the key
S
ON/OFF
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:
Menu: CLOCK SETTINGS Type: SETTINGS Password: NO It is accessed by pressing the key
S
CLOCK
In the menu the following screen is entered: 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:
Menu: MEASURES Type: VISUALISATION Password: NO It is accessed by pressing the key
S
MEASURES
In the menu the following screen is entered: 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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Front Panel 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. If in this menu the down key is pressed:
7
The following measures are accessed: 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. If in this menu the down key is pressed:
7
The following measures are accessed:
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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Front Panel 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:
Menu: ALARMS-STATUSES Type: VISUALISATION Password: NO It is accessed by pressing the key
S
ALARMS
In the menu the following screen is entered: 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:
The alarms and present statuses are scrolled:
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List of alarms A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 MAINS FAULT BLOWN FUSES HIGH TEMPERATURE OVERLOAD MAX OUTPUT VOLTAGE MIN OUTPUT VOLTAGE CHARGING FAULT FANS FAILURE OPEN CIRCUIT BREAKER EARTH FAULT PROGRAMMABLE - 1 PROGRAMMABLE - 2 PROGRAMMABLE - 3 PROGRAMMABLE - 4 EEPROM FAULT EMERGENCY VOLTAGE S1
List of statuses RECTIFIER OK
S2 S2-1 S2-2 S2-3
BATTERY DISCHARGE DISCHARGE LEVEL 1 DISCHARGE LEVEL 2 DISCHARGE LEVEL 3
S3 S3-1 S3-2 S3-3 S4 S4
BATTERY ON CHARGE FLOATING CHARGE BOOST CHARGE MANUAL CHARGE BATTERY OK 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 Wrong sequence Out of Tolerance RTB.e mains input failure due to:
1. wrong sequence 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 Blown Fuses On Bridge 1 Bridge 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 On Bridge 1 Bridge 2
High temperature of the heatsink relevant to: SCR bridge number 1 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 Rectifier Current > Than Nominal Current
if In < Iout < In*1.2 if In*1.2 < Iout < In*1.5 if Iout > In*1.5 Iout total current supplied by RTB.e exceeds In nominal shown in the technical specification. The overload is managed as follows: the overload is kept for 20 minutes; the overload is kept for 2 minutes the overload is kept for 20 seconds.
At the end of the time RTB.e following screen is shown: A4:Thermal Image Rectifier Stopped For 20 Minutes After The Overload
shuts down for 20 minutes. In this case the
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 Stop for Out Volt > Than Output Max Voltage
Vout output voltage of the RTB.e exceeds the max. programmed threshold. Such thresh. depends on the variable MAX_VRECT 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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Front Panel 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 Stop for Out Volt < Than Output Min Voltage
Vout, the output voltage of the RTB.e, goes belows the minimum programmed threshold. Such threshold depends on the variable MIN_VRECT 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 Wrong Floating High Wrong Floating Low Safety Timer Active
RTB.e charging system failure due to: 1. high floating voltage 2. low floating voltage 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 alarms is activated after the programmable delay. V_batteria < MIN_VBAT the
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 Alarm From Fans Monitor Card
The fans cooling monitoring board of the RTB.e has intervened.
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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Front Panel
A9: Open C. Breaker A9: Open C. Breaker RICB Open BCB Open ROCB Open
One of the breakers of the RTB.e in open: 1. mains input breaker 2. battery breaker 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 Alarm From Earth Fault Monitor Card
The earth fault relay signal has intervened due to an isolation loss towards earth of one of the controlled poles.
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 Internal Error Contact the Service A16: Emergency Volt A16:Emergency Level Output Voltage Forced at The Emergency
The output voltage Vout of the RTB.e is forced to a programmed fixed level. Such level depends on the variable LIVELLO4 and is forced by means, of an external contact. An internal error has occurred. It is necessary to contact the Service.
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 Active Alarms Present
No alarms are active.
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Front Panel S2: Battery Discharge

S2:Battery Discharge
Level 1 Level 2 Level 3
The battery is in discharge (due to mains failure) 1. the discharge has reached the 1 Level 2. the discharge has reached the 2 Level 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 Float Charge Mode Boost Charge Mode Manual Charge Mode
The battery is charged in the following mode: 1. Floating Charge 2. Boost Charge 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 Battery Connected Battery Test OK
The battery is completely efficient as: 1. it is connected to the load 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 Batt. Not Connect. Battery Test not OK
The battery is not completely efficient as: 1. it is not connected to the load 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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Front Panel 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:
Menu: CALL BOOST CHARGE Type: COMMAND Password: NO It is accessed by pressing the key
1
BOOST
In the menu the following screen is entered: 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:
Menu: NORMAL-MANUAL Type: COMMAND Password: NO It is accessed by pressing the key
2
NOR/MAN
In the menu the following screen is entered: NORMAL-MANUAL MENU NOW SET AT: NORMAL PRESS 0 TO MODIFY
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Front Panel After having pressed the key:
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: 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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Front Panel 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. 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. Re-start the RTB.e.
Step 6:
Step 7:
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:
Menu: RECTIFIER RESET Type: COMMAND Password: NO It is accessed by pressing the key
4
RESET
In the menu the following screen is entered: 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 TIMER_BOOST = 0 BOOST = 0 TIMER_EQUAL = 0 MAX_RAD = 0 TEMPO_MAX_RAD = 0 WRONG_HIGH = 0 TEMPO_MAX_BAT = 0 TEST_OK =1 Cancels the intervention of the boost charge safety timer Zeroing of the boost charge safety timer Cancels the intervention of the boost charge recall relay Zeroing of the manual charge safety timer Cancels the intervention of the max output voltage relay Zeroing of the max output voltage intervention relay Cancels the intervention of the max floating voltage relay Zeroing of the max floating voltage intervention relay Resets the battery test not OK alarm.
3.2.8 Parameter The menu is entered by pressing the key command:

Menu: PARAMETERS Type: SETTINGS Password: Yes It is accessed by pressing the key
8
PARAMETER
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.
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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Front Panel 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 After having pressed the key:
0
HISTORY The submenu is entered: BOOST CHARGE MODE VOLTAGE BOOST + OR TO CHANGE ENTER TO CONFIRM If you press the following key in this submenu:
5
+
And
6
CURRENT BOOST and
If the RTB.e is set in VOLTAGE BOOST, it switches to 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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Front Panel 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 After having pressed the key:
0
HISTORY The submenu is entered: 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 After having pressed the key:
0
HISTORY The submenu is entered: SAFETY TIMER (MIN) NOW SET AT: 0480 0000 ENTER TO CONFIRM 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) CUR REN T B OO S T, or rather recharge I1 I2 U This recharge is mainly used for Ni-Cd batteries. During the recharge the overcharge 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 After having pressed the key:
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 The submenu is entered: 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered:
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) VO LTA G E B OOST, or rather recharge U1 U2 I This recharge is mainly used for Ni-Cd batteries. During the recharge the overcharge 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 PRESS 0 TO MODIFY ARROWS TO SELECT After having pressed the key:
0
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BOOST CHARGE VOLTAGE NOW SET AT: xxx 000.0 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: FLOAT-BOOST VOLTAGE NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of the alphanumeric keyboard a new voltage in Volt can be set. That 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE
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0
HISTORY The submenu is entered: BOOST-FLOAT VOLTAGE NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of the alphanumeric keyboard a new voltage in Volt can be set. That 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 After having pressed the key:
0
HISTORY The submenu is entered: 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 doesnt 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: EQUAL.START. VOLTAGE NOW SET AT: xxx 000.0 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_EQUAL. The next screen enables to set up the max recharging current of the battery during the manual charge (limitation).
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Front Panel EQUAL. MAX CURRENT NOW SET AT: yyy PRESS 0 TO MODIFY ARROWS TO SELECT After having pressed the key:
0
HISTORY The submenu is entered: EQUAL. MAX 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_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 After having pressed the key:
0
HISTORY The submenu is entered: EQUAL. TIMER (MIN) NOW SET AT: 0540 0000 ENTER TO CONFIRM 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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Front Panel 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: FLOATING VOLTAGE NOW SET AT: xxx 000.0 ENTER TO CONFIRM 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 After having pressed the key:
0
RECHARGE MAX CURRENT NOW SET AT: yyy 000.0 ENTER TO CONFIRM
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Front Panel 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE
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0
HISTORY The submenu is entered: LOW FLOATING LEVEL NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: HIGH FLOATING LEVEL NOW SET AT: xxx 000.0 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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0
HISTORY The submenu is entered: 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: DISCHARGE LEVEL 1 NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. 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: DISCHARGE LEVEL 2 NOW SET AT: xxx PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
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0
HISTORY The submenu is entered: DISCHARGE LEVEL 2 NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. That voltage is memorized in the variable LIVELLO2. If the battery voltage goes below this threshold an alarm is given. The next screen enables to set the third discharge level: DISCHARGE LEVEL 3 NOW SET AT: xxx PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: DISCHARGE LEVEL 3 NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. That voltage is memorized in the variable LIVELLO3. If the battery voltage goes below this threshold an alarm is given. 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: MAX NOM MIN Using the keys: FREQUENCY fff HZ fff HZ fff HZ
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:
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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Front Panel 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: MAX OUTPUT VOLTAGE NOW SET AT: xxx 000.0 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_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 After having pressed the key:
0
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MAX-VOUT 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_RAD. The next screen enables to set the minimum output voltage: MIN OUTPUT VOLTAGE NOW SET AT: xxx PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: MIN OUTPUT VOLTAGE NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
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EMERGENCY LEVEL NOW SET AT: xxx 000.0 ENTER TO CONFIRM By means of an alphanumeric keyboard a new voltage in Volt can be set. 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 PRESS 0 TO MODIFY ARROWS TO NAVIGATE After having pressed the key:
0
HISTORY The submenu is entered: BATTERY SIZE (Ah) NOW SET AT: yyy 000.0 ENTER TO CONFIRM By means of the alphanumeric keyboard a new capacity in Ampere-hour can be set. The next screen shows (month/year): to set the battery installation date in format mm/yy
BATTERY INST. DATE NOW SET AT: 21/03 PRESS 0 TO MODIFY ARROWS TO NAVIGATE
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0
HISTORY The submenu is entered: BATTERY INST. DATE NOW SET AT: 21/03 000.0 ENTER TO CONFIRM 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 After having pressed the key:
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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Front Panel 3.2.9 Status This menu is entered by pressing the command:
Menu: BATTERY STATUS Type: VISUALISATION and COMMAND Password: YES It is accessed by pressing the key
9
STATUS
In the menu the next screen is entered: 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. 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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Front Panel 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: Step 2: Step 3: Step 4: The output voltage of the RTB.e is set at the first dicharge level LIVELLO1. The battery discharges at the current Idisc which depends on the connected load. The discharging current Idisc is compared to the output nominal current of the RTB.e Inom. The battery is discharged for Tdisc = Inom / Idisc (minutes), up to the max time of: Tdisc 3 (minutes). 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 doesnt reach LIVELLO1 the RTB.e is set back to the floating and the test is successful (TEST_OK = 1). 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.
Step 5:
Step 6:
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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Front Panel 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:
Menu: HYSTORY Type: SETTINGS Password: Yes It is accessed by pressing the key
0
HISTORY
In the menu the next screen is entered: 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. If the password is correct, the following screen is shown: 1. ALARMS HISTORY 2. RESET HISTORY PRESS ESC TO EXIT After having pressed the key:
1
BOOST
The events history which is structured as follows is accessed:
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Front Panel
Date Code A11* A12* A11 A12 05 05 05 05 01 01 01 01 03 03 03 03 09:20 09:19 09:15 09:15 Time
Using the keys:
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 If inside the following screen:
The cancelling of the events history is accessed
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.
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Front Panel
4.
SFP SYSTEM DATA
4.1 75A 125VDC BLOCK DC SYSTEMS

INPUT VOLTAGE Ph-N INPUT FREQUENCY INPUT CURRENT INPUT POWER FLOATING BOOST RECTIFIER CURRENT BATTERY CURRENT FLOAT-BOOST CURRENT BOOST-FLOAT CURRENT FLOAT-BOOST VOLTAGE BOOST-FLOAT VOLTAGE EQUAL. START VOLTAGE EQUAL. MAX. CURRENT RECHARGE MAX. CURRENT LOW FLOATING LEVEL HIGH FLOATING LEVEL DISCHARGE LEVEL 1 DISCHARGE LEVEL 2 DISCHARGE LEVEL 3 FREQUENCY MAX FREQUENCY NOMINAL FREQUENCY MIN NOMINAL OUTPUT CURRENT MAX. OUTPUT CURRENT MAX. OUTPUT VOLTAGE EMERGENCY LEVEL BATTERY SIZE 277 60 16 13,1 129,3 136,3 75 31 28 11 104 136 90 31 31 126 132 110 108 106 62 60 58 75 80 145 N.U. 308 Vac Hz A kVA Vdc Vdc A A A A Vdc Vdc Vdc A A Vdc Vdc Vdc Vdc Vdc Hz Hz Hz A A Vdc Ah
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Front Panel 4.2 160A 125VDC STATION DC SYSTEMS

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Front Panel 4.3 300A 125VDC GAS COMPRESSOR DC SYSTEMS

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Start-up and Shutdown
START-UP AND SHUTDOWN

Index 1. 2. 3. 4. INTRODUCTION................................................................................. 2 START-UP PROCEDURE .................................................................. 2 PROCEDURE OF SHUTDOWN AND DISCONNECTION ................. 4 SIMPLE SHUTDOWN PROCEDURE ................................................. 6
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Start-up and Shut-down
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 Q2-ROCB Q7-BCB RTB.e mains input circuit breaker. RTB.e output circuit breaker. 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) 2) Close Q1-RICB and wait that the display goes on. 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
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Start-up and Shutdown
In the menu following screens are entered: ON-OFF MENU NOW SET AT: OFF PRESS 0 TO MODIFY
0
HISTORY The submenu is entered: ON-OFF MENU NOW SET TO: OFF + OR FOR CHANGE AND CONFIRM 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.
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Start-up and Shut-down 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) 6) 7) Close Q7-BCB. Close Q2-ROCB. 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
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The submenu is entered::
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Issued 10.12.2008
Start-up and Shutdown ON-OFF MENU NOW SET AT: ON + OR FOR CHANGE AND CONFIRM 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) 3) 4) Open Q1-RICB. Open Q7-BCB. 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.
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Start-up and Shut-down
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) 2) 3) Open Q1-RICB. Open Q7-BCB. 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.
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BATTERY CHARGER Test Procedure
BATTERY CHARGER TEST PROCEDURE

Index 1. 2. 3. 4. 5. 6. 7. 8. 9. INTRODUCTION.................................................................................. 3 VISUAL CHECK .................................................................................. 3 SWITCH AND JUMPERS SETTING ................................................... 3 SETTING OF THE STARTING PARAMETERS .................................. 4 START-UP IN MANUAL MODE .......................................................... 6 START-UP IN AUTOMATIC MODE .................................................... 9 LOAD TESTS .................................................................................... 10 SETTING OF THE MANUAL CHARGE ............................................ 12 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
Rev.
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
Codice / Code
16
JUD411352
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
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1.
INTRODUCTION
The scope of this procedure is to guide the technician through the correct final testing of the equipment.
2.
1) 1)
VISUAL CHECK
Check the wiring harness Ensure that all the cables and connectors are correctly identified by the code and relevant number in compliance with the electric diagram. Check that the cables or the power bars section are those indicated on the relevant wiring list.
2)
3.
1)
SWITCH AND JUMPERS SETTING

Set SW1 of board DR16-COMP (N_FS3006) as required from the technical specification.
Dip n. 1 2 3 4 Status Off On Off On Off On Off On Description Battery test disabled Battery test enabled Rapid Charge disabled Rapid charge enabled Manual Charge disabled Manual Charge enabled Parallel configuration disabled 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 Hall effect ammeter I battery I total of I share nominal ratio recharge the output 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
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BATTERY CHARGER Test Procedure 3) 4)

Voltage: 24-48-110 Vdc 220-380 Vdc Rectifier JP10 JP11 No No yes yes JP12 No yes Battery JP13 No yes
Set jumpers JP10, JP11, JP12 and JP13 according to the following table and in function of the output voltage type of the rectifier.
Table 2 jumper settings JP10, JP11, JP12 and JP13 board DR16-COMP
4.
1)
SETTING OF THE STARTING PARAMETERS

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. 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. 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. Start-up the system by closing RICB. Check that following Leds are on of the board PS-DR16. Led +15 V Led -15 V Led +5 SER Led +5 FIR Led +5 SPI Led -12 SPI Green fix on Green fix on Green fix on Green fix on Green fix on Green fix on
2)
4)
5)
6)
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Check that following Leds are on of the microprocessor board DR16-COMP.

JUD411352
BATTERY CHARGER Test Procedure Led MicroOk Led +5 V Phase Sequence Green flashing Green fix on 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. Once you have carried out the instructions open RICB and wait until the boards are unenergized. 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.
8)
9)
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 KBI_BATT = 10 KC_CTOT = 100 KBI_CTOT = 10 KC_V = 100 (*) KBI_V = 20 Can be changed with KCBAxxx Can be changed with KIBAxxx Can be changed with KCTOxxx Can be changed with KITOxxx Can be changed with KCFRxxx 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 TIFSxxx TIFTxxx
xxx = value of the voltage measure referred to the neutral for phase R xxx = value of the voltage measure referred to the neutral for phase S xxx = value of the voltage measure referred to the neutral for
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BATTERY CHARGER Test Procedure 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 rectifiers control logic card (N_FS3006) is A.
5.
1)
START-UP IN MANUAL MODE

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. 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. 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.
2)
3)
Dont send the command MEEE000
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BATTERY CHARGER Test Procedure 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.
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BATTERY CHARGER Test Procedure 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. 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.
9)
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6.
1)
START-UP IN AUTOMATIC MODE

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). 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.
2)
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.
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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) 2) 3) Connect on both on the battery side than on the load side a resistive load. Close RICB and start-up the rectifier. 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 Dr16Test 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%). Connect a load equal to 50 % of the nominal and set the reading of the input current by means of the following commands.
5)
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BATTERY CHARGER Test Procedure TCIRxxx xxx = value of the measure of the absorbed current on the phase R. xxx = value of the measure of absorbed current on the phase S. xxx = value of the measure of the absorbed current on the phase T.
TCISxxx
TCITxxx
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) 7) Remove the load. 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. Shut-down the system and wait that the voltage goes to zero. Remove the resistite load on the battery side and connect the batteries.
9)
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.
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8.
1)
SETTING OF THE MANUAL CHARGE

To enable the manual charge function, operate on the Dip n.3 of the board DR16-COMP referring to fig. 1 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. 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.
2)
4)
9.
1)
SETTING OF THE BOOST CHARGE

To enable the boost charge function, operate on the DR16-COMP referring to fig. 1 Dip n.2 of the board
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. Connect the output load and close BCB; switch-off the rectifier modulation inducing a long battery discharge. 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.
3)
4)
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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 20C)
Memorize the command MEEE000. 3) 4) Check the temperature reading on the display on the menu MEASURES. 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. Verify the correct regulation of the eventual analog measuring instruments on the front of the equipment Reset hour and date by means of the appropriate key on the front keyboard. Reset the alarms event Shutdown the equipment, fix the bolts on the boards on the racks. Fill the measurement report
2)
3) 4) 5) 6)
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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. 2. 3. 4. In both the RTB.e, connect the board N_FS3011 on the board N_FS3006 (See operating instruction JRE409517). On board N_FS3006, set the DIPSW 4 in position ON. Verify that on the board N_FS3006 the setting have been carried out as per operating instruction JRE409518. 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. 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. For both the RTB.e, close RICB and put the rectifier on OFF mode. Send to RTB.e 1 the command POSI001 and memorize with command MEEE000. Send to RTB.e 2 the command MEEE000. POSI002 and memorize with command
5. 6. 7.
8.
9.
On RTB.e 1, verify the following led on the front of the rack on the control boards: TRX1 TRX2 fix on blinking
10. On RTB.e 2, verify the following led on the front of the rack on the control boards: TRX1 TRX2 blinking fix on
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BATTERY CHARGER Test Procedure 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. 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. 12f)
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
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BATTERY CHARGER Test Procedure 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.
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BATTERY CHARGER Configuration
BATTERY CHARGER CONFIGURATION

Index 1. 2. 3. INTRODUCTION.................................................................................. 2 CONFIGURATION VIA DIP SWITCHES............................................. 2 TEST AND MONITORING SOFTWARE ............................................. 3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 CONNECTION CABLE.....................................................................................3 SOFTWARE INSTALLATION...........................................................................3 SOFTWARE DESCRIPTION ............................................................................4 SERIAL MESSAGES FOR RTB.e SETTING ...................................................5 SERIAL MESSAGES FOR RTB.e SETTING ...................................................6 SERIAL MESSAGES TO SEND COMMANDS TO RTB.e ...............................8 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
Rev.
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
Codice / Code
JUD411353
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. 1 2 3 4 5 6 7 8 Status Off On Off On Off On Off On Off On Off On Off On Off On Description Battery test disabled Battery test enabled Boost charge disabled Boost charge enabled Manual charge disabled Manual charge enabled Parallel disabled Parallel enabled
Fig. 1 Dip Switches on card DR16-COMP
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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.
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BATTERY CHARGER Configuration 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.
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BATTERY CHARGER Configuration 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 TIFSXXX TIFTXXX TCIRXXX TCISXXX TCITXXX (XXX=161/279) (XXX=161/279) (XXX=161/279) (XXX=001/998) (XXX=001/998) (XXX=001/998) phase R voltage phase S voltage phase T voltage phase R current phase S current phase T current (Phase - Neutral) (Phase - Neutral) (Phase - Neutral)
DC VOLTAGE
VRECXXX VBATXXX ZCTO000 CTOTXXX ZCBT000 CBATXXX ZCBL000 CBALXXX (XXX=000/999) (XXX=000/999) (XXX=005/999) (XXX=005/999) (XXX=005/999) RTB.e output voltage battery voltage (Feedback) (Measurement)
Zero total output current Setting of total output current Zero battery current battery current setting Zero 12p balancing current Setting of 12p balancing current
SPECIAL
POTAXXX TEMPXXX (XXX=010/300) (XXX=000/100) Adjustment range of manual charge pot. (Vdc) Temperature in degrees (from thermal probe) charging current (parallel config.) setting of second battery
SBATXXX
(XXX=000/999)
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BATTERY CHARGER Configuration 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 MTMFXXX SFTYXXX BOOSXXX FLBOXXX BOFLXXX VFLBXXX VBFLXXX TIBOXXX STTB001 SETBXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) / (XXX=000/999)
Variable
TIMER_AFTER_MAINS_FAULT
Description
Mains failure delay (sec) Safety timer (min) Boost charge voltage (V) Float Boost switching current (A) Boost Float switching current (A) Float Boost switching voltage (V) Boost Float switching voltage (V) Return-to-float timer (min) Timed Boost cycle start Timed Boost cycle timer (min)
SAFETY_TIME_B SETP_VDC_BOOST CORR_FLOAT_BOOST CORR_ BOOST_FLOAT VOLT_FLOAT_BOOST VOLT_BOOST_FLOAT MAXTEMPO_BOOST_FLOAT / MaxTimeForced
MANUAL CHARGE PARAMETERS

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

Setting SPDCXXX CLBAXXX WRLOXXX WRHIXXX MTWHXXX COSTXXX LEVAXXX LEVBXXX LEVCXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/999) (XXX=000/198) (XXX=000/060) (XXX=000/999) (XXX=000/999) (XXX=000/999)
Variable
SETP_VDC_FLOAT CORR_LIM_AUTO MIN_VBAT MAX_VBAT TEMPO_MAX_BAT CONST_CMP_TEMP LIVELLO1 LIVELLO2 LIVELLO3
Description
Floating voltage (V) Maximum battery current (A) Minimum floating voltage (V) Maximum floating voltage (V) Delay due to max. float. volt. (sec) Battery thermal comp. (mV/C)*Cell 1st discharge level (V) 2nd discharge level (V) 3rd discharge level (V)
INPUT PARAMETERS
Setting FSUPXXX FRNOXXX FINFXXX VIMAXXX VINNXXX VIMIXXX
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Range
(XXX=000/005) (XXX=050/060) (XXX=000/005) (XXX=000/015) (XXX=000/999) (XXX=000/015)
Variable
FREQ_RETE_SUP FREQ_RETE_NOMI FREQ_RETE_INF MAX_VIN VIN_NOM MIN_VIN
Description
Upper frequency limit (%) Nominal frequency (Hz) Lower frequency limit (%) Upper voltage limit (%) Nominal input voltage (V) Lower voltage limit (%)
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BATTERY CHARGER Configuration OUTPUT PARAMETERS

Setting VOUNXXX IOUNXXX * CLTOXXX ** DRPOXXX DRNEXXX MAXRXXX MTMRXXX MINRXXX LEVDXXX Range
(XXX=000/999) (XXX=000/999) (XXX=001/998) (XXX=001/050) (XXX=001/050) (XXX=000/999) (XXX=000/198) (XXX=000/999) (XXX=000/999)
Variable
NOM_OUT_V NOM_OUT_I TOT_LIM_CURR CONST_CMP_DROOP CONST_CMP_DROOP MAX_RECT_V RECT_MAX_TIME MIN_RECT_V LEVEL4
Description
Nominal output voltage (V) Nominal output current (A) Maximum output current (A) Positive compensation of cable drop (%) Negative compensation of cable drop (%) Maximum output voltage (V) Delay due to max. output volt. (sec) Minimum output voltage (V) Emergency output level (V)
* : Example: IOUN020 Nominal output current = 200A **: Example: CLTO020 Maximum output current = 200A
BATTERY PARAMETERS (Battery Info)

Setting TYBAXXX / FULL000 FULL100 Range
(XXX=000/999) / / /
Variable
BATTERY_SIZE BATTERY_DATE Batt_Energy Batt_Energy
Description
Battery capacity (Ah) Battery installation date Forces the capacity stored in the battery to 0% Forces the capacity stored in the battery to 100%
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BATTERY CHARGER Configuration 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 RBOO000 MANU000 EEDF000 RESE000 HIZE000 ONOF000 TEBA001 TEBA002 TEBA000 Action on RTB.e Retrieves the boost charge level for 30 seconds If the unit is in automatic charge, it forces the manual charge and vice versa Retrieves default parameters Resets the unit Sets the alarm log to zero Shuts the RTB.e down when started, and vice versa Starts the Deep Battery Test Starts the Quick Battery Test Interrupts the Battery Test
ALARM LOG READING

The alarm log can be transferred to the computer by entering the following command: READXXX XXX = 000 XXX = 001 .. XXX = 004 the latest 100 events the 100 previous events The first 100 events
FORCING OF CONDUCTION ANGLE AND 12P BRIDGE BALANCING The conduction angle of the SCRs can be forced (eliminating the regulation loops) via the following command (to be only used during test):
ADEGXXX ADEG000 BPORXXX BNERXXX XXX = 001/179 XXX = 000/400 XXX = 000/400 forces the angle restores the loops Setting of the pos. phase difference of 12p bridges Setting of the neg. phase difference of 12p bridges
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BATTERY CHARGER Configuration 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 KCFRXXX KIFRXXX KDFRXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999)
Variable
KC_COS KBI_COS KBD_COS
Description
Proportional constant Integrating constant Derivative constant
PID TOTAL CURRENT REGULATOR

Setting KCTOXXX KITOXXX KDTOXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999)
Variable
TOT_KC_COS TOT_KBI_COS TOT_KBD_COS
Description
PID BATTERY CURRENT REGULATOR

Setting KCBAXXX KIBAXXX KDBAXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999)
Variable
BATT_KC_COS BATT_KBI_COS BATT_KBD_COS
Description
PID PARALLEL REGULATOR

Setting KCSHXXX KISHXXX KDSHXXX Range
(XXX=000/999) (XXX=000/999) (XXX=000/999)
Variable
SH_KC_COS SH_KBI_COS SH_KBD_COS
Description
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 XXX = 002 Position 1 Position 2
STORAGE
MEEE000 Stores the ratings and the settings made. (They become permanent).
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BATTERY CHARGER Block Diagrams
BATTERY CHARGER BLOCK DIAGRAMS

Index 1. GENERAL DESCRIPTION OF THE UNIT .......................................... 3
1.1 TYPOLOGY ......................................................................................................3 Basic structure .........................................................................................3 6-pulse Rectifier (Standard) ....................................................................4 12-pulse Rectifier (Optional) ...................................................................4 1.1.1 1.1.2 1.1.3
2.
2.1 2.2 2.3
PCB BLOCK DIAGRAMS .................................................................. 5

BACK PANEL: BP-DR16 N_FS3004 ............................................................5 POWER SUPPLY: PS-DR16 N_FS3005 .......................................................7 CONTROL: DR16-COMP N_FS3006 ............................................................8 Direct analog readings on AD .................................................................8 Direct analog readings on AD .................................................................9 Digital inputs ..........................................................................................10 Communication via RS232 ....................................................................11 SCR firing................................................................................................12
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5
Rev.
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
Codice / Code
12
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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
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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, cards: BP-DR16 PS-DR16 DR16-COMP CAN-LINK Id. no. N_FS3004 Id. no. N_FS3005 Id. no. N_FS3006 Id. no. N_FS3011 consists of the following
Interconnection panel System power supply Control card (CPU) Connection card CAN_BUS (optional for parallel redundant configuration)
The firing of the SCRs 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.
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BATTERY CHARGER Block Diagrams 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 SCRs 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.
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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
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BATTERY CHARGER Block Diagrams Terminal board M1 M2 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 Pin
1-3-5 1-2 1-2-3 1-2-3 1-2-3 1-2 3-4 1-2-3 1-2 1-2 1-2 1-2-3 1-2-3 1-4 1-4 1-2 3-4 5-6 7-8 9-10 11-12 13-14 15-16 17-18 19-20 21-22 23-24
Name
R-S-T +24V - Massa Pos-Misura-Neg Pos-Misura-Neg Pos-Misura-Neg C_INR-Massa C_INS-Massa Pos-Misura-Massa Ingresso digitale: Ing0 Ingresso digitale: Ing1 Ingresso digitale: Ing2 Pos-Misura-Massa Pos-Misura-Massa Neg-Pos Neg-Pos Caux_RICB-Massa Caux_BCB-Massa Caux_ROCB-Massa THSW_BR2-Massa FUSE_BR2-Massa THSW_BR1-Massa FUSE_BR1-Massa Sign_FANS-Massa Caux_CONG.-Massa COMM-ON/OFF-Massa Sign_EARTH_F-Massa PULS-ON/OFF-Massa
Description
M18
M19 M20 Connector CN3 CN4 CN5 CN6 CN7 CN8 CN9 CN10 CN11 CAN
Supplies on transf. secondary side 24Vdc auxiliary supply Hall effect of total current Hall Effect of 12p balancing current Hall Effect of battery current Input current phase R Input current phase S Manual charge potentiometer POT1 Imposition of LEVEL4 (Emergency) Spare personalization input Spare personalization input Spare for 0-20 mA measurement Temperature meas. from BTP probe RCN output feedback Battery voltage measurement Auxiliary contact RICB Auxiliary contact BCB Auxiliary contact ROCB Thermal sensor of Bridge 2 heat sink Auxiliary contact of Bridge 2 fuses Thermal sensor of Bridge 1 heat sink Auxiliary contact of Bridge 1 fuses Fan fault signal from FMC Auxiliary contact of parallel bus tie ON/ OFF changeover switch Pole-to-earth signal from ground relay RTB.e RESET button To be used for compatibility with standard UPS control logic Synchronism and measurement on transf. 1-3-5 U_IN-V_IN-W_IN primary side
Pin No.
20 10 10 10 10 10 10 10 10 DB 9
Connected to
CN1-SCP CN1-RTF Ponte 2 CN1-RTF Ponte 1 CN1-LED-DR16 CN1-ARC #1 CN1-ARC #2 CN1-ARC #3
Description
Mimic panel control Bridge 2 control Bridge 1 control Front Led Panel Control ARC #1 Card Control ARC #2 Card Control ARC #3 Card Control To be used for compatibility with standard UPS control logic Communication via RS232 and RS485 CN1-SER_CAN Communication on CAN for parallel Another RTB.e connection
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BATTERY CHARGER Block Diagrams 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.
J1-A J2-A U_IN J2-C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 U_IN V_IN W_IN +8V J1-C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 +8V
3 Syncr. and Measure Transformers
V_IN W_IN
R S T NEG-BATT NEG-BATT POS-BATT POS-BATT
V_MA_U V_MA_V V_MA_W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
Graetz Bridge
Multiple Outputs
GND_MICRO GND_MICRO +15V -15V
R S T NEG-BATT NEG-BATT POS-BATT POS-BATT GND_FIR GND_FIR +24FIR +5FIR
Insulated Forward Converter
GND_SPI +12SPI -12SPI +5SPI +12SER GND_SER
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
GND_MICRO +15V -15V AC1 AC2 GND_FIR GND_FIR +24FIR +5FIR
GND_SPI +12SPI -12SPI +5SPI +12SER +5SER +5SER GND_SER GND_SER
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 transformers 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).
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BATTERY CHARGER Block Diagrams 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 Voltage Phase U Input Voltage Phase V Input Voltage Phase W Battery Current Input Current Phase U (Total) Output Current Input Current Phase V 12p Balancing Current Input Current Phase W Input circuit Type 1 Type 1 Type 1 Type 2 Type 2 Type 2 Type 2 Type 2 Type 2 AD channel no. AD0 AD1 AD2 AD3 AD4 AD5 AD6 AD7 -(AD4+AD6)
CB R13 VMains_V +15V 3K92 -15V D5 BAT41 J1-C-4 V_MA_V 3K32 D6 BAT41 -15V R15 2 3 4 8 C26 100N 6 U6 OP-07/SO 470N
Variable VOLT_ING_R VOLT_ING_S VOLT_ING_S VOLT_VAL_CBAT CORR_ING_R VOLT_VAL_CTOT CORR_ING_S VOLT_VAL_CBAL CORR_ING_T
Zero No No No Yes No Yes No Yes No
7 1 C29 +15V 100N
Figure 4 DR16-COMP N_FS3006: Input circuit of Type 1
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C34 1uF R28 154K -15V
R29 J1-C-7 2 C_BATT 2 JP1 JUMPER-2 1 1 JP2 JUMPER-2 154K 2 3
4 8
U10 6
C38 100N CBAT
+15V R31 332R C41 4N7 R32 332R C42 4N7 R33 332R C43 4N7 R34 332R C44 4N7
7 1
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 Battery Temperature Manual Charge Pot. Used as (digital) Input 0 Used as (digital) Input 1 Used as (digital) Input 2 0-20 mA analog input RCN Feedback Voltage Battery Voltage Input circuit Type 3 Type 4 Type 4 Type 4 Type 4 Type 3 Type 5 Type 5
R123 10K +12SPI -12SPI
AD input no. IN0 IN1 IN2 IN3 IN4 IN5 IN6 IN7
R124 47K5
TEMPERATURA POT1 ING0 ING1 ING2 SPI_SPARE VRECT VBATT
4 8
D68 BAT41 R127 J2-A-2 TEMPERATURE 100K D70 BAT41 R130 33R GND_SPI C115 1uF 10K R128 3 2
U36 6
C111 100N
OP-07/SO C114 100N
+12SPI
Figure 6 DR1-COMP6 N_FS3006: Input circuit of Type 3
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OP-07/SO C40 100N
Variable
Zero No No No No No No No No
R271 SPI_TEMP 562R
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R133 10K +12SPI -12SPI R134 10K
4 8
D72 BAT41 R137 J2-A-3 POT-1 100K D74 BAT41 C121 1uF 10K R138 3 2
U37 6
C117 100N
R272 SPI_POT1 562R
R140 24K9 +12SPI 100N

R141 10K R143 10K R144 J2-C-6 V-RECT 100K R148 2K74 C129 4N7 1uF 4 8 C125 100N 6 OP-07/SO C130 100N R152 J2-C-7 V-RECT-RET 100K C133 1uF R154 100K +12SPI 100N +12SPI 10K C128 7 1 2 R147 3 U43 6 OP-07/SO 562R C124 100N 4 8 R277 SPI_VRECT 100K C123 -12SPI -12SPI C122 470N R142
7 1
R148 2K74
C129 4N7
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 A-14 A-9 C-14 A-12 C-9 C-10 C-11 C-12 A-10 A-11 A-13 C-13
OPTO ISO1 ISO1 ISO2 ISO2 ISO3 ISO3 ISO4 ISO4 ISO5 ISO5 ISO6 ISO6
7 1
J2
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BAT41
BAT41
Origin Auxiliary contact RICB Auxiliary contact BCB Auxiliary contact ROCB ON/ OFF changeover switch Fan fault signal from FMC Auxiliary contact of parallel bus tie Auxiliary contact of Bridge 2 fuses Auxiliary contact of Bridge 1 fuses Thermal probe of Bridge 2 heat sink Thermal probe of Bridge 1 heat sink Pole-to-earth signal from ground relay RTB.e RESET button
D75
D76
U42
OP-07/SO C120

+12SPI +5V +5V 1N4148 J2-C-11 FUSE_BR2_aux D29 C80 100N 1N4148 2 4 3 +12SPI +5V R94 1K54 D31 20 1N4148 U16 J2-C-12 FUSE_BR1_aux D33 C83 100N 1N4148 D7 D6 D5 D4 D3 D2 D1 D0 18 16 14 12 9 7 5 3 10 1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4 GND 74HC244 CS2 C82 100N 1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4 1G 2G 2 4 6 8 11 13 15 17 1 19 I_THSW_BR2 I_THSW_BR1 I_FUSE_BR1 I_FUSE_BR2 I_RADD_ON/OFF I_ROCB I_BCB I_RICB 8 6 5 I_FUSE_BR1 CS2 ISO4 1 7 I_FUSE_BR2 R90 4K7 R91 4K7 D15 D14 D13 D12 D11 D10 D9 D8 18 16 14 12 9 7 5 3 10 20 R88 1K54 D27 100N 1A1 1A2 1A3 1A4 2A1 2A2 2A3 2A4 1G 2G 2 4 6 8 11 13 15 17 1 19 DIP1 DIP2 DIP3 DIP4 I_RESET_MAX_VOUT I_RICHIAMO_CARICA_RAPIDA I_NORMALE/MANUALE I_FANS U15 1Y1 1Y2 1Y3 1Y4 2Y1 2Y2 2Y3 2Y4 GND 74HC244 C79
VCC
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 C195 U53A R225 365R CN1-16 TXD 1 2 2 OP8 HP2601 8 7 74HC14A 3 6 TXD_SER J2-A-31 100N R226 365R
VCC
0
+5V C196 OP9 HP2601 100N R227 365R 3 8 7 365R 3 CN1-17 RXD 4 6 2 R211 RXD_SER J2-C-31
U53B
0
74HC14A 5
Figure 10 DR16-COMP N_FS3006: Interface RS232
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BATTERY CHARGER Block Diagrams 2.3.5 SCR firing The following section allows to transfer the firings digitally generated microprocessor, to the SCRs of Bridge 1 and Bridge 2 (12p configuration).
C156 +5FIR
by the
BR1_ENABLE (Selects BR1) BR2_ENABLE (Selects BR2) +5V
3 4 7 8 13 14 17 18 11 1
20
100N 1D 2D 3D 4D 5D 6D 7D 8D
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
2 5 6 9 12 15 16 19
C225
CLK CLR GND
20
100N D0 D1 D2 D3 D4 D5 D6 D7 CS5 +5V R270 10K 3 4 7 8 13 14 17 18 11 1 1D 2D 3D 4D 5D 6D 7D 8D
Optocouplers
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
2 5 6 9 12 15 16 19
CLK CLR GND
VCC
U32 74HC273
C156
+5FIR
3 4 7 8 13 14 17 18 11 1
20
U62 74HC273
10
100N 1D 2D 3D 4D 5D 6D 7D 8D
10
1Q 2Q 3Q 4Q 5Q 6Q 7Q 8Q
2 5 6 9 12 15 16 19
Driver
FIR_BR2_SCR1 FIR_BR2_SCR2 FIR_BR2_SCR3 FIR_BR2_SCR4 FIR_BR2_SCR5 FIR_BR2_SCR6
VCC
J1-A-24 J1-C-24 J1-A-23 J1-C-23 J1-A-22 J1-C-22
CLK CLR GND
U33 74HC273
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.
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10
Driver
FIR_BR1_SCR1 FIR_BR1_SCR2 FIR_BR1_SCR3 FIR_BR1_SCR4 FIR_BR1_SCR5 FIR_BR1_SCR6
VCC
J1-A-21 J1-C-21 J1-A-20 J1-C-20 J1-A-19 J1-C-19
BATTERY CHARGER MAINTENANCE MANUAL
BATTERY CHARGER maintenance
BATTERY CHARGER MAINTENANCE MANUAL

Index 1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11
MAINTENANCE OPERATIONS............................................................ 2
VISUAL INSPECTION OF ELECTRICAL CONNECTIONS .....................................2 CHECK OF ALARMS ON FRONT PANEL DISLPAY..............................................2 AIR FILTER CHECK AND CLEANING ....................................................................3 FANS CONTROL AND CLEANING .........................................................................3 CHECK OF INPUT VOLTAGE .................................................................................3 CONTROLS ON DC VOLTAGE & BATTERY CHARGE FACILITIES.....................3 CURRENT ABSORBED BY DC FILTER .................................................................4 BATTERY TEST .......................................................................................................4 MEASURE OF OUTPUT VOLTAGE RIPPLE ..........................................................4 CLEANING OF MAGNETIC PARTS ........................................................................4 CLEANING OF ELECTRONIC BOARDS.................................................................4
MAINTENANCE PROGRAM ................................................................ 5
Index of pictures
Picture 1 Front panel .2
Rev.
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
Emissione
09.03.09
P. Conti
E. Simoni
E. Simoni
I
Codice / Code
JUD411546
1
1.1
MAINTENANCE OPERATIONS
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 First Issue 09/03/09
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LED 1 LED 2
Green light on = Rectifier Mains presence Red light on = Otherwise Green light on = RTB.e operating. Red light on = RTB.e failure or blocked Switched off for mains failure. Green light on = Rectifier in floating charge. Orange light on = Rectifier in rapid charge. Green light on = Battery in recharge and ok. Orange light on = Battery in discharge or battery test. Red light on = Battery KO. Green light on = Output OK and ROCB closed. Red light on = Otherwise
LED 3 LED 4
LED 5
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
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BATTERY CHARGER maintenance 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
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MAINTENANCE PROGRAM
Equipment
Operation
Visual inspection of electrical connections Check of alarms Air filter check and cleaning Fans control and cleaning Check of input voltage Control on DC voltage & Battery charger facilities Check of current absorbed by DC Filter Battery Test Measure of output voltage ripple Cleaning of magnetic parts Cleaning of electronic boards
Frequency
1 Year 6 Months 1 Year (*) 1 Year (*) 1 Year 1 Year 1 Year 1 Year 1 Year 2 Year (*) 2 Year (*)
RTB_e
(*) In case of equipment operating in places particularly dusty increase the frequency of operation
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.
WARNING
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BATTERY CHARGER Troubleshooting procedures
BATTERY CHARGER TROUBLESHOOTING PROCEDURES

Index 1 2 INTRODUCTION.................................................................................. 3 TROUBLESHOOTING PROCEDURES .............................................. 3
2.1 2.2 2.3 2.4 2.5 2.6 2.7 A1 MAINS FAULT .........................................................................................3 Troubleshooting procedure ....................................................................3 Troubleshooting procedure ....................................................................4 Troubleshooting procedure ....................................................................4 Troubleshooting procedure ....................................................................5 Troubleshooting procedure ....................................................................5 Troubleshooting procedure ....................................................................5 Troubleshooting procedure (Wrong Floating Low)...............................6 Troubleshooting procedure (Wrong Floating High)..............................6 Troubleshooting procedure (Safety timer).............................................6 Troubleshooting procedure ....................................................................7 Troubleshooting procedure ....................................................................7 A10 EARTH FAULT ...................................................................................7 Troubleshooting procedure.................................................................7 Troubleshooting procedure.................................................................8
Data Date Emesso Issued Controllato Checked Approvato Approved Lingua Language Pagina Page di Pag. of Pag.
2.1.1 2.2.1 2.3.1 2.4.1 2.5.1 2.6.1 2.7.1 2.7.2 2.7.3 2.8 2.9 2.10 2.11
Rev. Descrizione Description
A2 BLOWN FUSES .......................................................................................4 A3 HIGH TEMPERATURE ............................................................................4 A4 OVERLOAD / THERMAL IMAGE ............................................................4 A5 MAX OUTPUT VOLTAGE........................................................................5 A6 MIN OUTPUT VOLTAGE .........................................................................5 A7 CHARGING FAULT .................................................................................6
A8 FANS FAILURE .......................................................................................7 A9 OPEN CIRCUIT BREAKERS ...................................................................7
2.8.1 2.9.1 2.10.1 2.11.1

/ Emissione
A15 EEPROM ERROR...............................................................................8
24.01.09
P. Conti
E. Simoni
E. Simoni
E
Codice / Code
10
JUD411295
BATTERY CHARGER troubleshooting procedures 2.12 2.13 A16 EMERGENCY LEVEL........................................................................ 8 PROGRAMMABLE ALARMS ...................................................................... 8 PCBS SUBSTITUTION ................................................................................... 9 PS-DR16 (N_FS3005)............................................................................... 9 DR16-COMP (N_FS3006)......................................................................... 9 RECTIFIER BRIDGE THYRISTORS ...................................................... 10
PCBS AND COMPONENTS SUBSTITUTION....................................9

3.1 3.1.1 3.1.2 3.2 3.2.1
COMPONENTS SUBSTITUTION .................................................................. 10
Index of pictures
Picture 1 Rectifier input current waveform............................................................................................... 10
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JUD411295
BATTERY CHARGER troubleshooting procedures
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 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 Check the fuses F11. Is there any fuse blown? YES: replace the broken fuse(s) NO: go to step #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 Is the problem solver after replacing the card PS-DR16? YES: END NO: replace the card DR-16 Is the variable RMSOK active on the DR16-Test software? YES: go to step #7 NO: check the phase sequence Is the variable FROK active on the DR16-Test software? YES: replace the card DR-16 NO: go to step #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.
3.
4.
5.
6.
7.
8.
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BATTERY CHARGER troubleshooting procedures 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).

1. Check the rectifier input fuses. Are they OK? YES: go to step #2 NO: replace the broken fuse(s) 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.
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 (B1B3) mounted on the rectifier bridge heatsink(s) is normally closed, as the temperature exceeds 90C 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).

1. Is the temperature of the heatsink lower than 80C? YES: go to step #2 NO: go to step #4 Check the thermal switch contact. Is it OK? YES: go to step #3 NO: replace the faulty thermal switch 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 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.
3.
4.
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.
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JUD411295
BATTERY CHARGER troubleshooting procedures 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 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 Repeat the step #2. Is the value shown equal to the measured one? YES: END. Check that the load doesnt exceed the nominal load. NO: replace the card DR-16
2.
3.
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.

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 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 Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.
3.
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.

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 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
2.
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3. Check the fuses F13. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16 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 Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
4.
5.
2.7 A7 CHARGING FAULT

This alarm normally indicates that theres 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 Check the fuses F14. Is there any fuse blown? YES: replace the broken fuse(s) NO: replace the CARD DR-16 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 Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END Measure the battery voltage and compare the measure with the reading on the DR16Test 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 Re-start the rectifier. Does the alarm occur again? YES: replace the CARD DR-16 NO: END
2.
3.
4.
2.7.2 Troubleshooting procedure (Wrong Floating High)

1.
2.
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.
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JUD411295
BATTERY CHARGER troubleshooting procedures 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).

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 Re-start the rectifier. Does the alarm occur again? YES: replace the card FMC NO: END Is the green LED DL5 lit? YES: go to step #4 NO: replace the card FMC Check the connection between the card FMC and the connector M18 of the card BPDR16. Is it OK? YES: replace the card DR-16 NO: re-connect or replace the interconnection cable
2.
3.
4.
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.

1. Is the breaker open? YES: END NO: go to step #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.
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).

1. Check the external earth fault detector; is the internal alarm activated? YES: END. Theres a earth fault, check the loads and their connections to the rectifier. NO: go to step #2 JUD411295
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2. Check the connection between the detector and the connector M18 of the card BPDR16. 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.

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.
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JUD411295
3 PCBS 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 PCBS 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. 1 2 3 4 Status Off On Off On Off On Off On Description Battery test disabled Battery test enabled Rapid Charge disabled Rapid charge enabled Manual Charge disabled Manual Charge enabled Parallel configuration disabled 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 50 A 100 A 150 A 200 A 250 A 300 A 500 A 750 A >950 A JP1 JP2 JP8 JP9 JP3
Yes No Yes No Yes Yes No Yes No Yes No Yes No Yes Yes No Yes No Yes Yes Yes Yes Yes Yes Yes No Yes No Yes Yes No Yes No Yes Yes Yes Yes Yes Yes Yes Please refer to Operating Instructions PB132008
4. Set the jumpers JP10-JP11-JP12-JP13 according to the following table.

Nominal Voltage 24-48-110 Vdc 220-380 Vdc JP10 No Yes JP11 No Yes JP12 No Yes JP13 No Yes
5. Close the input breaker and start-up completely the rectifier.
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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
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JUD411295
BATTERY CHARGER APPENDIX SERVICE MANUAL

Index of sections Code
1 Operating instr. for termal probe mounting on RTB.e 2 Operating instr. for N_FS3011 board mounting 3 Operating instr. for battery recharge LEM use
JUD409515 JUD409517 JUD409518
JUD411479
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ISTRUZIONE OPERATIVA DI MONTAGGIO Sonda termica su RTB_e con compensazione termica

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.
MOUNTING OPERATING INSTRUCTION Thermal probe on RTB_e with thermal compensation

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
Rev.
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
First Issue
27.06.07
P. Conti
E. Simoni
E. Simoni
I/E
Codice / Code
JRE409515
ISTRUZIONE OPERATIVA Montaggio scheda N_FS3011 CAN-LINK

1) Montare la scheda N_FS3011 sulla scheda FS1420 come mostrato nella foto seguente. 1)
OPERATING INSTRUCTION Mounting board N_FS3011 CAN-LINK

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. Collegare il Pin 2 di M1 della N_FS3011 al Pin7 del connettore DB9 femmina posto sul frontale del rack delle schede di controllo.
Data Date
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. 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.
Controllato Checked Approvato Approved Lingua Language Pagina Page di Pag. of Pag.
3)
3)
Rev.
Emesso Issued
First Issue
27.06.07
P. Conti
E. Simoni
E. Simoni
I/E
Codice / Code
JRE409517
Cavo di collegamento CAN_BUS RTB_e in parallelo ridondante

Materiale: 2 connettori DB9 maschio, cavo bipolare 1) Collegare il Pin 2 di un connettore al Pin 2 dellaltro connettore. Collegare il Pin 7 di un connettore al Pin 7 dellaltro connettore.
Connection cable CAN_BUS parallel redundant RTB_e

Material: 2 DB9 male connectors, bipolar cable 1) Connect Pin 2 of DB9 connector to Pin 2 of other DB9 connector. Connect Pin 7 of DB9 connector to Pin 7 of other DB9 connector.
2)
2)
JRE409517 ISSUE
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 ununica barra e una batteria collegata anchessa 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.
Rev.
Data Date
Emesso Issued
Controllato Checked
Approvato Approved
Lingua Language
Pagina Page
di Pag. of Pag.
Emissione
27/06/07
P. Conti
E. Simoni
E. Simoni
I/E
Codice / Code
JRE409518
2.
Due RTB_e con diodo di blocco, connessi in parallelo su ununica barra e due batterie collegate anchesse 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 2 RTB_e1 RTB_e2 M7 M13 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 w R129 = in accordo alla seguente tabella Rapporto di trasformazione del sensore ad effetto Hall di batteria 2000/1 4000/1 5000/1 Massima corrente di ricarica della batteria 151A 230A 305A 300A 760A R 129 [kOhm] 1W 33 22 33 // 33 33 33 // 33
Il contatto ausiliario del congiuntore dovr essere portato ad entrambi gli RTB_e. Nel caso in cui il congiuntore non fosse previsto, si dovr provvedere a cortocircuitare con un jumper, in ogni RTB_e, i pin 17-18 del connettore M18 della N_FS3004.
JRE409518 ISSUE 2
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
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 RTB_e1 RTB_e2 M7 M13 BATTERY 2 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 w R129 = as according of following table Battery Hall effect ammeter ratio 2000/1 4000/1 5000/1 Maximum Battery recharge current 151A 230A 305A 300A 760A R 129 [kOhm] 1W 33 22 33 // 33 33 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.
JRE409518 ISSUE

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dSlt SaudiElectricity Gompany

ARA$IAN BEMCO CONTRACTING COLTD.

QURAYYAII COMBINED CYCLE POWER PLANT

INTEGRATED TRAINING MANUAL

Battery charger Training Manual

QURAYYAH SAUDI ARABIA

BATTERY CHARGER TRAINING MANUAL

24.06.2009 Cod. JGE411929

Battery charger Training Manual

BATTERY CHARGER TRAINING MANUAL

24.06.2009 Cod. JGE411929

BATTERY CHARGER SERIES RTB_E GENERAL TECHNICAL DATA

BATTERY CHARGER General data

BATTERY CHARGER GENERAL TECHNICAL DATA

First Issue Revision Revision JSE410375

24/10/05 07/06/07 17/03/08

A.Ferri P.Conti P.Conti

E. Simoni E. Simoni E. Simoni

E. Simoni E. Simoni E. Simoni

BATTERY CHARGER General data

For technical characteristics see the attached data sheet.

PROGRAMMING AND PARAMETER SETTING

ALARMS, STATUS AND SIGNALS

Rev.B JSE410375 17/03/08

BATTERY CHARGER FUNCTIONS

Rev.B JSE410375 17/03/08

TIMED BOOST CHARGE

Picture 6 RTB_e in parallel with single battery

Picture 5 Timed recharge

Picture 7 RTB_e in parallel with two separated batteries

PARALLEL REDUNDANT OPERATION

Rev.B JSE410375 17/03/08

Safety Protection degree Mechanical Semiconductors Protection devices Contactors Lamps

Picture 8 Single-line diagram

Rev.B JSE410375 17/03/08

RTB_e General data

12.1 RTB_E 24VDC OUTPUT

Parallelability (on request) Heat dissipation at nominal load - kW Cable wiring

Active Load Sharing - CAN bus Connection

See above mentioned standards

Rev.B JSE410375 17/03/08

BATTERY CHARGER General data

RTB_e 24Vdc - SIZE (A)

Rev.B JSE410375 17/03/08

RTB_e General data 12.2 RTB_E 48VDC OUTPUT

RTB_e 48Vdc - SIZE (A)

Parallelability (on request) Heat dissipation at nominal load kW Cable wiring

Active Load Sharing - CAN bus Connection

See above mentioned standards

Rev.B JSE410375 17/03/08

BATTERY CHARGER General data

RTB_e 48Vdc - SIZE (A)

Rev.B JSE410375 17/03/08

RTB_e General data 12.3 RTB_E 110VDC OUTPUT

RTB_e 110Vdc - SIZE (A)

Parallelability (on request) Heat dissipation at nominal load kW Cable wiring

Active Load Sharing - CAN bus Connection

See above mentioned standards

Rev.B JSE410375 17/03/08

BATTERY CHARGER General data

RTB_e 110Vdc - SIZE (A)

Rev.B JSE410375 17/03/08

RTB_e General data 12.4 RTB_E 220VDC OUTPUT