AEG battery Charger

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PROTECT RCS

Rectifiers Chargers and DC Systems

SPRe - Single Phase Rectifier

TPRe - Three Phase Rectifier

24V – 110V

10A – 500A

Designed for all

industrial applications

• Oil & Gas, Petrochemicals

Offshore, Onshore, Pipelines

• Energy and Power

Generation, Transmission, Distribution

• Transportation

Rail, Airports, Shipping

• Water

Desalination, Treatment

• Instrumentation & Process Control

Chemicals, Mining, Steel, Paper

• All Industrial Applications

Robust, Reliable and Flexible

These are the latest generation of robust, industrial rectifiers, chargers and DC Systems from Saft Power Systems. Using proven microprocessor controlled

thyristor technology to provide high-reliability power supply and battery charging capabilities.

A more flexible approach to providing exact solutions. Choose from:

• Standard system configurations and • Customized systems - designed to comply

with precise specifications

• Standard system configurations - cost effective, short lead time solutions

• Customized systems - enhance the standard system by selecting from an extensive range of options

• All systems built with advanced GCAU - Generic Control and Alarm Unit

• Communications system used to monitor and control the defined parameters locally or remotely. • Choice of several types of batteries:

- nickel-cadmium – vented or gas recombination - lead acid – vented or gas recombination

• Advance Battery Management • Parallel operation

• Simplified maintenance • High MTBF and low MTTR

- Bespoke documentation; drawings, manuals - Total solutions – including switchgear, load distribution • International Service support – comprehensive

packages including;

• Product Services: Installation, Commissioning, Service Contracts...

• Site Services: Load testing, monitoring…

>> KEY FEATURES

NEW RANGE

NEW RANGE: PROTECT RCS INDUSTRIAL RECTIFIERS, CHARGERS & DC SYSTEMS

Protect RCS is an evolution of the highly successful SPR/TPR range from Saft Power Systems which is installed globally and used for all Industrial applications.

The main advance of the new Protect RCS range is the introduction of the GCAU card which integrates more cutting-edge hardware functions.

The Protect RCS rectifiers are thyristor-controlled rectifiers suitable for charging nickel-cadmium or lead-acid batteries while supplying DC loads. They can also be used without batteries as direct power supplies.

This new range of DC Systems is available in three levels: • The first level consists of the Standard Rectifier

with a compact set of alarms.

• The second level offers a set of Basic Options, extensive functions and alarms.

• The third level offers a full set of Extended Options, extensive functions and alarms allowing customization of the systems to comply with special customer requirements.

The rectifiers are built as independent modules, optional equipment like distribution boards, diode droppers etc. are installed in separate cubicle sections.

Because of the high level of standardisation and integration, the design reduces the need for extensive internal wiring.

Cabinets are floor mounted and can be designed to meet special requirements. The batteries are mounted on free-standing racks or in cabinets together with or separated from the rectifier.

"GCAU" Generic Control and Alarm Unit (A1)

The main card is the GCAU (Generic Control and Alarm

Unit). It performs measurements, control and process

control (charge process control) and provides a wide range of alarm and monitoring options, a user-friendly control/display interface, and facilities for data logging and remote communication.

The card has all the necessary controls to pilot single and three phase thyristor chargers. For three phase systems a driver card is connected to the GCAU card.

The GCAU card uses a fully digital control algorithm to ensure the required flexibility.

The GCAU card incorporates two micro controllers, using the latest micro controller technology to ensure a high degree of safety.

The tasks of these micro controllers are: • Process communication and Monitoring • Regulation and synchronization

Each micro controller has its specific dedicated task. One micro controller is dedicated to the control algorithm while the second takes care of alarm, communication and charge process tasks. The two micro controllers check each other’s functionality and will shut down the system safely if an operating error is detected.

AC Line

Input InputTransformer

GCAU CARD Rectifier

Bridge RippleFilter

Rectifier Fuse Stabilizer (Option) DC Output Isolated Serial Port Out TPC Board (Three phase) Extended filter as option Battery AC Voltage PS Thyristor Gate Control OVP input Rectifier Current sense Rectifier Volatge sense Battery Temp. Sensor (Option) Battery Current Sense (Option) DC PC Load voltage sense Ambient Temp Sensor (Option) RS232 RS485 Serial Communication Board (Option) RJ 4-4 Connector

Front alpha numeric Display 2 LED indicators Keyboard RJ 4-4 Connector Relay Board (Option) LED box (Option) Remote Alarm Contacts 8 Multi functional spare inputs

Display: 9mm character height, two line by sixteen-character alpha numeric LCD with LED backlight.

SYSTEM DISPLAY

BLOCK DIAGRAM OF THE RECTIFIER

An extensive human interface ensures that all the important parameters are accessible from the front panel. A large 16 characters by 2 lines LCD unit displays all the relative information to the user. A three push button keyboard is used with 2 LEDs (green and red) indicating the charger state.

The Display card is mounted on the front of the system and is controlled by the GCAU card. It is a plug-in device and is connected through two RJ 4-4 connectors with a 4-wire cable. All data and necessary power supply voltages are transferred over this cable.

>> PROTECT RCS - SINGLE PHASE RANGE

NOMINAL NOMINAL STANDARDSYSTEMS& BASICOPTIONS WEIGHT2

DC OUTPUT DC OUTPUT DIMENSIONS1 _(APPROX)

RECTIFIER VOLTAGE CURRENT

TYPE V A HEIGHT(MM) WIDTH(MM) DEPTH(MM) KG

24SPRe10 24 10 1200 600 821 85 24SPRe15 24 15 1200 600 821 95 24SPRe25 24 25 1200 600 821 105 24SPRe50 24 50 1200 600 821 160 24SPRe75 24 75 1200 600 821 180 24SPRe100 24 100 1200 600 821 195 48SPRe10 48 10 1200 600 821 95 48SPRe15 48 15 1200 600 821 100 48SPRe25 48 25 1200 600 821 145 48SPRe50 48 50 1200 600 821 200 48SPRe75 48 75 1600 600 821 295 110SPRe10 110 10 1200 600 821 110 110SPRe15 110 15 1200 600 821 145 110SPRe25 110 25 1200 600 821 190 110SPRe50 110 50 1600 600 821 345

1. Dimensions may vary for systems with Extended Options.

2. Weights may vary depending on selection of Basic Options and Extended Options. Please consult Saft Power Systems for alternative systems.

(including systems with Basic Options)

APPLICATIONS

Designed to provide secure DC power for all Industrial applications; for Oil & Gas and Petrochemical Plants, Power Stations and Substations, Water Treatment Plants, Manufacturing Plants, Airports, Railways, etc

• Navigational Aids

• Emergency Lighting

• Fire & Gas Detection Systems

• Fire Fighting

• Emergency Shutdown Systems

• Radio & Telecommunications

• Signaling

• Telemetry

• Instrumentation & Process Control

• Gas Turbine Control

• Switchgear Tripping

• Motor Starting

• Lube-oil pump supply

• Power Generation, Transmission

and Distribution

>> PROTECT RCS - THREE PHASE RANGE

NOMINAL NOMINAL STANDARDSYSTEMS& BASICOPTIONS WEIGHT2

DC OUTPUT DC OUTPUT DIMENSIONS1 _(APPROX)

RECTIFIER VOLTAGE CURRENT

TYPE V A HEIGHT(MM) WIDTH(MM) DEPTH(MM) KG

24TPRe25 24 25 1200 600 821 145 24TPRe50 24 50 1200 600 821 185 24TPRe75 24 75 1200 600 821 250 24TPRe100 24 100 1600 600 821 285 24TPRe150 24 150 1600 600 821 305 24TPRe200 24 200 1600 600 821 345 24TPRe300 24 300 2000 600 821 *(4) 24TPRe400 24 400 2000 821 (2065 max)3 _{900 *}(4) 24TPRe500 24 500 2000 821 (2065 max)3 _{900 *}(4) 48TPRe25 48 25 1200 600 821 190 48TPRe50 48 50 1200 600 821 215 48TPRe75 48 75 1600 600 821 315 48TPRe100 48 100 1600 600 821 340 48TPRe150 48 150 1600 600 821 495 48TPRe200 48 200 1600 600 821 515 48TPRe300 48 300 2000 600 821 *(4) 48TPRe400 48 400 2000 821 (2065 max)3 _{900 *}(4) 48TPRe500 48 500 2000 821 (2065 max)3 _{900 *}(4) 110TPRe25 110 25 1200 600 821 215 110TPRe50 110 50 1600 600 821 365 110TPRe75 110 75 1600 600 821 495 110TPRe100 110 100 1600 600 821 520 110TPRe150 110 150 1600 600 821 585 110TPRe200 110 200 2000 821 770 (2065 max)3 ₉₀₀ 110TPRe300 110 300 2000 821 (2065 max)3 _{900 *}(4) 110TPRe400 110 400 2000 821 *(4) (2065 max)3 ₉₀₀ 110TPRe500 110 500 2080 1200 821 *(4)

1. Dimensions may vary for systems with Extended Options.

2. Weights may vary depending on selection of Basic Options and Extended Options. 3. Cabinet with additional fan cooling – top cover 65mm Height.

4. Weights on request.

Please consult Saft Power Systems for alternative systems.

SPECIFICATION

INPUT

Protect RCS single phase (SPRe) Single phase 230Vac ± 10%

OUTPUT

Nominal voltage (Udc) 24V 48V 110V (Other voltages available as non-standard option)

PROTECTION

ENVIRONMENTAL

• Polarity reversal of battery (blows battery fuse, optional) • Soft-start function 0 to 100%

• Short-circuits

• Limited to 100% of rated current • Internal DC fuse

• Non-volatile storage of system parameters and user setting • Mains failure shutdown

• Rectifier failure shutdown • High-voltage DC shutdown • Thermal protection

Acoustic noise Typical 45-65 dB(A)

Tropicalisation Suitable for ambient temperature and relative humidity specified above and for ambient air free from dust and corrosive gases.

Ambient temperature Operating: 0°C to + 40°C

Derate from 40°C to 55°C by lowering the output current by 1.25% per °C. Storage: -25°C to +70°C

Static voltage regulation ± 0.5% under the following conditions: • at float charge

• 0-100% DC load variation • input voltage ± 10% • input frequency ± 6% • temperature from 0°C to 40°C Exceptional variations + 15 / -20% (functional)

Long-term stability of UDC 0.15% for 1000 hours

Temperature coefficient of UDC 0.18% per °C

Safety According to EN 50178 standard

Input/Output isolation 2500 VAC between input/output and electrical earth

Relative humidity Operation: from 20% to 95% non condensing. Storage: from 15% to 90% (in original packaging).

Altitude Up to 1000m, derate from 1000 to 4000m by lowering the output current by 7% per 1000 m.

Ripple Max 2% rms of nom. DC voltage, with a battery Ah capacity

of 5 times the charger nom rating, battery connected (see our filter options). 2.5% rms typical (max 5%) on rectifier output, battery not connected.

EMC emissions Generic emission standards EN 50081-2 and generic immunity standards EN 50082-2 available as standard option.

Dynamic voltage regulation Using standard filter and the battery connected (capacity higher than 5 times I nom)

Load step Deviation 10-90% -5% 90%-10% +5%

Range of operating voltage Floating charge 75% to 125% of Udc Nominal High rate charge 75% to 135% of Udc Nominal Commissioning charge 75% to 140% of Udc Nominal Frequency 50Hz or 60Hz ± 6%

Protect RCS Three Phase (TPRe) Three phase 400Vac ± 10% Other voltages available as option

Charging characteristic Constant current / constant voltage (I/U as per IEC 478-1) during float charge

Insulation resistance > 200 MΩ, 500 VDC

>> PRODUCT RANGE ARCHITECTURE

Architecture Documentation Cabinet

Availability

A Standard Rectifier System (Building block) Standard Documentation Standard Size Short lead time Plus Basic Options (Building block) Standard Documentation Standard Size Short lead time Plus

Extended Options Documentation Customized or optional sizeStandard dependentProject The product range is configurable with three levels of architecture:

1

2

3

Cabinet construction

Floor Mounted 19” cabinet Protection degree IP21

Colour RAL 7035 - Powdered textured painting

Cabinet natural cooling (except TPRe 110V-400A and 110V-500A) Door with air inlet

Rear panel with air outlet (φ 5mm punched panel) (requires 10 cm minimum clearance at the rear of the cabinet)

Door swing 180 degrees with two key locks Logo/ Brand name on front

Bottom open (vermin proof as option) Standard cable entry at the bottom Standard cable gland plate on the roof

Bottom opening (10 cm) for pallet truck handling facilities Standard labelling/nameplate

Standard PVC cable Standard cable marking

None isolated aluminium earth bar (screwed directly in frame)

Electrical components

Terminal X1 and X2 (Mains, battery, load, common fault) Internal input power switch Q1

Input transformer T1 (with taps 220V-230V-240V for SPRe and 380V-400V-415V for TPRe) Rectifier bridge (SPRe: mixed diode/thyristor bridge V1-V5, TPRe: 6-pulse bridge V1-V7)

GCAU card A1 with non-volatile history and English display language + second language available (factory setting) TPC card A2 for TPRe only

Output filter L1-C1 ripple voltage < 5% RMS without battery Rectifier fuse F1

Rectifier shunt R2

Common fault remote alarm (changeover contact wired on terminal)

The Display card (A300) and keyboard assembly (A310) are mounted on the front of the system

STANDARD SYSTEM

The Protect RCS range of systems have been pre-configured with a number of the most commonly requested features built-in as standard. These systems are available “off-the-shelf”

with standard drawings and standard user documentation. A Standard Rectifier System without additional options provides a very cost effective, short lead time solution.

STANDARD SYSTEM

>> STANDARD SYSTEM PLUS BASIC OPTIONS

The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user documentation will be automatically generated to reflect the actual options configured

A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional system capabilities.

Option n°

Basic options

Select ( )

Alarm/signalling/measurement option

100 LED box signalling (A6) (all alarms, events, high rate charge, commissioning) 101 First 8 relays card ( A5.1)

102 Rectifier voltage analog DC meter (P2) 103 Rectifier current analog DC meter (P1) 104 Battery current analog DC meter (P3)

105 Temperature alarm (bridge natural cool. ≤50A,+TH1 shutdown+TH2 alarm)

Temperature alarm (bridge forced cool. ≥75A, TH1 shutdown, +TH2 alarm+TH3 fan assisted)

Communication options

200 EIA232 SPG* communication (A71) - WINSPARC software required 201 EIA485 SPG* communication (A71 + A72) - WINSPARC software required 202 EIA485 SPG* PC side interface (one set for PC)

203 WINSPARC software (CD-ROM + documentation) 204 EIA232 MODBUS communication (A71) 205 EIA485 MODBUS communication (A71 + A72)

Control and command options

300 Remote forced floating charge command

AC input options

400 Input fuse (without alarm) DIN (F34) 401 Input fuse (without alarm) Cylindrical (F34) 402 Input circuit breaker (without alarm) (Q1)

403 Input contactor (K1) controlled by ON-OFF switch S1 on front door 404 EMI filter (CE) (Z1) - mandatory for “CE” mark

Load options

500 Load fuse (without alarm) DIN (F23) 501 Load fuse (without alarm) Cylindrical (F23) 502 Load circuit breaker (without alarm) (Q2) 503 Load Switch (handle inside the cabinet) (Q2) 504 Blocking diode (V21)

505 0.1% filter SPRe ≤ 25A (Telecom filter for 24V and 48V) 506 1% filter

Battery options

600 Battery fuse (without alarm) DIN (F13) 601 Battery fuse (without alarm) Cylindrical (F13) 602 Battery circuit breaker (without alarm) (Q3) 603 Battery Switch (handle inside the cabinet)

604 Battery current limit/display (Battery shunt R3 same as rectifier shunt R2) 605 Battery voltage temperature compensation (5 m length sensor wire) (NTC) 606 Temperature sensor wires: 10m, 30m

607 Battery Low Voltage Disconnect contactor (K2) I Battery same as I Rectifier 608 VOM battery charging (Ni Cd gas recombination)

609 Dual rate charge C15 100 battery monitoring board (A3) 610 Single rate charge C15 100 monitoring board (A3)

611 High Rate interlock: (high rate inhibited as load switch is ON)

Cabinet options

700 Cabinet heating resistor (230V) controlled by thermostat 701 Eye bolts

702 IP42

WINSPARC SOFTWARE-SAMPLE SCREENSHOT

SPECIFICATION

WINSPARC SOFTWARE-SAMPLE SCREENSHOT

The WINSPARC software (WINDOWS based) is an application designed for local and remote supervision to have control of the entire GCAU configuration in order to monitor and configure the systems.

This software interacts with the GCAU through a serial data link. To do this the communication card A71 is plugged into the GCAU through the extension connector (See options 200, 201 and 202).

This software function allows visualizing on a PC screen system data such as alarms, measurements, modes, and history. Remote commands can be sent to the system. The available types of communication are:

• Locally (via PC port COMx)

• Remotely (via Modem -extended option 250)

If only one charger is to be connected to the PC, the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71). Option 200.

If more than one charger is to be connected to the same communication bus (centralized supervision of chargers), the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71) + one EIA485 interface & connecting board (A72). Option 201.

With Option 201 (EIA485 bus), the PC side is usually equipped with a PC side interface providing EIA485/EIA232 conversion. Option 202.

The rectifiers are acting as slaves and the central comput-er as the mastcomput-er. By giving the diffcomput-erent rectificomput-ers diffcomput-erent slave numbers, it is possible to command each individual rectifier.

WINSPARC is compliant with the WINSITE software (site management application).

Platform: PC compatible

Operating system: Windows NT4, Windows 2000 or Windows XP.

>> FURTHER CUSTOMIZATION WITH EXTENDED OPTIONS

The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user documentation will be automatically generated to reflect the actual options configured

A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional system capabilities.

Option n°

Extended options

Select ( )

Alarm /signalling/measurement options

150 LED Box LED test push button

151 AC input voltage analog meter (with phase selector switch for TPRe) 152 AC input current analog meter (with phase selector switch for TPRe) 153 AC input voltage and current analog meters with 3-phase selector switch 154 Load voltage analog DC meter

155 Load current analog DC meter

156 Additional spare input alarm (to centralize an external signalling with additional terminal and auxiliary relay – if isolated input required)

157 Second 8 relays signalling card (with additional auxiliary power supply required) 158 Alarm buzzer

159 High ripple voltage alarm 160 Low electrolyte level alarm 161 Battery circuit failure alarm

162 DC line permanent insulation controllers

See options Protection device (Fuse or MCB) with signalling alarm AC input,

Load or Battery

163 Ambient temperature indicator/alarm

Communication options

250 Modem communication

Control and command options

350 Remote rectifier shutdown command (Using one spare input)

351 Remote alarm reset / acknowledgement command (Using one spare input) 352 Battery room fan control (One relay of extension relay card required) 353 Remote high rate charge command (Using one spare input) 354 Float/Auto/High rate internal switch (Using two spare inputs)

AC input options

450 Input fuse (with alarm) DIN 451 Input fuse (with alarm) Cylindrical 452 Input circuit breaker (with alarm)

453 Special transformer( earth screen, tapping, lower inrush current)

454 Special mains input voltage (3x460/480V 60Hz; 3x500V 50Hz; 3x690V 50Hz; other) 455 AC surge arrestor

Load options

550 Load fuse (with alarm) DIN 551 Load fuse (with alarm) Cylindrical 552 Load circuit breaker (with alarm) 553 Diode dropper

554 0.1% filter all other models SPRe ≥50A & TPRe 555 High DC voltage trip mechanical

556 DC distribution 557 DC surge arrestor

ONS

Option n°

Extended options

Select ( )

Battery options

650 Battery fuse (with alarm) DIN 651 Battery fuse (with alarm) Cylindrical 652 Battery circuit breaker (with alarm)

653 Special battery current limit/display shunt (R3 # R2) 654 Special battery LVD contactor (I batt. # I red.) 655 Reversed battery protection

656 Cable drop compensation

657 Battery protection/isolation box (Fuse/fuse switch/MCB/MCCB/switch) See alarm options High ripple voltage alarm card

Low electrolyte level alarm Battery circuit failure alarm card See control options Battery room fan control

Float/Auto/High rate internal switch Remote high rate charge command

Cabinet options

750 Cabinet interior light and AC mains socket with circuit breaker (without differential) 751 Cabinet interior light and AC mains socket with differential protection circuit breaker 752 Interior light with circuit breaker (without differential)

753 AC mains socket with differential protection MCB 754 AC mains socket with circuit breaker (without differential) 755 IP20 Open Door

756 IP21 with back panel 757 Protection up to IP54 758 Special colour 759 Copper earth bar

760 Vermin proof protection plate 761 Tropicalisation (Varnished PCB’s)

762 Special wiring (low smoke low fume wiring and cable duct halogen free) 763 Identification of internal components by sticky labels on plexi strip 764 Identification of internal components by engraved labels on plexi strip 765 Cabinet coupling

766 Cabinet separation plate 767 Additional cabinets option 768 Battery cabinet

769 Battery separation plate

System options

850 Parallel high rate - Automatic high rate inhibition for the chargers in parallel 851 Passive loadsharing (droop factor)

852 Shared high rate

Option n°

Miscellaneous options

Select ( )

950 Extra drawing files 951 Factory acceptance test 952 Extra test (Heat run test) 953 Packing (various categories) 954 Freight (as required)

Detailed explanations of all Options are available on request.

Power Systems

Whenever wherever

wattever

Industry - IT - Telecoms - Transportation - Services For further information see SPS Service Brochure

For more information please refer to our website: www.powersupplysystems.com R e aliz ed b y yvyd y. P rotect R C S - 09/ 07 - EN-V1 .

Due to our policy of continuous de

v

elopment, dat

a

in this document is subject to c

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ange without notice and becomes contract

ual

only af

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ten confirmation.

BATTERIES

Saft Power Systems has considerable in-house knowledge in battery technology and is able to offer expert advice on the specifying, selection, operation and testing of batteries. Our total system solutions include a wide range of products using lead acid and nickel-cadmium batteries in vented and

gas recombination technologies. Batteries can be supplied on racks or inside cabinets which match the chargers and can be mechanically coupled to the charger cabinet if necessary. Replacement batteries can be supplied and installed by our Global Service Team.

POWER SERVICES

count on Saft Power Systems specialists to deliver the right service and support rapidly and efficiently.

A comprehensive range of services are available

Product Services Refurbishment Consulting

Load Bank & Capacity Testing Installation & Commissioning Facility & equipment Management Battery Monitoring Spare Parts Battery Replacement In-house/Express Repair Training Remote Monitoring Power Quality Services

Service Contracts - 24/7 Global Service Coverage Corrective Maintenance