Pmi Rda-rdat Series Batterycharger Userbook_en

THYRISTOR CONTROLLED BATTERY CHARGER / RECTIFIER RDA/RDAT SERIES USER MANUAL

© Copyright 2010. All rights reserved worldwide. The information contained in this document is proprietary and is subject to all relevant copyright, patent and other laws protecting intellectual property, as well as any specific agreement protecting the manufacturer’s rights in the aforesaid information. Neither this document nor the information contained herein may be published, or reproduced, in whole or in part, without the express, prior, written permission of the manufacturer. In addition, any use of this document or the information contained herein for any purposes other than those for which it was disclosed is strictly forbidden. The manufacturer reserves the right, without prior notice or liability, to make changes in equipment design or specifications. Information supplied by the manufacturer is believed to be accurate and reliable. However, no responsibility is assumed by the manufacturer for the use thereof nor for the rights of third parties which may be affected in any way by the use thereof. Any representation(s) in this document concerning performance of the product(s) described herein are for informational purposes only and are not warranties of future performance, either express or implied. The manufacturer’s standard limited warranty, available upon request, stated in its sales contract or order confirmation form, is the only warranty offered in relation thereto. This document may contain flaws, omissions or typesetting errors; no warranty is granted nor liability assumed in relation thereto unless specifically undertaken in the manufacturer’s sales contract or order confirmation. Information contained herein is periodically updated and changes will be incorporated into subsequent editions. If you have encountered an error, please notify your vendor. All specifications are subject to change without prior notice.

DC POWER SUPPLY / BATTERY CHARGER

ATTENTION! This manual contains instructions concerning the installation and putting into operation of the RECTIFIER. Read the manual carefully before currying out installation, which must be done by a trained person. Because of this, the manual contains essential information about the usage of the equipment and also the RECTIFIER must be kept in a safe place and consulted before operating.

SAFETY REGULATIONS THE RECTIFIER MUST NOT BE USED UNLESS IT IS CONNECTED TO EARTH The first connection to make is the connection between the grounding lead and the terminal indicated with the symbol:

HIGH VOLTAGES ARE PRESENT INSIDE THE EQUIPMENT EVEN WHEN THE INPUT AND BATTERY SWICHES ARE OPEN, BESIDES IN THE THREEPHASE OUTPUT VERSIONS A PART OF THE POWER CIRCUITS REMAINS CONNECTED TO THE INPUT NEUTRAL. All maintenance operations inside the RECTIFIER must the carried out only by trained personnel.

IF IT IS NECESSARY TO REPLACE THE FUSES, THEY MUST BE REPLACED WITH OTHER FUSES OF THE SAME TYPE. TO INTERRUPT THE POWER SUPPLY TO THE UTILITIES IN DANGEROUS CONDITIONS, OPEN ALL THE SWICHES LOCATED BEHIND THE FRONT DOOR.

THE BATTERY GROUP SHOULD BE CHANGED IF NECESSARY ONLY BY QUALIFIED PERSONNEL. TO ELIMINATE REPLACED PARTS IT IS OBLIGATORY TO DELIVER THEM TO ONE OF THE SPECIAL CONSORTIUMS FOR DISPOSAL BY RECYCLING. THE BATTERIES ARE CLASSIFIED TOXIC WASTE BY LAW.

The company reserves the right to make changes to the product described in this manual at any time and without notice for reasons of improvement.

3


RDA/RDAT AUTOMATION BATTERY CHARGER The Battery Charger is SCR controlled AC/DC rectifier with automatic constant voltage and constant current ability.On LCD panel , you can see all measurement values , real time base events and failures and communicate remotly with in RS 232 or RS485 port. All operations are controlled and progressed by micro controller. Adjustable timer is used for boost charging the batteries automatically. Output current, battery current , boost and Float Charge Voltages are adjustable on the control panel easily. The Timer is a decrementing counter by one hour. The Charger output gives the boost charging voltage by setting the timer to any value larger than zero. The Charger returns to floating voltage level when the timer value reaches to zero. Also automatic boost charge can be selected on menu.The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity. The user should set the suitable float and boost currents of the battery before selecting the automatic boost option. After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values. If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value. The input and output of the charger are protected against to misuse and line disturbances electronically. Input and output can be switched by circuit breakers individually. It has selfprotection against to over temperature. The alarm contacts can be used for external system in the case of any anomaly. The output is fully isolated from the AC line input. The Charger has a modular design to provide service and maintenance simplicity. The outputs of the Battery Chargers can be connected in parallel according to need. Standart Features • Adjustable Timer for Boost Charging • Adjustable Boost and Float Charge Voltages • Automatic Boost Charge Selection according to boost / float current set value • Adjustable Rectifier Output Current and Battery Charge Current • LCD Display for DC Load / Battery Voltage ,DC Load / Battery Current , Input AC Voltage / Line Current/ Frequency • Event History for all Electrical values and failures • Automatic and Manuel Battery Test • Boost inhibit facility for interlock redundant application • Output Filter Inductor and DC Longlife Capacitor • Electronic Over / Under Voltage, Over Current and Short Circuit Protections • Isolated Output by Input Transformer and output halleffect current module • Parallel Redundant Operation • Boost and Float dropper control output for Ni-Cd and Lead Acid Battery • Input Filter and input surge Voltage protection • Internal Over Temperature protection • Temperature Compensation for Battery • Low Battery Indication and Alarm contacts • Rectifier Failure Indication and Alarm contacts • Rectifier Over Voltage Indication and Alarm contacts 4

• • • • • • • •

DC POWER SUPPLY / BATTERY CHARGER Over Temperature Indication and Alarm contacts Line Failure Indication and Alarm contacts Input MCB Indication and Alarm contacts Load MCB Indication and Alarm contacts Battery MCB Indication and Alarm contacts Reverse Battery Connection Protection Reset Button RS- 232 communication

Options Communication RS485 (Monitoring and Parameter setting) Silicon Dropper Module For Load Output ( Load voltage output ± 5 % ) Rectifier and Battery Group with the same cabin LVD Deep Discharge Battery Protection contactor Earth Fault Indication and Alarm contacts Boost inhibit interlocking function with extra mechanical relays

5

DC POWER SUPPLY / BATTERY CHARGER TECHNICAL SPECIFICATIONS GENERAL

Model Topology

INPUT

Nominal Frequency Power Factor Transformer Input Protection

Output Voltage Adjustment Nominal Output Current Output Current Adjustment Boost Charge Voltage Boost voltage (V/C) Float voltage (V/C) Output Ripple Dynamic Response (w/out battery group) Dynamic Response (with battery group) Battery Charging Principle

Output Protection Filtering

Event History Boost Timer Cooling Isolation Voltage Efficiency at full load MTBF Operating Temperature Protection Level Enclosure Material Cable Entry Relative Humidity Circuit Breakers Ac Voltmeter

24 VDC ±1% / 48 VDC ±1% / 110 VDC ±1% / 220 VDC ±1% 24VDC system between 10VDC and 30VDC 48VDC system between 30VDC and 60VDC 110VDC system between 90VDC and 160VDC 220VDC system between 190VDC and 290VDC 30A/60A/100A / 200A / 400 A 0‐100% of Nominal Output Current 100% to 120% of Floating Output Voltage (1,60V NiCD battery (adjustable)) (1,40V NiCD battery (adjustable)) 1% RMS AC of Output Voltage ±10% of Output Voltage at 200msec (100% load change) ±2% of Output Voltage at 200msec (100% load change) Constant Current/ Constant Voltage 125% for 10 minutes 150% for 60 seconds 1000% for 5 cycles 105% continuous Short Circuit, MCB, Overvoltage protection and reverse polarity protection L‐C Filter

Over Voltage Rating

GENERAL Battery Test

220 VAC / 230 VAC / 240 VAC ±15% 380 VAC / 400 VAC / 415 VAC ±15% 50 / 60 Hz ±5% >0.8 Galvanically isolated / Primary & Secondary Earth Screened Thermic Magnetic Overcurrent protection MCB, Overvoltage protection

Nominal Voltage

OUTPUT Floating Output Voltage

RDA/RDAT Series 6 Pulse/12 Pulse Thyristor controlled AC/DC Rectifier with input isolation transformer

Automatic or manual selectable AC Line Input high / Low , Rectifier output high / Low , Battery test failed , Over temperature , Low Battery, Line / Battery / Load MCB events are displayed on time base in the front panel 0 – 99,9 hours adjustable by 1 minute accuracy Forced fans with smart fan controlling system

3000VAC input/chassis and output/chassis >90% 100,000 Hrs. (w/out battery group) ‐10 / + 40 ºC IP21 (Higher IP available as option) Mild Steel, Zinc‐phosphate coated; 100 µm electrostatic paint; 1.5 mm thickness Front Bottom 5% to 90% non condensing Input: Magnetic circuit breakers; Output: Magnetic circuit breakers At the Input

6

DC POWER SUPPLY / BATTERY CHARGER DISPLAY PANEL

LCD Displays for Load Output Voltage / Current , Battery Output Voltage / Current and Line Voltage / Frequency Boost Charging, Float Charging, Charger Failure, Over voltage , Over temperature , Low battery , Under voltage , Battery ending , Battery test , Earth Fault and Input Power OK Timer Setting, Boost Voltage Setting, Float Voltage Setting ,Output current setting, battery current setting , automatic boost setting and Reset buttons AC Line Input high / Low , Rectifier output high / Low , Battery test failed , Over temperature , Low Battery , Line / Battery / Load MCB events are displayed on time base.

Mains Switch Failure, Battery Switch Failure, Load Switch Failure, Rectifier Failure, Low Battery failure, Rectifier Over Output Voltage, Line Failure, Over Temperature, Earth Fault and Low Level Electrolyte(option)

Measurements Indicators Buttons

Event History

FREE ALARM CONTACTS Open or closed free alarm contacts

ENVIRONMENT

Operating Temperature

‐10 / +40 °C

Relative Humidity

5 ‐ 90 %

Operating Altitude

Max. 3000 Mt.

Noise Level

Max. 60 db

Electrical Standards

COMMUNICATION & PARALLELING

EN 50091‐1 (Security) / EN 50091‐2 (EMC)

Optional Communication Paralleling

DROPPER DIODES (OPTIONAL) Voltage Regulation via Dropper Diode

BOOST INHIBIT INTERLOCK (OPTIONAL) Boost Inhibit Interlock System

RS‐ 232 / 485 communication are available to monitor and control over Local Area Network & Internet N+1 (No need for extra part for paralleling)

Dropper diodes for float or boost charge may be utilized upon request. At discharge the dropper diodes will be eliminated out of the load circuit. When boost inhibit option is implemented parallel redundant mode for interlock application inhibits one of the rectifiers boost operation

LVD and EARTH FAULT PROTECTION (OPTIONAL) LVD and Earth Fault Protections

LVD protection through mechanical relay Earth Fault Protection via dedicated extra PCB

7


AUTO BOOST FUNCTION (STANDARD FUNCTION) Battery voltage

AUTO BOOST FUNCTION The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity.

Boost voltage Float voltage

Time hour 0

6

8

The user should set the suitable float and boost currents of the battery before selecting the automatic boost option.

Battery current

After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values.

Charge current

Boost current Float current Time hour 0

6

8

Battery automatic boost/float charge technique Voltage (V)

Boost

If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value.

Float

Amper ( I ) Battery

Output

Option: Boost inhibit function is available in parallel operations to prevent over voltage (page 9)

Constant voltage / constant current rectifier output V/I characteristics

BATTERY TEST FUNCTION (STANDARD FUNCTION) Battery test function tests the total battery voltage and gives information back to the user. Battery test duration is 20 second and this is a fixed value. When battery test starts the charging voltage is set to 100VDC for 20 second and microprocessor monitors the battery voltage during this period. If the battery voltage is below 100VDC then Battery Fail Alarm turns ON and charger returns back to float voltage. If the battery voltage is low this event is recorded to event log. The test intervals can be set from the front panel and user interface. The battery test can be automatic with set intervals or it can be started manually as per user instructions on page 12 and 13. 8


BOOST INHIBIT INTERLOCKING FUNCTION (OPTIONAL)

Boost Inhibit Function is necessarily employed when two DC Chargers with two battery groups operate in a parallel redundant mode. In parallel operation, if two rectifiers start boost-charging at the same time there is danger the load would be damaged by overvoltage. So, the principle idea of Inhibit facility is to block any one of the two chargers feeding the load in Boost mode when the other rectifier is charging the batteries in Boost mode; so the system prevents applying overvoltage to the load. This function is primarily handled by a powerful communication between two rectifiers and the use of contactors (demonstrated as C1 and C2 in above SLD). Operation: When first charger is in Boost mode C1 becomes OFF and Rectifier 2 continues to feed the load in Float mode (C2 is ON). Unless Rectifier 1 returns to Float mode, Rectifier 2 can’t switch to Boost mode continues to operate on Float mode. Rectifier 2 can only be taken to Boost mode when C1 becomes ON and Rectifier 1 returns to Float mode.

9


DROPPER DIODES IN PARALLEL OPERATION WITH ONE BATTERY GROUP (OPTIONAL) With one battery group boost inhibit interlock system can not be used. In parallel configuration with one battery group dropper diodes has to be installed to regulate the load voltage during boost charging as per below diagram.

10


BATTERY CHARGER USER INSTRUCTION PROCEED TO START UP THE CHARGER AS FOLLOWS: 1. MAKE THE ELECTRICAL CONNECTIONS OF THE CHARGER TO THE INPUT LINE TERMINALS AND CLOSE (MAKE ON) THE LINE SWITCH. 2. MAKE THE ELECTRICAL CONNECTIONS OF THE BATTERY GROUP TO THE BATTERY OUTPUT (+/-) TERMINALS OF THE CHARGER. 3. ON THE CHARGER DISPLAY, READ THE BATTERY VOLTAGE AND ADJUST IF IT IS NECESSARY. FOR EACH 12 VDC MAINTANANCE FREE LEAD ACID BATTERY, CHARGE VOLTAGE CAN BE BETWEEN 13.6 – 13.8 VDC. FOR EACH 1.2 VDC NI-CAD NICKEL CADMIUM BATTERY CELL, CHARGE VOLTAGE CAN BE BETWEEN 1.45 – 1.50 VDC. 4. CLOSE (MAKE ON) THE BATTERY SWITCH AND READ THE BATTERY CHARGE CURRENT ON THE CHARGER DISPLAY AND ADJUST IF IT IS NECESSARY. (NORMALY, BATTERY CHARGE CURRENT CAN BE 15 % OF BATTERY AMP – HOUR) 5. MAKE THE ELECTRICAL CONNECTIONS OF THE LOAD TO THE DC LOAD OUTPUT (+/-) THERMINALS OF THE CHARGER. 6. CLOSE (MAKE ON) THE LOAD SWITCH AND CONTROL DC VOLTAGE AND CURRENT ON THE CHARGER DISPLAY.

ATTENTION! 1. DON’T CONNECT THE BATTERY GROUP (+/-) TERMINALS IN REVERSE POLARITY CONNECTION. 2. DON’T MAKE SHORT CIRCUIT THE BATTERY / LOAD OUTPUT (+/-) TERMINALS. 3. THE BATTERY SWITCH MUST BE LEFT OPEN (OFF POSITION) WHEN THE CHARGER IS NOT OPERATING. 1 Phase Input/Output/Battery Connections

3 Phase Input/Output/Battery Connections

11


LCD FRONT PANEL USER INSTRUCTIONS

12


LCD FRONT PANEL USER INSTRUCTIONS MAIN MENU: BATTERY CHARGER UP: When UP button is pressed the charger is RESET the microprocessor DOWN: When DOWN button is pressed the charger turns OFF MENU1: L1, L2, L3: F: Lin:

Input voltage Input Frequency Input Current

MENU2: Vb: VI: Ib: IL:

Battery Voltage Load Voltage Battery Current Load Current

MENU3: Boost V: Float V:

Boost Voltage (can be set from front panel and user interface RS232/RS485) Float Voltage (can be set from front panel and user interface RS232/RS485)

MENU4: Low Bat V: Low battery value to give low battery alarm and cutoff load and battery connection with LVD contactor(contactor optional) (can be set from front panel and user interface RS232/RS485) MENU5: Boost I: Float I:

Boost Current (can be set from front panel and user interface RS232/RS485) Float Current (can be set from front panel and user interface RS232/RS485)

MENU6: Out I: Total output current (Load+Battery Current) (can be set from front panel and user interface RS232/RS485) Charge I: Battery charging current (can be set from front panel and user interface RS232/RS485) MENU7: A b Test: Auto battery test time. This time indicates the time interval for executing the battery test M Boost: Sets the boost charge timing. If manual boost option is selected this time will indicate the manual boost time or if auto boost option is selected this time will indicate the auto boost time (can be set from front panel and user interface RS232/RS485) MENU8: Boost Ch: This allows to select boost charging option. Boost charge options 1: Auto Boost, 2: Boost Charge OFF 3: Manual Boost Battery Test: This allows to select battery test option. Battery test options 1: Auto Test, 2: Battery Test OFF 3: Manual Battery Test MENU9: Date: Time:

Set the current date. This date will appear in event log during events Set the current time. This time will appear in event log during events

MENU10: Events:

Event logs can be monitored via this menu please refer to instructions in page12 13


COMMUNICATION INTERFACE Remote monitoring and parameter setting through RS232 / RS485 is available for the rectifier.

14

DC POWER SUPPLY / BATTERY CHARGER General procedures for the user interface: • • • • • • •

To start communication, select comport which is connected from the COMPORT box. And push START / STOP COMMUNICATION button. Do not use “,” while setting a parameter. Use “.” for float numbers Do not use ENTER to save a parameter. Use SAVE button to save. Push READ COMPLETE HISTORY button to read all event history. CLEAR HISTORY clears screen. But this operation does not erase history from the memory. Using READ COMPLETE HISTORY button, you can recall all history on screen at any time To set date and time, use the format given below. Use “:” between dates and times. And pres SAVE button. Example: 20:05:10 18:55 Parameter setting procedure: You can set parameters while START / STOP COMMUNICATION button is colored in RED. If START / STOP button is GREEN colored it means that data is being received through communication and while data is being received parameters can not be set before stopping the data transfer. You can push START / STOP button to stop data receiving mode and be ready to set parameters from the screen. Once the color is RED it is ready to set parameters. Set any value on the white boxes provided under SET PARAMETER screen and push SAVE button to set the parameters. And push START / STOP COMMUNICATION button to receive the real time data from the charger after setting the parameters. This action will turn on the monitoring mode back again Parameter descriptions: RECT Imax: Total rectifier output (Battery+Load current) current limit can be set. Rectifier output voltage will not allow higher currents than the set value BAT Imax: Battery charging current limit of battery can be set. Rectifier battery charging current will not allow higher currents than the set value Note: Max Load current value can be set indirectly by setting the RECT Imax and BAT I max values BAT TEST: This parameter sets battery test condition. If it is equal 1, automatic battery test is ON. If it is equal 2, battery test is OFF. If it is equal 3, manual battery test is available, select 3 and push save button to start battery test manually. BAT TEST TIME: This parameter sets automatic battery test time between 0.1 – 99.9 hour. LOW BATTERY VOLTAGE: This parameter sets min DC voltage value where rectifier gives low battery alarm and cut off the load connection of battery via LVD contactor(option) 15

DC POWER SUPPLY / BATTERY CHARGER FLOAT Vdc : Float charge voltage of battery group can be set. BOOST: This parameter sets boost charge condition. if it is equal 1, automatic boost is ON. If it is equal 2, boost is OFF. If it is equal 3, manual boost is available, select 3 and push save button to start boost charge manually. BOOST Vdc : Boost charge voltage of battery group can be set. BOOST TIME: This parameter sets manual/auto boost charge time between 0.1 – 99.9 hour. I FLOAT: This parameter sets current value where rectifier returns float charge from automatic boost charge. I BOOST: This parameter sets current value where rectifier go automatic boost charge from float charge. AUTO BOOST FUNCTION The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity. The user should set the suitable float and boost currents of the battery before selecting the automatic boost option. After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values. If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value.

16

DC POWER SUPPLY / BATTERY CHARGER Battery Charger Block Schema : FILTER & INPUT PROTECTION

ISOLATION TRANSFORMER

RECTIFIER MODULE

OUTPUT FILTER L

BATTERY GROUP

LINE

SUPPLY PCB

CONTROL PCB

BATTERY PROTECTION

µC

CONTROL PANEL

LOAD

AUTOMATION CONTROL PCB ALARM CONTACTS

BATTERY CHARGER CONTACTS INFORMATION Warning Contacts Battery charger gives 3 status information : Line : If line switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information. Battery : If battery switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information. Load : If load switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information.

Alarm Contacts Battery charger gives nine different failure warning information. Low Battery : After main electricity goes off, battery group which maintains load and when reaching end of discharge voltage, leaves load from battery group with contactor. Alarm LED on the front panel turns ON and also gives free contact information. Battery Ending : After main electricity goes off, battery group which maintains load and when reaching approximately 11 VDC (VRLA) for each battery. Alarm LED on the front panel turns ON Earth Fault : If the chassis of battery charger or ground line have leakage current greater than 30 mA. Alarm LED on the front panel turns ON and also gives free contact information. 17

DC POWER SUPPLY / BATTERY CHARGER Under Voltage : When a low voltage failure happens in the battery charger output voltage, the battery charger stops. Alarm LED on the front panel turns ON Over Voltage : When an over voltage failure happens in the battery charger output voltage, the battery charger stops. Alarm LED on the front panel turns ON and also gives free contact information. Mains Failure : When electricity goes off Alarm LED on the front panel turns ON and also gives free contact information. Charger Failure : When the battery charger failure occurs Alarm LED on the front panel turns ON and also gives free contact information.. Over Temperature : When the battery charger’s operating temperature is higher than 50 °C or Fan failure situation happens, battery charger cut off the output. Alarm LED on the front panel turns ON and also gives free contact information.

18


1 PHASE INPUT BATTERY CHARGER CONNECTIONS

D A O L

~

E N I L

=

N

BATTERY

+ _

T C E L E S U N E M

T E S U N E M

P

-Y R E T T A B +

R E G R A H CR YE RI F EI TT TC AE BR

LINE INPUT

LOAD

+ _

LINE INPUT

--

Phase

+

Neutral

-

Ground

+

LOAD

BATTERY

19


1 PHASE INPUT BATTERY CHARGERS VIEW

Supply Transformer Control PCB

Thermostat Thyristor Module Diyot Module

Input Isolation Transformer

LEM Current Module Filter Capasitor Filter Inductor

Side View (Right)

Side View (Left)

AD LO

E N LI

~ =

-

+


Front Panel

Y ER TT BA CT LE SE U EN M

T SE U EN M

220VAC Fan

Input / Output Connections

LINE INPUT

P N

BATTERY

+

_

LOAD

+

Front View

_

Back View

20


3 PHASE INPUT BATTERY CHARGER CONNECTIONS

FLOAT MODE BOOST MODE CURRENT MODE

LINE

BATTERY ENDING

LOAD

LOW BATTERY BATTERRY FAIL LINE FAILURE

BATTERY CHARGER RECTIFIER

OVER VOLTAGE

+

-

BATTERY

UNDER VOLTAGE OVER TEMPERATURE RECTIFIER FAILURE

MENU SET

LINE L1

L2

MENU SELECT

BATTERY

L3

N

+ _

LOAD

+ _

LINE INPUT

L1 L2

--

L3

+

Neutral

--

Ground

+

LOAD

BATTERY

21


3 PHASE INPUT PARALLEL BATTERY CHARGER CONNECTIONS

FLOAT MODE

FLOAT MODE

BOOST MODE

BOOST MODE

CURRENT MODE

CURRENT MODE

LINE

BATTERY ENDING

BATTERY ENDING

LOAD

LINE

LOAD

LOW BATTERY

LOW BATTERY

BATTERRY FAIL

BATTERRY FAIL

LINE FAILURE

LINE FAILURE


OVER VOLTAGE

+

OVER VOLTAGE

-

+

-

BATTERY

UNDER VOLTAGE

BATTERY

UNDER VOLTAGE


OVER TEMPERATURE

OVER TEMPERATURE

RECTIFIER FAILURE

RECTIFIER FAILURE

MENU SET

LINE INPUT

RECTIFIER 1

RECTIFER 2

L1L2L3 N

L1 L2 L3

L1 L2 L3

L1 L2 L3 N Ground LINE INPUT

MENU SET

MENU SELECT

RED. 1

+ _

RED. 2

+ _

BATTERY

+ _

+

--

BATTERY

MENU SELECT

LOAD + _

+

--

LOAD

22


3 PHASE INPUT BATTERY CHARGERS VIEW

Control PCB Thermostat Diode Supply Transformer PCB

Thyristor Module LEM Current Module-1

Output Isolation Transformer

Filter Inductor

Side View (Right)

D A O L

E N LI

~

Digital Front Panel

Side View (Left)

= -Y R E TT A +B


T C LE E S U N E M

T E S U N E M

220VAC Fan

Input / Output Connections

LINE L1

L2

BATTERY

L3

N

+

_

LOAD

+

_

Front View

Back View

23


48 VDC RECTIFIER WITH BATTERY GROUP DIMENSIONS: H: 94 x W:44 x D:55 in cm (4 x 160 Ah Batteries to be housed)

48VDC RECTIFIER KABINENT WITH BATTERY GROUP

NE LI

AD LO

~ =

Front Panel

Y ER TT

+ BA

-

R E G R A H CR YE RI E IF TT TC AE BR

CT LE SE

NU ME

T SE

NU ME

DC Power Supply / Battery Charger Group LINE SWITCH

LINE

P N

BATTERY SWITCH

BATT.

+ --

LOAD SWITCH

Line Input / Battery and Load Output Connections Input / Output Cable Canal Battery Group

48VDC SYSTEM BATTERY GROUP CONNECTIONS (4 BATTERIES IN SERIES) +

-

+ -

+

+ --

RED

+

BLACK

-

48VDC (48VDC ~ 51VDC)

24


110 VDC RECTIFIER WITH BATTERY GROUP DIMENSIONS: H: 174 x W:68 x D:64 in cm (9 x 200 Ah Batteries to be housed) 110VDC RECTIFIER KABINENT WITH BATTERY GROUP

NE LI

DC Power Supply / Battery Charger Group

AD LO

~

Front Panel

= +

-

R E G R A H CR YE R E FI T TI TC AE BR

Y ER TT BA CT LE SE

NU ME

T SE

NU ME

LINE L1

L2

BATTERY

L3

N

+ _

LOAD

+ _

Line Input / Battery and Load Output Connections

Input / Output Cable Canal

Battery Group

110VDC SYSTEM BATTERY GROUP CONNECTIONS (12VDC 9 Unit Serial Batteries)

-

+

+

-

-

-

+

+

+

-

-

-

+

+

+

-

-

+ RED BLACK

+ -

110VDC (110VDC ~ 115VDC)

25


1 PHASE ELECTRICAL BLOCK SCHEMA

26


1 PHASE RECTIFIER CONTROL PCB LAYOUT

27


1 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA

28


G5 K5 G6 K6

G3 K3 G4 K4

G1 K1 G2 K2

3 PHASE INPUT ELECTRICAL BLOCK SCHEMA

+15 -15 M GND

+15 -15 M GND 1

DIODE

2

29


3 PHASE RECTIFIER CONTROL PCB LAYOUT

30


3 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA

31


FREE CONTACTS & COMMUNICATION CONTROL PCB LAYOUT

32


COMMUNICATION PCB CIRCUIT SCHEMA

33

GRAUND

NEUTRAL

PHASE

LINE INPUT

RECTIFIER FAILURE

LOW BATTERY

RECTIFIER

LOAD RECTIFIER

GROUP

BATTERY

+

_ +

_

BATTERY

_

(LOAD)

OUTPUT

+

+

_

LOAD


1 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA

34

GRAUND

NEUTRAL

L3

L2

L1

LINE INPUT

+

_

RECTIFIER FAILURE

LOW BATTERY

RECTIFIER-1

LOAD RECTIFIER

GROUP

BATTERY

BATTERY

_ OUTPUT (LOAD)

+

LOAD


3 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA

35

AC INPUT

AC INPUT

BATTERY OUTPUT

+ _

BATTERY GROUP

LOAD OUTPUT

BATTERY GROUP

BATTERY OUTPUT

LOAD OUTPUT

+ _

RECTIFIER-2

+ _

+ _

RECTIFIER-1

+ _

LOAD DISTRIBUTION

BLOCKING DIODE


PARALLEL RECTIFIER WITH TWO BATTERY GROUPS BLOCK SCHEMA

36

AC INPUT

AC INPUT

+ _

+ _

RECTIFIER-2

+ _

+ _

RECTIFIER-1

BATTERY GROUP

+ _

LOAD DISTRIBUTION

BATTERY OUTPUT

LOAD OUTPUT

BATTERY OUTPUT

LOAD OUTPUT

BLOCKING DIODE


PARALLEL RECTIFIER WITH ONE BATTERY GROUP BLOCK SCHEMA

37


COMPONENT LIST Input Fuse

1 Unit

1 Unit

Output Load Fuse

1 Unit

1 Unit

Input Isolation Transformer

1 Unit

1 Unit

Filter Inductor

1 Unit

1 Unit

Thyristor Module

1 Unit

3 Unit

Diyot Module

1 Unit

-

Output Filter Capacitor

1 Unit

1 Unit

Relay

2 Unit

2 Unit

Fan 220VAC

1 Unit

1 Unit

Thermostat (40°C)

1 Unit

1 Unit

Thermostat (70°C)

1 Unit

1 Unit

DC Supply Control PCB

1 Unit

1 Unit

Digital Front Panel

1 Unit

1 Unit

Automation Control PCB (Optional)

1 Unit

1 Unit

Battery Charge Current Adjustment PCB (Optional)

1 Unit

1 Unit

Leakage Current PCB (Optional)

1 Unit

1 Unit

Contactor (Optional)

1 Unit

1 Unit

Supply Transformer

1 Unit

1 Unit

Heatsink

1 Unit

1 Unit

LEM Current Module

1 Unit

1 Unit

Case

1 Unit

1 Unit

38


WEIGHTS & DIMENSIONS

220 VAC (1 PHASE) INPUT LINE Output Voltage 12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 48 VDC 48 VDC 48 VDC 48 VDC 110 VDC 110 VDC 110 VDC 110 VDC

Output Current 10 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp.

Weight (kg) 15 36,5 51,5 95 144 20 40 65 188 45 65,5 80 190

Dimensions ( H x W x D ) (cm) 41 x 22 x 33 41 x 22 x 33 57 x 39 x 41 66 x 38 x 48 73 x 45 x 53 41 x 22 x 33 57 x 39 x 41 66 x 38 x 48 73 x 45 x 53 57 x 39 x 41 57 x 39 x 41 73 x 45 x 53 73 x 45 x 53

380 VAC (3 PHASE) INPUT LINE Output Voltage 12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 48 VDC 48 VDC 48 VDC 48 VDC 110 VDC 110 VDC 110 VDC 110 VDC 110 VDC 220 VDC 220 VDC 220 VDC 220 VDC 220 VDC

Output Current 30 Amp. 60 Amp. 100 Amp. 200 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 150 Amp.

Weight (kg) 45 73 90 120 55 65 90 120 65 78,5 92 169 210 78 90 110 235 365

Dimensions ( W x D x H ) (cm) 57 x 39 x 41 66 x 38 x 48 66 x 38 x 48 73 x 45 x 53 66 x 38 x 48 66 x 38 x 48 70 x 45 x 53 77 x 51 x 71 57 x 39 x 41 66 x 38 x 48 70 x 45 x 53 77 x 51 x 71 110 x 65 x 60 66 x 38 x 48 66 x 38 x 48 77 x 51 x 71 77 x 51 x 71 77 x 51 x 71

39


CABLE CROSS-SECTIONS 220 VAC (1 PHASE) INPUT Output Voltage 12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 48 VDC 48 VDC 48 VDC 48 VDC 110 VDC 110 VDC 110 VDC 110 VDC

Output Current 10 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp.

Input Cable Cross-Section (mm2) 2,5 2,5 2,5 4 10 2,5 2,5 4 10 2,5 6 10 16

Output Cable Cross-Section (mm2) Battery Load 4 4 6 6 16 16 25 25 35 35 4 4 6 6 10 10 25 25 4 4 6 6 10 16 25 25

380 VAC (3 PHASE) INPUT Output Voltage

Output Current

12-24 VDC 12-24 VDC 12-24 VDC 12-24 VDC 48 VDC 48 VDC 48 VDC 48 VDC 110 VDC 110 VDC 110 VDC 110 VDC 110 VDC 220 VDC 220 VDC 220 VDC 220 VDC 220 VDC

30 Amp. 60 Amp. 100 Amp. 200 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 200 Amp. 10 Amp. 30 Amp. 60 Amp. 100 Amp. 150 Amp.

Input Cable Cross-Section (mm2) 2,5 2,5 2,5 2,5 2,5 2,5 2,5 4 2,5 2,5 2,5 4 10 2,5 2,5 4 10 10

Output Cable Cross-Section (mm2) Battery

Load

6 10 25 35 6 16 25 35 4 10 16 25 35 4 10 16 25 35

6 10 25 35 6 16 25 35 4 10 16 25 35 4 10 16 25 35

40


FAILURE – CORRECTION INSTRUCTION

1. IF YOU CAN’T SEE VOLTAGE ON FRONT PANEL, PLEASE CHECK INPUT LINE THERMAL FUSE AND CHECK FRONT PANEL PCB FLAT CABLE. 2. IF THE LINE THERMAL FUSE IS OFF DURING OPERATION OF THE RECTIFIER, PLEASE CHECK TYRISTOR MODULES AND ALSO RELATED GATE FUSES ON THE DC SUPPLY COTROL PCB. IF THERE IS A FAILURE, PLEASE CHANGE TYRISTOR MODUL AND GATE FUSE WITH THE SAME RATING. 3. IF THERE IS A OVER TEMPERATURE FAILURE, PLEASE CHECK MECHANICAL 220VAC FAN. IF REQUIRED PLEASE CHANGE 220VAC FAN WITH SIMILAR ONE. 4. IF THE LOAD THERMAL FUSE IS OFF DURING OPERATION OF RECTIFIER, PLEASE REMOVE LOAD CONNECTIONS AND CHECK LOAD CURRENT FOR SHORT CIRCUIT PROTECTION. 5. IF THERE IS A PROBLEM ABOUT BATTERY GROUP (BOILING, OVER HEAT), PLEASE CHECK BATTERY GROUP CHARGE CURRENT (15% OF BATTREY AMPHOUR) AND FLOAT VOLTAGE ON CHARGER FRONT PANEL. 6. IF EVERYTING IS OKAY (INPUT LINE VOLTAGE, LOAD CONNECTIONS, BATTERY CONNECTIONS AND FUSE POSITIONS) FOR THE OPERATION OF THE RECTIFIER. BUT THERE IS NO OUTPUT, THAN PLEASE CHECK SUPPLY TRANSFORMER (DUAL 0-15VAC OUTPUT) VOLTAGE. IF THE SUPLLY TRANSFORMER OUTPUT IS OKAY, THAN PLEASE CHANGE DC SUPPLY CONTROL PCB. 7. DURING OPERATION OF THE RECTIFIER, IF YOU CAN’T READ OUTPUT CURRENT ON FRONT PANEL, PLEASE CHECK CURRENT MODULE SUPPLY VOLTAGE (+15 VDC, -15 VDC). IF THIS VOLTAGES ARE CORRECT, THAN PLEASE CHANGE CURRENT MODULE.

41

Manufacturers and Importers have to extend Warranty Certificate visa duration which is given by ministry as of permission date every year.

: 23 / 10 / 1995

Date of Permit :

Utilization of this Warranty Certificate has been permitted by The Republic of Turkey, The Ministry of Industry and Commerce, The General Administration of Protection of Consumer Right and Competition, in accordance with the law numbered 4077, and the decree numbered TRKGM95/116-117 based on this law.

: 51

WARRANTY CERTİFİCATE Certificate Number


42

:

:

:

: :

DATE – SIGNATURE – SEAL

Tel – Fax Billing Date and No

:

:

SELLER COMPANY Name

Address

: DC RECTIFIER / BATTERY CHARGER : : : : : : 1 MONTHS : YEARS

SYSTEM Type Brand Model Sequence No Seal and Serial No Max. Repairing Time Warranty

AUTHORIZED PERSON OF COMPANY Signature and Seal

Tel – Fax

Address

Name

IMPORTER or MANUFACTURER COMPANY 1. The warranty period is two years from the date of delivery. 2. The product including all its components is under the warranty of our company. 3. In case of defects within the warranty period, the period spent in repairing is added to the warranty period. The repairing period is maximum 30 days. This period starts from the date of delivery of the product to the services centres or to the seller, the agency the representative, the importer or the manufacturer of the product respectively, in case there are service centres. 4. In case the product has material, workmanship and manufacturing defects, the product will be repaired free of charge and expenses of any sort including labor, the value of the parts replaced or any our charges. 5. The product will be replaced free of charge, o If the product permanently dysfunctions, due to repeating the same defect for more than twice or different more than four times within the warranty period. o If the maximum period for repairing is exceeded. o If it is determined that the defect cannot be removed by report written by the service centre, or in the absence of service centres, by the seller, agency, representative, importer or manufacturer, of the product respectively. 6. The present warranty does not cover damages resulting from importer handling by deviating from the instructions in the manual. 7. General Administration of protection of Consumer Rights and competition in the Ministry of Industry and Commerce, may be applied for Problems concerning the warranty certificate.

WARRANTY TERMS AND CONDITIONS


43

DC POWER SUPPLY / BATTERY CHARGER INDEX ATTENTION! -------------------------------------------------------------------------------------------- 3 RDA/RDAT AUTOMATION BATTERY CHARGER ------------------------------------------ 4 TECHNICAL SPECIFICATIONS ------------------------------------------------------------------- 6 AUTO BOOST FUNCTION (STANDARD FUNCTION) --------------------------------------- 8 BATTERY TEST FUNCTION (STANDARD FUNCTION) ------------------------------------ 8 BOOST INHIBIT INTERLOCKING FUNCTION (OPTIONAL) ---------------------------- 9 DROPPER DIODES IN PARALLEL OPERATION WITH ONE BATTERY GROUP (OPTIONAL) -------------------------------------------------------------------------------------------- 10 BATTERY CHARGER USER INSTRUCTION ------------------------------------------------- 11 LCD FRONT PANEL USER INSTRUCTIONS -------------------------------------------------- 12 LCD FRONT PANEL USER INSTRUCTIONS -------------------------------------------------- 13 COMMUNICATION INTERFACE ---------------------------------------------------------------- 14 BATTERY CHARGER CONTACTS INFORMATION ---------------------------------------- 17 1 PHASE INPUT BATTERY CHARGER CONNECTIONS ---------------------------------- 19 1 PHASE INPUT BATTERY CHARGERS VIEW --------------------------------------------- 20 3 PHASE INPUT BATTERY CHARGER CONNECTIONS --------------------------------- 21 3 PHASE INPUT PARALLEL BATTERY CHARGER CONNECTIONS ---------------- 22 3 PHASE INPUT BATTERY CHARGERS VIEW --------------------------------------------- 23 48 VDC RECTIFIER WITH BATTERY GROUP ----------------------------------------------- 24 110 VDC RECTIFIER WITH BATTERY GROUP --------------------------------------------- 25 44

DC POWER SUPPLY / BATTERY CHARGER 1 PHASE ELECTRICAL BLOCK SCHEMA ---------------------------------------------------- 26 1 PHASE RECTIFIER CONTROL PCB LAYOUT ------------------------------------------- 27 1 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA ----------------------------- 28 3 PHASE INPUT ELECTRICAL BLOCK SCHEMA------------------------------------------ 29 3 PHASE RECTIFIER CONTROL PCB LAYOUT ------------------------------------------- 30 3 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA ----------------------------- 31 FREE CONTACTS & COMMUNICATION CONTROL PCB LAYOUT ---------------- 32 COMMUNICATION PCB CIRCUIT SCHEMA ------------------------------------------------ 33 1 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA ------------------------- 34 3 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA ------------------------- 35 PARALLEL RECTIFIER WITH TWO BATTERY GROUPS BLOCK SCHEMA ------ 36 PARALLEL RECTIFIER WITH ONE BATTERY GROUP BLOCK SCHEMA ------- 37 COMPONENT LIST ----------------------------------------------------------------------------------- 38 WEIGHTS & DIMENSIONS ------------------------------------------------------------------------- 39 CABLE CROSS-SECTIONS ------------------------------------------------------------------------- 40 FAILURE – CORRECTION INSTRUCTION---------------------------------------------------- 41 INDEX ----------------------------------------------------------------------------------------------------- 44

45

Pmi Rda-rdat Series Batterycharger Userbook_en

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