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DUCUMENTAZIONE TECNICA: Technical documentation:

CLIENTE - CUSTOMER:

COMMESSA - JOB:

I-4756 O R B I TA L P RO J EC T A ND S ERV I C ES
ORDINE N. ORDER N.:

OPS/CEG/485/11
MATRICOLA PART NUMBER:

I - 4 7 5 6 - 1 0 - 0 1 - 0 1 /1 2
PROGETTO - PROJECT:

BA T T ERY C H A RG ER S YS T EM 1 1 0 V DC 3 7 0 A
SPECIFICA N - SPC N:

IMPIANTO SITE:

N EW 2 2 0 / 1 3 2 KW WA DI A DA I G R I D S TA T I O N A ND A S S O C I A T E D T R A NS .
LOCALITA PLANT LOCATION:

O MA N
TITOLO - TITLE:

O P ER A T I NG M A NUA L
NUMERO DOCUMENTO DOCUMENT NUMBER: PROGETTISTA ENGINEER:

I -4 7 5 6 -1 0 -0 1 - O M

A . AC C IA I

A REV. Rev.

01/08/2012 DATA Date

ISSUE FOR APPROVAL DESCRIZIONE REVISIONI Revision description

E. DONATI EMESSO Issue

A. ACCIAI APPROVATO Approved

Documento di propriet CEG Elettr. Ind. S.p.A. La societ tuteler i propri diritti in sede civile e penale a termini di legge This document is the property of CEG Elettr. Ind. S.p.A. who will safeguard its right according to the civil and penal provisions of the low
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GENERAL SAFETY RULES


The our equipments are designed to create no hazardous situations involving either the operator or other equipment utilized. However, since dangerous voltages are present in the units which make up the system, it is of vital importance that all personnel, maintenance staff in particular, respect the following general safety rules: The Operator must not under any circumstances change the setting of the controls and adjustments located inside the units forming the system, and must promptly notify maintenance personnel of any abnormality observed in operation. Maintenance procedures must be carried out only by authorized technicians specifically trained for this job. Make sure that power is switched off during the removal and replacement of any malfunctioning component. Dangerous voltages, such as the charges on capacitors, may be present inside the units even when the power has been switched off. As a precautionary measure, ground and discharge circuits before beginning work on them. Never work alone. This rule ensures that first aid will be available in case of accident. Use tools with insulated handgrips and wear insulated shoes. Ensure that the insulation of each tool is appropriate to the purpose for which it will be used. Wear insulated gloves and, in performing work where gloves are too clumsy for the job, retain one glove at least on the hand which is not engaged in holding the tool. Stand on a rubber pad sized for the voltages involved. Always use only one hand in working. This keeps current from traversing the heart in case of contact with a point where voltage is present.

In addition, it essential as regards safety that personnel working with the UPS be qualified for both normal and emergency working conditions. Personnel should also: Be thoroughly familiar with the maintenance procedure of the equipments Diagnose any malfunction in collaboration with technical assistance staff; Know how to use fire extinguishers; Be able to apply first aid procedures in case of shock or burns caused by current discharge.

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Index
GENERAL SAFETY RULES ....................................................................................................................................................II 1 INTRODUCTION....................................................................................................................................... 5 1.1 MAIN RULES .............................................................................................................................................................................. 6 1.2 REFERENCE DOCUMENT ........................................................................................................................................................ 7 2 PACKING, TRANSPORTATION, STORAGE AND UNPACKING PROCEDURE ............................... 8 2.1 PACKING.................................................................................................................................................................................... 9 2.2 SELECTION OF PACKING STYLES ............................................................................................................................. 9 2.2.1 Seaworthy Packing ................................................................................................................................................................ 9 2.2.2 Wooden Framed Box or Crate .............................................................................................................................................. 9 2.3 DOCUMENTS ATTACHED TO THE PACKAGE ................................................................................................... 10 2.4 MARKING & IDENTIFICATION ................................................................................................................................ 10 2.4.1 Main Shipping Marks ........................................................................................................................................................10 2.4.2 Special Marking ..................................................................................................................................................................11 2.4.3 Auxiliary Shipping Marks .................................................................................................................................................11 2.5 TRANSPORTATION ......................................................................................................................................................... 12 2.6 RECEIPT, STORAGE, UNPACKING INSTRUCTIONS FOR MECHANICAL INSTALLATION AND STORAGE .................................................................................................................................................................................... 12 2.6.1 Lifting and handling modality .............................................................................................................................................13 2.6.2 Fastening .............................................................................................................................................................................14 3 INSTALLATION PROCEDURE .............................................................................................................. 15 3.1 CHECKS AND MEASURES TO BE TAKEN BEFORE START-UP..................................................................... 16 3.2 START - UP AND DISCONNECTION PROCEDURE ............................................................................................ 16 3.2.1 Equipment start-up .............................................................................................................................................................16 3.2.2 Equipment disconnection .....................................................................................................................................................17 4 EQUIPMENT DESCRIPTION ................................................................................................................. 18 4.1 SYSTEM DESCRIPTION .................................................................................................................................................. 19 4.1.1 General description of the unit..............................................................................................................................................19 4.1.2 110V DC Distribution board ...........................................................................................................................................19 4.1.3 Drop diodes Stabilizer operation ..........................................................................................................................................20 4.1.1 Battery junction switch (QBT) .............................................................................................................................................20 4.2 THREE-PHASE 6 PULSE RECTIFIER ......................................................................................................................... 21 4.2.1 Functional description ..........................................................................................................................................................21
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4.2.2 Rectifier battery charger operation and charging automatism ................................................................................................. 21

4.2.2.1 Floating charge ................................................................................................................................................................................. 22 4.2.2.2 Automatic charge operation with automatic disconnection.................................................................................................... 22 4.2.2.3 Boost charge with manual disconnection ................................................................................................................................... 24 4.2.2.4 Charing of sealed batteries (stationary type) ............................................................................................................................... 25 4.2.3.1 Failure on single branch Rectifier ................................................................................................................................................. 26 4.2.4.1 Rectifier .............................................................................................................................................................................................. 26 4.2.4.2 Battery and Rectifier interconnection .......................................................................................................................................... 27

4.2.3 Rectifier failure ....................................................................................................................................................................25 4.2.4 Circuit composing the Rectifier and their functions ................................................................................................................ 26

5 TECHNICAL DATA ................................................................................................................................. 28 5.1 MECHANICAL .................................................................................................................................................................... 29 5.2 ELECTRICAL ....................................................................................................................................................................... 30 5.2.1 Rectifier battery charger ........................................................................................................................................................30 5.2.2 Battery.................................................................................................................................................................................30

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1
Chapter

1Introduction
Main rules Reference document

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1.1 Main rules


CEG quality management system covers Engineering, Contract Review, Production and After Sales Service, and is ISO 9001 certified by RINA Quacer. CEG systems are designed and built in accordance to the Codes and rules stated in the Technical Specification received (IEC Publications), with particular to the following main and last standards: IEC 60348 and IEC 60950 EN 60950 (CEI 74-2) EN 50091 (CEI 74-4) IEC 60146 (CEI 22) IEC 60439 (EN 60439-1) IEC 60332-1 (CEI 20) IEC 60529 (CEI 70-1) IEC 60801-2 (CEI 65-6) IEC 60801-3 (CEI 65-7) IEC 60801-4 IEC 60801-5 IEC 60076 (CEI 14-4) IEC 332-3 (CEI 20-22) IEC 811 (CEI 20-11) CEI 20-37 IEC 754-1 (CEI 20-37) Safety Rules Information Technology Equipment (Safety Rules I.T.E.) UPS Safety Power electronic converters and semiconductors Low voltage electric switchgears & control gear assemblies Electrical cables Protection degree of enclosures Electrostatic discharge immunity (E.S.D.) Electromagnetic fields immunity Burst type over voltage immunity Lightning type over voltage immunity Power transformers Cables (Fire retarding) Category C Cables (Testing) Cables (Low emission of smoke) Max. density 2 Cables (Low emission of corrosive gasses) Max Hydrochloric acid content (HCI) 0,3% The a.m. IEC have to be considered as renumbered to the EN series 60000.

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1.2 Reference document


Please find below the list of the important documents to be referred together with this manual during all the activity on the system: installation, start-up & maintenance. Description G.A. Drawing and Single Line Diagram Electrical Drawing Factory Test Report Control and Replacement of electronic boards Inspection and Replacement of electronic boards Inspection and Replacement of electronic boards Number I-4756-10-01-01-M I-4756-10-01-01-E I-4756-10-01-01-TR General Section Battery Charger Rectifier Section Generic Auxiliary Card Section

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Packing Selection of packing styles Documents attached to the package Marking and identification Transportation Receipt, storage, unpacking instruction for mechanical installation and storage

Chapter

2PACKING, TRANSPORTATION, STORAGE AND UNPACKING PROCEDURE

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2.1 Packing
The packing shall be designed to ensure that all the materials arrive at the destination in undamaged conditions or safe delivered conditions by applying the packing with inside fastening and/or water moisture applications. Packing shall be carried out under the most technical up-to-date method. Appropriate standards and rules of the transit countries as well as of the country of destination have to be considered. The Supplier shall include and provide for securely protecting and packing the materials so as to avoid loss or damage during handling & transport by air, sea, rail and road. All packing shall allow for easy removal and checking at site. Special precaution shall be taken to prevent rusting of steel and iron parts during transit by sea. Gas seals or other materials shall to be adopted by the Supplier for protection against moisture during transit till its arrival at Project Site. The Supplier shall include and provide for securely protecting and packing the materials so as to avoid loss or damage during handling & transport by sea, air, rail and road. For the equipment transported by sea, the packing should be sea-worthy. Special precaution shall be taken to prevent rusting of steel and iron parts during transit by sea. The dimensions of each package shall not exceed the maximum dimensions of packing acceptable for transport by Rail/Road/Air. All packing materials shall be dry, clean and free from all defects against environmental corrosion caused by extremes of humidity, condensation, rain, dust, sand, salted air and sea spray.

2.2 SELECTION OF PACKING STYLES


Packing styles shall be selected depending on the property, weight and shape of items. 2.2.1 Seaworthy Packing All packages shall ensure that all packages of materials are as compact and durable as possible. All packages shall be properly and solidly made to be suitable for all mechanical and inland transportation. 2.2.2 Wooden Framed Box or Crate Materials shall be securely bolted to the box or crate floor and restrained in such a manner as not to permit any movement or vibrating during transportation. When moisture proof wooden cases are provided or the materials are hermetically sealed in polyethylene or similar covering, appropriate ventilation openings shall be incorporated into the case sides. In case of wood packing, the requirement for the attached International Standards for Phytosanitary Measures shall be satisfied and its Certificate shall be submitted with shipping documents. The Marking for Phytosanitary Measures should be stamped on all packing material (including pallets, dunnage, crating, packing blocks, drums, cases, load boards, pallets collars and etc.).

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2.3 DOCUMENTS ATTACHED TO THE PACKAGE


Each consignment shall be accompanied with two copies of the packing list each and other specifications describing the consignment. One copy of the above packing list shall be placed inside the crate or package and other in a watertight envelope outside the package or crate and shall be placed in such a manner not to be separated or lost during shipment. CEG will utilise your standard packing list if the customer dont require to utilise your format packing list .

2.4 MARKING & IDENTIFICATION


2.4.1 Main Shipping Marks The following details must be clearly and properly stencilled on at least two sides of each box/package with good quality non-fading indelible ink/paint. Each package shall have a marking such as description: (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) Consignee : Suppliers Name: Place of Dispatch : Destination : PURCHASERs Contract No. & Date : *Package No. : Gross Weight : Net Weight : Billing Schedule Item Number : Outer Dimensions of Package : Description of goods : Quantity :

Packing shall bear a special marking TOP, BOTTOM, DO NOT OVERTURN, KEEP DRY, HANDLE WITH CARE, FRAGILE etc according to the appendixes requirements.

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2.4.2 Special Marking Wherever necessary the packages shall be marked on all four sides with special marking such as TOP, BOTTOM, DO NOT OVERTURN, KEEP DRY, HANDLE WITH CARE, FRAGILE etc as well as special symbol indicating the top. (refer to par.5.2). Wherever required and due to unbalanced weight, the position of center of gravity shall be marked as appendix instruction. 2.4.3 Auxiliary Shipping Marks Auxiliary shipping marks shall be clearly stenciled as shown in the following table. To avoid delays in cargo handing and or event accidents, sling marks, canter of gravity marks and lifting method shall be stenciled on only after the Supplier has actually lifted each package with a hook and ascertained each correct position. Color bands and corner colors shall be stenciled on each package when specified in Special Packing Instruction. No. 1 Name of Mark Center of gravity Auxiliary Shipping Marks Table Stenciled Marked and Letters Remarks At the center of gravity

Sling

Where sling wire is to be applied

Top

When package cannot be placed upside down

Keep Dry KEEP DRY

For boxes that need protection from water and moisture

Handle with care HANDLE WITH CARE

For fragile cargo

Heavy weight this end HEAVY WEIGHT THIS END

When center of gravity is on one side

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No. 7

Name of Mark Danger

Auxiliary Shipping Marks Table Stenciled Marked and Letters

Remarks For boxes containing dangerous and toxic materials

DANGER

2.5 TRANSPORTATION
The handling of cases shall be executed with proper means (fork lift or pallet) and keeping to the warning (THIS SIDE UP-DOWN, etc.) applied outside.

2.6 RECEIPT , STORAGE, UNPACKING INSTRUCTIONS FOR MECHANICAL INSTALLATION AND STORAGE
After receiving the equipment, make sure the system has not been damaged during transportation. Timely notice of possible damages shall be given (within three days) in writing to C.E.G. Spa, including a detailed description. In case the system is not installed immediately, the following recommendations shall be followed: 1. The units shall be kept in their own original packaging. The cases shall be stored in compliance with the instructions (TOP - BOTTOM, etc.) shown outside. When storing the cases, provide for the space required for handling and easy removal/inspection. Should the package be damaged during storage, it is necessary to make sure the unit has not got any evident damages; restore the packages integrity before storing. The type of package does not assure a reliable protection and insulation if the cases (unless they are of ocean type) are stored in a damp place; the storage room in fact must be a dry environment free from dust, where temperature does not drop below the limit project value. 2. In case the system is stored already unpacked, make sure it is stored in an environment protected from dust, away from heat sources and equipment in motion. 3. The units shall be stored in their own original packaging. The cases shall be stored in conformance with the warring (THIS SIDE UP-DOWN, etc.) applied outside. When setting down the cases, provide for the space required for possible handling and easy removal, as well as possible inspections. 4. In case the packaging has been damaged during storage or transportation, make sure the unit has not suffered evident damages; restore the packaging integrity before storing. The packing assures no reliable protection and insulation if the cases (except of ocean type) are put in a damp place: in fact the storage room needs to be a dry environment with no dust, where temperature does not decrease below the minimum limit for which the operation of the equipment is assured (0C). Unpacking operations are easy to perform; however in order to prevent damages on the equipment, we recommend to keep to the following instructions:
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1. positions the case in conformance with the warning (THIS SIDE UP-DOWN) outside. Thus you can immediately find the cover to be removed; 2. unnail and remove the unit from the case; 3. take the unit out of the case; 4. release the unit from the protective envelope. 5. To unpack the unit, use the following tools: hammer, cutting nippers or hammer scissors and tong or "Sure Grip" to remove nails. If unpacking operations are carried out carefully, the material will not be damaged and it can be reused to possible dispatch of the equipment again 2.6.1 Lifting and handling modality The system, or the various units composing it, may be lifted and moved via a lift truck or a fork lift (see fig. 1).

For lifting by means of a fork lift, remove the protection panels on the basement (at the front and the rear). and unscrew the fastening screws to the pallet.

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The system may be lifted and moved using the eyebolts supplied with. Fasten the eyebolts at the top of the panel in the corresponding holes as shown in the picture (see fig. 2).

Make sure the draught of the lifting ropes and/or chains is perfectly vertical, compared with the eyebolts axis, so as to prevent them from bending, with consequent deformation of the ending part of the vertical supports. 2.6.2 Fastening The system shall be installed in a dry and clean room. Adequate measures shall be taken in order to assure the utmost heat dissipation. In addition, for any type of installation, provide for suitable aeration of the equipment over the whole external surface. In case the system is equipped with protective roof(s), it (they) shall be fastened at the top, above relevant spacers, using the eyebolts supplied with or suitable screws.

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3
3

Chapter

Installation procedure
Checks and measurement to be taken before start-up Start-up and disconnection procedure

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3.1 CHECKS AND MEASURES TO BE TAKEN BEFORE START-UP


After positioning the board correctly, perform the checks mentioned hereunder before starting the unit up: - Remove possible dust accumulated on insulating parts or on air vents by means of a clean and dry rag or air jets. - By visual inspection make sure all components are well tightened (relays on sockets, fuses on fuse carriers, etc.), that cards are correctly installed in relevant connectors and that no component has been damaged during transport and installation. - Carefully check for nuts of all electric connections (bars, cables, etc.) be well tightened. - Make sure the equipment is correctly earthed. - Make sure the connections between the units and those with mains and with the load have been carried out according to the indications shown in the terminal boards pages at the end of electrical wiring diagram and according to the System Interconnection document issued for each systems -Make sure also the storage batteries have been installed in compliance with the regulations and they have been connected respecting their polarities. At the end of the checks performed with the unit being disconnected, feed the unit and make sure the operation is correct.

3.2 START - UP AND DISCONNECTION PROCEDURE


At the end of the checks performed with the unit being disconnected, feed the unit and make sure the operation is correct.. This paragraph contains necessary information for the user to feed and disconnect the unit. 3.2.1 Equipment start-up For correct start-up of the rectifiers, follow the instructions mentioned hereunder: - Make sure all circuit breakers on d.c. and a.c. side are OPEN (OFF). - Connect a.c. supply cables to relevant terminals, respecting the cyclic sense. - Connect battery cables, paying attention to the polarities specified. - Check the exact value of mains incoming voltage - Set to position AUTOMATIC mode the four selector switches CLR/xx located in the front door. - Set to position ON changeover switch ON/OFF installed on the front of card ALR .
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- Close the main incoming fuse switch Q1A/Q1B - The rectifiers will start slowly (soft start), check the output voltage - Wait for Rectifier voltage to be stabilized and close the output switch Q3A/Q3B - Verify that the battery polarities are connected in the correct way - Close the battery switches Q2A/Q2B and QBA/QBB inside the external box. - Close the dropping diode incoming switch Q4A/Q4B. - The distribution main incoming switch QDA/QDB will automatically close 3.2.2 Equipment disconnection To disconnect the rectifier you need to: - Open the Rectifier output switch Q3A/Q3B (The battery bus coupler switch QBT will automatically close and the other active rectifier will charge both the batteries). - Open the main incoming fuse switch Q1A/Q1B - Open the battery switches Q2A/Q2B and QBA/QBB to disconnect also the battery - If requested, Open the dropping diode incoming switch Q4A/Q4B. In this case the relevant distribution main incoming QDA/QDB will automatically open and the distribution bus coupler QDC will automatically close so that the other branch will feed both the distribution bus bars. To connect the equipment again, perform the operations already described.

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4
4Equipment description
System description Three phase 6 pulse rectifier

Chapter

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4.1 SYSTEM DESCRIPTION


4.1.1 General description of the unit The present technical specification describes the technical characteristics, the modality of use and the instructions for a correct installation of a DC system designed to assure the supply to 110Vdc loads both in case of mains available and power failure, with stabilized voltage. The Unit basically consists of the following sections Pcs. 2 Three-phase 6 pulse totally controlled rectifiers A/B designed, under normal operating conditions, to supply the distribution section (through a dropping diode stabilizer) and recharge the relevant battery. Dropper diode stabilizers installed in the distribution panels and used to supply the feeders with a voltage comprise within their acceptable limits (110Vdc 10%). Distribution section including Nos. 2 bus bars composed each by automatic circuit breakers provided each with auxiliary contact to signal their fault status. All the contacts will be connected together and brought to distribution feeder C.B. tripped common alarm. The distribution is also provided with a motor operated bus coupler switch Battery junction switch Motor operated type (QBT) Battery disconnecting fuse switch (installed inside a wall mounting steel box) Storage vented Ni-Cd type batteries, designed to supply the 110V DC distribution

Pcs. 2 Pc. 1

Pcs. 1 Pcs. 2 Pcs. 2

The equipment described above are installed within metal panels made of flanged steel plate to be opened from the front side by means of hinged doors equipped with key lock. They can be inspected from the sides and the rear through removable panels fastened with screws if necessary, but however the normal maintenance activity can be performed only by the front. All the handling devices like switches, circuit breakers and all other controls are placed behind the front door to avoid unintended operations. The operating cycle will be totally automated; therefore service personnel shall only intervene in case of failure report.
Note

In the following chapters will be described the 110V DC Distribution board, the dropping diode stabilizer, the battery junction switch and the Rectifier sections, while for the batteries refer to the proper Vendor manual.

4.1.2 110V DC Distribution board 110V DC distribution board is housed in a separate cabinet and it includes num. 2 main bus bars and a certain number of outgoing feeders as shown in the relevant electrical drawing. Each outgoing circuit breaker is provided with an auxiliary contact to signal its fault status. All the contacts are connected
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together and brought to distribution feeder C.B. tripped common alarm. The distribution is also provided with a motor operated bus coupler switch (QDC) which operate normally open so that each bus bar is supplied from the proper rectifier/battery through the relevant dropping diode stabilizer, end when the incoming supply voltage in one section goes outside the acceptable limits, the distribution main incoming switch (QDA/QDB) will automatically open (through a motor operated disconnecting switch) and the distribution bus coupler (QDC) will automatically close so that both the distribution bus bar are being commonly supplied from the same dropping diode stabilizer still in service. Once the normal condition will be restored, the distribution incoming switch will automatically close again and the bus coupler will automatically open so that the system start again to operate as a dual single unit. 4.1.3 Drop diodes Stabilizer operation It is a DC stabilizer composed by more diodes connected in series ( number depend by the voltage needs to be reduce) and in parallel (number depend by the current that flow in the stabilizer). Scope of this device is to stabilize the voltage in the distribution incoming in a range as specified by the customer that is generally +/- 10% of the nominal voltage. When the battery is in charging condition (in floating or in boost charge), the stabilizer is in operation and limit the voltage in the output side, while when the main incoming is not present and the battery is in discharging condition, the stabilizer is bypassed by a single pole contactor and the battery voltage arrive directly in the distribution. The lower voltage level depend by the sizing of the battery and relevant number of cells. Operation of the contactor used to insert or bypass the dropper diode is checked by a voltage relay (59VRT/n) In the output of this stabilizer is present an additional voltage relay to verify that for any condition the voltage increase over the acceptable limits. Intervention of this relay produce an alarm signal and force the rectifier(s) in a lower charge level accepted by the distribution (Emergency level). This condition may be restored only by manual operation by pressing a red push-button located internally in the stabilizer cabinet. 4.1.1 Battery junction switch (QBT) Battery junction switch is a motorized disconnecting switch used to connect in parallel both the batteries. This switch works normally open and it will automatically close when at least one rectifier is fail or it is switched off or its mains incoming supply is not available. In this abnormal condition the second rectifier is able to charge in floating voltage both the batteries. The junction switch will be automatically opened as soon as all the parameters are restored and both the rectifier are in normal operation. Closing of this junction switch will force both the rectifiers in floating charge. Warning!!! When the operation of this breaker is set to MANUAL mode, before closing this switch be sure that both batteries are at the same charging level because the battery current limitation for the second batteries (the one connected to the charger failed) it is not activated. Also when in Manual mode, to avoid any unintended discharge of the battery if one charger fails, it is recommended to disconnect the dropping diode stabilizer or, alternatively, you can immediately close the witch QBT so that the dropping diode can be leave in operation.

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4.2 THREE-PHASE 6 PULSE RECTIFIER


4.2.1 Functional description The Rectifiers supplied with S.C.R.s, voltage stabilized and current self-limited, convert the mains alternate current into direct current for the loads supply and the recharge of relevant battery. The single branch Rectifier has the two following operations mode:
NORMAL FUNCTION

During the normal function, the Rectifier develop the following functions: Converter the incoming alternative current in to direct current Maintain the battery in floating charge or provide to recharge it after an eventual discharging cycle. Feeds the distribution with stabilized voltage: the same of battery charging voltage.

RECTIFIER FAILURE

Rectifier is directly connected to the battery and to the loads. In case of Rectifier OFF due to a failure or manual disconnection or mains power loss, the battery will continue to feed the loads until the minimum voltage is reached. As soon as the normal condition will be re-established, Rectifier will automatically restart its normal function.

4.2.2 Rectifier battery charger operation and charging automatism


Nota

The following description is applicable for Systems equipped with vented batteries; while if the supplied battery is Ni-cd type, even though the principle of charging cycle is the same, please refer to chapter 4.2.2.4 for detailed description. The battery charging operation modes are the following: Floating charge mode Automatic charge mode with automatic disconnection Manual charge mode with manual / automatic disconnection

The switching of operations from all the modalities is controlled by the automatism of the control logics in order to guarantee a correct function of the system on each moment. On each condition the
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system is maintained under control from the electronic circuit in order to guarantee a complete safety and reliability. This condition is the normal function
4.2.2.1 Floating charge

The main incoming supply feeds the Rectifier that keeps the battery to the float charge. The Rectifier output current limitation circuit is activated. After a battery discharge phase, as soon as the mains supply is coming back, the Rectifiers starts the automatic charging of the battery. It consist in carrying out the battery charge according with the DIN 41773 standards (Refer to Sheet 1) that consist of two phases: First phase (I Phase): With constant current and increasing voltage up to reach the level of Boost charge or High rate charge Second phase (II Phase): With constant voltage (at floating charge level) and decreasing current up to floating changeover. During the normal function the Rectifier remains in floating charge mode feeding a light current to keep the battery in charging condition .
Capacity (%Cn)
I Phase I=constant V=increasing
V=BOOST CHARGE V=FLOATING CHARGE

4.2.2.2 Automatic charge operation with automatic disconnection

II Phase I=decreasing V=constant

V=constant at floating charge

BATTERY END VOLTAGE (START CHARGING)

BATT. CURRENT LIMIT.

Time (hs)
II PHASE DURATION SAFETY TIMER

Sheet 1 Battery charging cycle according to DIN 41773


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Below are described the charging phases shown on Sheet 1 :


(I) I PHASE

During the battery discharging condition, the battery voltage is monitored from a voltage relay (with adjustable setting) that switch the Rectifier to automatic charge mode as soon as the mains supply will coming back. According to the indications shown in the curve of Sheet 1, the battery will start recharging with constant current When its voltage has reached the value of boost charging voltage, the rectifier control circuit will leave the current control (which will start decreasing) and will begin controlling at stabilizing voltage (second phase) on the value set and a timer will be started at the same time (second phase duration). The battery current limitation is electrical and it is adjustable through dedicated trimmers placed in the control logics that are not accessible from the front. Switching from the first phase to the second phase occur through a voltage relay with adjustable setting (Transfer setting point between boost to floating charge).
(II) II FASE

In the second phase, the battery will continue its recharge with constant voltage and decreasing current for the time set on the internal timer which after the time is elapsed, will change the operation over from boost charge to floating charge with stabilized voltage. The current limitation is still active. Duration monitoring of the boost charge is made electronically and it is adjustable by a timer placed in the control logics (not accessible from the front). Time duration of the second phase is adjustable in a range 0 99h and it is normally set to 4h. The setting values concern batteries under excellent efficiency conditions. As the battery state worsens, this time shall be so increased as to assure a more correct battery recharge.
(III) FAILURE ON THE CHARGING AUTOMATISM

In case the charging automatism fails (voltage relay + timer) a safety timer intervenes by changing over to floating condition after the time set starting from the beginning of the boost charge The intervention time of such timer (safety time) is adjustable in the range 099 hours and normally set at 13 h. The intervention of the safety timer is signalled through a led located on the panel front (Safety Timer).
(I) MANUAL SWITCHING ON AUTOMATIC BOOST CHARGE OPERATION

During the normal function, it is possible to start the Boost charging mode by pressing the push button Test charge placed in the front of the LCRD control card. It is possible to carry out this operation independently from that battery charging status. At this time the battery will be subject to a complete charging cycle with automatic disconnection (I Phase + II Phase) as already described on the above paragraph. The battery boost charging can be stopped on every time by pushing again the same push button Test charge and start again with new pressing. Hence this push button, permit the switching mode of the Rectifier between the boost / floating charge and vice versa. Each time that the Rectifier switch to floating charge, the internal timer used to monitor the II phase duration will be reset and it is ready for a new countdown in the next charging cycle
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A change over switch Charge mode selector with two positions: AUT. / MAN. is available inside the charger panel and it is used to manually force the boost charge of the battery with constant current and increasing adjustable voltage. This operation mode is called as Manual charge or Equalizing charge. Trimmer to adjust the setting of current limitation is placed in the front of the control logics, but it is accessible only after remove the control logics cover because normally it is not required to modify the factory setting. While the voltage level can be adjusted through the trimmer Manual voltage regulation placed in the panel front or inside the panel near the control logics box. In case the system is provided with the digital control panel PD-CAM, it can be used of modify the setting of the manual voltage level. Refer to the PD-CAM operating manual to check the operation in detail.

4.2.2.3 Boost charge with manual disconnection

Attention !
The trimmer to adjust the manual charging voltage level could be accessible from the front of the control logics or externally in the front panel. In this case before to start the manual charging mode it is necessary to be sure that this voltage level is admitted and supported from the feeder connected in the distribution. In such case it is provided a inhibition of this cycle that required a disconnection of the distribution bus bar before to activate the manual charging operation. Please verify it in the electrical schematic drawings enclosed in the supplied documentation.. The safety timer is started whenever the change-over switch is positioned on MANUAL charge. After the time set is elapsed, such timer brings the rectifier back to floating charge anyhow, although the change-over switch remains on MANUAL position. In this case both lamps will keep being ON so as to show that the rectifier has remained preset for the manual charge operation anyway. To restore the normal operation, it will be necessary to set the selector switch AUT./ MAN on AUT. position and reset the safety timer through the relevant push button placed in the control logics front. It is also to be pointed out that: In case of ventilation failure in the battery room, or when the battery junction switch is closed, the rectifier will be blocked in floating charge condition, regardless of the charging status in which it was operating. In case that the dropping diode stabilizer is failure, the rectifier will be blocked in Emergency charge condition, regardless of the charging status in which it was operating in order to ensure a correct supply in the load. If for any reason, the safety timer intervenes, the rectifier will set to the floating charge level automatically apart from the type of operation in progress at that moment. To resume normal operation, restore the conditions for a correct operation and reset the timer through relevant push button.

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When the System is equipped with sealed batteries, same automatisms are excluded in the functional modality. Due to composition of the adopted electrolyte, usually these type of batteries are no need of the boost charging phase with higher voltage level so, with reference to the function described in the previous chapter we observe the following differences: 1. The Rectifier output voltage level will not change in any condition: will be the float charging level. 2. In follow to a battery discharge, when the mains incoming supply will coma back, the battery will be charged however at the same floating charge instead of the higher voltage level (boost charge) as occur for the vented batteries. 3. The II phase of the charging cycle, as per DIN41773 standard, is not carried out because the Rectifier is locked in to floating charge mode. 4. The push button used to switch the Rectifier in to Boost charge is inhibit. It is however allowed to perform an equalizing charge of the battery with manual disconnection as already described on para.4.2.2.3. This operation is kept activated in order to guarantee the possibility to perform a complete charging of the battery during the commissioning activity; or at least one time in a year when it is required to carried out a complete equalizing of all the battery cells. 4.2.3 Rectifier failure Hereunder is described the Rectifier function in follows to happen a most common failure:
(II) MAINS FAILURE

4.2.2.4 Charing of sealed batteries (stationary type)

Loss of one phase, or decreasing below a pre-set limit of electronic relay used to monitor the incoming voltage, command the electrically shut down of the Rectifier. The mains incoming voltage relay is present into the ALR electronic card.
(III) RECTIFIER BRDIGE FUSE FAILURE

The blown of any fuse installed for protection of the thyristor command the electrically shut down of the Rectifier, and give an alarm signal locally and also remote if the system is provided with the optional relay card 7ALL.
(IV) LOSS / REDUCTION OF RECTIFIER OUTPUT VOLTAGE

Rectifier output voltage is electrically monitored through a voltage relay present in the ALR electronic card. This condition give an alarm signal locally and also remote if the system is provided with the optional relay card 7ALL.
(V) HIGH VOLTAGE ON RECTIFIER OUTPUT

Also this parameter is monitored from a voltage relay placed in the ALR electronic card. Intervention of this relay command the electrically shut down of the Rectifier, and give an alarm signal locally and
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also remote if the system is provided with the optional relay card 7ALL. This alarm still remains active until a manual reset operation by pressing the relevant push button. In the single branch Rectifier, each failure cause an automatically discharge of the battery ensuring continuity in the supply of the feeders for the required autonomy. All the alarms that are not critical for the System have an automatic reset, so normally the restoration of normal function, not require any intervention of the operator. All the alarms condition are however saved in the historic event of the control panel (PD-CAM), so it is possible to verify the beginning and restoration time on every moment. 4.2.4 Circuit composing the Rectifier and their functions On this section are described the main components that are present in the system. Refer to the mechanical and schematic drawings to identify each one. In the power circuit the alternate voltage coming from the supply mains is converted into stabilized direct voltage, adjustable and insensitive even to simultaneous variations of mains voltage and load. It basically consists of following parts:
T R I N C O M I N G T R A N S F O R M E R

4.2.3.1 Failure on single branch Rectifier

4.2.4.1 Rectifier

Three-phase 12 pulse transformer to reduce input voltage to the values required for a correct operation of the rectifier bridge and to galvanically uncouple the rectifier from outer power sources. The auxiliary supplies for rectifier logic box (BLR) have been carried out on the transformer secondary winding
T R - S R S Y N C H R O N I S M T R A N S F O R M E R

Electronic card including auxiliary transformer for Rectifier control logic box supply, synchronization of Thyristors pulse signals, and mains incoming voltage supply monitoring
F V - F U - F W F U S E S R E C T I F I E R B R I D G E

High speed fuses used for Thyristors protection. They are provided with trip indicator to give a signal the event of blown.
R E C T I F I E R B R D I G E R E C T I F I E R B R I D G E 1 2 P U L S E

Natural cooling ventilation Totally controlled bridge which operates in phase regulation carrying out the choking without considerable power losses of input voltage. The S.C.R.s are mounted in pairs on a heat sink cooled in air with natural convection. Also firing card PTT is installed near the S.C.R.s.
L B C L - C F I L T E R

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L-C filter consisting of an impedance LB and a bank of electrolytic capacitors C (disposed in parallel) to keep the ripple within the values required by the specifications.
S H R R E C T I F I E R S H U N T

Calibrated resistor used to take the signal (in mV) of the current feeds from the Rectifier for its measurement and limitation through the control circuit.
D B B L O C K I N G D I O D E

The battery rectifier/charger shall be designed to allow parallel operation and load sharing between two chargers connected to a common load, so a blocking diode (rated for the maximum output current of the rectifier/charger) is placed in the ungrounded output of both the charger to decoupling each other.

The principal components relevant to this section are the followings:


S H B B A T T E R Y S H U N T

4.2.4.2 Battery and Rectifier interconnection

Calibrated resistor used to take the signal (in mV) of the current flowing from / to the battery. Trough this signal is possible to measure and show the battery charge / discharge current and limit the maximum charging value through a dedicated control circuit.

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5
5Technical data
Mechanical Electrical

Chapter

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5.1 MECHANICAL
Enclosure Dimensions Weight Clearance required space Cable entry Protection degree The Rectifier is housed in a free-standing, fully metal enclosed cabinet arranged for floor mounting. 3340L x 2200H x 900D 2000 Kg 1000mm front / 900mm rear From bottom IP 41 in normal operation IP 20 with door open Painting Ventilation Installation altitude with full rating Installation altitude with derating factor of 7% per additional 1000 meter Ambient temperature range for operation Ambient temperature range for storage RAL 7032 Natural cooling Max. 1000 m ASL Max. 4000 m ASL 10 C +40 C -20 C +70 C for systems (For batteries in accordance with battery manufacturer data) Relative humidity Audible noise 95 %, not condensing approx. 65 dBA

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5.2 ELECTRICAL
5.2.1 Rectifier battery charger
D E S C R I P T I O N
S E T T I N G R A N G E N O T E

Rectifier type Incoming supply voltage Incoming current Incoming Frequency Floating charge voltage Boost charge voltage Manual charge voltage Static control tolerance Output voltage Ripple Max. Rectifier output current DC/DC converter rating Battery current limitation on automatic charging mode Battery current limitation on manual charging mode

6 pulse totally controlled 415 Vac, 3Ph 103A 50 Hz 127.8V 139.5V 148.5 1% <1% VRMS 370A 99A continuous load and 725A for 3 266A 266A 1020% C10 1020% C10 According to the load cycle 20% C10 20% C10 5% 10% 10% 10% 1.42 V/El. 1.55 V/El. 1.65 V/El. +10% / - 20%

5.2.2 Battery
Mounted on Manufacturer Type Nos. Of cells Capacity Charging current Steel rack HBL Ni-Cd 90 1330Ah / 10h 266A ( 0.20 C5 ) Model KBM 1330 P

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