Electronic Equipment With Battery Backup System Type Rarbi: Instruction Manual For Installation - Use - Maintenance

Instruction Manual Factory
for installation - use – maintenance BRESCIA

Electronic equipment RARBI Dept. Quality Assurance
ELECTRONIC EQUIPMENT WITH

BATTERY BACKUP SYSTEM
Type RARBI
INSTRUCTION MANUAL
FOR INSTALLATION - USE - MAINTENANCE
Manual Code: S10-80-RARBI-TRI-DCS800+AMS90-e-2016 rev 23_02_2016
Form N° Prep. by Approv. by File Rev. Date Page

S 10-80 UT DIR S10-80-RARBI-TRI-DCS800+AMS90-e-2016 rev 23_02_2016 1 / 29
MANUFACTURER: GAUSS MAGNETI S.R.L.

Via S. Scaroni 27 – Fraz. Fornaci
25131 BRESCIA (Italy)
________________________________________________________________________
PLATE DATA
MODEL : RARBI 16/C55/L3
Serial number : 33095/A
Voltage : 3/400 V - 50 Hz
Electric drawing : 02295-18-33095
Complete with air conditioning system
PRELIMINARY INFORMATION
FOREWORD
This manual is integral and essential part of the supplied product.
The equipment must be devoted to the exclusive use it has been conceived for; any other use is to be
considered improper and dangerous. The manufacturer cannot be considered responsible for eventual
damages arising from not proper or wrong or use.
Any intervention going to modify the equipment structure or working cycle must be approved by the
Technical Department of Gauss Magneti Srl.
Gauss Magneti Srl is not responsible for the consequence of use of not original or not authorized spare
parts.
Read carefully these instructions and the warnings, in order to grant safety by operation and
maintenance.
HANDBOOK ADDRESSEES
This handbook is addressed to:
 People responsible for plant, yard, work
 Personnel charged of installation
 Equipment operators
 Personnel charged of maintenance
This handbook must be looked after by a person in charge, in a suitable site, and must be always
available for consultation in its best preservation condition.
In case of loss or deterioration, a copy of this documentation can be obtained from:
GAUSS MAGNETI S.r.l. - Via Scaroni 1 - 25131 Fornaci - Brescia - Italy
Lifting dept.: Tel. + 39-030-3580375 Fax + 39-030-3580846
INDICATIONS AND NORMS
Please refer to the ones indicated in the enclosed CE Declaration (or attached to the
machine).

SAFETY INFORMATION
INTRODUCTION
In this section the safety norms to be complied with during installation, use and maintenance of the
electric equipment are reported.
Warnings:
Read carefully these instructions and examine the equipment in order to make oneself familiar with it
before starting any setting at work, use or maintenance operation. The following warnings may
appear in different part of this documentation or the equipment itself to warn out for risks or to draw
attention on information intended to clarify or simplify a procedure.
The following warnings point out the circumstances where indications must be complied
With in order to avoid serious mistakes and damages to the equipment and risks for people' s safety
and even life.
Warnings can be split into:
DANGER
This warning means that a faulty compliance to these warnings can jeopardize people' s safety (with
venture of life) or bring to damages to the equipment and plant components.
WARNING
Means a situation of potential danger, which, if not avoided, can jeopardize people' s safety or bring
to damages to the equipment and plant components
DANGEROUS VOLTAGES
This warning means that a faulty compliance to these warnings can jeopardize people' s safety (with
venture of life) or bring to damages to the equipment and plant components.
QUALIFIED PERSONNEL
Setting at works and operation of the plant or of its parts, electromagnets included, must be carried
out according to the instructions of this handbook
Any intervention onto the equipment must be only carried out by specialized and trained
personnel. This is intended to be personnel which has the qualification to connect, earth and
insert, according to safety standards, electrical circuits, equipments, systems.

REMARK
This handbook is an instruction manual for QUALIFIED PERSONNEL ONLY.
Faulty compliance to these warnings can jeopardize people' s safety (with venture of life) or bring to
damages to the equipment and plant components.
Before making any intervention on the components of the equipment and before using it, it is
mandatory to read the information reported in this section.
Any operation of electric plant drawing up (connections, earth connection, setting at works,
maintenance and every intervention inside the electric equipment or on any component) must be
carried out by specialized and trained personnel, which must operate within the valid laws and rules.
Also operation must be carried out only by trained personnel.
Any operation, manoeuvre, action or behaviour not listed in the present manual cannot be carried
out if not agreed with and authorized in writing by Gauss Magneti s.r.l.
ELECTRIC BOARD
AGREED USE: COMMAND OF ELECTROMAGNETS
The technical data and the electric connections according to the enclosed electric diagrams must be
complied with in order to use correctly the equipment.
Uses different from the technical data reported in the electric diagrams and in the section “General
characteristics of the electric board” are not allowed.
Uses different from the ones cited in this handbook are not allowed.
All operations of maintenance on the electric board must be carried out by personnel specialized
and trained in the electro technical and electronic technology.
DANGER
When the magnet is activated, if a fault occurs in the electrical equipment, in the supply line or inside
the magnet itself, the load falls down.
The presence of batteries cannot prevent the load from falling in any occasion; it is only an
alternative supply line in case of mains failure.
WARNING
The electric equipment and all electric components within the scope of supply must be suitably
earthed by specialized personnel.

WARNING
The electric equipment and all electric components within the scope of supply must be suitably
earthed by specialized personnel.
NEVER try to carry out interventions in the electric board or on any component with fed
equipment. Open the main switch and use a measure instrument to check that no voltage is
in the equipment. Only after this check the intervention can be carried out.
This procedure must always be followed when acting on the electric board or on the magnet.
DANGER
Cutting off the electric supply with magnet under voltage, because of faulty maneuvers, represents a
source of danger, as electric arcs of large dimensions and intensity can occur on the components
under direct voltage.
These electric arcs can be dangerous to people's safety (venturing their life) and to the equipment
components.
Faulty maneuvers:
 Do not open the magnet supply line with inserted magnet. For emergency switching off, open the
3-phase net switch.
 Do not open the fuses with inserted magnet
 Do not disconnect wires from their terminal with inserted magnet
 Do not disconnect plug sockets wit inserted magnet
 Do not open connecting boxes with inserted magnet
 Do not remove any protection from the electric components in the equipment.
 Do not carry out interventions on magnet when it is under voltage. Deactivate the magnet by
means of the relevant commands and open the main switch (check that there is no voltage using
a suitable measuring instruments)
WARNING
All operations of maintenance on the magnet must be carried out by specialized and trained
personnel.
NEVER carry out interventions on the magnet when it is on. Deactivate the magnet by means of
relevant commands and open the net supply switch. Use a measure instrument to check that no
voltage is in the equipment. Only after this check the intervention can be carried out.

DANGER
The electromagnet is fed by the net through the converter ABB DCS 800. When the electromagnet
is not magnetized, it is not physically disconnected from the 3-phase supply net, being the power
section of the converted controlled by semiconductors.
This means that even when deactivated the magnet IS NOT INSULATED from the electric net.
The electric part connecting the electromagnet or the electromagnet itself could give rise to sudden
dangerous voltages, because of failures or anomalies of the converter internal circuit.
In order to avoid risky situations to persons never carry out interventions on the magnet or on
electric components if the net switch IS NOT OPEN.
Never carry out the following operations, if previously the net supply has not been disconnected.
Following maneuvers are forbidden till the net line switch is not locked in open position:
 NEVER open terminal boxes between electric board and electromagnet

 NEVER open the brushes protection on the cable drum
 NEVER open plug / sockets because of maintenance to the electric board and the electromagnet
 NEVER open the electromagnet connecting box
 NEVER open or remove any protection on the electric part in the equipment
Non respect of these instructions can bring to serious risks for safety (even life) of the
personnel.
THREE PHASE CONVERTER
DANGER
All operations of maintenance on the electric board must be carried out by personnel specialized
and trained in the electro technical and electronic technology.
NEVER carry out interventions on the converter when it is on. Open the net supply switch and use a
measure instrument to check that no voltage is in the equipment. Only after this check the
intervention can be carried out.
Because of the internal control circuits, even after line tension disconnection, in the converter high
and dangerous voltages can be present. Always operate with due caution.
Non respect of these instructions can bring to serious risks for safety (even life) of the
personnel.

General warning
Controls by means of voltage must not be carried out on the converter components. Being the
converter an electronic equipment, it contains semiconductors which would not stand high voltages.
Carry out insulation measurements after having disconnected all converter connecting wires. Non
respect of these instructions can bring to serious damages to the converter.
BATTERY-CHARGER
DANGER
Any intervention on battery-charger must be carried out by qualified personnel, trained in electronic
technology.
Do not carry out interventions on battery-charger when it is ON. Open the main switch, the battery
switch and check that no voltage is present (using a voltmeter); only in this case it is possible to
intervene.
Because of internal control circuits, there can be high dangerous voltages in the battery-charger
even in case of power cable disconnection. Always operate with extreme caution.
Non respect of these instructions can cause serious risks of injuries or life for personnel.
Warning:
It is not allowed to check insulation on battery-charger components using voltage (risk of damaging
of semi-conductor electronic components).
Carry out insulation checks after having disconnected all cables of battery-charger.
Non respect of these instructions can cause serious damages to battery-charger.
BATTERY VOLTAGE CONTROL CARD
WARNING
It is not allowed to check insulation on control card using voltage (risk of damaging of semi-
conductor electronic components).
Carry out insulation checks after having disconnected all cables of control card.
Non respect of these instructions can cause serious damages to control card.

BATTERY LINE INSERTION SWITCH
WARNING
Any intervention on this switch must be carried out by qualified personnel, trained in electronic
technology.
Do not carry out interventions on this switch when the mains voltage is connected. Open the main
switch, the battery switch and check that no voltage is present (using a voltmeter); only in this case it
is possible to intervene.
Before switching on the equipment, check that the flame arresters are in the correct position.
Non respect of these instructions can cause serious risks of injuries or life for personnel.
PLC CONTROLLER
WARNING
General warning:
Controls by means of voltage must not be carried out on the bat controller components. Being the
controller an electronic equipment, it contains semiconductors which would not stand high voltages.
Carry out insulation measurements after having disconnected all controller connecting wires. Non
respect of these instructions can bring to serious damages to the controller.
ELECTRICAL CABINET
WARNING
Do not carry out manual interventions on equipment components which can modify sequences or
electrical interlocks.
Do not remove component safety protections, unless aware of the consequent risks.
Gauss Magneti Srl is not responsible for any consequence of improper or unauthorized use.

SCOPE OF SUPPLY
 Electric board
AT TIME OF DELIVERY
When receiving the material, check absence of damages to the different part of the supply due to
transport. If missing or damaged parts are noticed, inform immediately the supplier and the
forwarder.
Check that alI components in the electric board are correctly instaIIed and firmly tightened
TRANSPORT AND STORING
All instructions of correct transport, stock and use must be complied with. Environment and climate
conditions must be according to the product specifications and to the relevant norms.
Use certified and tested lifting equipments with correct capacity.
ELECTRIC BOARD INSTALLATION
The electric board is manufactured in order to be fixed on the floor in a flat area, sheltered and with
low environment pollution.
It must also be set in vertical position, as indicated.
It is not allowed positioning the electric board in the following conditions, if not otherwise specified in
the purchasing order:
 Direct sunlight
 Rain
 High humidity
 Oil fog, oil spray
 Salt fog
 Powder or metallic parts in the air
 Corroding gases or liquids
 Radioactive substances .
 Fuels
 Magnetic interferences
 Environment with ant bursting requirements
The back side of the electric board can be leant on a wall, as no electric devices is fixed on such
back side.
Keep the minimum distance from other boards or components installed on the right and on the left of
the electric board, according to their prescriptions, as this will enhance the thermal dissipation and
avoid mutual influence.

SUMMARY
1.1 - APPLICATION
1.2 - PRIORITY
1.3 - GENERAL CHARACTERISTICS
1.4 - ELECTRIC BOARD COMPONENTS
2.1 - FOREWORD TO THE ELECTRIC CONNECTIONS

2.2 - ELECTRIC CONNECTIONS
2.3 - CONNECTION OF THE 3-PHASE ELECTRIC SUPPLY
2.4 - BATTERY LINE CONNECTION
2.5 - CONNECTION OF THE ELECTROMAGNET WIRES
2.6 - CONNECTION OF AUXILIARY CIRCUITS AND SIGNALS
2.7 - BATTERIES CONNECTION
3.0 - SETTING AT WORK

3.1 - BATTERIES CONNECTION CHECK - TERMINAL BOX X1
3.2 - CLOSING 14QS1 BATTERIES SWITCH
3.3 - CLOSING 1QS1 ELECTRIC SUPPLY SWITCH
3.4 - CONVERTER ALARMS
3.5 - CONVERTER ALARM RESET
4.1 - OPERATION DESCRIPTION

4.2 - MAGNETIZATION
4.3 - DEMAGNETIZATION
4.4 - SETTING BY POTENTIOMETER
4.5 - PUSH BUTTON SETTING
4.6 - OVERHEATING SIGNALLING (only for equipment provided with this control)
4.7 - CONNECTION OF SELECTABLE ELECTROMAGNETS
4.8 - DISCONNECTION OF SELECTABLE ELECTROMAGNETS
4.9 - SIGNALLING OF MAX MAGNET INSERTION TIME (only for equipment provided with this
control)
4.10- MAGNETIZATION BOOST (only for equipment provided with this control)
4.11- TOUCH SCREEN HMI PANEL FRONT DOOR
5.1 - OPERATION OF 14KM2 INVERTED POLES CONTACTOR

(NORMALLY CLOSED)
5.2 - DESCRIPTION OF BATTERIES INTERVENTION
6.1 - EMERGENCY TEST
7.1 - BATTERY CHARGER DESCRIPTION
8.1 - DISCONNECTION OF 3-PHASE ELECTRIC SUPPLY

8.2 - MAINTENANCE
9.1 - SCR FUNCTIONS CHECK

1.1 - APPLICATION
CONTROL OF ELECTROMAGNETS
WARNING
1.2 - PRIORITY
THE HERE DESCRIBED EQUIPMENT, BECAUSE OF ITS CHARACTERISTICS AND OF THE

PRESENCE OF BATTERIES, MUST ALWAYS BE FED BY THE ELECTRIC NETWORK, AS THE
INTERNAL CIRCUITS COULD UNCHARGED THE BATTERIES IN CASE OF LONG TIME
EQUIPMENT DEACTIVATION.
In case of disconnection of the equipment from 3-phase network, open line switch and
batteries switch.
1.3 - GENERAL CHARACTERISTICS
RARBI electronic equipment consists of a digital, two-directional type, 3-phase AC / CC converter

(drive), used for electromagnet command, of an electromechanical system for batteries intervention
in case of loss of supply voltage or failure by the digital converter and of a battery charger for
complete battery charging and holding.
The magnet command consists of the main commands: magnetization, demagnetization, setting by
push button or potentiometer.
SUPPLY VOLTAGE 3 /400 Vac, 50 Hz
MAX POWER FROM NETWORK 39 KVA
BATTERY VOLTAGE 220 Vdc,
BATTERY CAPACITY 65 Ah
MAGNET VOLTAGE 220 V dc
MAX. MAGNET POWER 16000 W
AUX CIRCUITS VOLTAGE 24 Vdc
COOLING FORCED
OPERATING TEMPERATURE 0° ÷ +55 °C
RELATIVE HUMIDITY 20 - 90 %
PROTECTION GRADE IP 54

DRIVER PROTECTIONS:
In order to limit the short-circuit current, to reduce net voltage swinging and net current
di/dt: commutations reactances.
RC filters on tyristors
Protection from short-circuit: extra-fast fuses
From overload: Current limitation (Alarm F502)
From phase failure: alarm F512
From over-temperature: by thermal pad on the dissipater; alarm F504
LINE TO ELECTROMAGNET
Stop for disconnected magnet (only for equipment provided with this control)
The drive stop because of disconnected magnet is active 6 seconds after magnetization command.
It gets active if a current threshold is over passed.
The signal of disconnected magnet is shown by blinking of the magnetization warning light. The
converter remains blocked till opening the magnetization command.
Remark:
In case of potentiometer in the equipment, the signal of disconnected magnet is enabled if the
potentiometer is set over 10% of its end value.
WARNING
During the phase of “stop for disconnected magnet”, the drive does not deliver energy but the
system is in magnetization phase.
Therefore the battery insertion command is activated.
In this condition, operate immediately the demagnetisation command in order to deactivate the
system.
1.4 - ELECTRIC BOARD COMPONENTS
See the electrical diagram enclosed

2.0 INSTALLATION NORMS

2.1 FOREWORD TO THE ELECTRIC CONNECTIONS
Any operations referring to the electric circuit design, lay-out, connecting, setting at works,
maintenance and any intervention in the electric equipment or in the batteries must be carried out by
specialized personnel.
2.2 ELECTRIC CONNECTIONS
Respect all earthling connections according to existing norms and use material complying with
Norm CEI EN-60204-1, carry out all connections to terminal boxes according to enclosed drawings,
use wires with sections suitable to their current as per enclosed electric drawings.
2.3 NET SUPPLY CONNECTION
See enclosed electric drawing

 connect earth wire to relative earth terminal or bar
2.4 BATTERY LINE CONNECTION
WARNING
BEFORE CARRYING OUT THE CONNECTION, VERIFY BATTERY SWITCH TO BE IN OFF

POSITION. BATTERIES MUST BE CONNECTED AT LAST.
TERMINAL BOARD X1
L1-L2-L3 : TERMINALS FOR NET SUPPLY CONNECTION
- 235 terminal for wire from - battery terminal

+ 230 terminal for wire from + battery terminal
WARNING: incorrect batteries connection can damage the equipment
2.5 ELECTROMAGNET CONNECTION

(no polarity to be paid attention to)

2.6 AUXILIARY CIRCUIT CONNECTION
See the electrical diagram enclosed

If no potentiometer is used in the equipment, bridges the terminals according to the electric drawing
2.7 BATTERY CONNECTION
DANGEROUS VOLTAGES
BATTERIES ARE ALREADY CHARGED AND THEREFORE BETWEEN THEIR POLES THERE
IS A VOLTAGE OF ABOUT 12.2 V .
CARRY OUT BATTERIES CONNECTION USING INSULATING GLOVES AND INSULATED

SPANNERS.
Before connecting the batteries, make sure that the main switch and batteries switch OFF.
The wires in the electric board must already be connected to relative terminals - 235 and + 230.
1) consult connection electric drawing

2) batteries must be connected in series. Total voltage between connected batteries between void
terminals is 220 Vdc
3) before connecting batteries, make sure that batteries switch is OFF.
4) connect wire - 235 from electric board to negative battery terminal
5) connect wire + 230 from electric board to positive battery terminal
WARNING
Attention: a wrong batteries connection can damage the whole equipment
BEFORE SUPPLYING THE ELECTRICAL EQUIPMENT, CHECK ALL THE CONNECTIONS

3.0 SETTING AT WORKS
DANGEROUS VOLTAGES
During this phase it is necessary to read the converter display for eventual alarms and to carry out
functions tests. It is recommended to take actions to protect physical safety of all involved
personnel.
OPERATION SEQUENCE BY FIRST CONNECTION
During this operation, disconnect the magnets disconnecting plug / socket or acting on the magnet
power terminals (see el. dwg)
3.1 BATTERY CONNECTION CHECK – ELECTRIC BOARD TERMINAL BOX
DANGEROUS VOLTAGES
Batteries are already charged and therefore between their poles there is a voltage of about 12.2 V, if
no anomaly arises.
In case voltage drops under 190 Vdc, consult Gauss Magneti Service Department.
Use a DC voltmeter with minimum range 300 Vdc
1) apply voltmeter negative test lead on - 235 terminal

2) apply voltmeter positive test lead on + 230 terminal
3) Read value must be positive (for example 220 Vdc)
 if read value is negative (for example - 220 Vdc), connection is wrong. Change connection
between electric board and batteries before proceeding.
3.2 CLOSING BATTERIES SWITCH 14QS1
DANGEROUS VOLTAGES
By closing battery switch, the following conditions must take place:
1) 14KM2 coil ON
2) 14KM2 excites and open power contacts (with disconnected coils the contacts are closed)
These conditions must occur and stay after battery switch closing.

3.3 CLOSING 1QS1 MAIN SWITCH
DANGEROUS VOLTAGES
BEFORE CLOSING THE ELECTRIC EQUIPMENT MAIN SWITCH, CHECK THAT LINE
VOLTAGE LAYS IN A RANGE + 10 %  - 15 % AND 45-65 HZ
Batteries switch must be in ON (closed) position, according to above description.
 close 1QS1 line switch

 14KM2 contactor must stay ON
 Converter display
 After initial scanning, a point appears on the drive display; it means “drive OK”.
If the converter display shows other alarms, consult the converter instruction handbook
BATTERY CHARGER WHEN CLOSING THE MAIN SWITCH
1. Warning light for discharged batteries turns (see el. drw.)

2. The battery charger run LED must get “ON” when closing line switch 1QS1
3. When closing main switch 1QS1 complete batteries charging starts (see battery charger
description)
4. Wait till charging is complete charged batteries before acting magnetization command.
If the above mentioned conditions are fulfilled, close the electric board doors, connect the
electromagnet power plug and carry out the function test.
Note for equipments supplied with transformer in separate box (electrical connections
carried out by the user).
If the led “run” of battery-charger is ON but the battery-charger does not deliver energy,
the connection between transformer (IF ANY) and cabinet terminal board is wrong.
Check on the electrical drawing.
Before carrying out this operation, open the main switch and the battery switch; check that no
voltage is present downstream the main switch (using an ac voltmeter) and downstream the
battery switch (using a dc voltmeter).
3.4 CONVERTER ALARMS
The alarm intervention bringing to the converter stop is always visualized on the display by a
number identifying it and by a short description of the alarm type. Refer to the converter
handbook for failure identification.

3.5 CONVERTER ALARM RESET
When an alarm occurs, which brings to the converter stop, the converter logical structure
carries out the reset. The warning light Drive OK accomplishes then the following
functions:
- OFF Drive OK ( IF SIGNAL PROGRAMMED FAULT – SEE ELECTRICAL
DIAGRAM)
- ON Drive OK ( IF SIGNAL PROGRAMMED DRIVE OK – SEE ELECTRICAL
DIAGRAM)
- slow blinking, 1 sec. on – 8 sec. off, auto reset attempts, alarm does not reset. Read on
the drive segment display the alarm code.
By cutting voltage, the alarm is reset, but reoccurs if the condition bringing to the anomaly
is still present.
Warning lamp drive OK

6 seconds ON - 2 seconds OFF = Fault drive -U1 (6 sec. ON = alarm signal - 2 sec. OFF =
autoreset)
If the alarm does not reset, constantly repeats 6 sec. ON - 2 sec. OFF. Read on the
segment display of the drive U1, the alarm code.
If the alarm resets, the lamp remains off.
(By powering the equipment after opening the cabinet, the message will appear again if
the fault is still present)
2) Blinking, 1 sec. ON - 600 ms OFF: the "magnetize" control has been executed and the
drive has detected that the magnet is not connected. Run the "demagnetize" control.
Connect the magnet or check the 220 Vdc power circuit which feeds the magnet.
4.1 OPERATION
DANGEROUS VOLTAGES
 IT IS RECOMMENDED BEFORE CONNECTING OR DISCONNECTING THE

INSERTED PLUG IN THE BRIDGE CRANE SOCKET TO MAKE SURE THAT THE
ELECTROMAGNET IS NOT IN FUNCTION.
 NEVER CONNECT OR DISCONNECT THE PLUG WITH OPERATING

ELECTROMAGNET !
 Connect the electromagnet plug in the power plug installed on the bridge crane hook
 Close electric net 1QS1 switch and 14QS1 battery switch.

4.2 MAGNETIZATION
DANGER
When the magnet is activated, if a fault occurs in the electrical equipment, in the supply line or
inside the magnet itself, the load falls down.
The presence of batteries cannot prevent the load from falling in any occasion; it is only an
alternative supply line in case of mains failure.
Pressing magnetization button, the command can be activated if the following conditions are
present:
- aux circuit voltage ON
- batteries charged
- drive OK
- battery insertion contactor ON
- 220 Vdc battery voltage present
- other conditions for non-standard equipments: see el. dwg.
Magnetization contactor excites driving converter in run.
The converter starts feeding energy to the electromagnets at voltage 220 Vdc if the potentiometer
terminals are bridged. In presence of potentiometer, at voltage set by the potentiometer itself.
4.3 DEMAGNETIZATION
WARNING
By acting on the push button, the magnetization command is carried out if the following conditions
are fulfilled:
By acting on demagnetization push button, demagnetization contactor is excited.
1. Converter brings output voltage from 220 Vdc to 0 Vdc

2. When voltage attains 0 Vdc the converter reverses output voltage and starts again feeding
energy to the electromagnets for the time set by timer. This sequence is called COUNTER
EXCITATION and has purpose to give rise to a repulsive force on the material stuck onto the
electromagnet.
COUNTER EXCITATION consists in the electromagnets voltage polarity inversion.

4.4 SETTING BY POTENTIOMETER (only equipment with this control)
WARNING
are fulfilled:
Setting by potentiometer can be useful during magnetization in order to lift a reduced material
quantity, or, when magnetization has been carried out, in order to release excess material.
In both cases, before starting moving the charged, the potentiometer must be set at its max. value.
The use of the potentiometer in the push-button panel must be protected against eventual fault
maneuvers.
Gauss Magneti hold no liability for consequences due to not proper or not authorized use
4.5 SETTING BY PUSH-BUTTON
WARNING
are fulfilled:
The push button (see el. dwg.) with operating converter, acts as a setting device.
Setting by push button can be useful when magnetization has been carried out, in order to release
excess material.
By pushing the button the converter starts a descending ramp down to 0 V voltage. When the
button is released, the converter delivers again the maximum voltage.
The use of push button must be protected against eventual fault maneuvers.
The press-button must be protected against wrong operations, as an accidental command of

this press-button would bring to the fall of material lifted by the electromagnet
WARNING !!!
USE OF SLOW RELEASING PRESS BUTTON FOR USES OTHER THAN THE INDICATED
ONES IS NOT ALLOWED; IN PARTICULAR THIS PRESS-BUTTON MUST NOT BE PRESSED
AND RELEASED WITH HIGH FREQUENCY.
Any other action not indicated is not allowed by PRESS – BUTTON SLOW RELEASING
A NOT PROPER USE OF THIS BUTTON CAN DAMAGE IRREVERSIBLY THE EQUIPMENT.
Gauss Magneti hold no liability for consequences due to not proper or not authorized use

4.6 OVERHEATING SIGNALLING (only equipment with this control)

When the magnet reaches a dangerous internal temperature, acoustic and visual
alarms are activated (horn with an intermittent sound and lamp blinking, see
enclosed electric drawing).
It is necessary to remove the magnet from the heating source, demagnetize and let it
cool.
The alarms continue for approx 10 min, then it is possible to operate again the
magnet.
If the alarms appear again, it is necessary to let the magnet cool for a longer period
of time.
4.7 CONNECTION OF SELECTABLE ELECTROMAGNETS

(ONLY FOR EQUIPMENT WITH SELECTABLE MAGNETS)
The connection of a selectable magnet is carried out by means of an external selector, commanding
the power contactor insertion.
Connection can follow only when not active magnetization
WARNING
IT IS NOT ALLOWED TO MANUALLY FORCE THE CONTACTOR OR THE MECHANICAL

RETAINER IN ORDER TO INSERT THE SELECTION.
4.8 DISCONNECTION OF SELECTABLE ELECTROMAGNETS

(ONLY FOR EQUIPMENT WITH SELECTABLE MAGNETS)
The disconnection of a selectable magnet is carried out by means of an external selector,

commanding the unlock of the mechanical locks and opening the power contactors.
Disconnection can follow only when not active magnetization
WARNING
IT IS NOT ALLOWED TO MANUALLY FORCE THE CONTACTOR OR THE MECHANICAL

RETAINER IN ORDER TO INSERT THE SELECTION.
WITH MAGNET ACTIVATED, THE IMPROPER SELECTION UNLOCK EXCLUDES THE

CONTROL CIRCUIT AND CAN DAMAGE SERIOUSLY THE EQUIPMENT AND CAN CAUSE
INJURIES TO PERSONNEL.

4.9 - SIGNALLING OF MAX MAGNET INSERTION TIME (only for equipment provided with this
control)
A timer inside the PLC check the magnet insertion time, at end of counting a horn with intermittent
sound is activated..
(see enclosed el. dwg)
4.10- MAGNETIZATION BOOST (only for equipment provided with this control)
At magnetization command, the magnet is supplied with an over-voltage to accelerate current slope
and consequently reduce magnetization time.
When the current reaches the max value, voltage is reset to the rated value.
4.11- TOUCH SCREEN HMI PANEL FRONT DOOR
On controller front door there is an HMI panel that has three screen shots.
(N.B.: Images only for informations, not binding)
To be able to move within the three screen shots press the right or left arrow.
R key is the refresh to check the batteries status.
The main screen shot shows:
 Batteries current (Adc)

 Batteries voltage (Vdc)
In the lower part of the HMI screen shot there is a blue status bar where is displayed the system status and
the alarms.
 SYSTEM READY
The system is ready it is possible to magnetize.
 FAST CHARGE BATTERIES
Alarm that batteries are the fast charging phase, in this status the batteries are under charging.
It is not possible to magnetize.
 FAULT BATTERIES
Alarm batterieries fault, in this status it is not possible to magnetize.
 EMERGENCY BATTERIES ACTIVATED
The batteries are feeding the magnets, in this status the horn rings.
 FAULT FUSES DC DRIVE
Fuses 3FU3, that protect the drive 3G1 have intervened
 BATTERIES SWITCH OFF
The batteries switch is not ON, in this status it is not possible to magnetize.

 ELECTROMAGNET ON
Electromagnet activated, lamp 16H3 blinking means that the power is controlled by the
potentiometer, lamp 16H3 fix means that the power is at its maximum.
 FAULT DC DRIVE
The drive 3G1 is in alarm, on its operator panel it is possible to see the related alarm code.
 POWER LINE FAULT
The relay 1RSF reports a fault on the mains that feed the controller.
The second screen shot shows some default settings made by Gauss Magneti:
 Current threshold (fast charging disabled)
 Batteries fault current threshold (f.i batteries circuit failure, battery charger fuses fault, battery
charger fault or battery fuses fault)
 Batteries fault voltage threshold (f.i batteries circuit failure, battery charger fuses fault, battery
charger fault or battery fuses fault)
 Max electromagnet insertion time (magnetization)
 Batteries Voltage (Vdc)
The third screen shot shows the status of the PLC Input/Output.
5.1 OPERATION OF THE 14KM2 INVERTED POLES CONTACTOR

(NORMALLY CLOSED)
Powered coil 220 Vdc “on”, open power contacts and magnets disconnected from batteries.
Non powered coil 220 Vdc “off”, closed power contacts and magnets connected to batteries.
5.2 DESCRIPTION OF BATTERY INTERVENTION
WARNING
The system can be supplied by batteries only for the time indicated in the order technical
specification; a longer time can damage seriously the batteries and the control circuits.
It is therefore necessary to demagnetize within the indicated time.
REVERSE POLE CONTACTOR OPERATION (NORMALLY CLOSED) FOR INSERTION OF

BATTERY LINE
- 220 Vdc coil powered (ON): power contacts open, magnets disconnected from the batteries
- Coil not powered (OFF): power contacts closed, magnets connected to the batteries
The contactor in the normal operating condition is ON either with magnets switched on or off.
The causes that lead to the closing of the power contacts (unpowered coil OFF) with the subsequent
connection of the electromagnets to batteries, can be of the following type:

• interruption of the three phase supply for more than 0.4 seconds
In this condition the power contacts 14KM2 close and the magnets are powered by batteries.
WARNING
The system is powered by batteries in state of emergency, the discharge time of the batteries
cannot be higher than the contractually agreed upon purchase, a longer time irreparably damages
the batteries and compromises the correct functioning of command and control electrical circuits
installed inside the electrical panel, it is mandatory to demagnetize the magnets within the stipulated
time.
Gauss Magnets assumes no responsibility for any consequences arising from the improper or
unauthorized use caused by non-observance of this rule.
To exit from the state of emergency (magnets powered by batteries):
- The system can be automatic, if the power supply comes back, the contactor coil for battery
insertion switches ON and the batteries are disconnected from the magnets.
- Acting on the demagnetize buttons, the magnetization relay switches OFF, which will command
ON the coil of the contactor 14KM2 disconnecting the batteries from the magnets.
The demagnetize command is active even in the absence of mains voltage, when the system is in
the emergency phase supplied by the batteries.
6.1 TEST OF EMERGENCY (at least once a month)
- Run the command magnetize

- Cut off mains power to equipment
- The horn turns ON
- Verify that the material remains attracted by the electromagnets
Get out of the state of emergency in one of the following ways:

a) supply the cabinet with the mains voltage
b) press the button “demagnetize”
1a) supplying the cabinet, the batteries are switched off and the acoustic alarm stops.
1b) by pressing the button “demagnetize” contactor 14KM2 is energized, excluding batteries and
buzzer.
The command “demagnetize” is active even in the absence of the mains voltage, when the system
is in the emergency phase supplied by the batteries.
Check of the status of the battery capacity

This operation must be performed by qualified personnel trained in the use of electrical technology.

WARNING
WE RECOMMEND NOT TO LEAVE THE BATTERIES INSERTED FOR MORE THAN 10

MINUTES, a longer time can irreparably damage the batteries and compromise the correct
functioning of electrical circuits for monitoring and control installed inside the electrical cabinet.
Gauss Magnets assumes no responsibility for any consequences arising from the improper or
unauthorized use of this equipment, caused by non-observance of this rule.
The battery capacity must be measured under load, the system in an emergency phase, battery-
powered magnets. The measure, if not performed under load, is not valid and not real.
To check the status of the battery capacity, measure the battery voltage during the emergency
phase, after 10 minutes after the emergency, the battery voltage should not be less than 200 Vdc.
7.1 DESCRIPTION OF BATTERY-CHARGER OPERATION
The battery charge is carried by its converter, the charge cycles are controlled by the PLC and the
volt-meter relay.
It is essential that the equipment remains always energized even if it is not used for a long period, to
allow the charger automatically keep the batteries in trickle charge.
Otherwise the batteries could discharge quickly, irreparably compromising their durability and
function.
CHARGE CYCLE
The charging cycle of the battery charger is shown in Figure 3:
First phase (K):

When the current absorbed by the batteries exceeds the threshold value Is (0.3 x I), the phase of
fast charge constant current I begins (section K of the curve) where there is a gradual increase in
the battery voltage up to 2,41 V / cell (approximately 260Vdc for a 220VDC battery pack, and about
130Vdc for a 110Vdc one).
Second stage (S):

When the voltage has reached the value of 2,41 V / cell., charging continues with constant voltage
and decreasing current until the latter falls below the threshold value Is (0.3 x I) (S portion of the
curve ).
Third phase (M):

At this point through the threshold ammeter the voltage supplied to the batteries switches to a value
of 2.23 V per cell (about 240Vdc for a 220VDC battery pack, and about 120Vdc for a 110 Vdc one)
that corresponds to the maintenance charge.
During this phase, if there is no current absorption, there is a gradual reduction in current
consumption (section M of the curve).

CHARGING PHASE CYCLE
Tensione K S M
Corrente I
2.41V/el.
2.23V/el.
Is
Time
I : Fast charging current, I= 0,15 x C10 (C10= battery capacity in Ah

referred to 10 hours)
Is: Threshold value Is = 0,3 x I
2.41V/el. : fast charge voltage
2.23V/el. : maintenance charge voltage
( figure 3 )
It is not possible to define a general criterion for the choice of the charging current as a function of
the battery capacity, it also depends a lot on the duty cycle and on the use of batteries.
The longer the time available for charging and the lower will be the charging current required.
Ultimately the relation between the fast charge current I and the battery capacity is expressed by the
following formula:
I = A x C10
C10 = battery capacity in Ah (the capacity is related to the discharge regime of 10 hours)
A = constant which depends on the operating needs (usually between 0.1 and 0.25).
8.1 DISCONNECTION OF THE EQUIPMENT FROM MAINS
THE EQUIPMENT, IN VIEW OF ITS CHARACTERISTICS AND THE PRESENCE OF BATTERIES,

MUST ALWAYS BE SUPPLIED FROM THE MAINS SINCE INTERNAL CIRCUITS CAN
DISCHARGE THE BATTERIES IN THE EVENT OF LONG PERIOD DEACTIVATION.
In the case of exclusion of the equipment from the mains, open the main switch.

8.2 MAINTENANCE
Maintenance consists mainly of a periodic inspection to check the equipment conditions.

It is recommended a particular care and maintenance of the equipment, due to the importance of
emergency safety batteries.
DANGER
BEFORE CARRYING OUT ANY MAINTENANCE OPERATION ON ANY EQUIPMENT

COMPONENT, OPEN 3-PHASE LINE SWITCH AND BATTERY SWITCH
ELECTRIC BOARD
- open main switch, battery switch and power fuses

- check visually board conditions
- check terminal locking
- check all components connections
- clean the device
Do not use inflammable, conductive or explosive liquids or materials for cleaning.
Any damaged or worn component should be immediately replaced
BATTERIES
DANGEROUS VOLTAGES
VOLTAGE IN THE BATTERY BOX, WITH ALL BATTERIES CONNECTED IN SERIES, IS 220
VDC
THIS 220 VDC VOLTAGE IS PRESENT ON THE BATTERIES ALSO WHEN LINE SWITCH AND
BATTERY SWITCH ARE OPEN.
THEREFORE NEVER OPEN THE BOX AND NEVER APPROACH THE OPEN BATTERY BOX
WITH METAL OBJECTS
- check that batteries are not damaged or deformed.
- check with protection gloves and insulated wrenches terminals locking.
- check battery positioning
- cleaning
Do not use inflammable, conductive or explosive liquids or materials for cleaning.
Any damaged or worn component should be immediately replaced

ADDITIONAL INFORMATION ON THE USE AND STORAGE OF LEAD BATTERIES
Instructions for the discharge
- After a discharge, batteries must always be recharged.

- After a discharge test or during storage, the voltage of batteries should not drop below 1.8 V per
cell. If this happen, a reduction in capacity and life of batteries is likely.
Operating climatic conditions
- Batteries must be used in a temperature range 0 to 45°C.
Recharging during storage
To safeguard life and efficiency of batteries, it is recommended to recharge the batteries during
storage according to the time intervals indicated below:
Storage temperature recharging interval

0 ÷ 20°C 9 months
20 ÷ 30°C 6 months
30 ÷ 40°C 3 months
CABLE DRUM
- check brushes conditions and that they press the collector and that they are not worn
out, otherwise replace them
- check that the cable is not damaged and specially its insulation condition
- check that all components are steadily connected
- cleaning
ELECTROMAGNETS
- check terminal locking inside socket-plugs

- replace socket and plug if they do not grant a good mechanical lock
- check electromagnet wires and plug sheath, replace them if damaged
- check connections in terminal boxes, if available

9.1 S.C.R. FUNCTION TEST
DANGEROUS VOLTAGES
OPEN THE 3-PHASE MAIN SWITCH AND THE BATTERY SWITCH; BEFORE STARTING
OPERATING MAKE SURE THAT THE ELEMENTS WHICH YOU ARE GOING TO WORK ON
ARE NOT LIVE.
This test allows to check if the s.c.r. are still efficient after intervention of fast-blow fuses .
A tester is necessary to carry out the check:
1. remove fast-blow fuses

2. set the tester on a scale not higher that 10 K
3. connect a tester point to the converter terminal C1
4. connect the other tester point to co n v e r t e r terminal U1
5. read the value on the tester
 if value is higher than 1 K, first branch s.c.r. are OK
 if value is lower than 1 K (normally about 2-3 ) , an s.c.r. is defective and must be
replaced.
6. repeat the same sequence on converter terminal V1 and W1, keeping a tester
point on terminal C1.
replaced.
7. connect a tester point on the converter terminal D1
8. connect the other point on the converter terminal U1
9. read the value on the tester
replaced.
10. repeat the same sequence on converter terminal V1 and U1, keeping a tester point
on terminal D1.
replaced.

THE FOLLOWING TABLE SHOWS THE S.C.R. VALUES, WHEN CORRECTLY

WORKING
Terminal NO. Terminal NO. Value IN OHM Result
C1 U1 › 1000  OK
C1 V1 › 1000  OK
C1 W1 › 1000  OK
D1 U1 › 1000  OK
D1 V1 › 1000  OK
D1 W1 › 1000  OK
The following table gives the position of the defective s.c.r.
Terminal Terminal Value in S.C.R. to be

NO. NO. OHM replaced
C1 U1 0 - 1000  G24 C24
C1 V1 0 - 1000  G26 C26
C1 W1 0 - 1000  G22 C22
D1 U1 0 - 1000  C14 G14
D1 V1 0 - 1000  C16 G16
D1 W1 0 - 1000  C12 G12
EXAMPLE: with values as per the following table, s.c.r. G22 C22 / C16 G16 must be
replaced
Terminal Terminal Value in S.C.R. to be

NO. NO. OHM replaced
C1 U1 › 1000  G24 C24
C1 V1 › 1000  G26 C26
C1 W1 0 - 1000  G22 C22
D1 U1 › 1000  C14 G14
D1 V1 0 - 100  C16 G16
D1 W1 › 1000  C12 G12


Electronic Equipment With Battery Backup System Type Rarbi: Instruction Manual For Installation - Use - Maintenance

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Instruction Manual Factory

for installation - use – maintenance BRESCIA

ELECTRONIC EQUIPMENT WITH

Form N° Prep. by Approv. by File Rev. Date Page

MANUFACTURER: GAUSS MAGNETI S.R.L.

INDICATIONS AND NORMS

Form N° Prep. by Approv. by File Rev. Date Page

Form N° Prep. by Approv. by File Rev. Date Page

This handbook is an instruction manual for QUALIFIED PERSONNEL ONLY.

AGREED USE: COMMAND OF ELECTROMAGNETS

Form N° Prep. by Approv. by File Rev. Date Page

Form N° Prep. by Approv. by File Rev. Date Page

 NEVER open terminal boxes between electric board and electromagnet

THREE PHASE CONVERTER

Form N° Prep. by Approv. by File Rev. Date Page

BATTERY VOLTAGE CONTROL CARD

Form N° Prep. by Approv. by File Rev. Date Page

BATTERY LINE INSERTION SWITCH

Form N° Prep. by Approv. by File Rev. Date Page

TRANSPORT AND STORING

ELECTRIC BOARD INSTALLATION

Form N° Prep. by Approv. by File Rev. Date Page

2.1 - FOREWORD TO THE ELECTRIC CONNECTIONS

3.0 - SETTING AT WORK

4.1 - OPERATION DESCRIPTION

5.1 - OPERATION OF 14KM2 INVERTED POLES CONTACTOR

6.1 - EMERGENCY TEST

7.1 - BATTERY CHARGER DESCRIPTION

8.1 - DISCONNECTION OF 3-PHASE ELECTRIC SUPPLY

9.1 - SCR FUNCTIONS CHECK

Form N° Prep. by Approv. by File Rev. Date Page

THE HERE DESCRIBED EQUIPMENT, BECAUSE OF ITS CHARACTERISTICS AND OF THE

1.3 - GENERAL CHARACTERISTICS

RARBI electronic equipment consists of a digital, two-directional type, 3-phase AC / CC converter

SUPPLY VOLTAGE 3 /400 Vac, 50 Hz

MAX POWER FROM NETWORK 39 KVA

BATTERY VOLTAGE 220 Vdc,

MAGNET VOLTAGE 220 V dc

MAX. MAGNET POWER 16000 W

AUX CIRCUITS VOLTAGE 24 Vdc

OPERATING TEMPERATURE 0° ÷ +55 °C

Form N° Prep. by Approv. by File Rev. Date Page

1.4 - ELECTRIC BOARD COMPONENTS

See the electrical diagram enclosed

Form N° Prep. by Approv. by File Rev. Date Page

2.0 INSTALLATION NORMS

2.2 ELECTRIC CONNECTIONS

2.3 NET SUPPLY CONNECTION

See enclosed electric drawing

2.4 BATTERY LINE CONNECTION

See enclosed electric drawing

BEFORE CARRYING OUT THE CONNECTION, VERIFY BATTERY SWITCH TO BE IN OFF

- 235 terminal for wire from - battery terminal

WARNING: incorrect batteries connection can damage the equipment

2.5 ELECTROMAGNET CONNECTION

See enclosed electric drawing

 connect earth wire to relative earth terminal or bar

Form N° Prep. by Approv. by File Rev. Date Page

2.6 AUXILIARY CIRCUIT CONNECTION

See the electrical diagram enclosed

 connect earth wire to relative earth terminal or bar

2.7 BATTERY CONNECTION

CARRY OUT BATTERIES CONNECTION USING INSULATING GLOVES AND INSULATED