pmi rda-rdat series batterycharger userbook_en

THYRISTOR CONTROLLED

BATTERY CHARGER / RECTIFIER

RDA/RDAT SERIES USER MANUAL

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

3

DC POWER SUPPLY / BATTERY CHARGER

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

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

HIGH VOLTAGES ARE PRESENT INSIDE THE EQUIPMENT EVEN WHEN THE INPUT AND BATTERY SWICHES ARE OPEN, BESIDES IN THE THREEPHASE OUTPUT VERSIONS A PART OF THE POWER CIRCUITS REMAINS CONNECTED TO THE INPUT NEUTRAL. All maintenance operations inside the RECTIFIER must the carried out only by trained personnel. IF IT IS NECESSARY TO REPLACE THE FUSES, THEY MUST BE REPLACED WITH OTHER FUSES OF THE SAME TYPE. TO INTERRUPT THE POWER SUPPLY TO THE UTILITIES IN DANGEROUS CONDITIONS, OPEN ALL THE SWICHES LOCATED BEHIND THE FRONT DOOR.

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

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

4

DC POWER SUPPLY / BATTERY CHARGER RDA/RDAT AUTOMATION BATTERY CHARGER

The Battery Charger is SCR controlled AC/DC rectifier with automatic constant voltage and constant current ability.On LCD panel , you can see all measurement values , real time base events and failures and communicate remotly with in RS 232 or RS485 port. All operations are controlled and progressed by micro controller. Adjustable timer is used for boost charging the batteries automatically. Output current, battery current , boost and Float Charge Voltages are adjustable on the control panel easily. The Timer is a decrementing counter by one hour. The Charger output gives the boost charging voltage by setting the timer to any value larger than zero. The Charger returns to floating voltage level when the timer value reaches to zero.

Also automatic boost charge can be selected on menu.The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity. The user should set the suitable float and boost currents of the battery before selecting the automatic boost option. After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values. If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value.

The input and output of the charger are protected against to misuse and line disturbances electronically. Input and output can be switched by circuit breakers individually. It has self-protection against to over temperature. The alarm contacts can be used for external system in the case of any anomaly. The output is fully isolated from the AC line input. The Charger has a modular design to provide service and maintenance simplicity. The outputs of the Battery Chargers can be connected in parallel according to need. Standart Features

• Adjustable Timer for Boost Charging • Adjustable Boost and Float Charge Voltages • Automatic Boost Charge Selection according to boost / float current set value • Adjustable Rectifier Output Current and Battery Charge Current • LCD Display for DC Load / Battery Voltage ,DC Load / Battery Current , Input AC

Voltage / Line Current/ Frequency • Event History for all Electrical values and failures • Automatic and Manuel Battery Test • Boost inhibit facility for interlock redundant application • Output Filter Inductor and DC Longlife Capacitor • Electronic Over / Under Voltage, Over Current and Short Circuit Protections • Isolated Output by Input Transformer and output halleffect current module • Parallel Redundant Operation • Boost and Float dropper control output for Ni-Cd and Lead Acid Battery • Input Filter and input surge Voltage protection • Internal Over Temperature protection • Temperature Compensation for Battery • Low Battery Indication and Alarm contacts • Rectifier Failure Indication and Alarm contacts • Rectifier Over Voltage Indication and Alarm contacts

5

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

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

6

DC POWER SUPPLY / BATTERY CHARGER TECHNICAL SPECIFICATIONS GENERAL Model RDAT Series

Topology 6 Pulse/12 Pulse Thyristor controlled AC/DC Rectifier with input

isolation transformer

INPUT

Nominal Voltage 220 VAC / 230 VAC / 240 VAC ±15% 380 VAC / 400 VAC / 415 VAC ±15%

Nominal Frequency 50 / 60 Hz ±5% Power Factor >0.8 Transformer Galvanically isolated / Primary & Secondary Earth Screened

Input Protection Thermic Magnetic Overcurrent protection MCB, Overvoltage

protection

OUTPUT Floating Output Voltage 24 VDC ±1% / 48 VDC ±1% / 110 VDC ±1% / 220 VDC ±1%

Output Voltage Adjustment

24VDC system between 10VDC and 30VDC 48VDC system between 30VDC and 60VDC

110VDC system between 90VDC and 160VDC 220VDC system between 190VDC and 290VDC

Nominal Output Current 30A/60A/100A / 200A / 400 A Output Current Adjustment 0‐100% of Nominal Output Current Boost Charge Voltage 100% to 120% of Floating Output Voltage Boost voltage (V/C) (1,60V NiCD battery (adjustable)) Float voltage (V/C) (1,40V NiCD battery (adjustable)) Output Ripple 1% RMS AC of Output Voltage Dynamic Response (w/out battery group) ±10% of Output Voltage at 200msec (100% load change) Dynamic Response (with battery group) ±2% of Output Voltage at 200msec (100% load change) Battery Charging Principle Constant Current/ Constant Voltage

Over Voltage Rating

125% for 10 minutes 150% for 60 seconds 1000% for 5 cycles 105% continuous

Output Protection Short Circuit, MCB, Overvoltage protection and reverse polarity

protection Filtering L‐C Filter

GENERAL Battery Test Automatic or manual selectable

Event History AC Line Input high / Low , Rectifier output high / Low , Battery test failed , Over temperature , Low Battery, Line / Battery / Load MCB

events are displayed on time base in the front panel Boost Timer 0 – 99,9 hours adjustable by 1 minute accuracy Cooling Forced fans with smart fan controlling system

Isolation Voltage 3000VAC input/chassis and output/chassis Efficiency at full load >90% MTBF 100,000 Hrs. (w/out battery group) Operating Temperature ‐10 / + 40 ºC Protection Level IP21 (Higher IP available as option)

Enclosure Material Mild Steel, Zinc‐phosphate coated; 100 µm electrostatic paint; 1.5 mm

thickness Cable Entry Front Bottom Relative Humidity 5% to 90% non condensing Circuit Breakers Input: Magnetic circuit breakers; Output: Magnetic circuit breakers Ac Voltmeter At the Input

DISPLAY PANEL

Measurements LCD Displays for Load Output Voltage / Current , Battery Output

Voltage / Current and Line Voltage / Frequency

7


Indicators Boost Charging, Float Charging, Charger Failure, Over voltage , Over temperature , Low battery , Under voltage , Battery ending , Battery

test , Earth Fault and Input Power OKButtons Timer Setting, Boost Voltage Setting, Float Voltage Setting ,Output

current setting, battery current setting , automatic boost setting and Reset buttons

Event History AC Line Input high / Low , Rectifier output high / Low , Battery test failed , Over temperature , Low Battery , Line / Battery / Load MCB

events are displayed on time base.

FREE ALARM CONTACTS

Open or closed free alarm contacts

Mains Switch Failure, Battery Switch Failure, Load Switch Failure, Rectifier Failure, Low Battery failure, Rectifier Over Output Voltage,

Line Failure, Over Temperature, Earth Fault and Low Level Electrolyte(option)

ENVIRONMENT

Operating Temperature ‐10 / +50 °C

Relative Humidity 5 ‐ 90 %

Operating Altitude Max. 3000 Mt.

Noise Level Max. 60 db

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

COMMUNICATION & PARALLELING

Optional Communication RS‐ 232 / 485 communication are available to monitor and control

over Local Area Network & Internet

Paralleling N+1 (No need for extra part for paralleling)

DROPPER DIODES (OPTIONAL)

Voltage Regulation via Dropper Diode

Dropper diodes for float or boost charge may be utilized upon request. At discharge the dropper diodes will be eliminated out of the load circuit.

BOOST INHIBIT INTERLOCK (OPTIONAL)

Boost Inhibit Interlock System When boost inhibit option is implemented parallel redundant mode for interlock application inhibits one of the rectifiers boost operation

LVD and EARTH FAULT PROTECTION (OPTIONAL)

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

8

DC POWER SUPPLY / BATTERY CHARGER AUTO BOOST FUNCTION (STANDARD FUNCTION)

Battery voltage

Time hour

Boost voltageFloat voltage

6 80

Battery current

Time hour 86

Charge current

Boost current

Float current

0

Boost

Float

Battery Output

Amper ( I )

Voltage (V)

Battery automatic boost/float charge technique

Constant voltage / constant current rectifier output V/I characteristics

BATTERY TEST FUNCTION (STANDARD FUNCTION)

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

AUTO BOOST FUNCTION The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity. The user should set the suitable float and boost currents of the battery before selecting the automatic boost option. After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values. If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value. Option: Boost inhibit function is available in parallel operations to prevent over voltage (page 9)

9


BOOST INHIBIT INTERLOCKING FUNCTION (OPTIONAL)

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

10


DROPPER DIODES IN PARALLEL OPERATION WITH ONE BATTERY GROUP (OPTIONAL)

With one battery group boost inhibit interlock system can not be used. In parallel configuration with one battery group dropper diodes has to be installed to regulate the load voltage during boost charging as per below diagram.

11


BATTERY CHARGER USER INSTRUCTION PROCEED TO START UP THE CHARGER AS FOLLOWS:

1. MAKE THE ELECTRICAL CONNECTIONS OF THE CHARGER TO THE INPUT LINE

TERMINALS AND CLOSE (MAKE ON) THE LINE SWITCH.

2. MAKE THE ELECTRICAL CONNECTIONS OF THE BATTERY GROUP TO THE BATTERY OUTPUT (+/-) TERMINALS OF THE CHARGER.

3. ON THE CHARGER DISPLAY, READ THE BATTERY VOLTAGE AND ADJUST IF IT IS NECESSARY.

FOR EACH 12 VDC MAINTANANCE FREE LEAD ACID BATTERY, CHARGE VOLTAGE CAN BE BETWEEN 13.6 – 13.8 VDC.

FOR EACH 1.2 VDC NI-CAD NICKEL CADMIUM BATTERY CELL, CHARGE VOLTAGE CAN BE BETWEEN 1.45 – 1.50 VDC.

4. CLOSE (MAKE ON) THE BATTERY SWITCH AND READ THE BATTERY CHARGE CURRENT ON THE CHARGER DISPLAY AND ADJUST IF IT IS NECESSARY. (NORMALY, BATTERY CHARGE CURRENT CAN BE 15 % OF BATTERY AMP – HOUR)

5. MAKE THE ELECTRICAL CONNECTIONS OF THE LOAD TO THE DC LOAD OUTPUT (+/-) THERMINALS OF THE CHARGER.

6. CLOSE (MAKE ON) THE LOAD SWITCH AND CONTROL DC VOLTAGE AND CURRENT ON THE CHARGER DISPLAY.

ATTENTION!

1. DON’T CONNECT THE BATTERY GROUP (+/-) TERMINALS IN REVERSE

POLARITY CONNECTION.

2. DON’T MAKE SHORT CIRCUIT THE BATTERY / LOAD OUTPUT (+/-) TERMINALS.

3. THE BATTERY SWITCH MUST BE LEFT OPEN (OFF POSITION) WHEN THE CHARGER IS NOT OPERATING.

1 Phase Input/Output/Battery Connections

3 Phase Input/Output/Battery Connections

12


LCD FRONT PANEL USER INSTRUCTIONS

13

DC POWER SUPPLY / BATTERY CHARGER LCD FRONT PANEL USER INSTRUCTIONS

MAIN MENU: BATTERY CHARGER UP: When UP button is pressed the charger is RESET the microprocessor DOWN: When DOWN button is pressed the charger turns OFF

MENU1: L1, L2, L3: Input voltage F: Input Frequency Lin: Input Current

MENU2: Vb: Battery Voltage VI: Load Voltage Ib: Battery Current IL: Load Current

MENU3: Boost V: Boost Voltage (can be set from front panel and user interface RS232/RS485) Float V: Float Voltage (can be set from front panel and user interface RS232/RS485)

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

MENU5: Boost I: Boost Current (can be set from front panel and user interface RS232/RS485) Float I: Float Current (can be set from front panel and user interface RS232/RS485)

MENU6: Out I: Total output current (Load+Battery Current) (can be set from front panel and user interface RS232/RS485) Charge I: Battery charging current (can be set from front panel and user interface RS232/RS485)

MENU7: A b Test: Auto battery test time. This time indicates the time interval for executing the battery test M Boost: Sets the boost charge timing. If manual boost option is selected this time will indicate the manual boost time or if auto boost option is selected this time will indicate the auto boost time (can be set from front panel and user interface RS232/RS485)

MENU8: Boost Ch: This allows to select boost charging option. Boost charge options 1: Auto Boost, 2: Boost Charge OFF 3: Manual Boost Battery Test: This allows to select battery test option. Battery test options 1: Auto Test, 2: Battery Test OFF 3: Manual Battery Test

MENU9: Date: Set the current date. This date will appear in event log during events Time: Set the current time. This time will appear in event log during events

MENU10: Events: Event logs can be monitored via this menu please refer to instructions in page12

14

DC POWER SUPPLY / BATTERY CHARGER COMMUNICATION INTERFACE

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

15

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

• To start communication, select comport which is connected from the COMPORT box. • And push START / STOP COMMUNICATION button. • Do not use “,” while setting a parameter. Use “.” for float numbers • Do not use ENTER to save a parameter. Use SAVE button to save. • Push READ COMPLETE HISTORY button to read all event history. • CLEAR HISTORY clears screen. But this operation does not erase history from the memory.

Using READ COMPLETE HISTORY button, you can recall all history on screen at any time

• To set date and time, use the format given below. Use “:” between dates and times. And pres SAVE button. Example: 20:05:10 18:55

Parameter setting procedure: You can set parameters while START / STOP COMMUNICATION button is colored in RED. If START / STOP button is GREEN colored it means that data is being received through communication and while data is being received parameters can not be set before stopping the data transfer. You can push START / STOP button to stop data receiving mode and be ready to set parameters from the screen. Once the color is RED it is ready to set parameters. Set any value on the white boxes provided under SET PARAMETER screen and push SAVE button to set the parameters. And push START / STOP COMMUNICATION button to receive the real time data from the charger after setting the parameters. This action will turn on the monitoring mode back again

Parameter descriptions:

RECT Imax: Total rectifier output (Battery+Load current) current limit can be set. Rectifier output voltage will not allow higher currents than the set value BAT Imax: Battery charging current limit of battery can be set. Rectifier battery charging current will not allow higher currents than the set value Note: Max Load current value can be set indirectly by setting the RECT Imax and BAT I max values BAT TEST: This parameter sets battery test condition. If it is equal 1, automatic battery test is ON. If it is equal 2, battery test is OFF. If it is equal 3, manual battery test is available, select 3 and push save button to start battery test manually. BAT TEST TIME: This parameter sets automatic battery test time between 0.1 – 99.9 hour. LOW BATTERY VOLTAGE: This parameter sets min DC voltage value where rectifier gives low battery alarm and cut off the load connection of battery via LVD contactor(option)

16

DC POWER SUPPLY / BATTERY CHARGER FLOAT Vdc : Float charge voltage of battery group can be set. BOOST: This parameter sets boost charge condition. if it is equal 1, automatic boost is ON. If it is equal 2, boost is OFF. If it is equal 3, manual boost is available, select 3 and push save button to start boost charge manually. BOOST Vdc : Boost charge voltage of battery group can be set. BOOST TIME: This parameter sets manual/auto boost charge time between 0.1 – 99.9 hour.

I FLOAT: This parameter sets current value where rectifier returns float charge from automatic boost charge. I BOOST: This parameter sets current value where rectifier go automatic boost charge from float charge.

AUTO BOOST FUNCTION The automatic boost menu has the options for selecting the boost and float current accroding to battery capacity. The user should set the suitable float and boost currents of the battery before selecting the automatic boost option. After the set-up the automatic boost function will monitor the battery current and select boost or float option by referring to the set values. If the charging current is higher than set boost current the system will select boost and if the charging current is lower than set float current the system will select float option. In case low battery alarm the automatic boost will select boost option until the battery charging current reaches to the set float value.

17

DC POWER SUPPLY / BATTERY CHARGER Battery Charger Block Schema :

LOAD

LINE

PROTECTION

µC

L

CONTACTS

FILTER & INPUT ISOLATIONTRANSFORMER RECTIFIER MODULE OUTPUT FILTER

BATTERY PROTECTION

AUTOMATIONCONTROL PCB

CONTROL PCB

CONTROL PANEL

SUPPLY PCB

ALARM

BATTERYGROUP

BATTERY CHARGER CONTACTS INFORMATION

Warning Contacts Battery charger gives 3 status information : Line : If line switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information. Battery : If battery switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information. Load : If load switch closes or fails, warning light, on front panel, goes out and also warning relay leaves the contact and gives free contact information. Alarm Contacts Battery charger gives nine different failure warning information. Low Battery : After main electricity goes off, battery group which maintains load and when reaching end of discharge voltage, leaves load from battery group with contactor. Alarm LED on the front panel turns ON and also gives free contact information. Battery Ending : After main electricity goes off, battery group which maintains load and when reaching approximately 11 VDC (VRLA) for each battery. Alarm LED on the front panel turns ON Earth Fault : If the chassis of battery charger or ground line have leakage current greater than 30 mA. Alarm LED on the front panel turns ON and also gives free contact information.

18

DC POWER SUPPLY / BATTERY CHARGER Under Voltage : When a low voltage failure happens in the battery charger output voltage, the battery charger stops. Alarm LED on the front panel turns ON Over Voltage : When an over voltage failure happens in the battery charger output voltage, the battery charger stops. Alarm LED on the front panel turns ON and also gives free contact information. Mains Failure : When electricity goes off Alarm LED on the front panel turns ON and also gives free contact information. Charger Failure : When the battery charger failure occurs Alarm LED on the front panel turns ON and also gives free contact information..

Over Temperature : When the battery charger’s operating temperature is higher than 50 °C or Fan failure situation happens, battery charger cut off the output. Alarm LED on the front panel turns ON and also gives free contact information.

19

DC POWER SUPPLY / BATTERY CHARGER 1 PHASE INPUT BATTERY CHARGER CONNECTIONS

+LINE INPUT

P +NBATTERY_ _LOAD

LINEINPUT

Neutral

Ground

Phase

--

+--+

LOAD

BATTERY

BATTERY

BATTERY CHARGERRECTIFIER

MENU SET MENU SELECT

LINE ~ LOAD

=

-+

20


1 PHASE INPUT BATTERY CHARGERS VIEW

Input / OutputConnections

Side View (Right)

Front View

Front Panel

BATTERYLINE INPUT

P NLOAD_+ + _

ModuleDiyot

ModuleThyristorThermostat

CapasitorFilter

LEMCurrent Module

Filter Inductor

Transformer

Back View

Side View (Left)

220VAC Fan

Input IsolationTransformer

Control PCB

Supply

BATTERY CHARGERRECTIFIER

MENU SET

LINE ~

BATTERY

MENU SELECT

=

+ -

LOAD

21

DC POWER SUPPLY / BATTERY CHARGER 3 PHASE INPUT BATTERY CHARGER CONNECTIONS

LOAD

BATTERYGround

Neutral

--+--+

LOAD

+_BATTERY

+ _

LINEINPUT

L1

L2

L3

L2

LINE

L1 L3 N

BATTERY ENDING

CURRENT MODE

LOW BATTERY

BATTERRY FAIL

LINE FAILURE

OVER VOLTAGE

UNDER VOLTAGE

OVER TEMPERATURE

BATTERY CHARGER RECTIFIER

FLOAT MODE

BOOST MODE

RECTIFIER FAILURE

BATTERY

LOADLINE

+ -

MENU SELECTMENU SET

22

DC POWER SUPPLY / BATTERY CHARGER 3 PHASE INPUT PARALLEL BATTERY CHARGER CONNECTIONS

NLINE INPUT

L2L1 L3 + _ + _RECTIFIER 1 RECTIFER 2

+ _+ _RED. 1 RED. 2

NL2 L3L1 --++ --

L1 L1L2 L2L3 L3

GroundLINE INPUT BATTERY LOAD

BATTERY LOAD

BATTERY ENDING

CURRENT MODE

LOW BATTERY

BATTERRY FAIL

LINE FAILURE

OVER VOLTAGE

UNDER VOLTAGE

OVER TEMPERATURE


FLOAT MODE

BOOST MODE

RECTIFIER FAILURE

BATTERY

LOADLINE

+ -

MENU SELECTMENU SET

BATTERY ENDING

CURRENT MODE

LOW BATTERY

BATTERRY FAIL

LINE FAILURE

OVER VOLTAGE

UNDER VOLTAGE

OVER TEMPERATURE


FLOAT MODE

BOOST MODE

RECTIFIER FAILURE

BATTERY

LOADLINE

+ -

MENU SELECTMENU SET

23


3 PHASE INPUT BATTERY CHARGERS VIEW

ConnectionsInput / Output

Front View

Digital Front

Module-1LEM Current

Side View (Right)

Back View

220VAC Fan

Side View (Left)

Output IsolationTransformer

Thermostat

Diode

Control PCB

Supply TransformerPCBThyristor Module

Panel

NL3L1

LINE

L2_+

BATTERY_ +LOAD

Filter Inductor

=BATTERY CHARGERRECTIFIER

MENU SET

~LINE

MENU SELECT

+ -

LOAD

BATTERY

24

DC POWER SUPPLY / BATTERY CHARGER 48 VDC RECTIFIER WITH BATTERY GROUP

DIMENSIONS: H: 94 x W:44 x D:55 in cm (4 x 160 Ah Batteries to be housed)

LINE LINESWITCH P

BATTERY SWITCHN + --

BATT. LOADSWITCH

(48VDC ~ 51VDC)48VDC

--

+ --

--

+

+ --

--

+

+

GroupDC Power Supply / Battery Charger

Connections Line Input / Battery and Load Output

Cable CanalInput / Output

Battery Group

Front Panel

48VDC RECTIFIER KABINENT WITH BATTERY GROUP

RED

BLACK

BATTERY GROUP CONNECTIONS(4 BATTERIES IN SERIES)

48VDC SYSTEM


MENU SET

~LINE

MENU SELECT

+ -

LOAD

BATTERY

25

DC POWER SUPPLY / BATTERY CHARGER 110 VDC RECTIFIER WITH BATTERY GROUP

DIMENSIONS: H: 174 x W:68 x D:64 in cm (9 x 200 Ah Batteries to be housed)

DC Power Supply / Battery ChargerGroup

Connections Line Input / Battery and Load Output

Cable CanalInput / Output

Battery Group

Front Panel

110VDC RECTIFIER KABINENT WITH BATTERY GROUP

L1 L3L2

LINE

+LOAD

+BATTERY

N _ _

+--+--+

110VDC SYSTEM

(12VDC 9 Unit Serial Batteries)BATTERY GROUP CONNECTIONS

RED

--BLACK

+110VDC

+--+--+

--+--+--+

(110VDC ~ 115VDC)

--

--


MENU SET

~LINE

MENU SELECT

+ -

LOAD

BATTERY

26


1 PHASE ELECTRICAL BLOCK SCHEMA

27


1 PHASE RECTIFIER CONTROL PCB LAYOUT

28


1 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA

29


3 PHASE INPUT ELECTRICAL BLOCK SCHEMA

1

2

GNDM

-15+15

DIO

DE

GNDM

-15+15

K6

G6K5

G5

K4

G4K3

G3

G1

K1

G2

K2

30

DC POWER SUPPLY / BATTERY CHARGER 3 PHASE RECTIFIER CONTROL PCB LAYOUT

31

DC POWER SUPPLY / BATTERY CHARGER 3 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA

32

DC POWER SUPPLY / BATTERY CHARGER FREE CONTACTS & COMMUNICATION CONTROL PCB LAYOUT

33

DC POWER SUPPLY / BATTERY CHARGER COMMUNICATION PCB CIRCUIT SCHEMA

34


1 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA

PHA

SE

+

_

+

_

BA

TTER

Y

GR

OU

P

LOA

DB

ATT

ERY

NEU

TRA

L

LIN

E IN

PUT

REC

TIFI

ER

LOA

DR

ECTI

FIER

GR

AU

ND

_ +

+_

(LO

AD

)

OU

TPU

T

LOW

BA

TTER

Y

REC

TIFI

ER F

AIL

UR

E

35


3 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA

GR

AU

ND

NEU

TRA

L

(LO

AD

)O

UTP

UT

+_

GR

OU

P

LOA

D

BA

TTER

Y

BA

TTER

Y

L3L1 L2

LIN

E IN

PUT

_ +

REC

TIFI

ER-1

LOA

DR

ECTI

FIER

FAIL

UR

ER

ECTI

FIER

LOW

BA

TTER

Y

36


PARALLEL RECTIFIER WITH TWO BATTERY GROUPS BLOCK SCHEMA

REC

TIFI

ER-2

BA

TTER

YG

RO

UP

GR

OU

PB

ATT

ERY

REC

TIFI

ER-1

LOA

D O

UTP

UT

LOA

D O

UTP

UT

BA

TTER

Y O

UTP

UT

BA

TTER

Y O

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_+

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AC

INPU

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AC

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ING

DIO

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37

DC POWER SUPPLY / BATTERY CHARGER PARALLEL RECTIFIER WITH ONE BATTERY GROUP BLOCK SCHEMA

LOA

D D

ISTR

IBU

TIO

N

AC

INPU

T

AC

INPU

T

+ _+ _

+ _

+ __+

BA

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REC

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BA

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38

DC POWER SUPPLY / BATTERY CHARGER COMPONENT LIST

Input Fuse 1 Unit 1 Unit

Output Load Fuse 1 Unit 1 Unit

Input Isolation Transformer 1 Unit 1 Unit

Filter Inductor 1 Unit 1 Unit

Thyristor Module 1 Unit 3 Unit

Diyot Module 1 Unit -

Output Filter Capacitor 1 Unit 1 Unit

Relay 2 Unit 2 Unit

Fan 220VAC 1 Unit 1 Unit

Thermostat (40°C) 1 Unit 1 Unit

Thermostat (70°C) 1 Unit 1 Unit

DC Supply Control PCB 1 Unit 1 Unit

Digital Front Panel 1 Unit 1 Unit

Automation Control PCB (Optional) 1 Unit 1 Unit Battery Charge Current Adjustment PCB (Optional) 1 Unit 1 Unit

Leakage Current PCB (Optional) 1 Unit 1 Unit

Contactor (Optional) 1 Unit 1 Unit

Supply Transformer 1 Unit 1 Unit

Heatsink 1 Unit 1 Unit

LEM Current Module 1 Unit 1 Unit

Case 1 Unit 1 Unit

39

DC POWER SUPPLY / BATTERY CHARGER WEIGHTS & DIMENSIONS

220 VAC (1 PHASE) INPUT LINE Output Voltage

Output Current

Weight (kg)

Dimensions ( H x W x D ) (cm)

12-24 VDC 10 Amp. 15 41 x 22 x 33 12-24 VDC 30 Amp. 36,5 41 x 22 x 33 12-24 VDC 60 Amp. 51,5 57 x 39 x 41 12-24 VDC 100 Amp. 95 66 x 38 x 48 12-24 VDC 200 Amp. 144 73 x 45 x 53

48 VDC 10 Amp. 20 41 x 22 x 33 48 VDC 30 Amp. 40 57 x 39 x 41 48 VDC 60 Amp. 65 66 x 38 x 48 48 VDC 100 Amp. 188 73 x 45 x 53

110 VDC 10 Amp. 45 57 x 39 x 41 110 VDC 30 Amp. 65,5 57 x 39 x 41 110 VDC 60 Amp. 80 73 x 45 x 53 110 VDC 100 Amp. 190 73 x 45 x 53

380 VAC (3 PHASE) INPUT LINE

Output Voltage

Output Current

Weight (kg)

Dimensions ( W x D x H ) (cm)

12-24 VDC 30 Amp. 45 57 x 39 x 41 12-24 VDC 60 Amp. 73 66 x 38 x 48 12-24 VDC 100 Amp. 90 66 x 38 x 48 12-24 VDC 200 Amp. 120 73 x 45 x 53

48 VDC 30 Amp. 55 66 x 38 x 48 48 VDC 60 Amp. 65 66 x 38 x 48 48 VDC 100 Amp. 90 70 x 45 x 53 48 VDC 200 Amp. 120 77 x 51 x 71

110 VDC 10 Amp. 65 57 x 39 x 41 110 VDC 30 Amp. 78,5 66 x 38 x 48 110 VDC 60 Amp. 92 70 x 45 x 53 110 VDC 100 Amp. 169 77 x 51 x 71 110 VDC 200 Amp. 210 110 x 65 x 60 220 VDC 10 Amp. 78 66 x 38 x 48 220 VDC 30 Amp. 90 66 x 38 x 48 220 VDC 60 Amp. 110 77 x 51 x 71 220 VDC 100 Amp. 235 77 x 51 x 71 220 VDC 150 Amp. 365 77 x 51 x 71

40

DC POWER SUPPLY / BATTERY CHARGER CABLE CROSS-SECTIONS

220 VAC (1 PHASE) INPUT

Output Voltage

Output Current

Input Cable Cross-Section (mm2)

Output Cable Cross-Section (mm2)

Battery Load 12-24 VDC 10 Amp. 2,5 4 4 12-24 VDC 30 Amp. 2,5 6 6 12-24 VDC 60 Amp. 2,5 16 16 12-24 VDC 100 Amp. 4 25 25 12-24 VDC 200 Amp. 10 35 35

48 VDC 10 Amp. 2,5 4 4 48 VDC 30 Amp. 2,5 6 6 48 VDC 60 Amp. 4 10 10 48 VDC 100 Amp. 10 25 25

110 VDC 10 Amp. 2,5 4 4 110 VDC 30 Amp. 6 6 6 110 VDC 60 Amp. 10 10 16 110 VDC 100 Amp. 16 25 25

380 VAC (3 PHASE) INPUT

Output Voltage

Output Current

Input Cable Cross-Section (mm2)

Output Cable Cross-Section (mm2)

Battery Load

12-24 VDC 30 Amp. 2,5 6 6 12-24 VDC 60 Amp. 2,5 10 10 12-24 VDC 100 Amp. 2,5 25 25 12-24 VDC 200 Amp. 2,5 35 35

48 VDC 30 Amp. 2,5 6 6 48 VDC 60 Amp. 2,5 16 16 48 VDC 100 Amp. 2,5 25 25 48 VDC 200 Amp. 4 35 35

110 VDC 10 Amp. 2,5 4 4 110 VDC 30 Amp. 2,5 10 10 110 VDC 60 Amp. 2,5 16 16 110 VDC 100 Amp. 4 25 25 110 VDC 200 Amp. 10 35 35 220 VDC 10 Amp. 2,5 4 4 220 VDC 30 Amp. 2,5 10 10 220 VDC 60 Amp. 4 16 16 220 VDC 100 Amp. 10 25 25 220 VDC 150 Amp. 10 35 35

41

DC POWER SUPPLY / BATTERY CHARGER FAILURE – CORRECTION INSTRUCTION

1. IF YOU CAN’T SEE VOLTAGE ON FRONT PANEL, PLEASE CHECK INPUT LINE

THERMAL FUSE AND CHECK FRONT PANEL PCB FLAT CABLE.

2. IF THE LINE THERMAL FUSE IS OFF DURING OPERATION OF THE RECTIFIER, PLEASE CHECK TYRISTOR MODULES AND ALSO RELATED GATE FUSES ON THE DC SUPPLY COTROL PCB. IF THERE IS A FAILURE, PLEASE CHANGE TYRISTOR MODUL AND GATE FUSE WITH THE SAME RATING.

3. IF THERE IS A OVER TEMPERATURE FAILURE, PLEASE CHECK MECHANICAL

220VAC FAN. IF REQUIRED PLEASE CHANGE 220VAC FAN WITH SIMILAR ONE.

4. IF THE LOAD THERMAL FUSE IS OFF DURING OPERATION OF RECTIFIER, PLEASE REMOVE LOAD CONNECTIONS AND CHECK LOAD CURRENT FOR SHORT CIRCUIT PROTECTION.

5. IF THERE IS A PROBLEM ABOUT BATTERY GROUP (BOILING, OVER HEAT),

PLEASE CHECK BATTERY GROUP CHARGE CURRENT (15% OF BATTREY AMP-HOUR) AND FLOAT VOLTAGE ON CHARGER FRONT PANEL.

6. IF EVERYTING IS OKAY (INPUT LINE VOLTAGE, LOAD CONNECTIONS,

BATTERY CONNECTIONS AND FUSE POSITIONS) FOR THE OPERATION OF THE RECTIFIER. BUT THERE IS NO OUTPUT, THAN PLEASE CHECK SUPPLY TRANSFORMER (DUAL 0-15VAC OUTPUT) VOLTAGE. IF THE SUPLLY TRANSFORMER OUTPUT IS OKAY, THAN PLEASE CHANGE DC SUPPLY CONTROL PCB.

7. DURING OPERATION OF THE RECTIFIER, IF YOU CAN’T READ OUTPUT

CURRENT ON FRONT PANEL, PLEASE CHECK CURRENT MODULE SUPPLY VOLTAGE (+15 VDC, -15 VDC). IF THIS VOLTAGES ARE CORRECT, THAN PLEASE CHANGE CURRENT MODULE.

42


W

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43


W

AR

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TER

MS

AN

D C

ON

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S

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The

war

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is tw

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Th

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from

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Adm

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and

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and

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ay

be a

pplie

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s co

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the

war

rant

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IMPO

RTE

R o

r MA

NU

FAC

TUR

ER C

OM

PAN

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Nam

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:

Add

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:

Tel –

Fax

: A

UTH

OR

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PER

SON

OF

CO

MPA

NY

Sig

natu

re a

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SYST

EM

Type

: D

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TIFI

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illin

g D

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and

No

: D

ATE

– S

IGN

ATU

RE

– S

EA

L

44


INDEX

ATTENTION! -------------------------------------------------------------------------------------------- 3

RDA/RDAT AUTOMATION BATTERY CHARGER ------------------------------------------ 4

TECHNICAL SPECIFICATIONS ------------------------------------------------------------------- 6

AUTO BOOST FUNCTION (STANDARD FUNCTION) --------------------------------------- 8

BATTERY TEST FUNCTION (STANDARD FUNCTION) ------------------------------------ 8

BOOST INHIBIT INTERLOCKING FUNCTION (OPTIONAL) ---------------------------- 9

DROPPER DIODES IN PARALLEL OPERATION WITH ONE BATTERY GROUP (OPTIONAL) -------------------------------------------------------------------------------------------- 10

BATTERY CHARGER USER INSTRUCTION ------------------------------------------------- 11

LCD FRONT PANEL USER INSTRUCTIONS -------------------------------------------------- 12

LCD FRONT PANEL USER INSTRUCTIONS -------------------------------------------------- 13

COMMUNICATION INTERFACE ---------------------------------------------------------------- 14

BATTERY CHARGER CONTACTS INFORMATION ---------------------------------------- 17

1 PHASE INPUT BATTERY CHARGER CONNECTIONS ---------------------------------- 19

1 PHASE INPUT BATTERY CHARGERS VIEW --------------------------------------------- 20

3 PHASE INPUT BATTERY CHARGER CONNECTIONS --------------------------------- 21

3 PHASE INPUT PARALLEL BATTERY CHARGER CONNECTIONS ---------------- 22

3 PHASE INPUT BATTERY CHARGERS VIEW --------------------------------------------- 23

48 VDC RECTIFIER WITH BATTERY GROUP ----------------------------------------------- 24

110 VDC RECTIFIER WITH BATTERY GROUP --------------------------------------------- 25

45

DC POWER SUPPLY / BATTERY CHARGER 1 PHASE ELECTRICAL BLOCK SCHEMA ---------------------------------------------------- 26

1 PHASE RECTIFIER CONTROL PCB LAYOUT ------------------------------------------- 27

1 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA ----------------------------- 28

3 PHASE INPUT ELECTRICAL BLOCK SCHEMA------------------------------------------ 29

3 PHASE RECTIFIER CONTROL PCB LAYOUT ------------------------------------------- 30

3 PHASE RECTIFIER CONTROL PCB CIRCUIT SCHEMA ----------------------------- 31

FREE CONTACTS & COMMUNICATION CONTROL PCB LAYOUT ---------------- 32

COMMUNICATION PCB CIRCUIT SCHEMA ------------------------------------------------ 33

1 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA ------------------------- 34

3 PHASE AUTOMATION TYPE RECTIFIER BLOCK SCHEMA ------------------------- 35

PARALLEL RECTIFIER WITH TWO BATTERY GROUPS BLOCK SCHEMA ------ 36

PARALLEL RECTIFIER WITH ONE BATTERY GROUP BLOCK SCHEMA ------- 37

COMPONENT LIST ----------------------------------------------------------------------------------- 38

WEIGHTS & DIMENSIONS ------------------------------------------------------------------------- 39

CABLE CROSS-SECTIONS ------------------------------------------------------------------------- 40

FAILURE – CORRECTION INSTRUCTION ---------------------------------------------------- 41

INDEX ----------------------------------------------------------------------------------------------------- 44

pmi rda-rdat series batterycharger userbook_en

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prior notice

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