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RAN EW

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N

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PROTECT RCS Rectifiers Chargers and DC Systems SPRe - Single Phase Rectifier TPRe - Three Phase Rectifier 24V – 110V 10A – 500A

Designed for all industrial applications • Oil & Gas, Petrochemicals Offshore, Onshore, Pipelines

• Energy and Power Generation, Transmission, Distribution • Transportation Rail, Airports, Shipping

• Water Desalination, Treatment • Instrumentation & Process Control Chemicals, Mining, Steel, Paper • All Industrial Applications

www.powersupplysystems.com

Robust, Reliable and Flexible These are the latest generation of robust, industrial rectifiers, chargers and DC Systems from Saft Power Systems. Using proven microprocessor controlled thyristor technology to provide high-reliability power supply and battery charging capabilities. A more flexible approach to providing exact solutions. Choose from: • Standard system configurations and • Customized systems - designed to comply with precise specifications

>>

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>> KEY FEATURES • Standard system configurations - cost effective, short lead time solutions • Customized systems - enhance the standard system by selecting from an extensive range of options • All systems built with advanced GCAU - Generic Control and Alarm Unit • Communications system used to monitor and control the defined parameters locally or remotely. • Choice of several types of batteries: - nickel-cadmium – vented or gas recombination - lead acid – vented or gas recombination

• Advance Battery Management • Parallel operation • Simplified maintenance • High MTBF and low MTTR - Bespoke documentation; drawings, manuals -Total solutions – including switchgear, load distribution • International Service support – comprehensive packages including; • Product Services: Installation, Commissioning, Service Contracts... • Site Services: Load testing, monitoring…

NEW RANGE NEW RANGE: PROTECT RCS INDUSTRIAL RECTIFIERS, CHARGERS & DC SYSTEMS Protect RCS is an evolution of the highly successful SPR/TPR range from Saft Power Systems which is installed globally and used for all Industrial applications. The main advance of the new Protect RCS range is the introduction of the GCAU card which integrates more cutting-edge hardware functions. The Protect RCS rectifiers are thyristor-controlled rectifiers suitable for charging nickel-cadmium or lead-acid batteries while supplying DC loads. They can also be used without batteries as direct power supplies.

"GCAU" Generic Control and Alarm Unit (A1) The main card is the GCAU (Generic Control and Alarm Unit). It performs measurements, control and process control (charge process control) and provides a wide range of alarm and monitoring options, a user-friendly control/display interface, and facilities for data logging and remote communication. The card has all the necessary controls to pilot single and three phase thyristor chargers. For three phase systems a driver card is connected to the GCAU card.

This new range of DC Systems is available in three levels: • The first level consists of the Standard Rectifier with a compact set of alarms. • The second level offers a set of Basic Options, extensive functions and alarms. • The third level offers a full set of Extended Options, extensive functions and alarms allowing customization of the systems to comply with special customer requirements. The rectifiers are built as independent modules, optional equipment like distribution boards, diode droppers etc. are installed in separate cubicle sections. Because of the high level of standardisation and integration, the design reduces the need for extensive internal wiring. Cabinets are floor mounted and can be designed to meet special requirements. The batteries are mounted on free-standing racks or in cabinets together with or separated from the rectifier.

The GCAU card uses a fully digital control algorithm to ensure the required flexibility. The GCAU card incorporates two micro controllers, using the latest micro controller technology to ensure a high degree of safety. The tasks of these micro controllers are: • Process communication and Monitoring • Regulation and synchronization Each micro controller has its specific dedicated task. One micro controller is dedicated to the control algorithm while the second takes care of alarm, communication and charge process tasks. The two micro controllers check each other’s functionality and will shut down the system safely if an operating error is detected.

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SYSTEM DISPLAY An extensive human interface ensures that all the important parameters are accessible from the front panel. A large 16 characters by 2 lines LCD unit displays all the relative information to the user. A three push button keyboard is used with 2 LEDs (green and red) indicating the charger state. The Display card is mounted on the front of the system and is controlled by the GCAU card. It is a plug-in device and is connected through two RJ 4-4 connectors with a 4-wire cable. All data and necessary power supply voltages are transferred over this cable.

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

BLOCK DIAGRAM OF THE RECTIFIER AC Line Input

Input Transformer

Rectifier Bridge

Stabilizer (Option)

Ripple Filter

DC Output

Rectifier Fuse

TPC Board (Three phase)

RS232 RS485

Battery

Thyristor Gate Control

AC Voltage PS

Isolated Serial Port Out

Extended filter as option

OVP input

Serial Communication Board (Option)

Rectifier Current sense

Rectifier Volatge sense

Battery Temp. Sensor (Option)

Battery Current Sense (Option)

Load voltage sense

GCAU CARD Ambient Temp Sensor (Option)

RJ 4-4 Connector

RJ 4-4 Connector Relay Board

(Option)

Remote Alarm Contacts

Front alpha numeric Display 2 LED indicators Keyboard

DC PC

LED box (Option)

8 Multi functional spare inputs

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>> PROTECT RCS - SINGLE PHASE RANGE (including systems with Basic Options)

STANDARD SYSTEMS & BASIC OPTIONS DIMENSIONS1

WEIGHT2 (APPROX)

RECTIFIER TYPE

NOMINAL DC OUTPUT VOLTAGE V

NOMINAL DC OUTPUT CURRENT A

HEIGHT (MM)

WIDTH (MM)

DEPTH (MM)

24SPRe10

24

10

1200

600

821

85

24SPRe15

24

15

1200

600

821

95

24SPRe25 24SPRe50 24SPRe75 24SPRe100

24 24 24 24

25 50 75 100

1200 1200 1200 1200

600 600 600 600

821 821 821 821

105 160 180 195

48SPRe10 48SPRe15 48SPRe25 48SPRe50 48SPRe75

48 48 48 48 48

10 15 25 50 75

1200 1200 1200 1200 1600

600 600 600 600 600

821 821 821 821 821

95 100 145 200 295

110SPRe10 110SPRe15 110SPRe25 110SPRe50

110 110 110 110

10 15 25 50

1200 1200 1200 1600

600 600 600 600

821 821 821 821

110 145 190 345

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

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

• Navigational Aids • Emergency Lighting • Fire & Gas Detection Systems • Fire Fighting • Emergency Shutdown Systems • Radio & Telecommunications • Signaling • Telemetry

• Instrumentation & Process Control • Gas Turbine Control • Switchgear Tripping • Motor Starting • Lube-oil pump supply • Power Generation, Transmission and Distribution

KG

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>> PROTECT RCS - THREE PHASE RANGE (including systems with Basic Options)

NOMINAL DC OUTPUT

RECTIFIER TYPE

VOLTAGE

CURRENT

V

A

HEIGHT (MM)

WIDTH (MM)

DEPTH (MM)

KG

24TPRe25

24

25

1200

600

821

145

24TPRe50

24

50

1200

600

821

185

24TPRe75 24TPRe100 24TPRe150 24TPRe200 24TPRe300 24TPRe400

24 24 24 24 24 24

75 100 150 200 300 400

600 600 600 600 600

821 821 821 821 821 821

250 285 305 345 *(4)

24TPRe500

24

500

1200 1600 1600 1600 2000 2000 (2065 max)3 2000 (2065 max)3

48TPRe25 48TPRe50 48TPRe75 48TPRe100 48TPRe150 48TPRe200 48TPRe300 48TPRe400

48 48 48 48 48 48 48 48

25 50 75 100 150 200 300 400

48TPRe500

48

500

110TPRe25 110TPRe50 110TPRe75 110TPRe100 110TPRe150 110TPRe200

110 110 110 110 110 110

25 50 75 100 150 200

110TPRe300

110

300

110TPRe400

110

400

110TPRe500

110

500

STANDARD SYSTEMS & BASIC OPTIONS DIMENSIONS1

WEIGHT2 (APPROX)

NOMINAL DC OUTPUT

1200 1200 1600 1600 1600 1600 2000 2000 (2065 max)3 2000 (2065 max)3 1200 1600 1600 1600 1600 2000 (2065 max)3 2000 (2065 max)3 2000 (2065 max)3 2080

1. Dimensions may vary for systems with Extended Options. 2. Weights may vary depending on selection of Basic Options and Extended Options. 3. Cabinet with additional fan cooling – top cover 65mm Height. 4. Weights on request. Please consult Saft Power Systems for alternative systems.

*(4)

900 821

*(4)

900 600 600 600 600 600 600 600

821 821 821 821 821 821 821 821

190 215 315 340 495 515 *(4) *(4)

900 821

*(4)

900 600 600 600 600 600

821 821 821 821 821 821

215 365 495 520 585 770

900 821 821

*(4) *(4)

821

*(4)

900 900 1200

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SPECIFICATION INPUT Protect RCS single phase (SPRe)

Single phase 230Vac ± 10%

Protect RCS Three Phase (TPRe)

Three phase 400Vac ± 10% Other voltages available as option

Exceptional variations

+ 15 / -20% (functional)

Frequency

50Hz or 60Hz ± 6%

OUTPUT Nominal voltage (Udc) Range of operating voltage

24V 48V 110V Floating charge High rate charge Commissioning charge

Static voltage regulation

± 0.5% under the following conditions: • at float charge • 0-100% DC load variation • input voltage ± 10% • input frequency ± 6% • temperature from 0°C to 40°C Using standard filter and the battery connected (capacity higher than 5 times I nom) Load step Deviation 10-90% -5% 90%-10% +5%

Dynamic voltage regulation

(Other voltages available as non-standard option) 75% to 125% of Udc Nominal 75% to 135% of Udc Nominal 75% to 140% of Udc Nominal

Current regulation Long-term stability of UDC

0-2% of current limit

Temperature coefficient of UDC Charging characteristic Input/Output isolation Insulation resistance

0.18% per °C Constant current / constant voltage (I/U as per IEC 478-1) during float charge 2500 VAC between input/output and electrical earth

Ripple

0.15% for 1000 hours

> 200 MΩ, 500 VDC Max 2% rms of nom. DC voltage, with a battery Ah capacity of 5 times the charger nom rating, battery connected (see our filter options). 2.5% rms typical (max 5%) on rectifier output, battery not connected.

PROTECTION • Polarity reversal of battery (blows battery fuse, optional) • Soft-start function 0 to 100% • Short-circuits • Limited to 100% of rated current • Internal DC fuse • Non-volatile storage of system parameters and user setting • Mains failure shutdown • Rectifier failure shutdown • High-voltage DC shutdown • Thermal protection EMC emissions

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

Safety

According to EN 50178 standard

ENVIRONMENTAL Ambient temperature

Operating: 0°C to + 40°C Derate from 40°C to 55°C by lowering the output current by 1.25% per °C. Storage: -25°C to +70°C

Relative humidity

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

Acoustic noise

Typical 45-65 dB(A)

Altitude

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

Tropicalisation

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

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>> PRODUCT RANGE ARCHITECTURE The product range is configurable with three levels of architecture:

Architecture

1

A Standard Rectifier System

2

Plus Basic Options

3

(Building block)

(Building block)

Plus Extended Options

Documentation

Cabinet

Availability

Standard Documentation

Standard Size

Short lead time

Standard Documentation

Standard Size

Short lead time

Customized Documentation

Standard or optional size

Project dependent

Availability of TPRe 300A, 400A and 500A systems is project dependent

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

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

STANDARD SYSTEM Electrical components Terminal X1 and X2 (Mains, battery, load, common fault) Internal input power switch Q1 Input transformer T1 (with taps 220V-230V-240V for SPRe and 380V-400V-415V for TPRe) Rectifier bridge (SPRe: mixed diode/thyristor bridge V1-V5, TPRe: 6-pulse bridge V1-V7) GCAU card A1 with non-volatile history and English display language + second language available (factory setting) TPC card A2 for TPRe only Output filter L1-C1 ripple voltage < 5% RMS without battery Rectifier fuse F1 Rectifier shunt R2 Common fault remote alarm (changeover contact wired on terminal) The Display card (A300) and keyboard assembly (A310) are mounted on the front of the system Cabinet construction Floor Mounted 19” cabinet Protection degree IP21 Colour RAL 7035 - Powdered textured painting Cabinet natural cooling (except TPRe 110V-400A and 110V-500A) Door with air inlet Rear panel with air outlet (φ 5mm punched panel) (requires 10 cm minimum clearance at the rear of the cabinet) Door swing 180 degrees with two key locks Logo/ Brand name on front Bottom open (vermin proof as option) Standard cable entry at the bottom Standard cable gland plate on the roof Bottom opening (10 cm) for pallet truck handling facilities Standard labelling/nameplate Standard PVC cable Standard cable marking None isolated aluminium earth bar (screwed directly in frame)

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>> STANDARD SYSTEM PLUS BASIC OPTIONS The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user documentation will be automatically generated to reflect the actual options configured A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional system capabilities.

Option n°

Basic options

Select ( )

Alarm/signalling/measurement option 100 101 102 103 104 105

LED box signalling (A6) (all alarms, events, high rate charge, commissioning) First 8 relays card ( A5.1) Rectifier voltage analog DC meter (P2) Rectifier current analog DC meter (P1) Battery current analog DC meter (P3) Temperature alarm (bridge natural cool. ≤50A,+TH1 shutdown+TH2 alarm) Temperature alarm (bridge forced cool. ≥75A, TH1 shutdown, +TH2 alarm+TH3 fan assisted)

200 201 202 203 204 205

EIA232 SPG* communication (A71) - WINSPARC software required EIA485 SPG* communication (A71 + A72) - WINSPARC software required EIA485 SPG* PC side interface (one set for PC) WINSPARC software (CD-ROM + documentation) EIA232 MODBUS communication (A71) EIA485 MODBUS communication (A71 + A72)

300

Remote forced floating charge command

400 401 402 403 404

Input fuse (without alarm) DIN (F34) Input fuse (without alarm) Cylindrical (F34) Input circuit breaker (without alarm) (Q1) Input contactor (K1) controlled by ON-OFF switch S1 on front door EMI filter (CE) (Z1) - mandatory for “CE” mark

500 501 502 503 504 505 506

Load fuse (without alarm) DIN (F23) Load fuse (without alarm) Cylindrical (F23) Load circuit breaker (without alarm) (Q2) Load Switch (handle inside the cabinet) (Q2) Blocking diode (V21) 0.1% filter SPRe ≤ 25A (Telecom filter for 24V and 48V) 1% filter

600 601 602 603 604 605 606 607 608 609 610 611

Battery fuse (without alarm) DIN (F13) Battery fuse (without alarm) Cylindrical (F13) Battery circuit breaker (without alarm) (Q3) Battery Switch (handle inside the cabinet) Battery current limit/display (Battery shunt R3 same as rectifier shunt R2) Battery voltage temperature compensation (5 m length sensor wire) (NTC) Temperature sensor wires: 10m, 30m Battery Low Voltage Disconnect contactor (K2) I Battery same as I Rectifier VOM battery charging (Ni Cd gas recombination) Dual rate charge C15 100 battery monitoring board (A3) Single rate charge C15 100 monitoring board (A3) High Rate interlock: (high rate inhibited as load switch is ON)

700 701 702

Cabinet heating resistor (230V) controlled by thermostat Eye bolts IP42

Communication options

Control and command options AC input options

Load options

Battery options

Cabinet options

*SPG = Saft Power Systems Protocol for GCAU.

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WINSPARC SOFTWARE-SAMPLE SCREENSHOT The WINSPARC software (WINDOWS based) is an application designed for local and remote supervision to have control of the entire GCAU configuration in order to monitor and configure the systems. This software interacts with the GCAU through a serial data link. To do this the communication card A71 is plugged into the GCAU through the extension connector (See options 200, 201 and 202). This software function allows visualizing on a PC screen system data such as alarms, measurements, modes, and history. Remote commands can be sent to the system. The available types of communication are: • Locally (via PC port COMx) • Remotely (via Modem -extended option 250) If only one charger is to be connected to the PC, the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71). Option 200.

If more than one charger is to be connected to the same communication bus (centralized supervision of chargers), the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71) + one EIA485 interface & connecting board (A72). Option 201. With Option 201 (EIA485 bus), the PC side is usually equipped with a PC side interface providing EIA485/EIA232 conversion. Option 202. The rectifiers are acting as slaves and the central computer as the master. By giving the different rectifiers different slave numbers, it is possible to command each individual rectifier. WINSPARC is compliant with the WINSITE software (site management application).

SPECIFICATION Platform: PC compatible Operating system: Windows NT4, Windows 2000 or Windows XP.

WINSPARC SOFTWARE-SAMPLE SCREENSHOT

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>> FURTHER CUSTOMIZATION WITH EXTENDED OPTIONS The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user documentation will be automatically generated to reflect the actual options configured A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional system capabilities.

Option n°

Extended options Alarm /signalling/measurement options

150

LED Box LED test push button

151

AC input voltage analog meter (with phase selector switch for TPRe)

152

AC input current analog meter (with phase selector switch for TPRe)

153

AC input voltage and current analog meters with 3-phase selector switch

154

Load voltage analog DC meter

155

Load current analog DC meter

156

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

157

Second 8 relays signalling card (with additional auxiliary power supply required)

158

Alarm buzzer

159

High ripple voltage alarm

160

Low electrolyte level alarm

161

Battery circuit failure alarm

162

DC line permanent insulation controllers

See options AC input, Load or Battery

Protection device (Fuse or MCB) with signalling alarm

163

Ambient temperature indicator/alarm

250

Modem communication

350

Remote rectifier shutdown command (Using one spare input)

351

Remote alarm reset / acknowledgement command (Using one spare input)

Communication options Control and command options

352

Battery room fan control (One relay of extension relay card required)

353

Remote high rate charge command (Using one spare input)

354

Float/Auto/High rate internal switch (Using two spare inputs)

450

Input fuse (with alarm) DIN

451

Input fuse (with alarm) Cylindrical

452

Input circuit breaker (with alarm)

453

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

454

Special mains input voltage (3x460/480V 60Hz; 3x500V 50Hz; 3x690V 50Hz; other)

455

AC surge arrestor

550

Load fuse (with alarm) DIN

551

Load fuse (with alarm) Cylindrical

AC input options

Load options

552

Load circuit breaker (with alarm)

553

Diode dropper

554

0.1% filter all other models SPRe ≥50A & TPRe

555

High DC voltage trip mechanical

556

DC distribution

557

DC surge arrestor

Select ( )

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ONS Option n°

Extended options

Select ( )

Battery options 650 651 652 653 654 655 656 657 See alarm options

Battery fuse (with alarm) DIN Battery fuse (with alarm) Cylindrical Battery circuit breaker (with alarm) Special battery current limit/display shunt (R3 # R2) Special battery LVD contactor (I batt. # I red.) Reversed battery protection Cable drop compensation Battery protection/isolation box (Fuse/fuse switch/MCB/MCCB/switch) High ripple voltage alarm card Low electrolyte level alarm Battery circuit failure alarm card See control options Battery room fan control Float/Auto/High rate internal switch Remote high rate charge command

Cabinet options 750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769

Cabinet interior light and AC mains socket with circuit breaker (without differential) Cabinet interior light and AC mains socket with differential protection circuit breaker Interior light with circuit breaker (without differential) AC mains socket with differential protection MCB AC mains socket with circuit breaker (without differential) IP20 Open Door IP21 with back panel Protection up to IP54 Special colour Copper earth bar Vermin proof protection plate Tropicalisation (Varnished PCB’s) Special wiring (low smoke low fume wiring and cable duct halogen free) Identification of internal components by sticky labels on plexi strip Identification of internal components by engraved labels on plexi strip Cabinet coupling Cabinet separation plate Additional cabinets option Battery cabinet Battery separation plate

850 851 852

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

System options

Miscellaneous options Option n°

(Additional Miscellaneous Options can be selected and include);

Miscellaneous options

950

Extra drawing files

951

Factory acceptance test

952

Extra test (Heat run test)

953

Packing (various categories)

954

Freight (as required)

Detailed explanations of all Options are available on request.

Select ( )

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

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

POWER SERVICES Advanced power supplies require advanced technical service and support. Our customers know that they can

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

Battery Replacement In-house/Express Repair Training Remote Monitoring Power Quality Services Service Contracts - 24/7 Global Service Coverage Corrective Maintenance Design & Build - Turnkey Solutions

Product Services Refurbishment Consulting Load Bank & Capacity Testing Installation & Commissioning Facility & equipment Management Battery Monitoring Spare Parts

Power Systems Whenever wherever wattever Industry - IT - Telecoms - Transportation - Services For further information see SPS Service Brochure For more information please refer to our website: www.powersupplysystems.com

Realized by yvydy. - Protect RCS - 09/07 - EN-V1. Due to our policy of continuous development, data in this document is subject to change without notice and becomes contractual only after written confirmation.

A comprehensive range of services are available