PROTECT RCS

Battery charger

TPRe TD

Operation manual

BN 092671/01/01 – 07/04/2020
EN
 AEG Power Solutions is a world specialist in AC and DC power conversion.

The company designs and manufactures rectifiers, inverters and power electronics
systems associated with all types of batteries.

The applications range from Transmission and distribution, Oil & Gas,
Petrochemicals, Transport, Power, Manufacturing and Telecommunications
Industries through to Military applications.

AEG Power Solutions makes available to its customers its theoretical and practical
training centre at various locations.

This equipment has been designed to meet the requirements of the European Directives
applicable to the product concerned, i.e. Directive on Electromagnetic compatibility (EMC)
N° 2014/30/EU of 18-04-2014. To comply the units are equipped with the necessary input
filters where applicable. Together with the compliance to Low Voltage Directive
N° 2014/35/EU of 18-04-2014, the systems have the CE mark.
The delivered equipment is conform with these Directives as long as the user does not
change its electrical and mechanical characteristics.

This equipment is designed to be used in an industrial environment.

WARNING :
THIS PRODUCT IS FOR RESTRICTED DISTRIBUTION TO INFORMED INSTALLERS OR USERS.
INSTALLATION RESTRICTIONS OR ADDITIONAL MEASURES MAY BE NECESSARY TO AVOID
DISTURBANCES.

If the units are equipped with an EMI suppression filter on the AC input, high leakage currents to the chassis are
generated. Always connect the earth connection first before any other connection. Danger to the operator can
occur if the units are not firmly connected to earth.

The units contain DC capacitors on the output of the DC line. Allow 5 minutes for the discharge of the capacitor
bank when the system is completely powered down and in any case, always check the absence of voltage on the
system terminals and at capacitors terminals prior to maintenance operations.

This equipment has been designed to be connected to class II power supplies with over voltages not
exceeding 2500 V peak. All precautions should be taken to stay within these limits.

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CONTENTS
1 INTRODUCTION ............................................................................ 4
2 PRESENTATION OF THE SYSTEM .............................................. 5
3 INSTALLATION .............................................................................. 7
3.1 HANDLING ............................................................................................... 7
3.2 INSTALLING AND SECURING THE RECTIFIER CHARGER ................. 9
3.3 INSTALLING THE BATTERY ................................................................. 10
3.4 ENVIRONMENTAL REQUIREMENTS (EXCLUDING THE BATTERY) 10
4 CONNECTIONS (refer to the PRODUCT drawing) ...................... 11
4.1 MAINS INPUT CONNECTION ............................................................... 11
4.2 BATTERY CONNECTION ...................................................................... 12
4.3 CONNECTING THE COMMON REMOTE ALARM OUTPUT ................ 12
4.4 CONNECTING THE LOAD .................................................................... 13
5 START-UP (refer to the product drawing) ..................................... 13
5.1 PRELIMINARY CHECKS ....................................................................... 13
5.2 SWITCHING ON..................................................................................... 14
5.3 START-UP PROCEDURE OF TPRE TD PARALLELED SYSTEMS ..... 15
5.4 BATTERY COMMISSIONING CHARGE................................................ 15
6 OPERATING INSTRUCTIONS ..................................................... 16
6.1 DEFAULT MENU.................................................................................... 16
6.2 MAIN MENU ........................................................................................... 16
6.3 HUMAN INTERFACE STRUCTURE ...................................................... 18
6.4 STATUS INDICATION DISPLAY ........................................................... 18
6.5 MONITORING FUNCTION..................................................................... 19
6.6 COMMAND FUNCTION ......................................................................... 22
6.7 CONFIGURATION FUNCTIONS ........................................................... 29
7 FUNCTIONAL DESCRIPTION ..................................................... 34
7.1 OPERATING SEQUENCES ................................................................... 34
7.2 CHARGE MODES .................................................................................. 35
7.3 PRINCIPLE OF OPERATION ................................................................ 35
7.4 "GCAU" GENERIC CONTROL AND ALARM UNIT (A1) ....................... 36
7.5 "TPC" THREE- PHASE CONTROL BOARD (A2) .................................. 36
7.6 DISPLAY BOARD (A300) AND KEYBOARD ASSEMBLY (A310) ......... 37
8 OPTIONS ...................................................................................... 37
8.1 ALARM/SIGNALLING/MEASUREMENT OPTIONS .............................. 37
8.2 COMMUNICATION OPTIONS ............................................................... 39
8.3 LOAD OPTIONS..................................................................................... 40
8.4 BATTERY OPTIONS .............................................................................. 40
8.5 CABINET OPTIONS ............................................................................... 43
9 PARALLEL OPERATION .............................................................. 44
9.1 REDUNDANT SYSTEM CONFIGURATION .......................................... 44
9.2 PARALLEL SYSTEM CONFIGURATION .............................................. 44
9.3 OPTIONS FOR PARALLEL SYSTEM CONFIGURATIONS .................. 44
10 MAINTENANCE ............................................................................ 45
10.1 PREVENTIVE MAINTENANCE VISIT.................................................... 45
10.2 FAN MAINTENANCE ............................................................................. 46
10.3 CAPACITORS MAINTENANCE ............................................................. 46
11 ELEMENTARY TROUBLESHOOTING ........................................ 46

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1 INTRODUCTION

This manual is designed to familiarize the user with the operating principles, use and maintenance of the PROTECT
RCS TPRe TD range of rectifiers fitted in floor mounted cabinets. TPR means Three Phase Rectifier and "e" means
"evolution" brought by the GCAU control card. TD means that this range is designed to fulfill the electrical energy
Transmission and Distribution (T&D) market specifications, although it can be used in other applications provided
that the related specifications and rules are compatible.

To use the system properly, the user should first read this manual carefully.

AEG is not be responsible for damage due to improper use, neglect, alterations, or use of other than original parts
without our written consent.

Equipment access areas:

- Operator: door closed.
- Maintenance personnel: door open.

IMPORTANT RECOMMENDATIONS:

ANY OPERATION ON THE EQUIPMENT SHOULD BE CARRIED OUT BY QUALIFIED PERSONNEL,

AWARE OF SPECIFIC ELECTRICAL HAZARDS AND PRECAUTIONS TO BE TAKEN.

LETHAL VOLTAGES EXIST PERMANENTLY ACROSS THE BATTERY TERMINALS.

DO NOT MAKE ASSUMPTIONS AS TO THE PRESENCE OR ABSENCE OF A VOLTAGE: CHECK

USING A VOLTMETER OR AN ELECTRICAL SAFETY TESTER.

WEEE INFORMATION

The disposal of this product is covered by a selective processing of some components. For
this provision of services, please contact our Customer Service.
Refer to standards 2002/95/EC (LSDEEE or RoHS) and 2002/96/EC (WEEE)

For general information about operating principles of the charger: please refer first to Chapter 7 "Functional
description".

SYSTEM DRAWINGS:

This manual comes with a standard drawing package.

These documents will be needed for any operation at site.
All the documents are accessible on AEG Power Solution download center web site, the link to this
site is available on the system.

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2 PRESENTATION OF THE SYSTEM
The battery charger is composed of the following items :

1. Floor standing cabinet with air inlets and outlets, including a natural cooling and a fan forced cooling roof
depending on the system rating
2. Charger electrical components on a mounting plate
3. Mains transformer
4. Options depending on the system configuration

The door of the cabinet is equipped with the man-machine interface (MMI) allowing the operation and monitoring
of the system.

Cabinet with natural cooling roof Components internal mounting plate (door open)

Air inlets MMI Front door options Transformer behind Charger mounting Front door
the mounting plate plate and options options

The PROTECT RCS TPRe TD range offers the following standard ratings and cabinet cooling features :

PROTECT RCS TPRe TD

BATTERY 24 36 48 60 110 125/127
VOLTAGE (VDC)
Output current (A) 20A 20A 20A 20A 20A (N) 20A (N)
(N) (N) (N) (N) 220kg 220kg
Cabinet cooling : 110kg 110kg 120kg 120kg
N=natural 25A 25A 25A 25A 25A (N) 25A (N)
F = forced (N) (N) (N) (N) 220kg 220kg
110kg 110kg 120kg 120kg
Cabinet weight (kg) 40A 40A 40A 40A 40A (N) 40A (N)
(N) (N) (N) (N) 240kg 240kg
120kg 120kg 140kg 140kg
60A 60A 60A 60A 60A (N) 60A (N)
(N) (N) (N) (N) 260kg 260kg
140kg 140kg 160kg 160kg
100A 100A 100A 100A 100A 100A (F)
(N) (N) (N) (N) (F) 280kg
160kg 160kg 180kg 180kg 280kg

“N means cabinet natural cooling, “F” means cabinet fan forced cooling

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 Charger internal layout description :

Charger standard components : Charger options (marked with (*)

 Input/output terminal block (X1-X2)  Analog rectifier output ammeter (P1)

 Mains input EMC filter (Z1) depending on  Analog rectifier output voltmeter (P2-F21)
charger rating  Front panel alarm LEDs (A6)
 Mains input breaker (Q1)  8 relays alarm card (A5)
 Mains input transformer (T1)  RS485 modbus communication (A71)
 Rectifier bridge (PR1) – can be equipped with a  TCP/IP communication for SNMP or Modbus over IP (A73)
cooling fan depending on charger rating  IEC61850 communication (A74)
 Rectifier shunt (R2)  Internal DC power supply (A30) to energize
 Rectifier output protection fuse (F1) communication options
 Filter capacitor (C1) with discharge resistor  Internal lighting (H7) protected by F71, connected on X7
 Load output switch (Q2)  Anti-condensation heater (E50) protected by F72,
 GCAU control card (A1) connected on X7
 Thyristor intarfe card (A2)  Blocking diode for paralleling (V21)
 Cooling fan on some ratings (M1)  3x outgoing feeders (Q21-Q22-Q23) connected on X20
 Common alarm terminal block (X12)  Battery output (X3-F3-K3-R3)
 Battery temperature sensor with 5m cable (SD1)
 Lifting eyes M10 – Qty 2

Front door details

Terminal block details

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3 INSTALLATION
The system is delivered as shown hereafter.

Natural cooling cabinet Forced cooling cabinet

The equipment is fixed onto a pallet.

3.1 HANDLING
The equipment must be handled with care, always in a vertical position. Labels on the outside of the package show
the top and bottom.

CAUTION:
The transport of the system can be performed as follows:
- on pallet,
- by crane (in presence of lifting eye bolts),
- by forklift truck.

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The TPRe TD rectifiers are delivered on pallets for easy handling using a pallet truck.
For the transport of cabinets, always watch for the center of gravity.
Check that the eye bolts are screwed fully home. The length of the slings calculated so that a minimum angle is
given between the cable and the top edge of the cabinet. The total weight shall be equally balanced between all
the slings. The minimum capacity of each sling must be  0.5 times the weight of the cabinet. One sling must be
used for each eyelet.
The lifting capacity of the handling equipment used must always be greater than the weight of the cabinets
(specified on the packages).
In case of vermin proof plate on the floor, the cabinet must be installed using slings.

CAUTION:
- Only transport the cabinets in an upright position!
- Never tilt or cant, always observe the centre of gravity!
- Always keep the battery cells in a vertical position.
- Never lift a battery cell by its connections.
- Do not put or drop objects on the battery.
- Do not stay or walk under suspended loads.
- Always wear protective clothings and accessories.

Instuctions for lifting using the eye bolts :

Cabinet with 4 lifting eye bolts Cabinet with 2 lifting eye bolts

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3.2 INSTALLING AND SECURING THE
RECTIFIER CHARGER
Select an installation site with the following characteristics:
- Ambient temperature and relative humidity as specified in section 3.4.
- Ambient air free from dust and corrosive gases.
- Floor sufficiently flat.
- Floor sufficiently strong to carry the weight of the equipment.
- Sufficient space at the front to open the door (see picture below).
- So that the cabinet will not be distorted, some wedges can be used to ensure the mechanical interface
between the floor and cabinet fixations. This ensures a correct tightening torque.
- For the distances between hole centre, the location and the diameter of the fixing holes, refer to the
customer drawings.

The maximum door opening is 180°.

The minimum door opening in order to
carry out the maintenance tasks is 120°.

CAUTION:
Securing the cabinets to the floor is recommended.

CAUTION:
Do not touch the metal section near the heating resistor.
Do not touch the rectifier bridge heatsinks.

Installing a single cabinet :

- For the distances between floor fixing hole centers, the location and the diameter of the floor fixing holes, refer
to the product drawings.
- Mark the cabinet position on the floor.
- Perform the drillings (four holes).
- Position the cabinet.
- Fix the cabinet to the floor.

CAUTION: Make sure that a minimum distance of 100mm is available on both sides in
order to have a correct air intake on the side panels ventilation meshes and to ensure a
proper cabinet cooling.

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3.3 INSTALLING THE BATTERY
The ground or floor must be strong enough to carry the weight of the batteries and/or stands or cabinets in which
they are mounted.

3.4 ENVIRONMENTAL REQUIREMENTS

(EXCLUDING THE BATTERY)
Storage in standard carboard packing box
Temperature: - 25°C to +70°C
Relative humidity: 15% to 90% in the original package.
Maximum storage period: 3 months.

Storage in seaworthy packing

Temperature: - 25°C to +70°C
Relative humidity: 15% to 90% in the original package.
Maximum storage period: 12 months.

For a storage period exceeding the values recommended above, contact the factory in order to know the
required environmental conditions and the maximum storage duration.

Operating
Temperature: 0°C to +50°C
Above 50°C and up to 55°C, the output current must be de-rated (1.25% per °C).
Relative humidity: 20% to 95 % (non-condensing).

Altitude
 1000 m
Above 1000 m and up to 4000 m, the output current must be de-rated (7% per 1000 m).

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4 CONNECTIONS (REFER TO THE PRODUCT
DRAWING)

ANY OPERATION ON THE EQUIPMENT SHALL BE CARRIED OUT BY QUALIFIED

PERSONNEL AWARE OF SPECIFIC ELECTRICAL HAZARDS AND PRECAUTIONS TO
BE TAKEN. NEVER ASSUME THE ABSENCE OF VOLTAGE, ALWAYS CHECK WITH
A VOLTMETER BEFORE ANY OPERATION ON A SYSTEM.

Always make the connections with power off and the circuit-opening devices in the "open" position:
- Mains and load protective devices or disconnecting switch open.
- Battery protective device or disconnecting switch open.
- Power switch to "OFF" (option).

If an external protection or cut-off device is mounted between the charger output and
the battery shunt, it is necessary to provide an auxiliary contact "position open" of
this device to open the battery current measurement to avoid damaging the control
system.
The external battery shunt must be inserted on the negative polatity of the battery,
never on the positive polarity as this will damage the charger control board.
Please contact AEG Power Solutions Customer Service Department.

4.1 MAINS INPUT CONNECTION

DANGER, IF THE RECTIFIER IS EQUIPPED WITH AN OPTIONAL INPUT FILTER:
MAINS INPUT: HIGH LEAKAGE CURRENT.
EARTH CONNECTION IS MANDATORY BEFORE CONNECTING THE MAINS SUPPLY.

It is mandatory to install a mains input protection in the mains switchboard, upstream the charger.

Recommended rating: 2 x charger nominal input current.

- The nominal input current is specified on the electrical characteristics page of the customer drawing package.
- As standard, the inrush current is less than 20 times the input current.

Connect the mains input to the terminal block located in the connection area.

The Protect RCD TPRe TD units are not phase rotation sensitive.

Remember to connect the earth bar to the site reference earth.

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4.2 BATTERY CONNECTION

IMPORTANT RECOMMENDATIONS

REFER TO THE BATTERY MANUAL.

Refer to the battery manufacturer's instructions for the storage conditions.
Never short-circuit a battery.

IN ANY CASE, a battery short-circuit and overcurrent protection must be

connected between the battery and the charger if the charger is not equipped with
such a protective device.

Allow no flame nor sparks in the battery room. Never smoke in the battery room.
Never disconnect a battery being charged.

To handle the electrolyte, use gloves and safety goggles.

The electrolyte contained in a battery is dangerous to the skin and clothes.
Before doing work on a battery, make sure that there is an accessible supply of
water nearby. If electrolyte is splashed, wash immediately with water and refer to
battery safety data sheets.

Use tools with insulated handles.

Remove the shipping plugs from "open" Ni-Cd batteries. Always use
maintenance accessories (especially electrolyte handling tools) suited to the
batteries.

Reminder
Battery cells must be connected in series, the(+) pole of each cell must be connected to the(-) pole of the next one.

+ - + - + - + - + -
BATTERY (+)

BATTERY (-)
- + - + - + - + - + 
Series connection of battery cells
Battery installation procedure :

. Position the battery cells on their support and connect them in series.
. Check that no cell is missing.
. Check that the connections are tight.
. Connect the battery (-) to the (-) BATT terminal of the charger (via the fuse box if applicable).
Do not connect the positive cable until start-up time.

4.3 CONNECTING THE COMMON REMOTE

ALARM OUTPUT
Refer to the customer drawing package.

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4.4 CONNECTING THE LOAD
Connect the load (+) to the load (+) terminal of the equipment.
Connect the load (-) to the load (-) terminal of the equipment.

5 START-UP (REFER TO THE PRODUCT

DRAWING)

5.1 PRELIMINARY CHECKS

All circuit-opening devices must be in the "open" position.
Check that the mains line protective device rating has the appropriate rating (see section 4.1).
Check that the mains voltage and frequency are compatible with the equipment (see equipment nameplate).
Check that the mains, battery and load connections are tight.
Check the polarities and that the battery cells are correctly connected in series.

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5.2 SWITCHING ON
- Leave the positive side of the battery open, either through protective or opening device (e.g.
fuse F13: case 1 below) or through the battery cable not connected to the (+) BATT terminal of the charger (case
2 below).

- Close the negative side of the battery (-) (fuse, protective device, etc … ).
- Close the mains protective devices. Turn on the mains input and the rectifier.

The rectifier starts and the display shows:

v x.y.z V x.y.z = software version of the display controller

After a few seconds, the display shows:

AEG PS-GCAU Vxx.yy and aa.bb are the software versions of the
Vxx.yy/aa.bb two micro controllers of the GCAU board

After a few seconds, the display shows the floating voltage and the rectifier current (at no-load).

DC:xx.xV 0.5A
NOTA: The current value can be around 0.5 A.
Alarms:

To check that the battery polarities are correct, take a voltage reading using a DC voltmeter as shown below:

F13 + BATT
- + BATT

V V
+ - + -

F14
- BATT - BATT
F1 F1
+ +

LOAD LOAD

- -

- Case 1 - - Case 2 -
Configuration with battery fuse F13 Configuration without opening device

The voltage reading must not exceed 30% of the nominal voltage (refer to the customer drawings).

. If the voltage is outside of this tolerance, check the battery cables for correct polarity.

. If the voltage is correct, close fuse F13 or connect the battery (+) cable to the rectifier terminal. The rectifier
will charge the battery. During this operation, arcing may develop across the actuated device.

- Check that the displayed current increases (current to the battery).

DC:xx.xV
3.0A

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 Dangerous voltages exist across the battery and/or load terminals. Take the
necessary safety precautions.

We recommend to change “user” and “supervisor” passwords to prevent bad

handlings. Refer to paragraph 6.7.3.

5.3 START-UP PROCEDURE OF TPRE TD

PARALLELED SYSTEMS
In the case of TPRe TD units with battery (each one) connected in parallel for redundancy, respect the following
instructions :

- Check that the output protective device of each unit is open.

- Start-up the rectifier-battery assembly n°1 according to the previous paragraph 5.2.

- Start-up the rectifier-battery assembly n°2 according to the previous paragraph 5.2

Then close the output protective device of each unit.

5.4 BATTERY COMMISSIONING CHARGE

For open lead-acid and Nickel-Cadmium batteries, at initial start-up, a commissioning charge can be performed
according to the battery manufacturer's instructions (refer to the battery manual).

Open load circuit.

From the command menu, set the rectifier to the commissioning charge (refer to paragraph 6.6.2).
The initial start-up current and time are factory set. Refer to the "System setup" menu (refer to paragraph 6.7.3.2)
to see the adjustment value.

At the end of the commissioning charge:

- from the "Alarm" menu, reset the "HIGH DC VOLTAGE" alarm. This alarm can be triggered when
returning from commissioning charge to floating charge.

WARNING : as the commissioning charge voltage is higher than the usual floating
and high rate charge levels, make sure that the DC output loads are disconnected
from the battery and charger before initiating the commissioning charge.

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6 OPERATING INSTRUCTIONS
The following section explains the basic operator menu structure of your system. It allows you to access all
necessary functions in order to operate your system.
The menus, indications and controls available depend on the system configuration.

The keyboard assembly has two LEDs indicators:

green LED: "System OK" (indicates proper operation).
red LED: "Fault" (a fault is present).

The green LED is always on in case no alarms are present.

In case an alarm is present, the red LED comes on and flashes.
If the alarm is acknowledged, the red LED is on permanently provided the alarm is still active.
If no alarms are active after an acknowledgement, the red LED will be switched off and the green LED comes on
again.

6.1 DEFAULT MENU

DC output voltage value
Output informations DC output current value (this
display value can be
customized )

DC:XX.XV
XX.XA

Alarms information
Number of alarms

Left key menu Right key menu

Middle key menu
The top line ("DC") will display the charger voltage and the load current with battery shunt or the total charger
current (battery + load) when the battery shunt is not active.

Hit any key to go to main menu

6.2 MAIN MENU

Rectifier status FLOATING CHARGE
More than 1 line can be displayed Monit Confg Cmnd
In this case, end is shown with
“--END OF LIST--” message Menu keys

The different rectifier statuses are:

- FLOATING CHARGE
- HIGHRATE CHARGE
- COMMISSIONING
- CHARGER OFF (see Chapter 11 "ELEMENTARY TROUBLESHOOTING for more explanations)
- BATTERY TEST.

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 5 minutes inactivity
- Menu overview -
Default menu
see § 6.1 Left key menu
Monitoring Measurements Output voltage, battery current, load voltage, AC voltage, battery temperature, ambient
temperature, battery charge, charger timer, date and time
see § 6.5 see § 6.5.1
Alarm list Alarm text, “RESET” alarm
Hit any key see § 6.5.2
History list Events and alarms text with date, time, and set point
Middle key menu
see § 6.5.3
Main menu Configure
Set language English or your local language
see § 6.2 see § 6.7 Access usually granted with "Supervisor" password
see § 6.7.1
only (access rights are factory configurable)
Set date and time Enter hour, minutes, month, day and year
see § 6.7.2 “Supervisor”
password
Setup Nominal settings, highrate options,
System setup
“User” battery selection, password setting…
see § 6.7.3 Access granted with "Supervisor"
password
Calibrate setup Calibrate voltage, temperature, password only (access rights are not
“Factory” ground fault… configurable)
protected level
Right key menu Alarm setup Low/high voltage, current,
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spare inputs… Access usually granted with "User" (partly)

Command Set high rate Password * and "Supervisor" passwords (access rights
Activate high rate or floating charge
see § 6.6 /floating (if activated) are factory configurable)
see § 6.6.1 Available only in charger mode
Set commissioning Password *
/floating Activate commissioning or floating charge
(if activated)
see § 6.6.2
Manual adjustment Available only in power supply mode
Voltage and current power supply adjustment
see § 0
Battery test Password *
Activate or deactivate battery test
(if activated)
see § 6.6.5
Clear history Password * Clear history entries
see § 6.6.6
Reset AH meter Password * Reset at 100% battery charge level
see § 6.6.7
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Adjust contrast +/- LCD contrast adjust

see § 0 * “User” or “supervisor” password
Note: According to your equipment configuration, some menus may be inactivated.
6.3 HUMAN INTERFACE STRUCTURE
The human interface is based on consistency in operation. Consistency means that the functions are grouped
logically within the menu structure and will provide ease of use for the operator.

The LCD Display has 2 lines by 16 characters. The top line is always used to indicate information while the bottom
line is used for the menu structure indication.

XXXXXXXXXXXXXXXX Information line

Monit Confg Cmnd Menu Line

There are three major menu groups under which all functions are located.

These groups are defined as:

 Monitoring Displaying analog measurements and alarms
 Configuration Configuring the system
 Commands Manually activated functions (High rate, Battery test etc.)

XXXXXXXXXXXXXXXX
Monit Confg Cmnd

The menu indication uses five basic menu functions with the following functions:
Next One step forward in the menu
Back One step back in the menu
View Display a selection
Enter Acknowledge an entry
Exit Always return to default menu

XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXX

Next Back Exit Next View Exit Next Enter Exit
The following sections will clearly explain how you can access the various functions.

6.4 STATUS INDICATION DISPLAY

As explained in the previous chapter the top line of the display will indicate information about the status of the
system. If more than one message is active, the messages are displayed in sequence. Each message is displayed
for 1 second before the next message is displayed.

The following messages are displayed:

Alarm texts of the active alarms
Charge status messages
Events

FLOATING CHARGE Information line

Monit Confg Cmnd

The messages are dynamic meaning they are updated continuously. If the alarm texts are latched you must go into
the alarm menu to clear the text from the display. Refer to section 6.5.2 for details.

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6.5 MONITORING FUNCTION
6.5.1 How to Display the Measurements

You will find the measurements menus under the Monitoring function. The Monitoring function will display all relative
meter indications on the top line of the LCD.

Follow the instructions below.

FLOATING CHARGE From the main menu select ‘Monit’.

Monit Confg Cmnd

MEASUREMENTS Select ‘View’.

Next View Exit

The top line ("Outp") will display the battery voltage and the total charger current (battery + load).
Display resolution is 1 decimal for V and A <100 and no decimal for values > 100.

Outp:28.4V 23.5A The ‘Next’ key can be used to scroll through all available
Next Back Exit measurements.

In order of appearance the following measurements can be displayed:

Load voltage and current*

Battery current (charge and discharge)*
Battery voltage and total charger current
AC input voltage*
Battery temperature*
Ambient temperature*
AH Meter*
Remaining charge time* (if in High rate or Commissioning charge)
Date and Time
Customized measurements (depends on system configuration)

* Menu can be disabled on customer demand.

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6.5.2 How to Display the Alarm List

You will find the Alarm list indication under the Monitoring function. This Alarm List indication will display all active
alarms on the top line of the LCD.

Follow the instructions below.

FLOATING CHARGE From the main menu select ‘Monit’.

Monit Confg Cmnd

MEASUREMENTS Select ‘Next’.

Next View Exit

Alarm List: XX
Next View Exit
The display indication XX shows you how many alarms are in the alarm list. The list shows Active alarms and Non-
acknowledged (Reset) alarms based on the alarm configuration. If a “LCD Latch” function is selected for an alarm,
it will remain in the alarm list even if the alarm condition has disappeared. In this case, a manual alarm reset will
clear it from the alarm list.

Select ‘View’.

LOW DC VOLTAGE
Next Back Reset
The alarm is shown in clear text on the top line. Pressing ‘Next’ will show you the next alarm in the list and pressing
‘Back’ will show you the previous alarm in the list.

If an alarm has not been acknowledged the text 'Reset' will flash. If the alarm is acknowledged and the alarm option
“LCD latch” was activated (see Alarm Setup for details), the alarm will be removed from the list provided the
condition of the alarm has been cleared.

If an alarm is associated with a signalling relay with latching, the display of this alarm is imperatively "latch" set.
The acknowledgment of the alarm using the display causes the acknowledgment of the associated relay too.

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6.5.3 How to Read the Alarm and Event Memory List (History List)

The control board GCAU in your system is equipped with an Alarm and Event list. The GCAU board stores the
alarm and events, in order of appearance, in a non-volatile memory (permanent storage). Events in this context
means indicating if the system has been switched to High rate, Float or Commissioning, Entering the setup mode,
Clearing the history etc.
The memory is based on a FIFO mechanism (First In First Out), which means that if the memory is full the oldest
event or alarm will be removed from the list.
The alarm and events are time/date stamped using an RTC (Real Time Clock).

Follow the instructions below.

FLOATING CHARGE From the main menu select ‘Monit’.

Monit Confg Cmnd

MEASUREMENTS Select ‘Next’ until the top line shows below text.
Next View Exit

HISTORY LIST :12 SOFTWARE VERSION

Next View Exit V02.2n / 2.2
Select ‘View’ Example

The “history list” screen indicates the quantity of Alarm and Event in the list.
Viewing the “history list” will display first the internal software versions of the GCAU board for reference. This
message is displayed for two seconds. After two seconds the display will show:

‘Event or alarm’ xx/12 : nn_ttt

Next View Exit Next View Exit
Top line shows “event or alarm” text.
A non permanent screen will indicate during 1 s the place (xx) of the “alarm and event” in the history list, its internal
code (xx) and its internal acronym (ttt).

Select ‘View’

Data: 24.0 Top line shows set point (alarm level) if valid (analog alarms only)
Next Back Exit

Pressing ‘Next’ will show the date and time of the Alarm/Event:

Date: 16/12/05 Time: 11:28:38

Next Back Exit Next Back Exit
Date format is dd/mm/yy (if temperatures unit is °C) or mm/dd/yy (if temperatures unit is °F).

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6.6 COMMAND FUNCTION
According to the factory set configuration, your system can have several specific command functions. All these
commands are accessible through the Command function ‘Cmnd’.

The different command functions are:

Manual High rate Charge
Manual Commissioning Charge
Manual floating Charge
Manual Adjustment of Voltage and/or Current
Battery Test Function
Clear History List
Set Display Contrast
Reset Ah meter.

6.6.1 How to Activate Manual High rate Charge

The Manual High rate charge is a command function and is located under the Command (‘Cmnd’) key. To prevent
accidental activation, this command can be password protected if required. Follow the instructions below.

FLOATING CHARGE Starting from the main menu, select ‘Cmnd’.

Monit Confg Cmnd

Press ‘Next’ until the following indication is displayed:

SET HIGH RATE WRONG PASSWORD

Next Enter Exit
Press ‘Enter’

Password: 1111
  Enter
With the right pointing arrow '' the digit position can be selected and with the arrow up '' an alphanumeric
character between 0 and 9 or between A and Z can be set. When all four characters are set, press ‘Enter’.
If the password is correct, the display switches to the High rate on/off selection.
Incorrect passwords will cause a jump of two positions back in the menu tree and a message ‘WRONG
PASSWORD’ is displayed.

If no password is activated the High rate selection menu will be shown directly.

Start High rate? Correct password

Yes Cancel
The high rate charge can be switched on by pressing the “Yes” key.

To stop the high rate charge, the user can manually put the rectifier in floating charge mode via the command menu
(see the 6.6.3 paragraph) or wait for the timer times out. In this last case, the rectifier switches automatically in
floating charge mode.
The remaining high rate charge time can be read on the LCD display via the measurements menu.
See paragraph 6.5.1.

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6.6.2 How to Activate Manual Commissioning Charge

The Manual Commissioning charge is a command function and is located under the Command (‘Cmnd’) key. To
prevent accidental activation, this command can be password protected if required.

Follow the instructions below.

FLOATING CHARGE Starting from the main menu, select ‘Cmnd’.

Monit Confg Cmnd

Press ‘Next’ until the following indication is displayed:

SET COMMISSION. WRONG PASSWORD

Next Enter Exit

Press ‘Enter’.

Password: 1111
  Enter
With the right pointing arrow '' the digit position can be selected and with the arrow up '' an alphanumeric
character between 0 and 9 or between A and Z can be set. When all four characters are set, press ‘Enter’.
If the password is correct the display switches to the Commissioning on/off selection.
Incorrect passwords will cause a jump of one position back in the menu tree and a message ‘WRONG
PASSWORD’ is displayed.

If no password is activated the Commissioning selection menu will be shown directly.

Set Commission.? Correct password

Yes Cancel

With ‘Yes’, the Commissioning charge can be switched on.

To stop the commissioning charge, the user can manually put the rectifier in floating charge mode via the command
menu (see paragraph 6.6.3) or wait for the timer times out. In this last case, the rectifier switches automatically in
floating charge mode.

The remaining commissioning charge time can be read on the LCD display via the measurements menu. See
paragraph 6.5.1.

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6.6.3 How to activate Manual Floating Charge

When you are in high rate or commissioning charge mode, you can manually switch the rectifier in the floating
charge mode. Follow the instructions below.

HIGHRATE CHARGE COMMISSIONING

or
Monit Confg Cmnd Monit Confg Cmnd

Starting from the main menu, select ‘Cmnd’.

Press ‘Next’ until the following indication is displayed:

SET FLOATING Press ‘Enter’..

Next Enter Exit

Start Floating? Floating charge can be switched on by hitting the

‘Yes’ key
Yes Cancel

6.6.4 Manual Voltage and Current adjustment (OPTION)

If required, your system can be programmed as a power supply. It allows you to adjust the output voltage and
output current over a wide range. Both functions can be activated independently.
When only the output current adjustment is activated, the output voltage is the voltage of the current charge
(floating, highrate, commissioning).

Warning:
Do not activate this option when the charger is used for normal battery charging. Consult the nearest agent of your
system if you want to use this option. Activating this option without the necessary system knowledge can damage
the connected battery.

The rectifier operates as a power supply only. It delivers the adjusted voltage and, if activated, the manually adjusted
current. If the manual current adjustment is not activated the current limit is as specified on the nameplate of your
system.
The voltage adjustment is configured to operate within a window.

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How to Adjust the Voltage and Current (Manual Adjustment)

The procedure below explains how to adjust the voltage and current if the manual Voltage and/or Current option is
activated.

FLOATING CHARGE POWER SUPPLY

Monit Confg Cmnd Monit Confg Cmnd
Current adjustment only activated or Voltage adjustment activated
(current adjustment activated or no).

Starting from the main menu, select ‘Cmnd’.

MAN.ADJUSTMENT
Next Enter Exit
Press ‘Next’ until the text ‘ADJUSTMENT’ is displayed and press ‘Enter’.

ADJUSTMENT SET NOT ALLOWED

Volts Amps Exit
From this menu, the Voltage or Current adjustment can be selected. If one of these options is not active and the
function is selected, a message ‘SET. NOT ALLOWED’ is displayed for two seconds.

If you need to set the voltage, press ‘Volts’. If you need to set the current press ‘Amps’.

28.4 <- 28.2V 75.0 <- 68.2A

  Back   Back
Left: display of setpoint value (change with up or down arrow key).
Right: display of actual value (measurement).
When you press the arrow up '' the voltage or current increases. The arrow down '' will decrease the voltage
or current.
The values are saved in the system memory ensuring the values are permanently stored. Adjustment Resolution
is 1 decimal V or A <100 and no decimal for values >100.

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6.6.5 Battery capacity test Function (OPTION)

The Battery Test feature can be used to test the battery performance. The test can be initiated manually or
automatically.

Three programmable parameters define the battery test:

Discharge Current
End Voltage
Tolerance percentage.

Warning:
Contact the nearest agent of your equipment for details of the above settings.

Wrong settings can cause mis-interpreted battery performance or loss of DC power.

6.6.5.1 How to Activate the Battery Test

Before activating this test, make sure you are familiar with the Battery Test Operation as further described in
paragraph 0 BATTERY CAPACITY TEST.

Follow the instructions below.

FLOATING CHARGE
Monit Confg Cmnd
Starting from the main menu, select ‘Cmnd’.

Select ‘Next’ until the following menu is displayed.

BATTERY TEST WRONG PASSWORD

Next Enter Exit

Press ‘Enter’.

Password: 1111
  Enter
If protected by a password enter the password here.
With the right pointing arrow '' the digit position can be selected and with the arrow up '' an alphanumeric
character between 0 and 9 or between A and Z can be set. When all four characters are set, press ‘Enter’.
If the password is correct, the display switches to the Battery Test on/off selection. If the password is incorrect, a
message ‘WRONG PASSWORD’ is displayed for two seconds and the menu jumps one position back in the menu
tree.

Battery test Correct password

On Off Exit
Activate or de-activate the Battery Test by selecting 'On' or 'Off'.
The display will show if the battery test is on or off.

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6.6.6 How to Clear the Event and Alarm History List

If required, the event and alarm history list of your system can be cleared from the front panel. A password on
Supervisor or User level is mandatory to clear the list.

Follow the instructions below.

FLOATING CHARGE
Monit Confg Cmnd
Starting from the main menu, select ‘Cmnd’.

Select ‘Next’ until the following menu is displayed.

CLEAR HISTORY WRONG PASSWORD

Next Enter Exit
Press ‘Enter’.

Password: 1111
  Enter
A Supervisor or User level password is required to continue.

With the right pointing arrow '' the digit position can be selected and with the arrow up '' an alphanumeric
character between 0 and 9 or between A and Z can be set. If all four characters are set, press ‘Enter’.

When the password is correct, the display switches to the Clear History Yes/No selection. If the password is
incorrect, a message ‘WRONG PASSWORD’ is displayed for two seconds and the menu jumps one position back
in the menu tree.

Clear History ? Correct password

Yes No Cancel
Clear the History list by pressing the ‘Yes’ key. Pressing ‘No’ will cause a jump two menus back.

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6.6.7 How to reset Ah Meter (OPTION)

FLOATING CHARGE
Monit Confg Cmnd
Starting from the main menu, select ‘Cmnd’.

Select ‘Next’ until the following menu is displayed.

AH METER = 100 WRONG PASSWORD

Next Enter Exit
Press ‘Enter’.

Password: 1111
  Enter

A Supervisor or User level password is required to continue.

With the right pointing arrow '' the digit position can be selected and with the arrow up '' an alphanumeric
character between 0 and 9 or between A and Z can be set. If all four characters are set, press ‘Enter’.
When the password is correct, the display switches to the ‘Ah Meter = 100’ Yes/No selection. If the password is
incorrect a message ‘WRONG PASSWORD’ is displayed for two seconds and the menu jumps one position back
in the menu tree.

Ah Meter = 100 Correct password

Yes No Cancel

Reset Ah meter by pressing the ‘Yes’ key initiates the battery Ah counter to 100% and causes a jump to the default
menu. Pressing ‘No’ or ‘Cancel’ will cause a jump to ‘AH METER = 100’ menu.
This manipulation must be always done before a manual battery test.

6.6.8 How to Adjust the Display Contrast

Adjusting the Contrast from the Default Menu :

When the contrast is too low to read the display, the contrast can be adjusted directly from the default menu. If the
leftmost button from the default menu is held, the contrast will be decreased. If the rightmost button from the default
menu is held, the contrast will be increased. If you are not sure whether the default menu is displayed, do not touch
any button for 5 minutes. This will automatically activate the default menu.

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6.7 CONFIGURATION FUNCTIONS

6.7.1 How to Change the Language

Two languages are available in your GCAU board: the standard language (English) and a second one: the one you
specified when you ordered your equipment.

To change the language, follow the instructions below:

FLOATING CHARGE Starting from the main menu select ‘Confg’.

Monit Confg Cmnd

SET LANGUAGE Select ‘Next’ until the following menu is displayed.

Press ‘Enter’.
Next Enter Exit

Language:English Press ‘Next’ until the desired language is shown.

Pressing the ‘Change’ key will update the selected
Next Change Exit language.

6.7.2 How to set Date and Time

FLOATING CHARGE Starting from the main menu select ‘Confg’.

Monit Confg Cmnd

SET DATE & TIME Select ‘Next’ until the following menu is displayed.
Next Enter Exit Select ‘Enter’.

Hours: 10 Use the up/down arrows to select the set point of hours.
  Enter Hit ‘Enter’ key to go to next menu.

Use the up/down arrows to select the set point of minutes.

Minutes: 12
Hit ‘Enter’ key to go to next menu.
  Enter

Use the up/down arrows to select the set point of month.

Month: 4 Hit ‘Enter’ key to go to next menu.
  Enter

Day: 12 Use the up/down arrows to select your the set point of
  Enter day. Hit ‘Enter’ key to go to next menu.

Year: 2006 Use the up/down arrows to select the set point of year.
Hit ‘Enter’ key to come back to the ‘SET DATE & TIME’
  Enter menu.

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6.7.3 Setup

The setup menu is accessible with a “user” or “supervisor” password and it allows
the modification of your system configuration. The default “user” password is
1111. For supervisor access password please contact factory. Any modification of
your system configuration is your responsibility. You risk damages on your battery
or equipment if the modification is done by a non specialized staff.

According to the factory setting configuration, the access to the "alarms" and "system" setup menus can differ. The
following paragraphs describe the menus access usual setup for a standard equipment. When a menu is not
accessible to the user, it is not displayed. When there is no menu accessible to the user, the message "SET NOT
ALLOWED" is displayed.

6.7.3.1 How to change “user” and “supervisor” password

Enter the Password setting as follows:

FLOATING CHARGE Starting from the main menu select ‘Confg’.

Monit Confg Cmnd

SETUP
Next Enter Exit Select ‘Next’ until the following menu is displayed.
Press ‘Enter’.

Password: 1111 With arrow keys, select the “supervisor” password and hit
  Enter ‘Enter’ key.

SYSTEM SETUP Enter the system setup by hitting ‘Enter’ key.

Next Enter Exit

BATT.SELECTION Select ‘Next’ until the above menu is displayed.

Next Enter Exit

PASSWORD SETTING Select ‘Change’ to enter the password setting menu.

Next Change Exit

The first menu is to change the “supervisor” password.

SUPERVISOR LEVEL Select ‘Change’.

Next Change Exit

NEW PASSW: 1111 With arrow keys, enter the new “supervisor” password
and hit ‘Enter’ key.
  Enter

VERIFY NEW: 0000 With arrow keys, confirm the new password and hit
  Enter ‘Enter’ key.

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 We can distinguish 2 scenarios:

PASSWORD CHANGED or NOT THE SAME

In the second case, you must start again.

USER LEVEL
Next Change Exit

For the user level, apply the same procedure.

6.7.3.2 System setup

With the “supervisor” password, you have access to the following setup:
Battery selection: to select battery type, number of cells etc…
Nominal settings: to select mains, floating or high rate voltages, limit currents etc…
Meter selection: to select °C or °F.
High rate options: to allow manual high rate charge, activate the password protection etc…
Commissioning options: to allow manual, activate password, select commissioning parameters.
Manual adjustment: to switch the rectifier in the power supply mode.
Battery test options: to select battery test parameters.
LVD function: to select Low Voltage Disconnect parameters.
Temperature compensation: to implement the battery voltage temperature compensation (option).
Communication options: to select serial communication parameters.
Charge protections: to set battery charge limits.
“User” and “supervisor” passwords setting: to change “user” or “supervisor” passwords.
Output cable drop compensation

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 6.7.3.3 Alarms and events setup

The alarms setup menus are available with the “user” password and enable to set up the thresholds and the time-
delay of the accessible alarms.
The "supervisor" password enables to set up all parameters of the accessible alarms and events.

Alarms list:
High mains voltage alarm parameters.
Low mains voltage alarm parameters.
Charge fault alarm parameters.
High battery voltage alarm parameters.
Low battery voltage alarm parameters.
High DC voltage alarm parameters.
Low DC voltage alarm parameters.
Ground fault + alarm parameters.
Ground fault – alarm parameters.
Charger current limit alarm parameters.
Battery current limit alarm parameters.
High charger current alarm parameters.
High battery current alarm parameters.
High temperature alarm parameters.
Temperature sensor error alarm parameters.
Internal communication error alarm parameters.
Battery test failed alarm parameters.
Battery test abort alarm parameters.
High battery temperature alarm parameters.
Long charge time alarm parameters.
No power supply voltage alarm parameters.
Battery operation alarm parameters.
Battery symmetry alarm parameters.
Service alarms parameters (if applicable and activated at factory).

Procedure to activate an alarm which is disabled :

FLOATING CHARGE Starting from the main menu, select ‘Confg’.

Monit Confg Cmnd

SETUP Select ‘Next’ until the following menu is displayed.

Next Enter Exit Select ‘Enter’.

A Supervisor or User level password is required to continue.

Password: 1111 With the right pointing arrow '' the digit position can be selected
  Enter and with the arrow up '' an alphanumeric character between 0 and
9 or between A and Z can be set. If all four characters are set, press
‘Enter’.

Select ‘Next’ until the menu ‘Alarm setup’ is displayed,

SYSTEM SETUP then select ‘Enter’
Next Enter Exit

ALARM SETUP
Next Enter Exit

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 HIGH MAINS VOLT Select ‘Next’ until the required alarm name is displayed,
Next Enter Exit then select ‘Enter’. Example on ‘Charger current limit’

CHARGER CURR.LIM
Next Enter Exit

FUNCTION : OFF Select ‘Next’ until the ‘Function’ section is reached

  Next Use the arrow keys to select ‘ALARM’

FUNCTION : ALARM Select ‘Next’ until the following menu is displayed

  Next

CHARGER CURR.LIM Select ‘Exit’ to save the changes

Next Enter Exit

6.7.3.4 Calibration setup

All these setup menus are available with a “supervisor” password.

Battery voltage.
Positive battery current.
Negative battery current.
Charger current.
Earth impedance.
Load voltage.
Mains voltage.
Ambient temperature.
Battery temperature.

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7 FUNCTIONAL DESCRIPTION
The Protect RCS TPRe TD rectifiers are thyristor-controlled rectifiers suitable for charging nickel-cadmium or lead-
acid batteries while supplying DC loads. The rectifier can be also used without batteries as direct power supplies.

7.1 OPERATING SEQUENCES

Rectifier with associated battery
Mains power ON – battery on floating
            
   
Charger Load

Ild

Ifl
BT

The charger supplies the load (Ild) and delivers a "floating" charge current (Ifl) to battery BT.

Mains power ON – battery recharging

   Charger     
Load   
  
Ild   
  
Ihr
  
Ifl
BT

The charger recharges battery BT at a high rate (Ihr) and supplies the load (Ild). The charger automatically switches
to "floating" charge (Ifl) when the battery is fully charged.
Thereafter the battery is kept in floating (Ifl).

Mains power OFF      

   Charger
     
Load   
       

Mains

Ild
BT

The battery immediately substitutes for the charger in supplying the load (Ild).

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7.2 CHARGE MODES
The following battery charge modes are available (depending on the equipment):

Floating charge
Floating charge compensates for the self-discharge of the battery and, in normal operation, maintains the battery
in a fully charged condition.

High rate charge (or equalizing charge)

High rate charge restores the battery to full capacity.
Depending on the equipment, it can be activated:
- manually from the keyboard,
- automatically by the system which monitors the state of charge of the battery (mains off or rectifier in current-
limiting mode or on Ah drop),
- periodically by the system at fixed intervals (1 month, 6 months, 1 year: depending on factory setting).
The high rate charge time is factory-set to a value in the range from 0 to 99 hours.
During high rate charge, the remaining charge time can be displayed.

Commissioning charge (or boost charge) (option)

This mode can be used for initial battery charging and is manually activated from the front display.

Note : High rate and commissioning charges shall be activated depending on the batery manufacturer
recommendations. Refer to battery supplier’s operation manual.

7.3 PRINCIPLE OF OPERATION

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 The mains voltage is applied to the primary winding of the power transformer via the standard mains input breaker.
The rectifier is then in service, provided no fault has been detected and/or stored by the monitoring systems.
The power converter consisting of a full thyristor bridge rectifies the transformer secondary voltage.
The rectifier current is smoothed by an inductor integrated inside the transformer and the voltage is filtered by
capacitors.
The rectifier current is sensed across a rectifier shunt. A blocking diode (option) is connected to the rectifier output
and is used to isolate a faulty unit while the rectifiers are in the parallel configuration.

The GCAU control board is supplied either by the auxiliary secondary winding of the transformer or from the battery.
The GCAU board controls the power converter from internal references (which depend on the battery type and the
current charge mode) to regulate the rectifier output voltage and/or current. There is a protective fuse inserted in
the positive output polarity of the rectifier.

The battery current is sensed across a battery shunt (option).

A temperature sensor senses the battery temperature and compensates the rectifier output voltage according to
the temperature (option).

7.4 "GCAU" GENERIC CONTROL AND ALARM

UNIT (A1)
This board has two dedicated microcontrollers, memories for the microcontroller and all necessary analog interface
circuits to measure and control. The board is installed inside the cabinet, on charger mounting plate.

The board consists of two major functional blocks:

- an analog block providing the following main functions:

. analog signal (current and voltage) matching,
. synchronisation (in case of single phase),
. power converter thyristor gate firing by electrically isolated pulses (for single-phase only),
. electronic circuits power supply ,
. analog control signal 0-10V.

- a digital block with two micro controllers providing the following main functions:
. analog input (voltage, current and temperature) measurement,
. digital input/output monitoring,
. system operating and monitoring sequences controlled by a program stored in memory,
. setpoint (reference) generation for the analog regulators,
. full digital control algorithm (separate micro controller),
. serial communication for remote monitoring/programming,
. serial communication for display unit,
. on- board Flash memory and EEPROM.

The fuses for GCAU and TPC boards protection are integrated on the charger mounting plate.

7.5 "TPC" THREE- PHASE CONTROL

BOARD (A2)
The board is controlled via a link cable connected to the GCAU board.
The TPC has all necessary electronics to synchronise to the secondary transformer voltage and to control the
thyristors.
The board is phase insensitive meaning it will operate with all possible phase rotations.

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7.6 DISPLAY BOARD (A300) AND KEYBOARD
ASSEMBLY (A310)
The display board is mounted on the front of the system and is controlled by the GCAU board, via the interface
board A4. 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. The display is a 9mm character height two line
by sixteen-character alpha numeric LCD with LED backlight.
The Keyboard is connected to the display unit which decodes the three operating buttons and controls the two
indicator LEDs.
The display board is equipped with an USB type B port, which offers an insulated communication port for
maintenance purpose.

8 OPTIONS
The following options are part of the product portfolio and are clasified in two categories :

 Plug-in type : the option is delivered loose and can be plugged inside the equipment at site. Such option might
need some settings from the display and keyboard in front of the charger, or using the maintenance software
“Factory Sparc”.
 Factory integrated type : the option is integrated and tested in the charger during manufacturing process.

8.1 ALARM/SIGNALLING/MEASUREMENT
OPTIONS
8.1.1 LED box (A6) – Factory integrated type

The front door of the rectifier can be equipped with 16 electroluminescent diodes and related texts.
The LEDs indicate alarm or events as configured in the GCAU board.
The lighting of the LEDs can be tested through a long press (5 seconds) on the middle key (in default menu) of the
display/keyboard.
The default parameters available on this LED box and the LED colours are the following :

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8.1.2 Relay boards (A5) – Plug-in type

Relay boards A5 provide remote signalling of individual alarms on 8 dry contacts relays. The connection is achieved
on screw type terminals. The board cable is connected as per folio “I2C communication buses” in product drawing.
The default alarms available on alarm card are the following :

Alarm contact electrical details :

How to instal and activate this option on the control card : Refer to the option installation manual

8.1.3 Supplementary meter functions – Factory integrated type

As standard, load voltage and current, date and time are displayed in the measurements menu.

Your equipment can have supplementary meter functions if the battery output function is integrated :
"Ibatt meter", "Ah meter"

"Ibatt Meter"
If the system is equipped with the battery shunt option and "Ibatt Meter" is activated, the battery charge and
discharge currents can be displayed. The "-" sign preceding the displayed value indicates a discharge condition. In
this case, the load current will correspond to the rectifier current minus the battery current.

"Ah Meter"
The ampere-hour meter measures the battery charge and discharge Ahs. This value is displayed as a percentage
of the initial battery capacity.
The ampere-hour meter reads 100% in the following cases:
- the counting reaches 100%,
- the system has been operating in the floating mode for at least 100 hours.
NOTE:
During battery recharging, only 80% of Ahs are taken into account (battery average efficiency when recharging).
(Note: Efficiency factor is programmable).

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8.1.4 Analog meters – Factory integrated type
The digital measurements can be associated with needle analog meters (on the front panel). These meters provide
a direct reading of voltage and current.
These options are available for:
- Charger voltage and current.

8.1.5 Ground fault detection – Plug-in type option

The option is integrated into the GCAU board.

The ground fault detection circuit monitors the impedance of the connection between ground and the positive and
negative polarities of the DC output.
An alarm is delivered on detection of a leakage current 10 mA between ground and one of the output polarities.

How to activate this option on the control card : charger display, refer to § 6.7.3.3 “alarms and events”

8.2 COMMUNICATION OPTIONS

Depending on configuration the Protect RCS rectifier charger can be equipped with the following communication
options.

8.2.1 RS485 – Modbus RTU interface connection – Factory integrated type

This option includes is a piggy-back board (A71) connected to the extension bus of the GCAU control board and
additional EIA485 interface & connecting board (A72). It allows to connect several rectifier systems on one common
communication bus (centralized supervision of the rectifers) to communicate locally or remotely with a computer.

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 control each individual rectifier.

A 2,5 m cable with RJ (6/6) is supplied with this option to connect A71 and A72 boards.

The communication port is fully isolated from the charger output and/or internal control.

The complete MODBUS mapping of the various parameters are available.

The Communication speed is 2400, 4800, 9600, 19200 or 38400 Bauds.

For more details please refer to separate Modbus operation manual document.

8.2.2 IEC 61850 Server interface – Plug-in type

The Modbus RTU interface connection option needs to be installed in the charger so that the IEC61850
communication can be implemented.

Rectifier Alarms / Status and Analog measurements are cyclically polled from the rectifier supervision control board
GCAU A1 by the gateway and translated to IEC 61850 protocol available at the RJ45 Ethernet port.

The detail description is available in the separate IEC 61850 Server interface manual document.

How to instal and activate this option on the control card : Refer to the option installation manual

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8.2.3 TCP/IP Communication – Plug-in type

This option includes a NCS board connected to A71 (RS232 board) and allowing TCP/IP communication with the
GCAU control board. The Modbus RTU interface connection option needs to be installed in the charger so that the
TCP/IP communication can be implemented.
The board provides the following protocols: HTTP (Web navigator), SNMP, connection to Winsparc via a network,
Modbus TCP.

How to instal and activate this option on the control card : Refer to the option installation manual

For more details please refer to separate NCS manual document.

8.3 LOAD OPTIONS

8.3.1 Blocking diode – Factory integrated type

This diode is used to allow the charger to be connected to a second changer and prevents any reverse
current to flow inside the charger.

8.3.2 Supplementary protective devices – Factory integrated type

The protective devices (circuit breakers) are provided for the load lines protection.
The characteristics of those breakers are : 16A – C tripping curves, 6kA short circuit current.

8.3.3 Additional DC filtering – Factory integrated type

Additional DC filtering (additional capacitor or/and chokes) provides low voltage ripple on DC output without battery.
When the battery is connected, the ripple current of the battery is minimized by the additional filter.
1 % filter or 0.1% filter are available.

8.4 BATTERY OPTIONS

8.4.1 Battery output – Factory integrated type

The charger can be equipped with a battery connection branch composed of :

 A battery shunt for battery current measurement.
 A battery end of discharge contactor to protect the battery from deep discharges.
 A battery protection fuse adapted to the charger rating.
 Battery terminals.

Attention : make sure that the battery short circuit current generated by the battery is compatible with the fuse
protection rating and curve.

8.4.2 External battery protection devices – Plug-in type

A battery protection box can be fitted with the equipment. Refer to the option installation manual

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8.4.3 Battery temperature compensation – Plug-in type

The chargers can sense the battery ambient temperature. The sensor is located in a metal lug and can be mounted
to the wall, on the battery rack or inside the battery cabinet by a screw. The connection from sensor to board is a 4
wire telephone cable. The sensor is used to compensate the floating voltage or the high rate voltage if necessary
and is delivered with a 5m cable.

How to instal and activate this option on the control card : Refer to the option installation manual

8.4.4 Cable drop compensation

The rectifiers can be programmed (cable drop parameter) to compensate for cable voltage drop between the system
and the battery without the need of remote sensing.
If battery current limit/display option is present:
The output voltage will be increased as a function of the battery recharge current.
If battery current limit/display option is not present:
The output voltage will be increased as a function of the load current.

This option is used when load cables are connected to a common bus bar on which the battery and the load are
connected.

Voltage measurements on the display:

“Outp” (measurement menu): compensated voltage (value from calculation).
“DC” (default menu) and Load (measurement menu): actual voltage

Note: the cable drop parameter is the reverse function of “droop” factor used for passive load sharing.

Cable drop parameters setting procedure :

 Connect a load on the load output of the common DC bus.The load shall be as close as possible to the charger
nominal current to have a good adjustment accuracy.
 Measure the voltage drop across the cables : ΔUmeasured = V1-V2
 If the charger current during the test is different from its nominal value, calculate the equivalent voltage drop for
the nominal current : ΔUnominal = ΔUmeasured x charger nominal current / current during the measurement
 Enter the ΔUnominal value in the control card and through the display following the procedure below :

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 Enter the Password setting as follows:

FLOATING CHARGE Starting from the main menu, select ‘Confg’.

Monit Confg Cmnd Select ‘Next’ until the following menu is displayed.

SETUP Select ‘Enter’.

Next Enter Exit

Password: 1111 With arrow keys, select the “supervisor” password and hit
‘Enter’ key.
  Enter

SYSTEM SETUP Enter the system setup by hitting ‘Enter’ key

Next Enter Exit

BATT.SELECTION Select ‘Next’ until “Regul Setup” is displayed, then select

Next Enter Exit ‘Enter’.

REGUL SETUP
Next Enter Exit

DROP : 1,2 With arrow keys, reach the required value and hit ‘Enter’
  Enter key to come back to the ‘REGUL SETUP’ menu.

8.4.5 Battery capacity test

Battery current output option is necessary for this option.

In order to check the battery performance, a battery test can be activated. The battery test discharges the battery
until a predefined voltage. It discharges the battery with a constant current. To achieve this, the charger output
voltage is slowly decreased until the battery discharge current reaches the desired level. Both charger and battery
will deliver current. This ensures you do not loose system performance in case a battery is in a bad condition or
has an open cell.
The battery test can only be performed on a 100% charged battery and should discharge the battery up to 60%.

The Battery test can be activated by the operator/serial command or can be initiated periodically.
If initiated periodically but the conditions to start the battery test is not met (see below), the battery test will be
postponed 24 hours and a new try is given. After three retries the test will be terminated until the next periodic cycle.
During the three retries the periodic counter is stopped and started again after the battery test is initiated.
If the battery test is manually initiated and periodic battery test is active as well, the periodic timer is reset upon
selecting manual battery test to prevent sequential battery tests.
The time needed to reach the End Voltage level is compared to the time of the previous battery test. This previous
time is multiplied with a tolerance factor to compensate for battery performance. If the time is shorter than this
reference time, an alarm “BATT.TEST FAILED” is generated. If the time is longer than the predefined time, or
within the defined percentage, a text “BATT.TEST PASSED” is generated. This is not an alarm situation but only
a message. It will disappear from the screen as soon as another function is selected from the front panel. In both
cases this event is written to the history list. If the time is longer than the predefined time, this new time is updated
and will be used as the reference for the next battery test.

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 Vbatt
reference duration

test duration : new reference duration time

test starts test stops

The first time the battery test is performed the reference time is 0. This ensures that the first battery test logs a time
greater than the reference time.
Note:
If required, you can manually set the reference time to 0. Go to the Battery Test Setup in the System Setup and
select the discharge current. If you change this setting, the reference time will be set to 0 once you leave the setup.
(If you do not want to change the value, just go up and down with the setting until you have the previous setting.
This will have the same effect).
The Battery test is not allowed under the following conditions:
AC Failure
Standing load < discharge current
Battery capacity < 100%
Battery current is negative (Discharge)
System in High rate or commissioning charge

If you try to activate the battery test manually from the front panel and any of the above conditions is detected, the
top line will show the message “TEST NOT ALLOWED” for two seconds.
If an AC failure occurs during the battery test, the test will be cancelled and the system will return to normal operation
when the mains return.
The Battery test is aborted under the following conditions:
AC Failure
Manual Stop (From display, serial port or external digital input).
Discharge current is lower than the required current for 5 minutes.

In any of these cases, the battery test will be aborted and an alarm “BATT.TEST ABORT” is generated. This alarm
can be acknowledged (reset).

8.5 CABINET OPTIONS

8.5.1 Eye bolts – Plug-in type

For the handling of the system, the cabinet can be equipped with two eye bolts. Refer to the option installation
manual.

8.5.2 Cabinet heater and interior lighting – Factory integrated type

The cabinets are fitted with light and heating resistor. This circuit shall be supplied by a mains protected by a circuit
breaker or a fuse, maximum rating 10A.
The heater circuit must be supplied with an auxiliary mains of 110 VAC to 230 VAC during storage, before system
energization and during periods when the rectifier is not operating.
The heater can be isolated separately from the mains by opening F72 fuses.

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9 PARALLEL OPERATION
The Protect RCS rectifier charger can operate also as parallel system. The following configuration are available:

System:
Redundant - for a charger and/or battery redundancy.
Parallel - to increase the power or to increase the battery capacity.

Battery :
Common the chargers in parallel are connected to a common bus on which a single battery is connected.

Depending on the configuration the different options can be used in the system. The output blocking diode is
mandatory for this operation mode.

9.1 REDUNDANT SYSTEM CONFIGURATION

The purpose of a redundant system is to obtain maximum availability of the load supply, including any fault of the
battery chargers. The redundant configuration facilitates also the on-site maintenance operation.

In a redundant system, the aim is to limit the “common mode failures” between the 2 chargers: avoid anything that
could lead to the spread of a fault, of a process or a component failure, of a power source failure (charger, battery
etc.) to another, in order to ensure permanent supply of the load.

The “decoupling” method chosen in the Protect RCS is the most reliable one.

9.2 PARALLEL SYSTEM CONFIGURATION

The paralleling of the systems in not redundant configuration is used to increase of the power of the chargers.

The paralleling of the systems is used also for increasing the battery capacity when the direct paralleling of the
battery strings is not authorised (e.g.: VO battery). In this case, the management of each battery string is
independent. This topology system ensures optimum management of each battery string in terms of availability
(recharging), monitoring and ageing.

9.3 OPTIONS FOR PARALLEL SYSTEM

CONFIGURATIONS
The options described below are used depending on the system configuration

9.3.1 Passive Load sharing (“droop” factor) function

The option is a function of the GCAU control bard. It is used when two rectifiers are connected in the parallel
configuration and load sharing is required.

The load sharing is passive and is based upon changing the slope (“droop” factor parameter) of the rectifier output
voltage according to its output current. The droop factor reduces the output voltage if the system current rises.

The on-site installation must as far as possible minimize connection or installation dissymmetry (thermal conditions,
lengths and wire sections, protections etc.) of the chargers towards the batteries and the load.

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10 MAINTENANCE
AEG Power Solutions can provide a Global Service capability through regional Service Centres.

Electronic boards are sensitive to E.S.D. (electrostatic discharge).

When not installed in the equipment, they are delivered in antistatic bags.
Before handling a board, the operator must take care to be at the same potential as the
equipment to be worked on and take all customary precautions.

ANY OPERATION ON THE EQUIPMENT SHOULD BE CARRIED OUT BY QUALIFIED

PERSONNEL AWARE OF SPECIFIC ELECTRICAL HAZARDS AND PRECAUTIONS TO
BE TAKEN. NEVER ASSUME THE ABSENCE OF VOLTAGE, ALWAYS CHECK WITH
A VOLTMETER BEFORE ANY OPERATION ON A SYSTEM.

THE DC OUTPUT IS EQUIPPED WITH FILTERING CAPACITORS, DANGEROUS

VOLTAGES CAN REMAIN EVEN IF THE CHARGER IS STOPPED AND THE BATTERY
DISCONNECTED. ALWAYS CHECK THE ABSENCE OF VOLTAGE ON THE DC
CIRCUITS BEFORE TO START ANY WORKS ON THE SYSTEM.

DANGEROUS VOLTAGES CAN REMAIN ON THE SYSTEM EVEN IF IT IS SWITCHED

OFF AND INSULATED FROM MAINS AS LONG AS BATTERY IS CONNECTED.

10.1 PREVENTIVE MAINTENANCE VISIT

It is recommended to perform a maintenance visit every year.

10.1.1 Rectifier maintenance

Remove dust.
Carry out an inspection including the following:

1 - Disconnect the mains input line and the battery.

2 - Examine the components and the wiring. Pay special attention to signs of overheating and melted insulation.
Check all connections. Check for loose wires.
3 - Check that the cooling air flow is not impeded, clean the fans, the air inlets and outlets in case of presence of
dust.
4 - For rectifiers with air inlet filters (on the door and/or on the roof), check the filters for cleanliness.
5 - Check the operation of the rectifier and the voltage levels (see customer drawings).
6 - The GCAU board is equipped with a lithium battery for the Real Time Clock (RTC). This component has a life
time of about 10 years. Its replacement must be done by specialized personnel.

IMPORTANT
This component, mounted on a support, must be recycled in compliance with the European Directive
n° 91/157/EEC of 18.03.91. You can also apply to AEG Power Solutions by shipping back the used
board (prepaid shipment).

10.1.2 Battery maintenance

For the recommended battery maintenance procedures, refer to the battery manufacturer’s manual.
At the end of their service life, the batteries must be recycled in compliance with the European Directive
n° 91/157/EEC of 18.03.91 and WEEE directive. You can also apply to the battery manufacturer as indicated in the
battery manual.

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10.2 FAN MAINTENANCE
Rectifier bridge and cabinet fans:
It is recommended to replace the fans every five years. This operation must be done by specialized
personnel.

10.3 CAPACITORS MAINTENANCE

It is recommended to replace the DC capacitors, the AC filter Z1 and the DC EMC filter Z2 every seven years. This
operation must be done by specialized personnel.

11 ELEMENTARY TROUBLESHOOTING
When an alarm is activated, the green light is out and the red light flashes on the charger display. The "ALARM"
message can be displayed by pressing any key to go to main menu.

Note the descriptions of the alarms present (see Chapter 6 - OPERATING INSTRUCTIONS).

If pressing RESET (in the alarm menu) does not turn off the red light, refer to the following troubleshooting table for
the corrective action to be taken.

NOTE:
This elementary troubleshooting guide assumes that the usual protective options are fitted.
Your equipment may be different and some of alarms can be deactivated. Refer to the customer drawings.

ALARM or EVENT PROBABLE CAUSE CORRECTIVE ACTION

The display is white Contrast problem
Do not touch any button for 5
minutes. This will automatically
activate the default menu. Held the
rightmost button, the contrast will be
increased.
“HIGH MAINS VOLTS” Mains voltage out of limits. . Check the mains voltage.
Programmable threshold: default value or The voltage must as per the specified
customer demand value. value on the customer drawing
package.

“LOW MAINS VOLTS” . Rectifier off. . Switch on the rectifier.

. Mains protection opened. . Check the fuse(s). Replace if

necessary. Check the input
breaker/switch.

. Check the fuses. Replace the

defective fuses

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ALARM or EVENT PROBABLE CAUSE CORRECTIVE ACTION
“CHARGER FAULT” . Low floating voltage with the rectifier not . Check the F1 fuse
in current-limiting mode. Call the Customer Service
Department.

. Fuse F1 blown. . Check the mains voltage and the

proper operation of the fans.
“HIGH BATT.VOLTS” The rectifier output voltage is higher than . Call the Customer Service
the maximum allowable value. Department.
Programmable threshold: default value or
customer demand value.
“LOW BATT.VOLTS” Battery in discharge resulting from:

. rectifier off. . Switch on the rectifier.

. mains absence or low mains voltage. . Check the mains.

. missing phase (TPRe).

Programmable threshold: default value or
customer demand value.
"HIGH DC VOLTAGE" The rectifier output voltage is higher than . Call the Customer Service
the maximum allowable value. Department.
Programmable threshold: default value or
customer demand value.
"LOW DC VOLTAGE" Low load voltage resulting from:

. rectifier off. . Switch on the rectifier.

. mains absence or low mains voltage. . Check the mains.

. missing phase (TPRe).

Programmable threshold: default value or
customer demand value.
“GROUND FAULT +” Low resistance between positive output . Check for the insulation fault.
and cabinet ground.
Programmable threshold: default value or
customer demand value.
“GROUND FAULT –“ Low resistance between negative output . Check for the insulation fault.
and cabinet ground.
Programmable threshold: default value or
customer demand value.
"HIGH TEMPERATURE" High temperature on the bridge. Detection . Check the fan(s).
by thermo switch mounted on the heat
sink. . Check if no obstacles are blocking
the airflow.

. Check the ambient temperature.

. Check the thermo switch.

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 ALARM or EVENT PROBABLE CAUSE CORRECTIVE ACTION

“TEMP SENSE ERROR” . Short or open circuit temperature sensor. . Check the sensor connection.

. GCAU board fault (ADC) . Call the Customer Service

Department.
“HIGH BATT. TEMP.” High battery temperature. . Check the battery cabinet
temperature.
Programmable threshold: default value or
customer demand value.
“CHARGER CURR.LIM” Charger current limit indicator. . Check that load isn’t higher than
(this alarm is disabled by It appears when the rectifier cannot supply your customer drawings
default) the necessary power for the load. In this specifications
case, the rectifier operates in current-
limiting mode.
“BATTERY CURR.LIM” Battery current limit indicator. . This alarm is a warning. It should
(this alarm is disabled by It appears after battery discharge. When not stay more than the usual time
default) the mains power supply comes back, the charge.
battery is in current-limiting mode.
. Otherwise, call the Customer
Service Department.
“HIGH CHARGR CURR” High charger current. . Call the customer service
(this alarm is disabled by department
default)
“HIGH BATT. CURR” High battery current. . If battery current limit option is
(this alarm is disabled by activated, this alarm should not
default) appear.
Programmable threshold: default value or
customer demand value. . Call the customer service
department.

“BATT.TEST FAILED” Appears after a battery test. . Call the customer service
. Battery blackout. department
. Battery in end of life.
“BATT.TEST ABORT” Appears during a battery test. . Stop high rate or commissioning
. Discharge battery current is not charge manually
sufficient
. Battery charge was not initialized before . Initialize battery charge at 100% (in
the test. command menus “reset AH meter”).
. Battery test appears during high rate or . Restart the battery test manually.
commissioning charge.
“BATT. OPERATION” Battery in discharge resulting from:

. rectifier off. . Switch on the rectifier.

. mains absence or low mains voltage. . Check the mains.

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 ALARM or EVENT PROBABLE CAUSE CORRECTIVE ACTION
“INTERNAL CHECK” Communication error between the Call the customer service
microcontrollers or internal system error department.
(e.g.: DC overvoltage protection,
synchro pulse missed, TPC board error
… etc.)
“LONG CHARGE TIME” High rate charge time too long. Call the customer service
department.
“NO PS VOLTAGE” No more DC power supply to the board: . Check the fuse F1.
rectifier output voltage out of order . Call the customer service
department.
“CHARGER OFF” . Alarm activation. . Put the rectifier in floating charge
It can be due to a normal . Serial information input. mode.
system operation. . Manual shutdown. . Call the customer service
department to identify bad system
. Initialising delay.
configuration.

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 Garantiebescheinigung

Modell:
Seriennummer:
Kaufdatum:

Handelsmarke/Unterschrift

Data in this document is subject to change without notice and becomes

contractual only after confirmation. Photos are not contractual.

Operation manual
BN 09 2671/01/01

AEG Power Solutions

Parque Tecnológico de Álava I Albert Einstein, 31 I 01510 Miñano (Álava) I Spain I Tel.: +34 945 214 110 I Fax: +34 945 214 111
10 Rue Jean Perrin - ZI n°1 I 37170 Chambray Lès Tours I France I Tel. +33 2 47 80 88 60 I Fax +33 2 47 28 07 19 I www.aegps.com

AEG PS – Technical data in this document does not contain any binding guarantees or warranties. Content only serves for information purposes and can be modified at any time. We will make binding
commitments only upon receipt of concrete enquiries and customer notification of the relevant conditions. Due to the non-binding nature of these terms, we assume liability neither for the accuracy nor
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