RBC-1200 Three Phase Rectifier/Battery charger User Manual

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Index 1- Introduction

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2- Legal Disclaimer

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3- Quick Start --------------------------------------------------------------------------------------------------------- 43.1- Basic Structure ----------------------------------------------------------------------------------- 53.2- Protection --------------------------------------------------------------------------------------------- 63.3- Configuration --------------------------------------------------------------------------------------- 63.4- User Interface ------------------------------------------------------------------------------------- 63.5- Battery Charging Function --------------------------------------------------------------- 63.5.1- Automatic Charging --------------------------------------------------------------- 73.5.1.1- Float only charging ----------------------------------------------- 73.5.1.2- Boost and float charging ------------------------------------- 83.5.2- Manual Charge ------------------------------------------------------------------------- 83.6- Installation ----------------------------------------------------------------------------------------- 93.6.1- Visual Check --------------------------------------------------------------------------- 93.6.2- Handling ----------------------------------------------------------------------------------- 93.6.3- Placing The Unit In Its Location ----------------------------------- 93.6.4- Distances ---------------------------------------------------------------------------------103.6.5- Electrical Connection ---------------------------------------------------------104- Setting. ---------------------------------------------------------------------------------------------------------------104.1- User Interface -------------------------------------------------------------------------------------114.2- Keys Menu -----------------------------------------------------------------------------------------------124.3- On/Off Menu -------------------------------------------------------------------------------------------134.4- Time Menu -----------------------------------------------------------------------------------------------134.5- Alarms Menu -------------------------------------------------------------------------------------------144.6- Reset Menu ---------------------------------------------------------------------------------------------154.7- Boost Menu ---------------------------------------------------------------------------------------------154.8- Manual Charging Menu -------------------------------------------------------------------------164.9- Measures Menu ---------------------------------------------------------------------------------------174.10- Parameters Menu ---------------------------------------------------------------------------------174.10.1- Change Password -------------------------------------------------------------------194.10.2- charger type -------------------------------------------------------------------------194.10.3- Boost Charge -------------------------------------------------------------------------194.10.3.1- Mains Failure Delay ---------------------------------------------204.10.3.2- Boost Safety Timer -----------------------------------------------204.10.3.3- Boost Charge Maximum Voltage ---------------------------204.10.3.4- Boost Charge Maximum Current ---------------------------214.10.3.5- Float to Boost Current ---------------------------------------214.10.3.6- Boost to Float Current ---------------------------------------21Page 2/25

4.10.3.7- Timed Boost Period -----------------------------------------------224.10.4- Manual Charge -----------------------------------------------------------------------224.10.4.1- Manual Starting Voltage -------------------------------------224.10.4.2- Manual Maximum Current ---------------------------------------234.10.4.3- Manual Safety Timer ---------------------------------------------234.10.5- Floating Charge -------------------------------------------------------------------234.10.5.1- Floating Voltage ---------------------------------------------------234.10.5.2- Maximum Floating Current -----------------------------------244.10.6- Battery Info -------------------------------------------------------------------------244.10.6.1- Battery Size -----------------------------------------------------------244.10.6.2- Installation Date -------------------------------------------------254.10.7- Default Parameters -------------------------------------------------------------25-

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1- Introduction The purpose of this manual is to give you full description of how to use the rectifier/battery charger and to guide you through the correct installation of the unit in the site The rectifier/battery charger system consists of 6-pulse rectifier with SCR technology developed for general use, both as supply system for continuous loads and as battery-charger, All the main operating parameters can be adapted to the specific application, it being understood that the general control structure, the user interface and the main operating procedure remain the same. As all the functions of control and regulation are carried out completely digitally, by means of the use of a microprocessor board, the user interface allows to vary all the operating parameters such as the output voltage, the max. battery current and so on. We recommend expert personnel to carry out such functions. In order to protect the system from wrong programming the menus are protected by password. The default password is 1234, and the user can change this password using the user interface. 2- Legal Disclaimer By using this product, you agree that 01electronics will not be held legally responsible for any injury or damage to you or any person or property caused by the users improper operation and/or poor judgment while using our product. 3- Quick Start. The RBC-1200 converts the alternate voltage in the input into a continuous output voltage that is stabilized in voltage and controlled in current, by means of a three-phase SCR rectifier bridge. The galvanic isolation of the input mains is carried out by means of a transformer. The supplied present, RBC-1200 RBC-1200 can be connected to a battery system and therefore during the absence of mains. Ensure that no voltages are both alternate and continuous, before operating inside the equipment.

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3.1- Basic Structure

As shown in the figure The RBC-1200 basic structure is as the following: The input mains is filtered by the high frequency emission filter (EMI) and enters the primary of the input transformer T1, through the protection breaker. The synchronization signals for the control of the SCR firing angle and the measurement of the input currents and voltage and The supply voltage for the control logic are taken from the primary side of input transformer T1. The SCR bridge is connected to the secondary by means of the protection fuses. The rectified and controlled voltage is filtered by the capacitor, calculated in function of the maximum ripple allowed in the specification. The output at the capacitor is taken to the measurement of the total output current and voltage is always carried out and, if the battery charger functions are included, the discharge and recharge current and voltage of the battery are also measured. The RBC-1200 output is connected to the load by means of the on/off switch.

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3.2- Protection The main protections of the RBC-1200 are listed below: The thermal protection of the bridge is carried out by thermal switch, which are placed on the heat sink. The thermal image is calculated by measuring the output current. If it exceeds the 100% of the nominal current but remains lower than 120%, the overload is accepted for 20 minutes before the RBC-1200 is stopped. Over 120% normally the output current limitation intervenes and the RBC-1200 works as a current generator for 20 minutes. The electrical protection of the bridges is carried out by means of a fuses placed on each input phase and in series to the SCR. In addition, the output current limitation limits the peak current supplied by each SCR. The correct value of the supplied voltages is checked by means of the double measurement of the output and battery voltage. Moreover the correct operation of the control loop is also verified. Each step of the battery recharge is controlled and supervised by a safety timer. 3.3- Configuration. The standard configuration of the RBC-1200 is a 6 pulses three phase SCR bridge. It is designed to supply a continuous load and to recharge the battery at the maximum recharging current provided in the specification. The standard value of the harmonic distortion (THD) re-injected into the mains by a 6 pulse rectifier is < 27%. 3.4- User Interface The front panel RBC-1200 is composed by a 4X20 alphanumeric display and 4X4 alphanumeric multi-function keyboard. It allows the complete monitoring of the RBC-1200 status, the programming of the parameters and the execution of the main functions. 3.5- Battery Charging Function When the RBC-1200 is used as battery charger, the user can select the battery charging function to be automatic or manual charging. the automatic charging could be float only or boost & float. Page 6/25

3.5.1- Automatic Charging When selected, the RBC-1200 recharges the battery automatically according to the predefined parameters. The recharging cycle begins consequently according to one of the following events: - Mains failure for a longer period than the programmed value. - The battery current increase more than threshold current. The recharge undergoes two phases: - Phase 1: the current is constant and the voltage increases. - Phase 2: the current decreases and the voltage is constant. 3.5.1.1- Float only charging In float only charging, as in the figure below, the first phase is the current constant at the maximum float current and the voltage increase until it reaches the float voltage level, the charger will enter the second phase where the voltage is constant at the floating level and the current decreases.

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3.5.1.2- Boost and float charging In boost & float charging, as in the figure below, the first phase is the current constant at the maximum boost current and the voltage increase until it reaches the maximum boost voltage level, the charger will enter the second phase where the voltage is constant at the maximum boost voltage level and the current decrees. When the current fails below the boost to float current threshold, the rectifier returns to float charging and keeps the output voltage at the float voltage level.

When the recharging current goes below a certain value the battery is assumed fully recharged and the cycle ends, Consequently the output voltage is set at the floating level. During the floating the battery voltage is controlled as minimum value in order to avoid undesirable discharges, and towards as maximum value in order to avoid excessive heating of the electrolyte. 3.5.2- Manual Charge The manual recharge of the battery, called also of forming or equalizing, is a function offered by the RBC-1200 that allows the operator to carry out a recharge under his own manual control. This mode of recharging can be used to form the battery after that Page 8/25

it has been stocked for a long period, or after the electrolyte has been filled up, or in the case of batteries having been shipped dry, or in order to equalize the voltage of the battery cells after having been used for a certain period. The manual recharge procedure is described in detail in the relevant menu of the User Interface chapter. Generally, when manual recharge is selected it is possible to intervene manually on the output voltage by means of user interface to vary the recharging battery current. Such current is however always limited to a preselected maximum value. 3.6- Installation The installation of the RBC-1200 must be carried out by qualified personnel. The information contained in this manual will have to be integrated with the technical Book and the technical specification. In order to verify the updated status of such documentation please contact our Technical Office. 3.6.1- Visual Check Upon receipt of the RBC-1200, remove the packaging and carried out an accurate visual check in order to make sure that the equipment has not been damaged during transport. In case of damage during transport, please submit your claim directly to the shipping agency immediately after reception of the equipment. 3.6.2- Handling For the handling of the RBC-1200 before its final positioning we suggest to leave it on its wooden pallet. Before final positioning, remove the RBC-1200 from its pallet removing the fixing bolts. The RBC-1200 can be lifted and moved by means of a forklift. 3.6.3- Placing The Unit In Its Location The RBC-1200 must be installed in a clean ,dry and not dusty place. The installer must ensure that the environment has enough air exchange so that the equipment can cool itself adequately. This Should not be guaranteed then the environment will have to be cooled adequately. If the technical specification of a IPxx protection Page 9/25

degree higher than IP20, the installer will have to ensure that the environment is compatible with the requested protection degree. 3.6.4- Distances Below the suggested distances to be observed: Minimum distance from the rear wall: 20 cm. Minimum distance from the top: 5 cm. Minimum distance from the front wall: 100 cm. 3.6.5- Electrical Connection The electrical connections must be carried out by specialized personnel, following the indication of the technical book. The RBC1200 manufacturer is not responsible of the electrical connection. It is recommended to carry out the installation and input and output electrical connections according to the local standards. 4- Setting The RBC-1200 User interface consists of an 4X20 alphanumeric display and 16 operating keys. It allows the complete monitoring of the RBC1200 status and the setting of all operating parameters. Status List Float Charging Float CV Charging Float CC Charging Float charge at constant voltage in case of charger type Boost&Float Float charge at constant voltage in case of charger type Float only Float charge at constant current in case of charger type Float only

Boost Charge Phase 1 charging at constant current in case of charger type Boost&Float Boost Charge Phase 2 charging at constant voltage in case of charger type Boost&Float Automatic Boost Timed Boost Manual Charging Rectifier Off Constant voltage at boost level for 30sec Constant voltage at boost level for the predefined value Manual Charging Rectifier Off Page 10/25

4.1- User Interface. The figure below shows the user interface. The default screen is shown on the LCD panel when the RBC-1200 is operating normally (no sub menu selected), it shows the charge status and the measures of the output voltage and current. If there is any alarm active 'A' is shown on the second row. By pressing any operating key the relevant menu is entered, from which it is possible to access all the following listed operations.

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4.2- Keys Menu Key Name Parameters Time Measures On/Off Boost/1 Manual/4 7 Exit Alarm/2 5 8 0 Reset/3 Up/6 Down/9 Enter Type Setting Setting Command Command Password Protected Yes No No No

Command / Number 1 No Command / Number 4 No Number 7 Command No No

Command / Number 2 No Number 5 Number 8 Number 0 No No No

Command / Number 1 No Command / Number 6 No Command / Number 9 No Command No

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4.3- On/Off Menu This menu is accessed be pressing the On/Off key. It is not password protected. If you press the increase or decrease keys in this sub menu, if the RBC-1200 is on it will shutdown or vice versa.

This key works as a two position ON-OFF switch which remains positioned on the last selected position. This means that if you have selected ON, the RBC-1200 starts-up automatically until OFF is selected. 4.4- Time Menu The menu is entered by pressing the Time key, it is not password protected and In the menu the following screen is entered

After having pressed the Time key, a series of Sub menu is entered from which you can set all the time parameters. the following sub menu is used to set the years.

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If the Up or Down key is pressed the value of the years will increase or decrease depending on the key, after setting the right year if the Enter key is pressed the value will be saved and the next sub menu will entered for the setting of the rest of the time parameters. 4.5- Alarms Menu This menu is entered by pressing the key Alarms, it is not password protected. depend on the recorded alarms, if there is no recorded alarms the next screen is entered.

If there is any recorded alarms the following screen is entered.

The up and down keys used to browse the alarms from the last one to the first as in the following screen

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List of the alarms A1: Phase Loss A2: Out Of Tolerance A3: Blown Fuse A4: High Temperature A5: Overload Current A6: Fan Failure A7: C. Breaker Open A8: Safety Timer 4.6- Reset Menu This menu perform a general reset of all the failure conditions stored one or more phases are not connected out of amplitudes and/or frequency Blown mains input fuses on the bridge rectifier high temperature on the heatsink load current exceeds the rectifier nominal current the fan is off or jammed One or more of the circuit breakers are open Charging Safety Timer out

4.7- Boost Menu This menu is used to start automatic or timed boost. It is not protected by password. After entering the password the following screen is entered.

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If key 1 is pressed the rectifier will start automatic boost in which the rectifier output voltage regulated at boost level for 30 Sec then return to floating level if key 2 is pressed the rectifier will start timed boost in which the rectifier output voltage regulated at the boost level for the time preset in the parameters menu then return to floating level. 4.8- Manual Charging Menu This menu starts a manual charging. When the manual key is pressed ,the following screen will entered

This allows the user to perform a charge under his manual control,in the manual charging the following screen is entered.

The rectifier will follow the voltage set point unless the current increased the maximum allowed value, if so the rectifier will keep the current constant at the maximum value. The user can change the set point by using the up/down keys.

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4.9- Measures Menu The menu is entered by pressing the key Measures. In the menu the following screen is entered.

The screen shows the DC value of the rectifier voltage and current output and the battery voltage and current. If in this menu the down key is pressed the following measures are accessed, which shows the RMS value of the mains voltage and current

4.10- Parameters Menu This menu is entered by pressing the key command parameters, it is password protected. In this menu the following screen is accessed in which the password is entered.

Only if the correct password of 4 numbers is entered the next sub menus can be used. The menu of the parameters enables to vary the Page 17/25

operating modalities of the various procedures which are programmed on the RBC-1200, that are the thresholds and the delays of the protection interventions. For this purpose we recommend the use only by specialized personnel. All the available sub menus are browsed by using up/down keys. Depending on the entered sub menus various screens and options are shown.

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4.10.1- Change Password By default all rectifiers have the same password 1234,using this sub menu you can change this password. In the parameters menu if you press enter on this sub menu the following screen will entered.

In this screen, enter the new password digit by digit. After entering the four digits, the new password will be saved and you will return to the parameter menu 4.10.2- charger type This sub menu identify if the battery connected to the RBC-1200 will be charged with boost and float method or float only. in the parameters menu if you press enter the following screen will be entered

to change the charger type use the up/down keys and then press enter 4.10.3- Boost Charge This menu depend in the charger type, you can use it only if the charger type is Boost&float. If so and you pressed the enter key in the parameter menu, you will enter the next sub menus

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4.10.3.1- Mains Failure Delay After a power failure for time longer than this time the rectifier will start a boost charge. This value depend on the load and the batteries capacity

4.10.3.2- Boost Safety Timer This timer starts when the boost charge state. If the timer reach its maximum value before the end of charging, the rectifier will be forced to float charging and alarm flag will raised.

4.10.3.3- Boost Charge Maximum Voltage In the boost charge, the rectifier will keep the voltage at this level if the current is not exceed the maximum set value.

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4.10.3.4- Boost Charge Maximum Current If the boost charge current exceeds the programmed threshold, normally a certain percent of C10, the first phase of boost charge starts in which the current is constant at this set point and the voltage is increasing.

4.10.3.5- Float to Boost Current This is the threshold current to go from float to boost charging

4.10.3.6- Boost to Float Current In the second boost charge phase,the voltage is constant and the current is decreasing. If the current drop below this level, the boost charge will end and the rectifier will enter the float charge

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4.10.3.7- Timed Boost Period In case of timed boost is used, the output voltage will kept at the boost level for this time

4.10.4- Manual Charge The manual recharge of the battery, called also of forming or of equalizing is a function offered by the RBC-1200 that allows the operator to carry out a recharge under his own manual control. This mode of recharging can be used to form the battery after that it has been stocked for a long period, or after that the electrolyte has been filled up, in the case of batteries having been shipped dry, or in order to equalize the voltage of the battery cells after having been used for a certain period. In this sub menu all parameters relevant to the manual or equalizing charge can be set 4.10.4.1- Manual Starting Voltage The manual charging start at this voltage, this voltage is the initial value for the set point. The rectifier will keep the output voltage at this set point unless the current exceed the maximum value for manual charging

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4.10.4.2- Manual Maximum Current By default in the manual charging, the rectifier keep the voltage at the set point. But if the battery current exceed this manual maximum current, the rectifier stop following the voltage set point and start keeping the current at the maximum value

4.10.4.3- Manual Safety Timer This timer starts with the manual charging. If the timer reach its end before the end of the manual charging, the rectifier will forcing to float charging and alarm will be raised

4.10.5- Floating Charge In this menu you can set the parameters of the floating charge 4.10.5.1- Floating Voltage The rectifier will keep the output voltage at this level unless the current exceed the maximum value

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4.10.5.2- Maximum Floating Current In the floating charging the rectifier will keep the voltage at the floating level unless the current exceed this set point, if so, the rectifier will keep the current at its maximum value

4.10.6- Battery Info In this sub menu the parameters relevant to the type of battery installed can be visualized and varied with the RBC-1200. 4.10.6.1- Battery Size This sub menu enables to set the battery capacity in Amperehour.

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4.10.6.2- Installation Date The next sub menu is used to set the battery installation date in format D/M/Y.

By pressing enter, A series of sub menu will entered to set the day and month and year. 4.10.7- Default Parameters This sub menu enables to recall all the default operating parameters of the RBC-1200, or rather those that were memorized in the factory. The next screen enables to recall the default settings.

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