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PROTECT RCS
Rectifiers Chargers and DC Systems
SPRe - Single Phase Rectifier
TPRe - Three Phase Rectifier
24V 110V
10A 500A
Transportation
A more flexible approach to providing exact solutions.
Rail, Airports, Shipping
Choose from:
Water
Standard system configurations and
Desalination, Treatment
Customized systems - designed to comply
Instrumentation & Process Control with precise specifications
Chemicals, Mining, Steel, Paper
All Industrial Applications
>>
www.powersupplysystems.com
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 3
NEW RANGE
NEW RANGE: PROTECT RCS INDUSTRIAL RECTIFIERS, CHARGERS & DC SYSTEMS
Protect RCS is an evolution of the highly successful "GCAU" Generic Control and Alarm Unit (A1)
SPR/TPR range from Saft Power Systems which is installed The main card is the GCAU (Generic Control and Alarm
globally and used for all Industrial applications. Unit). It performs measurements, control and process
The main advance of the new Protect RCS range is the control (charge process control) and provides a wide
introduction of the GCAU card which integrates more range of alarm and monitoring options, a user-friendly
cutting-edge hardware functions. control/display interface, and facilities for data logging
The Protect RCS rectifiers are thyristor-controlled rectifiers and remote communication.
suitable for charging nickel-cadmium or lead-acid batteries
while supplying DC loads. They can also be used without The card has all the necessary controls to pilot single
batteries as direct power supplies. and three phase thyristor chargers. For three phase
systems a driver card is connected to the GCAU card.
This new range of DC Systems is available in three levels:
The first level consists of the Standard Rectifier The GCAU card uses a fully digital control algorithm
with a compact set of alarms. to ensure the required flexibility.
The second level offers a set of Basic Options,
extensive functions and alarms. The GCAU card incorporates two micro controllers, using
The third level offers a full set of Extended Options, the latest micro controller technology to ensure a high
extensive functions and alarms allowing customization degree of safety.
of the systems to comply with special customer
requirements. The tasks of these micro controllers are:
Process communication and Monitoring
The rectifiers are built as independent modules, optional Regulation and synchronization
equipment like distribution boards, diode droppers etc.
are installed in separate cubicle sections. Each micro controller has its specific dedicated task.
Because of the high level of standardisation and One micro controller is dedicated to the control
integration, the design reduces the need for extensive algorithm while the second takes care of alarm,
internal wiring. communication and charge process tasks.
Cabinets are floor mounted and can be designed The two micro controllers check each others
to meet special requirements. The batteries are mounted functionality and will shut down the system
on free-standing racks or in cabinets together with safely if an operating error is detected.
or separated from the rectifier.
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 4
SYSTEM DISPLAY
An extensive human interface ensures that all the important
parameters are accessible from the front panel. A large
16 characters by 2 lines LCD unit displays all the relative
information to the user. A three push button keyboard
is used with 2 LEDs (green and red) indicating
the charger state.
The Display card is mounted on the front of the system
and is controlled by the GCAU card. It is a plug-in device
and is connected through two RJ 4-4 connectors with
a 4-wire cable. All data and necessary power supply Display: 9mm character height,
voltages are transferred over this cable. two line by sixteen-character alpha
numeric LCD with LED backlight.
Extended filter
as option
TPC Board
(Three phase)
Battery
Isolated
Serial RS232 Serial GCAU CARD
Port Communication
RS485 Board (Option)
Out Ambient
Temp
Sensor (Option)
RJ 4-4
Connector RJ 4-4
Connector
Relay (Option)
Board
Remote 8 Multi
Alarm functional
Contacts spare
inputs
APPLICATIONS
Designed to provide secure DC power for all Industrial
applications; for Oil & Gas and Petrochemical Plants,
Power Stations and Substations, Water Treatment Plants,
Manufacturing Plants, Airports, Railways, etc
SPECIFICATION
INPUT
Protect RCS single phase (SPRe) Single phase 230Vac 10%
Protect RCS Three Phase (TPRe) Three phase 400Vac 10%
Other voltages available as option
Exceptional variations + 15 / -20% (functional)
Frequency 50Hz or 60Hz 6%
OUTPUT
Nominal voltage (Udc) 24V 48V 110V (Other voltages available as non-standard option)
Range of operating voltage Floating charge 75% to 125% of Udc Nominal
High rate charge 75% to 135% of Udc Nominal
Commissioning charge 75% to 140% of Udc Nominal
Static voltage regulation 0.5% under the following conditions:
at float charge
0-100% DC load variation
input voltage 10%
input frequency 6%
temperature from 0C to 40C
Dynamic voltage regulation Using standard filter and the battery connected
(capacity higher than 5 times I nom)
Load step Deviation
10-90% -5%
90%-10% +5%
Current regulation 0-2% of current limit
Long-term stability of UDC 0.15% for 1000 hours
Temperature coefficient of UDC 0.18% per C
Charging characteristic Constant current / constant voltage (I/U as per IEC 478-1) during float charge
Input/Output isolation 2500 VAC between input/output and electrical earth
Insulation resistance > 200 M, 500 VDC
Ripple Max 2% rms of nom. DC voltage, with a battery Ah capacity
of 5 times the charger nom rating, battery connected (see our filter options).
2.5% rms typical (max 5%) on rectifier output, battery not connected.
PROTECTION
Polarity reversal of battery (blows battery fuse, optional)
Soft-start function 0 to 100%
Short-circuits
Limited to 100% of rated current
Internal DC fuse
Non-volatile storage of system parameters and user setting
Mains failure shutdown
Rectifier failure shutdown
High-voltage DC shutdown
Thermal protection
EMC emissions Generic emission standards EN 50081-2 and generic immunity standards
EN 50082-2 available as standard option.
Safety According to EN 50178 standard
ENVIRONMENTAL
Ambient temperature Operating: 0C to + 40C
Derate from 40C to 55C by lowering the output current by 1.25% per C.
Storage: -25C to +70C
Relative humidity Operation: from 20% to 95% non condensing.
Storage: from 15% to 90% (in original packaging).
Acoustic noise Typical 45-65 dB(A)
Altitude Up to 1000m, derate from 1000 to 4000m by lowering
the output current by 7% per 1000 m.
Tropicalisation Suitable for ambient temperature and relative humidity specified above
and for ambient air free from dust and corrosive gases.
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 8
Plus
Standard Standard Short lead
2 Basic Options
Documentation Size time
(Building block)
3 Plus
Extended Options
Customized
Documentation
Standard
or optional size
Project
dependent
STANDARD SYSTEM
The Protect RCS range of systems have been pre-configured with standard drawings and standard user documentation.
with a number of the most commonly requested features A Standard Rectifier System without additional options
built-in as standard.These systems are available off-the-shelf provides a very cost effective, short lead time solution.
STANDARD SYSTEM
Electrical components
Terminal X1 and X2 (Mains, battery, load, common fault)
Internal input power switch Q1
Input transformer T1 (with taps 220V-230V-240V for SPRe and 380V-400V-415V for TPRe)
Rectifier bridge (SPRe: mixed diode/thyristor bridge V1-V5, TPRe: 6-pulse bridge V1-V7)
GCAU card A1 with non-volatile history and English display language + second language available (factory setting)
TPC card A2 for TPRe only
Output filter L1-C1 ripple voltage < 5% RMS without battery
Rectifier fuse F1
Rectifier shunt R2
Common fault remote alarm (changeover contact wired on terminal)
The Display card (A300) and keyboard assembly (A310) are mounted on the front of the system
Cabinet construction
Floor Mounted 19 cabinet
Protection degree IP21
Colour RAL 7035 - Powdered textured painting
Cabinet natural cooling (except TPRe 110V-400A and 110V-500A)
Door with air inlet
Rear panel with air outlet ( 5mm punched panel) (requires 10 cm minimum clearance
at the rear of the cabinet)
Door swing 180 degrees with two key locks
Logo/ Brand name on front
Bottom open (vermin proof as option)
Standard cable entry at the bottom
Standard cable gland plate on the roof
Bottom opening (10 cm) for pallet truck handling facilities
Standard labelling/nameplate
Standard PVC cable
Standard cable marking
None isolated aluminium earth bar (screwed directly in frame)
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 9
The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user
documentation will be automatically generated to reflect the actual options configured
A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional
system capabilities.
Alarm/signalling/measurement option
100 LED box signalling (A6) (all alarms, events, high rate charge, commissioning)
101 First 8 relays card ( A5.1)
102 Rectifier voltage analog DC meter (P2)
103 Rectifier current analog DC meter (P1)
104 Battery current analog DC meter (P3)
105 Temperature alarm (bridge natural cool. 50A,+TH1 shutdown+TH2 alarm)
Temperature alarm (bridge forced cool. 75A, TH1 shutdown, +TH2 alarm+TH3 fan assisted)
Communication options
200 EIA232 SPG* communication (A71) - WINSPARC software required
201 EIA485 SPG* communication (A71 + A72) - WINSPARC software required
202 EIA485 SPG* PC side interface (one set for PC)
203 WINSPARC software (CD-ROM + documentation)
204 EIA232 MODBUS communication (A71)
205 EIA485 MODBUS communication (A71 + A72)
AC input options
400 Input fuse (without alarm) DIN (F34)
401 Input fuse (without alarm) Cylindrical (F34)
402 Input circuit breaker (without alarm) (Q1)
403 Input contactor (K1) controlled by ON-OFF switch S1 on front door
404 EMI filter (CE) (Z1) - mandatory for CE mark
Load options
500 Load fuse (without alarm) DIN (F23)
501 Load fuse (without alarm) Cylindrical (F23)
502 Load circuit breaker (without alarm) (Q2)
503 Load Switch (handle inside the cabinet) (Q2)
504 Blocking diode (V21)
505 0.1% filter SPRe 25A (Telecom filter for 24V and 48V)
506 1% filter
Battery options
600 Battery fuse (without alarm) DIN (F13)
601 Battery fuse (without alarm) Cylindrical (F13)
602 Battery circuit breaker (without alarm) (Q3)
603 Battery Switch (handle inside the cabinet)
604 Battery current limit/display (Battery shunt R3 same as rectifier shunt R2)
605 Battery voltage temperature compensation (5 m length sensor wire) (NTC)
606 Temperature sensor wires: 10m, 30m
607 Battery Low Voltage Disconnect contactor (K2) I Battery same as I Rectifier
608 VOM battery charging (Ni Cd gas recombination)
609 Dual rate charge C15 100 battery monitoring board (A3)
610 Single rate charge C15 100 monitoring board (A3)
611 High Rate interlock: (high rate inhibited as load switch is ON)
Cabinet options
700 Cabinet heating resistor (230V) controlled by thermostat
701 Eye bolts
702 IP42
*SPG = Saft Power Systems Protocol for GCAU.
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 10
SPECIFICATION
Platform: PC compatible
Operating system: Windows NT4, Windows 2000
or Windows XP.
The Standard System can be enhanced by the addition of some Basic Options. System specific drawing packages and user
documentation will be automatically generated to reflect the actual options configured
A Standard Rectifier System with Basic Options provides a cost effective, short lead time solution with additional
system capabilities.
Communication options
250 Modem communication
AC input options
450 Input fuse (with alarm) DIN
451 Input fuse (with alarm) Cylindrical
452 Input circuit breaker (with alarm)
453 Special transformer( earth screen, tapping, lower inrush current)
454 Special mains input voltage (3x460/480V 60Hz; 3x500V 50Hz; 3x690V 50Hz; other)
455 AC surge arrestor
Load options
550 Load fuse (with alarm) DIN
551 Load fuse (with alarm) Cylindrical
552 Load circuit breaker (with alarm)
553 Diode dropper
554 0.1% filter all other models SPRe 50A & TPRe
555 High DC voltage trip mechanical
556 DC distribution
557 DC surge arrestor
Brochure RCS.qxd:PROTECT_1_DE.qxd 7/12/07 15:34 Page 12
ONS
Battery options
650 Battery fuse (with alarm) DIN
651 Battery fuse (with alarm) Cylindrical
652 Battery circuit breaker (with alarm)
653 Special battery current limit/display shunt (R3 # R2)
654 Special battery LVD contactor (I batt. # I red.)
655 Reversed battery protection
656 Cable drop compensation
657 Battery protection/isolation box (Fuse/fuse switch/MCB/MCCB/switch)
See alarm options High ripple voltage alarm card
Low electrolyte level alarm
Battery circuit failure alarm card
See control options Battery room fan control
Float/Auto/High rate internal switch
Remote high rate charge command
Cabinet options
750 Cabinet interior light and AC mains socket with circuit breaker (without differential)
751 Cabinet interior light and AC mains socket with differential protection circuit breaker
752 Interior light with circuit breaker (without differential)
753 AC mains socket with differential protection MCB
754 AC mains socket with circuit breaker (without differential)
755 IP20 Open Door
756 IP21 with back panel
757 Protection up to IP54
758 Special colour
759 Copper earth bar
760 Vermin proof protection plate
761 Tropicalisation (Varnished PCBs)
762 Special wiring (low smoke low fume wiring and cable duct halogen free)
763 Identification of internal components by sticky labels on plexi strip
764 Identification of internal components by engraved labels on plexi strip
765 Cabinet coupling
766 Cabinet separation plate
767 Additional cabinets option
768 Battery cabinet
769 Battery separation plate
System options
850 Parallel high rate - Automatic high rate inhibition for the chargers in parallel
851 Passive loadsharing (droop factor)
852 Shared high rate
BATTERIES
Saft Power Systems has considerable in-house knowledge in gas recombination technologies. Batteries can be supplied
battery technology and is able to offer expert advice on the on racks or inside cabinets which match the chargers and
specifying, selection, operation and testing of batteries. can be mechanically coupled to the charger cabinet if necessary.
Our total system solutions include a wide range of products Replacement batteries can be supplied and installed by our
using lead acid and nickel-cadmium batteries in vented and Global Service Team.
POWER SERVICES
Advanced power supplies require advanced technical count on Saft Power Systems specialists to deliver the
service and support. Our customers know that they can right service and support rapidly and efficiently.
Due to our policy of continuous development, data in this document is subject to change without notice and becomes contractual only after written confirmation.
Consulting Training
Load Bank & Capacity Testing Remote Monitoring
Installation & Commissioning Power Quality Services
Facility & equipment Management Service Contracts - 24/7 Global Service Coverage
Battery Monitoring Corrective Maintenance
Spare Parts Design & Build - Turnkey Solutions
Power Systems
Whenever wherever wattever Realized by yvydy. - Protect RCS - 09/07 - EN-V1.