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RAN EW

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

Designed for all industrial applications

Oil & Gas, Petrochemicals
Offshore, Onshore, Pipelines

Energy and Power Generation, Transmission, Distribution Transportation

Rail, Airports, Shipping

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

RAN EW

Robust, Reliable and Flexible

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

>>

www.powersupplysystems.com

>> KEY FEATURES

Standard system configurations - cost effective, short lead time solutions Customized systems - enhance the standard system by selecting from an extensive range of options All systems built with advanced GCAU - Generic Control and Alarm Unit Communications system used to monitor and control the defined parameters locally or remotely. Choice of several types of batteries: - nickel-cadmium vented or gas recombination - lead acid vented or gas recombination Advance Battery Management Parallel operation Simplified maintenance High MTBF and low MTTR - Bespoke documentation; drawings, manuals -Total solutions including switchgear, load distribution International Service support comprehensive packages including; Product Services: Installation, Commissioning, Service Contracts... Site Services: Load testing, monitoring

NEW RANGE
NEW RANGE: PROTECT RCS INDUSTRIAL RECTIFIERS, CHARGERS & DC SYSTEMS
Protect RCS is an evolution of the highly successful SPR/TPR range from Saft Power Systems which is installed globally and used for all Industrial applications. The main advance of the new Protect RCS range is the introduction of the GCAU card which integrates more cutting-edge hardware functions. The Protect RCS rectifiers are thyristor-controlled rectifiers suitable for charging nickel-cadmium or lead-acid batteries while supplying DC loads. They can also be used without batteries as direct power supplies. This new range of DC Systems is available in three levels: The first level consists of the Standard Rectifier with a compact set of alarms. The second level offers a set of Basic Options, extensive functions and alarms. The third level offers a full set of Extended Options, extensive functions and alarms allowing customization of the systems to comply with special customer requirements. The rectifiers are built as independent modules, optional equipment like distribution boards, diode droppers etc. are installed in separate cubicle sections. Because of the high level of standardisation and integration, the design reduces the need for extensive internal wiring. Cabinets are floor mounted and can be designed to meet special requirements. The batteries are mounted on free-standing racks or in cabinets together with or separated from the rectifier. The GCAU card uses a fully digital control algorithm to ensure the required flexibility. The GCAU card incorporates two micro controllers, using the latest micro controller technology to ensure a high degree of safety. The tasks of these micro controllers are: Process communication and Monitoring Regulation and synchronization Each micro controller has its specific dedicated task. One micro controller is dedicated to the control algorithm while the second takes care of alarm, communication and charge process tasks. The two micro controllers check each others functionality and will shut down the system safely if an operating error is detected. "GCAU" Generic Control and Alarm Unit (A1) The main card is the GCAU (Generic Control and Alarm Unit). It performs measurements, control and process control (charge process control) and provides a wide range of alarm and monitoring options, a user-friendly control/display interface, and facilities for data logging and remote communication. The card has all the necessary controls to pilot single and three phase thyristor chargers. For three phase systems a driver card is connected to the GCAU card.

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

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

BLOCK DIAGRAM OF THE RECTIFIER

AC Line Input Input Transformer Rectifier Bridge Ripple Filter Rectifier Fuse Stabilizer (Option) DC Output

TPC Board (Three phase)

Extended filter as option Battery

AC Voltage PS

Thyristor Gate Control

OVP input

Rectifier Current sense

Rectifier Volatge sense

Battery Temp. Sensor (Option)

Battery Current Sense (Option)

DC PC

Load voltage sense

Isolated Serial Port Out

RS232 RS485

Serial Communication Board (Option)

GCAU CARD Ambient Temp Sensor (Option)

RJ 4-4 Connector

RJ 4-4 Connector Relay Board (Option)

Remote Alarm Contacts LED box (Option)

8 Multi functional spare inputs

Front alpha numeric Display 2 LED indicators Keyboard

>> PROTECT RCS - SINGLE PHASE RANGE

(including systems with Basic Options)

RECTIFIER TYPE

NOMINAL DC OUTPUT VOLTAGE V

NOMINAL DC OUTPUT CURRENT A

STANDARD SYSTEMS & BASIC OPTIONS DIMENSIONS1 HEIGHT (MM) WIDTH (MM) DEPTH (MM)

WEIGHT2 (APPROX) KG

24SPRe10 24SPRe15 24SPRe25 24SPRe50 24SPRe75 24SPRe100 48SPRe10 48SPRe15 48SPRe25 48SPRe50 48SPRe75 110SPRe10 110SPRe15 110SPRe25 110SPRe50

24 24 24 24 24 24 48 48 48 48 48 110 110 110 110

10 15 25 50 75 100 10 15 25 50 75 10 15 25 50

1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1600 1200 1200 1200 1600

600 600 600 600 600 600 600 600 600 600 600 600 600 600 600

821 821 821 821 821 821 821 821 821 821 821 821 821 821 821

85 95 105 160 180 195 95 100 145 200 295 110 145 190 345

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

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

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

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

>> PROTECT RCS - THREE PHASE RANGE

(including systems with Basic Options)

NOMINAL DC OUTPUT RECTIFIER TYPE

VOLTAGE

NOMINAL DC OUTPUT
CURRENT

STANDARD SYSTEMS & BASIC OPTIONS DIMENSIONS1 HEIGHT (MM) WIDTH (MM) DEPTH (MM)

WEIGHT2 (APPROX) KG

24TPRe25 24TPRe50 24TPRe75 24TPRe100 24TPRe150 24TPRe200 24TPRe300 24TPRe400 24TPRe500

24 24 24 24 24 24 24 24 24

25 50 75 100 150 200 300 400 500

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

600 600 600 600 600 600 600 900

821 821 821 821 821 821 821 821 821

145 185 250 285 305 345 *(4) *(4) *(4)

900 600 600 600 600 600 600 600 900 821 900 600 600 600 600 600 900 821 900 821 900 1200 821 821 821 821 821 821 821 821 821 821 821 821 821 821 821

48TPRe25 48TPRe50 48TPRe75 48TPRe100 48TPRe150 48TPRe200 48TPRe300 48TPRe400 48TPRe500

48 48 48 48 48 48 48 48 48

25 50 75 100 150 200 300 400 500

190 215 315 340 495 515 *(4) *(4) *(4) 215 365 495 520 585 770

110TPRe25 110TPRe50 110TPRe75 110TPRe100 110TPRe150 110TPRe200 110TPRe300 110TPRe400 110TPRe500

110 110 110 110 110 110 110 110 110

25 50 75 100 150 200 300 400 500

*(4) *(4) *(4)

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

SPECIFICATION
INPUT
Protect RCS single phase (SPRe) Protect RCS Three Phase (TPRe) Exceptional variations Frequency
Single phase 230Vac 10% Three phase 400Vac 10% Other voltages available as option + 15 / -20% (functional) 50Hz or 60Hz 6%

OUTPUT
Nominal voltage (Udc) Range of operating voltage
24V 48V 110V Floating charge High rate charge Commissioning charge (Other voltages available as non-standard option) 75% to 125% of Udc Nominal 75% to 135% of Udc Nominal 75% to 140% of Udc Nominal

Static voltage regulation

Dynamic 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 Using standard filter and the battery connected (capacity higher than 5 times I nom) Load step Deviation 10-90% -5% 90%-10% +5% 0-2% of current limit

Current regulation Long-term stability of UDC Temperature coefficient of UDC Charging characteristic Input/Output isolation Insulation resistance Ripple

0.15% for 1000 hours 0.18% per C Constant current / constant voltage (I/U as per IEC 478-1) during float charge 2500 VAC between input/output and electrical earth > 200 M, 500 VDC Max 2% rms of nom. DC voltage, with a battery Ah capacity of 5 times the charger nom rating, battery connected (see our filter options). 2.5% rms typical (max 5%) on rectifier output, battery not connected.

PROTECTION
Polarity reversal of battery (blows battery fuse, optional) Soft-start function 0 to 100% Short-circuits Limited to 100% of rated current Internal DC fuse Non-volatile storage of system parameters and user setting Mains failure shutdown Rectifier failure shutdown High-voltage DC shutdown Thermal protection EMC emissions Safety Generic emission standards EN 50081-2 and generic immunity standards EN 50082-2 available as standard option. 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 Operation: from 20% to 95% non condensing. Storage: from 15% to 90% (in original packaging). Typical 45-65 dB(A) Up to 1000m, derate from 1000 to 4000m by lowering the output current by 7% per 1000 m. Suitable for ambient temperature and relative humidity specified above and for ambient air free from dust and corrosive gases.

Relative humidity Acoustic noise Altitude Tropicalisation

>> PRODUCT RANGE ARCHITECTURE

The product range is configurable with three levels of architecture:

Architecture

Documentation
Standard Documentation

Cabinet
Standard Size

Availability
Short lead time

1 2 3

A Standard Rectifier System

(Building block)

Plus Basic Options

(Building block)

Standard Documentation

Standard Size

Short lead time

Plus Extended Options

Customized Documentation

Standard or optional size

Project dependent

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

STANDARD SYSTEM
The Protect RCS range of systems have been pre-configured with a number of the most commonly requested features built-in as standard.These systems are available off-the-shelf with standard drawings and standard user documentation. A Standard Rectifier System without additional options provides a very cost effective, short lead time solution.

STANDARD SYSTEM
Electrical components Terminal X1 and X2 (Mains, battery, load, common fault) Internal input power switch Q1 Input transformer T1 (with taps 220V-230V-240V for SPRe and 380V-400V-415V for TPRe) Rectifier bridge (SPRe: mixed diode/thyristor bridge V1-V5, TPRe: 6-pulse bridge V1-V7) GCAU card A1 with non-volatile history and English display language + second language available (factory setting) TPC card A2 for TPRe only Output filter L1-C1 ripple voltage < 5% RMS without battery Rectifier fuse F1 Rectifier shunt R2 Common fault remote alarm (changeover contact wired on terminal) The Display card (A300) and keyboard assembly (A310) are mounted on the front of the system Cabinet construction Floor Mounted 19 cabinet Protection degree IP21 Colour RAL 7035 - Powdered textured painting Cabinet natural cooling (except TPRe 110V-400A and 110V-500A) Door with air inlet Rear panel with air outlet ( 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)

>> STANDARD SYSTEM PLUS BASIC OPTIONS

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

Option n
100 101 102 103 104 105

Basic options
Alarm/signalling/measurement option

Select ( )

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

Communication options
200 201 202 203 204 205 EIA232 SPG* communication (A71) - WINSPARC software required EIA485 SPG* communication (A71 + A72) - WINSPARC software required EIA485 SPG* PC side interface (one set for PC) WINSPARC software (CD-ROM + documentation) EIA232 MODBUS communication (A71) EIA485 MODBUS communication (A71 + A72)

Control and command options

300 Remote forced floating charge command

AC input options
400 401 402 403 404 Input fuse (without alarm) DIN (F34) Input fuse (without alarm) Cylindrical (F34) Input circuit breaker (without alarm) (Q1) Input contactor (K1) controlled by ON-OFF switch S1 on front door EMI filter (CE) (Z1) - mandatory for CE mark

Load options
500 501 502 503 504 505 506 Load fuse (without alarm) DIN (F23) Load fuse (without alarm) Cylindrical (F23) Load circuit breaker (without alarm) (Q2) Load Switch (handle inside the cabinet) (Q2) Blocking diode (V21) 0.1% filter SPRe 25A (Telecom filter for 24V and 48V) 1% filter

Battery options
600 601 602 603 604 605 606 607 608 609 610 611 Battery fuse (without alarm) DIN (F13) Battery fuse (without alarm) Cylindrical (F13) Battery circuit breaker (without alarm) (Q3) Battery Switch (handle inside the cabinet) Battery current limit/display (Battery shunt R3 same as rectifier shunt R2) Battery voltage temperature compensation (5 m length sensor wire) (NTC) Temperature sensor wires: 10m, 30m Battery Low Voltage Disconnect contactor (K2) I Battery same as I Rectifier VOM battery charging (Ni Cd gas recombination) Dual rate charge C15 100 battery monitoring board (A3) Single rate charge C15 100 monitoring board (A3) High Rate interlock: (high rate inhibited as load switch is ON)

Cabinet options
700 701 702 Cabinet heating resistor (230V) controlled by thermostat Eye bolts IP42

*SPG = Saft Power Systems Protocol for GCAU.

WINSPARC SOFTWARE-SAMPLE SCREENSHOT

The WINSPARC software (WINDOWS based) is an application designed for local and remote supervision to have control of the entire GCAU configuration in order to monitor and configure the systems. This software interacts with the GCAU through a serial data link. To do this the communication card A71 is plugged into the GCAU through the extension connector (See options 200, 201 and 202). This software function allows visualizing on a PC screen system data such as alarms, measurements, modes, and history. Remote commands can be sent to the system. The available types of communication are: Locally (via PC port COMx) Remotely (via Modem -extended option 250) If only one charger is to be connected to the PC, the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71). Option 200. If more than one charger is to be connected to the same communication bus (centralized supervision of chargers), the GCAU card has to be equipped with an isolated EIA232/EIA485 communication extension board (A71) + one EIA485 interface & connecting board (A72). Option 201. With Option 201 (EIA485 bus), the PC side is usually equipped with a PC side interface providing EIA485/EIA232 conversion. Option 202. The rectifiers are acting as slaves and the central computer as the master. By giving the different rectifiers different slave numbers, it is possible to command each individual rectifier. WINSPARC is compliant with the WINSITE software (site management application).

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

WINSPARC SOFTWARE-SAMPLE SCREENSHOT

>> FURTHER CUSTOMIZATION WITH EXTENDED OPTION

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

Option n
150 151 152 153 154 155 156 157 158 159 160 161 162 See options AC input, Load or Battery 163

Extended options
Alarm /signalling/measurement options
LED Box LED test push button AC input voltage analog meter (with phase selector switch for TPRe) AC input current analog meter (with phase selector switch for TPRe) AC input voltage and current analog meters with 3-phase selector switch Load voltage analog DC meter Load current analog DC meter Additional spare input alarm (to centralize an external signalling with additional terminal and auxiliary relay if isolated input required) Second 8 relays signalling card (with additional auxiliary power supply required) Alarm buzzer High ripple voltage alarm Low electrolyte level alarm Battery circuit failure alarm DC line permanent insulation controllers Protection device (Fuse or MCB) with signalling alarm

Select ( )

Ambient temperature indicator/alarm

Communication options
250 Modem communication

Control and command options

350 351 352 353 354 Remote rectifier shutdown command (Using one spare input) Remote alarm reset / acknowledgement command (Using one spare input) Battery room fan control (One relay of extension relay card required) Remote high rate charge command (Using one spare input) Float/Auto/High rate internal switch (Using two spare inputs)

AC input options
450 451 452 453 454 455 Input fuse (with alarm) DIN Input fuse (with alarm) Cylindrical Input circuit breaker (with alarm) Special transformer( earth screen, tapping, lower inrush current) Special mains input voltage (3x460/480V 60Hz; 3x500V 50Hz; 3x690V 50Hz; other) AC surge arrestor

Load options
550 551 552 553 554 555 556 557 Load fuse (with alarm) DIN Load fuse (with alarm) Cylindrical Load circuit breaker (with alarm) Diode dropper 0.1% filter all other models SPRe 50A & TPRe High DC voltage trip mechanical DC distribution DC surge arrestor

NS
Option n
650 651 652 653 654 655 656 657 See alarm options

Extended options
Battery options

Select ( )

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

Cabinet options
750 751 752 753 754 755 756 757 758 759 760 761 762 763 764 765 766 767 768 769 Cabinet interior light and AC mains socket with circuit breaker (without differential) Cabinet interior light and AC mains socket with differential protection circuit breaker Interior light with circuit breaker (without differential) AC mains socket with differential protection MCB AC mains socket with circuit breaker (without differential) IP20 Open Door IP21 with back panel Protection up to IP54 Special colour Copper earth bar Vermin proof protection plate Tropicalisation (Varnished PCBs) Special wiring (low smoke low fume wiring and cable duct halogen free) Identification of internal components by sticky labels on plexi strip Identification of internal components by engraved labels on plexi strip Cabinet coupling Cabinet separation plate Additional cabinets option Battery cabinet Battery separation plate

System options
850 851 852 Parallel high rate - Automatic high rate inhibition for the chargers in parallel Passive loadsharing (droop factor) Shared high rate
(Additional Miscellaneous Options can be selected and include);

Miscellaneous options Option n

950 951 952 953 954

Miscellaneous options
Extra drawing files Factory acceptance test Extra test (Heat run test) Packing (various categories) Freight (as required)

Select ( )

Detailed explanations of all Options are available on request.

BATTERIES
Saft Power Systems has considerable in-house knowledge in battery technology and is able to offer expert advice on the specifying, selection, operation and testing of batteries. Our total system solutions include a wide range of products using lead acid and nickel-cadmium batteries in vented and gas recombination technologies. Batteries can be supplied on racks or inside cabinets which match the chargers and can be mechanically coupled to the charger cabinet if necessary. Replacement batteries can be supplied and installed by our Global Service Team.

POWER SERVICES
Advanced power supplies require advanced technical service and support. Our customers know that they can count on Saft Power Systems specialists to deliver the right service and support rapidly and efficiently.

A comprehensive range of services are available

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

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

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

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