DOCUMENT TRANSMITTAL FORM

To: Sharjah Electricity & Water Authority Our Ref: 786/SEC/1016/17

P.O.Box. 135, Sharjah, United Arab Emirates Date: 23/05/2017

Attn: MCD Director

Sharjah Electricity & Water Authority YourRef:
Date:

Project: 33/11kV Substation Lamprell, Emirates Stone & Juraina Mall

Subject: 48V DC System FAT Design & FAT Procedure

FI – For Information with no reply FA – For Approval

MUD – Mark up Document/Drawing Submitted to Employer with “As implemented” stamp on it.

Revision Status
Title& Drawing No. Number FI FA MUD NA AN AP IN

✓
FAT Design & FAT Procedure for 48V DC A
System
NA = Not Approved AN = Approved except as Noted AP = Approved IN = For Information
only

Annexure Enclosed : Y Remarks

Hard & Soft Copies TO
SEWA MCD Head of MCD Project
SEWA MCD Head of Maintenance Section

SEWA MCD Head of CTS

SEWA MCD Head of Operation
SEWA MCD Archive

Signature

Umair Iqbal

SCAN Electromechanical Contracting Co. LLC

Date: 23/05/2017

SCAN ELECTROMECHANICAL CONTRACTING COMPANY L.L.C

 Automatismes Energie Electronique Systèmes
259, Allée Jacques Monod – 69792 ST PRIEST CEDEX - France
Tél. : (33) 04.72.47.63.77 – Fax : (33) 04.78.40.13.94
E-mail : aees@aees.fr

PROCEDURE D'ESSAI DE SERIE (essai individuel)

POUR SYSTEME CHARGEUR
SELON NORME CEI 146 (NF EN 60146-1-1)

ROUTINE TEST PROCEDURE (routine test)

FOR CHARGER SYSTEM
AS PER STANDARD IEC 146 (NF EN 60146-1-1)

Rédigé par Vérifié par Approuvé par Approuvé par

Prepared by Checked by Approved by Approved by
Nom / Name
Société / Company

Date

Visa

R 21.09.1999 Indice / Revision B 12/10/2010

Procédure d'essai de série CEI 146 Type
PrC146 v2012.DOC PrC146 1
Fichier / File
IEC 146 routine test procedure Notice N° Page
1 - GENERALITES
Les essais «de série» sont effectués en l’usine
d’A.E.E.S. sur chaque système chargeur, même si le
contrat fait état de plusieurs systèmes identiques et de
même calibre.
Le programme des essais individuels est limité à ceux
qui sont exigés par la norme CEI 146.1.1., section 7
(toutefois, ce programme ne mentionne pas la liste
complète des essais supplémentaires qui sont réalisés
par A.E.E.S. afin d’assurer le déverminage et le
fonctionnement optimal de l’équipement).
Les essais sont effectués dans des conditions
électriques équivalentes à celles du service réel et
figurant dans le contrat.
2 - DEROULEMENT ET SPECIFICATION
DES ESSAIS
Si un système comporte 2 chargeurs, les essais sont
réalisés sur chaque chargeur à charge nominale.
2-1 ESSAI D’ISOLEMENT
(Selon CEI 146.1.1. paragraphe 7.2.1.)
PRELIMINAIRES :
Vérification de l’équipotentialité des masses de sous-
ensembles devant être reliés galvaniquement à la terre
(y compris l’enveloppe métallique).
L’alimentation alternative, la charge continue et la
batterie (si elle existe) sont débranchées.
Les contacteurs, interrupteurs, disjoncteurs et
sectionneurs à fusibles sont fermés ou pontés.
Les bornes de l’alimentation alternative doivent être
court-circuitées entre elles. Il en va de même pour les
bornes + et - de la batterie (si elle existe) et de la sortie
continue.
Si l’équipement est composé de plusieurs armoires,
celles-ci peuvent subir séparément le test d’isolement
sans être obligatoirement interconnectées.
R 21.09.1999
Procédure d'essai de série CEI 146
PrC146 v2012.DOC
Fichier / File
IEC 146 routine test procedure
1 - GENERAL
The routine tests are performed at the A.E.E.S. factory
on each charger system, even if the contract specifies
several identical systems of the same gauge.
The programme of individual tests is limited to those
required by standard IEC 146-1-1, section 7. (However,
this programme does not mention the full list of additional
tests which A.E.E.S. performs in order to burn in the
equipment and to ensure it is working properly).
The tests are performed in electrical conditions
equivalent to those of actual duty, which are detailed in
the contract.
2 - TEST SEQUENCE AND TEST
SPECIFICATION
If a system is built with 2 chargers, the following tests are
performed on each charger at nominal load.
2-1 INSULATION TEST
(as per IEC 146-1-1 § 7.2.1.)
PRELIMINARIES :
Check that the equipotentiality of the non-current-carrying
metal parts of the sub-assemblies having to be
connected galvanically to the earth (including the metallic
casing).
The alternative power supply, the direct load and the
battery (if it exists) have been disconnected.
The contactors, switches, circuit-breakers and fused
isolators have been closed or shunted.
The alternative power supply terminals must be short-
circuited between themselves. The same applies to the +
and - terminals of the battery (if it exists) and of the direct
output.
If the equipment comprises several cabinets, these may
undergo the insulation test separately, without
necessarily needing to be interconnected.
Indice / Revision B 12/10/2010
Type
PrC146 2
Notice N° Page
2-1-1 ESSAI DIELECTRIQUE 2-1-1 DIELECTRIC TEST
Une tension continue est appliquée progressivement A direct voltage is applied gradually up to a value Utest,
jusqu’à une valeur Utest, d’abord entre l’entrée first between the alternating input and the ground, and
alternative et la masse, et par la suite entre la sortie then between the direct output and the ground. The test
continue et la masse. L’essai est considéré comme is considered to be satisfactory if no disruptive
satisfaisant si aucun claquage, même intempestif, n’est discharges, even of a spurious nature, are observed
observé pendant 10 secondes. during 10 secondes.
UM / √2 Tension d'essai (Utest) UM / √2 Testing voltage (Utest)
≤ 50V ≥ 1770V ≤ 50V ≥ 1770V
≤ 100V ≥1840V ≤ 100V ≥1840V
≤ 150V ≥ 1910V ≤ 150V ≥ 1910V
≤ 300V ≥ 2120V ≤ 300V ≥ 2120V
≤ 600V ≥ 2550V ≤ 600V ≥ 2550V
≤ 1000V ≥ 3110V ≤ 1000V ≥ 3110V
Les tensions d’essai mentionnées ci-dessus sont This voltage are available for equipments connected to
valables pour des équipements raccordés sur un normal voltage network.
réseau basse tension.
(UM étant la tension crête nominale prévue). (UM is the previous nominal peak voltage).
2-1-2 RESISTANCE D’ISOLEMENT 2-1-2 INSULATING RESISTANCE
La procédure est similaire à celle du paragraphe 2-1-1, The procedure is similar to that in paragraph 2-1-1, but a
mais en appliquant une tension continue Utest d’au direct voltage Utest of at least 500V is applied.
moins 500V.
La résistance mesurée doit être supérieure ou égale à The resistance measured must be greater than or equal
1MΩΩ pour une tension d’alimentation efficace du Ω for system effective supply voltage not exceeding
to 1MΩ
système n’excédant pas 1000V, ceci pendant 10 1000V, and should continue for at least 10 secondes.
secondes.
2-2 FONCTIONNEMENT ET ESSAIS 2-2 OPERATING AND TESTS
(Selon CEI 146.1.1 paragraphe 7.3.1./7.3.2) (as per IEC 146-1-1 § 7.3.1& 7.3.2)
Il consiste à vérifier que toutes les parties électriques This consists of checking that all the electrical parts of
de l’équipement sont opérationnelles, ce dernier étant the equipment are operational, the later being supplied
alimenté à tension assignée. by the assigned voltage.
Réglages du chargeur : Charger settings :
Certains points de contrôle sont réalisés notamment : A number of check points are performed, in particular :
- la montée et la stabilisation progressive de la - The rising and gradual stabilization of the
tension de sortie, output voltage,
- les niveaux de tension appliqués à la batterie, - The voltage levels applied to the battery,
c’est-à-dire : namely :
- la tension d’entretien (Floating), - The floating voltage,
Si applicable : If applicable :
- la tension de charge (boost), - The charge voltage (boost),
- la tension d’égalisation (formation) qui est - The equalizing voltage («initial» charge) ,
un régime manuel, which is a manual rating
- les temporisations liées au régime - The time delays linked to the automatic
automatique (entretien + charge). duty (maintenance + charge)
- la limitation électronique de courant: -The electronic limitation of current
-la limitation du courant chargeur - The total limitation on the charger.
Si applicable : If applicable :
-la limitation du courant de recharge - The limitation of battery recharge current.
batterie

R 21.09.1999 Indice / Revision B 12/10/2010

Procédure d'essai de série CEI 146 Type
PrC146 v2012.DOC PrC146 3
Fichier / File
IEC 146 routine test procedure Notice N° Page
2-3 VERIFICATION DES DISPOSITIFS
AUXILIAIRES ET DES PROTECTIONS
(Selon CEI 146.1.1. paragraphe 7.5.1./7.5.3.)
La vérification des dispositifs auxiliaires consiste à
contrôler notamment :
- Les protections par fusibles / disjoncteurs.
- Le fonctionnement des relayages, des
contacteurs et des automatismes divers.
- Le fonctionnement des reports d’alarmes, des
télécommandes, des signalisations et des
indicateurs de mesure (analog. ou numériques).
- Le fonctionnement des ventilateurs, des
diodes chutrices et/ou de couplage (s’ils
existent).
- Le fonctionnement de certaines fonctions
électroniques ou électriques spécifiques (si
elles existent).
La vérification des dispositifs de protection comprend
notamment :
- Le réglage des seuils de tension continue
(relais de tension) avec temporisations.
- Le test du contrôleur d’isolement continu (s’il
existe).
- Les coupures automatiques par surcharge ou
par bobines à émission (si elles existent).
3 - CONTROLES DU REPERAGE
(Selon CEI 146.1.1. paragraphe 6.6)
-Ces contrôles concernent le repérage interne
(bornes, câbles, plaques signalétiques,
étiquettes, les numéros des circuits) et externe
(indicateurs, signalisation / commandes,
étiquettes.
R 21.09.1999
Procédure d'essai de série CEI 146
PrC146 v2012.DOC
Fichier / File
IEC 146 routine test procedure
2-3 CHECKING OF AUXILIARY DEVICES
AND PROTECTIONS
(as per IEC 146-1-1 § 7.5.1& 7.5.3.)
Checking of the auxiliary devices consists in particular of
inspecting :
- The fuse and circuit-breaker protections.
- Working of the relays, contactors and
miscellaneous automatic controls.
- Working of the alarm transfers, remote
controls, signalling devices and measurement
indicators (analog or digital meters)
- Working of the fans, coupling diodes and/or
dropping diodes (if they exist).
- Working of certain specific electrical or
electronic functions (if they exist).
Checking of the protection devices consists of, in
particular :
- Adjustment of the DC voltage thresholds (DC
voltage relays) with time delays.
- The test of the DC earth fault monitor (if it
exists).
- The automatics cut-outs by overload or by
pulse-operated coils (if they exist).
3 – LABELLING INSPECTIONS
(as per IEC 146-1-1 § 6.6)
-These inspections concern the internal
identifications (terminals, wiring, nameplates,
labels, number’s circuits).and external
identifications ( indicators, operation signalling /
controls, labels).
Indice / Revision B 12/10/2010
Type
PrC146 4
Notice N° Page
 30 avenue Montgolfier – BP 90 – 69684 Chassieu Cedex – France

CERTIFICAT D'ESSAIS CHARGEUR

CHARGER TEST CERTIFICATE

Essai de série selon NF EN 60146-1-1 (CEI 146)

Routine test according to EN 60146-1-1 (IEC 146)

Client :
Customer :
POWERX INTERNATIONAL
Type d'équipement :
Equipment :
MC1810 – 2 x FP40R10 40 48 U NiCd 75 38
N° de Projet :
Project n°. :
60001169
Code : FP40R1I-641182
N° de série :
Serial n°. :

Essayé par : Vérifié par : Vérifié par :

Tested by : Checked by : Checked by :
Fonction : Fonction : Fonction :
Function : Technical agent Function : Function :
Date : Date : Date :
Date : Date : Date :

Signature : Signature : Signature :

Signature : Signature : Signature :

R 2.012.990 Indice / Revision C 06/10/2016

FP40R1I-641182-PV Certificat d'essais / Test certificate FP40R1I-641182 1 Type
Fichier / File Certificat N° Page
I) Contrôle visuel / Visual Inspection
Prévu Mesuré
Expected Measured
 Dimensions armoire Panel dimension Pass / Fail __________
 Couleur armoire Paint color Pass / Fail __________
 Epaisseur tôle Thickness Pass / Fail __________
 Nomenclature Bill of quantity Pass / Fail __________

II ) Contrôle de l'isolement / Insulation test (CEI 146 § 7.2.1)

Prévu Chargeur 1 Chargeur 2
II.1 ) Essai diélectrique / Dielectric strength (10 sec) Expected Charger 1 Charger 2
 Entrée / masse Input / ground 2120Vdc __________ __________
 Sortie / masse Output / ground 1770Vdc __________ __________
 Entrée / sortie Input / output 2120Vdc __________ __________

Prévu Chargeur 1 Chargeur 2

II.2 ) Résistance d'isolement / Insulation resistance (10 sec) Expected Charger 1 Charger 2
 Tension d'essai Testing voltage 500Vdc
 Entrée / masse Input / ground  1M _______M _______M
 Sortie / masse Output / ground  1M _______M _______M

III ) Fonctionnement et essais / Operation and tests (CEI 146 § 7.3.1 / 7.3.2)
Prévu Chargeur 1 Chargeur 2
Réglages du chargeur / Charger settings Expected Charger 1 Charger 2
 Floating (mode automatique) Valeur/Setting 54Vdc 1% ______Vdc ______Vdc
Floating (automatic mode)

 Charge / (mode automatique) Valeur/Setting 55.1Vdc 1% ______Vdc ______Vdc

Boost / (automatic mode)
 Durée du régime de charge Valeur/Setting 12h 10min _________h _________h
Boost charge duration
 Seuil de décharge batterie activant le régime de
Valeur/Setting 49.3Vdc 1% ______Vdc ______Vdc
charge
Battery discharge threshold commanding the boost
charge

 Formation / (mode manuel) Valeur/Setting 62.7Vdc 1% ______Vdc ______Vdc

Equalizing / (manual mode)
 Durée du régime de formation Valeur/Setting 12h 10min _________h _________h
Equalizing charge duration

 Limitation de courant chargeur Valeur/Setting 25A +5% ________A ________A

Charger current limitation

 Limitation de courant batterie Valeur/Setting 7.5A 3% ________A ________A

Battery current limitation

 Régulation et stabilité en tension (0 à In) 1.5% U Pass / Fail __________ __________

Voltage regulation and stability (from 0 to In)

R 2.012.990 Indice / Revision C 06/10/2016

FP40R1I-641182-PV Certificat d'essais / Test certificate FP40R1I-641182 2 Type
Fichier / File Certificat N° Page
IV ) Essai au courant assigné / Rated current test (CEI 146 § 7.3.2/7.3.5)
Mesuré Mesuré
Relevé de mesures / Measuring report Mode
Measured Measured
 Tension efficace d'entrée Input RMS voltage AC _________V _________V
 Intensité efficace d'entrée Input RMS current AC _________A _________A
 Puissance active à l'entrée Input active power AC _________W _________W
 Puissance apparente à l'entrée Input apparent power AC ________VA ________VA
 Tension moyenne du chargeur Charger mean voltage DC _________V _________V
 Intensité moyenne du chargeur Charger mean current DC _________A _________A
 Intensité efficace redresseur Rectifier RMS current AC+DC _________A _________A
 Tension résiduelle en sortie Output RMS ripple voltage AC ________mV
(Batterie déconnectée / Battery not connected) < 2.5% Ioutput=17.5Adc

V ) Essai des dispositifs auxiliaires et de protection / Auxiliary/protective devices test

(CEI 146 § 7.5.1/7.5.3)
Prévu Chargeur 1 Chargeur 2
V.1 ) Appareils de protections / Protective devices Expected Charger 1 Charger 2
 Fusibles / sectionneurs Fuses / fused switches Pass / Fail __________ __________
 Disjoncteurs Circuit breakers Pass / Fail __________ __________

V.2 ) Signalisations, alarmes / Signalling, alarms

 Indicateur alphanumérique LC display Pass / Fail __________ __________
 Signalisations lumineuses Lamps/LEDs signalling Pass / Fail __________ __________
 Alarmes/télécommandes Alarms/Remote controls Pass / Fail __________ __________
 Configuration de la fonction IOA Interface IOA configuration
Vérifier la position des switchs selon la programmation ci-dessous (cocher la case pour validation)
Check the position of switches as programmed below (tick for validation)

Switch 1 2 3 4 5 6

Chargeur 1 ON    
Charger 1 OFF  

Chargeur 2 ON    
Charger 2 OFF  

Distribution ON  
Distribution OFF    
Voir notice pour plus de détail / See user’s manual for more details

V.3 ) Vérification des dispositifs auxiliaires Prévu Distribution

Checking of auliliary devices Expected Distribution
Diode de couplage Coupling diode Pass / Fail __________ __________

Eclairage armoire Cabinet lighting Pass / Fail __________

R 2.012.990 Indice / Revision C 06/10/2016

FP40R1I-641182-PV Certificat d'essais / Test certificate FP40R1I-641182 3 Type
Fichier / File Certificat N° Page
VI ) Contrôle d’aspect marquage / Marking/Labelling inspections (CEI 146 § 6.6)
Identification Identification
 Bornes de raccordement Terminals Pass / Fail __________ __________
 Plaque signalétique Nameplate Pass / Fail __________ __________

Numéros de circuits Cards numbers UER __________ __________

(N° de série + version de nomenclature) CRL __________ __________
DIS __________ __________
IOA __________ __________
UTB3 __________
CRL3 __________
IOA3 __________
IOB3 __________

R 2.012.990 Indice / Revision C 06/10/2016

FP40R1I-641182-PV Certificat d'essais / Test certificate FP40R1I-641182 4 Type
Fichier / File Certificat N° Page
 Repères Qté Désignation Code Fournisseur
Marks Qty Description Code Supplier

TOLERIES / CABINETS

1 Armoire type MC1810 IP41 MC1810 cabinet EMERSON

H 1 Eclairage Slim-line série SL025 – 11W Fluorescent lamp 6000053 STEGO

TRANSFORMATEUR / TRANSFORMER

TR1 TR2 2 Transformateur monophasé Single-phase transformer 6013400 EMERSON

réf. M230M081 3K40 48V40 N

LC1 LC2 2 Self de lissage Smoothing choke 6013413 EMERSON

Réf. 4m1 45 64 48V40

TRA1 TRA2 2 Transformateur auxiliaire Auxiliary transformer 1003498 EMERSON

Réf. 40997 ND 400

CENTRALE DE SUPERVISION
MICRO CONTROLER MODULE

CRL1 CRL2 2 Fonction superviseur Crystal 6008348 EMERSON

Type 1050 - 24V/240V Microcontroller interface PCB

CRL3 1 Fonction superviseur Crystal Microcontroller interface 6013426 EMERSON

Type 1050 UTBAT- 24V/240V PCB

UTB3 1 Fonction interface 6012281 EMERSON

Type 1090 - 24V/240V Microcontroller interface PCB

DIS1 DIS2 DIS3 3 Fonction afficheur Signalling / digital display PCB 6008355 EMERSON
Type 1051

IOA1 IOA2 IOA3 3 Fonction Entrée / Sortie relais report 6006379 EMERSON
Type 1026 Remote alarms PCB

IOB3 1 Fonction Entrée / Sortie relais report 6008356 EMERSON

Type 1052 Remote alarms PCB

FONCTION REDRESSEUR / RECTIFIER UNIT

UER1 UER2 2 Fonction régulation Hexagone Rectifier control PCB 6007068 EMERSON
Type 1033 25A 48V

RED1 RED2 2 Pont redresseur monophasé Single-phase rectifier 6013584 ARCEL

Réf. MM45N
CIT1 CIT2 2 Capteur à effet Hall type 100A/4V±15V Hall effect sensor 6008056 TAMURA

CF1 CF2 2x2 Condensateur électrolytique aluminium 6009025 SIC SAFCO

Type 51x105 - 22000µF/63V Electrolytic capacitor

CFR1 CFR2 2 Fonction décharge 3k3Ω 2W Resistor 6009238 EMERSON

Type 1061

R 0.812.990 Indice / Revision 05 06/12/2016

FP40R1I-641182-Fnm Nomenclature / Equipment list FP40R1I-641182 Fnm1 Type
Fichier / File Plan N° Page
 Repères Qté Désignation Code Fournisseur
Marks Qty Description Code Supplier

PROTECTIONS / PROTECTIVE SYSTEMS

EMC1 EMC2 2 Fonction filtrage CEM EMC smoothing PCB 6011620 EMERSON
Type 1006-B
QS1 QS2 2 Disjoncteur bipolaire cal. 20A courbe D 1016228 ABB
Réf. S202 D20- 352264 2P MCB
QS1 QS2 2 Contact auxiliaire OF réf. S2C-H6R Position contact 6003361 ABB
QC1 QC2 2 Disjoncteur bipolaire cal. 32A courbe C 1013470 ABB
Réf. S202 C32- 352241 2P MCB
QC1 QC 2 Contact auxiliaire OF réf. S2C-H6R Position contact 6003361 ABB
QU 1 Disjoncteur bipolaire cal. 25A courbe D 5810200140 ABB
Réf. S202 D25 - 352265 2P MCB
QU 1 Contact auxiliaire OF réf. S2C-H6R Position contact 6003361 ABB
QB 1 Disjoncteur bipolaire cal. 40A courbe C 1013469 ABB
Réf. S202 C40 - 352242 2P MCB
QB 1 Contact auxiliaire OF réf. S2C-H6R Position contact 6003361 ABB
FE 1 Socle fusible bipolaire type CHM1DU 2P Socket 1002362 BUSSMANN
2 Fusible taille 10 x 38 - cal. 2A gG Fuse 1002307 BUSSMANN

DIVERS / MISCELLANEOUS
DC1 DC2 2 Diode de couplage 40A Coupling diode 1018276 ARCEL
Réf. DC40
CIB CIU 2 Capteur à effet Hall type 50A/4V±15V Hall effect sensor 6008055 ARCEL

DISTRIBUTION DC / DCDB
Q1 / Q2 2 Disjoncteur bipolaire cal. 10A courbe D 5810200137 ABB
Réf. S202-D10- 352261 2P MCB
Q3 1 Disjoncteur bipolaire cal. 10A courbe C 5810200124 ABB
Réf. S202-C10- 352261 2P MCB
Q4 / Q5 2 Disjoncteur bipolaire cal. 6A courbe D 5810200136 ABB
Réf. S202-D6- 352260 2P MCB
Q1 / Q5 5 Contact auxiliaire SD réf. S2C-S/H6R SD contact 6003362 ABB

BORNIER / TERMINAL
X1 X2 4 Borne M10/10 Terminal 1004603 ENTRELEC
X3 10 Borne M6/8 Terminal 1004602 ENTRELEC
X4 2 Borne M16/12 Terminal 1004606 ENTRELEC
EARTH 1 Barre cuivre 15x5x990mm Copper bar 1003924 SOCOMEC
B+ B- 4 Borne UT10/10 Ground terminal 5110300038 PHOENIX CONTACT
1 Barrette 2 pôles FBS 2-10 2P coupling bar 5110700003 PHOENIX CONTACT

X10 X20 X30 ENTRELEC

50 Borne M4/6 Terminal 1004600
X31

BATTERIE SUR CHANTIER

BATTERY ON RACK

1 Batterie CdNi / NiCd battery 48V 75Ah SAFT

38 éléments / cells 1,2V/75Ah type UP1M75
(5 x UP1M75-6 + 2 x UP1M75-4)

R 0.812.990 Indice / Revision 05 06/12/2016

FP40R1I-641182-Fnm Nomenclature / Equipment list FP40R1I-641182 Fnm2 Type
Fichier / File Plan N° Page
 FP40R Rectifier 1

DC Energy

FP40R rectifier
FP40R rectifier -- 641182
641182
 2
TABLE OF CONTENT

PRESENTATION............................................................................................................................................................................... 3
HANDLING ...................................................................................................................................................................................... 4
FITTING .......................................................................................................................................................................................... 6
LIFTING RINGS ................................................................................................................................................................................ 7
WALL MOUNTING ........................................................................................................................................................................... 8
CONNECTION .................................................................................................................................................................................. 9
PRESENTATION OF THE CRYSTAL SUPERVISOR .......................................................................................................................... 10
COMMISSIONING ........................................................................................................................................................................... 11
DISPLAY ........................................................................................................................................................................................ 12
USUAL SETTINGS AND COMMANDS .............................................................................................................................................. 14
RESTRICTED ACCESS .................................................................................................................................................................... 15
RANGE PARAMETERS SETTING..................................................................................................................................................... 16
ADVANCED FUNCTIONS................................................................................................................................................................ 18
MANUAL BATTERY EQUALIZING .................................................................................................................................................. 19
IOA INPUT / OUTPUT BOARD CONFIGURATION .......................................................................................................................... 20
ADDITIONAL I/O BOARDS ............................................................................................................................................................. 21
PRESENTATION OF THE UTBAT SUPERVISOR ............................................................................................................................. 22
DISPLAY SCREEN MENUS .............................................................................................................................................................. 23
SETTINGS RANGE FOR PARAMETERS ........................................................................................................................................... 24
BATTERY CHARGE CURRENT LIMITATION ................................................................................................................................... 25
BATTERY CIRCUIT TEST ............................................................................................................................................................... 25
CRYSTAL MAINTENANCE .............................................................................................................................................................. 26
SPECIFICATIONS ........................................................................................................................................................................... 27
SPARE PARTS................................................................................................................................................................................ 28

FP40R rectifier - 641182

 The FP40R rectifier is intended to serve medium and high-power Battery charger or DC power supply 3
applications. It controls the DC voltage, and offers a "UI" type current limitation.

Presentation

Rectifier synoptic diagram

RECTIFIER
TRANSFORMER BRIDGE
DC OUTPUT
MAINS

CONTROL
FILTER
CIRCUIT SUPERVISION
UER

Description
Power circuit
The alternative Mains current is rectified by a controlled SCR bridge, once adapted by the input transformer. A
second order filter, made of inductance and capacitors, filters the output voltage to the desired ripple voltage.
Control circuit
Voltage regulation and current limitation are provided by the control circuit. Voltage and current adaptation and
isolation allows the micro-processor based control circuit UER to monitor them and compute correction needed.
The control circuit 1033 also generates the SCR control pulses to regulate the direct voltage and limit the
current.
Supervision
Adjustment / protection / monitoring functions are performed by a supervisor equipped with programmable
microcontroller. The man/machine interface is located on the device's front panel. One or several inputs/outputs
boards, located inside the device, provide relays with the outside environment.

FP40R rectifier - 641182

 4
Handling

Acceptance
The equipment is generally delivered packaged and strapped, standing on a pallet for handling with a pallet lift
or forklift truck. Upon receipt, check visually that the equipment has not been damaged during transport. If
problem when unpacking, make reservations to use.
Storage
If the equipment is not installed immediately, it should be stored in its packaging, in a dry room, away from any
sources of heat.

Caution: when the equipment contains a battery, storage should not exceed 4 months to limit battery
self-discharge. Beyond this period of time, batteries should be recharged.

Storage conditions :

General data :

Parameters Plumb Nickel-Cadmium

Storage temperature -20 to + 45°C -20 to + 55°C
Relative humidity 5 to 95 % 5 to 95 %
70 to 106 kPa 70 to 106 kPa
Atmospheric pressure
(0,7 to 1,06 bar) (0,7 to 1,06 bar)

Storage time without recharging :

Battery type Temperature range °C Maximum storage time

-20 to +20 6 months
Plumb to recombination +20 to +30 3 months
+30 to +45 1.5 months
-20 to +20 3 months
Open plumb +20 to +30 2 months
+30 to +45 1 months
Open plumb without electrolyte No limitation of time

Nickel-Cadmium No limitation of time

After storage period even shorter than those indicated operations are commissioned to perform according to
manufacturer’s instructions. They require a minimum to full charge before any solicitation.

FP40R rectifier - 641182

 Handling 5
We recommend handling the equipment to its final location while still in its original packaging, on a wooden
pallet in the case of a box or cabinet. Proceed with unpacking by cutting the straps.

Caution: Take all necessary precautions to prevent the equipment from tipping over when handling.

To fit the equipment, it must be lifted off the wooden pallet. Four possibilities depending on the size and weight
of the system:
Manually for small boxes whose weight does not exceed 40-50 kg.
By mechanical means for equipment with a pallet
collar, or weighing more than 40-50 kg.

By its lifting rings when By means of slings for heavy systems

provided. without lifting rings.

FP40R rectifier - 641182

 6
Fitting

Recommendation
The room in which the equipment is fitted must conform to applicable local electrical installation standards. It
must be suitably ventilated (natural or forced), dry and clean.
The room's layout must allow free air circulation through the vents provided. Leave a space of approximately
10cm around the vents. The space in front of the equipment should be sufficient to allow the door to fully open.
Cables shall arrive from the bottom, except when specifically asked different (see layout diagram).

FP40R rectifier - 641182

 7
Lifting rings

Recommendations

- Do not exceed capacity of your handling equipment

- Pay attention to the slinging method and tilt angles.

Incorrect slinging Correct slinging

- Protect the slings from the sharp edges and angles

- Take the load's centre of gravity into consideration
- Insert the slings correctly through the lifting rings

FP40R rectifier - 641182

 8

Wall mounting

Recommendations
The equipment should be fastened to its definitive location to avoid tipping over.
The cabinet must be wall-mounted when it contains battery racks or drawers.

Caution: Equipment layout should allow free air circulation through the vents provided. Leave at least
10 to 15 cm around the vents. The space in front of the equipment should be sufficient to allow the door
to be fully opened.

To fix the equipment to the wall

- Drill two horizontal holes (for M12 screws - not provided) in the wall with a centre distance of
524mm for CR126 cabinet
724mm for CR128/188 cabinet
833mm for MC1810 cabinet
- Position the equipment as close as possible and parallel to the wall.
- Fix the equipment's lugs to the wall with two M12 screws (not provided)

M12

FP40R rectifier - 641182

Connection 9

Warning
All electrical equipment is hazardous. Workers may be exposed to electrical risks (electrocution, burns) by
direct or indirect contact when the equipment is live, or simply in standby mode. Certain live parts may be
subjected to high potentials (battery).
Consequently, any work on the equipment during installation must be performed by an authorised person
with training in the prevention of electrical risks.
Connection
Connection should be implemented as per the connection diagram, not forgetting to connect the ground
circuit to the equipment's ground
Conform to the equipment's supply voltage.

Caution: The phase order must be respected. Reverse order with prevent the rectifier from starting.

The power supply should be protected by a circuit breaker upstream of the equipment, whose
rating is defined on the characteristics page, mains power supply section.
All cables connected to the equipment must be adapted to the protective systems provided and to
applicable electrical facility standards (i.e. NF C 15-100 - EN 50091.1.1, etc.).
For assemblies comprising multiple cubicles, do not omit interconnections as per the connection
diagram.

Caution: To benefit fully from this equipment, its data reporting features should be used, in particular
to guarantee better operation reliability.

When the battery is external to the equipment, fitting and connection should take the following
recommendations into consideration:

At the charger system level

- Charger off
- Battery circuit breaker or isolating switch open

At the battery level

- A protective unit should be placed as close as possible to the battery. This unit shallprotects the battery
from accidental short-circuits.
- Conform to battery polarities

In order to ensure a high level of safety for the installation, the remote control contacts shall be connected.
- The minimum section to be used is 1mm2.
- Cabinets must be wired so as to avoid electromagnetic coupling (stranded wires or inside the same
sheath).
- Contact capacity: 250Vca 5A / 60Vdc 1A.

FP40R rectifier - 641182

Presentation of the CRYSTAL supervisor 10

The synoptic below represents the Crystal supervisor equipped with all the available options. These
options are integrated to the supervisor in function of technical data specified at the order.

Note: Refer to equipment list to determine the provided options.

DIS To SCR control circuit

Display screen 4x20 chters UER

LED
8 leds indicators
(Option)

UIF Mains
measurement (Option)

CRL
Supervisor
CRYSTAL

COM IOB IOC IOA TMP

External Digital inputs / outputs Digital outputs Digital inputs / outputs Temperature
communication (Option) (Option) probe
RS485 MODBUS (Option)
(Option)

FP40R rectifier - 641182

 11
Commissioning

Commissioning operations must be performed by qualified staffs that are familiar with equipment operation.
Prior checks
- Before commissioning a system, the wiring must be carefully checked (connections properly tightened,
polarities respected, etc.)
- All cut-off devices must be open (mains, output and battery).
- Ensure that the mains voltage matches the system's supply voltage.
- Ensure that the system is correctly earthed.

Energizing
- Establish mains supply.
- Close the unit's mains protection.
The unit goes through an initialization sequence. The following appear in succession on the display screen:
"Display ready", the type of supervisor "CRYSTAL SUPERVIS0R Version x.x", the charger rating
"CHARGER xxV xxA". While these initial screens are being displayed, the lighting of the 3 LEDs (green,
yellow and red) is on and then starts flashing.
The display screen displays alternately the charger measurements and, depending on the equipment
settings, the battery, output and mains measurements.
- Press the push button “ON” on the display to start the charger. The green and yellow LEDs stop flashing and
only the green LED stays on. The display screen displays alternately the charger measurements and,
depending on the equipment settings, the battery, output and mains measurements.
- The choice of language and date and time settings is proposed. If these settings are satisfactory, press the
RESET
ESC key to go to the sequential display. To change settings, see paragraph "Usual settings and
commands”.

Note: If the equipment is powered down for more than 10 days, the date and time must be set during
commissioning.

- Close the battery protection.

- Close the output protection to supply the dc load and check the value of the supplied current to the load.

Functional test
After the above-mentioned start-up operations, ensure that all system functionalities are operational. For this,
open the mains circuit breaker and check the following:
- Autonomous operation
- Operation of auxiliary devices and alarm relaying.
Close the circuit breaker. The system is now ready for use.

FP40R rectifier - 641182

Display 12

The CRYSTAL display screen features :

- 3 operating states LEDs:
- Green: Normal state ⇨ no action.
- Yellow: Temporary state ⇨monitoring recommended.
- Red: Fault state ⇨action required.
Note: The flashing LED indicates a higher level of the state.

- A 4x20 characters display screen

- 2 menus navigation keys and
- 2 selection keys and
RESET SET
- 2 function keys ESC and ENTER

ON OFF
- 2 charger operation keys and .

Sequential display of measurements CHARGER

54.5V 5.0A
In the absence of any particular events, Crystal displays sequentially pages Floating in progress
integrating output charger measurements, the charge mode in progress and,
depending on the selected configuration:
- Battery measurements : BATTERY
- Voltage, Current (the "-" sign corresponds to a current discharge), 51.3V -37.0A 27°C
Remaining backup T.:
Temperature near by the battery if heat sensor option. 02:32
- Remaining backup time (hours : minutes) if autonometer option.

OUTPUT
- Output measurements : 54.5V 5.0A
- Voltage, Current

- Mains measurements :
MAINS
- Voltages, Currents, Frequency L1 400V 1.0A 50Hz
If UIF Option, see « Mains measurements » chapter for more information.

Note: A specific page can be displayed for a while. Use the and keys to select the desired
page. This displayed page will maintained approximately 30 seconds then will come back to the sequential display. The sequential display
RESET
also comes back after pressing the ESC key.

Displaying of an event
When an event occurs, a page is inserted into the display sequence. The page EVENT
describes the event and date (DD/MM/YYYY) and time (HH:MM:SS) of No mains
occurrence.
27/03/2011 13:35:23
When the event disappears, the page is deleted from the display sequence.

FP40R rectifier - 641182

 Displaying of an alarm or a fault 13
When an alarm or a fault occurs, the supervisor immediately displays a page
describing it with the date (DD/MM/YYYY) and the time (HH:MM:SS) and stop the
sequential display. ALARM
Low battery
- Non-memorized alarm or fault : When the alarm or the fault disappears, the
27/03/2011 14:40:51
page is deleted and the sequential display returns.

FAULT
- Memorized fault : The page is maintained till the fault is acknowledged. For End of discharge
RESET
resetting the fault, press the ESC key. 27/03/2011 14:53:42

Note : When a fault is displayed, the other pages can be switched by pressing the or keys.
The sequential display of pages will take again automatically after 30 seconds.

Displaying of history of events

Use the and keys to go to the « HISTORY » page.

Use the and keys to view events, alarms and faults. The most recent
event, alarm or fault is <001>. HISTORY
<001> Beginning
End of discharge
27/03/2011 14:53:42
The pressure on the key allows to display the older events, alarms or fault
(maximum up to 100).

The event, alarm or fault state is indicated by "Beginning", "End" or "Reseted".

The description of the event, alarm or fault is indicated on the third line; the date (DD/MM/YYYY) and the time
(HH:MM:SS) on the fourth line.

RESET
Press the ESC key to return to the sequential display.

FP40R rectifier - 641182

Usual settings and commands
14
The settings and commands below can be accessed without a password from the display screen.

Use the and keys to go to the required screen.

Use the and keys to select the required value.
SET
Press the ENTER key to validate your choice.
RESET
Press the ESC key to return to the sequential display.
LANGUAGE
<English>
Choice of language
Confirm : ENTER

DATE YYYY/MM/DD
<27/03/2008>
Setting of the date
Confirm : ENTER

HOUR HH:MM
<13:30>
Setting of the time
Confirm : ENTER

BACKLIGHT
Setting of backlight <3>

Confirm : ENTER

CHARGER
<OFF>
Charger ON/OFF command
Confirm : ENTER

BOOST
<ON>
Boost command*
Confirm : ENTER

LED TEST
<ON>
LED test command
Confirm : ENTER

ONLINE BAT. TEST

<ON>
Online battery test command
Confirm : ENTER

BATTERY TEST
<ON>
Battery test command
* See « Advanced function » chapter Confirm : ENTER

FP40R rectifier - 641182

 15
Restricted access
Other commands and settings are available with a password:
RESTRICTED ACCESS
Use the and keys to go to the "RESTRICTED ACCESS" screen.
SET
Press the ENTER key to enter the menu. Confirm : ENTER

The password input screen is displayed.

PASSWORD
Enter the password using the 6 keys shown on the display screen and press the <****>
SET
ENTER key.

The factory –defined password is :

If the password is wrong, the following screen appears. PASSWORD

Wrong password

The flashing of 3 leds (green, yellow, red) indicates the restricted access mode.
Use the and keys to go to the required screen.
Use the and keys to select the required value.
SET
Press the ENTER key to validate your choice.
RESET
Press the ESC key to return to the sequential display.

The tree structure below gives the list of commands and settings available depending on the options and
system configuration.

FP40R rectifier - 641182

 16

* Depending on option and system configuration (see « data sheet » page).

** Depending on charging mode configuration

FP40R rectifier - 641182

Range parameters setting
17
Parameter designation List of choice
Language French / English / Russian / Spanish
Date YYYY/MM/DD
Time HH:MM
Backlight 1 to 5
Password 4 characters (combination of 6 keys). Factory setting :
MODBUS address(1) 1 to 127
Battery type Pb (lead acid) NiCd (nickel – cadmium)
Battery cells number(2) Rating Pb (Lead acid) NiCd
15V 4 to 7 6 to 11
30V 8 to 15 12 to 23
60V 15 to 30 22 to 47
120V 29 to 60 45 to 95
240V 58 to 120 92 to 191

Battery capacity From 1Ah à 25 times the charger current rating

Battery current 5 to 30% of battery capacity
Voltage drop 0 to 10V
Type of charge Single stage / Dual stage
Floating voltage 2.15 to 2.35V/cell for lead acid / 1.35 to 1.55V/cell for NiCd
Boost voltage(3) 2.20 to 2.45V/cell for lead acid / 1.40 to 1.65V/cell for NiCd
Boost duration(3) 1 to 99h
No mains duration(3) 0 to 60min
Equalizing voltage(4) 2.30 to 2.75V/cell for lead acid / 1.5 à 1.70V/cell for NiCd
Equalizing duration(4) 1 to 99h
Low battery threshold 1.70 to 1.95V/cell for lead acid / 0.95 to 1.15V/cell for NiCd
End of discharge threshold 1.60 to 1.85V/cell for lead acid / 0.90 to 1.10V/cell for NiCd
SID1 engage threshold (4) 0 à 100% of voltage range
SID1 disengage threshold (4) 0 à 100% of voltage range
SID2 engage threshold (4) 0 à 100% of voltage range
SID2 disengage threshold (4) 0 à 100% of voltage range
Programmable threshold 1-2-3-4-5(4) 0 à 100% of the programmed set value
Date of first battery test(4) YYYY/MM/DD
Time of first battery test(4) HH:MM
Frequency of battery test(4) 1 to 365 days

(1) In case of several units are connected to the RS485 bus.

(2) Maximum number of battery cells that the equipment can accept (the setting range on the display screen may be greater).
(3) According to charge type configuration.
(4) According to option.

For the factory setting values, see the « characteristics » page.

FP40R rectifier - 641182

Advanced functions
BOOST MODE 18
If the « Dual-stage » charge type is selected in the settings, the boost mode allows rapid battery charging by
applying a higher voltage during the (T4) duration: « Boost duration ».
The automatic launch of the boost mode can be realised according to two methods:
- Method n°1 : Launching due to the loss of mains for a time greater than the duration (T3) : « No mains
duration ».
- Method n°2 : Launching due to a voltage threshold of beginning of battery discharge passed through during
a time greater than the duration (T3) : « Battery discharge duration ».
This second method allows to engage the boost mode only after a significant battery discharge, thus
avoiding the phenomena of « cycling » that occur during short and frequent losses of mains. It is factory set
requires to know the type and the capacity of the battery as well as the output current when no mains.
See the « characteristics » page to know the method employed for the launching automatic of the boost.
It also can be manually started via the keyboard of the display. During the boost mode, the green LED of the
display flashes.
Automatic Manual
command T1 T2 command

ON / Charged

Mains / Battery

OFF / Discharged

t t
Udc T3 T3 T4 Udc T4

Boost Boost

Floating Floating

Settings are defined in-factory (see « Characteristics » t page). Protected by a password, they can also
t be
modified via the display (see « Restricted Access » paragraph):
- Floating voltage
- Boost voltage
- Boost duration
- Duration of no mains or of the discharge battery (T3)
- Battery discharge threshold commanding the boost in automatic mode (if method n°2 configurated)
MONITORING OF DC CURRENT
This four-threshold monitoring is used to prevent any charging system anomaly in order to protect the battery (in
compliance to the NF C 58 311 standard).
Threshold Consequence IOA board relay
Charger overvoltage Charger stopped RE4 switch: Fault
Charger undervoltage Charger stopped RE4 switch: Fault
Low battery Approaching end of battery back-up RE3 switch: Alarm
End of battery discharge End of battery back-up time RE4 switch: Fault
These thresholds are delayed 10 seconds (excepted charger undervoltage delayed of 60s) in order to avoid triggering on fast transients.
They further have an hysteresis of 2% to ensure clear switching.
* The « Charger undervoltage » threshold is inhibited during the phases of charger or battery current limitation.

Threshold values are defined in-factory (see « Characteristics » page). It is however possible to modify the
value of « Low battery » and « End of battery discharge » thresholds via the display (see « Restricted Access »
paragraph) :
Important : These thresholds generate alarms on IOA board relay that must be processed (see
« Input/output board configuration » paragraph).

FP40R rectifier - 641182

Manual battery equalizing
19
Used to equalize open cell lead or NiCd batteries, either as full or half batteries, depending on the equalizing
voltage. Equalizing must be performed under operator surveillance.

Equalizing mode is entered manually using the keyboard of the display (see "Restricted access" paragraph).
During equalizing, the green LED of the display flashes.

One of these two equalizing modes (see "Characteristics" page) was factory set:

Full battery equalizing:

This equalizing mode is implemented with the full battery string connected to
the charger. Ensure that the output voltage level is not detrimental to the EQUALIZING
equipments connected to the ouput. We recommend to disconnect the <OFF>
equipments connected to the output during equalizing operation. Battery full
Output: ESC
Once the equalizing duration has elapsed, the charger automatically returns to
floating mode.

Half-battery equalizing:
This equalizing mode is used when the equalizing voltage is higher than the
voltage the charger can deliver. In this case, the battery must be divided into
EQUALIZING
two identical branches. If the battery contains an odd number of cells, the
<OFF>
equalizing voltage applied will correspond to the branch with the most battery 1/2 battery
cells. To form the branch comprising the smallest number of cells, the number Output: ESC
of configured cells must be decreased by one cell via the display screen.
The output circuits must be open and each half-branch should be successively
connected then equalized. Once the equalizing duration has elapsed, the charger stops.

CAUTION: After equalizing, if the number of battery cells has been modified, it must be restored.

The following settings are available via the EQUALIZING VOLTAGE EQUAL. DURATION
keyboard of the display (see "Restricted access" <2.45> V/cell <10> Hour
paragraph): =58.8V
- Equalizing voltage Escape: ESC Escape: ESC
- Equalizing duration
- Battery current
- Number of cells
BATTERY CURRENT CELLS NUMBER
<10> A <24>

Escape: ESC Escape: ESC

FP40R rectifier - 641182

 IOA Input / Output board configuration
The PCB configuration from the factory is as follows : 20
27 15 14 13
Input Terminals Contact Switch
Output protection 27-26 Open = fault 1 ON

SID fan failure* 25-24 Closed = fault 2

Mains protection 23-22 Open = fault 3 123456
Battery protection 21-20 Open = fault 4 OFF
Insulation controller 19-18 Open = fault 5
Battery ventilation 17-16 Open = fault 6
The inputs operate in the logic « input operated = open loop ». When these are
used, commutate the switch corresponding to the input on OFF position; the
input operating being inhibited by the ON position
* The « SID fan failure » fault operates in the logic « active fault = closed loop ».
1 12
RE1 : Normal operation ⇨ contact 1-2 closed
Mains present with no alarms or faults and no battery

Battery-powered
discharge.
RE2 : Battery-powered operation ⇨ contact 4-5 closed

operation

operation
Battery discharge following lack of mains, manual shutdown or

Normal

Alarm
fault leading to battery discharge.

Fault
RE3 : Alarm ⇨ contact 8-9 closed
- No mains RE1 RE2 RE3 RE4
- Low battery
- No battery
- Control lost 1 2 3 4 5 6 7 8 9 10 11 12
- Output overload
The contacts are shown system
- Current limitation failure difference power off.
- Weak battery
- Battery room fan failure
- Loss of communication with peripheral boards (LED, UIF, UTB)
RE4 : Fault ⇨ contact 11-12 closed
- Charger overvoltage
- Charger undervoltage
- End of battery discharge
- Charger overheating
- Unit unplugged
- Unknown unit
- Module overvoltage
- Mains protection fault
- Battery protection fault
- Output protection fault
- Battery current sensor failure
- Loss of communication boards IOB / IOC

FP40R rectifier - 641182

Additional I/O boards
21
The Crystal supervisor can drive additional boards IOB and IOC.
31 30 29 15

IOB
Input Terminals Contact
Not used 29-28 Open = fault
Not used 27-26 Open = fault
Not used 25-24 Open = fault
Not used 23-21 Open = fault
Not used 22-20 Open = fault
Not used 19-18 Open = fault
Not used 17-16 Open = fault
Not used 15-16 Open = fault 1 8 9 14
The inputs operate in the logic « input operated = open loop »

- RE1 : Not available

31 30

available
Contact 2-3-4 used for the control of SID1 diodes.

used

used

used
RE2 : Not used ⇨ contact 6-7 closed

Not

Not

Not

Not
-

RE1 RE2 RE3 RE4

- RE3 : Not used ⇨ contact 9-10 closed

- RE4 : Not used ⇨ contact 12-13 closed 1 2 3 4 5 6 7 8 9 10 11 12 13 14

The contacts are shown system power off.

Note : When the equipment has a two step voltage limitation device (SID), IOB outputs 1 to 8 are used
for its control.

FP40R rectifier - 641182

Presentation of the UTBAT supervisor
The synoptic below represents the UTBAT supervisor equipped with all the available options. These options are 22
integrated in the supervisor based on the technical data specified in the order.
Note: Refer to the product parts list to determine the options supplied.

LED (Option) DIS DISPLAY SCREEN

8 LED indicators 4x20 characters
To FP40R 3 (CRL)
To FP40R 2 (CRL)
To FP40R 1 (CRL)

UTB interface UTB supervisor

COM (Option) IOB (Option) IOC (Option) IOA TMP

External Digital inputs / Digital outputs Digital inputs / TEMPERATURE
communication Outputs Outputs PROBE
RS485 MODBUS (Option)

FP40R rectifier - 641182

Display screen menus
23

* Depending on option

FP40R rectifier - 641182

Settings range for parameters 24

Parameter designation List of choices

Language French / English / Russian / Spanish
Date DD/MM/YYYY
Time HH:MM
Backlight 1 to 5
Password 4 characters (combination of 6 keys). By default:
MODBUS address(1) 1 to 127
Type of battery Pb (lead) / NiCd (nickel – cadmium)
(2)
Number of battery elements Rating Pb NiCd
15V 4 to 7 6 to 11
30V 8 to 15 12 to 23
60V 15 to 30 22 to 47
120V 29 to 60 45 to 95
240V 58 to 120 92 to 191
Battery capacity from 1Ah to 25 times the charger current rating
Low battery threshold 1.70 to 1.95V/Pb element / 0.95 to 1.15V/NiCd element
End of discharge threshold 1.60 to 1.85V/Pb element / 0.90 to 1.10V/NiCd element
(3)
SID1 engage threshold 0 to 100% of voltage range
(3)
SID1 disengage threshold 0 to 100% of voltage range
(3)
SID2 engage threshold 0 to 100% of voltage range
(3)
SID2 disengage threshold 0 to 100% of voltage range
(3)
Programmable threshold 1-2-3-4-5 0 to 100% of the programmed setting
(3)
Date of first battery test DD/MM/YYYY
(3)
Time of first battery test HH:MM
(3)
Frequency of battery test 1 to 365 days

(5) When several units are connected to the RS485 bus.

(6) Maximum number of battery elements that the equipment can accept (the settings range on the display
screen may be greater).
(7) Depending on option.

For the factory-set values, see the "characteristics" page.

Battery voltage remote control
The UTB supervisor can measure the battery voltage as close to the battery as possible. This measurement is
transferred to the CRL supervisors at the rectifier end for comparison to the configured voltage set-point. The
correction is applied to the voltage set-point.
Current equalization
The UTB supervisor can measure the operating current. This measurement is averaged based on the number of
rectifiers connected. This average value is transferred to the CRL supervisors at the rectifier end for comparison
to the rectifier output. The correction is applied to the voltage set-point.
Battery current limiting
The UTB supervisor can measure the battery current. This measurement is transferred to the Crystal
supervisors at the rectifier end for comparison to the configured battery current set-point. The correction is
applied to the voltage set-point.

FP40R rectifier - 641182

Battery charge current limitation
25

Following an operation on battery, on return of mains power, the battery naturally demands a strong recharge
current from the charger. As the total current limitation (lt) is generally too high to safely limit the current
absorbed by the battery, a battery current measurement is used to limit this recharge current to a lower set
value lb, thus preserving the battery.

Voltage / current characteristic

Un
It

Un: Rated regulation voltage

Ib
It: Total current limitation threshold

Ib: Battery recharge current limitation threshold

time

On return to mains power, the battery recharge current is limited to lb; consequently, the DC voltage
automatically drops. The DC voltage returns slowly to its nominal value Un, as long as the current is limited to
Ib. Once the recharge current drops below the limitation threshold lb, the DC voltage is maintained to Un.
During the battery recharge current limitation phase, the charger also delivers current for the load. The total
current limitation enters in action when the sum of battery and load current exceeds the value lt.

Battery circuit test

Ud
c
The Battery Circuit Test checks the continuity of the battery U fl
circuit. Once the charger has been started, this test will be
performed every 24 hours approximately. For 5 seconds, Fault threshold
the rectifier is put in standby mode and the supervisor Rectifier standby
monitors the battery voltage. If the fault threshold is
exceeded (battery protection open, cable disconnected,
etc.), an alarm is indicated.

t0 t1 t
RESET
Acknowledging by pressing ESC launches an additional Positive test Negative test
test.

FP40R rectifier - 641182

CRYSTAL maintenance
26

Preventive maintenance
As with any electrical installation, the technician in charge of maintenance or the electrician responsible for the
installation must regularly carry out the usual checks:
- Tighten connections
- Check that there is no overheating
- Ensure that the air intakes are clean
- Batteries require special monitoring. A full or partial autonomy test can be conducted according to the
facility's maintenance specifications in order to check the battery's condition, its ability to deliver energy
during the autonomy period, ageing, etc. The battery capacity test option provides battery status information
(see "Battery capacity test" chapter).

Corrective maintenance
Caution: it is essential to use alarm relaying to monitor the operating status of the facility.

As soon as a fault appears, the technician in charge of maintenance must intervene at the earliest possible
opportunity. Direct voltage measurement, indications, display screen messages and alarm / fault relaying status
and examination of the display screen history allow operators to troubleshoot the failure.

RESET
Note: When a fault page is displayed, pressing the ESC key acknowledges relays RE1, RE2, RE3 and
RE4, which fold back to normal position, floating mode for example. When a new fault appears, they will
switch again to signal the fault.
RESET
If the fault is memorised, pressing the ESC key again acknowledges memorisation, display and LED
notification. If the fault is still present, it will be displayed again after its time delay.

Switching off
- Open the upstream mains switch.
- Open the battery protection.
- Wait for a few minutes to allow the electrochemical capacitors to discharge.

Note: If the equipment is powered down for more than 10 days, the date and time must be set on
recommissioning.

Incompatible module detection

The supervisor checks the compatibility of the peripheral boards and charger with the factory-configured
parameters. If an incompatibility is detected, following electronic board replacement, a fault is generated and a
message displayed: "Unknown module". You must then contact our After-Sales Service.

For online assistance, call CIS maintenance services at +33 472 47 63 80.

FP40R rectifier - 641182

Specifications
MC1810 2xFP40R10 40 48U 27
Specifications
Environment Protection classes IP41
Cable inlet bottom entry
Cabinet colour RAL 7035
Operating temperature Min / Max 0°C / 40°C
Relative humidity Max 95% @20°C
Altitude Max 1000m
Power lost Max 360W
Grounding Grounding resistance
CEI / IEC 60146
Dielectric strength
Mains Voltage 230 Vac single phase +/-10%
Frequency 47/63Hz
Absorbed current (In) 15A
Inrush current limitation <15 In
Upstream circuit breaker recommended 32A
Min 6mm²
Connection wire size
Max 10mm²
Battery Type Nickel Cadmium
Number of cells 1.2 V / Cell 38 Cells
Capacity 75Ah
Current (no mains) 18A
Manufacturer SAFT
Reference UP1M 75
Battery fitting On rack
Settings Floating voltage 1.42V/Cell 54V
Boost voltage 1.45V/Cell 55.1V
Boost duration (T4) 12 hours
Duration of mains outage (T3) 3 minutes
Type of equalizing Battery full
Equalizing voltage 1.65V/Cell 62.7V
Max. equalizing duration 12 hours
Charger current limitation (It) 25A
Battery current limitation (Ib) 7.5
Use Voltage +-% 48V
Current (mains on) 18A
Battery
Residual undulation rate 2.5%
disconnected
Monitoring Charger max. voltage 10s 105% of current mode
thresholds Charger min. voltage 10s / hyst. 2% 92% floating voltage
Low battery voltage 10s / hyst. 2% 41.8V
Battery end-of-discharge voltage 10s / hyst. 2% 39.9V
Rectifier current overload 10s / hyst. 2% 25A +5%
Option Coupling diode included
Permanent ground controller not included
Standards CEM French standard EN 61000- 6-2, 6-4
DBT French standard EN 60439-1
Battery rectifier-charger complies to NF C58-311

Emerson Network Power IS FP40R Manual Edition: 04

30, avenue Montgolfier –BP90
69684 Chassieu – France
Tél. : +33 478 40 13 56 – Fax : +33 478 90 58 90
e-mail : industrial.sales.chloride@emerson.com 641182-EN Date : 06/10/2016
is a brand of
Emerson Network Power IS http://www.emersonnetworkpower.com
Spare parts 28
Recommended batch for commissioning

N° Designation Quantity

6010480 PCBA 1006-A - INTERFACE EMC HEXAGONE 1

1002281 FUSE - CYLINDRICAL 5 X 20 0.125A TIME LAG 3

1004503 FUSE - CYLINDRICAL 14 X 51 32A gG-P 2

1002307 FUSE - CYLINDRICAL 10 X 38 2A gG 2

Recommended batch for use

N° Designation Quantity
6010480 PCBA 1006-A - INTERFACE EMC HEXAGONE 1
1002281 FUSE - CYLINDRICAL 5 X 20 0.125A TIME LAG 3
1004503 FUSE - CYLINDRICAL 14 X 51 32A gG-P 2
1002307 FUSE - CYLINDRICAL 10 X 38 2A gG 2

6012034 PCBA 1033 - HEXAGONE - SETTINGS 1

1016228 CIRCUIT BREAKER S202-D20 - 352264 1
6013584 RECTIFIER BRIDGE MM 45 N 1
6006379 PCBA 1026 LOGICAL I/O 1
5810200140 CIRCUIT BREAKER S202-D25 - 352265 1
1013470 CIRCUIT BREAKER S202-C32 - 352241 1
5810200129 CIRCUIT BREAKER S202-C40 - 352242 1
5810200137 CIRCUIT BREAKER S202-D6 - 352260 1
5810200137 CIRCUIT BREAKER S202-D10 - 352261 1
1008315 CIRCUIT BREAKER S202-C10 - 352236 1
6008348 PCBA 1050 24/240V (15-300Vdc) 1
6008355 PCBA 1051 DISPLAY CRYSTAL 1
6008356 PCBA 1052 free voltage input output remote alarms Crystal 1
6012281 PCBA 1090 24/240V (15-300Vdc) 1

Emerson Network Power IS FP40R Manual Edition: 04

30, avenue Montgolfier –BP90
69684 Chassieu – France
Tél. : +33 478 40 13 56 – Fax : +33 478 90 58 90
e-mail : industrial.sales.chloride@emerson.com 641182-EN Date : 06/10/2016
is a brand of
Emerson Network Power IS http://www.emersonnetworkpower.com