TROOP AND COMPANY, S.A. DE C.V.

TRAINING COURSE

INSTALLATION, OPERATION AND MAINTENANCE

BATTERY CHARGERS

NICKEL-CADMIUM

AEG POWER SOLUTIONS

SPR and TPR MODEL

PREPARED BY: ENGINEER MANUEL RODRÍGUEZ ALCALÁ

JANUARY 2012
 CONTENT

BATTERY CHARGERS 1

SECURITY MEASURES 1

INSTALLATION 2

CONNECTIONS 4

OPERATION. 5

OPERATION. 14

MAINTENANCE 18

SERVICE 19
BATTERY CHARGERS

SECURITY MEASURES

Before using the charger, read all instructions and warning notices from:

The charger.
Battery
Any other equipment to be used together with the charger or the battery.

Remove all jewelry, watches, rings, bracelets, etc. Before starting any type of work with the
charger.

Make sure to use personal protective equipment.

Do not touch any part that is not isolated, especially the input and output connections as
There is a risk of electric shock.

Under normal operation, batteries can produce explosive gas. Never smoke or ignite a flame or produce sparks.
electricals near this equipment or the battery.

Turn off the charger before connecting or disconnecting the battery to avoid electric shock and damage to the equipment.

Connect or disconnect the battery only with the equipment turned off to avoid electrical arcs or burns.

Do not attempt to operate the charger if you notice that it is damaged in any way. Always refer to
trained and qualified personnel.

Do not attempt to disassemble any section or module of the charger. Incorrect assembly can cause severe
damage that can result in explosion, electric shock or fire.

Never install the charger or battery outdoors unless the enclosure is rated for it.
use.

Please read and observe all safety measures.

CHARGER COURSE - AEG POWER SOLUTIONS Page 1 of 20

[Link]
INSTALLATION

At the moment of receiving the material, a visual inspection of all the equipment must be carried out to
detect the possible anomalies due to transportation.

In case of storage before the installation of the equipment, place the material in a dry, ventilated location.
protected against rain, water projections, and chemical agents.

It is necessary to inventory the material and verify that all the items listed on the packing list are present.
presents before destroying the packaging. In case of breakdown or observed partial loss, the customer must
immediately file a claim within the deadlines required by the carrier, taking all the
necessary measures for the safeguarding of their rights.

Inspection list

The interior and exterior packaging is not damaged, broken, or torn.

There is no visible damage to exterior or interior components.
All interior components are secure.
All the printed circuit boards are securely in place.
All the screws are secure in their place.
All cable terminations are properly connected.

The material must be handled with care, always being moved in an upright position.
Labels placed on the outside of the packaging indicate the top and the bottom.

The installation site must comply with the following characteristics:

Ambient temperature and relative humidity in accordance with the environment (specified later)
Air environment free of dust and corrosive gases,
A sufficiently flat floor so as not to deform the cabinet when it is fixed to the ground.
Floor with the capacity to support the weight of the equipment.

The anchoring of cabinets to the floor is imperative in cases of built-in batteries, advisable in all other cases.
other cases. Consult the attached documentation to know the spacing and the diameter of the holes of
fixation.

Prepare for the installation:

Enough space to allow the door to open,
A minimum space of 10 cm behind the cabinet.
Note: in certain cases, this space can be modified (consult the attached documentation).

Placement of the wardrobes

The front and rear grills at the bottom of the cabinet (see attached figure) are delivered unassembled, inside.
from the cabinet. Install the cable pass-through plate (at the back) before placing the equipment.
The passage of the cables is done through the bottom. The assembly of the front grille must be done after having
The connections have been made. This grid can be a non-perforated sheet plate.

CHARGER COURSE - AEG POWER SOLUTIONS Page 2 of 20

[Link]
ENVIRONMENT (EXCEPT BATTERY)

Temperature
- In storage: -25 °C to +70 °C
- In operation: 0 °C to +40 °C
- Above 40 °C and up to 55 °C, decrease the output current by 1.25% per °C.

Relative humidity
- In storage: from 15% to 90% in its original packaging
- In operation: from 20% to 80% without condensation
Altitude
- ≤ 1000m
- Above 1000 m and up to 4000 m, decrease the current by 7% for every 1000 m section.

CHARGERS COURSE - AEG POWER SOLUTIONS Page 3 of 20

[Link]
CONNECTIONS

ANY INTERVENTION MUST BE CARRIED OUT BY QUALIFIED PERSONNEL WHO ARE AWARE OF THE DANGERS
SPECIFIC TO ELECTRICITY, AS WELL AS THE PRECAUTIONS THAT NEED TO BE TAKEN.

Connections must be made with everything turned off and with the circuit breakers in the 'open' position:
Network protection elements and open usage,
Battery protection element or disconnect switch open,
Power switch (option) in "STOP".

NETWORK CONNECTION

ATTENTION: IF THE RECTIFIER IS EQUIPPED, OPTIONALY, WITH AN INPUT FILTER: INPUT

RED: HIGH LEAKAGE CURRENT. CONNECTION TO GROUND ESSENTIAL BEFORE CONNECTION TO
THE NETWORK.

A network line protection is necessary if the equipment does not have an input protection option,
advising in all other cases.

Recommended gauge: 2 x Current absorbed.

Value of the current absorbed given in the attached documentation.
As standard, the starting current is less than 20 times the absorbed current. The connection with the
The electrical network is carried out with the terminal block located in the connection area.

In the case of a three-phase network (TPR), the phase order must be respected. Otherwise, the equipment will not function.

Don't forget to connect the equipment's ground bar to the ground.

LOAD CONNECTION

Connect the (+) of the use with the terminal (+) use of the equipment. Connect the (-) of the use with the
terminal (-) equipment utilization.

CHARGER COURSE - AEG POWER SOLUTIONS Page 4 of 20

[Link]
OPERATION.

STARTUP

ALL CUTTING ELEMENTS MUST BE IN 'OPEN' POSITION.

Check that the network line protection is well calibrated.

Check that the voltage and frequency of the network are compatible with the equipment (specification label).
Check the tightening of the connections (network, battery, usage).
Check the polarities, as well as the series connection of the battery blocks.

Leave the positive battery terminal open, either through the battery fuse (case No. 1 page
next), either by connecting the cable to the (+) BAT terminal of the rectifier (case No. 2 page
next).
Disconnect the negative battery terminal (-) (fuse, protection,...).
Close the network protections. Put the network into service and the rectifier into operation (optional).

The rectifier starts and the screen displays:

[Link]: version (xx) and edition (yy) internal program

version (xx) and edition (yy) text module.

After a few seconds, the screen displays the float voltage and the current of the rectifier (in open circuit).

RECT: 130.4V. 0.5A

MEASURE FUNC
NOTE: The current value is on the order of 0.5 A.

CHARGER COURSE - AEG POWER SOLUTIONS Page 5 of 20

[Link]
To ensure that the battery polarities are respected, measure with a DC voltmeter.
tension according to the following scheme.

CASE 1 CASE 2

BATTERY FUSE CONFIGURATION FUSELESS BATTERY CONFIGURATION

The measured voltage must be at most equal to 30% of the nominal voltage
If it is higher, check the polarities of the battery wires.
If the voltage is correct, close the fuse or connect the battery (+) wire to the rectifier terminal. The
The rectifier charges the battery. During this operation, electric arcs may appear at the terminals.
manipulated element.
Check that the current on the screen increases (current absorbed by the battery).

RECT: 130.4V. 100A

MEASURE FUNCTION

There are dangerous voltages at the battery terminals and/or usage. Take precautions.
of necessary security.

CHARGER COURSE - AEG POWER SOLUTIONS Page 6 of 20

[Link]
TURNING OFF THE EQUIPMENT.

ENSURE THAT ALL LOADS ARE TURNED OFF OR THE BATTERY IS CHARGED AND
IN GOOD CONDITION.

Open the output protections of the equipment (fuses, switches).

Open both internal and external network protections

If the battery is in good charge condition, the charge will be supplied by the battery.

OPERATION PANEL

The display of the charger information is obtained through a two-line LCD screen, the line of
information at the top and the menu bar at the bottom. To access the different options that
The screen is presented using a set of 3 buttons whose function will vary according to the information.
presented in the menu line.

For visual signaling, the operation panel has two LED-type light indicators. The green indicator
indicates that the system is operating correctly. When a failure or alarm occurs, the indicator
red will blink intermittently and the green indicator will turn off.

CHARGER COURSE - AEG POWER SOLUTIONS Page 7 of 20

[Link]
MENUS

The available menus are as follows:

Measures menu

From the default measures menu, various measures can be viewed. The transition from one measure to the
the following is carried out by means of the button marked 'MEASURE' on the screen. After the last available measurement, if one
press "MEASURE" to return to the default menu.

Load menu

From the default measurement menu, the user can activate the loading menu for the loading mode of the
rectifier in progress or consult certain load parameters.

Alarm menu

If an alarm is activated, the green light turns off and the red light blinks. Simultaneously, the message ‘ALARM’ is
visualize. By pressing the corresponding function button, the top line of the screen indicates the alarm
activated. If there are several alarms present simultaneously, this menu provides access to the alarm list.
The most recent alarm text appears flashing first on the list.

Historical menu

From the default measures menu, the user can activate the historical menu, which allows navigation through
from a chronological list of alarms or events. The historical content is deleted as soon as the equipment is powered off.
system cut-off (shutdown).

Configuration display menu

From the default settings menu, the user can view the configuration parameters of the
rectifier.

CHARGER COURSE - AEG POWER SOLUTIONS Page 8 of 20

[Link]
CHARGER COURSE - AEG POWER SOLUTIONS Page 9 of 20

[Link]
CHARGER COURSE - AEG POWER SOLUTIONS Page 10 of 20

[Link]
CHARGER COURSE - AEG POWER SOLUTIONS Page 11 of 20

[Link]
CHARGER COURSE - AEG POWER SOLUTIONS Page 12 of 20

[Link]
CHARGER COURSE - AEG POWER SOLUTIONS Page 13 of 20

[Link]
FUNCTIONING.

The SPR/TPR rectifiers are thyristor rectifiers suitable for charging Nickel-Cadmium batteries or
Lead without stopping to feed direct current loads. They can also be used as sources of
direct feeding without a battery.

MODES OF OPERATION

Operation with Network and Battery Presence

When the charger power supply network is present, it provides direct current energy to
the connected load while simultaneously keeping the battery in float state preventing it from discharging
due to the internal resistance of the battery.

Operation with absence of Network

In case the power supply is absent or experiences variations in voltage or frequency.

Outside of what is specified, the charger will stop operating and the batteries will provide the DC voltage instead.
What the load requires to continue operating. The time the system can operate in this way will depend on
the battery capacity and its state of charge.

CHARGER COURSE - AEG POWER SOLUTIONS Page 14 of 20

[Link]
Fast charging operation

The fast charging mode is necessary to recharge the battery after it has backed up to critical charge.
due to a failure in the power supply network. In this operating mode, the output voltage of the charger rises to
the levels indicated by the battery manufacturer for charging the battery, increasing the current consumption
from the battery.

The battery charging modes are:

Float: The float voltage compensates for the loss of battery capacity due to internal resistance and
therefore keeps the battery charged.

Fast charging (Equalization): This charging mode allows recovering the battery capacity after a
download. This charging mode can be activated manually through the operation panel, in a
automatic or can be programmed to be activated periodically (every month, 6 months, or 1 year). The voltage
Fast charging lasts for a time of 0 to 99 hours (according to factory settings).

CHARGER PROTECTIONS:

Thermal magnetic circuit breaker at the entrance.

Output fuses.
Surge protectors for AC and DC.
Current limit at 100% of its nominal capacity.
Slow ignition.

CHARGER COURSE - AEG POWER SOLUTIONS Page 15 of 20

[Link]
FUNCTIONING.

The supply voltage is applied to the primary of the isolation transformer through the
input switch. The secondary of the transformer is connected to a controlled three-phase rectifier.
complete six pulses. The output voltage of the rectifier contains alternating current components, therefore
A filter is placed, which is responsible for reducing the level of AC components to an acceptable level.

All functions of the charger are processed through the control card (CCU), which is powered through
from the power supply or through the battery. This board contains the microcontroller and memories in
where all the control and monitoring routines for all control parameters such as are
output voltage, rectifier current, battery current. The functions of this card are:

Convert analog signals (voltage and current) into digital signals.

Send the control signals for voltage and current regulation.
The measurement of voltage and current
Control of alarm cards (optional)
Control of the serial communication port.

TPC CARD

The TPC card is used, in combination with the CCU card, to control the three-phase rectifier bridge, for which
incorporates all the necessary electronics to synchronize and control the firing of the thyristors, including the

CHARGER COURSE - AEG POWER SOLUTIONS Page 16 of 20

[Link]
protection circuits. This board is powered by the auxiliary secondary of the transformer and receives the information
for the control of the thyristors on the CCU board.

BRIDGE RECTIFIER

The charger is made up of six silicon-controlled rectifiers (SCRs also known as thyristors),
two per phase. The SCR does not conduct or is off until a triggering pulse is applied in forward bias to the
gate terminal. Once triggered, the SCR remains in a conducting state until the current to
through its terminals is zero or until the polarity is reversed.

By varying the firing angle, the amount of energy at the output of the rectifier is controlled. If the current
the output demand from the rectifier is high, the triggering of the SCR will be at the beginning of the AC half-cycle and vice versa, in
In the event that the required current is low, the trigger will be after the start of the half-cycle of AC.

There are two closed control loops, the constant voltage one which is active under normal conditions of
operation and the constant current one that is active under overload conditions or current limit and nullifies all
action of the previous loop.

The floating mode is the normal operating mode of the charger and in this case the voltage control loop is active.
constant which is also active in the matching mode.

The voltage at the charger terminals is fed back to the control logic so that the voltage loop
Constant determine the firing angle of the losses to maintain the output at 1% deregulation.

When at the output of the charger a current greater than or equal to 100% of the nominal maximum capacity is demanded,
the closed current control loop goes into operation canceling all function of the voltage control loop
constant.

In this case, it will be observed that if the current demand continues to increase, the output current of the charger
remains constant at 100% while the output voltage decays, regardless of the mode of
operation (floating or equalization), proportionally to the overload current. This control loop also
It can be applied to the battery current by configuring the amount of current that should be delivered to the battery.

CHARGER COURSE - AEG POWER SOLUTIONS Page 17 of 20

[Link]
MAINTENANCE

Due to the technology used in the rectifiers, maintenance has been significantly reduced.
that no adjustment of the operating parameters is made by any mechanical means, all parameters
are contained in the microcontroller.

However, it is recommended that the following points be checked once a year:

Examine the components and the wiring, particularly watch for signs of overheating and
insulator fusion. Check all connections. Ensure that there are no loose wires.
disconnected.
Check that ventilation is not hindered.
For the rectifiers equipped with air intake filters (at the door), check the cleanliness of the
filters.
Check the operation of the rectifier and the voltage levels.
Equipment with a rating higher than 50 A is equipped with one or more fans whose lifespan
life is about 5 years. A thermostat (optional), mounted on the radiator of the power converter,
turn on the fan(s) above 64 °C.
It is recommended to replace the fans every three years. This operation should be carried out by personnel.
specialized.

CHARGER COURSE - AEG POWER SOLUTIONS Page 18 of 20

[Link]
SERVICE

When an alarm is activated, the green light turns off and the red light flashes. The message 'ALARM' is displayed.
Check the text of the present alarms. If, after pressing RESET (in the alarms menu), the red light does not turn off,
refer to the following help chart in order to remedy the found defect.

ALARM PROBABLE CAUSE ACTION TO BE TAKEN

Rectifier stopped Turn on the rectifier

Open network fuse(s) Check the fuse(s) and replace if necessary

RED ABSENCE
Network voltage out of limits Check the network voltage
The tension must be the specified one in the
attached documentation
Fuse rectifier fusion Check and replace the fuse if necessary. If
it melts again, contact the department of
FAIL Troop and Company service.
RECTIFIER
Low float tension without checking the network tension and the operation.
rectifier in current limiting suitable for the fans
TENSION The output voltage of the rectifier is Contact immediately with the department of
HIGH LOAD higher than the permitted maximum value Troop and Company service.
Battery discharging due to:

Rectifier stopped Turn on the rectifier.

TENSION
Network absence or low network voltage. Check the power supply.
LOW LOAD
Missing phase or phase sequence. Connect the power supply network correctly.
incorrect.

HIGH BLOOD PRESSURE The output voltage of the rectifier is Contact immediately with the department of
C. D. higher than the maximum allowed value Troop and Company service.
End battery discharge due to:

Rectifier stopped Turn on the rectifier.

LOW VOLTAGE
Network absence or low network voltage. Check the power supply.
C. D.
Missing phase or phase sequence Connect the power supply network correctly.
incorrect.

LAND + O Low resistance between the positive or Check for lack of insulation
EARTH negative output and ground
(< 100 Ω)

CHARGER COURSE - AEG POWER SOLUTIONS Page 19 of 20

[Link]
 Missing phase or phase sequence Correctly connect the network input
incorrect. food.

Network frequency out of bounds. Check the network frequency.

INACTIVE TPC Lack of synchronization. Contact immediately with the department of

Troop and Company service.

Electronic rectifier stop Contact the department immediately

due to a detection of high tension. Troop and Company service.

Connection failure between CCU and TPC. Check the cable.

Temperature sensor failure Check the sensor connection.
Check the sensors
COMP. FALL
TEMPERATURE
CCU-N ruling Contact immediately with the department of
Troop and Company service.
TEMPERATURE High temperature detection by the
Check the fans.
HIGH thermostat mounted on the radiator. Check that the airflow is not obstructed.
(only in Check the ambient temperature.
systems with Check the thermostat.
ventilation
forced and
option of
alarm of
temperature)

CHARGER COURSE - AEG POWER SOLUTIONS Page 20 of 20

[Link]