Project: GSS-106-021821 Date: 18-02-2021

REFERENCE STANDARDS

IEC
Low-voltage switchgear and controlgear assemblies 60439-1
60439-2
60439-3

Semi-conductor converters 60146-1-1

60146-1-3
60146-2

Degrees of protection provided by enclosures (IP Code) 60529

Low-voltage switchgear and controlgear

Circuit-breakers 60947-2
Contactors 60947-4
Low-voltage fuses 60269-2

Wiring 60332-1-1
60332-2-1

Direct acting indicating analogue electrical measuring instruments and their accessories 60051-1

Information technology equipment – Safety 60950

Electromagnetic compatibility (EMC) 61000-6-2

61000-6-4

Secciones Calibre
4x10x100 5x80 1250
3x10x100 10x80 1000
2x10x100 5x60 800
10x100 10x60 630
5x100 5x100 500
5x50 2x5x80 400
5x40 2x10x80 315
7x30 2x5x60 300
25x3 25x3 250
5x25 2x5x100 200
5x20 3x5x80 160
70 3x10x80 125
50 3x5x60 100
35 3x10x60 80
25 3x5x100 63
16 50
10 40
6 32
4 25
2.5 20
1.5 16
10
6
 DATASHEET

System description

No. of battery chargers: 2 Model: TB_Tronic Nominal voltage: 110 V

Nominal current: 300 A Manufacturer: Tecnibat Country: Spain
Technology: Thyristors No. of pulses: 12 pulses Operation mode: Parallel - redundant
Charger current limitation: 300 A

Dropping diodes voltage: Yes No. Of stages: 3 Location: Distribution board cabinet

Distribution board (DB): Yes No. of DB: 2 Location: Distribution board cabinet

No. of batteries: 2 Type: KM830 Battery technology: Ni-Cd Medium discharge

Manufacturer: Gaz Country: Germany Cell capacity: 830 Ah
No. of strings: 1 Total capacity: 830 Ah No. of cells per string: 86

Battery isolator: Yes Type: Circuit breaker Location: Separate box

Battery monitor: No Type: Not apply Location: Not apply

No. of battery racks: 2 Type:

System configuration

Charger output nominal current / charger output nominal power: 300 A / 33000 W
Nominal output voltage (Vdc): 110 V
Maximum voltage tolerance in DC loads services / Maximum dynamic loads voltage: 10 % / 121.0 V
Minimum voltage tolerance in DC loads / Minimum dynamic loads voltage: 15 % / 93.5 V
System configuration: 2 chargers working on parallel-redundant op. mode, sharing
loads and 2 battery

DC bus earth reference: Poles not referenced to ground

Design parameters

IP degree / Color of the cabinet IP42 / 7032

Cooling in the cabinet / Cooling for rectifier bridge: Natural convection / Natural convection
Maximum heat losses each charger (tolerance ± 10 %) < 9344.6 W
Noise level @ 1 meter (tolerances ± 2 dBA) < 65dBA
Charger MTBF value: 193300 h
International standard: IEC 60146
Quality standard: ISO 9001
Maximum altitude for nominal current / Design altitude and limit current: 1000 m / 1000 m
Minimum / Maximum operation temperature: 0 ºC / 50 ºC
Storage temperature range of the charger: -20 ºC to 70 ºC
Maximum air relative humidity (without condensation): 95%

Input

Input rated voltage / permisible variation / number of phases: 400 V ± 10 % 3 Ph

Nominal frecuency / tolerance: 50 Hz / ±5%
Current harmonic distortion level at maximum power THDi: <29%
Charger input power factor at maximum power and input rated voltage: 0.75
Input true power in float mode (Tolerance ± 10%): 44678 W
Input apparent power in float mode (Tolerance ± 10%): 59571 VA
Input true power in equalizing mode (Tolerance ± 10%): 51915 W
Input apparent power in equalizing mode (Tolerance ± 10%): 69220 VA
Input true power in pre-commissioning mode (Tolerance ± 10%): 0W
Input apparent power in pre-commissionning mode (Tolerance ± 10%): 0 VA
Maximum input current value: 99.9 A
Minimum recommended size for input protection (D or Gl curve): To confirm at 125 A
Breaking capacity of the input protection: engineering stage 15 kA
Minimum recommended cross section (mm²) for input terminals: 35.0 mm2
Output

Output rated voltage: 110 V

Charger permanent output current: 300.0 A
Charger output current limitation: 300.0 A
Battery charge current limit – Capacity / Current: C5 / 166 A
Battery charge voltage in float mode / Tolerance (±): 122.12 V 0.5 %
Output power in float mode: 36636 W
Battery charge voltage in equalizing mode / Tolerance (±): 141.90 V 0.5 %
Output power in equalizing mode: 42570 W
Battery charge voltage in pre-commissioning mode (loads not connected) / Tolerance (±): 0.00 V 0.5 %
Output power in pre-commissioning mode (loads not connected): #VALUE! 0W
Maximum charger output ripple voltage (battery not connected): 2%
Charger efficiency (Tolerance ± 3%): 82 %
Charger maximum losses value in float mode (W) / Tolerance: < 6594.5 W / ± 10%
Charger maximum losses value in equalizing mode (W) / Tolerance: < 7662.6 W / ± 10%
Minimum recommended cross section (mm²) for output terminals: 25 mm2

Battery

Manufacturer: Gaz
Battery technology: Ni-Cd Medium discharge
Cell type: KM830
Battery design life under manufacturer conditions: 20 years
Nominal capacity C5 (discharge voltage 1V/cell at 20ºC) 830 Ah
Battery charge current limit 166 A
Number of cells per string / Number of strings per battery: 86 / 1
Floating voltage per cell / per battery: 1.42 V / 122.12 V
Equalize voltage per cell / per battery: 1.65 V / 141.90 V
Pre-commissioning voltage per cell / per battery: 0.00 V / 0.00 V
Battery isolator within the DCDB / within the battery protection box: Load switch / Fuse 2P
Breaking capacity of the battery isolator: (To confirm at engineering stage): #N/A 200 A

DC voltage regulator – Dropping diodes stages

Maximum input voltage at dropping diodes stage: 141.9 V

Maximum input voltage at loads: 121.0 V
Minimum input voltage at loads: 93.5 V
Dropping diodes nominal current: 200.00 A
To confirm at
Number of dropping diodes per stage / Number of stages: engineering stage
10 / 3
Losses per stage (W) / Tolerance (±): 1500 W / ± 10%

Distribution board 1

Type Model No. Of poles Rated current Isc Aux.Contact Quantity

Incomer : MCB NZMN2-A-160 3 160 A 50 kA Yes 1
Bus Coupler MCB NZMN2-A-160 3 160 A 50 kA Yes 1
Outgoing (type 1): MCB FAZ6-C32/2 2 32 A 10 kA Yes 10
Outgoing (type 2): MCB FAZ6-C16/2 2 16 A 10 kA Yes 10

Distribution board 2

Type Model No. Of poles Rated current Isc Aux.Contact Quantity

Incomer : MCB NZMN2-A-160 3 160 A 50 kA Yes 1
Outgoing (type 1): MCB FAZ6-C32/2 2 32 A 10 kA Yes 10
Outgoing (type 2): MCB FAZ6-C16/2 2 16 A 10 kA Yes 10

System dimensions - per system (To confirm at engineering stage)

Unitary weight Load over floor

Height Large Deep Quantity
(kG) (kg/m2)
System cabinet: 2
Distribution board cabinet 2
Battery Rack: 2
 SYSTEM SPECIFICATION

Communications

Remote communications:
Volt-free contacts: Included Modbus RTU vía RS485: Included
Modbus TCP/IP via Ethernet: Optional

Local communications by front-panel display:

Parameters: Status:
- Secondary winding voltage of power transformer - Status of the power supply grid
- Rectifier bridge output current - Status of the battery
- Rectifier bridge output voltage - Float mode charge
- Battery current - Equalize mode charge
- Battery voltage - Pre-commissioning mode charge
- Loads voltage
- Loads current
- Percentage of battery charge

Management software:
- Software for managing the charger: Optional
Protections included within the charger

AC input: Circuit breaker Rectifier bridge input: Optional

Battery output: Circuit breaker Rectifier bridge output: Fuse 1P
Loads output: Circuit breaker RC network for rectifier bridge: Optional
AC capacitor: Not apply AC surge protection device: Optional
Auxiliary circuits: Not apply DC surge protection device: Optional
Sockets: Not apply Blocking diode: Included

Additional measuring instruments

Charger input voltage (AC): Analogue Charger input current (AC): Analogue
Rect.bridge voltage (DC): Optional Rect.bridge output current (DC): Optional
Battery voltage (DC): Optional Battery current (DC): Analogue
Loads voltage (DC): Analogue Loads current (DC): Analogue

Standard charger alarms

Description Local signalling Remote signalling Description Local signalling Remote signalling
Mains fault Display/Led Relay 1A High DC voltage Display/Led Relay 4A
No charge Display/Led Relay 2A I/O MCB/MCCB/Fuse Display/Led Relay 5A
Low DC voltage Display/Led Relay 3A High temperature Display/Led Relay 6A
Positive earth fault Display/Led Earth relay (+) Negative earth fault Display/Led Earth relay (-)
Charger 1 Failure Display/Led Rectifier ON Display/Led
Charger 2 Failure Display/Led Float Charge Display/Led
Charger ON Display/Led Boost Charge Display/Led

Charger optional alarms

Description Included Signalling Description Included Signalling

High temperature of battery Yes Local + remote Battery discharge test fault No Not apply
High ripple No Not apply Current limit No Not apply
Low electrolyte level Yes Local + remote Incorrect phase sequence No Not apply
Battery symmetry fault No Not apply Mains Yes Not apply
Battery fuse failure Yes Battery circuit faulty Yes
Diode assembly failure Optional MCB Trip Yes

Optional components

Interior lighting: Included + door contact Low voltage disconnection contactor: Optional
Power socket: Optional Protection panel against indirect contacts: Metallic panel
Heater resistance: Included Additional leds card for local signalling of alarms: Optional
Additional 6 relays card: Included
Operation modes:

1.- Soft start: Included

2.- Float charge mode according to IU curve as per DIN41773:

- Automatic: Included
- Manual: via push button Included

3.- Equalize charge mode:

- Automatic: Included
- Manual: via push button Included
- Inhibited: Equalize charge mode is inhibited via software Included

4.- Pre-commissioning charge mode:

- Manual: via push button Included
- Inhibited: Pre-commissioning charge mode is inhibited via software Included

Manufacturing specification

General:
- Reference standard for design and manufacture: IEC 60146
- Quality standard: ISO 9001 certification
- Tropicalisation: Included

Other protections:
- Electronic blocking of rectifier bridge trip in case of abnormal input voltage: Included
- Protection for control circuits: Fuse

Wiring:
- Power circuit: Black stranded wires ≥ 1,5 mm2, fire resistant,
(bar for large systems)
- Control and printed circuits connections: Stranded wires 1mm2 (except RJ45)

- Wire marking: Ferrules

- Cable ducts within the charger panel: Included
- Earth terminal in charger cubicle: Included

Identification of system and components:

- Identification of system and components -
Included
Front-door and inside mounted components identified by laminated plastic labels:
- Labels colour: Black characters / white background
- Language: English
- Nameplate: Included

Cabinet design:

- The charger is housed in a free standing, full metal enclosed cabinet arranged for floor mounting.

- Structure: 3 mm thickness
-Panels 1.5mm thickness with reinforcements.
- Non-structural cold roller steel
- Panel's steel is phosphated primed
- Panel's painting: see painting specification
- Front acces for components requiring maintenance: Included
- Rear acces (non essential): Removable panel
- Hinged doors: Included
- Door handle secured by lock and key: Included
- Painting thickness: >70 µm
- Internal structure: Zinc plated
- Location cable entry: Bottom of the cabinet
- Gland plate (cable glands not included) for entry/exit of cables: Included
 PAINTING SPECIFICATION

1.- Process type

Painting process “900 hours in the spray salt” is applied for all standard metallic boxes and cabinets manufactured for Tecnibat. It doesn’t apply for other boxes or
cabinets commercialized by other manufacturers.

2.- Surface preparation – Degreasing and phosphating

Cleaning is done using a spray system with a degreasing and phosphating solution with a minimum of 4.5 minutes. After that is done a prewash, a subsequent rinsing
and a final wash. As a final result, is achieved a phospated layer of 0,8 to 1 g/m².

3.- Enforcement

Apply primer, zinc-rich powder by electrostatic guns twelve robot and manual retouching with an average thickness of 80 µm. A primer is then polymerized and
applies a layer of powder in the same conditions as the above process.

4.- Dry process

Is performed in a forced air furnace at an average temperature of 190 ° C for 20 minutes.

Approximated average duration of works done under this methode is 900 hours in spray salt.

5.- Features

- Flexibility as per BS3900-E11: < 3 mm

- Adherence as per BS3900-06: 0
- Erichsen stamping as per BS3900-E4: > 7 mm
- Hardness test as per BS3900-E2 Comply
- Impact test as per BS3900-E3 2,5 J
- Thickness of spray salt as per ASTM B117: < 2 mm
- Humidity chamber test as per BS3900-F2: Comply without losses of shine
- Resistance to acids, alkalis and oils Yes