KraftPowercon PRM1 User manual

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
You must read this manual before installation, use or work on the product.
This product contains dangerous voltages that when touched can cause electric shock, burns
or death.
The product must be installed by qualified personnel and according to the installation
instructions. Service may only be performed by authorized service personnel. The equipment
housing may only be removed by authorised personnel when all power has been cut to the
equipment for at least five minutes. The protective covers and contact safety devices inside the
equipment may only be removed by authorised service personnel.
The power must always be disconnected in a safe way before starting any service/maintenance.
Warning for reverse voltage. Power is supplied from several sources.
Manual for
charging rectifier
type PRM1
SAFETY INSTRUCTIONS
Manual: 9-1718-A
P/n: 0001138

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
We reserve the right to make changes to the content of this manual without prior notification.

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
CONTENTS
1PRESENTATION.............................................................................................. 5
2SAFETY INSTRUCTIONS............................................................................... 6
3TECHNICAL DATA ........................................................................................ 7
3.1 ELEKTRICAL DATA.............................................................................................................................. 7
3.1.1 Assortment .......................................................................................................................................... 7
3.1.2 Common electrical input data .......................................................................................................... 7
3.1.3 Common electrical output data ........................................................................................................ 7
3.1.4 Electrical data for rectifier module................................................................................................... 8
3.2 ENVIRONMENTAL DATA .................................................................................................................. 8
3.3 MECHANICAL DATA .......................................................................................................................... 8
3.4 CONFORMITY WITH STANDARDS .................................................................................................. 9
4FUNCTIONAL DESCRIPTION.................................................................... 10
4.1 GENERAL .............................................................................................................................................. 10
4.2 APPLICATION EXAMPLE ................................................................................................................. 10
4.3 LIKRIKTARMODULER ....................................................................................................................... 11
4.4 RACK FOR RECTIFIER MODULES AND OPERATOR PANEL................................................... 11
4.5 TEST CONTACTS ................................................................................................................................. 11
4.6 I/O UNIT ................................................................................................................................................ 11
4.7 FUNCTIONS.......................................................................................................................................... 11
4.7.1 General............................................................................................................................................... 11
4.7.2 Float charging ................................................................................................................................... 12
4.7.3 Equalization charging...................................................................................................................... 12
4.7.4 Battery circuit test............................................................................................................................. 12
5OPERATION ................................................................................................... 13
5.1 GENERAL .............................................................................................................................................. 13
5.2 OPERATOR PANEL............................................................................................................................. 13
5.3 RECTIFIER MODULES ........................................................................................................................ 13
5.4 MAINS SUPPLY.................................................................................................................................... 13
5.5 TEST CONTACTS ................................................................................................................................. 14
6INSTALLATION INSTRUCTIONS ............................................................. 15
6.1 SAFETY INSTRUCTIONS ................................................................................................................... 15
6.2 GENERAL .............................................................................................................................................. 15
6.3 STORAGE AND PROTECTION ......................................................................................................... 15
6.4 MOUNTING .......................................................................................................................................... 15
6.4.1 General............................................................................................................................................... 15
6.4.2 Rack .................................................................................................................................................... 15
6.4.2.1 I/O Unit ......................................................................................................................................... 15
6.5 ELECTRICAL INSTALLATION ......................................................................................................... 15
6.5.1 General............................................................................................................................................... 15
6.5.2 Earthing ............................................................................................................................................. 16
6.5.3 Mains voltage.................................................................................................................................... 16
6.5.3.1 External fuse rating ..................................................................................................................... 16
6.5.3.2 Connection.................................................................................................................................... 16
6.5.4 Battery/Load...................................................................................................................................... 16

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
6.5.5 Rectifier modules.............................................................................................................................. 17
6.5.6 I/O Unit.............................................................................................................................................. 17
6.5.6.1 General .......................................................................................................................................... 17
6.5.6.2 Communication cable ................................................................................................................. 17
6.5.6.3 Power supply ............................................................................................................................... 17
6.5.7 Operator panel.................................................................................................................................. 18
6.5.8 Test contacts ...................................................................................................................................... 18
7STARTING UP ................................................................................................ 19
7.1 SAFETY INSTRUCTIONS ................................................................................................................... 19
7.2 PREPARATORY INSPECTION .......................................................................................................... 19
7.2.1 General............................................................................................................................................... 19
7.3 POWERING UP..................................................................................................................................... 19
7.3.1 DC....................................................................................................................................................... 19
7.3.2 AC....................................................................................................................................................... 19
7.4 CHECKING THE CHARGING VOLTAGE ...................................................................................... 19
7.5 CHECKING THE SETTINGS .............................................................................................................. 20
7.6 CHECKING THE OUTPUTS............................................................................................................... 20
8MAINTENANCE............................................................................................ 21
8.1 ANNUAL INSPECTION...................................................................................................................... 21
8.1.1 General............................................................................................................................................... 21
8.1.2 Checking the charging voltage ....................................................................................................... 21
8.1.3 Checking the cooling capacity........................................................................................................ 21
9FAULT TRACING.......................................................................................... 22
9.1 SAFETY INSTRUCTIONS ................................................................................................................... 22
9.2 FAULT TRACING FOLLOWING ALARM....................................................................................... 22
9.3 OTHER FAULT TRACING.................................................................................................................. 22
Bilagor
A LAYOUT AND DIMENSION, PRM1
B CIRCUIT DIAGRAM, PRM1

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
1PRESENTATION
PRM1 is a complete charge rectifier with built-in monitoring, intended for mounting in a 19”
rack.
The system is built on a modular basis for easy service and high flexibility. Its compact design
allows it to be used even in confined spaces. The clear display and well-arranged system of
menus of the monitoring unit make it easy and pleasant to work with. The rectifiers are of
“plug-in” type and can be connected in parallel to increase capacity and availability.
This description primarily deals with all installation, commissioning, service, maintenance
and technical data and is principally aimed at the personnel who are responsible for these
areas. An equivalent description of the parts of the equipment that relate to the monitoring
unit are detailed in the Manual for monitoring unit type PCM2.
Operation is handled primarily via the monitoring unit described in the Manual for monitoring
unit type PCM2. This is therefore chiefly aimed at the personnel that have the day to day
responsibility for the plant, but also to other personnel who have cause to work with the D.C.
system.
For a complete description, this manual is to be used together with the description for the
monitoring unit, Manual for monitoring unit type PCM2.

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
2SAFETY INSTRUCTIONS
This product contains dangerous voltages that when touched can cause electric shock, burns
or death.
For safety reasons the concerned personnel are classified according to the following
requirements for specific skills.
Authorised service personnel:
•Have electrical training and adequate experience to avoid the dangers that electricity can
cause.
•Are certified to meet authority requirements for the work in question.
•Have linguistic skills that ensure that the content of this description cannot be
misunderstood.
•Have undergone a product-specific training programme for authorised service personnel
that are approved by KraftPowercon Sweden AB.
Qualified personnel:
•Have electrical training and adequate experience to avoid the dangers that electricity can
cause.
•Are certified to meet authority requirements for the work in question.
•Have linguistic skills that ensure that the content of this description cannot be
misunderstood.
Installation, service, maintenance and fault tracing may only be carried out by authorised
personnel and in accordance with the installation instructions.
The protective covers and contact safety devices inside the equipment may only be removed by
authorised service personnel.

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
3TECHNICAL DATA
3.1 ELEKTRICAL DATA
3.1.1 Assortment
PRM1 can be equipped with up to three rectifier modules, depending on the model.
PRM1
Rectifier module
Model
designation
UNOM
IRATED
IRATED
Model
designation
(VDC)
(A)
(A)
PRM1 24/108
24
108
36
PCS 24/36
PRM1 24/210
210
70
PCS 24/70
PRM1 48/54
48
54
18
PCS 48/18
PRM1 48/150
150
50
PCS 48/50
PRM1 110/24
110
24
8
PCS 110/8
PRM1 110/48
48
16
PCS 110/16
PRM1 110/66
66
22
PCS 110/22
PRM1 220/30
220
30
10
PCS 220/10
3.1.2 Common electrical input data
Rated voltage ...............................................120*1/127*1/220/230/240 VAC 1- phase*2
Frequency .....................................................50/60 Hz
Power factor ................................................. > 0.99 at 230 VAC, full load
Connection ................................................... 6 mm2screw terminal block per module
Other .............................................................Mains switch and 2.5 m cable terminal rack included
*1: Power derating below 190 VAC.
*2: A single rectifier module is supplied from one phase, but several modules can each be
supplied from separate phases.
3.1.3 Common electrical output data
Voltage regulation (static) ..........................<±0.5 % of nominal output voltage
Voltage regulation (dynamic)....................<±1 % within 3 seconds, 0-100 / 100-10 % load change
Current regulation.......................................<±1 % of rated current
Setting range, current limit ........................0 –100 % of rated current
Ripple voltage..............................................<0.1 %RMS
Ripple current ..............................................<0.1 % of rated current
Efficiency, typical ........................................up to 92 %
Connection ................................................... For rated voltage:
24 V: 10 or 16 mm2cable, 3 m included *1
48 V: 10 mm2cable, 3 m included
110 V: 6 mm2cable, 3 m included
220 V: 6 mm2cable, 3 m included
*1: Depending on rectifier module

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
3.1.4 Electrical data for rectifier module
Model
designation,
rectifier
module
Output data
Input data
Power
loss*2
(W)
UNOM
Setting
range
IRATED
PMAX
Voltage
range *3
Mains
power*1
Mains
current*1
(VDC)
(VDC)
(A)
(W)
(VAC)
(VA)
(Arms)
PCS 24/36
24
22 –33
36
1000
90 - 290
1150
6
150
PCS 24/70
70
2000
90 - 290
2200
12
175
PCS 48/18
48
42 - 63
18
1000
90 - 290
1150
6
135
PCS 48/50
50
2700
90 - 290
2900
15
210
PCS 110/8
110
100 - 158
8
1000
90 - 290
1150
6
135
PCS 110/16
16
2000
90 - 290
2200
12
160
PCS 110/22
22
2700
90 - 290
2900
15
200
PCS 220/10
220
187 –292
10
2475
90 - 290
2700
14
200
*1: max at 195 VAC
*2: typical at 230 VAC and full load
*3: Power derating below 190 VAC.
3.2 ENVIRONMENTAL DATA
Class of enclosure...................................................... IP20 as per EN 60529
Cooling........................................................................ Temperature controlled fans in rectifier
modules
Ambient temperature (spec. data applies)............. 0 to +40 °C
Storage temperature.................................................. -40 to +70 °C
Humidity .................................................................... <90 % RH, non-condensed
Altitude a.s.l ............................................................... <2000 m
Noise level, at 1m ...................................................... <50 dBA at 25 % last
3.3 MECHANICAL DATA
Version.....................................Rack for 19” frame
Placement ................................Indoors in dry, clean room
Mounting, rack .......................Mounted in 19” rack
Mounting, I/O-module ..........Mounted on 35 mm guide
rails or directly on
mounting plate
Weight......................................14 kg, fully equipped with 3 rectifier modules
Dimensions, rack ....................2 HU, 88.2/481.5/315 mm (h/w/d), see also dimension diagram
Appendix_A
Dimensions, I/O-module.......117/224/66 mm (h/w/d), see also dimension diagram Appendix_A
Colour, rack.............................Colorless galvanized sheet

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
3.4 CONFORMITY WITH STANDARDS
EN 60529..............................Encapsulation class IP20
EN 50178..............................LVD. Electronic equipment, including power electronics in electrical
power installations.
EN 61000-6-2 .......................EMC. Immunity for industrial electronics
EN 61000-6-4 .......................EMC. Emission from equipment in an industrial environment

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
4FUNCTIONAL DESCRIPTION
4.1 GENERAL
PRM1 is a complete rectifier unit with
built-in monitoring, intended for
mounting in a 19” rack.
Most functions are handled by the monitoring unit and are described in the Manual for
monitoring unit PCM2. Only the functions that feature at a general rectifier level are described
here.
4.2 APPLICATION EXAMPLE
PRM1 is intended for integration in a complete DC system. An example of such is shown in the
simplified schematic below.
Figur 1 Applikationsexempel PRM1
1-3: Rectifier modules (T1-3), PRM1 9: I/O unit (K1), PRM1
5: Battery 10: Operator panel (P1), PRM1
6: Battery block 11: Alarm outputs
7-8: Distribution unit 12: Capacity test terminals