KraftPowercon PRX Series 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 voltage 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 authorised service personnel. The equipment
may only be opened by qualified personnel. Work in addition to replacing the rectifier modules
may only be carried out when all power has been cut to the equipment and when the mains
breaker has been closed 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! Multiple power sources. Dangerous voltage is possible even with mains power
shut off. The panel mains power switch does not give a dead condition.
Manual for
charging rectifier
type PRX
SAFETY INSTRUCTIONS
Dokumentnr: 9-1719-B
Artikelnr: 0001137

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
Vi förbehåller oss rätten till ändringar av innehållet utan föregående avisering.

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
INNEHÅLL
1PRESENTATION.............................................................................................. 5
2SAFETY INSTRUCTIONS............................................................................... 6
3TECHNICAL DATA ........................................................................................ 7
3.1 ELECTRICAL DATA.............................................................................................................................. 7
3.1.1 Range.................................................................................................................................................... 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 ................................................................................................................... 8
4FUNCTIONAL DESCRIPTION...................................................................... 9
4.1 GENERAL ................................................................................................................................................ 9
4.2 FRONT PANEL ....................................................................................................................................... 9
4.3 RECTIFIER MODULES .......................................................................................................................... 9
4.4 I/O UNIT ................................................................................................................................................ 10
4.5 FUNCTIONS.......................................................................................................................................... 10
4.5.1 General............................................................................................................................................... 10
4.5.2 Float charging ................................................................................................................................... 10
4.5.3 Equalizing charging ......................................................................................................................... 10
4.5.4 Battery circuit test............................................................................................................................. 10
5OPERATION ................................................................................................... 11
5.1 GENERAL .............................................................................................................................................. 11
5.2 MAINS FEED......................................................................................................................................... 11
5.3 OPERATOR PANEL............................................................................................................................. 11
5.4 LIKRIKTARMODULER ....................................................................................................................... 11
5.5 VOLTMETER TERMINALS ................................................................................................................ 12
6INSTALLATION INSTRUCTIONS ............................................................. 13
6.1 SAFETY INSTRUCTIONS ................................................................................................................... 13
6.2 GENERAL .............................................................................................................................................. 13
6.3 STORAGE AND PROTECTION ......................................................................................................... 13
6.4 MOUNTING .......................................................................................................................................... 13
6.5 ELECTRICAL INSTALLATION ......................................................................................................... 14
6.5.1 General............................................................................................................................................... 14
6.5.2 Earthing ............................................................................................................................................. 14
6.5.3 Mains voltage.................................................................................................................................... 14
6.5.4 Battery/Load...................................................................................................................................... 14
6.5.5 Rectifier modules.............................................................................................................................. 15
6.5.6 I/O unit............................................................................................................................................... 15
6.5.7 Battery voltage measurement ......................................................................................................... 15
6.5.8 Mid voltage measurement (option) ............................................................................................... 15
6.5.9 Battery temperature measurement (option) ................................................................................. 16
7COMMISSIONING......................................................................................... 17

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
7.1 SAFETY INSTRUCTIONS ................................................................................................................... 17
7.2 PREPERATORY INSPECTION ........................................................................................................... 17
7.3 ELECTRIFICATION ............................................................................................................................. 17
7.3.1 DC....................................................................................................................................................... 17
7.3.2 AC....................................................................................................................................................... 17
7.4 CHECK OF CHARGING VOLTAGE................................................................................................. 18
7.5 CHECK OF SETTINGS......................................................................................................................... 18
7.6 CHECK OF OUTPUTS ......................................................................................................................... 18
8MAINTENANCE............................................................................................ 19
8.1 ANNUAL INSPECTION...................................................................................................................... 19
8.1.1 General............................................................................................................................................... 19
8.1.2 Check of charging voltage............................................................................................................... 19
8.1.3 Check of cooling capacity................................................................................................................ 19
9FAULT TRACING.......................................................................................... 20
9.1 SAFETY INSTRUCTIONS ................................................................................................................... 20
9.2 OTHER FAULT TRACING.................................................................................................................. 20
Bilagor
A DIMENSION DIAGRAM
B CIRCUIT DIAGRAM PRX

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
1PRESENTATION
PRX is a family of charging rectifiers in single phase configuration with integrated monitoring
that are designed for wall mounting.
The charging rectifier is constructed using plug-in rectifier modules for simple maintenance
and high flexibility and availability. 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.
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
charging rectifier.
For a complete description, this manual is to be used together with the description for the
monitoring unit, Manual for monitoring unit type PCM2.
The term “charging rectifier” is replaced henceforth with the shorter term “rectifier”.

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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 voltage that when touched can cause electric shock, burns
or death.
For safety reasons the affected personnel are classified according to the following requirements
for specific skills.
Authorised service personnel:
•Have electrical training and adequate experience in avoiding the dangers that electricity
can cause.
•Are certified to meet authority requirements for the work in question.
•Have linguistic skills that ensure the content in 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 the content in 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.

7
KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
3TECHNICAL DATA
3.1 ELECTRICAL DATA
3.1.1 Range
PRX can be equipped with one or two rectifier modules.
PRX
Likriktarmodul
Model
designation
UNOM
IRATED
Mains
power*1
Mains
current*1
Mains
fuse*2
Power
loss*3
Number
of
modules
IRATED
Model
designation
(VDC)
(A)
(VA)
(ARMS)
(A)
(W)
(A)
PRX 24/36
24
36
1150
6
10
160
1
36
PCS 24/36
PRX 24/2x36
72
2300
12
16
310
2
36
PCS 24/36
PRX 24/70
70
2200
12
16
185
1
70
PCS 24/70
PRX 48/18
48
18
1150
6
10
145
1
18
PCS 48/18
PRX 48/2x18
36
2300
12
16
280
2
18
PCS 48/18
PRX 48/50
50
2900
15
20
220
1
50
PCS 48/50
PRX 110/8
110
8
1150
6
10
145
1
8
PCS 110/8
PRX 110/2x8
16
2300
12
16
280
2
8
PCS 110/8
PRX 110/16
16
2200
12
16
170
1
16
PCS 110/16
PRX 110/2x16
32
4400
23
25
330
2
16
PCS 110/16
PRX 110/22
22
2900
15
20
210
1
22
PCS 110/22
PRX 110/2x22
44
5800
30
35
410
2
22
PCS 110/22
PRX 220/10
220
10
2700
14
16
210
1
10
PCS 220/10
PRX 220/2x10
20
5400
28
35
410
2
10
PCS 220/10
*1: max at 195 VAC
*2: recommended value
*3: type at 230 VAC and full load. Also includes monitoring unit.
3.1.2 Common electrical input data
Rated voltage ...............................................120*1/127*1/220/230/240 VAC 1- phase
Frequency .....................................................50 –60 Hz
Power factor ................................................. > 0.99 at 230 VAC, full load
Connection screw terminal block.............. 0.5 –10 mm2
*1: Power derating below 190 VAC.
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 % at 230 VAC
Connection screw terminal block.............. 1.5 - 35 mm2

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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
UNOM
Setting
range
IRATED
Voltage
range*3
Mains
power*1
Mains
current*1
(VDC)
(VDC)
(A)
(VAC)
(VA)
(Arms)
PCS 24/36
24
22 –33
36
90 - 290
1150
6
150
PCS 24/70
70
90 - 290
2200
12
175
PCS 48/18
48
42 –63
18
90 - 290
1150
6
135
PCS 48/50
50
90 –290
2900
15
210
PCS 110/8
110
100 –158
8
90 –290
1150
6
135
PCS 110/16
16
90 –290
2200
12
160
PCS 110/22
22
90 –290
2900
15
200
PCS 220/10
220
187 –292
10
90 - 290
2700
14
200
*1: max at 195 VAC
*2: type at 230 VAC and full load
*3: Power derating below 190 VAC.
3.2 Environmental data
Class of enclosure...................................................... IP21 as per EN 60529
Cooling........................................................................ Temperature controlled fans in rectifier
modules
Ambient temperature (specified data applies)...... 0 to +40 °C
Storage temperature.................................................. -40 to +70 °C
Humidity .................................................................... <90 % RH, non-condensed
Altitude above sea..................................................... <2000 m
Noise level at 1 m, +20 °C, 25 % load..................... <50 dBA
3.3 Mechanical data
Design ......................................Wall cabinet
Arrangement...........................On a wall indoors in dry, clean room
Weight......................................18 kg, fully equipped
Dimensions..............................400/274/333 mm (h/w/d), see also dimension diagram Appendix_A
Colour ......................................RAL 7035 light grey
Cable inlets..............................From underneath
3.4 Conformity with standards
EN 60529..............................Class of enclosure IP21
EN 50178..............................LVD. Electronic equipment, including power electronics in electrical
power installations.
EN 50272-2...........................Safety requirements for secondary batteries and battery installations
EN 61000-6-2 .......................EMC. Immunity for industrial electronics
EN 61000-6-4 .......................EMC. Emission from industrial electronics

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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
PRX is a complete rectifier with integrated monitoring.
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 FRONT PANEL
The front panel includes the operator panel, mains breaker and voltmeter terminal.
The operator panel is the unit used as the user interface. It is fitted with a display, keypad and
indicator lamp for alarm.
The mains breaker handles the mains feed to the rectifier modules.
The voltmeter terminal has short-circuit protection for safe measurement of the battery voltage
and is designed for standard 4 mm banana plugs.
4.3 RECTIFIER MODULES
The rectifier modules are of the “plug-in” type and can in principle be replaced during
operation. There is room for up to two parallel modules. The rectifier modules are accessible
from the front without the need to loosen the cover
.
There are three indicator lamps on the front of the module:
AC OK - Green: Mains OK
Off: Mains power failure
WARNING- Yellow (permanent): Remote shutdown (standby) or
high temperature warning
Yellow (flashing): Communication fault
Off: Normal operation
ALARM - Off: OK
Red: Alarm (shutdown after DC overvoltage,
over temperature, fan error or internal fault)

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
4.4 I/O UNIT
The I/O unit contains an adapter for the external connections required for the monitoring unit.
It is fitted directly on the back plate together with the terminal blocks for AC input and DC
output.
4.5 FUNCTIONS
4.5.1 General
Only the most important functions are specified here. For more information, see the Manual for
monitoring unit PCM2.
4.5.2 Float charging
Float charging is the normal operating mode determined by the battery. The voltage level is to
be set according to the battery manufacturer instructions.
For more information, see the Manual for monitoring unit PCM2.
4.5.3 Equalizing charging
Equalizing charging means charging with raised voltage level over a limited period. It is used
partly for the initial charge, and partly for equalizing cell voltages if spread has occurred.
For more information, see the Manual for monitoring unit PCM2.
WARNING: Generally, batteries of VR-type (vent regulated) should not be subject to equalizing
charging. For some battery types equalizing charging could even be harmful to the batteries. Always
follow the instructions stated by the battery manufacturer.
4.5.4 Battery circuit test
A battery circuit test is automatically carried out at optional intervals (normally once a day).
The test involves checking that the entire battery circuit, i.e. not only the battery block is in
working order.
For more information, see the Manual for monitoring unit PCM2.