KraftPowercon PRX3 User manual

KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
This manual must be read 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 protective
covers and contact safety devices inside the equipment may only be removed by authorized
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 PRX3
SAFETY INSTRUCTIONS
Manual: 9-1636-B
P/n: 0001085

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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, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com

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www.kraftpowercon.com
CONTENTS
1 PRESENTATION..................................................................................................6
2 SAFETY INSTRUCTIONS ..................................................................................7
3 TECHNICAL DATA............................................................................................8
3.1 ASSORTMENT ...............................................................................................................................................8
3.2 Electrical data..................................................................................................................................................8
3.2.1 Electrical input data..................................................................................................................................8
3.2.2 Electrical output data ...............................................................................................................................8
3.3 ENVIRONMENTAL DATA ........................................................................................................................9
3.4 MECHANICAL DATA.................................................................................................................................9
3.5 CONFORMITY WITH STANDARDS .......................................................................................................9
4 FUNCTIONAL DESCRIPTION.......................................................................10
4.1 GENERAL......................................................................................................................................................10
4.2 RECTIFIER MODULES...............................................................................................................................10
4.2.1 General ......................................................................................................................................................10
4.2.2 Maneuvering and indications...............................................................................................................10
4.2.3 Voltage control.........................................................................................................................................10
4.2.4 Current control ........................................................................................................................................11
4.2.5 Temperature control...............................................................................................................................11
4.2.6 Output power control ............................................................................................................................11
4.2.7 Fan speed control....................................................................................................................................11
4.2.8 Loadsharing..............................................................................................................................................11
4.2.9 Overvoltage DC (HVSD).......................................................................................................................11
4.2.10 Over-/Undervoltage AC ........................................................................................................................12
4.2.11 External blocking.....................................................................................................................................12
4.2.12 Hot swap...................................................................................................................................................12
4.3 FUNCTIONS OF COMPLETE CHARGING RECTIFIER....................................................................12
4.3.1 General ......................................................................................................................................................12
4.3.2 Float charging ..........................................................................................................................................13
4.3.3 Equalizing charging................................................................................................................................13
4.3.4 Battery circuit test ...................................................................................................................................13
5 OPERATION .......................................................................................................14
5.1 GENERAL......................................................................................................................................................14
5.2 RECTIFIER MODULES...............................................................................................................................14
5.2.1 General ......................................................................................................................................................14
5.2.2 Manoeuvre................................................................................................................................................14
5.2.2.1 ON .........................................................................................................................................................14
5.2.2.2 STBY (standby) ...................................................................................................................................14
5.2.3 Indications ................................................................................................................................................14
5.2.3.1 AC OK ..................................................................................................................................................15
5.2.3.2 DC OK ..................................................................................................................................................15
5.2.3.3 ALARM ................................................................................................................................................15
5.2.3.4 CURRENT............................................................................................................................................15
5.2.3.5 <Indication table .................................................................................................................................16
5.3 MONITORING UNIT PCM2.....................................................................................................................16

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6 INSTALLATION INSTRUCTIONS ................................................................17
6.1 SAFETY INSTRUCTIONS..........................................................................................................................17
6.2 GENERAL......................................................................................................................................................17
6.3 STORAGE AND PROTECTION...............................................................................................................17
6.4 MOUNTING .................................................................................................................................................17
6.4.1 General ......................................................................................................................................................17
6.4.2 Erection of cubicle...................................................................................................................................17
6.4.2.1 Cubicle type F27 .................................................................................................................................17
6.4.2.2 Cubicle type F41................................................................................................................................18
6.4.2.3 Cubicle type S39 ................................................................................................................................18
6.4.3 Mounting of rectifier modules .............................................................................................................18
6.4.3.1 General .................................................................................................................................................18
6.4.3.2 Cubicle type F27 and F41..................................................................................................................18
6.4.3.3 Cubicle type S39 .................................................................................................................................19
6.5 ELECTRICAL INSTALLATION...............................................................................................................19
6.5.1 General ......................................................................................................................................................19
6.5.2 Grounding ................................................................................................................................................19
6.5.3 Mains voltage...........................................................................................................................................20
6.5.4 DC power output ....................................................................................................................................20
6.5.5 I/O unit ......................................................................................................................................................20
6.5.6 Rectifier modules.....................................................................................................................................21
6.5.6.1 Cubicle type F27 and F41..................................................................................................................21
6.5.6.2 Cubicle type S39 .................................................................................................................................21
7 COMMISSIONING ............................................................................................22
7.1 SAFETY INSTRUCTIONS..........................................................................................................................22
7.2 PREPARATORY INSPECTION................................................................................................................22
7.3 POWERING UP............................................................................................................................................22
7.3.1 DC...............................................................................................................................................................22
7.3.2 AC...............................................................................................................................................................22
7.4 CHECKING THE CHARGING VOLTAGE...........................................................................................23
7.5 CHECKING THE SETTINGS ....................................................................................................................23
7.6 CHECKING THE OUTPUTS.....................................................................................................................23
8 MAINTENANCE................................................................................................24
8.1 ANNUAL INSPECTION............................................................................................................................24
8.1.1 General ......................................................................................................................................................24
8.1.2 Checking the charging voltage.............................................................................................................24
8.1.3 Checking the cooling capacity..............................................................................................................24
9 FAULT TRACING AND SERVICE ................................................................25
9.1 SAFETY INSTRUCTIONS..........................................................................................................................25
9.2 FAULT TRACING ALARMS ....................................................................................................................25
9.3 OTHER FAULT TRACING........................................................................................................................25
9.4 INSTRUCTIONS FOR REPLACING RECTIFIER MODULE DURING OPERATION (HOT
SWAP) 27
9.4.1 Enclosure type F27 and F41 ..................................................................................................................27
9.4.2 Enclosure type S39 ..................................................................................................................................28

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Appendices
A LAYOUT AND DIMENSION DIAGRAM PRX3, CUBICLE TYPE F27
B LAYOUT AND DIMENSION DIAGRAM PRX3, CUBICLE TYPE F41
C LAYOUT AND DIMENSION DIAGRAM PRX3, CUBICLE TYPE S39
D DIMENSION DIAGRAM RECTIFIER MODULE PRM3
E CIRCUIT DIAGRAM PRX3
F CIRCUIT DIAGRAM RECTIFIER MODULE PRM3

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www.kraftpowercon.com
1 PRESENTATION
PRX3 is a complete modular charging rectifier for total output power up to 54 kW.
The main parts of the system are 3-phase rectifier modules type PRM3 working in parallel
aimed for mounting in 19” cabinet, monitoring unit type PCM2 specially designed for DC
systems and also fuses and disconnectors for highest safety and easy service and maintenance.
The rectifier modules can be connected in parallel for flexible adaption of output power and
the possibility of redundancy. They can also be swapped during operation (hot swap) with
easy maintenance and high availability as a result. Fans with speed control and monitoring
gives low noise levels. This, together with the clear display and well-arranged system of
menus of the monitoring unit makes 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. Equivalent descriptions 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.
The term “charging rectifier” is replaced henceforth with the shorter term “rectifier”.

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2 SAFETY 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.
Rectifier modules may only be opened by authorised service personnel.

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3 TECHNICAL DATA
3.1 ASSORTMENT
Model
PRX3
Output data
Input data
Power
loss**
Rect. module
Cubicle
/
weight
UNOM UMAX* IRAT ED
Output
power Terminal
Mains
power*
Mains
current*
Mains
fuse Terminal Number IRAT ED F27 F41 S39
V
DC
V
DC
A
kW
mm
2
kVA
A
rms
A
gL/gG
mm
2
kW
A
k
g
k
g
k
g
110/70
110 145
70 9 50 10.6 18 25 16 0.7 1
70
90 90 190
110/140 140 18 95 21.2 36 50 16 1.4 2 110 110 210
110/210 210 27 150 31.8 54 63 35 2.2 3 - 130 230
110/280 280 36 240 42.4 72 80 35 2.9 4 - - 250
110/350 350 45 2x150 53.0 90 100 50 3.6 5 - - 270
110/420 420 54 2x240 63.6 108 125 95 4.3 6 - - 290
220/36
220 270
36 9 35 10.6 18 25 16 0.7 1
36
90 90 190
220/72 72 18 50 21.2 36 50 16 1.4 2 110 110 210
220/108 108 27 95 31.8 54 63 35 2.2 3 - 130 230
220/144 144 36 95 42.4 72 80 35 2.9 4 - - 250
220/180 180 45 2x150 53.0 90 100 50 3.6 5 - - 270
220/216 216 54 2x150 63.6 108 125 95 4.3 6 - - 290
440/18
440 500
18 9 35 10.6 18 25 16 0.7 1
18
90 90 190
440/36 36 18 35 21.2 36 50 16 1.4 2 110 110 210
440/54 54 27 50 31.8 54 63 35 2.2 3 - 130 230
440/72 72 36 50 42.4 72 80 35 2.9 4 - - 250
440/90 90 45 50 53.0 90 100 50 3.6 5 - - 270
440/108 108 54 95 63.6 108 125 95 4.3 6 - - 290
* maximum at 3x340 VAC ** type at 3x400 VAC and full load
3.2 Electrical data
3.2.1 Electrical input data
Rated voltage..................................................380/400 VAC 3-phase, TN network
Input voltage range.......................................340-440 VAC
Overvoltage protection ................................> 580 VAC, rectifier module stops
Undervoltage protection..............................< 300 VAC, rectifier module stops
Frequency........................................................45 – 65 Hz
Power factor....................................................> 0.97 (at 3x400 VAC, full load)
Other, see table in section 3.1 ASSORTMENT.
3.2.2 Electrical output data
Voltage regulation (static) ...........................<±0.5 % of nominal output voltage
Voltage regulation (dynamic).....................<±1 % within 3 sec, 0-100 / 100-10 % load change
Current regulation.........................................<±1 % of rated current
Setting range, current limit..........................0 – 100 % of rated current
Ripple voltage ................................................<0.2 %RMS

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Ripple current.................................................<1 % of rated current
Efficiency, typical ..........................................>92 % at 3x400 VAC
Other, see table in section 3.1 ASSORTMENT.
3.3 ENVIRONMENTAL DATA
Class of enclosure.........................................................IP21 as per EN 60529
Cooling............................................................................Temperature controlled fans in rectifier
modules, otherwise natural convection
Ambient temperature ..................................................0 to +40 °C
Storage temperature.....................................................-40 to +70 °C
Humidity........................................................................<90 % RH, non-condensed
Altitude a.s.l...................................................................<2000 m
Noise level at +20 °C, 25% load .................................50-58 dBA depending on number of rectifier
modules
3.4 MECHANICAL DATA
Design ....................................... Floor cabinet with 19” rack frame
Placement................................. Standing on floor indoors in dry and clean area
Weight....................................... See table in section 3.1 ASSORTMENT .
Dimensions.............................. Cubicle type F27: 1361/600/600 mm (h/w/d),
Cubicle type F41: 2053/600/474 mm (h/w/d),
Cubicle type S39: 2100/840/654 mm (h/w/d),
see also layout drawing Appendix A
Colour ....................................... RAL 7035 light grey
Cable inlet ................................ From above or beneath (F27, F41)
From beneath, above as option (S39)
3.5 CONFORMITY WITH STANDARDS
EN 60529................................Protection degree 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 of equipment in an industrial environment
EN 61000-6-4.........................EMC. Emission from equipment in an industrial environment

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4 FUNCTIONAL DESCRIPTION
4.1 GENERAL
PRX3 is a complete charging rectifier equipped with up to six rectifier modules of the type
PRM3 working in parallel with three-phase mains power feeding. The monitoring unit PCM2 is
built in for monitoring of both rectifiers, battery and other parts of the complete DC system. For
each rectifier module there are fuse links for both AC and DC that can be used as disconnection
for safe and easy maintenance and service.
Most of the function is associated with the monitoring unit which is described in the Manual for
monitoring unit PCM2. Only functions added on rectifier system level are discussed in this
section.
4.2 RECTIFIER MODULES
4.2.1 General
Only functions related to the rectifier module itself are specified here. For information about
general functions, see the Manual for monitoring unit PCM2.
4.2.2 Maneuvering and indications
The front panel holds pushbuttons for maneuvering and a number of indication
lamps.
There is no built-in mains breaker in the module. Instead, there is an ON-button
and a STBY-button, where STBY means that the module is turned off by being
put into a standby mode. The ON and STBY states are saved in a non-volatile
memory which means that even after a total main outage, the module will return to the state
that was present at the moment of the outage.
For detailed description of the front panel functions, see section 5 OPERATION.
4.2.3 Voltage control
At normal operation, the rectifier module will regulate the output voltage according to a
setpoint provided by the monitoring unit.
The voltage reported from the module to the monitoring unit is measured on the “inside” of the
modules output blocking diode. Due to the diode voltage drop, it will therefore be slightly
higher than expected. The difference is dependent of the output current, but its size is about 1
V. The output voltage however, will always be correct because the monitoring unit measures
the voltage directly in the battery distribution board. By regulation of the setpoint, voltage drop
in both output diode and cables are compensated.
In case of an interruption of the communication between the module and the monitoring unit,
the module will continue with the last valid setpoint.

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After a cold-start of a rectifier module, it will begin with nominal voltage (110, 220, 440V) until
the communication with the monitoring unit is established.
In the monitoring unit there is a parameter holding the level for the overvoltage protection
(HVSD). No matter the level of the requested setpoint, the output voltage of the module will be
limited to maximum 1% below existing HVSD level.
4.2.4 Current control
At normal operation the rectifier module will regulate according to the setpoint (current limit)
provided from the monitoring unit.
The current limit is also used as a tool for the functions temperature control, power control and
load sharing.
4.2.5 Temperature control
To protect the rectifier module from overheating, the current limit is lowered gradually as the
internal temperature gets close to a critical level. Should the temperature after all rise above the
critical level, the module will turn off and be kept turned off until the temperature has fallen to
a reasonable level. Meantime the cooling fans will run at full speed.
4.2.6 Output power control
At high output voltages, the output power will be limited to rated power by lowering the
current limit.
4.2.7 Fan speed control
In order to reduce the noise level to a minimum and to extend the lifetime of the fans, the fan
speed is regulated by the internal temperature of the module. The fan speed is continuously
monitored in order to provide an early warning if any of the three fans shows sign of being
worn out. Note that the fans by design are meant to last for the whole lifetime of the module.
Directly after start the cooling fans are working at full speed for about half a minute before
speed controlled by temperature begins.
At stop the cooling fans continues to run for about half a minute in order to cool off the
remaining heat.
4.2.8 Loadsharing
In the PRX3 up to 6 rectifiers can be working in parallel while sharing the load using so called
active loadsharing. The loadsharing is active in the range of about 10 – 90 % of the rated current.
During loadsharing, the first rectifier module acts as a master. The loadsharing will therefore
change from active to passive mode if that particular module is turned off or is out of order.
4.2.9 Overvoltage DC (HVSD)
In order to protect the site from hazardous overvoltage, an overvoltage protection called HVSD
(High Voltage Shut Down) is built into every rectifier module. The level is settled as a
parameter setting in the monitoring unit.

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If the rectifier output voltage exceeds the HVSD level, the rectifier will turn off within about 100
ms. Since the voltage is measured on the “inside” of the blocking diode, the HVSD function is
selective, i.e. only the module that is responsible for the overvoltage will trip. Initially, the
ALARM-lamp turns on and the ON-lamp will start to flash slowly. With an interval of five
seconds, three restart attempts will be performed. If also the third attempt fails, the module will
be turned off for good while both the ON- and STBY-lamps are turned off and the ALARM-
lamp continues to shine.
Restart after tripped HVSD can be done by keeping the ON-button pressed for at least 5
seconds or by turning off the AC power for a short while. You can also put the module in
standby mode by keeping the STBY-button pressed for at least 5 seconds.
4.2.10 Over-/Undervoltage AC
The rectifier module has a built-in self protection that will stop the module when exceeding
harmful high or low voltages on the AC power feeding. For trip levels, see section 3.2.1. The
module will go back to normal operation as soon as the voltage returns within permissible
limits.
4.2.11 External blocking
The rectifier modules can also be turned off remotely via a digital input found on the
monitoring unit. The function is called “External blocking”. The output voltage will be turned
off, the ON-lamp will flash slowly and the STBY-lamp is off. When the blocking condition
ceases, the module returns to normal operation.
Even during blocking condition, the module can be turned off “for real” using the STBY-button.
In this way the module will remain off when the blocking condition ceases.
4.2.12 Hot swap
Connection of a rectifier module to a DC system during operation (hot swap) is normally not
entirely straightforward. Without certain measures you will get a heavy inrush current due to
charging of capacitors on the rectifier DC output. Except sparking at the point of connection,
you may get a short system voltage drop with possible consequences.
With PRM3, this problem is eliminated due to a built-in output diode that prevents charging of
the capacitors from the outside. An extra advantage with the diode is that it eliminates the risk
of sinking the whole DC system due to an internal module fault (short circuit). PRM3 modules
may consequently without problem be replaced during operation which to a great extent
simplifies maintenance and service and will also extend the availability of the DC system.
4.3 FUNCTIONS OF COMPLETE CHARGING RECTIFIER
4.3.1 General
A complete rectifier system of the type PRX3 may, depending on model, hold up to 6 rectifier
modules in parallel of the type PRM3.
Here, only the most considerable functions are described. For more information, see Manual for
monitoring unit PCM2.

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4.3.2 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.
4.3.3 Equalizing charging
Equalizing charging means charging with raised voltage level during 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.
4.3.4 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 is in working order.
For more information, see the Manual for monitoring unit PCM2.

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5 OPERATION
5.1 GENERAL
The bulk of the operation is associated to the monitoring unit. This is described in the Manual
for monitoring unit PCM2. Other operation is detailed in this section.
5.2 RECTIFIER MODULES
5.2.1 General
The front panel of the rectifier module has push-buttons for
manoeuvring of the module together with a number of led indication
lamps.
5.2.2 Manoeuvre
5.2.2.1 ON
To start the rectifier module, push the ON-button. A green led lamp on the upper left corner of
the button tells that the module has started and the orange led lamp by
the STBY-button will be put out. DC OK will be put out while ALARM
will go red.
If both the ON- and STBY-indications are put out but ALARM is red, the
overvoltage protection HVSD may have tripped the module. In this state, it is possible to try a
restart by keeping the ON-button pushed for about 5 seconds. Alternatively, you can put the
module in standby mode by keeping the STBY-button pressed for at least 5 seconds.
5.2.2.2 STBY (standby)
To stop the rectifier module, push the STBY-button as long as the orange led lamp on the upper
left corner of the button is flashing (about 3 seconds). In this way,
unintentional shutting off is avoided. When the module is in standby
state, the orange STBY-led is put on with steady light while the green
ON-led is put out.
If the ON-led is slowly flashing while the STBY-led is off, the output
voltage is set to zero as in standby state. The reason might be that the module has remotely been
turned off via the function “External blocking” or it may be due to high temperature. Also in
this state, it is possible to use the STBY-button to turn off the module “for real”.
WARNING: Note that the standby state does not make the equipment dead. For a total dead state, the
mains supply and the equipment's DC output must be cut externally. For isolation of individual rectifier
modules, the built-in miniature circuit breakers are used.
5.2.3 Indications

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5.2.3.1 AC OK
AC OK will be put on with green light if the mains supply is OK.
All indications put out, AC OK included, indicates that there is no mains
supply.
AC OK put out while the ALARM-led is red indicates that there is mains supply but not within
limits. The DC output is dead. See also section 4.2.10.
5.2.3.2 DC OK
DC OK will be put on with green light if the DC output is OK.
DC OK will be put out if the output voltage is below 50% of
nominal voltage. This means that it is also put out in normal standby state.
5.2.3.3 ALARM
The ALARM-led is put out in normal operation.
Red light indicates a fault condition. Also
standby state will give red light, because by the
systems point of view it is considered as a fault
condition.
The cause of the alarm can be studied in detail using the monitoring unit menu system, see
Manual for monitoring unit PCM2.
5.2.3.4 CURRENT
The output current of the rectifier module, 0-100%, is shown by
a led-bar equipped with 10 yellow led-lamps. I.e. there are one
led for each 10:th percent of the rated current.

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5.2.3.5 <Indication table
Indication
Interpretation
ON STBY AC
OK
DC
OK ALARM
Green Put out Green Green Put out Normal operation
Green Put out Green Green Red
1. UOUT low, 50-82% of UNOM
2. IOUT limited due to high temperature
3. Fan fault
Green Put out Green Put
out Red UOUT low, <50% of UNOM
Green Put out Put
out
Put
out Red Mains fault
Flash Put out Green Put
out Red
1. External blocking
2. HVSD tripped, waiting for restart
attempt
3. Turned off due to high temperature
Put out Put out Green Put
out Red Turned off due to tripped HVSD
Put out Put out Put
out
Put
out Red Turned off due to tripped HVSD + mains fault
Put out Orange Green Put
out Red Normal standby
Put out Orange Put
out
Put
out Red Mains fault in standby state
Put out Put out Put
out
Put
out Put out No mains supply
5.3 MONITORING UNIT PCM2
The operator panel is the visible part of the
monitoring unit PCM2. It is composed of a
display, push-buttons and a led-lamp. Operation
is described in the Manual for monitoring unit
PCM2.
When measuring the battery voltage you should avoid measuring directly at the battery
terminals due to the risk of arcing in the event of a possible short circuit. Use the short-circuit
protected voltmeter terminals on the front panel instead. The voltmeter terminal fits a standard
4 mm measuring pin. To avoid measurement errors, the voltmeter used should have high ohms,
10 Mohm or better.

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
6 INSTALLATION INSTRUCTIONS
6.1 SAFETY INSTRUCTIONS
WARNING! This product contains dangerous voltage that when touched can cause electric shock, burns
or death. Protective earth must always be connected in a reliable way to avoid the risk of live parts in the
equipment in the event of faults. No live parts are permitted during installation. The product must be
installed by qualified personnel (see section 2 SAFETY INSTRUCTIONS).
WARNING! Check both before and after setting-up that the equipment does not have any mechanical
damage. Check that the equipment and individual rectifier modules have the intended rated voltage.
Cables for input and output power must be correctly dimensioned to avoid fire hazard.
6.2 GENERAL
Installation of the parts that belong to the monitoring unit are not dealt with in this manual. For
complete installation instructions these instructions should therefore be used in combination
with the installation instructions included in the Manual for monitoring unit PCM2.
Normally, the rectifier modules are not installed by delivery. They are packed separately to be
mounted into the rectifier cubicle during installation on site.
6.3 STORAGE AND PROTECTION
Storage is to be in a dry area and at a temperature that does not exceed the -40 to +70 °C range.
6.4 MOUNTING
6.4.1 General
The equipment is intended for placement on floor in a dry, clean environment that is free from
conductive dust.
WARNING! Cubicle type F41 has a high center of gravity. Use the enclosed brackets to avoid the risk of
tipping.
Cubicle type S39 must with no exception be secured by the wall using the enclosed brackets and/or be
bolted to the floor before the rectifier modules are installed to avoid tipping forward when the door is
opened!
6.4.2 Erection of cubicle
6.4.2.1 Cubicle type F27
The cubicle has feet that can be adjusted up to 25 mm
vertically.
Note that the cubicle has air outlets on the rear why at least 50
A LARM
PCM2
OK

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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
mm free space must be left to the wall to ensure sufficient ventilation.
Cable inlet is either from beneath through an opening in the bottom plate (see layout drawing
F27 in Appendix A) or via an FL21 flange through the roof-plate.
6.4.2.2 Cubicle type F41
With rectifier modules installed, the center of gravity of the
cubicle will be high. As a consequence, the upper part of the
cubicle must be secured to the wall. Use the enclosed brackets,
see layout drawing F41 in Appendix B. Also leave at least 50 mm
free space to the wall to ensure sufficient ventilation.
For maximum safety it is recommended that the enclosure is also bolted to the floor according
to the layout drawing F41.
Cable inlet is primarily from the floor through the opening in the bottom of the enclosure.
Alternatively, the inlet can be done through the detachable roof plate. In that case, be careful to
maintain the environmental protection class.
6.4.2.3 Cubicle type S39
To eliminate the risk of tipping forward when the door is
opened, the cabinet must, with no exception, be secured to the
wall by using the enclosed brackets and/or be bolted to the floor
before the rectifier modules are installed. Also leave at least 100
mm free space to the wall to ensure sufficient ventilation, see
layout drawing S39 in Appendix_C.
The brackets are bolted on the top of the cubicle using holes
aimed for lifting lugs.
Cable inlet is primarily from the floor through the opening in the bottom of the enclosure. As an
option a roof-plate equipped with a number of FL21 flange openings is available.
6.4.3 Mounting of rectifier modules
6.4.3.1 General
The mounting of the rectifier modules can with advantage wait until the electrical installation is
finished. Check with the modules rating plate that the rated voltage corresponds to the nominal
voltage of the battery.
WARNING! The equipment may cause personal injury or damage to property if dropped. Use secure
lifting aids where appropriate.
6.4.3.2 Cubicle type F27 and F41
Connect the following cable sets to corresponding connectors on the rear of the module:
ALARM
PCM 2
OK
ALARM
PCM2
OK

19
KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
1. Connect the 4-pole cable set with connector
housing marked –X11 to the connector
marked L1/L2/L3/PE on the module T1. In the
same way, connect cable set marked –X12 to
module T2 and so on.
2. Connect the 2-pole cable set with connector housing marked –X31a to one of the two
connectors marked L+/L- on the module T1. In the same way, connect cable set marked
–X32a to module T2 and so on.
3. For modules with a rated voltage of 110V or 220V, a second 2-pole cable set with
connector housing marked –X31b
should be connected to the other of the two connectors marked L+/L- on the module T1.
In the same way, connect cable set marked –X32b to module T2 and so on.
4. Connect the RS485 bus (flat cable) with contact housing marked 1 to socket –X10 on the
module T1. In the same way, the RS485 bus (flat cable) with contact housing marked 2
is connected to module T2 and so on.
Push the module into its slot position while the cable sets are lead in behind the shelf without
getting jammed. Fasten the modules onto the rack frame using the four holes on the short sides
of the module.
6.4.3.3 Cubicle type S39
DANGER! Before mounting of the modules into the door slots, the risk of tipping must be eliminated by
securing the cubicle to the wall using the enclosed brackets and/or bolting to the floor!
Push the modules into its door slot positions.
Fasten the modules with four screws onto the rack frame using the holes on the short sides of
the module.
6.5 ELECTRICAL INSTALLATION
6.5.1 General
PRX3 is designed for permanent installation only. Protective earth must be connected before
any other installation.
6.5.2 Grounding
For ground wire connections up to 10 mm2the multi-
pole brass connector is used.
For incoming AC power in cubicle F41 and F39, there is connection clamps on the main
grounding bar while a ground screw terminal is available in cubicle F27.
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