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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-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, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com

3
KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
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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KraftPowercon Sweden AB, Hjalmar Petris väg 49, S-352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],
www.kraftpowercon.com
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