KraftPowercon PRM1 User Manual

Manual for

charging rectifier

type PRM1

SAFETY INSTRUCTIONS

Manual: 9-1718-A
P/n: 0001138

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.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

2

We reserve the right to make changes to the content of this manual without prior notification.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

3

CONTENTS

1 PRESENTATION .............................................................................................. 5

2 SAFETY INSTRUCTIONS ............................................................................... 6

3 TECHNICAL 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

4 FUNCTIONAL 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

5 OPERATION ................................................................................................... 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

6 INSTALLATION 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

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

4

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

7 STARTING 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

8 MAINTENANCE ............................................................................................ 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

9 FAULT 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

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

1 PRESENTATION

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.

5

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

6

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.

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

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 TECHNICAL DATA

3.1 ELEKTRICAL DATA

3.1.1 Assortment

PRM1 can be equipped with up to three rectifier modules, depending on the model.

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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 mm2 screw 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 mm2 cable, 3 m included
48 V: 10 mm2 cable, 3 m included
110 V: 6 mm2 cable, 3 m included
220 V: 6 mm2 cable, 3 m included

*1

*1

: Depending on rectifier module

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com

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

3.1.4 Electrical data for rectifier module

*1

: max at 195 VAC

*2

: typical at 230 VAC and full load

*3

: Power derating below 190 VAC.

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3.2 ENVIRONMENTAL DATA

Class of enclosure ...................................................... IP20 as per EN 60529

Cooling........................................................................ Temperature controlled fans in rectifier

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

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

Dimensions, I/O-module .......117/224/66 mm (h/w/d), see also dimension diagram Appendix_A

Colour, rack .............................Colorless galvanized sheet

modules

rails or directly on
mounting plate

Appendix_A

KraftPowercon Sweden AB, Hjalmar Petris väg 49, 352 46 Växjö, Sweden, Tel: [phone], Fax: [phone],

www.kraftpowercon.com