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Rectifier THYROTRONIC
with Thysat controller
Contents
1 General ........................................................................................................................... 6
2 Safety .............................................................................................................................. 8
5.2 Test and reset button......... ............... .. ...... ....... .. ......... ................................................... 25
5.3 Initial start-up and function test ................................. ............. ......... .. ............ ..... .... .....26
6 Messages ...................................................................................................................... 32
7 .3 Cleaning ........................................................................................................................ 46
Index of figures:
Fig. 8 LED bar with standard assignment and Test/Reset button ........................................... 24
1 General
These Operating Instructions serve to enable the secure operation of the rectifi-
er THYROTRONIC as intended.
The present Operating Instructions contain the information necessary for the
safe operation as intended of the rectifier.
The Operating Instructions must always be available and kept handy in the vi-
cinity of the rectifier.
The operating instructions must be read and observed by every person commis-
sioned with performing tasks on the rectifier; this comprises transport, setup
and installation, operator control, maintenance and dismantling.
In commercial use, the guidelines, standards and laws for safe and proper
working applicable at the place of operation or country of use must be ob-
served in addition to the Operating Instructions.
For this reason these Operating Instructions refer exclusively to the standard
configuration of the rectifier. Exact details concerning your version of the rec-
tifier can be taken from:
The rectifier is manufactured according to the generally accepted rules and the
current state of the art design techniques. Additional safety instructions are
provided in order to guarantee the personnel adequate safety. Adequate safety
when handling the rectifier is ensured only if these instructions are adhered to.
From time to time it is necessary to emphasise certain text passages. The pas-
sages marked thus have different meanings:
Please observe all warnings and measures that prevent the occur-
rence of damage on the rectifier and other property. Proceed with
particular care!
2 Safety
2.1 General
The operator will ensure that the Operating Instructions are always available on
the rectifier and that the operating personnel will pay attention to these guide-
lines.
In addition to the Operating Instructions and the valid regulations for accident
prevention applicable in the country concerned and at the place of operation it
is also necessary to observe the recognised special technical rules for safe and
correct working.
Only qualified and trained technical personnel may work on the rectifier. In
particular qualified electricians authorised for this purpose must only perform
the installation, initial start-up, maintenance and disassembly of the rectifier.
Qualified technical personnel in the sense of these basic instructions are per-
sons who are familiar with the installation, start-up, operation, maintenance,
shutdown and disassembly and who have the qualifications corresponding to
their activity.
The manufacturer points out that the manufacturer will not accept any liability
for damage and operating faults arising from a failure to observe the Operating
Instructions.
- The operator must be familiar with handling the rectifier through special
induction or training courses.
Danger of injury!!
All details concerning the use as intended, the residual risk, the installation, the
operation and maintenance contained in these Operating Instructions must
therefore be observed and adhered to. The rectifier THYROTRONIC is intended
to supply DC voltage loads. In addition to this the rectifier can be used for
charging suitable batteries. Only rechargeable lead and nickel-cadmium batter-
ies are suitable. The rectifier is not suitable for all other accumulators and non-
rechargeable batteries!
The instructions of the battery manufacturer must be observed and adhered to!
As part of the intended use, the details of the type plate and the details in the
supplied technical documentation must be observed and adhered to.
The rectifier may only be used for the applications provided in these operating
instructions and in the technical description and only with the accessories or
components recommended and approved by the manufacturer.
Use other than this or beyond this will not be considered as use as intended.
The operator or user of the rectifier will carry the sole responsibility for dam-
age resulting from such use.
In the case of a rectifier with subsequent modifications on the part of the opera-
tor (with regard to components, circuits, controller programming, etc.) it is
compulsory on the part of the operator to document the equipment status in the
technical documentation and to provide suitable instructions permanently on
the front of the unit if applicable.
• Entering liquids,
• entering conductive dusts (soot, metals),
• high humidity of the air and
• formation of condensate (for instance through airtight packaging) and
• ambient temperatures below 0 °C and above 40 °C
may damage the rectifier and must therefore be excluded.
Heat soak conditions on the rectifier for instance through heat sources or
blockage of the ventilation slits must be excluded. Although non-conductive
dusts do not impair the function of the rectifier they may however obstruct the
dissipation of heat if allowed to accumulate and consequently reduce the ser-
vice life of the rectifier.
Open flames and smoking in rooms with battery charging stations are prohibit-
ed!
Perform the electrical installation (line cross sections, fuses, earth connections)
according to the applicable regulations.
Adherence to the limit values as required by the EMC act is strongly connected
with the installation and combination with other pieces of equipment and the
type of operation. In order to comply with the EMC act, the installation must
take into account all details concerning screening, earthing, arrangement of fil-
ters and insulation of lines.
• Adhere to the mains connection values of the type plate (voltage and fre-
quency).
• Polarity reversal of poles with mains and battery connection must be se-
curely excluded.
Publicise location and operation of fire protection equipment and adhere to fire
alarm and fire fighting possibilities.
The rectifier may only be used in a technically perfect condition and as intend-
ed under consideration of safety and hazards and adhering to these Operating
Instructions. In particular, faults impairing the safety must be corrected imme-
diately.
Even when the rectifier has been switched off completely, individual compo-
nents will still carry voltage for as long as they are connected with the supply
system and/or the battery.
Prior to starting maintenance or repair work disconnect the rectifier input and
output from
After switching off, wait for at least five minutes before taking off the covers
of the housing. The capacitors of the control will have been discharged com-
pletely only after such time.
First check all disconnected components to ensure they are de-energised, then
earth, short circuit and insulate live adjacent components.
When working on high-voltage assemblies, connect the supply cable to the cas-
ing following the disconnection of the power. Short-circuit components such as
capacitors by way of an earth rod.
3 Product details
3.1 Description
Electrical loads are employed in all areas of industry and public life which
must be protected against failure of the power supply system. Together with
shunt-connected batteries, the rectifier THYROTRONIC forms a guaranteed
power supply.
(2)
(1)
(4)
--c:;:6- (5)
(1 ) Battery
(2) AC mains 230/3x400 V
(3 ) Rectifier
(4) Protected DC mains
(5 ) Load
Lead and nickel-cadmium batteries achieve maximum service life if they are in
a position of rest in the charged condition. This position of rest of the batteries
is achieved when the rectifier takes over the supply of the loads and the battery
is only utilised in the case of mains failure or high current loads. This operation
mode is termed standby parallel operation.
With a severely depleted battery, the rectifier will initially operate in the !-
branch of the ID-characteristic, the charging current being obtained from the
difference between the rated current of the rectifier and the load current.
-- l
E230 G60/30 BWrug -TOG
2.,~,.zu,,,tzbm~hoong (1)
Gerate-Eigenschaften @atterie- und Widerstands- (2)
last, Kenn linienregelung, .Ymschaltbare Kenn Iinie,
~~ geglatteter Ausga ngsstrom)
,. Ausgangsstromart und -nennspannung/ -nennstrom (3)
Eingangsstromart und -nennspannung ( 4)
The exact technical data are provided on the type plate on the rectifier, in the
order confirmation and in the technical data sheet.
The power supply and a battery and/or load contact must always be discon-
nected before intervening and working on the rectifier.
Danger!
Installation and start-up of the rectifier , especially in the case of units with bat-
tery connection, are only permitted by experienced and qualified electricians.
Explosion hazard!
You should never break the battery connection during a charging pro-
cess, since this could result in sparks or arcing, which could ignite the
oxyhydrogen gases.
Attention!
When batteries are being charged, caustic acid gases may be gener-
ated which can cause short-circuits in electrical equipment (fire
hazard) and corrode components!
Always place batteries so that the rising acid gases are able to freely dilute at
the place of operation and escape.
3.3.1 Battery
Danger!
Batteries contain sulphuric acid which is highly caustic. The ex-
posed metal parts of a battery always carry voltage. Do not open
any battery housings and do not touch any exposed metal parts!
Work on and with battery systems may therefore be carried out only
All control parts are clearly marked. All live assemblies are equipped with
housings, covers which can only be removed by means of tools. All cables and
plugs are properly screened and earthed.
All electrical and electronic components correspond to the European safety re-
quirements; all insulating clearances have been adhered to. All electric circuits
have been equipped with primary and secondary fuses of defined amperage and
tripping characteristic.
Prior to working in the unit, disconnect Attached to the inside of the front door.
mains and battery fuses.
Do not touch live parts. Individual termi- Attached to the inside of the front door.
nals and components may also carry volt-
age even with the switched off. (De-
energise first when performing mainte-
nance operations on the unit).
When connecting to the mains, connect the Attached to the inside of the front door.
PE conductor prior to L and N!
-- - IP: I ...:J
The sections on
Protect the rectifier against excessive contact voltages according to the local
regulations of the power supply company: It is considered an installation with
fixed connection and must be protected in the power-supply circuit (electrical
systems of the building) against short circuit or overcurrent.
• Protect with - mains fuses in accordance with the technical data sheet.
When connecting the cables, observe the details of the circuit diagrams and the
terminal diagrams!
The currents for determining the cross sections for the mains, battery and load
lines can be taken from the type plate. The resulting voltage drop between rec-
tifier and battery and load should be taken into account when determining the
cross sections.
Connect the rectifier with the earthed conductor by means of the earth screw
provided for this purpose.
1L - 1Lt 2L - 2L t
L1 L2 L3 N
1L- 1L+ 2L - 2L +
5 Operation
The power supply and a battery and/or load contact must always be discon-
nected before intervening and working on the rectifier.
The display and operating panel in the front of the unit allows the personnel to
monitor the operating status and the specialised electrical personnel authorised
and qualified for this purpose to change the programme settings (see descrip-
tion: Advanced operation and programming )
• the LCD alternately displays the current values of unit voltage and unit
current and
The individual operating steps are explained in more detail in the following
chapters. Prior to operating the rectifier for the first time, carefully read
these chapters.
[ THYROTRONIC
ml •••
~ o a o
U- ULl hi. ~
• perform unit tests and reset the messages by means of the Test/Reset but-
ton,
• Important unit states are indicated by means of four LEDs, e.g. unit On
LCD
The current operating values and the selected menu levels and menu options
and their values in the case of programme changes are displayed in the LCD.
The menu levels and items which allow monitoring and adjustments or settings
to be made can be accessed using the 4 buttons beneath the display (extract from
94032.00U003A3).
~ ...
0
u u t:::l ~ f1.
Buttons
All released statuses and measured values in the LCD can be queried and set
with the four buttons. Safety-critical menu levels can only be accessed by way
of a password. The meaning of the buttons is indicated in the display.
There are four LEDs arranged above the display providing information on the
basic unit condition.
!] red alarm
ii
I
} red urgent alarm
• The message unit ON shows that the unit has been switched on.
• The LED Battery operation indicates that any loads are supplied with bat-
tery current (by way of a battery bar, if applicable).
• The message Alarm does indicate "non-urgent" faults and continued op-
eration of the rectifier is possible. The alarm message is displayed in more
detail in interaction with the messages by way of the LED bar.
• The message Urgent alarm indicates faults which restrict or end the opera-
tion of the rectifier. Depending on requirement, urgent alarm messages are
coupled with a visual or acoustic fault signal (common fault). The respec-
tive form, for instance a signal tone in a control centre, depends on the sit-
uations on site.
In accordance with the standard configuration supplied ex factory, the LED bar
indicates the following statuses:
green
D I float charging
yellow
D I boost/equalizing charge
yellow
D Ibattery test
red
II Imains fault
red
red
•• Iequipment failure
Ihigh DC voltage
red
Ill I1ow battery voltage
red
red
II
• Ibattery test negative
Ibattery circuit fault
red
• I+earth fault
red
red
•• I - earth fault
I(spare)
red
Ill I(spare)
The meaning of the 13 LEDs is determined by the configuration file and de-
pendent on the programming of the controller.
The general meaning of the colour of the LEDs is fixed in the standard IEC
73/DIN VDE 0199. The following therefore applies:
. -
-
----
~ -
0 I
~ - ---~- -
This chapter must be thoroughly read before the initial start-up. More infor-
mation concerning display and operating elements can be found in the follow-
ing chapter.
- Compare the ratings on the type plate with the ratings of the supply con-
nections.
- Check to ensure that all input and output connections have correct polari-
ty.
- Check to ensure that all connections, contacts and fuses are firmly seated,
circuit breakers and motor protection switches are switched on.
Please note:
When connecting a charged battery to the rectifier, the de-energised filter ca-
pacitors will be charged by a large charge current surge. Under certain condi-
tions this may cause the battery fuses to trip. This can be prevented by charging
the filter capacitors to the approximate battery voltage before connecting the
battery.
Pr ocedure:
• Version number
• SAT address
• Unit is master/slave.
This phase is completed as soon as the LCD displays current and voltage.
--+ Switch off the rectifier with the switch as soon as the initialisation phase
has been completed. The filter capacitors have been pre-charged.
Danger!
-+ Now, do not delay establishing the battery contact. Any delay, any retrac-
tion will "draw" an arc and increase arcing-over and fire hazards.
During the following initialisation phase, various LEDs will initially start to
light up again, followed by flashing.
At the end of the initialisation phase and on the transition to Float charging
(basic state of boost charge), the LCD will display the current rated voltage and
the rated current and only the two LEDs Float charging and Operation should
be illuminated.
It is possible that the LEDs Low battery voltage and Alarm may light up.
Subsequently observe the operating state for some time. If additional alarms
are displayed, troubleshooting instructions can be found in chapter 6.10 Faults
and error messages.
Attention!
Following the successful initial start-up, mark the rectifier with all necessary
details clearly visible, permanently and legibly:
~ Note down the applicable battery types and loads and possible subse-
quent changes to the controller programme at a suitable place in the inte-
rior of the unit and in the technical documentation!
~ In particular mark any deviations from the details on the type plate.
The LCD permits the display of the selected menu levels or menu options and
their measured values.
Large menu areas comprise sub-menu for configuring the controller. These ar-
eas are password-protected.
The functions are described in more detail in a separate description (see no.
440S).
Various LEDs will light up and subsequently flash during the following initial-
isation phase.
By the end of the initialisation phase during the switch-over to Float charging
(basic mode of automatic operation), the LCD shows the current voltage and
current values. Only the two LEDs Float charging and Unit ON may be illumi-
nated.
If the LEDs Low battery voltage and Alarm should still be illuminated:
Subsequently observe the operating state for some time. If additional alarms
are displayed, troubleshooting instructions can be found in chapter 6.10 Faults
and error messages.
Programme start commences as soon as the control board is supplied with volt-
age by the basic controller board. The SMD LEDs H501, H502and H504 to in-
dicate supply voltage available are illuminated.
The controller receives a stop signal while initialisation and a 5-second LED
test are being performed.
Subsequently the software version followed by the unit address will be dis-
played subsequent to that. The standard operation then starts.
The basic charge status is Float charging. After an initialisation phase of ap-
prox. 30 seconds (in case of stand-alone operation without further internal bus
user; can be shortened pressing the Test/Reset button), the rectifier will run up
to the output voltage setpoint for float charging if the device address is not
equal to zero.
If another rectifier unit is shunt-connected by way of the internal bus and the
operation mode has not been selected on the master, changeover may take
some time until the changeover command has been sent by way of the bus.
All automatic operation mode changeover operations take place only from
Float charging!
Float charging is performed with a defined set voltage per cell, depending on
the rechargeable battery type (exact details see technical data sheet). This is the
basic charge status at every start.
With the option Automatic charging switched on, switching takes place auto-
matically. The trigger for changing over to Boost charging is the presence of
the battery or unit current limitation for more than 30 seconds.
If a gassing charge time has been programmed, switching back to float charg-
ing takes place after the set time (gassing charge time). In the event of a mains
failure the expired gassing charge time is not protected. Upon return of the
mains power Float charging and changeover takes place according to the cur-
rent measuring signals.
Equalizing charge can only be started manually by way of the operating panel.
The set equalise charging time (adjustable in the SYSTEM menu) starts to run
immediately.
In the event of a mains failure, the expired equalise charging time is saved;
when the power returns, the begun Equalizing charge operation is resumed at
the point of interruption. Following time-controlled or manual changeover
from Equalizing charge to Float charging, no overvoltage query is performed
for 10 seconds.
Direct supply is the operation mode for pure load supply. Direct supply is per-
formed at Usct = 2.0 V/cell and IMax = lset· Direct supply is started and stopped
manually.
The voltage limit values (<<U, >U etc.) remain constant and may be reached
under certain conditions!
6 Messages
LED bar
red
•
II
Imains fault
Iequipment failure
red
• Ihigh DC voltage
red
red
•
II
Ilow battery voltage
Ibattery test negative
red
red
•
II
Ibattery circuit fault
I+earth fault
red
red
•• I- earth fault
I(spare)
red
• I(spare)
like Fig. 8
Following the expiry of the switching-on delay following a mains failure, the
controller is enabled if no overvoltage is present and the rectifier has not been
switched off with the unit switch.
With the rectifier switched off, the controller and pulse blocking are set; the
mains power relay (if present) de-energises. The left LED above the LCD is
off; all monitoring operations except for equipment failure and sensor fracture
are performed.
6 .2 Mains fault
The stop signal for the controller is output; the mains relay drops out; after 60
seconds, the non-urgent alarm is released; after 30 seconds, the signalling relay
Mains fault drops out. The message is then maintained (LED flashing, if the
phase error is no longer active) until it is reset by way of the Test/Reset push
button. All queries are active.
The message Mains fault is generated on the basic controller board and passed
on to the Thysat control board as a digital signal. The response threshold can
be set with the potentiometer on the basic controller board.
• the actual voltage value is approximately 0 V (< 0.3 V/cell with Pb) de-
spite battery or unit current limitation or
• the set voltage value is exceeded by> 0.2 V/cell (with Pb) despite battery
or unit current limitation.
The message Sensor fracture and equipment failure will then be issued. The
message is held (LED flashing, if the equipment failure is no longer active) un-
til it is reset with the Test/Reset button.
If the current limitation was active (standard: 90% of Iser-rated, e.g. with current
peaks through additional connection of loads), the charge waiting time is start-
ed for 30 seconds.
If the battery charging current limitation was active (standard: 90% of Iset-Batt),
the 30-second charge waiting time will start. If the battery current is not detect-
ed (no battery shunt connected), the battery charging current limitation <Isan is
by default not active. Until 10 seconds later, the system is not interrogated for
overvoltage.
If an overvoltage is present (a voltage above the set voltage per cell which de-
pends on the accumulator type; for details, see technical data sheet), controller
blocking is set within < 10 msec for approx. 200 msec and then switch over to
the basic operating state of Float charging takes place. If the message High DC
voltage occurs four times within 30 seconds, the controller blocking and the re-
lay common message (urgent alarm) will be activated, the mains relay drops
out. The messages can only be reset by pressing the Test/Reset button. The
message is held until the button has been pressed (LED flashing, relay dropped
out, if the overvoltage is no longer active). During Equalizing charge and until
10 seconds after the equalize charging has finished, the system is not interro-
gated for overvoltage.
If less than the defined set voltage per cell is available depending on the re-
chargeable battery type (exact details see technical data sheet), the message
Low battery voltage is output without delay by way of LED and relay. It will
only be deleted on exceeding the hysteresis limit (<<U +0.2 V/cell). However,
the LED message is retained flashing until it is reset with the Test/Reset button.
• High DC voltage or
• Equipment failure.
6.9 Option 1 - 6
If the optional inputs of the controller are selected by external contacts, the rel-
evant LED is illuminated. If the option is no longer present, the LED starts to
flash. The message is retained until it is reset with the Test/Reset button. All
options are monitored also in the event of mains failure. As an option it is pos-
sible to programme a relay on the relay board.
'
23.10.09 Mo/Obs 34/57 4407 en
BENNING Rectifier THYROTRONIC with Thysat controller
TDG3
Faults and the status of the rectifier are indicated via the LEDs of the operating
and display panel. The following table gives an overview of the possible fault
causes and their remedies:
Mains fault Input voltage fault. Loose or incorrect Check all cables for mechanical-
connections. ly correct connections.
Check mains voltage at the recti-
fier terminals.
If available:
Check mains voltage on the con-
troller tenuinals (see wiring dia-
gram).
If available:
Check mains input fuses on the
basic controller board.
If correct:
Check jumpers Xl 1 to X13 for
correct position.
If correct:
Fault on controller and control
section Al is possible; Consult
supplier or manufacturer.
Battery circuit Battery circuit in- Check all cables for mechanical-
fault terrupted ly correct connections.
Check all isolating points or fus-
es in the battery circuit for their
switching status.
Check battery for cell breakage
or cell short circuit or
loose/incorrect cell connectors.
+ Earth fault I Earth fault In the case of paral- Deactivate the earth fault moni-
- Earth fault !el operation with toring in the controller of a recti-
other rectifiers with fier: See chapter 6.13.
earth fault monitor-
ing
With additional Check to see if the
earth fault monitor- THYROTRONIC rectifier has
ing in other system been earthed on one pole:
units If yes:
Deactivate earth fault monitoring
in the controller:
To enable the earth fault measurement, the following parameters must be met:
Insert the jumpers X300 and X301 on the lower controller board as stated in
the following table. Valid jumper assignment for earth faults:
For the signal output, the unit is equipped with 3 potential-free change-over
switches. By default, they are provided for the following messages:
common fault, low battery voltage and mains fault.
1 =Voltage switched
e1c hstrom- starenz kurve (2)
GI'
300
\ 2 = DC current load limit curve
zoo
\1\1\
100
3 = DC current load limit curve
(1~50 ........
........ ohmsche Last: -
- (3) 4 =Current switched
g'40
~ 30
.
c:
~20
;;:::
Parallel operation regulation does not take place when the rectifiers are subject
to battery charging current limiting.
With these two settings the controller is informed that it feeds a common bar in
parallel operation with one other rectifier by way of a decoupling diode.
Both flags must be active. In these operating conditions, the 2nd voltage chan-
nel of each rectifier must measure the bar voltage. The set voltage values are
increased by the constant value 0.8 Vin order to compensate the voltage drop
on the diode and to maintain the set voltages on the bar. The voltage adjust-
ment acts on the second voltage channel. The voltage monitoring with battery
(circuit) test acts on the second voltage channel. (controller terminal: X 400
Positive)
Configuration 1
Two independent units are each fitted with block-type diodes at the rectifier
output. Each unit has a battery output and a consumer load output.
Both units supply with their respective output one common battery. See block
diagram 1
Both units may operate simultaneously. There is no parallel operation line be-
tween the two controllers required. In one of the units, the earth fault monitor-
ing needs to be disabled. The function battery circuit monitoring may be used.
However, no battery availability test can be performed since the devices do not
share one common battery shunt. If this function is kept active on both units,
status report errors may occur.
Block diagram 1
Configuration 2
Two independent units are each fitted with block-type diodes which are how-
ever switched in the consumer load circuit. Each unit disposes of a separate
battery, both are switched in parallel with the consumer load circuit.
Only the consumer loads are switched in parallel. Each rectifier disposes of a
separate battery. A parallel operation line (synchronising line) is not required.
In one of the units, the earth fault monitoring needs to be disabled. The func-
tion battery circuit monitoring may be used. The function battery availability
test can be used since each unit has an own battery.
Block diagram 2
Configuration 3
Here, both units are designed for fully synchronised parallel operation. A paral-
lel operation line (synchronising line) between the two controllers ensures
equal load distribution. It is included in the delivery scope. All parameters are
preset accordingly.
Block diagram 3
Configuration 4
Both w1its feed one common battery shunt via their battery outputs. Here, the
measuring circuit is connected to one unit and analysed there. See block dia-
gram 4
If the devices are on site wired like this, the shunt line to the controller needs to
be removed on the second unit. Furthermore, jumper X41 has to be removed
from the upper controller board. On one unit, the earth fault monitoring must
be disabled. A parallel operation line must be plugged in to connect the two
controllers to each other. (SAT-BUS)
Block diagram 4
Since both rectifiers come standard with earth fault monitoring, this monitoring
function must be disabled on one of the two rectifiers. Otherwise, the earth
fault monitoring systems will yield faulty measurements. To do so, proceed as
follows:
On the controller:
The interval for the automatic battery (circuit) test is not changed by a
manually triggered battery (circuit) test, i.e. the next starting date for au-
tomatic battery (circuit) test remains intact.
During the battery test (not during battery circuit test), battery voltage,
duration of the battery test and Ah withdrawn (with connected battery
shunt) are recorded.
Set DIP switch no. 9 to "off': Function Battery test is disabled. See the
entry in the "technical data sheet" of the rectifier.
6.15.2 Manual
This is the sixth possible operation mode/voltage level. It is started and stopped
manually. This operation mode is only required and programmed for special
configurations (for instance for use in power stations for rectifier coupling).
Shutting down the rectifier is not practical or necessary during regular opera-
tion. Should shutting down of the rectifier be necessary for maintenance or re-
pair purposes, proceed as follows:
-+ Switch off the rectifier by placing the unit switch in the position "O".
In order to isolate the rectifier on the primary and secondary sides, proceed as
follows :
-+ Check to ensure that the rectifier has been switched off with the unit
switch or place the unit switch in the position "O".
• to the load,
• to the battery,
Please note:
---> Ensure the system is de-energised before commencing work on the recti-
fier.
7 Maintenance
7.1 General
The power supply and a battery and/or load contact must always be discon-
nected before intervening and working on the rectifier.
The chapter Maintenance comprises the areas visual inspection and cleaning as
well as maintenance and repair of the rectifier through qualified electrical per-
sonnel.
The specified maintenance interval of one year refers to the continuous opera-
tion of the rectifier. The details described in that chapter must be considered as
minimum recommendations. Depending on the operating conditions, these in-
structions may require expansion in order to ensure the serviceability of the
rectifier.
Special additional and supplementary information can be taken from the ac-
companying documents of the rectifier.
At least once per year, and if operation deviates from the nonnal , inspect and
maintain as required.
7.3 Cleaning
• You can remove dust or dirt in the rectifier with a brush and vacuum clean-
er.
~Inspect the plug connections for clean contact surfaces, pull relief and cor-
rect engagement.
Contactor K 1:
AC main contactor
~If necessary, remove any foreign bodies by removing the contactors con-
cerned.
Before commencing work, disconnect the rectifier from all primary and sec-
ondary connections.
Semiconductor unit
ln case of a fan failure, the rectifier is switched off by the temperature monitor-
ing system; the fault is optically signalled at the display unit and potential-free
signalled in the free central fault signal.
Transforn1ers
In case of a fan failure, the rectifier is switched off by the temperature monitor-
ing system; the fault is optically signalled at the display unit and potential-free
signalled in the free central fault signal. The fans can be pulled upwards out of
the fan duct for replacement, no tool is required for this.
Before commencing work, disconnect the rectifier from all primary and sec-
ondary connections.
The progran1111e of the controller has been preset at the factory. If any changes
are necessary, please contact the manufacturer.
7. 7 Replacement parts
Please contact the manufacturer or supplier quoting the unit data of the type
plate should your require replacement parts.
7.7.1 Disposal
If the rectifier is finally taken out of service at the end of its life, adhere to the
laws and regulations concerning disposal applicable at that time.
Detailed information in this regard can be obtained from the specialist disposal
operations or the responsible authorities.
Attention!
Electronic scrap with its various plastic, metal and heavy metal components
possesses a high hazard potential for the environment. For this reason electron-
ic scrap must be collected and disposed off separately from domestic and
commercial waste.
Electronic scrap should be disposed of to the internal disposal section who will
pass on the scrap to special companies (specialist disposal operations).
7.8 Batteries
Attention!
Old batteries contain heavy metals and caustic chemicals which may not enter
into the environment. Battery manufacturers are obligated to take these back
and to dispose of them free of charge.
Dispose of old batteries in the collection containers provided for this purpose
or contact your battery supplier.
Description Picture
A31 Indicator and operating panel
Generally, the operating panel offers the e
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Thysat controller /rectifier controlling
and monitoring
Terminals XlO:
Distribution station for DC control and
monitoring voltage
Terminals Xl 1:
Distribution station for digital inputs at
the Thysat controller
Description Picture
A6,A7
DC monitoring relay for switching the
counter-cell contactors
Kll, K12
Contactors for switching the counter-cells
F4
M.c.b. for the mains contactor
F19
M.c.b. for the heating units
F5,F6
M.c.b. for the DC control and measuring
voltage.
Fl 7, F20-F22, F26:
Fuses:
F17
Measuring voltage P2 and A30
F20 - F22
Measuring voltage for Pl
F26
Control voltage for K6
Description Picture
K6, K13 , K14 : Control relays:
K6
Battery electrolyte
K13
Common fault message
K14
High DC voltage:
F14
DC semiconductor fuse for counter-cells
Contactor K2:
Exhaustive discharge switch-off of the
battery
Description Picture
Coniacior K3:
For switching contactor K2
Contactor K 1:
AC main contactor
Transformers
T4 -T6: Current transformer for measur-
ing the AC input current
Ql 1
Battery fuse/load disconnector
Q20
Load Main Switch
Description Picture
F901 -F902:
DC overvoltage arrester
Description Picture
X3.1 + X3.2:
1-3 common alarm
4- 6 battery deep discharged
7-9 high DC voltage
10-12 equipment failure
13 -15 mains failure
16-18 load voltage too low 99 V
19-21 load voltage too high 126.5 V
22-24 earth fault
25-27 battery electrolyte low
28-30 input MCB and over voltage
protection
Xl :L1 -L3, N, PE: AC Input
X3 :PE I 100 Measuring earth for earth
fault monitoring
X2: 112: Battery temperature sensor con-
tact
X2:3/4: Battery electrolyte sensor contact
Choke Ll:
Part of the DC smoothing
Transformer Tl
Voltage regulation and galvanic separa-
tion from the mains
Description Picture
Them1ostat S 11:
Temperature measurement in the unit
Hygrometer S13:
Moisture measurement in the unit
Switching the heating units in the unit
bottom on and off
Battery set:
Supplies the loads for a certain period in
case of a rectifier failure.
20 4
40 10
60 16
80 25
100 35
125 50
160 70
200 95
300 150
400 30x5
500 40x5
600 40x5
800 40x10
1000 50x10
1200 50x10
1500 80x10