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Kraft Powercon PRX3, Manual

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Summary of Contents for PRX3

Page 1: ... 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 sup...

Page 2: ...ercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com We reserve the right to make changes to the content of this manual without prior notification ...

Page 3: ...2 KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com ...

Page 4: ...ns 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 Batter...

Page 5: ... 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 ANNUA...

Page 6: ...05201 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 ...

Page 7: ...vels 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 mo...

Page 8: ...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 en...

Page 9: ...6 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 maxim...

Page 10: ...CAL 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...

Page 11: ...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 descri...

Page 12: ...ntrol 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...

Page 13: ...ly 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 b...

Page 14: ...d 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...

Page 15: ... 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 ...

Page 16: ...ight 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 ...

Page 17: ...ed 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 la...

Page 18: ...s 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 ...

Page 19: ...nmental 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...

Page 20: ...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 tippi...

Page 21: ...C converter T7 used to create internal auxiliary power 6 5 4 DC power output Check that the rating plate of the cubical shows a rated voltage that conforms with the battery s nominal voltage Connect the DC system to the terminals marked L and L Use cables that are dimensioned for handling the rectifier s rated output current and the closest following fuse The picture shows an example from cubicle ...

Page 22: ...hub board In case of more modules continue with cable number 2 to socket number 2 and cable number 3 to socket number 3 6 5 6 2 Cubicle type S39 Connect the following cable sets to corresponding connectors on the rear of the module 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 mo...

Page 23: ...k that the rating plate of the cubical shows a rated voltage that conforms to the battery s nominal voltage and the rated voltage of the entire DC system 7 3 POWERING UP 7 3 1 DC First provide power to the measuring circuit and the auxiliary input power of the monitoring unit by for example connecting a fuse in the battery circuit After a few seconds the operator panel display lights up and after ...

Page 24: ...rging and equalizing charging conform to the battery manufacturer s specification see Manual for monitoring unit PCM2 When the battery is charged to a level where the High current alarm is no longer active you should check that the actual output voltage conforms to the setting of the float charging voltage see section 8 1 2 Checking the charging voltage 7 5 CHECKING THE SETTINGS Each time the moni...

Page 25: ...lled it is difficult to determine the expected output voltage The solution is to temporarily shut down the temperature control You do this using the menu option Functions battery temperature to specify that the temperature sensor is not installed see the Manual for monitoring unit PCM2 section Operation Functions Do not forget to reset the parameter for the installed temperature sensor following t...

Page 26: ...m is properly fused according to the instructions in section 3 Cause 2 Internal fault in a rectifier module Replace the defective module Internal primary MCB trips when a rectifier module is switched on Cause 1 Internal fault in a rectifier module Replace the defective module The rectifier has no output green indicator lamp AC OK is off on all rectifier modules Cause 1 No mains power Check that th...

Page 27: ...Umaximum must be increased see Manual for monitoring unit PCM2 Cause 4 High temperature in battery battery room Only applicable if the parameter settings allow temperature regulation of the float charging voltage In this case there is no fault related to the rectifier Look for the fault related to the high temperature instead Alternatively the temperature sensor could be defective Check whether th...

Page 28: ...ing on the left side of the contact plate For rectifier module T1 it is marked X111 for rectifier module T2 it is marked X112 etc Pull out the upper part of the contact Locate the 2 pole contact housing on the right side of the contact plate For rectifier module T1 it is marked X131 for rectifier module T2 it is marked X132 etc For the rated DC voltages 110V and 220V they are in addition doubled i...

Page 29: ...onding MCB F11 for module T1 F12 for module T2 etc Also turn off the DC output power for the module by switching off the corresponding MCB F31 for module T1 F32 for module T2 etc Pull out all cable sets from the rear of the module Loosen the four screws on the short sides of the front of the module and pull out the module Push in the new module and fasten it by restoring the four screws Connect th...

Page 30: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix A LAYOUT AND DIMENSION DIAGRAM PRX3 CUBICLE TYPE F27 P CM2 O K ...

Page 31: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix B LAYOUT AND DIMENSION DIAGRAM PRX3 CUBICLE TYPE F41 PC M 2 O K ...

Page 32: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix C LAYOUT AND DIMENSION DIAGRAM PRX3 CUBICLE TYPE S39 PC M 2 ...

Page 33: ... AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix D DIMENSION DIAGRAM RECTIFIER MODULE PRM3 364 361 177 440 483 In addition 30mm for plug connector and wires ...

Page 34: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix E CIRCUIT DIAGRAM PRX3 KraftPowe rcon Sweden AB ...

Page 35: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com KraftPowercon Swe de n AB ...

Page 36: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com Appendix F CIRCUIT DIAGRAM RECTIFIER MODULE PRM3 ...

Page 37: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com ...

Page 38: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com ...

Page 39: ...KraftPowercon Sweden AB Hjalmar Petris väg 49 S 352 46 Växjö Sweden Tel 46 470 705200 Fax 46 470 705201 www kraftpowercon com ...

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