Rect-Um 0421-En RV00 Rdat110-75 User Manual

RDAT 110-75
DC RECTIFIER / BATTERY CHARGER

USER MANUAL
DC RECTIFIER / BATTERY CHARGER USER MANUAL
In terms of helping the service and maintenance, please fill out and
save following information specified in the table below.
Warranty period is 2 years for both charger and battery as per standard
warranty conditions.
MODEL / TYPE
SERIAL NUMBER
APPLICATION
SHIPMENT DATE
COMMISSIONING DATE
ADMISSION DATE
FOREWORD
This user guide includes transportation, installation, commissioning, operation,

maintenance, etc. procedures for chargers.
DC Rectifier / Battery Chargers is mentioned as "Charger" in the user manual
This user manual may not be copied or reproduced without permission of .
Keep the user manual in a safe place on or near the rectifier.
When faced with any problems with the rectifier, if the problem can not be solved with the
instruction manual / procedures and information in this manual, please contact with our
technical service.
Although this guide is prepared in order to use the rectifier correctly and safely prepared,
though, arising from the use of the information contained in this book assumes no
responsibility or liability for any loss or damage has the right to make changes in the
products described in this manual at any time due to technological development and
improvement without notice.
RECT-UM 0521-EN RV00 Page 1 /56

TABLE OF CONTENTS
1. General ..................................................................................................................................................... 4
1.1 Uninterrupted Protection with Full Isolation ................................................................................................... 4
1.2 Protections....................................................................................................................................................... 4
1.3 Parallel / Serial Connection ............................................................................................................................. 4
1.4 Voltage Ripple < %1 ......................................................................................................................................... 5
1.5 Wide Usage ..................................................................................................................................................... 5
1.6 Boost Charge Protection Function (Boost Inhibit) ........................................................................................... 5
1.7 On-Line Battery Test ........................................................................................................................................ 5
1.8 Automatic Boost Charge (Autoboost) .............................................................................................................. 6
1.9 LVD .................................................................................................................................................................. 6
1.10 DROPPER ....................................................................................................................................................... 7
2. General Safety Instructions and Warnings ........................................................................................ 10

2.1 General .......................................................................................................................................................... 10
2.2 Transportation and Shipping ......................................................................................................................... 10
2.3 Storage .......................................................................................................................................................... 11
2.4 Installation Location ...................................................................................................................................... 11
2.5 Installation ..................................................................................................................................................... 12
2.6 Battery ........................................................................................................................................................... 13
2.7 Symbols.......................................................................................................................................................... 14
3. Electrical Connections .......................................................................................................................... 15

3.1 Cable Cross-Section ....................................................................................................................................... 15
3.2 Cable Connection ........................................................................................................................................... 15
3.2.1 Mains Input Connection ........................................................................................................................ 15
3.2.2 Battery Connection ................................................................................................................................ 15
3.2.3 Load Connection .................................................................................................................................... 17
3.2.4 Electrical Connection Layout ................................................................................................................ 18
3.2.5 Battery Heat Compensation Connection Diagram ................................................................................ 19
4. Commissioning / Operation ................................................................................................................ 19

4.1 Preliminary Checks ........................................................................................................................................ 19
4.2 Startup with Mains/Input Voltage ................................................................................................................. 20
5. Usage of LCD Front Panels ................................................................................................................... 21
6. Communication ..................................................................................................................................... 31
6.1 Serial Communication: .................................................................................................................................. 31
6.2 Free Alarm Contact: ....................................................................................................................................... 32
6.3 Hardware and Connection ............................................................................................................................. 33
6.3.1 Connection to Computer: ...................................................................................................................... 33
6.3.2 RS-485/RS-232 Converter: ..................................................................................................................... 34
6.3.3 Connection to PLC/Automation: .......................................................................................................... 34
6.3.4 Connection to Network: ....................................................................................................................... 35
6.4 Software ........................................................................................................................................................ 35
6.4.1 Setup:..................................................................................................................................................... 35
6.4.2 Usage: ................................................................................................................................................... 36
7. Electrical Schemas ................................................................................................................................ 46

7.1 Rectifier Single Line Diagram ..................................................................................................................... 46
7.2 Rectifier Power&Control Wiring Diagram .................................................................................................. 47

8. Cause &Actions&Troubleshooting ...................................................................................................... 48
9. Maintenance Instructions .................................................................................................................... 52

9.1 Scheduled Maintenance ............................................................................................................................. 52
9.2 Daily Maintenance ........................................................................................................................................ 52
9.3 Weekly Maintenance ..................................................................................................................................... 52
9.4 Annual Maintenance ..................................................................................................................................... 52
10. Cabin Weight and Dimensions ........................................................................................................ 52

10.1 Cabinet Drawing ........................................................................................................................................ 54
10.2 Cabinet Component Layouts ...................................................................................................................... 55

1. General
PMI Charger is SCR controlled AC/DC rectifier with automatic constant voltage and
constant current ability. Thanks to isolation transformer and DC current module, the load
is fully isolated from the system and so the load is protected against charger failure.
12 pulse and 6 pulse options are available according to the different application
requirements. The most important advantages of the 12-pulse charger are lower input
current harmonic (THDi<10%) and higher input power factor (cosφ >0.9). Total output
current, battery charge current, Boost and Float Charge voltages are adjustable on the
control panel easily. Also, smart Boost charger and battery test function can be activated
easily on the LCD front panel or with remote communications. Remote communication
options are RS485 / Modbus, Profibus or TCP-IP.
The AC ripple on the DC output is lower than 1% thanks to output LC filter and so the
battery life will be maximum. Input and output can be switched separately with the circuit
breaker and the condition of these circuit breakers can be monitored on the mimic diagram
via their auxiliary contacts. Also, there are LEDS on the front panel for 8 units critical alarms
and charge modes.
1.1 Uninterrupted Protection with Full Isolation

PMI Charger is completely isolated from the input thanks to usage of input isolation
transformer and DC current control by DC current module. Thus, the surge voltage at the
input and even in systems with high-frequency noise, the charger and load are under safety.
The standard LC filters at output allows to charger the battery safely.
3 Phase 6 Pulse Phase Angle Controlled Rectifier

1.2 Protections
Thanks to the input isolation transformer, the load is fully isolated from the mains and
protected. Input, load and battery outputs are protected by circuit breakers. In case of
excessive heat, the related alarms will be activated and output will be cut off after a while.
Electronic protections are available for short circuit, over / undervoltage. All components
can be accessed easily to do maintenance thanks to simple structure.
1.3 Parallel / Serial Connection

The charger is designed according to the easy accessibility principle to provide service
and maintenance easily and also it is simple to connect in series or parallel according to
need. In case of parallel connection with the correct capacity selection, one of the charger
will be redundant and will be able to continue uninterrupted to supply the load in the event
of any failure.

1.4 Voltage Ripple < %1

DC output is filtered by L/C, so DC ripple at full load always lower than 1% to increase
battery life.
1.5 Wide Usage

PM Rectifier Systems are reliable and ideal for transformer energy distribution centers,
gas oil energy distribution centers, natural gas energy distribution centers, mining industry
security and lighting, building automation systems and for special telecommunication
applications.
1.6 Boost Charge Protection Function (Boost Inhibit)

This function is designed for “Parallel Redundant Industrial Charger with Two Battery
Groups” systems. In parallel operation, if two rectifiers start boost-charging at the same
time there is danger the load would be damaged by overvoltage. So, the principle idea of
Inhibit facility is to block any one of the two chargers feeding the load in Boost mode when
the other rectifier is charging the batteries in Boost mode. Only one rectifiers can be in
boost mode, both rectifiers can not be on boost mode at the same time. When one rectifier
applies boost voltage, it will be disconnected from the load (only its battery will be charged
on boost) and other rectifier will supply the total load current on float charge mode. So, the
system prevents applying overvoltage to the load. This function is primarily handled by a
powerful communication between two rectifiers and the use of contactors.
1.7 On-Line Battery Test
Battery test function tests the battery capacity based on discharge current, minimum
voltage and authonomy time.
The operator adjusts battery discharge current (expected load current), expected
authonomy time and the voltage level that is assumed as battery discharged. Then the load
is fed through the battery during this authonomy time. If the voltage of the battery do not
fall to battery discharged alarm level in the adjusted authonomy time, the battery test result
is PASS. If not, the Battery Test Fail Alarm will be activated on front panel.
Battery test function can be activated manually or set automatically. Automatic battery test
intervals can be set from the front panel and communication interface.
EXAMPLE:
System Description for example:
Nominal Voltage: 110VDC
Charger Output: 60A
Adjustable Values:
Low Battery: 90VDC (Adjustable through front panel)
Disch I= 10A (Adjustable through front panel) Note: This value should be adjusted lower
than the load current. If the load is lower than the adjusted battery discharge current, then
test will be cancelled automatically.
Disch T=60minutes (Adjustable through front panel)
Considering the load as 15A, during battery test 10A will be supplied through battery and
remaining 5A will be supplied through rectifier. During battery test, battery charger will
check the battery voltage continuously. If battery voltage decreases to low battery level in
less than 60 minutes, then battery test will fail. But, if battery voltage does not reach to the
discharged voltage level in 60 minutes, then battery group will pass the test.

1.8 Automatic Boost Charge (Autoboost)

The Autoboost Charge is a function that provide charger make automatically a choice
between float or boost charge modes according to the battery discharge status. This feature
allows charging the battery quickly for the optimum duration after discharge without need
to intervene manually after each discharge.
Auto Charge Function is set as appropriate according to the battery characteristics and
is determined to be engaged in what value the boost charge. Automatic switching between
Boost Charge and Float Charge is done by measuring current drawn by battery after the
discharge. The user can set reference Battery charging current values via the front panel or
software.
Two reference current value must be set for Float Charge and Boost Charge. After being
discharged in any way the battery, while the battery being recharged, if the drwan charging
current value is greater than set reference Boost charge current then the Autoboost
function will begin to apply boost charge voltage to the battery. Applied Boost charge time
is determined by the charge current drawn by the battery. Battery charge current decreases
during charging battery. When the reduced battery charge current drops to the set
reference value, the recitifer will automatically switch to Float Charge from Boost Charge.
Thanks to Autoboost function, Boost charge voltage applied to the battery after the
discharge is not a fixed period. The boost charge duration will be determined according to
the battery need. This function will prevent to damage the battery and shortening of battery
life due to exposed long-term high voltage during boost charger.
1.9 LVD
Long mains failure (no AC on the input) period may cause deep charge on the battery
if the mains failure period is longer than the expected back up time of the battery.
Although battery run out and depleted, without AC voltage in the input of the charger,
battery will keep discharging to the lower voltage levels. This deep discharge may
damage some kind of battery types (especially AGM type). Additionally, the charging
time of a deep discharged battery will take longer time than normally. To protect the
battery from deep discharge, a contactor can be used to disconnect the battery and the

load from each other when battery voltage reaches to the minimum discharge value in
case of a mains failure. This protection is called as LVD (Low Voltage Disconnect).
Rectifier Control PCB operates the LVD contactor by monitoring the battery voltage.
The minimum discharge voltage (Low Battery value) can be adjusted from the LCD front
panel or through communication software. During battery discharge, if the battery
voltage decreases down to the adjusted “Low Battery” value, LVD Ccontactor will
disconnect the battery from load to protect the battery from deep discharge. When the
mains come back and input AC becomes “ON”, automatically DC bus voltage will be
generated, battery will be charged and load will be supplied.
LVD Block Schema
1.10 DROPPER
The function of this item is to drop/decrease the voltage on the load. If there is no
dropper diode, the battery voltage (float or boost) will be directly reflected to the load.
If there is no dropper in the system and float or boost voltage is higher than the
maximum operating voltage of the load, then load may not operate and damaged. The
dropper consists of diodes that are connected in serial and made on-line or off-line with
by a contactor. The quantity of the dropper diodes and steps on the dropper circuit is
based on the load operating voltage range, battery quantity and battery charge voltage
(float and boost).
Dropper Block Schema

General / Optional Features
Rectifier Standard Automation

Type Type
General
Input Isolation Transformer * *
DSP Thyristor Control * *
6 Pulse Phase Angle Controlled Rectifier * *
Separate Outputs for Battery and Load * *
Use as DC Current Source or Battery Charger * *
Adjustable Output Voltage / Current * *
Adjustable Battery Voltage / Current *
Adjustable Timer for Manual Boost Charge * *
Automatic or Manual Battery Test Function * *
Automatic Boost Charge Voltage Adjustment * *
Over / Under Voltage, Over Current, Short Circuit, Over * *
Temperature and Reverse Voltage Protection
Low Battery LED Indication and Free Contact * *
Main Input Normal / Failure LED Indication and Free Contact *
Rectifier Failure LED Indication and Free Contact * *
Over Temperature LED Indication and Free Contact *
Rectifier Overvoltage LED Indication and Free Contact *
Load MCB ON / OFF LED Indication and Free Contact *
Battery MCB ON / OFF LED Indication and Free Contact *
Earth Fault LED Indication and Free Contact *
Reset ON / OFF Switch * *
Bottom Cable Entry * *
IP21 Protection Class * *
Forced Fan Ventilation * *
Optional
12 Pulse Phase Angle Controlled Rectifier * *
Remote Communication: RS485/ModBus, ProfiBus or TCP-IP * *
Dropper Diode Circuit for the output voltage regulation (1-4 * *
Stages)
LVD Contactor for battery deep discharge protection * *
Active Load Sharing Parallel Operation *
Redundant Parallel Operation *
Rectifier Integrated Battery Rack * *
Front Access Cabin with Higher IP Protection (IP31-42-51-54-55) * *
Different Cabin Color * *
Temperature Compensation for Battery Group *
Remote Boost Charge Cancel Digital Output *
Analog / Digital DC Voltmeter / Ammeter, Power Analyzer * *
Distribution MCB *
Natural Cooling * *
Blocking Diode *
Lighting for Cabin * *
Heater for Cabin * *
Top Cable Entry * *

Technical Features
GENERAL
Model RDAT 110-75
Topology Thyristor controlled AC/DC Rectifier with input isolation transformer
Charging Principle Constant Current/ Constant Voltage
INPUT
Nominal Voltage 380VAC
Voltage Tolerance ± %15
Nominal Frequency 50 Hz ±%5
Cosφ >0.9 (12 Pulse)
Transformer Galvanically isolated Input Isolation Transformer
Protection Thermic-Magnetic Over Current Protection, Over Voltage Protection, Soft Start, MCB
THDi < 10% (12 Pulse)
OUTPUT
Nominal Voltage 110 VDC
Voltage Adjustment 110-160VDC
Nominal Currrent 75 A (DC/DC CONVERTER OUTPUT: 75A)
Current Adjustment 0-100% of Nominal Output Current
Battery Charge Current 0-100% of Nominal Output Current
Adjustment
Boost Charge Voltage up to 120% of Floating Output Voltage
Output Voltage Tolerance ±%1
Output Ripple < %1 RMS AC of Output Voltage
Dynamic Response (without ±%5 of Output Voltage (50% and 25% load change)
battery)
Dynamic Response (with battery) Dynamic Response (without battery)
Output Protection Short Circuit Protection, Over Voltage Protection, Reverse Voltage Protection, Short Circuit,
MCB or NH Fuse (based on current value)
Battery Protection L-C filters, Over Voltage Protection, Short Circuit, MCB or NH Fuse (based on current value)
DISPLAY PANEL
Front Panel Measured Values LCD Display for Output Voltage / Current, Battery Voltage / Current and Line Voltage / Line
Current (Monopahse) / Frequency
Front Panel Indicators Float mode, Boost mode, Current mode, Battery ending, Low battery, Battery test failure, Line
failure, Fan failure, Over voltage, Under voltage, Over temperature, Rectifier failure, Line /
Load / Battery MCB, Last 256 Events
Front Panel Set Menu Boost charge voltage, Float charge voltage, Low battery voltage, Battery test, Charger output
current, Battery charge current, Auto & Manual boost selection, Manual boost time, LED test
and ON–OFF, Rectifier ON-OFF, Time & Date settings.
COMMUNICATION & PARALLELING (OPTIONAL)
Communication Parameter settings via RS 485/ModBus, Profibus, TCP/IP or SMS/Mail Order:
Paralleling Active or Passive Load Sharing Parallel Operation
ALARM CONTACTS
Open or closed free contacts Low Battery, Line Input OK/Fail, Rectifier Failure, Over Temperature, Rectifier Over Voltage,
Load MCB ON/OFF, Battery MCB ON/OFF, Earth Fault
ENVIRONMENT
Electrical Standards IEC 60146-1-1 / EN 50091 -1 (Security) / EN 50091 -2 (EMC)
Cooling Forced fans with smart fan controlling system
Isolation Voltage 2500VAC input/chassis and output/chassis
Efficiency at full load >%90
Circuit Breakers Input: MCB; Battery and Load Output: MCCB
Protection Level / Color IP41/RAL 7035
Operating Temperature -10/+40°C
Relative Humidity %5 - %90
Operating Altitude Maximum 2000 Mt.
Noise Level Maximum 60 dB.

2. General Safety Instructions and Warnings

Do not start / interfere the rectifier before checking all the safety and usage instructions
in the manual. Please pay attention to the warnings and safety for the electrical connections
described below. Installation, commissioning, service and maintenance must be performed
by trained technical service personnel or authorized personnel.
2.1 General
1. Please check carefully the quantity and material integrity specified in the shipment
document. In case of any deficiencies, damages etc., please contact our technical
service or your supplier.
2. Do not open the product door without technical service assistant. There are not any
parts in rectifier or battery that the maintenance or service can be done by end user.
3. There is high voltage on the AC / DC electrolytic capacitors in the recitifer that
causes serious injury. This voltage will be discharged after a while (2-3 min.) after
the circuit breakers are made “OFF”.
4. There is battery group with high voltage in the circuit that causes serious injury.
Even the circuit breaker is taken "OFF" position; there is still potentially hazardous
voltage at the input terminal of the battery.
2.2 Transportation and Shipping
1. Please ship the rectifier in original packing against shock, damage etc. during
transportation.
2. Please take necessary precaution to prevent any damage in the rectifier cabin
during lifting.
3. Please move the rectifier in the upright position according to the center of gravity.
It may cause damage in rectifier to move in sideward due to heavy materials in it.
4. Excessive vibration and bounce may damage the charger during transportation.
5. Do not move the charger by pulling or pushing from the package. Always use
forklift, crane or transpallet to move it.
6. If the rectifier will be lifted by crane, please use appropriate distributor bar or
lifting strap.
7. Do not expose the rectifier to water directly even if it is packaged during
transportation.
8. Do not bend the rectifier more than +/-10° during transportation, otherwise it may
fall over and cause injury.
9. Do not place other packages on the rectifier package during transportation.
Otherwise, it may cause damage to the rectifier.
Please check capacity of sufficient floor and elevator / crane to
avoid causing serious injury in case falling tipping etc.

Transpallet Forklift
2.3 Storage
1. Store the rectifier in a dry place. The environment temperature should be in ideal
storage temperature range (-25°C/+55°C).
2. Optimum storage temperature range for battery is -20°C/+25°C and the battery
will be damaged beyond -20°C/+40°C range.
3. If the rectifier will be stored for a period more than 3 months, then the batteries
(over time depending on storage temperature) must be recharged periodically.
2.4 Installation Location
1. Due to the humidity casued by temperature difference, there may be condensation
on battery charger. In that case, wait for 2 hours before installation to adapt the
battery charger to the environment.
2. Do not keep explosives and subtances that may be affected from the heat in the
same area with battery charger.
3. Objects that may be affected from the magnetic field should be kept at least 1m
away from the battery charger.
4. The area that battery charger placed should be open and have free space (min
100mm). Do not install the battery charger to the places that receive direct
sunlight, next to the radiators, humid/damp areas and close with conductive
metarials.

5. Do not block the ventilation fans and other openings. Foreign objects must not be
inserted to the battery charger.
6. Battery charger must be protected against water or any other liquids that may
enter to the battery charger cubicle.
7. Battery charger must be protected against rodents or insects that may enter to the
battery charger cubicle.
2.5 Installation
All the connections must be done by the technical personnel.

- Ground line connection must be done before the other connections.

1. Please open the rectifier package carefully and check it against shock, impact,
scratches, breakage, damage etc. That may occur during transportation.
2. There is not any hardware available on the rectifier for protection against leakage
current. Therefore, the technical staff or user should put the warning labels on the
circuit breakers on the line during working on the rectifier. Warning labels will
remind the intervene on the line to technical staff who is working on the system.
MAINTENANCE / EXCAVATION IS DONE ON THIS LINE.

Do not interfere.
3.
Warning Label
4. For safe operation; please use suitable cross-sections for connection proper to
rectifier capacity. Thin wires or loose connections will cause dangerous
overheating in the cable connection and terminals.
5. Please use original accessories and insulated service tools while doing rectifier
connections.
2.6 Battery
Please pay attention to the following warnings when working

with batteries. Batteries pose a great risk for electrical shock.
Fire or life-threating may occur due to short circuit, spark etc.
occuring during working.
1. Please take off the conductive metal objects such as ring, tag, wristwatch etc. before
starting maintenance or replacement processes on the batteries.
2. Please use original accessories and insulated service tools while doing battery
connections.
3. Please do not leave the service tools and/or conductive metal objects on the
battery.
4. Please do not throw never the batteries in the fire to destroy them. The battery
exposed to high temperature may cause serious injury.
5. Please do not pierce the battery casing and do not absolutely open inside the
battery. The battery contains toxic gases and electrolytes that are extremely
harmful for skin and eyes.
6. Please do not make short circuit the battery negative (-) and positive (+) terminals.
Otherwise, the battery may be damaged and there may occur electrical shock or
burn in your body due to short circuit.
7. Even the Mains Input MCCB/MCB/Fuse is “OFF”, the hardware in the rectifier is
still connected to the battery and there is still battery total voltage on this
hardware. Therefore, the Battery MCCB/MCB/Fuse should be turned OFF and the

connection cables between batteries should be removed before doing any

maintenance or replacement for the battery.
8. Please make sure that there is not any voltage on the battery connection terminals
before makingintervention to the battery. Battery circuit has not been isolated
from the input voltage circuit. A voltage that may lead to life threatening, can occur
between battery terminals and ground (chasis)
9. The direction of the (-) and (+) terminals in battery connections is important.
Reverse connection may damage the rectifier. Please make connections to the
related terminals as per labels on the rectifier and wiring diagrams.
10. Please replace the battery with a new with same voltage, capacity and cells
number as per the one on the rectifier. Please pay attention to the same battery
manufacturer and production time of the new battery.
11. There are current and voltage on the battery that may lead to life-threatening.
Therefore, battery maintenance and replacement should be done by trained
technical service personnel. Battery replacement and maintenance should not be
carried out by unauthorized persons.
12. Please contact with technical service to change a higher capacity battery. It is
required to know the technical details of rectifier and connection to do this. The
uninformed transactions may damage the rectifier.
Batteries contain toxic substances such as lead- acid
etc. If they are not disposed of properly, they are
harmful for the environment and human health.
Recycling / reuse or hazardous waste process must
be carried out as per prescribed by local laws.
2.7 Symbols
Electrical hazards that may cause serious injury or loss of life if

the warning is not taken into account.
Serious injury, loss of life or rectifier failure may occur if the

warning is not taken into account.
Do not dispose of garbage: Do not

dispose of this product have not been
classified as urban waste. Such waste
Earthing Recycling should be collected separately for special
handling of the donated.

3. Electrical Connections
Before starting this process, please pay attention to the
substances of the safety and warning in "2. General Safety
Instructions and Warnings "section.
3.1 Cable Cross-Section

Cable size to be used in your equipment connections are given in the following table.
MODEL INPUT OUTPUT OUTPUT INPUT BATTERY/OUTPUT

VOLTAGE VOLTAGE CURRENT CABLE CROSS-SECTION CABLE CROSS-SECTION
(VAC) (VDC) (ADC) (mm2) (mm2)
RDAT 110-75 380 (3PH) 110 75 10 25/25
3.2 Cable Connection

3.2.1 Mains Input Connection

substances of the safety and warning in "2. General Safety
Instructions and Warnings "section.
1. Please make sure that there is no voltage on the cables to be connected.

2. Please use appropriate cable cross-section according to the rectifier power
and model.
3. Please check if the MCB/fuses on the rectifier are at OFF position.
4. For 3 Phase Input 6 Pulse Models; Please do the R, S, T Phases and ground
connections as specified in the labels of the Rectifier mains input
MCB/terminals.
5. Please check the robustness and accuracy of your connections. The loose
connections will cause dangerous overheating in cables and terminals.
Please do not turn ON the Mains Input MCB. Please check the
“Startup” section.
3.2.2 Battery Connection

substances of the safety and warning in "2.6 Battery"section.
1. Please keep as short as possible the connection cables between rectifier and
battery.

2. Please use colored cables to avoid confusion during this process. For example: Red
cable for positive (+) end, black or blue for negative (-) end.
3. Please connect batteries in series. The correct and wrong connection examples are
given below.
Correct Battery Connection
4. There is a total battery voltage between main (+) and (-) terminals. Please leave
the shunt connection between any two batteries open as indicated in the following
examples to avoid arc, burns etc. as a result of short circuit during battery
connections.
10 Batteries Serial Connection
5. Please connect battery main (+) and (-) terminals to the rectifier input battery fuse
/terminal as specified in example below by paying attention to the direction of (+)
and (-) as indicated on the label.

Please pay attention to the direction of the (+) and (-) terminals
while doing battery connections. Reverse connection may
damage the battery and rectifier.
6. Please connect the shunt left open while Battery Fuse is OFF. Please measure the
total battery voltage on the battery fuse/terminal by a measurement device (at DC
voltage level) with correct probe direction. Please check the accuracy of the
connections by this method.
Please do not turn ON the Battery Fuse. Please check the

“Startup” section.
3.2.3 Load Connection

1. Please use colored cable to avoid confusion during this process. For example: Red
cable for (+) en, black or blue cable for (-) end.

2. Please connect load connection main (+) and (-) terminals to the rectifier load
output fuse/ terminal as specified in example below, by paying attention to the
direction of (+) and (-) as indicated on the labe.
3. Please check the robustness and accuracy of your connections. The loose
connections will cause dangerous overheating in cables and terminals.
4. Please pay attention to the direction of the (+) and (-) terminals
5. while doing load connections. Reverse connection may damage the
load and rectifier.- Please do not turn ON the Load Fuse. Please
check the “Startup” section.
3.2.4 Electrical Connection Layout
+ - + -
L1 L2 L3 RS485 110VDC 110VDC
380VAC OUT LOAD
BATTERY
MAINS INPUT OUTPUT
INPUT
BATTERY
HEAT COMP.

3.2.5 Battery Heat Compensation Connection Diagram
If your device has battery heat compensation function, you should have thermistor
connection with 2 different ways. You can put the thermistor on one of the battery from
battery group or you can put it in close distance with battery group.
Connection is shown in below figure.
4. Commissioning / Operation
4.1 Preliminary Checks
1. Please turn ON the Mains Input MCCB/MCB/Fuse to energize the rectifier.
2. Please measure the Mains voltage over the Mains Input MCCB/MCB/Fuse/
terminal by an AC voltage level measurement device (Phase – Phase voltage for 3
phase rectifier) and check if the voltage is same with “Input Voltage” as written on the
rectifier label.
3. Please measure the Mains voltage over the Mains Input Fuse / terminal by a
measurement device at Hertz level (Phase – Phase frequency for 3 phase rectifier)
and check if the frequencye is same with “Input Freuency” as written on the rectifier
label.
4. Please measure the ground voltage over the netural and ground connection
terminal with a measurement device at AC voltage level and check it. The neutral to
ground voltage should be less than 3VAC. If it is greater than 3VAC, please strengthen
the ground line.
Note: Please check the neutral to ground voltage of the installation place for the 3
Phase rectifier without neutral.

4.2 Startup with Mains/Input Voltage

1. Please turn ON Input MCB.
After applying the Mains voltage to the rectifier, the rectifier will generate DC bus
voltage with help of soft start feature and LCD front panel will be energized.
*If the rectifier does not start, please change two phase connection sequence from
Mains input.
2. Please turn ON Battery MCCB.
Note: Please check battery charge voltage and current from the LCD front panel.
3. Please check the DC input voltage from DC/DC Converter Front Panel. Then, turn
ON the DC/DC Converter from DC/DC Converter Front Panel.
4. Please check the DC output voltage from DC/DC Converter Front Panel. Then,
turn ON Load Output MCCB and check load current on front panel.

5. Usage of LCD Front Panels
FLOAT MODE
BOOST MODE
CURRENT MODE
EQUALIZE MODE
BATTERY ENDING
RECTIFIER
MAINS LOAD
LOW BATTERY
BATTERY TEST FAILURE

BATTERY
LINE MCB OFF BATTERY
SCR FUSE CHARGER
FAN FAILURE FAILURE
LEAKAGE + -
OVER VOLTAGE
(+) (-) BATTERY
EARTH
UNDER VOLTAGE FAULT
OVER TEMPERATURE
RECTIFIER FAILURE
MENU SET MENU SELECT
LEFT RIGHT
Buttons for MENU SELECTION
MENU SELECT buttons are used to skip among the
windows.
UP DOWN
Buttons for MENU SETTINGS

SET MENU button is used to make parameter settings
on the window. Use UP button to adjust the above
parameters and use the DOWN button to set the
below parameters.
To activate the button, it should be hold down for 1
second. After the parameter is set, changes will be
recorded if you press the RIGHT button. If the LEFT
button of MENU SELECTION is pressed, then the
changes will not be saved.
The UP button is used to increase parameters.

Parameters can be increased until reach its maximum
value and then it returns to the its lowest value.
Therefore, to reduce any value, it firstly should reach
its maximum value.
NOTE-1: All following given values are chosen for Charger with 1Ph Input / 48VDC
Output and 3Ph Input / 110VDC Output
NOTE-2: The RED values can be set with the SET MENU buttons. After the
parameter is set, changes will be recorded if you press the RIGHT button. If the
LEFT button of MENU SELECTION is pressed, then the changes will not be saved. To
activate the button, it should be hold down for 1 second.

CHARGER ON LEFT RIGHT Menu-1: Opening Window

UP=ON DOWN=OFF UP button on this window must be pressed to start
the rectifier. When the DOWN button is pressed, the
rectifier will be stopped. If battery is connected while
the charger is OFF, the charger will continue to work
through the battery.
L12 =380 f=50.0 LEFT RIGHT Menu-2: Input Monitoring Window

L13=380 L23=380
L1 = 220 f=50.0 LEFT RIGHT (L1) Input Voltage, (Iin) Input Current, (f) Frequency
Iin=21 Vb=54.4 and (Vb) battery voltage can be monitored on this
window
L1-L2 Ph to Ph Input Voltage, L1-L3 Ph to Ph Input
Voltage, L2-L3 Ph to Ph Input Voltage and Frequency
can be monitored on this window.
I1 =10 f=50.0 LEFT RIGHT Menu-3: Input Current Monitoring Window

I2=10 I3=10 (I1) Input Phase Current of L1, (I2) Input Phase
Current of L2, (I3) Input Phase Current of L3 and (f)
Frequency can be monitored on this window.
Note: The input current reading is implemented as an

option because it requires a separate hardware. If
Input current value is "0", it means the device does
not have this feature.
Vb = 54.4 Vl=48.0 LEFT RIGHT Menu-4: Output Monitoring Window (Main Menu and
Ib=10.0 Ir=50.0 Screensavers)
Vb = 122 Vl=122 LEFT RIGHT (Vb) Battery Voltage, (Ib) Battery Charge / Discharge
Ib=10.0 Ir=50.0 Current, (Vl) Load Voltage and (Ir) Total Output
Current can be monitored on this window.
If there is not dropper circuit in the system, then load

voltage and battery voltage will be equal. (Vb=Vl)
boost V=56.8 UP DOWN Menu-5: Boost and Float Charge Voltage Adjustment
float V=54.4 Window
To adjust the Boost voltage, please use UP button and
boost V=127 UP DOWN to adjust the float voltage please use DOWN button on
float V=122 this window.
NOTE: The voltage settings should be done according

to the battery manufacturer original catalogue
values.

Equalize V= 56.8 UP DOWN Menu-6: Equalize Voltage Adjustment Window

set equalize V To increase the Equalize voltage please use UP button
Equalize V= 127.8 UP DOWN and to decrease it please use DOWN button.
set equalize V
NOTE: The voltage settings should be done according

to the battery manufacturer original catalogue
values.
LOW BAT. V= 42.0 UP DOWN Menu-7: Low Batt. Voltage and Battery Ending
BAT. END V= 43.0 Voltage Adjustment Window
LOW BAT. V= 95.0 UP DOWN To adjust Low Battery Voltage, please use UP button
BAT. END V= 96.0 and to adjust Battery Ending Voltage, please use
DOWN button.
If there is LVD protection in the system, the LVD will
operate according to the adjusted Low Battery
Voltage
Disch.I = 7A UP DOWN Menu-8: Battery Test Parameter Adjustment Window

Disch.T = 10min. Setting parameters for Battery Test is available in this
window.
To adjust discharge current, please use UP button and
to adjust discarge time, please use DOWN button.
NOTE: The real load current value should be higher

than set discharge current value. Otherwise the
battery test will not function correctly.
boost I=6 UP DOWN Menu-9: Automatic Boost Function (Autoboost)

float I=3 Adjustment Window
Setting parameters for Autoboost is available in this
window.
In order to switch the rectifier to Autoboost mode,
please adjust the current value by pressing the UP
button.
In order to switch the rectifier to float mode, please
adjust the current value by pressing the DOWN
button.
Operation Mode of Rectifier according to the values

of the sample display:
While “Autoboost Mode” is selected, if the battery
charger current is greater than 6A then the rectifier
will automatically pass to Boost mode. After that,
when the battery charger current discreases to below
3A then the rectifier will automatically return to Float
mode

out I = 50 UP DOWN Menu-10: Output Current and Output Voltage

charge I = 3 Adjustment Window
Please use UP button to adjust rectifier output
current (out I) to its upper limit and please use DOWN
button to adjust battery current (charge I) to its
upper limit.
a. b. test 17 hr UP DOWN Menu-11: Auto. Battery Test and Manual Boost Time
m. boost 8 hr Adjustment Window
Automatic battery test period of the rectifier can be
adjusted by pressing the UP button. Press the DOWN
button on the Manual Boost to set the dwell time of
the Manual Boost.
float ch. mod UP DOWN Menu-12: Manual / Auto. Battery Test and Operation
bat. test = closed Mode Selection Window Please use UP button to
select the rectifier operation mode. Please use DOWN
button to select Manual or Automatic Battery Test.
There are 3 options for Battery Test Mode;
1. Close 2. Manual (Start) 3. Automatic
There are 5 options for Rectifier Operation Mode;
1. Float 2. Manual Boost (Start) 3. Equalize 4. Slave
5. Autoboost
date 3 4 10 UP DOWN
Menu-13: Date & Time Settings Window The date on
time 12 32 55 the display is 3 of April, 2010 and the time is
12:32:55.
These values can be adjusted using the UP and DOWN
buttons. Use UP button to scroll through the
parameters and use DOWN button to increase the
values.
events 32 1 UP DOWN Menu-14: Event Memory Monitoring Window

7 180 3 4 12 35 Events recorded in the memory can be monitored
from this window. Up to 250 events are recorded.
There are total 30 event codes. All events can be
viewed by using UP-DOWN buttons.
The first event among the 32 events is displayed on
the left window:
7: Event code; 180: Event Value; 3: Day
4: Month; 12: Hour; 35: Minute
The all recorded event can be deleted by pressing
RIGHT button for 20 sec. with returning the rectifier
to factory settings.
Description of event codes is given in the following
table.

EVENT CODES
1. Line MCB ON 11. Battery OK 82. Slave Mod OFF
2. Line MCB OFF 12. Rectifier Over Voltage 90. Manual Boost Started
3. Battery MCB OFF 13. Rectifier Under Voltage 91. Auto Boost Started
4. Battery MCB ON 14. Rectifier OK 92. Battery Test Started
5. Load MCB OFF 15. Over Temperature 93. Battery Test Failure
6. Load MCB ON 16. Temperature OK 94. Battery Test OK
7. AC Input Low 33. Earth Fault (+) 95. Battery Test Continued
8. AC Input High 34. Earth Fault (-) 96. Auto Boost Finished
9. AC Input OK 35. Earth Fault OK 97. Manual Boost Finished
10. Low Battery 81. Slave Mode ON 98. Boost Continued
Event Codes Table
alarm = ON UP DOWN Menu-15: Alarm and Communication Window

slave no = 71 The alarm sound can be turned ON/OFF by using UP
button.
The RS-485 communication address number can be
set by using DOWN button.
Change password UP DOWN Menu-16: Password Window
0-0-0-0 To activate the user password, please create and save a
new password by using UP/DOWN buttons.
To remove the user password, enter the "current
password" and then enter "0-0-0-0" and save. if forgotten
the current password, you can reset the password by hold
on RIGHT button for 20 seconds with turning the
rectifier to factory settings
LED Explanations
Float Charge: The rectifier output voltage will be
FLOAT MODE equal to the adjusted (through front panel) FLOAT V
value in this mode. (Please refer to Menu-11 for the
details of switching between modes and related
settings details.)
Boost Charge: The rectifier output voltage will be
BOOST MODE equal to the adjusted (through front panel) BOOST V
value in this mode. (Please refer to Menu-11 for the
details of switching between modes and related
settings details.)
Current Limit: If this LED is ON, then either the
CURRENT MODE battery charging current or the total output current
has reached to its adjusted (through front panel)
maximum value.
Equalize Charge: The rectifier output voltage will be
EQUALIZE MODE equal to the adjusted (through front panel)
EQUALIZE V value in this mode. (Please refer to
Menu-11 for the details of switching between modes
and related settings details.)

In case of discharge, this LED will be “ON” if the

BATTERY ENDING battery voltage is lower than the adjusted (through
front panel) “Battery Ending” value.
In case of discharge, if the battery voltage decreases
LOW BATTERY to the adjusted (through front panel) “Low Battery”
voltage, this LED will be “ON”
The battery capacity can be tested by battery test
BATTERY TEST FAILURE feature and if the test fails, this LED will be “ON”.
(Please refer to Menu-10 for battery test details and
parameter settings.
Provide information about the position of the Line
LINE MCB OFF MCB. If the Line MCB is “OFF”, then this LED will be
“ON”.
If the internal temperature value is higher than the
OVER TEMPERATURE maximum value, this LED will be “ON”.
If the thyristor cooler temperature exceeds 70

FAN FAILURE degrees due to fan failure or over temperature, then
this LED will be ON. After this indication, if the
operator does not take any action, the system will
shut down itself automatically in 1.5 minutes with
“Over Temperature” and “Rectifier Failure” alarm.
If the Output Voltage exceeds 10% of the adjusted
OVER VOLTAGE value due to any reason, the rectifier will shut down
itself. In this case, “Rectifier Failure” LED will be “ON”
along with “Over Voltage” LED.
If the Output Voltage decreases below 10% of the
UNDER VOLTAGE adjusted value due to any reason, the rectifier will
shut down itself. In this case, “Rectifier Failure” LED
will be “ON” along with “Under Voltage” LED.
The rectifier will shut down itself in case of a failure
RECTIFIER FAILURE or critical alarm occurs (red indications). In order to
understand the reason, please check the active LEDs
along with this LED.
If the Mains Voltage is in the input voltage tolerance
MAINS
limit of the system, this LED will be “ON”
Provide information about the position of the Load

LOAD
MCB. If the Load MCB is “ON”, then the LED will be
“ON”.
Provide information about the position of the Battery
BATTERY
MCB. If the Battery MCB is “ON”, then the LED will be
“ON”.
This LED will be “ON” if there is (+) or (-) earth fault
LEAKAGE
(+) (-) from DC bus to ground or through the load that is
EARTH
FAULT
connected to the DC load output.

DC OUTPUT LOW
DC OUTPUT HIGH
DC INPUT LOW DC/DC

DC INPUT HIGH
DC CONVERTER DC
INPUT OUTPUT
INPUT MCB/FUSE OFF
OUTPUT MCB/FUSE OFF
OVER LOAD
IGBT SCR FUSE FAILURE
OVER TEMPERATURE
FAN FAILURE
DC/DC CONVERT. FAIL
MENU SET MENU SELECT
LEFT RIGHT
MENU SELECT Buttons

MENU SELECT buttons are used to skip among
the windows.
UP DOWN
MENU SET Buttons

MENU SET buttons are used to adjust the
parameters. To increase the value this is shown
above on the screen press UP button. And, to
increase the value which is shown below on the
screen press DOWN button.
You must hold the buttons for 1 second to
operate. After adjust the parameters, press
RIGHT button to save changes or press LEFT
button to not save changes.
When we press UP or DOWN buttons, the
parameters will be increase until its maximum
value and it will return to the start-up point.
Thus, we can decrease the parameters value by
this method.

NOTE-1 : All given values shown above are chosen for 125VDC input / 24VDC
output converter.
NOTE-2 : Red colored values can be set using MENU SET (up-down) buttons. Firstly
set the parameters and then press right button to save. Press left button to escape.
Hold along 1 sec to operate the buttons.
CONVERTER ON Menu-1 : Opening Window

UP=ON DOWN=OFF To operate the rectifier press UP button, to stop
the rectifier press DOWN button on this window.
If a battery group is connected, the system will
continue to operation on batteries.
OUTPUT
V=24 I=12A Menu-2 : Output Monitoring Window (Main
Menu and Screen Saver)
The output parameters of the device can be
monitoring on this window. (V) Output voltage
and (I) output current.
INPUT Menu-3 : Input Monitoring Window

V=135 I=10A The intput parameters of the device can be
monitoring on this window. (V) input voltage
and (I) input current.
internal Temp. °C Menu-4 : Internal Temperature Window

T=19 °C The internal temperature parameters of the
device can be monitoring on this window. (T)
Internal temperature.
The 4 window shown above are monitoring
UP DOWN
windows. So, the MENU-SET buttons

are not in use in this window.
set out voltage UP DOWN
Vdc=24.0V Menu-5 : Output Voltage Adjustment Window

To adjust output voltage please use UP and
DOWN buttons.
set out current UP DOWN
Iout=12.0A Menu-6 : Output Current Adjustment Window

To adjust output current please use UP and
DOWN buttons.
date 3 4 10 UP DOWN
Menu-7 : Date&Time Window
time 12 32 55 The date is shown on the screen 03.April.2010
and time is 12:32:55. You can adjust all of these
parameters by using UP and DOWN button. To
skip among the parameters press UP button and
to change the parameters press DOWN button.

events 32 1 UP DOWN Menu-8 : Event History Monitoring Window

1 150 3 4 12 35 You can monitoring the event history on this
window. Maximum 250 event code can storage
in memory and also there are 17 different event
code. On example screen, there are 32 events on
the memory and the 1st event’s details are
shown.
0 : Event code 150 : Event Value
3 : Day 4 : Month 12 : Hour

35:Second
The means of the event codes are given on the
table below. To see the other event, press UP and
DOWN buttons.
Event memory can delete (reset) by pressing
RIGHT button during 20 second. After reset, all
the parameters of device turns to Factory
settings also!.
EVENT CODES
0. DC INPUT HIGH 6. CONVERTER FAILURE 12. INPUT MCB OFF
1. DC INPUT LOW 7. CONVERTER OK 13. INPUT MCB ON
2. DC INPUT OK 8. IGBT SCR FUSE FAILURE 14. OUTPUT MCB OFF
3. DC OUTPUT HIGH 9. IGBT SCR FUSE OK 15. OUTPUT MCB ON
4. DC OUTPUT LOW 10. OVER LOAD 16. OVER TEMPERATURE
5. DC OUTPUT OK 11. LOAD OK 17. TEMPERATURE OK
alarm = ON UP DOWN
slave no = 33 Menu-9 : Alarm and Communication Window

To close or open the alarm sound press UP
button. To adjust the slave number which is used
for RS-485 communication press DOWN button.
Change password UP DOWN Menu-10 : Password Window This is the last

0-0-0-0 window. To activate user password firstly create
“a new password” with UP/DOWN buttons then
save with RIGHT button.
To deactivate user password firstly enter “used
password” save, enter “0-0-0-0”save.
In the case of forgotten password press RIGHT
button 20 sec. and reset the rectifier to factory
settings.

LED EXPLANATIONS The rectifier output voltage will be equal to the

adjusted (through front panel) FLOAT V value.
DC OUTPUT LOW
Please refer to front panel user manual section
for the details of switching between modes.
The rectifier output voltage will be equal to the

DC OUTPUT HIGH
adjusted (through front panel) BOOST V value.
Please refer to front panel user manual section
for the details of switching between modes.
DC bus voltage value is lower than the minimum

DC INPUT LOW
DC Bus voltage value (Min. DC Bus voltage=
10,5VDC x Battery Quantity). If this LED becomes
on, then the Inverter will be shut down.
DC bus voltage value is higher the maximum DC

DC INPUT HIGH
Bus voltage value (Max. DC Bus voltage= 17VDC
x Battery Quantity). If this LED becomes on, then
the Inverter will be shut down.
Input MCB/fuse is in “OFF” position or it is

INPUT MCB/FUSE OFF tripped.
Output MCB/fuse is in “OFF” position or it is

OUTPUT MCB/FUSE OFF tripped.
Output load current exceeds %100 load current

OVER LOAD
limit. In this condition, the operating periods are
as follow: %100-%125 10min, %125-%150 1
min, %150-%300 1 sec, %300 0 sec.
The fast acting fuse which protects the IGBT
IGBT SCR FUSE FAILURE modules is tripped (open circuit).
Becomes ON in an overheat condition on IGBT

OVER TEMPERATURE heatsink.
If IGBT heatsink temperature increases more

FAN FAILURE
than 70 degree because of failed Fans or high
ambient temperature, then this LED will be “ON”.
After this indication, if the operator does not take
any action, the system will shut down itself
automatically in 1.5 minutes with “Over
Temperature” and “Converter Failure” alarm.

The system will shut down itself in critical

DC/DC CONVERT. FAIL alarms (red indications). In order to locate the
source of the failure, other LEDs should check as
well.
DC If the Input Voltage is in the input voltage
INPUT tolerance limit of the system, this LED will be
“ON”
DC If the Output Voltage is in the output voltage
OUTPUT tolerance limit of the system, this LED will be
“ON”
6. Communication
The rectifier communication can be done via 2 options (serial communication and free
alarm contact).
6.1 Serial Communication:
You can access to all information related to the product via serial communication. All
measurements (voltage, current, load percantage, etc.), alarm / warning situations and the
status of the product at that moment can be monitored. Since the communication system is
interactive, the user can turn OFF / ON the product and make adjustments that he wants.
The product can communicate with computers over RS-485 / RS-232 converter, with PLC
/ the automation over RS-485 Modbus output, with PLC / Automation over RS-485 /
Profibus converter and with a network over RS-485 Modbus / TCP-IP converter.
Intermediate hardware and software are provided by PMI. The communication interface is
an option. If your device includes the communication interface then you may find program
CD inside pocket which is located on the internal side of the product front door.

6.2 Free Alarm Contact:
There are 8 units free alarm contacts with automation type products. The warning LEDs’
situations, that are on the communication PCB, LCD panel and communication interface,
can be monitored via these free contacts.
TECHNICAL FEATURES OF FREE ALARM CONTACT

Nominal Switching Capacity (Resistive Load) 10A/250VAC, 10A/30VDC
Max. Switching Power (Resistive load) 2.500VA, 300W
Max. Switching Voltage 250VAC, 30VDC

Max. Switching Current 10A
Communication PCB
Free alarm contact outputs are programmed in the factory as follows. The user can program
these free alarm contact outputs with the computer interface. The programming of the free
alarm contact outputs is explained in the software section.

Automation Type Free Alarm Contacts
ALARMS NORMAL CASE WARNING CASE

1- Low Battery Normally Open Normally Closed
2- Mains Input Normal/Failure Normally Closed Normally Open
3- Rectifier Failure Normally Open Normally Closed
4- Over Temperature Normally Open Normally Closed
5- Rectifier Over Voltage Normally Open Normally Closed
6- Load MCB ON/OFF Normally Closed Normally Open
7- Battery MCB ON/OFF Normally Closed Normally Open
8- Earth Fault Normally Open Normally Closed
6.3 Hardware and Connection

6.3.1 Connection to Computer:
RS-485 (max.1200mt) RS-232 (max.20mt)
Communication PCB RS-485/RS-232 PC (RS-232 Port)

Converter
RS-485 (max.1200mt)
Communication PCB RS-485/RS-232 RS-232/USB PC (USB Port)

Converter Converter
To perform the communication between the computer and the product, you need to make
the connection as noted above. DB-9 output of the RS232 on the RS-485/RS-232 converter
is female type connector. The user can make the connection between RS-232 port of the
computer with a standard type RS-232 cable. The user can use RS-232/USB converter for
devices without RS-232 port such as laptops.
NOTE: RS-485 cable length and quality will affect the communication quality. Please
consider the following notes regarding the wiring to ensure quality communication.
- Cross-section: min. 2 x 0.22 mm² or min. 2 x AWG 2

- CAT 5 (shielded)
- Twisted-pair
- UV resistant (only for outdoor use)

6.3.2 RS-485/RS-232 Converter:
A
RS-485
B
8-17VDC _
SUPPLY + RS-232
8-17VDC ADAPTER
6.3.3 Connection to PLC/Automation:
RS-485 (max.1200mt)
Communication PCB PLC/Automation
RS-485 (max.1200mt) PROFIBUS DP
Communication PCB LUFP7 PLC/Automation
It is possible to communicate with product via Profibus DP protocol by using RS-485

Modbus or LUFP7 Modbus / Profibus DP converter for PLC / Automation Applications.
LUFP7 Modbus / Profibus DP converter related technical document can be accessed from
the following link.
LUFP7 Datasheet
Modbus table for product is given on the last page of this part.

6.3.4 Connection to Network:
Communication PCB RS-485/RS-232 Modbus/TCP-IP Network

Converter Converter
The user should make above connections to communicate with the product via TCP-IP
protocol over the network.
6.4 Software
The program is compatible with Windows 7 and XP. The PC connection is done via USB
port through RS485/RS232 protocols.
6.4.1 Setup:
a. Insert the CD into the computer.
b. Open the “Setup” application file located in the Setup folder.
c. “Download-Security Application Warning” window will appear as seen below.

Please click the “Install (Yükle)” icon to start the process.
d. After installing the program, the following warning message will appear. This
message means that the user firstly should select the type of communication
when program is opened. Press the OK icon.

Rectifier shortcut that appears on the left will be created on your desktop
during installation. Then you can use this shortcut to run the program.
e. The mimic diagram will be displayed as seen below.
6.4.2 Usage:
a. Language
Select the language by using this option.

b. Communication type
Select the type of communication by using these icons
c. Address-Port
For RS485 type communication, please enter the slave ID value

that is defined in the front panel of the product and the com port value assigned to your
computer.
NOT : For the Com Port value; please check Device Manager \ Connection Ports (COM &
LPT) on your computer.
For TCI/IP, DNP3 and SNMP type communication; please enter the slave ID value that is
defined in the front panel of the product and the IP value assigned to your converter.
NOTE: In case the serial port (IP) value to be changed as factory setting needs to be
changed, it is necessary to use the TCP / IP Converter setting interface in the CD
"WIZ1xxSR_config_v3.0.2_install.zip" or by downloading from the internet address given
below.
Download link for TCP / IP and DNP3;
http://old.wiznet.co.kr/sub_modules/kr/resources/Download_View.asp?PK_Num=711&
page=3&SF_Part=&SF_KeyWord=
Download link for SNMP;
http://old.wiznet.co.kr/sub_modules/kr/resources/Download_View.asp?PK_Num=193&
page=1&SF_Part=&SF_KeyWord=

LCD Front Panel Alarm and Communication Window

UP DOWN
alarm = ON
slave no = 71
The alarm sound can be turned OFF / ON with UP button. RS-
485 communication address value can be set between 0-255 with DOWN button. After the
adjustment, please push the right button to save the settings.
The Slave ID should be different for each product in systems where multiple or different
types of products are used as seen in the following example blocks.
To communicate with multiple identical or different types of products that are

connected to one unit com port, the user must change the Slave ID on the related interface.
The user can start communication with the help of this icon.
The user can finish the communication with the help of this
icon.
Please start the communication by clicking the “start” icon. Error message will appear
on the screen if there is any wrong with the settings you made. In this case, check again the
connections and settings you have made. If there is no problem in connection and setting,

data of the product will appear on the screen as seen in the following picture. All
parameters and lighted warnings can be monitored on this screen.
The device can be remotely turned on / off with the help of this icon
d. View;
or
The View Section is divided into 3 sections; Standart, Detail, Diagram
➢ Standart
Input, Load and Battery voltage can be monitored graphically and numerically in the
"Standard" section. In the other values, the same values and frequency values. It is read.
The Alarm and Status section contains the latest event information from the rectifier

➢ Detail
In detail, voltage, current and frequency information of Input, Load and Battery are
included.
➢ Diagram

In the diagram part, input energy of device, fuse, SCR, thyristor / rectification part and DC
leakage parts are shown as a diagram. Parts with AC energy are blue, parts with DC
energy are green. The non-energy parts are off-white.
Also in case of DC leak, error mark is visible.
Note: The above sample screen is for Phase Rectifier. For 3 phase rectifier applications, the
software will automatically adjust the parameters.
e. Device Settings:
or
The device settings can be accessed by clicking on the Settings icon in the Configuration /
Settings section.
This page is the device parameter setting and event log monitoring screen. The values
shown as red (sampled according to 110VDC-30A) are factory settings. You can adjust
these values according to the characteristics of your system.

➢ Change device values
The left red values are factory settings. In order to set a new value please write new value
in the empty boxes and click on SET button to save the new
value.
After this action the RED values will be changed to your new
setting. If the entered SET value is an invalid value, then the
program will ignore it and will not affect the change.
➢ Time / Date Settings:
The time / date setting of the system can be set from the
numerical menu. After setting the hour, minute, day, month
and year values, click on SET button to save the new values.
The settings can be both changed from the front panel of
product and software interface. When any setting is done, it
will be recorded, and the user will see the same value in both
panels.
➢ Event Log:
The total number of events will be given under "Total Number of Errors". A total of 255
events are recorded in the memory. Events on the top screen will be displayed as a list with
time and date. Any malfunction, change, etc. you can use this screen to get information
about the device status.
The "Read" button is used to monitor the event log. Click on this button icon to see
the events.
"Delete" button Used to clear the Event log list.
The "Save" button is used to save events as a text file ".txt". The text file is saved to
the desired location.
➢ Programming of the Free Alarm Contacts:
The free alarm contacts can be programmed via software interface. For settings, firstly
press buttons and read the stored settings from the list, then select the desired free
contacts by clickin left side the empty boxes and save settings by pressing button.
Order of the contacts are as in the below list. Maximum 8 unit free contacts can be selected.

1. Line MCB OFF/ON

2. Battery Test Fail
3. Low Battery
4. Battery Ending
5. Equalize Boost
6. Current Mode
7. Boost Mode
8. Float Mode
9. Line Input OK/Fail
10. Rectifier Failure
11. Over Temperature
12. Rectifier Under
13. Rectifier Over
14. Fan Failure
15. SCR Fuse OFF
16. Load MCB ON/OFF
17. Battery MCB ON/OFF
18. Earth Fault
19. Remote Power Off
a. Remote Power Off (Optional):
This button is designed to remotely stop the system by controlling an

electromagnetic switch for some specific Applications. This icon will be functionless if this
feature is not available in the system
MODBUS device datasheet is given below.
DATA
READ/WRIT COEFFICIEN
ADDRES DATA=USIGNED INT16 EXPLANATION
E T
S EVENTCODE TABLE
READ /
0 V_FLOAT_SET x10 battery float charge voltage
WRITE
READ /
1 V_BOOST_SET x10 battery boost charge voltage 1 LINE MCB ON
WRITE
READ /
2 V_LOWBAT_SET x10 low battery voltage level 2 LINE MCB OFF
WRITE
READ /
3 I_FLOAT_SET x10 return to float from auto boost current level 3 BATTERY MCB OFF
WRITE
READ /
4 I_BOOST_SET x10 current level to go auto boost 4 BATTERY MCB ON
WRITE
READ /
5 I_BAT_SET x10 battery current limit 5 LOAD MCB OFF
WRITE
READ /
6 I_OUT_SET x10 rectifier output current limit 6 LOAD MCB ON
WRITE
READ /
7 MAN_BOOST_TIME_HR x10 manual boost duration in hours 7 LINE LOW
WRITE
READ / AUTO_BAT_TEST_TIME_H
8 x10 auto battery test period in hours 8 LINE HIGH
WRITE R
READ / batt. test condition 1=auto,
9 BAT_TEST_SWITCH(1,2,3) x1 9 LINE OK, IN ACCEPTABLE LIMITS
WRITE 2=closed,3=manual
READ / 1=auto boost, 2=float, 3=manual, 4=equalize,
10 MODE_SWITCH(1,2,3,4,5) x1 10 BATTERY LOW
WRITE 5=slave
READ /
11 EVENT NUMBER x1 reading event number from event history 11 BATTERY OK
WRITE
READ /
12 RECTF.(ON/OFF)(0-1) x1 rectifier on/off switch 0=off, 1=on 12 RECTIFIER OVER VOLTAGE
WRITE
READ /
13 EQ_BOOST_SET X10 battery equalize boost charge voltage 13 RECTIFIER UNDER VOLTAGE
WRITE
READ /
14 END_BATTERY_LEVEL X10 battery ending voltage level 14 RECTIFIER VOLTAGE OK
WRITE
READ /
15 DISCHARGE CURRENT X1 discharge current during battery test 15 OVERTEMPERATURE
WRITE
READ / DISCHARGE TIME min. discharge time in hours during battery
16 X1 16 NORMAL TEMPERATURE
WRITE MINUTE test
READ /
17 DRY_CONTACT_UPPER x1 dry contact selection code upper word
WRITE
READ /
18 DRY_CONTACT_UPPER x1 dry contact selection code lower word 33 EARTH FAULTH +
WRITE

READ /
19 NO DATA 34 EARTH FAULTH -
WRITE
READ /
20 DAY x1 day of DATE 35 EARTH FAULTH OK
WRITE
READ /
21 MONTH x1 month of DATE
WRITE
READ /
22 YEAR x1 year of DATE 81 SLAVE MODE SELECTED
WRITE
READ /
23 HOUR x1 hour of TIME 82 SLAVE MODE CANCELLED
WRITE
READ /
24 MINUTE x1 minute of TIME
WRITE
25 READ FREQ. x10 line frequency 90 MANUEL BOOST STARTED
26 READ V_LINE1 x10 line voltage1 91 AUTO BOOST STARTED
27 READ V_BAT x10 battery output voltage 92 BATTERY TEST STARTED
28 READ V_LOAD x10 load output voltage 93 BATTERY TEST = FAILED BATTERY
29 READ I_BAT (signed int16) x10 battery output current (signed int16) 94 BATTERY TEST RESULT=OK
30 READ I_LOAD x10 load output current 95 BATTERY TEST SKIPPED
MONITORRING LEDS 96 AUTO BOOST END
BIT_0=SCR_FUSE_FAIL 97 MANUEL BOOST END
BIT_1=NO DATA 98 BOOST SKIPPED
BIT_2=LOAD_MCB_OK
BIT_3=NO DATA
BIT_4=BATTERY_MCB_OK
BIT_5=NO DATA PROGRAMMABLE DRY CONTAC TABLE(32 bit DEFAUL
BIT_6=EARTH FAULTH - code) T
31 READ LEDS x1 BIT_7=EARTH FAULTH + BIT_0=LINE_MCB_OFF
BIT_8=NO DATA BIT_1=BAT_TEST_FAIL
BIT_9=NO DATA BIT_2=LOW BATTERY 1.
BIT_10=NO DATA BIT_3=BATTERY ENDING
BIT_11=NO DATA BIT_4=EQ_BOOST MODE
BIT_12=NO DATA BIT_5=CURRENT MODE
BIT_13=NO DATA BIT_6=BOOST MODE
BIT_14=NO DATA BIT_7=FLOAT MODE
BIT_15=NO DATA BIT_8=NO DATA
MONITORRING LEDS BIT_9=LINE OK/LINE MCB OK 2.
BIT_0=LINE_MCB_OFF BIT_10=NO DATA
BIT_1=BAT_TEST_FAIL BIT_11=RECTIFIER FAILURE 3.
BIT_2=LOW BATTERY BIT_12=OVERTEMPERATURE 4.
BIT_3=BATTERY ENDING BIT_13=RECTIFIER UNDER VOLTAGE 5.
BIT_4=EQ_BOOST MODE BIT_14=RECTIFIER OVER VOLTAGE 6.
BIT_5=CURRENT MODE BIT_15=FAN FAILURE
BIT_6=BOOST MODE BIT_16=SCR_FUSE_FAIL
32 READ LEDS_2 X1 BIT_7=FLOAT MODE BIT_17=NO DATA
BIT_8=NO DATA BIT_18=LOAD_MCB_OK 7.
BIT_9=LINE OK/LINE MCB OK BIT_19=NO DATA
BIT_10=NO DATA BIT_20=BATTERY_MCB_OK 8.
BIT_11=RECTIFIER FAILURE BIT_21=NO DATA
BIT_12=OVERTEMPERATURE BIT_22=EARTH FAULTH -
BIT_13=RECTIFIER UNDER VOLTAGE BIT_23=EARTH FAULTH +
BIT_14=RECTIFIER OVER VOLTAGE BIT_24=NO DATA
BIT_15=FAN FAILURE BIT_25=NO DATA
33 READ RECTF.(ON/OFF) X1 rectifier working or not working BIT_26=NO DATA
34 READ V_LINE2 X10 line voltage2 (observable only 3 phase) BIT_27=NO DATA
35 READ V_LINE3 X10 line voltage3 (observable only 3 phase) BIT_28=NO DATA
36 READ I_LINE X10 line current (observable only 1 phase) BIT_29=NO DATA
37 READ RELAY OUTPUTS x1 programmed 8 dry contacts positions BIT_30=NO DATA
38 READ NO DATA BIT_31=NO DATA
39 READ NO DATA
40 READ NO DATA * YOU CAN SELECT 8 RELAY THROUGH 32 INFORMATIONS.
41 READ NO DATA * YOU CAN USE NORMALLY CLOSED OUTPUTS
42 READ NO DATA AS REVERSE İNFORMATION.FOR EX;
43 READ TOTAL EVENT NUMBER x1 event history total event number LOAD MCB ON(N.O.)&LOAD MCB OFF(N.C.)
44 READ EVENT NUMBER x1 reading event number from event history
45 READ EVENT CODE x1 event code, check from event code table
46 READ EVENT VALUE x1 not important
47 READ DAY /EVENT DATE x1
48 READ MONTH /EVENT DATE x1
49 READ HOUR /EVENT DATE x1
50 READ MINUTE /EVENT DATE x1

7. Electrical Schemas
7.1 Rectifier Single Line Diagram

7.2 Rectifier Power&Control Wiring Diagram

8. Cause &Actions&Troubleshooting
- Please check the substance of the safety and warning in "2. General Safety
Instructions and Warnings "section, before starting troubleshoot.
- All the necessary interventions must be performed by trained service
personnel.
Please perfom the following procedures to solve the common failures / problems quickly. If
the fault / problem can not be solved by using this table, then please contact the technical
service.
Case Causes Actions&Troubleshooting
Case 1
The Product Mains AC Voltage may not be Please check Mains Input MCB. Is it at “ON”
is not available position?
operating Please check Mains Input voltage. Are phase-
including the neutral voltage or L1-L2-L3 phase voltages correct?
front panel! Mains Input MCB may be Please check Mains Input MCB. If it is defective, then
defective. please change it with a new one of the same value /
characteristics.
DC Battery Voltage may not be Please check Battery MCB/Fuse. Is it at “ON”
available (for cases where there position?
is not Mains Voltage) Please check total Battery Voltage
LCD front panel connectors can Please check connections of the connectors.
be interruption.
DC Supply PCB may be defective Trained service personnel must intervene to this
issue. Please contact with the technical service.
The battery may be deeply Trained service personnel must intervene to this
discharged with thyristor or issue. Please contact with the technical service.
diode failure
Thyristor fast acting fuse Trained service personnel must intervene to this
(optional) may be open- issue. Please contact with the technical service.
circuited and battery may be
deeply discharged
Case 2
Mains Input Thyristor or diode may be Trained service personnel must intervene to this
MCB OFF defective issue. Please contact with the technical service.
Varistor may be short-circuited Please turn ON the MCB by disabling the varistor.
as a result of high voltage
Case 3
Shock when There may be earthing problem Please check grounding line
touching or electrical leakage Please check the insulation of the Input Cables.
rectifier
chassis
Case 4
Rectifier Newly started / commissioned It will reduce and not smell in time
smells It has worked for a long time Please disconnect the power / turn OFF the Mains
and there is a heavy smell. Please turn OFF the Battery MCB/Fuse. Please check
the battery against the possibility of the short circuit
Trained service personnel must intervene to this
issue. Please contact with the technical service.

Case 5
DC Load is Battery MCB/ Fuse may be Please check Battery MCB/Fuse. If it is defective,
switched OFF defective or at OFF position then please replace it with a new one of the same
instantly or value / characteristics.
in a short Battery group may be damaged Please check battery group. Please change it with a
time when new one of the same value if necessary.
power is
outage
Case 6
There is more Fan may be defective Please check if the fan is operating
sound than There could be a short-term The sound will decrease when the charging of the
normal in noise after a prolonged power battery is finished
rectifier. outage If the problem continues, please contact with
technical service.
Case 7
Battery MCB There may be a fault that causes Please check battery group. Please replace it with a
/ Fuse OFF drawing an excessive current in new one of the same value if it is defective
the battery
Battery MCB/ Fuse may be Please check Battery MCB/Fuse. If it is defective,
defective then please replace it with a new one of the same
value / characteristics.
Case 8
Load MCB / There may be a fault that causes Please chek the load and load line.
Fuse OFF drawing an excessive current in
the load line or short circuit
Load MCB/ Fuse may be Please check Load MCB/Fuse. If it is defective, then
defective please replace it with a new one of the same value /
characteristics.
Case 9
Output Load current may be extremely Please decrease the load value
voltage is too high.
low and the The battery is not fully charged. Please check Battery Voltage. It will increase after a
current is while.
maximum.
Case 10
Charge Battery may be nearly full It is a normal situation.
Current is too discharged
low.
Case 11
The battery Charge current may be set too Please check charger current settings from the LCD
can not be low. front panel.
fully charged. Charging time may be too short. Please check charging time settings from the LCD
front panel.
Equalize voltage may be set Please check Equalize voltage settings from the LCD
incorrectly. front panel.
Battery MCB/ Fuse may be Please check Battery MCB/Fuse. If it is defective,
defective then please replace it with a new one of the same
value / characteristics.
The battery temperature may Please use the battery temperature sensor.
be too low. (Optional feature)
The load current may be high Please decrease the load value.
according to the battery
capacity
Battery group may be damaged Please check battery group. Please replace it with a
/ defective new one of the same value if necessary.

Case 12
Batteries are Battery capacity may be Please charge and discharge the battery a few times.
discharged reduced. Please check battery group. Please replace it with a
very quickly. new one of the same value if necessary.
Case 13
Batteries are There may be defective Please check battery group. Please replace it with a
too hot, the batteries (Short-circuit between new one of the same value if necessary.
gas is coming cells)
out. Charge voltage may be very Please check charger voltage settings from the LCD
high. front panel.
Case 14 Over
Temperature The cooling fan may be Please check if the fan is operating.
LED is ON defective.
Ambient temperature may be Please check the operating environment
high. temperature. If it is high, please take the necessary
precautions.
Fan thermostat may be Please check the fan thermostat. If defective, please
defective. replace with a new one of the same value.
Case 15
Fan Failure The cooling fan may be Please check if the fan is operating. If defective,
LED is ON defective. please replace with a new one of the same value.
Ambient temperature may be Please check the operating environment
high. temperature. If it is high, please take the necessary
precautions.
Case 16 Over Voltage LED is ON
Over Voltage A different source connected in Please check the different sources connected in
LED is ON parallel to the rectifier output parallel.
may cause overvoltage.
There may be a voltage leakage Please check the voltage leakage.
at rectifier output exposed by
external factors
Thyristor or diode may be Trained service personnel must intervene to this
defective issue. Please contact with the technical service.
Case 17
Under Rectifier output may be Please decrease the load value.
Voltage LED overloading and switching to
is ON Current Mode
The control PCB may not Trained service personnel must intervene to this
perceive the feedback voltage. issue. Please contact with the technical service.
Thyristor or diode may be Trained service personnel must intervene to this
defective issue. Please contact with the technical service.
Case 18
Rectifier The rectifier shuts down itself in In order to locate the source of the failure, other
Failure LED is case of a negative situation and active LEDs should check as well.
ON give warning by turning ON
Rectifier Failure LED.
Case 19
Mains LED is Mains Input MCB may be OFF Please check Mains Input MCB.
not Mains voltage / frequency or Please check Mains voltage / frequency or generator
illuminated. generator voltage / frequency voltage / frequency.
may not be within the
acceptable range.

Case 20
Load LED is Load MCB / Fuse may be OFF Please check Load MCB / Fuse.
not Auxiliary contacts of Load MCB Please check auxiliary contacts of Load MCB / Fuse
illuminated. / Fuse may be defective or there and connection.
may be an interruption in
connections
Case 21
Battery LED Battery MCB / Fuse may be OFF Please check Battery MCB / Fuse.
is not Auxiliary contacts of Battery Please check auxiliary contacts of Battery MCB /
illuminated. MCB / Fuse may be defective or Fuse and connection.
there may be an interruption in
connections.
Case 22
Earth Fault) There is leakage in DC bus Please determine the leakage between (+) or (-)
(+) or (-) LED (Battery and Load Line) polarity and chassis (ground) and detect it.
is ON between (+) or (-) polarity and
chassis (ground)
Case 23
Float Mode Rectifier is operating in the It is a normal situation.
LED is ON Float charging mode.
Case 24
Boost Mode Rectifier is operating in the It is a normal situation.
LED is ON Boost charging mode.
Case 25
Current Mode Rectifier is operating in the If the load is increased after the “Current Mode” LED
LED is ON Current mode. is on, then the output voltage of rectifier will start to
decrease until reaching to the minimum voltage
value. After reaching minimum voltage value,
rectifier will shut down itself in order to protect the
load and the product.
The current limitation due to the battery charge
current will be temporary since the battery current
will decrease as the battery charged. Battery and
load should be checked against to shutdown due to
faulty battery and problems in load.
Case 26
Equalize Rectifier is operating in the It is a normal situation.
Mode LED is Equalize mode.
ON
Case 27
Battery After this warning LED is ON, if This is not healthy for batteries that are not
Ending LED is the batteries continue to be suitable for deep discharge.
ON discharged, then batteries
would have been deeply
discharged
Case 28
Low Battery After this warning LED is ON, if This is not healthy for batteries that are not suitable
LED is ON the batteries continue to be for deep discharge.
discharged, then batteries
would have been deeply
discharged
Case 29
Battery Test There may be defective battery Please check battery group. Please replace it with a
Failure LED is in battery group new one of the same value if necessary.
ON

Case 30
Line MCB OFF Mains Input MCB is OFF. Please check Mains Input MCB
LED is ON Auxiliary contacts of Mains Please check auxiliary contacts of Mains Input MCB
Input MCB may be defective or and connection.
there may be an interruption in
connections.
9. Maintenance Instructions
There are not any parts in rectifier or battery that the maintenance or service
can be done by end user. DO NOT OPEN THE PRODUCT DOOR WITHOUT
TECHNICAL SERVICE ASSISTANT.
9.1 Scheduled Maintenance

There are maintenance-free semiconductor components inside the charger. If the
environment is kept clean and cool enough, then scheduled maintenance requirement will
be at the minimum level.
Your device is designed to require minimum maintenance. Users must fulfill the
following instructions.
9.2 Daily Maintenance
Please check the charger every day and pay attention to the followings:
1. Check the front panel. All LED indicators and measurement parameters must
be normal and there must not be any alarm or warning message on the panel.
2. Check whether there are any symptoms for overheats of the charger.
3. Check the rotation of the cooling fan of the product.
4. Check whether there is a remarkable change in the sound of the charger
5. The ventilation grills must not be filled / closed by dust. If the dust fills these
grills, please clean it with a vacuum cleaner.
6. There must be nothing on the charger.
9.3 Weekly Maintenance
1. Check the front panel and record the results.
2. Measure and record the output voltage of charger.
3. Measure and record the output line currents of charger.
4. Cover of the charger can be cleaned with a dry cloth.
If possible, please save the results. Try to find whether there is a significant different
between new result and previous ones. If there is a significant different between them,
if possible, please try to find whether a load was connected to the system in previous
maintenance. If load was connected, please try to find load value, place and type of load.
These records may help the technical service assistant.
If there is any significant different between two results although there is not any
reason, please call for an authorized service immediately.
9.4 Annual Maintenance
Please call for an authorized service once in a year for a healthy and safely operation
of the charger and battery.
10. Cabin Weight and Dimensions

PMI / GESS own production cabins are produced under the following process steps.

CAD / Design / R&D

The drawings are prepared according to R & D department’s development for the
existing products and for the new designs. If the technical drawings of the products are
available, then they will be controlled and the manufacturing drawings will be
prepared.
CAM / Manufacturing
Cutting: CNC cutting method is determined according to the manufacturing drawings,
placement and cutting programs are prepared and transferred to the appropriate
cutting unit. The cutting process is completed in precision of CNC Laser, CNC punch and
NC guillotine.
Twist: After cutting, twists on the basis of parts are completed with precise CNC
bending unit and will be referral to the next manufacturing station.
Weld / Leveling
The welding process will be performed on the twisted product as per specified in the
formal manufacturing. The welding process is determined according to the part
material (steel, stainless steel or aluminum) and the welding process is completed at
appropriate welding station. The welded part will be brought to the appropriate
surface quality with one or more of the suitable leveling method and delivered to the
next station.
Before Paint / Paint
The levelled part is ready for surface cleaning and zinc-phosphate coating before
painting. The steel parts that the surface contaminants and oil is cleaned at the cleaning
bath, will be subjected to a zinc phosphate coating to increase the corrosion resistance
after rinsed. After drying, the parts will be coated with paint in the appropriate color
at powder coating unit and put iin the oven at required temperature for a time. Then
parts will be left to cool.
Mechanical Assembly
A specialized team will assemble the workpieces that have reached by using special
installation equipment. The final version of semi-finished products is shipped to the
relevant department for the electrical and electronics assembly. Cabin Features is
specified in the table below.
FEATURE STANDARD
Protection Class IP41
Cabin Color RAL-7035
Cable Entry Bottom
Ventilation Forced Fan
Cabin Lighting YES
Cabin Heater NO
The following table shows the equipment and unpacked weight and size (except battery).
MODEL OUTPUT VOLTAGE OUTPUT CURRENT WEIGHT DIMENSIONS

(VDC) (ADC) (kg) (H)x(W)x(D) (mm)
RDAT 110-75 110 75 302 1655x650x700

10.1 Cabinet Drawing

10.2 Cabinet Component Layouts
3 8
1
9 10
4
2
7
11
16
12
18
17
14 15
7
5
13

19
20 21 22 23 24 25
NO COMPONENTS
26 1 DELTA THYRISTOR TRIGGER PCB
2 STAR THYRISTOR TRIGGER PCB
3 DELTA THYRISTORS
4 STAR THYRISTORS
5 INPUT SCR FUSE
6 BLOCKING DIODE
7 DC BUS CAPACITORS
8 IGBT SCR FUSE
9 IGBT MODULE
10 IGBT DRIVER PCB
11 DC/DC CONVERTER CONTROL PCB
27 28 12 RECTIFIER CONTROL PCB
13 CURRENT MODULES
14 MAINS MONITORING TRF.
15 AC SUPPLY TRF.
16 SUPPLY RECTIFIER PCB
17 DC SUPPLY TRF.
18 SUPPLY CONTROL PCB
19 FREE ALARM CONTACTS
20 INPUT MCB
21 RS-485 OUT
22 BATTERY HEAT COMPENSATION
23 BATTERY MCCB
29 24 LOAD OUTPUT MCCB
25 RELAY PCB
26 CONVERTER INDUCTOR
27 RECTIFIER STAR INDUCTOR
28 RECTIFIER DELTA INDUCTOR
29 INPUT ISOLATION TRF.

GROUP COMPANIES
Ortadoğu Elektronik Sanayi Ltd. Şti.
PMI Elektrik Sistemleri Dis Tic. Ltd. Sti
SALES & MARKETING

Kavacık Mah. Ekinciler Cad.
Ertürk Sk. No:5
Beykoz/ ISTANBUL / TURKEY
Tel: +90 216 693 35 55 - 56 / +90 216 693 35 56

Fax: +90 216 693 34 66
E-mail: [email protected]
MANUFACTURING PLANT AND R&D

Saray Mah. Saraykent Sanayi Sitesi 32. Cad. No:15
Kahramankazan / ANKARA / TURKEY
www.pmienergy.com

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RDAT 110-75

DC RECTIFIER / BATTERY CHARGER

This user guide includes transportation, installation, commissioning, operation,

DC Rectifier / Battery Chargers is mentioned as "Charger" in the user manual

This user manual may not be copied or reproduced without permission of .

Keep the user manual in a safe place on or near the rectifier.

RECT-UM 0521-EN RV00 Page 1 /56

2. General Safety Instructions and Warnings ........................................................................................ 10

3. Electrical Connections .......................................................................................................................... 15

4. Commissioning / Operation ................................................................................................................ 19

5. Usage of LCD Front Panels ................................................................................................................... 21

7. Electrical Schemas ................................................................................................................................ 46

RECT-UM 0521-EN RV00 Page 2 /56

8. Cause &Actions&Troubleshooting ...................................................................................................... 48

9. Maintenance Instructions .................................................................................................................... 52

10. Cabin Weight and Dimensions ........................................................................................................ 52

RECT-UM 0521-EN RV00 Page 3 /56

1.1 Uninterrupted Protection with Full Isolation

3 Phase 6 Pulse Phase Angle Controlled Rectifier

1.3 Parallel / Serial Connection

RECT-UM 0521-EN RV00 Page 4 /56

1.4 Voltage Ripple < %1

1.5 Wide Usage

1.6 Boost Charge Protection Function (Boost Inhibit)

RECT-UM 0521-EN RV00 Page 5 /56

1.8 Automatic Boost Charge (Autoboost)

RECT-UM 0521-EN RV00 Page 6 /56

LVD Block Schema

Dropper Block Schema

RECT-UM 0521-EN RV00 Page 7 /56

General / Optional Features

Rectifier Standard Automation

RECT-UM 0521-EN RV00 Page 8 /56

RECT-UM 0521-EN RV00 Page 9 /56

2. General Safety Instructions and Warnings

RECT-UM 0521-EN RV00 Page 10 /56

RECT-UM 0521-EN RV00 Page 11 /56

All the connections must be done by the technical personnel.

RECT-UM 0521-EN RV00 Page 12 /56

MAINTENANCE / EXCAVATION IS DONE ON THIS LINE.

Please pay attention to the following warnings when working

RECT-UM 0521-EN RV00 Page 13 /56

connection cables between batteries should be removed before doing any

Electrical hazards that may cause serious injury or loss of life if

Serious injury, loss of life or rectifier failure may occur if the

Do not dispose of garbage: Do not

RECT-UM 0521-EN RV00 Page 14 /56

3.1 Cable Cross-Section

MODEL INPUT OUTPUT OUTPUT INPUT BATTERY/OUTPUT

3.2 Cable Connection

Before starting this process, please pay attention to the

1. Please make sure that there is no voltage on the cables to be connected.

3.2.2 Battery Connection

Before starting this process, please pay attention to the

RECT-UM 0521-EN RV00 Page 15 /56

Correct Battery Connection

10 Batteries Serial Connection

RECT-UM 0521-EN RV00 Page 16 /56

10 Batteries Serial Connection