Installation manual for

charging rectifier type PCR3

SAFETY INSTRUCTION

This manual must be read before installation, usage or work in the product.

This product contains dangerous voltage that when touched can cause electrical
chock, burn or death.

The product must be installed by qualified personnel and according to the installation
instructions. Service may only be performed by authorized service personnel. The protective
cover of the connection compartment may only be removed by qualified personnel. Other
protective covers may only be removed by authorized service personnel. The power must
always be disconnected in a safe way before any service/maintenance work begins.

WARNING! Multiple power sources. Dangerous voltage is possible even with

mains power shut off.

Manual 9-1578-C
P/n 0001048

Kraftelektronik AB, Verkstadsgatan 18, S-352 46 Växjö, Sweden, Tel: +46 470-45800, Fax: +46 470-18345
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CONTENTS
1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 TECHNICAL DATA ..................................................... 4

2.1 ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1 Common electrical input data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.2 Common electrical output data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.3 Common electrical data for monitoring unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.1.4 Model depending electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 ENVIRONMENTAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 MECHANICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4 CONFORMITY WITH STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.3.2 Connection of mains power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.3 Connection of battery/load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.4 Connection of measuring inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.4.1 Connection of monitored battery voltage . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.4.2 Connection of measuring earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3.4.3 Connection of temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.5 Connection of digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3.5.2 Connection of equalization charging blocking input . . . . . . . . . . . . . . . . 9
3.3.5.3 Connection of parallel operation control input . . . . . . . . . . . . . . . . . . . . 9
3.3.5.4 Connection of fuse monitoring input . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.5.5 Connection of rectifier blocking input . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.6 Connection of digital outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.6.2 Connection of alarm output relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3.6.3 Connection of battery compartment fan ventilator . . . . . . . . . . . . . . . . . 11
3.3.7 Connection of serial data communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.7.2 Connection of KraftNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3.7.3 Connection of I2C-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4 STARTING UP ......................................................... 12
4.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 SETTING ALIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.3 START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.4 CHECKING OF THE CHARGING VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.5 CHECKING OF THE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.6 CHECKING OF THE ALARM OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 MAINTENANCE ....................................................... 13
5.1 SAFETY INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2 ANNUAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.1 Checking of charging voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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5.2.2 Checking of measuring instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5.2.3 Checking of alarm circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.2.4 Checking of fans and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 5-YEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.1 SAFETY INSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 FAULT TRACING BY AN ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.3 OTHER FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 OTHER DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CIRCUIT DIAGRAM PCR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ADDITIONS AND CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

We retain the rights to make changes to these specifications without further notice.

Kraftelektronik AB, Verkstadsgatan 18, S-352 46 Växjö, Sweden, Tel: +46 470-45800, Fax: +46 470-18345
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1 GENERAL

Charging rectifier type PCR is a primary switched mode charging rectifier family with integrated
monitoring unit.

This description only treats charging rectifiers in 3-phase variant, i.e. charging rectifiers with type
designation PCR3. The description mainly applies to designers and personnel that are responsible
for installation, service and maintenance.

For information regarding usage of the charging rectifier, see the Users manual.

For systems with charging rectifiers in parallel operation and double DC-systems, additional
information can be found in the Supplementary installation manual.

The term "charging rectifier" will henceforth be substituted by the term "rectifier".

By safety reasons, concerned personnel are divided into different classes with the following demands
on specific qualifications:

Authorized service personnel:

• Has electrical education and adequate experience to avoid the dangers that electricity
can cause.
• Has certificated qualification according to competent authorities for the work in
question.
• Has knowledge of languages that implies that the content in this description can not
be misunderstood.
• Has went through a product specific education programme for authorized service
personnel that is approved by Kraftelektronik AB.

Qualified personnel:
• Has electrical education and adequate experience to avoid the dangers that electricity
can cause.
• Has certificated qualification according to competent authorities for the work in
question.
• Has knowledge of languages that implies that the content in this description can not
be misunderstood.

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2 TECHNICAL DATA

2.1 ELECTRICAL DATA

2.1.1 Common electrical input data

Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380V/400V/415V AC 3-phase

Input voltage, range . . . . . . . . . . . . . . . . . . . . . . . 342 - 457VAC
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45-65Hz
Power factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.97 (fundamental at nominal load)
Terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . 0-10mm2

2.1.2 Common electrical output data

Output voltage . . . . . . . . . . . . . . . . . . . . . . . . . . See "Model depending electrical data"

Voltage regulation (static) . . . . . . . . . . . . . . . . . . <±0.5% of nominal output voltage (UNOM)
Voltage regulation (dynamicâ) . . . . . . . . . . . . . . <±1% within 3 seconds
Setting range, float charging . . . . . . . . . . . . . . . . . 0 - maximum output voltage (UMAX)
Setting range, equalizing charging . . . . . . . . . . . . 0 - maximum output voltage (UMAX)
Current regulation . . . . . . . . . . . . . . . . . . . . . . . . <±1% of rated current (IRATED)
Setting range, current limit . . . . . . . . . . . . . . . . . . 0 - 100% of rated current (IRATED)
Ripple voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . <0.2%RMS
Ripple current . . . . . . . . . . . . . . . . . . . . . . . . . . . <1% of rated current (I RATED)
Efficiency, typical . . . . . . . . . . . . . . . . . . . . . . . . 93%
Terminal block . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70mm2

â during change of load 0-100% and 100-10% respectively.

2.1.3 Common electrical data for monitoring unit

Voltage measuring, inaccuracy . . . . . . . . . . . . . . <±0.2% of nominal output voltage (UNOM)

Voltage measuring, range . . . . . . . . . . . . . . . . . . See "Model depending electrical data"
Current measuring, inaccuracy . . . . . . . . . . . . . . <±1%of rated current (IRATED)
Current measuring, range . . . . . . . . . . . . . . . . . . 0 - 100.9%of rated current (IRATED)
Battery temperature measuring, inaccuracy . . . . . <±1.5-C
Battery temperature measuring, range . . . . . . . . . 0 - 50-C
Earth fault resistance measuring, inaccuracy . . . . <±15%, 50k5 - 1M5
Earth fault resistance measuring, range . . . . . . . . 0 - 5M5
Earth fault terminal, internal resistance RIN . . . . . . >200K5 (24-220V), >900K5 (440-500V)
Pluggable terminal block for monitoring . . . . . . . 0-2.5mm2
Alarm relay, contact data, maximum . . . . . . . . . . AC: 250V 8A
DC:125V 0.15A (30V 5A) at L/R=7ms

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3.1.4 Model depending electrical data

Rectifier Monitor-
Output data Connection data
unit ing unit
Mains
Model of Maxi- Voltage
Recommended num- Mains Mains fuse,
PCR3 UNOM UMAX IRATED mum loss measuring
ber of cells power current maxi-
of power range
mum
(V) (V) (A) Lead Alkal. (VA) (ARMS) (ASLOW) (W) (V)
PCR3 24/100 24 32 100 11-13 17-21 6300 9 16 620 35.84
PCR3 48/60 48 60 60 22-26 35-40 7620 11 16 390 71.68
PCR3 48/100 48 60 100 22-26 35-40 11570 17 20 730 71.68
PCR3 110/30 110 150 30 52-54 78-85 7650 11 16 280 163.8
PCR3 110/50 110 150 50 52-54 78-85 11780 17 20 580 163.8
PCR3 110/100 110 150 100 52-54 78-85 21500 31 35 920 163.8
PCR3 125/30 125 160 30 55-60 86-92 8310 12 16 310 163.8
PCR3 125/75 125 160 75 55-60 86-92 18300 27 35 750 163.8
PCR3 220/25 220 280 25 102-112 156-184 12150 18 25 470 327.7
PCR3 220/50 220 280 50 102-112 156-184 22200 32 35 770 327.7
PCR3 440/10 440 500 10 204-216 270-306 9430 14 16 160 614.4
PCR3 440/15 440 500 15 204-216 270-306 13800 20 25 350 614.4
PCR3 440/25 440 500 25 204-216 270-306 21400 31 35 700 614.4
PCR3 500/10 500 550 10 240-252 320-356 10950 16 20 190 614.4
PCR3 500/20 500 550 20 240-252 320-356 20450 30 35 590 614.4

2.2 ENVIRONMENTAL DATA

Class of enclosure . . . . . . . . . . . . . . . . . . . . . . . . IP20 according to SS-EN 60529

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . By fan ventilator
Ambient temperature (specified data is valid) . . . . 0 to +40-C
Ambient temperature (specified data is not valid) . +40 to +50-C at reduced power â
Storage temperature . . . . . . . . . . . . . . . . . . . . . . . -40 to +70-C
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <90%RH
Altitude above see level . . . . . . . . . . . . . . . . . . . . <1000m
Noise level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . <50dBA

â Above +40-C, the rated output current is decreased 3.5% for every additional 1-C. This must be
manually adjusted, see Users Manual, section Operation, Settings, Adjust current limit level.

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2.3 MECHANICAL DATA

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47kg, valid for PCR3 model 24/100, 48/60,

110/30, 125/30, 220/15, 440/10
52kg, valid for PCR3 model 48/100, 110/50,
110/100, 125/75, 220/25, 220/50,
440/15, 440/25, 500/10, 500/20
Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall mounting
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See dimensional drawing below
Colour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RAL 7035

Dimensional drawing, PCR3

2.4 CONFORMITY WITH STANDARDS

SS-EN 50081-1 . . . . . . . . . . . . . . . . . . . . . . . . . . EMC. Generic emission standard, light indus-

try.
SS-EN 50082-2 . . . . . . . . . . . . . . . . . . . . . . . . . . EMC. Generic immunity standard, industrial
environment.
SS-EN 50178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . LVD. Electronic equipment for use in power
installations.
SS-EN 60529 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Class of enclosure, IP20.

Kraftelektronik AB, Verkstadsgatan 18, S-352 46 Växjö, Sweden, Tel: +46 470-45800, Fax: +46 470-18345
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3 INSTALLATION INSTRUCTIONS

3.1 SAFETY INSTRUCTIONS

WARNING! This product contains dangerous voltage that when touched can cause electrical chock,
burn or death. Protective earth must always be properly connected. No alive parts is permitted
during installation. The product must be installed by qualified personnel (see chapter 1, General).

WARNING! Check both before and after setting-up that the product does not have any mechanical
damages. Cables for input and output power must be correctly dimensioned to avoid fire hazard.

3.2 MOUNTING

The rectifier is intended for wall mounting indoors in a dry and clean room. First, fasten the two
upper mounting bolts on the wall. Then, fit in the "keyhole" tappings on the rectifier so the rectifier
is hanging on the bolts. Finally, fasten the two lower mounting holes.

WARNING! Due to a fall, the device can cause physical injury and damage on property. Always use
safe lifting equipment. Carefully ensure that mounting bolts and their attachment into the wall, with
safe margin and in a safe way, are able to carry the weight of the rectifier.

3.3 ELECTRICAL INSTALLATION

3.3.1 General
Only permanent mains feeding connection is permitted. Protective earth must be connected before
any other installation. All installations are made in the so called "connection compartment" (see the
component location drawing below). Remove the lower part of the enclosure that covers the
connection compartment by undoing the screw on the upper part of the cover.

WARNING! Hold the cover carefully when undoing the screw, or else the cover may fall down and
cause damage or injury.

Component location, connection compartment PCR3

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3.3.2 Connection of mains power

The required primary fuse rating is stated in the table found in section Technical data, or in appendix
Additions and changes if the rectifier has non-standard primary data.

Connect 3-phase mains voltage to the three terminal blocks marked L1, L2 and L3 on the mains filter
A1 placed on the right side of the connection compartment. The phase sequence is of no importance.

3.3.3 Connection of battery/load

Verify that the rated voltage specified on the rectifier marking sign corresponds to the nominal
voltage of the battery.

Connect the DC system to the output fuse terminals marked + and - respectively. Choose cables that
can handle the rated current of the rectifier. The rectifier output is supplied with two-pole fusing.

3.3.4 Connection of measuring inputs

3.3.4.1 Connection of monitored battery voltage

All the voltages that are monitored should be measured as close to the battery and distribution unit
as possible in order to avoid measuring errors due to voltage drop in cables.

Ubattery- is the minus pole common to all the voltage measurings. Connetct from the minus pole
of the battery to terminal X8:2.

Ubattery+ measures the total voltage of the battery. Connetct from the plus pole of the battery to
terminal X8:4.

Ubattery½ measures the midpoint voltage of the battery. Connect from the mid point of the battery
to terminal X8:3.
By measuring the voltage level of the mid point of the battery and thereby compare the two halves,
you can in a simple but effective way catch a number of important fault conditions as for example
unequal charging distribution, short-circuit in battery cells, etc.
If the midpoint voltage should be used, the midpoint voltage measuring must be activated and set
with the proper parameters, see Users Manual, section Operation, Selection of functions, Midvoltage.
The parameter that is set states the percentage of the total battery voltage that is expected in the mid
point. It will not always be exactly 50% because it is not always possible to make a connection in
the theoretical mid point. Therefore, always check that the actual measuring point corresponds to
the setting.

3.3.4.2 Connection of measuring earth

Earth fault measuring are done by continuously measuring the voltage in a constructed midpoint to
which the monitored earth point is connected.

If earth fault measuring is used, connect terminal X8:1 to the earth distribution bar that is found in
the connection compartment.

Note that the measuring point must not be located outside the connection compartment by EMC
reasons. In those cases you need a disconnectable measuring earth, e.g. in double DC systems, you
can use the internal facility for disconnection of the measuring earth. The disconnection control is
handled via the digital input for parallel operation. Additional information can be found in the
Supplementary installation manual.

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Earth fault measuring can be disabled, see Users Manual, section Operation, Selection of functions,
Earth fault measuring. A galvanic separation of the measuring input terminal will then be done
internally without the need of any external disconnection.

3.3.4.3 Connection of temperature sensor

Measuring of the battery temperature is needed if you intend to

use temperature regulated float charging voltage. At the same
time you get a monitoring of extreme temperatures with
matching alarms.

The external temperature sensor is a standard Pt-1000 resistive

sensor built into a hermetic sealed enclosure, commercially
named "outdoor sensor". Since the sensor is of the type Temperature sensor (without
Pt-1000, a two pole measuring will do, in contrast to the more covering)
commonly used Pt-100 that usually needs a four-pole measur-
ing to prevent the measuring wire resistance to have an effect
on the measuring result.

Place the sensor on a spot that will best represent the battery temperature, normally the most central
located point on the top of the battery.

Connect the temperature sensor to terminal X11:11-12.

The temperature sensor is an option and is therefore installed only whenever applicable. If a
temperature sensor should be used, the temperature measuring function must be enabled, see Users
Manual, section Operation, Selection of functions, Temperature measuring.

3.3.5 Connection of digital inputs

3.3.5.1 General

The digital inputs are power supplied from the internal auxiliary power of the rectifier (approximately
12VDC) . Therefore, they may only be connected to zero-potential contacts.

Closed input means normal state. Open input is activated state. It means that the two terminals of
each input that is not used must be interconnected!

3.3.5.2 Connection of equalization charging blocking input

In open state, the equalization charging is prohibited. Is mainly used to, via a vent flow monitor,
prevent equalization charging in case of a malfunctioning battery compartment fan ventilator.

Is connected to terminal X11:3-4.

3.3.5.3 Connection of parallel operation control input

Open input means that the DC system in which the rectifier is part of, operates in connection with
another DC system. It means, among other things, that the earth fault measuring automatically is
measured in only one rectifier in the complete double DC system. For additional information, see
the Supplementary installation manual.

Is connected to terminal X11:5-6.

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3.3.5.4 Connection of fuse monitoring input

Monitors an optional number of fuses through auxiliary fuse contacts connected i series. Open loop
means tripped fuse.

Is connected to terminal X11:7-8.

3.3.5.5 Connection of rectifier blocking input

An open input immediately results in a shutting off of the rectifier. Is functionally placed side by side
with the mains switch in off position.

Is connected to terminal X11:9-10.

3.3.6 Connection of digital outputs

3.3.6.1 General

The digital outputs consists of zero-voltage relay contacts. Electrical ratings for the contacts are
found-in section Electrical data earlier in this chapter.

The terminals for the outputs are marked C, NC and NO respectively. The implication of this is:

• C - Point for Common connection.

• NC - Connection point for Normally Closed contact.
• NO - Connection point for Normally Open contact.

The meaning of the word normally is in this case "no alarm" and "not activated" respectively. We
recommend the use of the condition NC. It increases the reliability since also a bad contact function
will give an alarm. In order to further raising the reliability, all alarm relays are close circuit working,
i.e. an energized relay indicates normal state while a fallen relay gives alarm. It means that also a
faulty relay or lack of auxiliary power will cause an alarm indication.

3.3.6.2 Connection of alarm output relays

Connections to the alarm output relays are done according to the following:

• Alarm relay A . . . . . C . . . . . . . . . . . . . Terminal X16:1

NC . . . . . . . . . . . Terminal X16:2
NO . . . . . . . . . . . Terminal X16:3
• Alarm relay B . . . . . C . . . . . . . . . . . . . Terminal X16:4
NC . . . . . . . . . . . Terminal X16:5
NO . . . . . . . . . . . Terminal X16:6
• Alarm relay C . . . . . C . . . . . . . . . . . . . Terminal X16:7
NC . . . . . . . . . . . Terminal X16:8
NO . . . . . . . . . . . Terminal X16:9
• Alarm relay D . . . . . C . . . . . . . . . . . . . Terminal X16:10
NC . . . . . . . . . . . Terminal X16:11
NO . . . . . . . . . . . Terminal X16:12

The relations between the alarm relays and existing alarm alternatives can be set with in principle
unlimited degree of freedom, see Users Manual, section Operation, Alarm settings. See also in the
same manual, section Operation, Test for a description of how the alarm circuits, in a simple way,
can be tested.

For usage of alarm relay D in double DC systems, see the Supplementary installation manual.

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3.3.6.3 Connection of battery compartment fan ventilator

The output for control of a battery compartment fan ventilator is automatically activated by an
equalization charging. To ensure that all hydrogen gas is vented out, the output continues to be
activated for another 10 minutes after finished equalization charging.

Is connected to terminal X16:13-14. The relay contact is normally open (NO) and is closed for the
fan to start.
3.3.7 Connection of serial data communication

3.3.7.1 General

The rectifier is supplied with two different systems for serial communication. KraftNet is mainly used
for communication with other rectifiers but also for communication with superior systems of the type
KraftMaster. The I2C bus is mainly an internal serial channel for communication between the
control-board and the display unit. In some cases, the I2C bus could also be connected to external
units which then is located either inside the connection compartment or very close to the rectifier.
The I2C connection between control board and display unit also gives an opportunity to an alternate
location of the display unit, e.g. on the front door of a cabinet in case the rectifier is mounted inside
a cabinet.

3.3.7.2 Connection of KraftNet

KraftNet is connected to X11:1-2 using shielded cable. The polarization does not matter. The shield
should be grounded in both ends.

3.3.7.3 Connection of I2C-bus

The I2C bus is always connected using a cable assembly of so called USB-type (commonly used
between computers and their peripheral units). In a standard PCR3 rectifier, the cable assembly is
already connected with one end visible in the terminal X7 while the other end disappears into the
rectifier where it is connected to the display unit. I those cases where the display unit should
be-mounted in some other way or other peripheral units should be connected, then see the separate
installation instructions that should be supplied for this matter.

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4 STARTING UP

4.1 SAFETY INSTRUCTIONS

WARNING! This product contains dangerous voltage that when touched can cause electrical chock,
burn or death. All protective coverings and plates must be mounted during operation.

4.2 SETTING ALIVE

First, connect battery power, for instance by using a fuse to close the battery circuit. The monitoring
unit will now start. Note that a starting current surge occurs when the filter capacitors in the rectifier
are charged. It may cause sparking at the engaging point.

The set the voltage measuring inputs alive.

At last, switch on the mains power.

4.3 START

Turn the panel mains switch in position 1 (On).

Battery charging now commences. If the battery was deeply discharged, charging will commence
at the rated current, and this will continue until the float charging level is reached. Some battery
types needs an initial equalizing charging. Always follow the instructions stated by the battery
manufacturer.

4.4 CHECKING OF THE CHARGING VOLTAGE

Check that the rectifier voltage settings corresponds to the specifications stated by the battery
manufacturer, see Users manual, section Operation, Settings.

When the battery reached such a charging level so that the alarm "High current" no longer is active,
you should check that the actual output voltage really corresponds to the preset float charging
voltage. See section Maintenance, Annual inspection, Checking of charging voltage.

4.5 CHECKING OF THE SETTINGS

Check that displayed measures corresponds to real values. Check alarm settings and other parameters
so they corresponds to intended function, see Users manual, section Operation.

For maximum safety, see that the OVP function (OverVoltage Protection) is activated (see Users
manual, section Operation, Advanced, Selection of functions, Overvoltage protection). The
protection is normally activated at the time of delivery.

4.6 CHECKING OF THE ALARM OUTPUTS

The alarm relays A-D can be manually manoeuvred for checking of the external circuits that are
connected to the alarm output relays, see Users manual, section Operation, Test.

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5 MAINTENANCE

5.1 SAFETY INSTRUCTION

WARNING! This product contains dangerous voltage that when touched can cause electrical chock,
burn or death. Maintenance work that involves work with removed connection compartment
protective covering may only be done by qualified personnel.

5.2 ANNUAL INSPECTION

5.2.1 Checking of charging voltage

Connect an external voltmeter to the panel voltmeter terminals and check that the output voltage
corresponds to the preset value.

Note that if the float charging voltage is temperature regulated, the rectifier must be forced into a
state where the temperature regulation stops in order to make the checking possible. In order to
achieve this state and by trimming eliminating a possible divergence, see Users manual, section
Operation, Trimming of rectifier.

5.2.2 Checking of measuring instrument

Check that the internal measuring instrument (display) shows a correct value. Follow the instructions
stated in the Users manual, section Operation, Calibration of measuring instrument.

5.2.3 Checking of alarm circuits

Check the circuits that are parts of the alarm system. Follow the instructions stated in the Users
manual, section Operation, Test.

5.2.4 Checking of fans and filters

The connection compartment there is either one or two cooling fans. Check that the fans are
functioning properly. Listen for jarring sounds that may indicate worn out bearings and in that case,
replace the fans in preventing purpose. If the fans are supplied with filters, the filters should be
replaced.

If you suspect that there is any substantial amount of dust in the rectifier, call for authorized service
personnel. Do under no circumstances own encroachments beyond those which are possible to do
from the connection compartment.

5.3 5-YEAR INSPECTION

Beyond the annual inspection, the cooling fans should be replaced in preventing purpose.

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 14

6 FAULT TRACING

6.1 SAFETY INSTRUCTION

WARNING! This product contains dangerous voltage that when touched can cause electrical chock,
burn or death.
Service/maintenance work that involves work with removed connection compartment protective
covering may only be done by qualified personnel. Other protective coverings may only be removed
by authorized service personnel.

6.2 FAULT TRACING BY AN ALARM

When there is an alarm message, the fault tracing should in first case be based on the information
given in the Users manual, section Operation, Alarm messages, Alarm descriptions. Only after that,
or if there are no relevant alarms, you proceed to the instructions in section Other fault tracing.

6.3 OTHER FAULT TRACING

The primary fuse is tripping when the rectifier is turned on

Cause 1: Incorrect type of mains fuse. Check that mains fuse follows the specifications in section
Technical data. Note that delayed-action fuses must be used.
Cause 2: Internal rectifier fault. Call for authorized service personnel.

No rectifier output
Cause 1: The output fuses has tripped. Check that the output fuse rating is sufficient compared to
the rated output current of the rectifier.
Cause 2: The input for external blocking is in open state.
Cause 3: Internal rectifier fault. Call for authorized service personnel.

The rectifier output voltage is too low

Cause 1: High temperature in the battery or battery compartment. Applicable only if the output
voltage is temperature regulated. In that case, the rectifier is O.K. Instead, seek the cause
of the high temperature. The temperature sensor may also be faulty. Check if the display
reports correct battery temperature.
Cause 2: Incorrect setting of float charging voltage level. Change the setting.
Cause 3: Incorrect trimming of output voltage. Make a new trimming of the output voltage.
Cause 4: Internal rectifier fault. Call for authorized service personnel.

The rectifier output voltage is too high

Cause 1: Low temperature in the battery or battery compartment. Applicable only if the output
voltage is temperature regulated. In that case, the rectifier is O.K. Instead, seek the cause
of the low temperature. The temperature sensor may also be faulty. Check if the display
reports correct battery temperature.
Cause 2: Incorrect setting of float charging voltage level. Change the setting.
Cause 3: Incorrect trimming of output voltage. Make a new trimming of the output voltage.
Cause 4: Internal rectifier fault. Call for authorized service personnel.

The rectifier output current is too high

Cause 1: Incorrect setting of current limit. Change the setting.
Cause 2: Internal rectifier fault. Call for authorized service personnel.

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 15

Cooling fan is not rotating, eventually together with the alarm "High temp, rect"
Cause: Faulty fan. Replace the fan.

The rectifier sound odd

Cause: In an idling running state there might be a twittering sound. This is no fault but is
compleatly normal. The sound will disappear as soon as even a minor load is impressed.

The display is turned off but the rest of the rectifier is functioning
Cause 1: The I2C cable has came loose from the connector X7. Restore the connection. The display
backlight now should be turned on but then it may take as long as one hour before the
display shows relevant information again. It might happen that the alarm "Internal fault
xx01" then is shown. Acknowledge the alarm and it should not come back.
Cause 2: Internal rectifier fault. Call for authorized service personnel.

The pushbuttons doesn't work and/or the display shows rubbish

Cause 1: Indicates that the internal microcomputer has locked up. The control electronics has to be
restarted by first making it dead. The dead state is achieved by first turning off the rectifier
using the mains switch and then disconnect the rectifier from the battery. This is most
easily done by removing the rectifier output fuse marked with +. Let it remain open for a
while until the display has completely turned off. Then restart by restoring the fuse and
then turn on the rectifier mains switch again.
Cause 2: Internal rectifier fault. Call for authorized service personnel.

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 16

7 OTHER DOCUMENTS

As appendixes follows on following pages in turn:

• Circuit diagram PCR3

• Additions and changes

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ADDITIONS AND CHANGES

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