Ups Operation Manual

Operation & Maintenance
Manual
G
N
DC UNITERRUPTIPLE POWER SUPPLY

I
N
Customer : Schneider (Thailand) Limited.

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Job number: BSO - 04173
Ser. No. BS 23945

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System Model: D415 D110-35 Bwrug-TDG

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Manufacturer
Benning Power Electronics Pte Ltd
85 Defu Lane 10 #05-00
Singapore 539218
E-mail: service-info@benning.com.sg
Operating Instruction
Rectifier unit THYROTRONIC

with Thysat regulator
Date Name No. 3728 en

Issued: 06.07.01 Mo/Obs Page 1/66 Pages
Revision 23.12.05 Mo/Obs
Geprüft: 27.12.05 Mohr
D:\MANAUAL\Manual For PO13-08 - Star Cement Yemen\RECT_MANUAL.DOC
Rectifier unit THYROTRONIC with Thysat regulator
General
1.1 Purpose of the Operating Instructions
These Operating Instructions serve to enable the secure operation of the rectifier unit
THYROTRONIC as intended.
The present Operating Instructions contain the information necessary for the safe operation
as intended of the rectifier unit.
The Operating Instructions must always be available and kept handy in the vicinity of the
rectifier unit.
The Operating Instructions must be read and applied by any person entrusted with operat-
ing processes on the rectifier unit; these include transport, erection and disassembly.
In addition to the Operating Instructions, the valid applicable guidelines, standards and
laws for safe and correct working at the place of installation must be observed in commer-
cial use.
Information in addition to these Operating Instructions can be obtained from the specialists
of the manufacturer or supplier.
All documentation is protected under copyright law. Passing on and copying of documents,
even in form of extracts, and utilisation and dissemination of its contents is not permitted
unless expressly approved.
1.2 Scope of the Operating Instructions
If required as a result of the site conditions, the rectifier unit can be supplied in a large
number of versions. A description of all versions would reduce the benefit and compact na-
ture of your Operating Instructions.
For this reason these Operating Instructions refer exclusively to the standard configuration
of the rectifier unit. Exact details concerning your version of the rectifier unit can be taken
from:
→ the order confirmation,
→ the equipment data sheet,
→ the rating plate on the inside of the front door,
→ the technical documentation in chapters 18/19 of these Operating Instructions.
These details concerning your version are of prior validity compared with possibly deviat-
ing details concerning the standard configuration in these Operating Instructions.
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1.3 Presentation remarks
The rectifier unit is manufactured according to the generally accepted rules and the current
state of the art design techniques. Additional safety instructions are provided in order to
guarantee the personnel adequate safety. Adequate safety when handling the rectifier unit
is ensured only if these instructions are adhered to.
From time to time it is necessary to emphasise certain text passages. The passages marked
thus have different meanings:
+ Notes contain additional information facilitating safe and efficient handling of

the rectifier unit.
This warning draws attention to possible damage to property which may result
from a failure to adhere to precautionary measures or from incorrect handling.
Please observe all warnings and measures that prevent the occurrence of dam-
age on the rectifier unit and other property. Proceed with particular care!
This warning refers to possible injuries to persons which may result due to a
failure of adhering to precautionary measures or through incorrect handling.
Please observe all warnings and measures that prevent injuries to yourself or
third parties. Proceed with particular care!
23.12.05- TB-Mo/Obs 3/66 3728 en

2 Safety
2.1 General
These Operating Instructions are an essential part of the rectifier unit.
The operator has to ensure that these Operating Instructions are always available near the
rectifier unit and that the operating staff get acquainted with these instructions.
The Operating Instructions must be supplemented by the operator, with operating instruc-
tions on the basis of existing national regulations for accident prevention and environ-
mental protection. These additional instructions should include information concerning su-
pervisory and notification obligations for the consideration of special operational features,
for instance with regard to work organisation, working processes and personnel employed.
In addition to the Operating Instructions and the valid regulations for accident prevention
applicable in the country concerned and at the place of operation it is also necessary to ob-
serve the recognised special technical rules for safe and correct working.
2.2 Personnel qualifications
Only qualified and trained technical personnel may work on the rectifier unit. In particular
qualified electricians authorised for this purpose must only perform the installation, initial
start-up, maintenance and disassembly of the rectifier unit.
The competencies of the personnel for operation must be clearly separated from those of
installation, programming and repair. Only service personnel must be able to
→ open the housing of the rectifier unit,
→ get to the password-protected menu levels of the regulator programme.
Qualified technical personnel in the sense of these basic instructions are persons who are
familiar with the installation, start-up, operation, maintenance, shutdown and disassembly
and who have the qualifications corresponding to these activities.
With qualified electricians it must be assumed that the applicable regulations of the local
power supply company (EVU) and the safety instructions of the accident prevention regu-
lations of the trade associations (for instance BGV A2) and all rules for safe and correct
working (for instance DIN VDE 0100 and IEC 664 or DIN VDE 0110) are observed and
adhered to.
The manufacturer points out that the manufacturer will not accept any liability for damage
and operating faults arising from a failure to observe the operating instructions.
2.2.1 Commercial use
If the rectifier unit is employed commercially, the following will apply in addition:
→ The operator must be familiar with handling the rectifier unit through special induc-
tion or training courses.
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→ Only authorised personnel may become active.
2.3 Use as intended
Risk of injury!
Danger of serious injuries to persons and property may result from:
- incorrect use or incorrect operation,

- unauthorised opening of the rectifier unit,
- incorrect installation or incorrect maintenance and repair.
All details concerning the intended use, the residual risk, the installation, the operation and
maintenance contained in these Operating Instructions must therefore be observed and ad-
hered to.
The rectifier unit THYROTRONIC is intended to supply DC voltage loads. In addition to

this the rectifier unit can be used for charging suitable batteries. Only rechargeable lead
and nickel-cadmium batteries are suitable. The rectifier unit is not suitable for all other ac-
cumulators and non-rechargeable batteries!
The instructions of the battery manufacturer must be observed and adhered to!
As part of the intended use, the details of the rating plate and the details in the supplied
technical documentation must be observed and adhered to.
The rectifier unit may only be used for the applications provided in these Operating In-
structions and in the technical description, with the accessories or components recom-
mended and approved by the manufacturer.
Use other than this or beyond this will not be considered as use as intended. The operator
or user of the rectifier unit will carry the sole responsibility for damage resulting from such
use.
Start-up of the rectifier unit is only permitted subject to adherence to the guideline for elec-
tromagnetic compatibility (89/336/EEC). The limit value class is specified in the equip-
ment data sheet.
In the case of a rectifier unit with subsequent modifications on the part of the operator
(with regard to components, circuits, regulator programming, etc.) it is compulsory on the
part of the operator to document the equipment status in the technical documentation and
to provide suitable instructions permanently on the front of the unit if applicable.
2.4 Safety instructions concerning place of use and storage
The rectifier unit must be protected from inadmissible loads. In particular, no components
must be damaged during transport and handling. Avoid contact with electronic compo-
nents.
entering liquids,
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entering conductive dusts (soot, metals),
high humidity of the air and
formation of condensate (for instance through airtight packaging) and
ambient temperatures below 0 °C and above 40 °C
may damage the rectifier unit and must therefore be excluded.
Heat soak conditions on the rectifier unit for instance through heat sources or blockage of
the ventilation slits must be excluded. Although non-conductive dusts do not impair the
function of the rectifier unit they may however obstruct the dissipation of heat if allowed to
accumulate and consequently reduce the service life of the rectifier unit.
If the rectifier unit is supplied in a particularly protected version, the details in the order
confirmation must be observed and adhered to.
2.4.1 Safety instructions for battery use
Open flames and smoking in rooms with battery charging stations are prohibited!
No combustible materials and spark-forming equipment may be located in a vicinity of 2 m

around battery charging stations.
The place of operation must be adequately ventilated so that resulting charging gases (acid
fog, oxyhydrogen) are able to dilute sufficiently, securely preventing the occurrence of ex-
plosive gas mixtures.
2.5 Safety instructions concerning installation
The rectifier unit contains electrostatically susceptible components which can be easily
damaged through incorrect handling. Electrical components may not be mechanically
damaged or destroyed.
Perform the electrical installation (line cross sections, fuses, earth connections) according
to the applicable regulations.
Adherence to the limit values as required by the EMC act is strongly connected with the
installation and combination with other pieces of equipment and the type of operation. In
order to comply with the EMC act, the installation must take into account all details con-
cerning screening, earthing, arrangement of filters and insulation of lines.
Prior to performing the electrical installation, compare the ratings on the rating plate
with the ratings of the supply connections:
Protect the rectifier unit against overcurrent by means of an upstream mains fuse.
Adhere to the mains connection values of the rating plate (voltage and frequency).
Switching (confusion) of poles with mains and battery connection must be securely
excluded.
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2.6 Safety instructions concerning operation
Publicise location and operation of fire protection equipment and adhere to fire alarm and
fire fighting possibilities.
The rectifier unit may only be used in a technically perfect condition and as intended under
consideration of safety and hazards and adhering to these Operating Instructions. In par-
ticular, faults impairing the safety must be corrected immediately.
In the event of safety-relevant changes to the rectifier unit or the operating behaviour, the
rectifier unit must be stopped immediately and the fault reported to the responsible office.
Even when the rectifier unit has been switched off completely, individual components will
still carry voltage for as long as they are connected with the supply system and/or the bat-
tery.
2.7 Safety instructions concerning troubleshooting and repair
Consult the manufacturer prior to performing conversions and major repairs.
No changes or modifications may be made to the rectifier unit without the approval of the
manufacturer! This applies also to the installation and adjustment of safety installations:
Especially ensure that creep and air gap distances are not reduced.
Replacement parts used must satisfy the technical requirements determined by the manu-
facturer. This is always ensured when using original replacement parts.
Use only insulated tools for performing maintenance work.
Prior to starting maintenance or repair work disconnect the rectifier unit input and output
from
the mains power,
the battery if applicable and
all loads.
Equipment used for disconnection must be locked to prevent inadvertent or spontaneous

switching on. Use additional signs to warn against switching on, if applicable.
After switching off, wait for at least five minutes before taking off the covers of the hous-
ing. The capacitors of the control will have been discharged completely only after such
time.
If work on live equipment is unavoidable, a second person must be involved to isolate the
rectifier unit or initiate first aid measures in the case of an emergency.
First check all disconnected components to ensure they are de-energised, then earth, short
circuit and insulate live adjacent components.
23.12.05- TB-Mo/Obs 7/66 3728 en

When working on high-voltage assemblies, connect the supply cable to the casing follow-
ing the disconnection of the power. Short-circuit components such as capacitors by way of
an earth rod.
If the repair measures require the disassembly of protective installations, reinstallation and
testing of the protective installations must be performed immediately after the completion
of the work.
23.12.05- TB-Mo/Obs 8/66 3728 en

3 Product details
3.1 Description
Electrical loads are employed in all areas of industry and public life which must be pro-
tected against failure of the power supply system. Together with shunt-connected batteries,
the rectifier unit THYROTRONIC forms a guaranteed power supply.
The mains voltage is supplied to the transformer by way of a mains switch and contactor.
This is where the galvanic separation of battery and mains and the adjustment of the volt-
age to the corresponding battery voltage take place.
The alternating voltage is converted into a direct voltage in a three-phase or single-phase

bridge circuit (thyristor bridge). The thyristors are activated by the microprocessor-
controlled Thysat regulator. Smoothing of the direct current is achieved by way of a filter.
This consists of a smoothing choke situated in the direct current circuit and several shunt-
connected electrolyte capacitors. Voltage and current can be read off the built-in instru-
ments.
The rectifier unit operates with an IU characteristic according to DIN 41773, by means of
which the set output voltage is kept constant within a load range of 0 and 100% of the
equipment current with a deviation of ± 0.5 %. Mains voltage and mains frequency fluctua-
tions are compensated.
Mainly sealed or closed low-maintenance lead batteries are employed as energy storage
units today depending on application; nickel-cadmium batteries can be found in a large
number of special applications.
Lead and nickel-cadmium batteries achieve maximum service life if they are in a position
of rest in the charged condition. This position of rest of the batteries is achieved when the
rectifier unit takes over the supply of the loads and the battery is only utilised in the case of
mains power failure or high current loads. This operating mode is termed standby parallel
operation.
With a severely depleted battery, the rectifier unit will initially operate in the I-branch of
the IU characteristic, the charging current being obtained from the difference between the
rated current of the rectifier unit and the load current.
The transition to constant voltage charging (U-branch) follows on reaching the set output
voltage of the rectifier unit.
Accelerated charging takes place by switching over the characteristic from float charging
to charging. This changeover is performed automatically but can also be done manually.
For temperature-controlled charging, the rectifier unit may be designed with a charge char-
acteristic. The battery temperature-dependent inclined float charging characteristic pos-
sesses an adjustable inclination and adjustable point of operation. A separate temperature
sensor is necessary for this function.
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3.2 Type designation
The rectifier unit THYROTRONIC is available in different versions. The following is an

example of a decoded type designation:
Additional manufacturer designation
Equipment characteristics (battery and resistance load, character-

istic control, switchable characteristic, smoothed output current
Output current type and rated output voltage/rated output current

Output current type and rated output voltage/rated output current
Figure 1 Type Code
The exact technical data are provided on the rating plate on the rectifier unit and the order
confirmation, the equipment data sheet and the technical data in chapter 19.
3.3 Remaining risk
Dangerous electrical voltage warning!
The rectifier is a piece of electrical equipment carrying voltages and currents that are dan-
gerous to human beings.
The rectifier unit may therefore only be:
operated by instructed and trained specialists.
installed, opened, repaired and dismantled if required by qualified electricians!
The power supply and a battery and/or load contact must always be disconnected before in-
tervening and working on the rectifier unit.
Danger!
Switching on a battery in addition to the rectifier unit will cause an arc, which
may cause severe injuries to yourself and others if handled incorrectly. There is
an increased fire hazard.
Installation and start-up of the rectifier unit, especially in the case of units with battery
connection, are only permitted by experienced and qualified electricians.
23.12.05- TB-Mo/Obs 10/66 3728 en

Explosion hazard!
Explosive gases may escape during battery charging.
The operation of the rectifier unit is therefore permitted only in adequately ven-
tilated rooms.
Never remove the battery connection during a charging process since this
could result in sparks or arcing, which could ignite the oxyhydrogen gases.
Attention!
When batteries are being charged, caustic acid gases may be generated which
can cause short circuits in electrical equipment (fire hazard) and corrode com-
ponents!
Always place batteries so that the rising acid gases are able to freely dilute at the place of
operation and escape.
3.3.1 Battery
Danger!
Batteries contain sulphuric acid which is highly caustic. The exposed metal
parts of a battery always carry voltage. Do not open any battery housings and
do not touch any exposed metal parts!
Work on and with battery systems may therefore be carried out only
by correspondingly qualified personnel and
complying with the operating instructions of the battery manufacturer.
3.4 Description of protective installations
The rectifier unit has been designed and built according to the accepted rules of engineer-
ing. When used as intended there are no consequent safety and health hazards to operating
personnel or third parties.
All control parts are clearly marked. All live assemblies are equipped with housings, cov-
ers which can only be removed by means of tools. All cables and plugs are properly
screened and earthed.
All electrical and electronic components correspond to the European safety requirements;
all necessary insulating distances have been maintained. All electric circuits have been
equipped with primary and secondary fuses of defined amperage and tripping characteris-
tic.
23.12.05- TB-Mo/Obs 11/66 3728 en

All metallic components are grounded via a grounding conductor system.
The rectifier unit is equipped with an overvoltage cut-off function, which is activated when
preset charge voltages are exceeded. This prevents battery overcharging and excessive
formation of explosive gases. (Note: The overvoltage cut-off function is not operational
when the rectifier unit is in the operating mode equalise charging; see chapter 7.7.3 Equal-
ise charging.)
In its standard configuration the rectifier unit is designed in accordance with protection
class IP 20. Deviating from this, the details concerning specially protected versions can be
taken from the order confirmation, the equipment data sheet and the technical data in chap-
ter 19.
3.5 Identifications and signs on the rectifier unit
Attached in the interior of the unit.
Important! Adhesive label
Prior to working in the unit, disconnect Attached to the inside of the front door.
mains and battery fuses.
Important! Adhesive label
Do not touch live parts. Individual ter- Attached to the inside of the front door.
minals and components may also carry
voltage even with the switched off.
(De-energise first when performing
maintenance operations on the unit).
Use only fuses of the same type and

characteristic.
High discharging current! Adhesive label
With mains connection before L and N Attached to the inside of the front door.
connect PE conductor!
23.12.05- TB-Mo/Obs 12/66 3728 en

23.12.05- TB-Mo/Obs 13/66 3728 en

4 Transport, handling and storage

Following the arrival of the rectifier unit at its destination, immediately inspect it for pos-
sible damage. Also check if all parts are present by comparing it with the packing list. Im-
mediately inform the manufacturer or supplier in writing should there be any damage.
4.1 Scope of delivery
The delivery consists at least of the following parts:
Rectifier unit with preset regulator programme,
Operating Instructions,
Delivery note.
The scope of delivery and the version of the rectifier unit may deviate from the above de-
pending on the customer request. Additional technical details are noted in the enclosed de-
livery documents (and in the order confirmation).
→ Immediately after delivery, check for completeness and damage.
→ By means of the delivery note and the rating plate, check to see if the data coincides.
→ If there are defects, immediately contact the manufacturer and the transport company
if applicable.
→ Check the rectifier unit for loose screw connections and secure them if required.
4.2 Packaging
Depending on the applicable type of transport, the rectifier unit will be supplied in a card-
board box or wooden crate on a transport pallet. The rectifier unit is generally supplied in
upright position and should also be transported in that way.
Note the instructions on the carton with regard to transport, handling and storage:
Protect from the effects of the weather!
Fragile!
Top!
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4.3 Transport
Observe the applicable accident prevention and industrial safety regulations.
It is imperative that the transport equipment is approved for the total weight of the rectifier
unit.
Always lash down the rectifier unit so that it cannot skid or topple over. In particular en-
sure that the paint finish is not scuffed and scratched.
Stay clear of obstacles.
Avoid shock impacts when transporting the rectifier unit.
Having unloaded the rectifier unit, immediately inspect it for possible damage.
4.3.1 With forklift trucks
If the rectifier unit is transported with a forklift, always start the forks at the back of the
rectifier unit to avoid damaging the door with instruments mounted on the front.
4.3.2 With crane
Larger rectifier units have lifting eyes attached at the top of the housing.
Entrust only persons experienced with rigging and directing cranes when moving loads!
The instructor must be in the field of vision of the operator or in speaking contact!
Use only technically perfect lifting equipment and lifting tackle with sufficient lifting ca-
pacity!
Carefully attach and secure the rectifier unit to the lifting equipment.
Ensure even loading of the ropes / belts. Avoid inclination.
Do not dwell or work under suspended loads.
4.4 Storage
The storability of the rectifier unit depends on the chosen packaging.
A rectifier unit with short-term packaging should be unpacked immediately on reaching the
destination and stored in a suitable place. Excessive temperature fluctuations should be
avoided, especially temperature drops likely to cause condensation to form on the unit (see
DIN 55 474).
If it is intended to store the rectifier unit, open the doors for several hours so that the recti-
fier unit is able to adjust to the new temperature without the formation of condensate. If the
rectifier unit is placed in intermediate storage for a prolonged period of time, cover it with
foil and check for the formation of condensate from time to time.
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If the rectifier unit is supplied with long-term packaging it should be stored in that packag-
ing. Check the packaging for damage beforehand. During the storage period, check the
desiccant and renew if required (see packaging instructions). The desiccant is still useful
while blue in colour. As soon as it changes to red, replace. Thereafter seal the foil airtight.
23.12.05- TB-Mo/Obs 16/66 3728 en

5 Assembly, installation and start-up

Adhere to all safety instructions in chapter 2.4 Safety instructions concerning place of in-
stallation and storage and in chapter 2.5 Safety instructions concerning installation.
5.1 Assembly
Depending on requirement the rectifier unit is designed for level ground assembly or floor
or wall mounting.
The floor must be level and clean. Check all provided basic frames; cable ducts and ceiling
breakthrough must be completed and checked.
If the rectifier unit is set up on a basic frame, the latter must be checked for exact installa-
tion. With a length of 5 m the deviation from the horizontal may not exceed ±1.5 mm and
no warpage is permitted.
5.2 Mains connections and mains fuses
The rectifier is a piece of electrical equipment carrying voltages and currents

that are dangerous to human beings.
Protect the rectifier unit against excessive contact voltages according to the local regula-
tions of the power supply company: It is considered an installation with fixed connection
and must be protected in the supply current circuit (electrical systems of the building)
against short circuit or overcurrent.
A mains connection is necessary at the intended place of operation to operate the rectifier
unit. The mains voltage and frequency must correspond to the details on the rating plate.
The housing must be earthed properly.
We cannot unconditionally recommend the operation of the unit by way of leakage current
protection switch since it can be triggered by the specified interference suppression capaci-
tors.
Protect with a mains fuse in accordance with the equipment data sheet.
When connecting the cables, observe the details of the circuit diagrams and the terminal
diagrams!
When connecting the battery, ensure correct polarity (+ to +; - to -)!
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The currents for determining the cross sections for the mains, battery and load lines can be
taken from the rating plate. The resulting voltage drop between rectifier unit and battery
and load should be taken into account when determining the cross sections.
Connect the rectifier unit with the earthed conductor by means of the earth screw provided
for this purpose.
5.3 Initial start-up and function test
Completely read this chapter every time on initial start-up. More information concerning
display and operating elements can be found in the following section.
For initial operation, proceed as follows:
→ Compare the ratings on the rating plate with the ratings of the supply connections.
→ Check to ensure that all input and output connections have correct polarity.
→ Check to ensure that all connections, contacts and fuses are firmly seated, expulsion
fuses and motor protection switches are switched on.
Please note:
When connecting a charged battery to the rectifier unit, the de-energised filter capacitors
are subjected to a severe shock charging current. Under certain conditions this may cause
the battery fuses to trip. This can be prevented by charging the filter capacitors approxi-
mately to the battery voltage before the battery is connected.
Procedure:
→ Ensure that no loads are switched on initially.
→ Switch on the rectifier unit without battery connected using the equipment switch in
the front door.
The initialisation phase of the rectifier unit takes approximately 30 seconds. Various LEDs
will initially light up during this time but will then change to flashing mode. These fault
messages have no significance at this point (without battery and load connected). This
phase is completed as soon as the LCD displays the value 0 for current and voltage.
Danger!
Switching on a battery in addition to the rectifier unit will cause an arc, which
may cause severe injuries to yourself and others if handled incorrectly. There is
an increased fire hazard.
It is imperative to wear the protective glove with arm protection and safety vi-
sor.
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Do not delay establishing the battery contact. Any delay, any retraction will "draw” an arc
and increase arcing-over and fire hazards.
→ Switch off the rectifier unit with the switch as soon as the initialisation phase has
been completed. The filter capacitors have been pre-charged.
→ Immediately thereafter switch on the battery.
→ Again switch on the rectifier with the switch.
→ Switch on the loads.
During the following initialisation phase, various LEDs will initially start to light up again,
followed by flashing.
At the end of the initialisation phase and on the transition to float charging (basic state of
charge operation) the LCD will alternately display the current rated voltage and the rated
current and only the two green LEDs float charging and operation should be illuminated.
It is possible that the red LEDs battery voltage too low and alarm may light up.
→ Reset all fault messages by pressing the test / reset button.
Subsequently observe the operating condition for some time. If additional fault messages
are displayed, troubleshooting instructions can be found in section 6.4 Faults and error
messages.
Attention!
Connecting a battery that has not been approved to the rectifier unit may result
in damage to the battery and the rectifier unit and subsequently to the load!
As operator and responsible service personnel, exclude any possibility of con-

fusing battery and loads connections!
Following the successful initial start-up, mark the rectifier unit with all necessary details
clearly visible, permanently and legibly:
→ Note down the applicable battery types and loads and possible subsequent changes to
the regulator programme at a suitable place in the interior of the unit and in the tech-
nical documentation in chapter 19 of these Operating Instructions!
→ In particular mark any deviations from the details on the rating plate.
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6 Operation

The rectifier unit THYROTRONIC, more exactly the thyristor bridge, is controlled and op-
erated by way of the Thysat regulator. The regulator is a programme-controlled microproc-
essor.
The display and operating panel in the front of the unit allows the personnel to monitor the
operating status and the specialised electrical personnel authorised and qualified for this
purpose to change the programme settings (see chapter 7 Advanced operation and pro-
gramming).
While the rectifier unit operates normally (Automatic mode), it requires no operator inter-
vention; the rectifier unit operates properly in Float Charging mode if:
the equipment switch is in position I (one),
the LED Unit on in the Test / Reset button is illuminated,
only the two green LEDs Float charging and Operation are illuminated or, alterna-
tively,
only the yellow LED Charging/equalise charging and the green LED Operation are
illuminated and
the LCD alternately displays the present values of unit voltage and unit current and
no red LEDs are illuminated.
The individual operating steps are explained in more detail in the following chapters. Prior
to operating the rectifier unit for the first time, carefully read these chapters.
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6.1 Display and operating panel (4 button panel)
Figure 2 Display and operating panel
Top left: LED bar; left bottom: Test / Reset button with LED Unit on;
Centre right: LCD operating field, four buttons and four LEDs;
Bottom right: Equipment switch off/on (0 I)
The display and operating panel serves to:
indicate fault and operating statuses by means of LED (LED bar and LED in the Test
/ Reset button),
perform unit test and correct faults with the Test / Reset button,
in the LCD operating field:
values are displayed by means of LCD,
settings changed by way of four buttons,
general unit statuses indicated by way of four LEDs.
6.1.1 LCD operating field
LCD
The current operating values and the selected menu levels and menu options and their val-
ues in the case of programme changes are displayed in the LCD.
The menu levels and items with allow monitoring and adjustments or settings to be made,
can be accessed using the 4 buttons beneath the display.
23.12.05- TB-Mo/Obs 21/66 3728 en

E C
Figure 3 LCD and buttons
Buttons
All released statuses and measured values in the LCD can be queried and set with the four
buttons. Safety-critical menu levels can only be accessed by way of a password.
DOWN Select a menu option in a menu level.
In a menu option, select another value.
UP
Confirm a menu option.
Safe a newly selected value.

E
ENTER Call up the next menu level.
Password query.
Leave a menu option without changing the value.

C
CANCEL Call up the next higher menu level.
Figure 4 Meaning of the buttons in the LCD operating field
Operating examples are presented in chapter 18 of the Operating Instructions
6.2 Description of the general menu levels/options
The LCD permits the display of the selected menu levels or menu options and their meas-
ured values.
Large menu areas comprise sub-menu for configuring the regulator. These areas are pass-
word protected.
The following figure shows the freely accessible menu structure:
23.12.05- TB-Mo/Obs 22/66 3728 en

Figure 5 Open menu structure
Main menu
Unless another selection is made, the LCD will alternately display the current standard
values for current and voltage.
Menu items of the freely accessible menu structure:
MESS
The following measured values can be called up in the MESS menu:
U rec Unit voltage

I rec Unit current
I bat Battery current
t bat Battery temperature
t rec Unit temperature
EArtH Earth resistance
15VDC 15 V supply from the DC converter
15VAC 15 V supply from mains
USet Setpoint U
iSet Setpoint I
U2 Second U-channel / voltage behind decoupling diode
b-cAp Capacity last battery test
bttim Time expired last battery test
bt-U Voltage last battery test
i tot Total current rectifier
CHtiM Remaining time AL/L/BT
23.12.05- TB-Mo/Obs 23/66 3728 en

diSP
Three sub-menus are available in the diSP menu (display menu):

LEd-t: The function test of the LEDs can be started from here.
diSP0: Display of the standard measured value of the unit voltage
diSP1: Display of the standard measured value of the unit current
State
The status of the locked-in components is displayed in the State menu.
Menu items of the password protected level 1
This level can only be accessed via menu item "test" and by entering a password in menu
item "P1.000" . The password is a number between 000 and 255 and is selected using the
UP and DOWN buttons.
The standard password set by the manufacturer for menu level 1 is “001”. This prevents
accidental incorrect operation. The customer is advised to change this password as soon as
possible.
tESt
Subject to password protection, the sub-menus of the six operating modes can be accessed
from here: Float charging (EL), charging (LA), equalise charging (AL, not with mainte-
nance free batteries), manual (Man, only necessary with special configuration), direct feed
(dr, only when using the rectifier unit as a power supply unit) and battery (circuit) test (tb
and tbcr).
Menu items of the password protected level 2
This level can only be accessed via menu item "SYS" or "digin" and by entering a pass-
word in menu item "P2.000". The password is a number between 000 and 255 and is se-
lected using the UP and DOWN buttons.
The standard password set by the manufacturer for menu level 2 is “002”. This prevents
accidental incorrect operation. The customer is advised to change this password as soon as
possible.
SyS
Subject to password protection, the configuration settings of the regulator can be accessed
in the SyS menu (system programme).
A complete summary of the programme menu with some explanations is included in the
chapter 18/19.
23.12.05- TB-Mo/Obs 24/66 3728 en

diGin
The binary status of the 64 possible digital inputs of the regulator is displayed in the diGin
menu (digital input). For the input terminal assignment, see the menu explanations in chap-
ter 19.
The sub-menus of the filter flags and the MCU input can be accessed from here subject to
password protection.
Display units include:
LEDs
The four LEDs indicated the general operating modes of the rectifier unit:
green Operation
yellow Battery operation
red Alarm
red Urgent alarm
Figure 6: Meaning of the LEDs in the LCD operating panel
The message Operation indicates the mains power supply of the rectifier unit.
The message Battery operation indicates that any loads are supplied with battery current
(by way of a battery rail, if applicable).
The message Battery operation is illuminated when:
the battery current is negative and
the DC voltage is smaller than the float charging voltage or
does not generate any output voltage (for instance during a mains power failure,
equipment switch off and in the event of a disconnecting fault).
As soon as the message Battery operation is illuminated, the message Operation goes out.
The message Alarm indicate "non-urgent" faults and continued operation of the rectifier
unit is possible. The alarm message is displayed in more detail in interaction with the mes-
sages by way of the LED bar.
Repair of a non-urgent fault should be performed within 24 hours. How to perform trou-
bleshooting, see section 6.4 Faults and error messages.
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The message Urgent alarm indicates faults which restrict or end the operation of the recti-
fier unit. Depending on requirement, urgent alarm messages are coupled with a visual or
acoustic fault signal (aggregate fault). The respective form, for instance a signal tone in a
control centre, depends on the situations on site.
Urgent faults should be repaired immediately. How to perform troubleshooting, see section
6.4 Faults and error messages.
6.2.1 LED bar
In accordance with the standard configuration supplied ex factory, the LED bar indicates
the following statuses:
green Float charge
yellow Boost charge/equalise charge
yellow Battery test
red Mains power failure
red Unit fault
red DC voltage too high
red Battery voltage too low
red Battery test negative
red Battery circuit fault
red Earth fault positive
red Earth fault negative
red (Spare)
red (Spare)
LED test/ reset
Figure 7 LED bar with standard assignment and Test / Reset button with LED
23.12.05- TB-Mo/Obs 26/66 3728 en

The meaning of the 14 LEDs is determined by the configuration file and dependent on the
programming of the regulator.
The basic meaning of the LED colours is defined in IEC 73/DIN VDE 0199. The following
therefore applies:
RED Danger or alarm Warning indicating possible dangers or conditions

requiring immediate intervention or accurate obser-
vation of the condition.
YELLOW Caution Changes or imminent changes of the normal operat-

ing conditions.
GREEN Safety Indicates safe operating conditions or further operat-

ing process release.
Figure 8 General meaning of the LED colours
6.3 Test and reset button

The green LED Unit on is housed in the Test / Reset push button. It is illuminated during
the unit operation. The LED Unit on goes out as soon as the rectifier unit switches off for
whatever reason or is switched off with the off/on unit switch.
A function test of the LED status indication and the LCD measured value display is possi-
ble with the Test / Reset push button. If the button is pushed for at least 3 seconds, all the
LEDs light up. , while all segments of the display are alternately activated in the LCD and
the current software version and address of the regulator are displayed.
Faults can be acknowledged by pressing briefly (reset):
disconnecting fault messages such as overvoltage or unit faults and fault messages
from auxiliary monitoring systems are cancelled, the rectifier unit switches on again,
pending messages, identifiable by flashing LEDs, will be deleted.
6.3.1 Equipment switch off/on
The equipment switch serves to switch the rectifier unit off and on, however without:
disconnecting the connections from mains power supply, battery, load,
switching off the regulator.
6.4 Start-up
The rectifier unit is an installation with permanent connection to the local electrical system
and is therefore always live. The rectifier unit s switched on and off with the Off/On unit
switch; the regulator remains always switched on and registers the operating condition of
the rectifier unit .
For start-up, proceed as follows:
23.12.05- TB-Mo/Obs 27/66 3728 en

→ Switch on the rectifier unit with the switch.
Various LEDs will light up and subsequently flash during the following initialisation
phase.
At the end of the initialisation phase and on transition to Float charging (basic status of
automatic operation), the LCD displays the current voltage and current values. Only the
two green LEDs Float Charging and Operation may still be on.
If the red LEDs Battery voltage too low and Alarm should still be illuminated:
→ Reset all fault messages by pressing the Test / Reset button.
Subsequently observe the operating condition for some time. If additional fault messages
are displayed, troubleshooting instructions can be found in section 6.4 Faults and error
messages.
6.5 Faults and error messages
Faults and the status of the rectifier unit are indicated via the LEDs of the operating and
display panel. The following table gives an overview of the possible fault causes and their
remedies:
LED display Meaning Possible cause Test / Repair
Mains distur- Input voltage fault. Loose or incorrect Check all cables for mechani-
bance connections. cally correct connections.
Check mains voltage at the

rectifier unit terminals.
If available:
Check mains voltage on the
regulator terminals (see wir-
ing diagram).
If available:
Check mains input fuses on
the basic regulator card.
If correct:
Check jumpers X11 to X13
for correct position.
If correct:
Possible defect on regulator
and control unit A1; consult
supplier or manufacturer.
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Unit error Unit output voltage - Mains fault Switch off rectifier unit, con-
too low: tactor K1 drops off.
Less than 2.1 V/cell
and less than 80 % - Mains contactor Check to see if DC voltage
Irated output current. dropped fuse F3(ur) or control fuses
off F1 ave been interrupted.
- Sensor circuit open If correct:

Check all cables for mechani-
cally correct connections
- Regulator failure With 3-phase voltage input:

LED on impulse transmission
card must be illuminated.
- Defective semi- Check disconnection point

conductor (option) in the DC circuit of
the charger (below choke L1).
If correct:
Additional tests only with
separate equipment. consult
supplier or manufacturer
DC voltage too Overvoltage cut-out Dynamic load of the Check dynamic load of the
high through regulator unit regulator too unit regulator.
high.
Incorrect number of Check number of batteries

battery cells. (see unit data sheet).
No set / actual value Regulator possibly defective,

registration by regu- replace.
lator.
Battery voltage - Mains disturbance, Check all points described

too low above.
- Unit fault,
- Short circuit in the

load,
- Battery lines inter-

rupted,
- Battery defective.
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Battery test nega- - Battery not fully - Check all points described
tive charged, above.
- Battery lines inter- - Charge battery.

rupted,
- Check battery and load cur-
- Battery defective. rents.
Battery circuit Battery circuit inter- Check all cables for mechani-
fault rupted cally correct connections.
Check all disconnecting

points or fuses in the battery
circuit for their switching
status.
Check battery for cell break-

age or cell short circuit or
loose/incorrect cell connec-
tors.
Earth fault posi- Earth fault In the case of paral- In a rectifier unit, deactivate
tive/negative lel operation with the leakage current control in
other rectifier units the regulator: See chapter 7.8.
with leakage current
control
With additional Check to see if the rectifier

leakage current con- unit THYROTRONIC has
trols in other system been earthed on one pole:
units If yes:
Deactivate leakage current
control in the regulator:
Operating earth Check if no-earth operation of

connection of the the rectifier unit is provided.
system
Check if there is an earth fault
in the rectifier unit or load.
6.6 Shutting down
6.6.1 Switching off rectifier unit
Shutting down the rectifier unit is not practical or necessary during regular operation.
Should shutting down of the rectifier unit be necessary maintenance or repair purposes,
proceed as follows:
→ Switch off the rectifier unit by placing the unit switch in the position 0.
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6.6.2 Isolating the rectifier unit
In order to isolate the rectifier unit on the primary and secondary sides, proceed as follows:
→ Check to ensure that the rectifier unit has been switched off with the switch or place
the unit switch in the position 0.
→ Disconnect the connections in the following sequence:
to the load,
to the battery,
to the mains power supply.
Please note:
→ Wait for approximately 5 minutes until all voltage-carrying components have been
fully discharged.
→ Ensure the system is de-energised before commencing work on the rectifier unit.
23.12.05- TB-Mo/Obs 31/66 3728 en

7 Advanced operation and programming
7.1 Description of Thysat regulator
The Thysat regulator is a microprocessor-controlled, configurable assembly and serves to

monitor and control the rectifier unit.
Regulation, activation of thyristors, measuring signal processing and provision of supply

voltages takes place on the basic regulator card. Control unit and basic regulator card are
an integral assembly; they are designed to complement each other and function only as a
unit.
Thanks to flash technology and interface, the microprocessor firmware can be updated eas-
ily; see chapter 7.5.1 Flash Programming
Communication:
to other internal bus components such as shunt-connected thyristor units, remote

monitoring system MCU xxx, relay cards,
to the service PC or laptop for the purpose of configuration, querying statuses, meas-
ured values or settings.
The display and operating panel installed in the front panel of the rectifier unit serves to
display measured values such as current, voltage, battery temperature and statuses and to
display and possibly change configuration parameters. Several LEDs signal operating and
error statuses.
7.2 Functions
The functions of the regulator in the standard configuration are as follows:
Six adjustable operating modes/characteristics,
battery temperature compensated float charge characteristic (slope and threshold

point adjustable; function only available with separate temperature sensor,
unit temperature-dependent unit current reduction to 60% of rated current (operating

point adjustable by way of GSR unit temperature too high; function only available
with separate temperature sensor,
mains control with linked alarm (time delay of the alarms adjustable),
unit control with linked alarm and issue of an aggregate message,
current-dependent automatic charging (recharging time and limit value current limi-
tation adjustable),
current-dependent compensation of the voltage drop on the line to the battery

(I x R compensation),
possibility of replacing internal mains monitoring by an external mains monitor,
23.12.05- TB-Mo/Obs 32/66 3728 en

voltage adjustment (UrEG adjustment),
serial RS485 (internal bus) interface for communication of several shunt-connected

rectifier units,
serial RS232 interface for communication and programming by way of laptop/PC,
display of measured values (for instance current, voltage, battery temperature) and
statuses and characteristic changeover or display and change of configuration pa-
rameters by way of the display and operating panel,
static current limitation: Irated % of rated unit current,
current limitation battery circuit: Irated % of rated battery shunt value,
current-dependent voltage adjustment.
7.3 Hardware
7.3.1 Serial interfaces
Two serial interfaces are available. The data traffic can be visually monitored through
light-emitting diodes (H60, H61 for internal bus, H62, H63 for RS232). Yellow signals re-
ceived data, red signals sent data.
Internal bus interface RS485
A serial interface according to RS485 standard can be connected (internal bus) to the
plugs/ports X1, X2, X201, X202. It enables the communication of the internal busable
manufacturer components among each other. This interface operates at 9600 Baud; it uses
8 data bits, even-parity bit and stop bit.
Completely designed screened cables are available under:
TN: 734365 both sides RJ45 8-pin plug, 1 m
TN: 734366 both sides RJ45 8-pin plug, 2 m
TN: 734367 both sides RJ45 8-pin plug, 3.5 m
TN: 734368 RJ45 8-pin plug / 4-pin DIN plug

(previous SAT connection), 2 m
23.12.05- TB-Mo/Obs 33/66 3728 en

Diagnostic interface RS232
An interface according to RS232 standard with 9-pin SUB-D plug (male/pin contacts) to
X102 is available for programming and configuring the regulator and for error querying on
site. The interface operates in standard operation at 9,600 baud, 8 data bits, no parity and a
stop bit.
During flash programming, the RS232 interface is operated at 19,200 baud, 8 data bits and
even parity.
The interface cable for the service PC is a twisted RS 232 cable. Both ends of the cable
must be fitted with 9-pole SUB-D sockets (female).
It is practical to use a commercially available "zero modem cable” to ensure that both 9-pin
D-SUB ports are connected identically and the cable can be turned around.
A fully ready-to-use cable can be ordered under the following number:
TN: 734624 Link cable RS232/DB9 FEM./FEM. 3 m.
I²C bus
The I²C bus interface is basically a third serial interface. It serves to connect the I²C bus
peripherals (the display and operating panel with 14-way LED card with buttons, LCD
card with 4 LEDs and 4 buttons) by way of a 5-core cable.
By way of these peripherals it is possible to display error and operating statuses (LED,
LCD) or measured values (LCD card), and change threshold values, settings, charge
statuses, battery test, etc., (button on LCD card). It is connected to the plugs X100, X101.
The I2C bus must always be installed separate from other lines and only within the unit.
The line length should be kept as short as possible.
Detailed information concerning operation of the display and operating panel are furnished
in chapter 6.1 Display and operating panel.
7.3.2 Digital inputs

11 digital inputs are connected to X36 (X36.1-X36.11) which in connection with the also
connected 15 V supply (X36.12 or X11) are able to generate a signal. If the inputs are not
connected, a low signal is active by way of an internal pull-down resistor.
If connected externally, a contact current of approximately 10 mA will flow. In this way it

is possible to use standard relays. The inputs and battery bus are not floating-type inter-
connections. It is imperative to avoid coupling to external potential!
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7.3.3 Analogue inputs
The Thysat regulator has 11 analogue inputs. 6 of these are registered and processed on the
basic regulator card (unit voltage, unit current, battery current, resistance to earth, 15 V
supply system, 15 V supply DC). 3 measured values are directly connected and processed
on the regulator (second U-channel / bus voltage with parallel operation, battery tempera-
ture, unit temperature). Two measured values (setpoint U and I) are registered internally in
the regulator.
In addition to this, 5 measured values are calculated internally (used up capacity, duration
and last voltage last battery test, total rectifier current and remaining time (LA/AL/B test).
When connecting the second U-channel it is imperative to place the jumper X401 accord-
ing to the voltage range and to specify this in the configuration!
7.3.4 Error message relay
The Thysat regulator has 4 relays. Three relays each with a two-way switch are provided
for wire-bound error messages. A relay is used to activate the mains contactor. The relay
status is indicated by the LED situated directly below the corresponding relay in the unit. If
an LED is on, this means relay is energised. The relays are rated 8A for AC 15...250V, 8A
for DC 24V and 0.2A for DC 220V. If required, additional relays can be accessed by way
of the internal bus.
7.3.5 Manual operation as emergency mode
In addition to the normal operating modes the regulator has also a manual operation mode.
It serves as an emergency function in order to ensure the supply even if the microcontroller
should be faulty or fail. In this mode, the U and I setpoints are switched over to analog val-
ues; the regulator and pulse blocking is disabled and the relay which controls the mains
contactor is energised. Should the microcontroller fail, the system changes automatically
over to manual operation by way of an external monitoring logic (watchdog).
In the case of malfunction and to set the setpoints in manual mode it is also possible to
change over manually. This is done removing jumper X302 on the upper regulator board.
By way of the emergency potentiometers R304 and R305, set the setpoints for U and I
manually (see component diagram of the regulator).
Correct monitoring (sensor wire breakage, unit fault) may no longer be performed in man-
ual mode under certain conditions since the microcontroller is no longer able to influence
the rectifier unit THYROTRONIC.
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7.4 Assignation of connection terminals
In the standard version, the regulator terminals are assigned as follows. However, the as-
signment may vary depending on the unit design:
Input terminal X36
X36.1 External input 1

X36.4 External unit fault
X36.5 Unit off via switch
X36.7 Equalise charging lockout
X36.8 Boost charging lockout
X36.9 Battery (circuit) test lockout
Relay connections X10-X13
X10.1 K1, battery undervoltage, NCC

X10.2 K1, battery undervoltage, common
X10.3 K1, battery undervoltage, NOC
X11.1 K2, aggregate message urgent fault, NCC
X11.2 K2, aggregate message urgent fault, common
X11.3 K2, aggregate message urgent fault, NOC
X12.1 K3, mains contactor activation, NCC
X12.2 K3, mains contactor activation, common
X12.3 K3, mains contactor activation, NOC
X13.1 K4, mains fault, NCC
X13.2 K4, mains fault, common
X13.3 K4, mains fault, NOC
I2C-Bus X100, X101
X100.1=X101.1 +8 V
X100.2=X101.2 SDA (data line)
X100.3=X101.3 SCL (clock line)
23.12.05- TB-Mo/Obs 36/66 3728 en

I2C-Bus X100, X101
X100.4=X101.4 I2C_Int (interrupt request / press button)

X100.5=X101.5 GND
X1, X2, X201, X202
SAT-Bus RS485
Service interface RS232 X102
X102.2 RXD
X102.3 TXD
X102.4 DTR, internally bridged with X102.6
X102.5 GND
X102.6 DSR, internally bridged with X102.4
X102.7 RTS, internally bridged with X102.8
X102.8 CTS, internally bridged with X102.7
Connections to basic regulator card X5, X4, X7:
X5.1 +8V supply

X5.2 Measured value +15V mains
X5.3 +15V supply
X5.4 -15V supply
X5.5 Measured value +15V DC
X5.6 GND
X5.7 GND
X4.1 U unit
X4.2 U earth
X4.3 I battery (only when battery shunt connected)
X4.4 I unit
X4.5 +U unit
X4.6 Mains fault
X7.1 Setpoint U
X7.2 Setpoint I
X7.3 Impulse trap
X7.4 GND
23.12.05- TB-Mo/Obs 37/66 3728 en

Connections to basic regulator card X5, X4, X7:
X7.5 Regulator lockout
If a battery shunt is connected, the jumper X41.1-2 must be inserted! The measured value
earth resistance is activated on the basic regulator card by way of the jumpers X300, X301,
X302.
In parallel operation, the measured values battery current (for battery current limitation),
battery temperature and earth resistance may be present only once. In parallel operation
with decoupling diodes, the second U-channel/rail voltage must be connected with all units.
Measured value connections X20, X21, X400
X20.1 +Battery temperature sensor
X20.2 Battery temperature sensor GND
X21.1 +Unit temperature sensor
X21.2 Unit temperature sensor GND
X400.1 + Second U-channel / rail voltage with parallel operation using decoup-
ling diode
X400.3 - Second U-channel /
Jumper for connected battery shunt
X41.1-2 Battery shunt connected
Jumper for second U-channel
X401 open Voltage range 0..500V
X401.1-3 Voltage range 0..250V
X401.3-5 Voltage range 0..125V
All measuring inputs refer to the common potential U-unit
Test bridge
X40.1-2 Test bridge
Some parameters of the regulator (rated values, calibration, etc.) can only be changed with
the test bridge inserted.
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7.5 Software
Monitoring and settings of the thyristor bridge can be performed even without service
software. The menu overview of the regulator programme with explanations of the indi-
vidual menu options is added in chapter 18.
7.5.1 Flash Programming
Thanks to flash technology, the microprocessor firmware can be updated easily via the RS232
interface, using a laptop/PC. There is no longer any need to replace the EEPROM.
The flash programming requires jumper X61 to be plugged in!
The reprogramming is done by the PC programme 'flash.exe'.
Parameters: 8 data bits, 1 stop bit, even parity, no data link control, 19200 Baud.
'Boot block backup' should be active; Command (flash.ini 'boot block command'):
96990
Command for the switch-over to flash reprogramming (flash.ini 'command'): 96991
Execution of the flash reprogramming:
Select of a new HEX file from the program 'flash.exe'
Enter the unit address into the program 'flash.exe'
The button 'Transfer' starts the flash reprogramming
If 'backup boot block' is active, this is signalled visualising 'Flash' and 'to.EEP'
During the program transfer, the SMD-LED H60 flashes
Finally, a reset should be triggered; the Thysat will then start with the new software.
It may be necessary to reconfigure the Thysat, if new EEPROM cells have been
added in the new program version.
If the flash reprogramming was not successful (and the programme does not re-
start after reprogramming and reset / no LCD display etc.), it is possible trying
to access the flash boot programme via an "emergency jumper" and to initiate
another flash reprogramming sequence. To do so, switch the Thysat dead and
insert the emergency jumper X25. Then, reconnect the Thysat to the supply
voltage. The SMD-LED H60 will flash twice. Next, the reprogramming can be
carried out using the programme 'flash.exe'. In this case, neither can the boot
block be backed up, nor will the changeover to the reprogramming mode be
confirmed. The jumper X25 must be removed again before the reset is trig-
gered!
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7.6 Switching-on process on the regulator
Programme start commences as soon as the control card is supplied with voltage by the ba-
sic regulator card. The SMD LEDs H5, H6 and H500 to indicate supply voltage available
are illuminated.
The regulator receives a stop signal while initialisation and a 5-second LED test is being
performed. The display alternately shows Init and all segments. If the EEPROM has not
yet been initialised, EEPROM initialisation with display -EEP- follows after two seconds.
Subsequently the software version followed by the unit address will be displayed subse-
quent to that. The standard operation then starts.
The basic charge condition is Float charging. Following an initialisation phase (in stand-
alone mode; no other internal bus subscribers; can be shortened by pressing the Test / Reset
button) lasting approximately 30 seconds, the rectifier unit runs up to the output voltage set
for float charging if the unit address is unequal to zero.
7.7 Operating modes – charge statuses
The abbreviations from the menu used here (like tESt) refer to the 4 button operating
panel.
If the ABE operating panel is fitted, please refer to chapters 13 and 15 for access to the
menu items.
Manual operating mode selection

The desired operating mode can be selected manually in the tESt menu at any time (pass-
word required). The unit switches over instantly.
If another rectifier unit is shunt-connected by way of the internal bus and the operating
mode has not been selected on the master, changeover may take some time until the
changeover command has been sent by way of the bus.
All automatic operating mode changeover operations take place only from Float charging!
7.7.1 Float charging
Float charging is performed with a defined set voltage per cell, depending on the re-
chargeable battery type (exact details see equipment data sheet). This is the basic charge
status at every start.
7.7.2 Charging
With the option Automatic charging switched on, switching takes place automatically. The
trigger for changing over to charging is the presence of the battery or unit current limita-
tion for more than 30 seconds.
Switching back is always automatically in order to prevent continuous charging. Once the
current has dropped below the current limitation threshold (0.8 x Irated) and below the bat-
tery current limitation threshold the system switches back immediately.
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If a recharging time has been programmed, switching back to float charging takes place af-
ter the set time (recharging time). In the event of a mains power failure the expired re-
charging time is not protected. Upon return of the mains power float charging and change-
over takes place according to the current measuring signals.
Manually it is possible to start charging also from the menu by way of the operating field.
If jumper X36.8-X11 (AL lock) has been removed from the regulator, Charging is disabled
(see data sheet of the unit).
7.7.3 Equalise charging
Equalise charging is the start-up mode for non-maintenance free batteries to form the bat-
tery cells. Equalise charging takes place with a defined set voltage per cell depending on
the rechargeable battery type (exact details see equipment data sheet) and with
IMax= 0.2 x Irated (in the normal case).
Equalisation charging can only be started manually by way of the operating field. The set
equalise charging time (adjustable in the menu Sys/deLay/ALdeL) starts to run down im-
mediately.
The expired equalise charging time is protected in the event of mains power failure; upon
return of the mains power, equalise charging continues at the time of interruption. Follow-
ing time-controlled or manual changeover from equalise charging to Float charging, no
overvoltage query is performed for 10 seconds.
If jumper X36.7-X11 (LA lock) has been removed from the regulator, Equalise Charging
is disabled (see data sheet of the unit).
7.7.4 Direct feeding
Direct feeding is the operating mode for pure load feeding. Direct feeding is done at
USetl = 2.0 V/cell and IMax = Irated. Start and stop need to be triggered manually.
7.7.5 Battery test
A battery test is done at USetl = 1.8 V/cell and IMax=Irated. There are 4 types of battery tests:
Manual battery test
Start is performed manually and stoppage is automatic on reaching the battery test period
(battery test positive) or the set cancellation voltage (battery test negative).
Manual battery circuit test
Start is performed manually and stoppage automatically on reaching the battery circuit test
period (for instance 10 seconds, battery circuit test positive) or the set battery circuit can-
cellation voltage (battery circuit failure).
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Automatic battery test
This is automatically started at fixed intervals (for instance every 3 months) and stopped
automatically on reaching the battery test period (for instance 3 h, battery test positive) or
the set cancellation voltage (battery test negative).
Automatic battery circuit test
This is automatically started at fixed intervals (for instance every 24 hours) and stopped
automatically on reaching the battery circuit test period (for instance 10 seconds, battery
circuit test positive) or the set battery circuit cancellation voltage (battery circuit failure).
The interval for the automatic battery (circuit) test is not re-triggered by a manually trig-
gered battery (circuit) test, i.e. the next starting date for automatic battery (circuit) test re-
mains intact.
During the battery test (not during battery circuit test), battery voltage, duration of the bat-
tery test and Ah withdrawn (with connected battery shunt) are recorded.
If bridge X36.9-X36. on the regulator (BT lock) is removed, the battery test characteristic
is suppressed.
7.7.6 Manual
This is the sixth possible operating mode/voltage level. It is started and stopped manually.
This operating mode is only required and programmed for special configurations (for in-
stance for use in power stations for rectifier coupling).
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7.8 Parallel operation of two rectifier units
There are several configurations to support parallel operation of multiple units. This requires
each unit to be equipped with block-type diodes!
Configuration 1
Two independent units are each fitted with block-type diodes at the rectifier output. Each unit
has a battery output and a consumer load output.
Both units supply with their respective output one common battery.
See block diagram 1
Diagram 1
Both units may operate simultaneously. A parallel operation line (synchronising line) between
the two regulators is not required. In one of the units, the earth fault monitoring needs to be
disabled. The function battery circuit monitoring may be used. However, no battery availability
test can be performed since the devices do not share one common battery shunt. If this function
is kept active on both units, status report errors may occur.
23.12.05- TB-Mo/Obs 43/66 3728 en

Configuration 2
Two independent units are each fitted with block-type diodes which are however switched in
the consumer load circuit. Each unit disposes of a separate battery, both are switched in paral-
lel with the consumer load circuit.
Diagram 2
Configuration 2: Only the consumer loads are switched in parallel. Each unit disposes of a
separate battery. A parallel operation line (synchronising line) is not required. In one of the
units, the earth fault monitoring needs to be disabled. The function battery circuit monitoring
may be used. The function battery availability test can be used since each unit has an own bat-
tery.
Configuration 3
This is a system which is specifically designed for parallel operation. It features a single bat-
tery output and one (or several) common consumer load outputs.
See block diagram 3
Diagram 3
Configuration 3: Here, both units are designed for fully synchronised parallel operation. A par-
allel operation line (synchronising line) between the two regulators ensures equal load distribu-
tion. It is included in the delivery scope. All parameters are preset accordingly.
23.12.05- TB-Mo/Obs 44/66 3728 en

Configuration 4
Both units feed one common battery shunt via their battery outputs. Here, the measuring circuit
is connected to one unit and analysed there.
See block diagram 4
Diagram 4
Configuration 4: If the devices are on site wired like this, the shunt line to the regulator needs
to be removed on the second unit. Furthermore, jumper X41 must be removed from the upper
regulator board. On one unit, the earth fault monitoring must be disabled. The two regulators
need to be connected via a parallel operation line (synchronising line). (SAT bus)
If units, which do not correspond to configuration 3, are interconnected on site, you need to
make the following changes and settings:
Since both units come standard with earth fault monitoring, this monitoring function must be
disabled on one of the two units. Otherwise, the earth fault monitoring systems will measure
erroneous values. To do so, proceed as follows:
On the regulator:
→ Remove jumpers X8, X300, X301, X302

all jumpers are located on the lower board !!!
In the rectifier unit
→ Remove the cable link from terminal panel X 3: Between terminal No.100 and PE
Configurations 3 and 4 require a temperature sensor on the first unit only for battery tempera-
ture-guided charge.
23.12.05- TB-Mo/Obs 45/66 3728 en

8 Messages
8.1 Mains power available
Following the expiry of the switching-on delay following a mains power failure, the regulator
is enabled if no overvoltage is present and the unit has not been switched off with the switch.
If the rectifier unit is switched off, the regulator and pulse blocking is set; the mains relay de-
energises. The LED in the push button is off; all monitoring operations except for unit failure
and sensor breakage are performed.
8.2 Mains disturbance
The stop signal is set on the regulator; the mains relay de-energises. After 60 seconds, the low-
priority fault message is issued; after 30 seconds, the signalling relay Mains fault de-energises.
The message is then maintained (LED flashing, if the phase error is no longer active) until it is
reset by way of the Test / Reset push button. All queries are active.
The message Mains power failure is generated on the basic regulator card and passed on to the
thysat control card as a digital signal. The response threshold can be set with the potentiometer
on the basic regulator card.
8.3 Unit failure
A unit failure is output if no battery or unit current limitation is present with running unit de-
spite a drop below the set voltage value by >0.1V/cell (with Pb).
Sensor cable breakage is additionally monitored if
the actual voltage value is approximately 0 V (< 0.3 V/cell with Pb) despite battery or
unit current limitation or
the set voltage value is exceeded by > 0.2 V/cell (with Pb) despite battery or unit current
limitation.
The message sensor breakage and unit failure will then be issued. The message is held (LED
flashing, if the unit failure is no longer active) until it is reset with the Test / Reset button.
8.4 Current limitation (optional)
If the current limitation was active (standard: 90% of ISet-rated, e.g. with current peaks through
additional connection of loads), the charge waiting time is started for 30 seconds.
8.5 Battery charging current limitation (optional)
If the battery charging current limitation was active (standard: 90% of ISet-Batt), the 30-second
charge waiting time will start. If the battery current is not measured (no battery shunt con-
nected), the battery charging current limitation <IBatt is by default not active and no overvoltage
is queried until 10 seconds later.
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8.6 DC voltage too high
If an overvoltage is present (i.e. more than the defined set voltage per cell, which depends on
the accumulator type - for detailed specifications, see the unit's data sheet), the regulator block-
ing is set within an interval of < 10 msec for approximately 200 msec and then, the unit
changes over to the basic operating mode Float charging. If the message DC voltage too high
occurs four times within 30 seconds, the regulator lock and the relay aggregate message (ur-
gent alarm) will be activated, the mains power relay drops off. The messages can only be reset
by pressing the Test / Reset button. The message is held until the button has been pressed
(LED flashing, relay drops off, if the overvoltage is no longer active). During Equalising
charge and until approx. 10 seconds after termination of equalising charge, the condition over-
voltage is not queried.
8.7 Battery voltage too low
If less than the defined set voltage per cell is available depending on the rechargeable battery
type (exact details see equipment data sheet), the message battery voltage too low is output
without delay by way of LED and relay. It will only be deleted on exceeding the hysteresis
limit (<<U +0.2V/cell). However, the LED message is retained flashing until it is reset with the
Test / Reset button.
8.8 Aggregate message (relay contact)
An aggregate message is output if one of the faults is indicated as urgent alarm for instance
DC voltage too high or
Unit failure.
8.9 Option 1 – 6
If the optional inputs of the regulator are selected by external contacts, the relevant LED is il-
luminated. If the option is no longer present, the LED starts to flash. The message is retained
until it is reset with the Test / Reset button. All options are monitored also in the event of mains
power failure. As an option it is possible to programme a relay on the relay card.
8.10 Switching-on and off behaviour – impulse and regulator lockout
The regulator has several options of switching off the entire unit or reducing the output voltage
to zero. Impulse lockout, regulator lockout, mains power contactor selection and default set-
points for U and I.
With the regulator lockout the set regulator value at the aggregate point is reduced to zero very
rapidly. This corresponds to a default setpoint of zero for U and I, but acts at the aggregate
point and consequently without regulating delays.
The impulse lockout prevents that any impulses are output to the thyristor bridge.
Switching on procedure:
− Setpoints U and I are at zero,

− mains power contactor picks up,
23.12.05- TB-Mo/Obs 47/66 3728 en

− impulse lockout is deactivated after approximately 0.5 seconds,

− regulator lockout is deactivated,
− Setpoints U and I are activated by way of low pass function.
switching off procedure:
− regulator lockout is activated,

− Setpoints U and I are reduced to zero,
− impulse lockout is activated after one second,
− the mains power contactor drops off after 2 seconds (relay delay).
When switched off briefly (temporary overvoltage), only the regulator lockout is activated for
approximately 200 msec.
8.11 LED board
LED card jumper encoding:
The LED board is encoded for address 0 (upper 8 LED's, no jumper on X3) and 1 (lower
LED's, jumper on X4.1-2) in standard configuration.
8.12 Configuration
Most settings of the regulator can be configured by way of the diagnostic interface and saved
in the EEPROM.
8.13 Digital inputs
64 digital inputs exist (external contacts and other detectable events called virtual inputs, e.g.
switch over to direct feed, battery test,etc.). These are all processed in a filter matrix according
to Figure 9, Filter matrix for digital input signals and events.
Figure 9 Filter matrix for digital input signals and events
Ext. Eingang external input

ext. Gerätefehler external unit fault
MCU Eingang MCU input
23.12.05- TB-Mo/Obs 48/66 3728 en

Symbol Meaning
Generally enabled
Linked with aggregate message urgent alarm
Linked with aggregate message non-urgent alarm
Linked with aggregate message mains power contactor off
Switch off module (temporary, automatically switched on again

after fault correction)
Switch off module (permanently, must be switched on again by

way of button)
Send input to MCU input xy (input designation of the MCU at

the very right)
8.14 Limit value monitoring (GSR relay)
Nine limit value monitoring instances act on each fixed measured value (see figure 10 Limit
value monitoring and filter matrix for analogue measured values). To do so there is an adjust-
able threshold (UG or OG) and a hysteresis value. Leaving the outer limit band generates an
event according to figure 11 Filter matrix for digital input signals and events, entering the in-
ner limit band will again delete the event.
23.12.05- TB-Mo/Obs 49/66 3728 en

beliebiger Meßeingang
OG
H
Grenzwert-Überwachung
H
UG Schwellen einstellbar
generelle Freigabe (0)
Eingang invertieren (5)
Verkn. (1) Verkn. (2) Verkn. (6) Meldetext (3) Meldung (4)
SVA SVB SVC einfügen auslösen
benutzerdefinierte
Meldung
Meldeprotokoll
Figure 10 Limit-value monitoring and filter matrix for analogue measured value
Beliebiger Meßeingang any measuring input

Grenzwert-Überwachung limit value monitoring
Schwellen einstellbar thresholds adjustable
generelle Freigabe (0) generally enabled (0)
Eingang invertieren (5) invert input (5)
Vernk. link
Meldetext (3) einfügen insert message text (3)
Meldung (4) auslöschen trigger message (4)
benutzerdefinierte Meldung user-designed message
Meldeprotokoll message record
23.12.05- TB-Mo/Obs 50/66 3728 en

8.15 Relay functions:
Up to 11 relays each can be connected to one of the 64 digital inputs and individually inverted,
provided with hold function and delayed (see figure 11 Relay wiring to one input).
Eingänge und Ereignisse / Zustände
Multiplexer 1 aus 80 Ruhestrom oder Laststrom
Relais 1 - 10
Figure 11 Wiring of the relay to one input
Eingänge und Ergebnisse / Zustände inputs and events / statuses

Multiplexer 1 aus 80 multiplexer 1 from 80
Ruhestrom oder Laststrom no-load current or load current
Relais 1 - 10 relay 1 - 10
Four relays are situated directly on the regulator and additional ones can be furnished. As an
alternative it is also possible to connect data bus relay cards for linking with the inputs.
8.16 LED functions
Up to 18 LEDs (14 on the LED card, 4 on the LCD card with buttons) each can be connected
to one of the 64 digital inputs and be individually inverted, equipped with hold function and
delayed.
8.17 Measured values
12 measured values are always available:
0 Voltage
1 Current
23.12.05- TB-Mo/Obs 51/66 3728 en

2 Battery current
Battery current is registered bidirectionally so that for instance Ah-balancing in the bat-
tery test can be performed through the discharging current.
In parallel operation, the battery current is only displayed by the master and the unit to
which the battery shunt is connected.
The battery shunt must be dimensioned so that the maximum charge and discharging
currents can be measured.
3 Battery temperature
4 Unit temperature
Should no temperature sensor be connected to the rectifier unit, 20°C battery/unit tem-
perature or the reference temperature will be displayed in the LCD.
5 Earth resistance
If the earth resistance measurement should not be enabled, the LCD display will indicate
an earth resistance of 100 MΩ.
The earth resistance measurement requires the following parameters to be met:
Unit in stand-alone operation.

Set the jumpers X300 and X301 on the lower regulator board according to the following
table. Valid jumper assignment for earth faults:
X300, X301 18 to 60 V 33 to 120 V 80 to 330 V
1–2 - 80 V 220 V
3–4 36 V 60 V 110 V
5–6 24 V 48 V -
23.12.05- TB-Mo/Obs 52/66 3728 en

9 Settings
9.1 Unit address (Adr)
The unit address is assigned automatically during the initialisation phase of the rectifier unit
(satellite). For this reason, no manual setting of the unit address is required as a rule. A manual
unit address change is nevertheless possible in the system menu.
A setting range of address 1 - 24 is possible.
A unit with address 0 cannot become master and must be manually changed over!
9.2 Settings - options
This menu is used for activating or deactivating the following functions: These are:
rEGu Voltage adjustment (Default OFF)
tEMP Battery temperature-guided (Default OFF)

charge
booS Automatic charging (Default ON)
Errh Fault holding function (Default OFF)
9.3 Voltage adjustment (U-rEG)
The output voltage is measured constantly (actual value) and compared to the desired value.
(In the case of parallel operation with decoupling diodes, the bar voltage is measured which is
detected via the 2nd voltage channel.) Deviations are balanced out (gradually). In this way,
unit-internal temperature drift or slight errors in rectifier calibration can be compensated.
At the same time, units interconnected by a parallel operation line (synchronising line) perform
a control action which ensures an equal load balance among the units. To do so, the unit with
the greatest deviation from the mean unit current is selected from among the switched on units
and the voltage slowly increased or decreased.
Parallel operation regulation does not take place when the units are subject to battery charging
current limitation!
Mixed equipment (different nominal currents) is not allowed.
9.4 Battery temperature-inclined characteristic (tEMP)
If required, the maintenance-charge characteristic can also be temperature tracked. If this op-
tion is disabled, the unit will run with the set nominal voltage (for instance B. 2.23V/cell).
With temperature compensation enabled, the starting point (reference temperature, standard 20
°C) and the characteristic inclination (standard 4mV/cellK) must still be set. Compensation
takes place in both directions and thus, depending on the actual temperature, leads to increase
or decrease of the output voltage.
23.12.05- TB-Mo/Obs 53/66 3728 en

The voltage limit values (<<U, >U etc.) remain constant and may be reached under certain
conditions!
9.5 Fault holding function (Err-H)
If a fault occurs in the rectifier unit, this will be signalled by way of the serial RS485 interface.
The fault (e.g. breakage of temperature sensor) is cancelled once it has been corrected. How-
ever, if the option is activated (for instance for troubleshooting), all fault occurrences will be
saved. This option is not identical with the holding function of the LEDs or relays!
The faults can be deleted by deactivating the fault holding function.
9.6 Flags
Parallel operation:
"Parallel operation with decoupling diode" together with "inclined characteristic"
These two settings configure the regulator in a way that it will feed a common bar together
with another unit via a decoupling diode.
Both flags must be set. In this operating instance the second voltage channel of each unit must
register the rail voltage. The set voltage values are increased by the constant value 0.8 V in or-
der to compensate the voltage drop on the diode and to maintain the set voltages on the rail.
The voltage adjustment acts on the second voltage channel. The voltage monitoring with bat-
tery (circuit) test acts on the second voltage channel. (Regulator terminal: X 400 Pluss)
9.7 Time delays (dEL’S)
Seven time delays are adjustable in the unit. These are listed below:
− urgent failure,
− non-urgent failure,
− aggregate message for mains power contactor (should stay = 0),
− on-delay following mains power failure (cascaded switching on of several units to avoid
mains load peaks),
− delay sensor breakage,
− equalise charging time,
− charging time.
23.12.05- TB-Mo/Obs 54/66 3728 en

10 Maintenance
10.1 General

operated by skilled and trained specialised personnel.

opened, repaired and possibly disassembled by qualified electricians!
All information in chapter 2.7 Safety instructions for troubleshooting and maintenance
must be observed and adhered to.
The chapter Maintenance comprises the areas visual inspection and cleaning as well as
maintenance and repair of the rectifier unit through qualified electrical personnel.
The specified maintenance interval of one year refers to the continuous operation of the
rectifier unit. The details described in that chapter must be considered as minimum recom-
mendations. Depending on the operating conditions, these instructions may require expan-
sion in order to ensure the serviceability of the rectifier unit.
Special additional and supplementary information can be taken from the accompanying
documents of the rectifier unit and the chapters 18/19 of these Operating Instructions.
10.2 Inspection and maintenance

The rectifier unit must be inspected at least once per year and in the event of deviations
from the normal operating behaviour and maintained if applicable.
Following major maintenance measures, all measured values must be verified with a preci-
sion instrument following the start-up of the rectifier unit.
10.3 Cleaning
Avoid damaging transformer windings and chokes.
• You can remove dust or dirt in the rectifier unit with a brush and vacuum cleaner.
10.3.1 Terminals and plug connections

→ Check the terminals and plug connections and tighten if required.
23.12.05- TB-Mo/Obs 55/66 3728 en

→ Inspect the plug connections for clean contact surfaces, pull relief and correct engage-
ment.
10.3.2 Contactors, relays

→ Check the contactors for ease of operation by pushing on by hand. (Remove the arc
chamber beforehand, if necessary.)
→ If necessary, remove any foreign bodies by removing the contactors concerned.
→ Check the condition of the protective contacts: Remove burns (welding splatter) with a
suitable file. Do not use emery cloth or sandpaper for that purpose.
→ Never grease contacts!
Dark, discoloured switch gear does not impair the operation.
10.3.3 Monitoring installations

→ Check the response values of the monitoring functions of the regulator.
The response values can be found in the technical documentation in chapters 18/19.
10.4 Exchange of electrolyte capacitors

In order to retain the smoothing requirements, the electrolyte capacitors must be replaced
after 10 years of operation.

Before commencing work, disconnect the rectifier unit from all primary and secondary
connections.
To do so, proceed as described in chapter 6.5 Shutting down.
In case of doubt or with regard to questions concerning the procedure, consult the manu-
facturer or supplier.
10.5 Changing the regulator programme

The programme of the regulator has been preset at the factory. If any changes are neces-
sary, please contact the manufacturer.
10.6 Spare parts

Please contact the manufacturer or supplier quoting the unit data from the rating plate
should your require replacement parts.
23.12.05- TB-Mo/Obs 56/66 3728 en

11 Disposal
If the rectifier unit is finally taken out of service at the end of its life, adhere to the laws
and regulations concerning disposal applicable at that time.
Detailed information in this regard can be obtained from the specialist disposal operations
or the responsible authorities.
Attention!
Electronic scrap with its various plastic, metal and heavy metal components possesses a
high hazard potential for the environment. For this reason electronic scrap must be col-
lected and disposed off separately from domestic and commercial waste.
Electronic scrap should be disposed of to the internal disposal section who will pass on the
scrap to special companies (specialist disposal operations).
The rectifier unit packaging must be disposed of separately. Paper, cardboard and plastics
must be recycled.
11.1 Batteries
Important!
Old batteries contain heavy metals and caustic chemicals which may not enter into the en-
vironment. Battery manufacturers are obligated to take these back and to dispose of them
free of charge.
Dispose of old batteries in the collection containers provided for this purpose or contact
your battery supplier.
23.12.05- TB-Mo/Obs 57/66 3728 en

12 Regulator menu overview
23.12.05- TB-Mo/Obs 58/66 3728 en

13 Explanation of menu options
Delays
SadEL SVA Delay [s]
SbdEL SVB Delay [s]
ScdEL SVC Delay [s] (aggregate message mains power connector)
LAdEL Recharging time [s]
ALdEL Equalise charging time [s]
ondEL Switch-on delay following mains power failure [s]
SEnS Delay sensor breakage [s]
Flags
0 droP addicted characteristic/parallel operation cable
1 SenS U-regulation by way of MCU sensor
2 to 5 b2 to b5 Currently not supported
6 diod Parallel operation via decoupling diode; Voltage
setpoint + 0.8 V
7 to 15 b7 to b15 Currently not supported
Options
0 ReGu Regulator/voltage adjustment, also parallel operation regula-
tion/current distribution
1 temP Temperature-controlled characteristic
2 o2 Currently not supported
3 boos Automatic charging
4 Errh Enter hold function (status error not self-deleting)
5 PoWM Power management, units can be switched off/shut down
selectively
Dig_Inputs
Dig_Inputs
23.12.05- TB-Mo/Obs 59/66 3728 en

GSR relay
G <<U Undervoltage (Std:1.8 V/cell)
G >U Overvoltage (Std: 2.5 V/cell)
G >I Current limitation (Std: 90 % of unit rated current)
G >Ib Current limitation battery (Std: 90 % of battery rated current)
G <r Earth fault (Std: 0.5 MΩ)
G >tG Unit temperature too high (Std: 70 °C)
GSR.E1..3 Free GSR 1..3
input Measured value input
lo hi Monitoring value for exceeding upper or lower limits (lo.liM) (hi.liM)
limit (Lower/upper) limits
HySt Hysteresis
LED, relay hold functions

inPut Digital input of the Thysat
inV Inversion
dELAy Delay
hoLd Hold function
Current limitations
i MAX Unit current limitation in % of rated unit current
i bAt Battery charging current limitation in % of the battery shunt rated current
i MAX Unit current limitation in % of rated unit current
Calibration
FAct Factor/Setpoint
ZEro Offset compensation
rESEt Resetting calibration values
23.12.05- TB-Mo/Obs 60/66 3728 en

Error flags
0 Satellite in self-test
1 Module in configuration phase
2 Watchdog reset
3 Bus error
4 Master time-out
5 Fan fault
6 Illegal command received
7 Current failure
8 Temperature sensor failure
9 Mains fault
10 Subscriber fails to answer
11 Module failure
12 Module switched off due to overvoltage
13 Module switched off due to overtemperature
14 Module switched off with switch or remote
15 Not in use
Measured value
U rec Unit voltage
I rec Unit current
I bat Battery current
t bat Battery temperature
t rec Unit temperature
EArtH Earth resistance
15VDC 15 V supply from the DC converter
15VAC 15 V supply from mains
USet Setpoint U
iSet Setpoint I
U2 Second U-channel / voltage behind decoupling diode
b-cAp Capacity last battery test
bttim Time expired last battery test
bt-U Voltage last battery test
i tot Total current rectifier
CHtiM Remaining time AL/L/BT
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Filter flags
Gen Generally enabled
SVA Linked with urgent fault
SVb Linked with non-urgent fault
off Thysat temporarily off
Smcu Set input in MCU
inV Invert input
SVC Link with aggregate message / mains contactor off
offh Thysat permanently off (reset only via button or interface possible)
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Menu level Display shows: Press Description

button
Basic state 240 U ↔ 10 A Ì Alternating display of output voltage and power
E Calling up of Main menu level
Ë
Main menu MESS Ì Display of the first Main menu (querying measured values)
E Calling up of displayed Main menu
Ë
Menu point t bat → 20.0 °C Ì Display of the first menu point (battery temperature) fol-
lowed by the present value
Alternation to the next menu point
Ë
Menu point t rec → 20.0 °C Ì Display of the next menu point followed by the present
value
C Back to the Main menu level
Ë
Main menu MESS Ì Display of the Main menu
Alternation to the next Main menu

Ë
Main menu tESt Ì Display of the Main menu (function tests and operating
P1.000 modes, password query
Enter the password (Figures from 001 to 999)
E Confirm password
Ë
Menu point tb Ì Display of the first menu point (battery test)
E Carry out battery test

Ë
ok Ì OK (battery is working properly)
↔ Alternation to the next or previous menu point resp.
C Back to the Main menu level
Main menu tESt Ì Display of the Main menu
C Back to the basic state
Basic state 240 U ↔ 10 A Alternating display of output voltage and power
23.12.05- TB-Mo/Obs 63/66 3728 en

Main menu Main menu

Menu point Menu point
Sub-menu point
Display Function Display Function
MESS Display values SYS System configuration
t bAt Battery temperature P2.000 2nd password required
t rec Unit temperature CALib Calibration of measuring system
EArth Earth resistance iLin Power limits
ISUdC Supply voltage DC/DC ChLev Charging level
ISUAC Supply voltage Mains Adr Address (1-24)
USet Set voltage intAD Internal Address (0-255)
iSet Set power P2 Determine 2nd password
U2 Voltage behind decoupl. diode P1 Determine 1st password
b-CAP Capacity last battery test EPres EEPROM set standard
bttin Time after last battery test thomp Temperature correction
bt-U Voltage last battery test tFAh T-Correction factor
i tot Total current rectifier tref T-Reference
cHtiN Residual time at AL, L, BT reLAY Relay hold functions (1-11)
Led LED hold functions (1-18)
digin Digital inputs of regulator d.NAin Mains faults external input Y
P2.000 2nd password required N.EArt Earth resistance at MCU-MW index Y
FiLt Filter flags N.ibAt Battery power at MCU-MW index Y
NCUin MCU-inputs gSr Limit value monitoring GSR (0-8)
tiNe Time
StAtE Status regulator components bSenS Battery sensor parameters
Adr01 Rectifier address 1 SenSL Length of charging line [m]
Adr25 Measured value board address 25 SenSA Cross section of charging line [mm2]
Adr26 Addit. relay card address 26 oPtio Software options
FLAgS Configuration flags
tESt Change test and operat. mode btESt Battery test parameters
P1.000 1st password required btdUr Test period [min]
tb Battery test bt Lo Cancellation voltage [V/cell]
tbCr Battery circuit test btint Autom. test interval
EL Oper. mode Float charging bCrdU Circuit test period
AL Operating mode Equalise charging bCrLo Cancellation voltage
NAn Operating mode Manually bCrin Automat. circuit test interval
dr Operating mode Direct feed btFoL Next start test (display)
rEL01 Relay test (1-11) bCFoL Next start circuit test (display)
deLAY Delay times [s]
diSP Display noNin Nominal values
Led-t Test LED function U non Nominal unit voltage
diSP0 1st display value (basic state) i non Nominal unit power
diSP1 2nd display value (basic state) CELLS Number of battery cells
VCELLS Cell voltage battery
U2Cod Coding U2
Shunt Rated battery shunt current [A]
Shun2 Rated battery shunt current [A]
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Thysat - change number of battery Thysat - change current limitation battery

cells: shunt:
" Sys " " Sys "
Enter Enter
E E
noMin " iLim "
Enter Enter
E E
Cells " ibat "
Enter Enter
E E
number of cells 64%----84%
Enter Enter
E E
3 x Enter 3 x Enter
C C
Change battery shunt value: Setting "Change Equalise charging time"
" Sys " " Sys "
Enter Enter
E E
noMin dELAY
Enter Enter
E E
„shun 2“ AldEL
23.12.05- TB-Mo/Obs 65/66 3728 en

Enter Enter
E E
200 A – 150 A s = sec./
n = min./
h = hrs.
Enter Enter
E E
3 x Enter 3 x Enter
C C
Change Equalise charging voltage: Change Equalise charging current:
" Sys " " Sys "
Enter Enter
E E
ChleU " iLim "
Enter Enter
E E
AL " iAL"
Enter Enter
E E
Volt/cell 20%----30%
Enter Enter
E E
3 x Enter 3 x Enter
C C
23.12.05- TB-Mo/Obs 66/66 3728 en

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Operation & Maintenance

DC UNITERRUPTIPLE POWER SUPPLY

Customer : Schneider (Thailand) Limited.

Job number: BSO - 04173

Ser. No. BS 23945

System Model: D415 D110-35 Bwrug-TDG

Rectifier unit THYROTRONIC

Date Name No. 3728 en

1.2 Scope of the Operating Instructions

→ the order confirmation,

→ the equipment data sheet,

→ the rating plate on the inside of the front door,

→ the technical documentation in chapters 18/19 of these Operating Instructions.

23.12.05- TB-Mo/Obs 2/66 3728 en

1.3 Presentation remarks

+ Notes contain additional information facilitating safe and efficient handling of

23.12.05- TB-Mo/Obs 3/66 3728 en

These Operating Instructions are an essential part of the rectifier unit.

2.2 Personnel qualifications

→ open the housing of the rectifier unit,

→ get to the password-protected menu levels of the regulator programme.

2.2.1 Commercial use

23.12.05- TB-Mo/Obs 4/66 3728 en

→ Only authorised personnel may become active.

2.3 Use as intended

Danger of serious injuries to persons and property may result from:

- incorrect use or incorrect operation,

The rectifier unit THYROTRONIC is intended to supply DC voltage loads. In addition to

2.4 Safety instructions concerning place of use and storage

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 entering conductive dusts (soot, metals),

 high humidity of the air and

 formation of condensate (for instance through airtight packaging) and

 ambient temperatures below 0 °C and above 40 °C

 may damage the rectifier unit and must therefore be excluded.

2.4.1 Safety instructions for battery use

No combustible materials and spark-forming equipment may be located in a vicinity of 2 m

2.5 Safety instructions concerning installation

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2.6 Safety instructions concerning operation

2.7 Safety instructions concerning troubleshooting and repair

Consult the manufacturer prior to performing conversions and major repairs.

Use only insulated tools for performing maintenance work.

 the mains power,

 the battery if applicable and

Equipment used for disconnection must be locked to prevent inadvertent or spontaneous

23.12.05- TB-Mo/Obs 7/66 3728 en

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The alternating voltage is converted into a direct voltage in a three-phase or single-phase

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3.2 Type designation

The rectifier unit THYROTRONIC is available in different versions. The following is an

Additional manufacturer designation

Equipment characteristics (battery and resistance load, character-

Output current type and rated output voltage/rated output current

Figure 1 Type Code

3.3 Remaining risk

Dangerous electrical voltage warning!

The rectifier unit may therefore only be:

 operated by instructed and trained specialists.

 installed, opened, repaired and dismantled if required by qualified electricians!

23.12.05- TB-Mo/Obs 10/66 3728 en

Explosive gases may escape during battery charging.

entering conductive dusts (soot, metals),

high humidity of the air and

formation of condensate (for instance through airtight packaging) and

ambient temperatures below 0 °C and above 40 °C

may damage the rectifier unit and must therefore be excluded.

the mains power,

the battery if applicable and

operated by instructed and trained specialists.

installed, opened, repaired and dismantled if required by qualified electricians!

by correspondingly qualified personnel and

complying with the operating instructions of the battery manufacturer.

Rectifier unit with preset regulator programme,

operated by instructed and trained specialists.

installed, opened, repaired and dismantled if required by qualified electricians!

operated by instructed and trained specialists.

installed, opened, repaired and dismantled if required by qualified electricians!

the equipment switch is in position I (one),

the LED Unit on in the Test / Reset button is illuminated,

no red LEDs are illuminated.

values are displayed by means of LCD,

settings changed by way of four buttons,

general unit statuses indicated by way of four LEDs.