kannweg 09.05.

2000 14:48 Uhr Seite 1

RECTIFIERS
for stationary battery systems
Standard thyristor-controlled rectifiers
Thyrotronic Line

Float charge
Float charge/boost charge
Battery test
Mains fault
Unit fault
High voltage
Low battery voltage
Battery circuit fault
Battery test negative
Earth fault plus
Earth fault minus
Option 1
Option 2

Power ON / OFF
kannweg 09.05.2000 14:48 Uhr Seite 2

1. General 2. Operation

In all fields of industry and commerce the
need for auxiliary power supplies to pro-
tect equipment against power failure is
increasing. For many years the DC power
supply and battery combination have been
used in areas such as measurement, con-
trol, and data back up for the supply of the
power and protection of the load.
Battery backed DC power supply systems
are used in a wide range of applications.
Such as, monitoring and controlling of
production processes, supply of mea-
surement equipment, telemetry, tele-
comunication and radio systems.
Lead-acid and nickel-cadmium batteries achieve optimum service
life when remaining on float, in a charge condition. The charger
floats the battery in a charged state and also supplies the load
with power. In the event of mains power failure the battery will
then supply the load its required power. This is called ”parallel
operation” (see fig. 2).
With substantially discharged batteries, the rectifier unit at
first operates in the I-branch of the IU-characteristic line, whereby
the charging current for the batteries results from the difference
between the nominal current of the rectifier unit and the load
current.
When the set output voltage of the rectifier unit (U-branch) has
been reached, the unit is changed to constant voltage charging
(see fig. 3).

These systems can be found in:

power supply unit

• Hospitals
• Power plants and substations
• Chemical plants Fig. 2:
• Petrochemical plants Standby paralles
• Railway equipment operation
• Offshore projects
• Oil and gas pipeline systems battery

Rectifier units presently employed for DC power supplies operate

almost without exception with a controlled output characteristic
(IU-characteristic line in accordance with DIN 41773).

load
The output voltage is kept
constant to the set value
with a permissible devia-
tion of ± 1 % within a load
range between 0 % and Fig.1:
100 % of the unit current. Thyrotronic
Mains voltage fluctuations rectifier Switching the charge characteris-
of ± 10 % and mains tic, from float charging (e.g.
frequency fluctuations of 2.23 V/cell with lead-acid batteries)
± 5 % will be controlled to boost charging (2.4 V/cell with
automatically by the lead-acid batteries) gives an accel-
thyristor regulator. erated recharge which can be man-
ual, dependent on voltage or
Dependant on the applica- dependent on voltage and time.
tion, flooded or valve regu-
lated lead-acid batteries After the battery has been fully
are the main mediums charged, a small charge current
used for energy storage in flows (approx. 0.3 mA to 1 mA
the power supply systems, per 1 Ah) to balance the internal
in some specialised appli- losses of the battery.
cations nickel-cadmium
batteries are also used.
kannweg 09.05.2000 14:49 Uhr Seite 3

The required autonomy is taken into consideration for calculating

the battery size. The standby times vary depending on type of
load and mains conditions.

V/C
Fig 3: Charging
boost charge characteristic for
2.4 lead-acid batteries in
2.3 float charge accordance with DIN 41773
2.23
2.2
2.1
2.0
0 IN
0 20% 40% 60% 80% 100%

Typical values:
• 10 - 30 minutes for EDP-systems
• 1 - 3 hours for DC power supply equipment in hospitals
and emergency lighting equipment
• 2 - 10 hours for telecommunication systems
3. Rectifier series
The Thyrotronic series operates with a thyristor-controlled power
unit which is combined with a microprocessor-controlled moni-
toring and control unit.The special feature of this series is the
integrated monitoring and signalling concept with the following
functions:

• Mains monitoring
• Charger output monitoring, current-dependent
low voltage monitoring
• High voltage monitoring with impulse blocking
• Battery low voltage monitoring
• Cyclic battery-circuit test
• Battery availability test
• Earth fault monitoring
• Temperature-dependent floating charge voltage control
(temperature sensor required)
• IxR Compensation of voltage drop on the battery lead
• Programmable automatic charging
• Indication of operating mode
Back up of • Possibility of parallel connection without decoupling
Electronic Data diodes
Processing • Hardware basic setting of the controller in case of
Systems processor fault
• Interface for PC or laptop
• Six digital ports for external monitoring functions
kannweg 09.05.2000 14:50 Uhr Seite 6

4. Integrated functions

The frontpanel with integrated LED’s and Description of the integrated functions:
the LCD-display for indication of current
and voltage (see picture 4) enables the
use of different languages by way of an
exchangeable inscription panel.
Mains monitoring

In case of a mains failure , an electronic regulator block is placed

The LED’s which are integrated beside the and the LED and the "mains failure relay " will be activated. If the
push button in the display are provided mains volatge returns the unit is automatically switched on after a
for fixed functions. set time.

Charger output monitoring

The charger output monitoring is a current-dependent low voltage

monitoring and monitors the IU-characteristic of the rectifier unit.
operation If the charger output falls below a set value of 2,1 V/cell and the
output current falls below 90 % of the rated current the alarm will
battery operation activate and indicate "unit fault".The corresponding LED and the
common relay will be activated.
general failure

urgent failure

The LED’s in the indicator panel have the following standard func-
Float charge
tions: Float charge/boost charge
Battery test
Mains fault

• float charge Unit fault

High voltage

• float charge/boost charge Low battery voltage

Battery circuit fault

• battery test Battery test negative

Earth fault plus

• mains fault Fig.4: Front view of the Earth fault minus

• unit fault
Option 1
thyristor range Option 2

• high voltage Thyrotronic

• low battery voltage Power ON / OFF

• battery circuit fault

• battery test negative
• earth fault plus
• earth fault minus
• option 1
• option 2 High voltage monitoring

If the output voltage rises too high ( value is adjustable) due to an

There are 3 potential free relays for the following alarms internal or external interference, over 20 msec. the impulse block-
ing will be activated and the output voltage will be set to zero.
• „mains failure“ This high voltage monitoring works as dynamic monitoring with
• „common alarm“ an automatic reset. If the monitoring responds 4 times within a
• „low battery voltage“. period of 30 seconds, the mains contactor will be disconnected,
the LED "high voltage" and common relay will be activated.
A relay card with a further 7 potential free alarm relays is available
as an option.
kannweg 09.05.2000 14:49 Uhr Seite 4
Low battery voltage
If the battery voltage falls below a set value, e.g. 1,8 V/cell (value
adjustable) during discharge in a case of mains failure, the alarm
"low battery voltage" will appear. LED and common alarm will be
activated.
Use as power
station power
supply
Battery circuit test
The battery circuit of the power supply system is tested cyclically
every 24 hours. For this, the rectifier output voltage is dropped
down to 1.9 V/C for a period of 5 secs. and, as a result, the bat-
tery is discharged. At the same time, the battery voltage is
checked. If the battery voltage stays above 1.9 V/C, the battery
circuit will be all right. If it falls below the limiting value, a "battery
circuit fault" will be indicated and the LED as well as the common
fault signalling relay will be activated.
Caution!
It is not intended that this test schould replace battery circuit
monitoring!
Battery availability test
During the battery availability test the rectifier output voltage will
be dropped and the battery will be discharged as it is the case
during the battery circuit test. But the battery will be discharged
down to an adjustable minimum voltage limit during an
adjustable time. These limits depend on the proportional battery
capacity withdrawn during the discharge and can be taken from
the discharging curves of the connected battery.
If, during the availability test, the values fall below the adjusted
limits, the message "battery test negative" will be indicated by the
corresponding LED and the collective fault signalling relay.
After the test the rectifier automatically switches back to boost
charge or floating charge.
Earth fault monitoring
The earth fault monitoring function moni-
tors the insulation resistance of the DC-
output to earth. Plus and minus are mea-
sured and monitored alternately. If the
insulation resistance falls below the
adjusted value (adjustable from 100 kOhm to 1 MOhm), this will
be indicated by the LEDs and the common alarm.
I*R Compensation
With I*R Compensation it is possible to balance the voltage drop
on the cable between rectifier and battery by entry of cable length
and cross-section of the cable.
Programmable float/boost charge change over
If the battery voltage lowers due to mains failure or any other cir-
cumstances the rectifier unit will work in current limit. If it oper-
ates for more than 30 seconds after the charge start it will auto-
matically be switched over to boost charge characteristic. After
the boost charge voltage (current limitation) has been reached
and after decreasing to < 90 %, a time stage will be activated.
Upon expiry of the set time (0 to 6 h) it will automatically be
switched back to float charge.
The automatic charging can be switched off so that only a manual
switch-over via the plastic foil key board on the front panel is pos-
sible. Switching back to float charge can be done manually as
well.If this is not done, the controller will switch back as in the
case of automatic charging.
The switch-over to boost charge can be blocked by an external
contact or a fixed bridge on the controller.
Equalise charge stage
It is possible to switch to an equalise charge stage via a switch on
the front panel.
Here the voltage limitation will be abolished and the nominal unit
current will be reduced to 20 % (adjustable from 20-30).
An equalise and comissioning charge follows with an I-character-
istic up to the final charge voltage of the battery.
kannweg 09.05.2000 14:49 Uhr Seite 5

5. Technical data

After switching to equalise charge, a timer

Mains input
automatically switches back to the float
charge on expiry of the set time (16 hours Input voltage: 230 V ± 10 % single phase
to 72 hours). 3 x 400 ± 10% three phase
Input current: see table
Using an external contact or a fixed bridge Frequency: 50 Hz ± 5 %
at the regulator, the equalise charge can
be blocked and a switch over to the
Rectifier output
I-characteristic can be prevented.
Output voltage: 24, 48, 60, 110, and 220 V
Output current: see table
Adjustment: ±5%
Possibility of parallel connection Boast voltage: 2,40 V/Z Pb battery
without decoupling diodes 1,55 V/Z NiCd battery
Float voltage: 2,23 V/Z Pb battery
If, in case of a fault during parallel opera- 1,40 V/Z NiCd battery
tion of two rectifiers a quick over voltage Equalise voltage: 2,70 V/Z Pb battery
switch-off is not necessary, no decou- 1,70 V/Z NiCd battery
pling diodes are required. Regulation tolerance: ± 0,5 %
Ripple voltage: < 5 % eff without battery
for option 2 % eff
Simultaneously, an active loadsharing to Cooling: self-cooling
± 10 % is possible by means of an inter- Ambient temperature: 40 °C
nal bus connection. Protection: IP 20
Painting: RAL 7032
Acoustic noise level: Max. 60 dB (A)
Cabinet type: see table
Hardware basic setting

In the case of microprocessor failure in the control unit,the con-

troller internally switches over to a basic setting. That is, the rec- 6. Cabinet type table
tifier continues to operate at the adjusted floating charge voltage
and supplies the load as well as the battery.
Cabinet type H B T
In this case, a fault signal will be indicated by the common fault WG 654 650 500 400
signalling relay. PSJ 1264 1200 600 400
PSJ 1566 1500 600 600
PSJ 1866 1800 600 600
PSJ 1896 1800 900 600
PS 220808 2200 800 800
PS 221008 2200 1000 800
PS 221208 2200 1200 800

WG - wall mounted cabinet

PSJ / PS - floor standing cabinet

Supply of railway
track signalling
equipment
7. Single - Phase Battery Charger - TDG E series

NOM. NOM. NOM. NOM.

TYPE TYPE
VOLT. CUR. CABINET WEIGHT VOLT. CUR. CABINET WEIGHT
TDG E 12 - 3 12 3 WG 442 13 TDG E 48 - 3 48 3 WG 442 20
TDG E 12 - 6 12 6 WG 442 15 TDG E 48 - 6 48 6 WG 442 24
TDG E 12 - 10 12 10 WG 442 17 TDG E 48 - 10 48 10 WG 643 24
TDG E 12 - 15 12 15 WG 442 20 TDG E 48 - 15 48 15 WG 643 39
TDG E 12 - 20 12 20 WG 643 24 TDG E 48 - 20 48 20 WG 753 80
TDG E 12 - 25 12 25 WG 643 30 TDG E 48 - 25 48 25 WG 753 83
TDG E 12 - 35 12 35 WG 753 35 TDG E 48 - 35 48 35 WG 753 90
TDG E 12 - 50 12 50 WG 753 40 TDG E 48 - 50 48 50 PSJ 1264 135
TDG E 12 - 75 12 75 PSJ 1264 45 TDG E 48 - 75 48 75 PSJ 1264 200
TDG E 12 - 100 12 100 PSJ 1264 92 TDG E 48 - 100 48 100 PSJ 1664 230
TDG E 12 - 125 12 125 PSJ 1264 103 TDG E 48 - 125 48 125 PSJ 1664 250
TDG E 12 - 150 12 150 PSJ 1264 113 TDG E 48 - 150 48 150 PSJ 2086 275
TDG E 12 - 175 12 175 PSJ 1264 133 TDG E 48 - 175 48 175 PSJ 2086 295
TDG E 12 - 200 12 200 PSJ 1664 150 TDG E 48 - 200 48 200 PSJ 2086 320
TDG E 12 - 250 12 250 PSJ 1664 165 TDG E 48 - 250 48 250 PSJ 2086 400

TDG E 24 - 3 24 3 WG 442 17 TDG E 110 - 3 110 3 WG 442 25

TDG E 24 - 6 24 6 WG 442 19 TDG E 110 - 6 110 6 WG 442 30
TDG E 24 - 10 24 10 WG 643 27 TDG E 110 - 10 110 10 WG 643 45
TDG E 24 - 15 24 15 WG 643 32 TDG E 110 - 15 110 15 WG 643 80
TDG E 24 - 20 24 20 WG 643 35 TDG E 110 - 20 110 20 WG 743 90
TDG E 24 - 25 24 25 WG 753 42 TDG E 110 - 25 110 25 WG 743 125
TDG E 24 - 35 24 35 WG 753 45 TDG E 110 - 35 110 35 PSJ 1264 220
TDG E 24 - 50 24 50 PSJ 1264 95 TDG E 110 - 50 110 50 PSJ 1664 250
TDG E 24 - 75 24 75 PSJ 1264 115 TDG E 110 - 75 110 75 PSJ 1664 290
TDG E 24 - 100 24 100 PSJ 1264 130 TDG E 110 - 100 110 100 PSJ 2086 340
TDG E 24 - 125 24 125 PSJ 1664 150 TDG E 110 - 125 110 125 PSJ 2086 400
TDG E 24 - 150 24 150 PSJ 2086 185 TDG E 110 - 150 110 150 PSJ 2086 460
TDG E 24 - 175 24 175 PSJ 2086 230 TDG E 110 - 175 110 175 PSJ 2086 485
TDG E 24 - 200 24 200 PSJ 2086 265 TDG E 110 - 200 110 200 PSJ 2086 510
TDG E 24 - 250 24 250 PSJ 2086 310 TDG E 110 - 250 110 250 PSJ 2086 550

TDG E 30 - 3 30 3 WG 442 17 TDG E 220 - 3 220 3 WG 753 20

TDG E 30 - 6 30 6 WG 442 19 TDG E 220 - 6 220 6 WG 753 45
TDG E 30 - 10 30 10 WG 643 27 TDG E 220 - 10 220 10 WG 753 90
TDG E 30 - 15 30 15 WG 643 32 TDG E 220 - 15 220 15 WG 753 140
TDG E 30 - 20 30 20 WG 753 35 TDG E 220 - 20 220 20 WG 753 215
TDG E 30 - 25 30 25 WG 753 42 TDG E 220 - 25 220 25 WG 753 270
TDG E 30 - 35 30 35 WG 753 45 TDG E 220 - 35 220 35 PSJ 1264 400
TDG E 30 - 50 30 50 PSJ 1264 95 TDG E 220 - 50 220 50 PSJ 1264 500
TDG E 30 - 75 30 75 PSJ 1264 115 TDG E 220 - 75 220 75 PSJ 1264 550
TDG E 30 - 100 30 100 PSJ 1664 130 TDG E 220 - 100 220 100 PSJ 2086 625
TDG E 30 - 125 30 125 PSJ 1664 150 TDG E 220 - 125 220 125 PSJ 2086 655
TDG E 30 - 150 30 150 PSJ 2086 185 TDG E 220 - 150 220 150 PSJ 2086 690
TDG E 30 - 175 30 175 PSJ 2086 230 TDG E 220 - 175 220 175 PSJ 2086 720
TDG E 30 - 200 30 200 PSJ 2086 265 TDG E 220 - 200 220 200 PSJ 2086 750
TDG E 30 - 250 30 250 PSJ 2086 310 TDG E 220 - 250 220 250 PSJ 2086 785
8. Three - Phase Battery Charger - TDG D series
NOM. NOM. NOM. NOM.
TYPE TYPE
VOLT. CUR. CABINET WEIGHT VOLT. CUR. CABINET WEIGHT
TDG D 12 - 25 12 25 PSJ 1264 60 TDG D 110 - 25 110 25 PSJ 1264 150
TDG D 12 - 35 12 35 PSJ 1264 70 TDG D 110 - 35 110 35 PSJ 1264 170
TDG D 12 - 50 12 50 PSJ 1264 70 TDG D 110 - 50 110 50 PSJ 1264 270
TDG D 12 - 75 12 75 PSJ 1264 100 TDG D 110 - 75 110 75 PSJ 1264 400
TDG D 12 - 100 12 100 PSJ 1264 125 TDG D 110 - 100 110 100 PSJ 1664 425
TDG D 12 - 125 12 125 PSJ 1264 135 TDG D 110 - 125 110 125 PSJ 1664 455
TDG D 12 - 150 12 150 PSJ 1264 150 TDG D 110 - 150 110 150 PSJ 2066 500
TDG D 12 - 175 12 175 PSJ 1264 175 TDG D 110 - 175 110 175 PSJ 2066 520
TDG D 12 - 200 12 200 PSJ 1264 190 TDG D 110 - 200 110 200 PSJ 2066 630
TDG D 12 - 250 12 250 PSJ 1264 220 TDG D 110 - 250 110 250 PSJ 2066 720
TDG D 12 - 300 12 300 PSJ 1264 370 TDG D 110 - 300 110 300 PSJ 2066 920
TDG D 12 - 400 12 400 PSJ 1264 480 TDG D 110 - 400 110 400 PSJ 2086 1090
TDG D 110 - 500 110 500 PSJ 2088 1120
TDG D 24 - 25 24 25 PSJ 1264 80 TDG D 110 - 600 110 600 PSJ 2088 1350
TDG D 24 - 35 24 35 PSJ 1264 100 TDG D 110 - 700 110 700 PSJ 2088 1450
TDG D 24 - 50 24 50 PSJ 1264 120 TDG D 110 - 1000 110 1000 PSJ 2098 1750
TDG D 24 - 75 24 75 PSJ 1264 185 TDG D 110 - 1200 110 1200 PSJ 2098D 1890
TDG D 24 - 100 24 100 PSJ 1264 190
TDG D 24 - 125 24 125 PSJ 1264 200 TDG D 220 - 25 220 25 PSJ 1264 190
TDG D 24 - 150 24 150 PSJ 1264 210 TDG D 220 - 35 220 35 PSJ 1264 210
TDG D 24 - 175 24 175 PSJ 1664 230 TDG D 220 - 50 220 50 PSJ 1664 390
TDG D 24 - 200 24 200 PSJ 1664 250 TDG D 220 - 75 220 75 PSJ 1664 490
TDG D 24 - 250 24 250 PSJ 2066 385 TDG D 220 - 100 220 100 PSJ 1664 530
TDG D 24 - 300 24 300 PSJ 2066 410 TDG D 220 - 125 220 125 PSJ 2066 570
TDG D 24 - 400 24 400 PSJ 2066 525 TDG D 220 - 150 220 150 PSJ 2066 750
TDG D 24 - 500 24 500 PSJ 2086 650 TDG D 220 - 175 220 175 PSJ 2066 810
TDG D 24 - 600 24 600 PSJ 2086 720 TDG D 220 - 200 220 200 PSJ 2066 860
TDG D 24 - 700 24 700 PSJ 2086 850 TDG D 220 - 250 220 250 PSJ 2088 1000
TDG D 24 - 1000 24 1000 PSJ 2086 1200 TDG D 220 - 300 220 300 PSJ 2088 1275
TDG D 24 - 1200 24 1200 PSJ 2086 1350 TDG D 220 - 400 220 400 PSJ 2088 1600
TDG D 220 - 500 220 500 PSJ 2088 1900
TDG D 48 - 25 48 25 PSJ 1264 125 TDG D 220 - 600 220 600 PSJ 2098D 2200
TDG D 48 - 35 48 35 PSJ 1264 130 TDG D 220 - 700 220 700 PSJ 2098D 2680
TDG D 48 - 50 48 50 PSJ 1264 150 TDG D 220 - 1000 220 1000 PSJ 2098D 2780
TDG D 48 - 75 48 75 PSJ 1264 220 TDG D 220 - 1200 220 1200 PSJ 2098D 2780
TDG D 48 - 100 48 100 PSJ 1264 245
TDG D 48 - 125 48 125 PSJ 1264 300 HEIGHT WIDTH DEPT
TDG D 48 - 150 48 150 PSJ 1664 380 CABINET mm mm mm
TDG D 48 - 175 48 175 PSJ 1664 410 WG 442 460 400 270
TDG D 48 - 200 48 200 PSJ 1664 420 WG 643 610 430 330
TDG D 48 - 250 48 250 PSJ 2066 515 WG 753 790 500 380
TDG D 48 - 300 48 300 PSJ 2066 555 PSJ 1264 1200 670 490
TDG D 48 - 400 48 400 PSJ 2086 610 PSJ 1664 1630 670 490
TDG D 48 - 500 48 500 PSJ 2088 720 PSJ 2066 2028 670 625
TDG D 48 - 600 48 600 PSJ 2088 870 PSJ 2086 2028 840 625
TDG D 48 - 700 48 700 PSJ 2088 950 PSJ 2088 2028 840 800
TDG D 48 - 1000 48 1000 PSJ 2098 1270 PSJ 2098 2028 940 800
TDG D 48 - 1200 48 1200 PSJ 2088D 1480
WG - Wallmounted PSJ - Floor standing
ruekseitenaufbau180400 16.05.2000 15:09 Uhr Seite 2

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