Bennign Rectifier 4253 en Tdg2 - A3200902

Operating Instruction
Rectifier THYROTRONIC
with Thysat regulator
Date Name No. 4253 en

Issued: 11.05.05 Mo/Obs Page 1/107 Pages
Revision 23.06.08 Mo/Obs
Geprüft: 23.06.08 Mohr
C:\Benning\Product Information\Thyrotronic\4253 EN TDG2(A3200902).doc
Rectifier THYROTRONIC with Thysat regulator
Contents
1 General ..................................................................................................10
1.1 Purpose of the Operating instructions ...................................................10
1.2 Scope of the Operating Instructions ......................................................10
1.3 Presentation remarks.............................................................................11
2 Safety ....................................................................................................12
2.1 General .................................................................................................12
2.2 Personnel qualifications ........................................................................12
2.2.1 Commercial use ....................................................................................13
2.3 Use as intended.....................................................................................13
2.4 Safety instructions concerning place of use and storage ........................14
2.4.1 Safety instructions for battery use .........................................................14
2.5 Safety instructions concerning installation ............................................15
2.6 Safety instructions concerning operation...............................................15
2.7 Safety instructions concerning troubleshooting and repair ....................16
3 Product details ........................................................................................17
3.1 Description ...........................................................................................17
3.2 Type designation...................................................................................18
3.3 Remaining risk......................................................................................18
3.3.1 Battery ..................................................................................................19
3.4 Description of protective installations ...................................................20
3.5 Identifications and signs on the rectifier................................................20
4 Transport, handling and storage ................................................................22
4.1 Scope of delivery ..................................................................................22
4.2 Packaging .............................................................................................22
4.3 Transport ..............................................................................................23
4.3.1 With forklift trucks ...............................................................................23
4.3.2 With crane ............................................................................................23
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4.4 Storage .................................................................................................23

5 Assembly, installation and start-up ...........................................................25
5.1 Assembly..............................................................................................25
5.2 Mains connections and mains fuses ......................................................25
5.3 Initial start-up and function test.............................................................26
6 Operation ...............................................................................................29
6.1 Display and operating panel (4 button panel) ........................................30
6.1.1 LCD operating field ..............................................................................30
6.2 Description of the general menu levels/options .....................................31
6.3 Operating panel "ABE" - an optional extension of the 4 button panel ...34
6.3.1 Display and operating elements ............................................................35
6.3.2 LED bar................................................................................................37
6.4 Test and reset button .............................................................................39
6.4.1 Equipment switch off/on.......................................................................39
6.5 Start-up.................................................................................................39
6.6 Faults and error messages .....................................................................40
6.7 Shutting down.......................................................................................43
6.7.1 Switching off rectifier ...........................................................................43
6.7.2 Isolating the rectifier.............................................................................43
7 Advanced operation and programming ......................................................44
7.1 Description of Thysat regulator.............................................................44
7.2 Functions ..............................................................................................44
7.3 Hardware ..............................................................................................45
7.3.1 Serial interfaces ....................................................................................45
7.3.2 Digital inputs ........................................................................................47
7.3.3 Analogue inputs....................................................................................47
7.3.4 Error message relay ..............................................................................48
7.3.5 Manual operation as emergency mode ..................................................48
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7.4 Assignation of connection terminals .....................................................48

7.5 Software ...............................................................................................51
7.5.1 Flash Programming...............................................................................51
7.6 Switching-on process on the regulator .................................................52
7.7 Operating modes – charge statuses........................................................52
7.7.1 Float charging.......................................................................................53
7.7.2 Charging ...............................................................................................53
7.7.3 Equalise charging .................................................................................53
7.7.4 Direct feeding .......................................................................................54
7.7.5 Battery test............................................................................................54
7.7.6 Manual .................................................................................................55
7.8 Parallel operation of two rectifiers ........................................................55
8 Messages ...............................................................................................59
8.1 Mains power available ..........................................................................59
8.2 Mains disturbance.................................................................................59
8.3 Unit failure ...........................................................................................59
8.4 Current limitation (optional) .................................................................59
8.5 Battery charging current limitation (optional) .......................................60
8.6 DC voltage too high..............................................................................60
8.7 Battery voltage too low.........................................................................60
8.8 Aggregate message (relay contact)........................................................60
8.9 Option 1 – 6..........................................................................................60
8.10 Switching-on and off behaviour – impulse and regulator lockout..........61
8.11 LED board ............................................................................................61
8.12 Configuration........................................................................................61
8.13 Digital inputs ........................................................................................62
8.14 Limit value monitoring (DC monitoring relay) .....................................63
8.15 Relay functions:....................................................................................63
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8.16 LED functions ......................................................................................64

8.17 Measured values ...................................................................................64
9 Settings ..................................................................................................66
9.1 Unit address (Adr) ................................................................................66
9.2 Settings - options ..................................................................................66
9.3 Voltage adjustment (U-rEG) .................................................................66
9.4 Battery temperature-inclined characteristic (tEMP)...............................67
9.5 Fault holding function (Err-H) ..............................................................67
9.6 Flags.....................................................................................................67
9.7 Time delays (dEL’S).............................................................................68
9.8 Main menu of the ABE display unit......................................................68
10 Error memory .........................................................................................70
11 Error level and fault classes......................................................................71
11.1 Error levels for ABE and common fault messages ................................71
11.2 Error level for the external and internal monitoring logic......................71
11.3 Error level for SAT-bus devices............................................................72
12 Error log ................................................................................................73
13 Details of the menus ................................................................................74
13.1 Control .................................................................................................74
13.1.1 Characteristic changeover .....................................................................74
13.1.2 Relay test ..............................................................................................75
13.1.3 Resetting the hold function ...................................................................75
13.1.4 Freely defined commands .....................................................................75
13.2 Settings.................................................................................................76
13.2.1 Change date and time............................................................................76
13.2.2 Battery test interval...............................................................................76
13.2.3 Duration of battery test .........................................................................76
13.2.4 Abort voltage battery test......................................................................76
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13.2.5 Measuring channel for battery test ........................................................77

13.2.6 Limit value monitoring .........................................................................77
13.3 Measured values ...................................................................................78
13.3.1 Present measured values .......................................................................78
13.3.2 Measured value recording .....................................................................78
13.3.3 Display history......................................................................................79
13.3.4 Scan interval .........................................................................................79
13.3.5 Measured values to be recorded ............................................................79
13.3.6 Delete records.......................................................................................79
13.4 States ....................................................................................................80
13.5 LED......................................................................................................80
13.5.1 Setting the default values ......................................................................82
13.5.2 System info...........................................................................................82
13.5.3 Measured values to be displayed...........................................................83
13.5.4 Load texts from the MCU base .............................................................83
13.5.5 Configuration flags ...............................................................................83
13.5.6 ESC function ........................................................................................84
13.5.7 Illumination control ..............................................................................84
13.5.8 Display lock..........................................................................................84
13.5.9 Changing the passwords .......................................................................84
14 Menu language .......................................................................................85
15 System setup ..........................................................................................86
15.1 MCU basic card ....................................................................................86
15.1.1 Modem initialisation .............................................................................86
15.1.2 Dial prefix ............................................................................................87
15.1.3 First telephone number .........................................................................87
15.1.4 Second telephone number .....................................................................87
15.1.5 Passwords .............................................................................................87
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15.1.6 On site unit identifier ............................................................................88

15.1.7 Times....................................................................................................88
15.1.8 Duration of modem connection.............................................................88
15.1.9 Waiting period if line busy....................................................................88
15.1.10 Delay SVA/SVB/SVC ..........................................................................88
15.1.11 Duration of relay test ............................................................................88
15.1.12 Number of battery cells (Not supported on TDG units).....................89
15.1.13 Options .................................................................................................89
15.1.14 Modem enabled ....................................................................................89
15.1.15 Automatic battery test ...........................................................................89
15.1.16 Battery test for two batteries .................................................................89
15.2 Thysat...................................................................................................89
15.2.1 Charging voltage...................................................................................89
15.2.2 Float charging voltage ..........................................................................90
15.2.3 Overvoltage switch-off .........................................................................90
15.2.4 Undervoltage limit ................................................................................90
15.2.5 Abort voltage battery test......................................................................90
15.2.6 Equalise charging current......................................................................90
15.2.7 Battery charging current limitation .......................................................90
15.2.8 Aftercharging........................................................................................90
15.2.9 Equalise charging time..........................................................................90
15.2.10 Resume delay .......................................................................................90
15.2.11 Battery testing time...............................................................................90
15.2.12 Battery test interval...............................................................................90
15.2.13 Earth fault resistance.............................................................................91
16 Maintenance ...........................................................................................92
16.1 General .................................................................................................92
16.2 Inspection and maintenance ..................................................................92
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16.3 Cleaning ...............................................................................................92

16.3.1 Terminals and plug connections............................................................93
16.3.2 Contactors, relays .................................................................................93
16.3.3 Monitoring installations ........................................................................93
16.4 Exchange of electrolyte capacitors ........................................................93
16.5 Externally ventilated semiconductors, power parts and transformers
(optional) ..............................................................................................94
16.6 Changing the regulator programme.......................................................95
16.7 Spare parts ............................................................................................95
17 Disposal .................................................................................................96
17.1 Batteries................................................................................................96
18 Regulator menu overview ........................................................................97
19 Explanation of menu options ....................................................................98
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Index of figures
Figure 1 Type Code .............................................................................................................. 18

Figure 2 Display and operating panel.................................................................................... 30
Figure 3 LCD and buttons..................................................................................................... 31
Figure 4 Meaning of the buttons in the LCD operating field.................................................. 31
Figure 5 Open menu structure............................................................................................... 32
Figure 6 Meaning of the LEDs in the LCD operating panel................................................... 36
Figure 7 LED bar with standard assignment and Test / Reset button with LED ..................... 36
Figure 8 General meaning of the LED colours ...................................................................... 38
Figure 9 Filter matrix for digital input signals and events...................................................... 58
Figure 10 Limit-value monitor and filter matrix for analogue measured value......................... 63
Figure 11 Wiring of the relay to one input .............................................................................. 61
Figure 12 Menu structure........................................................................................................ 68
Figure 13 Adjustment of the monitoring parameters ............................................................... 76
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1 General
1.1 Purpose of the Operating instructions
These operating instructions serve to enable the secure operation of the rectifier
THYROTRONIC as intended.
The present operating instructions contain the information necessary for the safe
operation as intended of the rectifier.
The operating instructions must always be available and kept handy in the vicinity
of the rectifier.
The operating instructions must be read and applied by any person entrusted with
operating processes on the rectifier; these include transport, erection and disas-
sembly.
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 commercial 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 con-
tents is not permitted unless expressly approved.
1.2 Scope of the Operating Instructions
If required as a result of the site conditions, the rectifier can be supplied in a large
number of versions. A description of all versions would reduce the benefit and
compact nature of your operating instructions.
For this reason these operating instructions refer exclusively to the standard con-
figuration of the rectifier. Exact details concerning your version of the rectifier
can be taken from:
→ the order confirmation,
→ the technical data sheet ,
→ the rating plate on the inside of the front door,
→ the technical documentation in chapters 18/19 of these operating instruc-

tions.
These details concerning your version are of prior validity compared with possi-
bly deviating details concerning the standard configuration in these operating in-
structions.
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1.3 Presentation remarks
The rectifier is manufactured according to the generally accepted rules and the
current state of the art design techniques. Additional safety instructions are pro-
vided in order to guarantee the personnel adequate safety. Adequate safety when
handling the rectifier 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.
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 damage on the rectifier 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 in-
correct handling.
Please observe all warnings and measures that prevent injuries to

yourself or third parties. Proceed with particular care!
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2 Safety
2.1 General
These operating instructions are an essential part of the rectifier.
The operator has to ensure that these operating instructions are always available
near the rectifier and that the operating staff get acquainted with these instruc-
tions.
The operating instructions must be supplemented by the operator, with operating

instructions on the basis of existing national regulations for accident prevention
and environmental protection. These additional instructions should include infor-
mation concerning supervisory 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 pre-
vention applicable in the country concerned and at the place of operation it is also
necessary to observe 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. In par-
ticular qualified electricians authorised for this purpose must only perform the in-
stallation, initial start-up, maintenance and disassembly of the rectifier.
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,
→ 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 activi-
ties.
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 regulations of the trade associations (for instance BGV A3) 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.
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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 in-
structions.
2.2.1 Commercial use
If the rectifier is employed commercially, the following will apply in addition:
→ The operator must be familiar with handling the rectifier through special in-
duction or training courses.
→ 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,
- incorrect installation or incorrect maintenance and repair.
All details concerning the intended use, the residual risk, the installation, the op-
eration and maintenance contained in these operating instructions must therefore
be observed and adhered to.
The rectifier THYROTRONIC is intended to supply DC voltage loads. In addition

to this the rectifier can be used for charging suitable batteries. Only rechargeable
lead and nickel-cadmium batteries are suitable. The rectifier is not suitable for all
other accumulators 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 may only be used for the applications provided in these operating in-
structions and in the technical description, with the accessories or components
recommended 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 will carry the sole responsibility for damage result-
ing from such use.
Start-up of the rectifier is only permitted subject to adherence to the guideline for
electromagnetic compatibility (89/336/EEC). The limit value class is specified in
the technical data sheet .
23.06.08- TB-Mo/Obs 13/107 4253 en

In the case of a rectifier with subsequent modifications on the part of the operator
(with regard to components, circuits, regulator programming, etc.) it is compul-
sory 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 must be protected from inadmissible loads. In particular, no compo-

nents must be damaged during transport and handling. Avoid contact with elec-
tronic components.
entering liquids,
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 and must therefore be excluded.
Heat soak conditions on the rectifier 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 they may however obstruct the dissipation of
heat if allowed to accumulate and consequently reduce the service life of the recti-
fier.
If the rectifier is supplied in a particularly protected version, the details in the or-
der 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 vicin-

ity 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 explosive gas mixtures.
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2.5 Safety instructions concerning installation
The rectifier contains electrostatically susceptible components which can be easily

damaged through incorrect handling. Electrical components may not be mechani-
cally 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 concerning screening, earthing, arrangement of filters and insu-
lation of lines.
Prior to performing the electrical installation, compare the ratings on the rat-
ing plate with the ratings of the supply connections:
Protect the rectifier against overcurrent by means of an upstream mains

fuse.
Adhere to the mains connection values of the rating plate (voltage and fre-
quency).
Switching (confusion) of poles with mains and battery connection must be

securely excluded.
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 may only be used in a technically perfect condition and as intended
under consideration of safety and hazards and adhering to these operating instruc-
tions. In particular, faults impairing the safety must be corrected immediately.
In the event of safety-relevant changes to the rectifier or the operating behaviour,

the rectifier must be stopped immediately and the fault reported to the responsible
office.
Even when the rectifier 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 battery.
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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 without the approval of

the manufacturer! This applies also to the installation and adjustment of safety in-
stallations: Especially ensure that creep and air gap distances are not reduced.
Replacement parts used must satisfy the technical requirements determined by the
manufacturer. 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 input and out-
put from
the mains power,
the battery if applicable and
all loads.
Equipment used for disconnection must be locked to prevent inadvertent or spon-

taneous switching on. Use additional signs to warn against switching on, if appli-
cable.
After switching off, wait for at least five minutes before taking off the covers of
the housing. 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 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.
When working on high-voltage assemblies, connect the supply cable to the casing
following the disconnection of the power. Short-circuit components such as ca-
pacitors by way of an earth rod.
If the repair measures require the disassembly of protective installations, reinstal-

lation and testing of the protective installations must be performed immediately
after the completion of the work.
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3 Product details
3.1 Description
Electrical loads are employed in all areas of industry and public life which must
be protected against failure of the power supply system. Together with shunt-
connected batteries, the rectifier THYROTRONIC forms a guaranteed power sup-
ply.
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 ad-
justment of the voltage to the corresponding battery voltage take place.
The alternating voltage is converted into a direct voltage in a three-phase or sin-

gle-phase bridge circuit (thyristor bridge). The thyristors are activated by the mi-
croprocessor-controlled Thysat regulator. Smoothing of the direct current is
achieved by way of a filter. This consists of a smoothing choke situated in the di-
rect current circuit and several shunt-connected electrolyte capacitors. Voltage
and current can be read off the built-in instruments.
The rectifier 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 fluctuations 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 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 operat-
ing mode is termed standby parallel operation.
With a severely depleted battery, the rectifier 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 and the load current.
The transition to constant voltage charging (U-branch) follows on reaching the set
output voltage of the rectifier.
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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 may be designed with a charge

characteristic. The battery temperature-dependent inclined float charging charac-
teristic possesses an adjustable inclination and adjustable point of operation. A
separate temperature sensor is necessary for this function.
3.2 Type designation
The rectifier 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 and the
order confirmation, the technical 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 dangerous to human beings.
The rectifier may therefore only be:
operated by instructed and trained specialists.
installed, opened, repaired and dismantled if required by qualified electri-

cians!
The power supply and a battery and/or load contact must always be disconnected
before intervening and working on the rectifier.
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Danger!
Switching on a battery in addition to the rectifier will cause an arc,

which may cause severe injuries to yourself and others if handled in-
correctly. There is an increased fire hazard.
Installation and start-up of the rectifier, especially in the case of units with battery
connection, are only permitted by experienced and qualified electricians.
Explosion hazard!
Explosive gases may escape during battery charging.
The operation of the rectifier is therefore permitted only in adequately

ventilated rooms.
Never remove the battery connection during a charging process since

this could result in sparks or arcing, which could ignite the oxyhydro-
gen 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 components!
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.
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3.4 Description of protective installations
The rectifier has been designed and built according to the accepted rules of engi-
neering. 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 hous-
ings, covers 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 re-
quirements; all necessary insulating distances have been maintained. All electric
circuits have been equipped with primary and secondary fuses of defined amper-
age and tripping characteristic.
All metallic components are grounded via a grounding conductor system.
The rectifier 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 is in the operating mode equalise charging; see
chapter 7.7.3 Equalise charging.)
In its standard configuration the rectifier is designed in accordance with protection

class IP 20. Deviating from this, the details concerning specially protected ver-
sions can be taken from the order confirmation, the technical data sheet and the
technical data in chapter 19.
3.5 Identifications and signs on the rectifier
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.
23.06.08- TB-Mo/Obs 20/107 4253 en

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!
Rating plate
Type Attached in the interior of the rectifier
No.
Overvoltage category Input Output
Type of current
Rated frequency Hz
Rated voltage V
Rated current A
With 100 % Irated u. V
Type of operation Model year
Part no. Opt.
23.06.08- TB-Mo/Obs 21/107 4253 en

4 Transport, handling and storage

Following the arrival of the rectifier at its destination, immediately inspect it for
possible damage. Also check if all parts are present by comparing it with the
packing list. Immediately 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 with preset regulator programme,
Operating Instructions,
Delivery note.
The scope of delivery and the version of the rectifier may deviate from the above
depending on the customer request. Additional technical details are noted in the
enclosed delivery 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 for loose screw connections and secure them if required.
4.2 Packaging
Depending on the applicable type of transport, the rectifier will be supplied in a

cardboard box or wooden crate on a transport pallet. The rectifier 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!
23.06.08- TB-Mo/Obs 22/107 4253 en

Top!
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.
Always lash down the rectifier so that it cannot skid or topple over. In particular
ensure that the paint finish is not scuffed and scratched.
Stay clear of obstacles.
Avoid shock impacts when transporting the rectifier.
Having unloaded the rectifier, immediately inspect it for possible damage.
4.3.1 With forklift trucks
If the rectifier is transported with a forklift, always start the forks at the back of
the rectifier to avoid damaging the door with instruments mounted on the front.
4.3.2 With crane
Larger rectifiers 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 capacity!
Carefully attach and secure the rectifier 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 depends on the chosen packaging.
23.06.08- TB-Mo/Obs 23/107 4253 en

A rectifier with short-term packaging should be unpacked immediately on reach-

ing the destination and stored in a suitable place. Excessive temperature fluctua-
tions should be avoided, especially temperature drops likely to cause condensation
to form on the unit (see DIN 55474).
If it is intended to store the rectifier, open the doors for several hours so that the
rectifier is able to adjust to the new temperature without the formation of conden-
sate. If the rectifier 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.
If the rectifier is supplied with long-term packaging it should be stored in that

packaging. Check the packaging for damage beforehand. During the storage pe-
riod, 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.
23.06.08- TB-Mo/Obs 24/107 4253 en

5 Assembly, installation and start-up

Adhere to all safety instructions
in chapter 2.4 Safety instructions concerning place of installation and storage and
in chapter 2.5 Safety instructions concerning installation.
5.1 Assembly
Depending on requirement the rectifier 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 is set up on a basic frame, the latter must be checked for exact in-
stallation. 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.

cians!
Protect the rectifier against excessive contact voltages according to the local regu-
lations 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. The mains voltage and frequency must correspond to the details on the
rating plate. The housing must be earthed properly.
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We cannot unconditionally recommend the operation of the unit by way of leak-

age current protection switch since it can be triggered by the specified interference
suppression capacitors.
Protect with a mains fuse in accordance with the technical 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 -)!
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 recti-
fier and battery and load should be taken into account when determining the cross
sections.
Connect the rectifier with the earthed conductor by means of the earth screw pro-
vided for this purpose.
5.3 Initial start-up and function test
Completely read this chapter every time on initial start-up. More information con-
cerning 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 con-
nections.
→ 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, the de-energised filter capaci-
tors 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 approximately to the battery voltage before the battery is connected.
Procedure:
→ Ensure that no loads are switched on initially.
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→ Switch on the rectifier without battery connected using the equipment

switch in the front door.
The initialisation phase of the rectifier 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 will cause an arc,

which may cause severe injuries to yourself and others if handled in-
correctly. There is an increased fire hazard.
It is imperative to wear the protective glove with arm protection and

safety visor.
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 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 volt-
age and the rated current and only the two green LEDs float charging and opera-
tion 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.
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Subsequently observe the operating condition for some time. If additional fault
messages are displayed, troubleshooting instructions can be found in section 6.6
Faults and error messages.
Attention!
Connecting a battery that has not been approved to the rectifier may
result in damage to the battery and the rectifier and subsequently to
the load!
As operator and responsible service personnel, exclude any possibility

of confusing battery and loads connections!
Following the successful initial start-up, mark the rectifier with all necessary de-
tails 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 technical documentation in chapter 19 of these operating in-
structions!
→ In particular mark any deviations from the details on the rating plate.
23.06.08- TB-Mo/Obs 28/107 4253 en

6 Operation


cians!
The rectifier THYROTRONIC, more exactly the thyristor bridge, is controlled and
operated by way of the Thysat regulator. The regulator is a programme-controlled
microprocessor.
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 programming).
While the rectifier operates normally (Automatic mode), it requires no operator

intervention; the rectifier 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,
alternatively,
only the yellow LED Charging/equalise charging and the green LED Op-
eration are illuminated and
the LCD alternately displays the present values of unit voltage and unit cur-
rent and
no red LEDs are illuminated.
23.06.08- TB-Mo/Obs 29/107 4253 en

The individual operating steps are explained in more detail in the following chap-
ters. Prior to operating the rectifier for the first time, carefully read these chapters.
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 values 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.
23.06.08- TB-Mo/Obs 30/107 4253 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 measured values.
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Large menu areas comprise sub-menu for configuring the regulator. These areas
are password protected.
The following figure shows the freely accessible menu structure:
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
23.06.08- TB-Mo/Obs 32/107 4253 en

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
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 maintenance free batteries),
manual (Man, only necessary with special configuration),
direct feed (dr, only when using the rectifier as a power supply unit) and
battery (circuit) test (tb and tbcr).
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Menu items of the password protected level 2
This level can only be accessed via menu item "SYS" or "digin" and by entering
a password in menu item "P2.000". 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 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.
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 chapter 19.
The sub-menus of the filter flags and the MCU input can be accessed from here
subject to password protection.
6.3 Operating panel "ABE" - an optional extension of the 4 button panel

Introduction
The operating panel ABE enables monitoring and setting of the regulator and of
the entire power supply system.
It features a display with plain text messages and a jog dial to select the com-
mands. The LED status displays are unchanged when compared to the standard
display and operating panel (4 button panel). The other hardware and software
equipment of the rectifier differs slightly from the standard version (4 button
panel) with respect to some features.
These features are:

♦ Illuminated graphic LC display
♦ Jog dial for speedy adjustment of the selections
♦ Standard measured-value display can be selected as desired
♦ Menu-driven data input
♦ Menu language can be selected among 3 preset languages and 1 custom lan-
guage
23.06.08- TB-Mo/Obs 34/107 4253 en

♦ Freely definable message texts and measured value texts

♦ 4 password levels allow to manage different access authorisations
♦ Error memory for the last 200 events (malfunction log)
♦ Measured value recording for 2000 measured values
6.3.1 Display and operating elements
Standard display of measuring Status line:

values current error signal
ENTER key
Confirm input
S-key
Display error signals
ESC key
Abort input
Knob for selecting menu item or

changing setting
Verbraucherspannung load voltage

Geräte Gesamtstrom rectifier total current
keine Störung no error occured
23.06.08- TB-Mo/Obs 35/107 4253 en

Help function
Cursor rauf/runter cursor up/down

Eingabe bestätigen input confirm
Abbruch interrupt
keine Störung no error occured
Almost any menu allows to activate a help text explaining the button functions.
To do so, press the S button twice and then additionally the ENTER (E) button.
How to select menu items
If you turn the jog dial, you enter the main menu where further sub-menus can be
selected using the E button.
You can leave any menu pressing the C button (ESC). You will step by step navi-
gate back to the higher menu levels.
If you don't press any button for a time which can be set, the display will auto-
matically return to the standard view.
Figure 5 gives an overview of the menu structure. The access authorisation (pass-
word level) is stated in brackets.
You will find all further operating instructions for the operating panel "ABE" in
the main menu of the ABE Display and Operating Panel.
Both display units include:
LEDs
four LEDs indicated the general operating modes of the rectifier:
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.
23.06.08- TB-Mo/Obs 36/107 4253 en

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 Op-

eration goes out.
The message Alarm indicate "non-urgent" faults and continued operation of

the rectifier is possible. The alarm message is displayed in more detail in in-
teraction with the messages by way of the LED bar.
Repair of a non-urgent fault should be performed within 24 hours. How to

perform troubleshooting, see section 6.6 Faults and error messages.
The message Urgent alarm indicates faults which restrict or end the opera-
tion of the rectifier. Depending on requirement, urgent alarm messages are
coupled with a visual or acoustic fault signal (aggregate fault). The respec-
tive form, for instance a signal tone in a control centre, depends on the situa-
tions on site.
Urgent faults should be repaired immediately. How to perform troubleshoot-

ing, see section 6.6 Faults and error messages.
6.3.2 LED bar
In accordance with the standard configuration supplied ex factory, the LED bar
indicates the following statuses:
23.06.08- TB-Mo/Obs 37/107 4253 en

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
The meaning of the 14 LEDs is determined by the configuration file and depend-
ent 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
23.06.08- TB-Mo/Obs 38/107 4253 en

6.4 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
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 possible 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
switches on again,
pending messages, identifiable by flashing LEDs, will be deleted.
6.4.1 Equipment switch off/on
The equipment switch serves to switch the rectifier off and on, however without:
disconnecting the connections from mains power supply, battery, load,
switching off the regulator.
6.5 Start-up
The rectifier is an installation with permanent connection to the local electrical

system and is therefore always live. The rectifier s switched on and off with the
Off/On unit switch; the regulator remains always switched on and registers the op-
erating condition of the rectifier .
For start-up, proceed as follows:
→ Switch on the rectifier with the switch.
Various LEDs will light up and subsequently flash during the following initialisa-
tion 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.
23.06.08- TB-Mo/Obs 39/107 4253 en

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 6.6
Faults and error messages.
6.6 Faults and error messages
Faults and the status of the rectifier 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 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.
Unit error Unit output voltage - Mains fault Switch off rectifier, contactor
too low: 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 F7 (ur) or control fuses
off F4, F5, F6 have been inter-
rupted.
23.06.08- TB-Mo/Obs 40/107 4253 en

- 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.
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.
23.06.08- TB-Mo/Obs 41/107 4253 en

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, deactivate the
tive/negative lel operation with leakage current control in the
other rectifiers with regulator: See chapter 7.8.
leakage current con-
trol
With additional Check to see if the rectifier

leakage current con- THYROTRONIC has been
trols in other system 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 is provided.
system
Check if there is an earth fault
in the rectifier or load.
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6.7 Shutting down
6.7.1 Switching off rectifier
Shutting down the rectifier is not practical or necessary during regular operation.
Should shutting down of the rectifier be necessary maintenance or repair pur-
poses, proceed as follows:
→ Switch off the rectifier by placing the unit switch in the position 0.
6.7.2 Isolating the rectifier
In order to isolate the rectifier on the primary and secondary sides, proceed as fol-
lows:
→ Check to ensure that the rectifier 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.
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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.
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 up-
dated easily; 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,
- measured values or
- settings.
The display and operating panel installed in the front panel of the rectifier 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 DC monitoring relay (GSR) unit tem-
perature too high; function only available with separate temperature sensor,
23.06.08- TB-Mo/Obs 44/107 4253 en

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 cur-

rent limitation adjustable),
current-dependent compensation of the voltage drop on the line to the bat-

tery
(I x R compensation),
possibility of replacing internal mains monitoring by an external mains

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

connected rectifiers,
serial RS232 interface for communication and programming by way of lap-

top/PC,
display of measured values (for instance current, voltage, battery tempera-

ture) and statuses and characteristic changeover or display and change of
configuration parameters 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 received 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.
23.06.08- TB-Mo/Obs 45/107 4253 en

Completely designed screened cables are available under (part no. = TN):
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
Diagnostic interface RS232
An interface according to RS232 standard with 9-pin SUB-D plug (male/pin con-
tacts) 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, set-
tings, 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.
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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 interconnections. It is imperative to avoid coupling to external po-
tential!
DIP switch
Behind the terminal panel X36, a series of DIP switches is located on the
controller. The switches no. 1 – no. 11 are associated to the digital inputs X36.1 –
X36.11. In position "ON", the related input is internally connected to the 15V
supply. Since the input is "inverted" in the controller input filter program, no
reaction will occur if the input circuit is open (if the input is not connected).
Switch no. 12 will release the 15V supply for the terminal panel X11 if set to
position "ON". If an input is connected to a contact, the associated DIP switch
needs to be set to "OFF".
If the connection between X11xx and X36xx is interrupted, the controller will
show a response.
7.3.3 Analogue inputs
The Thysat regulator has 11 analogue inputs. 6 of these are registered and proc-
essed on the basic regulator card (unit voltage, unit current, battery current, resis-
tance to earth, 15 V supply system, 15 V supply DC). 3 measured values are di-
rectly connected and processed on the regulator (second U-channel / bus voltage
with parallel operation, battery temperature, 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
according to the voltage range and to specify this in the configuration!
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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 con-
tactor. The relay status is indicated by the LED situated directly below the corre-
sponding relay in the unit. If an LED is on, this means relay is energised. The re-
lays are rated 8A for AC 15...250V, 8A for DC 24V and 0.2A for DC 220V. If re-
quired, 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 opera-
tion 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 values; the regulator and pulse blocking is disabled and
the relay which controls the mains contactor is energised. Should the microcon-
troller 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 possi-
ble 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 manual mode under certain conditions since the microcontroller is no longer
able to influence the rectifier THYROTRONIC.
7.4 Assignation of connection terminals
In the standard version, the regulator terminals are assigned as follows. However,
the assignment 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
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Input terminal X36
I2C-Bus X100, X101
X100.1=X101.1 +8 V
X100.2=X101.2 SDA (data line)
X100.3=X101.3 SCL (clock line)
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
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Connections to basic regulator card X5, X4, X7:
X4.3 I battery (only when battery shunt con-

nected)
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
X7.5 Regulator lockout
If a battery shunt is connected, the jumper X41.1-2 must be inserted! The

measured value "Earth resistance" is enabled or disabled by means of the jumpers
X300, X301, on the lower controller board and by means of jumper X9 (directly
behind the connector X 4) on the upper controller board.
In parallel operation, the measured values battery current (for battery current limi-
tation), battery temperature and earth resistance may be present only once. In par-
allel 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
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Jumper for second U-channel

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.
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 explana-
tions of the individual 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
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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 restart after reprogramming and reset / no LCD display etc.),
it is possible trying to access the flash boot programme via an "emer-
gency 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 triggered!
7.6 Switching-on process on the regulator
Programme start commences as soon as the control card is supplied with voltage
by the basic 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 subsequent 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 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 oper-
ating 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 (password required). The unit switches over instantly.
If another rectifier 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.
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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
rechargeable battery type (exact details see technical 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 automati-
cally. The trigger for changing over to charging is the presence of the battery or
unit current limitation 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 battery current limitation threshold the system switches back im-
mediately.
If a recharging time has been programmed, switching back to float charging takes
place after the set time (recharging time). In the event of a mains power failure the
expired recharging time is not protected. Upon return of the mains power float
charging and changeover takes place according to the current measuring signals.
Set DIP switch no. 8 to "OFF": Function CHARGE is disabled. See the entry in
the "technical data sheet" of the rectifier.
7.7.3 Equalise charging
Equalise charging is the start-up mode for non-maintenance free batteries to form
the battery cells. Equalise charging takes place with a defined set voltage per cell
depending on the rechargeable battery type (exact details see technical 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 immediately.
The expired equalise charging time is protected in the event of mains power fail-
ure; upon return of the mains power, equalise charging continues at the time of
interruption. Following time-controlled or manual changeover from equalise
charging to Float charging, no overvoltage query is performed for 10 seconds.
Set DIP switch no. 7 to "OFF": Function EQUALISE CHARGE is disabled. See
the entry in the "technical data sheet" of the rectifier.
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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 bat-

tery 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 bat-

tery circuit test period (for instance 10 seconds, battery circuit test positive)
or the set battery circuit cancellation voltage (battery circuit failure).
• 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 in-
stance 10 seconds, battery circuit test positive) or the set battery circuit can-
cellation voltage (battery circuit failure).
The interval for the automatic battery (circuit) test is not re-triggered by a
manually triggered battery (circuit) test, i.e. the next starting date for auto-
matic battery (circuit) test remains intact.
During the battery test (not during battery circuit test), battery voltage, dura-
tion of the battery test and Ah withdrawn (with connected battery shunt) are
recorded.
Set DIP switch no. 9 to "OFF": Function Battery test is disabled. See the
entry in the "technical data sheet" of the rectifier.
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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 con-
figurations (for instance for use in power stations for rectifier coupling).
7.8 Parallel operation of two rectifiers
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 out-
put. 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
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 can
not be used. However, no battery availability test can be performed since the de-
vices do not share one common battery shunt. If this function is kept active on
both units, status report errors may occur.
Block diagram 1
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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 parallel with the consumer load circuit.
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 battery.
Block diagram 2
Configuration 3
This is a system which is specifically designed for parallel operation. It features a

single battery output and one (or several) common consumer load outputs.
See block diagram 3
Here, both units are designed for fully synchronised parallel operation. A parallel
operation line (synchronising line) between the two regulators ensures equal load
distribution. It is included in the delivery scope. All parameters are preset accord-
ingly.
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Block diagram 3
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
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 monitor-
ing must be disabled. The two regulators need to be connected via a parallel op-
eration line (synchronising line). (SAT bus)
Block diagram 4
If rectifiers, which do not correspond to configuration 3, are interconnected on

site, you need to make the following changes and settings:
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Since both rectifiers come standard with earth fault monitoring, this monitoring
function must be disabled on one of the two rectifiers. Otherwise, the earth fault
monitoring systems will measure erroneous values. To do so, proceed as follows:
On the regulator:
→ Remove jumpers X8, X300, X301,

all jumpers are located on the lower board
→ Remove jumper X9 (behind X4) located on upper board.
In the rectifier
→ 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 temperature-guided charge.
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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 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 sec-
onds, the low-priority fault message is issued; after 30 seconds, the signalling re-
lay 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 run-
ning unit despite 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.
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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 connected), the battery charging current limitation <IBatt is by default
not active and no overvoltage is queried until 10 seconds later.
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 blocking is set within an interval of < 10 msec for approxi-
mately 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 (urgent 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 equal-
ising charge, the condition overvoltage is not queried.
8.7 Battery voltage too low
If less than the defined set voltage per cell is available depending on the recharge-
able battery type (exact details see technical 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 rele-
vant LED is illuminated. 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.
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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 setpoints 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,
− 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 LEDs, 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.
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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
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 but-
ton)
Send input to MCU input xy (input designation of the MCU at the very
right)
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8.14 Limit value monitoring (DC monitoring relay)
Nine limit value monitoring instances act on each fixed measured value (see fig-
ure 10 Limit value monitoring and filter matrix for analogue measured values). To
do so there is an adjustable 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 inner limit band will again delete the
event.
Any measuring input
OG Limit value monitoring

H
H
UG Thresholds adjustable
generally enabled (0)

(0)
Invert input (5)
insert
Link (1) Link (2) Link (6) message text trigger
SVA SVB SVC (3) message (4)
user-designed
message
Message record
Figure 10 Limit-value monitoring and filter matrix for analogue measured value
8.15 Relay functions:
Up to 11 relays each can be connected to one of the 64 digital inputs and indi-
vidually inverted, provided with hold function and delayed (see figure 11 Relay
wiring to one input).
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In p u ts a n d e ve n ts/sta tu se s
M u ltip le x er 1 from 80
N o -lo a d c u rren t or lo ad
c urre n t
re la y 1 - … .
Figure 11 Wiring of the relay to one input
Four relays are situated directly on the regulator and additional ones can be fur-
nished. 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
2 Battery current
Battery current is registered bidirectionally so that for instance Ah-

balancing in the battery test can be performed through the discharging cur-
rent.
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.
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3 Battery temperature
4 Unit temperature
Should no temperature sensor be connected to the rectifier, 20°C bat-

tery/unit temperature 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 -
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9 Settings
9.1 Unit address (Adr)
The unit address is assigned automatically during the initialisation phase of the
rectifier (satellite). For this reason, no manual setting of the unit address is re-
quired as a rule. A manual unit address change is nevertheless possible in the sys-
tem 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 de-
sired value. (In the case of parallel operation with decoupling diodes, the bar volt-
age is measured which is detected via the 2nd voltage channel.) Deviations are
balanced out (gradually). In this way, unit-internal temperature drift or slight er-
rors 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 bat-
tery charging current limitation!
Mixed equipment (different nominal currents) is not allowed.
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9.4 Battery temperature-inclined characteristic (tEMP)
If required, the maintenance-charge characteristic can also be temperature tracked.

If this option is disabled, the unit will run with the set nominal voltage (for in-
stance 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 ac-
tual temperature, leads to increase or decrease of the output voltage.
The voltage limit values (<<U, >U etc.) remain constant and may be reached un-
der certain conditions!
9.5 Fault holding function (Err-H)
If a fault occurs in the rectifier, 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. However, if the option is activated (for instance for troubleshoot-
ing), all fault occurrences will be saved. This option is not identical with the hold-
ing 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 order 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 battery (circuit) test acts on the sec-
ond voltage channel. (Regulator terminal: X 400 Plus)
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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.
9.8 Main menu of the ABE display unit
Figure 12 shows an overview of the menu structure. The access authorisation

(password level) is stated in brackets.
standard measurement key S error log is dis- key E error log is

value display played cancelled
control
settings
measurement
values
statuses
display
menu lan-
guage
plant set-up
Figure 12 Menu structure
Some settings of the ABE or of the system (e.g. passwords) require text to be en-
tered. The cursor shows up in the form of:
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1. An underscore ‘_’:
With the jog dial, you can move the cursor position. Pressing the S button,
you activate the input mode (see chapter 6.3.1). With button E, you confirm
the entered data and terminate the input. Button C aborts the input procedure
(Escape).
2. A block ‘¦‘:
You can scroll through the characters available for input. Pressing the S but-
ton, you toggle over to the curser moving mode (see chapter 6.3.1). With
button E, you confirm all entered data and terminate the input. Button C
aborts the input procedure (Escape).
☞ For this input procedure, a help text is as well available; to activate it, press
S and then additionally E.
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10 Error memory
* Error message list

+ (06) 01.05.96-12.:00
no modem response
* no urgent fault *
In the ABE unit, a buffer loop memorises the last 200 fault conditions (error log).
The fault log can be called up from the standard display at any time by pressing
the fault button S. Now, you can scroll through the entries using the jog dial. The
most recent entry appears first. Button E deletes all entries.
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11 Error level and fault classes

All faults on the regulator or external monitoring units and on the SAT-bus de-
vices are associated with an error level which allows to display and memorise the
errors selectively. The higher the error level, the more severe the fault.
The error levels cannot be programmed but are determined according to the sig-
nalling filters (set in the MCU).
Generally, there are three error classes:
1. Errors of ABE and common messages
2. Errors of the external and internal monitoring logic
3. Errors on the SAT-bus devices
11.1 Error levels for ABE and common fault messages

Error Error level
Reception error 02
Inadmissible command 02
Common fault (SVC) 08
MCU communication error 09
Common fault (SVB) 09
Common fault (SVA) 10
11.2 Error level for the external and internal monitoring logic
Signalling filter Error level
Input not released (/GEN) 00 (no error)
Release (GEN) but nothing else 01 (internal system state)
(GEN) and insert message (ME) 04 (e.g. service switch)
(GEN) and logic linkage with SVC 05
(GEN) and logic linkage with SVB 06
(GEN) and logic linkage with SVA 07
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11.3 Error level for SAT-bus devices

Signalling filter Error level
Fault released 01 (internal system state)
" and logic linkage with SVB 06
" and logic linkage with SVA 07
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12 Error log
The error log displays time, error level and state.
A line of the error log looks like this:
1. +(07) 24.06.96 - 10:12 where:
'+' Symbol for "Fault has occurred"

(07) Error level
24.... Time of fault occurrence
2. Overvoltage on unit 02 Fault message text
If a faulty state terminates, a similar log entry including the respective time is
generated which starts with the '-' symbol to indicate "Fault has disappeared".
Example of an error log:
+(07) 24.06.96 - 10:11

Overvoltage on unit 02
+(07) 24.06.96 - 10:11

Fault on unit 02
+(10) 24.06.96 - 10:11

*** Urgent Fault ***
-(07) 24.06.96 - 10:12

Fault on unit 02
+(01) 24.06.96 - 10:12

Unit 02 was switched off
-(01) 24.06.96 - 10:12

Unit 02 was switched off
-(10) 24.06.96 - 10:12

*** Urgent Fault ***
-(07) 24.06.96 - 10:12

Overvoltage on unit 02
The causes of a fault will not always be recorded accurately to the second in the
order of occurrence because units, modem boards and ABEs access the system
states quite asynchronously, which may cause a delay in the fault messages of the
THYROTRONIC rectifier. This explains why the "Urgent fault" disappears first
and the overvoltage message is cancelled only later.
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13 Details of the menus

13.1 Control
These menu items allow to influence the rectifier via the ABE operating panel.
Control (0)
Characteristics change-over (2)
Boost (2)
Floating operation (2)
Direct feeding (2)
Battery test (2)
Abort battery test (2)
Equalising charing (2)
Battery circuit test (2)
Relay test (2)

Relay 1 (2)
Relay 2 (2)
....
Relay 10 (2)
Reset holding functions (1)
Freely defined commands

Command 1 (2)
Command 2 (2)
Command 3 (3)
Command 4 (2)
13.1.1 Characteristic changeover

The rectifier can match 5 different voltage levels which can be selected here.
Charging,
float charging,
direct feeding (for mains units),
battery test and
equalise charging.
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☞ When changing over to the Battery test characteristic, the unit per-
forms an entire battery testing cycle using parameters which are
stored in the regulator.
This test cycle can be terminated prematurely by the command ”Abort
battery test” or by a switch-over to one of the other characteristics.
☞ The characteristics Charging, Equalise Charging and Battery test can

be disabled separately on the regulator. In this case, no switch-over
will be carried out!
13.1.2 Relay test
Not supported on TDG rectifiers
13.1.3 Resetting the hold function

The LEDs on the LED board can all be configured for modal operation (lockup).
This menu item causes all modal (locked-up) functions to fall back to their default
mode (idle state) as soon as their activation condition is no longer present. The re-
set button below the LEDs has the same function.
13.1.4 Freely defined commands
Not supported on TDG rectifiers
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13.2 Settings
These menu items allow the user to change the monitoring parameters of the regu-
lator.
Settings (0)
Change date and time (1)
Battery test interval (2)
Duration of battery test (2)
Abort voltage battery test (2)
Measuring channel for battery test (0)
Voltage of battery 1 (3)
Current of battery 1 (3)
Voltage of battery 2 (3)
Current of battery 2 (3)
Limit value monitoring (0)
Measured value of input (4)
Lower limit value (3)
Upper limit value (3)
Hysteresis (3)
Figure 13 Adjustment of the monitoring parameters
13.2.1 Change date and time.

Changes the real time clock setting on the MCU main board.
13.2.2 Battery test interval

This menu item is not intended for TDG units. This value can be changed in the
"System setup / Thysat“ menu.
13.2.3 Duration of battery test

13.2.4 Abort voltage battery test

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13.2.5 Measuring channel for battery test

For the battery test, the regulator uses a voltage value (battery voltage: is used to
monitor the termination threshold) and a current value (battery discharging cur-
rent: is used to calculate consumption and capacity). This sub-menu allows to
specify the measured values to be used.
If the extended battery test is enabled, these measured values can be specified
separately for two batteries. (Not supported on TDG units.)
☞ If there are no specific measuring channels for battery voltage and

current installed on the THYROTRONIC rectifier, it is recommended
to maintain the system default values. In this case, the bar voltage is
used as battery voltage and the battery current is used as current
value!
13.2.6 Limit value monitoring

There are three adjustable measured value monitoring circuits available on the
regulator. Their setpoints (lower limit value, upper limit value, hysteresis and the
measured value to be monitored) can be changed.
☞ The menu will give you access only to released monitoring functions
which are listed together with the respective message text (e.g. 'Unit
voltage low'). All other limit value monitoring functions will be dis-
played in scrambled types, which are almost illegible. Limit value
monitoring functions may be released only by means of a special con-
figuration program!
Grenzwertüberwachung limit value monitoring

Gerätespannung zu tief unit voltage low …
keine Störung no fault
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13.3 Measured values

Includes menu items which display and record the measured values available in
the unit.
Measured values (0)

Present measured values (0)
Readings of installed measurements are
displayed
Measured value recording (0)
Display history (0)
Scan interval (2)
Measured values to be recorded (2)
Measured value 1 (0)
Delete records (2)
13.3.1 Present measured values

Shows the present readings of all installed measurements.
Spannung Batterie 1 voltage battery 1

13.3.2 Measured value recording

Sets the parameters for the measured value recording done in the ABE operating
panel. A total of 2000 data points can be split up among up to 4 measuring vari-
ables and be recorded.
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13.3.3 Display history

All measured graphs are normalised and displayed as a diagram. This is a mere
quality trend representation. All measured values can be selected individually by
means of the jog dial moving the cursor. First, the measured value label is dis-
played and next, the precise measured value including the time of capture.
Button E shifts the cursor to the next measuring graph at the same time of capture.
Then, the cursor can be moved again.
13.3.4 Scan interval

Enter the scan intervals of the measurement in hours and minutes.
Values below one minute will be refused.
13.3.5 Measured values to be recorded

You can choose one to four measuring variables you want to be scanned and re-
corded.
13.3.6 Delete records

After a scan has been started, the ABE will scroll and overwrite the measured val-
ues after the memory overflow. This command deletes all measured values so far
recorded.
☞ Any change in the scan interval or the type of measured value to be re-
corded will also delete all records. A message will warn you about this be-
fore you execute this command.
Cursor für Meßwerte
Zeitpunkt der Aufzeichnung Exakter Meßwert Meßpunkt-Index
Cursor für Meßwerte Cursor for measured values

Zeitpunkt der Aufzeichnung time of scan
Exakter Meßwert exact measurement value
Meßpunkt-Index measurement point index
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13.4 States
The states of the digital inputs and of the internal monitoring logic can be visual-
ised using the jog dial.
Example:
externe Batteriestörung external battery fault

nicht aktiv not active
The (6) marks the logic index of the state in the configuration file. Depending on
the state (active, inactive), messages which will result in a common fault are dis-
played along with a smilie indicator.
13.5 LED
Includes the menus which allow to configure the display and operating panel.
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Display (0)
Restoring the default values (4)
System info
Integrated units are displayed
Button E
Load distribution GR 1-24 (1)
Measured values to be displayed (1)

Load texts from the MCU (3)
Configuration flags (1)

Time display (1)
ESC function (1)
Illumination control (1)

Display lock (0)
Changing the passwords (1)
Password 1 (1)
Password 2 (2)
Password 3 (3)
Password 4 (4)
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13.5.1 Setting the default values

Set all adjustable settings in the display to factory default values, e.g. the meas-
ured value displayed as a standard and the settings regarding measured value
scanning and recording. All programmed texts and passwords remain unchanged.
Before you execute this command, a warning message will be issued.
Alle Einstellungen der Anzeige werden gelöscht All display settings will be deleted
13.5.2 System info

Displays all occupied unit addresses in the THYROTRONIC rectifier along with a
symbol of the respective device.
Geräteadresse 26 unit address 26

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Using button E, a table with the load distribution among the rectifiers (in A) is
additionally displayed.
Lastverteilung Load distribution (A)

13.5.3 Measured values to be displayed

The standard display permanently shows 0 - 4 measurement readings.
This setting allows to select how many and which measured values are displayed.
All permanently accessible measurements of the unit are available.
13.5.4 Load texts from the MCU base

In the MCU base, there are identifiers stored for all measured values and mes-
sages which are transmitted together with the fault log. These can be loaded into
the ABE panel. However, this will cause the loss of all texts previously pro-
grammed in the ABE!
A message will warn you about this before you execute this com-
mand.
13.5.5 Configuration flags

These are configuration settings which distinguish between two possibilities.
Time display
Possible settings: analog 08.07.96

digital 19:00-08.07.96
If more than two measurement readings are represented on the standard display,
the time will be displayed in 'digital' mode in any case.
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13.5.6 ESC function

After an adjustable period of inactivity where no button is pressed, the ABE will
return from any sub-menu level to the standard display (ESC function). This is
where you can set this period (0 - 240 seconds). The setting ‘0’ prevents the dis-
play from switching back to the standard display.
13.5.7 Illumination control

The ABE display backlight will automatically light up whenever a button is
pressed. After an adjustable period of inactivity where no button is pressed, the
display backlight is switched off. This period can be set from 10 to 240 seconds.
13.5.8 Display lock

The various menu items are protected by four password levels. When a password
has been entered, a certain level (1 - 4) will be accessible to the user.
Sie benötigen Passwort-Level 3 (akt. = 0) You require password level 3 (pres. = 0)

Passwort eingeben?e enter passord?
This menu item resets the password level down to 0 and thus locks all menu
items, which require password authorisation. Once the display has been locked, a
small key symbol appears in the status bar.
After two hours of inactivity where no button is pressed, the display will lock it-
self automatically.
The default settings of the four password levels are ”PW 1”, ”PW 2”, ”PW 3” and
”PW 4” (note the space between PW and digit).
13.5.9 Changing the passwords

This menu allows to change the passwords. The menu items are protected by the
respective password level.
Accordingly, the level 3 password can be changed only after a valid password of
level 3 or 4 has been entered.
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14 Menu language
Here, one out of 4 languages can be selected for the menu texts.
German
English
French
Custom defined language
The measured value texts and message texts are not available in four languages
since they can anyway be defined as desired (and will often be specific to the
unit).
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15 System setup
Includes menus allowing to configure the MCU basic card and other system pe-
riphery. Menus for parameterising the Thysat rectifier
System setup ( 0 )
MCU basic card ( 0 )
Rectifier ( 0 )
Thysat ( 0 )
15.1 MCU basic card
Menus to parameterise the MCU main componentry.
MCU basic board (0)

Modem initialisation (4)
Dialling prefix (3)
First telephone number (3)
Second telephone number (3)
Passwords (0)
Interrogation of operating location (4)
Call redirection step 1 (3)
Identification of operating location (4)
Times (0)
Duration of modem connection (2)
Wait if line engaged (3)
Delay SVA (2)
Delay SVB (2)
Delay SVC (2)
Duration relay test (1)
Cell number of batteries (3)
Options (0)
Control modem (2)
Automatic battery test (2)
Battery test for 2 batteries (3)
15.1.1 Modem initialisation

Edits the command string, which initialises the PSTN modem (option). This text
contains information about the communication MCU <=> modem and modem
<=> modem.
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The default command sequence should be changed only by personnel

who are very familiar with remote data transmission since any wrong
entry will affect the data transmission or even make it impossible.
15.1.2 Dial prefix

Processes the command transmitted to the modem before the actual number to be
dialled.
Examples:
ATDT AT initiates any modem command.

D means ‘dial’.
T means ‘tone’. The modem uses voice frequency dialling.
ATDP See above. P means pulse dialling.
ATDT0W Prior to dialling the actual number, a zero is dialled followed by a 1

second delay. This command is typical of subscriber extension sta-
tions where a '0' needs to be dialled to get an exchange line.
15.1.3 First telephone number

States the entire telephone number of the control centre workstation. This number
will be dialled by the MCU in case of a fault or if it is requested to ring back. If
this entry is blank, the system cannot ring back.
15.1.4 Second telephone number

States an alternative telephone number of the control centre PC. If the attempt to
connect via the first number fails (busy or no response), this second number is di-
alled. Subsequently, it will be dialled first until the attempt to connect fails here,
as well.
If this entry is blank, the system will always dial the first telephone number.
15.1.5 Passwords
Changes the 4 passwords stored in the MCU. One of them authorises the access to
the control centre PC, the other three verify the authorisation of incoming calls.
The password for the control centre is transmitted during every con-
nection with a PC and will usually be predetermined there.
Should this password be changed on the MCU, no remote connection

to the system can be established any more.
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15.1.6 On site unit identifier

This may be any desired text and enables the control centre PC to accept incoming
calls and to identify each system and its log file.
This identifier must meet two criteria:
1. It must be unambiguous, i.e. different for each unit.
2. The entry on the control centre PC must be the same as the selected identi-
fier (also with respect to upper and lower case).
15.1.7 Times
The MCU uses different times to run the program. Some of these can be selected
so as to suit your needs.
15.1.8 Duration of modem connection

Determines how long the MCU keeps the line towards the workstation alive after
a log has been sent and the user does not respond with other requests to the MCU.
15.1.9 Waiting period if line busy

If the control centre number is busy when the MCU calls up, it will make up to
seven further attempts to get the line. This menu defines the intervals between
these attempts in seconds.
☞ Depending on common carrier and modem type, there may apply

regulations regarding the minimum pause between two calls to the
same number!
15.1.10 Delay SVA/SVB/SVC

Defines the delay between the occurrence of a SVA/SVB or SVC fault and the re-
lated communication by means of relay or modem.
15.1.11 Duration of relay test

Defines the time interval where a relay remains in energised state after the relay
test has been triggered until it returns to the state which corresponds to its signal-
ling function.
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15.1.12 Number of battery cells (Not supported on TDG units)

This display view shows the number of cells stored in the internal MCU main
board. This value must correspond to the number of cells of the battery. Changes
in the displayed number of cells do not influence the voltage setting stored in the
Thysat regulator. The voltage settings can be effected at the menu item "System
setup / Thysat".
15.1.13 Options
Releases optional MCU functions.
15.1.14 Modem enabled

Releases data transmission via modem or disables the modem.
15.1.15 Automatic battery test

This menu item is not intended for TDG units. The settings can be effected at the
menu item "System setup / Thysat".
15.1.16 Battery test for two batteries
(Not supported on TDG units)

15.2 Thysat
Menus to set the Thysat rectifier parameters in the MCU system.
Thysat (0)
Charging voltage (2)

Float charging voltage (2)
Overvoltage switch-off (2)
Undervoltage limit (2)
Abort voltage battery test (2)
Equalise charging current (2)
Battery current limitation (2)
Recharging (2)
Equalise charging time (2)
Resume delay (2)
Battery testing time (2)
Battery test interval (2)
Earth fault resistance (2)
15.2.1 Charging voltage

Allows to change the CHARGING voltage setpoint.
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15.2.2 Float charging voltage

Allows to set the FLOAT CHARGING voltage setpoint.
15.2.3 Overvoltage switch-off

Determines the highest admissible output voltage before the unit is switched off.
15.2.4 Undervoltage limit

Voltage where the unit signals that the battery has touched the discharge limit.
15.2.5 Abort voltage battery test

Limit voltage where the battery test is aborted. If the voltage drops below this set-
point during a battery test, the test is aborted with negative result.
15.2.6 Equalise charging current

Current limit value for operating mode EQUALISE CHARGING.
15.2.7 Battery charging current limitation

Limit value for the battery (charging) current. The Thysat regulator monitors this
value in all operating modes.
15.2.8 Aftercharging
Determines the time delay before switching back to float charging.
15.2.9 Equalise charging time

Determines the time when to switch back to float charging with a delay
15.2.10 Resume delay

After a mains failure, the unit can resume operation with a delay. This time delay
is set here.
15.2.11 Battery testing time

Determines the time interval where the unit keeps on using the BATTERY TEST
characteristic to subject the battery to a backup test.
15.2.12 Battery test interval

The regulator can automatically trigger the battery test at regular intervals. This
time interval is entered here. The entry consists of days, months and years.
Example:
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If you set the interval to 03.02.00, the Thysat will perform an automatic battery
test every ”2 months and 3 days”.
15.2.13 Earth fault resistance

Threshold for triggering the "Earth fault" message. If the earth fault resistance
goes below the programmed setpoint, a related alarm is triggered off.
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16 Maintenance
16.1 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 mainte-
nance 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 through qualified electrical person-
nel.
The specified maintenance interval of one year refers to the continuous operation
of the rectifier. The details described in that chapter must be considered as mini-
mum recommendations. Depending on the operating conditions, these instructions
may require expansion in order to ensure the serviceability of the rectifier.
Special additional and supplementary information can be taken from the accom-
panying documents of the rectifier and the chapters 18/19 of these Operating in-
structions.
16.2 Inspection and maintenance

The rectifier must be inspected at least once per year and in the event of devia-
tions from the normal operating behaviour and maintained if applicable.
Following major maintenance measures, all measured values must be verified

with a precision instrument following the start-up of the rectifier.
16.3 Cleaning
Avoid damaging transformer windings and chokes.
• You can remove dust or dirt in the rectifier with a brush and vacuum cleaner.
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16.3.1 Terminals and plug connections

→ Check the terminals and plug connections and tighten if required.
→ Inspect the plug connections for clean contact surfaces, pull relief and correct
engagement.
16.3.2 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 con-

cerned.
→ Check the condition of the protective contacts: Remove burns (welding splat-
ter) 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.
16.3.3 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.
16.4 Exchange of electrolyte capacitors

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

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Before commencing work, disconnect the rectifier 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
manufacturer or supplier.
16.5 Externally ventilated semiconductors, power parts and transformers

(optional)
To make sure the faultless function it is recommended to check regularly (in very
dusty environments monthly) the air inlet and outlet and if necessary to clean
them.
To preserve the faultless function of the rectifier it is recommended to change the

ventilators after 5 years of operation.
Semiconductor power part
In case of fan failure the rectifier will be switched off via the temperature
monitoring device. The failure will be indicated optically on the display board and
as potential free contact (common alarm).
Transformators
In case of fan failure the rectifier will be switched off via the temperature
monitoring device. The failure will be indicated optically on the display board and
as potential free contact (common alarm). To change the fans they upward can be
pulled out of the air duct; tool is not necessary.

Before commencing work, disconnect the rectifier from all primary and secondary
connections.
To do so, proceed as described in chapter 6.7 Shutting down.
In case of doubt or with regard to questions concerning the procedure, consult the
manufacturer or supplier.
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16.6 Changing the regulator programme

The programme of the regulator has been preset at the factory. If any changes are
necessary, please contact the manufacturer.
16.7 Spare parts

Please contact the manufacturer or supplier quoting the unit data from the rating
plate should your require replacement parts.
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17 Disposal
If the rectifier 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 pos-
sesses a high hazard potential for the environment. For this reason electronic scrap
must be collected 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 packaging must be disposed of separately. Paper, cardboard and plas-
tics must be recycled.
17.1 Batteries
Important!
Old batteries contain heavy metals and caustic chemicals which may not enter into
the environment. 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.
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18 Regulator menu overview
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19 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
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DC monitoring 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
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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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// Identification digital inputs / events dig-inputs[]

// Inputs 0..13 are physically present (0..10 to bar, mains, 2 short-circuit bridges)!
//Physical inputs
#define DIG_OPT1 0
#define DIG_OPT2 1
#define DIG_OPT3 2
#define DIG_EXT_GR_FEHLER 3 // External unit fault
#define DIG_SWITCHOFF 4 // Unit off per door switch
#define DIG_OPT6 5
#define DIG_AL_LOCK 6 //AL lockout
#define DIG_L_LOCK 7 //L lockout
#define DIG_BT_LOCK 8 //Btest lockout
#define DIG_OPT4 9
#define DIG_OPT5 10
#define DIG_MAINS_FAULT 11 //Mains fault
#define DIG_P6_0 12 //P6_0, X41.3-4
#define DIG_P6_3 13 //P6_3, X41.1-2
//Virtual inputs
#define DIG_TEMPF 14 //Temperature sensor missing or defective
#define DIG_GTEMPF 15 //Unit temperature sensor defective/not available
#define DIG_GTEMP_HIGH 16 //1stGSR, unit temperature too high
#define DIG_U_VERYLOW 17 //<<U
#define DIG_U_HIGH 18 //>U (GSR, also temperature set from
dig_u_high_dyn)
#define DIG_I_LIMIT 19 //Current limitation
#define DIG_I_BAT_LIMIT 20 //Current limitation battery
#define DIG_EARTHF_POS 21 //+Earth fault
#define DIG_EARTHF_NEG 22 //–Earth fault
#define DIG_GSR_EXTRA_1 23 //Free extra GSR1
#define DIG_MODUL_FAULT 26 //Unit fault / module fault
//#########OR from unit fault and sensor
//breakage/regulator loop fault
#define DIG_BTFAIL 27 //Battery test fault
#define DIG_BKRFAIL 28 //Battery circuit fault
#define DIG_SVA 29
#define DIG_SVB 30
#define DIG_SVC 31
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#define DIG_U_I_SENS 32 //Spgs-/Current sensor breakage/regulator loop
fault
#define DIG_15V_DC 33 //No supply +15 V DC (limit value 10 V, Hyst
//1V)
#define DIG_15V_MAINS 34 //No supply +15 V mains (limit value 10 V,
//Hyst 1V)
#define DIG_MODUL_OFF 35 //Module off (or linked from off_hold and
//temp_off) for button LED
#define 36 //Module off and held, only via LED button
DIG_MODUL_OFF_HOLD //or SS unlockable if module _temp_off not
//no longer active
#define 37 //Module temporary for as long as fault present
DIG_MODUL_TEMP_OFF
#define DIG_U_HIGH_DYN 38 //>U dynamic (from interrupt): Filter_gen: From int
// perform,
//off_hold: Go to permanent off after 4*
//after 1*, should be permanently set off,
//in DIG_U_HIGH must be set to //filter_off_hold!
//Do not set a filter_off here, otherwise switching on
//again not possible!!
#define DIG_MODE_AUS 39 //Sequence must remain like b_mode!!
#define DIG_MODE_LADEN 40
#define 41
DIG_MODE_DAUERLADEN
#define DIG_MODE_DIREKT 42
#define 43
DIG_MODE_BATT_TEST
#define DIG_MODE_MANUELL 44
#define DIG_MODE_ALADEN 45
#define DIG_L_OR_AL 46 //OR from LA and AL, for LED
#define DIG_BATT_BETRIEB 47 //Battery operation, battery discharge
#define DIG_HOLDRESET 48 //Reset of hold function LEDs, relay
//(via button LED card)
#define DIG_AUS 63 //Input always 0 (with | INPUT_INVERT always 1)
//Measured value identification

#define KANAL_U 0 //AD measuring channels
#define KANAL_I 1
#define KANAL_IBAT 2
#define KANAL_T 3 //Battery temp.
#define KANAL_T2 4 //Unit temperature
#define KANAL_R 5 //Earth fault
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#define KANAL_15VDC 6 //15V supply from DC converter
#define KANAL_15VNETZ 7 //15V supply from mains
#define KANAL_U_SOLL 8 //Setpoint readjusted
#define KANAL_I_SOLL 9
#define KANAL_U2 10
//Miscellaneous measured values (for display / measured values)

#define KANAL_BKAP 11
#define KANAL_BT_TIM 12
#define KANAL_BT_U 13
#define KANAL_I_GES 14
#define KANAL_CH_TIM 15
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 button Description

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


ok OK (battery is working properly)
↔ Alternation to the next or previous menu point resp.
C Back to the Main menu level

Main menu tESt Display of the Main menu
C Back to the basic state

Basic state 240 U ↔ 10 A Alternating display of output voltage and power
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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 cells: Thysat - change current limitation battery 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
Enter Enter
E E
200 A – 150 A s = sec./
n = min./
h = hrs.
Enter Enter
E E
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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
23.06.08- TB-Mo/Obs 107/107 4253 en

Bennign Rectifier 4253 en Tdg2 - A3200902

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Bennign Rectifier 4253 en Tdg2 - A3200902

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Operating Instruction

Date Name No. 4253 en

23.06.08- TB-Mo/Obs 2/107 4253 en

4.4 Storage .................................................................................................23

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7.4 Assignation of connection terminals .....................................................48

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8.16 LED functions ......................................................................................64

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13.2.5 Measuring channel for battery test ........................................................77

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15.1.6 On site unit identifier ............................................................................88

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16.3 Cleaning ...............................................................................................92

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Figure 1 Type Code .............................................................................................................. 18

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In addition to the operating instructions, the valid applicable guidelines, standards

Information in addition to these operating instructions can be obtained from the

All documentation is protected under copyright law. Passing on and copying of

1.2 Scope of the Operating Instructions

→ the order confirmation,

→ the technical data sheet ,

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

→ the technical documentation in chapters 18/19 of these operating instruc-

23.06.08- TB-Mo/Obs 10/107 4253 en

1.3 Presentation remarks

☞ Notes contain additional information facilitating safe and efficient

This warning draws attention to possible damage to property which

This warning refers to possible injuries to persons which may result

Please observe all warnings and measures that prevent injuries to

23.06.08- TB-Mo/Obs 11/107 4253 en

These operating instructions are an essential part of the rectifier.

The operating instructions must be supplemented by the operator, with operating

2.2 Personnel qualifications

→ open the housing of the rectifier,

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

With qualified electricians it must be assumed that the applicable regulations of

23.06.08- TB-Mo/Obs 12/107 4253 en

2.2.1 Commercial use

If the rectifier is employed commercially, the following will apply in addition:

→ 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 THYROTRONIC is intended to supply DC voltage loads. In addition

23.06.08- TB-Mo/Obs 13/107 4253 en

2.4 Safety instructions concerning place of use and storage

The rectifier must be protected from inadmissible loads. In particular, no compo-

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 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 vicin-

The place of operation must be adequately ventilated so that resulting charging

23.06.08- TB-Mo/Obs 14/107 4253 en

2.5 Safety instructions concerning installation

The rectifier contains electrostatically susceptible components which can be easily

Protect the rectifier against overcurrent by means of an upstream mains

Switching (confusion) of poles with mains and battery connection must be

2.6 Safety instructions concerning operation