4830E Manual - Rectificador Jovyatlas

Operating Manual
IU Charging/Supply Rectifier
THYRIDIN
Models
UGV
Uninterruptible DC Voltage Supply Unit
BAX 4830
0
27. 08. 2012
Rev.
Date
A.Doyen
Author
Doyen
Checked
by
Original
Change no.
Notes
JOVYATLAS
GmbH
Groninger Strae 29-37
D-26789 Leer/Ostfriesland, Germany
Postfach 1580 / D-26765 Leer
Tel.: + 49 (0) 491 - 6002 - 0
Fax: + 49 (0) 491 - 6002 - 10
E-mail: ta@jovyatlas.de
Internet: http://www.jovyatlas.de
IU Rectifier Series THYRIDIN
Notes on this manual
Duty of instruction
This Operating Manual must be read carefully prior to assembly and initial commissioning of the
rectifier by the personnel assigned to work with and on it.
This Operating Manual is an integral element of the rectifier package. The company operating the
rectifier is obligated to make available this Operating Manual without restriction to personnel engaged
in transporting, commissioning, servicing and otherwise working on the unit.
Important instructions are indicated by the terms "CAUTION", "ATTENTION" and "NOTE", and by indented
text passages.
CAUTION:
Indicates instructions and procedures which must be precisely followed in order to avoid danger to
personnel.
ATTENTION:
Indicates instructions and procedures which must be precisely followed in order to avoid damage
to or destruction of the power supply unit, or parts of it.
NOTE:
Indicates technical requirements and additional information for the attention of the user.
i
Scope
This Operating Manual reflects the technical standing of the rectifier at the time of publication. Its
content does not form part of the contractual agreement, but is provided for information purposes only.
JOVYATLAS GmbH reserves the right to make substantive and technical changes relative to the
content of this Operating Manual without prior notification. JOVYATLAS GmbH cannot be held liable
for any errors or inaccuracies in this Operating Manual, in view of the fact that no obligation to provide
regular updates to it exists.
Loss of warranty
Our supplies and services are subject to the general conditions governing the supply of electrical
products and to our own general terms and conditions of sale. We reserve the right to make changes
to this Operating Manual in particular the technical data, operating instructions and weights and
measures stipulated in it at any time. We ask that any claims regarding deliveries be submitted within
eight days of receipt of goods, enclosing the relevant packing note. Claims made at a later time cannot
be considered.
JOVYATLAS GmbH will cancel without notice all obligations entered into by JOVYATLAS GmbH and
its agents, such as warranties, service agreements etc., if replacement parts other than original
JOVYATLAS GmbH parts or parts purchased from JOVYATLAS GmbH are used in servicing and
repair.
Operating Manual BAX 4830
Page 2 of 57
Handling
This Operating Manual is designed to enable all necessary commissioning, servicing and repair work
on the rectifier to be carried out by appropriately qualified personnel.
Hotline
Do you have any ideas or suggestions as to how we might improve this Operating Manual?
Do you perhaps have questions about matters covered in the Operating Manual?
Our Service Hotline is available to answer all your questions:
JOVYATLAS GmbH
26789 Leer, Germany
(0491) 6002-0
Fax
(0491) 6002-10
http://www.JOVYATLAS.de
Copyright
Any disclosure, reproduction and/or copying of this Operating Manual, by electronic or mechanical
means, in whole or in part, requires the express prior written consent of JOVYATLAS GmbH.
Copyright JOVYATLAS GmbH 2012.

All rights reserved.
Page 3 of 57
Contents
Notes on this manual
Technical data
General description
2.1
2.2
2.3
2.3.1
2.3.2
2.3.2.1
2.3.2.2
2.3.2.3
2.3.2.4
2.3.3
2.3.4
2.3.5
2.3.5.1
General information
Charging rectifier function
Functions of the individual modules
Thyristor module
Control board
Control electronics modules
EMERGENCY RUNNING switchover (optional)
Monitors
Signals, setting potentiometers, controls
Supply/synchronization module
Controller board AT90
Operator panel
Keypad assignment
8
8
9
9
10
10
10
11
11
12
12
13
14
Menu
15
3.1
3.2
3.3
3.3.1
3.3.2
3.3.3
3.3.4
3.4
3.4.1
3.4.1.1
3.4.1.2
3.4.1.3
3.4.1.4
3.4.1.5
3.4.1.6
3.4.2
3.4.2.1
3.4.2.2
3.4.2.3
3.4.2.4
3.4.2.5
3.4.2.6
Menu structure
Measured value/status displays
Standard parameter level
Language selection
Device type/firmware version
Show status table
Date/time setting / Alarm ON/OFF
Customer parameter setting / Password
Change charging characteristics
Float charge voltage setting
Battery charging current setting (optional)
Boost voltage setting (optional)
Current-dependent boost stage setting (optional)
Time-dependent recharge stage setting (optional)
Equalization charging stage setting (optional)
Changing battery data
Battery capacity setting
Discharge time setting
End-point voltage setting
Temperature coefficient setting (optional)
Manual temperature tracking
Max. battery temperature setting (optional)
15
16
16
16
17
17
18
19
20
21
21
22
22
23
24
25
26
27
27
28
29
29
Page 4 of 57
3.4.3
3.4.4
3.4.5
Cable compensation
Change mode / automatic charger
Capacity test mode
30
31
33
Computerized operation
35
4.1
4.2
4.3
4.3.1
4.4
4.4.1
4.4.2
4.4.3
4.4.4
4.4.4.1
4.4.4.2
4.4.4.3
4.4.4.4
4.4.4.5
RS232 interface
Reading the current data
System log
Deleting the system log
Commands
Overview of all commands
Commands for customer parameter setting
Download customer parameters
Upload customer parameters
Upload charging characteristics
Upload battery data
Upload cable compensation
Upload operating mode
Additional commands
35
36
38
38
39
39
39
40
41
42
42
43
43
45
Monitors / Messages
46
5.1
5.2
5.3
5.4
5.5
Earth fault monitor

Current-dependent low voltage monitor
DC high voltage monitor
DC low voltage monitor
Overview of fault and status messages
46
46
46
46
47
Transportation, storage and installation
49
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
General
Visual check
Packaging
Crane transport (option)
Transportation by forklift or hand lift truck
Location requirements
Floor fixing
Storage
49
49
49
49
50
51
52
52
Installation
52
7.1
Connecting up the unit
53
Commissioning
53
8.1
8.2
8.2.1
Power-up
53
Shutdown
53
Shutdown of uninterruptible DC power supply unit (UGV)
54
Page 5 of 57
Maintenance
54
9.1
9.2
9.3
9.4
9.5
Introduction
Preventive maintenance
Troubleshooting
Fuse list / Fans
Spares and service
54
54
54
55
56
10
Annex Standard
56
Page 6 of 57
Technical data
Control and display:

A1 Operating- and indication panel Rectifier 1
S1 1-Rectifier 1 ON
2-OFF
3-Rectifier 2 ON
Page 7 of 57
2
2.1
General description
General information
Wherever increased operating safety and high outputs are specified in DC voltage supply
to consumers, the thyristor-controlled rectifier is the most frequent technique employed. In
the JOVYATLAS "THYRIDYN" model series, the rectifier bridge is deployed in a fullycontrolled 6-pulse or optional 12-pulse circuit, depending on requirements. A 12-pulse
rectifier bridge is recommended whenever increased demands are imposed on the output
voltage in terms of current and voltage ripple. Another key point is reduction of the
harmonic currents from the power company supply network based on the use of 12-pulse
rectification.
The THYRIDIN series comprises the following models:
- supply rectifier
VG
- charging rectifier
LG
- uninterruptible DC voltage supply unit
UGV
If a secure power supply independent of the power company network is required, the
power supply units must be deployed with parallel-configured batteries. In this case, in the
event of a mains power failure the supply is maintained for a time (the bridging time) by
the battery. These systems are known as uninterruptible power supply (UPS) units,
designated here as UVG based on the German abbreviation. The DC voltage supply
consists of a regulated charging/supply rectifier with a float charge and boost device
adapted to the battery.
If increased demands are imposed, independent of the battery charging voltage, on the
consumer voltage tolerance limits, an optional single-stage or two-stage counter-cell unit
is used to stabilize the consumer output.
In line with the state of the art in power supply and battery charging technology, the
"THYRIDYN" series incorporates an electronic closed-loop and open-loop controller. The
integrated automatic charger enables users to freely configure the type of charge
characteristic and the battery charging voltage and current based on a menu-guided
program.
2.2
Charging rectifier function

The supply is connected to the charging rectifier on connector block X1.
ATTENTION:
When connecting the mains supply, ensure clockwise phase sequence!
The transformer (T1) transforms the mains input voltage into a level required for the
respective output voltage. The downstream fully controlled thyristor bridge (A1) rectifies
the AC output voltage of the transformer into a DC voltage with an overlaid AC voltage
component. The filter combination, comprising a smoothing reactor L1 and a smoothing
capacitor C1, reduces the output voltage ripple due to the operating angle.
All the components required for rectifier operation and monitoring of those components
are mounted on the control board 'P0034201' with the higher-level controller board
'P0034001.
Page 8 of 57
2.3
Functions of the individual modules
2.3.1
Thyristor module
The fully controlled thyristor bridge rectifies the AC output voltage of the transformer into a DC
voltage with an overlaid AC voltage component. According to the phase angle of the thyristors,
the output voltage or output current is regulated by way of the control board (A2).
The filter combination, comprising a smoothing reactor and a smoothing capacitor, reduces the
output voltage ripple due to the operating angle.
Super-fast fuses are connected upstream of the rectifier thyristors. They protect the thyristors in
the event of a short.
The fully controlled thyristor bridge used is equipped with a thermo-switch and a fuse monitor.
Overheating or fuse failure results in immediate shutdown of the rectifier.
Page 9 of 57
2.3.2
Control board
The control board is the interface between the higher-level controller board (A2) and the rectifier
power circuit. On it, all measurement data such as currents, voltages and temperature are
scaled and delivered to the controller board for further processing.
2.3.2.1 Control electronics modules

- Measured value scaling
for rectifier and battery current; consumer, DC link and battery voltages (UB and UB/2);
mains voltages and currents; and battery temperature
- Regulators
2 current regulators for the rectifier and battery current
1 voltage regulator for the output/battery voltage
LEDs on the control board indicate which of the regulators are active.
V9
Yellow LED lit voltage regulator active
V36
Yellow LED lit Battery charging current regulator active
V43
Yellow LED lit (Total) rectifier current regulator active
- Phase control electronics with pulse driver output stages
for phase control of a 6-pulse thyristor module, including interface for expansion to 12-pulse
rectification
- Interface/signal relays
K1 for rectifier ON/OFF , K2 and K3 for the 1-stage or 2-stage counter-cell control options,
K3 for the flat-battery monitor option.
2.3.2.2 EMERGENCY RUNNING switchover (optional)

Depending on the application, in the event of a fault in the microprocessor control an
automatic switch is made to 'emergency running' mode. In this case, the rectifier continues
operating with the pre-set basic current and voltage settings. With this option, it is also
possible to switch to emergency running mode manually by way of an additional switch in the
rectifier cabinet. In emergency running mode, an updated firmware version can be
downloaded without interrupting the battery charge or the supply to the consumers for
example.
Signalling on the control board: Yellow LED V96 lit
Closed by floating contact (K5) X8-9/10
Signalling via panel: "EMERGENCY RUNNING" display and yellow "Warning" LED
Basic setting for emergency running:
Parameter
Charge/output current
Battery charging current
Rectifier current (total)
Potentiometer
R31
R64
R47
Setting
UEL / Urated
Approx. AhBatt / 8
Rated current
ATTENTION:
In emergency running mode an installed counter-cell unit (optional) is
shorted. In UPS systems the basic setting for emergency running must never
be greater than the maximum operating voltage permitted at the consumer!
Page 10 of 57
2.3.2.3 Monitors
In addition to a large number of parameters monitored by the microprocessor controller, the
following values are monitored by hardware on the control board:
-
Rotating field fault

The supply system is monitored for clockwise phase sequencing. If an anti-clockwise
phase sequence is detected the start phase is locked. The phase control and thus the
output voltage of the rectifier is disabled. The phase angle of the mains feed must be
rotated!
Signalling on control board: red LED V61 lit
Signaling via panel: "Please check rotating field"
Phase fault
Activated in event of phase fault or mains voltages < 70%/Urated. In the event of a fault,
disables phase control and thus the output voltage of the rectifier. The supply rectifier
(VG) and charging rectifier (LG) can only be restarted after switching the rectifier off and
back on. In the case of uninterruptible DC power supply units, an autostart is executed
when the mains power is restored.
Signalling on control board: green LED V75 off
Signalling via panel: "Phase fault" display and red "fault" LED
DC high voltage
If the internal rectifier voltage exceeds the maximum threshold value pre-set
potentiometer R133, the phase control is immediately disabled and the output voltage of
the rectifier thus locked. A serious fault has occurred. It can only be reset by pressing the
RESET key S1 on the control board or switching the rectifier off and back on. If the fault
is then still present, please contact Service!
Signalling only on control board: red LED V88 lit
Auxiliary voltage
If the auxiliary voltage supply falls to <10V, safe operation of the charging/supply rectifier
is no longer guaranteed. The phase control is disabled and thus the output voltage of the
rectifier is locked. A serious fault has occurred. If the fault is still present after switching
the rectifier off and back on, please contact Service!
Signalling only on control board: green LED V86 lit
2.3.2.4 Signals, setting potentiometers, controls

On the control board are various potentiometers, signal elements and controls. They are
listed in the following table:
Potentiometer
R22
R70
R47
R31
R64
R47
R175
R187
R196
R169
Parameter
Comments
Voltage (U/UB) setpoint correction

Battery charging current (IB) setpoint correction
Rectifier current (IGR) setpoint correction
Charging/output voltage (emergency running)
Battery charging current (emergency running)
Rectifier current
(emergency running)
Phase angle adjustment, phase L1
Control voltage, phase control unregulated.
Factory calibration of
operating values
Factory basic setting for
emergency running (optional)
Factory calibration
Only for test purposes when

jumper JP21 1-2 set
Page 11 of 57
Keys
S1
LEDs
V9 Yellow LED
V36 Yellow LED
V43 Yellow LED
V61 Red LED
V75 Green LED
V86 Green LED
V88 Red LED
V96 Yellow LED
V128, V130,
V135, V138,
V142, V144,
yellow LEDs
2.3.3
Function
RESET DC high voltage
RESET emergency running
Display
Comments
Rectifier/charging voltage regulator active

Battery charging current regulator active
Rectifier current regulator active
Rotating field monitor (clockwise)
Phase fault or mains voltage <0.8xUrated
Electronics auxiliary voltage <10V
Emergency running mode
Thyristor gate activation active
LED ON when regulator active

LED ON in case of fault
LED OFF in case of fault
LED OFF in case of fault
LED ON in case of fault
LED ON when active
LEDs lit brighter at larger
phase angles
Press only in case of fault
Observe panel instructions!

Comments
Supply/synchronization module
The supply/synchronization module transforms the mains voltage into the low voltages required
for the electronics. Small auxiliary transformers deliver the synchronization signal for the
activation stages of a 6-pulse or 12-pulse thyristor rectifier bridge.
2.3.4
Controller board AT90

Mechanically, the controller board is located directly on the control board. It is the central
interface between the CPU (AT90) and the control board (P0034201).
The controller board also includes the following interfaces:
- Serial interface for the operator panel
- RS232 interface for computerized operation, alternatively connection of an
additional external panel possible.
- CAN bus interface for paralleling of multiple rectifiers.
- Programming (flash) interface for RISC controller AT90CAN128
- LED box interface
- Relay board interface
On the controller board AT90 are the following signals and controls. They are listed in the
following table:
Relays
K1
K2
K3
K4
Keys
S1
LEDs
V1
Green LED
Display
Comments
Collective alarm
Battery operation
Battery low voltage
Lamp test
-X9 1-2 open in case of fault

-X9 3-4 open in battery mode
-X9 5-6 open in case of fault
-X9 7-8 closed during lamp test function
V17
V18
V19
INTERLOCK
Voltage sense External
EMERGENCY RUNNING
Yellow LED
Yellow LED
Yellow LED
Function
RESET controller
Display
CPU OK
In the event of a CPU error the switch is made to

emergency running mode (optional)
Thyristor activation is blocked
Voltage regulator feedback
Emergency running control is set.
Page 12 of 57
2.3.5
Operator panel
The operator panel comprises a two-line LC display with 20 characters per line, an operator
keypad, a warning and fault signal generator and additional LEDs signalling the basic operating
states of the unit.
LED array:
Label
Rectifier ON
WARNING
FAULT
Battery operation
Colour
Green
Yellow
Red
Yellow
Display for
Mains power switch ON
Warning
Fault message
Emergency running mode via battery
(display only on UGV model)
By way of the operator panel all parameters required for charging/power supply can be preprogrammed and started. Release is password-protected.
Input and output values for current and voltages as well as the latest status and fault messages
are indicated on the display.
Page 13 of 57
2.3.5.1 Keypad assignment
Keypad:
Descriptions of the individual keys:
Arrow keys:
- Toggle between the readouts
- Toggle cursor between "YES" or "NO" when answering questions
- Select between "Exit" or "Save" after entering parameters.
- To scroll through the settings on configuration change.
ENTER key:
- Jump from the measured value/status display to the menu structure.
- Confirm inputs
RESET and Back key
- Go back to the previous menu item, cancelling the last input
- RESET fault messages
More functions appear after holding down key for 5 seconds
- Cancel an activated equalizing charge
- Cancel an activated capacity test
- RESET from emergency running back to normal operation
- RESET serious device faults, such as fuse fault, DC high voltage
Signal key (Test/Reset)
- Test visual and acoustic signal generators
- Reset acoustic signal generator in case of fault
Page 14 of 57
Menu
Operator control of the Thyridin rectifier is menu-guided. The menu is hierarchically structured.
The various options can be selected and set by keys.
3.1
Menu structure
The menu has three levels:
- Standard parameter level
- Password level 1
- Password level 2
Standard parameter level: At this level the following settings and queries can be made:
- Language
- Date/time
- Alarm tone ON/OFF
- History of last 99 status and fault messages
- Query device type and current firmware version
Password level 1: At this level the user can make changes to the factory-set parameters.
ATTENTION:
Changes should only be made by trained, authorized personnel. Consequently, this level is
password-protected.
Password: 1 2 3
At password level 1 (customer parameter setting) the following settings can be made:
- Charging characteristics
- Battery data
- Operating mode
Password level 2: In this area the factory parameter setting is carried out by the JOVYATLAS
test field technician. This level is password-protected and not accessible to customers. The
values specified here are automatically applied in the customer parameter set after each save
command.
Attention: Parameters set subsequently by the customer are reset to their factory settings after
confirmation of the "Enter device data" prompt with "YES".
NOTE:
Factory parameter settings at password level 2 are automatically applied at

password level 1 (customer parameter level) after confirmation of the "Enter
device data" prompt with "YES". This means old entries are also overwritten here.
Page 15 of 57
3.2
Measured value/status displays
Readout on UGV model:

UB:067.3
IB:017.3
I:120A
T:27C
Readout on LG model:
UB:067.3
IB:017.5
T:27C
Readout on VG model:
U:060.0
I:042.3
Example status message:

STATUS!
Float charge
When the rectifier is in normal operating mode the current measured values (4 sec.) and
status (2 sec.) are displayed alternately, including when one or more alarms has occurred.
All occurring alarms are displayed in sequence as STATUS.
When pressed, the readout toggles between the various measured value displays
for rectifier output/battery, mains voltage/frequency values and mains currents.
The mains input values for voltages and currents are only displayed optionally.
When the ENTER key is pressed the display switches to the standard parameter level
with all its functions and parameters. See next section, "Standard parameter level"
Optional displays:
Mains voltages/currents
UL1 UL2 UL3 Freq
231V 229V 230V 50Hz
IL1
124A
IL2
128A
3.3
IL3
125A
Standard parameter level

At the standard parameter level the following settings and queries can be made:
- Language
- Query device type / firmware version
- Query status table (history)
- Display/Alarm (date/time, acoustic alarm ON/OFF)
Starting point: Output of measured value and status messages.
When the
key is pressed the program switches to the standard parameter level. Each further
time the
key is pressed the program switches to the next menu item. Pressing the
key
moves step back in the menu structure.
3.3.1
Language selection
Either German or English can be selected as the language. Other languages are possible on request.
Display readouts:
Starting point display: Output of measured value and status messages.

Go to standard parameter level.
Select language
Language
Select German
Confirm language selection with jump to next menu item
Language
Select English
If no more keys are pressed, after 10 seconds the program automatically switches back to
output of the measured value and status displays. Alternatively press and hold down the
key until the STATUS display appears!
Page 16 of 57
3.3.2
Device type/firmware version
Procedure for output of device type and firmware version:

Display readouts:
x2
Version / ID
Display?
No
Go to standard parameter level. Repeatedly press

is displayed.
until the "Version/ID" menu item
>Yes
Device type
UGV 60V / 150A / 63Ah
GR Jovyatlas
Software ver.
GR1-1.0
3.3.3
Starting point display: Output of measured value and status messages.
Use the arrow key to place the cursor (>) on Yes and confirm with
. The device type
and firmware version are automatically displayed for 4 seconds each. Then the program
automatically jumps to the next menu item.
Show status table
The last 99 status/fault messages can be called up. The output and numbering is in reverse order, meaning
the last message to occur is number 1, and so on. The fault or operating states derived from the history serve
merely as advisories, and are not dated or timed.
If dated and timed data with the latest measured values is required for service purposes, it can be read-out
via the RS232 interface. The data can then be read by the "F" command in a conventional terminal program,
such as Windows HyperTerminal.
Procedure for output of status table/history:
Display readouts:
x3
Status memory
Display?
No
>Yes
Starting point display: Output of current measured value and status messages.
item is displayed.
Examples of status
messages:
STATUS:
Battery test
A1
STATUS:
Battery test
E2
until the "Status memory" menu
Use the arrow key to place the cursor (>) on "Yes" and confirm with
Scrolling through the Status memory

STATUS:
P3
Programm. EEPROM
Comments: Each serial number is prefixed by an identifier.

Three different identifiers may occur: "A" , "E" or "P"
- "A" stands for status message OFF (cancelled)
- "B" stands for status message ON (present)
- "P" on configuration changes, after saving data to the EEPROM
Page 17 of 57
3.3.4
Date/time setting / Alarm ON/OFF
Date and time setting:

According to the semiconductor manufacturer, the installed system clock has a variation of about 1 minute
per year. It is used only for correctly dated and timed logging of status and fault messages in the error log.
The clock should be checked and reset at least once a year.
Procedure for checking and setting the system time:
Display readouts:
x4
Display / Alarm
Change?
No
Date / time
Change?
No
>Yes
>Yes

item is displayed.
until the "Display/Alarm" menu
submenu is displayed.
Year
2007
. The "Date/time"
select
selection is displayed.
Month
8
Hour
11
select
. The "Year"
Select the year using the arrow keys and confirm with
. A dialog box opens to set
the month, and so on, until the day, hours and minutes have been set. Then comes the
prompt: Set date/time No/Yes
select
The date and time is set. Automatic jump to next menu item.
Minutes
21
select
Date / time setting

Change?
No
>Yes
Acoustic ALARM ON/OFF

Acoustic signalling of faults is enabled by factory default. In the event of a fault the signal generator behind
the operator panel is activated and can be reset by pressing the
key or via the RS232 interface by the
"E0" command.
If no acoustic signal is generated when a fault occurs, do the following:
Page 18 of 57
- Procedure for enabling and disabling acoustic signal:

Display readouts:

item is displayed.
x4
Display / Alarm
Change?
No
Date / time
Change?
>Yes
>No
Yes
until the "Display/Alarm" menu
The "Date/time" submenu is displayed.
Press
again. The "Alarm tone ON/OFF" submenu is displayed.
Use the arrow keys to place the cursor (>) on the desired setting here on "- Off -" and
.
confirm with
Alarm tone ON/OFF

-OFFselect
The acoustic signal generator is disabled and the program automatically moves on to the
next menu item.
3.4
Customer parameter setting / Password

At this level the user can make changes to the basic factory settings.
ATTENTION:
Changes should only be made by trained, authorized personnel. Consequently, this level is
password-protected.
Password: 1 2 3
At password level 1 (customer parameter setting) the following settings can be made:
- Charging characteristics
(not on VG)
- Battery data
(not on VG)
- Cable compensation
- Operating mode
(not on VG)
Comments: The factory-set default parameters are always displayed in brackets at the bottom right of the
display.
- Procedure for opening customer parameter setting:
Display readouts:
x5
Customer parameters
Change?
No >Yes
Password 1
123
Chrg.characteristics
Change?
>No
Yes

Press
repeatedly until the "Change customer parameter setting?" menu item is
displayed.
Use the arrow key to place the cursor (>) on the first digit of the password and confirm
with
.
Do the same for the second and third digits.
If the password input is incorrect, return to the "Change customer parameter setting?"
menu item.
If the password is correct (default: 123), you are prompted to open the first of 4 main
directories. "Change charging characteristics >No YES".
Page 19 of 57
3.4.1
Change charging characteristics

In this directory the parameters of the charging characteristics can be changed. Depending on
the rectifier configuration, irrelevant parameters may be removed from the menu options.
The following settings can be made in the "Charging characteristics" directory:
o Float charge voltage
o Battery charging current
o Boost voltage
o Current-dependent boost stage
Current threshold value (%/IB)
o Time-dependent boost stage
Recharge time
o Equalization charging stage
End-of-charge voltage
Equalization charging current
Equalization charging time
NOTE:
The settings in the "Charging characteristics" directory do not automatically result

in activation of the various boost stages. The preconditions is that the required
charging stage is activated in the "Mode" directory. See "Changing mode" section
on this.
i
NOTE:
Changes to the customer parameter settings are at first only buffered. Only when
the "Enter system? NO / YES" in the last menu item of the customer parameter
setting is set to "YES" and confirmed with "ENTER" is the data copied to the area
used by the regulator and written to the EEPROM. The display then shows: "Start
procedure softstart UB 10 sec.".
Page 20 of 57
3.4.1.1 Float charge voltage setting

The value of the float charge voltage also termed the trickle charge voltage is factory-set according to the
battery manufacturer's specifications.
Default values for the float charge voltage:
- Lead-acid battery: 2.23V/Z
- NiCd battery:1.40V/Z
- Procedure for setting the float charge voltage:

Display readouts:
Change?
No
>Yes
Float charge voltage

Change?
No >Yes
Starting point: Correct password input with access to the customer parameters. (See
"Customer parameter setting/Password section). The "Change charging characteristics?"
directory is displayed.
float charge voltage?" submenu is displayed.

2.30V/Z
(2.23)

2.30V/Z
Exit >Save
Enter system
Change?
No
>Yes
. The "Change
Use the arrow keys to set the desired value here "2.30V/Z" and confirm with
Use the arrow key to place the cursor (>) on ">Save" and confirm with
value is imported into the buffer.
. The new
Press repeatedly until the "Enter system" menu item is displayed. Use
to place the
cursor (>) on "Yes" and confirm with
. The start procedure is executed and the new value
is applied in active operation.
3.4.1.2 Battery charging current setting (optional)

The battery charging current is factory-set according to the battery manufacturer's specifications.
When setting the battery current, note the following:
The battery charging current of a UPS ("UGV") must be set so that a flat battery is recharged to 80% capacity within a
specified time.
According to the battery selection, the following charge factors are taken into account:
Charge factor for Pb batteries = 1.2
Charge factor for Ni-Cd batteries =1.4
Calculation of charging current (with boost stage) with a recharge time of 10h to 80 % of rated capacity:
Battery charging current = (battery_capacity(Ah) x charge factor) x 80 % : (10h x 100 %) = charging current (A)
- Procedure for setting battery charging current:
Page 21 of 57
Display readouts:
Change?
No
>Yes
Battery chrg.current
Change?
No
>Yes
Use the arrow key to place the cursor (>) on "Yes" and press
"Change battery charging current?" submenu is displayed.
100A
(120)
100A
Exit >Save
Enter system
Change?
No
>Yes
repeatedly until the
Use the arrow keys to set the desired value here "100A" and confirm with
. The new
to place the
3.4.1.3 Boost voltage setting (optional)

The boost voltage (IUU characteristic) is factory-set according to the battery manufacturer's specifications.
Default values for the boost voltage:
- Lead-acid battery: 2.40V/Z
- NiCd battery:1.55V/Z
- Procedure for setting the boost voltage:
Display readouts:
Change?
No
>Yes
Boost voltage
Change?
>Yes
No
Starting point: Correct password input with access to the customer parameters.
(See "Customer parameter setting/Password section). The "Change charging
characteristics?" directory is displayed.
"Change boost voltage?" submenu is displayed.
Boost voltage
2.45V/Z
(2.40)
Boost voltage
2.45V/Z
Exit >Save
Enter system
Change?
No
>Yes
. The new
to place the
3.4.1.4 Current-dependent boost stage setting (optional)

The current-dependent boost stage (IUU/ I-characteristic) is an extension of the standard boost stage (IUU
characteristic). Here, the switch back to float charge is not made on reaching the boost voltage but only once
the battery charging current falls to a pre-set value. The most frequent application is in charging of NiCd
batteries to shorten the time until the maximum battery capacity (full charge) is reached.
As this value must not be greater than the maximum battery charging current setting, the setting is made as a
percentage dependent on the configured battery charging current.
Page 22 of 57
- Procedure for setting the current-dependent boost stage:

Display readouts:
Change?
No
>Yes
Curr.-dep.boost stage
Change?
No >Yes
"Change curr.-dep. boost stage?" submenu is displayed.
60%
(50)
60%
Exit >Save
Enter system
Change?
No
>Yes
Use the arrow keys to set the desired value here "60%/IB" and confirm with
. The new
to place the
3.4.1.5 Time-dependent recharge stage setting (optional)

The time-dependent boost stage (IUU/ T-characteristic) is an extension of the standard boost stage (IUU
characteristic). Here, the switch back to float charge (EL) is not made directly on reaching the boost voltage
but only once a pre-set time has elapsed. The most frequent application is in charging of NiCd batteries in
conjunction with the "current-dependent boost stage". If current- and time-dependent charging stages are set
on the "Mode" menu, on reaching the pre-set current the current-dependent boost stage timer is activated.
When the pre-set time elapses the switch is made to float charge.
The time-dependent boost stage setting is freely configurable from 1 to 360 minutes.
- Procedure for setting the current-dependent boost stage:
Display readouts:
Change?
No
>Yes
Time-dep.rechrge st.
Change?
No >Yes
"Change time-dep. rechrge st.?" submenu is displayed.
120min.
(60)
120min.
Exit >Save
Enter system
Change?
No
>Yes
Use the arrow keys to set the desired value here "120min" and confirm with
. The new
to place the
Page 23 of 57
3.4.1.6 Equalization charging stage setting (optional)

For start-up or maintenance charging of a NiCd battery, the JOVYATLAS Thyridyn rectifiers can be fitted with
an additional equalization charging stage.
The default settings for end-of-charge voltage, equalization charging current and equalization charging time
are then freely configurable via the menu.
- End-of-charge voltage/equalization charging time: On reaching the end-of-charge voltage or at the end of
the pre-set time (10-72 hrs.) the switch is made back to float charge.
- Equalization charging current: To maintain the setting globally for all power classes, the pre-setting is made
as a percentage of the device rated current. %/IGR. The equalization charging current is selected according
to the battery manufacturer's specifications and converted to the percentage value of the rectifier rated
current.
- Procedure for setting equalization charging stage:
Display readouts:
Change?
No
>Yes
Equaliz.charge stage
Change?
No >Yes
"Change equalization charging stage?" submenu is displayed.
End-of-chrge voltage
2.65V/Z
(2.70)
Equaliz.chrg.current
30%/IGR
(20)
30%/IGR
Exit >Save
Use the arrow keys to set the end-of-charge voltage here "2.65V/Z" and confirm
with
End-of-chrge voltage
2.65V/Z
Exit >Save
. The new
Use the arrow keys to set the equalization charging current here "30%/IGR" and
confirm with
.
. The new
Equaliz.charge time
12hrs.
(24)
Use the arrow keys to set the equalization charging time here "12 hrs." and
confirm with
.
Equaliz.charge time
12hrs.
Exit >Save
Enter system
Change?
No
>Yes
. The new
to place the
. The start procedure is executed and the updated
values are applied.
NOTE:
The settings of the "equalization charging stage" do not automatically result in

activation. The "equalization charging stage" is started in the "Change mode"
directory. See "Changing mode" section on this.
Please observe the following warning!
Page 24 of 57
ATTENTION:
Before activating equalization charging, in UPS systems the consumers must always be disconnected
from the UPS. The increased equalization charging voltage may destroy the consumers. The
consumers are disconnected by opening the OCB in the UPS cabinet. When equalization charging
finishes the OCB must be closed again!
3.4.2
Changing battery data

This directory is only present in the UGV and LG models. Here the parameters of the connected
battery can be changed.
The following settings can be made in the "Battery data" directory:
o
o
o
o
o
o
Battery capacity
Discharge time
End-point voltage
Temperature coefficient for charging voltage tracking
Maximum battery temperature (optional)
Manual battery temperature tracking
NOTE:
When customer parameter settings are changed, they are only buffered.
Only when the "Enter system? NO / YES" in the last menu item of the
customer parameter setting is set to "YES" and confirmed with "ENTER" is the
data copied to the area used by the regulator and written to the EEPROM.
Page 25 of 57
3.4.2.1 Battery capacity setting

This value is factory-set to the battery manufacturer's rated capacity specification. The battery manufacturer's
rated capacity relates to a specific battery discharge time.
For example, the specification "C10" stands for a 10-hour discharge at nominal temperature; the specification
"C20" represents a 20-hour discharge. With shorter discharge times or in the case of battery quick
discharging, depending on the battery type the actual available capacity may fall to less than half the rated
capacity.
Comments: The battery capacity entered here has no influence on the charging characteristic of the device.
It is provided for information purposes only.
- Procedure for changing the battery capacity (LG and UGV only):
Display readouts:
Change?
>No
Yes
Battery data
Change?
>Yes
Press
No
. The "Change battery data?" menu item is displayed.
battery capacity?" submenu is displayed.
Battery capacity
Change?
No
>Yes
Enter system
Change?
No
>Yes
Use the arrow keys to set the desired value here "250Ah" and confirm with
Battery capacity
250Ah
(200)
Battery capacity
250Ah
Exit >Save
. The "Change
. The new
to place the
is applied.
Page 26 of 57
3.4.2.2 Discharge time setting

The value is factory-set to the maximum possible bridging time at consumer rated load.
Changes should only be made:
- if the bridging time has changed after inserting a new battery.
- if, in "capacity test" mode, the battery discharge is to be aborted before the endpoint voltage is reached. This function is only active when both modes
"capacity test" and "discharge time" are active. See "Capacity test/Discharge
time mode" section.
NOTE:
In contrast to the capacity test, the time set here has no influence on the bridging time in
the event of mains power failure.
- Procedure for changing the discharge time (LG and UGV only):
Display readouts:
Change?
>No
Battery data
Change?
Yes
Press
No
>Yes
"Change discharge time?" submenu is displayed.
Discharge time
Change?
Discharge time
180min.
No
>Yes
No
>Yes
Use the arrow keys to set the desired value here "180min" and confirm with
(120)
Battery capacity
180min.
Exit >Save
Enter system
Change?
. The new
to place the
is applied.
3.4.2.3 End-point voltage setting

The end-point voltage is factory-set according to the battery manufacturer's specifications. With the "flatbattery monitor" option, when the minimum end-point voltage is infringed the battery is automatically isolated
from the consumers by way of a contactor.
When making the setting note the following:
- The minimum end-point voltage of the battery should be set according to the
required bridging time and consumer current specified on the battery
manufacturer's data sheet.
- The minimum voltage permitted at the consumers should not be infringed.
ATTENTION:
If the minimum end-point voltage is infringed, depending on the battery
type (battery resistance to exhaustive discharge) the battery may be
destroyed.
Page 27 of 57
- Procedure for setting the end-point voltage (LG and UGV only):
Display readouts:
Change?
>No
Battery data
Change?
Yes
Press
No
>Yes
"Change end-point voltage?" submenu is displayed.
End-point voltage
Change?
No
>Yes
Enter system
Change?
No
>Yes
End-point voltage
1.65V/Z
(1.70)
End-point voltage
1.65V/Z
Exit >Save
. The new
to place the
is applied.
3.4.2.4 Temperature coefficient setting (optional)

The temperature coefficient is factory-set according to the battery manufacturer's specifications. Default
value: 3mV/C. With the "temperature-controlled charging voltage tracking with sensor" option the charging
voltage is automatically tracked according to the measured battery temperature.
- Procedure for setting the temperature coefficient (LG and UGV only):
Display readouts:
Change?
>No
Battery data
Change?
Yes
Press
No
>Yes
"Change temp.coefficient?" submenu is displayed.
Temp.coefficient
Change?
No
Temp.coefficient
4mV/C
>Yes
No
>Yes
Use the arrow keys to set the desired value here "4mV/C" and confirm with
(3)
Temp.coefficient
4mV/C
Exit >Save
Enter system
Change?
. The new
to place the
is applied.
Page 28 of 57
3.4.2.5 Manual temperature tracking

This setting option only exists if no temperature sensor is connected. The battery charging voltage of
charging rectifiers with temperature sensor on the battery is automatically tracked.
In manual charging voltage tracking the user can enter the actual temperature measured on the battery via
the panel as opposed to the battery nominal temperature (20 C). The battery charging voltage is recalculated
and successively tracked depending on the temperature difference and the temperature coefficient (see
previous section).
NOTE:
With manual temperature tracking there is no temperature output in the measured value
readouts
- Procedure for setting the manual battery temperature (LG and UGV only):
Display readouts:
Change?
>No
Battery data
Change?
Yes
Press
No
>Yes
"Change battery temp. manually?" submenu is displayed.
Battery temp. manual
Change?
No >Yes
Enter system
Change?
No
>Yes
Use the arrow keys to set the desired value here "30C" and confirm with

30C
(40)

30C
Exit >Save
. The new
to place the
is applied.
3.4.2.6 Max. battery temperature setting (optional)

This setting optional exists only in conjunction with the "temperature-controlled charging voltage tracking with
sensor" option. The battery charging voltage of charging rectifiers with temperature sensor on the battery is
automatically tracked and the maximum battery temperature monitored.
The limit value for the maximum battery temperature is factory-set to 40 C. When the limit value is exceeded
a warning is delivered.
ATTENTION:
Overheating of the battery will dramatically reduce its useful life.
At 30 C its life is halved. At 40 C it is only a quarter of the specified
lifetime (20 C).
Page 29 of 57
- Procedure for setting the maximum battery temperature (LG and UGV only):
Display readouts:
Change?
>No
Battery data
Change?
Yes
Press
No
>Yes
"Change battery temp. (max)?" submenu is displayed.
Battery temp. (max)
Change?
No
>Yes
Battery temp. (max)

30C
Exit >Save
3.4.3
No
Use the arrow keys to set the desired value here "30C" and confirm with
Battery temp. (max)

30C
(40)
Enter system
Change?
. The new
to place the
is applied.
>Yes
Cable compensation
This directory is present for all models UGV, LG and VG. Here the voltage drops on the
connecting cables caused by the charging current on the UGV and LG models and the load
current on the VG model can be compensated by entering the conductor length and cable crosssection!
The following settings can be made in the "Cable compensation" directory:
o
o
Conductor length
Conductor cross-section
NOTE:
In measured value readout for the battery voltage, panel output for UB, the
calculated value for the voltage drop on the cables to the battery is subtracted
from the output terminal voltage (B+/B-) and displayed. This calculated value is
also taken as the basis for the characteristic monitors.
ATTENTION:
After entering the conductor cross-section and length, the voltage should be
checked directly on the battery. The value measured with a DVM should
correspond to the output value, UB on the panel (+-1%). A correct check can only
be made if the battery current is >50 % of the pre-set charging current (IB).
Reason: The charging voltage correction dependent on the charging current.
Page 30 of 57
- Procedure for setting the cable compensation:

Display readouts:
Change?
>No
Yes
Press
repeatedly until the "Change cable compensation" menu item is displayed.
Cable compensation
Change?
No >Yes
conductor length?" submenu is displayed.
. The "Change
Batt.conductorlength
Change?
No >Yes
15 m
(0)
15 m
Exit >Save
Conductor x-section
Change?
No
>Yes
Conductor x-section
10 mm
(16)
Use the arrow keys to set the conductor length here "15m" and confirm with
Comments: Conductor length = add together + and wires. In this case 2x7.5m=15m.
The "Change conductor cross-section?" submenu is displayed.
. The new
Use the arrow keys to set the conductor cross-section used here "10mm" and
.
confirm with
Conductor x-section
10 mm
Exit >Save
Enter system
Change?
to place the
. The start procedure is executed and the new
settings are applied.
3.4.4
No
>Yes
. The new
Change mode / automatic charger

This directory is not present for the VG (supply rectifier) model.
Here the required charging characteristic(s) can be activated or deactivated for the UGV and LG
models. A capacity test or battery equalization charging can also be started.
Comments: The specified battery charging characteristic is factory-enabled according to
customer specifications.
The following charging characteristics/operating modes can be enabled in the "Mode" directory:
o Boost
IUU
o Current-dependent boost stage IUU/I
o Time-dependent boost stage
IUU/T
o Equalization charging stage
o Capacity test
o Discharge time
Page 31 of 57
NOTE:
The individual charging characteristics/operating modes are configured under the

"Charging characteristics" menu item. See the relevant sections under the main
directory "Change charging characteristics".
- Procedure for setting operating mode:

As an example, activation of a current- and time-dependent boost stage!
Display readouts:
Change?
>No
Yes
Operating mode
Change?
No
>Yes
Boost IUU
Change?
No
>Yes
Press
repeatedly until the "Change mode" menu item is displayed.
IUU? " submenu is displayed.
. The "Change boost
Attention: If a time- or current-dependent boost is required, the "boost IUU" must always be additionally
activated. Reason: A current- and/or time-dependent boost is always preceded by a voltage-dependent
boost stage IUU!
Boost IUU
ON
(1)
Boost IUU
ON
Exit >Save
IUU current-depndent
Change?
No >Yes
Use the arrow keys to set "ON" and confirm with
mode is imported into the buffer.
ON
(1)
mode is imported into the buffer.
IUU time-dependent
Change?
No
The "Change IUU time-dependent?" submenu is displayed.

IUU time-dependent
ON
(1)
IUU time-dependent
ON
Exit >Save
Operating mode
Save?
Exit >Save
ON
Exit >Save
.
.
.
.
.
.
.
.
. The selected
The "Change IUU current-dependent?" submenu is displayed.

>Yes
. The selected
Press 2 x
(jump to the next menu item)
The "Save mode?" menu item is displayed
The start procedure is executed and the new settings are applied.
Page 32 of 57
NOTE:
If the battery is (partially) discharged during a power failure and after the mains
power is restored the float charge voltage is not reached within 5 seconds, the
selected boost stage is automatically activated. The panel displays the activated
charging stage alternately with the measured values. In our above configuration
example the outputs "Boost IUU" and "Boost IUU /I /T".
(The voltage-dependent boost stage IUU current- and time-dependent is active)
3.4.5
Capacity test mode
It is possible to perform a battery test and so rate the connected battery. The test is started from the "Modes"
menu.
NOTE:
If the capacity test is activated during a boost charge, it is automatically started

only once the boost is complete, and provided the external control contact to
enable the capacity test is closed. The control contact is connected to X5 5/6
(optional).
Description:
In a battery test the output voltage of the charging rectifier is reduced so that the connected consumers are
being powered solely by the battery. The panel indicates "Capacity test active", with the battery discharge
time.
The switch-off condition is the end-point voltage. When the end-point voltage falls below the minimum, the
system switches automatically back to battery power. A result notification is only outputted if the minimum
end-point voltage is infringed before the discharge time is reached. The display then shows: "Cap.test
negative", the red "fault" LED lights up and the acoustic signal generator sounds. The message is reset by
way of the "RESET" key
. If the capacity test is positive, no result output is generated.
Default settings:
The end-point voltage and discharge time are factory preset according to the battery manufacturer's
specifications with regard to the maximum consumer current (rated load). The settings can be adjusted to
actual on-site conditions on the "Change battery data" menu. See "Discharge time setting" and "End-point
voltage setting" sections.
NOTE:
If the capacity test is specified exactly at rated load, and if the required load
cannot be simulated locally by the connected consumers, JOVYATLAS can
supply load resistors.
Selection options:
On the "Modes" menu users can choose between two modes for execution of the capacity test:
1) If only the "Capacity test" option is selected on the "Modes" menu, the test is only ended once the endpoint voltage has been reached. The battery is fully discharged.
2) If "Capacity test" and "Discharge time" are selected on the "Modes" menu, provided the minimum endpoint voltage has not been infringed beforehand the test is ended when the discharge time is reached.
Page 33 of 57
Procedure: Select Capacity test with Discharge time

Display readouts:
Charging chars.
Change?
>No
Yes
Operating mode
Change?
No
>Yes
Boost IUU
Change?
>No
Press repeatedly until the "Change mode" menu item is displayed.
.
The "Change boost IUU? " selection menu is displayed.
Yes
Press repeatedly until the "Change capacity test?" menu item is displayed.
Capacity test
Change?
No
Capacity test
ON
Capacity test
ON
Discharge time
Change?
>Yes
(1)
Exit >Save
No
>Yes
Use the arrow key to place the cursor (>) on "Save" and confirm with
The selected mode is imported into the buffer.
(1)

Discharge time
ON
Exit >Save
Save mode
Change?
The "Change discharge time?" selection menu is displayed.

Discharge time
ON
The selected mode is imported into the buffer.
The "Save mode?" menu item is displayed

Exit >Save
The capacity test is activated, provided no boost charge is active and the external control
contact is closed.
Capacity test
Activ e
UB:067,3V
IB:017,3V
xxx Min.
I: --A
T: 27C
The panel indicates "Capacity test active", with the battery discharge time.
Press the left arrow key to display the momentary measured values. Hold down the
arrow key until the measured value outputs for battery current (IB) and battery voltage (UB)
are displayed. The measured values are displayed for 5 seconds.
Capacity test abort:
1) By pressing the "RESET" key.
Press and hold down the RESET key
until the restart is initiated (after about
5 seconds). No confirmation message is displayed.
2) By way of the external control contact (optional).
Pin on X5 5/6. When the control contact is opened the charging rectifier restarts. Then,
among other status messages, the panel indicates "Batt.test aborted". The panel output can
be reset by tapping the RESET key
.
Page 34 of 57
4
4.1
Computerized operation
RS232 interface
The RS232 interface of the rectifier is mounted inside the unit. It permits
operation of the rectifier from an external computer. For this, the computer is
connected to the rectifier by way of a cable.
The technical data of the cable:
9-pole with SUB-D9 connector (1 x male, 1 x female)
Wiring:
1:1
The interface of the external computer is set to:
9600 Baud 8N1, no hardware handshake
Required software: A terminal program such as has been shipped with every
operating system since 1995.
The serial interface is used in the following to:
- read the ongoing rectifier data
- read out the status/fault memory
- download/upload factory parameters
- download/upload customer parameters
- shut down the rectifier
- transfer a manually measured temperature
- query the rectifier software version
- set the system time and date
- output error messages in the event of incorrect queries
- reset fault messages/acoustic signal generators
Some of these functions can be initiated by way of the terminal program:
The commands for this are included in the detailed description, together with
examples.
As soon as the rectifier is switched on, the current measured values and
device configurations are transferred via the rectifier's RS-232 interface and
displayed on-screen in table form.
The measured values are updated every second. This output is intended
solely for the service technician, to provide a rapid overview of the current
measured values and setpoint inputs for ongoing operation.
Continuous output of the momentary measured values and setpoint inputs
can be blocked by way of a DIP switch on the controller board P0034001.
Outputs then only appear following command inputs.
DIP switch array (S2) DIP8=ON
Page 35 of 57
4.2
Reading the current data

Reading out the current measured values
The syntax for this is:
S <ENTER>
#SI50|3|1|1:099:03:21|227||230|228|1001|1002|1000||0235.5|0792.0|518.6|513.4|500.2|20
|99|0Rectifier ON |0Float charge |1Earth fault |GB|1GS|0
The first string is terminated by 0x0d; 0x0a (<CR> , <LF>).
Meanings of the entries:
No. Entry
1 50
2 3
3 1
4 1:099:23:21
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
227
230
228
1001
1002
1000
0235.3
0792.0
518.6
513.4
500.2
20
99|0 Rectifier ON
GB|1
GS|0
(*)
Comments
Runtime phase
(*)
Characteristic type (mode)
(**)
Operating status
(***)
Runtime in operating mode
(previously i.e. 1 year, 099 days, 23 hours, 21 minutes;
Mains voltage UL1 phase (Volts)
Input AC IL1 (Amperes)
Rectifier current IGR (Amperes)
Battery current IB (Amperes)
Internal DC voltage UINT (Volts)
Battery voltage UB (Volts)
Consumer voltage UL (Volts)
Current battery temperature (C)
Output of status/fault messages
(****)
Rectifier active
( not aktive GB|0 )
Rectifier collective fault active
( not active GS|1 )
Possible runtime phases are:
|1 Initialization of variables for cold start

|2 Init variables for warm start (access on Reset via key on panel)
|3 External fault port 1
|4 Fuse fault
|5 Query emergency running switch
|6 Query energy counter mains voltage -15% +10%
|7 Mains rotating field fault
|8 ---|9 Temperature
|10 Mains contactor switched
|11 Insulation fault
|12 Check connected battery voltage UB
|13 Setpoints are outputted (10 sec. soft start)
|14 Battery contactor ON (optional)
|15 Query BCB ON, emergency running ON
|16 Set voltage sensor from Internal to External
|17 Increase voltage setpoint in 2 sec to final value
|18 Status float charge is activated
|19 Display text on OCB wait 1 sec.
|20 Wait for OCB ON, closed jump to phase 50)
|50 Rectifier active
|60 Battery operation Wait for autostart
|100 Off state. Jump to here in case of fault. Only reset is possible.
|150 Shutdown procedure, for LG and VG jump to phase 190
Page 36 of 57
|151 Countdown 5 sec

|152 Battery contactor is switched off
|153 Prompt to "switch off BCB"
|154 Wait until BCB switched off
|155 Interlock thyristor assembly
|156 Wait until OCB switched off
|157 Mains contactor off, disable text output GR
|158 Wait until ICB switched off
|159 If ICB off, jump to 200
|190 Access shutdown procedure for LG and VG
INTERLOCK is set (rectifier is disabled)
|191 Switch off battery contactor
|192 Switch off mains contactor, jump to phase 200
|200 Regulator has shut down, wait for reset
(**) Characteristic types:
The following outputs for the characteristic identifier are possible:
0: IU Float charge characteristic
1: IUU Boost characteristic, voltage-dependent
2: IUU/I Boost characteristic, current-dependent
3: IUU/T Boost characteristic, time-dependent
4: IUU/I/T Boost characteristic, time- and current-dependent
5: Ia Equalization charging stage
6: Capacity test
(***) Operating status
The following outputs for operating status are possible:
0: Start phase
1: Mains operation
2: Battery operation
3: Emergency running
(****)
Output of status/fault messages
The status is transferred as follows:

I99|<STATUS> <TEXT>
Key:
<STATUS> = 0
=1
<TEXT>
(non-fatal condition / status message)

(fatal condition / fault message)
Rectifier ON
Float charge
Boost IUU
Boost IUU/I
DC low voltage
etc.
For a complete overview of all status and fault messages see "Overview of fault
and status messages".
Page 37 of 57
4.3
System log
The system log is a circular buffer for a maximum of 99 entries. The entries
are used by the service technician when carrying out repairs to the unit. Data
is saved on program start-up, on program termination with an appropriate
abort criterion and in the event of a system fault.
The system log registers every change of status or fault message. Each
entry comprises 3 lines. Each line is terminated by 0x0d; 0x0a (<CR>, <LF>).
7 messages are read out with the command.
F <ENTER>
After each further command input 7 more messages. Maximum 99

messages.
Example:
1 15 E 41
Counter-cell 1 active 20.09.2006 13:47:04 IU
IB:4.6A IGR:59.3A UINT:26.1V UB:26.3V UB/2:13.1V UL:27.0V
TEMP:23Grad UBSOLL:24,3V IGRSOLL:60A IBSOLL:5A
2 etc. up to a maximum of 99 entries
Decoding fault code:
The entries in the system log correspond to the current measured values at the time of
identifying the status or fault:
1
15
E
41
Counter-cell 1 active
20.09.2006
13:47:04
IU
IB:4.6A
IGR:59.3A
UINT:26.1V
UB:26.3V
UB/2:13.1V
UL:27.0V
TEMP:23 degrees
UBSOLL:24.3V
IGRSOLL:60A
IBSOLL:5A
(1-99)
: Serial number
: Program phase
: ON
(E = ON A = OFF)
: Fault/status number
(*)
: Status or fault message as string
(*)
: Date
: Time output
: IU characteristic = float charge (on UGV and LG)
: Battery current
: Rectifier current
: Internal DC voltage
: Battery voltage
: Battery mean voltage
: Consumer voltage
: Battery temperature
: Setpoint for the battery voltage
: Setpoint for the rectifier current
: Setpoint for the battery current
(*)
The Overview of fault and status messages section sets out a listing of all
messages
4.3.1
Deleting the system log

The circular buffer memory can hold a maximum of 99 fault and status messages. If the
memory is full, old messages are overwritten.
The system log memory can be deleted with the following syntax:
DELS <ENTER>
If stored data is then requested from the system log memory with the command F <ENTER>,
the returned message is #Empty
Page 38 of 57
4.4
Commands
The customer parameters (password level 1) contain parameters which can be changed
by the customer by way of the operator panel or via the RS232 interface.
If the syntax is incorrect a fault message is returned. Fault numbers less than 100 indicate
the position in the string as from which a fault occurs.
Example: -Error- ____001___
Error (fault) numbers >=100 are parameter-specific and so not separately described.
4.4.1
Overview of all commands

The following listing merely presents an overview of all commands. They are not all intended for
the user and so are not described in detail. Parameter changes via the RS232 interface by the
operator are described in the next section.
dk
dkn
ukn|xx
prk
dw
dwa
dwb
dwc
dwn
uwn|xx
prk
v
e0
e1
f
dels
stp
c1|xx
s
tx
res
4.4.2
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
Download all customer parameters

Download individual customer parameters
(n=1-16)
(n=1-16, xx=parameter value)
Apply customer parameters
Download all factory parameters
Download factory parameters 1-18
(n=1-52)
Download individual factory parameters
Upload factory parameters
Apply factory parameters
Firmware version info
Reset buzzer
Warm start, abort capacity test, abort equalization charging
Download fault/status memory,7 messages per query, max. 99
Delete fault/status memory
Shutdown procedure is initiated
Set system time
(xx = DDMMYYYYHHMM00)
Status output
Set battery temperature
Complete restart (cold start)
Commands for customer parameter setting

With the following commands operators can read out and change the current parameter
settings.
dk
dkn
ukn|xx
prk
v
e0
e1
c1|xx
s
tx
res
:
:
:
:
:
:
:
:
:
:
:
Download all customer parameters

Download individual customer parameters
(n=1-16)
Apply customer parameters
Firmware version info
Reset buzzer
Warm start, abort capacity test, abort equalization charging
Set system time
(xx = DDMMYYYYHHMM00)
Status output
Set battery temperature
Complete restart (cold start)
Page 39 of 57
4.4.3
Download customer parameters

With the following command the current customer parameters (01- 16) can be read out.
The syntax for this is: dk <ENTER>
Reply:
#DK01|2,32
#DK02|10
#DK03|2,40
#DK04|60
#DK05|360
#DK06|2,65
#DK07|20
#DK08|24
#DK09|63
#DK10|180
#DK11|1,70
#DK12|3
#DK13|45
#DK14|10
#DK15|10,0
#DK16|001
(*)
0
1
2
4
8
16
32
Float charge voltage (V)

Battery charging current (A)
Boost voltage (V)
Threshold value current-dependent boost stage (%/IB)
Time-dependent boost stage (Min)
End-of-charge voltage (V)
Equalization charging current (%/IB)
Equalization charging time (Hrs)
Battery capacity (Ah)
Discharge time (Min)
End-point voltage (V)
Temperaturee coefficient (mV/C)
Battery temperature max. (C)
Conductor length (m)
Conductor cross-section (mm)
Modes,
see below! (*)
Coding for the modes

Float charge
Boost
Boost current-dependent
Boost time-dependent
Equalization charging
Capacity test
Discharge time
IU
IUU
IUU/I
IUU/T
Multiple modes may also be set simultaneously!

Here is an example of coding/decoding the mode:
DK16|7
7 signifies "mode is set to current- and time-dependent boost".
Composed of:
Boost charge (1) + boost current-dependent (2) + boost time-dependent (4)
Decoding mode 7 = 1+2+4
- Download individual customer parameters
The customer parameters can also be read out individually by suffixing the relevant identifier.
The syntax for this is: dkn <ENTER>
(for n=1-16)
Example of readout of the current float charge voltage:

Syntax:
dk1<ENTER>
Reply: #dk01|2,32
Page 40 of 57
4.4.4

The customer parameters (password level 1) contain parameters which can be changed
by the customer by way of the operator panel or via the RS232 interface.
With the commands UK1|x to UK16|x the user can directly influence the output
parameters of the rectifier.
The data changed with UK|x is neither already being used in the regulator nor is it stored
in the EEPROM. It is located initially in a separate working area. Only with the command
"PRK" is the data copied to the area used by the regulator and written to the EEPROM.
The acknowledgement returned is: #PRK
Syntax : UKn|x <ENTER>
(for n=1-16, for x = new value)
Example for changing the battery charging current to 11A and the boost voltage to 2.38V:
Syntax:
Reply:
Syntax:
Reply:
Syntax:
Reply:
uk2|11<ENTER>
#uk01|11
uk3|2,38<ENTER
#dk01|11
PRK
#PRK
; set battery charging current to 11A
; write new value(s) to EEPROM
If the syntax is incorrect a fault message is returned. Fault numbers less than 100 indicate
the position in the string as from which a fault occurs.
Error (fault) numbers >=100 are parameter-specific and so not separately described.
NOTE:
If the syntax is incorrect a fault message is returned. Fault numbers less

than 100 indicate the position in the string as from which a fault occurs.
Error (fault) numbers >=100 are parameter-specific and so not separately
described.
Page 41 of 57
4.4.4.1 Upload charging characteristics

The parameters listed under "Charging characteristics" can be changed during operation and applied as current
parameters with the terminating command "PRK".
Charging characteristics
Parameter
Input
Reply
Selection
Setting range
Explanation / Comments
UK1|x,xx
#UK1|x,xx
Pb:2.00-2.35 V/Z
NiCd: 1.20-1.45
Value for the float charge voltage on a charging rectifier (LG or UGV)
Value for the consumer voltage on a supply rectifier (VG)
UK2|xxxx
0-rated current
Only in case of charging rectifier with "boost stage" option
Boost voltage
UK3|x,xx
#UK3|x,xx
Pb:2.30-2.45 V/Z
NiCd: 1.50-1.65
Current-dependent
boost stage
UK4|xx
#UK4|xx
10-98%
Time-dependent
boost stage
UK5|xxx
#UK5|xxx
1-360 Min
End-of-charge
voltage
UK6|x,xx
#UK6|x,xx
NiCd: 1.60-1.80
Pb:2.50-2.80 V/Z
UK7|xx
#UK7|xx
0-30% / IGR
Only in case of charging rectifier with "boost stage" option

Current value in %/battery charging current at which the switch is made to
float charge.
Only in case of charging rectifier with "current-dependent boost
stage" option
Time at which the boost stage remains active on reaching the boost
voltage.
Only in case of charging rectifier with "time-dependent boost stage"
option
Switching threshold to float charge with activated equalizing charge
Only in case of charging rectifier with the "equalization charging"
option
Battery equalization charging current with active equalization
charging. Entry in %/IGR.
Only in case of charging rectifier with "equalization charging" option
Equaliz.charge time
UK8|xx
#UK8|xx
0-72 Hrs
When the configured time elapses the switch is made to float charge.
Only in case of charging rectifier with "equalization charging" option
4.4.4.2 Upload battery data

Battery data (LG and UGV)
Parameter
Input
Reply
Selection
Setting range
Battery capacity
UK9|xxx
#UK9|xxx
0-999Ah
Discharge time
UK10|xxx
#UK10|xxx
1-999Min
End-point voltage
UK11|x,xx
#UK11|x,xx
NiCd: 0.65-1.10
Pb:1.40-1.90 V/Z
Temperature
coefficient
UK12|x
#UK12|x
0-5 mV/C
Battery temperature
(max)
"Change battery
temperature
manually"
UK13|xx
#UK13|xx
30-50C
Capacity of the connected battery.

This entry has no influence on the program.
Battery bridging time in rated load operation.
In a capacity test and with "discharge time" mode additionally
activated, this value serves as a reference value for assessment of
whether the capacity is adequate or not.
Switching threshold in case of a fully discharged battery with the
message "End-point voltage" and isolation of the battery by a
contactor (option) in the battery circuit.
Temperature-dependent charging voltage tracking
Only with the "temperature-dependent charging voltage tracking with
sensor" option
Setting of the max. permitted battery temperature.
Only with the "temperature-dependent charging voltage tracking with
sensor" option.
UK13|xx
#UK13|xx
0-50C
Option for battery temperature tracking in case of charging rectifiers

without temperature sensor during ongoing operation.
Page 42 of 57
4.4.4.3 Upload cable compensation

Used for voltage compensation on the battery connecting cables or the consumer cables.
In the case of charging rectifiers (models UGV and LG) on the battery connecting cables.
In the case of supply rectifiers (model VG) on the consumer cables.
Cable compensation
Parameter
Input
Reply
Cable length
UK14|xxx
#UK14|xxx
Conductor x-section
UK15|xxx,x
#UK15|xxx,x
Selection
Setting range
0-100m
1.5, 2.5, 4, 6, 10,
16, 25, 35, 50, 70,
95, 120, 150, 185,
240, 300, 400, 500
The advance and return lines must be taken into account when
setting.
Entry for the cable cross-section used
4.4.4.4 Upload operating mode

Here the desired modes for battery charging or discharging can be set. All modes can be
activated via menu (see "Menu" section) or PC terminal. Active modes are indicated alternately
with the measured values on the rectifier display.
Setting mode/charging characteristic via PC terminal:
To set multiple modes simultaneously, they have to be added together. This is necessary, for
example, when the boost stage is to be reactivated after equalization charging or a capacity test.
The modes have the following significance:
Boost IUU
:1
IUU current-dependent : 2
IUU time-dependent
:4
Equalization charging
:8
Capacity test
: 16
Discharge time
: 32
Example: after the capacity test the current-dependent and time-dependent boost stage is to be
reactivated.
Composed of the significances for:
Boost IUU
= 1
IUU current-dependent = 2
IUU time-dependent
= 4
Capacity test
= 16
1+2+4+16=23
dk16|23 <ENTER>
prk >ENTER<
Additional conditions for execution of the selected modes are:

- External control contacts (optional) for the boost charge, equalization charging or
capacity test must be closed
- The boost and equalization charging options must be set in the factory
parameters.
Page 43 of 57
Operating mode
Not available for the supply rectifier (VG)
Parameter
Input
Reply
UK16|1
#UK16|001
Boost IUU
IUU currentdependent
UK16|3
#UK16|003
UK16|5
#UK16|005
IUU time-dependent
Equalization
charging
UK16|8
#UK16|008
UK16|16
#UK16|016
Capacity test
Discharge time
UK16|048
#UK16|048
(16+32=48)
Selection
Setting range
Boost stage with voltage-dependent switchover to float charge.
Condition: "Boost stage" option must be factory-set and external
control contact for boost charging (optional) must be closed
Boost stage with current-dependent switchover to float charge.
Condition: "Current-dependent boost stage" option must be factoryset and external control contact for boost charging (optional) must be
closed
Boost stage with time-dependent switchover to float charge.
Condition: "Time-dependent boost stage" option must be factory-set
and external control contact for boost charging (optional) must be
closed
Maintenance charge for the battery. Start only when no more boost is
active. When the end-of-charge voltage is reached or the maximum
equalization charging time has elapsed, the switch is made
automatically to float charge.
Additional conditions: "Equalization charging stage" option must be
factory-set and external control contact for equalization charging
(optional) must be closed.
Start only when no more boost or equalization charging is active.
Additional condition: External control contact for the capacity test
(optional) must be closed.
Only a negative result "Battery test negative" or an abort via
external control contact "Abort cap.test" is stored in the status string.
See "Reading the current data" section.
Only in conjunction with "capacity test" mode
When set, the capacity test is terminated after the discharge time
(DK10), taking into account the end-point voltage (DW21).
Page 44 of 57
4.4.4.5 Additional commands
Parameter
Set
battery temperature
Input
Reply
Tx
#Tx
Selection
Setting range
x stands for
1 to 50
Charging voltage tracking by transfer of the current battery
temperature.
Only possible when no temperature sensor is connected.
The following return messages may occur:
-Error-____100___ DIP switch 5 for "Manual temperature
tracking" on controller board not set to ON
-Error-____101___ A temperature sensor is connected
-Error-____102___ The transmitted temperature is in the
incorrect range (1-50C)
If no error occurs, the acknowledgement is: #Tx (x = transferred
temperature)
Firmware version
query
V
#V|GRJovyAtlas...........
Output of the current firmware version

Reply: #V|GR-JovyAtlas Version E0004000.00
Reset
buzzer
E0
Reset acoustic signal generator in case of fault.

Same function as when the signal key (buzzer/lamp) on the rectifier
operator panel is pressed.
Reset
alarms, modes
(warm start)
E1
1. Reset all accumulated fault messages on the relay board and the
operator panel. Current status and fault messages are redisplayed if
still active.
2. Abort an active capacity test
3. Abort active equalization charging
Comment: Same function as when the RESET key on the operator
panel is pressed and held down for 5 seconds.
Set date and time
C1|ddmmyyyyhhMM00
#|C1
C1|ddmmyyyyhhMM00 (day, month, year, hour, minute, seconds

always 00)
System RESET
(cold start)
RES
#RES
A complete restart of the rectifier is executed.
Reset to factory
parameters
PRW
#PRW
The parameters of the rectifier are reset to their factory default

settings.
Page 45 of 57
Monitors / Messages
All parameters important for operation are monitored by the controller. Status and fault
messages are displayed on the panel. In the standard configuration, only the collective alarm,
DC low voltage and battery operation (UGV only) messages are delivered via relay contacts
for external processing.
Additional messages can optionally be delivered via a relay board. See "Option: Relay board
P0037501".
If customer-specific circuits/monitors with corresponding messages for external signal
processing are installed, you will find them listed in the "Annex" to this document. See
connection diagram Gxx xxx 00.AS3.
5.1
Earth fault monitor

The DC system is monitored for insulation faults, meaning that if an
insulation fault occurs it is signalled potential-free by the insulation monitor.
The status is indicated on the panel: "Earth fault"; the buzzer and the red
fault LED are activated. By way of the collective fault relay the fault is
signalled potential-free. Optionally also discrete message via relay board
P0037501.
5.2
Current-dependent low voltage monitor

The current-dependent low voltage monitor corresponds to a device failure monitor. The output
characteristic (IU characteristic) of the rectifier is monitored. If the output voltage and the output
current/battery current fall to <90% of the setpoint value, a serious system fault has occurred.
The status is indicated on the panel: "Curr.-dep.lowvoltage"; the buzzer and the red fault LED are
activated. By way of the collective fault relay the fault is signalled potential-free.
5.3

The output voltage/battery voltage, and so the function of the rectifier unit, is monitored.
The response threshold is factory-set to 10% above the maximum voltage setpoint. The rectifier
output is immediately blocked in the event of a fault.
The status is indicated on the panel: "DC high voltage"; the buzzer and the red fault LED are
5.4
DC low voltage monitor

The output voltage/battery voltage, and so the function of the rectifier unit, is monitored.
The response threshold is factory-set to 10% below the maximum voltage setpoint. The rectifier
output is immediately blocked in the event of a fault.
The status is indicated on the panel: "DC over voltage"; the buzzer and the red fault LED are
Page 46 of 57
5.5
Overview of fault and status messages
The following table lists all status and fault (error) messages registered by the controller.
Explanatory notes:
Fault/status no.: Each message is assigned a fixed number which is stored in the system log.
Type S= Status F=Fault: Here the message is classified as a fault or status message.
Display output/log entry: Output string on the operator panel and in the system log
LED display: Assignment of the LEDs on the operator panel.
Standard relays: Assignment of the fault relays. K1: Collective alarm K2: Battery operation K3: Battery
almost flat.
RESET message: How the message on the operator panel is reset.
Fault/
status no.
1
Type
S=Status Display output /
F=Fault Log entry
Rectifier ON
S
LED display
Rectifier ON
Standard
relays
--
RESET
message
-
Explanation
Rectifier is switched on
Battery operation
Battery
operation
K2
Auto-Reset
Trickle charge
--
--
Auto-Reset
Boost charge
--
--
Auto-Reset
Equalization charge
--
--
Auto-Reset
Emergency op.
Warning
K1
Reset key
Press 5 sec.
CPU/device fault, controller control

deactivated and analog basic setting
activated.
Battery/cap.test
Battery
operation
--
Auto-Reset
Capacity test was initiated manually
Mains fault
Warning
K1
Auto-Reset
Mains voltage outside tolerance

Urated : -15% / +10%
Curr.-dep.lowvoltage
Fault
K1
Reset key
Device fault, incorrect IU output

characteristic
10
DC low voltage
Warning
K3
Auto-Reset
Battery almost flat

Device fault, high voltage at output
Consumers are powered by the battery

Maintenance of the full battery charge
condition
Boost stage active (optional)
Equalization charging stage active
(optional)
11
DC-overvoltage
Fault
K1
Reset key
Press 5 sec.
12
Batt.circuit fault
Fault
K1
Reset key
Battery open circuit or battery faulty.
13
Cap.-check negative
Fault
K1
Reset key
Negative message after capacity check
14
Earth fault
Fault
K1
Auto-Reset
Optional: Insulation fault, rectifier output
15
Fan/Temp. fault
Warning
K1
Auto-Reset
Fan fault or device interior temperature too

high.
16
Fuse fault
Fault
K1
Reset key
Press 5 sec.
Thyristor semiconductor fuses defective.
17
External fault
Fault
K1
Auto-Reset
Fault at external fault input 1 or external

fault input 2 (optional)
18 .1
Please check !
Rotating field
Fault
K1
Auto-Reset
Rotating field fault in start phase
18 .2
Please check !
Mains voltage
Fault
K1
Auto-Reset
Mains voltage fault in start phase
18 .3
Phase fault
Fault
K1
Auto-Reset
Phase fault (detected by hardware)
Reset key
Press 5 sec.
Rectifier current too high (>115 %)
19
Overcurr. rectifier
Fault
K1
20
Overcurrent battery
Fault
K1
21
Fault Softstart
Fault
K1
Reset key
Press 5 sec.
Rectifier
OFF/ON
Battery charge-current too high (>115 %)

Fault in start phase
Page 47 of 57
Fault/
status no.
Type
S=Status Display output /
F=Fault Log entry
LED display
Standard
relays
RESET
message
Explanation
22
Fault ICB
Warning
K1
Auto-Reset
Device On/Off switch turned off during

operation or input fuses defective
(optional).
23
Fault BCB
Fault
K1
Auto-Reset
Battery switch (BCB) open or battery fuses

defective (optional)
24
Shut down
--
K1
--
25
Batt.temp. sensor
Fault
K1
Reset key
26
Batt.overheating
Warning
K1
Auto-Reset
27
Battery asymmetry
Warning
K1
Reset key
28
Current symmetry
Warning
K1
Auto-Reset
29
Overheating
Fault
K1
Reset key
Press 5 sec.
30
---- Power Down ----
--
K1
--
31
--- Warm start --(only log entry)
--
--
--
32
Boost IUU
--
--
33
Boost IUU /I
--
--
--
Boost stage with voltage- and currentdependent charging voltage switchover is

active (optional)
34
Boost IUU /T
--
--
--
Boost stage with voltage- and timedependent charging voltage switchover is

active (optional)
35
Boost IUU /I /T
--
--
--
Boost stage with voltage- and currentdependent charging voltage switchover is

active (optional)
36
Charge finish time
--
--
Reset key
End of equalization charging after reaching

the set time (optional)
37
Charge finish volt
--
--
Reset key
End of equalization charging after reaching

the end-point voltage (optional)
38
Abort equaliz.charg.
--
--
Reset key
Abort of equalization charging by the

external Interlock input (optional)
39
final discharge volt
--
Auto-Reset
Battery is flat
40
Battery circuit test
--
--
---
41
Abort cap.test
--
--
Reset key
In the event of aborting the capacity test via

the external control input (optional)
47
Interconnect fault
K1
Auto-Reset
Fault on CAN bus or fault in one of the

parallel-configured devices
Error EEPROM
Fault
Fault
-
Shutdown initiated
Battery temperature sensor defective
(optional)
Battery temperature too high (optional)
Individual battery cells in battery pack faulty
(optional)
Asymmetrical current split across parallelconnected devices. Consequence of
different output voltage pre-setting or due to
contact resistances in the parallel
configuration caused by contact
resistances or differing cable crosssections.
Maximum limit temperature on thyristor
rectifier assembly exceeded. Fan of A1
defective or ventilation problem
Shutdown process ended
Warm start after pressing the RESET key
following a serious device fault. RESET key
on panel held down for 5 seconds!
Boost stage with voltage-dependent
charging voltage switchover active
Cyclic battery circuit monitoring is active.

(optional)
Parameter set in EEPROM incorrect
Page 48 of 57
6
6.1
Transportation, storage and installation

General
This section describes the process of installing the complete unit, including
placement and connection. The relevant drawings are to be found in the
Annex to this manual.
6.2
Visual check
Prior to installing at the destination, a thorough visual check must be carried
out. All parts should be checked for damage or other abnormal changes. All
modules and plug-in boards should be checked to ensure they are firmly
seated. All markings on flaps, covers and modules should be readable. In the
event of complaints, notify the manufacturer immediately.
6.3
Packaging
The rectifier is packed at the factory in an appropriate way for transportation
by rail or truck. The switch cabinet is attached by straps to the transport
pallet. To protect against paintwork damage and potential damp incursion,
the unit is enclosed in plastic sheeting.
NOTE:
To avoid damage, the sheeting should not be removed until
immediately prior to installation.
Then a knife can be used to cut the fastening straps.
6.4
Crane transport (option)
CAUTION:
Do not walk beneath suspended loads!
Wear personal protective equipment, such as a helmet, safety shoes
and work gloves!
Transport items with due care and attention, observing the safety rules!
ATTENTION:
Transport the unit only upright!
Do not tip or tilt it; avoid shifting its centre of gravity!
Page 49 of 57
Transportation
hoops
Transportation
hoops
The lengths of the load-carrying cables should be set so as to produce an

angle of 45 between the cable and the top of the cabinet (DIN 580). The
load-bearing capacity per cable must support at least half the cabinet
weight (DIN 580). For the weight refer to the technical data. Attach one cable
to each transportation hoop.
Procedure for transportation by crane:
Check that the transport hoops on the top of the cabinet are securely
fixed.
Attach the cables to the hoops on the top of the cabinet.
Carefully lift the cabinet and transport it to its intended location.
Carefully lower the cabinet, without bumping.
Remove the cables and transportation hoops.
6.5
Transportation by forklift or hand lift truck

ATTENTION:
Prior to transporting items by forklift or hand lift truck, make sure the
equipment is capable of supporting the load.
NOTE:
Particularly on assembly platforms and/or on uneven ground,
transportation by forklift or hand lift truck should be restricted to the
unavoidable minimum.
Transportation by crane is preferable!
Preparation:
Leave the unit on the transport pallet.
Remove the base coverings (if fitted).
Page 50 of 57
Transportation
by hand lift truck
Transport mit Hubwagen
Transportation
by forklift
Transport mit Gabelstapler
ATTENTION:
Pay attention to the unit's centre of gravity!
The forks must be of adequate length and
far enough apart.
Transportation procedure:
Run the forks between the pallet and the unit.
Carefully lift the unit and transport it to its intended location.
Carefully lower the unit, without bumping.
Move back the forklift or hand lift truck.
Re-attach the base coverings (if available) using the appropriate screws.
6.6
Location requirements
Suitable base surfaces for installation of the rectifier may be:
double floors,
above cable ducts, or
directly on flat surfaces.
Make sure the weight of the rectifier does not exceed the maximum floor
load capacity.
The location must also meet the following requirements:
The location must be free of conductive dust.
No aggressive or acid vapours must be emitted.
The maximum unit inlet temperature is 45 C.
The vents on the unit must not be covered over by structural elements or
other objects.
A depth of at least 80 cm must be allowed in front of the cabinets for
servicing purposes.
The unit must be protected against direct sunlight and heat from other
sources.
Page 51 of 57
6.7
Floor fixing
In the base frame of the rectifier there are holes for the fixing screws. For the
dimensions refer to the dimensional drawing in the Annex.
Before the unit is fixed to the floor, ensure it is vertical and even out any
irregularity (such as by inserting shim plates).
ATTENTION:
Pay attention to the unit's centre of gravity!
In some locations, such as onboard ships in maritime applications, the
switch cabinets must additionally be secured at the top to prevent
movement as the ship rolls and pitches in heavy seas.
6.8
Storage
The unit may only be stored, in its original packaging, for a maximum of six
months, in dry, ventilated premises with a solid roof. The ambient
temperature must be within the range from 35 C to +70 C at a relative air
humidity of 95 %.
If the rectifier is stored for longer than six months, it must be packed in airtight film with standard commercially available desiccant material placed
inside.
Installation
CAUTION:
First make sure the power is cut to the cables you are going to connect
and secure external switches against being turned back on!
CAUTION:
Components, cables and fuses may only be fitted or removed by
qualified personnel! It is essential that the following rules be observed
when carrying out any work on this unit:
- Never work on the unit alone.
- Cut the input voltage.
- Completely isolate the unit from the power.
- Remove input fuses (open ICB)
- Remove output fuses (open BCB/OCB)
- Make sure no voltage is connected either to the input or to the
output of the unit.
Ensure adequate air supply from the front when installing. The air escapes
from the top of the unit. Adequate space must be provided there for the air to
escape.
The cables are fed in from below. Cables coming in from overhead must first
be routed down the outside of the cabinet.
Page 52 of 57
7.1
Connecting up the unit

The mains power is connected by way of permanently laid cables in
accordance with local regulations.
The cross-sections of the outgoing cabling should be selected according to
the output current.
The mains feed, battery, consumers and signalling cables are connected as
per the current flow and connection diagrams.
If the battery is fitted in a separate cabinet, the connection is made to
terminals B+ and B- in the rectifier cabinet.
It must be ensured that the minimum required cable cross-sections are
observed with regard to cable length, temperature and bundling.
8
8.1
Commissioning
Power-up
ATTENTION:
In the case of models UGV and LG, the BCB with the battery fuses
F4/F5 may only be activated when the charging rectifier is running.
Otherwise there is a risk that components may be destroyed! After
powering up the rectifier, always follow the prompts indicated on the
panel!
Turn on the 'ON/OFF' rocker switch on the operator panel. All signal units
(lamps and buzzer) are briefly activated and the start phase is initiated.
Follow the prompts indicated on the panel. When the switching actions are
complete (e.g. in case of a UGV mode: close ICB, BCB, OCB) the unit is in
operation. The current measured values and status messages are displayed.
If the requirements with regard to charging voltage/current or charging
characteristic type have changed relative to your order specifications, it is
possible to change the required parameters in the customer parameter
settings. This is also where the cable compensation is set, by specifying the
cable lengths and cross-sections to the battery used on-site as well as the
average battery ambient temperature. This can be done immediately after
powering up the rectifier, or while it is running. For more information on the
setting options and procedures refer to the "Customer parameter setting"
section.
This completes the commissioning process.
8.2
Shutdown
The shutdown procedures for the various models differ. Please refer to the
following subsections.
ATTENTION:
In the case of the UGV and LG models, if the rectifier is switched off for a
lengthy period of time the battery fuses should be removed or the battery
disconnected. This prevents uncontrolled discharging of the battery!
.
Page 53 of 57
8.2.1
Shutdown of uninterruptible DC power supply unit (UGV)

Open the switch cabinet door of the UGV unit.
Press and hold down the "Shut-Down" key for 3 seconds.
The shutdown is initiated.
Follow the prompts indicated on the panel.
When the switching actions are complete (open BCB, open OCB and switch
off rectifier) the unit is shut down. The battery and consumers are
disconnected from the UGV unit.
9
9.1
Maintenance
Introduction
This section provides information on preventive maintenance and on
detection of general faults. Maintenance and inspection of the unit may only
be carried out by trained personnel. Other personnel should limit their
troubleshooting actions to providing a detailed description of the symptoms.
ATTENTION:
Before beginning any work inside the cabinet, shut down the unit.
9.2
Preventive maintenance

9.3
Monitoring of the unit's operation is essential to maintaining system reliability.

The operating personnel must be familiar with all the unit's controls and
displays. Routine records should be kept of the unit's condition, in order to
enable maintenance and service work to be carried out.
The rectifier requires regular maintenance. The following steps must be
carried out by trained personnel with knowledge of electronics.
The unit's cooling air ducts should be regularly cleaned.
The settings for the output voltage and the monitors should be regularly
checked.
Blown fuses may only be replaced by fuses of the same type (current rating
and trip characteristic).
Ensure adequate air exchange is possible at all times.
Check for abnormal noises or odours.
Check the display readouts; make a note of any fault messages.
Check the air inlet filter; clean and replace as necessary.
Troubleshooting
Troubleshooting is a logical, methodical process comprising tests,
measurements and observations, and resultant drawing of conclusions. It is
founded on the general rule that an observed fault results from one or more
causes which, in turn, result from faults in one or more model-specific
components.
Successful troubleshooting to detect all faults except obvious faults such
as defective fans demands detailed knowledge of electronics. It also
demands knowledge of power engineering. Troubleshooting tools and
equipment (two-channel oscilloscope, rotating field meter, digital voltmeter
etc.) must be employed with the due competence. Many faults are in fact
detected by the controller and displayed in message form on the operator
panel. See Overview of fault and status messages.
Page 54 of 57
9.4
Fuse list / Fans
Table: Assignment of fuses to the protected circuits

Bezeichnung
Bemerkung
F1
F2,F20
F3,F30
F100,F102
F103
F104-F106
F4-F7,F40-F70
mains power supply

Output fuse
Battery fuse
Fuse for control circuits, fans
Insulation monitoring
Consumer fuse
Sensor/measurement cables
Rectifier bridge semiconductor fuses
Page 55 of 57
9.5
Spares and service
NOTE:
When order spare parts, please quote the designation (item/component)
and unit number.
Please be advised that spares not supplied by us are neither tested nor
approved. Consequently, fitting such spares may negatively affect the
functional performance and passive safety of the unit. We cannot accept
liability for any resultant loss suffered.
Our Service department will of course be glad to send you a complete parts
list for your THYRIDIN power supply unit on request.
To request a parts list, or if you have any other questions or suggestions,
please contact the following address:
JOVYATLAS GmbH
26789 Leer, Germany
+49 (0491) 6002-0
Fax
+49 (0491) 6002-10
http://www.JOVYATLAS.de
10 Annex Standard
Contents
Cover Sheet
Block diagram
Technical data
Dimensional drawing
Terminal diagram
Circuit diagram
Battery instruction guide
Drawing-no.
G72 015 00.DB4
G72 015 00.DB4
G72 015 00.TE4
G72 015 00.MZ4
G72 015 00.AS4
G72 015 00.SP4
Types JOVYATLAS J / JL *)
**) When using a different battery instead of the above mentioned type J or JL, the applicable operating instructions must be
followed. Either the battery manufacturer or our service department shall be consulted in this case.
Page 56 of 57
Page 57 of 57
F26_001_JOVY_Englisch_09_050
JOVYATLAS GmbH
26789 Leer
Germany
www.jovyatlas.de
Client
ABB Automation GmbH

Gaglower Strae 17-18
03048 Cottbus
Germany
Project description
DC-UPS Thyridin
D400 G120/10 BWrg
Job number
Drawing number
Operating instructions
116256 - Pos.: 20
G72 015 00
BAX 4830
Person in charge
A.Doyen
Project file
G:\TECHNIK2\Zeichnungen_EPLAN\Zeichnungen_G\G7201500.elk
Created at
03.09.2012
Last edited at 07.11.2012 by Andreas.Doyen
Number of pages: 14
2
Date
24.08.2012
Drawn by A.Doyen
12/060
Revision
01.02.2012
Date
A.Doyen
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of
JOVYATLAS GmbH DC-UPS Thyridin

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Cover sheet
Job number
Drawing number
116256 - Pos.: 20 G91 002 00.DB4
Sheet
Sh.
1
14
1-Rectifier 1 ON
2-OFF
3-Rectifier 2 ON
AC-Filter
Transformer
DC-Filter
Rectifier
Decoupling diode
OCB
ICB
-X1
Input
3~400Vac
EMI
Power-Controller
-X2
-X2
-X2
RS 232
Transformer
DC-Filter
Rectifier
Output
136,2Vdc
Decoupling diode
OCB
DEEP DISCHARGE
PROTECTION
Power-Controller
BCB
BCB
RS 232
3
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Block diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.BL4
Sheet
Sh.
2
14
INPUT
OUTPUT
BATTERY
GENERAL
Input voltage
3~ 400V 10%
Mains frequency
50Hz 5%
Input maximal current
3~5A
Type of rectifier
Thyristor-Rectifier
Total harmonic distortion at input
< 5% (@100% of nom. power, nom. voltage)
Required Prefuse
16A gG
Output voltage
136,2V DC 1%
Ripple of DC-voltage
max. 5% RMS (disconnected battery)
Output current
10A DC 2%
Tolerance of output current
1% static
Battery type
CTL 10-12
Battery lifetime
approx. 10 years acc. to EUROBAT recommendation
Battery capacity
12 Ah/C20
Battery ambient temperature
0C to +20C (Battery lifetime will be reduced at storing temperatures >20C)
Number of battery blocks
10 serial
Battery nominal voltage
120V (10x12V series connection)
Battery trickle charge voltage
136,2V (2,27V/cell)
Ripple of DC-voltage
max. 5% RMS (disconnected battery)
Battery charge current
1,2A
Characteristic
IU acc. to DIN 41773
Operation mode
permanent operation
Power loss (100% load, with charged battery)
Approx. 170W
Radio interference level
Acc. EN 62040 - 2: 2007 class C3
Acoustic noise level
Approx. 65dB(A)
Protection degree
IP 54 according to DIN 40050
Protection class (IEC EN 62040-3)
VFI SS 111
Ambient temperature
0C to +40C
Storage temperature
-40C to +70C
Air flow
265m/h
Weight
Approx. 200kg
Colour
RAL 1017
Humidity
F acc. to DIN 40 040
Manufacturers standards
DIN, VDE, IEC
4
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Technical data
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.TE4
Sheet
Sh.
3
14
Front view
Left side view
806 mm
605 mm
Air Outlet
Control and display:
S1 1-Rectifier 1 ON
2-OFF
3-Rectifier 2 ON
Rectifier ON
Rectifier ON
Warning
Warning
Failure
Failure
R ES ET
R ES ET
A1
A10
S1
2005 mm
Cutaway view A-A (Foundation)
806 mm
640 mm
606 mm
440 mm
535 mm
597 mm
M12
Air Inlet
735 mm
797 mm
5
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
Dimensional drawing
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.MZ4
=
+
Sheet
Sh.
4
14
01 03 05 07 09 11 13 15 17 19 21
01
02
03
PE
01
02
03
04
05
06
02 04 06 08 10 12 14 16 18 20 22
-X4
X1
X1
X2
X2
X3
-X40
X3
RS232
L1
L2
L3
PE
L+
L-
L+
L-
L+
L-
RS232
02 04 06 08 10 12 14 16 18 20 22
01 03 05 07 09 11 13 15 17 19 21
1,5 - 10mm
1,5 - 10mm
2,5 - 4mm
Output
136,2Vdc
10A
Mains Input
3~ 400 50Hz
3~ 5A
POTENTIALFREE MESSAGES
FAULT CHARGING RECTIFIER 1
01 - 02 OPEN
03 - 04 OPEN
RECTIFIER 1 ON
05 - 06 CLOSED
RECTIFIER 2 ON
07 - 08 CLOSED
BATTERY FEED LOAD
09 - 10 CLOSED
MAINS FAILURE
11 - 12 OPEN
-X0
DC-UNDERVOLTAGE
13 - 14 OPEN
DC-OVERVOLTAGE
15 - 16 OPEN
EARTH FAULT
17 - 18 OPEN
DEEP DISCHARGE PROTECTION
19 - 20 OPEN
FUSE FAULT
21 - 22 OPEN
6
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Terminal diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.AS4
Sheet
Sh.
5
14
ICB
-F1
-X1
1
L1
L2
L3
-Z1
EMI
L1
L1'
-L1 / 7.0
L2
L2'
-L2 / 7.0
L3
PE
-L3 / 7.0
L3'
6A
PE
-X0
-X0
-F100
6A
-T100
0V
0V
400V
230V
-F101
2A
Thermostat
>25C
-F102
-B100
SK3110
2A
-B101
115V N
250V N
L
Khlbetrieb
Heizbetrieb
24V N
48V 60V N
7
6
5
4
3
2
1
Thermo
Hydro
L
N
L
heating
1
2
3
4
5
M
1~
N
-E2
-E3
L
PE
-X0
-X0
7
Date
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Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
6
14
1-Rectifier 1 ON
2-OFF
3-Rectifier 2 ON
-S1
-T1
1
U1
U2
V1
V2
W1
W2
-L1_1 / 8.0
6.9 / -L1
-L2_1 / 8.0
6.9 / -L2
-L3_1 / 8.0
6.9 / -L3
Dy11
-Sync_L1_1 / 8.0
-Sync_L2_1 / 8.0
-Sync_L3_1 / 8.0
-T10
U1
U2
V1
V2
W1
W2
-L1_2 / 9.0
-L2_2 / 9.0
-L3_2 / 9.0
Dy11
-Sync_L1_2 / 9.0
-Sync_L2_2 / 9.0
-Sync_L3_2 / 9.0
8
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
7
14
OCB 1
-A1
-L1
-V1
-V2
-V4
x1
L+
-V3
-F2
x2
-L+_1 / 11.1
-R1
L1
7.9 / -L1_1
7.9 / -L2_1
7.9 / -L3_1
L2
-R2
L3
F1...F3
-C1
-R3
THERMO
-R4
60mV
K5
G5
K6
G6
K3
G3
K4
G4
K1
G1
K2
G2
L-
+
-S2
-L-_1 / 11.1
4
/12.4
K5
G5
K6
G6
K1
G1
K2
G2
/12.3
2
/12.6
K3
G3
K4
G4
-E1
1
BCB 1
-K1
11
12
/8.8
-K1
-R5
60mV
2
-F3
1
-F5
-A6
-F6
10x38
2A
L
DEEP DISCHARGE
PROTECTION
-B-_1 / 10.1
1
1
-B+_1 / 10.1
/8.8
/8.8
-F4
10x38
2A
/12.3
-K10
/9.8
-K1
10x38
2A
-F7
10x38
2A
CP-E 24/1.25
X7:1
G5
K5
X8:1 2
Emergency operation activ
X1:1-20
Counter cell 2 on
Battery on
X4:1-10
Counter cell 1 on
3 4 5 6 7 8 9 10
X9:1 2 3 4 5 6 7 8 9 10
UL +
UL-
UB2 UB/2 +
UB+
UB1 -
8.2 / A2_X8.3
8.2 / A2_X8.4
7 8
X6:1
2
3
A1
11
13
23
A2
12
14
24
X8:1-10
IC-Bus
X9:1 2 3 4 5 6 7 8
/13.6
P0034001
Controller Board AT90
/9.4
-K1
-A3
/12.3
1A tr
5 6
/8.7
P0040407
Voltage divider
220V
Jumper P0034201
JP04 -JP05 -JP06 ICB ON
JP07 OCB ON
JP08 BCB ON
JP09 Fan Temp. fail
JP10 Temp. fail
JP11 Earth fail
JP12 Shutdown
JP13 SL enable
JP14 AL enable
JP15 Kap. Test enable
JP16 ext. fault 1
JP17 --JP18 ext. fault 2
JP19 fuse fault
3 4
U_INT+
U_INT -
1A tr
L3
-A2.1
X3:1 2
- + - +
/8.7
X3:1-10
L2
X2:4 3 2 1
X7:1-10
-A3_Relay / 13.3
X6:1-10
DO LOW VOLTAGE
12puls GR
Control-/Regulator board
IN_TEMP_FAIL
IN_EARTH_FAIL
IN_SHU_DOWN
SL_INTERLOCK
AL_INTERLOCK
KAP_INTERLOCK
IN_EXT1_FAIL
NC
IN_EXT2_FAIL
IN_FUSE_FAIL
X5:1-10
X16:1 2 3 4 5
18V_IO
18V_IO
15V_S
15V_S
GND_IO
IN_NOTBETRIEB
ICB_ON
OCB_ON
BCB_ON
IN_FAN_TEMP_WARN
X2:1-10
X15:1 2 3 4 5
BATTERY OPERATION
L1
P0034201 / Version 120V
Vers.-/Synchr.
6puls GR
X1:1
X14:1 2 3 4 5
COLLECTIVE ALARM
X13:1 2 3 4 5 6
P00034401
/8.7
G6
K6
G3
K3
G4
K4
L-
-A2
-A4
7.9 / -Sync_L1_1
7.9 / -Sync_L2_1
7.9 / -Sync_L3_1
G1
K1
G2
K2
DC OK
L+
X5:1-10
CAN-Bus
X2:1 2 3
X4:1-10
1-9
X3:1 2 3
X9a:1 2 3 4 5 6 7 8 9 10
-X4
-A5
X1:1-10
8 9
11 12 13
20
A2_X9 / 12.0
-X3
RS232
1 2
P0034102
Operationpanel
A2_X8.3 / 8.7
A2_X8.4 / 8.7
01 - 02 OPEN
9
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
8
14
OCB 2
-A10
-L10
-V10
-V20
-V40
x1
x2
L+
-V30
-F20
1
-L+_2 / 11.1
-R10
L1
7.9 / -L1_2
7.9 / -L2_2
7.9 / -L3_2
L2
-R20
L3
F1...F3
-C10
-R30
THERMO
-R40
60mV
K5
G5
K6
G6
K3
G3
K4
G4
K1
G1
K2
G2
L-
+
-S20
-L-_2 / 11.1
4
/12.4
K5
G5
K6
G6
K1
G1
K2
G2
/12.3
2
/12.6
K3
G3
K4
G4
-E10
1
BCB 2
11
12
-R50
60mV
2
-B-_2 / 10.1
-F60
10x38
2A
-B+_2 / 10.1
-F50
-A60
L
/9.8
DEEP DISCHARGE
PROTECTION
/9.8
-K10
6
5
-F30
1
/9.8
-F40
10x38
2A
-K10
2
1
/12.3
-K1
/8.8
-K10
4
3
10x38
2A
-F70
10x38
2A
CP-E 24/1.25
X7:1
G5
K5
X8:1 2
Emergency operation activ
X1:1-20
Counter cell 2 on
Battery on
X4:1-10
Counter cell 1 on
3 4 5 6 7 8 9 10
X9:1 2 3 4 5 6 7 8 9 10
UL +
UL-
UB2 UB/2 +
UB+
UB1 -
9.2 / A20_X8.3
9.2 / A20_X8.4
7 8
X6:1
2
3
A1
11
13
23
A2
12
14
24
X8:1-10
IC-Bus
X9:1 2 3 4 5 6 7 8
/13.6
P0034001
Controller Board AT90
/8.4
-K10
-A30
/12.3
1A tr
5 6
/9.7
P0040407
Voltage divider
220V
Jumper P0034201
JP04 -JP05 -JP06 ICB ON
JP07 OCB ON
JP08 BCB ON
JP09 Fan Temp. fail
JP10 Temp. fail
JP11 Earth fail
JP12 Shutdown
JP13 SL enable
JP14 AL enable
JP15 Kap. Test enable
JP16 ext. fault 1
JP17 --JP18 ext. fault 2
JP19 fuse fault
3 4
U_INT+
U_INT -
1A tr
L3
-A20.1
X3:1 2
- + - +
/9.7
X3:1-10
L2
X2:4 3 2 1
X7:1-10
-A30_Relay / 13.5
X6:1-10
DO LOW VOLTAGE
12puls GR
Control-/Regulator board
IN_TEMP_FAIL
IN_EARTH_FAIL
IN_SHU_DOWN
SL_INTERLOCK
AL_INTERLOCK
KAP_INTERLOCK
IN_EXT1_FAIL
NC
IN_EXT2_FAIL
IN_FUSE_FAIL
X5:1-10
X16:1 2 3 4 5
18V_IO
18V_IO
15V_S
15V_S
GND_IO
IN_NOTBETRIEB
ICB_ON
OCB_ON
BCB_ON
IN_FAN_TEMP_WARN
X2:1-10
X15:1 2 3 4 5
BATTERY OPERATION
L1
P0034201 / Version 120V
Vers.-/Synchr.
6puls GR
X1:1
X14:1 2 3 4 5
COLLECTIVE ALARM
X13:1 2 3 4 5 6
P00034401
/9.7
G6
K6
G3
K3
G4
K4
L-
-A20
-A40
7.9 / -Sync_L1_2
7.9 / -Sync_L2_2
7.9 / -Sync_L3_2
G1
K1
G2
K2
DC OK
L+
X5:1-10
CAN-Bus
X2:1 2 3
X4:1-10
1-9
X3:1 2 3
X9a:1 2 3 4 5 6 7 8 9 10
-X40
-A50
X1:1-10
8 9
11 12 13
20
A20_X9 / 12.0
-X3
RS232
3 4
P0034102
Operationpanel
A20_X8.3 / 9.7
A20_X8.4 / 9.7
03 - 04 OPEN
10
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
9
14
8.9 / -B+_1
9.9 / -B+_2
-G1
8.9 / -B-_1
9.9 / -B-_2
-G2
-G3
-G4
-G5
-G6
-G7
-G8
-G9
-G10
11
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
10
14
EARTH FAULT MONITORING
8.9 / -L+_1
8.9 / -L-_1
9.9 / -L+_2
-F103
9.9 / -L-_2
10x38
2A
-A100
A1
A2
L+
LS1
S2
S3
ABB
CM-IWN.1
12
14
22
11
24
21
PE
14
12
24
22
13.7 / -OUT_Fuse_1
13.7 / -OUT_Fuse_2
11
12
13
1
-F104
B10A
VS
V1+
V1KE
PE
13
14
1
-F105
B10A
13
14
-F106
B10A
13
14
11 /12.5
21 /12.5
L+
L-
L+
L-
L+
L-
-X2
1
Output
10
12
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
11
14
13
-S3
Emergency
ON/OFF
5
-F2
/8.8
14
11
5
-F3
/8.8
12
13
12
-A1
/8.0
-A100
/11.1
14
14
Shutdown
ON/OFF
20
13
-S4
11
IN_FUSE_FAIL
IN_SHUT_DOWN
IN_EARTH_FAIL
BCB_ON
IN_EMERGENCY
15V_S
8.4 / -A2_X9
IN_TEMP_FAIL
OCB_ON
1
-A1
/8.0
13
-K1
/8.8
13
-S30
Emergency
ON/OFF
14
5
-F30
/9.8
12
3
-A10
/9.0
13
22
-A100
/11.1
20
24
IN_FUSE_FAIL
BCB_ON
5
-F20
/9.8
11
IN_SHUT_DOWN
IN_EARTH_FAIL
IN_TEMP_FAIL
OCB_ON
IN_EMERGENCY
15V_S
9.4 / -A20_X9
14
13
-S40
21
Shutdown
ON/OFF
14
1
-A10
/9.0
13
-K10
/9.8
14
11
13
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
12
14
8.9 / -A3_Relay
X1:1-10
P0037501
P0037501
Relais-Karte
Relais-Karte
Rel1
Rel2
Rel3
Rel4
Rel5
Rel6
Rel7
Rel1
X2:1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
-A7
/13.3
Rel2
-A70
/13.5
4
-A7
/13.3
4
-A70
/13.5
7
-A7
/13.3
6
5
Rel4
7
-A70
/13.5
10
-A7
/13.3
9
8
Rel2
Rel3
Rel4
Rel5
Rel6
Rel7
X2:1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Rel3
-A70
X1:1-10
Rel1
9.9 / -A30_Relay
-A7
Rel1
Rel5
12
11
10
-A70
/13.5
13
-A7
/13.3
12
11
Rel5
15
14
13
-A70
/13.5
16
-A7
/13.3
15
14
18
17
16
-A70
/13.5
23
-K1
/8.8
24
18
17
11.5
11.5
-OUT_Fuse_1 -OUT_Fuse_2
23
-K10
/9.8
24
-X3
5
10
11
12
13
14
15
16
17
18
19
20
21
22
RECTIFIER 1 ON
05 - 06 CLOSED
RECTIFIER 2 ON
07 - 08 CLOSED
BATTERY FEED LOAD
09 - 10 CLOSED
MAINS FAILURE
11 - 12 OPEN
DC-UNDERVOLTAGE
13 - 14 OPEN
DC-OVERVOLTAGE
15 - 16 OPEN
EARTH FAULT
17 - 18 OPEN
DEEP DISCHARGE PROTECTION
19 - 20 OPEN
FUSE FAULT
21 - 22 OPEN
12
14
Date
24.08.2012
Drawn by A.Doyen
Revision
Date
Name
Checked
Origin
Client
Description
ABB Automation GmbH

03048 Cottbus
Germany
Substitution of

26789 Leer
Germany
Substituted by
www.jovyatlas.de
D400 G120/10 BWrg
Designation
=
+
Circuit diagram
Job number
Drawing number
116256 - Pos.: 20 G72 015 00.SP4
Sheet
Sh.
13
14
JOVYATLAS GmbH
Operating instructions for valve regulated
lead-acid batteries in AGM - Technology
Type GiV: J/JL
Nominal data:
Depending on the installation, charging (acc. to DIN
VDE 0510 Part l draft) may be carried out in the
following operations.
Nominal voltage UN:
2,0 V x number of cells (1 2 V/ 6V)
Nominal capacity C20
20h discharge
Nominal temperture TN:
20C
Factors of reduction:
For ventilation (draft DIN/VDE 051 Opart1) Factor fl
Nominal discharge curr.: h= 1
CV20h
= 0,5 f2 = 0,5
Battery type:
Assembly by:
Date:
Commissioned by:
Date:
Sicherheitskennzeichen angebracht durch:

am:
Observe these instructions and keep them located nearby the battery for future
reference! Work on the battery should only be carried out by quilified personnel!
Do not smoke! Do not use any naked flame or other sources of ignition.
Explosion and fire hazard are present!
While working on batteries wear protective eye-glasses and clothing!

Observe the accident prevention rules as well as DIN VDE 0510, VDE 0105 part l!
Any acid splashes on the skin or the eyes must be flushed with plenty of water immediately.
Then seek medical assistance. Spillages on clothing should be rinsed out with water!
Explosion and fire hazard, avoid short circuits! Caution! Metal parts of the battery are always
alive, therefore do not place items or tools on the battery!
Electrolyte is strongly corrosive and acidic. In normal working conditions the contact with
electrolyte is nearly impossible; electrolyte may leak from the vent valves in case of over
charging the battery or in case of mechanical damage to the container. In case of any contact
with electrolyte please flush water abundantly and get in touch with a physician.
Batteries/cells are heavy! Ensure adequate mounting security and always use suitable
handling equipment for transportation!
Non-compliance with operation instructions, repairs made with other than original parts, or
repairs made without authorization (e.g. opening valves) render the warranty void.
Disposal of batteries:
Batteries marked with the recycling symbol should be processed via a recognised recycling agency.
By agreement, they might be returned to the manufacturer. Batteries must not be mixed with
domestic or industrial waste.
Valve-regulated lead acid batteries consist of cells

which do not require water topping during the
operation.
1. Start up
Check all cells/blocks for mechanical damage,
correct polarity and firmly seated connectors. The
following torques apply for screw connectors:
M5
M6
M8
M 10
2 - 3 Nm
4 - 5,5 Nm
5 - 6 Nm
14-22 Nm
Connect the battery with the correct polarity to the

charger. The charger should not be switched on
during this process. The load should not be
connected (pos. pole to pos. terminal).
Switch on charger and start charging following
instruction no. 2.2.
.
2. Operation
a) Standby Parallel Operation and

Buffer Operation
Here the load, direct current source and battery are
continuously in parallel. Thereby the charging
voltage is the operation-voltage and, at the same
time, the battery-installation voltage. With the
standby parallel operation, the direct current source
is at any time capable of supplying the maximum
load current and the battery charging current. The
battery only supplies current when the direct
current source fails. The charging voltage should
be set at 2,275V 0,005V (at 20C) x number of
cells in series measured at the terminals of the
battery. With buffer operation the direct current
source is not able to supply the maximum loadcurrent at all times. The load-current intermittently
exceeds the nominal current of the direct source.
During this period the battery supplies power. The
battery is not fully charged at all times but the floatcharge voltage of 2.275 V/cell 0.005 V (at 20 C)
x number of cells in series provides a reasonable
recharge duration under normal conditions.
Dependent on load and number of cells in series, it
is recommended to consult the battery
manufacturer in any doubtful case.
b) Switch-mode Operation
When charging, the battery is separated from the
load. To reduce the charging time, a three phase
boost charge mode can be applied by charging the
battery at 2,45 2,5 V/cell until the charging current
drops to 0,07 C(A) (trip point for the first phase of
charging t1). The duration of charging of the first
phase is measured by a timer so that the second
phase should be half of the first phase (t2 = 0,5 x
t1) when the batteries are kept on charge at 2,45
2,5 V /cell.
After the total charging of t=t1 +0.5t1 has elapsed,
the charger reduces the voltage to a normal floatcharge level of 2,275 V/cell ( 0,005V) at 20 C.
c) Battery Operation
(Charge / Discharge Operation)
For the installation and operation of the batteries

DIN VDE 0510 is mandatory. Battery installation
should be made such
that temperature difference between individual units
does not exceed 3 degrees Celsius/Kelvin.
The load is only supplied by the battery. The

charging process depends on the application and
must be carried out in accordance with the
recommendations of the battery manufacturer.
2.1 Discharge
2.3 Maintaining the full charge

(Float charge)
Discharge must not be continued beyond the level

specified for the specific discharge current. Deeper
discharges must not occur unless specifically
agreed
with
the
manufacturer.
Recharge
immediately following complete or partial discharge.
Devices complying with the stipulations under DIN

41773 must be used. They are to be set so that the
average cell voltage is 2.275 V 0.005V
.
2.2 Charge
Applicable are all charging procedures with their
limit values according to DIN 41773 (IUcharacteristic). According to the charging
equipment specification and characteristics,
alternating currents (< 0.1 C(A)) flow through the
battery superimposing into the direct current during
charging operation. These alternating current and
the reaction from the loads lead to an additional
temperature increase of the battery and strain the
electrodes with possible damages (2.5)
2.4 Supplementary and Equalizing charge

To ensure maximum service life, a supplementary
charge may be required prior to installation on
condition that the batteries have been in storage for
more than 6 months or more, latest after 9 months
age from the date of production and that the open
circuit voltage is less than 2,1 Volts per cell.
A supplementary charge should be applied in
accordance with figures shown in the table:
Storage
period
Charge voltage/
cell at 20 C
Less than 9
Months
2,275 V/cell
Up to 1 year
2,35 V/cell
1 - 2 years
2,35 V/cell
Charge time
More than
72 hours
48 - 144
hours
72 - 144
hours
Batteries kept at normal float charge level within a

string do not require any equalizing charge in case
of partial replacement, in order to narrow the
bandwidth of open-circuit voltages.
2.5 Alternating currents

On recharging up to 2,4 V/cell under operation
modes 2.2 the actual value of the alternating current
is for a very short time permitted to reach 0,1 C(A)
nominal capacity. In a fully charged state during
float charge or standby parallel operation the actual
value of the alternating current must not exceed 5A
/ l00Ah nominal capacity.
2.6 Charging currents

During float charge or standby parallel-operation
without recharging state the charging currents are
not limited. The charging current should range
between 10 A to 20 A / l00 Ah nominal capacity.
2.7 Temperature
The nominal operation temperature range for leadbatteries is 10C to 30C (best 20C 5 K). Higher
temperatures will seriously reduce service life. All
technical data are produced for a nominal
temperature of 20C. Lower temperatures reduce
the available capacity. The absolute maximum
temperature is 50C and should not permanently
exceed 40C in service.
2.8 Temperature related float charge voltage

and boost charge voltage
The float charge voltage of 2,275V /cell
0,005V/cell refers to a battery temperature of 20C.
Temperature compensated charging is required in
order to avoid overcharge at high temperatures and
undercharge at low temperatures. The recommended temperature compensation factor is -3m
V/cell/C for float charge operation. In order to avoid
thermal runaway, it is mandatory to temperaturecompensate
the
float-charge
voltage
for
temperatures above 40C.
The boost charge mode can be applied if a quick
recharge is required on condition that the charging
current does not exceed 0,25C(A) and constantly
drops to 0,01C from where normal float charge
voltage should be applied.
Boost charging
voltage (V/cell)
Maintenance
charge
voltage(V/cell)
- 10
2,58
2,36
2,53
2,33
10
2,48
2,30
20
30
2,45
2,4
2,275
2,24
40
2,34
2,21
Temperature
(C
2.9 Electrolyte
The electrolyte is diluted sulphuric acid and is
absorbed in glass-matt separator.
3. Battery maintenance and control

Keep the battery clean and dry to avoid leakage
currents.
Plastic parts of the battery, especially containers,
must be cleaned with pure water without additives,
any organic solvents are prohibited.
At least every 6 months measure and record:

- battery voltage
- voltage of several cells/blocks
- surface-temperature of several cells/blocks
- battery-room temperature
If the difference of the average float-chargevoltage/cell is exceeding 0,1V/cell within a string
or if the surface temperature-difference between
cells/blocks is exceeding 5 K, the service-agent
should be contacted.
Annual measurement and recording:
- voltage of all cells/blocks
- surface temperature of all cells/blocks
- battery-room temperature
- insulation-resistance according to
DIN 43539 part 1
Annual visual check:
- screw-connections, any screw-connections
without locking devices have to be checked
for tightness
- battery installation and arrangement
- ventilation
4. Tests
Tests have to be carried out according to
IEC 896-2, DIN 43539 part 1 and 100(draft)
Special instructions like DIN VDE 0107 and
DIN VDE 0108 have to be observed.
8. Technical data
Type
20h
C20 (Ah)
to
1,85V/cell
5. Faults
Call the service agents immediately in case of
faults in the battery or the charging unit. The
availability of the recorded data described in point
3, will be very helpful to find the cause of failure. A
service-contract simplifies troubleshooting.
6. Storage and taking out of operation

To store or decommission cells/batteries for a
longer period of time, they should be fully charged
and stored in a dry frost-free room.
Ta avoid damage, batteries should be regularly
subjected to supplementary charge cycles in
accordance with 2.4.
7. Transport
VRLA batteries, which by no means show any kind
of damage, are classified as non-dangerous goods
for transportation via rail, lorry or air (according to
GGVS, GGVE and IATA Regulations) if they are
safeguarded during transportation against shortcircuiting, tossing about, slipping or any damage.
Batteries to be classified under afore-mentioned
paragraph must mandatory not display any traces
of electrolyte on the exterior of the battery
container.
As for VRLA batteries being damaged, assumed to
be leaking of electrolyte and to be transported
under warranty, or assumed not to be tight in any
aspect anymore, they are to be handled in
accordance
with exception regulations
of
dangerous goods transportation rules concerned.
Capacities (Cn) at different discharge times (tn) until the final discharge
voltage (US) at battery temperature 20C
10h
5h
3h
1h
30Min.
C10 (Ah)
C5 (Ah)
C3 (Ah)
C1 (Ah)
C1/2 (Ah)
to
to
to
to
to
1,80V/cell
1,79V/cell
1,78V/cell
1,74V/cell
1,720V/cell
10Min.
C1/6 (Ah)
to
1,70V/cell
4,8
6,5
11,2
15,5
22,8
28,3
35,9
45,8
56
54,4
91
89,5
118
150
200
C10 (Ah)
to
1,80V/cell
2,93
3,24
5,56
7,9
13
13,9
19
22,8
31,5
26,5
40,9
38,8
47,5
60,5
66,8
C1/6 (Ah)
to
1,70V/cell
J - series 6 9 years
J1005000
J1005100
J1005200
J1005300
J1005400
J1005500
J1005600
J1005700
J1005800
J1005900
J1006000
J1006100
J1006200
J1006300
J1006400
5
7
12
17
24
32
38,9
52,7
62,9
61
97
97
125
160
210
C20 (Ah)
Type
to
1,85V/cell
JL - series 10 12 years
JL205500
17,2
JL205510
26
JL205520
28
JL205530
32
JL205540
38,9
JL205550
50,9
JL205560
64,2
JL205570
73,1
JL205580
91,9
JL205590
102
JL205600
112
JL205610
123
JL205620
139
JL205630
186
15,3
23,4
25,3
28,3
35,9
45,8
57,2
65,9
85,1
93,1
104
115
128
172
4,3
5,5
9,5
13,5
19,9
25
31,9
41,2
50,9
49,5
80
78,5
106
136
185
C5 (Ah)
to
1,75V/cell
4,03
5,3
9
13
19,5
23,2
31
38,8
49,2
47,3
72,5
73,5
96
129
162
C3 (Ah)
to
1,75V/cell
14,3
21,3
23
25
32,2
41,6
52,5
61,2
75,8
83,3
93
105
115
158
13,5
19,6
20,7
23,2
31
39,1
50,9
58
72,5
78,7
90
103
110
151
3,45
4,2
7,1
10
16
21,5
28,1
34,5
45
42,7
58
62,5
78
100
136
C1 (Ah)
to
1,74V/cell
11
18,1
19,5
21,5
28,7
35,5
47,8
55,6
65
69,8
80,7
100
104
140
3,07
3,45
5,9
8,36
15,1
19,25
25,6
29,9
39,3
36
55
54,7
67,5
89
109
C1/2 (Ah)
to
1,70V/cell
9,6
17,35
18,7
19,25
25,5
30,2
41,1
46,5
56
62,5
68,5
84
90
110,5
6,9
11,3
12,2
13,9
19
23,66
29,66
31,66
40,5
43,66
46,8
53,8
56,3
63
JOVYATLAS GmbH
Groninger Strae 29-37 D-26789 Leer
Phone +49 (0) 491/6002-0 Fax +49 (0) 491/6002-10
e-mail: vt@jovyatlas.de

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Operating Manual

27. 08. 2012

IU Rectifier Series THYRIDIN

Notes on this manual

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Copyright JOVYATLAS GmbH 2012.

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Operating Manual BAX 4830

Notes on this manual

IU Rectifier Series THYRIDIN

Operating Manual BAX 4830

Earth fault monitor

Transportation, storage and installation

Connecting up the unit

IU Rectifier Series THYRIDIN

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Control and display:

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Charging rectifier function

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Functions of the individual modules

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

2.3.2.1 Control electronics modules

2.3.2.2 EMERGENCY RUNNING switchover (optional)

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Rotating field fault

2.3.2.4 Signals, setting potentiometers, controls

Operating Manual BAX 4830

Voltage (U/UB) setpoint correction

Only for test purposes when

IU Rectifier Series THYRIDIN

Rectifier/charging voltage regulator active

LED ON when regulator active

Press only in case of fault

Observe panel instructions!

Controller board AT90

-X9 1-2 open in case of fault

Operating Manual BAX 4830

In the event of a CPU error the switch is made to

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Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

2.3.5.1 Keypad assignment

Descriptions of the individual keys:

Operating Manual BAX 4830

IU Rectifier Series THYRIDIN

Operating Manual BAX 4830

Factory parameter settings at password level 2 are automatically applied at

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Measured value/status displays

Readout on UGV model:

Example status message:

Standard parameter level

Starting point display: Output of measured value and status messages.

Confirm language selection with jump to next menu item

Operating Manual BAX 4830