RF-141_Rectifier operation Manual_GiPower
RF-141_Rectifier operation Manual_GiPower
0
2019.08
Copying or reproduction of this manual by all means, including photocopying or data reproduction system,
Table of Contents
1-2. Factors and Details of Risks -3- 5-2. MAIN CONTROL -36-
3-1. External Measurements and Weight -9- 6-3. Upper Part of Module -41-
3-2. Cautions for Transportation -11- 6-4. Lower Part of Module -42-
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Be sure to obey the followings, which contain important directions about safety.
In this manual, the risks of mishandling the product are categorized into the following two levels:
▲ For safety, make sure all installation, operation and maintenance works are performed by a licensed personal
or an expert in electronics.
▲ The following signs are used in this manuals to indicate dangerous elements that requires extra cautions. Be
careful in handling the products when you see the following signs and follow the directions on this manual.
▲ All relevant personnel must obey the following directions while the product is in operation and any personnel,
such as children or elderlies, who lack judging abilities shall not be near the product.
▲ The producer is not responsible for any troubles caused by inappropriate usages of the product, including
transformation of the product, such as random designing or functioning by user, or operation of the product in
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DANGER
☞ Parts with the label indicates the danger that you must be careful with.
CAUTION
Electrical contacts on human body may cause fatal shocks or severe burns on skin.
Electrical current will be flowing whenever the output cable is operating. Also be careful
with the output production through the input power circuit and internal circuits.
• Perform grounding works on electrically connected parts on the power case according to the regulations. Make
• Make sure to cut all the power from the product, whenever it is not on in use.
• Installation or maintenance works must be done at least 5 minutes after cutting power off from the input of
electricity distributor.
• Refer to the international and domestic safety regulations for installation or dissemblance of the input power.
• Do not use any cables of which the cross-sectional area is smaller than the standard or damaged so much than
• An electricity manager must check the product before connecting or separating input cables.
• Perform regular inspection, at least once a day, on the input and output cables. Damaged cable may cause
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• Only use the normally operating devices. Do no use any devices that are under repair works or malfunctioning.
• Avoid installing the product in places where it can be directed exposed to rainstorms.
• Make sure to secure sufficient space around the product for safe works.
• Maintain the original state of the product as described in the original product design provided by the supplier.
• Do not use the product for any other purposes than electrolysis.
Control characteristic CC
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☞ Make sure to fix the product securely on transportation device whenever moving or
☞ Make sure that all power installation or separation is performed by licensed expert
in electronics.
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In order to safely move the product, make sure to thoroughly read and follow the below directions for
Transportation.
Caution
☞ Before moving the rectifier disconnect the input power through which current flows.
☞ Make sure to double check the condition of the transporter before Transportation.
☞ Before moving the rectifier, separate the main body of the rectifier and each cables.
☞ Dropping the machine may cause serious damages on human body as well as the machine
itself.
☞ Double check the capacity of hoist, and the safeness and capacity of transportation
equipment and devices, such as chains, when using the hoist for transportation.
☞ Human approaches are strictly forbidden while transporting the product using hoist and the
☞ Transport the machine at the slowest speed possible so that the machine is not disturbed by
the movement.
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. Transporting LUG
Description of
proper
transportation
Caution - Mount all hook-locks on all 4 LUGs at the top of the product.
- Weight 15D (350 kg), 35D (350 kg), 50D (480 kg), 100D (560 kg)
3-4. Installation
Following directions are for safe and strong arrangement and installation of the transported rectifier.
- Basically, the bottom and the back of the rectifier need to be fixed on surfaces.
- Following is a reference diagram for fixing the rectifier on floor and a wall.
- Install the product by considering the locations and sizes of holes. (Refer to below diagram)
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A sufficient space around the product is required when installing it in a place, for door opening, cooling
For proper opening and closing of the front door, make sure space “A,” when installing 15D,35D,50D or 100D, is
at least 800mm.
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Completely and precisely connect the external cables at appropriate locations as indicated on the cable
panel information.
Connections made differently from the directions may cause malfunctioning of or damages on the machine.
120Ὠ resistance of RS485 communication line is inserted inside the main PCB.
※ MODBUS Method
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Caution
☞ Make sure that the output cables are properly fixed before operating the machine.
☞ Cables may be lost or damaged while moving as the connecting part is loosened.
1. Excessive pressure on fixing bolts for output cables may cause damages on insulating material.
2. Connect the output cables by distinguishing between + and – terminals. (Refer to the cover printout for output
4. Connect the output cables after completely cutting power from the machine.
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1. Use cables with insulating voltage that is higher than the unloaded voltage of power (O.C.V).
Danger
☞ Make sure connecting input power, changing voltages and other works are done by a
☞ Use input power equipment (transformer, molded circuit breaker, fuse and cables)
☞ Perform the works after breaking the circuit for input power.
☞ Make sure to check the current and voltage of power before and after turning the
power on.
☞ Be aware of and thoroughly read all the name plate or rectifier and user manual
☞ The company is not responsible for any problems caused by disobeying the informed
☞ Make sure to connect input power as directed below and to use ground cables.
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2. If engine generator is used, use the one with over 3 times larger output than the rectifier Rated Input (kVA).
3. Install circuit breaker for each rectifier and use a circuit breaker and fuse with directed capacities.
4. The acceptable range of power voltage fluctuation is ±15% of rated output voltage.
3 phase, 440V, 60Hz of power is required to operate the rectifier and the power must not contain any
interferences (noise or high frequencies). To avoid influences from external loads, keep the power separated
when using.
Particularly, high-frequency operation or any other interferences occur while motor is driving negatively
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>
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Chapter 4 - Operation
4-1. Arrangement and Functions of Front Control Panel
7. 5.
2.
1.
4. 6. 3.
Indicates voltage.
1 VOLTAGE
(Shows error code in case error occurs)
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1) VOLTAGE
2) AMPERE Indication
- Shows output current value while the rectifier is normally operating.
3) CURRENT SETTING
- Set the minimum and maximum output current values.
* The indicated value and actual output value may vary.
4) POWER
- Once you supply power on control circuit, the voltmeter and ammeter will start to operate.
- Make sure the RUN/STOP switch is turned off before turning it on.
5) Operation Modes
Rectifier provides 3 modes. (LOCAL, LOCAL/REMOTE, REMOTE)
Each mode has its own function.
Remote (Standard)
You can remotely control the operation using communication cable and H/W.
For the detail, please follow Chapter 4-3-1.
Local/Remote
In LOCAL/REMOTE mode, you can control the operation using external I/O.
(Yet, the current setting must be done on the machine as in local mode)
For the detail, please follow Chapter 4-3-2.
Local
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6) RUN/STOP
- You can start producing output current and voltage once by turning the switch on.
- Make sure there is no foreign materials in the output cable before start operation.
7) CONTROL FUSE
- The required capacity of the fuse is 250V and 3A, so make sure to use once with the same capacity when
replacing it.
- Make sure the control power is completely turned off before replacing the fuse.
1. 2.
4.
3.
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1) POWER LAMP
- Perform any maintenance or repair works after turning off the circuit breaker on the primary power circuit.
2) WARNING
3) RUN LAMP
- The lamp turns on when the rectifier is turned on and normally running.
- Pressing the emergency stop switch will stop the output and turn on the warning lamp.
- You can return to the original state by turning the emergency switch to right.
Return the switch once you have removed the cause emergency and checked that the RUN/STOP switch is
turned off.
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For the functions of each mode, please refer to the table below.
Operation Mode
Functions Control Input
LOCAL REMOTE LOCAL/REMOTE
Local Machine ● ● ●
E-STOP
Hard Wiring ● ●
Local Machine ●
RUN/STOP Hard Wiring ● ●
Communication ●
Local Machine ● ● ●
READY/ERROR Lamp
Hard Wiring ● ●
Local Machine(KNOB) ● ●
current setting
Communication ●
Various monitoring Communication ● ● ●
※ Restrictions
Operation
Description
Mode
By setting this mode, currents cannot be controlled by TRO value at BWTS software panel.
※ Not following the proper operation directions may cause malfunction or damages
Local on the machine.
※ This mode is only allowed to BWTS maker engineer. Crews aren’t allowed to operate
this mode without Maker consultation.
By setting this mode, currents can be controlled by TRO value at BWTS software panel.
※ Standard Mode
Remote
※ Only E-stop function can act at local machine.
※ RUN/STOP, Knobs are not working with this mode.
By setting this mode, currents can be controlled by TRO value at BWTS software panel.
Local/ A person should be stand-by for monitoring the local machine.
Remote ※ This mode is only allowed to BWTS maker engineer. Crews aren’t allowed to operate
this mode without Maker consultation.
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MODE
Also, the current value can be adjusted by controlling the knob at local.
However, BWTS controller cannot control the status of rectifier with this mode.
Make sure to properly connect the input power and output cables before using the machine as directed below.
PROCEDURE
6) Wait for about 10 seconds. (Time required for the settlement and self-inspection of the rectifier)
8) Slowly rotate the ‘CURRENT SETTING’ KNOB to set desired output current
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MODE
This mode can make rectifier RUN/STOP, adjusting current value with controller. (Without using knob at local)
PROCEDURE
Description of operation
a. RUN command is H / W + communication AND condition and two conditions must be input at the same time
c. When External E-STOP command is input, A16 is displayed and E-STOP state is maintained.
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1)rectifier ID
※ MODBUS Method
You can set ID at PCB (HIRS38-04) on the machine using rotary switch
1 142A
2 142B
3 142C
4 142D
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MODE
While BWTS controller can turn the rectifier RUN/STOP, value setting can be adjusted by controlling the knob at local.
PROCEDURE
7) Slowly rotate the ‘CURRENT SETTING’ KNOB to set desired output current
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Alarms you may find during an operation of the rectifier are as follows. Refer to the following to analyze the cause of
- Alarm will sound when output from each cable does not fall into the unbalance error range of the standard
output (±50%).
- Error will occur when resistance is changed according to the external load.
- Alarm will sound if the output exceeds the standard output by 15%
* The output may be hunted if there is excessively high input voltage or change in frequency
Fan Normal(L),Error(H)
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5-3. MODULE
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5-4. POWER
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13
12
1
11
3
10
5 6 7 8 9
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3 2 1 9 8
1 Circuit breaker for wiring UCB 100L UCB 100L UCB 100L UCB 250S 3P 1
2 Output cable DFT100A-4P DFT100A-4P DFT100A-4P DFT200A-4P 2
3 Cable board 10A 10P 1
4 Electric contactor UMC25 1
5 Cement resistor PRV 200W 100Ω 2
HTM4A100- HTM4A100- HTM4A100- HTM4A300-
6 Current sensor 4
04VD15 04VD15 04VD15 04VD15
KHA400- KHA400-04VD15 KHA400-04VD15 KHA800-04VD15
7 Current sensor 1
04VD15
8 Input line filter 60A 60A 100A 180A 1
UMC75 00NS UMC75 00NS UMC100 00NS UMC225 22NS
9 Electric contactor 3
A220 A220 A220 F220
10 Aux. transformer GI701 1
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10 11 12 13
4 5 6 7 8 9
1 FAN E20060V2HBL-YH-RD 2
Module output Cable 400A produced output
2 2
board
Module input Cable BR-2100YDC-3P
3 1
board
Electrolysis ATUX-HR682M-400DF1
4 2
condenser
5 IGBT FF200R 12KT4 2
6 Diode MDD 95/16 3
7 Current sensor HTM4A300-04VD15 1
8 DC reactor GiPower reactor 1
9 Transistor GiPower 15D35D TR GiPower 50D100D TR 1
10 Drive PCB HICK92-06 3
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11 MS connector 11Pin,14핀 Pin 2
12 Temperature sensor PT100 1
input overcurrent JR62-125IS
13 3
fuse
1 2
6-5. Door
1
2
3
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2. If you find any flaws from the machine, you can request for free AS during the first 12 months from the date
of purchase. Even after the free warranty period, we provide charged repair services (parts + service prices)
4. If the product malfunctions, please make contact to the place of purchase or our sales department.
3. Damages caused by repair works performed by a person other than the AS manager or electronics technician
5. In case of user’s faults, such as dropping the machine while moving or installing the machine.
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