World

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

Power ON / OFF

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

Class

Power

Systems

1. General

2. Operation
In all fields of industry and commerce the
need for auxiliary power supplies to protect equipment against power failure is
increasing. For many years the DC power
supply and battery combination have been
used in areas such as measurement, control, and data back up for the supply of the
power and protection of the load.
Battery backed DC power supply systems
are used in a wide range of applications,
such as, monitoring and controlling of
production processes, supply of measurement equipment, telemetry, telecomunication and radio systems.

Lead-acid and nickel-cadmium batteries achieve optimum service

life when remaining on float, in a charge condition. The charger
floats the battery in a charged state and also supplies the load
with power. In the event of mains power failure the battery will
then supply the load its required power. This is called parallel
operation (see fig. 2).
With substantially discharged batteries, the rectifier unit at
first operates in the I-branch of the IU-characteristic line, whereby
the charging current for the batteries results from the difference
between the nominal current of the rectifier unit and the load
current.
When the set output voltage of the rectifier unit (U-branch) has
been reached, the unit is changed to constant voltage charging
(see fig. 3).

These systems can be found in:

power supply unit

Hospitals
Power plants and substations
Chemical plants
Petrochemical plants
Railway equipment
Offshore projects
Oil and gas pipeline systems

Fig. 2:
Standby paralles
operation
battery

Rectifier units presently employed for DC power supplies operate

almost without exception with a controlled output characteristic
(IU-characteristic line in accordance with DIN 41773).
The output voltage is kept
constant to the set value
with a permissible deviation of 1 % within a load
range between 0 % and
100 % of the unit current.
Mains voltage fluctuations
of 10 % and mains
frequency fluctuations of
5 % will be controlled
automatically
by
the
thyristor regulator.
Dependant on the application, flooded or valve regulated lead-acid batteries
are the main mediums
used for energy storage in
the power supply systems,
in some specialised applications
nickel-cadmium
batteries are also used.

load

Fig.1:
Thyrotronic
rectifier

Switching the charge characteristic, from float charging (e.g.

2.23 V/cell with lead-acid batteries)
to boost charging (2.4 V/cell with
lead-acid batteries) gives an accelerated recharge which can be manual, dependent on voltage or
dependent on voltage and time.
After the battery has been fully
charged, a small charge current
flows (approx. 0.3 mA to 1 mA
per 1 Ah) to balance the internal
losses of the battery.

The required autonomy is taken into consideration for calculating

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

V/C
Fig 3: Charging characteristic
for lead-acid batteries in
accordance with DIN 41773

boost charge
2.4

float charge

2.3
2.23
2.2
2.1
2.0

IN

0
0

20%

40%

60%

80%

100%

Typical values:

3. Rectifier series

10 - 30 minutes for EDP-systems

1 - 3 hours for DC power supply equipment in hospitals

and emergency lighting equipment

2 - 10 hours for telecommunication systems

The Thyrotronic series operates with a thyristor-controlled power

unit which is combined with a microprocessor-controlled monitoring and control unit. The special feature of this series is the
integrated monitoring and signalling concept with the following
functions:

Mains monitoring
Charger output monitoring, current-dependent

Back up of
Electronic Data
Processing
Systems

low voltage monitoring

High voltage monitoring with impulse blocking
Battery low voltage monitoring
Cyclic battery-circuit test
Battery availability test
Earth fault monitoring
Temperature-dependent floating charge voltage control
(temperature sensor required)
IxR Compensation of voltage drop on the battery lead
Programmable automatic charging
Indication of operating mode
Active load sharing
Hardware basic setting of the controller in case of
processor fault
Interface for PC or laptop
Six digital ports for external monitoring functions

4. Integrated functions
The frontpanel with integrated LEDs and
the LCD-display for indication of current
and voltage (see picture 4) enables the
use of different languages by way of an
exchangeable inscription panel.

Description of the integrated functions:

Mains monitoring

The LEDs which are integrated beside the

push button in the display are provided
for fixed functions.

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

and the LED and the "mains failure relay " will be activated. If the
mains volatge returns the unit is automatically switched on after a
set time.

Charger output monitoring

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

operation
battery operation
general failure
urgent failure

The LEDs in the indicator panel have the following standard functions:

Float charge
Float charge/boost charge
Battery test

float charge
float charge/boost charge
battery test
mains fault
unit fault
high voltage
low battery voltage
battery circuit fault
battery test negative
earth fault plus
earth fault minus
option 1
option 2

Mains fault
Unit fault
High voltage
Low battery voltage
Battery circuit fault
Battery test negative

Fig.4: Front view of the

thyristor range
Thyrotronic

There are 3 potential free relays for the following alarms

mains failure
common alarm
low battery voltage.
A relay card with a further 7 potential free alarm relays is available
as an option.

Earth fault plus

Earth fault minus
Option 1
Option 2

Power ON / OFF

High voltage monitoring

If the output voltage rises too high (value is adjustable) due to an
internal or external interference, over 20 msec. The impulse blocking will be activated and the output voltage will be set to zero.
This high voltage monitoring works as dynamic monitoring with
an automatic reset. If the monitoring responds 4 times within a
period of 30 seconds, the mains contactor will be disconnected,
the LED "high voltage" and common relay will be activated.

Low battery voltage

Earth fault monitoring

If the battery voltage falls below a set value, e.g. 1,8 V/cell (value
adjustable) during discharge in a case of mains failure, the alarm
"low battery voltage" will appear. LED and common alarm will be
activated.

The earth fault monitoring function monitors the insulation resistance of the DCoutput to earth. Plus and minus are measured and monitored alternately. If the
insulation resistance falls below the
adjusted value (adjustable from 100 kOhm to 1 MOhm), this will
be indicated by the LEDs and the common alarm.

Use as power
station power
supply

I*R Compensation
With I*R Compensation it is possible to balance the voltage drop
on the cable between rectifier and battery by entry of cable length
and cross-section of the cable.

Battery circuit test

Programmable float/boost charge change over

The battery circuit of the power supply system is tested cyclically

every 24 hours. For this, the rectifier output voltage is dropped
down to 1.9 V/C for a period of 5 secs. and, as a result, the battery is discharged. At the same time, the battery voltage is
checked. If the battery voltage stays above 1.9 V/C, the battery
circuit will be all right. If it falls below the limiting value, a "battery
circuit fault" will be indicated and the LED as well as the common
fault signalling relay will be activated.

If the battery voltage lowers due to mains failure or any other circumstances the rectifier unit will work in current limit. If it operates for more than 30 seconds after the charge start it will automatically be switched over to boost charge characteristic. After
the boost charge voltage (current limitation) has been reached
and after decreasing to < 90 %, a time stage will be activated.
Upon expiry of the set time (0 to 6 h) it will automatically be
switched back to float charge.
The automatic charging can be switched off so that only a manual
switch-over via the plastic foil key board on the front panel is possible. Switching back to float charge can be done manually as
well.If this is not done, the controller will switch back as in the
case of automatic charging.
The switch-over to boost charge can be blocked by an external
contact or a fixed bridge on the controller.

Caution!
It is not intended that this test should replace battery circuit
monitoring!

Battery availability test

During the battery availability test the rectifier output voltage will
be dropped and the battery will be discharged as it is the case
during the battery circuit test. But the battery will be discharged
down to an adjustable minimum voltage limit during an
adjustable time. These limits depend on the proportional battery
capacity withdrawn during the discharge and can be taken from
the discharging curves of the connected battery.
If, during the availability test, the values fall below the adjusted
limits, the message "battery test negative" will be indicated by the
corresponding LED and the collective fault signalling relay.
After the test the rectifier automatically switches back to boost
charge or floating charge.

Equalise charge stage

It is possible to switch to an equalise charge stage via a switch on
the front panel.
Here the voltage limitation will be abolished and the nominal unit
current will be reduced to 20 % (adjustable from 20-30).
An equalise and comissioning charge follows with an I-characteristic up to the final charge voltage of the battery.

5. Technical data
After switching to equalise charge, a timer
automatically switches back to the float
charge on expiry of the set time (16 hours
to 72 hours).
Using an external contact or a fixed bridge
at the regulator, the equalise charge can
be blocked and a switch over to the
I-characteristic can be prevented.

Active load sharing

Mains input
Input voltage:

230 V 10 % single phase

3 x 400 10% three phase
see table
50 Hz 5 %

Input current:
Frequency:

Rectifier output
Output voltage:
Output current:
Adjustment:
Boast voltage:
Float voltage:

Due to an internal bus connetion between

several rectifiers an active load sharing
of 10 % is possible.

Equalise voltage:
Regulation tolerance:
Ripple voltage:
Cooling:
Ambient temperature:
Protection:
Painting:
Acoustic noise level:
Cabinet type:

24, 48, 60, 110, and 220 V

see table
5%
2,40 V/Z Pb battery
1,55 V/Z NiCd battery
2,23 V/Z Pb battery
1,40 V/Z NiCd battery
2,70 V/Z Pb battery
1,70 V/Z NiCd battery
0,5 %
< 5 % eff without battery
for option 2 % eff
self-cooling
40 C
IP 20
RAL 7032
Max. 60 dB (A)
see table

Hardware basic setting

In the case of microprocessor failure in the control unit, the controller internally switches over to a basic setting. That is, the rectifier continues to operate at the adjusted floating charge voltage
and supplies the load as well as the battery.
In this case, a fault signal will be indicated by the common fault
signalling relay.

Option
As an option, the display and operation unit of MCU 2000 is
available with a graphic and alphanumeric display.
Additionally, the unit
is equipped with an
Thyrotronic
interface for remote
Float charge

Float charge/boost charge

Battery test

data transfer.

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

Power ON / OFF

6. Cabinet type table

Cabinet type
WGZ
755
PSJ
1564
PSJ
1566
PSJ
1866
PSJ
1896
PS 220808
PS 221008
PS 221208

H
758
1500
1500
1800
1500
2200
2200
2200

W
534
600
600
600
900
800
1000
1200

WGZ - wall mounted cabinet

PSJ / PS - floor standing cabinet

D
470
400
600
600
600
800
800
800

7. Type table
Nom.
voltage
V
24
24
24
24
24
24
24
24
24
24
48
48
48
48
48
48
48
48
48
48
48
48
48
60
60
60
60
60
60
60
60
60
60
60
60
60
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
216
216
216
216
216
216
216
216
216
216
216
216
216
216
216
216

No. of
cells
Pb
12
12
12
12
12
12
12
12
12
12
24
24
24
24
24
24
24
24
24
24
24
24
24
30
30
30
30
30
30
30
30
30
30
30
30
30
54
54
54
54
54
54
54
54
54
54
54
54
54
54
54
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108
108

No. of
cells
NiCd
20
20
20
20
20
20
20
20
20
20
40
40
40
40
40
40
40
40
40
40
40
40
40
50
50
50
50
50
50
50
50
50
50
50
50
50
90
90
90
90
90
90
90
90
90
90
90
90
90
90
90
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180
180

Subject to technical change without notice.

Type
E 230
E 230
E 230
E 230
D 400
D 400
D 400
D 400
D 400
D 400
E 230
E 230
E 230
E 230
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
E 230
E 230
E 230
E 230
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
E 230
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400
D 400

G 24
G 24
G 24
G 24
G 24
G 24
G 24
G 24
G 24
G 24
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 48
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 60
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 108
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216
G 216

/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/
/

20
40
60
80
100
125
160
200
300
400
10
20
30
40
50
60
80
100
125
160
200
300
400
10
20
30
40
50
60
80
100
125
160
200
300
400
5
10
16
25
30
40
50
60
80
100
125
160
200
300
400
5
10
16
20
25
30
40
50
60
80
100
125
160
200
300
400

BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG
BWrug-TDG

Main
voltage
V
230
230
230
230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
230
230
230
230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
230
230
230
230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
230
230
230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
230
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400
3 x 400

Curr.
consump.
A
4,6
9,2
13,6
17,8
5,5
6,8
8,7
10,8
19,0
24,3
4,6
9,1
12,3
16,3
5,8
6,7
8,9
10,8
13,8
17,6
21,9
32,0
48,0
5,1
10,3
17,5
20,4
6,8
8,1
10,8
13,5
17,1
21,7
26,5
40,5
53,0
4,0
8,0
13,2
6,5
7,5
10,0
12,9
14,7
20,0
24,7
31,5
40,0
50,0
70,0
100,0
9,4
5,1
8,0
9,8
12,4
15,2
21,0
25,2
30,5
40,0
50,0
63,0
81,0
100,0
152,0
203,0

Cabinet
type
WGZ 755
WGZ 755
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1596
WGZ 755
WGZ 755
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1866
PSJ 1866
PSJ 1896
WGZ 755
WGZ 755
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1866
PSJ 1866
PSJ 1896
WGZ 755
WGZ 755
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1866
PSJ 1866
PSJ 1866
PSJ 1896
PSJ 1896
PS 220808
WGZ 755
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1564
PSJ 1866
PSJ 1866
PSJ 1866
PSJ 1896
PSJ 1896
PSJ 1896
PS 220808
PS 221208
PS 221208

Weight
Kg
30
40
60
75
150
200
240
290
400
510
30
40
60
75
145
190
220
270
290
340
400
500
600
30
40
60
75
150
220
250
280
300
350
420
520
620
30
40
60
75
95
180
220
260
330
400
450
500
520
850
1100
40
60
80
120
220
260
330
400
450
500
620
720
800
1050
1300
1600

BENNING World Class Power Systems

www.benning.de

India
Benning SMC Power Systems (P) Ltd.
10, Electronic City, Sec.-18,
IND-Gurgaon -122015, Haryana
Tel. 0124 / 6 45 52 03 09
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E-Mail: [email protected]

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RF-105122 Moscow
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1, Kaki Bukit View
# 05-03/04 Techview
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Laor Energy ltd.
P.O.B. 570
IL-Nazereth Elite 17105
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Elektrotechnik und Elektronik GmbH & Co.KG
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784144.00 02/2002 paus Design & Medien, Bocholt Subject to alterations. Printed on chlorine free paper.

Austria
Benning GmbH Elektrotechnik und Elektronik
Eduard-Klinger-Str. 9
A-3423 St. Andr-Wrdern
Tel. 0 22 42 / 3 24 16-0
Fax 0 22 42 / 3 24 23
E-Mail: [email protected]

ISO 14001

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