KraftPowercon - Rectifier - 77-107.0222 GB Rev.I1 (IM-EN) PDF

User Guide
FlexKraft
77-107.0222 GB Rev.I1
KraftPowercon Sweden AB. P.O.Box 2102. SE-445 02 SURTE. Sweden Tel: +46 31 97 97 00. Fax: +46 31 97 97 97
User Guide Page 1(45) 77-107.0222 GB
FlexKraft 2015-12-08
Rev. I1
1 Safety Instruction
SAFETY INSTRUCTION
This product contains highly dangerous voltage that on

contact can cause electric shock, burns or death.
This product is only intended for use as a constant DC-power supply for industrial
processes, the product may only be used for other purposes after approval from
KraftPowercon. The product must not be used for charging batteries or welding.
The User Guide must be read before installation, use in production or work on the
production.
WARNING! Only allow qualified personnel to carry out installation

according to the installation guide and local regulations.
WARNING! Only allow qualified personnel to carry out servicing or

maintenance.
WARNING! Always disconnect the main supply in a safe manner

before servicing/maintenance work is started. Work shall
follow the service instruction in the Technical description.
The equipment is only intended for professional use and must not be used in home or
office environments.
Rev. I1
Table of Contents
1 SAFETY INSTRUCTION ................................................................................ 1

1.1 Description of safety symbols used on FlexKraft: ....................................................4
1.2 Standards ......................................................................................................................4
2 GENERAL ...................................................................................................... 5
3 BASIC CONTROL .......................................................................................... 7
3.1 Normal operation ..........................................................................................................7
3.1.1 Keypad ............................................................................................................8
3.1.2 LED indication .................................................................................................8
3.1.3 Audio signals ...................................................................................................8
3.1.4 LCD display .....................................................................................................8
3.1.5 Special functions .............................................................................................9
3.1.6 Alarms / Warnings / Fault messages ..............................................................9
3.1.7 Operating modes ...........................................................................................11
3.1.8 Brief overview of functions ............................................................................12
3.1.9 Starting the rectifier .......................................................................................13
3.1.10 Stopping the rectifier .....................................................................................14
3.1.11 Blocking the rectifier RUN/BLOCK ................................................................15
3.1.12 Blocking rectifier START/STOP ....................................................................15
3.1.13 Setting the current and voltage .....................................................................16
3.1.14 Setting the time limit ......................................................................................17
3.1.15 Setting the Ah limit.........................................................................................18
3.1.16 Setting the start ramp ....................................................................................20
3.1.17 Setting the auto-dosing function (optional)....................................................21
3.1.18 Running program ...........................................................................................23
3.1.19 Setting the remote control .............................................................................24
3.1.20 Locking keypad to enter parameters in SLAVE mode ..................................25
3.1.21 Setting the under voltage / short circuit detection .........................................25
3.2 Calibration/Configuration ..........................................................................................25
3.3 Password .....................................................................................................................25
4 INSTALLATION GUIDE ............................................................................... 25
4.1 Essential electrical knowledge..................................................................................25
4.2 Transport and handling..............................................................................................26
4.3 Set up ...........................................................................................................................27
4.3.1 General ..........................................................................................................27
4.3.2 Recommendations for installation .................................................................27
4.3.3 Installation .....................................................................................................28
4.4 Electrical installation ..................................................................................................30
4.4.1 Power supply .................................................................................................31
4.4.2 Load connection ............................................................................................32
4.4.3 Reduction of output .......................................................................................35
4.4.4 Control cables ...............................................................................................35
4.4.4.1 Control cables RS-485 .............................................................................36
4.4.4.2 Control cables RS-232 .............................................................................38
4.4.4.3 Control cables analogue control ..............................................................38
4.4.4.4 Control cables for parallel duty.................................................................39
4.4.4.5 Control cables for emergency stop ..........................................................40
4.5 Checks when powering up ........................................................................................40
4.5.1 Operating check without load ........................................................................41
4.5.2 Operating check with load .............................................................................41
4.6 Initial Calibration/Configuration ................................................................................42
Rev. I1
5 WARRANTY ................................................................................................. 42

6 APPENDICES, SEE FOLLOWING PAGES ................................................. 42
6.1 Equipment diagram, stand-alone rectifier and parallel-master .............................43
6.2 Equipment diagram, parallel-slave ...........................................................................45
6.3 Description of order-specific equipment, where applicable ..................................45
This description applies to software version FLX-01 VER. 02.90 and higher.
Slight differences can exist between the program versions.
When upgrading to firmware version 2.5x from 2.xx no special action is needed.
To upgrade the software from earlier versions, contact KraftPowercon service.
NOTE!
If upgrading from version 01.xx to version 02.xx, please make a note of the settings
of the CFG and SET menus, as it may be necessary to re-enter these settings after
upgrading the software.
The manufacturer reserves the right to change specifications.

Rev. I1
1.1 Description of safety symbols used on FlexKraft:
Warning, risk of electric shock!
Before operating the unit:

- Carefully read the manual.
Warning, risk of electric shock!
Before opening the unit:

- Isolate from the electrical supply.
Connection point for the protective earth.
1.2 Standards
The following European standards or technical specifications apply:
Electrical safety:
EN 50178 Electronic equipment for use in power installations
EMC Immunity:
EN 61000-6-2 Electromagnetic compatibility -
Immunity for industrial equipment
EMC Emissions:
EN 61000-6-4 Electromagnetic compatibility -
Generic immunity standard
- Part 2: Industrial environment
This means that a device installed correctly does not disturb other CE marked equipment
via conducted or radiated RF effects.
Rev. I1
2 General
FlexKraft is a modular designed rectifier for galvanic processes. The rectifier consists of
one control module and one to ten identical power modules. If more current or power is
needed from an existing rectifier, power modules can be added, up to a maximum of 10.
FlexKraft has built in EMC filter according to the EMC directive.
1
5 A B 1 Roof
6 7 2 2 Control module
3 3 Power module
4 Base
8 5 Display with keys
6 Power connection
7 Control cable connection
Labels with information for
connecting
4 8 DC bus bars
Side A is to the left seen towards

the front of the rectifier
Figure 1. FlexKraft components.
Figure 2. : FlexKraft with four power modules and control module on top (standard configuration).
Figure 3. FlexKraft , two and four rectifiers configured as stack, rectifier with control module moved,
and bench-top model.
Rev. I1
Figure 4. FlexKraft , four parallel rectifiers, Master rectifier to the left

Master rectifier must always be at one end.
Example.
Three rectifier stacks connected

in parallel
Output voltage: 12-15VDC
Output current: 18000ADC-
15000ADC
On stacks in parallel shall output
bus bars be connected tight
together in the middle of the
rectifiers, see Figure 12.
Example of power cable
connections on DC side
Figure 5 Three rectifier stacks connected in parallel Connections must not be made
at one end of the busbar
Rev. I1
3 Basic Control
This chapter deals with control from the local display. The rectifier will, in most cases,
probably be remotely controlled from an external control system. The local display unit is
useful for service and troubleshooting.
3.1 Normal operation

The rectifier is operated using the display unit on the front of the control module.
Figure 6. FlexKraft display unit

For more functions and detailed information see the Technical description 77-107.0223.
Chapter Operating instructions
Rev. I1
3.1.1 Keypad
FlexKraft has the following keys on its membrane keypad:
ON Starts the rectifier, (contactor closes, if installed)

OFF Stops the rectifier, (contactor opens, if installed)
Current  Increases the current
Current  Decreases the current
Voltage  Increases the voltage
Voltage  Decreases the voltage
Menu keys A–D Menu selections
OK! Used to confirm a change (Deactivated in some sub-menus)
ESC Used to undo a change or exit a menu
(Deactivated in some sub-menus)
In REMOTE mode, some or all control functions cannot be operated from the display unit
and are instead controlled by serial communication or by external analogue control signals.
If the rectifier is not in REMOTE mode it can only be operated from the display unit.
When SLAVE MODE is active, the keypad is disabled and no operating parameters can be
changed, see section 3.1.19. The keypad is activated using a password-protected menu.
3.1.2 LED indication

The panel is equipped with LED status lamps for the following functions:
ON Green LED Indicates the rectifier is switched on (opt. contactor switched).

ALARM Red LED Indicates the end of the process or rectifier fault.
LED flashes in case of a WARNING and glows steadily
in case of an ALARM
REMOTE Yellow LED Indicates the rectifier is controlled by remote control
3.1.3 Audio signals

The panel is equipped with a piezo buzzer that sounds to confirm keypad use, end of
process (EOP) and a rectifier fault. The buzzer sound indication can be turned off in the
CFG/USR menu. See in the Technical Description 77-107.0223 Chapter Operating
instructions
3.1.4 LCD display

The LCD display is a high contrast graphic type with integrated background lighting.
The display contrast may need to be adjusted depending on the ambient temperature and
age. Adjustment is made from the configuration menu.
Background lighting comes on when a key is pressed and remains on for 60 seconds after
the last key is pressed.
Rev. I1
3.1.5 Special functions

The rectifier control system is configured on delivery, however, if for some reason you wish
to reset the settings to their default values this can be done by holding down the ESC key
for more than 8 seconds.
NOTE - The SET parameters, Ah counter and process timer are reset to zero.
- The CFG settings are not changed (the buzzer is switched on if it has
been switched off)
-The loaded software is not changed.
The buzzer sounds when the system has been reset.
The system is reset if the OFF key is held down for 5 seconds. The buzzer sounds to
indicate that reset has occurred.
3.1.6 Alarms / Warnings / Fault messages

An alarm signal from the rectifier is indicated by a red LED on the display unit. The reason
for the alarm is shown on the display.
If the rectifier is fitted with the optional CONTACTOR, the contactor opens at the alarm. If
the sound indication is set to “ON” in the CFG/USR menu, see the Technical Description
77-107.0223 Chapter Operating instructions , the buzzer goes on at the alarm. The buzzer
is turned off by pressing any button.
To reset from fault mode: switch the rectifier off using the keypad or serial
communication. Alternatively, send the ALARM RESET command using the DIG IN digital
input.
ALARM = The rectifier stops.

WARNING = The rectifier continues to operate but possibly with reduced output.
The ALARM signal is activated in the event of either an ALARM or WARNING.
The POWER GOOD signal is deactivated when there is an ALARM or WARNING.
Message Explanation
“HIGH TEMP! P-M” Excess temperature in a power module. Too high temperature on
the output causes over temperature in the power module. (The
output from the affected power module is cut as long as the temperature
remains too high. The “power good” LED is off on the power module that has
sent the high temperature signal.)- The rectifier remains running with the
remaining power modules, the output current is decreased
accordingly.
“HIGH TEMP C-M” Excess temperature in the control module. The rectifier runs.
The output current is unaffected.
“REGULATIONERR” Regulator control error in a power module. (The rectifier runs. The
“powergood” LED is off on the power module that has sent the warning
signal).Tthe output current is decreased accordingly.
If all modules have “Power Good” LED off, check main supply,
out of range or one phase missing
Rev. I1
“MODULE FAILED!” Reverse current in a power module. (The rectifier stops. The
“powergood” LED is off on the power module that has sent the alarm signal)
“SHORT CKT!” The output voltage has been below the under voltage set value
for a longer period of time than set time value.
In the case of an ALARM, the reason for the ALARM should be determined. See
chapter 8 in technical description 77-107.0223 Chapter Service and Maintenance
The display can also show fault messages.
Message Explanation
“CHK USRCFG” Only applies with pole reversal option. Fault in
configuration of DIG IN or DIG OUT signals.
“ILLEGAL PARAMETER” Shows that a set value sent via serial communication is
out of range. If the set value is above range, it will be set
to maximum range value. If the set value is below range,
it will be set to minimum range value.
“INTERNAL FAULT 256” Shows an internal software problem. Restart the rectifier
(OFF) and check if the fault disappears. Please call
KraftPowercon and report when the fault occurred.
“MAX POWER” The output of the rectifier does not correspond to the
(ALARM LED flashes) set values of current and voltage due to power limitation.
The set values for current and voltage is within the
triangle 12-15V/300A.
Effektgräns
Power limit
15V
12V
Spänning/Voltage
I
Ström/Current 250A 300A
When an EOP for elapsed time limit or ampere hour limit is reached the “ALARM” LED
flashes, see “Setting the time limit” and “Setting the Ah limit” for information.
Rev. I1
3.1.7 Operating modes

The rectifier has four operating modes:
Parallel Power module sub-modules are connected in parallel and
supply
0-12(15)V 600(500) A/module at 380-480V primary voltage
0-7V 600 A/module at 220v primary voltage
Series Power module sub-modules are connected in series and

supply
0-24(30)V 300(250) A/module at 380-480V primary voltage
0-14V 300 A/module at 220V primary voltage
Dual Power module sub-modules are independent and supply

2x 0-12(15)V 300(250) A/module at 380-480V primary voltage
2x 0-7V 300 A/module at 220V primary voltage
Both sides are switched on and off at the same time.
The set values for current and voltage can be different for
each side
Dual-2 Power module sub-modules are independent and supply

2x 0-12(15)V 300(250) A/module at 380-480V primary voltage
2x 0-7V 300 A/module at 220V primary voltage
Sides A and B can be switched on and off independently and
behave like two rectifiers.
The set values for current and voltage can be different for
each side
If the current requirement increases, additional power modules can be added (up to a
maximum of 10). Contact the service department at KraftPowercon.
Several rectifiers can be connected in parallel to obtain higher output current, but
they must be equipped with the parallel configuration option. NOTE that if more than
one rectifier stack shall be connected in parallel then each stacks bus bar shall be
connected together with the other stacks DC outputs. Please see Figure 5 Three
rectifier stacks connected in parallel.
Rev. I1
3.1.8 Brief overview of functions
Please note that some functions require that options are installed.
Heading Sub-function 1 Sub-function 2 Sub-function 3
Operating modes PARALLEL Pole reversal

SERIES Watercooling
DUAL
DUAL-2
Remote control Serial communication RS485 PROFIBUS DP

MODBUS RTU
RS232 MODBUS RTU (one unit)
Analogue current 0-20mA

4-20mA
voltage 0-10VDC
0-6 VDC
0-5 VDC
6-0 VDC
10-0 VDC
contacts Increase/decrease current
Increase/decrease voltage
ON/OFF
START/STOP
RUN/BLOCK
Program No. 1-4 STEP
U-RAMP
I-RAMP
PULSE
REPEAT
Limits Ah limit Side A Stop rectifier

Side B Signal
HOLD function U/I
Time limit Side A+B Stop rectifier
Signal
HOLD function U/I
Under voltage Limits Side A Voltage
Limits Side B Time
Time limit Side A
Time limit Side B
Dosing function Side A Dosing pulse time
Side B
Total A+B
Monitoring Temperature
Regulation
Configuration
External emergency stop
See Technical Description 77-107.0223 for more information.

Rev. I1
3.1.9 Starting the rectifier

When first switched on the display is dimmed and shows the following start displays.
Side
A B
STATUS: - OFF - - OFF - - OFF -
FlexKraft PRESS ON TO START PRESS ON TO START
www.kraftpowercon.com DUTY SET BLOCK CFG DUTY SET BLOCK CFG
Welcome screen Example of start screen

Displayed for some seconds The rectifier can be configured to go to OFF,
REMOTE, CONTINUE or RUN
when mains power is connected.
PARALLEL, SERIES DUAL, DUAL-2

Switch on the rectifier
with the “ON” key. STATUS: STANDBY STANDBY STANDBY
The backlight comes

on and the display 00.00 V 000.0 A 00.00 V 00.00 V
changes. 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG

Start the rectifier by
pressing the on key STATUS: RUN DC RUN DC RUN DC
-output current and
voltage is delivered.
00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
In order to control the rectifier locally, set the Remote control option to “NO”
See Technical description 77-107.0223 Chapter “Set menu” for further information.
Rev. I1
3.1.10 Stopping the rectifier

Switch the rectifier from “RUN” mode to “STANDBY” mode with the “OFF” key.
Shut down the rectifier by pressing the “OFF” key again to switch from “STANDBY” mode
to “OFF” mode.
Also see 3.1.19 Setting the remote control

Rectifier, stops after
set time. STATUS: TLIMIT! T-LIMIT! T-LIMIT!
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
Rectifier, stops after STATUS: AHLIMIT! AH-LIMIT! AH-LIMIT!

set number of Ah
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
Rectifier, stops due STATUS: HIGH TEMP HIGH TEMP HIGH TEMP
to. excess
temperature
00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
Rectifier, stops due SHORT CKT! SHORT

to. Under voltage STATUS: SHORT CKT!
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET BLOCK DUTY SET BLOCK

Rev. I1
3.1.11 Blocking the rectifier RUN/BLOCK

The rectifier can be blocked and stopped without entering “STANDBY”.
The blocking function turns the rectifier output off and it restarts with the set values.
In DUAL-2 mode output A and B are blocked independently.
This can be done using the “BLOCK” key, from the main menu, from the SET menu,
or by remote control. In DUAL-2 mode the rectifiers can only be operated
independently from the SET menu, or by remote control.
3.1.12 Blocking rectifier START/STOP

The rectifier can be blocked and stopped without going to “OFF”.
The start function turns the rectifier output off immediately and it restarts with a start
ramp to the set values.
In DUAL-2 mode outputs A and B can be operated independently.
Can only be done from the SET menu, or by remote control.

Rev. I1
3.1.13 Setting the current and voltage

The current and voltage can be set during operation or before starting the rectifier.
Change the voltage during operation with the “VOLTAGE” arrow keys to increase or
decrease the values.
Change the current during operation with the “CURRENT” arrow keys to increase or
decrease the value.
NB! If the rectifier is in DUAL mode the set values for both sides are changed equally and
simultaneously if the arrow keys on the keypad are used. The set values can be set
individually in the SET menu.
If required, set the initial voltage and current values before starting using the SET menu.
Both methods can be used in STANDBY and RUN mode.
STATUS: STANDBY STANDBY STANDBY STANDBY STANDBY
00.00 V 000.0 A 00.00 V 00.00 V 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A 000.0 A 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG DUTY SET BLOCK CFG
The set menu The set menu The set menu
REMOTE CONTROL : NO REMOTE CONTROL : NO REMOTE CONTROL : NO

SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V SETVOLTAGE A: 00.00 V
SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V SETVOLTAGE B: 00.00 V
RUN/BLOCK : RUN SETCURRENT A: 000.0 A SETCURRENT A: 000.0 A
START/STOP : STOP SETCURRENT B: 000.0 A SETCURRENT B: 000.0 A
POLARITY : FWD RUN/BLOCK : RUN RUN/BLOCK A : RUN
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Rev. I1
3.1.14 Setting the time limit

The rectifier can be set, once a specific time has elapsed, to:
-Stop and give a signal
-Continue with operations and give a signal
-Change the output data to a HOLD level and give a signal.
Set in CFG/USR menu using EOP MODE
The time is set in the SET menu using TIMERLIMIT.

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get TIMERLIMIT
Setting whether the rectifier should stop, use HOLD level or only light the ALARM LED
when the set limit has been reached (option: contact to remote system) is set using the
CFG/USER menu with the EOP MODE parameter.
NOTE that the settings also apply for the Ah limit. The CFG menu is password protected.
STATUS: STANDBY STANDBY STANDBY
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
SELECT SUB-MENU OR SELECT SUB-MENU OR

PRESS ESC TO EXIT! PRESS ESC TO EXIT!
FIRMWARE FIRMWARE
FLX-01 VER xx.xx FLX-01 VER xx.xx
PROG USER CAL KRAFT PROG USER CAL KRAFT

Rev. I1

LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 %
PASSWORD :000001 PASSWORD :000001
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP
BYTESWAP : YES BYTESWAP : YES
ADDRESS : 00002 ADDRESS : 00002
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT
← → ↓ ↑ ← → ↓ ↑
Press ↓ to get EOP MODE Press ↓ to get EOP MODE
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS

SLAVEMODE: NO SLAVEMODE: NO
POWERONMODE: OFF POWERONMODE: OFF
OUTPUTMODE : SERIES OUTPUTMODE : SERIES
EOP MODE : STOP EOP MODE : STOP
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0%
← → ↓ ↑ ← → ↓ ↑
Press “OK” to activate change.
Switch off the buzzer by pressing ESC.
Pausing the process:

The process can be paused before the set limit is reached by pressing the “OFF” key and
then restarted by pressing “ON” key. A restart is also made if the “OFF” key has been
pressed twice so that the rectifier is in “OFF” mode.
Interrupting the process:

Pause the process using the “OFF” key. Reset the counter in the DUTY menu with
CLEAR. Restart the process from zero with the “ON” key.
Restart the process:

When the process has completed and an EOP has been obtained, the rectifier is
stopped/set in STANDBY mode using the “OFF” key. Restart the process from zero with
the “ON” key.
See the Technical description for further setting options and programming functions.
3.1.15 Setting the Ah limit

The rectifier can be set, once a specific number of ampere hours have elapsed, to:
-Stop and give a signal
-Continue with operations and give a signal
-Change the output data to a HOLD level and give a signal.
Set in CFG/USR menu using EOP MODE
The number of ampere hours is set in the SET menu using AH-LIMIT A and AH-LIMIT
B.
Rev. I1
00.00 V 000.0 A 00.00 V 00.00 V 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A 000.0 A 000.0 A

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get AH-LIMIT A Press ↓ to get AH-LIMIT A Press ↓ to get AH-LIMIT A
SETCURRENT : 000.0 A START/STOP : STOP POLARITY A : FWD

RUN/BLOCK : RUN POLARITY : FWD POLARITY B : FWD
START/STOP : STOP TIMERLIMIT : -OFF- S TIMERLIMIT : -OFF- S
POLARITY : FWD AH-LIMIT A : -OFF-AH AH-LIMIT A : -OFF-AH
TIMERLIMIT : -OFF- S AH-LIMIT B : -OFF-AH AH-LIMIT B : -OFF-AH
AH-LIMIT : -OFF-AH START RAMP : 0000.5 S START RAMP : 0000.5 S
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Setting whether the rectifier should; stop, use HOLD level or only light the ALARM LED
when the set limit has been reached (option: contact to remote system) is set using the
CFG/USER menu with the EOP MODE parameter.
NOTE that the settings also apply for the time limit. The CFG menu is password protected.
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
Rev. I1

FIRMWARE FIRMWARE

← → ↓ ↑ ← → ↓ ↑
Press ↓ to get EOP MODE
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS

SLAVEMODE: NO SLAVEMODE: NO
POWERONMODE: OFF POWERONMODE: OFF
OUTPUTMODE : SERIES OUTPUTMODE : DUAL
EOP MODE : STOP EOP MODE : STOP
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0%
← → ↓ ↑ ← → ↓ ↑
Switch off the buzzer by pressing ESC.
See the Technical description 77-107.0223 Chapter Operating Instructions for further
setting options and programming functions.
3.1.16 Setting the start ramp

The rectifier can be set to ramp up voltage and current from zero to set value during a
preset time. The time is set using the SET menu and the parameter START RAMP for
both side A and side B.
Rev. I1
00.00 V 000.0 A 00.00 V 00.00 V 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A 000.0 A 000.0 A

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get START RAMP Press ↓ to get START RAMP Press ↓ to get START RAMP
SETCURRENT : 000.0 A START/STOP : STOP POLARITY A : FWD

RUN/BLOCK : RUN POLARITY : FWD POLARITY B : FWD
START/STOP : STOP TIMERLIMIT : -OFF- S TIMERLIMIT : -OFF- S
POLARITY : FWD AH-LIMIT A : -OFF-AH AH-LIMIT A : -OFF-AH
TIMERLIMIT : -OFF- S AH-LIMIT B : -OFF-AH AH-LIMIT B : -OFF-AH
AH-LIMIT : -OFF-AH START RAMP : 0000.5 S START RAMP : 0000.5 S
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
3.1.17 Setting the auto-dosing function (optional)

The rectifier can be equipped with an auto-dosing function. This function requires that the
digital I/O or analogue I/O option be fitted to the rectifier.
The rectifier can be set to close a potential free contact when a preset number of Ah hours
have elapsed. The number of Ah hours between the start of each pulse is set using
parameter AUTODOS, and the closed time for the contacts is set by the parameter
PULSLENG in the CFG/USER menu. The menu is password protected.
There are three adjustable Ah counters and three adjustable times.
Side Parameter AH Parameter pulse time

A AUTODOS.A PULSELENG.A
B AUTODOS.B PULSELENG.B
A+B AUTODOS. PULSELENG.
Rev. I1
AUTODOS has a range of 0-30,000 Ah, and sets the number of ampere hours between
dosing.
PULSELENG has a range of 0-999.9 s, and sets the length of time that the contacts
remains closed.
The DIG OUT 1 to DIG OUT 4 parameter determines which contacts are used.
Parameters are set in the CFG/USER menu.
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

FIRMWARE FIRMWARE

← → ↓ ↑ ← → ↓ ↑
Press ↓ to get PULSELENG.B
AUTODOS. : -OFF-AH AUTODOS. : -OFF-AH

PULSELENG. : 000.5 S PULSELENG. : 000.5 S
AUTODOS. A : -OFF-AH AUTODOS. A : -OFF-AH
PULSELENG.A: 000.5 S PULSELENG.A: 000.5 S
AUTODOS. B : -OFF-AH AUTODOS. B : -OFF-AH
PULSELENG.B: 000.5 S PULSELENG.B: 000.5 S
← → ↓ ↑ ← → ↓ ↑
See the Technical description Press “OK” to activate change.

77-107.0023 Chapter Operating Instructions for further setting options and programming
information.
Rev. I1
3.1.18 Running program

The rectifier can be programmed with 4 different programs.
The program and operating mode are selected using the PROGRAMMODE and PROGRAM
NO parameters in the SET menu.
00.00 V 000.0 A 00.00 V 00.00 V 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A 000.0 A 000.0 A

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get PROGRAMMODE Press ↓ to get PROGRAMMODE Press ↓ to get PROGRAMMODE
POLARITY : FWD AH-LIMIT B : -OFF-AH AH-LIMIT B : -OFF-AH

TIMERLIMIT : -OFF- START RAMP :0000.5 S START RAMP :0000.5 S
AH-LIMIT : -OFF-AH PROGRAMMODE A : NO PROGRAMMODE A : NO
START RAMP :0000.5 S PROGRAMMODE B : NO PROGRAMMODE B : NO
PROGRAMMODE : NO PROGRAM A NO : 01 PROGRAM A NO : 01
PROGRAM NO : 01 PROGRAM B NO : 01 PROGRAM B NO : 01
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Programs are entered using the CFG/PROG menu. The menu is password protected.
Basic functions: Press “OK” to

Number of programs: 4 activate change.
Program steps per program: 8
Program repeat Yes, possible
Basic
functions:
RAMP STEP PULSE

Individual adjustment of voltage and current for each program step.
Rev. I1
3.1.19 Setting the remote control

The rectifier can be remotely controlled by serial communication or analogue signals.
When the rectifier is remotely controlled, the local control is disabled. When controlled
remotely, parameters that are controlled by the analogue interface have precedence over
parameters sent by serial communication.
Special case: When using analogue remote control, some set values and functions can be
remotely controlled and others locally controlled from the keypad, REMOTE=ON
PROTOCOL=NONE. However it is possible to read out actual values The rectifier cannot
be switched OFF with the OFF key. LOCAL mode must first be selected in the SET menu
by setting REMOTE=NO.
If the rectifier loses contact with the master during PROFIBUS control, the keypad will be
re-activated.
Remote control via serial communication is selected with the parameter REMOTE in the
SET menu.
00.00 V 000.0 A 00.00 V 00.00 V 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A 000.0 A 000.0 A

← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
The parameters for remote control must to be set to give correct remote control
functionality.
The protocol and parameters must be set for serial communication.

For analogue remote control, the inputs must be activated and configured.
Use the CFG/USER menu (the menu is password protected).
If the rectifier is delivered with remote digital or analogue control box, the parameters are
factory set.
NOTE If the rectifier is set for analogue remote control of set values these values
take, in REMOTE mode, priority over set values via serial communication.
See the Technical description 77-107.0223 Chapter Programming for further information.
Rev. I1
3.1.20 Locking keypad to enter parameters in SLAVE mode

When the rectifier is in SLAVEMODE the keys are disabled and no operating parameters
can be changed. The operating parameters can be displayed.
The keypad is unlocked by deactivating SLAVEMODE using the password-protected
CFG/USER menu.
3.1.21 Setting the under voltage / short circuit detection

Due to voltage drop in DC-cabling a S.C: Level of 2-4V is appropriate.
A time delay of 30 -120 sec before shutdown effectively prohibits false alarms due to
normal variation of current.
Default settings:
S.C. LEVEL 2,00V
S.C. DELAY 0sec = -OFF-
For SERIES and PARALLEL rectifiers the “A-side” parameters shall be used.
NB! The output voltage set value must be higher than the under voltage/short circuit
detection voltage. Otherwise the under voltage/short circuit detection is disabled
3.2 Calibration/Configuration
The rectifier is calibrated and configured at the factory before delivery.
The rectifier can be calibrated from the CFG/CAL menu. The calibration menu is password
protected.
The rectifier needs to be reconfigured if the DC output's connection changes from parallel
(0–15VDC) to series (0–30VDC) or vice versa.
See Technical description 77-107.0223 Chapter Operating Instructions for further
information
3.3 Password
Some menus and settings are password protected. KraftPowercon service can set a new
password should the old one be lost.
See the Technical description 77-107.0223 Chapter Operating Instructions for further
information.
4 Installation guide
4.1 Essential electrical knowledge
Installation of the rectifier may only be carried out by qualified personnel, i.e. trained
electricians that have sufficient experience to avoid the dangers that electricity can bring
about.
Rev. I1
4.2 Transport and handling
CAUTION! The rectifier is heavy when equipped with many modules. Use
lifting equipment and secure the load when lifting. Serious
personal injury and material damage can result should the unit
be dropped.
Check that the equipment has not been damaged during transport.
Protect FlexKraft against harsh treatment, vibrations and harmful substances.
The equipment can be lifted with a lift truck or with a sling/rope (or the optional lifting
eyes).
If the rectifier is lifted with a lifting sling or rope, you must check that the distance between
the top of the rectifier and the lifting point is sufficient. Alternatively, a bar, that spreads the
lifting sling above the rectifier, can be used.
NOTE! Take care to ensure that the sling/rope cannot slip off or that hooks can slip out of
place during lifting.
Lifting with a sling/rope
A= min 2m a= min 0.5 m
NOTE! When lifting heavier equipment (>=5 modules) use timber studding (approx.
40 x 80 x 600 mm) for additional support and use a lifting yoke if possible.
It may be necessary to increase the dimensions shows depending on the lifting capacity of
the sling.
Rev. I1
Lifting with lifting eyes
NOTE! Avoid this Use lifting yoke.

lifting method
a= min 0.5 m
4.3 Set up
4.3.1 General
The galvanic rectifier FlexKraft is designed and manufactured to withstand the
environment in a modern surface treatment facility. The component parts and modules of
the rectifier have been treated so that the effects from the surrounding environment are
minimal. The device is air-cooled, the fans should be checked regularly and replaced when
necessary.
The control module is mounted as standard on top of the stack, but can be mounted in
other positions. Should the control module need to be moved, contact the service
department at KraftPowercon Sweden AB.
The rectifier can be expanded with power modules when the current/output need
increases. Contact KraftPowercon Sweden AB.
4.3.2 Recommendations for installation

The maximum service life is obtained from the rectifier when the following advice is
observed during installation:
 Installation in an area solely intended for electrical equipment and rectifiers is optimal.
The environment in this area should be clean and dry (Max. relative humidity 85 %)
 When installing in the direct vicinity of the galvanising process, ensure that the rectifier
is not directly exposed to the vapours/chemicals used in the process, for example, by
shielding.
The rectifier can be equipped with an optional fresh air intake.
 The rectifier should be protected from mechanical damage and sprayed water.
Obvious incorrect installation or operation will limit KraftPowercon Sweden AB's warranty
undertaking.
Rev. I1
4.3.3 Installation
The rectifier should be installed to facilitate service and maintenance.
The rectifier needs to be accessible at the rear to connect cables to the load and to
remove the power modules from the chassis when replacing modules. At the front a free
space of at least 1 m is needed to pull out the power modules, and for servicing.
It is recommended that clearance of at least 500 mm is provided at the rear of the rectifier
to provide access for load connections.
0,5-1m clearance for

service access
Space for load

connections.
Rear side
Rectifier
Front side
At least 1m clearance for

service access
At least 15 mm clearance for

panel removal.
When placing rectifiers side by side, make sure that there is at least a space of 15mm
between the rectifiers. The front panels is removed by loosing 4 screws and then sliding
the panel to the left.
The rectifier can be installed without the need to open the enclosure, only the cover plate
over the connection terminals needs to be opened.
The following should be observed during installation:

Check both before and after installation that the rectifier has not suffered any mechanical
damage.
When damage has occurred, KraftPowercon must be notified in the first instance. Agreed
repairs must be made before installation and commissioning. If this procedure is not
followed the Warranty may be invalidated.
Rev. I1
The rectifier should be installed so it has free access to air from the front and that the air
outlets at the rear are not blocked.
NB! Check that the exhaust air can freely depart from the rectifier and not recirculate to
the air intake.
X X
Figure 7. Air flow through the equipment.

Bearing in mind the weight of the rectifier, appropriate lifting equipment must be used.
The rectifier should be well anchored so that it cannot tip and cause damage.
See the Technical description 77-107.0223 Chapter Technical Data for information about
measurements and weights.
Rev. I1
4.4 Electrical installation

The rectifier should be connected to a 3-phase power supply with voltage according to the
rating plate on the rectifier, loads consist of the galvanic bath and control signals.
WARNING! Only allow qualified personnel to carry out servicing or

maintenance.
WARNING! HIGH LEAKAGE CURRENT. The protective earth should

always be connected in a reliable manner so that the rectifier
does not become live in the event of a fault. The earth
conductor on the rectifier's terminal should be approximately 5
cm longer than the phase conductors.
CAUTION! Check that contact between the output busbars and
cables/busbars is good. This is to keep down the temperature
on the output busbars. Bad contact can cause the temperature
to rise significantly.
The control system or separate controller is connected to the control module. Control is
connected depending on the rectifier´s equipment by one of the following options:
Serial communication via RS 485
Serial communication via RS 232
Analogue signals.
Connection of the DC conductors is made on the output busbars by using cable or

busbars. Recommended cross sectional area of the DC conductors can be found in the
Technical description 77-107.0223. Chapter Technical Data Observe local regulations.
The power module halves can be connected in series for an output voltage of
0-30 VDC, or in parallel for an output voltage of 0-15 VDC.
The control module is mounted as standard on top of the stack, but can be mounted in
other positions. Should the control module need to be moved, contact the service
department at KraftPowercon Sweden AB.
Rev. I1
4.4.1 Power supply

WARNING! HIGH LEAKAGE CURRENT. The protective earth should
always be connected in a reliable manner so that the rectifier
does not become live in the event of a fault. The earth
conductor by the rectifier's terminals should be approximately 5
cm longer than the phase conductors to ensure the earth
connection.
NB! The rectifier must be connected to protective earth. The rectifier must be
connected to a Y-connected transformer with earthed zero point.
(Voltage phase to zero point (earth) = voltage phase to phase/√3. This is the
normal connection of a power distribution net)
NB! Each rectifier must be fused separately. Only one rectifier should be
connected to the same fuse
NB! The rectifier has high leakage current to earth. (The leakage current due to EMC
components) Protective earth should always be connected in a reliable manner
so that the rectifier does not become live in the event of a fault.
NB! If earth fault breakers are fitted, there must be one for each rectifier. The type
of the earth fault breaker shall be B.
NB! If several rectifiers are connected in parallel, they should be maintained

at the same potential by connecting a cable between the rectifier
chassis.
The maximum output current or output voltage can be limited in the configuration menu.
Rectifier with 1-7 (1-5) power modules

The power cable connection in the box to
the left.
Holes for cable need to be made in the

HIGH LEAKAGE
CURRENT
Earth connection essential
before connecting supply
cover lid or gable
Rectifier with 8-10 (6-10) power modules

The control module consists of two
modules with primary connection in the
top module. HIGH LEAKAGE
CURRE NT
Earth connection essential
before connecting suppl
The same principle of primary cable

connection.
Hole diam 64mm in the gable

Figure 8. Rear of the control module with power cable connections
The rectifier should be connected to a 3-phase supply with voltage according to the rating
plate on the rectifier.
Rev. I1
The three phases are connected to the terminal A1:X1 on the control module and the
protective earth to the earth bolt next to the terminal A1:X1 on the control module. If
rectifiers are connected in parallel their chassis must kept at the same potential, as
described above.
The equipment is not phase sensitive. The primary currents for rectifiers with a different
number of power modules and the recommended cable cross section can be found in the
Technical description 77-107.0223. Chapter Technical Data Observe local regulations for
cables and cable sizes.
Power cable connection X1 is in the box to the left of the control module. Open the cover
plate and connect the cable. It is possible to connect the cable from either end of the box.
4.4.2 Load connection

CAUTION! Check that the contact between the output busbars and
cables/busbars is good as bad contact can cause the
temperature to rise significantly.
The maximal allowable temperature on the DC busbars is 75C
The busbar temperature is supervised and the rectifier stops when the temperature is over
limit. See chapter 3.1.6 Alarms / Warnings / Fault messages
Loads connected at the rear of the rectifier. The module outputs are connected in series
for an output voltage of 30V and connected in parallel for an output voltage of 15V. See
figure 7. Recommended cable cross section can be found in Technical description 77-
107.0223. Chapter Technical Data Observe local regulations.
For parallel connection the module halves are connected individually so that there are four
interconnected busbars, two positive and two negative. This means the bath can be fed
from “two directions” to give balanced current distribution.
This is the optimum method of connecting the bath. When only one feed is required, the
two positive busbars are interconnected, as well as the two negative busbars.
See Figure 9 below.
Figure 9. Connection of FlexKraft to galvanic bath with 4 cables: in PARALLEL mode from
“two directions”
Rev. I1
The rectifier can, in parallel mode, compensate for differences in cable length to the bath,
and tries to give the same output current from both sides. The maximum voltage difference
between sides is 0.5V, corresponding to approximately 10m of cable.
Figure 10. Connection of FlexKraft to galvanic bath: 2 cables in SERIES mode
SIDA/SIDE SIDA/SIDE
B A
Figure 11. Connection of FlexKraft to the bath: 2 cables in DUAL mode
When the rectifier has several modules, the DC-connection cables are to be connected in
the middle of the busbar or distributed across the interconnecting busbars at the rear of
the rectifier. Connections must not be made at one end of the busbar. If connection of the
load takes place at one end of the interconnecting busbar in a rectifier with several power
Rev. I1
modules, the interconnected busbar will be overloaded. NB that if more than one rectifier
stack shall be connected in parallel then each stacks bus bar shall be connected together
with the other stacks DC outputs. Please see Figure 5 Three rectifier stacks connected in
parallel.
Figure 12. Example of power cable connections on DC side
Side
B A
Series connection parallel connection and DUAL

Figure 13. Rear of the rectifier
B A
- + + -
Figure 14. Rear of the power module

See Technical description 77-107.0223 Chapter Technical Data for dimensions.
Rev. I1
4.4.3 Reduction of output

The rectifier can be configured for a lower maximum output current than the rated current.
If the rectifier outputs have been reduced at the factory, the reduced values are stated on
the rating plate. The output current and output voltage can be reduced in the configuration
menu.
NB! If the output current and\or output voltage are increased from reduced values, the
installation must be assessed, and altered if necessary, to cope with the increases in
output.
4.4.4 Control cables

NB! 24V is the maximum voltage allowed on signal inputs and outputs.
If too high voltage is applied the rectifier may break down.
The rectifier can be equipped for different types of control.
The rectifier can be equipped with the following options:

Profibus DP RS-485
Modbus RTU RS-232
Modbus RTU RS-485
Analogue control voltage.
Digital control (increase/decrease)
External Emergency stop
NOTE: all the options can not be fitted at the same time.
See the rear of the control module to see which option/options are fitted at delivery.
On the outside of the cover-plate a label indicates the options that are fitted to the rectifier.
On the inside of the cover-plate a label gives information about terminals and signal
configuration that was set at the factory..
Typical labels
The rectifier is equipped with serial communication I/O for RS485, analogue/digital I/O for
analogue control box/PLC and interface for external emergency stop.
Rev. I1
1
Analogue/Digital I/O A10
Serial/parallell (Dualmode A-side)
RS 485 A4 1
Adress
(Dualmode B-side)
X2 Note: Switch for
X2 X3 1 A termination resistors is
1 A-meter (0-10V) 1 A-meter (0-10V) 2 B located on internal PCB
2 V-Meter (0-10V) 2 V-Meter (0-10V) 3 0
3 Signal ground 3 Signal ground Interface A12
X Serial A4 X2 4 Iset (0-10V)

Uref (10V)
4 Iset (0-10V) 1
X2
Serial A5 1 3 5 5 Uref (10V) 2
Analogue I/O A10 6 Uset (0-10V) 6 Uset (0-10V) 3 Emergency stop circuit
X2 X3 4 Emergency stop circuit
X Digital 1 12 1 12
7 Power ground
8 ON/OFF
7 Power ground
8 BLOCK/RUN A
5
6
7 -
Interface A12 X2 9 BLOCK/RUN A+B 9 BLOCK/RUN B 8 -
X 1 12 10 +24VDC (200mA)
11 "ON" (24V)
10 +24VDC (200mA)
11 Dig OUT 3
See manual,chapter
9
10
-
-
Konfigurering se skylt på insidan / Configuration, see sign on the inside options 11 -

12 "Alarm" (24V) 12 Dig OUT 4 12 -
Label on the outside of the coverplate Label on the inside of the coverplate.
Example:
The rectifier is equipped with the Inputs/outputs/signals:
following options:
Interface PCB A12 - - - - - - - - - - - - - - - - Emergency stop A12:X2:3 – A12:X2:4
Analogue/Digital I/O PCB A10 - - - - - - - - Configutated according to the table
Seriellt I/O PCB A4 - - - - - - - - - - - - - - - - RS485
Loosen the lid with holes for cable (4 screws)
Open the cover plate with knockouts for cable glands (4 screws).
Signal connections on terminal blocks inside the control module are made using pluggable
connectors (the female part of the connector is supplied with the rectifier), so that the cable
can be secured in the cable gland and the connector/connectors fitted with the cover plate
removed from the control module. To assemble, fit the connectors in the control module
and then secure the cover plate.
Labels for options.
Connecting control cables
Hole for cables diameter 21mm (plastic

plug fitted at delivery)
Figure 15. Rear of the control module with cable connections
4.4.4.1 Control cables RS-485

The cable for serial control via RS-485 is connected to connector A4:X2 at the rear of the
control module.
Use a cable intended for RS-485 serial communication.
PCB in the rectifier. The PCB has built in, switchable, termination resistors.
Figure 16. Connection of serial communication PCB for RS485

Rev. I1
If a 9-way D-sub connector is fitted it should be connected as per figure below.
Figure 17. Connection of 9-pole Dsub to control module

Several rectifiers connected in chain, 4 shown, maximum 32 pc. (1 controller and 31
rectifiers)
Figure 18. Connection of control cables for RS485 to several rectifiers
Use a PROFIBUS approved cable. The cable must be terminated at both ends. This is
done on the rectifier that is last on the loop by switching two DIP switches located on the
circuit card that the fieldbus cable is connected to.
Terminering
NOTE! It is important from operating and EMC standpoints that the correct cable is used
(screened and twisted pair).
It is a standard RS-485 connection, observe the limitations that exist concerning the
maximal length, termination, maximum number of devices, etc.
Serial communications can cease to work if the cabling is not installed correctly.
Rev. I1
Example of cables: Belden 3079A 444880-88, diameter 8 mm

Alpha 6462 PROFIBUS, diameter 8 mm
SIEMENS Profibus LAN cable 6XV1 830-0AH10, diameter 8 mm
Alpha 6460 RS485, diameter 5 mm
Cable specification: Twisted pair shielded tinned copper cable.

Impedance 135-165 ohm
Capacitance <30 pF/M
Loop Resistance 110 ohm/km
Wire Gauge 0.63 mm
Conductor area >0.34 mm2
4.4.4.2 Control cables RS-232

The cable for serial control via RS-232 is connected to connector A5:X2 at the rear of the
control module.
Use a cable intended for RS-232 serial communication.
Only one rectifier can be controlled with RS232.
Figure 19. Connection of serial communication PCB for RS232
NOTE! It is a standard RS-232 connection, observe the limitations that exist

concerning the maximal length, etc.
Example of cables: Alpha XTRA Guard 1, 5192C, diameter 4.4 mm

Belden CDT 88641, diameter 2.7 mm
Cable specification: Twisted pair shielded tinned copper cable.

Max capacitance 2500 pF total
Loop Resistance 110 ohm/km
Cable diameter 0.63 mm
Conductor area >0.34 mm2
4.4.4.3 Control cables analogue control

The cable between the analogue control unit and rectifier should normally be screened 12-
core 0.5 mm2. (The number of cores varies with the number of functions used). Max.
permitted length 30 m. The screen should be earthed at one end only. Connection can be
done on the inside of the plate for cable glands.
Rev. I1
The cable for analogue control is connected to combinations of, PCB A9, A10, A11, A12 at
the rear of the control module, depending on options fitted.
NB! Analogue remote control boxes for DUAL are not equal.
Example of cable: LiYCY 12X0.5 mm2 tinned conductors.
See equipment diagram and the Technical description 77-107.0223. Chapter

Options/Optional functions.
4.4.4.4 Control cables for parallel duty

The cable between the rectifiers should normally be two screened 12-core 0.5 mm2. Max.
permitted length 2 m. The screen should be connected at both ends. Connection can be
done on the inside of the plate for cable couplings.
The cable for parallel duty is connected between the parallel duty PCB A13 in the
rectifiers. Connect terminals. A13:X5:1 to A13:X5:1 etc. If more than two rectifiers are
connected in parallel the cables must be connected to all the rectifiers.
MASTER SLAVE
MASTER SLAVE 1 SLAVE 2 SLAVE 3
Example of cable: LiYCY 12X0.5 mm2 tinned conductors.
The rectifiers must be kept at the same potential by connecting a cable between the
rectifier chassis. See section 4.4.1 Power supply.
NB that if more than one rectifier stack shall be connected in parallel then each stacks bus
bar shall be connected together with the other stacks DC outputs. Please see Figure 5
Three rectifier stacks connected in parallel
Rev. I1
See equipment diagram and the Technical description 77-107.0223. Chapter

Options/Optional functions.
4.4.4.5 Control cables for emergency stop

The external emergency stop must be connected to circuit board A12, terminals X2:3 and
X2:4 in the control module. The contacts must be isolated. The current across the contacts
varies depending on the number of power modules, see the table below. Voltage 24VDC
Number of Current in loop, typical value.

modules Nominal (A) Maximum at contactor pull in (A)
1-2 0,3 0,5
3-5 0,3 9
6-8 0,5 9
9-10 0,5 17
Inrush current, cable length and voltage drop affects the choice of cable area.
The conductor area should preferably be 1,5 or 2,5 mm2.
If rectifiers are connected in parallel the contacts for each rectifier must be isolated from
each other.
See Technical description 77-107.0223 Chapter Options/Optional functions.
4.5 Checks when powering up

Check that there is no condensation or risk of condensation before connecting to the
mains supply.
Condensation can form if the rectifier is cold and is then taken into a warm, damp building.
When this is the case, let the rectifier stand in the building for 24 hours before powering up
the rectifier.
Rev. I1
Check that the rectifier and control unit are connected according to the wiring diagram in
the appendices. When the rectifier is equipped with options, see the enclosed
description/descriptions.
4.5.1 Operating check without load

See chapter 3 Basic control.
Operating check without a load connected:
Switch on the 3-phase mains supply. The rectifier should start in OFF mode.
The display should now show information. If the unit is set to REMOTE, switch to LOCAL.
Start the rectifier in STANDBY mode by pressing the “ON” key.
The display should come on and the rectifier should be in STANDBY mode.
Adjust the set point values for the current and voltage to Min.
Permit output current/voltage and switch the rectifier to RUN by pressing the “ON” key.
Check that no current or voltage is obtained on the outgoing busbars.

Adjust the set point value for the current to approximately 10 % of the rated current.
Check that the output voltage can be set to between 0 volt and the rated voltage.
It takes a long time (up to one minute) for the output voltage to drop to the new set value
when lowering the set point value when no load is connected. To shorten the time, a
resistor can be used for discharging the output. A resistor that gives a load current of 1-2 A
can be connected for easier check.
The fans in the power modules will not run if the output is low or zero.
Switch off the rectifier by pressing the “OFF” key to switch to STANDBY mode; press
“OFF” again to switch to OFF mode.
4.5.2 Operating check with load

See chapter 3 Basic control.
If there is a load available, connect this and check that it can provide a suitable load.
The load can be checked from the data sheet, measured or by running the test and using
voltage and current values to determine whether or not the load is suitable. At 20-100% of
the nominal current the voltage should be 20-100% of the nominal voltage.
When no load is available, the outputs can be short circuited using a cable with an
appropriate cross section depending on the rectifier's rated current.
Switch on the 3-phase mains supply. The rectifier should start in OFF mode.
The display should now show information. If there is no information on the display, check
that there is mains power to the rectifier
Start the rectifier in STANDBY mode by pressing the “ON” key

If the unit is set to REMOTE, switch to LOCAL.
Rev. I1
Adjust the set point value for the voltage to approximately 50% of the rated voltage.
Adjust the set point value for the current to zero.
Permit output current/voltage and switch the rectifier to RUN by pressing the “ON” key.
Check that the current and voltage can be increased and decreased to values that the
rectifier's rating and connected load permit.
Check that the fans in the power modules are running if the output current >20% In.
Switch off the rectifier by pressing the “OFF” key to switch to STANDBY mode; press
“OFF” again to switch to OFF mode.
See Technical description for further information.
4.6 Initial Calibration/Configuration

The rectifier is calibrated and configured at the factory.
See Technical description 77-107.0223 Chapter Calibrating Instructions for further

information.
5 Warranty
KraftPowercon Sweden AB provides a warranty as stated in the order acknowledgement
or contract. The warranty covers defects in design, materials and manufacturing. Defects
that can be shown to have arisen as a consequence of incorrect use and/or maintenance
are not covered. If a fault develops during the warranty period, KraftPowercon Sweden AB
or local representative must be contacted before any work is undertaken on the rectifier.
KraftPowercon Sweden AB
P.O. Box 2102 Telephone: +46 31-979700
SE-445 02 SURTE Fax: +46 31-979797
Sweden E-mail: service@kraftpowercon.com
6 Appendices, see following pages
6.1 Equipment diagram, stand-alone rectifier and parallel-master
6.2 Equipment diagram, parallel-slave
6.3 Description of order-specific equipment, where applicable

Rev. I1
Appendix 1
6.1 Equipment diagram, stand-alone rectifier and parallel-master

Rev. I1
Appendix 1
Partial enlargement of circuit drawing on the previous
The 24 VDC
output is a source
for feeding
optocouplers and
switches for input
signals to the
rectifier.
Applies to all
PCB:s.
NOTE! +24VDC on the circuit board is the power supply for signals. See the relevant
option in Technical description 77-107.0223
Rev. I1
Appendix 1
6.2 Equipment diagram, parallel-slave
6.3 Description of order-specific equipment, where applicable

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User Guide

This product contains highly dangerous voltage that on

WARNING! Only allow qualified personnel to carry out installation

WARNING! Only allow qualified personnel to carry out servicing or

WARNING! Always disconnect the main supply in a safe manner

1 SAFETY INSTRUCTION ................................................................................ 1

5 WARRANTY ................................................................................................. 42

To upgrade the software from earlier versions, contact KraftPowercon service.

The manufacturer reserves the right to change specifications.

1.1 Description of safety symbols used on FlexKraft:

Warning, risk of electric shock!

Before operating the unit:

Warning, risk of electric shock!

Before opening the unit:

Connection point for the protective earth.

Side A is to the left seen towards

Figure 1. FlexKraft components.

Figure 4. FlexKraft , four parallel rectifiers, Master rectifier to the left

Three rectifier stacks connected

3.1 Normal operation

Figure 6. FlexKraft display unit

ON Starts the rectifier, (contactor closes, if installed)

3.1.2 LED indication

ON Green LED Indicates the rectifier is switched on (opt. contactor switched).

3.1.3 Audio signals

3.1.4 LCD display

3.1.5 Special functions

3.1.6 Alarms / Warnings / Fault messages

ALARM = The rectifier stops.

The display can also show fault messages.

3.1.7 Operating modes

Series Power module sub-modules are connected in series and

Dual Power module sub-modules are independent and supply

Dual-2 Power module sub-modules are independent and supply

3.1.8 Brief overview of functions

Heading Sub-function 1 Sub-function 2 Sub-function 3

Operating modes PARALLEL Pole reversal

Remote control Serial communication RS485 PROFIBUS DP

RS232 MODBUS RTU (one unit)

Analogue current 0-20mA

Limits Ah limit Side A Stop rectifier

See Technical Description 77-107.0223 for more information.

3.1.9 Starting the rectifier

STATUS: - OFF - - OFF - - OFF -

FlexKraft PRESS ON TO START PRESS ON TO START

www.kraftpowercon.com DUTY SET BLOCK CFG DUTY SET BLOCK CFG

Welcome screen Example of start screen

PARALLEL, SERIES DUAL, DUAL-2

The backlight comes

PARALLEL, SERIES DUAL, DUAL-2

3.1.10 Stopping the rectifier

Also see 3.1.19 Setting the remote control

PARALLEL, SERIES DUAL, DUAL-2

00.00 V 000.0 A 00.00 V 00.00 V

Rectifier, stops after STATUS: AHLIMIT! AH-LIMIT! AH-LIMIT!

00.00 V 000.0 A 00.00 V 00.00 V

Rectifier, stops due SHORT CKT! SHORT

00.00 V 000.0 A 00.00 V 00.00 V

DUTY SET BLOCK DUTY SET BLOCK

3.1.11 Blocking the rectifier RUN/BLOCK

3.1.12 Blocking rectifier START/STOP

Can only be done from the SET menu, or by remote control.

3.1.13 Setting the current and voltage