Rectifier User Manual

Technical Description
FlexKraft
77-107.0223 GB Rev.H
KraftPowercon Sweden AB. P.O.Box 2102. SE-445 02 SURTE. Sweden Tel: +46 31 97 97 00. Fax: +46 31 97 97 97
Page 1 (122) 77-107.0223 GB
FlexKraft 2012-07-05
Rev. H
1 Safety instructions
SAFETY INSTRUCTION
There are hazardous voltages inside this product. If

touched, they may 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.
Read the instruction manual before installing, using or working on the product.
WARNING! Only authorised personnel may install this product. It

must be installed in accordance with the installation
instructions and local regulations.
WARNING! Only authorised personnel may carry out servicing or

maintenance.
WARNING! Always safely disconnect the electric power supply

before starting servicing or maintenance work. The
work must be done in accordance with the service
instructions in the Technical Description.
The product is intended only for professional use. It must not be used in homes and
offices.
Page 2 (122) 77-107.0223 GB
Rev. H
Contents, overview
1 SAFETY INSTRUCTIONS ........................................................................................................1

CONTENTS, OVERVIEW ...................................................................................................................2
CONTENTS, DETAILED.....................................................................................................................3
2 GENERAL.................................................................................................................................7
3 TECHNICAL DATA ................................................................................................................10
4 OPERATION...........................................................................................................................17
5 OPERATING INSTRUCTIONS...............................................................................................24
6 OPTIONS/OPTIONAL FUNCTIONS ......................................................................................52
7 EXAMPLES, CONFIGURATIONS AND OPTIONS ...............................................................74
8 SERVICING AND MAINTENANCE........................................................................................99
9 PROGRAMMING ................................................................................................................. 104
10 WARRANTY ........................................................................................................................ 118
11 APPENDICES...................................................................................................................... 118
The manufacturer reserves the right to change specifications.

Page 3 (122) 77-107.0223 GB
Rev. H
Contents, detailed
1 SAFETY INSTRUCTIONS ........................................................................................................1
CONTENTS, OVERVIEW ...................................................................................................................2
CONTENTS, DETAILED.....................................................................................................................3
2 GENERAL.................................................................................................................................7
2.1 Summary and key components...................................................................................7
2.2 Different configurations ...............................................................................................8
2.3 Brief overview of functions..........................................................................................9
3 TECHNICAL DATA ................................................................................................................10
3.1 General data ................................................................................................................10
3.2 Mechanical data ..........................................................................................................10
3.2.1 Rectifier .........................................................................................................10
3.2.2 Busbars .........................................................................................................11
3.2.3 Rectifier DC connection.................................................................................13
3.2.4 Control cabinet ..............................................................................................14
3.3 Supply side..................................................................................................................14
3.4 Load side .....................................................................................................................16
3.5 Controller/control signals ..........................................................................................17
3.6 Options ........................................................................................................................17
3.7 Standards ....................................................................................................................17
4 OPERATION...........................................................................................................................17
4.1 General.........................................................................................................................17
4.1.1 Operating modes ...........................................................................................18
4.2 Running programs, programming features .............................................................18
4.2.1 Basic data......................................................................................................18
4.2.2 Profiles...........................................................................................................19
4.2.3 Functions .......................................................................................................21
4.3 Block schematic..........................................................................................................22
4.4 Control .........................................................................................................................23
4.4.1 Protection circuits ..........................................................................................23
5 OPERATING INSTRUCTIONS...............................................................................................24
5.1 Manual operation ........................................................................................................24
5.1.1 General..........................................................................................................24
5.1.2 Keypad ..........................................................................................................24
5.1.3 LED indication ...............................................................................................25
5.1.4 Sound indication ............................................................................................25
5.1.5 LCD display ...................................................................................................25
5.1.6 Special functions ...........................................................................................25
5.1.7 Alarms / Warnings / Fault messages.............................................................25
5.1.8 Increase/decrease keys for current and voltage ...........................................27
5.2 Menu system ...............................................................................................................27
5.2.1 Overview of the menu tree with chapter reference .......................................28
5.2.2 Overview of the menu tree for SERIES and PARALLEL ..............................29
5.2.3 Overview of the menu tree for DUAL and DUAL-2 .......................................31
5.2.4 Start menu .....................................................................................................33
5.2.5 Main menu.....................................................................................................33
5.2.6 Duty menu .....................................................................................................36
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Rev. H
5.2.6.1 PARALLEL and SERIES mode................................................................36

5.2.6.2 DUAL and DUAL-2 mod ...........................................................................37
5.2.6.3 COMMUNICATION for no protocol ..........................................................37
5.2.6.4 COMMUNICATION for MODBUS RTU....................................................38
5.2.6.5 COMMUNICATION for PROFIBUS .........................................................38
5.2.6.6 DIAGNOSTICS.........................................................................................38
5.2.7 Set menu .......................................................................................................39
5.2.8 Block..............................................................................................................40
5.2.8.1 Pausing a program ...................................................................................40
5.2.8.2 Restarting paused program......................................................................41
5.2.9 CFG menu .....................................................................................................41
5.2.9.1 Prog menu................................................................................................41
5.2.9.1.1 Edit menu ............................................................................................42
5.2.9.1.2 Copy menu ..........................................................................................43
5.2.9.2 User menu................................................................................................43
5.2.9.3 Cal menu ..................................................................................................46
5.2.9.4 KRAFT menu............................................................................................48
5.3 Remote control............................................................................................................48
5.4 Functions.....................................................................................................................49
5.4.1 Process timer.................................................................................................49
5.4.2 Ah counter function........................................................................................49
5.4.3 Start ramp......................................................................................................49
5.4.4 EOP (End Of Process) ..................................................................................49
5.4.5 Resolution, current indication ........................................................................50
5.4.6 Reduction of output current and output voltage ............................................50
5.4.7 Blocking .........................................................................................................50
5.4.8 Fan control.....................................................................................................50
5.4.9 Locking keypad to input parameters, SLAVE mode......................................50
5.4.10 Under voltage / short circuit detection ...........................................................51
6 OPTIONS/OPTIONAL FUNCTIONS ......................................................................................52
6.1 Signal names and explanations ................................................................................53
6.2 Control via RS 485 A4 ................................................................................................53
6.2.1 Connection ....................................................................................................54
6.3 Control via RS-232 A5 ................................................................................................54
6.3.1 Connection ....................................................................................................54
6.4 Analogue control I/O A9.............................................................................................55
6.4.1 Connection ....................................................................................................56
6.4.2 Technical data ...............................................................................................57
6.5 Analogue digital I/O for analogue control box or PC/PLC A10 ..............................57
6.5.1 Connection ....................................................................................................58
6.5.2 Wiring example..............................................................................................59
6.5.3 Technical data ...............................................................................................60
6.6 Digital I/O A11..............................................................................................................60
6.6.1 Connection ....................................................................................................61
6.6.2 Wiring example..............................................................................................62
6.6.3 Technical data ...............................................................................................62
6.7 Parallel duty I/O A13 Master/Slave ............................................................................62
6.7.1 Connection ....................................................................................................63
6.8 Dosing function...........................................................................................................63
6.9 Contactor .....................................................................................................................64
6.10 External emergency stop ...........................................................................................64
6.10.1 Connection ....................................................................................................65
6.10.2 Additional parts in the rectifier. ......................................................................66
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Rev. H
6.11 Remote FlexKraft panel..............................................................................................66

6.11.1 Connection ....................................................................................................67
6.11.2 Additional components in the rectifier ...........................................................67
6.12 Analogue control box .................................................................................................68
6.12.1 Connection ....................................................................................................69
6.12.2 Additional components in rectifier .................................................................70
6.13 Control KRAFT analogue ...........................................................................................70
6.13.1 Connection ....................................................................................................71
6.13.2 Additional components in the rectifier ...........................................................72
6.13.3 Configuration of FlexKraft..............................................................................72
6.14 Air filter in power module ..........................................................................................72
6.15 Fresh air coupling for power modules .....................................................................73
6.16 Lifting eyes ..................................................................................................................73
6.17 Option, order specific.................................................................................................73
7 EXAMPLES, CONFIGURATIONS AND OPTIONS ...............................................................74
7.1 Normal configuration, without program control......................................................74
7.2 Program control, PARALLEL or SERIES mode. ......................................................76
7.2.1 DC current, switching off ...............................................................................76
7.2.2 DC current, time limit, HOLD.........................................................................77
7.2.3 DC current, time limit, BUZZER only.............................................................78
7.2.4 Ah limit, without HOLD ..................................................................................79
7.2.5 Anodising, voltage control .............................................................................80
7.2.6 Anodising, current control/voltage control .....................................................82
7.3 Program control, DUAL mode. ..................................................................................84
7.3.1 With/without HOLD ........................................................................................84
7.4 Program mode, Polarity reversal ..............................................................................87
7.4.1 Hard-chroming, polarity rev., HOLD, ext. alarm, PARALLEL/SERIES mode87
7.4.2 DUAL mode, with/without HOLD ...................................................................89
7.4.3 Polarity reversal with start ramp ....................................................................92
7.5 Program mode, Repeat function ...............................................................................93
7.5.1 Polarity reversal with start ramp and repeat..................................................93
7.6 Option ..........................................................................................................................95
7.6.1 Dosing function..............................................................................................95
7.6.2 Remote control ..............................................................................................96
7.6.2.1 Serial communication ...............................................................................96
7.6.2.2 Analogue control ......................................................................................97
7.6.2.3 Digital I/O..................................................................................................97
7.6.2.4 Remote and local control..........................................................................98
8 SERVICING AND MAINTENANCE........................................................................................99
8.1 Preventive maintenance.............................................................................................99
8.2 Troubleshooting instructions....................................................................................99
8.3 Replacement of components.................................................................................. 100
8.3.1 If several rectifiers are placed close together............................................. 100
8.3.2 Changing the filter ...................................................................................... 100
8.3.3 Replacing of the fan in the power module.................................................. 101
8.3.4 Replacing the power module...................................................................... 101
8.3.5 Replacing a fuse in the control unit supply................................................. 102
8.3.6 Replacing a fuse in the power module ....................................................... 102
8.4 Calibration instructions .......................................................................................... 103
9 PROGRAMMING ................................................................................................................. 104
Page 6 (122) 77-107.0223 GB
Rev. H
9.1 General...................................................................................................................... 104

9.1.1 Remote control ........................................................................................... 104
9.1.2 RS-232 ....................................................................................................... 104
9.1.3 RS-485 ....................................................................................................... 104
9.1.4 Westermo MA-45 RS232/RS485 converter ............................................... 105
9.2 Profibus DP .............................................................................................................. 105
9.2.1 Overview of registers.................................................................................. 106
9.2.2 Programming examples ............................................................................. 109
9.2.3 Troubleshooting Profibus communication .................................................. 109
9.2.4 GSD file ...................................................................................................... 110
9.2.5 Tips & Tricks............................................................................................... 110
9.3 Modbus RTU............................................................................................................. 110
9.3.1 Overview of registers.................................................................................. 111
9.3.2 Programming examples ............................................................................. 117
9.3.3 Troubleshooting MODBUS communication ............................................... 117
9.3.4 Troubleshooting Modbus RTU ................................................................... 117
10 WARRANTY ........................................................................................................................ 118
11 APPENDICES...................................................................................................................... 118
11.1 Equipment diagram, stand-alone rectifier and parallel -master ......................... 119
11.2 Equipment diagram, parallel-slave ........................................................................ 121
11.3 Spare part list ........................................................................................................... 122
11.4 Description of order-specific equipment, where applicable. .............................. 122
This description applies to software version FLX-01 VER. 02.50 and later.
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.

Page 7 (122) 77-107.0223 GB
Rev. H
2 General
FlexKraft is a modular rectifier developed for professional users. High operational reliability and
adaptation to automatic control systems are significant properties of this rectifier.
The rectifier is primarily intended to supply power to galvanic baths in surface treatment processes
such as electroplating, anodising and PCB plating.
This rectifier was designed with KraftPowercon Sweden AB’s many years of experience of switched-
mode static converters for galvanic electroplating, to be used in applications where small size, high
reliability and good current quality are important. The main distinguishing features of the FlexKraft
rectifier are:
• Ruggedness
• Modular design
• Suitability for the electroplating environment
• Suitability for connection to automatic control systems
• Low DC ripple
• High accuracy
• Compactness
• High efficiency
A rectifier may be made up of one to ten power modules. The power modules are identical.
If more current is needed, up to 10 power modules can be used with a single rectifier. Contact the
service department at KraftPowercon Sweden AB.
Several rectifiers can be mounted in a stack up to 10 modules high. The control module does not have
to be on the top of the stack.
Several rectifiers can be connected in parallel if higher currents are required.
The rectifier is intended to be controlled from a master control system or a built-in control unit. The
controller has a display and a data entry unit for setting voltage and current, rectifier start/stop and
readout of operational data and faults.
FlexKraft is equipped with EMC filters according to the EMC directive.
2.1 Summary and key components

1
6 7 5 A B 2 1 Top
3 2 Control module
3 Power module
8 4 Base
5 Display with keys
6 Connection to mains supply
7 Connections for control
signals
4 Signs with connection
information.
8 Busbars
Side A is on the left when

viewed from in front
Page 8 (122) 77-107.0223 GB
Rev. H
2.2 Different configurations
Rectifier for PARALLEL or DUAL mode
Stack of four Stack of one Rectifier with Bench-top

single-module three-module and control module model
rectifiers one four-module in middle
rectifier
Four rectifiers connected in parallel with 10 power modules in each. Master rectifier located to the left.
Master rectifier must be at one end
Page 9 (122) 77-107.0223 GB
Rev. H
2.3 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 Water cooling
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

Please note that some functions require that options are installed.
Page 10 (122) 77-107.0223 GB
Rev. H
3 Technical data
3.1 General data
Parameter Value Comment
Operating 0 - 40 ºC 0 - 50 °C with reduced rated data. Contact
temperature KraftPowercon Sweden AB
Air humidity Max 95% RH Non-condensing
Weight See mechanical data Chapter 3.2
Dimensions See mechanical data Chapter 3.2
Degree of protection IP 32 Does not apply to the fan.
Cooling Forced air Each power module: Air consumption 170m3/h
Maximum power loss at full load 1000W
Typ.value @12/600:980W @15/500: 830W
Altitude Max 1000m above sea level For higher altitudes Contact KraftPowercon
Sweden AB
Duty Continuous
Load Electroplating baths
Installation, see User Guide 77-107.0222, chapter Installation.
3.2 Mechanical data

3.2.1 Rectifier
H1
B1
H
H
B D D
1-7 (1-5) modules 8-10 (6-10) modules (Applies to rectifiers equipped with option contactor)
Height Höjd Weight Vikt Width Height

Number of Width Without contactor With contactor Depth Without contactor With contactor B1 mm H1 mm
modules B mm H mm H mm D mm kg kg
1 500 450 450 600 49 49 380 95
2 500 590 590 600 76 76 380 95
3 500 730 730 600 102 102 380 95
4 500 870 870 600 133 133 380 95
5 500 1010 1010 600 160 160 380 95
6 500 1150 1290 600 188 194 380 95
7 500 1290 1430 600 220 226 380 95
8 500 1570 1570 600 252 258 380 95
9 500 1710 1710 610 286 292 380 95
10 500 1850 1850 610 315 322 380 95
Table 1. Dimensions and weight
Page 11 (122) 77-107.0223 GB
Rev. H
Base height 125 mm. Weight including DC busbars. Dimensions do not include lifting eyes, if fitted (+50 mm).
3.2.2 Busbars
Busbars 8,9,10 power modules.
10 modules 9 modules 8 modules
Busbars 5,6,7 power modules.

Dimensions are typical, normal manufacturing tolerances apply.
Page 12 (122) 77-107.0223 GB
Rev. H
Busbars 2, 3, 4 power modules.
Dimensions are typical, normal manufacturing tolerances apply.
Hole diameters in the DC busbars are 11 mm and intended for M10 bolts. On rectifiers with more than
one power module, the load cable shall be connected in the middle of the bus bar or evenly distributed
along the interconnected busbars at the rear of the rectifier.
Connection must not be made at one end of the busbar, the interconnecting busbar might be
overloaded, resulting in a risk of rectifier failure.
Example of load connection.
If the connection to the load are made with too small dimension and in the wrong way, the temperature
of the busbars will rise over the allowed limit of 75ºC. The over temperture guard inside the power
module will the shut off the rectifier-
Page 13 (122) 77-107.0223 GB
Rev. H
3.2.3 Rectifier DC connection

Busbar projection from rear of rectifier, PARALLEL, DUAL or DUAL-2 mode.
1 power module
Busbar width 50 mm 60 mm 75 mm
2-6 power modules 7-8 power modules 9-10 power modules
Dimensions are typical, normal manufacturing tolerances apply
Busbar projection from rear of rectifier with busbar connected in SERIES mode.
1 power module
Busbar width 50 mm 60 mm 75 mm
2-6 power modules 7-8 power modules 9-10 power modules
Dimensions are typical, normal manufacturing tolerances apply

Page 14 (122) 77-107.0223 GB
Rev. H
3.2.4 Control cabinet
3.3 Supply side

Primary voltage 3x 380-480 V AC +-10%
(Phase to phase) or See chapter 3.4 Load side
3x220 V AC +-10% with
reduced output
Primary current See table below. See rating
plate.
Mains frequency 47 – 63 Hz. Sinusoidal
Power factor ≥ 0.93 at rated load
Efficiency Typically 0.9 at rated load Typically 0.8 at primary voltage
Efficiency is better at 15/500 220VAC and 2x7V/300A per
than 12/600. power module
Contactor Optional equipment
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.
The maximum output current or output voltage can be reduced in the CFG/USER menu. See chapter 5.2.9.2
User menu.
The maximum output current or output voltage can be factory limited, this factory limitation can be decreased
but not increased in the CFG/USER menu.
Page 15 (122) 77-107.0223 GB
Rev. H
Primary current at primary voltage 380-415VAC. Module output 2x12-15V/300-250A

Uprim V 380V 400V 415V
Conn. Conn. Conn.
area area area
2 2 2
Number Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse
@25°C @25°2 @25°
of modules Unom U-10% A Unom U-10% A Unom U-10% A
1 14 16 1,5 16 13 15 1,5 16 13 14 1,5 16
2 28 31 6 32 26 29 6 32 26 28 6 32
3 42 46 10 50 39 44 10 50 38 42 10 50
4 55 61 16 63 52 58 16 63 51 56 16 63
5 69 76 25 80 65 73 25 80 63 70 25 80
6 83 92 25 100 78 87 25 100 76 84 25 100
7 96 107 50 125 91 102 50 125 88 98 25 100
8 110 122 50 125 104 116 50 125 101 112 50 125
9 124 137 70 160 117 130 70 160 113 126 70 160
10 137 152 70 160 130 145 70 160 126 140 70 160
Primary current at primary voltage 440-480VAC. Module output 2x12-15V/300-250A

Uprim V 440V 460V 480V
Conn. Conn. Conn.
area area area
2 2 2
Number Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse Iprim A Iprim A mm Fuse
@25° @25° @25°
of modules Unom U-10% A Unom U-10% A Unom U-10% A
1 12 14 1,5 16 12 13 1,5 16 11 13 1,5 16
2 24 27 6 32 23 26 6 32 22 25 4 25
3 36 40 10 40 34 38 10 50 33 37 10 40
4 48 53 16 63 46 51 16 63 44 49 10 50
5 60 66 25 80 57 63 16 63 55 61 16 63
6 71 79 25 80 68 76 25 80 65 73 25 80
7 83 92 25 100 80 88 25 100 76 85 25 100
8 95 106 50 125 91 101 50 125 87 97 25 100
9 107 119 50 125 102 114 50 125 98 109 50 125
10 119 132 70 160 114 126 70 160 109 121 50 125
Primary current at primary voltage 220VAC. Module output 2x7V/300A

Uprim V 220V
Conn.
area
2
Number Iprim A Iprim A mm Fuse
@25°
of modules Unom U-10% A
1 14.5 17 2,5 20
2 29 33 10 40
3 43.5 49 10 50
4 58 65 25 80
5 72.5 81 25 100
6 87 97 25 100
7 101.5 113 50 125
8 116 129 70 160
9 130.5 146 70 160
10 145 162 95 200
Cable areas (at 25 ºC ambient) and fuse ratings are guideline figures.
Observe local regulations and ambient temperatures when dimensioning cables.
Rectifiers that are intended for connection to a 380-480VAC supply cannot be used at 220VAC.
Page 16 (122) 77-107.0223 GB
Rev. H
3.4 Load side

Primary voltage 380-480 VAC
Voltage 2x0-15V Series connection 0-30 V DC
Current 0-12V 2x300 A/module
0-15V 2x250 A/module
Current ripple < 2% of rated current with RMS
current control over the entire <4% at primary voltage <360VAC
control range
Linearity <+-1% of rated current.
Effektgräns
Power limit
15V
12V
The power module is equipped with a power
Spänning/Voltage
limit:
I
Ström/Current 250A 300A
Primary voltage 220 VAC

Voltage 2x0-7V Series connection 0-14 V DC
Current 0-7V 2x300 A/module
Current ripple < 2% of rated current with RMS
current control over the entire
control range
Linearity <+-1% of rated current.
Observe local regulations when dimensioning cables/busbars. 1.5A/mm2 can be used as a guide for
copper cables/busbars.
Note that the load capacity of a cable / busbar depends on how it is routed.
The maximum temperature allowed on the power module DC busbars is 75ºC. The temperature is
monitored and the rectifier is shut off in case of over temperature.
The maximum output current or output voltage can be limited in the CFG/USER menu. See chapter 5.2.9.2
The rectifier has in parallel mode an output current balancing function. Maximum voltage difference
between sides, at the rectifier, is for equal output current 0.5V
The rectifier output is insulated from the chassis.
Side
B A
Series connection Parallel connection or DUAL

Figure 1. Rear view of rectifier
Page 17 (122) 77-107.0223 GB
Rev. H
3.5 Controller/control signals

Display LCD 128x64 pixel, backlit
LED indication ON, Alarm, Remote
Sound indication Yes
Keypad Yes
Processor 16-bit microcontroller
A/D D/A resolution 10/12 bit
Interface option RS-485 Protocol Modbus RTU and Profibus
DP
Interface option RS-232 Protocol Modbus RTU
Interface option Analogue I/O, galvanically The unit can be controlled with
isolated. analogue signals or increase/
Analogue I/O, decrease contacts.
Digital I/O
3.6 Options
For relay contact data, see chapter 6 Options/optional functions, when applicable.
3.7 Standards
Type Standards Comment
Safety EN 50 178 Class/grade 3k3
EMC immunity EN 61000-6-2 Industrial applications
EMC emission EN 61000-6-4 Industrial applications
4 Operation
4.1 General
The FlexKraft rectifier has been designed to give the best electrical performance and at the same time
withstand the harsh industrial environment. The design is based on primary switching technology, a
field in which KraftPowercon Sweden AB has played a pioneering role in the electroplating industry.
With this technology, the mains voltage is rectified and then switched at a high frequency (fs=75 kHz)
over a ferrite transformer. Converting the voltage at this high frequency makes it possible to keep the
transformer and filters very small. FlexKraft is modular, meaning that the rectifier is made up of a
control module and a number of identical power modules.
The rectifier loads the supply network with the power determined by the load. This means that, for the
same DC load, the primary current is higher at a lower mains voltage.
The principle is shown in the block diagram chapter 4.3 Block schematic
The rectifier has a modular design with one control unit consisting of one or two control modules, and
a power unit consisting of one to ten power modules.
The power module consists of two sub-modules whose outputs can be connected in series for higher
output voltage or in parallel for higher output current.
Several rectifiers can be connected in parallel for higher currents.

Page 18 (122) 77-107.0223 GB
Rev. H
4.1.1 Operating modes

The rectifier has four modes of operation:
Parallel The sub-modules are connected in parallel and the output is
0-12(15)V 600(500)A/power module at 380-480V mains
0-7V 600 A/power module at 220V mains
Series The sub-modules are connected in series and the output is

0-24(30)V 300(250)A/power module at 380-480V mains
0-14V 300 A/power module at 220V mains
Dual The sub-modules are individual and the output is

2x 0-12(15)V 300(250)A/power module at 380-480V mains
2x 0-7V 300 A/power module at 220V mains.
Both sides are started and stopped simultaneously.
Each side can have different set values for current and voltage.
The time limits are the same for both sides. The Ah limit can be set
independently for each side.
Dual-2 Power module sub-modules are independent and supply:

2x 0-12(15)V 300(250) A/module with a primary voltage of 380-480V.
2x 0-7V 300 A/module with a primary voltage of 220V.
Sides A and B can be started and stopped independently and behave like
two rectifiers.
Each side can have different set values for current and voltage.
The time limits are the same for both sides. The Ah limit can be set
independently for each side.
If more current is needed, a power module can be added (total maximum of 10 power modules).
Contact the service department at KraftPowercon Sweden AB.
It is possible to connect several rectifiers in parallel to obtain higher output currents. The rectifiers
must be equipped with option for parallel duty.
4.2 Running programs, programming features

4.2.1 Basic data
Number of programs: 4
Program steps per program: 8
Program repeat: Yes, possible
Basic functions:
RAMP STEP PULSE

Voltage and current can be set individually for each program step.
Time per program step: 0–30000 sec. Resolution 1 second

Ah-limit: 0–999999 Ah. Resolution 1 Ah
Time between updates: 100ms
End Of Process: Current and voltage are controlled at programmable levels.
Indication is given on display. Buzzer & LED.
Indication can also be provided at contact. (requires DIG I/O option)
Support for dual mode: Yes
Support for polarity reversal: Yes (requires polarity reversal option)
Page 19 (122) 77-107.0223 GB
Rev. H
Other features:
• Indication of current program step on display.
• Indication of process time on display.
• Indication of remaining process time on display.
• Pauses process at current program step and allows it to be resumed later.
• In DUAL mode two different or identical programs can be run at the same time. The programs
can be started and stopped independently.
• In DUAL-2 mode two different or identical programs can be run independently of each other. The
programs can be started and stopped independently.
• Programs can be edited while running. The changes take effect the next time the program is run.
• Programs can be started from the keypad, by serial communication or by an external switch
(requires serial communication option or digital inputs option).
Typical applications
- Electro-degreasing
- Hard-chroming
- Anodising
4.2.2 Profiles
Voltage or
current
5 Set EOP alarms/signals activated 7
1
Manual stop
Time
Step 01 Step 02 Step 03 Step 04 Step 05 Step 06-07 Step 08
1-30000s
9
8
2 Set HOLD level
4 Step 02-08, 0-30000s/Step
3 Ahlimit 0-999999 Ah
EOP
6
Up to 4 different user programs can be programmed with 8 steps each.
The following parameters are set for each program:

AH-LIMIT Process time for program in Ah.
EOP (End Of Process) Whichever is reached first, program end or Ah limit, triggers EOP.
HOLD.CURRENT Set value for current after EOP.
HOLD.VOLTAGE Set value for voltage after EOP.
Page 20 (122) 77-107.0223 GB
Rev. H
The following functions can be used in each program step:

FUNCTION: Chosen function for program step.
STEP Changes set values for current and voltage in steps.
U-RAMP Changes set value for voltage ramp and changes current in steps.
I-RAMP Changes set value for current ramp and changes voltage in steps.
PULSE Pulses output current and voltage between two levels.
REPEAT Repeats program from start. Timer is reset, Ah counter continues.
VOLTAGELEVEL Set value for voltage at end of program.

CURRENTLEVEL Set value for current at end of program.
VOLT.LEVEL 1 Set value for voltage, 1st level during PULSE.
CURR.LEVEL 1 Set value for current, 1st level during PULSE.
VOLT.LEVEL 2 Set value for voltage, 2nd level during PULSE.
CURR.LEVEL 2 Set value for current, 2nd level during PULSE.
TIME 1 Time for 1st level during PULSE.
TIME 2 Time for 2nd level during PULSE.
STEP TIME Time for program step =(TIME 1+TIME 2)*CYCLES).
CYCLES Number of cycles for FUNCTION=PULSE. = STEP TIME/(TIME 1+TIME
2).
The following applies to all programs:

STARTRAMP Applies to all programs overwritten.
BUZZER Applies to all programs overwritten.
Programming is carried out in the CFG/PROG menu, see section 1 chapter 5.2.9.1 Prog menu.
See chapter 7 Examples, configurations and options

Page 21 (122) 77-107.0223 GB
Rev. H
4.2.3 Functions
Function Description
I-I-RAMP Ramp function. Function value starts at end
“Ramp current to” value of previous step and ends at specified
CURR.LEVEL after STEP TIME.
Set current is ramped up.

Set voltage is changed in steps.
Example:
CURRENTLEVEL: 3000 A
VOLTAGELEVEL: 15.00 V
STEP TIME: 100 S
U-RAMP Ramp function. Function value starts at end

“Ramp voltage to” value of previous step and ends at specified
VOLT.LEVEL after STEP TIME.
Set current is changed in steps.

Set voltage is ramped up.
Example:
CURRENTLEVEL 6000 A
STEP TIME: 230 S
STEP Level is kept constant at CURR.LEVEL or

“Step to” VOLT.LEVEL for period STEP TIME
Example:
CURRENTLEVEL: 200 A
STEP TIME: 600 S
PULSE LVL1 LVL2 Set values are pulsed between CURR.LVL1

“Pulse between” and 2 and VOLT.LVL1 and 2 for intervals
TIME.LVL1 and 2 for step time set by STEP
TIME.
Example:
CURR.LEVEL 1: 5000A
CURR.LEVEL 2: 11000A
VOLT.LEVEL 1: 4.00V
VOLT.LEVEL 2: 14.00V
TIME 1 : 6 S
TIME 2 : 60 S
STEP TIME : 198 S
CYCLES: : 3
REPEAT Repeat program from step 1.

“Repeat program
from start”
Page 22 (122) 77-107.0223 GB
Rev. H
4.3 Block schematic

Unit
3-phase L1 Styrmodul 1 Kraftmodul 2 3

mains L2 Control Powermodule DC koppling
supply L3 module DC connection
PE DC utgång
EMC filter
DC output
Optional control EMC filter
0-10 VDC Kraftmodul 2

0-20mA Powermodule DC utgång
4-20mA DC output
RS-232
EMC filter
RS-485
Increase/decrease
Kraftmodul 2
Powermodule
EMC filter
1. Control module
2. Power module
3. DC busbars
Control module
1 3
3-phase L1
mains L2 3-phase
supply L3
PE EMC filter
2 4
Styrning
Control PCB
~ 5
6 7
Tangentbord Styrsignalbuss
Keypad LCD display
(Optional) Controlsignal
(Optional)
bus
Optional control
0-10 VDC
I/O kort 8 Styrkraftbuss
0-20mA I/O PCB
4-20mA Aux. power
(Optional)
RS-232 bus
RS-485
1. Mains filter
2. Fuses
3. Contactor (option)
4. Control PCB
5. Power supply
6. Keypad (option)
7. LCD display (option)
8. I/O card (option) RS 232 serial communication
RS 485 serial communication
Analogue control
Page 23 (122) 77-107.0223 GB
Rev. H
Power module
3 fas
kraftbus
L1
L2
1 2
~ 4
DC utgång
3-phase L3 DC output
powerbus PE EMC filter
3
Styrkort
Styrsignalbuss Control PCB
Controlsignal bus
Strömavkänning utan shunt
Styrkraftbuss
Current sensing without shunt
Aux. power bus
~ 4
DC utgång
DC output
1 Mains filter
2 Fuses
3 Control board
4.4 Control 4 Rectifier sub-module (two equal)
4.4.1 Protection circuits
The rectifier is equipped with the following forms of active protection to reduce the risk of faults and
breakdowns:
• Fast current protection: This protection measures the current in the switching transistors and
shuts off any current pulses that are too high. This provides effective protection for the
switching transistors.
• Temperature protection: Heat-sensitive components are fitted with sensors which sense the
temperature to ensure that the components are not damaged (if the ambient temperature is
too high, for instance. Or the busbar temperature). If the temperature goes too high, the
rectifier is shut down and an alarm is given.
• Reverse current detector: This protection device checks whether the current is flowing the
wrong direction in the power module output circuits. This prevents phase sequence faults in a
power module.
• Soft start: When the rectifier is switched on, there is a delay before it can deliver current. This
allows the control system to stabilise, ensuring that the rectifier delivers the correct current.
• Regulator detector: If the rectifier control system malfunctions, a warning is given and the
rectifier continues. Possible causes of faults: loss of a phase, incorrect mains voltage, power
component failure, etc.
• Voltage monitor: The rectifier monitors the voltage between output DC busbars and chassis,
and the voltage between DC busbars. If the voltage is too high, the rectifier is shut down and
an alarm is given.
• Fuses: The rectifier has two or three fuses in the control module for power feed of the control
system and each power module has three fuses on incoming power.
NOTE: After an alarm, the rectifier must be reset on the display or from a master system. If the fault is
not serious or remaining, output current is obtained when the rectifier is switched on again. Alarm
reset is made by setting the rectifier to OFF.
Page 24 (122) 77-107.0223 GB
Rev. H
5 Operating instructions
5.1 Manual operation
The rectifier can be controlled from the built-in display or from an external control cabinet. If the
rectifier is controlled from an external digital control box, it cannot be controlled from RS-232/RS-485.
5.1.1 General
The display unit is KraftPowercon Sweden AB’s microprocessor-based control panel for the control of
rectifiers for electroplating baths. It contains the most commonly used functions for effective control of
rectifiers. The display unit comes ready calibrated and set up for the relevant rectifier type.
For operating instructions see Instruction manual 77-107.0222
Using the display unit, the rectifier is switched on and off, voltage and current limits can be set
independently of each other, and the rectifier can be blocked during pauses in the process. There are
also a number of optional functions for more efficient process control (for options, see chapter
“Options”). The most common settings are made directly with dedicated keys on the panel. Less
frequently used settings are made by means of menu options in response to plain text messages on
the LCD display.
5.1.2 Keypad
The display unit membrane keypad has the following keys:
ON Starts the rectifier; (the contactor closes if fitted)

OFF Stops the rectifier; (the contactor opens if fitted)
Current ⇑ Increase current
Current ⇓ Decrease current
Voltage ⇑ Increase voltage
Voltage ⇓ Decrease voltage
Menu keys A – D Menu options
OK! Used to confirm a change (disabled in some submenus)
ESC Used to undo a change or back out of a menu
(disabled in some submenus)
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.
The OFF key is also disabled, also then the rectifier is in LOCAL mode-
The keypad is activated using a password-protected menu.
The longer the key is held, the faster the set values change. The values stop at zero. To change
polarity release the key and press again to continue changing the set value.
Page 25 (122) 77-107.0223 GB
Rev. H
5.1.3 LED indication

The panel has LED indication for the following functions:
ON Green LED Indicates rectifier on (contactor closed)

ALARM Red LED Indicates end of process or rectifier fault
The LED flashes to indicate a WARNING and glows steadily to indicate
an ALARM
REMOTE Yellow LED Indicates the rectifier is controlled by a remote control
5.1.4 Sound indication

The panel has a piezo-electric buzzer which sounds to confirm key presses, end of process (EOP) and on
rectifier faults. The buzzer sound indication can be turned off in the CFG/USR menu. See chapter 5.2.9.2
User menu
5.1.5 LCD display

The LCD display is a graphical high-contrast type with integral backlighting.
The contrast of the display may need to be adjusted to take account of ambient temperature and
ageing. This is done in the CFG/USER menu.
Background lighting comes on when a key is pressed and remains on for 60 seconds after the last key
is pressed.
5.1.6 Special functions

The rectifier control system comes ready configured, but if for some reason it is necessary to reset to the
default settings, this can be done by pressing the ESC key for more than eight seconds.
NOTE -The SET parameters, Ah counter and process timer are zeroed.
-The CFG settings are not changed (Buzzer is switched on if it had been switched off).
-The loaded program 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.
5.1.7 Alarms / Warnings / Fault messages

The control unit continuously monitors the rectifier and tries, in an intelligent way, to recover from
different fault modes that can occur during operation. This function can also be used if the controller
has for some reason entered the wrong program mode or appears to have locked up. While the
rectifier is trying to correct a fault the alarm LED on the control panel flashes and a fault message is
displayed. If the rectifier is equipped with I/O PCB a signal can be sent to an external control system. If
a major fault occurs, which cannot be corrected, an ALARM is triggered. This is indicated by a
continuously lit red LED on the control panel and a fault message on the display.
If sound indication is set to ON, the buzzer will sound. The buzzer is turned off by pressing any key.
If the rectifier is equipped with a contactor it is released.
Fault mode is reset by switching 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 with reduced output power.
The ALARM signal is activated in the event of either an ALARM or WARNING.
The “POWER GOOD” signal is deactivated in the event of an ALARM or WARNING.
Page 26 (122) 77-107.0223 GB
Rev. H
Message Explanation
“HIGH TEMP P-M” Excess temperature in a power module. Too high temperature on the busbars
causing excess temperature in the power module. (The output from the affected
power module is cut as long as the temperature remains too high. The LED “power
good” LED is off on the power module that has triggered the alarm). The rectifier
continues to run with the remaining power modules, The output current is decreased
in proportion.
“HIGH TEMP C-M” Excess temperature in the control module. The rectifier continues to run.
“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) The output current might decrease.
If all modules have “PowerGood” LED off check that mains supply is within range
and has not dropped a phase.
“MODULE FAILED!” Reverse current in a power module. (The rectifier stops. The
“power good” 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.
The cause of an ALARM must be identified. See chapter 8.2 Troubleshooting instructions
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 set
(ALARM LED flashes) values of current and voltage due to power limitation. The set values
for current and voltage are within the triangle 12-15V/250-300A.
Effektgräns
Power limit
15V
12V
Spänning/Voltage
I
Ström/Current 250A 300A
Page 27 (122) 77-107.0223 GB
Rev. H
5.1.8 Increase/decrease keys for current and voltage

When any of the arrow keys are pressed for current or voltage, the display changes from showing
large numbers to showing small numbers. The display reverts to normal after 10 seconds.
Example:
PARALLEL and SERIES DUAL and DUAL-2
STATUS: RUN DC RUN DC RUN DC
11.83 V 010.0 A 11.83 V 11.83 V

000300 Ah 00020 S 010.0 A 010.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG
SET VOLTAGE : 11.83 V SET VOLTAGEA: 11.83 V

SET CURRENT : 010.0 A SET CURRENTA: 010.0 A
ACT VOLTAGE : 11.83 V SET VOLTAGEB: 11.83 V
ACT CURRENT : 010.0 A SET CURRENTB: 010.0 A
When the arrow keys for current or voltage are

pressed it changes the set value for both sides
by the same amount. To change each side by
different amounts, use the SET menu.
5.2 Menu system

Parameters are set by increasing or decreasing the relevant parameter with the corresponding key on the
keypad. If the key is held down, the parameter counts up or down at an increasing rate. If a parameter can
change sign, the value stops at zero. To change sign and continue, release the key and press again.
On some menus there is not enough space on the display for all the information. The menu keys can then be
used to scroll the information up and down.
Some menu settings require options to be fitted. When these options are not available the menu
settings should be set to OFF(-NONE-).
Page 28 (122) 77-107.0223 GB
Rev. H
5.2.1 Overview of the menu tree with chapter reference
The menus will be/may be different depending on rectifier configuration.
Chapter 5.2.4
KRAFT
Chapter 5.2.5
"Press on"
Chapter 5.2.5
Normal Run
display
Chapter 5.2.6 Chapter 5.2.7 Chapter 5.2.9
DUTY SET CFG
Password protection
Chapter 5.2.9.1 Chapter 5.2.9.2 Chapter 5.2.9.3 Chapter 5.2.9.4
PROG USER CAL KRAFT
Chapter 5.2.9.1.1 Chapter 5.2.9.1.2
EDIT COPY
Page 29 (122) 77-107.0223 GB
Rev. H
5.2.2 Overview of the menu tree for SERIES and PARALLEL
STATUS: -OFF-
PRESS ON TO START
DUTY SET RUN CFG
RUN/BLOCK
---------ACTUALS--------- REMOTE CONTROL: NO SELECT SUB-MENU OR

VOLTAGE SETVOLTAGE : --.--V PRESS ESC TO EXIT!
CURRENT SETCURRENT : ---.-A FIRMWARE:
AHCOUNTER RUN/ BLOCK : BLOCK/RUN FLX-01 VER. 02. 50
PROCESS TMR START/STOP: START /STOP
REMAINING POLARITY :FWD/REV PROG USER CAL KRAFT
---------SETTINGS--------- TIMER LIMIT : -OFF-S
SET VOLTAGE AH-LIMIT : -OFF-S
SET CURRENT STARTRAMP : ----.-S
AH-LIMIT PROGRAMMODE :YES/NO
TIMERLIMIT PROGRAM NO : 01
STARTRAMP
---COMMUNICATION---
PROTOCOL
ADDRESS
BAUDRATE
CTRL
STAT
MSG RECIEVED
CHR RECEIVED
-------DIAGNOSTICS-----
PARAMERROR
MODULESFOUND
MAX CURRENT1
AT VOLTAGE1
MAX CURRENT2
AT VOLTAGE2
R01
R02
R03
R04
R05
R06
R07
R08
R09
R11
R12
R13
R14
R15
R16
CLEAR
Page 30 (122) 77-107.0223 GB
Rev. H
CFG
PROG USER CAL KRAFT
ENTER ENTER ENTER ENTER

PASSWORD: PASSWORD: PASSWORD: PASSWORD:
000000 000000 000000 000000
(PRESS OK) (PRESS OK) (PRESS OK) (PRESS OK)
SELECT POGRAM TO LCD-CONTRAST:---.-%

EDIT OR COPY PASSWORD : 000001
PROGRAM: 01 PROTOCOL : MODBUS RTU, PROFIBUS DP
BYTESWAP : YES, NO
ADDRESS : 000002
EDIT COPY BAUDRATE : 4800BPS, 9600BPS, 19.2KBPS,
38.4KBPS
MBTIMEOUT: 000000MS
SLAVEMODE: YES, NO
POWERONMODE: REMOTE, CONTINUE, RUN
PROGRAM 01 OUTPUTMODE: DUAL, PARALLEL, SERIES,
AH-LIMIT DUAL-2
HOLD VOLTAGE EOP MODE : STOP, CONTINUE, HOLD CALIBRATING STEP 001
HOLD CURRENT HOLD LEVEL : ---.-%
PROGRAM STEP AUTODOS. : ------AH SET : _ . _ V _. _ A
FUNCTION PULSELENG. : ---.-S ACT : _ . _ V _._A
VOLTAGELEVEL AUTODOS.A : ------ AH
PULSELENG.A : ---.-S
CURRENTLEVEL ISET ( A) OFFS : _ _ %
STEP TIME AUTODOS.B : ------ AH
PULSELENG.B: ---.-S
BUZZER : ON, OFF
CURR.HIRES :OFF, ON, AUTO
MAX VOLTAGE: MAX.V
MAX CURRENT: MAX.A
S.C. LEVEL A: 02.00 V
S.C. DELAY A: 0 S
SELECT POGRAM TO S.C. LEVEL B: 02.00 V
EDIT OR COPY S.C. DELAY B: 0 S
PROGRAM: 01 POL.REV. : YES, NO
COPY TO : 01 DIG IN 1 ON/OFF,START/STOP,
PRESS OK! TO COPY DIG IN 2 INC CURR,DEC CURR,
DIG IN 3 BLOCK/RUN,RESTART,
DIG IN 4 INC VOLT.A,DEC VOLT.
DIG OUT 1 POWER GOOD,ALARM,

DIG OUT 2 PROCESSEND,
DIG OUT 3 AUTODOSING POWERON,
DIG OUT 4 AUXOUT
ANAIN1
ANAIN2 USET ISET
ANAIN3
ANAIN4
ANAOUT1
ANAOUT2 UACT, IACT, USET, ISET
ANAOUT3
ANAOUT4
Page 31 (122) 77-107.0223 GB
Rev. H
5.2.3 Overview of the menu tree for DUAL and DUAL-2
STATUS: -OFF-
PRESS ON TO START
---ACTUALS A- SIDE----
VOLTAGE
CURRENT DUTY SET RUN CFG
AHCOUNTER
PROCESS TMR
REMAINING
---SETTINGS A- SIDE--
SET VOLTAGE
SET CURRENT RUN/BLOCK
AH-LIMIT
TIMERLIMIT
STARTRAMP REMOTE CONTROL: NO SELECT SUB-MENU OR
---ACTUALS B- SIDE---- SETVOLTAGE A : --.--V PRESS ESC TO EXIT!
VOLTAGE SETVOLTAGE B : --.--V FIRMWARE:
CURRENT SETCURRENT A : ---.-A FLX-01 VER. 02. 50
AHCOUNTER SETCURRENT B : ---.-A
PROCESS TMR RUN/ BLOCK : BLOCK/RUN PROG USER CAL KRAFT
REMAINING START/STOP: START /STOP
---SETTINGS B- SIDE-- POLARITY :FWD/REV
SET VOLTAGE TIMER LIMIT : -OFF-S
SET CURRENT AH-LIMIT A : -OFF-S
AH-LIMIT AH-LIMIT B : -OFF-S
TIMERLIMIT STARTRAMP : ----.-S
STARTRAMP PROGRAMMODE :YES/NO
---COMMUNICATION--- PROGRAM A NO : 01
PROTOCOL PROGRAM B NO : 01
ADDRESS
BAUDRATE
CTRL
STAT
MSG RECIEVED
CHR RECEIVED
-------DIAGNOSTICS-----
PARAMERROR
MODULESFOUND
MAX CURRENT1
AT VOLTAGE1
MAX CURRENT2
AT VOLTAGE2
R01
R02
R03
R04
R05
R06
R07
R08
R09
R11
R12
R13
R14
R15
R16
CLEAR
Page 32 (122) 77-107.0223 GB
Rev. H
CFG
PROG USER CAL KRAFT
ENTER ENTER ENTER ENTER

PASSWORD: PASSWORD: PASSWORD: PASSWORD:
000000 000000 000000 000000
(PRESS OK) (PRESS OK) (PRESS OK) (PRESS OK)
SELECT POGRAM TO LCD-CONTRAST:---.-%

EDIT OR COPY PASSWORD : 000001
PROGRAM: 01 PROTOCOL : MODBUS RTU, PROFIBUS DP
BYTESWAP : YES, NO
ADDRESS : 000002
EDIT COPY BAUDRATE : 4800BPS, 9600BPS, 19.2KBPS,
38.4KBPS
MBTIMEOUT: 000000MS
SLAVEMODE: YES, NO
POWERONMODE: REMOTE, CONTINUE, RUN
PROGRAM 01 OUTPUTMODE: DUAL, PARALLEL, SERIES,
AH-LIMIT DUAL-2
HOLD VOLTAGE EOP MODE : STOP, CONTINUE, HOLD CALIBRATING STEP 001
HOLD CURRENT HOLD LEVEL : ---.-%
PROGRAM STEP AUTODOS. : ------AH SET : _ . _ V _. _ A
FUNCTION PULSELENG. : ---.-S ACT : _ . _ V _._A
VOLTAGELEVEL AUTODOS.A : ------ AH
PULSELENG.A : ---.-S
CURRENTLEVEL ISET ( A) OFFS : _ _ %
STEP TIME AUTODOS.B : ------ AH
PULSELENG.B: ---.-S
BUZZER : ON, OFF
CURR.HIRES :OFF, ON, AUTO
MAX VOLTAGE: MAX.V
MAX CURRENT: MAX.A
S.C. LEVEL A: 02.00 V
S.C. DELAY A: 0 S
SELECT POGRAM TO S.C. LEVEL B: 02.00 V
EDIT OR COPY S.C. DELAY B: 0 S
PROGRAM: 01 POL.REV. : YES, NO
COPY TO : 01 DIG IN 1 ON/OFF,START/STOP,
PRESS OK! TO COPY DIG IN 2 INC CURR,DEC CURR,
DIG IN 3 BLOCK/RUN,RESTART,
DIG IN 4 INC VOLT.A,DEC VOLT.
DIG OUT 1 POWER GOOD,ALARM,

DIG OUT 2 PROCESSEND,
DIG OUT 3 AUTODOSING POWERON,
DIG OUT 4 AUXOUT
ANAIN1
ANAIN2 USET ISET
ANAIN3
ANAIN4
ANAOUT1
ANAOUT2 UACT, IACT, USET, ISET
ANAOUT3
ANAOUT4
Page 33 (122) 77-107.0223 GB
Rev. H
5.2.4 Start menu

Side
A B
STATUS: - OFF - - OFF - - OFF -
Flex Kraft PRESS ON TO START PRESS ON TO START
www.kraftelektronik.se DUTY SET BLOCK CFG DUTY SET BLOCK CFG

Welcome screen Example of permanent start screen
The rectifier can be configured to go to OFF, REMOTE
CONTINUE or RUN when mains power is connected.
5.2.5 Main menu

PARALLEL and SERIES DUAL, DUAL-2
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

STANDBY mode STANDBY mode
STATUS: BLOCKING BLOCKING BLOCKING
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET RUN CFG DUTY SET RUN CFG

Rectifier blocked Rectifier blocked
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

RUN mode DC RUN mode DC
Page 34 (122) 77-107.0223 GB
Rev. H
STATUS: RUN PROG01 RUN PROG01 RUN PROG02
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

RUN mode PROGRAM RUN mode PROGRAM
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

Time limit passed Time limit passed
ALARM LED flashes and Buzzer sounds ALARM LED flashes and Buzzer sounds
if BUZZER=ON if BUZZER=ON
In program mode with DUAL and DUAL-2, one
side can stop at T-LIMIT! while the other
continues to run. In program mode T-LIMIT!
is equal to program end.
In normal mode, T-LIMIT! is the same for both
sides.
STATUS: AHLIMIT! AH-LIMIT! AH-LIMIT!
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A
Ah limit passed Ah limit passed

ALARM LED flashes and Buzzer sounds ALARM LED flashes and Buzzer sounds
if BUZZER=ON if BUZZER=ON.
In program mode and normal mode with DUAL
and DUAL-2, one side can stop at AH-LIMIT!
while the other continues to run.
Page 35 (122) 77-107.0223 GB
Rev. H
STATUS: HIGH TEMP HIGH TEMP HIGH TEMP
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

Temperature alarm from power module. Temperature alarm from power module.
STATUS: SHORT CKT! SHORT CKT! SHORT CKT!
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

Short circuit alarm. Short circuit alarm.
STATUS: MODULEFAIL MODULEFAIL MODULEFAIL
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

Alarm from power module. Alarm from power module.
STATUS: REGUL.ERR REGUL.ERR REGUL.ERR
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

Control fault from power module. Control fault from power module.
Page 36 (122) 77-107.0223 GB
Rev. H
STATUS: CHK USRCFG CHK USRCFG CHK USRCFG
00.00 V 000.0 A 00.00 V 00.00 V

000000 Ah 00000 S 000.0 A 000.0 A

Rectifier is incorrectly configured. Rectifier is incorrectly configured.
Check settings, especially for pole reversal DIG IN and DIG OUT.
The BLOCK key toggles between BLOCK and RUN
5.2.6 Duty menu

Information is displayed in the following order in the Duty menu.
██████ ACTUALS ██████

█████ SETTINGS ██████
███ COMMUNICATION ███
████ DIAGNOSTICS ████
The information under each heading changes depending on FlexKraft settings for operating mode, program
mode and communication. See below.
5.2.6.1 PARALLEL and SERIES mode

Without program function With program function
First menu display First menu display
██████ ACTUALS ██████ ██████ PROGRAM ██████

VOLTAGE : 00.00 V PROGRAM NO : 01
CURRENT : 000.0 A PROGRAM STEP: 001
AHCOUNTER : 000021AH AH-COUNTER :000021AH
PROCESS TMR : 080988 S PROCESS TMR :080988 S
REMAINING : 00006 M REMAINING : 00006 M
CLEAR ↓ ↑ CLEAR ↓ ↑
██████ ACTUALS ██████ ██████ ACTUALS ██████

AHCOUNTER :000021AH AH-COUNTER :000021AH
PROCESS TMR :080988 S PROCESS TMR :080988 S
REMAINING :-00006 M REMAINING : 00006 M
█████ SETTINGS ██████ VOLTAGE : 00.00 V
SETVOLTAGE : 00.00 V CURRENT : 000.0 A
SETCURRENT : 000.0 A █████ SETTINGS ██████
AH-LIMIT : -OFF-AH SETVOLTAGE : 00.00 V
TIMERLIMIT : -OFF- S SETCURRENT : 000.0 A
STARTRAMP :0001.0 S STARTRAMP :0001.0 S
Page 37 (122) 77-107.0223 GB
Rev. H
5.2.6.2 DUAL and DUAL-2 mod

Without program function With program function
First menu display First menu display
██ ACTUALS A-SIDE ███ ██ ACTUALS A-SIDE ███

CLEAR ↓ ↑ CLEAR ↓ ↑
██ ACTUALS A-SIDE ███ ██ ACTUALS A-SIDE ███

██ SETTINGS A-SIDE ██ VOLTAGE : 00.00 V
SETCURRENT : 000.0 A ██ SETTINGS A-SIDE ██
AH-LIMIT : -OFF-AH SETVOLTAGE : 00.00 V
██ ACTUALS B-SIDE ███ ██ ACTUALS B-SIDE ███
██ SETTINGS B-SIDE ██ VOLTAGE : 00.00 V
SETCURRENT : 000.0 A ██ SETTINGS B-SIDE ██
AH-LIMIT :000002AH SETVOLTAGE : 00.00 V
███ ACTUALS COMMON ██ ███ ACTUALS COMMON ██
VOLTAGE AVG : 00.00 V VOLTAGE AVG : 00.00 V
VOLTAGE A+B : 00.00 V VOLTAGE A+B : 00.00 V
CURRENT A+B : 000.0 A CURRENT A+B : 000.0 A
AHCOUNTERA+B:000021AH AHCOUNTERA+B:000021AH
PROCESS TMR shows the time elapsed in the current program step.
REMAINING shows the time remaining until the end of program step 8.
5.2.6.3 COMMUNICATION for no protocol

All choices: Choice/indication alternative
PROTOCOL : -- NONE --
ADDRESS : 000002
BAUDRATE : ---- BPS
CTRL:0000000000000001
STAT:0000000100000000
PROTOCOL: -- NONE --
PROTOCOL: -- NONE --
Page 38 (122) 77-107.0223 GB
Rev. H
5.2.6.4 COMMUNICATION for MODBUS RTU

PROTOCOL : MODBUS RTU
ADDRESS : 000002
BAUDRATE : 38.4KBPS
CTRL:0000000000000001 See section 9.2.1 Overview of registers
STAT:0000001000000000 See section 9.2.1 Overview of registers
MSG RECEIVED: 000000
CHR RECEIVED: 000000
5.2.6.5 COMMUNICATION for PROFIBUS

PROTOCOL :PROFIBUS DP
ADDRESS : 000002
BAUDRATE : AUTODETECT
CTRL:0000000010000001 See section 9.2.1 Overview of registers
STAT:0000001101000000 See section 9.2.1 Overview of registers
DP-STATE :WAIT PRM
WD-STATE :BAUDSRCH
5.2.6.6 DIAGNOSTICS
████ DIAGNOSTICS ████
PARAMERROR : 000000
MODULESFOUND: 000005
MAX CURRENT1: 01500 A Limited values are not shown
AT VOLTAGE1: 24.00 V Limited values are not shown
MAX CURRENT2: 01500 A Limited values are not shown
AT VOLTAGE2: 24.00 V Limited values are not shown
R01 :1101000000000000 For troubleshooting.
R04 : 000046 For troubleshooting.
R09 : 000.0 A For troubleshooting.
R13 : 00.00 V For troubleshooting.
Page 39 (122) 77-107.0223 GB
Rev. H
5.2.7 Set menu
PARALLEL and SERIES DUAL DUAL -2

First menu display First menu display First menu display
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
TIMERLIMIT : -OFF- S RUN/BLOCK : RUN RUN/BLOCK A : RUN
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
SET MENU FOR PARALLEL AND SERIES

REMOTE CONTROL : NO NO, YES
SETVOLTAGE : 00.00 V Increase/decrease with arrow keys
SETCURRENT : 000.0 A Increase/decrease with arrow keys
RUN/BLOCK : RUN RUN, BLOCK
START/STOP : STOP START, STOP
POLARITY : FWD FWD, REV
TIMERLIMIT : -OFF- S OFF, 0-999999 s
AH-LIMIT : -OFF-AH OFF, 0-999999 Ah
START RAMP :0000.5 S 0000.5-3000,0 s
PROGRAMMODE : NO YES, NO
PROGRAM NO : 01 01, 02, 03, 04 Press ”OK” to activate change.
SET MENU FOR DUAL

SETVOLTAGE A: 00.00 V Increase/decrease with arrow keys
SETVOLTAGE B: 00.00 V Increase/decrease with arrow keys
SETCURRENT A: 000.0 A Increase/decrease with arrow keys
SETCURRENT B: 000.0 A Increase/decrease with arrow keys
RUN/BLOCK : RUN RUN, BLOCK
START/STOP : STOP START, STOP
POLARITY : FWD FWD, REV
TIMERLIMIT : -OFF- S OFF, 0-999999 s. Applies to side A and side B
AH-LIMIT A : -OFF-AH OFF, 0-999999 Ah
AH-LIMIT B : -OFF-AH OFF, 0-999999 Ah
START RAMP :0000.5 S 0000.5-3000,0 s (0.1–3000.0s via serial
communication) Applies to side A and side B.
PROGRAMMODE A : NO YES, NO
PROGRAMMODE B : NO YES, NO
PROGRAM A NO : 01 01, 02, 03, 04
PROGRAM B NO : 01 01, 02, 03, 04 Press “OK” to activate change.
SET MENU FOR DUAL-2

SETVOLTAGE A: 00.00 V Increase/decrease with arrow keys
SETVOLTAGE B: 00.00 V Increase/decrease with arrow keys
SETCURRENT A: 000.0 A Increase/decrease with arrow keys
Page 40 (122) 77-107.0223 GB
Rev. H

SETCURRENT B: 000.0 A Increase/decrease with arrow keys
RUN/BLOCK A : RUN RUN, BLOCK
RUN/BLOCK B : RUN RUN, BLOCK
START/STOP A: STOP START, STOP
START/STOP B: STOP START, STOP
POLARITY A : FWD FWD, REV
POLARITY B : FWD FWD, REV
TIMERLIMIT : -OFF- S OFF, 0-999999 s. Applies to side A and side B
AH-LIMIT A : -OFF-AH OFF, 0-999999 Ah
AH-LIMIT B : -OFF-AH OFF, 0-999999 Ah
START RAMP :0000.5 S 0000.5-3000.0 s (0.1–3000.0s via serial
communication) Applies to side A and side B.
PROGRAMMODE A : NO YES, NO
PROGRAMMODE B : NO YES, NO
PROGRAM A NO : 01 01, 02, 03, 04
PROGRAM B NO : 01 01, 02, 03, 04
Press “OK” to activate change.
5.2.8 Block
Note that the keys are disabled during serial communication.
(If the rectifier is configured for PROFIBUS serial communication and loses contact with the PROFIBUS
MASTER the keys will be activated.)
5.2.8.1 Pausing a program

STATUS: RUN DC RUN DC RUN DC RUN DC RUN DC
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
Press ”BLOCK” Press ”BLOCK” Press ”BLOCK” to pause side A

and side B at same time.
SETCURRENT A: 000.0 A
SETCURRENT B: 000.0 A
RUN/BLOCK A : RUN
RUN/BLOCK B : RUN
START/STOP A: START
START/STOP B: START
← → ↓ ↑
SET menu. Stops program
independently for side A and side B.
Change RUN to BLOCK using
arrow keys on left.
Page 41 (122) 77-107.0223 GB
Rev. H
5.2.8.2 Restarting paused program

STATUS: BLOCKING BLOCKING BLOCKING BLOCKING BLOCKING
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 RUN CFG DUTY SET RUN CFG DUTY SET RUN CFG
Press “RUN” Press “RUN” Press “RUN” to start
sides A and B at same time.
SETCURRENT A: 000.0 A
SETCURRENT B: 000.0 A
RUN/BLOCK A : BLOCK
RUN/BLOCK B : BLOCK
START/STOP A: START
START/STOP B: START
← → ↓ ↑
SET menu
Change RUN to BLOCK using
arrow keys on left
5.2.9 CFG menu
SELECT SUB-MENU OR
PRESS ESC TO EXIT!
FIRMWARE
FLX-01 VER xx.xx
PROG USER CAL KRAFT
5.2.9.1 Prog menu
ENTER Default password is 000001

PASSWORD. 000000
(PRESS OK)
← →
If you forget a password contact the KraftPowercon service department to set a new one.
Page 42 (122) 77-107.0223 GB
Rev. H
SELECT PROGRAM TO
EDIT OR COPY.
PROGRAM: 01
← → EDIT COPY
5.2.9.1.1 Edit menu
████ PROGRAM 01 █████

AH-LIMIT :080988AH
HOLD.VOLTAGE: 00.00 V
HOLD.CURRENT: 000.0 A
PROG.STEP: 001
FUNCTION : PULSE
← → ↓ ↑

████ PROGRAM 01 █████ Program number
AH-LIMIT :080988AH -OFF-, 0-999999Ah
HOLD.VOLTAGE: 00.00 V 0-max nominal voltage. Step 0.01 V
HOLD.CURRENT: 000.0 A 0-max nominal current. Step 1 A
PROG.STEP: 001 1-8. Change PROG.STEP number to show parameters.
FUNCTION : PULSE STEP, U-RAMP, I-RAMP, PULSE, REPEAT
Lines under FUNCTION change depending on which FUNCTION is chosen. See below.
Function: STEP Choice/indication alternative

FUNCTION : STEP
VOLTAGELEVEL: 06.00 V 0-max nominal voltage
CURRENTLEVEL: 150.0 A 0-max nominal current
STEP TIME: 000088 S 0-30000 sec
Function: U-RAMP Choice/indication alternative

FUNCTION : U-RAMP
STEP TIME: 000088 S 0-30000sek
Function: I-RAMP Choice/indication alternative

FUNCTION : I-RAMP
STEP TIME: 000088 S 0-30000 sec
Page 43 (122) 77-107.0223 GB
Rev. H
Function: Pulse Val/indikerings-alternativ

FUNCTION : PULSE
VOLT.LEVEL 1: 06.00 V 0-max nominal voltage
CURR.LEVEL 1: 150.0 A 0-max nominal current
VOLT.LEVEL 2: 04.00 V 0-max nominal voltage
CURR.LEVEL 2: 150.0 A 0-max nominal current
TIME 1 :000002 S 0-30000 sec. Step 1 sec
TIME 2 : 00007 S 0-30000 sec. Step 1 sec
STEP TIME :000090 S 0-500000 hours, (=(TIME 1+TIME 2)*CYCLES)
CYCLES: :000010 0-30000 (= STEP TIME/(TIME 1+TIME 2)
Press ”OK” to activate change.
STEP TIME or CYCLES can be used to set time/number of cycles. The parameter that is not used is
calculated automatically.
NOTE! The start ramp in the CFG/USER menu affects the start sequence and overwrites whatever is set in
the program.
5.2.9.1.2 Copy menu
SELECT PROGRAM TO
EDIT OR COPY.
PROGRAM: 01
COPY TO: 03
PRESS OK! TO COPY
← → ↓ ↑
PROGRAM: 01 01, 02, 03, 04
COPY TO: 03 01, 02, 03, 04

5.2.9.2 User menu
ENTER Default password is 000001

PASSWORD. 000000
(PRESS OK)
← →
If you forget a password contact the KraftPowercon service department to set a new one.
Page 44 (122) 77-107.0223 GB
Rev. H
LCD-CONTRAST: 050.0 %
First menu display PASSWORD :000001
PROTOCOL :PROFIBUS DP
BYTESWAP : YES
ADDRESS : 00002
BAUDRATE : AUTODETECT
← → ↓ ↑

LCD-CONTRAST: 050.0 % Set contrast using arrow keys
PASSWORD :000001 Set password using arrow keys
PROTOCOL :PROFIBUS DP --NONE--, PROFIBUS DP, MODBUS RTU
BYTESWAP : YES YES,NO
ADDRESS : 00002 Set address using arrow keys. Default=2
0-247 for PROFIBUS DP, 0-230 for MODBUS RTU
BAUDRATE : AUTODETECT MODBUS: 4800, 9600, 19200, 38000 BPS
PROFIBUS: AUTODETECT (9.6kBPS to 12MBPS)
MBTIMEOUT: 000000MS 0-50MS
SLAVEMODE: NO YES,NO
POWERONMODE: OFF OFF, REMOTE, CONTINUE, RUN
OUTPUTMODE : SERIES DUAL, PARALLEL, SERIES, DUAL-2
EOP MODE : STOP STOP, CONTINUE, HOLD
HOLD LEVEL : 010.0% 0-100% of set value.
AUTODOS. : -OFF-AH -OFF-, 0-30000 Ah
PULSELENG. : 000.5 S 0 to 999.9 s
AUTODOS. A : -OFF-AH -OFF-, 0-30000 Ah
PULSELENG.A: 000.5 S 0 to 999.9 s
AUTODOS. B : -OFF-AH -OFF-, 0-30000 Ah
PULSELENG.B: 000.5 S 0 to 999.9 s
BUZZER : OFF OFF, ON
CURR.HIRES: AUTO OFF, ON, AUTO
MAX VOLTAGE: 30.00 V 0-MAX output voltage at rectifier
MAX CURRENT: 03000 A 0-MAX output current at rectifier
S.C. LEVEL A: 02.00 V 0-MAX output voltage at rectifier Step 0.01 V
S.C. DELAY A: 0 S 0=-OFF, 1-600,s Step 1sec
S.C. LEVEL B: 02.00 V 0-MAX output voltage at rectifier Step 0.01 V
S.C. DELAY B: 60 S 0=-OFF-, 1-600,s Step 1sec
POL.REV.: YES NO, YES
DIG IN inputs can have the following signals.

Signals are in the order shown on the display.
DIG IN 1: - NONE - –NONE-,ON/OFF,START/STOP,BLOCK/RUN,RESTART,
DIG IN 2: - NONE - INC VOLT. A, DEC VOLT. A,INC CURR. A,
DIG IN 3: - NONE - DEC CURR. A, INC VOLT. B, DEC VOLT. B,
DIG IN 4: - NONE - INC CURR. B, DEC CURR. B, BLOCK/RUN A ,
BLOCK/RUN B,AUX IN A, AUX IN B,
START/STOPA, START/STOPB, POL.CTRL A,
POL.CTRL B, EXT.ALARM A, EXT.ALARM B,
RUN/BLOCK, RUN/BLOCK A, RUN/BLOCK B, ENABLE,
ENABLE A, ENABLE B, EXT.ALARM 1, ALARM RESET
(Current at input gives first function
Example: current at signal ON/OFF input gives ON)
INCREASE/DECREASE function: 0-100% in 10 seconds.

If the EXT.ALARM 1 parameter is configured as a digital input, it is activated
regardless of the setting of the REMOTE parameter. The signal is inverted and
must be false (current at input), otherwise the rectifier will not start.
Page 45 (122) 77-107.0223 GB
Rev. H
DIG OUT outputs can have the following signals.

DIG OUT 1: - NONE - –NONE-,POWERGOOD, ALARM, PROCESS END,
DIG OUT 2: - NONE - AUTODOSING, POWER ON, AUX OUT A, AUX OUT B,
DIG OUT 3: - NONE - AUTODOS. A, AUTODOS. B, POL.CTRL. A, POL.CTRL. B,
DIG OUT 4: - NONE - POL.STAT. A, POL.STAT. B, RUN.STAT. A, RUN.STAT. B
PROC. END A, PROC. END B,
ANAIN inputs can have the following signals.

ANAIN1: - NONE - –NONE-,USET(A) 0-10V, ISET(A) 0-10V, USET(B) 0-10V,
ANAIN2: - NONE - ISET(B) 0-10V, USET(A) 0-20mA, ISET(A) 0-20mA,
ANAIN3: - NONE - USET(B) 0-20mA, ISET(B) 0-20mA, USET(A) 4-20mA,
ANAIN4: - NONE – ISET(A) 4-20mA, USET(B) 4-20mA, ISET(B) 4-20mA
USET(A) 0- 5V, ISET(A) 0- 5V, USET(B) 0- 5V,
ISET(B) 0- 5V, USET(A) 6- 0V, ISET(A) 6- 0V,
USET(B) 6- 0V, ISET(B) 6- 0V, USET(A) 10-0V,
ISET(A) 10-0V, USET(B) 10-0V, ISET(B) 10-0V.
ANAOUT outputs can have the following signals.

ANAOUT1: - NONE - –NONE-, UACT(A) 0-10V, IACT(A) 0-10V, UACT(B) 0-10V,
ANAOUT2: - NONE - IACT(B) 0-10V, UACT(A)0-20mA, IACT(A)0-20mA,
ANAOUT3: - NONE - UACT(B)0-20mA, IACT(B)0-20mA, UACT(A)4-20mA,
ANAOUT4: - NONE - IACT(A)4-20mA, UACT(B)4-20mA, IACT(B)4-20mA
USET(A) 0-10V, ISET(A) 0-10V, USET(B) 0-10V,
ISET(B) 0-10V, UACT(A) 0- 5V, IACT(A) 0- 5V,
UACT(B) 0- 5V, IACT(B) 0- 5V, UACT(A) 0- 6V,
UACT(B) 0- 6V,
With option board for 0-60mV and 0-1V output is set for 0-10VDC
The analogue and digital outputs can be configured so that the same signal appears at one or more outputs.
Parameters that are not configured for remote control via analogue/digital inputs are controlled locally from
the keypad or by serial communication.
Keys are disabled when REMOTE=YES and PROTOCOL=PROFIBUS or MODBUS. If the rectifier loses
contact with the PROFIBUS MASTER the keys will be activated.
The keys are activated when REMOTE=YES and PROTOCOL=-NONE-, but have lowest priority.
Keys are disabled when SLAVEMODE=YES.

STATUS: STANDBY
The OFF key is also disabled at
SLAVEMODE=YES, this also applies when
the rectifier is in LOCAL mode.
00.00 V 000.0 A
See also chapter 5.3 Remote control. 000000 Ah 00000 S
“SET” and “BLOCK” are removed first
DUTY CFG
The EXT.ALARM 1 digital input parameter is active if it has been configured, regardless of the REMOTE
settings.
The signal is inverted and must be false (current at input), otherwise the rectifier will not start.
Page 46 (122) 77-107.0223 GB
Rev. H
5.2.9.3 Cal menu

The rectifier has a calibration function. The calibration menu is password protected with the same password
as the USER menu. Calibration of the rectifier should be done regularly, how often depends on the type of
operation. A recommendation is once a year.
Requisite equipment includes instruments for voltage and current measurement. For the DC current, a
current sensor, a shunt or a contact free measuring device is required (Clamp-on ammeter for DC).
Explanation of the calibration menu
CALIBRATING STEP001 Shows the calibration step

SET: 15.00V 012.0A
ACT: 00.00V 000.0A
ISET(A) OFFS: 000.2 %
← → ↓ ↑
CALIBRATING STEP001
SET: 15.00V 012.0A Shows the actual and set value for this
ACT: 00.00V 000.0A
calibration step
ISET(A) OFFS: 000.2 %
← → ↓ ↑
CALIBRATING STEP001
SET: 15.00V 012.0A
ACT: 00.00V 000.0A
ISET(A) OFFS: 000.2 % Shows value and type to be calibrated

← → ↓ ↑
When calibrating SET values, adjust with arrows ← → until the external instrument shows the set value on
the display.
When calibrating ACT values, adjust with arrows ← → until the ACT value shows the set value on the
display.
The values on the displays vary with the number of power modules.
Calibration steps 1 to 16 are valid for standard rectifiers. For rectifiers equipped with analogue options
calibration step 0 to 32 are valid.
Calibrating all equipment.
Password as for CFG/USER menu

Page 47 (122) 77-107.0223 GB
Rev. H
Calibration of offset (zero)
CALIBRATING STEP001 All steps in this menu layout

SET: 15.00V 012.0A STEP: Parameter
ACT: 00.00V 000.0A 001 ISET (A)
002 ISET (B)
ISET(A) OFFS: 000.2 % 003 USET (A)
004 USET (B)
005 IACT (A)
← → ↓ ↑ 006 IACT (B)
007 UACT (A)
008 UACT (B)
Calibration of span.(maximum)

SET: 15.00V 01250A STEP: Parameter
ACT: 00.00V 000.0A 009 ISET (A)
010 ISET (B)
ISET(A) SPAN: 100.0 % 011 USET (A)
012 USET (B)
013 IACT (A)
014 IACT (B)
015 UACT (A)
016 UACT (B)
Calibrating equipment with analogue options.

Calibration of output signal offset
at terminal.
CALIBRATING STEP017
ANALOG OUT 1: 001.0 % All steps in this menu layout
MEASURE AT TERMINAL! STEP: Parameter
017 ANAOUT1
ANAOUT1 OFFS: 000.2 % 018 ANAOUT2
019 ANAOUT3
020 ANAOUT4
← → ↓ ↑
Calibration of input signal offset.

ANALOG OUT 1: 001.0 % STEP: Parameter
ANALOGINPUT1: 000,0 % 021 ANAIN1
022 ANAIN2
ANAIN1 OFFS: 000.2 % 023 ANAIN3
024 ANAIN4
← → ↓ ↑
Page 48 (122) 77-107.0223 GB
Rev. H
Calibration of output signal span at

terminal.
CALIBRATING STEP025
ANALOG OUT 1: 001.0 % All steps in this menu layout
MEASURE AT TERMINAL! STEP: Parameter
025 ANAOUT1
ANAOUT1 SPAN: 100.0% 026 ANAOUT2
027 ANAOUT3
028 ANAOUT4
← → ↓ ↑
Calibration of input signal span

ANALOG OUT 1: 001.0 % STEP: Parameter
ANALOGINPUT1: 048,0 % 029 ANAIN1
030 ANAIN2
ANAIN1 SPAN: 100.0 % 031 ANAIN3
032 ANAIN4
← → ↓ ↑
Press the “OK” key to activate the changes.
5.2.9.4 KRAFT menu

This is an internal KraftPowercon menu intended for configuration and diagnosis.
5.3 Remote control

The rectifier can be remote-controlled via serial communication or analogue control.
Remote control is chosen in the SET menu, with the REMOTE parameter. When using analogue
remote control, some set values and functions can be remotely controlled and others locally controlled
from the keypad. The REMOTE parameter must be set to ON and PROTOCOL parameter must be set
to NONE. In serial communication, REMOTE=ON and PROTOCOL=PROFIBUS DP or MODBUS
RTU, some set values/functions can be controlled by serial communication and others by means of
the analogue inputs.
Signal priority: Lowest = Keypad / serial communication / Highest = analogue signals.
When using remote control via serial communication the keys are disabled.
It is however possible to check settings and actual values locally.
The rectifier cannot be switched off with the OFF key. It must be reconfigured to LOCAL in the SET
menu before the OFF key will work again.
NB! The rectifier cannot be switched off with the OFF key when it is in slave mode,
SLAVEMODE=YES. This also applies when the rectifier is in LOCAL mode. The SLAVEMODE is shut
off in the CFG/USER menu.
Remote control using an analogue signal is activated by using the CFG/USER menu and setting a set
value for some or several of the analogue inputs ANA IN 1 to ANA IN 4. Remote control using digital
input (switches) is activated by using the CFG/USER menu and setting a SET value for some or
several of the digital inputs DIG IN 1 to DIG IN 4.
NOTE! If the rectifier is set for analogue/digital (by switches) remote control of parameters , these
values have priority over those from serial communication.
See chapter 7.6.2.4 Remote and local control

Page 49 (122) 77-107.0223 GB
Rev. H
5.4 Functions
5.4.1 Process timer
The rectifier has a facility for setting a time limit. When this time limit has expired, an EOP (End of
Process) signal is generated. EOP see 5.4.4 EOP (End Of Process)
The number of seconds since the start of the process is shown on the normal display.
The rectifier resumes operation after power loss if the parameter POWERONMODE is set to
CONTINUE, and the timer resumes from the value at the time of the power loss.???
The Time limit,0-999999s, is set in the SET menu. See chapter 5.2.7. The EOP mode is set in the
menu CFG/USR, see chapter5.2.9.2 User menu
Timer accuracy: +- 0.1% (resolution 1s) Example: At set value 1000s the time will be +- 1s.
If you need to reset the timer, use the OFF key to Standby mode, at restart of the rectifier with the ON
key, the timer is reset.
The process timer can also be reset using the ’CLEAR’ command in the DUTY menu, or by using a
digital input, or serial communication.
5.4.2 Ah counter function

The rectifier has a facility for setting an Ah limit. When the Ah limit has expired, an EOP (end of
process) signal is generated. see 5.4.4 EOP (End Of Process)
The number of Ah since the start of the process is shown on the normal display.
The rectifier resumes operation after power loss if the parameter POWERONMODE is set to
CONTINUE, and the counter resumes from the value at the time of the power loss.
The Ah limit,0-999999Ah, and STARTUP mode is set in the SET menu. See chapter 5.2.7.
The EOP mode is set in the menu CFG/USR, see chapter5.2.9.2 User menu
Ah counter accuracy: +- 1% of output current 10-100% of rated current.

Example: At set value 100Ah the limit will be +- 1Ah .
If you need to reset the AH counter, use the OFF key to Standby mode, at restart of the rectifier with
the ON key, the Ah counter is reset.
The ampere hour counter can also be reset using the ’CLEAR’ command in the DUTY menu, or by
using a digital input, or serial communication.
5.4.3 Start ramp

The rectifier is equipped with the possibility to set a time, under which the voltage and current ramps from
zero to set value during a preset time. The time is set using the SET menu and the parameter STARTRAMP.
The start ramp time, 0,5-3000s is set in the SET menu by the parameter STARTRAMP. See chapter 5.2.7.
The start ramp time applies to both sides in DUAL and DUAL-2 modes. This time also applies in program
mode.
5.4.4 EOP (End Of Process)

EOP is obtained when the set time expires or the set Ah is reached.
At EOP, the rectifier can block, go to a set HOLD level or only give a signal with LED and buzzer, and
continue operation.
EOP can be obtained via digital output if option for this is fitted, see chapter 5.2.9.2 User menu and 6
Options/optional functions EOP settings also apply in program.
These settings are made in the CFG/USER menu. See chapter 5.2.9.2 User menu
The OFF command restarts in STANDBY mode; ON restarts the rectifier.
Page 50 (122) 77-107.0223 GB
Rev. H
5.4.5 Resolution, current indication

The resolution of the current value can be set to 0,1A or 1A. The settings are made by the parameter HIRES
in the CFG/USER menu. See chapter 5.2.9.2 User menu
0,1A resolution is available on rectifiers with nominal output current of 3000A or less only.
0,1 A resolution is automatically enabled on rectifiers with nominal output current of 100A or less
Actual values and set values from serial communication and set values set from keyboard.
Nominal Resolution default Available resolutions
1-100A 0.1A 0.1A 1A
100-3000A 1A 0.1A 1A
3000-6000A 1A 1A
NB! The resolution affects the scaling in the serial communication.
Which resolution that is effective is accessible in status register b10.
The LCD display shows the actual current with 0,1A resolution up to 999,9A and 1A resolution from 1000A
and above independent of the setting of HIRES. The LCD current resolution does not affect the accuracy of
the rectifier.
5.4.6 Reduction of output current and output voltage

The rectifiers maximum set value for output current and output voltage can be reduced in the CFG/USER
menu. See chapter 5.2.9.2 User menu. This function can be used if output current, output voltage or max
input power needs to be limited.
If the rectifiers output is reduced at the factory, these values are on the rating plate.
NB! If the output current and\or output voltage are increased from the limited values, the installation must be
assessed regarding cable cross-sections, fuses, etc.
Analogue remote control gives the reduced output value at max control voltage
5.4.7 Blocking
In DUAL, SERIES and PARALLEL mode the rectifier can be blocked from the keypad, using the SET
menu, by serial communication or digital I/O.
In DUAL-2 mode, outputs A and B can be blocked at the same time from the keypad, and
independently using serial communication, digital I/O PCB or the SET menu.
5.4.8 Fan control

The fans in the power modules are controlled by the output current and switch off when this is low (<
approx. 5%). There is a delay of a few seconds before a fan switches on or off.
5.4.9 Locking keypad to input parameters, SLAVE mode

When the rectifier is in SLAVEMODE it acts as a slave and no operating parameters can be changed.
The OFF key is disabled, this also applies when the rectifier is in LOCAL mode.
The keypad is unlocked by deactivating SLAVEMODE from the password-protected ”CFG/USER”

menu. The actual values are displayed.
Page 51 (122) 77-107.0223 GB
Rev. H
5.4.10 Under voltage / short circuit detection

If voltage is below set level for the pre-set time while the output current is more than approx 10% of rated
current, the output is considered a short circuit.
In DUAL and DUAL-2 mode the voltage and delay settings are separated for A and B side
In SERIES and PARALLEL mode settings for A-side shall be used.
When under voltage is detected an alarm is generated and the rectifier is shut off, i.e. both sides are turned
off in dual modes.
The reason for the alarm is presented on the display, it is also possible to read out via serial port (the alarm
word). For SERIES and PARALLEL rectifiers the information is in “A-side”.
The alarm is reset by setting the rectifier to ‘OFF’ mode, either by keyboard or via serial port.
The output voltage setting must be higher than the detection level. If the output voltage set level is lower
than the under voltage detection level the under voltage detection is disabled.
If the process incorporates extremely long ramp from 0V, special care might be needed.
Voltage level and delay time must be set on rectifier keyboard.

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.
The under voltage is disabled as default.

Page 52 (122) 77-107.0223 GB
Rev. H
6 Options/optional functions
Options can differ from the description below. If an option differs from the description below, an additional
description is added to this description.
NB! 24V is the maximum voltage allowed on signal inputs and outputs.
If too high a voltage is applied the rectifier may break down.
See the rear of the control module to see which option/options are fitted.
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, signals and the
configurations made at the factory.
Typical labels
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)

5 Uref (10V)
4 Iset (0-10V)
5 Uref (10V)
1
X2
Serial A5 1 3 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 outside of the cover plate Label on the inside of the cover plate.
Example:
The rectifier is equipped with the following options: Ingångar/utgångar/signaler:
Interface PCB A12 - - - - - - - - - - - - - - - - - - - - - - - Emergency stop A12:X2:3 – A12:X2:4
Analogue/Digital I/O PCB A10 - - - - - - - - - - - - - - - Configured according to the table
Serial I/O PCB A4 - - - - - - - - - - - - - - - - - - - - - - - RS485
Terminals to A4, A5 are 3-pole screw

terminals.
The terminal accepts conductor
areas: 0.2-2.5 mm2.
Terminals to A9, A10, A11, A12, A13 and

centre terminal A14 are 12-pin screw
terminals.
Terminals are pluggable. The removable
female part is supplied with the rectifier fitted
to terminal.
The PCB is situated behind the plate for
control signals at the rear right of the control
module.
The terminal accepts conductor
areas: 0.14 -1.5 mm2
See User Guide 77-107.0222 chapter

Installation guide for information on
connections.
Page 53 (122) 77-107.0223 GB
Rev. H
6.1 Signal names and explanations

In the rectifiers’ control system a number of signals are used. An explanation of some of the names is given
below. Signal names not mentioned may be explained elsewhere in this document unless the name is self
explanatory.
ON/OFF On/Off of the rectifier. The rectifier is blocked and the display is turned off. If the
rectifier is equipped with a contactor, the contactor is deactivated.
START/STOP The rectifier is blocked and started with a starting ramp. Restarts any program that
is running.
BLOCK/RUN The rectifier is blocked and started without a starting ramp.
RESTART Time and Ah counters are reset and restarted.
POWERGOOD Signal that indicates that the rectifier is functioning and supplying current, or is
ready to supply current.
ALARM Fault signal from the rectifier.
PROCESS END Signal that indicates that the conditions for PROCESS END is fulfilled.
AUTODOSING Signal to the dosing system.
PULSELENG. Length of signal to dosing system.
POWER ON The rectifier is ON.

AUX IN A-B Customer input, to read a digital signal, for example, a limit switch.
The signal comes from a DIG IN input and reads through serial communication.
AUX OUT A-B Customer output for control of equipment, for example, a heater (a relay is
needed). The signal goes to a DIG OUT and comes from serial communication.
DIG IN 1-4 Name on physical digital input
DIG OUT 1-4 Name on physical digital output
ANA IN 1-4 Name on physical analogue input.
ANA OUT 1-4 Name on physical analogue output.
6.2 Control via RS 485 A4

This function is implemented on a PCB located behind the cover plate for control signals at the rear of
the control module.
One or several rectifiers can be controlled via RS-485 serial communication.
The databus from the control unit is daisy-chained between the units. On the last unit the termination
resistors are switched on, DIP switch A4:S1=ON. The termination minimises disturbances on the data
bus, avoiding communication problems. On the other units the termination resistors is disconnected,
DIP switch A4:S1=OFF
Protocol MODBUS RTU or PROFIBUS DP. The protocol is set in CFG/USER menu, See chapter
5.2.9.2 User menu
Page 54 (122) 77-107.0223 GB
Rev. H
6.2.1 Connection
PCB in the rectifier The PCB has built in switchable termination resistors.
DIP switch A4:S1=ON, the termination resistors is connected.
DIP switch A4:S1=OFF, the termination resistors is disconnected.
Termination switch OFF--ON

Several rectifiers connected in chain, 4 shown, maximum 32 pc.
For terminals and PCB location, see 6 Options/optional functions. Also see labels on the backside of
the control module for PCB placement and signal configuration at time of delivery.
Examples of cable types, see User guide 77-107.0222.
6.3 Control via RS-232 A5

The function is implemented on a PCB located behind the cover plate for control signals at the rear of
the control module.
One rectifier can be controlled via RS-232 serial communication. The protocol is set in CFG/USER
menu, See chapter 5.2.9.2 User menu.
6.3.1 Connection
Rx and Tx seen from the rectifier. The rectifier receives on terminal 1 and transmits on terminal 2.
the control module for PCB placement and configuration at time of delivery.
Page 55 (122) 77-107.0223 GB
Rev. H
6.4 Analogue control I/O A9

the control module.
Inputs and outputs are galvanically insulated, maximum 50V difference, between rectifiers and external
control system, and between channels.
The rectifier’s set points for current and voltage can be controlled by analogue signals: 0-20 mA, 4-20 mA or
by 0-10VDC, 0-5VDC, 6-0VDC or 10-0VDC.
The rectifier’s actual values for current and voltage can be obtained using analogue signals: 0-20 mA, 4-20
mA or by 0-10VDC, 0-5VDC, 6-0VDC or 10-0VDC.
The 20 mA and 10V (for 0-10VDC control) signals represent the maximum output current/voltage of the
rectifier. If the rectifier output is limited these correspond to the set maximum values.
NOTE! The current and voltage control signals for set values and actual values cannot be mixed. The PCB
is differently assembled for voltage or current set point/actual signals. Setting of 0-20mA, 4-20mA
or 0-10V, 0-5VDC, 6-0VDC or 10-0VDC is done in the software in the CFG/USER menu, see
chapter 5.2.9.2 User menu.
Settings are made with the following parameters: ANA IN 1 to ANA IN 4, ANA OUT 1 to ANA OUT 4 in the
CFG/USER menu, see chapter 5.2.9.2 User menu
NOTE! If the rectifier is set for analogue/digital (by switches) remote control of parameters, these
Functions that have not been configured for remote control are locally controlled from the keyboard.
Page 56 (122) 77-107.0223 GB
Rev. H
6.4.1 Connection
Unconfigured board
+24V is the supply from the board. This voltage is intended to drive digital inputs in the FlexKraft rectifier
using external zero potential switches, or for driving optocouplers in a PLC unit, for example, using zero
potential switches in FlexKraft, where no external supply is available for the signal.
If the rectifier is delivered with the PCB assembled it is configured as below, if not, configuration will be as
stated on the order.
See the label on the inside of the plate through which the control cables pass at the rear of the control
module for the supplied configuration.
PARALLEL, SERIES DUAL, DUAL-2 In parallel and series mode the actual
values apply to side A even if side B has
ANA IN 1: ISET(A) 4-20mA ISET(A) 4-20mA been configured.
ANA IN 2: USET(A) 4-20mA USET(A) 4-20mA
ANA IN 3: NONE ISET(B) 4-20mA See the drawing in the appendix for
ANA IN 4: NONE USET(B) 4-20mA schematic circuit board location and the
signs on the rear of the rectifier control
ANA OUT 1: IACT(A) 4-20mA IACT(A) 4-20mA module for actual board placement and
ANA OUT 2: UACT(A) 4-20mA UACT(A) 4-20mA signal configuration.
ANA OUT 3: NONE IACT (B) 4-20mA
ANA OUT 4: NONE UACT (B) 4-20mA NOTE! The rectifier is equipped with
different circuit boards depending on
whether it uses current or voltage outputs.
Page 57 (122) 77-107.0223 GB
Rev. H
6.4.2 Technical data

Max insulation voltage 50V
Analogue signals: Input signals 0-10VDC input impedance >10kΩ

Output signals 0-10VDC min load impedance 500Ω
or
Input signal 0(4)-20mA
Output signals 0(4)-20mA, maximum 10V@20mA
NB! Voltage and current signals require different PCB:s, and can not be used
simultaneously.
+24VDC Max load each output and total PCB 200mA

+24VDC floating potential relative to rectifier output
6.5 Analogue digital I/O for analogue control box or PC/PLC A10
The function is implemented on a PCB located behind the cover through which the control cables pass
at the rear of the control module.
Inputs and outputs are not galvanically insulated between channels or rectifier output.
The inputs and outputs are allowed to float against the rectifier output up to 50VDC, This is to prevent
circulating currents in the control system.
The rectifier’s current and voltage set points can be controlled with one of the following analogue signals: 0-
10 V DC, 0-5VDC, 6-0VDC or 10-0VDC.
The actual values for rectifier current and voltage are available as 0-10VDC, 0-5VDC, or 0-6VDC signals.
NOTE! It is not possible to have current control 0(4)-20mA on this PCB, see Analogue I/O A9, section 6.4.
A special version of the PCB is available with actual values of 0-60mVDC or 0-1VDC for ANAOUT 1 and
ANAOUT 3, FlexKraft configuration in these cases is 0-10VDC.
If the rectifier output is limited, 10V corresponds to the maximum output (for control voltage 0-10VDC).
If the rectifier output is limited these correspond to the set maximum values.
The following rectifier functions: ON/OFF, START/STOP, BLOCK/RUN or RESTART can be controlled via
volt free (NO) contacts. See section 5.2.7.2 User menu for all the alternatives.
POWERGOOD, ALARM, PROCESS END, AUTODOSING, POWER ON, AUX OUT A and AUX OUT B
signal can be received as a voltage, for current rating, see section 6.5.3 Technical data
Settings are made with the following parameters: DIG IN 1 to DIG IN 4, ANA IN 1 to ANA IN 4, DIG OUT 1 to
DIG OUT 4, and ANA OUT 1 to ANA OUT 4 in the CFG/USER menu. See chapter 5.2.9.2 User menu.
If the load is inductive the digital outputs must be protected against sparks and over voltages. This is done by
for example a freewheel diode across the load. Take care about diode polarity.
Parameters that have not been configured for remote control are locally controlled from the keyboard.
Page 58 (122) 77-107.0223 GB
Rev. H
6.5.1 Connection
Unconfigured PCB
+24V is the supply from the PCB. It is not normally required for this circuit board. See the wiring example
below.
PARALLEL or SERIES DUAL and DUAL-2 for DUAL and DUAL -2

for 1 control box 2 control boxes for PC/PLC
and PLC
ANA IN 1: ISET(A) 0-10V ISET(A) 0-10V ISET(A) 0-10V

ANA IN 2: USET(A) 0-10V USET(A) 0-10V USET(A) 0-10V
ANA IN 3: NONE ISET(B) 0-10V ISET(B) 0-10V
ANA IN 4: NONE USET(B) 0-10V USET(B) 0-10V
ANA OUT 1: IACT(A) 0-10V IACT(A) 0-10V IACT(A) 0-10V

ANA OUT 2: UACT(A) 0-10V UACT(A) 0-10V UACT(A) 0-10V
ANA OUT 3: NONE IACT (B) 0-10V IACT (B) 0-10V
ANA OUT 4: NONE UACT (B) 0-10V UACT (B) 0-10V
DIG IN 1: ON/OFF ON/OFF ON/OFF

DIG IN 2: START/STOP START/STOP A START/STOP
DIG IN 3: NONE NONE START/STOP A
DIG IN 4: NONE START/STOP B START/STOP B
DIG OUT 1: POWER ON POWER ON POWER ON

DIG OUT 2: ALARM ALARM ALARM
DIG OUT 3: NONE POWER ON NONE
DIG OUT 4: NONE ALARM NONE
In series and parallel mode, control signals for (A) are valid, control signals for (B) are deactivated.
Digital inputs: The function or the first of two functions (START/STOPP) active when current flows in the
input.
Page 59 (122) 77-107.0223 GB
Rev. H
NOTE! Use only normally open potential free operation as shown in the diagram below. Do not use a voltage
supply.
Digital outputs: When the function is true the output is high (+24 VDC)
If the pole reversal option is fitted, some of the inputs and outputs are allocated and configured differently for
the pole reverse option. The number of digital inputs and outputs for free use is limited. The number of free
inputs and outputs are substantially limited with option DUAL and DUAL-2 mode pole reverse.
The PCB is available in versions with ANA OUT 1 as older type control signal voltages to enable
compatibility with existing control systems.
6.5.2 Wiring example
PARALLEL and SERIES DUAL and DUAL-2

for control box and PC/PLC for 2 control boxes
DUAL and DUAL-2 for PC/PLC

Page 60 (122) 77-107.0223 GB
Rev. H

Max voltage between signal ground and rectifier output 50V.
Digital signals: Input current 15 mA@24VDC Optocoupler

Output current max 50mA@24VDC. Transistor output
must be protected against sparks and over voltages.
Analogue signals: Input signals 0-10V, internal impedance 200k, equals 0-100%
Output signals 0-10VDC, min load impedance 3.4k (max 3 mA, equals 0-100%
Special case if rectifier is equipped with card for 0-60mV or 0-1V on two analogue
outputs:
Output signal 0-10VDC, min load impedance >50K. (ANAOUT 1 and ANAOUT3)
Output signal 0-1V min load impedance >500K. (ANAOUT 1 and ANAOUT3)
Reference voltage: Max load 4mA@10,0VDC
+24VDC Max load each output and total PCB 200mA@24VDC

+24VDC floating potential relative to rectifier output.
The version fitted to a rectifier can be determined from the label on the inside of the plate through which the
signal cables pass.
6.6 Digital I/O A11

the control module.
Inputs and outputs are galvanically insulated. See chapter 6.6.3 Technical data
The rectifier’s current and voltage set points can also be controlled with increase/decrease contacts.
The following rectifier functions: ON/OFF, START/STOP, BLOCK/RUN or RESTART can be controlled via
(NO) contacts. Please observe that the circuit must contain a voltage source.
The rectifier has two customer programmable inputs and two outputs. They can be used to control pumps
and pole reversing utilities etc. thereby reducing the amount of I/O needed in the PLC.
The outputs function both in local and remote modes, inputs function only in remote mode.
Serial communication RS-485,see chapter 6.2, or serial communication RS-232, see chapter 6.3, must be
installed for customer programmable inputs and outputs.
Settings are made with the following parameters: DIG IN 1 to DIG IN 4, DIG OUT 1 to DIG OUT 4, in the
CFG/USER menu. See section 5.2.7.2 User menu for all alternatives.
Parameters that have not been configured for remote control are locally controlled from the keyboard.
Page 61 (122) 77-107.0223 GB
Rev. H
6.6.1 Connection
+24V is the supply from the board. This voltage is intended to drive digital inputs in the FlexKraft rectifier
using external zero potential switches, or for driving optocouplers in a PLC unit, for example, using zero
potential switches in FlexKraft, where no external supply is available for the signal.
PARALLEL, SERIES DUAL, DUAL-2
DIG IN 1: ON/OFF ON/OFF

DIG IN 2: START/STOP START/STOP
DIG IN 3: NONE START/STOP A
DIG IN 4: NONE START/STOP B
DIG OUT 1: POWER ON POWER ON

DIG OUT 2: ALARM ALARM
DIG OUT 3: NONE NONE
DIG OUT 4: NONE NONE
In series and parallel mode, control signals for (A) are valid, control signals for (B) are deactivated
Digital inputs: The function or the first of two functions (ON/OFF) active when current flows in the input.
Digital outputs: When the function is true the output is high, or in the case of relay control, the relay contact is
closed.
For terminals and PCB location, see chapter 6 Options/optional functions. Also see labels on the
backside of the control module for PCB placement and configuration at time of delivery.
If the pole reversal option is fitted, inputs and outputs are configured differently. The number of digital inputs
and outputs is limited, a number are reserved for pole reversal and in DUAL mode the number of free inputs
and outputs is limited.
Page 62 (122) 77-107.0223 GB
Rev. H
6.6.2 Wiring example

Input signals:
X2:3 and 4 supplied from external voltage supply.
X2:7 and 8 supplied from PCB internal voltage supply
Output signal:
X3:1 and 2 to PLC opto input supplied from external voltage supply.
X3:7 and 8 to PLC opto input supplied from PCB internal voltage supply.

Max insulation voltage 50V
Digital signals: Input current 15 mA@24VDC non polarized, recommended polarization shown in
diagram see chapter 0.
Output contacts: 24VAC 1 A; or 24VDC 1A L/R 48ms

Minimum contact load 100mA 12V for reliable operation.
If the load is inductive the relay contacts must be protected against sparks. This
is done by for example a RC snubber, or in the case of DC, a freewheel diode
across the load. Take care about diode polarity.
+24VDC Max load each output and total PCB 200mA@24VDC

+24VDC floating potential relative to rectifier output.
This voltage is intended to feed input signals coming from volt free contacts
6.7 Parallel duty I/O A13 Master/Slave

the control module.
Two or several rectifiers can be connected in parallel to achieve higher output current.
One rectifier is master. The master can be equipped with options. The slave(s) is not equipped with
LCD display/keyboard and can only be fitted with the option contactor.
Page 63 (122) 77-107.0223 GB
Rev. H
6.7.1 Connection
The parallel duty I/O PCBs in the master and the slave(s) shall be connected terminal equal.
MASTER SLAVE
MASTER SLAVE 1 SLAVE 2 SLAVE 3
For switches and placement of the PCB, see 6 Options/optional functions. For placement of PCB and signal
configuration on delivery, see labels at the rear of the control module.
Rectifiers must be grounded by connecting a cable between the rectifier chassis. Ground the control cables
at both ends.
6.8 Dosing function

Digital I/O A11, see chapter 6.6, or analogue/digital I/O A10 for analogue control box, see chapter 6.5, must
be installed for this option.
If the rectifier is ordered with the dosing function this option card will be pre-installed.
The rectifier can be fitted with a facility to control dosing equipment.

After a set number of Ampere hours (Ah) a contact closes.
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.
The number of Ah between dosages is set with the AUTODOS parameter. Setting range 0-30000 Ah.
The length of time for which the contact must be closed is set with the PULSLENG parameter. Setting range
0 to 999.9 seconds.
The contact(s) to be used is/are set with the DIG OUT 1 to DIG OUT 4 parameters.
These settings are made in the CFG/USER menu.
Page 64 (122) 77-107.0223 GB
Rev. H
Wiring configurations
SERIES mode Current out is the same for A and B.
A Sum of A+B is twice the Ah output of the rectifier.
IA
Setting Ah value Setting pulse time
AUTODOS. A PULSELENG.A
IA=B AUTODOS. B PULSELENG.B
-------------------------------------------------------
AUTODOS. PULSELENG.
NOTE! Twice the desired Ah output must
IB be specified for AUTODOS.
B
PARALLEL Current out is the same for A and B.
mode A Sum of A+B is twice the Ah output of the rectifier.
IA
IA+B AUTODOS. PULSELENG.
-----------------------------------------------------
AUTODOS. B PULSELENG.B
NOTE! Half the desired Ah output must
IB be specified for AUTODOS. A and AUTODOS. B.
B
DUAL mode
IA
A
IA
AUTODOS. B PULSELENG.B
AUTODOS. PULSELENG.
IB
IB
B
DUAL-2 mode See DUAL See DUAL
Se example in section 7.6.1 Dosing function.

6.9 Contactor
The rectifier can be fitted with a contactor that cuts off the power supply to the power modules. The contactor
is installed in the control module. The control system in the control module has a supply voltage, so that
communication and/or manual operation are possible, even with the contactor switched OFF.
6.10 External emergency stop

Rectifiers equipped with external emergency stops are also equipped with contactors.
The emergency stop circuit breaks the control voltage to the contactor/contactors
To enable the contactor/contactors to be operated, the external emergency circuit must be closed.
The mains power feed to the power modules is switched off when the contactor is released, and there is no
output voltage from the power modules.
The control module provides power to the control unit, which makes it possible to maintain serial
communication to the rectifier.
Page 65 (122) 77-107.0223 GB
Rev. H
6.10.1 Connection
The external emergency stop loop is connected between terminal X2:3 and terminal X2:4 on interface
PCB A12 located behind the cover plate for control signals at the rear of the control module. The
current in the loop varies depending on the number of power modules, see table below. Voltage 24
VDC.
Each rectifier’s emergency stop circuit must be isolated from those of other rectifiers. This also applies to
rectifiers in the same stack. (Applies to each control module).
Number of modules Current in loop, typical value.

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
The inrush current and cable length must be considered when selecting cable area. Preferably 1,5 or
2,5 mm2.
For terminals and PCB location,

see chapter 6 Options/optional
functions. Also see labels on the
backside of the control module
for PCB placement and
configuration at time of delivery
Example with rectifiers connected in parallel:

Page 66 (122) 77-107.0223 GB
Rev. H
6.10.2 Additional parts in the rectifier.

The conductor from A2:X1:4 to contactor coil is replaced by a conductor from A2:X1:4 to the PCB
A12:X1:3 and a conductor from PCB A12:X1:4 to the contactor coil.
When a rectifier is ordered with the external emergency stop option the components are pre-installed.
6.11 Remote FlexKraft panel

The controller in the external digital control box is the same as in the FlexKraft. The functionality of the
control box corresponds with the functionality of FlexKraft with some exceptions in the communication
section. The deactivated settings are still visible on the display, but they read “N/A” (Protocols etc).
A rectifier with remote FlexKraft panel cannot be controlled by RS485. The serial communication port
in FlexKraft is used by the remote FlexKraft panel. It is not possible to switch between remote control
via RS485 and the remote FlexKraft panel.
If the OUTPUTMODE is changed from a remote Flex Panel, the power to the rectifier must be
switched off before the change takes effect.
For functions in display, function and menus, see “Manual operation”.
A rectifier with external digital control box will be supplied without display and keyboard.
If the communication between the rectifier and the external digital control panel is interrupted, the
rectifier is switched off after 10 seconds.
NOTE! The program versions used by the rectifier and remote FlexKraft panel must be compatible. If
the rectifier and FlexKraft panel are supplied at the same time they will have compatible program
versions and the rectifier will be correctly equipped. For information on how to connect a remote
FlexKraft panel to a rectifier that was supplied earlier, or any other questions, please contact the
service department at KraftPowercon. Operation may differ slightly from the information given in this
manual.
Page 67 (122) 77-107.0223 GB
Rev. H
6.11.1 Connection
The external control box is connected to the control module in FlexKraft.
The serial communication cable shall be of a RS-485 approved type.
Conductor area for 24 V connections, minimum 0,5 mm2, at distances over 30m the conductor area
must be increased. Examples of cable types, see User guide 77-107.0222.
Terminal X1 is situated behind the rectangular plastic cover under the front panel. The terminal
accepts connecting area 0.5-2.5 mm2
Instructions for cable terminations
DIP-switches for configuring address and protocol are situated on control board A2 situated in the
control module. These switches are configured if the remote control box was delivered together with
the rectifier. See chapter 6.11.2 for DIP switch information.
6.11.2 Additional components in the rectifier

24 VDC is required to power the external control box and communicate with the rectifier. Circuit
boards A12 and A4are added to the rectifier. The rectifier must also be equipped with an A4 serial
communication board for RS485 and have a front panel without display or keypad.
If the rectifier and remote FlexKraft panel are supplied at the same time these components are pre-
installed.
Page 68 (122) 77-107.0223 GB
Rev. H
For terminals and PCB location, see 6 Options/optional functions. Also see labels on the backside
of the control module for PCB placement and configuration at time of delivery.
DIP switches S1 situated on control board A2 in the control module.

S0 (1) OFF
S1 (2) OFF
S2 (4) OFF
S3 (8) OFF
S4 (16) OFF
S5 (32) OFF
S6 (64) OFF
S7 (128) ON
NOTE! The program versions used by the rectifier and remote FlexKraft panel must be compatible.
6.12 Analogue control box

An analogue control box requires that the Analogue Digital I/O for analogue control box or PC/PLC
option is fitted, See chapter 6.5, Analogue digital I/O for analogue control box or PC/PLC.
The rectifier is controlled by an analogue voltage and actual values are presented by analogue voltage.
With one remote control box for parallel or series mode it should be connected to side A. If the rectifier is to
be run in DUAL mode , two remote control boxes are needed.
NB! The signals on side A differ from the signals on side B.
See also separate description for control boxes.
Control box for PARALLEL, SERIES Control box for DUAL side B.
and DUAL side A.
Page 69 (122) 77-107.0223 GB
Rev. H
6.12.1 Connection
The external control box is connected to the control module in FlexKraft. The cable shall be multi-
conductor with a common screen.
Conductor area, minimum 0.5 mm2, at distances over 30m the conductor area must be increased.
Parallel or Series mode

Connections remote control box - rectifier
DUAL mode
Connections remote control boxes - rectifier
NB! Control boxes delivered together with a rectifier are calibrated together with the rectifier and
therefore it is essential that the control box for side A is connected to analogue input for side A. The
control boxes are marked “A” and “B”.
(Rectifiers with an analogue control box may have an order specific connecting diagram. If this is the
case, please see separate documentation)
Page 70 (122) 77-107.0223 GB
Rev. H
Terminal X1 is situated behind the rectangular plastic cover under the front panel. The terminal
accepts connecting area 0.5-2.5 mm2
Control box for PARALLEL, SERIES Control box for DUAL side B.
and DUAL side A.
6.12.2 Additional components in rectifier

The rectifier must be fitted with an A10 analogue/digital circuit board to enable communication with the
analogue control box(es).
If the rectifier and control box(es) are supplied at the same time these components will be pre-
installed.
6.13 Control KRAFT analogue

ControlKraft requires that the Analogue Digital I/O for analogue control box option, see chapter 6.5,
Analogue digital I/O for analogue control box or PC/PLC, see chapter 6.13.2, are fitted.
Set values are adjusted and actual values are communicated digitally by the Control Kraft control
panel. The rectifier is controlled by analogue voltages and the actual values are communicated as
analogue voltages.
For a technical description of ControlKraft and its features, see separate technical description for
ControlKraft 77-107.0221.
Page 71 (122) 77-107.0223 GB
Rev. H
6.13.1 Connection
The ControlKraft is connected to the control module in FlexKraft. The cable shall be multi-conductor
with a common screen.
Conductor area, minimum 0,5 mm2, at distances over 30m the conductor area must be increased.
Terminals X1 and X2 are situated behind the rectangular plastic cover under the front panel. The
terminals accept conductor areas 0.5-2.5 mm2
Notches for cable terminations

Page 72 (122) 77-107.0223 GB
Rev. H
6.13.2 Additional components in the rectifier

An additional A10 analogue/digital circuit board must be fitted to the rectifier to provide ControlKraft
with power and enable communication. If the rectifier and control box are ordered at the same time
these components will bee pre-installed.
…………
6.13.3 Configuration of FlexKraft

The rectifier is configured and calibrated when delivered together with a Control KRAFT.
Configuration in the CFG/USER menu

ANA IN 1: ISET A 0-10V
ANA IN 2: USET A 0-10V
ANA IN 3: -NONE-
ANA IN 4: -NONE-
ANA OUT 1: IACT A 0-10V
ANA OUT 2: UACT A 0-10V
ANA OUT 3: -NONE-
ANA OUT 4: -NONE-
DIG IN 1: ON/OFF
DIG IN 2: BLOCK/RUN
DIG IN 3: -NONE-
DIG IN 4: -NONE-
DIG OUT 1: POWER ON
DIG OUT 2: ALARM
DIG OUT 3: -NONE-
DIG OUT 4: -NONE-
6.14 Air filter in power module

An air filter can be installed in the power module to filter incoming air. The air filter is washable.
1 Filter
Page 73 (122) 77-107.0223 GB
Rev. H
6.15 Fresh air coupling for power modules

The rectifier can be fitted with a fresh air coupling. Contact KraftPowercon Sweden AB.
6.16 Lifting eyes

The rectifier can be fitted with lifting eyes to make handling easier during installation. The lifting eyes are
attached to a threaded rod that runs through the rectifier to its base. The lifting eyes have a hole diameter of
25mm.
Lifting eyes on top Rod running from base through to lifting eye
Lifting should be carried out with a yoke to minimise compressive forces. See User manual 77-107.0222.
6.17 Option, order specific.

The rectifier may be equipped with an order specific option. If the rectifier is equipped with an order specific
option the technical description for the option is added to this technical description. The circuit drawing in this
document, see appendix 11.1 may be added or replaced.
Page 74 (122) 77-107.0223 GB
Rev. H
7 Examples, configurations and options

7.1 Normal configuration, without program control
The rectifier is switched on by pressing the “ON” key to put the rectifier in RUN mode. The rectifier
remembers the last current and voltage settings and automatically starts up in the same mode as when it
was last switched off. The rectifier can be set up to start when the mains voltage is switched on. The rectifier
can also be set up to start in REMOTE mode.
With TIMELIMIT or AHLIMIT, the rectifier can be blocked when the set limit is reached.
With TIMELIMIT or AHLIMIT the rectifier can also give a signal and the HOLD function can preserve an
adjustable current/voltage value. If both TIMELIMIT and AHLIMIT are set, the limit that is reached first
applies.
The three examples below assume current control and that the rectifier is ON and at STANDBY.
The rectifier must deliver current for three hours and then shut down.
Ström
Timelimit 3X60X60 = 10800s Tid
EOP
Settings: TIMELIMIT = 10800s (3hx60minx60s) in the SET menu

EOP.MODE=STOP in the CFG/USER menu
VOLTAGE set to max with “VOLTAGE ⇑“
CURRENT set with “Current ⇑“
Start with “ON”
The rectifier must deliver current for three hours and then give a HOLD level of 5%.
Ström
Timelimit 3X60x60s = 10800s Tid
EOP

EOP.MODE=HOLD in the CFG/USER menu
HOLD LEVEL=005% in the “CFG/SETUP” menu
Start with “ON”
Stop with “OFF”
Page 75 (122) 77-107.0223 GB
Rev. H
NOTE! The HOLD level affects both voltage and current set values. This can cause the
rectifier to switch to VOLTAGE mode with HOLD if the voltage set value is close to the bath
voltage.
The rectifier must deliver current for three hours and then give a sound signal and an external alarm, but
continue to deliver current without shutting down.
Ström
Timelimit 3X60min = 180min Tid
EOP

EOP.MODE=CONTINUE in the CFG/USER menu
Start with “ON”
Silence buzzer with “ESC”
Stop rectifier and silence external alarm with “OFF”.
The rectifier must have a start ramp of 1 minute (60 seconds) Current mode.
Ström
Startramp 60 sekunder Tid
Settings: START RAMP = 60s (1minx60s) in the SET menu

Start with “ON”
Stop with “OFF”
The start ramp is valid for both current and voltage SET values.
Page 76 (122) 77-107.0223 GB
Rev. H
7.2 Program control, PARALLEL or SERIES mode.

7.2.1 DC current, switching off
The rectifier supplies 100A DC current for 3 hours then switches off.
Current
1
2 4 Time
Timelimit 3 hours = 180min = 10800s
3 EOP
Settings in CFG/PROG menu:

Select program 1. 1 Voltage or current
Press Edit. 2 Time limit 3 hours = 10800s
3 Program end End Of Process
AH-LIMIT : -OFF-AH 4 Time
HOLD.CURRENT: 00000 A
PROG.STEP: 1
FUNCTION : STEP
VOLTAGELEVEL: 15.00 V Set to maximum voltage.
STEP TIME: 10800 S
PROG.STEP: 002
FUNCTION : XXXX Not relevant when STEP TIME=0
VOLT.LEVEL: XX.XX V Not relevant when STEP TIME=0
CURR.LEVEL: XXXXX A Not relevant when STEP TIME=0
STEP TIME: 000000 S Jumps over program steps when STEP TIME=0
PROG.STEP: 003-8
Settings in CFG/USER menu:

EOP MODE : STOP
Set program mode in SET menu.

Set program number in SET menu.
START RAMP :0000.5 S

PROGRAMMODE : YES
PROGRAM A NO : 01
Start rectifier by pressing ‘ON’
When program is complete, press ‘OFF’

To restart, press ‘ON’ again.
Page 77 (122) 77-107.0223 GB
Rev. H
7.2.2 DC current, time limit, HOLD.

The rectifier supplies 200A DC for 3 hours, then HOLDs the current at 25A. Must be switched off
manually.
Current
1
2 Step 01 3Hours = 180min = 10800s Time

4
3 EOP
Settings in CFG/PROG menu: 1 Voltage or current

Select program 1. 2 Time limit 3 hours = 180min
Press Edit. 3 Program end End Of Process
4 Time
AH-LIMIT : -OFF-AH
HOLD.VOLTAGE: 15.00 V Set to maximum.
HOLD.CURRENT: 00025 A Desired Hold current
PROG.STEP: 001
FUNCTION : STEP
STEP TIME: 10800 S
PROG.STEP: 002
STEP TIME: 000000 S Jumps over program steps
PROG.STEP: 003-8
VOLTAGELEVEL: XX.XX V Not relevant when STEP TIME=0
CURRENTLEVEL: XXXXX A Not relevant when STEP TIME=0

EOP MODE : HOLD


PROGRAMMODE : YES
PROGRAM A NO : 01

Page 78 (122) 77-107.0223 GB
Rev. H
7.2.3 DC current, time limit, BUZZER only

The rectifier supplies 200A DC current for 3 hours, then sounds a buzzer and triggers an external alarm,
but continues to supply current without switching off. Must be switched off manually.
Current
2 Step 01 3 Hours = 180min = 10800sec Time

4
3 EOP

Select program 1.
Press Edit. 1 Voltage or current
2 Time limit 3 hours = 180min
AH-LIMIT : -OFF-AH 3 Program end End Of Process
HOLD.VOLTAGE: 15.00 V Set to maximum. 4 Time
PROG.STEP: 001
FUNCTION : STEP
VOLTAGELEVEL: 15.00 V Set to maximum.
STEP TIME: 10800 S
PROG.STEP: 002
PROG.STEP: 003-8
STEP TIME: 000000 S Jumps over program steps when STEP TIME=0.

EOP MODE :CONTINUE
BUZZER : ON
DIG OUT X:PROCESS END X=Select output 1-4


PROGRAMMODE : YES
PROGRAM A NO : 01

Page 79 (122) 77-107.0223 GB
Rev. H
7.2.4 Ah limit, without HOLD

The rectifier provides constant current control.
The cycle starts with current ramping up from zero to 100A over 25 seconds, the output current is then
held at 100A for 2 minutes, after which it rises to 300A over a period of 5 minutes and then drops to 10A
until the cycle is complete after 30Ah have been supplied. A buzzer is sounded and an external alarm
triggered when the cycle is complete.
Current
1
T im e
Step 02 Step 03 Step 04
5
Step 01
2
3 Ahlimit
4 EOP

Select program 1.
Press Edit.
1 Current
AH-LIMIT :000030AH 2 Program steps 01–04
HOLD.VOLTAGE: 30.00 V 3 Ah limit 30 Ah
HOLD.CURRENT: 00010 A 4 Program end End Of Process
PROG.STEP: 001 5 Time
FUNCTION : I-RAMP
STEP TIME: 000025 S
PROG.STEP: 002
FUNCTION : STEP
STEP TIME: 000120 S
PROG.STEP: 003
FUNCTION : I-RAMP
STEP TIME: 000300 S
PROG.STEP: 004
FUNCTION : STEP
Page 80 (122) 77-107.0223 GB
Rev. H
STEP TIME: 030000 S Set time including margin
PROG.STEP: 005-8
STEP TIME: 000000 S Jumps over program steps when STEP TIME=0.
Settings in CFG/USR menu:

EOP MODE : OFF
BUZZER : ON
Settings in SET menu:

PROGRAMMODE : YES
PROGRAM A NO : 01
Start by pressing ‘ON’

7.2.5 Anodising, voltage control

Seven ramp steps with current control at start, followed by voltage control.
Start at 0V, with different ramps to 7V after 16 minutes. Ends at a level of 7V for 7 minutes.
Voltage
10 V
1
Time
Step Step Step Step Step Step Step Step 08
01 02 03 04 07
4
05 06
2
3 EOP
1 Voltage
Settings in CFG/PROG menu: 2 Program steps 01 to 08
Select program 1. 3 Program end End Of Process
Press Edit. 4 Time
AH-LIMIT : -OFF-AH
HOLD.VOLTAGE: 00.00 V Set to zero.
HOLD.CURRENT: 00000 A Set to zero.
PROG.STEP: 001
Page 81 (122) 77-107.0223 GB
Rev. H
FUNCTION : U-RAMP
CURRENTLEVEL: 00300 A Set to maximum nominal current.
STEP TIME: 00120 S
PROG.STEP: 002
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 003
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 004
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 005
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 006
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 007
FUNCTION : U-RAMP
STEP TIME: 000120 S
PROG.STEP: 008
FUNCTION : STEP
STEP TIME: 000420 S

EOP MODE : STOP
BUZZER : OFF


PROGRAMMODE : YES
PROGRAM A NO : 01

Page 82 (122) 77-107.0223 GB
Rev. H

7.2.6 Anodising, current control/voltage control

Current control, with four ramps to 350A over 9 minutes and with voltage limited to 10V, followed by
voltage control at 7V for 12 minutes with current limited to 500A.
6
Voltage Current
10 V 500A
1 3 Current mode 4 Voltage mode
Time
Step Step Step Step 04 Step 05
01 02 03 7
2
5 EOP
1 Voltage
Settings in CFG/PROG menu: 2 Program steps 01–05
Select program 1. 3 Current control
Press Edit. 4 Voltage control
AH-LIMIT : -OFF-AH 6 Current
HOLD.VOLTAGE: 00.00 V Set to zero. 7 Time
HOLD.CURRENT: 00000 A Set to zero.
PROG.STEP: 001
FUNCTION : I-RAMP
STEP TIME: 00120 S
PROG.STEP: 002
FUNCTION : I-RAMP
STEP TIME: 000120 S
PROG.STEP: 003
FUNCTION : I-RAMP
STEP TIME: 000120 S
Page 83 (122) 77-107.0223 GB
Rev. H
PROG.STEP: 004
FUNCTION : I-RAMP
STEP TIME: 000180 S
PROG.STEP: 005
FUNCTION : STEP
STEP TIME: 000720 S
PROG.STEP: 006
STEP TIME: 000000 S Program step is skipped when STEP TIME=0
PROG.STEP: 007
PROG.STEP: 008

EOP MODE : STOP
BUZZER : OFF

PROGRAMMODE : YES
PROGRAM A NO : 01

Page 84 (122) 77-107.0223 GB
Rev. H
7.3 Program control, DUAL mode.

7.3.1 With/without HOLD
Side A: Ramp to 200A over 5 minutes, maintain at 200A for 5 minutes, maintain at 300A for 8 minutes,
ramp down to 0A over 2 minutes.
Current
500A
1
Time
Step 01 Step 02 Step Step 4
03 04
2
3 EOP
1 Current
Settings in CFG/PROG menu: 2 Program steps 01–04
Press Edit. 4 Time
AH-LIMIT : -OFF-AH
HOLD.VOLTAGE: 00.00 V HOLD=0
HOLD.CURRENT: 00000 A HOLD=0
PROG.STEP: 001
FUNCTION : I-RAMP
VOLT.LEVEL: 15.00 V Set to maximum voltage.
CURR.LEVEL: 00200 A
STEP TIME: 000300 S
PROG.STEP: 002
FUNCTION : STEP
VOLT.LEVEL: 15.00 V
CURR.LEVEL: 00200 A
STEP TIME: 000300 S
PROG.STEP: 003
FUNCTION : STEP
VOLT.LEVEL: 15.00 V
CURR.LEVEL: 00300 A
STEP TIME: 000480 S
PROG.STEP: 004
FUNCTION : I-RAMP
VOLT.LEVEL: 15.00 V
CURR.LEVEL: 00000 A
STEP TIME: 000120 S
Page 85 (122) 77-107.0223 GB
Rev. H
PROG.STEP: 005-8
STEP TIME: 000000 S Program step is skipped when STEP TIME=0.
Side B: Ramp to 300A over 3 minutes, maintain at 300A for 7 minutes; maintain at 100A for 6 minutes,
HOLD at 50A.
Current
500A
3
5 HOLD Time
Step 01 Step 02 Step 03
6
2
4 Manual stop
3 EOP
Settings in CFG/PROG menu: 1 Current

Select program 2. 2 Program steps 01–03
Press Edit. 3 Program end End Of
Process
AH-LIMIT : -OFF-AH 4 Manual stop
HOLD.VOLTAGE: 15.00 V Set to maximal 5 HOLD level
PROG.STEP: 001
FUNCTION : I-RAMP
VOLTAGELEVEL: 15.00 V Set to maximum nominal voltage.
STEP TIME: 000180 S
PROG.STEP: 002
FUNCTION : STEP
STEP TIME: 000420 S
PROG.STEP: 003
FUNCTION : STEP
CURRENTLEVEL: 00100 A 0
STEP TIME: 000360 S
Page 86 (122) 77-107.0223 GB
Rev. H
PROG.STEP: 004-8

EOP MODE : STOP
BUZZER : OFF

PROGRAMMODE A : YES
PROGRAMMODE B : YES
PROGRAM A NO : 01
PROGRAM B NO : 02
Start rectifier by pressing ‘ON’ if both sides are to be started simultaneously.
Start using SET if each side is to be started separately in DUAL-2 MODE.
Or start using serial communication.

Page 87 (122) 77-107.0223 GB
Rev. H
7.4 Program mode, Polarity reversal

NOTE! Polarity reversal option is required
7.4.1 Hard-chroming, polarity rev., HOLD, ext. alarm, PARALLEL/SERIES mode
Start ramp over 10 minutes to 400A, maintain at 400A for 10 minutes, zero ramp down to 0A, ramp
down over 10 minutes to -500A, maintain for 10 minutes at -500A, ramp up over 5 minutes to -300A,
maintain for 40 minutes. After program end HOLD at -100A with external alarm to operator.
Current
500
1
4 Manual stop
Tim
Step 01 Step 02 Step 04 Step 05 Step Step 07
6
06
2 HOLD
Step 03 5
-500
3
EOP
1 Current
2 Program steps 01–07
Settings in CFG/PROG menu: 3 Program end End Of Process
Select program 1. 4 Manual stop
Press Edit. 5 HOLD level
6 Time
AH-LIMIT : -OFF-AH
HOLD.VOLTAGE:-15.00 V Set to maximum negative voltage.
HOLD.CURRENT:-00100 A Desired Hold current.
PROG.STEP: 001
FUNCTION : I-RAMP
STEP TIME: 000600 S
PROG.STEP: 002
FUNCTION : STEP
STEP TIME: 000600 S
PROG.STEP: 003
FUNCTION : I-RAMP
STEP TIME: 000001 S
PROG.STEP: 004
Page 88 (122) 77-107.0223 GB
Rev. H
FUNCTION : I-RAMP
VOLTAGELEVEL:-15.00 V
CURRENTLEVEL:-00500 A
STEP TIME: 000600 S
PROG.STEP: 005
FUNCTION : STEP
STEP TIME: 000600 S
PROG.STEP: 006
FUNCTION : I-RAMP
STEP TIME: 000300 S
PROG.STEP: 007
FUNCTION : STEP
STEP TIME: 002400 S
PROG.STEP: 008

EOP MODE : HOLD
BUZZER : OFF
POL.REV.: YES

PROGRAMMODE : YES
PROGRAM A NO : 01

Page 89 (122) 77-107.0223 GB
Rev. H
7.4.2 DUAL mode, with/without HOLD

Dual mode
Side A: Ramp to 200A over 5 minutes, maintain at 200A for 5 minutes, maintain at 300A for 8 minutes,
ramp down to 0A over 2 minutes.
Current
500A
1
Step 01 Step 02 Step Step

4 Time
03 04
2
3 EOP

1 Current
Select program 1.
2 Program steps 01–04
Press Edit.
HOLD.VOLTAGE: 00.00 V No HOLD
HOLD.CURRENT: 00000 A No HOLD
PROG.STEP: 001
FUNCTION : I-RAMP
VOLTAGELEVEL: 15.00 V Set to maximum nominal voltage.
STEP TIME: 000300 S
PROG.STEP: 002
FUNCTION : STEP
STEP TIME: 000300 S
PROG.STEP: 003
FUNCTION : STEP
STEP TIME: 000480 S
Page 90 (122) 77-107.0223 GB
Rev. H
PROG.STEP: 004
FUNCTION : I-RAMP
STEP TIME: 000120 S
PROG.STEP: 005-8
Side B: Ramp up to 300A over 3 minutes, reverse polarity pulsing at 300A/1 minute; -200A/30 seconds
for 10 full pulse cycles ending with a positive pulse, maintain at 100A for 6 minutes, HOLD at 50A. The
pulse function requires complete cycles. Ending halfway through a cycle requires a separate program
step before or after the pulse step.
Current
500A
1
Time
Step 01 Step 5 HOLD
04 6
2
4 Manual stop
Step 03
Step
02
3 EOP
Settings in CFG/PROG menu: 1 Current

Select program 2. 2 Program steps 01–04
Press Edit. 3 Program end End Of Process
4 Manual stop
AH-LIMIT : -OFF-AH
5 HOLD level
HOLD.VOLTAGE: 15.00 V Set to maximum
6 Time
PROG.STEP: 001
FUNCTION : I-RAMP
STEP TIME: 000180 S
Page 91 (122) 77-107.0223 GB
Rev. H
PROG.STEP: 002
FUNCTION : STEP
STEP TIME: 000060 S
PROG.STEP: 003
FUNCTION : PULSE
VOLT.LEVEL1: -15.00 V Set to maximum voltage
VOLT.LEVEL2: 15.00 V Set to maximum voltage
CURR.LEVEL1: -0200 A
CURR.LEVEL2: 0300 A
TIME 1: 00030 S
TIME 2: 00060 S
STEP TIME: 000900 S Enter time or number of cycles
CYCLES: 00010
PROG.STEP: 004
FUNCTION : STEP
STEP TIME: 00360 S
PROG.STEP: 005-8

EOP MODE : HOLD
BUZZER : OFF
POL.REV.: YES

PROGRAMMODE A : YES
PROGRAMMODE B : YES
PROGRAM A NO : 01
PROGRAM B NO : 02
Start using SET if each side is to be started separately in DUAL-2 MODE
When program is complete, press ‘OFF’.

Page 92 (122) 77-107.0223 GB
Rev. H
7.4.3 Polarity reversal with start ramp

Ramp till full pulse current over 10 minutes, reverse polarity pulsing at 300A/30 seconds -150A/30
seconds, pulsed for 30 minutes including start ramp, HOLD +50A.
Current
500A
1
Time
5 HOLD
6
4 Manual stop
2 Step 01
3 EOP
1 Current
Settings in CFG/PROG menu: 2 Program step 01
Press Edit. 4 Manual stop
5 HOLD level
HOLD.VOLTAGE: 15.00 V Set to maximum
PROG.STEP: 001
FUNCTION : PULSE
VOLT.LEVEL1: -15.00 V Set to maximum negative voltage
VOLT.LEVEL2: 15.00 V Set to maximum voltage
CURR.LEVEL2: 0300 A
TIME 1: 00030 S
TIME 2: 00030 S
STEP TIME: 001800 S Enter time or number of cycles
CYCLES: 00030
PROG.STEP: 002-8
FUNCTION XXXX Not relevant when STEP TIME=0

EOP MODE : HOLD
BUZZER : OFF
POL.REV.: YES
Set start ramp in SET menu.

Page 93 (122) 77-107.0223 GB
Rev. H

PROGRAMMODE : YES
PROGRAM A NO : 02
NOTE! Start ramp time affects both sides in DUAL mode. Overwrites program setting.
Start using SET if each side is to be started separately in DUAL-2 MODE.
When program is complete, press ‘OFF’.

7.5 Program mode, Repeat function

7.5.1 Polarity reversal with start ramp and repeat
Ramp till full pulse current over 10 minutes, reverse polarity pulsing at 300A/30 seconds -150A/30
seconds, continuous pulsing.
Current
500A
1
Time
6
Repeat
2 Step 01 5 Step 01
4 Manual stop
Current
2 Program step 01
3 Start ramp
4 Manual stop
5 Repeat step 1
6 Time
Page 94 (122) 77-107.0223 GB
Rev. H
Current
500A
1
Time
6
2 Step 01
4 Manual stop
1 Current
Settings in CFG/PROG menu: 2 Program step 01
Select program. 3 Start ramp
Press Edit. 4 Manual stop
5 ---
PROG.STEP: 001
FUNCTION : PULSE
VOLT.LEVEL1: -15.00 V Set to maximum nominal voltage
VOLT.LEVEL2: 15.00 V Set to maximum nominal voltage
CURR.LEVEL2: 0300 A
TIME 1: 00030 S
TIME 2: 00030 S
STEP TIME: 007200 S Enter time or number of cycles.
CYCLES: 000120 Time has no practical significance for program, but
it can be useful to give an idea of program time
where program steps are of long duration.
PROG.STEP: 002
FUNCTION : REPEAT

EOP MODE : STOP Not relevant when program is repeated and no time limit
or Ah limits are set.
BUZZER : OFF
POL.REV.: YES
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Set start ramp in SET menu.

PROGRAMMODE : YES
PROGRAM A NO : 01
NOTE! Start ramp time is only significant at start, not in first program step.
Start rectifier by pressing ‘ON’, or start using serial communication.
To stop program, press ‘OFF’.

7.6 Option
7.6.1 Dosing function
The dosing function requires that the digital I/O A or analogue/digital PCB is fitted to the rectifier. See section
6.8 Dosing function.
The rectifier (in PARALLEL mode) must give a pulse of 30 seconds duration every 10,000 Ah on DIG OUT 4
Contact
closure
Closing time Time

10 000 Ah
Settings: All settings in menu CFG/USER (protected by password)

DIG OUT 4 = AUTODOSING
PULSELENGTH=030.0s
AUTODOSING=10000AH
End with “OK”
VOLTAGE set with “VOLTAGE ⇑“
Start with “ON”
Stop with “OFF”
The rectifier (in PARALLEL mode) must give a pulse of 30 seconds duration every 10,000 Ah on DIG OUT 4
and a pulse of 60 seconds on DIG OUT 3.

DIG OUT 4 = AUTODOS.
DIG OUT 3 = AUTODOS. A
PULSELENG=030.0s
PULSELENG.A=060.0s
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AUTODOS.=10000AH
AUTODOS. A=5000AH (approx. half current per rectifier side)
End with “OK”
VOLTAGE set to max with "Voltage ⇑"
CURRENT set with "Current ⇑"
Start with "ON"
Stop with "OFF
The rectifier (in SERIES mode) must give a pulse of 30 seconds duration every 10,000 Ah on DIG OUT 4, a
pulse of 60 seconds on DIG OUT 3, and a closed switching action on DIG OUT2 every 2000Ah.

DIG OUT 4 = AUTODOS.
DIG OUT 3 = AUTODOS. A
PULSELENG=030.0s
PULSELENG.A=060.0s
AUTODOS.=10000AH
AUTODOS. A=5000AH (approx. half current per rectifier side)
End with “OK”
VOLTAGE set to max with "Voltage ⇑"
CURRENT set with "Current ⇑"
Start with "ON"
Stop with "OFF
7.6.2 Remote control

The rectifier can be remote-controlled via serial communication or analogue signals.
Serial communication:
Remote control of one rectifier from a PC or other computer device via RS-232
Remote control of one or several rectifier from a PC, PLC or other computer device via RS-485 PROFIBUS
DP or RS-485 MODBUS RTU
See the programming part of this manual for information regarding commands and procedures.
Analogue signals:
Control of one rectifier with voltage 0-10 VDC, 0-5VDC, 6-0VDC, 10-0VDC, current loop 0-20 mA, 4-20 mA
or zero potential switching (pushbuttons or relay output from PLC).
The rectifier must be put in REMOTE mode to enable remote control.

In remote mode the analogue remote control, if configured, has priority over set values via serial
communication. It is not essential for all set values to be controlled by analogue or serial communication;
some set values can be controlled by analogue inputs and some by serial communication.
7.6.2.1 Serial communication

When controlling via serial communication, the optional Control via RS-232, see chapter 6.3, must be fitted
for RS232, or option Control via RS 485, see chapter 6.2, must be fitted for RS485 (Modbus or Profibus)
Reconfiguration can be made in menu CFG/USR, see chapter 5.2.9.2, where the function options also are
listed.
NB all functions not available on all options, see chapter for respectively option
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Example:
Serial communication from PROFIBUS DP be set
-Access menu CFG/USR
-Browse with ↑ ↓ keys until PROTOCOL is marked
-Browse with ← → keys until PROFIBUS DP is visible on the display
-Set ADDRESS, BAUDRATE (normally auto) and, if needed, BYTESWAP
-Press the OK key.
-Go to the SET menu, see section 5.2.7.
-Browse with ↑ ↓ keys until REMOTE CONTROL is marked
-Browse with ← → keys until YES is visible on the display
-Press the OK key
7.6.2.2 Analogue control

When controlling set values with analogue signals, option Analogue I/O, see chapter 6.4, or Analogue digital
I/O, see chapter 6.5, must be fitted.
In and outputs must be configured for the desired function to the desired terminal.
If analogue control is delivered in the rectifier, the inputs and outputs are configured according to option
standard or order. For standard configuration see chapter reference above.
Reconfiguration can be made in menu CFG/USR, see chapter 5.2.9.2, where the function options also are
listed.
NB all functions are not available on all options, see relevant chapter for respective options.
Example:
Analogue input 1 to be change from ISET (A) 0-10VDC to USET (B) 0-10VDC
-Access menu CFG/USER, see section 5.2.9.2
-Browse with ↑ ↓ keys until ANA IN 1 is marked
-Browse with ← → keys until USET (B) 0-10V is visible on the display
-Press the OK key.
-To activate the analogue input, REMOTE CONTROL must be set to YES
-Set REMOTE CONTROL to YES
-Press the OK key
Se chapter 6 Options/optional functions for more information on signals and configuration.
7.6.2.3 Digital I/O

When using digital I/O, option Digital I/O, see chapter 6.6, or option Analogue digital I/O, see chapter 6.5,
must be fitted.
In and outputs must be configured for the desired function to the desired terminal.
If digital I/O is delivered in the rectifier, the inputs and outputs are configured according to option standard or
order. For standard configuration see chapter reference above.
Reconfiguration can be made in menu CFG/USR, see chapter 5.2.9.2 User menu, where the function options
also are listed.
Example:
Digital output 4 to be changed from NONE to AUX OUT A
-Access menu CFG/USR
-Browse with ↑ ↓ keys until DIG OUT 4 is marked
-Browse with ← → keys until AUX OUT A is visible on the display
-Press the OK key.
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To activate the analogue input, REMOTE CONTROL must be set to YES

-Set REMOTE CONTROL to YES
-Press the OK key
The output DIG OUT 4 has now been changed from NONE (No function) to be customer output AUX OUT A.
Digital I/O A11: input signals to X2:3 and 4 is supplied from an external voltage supply. Signals to X2:7 and 8
are supplied from the circuit board’s internal voltage supply.
Output signals from X3:1 and 2 to the PLC opto input are supplied from an external voltage supply. Output
signals from X3:7 and 8 to the PLC opto input are supplied from the circuit board’s internal voltage supply.
Se section 6 Options/optional functions for more information on signals and configuration.
7.6.2.4 Remote and local control

When using this possibility, depending on what parameters are to be controlled remotely, option Digital I/O,
Analogue digital I/O, or Analogue I/O must be fitted. See chapter 6 Options/optional functions.
Functions that have not been configured for remote control are locally controlled from the keyboard,
parameter PROTOCOL must be set to NONE.
NB! Local control is not possible when the rectifier is controlled from serial communication.
Example: Set values to be controlled local from keyboard, START/STOP to be controlled from remote.
Option Digital I/O or Analogue digital I/O must be fitted to the rectifier.
Rectifier in PARALLEL or SERIES mode
-Access menu CFG/USER

-Browse with ↑ ↓ keys until DIG IN 2 is marked
-Browse with ← → keys until START/STOP is visible on the display
-Press the OK key.
-Browse with ↑ ↓ keys until PROTOCOL is marked
-Browse with ← → keys until -NONE- is visible on the display
-Press the OK key.
-Access menu SET, see section 5.2.5.

-Browse with ↑ ↓ keys until REMOTE CONTROL is marked
-Browse with ← → keys until YES is visible on the display
-Press the OK key.
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8 Servicing and maintenance
WARNING! Always isolate the rectifier from the supply before working on it.
8.1 Preventive maintenance

WARNING! Maintenance work on the rectifier must only be done by authorised
personnel.
The maintenance intervals depend on the amount of fouling, moisture, etc. the rectifier is exposed to. The
following maintenance must be done yearly:
• Clean heat sink with compressed air

• Check fans for correct operation and any undue noise. Replace if necessary.
• Check/cleaning of the contact surfaces of the output busbars.
• Check that bolts are tight
• Clean any filters that are fitted
8.2 Troubleshooting instructions

WARNING! Troubleshooting must only be done by authorised personnel.
WARNING! Mains voltage is present behind the control PCB of the power module .
WARNING! If the front is dismantled and the power module front is exposed, take
care not to come close to the blades of the fan. Mind your fingers..
If a fault has occurred in the rectifier, it can often be traced on the basis of the fault symptoms to a particular
main unit, sub-unit or component, which can then be replaced or repaired.
Check which alarm is set - control module

- power module
The POWER GOOD LED on the power module that has sent the alarm is OFF. The LED does not turn on
before the rectifier has been restarted, even if the reason for the alarm has disappeared and the rectifier is
functioning normally.
Check if the POWER GOOD LED on the power module is lit after restart.
Tip:
If the mains loses a phase, the rectifier works on low load, with increasing load, the rectifier sends a
regulation error and turns off all LEDs on the power modules.
If the rectifier is equipped with air filters on the power modules and the rectifier is sending high temperature
alarm from the power modules, it can be an indication that the filter needs to be replaced or washed
Page 100 (122) 77-107.0223 GB
Rev. H
If the fault cannot be traced to a particular component, the quickest way is usually to divide the rectifier into
main parts and start by checking the main part closest to the supply network, then work through the rectifier,
finishing with the main part closest to the load. For assistance with troubleshooting, contact KraftPowercon
Sweden AB’s service department.
WARNING! Before cables or connectors are disconnected during troubleshooting, the

rectifier must first be isolated from the supply.
8.3 Replacement of components

WARNING! Before components are replaced, the rectifier must be isolated from the
supply.
The rectifier does not have primary fuses on the incoming supply.
After changing a component, check that all connections are correct and that the component is securely fixed.
8.3.1 If several rectifiers are placed close together

It will not be possible to slide the front panel to the left in some cases. In this case use the alternative
procedure for removing the front.
The standard procedure for removing the front panel is as follows:
• Undo (about one turn) the four screws that hold the front panel, slide the panel to the left and lift off
the front panel. If rectifiers are stacked close together:
The alternative procedure for removing the front panel is as follows:
• Remove the screws from the left side (use a screwdriver with magnet to avoid losing the screws).
and undo the screws on the right a few turns so that the front panel can be lifted out and slid to the
left (10-15mm), lift off the front panel, taking care not to damage the light guide.
8.3.2 Changing the filter

• Isolate the rectifier from the supply.
• Undo (about one turn) the four screws that hold the front panel, slide the panel to the left and lift off
the front panel. Take care not to damage the light guide.
• Remove the old filter. Take care with the light guide.
• Install a new or cleaned filter and install the light guide in the hole.
• Refit the front panel and the light guide to the indicator on the front panel.
• Check that there is nothing in the fan that can prevent rotation, the fan is powerful. Mind your fingers.
2
1 Light guide
3 2 Screws, 2pc
3 Screws, 2pc
4 Filter
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8.3.3 Replacing of the fan in the power module

• Undo (about one turn) the four screws that hold the front panel, slide the panel to the left (10-15mm)
and lift off the front panel. Take care not to damage the light guide.
• Disconnect the terminal to the left on the control PCB on the left side inside the power module.
• Unscrew the two screws on the fan.
• Remove the fan.
• Fit a new fan.
• Connect the terminal on the PCB
• Refit the front panel, fit in the light conductor for indicating on the front plate.
1 Fan cable terminal

2 Screws, 2 or 4
8.3.4 Replacing the power module

• Release the 2-(3) ribbon cables to the left of the power module (5), disconnect the ribbon cables
from the power module above and below for easier access.
• Disconnect the power connection on the right (three wires).
NB! Pull in the plastic house NOT in the cable. The terminal is equipped with lock function NB!
• Disconnect the protective earth conductor
• Disconnect the DC connection to the busbars at the back.
• Unscrew four screws on the back that secure the power module.
• Pull out the power module forwards.
• Re-install in the reverse order.
If the rectifier is equipped wth more than 5 power modules. The narrow ribbon cable may not be
connected to more tha 5 power modules. If more than 5 power modules are fitted, there are two
narrow ribbon cables. One is connected to power module 1-5 and the other to power module 6-x.
Remember to refit the protective earth conductor and the light guide to the indicator on the front of
the power module.
5
2 1 Screws in the busbars
2 Screws in rear panel, 4pc
3 Screws in the front, 4pc
4 Power cable connection
5. Control cable connection
4
3
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Rev. H
8.3.5 Replacing a fuse in the control unit supply

Remove the cover / expose the control module for access from above.

• Unscrew the two screws on the rear of the cover.
• Pull the cover backwards (about 15mm) and lift it off.
• Replace the fuses (two or three). They are 10.3x38.1 mm 20A fuses with high breaking capacity,
Bussman KLK20 or equal..
• Refit the cover.
1
1 Screws in the top, 2pc
2 Fuses
If the control module is fitted in a position other than on top in the rectifier, dismantle the power modules
above the control module.
Alternative when the rectifier is fitted with two control modules (8-10 (6-10) power modules) or the control
module is assembled in a pile.
• Unscrew the four screws that secure the front panel (the lower of two) and lift off the front panel.
• Release the ribbon cable to display and keyboard (if fitted).
• Unscrew the screws that secure protection for the power cables on the right .
• Replace the fuses (two or three). They are 10.3x38.1 mm 20A fuses with high breaking capacity,
Bussman KLK20 or equal..
• Re-install in the reverse order.
8.3.6 Replacing a fuse in the power module

• Take off the safety guard over the fuses, located on the right-hand side.
• Replace the fuses. They are 10.3x38.1 mm 20A fuses with high breaking capacity, Bussman KLK20
or equal.
• Refit the safety guard.
• Refit the front panel and the light guide to the indicator on the front panel.
4 1 Screws in the front, 4pc

2 Screws in the protection, 4pc
3 Safety guard
3 4 Fuses
1
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8.4 Calibration instructions
WARNING! Calibration must only be done by authorised personnel.
Calibration of the rectifier should be done on a regular basis, how often depends on the type of operation. A
recommendation is once a year.
The rectifier has a built-in calibration table. See the menu CFG/CAL above.
When calibrating, external calibrated current and voltage measuring devices with sufficient accuracy for the
process are connected.
Calibration may be necessary if components that influence regulation have been replaced.
If the rectifier outputs are reduced in relation to the rated capacity, the calibration routine takes this into
account.
Side reference outputs Side

B A
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9 Programming
9.1 General
FlexKraft rectifiers are designed to be controlled via a serial data bus.
Protocols: Data bus

- Profibus DP (compatible) RS 485
- Modbus RTU RS 485 alternative RS232
In the case of an address it is factory set as default to 2.
9.1.1 Remote control

Before the rectifier can be remotely controlled it must be set to REMOTE Mode.
All parameters can be read even if the rectifier is in LOCAL Mode and is being controlled manually.
The ‘POWERONMODE’ parameter in the CFG/USER submenu is set to REMOTE if the rectifier must always
start in remote control mode when switched on.
To control remotely via

PROFIBUS DP, set PROTOCOL in CFG/USER to PROFIBUS DP
MODBUS RTU, set PROTOCOL in CFG/USER to MODBUS RTU
Analogue signals, set PROTOCOL in CFG/USER to -NONE-
When remote control is used via a serial connection and a parameter is also configured for analogue control
via ANAIN or DIG IN, the analogue signals have priority over serial communication.
Signal priority: Lowest = Keypad / serial communication / Highest = analogue signals.
When the rectifier is remotely controlled using serial communication, no parameters can be changed locally
on the keypad.
9.1.2 RS-232
It is important to use a cable that is intended for communication by RS-485 (twisted pair, screened).
If the wiring is not correctly installed, the serial communication may stop working.
Transmission errors are detected and dealt with by the software.
For the rectifier to be able to communicate, it must be configured in the CFG/USER submenu.
The protocol must be chosen. Depending on the type of PLC, the BYTESWAP function may have to be
activated. Each register contains 16 bits, which are divided into two, eight-bit parts when the content is sent
over the serial link. The order of these eight-bit parts can be changed with the BYTESWAP function.
Only one rectifier can be controlled via the RS-232 bus.
9.1.3 RS-485
It is important to use a cable that is intended for communication by RS-485 (twisted pair, screened).
For Profibus, approved Profibus cable must be used. The Profibus cable must be terminated at both ends.
If the wiring is not correctly installed, the serial communication may stop working.
Transmission errors are detected and dealt with by the software.
For the rectifier to be able to communicate, it must be configured in the CFG/USER submenu.
The protocol must be chosen and the rectifier must be given an address. Depending on the type of PLC, the
BYTESWAP function may have to be activated.
Each register contains 16 bits, which are divided into two, eight-bit parts when the content is sent over the
serial link. The order of these eight-bit parts can be changed with the BYTESWAP function.
Several rectifiers can be controlled via the RS-485 bus.

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Rev. H
9.1.4 Westermo MA-45 RS232/RS485 converter
Wiring diagram
9pin Dsub 25pin 5pin A4:X2

COM1 Dsub Connector
A
Personal
Computer WESTERMO MA-45 Rectifier FlexKraft
Dipswitches, Westermo MA-45:

S1: 230 or 115 VAC
1 2 3 4 5 6 7 8
S2: Baud rate 9600 bps: On On Off Off On On Off Off
S2: Baud rate 38400 bps: On Off On Off On On Off Off
S3: Terminated: Off Off On On
Several rectifiers connected in chain, 4 shown, maximum 32 pc.
9.2 Profibus DP
Technical data: serial interface
Interface: RS-485
Baud rate: max 12Mbps, auto-detect
Maximum number of nodes on the bus: 32 (1 controller and 31 rectifiers)
Control
No special configuration of the parameter settings is needed.
The settings are stored in the GSD file krft094b.gsd.
The file is obtained from KraftPowercon Sweden AB.
The rectifier is controlled with Profibus data exchange telegrams.

The data content of a telegram is described in 9.2.1 Overview of registers
Internet links: For further information about the Profibus protocol, use the following links.
http://www.profibus.com http://www.sea.siemens.com/
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9.2.1 Overview of registers

GSD-File krft094b.gsd
SubModule Std
Cfg 0x5f 0x51 0x68
Output Mode: Series or Parallel
PLC Use
Reg.No R/W Name Type MultiplierDescription Default Range
0 R/W PageNo Unsigned 16bit Reserved 0 0
Controls On/Off,
1 R/W Controlregister Unsigned 16bit Start/Stop etc. See below 0 0 - 65535
2 R/W Set Voltage Signed 16bit *0,01V Set Voltage 0 0 - (Rated Voltage*100)
3 R/W Set Current Signed 16bit *1A/*0.1A Set Current 0 0 - Rated Current (2)
Process Timer Pre-set for process timer.
4 R/W Limit High Word Unsigned 16bit *65535 s High Word 0 0 - 999999
5 R/W Limit Low Word Unsigned 16bit *1 s Low Word 0
Pre-set for Ah-Counter.
6 R/W Ah-Limit High Word Unsigned 16bit *65536Ah High Word 0 0 - 999999
Pre-set for Ah-Counter.
7 R/W Ah-Limit Low Word Unsigned 16bit *1Ah Low Word 0
Initial start ramp after
8 R/W Startramp Unsigned 16bit *0.1 s activation of start bit 0 0-30000
Bit register, Indicates
9 R StatusRegister Unsigned 16bit status of unit. See below 0 0 - 65535
10 R WarningsRegister Unsigned 16bit warnings. See below 0 0 - 65535
11 R AlarmsRegister Unsigned 16bit alarms. See below 0 0 - 65535
12 R Output Voltage Signed 16bit *0,01V Output Voltage 0 -30000 - 30000
13 R Output Current Signed 16bit *1A/*0.1A Output Current 0 -30000 – 30000 (1)
Number of seconds
elapsed since Reset of
Process Time High Process Timer. High
14 R Word Unsigned 16bit *65536 s Word 0 0 - 999999
Number of seconds
Process Time Low Process Timer. Low
15 R Word Unsigned 16bit *1 s Word 0
Number of Ah since
Reset of Ah-Counter.
16 R Ah High Word Unsigned 16bit *65536 Ah High Word 0 0 - 999999
Number of Ah since
17 R Ah Low Word Unsigned 16bit *1Ah Low Word 0
Registers 1-8 are set values
Registers 9-17 are actual values
SubModule Std dual
Cfg 0x5f 0x59 0x6c
Output Mode: Dual
PLC Use
Reg.No R/W Name Type Multiplier Description Default
0 R/W PageNo Unsigned 16bit Reserved 0 0
Controls On/Off,
1 R/W Controlregister Unsigned 16bit Start/Stop etc. See below 0 0 - 65535
2 R/W Set Voltage A Signed 16bit *0,01V Set Voltage A-Side 0 0 - (Rated Voltage*100)
3 R/W Set Current A Signed 16bit *1A/*0.1A Set Current A-Side 0 0 - Rated Current (2)
4 R/W Set Voltage B Signed 16bit *0,01V Set Voltage B-Side 0 0 - (Rated Voltage*100)
5 R/W Set Current B Signed 16bit *1A/*0.1A Set Current B-Side 0 0 - Rated Current (2)
6 R/W Limit High Word Unsigned 16bit *65535 s High Word 0 0 - 999999
7 R/W Limit Low Word Unsigned 16bit *1 s Low Word 0
Ah-Limit A High Pre-set for Ah-Counter A-
8 R/W Word Unsigned 16bit *65536Ah Side. High Word 0 0 - 999999
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Rev. H
SubModule Std dual
Cfg 0x5f 0x59 0x6c
Output Mode: Dual
PLC Use
Reg.No R/W Name Type Multiplier Description Default
Ah-Limit A Low Pre-set for Ah-Counter A-
9 R/W Word Unsigned 16bit *1Ah Side. Low Word 0
Ah-Limit B High Pre-set for Ah-Counter B-
10 R/W Word Unsigned 16bit *65536Ah Side. High Word 0 0 - 999999
Ah-Limit B Low Pre-set for Ah-Counter B-
11 R/W Word Unsigned 16bit *1Ah Side. Low Word 0
Initial start ramp after
12 R/W Startramp Unsigned 16bit *0.1 s activation of start bit 0 0-30000
13 R StatusRegister Unsigned 16bit status of unit. See below 0 - 65535
14 R WarningsRegister Unsigned 16bit warnings. See below 0 - 65535
15 R AlarmsRegister Unsigned 16bit alarms. See below 0 - 65535
16 R Output Voltage A Signed 16bit *0,01V Output Voltage A-Side -30000 - 30000
17 R Output Current A Signed 16bit *1A/*0.1A Output Current A-Side -30000 – 30000 (1)
18 R Output Voltage B Signed 16bit *0,01V Output Voltage B-Side -30000 - 30000
19 R Output Current B Signed 16bit *1A/*0.1A Output Current B-Side -30000 – 30000 (1)
Number of seconds
Process Time High Process Timer. High
20 R Word Unsigned 16bit *65536 s Word 0 - 999999
Number of seconds
Process Time Low Process Timer. Low
21 R Word Unsigned 16bit *1 s Word
Number of Ah for A-side
*65536 since Reset of Ah-
22 R Ah High Word A Unsigned 16bit Ah Counter. High Word 0 - 999999
Number of Ah for A-side
since Reset of Ah-
23 R Ah Low Word A Unsigned 16bit *1Ah Counter. Low Word
Number of Ah for B-side
*65536 since Reset of Ah-
24 R Ah High Word B Unsigned 16bit Ah Counter. High Word 0 - 999999
Number of Ah for B-side
since Reset of Ah-
25 R Ah Low Word B Unsigned 16bit *1Ah Counter. Low Word
Registers 1-12 are set values
Registers 13-25 are actual values
Bit registers: Controlregister
R/W Register 1 0 Function
R/W Controlregister bit00 On Off Turn rectifier on or off
R/W Controlregister bit01 Start A Stop A Start or stop process for A-side
R/W Controlregister bit02 Block A Run A Pause process for A-side
R/W Controlregister bit03 Run prog A Program Run A-side
Reverse Current
R/W Controlregister bit04 A Side Pole reverse A-side
Reverse Current
R/W Controlregister bit05 B Side Pole reverse B-side
R/W Controlregister bit06
R/W Controlregister bit07 Start B Stop B Start or stop process for B-side
R/W Controlregister bit08 Clear Ah A Clear Ah counter A-side
R/W Controlregister bit09 Clear Ah B Clear Ah counter B side
R/W Controlregister bit10 Clear Timer Clear process timer
R/W Controlregister bit11
R/W Controlregister bit12 Block B Run B Pause process for B-side
R/W Controlregister bit13 Auxiliary Out A Programmable Digital Output A
R/W Controlregister bit14 Auxiliary Out B Programmable Digital Output B
R/W Controlregister bit15 Run prog B Program Run B
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Bit registers: Statusregister

The cause of alarm is to be found in the Alarms
R Statusregister b00 Alarm No Alarm register
The cause of warning is to be found in the Warnings
R Statusregister b01 Warning No Warning register
R Statusregister b02 Remote Local When in local, unit can not be controlled by serial bus
if Running, unit is working according to set parameters
R Statusregister b03 Running A Not running A A
Shows if pre-set Ah-Limit is reached. (A-side if dual
R Statusregister b04 Ah A>Ah-Limit A Ah A<Ah-Limit A output).
Shows if pre-set Ah-Limit is reached. (B-side if dual
R Statusregister b05 Ah B>Ah-Limit B Ah B<Ah-Limit B output).
Timer>TimerLimit Timer<TimerLimit Shows if pre-set Process Timer Limit is reached
R Statusregister b06 A A A-side
Shows if A-Side is running in Voltage Mode. Load
R Statusregister b07 Voltage Mode A Current Mode A Impedance may be too high.
Shows if B-Side is running in Voltage Mode. Load
R Statusregister b08 Voltage Mode B Current Mode B Impedance may be to high.
R Statusregister b09 On or StandBy Off Status of unit (Same as green LED on display)
The bit is set if the resolution for current registers are
R Statusregister b10 Current Hires Current normal 0.1A. (1), (2)
if Running, unit is working according to set parameters
R Statusregister b11 Running B Not running B B
Timer>TimerLimit Timer<TimerLimit Shows if pre-set Process Timer Limit is reached
R Statusregister b12 B B B-side
Auxiliary In A
R Statusregister b13 active Programmable Digital Input A
Auxiliary In B
R Statusregister b14 active Programmable Digital Input B
R Statusregister b15
(1) When reading actual current, divide by 10 if Hires, status register 10; is activated
(2) When writing set current, multiply by 10 if Hires, status register 10; is activated
Bit registers: Warningregister
R Warningsregister b00
R Warningsregister b03 Activated OK Alarm from pole reverser A
R Warningsregister b04 Activated OK Alarm from pole reverser B
R Warningsregister b05 Activated OK Unit delivers maximum power
Illegal Parameter. One or more parameters are in
R Warningsregister b06 Activated OK conflict. Check Parameters.
High temp warning. One or more power-modules have
R Warningsregister b07 Activated OK shut down, or will do shortly
Rectifiers fails to deliver requested output power. May
R Warningsregister b10 Activated OK be due to mains fault.
Bit registers: Alarmregister

Internal temperatures too high. Unit has shut down.
R Alarmsregister b00 Activated OK Check cooling.
R Alarmsregister b01
Critical error on one or more power modules. May
R Alarmsregister b02 Activated OK need service.
R Alarmsregister b03 Activated OK Alarm Ext A
R Alarmsregister b04 Activated OK Alarm Ext B
R Alarmsregister b05 Activated OK Polarity control. Fault in CFG of pole reverse
R Alarmsregister b06 Activated OK External alarm 1
R Alarmsregister b07 Activated OK Short circuit detected A-side
Page 109 (122) 77-107.0223 GB
Rev. H

R Alarmsregister b08 Activated OK Short circuit detected B-side
9.2.2 Programming examples

Example 1
The rectifier is controlled from a Profibus master (PC or PLC), parallel output.
Control the rectifier as follows:

1. Start the rectifier by writing 3 to register 1
2. Set the voltage by writing to register 2
3. Set the current by writing to register 3
Operation is supervised by reading registers 9, 12 and 13.
9.2.3 Troubleshooting Profibus communication

If communication cannot be established:
- Check that the rectifier is in Remote mode (yellow LED on front panel).
- Check that the rectifier has the correct address.
- Check that the cable is correctly terminated. (terminated at the last device in the loop)
- Try reversing the polarity of the field bus cable.
- Check that the correct sub-module has been selected in the .GSD file.
- Go into the Duty menu and check DP-State. When communication is working as it should, ‘Data
Exchange’ should be displayed. If ‘Wait prm’ is displayed, no contact has been established.
- Check that there are not two devices with the same address on the field bus.
- Check that the Digital/Analogue inputs are configured correctly.
The status of Profibus communication can be found in the DUTY submenu.
WD state Watchdog state machine:

Baud Search state The device listens to the serial bus and attempts to determine the baud rate with
autodetect.
Baud Control Baud rate determined, ready to communicate.
DP Control Communicating
DP State DP State machine:

Wait Prm Waiting for parameterisation telegram from Profibus Master.
Wait Cfg Waiting for configuration telegram from Profibus Master.
Data Exchange Running OK, data is being exchanged between the rectifier and Profibus Master.
Register content of control register and status register is also available.

Use it to check that reading and writing from/to registers is working.
There is no need to set the baud rate for Profibus communication. The rectifier automatically detects the
baud rate between 9600 bps and 12Mbps.
The rectifier sends low byte first (default). High byte can be sent first if required, by activating the
BYTESWAP function.
If communication is working but the rectifier is not being properly controlled:

- Try changing BYTESWAP in the CFG/USER menu.
Page 110 (122) 77-107.0223 GB
Rev. H
9.2.4 GSD file

The GSD file describes how telegrams are to be sent with the Profibus protocol.
Depending on how the rectifier is configured, one of several ‘submodules’ must be chosen:
FlexKraft Std Used when the outputs are connected in series or parallel.
FlexKraft Std Dual Used when the outputs are controlled individually.
Contact KraftPowercon Sweden AB for receiving the GSD file on email.

9.2.5 Tips & Tricks
Communication information can be read on DUTY menu.
Set protocol
Set address
Detected baud rate
ControlWord A write register. Used to control sending
StatusWord A read register. Used to control reading.
WD-State
DP-State
There are 16 bits in each register. For transfer on the fieldbus the register is divided into two eight-bit words.
Which word is sent first is determined by Hi byte or Low byte, using the BYTESWAP setting. This is different
for different makes of PLC. Siemens often requires that Byteswap is activated, While Japanese PLCs often
require that Byteswap is OFF.
9.3 Modbus RTU

Technical data: serial interface, RS-232 alternative RS-485
Interface: RS-232
Baud rates : 4800, 9600, 19200, 38400 bit/s
Data length 8 bits
Parity Even
Stop bits 1 bit
Maximum number of nodes on the bus: 1
Interface: RS-485
Baud rate: 4800, 9600, 19200, 38400 bit/s
Maximum number of nodes on the bus: 32 (1 controller and 31 rectifiers). The system tends to be
slower with more than 10 nodes.
Recommended RS-232/RS-485 converter: Westermo MA-45.
Modbus-specific data
Address range 1-247
Functions F01, 02, 03, 04, 05, 06, 16
Broadcast support Yes
Turn around delay 4.5 character time, or as defined in MBTimeout.
Control
Modbus RTU is a simple and efficient protocol which is easy to implement on most platforms. It is used world
wide. Data can be sent and received as single bits, whole words or several words in one command.
Messages contain little overhead and are relatively secure as a result of using checksums and timeout.
A typical control sequence might look like this:

1. Read actual values from the rectifier with Modbus command F04
2. Process data
3. Send new settings to the rectifier with Modbus command F16
4. Go to step 1
Page 111 (122) 77-107.0223 GB
Rev. H
If PC software is running under Windows, timeout errors will probably occur during communication with the
Modbus RTU. This can be avoided by using the MBTimeOut parameter. The actual value needs to be tested
on each individual installation.
It is important that the serial communication settings are the same for all connected devices.
Recommended baud rate: 38400 bit
Internet links
For further information about the Modbus protocol, use the following links.
www.modbus.org www.westermo.se
9.3.1 Overview of registers

Modbus RTU Communication Parameters
Protocol Modbus RTU
Baudrates 4800, 9600, 19200, 38400 kbps
Start bits 1 bit
Least significant bit sent
Data lenght 8 bits first
Parity Even
Stop bits 1 bit
Supported Functions F01, 02, 03, 04, 05, 06, 16
Address Range 1 - 247
Broadcast supported Yes
Note1: The entire message frame must be transmitted as a continuos stream of

characters
If a silent interval of more than 1.5 character times occurs between two characters, the message is declared incomplete and is
discarded
If the master device is a PC running Windows, this can be difficult to achieve, thus there is a setting on the Cfg/User menu,
MBTimeout,
which can be used to increase this time. This will also lower communication rate slightly.
Note2: It is important that the master device waits for >3.5 character times after a response, before sending a new request.
Note3: Modbus ASCII is not supported.
Note4: Most PLCs start the addressing range with adress 1, PC-software often start with adress 0. Be careful with
this…
Modbus functions Name Note

F01 Read Coil Status Use to read back previously set bits in Controlregister (setvalues)
F02 Read Input Status Use to read bits set in status registers (actual values)
F03 Read Holding registers Use to read back previously set registers (setvalues)
F04 Read Input Registers Use to read registers (actual values)
F05 Force Single Coil Use to set single bit in Controlregister
F06 Preset Single Register Use to set register
F16 Preset Multiple Registers Use to set multiple registers
Output Mode
The FlexKraft rectifiers has two separate outputs for the DC-Voltage. These can be configured for Serial, Parallel or dual output
mode.
In case of dual output mode, the rectifier can deliver two independent outputs of current, A and B side.
Page 112 (122) 77-107.0223 GB
Rev. H
Modbus Parameterlist
Digital Setvalues
PLC PC Use
Coil No. Coil No. R/W Name 1 0 Description Default
00017 16 R/W On/Off On Off 0 - Off, 1- On 0 Controlregister bit00
00018 17 R/W Start/Stop A Start Stop 0 – Stop A, 1 – Start A 0 Controlregister bit01
00019 18 R/W Block/Run A Block Run 0 – Run A, 1- Block A 0 Controlregister bit02
00020 19 R/W Run Prog A Program Run A-side 0 Controlregister bit03
Reverse
00021 20 R/W Current A Side Pole reverse A-side 0 Controlregister bit04
Reverse
00022 21 R/W Current B Side Pole reverse B-side 0 Controlregister bit05
00023 22 R/W 0 Controlregister bit06
Start or stop process for
00024 23 R/W Start/Stop B Start B Stop B B-side 0 Controlregister bit07
00025 24 R/W ClrAhA Clear Count 1 - Clear AhCounter A 0 Controlregister bit08
00026 25 R/W ClrAhB Clear Count 1 - Clear AhCounter B 0 Controlregister bit09
00027 26 R/W ClrTimer Clear Count 1 - Clear Process Timer 0 Controlregister bit10
00028 27 R/W 0 Controlregister bit11
Pause process for B-
00029 28 R/W Block B Block Run side 0 Controlregister bit12
Programmable Digital
00030 29 R/W Auxiliary Out A Output A 0 Controlregister bit13
Programmable Digital
00031 30 R/W Auxiliary Out B Output B 0 Controlregister bit14
00032 31 R/W Run Prog B Program Run B-side 0 Controlregister bit15
Digital Actual values
PLC PC
Input Input
No. No. R/W Name 1 0 Description Note
The cause of alarm
is to be found in
10017 16 R AlarmPresent Alarm No Alarm the Alarms register Statusregister b00
The cause of
warning is to be
found in the
10018 17 R WarningPresent Warning No Warning Warnings register Statusregister b01
When in local, unit
can not be
controlled by serial
10019 18 R Remote/Local Remote Local bus Statusregister b02
if Running, unit is
working according
to set parameters
10020 19 R Running A Running Not running A-side Statusregister b03
Shows if pre-set
Ah-Limit is
reached. (A-side if
10021 20 R AhLimitAReachedA Ah A>Ah-Limit A Ah A<Ah-Limit A dual output) Statusregister b04
Shows if pre-set
Ah-Limit is
reached. (B-side if
10022 21 R AhLimitBReachedB Ah B>Ah-Limit B Ah B<Ah-LimitB dual output) Statusregister b05
Shows if pre-set
Timer A> Timer A< Process Timer
10023 22 R ProcessTimerLimitReachedA TimerLimit A TimerLimit A Limit is reached A Statusregister b06
Shows if A-Side is
running in Voltage
Mode. Load
Impedance may be
10024 23 R C/V-mode A Voltage Mode Current Mode to high. Statusregister b07
Shows if B-Side is
running in Voltage
Mode. Load
Impedance may be
10025 24 R C/V-mode B Voltage Mode Current Mode to high. Statusregister b08
Page 113 (122) 77-107.0223 GB
Rev. H
PLC PC
Input Input
Status of unit
(Same as green
10026 25 R On On or StandBy Off LED on display) Statusregister b09
The bit is set if the
resolution for
current registers
10027 26 R Current HiRes Current Hires Current normal are 0.1A. Statusregister b10
if Running, unit is
working according
to set parameters
10028 27 R Running B Running Not running B-side Statusregister b11
Shows if pre-set
Timer B> Timer B< Process Timer
10029 28 R ProcessTimerLimitReachedB TimerLimit B TimerLimit B Limit is reached B Statusregister b12
Auxiliary In A Programmable
10030 29 R Aux In A active Digital Input A Statusregister b13
Auxiliary In B Programmable
10031 30 R Aux In B active Digital Input B Statusregister b14
10032 31 R Statusregister b15
PLC PC
Input Input
Warningsregister
10033 32 R b00
Warningsregister
10034 33 R b01
Warningsregister
10035 34 R b02
Alarm from pole Warningsregister
10036 35 R External Alarm A Activated OK reverser A b03
Alarm from pole Warningsregister
10037 36 R External Alarm B Activated OK reverser B b04
Unit delivers Warningsregister
10038 37 R Maximum Power Activated OK maximum power b05
Illegal Parameter.
One or more
parameters are in
conflict. Check Warningsregister
10039 38 R IllegalParam Activated OK Parameters. b06
High temp warning.
One or more
power-modules
have shut down, or Warningsregister
10040 39 R HighTemp Activated OK will do shortly b07
Warningsregister
10041 40 R b08
Warningsregister
10042 41 R b09
Rectifiers fails to
deliver requested
output power, May
be due to mains Warningsregister
10043 42 R Regulation Error Activated OK fault. b10
Warningsregister
10044 43 R b11
Warningsregister
10045 44 R b12
Warningsregister
10046 45 R b13
Warningsregister
10047 46 R b14
Warningsregister
10048 47 R b15
Page 114 (122) 77-107.0223 GB
Rev. H
PLC PC
Input Input
Internal
temperatures too
high. Unit has shut
down. Check
10049 48 R Overtemp Activated OK cooling Alarmsregister b00
10050 49 R Alarmsregister b01
Critical error on
one or more power
modules. May
10051 50 R Module failiure Activated OK need service. Alarmsregister b02
10052 51 R Alarm Ext A Activated OK Alarm Ext A Alarmsregister b03
10053 52 R Alarm Ext B Activated OK Alarm Ext B Alarmsregister b04
Polarity control
Fault in CFG of
10054 53 R Polarity control Activated OK pole reverse Alarmsregister b05
10055 54 R External alarm 1 Activated OK External alarm 1 Alarmsregister b06
10056 55 R Short circuit A-side Activated OK Short CKT A-side Alarmsregister b07
10057 56 R Short circuit B-side Activated OK Short CKT B-side Alarmsregister b08
Actual values
Output Mode: Series or
Parallel
PLC PLC PC
Reg
Reg.No Discr. Inputs .No R/W Name Type Multiplier Description Range
30001 0 R Reserved Unsigned 16bit Must be zero. 0
status of unit. See
30002 10017-10032 1 R StatusRegister Unsigned 16bit above 0 - 65535
30003 10033-10048 2 R WarningsRegister Unsigned 16bit warnings. See above 0 - 65535
30004 10049-10064 3 R AlarmsRegister Unsigned 16bit alarms. See above 0 - 65535
30005 4 R Output Voltage Signed 16bit *0,01V Output Voltage -30000 - 30000
-30000 – 30000
30006 5 R Output Current Signed 16bit *1A/*0.1A Output Current (1)
Number of seconds
elapsed since Reset
Process Time High of Process Timer.
30007 6 R Word Unsigned 16bit *65536 s High Word 0 - 999999
Number of seconds
elapsed since Reset
Process Time Low of Process Timer.
30008 7 R Word Unsigned 16bit *1 s Low Word
Number of Ah since
30009 8 R Ah High Word Unsigned 16bit *65536 Ah High Word 0 - 999999
Number of Ah since
30010 9 R Ah Low Word Unsigned 16bit *1Ah Low Word
30011 10 R
30012 11 R
30013 12 R
30014 13 R
Page 115 (122) 77-107.0223 GB
Rev. H
Actual values
Parallel
PLC PLC PC
Reg
30015 14 R
30016 15 R
Output Mode: Dual

PLC PLC PC
Reg
30001 0 R Reserved Unsigned 16bit Must be zero. 0
status of unit. See
30002 10017-10032 1 R StatusRegister Unsigned 16bit above 0 - 65535
30003 10033-10048 2 R WarningsRegister Unsigned 16bit warnings. See above 0 - 65535
30004 10049-10064 3 R AlarmsRegister Unsigned 16bit alarms. See above 0 - 65535
Output Voltage A-
30005 4 R Output Voltage A Signed 16bit *0,01V Side -30000 - 30000
Output Current A- -30000 – 30000
30006 5 R Output Current A Signed 16bit *1A/*0.1A Side (1)
Output Voltage B-
30007 6 R Output Voltage B Signed 16bit *0,01V Side -30000 - 30000
Output Current B- -30000 – 30000
30008 7 R Output Current B Signed 16bit *1A/*0.1A Side (1)
Number of seconds
elapsed since Reset
Process Time High of Process Timer.
30009 8 R Word Unsigned 16bit *65536 s High Word 0 - 999999
Number of seconds
elapsed since Reset
Process Time Low of Process Timer.
30010 9 R Word Unsigned 16bit *1 s Low Word
Number of Ah for A-
side since Reset of
Ah-Counter. High
30011 10 R Ah High Word A Unsigned 16bit *65536 Ah Word 0 - 999999
Number of Ah for A-
side since Reset of
Ah-Counter. Low
30012 11 R Ah Low Word A Unsigned 16bit *1Ah Word
Number of Ah for B-
side since Reset of
Ah-Counter. High
30013 12 R Ah High Word B Unsigned 16bit *65536 Ah Word 0 - 999999
Number of Ah for B-
side since Reset of
Ah-Counter. Low
30014 13 R Ah Low Word B Unsigned 16bit *1Ah Word
30015 14 R
30016 15 R
Page 116 (122) 77-107.0223 GB
Rev. H
Analog setvalues
Parallel
PLC PLC PC Use
Reg.No Coils Reg.No R/W Name Type Multiplier Description Def. Range
40001 0 R/W PageNo Unsigned 16bit Reserved 0 0
Controls On/Off,
Start/Stop etc. Also
00017- bit accessible. See
40002 00032 1 R/W Controlregister Unsigned 16bit above 0 0 - 65535
0 - (Rated
40003 2 R/W Set Voltage Signed 16bit *0,01V Set Voltage 0 Voltage*100)
0 - Rated Current
40004 3 R/W Set Current Signed 16bit *1A/*0.1A Set Current 0 (2)
Process Timer Pre-set for process
40005 4 R/W Limit High Word Unsigned 16bit *65535 s timer. High Word 0 0 - 999999
40006 5 R/W Limit Low Word Unsigned 16bit *1 s timer. Low Word 0
Ah-Limit High Pre-set for Ah-
40007 6 R/W Word Unsigned 16bit *65536Ah Counter. High Word 0 0 - 999999
Ah-Limit Low Pre-set for Ah-
40008 7 R/W Word Unsigned 16bit *1Ah Counter. Low Word 0
Initial start ramp
after activation of
40009 8 R/W Startramp Unsigned 16bit *0.1 s start bit 0 0-30000
40010 9 R/W
40011 10 R/W
40012 11 R/W
40013 12 R/W
40014 13 R/W
40015 14 R/W
40016 15 R/W
Output Mode:
Dual
PLC PLC PC Use
40001 0 R/W PageNo Unsigned 16bit Reserved 0 0
Controls On/Off,
Start/Stop etc. Also
00017- bit accessible. See
40002 00032 1 R/W Controlregister Unsigned 16bit above 0 0 - 65535
0 - (Rated
40003 2 R/W Set Voltage A Signed 16bit *0,01V Set Voltage A-Side 0 Voltage*100)
0 - Rated Current
40004 3 R/W Set Current A Signed 16bit *1A/*0.1A Set Current A-Side 0 (2)
0 - (Rated
40005 4 R/W Set Voltage B Signed 16bit *0,01V Set Voltage B-Side 0 Voltage*100)
0 - Rated Current
40006 5 R/W Set Current B Signed 16bit *1A/*0.1A Set Current B-Side 0 (2)
40007 6 R/W Limit High Word Unsigned 16bit *65535 s timer. High Word 0 0 - 999999
Output Mode:
Dual
PLC PLC PC Use
40008 7 R/W Limit Low Word Unsigned 16bit *1 s timer. Low Word 0
Pre-set for Ah-
Ah-Limit A High Counter A-Side.
40009 8 R/W Word Unsigned 16bit *65536Ah High Word 0 0 - 999999
Pre-set for Ah-
Ah-Limit A Low Counter A-Side. Low
40010 9 R/W Word Unsigned 16bit *1Ah Word 0
Page 117 (122) 77-107.0223 GB
Rev. H
Analog setvalues
Pre-set for Ah-
Ah-Limit B High Counter B-Side.
40011 10 R/W Word Unsigned 16bit *65536Ah High Word 0 0 - 999999
Pre-set for Ah-
Ah-Limit B Low Counter B-Side. Low
40012 11 R/W Word Unsigned 16bit *1Ah Word 0
Initial start ramp
after activation of
40013 12 R/W Startramp Unsigned 16bit *0.1 s start bit 0 0-30000
40014 13 R/W
40015 14 R/W
40016 15 R/W
(1) When reading actual current, divide by 10 if Hires, status register 10; is activated
(2) When writing set current, multiply by 10 if Hires, status register 10; is activated
9.3.2 Programming examples

Example 1
The rectifier is controlled from a Profibus master (PC or PLC), parallel duty.
Control the rectifier as follows:

1. Start the rectifier by writing 3 to register 40002
2. Set the voltage by writing to register 40003
3. Set the current by writing to register 40004
Operation is supervised by reading registers 30002, 30005 and 30006.
9.3.3 Troubleshooting MODBUS communication

If communication cannot be established:
- Check the communication settings, Baudrate, number of bits, parity, stop bit
- Check that the rectifier is in Remote mode (yellow LED on front panel).
- Check that the rectifier has the correct address.
- Check that the cable is correctly terminated. (terminated at the last device in the loop)
- Try reversing the polarity of the fieldbus cable.
- Check that there are not two devices with the same address on the field bus.
- Check that the Digital/Analogue inputs are configured correctly.
9.3.4 Troubleshooting Modbus RTU

The rectifier sends low byte first (default). High byte can be sent first if required, by activating the
BYTESWAP function.
Page 118 (122) 77-107.0223 GB
Rev. H
10 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 Phone: +46 31 - 979700
SE-445 02 SURTE Fax: +46 31 - 979797
Sweden E-mail: service@kraftpowercon.com
11 Appendices
The appendices are on the pages that follow.
Page 119 (122) 77-107.0223 GB
Appendices Rev.H
11.1 Equipment diagram, stand-alone rectifier and parallel -master

Page 120 (122) 77-107.0223 GB
Appendices Rev.H
Partial enlargement of circuit drawing on the previous page
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 PCB is supply for signals. See relevant option in chapter 6.
Page 121 (122) 77-107.0223 GB
Appendices Rev.H
11.2 Equipment diagram, parallel-slave

Page 122 (122) 77-107.0223 GB
Appendices Rev.H
11.3 Spare part list

FlexKraft Spare part List
Det.No. Denomination
Control Module
A1,8 RFI-Filter
A2 PCA Control unit MK 445
A3 PCA LCD display MK 446
A4 PCA RS 485 converter MK 436
A5 PCA RS 232 converter MK 436
A7 Keyboard
A9 PCA insulated analog I/O MK 451
A10 PCA analog digital I/O MK 450
A11 PCA digital I/O MK 452
A12 PCA Adaption unit MK 453
A13 PCA Parallel duty MK 449
A14 PCA Pole reverse MK 490
E1 Fan
F1-3 Fuse
F1-3 Fuse holder
K1,2 Contactor
U1 Power supply
X1 Connection block main supply
X2,3 Connection terminals 6 pol.
Ribbon cable set
Power Module
Complete power module
A1:A,B PCA Primary MK 470
A2-3:A,B PCA Snubber MK 468
A4:A,B PCA Output MK 471
A5 PCA fuse unit MK 469
A5:F1-3 Fuse
A6 PCA control unit MK 444
E1 Fan
L1:A,B Choke
T1:A,B Transformer
T2:A,B Current sensor
V1:A,B Rectifier
V2-4:A,B Diode
Ribbon cable set
Led indicator
Always supply the rectifiers order number Cxxxxxx or xxxxxxxxxx at spare part order.
11.4 Description of order-specific equipment, where applicable.

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Technical Description

There are hazardous voltages inside this product. If

WARNING! Only authorised personnel may install this product. It

WARNING! Only authorised personnel may carry out servicing or

WARNING! Always safely disconnect the electric power supply

1 SAFETY INSTRUCTIONS ........................................................................................................1

The manufacturer reserves the right to change specifications.

5.2.6.1 PARALLEL and SERIES mode................................................................36

6.11 Remote FlexKraft panel..............................................................................................66

9.1 General...................................................................................................................... 104

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

The manufacturer reserves the right to change specifications.

FlexKraft is equipped with EMC filters according to the EMC directive.

2.1 Summary and key components

Side A is on the left when

2.2 Different configurations

Rectifier for PARALLEL or DUAL mode

Stack of four Stack of one Rectifier with Bench-top

2.3 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

External emergency stop

3.2 Mechanical data

Height Höjd Weight Vikt Width Height

10 modules 9 modules 8 modules

Busbars 5,6,7 power modules.

7 modules 6 modules 5 modules

Busbars 2, 3, 4 power modules.

4 modules 3 modules 2 modules

Dimensions are typical, normal manufacturing tolerances apply.

Example of load connection.

3.2.3 Rectifier DC connection

2-6 power modules 7-8 power modules 9-10 power modules

Dimensions are typical, normal manufacturing tolerances apply

2-6 power modules 7-8 power modules 9-10 power modules

Dimensions are typical, normal manufacturing tolerances apply

3.2.4 Control cabinet

3.3 Supply side

Primary current at primary voltage 380-415VAC. Module output 2x12-15V/300-250A

Primary current at primary voltage 440-480VAC. Module output 2x12-15V/300-250A

Primary current at primary voltage 220VAC. Module output 2x7V/300A

3.4 Load side

Primary voltage 220 VAC

Series connection Parallel connection or DUAL

3.5 Controller/control signals

Several rectifiers can be connected in parallel for higher currents.

4.1.1 Operating modes

Series The sub-modules are connected in series and the output is

Dual The sub-modules are individual and the output is

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

4.2 Running programs, programming features

RAMP STEP PULSE

Time per program step: 0–30000 sec. Resolution 1 second

4 Step 02-08, 0-30000s/Step

Up to 4 different user programs can be programmed with 8 steps each.

The following parameters are set for each program:

The following functions can be used in each program step:

VOLTAGELEVEL Set value for voltage at end of program.

The following applies to all programs:

See chapter 7 Examples, configurations and options