WEG Rectifier User Manual 10005817193 en

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Rectifier
Digital Three-Phase Rectifier | Battery

Charger
User’s Manual
User's Manual
Series: Digital Three-Phase Rectifier | Battery Charger
Language: English
Document: 10005817193 / 01
Publication Date: 01/2019

Summary of the Revisions
The information below describes the revisions made to this manual.
Version Revision Description

- R00 First edition
- R01 General revision
Contents
1 SAFETY INSTRUCTIONS.................................................................. 1-1

1.1 SAFETY WARNINGS IN THE MANUAL................................................. 1-1
1.2 PRELIMINARY RECOMMENDATIONS.................................................. 1-1
2 GENERAL INFORMATION................................................................. 2-1

2.1 ABOUT THE MANUAL............................................................................ 2-1
2.2 TERMS AND DEFINITIONS USED IN THE MANUAL........................... 2-1
2.3 SYSTEM COMPONENTS....................................................................... 2-2
2.4 OPERATION............................................................................................ 2-2
2.5 RECEPTION AND STORAGE................................................................. 2-3
3 INSTALLATION AND OPERATION.................................................... 3-1

3.1 INITIAL SETTINGS.................................................................................. 3-3
3.2 SPACE HEATER AND THERMOSTAT.................................................... 3-5
3.3 OPERATION............................................................................................ 3-5
4 CONTROL PANEL.............................................................................. 4-1

4.1 MANUAL COMMANDS........................................................................... 4-1
4.2 INDICATIONS.......................................................................................... 4-2
4.3 MEASUREMENTS................................................................................... 4-2
4.4 ALARMS.................................................................................................. 4-3
5 SUPERVISORY SYSTEM................................................................... 5-1
6 PREVENTIVE MAINTENANCE.......................................................... 6-1

6.1 PROCEDURE TO ENTER THE MAINTENANCE MODE (MANUAL
BYPASS)........................................................................................................ 6-2
6.2 PROCEDURE TO EXIT THE MAINTENANCE MODE (MANUAL
BYPASS)........................................................................................................ 6-2
6.3 RESET TO THE FACTORY SETTINGS................................................... 6-2
6.4 REVISION TIME RESET.......................................................................... 6-3
7 COMMUNICATION............................................................................. 7-1
7.1 MODBUS-RTU COMMUNICATION....................................................... 7-1
7.1.1 Installation of the Modbus-RTU Network................................. 7-1
7.1.2 Modbus-RTU Protocol................................................................ 7-2
8 TECHNICAL DATA............................................................................. 8-1

Contents
Safety Instructions
1 SAFETY INSTRUCTIONS
This manual contains the information necessary for the correct use of the Digital Rectifier. The
following instructions are extremely important for the good performance of the Digital Rectifier
and must be fully observed during the system installation, maintenance and operation. Failure
to comply with the product instructions may cause operating accidents and damage to the
environment, to the Rectifier and to the equipment connected to it, in addition to voiding the
warranty.
After reading the user manual, keep it in a place with easy access for the users.
1.1 SAFETY WARNINGS IN THE MANUAL
The following safety notices are used in this manual:
DANGER!
Failure to comply with the procedures recommended in this warning may lead
to death, serious injuries and considerable material damage.
ATTENTION!
Not following the procedures recommended in this warning may cause material
damage.
NOTE!
The text aims at providing important information for the full understanding and
proper operation of the product.
1.2 PRELIMINARY RECOMMENDATIONS
DANGER!
Make sure the power is disconnected before installation. (Otherwise, electric
shock may cause serious injury or death).
Always work with the equipment disconnected from the power supply.
(Otherwise, electric shocks or short circuits may occur.)
When performing any tests, maintenance or repairs, first disconnect the
power supply and then disassemble the equipment.
Do not install the product, unless you hold a national certification and have
received relevant information on the product. (Otherwise, electric shocks or
short circuits may occur.)
ATTENTION!
Before installation, make sure the used voltage matches the rated voltage.
When you are installing or testing this product, check the ratings and
specifications.
Do not disassemble the product when it is energized or running.
Dispose of the product as industrial waste.
Digital Three-Phase Rectifier | 1-1

Safety Instructions
NOTE!
Read the entire manual before installing or operating this Digital Rectifier.
DANGER!
When in operation, electric energy systems – such as transformers, converters,
motors and cables – generate electromagnetic fields (EMF). Therefore, there
is risk for people with pacemakers or implants that stay in close proximity
to those systems. Thus, such people must stay at least 2 meters away from
those devices.
1-2 | Digital Three-Phase Rectifier

General Information
2 GENERAL INFORMATION
The generation of Digital Three-phase Rectifiers (RTD, or Retificador Trifásico Digital) has
double energy conversion and full digital control.
Thanks to those innovations, the new RTD presents significant improvement in performance,
efficiency, operation and reliability in comparison to conventional rectifiers.
2.1 ABOUT THE MANUAL
This manual briefly describes the operation and technical characteristics of the controlled rectifier.
This manual is available for download at WEG website: www.weg.net.
2.2 TERMS AND DEFINITIONS USED IN THE MANUAL
Amp, A: Ampere.
°C: Degrees Celsius.
°F: Fahrenheit degree.
AC: Alternating current.
DC: Direct current.
cm: Centimeter.
Hz: Hertz.
kg: Kilogram = 1000 grams.
m: Meter.
mA: Milliampere = 0.001 ampere.
min: Minute.
mm: Millimeter.
rms: Root mean square; effective value.
V: Volts.
RTD: from Portuguese "Retificador Trifásico Digital"; Digital Three-phase rectifier.
UCQ: from Portuguese "Unidade Conversora de Queda"; Voltage drop converter.
Date and time format used in this manual and on the equipment: dd/mm/yy hh:mm.
Digital Three-PhaseRectifier | 2-1

General Information
2.3 SYSTEM COMPONENTS
The system is basically composed of:
Isolated three-phase rectifier.
Battery (outside the panel; sold separately).
Voltage drop converter UCQ.
K1
Voltage drop
AC Power
Rectifier converter (UCQ)
supply 3Ø
DJR DJC Consumer
125 Vdc
±1 %
DJB
DJBP
120 Vdc
Digital control
RS485
interface HMI panel
dry contact
Figure 2.1: Digital rectifier
2.4 OPERATION
In Normal mode (AC power supply present), the first converter (rectifier) supplies energy to
charge/maintain the battery bank and simultaneously supplies energy to the output converter
(UCQ), which supplies the consumer.
In case of an AC power supply outage, the consumer starts receiving uninterrupted power
from the batteries through the output converter (UCQ) or directly via Bypass. When the AC
power supply is restored, the rectifier returns to normal operation, charging the battery bank if
necessary and powering the rest of the system.
The digital rectifier has a dedicated circuit that detects occasional leakage currents from the
equipment positive and negative terminals or from the loads.
With automatic operation, it provides isolation between the positive/negative terminals and the
equipment grounding, generating events and alarms when faults occur.
In case of a long AC power supply outage, the battery discharges to a minimum voltage limit;
at this moment, the consumer is shut down.

General Information
The supervisory system works as redundancy in case of failure in the consumer's power supply.
Digital Three-Phase Rectifier (RTD) Parallelism

Thyristor diode
rectifier Voltage drop converter (UCQ) (optional)
AC Power
supply 3Ø DJR DJC
Consumer
K1
Normal energy flow
Flow in battery mode
Flow in auto Bypass mode
Flow in manual Bypass
mode DJB
DJR - AC power supply Supervision
circuit breaker
DJB - Battery circuit breaker
DJBP - Manual Bypass
DJBP
circuit breaker
DJC - Consumer circuit
breaker
K1 - Bypass contactor
Batteries
120 Vdc
Figure 2.2: One-line diagram
2.5 RECEPTION AND STORAGE
When opening the package, visually check for signs of violation or points that may indicate any
damage to the equipment during transportation.
Report any problems immediately to the carrier.
If the equipment will not be installed after the delivery, some safety measures should be taken
in order to ensure the integrity and warranty of your product during storage:
a) The air must be free of corrosive chemicals.
b) The place must not present water infiltration or dripping.
c) Good ventilation.
d) The panel must be kept on the wooden base (pallet).
e) The packages must not be removed.
f) The air relative humidity level must be low (see Section 3.2 SPACE HEATER AND THERMOSTAT
on page 3-5 of this manual).
g) Vermin must not be present.
Digital Three-PhaseRectifier | 2-3

General Information
Handling:
Transportation must be done in the vertical position with the panel door locked.
The handling is done by means of the lifting lugs on top of the panel with the aid of a lifting
beam with the cables at its ends connected to each lug.
The panels must be lifted by the lifting lugs with lifting equipment of capacity above 2000 kg.

Installation and Operation
3 INSTALLATION AND OPERATION

Make a visual inspection so as to make sure no damage occurred during transportation and
check the tightening of screws and electric connections.
Mount the equipment in a ventilated place free of explosive gases.
Temperature Sensor Connection
Install one end of the 5-meter cable of the temperature sensor near the batteries.
Connect the other cable end to connector CN11 of the relay board.
In case the temperature sensor is not connected, the equipment will set the standard temperature
of 25 °C (77 °F).
Dry Contacts
RTD 15 A to 500 A
RL1 Consumer turned on
RL2 AC Fault
RL3 Rectifier turned on
RL4 Low voltage in the consumer
RL5 High voltage in the consumer
RL6 Low voltage in the batteries
RL7 Current limitation
RL8 Overload
RL9 Earth leakage + or -
RL10 Ventilation fault 1 or 2
RL11 Circuit breakers open (input power supply, battery or consumer) or Bypass circuit breaker closed
Power Connections
The following care must be taken:
Make sure the AC power supply and battery cables have no power and will not be inadvertently
energized.
Make sure the AC input, batteries and consumer circuit breakers are open.

For AC power supply, battery and consumer, use the minimum gauges indicated in the table
below:
RTD Model AC Power Supply DC Power Supply

Output (A) 220 V 380/440 V Battery / Consumer
15 4 mm²
25 4 mm²
35 4 mm²
50 4 mm² 10 mm²
75 4 mm² 16 mm²
100 16 mm² 6 mm² 25 mm²
125 16 mm² 10 mm² 35 mm²
150 25 mm² 10 mm² 50 mm²
200 35 mm² 16 mm² 70 mm²
300 70 mm² 25 mm² 120 mm²
400 95 mm² 50 mm² 185 mm²
500 120 mm² 70 mm² 300 mm²
Start by connecting the grounding cable that will be fastened to the corresponding terminal
or bar.
Introduce the power supply cables and connect them to the DJR circuit breaker in the lower
part of the panel, observing the correct phase sequence of the three-phase AC power
supply. R, S and T.
Connect the battery cables to the corresponding terminals, observing the correct polarity.
Connect the consumer cables to the corresponding terminals, observing the correct polarity.
ATTENTION!
Whenever you have to handle the DC link, disconnect the battery cable, since
a pre-charge voltage is present even with the circuit breakers open.
Thermal dissipation
RTD (A) 15 25 35 50 75 100

Cooling (kW) 0.6 0.9 0.85 1 1.5 1.9
BTU/h 2050 3070 2900 3400 5100 6480
RTD (A) 125 150 200 300 400 500

Cooling (kW) 2 2.5 2.7 3.75 5 6.25
BTU/h 6820 8530 9210 12790 17060 21320

3.1 INITIAL SETTINGS
Input voltage configuration
ATTENTION!
Before closing the DJR, check with a multimeter if the AC input voltage is
compatible with the voltage set in the terminals and if the battery voltage
polarity is correct.
Close the DJR and check if the display turns on with the opening menu.
After some seconds, the opening menu changes to the clock setting menu. Set the date and
time using the navigation keys. After one minute without any changes in date and time, the
clock adopts the factory settings.
Configure the equipment input voltage. Navigate in the “ROOT” menu up to the “AC INPUT”
menu.
In the “AC INPUT” menu, press the “ENTER” key for three seconds in order to enter the
Submenu (1st level) of the input voltage selection.
In the Submenu (1st level) of the input voltage selection, press the arrows to select the input
voltage from the options 220 V / 380 V / 440 V. In order to confirm, press "ENTER" for three
seconds.
Note: In case an alarm occurs indicating phase loss, change the input phase sequence on the DJR circuit
breaker until the phase fault indication is cleared.
ATTENTION!
Make sure the cables are not energized.

Battery charger configuration
Navigate in the “ROOT” menu up to the “BATTERIES” menu.
In the “BATTERIES” menu, press the “ENTER” key for three seconds so as to access the
submenu (1st level) with the battery charger settings.
If the charger settings are correct, exit the submenu by pressing “ENTER” for three seconds
or wait for thirty seconds, and the system will go back to the main menu.
If necessary, in order to make the modifications, press the “ENTER” key again for ten seconds
within the submenu (1st level) until the modification menu (2nd level) appears.
Root Menu Submenu (1st level)
Submenu (2nd level) Submenu (3rd level)
Within the modification menu (2nd level), choose the parameter to be changed by pressing
the “ENTER” key to navigate the options.
In order to change the chosen parameter, press the arrows to increase or decrease the values.
Choose the charging current.
It is recommended to select a charging current equivalent to 10 % of the battery bank capacity.
E.g.: For batteries of 100 Ah, the recommended charging current is 10 A.
Note: The battery charging current will be discounted from the maximum limit of the consumer's current.
Choose the charger operating mode from:
Forced float:
In this mode, the charger will keep the battery bank in float until the operating mode is
manually changed.
Forced Equalization:
When selected, this mode will execute a recharge cycle (or equalization) in the battery bank.
After the cycle, the equipment will go into the float mode and remain in such mode until it
is manually changed. The equipment can remain in this mode for up to six hours; after that,
the forced float mode is activated to protect the batteries.
Automatic (factory default):

In this mode, the equipment will keep the battery bank in float, and whenever a relevant
discharge of the batteries is detected, a recharge cycle (or equalization) is executed after the
normalization of the situation that caused the battery bank discharge.

NOTE!
Regardless of the operating mode, the rectifier voltage for the batteries will be
regulated observing the current limitation selected in the BATTERIES menu by
the "CHARGING CURRENT" parameter.
In order to “SAVE” the changes, press the “ENTER” key to access the menu with the “SAVE”
or “CANCEL” options (3rd level).
Confirm the desired operation.
3.2 SPACE HEATER AND THERMOSTAT
The digital rectifier has an internal heating system which can be adjusted by means of a
thermostat in order to keep the equipment properly warm and free of humidity. This circuit is
designed to be used during the equipment storage, installation or maintenance.
NOTE!
The system must not be used with the equipment in operation, which may
cause overtemperature, output voltage drop (consumer), operation above
the recommended temperature with damage to the internal parts, and so on.
3.3 OPERATION
Activation of the Rectifier/Charger
Energize the equipment via the input circuit breaker DJR.
Upon energization, the boot menu with the equipment data is displayed for four seconds.
Check if the pre-charge occurred.
Close the battery circuit breaker DJB.
Observe the parameters of the batteries on the “Batteries" menu, and if it is necessary to check
or change the charger configuration, see the “installation” chapter.
Press the rectifier key on the panel until you hear the sound signal and see the corresponding
LED turn on.
Note: The LED of the rectifier key will flash when the rectifier is without AC power supply.
Activation of the Consumer
In order to turn on the Consumer, press the panel key until you hear the sound signal and
see the key LED turn on.

Check the output voltage of 125 Vdc ± 1 % on the “Consumer” menu and the load consumption
percentage, which must be below 100 %.
Connect the load and close the consumer circuit breaker DJC.
Under those conditions, the equipment will be in normal operating condition, supplying the
battery and the consumer.
Shutdown of the consumer
It is only possible to interrupt the consumer's supply by opening the consumer circuit breaker
(DJC). Once the consumer button is activated, it can only be deactivated by carrying out the
full system shutdown procedure.
The Rectifier may remain turned on in order to maintain the battery charge.
Shutdown of the Rectifier/Charger
It is possible to turn off the rectifier by pressing the corresponding key on the panel for four
seconds.
ATTENTION!
Under that condition, the batteries will discharge if the consumer is turned on.
Full system shutdown
In order to shut down the system completely, the three circuit breakers must be open and the
batteries disconnected from the rectifier terminals.

DISPLAY MENUS
Lettering
Text in white font Fixed text
Text in yellow font Dynamic text
Text in red font Values that can be modified by the up and down buttons
Root Submenu level 1 (3 s) Submenu level 2 (10 s) Submenu level 3
W EG AU TO M AT I O N
D I G I TA L R EC T I FI E R
MODEL XXXV XXXA
FW VERSION X.X.X
O P E R AT I O N M O D E AD JUST DATE / TIME

CONSUMER X X X% < X X >/< X X >/< X X >
B AT T E R Y XXXV < X X >:< X X >
X X / X X / X X X X : X X X XºC + NE X T -
CONSUMER V O LTA G E R E F XXX,XV V O LTA G E R E F <XXX, X> V AT TENTION!

VO LTAG E XXX ,XV CURRENT LIMIT XXXA CURRENT LIM <XXX> A SAVE PAR AMETER
CURRENT XXX ,XA UV XXX,XV OV X X X , X V UV <XXX, X> OV <X X X, X> CHANGES
CAPACIT Y X X X% L O W B AT B Y P XXX,XV L O W B AT BY P <XXX, X> SAVE CANCEL
B AT T E R Y F L OAT R E F XXX,XV F L OAT R E F <XXX,X> AT TENTION!

VO LTAG E XXX ,XV EQUAL. REF XXX,XV EQUAL. REF <XXX,X> SAVE PAR AMETER
CURRENT -XXX , X A CHARGE CURRENT XXXA CHARGE CURRENT <XXX> CHANGES
MODE X X X% O P E R AT I O N X X X X X X X X X X O P E R AT I O N < X X X X X X X X X X > SAVE CANCEL
AC INPUT XX , XHz R AT E D V O LTA G E <XXX> V R AT E D V O LTA G E <XXX> V AT TENTION!

P - R XXXV XXX ,XA O V E R V O LTA G E XXXV O V E R V O LTA G E <XXX> V SAVE PAR AMETER
P - S XXXV XXX ,XA U N D E R V O LTA G E XXXV U N D E R V O LTA G E <XXX> V CHANGES
P - T XXXV XXX ,XA AC INPUTS STATUS SAVE CANCEL
LAST EVENT EVENT LOG

EVENT DESCRIPTION EVENT DESCRIPTION
X X / X X / X X X X : X X XX/XX/XX XX:XX #XX
EVENT LOG -> <- BACK ->
MAINTENANCE MAINTENANCE MAINTENANCE AT TENTION!

REVISION 1 X X X DAYS PRESS THE BUTTON FOR RESTORE FACTORY ALL CHANGES
REVISION 2 X X X DAYS 3 S EC O N D S TO R ES TA R T D E FAU LT VA L U E S WILL BE LOST
O PE R AT I N G DAYS XXXX REVISION1 REVISION2 ENTER TO CONTINUE CONTINUE CANCEL
C O M M U N I CAT I O N ADDRESS XXX

MODBUS-RTU PROTOCOL STOP BIT X
ADDRESS XX PARIT Y NONE / EVEN / ODD
SERIAL 9600 8 N 1 BAUD R ATE 9600 / 19200
This screen is not normally accessible via navigation keys.

I M P O R TA N T E V E N T
EVENT DESCRIPTION It appears when an important event occurs.
XX/XX/XX XX:XX And it disappears after pressing enter.
PRESS ENTER
Event Log
The Digital Three-Phase Rectifier has a system which allows recording 200 events with date
and time.
The last event will appear on the display and will disappear after pressing the “ENTER” key.
In order to check the event list, navigate on the “ROOT” menu up to the “LAST EVENT” menu.
In the “LAST EVENT” menu, press the “ENTER” key for three seconds in order to access the
event sequence on the Submenu (1st level).

Submenu (1st level)
Table 3.1: Event identifiers
RTD N o. (1)
Event RTD No. (1) Event
0 Rectifier turned on 5 Consumer undervoltage
1 Rectifier turned off 10 Consumer overload
2 Consumer turned on 13 Manual Bypass mode
3 Consumer turned off 17 Overtemperature
4 Consumer overvoltage 18 Phase sequence fault
6 Battery overvoltage 19 Low battery Bypass
7 Battery undervoltage 20 Battery overload
8 Input overvoltage 21 Positive earth leakage
Critical
9 Input undervoltage 22 Negative earth leakage

11 Normal mode 23 Consumer current limitation
12 Battery mode 24 Auto Bypass mode
14 Charger mode 25 High battery temperature
Normal
15 OFF mode 34 Ventilation 1 failure

16 Clock set 35 Ventilation 2 failure
26 Normal battery temperature 37 Input circuit breaker open
27 Consumer parameter set 38 Bypass circuit breaker closed
28 Battery parameter set 41 Battery circuit breaker open
29 Input parameter set 43 Consumer circuit breaker open
30 Communication parameter set
31 Reset revision 1
32 Reset revision 2
33 Reset to factory definition
36 Input circuit breaker closed
39 Bypass circuit breaker open
40 Battery circuit breaker closed
(1) Number that identifies the event when read via Modbus RTU communication.

Control Panel
4 CONTROL PANEL
The control panel contains:
LED-backlit LCD with 4 lines x 20 columns.
Five keys.
Eight indication LED.
4.1 MANUAL COMMANDS
1 Rectifier Power Switch.
2 Consumer Power Switch.

Note: by holding keys 1 and 2 simultaneously pressed, it is possible to activate/deactivate the manual
Bypass, as well as to deactivate the automatic Bypass.
Navigation commands:
3 UP key.
4 ENTER key.
5 DOWN key.

Control Panel
4.2 INDICATIONS
The LEDs on the control panel warn the operator of the current state of the equipment as follows:
LED Name Color State Indication

Off Rectifier turned off
1 Rectifier Green On Rectifier turned on
Flashing Rectifier turned on, but not operating
Off Consumer turned off
2 Consumer Green
On Consumer turned on
Off No active alarms
6 Alarm Red
On One or more active alarms
Off Batteries charging or idle
7 Batteries Yellow On Batteries supplying power to the consumer
Flashing Batteries in critical level
Off AC power supply is normal
8 AC Fault Yellow
On AC power supply is abnormal or phase sequence fault
Off Normal DC voltage in the consumer and battery
9 Low DC Yellow
On Low DC voltage in the consumer or battery
Off Normal DC voltage in the consumer and battery
10 DC high Red
On High DC voltage in the consumer or battery
Off Consumer current is normal
11 Overload Red
On Overload (load > 125 %)
4.3 MEASUREMENTS
AC Input:
True rms AC voltage of the three phases.
True rms AC current of the three phases.
AC power supply frequency (Hz).
Batteries:
DC voltage (Vdc).
Charging and discharging DC current (Adc).
Charge percentage (%).
Consumer:
DC voltage (Vdc).
DC current (Vdc).
Percentage of charge in the consumer (%).

Control Panel
NOTE!
Due to the tolerance of the transducers and other parts used in the measurement
system, the readings may show a deviation in comparison to measurements
made with other devices.
4.4 ALARMS
In addition to the current state of the equipment shown by the LEDs on the panel, the HMI
indicates when an Alarm is activated. Those alarms are listed in Table 4.1 on page 4-4.

Control Panel
Table 4.1: Alarm List

Event Shown on the Critical Condition for Condition to Exit the
Alarm
HMI ? Alarm Alarm
VR, S or T >
Input overvoltage "INPUT OVERVOLTAGE" N
(110 % VInp) (1) (90 % VInp + 5 V) < VR, S or T
"INPUT VR, S or T < < (110 % VInp - 5 V) (1)
Input undervoltage N
UNDERVOLTAGE" (90 % VInp) (1)
"BATTERY
Battery overvoltage N VBattery > 148 V VBattery < 148 V
OVERVOLTAGE"
"BATTERY
Battery undervoltage N VBattery < 105 V (1) VBattery > 125 V
UNDERVOLTAGE"
Consumer "CONSUMER VConsumer >
N
overvoltage OVERVOLTAGE" 132 V (1) 111 V < VConsumer < 131 V
(2) (3)
Consumer "CONS. VConsumer <
Y
undervoltage UNDERVOLTAGE" 110 V (1)
Limiting the "CONSU. CURRENT IConsumer >
Y
consumer current LIMIT" HMI Setting
IConsumer > IConsumer < HMI Setting
"CONSUMER
Consumer overload Y 125 % HMI
OVERLOAD"
Setting
Battery high "HIGH BATTERY TBatteries >
Y TBatteries < 40 °C (104 °F)
temperature TEMP." 45 °C (113 °F)
Equipment Activated by a Thermostat installed in the
"OVERTEMPERATURE" Y
overtemperature panel
Manual Bypass "MANUAL BYPASS Press the Rectifier and Consumer keys
Y
mode MODE" simultaneously for three seconds
Automatic Bypass
"AUTO BYPASS MODE" Y Activated by other alarms
mode
Input phase "PHASE SEQUENCE
Y
sequence fault FAULT"
Negative earth "N EARTH LEAKAGE
Y Detected by an electronic circuit
leakage CURR"
Positive earth "P EARTH LEAKAGE
Y
leakage CURR"
Ventilation 1 failure "VENT 1 FAILURE" Y Detected by fan 1 feedback
Ventilation 2 failure "VENT 2 FAILURE" Y Detected by fan 2 feedback
AC power supply "INPUT C BREAKER
N
circuit breaker closed ON"
AC power supply "INPUT C BREAKER
Y
circuit breaker open OFF"
Bypass circuit "BYPASS C BREAKER
Y
breaker closed ON"
Bypass circuit "BYPASS C BREAKER
N
breaker open OFF" Detected by the circuit breaker auxiliary
Battery circuit "BAT CIRC BREAKER contact
N
breaker closed ON"
Battery circuit "BAT CIRC BREAKER
Y
breaker open OFF"
Consumer circuit "CONS. C BREAKER
N
breaker closed ON"
Consumer circuit "CONS. C BREAKER
Y
breaker open OFF"
Note:
(1) Factory default value; however, the user can change it via HMI.
(2) The 111 V value refers to the consumer undervoltage +1 V, and the 131 V value refers to the consumer overvoltage -1 V.
(3) Two attempts to return in 30 seconds. Then, only via manual Bypass.

Supervisory System
5 SUPERVISORY SYSTEM
It is a redundant protection system that monitors the battery and consumer voltages, ensuring
the correct voltage on the loads connected to the Digital Rectifier.
Operation
When an event that compromises the specified output voltage is generated, the system activates
the Bypass and connects the rectifier/battery to the consumer output.
The Supervisory System is composed of two protection levels; the first by means of the control
firmware itself, and the second via dedicated circuit, ensuring even more robustness to the
Digital Rectifier.
1st Level - Protection via microcontroller: the firmware activates the Bypass according to
the events shown in Table 5.1 on page 5-1 - Bypass Conditions. After the issue that activated
the bypass is solved, the equipment returns to the normal operating mode at the end of the
return time countdown.
Note: In case the batteries discharge, they will go into the recharging mode.
2nd Level - Protection via dedicated circuit: likewise, the circuit monitors the battery and
consumer voltages, with the protections actuating when necessary.
Table 5.1: Bypass conditions

Level Event Time for Actuation Return Time
1st Loss of AC power supply 10 s (2) 10 s
< 25 % 30 s 10 s
Output overcurrent
> 25 % Immediate 10 s
Output overvoltage 5s Immediate
Overtemperature 5s 5s
< 110 V 10 s (1)
2nd Fault in the output Immediate Follow the instructions: operation to
< 105 V
return from protection by 2nd level
(1) Two attempts to return in 30 seconds. Then, only via manual Bypass.
(2) The BYPASS actuates in case of an AC power supply outage after ten seconds when the battery bank voltage is low.
Table 5.2: Output voltages in Bypass mode

Protection Minimum Voltage Maximum Voltage
1st Level – Microcontroller > 105 V
< 128 V
2nd Level – Dedicated circuit > 80 V
Minimum voltage: below this value, the equipment will shut down to ensure the integrity of
the batteries.
Maximum voltage: in case the equipment is in overload, this voltage value will be proportionally
equal to the battery voltage.

Supervisory System
Indications and working voltages of the dedicated circuit
The dedicated circuit works with different voltage levels on the battery and on the consumer,
indicating the operating conditions via two LEDs and dry contacts, as follows.
Once the board is energized and the battery voltage is above 80 V, the circuit goes into operation,
indicating via dry contact. Only after the battery and consumer voltage exceeds the value of
110 V will the circuit be enabled and start supervising the output voltage, with minimum limit
of 105 V to activate the Bypass.
Table 5.3: Reference voltages – dedicated circuit

Reference Voltage Condition
< 80 V Disabled
Vbattery
Enabled
> 110 V
SUPERVISING
Vconsumer
< 105 V BYPASS ACTIVATED
Table 5.4: LED indicators and dry contacts – dedicated circuit

Bypass
Indication De-energized Not Enabled Supervised
Activated
LED - Green On
Off On
LED - Red Off
Dry Contact
Common + NC Common + NO
BYPASS ACTIVATED
Dry Contact ON Common + NC Common + NO
Operation to RETURN from the protection by 2nd level – Dedicated circuit
This instruction informs the correct way to return to the normal operating mode after a possible
activation of the supervisory system via dedicated circuit:
1. Open the AC POWER SUPPLY circuit breaker (DJR).

2. Close the MANUAL Bypass circuit breaker (DJBP).
3. Open the BATTERY circuit breaker (DJB) and the CONSUMER circuit breaker (DJC).
4. Disconnect the power supply of the Supervisory Board (CN2).
5. Execute the necessary repair or inspection.
6. CONNECT the power supply of the Supervisory Board (CN2).
7. CLOSE the AC POWER SUPPLY circuit breaker (DJR).
8. Set the clock or wait for thirty seconds.
9. Navigate through the display menus to set the configurations if necessary.
10. PRESS the RECTIFIER button for two seconds.
11. Check the battery voltage; it must be equal to the setting of the float parameter.
12. CLOSE the BATTERY circuit breaker (DJB), and check the battery charging.
13. PRESS the CONSUMER button for two seconds.
14. Check the Consumer voltage; it must be equal to the setting of the reference parameter.
15. CLOSE the CONSUMER circuit breaker (DJC), and check if the voltage is equal to the
battery voltage.
16. PRESS the equipment Bypass Reset pushbutton.
17. Open the BYPASS circuit breaker (DJBP).

Preventive Maintenance
6 PREVENTIVE MAINTENANCE
We recommend the periodical preventive maintenance so as to increase the operation reliability
of the system and the useful life of components and integrated circuits.
Navigate on the “ROOT” menu up to the “MAINTENANCE” menu. On the “MAINTENANCE”

menu, you can check:
Remaining time to the next Revision I.
Remaining time to the next Revision II.
Accumulated operation time of the equipment.
After finishing the revision, the user may reset the timers on the “Maintenance” submenu.
Submenu
Revision I - Every 365 days (one year)
Keep the screen openings clean in order to enable the air inflow and outflow so as to keep the
equipment cooled, thus preventing the internal temperature from rising and ensuring proper
operation.
Keep the electronic boards always clean in order to avoid short circuits. Check the mechanical
connections whenever possible, or at least once a year.
Revision II - Every 730 days (two years)
Keep the screen openings clean in order to enable the air inflow and outflow so as to keep the
equipment cooled, thus preventing the internal temperature from rising and ensuring proper
operation.
Keep the electronic boards always clean in order to avoid short circuits. Check the mechanical
connections whenever possible, or at least once a year.
Check or replace the internal fans.
Check the batteries and replace them if necessary.
ATTENTION!
Before beginning the maintenance jobs, check if voltage is not present on the
terminals.

6.1 PROCEDURE TO ENTER THE MAINTENANCE MODE (MANUAL BYPASS)
ATTENTION!
During this operation, the consumer will be supplied by the batteries; therefore,
check the battery conditions.
1. Open the AC POWER SUPPLY circuit breaker (DJR).

2. Close the MANUAL Bypass circuit breaker (DJBP).
3. Open the BATTERY circuit breaker (DJB) and the CONSUMER circuit breaker (DJC).
4. Disconnect the power supply of the Supervisory Board (CN2).
6.2 PROCEDURE TO EXIT THE MAINTENANCE MODE (MANUAL BYPASS)
ATTENTION!
Check the connections and fastening of the replaced components.
1. CONNECT the power supply of the Supervisory Board (CN2).

2. CLOSE the AC POWER SUPPLY circuit breaker (DJR).
3. Set the clock or wait for thirty seconds.
4. Navigate through the display menus to set the configurations if necessary.
5. PRESS the RECTIFIER button for two seconds.
6. Check the battery voltage; it must be equal to the setting of the float parameter.
7. CLOSE the BATTERY circuit breaker (DJB), and check the battery charging.
8. PRESS the CONSUMER button for two seconds.
9. Check the Consumer voltage; it must be equal to the setting of the reference parameter.
10. CLOSE the CONSUMER circuit breaker (DJC), and check if the voltage equal to the battery
voltage.
11. OPEN the Bypass circuit breaker (DJBP).
6.3 RESET TO THE FACTORY SETTINGS
The Digital Rectifier has a function which resets all the configuration values to their factory
settings. In order to access it, follow the steps below:
Navigate on the “ROOT” menu up to the “MAINTENANCE” menu.
On the “MAINTENANCE” menu, press the “ENTER” key for three seconds so as to access
the submenu (1st level) with the options to reset the maintenance dates.
Press the “ENTER” key again for 10 seconds in the submenu (1st level) to access the reset
menu (2nd level).
Press “ENTER” to access the confirmation screen.
Press “UP” for three seconds in order to reset all the parameters or wait for 30 seconds to
return to the root menu.

6.4 REVISION TIME RESET
Navigate on the “ROOT” menu up to the “MAINTENANCE” menu.
On the “MAINTENANCE” menu, press the “ENTER” key for three seconds.
Press the “up” key for three seconds to reset revision1 or “down” to reset revision2.
In order to exit, hold “ENTER” pressed for three seconds.


Communication
7 COMMUNICATION
7.1 MODBUS-RTU COMMUNICATION
The Digital Rectifier with Modbus-RTU communication has two different physical interfaces:
USB and RS485. Both physical interfaces share the same communication port and, therefore,
only one of them can be active. The selection of the interface is done by means of a sliding
switch located on the equipment door, and it can be accessed through the side opening on
the control module protection, next to the USB connector.
The USB interface is located inside the equipment door and has a USB type B standard
connector. This interface enables local communication with the equipment.
The RS485 interface can be accessed on the dry contact terminal block, and it has a SAK
connector. This interface allows the creation of a network with more devices compatible with
the Modbus-RTU.
7.1.1 Installation of the Modbus-RTU Network
For the connection of the Digital Rectifier using the Modbus-RTU interface, the following points
must be observed:
COMMUNICATION PARAMETERS
The Modbus-RTU communication of the Digital Rectifier operates with rates of 9600 bps or
19200 bps, with 8 data bits, adjustable parity (even, odd or none) and 1 or 2 stop bits, with
minimum time between frames of 50 ms, configurable via the equipment HMI. In case the
stop bit is set to 2, the Parity will be disabled.
Configuration of the communication parameters
Navigate on the “ROOT” menu up to the “COMMUNICATION” menu.
On the “COMMUNICATION” menu, press the “ENTER” key for three seconds in order to
access the submenu (1st level) with the communication settings.
If the communication parameters are OK, exit the submenu by pressing "ENTER" on all
parameters without changing them.
Within the configuration menu (1st level), choose the parameter to be changed by pressing
the “ENTER” key in order to see the options.
In order to change the chosen parameter, press the arrows to increase or decrease the values.
ADDRESS
Every device on the Modbus-RTU network, whether master or slave, is identified by means of
an address. This address must be different for each device. Valid values: 1 to 247. This address
can be modified on the equipment panel, on the communication submenu.

Communication
NOTE!
The address effectively changes when you return and exit the communication
submenu.
TERMINATION RESISTORS
For each segment of the Modbus-RTU network using RS485, it is necessary to enable a
termination resistor at the ends of the main bus. It is worth to mention that, in order to allow the
disconnection of the element from the network without damaging the bus, it is interesting to put
active terminations, which are elements that only play the role of the termination. Thus, any device
in the supply (network) can be disconnected from the bus without damaging the termination.
The Digital Rectifier has termination resistors that can be turned on and off via the dip switch
located next to the sliding switch for physical interface selection.
USB COMMUNICATION DRIVE

For the computer to recognize the Digital Rectifier when connected to the USB port, it is
necessary to install the "Device Driver". This "Device Driver" is available for Windows, Linux
and Mac OS operating systems in the 32 and 64-bit versions.
Once the "Device Driver" is installed, the connected Digital Rectifier will be recognized as a
Virtual "Com" port, over which the Modbus-RTU protocol will flow.
7.1.2 Modbus-RTU Protocol
The Modbus protocol was initially developed in 1979. Currently, it is an open protocol widely
used by several manufacturers in different kinds of equipment. The Modbus-RTU communication
of the Rectifier was developed based on the following documents:
MODBUS Application Protocol Specification.
MODBUS over Serial Line.
Those documents define the formats of messages used by the elements that are part of the
Modbus network, the services (or functions) that can be provided via network, and how those
elements exchange data on the network. Those documents are available on: www.modbus.org.
Available Functions
For the Digital Rectifier, all the parameters were organized as Input Registers. Those registers
may be read by the Read Input Registers function (code 04). In order to keep compatibility
with legacy systems, those registers may be accessed as Holding Registers, via Read Holding
Registers function (code 03). The writing of parameters may be done via the Write Single
Register function (code 06).
The Digital Rectifier also supports the Read Device Identification function (code 43). This function
allows the reading of three strings, which represent the manufacturer’s name, the product name
and product software version.

Communication
Digital Rectifier Parameter Setting
The Table 7.1 on page 7-3 contains the parameters available on the Digital Rectifier. The
"Access" column indicates if the parameter is reading/writing (RW), read only (R), write only (W).
Parameter format: 16 bits unsigned integer.
Table 7.1: Parameters of the digital rectifier

Address Access Name Value
Operating Parameters
Indicates the current operating mode of the
equipment:
0 - OFF Mode
1 - Normal Mode
2 - Battery Mode
10 R Operating Mode 3 - Charger Mode
4 - Manual Bypass Mode
5 - Automatic Bypass Mode
6 - Low Battery Bypass Mode
7 - Overtemperature Bypass Mode
8 - Output Overload Bypass Mode
Indicates the current Rectifier state:
0 - OFF
1 - On
11 R/W Rectifier State 2 - Inhibited
The Inhibited State only appears on the reading and
indicates that, in spite of being ON, the Rectifier is
inhibited by the presence of some alarm.
Indicates the current state of the Consumer:
0 - OFF
1 - On
Consumer
12 R/W 2 - Inhibited
Status
The Inhibited State only appears on the reading and
indicates that, in spite of being ON, the Consumer is
inhibited by the presence of some alarm.
In this variable, each bit of the word represents an
alarm. Value 1 on the bit represents alarm present and
value 0 indicates alarm not present.
Bit 0 - High AC voltage
Bit 1 - Low AC voltage
Bit 2 - Phase sequence fault
Bit 3 - High battery voltage
Bit 4 - Low battery voltage
Bit 5 - High consumer voltage
20 R Alarms Bit 6 - Low consumer Voltage
Bit 7 - Consumer current limitation
Bit 8 - Overtemperature
Bit 9 - Output overload
Bit 10 - Reserved (always 0)
Bit 11 - Negative Earth Leakage
Bit 12 - Positive Earth Leakage
Bit 13 - Manual Bypass Active
Bit 14 - Automatic Bypass Active
Bit 15 - Reserved (always 0)

Communication
AC Input
100 R Phase Voltage RMS AC Voltage in V
101 S Phase Voltage RMS AC Voltage in V
102 T Phase Voltage RMS AC Voltage in V
103 R Phase Current RMS AC Current in 0.1 A
R
104 S Phase Current RMS AC Current in 0.1 A
105 T Phase Current RMS AC Current in 0.1 A
AC Power Supply
106 Frequency in Hz
Frequency
Batteries
200 Battery Voltage DC voltage in 0.1 V
201 Battery Current DC Current in 0.1 A
R
202 Battery Charge Battery Charge Percentage (%)
203 Battery Temperature Temperature in ºC
Consumer
300 Consumer Voltage DC voltage in 0.1 V
301 R Consumer Current DC Current in 0.1 A
302 Consumer Load Consumer load percentage (%)
Time and Date
400 Day Value of the day (1 to 31)
401 Month Value of the month (1 to 12)
402 R/W Year Value of the year (0 to 9999)
403 Hour Value of the hour (1 to 23)
404 Minute Value of the minute (1 to 59)
Event Log
The value recorded in this register represents the
index of the event to be read. The last registered event
receives the index 0, the penultimate registered event
receives the index 1, and so on.
Index of the event to
1000 W In case the requested index is greater than the number
be Read
of registered events, the last registered event will be
read. After that registration is written, the data of the
requested event can be read in registrations 1001 to
1007.
1001 R Day of the Event Day of the Requested Event
1002 R Month of the Event Month of the Requested Event
1003 R Year of the Event Year of the Requested Event
1004 R Hour of the Event Hour of the Requested Event
1005 R Minute of the Event Minute of the Requested Event
Number that identifies the event See Table 3.1 on page
1006 R Event Identifier
3-8
Index of the Current
1007 R It can be compared to the requested index.
Event

Technical Data
8 TECHNICAL DATA
AC Input
Power Supply 220 / 380 / 440 V AC +/- 10 % (1) (other on request)

Frequency 60 Hz or 50 Hz +/- 5 %
Power Supply System Three-phase
Power Factor > 0.85 (Default) or > 0.92 (Optional)
Protection/Disconnection Circuit breaker
(1) Rectifier in float.
Rectifier output
Voltage in Float 136 V (2.27 V / element)

Thermal Compensation 0.4 V / 1 °C (1.8 °F), above and below 25 °C (77 °F)
Ripple ≤ 2 % without battery and ≤ 1 % with battery
Dynamic Regulation (1) < 100 ms @ ±30 % overshoot with load step from 0 % to 100 % In
Voltage when Recharging 144 V (2.4 V / element)
Voltage when Discharging 120 V (2 V / element)
Minimum Voltage 105 V (1.75 V / element)
Battery Charge 0.1 x C10 (Ah/10h)
(1) Without battery.
Consumer output (1)
Rated Voltage 125 V

Rated Current 15 A to 500 A
Output Current Limit Adjustable between 50 % to 100 % of In
Static Regulation ≤ ±1 % for variations from 10 % to 105 % In
Dynamic Regulation ±10 % overshoot for load step from 10 % to 100 % In
Ripple < 1 % (without battery)
Efficiency > 85 %
Insulation > 5 Mega Ohms
(1) For standard equipment with UCQ.

Frame
Technical Data

Model (A) 15 25 35 50 75 100 125 150 200 300 400 500
Weight (kg) 250 300 310 340 390 460 500 545 600 800 1000 1450
Dimensions -
1718 x 600 x 450 2208 x 600 x 650 2208 x 800 x 650 2254 x 800 x 650 2254 x 1000 x 650 2254 x 1600 x 650 2254 x 1800 x 650
H x W x D (mm)
Dissipation (W) 600 900 850 1000 1500 1900 2000 2500 2700 3750 5000 6250
Technical Data
Operating conditions
Operating Duty Continuous

Temperature Range 0 °C to 40 °C (32 °F to 104 °F)
Relative humidity 0 to 95% non-condensing
Altitude Up to 1000 m above sea level
Ventilation Forced with fan
Noise Level > 60 dB
Protections
Circuit breaker Power supply, batteries, consumer and manual bypass (maintenance)
Current Limitations Charge/discharge of the battery and consumer (1)
Filters Against AC surges
(1) Below 110 V, the bypass is activated, remaining only the limitations of the battery and circuit breaker.
Remote interface
USB communication with Modbus-RTU protocol

Default RS485 interface with Modbus-RTU protocol
NO and NC dry contacts with capacity of 2 A at 250 Vac

Technical Data

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Motors I Automation I Energy I Transmission & Distribution I Coatings

Digital Three-Phase Rectifier | Battery

Publication Date: 01/2019

The information below describes the revisions made to this manual.

Version Revision Description

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

2 GENERAL INFORMATION................................................................. 2-1

3 INSTALLATION AND OPERATION.................................................... 3-1

4 CONTROL PANEL.............................................................................. 4-1

5 SUPERVISORY SYSTEM................................................................... 5-1

6 PREVENTIVE MAINTENANCE.......................................................... 6-1

8 TECHNICAL DATA............................................................................. 8-1

1.1 SAFETY WARNINGS IN THE MANUAL

The following safety notices are used in this manual:

1.2 PRELIMINARY RECOMMENDATIONS

Digital Three-Phase Rectifier | 1-1

1-2 | Digital Three-Phase Rectifier

2.1 ABOUT THE MANUAL

This manual is available for download at WEG website: www.weg.net.

2.2 TERMS AND DEFINITIONS USED IN THE MANUAL

°C: Degrees Celsius.

°F: Fahrenheit degree.

AC: Alternating current.

DC: Direct current.

kg: Kilogram = 1000 grams.

mA: Milliampere = 0.001 ampere.

rms: Root mean square; effective value.

RTD: from Portuguese "Retificador Trifásico Digital"; Digital Three-phase rectifier.

UCQ: from Portuguese "Unidade Conversora de Queda"; Voltage drop converter.

Digital Three-PhaseRectifier | 2-1

2.3 SYSTEM COMPONENTS

The system is basically composed of:

 Isolated three-phase rectifier.

 Battery (outside the panel; sold separately).

 Voltage drop converter UCQ.

Figure 2.1: Digital rectifier

2-2 | Digital Three-Phase Rectifier

Digital Three-Phase Rectifier (RTD) Parallelism

2.5 RECEPTION AND STORAGE

Report any problems immediately to the carrier.

a) The air must be free of corrosive chemicals.

b) The place must not present water infiltration or dripping.

d) The panel must be kept on the wooden base (pallet).

e) The packages must not be removed.

g) Vermin must not be present.

Digital Three-PhaseRectifier | 2-3

2-4 | Digital Three-Phase Rectifier

3 INSTALLATION AND OPERATION

Mount the equipment in a ventilated place free of explosive gases.

Temperature Sensor Connection

The following care must be taken:

Digital Three-Phase Rectifier | 3-1

RTD Model AC Power Supply DC Power Supply

RTD (A) 15 25 35 50 75 100

RTD (A) 125 150 200 300 400 500

3-2 | Digital Three-Phase Rectifier

3.1 INITIAL SETTINGS

Input voltage configuration

Isolated three-phase rectifier.

Battery (outside the panel; sold separately).

Voltage drop converter UCQ.

Navigate in the “ROOT” menu up to the “BATTERIES” menu.

Choose the charging current.

Automatic (factory default):

Confirm the desired operation.

Energize the equipment via the input circuit breaker DJR.

Check if the pre-charge occurred.

Close the battery circuit breaker DJB.

LED-backlit LCD with 4 lines x 20 columns.

Eight indication LED.

True rms AC voltage of the three phases.

True rms AC current of the three phases.

AC power supply frequency (Hz).

Charging and discharging DC current (Adc).

Charge percentage (%).

Percentage of charge in the consumer (%).

Remaining time to the next Revision I.

Remaining time to the next Revision II.

Accumulated operation time of the equipment.