PA 5840 User Manual english.indd
Contents
1. document has been carefully checked However Teseq does not assume any liability for errors or inaccuracies2. Advanced Test Solutions for EMC 33 34 Headquarters Teseq AG 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 sales teseq com www teseq com China Teseq Company Limited T 86 10 8460 8080 F 86 10 8460 8078 chinasales teseg com Germany Teseq GmbH T 49 30 5659 8835 F 49 30 5659 8834 desales Singapore Teseq Pte Ltd T 65 6846 2488 F 65 6841 4282 singaporesales teseg com Taiwan Teseq Ltd T 886 2 2917 8080 F 886 2 2917 2626 taiwansales teseq com USA Teseq Inc T 1 732 417 0501 F 1 732 417 0511 Toll free 1 888 417 0501 usasales teseq com To find your local partner within Teseq s global network please go to www teseq com Manufacturer Teseq AG 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 sales teseq com France Teseq Sarl 33 139 47 42 21 33 1 39 47 40 92 francesales teseq com Japan Teseq K K T 81 35725 9460 81 3 5725 9461 japansales teseq com Switzerland Teseq AG T 41 32 681 40 50 F 41 32 681 40 48 sales teseq com UK Teseq Ltd T 44 845 074 0660 F 44 845 074 0656 uksales teseq com December 2010 Teseq Specifi cations subject to change without notice Teseq is an ISO registered company Its products are design ed and manufactured under the strict quality and environmental requirements of the ISO 9001 This
3. CAPACITIVE HIGH FREQ This is the normal operating mode with a good compromise between stability and bandwidth The bandwidth in this selection is approximately 40 kHz This mode is specifically designed for capacitive and or reactive loads This reduced bandwidth high stability mode is perfect for using during normal transient testing conducted sine wave CSW testing The bandwith in this mode is limited to approximately 3 kHz This mode is for testing where high bandwidths are required This mode allows frequencies up to 150 kHz CAUTION As with all fast amplifiers the user should monitor the DUT to ensure no ringing or excessive over shoot is present that could result in damage to the DUT or couplers In case there is a question the CAPACI TIVE mode should be used TASEO Advanced Test Solutions for EMC 21 22 4 8 The gain button This button toggles between the available gain options of the amplifier GAIN HIGH X7 Indicates a gain of seven 1 V in will result in 7 V output voltage GAIN LOW x1 indicates a gain of one 1 V in will result in 1 V output voltage 4 9 The current limitation button This button toggles between the three current limitation modes PA 5840 PEAK OFF this selection enables no inrush current above what is set by 23 the current limit control from the DB9 or to the INPUT BNC connector The current limit circuitry will start immediately 3x CONTROL this selecti
4. ISO 16750 JASO D001 MIL STD 461E SAE J1113 as well as automobile manufacturer specifications Types of testing include supply voltage variations dips and drops ISO pulses 2b and 4 load dump pulse starting profiles power cycling battery recovery reset behaviour fuel pump transient conducted sine waves ground shift jump start and over voltage as well as providing a programmable DUT power source during all phases of testing 2 2 Features The output is programmable over a minimum voltage range from 15 to 60 V which allows the simulation of a large range of pulses and voltage variations A remote sensing input is provided to compensate for output cable voltage drop up to 4 V The output provides a wide bandwidth DC to gt 150 kHz a fast output slew rate low source impedance 10 and high peak output current typically 3 times nominal TASEO Advanced Test Solutions for EMC 10 and visibility These facilities include voltage input current limit input current limit indicator and display compensation mode gain setting output range current limitation system stop and output and sense connectors For convenience voltage and current control and monitoring interfaces have been duplicated BNC connectors are provided for general purpose connec tion to signal generators and an integrated control D type connector for direct connection to the Teseq NSG 5000 series The output terminals are duplicated with 6 mm
5. V 3 400 V 2x12A PA 5840 7 SPECIFICATIONS 7 1 Environmental conditions Temperature range Humidity Air pressure Protection class 29 Operation at 10 to 40 C storage at 10 to 60 C 30 to 75 non condensing 860 to 1060 hPa IP20 7 2 Technical capabilities PA 5840 75 PA 5840 150 PA 5840 300 75 Amp pk 150 Amp pk 300 Amp pk General Forward voltage gain switchable 7 1 7 1 7A Bandwidth 3 dB DC to 40 kHz DC to 40 kHz DC to 40 kHz standard standard standard to 150 kHz to 150 kHz to 135 kHz high freq high freq high freq Overtemperature shutdown Several redundant hermal sensors trip at 80 and 90 C Supply Supply voltage 1 phase 3 phase 200 400 V 10 L1 L2 L3 PE 100 120 230 V 10 L N PE Supply frequency 47 to 63 Hz Supply power kVA 6 12 kVA TASEO Advanced Test Solutions for EMC PA 5840 75 PA 5840 150 PA 5840 300 75 Amp pk 150 Amp pk 300 Amp pk Output Peak output power 200 ms 4 5 kW 9 kW 18 kW Max continuous output current 50A Peak output current for 200 ms 150 A Output impedance 10 Output accuracy Typical 196 DC 296 AC signals 296 Long term drift Uout 0 196 max Temperature drift Uout 0 0296 C 10 mvrms for more details and measurement methods see the calibration report Output ripple Uout Recovery gt 90 of exc
6. described as U OUTPUT U INPUT X GAIN INPUT is the analog control of the current limit The input limitation is 1 10 V as a ration of the available current limit where 1 V 1096 and 10 V 100 current limit For example for a PA 5840 150 which has a maximum constant current of 50A a5 V input will set a current limit of 25 A and a maximum peak current of 75 A when the CURRENT LIMITATION selection is 3X I CONTROL nectors at the same time Use either the Input BNC connector or the I Input of the control D Subconnector Never terminate the I input BNC or D Sub connectors m CAUTION Do not use both Input and control con CAUTION If used the input voltage at the I Input con nector must be at least 1 V 1096 output limitation 3 4 4 The output connectors TASEO Advanced Test Solutions for EMC 16 3 4 5 The power output connectors The POSITIVE NEGATIVE POWER connectors are used to connect the output to the DUT device under test or to the NSG 5000 series NOTE See the hardware guide of the appropriate test system for more details modularity For greatest accuracy Please use the upper connector i NOTE The PA 5840 300 has two output connectors 3 4 6 The sense output connectors The SENSE connectors may be connected to compensate for voltage drop of the cables to the DUT or to the NSG 5000 series 3 4 7 Rear panel connectors The connectors on the rear panel normally are configured by the factory P
7. socket type connectors for push in termination as supplied with the Teseq Automotive test systems Power dissipation is always a consideration with amplifiers To avoid excessive heat the PA 5840 range includes a range selection switch on the front panel to enable the amplifier to deliver more power continuously when simulating a 12 V system the low voltage range is selected which can provide a reduction in power dissipation which allows continuous operation for longer under high load conditions The amplifier inputs are over voltage protected and outputs short circuit pro tected Overtemperature protection is monitored on the internal heat sink and transformer There are three selectable ranges for compensation bandwidth for the PA 5840 Bandwidths are high allowing fast slew rates as required by numerous standards The current limit is programmable from 10 to 100 of the output current capa bility PA 5840 3 INSTALLATION SET UP mmm 3 1 Checking the shipment Upon receiving the shipment first check the packaging and outer equipment for visible damage Also check packaging and casings of peripherals if any Record in writing any defects which were possibly caused in transit If the shipment shows damage or is not complete immediately advise the shipping agency and or your dealer 3 2 Delivery contents The standard delivery contains the basic unit as well as several attachments and accessories 3 2 1 Standard accessor
8. 55011 TASEO Advanced Test Solutions for EMC 32 7 3 Pictures 7 3 1 Front view 7 3 1 Rear view PA 5840 7 3 3 DECLARATION OF CONFORMITY CE Declaration of conformity Manufacturer Address Product Options Generic standards Technical file THSEO Advanced Test Solutions for EMC Teseq AG Nordstrasse 11F 4542 Luterbach Switzerland T 41 32 681 40 40 F 41 32 681 40 48 www teseg com Teseq AG Nordstrasse 11F 4542 Luterbach Switzerland declares that the following product PA 5840 Automotive Battery Simulator all conforms to the following Directives and Regulations EMC Directive 2004 108 EEC LVD Directive 2006 95 EEC EN61326 1 2005 EN61326 2 1 2005 EN61010 1 2001 The relevant technical file is available for inspection N EMC_PA5840_2006 LVD_PA5840_2006 Teseq AG CH 4542 Luterbach The purpose of this instrument is the generation of defined interference signals for EMI immunity testing Depending on the arrangement of the test rig the configuration the cabling and the properties of the EUT itself a significant amount of electromagnetic radiation may result that could also affect other equipment and systems The user himself or herself is ultimately responsible for the correct and controlled operation of the rig In case of doubt the tests should be carried out in a Faraday cage Place and Date Luterbach December 12 2006 Johannes Schmid President TASEO
9. Advanced Test Equipment Rentals Established 1981 www atecorp com 800 404 ATEC 2832 PA 5840 AUTOMOTIVE BATTERY SIMULATORS USER MANUAL 601 306A Advanced Test Solutions for EMC PA 5840 AUTOMOTIVE BATTERY SIMULATORS USER MANUAL CONTENTS Safety Instructions Classification of dangers Warning symbols on the test system Excess voltage category Range of validity Safety of operation Personnel Responsibility for safety precaution Reduction in operational safety As agreed use 2 Introduction 2 1 Introduction 2 2 Features 3 Installation set up 3 1 Checking the shipment 3 2 Delivery contents 3 2 1 Standard accessories 3 2 2 Documentation 3 3 Setup 3 3 1 Operating position 3 3 2 Line voltage connection and grounding 3 4 5840 front panel connectors 3 4 1 The control connector 3 4 2 Pin count of the control I O DSub connector 3 4 3 The function generator input connector 3 4 4 The output connectors 3 4 5 The power output connectors 3 4 6 The sense output connectors 3 4 7 Rear panel connectors CE aS gt 4 4 1 4 2 4 3 4 4 4 5 4 6 4 7 4 8 4 9 4 10 5 5 1 5 2 5 3 5 4 5 5 6 6 1 6 2 6 3 7 7 1 7 2 7 3 Operation The main switch The system stop button The output voltage RMS display The output current RMS display The view current limit button The
10. accident prevention regulations See also the safety instructions in the manufacturer s manual included with any additional instru ment or device you intend to use with your Teseq test equipment 1 8 Reduction in operational safety If you have any reasons to suppose that the test equipment is not completely safe you must shut it down and put it out of operation Moreover you must mark or label the equipment appropriately so it will not inadvertently be put into operation again You should then call authorized service personnel for assistance 1 9 As agreed use The test equipment must exclusively be used for testing electrical devices and components indicated in the technical specifications PA 5840 2 INTRODUCTION E 2 1 Introduction The PA 5840 range of battery simulators are high performance power amplifiers providing a stable and rugged power source for laboratory applications The amplifiers have been designed specifically to simulate battery supplies such as 12 24 and 42 V vehicle electrical systems They may be used on their own or integrated with the Teseq Automotive EMC Test System consisting of NSG 5000 NSG 5200 NSG 5500 NSG 5600 hereafter referred to as NSG 5000 series and AutoStar Software The amplifiers are offered in three frame sizes with nominal output currents of 75 150 and 300 A peak values Designed to meet EMC immunity testing requirements for the automotive indu stry Applicable standards include ISO 7637
11. elevant general precautions as well as all safety instructions given in this manual are observed In particular observe the following m Connect the device only to line voltage that confirms to the power specification given on the type label on the back of the test equipment m Donot touch any conductive parts at the output connectors the fixture and the test object during a test run m Disconnect the device from the mains before opening the casing for main tenance or repair m During the operation of the test equipment always observe the relevant rules of ESD Electro Static Discharge protection m To guarantee the EMC features of the device the control computer must meet the requirements of the EN 50082 55011 61000 standard m Make sure the environmental conditions described in chapter 7 1 Environmental conditions exist 1 6 Personnel The equipment may be operated by qualified personnel only It may be opened for adjustment maintenance or repair by authorized staff only Teseg or its representative may not be held responsible for service not performed by Teseq personnel TASEO Advanced Test Solutions for EMC 1 7 Responsibility for safety precaution The owner operation supervisor and or operator of the equipment are respon sible for safety The owner operation Supervisor and or operator are in charge of any safety measures that do not directly concern the test equipment itself For details see the relevant
12. errors LEDs The compensation button The gain button The current limitation button The output range button Applications Compliant with ISO 7636 and similar for transient immunity Voltage variations for starting profiles Fast rise time for callenging voltage dip applications Voltage ripple and sine wave noise simulations Example application with NSG 5500 and NSG 5600 Maintenance Cleaning the equipment Moving and storing the amplifier Protection Specifications Envionmental conditions Technical capabilities Pictures 7 3 1 Front view 7 3 2 Rear view 7 3 3 Declaration of confirmity CE 8 Addresses PA 5840 17 17 18 19 19 19 20 21 22 22 23 24 24 24 25 25 26 27 27 27 28 29 29 29 32 32 32 33 34 1 SAFETY INSTRUCTIONS 1 1 Classification of dangers CAUTION It is imperative that you read the follow ing safety instructions and all safety instructions in the manuals of connected peripheral systems before installing and starting the tester for the first time The electrical and mechanical safety equipment must not be removed put out of operation or bypassed Handle all safety equipment with care If a safety device should be broken or is not working the system must be put out of operation until the safety equipment is repaired or exchanged and fully in working order again The safety instructions in this manual are classified in different levels The table below shows a
13. ies m One power cable 3 2 2 Documentation The following manuals are supplied m This PA 5840 Automotive battery simulators hardware guide 3 3 Set up personnel only It is imperative to observe the safety instructions at the beginning of this manual The equip ment will be safe to operate and perform to its specifi cations only under the environmental conditions found in chapter 7 1 Environmental conditions m CAUTION The equipment may be set up by qualified TASEO Advanced Test Solutions for EMC 12 3 3 1 Operating postition ating is only allowed in vertical position There must be enough space around the equipment to ensure a sufficient air flow for cooling The ventilation grilles must be kept free HE CAUTION The equipment must be set up stable Oper 3 3 2 Line voltage connection and grounding conforming to the power specification given on the type label on the back of the equipment If the grounding is interrupted inside or outside the equipment the PA 5840 will become a source of danger Carefully observe grounding precautions The plug on the power cord may be replaced by qualified personnel only DANGER Connect the equipment only to line voltage The power cord of the equipment is located on the back of the equipment The power input is secured with a thermal magnetic circuit breaker for details refer to chapter 6 3 Protection The power plug and outlet must have grounding contacts The supplied ma
14. iles with up to four synchronized starting profiles See the specifications of the NSG 5000 series for details Ue OV PA 5840 5 3 Fast rise time for challanging voltage dip applications Certain standards such as Ford ES XW7T 1A278 AC specify 10 us rise and fall times for the battery simulator The PA 5840 is designed to fully meet the relevant standards and is often used for dips and drops applications where lt 10 us rise times are specified 5 4 Voltage ripple and sine wave noise simulations The PA 5840 is also commonly used to simulate sine wave noise on battery voltage A user could for example simulate a 1 V p p sine wave onto a 42 V network using high battery current This is a common requirement of manu facturers standards TASEO Advanced Test Solutions for EMC 25 th NSG 5500 and NSG 5600 lon WI 5 5 Example applicat 26 Jojjonuo2 OLSS LIN OESS 14 9908 0098 9SN 0198 19 099 94 2015 0598 21 zZ 7 yndjno 103 09S Yd 0295 Sd 0098 9SN sindjno 95095 z indino 103 10 Wd Mis jndino IAS indui syndyno 95095 2 indui Auayeg Ot 8S Vd jeg PA 5840 6 MAINTENANCE Mls Under normal conditions it does not take much effort to keep your test equip ment in good working order CAUTION Protect the equipment against moisture heat and dust 6 1 C
15. ins cable may be configured on request or with 3 phase con nectors or it is left with only the connector to the PA 5840 and on the other end can be wired per the user s needs CAUTION 3 phase mains connectors must be installed only by qualified personnel When the equipment is brought from cold to warm environment the ensuing condensation may bring about dangerous conditions PA 5840 DANGER The equipment may only be switched on after 13 all parts have fully acclimatized 3 4 PA 5840 Front panel connectors 3 4 1 The control connector The CONTROL connector is an input port from the function generator card Connect the 9 pin DSub CONTROL connector to the appropriate connector at the function generator card of your NSG 5000 series TASEO Advanced Test Solutions for EMC 14 3 4 2 Pin count of the control I O DSub connector 1 limt 5 4 3 2 2 leef Vprogt 4 Viet 5 98 76 3 4 3 The function generator input connector PA 5840 POWER AMPLIFIER BATTERY SIMULATOR A OUTPUT VOLTAGE RMS OUTPUT CURRENT RMS CONTROL U INPUT INPUT 4 9 5840 This inputs may be used in special applications when the NSG 5000 series is not used Another function generator may be used to control the DC amplifier 1 V input is 7 V output The U INPUT is the driving voltage of the battery simulator The output of the battery simulator can be
16. leaning the equipment To clean the equipment use a dry clean cloth Never use water any other liquid or detergent 6 2 Moving and storing the amplifier The amplifier must be installed uninstalled only by qualified personnel Before moving the equipment even over a short distance you must first turn it off and disconnect it from the mains Remove any fixturing devices and or test objects Also disconnect the amplifier from any peripherals For longer transit protect the equipment against humidity dust and shock by proper packaging The equip ment must be stored in upright working position Make sure the equipment is protected against humidity dust and dirt Observe the environmental conditions specified in chapter 7 1 Environmental conditions TASEO Advanced Test Solutions for EMC 27 28 6 3 Protection The PA 5840 Automotive battery simulators are protected with a thermal mag netic circuit breaker The thermal element is a slow breaker to allow high inrush currents The magnetic element is a fast breaker but set to a higher current limit than the thermal element The different versions of the PA 5840 are equipped as follows Type No of phases Supply voltage U Primary current I PA 5840 75 100 V 1 100 V 25A PA 5840 75 120 V 1 120V 24A PA 5840 75 230 V 1 230V 12A PA 5840 150 200 V 3 200V 24A PA 5840 150 400 V 3 400 V 12A PA 5840 300 200 V 3 200 V 2 24 PA 5840 300 400
17. lease ensure the connections are made as shown in the picture below PA 5840 4 OPERATION 7 4 1 The main switch The test system PA 5840 can be switched ON and OFF with the main switch The output range is selectable between 30 and 60 V by pressing the output range button NOTE The 30 Volts range is for greater efficiency during normal 12 and 24 V battery voltage operation TASEO Advanced Test Solutions for EMC 18 OFF system is completely powered off ON The system is in standby mode when first starting the system or after an error condition In order to start the system the first time or after an error condition the key must temporarily be placed in the START position START Momentary Used to enable the amplifier output key can be removed in either the ON or OFF posi tion Please do not lose this key as the system will be unusable without it HE CAUTION For safety the POWER switch is keyed The 4 2 The system stop button In case an EUT needs to be exchanged frequently the optional safety banana plug set INA 163 gives the possibility to connect the EUT in an easy and safe way With this option the max current consumption of the EUT must not exceed 32 A DANGER The STOP button does not disconnect the tester from the line voltage PA 5840 4 3 The output voltage RMS display 19 This display shows the output voltage in RMS 4 4 The output current RMS display Thi
18. on will allow an inrush current of three times the programmed current limit for 200 ms before the current imitation starts 3x MAX this selection will allow an inrush current of three times the maximum current available from the battery simulator for 200 ms before the current limitation starts 4 10 The output range button This button toggles between the two available output ranges 30 V this option selects a maximum usable range of 30 15 V for greater efficiency 60 V this options selects a maximum usable range of 60 15 V for testing up to the full power of the battery simulator TASEO Advanced Test Solutions for EMC 24 5 APPLICATIONS 5 1 Compliant with ISO 7637 and similar for transient immunity The PA 5840 is designed to act as the battery source for transient immunity tests Most transients must be coupled onto battery voltage and the NSG 5000 series with its internal coupling couples the transient and the DC voltage as required by the standards Designed with low internal resistance low noise and high inrush current the PA 5840 is compliant with section 5 4 of ISO 7637 2 2004 5 2 Voltage variations for starting profiles The PA 5840 series is often used for starting profile simulation pulse 4 and variants In addition several standards require synchronized starting profiles Utilizing the NSG 5000 series for control the PA 5840 is the best solution for all nown starting prof
19. s display shows the actual output current or the programmed current limit when pressing the VIEW CURRENT LIMIT button 4 5 The view current limit button This LED indicates that the current limit has been reached The current does not take effect until the conditions from the CURRENT LIMITATION field are met Pressing the VIEW CURRENT LIMIT button displays the current limit on the OUTPUT CURRENT display TASEO Advanced Test Solutions for EMC 20 4 6 The errors LED SAFETY FAIL POWER FAIL OVERTEMP PA 5840 This LED lights in the event of the SYSTEM STOP button being pressed this LED will light if any of the internal system voltage check fails this LED blinks as a warning that the internal operating temperature is reaching shutdown range This LED stays constant when the internal operating range reaches critical and the system is turned to a special cooling mode that means that the amplifier is turned on and the fans are cooling but no output is allowed Turning the POWER key to START after allowing a suitable cooling time will return to normal operation NOTE Turning the POWER key to START will clear all errors and return the system to normal operation NOTE During the system power up the LEDs and the temperature warning beeper will be tested for approxi mately one second 4 7 The compensation button Pressing this button toggles between the available compensation modes STANDARD
20. survey over the relation of symbols ideograms and keywords to the specific risk and the possible consequences TASEO Advanced Test Solutions for EMC Warning symbol Signal word Definition DANGER damage to persons or heavy damage to the Possibly dangerous situation that may cause tester and or the equipment CAUTION Situation that may cause damage to the tester and or the equipment Ea NOTE User tips and other important or useful infor mation and comments 1 2 Warning symbols on the test system Different warning symbols are placed on the test system The table below shows a survey over the relation of symbols ideograms and keywords to the specific risk and the possible consequences Pictogramm Definition Possibly dangerous situation that can result in injuries and serious damage to the equipment LN A Situation that can result in damage to the equipment 1 3 Excess voltage category The test equipment PA 5840 as described in this manual is related to the excess voltage category according IEC 60664 PA 5840 1 4 Range of validity These instructions are valid for the complete installation Further safety regula tions for components installed in this test equipment or additional installed devices are not suspended by these instructions 1 5 Safety of operation Reliable function and safe operation of the test equipment are ensured only if the r
21. ursion within 25 us Output rise time 3 us high freq 10 us standard Remote sensing Auto compensation for up to 4 V cable loss Control signals Input impedance 10 kOhm U Input in X1 1 V 1 V output in X7 1 V 2 7 V output Input 10V 25 50 10V 100A Display for output voltage Oto 60 V 1 digit 296 of reading Display for output current 0 to Imax continuous 1 digit 2 of reading PA 5840 PA 5840 300 31 PA 5840 75 PA 5840 150 75 Amp pk 150 Amp pk 300 Amp pk Mechanical specification Standard housing style 19 wheeled cabine construction Overall dimensions H x W x D 700x650x720mm 700x650x720mm 700x600x 1300 mm 27 6 X22 X 28 3 27 6X22X 28 3 276x23 6x512 Masse kg 100 kg 220 Ibs 195 kg 429 lbs 290 kg 780 Ibs Control panel top front 2 x Display 37 digit red LED Voltage current 1 x Connector 9 pole male D d lorog 2 x Connector BNC U prog prog Front panel low front Connector for output power 2x6mm 100 A female Connector for output power sense 2 2 banana female Power switch 3 position OFF ON START Rear panel Protective breaker 2 pole 3 pole Connector for line supply 1 phase socket 3 phase socket Standard compliance Safety IEC 1010 1 EMC EN 50082 1 EN
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