PU1000/PU600 Installation manual
Contents
1. LED is lit when the output voltage is approximately 15 higher or 10 lower than nominal output voltage When the output voltage is normal the relay contact is in the position printed on the front panel 5 2 Over temperature All models have thermal protection If the converter is overheated it reduces its maximum output power The OVER TEMP LED is lit and the alarm relay is set to alarm This will not occur in normal operation with an ambient temperature below 55 C when the unit has sufficient cooling The converter is convection cooled and there should be a minimum of 30 50mm of free space at upper and lower parts of the converter If this is not possible we recommend the use of an external fan Note that the expected life of the converter is dependant on converter temperature For every 10 C that the temperature is decreased the expected life is approximately doubled It is therefore crucial to cater for good ventilation and if possible reduce ambient temperature 6 Sense 6 1 External sense External sense is used when voltage regulation at the load is critical The converter regulates the voltage at the load and not at the output of the converter and does thereby compensate for voltage drop in the cables between the converter and the 10229 15 doc Page 7 10 POLYAMP LAL INSTALLATION MANUAL load The maximum voltage compensation is 5 of nominal output voltage Do not disconnect the negative power conne2. BNE eas Bo EERE Beak BEERS 10 10229 15 doc Polyamp AB Sweden www polyamp com Page 3 10 POLYAMP i INSTALLATION MANUAL 1 Before installation On the front panel label the following is displayed Converter type input voltage range nominal output voltage serial number options article number isolation voltages and ambient temperature range The converter type name consists of model name PU1000 or PU600 followed by input code and output voltage Two examples e PU1000 110 48 has input code 110 and nominal output voltage 48Vd c e PU600B24 has input code B and nominal output voltage 24Vd c Input output and case are galvanically separated from each other You can thus choose how you want the system connected The input is protected against reverse polarity by a parallel diode at the input on models with input code 24 48 72 A B and C This diode however is only intended to blow an external input fuse 110 220 440 and D input codes have an inrush current limit thyristor which also works as a series diode The input shall be fused with an approved fuse with a slow blow characteristic and high breaking capacity See table 1 PU1000 input fuses Time delay fuse Input voltage code PU600 input fuses Input voltage code Time delay fuse A 80 A B 50 C 20 10 Table 1 Recommended input fuses There are two reasons we do not include the fuse 1
3. E E OTO EEE OTA E A 8 8 OUTPUT OVER VOLTAGE PROTECTION eseessecessseessccecsseceessecesssecssoceesseceesecsscoeesseceesseceessecsssseessoceesse 8 9 INRUSH CURRENT LIME visa iscesccscscecssessieeactaestcasiacteoscudestcasesogsvacsbeatessessecadeassasesscsesedessdasseassesdeescedvascasedeesosss 8 10 ISOLATION VOLTAGE TEST sssssssessstsossvecsesssvecsssesensesvnsesisonssessevensessesvasesdescsdevisccssesessecseseossssabiosesecsoosssee 8 10 1 DC ISOLATION TEST OUTPUT TO CASE s 8 10 2 DC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ccccccececececececececececececececececececececececececeeeeeeeeess 9 10 3 AC ISOLATION TEST INPUT TO OUTPUT AND INPUT TO CASE ccccccecececececececececececececececececececececececececeeseesecs 9 11 TROUBLE SHOOTING i essscssesscssssevssscvssccsestsccseevscsesvectecssacceeseebessssusdeccedectesessssessbsoessssubscssedsssesseutenccoseseiossense 9 THERE IS N OUTPUT 9 11 2 THE INPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED cccccececececececececececececececececececececececececeeseececeeecs 9 11 3 THE CONVERTER STARTS AND STOPS REPEATEDLY ccccccecececececececececececececececececececececececececececececececececcs 10 11 4 THE CONVERTER STOPS AFTER SEVERAL HOURS ccccccecececececececececececececececececececececececececececececececececececececs 10 11 5 FAULT REPORT bs duces bas Bo eis Beck
4. a short circuit e If there is an external short circuit remove 1t e Ifthe load is too large decrease the load or consult your Polyamp dealer 4 Check that the INHIBIT input is not short circuited See 7 Inhibit on page 8 5 Check that the SENSE is connected correctly See 6 Sense on page 7 6 The unit is broken Contact your Polyamp dealer 11 2 The input fuse blows when the input is connected 1 Check that the input voltage polarity is correct 2 Check that the input fuse is of time delay type and with correct current rating See Table 1 10229 15 doc Page 9 10 POLYAMP LAL INSTALLATION MANUAL Some models have inrush current limit Fore further information consult 9 Inrush current limit on page 8 2 The unit is broken Contact your Polyamp dealer 11 3 The converter starts and stops repeatedly All models have an over under voltage protection which shuts down the converter if the input voltage is not within specified limits see front label 1 The cables to the converter input may be under sized causing too high voltage drop in the supply cables 2 Your supply does not have enough current capacity so the input voltage to the converter drops below specified limit 11 4 The converter stops after several hours If the red gt OVER TEMP LED is lit the unit has not sufficient cooling or the ambient temperature is to high See 5 2 Over temperature on page 7 for further
5. information 11 5 Fault report We suggest that you return a faulty converter to POLYAMP AB Box 229 Backgatan 10 597 25 TVIDABERG SWEDEN Tel 46 120 85400 Fax 46 120 85405 or to your local Polyamp distributor To help us locate the fault please describe the fault and how and when it occurred Polyamp AB Sweden www polyamp com 10229 15 doc Page 10 10
6. DC networks should be fused at the distribution point to protect the cable 2 Different applications require different types of fuses If the converter is mounted in an electric vehicle an external series diode on the input is recommended Please contact your Polyamp dealer Polyamp AB Sweden www polyamp com If the converter supplies a DC motor we recommend an external parallel diode at the motor poles to protect against reverse voltages For the disconnection ability an external disconnection device which is able to disconnect both polarities shall be incorporated with the input power supply cord The disconnection device must be properly labelled and easy accessible 2 Installation The converter shall be mounted in an enclosure which meets the demands of EN60950 regarding fire voltage hazard and mechanical strength The converter is supplied with mounting brackets With these you can mount the converter in any direction The converter is convection cooled and in order to get sufficient cooling there shall be a minimum of 30 to 50 mm space at upper and lower parts of the converter If this is not possible we recommend the use of an external fan Note that the expected life of the converter is dependant on converter temperature For every 10 C that the temperature is lowered the expected life is approximately doubled It is therefore crucial to cater for good ventilation and if possible to reduce ambient temperat
7. POLYAMP LAL pu1o0PU60 INSTALLATION MANUAL PU1000 PU600 Installation manual fae geome or tOO out 6 pas r a Bg Schulz Y Electronic Schulz Electronic GmbH Dr Rudolf Eberle Stra e 2 D 76534 Baden Baden Fon 49 7223 9636 0 Fax 49 7223 9636 90 vertrieb schulz electronic de www schulz electronic de 10229 15 doc Polyamp AB Sweden www polyamp com Page 1 10 POLYAMP ueu pu1o90Pu60o INSTALLATION MANUAL Warranty All Polyamp DC DC converters are warranted against defective material and workmanship This warranty is valid for 24 months from the date of delivery We will repair or replace products which prove to be defective during the warranty period The warranty is valid only if the converter is used within specification Manual This manual is as complete and actual as possible at the time of printing However the information may have been updated since then Polyamp AB reserves the right to make changes in this manual without notice The exclamation point within an equilateral triangle is intended to alert the user to presence of important operating and maintenance instructions in the literature accompanying The lightning flash with arrowhead within an equilateral triangle is intended to alert the user to presence of uninsulated dangerous voltage within the products enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons Caution To prevent the risk of electr
8. Turn the V ADJ potentiometer approximately one 1 turn counter clockwise on all converters but one This will not affect the output voltage yet 2 Turn the V ADJ potentiometer counter clockwise on the remaining converter if your load current exceeds 5 of the total rated current this should be the only unit with the MASTER LED lit until you reach the output voltage you desire If you turn more than one 1 turn counter clockwise you must repeat from step 1 3 The other units should now also be adjusted to approximately the same output voltage Otherwise the output voltage will drop if the master converter breaks down Turn clockwise on the V ADJ potentiometer on the other units slowly until the C MASTER LED is lit or almost lit 4 Multiple loads at the output If you are using several loads we recommend fusing them separately with fast acting fuses on the positive output branch Some considerations regarding short circuits should be taken See below 4 1 Short circuits 1 If there is a short circuit in one branch and the total current in all branches does not exceed 105 of the nominal current of the converter see label on front panel the output voltage will not be affected The time for the fuse to blow can be calculated from the data sheet of the fuse if you know the short circuit current trough the fuse If there is a short circuit in one branch and the total current in all branches does e
9. ction from the converter to the load before the positive when the converter is running and external sense is used This might damage the converter and it is also not advisable for Your own protection to make adjustments in the installation with voltage applied 1 Remove the jumpers from the sense inputs at the removable connector 2 Connect a twisted pair 0 25mm 1 5 between the sense terminals of the converter and the load see Figure 4 The sense leads and the power cables shall be of approximately the same length and drawn as close to each other as possible Beware of correct polarity 5 51 52 53 54 55 56 Figure 5 Feature contact 6 2 Internal sense If external sense is not used the jumpers shall be connected between SENSE V between SENSE and V as they are at delivery The converter then regulates the voltage at its output screw terminals 7 Inhibit The converter is shut down if the inhibit input is short circuited by a relay or an electrical switch The current through the short circuit is 20mA Note that there is no electrical isolation between the inhibit and the output Polyamp AB Sweden www polyamp com 1 Use a twisted pair 0 25mm 1 5mm with a maximum length of 3 0m for connection of the inhibit 8 Output over voltage protection All models are equipped with an internal output over voltage protection circuit OVP It consists of an a
10. dditional voltage regulator operating in parallel with the main regulator The output voltage is limited to approximately 15 above the nominal output voltage As long as the OVP circuit is active the alarm relay is set to ALARM state and the red NOT OK LED is lit 9 Inrush current limit Models with input codes 110 220 440 and D are equipped with inrush current limit feature The input capacitors are charged through a resistor to reduce the input current during start up When the converter starts this resistor is shunted by a thyristor which also acts as a series diode All models have a slow start feature To reduce input current during start up the output capacitors are charged slowly approximately 0 15 10 Isolation voltage test Each converter has been isolation tested in factory before delivery see Table 2 Warning An isolation test shall only be performed by personnel aware of the dangers and hazards of the test Input Isolation Output Isolation code In out voltage out case In case Vd c 24 48 2 0kVd c 72 110 220 2 5kVa c 440 C D Table 2 Isolation voltages on different converters 10 1 DC isolation test output to case 1 Disconnect all cables from the converter 2 Connect the input terminals of the converter to case 3 Connect the output terminals together 4 Connect your isolation tester between output and case See Figure 6 Raise the vol
11. e reason breaks down another converter automatically becomes current master To achieve good power sharing the voltage drop between the minus poles must be kept as low as possible see Figure 1 The plus poles can either be connected as in Figure J or have separate cables to the load At light load if the total load is less than 5 of the total rated power the yellow C MASTER LED might flicker between the units As the load changes different units C MASTER LED might be lit All this is normal 10229 15 doc Page 5 10 POLYAMP a gt bani INSTAL EATON MANDAT Figure 1 Current share connection with series diode 3 3 Voltage adjustment with current sharing The converters must be running with 5 of nom load or more and the current share must be connected If each converter output voltage is adjusted to the same voltage which they are at delivery the yellow MASTER LED might be lit on most units To increase the output voltage 1 Choose a unit where the MASTER LED is lit Turn the V ADJ potentiometer clockwise until you reach your desired output voltage 2 The other units should now also be adjusted to approximately the same output voltage otherwise the output voltage will drop if the master converter breaks down Turn the V ADJ potentiometer slowly clockwise on the other units until the C MASTER LED is lit or almost lit To decrease the output voltage 1
12. ic shock do not open enclosure No serviceable parts inside Refer servicing to qualified service personnel only 10229 15 doc Polyamp AB Sweden www polyamp com Page 2 10 POLYAMP LAT _pu1o90PU600 INSTALLATION MANUAL CONTENTS 1 BEFORE INSTALLATION S raiti iS aS 4 2 INSTALLATION ateo 4 3 PARALLEL CONNECTION eseesseceessecesssecssccecssoceessecescsecsscceesseceessessccsecsscccesseceesoecsssseesscceesseceessseesssseesseceesse 5 32 1 SERIES DIODE ON THE OUTPUT ontran anan a Or E E E E E 5 322 CURRENT SHARING C AEE A EEEE EE E EE EE 5 3 3 VOLTAGE ADJUSTMENT WITH CURRENT SHARING s seserererererertrtrtrtrtrtrtrtrtrtrtttrtrtrtrtrtrertrerererererererererere 6 4 MULTIPLE LOADS AT THE OUTPUT e sseeessececssecesssecsscceessececssecsssseesscceesseceessecesscessoceesseceesseesscseessoceessee 6 4 1 SHORT CIRCUITS Sn 6 E S A EEA TA E S O E EER E EEEO T 7 5 1 OVER AND UNDER VOLTAGE ALARM cccccccccccccccccecececececesesesesecesecesesesesscesesesesesecssssssessescssssaseceseuseseeesseuseaeanaes 7 5 2 OVER TEMPERA TURE e neh aes eas 7 I aI ETA E E T E EEEE E E E E A 7 6 1 EXTERNAL SENSE u cccccccccccccccccccccscceccscsesesesesesesesesesesesesesesssesesssssesesesssesecesscesesssasesesesscesscssesasasessssusesseseseseeeuaes 7 6 2 DNH N EA ANS ERI INR EA E E E 8 anA A E E E E E E O E
13. olyamp com If your isolation test equipment cannot supply this current you can perform a DC isolation test with 4000Vd c 2500V x V2 x 1 1 4000Vd c where 1 1 safety factor Follow the instructions in 0 10 2 DC isolation test input to output and input to case above but test with 4000Vd c instead of 2000Vd c The leakage current should not exceed 5 AC isolation test Disconnect all cables from the converter Connect the output terminals of the converter to case See Figure 7 3 Connect the input terminals together 4 Connect your isolation tester between input and case See Figure 7 Raise the voltage of the isolation tester from 0 to 2500Va c The voltage should not be applied for more than one 1 minute or the Y capacitors might be damaged 5 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between input and case Ne 11 Trouble shooting 11 1 There is no output voltage 1 Check that the input fuse is not broken 2 Check that the input voltage polarity is correct 3 Check that the input voltage is within the specified limits see front label 4 If the red NOT OK LED is lit the converter may be in current limit due to excessive output current or an external short circuit on the output e Disconnect the input e Disconnect the load e Connect the input again and measure the output voltage If the converter now starts the load was too heavy or there was
14. tage of the isolation tester from 0 to 2000Vd c Check that 10229 15 doc Page 8 10 POLYAMP LAL INSTALLATION MANUAL the leakage current does not exceed 5uA The voltage should not be applied for more than a few seconds or the Y capacitors might be damaged 5 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between output and case Figure 6 Output to case isolation voltage test 10 2 DC isolation test input to output and input to case Disconnect all cables from the converter 2 Connect the output terminals of the converter to case 3 Connect the input terminals together 4 Connect your isolation tester between input and case See Figure 7 Raise the voltage of the isolation tester from 0 to 2000Vd c Check that the leakage current does not exceed 5uA The voltage should not be applied for more than a few seconds or the Y capacitors might be damaged 5 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between input and case Figure 7 Input to output and input to case isolation voltage test 10 3 AC isolation test input to output and input to case You can also test 2500Va c for one 1 minute between input to output and case on units with input codes 110 220 440 C and D Beware of the rather high capacitive earth currents about 100mA that will occur during this test Polyamp AB Sweden www p
15. th your external input disconnection device Beware of hazardous voltages e The output voltage can be adjusted 10 to 5 of nominal output voltage with the potentiometer marked V ADJ on the front panel Clockwise turn increases the output voltage The potentiometer has 15 turns If you are using current sharing the procedure of adjusting the output voltage is described in3 3 Voltage adjustment with current sharing on page 6 Replace plastic cover 6 When the converter is disconnected switch off the input voltage with the disconnecting unit Disconnect the input cables first then output and last the protective case connection 3 Parallel connection If a redundant power supply system is requested two or more converters can be connected in parallel To achieve redundancy the number of converters must be dimensioned to carry the whole load even if one converter is faulty Connect your load to the output after the series diode see Figure 1 Another reason for connecting two or more converters in parallel is to get more power Use the output with series diode see Figure 1 You should not use external sense when the unit are in parallel on the output 3 1 Series diode on the output The series diode protects the converter output from external voltage sources A series diode is necessary if the output is connected in parallel with another power supply or if you require redundant operation If a converter breaks do
16. ure To meet the EMC specifications in the enclosed declaration of conformity use twisted pairs for connecting input output alarm inhibit and voltage sense Shielded cables are not necessary 1 Remove plastic cover 2 Connect protective earth to the connection marked no 40 Use a ring terminal that has been crimped by an appropriate tool 3 Connect the output The converter output is short circuit proof by a constant current limit which works unlimited in time Therefore there is no need to fuse the load unless you use multiple loads see below The current limit is fixed to 105 of nominal output current e If the converter is to be connected in parallel at the output or if you use current sharing for equal current sharing please consult 3 Parallel connection on page 5 e If you intend to use multiple loads please consult 4 Multiple loads at the output on page 6 e If you intend to use the alarm please consult 5 Alarm on page 7 e If you intend to use output voltage sense please consult 6 Sense on page 7 e If you intend to use inhibit please consult 7 Inhibit on page 8 10229 15 doc Page 4 10 POLYAMP LAL INSTALLATION MANUAL 4 Connect the input cables Bundle input cables together at the terminals separated from the output cables Make the same arrangement on the output side This is to make sure one cable will not bridge the insulation barrier in case of coming lose 5 Start the converter wi
17. voltage of at least 115 of nominal output voltage of the converter Repeat this calculation for all branches and choose the highest capacitance value 3 It is sometimes difficult to estimate the short circuit current when the nature of a fault is unknown In this case a voltage dip might appear under some short circuit conditions even with a large capacitor present If a voltage dip is critical in one branch it is recommended to use a separate DC DC converter supplying this branch Fl on F Figure 2 Connecting multiple loads 5 Alarm The alarm relay switches to ALARM state if e The output voltage is not within 15 10 of nominal output voltage e The converter is overheated Otherwise the relay contact is in the position NORMAL The alarm relay can be connected in two ways 1 Normally Open NO i Connect twisted pair 0 25mm 1 5mm from centre pin of the removable alarm connector and connector pin marked Polyamp AB Sweden www polyamp com 2 Normally Closed NC i Connect twisted pair 0 25mm 1 5mm from centre pin of the removable alarm connector and connector pin marked NORMAL ALARM NORMAL 31 32 Figure 3 Alarm contact The relay is isolated 2500Va c from input output and case The relay can switch maximum 30V 5A a c and d c values 5 1 Over and under voltage alarm The alarm relay switches to alarm and the NOT OK
18. wn with an internal short circuit on the output and other converters are connected in parallel on the output the broken unit will short circuit the others if the Polyamp AB Sweden www polyamp com series diode is not used This might cause excessive heat or even fire in the faulty unit If the series diode is used the alarm relay will switch to ALARM on the faulty unit if one converter breaks down in a redundant power supply system Otherwise there will be no alarm indication from a faulty converter unless all units are in current limit and the output voltage drops 10 below nominal output voltage When the series diode is used the total output power of the converter must be derated See data sheet e 24Vd c output by 10 On 48Vd c output by 5 Do not forget to fuse the inputs separately to achieve redundancy 3 2 Current sharing All models include the automatic current sharing feature which we recommend to use in parallel configuration A maximum of 10 10 units can be connected in parallel If more than 10 units should be connected in parallel contact Polyamp Connect a cable 0 25 1 0mm with a maximum length of 3 0m between the gt CURRENT SHARE connectors of all units The converter with the highest output voltage will then automatically become current master This converter will then run with a few percent higher output current than the others If the master converter for som
19. xceed 105 of the nominal current of the converter the output voltage will drop until the fuse is blown Depending on the impedance of the short circuit whether it is abrupt or merely an overload and the resistance of the load cables the effects of a short circuit will vary Long cables reduce short circuit currents resulting in longer delay until the fuse is blown and hence an increased voltage dip Light overload does not necessarily result in a blown fuse To reduce the voltage drop at short circuit and if any branch has more than approximately 30 of the total output current of the converter a large external capacitor is recommended Such a capacitor will supply the peak current needed to blow the fuse see Figure 2 To calculate the capacitor needed use the following formula C 1 2x Isx At AU 1 2 Safety margin Is Short circuit current through the fuse At Time before the fuse blows see data sheet on the fuse AU Acceptable voltage dip before the fuse blows Example You have a 5 fuse with fast characteristic and the short circuit current is 50 The data sheet 10229 15 doc Polyamp AB Sweden www polyamp com Page 6 10 POLYAMP LAL pu1o9Pusoo INSTALLATION MANUAL gives you that At 10ms The output voltage is 24V and you can accept 10 voltage drop gt AU 24 x 0 1 2 4V The capacitance you need C 1 2x Is x At AU 1 2x 50x 0 01 2 4 250 000uUF Choose a capacitance with a rated
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