Eltek Valere PSC18 Manual de usuario

DC/DC CONVERTER

PSC18

USER MANUAL

BHB.PSC-18.D30-1020.HB101

DC/DC Converter

PSC18

User Manual

Page 2 ( 22 )

Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

General information

IMPORTANT! Please read this operation and maintenance manual carefully before assembling and start up the unit!

The operation and maintenance manual is part of this unit, i.e. it should be made available to each and every person

concerned with the start up, maintenance or operation of the unit. The unit should be moved, mounted, started,

operated and maintained only by skilled personnel. The local specifications for the prevention of accidents as well

as the general guidelines according to IEC 364 should always be followed!

The functional description in the operation and maintenance manual correspond to those at the time of the publi-

cation. Technical design modifications or those of power ratings can be carried out by the supplier without an-

nouncing any revision or announcement. There is no responsibility for the constant revision of the operation and

maintenance manual

The module is manufactured in accordance with applicable DIN and VDE standards such as VDE 0106 (part 100) and

VDE 0100 (part 410). The CE marking on the module confirms compliance with EU standards 2006-95-EG (low volt-

age) and 2004-108-EG (electromagnetic compatibility) if the installation and operation instructions are followed.

The units are delivered according to our delivery conditions. Rights to alterations in the technical details in this

operation and maintenance manual as well as in the respective data sheets are reserved.

Claims about faulty goods have to be made as soon as possible after receipt of material. Packing note and invoice

as well as the information about the type, serial number and damage description have to be transmitted to the

supplier.

Warranty claims not be accepted in case of visible external influences (e.g. missing or loose screws, welding, loose

sheets, etc.), which could be attributed to an unauthorised opening of the unit. The supplier is not responsible for

applications of the unit, not intended by the manufacturer. The end user is responsible to take the necessary ac-

tion for the prevention of damage to personnel and material (see the upper text section).

Supplier

ELTEK VALERE INDUSTRIAL GmbH

Schillerstraße 16

D-32052 Herford

+ 49 (0) 5221 1708-210

FAX + 49 (0) 5221 1708-222

Email [email protected]

Internet http://www.eltekvalere-industrial.com

IMPORTANT!

Repetition, copying and /or taking possession of this operation and maintenance manual, even in ex-

tracts, with electronic or mechanical means, requires the written, prior permission of the SUPPLIER.

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

Table of Contents

1. GENERAL INFORMATION ...................................................................................................................................... 4

2. TYPE RANGE....................................................................................................................................................... 4

3. START UP PROCEDURE........................................................................................................................................ 4

4. OPERATION ........................................................................................................................................................ 5

5. FUNCTIONS......................................................................................................................................................... 6

5.1 Circuit diagram..................................................................................................................................... 6

5.2 Electrical function description......................................................................................................... 7

5.2.1 Electrical insulation....................................................................................................................................... 7

5.2.2 Input.................................................................................................................................................................. 8

5.2.3 Output .............................................................................................................................................................. 8

5.2.4 Output voltage dynamic behaviour........................................................................................................... 8

5.2.5 RFI suppression .............................................................................................................................................. 8

5.2.6 Parallel operation mode ............................................................................................................................... 8

5.3 Monitoring ............................................................................................................................................. 9

5.3.1 Mains Voltage Monitoring............................................................................................................................ 9

5.3.2 Operation Monitoring.................................................................................................................................... 9

5.3.3 Output Voltage Low...................................................................................................................................... 9

5.3.4 Output Voltage High...................................................................................................................................... 9

5.3.5 Protection Against Overheating ................................................................................................................ 9

5.3.6 Signals .............................................................................................................................................................. 9

5.4 Output and threshold adjustment................................................................................................10

6. EXTERNAL FUNCTIONS .....................................................................................................................................10

6.1 Output voltage sensor leads .........................................................................................................10

6.2 Temperature Compensation of Charging voltage....................................................................11

6.3 External Switch ON/OFF..................................................................................................................11

6.4 Discharge Test...................................................................................................................................11

6.5 Boost Charge Mode ..........................................................................................................................11

7. OPERATION ELEMENTS AND CONNECTORS ......................................................................................................12

7.1 Front View / Operation Elements .................................................................................................12

7.2 Front View / Operation Elements .................................................................................................12

7.3 Indication Instruments.....................................................................................................................13

7.4 Electrical Connectors of Input and Output.................................................................................13

8. MAINTENANCE .................................................................................................................................................15

9. FAULT FINDING INSTRUCTIONS...........................................................................................................................16

9.1 No Output Voltage............................................................................................................................16

9.2 Deviation of Output Voltage ..........................................................................................................16

10. TECHNICAL DATA.............................................................................................................................................17

10.1 General Technical Data ...................................................................................................................17

10.2 Type Specific Data............................................................................................................................20

11. DIMENSIONS /FRONT VIEW.............................................................................................................................21

11.1 Dimensions / Front View - PSC18 (24, 48, 60 and 110V Version) ........................................21

11.2 Dimensions / Front View - PSC18 (220V Version) ....................................................................22

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

1. General Information

The Switch Mode Power Supply units PSC18 (named SMPS in the following) supply an output power of 1500W (max.

1800W).

A typical application is a mains-connected secured DC-power supply source feeding the connected battery as well

as the consumer load. Hereby, the dynamic regulating performances are particularly advantageous during input

voltage and consumer load deviations.

The SMPS unit operates to an IV-characteristic according to DIN 41772/41773 and represents a complete unit for

implementation in a 19” assembly carrier according to DIN 41494. The operation and indication elements as well as

the plugs are located on the front plate of the unit.

2. Type range

PSC18

Type designation

Article code Input-voltage

in V DC

Output-

voltage

in V DC

Output-current

in A DC

110/24-40 200-018-740.00 110 24 40

110/48-30 200-018-750.00 110 48 30

110/60-25 200-018-760.00 110 60 25

110/110-13.4 200-018-770.00 110 110 13.4

110/220-6.7 200-018-780.00 110 220 6.7

110/220-6.7 Relay 200-018-780.01 110 220 6.7

220/24-40 200-018-840.00 220 24 40

220/48-30 200-018-850.00 220 48 30

220/60-25 200-018-860.00 220 60 25

220/110-13.4 200-018-870.00 220 110 13.4

220/220-6.7 200-018-880.00 220 220 6.7

Available options and accessories:

Temperature sensor lead LM 335 (sensor lead in M5 cable shoes with 2m

wire)

CAN-Bus-interface

One set input and output plug:

24 – 110V DC

220V DC

3. Start up procedure

Before connecting to the input voltage, it should be checked whether the voltage information on the rating plate

corresponds to the available voltage and also that the polarity corresponds to the connection plan of the plug. The

mains connection is done via a unit plug at the front side. The protective conductor should be generally connected

(protection class 1, leakage current 3.5 mA).

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

Important:

If a pole of the output side has been earthed, then the SMPS unit should be grounded via the separate PE connec-

tion on the front plate at the left side near the DC- output connection.

In this case, the protective conductor at the input side should not be connected via the input plug (earth circuit).

This is particularly important for parallel connection without external decoupling diodes.

The DC-output connection is done via a SUB-MIN-D-plug of design 21 WA4 on the front side. The output plug also

contains the connections for the signals, sensor cable connections, symmetry regulation and temperature sensor

lead.

Note:

The SMPS is equipped with a high capacitive capacitor connected in the output. If the SMPS output in the dead

state is connected “hard” to a battery or other parallel operating SMPS, then it results in a considerable surge of

charging current, which could lead in welding the plug contacts when the plug is inserted.

This can be avoided by the following proceedings:

Switch on the SMPS before mounting without the output plug; insert the

connection plug only after the adjusted output voltage is attained.

Disconnecting the DC- circuit with a switch or a fuse

Charging with a protective resistance (approx. 1 Ohm/V)

Use of decoupling diodes

After switching off the unit, the capacitors in the input and output circuits can still conduct voltage; the discharge

time of the input circuit is approx. four seconds, that of the output circuit is approx. 15 seconds.

The SMPS unit operates with natural air cooling. The temperature of the inflow air should not exceed 45oC. If sev-

eral units are operated via one another in the cabinet, then either forced cooling should be provided or a vertical

distance of at least 134 mm = 3 HU should be maintained between the units. Air flaps should be mounted between

the mounting levels such that the temperature of the inflow air of the individual mounting levels does not exceed

the permissible operation temperature. Cabinet rooms should be designed for a max. ambient temperature of

40oC. Temperatures upto 60oC are permitted for a short time or in the case of forced cooling in the cabinet, but

should be avoided in the interest of the lifetime of the unit.

The power loss per unit is approx. 150 W to 170 W (depending on the type).

4. Operation

The unit is operated using the operating elements arranged on the front plate. The operating elements are de-

scribed in the respective sections and are assigned by the labels on the front plate of the unit (see Pt. 7.1/7.2).

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

5. Functions

5.1 Circuit diagram

Fig. 1:

Circuit diagram

PSC18

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

5.2 Electrical function description

The SMPS unit consists of the following main functional components:

1. Input filter suppressing the feedback of high frequency interference pro-

duced by the unit into the mains as well as for the attenuation of the inter-

ference voltages and voltage transients superimposed on the mains.

2. Rectifier (polar protection) with synchronised power controller (operating

frequency 100 kHz) for converting the input voltage into a pre-regulated DC-

voltage of approx. 380V (DC – Input 110V DC: 170V ), regulating the input

voltage curve and restricting the inrush current.

3. Transistor bridge circuit for converting the 380 (170)V DC into a pulse-width

regulated stepped voltage with a frequency of 100 kHz.

4. Power transmitter to the potential separation and voltage adaptation at the

secondary side

5. Rectifier with fast switching diodes

6. LC filter for smoothing the DC- voltage ripple at the rectifier output

7. Output filter for smoothing the interfering voltages on the output voltage

8. Auxiliary current supply for the internal power supply to the control compo-

nents with potential separation at the primary and secondary side.

9. Regulating line with potential separation by optocoupler.

10. Operating component with parameter adjustments, signalling, monitoring

and indication elements

5.2.1 Electrical insulation

Due to the design of the unit and of the components as well as design of separated connections of the input and

output circuits

the SMPS series with UA60 V DC fulfil the EN 60950 and VDE 0100 Stan-

dard; i.e. protection against shock currents due to the functional extra low

voltage with a safe electrical insulation.

the SMPS series UA> 60 V DC satisfy the safe electrical insulation up to UA=

220 V DC according to EN 60950 and VDE 0160 Standard.

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PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

5.2.2 Input

The input is protected by a 2-pole circuit breaker. This circuit breaker is used also as on/off-switch.

The MCB is situated before the input filter. The SMPS has a current limitation which limits the inrush current to the

level of nominal input current.

5.2.3 Output

The output-characteristic is an IV-characteristic according to DIN 41772 or DIN 41773. An active current distribu-

tion or a characteristic curve (- 1% for 100 % Inom can be selected for parallel operation (factory adjustment: char-

acteristic curve)

The output is continuously short circuit proof due to a constant current regulation.

5.2.4 Output voltage dynamic behaviour

In case of load changes in the load between 10% and 90% Inom or 90% and 10% Inom the dynamic voltage deviation is

max. 3% and is compensated to the static limits within max. 1.5 ms.

5.2.5 RFI suppression

The SMPS unit fulfils the conditions of the RFI class “ B “ according to VDE 0878 T 1 or EN 5501 /55022. When

measured with a filter according to CCITT-recommendations, the output ripple is psophometric < 1 mV (24V), < 1.8

mV (48V) as well as < 2 mV (60V).

5.2.6 Parallel operation mode

Due to the parallel operation ability of the SMPS it is possible to design the redundant cabinets according to the

principle n+1.

Due to the 1% characteristic curve (factory adjustment) a load distribution of about 10% and due to the optional

active current distribution (see pt. 7.3, factory adjustment necessary), about 5% is attained.

During the adjustment of the characteristic curve, the load distribution can be optimised by increasing the output

voltage in the unit having the smallest load current and decreasing the output voltage in the unit having the larg-

est load current (see pt. 5.4).

The selective monitoring of the individual SMPS is possible only with internal or external decoupling diodes in the

output.

The delivery of units with an output voltage 60 V DC with already incorporated internal decoupling diodes is op-

tional. The units are labelled with p (internal decoupling diode in the plus branch) or m (internal decoupling diode in

the minus branch).

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

5.3 Monitoring

5.3.1 Mains Voltage Monitoring

Mains voltage monitoring; signaling with LED "Mains", criterion: output voltage of step-up-converter 370 V (165V),

at the same time operation monitoring of step-up-converter (equivalent to main voltage of appr. 195 (100)VAC;

depends on load).

The LED is dark if mains voltage low or the step-up-converter is out of order.

This signal is included in collective failure signal. Additional there is an optocouppler signal (mains O.K.)

5.3.2 Operation Monitoring

Functional monitoring; signaling with LED "UA1", criterion: output voltage 97 % of adjusted output voltage without

constant current regulation and 85 % of the adjusted output voltage with constant current regulation. The sig-

naling threshold of this monitoring follows the adjusted nominal output voltage automaticly.

This signal is included in collective failure signal of rectifier. Additional there is an optocouppler signal (UAO.K.)

At operation with internal decoupling diodes the voltage before diodes will be measured.

5.3.3 Output Voltage Low

Output voltage low monitoring; signaling with LED "U<", criterion: output voltage is higher than adjusted level U<;

This signal is included in collective failure signal. It has its own relay contact on signaling connector too. If the volt-

age value is O.K. Pin 13 and Pin 17 of X2 or Pin 11 and Pin 15 of X4 (220V – output voltage)are closed.

5.3.4 Output Voltage High

Output voltage high monitoring; signaling with red LED "U>", criterion: output voltage higher than adjusted level U>;

This signal is included in collective failure signal of SMPS. If there is an error the LED burnes and the SMPS switches

off internal. This protective unit has an automatic locking and should be set back with the mains switch or remote

ON/OFF.

5.3.5 Protection Against Overheating

Protection against overheating; signaling with red LED "Alarm", criterion: temperature of heat sink > 90°C.

The over-temperature protection switches OFF the SMPS when the limited temperature is attained.

This signal is included in collective failure signal. You have to reset the unit by ON/OFF switch.

5.3.6 Signals

The signals "UAO.K.", "Mains O.K." and "Constant Current Mode Iconst" are optocouppler signals with a loading of 30

V/5 mA. The optocoupplers switches off at error. The collective failure signal is delayed for appr. 10 sec. The relay

contacts between Pin 14 and Pin 15 of X2 and Pin 12 to Pin 14 of X4 (220V – Output voltage) are open and be-

tween Pin 15 and Pin 16 are closed at error.

DC/DC Converter

PSC18

User Manual

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Eltek Valere Industrial GmbH 2007 BHB.PSC-18.D30-1020.DB101

5.4 Output and threshold adjustment

The adjustment of output values and monitoring thresholds are very easy. All values will be adjusted with front

keys by showing the actual value in the front side digital displays.

In normal operation the top display shows the output voltage (UA1/UA2/UA3) and the bottom display shows the out-

put current (IA).

For any adjustment please follow these instructions:

press both keys UP/DOWN() together for a short time; the SMPS

changes to adjustment mode

press the key UP() or DOWN() to change the adjustment parameter

(see also table on bottom)

press both keys UP/DOWN() together for a short time; the SMPS

changes to value change mode

press the key UP() or DOWN() to change the adjustment value (if you

hold the key the value changes quicker)

press both keys UP/DOWN() together for a short time; the SMPS

changes back to adjustment mode (at this moment the changed value

will be storaged)

press both keys UP/DOWN() for appr. 3 sec. to change back in opera-

tion mode

Adjustable parameters in adjustment mode:

Display Parameter

Uo1 (=UA1) tripple charge voltage

Uo2 (=UA2) boost charge voltage (look also cap. 6.5)

Uo3 (=UA3) voltage at discharge test (look also cap. 6.4)

Io (=IA) output current

U< output voltage low threshold (look also cap. 5.3.3)

U> output voltage high threshold (look also cap.

5.3.4)

t coefficient of temperature for temperature

compensation of charge voltage (look also cap.

6.2)

The monitoring thresholds follow automaticly the adjusted nominal values of output voltage. The monitoring

thresholds for mains/step-up-converter and over heating are not changeable.

The adjustment ranges for several thresholds you can find in technical specifications.

6. External Functions

6.1 Output voltage sensor leads

With sense links for output voltage you can compensate voltage losses over wires or diodes.

The max. regulation difference is approx. 4 % of the nominal voltage.

Interruption on sense links, confusing of poles or short circuit can`t damage the rectifier. At interrupt it can be a

voltage increase of max. 4%.

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