Operating Instructions
Switch Mode Power Supply
DC 3000 CAN
AEG Power Supply Systems GmbH
Department: AE
Name:
Schenuit
Version:
04
Date:
13.11.2006
Operating Instructions
0274 BAL, en
Switch Mode Power Supply DC 3000 CAN
Table of Contents
TABLE OF CONTENTS
2
NOTES ON THESE OPERATING INSTRUCTIONS
Instruction Obligation
Validity
Warranty
Structure
Hotline 5
Copyright
4
4
4
4
4
1.
1.1
1.2
1.3
1.4
1.5
SAFETY INSTRUCTIONS!
Important Instructions and Explanations
Accident Prevention Regulations
Qualified Personnel
Liability
Regulations
6
6
6
6
7
7
2.
2.1
2.2
2.3
2.4
GENERAL INFORMATION
System Description
Type Overview DC3000
Principle of Operation, Electrical
Circuit Diagram
8
8
8
8
9
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
FUNCTIONAL DESCRIPTION
Input
Output Curve
Changing the CVCC Curves
External Setpoint
Temperature-Dependent Voltage Control
External Sensor Lead Output Voltage U0
Input Voltage Monitoring
Output Voltage Monitoring
Monitoring of Functions
Temperature Monitoring
Reset
ON / OFF Switch
External ON / OFF
Parallel Operation
CAN BUS Interface X12
RS 232 Service Interface X13
DIL Switch S3
DIL Switch S4
Signalling
Pin Assignment X11
10
10
10
11
11
11
12
12
13
13
14
14
14
14
14
15
15
15
16
17
17
4.
4.1
4.2
4.3
4.4
START-UP
Installation
Connections
Connecting the Loads / Battery
Isolation
18
18
18
18
19
5.
5.1
5.2
5.3
OPERATION
Menu
Key Assignment
Significance of the Boxes
19
19
20
20
6.
MAINTENANCE
26
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5
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Switch Mode Power Supply DC 3000 CAN
7.
7.1
7.2
TROUBLE-SHOOTING
No Output Voltage Present
Output Voltage Deviation
26
26
26
8.
8.1
8.2
TECHNICAL DATA
General Technical Data
Technical Data of the DC 3000 Series
27
27
29
9.
DIMENSIONED DRAWING
30
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Switch Mode Power Supply DC 3000 CAN
Notes on these Operating Instructions
Instruction Obligation
These operating instructions must be read carefully by all persons
working with or on the switch mode power supply prior to installation and
initial start-up.
These operating instructions are a composite part of the switch mode
power supply.
The operator of this unit is obliged to communicate these instructions to
all personnel transporting or starting the switch mode power supply or
performing maintenance or any other work on the unit.
Validity
These operating instructions comply with the current technical
specifications of the switch mode power supply at the time of publication.
The contents do not constitute a subject of contract, but serve
information purposes only.
AEG reserves the right to make modifications with regard to contents
and technical data in these operating instructions without prior
notification. AEG cannot be held liable for any inaccuracies or
inapplicable information in these operating instructions, as no obligation
to continuously update the data and maintain their validity has been
entered into.
Warranty
Our goods and services are subject to the general conditions of supply
for products of the electrical industry and our general sales conditions.
We reserve the right to alter any specifications given in these operating
instructions, especially with regard to technical data, operation, weights
and dimensions. Claims in connection with supplied goods must be
submitted within one week of receipt along with the packing slip.
Subsequent claims cannot be considered.
AEG will rescind all obligations such as warranty agreements, service
contracts etc. entered into by AEG or its representatives without notice
in the event of maintenance and repairs being carried out with anything
other than original AEG parts or spare parts purchased by AEG.
Structure
These operating instructions for the switch mode power supply are
structured so that all work necessary for starting up, maintenance and
repair of the unit can be performed by qualified personnel.
Illustrations are provided to elucidate and facilitate certain steps.
If any work poses possible danger to personnel and the unit, the safety
instructions in chapter 1 are to be observed.
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Hotline
Suggestions for improvement, Hotline
Do you have any suggestions for improving these operating
instructions?
Do you have any questions on any of the subjects dealt with?
Our service department is at your disposal on the Hotline number given
below:
AEG Power Supply Systems GmbH
Emil-Siepmann-Strasse 32
D-59581 Warstein
++49-29 02-763-100
FAX ++49-29 02-763-680
http://www.aegpss.de
Copyright
No part of these operating instructions may be reproduced or transmitted
by any mechanical or electronic means without the express prior written
permission of AEG.
©
Copyright AEG 1998. All rights reserved.
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Switch Mode Power Supply DC 3000 CAN
1.
Safety Instructions!
1.1
Important Instructions and Explanations
The instructions for operation and maintenance as well as the following
safety regulations must be complied with to safeguard the safety of
personnel as well as the function of the unit. All personnel
installing/dismantling, starting up or servicing the unit must be familiar
with and observe these safety regulations. Only qualified personnel may
perform the described work with suitable and intact tools, equipment,
test equipment and materials.
1.2
Accident Prevention Regulations
Compliance with the accident prevention regulations valid in the
respective country and the general safety regulations in accordance with
IEC 364 is mandatory.
The following must be observed prior to any work on the switch mode
power supply:
-
1.3
disconnect the power supply,
secure against reactivation,
verify that the unit is disconnected from the power supply,
earth and short the circuit,
cover or isolate any neighbouring power-supplied units.
Qualified Personnel
The switch mode power supply may only be transported, installed,
connected, started, serviced and operated by qualified personnel who
are familiar with the pertinent safety and installation regulations. All work
performed must be inspected by responsible experts.
The qualified personnel must be authorised to perform the work by the
responsible safety officer.
Qualified personnel is defined as personnel
having completed training and gained experience in the respective
field,
familiar with the pertinent standards, rules and regulations and
accident prevention regulations,
having received instruction on the mode of operation and operating
conditions of the switch mode power supply,
capable of recognising and preventing dangers.
Regulations and definitions for qualified personnel are contained in
DIN 57105/VDE 0105, Part 1.
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1.4
Liability
No liability is accepted if the switch mode power supply is used for
applications not intended by the manufacturer. Any necessary measures
for prevention of injury or damage to equipment is the responsibility of
the operator or user. In the event of any claims in connection with the
switch mode power supply please contact us quoting:
-
1.5
the type designation
works number
reason for claim
period of use
ambient conditions
operating mode
Regulations
The switch mode power supply units comply with current DIN and VDE
regulations. VBG4 is met on the basis of compliance with the regulation
VDE 0106, Part 100.
The specifications of VDE 0100, Part 410, "Functional extra-low voltage
with safe isolation" are complied with when applicable.
The CE sign on the unit confirms the conformance to the basic EC
regulations for 73/23 EEC - Low voltage and for -89/336 EEC Electromagnetic compatibility, if the installation and commissioning
instructions described in the operating manual are observed!
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Switch Mode Power Supply DC 3000 CAN
2.
General Information
2.1
System Description
The switch mode power supply DC 3000 provides an output power of
3.0 kW. A typical application is the use as power supply unit without
battery connected in parallel.
To enable short circuits in selectively protected load circuits to be
switched off quickly, the switch mode power supply can provide twice
the output current for a period of one second.
The switch mode power supply works in accordance with a CVCC curve
acc. to DIN 41772 or DIN 41773. It is a preassembled unit ready for
connection. The connections are provided on the front of the unit for
easy access. The operating and indication elements are installed on the
front of the unit.
Due to its high efficiency, the unit is of compact design as a 19 inch
panel mounting unit with 6 height modules.
It is ready for installation in module rack according to DIN 41494.
2.2
2.3
Type Overview DC3000
Type designation
Connection
voltage
Output
voltage
Output
current
G110 G26/100 Wrug-Cpü
110V DC
26 V DC
100 A
G220 G26/100 Wrug-Cpü
220V DC
26 V DC
100 A
Principle of Operation, Electrical
By means of transistors, the unit converts the input voltage into an AC
voltage of 70 kHz.
Electrical isolation and
voltage adjustment to the secondary side
is performed with the aid of a transformer.
The 70 kHz AC voltage on the secondary side is rectified by diodes. The
voltage ripple is reduced by a downstream output filter. The output
voltage and output current are controlled by pulse-width modulation of
the transistor switches on the primary side.
For further details, please refer to the circuit diagram on the following
page.
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Switch Mode Power Supply DC 3000 CAN
2.4
Circuit Diagram
Figure 1
Circuit diagram DC 3000 CAN
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Switch Mode Power Supply DC 3000 CAN
3.
Functional Description
The respective unit settings can be found in Technical Data Sheet (see
chapter 8).
3.1
Input
The switch mode power supplies DC3000 are operated in the 110V DC
circuit. The input voltage is protected against short circuits outside the
rack. Protection must therefore be provided individually for each rack.
An integrated acceleration stage limits the making current of the switch
mode power supply to a value smaller than the rated input current.
3.2
Output Curve
The output curve is a CVCC curve in accordance with DIN 41772 with
approx. 1 % voltage step inclination. From approx. 95% Irated the
inclination of the voltage curve is approx. 25%. Due to the inclination, the
load can be distributed quite evenly in the case of parallel operation of
several switch mode power supplies. The pivot of the inclined curve is at
50% Irated. The rated value of the output voltage is defined at 50% Irated.
The voltage step in dependence of the output current is inclined by a
corresponding connection of the analog controller. In the case of a short
circuit, the switch mode power supply provides twice the output current
for a period of one second. For this purpose, the output current and the
voltage are permanently monitored. If the output current exceeds 105%
Irated, the 1 sec. timer is started. When the timer has stopped, the output
current is reduced to 100 % Irated .
If the output voltage rises to values higher than 97% Urated after the short
circuit, the timer is set back. Only then can the switch mode power
supply provide twice the output current for a period of one second in the
case of a new short circuit.
UA
100,5%
Inclination approx. 1%
Urated
Inclin
a
tion a
p
prox.
25%
75%
Operation for
1 sec.
50%
100%
200%
IA
Irated
Figure 2 Output curve
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Switch Mode Power Supply DC 3000 CAN
3.3
Changing the CVCC Curves
At time of delivery, the first CVCC curve is active. By inserting wire
bridges on X11, the characteristic curves can be adjusted for the
respective unit application.
The following curves are to be adjusted:
1. CVCC curve
Factory settings
2. CVCC curve, diode check
Bridge X11:5 and +UO
3. CVCC curve
Bridge X11:6 and + UO
4. CVCC curve
Bridge X11:5, X11:6 and U0
Caution!
If the CVCC curve is changed, it might be necessary to readjust the
overvoltage monitoring of the output voltage.
3.4
External Setpoint
The switch mode power supply DC3000 has two setpoint inputs which
are bound to the unit output with respect to their potential. The setpoint
levels on X11.2 and X11.4 are to be switched with reference to the
analog ground X11.1, whereby the analog ground must be equated with
the unit output L-.
The voltage and/or current setpoint can be switched from internal to
external setpoint with the menu box 22 (refer to chap. 5.3). As a
standard, the setpoint is set to internal values.
In order to adapt the supplied level as well as possible to the existing
automation systems, the level range can be switched by means of the
DIL switches S4.3 to 6. The following level ranges can be set:
0 - 20mA
Ri = 494Ω
0 - 4V
Ri = >10kΩ
0 - 10V
Ri = 10kΩ3.5
3.5
Temperature-Dependent Voltage Control
When operating the switch mode power supply with a battery connected
in parallel, the voltage step inclination of the first CVCC curve can be
adjusted for different temperatures. This is achieved by connecting a
thermistor of 10kΩ to Pin 1 and 11 of the signal connector X11. For this
operating mode, the DIL switch S3.6 must be switched on and switch
S3.7 switched off.
The sensor (AEG reference no. 8000001495) available as an option, is
connected using a two-pin supply line with a cross-section of ≥0.25mm².
For larger distances (over 2m) the use of a shielded line is
recommendable; connect the shield to the unit housing.
The inclination of the temperature-dependent voltage curve can be
changed by the temperature coefficient. The standard setting of the
temperature coefficient is -4mV/K*12 within a range of -10 to +50°C. The
break points of the voltage curve result either from the voltage value at 10°C or +50°C, or from the setting range of the output voltage. The pivot
of the temperature-dependent voltage curve is fixed at a reference
temperature of 20°C.
If the active sensor is faulty (sensor lead broken or short circuit)
the output voltage returns to the value at 20°C.
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Caution!
If necessary, the response values of the output voltage monitoring
must be readjusted.
Ub [V]
30
24
18
-30 -20 -10
10
20 30 40 50 60 70 80 Tb [°C]
Figure 3 Temperature-dependent charging voltage
3.6
External Sensor Lead Output Voltage U0
Unwanted voltage drops in the load circuit, e.g. caused by terminals,
supply lines, decoupling diodes, etc. can be compensated via sensor
leads by means of the output voltage control.
The maximum voltage drop to be compensated is approx. 4V with
U0=26V.
The connection points for the sensor leads are connected internally to
the unit output via thermistors (overload protection). This prevents
damage to the unit due to sensor lead break, polarity reversal or short
circuit.
Caution!
If necessary, the response values of the output voltage monitoring
must be readjusted.
When operated with external sensor lead connection, correct function is
only possible when the supply line resistance is <5 Ω.
3.7
Input Voltage Monitoring
The input voltage monitoring ensures the intrinsic safety of the unit
against overloads and overvoltages. The response values are fixed
factory settings.
Input Voltage Monitoring:
The unit is switched off if the value drops below the switching point.
Display:
The LED "Mains" goes off.
Message:
Indicator relay "Collective fault"
When the hysteresis voltage is exceeded, the unit automatically
resumes operation.
Input Voltage Monitoring:
The unit is switched off if the value exceeds the switching point.
Display:
The LED "mains" goes off.
Message:
Indicator relay "Collective fault"
When the voltage level drops below the hysteresis voltage, the unit
automatically resumes operation.
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Switch Mode Power Supply DC 3000 CAN
3.8
Output Voltage Monitoring
Overvoltage monitoring UO>:
The unit switches off if the output voltage reaches the disconnecting
threshold. The unit switches back on if the voltage falls below the
disconnecting threshold within a certain period of time.
If the output voltage remains above the disconnecting threshold after 3
internal tests, the unit is switched off permanently after a delay of
approx. 60 sec.
Display:
LED "UO>" is on
Message:
Indicator relay "Collective fault"
Deactivation: Reset via On / Off switch of the unit
Reset button, external On / Off or CAN bus command.
Undervoltage monitoring UO<:
As soon as the output voltage drops below the monitoring threshold, the
unit is switched off with a response delay of t = approx. 3 s. The monitor
remains locked in (latching).
Display:
LED "UO<" is on
Message:
Indicator relay "Collective fault"
Deactivation: Reset via On / Off switch of the unit, Reset button,
external On / Off or CAN bus command.
If the DIL switch S4.1 is opened, the unit is not switched off when the
monitor responds UO < . The LED UO < merely lights up and the
message is transmitted via the collective fault relay (refer to chap. 3.18).
3.9
Monitoring of Functions
As soon as the input voltage is connected and the unit is switched on,
the following routines are automatically carried out:
Self test of the µ controller
Input voltage within the tolerance range?
Unit switch and ext. On ?
Unit address set to 0? *
Switch on DC/DC transformer
Output overvoltage monitor did not respond?
Display:
LED "Operation" is on.
* If a unit address from 1- 15 is set, the switch mode power supply
expects a control command from the CAN bus. On receipt of a control
command, the switch mode power supply follows the control command.
If no CAN connection is recognized, the unit switches on after a delay
time and continues working with the stored voltage and current values.
Display:
LED "ϑ" flashes.
If during operation the contact via CAN bus is interrupted, the switch
mode power supply automatically returns to the saved value after a time
delay of approx. 10 seconds.
Display:
LED "ϑ" flashes.
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Switch Mode Power Supply DC 3000 CAN
3.10
Temperature Monitoring
If the temperature on the heat sink rises to > 90°C, the output capacity of
the switch mode power supply is reduced to ensure intrinsic safety.
Display:
LED "ϑ" is on
If the temperature on the heat sink rises to > 100°C, the unit turns off.
When it has cooled down to < 94°C, the unit automatically turns on
again.
Display:
LED "ϑ" is on
Message:
Indicator relay "Collective fault"
3.11
Reset
A fault signal (response of an output monitoring) can be acknowledged
with the Reset button S1 on the front panel. The unit resumes operation,
if it has been switched on before.
A fault can also be acknowledged by switching off the unit, by switching
off the output voltage, by means of a CAN bus command, or the external
On/Off function.
3.12
ON / OFF Switch
The switch mode power supply can be switched on or set to standby
mode using the S2 switch on the front panel.
3.13
External ON / OFF
The switch mode power supply can be switched off by an external
signal. The signal is applied to X11.7 and X11.8 and switches off the unit
via an optocoupler. The control voltage range lies between 10 and 24 V,
the internal resistance is approx.1.4 kΩ. The input is protected against
polarity reversal. With higher operation voltages, the current in the
control loop must be limited to 5 - 10mA using a suitable resistor.
3.14
Parallel Operation
Due to the inclination of the individual voltage curves, the load can be
distributed quite evenly in the case of parallel operation of several switch
mode power supplies. (±10 % of the rated current of the unit). A major
prerequisite for this is that the unit outputs are connected to the load
having the same line diameter and length.
Safe selective monitoring of the individual switch mode power supplies is
only possible using external decoupling diodes in the output. Due to the
fact that the units can be connected in parallel, it is possible to build
systems for redundant operation in accordance with the n+1 principle. If
the switch mode power supplies are interconnected in the respective
output without decoupling diodes or fuses, the system wiring must be
dimensioned for the max. possible current.
Parallel operation of the switch mode power supplies with a temperature
sensor is possible, refer to chapters 3.5 and 3.17. The DIL switch S3
must be switched on according to chap. 3.17.
Caution! Parallel operation with temperature-dependent voltage
control and external decoupling diode in the negative branch is not
permissible.
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Switch Mode Power Supply DC 3000 CAN
3.15
CAN BUS Interface X12
The unit can be completely controlled via the CAN bus connector X12,
with the aid of a text-ABE and the PSM control unit (possible component
of the power supply cabinet).
In addition to the fault message on X11, a potential-free relay contact is
connected to X12:14 - 15. In the case of a message, the contact is
connected to X12:14 - 15.
3.16
RS 232 Service Interface X13
During the test, the unit is completey adjusted via of the RS 232
interface and a special software. In addition, all operating parameters
can be adjusted and visualized.
Caution!
The interface X13 is not a potential-free interface. The reference
potential is - UO.
The PC interface must therefore be connected to the unit via an
optical coupler.
3.17
DIL Switch S3
The DIL switch is installed below the front panel and can be accessed
after removal of the power connection cover. The DIL switch S3.1 points
to the upper edge of the unit.
All settings / changes in the setting of the DIL switch are only activated
on connection of the mains voltage or when pressing the Reset button.
Switches S3.1 to S3.5
Standard setting:
Address 0all switches open
The address of the unit can be set using these five switches. The
switches are binary coded. Switch S3.1 represents the highest bit
equivalent to the value 16.
Value
24
23
22
21
20
Switch
S3.1
S3.2
S3.3
S3.4
S3.5
The address set by means of the switches always has priority. The
setting can then no longer be changed via the menu. If unit addresses
are over 15, the ERROR ADDRESS message and the flashing LED
"Operation" appear.
If the previously set address is reset to 0, the address must additionally
be reset to 0 via the menu after the next reset.
Switch S3.6
Standard setting:
Switch closed
Reference for temperature-dependent voltage control.
Switch S3.7
Standard setting:
Switch closed
The temperature-dependent voltage control is switched on via this
switch. At the same time it is possible to check if the battery temperature
sensor is connected correctly.
If a temperature sensor controls several units connected in parallel, the
DIL switch S3.6 must be switched on and S3.7 switched off on one unit.
On all other units the DIL switches S3.6 and S3.7 must be switched off.
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Switch Mode Power Supply DC 3000 CAN
Switch S3.8
Standard setting:
Switch open
Switch open: Suppression of the fault message on X12 when the unit is
switched off.
3.18
DIL Switch S4
The DIL switch is installed below the upper unit cover near the front
panel and can be easily accessed after removal of the upper unit cover.
The DIL switch S4.1 points to the left side of the unit.
Switch S4.1
Standard setting:
ON
If S4.1 is switched off, no switch-off is triggered on response of the
output voltage monitor UO <.
Switch S4.2
Standard setting:
OFF / not assigned
Switches S4.3 to S4.4
Standard setting:
S4.3 OFF, S4.4 OFF
The level range for the external setpoint can be set using these two
switches.
Level range
Internal
S4.3
S4.4
resistance
ON
ON
0 - 20mA
494Ω
OFF
ON
0 - 10V
10kΩ
OFF
OFF
0 - 4V
>10kΩ
Switches S4.5 to S4.6
Standard setting:
S4.5 OFF, S4.6 OFF
The level range for the external current setpoint can be set using these
two switches.
Level range
Internal
S4.5
S4.6
resistance
ON
ON
0 - 20mA
494Ω
OFF
ON
0 - 10V
10kΩ
OFF
OFF
0 - 4V
>10kΩ
Switches S4.7 to S4.8
Standard setting:
Page 16 of 30
all switches OFF / not assigned.
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Switch Mode Power Supply DC 3000 CAN
3.19
Signalling
The following signals are indicated via LEDs on the front side.
-
Mains:
Input voltage within the permissible tolerance
Operation:
Unit can be operated without faults and loss of
power
UA>
Output overvoltage monitor responded
-
UA<
Output undervoltage monitor responded
ϑ
Unit heat sink too hot
The unit is equipped with a liquid-crystal display. The voltage and
current values are displayed with two decimals before and one decimal
after the decimal point. When Displayed values are > 100, no decimals
are displayed after the decimal point. The display accuracy corresponds
to class 1 related to the nominal output value of the unit.
3.20
Pin Assignment X11
If a temperature sensor controls several units connected in parallel,
X11:1 and X11:11 must be connected on all units. The DIL switch S3.6
and S3.7 must be switched off on one unit. On all other units, the DIL
switches S3.6 and S3.7 must be switched off.
Pin
Function
1
Analog ground
2
+ ext. voltage adjustment
3
unassigned
4
+ ext. current adjustment
5
2. Voltage curve
6
3. Voltage curve
7
(+) Remote shut-down
8
(-) Remote shut-down
9
+ UO sensor lead
10
- UO sensor lead
11
Battery temperature sensor
12
Indicator relay Collective fault NC
13
Indicator relay Collective fault COM
14
Indicator relay Collective fault NO
Table 1
Terminal assignment X11 (signal interface)
Potential-free relay contact (changeover contact)
"Collective fault" If this message appears, X11:13 - 14 open
or X11:12 - 13 close"
The maximum contact load is 60V DC ≤0.6A
Electrical isolation to the unit output max. 60V
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Switch Mode Power Supply DC 3000 CAN
4.
Start-Up
4.1
Installation
The switch mode power supplies (SMPS) are to be installed in suitable
module racks in acc. with DIN 41494.
The SMPS functions with natural air cooling. The intake air temperature
must not exceed 45 °C. If several units are installed one above the other
in one cabinet, there must be either a forced-air cooling system installed,
or a vertical distance between the units of at least 134 mm = 3 height
modules must be guaranteed. Air guides must be installed between the
installation levels in such a way that the air intake temperature of the
individual installation levels does not exceed the permanently
permissible ambient temperature. Cabinets must be designed for an
ambient temperature of 40 °C. The power loss per unit is approx. 330 W.
4.2
Connections
Before connecting the unit to the DC mains supply, ensure that the
voltage given on the rating plate complies with the supplied DC voltage.
The unit is connected to the mains with a 3-pin terminal (L-, L+, PE) on
the front of the unit (X1). If one pin on the output side is grounded, the
SMPS must be grounded via the separate PE connection near the
output terminals. In this case, the PE conductor must not be connected
to terminal X1 (ground loops). The cross-section of the PE conductor
must be chosen in acc. with VDE 0100 Part 540 depending on the type
of installation.
The discharge current lies below 3.5 mA. Prior to start-up, a PE
conductor connection must be established.
The DC connection (X2) and the PE connection of the unit are
established with the connection bolt behind the cover on the right-hand
side of the unit.
Caution!
When the DC mains is connected, potentially fatal voltages are
applied to the switch mode power supply.
4.3
Connecting the Loads / Battery
The switch mode power supply has an amplified smoothing module with
electrolytic capacitors in the output. If the de-energized capacitors are
switched over to an energized load busbar by engaging the DC isolator
or DC fuse, this causes a large surge of charging current. This can be
avoided by switching the unit on before engaging the isolator. This is the
only way to ensure the capacitors are charged to the unit output voltage
with a high charging stage.
Only now may the output circuit be closed by engaging the DC isolator
or the DC fuse.
The output circuit can be immediately closed in the case of units with a
decoupling diode.
Observe correct polarity of the DC lines.
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Switch Mode Power Supply DC 3000 CAN
4.4
Isolation
Even when switched off, the switch mode power supply can carry
voltage from charged capacitors and external signals. For this reason
the terminals must be tested prior to dismantling the unit to ensure that
they are de-energized.
The capacitors can be discharged via an external resistor on the mains
terminals X1 or DC terminals X2: L+ and L-.
Switch the unit off
Disconnect the mains voltage.
Isolate the SMPS output from the load
Disconnect interfaces X11, X12
5.
Operation
5.1
Menu
The switch mode power supply is equipped with a liquid-crystal display
and three keys for operation on the front of the unit. The functions of the
unit are split up in a software menu. The menu comprises menu boxes
and input boxes. The menu boxes serve for indication only, while values
can be changed in the input boxes.
S O F TW AR E
PUx x x E x x
01
2 4 V / 1 0 0 A
I U
NO
ERROR
02
U a =
I a =
,
,
V
A
03
U1 =
I 1 =
,
,
04
V
A
U > =
U < =
,
,
05
V
V
:
ADDRE S S
2 3
06
07
Operating Display
03
NO
ER R O R S
E RR O R
U>
C H A NGE
A DD R= 2 3
03
1
09
08
E RROR
1 0
T _ B _ TRCR
09
18
DE L E T E
E RRORS
19
DE L E T E
<- Y
N- >
20
02
02
C H A NG E
U / I
C TR L
C H A NG E
MO N I T O R
21
02
C H A NG E
U - C HA R .
22
02
CHA NGE
I - CH AR .
23
CHA NGE
T . CO E F F .
24
25
== Menu box
CHANG. U>
, V
U> =
26
CHANG. U <
, V
U< =
31
U CT R L
I NT ER N A L
U 1 CHA R .
, V
U1 =
27
I CT R L
I NT ER N A L
I1, I 2, I3
, A
=
28
U 2 CHA R .
, V
U2 =
32
32
29
I 4 CHA R .
, A
I 4=
33
34
U 3 CHA R .
, V
U3 =
T . COE F F .
- 4mV
== Input box
30
(system always returns to the
menu box one level higher)
Menu selection:
via
via
-key
-key
via
-key
via
+
-key
The system returns to the operating display from all
menus after no key has been pressed for a certain period:
Menu 01-03: after 1s
Menu boxes: after 10s
Input boxes:
after 2min.
35
U 4 CHA R .
, V
U4 =
36
Figure 4
Software menu tree
When the unit is switched on, the menu boxes 01 to 04 are briefly
displayed one after the other, menu box 04 is always active in normal
mode. In the case of a fault, the system automatically switches to menu
box 03. This box displays the current error message until the error is
eliminated or another box is selected by pressing a button.
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Switch Mode Power Supply DC 3000 CAN
5.2
Key Assignment
Within the different boxes, the buttons have different functions.
Key functions within a
menu box:
Key functions within an
input box:
Box to the left
Reduce value
Box to the right
Increase value
Box down
Accept value and
continue
Figure 5 Key assignment
The arrow keys ⇐ and ⇒ take you to the various menu boxes within a
level. At certain locations within a level, e.g. on box 02, 03, 07...
the ⇓ key takes you to the boxes below this level.
If, for example, the menu box 25 is selected and, for a longer period, no
button is pressed, the system automatically returns to the error state
(box 03) or the operating display (box 04).
As a rule, the current parameter value is copied into a buffer when an
input box is activated. This buffer value can then be changed. The buffer
value is only transferred to the parameter memory when the take-over
key ⇓ has been pressed. If you do not want to take over the new value,
the process can be interrupted using the cancel function.
Cancel function
You can return to menu box 02 from anywhere within the menu tree
using the cancel function. The arrow keys ⇐ and ⇒ must be
pressed simultaneously to activate the cancel function.
5.3
Significance of the Boxes
Menu box 01
Designation of the software used, saved on EPROM
S O F T W A R E
P U x x x E x x
xxx refers of the date of the software
xx refers to the revision status
Menu box 02
Set unit type
2 4 V / 1 0 0 A
I U
alternatively:
2 4 V / 1 0 0 A
I U / T
/T automatic recognition when operated with a temperature sensor
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Menu box 03
Unit status
N O
E R R O R
alternatively:
S U P P L Y
S T A N D
B Y
Unit in standby operation, via unit switch
S U P P L Y
B U S
O F F
Unit in standby operation, via CAN bus command
R E M O T E
E X T .
O F F
Unit in standby operation, via external contact
E R R O R
U >
Monitor U> responded
E R R O R
U <
Monitor U< responded
E R R O R
T _ B _ S E N S
Battery temperature sensor lead broken or short circuit
E R R O R
H E A T S I N K
Heat sink too hot, lead broken or short circuit
E R R O R
I N P U T
Input voltage not within the tolerance
E R R O R
A D D R E S S
Switches S3.1- S3.5 address set > 15
E R R O R
B O O S T E R
Booster fault
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Switch Mode Power Supply DC 3000 CAN
Menu box 04
Actual values
U a =
I a =
, V
, A
present actual voltage and actual current value
Menu box 05
Setpoints, independent of the selected voltage curve
U 1 =
I 1 =
,
,
V
A
present voltage and current setpoint
Menu box 06
Output voltage monitoring
U > =
U < =
,
,
V
V
Response value overvoltage or undervoltage monitor
Menu box 07
Unit address
A D D R E S S :
0
Unit addresses from 0 to 15 are possible
Input box 08
Changing unit address
Access via box 07 with arrow key ⇓
C H A N G E
A D D R
Unit addresses from 0 to 15 are possible
Adjustment is only possible when address is set to 0
on the DIL switch S3.
Menu box 09 - 18 Error journal
E R R O R
x
x corresponds to the error code as described in menu box 03
The last ten messages are saved.
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Switch Mode Power Supply DC 3000 CAN
Menu box 19
Delete error journal
Access via boxes 09 - 18
D E L E T E
E R R O R S
Input box 20
Delete error journal
Access via box 19 with arrow key ⇓
D E L E T E
< - Y
N - >
Then the system automatically switches to menu box 03
Menu box 22
Changing external setpoint U / IAccess via box 02
with arrow key ⇓
C H A N G E
U / I
C T R L
Input box 27
Changeover setpoint U internal / external
Access via box 22 with arrow key ⇓
U
C R T L
I N T E R N A L
alternatively:
U
C R T L
E X T E R N A L
You can switch from one setting to the other using
the arrow keys ⇐ and ⇒.
Input box 32
Changeover setpoint I internal / externalAccess via box 27
with arrow key ⇓
I
C R T L
I N T E R N A L
alternatively:
I
C R T L
E X T E R N A L
You can switch from one setting to the other using
the arrow keys ⇐ and ⇒.
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Switch Mode Power Supply DC 3000 CAN
Menu box 21
Changing response values of the monitors
Access via box 22 with arrow key ⇐ or box 25 with key ⇒
C H A N G E
M O N I T O R
Input box 26
Changing response value monitor U>Access via box 21
with arrow key ⇓
C H A N G . U >
U > =
,
V
Changing the value in steps of 0.1 V
Input box 31
Changing response value monitor U<
Access via box 26 with arrow key ⇓
C H A N G . U <
U < =
,
V
Changing the value in steps of 0.1 V
Then the system automatically switches to menu box 21
Menu box 23
Changing voltage curves
Access via box 22 with arrow key ⇒ or box 24 with key ⇐
C H A N G E
U - C H A R .
Input box 28
Changing characteristic curve U1
Access via box 23 with arrow key ⇓
U 1 - C H A R .
U 1 =
,
V
Changing the value in steps of 0.1 V
Input box 33
Changing characteristic curve U2
Access via box 28 with arrow key ⇓
U 2 - C H A R .
U 2 =
,
V
Changing the value in steps of 0.1 V
Input box 35
Changing U3 characteristic curve
Access via box 33 with arrow key ⇓
U 3 - C H A R .
U 3 =
,
V
Changing the value in steps of 0.1 V
Input box 36
Changing characteristic curve U4
Access via box 36 with arrow key ⇓
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Switch Mode Power Supply DC 3000 CAN
U 4 - C H A R .
U 4 =
,
V
Changing the value in steps of 0.1 V
Then the system automatically switches to menu box 23
Menu box 24
Changing current curves
Access via box 23 with arrow key ⇒ or box 25 with key ⇐
C H A N G E
I - C H A R .
Input box 29
Changing characteristic curve I1, I2, I3.
Access via box 24 with arrow key ⇓
I 1 , I 2 , I 3
=
,
A
Changing the value in steps of 0.1 V / 1A
Input box 34
Changing characteristic curve I4.
Access via box 29 with arrow key ⇓
I 4 - C H A R .
I 4 =
,
A
Changing the value in steps of 0.1A
Then the system automatically switches to menu box 24
Menu box 25
Changing the temperature coefficient
Access via box 24 with arrow key ⇒ or box 21 with key ⇐
C H A N G E
T . C O E F F .
Input box 30
Changing the temperature coefficient
Access via box 25 with arrow key ⇓
T . C O E F F .
- 4
m V
Changing the value in steps of 1mV Value range:-1 mV to -6 mV
Then the system automatically switches to menu box 25
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Switch Mode Power Supply DC 3000 CAN
6.
Maintenance
Caution!
Disconnect the unit from the power supply for maintenance work.
Always observe the safety regulations! (see chap.1)
The SMPS comprises state-of-the-art components which are almost
non-wearing. We do, however, recommend regular visual and functional
tests of the equipment to maintain its operational reliability and
availability.
When visually inspecting the unit, check whether:
- there is any mechanical damage or foreign bodies are present,
- any conductive dirt or dust has accumulated in the unit,
- accumulation of dust affects heat supply and dissipation.
If large quantities of dust have accumulated, the unit should be cleaned
with dry compressed air as a precaution, in order to ensure adequate
heat exchange.
The intervals at which visual checks should be performed are
determined by the site conditions. The unit may not be operated in an
aggressive atmosphere.
7.
Trouble-Shooting
All work on the unit may be carried out by specially trained
personnel only. Always observe the safety regulations! (see chap.1)
7.1
No Output Voltage Present
-
Input voltage present or correct polarity?
Switch S2 switched on?
Unit externally switched off?
Polarity reversal on output?
With parallel operation: Polarity reversal on decoupling diodes?
Has monitor UO> responded (LED UO> is on)?
Press reset and check setting UO>
If all aforementioned points are o.k., proceed as follows:
Unscrew the cover
Observe safety instructions on the front of the unit!
Check fuses on the printed board A1
Check plug connections for correct position
It the fault cannot be eliminated, return the unit to the works for repair
and enclose a fault description.
7.2
Output Voltage Deviation
-
Is the unit running in current limitation due to overload?
Reduce the load!
Is the UO setting incorrect?
Adjust the output voltage!
If an external sensor lead is used, is the sensor lead open?
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8.
Technical Data
8.1
General Technical Data
Making current............................... < rated input current
Required mains protection............. gL 40 A
Characteristic curve....................... CVCC curve in acc. with DIN 41772
or 41773
Manufacturing and type test
in accordance with DIN 60146 Part 1-1
Emitted interference to EN 50081-1
- Conducted interference ................ in accordance with EN 55022 class "B"
- Emission ......................................... in accordance with EN 55022 class "B"
Noise immunity to EN 50082-2
- Housing ....................................... ESD-Test to EN 61000-4-2,
6 kV contact, 8 kV air discharge
HF field to EN 61000-4-3,
10 V/m (30 MHz - 1 Ghz)
- Power cables ................................. Burst test to EN 61000-4-4, 2 kV
Surge test to EN 61000-4-5,
0.5 kV asymmetrical; 0.5 kV
symmetrical
- Control cables................................ Burst test to EN 61000-4-4, 2 kV
Surge test to EN 61000-4-5,
2 kV asymmetrical
Functional extra-low voltage .......... with safe isolation at UA ≤ 60 V DC to
VDE 0100 Part 410 11.83
Section 4.3.2
Dynamic response ......................... ≤ 5% with sudden load fluctuations
between 10%-90%-10% rated output
current (adjustment time t < 5 ms)
Short circuiting............................... continued short circuit protected,
1 x rated output current
2 x rated current for 1 sec.
Monitoring
- input voltage: green LED
- operation: green LED
- overtemperature: red LED
- output undervoltage: red LED
- output overvoltage: red LED
- collective fault message
max. contact rating:
60 V DC ≤ 0,6 A
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Switch Mode Power Supply DC 3000 CAN
Parallel operation........................... 15 units max. when connected to
CAN bus
load distribution approx. 10 % of
rated current.
Design ........................................... 19" x 4 height modules, panel
mounting unit for installation in
module rack according to DIN 41494.
Protection class ............................. IP 20
Cooling .......................................... natural air cooling
Ambient temperature ..................... at UA = 28 V and IA =100 A
0°C to 45°C for individual unit
0°C to 40°C for cabinet installation
Storage temperature...................... - 20°C to + 70°C
Environmental conditions ............. IEC 721 Part 3-3 Class 3K3 / 3Z1 /
3B1 / 3C2 / 3S2 / 3M2
Site altitude.................................... up to 1000 m above sea level
Mechanical stability
and vibration resistance................. to EN 50178 section 9.4.3.2
Surface painted with ...................... RAL 7032 (front panel)
Dimensions (w x h x d) .................. 483 x 177 x 270 mm
(19" x 4 height modules)
Weight ........................................... approx. 15 kg
Connections
Input voltage connection X1: ......... Terminal HDFKV 10-VP
DC output X2: ................................ Threaded bolt M8
PE conductor: ................................ Threaded bolt M6
Signal interface X11: ..................... Signal connector, type MCVW 1.5/14ST-3.81*
CAN bus interface X12 .................. 16-pin socket connector*
Manufacturer, for example,
Thomas & Betts
No. 622-1641
Service interface X13 .................... 9-pin SUB D socket connector
(* supplied with the unit)
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Switch Mode Power Supply DC 3000 CAN
8.2
Technical Data of the DC 3000 Series
Type
G110 G26/100 Wrug- G220 G26/100 WrugCpü
Cpü
3000000061
3000000117
E Number
Rated connection voltage
Current consumption
Settings
Output voltage
Set value U1
110 V DC -15 +35 % 220 V DC -15 +35 %
26 A DC
13 A DC
Works setting
26.0 V DC ± 1 %*
Set value U2
25.5 V DC ± 1 %*
Set value U3
24.0 V DC ± 1 %*
Setting range U1 - U3:
Set value U4:
Setting range U4:
1 to 28 V DC
28.0 V DC ± 1 %*
1 to 28 V DC
0 - 4V / 0 - 10V / 0 - 20mA ≡
0 to 30V DC
Setting range external
voltage setpoint:
Output current
Set value I1-I3
Setting range
Set value I4
Setting range
Setting range external
current setpoint:
Temperature coefficient:
Setting range:
Voltage ripple
Interference voltage
according to CCITT
Efficiency
Set value
100 A DC ± 2 %
5 to 100 A DC
100 A DC ± 2 %
5 to 100 A DC
0 - 4V / 0 - 10V / 0 - 20mA ≡
0 to 100A DC
-4 mV*12/K
-1 mV*12/K to -6 mV*12/K
< 50 mV pp
< 1.8 mV
90 % at 26V / 100A
Monitoring
Input undervoltage
Unit OFF / Unit ON
Input overvoltage
Unit OFF / Unit ON
DC undervoltage
Response value
Setting range
< 85 V / > 93 V
< 175 V / > 185 V
> 160 V / < 150 V
> 300 V / < 290 V
22.8 V DC
0.5 V DC to 28 V
DC overvoltage
Response value
Setting range
29 V DC
5 V to 30 V DC
*) from approx. 95 % Irated, use of the declining/falling characteristic curve with 25 %
Table 2
Technical data
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Switch Mode Power Supply DC 3000 CAN
9.
Dimensioned Drawing
Figure 6
Dimensions
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