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INSTALLATION MANUAL PSC600 series

2011-04-26 Copyright 2000-2011 (13)

1 Before installation .............................................................................................................. 4 1.1 Cable and pin dimensioning ..................................................................................... 4 1.2 Reverse polarity protection ...................................................................................... 4 1.3 Input fuse ................................................................................................................. 5 1.4 Inrush current limit .................................................................................................. 5

2 Installation .......................................................................................................................... 5 3 Parallel connection ............................................................................................................. 7

3.1 Series diode on the output, option C ........................................................................ 7 3.2 Series diode with series resistor, option CR ............................................................ 7 3.3 Output under voltage alarm ..................................................................................... 7 3.4 Connecting systems in N+1 configuration ............................................................... 7 3.5 Connecting converters in parallel on the output ...................................................... 8 3.6 Adjusting output voltage when units are paralleled on the output ........................... 8

5 Multiple loads at the output ................................................................................................ 9 5.1 Short-circuits ............................................................................................................ 9

6 Output voltage sense, option S. ........................................................................................ 10 7 Output over voltage protection OVP ................................................................................ 10

7.1 Standard feature ..................................................................................................... 10 7.2 OVP option A ........................................................................................................ 10

8 Under voltage Alarm relay ............................................................................................... 10 9 Higher isolation voltage, Option E1 & E2 ....................................................................... 11 10 Insulation voltage test ....................................................................................................... 11 10.1 DC isolation test output to case ..................................................................................... 11 10.2 AC isolation test output to case, option E2 ................................................................... 11 10.3 DC isolation test input to output and input to case ....................................................... 12 10.4 AC isolation test input to output and input to case ....................................................... 12 11 Trouble shooting .............................................................................................................. 13

11.1 There is no or wrong output voltage .................................................................. 13 11.2 The input fuse blows when the input is connected ............................................. 13 11.3 The converter starts and stops repeatedly .......................................................... 13 11.4 Fault report ......................................................................................................... 13


2011-04-26 Copyright 2000-2011 (13)

1 Before installation Before installation, please read this section and minimum section 2. This installation manual shall also be read together with the datasheet of the product. Download the datasheet from www.polyamp.com and check the File archive where in section Datasheet you will find PSC600.pdf. If any problem occurs during installation please check section 11 Trouble shooting. This product family is called PSC600. The product is labelled as below example:

The DC/DC converter type name consists of model name PSC300, PSC400, PSC600, PSC700 and PSC800 followed by input code and output voltage. Two examples: • ”Type: PSC600 24/48” has input code

”24” and nominal output voltage 48 Vd.c. The 600 indicates around 600 W output power.

• ”Type: PSC800 110/24” has

input code ”110” and nominal output voltage 24 Vd.c. The 800 indicates around 800 W output power.

The Options are block letters separated by comma(,). You will find explanation within this manual what the letter code means. The input states the nominal input voltage and maximum input current at any conditions. It means the output is adjusted +10% above nominal voltage and close to the current limit, which is the stated output current +5% and a lowest input voltage level. Input range is the input range that the unit can operate normally. Output indicates the nominal output voltage and the rated current.

The output is current limited with a so called rectangular characteristic. When the current limit is reached, which is adjusted to +5% of above mentioned nominal output current, this is the maximum current that will continuously flow. The output voltage drops very quickly down towards zero volt (depends on the series resistance of the load circuit as the unit can be regarded as a constant current generator at over current condition). We have no time limit on over current condition. Temperature range is the rated operation temperature at 100% load condition. Input, output and case are galvanically separated from each other. This is a Class I Insulation system, which is dependent of correct earth connection on the input. All outputs are insulated from case with minimum 2000 Vd.c. Section 10 Insulation voltage test, describes the insulation rating depending on input voltage. See section 9 if higher insulation is required. Series number is stamped on the panel under the connector

1.1 Cable and pin dimensioning The PSC600 series is using two DIN 41621 H15 connectors intended for 6HE Euro format mounting. Each pin has a continuous current rating of 15A @+55°C and 12A @+70°C ambient temperature. All pins in one pole are parallel connected internally, see Figure 1. Therefore on C, D, 110, and 220 inputs only one input pin per pole needs to be used. It is also possible to supply 6 different outputs/loads or use a limited number of pins depending on the output current. E.g. 24V 25A only need two pins.

1.2 Reverse polarity protection The input is protected from reverse polarity. The method used is dependent of the input. On A, B, 24, 36 input a parallel diode is used that is dimensioned to blow an external fuse. On C, D, 48, 72, 110, 220 input a series diode is provided. The converter will not start if reverse voltage is applied.

PSC600 110/24 Input: 110Vd.c.: 6 A; Input range: 88 – 150 Vd.c. Output: 24V 25A Option: L, C


2011-04-26 Copyright 2000-2011 (13)

It is possible to use series diode on input A, B, 24, 36 with derated performances due to higher power losses. Please contact your local distributor or factory, for more information.

1.3 Input fuse The input should be fused with an approved fuse with a slow blow characteristic and high breaking capacity. Select a stand current rating equal or above the below specified value, see Table 1 to 3. Input voltage

code Slow blow fuse

PSC400 A 46 A B 23 A C 10 A D 5 A

Table 1. Recommended input fuses.

Input voltage

code

Slow blow fuse PSC400



24 25 A 37 A 63 A 48 13 A 19 A 25 A 110 5 A 7.5 A 12 A 220 2.5 A 3.7 A 6 A

Table 2. Recommended input fuses.

Input voltage

code




24T 31 A 47 A 63 A 36T 25 A 35 A 50 A 48T 16 A 24 A 35 A 72T 12.5 16 A 25 A

110T 7 A 10 A 15 A Table 3. Recommended input fuses. There are two reasons we do not include an input fuse:

1. DC-networks should be fused at the distribution point to protect the cable.

2. Different applications require different types of fuses.

A switching device able to switch off both polarities input cables has to be mounted externally. The switching device shall be

marked accordingly and easy accessible. If the converter is mounted in an electric vehicle, an external series diode on the input is recommended. Please contact your Polyamp dealer.

1.4 Inrush current limit The input capacitors are charged through an active inrush current limit circuit that reduces the input inrush current during start up. This feature is standard on the PC600 series with input codes C, D and 48, 72, 110, 220. For B and 24, 36 input codes the inrush current limit circuit is optional. On those this circuit will affect the input voltage range and the output power due to voltage drop losses in combination with high input currents. All models has an ”output soft start” that do not increase the input current above the unit rated current during start up (approx.. 0.1s).

2 Installation The converter is designed to be mounted in a 6HE 19” sub rack unit, in such case the L-version must be ordered. The PSC600 version with N mounting, a location only accessible for service, which meets the demand of EN60950 regarding fire enclosure, voltage hazard protection and mechanical strength, shall be used. With option N, wall mounting set you can mount the converter in any direction on a wall or with optional mounting clips on DIN rail TS35. The converter is convection cooled and in order to get sufficient cooling there shall be a free air around the converter. If this is not possible, we recommend the use of an external fan. Note that the expected life of the converter is dependent 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 temperature. To meet the EMC specifications in the enclosed ”declaration of conformity” use

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2011-04-26 Copyright 2000-2011 (13)

11 Trouble shooting

11.1 There is no or wrong 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. 4 The converter may be in current limit due

to excessive output current or an external short-circuit on the output. • Measure the output voltage. If shows

> 0.5 V the thyristor OVP, see section 7.2, might have trigged.

• Disconnect the input by removing the fuse.

• Disconnect the load. • Connect input fuse again and measure

the output voltage. If the converter now starts, the load is too high or there is a short circuit on the load side.

• If there is an external short-circuit, remove it.

• If the load is too large decrease the load or consult your Polyamp dealer.

5 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 to 3.

3. 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: 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 Fault report We do not recommend you to repair a faulty unit. All unit opened by customer will not be repaired under warranty. Please use our RMA system from our webpage www.polyamp.com 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. Please describe the conditions when the fault occurred and please return a faulty converter to: Your local distributor or: SWITCH CRAFT S.A. Bel Air 63 CH-2300 La Chaux-de-Fonds Switzerland Tel: +41 32 9678800 Fax: +41 32 9678809 e-mail: [email protected] Latest version of this manual

www.polyamp.com

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