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1. gt 400VDC as well as a higher surge current rating than the internal input Fuse Protection for Reversed Connection of Input 21 02 2010 AES User s Manual DC DC Converter 600 280 12 page 5 6 Faulty Conditions If OCP trips i e there s an Over Current Protection Condition there will be an automatic recovery reset If OTP trips i e there s an Over Thermal Protection Condition remove the input amp cool the unit down for a few minutes Then re input If OVP trips i e there s an Over Voltage Protection Condition remove the input for a few seconds Then re input Normal or abnormal operation of the power module can be monitored by the OG terminal IOG terminal tripping is shown by means of a red LED i e a Light Emitting Diode mounted in the enclosure This signal is LOW i e red LED is of when inverter has normal operation and HIGH i e red LED is on when the device stops or is operating abnormal The current of the low current red LED is approx 2mMA Also note that IOG trips when OCP condition occurs e Light load conditions at parallel operation occur e Dynamic Load operation occur 7 Warranty This product carries a warranty covering defects in materials and workmanship for a period of 24 months based on an 8 hours day operation During this warranty period AES will as it s option will either repair or replace products proved to be defective Warranty applies but not limited to the foll2. User s Manual DC DC Converter 600 280 12 page 1 USER S MANUAL DC DC CONVERTER 600 280 12 Version la AES International S a r 1 18 rue des Moulins info aes int eu L 7784 Bissen www aes int eu Luxembourg Table of Content T OESCH UOI Ieee ene earn ene ee ee 2 2 CONNEC 0 9 a ne ee ee eer ee 3 3 OPEIN PRR ee a eee ae OOA ee ee 4 Be MOUNINO siase ceria E eens tune E E a a a A Dn TOLCCUOMN ssiiririi ionin irrien rA EErEE EEEa a Er e A 6 Faull CONOINION aoa ces oe sce gasses EEE EE 5 AR Ea EE a A ETE A E E E E viedo ssmeons seecenuseuses 5 8 Caution Modifications of this manual are subjected to changes without giving notice 21 02 2010 AES User s Manual DC DC Converter 600 280 12 page 2 To take advantage of its features and to avoid danger for man and material please read the operating instructions below carefully before operating the unit We recommend to keep the user s manual for later reference 1 Description The DC DC converter 600 280 12 supplies the 12V Circuitry of the electric vehicle with power from the traction battery It has the same function as an alternator in conventional vehicles The output of the converter is self protecting through Over Voltage OVP Converter shut down amp manual reset Over Current OCP and Over Thermal Protection OTP It has a galvanic insulation between the high voltage and low voltage circuit The device is based on a the principle of a buck converter that
3. age connections before being sure that there is no high voltage on the DC link anymore e Use an insulation failure detector in order to check the galvanic insulation between the high and the low voltage DC link e Never operate the unit under over current or shorted conditions for more than 30 seconds otherwise this may lead to damage e This unit produces waste heat Touching the hot unit can cause injuries and burnings Please do not install easy flammable materials close to the unit Avoid operation of the device next to a heat source or in direct sunlight e Take note that moisture could lead to power module abnormal operation or damage Ensure sufficient ambient cooling of the device Proper cooling has a positive effect on the life time e Not withstanding the proper IP protection IP54 we recommend not to expose the unit to rain or splash water 21 02 2010 AES
4. d base plate and 3kKVAC between input and output for 1 minute When conducting withstand voltage test during incoming inspection be sure to set the current limit value of the withstand voltage testing equipment to 20mA This power module is designed to have a withstand value of SOOVDC between output and base plate for 1 minute 21 02 2010 AES User s Manual DC DC Converter 600 280 12 page 3 2 Connections The converter has 4 cable wires i e two input and two output The output cables have a bigger cross sectional area compared to the input cables as the latter conduct more current Input wiring and output wiring must be separated to improve noise sensibility Keep the cable distance between load and device as short as possible lt 3m otherwise output voltage may become unstable and EMC may get worse due to an increased impedance of wiring and load condition Blue Red Plus traction battery Ey 124 Thin cables 5 Thick cables Winus fraction battery Blue 0 Output current of the device should be less than 40A The Converter has an internal high voltage fast blow type input Fuse of 6A refer to scheme above Specifications of this input Fuse are Brand Bussmann Type BBS 6A Voltage 600VAC Current rating 6A Dimensions 10 3 35 mm Basic Connection Traction Battery Load Baseplate 21 02 2010 AES User s Manual DC DC Converter 600 280 12 page 4 The Base plate of the internal switched pow
5. er supply is connected earthed to the aluminium enclosure and should be connected to the vehicle chassis 3 Operation As like an alternator the converter acts as a charging device for charging the 12V battery The Charge Voltage is set to 13 8VDC by default Depending on the application this value can be set from 7 2 to 14 4VDC by turning the trim potentiometer on the PCB inside of the converter For adjustment remove the lid The converter is designed for operation in conjunction with an on board 12V Auxiliary battery Hence the battery will act as a buffer in order to stabilise the 12V Circuitry from short current peaks e g caused by switching of headlamps and or other 12V equipment For improved protection it is recommended to connect an output Fuse of 50A as per schematic below Plus traction battery Winus traction battery 4 Mounting There is no restriction on mounting direction but there should be enough consideration for airflow so that heat does not accumulate around the power module vicinity 5 Protection Reverse input connections Please pay attention to connect the input terminals of the converter to the right polarity Reverse input polarity could normally cause module damage In order to reduce the risk of damage a protective diode has been installed inside of the converter to protect the converter from reversed polarity This protective diode has a higher voltage rating than the input voltage i e
6. operates interleaved in order to reduce ripple currents and allows adjustment of the required voltage level in the corresponding operation mode It has both an input and output filter which gives good EMC behaviour The specifications are Input Voltage up to a maximum of 400VDC Input Current 2 41A Nominal Output Voltage 12VDC Adjustable Output Voltage range 7 2 14 4VDC Default Output voltage setting 13 8VDC Maximum Output Current Current 50A Output Voltage accuracy 1 Maximum Ripple amp Noise 120mV Maximum Line amp Load Regulation 48mV Efficiency gt 90 Maximum Output Power 600W Equipped with Heat sink Packed in Aluminium Enclosure IP54 Typical Operating amp Storage temperature 40 up to 50 degrees Celsius Over Thermal Protection 100 Degrees Celsius Base plate temp Over Current Protection 105 140 Over Voltage Protection 125 145 Polarity Protection by internal Input Diode Operating amp Storage Humidity 5 95 RH Cooling Conduction Cooled Temperature coefficient 0 02 per degree Celsius Isolation resistance output to base plate 500VDC gt 100MegaOhms 25 degrees C 7 0 RH Shock 196 m s2 Switched Power Supply Package Switched Power Supply Package Safety Appr UL60950 1 CSA60950 1 EN60950 1 CE LVD Both Parallel amp Series operation possible Max 11 units of the same model can be connected Warranty 2 Years This power module is designed to have a withstand voltage of 2 5kVAC between input an
7. owing e average operating temperature is under 40 Degrees Celsius e average load factor is 80 or less Following cases are not covered by warranty e improper usage and mishandling like dropping or applying shock to the unit and defects from operation exceeding specification of the product e defects resulting from natural disaster fire flood etc e unauthorised or incompetent modification or repair Specifications of this product may be subjected to changes without giving notice 21 02 2010 AES User s Manual DC DC Converter 600 280 12 page 6 8 Caution Caution High Voltage inside Have the unit installed and made operational by a skilled professional e This converter must be earthed Do not make unauthorised modifications to the unit otherwise you may have an electric shock and void warranty e Please note that careless handling of high DC voltages can be very dangerous and lethal After the DC DC Converter is installed in the vehicle some terminals inside of the converter conduct high voltages Touching these terminals could cause a severe electric shock which may lead to injuries or even death For adjusting the output voltage by turning the trim potentiometer we recommend to wear non conducting rubber gloves and the use of a non conducting or insulated screw driver e Do not connect the high voltage connections before being sure that there is no high voltage on the connections itself e Never disconnect the high volt
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