PM500 Installation manual
Contents
1. 7 7 ISOLATION VOLTAGE TESTI J ec cee U teehee eee ete eae eee 7 7 1 DC ISOLATION TEST OUTPUT TO INPUT CASE AND ALARM ea ah ie eset engl oe ees 7 7 2 OGISOLATION TES TINPUN TO OUTPUT seston l u u u Z uuu es ead ieee au enn m u y us 8 7 3 DGISOLATION TESTINPUT aux L mutu m ku uum D as ahi k a ma al 8 7 4 AC ISOLATION TEST INPUT TO OUTPUT CASE AND ALARM a a ts ik ae 8 S TROUBLE SHOO TIN G iu uuu u uyu uu unu uuu u OU uu uu uyu s 9 8 1 THERES NOOU PUTVOLTAGE u z n Lu Du ert te u aS a a Q ia uw un a Eana 9 8 2 THE INPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED 9 8 3 THE CONVERTER STARTS AND STOPS REPEATEDLY scecececececececccccacucacaeucueutaeaeauaeauatataeaeatataeaterstenetenenenenenenenenenes 9 FAULT mun a ECR uu S 9 7291 3 doc Polyamp AB Sweden www polyamp com Page 3 9 POLYAMP D 1 Before installation On the front panel label the following is displayed Converter type name maximum input current input voltage range nominal output voltage nominal output current article2. PM500 INSTALLATION MANUAL PM500 Installation manual 500 110 48 Option 1107 ins SA Input range 33 1504 Qut v 10 a POLYAMRP ee 8645 Selena j Distribution Schulz W Electronic Schulz Electronic GmbH Dr Rudolf Eberle Stra e 2 D 76534 Baden Baden Fon 49 7223 9636 30 Fax 49 7223 9636 90 vertrieb schulzzet ectronic de www schulz et ctronic de 7291 3 Page 1 9 Polyamp AB Sweden www polyamp com POLYAMP gt PM500 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 danger
3. 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 alarm panel Clockwise turn increases the output voltage The potentiometer has 15 or 20 turns If you have connected units in parallel on the output the procedure of adjusting the output voltage is described in 3 3 Adjusting output voltage when units are paralleled on the output on page 6 5 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 15 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 cathode 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 7 Series diode output Figure 1 The series diode output marked with an arrow Polyamp AB Sweden www polyamp com PM500 INSTALLATION MANUAL 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 pa
4. 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 7 Isolation voltage test Each converter has been isolation tested in factory before delivery Warning Isolation test shall only be performed by personnel aware of the dangers and hazards of the test 7 1 DC isolation test output to input case and alarm 1 Disconnect all cables from the converter 2 Connect the alarm terminals of the converter to case Connect the input terminals to case 3 Connect the output terminals to each other 4 Connect your isolation tester between output and case See Figure 6 5 Raise the voltage of the isolation tester from 0 to 2 5kVd c Check that the leakage current does not exceed The voltage should not be applied for more than a few seconds or the Y capacitors might be damaged 6 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between output and case 7291 3 doc Page 7 9 POLYAMP D PM500 INSTALLATION MANUAL 7 3 DC isolation test input to case a ALARDA HORMA Fran LE a N J CONVERTER r m ira YADI n Store DC ra OVER TEMP ai _ 1 Figure 6 Output to case isolation voltage test 7 2 DC isolation test input to output 1 Disconnect all cables from the converter 2 Connect the alarm
5. terminals of the converter to the output terminals Connect the input terminals to each other 4 Connect your isolation tester between input and output See Figure 7 5 Raise the voltage of the isolation tester from 0 to 4 3kVd c Check that the leakage current does not exceed 5 The voltage should not be applied for more than a few seconds or the Y capacitors might be damaged 1 Disconnect all cables from the converter Connect the input terminals to each other 3 Connect your isolation tester between input and case See Figure 8 4 Raise the voltage of the isolation tester from 0 to 3 6kVd c Check that the leakage current does not exceed 5 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 8 Input to case isolation voltage test 7 4 AC isolation test input to output case and 6 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between input and output Figure 7 Input to output isolation voltage test Polyamp AB Sweden www polyamp com alarm Beware of the rather high capacitive earth currents about 100mA that will occur during this test 1 2 Disconnect all cables from the converter Connect the output terminals and alarm terminals of the converter to case Connect the inp
6. 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 7291 3 doc Page 6 9 POLYAMP D 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 5 To calculate the capacitor needed use the following formula C 1 2 x ls x At AU 1 2 Safety margin ls 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 1A fuse with fast characteristic and the short circuit current is 10A The data sheet 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 1 2 15 x At AU 1 2 x 10 x 0 01 2 4 50 000 Choose a capacitance with a rated voltage of at least 115 of nominal output voltage of the convert
7. al 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 For recommended disconnection devices see Table 1 Polyamp AB Sweden 110 Schneider Electric 220D www polyamp com PM500 INSTALLATION MANUAL PM500 PM260 disconnection devices 10A Schneider Electric MGN61528 MGN61526 Table 1 Recommend disconnection devices 2 Installation The converter is supplied with mounting plates With these you can mount the converter in any direction However to fulfil fire enclosure requirements the converter should not be mounted with the alarm connector side facing downwards Also if the converter is mounted with the input and output connectors facing downwards the four M6 mounting holes on that side should be blocked with non flammable material e g metal screws At full output power the converter produces up to about 45 watts of heat that has to be dissipated from the convection cooled converter to ambient air In order to avoid overheating the converter thus tripping the overtemperature protection circuit and thereby causing temporary shutdown ambient air must not exceed 55 C and a sufficient volume of air must be allowed to flow freely around the converter If the converter is mounted in a narrow Space an external fan is recommended Note that the expected life of
8. er 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 F1 F2 21 F3 C F4 22 S 23 Figure 5 Connecting multiple loads Polyamp AB Sweden www polyamp com PM500 INSTALLATION MANUAL 5 Alarm The alarm relay switches to ALARM state if the output voltage is not within 15 10 of nominal output voltage Otherwise the relay contact is in the position NORMAL The alarm relay can be connected in two ways 1 Normally Open Connect twisted pair 0 25mm 1 5mm from centre pin of the removable alarm connector and connector pin marked ALARM 2 Normally Closed NC Connect twisted pair 0 25mm 1 5mm from centre pin of the removable alarm connector and connector pin marked NORMAL The relay is isolated 4 3kVd c from input and 2 5kVd c from output and case The relay can switch maximum 30V 5A a c and d c values 6 Output over voltage protection All models are equipped with an internal output over voltage protection circuit OVP It consists of an additional voltage regulator operating in parallel with
9. iode 7291 3 doc Page 5 9 POLYAMP b When series diode is not used this is not recommended the voltage drop should be approximately 0 5 of nominal output voltage Note that the voltage drop affects the load regulation the voltage at the load see Figure 3 Uload vaj 105 Figure 3 Load regulation with voltage drop between output and load 3 3 Adjusting output voltage when units are paralleled on the output 1 Connect and start all converters according to 2 Installation on page 4 We recommend using the series diode and separate cables as mentioned above 3 2 Connecting converters in parallel on the output 2 Measure the voltage at the load and on the converters Connect voltmeters as showed in Figure 4 If you have only access to one voltmeter you must move it around to make the adjustments This will take time but is of course possible 20 23 Figure 4 Adjusting output voltage Polyamp AB Sweden PM500 INSTALLATION MANUAL 4 increase the output voltage Increase the output voltage by turning the potentiometer marked V ADJ clockwise on the unit with the lowest output voltage until you reach the desired voltage at the load or until the output voltage does not increase anymore as the unit is in current limit To find the unit with the lowest output voltage you can measure the voltage difference before the series diode as in Figure 4 Repeat until
10. number batch number and serial number The converter type name consists of model name PM500 or PM260 followed by input code and output voltage Two examples e Type PM500 110C 24 has input code 110C and nominal output voltage 24Vd c e Type PM500 110 48 has input code 110 and nominal output voltage 48Vd c Input output and case are galvanically separated from each other You can thus choose how you want the system connected The electrical safety system is a class which means that protective earth has to be connected The input is protected against reverse polarity by a combination circuit with inrush current limit circuit If reverse voltage occurs at installation the converter will not start The reverse voltage will not cause damage to the unit The input shall be fused with an approved fuse with a slow blow characteristic and high breaking capacity Fuses are not included due to the following two reasons 1 DC networks should be fused at the distribution point to protect the cable Siemens 3NA3 series are recommended 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 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 extern
11. our Polyamp dealer Polyamp AB Sweden PM500 INSTALLATION MANUAL 8 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 8 4 Fault report We suggest that you return a faulty converter to POLYAMP AB Box 229 Backgatan 10 S 597 25 ATVIDABERG 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 7291 3 doc www polyamp com Page 9 9
12. ous 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 electric shock do not open enclosure No serviceable parts inside Refer servicing to qualified service personnel only 7291 3 doc Polyamp AB Sweden www polyamp com Page 2 9 POLYAMP gt PM500 INSTALLATION MANUAL CONTENTS 1 BEFORE INSTALLATION J J U U U I een aT l ieee 4 2 INSIAPEATIONu termina an meena u u ON zy A Ae 4 3 PARALLEL CGCONNECTION uuuu ui scene ee x u u u Shubert Abate ua upa se 5 E SEPIESBISODEONTEEGDUTBUTPZ aula pi mu Buaya iwa s Mi Qa oi ua w si 5 3 2 CONNECTING CONVERTERS IN PARALLEL ON THE OUTPUT rr rr cts 5 3 3 ADJUSTING OUTPUT VOLTAGE WHEN UNITS ARE PARALLELED ON THE OUTPUT ecececececececececacecacacacacauavaeavavanaeanes 6 4 MULTIPLE LOADS AT THE U UU U UU 6 A SHOR TM CIROUING S Sulu n suami asnata 6 POALARN emer en ss uyu otu uyu u y yu Sy uy Teo sa ua au Tora EOS ere b2s 7 6 OUTPUT OVER VOLTAGE
13. rallel with another power supply or if you require redundant operation If a converter breaks down 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 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 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 Fuse the inputs separately to achieve redundancy 3 2 Connecting converters in parallel on the output The expected life of the converter is dependent on converter temperature It is therefore important for paralleled unit to share the load as equal as possible to reduce the converter temperature To achieve good current sharing the converters must have separate cables to the load The cables should be dimensioned to have a voltage drop Ud between the converter and the load at maximum current capacity see Figure 2 and Figure 3 Figure 2 Voltage drop Ug When series diode is used which we recommend the voltage drop should be approximately 1 0 of nominal output voltage to also compensate for the negative temperature coefficient of the d
14. 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 twisted pairs for connecting input output and alarm Shielded cables are not necessary 1 Connect protective earth to the connection marked no 40 Use a ring terminal that has been crimped with an appropriate tool 2 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 approximately 105 of nominal output current 7291 3 doc Page 4 9 POLYAMP b If the converter is to be connected in parallel at the output please consult 3 Parallel connection on page 5 If you use multiple loads please consult 4 Multiple loads at the output on page 6 If you intend to use the alarm please consult 5 Alarm on page 7 3 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 4 Startthe converter with your external input disconnection device
15. ut terminals to each other Connect your isolation tester between input and output See Figure 9 Raise the voltage of the isolation tester from 0 to 2 5kVa c The voltage should not be applied for more than one 1 minute or the Y capacitors might be damaged Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between input and case 7291 3 doc Page 8 9 POLYAMP b Figure 9 Input to output case and alarm isolation voltage test 8 Trouble shooting 8 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 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 a short circuit e there is an external short circuit remove it e load is too large decrease the load consult your Polyamp dealer 5 The unit is broken Contact your Polyamp dealer 8 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 7 3 The unit is broken Contact y
16. you reach the desired output voltage at the load To decrease the output voltage Decrease the output voltage by turning the potentiometer marked V ADJ counter clockwise on the unit with the highest output voltage until you reach the desired voltage at the load or until the output voltage does not decrease anymore as the other units supply all current To find the unit with the highest output voltage measure the voltage difference before the series diode as in Figure 4 Repeat until you reach the desired output voltage at the load To achieve good current sharing adjust all converters so that the voltage difference before the series diode is 0 00V between all units that are connected in parallel and so that the voltage at the load is still the desired 4 Multiple loads at the output If you are using several loads we recommend fusing them separately with fast acting fuses Some considerations regarding short circuits should be taken See below 4 1 Short circuits 1 www polyamp com 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 exceed
Download Pdf Manuals
Related Search