PU300/PU500 Installation manual
Contents
1. 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 If there is an external short circuit remove it e 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 15 of time delay type and with correct current rating See Table 1 Polyamp AB Sweden www polyamp com 3 The unit is broken Contact your Polyamp dealer 11 3 The converter starts and stops repeatedly All models have an under voltage protection which shuts down the converter if the input voltage 1s below specified limit 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 11 4 Fault report We suggest that you return a faulty con2. 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 by 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 105 of nominal output current e If the converter is to be connected in parallel at the output please consult 3 Parallel connection on page 10 e If you use multiple loads please consult 4 Multiple loads at the output on page 14 e If you intend to use the alarm please consult 6 Alarm on page 15 e If you intend to use output voltage sense please consult 5 Sense on page 15 e If you intend to use inhibit please consult 7 Inhibit on page 17 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 10232 8 doc Page 4 10 POLYAMP Pertre INSTALLATION MANUAL cable will not bridge the insulation barrier in case of coming lose 4 Start the converter with your external input disconnection device Beware of haz
3. mA on this input will stop the converter This input is isolated from input output case and alarm relay outputs see Table 2 8 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 the main regulator The output voltage is limited to approximately 15 above the nominal value As long as the OVP circuit is active the alarm relay is set to ALARM state 9 Isolation voltage test Each converter has been isolation tested in factory before delivery Warning An isolation test shall only be performed by personnel aware of the dangers and hazards of the test Test points Test level Input Output case signal 2kVd c Input code A B 2 5kVa c 24 48 4kVd c Input code D 110 220 Output Case signal 2kVd c Signal Case Input code A B 2kVd c 24 48 2 5kVa c Input code D 110 4kVd c 220 Alarm Inhibit 2 5kVa c 4k Vd c Table 2 Isolation test voltages Polyamp AB Sweden www polyamp com If your AC isolation test equipment cannot supply enough current you can perform a DC isolation test with 4000Vd c 2500V x V2 x 1 1 4000Vd c where 1 1 safety factor 9 1 DC isolation test output to case 1 Disconnect all cables from the converter 2 Connect the input terminals of the converter to case 3 Connect the output terminals together 4 C
4. uy u D u uu u Q i u i u D u si Su ass 16 7 INTIHTHIBITPTQ Zu Zu yau awu awisa s uw ayu ma Qi u aS Qakay za 17 8 OUTPUT OVER VOLTAGE PROTECTIONN 17 9 ISOLATION VOLTAGE TEST 17 9T DC ISOLATION FES TOUTPUT TOCAS E oeur Gaai EA EARE O E TEETE 18 9 2 DC ISOLATION TEST INPUT TO OUTPUT AND INPUT CASE ccccceccsceccsceccsceccececescscescscesescesescusescesecs 19 9 3 AC ISOLATION TEST INPUT TO OUTPUT AND INPUT CASE ccsceccsceccsceccsceccsceccscscscscescscusescesescesescs 20 9 4 AC ISOLATION TEST SIGNAL TERMINALS TOCAS Bcd 20 9 5 DC ISOLATION TEST SIGNAL TERMINALS TO CASE wicca L woes acetate eects wearin ean 21 9 6 AC ISOLATION TEST ALARM TO INHIBIT TERMINALS 0 cscoscscoscscescsceccececcscercscersecessscncescscescncesseceesecs 21 OPTION H INRUSH CURRENT LEIMI IP D S l S a am aa BnR 21 IL O TROUDDBEESHOOQTINCS Xu u A 22 11 1 THERE IS NO OUTPUT VOLTAGE ccccecosceccsceccscsccscscscscascscascecsseecssescssascscscscsescaseecesescssescesescesescssasences 22 11 2 THEINPUT FUSE BLOWS WHEN THE INPUT IS CONNECTED 0ccsceccecscecscececcscccsceccscecescecescecesescusesces 23 11 3 THECONVERTER STARTS AND STOPS REPEATEDLY ccsceccsceccececcececcscscscecescsce
5. 4 Connect your isolation tester between signal terminals and case Raise the voltage of the isolation tester from OV to corresponding value in Table 2 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 the signal terminals and case 9 6 AC isolation test alarm to inhibit terminals Disconnect all cables from the converter 2 Connect the output inhibit and the input terminals of the converter to case Connect the alarm terminals together 4 Connect your isolation tester between the alarm terminals and case Raise the voltage of the isolation tester from OV to the corresponding value in Table 2 The voltage should not be applied for more than one 1 minute or the Y capacitors might be damaged 5 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between the alarm terminals and case 10 Option inrush current limit Converters marked with Options H on the front label are equipped with inrush current limit feature The input capacitors are charged through an NTC resistor to reduce the input current during start up This feature is available on the PU300 models with input codes C and D and on PU500 models with input codes 110 and 220V PU500 will have a minor degradati
6. POLYAMP LALLA _pu300 PUS00 INSTALLATION MANUAL Schulz W Electronic Schulz Electronic GmbH Dr Rudolf Eberle Strake 2 D 76534 Baden Baden Fon 49 7223 9636 0 Fax 49 7223 9636 90 vertrieb schulz electronic de www schulz electronic de PU300 PU500 Installation manual CONVERTER j ae i Liu rating Quipue rating Article mit Serial ee ee ALARH 10232 8 doc Polyamp AB Sweden www polyamp com Page 10 POLYAMP LAA _pu300 PUS00 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 dangerous voltage within the products
7. ardous voltages e The output voltage can be adjusted 10 to 5 of nominal output voltage with the potentiometer marked V ADJ on the front panel Clockwise turn increases the output voltage The potentiometer has 15 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 12 4 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 is 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 15 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 1 D O PuUSOO Wao DC OUT Fan PUSDD IN fat al 30 31 32 ajo gd EEE ay ojo EzE 10 11 50 51 60 61 63 seres diode output Figure 1 The series diod output marked with an arrow option on PU500 3 1 Series diode on the output The series diode protects the converter output from external voltage sources A series diode is necessary if t
8. e removable connector 2 Connect a twisted pair 0 25mm 1 5mm_ between the sense terminals of the converter and the load see Figure 6 The sense leads and the power cables shall be of approximately the same length and drawn as close to each other as possible Beware of correct polarity Serer O 900 V ADJ DC OUT FUSOO Load Figure 6 External sense 5 2 Internal sense If external sense is not used the jumpers shall be connected between S and and between S and as they are at delivery The converter then regulates the voltage at its output terminals 6 Alarm The alarm relay switches to ALARM state if e 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 i Connect twisted pair 0 25mm 1 5 from centre pin of the removable alarm connector and connector pin marked ALARM 2 Normally Closed NC 10232 8 doc Page 7 10 POLYAMP LALL W gt _py300 PUS00 INSTALLATION MANUAL i Connect twisted pair 0 25mm 1 5mm_ from centre pin of the removable alarm connector and connector pin marked NORMAL The relay is isolated from input output inhibit and case see Table 2 The relay can switch maximum 30V 5A a c and d c values 7 Inhibit A voltage of 5 12Vd c max 35
9. easons why we do not include the fuse 1 DC networks should be fused at the distribution point to protect the cable 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 Polyamp AB Sweden www polyamp com 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 external 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 2 Installation The converter shall be mounted in an enclosure which meets the demands of EN60950 regarding fire voltage hazard and mechanical strength The converter is supplied with mounting plates With these you can mount the converter in any direction The converter is convection cooled and in order to get sufficient cooling there shall be a minimum of 30 to 50 mm space at upper and lower parts of the converter If this 1s not possible we recommend the use of an external fan Note that the expected life of the converter is dependant 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
10. ed from the data sheet of the fuse if you know the short circuit current trough the fuse 2 If there 15 a short circuit in one branch and the total current in all branches does exceed 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 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 10232 8 doc Page 6 10 POLYAMP LALA INSTALLATION MANUAL C 1 2x Isx At AU 1 2 Safety margin Is 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 fuse with fast characteristic and the short circuit current is The data sheet gives you that At 10ms The output voltage is 24V and you can accept 10 voltage dr
11. 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 10232 8 doc Polyamp AB Sweden www polyamp com Page 2 10 POLYAMP LAA _pu300 PUS00 INSTALLATION MANUAL CONTENTS 1 DEFORETNSTALLATDTPION 2 uuu uy ua uy uu u ai u Qu u aS us as 7 2 TINS TAT TA TION u uuu u u arai 8 3 PARALLEL CONNECTION bacauanedsecedsacdestascvscesenaessecaeee 10 SERIES DIODE ON THE OUTPUT 2 aa S as eee 10 3 2 CONNECTING CONVERTERS IN PARALLEL ON THE OUTPUT r sasa 11 3 3 ADJUSTING OUTPUT VOLTAGE WHEN UNITS ARE PARALLELED ON THE OUTPUT 12 4 MULTIPLE LOADS AT THE OUTPUIT 14 A SHOR TCI RGU IMS a Su a 14 ma a ma Gq Qa mo mos ma Pf a ma Qu ma 15 akay ed OREN ESE us up Sa a a PSR AE at ORME tusa 15 NS e ee ee sua E A 16 6 ALARM
12. est 1 Disconnect all cables from the converter 2 Connect the output terminals of the converter to case See Figure 6 3 Connect the input terminals together 4 Connect your isolation tester between input and case See Figure 8 Raise the voltage of the isolation tester from OV to the corresponding value in Table 2 The voltage should not be applied for more than one 1 minute 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 9 4 AC isolation test signal terminals to Case 1 Disconnect all cables from the converter 2 Connect the output and the input terminals of the converter to case 3 Connect the signal terminals alarm and the inhibit terminals together 4 Connect your isolation tester between the signal terminals and case Raise the voltage of the isolation tester from OV to the corresponding value in Table 2 The voltage should not be applied for more than one 1 minute or the Y capacitors might be damaged 5 Turn off the isolation tester and discharge the test voltage with a 10 MQ resistor between the signal terminals and case 9 5 DC isolation test signal terminals to case 1 Disconnect all cables from the converter Polyamp AB Sweden www polyamp com 2 Connect the output and input terminals of the converter to case 3 Connect the signal terminals alarm and the inhibit terminals together
13. he output is connected in parallel 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 Polyamp AB Sweden www polyamp com 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 on 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 Max output current may have to be derated when using series diode See data sheet Do not forget to fuse the inputs separately to achieve redundancy 3 2 Connecting converters in parallel on the output The expected life of the converter is dependant 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 Ua between the converter and the load at maximum current capacity see Figure 2 and Figure 3 Figure 2 Voltage drop Ug Utoaa e When the
14. on in performance see below The input voltage range 15 changed when this option is included see Table 3 This is because if the load changes from 0 to 100 abruptly the input current also changes abruptly This will cause a voltage drop across the NTC resistor until it heats up If the input voltage is only slightly higher than the start voltage of the converter this voltage drop will cause the converter to stop The converter will then start and stop several times until the NTC resistor 15 heated up This is the behaviour of PU500 models with NTC We have therefore on PU300 models increased the lowest input voltage on units with a NTC resistor to prevent this to happen 10232 8 doc Page 9 10 POLYAMP LALLA INSTALLATION MANUAL PU300 normal input voltage range Input voltage code Input voltage range C 50 150Vd c D 90 270Vd c PU300 with option H Input voltage code Input voltage range C 85 150Vd c D 130 270Vd c Table 3 Input voltage range with and without option H The unit starts if the voltage is within the normal input voltage range but depending on the load if the NTC is heated up a load change might cause the converter to stop and start as described before All models have slow start feature To reduce input current during start up the output capacitors are charged slowly approximately 0 15 11 Trouble shooting 11 1 There is no output voltage
15. onnect your isolation tester between output and case See Figure 7 Raise the voltage of the isolation tester from 0 to 2000Vd c Check that the leakage current does not exceed 5u A 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 output and case eos D O T PANE DC OLUT FUS0D Figure 7 Output to case isolation voltage test 9 2 DC isolation test input to output and input to case 1 Disconnect all cables from the converter 2 Connect the output terminals of the converter to case Connect the input terminals together 4 Connect your isolation tester between input and case See Figure 8 Raise the voltage of the isolation tester from OV to corresponding value in Table 2 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 10232 8 doc Page 8 10 POLYAMP Pertre eam E A INSTALLATION MANUAL PU300 VACU DC OUT PUSOO Figure 8 Input to output and input to case isolation voltage test 9 3 AC isolation test input to output and input to case Beware of the rather high capacitive earth currents about 100mA that will occur during this t
16. op gt AU 24 x 0 1 2 4V The capacitance you need C 1 2x Isx At AU 12x 10x 0 01 2 4 50 000u F Choose a capacitance with a rated voltage of at least 115 of nominal output voltage of the converter Repeat this calculation for all branches and choose the highest capacitance value 3 Itis 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 Fe 23 F3 20 21 Figure 5 Connecting multiple loads 5 Sense 5 1 External sense External sense is used when voltage regulation at the load is critical The converter regulates the voltage at the load and not at the output of the Polyamp AB Sweden www polyamp com converter and does thereby compensate for voltage drop in the cables between the converter and the load The maximum voltage compensation 15 5 of nominal output voltage Do not disconnect the negative power connection from the converter to the load before the positive when the converter is running and external sense 1s used This might damage the converter and it is also not advisable for Your own protection to make adjustments in the installation with voltage applied 1 Remove the jumpers from the sense inputs at th
17. 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 diode e When the 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 10232 8 doc Page 5 10 POLYAMP LAA A gt _pu300 PUS00 INSTALLATION MANUAL 105 Figure 3 Load regulation with voltage drop Ua 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 8 We recommend using the series diode and separate cables as mentioned above in 3 2 Connecting converters in parallel on the output 2 Measure the voltage at the load 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 Figure 4 Adjusting output voltage 3 To increase the output voltage 1 Increase the output voltage by turning the potentiometer marked 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
18. sescecescecescecescscesescusesces 23 2 OR haan N aaa a tune muat 23 10232 8 doc Polyamp AB Sweden www polyamp com Page 3 10 POLYAMP LALA INSTALLATION MANUAL 1 Before installation On the front panel label the following is displayed Converter type name input voltage range nominal output voltage serial number options and article number The converter type name consists of model name PU300 or PU500 followed by input code and output voltage Two examples PU300B24 has input code B and nominal output voltage 24Vd c e 500 110 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 input is protected against reverse polarity by a parallel diode at the input on models with input code A B 24 and 48 This diode however is only intended to blow an external input fuse C D 110 and 220 input codes have a series diode The input shall be fused with an approved fuse with a slow blow characteristic and high breaking capacity See Table 1 PU300 input fuses Input voltage code Time delay fuse A 35 25 8 A D 5A PU500 input fuses Input voltage code Time delay fuse 24 30 A 48 20 A 110 8 A 220 4 A Table 1 Recommended input fuses There are two r
19. unit with the lowest output voltage you can measure the voltage difference before the series diode as in Figure 4 H Repeat from 1 until you reach the desired output voltage at the load Polyamp AB Sweden www polyamp com 4 To decrease the output voltage 1 Decrease the output voltage by turning the potentiometer marked 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 H Repeat from 1 until you reach the desired output voltage at the load 5 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 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 calculat
20. verter to POLY AMP 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 10232 8 doc Page 10 10
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